R&M Model Feasibility Report

RENOVATION & MODERNISATION
OF
FOSSIL FUEL BASED POWER PLANTS IN INDIA
MODEL FEASIBILITY REPORT
PREPARED BY
LAHMEYER INTERNATIONAL (INDIA) PVT. LTD.
(CONSULTING ENGINEERS)
(AN ISO: 9001:2008 CERTIFIED COMPANY)
LII-GETS12021-G-00100-002 R05
January 2016
Feasibility Report For R&M of Unit No.[..]Capacity [..]of [Name of the

Power Plant]
[Logo of Utility]
History of Revision
Revision
No.
Date
Prepared/Revised
by
R00
21st Aug 2012
R.K.Soni (RKS)
R01
22nd Aug 2012
Description
First edition Issued (Draft Report).
RKS
Minor Revision (Draft Report).
R02
04th Dec 2012
RKS
Revised edition submitted based on

the discussions held in CEA on7th
Sep 2012
R03
16th July 2013
RKS

the comments of the Task Force
received on 14th May 2013 and the
meeting held in CEA on 11th June
2013.
R04
25th Sep 2014
RKS
Revised to
comments
R05
15th Jan 2016
RKS
Clause 6.4.12 revised to include

Possibility of Automatic Switching
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BACKGROUND
What is R&M (Renovation & Modernization) of Thermal Power Plants?
Coal based power stations contribute more than 70% share of total power generation in India.
Thermal Power Stations are designed for an economical and stable life span of 25 years, after
which, the level of performance starts deteriorating as a result of degradation of its equipments,
components and materials. Deterioration in performance can also take place before the
completion of useful life of 25 years, if the units are not properly operated and maintained.
Deterioration in performance is reflected in frequent forced outages, reduced outputs,
decreased efficiency and increased cost of generation. This results in costly repair and loss of
revenue. Renovations & Modernization (R&M) and Life Extension (LE) programme of thermal
power station is an activity of carrying out repairs, refurbishments and replacement of defective
equipments & components so as to extend the life of the power plant by at least 20 years and
to restore the performance parameters to equal or better than the original design parameters.
Need of R&M
In spite of new capacity additions, India continues to face shortages of varying degree in the
supply of energy and peaking power. Implementation of fresh capacity additions for bridging the
demand supply gap involves huge investments and long gestation periods primarily due to the
process of land acquisition and getting the required fuel and water allocations, permits &
clearances, particularly, the environmental clearance.
On the other hand, R&M activity of existing old power plants which requires less investment and
can be completed in shorter duration has been recognized as a techno-economically viable
option to supplement the fresh capacity addition for maximizing the energy generation. Also it
helps in reducing the emissions by adopting upgraded modern technologies.
Objectives of R&M and R&M/LE Programme
As per the Guidelines issued by Central Electricity Authority (CEA) the following should be the
objectives of R&M and R&M/LE Programmes.
Objectives of R&M Programme:
To restore rated capacity and design parameters such as Heat Rate, Auxiliary Power
Consumption and Secondary Oil Consumption etc.
To make the operating units well equipped with modified/ augmented latest technology.
To overcome technological obsolescence and non-availability of spares.
To improve the performance parameters in terms of Plant Load Factor, Efficiency,

Forced Outages, Availability and Reliability.
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To reduce maintenance requirements and enhance the ease in maintenance.
Compliance of stringent environmental norms, safety and other statutory requirements.
Objectives of R&M/LE Programme:
Extension of useful economic life of generating units by another 20 years.
To focus on full load operation of the unit beyond their original design life.
To restore rated capacity and design parameters such as heat rate,
Improvement in Auxiliary Power Consumption Secondary Oil Consumption etc
Up-rating of Generating Unit.
Improvement beyond design parameters.
Criteria for the Consideration of R&M and R&M/LE Programmes

As per the Guidelines issued by Central Electricity Authority (CEA) the following criteria is to be
adopted for considering the R&M and R&M/LE Programmes.
Estimated cost of unit for complete R&M/ LE works should be limited to 50% of cost of
new unit.
Cost of Main Plant (BTG) should be limited to 50% cost of new BTG unit.
Plant Life should be extended by about 20 years.
The Pay Back Period should be from 5 to 7 years.
Need of Preparation of Model R&M Documents

The countrywide R&M programme was first initiated in 1980 when Government of India
approved the scheme of Central Loan Assistance (CLA) of Rs. 500 crores benefitting 34 power
stations mostly of 50/60/100/110/120/140 MW capacities. R&M in a structured manner was
initiated as a centrally sponsored programme during the 7th Five Year Plan. The momentum of
carrying out R&M works was continued through 8th and 9th Plans but the same could not be
sustained during the 10th Plan.
Based on the discussions held with Ministry of Power, various utilities, PFC and BHEL, CEA
prepared a document on National Perspective Plan for Renovation & Modernization and Life
Extension and Up-rating (LE&U) of thermal power stations up to the year 2016-17. This
document which also includes revised guidelines for Renovation & Modernization / Life
Extension works on coal/lignite based thermal power stations was released by Honourable
Minister of Power on 14th December 2009. Plan-wise Achievements of R&M and R&M/LE
Programmes starting from 7th Five Year Plan till 11th Five Year Plan is furnished below:
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PlanWise Achievements
S.No.
Plan
Year
7th Plan
and Two
Annual
Plans
8th Plan
(R&M)
(LEP)
No. of TPS /
No. of Units
Capacity
(MW)
85-86 to 89-90 &

90-91, 91-92
34 / 163
13570
92-93
to
96-97
44 / 198
43/(194)
1/ (4)
9th Plan
(R&M)
(LEP)
97-98
to
2001-02
10th Plan
(R&M)
(LEP)
2002-03 to
2006-07
Additional
Generation
Achieved
MU/ Annum
10000
Equivalent
MW
20869
(20569)
(300)
5085
763
37 / 152
29/ (127)
8/ (25)
18991
(17306)
(1685)
14500
2200
9/ 25
(14 out of 57
planned )
(11 out of
106 )
3445
(2460)
(985)
2000
300
2000
11th Plan R&M Programme & Achievements (2007-12)

Programme
Achievement
(MW)
(MW)
Life Extension
Programme (LEP)
R&M Programme
7318
1291
(53 units)
(13 Units)
18965
14855
(76 units)
(59 units)
Total
26383
16146
(129 units)
(72 units)
In the past, R&M measures were hampered due to lack of proper planning. Proper investigation
to identify the R&M works to be carried out and preparation of technical bid documents based
on the investigation was not done. This resulted in unsystematic and additional work during
execution phase and uncertainty about costs resulting in excessive implementation time, long
shutdown periods of plants and cost overruns. In the absence of standard commercial rules and
policies, suppliers showed little interest in R&M work. Therefore a strong need was felt for
providing standardized bidding procedures as well as model contracts, formats and
specifications etc. to the utilities. Standardization will harmonize the requirements of all the
stakeholders and will lead to their increased participation.
The Indo-German Energy Forum (IGEF)
The Indo-German Energy Forum (IGEF), inaugurated in 2006, provides a platform to discuss
energy related issues of mutual interest. The first meeting of the ad-hoc sub-group on energy
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efficiency in thermal power stations, constituted as per decision of meeting of IGEF in

December 2007, was held under the chairmanship of Joint Secretary (Thermal), Ministry of
Power on 12th March, 2008 in which preparation of standard tendering document for the
purpose of R&M activities was, inter-alia, identified as an area of the activities. The scope of the
assignment was divided in two parts as under:Phase-I Activity:
Phase-I activity comprised an assessment of tendering procedures currently being followed by
public utilities in India and a review of documents used for standard R&M projects and the
documents which have already been developed for energy efficient R&M projects financed by
particularly World Bank. This activity was carried out by M/s Evonik (India) under the grant
provided by GTZ. M/s Evonik (India) submitted the report in September 2009.
Phase-II Activity
Phase-II activity comprised the preparation of the model documents / templates in consultation
with Task Force, power utilities & financing agencies.
In the 3rd meeting of Indo-German Energy Forum (IGEF) convened in Berlin on 4th November
2009, KfW proposed to finance and carryout the work programme of phase-II Activity, on behalf
of CEA & in consultation with the Task Force. In a meeting held in MOP on 17th December
2009, chaired by Joint Secretary (Thermal), MOP, the representative of KfW suggested that
CEA may act as Project Executing Agency for the phase-II activity. Accordingly Ministry of
Power, Govt. of India have entrusted the task of Project Executing Agency to CEA for
implementing Phase-II activity. Under Indo-German Energy Forum (IGEF) assisted programme,
M/s Lahmeyer International (India) was appointed on16th March 2012 to provide the consultancy
services for Development of tendering procedures and model contract document for R&M of
Fossil Fuel Based Power Plants in India. The scope of consultancy services included the
preparation of the following model documents:
I)
Standard Bidding Procedure for engagement of Consultants and R&M Works

Contractor.
II) Residual Life Assessment (RLA) / Condition Assessment (CA) Report.

III) Energy Audit (EA) Report.
IV) Feasibility Report.
V) Detailed Project Report.
VI) Request for Qualification (RFQ) & (RFP) Documents for R&M Consultants and R&M
Contractors.
VII) Technical Specifications.
Due Diligence done by LII of the R&M Documents of other Projects

Before the preparation of this model document, LII did a thorough review of the R&M
Documents of the following Power Plants:
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Documents Provided by CEA
Remaining Life Assessment I Condition Assessment Report- Nasik Unit-3 of

MAHAGENCO.
Energy Audit Report- Nasik Unit- 3 of MAHAGENCO.
Detailed Feasibility Report- Nasik Unit-3 of MAHAGENCO.
Draft Detailed Project Report -Kolaghat Unit-3 of WBPDCL.
Service Contract- R&M of Unit-1 Panipat TPS of HPGCL.
Tender document for Supply, Erection, Testing and Commissioning of Air Preheater for
Unit 5 & 6 Koradi TPS, MAHAGENCO.
Tender document for replacement of 6.6 KV station transformer incoming breaker & Tie
breaker of Koradi TPS, MAHAGENCO.
Tender specification for Design, Engineering, Supply, Erection, Testing and
Commissioning of Rotary Air Preheter for Units 4 & 5, Nasik TPS of MAHAGENCO.
Documents Provided by WBPDCL
Energy Audit Report of Bandel Unit -5 (210 MW) of WBPDCL.

Detailed Project Report of Bandel Unit -5 (210 MW) of WBPDCL.
Project Design Report of Bandel Unit -5 (210 MW) of WBPDCL.
Technical Specifications. (Vol. II of RFP Document for R&M Contractor).
RLA for Boiler for Bandel Unit -5.
RFP for R&M Consultant for Bandel Unit -5.
Commercial Volume-I of RFP for Bandel Unit -5 for R&M Contractor.
KfW Documents
Model Contract Document issued by KfW.

Guidelines issued by KfW for the assignment of Consultants.
World Bank Documents

Standard Bidding Document for Procurement of Plant, Design, Supply and Installation.
Standard Request for Proposal for the Selection of Consultants
This Feasibility Report has been prepared to conceptualize the systematic methods
and procedures to be implemented for carrying out R&M works for the Thermal Power
Plants, taking into account the different practices followed in the past, the practices
and methodologies being adopted by KfW and World Bank, as indicated in the various
documents indicated above. Detailed standard documents like DPR, RFP & RFQ
documents to carry out R&M works for the Thermal Power Plants shall be prepared
based on this Feasibility Report.
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GUIDELINES FOR USING THE MODEL FEASIBILITY REPORT

Central Electricity Authority (CEA), the Project Executing Agency / Employer has appointed
Lahmeyer International India Pvt. Ltd. (LII), the Consultant to Develop Standard Procedures and
Model Documents for the Renovation and Modernization (R&M) of Fossil Fuel based Power
Plants in India. The above assignment is being financed by KfW Entwicklungsbank. Accordingly,
this Model Feasibility Report has been prepared for the guidance of Project Authorities who may
decide to carryout R&M of their old Coal based Power Plants so as to extend the life of their
plants and make them energy efficient and reduce emissions.
The purpose of this model document is to standardize the format of the Feasibility Report for
R&M works. Since majority of 200/210 MW units are potential candidates for consideration of
Renovation as they have crossed 20 to 25 years of useful life, the enclosed format has been
prepared keeping those 200 MW/210 MW units in view. Since in due course of time, many 500
MW units will also become due for R&M, the Utilities are advised to suitably modify this
document for its application to 500 MW units.
The format of Feasibility Report contains two kinds of texts written in black and in blue colours.
The text in blue italics and enclosed in square bracket ([...]) represents variable information
which may differ from project to project. The text and numbers in blue colour are written for the
sake of citing an example. The Utilities and their Consultants are advised to check the relevance
of the same and replace these texts and numbers with the ones as may be applicable to their
specific Project. A few guidelines have also been provided in blue italics enclosed within red
curly brackets ({}), wherever applicable.
**************
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MODEL FEASIBILITY REPORT

FOR
OF
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TABLE OF CONTENT
1
EXECUTIVE SUMMARY
INTRODUCTION
2.1
Description
2.2
Operational Background
2.3
Objective of the Feasibility Study
SALIENT FEATURES OF POWER PLANT
3.1
Boiler & Auxiliaries
3.2
Turbine & Auxiliaries
11
3.3
Electrical System
16
3.4
Control & Instrumentation
19
3.5
Balance of Plant
20
3.6
Civil Works
23
OPERATIONAL HISTORY OF THE UNIT
25
4.1
Operational History of the Plant
25
4.2
Stack Emissions, Ambient Air Quality and Process Effluents
25
4.3
Tripping and Maintenance Record
27
4.4
Maximum Achievable Load due to Performance Constraint of ESP
28
4.5
Record of Reportable Accidents
28
4.6
Operation & Maintenance Difficulties due to Plant Limitations
29
RESULTS OF RLA/CA AND EA STUDIES AND TECHNICAL SOLUTIONS
30
5.1
Approach Adopted
30
5.2
Equipments/Components subjected to Health Condition Assessment
31
5.3
Formulation of R&M Options
38
5.4
R&M option identified for Implementation
41
PROPOSED MODIFICATIONS AND REFURBISHMENTS

6.1
42
Boiler and Auxiliaries
42
6.1.1
Boilers
42
6.1.2
Coal Mills
42
6.1.3
PA Fans
42
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6.1.4
ID Fans
43
6.1.5
F D Fans
43
6.1.6
ESP
43
6.2
Steam Turbine & Auxiliaries
43
6.2.1
Steam Turbine
44
6.2.2
Condenser
44
6.2.3
Ejectors
44
6.2.4
Condensate Extraction Pumps
44
6.2.5
LP Heaters
45
6.2.6
Deaerator
45
6.2.7
Boiler Feed Pumps
45
6.2.8
HP Heaters
45
6.2.9
Critical Piping including valves
45
6.3
Balance of Plant
46
6.3.1
Coal Handling Plant
46
6.3.2
Ash Handling Plant
46
6.3.3
Water Intake System
46
6.3.4
Water Pre-Treatment Plant
47
6.3.5
DM Plant
47
6.3.6
CW & ACW System
47
6.3.7
Cooling Towers
47
6.3.8
Fire Detection and Protection System
47
6.3.9
Fuel Oil Handling System
48
6.3.10
Compressed Air System
48
6.3.11
Air Conditioning & Ventilation System
48
6.3.12
EOT Crane in TG Hall
48
6.3.13
Effluent Treatment Plant
48
6.4
Electrical System
49
6.4.1
Generator- Stator
49
6.4.2
Generator-Rotor
49
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6.4.3
Generator Transformer
49
6.4.4
Unit Auxiliary Transformer
49
6.4.5
Generator Protection & Synchronization
50
6.4.6
Station Service Transformer
50
6.4.7
6.6 kV System
50
6.4.8
415 V System
50
6.4.9
HT & LT Motors
51
6.4.10
DC system
51
6.4.11
Public Address system
51
6.4.12
Illumination System
51
6.4.13
DG Sets
51
6.5
52
6.5.1
DDCMIS
56
6.5.2
Closed Loop Control System
56
6.5.3
56
6.5.4
57
6.5.5
Primary, Secondary Instruments
59
6.5.6
Control Valves
59
6.5.7
UPS
59
6.5.8
Analyzers, Steam and Water Analysis System
59
6.5.9
Continuous Emission Monitoring System
59
6.5.10
Pipes & tubes
59
6.5.11
Cables
59
Civil Works
60
6.6
6.6.1
60
6.6.2
TG-Building
60
6.6.3
Chimney
60
6.6.4
Coal Handling Plant
61
6.6.5
Ash Handling Plant
61
6.6.6
Water Treatment Plant
61
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6.6.7
Raw Water Reservoir
61
6.6.8
CW System
61
6.6.9
Ash Pond
61
6.6.10
Miscellaneous Works
62
FINANCIAL EVALUATION OF R&M OPTIONS
63
7.1
Introduction
63
7.2
Capital Expenditure for R&M
63
7.3
Impact on Tariff
63
7.4
Basis of Comparison
63
7.5
Assumptions for Financial Comparison
64
7.6
Comparison of Input for Different Options
65
7.7
Selection of R&M Option
67
7.8
Impact of Adverse Scenarios
67
CARBON CREDIT AND ENERGY EFFICIENCY CREDIT
71
PROJECT FINANCE AND MARKET SCENARIO
72
9.1
About the Utility
72
9.2
Financial Performance
72
9.3
Means of Finance
73
9.4
Market Scenario
74
10
IMPLEMENTATION OF R&M PROJECT
75
10.1
Project Team
75
10.2
Project Schedule
75
10.3
Project Management
75
10.4
Project Monitoring
75
10.5
Role of R&M Consultant
76
10.6
Role of the ISC Consultant
76
10.7
Quality Management
76
10.8
Performance Guarantee Test
76
10.9
Liquidated Damages
77
10.10
Health, Safety and Environment (HSE)
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10.11
Supply of Spares and Special Tools and Tackles
78
10.12
Training
78
10.13
O&M Manuals
78
10.14
Operation and Maintenance
78
11
RISKS
80
11.1
Limitation of CA, RLA and LE Studies
80
11.2
Regulatory Risk
80
11.3
Risk of R&M Contractor and Personnel
80
11.4
Risk of Non-Availability of Spares.
81
11.5
Risk of Getting Shutdown for Implementation
81
11.6
Financing Risk
81
11.7
Implementation Risk
81
11.8
Equipment Underperformance Risk
81
12
CONFORMITY TO STATUTORY ENVIRONMENTAL NORMS
82
12.1
Environmental Monitoring Cell
82
12.2
Stack Emissions
82
12.3
Ambient Air Quality (AAQ)
82
12.4
Liquid Effluents
82
12.5
Noise
83
12.6
Ash Utilization
83
12.7
Corporate Social Responsibility
83
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LIST OF ANNEXURE
ANNEXURE DESCRIPTION
PAGE
6.1
BOILER AND AUXILIARIES
90
6.2
STEAM TURBINE AND AUXILIARIES
94
6.3
BALANCE OF PLANT
97
6.4
ELECTRICAL SYSTEM
101
6.5
CONTROL AND INSTRUMENTATION
105
6.6
CIVIL WORKS
113
7.1
SUMMARY OF CAPITAL COST FOR VARIOUS R&M OPTIONS
117
7.2
TARIFF CALCULATION FOR VARIOUS R&M OPTIONS
118
7.3
CASH FLOW AND RETURN ANALYSIS FOR VARIOUS R&M OPTIONS
122
10.1
PROJECT MILESTONE SCHEDULE
127
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ABBREVIATIONS TO BE USED
{The utilities are advised to use the following standard abbreviations while preparing Feasibility
Report for their power plant.}
AAQ
Ambient Air Quality
ACB
Air Circuit Breaker
ACG
Automatic Control Gear
AHP
Ash Handling Plant
AHU
Air Handling Unit
ANSI
American National Standard Institutte
ASME
American Society of Mechanical Engineers
ATRS
Automatic Turbine Run up System
ATT
Automatic Turbine Testing
AVR
Automatic Voltage Regulator
BAS
Boiler Auxiliary Steam
BFD
Boiler Feed Pump Discharge
BFP
Boiler Feed Water Pump
BMCR
Boiler Maximum Continuous Rating
BOP
Balance of Plant
CAVT
Cold Air Velocity Air Flow Test
CBD
Continuous Blow Down
CCTV
Closed Circuit Television
CDM
Clean Development Mechanism
CEA
Central Electricity Authority
CEMS
CER
Certified Emission Reduction
CERC
Central Electricity Regulatory Commission
CHP
Coal Handling Plant
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CRH
Cold Re-Heat
CLCS
COC
Cycle of Concentration
COG
Cost of Generation
CT
Cooling Tower
CV
Control Valve
CW
Cooling Water
CWIP
Capitalized Work in Progress
DCDB
Direct Current Distribution Board
DDCMIS
Digital Distributed Control Monitoring Information

System
DG
Diesel Generator
DGA
Dissolved Gas Analyzer
DM
Demineralization
DMCW
Demineralised Cooling Water
DP
Differential Pressure
ECO
Economizer
EEP
Energy Efficiency Programme
EHC
Electro-Hydraulic Control
ELCID
Electromagnetic Core Imperfection Detection
EOT
Electrically Operated Travelling Crane
ESP
Electro Static Precipitator
ESV
Emergency Stop Valve
ETP
EWS
Engineers Work Station
FO
Fuel Oil
FSSS
Furnace Safeguard Supervisory System
GC
Gland Condenser
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GCV
Gross Calorific Value
GT
HART
Highway Addressable Remote Transducer
HCA
Host Country Approval
HEA
High Energy Pulsed Arc
HMI
Human Machine Interface
HP
High Pressure
HRH
Hot Re-Heat
HT
High Tension
HVAC
Heating, Ventilation and Air Conditioning
HVWS
High Velocity Water Spray System
IBD
Intermittent Blow Down
ICB
International Competitive Bidding
IFI
International Financing Institution
IGV
Inlet Guide Vane
I/O
Input / Output
IPT
Intermediate Pressure Turbine
IPR
Inter Posing Relay
IRR
Internal Rate of Return
ISMB
Indian Standard Medium Beam
IV
Interceptive Valve
LCP
Local Control Panel
LDO
Light Diesel Oil
LE
Life Extension
LMZ
Leningradsky Mettallichesky Zavod
LP
Low Pressure
LPA
Loss Prevention Association of India
LPT
Low Pressure Turbine
Document Number
LII-GETS12021-G-00100-002
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LRSB
Long Retractable Soot Blower
LT
Low Tension
LTSH
Low Temperature Super Heater
LVS
Large Video Screen
MCCB
Module Case Circuit Breaker
MOCB
Minimum Oil Circuit Breaker
MoEF
Ministry of Environment & Forest
MS
Main Steam
MSSV
Main Stream Safety Valve
OPC
Object linked embedded Process Control
OWS
Operator Working Station
PA
Primary Air
PCN
Project Concept Note
PDD
Project Design Document
PLF
Plant Load Factor
PRDS
Pressure Reducing De-superheating Station
PLC
Programmable Logic Controller
R&M
Renovation & Modernization
RfP
Request for Proposal
RfQ
Request for Qualification
RH
Reheater
RLA
Residual Life Assessment
RO
Reverse Osmosis
RSO
Recurrent Surge Oscillograph
RTD
Resistance Temperature Detector
SADC
Secondary Air Damper Control
SH
Super Heater
SWAS
Steam and Water Analysis System
Document Number
LII-GETS12021-G-00100-002
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TDH
Total Dynamic Head
TFT
Thin Film Transistor (Monitor)
TMCR
Turbine Maximum Continuous Rating
TPS
Thermal Power Station
TR
Tons of Refrigeration
TAC
Tariff Advisory Committee
TC
Thermocouple
TSE
Turbine Stress Evaluator
TSI
Turbine Supervisory Instruments
UCR
Unit Control Room
UPS
Uninterruptible Power Supply
VVVFD
Variable Voltage and Variable Frequency Drive
WACC
Weighted Average Cost of Capital
Document Number
LII-GETS12021-G-00100-002
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MEASUREMENT UNITS
{The utilities are advised to use the following abbreviations for the measurement units while
preparing Feasibility Report for their power plant.}
C
Degree Celsius
cm2
Square Centimeter
dB (A)
Decibels Absolute
hr
Hour
Hz
Hertz
kCal
Kilo Calorie
kg
Kilogram
kl
Kilo Liter
km
kilo meter
kV
kilo Volt
kVA
kilo Volt Ampere
kW
kilo Watt
kWh
Kilo Watt hour
Meter
m2
Square Meter
cubic meter
mg
Milligram
MJ
Millions of Joule
mm
Millimeter
cm
centimeter
MVA
Mega Volt Ampere
MW
Mega Watt
ppm
Parts per million
rpm
Revolutions per minute
Document Number
LII-GETS12021-G-00100-002
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TPH / T/hr
Tonnes Per Hour
mg/Nm3
Milligram per Normal cubic meter
g/m
Micrograms per cubic meter
Document Number
LII-GETS12021-G-00100-002
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EXECUTIVE SUMMARY
This Feasibility Report has been prepared for carrying out the Renovation &
Modernization (R&M)/ Life Extension (LE) of Unit No... of ......Thermal Power
Plant, located at [.], in District [.] in the State of [.] and having a
configuration of [xMW].
The unit no. [...] was first commissioned in the year [.]. After [.] years of
operation, the performance of the unit has gradually deteriorated resulting in
frequent forced outages, reduced outputs, decreased efficiency and increased
cost of generation. It is proposed to carry out required refurbishments and
replacements in the plant so as to restore the units performance parameters and
to extend its life of by at least [.] years.
The report discusses the salient features and operational history of the power
plant and also the specific problems being faced from the operation of various
plant equipment & systems.
To determine the residual life of critical components of the plant, various studies
namely the Residual Life Assessment (RLA), Condition Assessment (CA) and
Energy Audit have been conducted during the period [.]. Based on the
recommendations of RLA/CA & EA Studies, review of the performance data and
discussions with the plant engineers, [five R&M options] were formulated by the
R&M Consultant.
Estimated cost for each option was worked out after taking into account the
scope of R&M measures to be implemented for each option. Cost Benefit
analysis of each option was then performed. After cost-benefit analysis of [Five]
options, the most attractive option has been identified for implementation of the
R&M Project.
The cost of the R&M Project is estimated as [RsCrores]. The Payback
Period is estimated as [..Years]. The R&M activity is expected to bring out the
improvements as indicated in the following table:
Improvements Expected after R&M of the Unit
S.No.
Parameters
Units
1.
Residual Plant Life
Years
2.
Capacity
MW
3.
Plant Load Factor
Document Number
LII-GETS12021-G-00100-002
Before R&M
After R&M
[.]
[.]
[.]
[.]
[.]
[.]
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S.No.
Parameters
Units
4.
Heat Rate
kCal/ kWh
5.
Auxiliary
Consumption
6.
Specific Oil Consumption
Specific
Consumption
Coal kg/kWh
8.
Emission
of
Particulate Matter
9.
[Logo of Utility]
Before R&M
After R&M
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Solid mg/Nm3
[.]
[.]
SOx(Ground
Concentration)
Level g/m3
[.]
[.]
10.
NOx(Ground
Concentration)
Level g/m3
[.]
[.]
11.
Noise Level during day dB (A)

time at plant boundary.
[.]
[.]
12
Noise Level during night dB (A)

time at plant boundary
[.]
[.]
Document Number
LII-GETS12021-G-00100-002
Power %
ml/kWh
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2
2.1
[Logo of Utility]
INTRODUCTION
Description
The Power Plant, having a configuration of [xMW] is located at [.], in District [.]
in the state of [.].The Unit no. [.] of the power plant, which is proposed to be taken
up for Renovation and Modernization was first commissioned in the year [.]. For the
above unit, M/s [..] and M/s [.] are the Original Equipment Manufacturers (OEMs)
for the Boiler and Turbo-Generator, respectively. The consumptive water for the unit is
being sourced from [.]. The primary fuel [coal / lignite] for the unit is being sourced
from [.]. The boiler for the unit is of [PF/CFBC] design. The boiler is provided with
[front & rear/ corner/down shot] firing system. LP stage of Turbine is designed with
[Bauman] exhaust. Condenser cooling system of the unit is designed on [once through
/ re-circulation system]. Power generated from the unit is being supplied to
[...State/Central grid]. Power is being evacuated through [.numbers of 220/400kV
Double/Single Circuit lines] to [. substation]. The primary fuel is
[domestic/imported/blended] [coal/lignite] fuel being sourced from [..&] coal
mines. The consumptive water for the power plant is being sourced from
[.river/sea].
2.2
After the first commissioning during the year [.], the unit was giving a stable
operation with [. MW] of Gross Power Output at an average PLF of [. %] and a
Gross Heat Rate of [.kCal/kWh]. The Auxiliary Power Consumption after the first
commissioning was [%]. [Based upon the recommendations of RLA / CA and EA
Studies conducted during the year .. major replacements were made during the
year.. comprising..and .]. The unit is presently performing with a
maximum Gross Power Output of [. MW] with an average PLF of [%] and a Gross
Heat Rate of [.kCal/kWh]. The present Auxiliary Power Consumption is [%].
2.3
Objective of the Feasibility Study

The feasibility study has been carried out to establish the cost effectiveness of the
proposal for taking up R&M measures to improve the efficiency and performance
parameters of the plant and to extend its life. During the course of feasibility study, the
following sub-studies were carried out.
a. Cold Walk-down and Hot Walk-down Survey.
b. Discussion with the Plant Engineers.
c. Review of the operational history of the power plant, reports of Condition
Assessment (CA) and Residual Life Assessment (RLA) studies carried out earlier
and major replacements done in the past, prior to taking up this study.
d. Review of reports of Condition assessment (CA) and Residual Life Assessment
(RLA) of major equipment and systems of the power plant carried out recently.
e. Review of reports of Energy Audit of main equipments and auxiliary systems
carried out recently to identify the reasons and sources of excess power
consumption.
Document Number
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f.
Review of recommendations of R&M Consultant for carrying out R&M measures

for increasing the useful life, efficiency and output of the plant as well as for
meeting the latest environment standards prescribed by the regulating agencies at
the national and state level.
g. Study of the financial impact of the R&M Measures proposed.
h. Financial analysis based on internal rate of return and cost benefit ratio.
Document Number
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{Describe in this chapter, the Design Parameters and Salient Features of all the
important Equipment and Systems of the Power Plant as mentioned below}
3.1

a) Boiler
[The Steam Generator is of natural circulation, pulverized fuel fired, dry bottom, balanced
draft using direct firing system. The design parameters of the Boiler are furnished
below]
Description
Units
Design
Parameters
Steam Flow at Final SH outlet
T / hr
[.]
Steam Pressure at SH outlet
kg/cm2
[.]
Steam Temperature at SH outlet
[.]
Re-heater Flow
T / hr
[.]
Steam Pressure at RH outlet
kg/cm2
[.]
Steam Temperature at RH outlet
[.]
Feed Water Flow
T / hr
[.]
Feed Water Pressure at inlet of

Economiser
Feed Water Temperature at inlet of
Economiser.
kg/cm2
[.]
[.]
b) Furnace
[The boiler is equipped with a water cooled furnace of balanced draft and fusion
welded membrane wall construction. It is equipped with..numbers of coal burners
andnumbers of oil burners located at numbers of elevations. The design
parameters of the Furnace are furnished below.]
Description
Units
Type of Firing
Combustion
Volume
Document Number
LII-GETS12021-G-00100-002
Design Parameters
........
[..............]
Chamber m3
[..............]
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Description
Units
Furnace Dimensions
[Logo of Utility]
Design Parameters
(Width x Depth x Height)
[..............]
Heating Surface Areas
[..............]
m2
[..............]
ii) Superheaters
m2
[..............]
iii) Reheaters
m2
[..............]
iv) Economiser
m2
[..............]
v) Air Heater
m2
[..............]
vi) Steam Coil Air

Heater
m2
vii) Temperature
Measurement of
Super-heater
tubes
Yes / No
viii) Temperature
Measurement of
Re-heater tubes
Yes / No
i)
Water Walls
[..............]
[..............]
[..............]
c) Super Heaters and Re-Heater

[The super heaters are composed of four sections, a platen section, a pendant section,
a rear low temperature section and a steam cooled wall & roof section. The Re-heater
consists of two sections, the front pendant and the rear pendant sections. The details
are given below:]
Description
Low
Temperature
Super Heater
Document Number
LII-GETS12021-G-00100-002
No. of coils Pitch

/ tubes
(mm)
[.]
Dia.x Thickness Heating

(mm)
Surface (m2)
[.]
[.]
[.]
Material
[.]
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Description
No. of coils Pitch

/ tubes
(mm)
[Logo of Utility]

(mm)
Surface (m2)
Material
Platen Super
Heater
[.]
[.]
[.]
[.]
[.]
Pendant
Super Heater
[.]
[.]
[.]
[.]
[.]
Ceiling and
Enclosure
Super Heater
[.]
[.]
[.]
[.]
[.]
ReheaterFront
Assembly
[.]
[.]
[.]
[.]
[.]
ReheaterRear
Assembly
[.]
[.]
[.]
[.]
[.]
d) Economiser
[The Economizer is of a single stage, continuous finned tube and horizontal, mixed
flow type, located in the second pass of the boiler]
e) Air Pre-Heater
[The air pre-heater is of regenerative rotary type. Special sealing arrangements have
been provided in the air pre-heater to prevent leakage between air and gas sides.
Adjustable sector plates have also been provided to prevent the leakage during
expansion. The heating surfaces of the air pre-heater have been provided with two
types of cleaning systems, soot blowing and water washing system. ]
f)
Raw Coal Bunkers
[Each boiler is provided with [] raw coal bunkers. The total capacity of the bunkers is
to meet [] hours requirement at maximum mills capacity of the unit. The upper
portion of the bunkers is of cylindrical shape made of carbon steel plate, while the
conical portion is made of stainless steel plate. Each outlet of the bunker is provided
with an isolation gate which is motor operated. In addition to the isolation gates, rod
gates have been provided to control the flow of coal from the bunkers]
g) Raw Coal Feeders
[One gravimetric type of raw coal feeder has been provided for each coal mill. The
coal feeders have been provided with micro-processor based controls with variable
frequency drive. The feeders have been provided with dual independently measuring
Document Number
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load cells. All parts of the feeders coming in contact with coal, except the belt, are
made of stainless steel]
h) Fuel Firing System
[The boiler is working on a direct firing system. The pulverized coal is being dried and
transported to the coal burners by means of hot primary air being supplied by two
primary air fans. The boiler is having [front and rear/corner/down shot] firing system.
There are [] pulverized coal burners and [] oil burners. The burners are located at
[] floors.
i)
Coal Mills
[The unit is provided with . numbers of BHEL make XRP-783 bowl type mills, out of
which mills are designed to work with designed coal and ..numbers of mills are
standby . The rated capacity of each mill is ..T/hr.]
Description
Units
Design Parameters
Make and Model of Mills
..
[.]
Capacity of Mills
T/hr
[.]
Total Number of Mills per boiler
Nos.
[.]
Number of Mills to work per boiler with

design coal quality
Nos.
[.]
Motor Rating
kW
[.]
j)
Primary Air Fans
[Two Primary Air (PA) Fans have been provided for each boiler. Each PA Fan is
designed to meet 60% MCR condition of the boiler. The PA Fans are Hot PA Fans.
Details are given below:]
Description
Units
Design Parameters
Make and Model of Fans
..
[.]
Number of fans per boiler
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
Temperature of Hot Air
[.]
Document Number
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Description
Units
[Logo of Utility]
Design Parameters
Motor Rating
kW
[.]
Method of Regulation
[.]
k) Forced Draft Fans

[Two Forced Draft (FD) Fans have been provided for each boiler. Each FD Fan is
designed to meet 60% MCR condition of the boiler. The FD Fans supply combustion
air to the boiler, mill air through PA Fans and tempering air to control the classifier
temperature of the mills. Details are given below:]
Description
Units
Design Parameters
..
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
Temperature of Air
[.]
Motor Rating
kW
[.]
[.]
l)
Induced Draft Fans
[Two Induced Draft (ID) Fans have been provided for each boiler. Each ID Fan is
designed to meet 60% MCR condition of the boiler. Each ID Fan evacuates flue gases
through two parallel paths of ESP and discharge them into stack through separate
ducting. Details are given below:]
Description
Units
Design Parameters
..
[.]
Number of Fans per Boiler
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
Document Number
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Description
Units
[Logo of Utility]
Design Parameters
Temperature of Flue Gases
[.]
Motor Rating
kW
[.]
[.]
m) Wall Blowers and Long Retractable Soot Blowers (LRSBs)

[Adequate number of Wall Blowers and Long Retractable Soot Blowers (LRSBs) are
being used for cleaning the soot deposited on the heating surfaces of the water walls
and super heaters respectively. Automatic sequential soot blowing system has been
provided. Details are given below:]
Description
Units
Design Parameters
Wall Blowers
Make and Model of Wall Blowers
..
[]
No. of Wall Blowers per boiler at water

walls
Nos.
[.]
Medium of soot blowing at water walls
..
[.]
Make and Model of LRSBs
[.]
No. of LRSBs per boiler at pendant

surfaces of pressure parts
Nos.
[.]
Medium of soot blowing at pendant

[.]
No. of LRSBs per boiler at convection

pass tube banks
Nos.
[.]
Medium of soot blowing at convection

pass tube banks
[.]
LRSBs
n) ESP
[An Electrostatic Precipitator (ESP) has been installed on the cold end side of the Air
Pre-heater to remove the particulate matter from the flue gases. The ESP has been
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provided with Gas Distribution System, Collecting Electrodes, Discharge Electrodes,

Transformer Rectifier Sets and [electrically/mechanically] operated rapping system.
The hoppers of ESP have been provided with capacitance type level indicators and
thermostatically controlled heating elements. Details are given below:]
Description
3.2
Units
Design Parameters
Make and Model of ESP
[.]
Number of Passes per ESP
Nos.
[.]
Number of fields per pass
Nos.
[.]
Dust concentration at outlet
mg/Nm3
[.]
Type of Control
[.]
Gas Velocity in ESP
m/sec
[.]
Specific Collection Area
m2/m3/sec
[.]
Aspect Ratio
..
[.]
Particle Migration Velocity
cm/sec
[.]
Plate Area/TR Set
m2/TR Set
[.]
Storage Capacity of ESP Hoppers
hrs
[.]
Pressure Drop
mmwc
[.]
Dust Collection Efficiency with (N-1)

fields in operation
[.]

a) Steam Turbine
[The steam turbine is of three cylinder, 3000rpm, tandem compound, condensing type
designed to operate on a re-heat and re-generative feed water cycle. The LP stage of
turbine is designed with Bauman exhaust. The turbine is provided with HP/LP bypass
system of 60% capacity of Steam Generator MCR. The turbine is provided with an
electro - hydraulic control system, automatic turbine run up system and turbo
supervisory instrumentation. The condensing system consists of a surface condenser
of single shell and two pass, divided water box construction. Cooling water being
supplied to the condenser is of raw water/ clarified water quality. The design
parameters of the steam turbine are furnished below]
Document Number
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Description
[Logo of Utility]
Units
Design Parameters
Pressure of Steam at inlet of ESV of

HPT
kg/cm2
[.]
Temperature of Steam at inlet of ESV

of HPT
[.]
Pressure of Cold Reheat (CRH) Steam kg/cm2
[.]
Temperature of Cold Reheat (CRH)

Steam
Pressure of Hot Reheat (HRH) Steam
[.]
kg/cm2
[.]
Temperature of Hot Reheat (HRH)

Steam
Pressure at the inlet of LP Turbine
[.]
kg/cm2
[.]
Temperature at the inlet of LP Turbine
[.]
b) Condenser
[The condenser is a [single/twin] shell, horizontal, surface type with integral air cooling
section designed to maintain a pressure of 76 mm of Hg at turbine exhaust with a
cooling water temperature of [] deg C and an outlet temp of [] deg C. The
condenser is capable of operation with [] % tubes plugged and has hot well storage
capacity of [] minutes.]
Description
Units
Design Parameters
Make and Model
[.]
Type of Condenser
[.]
Total Cooling Surface
m2
[.]
Number of Cooling Water Tubes
..
[.]
Material of Tubes
..
[.]
Diameter and thickness of tubes
mm
[.]
Cooling Water Quantity through

Condenser
Cooling Water Temperature at the inlet
to Condenser
m3/h
[.]
[.]
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Description
Units
Condenser Vacuum
[Logo of Utility]
Design Parameters
mm Hg
[.]
c) Ejectors
[The Condenser is provided with two quick starting ejectors which operate in parallel to
remove large volumes of air for raising the initial vacuum during the starting of the Unit.
Two main ejectors of 100% capacity each have been provided remove air and non
condensable gases from the condenser to maintain the required vacuum in the
condenser during the normal operation of the unit.]
d) Condensate Extraction Pumps
[Condensate extraction pumps are of vertical, multistage, centrifugal pumps of cannister
type.]
Description
Units
Design Parameters
Make and Model
[.]
Type
[.]
Capacity
m3/h
[.]
TDH
mwc
[.]
Speed
rpm
[.]
Motor Rating
kW
[.]
e) Gland Steam Cooler

[A Gland Steam Cooler has been provided to condensate the leak-off steam from
intermediate chambers of end sealings of HP and IP turbine, thereby heating the main
condensate water. The Gland Steam Cooler consists of shell, tube bundle and
removable water box.]
f)
LP Heaters and Drain Coolers
[Each steam turbine is provided with four numbers of low pressure heaters to increase
the temperature of the condensate in stages. LP Heater -1 consists of two halves and
is installed in neck of the condenser. The remaining LP Heaters are of shell and tube
design and have been placed vertically. An integral drain cooling section is provided in
each LP Heater. The design details of LP Heaters are furnished in the table below.]
Heater No.
Extraction
[...] stage of IP [...] stage of [...] stage of [...] stage of
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Steam
from
taken turbine
IP turbine
[Logo of Utility]
IP turbine
IP turbine
Bled
Steam
Pressure
(kg/cm2))
[...]
[...]
[...]
[...]
Bled
Steam
Temperature
(deg C)
[...]
[...]
[...]
[...]
g) Deaerator
[The deaerator is of [horizontal spray cum tray type]. It is designed to remove
dissolved oxygen from the condensate in excess of 0.005 cc per liter. The feed
water storage tank has a capacity of [] minutes feed water requirement of the
boiler corresponding to TMCR Heat Balance]
h)
Boiler Feed Pumps
[The boiler feed pumps are horizontal, multi stage centrifugal pumps of barrel type,
motor driven pumps taking the suction from the deaerator. The boiler feed pumps
discharge feed water through HP heaters to the economizer of the boiler.]
Description
Units
Design Parameters
Make and Model
..
[.]
Type
...
[.]
No of stages
Nos.
[.]
Capacity
m3/h
[.]
Head
mwc
[.]
Feed water temp
[.]
Gland sealing arrangement
[.]
Minimum flow
m3/h
[.]
NPSH required at design condition
mwc
[.]
Document Number
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Description
Units
[Logo of Utility]
Design Parameters
Method of Speed Regulation
[.]
Type of Coupling
[.]
Motor Rating
kW
[.]
i)
HP Heaters
[Each steam turbine is provided with three numbers of high pressure heaters to
increase the temperature of the feed water in stages. The Heaters are of shell and
tube design and have been placed vertically. The design details of HP Heaters are
furnished in the table below.]
Heater No.
Extraction
[...] stage of HP [...] stage of HP [...] stage
Steam
taken turbine
turbine
turbine
from
Bled
Steam
Pressure
(kg/cm2))
[...]
[...]
[...]
Bled
Steam
Temperature
(deg C)
[...]
[...]
[...]
j)
of
HP
HP/ LP Bypass
[HP/LP bypass system has a capacity of 60% of BMCR (Boiler Maximum
Continuous Rating). HP bypass system has been provided between the Main
Steam Line and Cold Reheat Line. LP bypass system has been provided between
the Hot Reheat Line and the Condenser. HP bypass water spray has been taken
from the discharge of Boiler Feed Pumps. LP bypass water spray has been
provided from the discharge of Condensate Extraction Pumps.
k) Turbine Governing System

[The turbine is equipped with a electro-hydraulic system of automatic governing for
the smooth and stable operation of turbo-set under all conditions of operation. The
system is designed to sustain full load dump from the generator. The system is
provided with a quick closing Emergency Stop Valve (ESV), to interrupt the supply
of steam from the boiler and stop the turbine under emergency conditions. The
turbine governing system includes, speed governor,]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
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Power Plant]
l)
[Logo of Utility]
Lube Oil System

[The lube oil system consists of Main Oil Tank, Turbine driven main oil pump, AC
driven bearing oil pump, DC driven emergency oil pump, AC driven jacking oil
pump and oil coolers of 3x50% capacity, Lube oil is being purified by means of a
centrifuge. Oil storage tanks consisting of Clean Oil Tank and Dirty Oil Tank have
been provided.]
m) Turbine Gland Sealing System

[Turbine Gland Sealing System consists of gland steam condenser, gland steam
exhauster, all associated motors, associated piping, valves & fittings, strainers / filters
etc]
3.3
Electrical System
a) Generator
[The Generator is a 15.75 kV, 50 Hz, 0.85 power factor machine, operating at 3000
rpm, withtype of excitation system and digital programmable voltage regulator.
The Generator has direct water cooled stator winding and direct hydrogen cooled
rotor winding. The stator winding cooling water is cooled in a closed cycle cooling
system using DM water, while the hydrogen in the machine is cooled in gas to water
hydrogen coolers mounted inside the machine. The Parameters of the Generator are
briefly mentioned below.]
Description
Units
Design Parameters
Rated MW Capacity
MW
[.]
Rated MVA Capacity
MVA
[.]
Rated Terminal Voltage
kV
[.]
Rated Power Factor
..
[.]
Rated Stator Current
kA
[.]
Rated Speed
rpm
[.]
Rated Frequency
Hz
[.]
Efficiency at Rated Power Output and

Rated Power Factor
[.]
Excitation Current
kA
[.]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
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Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Excitation Voltage at Rated Power

Output and Rated Power Factor
Short Circuit Ratio
kV
[.]
..
[.]
Rated Hydrogen Pressure
kg/cm2
[.]
Negative Sequence Current
Amp
[.]
Phase Connection
[.]
Type of Excitation
[.]
Method of Cooling the Rotor
[.]
Method of Cooling the Stator
[.]
b) Station Transformer
[Two Station Transformers have been provided to meet the station auxiliary loads of
the power plant. The Station Transformers have been provided with on-load tap
changers to keep the station 6.6 kV voltage constant. Cooling of this transformer is
ONAN/ONAF/OFAF and has 2x50 % separately mounted radiators and 2x50% oil
pumps. The Parameters of the Station Transformers are briefly mentioned below]
Description
Units
Design Parameters
Make
[.]
Capacity / Rating
MVA
[.]
Voltage Ratio
[.]
Type of Cooling
[.]
Quantity
Nos.
[.]
c) Generator Transformer
[The power output from each Generator is being stepped up to 220/400 kV through a
240 MVA step up Generator Transformer. It has 3x50% coolers and 3x50% oil pumps.
The Parameters of the Generator Transformer are briefly mentioned below]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
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Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
Make
[.]
Capacity
MVA
[.]
Voltage Ratio
[.]
Type of Cooling
[.]
d) Unit Auxiliary Transformer

[Two unit auxiliary transformers have been provided for each unit for meeting all unit
auxiliary loads. These transformers have been provided on-load tap changers. The
Parameters of unit auxiliary transformers are briefly mentioned below]
Description
Units
Design Parameters
Make
..
[.]
Capacity
MVA
[.]
Voltage Ratio
..
[.]
Type of Cooling
..
[.]
Quantity
Nos.
[.]
e) Electrical Distribution System

[Unit auxiliaries receive their normal power supplies at 6.6 kV through two (2) nos. unit
transformers. For lower size drives, 6.6 kV is further stepped down to 415 V by two
(2) nos. unit service transformers. The 415 V distribution system feeds a number of
Motor Control Centers (MCCs) for running 415 V drives. 6.6 kV unit switchgears are
connected to station switchgear for start up and emergency power supply. The details
are mentioned below]
Description
Units
Design Parameters
Voltage Level
kV
[.]
Type of Breaker
[.]
Type of Grounding
[.]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
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Power Plant]
Type of Protection
[Logo of Utility]
[.]
f) DC System
[Each unit has its own DC system located in the BC bay at ground floor of the Power
House. Separate DC systems have been provided in switchgear control room, intake
pump house and DM plant for controlling the systems. Each DC system comprises of
the Storage Battery, the Battery charger and the distribution boards. The details are
mentioned below]
Description
Units
Design Parameters
Make
[.]
Capacity / Rating
[.]
[.]
Type of Charger
..
[.]
Area of Application
..
[.]
Area of Application
..
[.]
Voltage
g) Emergency Power Supply System

[Diesel generating sets are installed for meeting the power requirements of essential
auxiliaries (viz. jacking oil pumps, AC lube oil pump, hydrogen seal oil pump, float
charger for DC battery, emergency lighting, scanner air fan and stator cooling water
pump) during total failure of AC Power Supply in the power station. Diesel generating
sets are located in the CD bay at the ground floor. The details are mentioned below]
Description
3.4
Units
Design Parameters
Make of DG Sets
[.]
Rating of DG Sets
kVA
[.]
Quantity
Nos.
[.]

[The existing control and instrumentation system generally is an old analogue based
system and requires large scale replacement owing to obsolescence of the existing
equipments. Furnace Supervisory Safeguard System (FSSS) is of obsolete design for
which, no spares are available. Soot blowers are of manual type. No online Boiler
Tube Leakage detection system has been provided. Control system for the existing
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
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Power Plant]
[Logo of Utility]
turbine auxiliaries is relay based. Turbine Supervisory system is of electromagnetic

type. No continuous monitoring system has been provided for observing the health of
the turbine. HP- LP bypass system is in the form of standalone control panel.
Integrated microprocessor based closed loop control, open loop control, sequential
control and bulk data acquisition system for SG & auxiliaries, TG & auxiliaries, station
C&I including auxiliaries in hierarchical levels and integrated unit monitoring and
station monitoring systems in the upper level are therefore to be envisaged for the
plant.]
3.5
Balance of Plant
a) Coal Handling Plant
[Coal Handling Plant is a common facility which is feeding all the units of the power
plant having a total installed capacity ofx..MW. Coal to the power plant is brought
through railways by Box N wagons and is unloaded by wagon tipplers. One crusher
has been provided for crushing the coal from 250 mm size to 25 mm size. The plant is
provided with one stacker reclaimer to stock the crushed coal. The coal stock yard has
a storage capacity of 20 days. For feeding the coal to the bunkers of all the units, two
streams of conveyors having a capacity of .TPH have been provided. The coal
handling plant operates for 16 hrs a day.]
Description
Units
Design Parameters
Track Hopper Size
No. of Wagon Tipplers
Nos.
[.]
Rating of Wagon Tipplers
T/hr
[.]
No. of streams of conveyor
Nos.
[.]
Capacity of each conveyor
T/hr
[.]
Type of Crushers
Nos.
[.]
Number of Crushers
Nos.
[.]
Capacity of Crushers
T/ hr
[.]
No. of Stacker Reclaimers
Nos.
[.]
Stacking Reclaiming Capacity
TPH
[.]
Storage Capacity of Stock Yard
days
[.]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
[20]
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Power Plant]
[Logo of Utility]
b) Ash Handling Plant

[Ash Handling System is of continuous type. The bottom ash from the furnace falls into
bottom ash hopper having a storage capacity of [] hrs. The ash is ground to the size
[] mm by the clinker grinders and is removed with the help of submerged Scrapper
Chain Conveyors. The ash from the air pre-heater and economizer hoppers is being
disposed off along with bottom ash. The ash in the form of ash slurry is conveyed
through sluice channels to the ash slurry pump house with the help of high pressure
jets, from where, it is pumped to the ash pond located the distance of [] km. The ash
slurry disposal system is having [].numbers of identical streams of ash slurry pumps
connected to [] numbers of ash slurry pipelines going to the ash pond. Fly ash is
collected in dry form below the ESP hoppers and the same is then conveyed by
vacuum system to surge hoppers from where it is either conveyed through pressurized
system to dry fly ash silos or is sent to ash pond in the form of slurry. From the dry fly
ash silos, the ash is disposed off through the covered trucks. The datasheet indicating
the particulars of major equipments for hopper ash handling and fly ash handling
system is furnished below.]
c) Raw Water System
[The consumptive water for the plant is sourced from [] river/sea located at a
distance of [] km from the plant boundary. The intake water pump house is installed
with [] intake pumps of capacity [] m3/hr, out of which [] pumps are normally
working and the remaining [] pumps are standby. The raw water is pumped from the
intake water pump house to the in-plant raw water reservoir, which has a storage
capacity of [] days.]
d) CW / ACW System and Cooling Towers
[CW system for the power plant works on re-circulating system with induced draft
cooling towers. The CW system uses raw/clarified quality of water and is working on
[] cycles of concentration. CW pump house is a common facility for all the units of
the power plant. There are two CW pumps of capacity [] m3/hr provided for each
unit. In addition, there are two standby CW pumps common to all the units. The
requirement of ACW system is being tapped from the cold CW header feeding the
condenser. The hot return ACW water after cooling the auxiliaries of boiler and turbine
joins the hot CW header and is sent to the cooling towers for cooling. The cold water
from the cooling water flows to the fore bay of CW Pump House for recirculation into
the system. One (Induced draft / Natural Draft) Cooling Tower has been provided for
each unit. The cooling tower cools the water from [] deg C to [] deg C. The cooling
tower has been designed for an ambient wet bulb temperature of [] deg C and
Relative Humidity of [] %. The cooling towers are of cross flow/ counter flow design.
The Cooling Tower fills are made of (RCC/PVC/ Polypropylene].
e) Water Pre-Treatment Plant
Water Pre-Treatment Plant is a common facility for all the units of the power plant. Pretreatment plant supplies clarified water to DM plant, cooling water to the auxiliaries of
BOP system, coal handling plant dust suppression and to the drinking water system.
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
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There are two numbers of clarifiers of [].m3/hr capacity to meet all the clarified water
requirements of the whole plant, except DM plant. The clarified water requirement for
DM plant is met by a separate clarifier of capacity [] m3/hr.]
f) DM Plant
[DM plant consists of three streams, each of [] m3/hr capacity. There are two DM
water tanks of [].m3 capacity. A common regeneration system has been provided for
all the three streams. DM plant operates on semi-automatic system with PLC controls.]
g) Air-Conditioning and Ventilation System
[The central control room, switchyard control room, ESP controls room and selected
areas of service building have been provided with centralized air-conditioning system.
The central air-conditioning system of chilled water type has been provided for various
control rooms and DX type of plant has been provided for ESP control room,
switchyard control room and other areas in the service building. Packaged type of airconditioners has been provided for water treatment plant control room. Evaporative
ventilation system has been provided for TG building along with roof extractors. Other
areas are ventilated by a combination of exhaust and supply air fans].
h) Fire Fighting System
[Fire fighting system is a common facility provided for all the units. This consists of
pressured hydrant system for all the auxiliary buildings, pump houses and
administrative building. Automatic high velocity sprinklers system has been provided
for power transformers, turbine oil tanks and lube oil system equipments. Medium
velocity sprinkler system has been provided for cable galleries and coal conveyor
galleries. Portable types of fire extinguishers have been provided throughout the plant
for fighting small and localized fires.]
i)
Plant and Instrument Air System
[Plant and instrument air system is a common facility for all the units of the plant. For
meeting the instrument air requirement, [] number of oil free screw compressors []
working and [] standby, each of [] m3/hr capacity and discharge pressure of []
kg/cm (g) have been provided along with dryers. Equal number of air compressors of
similar rating has been provided to meet the requirement of plant air system. The air
drying plant for the instrument air has been provided to achieve a dew point of (-) 40oC
at atmospheric pressure.]
j)
Fuel Oil System
The fuel oil system has been designed for the use of Light Diesel Oil (LDO) for startup and Heavy Fuel Oil (HFO) for load carrying and flame stabilization purposes. Two
tanks of [] kl each have been provided for the storage of HFO and two tanks of []
kl each have been provided for the storage of LDO. The system has been provided
with unloading, transferring and pressurization pumps along with necessary filters and
heating arrangement.]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
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3.6
[Logo of Utility]
Civil Works
Major civil facilities consist of the following:
a) Main Power House Building:
[3x200 MW units have been placed side by side. Centre to centre placing of units is
[67.5 m.] The railway entry has been provided from the rear side of Power House
Building. Turbine Generator (TG) Sets have been placed between AB rows of columns
are laid out longitudinally. The TG bay, also houses, the Boiler Feed Pumps,
Regenerative Heaters, Lube Oil System and other TG accessories. The total length of
TG bay for 3x210 MW units is [276 m] and width [30 m]. The spacing of the column is
at [7.5 m]. TG bay is provided with 2 Nos. of overhead EOT Cranes. In order to make
the handling facilities of the cranes available to the heat exchangers, boiler feed
pumps and other equipments, removable chequered plates have been provided at
appropriate locations.
A sub zero floor has been avoided except for the localized pits required for
Condensate Pump, pipe channels and HP Heaters etc. This sub zero pits are suitably
connected and provided with a common sump for drainage purposes.
Three stairs for approaching the operating floor level at [+10 m] have been provided in
this bay adjacent to B row columns. In addition, there are stairs for providing access to
various equipments at intermediate platforms and sub zero pits.
Switchgear and Control Room bay has been provided in the BC bay which is [12 m]
wide. The length of the bay is [249.0 m]. A common Control Room for all the three
units is provided at [10 m] floor. In BC bay at [16 m] elevation, equipments for chemical
dosing, air handling and MCC for soot blowers etc have been located. The deaerator is
placed at an elevation of [23.0 m]. Air washer units and cooling water tanks are also
located at [23.0 m] floor.
Mill Bunker Bay, designated as CD bay, has a span of [10.5 m] which accommodates
coal bunkers, coal feeders and coal mills. CD bay houses the vertical mills at Zero m
and has space for collection of disposal of mill rejects at sub zero levels adjacent to D
row. A stair to connect operating floor at [16.0 & 23.0 m] of BC & CD bay has been
provided.]
b) Boiler Area
[In boiler area, the boiler with its auxiliaries like PA fan, FD fan, ID fan as well as
Electrostatic Precipitator has been located.]
c) Transformer Yard
[A [60] m wide yard has been provided outside the A row columns. The transformer
yard houses station transformer, unit auxiliary transformers and generator
transformers along with oil pits etc. To facilitating erection and maintenance of
transformers, the area has been provided with rail tracks parallel to A row at a
distance of [45 m] from A row which is further connected through cross tracks. In
addition, space has been provided for laying the CW pipelines and locating the
butterfly valve chambers.]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
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Power Plant]
[Logo of Utility]
d) Service building
[A common four storey building has been provided near the main plant building and it
is connected with the operating floor of TG bay at [10 m] level.].
e) Chimney
[A single chimney having a height of [] meters comprising of concrete wind shield
has been provided for [] units. The flue gases from each unit are let out through
independent steel flues. The Chimney is provided with an elevator]
f) Cooling Tower.
[One Cooling Tower of (Induced draft / Natural Draft) has been provided for each unit.
The dimensions of each Cooling Tower are []. The cooling towers are of cross flow/
counter flow design. The Cooling Tower fills are made of (RCC/PVC/ Polypropylene].
g) Miscellaneous buildings
[Besides the above, miscellaneous buildings like administrative building, CW Pump
House, Fire Water Pump House, CHP Control Room, ESP Control Room, DM Plant
Building, Chemical House and Ash Silos have been provided.]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
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4.1
[Logo of Utility]
Unit No [] of [] Thermal Power Station having a Generating Capacity

of [210 MW] was commissioned in the year [..]. The boiler is of [] design
and the turbine is of [LMZ/KWU] design. Though the boiler was originally designed for
coal with Gross Calorific Value (GCV) of [.kCal/kg], it presently operates on coal
supplied with GCV of about [..kCal/kg]. The deterioration experienced over the years
in Plants performance parameters is shown in Table 4.1. Table 4.2 illustrates
variations over the last three years in the performance parameters.
Table 4.1- Units Performance Parameters over the life
Years after
Installation
PLF
(%)
Availa
bility
(%)
Output
(MW)
Aux. Power
Consumptio
n (%)
Specific Oil
Consumptio
n (ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross
Heat Rate
(kCal/kWh)
[]
[]
[]
[]
[]
[]
[]
10
[]
[]
[]
[]
[]
[]
[]
15
[]
[]
[]
[]
[]
[]
[]
20
[]
[]
[]
[]
[]
[]
[]
25
[]
[]
[]
[]
[]
[]
[]
Table 4.2- Units Performance Parameters in last three years
4.2
Period
PLF
(%)
Availa
bility
(%)
Output
(MW)
Aux. Power
Consumptio
n (%)
Specific Oil
Consumptio
n (ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross
Heat Rate
(kCal/kWh)
2 years back
[]
[]
[]
[]
[]
[]
[]
1 year back
[]
[]
[]
[]
[]
[]
[]
Current year
[]
[]
[]
[]
[]
[]
[]

The Project has been regularly monitoring the environmental parameters such as stack
monitoring, ambient air quality (AAQ), noise pollution and liquid waste pollution by
employing an agency approved by State Pollution Control Board and in accordance
with applicable norms.
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
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[Logo of Utility]
{Indicate the environmental data of the unit for the past three years against the limits
specified for different pollutants. Furnish the information for each year as per the table
4.3 below. Also provide the map(s) showing the locations for various measurements as
Annexure to the Feasibility Report.}
Table 4.3
Status of Stack Emissions, Ambient Air Quality and Process Effluents
Environmental
Aspects
Parameters Specified by
State Pollution and
Control Board (SPCB)
Stack
Emissions
SPM
3
(mg/Nm )
Ambient Air
Quality
SPM
Parameters
Achieved
Not to exceed
[]
On
24
Hrs
Basis
On
Annual
Basis
[]
[]
No. of
locations for
measurement
[]
On
24
Hrs
Basis
On
Annual
Basis
[]
[]
Frequency
of
Sampling.
[]
[]
[]
[]
(g/m )
RPM
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
(g/m )
SO2
3
(g/m )
NOX
3
(g/m )
Process
Effluent
Leaving the
Plant Boundary
Document Number
LII-GETS12021-G-00100-002
ETP Treated Water Quality

pH
[]
[]
Colour
[]
[]
Odour
[]
[]
Temperat
ure
[]
[]
TSS
[]
[]
Rev
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Environmental
Aspects
State Pollution and
Parameters
Achieved
[Logo of Utility]
No. of
locations for
measurement
Frequency
of
Sampling.
(mg/l)
4.3
Oil &
grease
(mg/l)
[]
[]
COD
(mg/l)
(mg/l)
[]
[]
BOD
(mg/l)
[]
[]
Chloride
(mg/l)
[]
[]
Sulphate
(mg/l)
[]
[]
TDS
(mg/l)
[]
[]
Zinc
(mg/l)
[]
[]
Fluoride
(mg/l)
[]
[]
Mercury
(mg/l)
[]
[]
[]
[]

{Indicate in the table below tripping & maintenance record for past three years.}
Table 4.4
Year
Two Years
Document Number
LII-GETS12021-G-00100-002
Total
Trippings
No. of Trippings
due to Boiler Tube
Leakages
Other Major
Causes of
Trippings
Maintenance
carried out
[]
[]
[]
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No.
Description
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Year
Total
Trippings
No. of Trippings
due to Boiler Tube
Leakages
[Logo of Utility]
Other Major
Causes of
Trippings
Maintenance
carried out
Back
4.4
One Year
Back
[]
[]
[]
Current
Year
[]
[]
[]

[Due to ESPs performance constraint, the maximum generation from the unit is
restricted to ..MW, in order to keep SPM emission within the statutory limit of 50
mg/Nm3. The operational data at the above maximum load is indicated in the table
below.]
Table 4.5
Nature of constraints causing limited Generation
4.5
Nature of
constraint
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units Gross
Efficiency
(%)
[]
[]
[]
[]
[]
Units Gross
Heat Rate
(kCal/kWh)
[]

[The record of reportable accidents for the past three years, is mentioned in the Table
below]
Table 4.6
Year
Man hours lost

due to
accidents
No. of Fatal
Accidents
No. of Accidents
leading to
Permanent
Disablement
Actions taken to
reduce the
number of
accidents
Two
Years
Back
[]
[]
[]
[]
One Year
Back
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
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Year
Man hours lost

due to
accidents
Current
Year
4.6
[]
No. of Fatal
Accidents
[]
[Logo of Utility]
No. of Accidents
leading to
Permanent
Disablement
Actions taken to
reduce the
number of
accidents
[]
[]

[Difficulties are being experienced in day to day maintenance of the plant due to
design deficiency, layout of the plant, obsolescence of equipment and non availability
of spare parts etc. These are mentioned in the Table below]
Table 4.7
S.No.
Nature of Difficulty
Specific Reason
(Design deficiency/ layout of the plant / obsolescence of
equipment / non availability of spare parts etc)
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
RESULTS OF RLA/CA AND EA STUDIES AND TECHNICAL SOLUTIONS
5.1
Approach Adopted
Complete approach adopted for finalizing the R&M option is shown in Figure 5.1.
Figure 5.1
Steps followed in arriving at the most cost effective R&M solution
COLLECTION OF OPERATIONAL
DATA AND TRIP REPORTS
ANALYSIS OF OPERATIONAL DATA

AND TRIP REPORTS
HOT WALK DOWN SURVEY
COLD WALK DOWN SURVEY
REVIEW OF EARLIER RLA/CA/EA

STUDIES
REVIEW OF SCHEDULED &

UNSCHEDULED MAINTENANCE WORK
DONE
IDENTIFICATION OF AREAS WHERE

MORE INVESTIGATIONS ARE REQUIRED
FINALIZING THE BID DOCUMENTS

FOR RLA/CA/EA STUDIES
CONDCUTING OF RLA/CA/EA
STUDIES
WORKING OUT OF R&M OPTIONS

ON THE OUTCOME OF STUDIES
FINALIZING MOST COST

EFFECTIVE R&M OPTION
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
The existing condition of the Plant was assessed on the basis of the results of RLA/CA
and EA studies. Various R&M options were formulated based on the alternative
solutions available to extend the life and improve the efficiency of the unit. The above
R&M options were examined on the basis of cost benefit analysis and the most
attractive option was then selected for implementing the R&M works.
5.2
Equipments/Components subjected to Health Condition Assessment

The health condition of the unit was investigated by carrying out RLA/CA and EA
Studies. The required tests were performed on the sub-systems / components listed
below.
A) Boiler and Auxiliaries
S.No
Name of Sub
System /
Equipment
1.
2.
4.
Document Number
LII-GETS12021-G-00100-002
[Mills]
[Furnace]
[Boiler Pressure
Parts]
[Air Pre-heater]
Name of the
Component
Type of
Test(s)
Conducted
Brief Results/
Findings of the
Tests
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
Rev
No.
Description
Page
No.
Date of Issue
05
[31]
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Power Plant]
S.No
5.
6.
7.
8.
9.
10.
Document Number
LII-GETS12021-G-00100-002
[Logo of Utility]
Name of Sub
System /
Equipment
Name of the
Component
[Critical Piping]
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
[FD FANS]
[PA Fans]
[ID Fans]
[Wall Blowers &

LRSBs]
[Electrostatic
Precipitator]
Type of
Test(s)
Conducted
Brief Results/
Findings of the
Tests
Rev
No.
Description
Page
No.
Date of Issue
05
[32]
15.01.2016

Power Plant]
S.No
11.
[Logo of Utility]
Name of Sub
System /
Equipment
Name of the
Component
Type of
Test(s)
Conducted
Brief Results/
Findings of the
Tests
[ Any other
Equipments]
[]
[]
[]
[]
[]
[]
B) Turbine and Auxiliaries

S.No
Name of Sub
System /
Equipment
1.
2.
3.
4.
5.
6.
7.
Document Number
LII-GETS12021-G-00100-002
[Steam Turbine]
[Condenser]
[Ejectors]
[Condensate
Extraction Pumps]
[Gland Steam
Cooler]
[LP Heaters and
Drain Coolers]
[Deaerator]
Name of the
Component
Type of
Test(s)
Conducted
Brief Results/
Findings of the
Tests
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
Rev
No.
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No.
Date of Issue
05
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8.
9.
10.
11.
12.
[Boiler Feed Water

Pumps]
[HP Heaters]
[HP and LP Bypass

System]
[Turbine Governing
System]
[Lube Oil System]
[Logo of Utility]
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
C) Electrical System
S.No
Name of Sub
System /
Equipment
1.
2.
3.
4.
Document Number
LII-GETS12021-G-00100-002
[Generator]
[Station
Transformers]
[Generator
Transformer]
[Unit Auxiliary
Transformer]
Name of the
Component
Type of
Test(s)
Conducted
Brief Results/
Findings of the
Tests
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
Rev
No.
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No.
Date of Issue
05
[34]
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Power Plant]
S.No
Name of Sub
System /
Equipment
5.
6.
7.
Name of the
Component
[Electrical
Distribution System]
[DC System]
[Emergency Power
Supply System]
[Logo of Utility]
Type of
Test(s)
Conducted
Brief Results/
Findings of the
Tests
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
D) Balance of Plant
S.No
1..
2..
3.
Document Number
LII-GETS12021-G-00100-002
Name of Sub
System /
Equipment
Name of the
Component
[Coal Handling
Plant].
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
[Ash Handling
Plant.]
[Raw Water System]
[CW/ACW System
and Cooling Towers]
Type of
Test(s)
Conducted
Brief Results/
Findings of the
Tests
Rev
No.
Description
Page
No.
Date of Issue
05
[35]
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S.No
Name of Sub
System /
Equipment
5.
6..
7.
8.
9.
10.
Document Number
LII-GETS12021-G-00100-002
[Water PreTreatment Plant]
[DM Plant]
[Air Conditioning
and Ventilation
System]
[Fire Fighting
System.]
Name of the
Component
[Logo of Utility]
Type of
Test(s)
Conducted
Brief Results/
Findings of the
Tests
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
[Plant and
Instrument Air
System.]
i) []
i) []
i) []
ii) []
ii) []
ii) []
[Fuel Oil System]
i) []
i) []
i) []
ii) []
ii) []
ii) []
Rev
No.
Description
Page
No.
Date of Issue
05
[36]
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[Logo of Utility]
E) Civil Works
Name of Sub
System /
Equipment
S.No
1..
2..
3.
4.
5.
6.
Document Number
LII-GETS12021-G-00100-002
[Boiler].
[TG Building.]
[Chimney]
[Coal Handling
Plant]
[Ash Handling Plant]
[Water PreTreatment Plant]
Name of the
Component
Type of
Test(s)
Conducted
Brief Results/
Findings of the
Tests
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
Rev
No.
Description
Page
No.
Date of Issue
05
[37]
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Name of Sub
System /
Equipment
S.No
7.
8.
9.
10.
11.
5.3
[DM Plant]
[CW Pump House]
[ Cooling Towers]
[Ash Dyke]
[Misc. Works]
Name of the
Component
[Logo of Utility]
Type of
Test(s)
Conducted
Brief Results/
Findings of the
Tests
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
ii) []
ii) []
ii) []

[Based on the recommendations of RLA/CA & EA Studies, review of the performance
data and discussions with the plant engineers, various R&M options were formulated.
All the R&M options were aimed at achieving the following minimum objectives:
i)
ii)
iii)
iv)
v)
vi)
vii)
Redesigning the boiler to suit the average coal quality likely to be available for
the next 20 years.
Restoring the performance parameters to the original design values.
Extending the life of the unit by a minimum of 20 years.
Replacing the existing obsolete technology.
Meeting the revised statutory emission standards.
Increasing Efficiency.
Reducing Auxiliary Power Consumption
The first option considered for R&M was for the case, in which the objectives were
restricted to the bare minimum for restoring design output, design heat rate and
Auxiliary Power Consumption of the unit and to extend the unit life by 15 years. Other
options were formulated for not only the life extension of the unit but also for further
improving its output, heat rate and auxiliary power consumption from the original
design values, as discussed in the Table 5.1 below.]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
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[Logo of Utility]
Table 5.1- R&M Options Considered for Cost Benefit Analysis

Option
Objectives to be achieved by carrying out

R&M
i)
Shut
Down
Period
[Designing Boiler to suit average coal

quality likely to be available for the next 20
Years.
[]
ii) Increasing the output of the unit to [215

MW] from 200/210 MW by retrofitting the LP
turbine without retrofitting Generator.
Improving heat rate beyond the original
design heat rate and restoring the Auxiliary
Power Consumption to the original design
values.
[Life
Extension
.. Years]
[Output
..MW]
[Heat Rate
kCal/kWh]
iii) Replacing the existing obsolete technology.

iv) Meeting the revised statutory emission
standards.
[Aux. Power
Consumption
v) Extending the life of the unit by a minimum

of 20 years.]
II
Major
Parameters
after R&M
..%]
i) [Designing Boiler to suit average coal quality

likely to be available for the next 20 Years.
[]
[Life
Extension
.. Years]
ii) Increasing the output of the unit to [215 MW]

from 200/210 MW by retrofitting the LP and
HP turbine without retrofitting Generator.
design heat rate and restoring the Auxiliary
Power Consumption to the original design
values.
[Heat Rate
kCal/kWh]
[Output
..MW]

standards.
III
v)
Extending the life of the unit by a minimum

of 20 years.]
[Aux. Power
Consumption
%]
i)

Years.
[Life
Extension
.. Years]
[]
ii) Increasing the output of the unit to [215

Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
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No.
Date of Issue
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Power Plant]
Option
[Logo of Utility]

R&M
Shut
Down
Period
MW] from 200/210 MW by retrofitting

complete new energy efficient turbine
without retrofitting Generator. Improving
heat rate beyond the heat rate of option II
and restoring the Auxiliary
Power
Consumption to the original design values.
Major
Parameters
after R&M
[Output
..MW]
[Heat Rate
kCal/kWh]

standards.
[Aux. Power
Consumption

of 20 years.]
..%]
IV
i)

Years.
[]
ii) Increasing the Output to [220 MW] MW from

200/210 MW by retrofitting complete new
energy efficient turbine along with new
Generator, Generator Transformer and new
static Excitation System. Improving heat
rate better than the level of option III and
restoring the Auxiliary Power Consumption
to the original design values.
[Life
Extension
.. Years]
[Output
..MW]
[Heat Rate
kCal/kWh]

standards.
[Aux. Power
Consumption

of 20 years].
..%]
i)
[Life
Extension
.. Years]
[In situ major replacement of Boiler on the

existing foundations, retrofitting complete
new energy efficient turbine along with new
Generator, Generator Transformer and new
static Excitation System. Designing the
boiler to suit the average coal quality likely
to be available for the next 25 years.
[]
[Output
..MW]
ii) Increasing the Output to [250/300 MW].

Achieving heat rate and Auxiliary Power
Document Number
LII-GETS12021-G-00100-002
Rev
No.
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No.
Date of Issue
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Power Plant]
Option

R&M
[Logo of Utility]
Shut
Down
Period
Consumption better than Options III & IV.
Major
Parameters
after R&M
[Heat Rate
kCal/kWh]

standards.
[Aux. Power
Consumption

of 25 years.]
..%]
{This option is advised only when the unit to be

renovated is either the first or last unit of the
power plant, since intermediate units are likely
to have space constraint for installation of new
Boiler and TG.}
{While evaluating the options, the utilities are advised to also check the residual life of
the switchyard, the Balance of Plant and the Material Handling System. Further, the
utilities should note that if the proposed calorific value of coal is inferior to the original
calorific value for which the boiler was designed, then the boiler will require reengineering.}
Estimated cost for each option was worked out after taking into account the scope of
R&M measures to be implemented for each option. Cost Benefit analysis of each
option was then performed. After cost-benefit analysis of [Five] options mentioned
above, option [...] has been identified as most attractive option for implementation.
Cost-benefit analysis of various options is discussed in Section 7.0.
5.4

Option [...] has been selected for implementation. This is expected to bring out the
following improvements:
i) Extending the Plant life to [.] years.
ii) Increasing the output rating to [ MW].
iii) Improving the Heat Rate to [ kCal/kWh].
iv) Restoring the Auxiliary Power Consumption to the original level and attempting to
achieve the same to the level of CERC/SERC norms.
v) Achieving the revised statutory emission standards.
System wise / Equipment wise Modifications / replacements proposed on the basis of
CA/RLA/EA studies are discussed in Section 6.0
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
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No.
Date of Issue
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Power Plant]
PROPOSED MODIFICATIONS AND REFURBISHMENTS
6.1
[Logo of Utility]
{Discuss in this section the following aspects for each item of the Boiler and its
Auxiliaries:
i) The problems being faced from in view of the shortfall in achieving the performance
parameters and
ii) The R&M measures to be adopted based on the recommendation of RLA/CA and
EA studies.
It may please be noted that the check points mentioned in paragraphs below are of
indicative nature only, whereas the same has to be as per the project specific
requirements.}
6.1.1
Boilers
[
]
{Note: Check the requirement of re-engineering the boiler and the capacity of the
furnace in view of more quantity of coal of lower GCV is to be burnt in the boiler in
place of existing design for higher GCV coal. Check for the possible requirements of
refurbishment / replacement of boiler structure, down comers, safety valves, pressure
parts like, drum, drum internals, water wall tubes, tube bends near gooseneck, bottom
s-panels, coils and headers of super heaters, re-heater & economizers, refurbishing
of air pre-heater by replacement of baskets & seals, modification of attemperators,
retrofitting of low NOx burners, oil burners, wind box, burner tilting arrangement, high
energy arc igniters, reapplication of refractory & insulation, penthouse pressurizing
fans, buck stays, ducting, insulation, soot blowers, LRSBs, bottom ash evacuation
system, clinker grinders, hangers and supports etc.}
6.1.2
Coal Mills
[..
]
{Note: Check for the possible requirements of replacement of existing mills with higher
capacity mills in view of increased quantum of low quality coal to be fed to the boiler.
Also check for the requirements of changing the grinding rolls, grinding rings,
classifiers, drive motors, gears, oil pumps, cooling water circuit, sealing air system etc.
Incorporate the recommendation of Performance Test.}
6.1.3
PA Fans
[..
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
[42]
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Power Plant]
[Logo of Utility]
{Note: Check the capacity of fans in view of the higher capacity of mills. Check for the
possible requirements of the replacement of impellers, casing, bearings etc.
Incorporate the recommendation of Energy Audit Studies.}
6.1.4
ID Fans
[
...............]
possible requirements of the replacement of impellers, casing, bearings, VFD etc.
Incorporate the recommendation of Energy Audit Studies.}
6.1.5
F D Fans
[
..]
possible requirements of the replacing the impellers, casing, bearings, inlet vanes etc.
Incorporate the recommendation of Energy Audit Studies. }
6.1.6
ESP
[
.]
{Note: Check the capacity of the ESP in view of more quantity of inferior quality of fuel
to be burnt in the boiler. Check for the possible requirements of refurbishment
/replacement of Transformer Rectifier sets and ESP controllers, addition of fields,
installation of bag filters etc. for meeting the revised statutory emission norms
prescribed by the pollution control authorities. Incorporate the recommendation of the
Performance Test.}
Summary of R&M Measures
R&M Measures to be adopted for the Boiler and its Auxiliaries have been discussed in
detail at Annexure 6.1 for all the [five] options along with their cost impact for each
option.
6.2

{Discuss in this section the following aspects for each item of the Steam Turbine and
its Auxiliaries:
parameters and
EA studies.
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
[43]
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[Logo of Utility]
requirements.}
6.2.1
Steam Turbine
[
.]
{Note: Check for the possible requirements of refurbishing / replacing the existing LP
Turbine having Baumann Exhaust with more efficient LP turbine designed to suit local
condensing conditions, replacing the HP/IP turbine rotors with three dimensional blade
designs, replacement of HP / IP casings/ diaphragms, gland sealing, inter-stage
packing, internal parts of ESV, IV, CV, servomotors, governing system, turning gear,
jacking oil system etc.}
6.2.2
Condenser
[
.]
{Note: Check for the possible requirements of replacing the condenser tubes,
refurbishment/replacement of online tube cleaning system/ debris filter, application of
anti-corrosive coating on water box/tube plates, replacement of air ejector with vacuum
pump etc. Check the existing capacity of condenser, if a turbine of higher capacity is
proposed. Incorporate the recommendation of Performance Test.}
6.2.3
Ejectors
[
.]
{Note: Check the condition of nozzles and diffusers of starting ejectors and main
ejectors. Check the requirement of replacing the ejectors with the vacuum pumps.
Check the existing capacity of ejectors, if a turbine of higher capacity is proposed.}
6.2.4

[
.]
{Note: Check for the possible requirements of replacing the impellers & bowl
assemblies, retrofitting of energy efficient motors, replacement of recirculation valves,
provision of auto changeover to standby pump, replacement of thrust bearings etc.
Check the existing capacity of condensate extraction pumps, if a turbine of higher
capacity is proposed. Incorporate the recommendation of performance Test.}
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
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6.2.5
[Logo of Utility]
LP Heaters
[
.]
{Note: Check for the possible requirements of replacing the tube bundles with the new
ones having the same material or alternatively with the material of stainless steel,
retrofitting the LP Heaters with the modified ones having better Drain Cooler Approach
etc. Check the existing capacity of LP Heaters, if a turbine of higher capacity is
6.2.6
Deaerator
[
.]
{Note: Check for the possible requirements of replacing the spray nozzles and
internals etc. Check the existing capacity of deaerator, if a turbine of higher capacity is
proposed.}
6.2.7
Boiler Feed Pumps

[
.]
{Note: Check for the possible requirements of replacing the cartridges with energy
efficient models, replacement of booster pumps with modified versions, modification of
cooling water circuit etc. Check the existing capacity of BFPs, if a turbine of higher
capacity is proposed. Incorporate the recommendation of Energy Audit Studies.}
6.2.8
HP Heaters
[
.]
{Note: Check for the possible requirements of replacing the tube bundles with the new
ones having the same material or alternatively with the material of stainless steel,
retrofitting the LP Heaters with the modified ones having better Drain Cooler Approach
etc. Check the existing capacity of HP Heaters, if a turbine of higher capacity is
6.2.9
Critical Piping including valves

[
.]
{Note: Check for the possible requirements of replacing the pipes, valves, fittings,
hangers and supports for MS, CRH, HRH and Feed water piping, check for the
replacement of bends and clamping areas, since these are prone to develop leakage.}
Summary of R&M Measures to be adopted for the Steam Turbine and its Auxiliaries
has been discussed in detail at Annexure 6.2 for all the [five] options along with their
cost impact.
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
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6.3
[Logo of Utility]
Balance of Plant
{Discuss in this section the following aspects for each item of the Balance of Plant:
parameters and
EA studies.
requirements.}
6.3.1
Coal Handling Plant

[
.
]
{Note: Check for the possible requirements of augmenting the capacity of the existing
coal handling plant due to much lower calorific value of coal being received than the
calorific value for which the boiler was designed, requirement of installing additional
wagon tippler, increasing the storage capacity of coal stock yard, refurbishment of coal
crushers, installation of more effective dry fog dust suppression system at Wagon
Tippler, Stock Pile, Transfer Points and Junction Towers, provision of stackerreclaimer and facilities for coal blending etc.}
6.3.2
Ash Handling Plant

[
.
]
{Note: Check for the possible requirements of augmenting the capacity of the existing
ash handling plant due to higher consumption of coal having higher ash content,
improvements in bottom ash handling system/ fly ash handling system, storage
capacity of ash silos & ash dyke, installing of evacuation & disposal system for the dry
fly ash, installing of ash water recycling system (AWRS) for the bottom ash handling
system, providing arrangement for maintaining continuous water blanket over the ash
dyke to prevent pollution due to blowing of fugitive ash from the dried portion of ash
dyke, checking the adequacy of the existing system for 100% utilization of fly ash etc.
etc.}
6.3.3
Water Intake System

[
.
..]
{Note: Check for the possible requirements of installation of Travelling water screens
at the makeup water pump house, replacement of line shafts/ impellers / bowl
assemblies of water intake pumps, motors, piping and valves etc }
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
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6.3.4
[Logo of Utility]

[
.
..]
Note: Check for the possible requirements of renovating the pretreatment plant for a
smaller output rating in view of substantial reduction in the requirement of makeup
water quantity as a result of installation of dry fly ash handling system/ash water
recycling system / increasing the value of COC etc. Check the condition of stirrers,
mixing chambers rotating bridge, chlorination plant etc.}
6.3.5
DM Plant
[
.
..]
{Note: Check for the possible requirements of refurbishing the pressure vessels, pipes,
pumps, air blowers, valves, acid and alkali storage tanks, DM Water tanks etc}
6.3.6
CW & ACW System

[
.
..]
{Note: Check for the possible requirements of installation of Travelling water screens at
the CW pump house, replacement of line shafts/ impellers / bowl assemblies of CW
pumps/ ACW pumps, motors, piping and valves etc}
6.3.7
Cooling Towers
[
.
..]
{Note: Check for the possible requirements of refurbishing of riser pipes water
distribution system, valves, fan motors, gear boxes, splash pipes and fills etc.
Incorporate the recommendation of Performance Test.}
6.3.8
Fire Detection and Protection System

[
.
]
{Note: Check for the possible requirements of replacing the hydrants and sprinklers
which do not work properly, replacement of air compressor, hydro pneumatic tank and
jockey pump, renovation of emulsifier system for the transformers, provision of fire
detection and protection system for the cable galleries etc. Check for the required
changes to be made to ensure that the system meets the statutory requirements of
TAC / LPA of Insurance Association of India.}
Document Number
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6.3.9
[Logo of Utility]
Fuel Oil Handling System

[
.
]
{Note: Check for the possible requirements of replacing the damaged unloading hoses
/ defective portion of fuel oil pipeline, replacement of heat tracing system /pumps/
fittings / valves of fuel forwarding system etc.}
6.3.10

[
.
]
{Note: Check for the possible requirements of replacing the existing reciprocating type
of air compressors with screw type air compressors, replacement of existing air driers
with energy efficient Heat of Compression type air driers, replacement of damaged
pipelines etc.}
6.3.11

[
.
]
{Note: Check for the possible requirements of augmenting the existing air conditioning
and ventilation system including the need of its relocation from relatively dusty to
cleaner location. Explore the option of vapour absorption machines.}
6.3.12
EOT Crane in TG Hall

[
]
{Note: Check for the possible requirements of replacing the damaged / misaligned
portions of railings, installing system for the remote operation & control of EOT Crane
etc. Check the capacity of the crane by carrying out the load test.}
6.3.13

[
]
{Note: Check for the possible requirements of modifying the existing ETP to have zero
discharge in line with the current practice of the Industry / the requirement of most of
the State Pollution Control Boards, to recycle treated water from the ETP for use in
ash handling system / coal dust suppression system etc.}
R&M Measures to be adopted for the Balance of Plant have been discussed in detail
at Annexure 6.3 for all the [five] options along with the cost impact for each option.
Document Number
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6.4
[Logo of Utility]
Electrical System
{Discuss in this section the following aspects for each item of the Electrical System:
parameters and
EA studies.
requirements.}
6.4.1
Generator- Stator
[
.
]
{Note: Check for the possible requirements of replacing the stator winding bars,
replacing the Class B bitumen based insulation with epoxy based Class F insulation
etc.}
6.4.2
Generator-Rotor
[
.
]
{Note: Check for the possible requirements of replacing the existing retaining ring with
new type made of better material, replacement of Desiccant type of dryer with
refrigerant type of dryer, providing the system for on-line dew point measurement of H2,
replacement of excitation system with dual channel Digital Voltage Regulator (DVR)
etc.}
6.4.3
[
.
]
{Note: Check for the possible requirements of replacing the existing Generator
Transformer with higher capacity Generator Transformer in case the capacity of the
unit is being revised upwards. In case the existing Generator Transformer is to be
retained, check for the need of replacing the windings/ bushings/ cooling system/
emulsifier system etc.}
6.4.4

[
.
]
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[Logo of Utility]
{Note: Check for the possible requirements of replacing the existing Transformer with a
new transformer of higher capacity to safely meet the increased auxiliary load of mills,
coal handling plant and Ash Handling plant etc.}
6.4.5
Generator Protection & Synchronization

[
.
]
{Note: Check for the implementation of latest protections. Check for the possible
requirements of replacing the existing electromagnetic / static relays with numerical
relays, replacement of existing system of manual synchronization with Auto
synchronizer etc.}
6.4.6
Station Service Transformer

[
.
]
{Note: Check for the possible requirements of replacing the existing Station Service
Transformer with a new transformer of higher capacity to safely meet the increased
auxiliary load of mills, coal handling plant and Ash Handling plant etc.}
6.4.7
6.6 kV System
[
.
]
{Note: Check for the need of replacement/ retrofitting of the system due to increase in
the electrical load as a result of replacement of existing mills with the higher capacity
mills. Check for the possible requirements of change in the type of Circuit Breakers
with SF6 breakers, replacement of electromagnetic / static type relays, with numerical
relays, replacement of control wiring, providing Interposing relay (IPR) cabinet in
Switchgear / Control Room to control the HT feeders / motors and selected LT
feeders / motors from the DDCMIS etc.}
6.4.8
415 V System
[
.
]
{Note: Check for the need of replacement/ retrofitting of the system due to increase in
the electrical load as a result of addition of additional equipment, if any. Check for the
possible requirements of replacing the existing LT boards with LT boards of draw out
type, installing Air Circuit breakers (ACBs) for motors above 110 kW rating, providing
latest microprocessor based protection for the motors, replacing electromagnetic relay
based protection with numerical relay based protection, installing ammeters for motors
above 30 kW rating and electronic energy meters for motors above 110 kW rating etc}
Document Number
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No.
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6.4.9
[Logo of Utility]
HT & LT Motors
[
.
]
{Note: Check for the possible requirements of replacing/refurbishing the Class B
insulation Motors with Class F insulation energy efficient motors, modification of
motors foundations etc}
6.4.10
DC system
[
.
]
{Note: Check for the possible requirements of augmenting the ventilation system,
replacing / refurbishing the battery charger and batteries, DC Distribution Boards,
improvement of availability of redundant system etc.}
6.4.11
Public Address system

[
.
]
{Note: Check for the possible requirement of a better and clearly audible public
address system with latest modern features for providing good communication inside
the power plant.}
6.4.12
Illumination System
[
.
]
{Note: Check for the possible requirement of a better illumination system for providing
optimum lux level at all important locations of the plant. The possibility of providing
Automatic Switching System should also be checked.}
6.4.13
DG Sets
[
.
]
{Note: Check for the possible requirement of refurbishing/ replacing/ augmenting the
DG Sets for providing the power back up required. Explore the possibility of providing
automatic switch on/off for energy conservation.}
R&M Measures to be adopted for the Electrical System have been discussed in detail
at Annexure 6.4 for all the [five] options along with their cost impact.
Document Number
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6.5
[Logo of Utility]

[The total control and instrumentation system generally requires large scale
replacement owing to obsolescence of the existing equipments.
Integrated microprocessor based closed loop control, open loop control, sequential
control and bulk data acquisition system for SG & auxiliaries, TG & auxiliaries, station
C&I including auxiliaries in hierarchical levels and integrated unit monitoring and
station monitoring systems in the upper level are to be envisaged for the plant.
The unit control and instrumentation system and other major proprietary control
systems will be based on integrated Microprocessor Based Distributed Digital Control
and Management Information System (DDCMIS). Complete operation and control of
Steam Generator, Turbine Generator, Station C&I and auxiliary systems will be carried
out from DDCMIS.
Field process transmitters, Pneumatic control valves & dampers positioners will be
smart type. Each transmitter and positioner will communicate with the control system
in the form of analog signal 4 20 mA DC along with superimposed digital signal
through HART protocol to facilitate configuration, zero adjust, calibration and
diagnostic from remote station in addition to configuration by hand held smart
configurator. Separate PC based configuration station with 22 TFT monitor along with
maintenance and diagnostic facility for HART devices will be provided in case the
features are not achievable in DDCMIS. The DDCMIS will be interfaced with BOP
control systems using soft links. DDCMIS Interface Requirements for Packages will be
as per the Table given below]
Table 6.1
DDCMIS Interface Requirements for Packages
S.No.
System /
package
Control
System /
Scope
Operation From
Local
Contro
l
UCR
Interface with
DDCMIS
Remarks
1.
Coal
Handling
Plant &
Auxiliaries
PLC based /
BOP
Package
Bidder
Yes
No
Redundant, UniDirectional OPC

Link
PLC with
Redundant hot
standby
processor and
necessary
HMI will be
considered.
2.
Ash Handling
Plant &
PLC based /
BOP
Yes
Yes
PLC with
Redundant hot
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S.No.
3.
System /
package
Control
System /
Scope
Operation From
Local
Contro
l
Auxiliaries
Package
Bidder
Fuel Oil
Handling
System
PLC based /
Relay based
/ BOP
Package
Bidder
Yes
[Logo of Utility]
Interface with
DDCMIS
Remarks
Link
standby
processor and
necessary
HMI will be
considered.
Redundant , BiDirectional
PLC with
Redundant hot
standby
processor and
necessary
HMI will be
considered.
UCR
Yes
OPC LINK
4.
Fire Alarm &

protection
System
PLC based /
BOP
Package
Bidder
Yes
Yes

Link
PLC with
Redundant hot
standby
processor and
necessary
HMI will be
considered.
5.
Compressed
Air system
PLC based /
BOP
Package
Bidder
Yes
Yes
Redundant, BiDirectional OPC

Link
PLC with
Redundant hot
standby
processor and
necessary
HMI will be
considered.
6.
HVAC
PLC based /
BOP
Package
Yes
PLC with
Redundant hot
standby
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S.No.
System /
package
Control
System /
Scope
Operation From
Local
Contro
l
Raw Water
System / PreTreatment
Plant
PLC based /
Relay Based
/ BOP
Package
Bidder
Yes
Interface with
DDCMIS
Remarks
Link
processor and
necessary
HMI will be
considered.

Link
PLC with
Redundant hot
standby
processor and
necessary
HMI will be
considered.
UCR
Vendor
7.
[Logo of Utility]
No
(Optional)
8.
DM Plant &
Auxiliaries
PLC based /
BOP
Package
Bidder
Yes
No

Link
PLC with
Redundant hot
standby
processor and
necessary
HMI will be
considered.
9.
Chlorination
Plant &
Auxiliaries
PLC based /
BOP
Package
Bidder
Yes
No

Link
PLC with
Redundant hot
standby
processor and
necessary
HMI will be
considered
10.
Effluent
Treatment
Plant &
PLC based /
Relay based
/ BOP
Package
Yes
No
Redundant, Unidirectional OPC

Link
PLC with
Redundant hot
standby
processor and
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S.No.
System /
package
Control
System /
Scope
Operation From
Local
Contro
l
[Logo of Utility]
Interface with
DDCMIS
Remarks
(Optional)
necessary
HMI will be
considered.
UCR
Auxiliaries
Bidder
11.
CW System
& Auxiliaries
DDCMIS /
BTG
Package
Vendor
Yes
(Option
al)
Yes
through
DDCMIS
Remote I/O
Cabinet
For each set

of CW
systems,
Control &
Monitoring Will
be through
DDCMIS
operating
stations from
CCR as well
as from local
control panel
Room.
12.
ACW System
& Auxiliaries
DDCMIS /
BTG
Package
Vendor
Yes
(Option
al)
Yes
through
DDCMIS
Remote I/O
cabinet
Control &
Monitoring
through OWS
at Central
Control Room
will be
provided.
13.
Switch Gear
system and
Auxiliaries
(Switch Yard)
SCADA
based / 400
kV Switch
Yard Scope
Yes
No
Remote
consoles to be
mounted in
Control Room.
Switch yard
control system
will be
controlled and
monitored
from Local
switch yard
control room.
Generator
synchronizatio
n facility will
be provided
(See
Remar
ks)
Proven OPC
LINK to SCADA
to acquire
monitoring data.
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S.No.
System /
package
Control
System /
Scope
Operation From
Local
Contro
l
[Logo of Utility]
Interface with
DDCMIS
Remarks
UCR
from unit
control room
also through
Hard ware /
soft ware
interface.]
6.5.1
DDCMIS
[The existing control system is old analogue based station controls, which have
become obsolete and spares are no longer available. Hence DDCMIS should be
provided. Boiler controls, turbine controls and station controls should be included in
DDCMIS. DDCMIS operation will be from a set of TFT based Operator Workstations,
TFT based EWS & TFT based shift in charge OWS. LVS will be provided to enable
continuous display of many useful parameters and equipment status.
All Closed Loops, Open Loops as well as monitoring functions of both boiler and
turbine will be included in DDCMIS.
Sequence of Events should be included within DDCMIS within the OWS. Data
Communication system, Historical Storage and retrieval system, plant Performance
Calculations and Optimization System, Management Information System will also be
included in DDCMIS. Automatic Run-back will be provided on loss of critical auxiliaries.
Master Clock system based on Global Positioning System will be provided and it
should be linked to plant DDCMIS and other PLC based system clock.
The DDCMIS will be compatible with OPC, Ethernet, TCP/IP communication for high
speed LAN so that it can be connected seamlessly with other OPC compliant PLC I
DDCMIS.]
6.5.2

[All control loops for boiler as well as TG will be included in the DDCMIS.]
6.5.3

i)
Existing Furnace Safeguard and Supervisory System (FSSS)
[Existing system is old obsolete system based on [..] technology. Existing flame
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[Logo of Utility]
scanners are of old version being obsolete and spares are not available presently.
Hence considering all these facts, fully proven microprocessor based system for
Furnace Safeguard & Supervisory System will be provided for boiler protection i.e.
Master Fuel Trip (MFT), Boiler purge, oil burner controls, Pulverizer sequence control
& protection; control of Seal air fans and scanner cooling fans and fuel oil systems etc.
Furnace supervisory and safeguard System (FSSS) will be preferably implemented in
the DDCMIS or within a proven PLC system with adequate safety, self-diagnostic and
redundancy with fault tolerant hardware and software.
ii) Soot Blower control
As per modern practice in thermal power plants the microprocessor based control
system shall be provided for sequence operation replacing the existing manual
operation.
iii) Automatic Tube leak detecting system
[At present there is no Online Boiler tube leak detection system. Automatic steam leak
detection system will be provided for detecting leaks at different zones of boiler. The
detecting sensors will be mounted in the boiler at suitable locations. The system will
include necessary acoustic signal generator, signal receiver, air purging system, signal
processor & controller, PC with KB & TFT colour monitor, cabinet, junction boxes,
connecting cables and interface to DDCMIS. The system will be able to eliminate the
affect of varying surrounding noise to obtain a high accuracy of leak detection.
Separately isolated 4-20mA DC analog signals will be provided for monitoring the
acoustic level in DDCMIS.]
6.5.4

Turbine Protections
[Existing Turbine Protections are Relay based.Turbine Protections should be shifted to
DDCMIS or within a proven PLC based system with suitable interface with DDCMIS by
hardwire and software.
Existing over speed protection is only mechanical. Existing one tacho-generator gives
speed measurement signal to control room. New eddy current type speed
measurement system (redundant measuring probe and module will be incorporated
within the new Turbine supervisory system. Electronic over speed sensing with tripping
interlocks to be implemented with latest hardwires and software.)
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i)
[Logo of Utility]
Turbine EHC
[The existing Hydraulic governing control will be replaced with electro--hydraulic control
(EHC).
ii) Turbine ATRS
[An automatic run-up system will be provided for safe and reliable automatic startup &
shutdown of the Turbine.
Turbine Supervisory System
[Old electromagnetic type TSI System is installed. TSI can be replaced with new
system (Eddy Current type) with monitoring software.]
iii) Machine Condition Monitoring System
[At present there is no Continuous monitoring and analysis of the mechanical health of
the turbine. This will be performed with proven and latest on-line Rotating Machine
Condition Monitoring Systems. It will display shaft vibration, bearing vibration, key
phasor and other relevant machine data like speed for the Turbine, Generator &
Exciter.
iv) Turbine Stress Evaluator
[At present Turbine Stress Evaluator (TSE) system is not included within the turbine
control and monitoring system. A proven turbine stress evaluation and control system
is to be provided, which will work in conjunction with turbine governing system and
ATRS.
v) Automatic Turbine Testing
[Automatic Turbine Testing (ATT) will be provided as presently it is not included.
vi) HP-LP bypass & Aux PRDS system
[HPLP bypass control will be included in DDCMIS, in place of existing stand alone
control panel. Auxiliary PRDS system control should be included in DDCMIS. PRDS
(2nos. Pressure CV and one Temperature CV) should be replaced by Special critical
zero leak type valves with actuators.]
vii) Gland steam pressure control
[Existing pneumatic control valve is provided with electronic controller. Controller
should be included in new DDCMIS].
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No.
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6.5.5
[Logo of Utility]
Primary, Secondary Instruments

All the existing Primary & Secondary instruments shall be replaced with latest available
instruments. All transmitters shall be replaced with Smart type transmitters with HART
protocol compatibility.
6.5.6
Control Valves
All the existing Control Valves will be replaced with new control valves with pneumatic
actuators having smart HART compatible poistioners
6.5.7
UPS
[Existing UPS system is obsolete and battery condition is also very poor. Hence new
redundant UPS with suitable AC power distribution panel along with VRLS type Battery
set should be provided to cover power supply for DDCMIS and other related control
cabinets and operator stations.]
6.5.8
Analyzers, Steam and Water Analysis System

[Existing SWAS (Steam and Water Analyser System) are not working properly.
Individual analysers are not in working condition. Total monitoring system is mainly
based on manual measurement from plant chemical laboratory. Hence this system is
required to be provided in totality. Complete Steam and Water Analysis System
(SWAS) with dry and wet panel, stainless steel sampling line and sample conditioning
system, analyzer monitors, and stainless steel grab sampling system with tray are to
be considered.
6.5.9

New CEMS will be provided to monitor SOx , NOx , Particulates matter, CO & CO2
emission from the chimney as per the latest guidelines received from the pollution
control board.
6.5.10
Pipes & tubes

[Quality of existing Impulse lines in flue gas systems and other high pressure (more
than 40 kg/cm2) systems are very poor. Hence total impulse lines should be replaced
including root valves and drain valves. Process connection for instruments on line and
vessel will be in accordance to standards such as ASME and other recognized
international standards.]
6.5.11
Cables
[Old instrumentation cables will be replaced with are of 2.5 sq. mm. Height of cable
gallery is very low. Removal of existing cables and laying of new cables in cable gallery
will be very difficult. Suitable ventilation system in cable gallery should be provided.
Terminating of all old field cables (2.5 sq. mm.) into marshalling cabinets and then,
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[Logo of Utility]
using of max 1 sq mm cable from marshalling cabinet to DDCMIS cabinets are to be

followed.]
R&M Measures to be adopted for C&I have been discussed in detail at Annexure 6.5
for all the [five] options along with their cost impact.
6.6
Civil Works
{Discuss in this chapter the following aspects:
i) the nature of damage & distress caused to the foundations and civil & structural
works of TG Building / Boiler Supporting Structure / Coal Handling Plant /Ash Handling
Plant / Water Treatment Plant / Cooling Tower / CW Pump House / Chimney and
Equipment foundations etc. and
ii) the R&M measures to be adopted based on the recommendation of visual
examination, destructive & non destructive tests etc.
requirements.}
6.6.1

[..
]
{Note: Check for the requirement of repair / replacement of the foundations of boiler,
mills and fans etc.}
6.6.2
TG-Building
[..
]
{Note: Check for the requirement of repair / replacement of TG Building foundations,
main and auxiliary columns, beams, bracings, walls, flooring, EOT crane rails etc.}
6.6.3
Chimney
[..
]
{Note: Check for the requirement of repair of concrete surface due to local spalling of
concrete, exposure of reinforcement, damage to corbels etc.}
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6.6.4
[Logo of Utility]
Coal Handling Plant

[
]
{Note: Check for the requirement of repair /replacement to the foundations &
supporting structure of crusher house / coal conveying gallery, repair of concrete and
plastered surfaces of track hopper/ wagon tippler hopper/ CHP control room building,
civil works for the additional wagon tippler if any.}
6.6.5
Ash Handling Plant

[
]
{Note: Check for the requirement of repair of ash silos, ash slurry pump house, ash
pipe racks, pedestals of slurry disposal pipelines, ash dyke etc.}
6.6.6

[
]
{Note: Check for the requirement of repairing the clariflocculator / chemical house /
DM Plant building/ pump house, arresting the water seepage through the structures,
fixing the displaced tiles in the neutralizing pit etc.}
6.6.7
Raw Water Reservoir

[
]
{Note: Check for the requirement of repairing the dyke of the reservoir, de-silting the
reservoir basin, replacement of lining, replacement of tilesetc..}
6.6.8
CW System
[
]
{Note: Check for the requirement of repairing the fore bay, cold water ducts, leaking
joints, anchors of CW piping bends, super structure & basin of cooling towers etc.}
6.6.9
Ash Pond
[
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[Logo of Utility]
]
{Note: Check for the requirement of increasing the height of ash dyke to increase the
capacity of Ash Pond, replacement of lining, replacement of tilesetc..}
6.6.10
Miscellaneous Works
[
]
{Note: Check for the requirement of repairing the civil works of other buildings like,
Administrative building, service building, canteen, stores, security building, de-silting
basin, raw water reservoir, etc.}
R&M Measures to be adopted for the Civil Works have been discussed in detail at
Annexure-6.6 for all the [five] options along with their cost impact.
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FINANCIAL EVALUATION OF R&M OPTIONS
7.1
Introduction
[Logo of Utility]
The scope and technical details of the [five R&M options] considered have already
been discussed. This chapter evaluates the financial implication of the R&M options to
decide whether to go for R&M and if yes, which R&M option is to be adopted for
implementation. The objective of the financial evaluation is to make a comparative
analysis of the financial implications of the [five R&M options] as well as the base case
option of not undertaking any R&M project at all.
7.2
Capital Expenditure for R&M

The estimate of capital expenditure likely to be incurred for each R&M option
comprises dismantling cost, supply cost, construction /erection /commissioning cost,
taxes/duties, interest during construction, financing cost and contingency. The hard
cost of each R&M option was estimated by summing up the estimated cost for the
different components/activities of the R&M project. The cost for different constituent
parts of the project was estimated on the basis of past cost data for similar work
wherever available and/or budgetary quotes. The estimated capital cost of different
R&M options is summarized at Annexure 7.1.
7.3
Impact on Tariff
[The tariff for electricity sent out from this power plant is determined by Tariff Norms of
appropriate Electricity Regulator]. Capitalization of capital expenditure incurred for the
project will affect cost of generation. Capitalization may increase Capacity Charge
where as improvement in plant heat rate may bring down Energy Charge. Owner will
have to take up the regulatory commission for acceptance of the revised tariff. The
estimated Cost of Generation for different R&M options is shown in Annexure 7.2.
7.4
Basis of Comparison
Net Present Value (NPV) and Internal Rate of Return (IRR) have been used to
compare the relative financial merit of different R&M options. Considering that
expected economic plant life after R&M under different R&M options differ among
themselves and also from the residual plant life without R&M, NPV has been used as
the criterion for final decision as to whether R&M will be carried out and which R&M
option will be adopted. Net Present Value is the sum of present value of all the project
cash outflows and inflows using an appropriate discount rate. IRR is another metric
used to assess the financial attractiveness of the different R&M options. IRR is the
discount rate that makes the project NPV zero.
For the sake of comparison of different R&M options, the revenue stream of all the
options have been calculated on the basis of a single indicative tariff per kWh of
electricity for each year. Assuming that the regulator will prefer minimum tariff, the
indicative tariff per unit for a year has been taken to be the minimum value among the
calculated Costs of Generation (COG) as per Electricity Regulators Norm for the
different R&M options and base case tariff for that year. The estimated capital cost of
each R&M option is used for calculation of Return on Equity and Depreciation.
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Normative Debt Equity ratio and depreciation rates are as per Tariff Regulation of
appropriate Electricity Regulator. The revenue from electricity generation during a
year in which plant is shut down is calculated considering normative availability/plant
load factor. The loss of generation due to shut down for R&M is accounted for by
considering that equivalent amount of electricity will have to be procured from the
grid/market at the prevailing tariff. Therefore, the tariff at which power will be procured
during shut down also affects the financial analysis. The negative cash flow due to
shut down is calculated as the product of loss of generation and average tariff at which
power will be procured from the grid net of variable cost .
7.5
Cost of Generation calculation is done as per Tariff norms of appropriate Electricity

Regulator
O&M cost is taken as per Tariff norms of appropriate Electricity Regulator
Average annual Availability/PLF of [85%] is considered for all R&M options for
financial analysis. This is in line with Normative Availability Factor prescribed by
Electricity Regulator. If any unit is operating at PLF higher than 85%, such higher
PLF may be considered for Financial Analysis.
Operating life of plant without R&M is [ years]. The lower plant life in base case
captures the cost of closure of unit instead of undertaking R&M.
Without R&M, the present Availability/PLF is considered [.% with linear reduction
of PLF to .% in . year.]
[For calculating the financial quantities of the Base Case of operating the plant for
the residual economic life without undertaking any Renovation and Modernization
activity, actual observed average annual Heat Rate is considered the plant Heat
Rate during RLA and the plant heat rate is considered to increase by [ %] per
annum. For calculating the financial quantities of each option for which some
Renovation & Modernization is undertaken, the design/guaranteed heat rate with
operating margin of [6.5%] is considered the plant Heat Rate for all the years
during the economic life after Renovation & Modernization.]
In line with the approach followed in Tariff Norms of Electricity Regulators, single
value is considered for Plant Gross Heat Rate for financial analysis over the plant
life after R&M. This single value of Heat Rate includes suitable operating margin
over Design Heat Rate. Similarly, single value of auxiliary power consumption and
specific oil consumption is considered over the entire plant life after R&M for
financial analysis.
Specific oil consumption is considered [actual consumption in ml/kWh without
R&M and 1 ml/kWh with R&M]
An operating margin of [6.5%] on Design Gross Heat Rate is considered for all
R&M options. For base case without R&M, [Heat Rate is escalated by .% every
year from present actual average heat rate.]
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Present coal price and fuel oil prices are considered to be equal to the actual coal
price and fuel oil prices for the unit.
The discount factor and coal price escalation rate are taken to be [that notified by
appropriate Electricity Regulator].
Table- 7.1
Factors for Financial Analysis
Description
7.6
Value of Factors
Escalation rate for domestic coal
[%]
Discount Rate
[.%]
Return on Equity
[.%]
Interest Rate on Rupee Term Loan
[%]
Interest Rate on Forex Loan plus cost of Forex Rate

Coverage
[%]
Comparison of Input for Different Options

Table 7.2
Inputs for Options
Base
Option I
Case(No
R&M)
Option II
Option III Option IV
Option V
Capacity (MW)
[.]
[.]
[.]
[.]
[.]
[.]
Operating Life
[.]
[.]
[.]
[.]
[.]
[.]
--
[.]
[]
[.]
[.]
[.]
--
[.]
(in years)
Shutdown for
R&M
(months)
Project
Implementation
Period (months)
Document Number
LII-GETS12021-G-00100-002
[.]
[.]
[.]
[.]
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Base
Option I
Case(No
R&M)
Gross Heat
Rate (kcal/kWh)
Coal GCV
[]
[]
Option II
[..]
[Logo of Utility]
[]
[.]
Option V
[..]
(actual)
[]
[]
[..]
[]
[.]
[..]
[]
[..]
[]
[.]
[..]
(actual)
Operating
Margin on Heat
Rate
Annual
Degradation of
Heat Rate
[..]
Auxiliary
Consumption
[]
[]
[]
[]
[]
[]
Specific Coal
Consumption
[]
[]
[]
[]
[]
[]
Rate of annual
increase of
Specific Coal
Consumption
[]
Specific Oil
Consumption
[]
[]
[]
[]
[]
[]
Rate of annual
increase of
Specific Oil
Consumption
[]
Project Cost:
----
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Tariff for
purchase of
Power during
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Base
Option I
Case(No
R&M)
Option II
[Logo of Utility]
Option V
unit shutdown
7.7
Selection of R&M Option

The NPV, IRR and Payback Period calculation for different R&M options and NPV for
base case is summarized at Annexure-7.3. R&M option [.] is found to be having the
highest NPV and hence selected for implementation.
Table 7.3
Financial Evaluation of R&M Options
Option
Levelized
COG
(Rs/kWh)
IRR (%)
NPV
(Rs Million)
Differential
NPV w.r.t
Base Case
(Rs Million)
Payback
Period
(Years)
Base
Case( No
R&M)
I
[.]
[.]
[.]
[.]
[.]
[.]
[.]
II
[.]
[.]
[.]
[.]
[.]
III
[.]
[.]
[.]
[.]
[.]
IV
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
The selected R&M option [.] has Differential NPV of Rs [.] Million with respect to
the base case for a project cost of [.]. The selected R&M option has IRR of [%]
against cost of capital of [. %]. The selected R&M option has payback period of [.]
years.
7.8

R&M projects are complex in nature and are associated with many uncertainties. The
cost and time for execution of the project may overshoot estimates and the project
may fall short of achieving its objectives. The financial viability of the selected R&M
option should have some level of tolerance for such uncertainties.
Renovation & Modernization projects are associated with high risk of Time overrun and
cost overrun due to unique nature of each project and also due to the complexities
and uncertainties associated with retrofitting work. The reasons for Time/Cost overrun
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are discussed in the Chapter on Risks (Chapter-11). Time overrun itself is a reason for
Cost Overrun due escalation of hard cost, increase in overheads and increase in
interest during construction. Therefore, R&M projects very often run into time overrun
and cost overrun simultaneously. Time and/or cost overrun adversely affect the
financial viability/attractiveness of R&M projects by negatively affecting Net Present
Value and Internal Rate of Return of the project.
The three prime objectives of any R&M project are Heat Rate improvement, Electricity
Output restoration/up rating and Plant Availability/Reliability enhancement with
concomitant adverse impact on project financials. R&M projects are associated with
the risk of partially or fully failing to achieve these objectives. Failure to achieve the
desired Heat Rate may itself contribute to less than targeted electrical output.
Therefore, in many cases, R&M projects are likely to miss Heat Rate and Output
objectives simultaneously.
The financial impact of certain level of cost overrun, time overrun and shortfall in
performance is depicted in Table-7.4.
Table 7.4
Impact of Adverse Scenarios on Selected R&M Option
NPV
(Rs Million)
Differential
NPV w.r.t
Base Case
(Rs Million)
Scenario
Levelized
COG
(Rs/kWh)
IRR (%)
Cost Overrun
(+10%)
[.]
[.]
[.]
[.]
Cost Overrun
(+15%)
[.]
[.]
[.]
[.]
Time overrun (+6

months)
[.]
[.]
[.]
[.]
Time overrun
(+12months)
[.]
[.]
[.]
[.]
Time overrun
(+18months)
[.]
[.]
[.]
[.]
Cost Overrun
(+10%) and Time
overrun (+6 months)
[.]
[.]
[.]
[.]
Cost Overrun
(+20%)
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NPV
(Rs Million)
Differential
NPV w.r.t
Base Case
(Rs Million)
Scenario
Levelized
COG
(Rs/kWh)
IRR (%)
Cost Overrun
(+15%) and Time
overrun (+12
months)
[.]
[.]
[.]
[.]
Cost Overrun
(+20%) and Time
overrun (+18
months)
[.]
[.]
[.]
[.]
Capacity shortfall(-2
MW)
[.]
[.]
[.]
[.]
MW)
[.]
[.]
[.]
[.]
MW)
[.]
[.]
[.]
[.]
Heat Rate Increase

(+1%)
[.]
[.]
[.]
[.]
Heat Rate Increase

(+2%)
[.]
[.]
[.]
[.]
Heat Rate Increase

(+4%)
[.]
[.]
[.]
[.]
Capacity shortfall (-2

MW) and Heat Rate
Increase (+1%)
[.]
[.]
[.]
[.]

MW) and Heat Rate
Increase (+2%)
[.]
[.]
[.]
[.]

MW) and Heat Rate
Increase (+4%)
[.]
[.]
[.]
[.]
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NPV
(Rs Million)
Differential
NPV w.r.t
Base Case
(Rs Million)
Scenario
Levelized
COG
(Rs/kWh)
IRR (%)
Availability variation
(-3%)
[.]
[.]
[.]
[.]
Availability variation
(-5%)
[.]
[.]
[.]
[.]
{Note: Identify the scenarios for which the NPV of chosen R&M option becomes
negative and analyze them in detail. Discuss the likelihood of occurrence of each such
negative NPV scenarios. If a negative NPV scenario appears to be highly unlikely or
remote possibility, then it may be neglected. However, in case a negative NPV
scenario has a fair chance of becoming a reality, the impact of such a scenario on the
owner utility may be deliberated upon and accordingly decide whether to go ahead
with the implementation of the chosen R&M option.}
If the Project qualifies for any financial benefit due to reduction in carbon emission or
enhancement of energy efficiency, resulting from Renovation and Modernization, it will
enhance the financial viability/attractiveness of the R&M Project. However, it will be
project specific. In case the project is likely to get any such benefit, it shall be factored
into the financial evaluation. }
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[With growing worldwide concern regarding carbon emission and depletion of
energy resources, governments and international bodies are trying to put in place
incentive mechanisms to encourage reduction in carbon intensity of economic
activities and promote energy efficiencies. The various initiatives in this regard
are evolving both nationally and internationally. Projects that lead to carbon
emission reduction and energy efficiency improvement have the potential to earn
carbon credit and energy efficiency credit that can be sold and serve as an
additional revenue stream.
The R&M project will increase plant efficiency and reduce plant heat rate and
specific coal consumption. This in turn, will result in reduction of emissions of
Green House Gas carbon dioxide (CO2) per unit of electricity generated. The
selected R&M option envisages change in plant design (particularly change in
turbine) so as to increase its efficiency beyond the original design efficiency and
involves additional investment on this account. This R&M project may qualify for
carbon credit benefits. Further, implementation of this energy efficient R&M
project involves overcoming technological barriers as infrastructure for this kind
of project implementation is not well established in India. Carbon Credit benefit
will help make this project viable which is as such a challenging project from
financial and technological stand point.]
{There are various mechanisms such as Clean Development Mechanism under
Kyoto Protocol, Verified Carbon Standard, National Action Plan on Climate
Change (PAT mechanism of National Mission on Enhanced Energy Efficiency)
etc. that can be explored to have financial benefit on account of reduction in
carbon emission and enhancement of energy efficiency. However, success in
securing any benefit under these schemes will be project specific.}
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Feasibility Report For R&M of Unit No.[..] of [Name of the Power Plant]
PROJECT FINANCE AND MARKET SCENARIO
9.1
About the Utility
[Logo of Utility]
{Give a description of the background of the company including its inception,

history, ownership, nature of business, operating power stations portfolio,
projects under implementation, R&M initiative etc.}
9.2
Financial Performance
The balance sheet and income statement information of Utility for the last 3
financial years is summarized below:
Table 9.1
Profit and Loss Statement Particulars
Amount in Rs.
Crores
Income from Sale of Power

Other Income
Total Income
Fuel Cost
Employee Expenses
Other Expense
PBDIT (Profit Before Depreciation,
Interest and Tax)
Depreciation and Amortization
PBIT (Profit Before Interest and Tax)
Interest Expense
PBT (Profit Before Tax)
Tax
PAT (Profit After Tax)
Balance Sheet Particulars
Document Number
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Amount in Rs
Crores
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[Logo of Utility]
Fixed Asset/CWIP
Less Accumulated Depreciation
Net Fixed Asset
Investments
Current Assets excluding cash
Cash
Total Asset
Long Term Loan
Working capital Loan
Equity Share Capital
Reserves and Surplus
Total Liability
9.3
Means of Finance
[Utility is implementing the project by leveraging the existing balance sheet to
raise the debt required for the project. At present the Company has a debt equity
ratio of , which is being leveraged to finance various projects including this
R&M project.
The cost of the Project is estimated to be Rs. [] million. Utility plans to fund it
at a debt-equity ratio of 70:30, which is same as the normative debt equity ratio
for financing of generation projects by the Central Electricity Regulatory
Commission (CERC) in the CERC (Terms and Conditions of Tariff) Regulations
2009. The debt and equity requirement for the Project works out to approximately
Rs. [] million and Rs. [] million respectively. Utility plans to fund the
equity component from internal accruals. Utility plans to raise the debt
component of the Project cost through a combination of rupee term loan and
foreign currency loan as follows]:
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[Logo of Utility]
Table 9.2
Means of Financing
Means of Financing
Amount
Equity
[.]
Debt:
[.]
Rupee Term Loan
[ .]
Foreign Currency Loan
[.]
Total
[.]
[Given the strong balance sheet, the utility can support this kind of financing
arrangement.]
9.4
Market Scenario
{Discuss about the scarcity and demand of power in the state or region where the
project is located. Discuss about the likely prospect of future demand growth and
infer about the prospect of demand for power from the project after
implementation}
Table 9.3
Energy and Peak Deficit in Electricity supply during the last Financial
Year
Period
Peak
Demand
Peak
Met
Peak
Deficit/
Surplus
Peak
Deficit/
Surplus
Energy
Requiremen
t
Energy
Availability
Energy
Deficit/
Surplus
Energy
Deficit /
Surplus
(MW)
(MW)
(MW)
(%)
(MU)
(MU)
(MU)
(%)
India
130,250
115,847
-14,403
-11.1
936,568
857,239
-79,329
-8.5
[Region]
[42,352]
36509
-5,843
-13.8
290423
257,408
-33,015
-11.4
[State]
21069
16417
-4,652
-22.1
141464
117804
--23660
-16.7]
[Availability of power in the state is not adequate to meet the present

requirement. With rapid economic growth and socio-economic development, the
power deficit is likely to widen in coming years. Therefore, the power generated
from the renovated unit is likely to be sold without any special effort. Therefore,
there
is
no
demand-side
constraint
for
this
R&M
project.]
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10
[Logo of Utility]

[The scope of R&M works was decided on the basis of the most attractive option
which was selected after the cost-benefit analysis and detailed study of various
options recommended by R&M Consultant. For implementing the R&M Project,
the total work will be divided in suitable number of packages. A PERT Chart is
attached with this Report highlighting the various timelines, parallel activities and
critical paths for the implementation of the R&M project. For the selection of R&M
Contractors, the tendering procedure and bidding norms will be designed to
ensure a fair and transparent competition.]
10.1
Project Team
[
]
{Explain the organization structure of the Project Team along with the
Organization Chart}
10.2
Project Schedule
[
]
{Discuss the project completion schedule along with the schedule of completion
of critical activities. Refer Annexure- 10.1}
10.3
Project Management
[
]
{Discuss the various aspects of Project Management like, Contracting,
Engineering, Procurement, Construction, Erection and Commissioning so as to
ensure that the quality of work conforms to relevant codes / standards and
statutory requirements.}
10.4
Project Monitoring
[
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[Logo of Utility]
{Discuss the methods to be used for regular monitoring the progress of R&M
activities, holding of progress review meetings etc to ensure the timely and
successful completion of Project.}
10.5

[
]
{Discuss the role of the R&M Consultant to carry out the activities from initial
study stage up to the stage of finalizing the R&M contract and to facilitate
approval from regulatory agencies if required.}
10.6
Role of the ISC Consultant

[
]
{Discuss the role of the Implementation Support Consultant for the review of
design documents & drawings to ensure compliance with the spirit, intent &
contents of the EPC contract, inspection & testing before dispatch, site
supervision and witnessing of Performance Guarantee Tests of the equipments.}
10.7
Quality Management
[
]
{Discuss the aspects of Field Quality Plans to ensure that the work performed by
the contractor is as per the relevant codes / standards and statutory
requirements.}
10.8

After the commissioning of the unit post completion of R&M works, the unit shall
be tested to demonstrate the following Guaranteed Parameters as per the
provisions of the R&M Contract.
Table 10.1
Performance Guarantee Parameters
S. No.
1.0
Performance Guarantee Parameter
Value
Gross Output for the unit at Generator

terminals at 100% TMCR
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[]
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S. No.
2.0
3.0
4.0
5.0
6.0
7.0
10.9
[Logo of Utility]
Value
[]
Steam Turbine Heat Rate for the unit

at100% TMCR conditions with 0%
makeup.
Boiler Efficiency at 100% TMCR
conditions while firing design coal
Auxiliary Power Consumption@ 100%
TMCR while firing design coal
Emissions of SPM @ 100% TMCR while
firing worst coal
Noise Level during day time at plant
boundary.
Noise Level during night time at plant
boundary.
[]
[]
[]
[]
[]
Liquidated Damages
The R&M Contract shall have provisions of levying Liquidated Damages (LD) for:
a) Delay in Completion of the Project and
b) Shortfall in Performance.
LD for delay in shall accrue at a rate of Rs. [] per MW per day for each day of
delay up to [] days of delay and Rs. [] per MW per day for each day of delay
beyond [] days of delay. LD for shortfall in performance of the Unit shall be as
per the values given in the following table.
Sl. No.
Condition
1.0
Gross Output
2.0
Turbine Heat Rate For each 1 kCal/kWh of

increase
Steam Generator For every 0.1% short fall
efficiency
in efficiency
Auxiliary
Power For each 1 kW of
Consumption
increase
3.0
4.0
10.10
Parameter
LD Amount
[]
For each kW of shortfall.
[]
[]
[]

[
]
{Discuss the steps to be taken for the maintenance of healthy and safe working
environment with the aim to complete the project without any accident and any
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adverse effect on the health of manpower. Discuss also the implementation of

HSE Plan by the EPC contractor.}
10.11
Supply of Spares and Special Tools and Tackles

[
]
{Discuss the R&M Contractors scope to include the supply of spares and special
tools & tackles.}
10.12
Training
[
]
{Discuss the R&M Contractors scope to impart training to the O&M staff of the
utility for the required up-gradation in their skills.}
10.13
O&M Manuals
[
]
{Discuss the R&M Contractors scope to prepare and submit sufficient number of
O&M Manuals, Technical Diaries indicating various Equipment Specifications,
Process Parameters, Key Schematic Diagrams and As Built Drawings.}
10.14

[
]
{Discuss the O&M Philosophy of the utility to carry out safe, efficient and reliable
plant operation of the plant in compliance with environmental legislation. Discuss
the strengthening of existing O&M Organization on modern lines. The O&M
organization should necessarily include an Operation & Efficiency Cell to
evaluate the actual efficiency, Heat Rate and Cost Of Generation on day to day
basis, a Maintenance Planning Department for maintaining updated data base of
assets of the unit as well as for carrying out condition monitoring of the rotating
equipments on a weekly basis and for detailed planning of Annual and Capital
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[Logo of Utility]
Overhauls. A Trip Committee to diagnose the root cause of trippings and to

minimize the incidents of forced outages should be set up.}
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11
[Logo of Utility]
RISKS
Renovation and Modernization projects are very complex in nature and
associated with high level of uncertainty. The various risk factors along with
mitigation measures are discussed below.
11.1

Information and inference flowing from Condition Assessment, Residual Life
Assessment and Life Extension studies forms the basis of planning, designing,
costing and tendering of R&M projects. However, these reports may not give
accurate idea about actual state of the plant and equipment. Similarly, the
rehabilitation and retrofitting programme may not lead to the intended life,
reliability and performance of the plant. In some cases serious damage might be
detected for plant and equipment during the implementation stage which could
not be detected during the CA studies. Such surprises may adversely affect the
cost estimate and schedule.
The probability and impact of such risks may be moderated by designing proper
condition assessment plans. Further, contingencies may be built into cost
estimates and contractual clauses may be suitably designed to take care of such
surprises.
11.2
Regulatory Risk
The capital expenditure incurred for the R&M project has to be serviced by
suitable electricity tariff. If the concerned Electricity Regulatory Commission does
not allow adequate tariff to cover the expenses incurred, it will adversely affect
the cash flow and net worth of the owner.
The regulatory risk may be mitigated by designing and implementing the R&M
Project in compliance and in sync with the extant regulatory regime.
11.3

There is limited availability of competent contractors and personnel for carrying
out R&M works. There is dearth of contractors and personnel with expertise and
experience in implementation of energy efficient R&M works.
Government and industry bodies can play big role in mitigating this risk by taking
initiative expands contractor base and talent pool. Owner on its part can
somewhat mitigate this risk by designing tendering process and contracts that
encourages better participation by available contractors.
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11.4
[Logo of Utility]
Risk of Non-Availability of Spares.

As the units are very old, there may be difficulty in sourcing many spare parts.
This risk may be obviated in some cases by devising suitable sourcing strategy
or design modifications or reverse engineering.
11.5

As R&M of the complete plant calls for shutdown for considerable time and there
is acute shortage of electricity, the grid condition may not permit shutdown
period. This risk may be mitigated by proper planning and taking all stakeholders
into confidence during the planning phase and adhering to the planned schedule.
11.6
Financing Risk
The owner may find it difficult to arrange equity and debt financing for the R&M
project. This risk may be mitigated by proper financial planning. Similarly, the
R&M contractor may face cash flow problem. This risk may be mitigated by
specifying suitable financial qualification criteria in tender specification and
incorporating suitable payment term in the contract.
11.7
Implementation Risk
Poor implementation of project may lead to cost and/or time overrun and
deficiency in quality. This risk may be mitigated by efficient Project Management
set up and selection of reliable R&M contractor.
11.8

The renovated plant and equipment may not perform as envisaged due to
deficiency in design, manufacturing and O&M practices. The risk of
underperformance due to design and manufacturing shortcomings may be
managed by selecting reliable contractor and incorporating appropriate LD
clause in the contract. The risk of O&M deficiency can be mitigated by proper
training of O&M personnel.
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
[81]
15.01.2016
12
[Logo of Utility]

{Discuss in this chapter, the need of compliance to the conditions prescribed by
MOEF and State Pollution Control Board (SPCB)}
12.1

[
]
{Discuss the role of Environment Monitoring Cell established at the project.
Discuss the steps to be taken for strengthening the above cell to monitor and
control the environmental impacts from the renovated plant, as per the revised
stringent norms prescribed by the regulating authorities.}
12.2
Stack Emissions
[
]
{Discuss the present levels of emissions of SPM, SO2, NOx and NH3 from the
stack, levels of Ground Level concentrations and the pollutants in the liquid
effluents with respect to the statutory norms vis a vis the levels of emissions after
the implementation of R&M Project. Discuss the methods and frequency to be
adopted by the utility for monitoring and controlling these emissions as per the
revised conditions prescribed by the regulating authorities.}
12.3

[
]
{Discuss the National Ambient Air Quality Standards prescribed by MOEF and
SPCB. Discuss the methods and frequency to be adopted by the utility for
monitoring and controlling the Ground Level Concentrations (GLC).}
12.4
Liquid Effluents
[
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
[82]
15.01.2016
[Logo of Utility]
{Discuss the quality of liquid effluents permitted by SPCB from different systems
of the plant like, effluent from Water Treatment Plant, Boiler Blow down, Cooling
Tower Blow down, recycled water from ash pond and sewage disposal from plant
and colony. Discuss the recycling of ash water from ash pond and reuse of
Cooling Tower Blow down for ash handling and coal dust suppression. Discuss
the proposal of zero discharge, if applicable to your project.}
12.5
Noise
[
]
{Discuss the noise level permitted during day and night and methods proposed to
contain the noise level produced from power plant equipment within the limits
imposed.}
12.6
Ash Utilization
[
]
{Discuss the norms for the utilization of ash from the thermal power plants as per
the latest notification from MOEF. Discuss the quantum of fly ash & bottom ash
to be produced from the plant and implementation of ash utilization plan by the
utility, after the completion of R&M project. Please note that as per MoEF
notification dated 3rd November 2009, all the coal and lignite based thermal
power stations operating before the date of the above notification are required to
achieve the target of 100% utilization of fly ash before the expiry of a period of
five years from the date of issue of the said notification.}
12.7
Corporate Social Responsibility

[
]
{Discuss the initiatives proposed to be taken by the Project to actively contribute
to the social and economic development of the weaker sections of the
communities around which the Project is going to operate.}
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
[83]
15.01.2016
[Logo of Utility]
ANNEXURE-6.1
Components
Furnace
Recommendation
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Drum
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Down Comers
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Water Walls
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Super Heaters
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Re-Heaters
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Economiser
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Pressure Parts
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[84]
15.01.2016
Components
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Oil Burners
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Low Nox Burners
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Refractory
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
insulation
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Buckstays
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Air pre-Heater
Oil guns
Igniters
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[85]
15.01.2016
Components
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
Ducting
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Wall Soot blowers
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
LRSBs
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Pent House
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Attemperators
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Bottom Ash
Hoppers
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Clinker Grinder
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
PA Fans
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Coal Mills
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[86]
15.01.2016
Components
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
ID Fans
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
FD Fans
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
ESP
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Any other systems
Cost Impact for Boiler & Auxiliaries [.]
{Note: Under Columns I to V, indicate ( ) if the specific proposal is applicable and (x) if the same is not applicable.}
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[87]
15.01.2016
[Logo of Utility]
ANNEXURE-6.2
STEAM TURBINE & AUXILIARIES
Components
Steam Turbine
Recommendation
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Ejectors
[....]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Condensate
Extraction Pumps
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Condenser
LP Heaters
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[88]
15.01.2016
Components
Deaerator
Boiler Feed Pumps
HP Heaters
Document Number
LII-GETS12021-G-00100-002
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[....]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page No.
Date of Issue
05
[89]
15.01.2016
Components
Critical Piping
Any other systems
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Cost Impact for Steam Turbine & Auxiliaries [.]

Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[90]
15.01.2016
[Logo of Utility]
ANNEXURE-6.3
BALANCE OF PLANT
Components
Coal Handling Plant
Ash Handling Plant
Water Intake System

Document Number
LII-GETS12021-G-00100-002
Recommendation
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page No.
Date of Issue
05
[91]
15.01.2016
Components
Water Pre-Treatment
Plant
DM Plant
CW & ACW System
Cooling Towers
Fire Fighting System
Document Number
LII-GETS12021-G-00100-002
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[....]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[...]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[....]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[...]
[..]
[..]
[..]
[..]
[..]
[..]
[.. .]
[...]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[....]
[...]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[...]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page No.
Date of Issue
05
[92]
15.01.2016
Components
Fuel Oil Handling

system
Compressed Air
System
Air Conditioning &
Ventilation System
Effluent Treatment
Plant
Any other systems
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Cost Impact for Balance of Plant [.]

Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[93]
15.01.2016
[Logo of Utility]
ANNEXURE6.4
ELECTRICAL SYSTEM
Components
Generator Stator
Generator Rotor
Unit Auxiliary
Transformer
Recommendation
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[94]
15.01.2016
Components
Generator Protection and

Synchronizer
Station Service
Transformer
6.6 kV System
415 V System
HT & LT motors
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[...]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[95]
15.01.2016
Components
DC System
Public Address System
Illumination System
DG Sets
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[96]
15.01.2016
Components
Any other Systems
Recommendation
[Logo of Utility]
Reasons
[.]
Cost
Impact
[.]
[..]
Options
II
III
IV
[..]
[..]
[..]
[..]
[..]
Cost Impact for Electrical System [.]

Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[97]
15.01.2016
[Logo of Utility]
ANNEXURE 6.5
CONTROL AND INSTRUMENTATION
Component
DDCMIS
Soot Blowers
Burner Tilt
Document Number
LII-GETS12021-G-00100-002
Recommendation
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page No.
Date of Issue
05
[98]
15.01.2016
Component
Boiler temperature MI
thermocouple ( K-Type)
Boiler protections
Turbine Protection
Turbine Controls -EHC

Document Number
LII-GETS12021-G-00100-002
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page No.
Date of Issue
05
[99]
15.01.2016
Component
Turbine -ATRS
Turbine supervisory system
Machine conditioning monitoring

system
Automatic turbine testing
Document Number
LII-GETS12021-G-00100-002
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page No.
Date of Issue
05
[100]
15.01.2016
Component
Turbine Stress Evaluator ( TSE)
HP LP Bypass , PRDS
Gland steam pressure control
Control valves/ Dampers
Furnace Draft
Total Air Flow
Document Number
LII-GETS12021-G-00100-002
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page No.
Date of Issue
05
[101]
15.01.2016
Component
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
Mill A TEMP to --- MILL F TEMP
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
SH STM TEMP
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
RH STM TEMP
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
DRUM Level
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
BFP Scoop Tube
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Deaerator level
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Deaerator press
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Hot well LVL
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
HP Heaters LVL 5,6 & 7( 3 no)
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
LP heaters LVL 2,3 GC2 &4 ( 4

no)
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Fuel oil
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
BFP Recirculation valve
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Feed water control valve
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[102]
15.01.2016
Component
Transmitters
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Pressure / DP Gauges
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Temp Gauges
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Pressure / DP Switch
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Temp Switch
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
RTD / TC s
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Level measurement
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Flow measurement & primary

Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[103]
15.01.2016
Component
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
flow sensors
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Fuel flow measurement
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Analyzers
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
UPS
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Impulse pipe
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Flow measurement & primary

flow sensors
Any other systems
Cost Impact for Control & Instrumentation [.]

Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[104]
15.01.2016
[Logo of Utility]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[105]
15.01.2016
[Logo of Utility]
ANNEXURE-6.6
Civil Works
Components
Boiler Foundations
Mill Foundations
Fan Foundations
ESP Foundations
TG Building
Recommendation
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[...]
[..]
[..]
[..]
[..]
[..]
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[...]
[...]
[..]
[..]
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[..]
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[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[..]
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[..]
[..]
[..]
[...]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[106]
15.01.2016
Components
Chimney
Coal Handling Plant
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[107]
15.01.2016
Components
Ash Handling Plant
CW Pump House
Cooling Towers
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[...]
[..]
[..]
[..]
[..]
[..]
[..]
[...]
[...]
[..]
[..]
[..]
[..]
[..]
[..]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[108]
15.01.2016
Components
Miscellaneous Works
Any other Systems
Recommendation
[Logo of Utility]
Reasons
Cost
Impact
Options
II
III
IV
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
[.]
[.]
[..]
[..]
[..]
[..]
[..]
[..]
Cost Impact for Civil Works [.]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[109]
15.01.2016
[Logo of Utility]
ANNEXURE-7.1
SUMMARY OF CAPITAL COST FOR VARIOUS R&M OPTIONS
Sl. No.
Item
FC
IC
Total
Equiv. Rs.
Rs.
Rs.
Civil Works
[...]
[...]
[...]
Plant & Equipment
[...]
[...]
[...]
2.1
Mechanical Equipment
[...]
[...]
[...]
2.2
Electrical Equipment
[...]
[...]
[...]
2.3
Miscellaneous Equipment
[...]
[...]
[...]
[...]
[...]
[...]
Sub-Total (2.0)
Contingency
[...]
[...]
[...]
Pre Commissioning Expenses
[...]
[...]
[...]
Project Engineering and

Management
[...]
[...]
[...]
Project Cost excluding IDC and

FC (1.0 to 50)
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
6
Financing Charges
7
Interest During Construction (IDC)
IDC + Financing Charges
Project Cost incl. IDC &FC (1.0 to
7.0)
{Note: Project Capital Cost Summary for each of the R&M option is to be attached.}
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
[110]
15.1.2016
[Logo of Utility]
ANNEXURE 7.2
COST OF GENERATION (COG) CALCULATION FOR VARIOUS R&M OPTIONS
Year
10
11
12
13
14
15
16
17
18
19
20
PLF (%)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Heat Rate
(kCal/kWh)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Secondary
Fuel
Consumption
(ml/kWh)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Landed Cost of
Coal
(Rs/tonne)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Landed Cost of
Secondary
Fuel (Rs/KL)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Auxiliary
Consumption
(%)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Energy
Generated
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[111]
15.01.2016
[Logo of Utility]
(MU)
Energy Sent
Out (MU)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Energy Charge
per Unit
(Rs/kWh)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Annual Energy
Charge (Rs
Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Return on
Equity (Rs
Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Interest on
Loan Capital
(Rs Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Interest on
Working
Capital (Rs
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[.]
Energy
Charges:
Capacity
Charge:
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[112]
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[Logo of Utility]
Million)
Depreciation
(Rs Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[]
O&M Charge
(Rs Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[]
Secondary
Fuel Charge
(Rs Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[]
Capacity
Charge per
Unit (Rs/kWh)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[]
Annual
Capacity
Charge (Rs
Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[]
Cost of
Generation
(Rs/kWh)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[]
Discounting
Factor
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[]
[.]
[]
[.]
[.]
[]
[.]
[]
[]
Levelized
Cost of
Generation
[.]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[113]
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[Logo of Utility]
(Rs/kWh)
{Note: Cost of Generation calculation for each of the R&M option is to be attached.
The number of years in the above table is indicative only. The CoG calculation will be done for each option for the number of years
spanning the economic plant life after R&M. For base case, the calculation will be carried out for the residual life of the plant. }
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[114]
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[Logo of Utility]
ANNEXURE-7.3
CASH FLOW AND RETURN ANALYSIS FOR VARIOUS R&M OPTIONS
Year
-2
-1
PLF (%)
10 11 12 13 14 15 16 17 18 19 20
[...] [...] [...] [...] [...] [...] [...] [...] [...] [...] [...] [...] [...] [...] [...] [...] [...] [...] [...] [...]
(Normative PLF for

R&M options and
expected PLF for base
case)
Average Heat Rate
(kCal/kWh)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Auxiliary Consumption
(%)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Coal GCV (Kcal/kg)

Specific Coal
Consumption
(kg/kWhr)
Specific Oil
Consumption
(ml/kWhr)
Normative Energy
Document Number
LII-GETS12021-G-00100-002
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Rev
No.
Description
Page No.
Date of Issue
05
[115]
15.01.2016
[Logo of Utility]
Generated (MU)
Energy Sent Out (MU)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Loss of generation
due to shut down for
R&M (MU)
[..] [..]
Landed Cost of Coal

(Rs/tonne)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Landed Cost of
Secondary Fuel
(Rs/KL)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Indicative Tariff
(Rs/kWh)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Cost of Purchasing
Power from Grid net of
variable charge
(Rs/kWh)
[..] [..]
Cash Inflow:
Annual Revenue (Rs
Million)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Cash Outflow
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[116]
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[Logo of Utility]
Annual Coal Cost (Rs

Million)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Annual Oil Cost (Rs

Million)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Annual O&M Cost (Rs

Million)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Cost of Loss of
Generation due to shut
down for R&M (Rs
Million)
[..] [..]
Capex (Rs Million)
[..] [..] [..] [..] [..]
Interest Payment (Rs

Million)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Principal Repayment
(Rs Million)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Net Cash Flow (Rs

Million)
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Discount Factor
[..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..] [..]
Net Present Value of

Cash Flows (Rs
Million)
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[117]
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[Logo of Utility]
IRR (%)
Payback Period
(Years)
{Note: Cash Flow and Return analysis for each of the R&M option and base case to be attached.
The number of years in the above table is indicative only. The analysis will be done for each R&M option for the number of years
spanning the economic plant life after R&M. For base case, the analysis will be carried out for the residual life of the plant. }
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page No.
Date of Issue
05
[118]
15.01.2016
Feasibility Report For R&M of Unit No.[..] of [Name of

the Power Plant]
[Logo of Utility]
ANNEXURE 10.1
PROJECT MILESTONE SCHEDULE FOR R&M CONTRACT
Milestones
Scheduled Start Date
Scheduled Finish Date
Zero Date
[..]
[..]
Site Office Development
[..]
[..]
Site visit and assessment of

Equipment & System
[..]
[..]
Re-Engineering and
Development
[..]
[..]
Supply of Equipment
[..]
[..]
Unit Shut-down
[..]
[..]
Dismantling Activities
[..]
[..]
Erection activities
[..]
[..]
Boiler Erection
[..]
[..]
Turbine Erection
[..]
[..]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
[119]
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Feasibility Report For R&M of Unit No.[..] of [Name of

the Power Plant]
Milestones
[Logo of Utility]
Erection of Balance of Plant
[..]
[..]
Erection of Electrical Equipment
[..]
[..]
Erection of C&I Equipment
[..]
[..]
Testing & Commissioning
[..]
[..]
Commercial Operation
[..]
[..]
Document Number
LII-GETS12021-G-00100-002
Rev
No.
Description
Page
No.
Date of Issue
05
[120]
15.01.2016

OF
MODEL RESIDUAL LIFE ASSESSMENT /

CONDITION ASSESSMENT REPORT
PREPARED BY

LII-GETS12021-G-00100-003 R04
September 2014
Model RLA/CA Report For R&M of Unit No. [..] Capacity [] of [Name of the
Power Plant]
[LOGO OF
UTILITY]
History of Revisions
Revision No.
Date
Prepared /Revised by
R00
28.08.2012
R.K.Soni (RKS)
R01
30.08.2012
RKS
Minor Revision (Draft Report).
R02
12.01.2013
RKS

the discussions held in CEA on 7th Sep
2012.
R03
31.07.2013
RKS

the comments of the Task Force
2013.
R04
25.09.2014
RKS

CEAs Requirement on left out
comments.
Document Number
LII-GETS12021-G-00100-003
Description
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[i]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
BACKGROUND
Coal based power stations contribute more than 70% share of total power generation in
India. Thermal Power Stations are designed for an economical and stable life span of 25
years, after which, the level of performance starts deteriorating as a result of degradation
of its equipments, components and materials. Deterioration may also take place before the
completion of useful life of 25 years, if the units are not operated and maintained properly.
decreased efficiency and increased cost of generation. This results in costly repair and
loss of revenue. Renovations & Modernization (R&M) and Life Extension (LE) Programme
of thermal power station is an activity of carrying out repairs, refurbishments and
replacement of defective equipments & components so as to extend the life of the power
plant by at least 20 years and to restore the performance parameters to equal or better
than the original design parameters.
Need of R&M
In spite of new capacity additions, India continues to face shortages of varying degree in
the supply of energy and peaking power. Implementation of fresh capacity additions for
bridging the demand supply gap involves huge investments and long gestation periods
primarily due to the process of land acquisition and getting the required fuel and water
allocations, permits & clearances, particularly, the environmental clearance.
On the other hand, R&M activity of existing old power plants which requires less
investment and can be completed in shorter duration has been recognized as a technoeconomically viable option to supplement the fresh capacity addition for maximizing the
energy generation. Also it helps in reducing the emissions by adopting upgraded modern
technologies.
As per the Guidelines issued by Central Electricity Authority (CEA) the following should be
the objectives of R&M and R&M/LE Programmes.
Consumption and Secondary Oil Consumption etc.
To make the operating units well equipped with modified/ augmented latest
technology.

Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[ii]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]

Compliance of
requirements.
stringent
environmental norms,
safety and
other statutory

As per the Guidelines issued by Central Electricity Authority (CEA) the following criteria is
to be adopted for considering the R&M and R&M/LE Programmes.
Estimated cost of unit for complete R&M/ LE works should be limited to 50% of
cost of new unit.

approved the scheme of Central Loan Assistance (CLA) of Rs. 500 crores benefitting 34
power stations mostly of 50/60/100/110/120/140 MW capacities. R&M in a structured
manner was initiated as a centrally sponsored programme during the 7th Five Year Plan.
The momentum of carrying out R&M works was continued through 8th and 9th Plans but
the same could not be sustained during the 10th Plan.
prepared a document on National Perspective Plan for Renovation & Modernization and
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[iii]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
Life Extension and Up-rating (LE&U) of thermal power stations up to the year 2016-17.
This document which also includes revised guidelines for Renovation & Modernization / Life
S.No.
Plan
Year
7th Plan
and Two
Annual
Plans
8th Plan
(R&M)
(LEP)
9th Plan
(R&M)
(LEP)
10th Plan
(R&M)
(LEP)
No. of TPS /
No. of Units
Capacity
(MW)
85-86 to 89-90
& 90-91, 91-92
34 / 163
13570
92-93
to
96-97
44 / 198
43/(194)
1/ (4)
37 / 152
29/ (127)
8/ (25)
97-98
to
2001-02
2002-03 to
2006-07
9/ 25
(14 out of
57 planned )
(11 out of
106 )
Additional
Generation
Achieved
MU/ Annum
10000
Equivalent
MW
20869
(20569)
(300)
5085
763
18991
(17306)
(1685)
14500
2200
3445
(2460)
(985)
2000
300
2000
Life Extension
Programme (LEP)
R&M Programme
Total
Programme
(MW)
Achievement
(MW)
7318
(53 units)
18965
(76 units)
26383
(129 units)
1291
(13 Units)
14855
(59 units)
16146
(72 units)
In the past, R&M measures were hampered due to lack of proper planning. Proper
investigation to identify the R&M works to be carried out and preparation of technical bid
documents based on the investigation was not done. This resulted in unsystematic and
additional work during execution phase and uncertainty about costs resulting in excessive
implementation time, long shutdown periods of plants and cost overruns. In the absence of
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[iv]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
standard commercial rules and policies, suppliers showed little interest in R&M work.
Therefore a strong need was felt for providing standardized bidding procedures as well as
model contracts, formats and specifications etc. to the utilities. Standardization will
harmonize the requirements of all the stakeholders and will lead to their increased
participation.
The Indo-German Energy Forum (IGEF), inaugurated in 2006, provides a platform to
discuss energy related issues of mutual interest. The first meeting of the ad-hoc sub-group
on energy efficiency in thermal power stations, constituted as per decision of meeting of
IGEF in December 2007, was held under the chairmanship of Joint Secretary (Thermal),
Ministry of Power on 12th March, 2008 in which preparation of standard tendering
document for the purpose of R&M activities was, inter-alia, identified as an area of the
activities. The scope of the assignment was divided in two parts as under:Phase-I Activity:
Phase-I activity comprised an assessment of tendering procedures currently being followed
by public utilities in India and a review of documents used for standard R&M projects and
the documents which have already been developed for energy efficient R&M projects
financed by particularly World Bank. This activity was carried out by M/s Evonik (India)
under the grant provided by GTZ. M/s Evonik (India) submitted the report in September
2009.
Phase-II Activity
Phase-II activity comprised the preparation of the model documents / templates in
consultation with Task Force, power utilities & financing agencies.
In the 3rd meeting of Indo-German Energy Forum (IGEF) convened in Berlin on 4th
November 2009, KfW proposed to finance and carryout the work programme of phase-II
Activity, on behalf of CEA & in consultation with the Task Force. In a meeting held in MOP
on 17th December 2009, chaired by Joint Secretary (Thermal), MOP, the representative of
KfW suggested that CEA may act as Project Executing Agency for the phase-II activity.
Accordingly Ministry of Power, Govt. of India have entrusted the task of Project Executing
Agency to CEA for implementing Phase-II activity. Under Indo-German Energy Forum
(IGEF) assisted programme, M/s Lahmeyer International (India) was appointed on16th March
2012 to provide the consultancy services for Development of tendering procedures and
model contract document for R&M of Fossil Fuel Based Power Plants in India. The scope
of consultancy services included the preparation of the following model documents:
I)

Contractor.

Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[v]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]

Contractors.


MAHAGENCO.
Tender document for Supply, Erection, Testing and Commissioning of Air Preheater
for Unit 5 & 6 Koradi TPS, MAHAGENCO.
Tender document for replacement of 6.6 KV station transformer incoming breaker &
Tie breaker of Koradi TPS, MAHAGENCO.

KfW Documents


Standard Bidding Document for Procurement of Plant, Design, Supply and
Installation.
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[vi]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
This Model Residual Life Assessment (RLA) / Condition Assessment (CA) Report has
been prepared to conceptualize the format of the Report based on the systematic
methods and procedures to be applied for checking the health of various equipments
and components so as to identify such equipments and components which require
replacement or refurbishments. Detailed standard documents like FR, DPR, RFP & RFQ
documents to carry out R&M works for the Thermal Power Plants shall be prepared
based on this RLA/CA Report.
**************
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[vii]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
NOTES & GUIDELINES FOR USING THE MODEL RLA/CA REPORT

Lahmeyer International India Pvt. Ltd. (LII), the Consultant to Develop Standard Procedures
and Model Documents for the Renovation and Modernization (R&M) of Fossil Fuel based
Power Plants in India. The above assignment is being financed by KfW Entwicklungsbank.
Accordingly, this Model RLA/CA Report has been prepared for the guidance of Project
Authorities who may decide to carryout R&M of their old Coal based Power Plants so as to
extend the life of their plants and make them energy efficient and reduce emissions.
The purpose of this model document is to standardize the format of the RLA/CA Report for
R&M works. Since majority of 200/210 MW units are potential candidates for
consideration of Renovation as they have crossed 20 to 25 years of useful life, the
enclosed format has been prepared keeping those 200 MW/210 MW units in view. Since in
due course of time, many 500 MW units will also become due for R&M, the Utilities are
advised to suitably modify this document for its application to 500 MW units.
This format of RLA/CA Report contains two kinds of texts written in black and in blue
colours. The text in blue italics and enclosed in square bracket ([...]) represents variable
information which may differ from project to project. The text and numbers in blue colour
are written for the sake of citing an example. The Utilities and their Consultants are
advised to check the relevance of the same and replace these texts and numbers with the
ones as may be applicable to their specific Project. A few guidelines have also been
provided in blue italics enclosed within red curly brackets ({}), wherever applicable.
**************
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[viii]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
TABLE OF CONTENTS
1
EXECUTIVE SUMMARY
INTRODUCTION
DESCRIPTION AND OPERATIONAL HISTORY OF THE UNIT
3.1 Description
3.2 Salient Features and Details of the Unit
3.2.1 Boiler & Auxiliaries
3.2.2 Steam Turbine & Auxiliaries
3.2.3 Electrical System
3.2.4 Control & Instrumentation
3.2.5 Balance of Plant
3.2.6 Civil Works
3.3 Operational History of the Plant
3.4 Stack Emissions, Ambient Air Quality and Process Effluents
3.5 Feedback from the Plant Operators
3.6 History of Failures and Trend Analysis
3.7 Major Replacements done in the Plant
3.8 Objectives of R&M Solution
4
RESIDUAL LIFE AND CONDITION ASSESSMENT OF EQUIPMENTS AND

COMPONENTS
4.1
4.2
4.3
31
General
Operating Data Collected During the Hot Walk Down Survey
Equipments Subjected to Various Tests and Results Obtained
31
31
35
CONDITION ASSESSMENT OF CIVIL AND STRUCTURAL WORKS
48
5.1
5.2
6
4
4
4
11
15
19
19
22
24
25
27
28
29
30
General
Tests Conducted and Results Obtained
48
48
RECOMMENDATIONS
Document Number
LII-GETS12021-G-00100-003
51
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[ix]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
LIST OF APPENDICES
TITLE
DESCRIPTION
APPENDIX-A
GUIDELINES FOR RLA/ CA STUDIES OF EQUIPMENTS AND

COMPONENTS
75
ANNEXURE-A TO APPENDIX-A
84
GUIDELINES FOR CONDITITION ASSESSMENT OF CIVIL /

STRUCTURAL WORKS.
86
ANNEXURE-B TO APPENDIX-B
94
ANNEXURE-C TO APPENDIX-B
96
APPENDIX-B
PAGE
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[x]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
LIST OF ANNEXURES
ANNEXURE
DESCRIPTION
PAGE
4.1
VISUAL INSPECTION REPORT OF PLANT AND EQUIPMENT
97
4.2
FIBROSCOPIC INSPECTION
98
4.3
BOROSCOPIC INSPECTION
99
4.4
DYE PENETRATION TEST REPORT
100
4.5
MAGNETIC PARTICLE INSPECTION REPORT
102
4.6
ULTRASONIC TEST REPORT
104
4.7
ULTRASONIC THICKNESS TEST REPORT
106
4.8
OXIDE SCALE THICKNESS MEASUREMENT REPORT
108
4.9
IN-SITU METALLOGRAPHIC REPORT
111
4.10
HARDNESS TEST REPORT (HB)
112
4.11
DIMENSIONAL MEASUREMENT TEST REPORT
113
4.12
POWER GENERATION LOSS DUE TO DETERIORATED CONDITION OF

TURBINE
114
4.13
INCREASE IN HEAT RATE DUE TO DETERIORATED CONDITION OF

TURBINE
115
4.14
ELCID TEST
116
4.15
TAN DELTA TEST
117
4.16
DESTRUCTIVE TEST REPORT
119
4.17
EDDY CURRENT TEST
121
4.18
FUFURAL TEST
122
5.1
VISUAL EXAMINATION REPORT OF CIVIL AND STRUCTURAL

WORKS
123
5.2
DETAILED INVESTIGATION REPORT
126
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[xi]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
LIST OF ABBREVIATIONS
{The utilities are advised to use the following standard abbreviations while preparing
RLA/CA Report for their power plant.}
ACB
Air Circuit Breaker
ACG
AHP
Ash Handling Plant
AHU
Air Handling Unit
ASTM
American Society of Testing and Materials
ATRS
ATT
AVR
BFP
BOD
Biological Oxygen Demand
BOP
Balance of Plant
CA
Condition ASSESSMENT
CAPO
A Trade Name of Pull Out Test
CCTV
CEA
CHP
Coal Handling Plant
DGA
Dissolved Gas Analysis
DM
Demineralization
ECO
Economizer
EHC
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[xii]
25.09.2014
Power Plant]
ELCID
EOT
ESCOT
A Trade Name of Pull Out Test
ESP
FO
Fuel Oil
FSSS
GC
Gland Condenser
GCV
GT
HCA
HEA
HP
High Pressure
HT
High Tension
HVAC
Heating Ventilation Air Conditioning
HVWS
IGV
Inlet Guide Vane
IPT
IPR
Inter Posing Relay
IS
Indian Standards
LDO
Light Diesel Oil
LE
Life Extension
LP
Low Pressure
Document Number
LII-GETS12021-G-00100-003
[LOGO OF
UTILITY]
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[xiii]
25.09.2014
Power Plant]
LPT
LRSB
LT
Low Tension
LTSH
LVS
Large Video Screen
MCCB
MOCB
MoEF
Ministry of Environment and Forest
MSSV
OWS
PA
Primary Air
PCN
PDD
PLF
Plant Load Factor
PRDS
PLC
R&M
RH
Re-heater
RLA
RO
Reverse Osmosis
RSO
SADC
Document Number
LII-GETS12021-G-00100-003
[LOGO OF
UTILITY]
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[xiv]
25.09.2014
Power Plant]
SG
Steam Generator
SH
Super Heater
SPA
Steam Path Audit
SPM
Solid Particulate Matter
SPT
Special Purpose Test
SS
Stainless Steel
SWAS
TDH
Total Dynamic Head
TFT
TPS
TR
TC
Thermocouple
TSE
UPS
VVVFD
Document Number
LII-GETS12021-G-00100-003
[LOGO OF
UTILITY]
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[xv]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
MEASUREMENT UNITS
{The utilities are advised to use the following abbreviations of measuring units while
preparing RLA/CA Report for their power plant.}
C
Degree Celsius
cm2
Square Centimeter
dB (A)
Decibels Absolute
hr
Hour
Hz
Hertz
kCal
Kilo Calorie
kg
Kilogram
kl
Kilo Liter
km
kilo meter
kV
kilo Volt
kVA
kilo Volt Ampere
kW
kilo Watt
kWh
Kilo Watt hour
Meter
m2
Square Meter
m3
cubic meter
mg
Milligram
mm
Millimeter
cm
centimeter
MVA
Mega Volt Ampere
MW
Mega Watt
ppm
Parts per million
rpm
TPH / T/h
Tonnes Per Hour
mg/Nm3
g/m
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[xvi]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
MODEL RESIDUAL LIFE ASSESSMENT

AND
CONDITION ASSESSMENT REPORT
FOR
OF
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
04
MODEL RLA/CA REPORT
[i]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
EXECUTIVE SUMMARY
This Residual Life Assessment and Condition Assessment Report has been
prepared for carrying out the Renovation & Modernization (R&M) / Life
Extension (LE) of Unit No [...] of [...] Thermal Power Plant, located at [.],
in District [.] in the State of [.] and having a configuration of
[xMW].
The unit no. [...] was first commissioned in the year [.]. After [.] years
of operation, the performance of the unit has gradually deteriorated resulting
in frequent forced outages, reduced outputs, decreased efficiency and
increased cost of generation. It is proposed to carry out required
refurbishments and replacements in the plant so as to restore the units
performance parameters and to extend its life of by at least [.] years.
The report discusses the salient features and operational history of the
power plant and also the specific problems being faced from the operation
of various plant equipment & systems.
To assess the health and determine the residual life of all the major
components of the plant, various Residual Life Assessment (RLA) and
Condition Assessment studies were conducted during the period [.].The
studies and tests conducted were based on the latest available technology.
Summary of Recommendations of RLA/ CA Studies are furnished below:
[
..]
{Describe above the major recommendations of RLA/ CA studies which
could comprise Replacement/ Refurbishment of Boiler drum internals, Down
comers, Water Wall Headers / Tubes, Headers/ Coils of Platen Super
Heaters/ Final Super Heaters/ Convection Super Heaters/ Re-Heaters, Inlet/
Outlet Headers/ Coils of Economisers, Baskets/ Seals of Rotary Regenerative
Air Pre-Heater, Wall Soot Blowers/ LRSBs, Coal Feeders, Wind Box, Low
NOx Burners, Burner Tilting Arrangement, Boiler Structure, Buckstays,
Ducting & Insulation, Bottom ash Hoppers, Clinker Grinders, ID/ FD/PA Fans,
Grinding Rolls/ Gear Boxes/ Classifiers of Mills, Collecting Electrodes/
Emitting Electrodes/ Transformer Rectifier Sets of ESP, HP/IP/LP Modules of
Steam Turbines, HP / IP Casings/ Diaphragms/ Gland Sealing System/ InterStage Packing of Steam Turbines, Emergency Stop Valve, Interceptor
Valves, Control Valves, Servomotors, Governing System, Turning Gear,
Jacking Oil System, Online Tube Cleaning System of Condensers, Ejectors,
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[1]
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Power Plant]
[LOGO OF
UTILITY]
Impellers of Condensate Extraction Pumps, Tube bundles of LP / HP Heaters,

Booster Pumps/ Coupling/ Cartridges of Boiler Feed Pumps, Critical Piping,
Hangers & Supports, Line shafts/ Impellers / Bowl assemblies/ Pumps/
Motors/ Piping/ Valves of CW/ ACW/ Intake Water Systems, Water
Pretreatment Plant, Pressure Vessels/ Pipes/ Pumps/ Air blowers/ Valves/
Acid Storage Tanks/ Alkali Storage Tanks/ DM Water Storage Tanks of DM
Plant, Wagon Tipplers/ Track Hoppers/ Stacker-Reclaimer/ Crushers/
Conveyor Belts of Coal Handling Plant, Dry Fly Ash Evacuation System, Ash
Water Recycling System (AWRS), Ash Silos, Ash Dyke, Hydrants
/Sprinklers/ Emulsifiers/ Hydro Pneumatic Tank / Jockey Pump of Fire
Fighting System, Heat Tracing System /Pumps/ Fittings/ Valves of Fuel
Handling System, Vapour Absorption Machines of Air Conditioning System,
Screw Type Air Compressors/ Air Driers of Compressed Air System, Stator
Winding Bars/ Insulation/ Retaining Rings/ Excitation System/ Hydrogen &
Water Cooling System of Generator, Windings/ Bushings/ Cooling System of
Power Transformers, Circuit Breakers, Switchgears, Battery Charger/
Batteries/ Distribution Boards of DC System, DG Sets, Public Address
System, Illumination System, Power and Control Cables, Foundations of
Boilers & TG Building, Steel Structures of Coal Handling/ Ash Handling Plant,
Buildings of DM Plant/Chemical House/ Chlorination Plant, Chimney and Ash
Dyke etc]
These recommendations are being hereby submitted to the Project
Authorities for further discussions and for evolving various options for
Renovation and Modernization of the Unit.
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[2]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
INTRODUCTION
Unit No [...] of [] Thermal Power Station was first synchronized
on [.]. The Unit has been operating for more than [.] years and its
performance has deteriorated gradually over the years. Extending the life of
the unit and increasing its efficiency and output appears feasible by carrying
out Renovation and Modernization of the Unit. This Residual Life
Assessment (RLA) and Condition Assessment (CA) Report has identified
those equipments and components of the Unit which need to be
rehabilitated to prevent loss of generation, improve efficiency, enhance
availability and enable the unit to produce power in conformity with the
statutory environmental regulations in force.
The RLA & CA studies were conducted to assess the health condition and
determine the residual life of all the major equipments like Boilers, Turbines,
Generators, Power Transformers, Electrical Systems, Coal Handling Plant,
Ash Handling Plant, Water Systems, Equipment Foundations and Civil
Structures etc, which are the backbone of the generating unit to give its
sustained performance. The studies comprised Visual Examination through
Cold Walk Down Survey / Hot Walk Down Survey, Dimensional
Measurements, Destructive & Non-Destructive Tests, Steam Path Audit and
InSitu Metallographic Tests etc. The studies and tests conducted were
based on the latest available technology.
This report is based upon review of RLA & CA studies done during the
period [...], review of the operation data of the unit and detailed
discussions held with the project authorities as well as operating personnel.
The recommendations of the RLA/ CA studies have been discussed in detail
in section 6.0 of this report. These recommendations are being hereby
submitted to the Project Authorities for further discussions and for evolving
various options for Renovation and Modernization of the Unit.
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
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[3]
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Power Plant]
[LOGO OF
UTILITY]
DESCRIPTION AND OPERATIONAL HISTORY OF THE UNIT
3.1
Description
The Power Plant, having a configuration of [xMW] is located at [.], in
District [.] in the state of [.].The Unit no. [.] of the power plant, which
is proposed to be taken up for Renovation and Modernization was first
commissioned in the year [.]. For the above unit, M/s [..] and M/s [.]
are the Original Equipment Manufacturers (OEMs) for the Boiler and TurboGenerator, respectively. The boiler for the unit is of [PF/CFBC] design. The
boiler is provided with [front & rear/ corner/down shot] firing system. LP
stage of Turbine is designed with [Bauman] exhaust. Condenser cooling
system of the unit is designed on [once through / re-circulation system].
Power generated from the unit is being supplied to [...State/Central grid].
Power is being evacuated through [.numbers of 220/400kV Double/Single
to
[.
substation.]
The
primary
fuel
is
Circuit
lines]
[domestic/imported/blended] [coal/lignite] fuel being sourced from
[..&] coal mines. The consumptive water for the power plant is being
sourced from [.river /sea].
3.2
Salient Features and Details of the Unit

{Describe in this sub-section, the Design Parameters and Salient Features of
all the important Equipment and Systems of the Power Plant as mentioned
below}
3.2.1

a)
Boiler
[The Boiler is of natural circulation, pulverized fuel fired, dry bottom,

balanced draft using direct firing system. The design parameters of the
Boiler are furnished below]
Description
Units
Design
Parameters
T / hr
[.]
kg/cm2
[.]
[.]
Re-heater Flow
T / hr
[.]
kg/cm2
[.]
[.]
Feed Water Flow
T / hr
Document Number
LII-GETS12021-G-00100-003
[.]
Rev
No.
Description
Page
No.
Date of Issue
03
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[4]
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Power Plant]
Description
Units

Economiser
Economiser.
b)
[LOGO OF
UTILITY]
Design
Parameters
kg/cm2
[.]
[.]
Furnace
[The boiler is equipped with a water cooled furnace of balanced draft and
fusion welded membrane wall construction. It is equipped with..numbers
of coal burners andnumbers of oil burners located at numbers of
elevations. The design parameters of the Furnace are furnished below.]
Description
Units
Type of Firing
Design Parameters
........
Combustion Chamber
Volume
m3
Furnace Dimensions
[..............]
[..............]
[..............]
[..............]
m2
[..............]
ii) Superheaters
m2
[..............]
iii) Reheaters
m2
[..............]
iv) Economiser
m2
[..............]
v) Air Heater
m2
[..............]
vi) Steam Coil Air

Heater
m2
vii) Temperature
Measurement of
Super-heater
tubes
Yes / No
viii) Temperature
Measurement of
Yes / No
i)
Water Walls
Document Number
LII-GETS12021-G-00100-003
[..............]
[..............]
[..............]
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[5]
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Power Plant]
Description
Units
[LOGO OF
UTILITY]
Design Parameters
Re-heater tubes
c)
Super Heaters and Re-Heater
[The super heaters are composed of four sections, a platen section, a

pendant section, a rear low temperature section and a steam cooled wall &
roof section. The Re-heater consists of two sections, the front pendant and
the rear pendant sections. The details are given below:]
Description
No. of coils
/ tubes
Pitch
(mm)
Dia.x Thickness
(mm)
Heating
Surface (m2)
Material
Low
Temperature
Super Heater
[.]
[.]
[.]
[.]
[.]
Platen Super
Heater
[.]
[.]
[.]
[.]
[.]
Pendant
Super Heater
[.]
[.]
[.]
[.]
[.]
Ceiling and
Enclosure
Super Heater
[.]
[.]
[.]
[.]
[.]
ReheaterFront
Assembly
[.]
[.]
[.]
[.]
[.]
ReheaterRear
Assembly
[.]
[.]
[.]
[.]
[.]
d)
Economiser
[The Economizer is of a single stage, continuous plane tube and horizontal,

mixed flow type, located in the second pass of the boiler]
e)
Air Pre-Heater
[The air pre-heater is of regenerative rotary type. Special sealing

arrangements have been provided in the air pre-heater to prevent leakage
between air and gas sides. Adjustable sector plates have also been provided
to prevent the leakage during expansion. The heating surfaces of the air preDocument Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
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[LOGO OF
UTILITY]
heater have been provided with two types of cleaning systems, soot
blowing and water washing system. ]
f)
Raw Coal Bunkers
[Each boiler is provided with [] raw coal bunkers. The total capacity of the
bunkers is to meet [] hours requirement at maximum mills capacity of the
unit. The upper portion of the bunkers is of cylindrical shape made of carbon
steel plate, while the conical portion is made of stainless steel plate. Each
outlet of the bunker is provided with an isolation gate which is motor
operated. In addition to the isolation gates, rod gates have been provided to
control the flow of coal from the bunkers]
g)
Raw Coal Feeders
[One gravimetric type of raw coal feeder has been provided for each coal
mill. The coal feeders have been provided with micro-processor based
controls with variable frequency drive. The feeders have been provided with
dual independently measuring load cells. All parts of the feeders coming in
contact with coal, except the belt, are made of stainless steel]
h)
Fuel Firing System
[The boiler is working on a direct firing system. The pulverized coal is being
dried and transported to the coal burners by means of hot primary air being
supplied by two primary air fans. The boiler is having [front and
rear/corner/down shot] firing system. There are [] pulverized coal burners
and [] oil burners. The burners are located at [] floors.
i)
Coal Mills
[The unit is provided with . numbers of [BHEL] Make [XRP-783] bowl type
mills, out of which mills are designed to work with designed coal and
..numbers of mills are standby . The rated capacity of each mill is ..T/h.]
Description
Units
Design Parameters
..
[.]
Capacity of Mills
T/h
[.]
Nos.
[.]
Number of Mills to work per boiler

with design coal quality
Nos.
[.]
Motor Rating
kW
[.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
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[7]
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Power Plant]
j)
[LOGO OF
UTILITY]
Primary Air Fans
[Two Primary Air (PA) Fans have been provided for each boiler. Each PA Fan
is designed to meet 60% MCR condition of the boiler. The PA Fans are Hot
PA Fans. Details are given below:]
Description
Units
..
Type of Fans
..
Design Parameters
[.]
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
[.]
Motor Rating
kW
[.]
[.]
k)
Forced Draft Fans
[Two Forced Draft (FD) Fans have been provided for each boiler. Each FD
Fan is designed to meet 60% MCR condition of the boiler. The FD Fans
supply combustion air to the boiler, mill air through PA Fans and tempering
air to control the classifier temperature of the mills. Details are given below:]
Description
Units
..
Type of Fans
..
Design Parameters
[.]
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
Temperature of Air
[.]
Motor Rating
kW
[.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
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[8]
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Power Plant]
Description
Units
l)
[LOGO OF
UTILITY]
Design Parameters
[.]
Induced Draft Fans
[Two Induced Draft (ID) Fans have been provided for each boiler. Each ID
Fan is designed to meet 60% MCR condition of the boiler. Each ID Fan
evacuates flue gases through two parallel paths of ESP and discharge them
into stack through separate ducting. Details are given below:]
Description
Units
..
Type of Fans
..
Design Parameters
[.]
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
[.]
Motor Rating
kW
[.]
[.]

[Adequate number of Wall Blowers and Long Retractable Soot Blowers
(LRSBs) are being used for cleaning the soot deposited on the heating
surfaces of the water walls and super heaters respectively. Manually
operated soot blowing system has been provided. Details are given below:]
Description
Units
Design Parameters
Wall Blowers
..
[]
No. of Wall Blowers per boiler at

water walls
Nos.
[.]
Medium of soot blowing at water
..
[.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
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[9]
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Power Plant]
Description
[LOGO OF
UTILITY]
Units
Design Parameters
[.]

Nos.
[.]

[.]

pass tube banks
Nos.
[.]
Medium of soot blowing at

convection pass tube banks
[.]
walls
LRSBs
n)
ESP
[An Electrostatic Precipitator (ESP) has been installed on the cold end side of
the Air Pre-heater to remove the particulate matter from the flue gases. The
ESP has been provided with Gas Distribution System, Collecting Electrodes,
Discharge
Electrodes,
Transformer
Rectifier
Sets
and
[electrically/mechanically] operated rapping system. The hoppers of ESP
have been provided with [capacitance] type level indicators and
Description
Units
Design Parameters
[.]
Nos.
[.]
Nos.
[.]
mg/Nm3
[.]
Type of Control
[.]
Gas Velocity in ESP
m/sec
[.]
m2/m3/sec
[.]
Aspect Ratio
..
[.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
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[10]
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Description
Units
Design Parameters
cm/sec
[.]
Numbers of TR Sets
..
[.]
Rating of TR Sets
..
[.]
[.]
m2/TR
Set
hrs
Pressure Drop
mmwc
[.]
Dust Collection Efficiency with (N1) fields in operation
[.]
Plate Area/TR Set
3.2.2
[LOGO OF
UTILITY]
[.]

a) Steam Turbine
[The steam turbine is of three cylinder, 3000rpm, tandem compound,
condensing type designed to operate on a re-heat and re-generative feed
water cycle. The LP stage of turbine is designed with Bauman exhaust. The
turbine is provided with HP/LP bypass system of 60% capacity of Steam
Generator MCR. The turbine is provided with an electro - hydraulic control
system, automatic turbine run up system and turbo supervisory
instrumentation. The condensing system consists of a surface condenser of
single shell and two pass, divided water box construction. Cooling water
being supplied to the condenser is of raw water/ clarified water quality. The
design parameters of the steam turbine are furnished below]
Description
Units
Design Parameters

HPT
kg/cm2
[.]
Temperature of Steam at inlet of

ESV of HPT
[.]
Pressure of Cold Reheat (CRH)

Steam
Steam
kg/cm2
[.]
[.]
kg/cm2
[.]

Steam
[.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
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Description
Units
[LOGO OF
UTILITY]
Design Parameters
kg/cm2
[.]
Temperature at the inlet of LP

Turbine
[.]
b) Condenser
[The condenser is a [single/double] pass, horizontal, surface type with
integral air cooling section designed to maintain a pressure of 76 mm of Hg
at turbine exhaust with a cooling water temperature of [] deg C and an
outlet temp of [] deg C. The condenser is capable of operation with []
tubes plugged and has hot well storage capacity of [] minutes
Description
Units
Design Parameters
Make and Model
[.]
Type of Condenser
[.]
m2
[.]
..
[.]
Material of Tubes
..
[.]
mmxmm
[.]

Condenser
Cooling Water Temperature at the
inlet to Condenser
Condenser Vacuum
m3/h
[.]
[.]
mm Hg
[.]
c) Ejectors
[The Condenser is provided with two quick starting ejectors which operate
in parallel to remove large volumes of air for raising the initial vacuum during
the starting of the Unit. Two main ejectors of 100% capacity each have
been provided remove air and non condensable gases from the condenser to
maintain the required vacuum in the condenser during the normal operation
of the unit.]
[Condensate extraction pumps are of vertical, multistage, centrifugal pumps
of canister type.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
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[12]
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Power Plant]
Description
[LOGO OF
UTILITY]
Units
Design Parameters
Make and Model
[.]
Type
[.]
Capacity
m3/h
[.]
TDH
mwc
[.]
Speed
rpm
[.]
Motor Rating
kW
[.]

[A Gland Steam Cooler has been provided to condensate the leak-off steam
from intermediate chambers of end sealings of HP and IP turbine, thereby
heating the main condensate water. The Gland Steam Cooler consists of
shell, tube bundle and removable water box.]
f) LP Heaters and Drain Coolers
[Each steam turbine is provided with four numbers of low pressure heaters
to increase the temperature of the condensate in stages. LP Heater -1
consists of two halves and is installed in neck of the condenser. The
remaining LP Heaters are of shell and tube design and have been placed
vertically. An integral drain cooling section is provided in each LP Heater.
The design details of LP Heaters are furnished in the table below.]
Heater No.
Extraction
Steam taken
from
[...] stage of
IP turbine
[...] stage of
IP turbine
[...] stage of
IP turbine
[...] stage of
IP turbine
Bled Steam
Pressure
(kg/cm2))
[...]
[...]
[...]
[...]
Bled Steam
Temperature
(deg C)
[...]
[...]
[...]
[...]
g) Deaerator
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[13]
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Power Plant]
[LOGO OF
UTILITY]
[The deaerator is of [horizontal spray cum tray type]. It is designed to

remove dissolved oxygen from the condensate in excess of 0.005 cc per
liter. The feed water storage tank has a capacity of [] minutes feed water
requirement of the boiler corresponding to TMCR Heat Balance]
h) Boiler Feed Pumps
[The boiler feed pumps are horizontal, multi stage centrifugal pumps of
barrel type, motor driven pumps coupled with hydraulic coupling, taking the
suction from the deaerator. The boiler feed pumps discharge feed water
through HP heaters to the economizer of the boiler.]
Description
Units
Design Parameters
Make and Model
..
[.]
Type
...
[.]
No of stages
Nos.
[.]
Capacity
m3/h
[.]
Head
mwc
[.]
Feed water temp
[.]
..
[.]
Minimum flow
m3/h
[.]
..
[.]
Type of Hydraulic Coupling
[.]
mwc
[.]
Motor Rating
kW
[.]
i)
HP Heaters
[Each steam turbine is provided with three numbers of high pressure heaters
to increase the temperature of the feed water in stages. The Heaters are of
shell and tube design and have been placed vertically. The design details of
HP Heaters are furnished in the table below.]
Heater No.
Extraction
[...] stage of HP
[...] stage of HP
[...] stage of HP
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[14]
25.09.2013
Power Plant]
Steam taken
from
turbine
turbine
[LOGO OF
UTILITY]
turbine
Bled Steam
Pressure
(kg/cm2))
[...]
[...]
[...]
Bled Steam
Temperature
(deg C)
[...]
[...]
[...]
j)
HP/ LP Bypass

Steam Line and Cold Reheat Line. LP bypass system has been provided
between the Hot Reheat Line and the Condenser. HP bypass water spray
has been taken from the discharge of Boiler Feed Pumps. LP bypass water
spray has been provided from the discharge of Condensate Extraction
Pumps.
[The turbine is equipped with an electro-hydraulic system of automatic
governing for the smooth and stable operation of turbo-set under all
conditions of operation. The system is designed to sustain full load dump
from the generator. The system is provided with a quick closing Emergency
Stop Valve (ESV), to interrupt the supply of steam from the boiler and stop
the turbine under emergency conditions. The turbine governing system
includes, speed governor,]
l) Lube Oil System
[The lube oil system consists of Main Oil Tank, Turbine driven main oil
pump, AC driven bearing oil pump, DC driven emergency oil pump, AC
driven jacking oil pump and oil coolers of 3x50% capacity, Lube oil is being
purified by means of a centrifuge. Oil storage tanks consisting of Clean Oil
Tank and Dirty Oil Tank have been provided.]
3.2.3
Electrical System
a) Generator
[The Generator is a 15.75 kV, 50 Hz, 0.85 power factor machine, directly
coupled with steam turbine operating at 3000 rpm, withtype of
excitation system and digital programmable voltage regulator. The
Generator has direct water cooled stator winding and direct hydrogen
cooled rotor winding. The stator winding cooling water is cooled in a closed
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[15]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
cycle cooling system using DM water, while the hydrogen in the machine is
cooled in gas to water hydrogen coolers mounted inside the machine. The
Parameters of the Generator are briefly mentioned below.]
Description
Units
Design Parameters
Rated MW Capacity
MW
[.]
Rated MVA Capacity
MVA
[.]
kV
[.]
Rated Power Factor
..
[.]
kA
[.]
Rated Speed
rpm
[.]
Rated Frequency
Hz
[.]

Rated Power Factor
[.]
Excitation Current
kA
[.]

Short Circuit Ratio
kV
[.]
..
[.]
Amp
[.]
Phase Connection
[.]
Type of Excitation
[.]
[.]
[.]
kg/cm2
[.]
b)
Station Transformer
[Two Station Transformers have been provided to meet the station

[common] auxiliary loads of the power plant. The Station Transformers have
been provided with on-load tap changers to keep the station 6.6 kV voltage
constant. Cooling of this transformer is ONAN/ONAF/OFAF and has 2x50 %
separately mounted radiators and 2x50% oil pumps. The Parameters of the
Station Transformers are briefly mentioned below]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[16]
25.09.2013
Power Plant]
Description
[LOGO OF
UTILITY]
Units
Design Parameters
Make
[.]
Capacity / Rating
MVA
[.]
Voltage Ratio
[.]
Type of Cooling
[.]
Quantity
Nos.
[.]
c)
[The power output from each Generator is being stepped up to 220/400 kV

through a 240 MVA step up Generator Transformer. It has 3x50% coolers
and 3x50% oil pumps. The Parameters of the Generator Transformer are
briefly mentioned below]
Description
Units
Design Parameters
Make
[.]
Capacity
MVA
[.]
Voltage Ratio
[.]
Type of Cooling
[.]
d)
[Two unit auxiliary transformers have been provided for each unit for
meeting all unit auxiliary loads. These transformers have been provided onload tap changers. The Parameters of unit auxiliary transformers are briefly
mentioned below]
Description
Units
Design Parameters
Make
..
[.]
Capacity
MVA
[.]
Voltage Ratio
..
[.]
Type of Cooling
..
[.]
Quantity
Nos.
[.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[17]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
e) Electrical Auxiliary Power Distribution System

[Unit auxiliaries receive their normal power supplies at 6.6 kV through two
(2) nos. unit transformers. For lower rating drives, 6.6 kV is further stepped
down to 415 V by two (2) nos. unit service transformers. The 415 V
distribution system feeds a number of Motor Control Centers (MCCs) for
running 415 V drives. 6.6 kV unit switchgears are connected to station
switchgear for start up and emergency power supply. The details are
mentioned below]
Description
Units
Design Parameters
Voltage Level
kV
[.]
Type of Breaker
[.]
Type of Grounding
[.]
Type of Protection
[.]
f) DC System
[Each unit has its own DC system located in the BC bay at ground floor of
the Power House. Separate DC systems have been provided in switchyard
control room, intake pump house and DM plant for controlling the systems.
Each DC system comprises of the Storage Battery, the Battery charger and
the distribution boards. The details are mentioned below]
Description
Units
Design Parameters
Make
[.]
Capacity /Rating
[.]
[.]
Type of Charger
..
[.]
Area of Application
..
[.]
Voltage

[Diesel generating sets are installed for meeting the power requirements of
essential auxiliaries (viz. jacking oil pumps, AC lube oil pump, hydrogen seal
oil pump, float charger for DC battery, emergency lighting, scanner air fan
and stator cooling water pump) during total failure of AC Power Supply in
the power station. Diesel generating sets are located in the CD bay at the
ground floor. The details are mentioned below]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[18]
25.09.2013
Power Plant]
Description
[LOGO OF
UTILITY]
Units
Design Parameters
Make of DG Sets
[.]
Rating of DG Sets
kVA
[.]
Quantity
Nos.
[.]
h) Public Address System

[The unit is provided with paging and party channels comprising handset
stations with amplifiers, transmitters, receivers and loud speakers. The
system facilitates paging, communication and also private conversation as
on conventional telephone.]
i)
Illumination System
[For indoor application, fluorescent/ energy saving compact fluorescent

fixtures have been provided. For high bay areas and outdoorapplication,
suitable high intensity discharge Mercury Vapour/ Sodium Vapour lighting
fixtures have been installed. Aviation type fixtures have been installed at the
Chimney]
3.2.4

[The existing control and instrumentation system generally is an old
analogue based system and requires large scale replacement owing to
obsolescence of the existing equipments. Furnace Supervisory Safeguard
System (FSSS) is of obsolete design for which, no spares are available. Soot
blowers are of manual type. No online Boiler Tube Leakage detection system
has been provided. The turbine is equipped with an electro-hydraulic system
of automatic governing for the smooth and stable operation of turbo-set
under all conditions of operation. Turbine Supervisory system is of
electromagnetic type. No continuous monitoring system has been provided
for observing the health of the turbine. HP- LP bypass system is in the form
of standalone control panel. Integrated microprocessor based closed loop
control, open loop control, sequential control and bulk data acquisition
system for SG & auxiliaries, TG & auxiliaries, station C&I including
auxiliaries in hierarchical levels and integrated unit monitoring and station
monitoring systems in the upper level are therefore to be envisaged for the
plant.]
3.2.5
Balance of Plant
[Coal Handling Plant is a common facility which is feeding all the units of
the power plant having a total installed capacity ofx..MW. Coal to the
power plant is brought through railways by Box N /BOBR wagons and is
unloaded by wagon tipplers/ track hopper. One crusher has been provided
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
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[19]
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Power Plant]
[LOGO OF
UTILITY]
for crushing the coal from 250 mm size to 25 mm size. The plant is
provided with one stacker reclaimer to stock the crushed coal. The coal
stock yard has a storage capacity of 20 days. For feeding the coal to the
bunkers of all the units, two streams of conveyors having a capacity of
.TPH have been provided. The coal handling plant operates for 16 hrs
a day.]
Description
Units
Design Parameters
Nos.
[.]
T/h
[.]
Length of the Track Hopper
[.]
Nos.
[.]
T/h
[.]
Type of Crushers
Nos.
[.]
Number of Crushers
Nos.
[.]
T/ hr
[.]
Nos.
[.]
Stacking Capacity
TPH
[.]
Reclaiming Capacity
TPH
[.]
days
[.]

[Ash Handling System is of continuous type. The bottom ash from the
furnace falls into bottom ash hopper having a storage capacity of [] hrs.
The ash is removed with the help of submerged Scrapper Chain Conveyors.
The ash from the air pre-heater and economizer hoppers is being disposed
off along with bottom ash. The ash in the form of ash slurry is conveyed
through sluice channels to the ash slurry pump house with the help of high
pressure jets, from where, it is pumped to the ash pond located the distance
of [] km. [] The ash slurry pump house is provided with [] numbers of
ash slurry pumps of rating [], out of which [] pumps are normally
working. The ash slurry disposal system is having [].numbers of identical
streams of ash slurry pumps connected to [] numbers of ash slurry
pipelines going to the ash pond. Fly ash is collected in dry form below the
ESP hoppers and the same is then conveyed by vacuum system to surge
hoppers from where it is either conveyed through pressurized system to dry
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
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[20]
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Power Plant]
[LOGO OF
UTILITY]
fly ash silos or is sent to ash pond in the form of slurry. From the dry fly ash
silos, the ash is disposed off through the covered trucks.]
c) Raw Water System
[The consumptive water for the plant is sourced from [] river/sea located
at a distance of [] km from the plant boundary. The intake water pump
house is installed with [] intake pumps of capacity [] m3/hr, out of which
[] pumps are normally working and the remaining [] pumps are standby.
The raw water is pumped from the intake water pump house to the in-plant
raw water reservoir, which has a storage capacity of [] days.]
[CW system for the power plant works on re-circulating system with
induced draft cooling towers. The CW system uses raw/clarified quality of
water and is working on [] cycles of concentration. CW pump house is a
common facility for all the units of the power plant. There are two CW
pumps of capacity [] m3/hr provided for each unit. In addition, there are
two standby CW pumps common to all the units. The requirement of ACW
system is being tapped from the cold CW header feeding the condenser. The
hot return ACW water after cooling the auxiliaries of boiler and turbine joins
the hot CW header and is sent to the cooling towers for cooling. The cold
water from the cooling water flows to the fore bay of CW Pump House for
recirculation into the system. One induced draft cooling tower (IDCT) has
been provided for each unit. The cooling tower cools the water from []
deg C to [] deg C. The cooling tower has been designed for an inlet wet
bulb temperature of [] deg C].
[Water Pre-Treatment Plant is a common facility for all the units of the
power plant. Pre-treatment plant supplies clarified water to DM plant,
cooling water to the auxiliaries of BOP system, coal handling plant dust
suppression and to the drinking water system. There are two numbers of
clarifiers of [].m3/hr capacity to meet all the clarified water requirements
of the whole plant, except DM plant. The clarified water requirement for DM
plant is met by a separate clarifier of capacity [] m3/hr.]
f) DM Plant
[DM plant consists of three streams, each of [] m3/hr capacity. There are
two DM water tanks of [].m3 capacity. A common regeneration system
has been provided for all the three streams. DM plant operates on semiautomatic system with PLC controls.]
[The central control room, switchyard control room, ESP controls room and
selected areas of service building have been provided with centralized airconditioning system. The central air-conditioning system of chilled water
type has been provided for various control rooms and DX type of plant has
been provided for ESP control room, switchyard control room and other
areas in the service building. Packaged type of air-conditioners has been
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[21]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
provided for water treatment plant control room. Evaporative ventilation

system has been provided for TG building along with roof extractors. Other
[Fire fighting system is a common facility provided for all the units. This
consists of pressured hydrant system for all the auxiliary buildings, pump
houses and administrative building. Automatic high velocity sprinklers
system has been provided for power transformers, turbine oil tanks and lube
oil system equipments. Medium velocity sprinkler system has been provided
for cable galleries and coal conveyor galleries. Portable types of fire
extinguishers have been provided throughout the plant for fighting small and
localized fires.]
i)
[Plant and instrument air system is a common facility for all the units of the
plant. For meeting the instrument air requirement, [] number of oil free
screw compressors [] working and [] standby, each of [] m3/hr
capacity and discharge pressure of [] kg/cm (g) have been provided along
with dryers. Equal number of air compressors of similar rating has been
provided to meet the requirement of plant air system. The air drying plant
for the instrument air has been provided to achieve a dew point of (-) 40oC
at atmospheric pressure.]
j)
Fuel Oil System
[The fuel oil system has been designed for the use of Light Diesel Oil (LDO)
for start- up and Heavy Fuel Oil (HFO) for load carrying and flame
stabilization purposes. Two tanks of [] kl each have been provided for the
storage of HFO and two tanks of [] kl each have been provided for the
storage of LDO. The system has been provided with unloading, transferring
and pressurization pumps along with necessary filters and heating
arrangement.]
k) Cranes/Hoists
[For the maintenance of various equipments, manually /electrically operated
cranes and hoists have been provided.]
3.2.6
Civil Works
Major civil works of the unit consist of the following:
(a)
Main Power House Building:
[A common Power House Building has been provided to house [3x200 MW]
units which are placed side by side. Centre to centre placing of units is
[67.5 m.] The railway entry has been provided from the rear side of Power
House Building. Turbine Generator (TG) Sets have been placed between AB
rows of columns are laid out longitudinally. The TG bay, also houses, the
Boiler Feed Pumps, Regenerative Heaters, Lube Oil System and other TG
accessories. The total length of TG bay for 3x210 MW units is [276 m] and
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
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[22]
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Power Plant]
[LOGO OF
UTILITY]
width [30 m]. The spacing of the column is at [7.5 m]. TG bay is provided
with 2 Nos. of overhead EOT Cranes. In order to make the handling facilities
of the cranes available to the heat exchangers, boiler feed pumps and other
equipments, removable chequered plates have been provided at appropriate
locations.
Condensate Pump, pipe channels and HP Heaters etc. This sub zero pits are
suitably connected and provided with a common sump for drainage
purposes.
Three stairs for approaching the operating floor level at [+10 m] have been
provided in this bay adjacent to B row columns. In addition, there are stairs
for providing access to various equipments at intermediate platforms and
sub zero pits.
Switchgear and Control Room bay has been provided in the BC bay which is
[12 m] wide. The length of the bay is [249.0 m]. A common Control Room
for all the three units is provided at [10 m] floor. In BC bay at [16 m]
elevation, equipments for chemical dosing, air handling and MCC for soot
blowers etc have been located. The deaerator is placed at an elevation of
[23.0 m]. Air washer units and cooling water tanks are also located at [23.0
m] floor.
Mill Bunker Bay, designated as CD bay, has a span of [10.5 m] which
accommodates coal bunkers, coal feeders and coal mills. CD bay houses the
vertical mills at Zero m and has space for collection of disposal of mill
rejects at sub zero levels adjacent to D row. A stair to connect operating
floor at [16.0 & 23.0 m] of BC & CD bay has been provided.]
(b)
Boiler Area
[In boiler area, the boiler with its auxiliaries like PA fan, FD fan, ID fan as
well as Electrostatic Precipitator has been located.]
(c)
Chimney
[A common multi-flue Chimney of 220 m height has been constructed in

which, flue cans of [3x200 MW] have been erected.]
(d)
Transformer Yard
[A [60] m wide yard has been provided outside the A row columns. The
transformer yard houses station transformer, unit auxiliary transformers and
generator transformers along with oil pits etc. To facilitating erection and
maintenance of transformers, the area has been provided with rail tracks
parallel to A row at a distance of [45 m] from A row which is further
connected through cross tracks. In addition, space has been provided for
laying the CW pipelines and locating the butterfly valve chambers.]
(e)
Service building
[A common four storey building has been provided near the main plant
building and it is connected with the operating floor of TG bay at [10 m]
level.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
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[23]
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Power Plant]
(f)
[LOGO OF
UTILITY]
Miscellaneous buildings
[Besides the above, miscellaneous buildings like administrative building, CW

Pump House, Fire Water Pump House, CHP Control Room, ESP Control
Room, Chimney, DM Plant Building, Chemical House and Ash Silos have
been provided.]
3.3

Unit No [] of [] Thermal Power Station having a Generating
Capacity of [210 MW] was commissioned in the year [..]. The boiler is
of [] design and the turbine is of [LMZ] design. Though the boiler
was originally designed for coal with Gross Calorific Value (GCV) of
[.kCal/kg], it presently operates on coal supplied with GCV of about
[..kCal/kg]. The deterioration experienced over the years in Plants
Average Performance Parameters is shown in Table 3.1.
Table 3.1
Units Average Performance Parameters over the Life
Years after
Installation
PLF
(%)
Availability
(%)
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross Heat
Rate
(kCal/kWh)
[]
[]
[]
[]
[]
[]
[]
10
[]
[]
[]
[]
[]
[]
[]
15
[]
[]
[]
[]
[]
[]
[]
20
[]
[]
[]
[]
[]
[]
[]
25
[]
[]
[]
[]
[]
[]
[]
Table 3.2 indicated below, illustrates variations over the last three years in
the performance parameters.
{Furnish in the Table 3.2 below, the Average Values for the last three years,
Maximum & Minimum values for Current year and the readings on the last
day.}
Table 3.2
Units Performance Parameters during the Last Three Years
Period
Average
value for
the last
PLF
(%)
Availability
(%)
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross
Heat Rate
(kCal/kW
h)
[]
[]
[]
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
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[24]
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Power Plant]
Period
[LOGO OF
UTILITY]
PLF
(%)
Availability
(%)
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross
Heat Rate
(kCal/kW
h)
Average
value for
the last
Two Years
[]
[]
[]
[]
[]
[]
[]
Average
value for
the last
one Year.
[]
[]
[]
[]
[]
[]
[]
Maximum
&
Minimum
values for
Current
year.
[]
[]
[]
[]
[]
[]
[]
Reading as
on the last
day.
[]
[]
[]
[]
[]
[]
[]
Three
Years
3.4

The Project has been regularly monitoring the environmental parameters
such as stack monitoring, ambient air quality (AAQ), noise pollution and
liquid waste pollution in accordance with applicable norms by employing
[M/s., which is an agency approved by State Pollution Control Board].
The existing environmental data and the limits specified for different
pollutants, the locations of their measurements and the frequency of
monitoring are given in the table below.
Table 3.3
Environmental
Aspects
Stack
Emissions
Document Number
LII-GETS12021-G-00100-003
State Pollution and
SPM
(mg/Nm3)
Parameters
Achieved
Not to exceed
[]
[]
No. of
locations for
measurement
[]
Frequency
of
Sampling.
[]
Rev
No.
Description
Page
No.
Date of Issue
03
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[25]
25.09.2013
Power Plant]
Environmental
Aspects
State Pollution and
Ambient Air
Quality
SPM
On
24
Hrs
Basis
On
Annual
Basis
[]
[]
Parameters
Achieved
On
24
Hrs
Basis
On
Annual
Basis
[]
[]
(g/m3)
RPM
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[LOGO OF
UTILITY]
No. of
locations for
measurement
Frequency
of
Sampling.
[]
[]
[]
[]
(g/m3)
SO2
(g/m3)
NOX
(g/m3)
Process
Effluent
Leaving the
Plant Boundary
Document Number
LII-GETS12021-G-00100-003

pH
[]
[]
Colour
[]
[]
Odour
[]
[]
Tempera
ture
[]
[]
TSS
(mg/l)
[]
[]
Oil &
grease
(mg/l)
[]
[]
COD
(mg/l)
(mg/l)
[]
[]
BOD
(mg/l)
[]
[]
Rev
No.
Description
Page
No.
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[26]
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Power Plant]
Environmental
Aspects
3.5
State Pollution and
Parameters
Achieved
Chloride
(mg/l)
[]
[]
Sulphate
(mg/l)
[]
[]
TDS
(mg/l)
[]
[]
Zinc
(mg/l)
[]
[]
Fluoride
(mg/l)
[]
[]
Mercury
(mg/l)
[]
[]
[LOGO OF
UTILITY]
No. of
locations for
measurement
Frequency
of
Sampling.
Feedback from the Plant Operators

Detailed discussions with the Plant operators provided the feedback about
the design and operation related problems about the various systems which
are listed in the Table 3.4 below.
Table 3.4
S. No.
Name of the
System/Equipment
Type of Problem
Probable Solution
as per the
Operators
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
03
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[27]
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LII-GETS12021-G-00100-003
Power Plant]
S. No.
3.6
Name of the
System/Equipment
Type of Problem
[LOGO OF
UTILITY]
Probable Solution
as per the
Operators
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
History of Failures and Trend Analysis

The year wise record of failures experienced by the plant during the period
of last ten (10) years is furnished in the Table 3.5 below.
{While giving the History of Failures during the last ten (10) years in the
Table below, categorize the Failures into two types as follows:
i) Failures leading to Tripping of Unit and
ii) Failures leading to Reduced Generation.
Further, indicate for each category, the total number of occurrences of such
incidents in a year and the corresponding time in hours for which the
incidents persisted.}
Table 3.5
History of Failures
Year
Total
Number of
Failures in
a Year
Incidents Leading to Tripping

of Unit
Incidents Leading to
Reduced Generation
Remarks
Total
Number
of Boiler
Tube
Leakages
in the
Year
Total
Numbe
r of
Trappin
gs in
the
Year
Total
Hours
of
Trippin
g in
the
Year
Total
Incidents
in the Year
Total Hours
of Reduced
Generation
[....]
[]
[]
[]
[]
[]
[]
[]
[....]
[]
[]
[]
[]
[]
[]
[]
[....]
[]
[]
[]
[..]
[]
[]
[]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[28]
25.09.2013
Power Plant]
Year
[....]
Total
Number of
Failures in
[]
Incidents Leading to Tripping

of Unit
[....]
[]
[]
[....]
[]
[....]
[]
[]
[LOGO OF
UTILITY]
Incidents Leading to
Reduced Generation
Remarks
[..]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[....]
[]
[]
[]
[]
[]
[]
[]
[....]
[]
[]
[]
[]
[]
[]
[]
[....]
[]
[]
[]
[]
[]
[]
[]
{Furnish the trend chart by plotting (i) number of trippings (ii) number of
boiler tube leakages and (iii) number of incidents leading to reduced
generation of the unit against successive years of operation since
commissioning. Analyze the trend of failures and discuss the underlying
reasons. Expand the table for the total years of operation.}
3.7
Major Replacements done in the Plant

{Furnish the record of major replacements done for the main plant (BTG) and
the Balance of Plant right from the first date of commissioning. Expand the
table for the total years of operation.}
Table 3.6
Major Replacements done till now
S.No.
Name of the System/Equipment
Reason for Replacement
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[29]
25.09.2013
Power Plant]
S.No.
[LOGO OF
UTILITY]
Name of the System/Equipment
Reason for Replacement
[]
[]
10
[]
[]
[]
[]
{Note: Reports on major failure in the past should be reviewed by the

consultant to identify any major cause of fault, rectifications carried out and
performance after rectification. Based on such review, if any further
Condition Assessment of test, over and above specified in this Model Report
are required, same should be carried out and results and recommendations
should be incorporated in Project specific Report.}
3.8
Objectives of R&M Solution

[Based on the condition and age, it is necessary to study the following
renovation possibilities, if the units performance is to be improved;
Restoring / up-rating of Generation Capacity on a continuous, safe
and reliable basis to suit the present coal quality.
Increasing unit availability and reliability on a sustainable basis to
meet the current requirements like availability based tariff.
Achieving rated or better efficiency of the unit so that the Cost of
Generation (COG) remains competitive.
Achieving an extended plant life by minimum twenty (20) years.
Different options as per the FR are to be explored.
Meeting current statutory environmental norms.
Improving safety of plant and personnel.
Reduction of Auxiliary Power Consumption.
Replacing the existing obsolete technology.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[30]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
RESIDUAL LIFE AND CONDITION ASSESSMENT OF EQUIPMENTS AND

COMPONENTS
4.1
General
{Describe in this section, the operating data collected during the Walk
Down Survey and the results and findings of various Residual Life
Assessment and Condition Assessment Studies conducted on the
equipments and components of the Boiler & Auxiliaries, Turbo Generator &
Auxiliaries and all the systems of the Balance of Plant.}
4.2
Operating Data Collected During the Hot Walk Down Survey

Major Operating Parameters of the Plant as noted during the Hot Walk Down
Survey are indicated in the Table 4.1 below:
Table 4.1
Operating Parameters of the Plant as per Hot Walk Down Survey
Description
Units
Design
Parameters
Operating
Parameters
Load
MW
[..]
[..]
GCV
kCal/kg
[..]
[..]
Main Steam Flow
T/h
[..]
[..]
Main Steam Temp.
Deg C
[..]
[..]
Main Steam Pressure
kg/cm2
[..]
[..]
Cold Reheat Steam Pressure
kg/cm2
[..]
[..]
Hot Reheat Steam Pressure
kg/cm2
[..]
[..]
Hot Reheat Steam Temp (Left

and Right)
Deg C
[..]
[..]
Cold Reheat Steam Temp (Left

and Right)
Deg C
[..]
[..]
IP Turbine Exhaust Steam

Temp (Left and Right)
Deg C
[..]
[..]
IP Turbine Exhaust Pressure
kg/cm2
[..]
[..]
Turbine Exhaust Hood

Temperature.
[..]
[..]
Hot Well T Temperature.
[..]
[..]
Water & Steam Parameters
Document Number
LII-GETS12021-G-00100-003
C
C
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[31]
25.09.2013
Power Plant]
Description
Units
Condenser Vacuum
[LOGO OF
UTILITY]
Design
Parameters
Operating
Parameters
mmHg
[..]
[..]
C.W. Water flow
T/h
[..]
[..]
C.W. Inlet Temperature (L and

R)
Deg C
[..]
[..]
C.W. Outlet Temperature (L

and R)
Deg C
[..]
[..]
Drum pressure
kg/cm2
[..]
[..]
Feed water flow
T/h
[..]
[..]
Feed water inlet temp to ECO
Deg C
[..]
[..]
Feed Water Pressure
kg/cm2
[..]
[..]
Super Heater Spray
T/h
[..]
[..]
Reheater Spray
T/h
[..]
[..]
Air temperature at Air PreHeater Inlet.
Deg C
[..]
[..]
Primary Air temperature at Air

Pre-Heater Outlet.
Deg C
[..]
[..]
Secondary Air temperature at

Air Pre-Heater Outlet.
Deg C
[..]
[..]
Total Quantity of Air
T/h
[..]
[..]
Flue Gas temperature at Air

Pre-Heater Inlet.
Deg C
[..]
[..]

Pre-Heater Outlet.
Deg C
[..]
[..]
CO2 in Flue Gas
[..]
[..]
CO2 at Inlet of Air Pre-Heater
[..]
[..]
CO2 at Air Pre-Heater Outlet
[..]
[..]
CO2 in Flue Gas Air PreHeater Outlet
[..]
[..]
Air and Flue Gas Parameters
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[32]
25.09.2013
Power Plant]
Description
Units
CO2 in Flue Gas Air PreHeater Inlet
[LOGO OF
UTILITY]
Design
Parameters
Operating
Parameters
[..]
[..]
% of Excess Air in Flue Gas at

ID fan Outlet
[..]
[..]
No. of Mills in operation for full

load.
Nos
[..]
[..]
Wind box Differential Pressure

(Left and Right)
mmwc
[..]
[..]
Air Temperature
Deg C
[..]
[..]
Furnace Draft
mmwc
[..]
[..]
ID Fan margin
[..]
[..]
Extraction Steam Pressure HP

Heater (HPH) No.7 at Heater
End
kg/cm2
[..]
[..]
Extraction Steam Pressure

HPH No.6 at Heater End
kg/cm2
[..]
[..]

kg/cm2
[..]
[..]
Feed Water (FW) Pressure

Entering HPH-5
kg/cm2
[..]
[..]
F.W. Pressure Entering HPH-6
kg/cm2
[..]
[..]
kg/cm2
[..]
[..]
F.W. Pressure Common Outlet

of HPH
kg/cm2
[..]
[..]
F.W. Temperature Entering

HPH-5
Deg C
[..]
[..]
F.W. Temperature Leaving

HPH-5
Deg C
[..]
[..]

HPH-6
Deg C
[..]
[..]

HPH-6
Deg C
[..]
[..]
HP Heaters Parameters
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[33]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
Description
Units
Design
Parameters
Operating
Parameters

HPH-7
Deg C
[..]
[..]
F.W. Temperature Common

Outlet of HPH
Deg C
[..]
[..]
Drain Temperature Heater No.5 Deg C
[..]
[..]
[..]
[..]
[..]
[..]
Extraction Steam Temperature

HPH-5 (Heater end)
Deg C
[..]
[..]
Extn. Steam Temp. HPH-6

(Heater end)
Deg C
[..]
[..]
Extraction Steam Temp. HPH-7 Deg C

(Heater end)
[..]
[..]
Deaerator Pressure
kg/cm2
[..]
[..]
Gauge Glass on HPH-5, 6 and

7
mmwc
[..]
[..]
Level indication in UCB for

HPH-5, 6 and 7
mmwc
[..]
[..]
Relative humidity
[..]
[..]
Oxygen in fuel
[..]
[..]
Distribution of fly ash
[..]
[..]
Distribution of bottom ash
[..]
[..]
Distribution of duct ash
[..]
[..]
Distribution of air heater ash
[..]
[..]
Secondary Fuel Oil

Consumption
ml/ kWh
[..]
[..]
[..]
[..]
Other Information
Currents Drawn by Auxiliary Equipments

Boiler Feed Pump Current
Document Number
LII-GETS12021-G-00100-003
Amp
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[34]
25.09.2013
Power Plant]
4.3
[LOGO OF
UTILITY]
Description
Units
Design
Parameters
Operating
Parameters
Mills Motor Current
Amp
[..]
[..]
ID Fan Motor Current
Amp
[..]
[..]
FD Fan Motor Current
Amp
[..]
[..]
PA Fan Motor Current
Amp
[..]
[..]
CEP Motor Current
Amp
[..]
[..]
CW Pumps Motor Current
Amp
[..]
[..]
Equipments Subjected to Various Tests and Results Obtained

{Summarize in the table below, various equipment & their components,
subjected to various types of RLA&CA tests / inspections starting from
the Walk Down Surveys and mention the results obtained from each of
these tests. Identify each equipment by its unique tag number wherever
applicable. Also attach the test reports of each test in the form of
Annexure.
The Guidelines for conducting various Destructive and Non-Destructive
type of tests, which are normally performed for the major equipments of
the Power Plant are appended at the end of this report for general
reference.
Formats for reporting the test results are also appended at the end of this
report, for general reference.
Also attach the Major Operational Parameters of the Plant as noted down
during the Hot Walk Down Survey.}
Table-4.2
Summary of Tests Conducted on Equipments and Results obtained
A) Boiler & Auxiliaries
S.No
1.
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
[Boiler Drum]
Document Number
LII-GETS12021-G-00100-003
Brief
Results/Findings
of the Tests
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[35]
25.09.2013
Power Plant]
S.No
2.
3.
4.
5.
6.
7.
8.
9.
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
[Down
Comers]
[Water Walls]
[Water Wall
Headers]
[Primary Super
Heater]
[Ceiling Super
Heater]
[Platen Super
Heater]
[Final Super
Heater]
{Steam
Document Number
LII-GETS12021-G-00100-003
[LOGO OF
UTILITY]
Brief
Results/Findings
of the Tests
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[36]
25.09.2013
Power Plant]
S.No
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i)[]
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
Headers]
10.
11.
12.
13.
14.
15.
16.
[Economiser]
[Air Preheater]
[Wall Blowers]
[ LRSBs]
[Coal Feeders]
[Coal Pipes]
[Coal Piping
Control
Valves]
Document Number
LII-GETS12021-G-00100-003
[LOGO OF
UTILITY]
Brief
Results/Findings
of the Tests
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[37]
25.09.2013
Power Plant]
S.No
17.
18.
19.
20.
21.
22.
23.
24.
[LOGO OF
UTILITY]
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
[Wind Box]
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
[Dampers]
[Motors]
[Pulverized
Fuel Burners]
[Oil Burners]
[Flame
Scanners]
[Burner Tilting
Arrangement]
[Critical Piping]
Document Number
LII-GETS12021-G-00100-003
Brief
Results/Findings
of the Tests
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[38]
25.09.2013
Power Plant]
S.No
25.
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
[Hangers and
Supports]
iii) []
26.
27.
28.
29.
30.
31.
32.
[Buckstays]
[Ducts]
[Insulation]
[Cladding]
[Refractory]
[ Boiler
Structure]
[Mills]
Document Number
LII-GETS12021-G-00100-003
[LOGO OF
UTILITY]
Brief
Results/Findings
of the Tests
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[39]
25.09.2013
Power Plant]
S.No
33.
34.
35.
36.
37.
[LOGO OF
UTILITY]
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
[FD FANS]
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
[PA Fans]
[ID Fans]
[Electrostatic
Precipitator]
[ Any other
Equipments]
Brief
Results/Findings
of the Tests
B) Turbine and Auxiliaries

S.No
1.
2.
Name of
Equipment
[HP Rotor]
[IP Rotor]
Document Number
LII-GETS12021-G-00100-003
Brief
Results/Findings
of the Tests
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[40]
25.09.2013
Power Plant]
S.No
3.
4.
5.
6.
7.
8.
9.
10
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
[LP Rotor]
[HP Turbine
Casing]
[IP Turbine
Casing]
[LP Turbine
Casing]
[ Diaphragms]
[ HP Turbine
Bolts]
[ IP Turbine
Bolts]
[Bearings]
Document Number
LII-GETS12021-G-00100-003
[LOGO OF
UTILITY]
Brief
Results/Findings
of the Tests
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[41]
25.09.2013
Power Plant]
S.No
11.
12.
13.
14.
15.
16.
17.
18.
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
[Condenser
Tube Plates]
[ Condenser
Online Tube
Cleaning
System]
[Condenser
Tubes]
[Condensate
Extraction
Pumps]
[Gland Steam
Cooler]
[LP Heaters
and Drain
Coolers]
[Deaerator]
[Boiler Feed
Pumps]
Document Number
LII-GETS12021-G-00100-003
[LOGO OF
UTILITY]
Brief
Results/Findings
of the Tests
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[42]
25.09.2013
Power Plant]
S.No
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
[HP Heaters]
19.
[HP Bypass
System]
20.
[LP Bypass
System]
21
[Turbine
Governing
System]
22.
[Lube Oil
System]
23.
[LOGO OF
UTILITY]
Brief
Results/Findings
of the Tests
iii) []
[Any Other
Equipments]
24.
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
C) Electrical System
S.No
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
1.
[Generator
Stator Winding
Bars]
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
Document Number
LII-GETS12021-G-00100-003
Brief
Results/Findings
of the Tests
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[43]
25.09.2013
Power Plant]
S.No
2.
3.
4.
5.
6.
7.
8.
9.
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
[Retaining
Rings of
Generator]
[Hydrogen
Coolers]
[Excitation
System]
[Automatic
Voltage
Regulator]
[Station
Transformers]
[Generator
Transformer]
[Unit Auxiliary
Transformer]
[Circuit
Breakers]
Document Number
LII-GETS12021-G-00100-003
[LOGO OF
UTILITY]
Brief
Results/Findings
of the Tests
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[44]
25.09.2013
Power Plant]
S.No
10.
11.
12
13.
14.
15.
16.
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
[415 V
Switchgears]
[Battery
Charger]
[ Distribution
Boards]
[DG Sets]
[Illumination
System]
[ Public
Address
System]
[Any other
Equipment]
Document Number
LII-GETS12021-G-00100-003
[LOGO OF
UTILITY]
Brief
Results/Findings
of the Tests
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[45]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
D) Balance of Plant
S.No
1.
2.
3.
Name of
Equipment
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
[Coal Handling
Plant].
[Ash Handling
Plant.]
[Raw Water
System]
[CW/ACW
System]
[DMCW
System]
[Cooling
Towers]
Brief
Results/Findings
of the Tests
iii) []
7.
8.
[Water PreTreatment
Plant]
[DM Plant]
Document Number
LII-GETS12021-G-00100-003
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[46]
25.09.2013
Power Plant]
S.No
9.
10.
Name of
Equipment
[LOGO OF
UTILITY]
Name of the
Component
Unique Tag
Number
Type of
Test(s)
Conducted
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
[Air
Conditioning
and Ventilation
System]
Brief
Results/Findings
of the Tests
iii) []
[Fire Fighting
System.]
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
11.
[Plant and
Instrument Air
System.]
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
12.
[Fuel Oil
System]
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
13
[Any other
Equipment]
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
Results of various RLA/CA Tests and Inspections have been attached at

Annexure [4.1 to 4.18] of the Report.
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[47]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
CONDITION ASSESSMENT OF CIVIL AND STRUCTURAL WORKS
5.1
General
{Describe the methods adopted to assess the condition and residual life of
the Civil and Structural Works.}
5.2
Tests Conducted and Results Obtained

{Summarize in the table below, one by one, the Equipment Foundations,
and Civil Structures & Foundations of various Buildings, which were
subjected to various RLA&CA tests /inspections, starting from the Walk
Down Surveys, clearly mentioning the method of each test, the tools used
and the foundations/ civil structures of the equipments/ buildings/ systems
on which the respective test was performed. Also attach the test reports
of each test in the form of Annexure.
The Guidelines for conducting various Non-Destructive and Partially
Destructive tests, which are normally performed for this purpose, are
appended at the end of this report, for general reference
Formats for reporting the test results are also appended are appended at
the end of this report, for general reference.}
Table-5.1
Summary of Tests / Inspections Conducted and Results Obtained
S.No
1.
2.
Name of
Equipment
Foundation/
Building
Foundation
/Civil
Structure
Name of
the
Foundation
/ Civil
Structure
[Boiler].
[TG
Building.]
Document Number
LII-GETS12021-G-00100-003
Unique
Tag
Number
Type of
Test(s)
Conducted
Brief
Results/Findings
of the Tests
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
iv) []
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[48]
25.09.2013
Power Plant]
S.No
3.
4.
5.
6.
7.
8.
9.
Name of
Equipment
Foundation/
Building
Foundation
/Civil
Structure
Name of
the
Foundation
/ Civil
Structure
[Chimney]
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
iv) []
iv) []
iv) []
iv) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
iii) []
iii) []
iii) []
iii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
[Coal
Handling
Plant]
[Ash
Handling
Plant]
[ Raw Water
Reservoir]
[Water PreTreatment
Plant]
[ Chemical
House]
[DM Plant
Building]
Document Number
LII-GETS12021-G-00100-003
Unique
Tag
Number
Type of
Test(s)
Conducted
[LOGO OF
UTILITY]
Brief
Results/Findings
of the Tests
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[49]
25.09.2013
Power Plant]
S.No
10.
11.
12.
13.
Name of
Equipment
Foundation/
Building
Foundation
/Civil
Structure
Name of
the
Foundation
/ Civil
Structure
[CW Pump
House]
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
i) []
i) []
i) []
i) []
ii) []
ii) []
ii) []
ii) []
[Cooling
Tower]
[Ash Dyke]
[Misc.
Works]
Unique
Tag
Number
Type of
Test(s)
Conducted
[LOGO OF
UTILITY]
Brief
Results/Findings
of the Tests
The Visual Examination Report is furnished at [Annexure-5.1] and the

Detailed Examination Report is placed at [Annexure- 5.2].
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[50]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
RECOMMENDATIONS
The findings and recommendations of the RLA/ CA Tests are discussed as
follows:
Equipment /
Component
Recommendation
Reasons
Reference of
RLA/CA Test
Report
Boiler
[Boiler
Structure]
[Boiler Drum]
[Down Comers]
[Water Walls]
[Water Headers]
[Wind Box]
Document Number
LII-GETS12021-G-00100-003
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[51]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Primary Super
Heater]
[Platen Super
Heater]
[Ceiling Super
Heater]
[Final Super
Heater]
[Re-Heater]
[Steam
Headers]
Document Number
LII-GETS12021-G-00100-003
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[52]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Economiser]
[Air pre-Heater]
[Coal Feeders]
[Coal Piping
Control Valves]
[Dampers]
[Motors]
[Oil Burners]
Document Number
LII-GETS12021-G-00100-003
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[53]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Pulverised Coal
Burners]
[Oil Guns]
[Igniters]
[Flame
Scanners]
[Refractory]
[Insulation]
[Buckstays]
Document Number
LII-GETS12021-G-00100-003
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[54]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Ducting]
[Wall blowers]
[LRSBs]
[Pent House]
[Cladding]
[Mills]
Document Number
LII-GETS12021-G-00100-003
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[55]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Attemperators]
[Clinker Grinder]
[Bottom Ash
Hopper]
[PA Fans
including their
drive shafts/
couplings etc.]
[ID Fans
including their
drive shafts/
couplings etc.]
[FD Fans
including their
drive shafts/
couplings etc.]
Document Number
LII-GETS12021-G-00100-003
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[56]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Electrostatic
Precipitator
(Emitting/
Collecting
Electrodes/
Transformer
Rectifier Sets ]
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Hangers &
Supports]
[.]
[.]
[.]
[.]
[.]
[.]
[Emergency
[.]
[.]
[.]
[Any other
systems]
Steam Turbine and Auxiliaries

[Steam Turbine
including
casings,
diaphragms,
rotating discs,
and blades etc.]
[Condenser]
[Critical Piping]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[57]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
Stop Valve]
[.]
[.]
[.]
[Control Valves]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Condensate
Extraction
Pumps]
[.]
[.]
[.]
[.]
[.]
[.]
[Shells and
Tube Bundles of
LP Heaters]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[HP Bypass]
[LP Bypass]
[Deaerator]
[Boiler Feed
Pumps/
Cartridges/
Couplings/Boost
er Pumps]
[Shells and
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[58]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
Tube Bundles of
HP Heaters]
[Any other
systems]
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Balance of Plant
[Wagon
Tipplers]
[Track Hopper]
[Crushers]
[Conveyor
Belts]
[Drive Pulleys]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[59]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Idlers]
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Magnetic
Separator]
[.]
[.]
[.]
[.]
[.]
[.]
[Ash Slurry
Pumps]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Ash Slurry
Pipes]
[.]
[.]
[.]
[Ash Dyke]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Metal Detector]
[Ash Water
Recycling
System]
[Water Intake
Pumps]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[60]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[Pre-Treatment
Plant]
[.]
[.]
[.]
[Clarified Water
Pumps]
[.]
[.]
[.]
[DM Plant
Pressure
Vessels]
[.]
[.]
[.]
[.]
[.]
[.]
[Interconnecting
pumps and
piping of DM
Plant]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[DM Storage
Tanks]
[.]
[.]
[.]
[.]
[.]
[.]
[CW Pumps]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[ACW Pumps]
[Cooling Towers
Fans/ Gear
Boxes/ Drive
Shafts etc]
[Fire Fighting
Pumps- Motor
Driven]
[Fire Fighting
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[61]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
Pumps- Diesel
Engine Driven]
[.]
[.]
[.]
[Fire Hydrants]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Fuel Oil
Unloading
Pumps]
[.]
[.]
[.]
[.]
[.]
[.]
[Suction
Heaters]
[.]
[.]
[.]
[Steam/ Electric
Heat Tracing]
[.]
[.]
[.]
[Fuel Oil
Pressuring &
Forwarding
Pumps]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Compressors]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Emulsifiers]
[Hydro
Pneumatic
Tanks]
[Jockey Pumps]
[Air Receivers]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[62]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Air Driers]
[Air
Conditioning
System]
[Ventilation
System]
[Effluent
Treatment
Plant]
[Any other
systems]
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Electrical System
[Generator
Stator ]
[Generator
Rotor]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[63]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Generator
Circuit Breaker]
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Unit Auxiliary
Transformer]
[.]
[.]
[.]
[.]
[.]
[.]
[Circuit
Breakers]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Generator
Transformer]
[Station
Transformer]
[LT Switchgear]
[HT Switchgear]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[64]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Public Address
System]
[.]
[.]
[.]
[.]
[.]
[.]
[Illumination
System]
[.]
[.]
[.]
[.]
[.]
[.]
[DG Sets]
[.]
[.]
[.]
[.]
[.]
[.]
[6.6 kV
System]
[415 V System]
[HT & LT
Motors ]
[DC System]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[65]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Any other
Systems]
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Switchyard
[Circuit
Breakers]
[Isolators]
[Lighting
Arrestors]
[Any other
Systems]
Control and Instrumentation

[DDCMIS]
[Soot Blowers]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[66]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Boiler
Temperature MI
Thermocouple
[.]
[.]
[.]
[.]
[.]
[.]
(K-Type)]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Burner Tilting
Arrangement]
[Boiler
Protections]
[Turbine
Protection]
[Turbine
Controls EHC]
[Turbine
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[67]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
ATRS]
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Machine
Conditioning
Monitoring
System]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Automatic
Turbine Testing]
[.]
[.]
[.]
[.]
[.]
[.]
[Turbine Stress
Evaluator (
TSE)]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[HP LP Bypass ,
PRDS]
[.]
[.]
[.]
[.]
[.]
[.]
[Gland Steam
Pressure
Control]
[.]
[.]
[.]
[.]
[.]
[.]
[Control Valves/
Dampers]
[.]
[.]
[.]
[.]
[.]
[.]
[Furnace Draft
Control System]
[.]
[.]
[.]
[.]
[.]
[.]
[Turbine
Supervisory
System]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[68]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Total Air Flow

Control System]
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Mill A Temp to
--- Mill F
Temp Control
System]
[.]
[.]
[.]
[Super Heater
Steam Temp
Control System]
[.]
[.]
[.]
[Re- Heater
Steam Temp
Control System]
[.]
[.]
[.]
[Drum Level
Control System]
[.]
[.]
[.]
[BFP Scoop
Tube]
[.]
[.]
[.]
[Deaerator Level
Control System]
[.]
[.]
[.]
[Deaerator
Pressure]
[.]
[.]
[.]
[Hot Well Level]
[.]
[.]
[.]
[HP Heaters
Level ]
[.]
[.]
[.]
[LP heaters
Level ]
[.]
[.]
[.]
[BFP
[.]
[.]
[.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[69]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
Recirculation
Valve]
[Feed Water
Control Valve]
[.]
[.]
[.]
[Transmitters]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Pressure / DP
Gauges]
[.]
[.]
[.]
[Temp Gauges]
[.]
[.]
[.]
[Pressure / DP
Switch]
[.]
[.]
[.]
[Temperature
Switch]
[.]
[.]
[.]
[Resistance
Temperature
Detectors /
Thermo
Couples]
[.]
[.]
[.]
[Level
Measurement]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Flow
Measurement &
Primary Flow
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[70]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
Sensors]
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[UPS]
[.]
[.]
[.]
[Impulse Pipe &

Fittings]
[.]
[.]
[.]
[.]
[.]
[.]
[Steam & Water

Analysis
System]
[.]
[.]
[.]
[.]
[.]
[.]
[PLCs]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Junction
Boxes]
[.]
[.]
[.]
[.]
[.]
[.]
[Cable & Cable

Trays]
[.]
[.]
[.]
[.]
[.]
[.]
[Fuel Flow
Measurement ]
[Transmitter
Enclosures &
Racks]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[71]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Any other
systems]
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Civil Works
[Boiler
Foundations]
[TG Building
Foundations/
Civil Structures]
[Chimney]
[Wagon Tippler
Hoppers/ Track
Hopper]
[Coal Handling
Plant Crusher
House/ Junction
Towers/
Conveyor
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[72]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
Reasons
[LOGO OF
UTILITY]
Reference of
RLA/CA Test
Report
Galleries]
[.]
[.]
[.]
[Ash Slurry
Pump House]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Clarifiers/
Chemical House
of PreTreatment
Plant]
[DM Plant
Building]
[CW Pump
House]
[Cooling Tower]
[Miscellaneous
Works]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[73]
25.09.2013
Power Plant]
Equipment /
Component
Recommendation
[Any other
Systems]
Document Number
LII-GETS12021-G-00100-003
Reasons
[LOGO OF
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Reference of
RLA/CA Test
Report
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{GUIDELINES FOR RLA AND CA STUDIES ON EQUIPMENTS/COMPONENTS}

{The life assessment studies involve knowledge of prior history of operation
and information of design & manufacturing of components of equipment. To
carry out exhaustive diagnostic analysis about the condition of the critical
components of the unit, various RLA/CA studies are conducted at the time
of shut down of the unit .The purpose of these tests is to determine the
extent of deterioration of the components from the original specifications.
Various tests which are generally conducted for such RLA/CA studies are
mentioned below.
These tests are over and above the routine tests which are normally required
to be conducted at an interval of two to three years as per the
recommendations of the Original Equipment Suppliers namely the Insulation
Resistance (IR) test & Polarization Index (PI) test etc for Generators / HT
Motors, Dissolved Gas Analysis (DGA) for Transformers and Hydraulic &
Pneumatic tests for the Generator Cooling System and Hydraulic Test for
Regenerative LP/HP Heaters & Steam Condensers.
A Check List for conducting various RLA&CA Tests for Equipments and
Components of the main plant is placed at Annexure - A.
(A) Non Destructive Tests (NDTs)
Non Destructive Tests are carried out to assess the integrity of a system or
component without compromising its performance. A brief discussion on
various tests is discussed below:
a) Visual Examination (VE)
Visual examination is the simplest NDT method which is carried out to
broadly assess the material deterioration due to corrosion, erosion, swelling,
cracking, bowing, sagging and misalignment etc of all the equipments and
components of the Power Plant. Visual examination covers all equipments
and their components.
Visual examinations are carried out both when the unit is in operation (Hot
Walk Down Survey) and when the unit is shut down (Cold Walk Down
Survey).
b) Fiberscopic/ Boroscopic Inspection
Fiberscopic / Boroscopic Inspections are extension of visual examinations.
Borescope and fiberscope are two different instruments, commonly used for
various visual inspections. Users can insert these typical instruments into
confined spaces to see or even record images detected by these
instruments. The purpose of both these scopes is to do non destructive
inspection in confined spaces.
A Fiberscope is a flexible instrument made from optical fibers. A Fiberscope
can be snaked and threaded into spaces located at an angle. In case of a
fiberscope, light transmits down the optic fibers, thus illuminating the entire
area.
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A Borescope, on the other hand, is relatively a rigid instrument fitted with

lenses and mirrors, which allows light to bounce from the mirrors. The entire
process is responsible for illuminating a particular area.
In order to carry out the inspection successfully, the inspector must be
familiar with equipment internals, suspected locations of damage and should
be able to recognize propagation of cracks and whether a condition is
merely an insignificant aberration or potentially catastrophic.
Fiberscopic Inspections can be carried out to examine the internal condition
of Water wall Headers and inlet & Outlet Headers of Final Super Heaters.
Boroscopic Inspections can be carried out to examine the internal condition
of bores which are less deep, like studying the cracks in bore surfaces of
rotors of HP/IP/LP Turbines (if rotors are provided with bores).
c) Dye Penetrant Test (DPT)
This test is carried out primarily to locate surface defects such as
cracks, pitting, weld pinholes, porosity, and other flaws which occur in
almost any material. This method involves application of [coloured /
fluorescent] liquid dye on oxide-free, smooth cleaned surface, which
penetrates into the surface flaw and is highlighted by using a developer. The
developer absorbs the penetrant by capillary action thereby highlighting the
flaw. Applicable Standard for Testing is ASTM D5 117-09.
Components like Economiser Outlet Header, Boiler Drum, Down-comers,
Inlet and Outlet Headers of Super heaters & Re-heaters, Main Steam Piping,
CRH & HRH Headers, CRH & HRH Piping, Steam inlet pipe weld joints,
Strainer, Valve body, Turbine Rotors, Impellers of ID/FD/BFP/CEP Fans,
Casings of Turbines, Casings of Gear Boxes, Turbine Blades, Diaphragms
and bearing etc. can be subjected to DPT to locate surface defects such
as cracks, pitting, porosity, and other flaws.
DPT can also be usefully conducted to assess the soundness of welds of
Boiler structure & platforms etc and those of the Trestles of coal conveyors/
pipe-lines/ cables etc.
d) Magnetic Particle Inspection (MPI)
Magnetic Particle Inspection (MPI) is utilized to detect surface and subsurface flaws in ferrite materials by inducing a magnetic field into the parent
material. By sprinkling fluorescent magnetic particles on the surface of the
parent material after the magnetic fields are induced, discontinuities are
located by observing the patterns formed due to the distortions of the
magnetic fields. Magnetizing is done at two mutually perpendicular fields to
ensure detection of defects in all possible directions. Applicable Standard for
Inspection is ASTM E 709-1995.
Components like Boiler Drum, Main Steam piping, CRH & HRH Headers,
CRH Piping, HRH Piping, Turbine Rotors, Casings and Diaphragms, etc. can
be subjected to Magnetic Particle Inspection.
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e) Ultrasonic Test -Scanning (UT-S)

One of the most effective examination techniques is ultrasonic testing. The
UT-S technique for scanning is used to detect with high accuracy, the
internal defects like wall thinning, pitting, metal embrittlement, cracking, or
material defects. For flaw detection standard ultrasonic flaw detector is
used. Applicable Standard for Testing is ASTM E164 and ASTM E114.
CRH & HRH Headers, CRH & HRH Piping, Turbine Rotors and Casings etc.
can be subjected to (UT-S).
f) Ultrasonic Thickness Testing (UT-T)
Ultrasonic techniques are also used to measure the wall thickness. For
thickness measurement a pulse-echo ultrasonic transducer is used. The
ultrasonic thickness gauge determines the thickness of a part by accurately
measuring the time required for a short ultrasonic pulse generated by a
transducer to travel through the thickness of the material reflected from the
back and inside surface. Applicable Standard for Testing is ASTM-E787-05.
CRH & HRH Headers, CRH & HRH Piping, Turbine Rotors, Blades and
Casings etc. can be subjected to (UT-T).
g) Oxide Scale Thickness Measurement
Scale Deposits on the water side of the boiler tubes undesirably increase the
heat transfer resistance and have long been recognized as a cause of boiler
tube failures.
The oxide scale is generally a concern in Heat Affected Zones (HAZ) of
Super Heaters and Re-Heaters. The scale thickness within these zones may
vary because of the range of temperatures. Selecting the circumferential
location for scale thickness measurement is very important. Because of the
temperature variations, the scale thickness may vary around the tube
circumference. Oxide scale measurements should be performed at
circumferential locations, which are expected to have experienced the
highest temperature.
The thickest scale is expected on tubes located in the hottest sections.
Thermocouple measurements are used to plan oxide scale measurement.
History of prior overheat failures is also used to identify tubes for oxide
scale measurement. Locations which have history of a large number of high
temperature failures can be identified for inspection. Generally speaking,
oxide scale thickness up to 200-250 microns is not critical for failure for the
given tube material specification at corresponding temperature and pressure
and hence the tubes having oxide scale deposition of more than the above
stated value are only considered for calculation of residual life.
The ultrasonic method is used which is based on transmitting a high
frequency sound wave of more than 50 MHz through the tube thickness.
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The thickness of oxide scale is calculated by measuring the time difference

between the signals reflected from the tube / scale interface and the scale /
fluid interface. The outer surface of the tube under inspection region is made
free of fireside oxide deposit and polished to expose the base metal.
Using oxidation growth rate data for the specific material, the equivalent
metal temperature of the tube under which it has been operating, can be
determined indirectly.
The expected creep rupture life of a material is predicted with the
knowledge of a commonly known parameter, the Larson Miller Parameter
(LMP or PLM) given by the following equation:
LMP or PLM = T [Log tr +C]
Where, T =Temperature in Kelvin,
tr =Stress Rupture Time (or Life) in hours and
C= a constant usually of the order 20.
Manufacturers usually conduct accelerated creep rupture life tests of
various materials. The data obtained from these tests includes temperature,
stress and time to rupture. Based upon the test data, plots are generated
between the values of stress and LMP, as shown in the figure below.
With the knowledge of working hoop stress and metal temperature, it is

possible to determine the time for creep rupture failure. The remaining life of
the tube is arrived at by calculating the difference between total expected
creep rupture life at a given set of conditions minus the life the tube has
already spent at those conditions.
The following methodology is used for the calculation of the residual life:
(i)
Data / Empirical formula that correlates the growth rate of oxide scale
thickness with time is first used to compute the equivalent temperature
of the tube metal under which it has been operating.
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(ii) Larson Miller Parameter (LMP) is then determined for the hoop stress in
the tube.
(iii) Knowing the LMP and the tube metal temperature, the Stress Rupture
Time (or Life) in hours is calculated.
(iv) The remaining life of the tube is arrived at by calculating the difference
between total expected creep rupture life at a given set of conditions
minus the life the tube has already spent at those conditions.
Components like Final Super Heater Tubes, Platen Super Heater Tubes, and
Re-Heater tubes can be subjected to oxide scale thickness measurement.
h) In-situ Microstructure Replica Analysis
Creep is one of the most critical factors affecting the integrity of the
components working at elevated temperatures. Components subjected to
creep stress have a limited lifetime. Under the influence of temperature and
stress, materials undergo transformation which leads to segregation and
precipitation in their micro-structure. Microstructure degradation norms
being universally followed by the industry are based on the following
classification of damage rating:
Damage Rating
Status of Microstructure
Class 1
Undamaged
Class 2
Isolated Cavities
Class 3
Oriented Cavities
Class 4
Linked Cavities / Micro Cracks
Class 5
Macro Cracks
For examining the microstructure, a cellulose acetate sheet is applied to a

polished and etched surface to be examined which is first wetted with
acetone. The details of component microstructure are retained by the
acetate sheets in the form of replicas. These replicas are then examined
under the microscope to determine the extent of damage caused to the
microstructure. Damage rating is then correlated with the creep curve to
estimate the remaining life of the components. Applicable Standard for
Testing is ASTM E135.
Components like Boiler Drum and Headers of Super Heaters & Attemprators,
Critical Piping, Turbine Rotors, Turbine Casings and Control Valves which
are subjected to high temperatures continuously and where sample removal
is either difficult or economically not viable can be subjected to in-situ
metallographic Replica Analysis.
i)
Hardness Measurement
Hardness measurements are indicators of real time mechanical properties

and micro structural degradation due to thermal exposure and creep damage
in components operating at high temperatures and pressures. A portable
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hardness tester is used for in-situ measurement of hardness of various

critical components. All critical areas, especially the high temperature weld
joints and heat affected zones are tested for their hardness values.
Applicable Standard for Testing is ASTM E18-11.
j)
Dimensional Measurement (DIM):
The components liable for deformation/ bulging due to wear/ creep, namely
bolts, valves stems, bushing, bearings etc are thoroughly cleaned and
dimension measured to compare with original dimensions. The Dimensional
Measurement of outside diameter and thickness are carried out with the
help of various precision measuring instruments like digital vernier calipers,
screw gauges and bow gauges.
k) Steam Path Audit (SPA)
The purpose of the steam path audit is to verify the internal condition of the
steam turbine. A steam path audit typically addresses the following areas of
concern:1)
2)
Leakages:
- Past stationary stage blading.
- Past rotating stage blading.
- Past shaft end packings, where rotors emerge from
casings.
- Across poorly fitting joints.
- Other miscellaneous leakages.
Surface finish degradation:- Deposits.
- Corrosion.
- Solid particle erosion.
- Mechanical damage.
3) Flow blockages from:

- Deposits.
- Foreign objects.
- Mechanical damage.
4)
Flow path modification from:

- Solid particle erosion.
- Water droplet erosion.
- Mechanical damage
The steam turbine is opened to examine the condition of all the components
coming in the steam flow path, stage by stage. Sources of excess leakage
are identified at the horizontal joint of the casing and packing at both the
shafts ends and at the inter-stage. For determining the sources of excess
leakage, radial clearances are measured at respective places.
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In addition, inspection is done on the blade geometry, increased surface

roughness, solid particle erosion and mechanical damage caused due to
foreign objects.
The Audit data so collected is compared with the new and clean condition
of the turbine to quantify the impact of each problem on heat rate, power
output and efficiency.
l)
Eddy Current Test
Eddy current tests are used to detect cracks, discontinuities measurement of

metal thickness, detection of metal thinning due to corrosion / erosion,
determination of coating thickness and the measurement of electrical
conductivity and magnetic permeability.
Recent advances in instrumentation technology has created significant
opportunities for in place inspection of stationary and rotating blades of
steam turbines for cracks and other damages. Eddy current inspections can
also be performed on condenser tubes to find any defects that may be
present before the tubes develop leakages.
The most basic eddy current testing instrument consists of an alternating
current source, a coil of wire in the form of an inspection probe and an
analog or digital instrument to measure the change in impedance/voltage.
Eddy current probes are available in a large variety of shapes & sizes and
can be custom designed for a variety of applications. As long as the material
being tested is very uniform, the eddy current will be uniform and
consistent. If there is any defect, the eddy current will be disturbed and the
disturbance will be indicated by the instrument.
m) ELCID Test
The Electromagnetic Core Imperfection Detection (ELCID) Test is done to
detect healthiness of stator core inter-laminar insulations of the Generator.
Generator ranks high in terms of criticality and value among the major
equipments in the power plant. As there is no standby Generator available at
sites, its reliability is of paramount importance.
ELCID test is conducted to detect insulation failure between laminations of
stator core of the Generator. The test has the advantage that it does not
require a large energy source to test a large machine. Generally speaking,
the test can be conducted with only 4% of a machines rated flux using a
toroidal winding of a few turns. A 3 kVA supply at 110 V is sufficient to
produce the required excitation.
n) Recurrent Surge Oscillograph (RSO) Test
RSO test is performed to detect faults in rotor windings. The electrical faults
in generator rotors fall into two main categories; faults from the winding
to the rotor body (earth faults) and faults between parts of the
winding (inter-turn winding faults). The existence of these faults frequently
display excessive mechanical vibration and cause serious concern. An RSO
test identifies the type of fault and pinpoints the position of the fault.
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The test is conducted by applying a 12V D.C Voltage step between one end
of the rotor winding and the rotor body. The transmitted wave at the far end
of the winding and the reflected wave at the input end of the winding is
monitored using two oscilloscope channels. A healthy rotor winding will
have two identical traces, which can be superimposed. A rotor with a fault
has different traces and the position of the fault is deduced by scaling in the
time domain.
o) Tan Delta Test
The Dielectric Loss Analysis (DLA) is an off line test used to determine
both the dielectric loss energy and the loss tangent (Tan Delta) of a
machine at various voltage steps up to line voltage. Dielectric Loss Analysis
(DLA) and Tan Delta testing are well established tests and have been
used for many years to evaluate the condition of the windings and the
bushings of the transformers. Both dielectric loss energy and loss tangent
are affected by the void content of the insulation, the higher the void
content the higher the loss tangent and dielectric loss. The loss tangent
represents the sum of solid material (conductive type) losses and the
gaseous losses, as the voids within the insulation discharge causes
breakdown and ionization. The dielectric loss energy is representative of the
gaseous discharge losses within the voids and can also be affected by other
external sparking type discharges. The results can also be affected by
contamination, damp, corona shield and stress grading problems.
p) Furfural Test
Condition of a transformer is mainly decided by the condition of its
insulating materials. The two major insulating materials in the Transformer
are mineral insulating oil and insulating paper. Transformer core and winding
have mainly paper insulation. Base of paper is cellulose.
While the condition of insulating oil of a transformer is periodically checked
in the power plants through Dissolved Gas Analysis (DGA) test as a
preventive maintenance measure, the condition of insulating paper of old
transformers is checked by Furfural Test. The condition of insulating paper is
determined by Furfural Test as per IEC: 1198.
The insulating paper degrades with time at rates which depend on factors
like temperature, amount of air and moisture present. As the degradation
progresses, the products of degradation are released in the oil in the form of
organic compounds known as furfuraldehyde compounds and commonly
referred to as furans.
It is not possible to bring out a piece of paper insulation from a transformer
in service, for testing purpose. However, through Furfural Test, the
condition of paper insulation can be examined without touching it. This
method is called Furfuraldehyde Analysis Test or in short Furfural Test.
For conducting this test, samples are taken from the transformer oil and are
tested for the presence of furans. Generally a value of less than 100 ppb
(parts per billion) is considered normal and a value above than 1500 ppb in
oil indicates high risk of insulation failure. In case the total furan content is
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more than 2500 ppb, the windings of the transformer need to be replaced or
rewound.
Through DGA test also, it is possible to predict the condition of the
insulating paper. In DGA test, the gases in the oil are extracted and the
quantity of gases in a specific amount of oil is analyzed. By observing
percentages of different gasses present in the oil, like Hydrogen (H2),
Methane (CH4), Ethane (C2H6), Ethylene (C2H4), Acetylene (C2H3), Carbon
Monoxide (CO), Carbon Dioxide (CO2), Nitrogen (N2) and Oxygen (O2), one
can predict the condition of transformer oil and take corrective action for its
replacement. During DGA test, if the ratio of CO2 / CO is less than 5.0, it is
predicted that decomposition of insulation paper has set in. If the ratio of
CO2 / CO is less than 3.0, it can be concluded that severe deterioration of
cellulose is taking place.
(B) Destructive Tests
Samples of selected portions of Water Wall Tubes and Super Heater Tubes
are taken to evaluate their mechanical properties like Tensile Strength, Yield
Strength and Elongation. The results of these destructive tests are
correlated with the results of non destructive tests to finalize the
assessment and recommendations.}
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ANNEXURE A
INSPECTION CHECK LIST FOR RLA/ CA STUDIES OF BTG EQUIPMENT
COMPONENT
1.
2.
3.
4.
5.
Boiler Drum
Steam Headers
Water Headers
Steam Piping
Super-Heater &
Re-Heater Tubes
INSPECTION TECHNIQUES FOR RLA/CA STUDIES

VE UT-T UT-S DPT MPI ET
HM REP FBT DT CA
BOILER & AUXILIARIES
6. Water Wall Tubes
7. Ducting
8.Impeller and Shafts

of FD/ID/PA Fans
9. Impeller Hub &

Bearing Shell of
FD/ID/PA Fans
110. Casings of
Boiler/APH/Hoppers
and Ducts.
11. ESP
1.
2.
3.
4.
Turbine Assembly
Rotor
Steam Chest
Casing
5. Blades
6. High Temperature.
Bolts
7. Condenser &
LP/HP Heaters
STEAM TURBINE & AUXILIARIES

B
SPT
F,
G
GENERATOR, TRANSFORMERS & HT MOTORS

1. Stator
2. Rotor
3. Retaining Rings
4.Transformers
5.Generators/ HT
Motors
C
D
NOTE: FOR LEGEND, REFER THE NEXT PAGE
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LEGEND
VE
Visual Examination
CA
Chemical Analysis
UT-T
Ultrasonic Thickness Testing
SPT
Special Purpose Testing
UT-S
Ultrasonic Test Scanning
Oxide Scale Thickness Measurement
DPT
Dye Penetrant Testing
Steam Path Audit
MPI
Magnetic Particle Inspection
ELCID Test
ET
Eddy Current Testing
RSO Test
HM
DGA Test, Tan Delta Test, Furfural Test
REP
In-situ Microscopic Replica Analysis
Helium Leak Detection Technique for Condensers.
FBT
Fiberscopic/ Boroscopic Inspection
Hydraulic Testing to identify failed tubes.
DT
Destructive Testing
Insulation Resistance (IR) Test & Polarization

Index (PI) Test
INSPECTION CHECK LIST FOR BOP EQUIPMENT

Condition Assessment of BOP Equipment should be done during the visual examination of
cold walk down and Hot walk Down Survey. In addition, Performance Test and Auxiliary
Power Consumption Test should be carried out as covered in the Energy Audit Report.
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{GUIDELINES FOR CONDITION ASSESSMENT OF CIVIL / STRUCTURAL WORKS}

{Normally, the life of Civil and Structural Works should be of the order of
sixty (60) years and above, which is much more than the life of Mechanical
and Electrical Components of Thermal Power Plants. However, in certain
cases like exposure to harsh and corrosive environment or natural
calamities, the buildings / structures/ foundations of a plant may get
damaged or become weak due to corrosion or rusting etc. Therefore before
taking up the R&M activity of any plant, it is utmost important to critically
examine the condition of all the civil and structural works. Based on the
examination, any part(s) of the civil and structural works which might have
become weak or defective must be identified and solutions found for their
repair, retrofitting or replacement so as to increase their service life.
On the basis of condition assessment, a building / structure can be placed
into one of the following three categories:
The building / structure does not show any signs of distress and It
satisfies all the safety and serviceability requirements according to
relevant Codes of Practice and hence, no action is needed towards
retrofitting.
The building/structure is seen to be deficient (or distressed) but it can
be repaired and strengthened to satisfy the Codal safety
requirements or performance criteria set by the user.
The building/structure is badly damaged. It is to be demolished and a
new building is to be built.
One needs complete record of building and structure design, construction
drawings including that of foundations, architectural details, specifications
of materials used, geotechnical details of the area, details of any repair or
retrofitting done from the time of construction and details of usage of the
building including the loads. Some Non-Destructive Tests or Partially
Destructive Tests may also be required to check the strength of concrete
masonry etc. The various tests which should be conducted are listed below.
Condition Assessment can be made both through visual examination and
through detailed investigation.
(A)
Visual Examination
The main purpose of visual investigation is to observe and note down all the
items of distress or design deficiency and their locations, supported by
sketches and drawings. The visual inspection includes:
Identification of visible structural damage, such as concrete cracking or
spalling and observations on quality of construction.
Identification of potential non-structural falling hazards, including ceilings,
partitions, curtain Walls, parapets, fixtures, and other non-structural
building elements.
Identification of major alterations made during the operating life of the
plant.
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Observations on the changed condition of soil in very special cases like

that of a natural calamity requiring a fresh geotechnical investigation,
particularly when new equipment is required to be installed within the
plant area.
Documentation of existing conditions with photographs at key locations.
Based on the data collected about the details of the building, visual
observation of damage/distress in different structural components and the
system, the structural engineering experts can categorize the type and
seriousness of damage and make judgments about further course of action.
A Check List for conducting Visual Examination is placed at Annexure B.
(B)
Detailed Investigations
Detailed investigations may have to be carried out in the following events:
When the visual examinations suggest corrosion and rusting of
foundations/structures due to weathering effect, say, as a result of
exposure to corrosive environment.
When the adequacy of existing foundations is required to be checked for
retrofitting of the machines and equipments and especially when the
original construction drawings for the foundations may not be available.
When a part of the building or structure might have been severely
damaged due to a major accident.
Detailed investigations are required for making following types of checks.
i)
ii)
iii)
iv)
v)
Checking the Strength of Concrete Structures.

Assessment of Corrosion of Concrete in RCC Structures.
Assessment of Corrosion of Reinforcement in RCC Structures.
Health Assessment of Structural Steel Works.
Checking the Strength of Concrete Structures.
The investigations may either be in the form of Non-Destructive Tests or

Partially Destructive Tests which are discussed below.
Check List for conducting Detailed Investigations is placed at Annexure-C.
(a) Checking the Strength of Concrete Structures
Non Destructive Tests
i)
Rebound Hammer Test
This test is based on the principle that when a spring-loaded mass strikes
the surface of concrete, the rebound distance can be used to determine the
surface hardness. A standard equipment known as Rebound Hammer or
Schmidt Hammer is used for this purpose which gives the rebound number.
Surface hardness determined during the test also gives an idea about the
soundness and quality of cover concrete. Locations having very low rebound
numbers indicate weak surface concrete that may be affected by corrosion.
The quality of concrete may be interpreted as shown in the Table below.
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Table A- Average Rebound Number and Quality of Concrete

Average Rebound Number
Quality of Concrete
>40
Very good hard layer
30 to 40
Good layer
20 to 30
Fair
< 20
Poor concrete
Delaminated
ii) Ultrasonic Pulse Velocity (UPV) Test

The dynamic modulus of elasticity of concrete is determined by measuring
the velocity of ultrasonic pulse through the concrete. The test equipment
has provisions for generating ultrasonic pulse, transmitting it to concrete,
receiving, amplifying and measuring the pulse and displaying its travel time.
For this test, a good acoustic coupling is required to be established between
the transducers and the concrete for correct measurement of the speed.
Applicable Standard for Testing is BS1881 Part 203, IS: 13311 Part-2,
IS:516-1959, IS:8900
By this test, one can assess the quality of concrete, such as, honey
combing or quality of compaction as per the guidelines indicated in the table
below. However, conducting this test requires special expertise. In case of
any doubt, it will be desirable to carry out further tests.
Table B - UPV Value and Concrete Quality
UPV Value in km/sec
Concrete quality
> 4.5
Excellent
Between 3.5 and 4.0
Good
Between 3.0 and 3.5
Medium
Below 3.0
Doubtful
Partially Destructive Tests

These are surface zone tests, which require access to one exposed concrete
face and cause some localized damage. This damage is sufficiently small to
cause no loss in structural performance. The strength of concrete is
estimated with the help of correlation charts. Different tests in this category
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are based on core sampling, penetration resistance, pull-out, pull-off and

break-off.
i) Core Test
For core test, the samples are taken from the interior of the concrete. The
core samples provide the visual inspection of the interior of the concrete and
can be subjected to direct measurement of the compressive strength. Other
physical properties, such as, density, water absorption, indirect tensile
strength and expansion due to alkali-aggregate reaction can also be
determined. After testing the compressive strength, these samples can be
used for chemical analysis. Applicable Standard for Testing is BS 1881 Part
120.
In core testing, the determination of core size and location is a crucial
factor. The test should be taken at points where minimum strength and
maximum stress are likely to coincide. But, at the same time, the core
cutting causes some damage to the member and may impair the future
performance of the member. Therefore, in slender members, the core should
be taken, away from the critical section. For compression testing, the
diameter of the core should be at least three times the nominal maximum
aggregate size. The accuracy of the test increases with the ratio of core
diameter to the aggregate size. The generally recommended length to
diameter ratio of the cores is between1 to 2.
The core samples can be used for determination of voids and chemical
analysis. Broken samples from the cores can also be used to determine the
pH value and the chloride content in the sample. The chemical tests of core
samples also provide information to assess the state of corrosion of
reinforcing steel.
ii) Penetration Resistance
In penetration resistance testing, a specially designed bolt is fired into
concrete with the help of a standardized explosive cartridge. The equipment
and testing procedure have been standardized by ASTM C803. A consistent
correlation has been found between the depth of penetration and the
strength of concrete.
iii) Pull-Out Testing
In pull-out testing, the force needed to pull a bolt or some similar device
embedded into concrete is measured and correlated with the strength of
concrete. This correlation has been shown to be unaffected by the mix
characteristics and the curing history. The bolt may be inserted at the time
of casting of the concrete or it may be epoxy grouted into a hole drilled into
the hardened concrete. Different versions of this test are in practice in
different parts of the world, such as, Lok-test, North American Pull-out
Method, Internal fracture test, ESCOT, CAPO test etc.
iv) Pull-off Testing
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Two versions of the test are possible. One application consists of in-situ
measurement of tensile strength of concrete. Another application of the test
is in testing of the bond between original and new concrete in repairs and
strengthening. In first case a metallic disk is glued directly to the surface of
concrete and pulled off to measure the force necessary to pull a piece of
concrete away from the surface. In the second case partial coring is done
with a standard diameter of 75 mm and the above procedure is repeated by
gluing the disk at the top of the partial core. For assessing the bonding
strength of the repairs with the original concrete, the depth of the partial
coring should be below the surface of the original concrete.
(b) Corrosion Assessment of Concrete in Reinforced Concrete Structures
For effective inspection and monitoring of reinforced concrete structure, the
condition assessment of reinforcement is an important step. Even for
deciding appropriate repair strategy for a distressed concrete structure, the
determination of corrosion status of reinforcing bars is a must. Most of NDT
methods used for corrosion assessment are based on electrochemical
process. The following Table gives guidelines for interpretation about
corrosion.
Table C-Interpretation of Test Results on Corrosion
Test Results from Chemical Analysis
Interpretation
High pH value (>11.5) and very low

(<0.30%) chloride content.
No corrosion
High pH value (9.5) and high

chloride content greater than 0.4% 0.6% by weight of cement
Corrosion prone
Low pH value (<7) and high chloride

content greater than 0.4% - 0.6% by
weight of cement.
Highly corrosion prone
Corrosion assessment of concrete in reinforced concrete structures can be

made by conducting the following non-destructive tests.
i) Carbonation Test
This test measures the pH of the concrete. Freshly placed concrete normally
has a pH between 12 and 13, which provides protection of the embedded
steel and prevents corrosion even in the presence of water and oxygen.
Concrete is considered carbonated when the pH falls below 11.5. At this pH
level, only moisture is needed to initiate corrosion. Phenolphthalein solution
is a typical color changing indicator that is used to perform the carbonation
tests. The test solution is colorless at and below a pH of 8.2 and is
pink/purple at a pH greater than 10.0. Other indicators are available that
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measure different pH intervals. One commercially available indicator

measures pH from 1 to 14 with a rainbow spectrum.
Testing is performed by exposing a freshly broken face of a concrete
surface. This is accomplished either by chipping off a small piece of
concrete with a rock hammer and chisel, if the carbonation is shallow, or by
drilling a hole with an electric hammer drill. The broken surface is washed
with distilled water to remove dust that may contaminate the surface. The
indicator solution is then sprayed on and the results recorded. The depth of
the probe will need to be increased if only carbonated concrete is found.
Applicable Standard for Testing is ASTM C 457.
ii) Chloride Concentration Test
In coastal areas, saline water may corrode structures; penetrate the
concrete, eventually initiating the corrosion of any uncoated embedded
reinforcement. The accepted threshold value for chloride content in concrete
is 300 parts per million (ppm), above which active corrosion in the
embedded steel will occur. This threshold becomes lower if the concrete is
carbonated.
To determine the durability of the structure, it is important to determine the
chloride environment around the location of rebar. Testing is performed by
taking powder samples from the concrete with a small electric impact
hammer to create a profile of chloride content versus depth. The sampling
should be taken at approximately 25 mm intervals to a depth below the
nearest level of reinforcement. Samples should be taken from visibly
deteriorated areas, from visibly "clean" areas, and from areas where
exposure to contaminants is unlikely, such as the un-cracked soffit of a
parking structure. This last sampling area is necessary to establish
background levels of chloride. There is always some level of chloride present
in concrete that comes from the individual components. This is allowed, but
limited, by codes. Applicable Standard for Testing is BS 1881 Part 124.
(c) Corrosion Tests for Embedded Steel in Reinforced Concrete Structures
Corrosion of reinforcement in concrete structures is a complex
electrochemical process. Migration of moisture and aggressive chemicals
through the porous cover concrete would cause corrosion of steel
reinforcement. The factors that influence corrosion are:
Cover thickness,
Quality of concrete in the cover region, especially its permeability and
diffusivity,
Environmental conditions,
Value of pH and level of chloride in concrete, and
Presence of cracks.
Following non-destructive tests are found useful for the determination of

corrosion of reinforcement.
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i) Half-Cell Potential Test

This test can give the probability of corrosion activity taking place at the
point where the measurements of potentials are taken from a half-cell,
typically, a copper-copper sulphate half-cell. An electrical contact
established with the exposed steel and the half-cell is moved across the
surface of concrete for measuring the potentials.
ii) Cover Thickness Test
This test is useful for the determination of concrete cover, location of
embedded rebars & estimation of size of embedded rebars. The instrument
is based on the magnetic technique and is calibrated for different purposes.
The cover thickness is important from the point of view of estimation of
initiation of corrosion. The location and estimation of bar diameter becomes
useful in structures where no structural drawings are available. Applicable
Standard is BS 1881 Part 204.
d)
Health Assessment of Structural Steel

Flaws and cracks can play havoc with the performance of structures and for
improving the performance, detection of these defects is very much
necessary. Visual inspections do not give correct picture of internal
structural defects. By using non-destructive testing methods, the structures
can be evaluated to a greater degree of accuracy, without damaging them.
The following non-destructive tests can be done for evaluating the quality of
steel structures.
i) Dye Penetration Inspection (DPI).
ii) Magnetic Particle Inspection.
iii) Eddy current testing.
iv) Radiography testing.
v) Ultrasonic testing.
i)
Dye Penetration Inspection (DPI)
Dye Penetration Inspection is a method that is used to reveal surface

breaking flaws by bleed out of a colored or fluorescent dye from the flaw.
The technique is based on the ability of a liquid to be drawn into a "clean"
surface breaking flaw by capillary action. After a period of time called the
"dwell," excess surface penetrant is removed and a developer applied. This
acts as a "blotter." It draws the penetrant from the flaw to reveal its
presence. Colored (contrast) penetrants require good white light while
fluorescent penetrants need to be used in darkened conditions with an
ultraviolet "black light". Applicable Standard for Testing is IS: 822-1957.
ii) Magnetic Particle Inspection (MPI)
Magnetic particle inspection is a NDT method used for defect detection in
steel structures. This is a fast and relatively easy method to apply in field.
MPI uses magnetic fields and small magnetic particles, such as iron fillings
to detect flaws in components. The component being inspected must be
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made of a ferromagnetic particle such as iron, nickel, cobalt or some of their

alloys. Ferromagnetic materials are materials that can be magnetic to a level
that will allow the inspection to be effective.
The method may be used effectively for inspection of steel girders and other
parts made of steel. Applicable Standard for Testing is IS: 822-1957.
iii) Eddy Current Test
Eddy current equipment can be used for a variety of applications such as
detection of cracks, discontinuity, measurement of metal thickness,
detection of metal thinning due to corrosion / erosion, determination of
coating thickness and the measurement of electrical conductivity and
magnetic permeability.
The most basic eddy current testing instrument consists of an alternating
current source, a coil of wire connected to this source, and a voltmeter to
measure the voltage change across the coil. An ammeter could also be used
to measure the current change in the circuit instead of using the voltmeter.
Applicable Standard for Testing is IS: 822-1957.
For inspection of major steel beams and columns, this technique can be
used for detection of surface breaking cracks. This is an excellent method
for detecting surface and near surface defects when the probable defect
location and orientation is well known. Defects such as cracks are detected
when they disrupt the path of eddy current and weaken their strength.
iv) Radiographic Testing
This is the technique of obtaining a shadow image of a solid using
penetrating radiation such as X-rays or Gamma rays. These rays are used to
produce a shadow image of an object on film. Thus if X-ray or Gamma ray
source is placed on one side of a specimen and a photographic film on the
other side, an image is obtained on the film which is in projection, with no
details of depth within the solid. Images recorded on the films are known as
radiographs. Applicable Standard for Testing is IS: 822-1957.
The contrast in a radiograph is due to different degrees of absorption of Xrays in the specimen and depends on variations in specimen thickness,
different
chemical
constituents,
non-uniform
densities,
flaws,
discontinuities, or to scattering processes within the specimen.
v) Ultrasonic Testing
Mechanical vibrations of different kinds can travel through solids due to their
elastic properties. Ultrasonic waves due to their higher frequency and
smaller wave length provide a much better possibility to find defects and
determine their size and their position. The vibrations are normally generated
by the use of a piezoelectric crystal, which can be excited by an electrical
pulse. The two most common test methods, the through transmission
technique and the pulse echo technique are used to determine the test.
Applicable Standard for Testing is IS: 822-1957.}
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ANNEXURE B
Check List for Conducting Visual Examination of Civil / Structural Works.
Name of the
Civil
/Structural
Works.
Name of Element
Foundations
Columns
Main Power
House
Building
Beams/
Slab/
Roof
TG
Foundation
Boiler
Structure
Chimney
ESP
Steel
Frame
Bracings
Surface finish/
Painting/Cladding/
Lining
Structure
Transformer
Yard
(foundation)
Machine
foundations
Switchyard
Substation
Cooling
Towers
Water
Treatment
Plant
CW Pump
House
Coal
Handling
Plant and
Railway
siding
Ash
Handling
System.
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Name of the
Civil
/Structural
Works.
[LOGO OF
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Name of Element
Foundations
Columns
Beams/
Slab/
Roof
Steel
Frame
Bracings
Pipe racks
Cable and
Pipe
Trenches
Supporting
system for
Monorail /
Hoist / EOT
crane
Roads and
cross
drainage
works
Document Number
LII-GETS12021-G-00100-003
Surface finish/
Painting/Cladding/
Lining
Rev
No.
Description
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ANNEXURE- C
Check List for Conducting Detailed Investigations of Civil / Structural Works
Sl.
No.
1.
Property under
investigation
Concrete
Strength
(*See Note
Below)
2.
3.
4.
Corrosion
Resistance of
Concrete in RC
Structures.
Corrosion of
Embedded
Steel
Test
Equipment type
Rebound Hammer
Test
Ultrasonic Pulse
Velocity Test
Mechanical
Core Test
Mechanical
Penetration
Resistance Test
Pull-Out Test
Mechanical
Pull-Off Test
Mechanical
Carbonation Test
Chemical/Mi
croscopic
ASTM
C457
Chloride
Concentration Test
Half-Cell Potential
Test
Cover Depth Test
Chemical/Electrical
BS1881 Part 124
Electromagnetic
BS1881 Part 204
Carbonation depth
Chemical/Microscopic
ASTM C457
Chemical/Electrical
BS1881 Part 124
Chemical
IS:822-1997
Electrical
IS:822-1997
Electrical
IS:822-1997
Radioactive
IS:822-1997
Electrical/ Mechanical
IS:822-1997
Electronic
BS1881 Part
203, IS: 13311
Part-2, IS:5161959, IS:8900
BS1881 Part 120
Mechanical
Electrical
Chloride
Concentration
Structural Steel Dye Penetration Test
Health
(DPT)
(For checking
Magnetic Particle
cracks,
Inspection (MPI)
porosity,
Eddy Current Test
inclusions etc.)
Radiography Test
Ultrasonic Test
Reference Codes/
Standard
*Note: Generally the first activity for rehabilitation work is to carry out conditional survey
or visual examination of the structure. Visual examination should be carried out by a
consultant in association with an experienced structural engineer. The kind of specific
tests to be conducted has to be decided on the basis of the findings of the visual
inspection of the structure and its future requirement.
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ANNEXURE- 4.1
VISUAL INSPECTION REPORT OF PLANT AND EQUIPMENT
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Inspection No.
[..]
Component
[..]
W.O. No.
[..]
Material Specification
[..]
Type of Inspection
[Hot Walk Down Survey / Cold Walk Down Survey]
Observation:
1. [...]
2. [...]
3. [...]
4. [...]
5. [...]
6. [...]
7. [...]
Recommendations:
[..........
...........................................................................................................
...........................................................................................................
...........................................................................................................
.................................]
[Signature]
[Name and Designation of Inspecting Engineer]
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ANNEXURE- 4.2
FIBROSCOPIC INSPECTION
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Inspection No.
[..]
Component
[..]
W.O. No.
[..]
[INSERT IMAGES OF FIBROROSCOPIC INSPECTON]
Observation Table
S.No.
Location
Observation
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Recommendation:
[..........
...........................................................................................................
...........................................................................................................
...........................................................................................................
.................................]
[Signature]
Document Number
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ANNEXURE- 4.3
BOROSCOPIC INSPECTION
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Inspection No.
[..]
Component
[..]
W.O. No.
[..]
[INSERT IMAGES OF BOROSCOPIC INSPECTON]
Observation Table
S.No.
Location
Observation
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Recommendation:
[..........
...........................................................................................................
...........................................................................................................
...........................................................................................................
.................................]
[Signature]
Document Number
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No.
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ANNEXURE- 4.4
DYE PENETRATION TEST REPORT
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Inspection No.
[..]
Component
[..]
W.O. No.
[..]
[..]
Test Details
Surface condition
[Free from loose scale, dust, paint, oil &

Surface was clean & dry.]
Temperature of part
[..]
Penetrant material used
Name
[Colored / Fluorescent]
Make
Penetant
[ ]
Model
Expiry Date
[ ]
[ ]
Cleaner
[ ]
[ ]
[ ]
Developer
[ ]
[ ]
[ ]
Penetrating time
[..]
Developing time
[..]
Standard
[ASTM E709-1995]
Test Result
[ ]
Quantity
Defect
Inspected Noticed
[%]
[..]
[ ]
[%]
[..]
[....]
[.]
3.
[ ]
[%]
[..]
[....]
[....]
S.No
.
Name of parts
Document Number
LII-GETS12021-G-00100-003
Finding/
Observation
Remark
[.....]
[.]
Rev
No.
Description
Page
No.
Date of Issue
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Recommendations
[.
..
]
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
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No.
Date of Issue
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ANNEXURE 4.5
MAGNETIC PARTICLE INSPECTION REPORT
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Test No.
[..]
Component
[..]
W.O. No.
[..]
[..]
Test Details:
Surface condition
[.]
Equipment used
[.], Make []
Type of Magnetic Particles
[. ]
Method of Magnetizing
[. ]
Magnetising Current
[.]
Direction of Field
[.]
Sensitivity Checks
[.]
Method of Demagnetization
[ .. ]
Test Code Followed
[.]
Test Result
Quantity
Defect
Inspected Noticed
S.
No.
Name of parts
Finding/
Observation
Remark
[.]
[%]
[..]
[]
[]
[.]
[%]
[..]
[]
[]
[.]
[%]
[..]
[]
[]
[.]
[%]
[..]
[]
[]
[.]
[%]
[..]
[]
[]
Document Number
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No.
Description
Page
No.
Date of Issue
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Recommendation
[
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
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ANNEXURE- 4.6
ULTRASONIC TEST REPORT
Plant Name
[]
Unit No.
[]
Capacity
[]
Inspection No.
[]
Component
[]
W.O. No.
[]
[]
Test Details
Equipment used
[Ultrasonic flaw detector, Model: ,]
Make
[..]
Technique
[Pulse echo, A-scan direct contact]
Surface condition
[Free from loose scale, dust, paint,

Surface was clean]
Scanning
[Manual]
Standard
[ASME Sec 5 & ASTM E164 & ASTM E114]
Test Results
Quantity
Finding/
Observation
Remark
[]
[]
[]
[%]
[]
[]
[]
[]
[%]
[]
[]
[]
[]
[%]
[]
[]
[]
[]
[%]
[]
[]
[]
[]
[%]
[]
[]
[]
S. No.
Name of parts
Inspected
Defect
Noticed
[]
[%]
[]
Document Number
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No.
Description
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No.
Date of Issue
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Recommendations
[
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
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ANNEXURE- 4.7
ULTRASONIC THICKNESS TEST REPORT
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Test No.
[..]
Component
[..]
W.O. No.
[..]
[..]
Equipment used
: [Ultrasonic flaw detector:; Make : ]
Test Details:
S. No.
Location
Thickness (mm)
Rear
Top
Bottom
[]
[]
[]
[.. ]
Front
[]
[.. ]
[]
[]
[]
[]
[.. ]
[]
[]
[]
[]
[.. ]
[]
[]
[]
[]
[.. ]
[]
[]
[]
[]
Test Results
S. No.
1
Finding/ Observation
[.. ]
[.. ]
[.. ]
[.. ]
[.. ]
[.. ]
[.. ]
[.. ]
[.. ]
[.. ]
Document Number
LII-GETS12021-G-00100-003
Remarks
Rev
No.
Description
Page
No.
Date of Issue
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Recommendations
[
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
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ANNEXURE- 4.8
OXIDE SCALE THICKNESS MEASUREMENT REPORT
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Test No.
[..]
Component
[..]
W.O. No.
[..]
[..]
Equipment used
[Name: ..Make: Model: .]

OBSERVATIONS:
Panel
No.
[.]
Tube
No.
[.]
Oxide scale
readings (Microns)
[.]
Panel
No.
[.]
Tube
No.
[.]
Oxide scale readings

(Microns)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[108]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
Panel
No.
[.]
Tube
No.
[.]
Oxide scale
readings (Microns)
[.]
Panel
No.
[.]
Tube
No.
[.]
Oxide scale readings

(Microns)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Recommendations
[
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[109]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
ANNEXURE- 4.9
IN-SITU METALLOGRAPHIC REPORT
[INSERT IMAGES OF MICRO STRUCTURES]
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[110]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
Annexure 4.9 (continued)

OBSERVATIONS
Replica
No.
[.]
Location
Metallographic Observation
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
[.]
[..]
[..]
Recommendations
[
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[111]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
ANNEXURE 4.10
HARDNESS TEST REPORT (HB)
Instrument Used
[..]
Model
[..]
Make
[..]
Measurement Mode
Accuracy
[.]
[Mean uncertainty . % ]
Location
Hardness Measured (BHN)
Average Hardness
(BHN)
Metal
HAZ
Weld
[..]
[]
[]
[]
[]
[..]
[]
[]
[]
[]
[..]
[]
[]
[]
[]
[..]
[]
[]
[]
[]
[..]
[]
[]
[]
[]
[..]
[]
[]
[]
[]
REMARKS
[..
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[112]
25.09.2013
Power Plant]
[LOGO OF
UTILITY]
ANNEXURE- 4.11
DIMENSIONAL MEASUREMENT TEST REPORT
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Test No.
[..]
Component
[..]
W.O. No.
[..]
[..]
Equipment used
[Name: ..Make: Model: .]
Test Details:
S.No.
Location
Inside Diameter (mm)

X-X
Y-Y
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Recommendations
[The component is found suitable for extended service till next major
overhaul inspection].
[Signature ]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[113]
25.09.2013
Model RLA/CA Report For R&M of Unit No.[..] Capacity [] of [Name of the Power Plant]
[LOGO OF UTILITY]
ANNEXURE- 4.12
Power Generation Loss Due to Deteriorated Condition of Turbine
S.No.
Turbine Part
Inter-stage
Packing
Tip
Seal
Strips
End
Packings
Flow
Path
Damage
Flow
Change
Impact
Cover
Deposit
Surface
Loss
Loss
(kW)
[.]
Steam
Seal
System
Loss
[.]
HP Turbine
[.]
[.]
[.]
[.]
[.]
[.]
[.]
IP Turbine
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
LP- Governor End
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
LP - Generator End
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Total Loss (kW)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page No.
Date of Issue
03
MODEL RLA/CA REPORT
[114]
25.09.214
Model RLA/CA Report For R&M of Unit No.[..] Capacity [] of [Name of the Power Plant]
[LOGO OF UTILITY]
ANNEXURE- 4.13
Increase in Heat Rate Due to Deteriorated Condition of Turbine
S.No
1
2
3
4
5
Turbine Part
Inter-stage
Packing
Tip
Seal
Strips
End
Packings
Flow
Path
Damage
Flow
Change
Impact
[.]
Steam
Seal
System
Loss
[.]
HP Turbine
[.]
[.]
IP Turbine
[.]
LP- Governor End

LP - Generator
End
Total Increase in
Heat Rate
(Kcal/kWh)
Cover
Deposit
Increase
in Heat
Rate
[.]
[.]
[.]
[.]
Total
Increase in
Heat Rate
(kCal/kWh)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[Signature]
[Name and Designation of Inspecting Engine
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page No.
Date of Issue
03
MODEL RLA/CA REPORT
[115]
25.09.214
Model RLA/CA Report For R&M of Unit No.[..] Capacity [] of [Name of the
Power Plant]
[LOGO OF
UTILITY]
ANNEXURE- 4.14
ELCID TEST
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Inspection No.
[..]
Component
[..]
W.O. No.
[..]
[..]
Instruments used
[..]
EXCESSIVE LEAKAGE CURRENTS OBSERVED DURING ELCID TEST

S.No.
Slot No.
Pocket No.
Leakage
Current (mA)
Observation
[.]
[.]
[.]
[........................... ]
[.]
[.]
[.]
[........................... ]
[.]
[.]
[.]
[........................... ]
[.]
[.]
[.]
[........................... ]
[.]
[.]
[.]
[........................... ]
[.]
[.]
[.]
[........................... ]
[.]
[.]
[.]
[........................... ]
[.]
[.]
[.]
[........................... ]
[.]
[.]
[.]
[........................... ]
10
[.]
[.]
[.]
[........................... ]
Recommendations
[
]
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[116]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
ANNEXURE- 4.15
TAN DELTA TEST
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Inspection No.
[..]
Component
[..]
W.O. No.
[..]
[..]
Type of Inspection
[..]
Instruments used
OBSERVATIONS:
Winding Tan Delta Report
Phase Reference
[HV/LV+ Earth]
[HV LV]
[LV/HV + Earth]
Document Number
LII-GETS12021-G-00100-003
Mode
Applied
Voltage (V)
Measured
Current (mA)
Capacitance
(nf)
Dissipation
Factor
[GST]
[..]
[..]
[..]
[.]
[GST]
[..]
[..]
[..]
[.]
[GST]
[..]
[..]
[..]
[.]
[UST]
[..]
[..]
[..]
[.]
[UST]
[..]
[..]
[..]
[.]
[UST]
[..]
[..]
[..]
[.]
[GST]
[..]
[..]
[..]
[.]
[GST]
[..]
[..]
[..]
[.]
[GST]
[..]
[..]
[..]
[.]
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[117]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
HV Bushing Tan Delta Report
Phase Reference
Applied
Voltage (V)
Measured
Current (mA)
Capacitance
[UST]
[..]
[..]
[..]
[.]
[UST]
[..]
[..]
[..]
[.]
[UST]
[..]
[..]
[..]
[.]
[UST]
[..]
[..]
[..]
[.]
[UST]
[..]
[..]
[..]
[.]
[UST]
[..]
[..]
[..]
[.]
[UST]
[..]
[..]
[..]
[.]
[UST]
[..]
[..]
[..]
[.]
[UST]
[..]
[..]
[..]
[.]
Mode
R ph
Y ph
B ph
(pf)
Dissipation
Factor
Recommendations
[
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[118]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
ANNEXURE- 4.16
DESTRUCTIVE TEST REPORT
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Inspection No.
[..]
Component
[..]
W.O. No.
[..]
[..]
Type of Inspection
Particulars of Sample Tested [..]

[..]
Applicable Standard
[Following tube samples were collected for destructive test:]

1) [WW Tube front side . Nos.]
2) [WW Tube RHS side . Nos.]
3) [WW Tubes rear side . Nos.]
4) [WW Tubes LHS side . Nos.]
5) [Platen super heater tube nos... & .]
6) [Final super heater tube nos. . . .... & .]
OBSERVATIONS:
[]
[]
Cross
sectional
area
mm2
[.]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
S.
No.
Details
of Item
Dia width
mm
Document Number
LII-GETS12021-G-00100-003
Tensile
strength
Yield
Strength
Hardness
Elongation %
[]
[..]
[..]
[]
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[119]
25.09.2014
Power Plant]
[]
[]
Cross
sectional
area
mm2
[]
[]
[]
[]
S.
No.
Details
of Item
Dia width
mm
Tensile
strength
Yield
Strength
[LOGO OF
UTILITY]
Hardness
Elongation %
[]
[]
[]
[]
[]
[]
[]
[]
Recommendations
[
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[120]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
ANNEXURE- 4.17
EDDY CURRENT TEST

Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Inspection No.
[..]
Component
[..]
W.O. No.
[..]
Instrument Used
[MakeModel..]
Observation Table
S.No.
Location
Observation
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Recommendation:
[......
.......................................................................................................
.......................................................................................................
.......................................................................................................
.................................................]
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[121]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
ANNEXURE- 4.18
FUFURAL TEST
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Inspection No.
[..]
Details of Transformer
[..]
W.O. No.
[..]
Furan Analysis
Quantity of
Transformer
Oil Sample
Quantity of Furans present in Sample

S.No.
Quantity
1.
Name of Furan
Compound
[..]
2.
[..]
[.]
[..]
[.]
[..]
[.]
[..]
[.]
Total Quantity
[.]
Total Furan
Concentration
[]
[.]
Recommendation:
[......
.......................................................................................................
.......................................................................................................
.......................................................................................................
.................................................]
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[122]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
ANNEXURE 5.1
VISUAL EXAMINATION REPORT OF CIVIL AND STRUCTURAL WORKS

Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Inspection No.
[..]
Component
[..]
W.O. No.
[..]
[..]
Type of Inspection
OBSERVATIONS:
Sl.
No.
Description
Observation
1.
Verification with original

drawings
[.]
2.
Identification of major alterations

with respect to original drawings
[.]
3.
Identification of visible structural

damage
[.]
3.1
Quality of construction
[.]
3.2
Surface defects in concrete
[.]
3.3
Concrete cracking or spalling
[.]
3.4
Joints condition
[.]
3.5
Surface defects in structural

steel members
[.]
4.
Identification of visible finishing

damage
[.]
4.1
Quality of painting
[.]
4.2
Condition of plastering
[.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[123]
25.09.2014
Power Plant]
Sl.
No.
Description
[LOGO OF
UTILITY]
Observation
4.3
Structural Painting
[.]
4.4
Cladding
[.]
4.5
Roof condition
[.]
5.
Masonry condition
[.]
6.
Road and drain condition
[.]
7.
Patch Repair Requirement
[.]
8.
Major Repair Requirement
[.]
8.1
Addition and replacement of

reinforcement
[.]
8.2
Addition and replacement of

structural steel
[.]
8.3
Strengthening of structural
element
[.]
8.4
Strengthening of joints
[.]
9.
Retro fitting requirement
[.]
9.1
Alternative structural
arrangement
[.]
9.2
Requirement of redesigning
[.]
9.3
Replacement and strengthening
[.]
10.
Requirement of protective
measures
[.]
10.1
Protective coatings and special

painting
[.]
8.
Requirement of new
construction
[.]
10.
Condition of Lining
[.]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[124]
25.09.2014
Power Plant]
Sl.
No.
11.
Description
Attached details
[LOGO OF
UTILITY]
Observation
[.]
RECOMMENDATIONS:
[
..]
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[125]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
ANNEXURE 5.2
DETAILED INVESTIGATION REPORT
Plant Name
[..]
Unit No.
[..]
Capacity
[..]
Inspection No.
[..]
Component
[..]
W.O. No.
[..]
[..]
Type of Inspection
OBSERVATIONS:
Plant Name
[.]
Unit Name
[.]
Capacity
[.]
Inspection No
[.]
Component
[.]
Element
[.]
Name of Test
[.]
Name of
Agency
[.]
Reference
code
[.]
Test Result
[.
..]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[126]
25.09.2014
Power Plant]
[LOGO OF
UTILITY]
RECOMMENDATIONS:
[
[Signature]
Document Number
LII-GETS12021-G-00100-003
Rev
No.
Description
Page
No.
Date of Issue
03
MODEL RLA/CA REPORT
[127]
25.09.2014

OF
MODEL DETAILED PROJECT REPORT

PREPARED BY
CONSULTING ENGINEERS
LII-GETS12021-G-00100-004 R04
September 2014
Detailed Project Report For R&M of Unit No. [..] Capacity [..] of [Name of the
Power Plant]
[Logo of
Utility]
Revision No.
Date
Prepared /Revised by
R00
04.09.2012
R.K.Soni (RKS)
R01
08.02.2013
RKS
Revised on the basis of Comments

received from CEA
R02
14.02.2013
RKS
Minor Revision
R03
31.07.2013
RKS
Revised on the basis of Comments of

Task Force Received on 14th May
2013 and the discussions with CEA
on 11th June 2013.
R04
25.09.2014
RKS
Left out comments incorporated
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
First edition Issued.
Description
DETAILED PROJECT REPORT FOR R&M WORKS
Page
No.
Date of Issue
[i]
25.09.2014
Power Plant]
[Logo of
Utility]
BACKGROUND
India. Thermal Power Stations are designed for an economical and stable life span of 25
years, after which, the level of performance starts deteriorating as a result of degradation
of its equipments, components and materials. Deterioration may also take place before the
completion of useful life of 25 years, if the units are not operated and maintained properly.
decreased efficiency and increased cost of generation. This results in costly repair and
loss of revenue. Renovations & Modernization (R&M) and Life Extension (LE) programme
of thermal power station is an activity of carrying out repairs, refurbishments and
replacement of defective equipments & components so as to extend the life of the power
plant by at least 20 years and to restore the performance parameters to equal or better
than the original design parameters.
Need of R&M
In spite of new capacity additions, India continues to face shortages of varying degree in
the supply of energy and peaking power. Implementation of fresh capacity additions for
bridging the demand supply gap involves huge investments and long gestation periods
primarily due to the process of land acquisition and getting the required fuel and water
allocations, permits & clearances, particularly, the environmental clearance.
technologies.
As per the Guidelines issued by Central Electricity Authority (CEA) the following should be
the objectives of R&Mand R&M/LE Programmes.
Consumption, Secondary Oil Consumption etc.
technology.
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[ii]
25.09.2014
Power Plant]
[Logo of
Utility]

Compliance of
requirements.
stringent
environmental norms,
safety and
other statutory

As per the Guidelines issued by Central Electricity Authority (CEA) the following criteria is
to be adopted for considering the R&M and R&M/LE Programmes.
cost of new unit.

Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[iii]
25.09.2014
Power Plant]
[Logo of
Utility]
prepared a document on National Perspective Plan for Renovation & Modernization and
Life Extension and Up-rating (LE&U) of thermal power stations up to the year 2016-17.
This document which also includes revised guidelines for Renovation & Modernization / Life
S.No.
Plan
Year
7th Plan
and Two
Annual
Plans
8th Plan
(R&M)
(LEP)
9th Plan
(R&M)
(LEP)
10th Plan
(R&M)
(LEP)
No. of TPS /
No. of Units
Capacity
(MW)
85-86 to 89-90
& 90-91, 91-92
34 / 163
13570
92-93
to
96-97
44 / 198
43/(194)
1/ (4)
37 / 152
29/ (127)
8/ (25)
97-98
to
2001-02
2002-03 to
2006-07
9/ 25
(14 out of
57 planned )
(11 out of
106 )
Additional
Generation
Achieved
MU/ Annum
10000
Equivalent
MW
20869
(20569)
(300)
5085
763
18991
(17306)
(1685)
14500
2200
3445
(2460)
(985)
2000
300
2000

Programme
(MW)
Achievement
(MW)
Life Extension
Programme (LEP)
R&M Programme
7318
1291
(53 units)
(13 Units)
18965
14855
(76 units)
(59 units)
Total
26383
16146
(129 units)
(72 units)
investigation to identify the R&M works to be carried out and preparation of technical bid
documents based on the investigation was not done. This resulted in unsystematic and
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[iv]
25.09.2014
Power Plant]
[Logo of
Utility]
additional work during execution phase and uncertainty about costs resulting in excessive
implementation time, long shutdown periods of plants and cost overruns. In the absence of
standard commercial rules and policies, suppliers showed little interest in R&M work.
Therefore a strong need was felt for providing standardized bidding procedures as well as
model contracts, formats and specifications etc. to the utilities. Standardization will
harmonize the requirements of all the stakeholders and will lead to their increased
participation.
discuss energy related issues of mutual interest. The first meeting of the ad-hoc sub-group
on energy efficiency in thermal power stations, constituted as per decision of meeting of
IGEF in December 2007, was held under the chairmanship of Joint Secretary (Thermal),
Ministry of Power on 12th March, 2008 in which preparation of standard tendering
document for the purpose of R&M activities was, inter-alia, identified as an area of the
activities. The scope of the assignment was divided in two parts as under:Phase-I Activity:
Phase-I activity comprised an assessment of tendering procedures currently being followed
by public utilities in India and a review of documents used for standard R&M projects and
the documents which have already been developed for energy efficient R&M projects
financed by particularly World Bank. This activity was carried out by M/s Evonik (India)
under the grant provided by GTZ. M/s Evonik (India) submitted the report in September
2009.
Phase-II Activity
November 2009, KfW proposed to finance and carryout the work programme of phase-II
Activity, on behalf of CEA & in consultation with the Task Force. In a meeting held in MOP
on 17th December 2009, chaired by Joint Secretary (Thermal), MOP, the representative of
KfW suggested that CEA may act as Project Executing Agency for the phase-II activity.
Accordingly Ministry of Power, Govt. of India have entrusted the task of Project Executing
Agency to CEA for implementing Phase-II activity. Under Indo-German Energy Forum
(IGEF) assisted programme, M/s Lahmeyer International (India) was appointed on16th March
2012 to provide the consultancy services for Development of tendering procedures and
model contract document for R&M of Fossil Fuel Based Power Plants in India. The scope
of consultancy services included the preparation of the following model documents:
I)

Contractor.

Document Number
Rev
No.
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04
Description
Page
No.
Date of Issue
[v]
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Contractors.

MAHAGENCO.
Tender document for Supply, Erection, Testing and Commissioning of Air Preheater
for Unit 5 & 6 Koradi TPS, MAHAGENCO.
Tender document for replacement of 6.6 KV station transformer incoming breaker &
Tie breaker of Koradi TPS, MAHAGENCO.
KfW Documents
Installation.
Document Number
Rev
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LII-GETS12021-G-00100-004
04
Description
Page
No.
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**************
This Detailed Project Report has been prepared to conceptualize the systematic methods
and procedures to be implemented for carrying out R&M works for the Thermal Power
Plants, taking into account the different practices followed in the past, the practices and
methodologies being adopted by KfW and World Bank, as indicated in the various
documents indicated above. Detailed standard documents like RFP & RFQ documents to
carry out R&M works for the Thermal Power Plants shall be prepared based on this
Detailed Project Report.
**************
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
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NOTES & GUIDELINES FOR USING THE MODEL DETAILED PROJECT REPORT
Lahmeyer International India Pvt. Ltd. (LII), the Consultant to Develop Standard Procedures
and Model Documents for the Renovation and Modernization (R&M) of Fossil Fuel based
Power Plants in India. The above assignment is being financed by KfW Entwicklungsbank.
Accordingly, this Model Detailed Project Report (DPR) has been prepared for the guidance
of Project Authorities who may decide to carryout R&M of their old Coal based Power
Plants so as to extend the life of their plants and make them energy efficient and reduce
emissions.
The purpose of this model document is to standardize the format of the DPR for R&M
works. Since majority of 200/210 MW units are potential candidates for consideration of
Renovation as they have crossed 20 to 25 years of useful life, the enclosed format has
been prepared keeping those 200 MW/210 MW units in view. However, within a few
years, some of the 500 MW Units will also become due for R&M. The utilities are therefore
advised to suitably modify this model document, as applicable, before adopting the same
for 500 MW Units.
This format of DPR (Detailed Project Report) contains two kinds of texts written in black
and in blue colours. The text in blue italics and enclosed in square bracket ([...]) represents
variable information which may differ from project to project. The text and numbers in blue
colour are written for the sake of citing an example. The Utilities and their Consultants are
advised to check the relevance of the same and replace these texts and numbers with the
ones as may be applicable to their specific Project. A few guidelines have also been
provided in blue italics enclosed within red curly brackets ({}), wherever applicable.
*******************
Document Number
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Description
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No.
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MODEL DETAILED PROJECT REPORT

FOR
OF
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
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TABLE OF CONTENT
1
EXECUTIVE SUMMARY..................................................................................... 1
INRODUCTION ................................................................................................. 3
2.1
Description ................................................................................................ 3
2.2
Operational Background ............................................................................... 3
2.3
Objective of undertaking Renovation & Modernisation ...................................... 3
SALIENT FEATURES OF POWER PLANT .............................................................. 5

3.1
Boiler & Auxiliaries...................................................................................... 5
3.2
Turbine & Auxiliaries ................................................................................. 12
3.3
Electrical System ...................................................................................... 17
3.4
Control & Instrumentation .......................................................................... 21
3.5
Balance of Plant ....................................................................................... 21
3.6
Civil Works .............................................................................................. 25
OPERATIONAL HISTORY OF THE UNIT ............................................................. 27

4.1
Performance Parameters of the Unit ............................................................ 27
4.2
Stack Emissions, Ambient Air Quality and Process Effluents ........................... 28
4.3
Tripping and Maintenance Record ............................................................... 30
4.4
Maximum Achievable Load Due To Performance Constraint of ESP .................. 31
4.5
Record of Reportable Accidents .................................................................. 31
4.6
Operation & Maintenance Difficulties Due To Plant Limitations ........................ 32
4.7
Operating Data Collected During Hot Walk Down Survey ................................ 32
SELECTION OF R&M OPTION TO BE IMPLEMENTED ........................................... 37

5.1
Formulation of R&M Options ...................................................................... 37
5.2
R&M option identified for Implementation..................................................... 40
DETAILED SCOPE OF R&M WORK .................................................................... 42

6.1
Boiler and Auxiliaries ................................................................................. 42
6.2
Steam Turbine and Auxiliaries .................................................................... 46
6.3
Balance of Plant ....................................................................................... 48
6.4
Electrical System ...................................................................................... 50
6.5
Instrumentation and Control ....................................................................... 52

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6.6
7
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Civil Works .............................................................................................. 57
PROJECT COST AND COST BENEFIT ANALYSIS ................................................ 59

7.1
Introduction ............................................................................................. 59
7.2
Capital Expenditure for the selected R&M option ........................................... 59
7.3
Cost Estimate for R&M Contract Packages ................................................... 59
7.4
Impact on Tariff ....................................................................................... 59
7.5
Financial Impact ....................................................................................... 60
7.6
Assumptions for Financial Comparison ......................................................... 60
7.7
Inputs for Financial Analysis ....................................................................... 61
7.8
Financial Impact of Selected R&M Option ..................................................... 62
7.9
Other Benefits .......................................................................................... 62
7.10
Impact of Adverse Scenarios ................................................................... 63
CARBON CREDIT AND ENERGY EFFICIENCY CREDIT .......................................... 67
FINANCING OF R&M PROJECT ........................................................................ 68

9.1
Financial Performance of Utility .................................................................. 68
9.2
Means of Finance ..................................................................................... 69
10
IMPLEMENTATION OF R&M PROJECT ........................................................... 71
10.1
Project Team ........................................................................................ 71
10.2
Project Schedule.................................................................................... 71
10.3
Project Management .............................................................................. 71
10.4
Project Monitoring ................................................................................. 72
10.5
Role of R&M Consultant ......................................................................... 72
10.6
Role of the Implementation Support Consultant .......................................... 72
10.7
Quality Management .............................................................................. 72
10.8
Performance Guarantee Test ................................................................... 72
10.9
Liquidated Damages ............................................................................... 73
10.10
Health, Safety and Environment (HSE) ...................................................... 74
10.11
Supply of Spares and Special tools and tackles .......................................... 74
10.12
Training ............................................................................................... 74
10.13
O&M Manuals ....................................................................................... 74
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10.14
11
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Operation and Maintenance ................................................................. 74
SELECTION OF R&M CONTRACTOR .............................................................. 75
11.1
Introduction .......................................................................................... 75
11.2
Bidding Process ..................................................................................... 75
11.2.1 Qualification of Bidders ....................................................................... 75

11.2.2 Stages of Bidding Process ................................................................... 75
11.3
Pre-Qualification .................................................................................... 77
11.3.1 Objective .......................................................................................... 77

11.3.2 Qualification Requirement .................................................................... 77
11.3.3 Documentary Evidence for Qualification................................................. 78
11.4
Request for Proposal and Selection of Successful Bidder ............................. 78
11.4.1 Techno-Commercial Bid (Stage-I) .......................................................... 78

11.4.2 Price Bid (Part-II) ................................................................................ 78
11.5
Packaging and Contracting Concept ......................................................... 79
11.5.1 Packaging ......................................................................................... 79

11.5.2 Contracting ....................................................................................... 80
12
RISKS ........................................................................................................ 82
12.1
Limitation of CA, RLA and LE Studies ....................................................... 82
12.2
Regulatory Risk ..................................................................................... 82
12.3
Risk of R&M Contractor and Personnel ..................................................... 82
12.4
Risk of too weak or too stringent QR for R&M Contractor ............................ 82
12.5
Risk of Non-availability of Spares ............................................................. 83
12.6
Risk of Getting Shutdown for Implementation ............................................ 83
12.7
Financing Risk ....................................................................................... 83
12.8
Implementation Risk ............................................................................... 83
12.9
Equipment Underperformance Risk ........................................................... 83
13
CONFORMITY TO STATUTORY ENVIRONMENTAL NORMS ............................... 84
13.1
Environmental Monitoring Cell ................................................................. 84
13.2
Stack Emissions .................................................................................... 84
13.3
Ambient Air Quality (AAQ) ...................................................................... 84

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13.4
Liquid Effluents ..................................................................................... 84
13.5
Ambient Noise ...................................................................................... 85
13.6
Ash Utilization....................................................................................... 85
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No.
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LIST OF ANNEXURE
ANNEXURE
DESCRIPTION
7.1
SUMMARY OF CAPITAL COST FOR SELECTED R&M OPTION
86
7.2
SUMMARY OF COST ESTIMATE FOR EACH R&M PACKAGE
87
7.3
COST OF GENERATION (COG) CALCULATION FOR VARIOUS

R&M OPTIONS
88
7.4
CASH FLOW AND RETURN ANALYSIS FOR VARIOUS R&M

OPTIONS
PROJECT MILESTONE SCHEDULE
91
10.1
Page No.
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Description
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ABBREVIATIONS TO BE USED
Detailed Project Report for their power plant.}
AAQ
Ambient Air Quality
ACB
Air Circuit Breaker
ACG
AHP
Ash Handling Plant
AHU
Air Handling Unit
ATRS
ATT
AVR
BFP
BOP
Balance of Plant
CAVT
CBD
CCTV
CDM
Clean Development Mechanism
CEA
CER
Certified Emission Reduction
CERC
CFBC
Circulating Fluidized Bed Combustion
CHP
Coal Handling Plant
CRH
Cold Re-Heat
CLCS
Document Number
Rev
No.
LII-GETS12021-G-00100-004
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Description
Page
No.
Date of Issue
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COG
Cost of Generation
CT
Cooling Tower
CV
Control Valve
CW
Cooling Water
CWIP
Capitalized Work in Progress
DCDB
DDCMIS
Digital Distributed Control Monitoring

Information System
DG
Diesel Generator
DGA
Dissolved Gas Analyser
DM
Demineralization
DX
Direct Expansion Type of Air Conditioning Plant
EA
Energy Audit
ECO
Economizer
EEP
Energy Efficiency Programme
EHC
ELCID
EOT
ESP
ESV
EWS
FO
Fuel Oil
FSSS
GC
Gland Condenser
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
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Page
No.
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GCV
GT
HCA
HEA
HP
High Pressure
HRH
Hot Re-Heat
HT
High Tension
HVAC
HVWS
IBD
ICB
IFI
International Financing Institution
IGV
Inlet Guide Vane
IPT
IPR
Inter Posing Relay
IRR
Internal Rate of Return
ISMB
IV
Interceptive Valve
LDO
Light Diesel Oil
LE
Life Extension
LMZ
Leningradsky Mettallichesky Zavod
LPT
LRSB
Document Number
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LII-GETS12021-G-00100-004
04
Description
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No.
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LT
Low Tension
LTSH
LVS
Large Video Screen
MCCB
MOCB
MoEF
Ministry of Environment and Forest
MS
Main Steam
MSSV
NOx
Oxides of Nitrogen
OPC
OWS
PA
Primary Air
PF
Pulverized Fuel
PCN
PDD
PLF
Plant Load Factor
PRDS
PLC
R&M
RFP
RFQ
RH
Reheater
RLA
Document Number
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Description
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No.
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RO
Reverse Osmosis
RPM
Revolution Per Minute
RSO
SADC
SH
Super Heater
SOC
Secondary Oil Consumption
SPM
SOx
Oxides of Sulphur
SS
Stainless Steel
SWAS
TPH/T/hr
Tonnes per Hour
TFT
TPS
TR
TC
Thermocouple
TSE
UPS
VVVFD
WACC
Weighted Average Cost of Capital
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
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Page
No.
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MEASUREMENT UNITS
{The utilities are advised to use the following abbreviations of measuring units while
preparing Detailed Project Report for their power plant.}
C
Degree Celsius
cm2
Square Centimeter
dB (A)
Decibels Absolute
hr
Hour
Hz
Hertz
kCal
Kilo Calorie
kg
Kilogram
kl
Kilo Liter
km
kilo meter
kV
kilo Volt
kVA
kilo Volt Ampere
kW
kilo Watt
kWh
Kilo Watt hour
Meter
m2
Square Meter
m3
cubic meter
mg
Milligram
MJ
Millions of Joule
mm
Millimeter
cm
centimeter
MVA
Mega Volt Ampere
MW
Mega Watt
ppm
Parts per million
rpm
TPH / T/h
Tonnes Per Hour
mg/Nm3
g/m
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
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EXECUTIVE SUMMARY
This Detailed Project Report has been prepared for carrying out the
Renovation & Modernization (R&M)/ Life Extension (LE) of Unit No [...] of
[...].Thermal Power Plant, located at [.], in District [.] in the state of [.]
and having a configuration of [xMW].
The unit no. [] was first commissioned in the year [.]. After [].years of
operation, the performance of the unit has gradually deteriorated resulting in
frequent forced outages, reduced outputs, decreased efficiency and
increased cost of generation. It is proposed to carry out required
refurbishments and replacements in the plant so as to restore the units
performance parameters and to extend its life of by at least [] years. This
report is based on the outcome of the Feasibility Report in which various
options of renovating the plant were discussed through corresponding
financial cost benefit analysis, to arrive at the most appropriate option.
The cost of the R&M Project is estimated as Rs. [] crores. The Payback
Period is estimated as [] years. The R&M activity is expected to bring out
the improvements as indicated in the following table:
[Improvements Expected after R&M of the Unit]
S.No.
Parameters
Units
1.
Residual Plant Life
Years
2.
Capacity
MW
3.
Plant Load Factor
4.
Heat Rate
kCal/ kWh
5.
Auxiliary
Consumption
6.
Specific Oil Consumption ml/kWh
Specific
Consumption
Coal kg/kWh
8.
Emission
of
Particulate Matter
Solid mg/Nm3
Document Number
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LII-GETS12021-G-00100-004
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Power %
Before R&M
After R&M
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Description
Page
No.
Date of Issue
[1]
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S.No.
9.
Parameters
SOx(Ground
Concentration)
10.
Units
Before R&M
After R&M
g/m3
[.]
[.]
g/m3
[.]
[.]
[.]
[.]
[.]
[.]
Level
NOx(Ground
Concentration)
Level
11.

12

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INRODUCTION
2.1
Description
[Logo of
Utility]
The Power Plant, having a configuration of [xMW] is located at [.], in

District [.] in the state of [.].The Unit no. [.] of the power plant, which
is proposed to be taken up for Renovation and Modernization was first
commissioned in the year [.]. For the above unit, M/s [..] and M/s [.]
are the Original Equipment Manufacturers (OEMs) for the Boiler and TurboGenerator, respectively. The boiler is provided with [front & rear/
corner/down shot] firing system. LP stage of Turbine is designed with
[Bauman] exhaust. Condenser cooling system of the unit is designed on
[once through / re-circulation system]. Power generated from the unit is
being supplied to [...State/Central grid]. Power is being evacuated through
[.numbers of 220/400kV Double/Single Circuit lines] to [. substation.]
The primary fuel is [domestic/imported/blended] [coal/lignite] fuel being
sourced from [..&] coal mines. The consumptive water for the power
plant is being sourced from [.river/sea].
2.2
After the first commissioning during the year [.], the unit was giving a
stable operation with [. MW] of Gross Power Output at an average PLF of
[. %] and a Gross Heat Rate of [.kCal/kWh]. The Auxiliary Power
Consumption after the first commissioning was [%]. [Based upon the
recommendations of RLA / CA and EA Studies conducted during the year
..
major
replacements
were
made
during
the
year..
comprising..and .]. The unit is presently performing with a
maximum Gross Power Output of [. MW] with an average PLF of [%]
and a Gross Heat Rate of [.kCal/kWh]. The present Auxiliary Power
Consumption is [%].
2.3
Objective of undertaking Renovation & Modernisation

Renovation and Modernisation of the unit is proposed for refurbishing the
unit in a cost effective manner so as to extend its life, increase its output
and efficiency and to ensure that the its performance is in compliance with
the revised statutory standards prescribed by the environmental authorities.
A detailed Feasibility Study consisting of the following sub-studies has
already been carried out to arrive at the most cost effective and feasible
solution.
a. [Cold Walk-down and Hot Walk-down Survey.
b. Discussion with the Plant Engineers.
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c. Review of the operational history of the power plant, reports of Condition

Assessment (CA) and Residual Life Assessment (RLA) studies carried out
earlier and major replacements done in the past, prior to taking up this
study.
d. Review of reports of Condition assessment (CA) and Residual Life
Assessment (RLA) of major equipment and systems of the power plant
carried out recently.
e. Review of reports of Energy Audit of main equipments and auxiliary
systems carried out recently to identify the reasons and sources of
excess power consumption.
f. Review of recommendations of R&M Consultant for carrying out R&M
measures for increasing the useful life, efficiency and output of the plant
as well as for meeting the latest environment standards prescribed by the
regulating agencies at the national and state level.
g. Study of the financial impact of the R&M Measures proposed.
h. Financial analysis based on internal rate of return and cost benefit ratio.]
Document Number
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{Describe in this chapter, the Design Parameters and Salient Features of all
the important Equipment and Systems of the Power Plant as mentioned
below}
3.1

a) Boiler
[The Boiler is of natural circulation, pulverized fuel fired, dry bottom, balanced
draft using direct firing system. The design parameters of the Boiler are
furnished below]
Description
Units
Design
Parameters
T / hr
[.]
kg/cm2
[.]
[.]
Re-heater Flow
T / hr
[.]
kg/cm2
[.]
[.]
Feed Water Flow
T / hr
[.]

Economiser
Economiser.
kg/cm2
[.]
[.]
b) Furnace
fusion welded membrane wall construction. It is equipped with..numbers
of coal burners andnumbers of oil burners located at numbers of
elevations. The design parameters of the Furnace are furnished below.]
Description
Units
Type of Firing
Design Parameters
........
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
[..............]
Description
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No.
Date of Issue
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Description
Combustion
Volume
Units
Design Parameters
Chamber m3
[..............]
Furnace Dimensions
[..............]
[..............]
m2
[..............]
ii) Superheaters
m2
[..............]
iii) Reheaters
m2
[..............]
iv) Economiser
m2
[..............]
v) Air Heater
m2
[..............]
vi) Steam Coil Air

Heater
m2
vii) Temperature
Measurement of
Super-heater
tubes
Yes / No
viii)Temperature
Measurement of
Re-heater tubes
Yes / No
i)
[Logo of
Utility]
Water Walls
[..............]
[..............]
[..............]
c) Super Heaters and Re-Heater

pendant section, a rear low temperature section and a steam cooled wall &
roof section. The Re-heater consists of two sections, the front pendant and
the rear pendant sections. The details are given below:]
Description
Low
No. of coils Pitch

/ tubes
(mm)
[.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Dia.x Thickness
(mm)
Heating
Surface (m2)
Material
[.]
[.]
[.]
[.]
Description
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No.
Date of Issue
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Description
No. of coils Pitch

/ tubes
(mm)
[Logo of
Utility]
Dia.x Thickness
(mm)
Heating
Surface (m2)
Material
Temperature
Super Heater
Platen Super
Heater
[.]
[.]
[.]
[.]
[.]
Pendant
Super Heater
[.]
[.]
[.]
[.]
[.]
Ceiling and
Enclosure
Super Heater
[.]
[.]
[.]
[.]
[.]
ReheaterFront
Assembly
[.]
[.]
[.]
[.]
[.]
ReheaterRear
Assembly
[.]
[.]
[.]
[.]
[.]
d) Economiser
[The Economizer is of a single stage, continuous plain tube and horizontal,
mixed flow type, located in the second pass of the boiler]
e) Air Pre-Heater
between air and gas sides. Adjustable sector plates have also been provided
to prevent the leakage during expansion. The heating surfaces of the air preheater have been provided with two types of cleaning systems, soot blowing
and water washing system. ]
f) Raw Coal Bunkers
[Each boiler is provided with [] raw coal bunkers. The total capacity of the
bunkers is to meet [] hours requirement at maximum mills capacity of the
unit. The upper portion of the bunkers is of cylindrical shape made of carbon
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steel plate, while the conical portion is made of stainless steel plate. Each
outlet of the bunker is provided with an isolation gate which is motor
operated. In addition to the isolation gates, rod gates have been provided to
control the flow of coal from the bunkers]
g) Raw Coal Feeders
controls with variable frequency drive. The feeders have been provided with
dual independently measuring load cells. All parts of the feeders coming in
contact with coal, except the belt, are made of stainless steel]
h) Fuel Firing System
[The boiler is working on a direct firing system. The pulverized coal is being
dried and transported to the coal burners by means of hot primary air being
supplied by two primary air fans. The boiler is having [front and
rear/corner/down shot] firing system. There are [] pulverized coal burners
and [] oil burners. The burners are located at [] floors.
i)
Coal Mills
[The unit is provided with . numbers of [BHEL] make [XRP-783] bowl type
mills, out of which mills are designed to work with designed coal and
..numbers of mills are standby . The rated capacity of each mill is ..T/hr]
Description
Units
Design Parameters
..
[.]
Capacity of Mills
T/hr
[.]
Nos.
[.]

Nos.
[.]
Motor Rating
kW
[.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[8]
25.09.2014
Power Plant]
j)
[Logo of
Utility]
Primary Air Fans
[Two Primary Air (PA) Fans have been provided for each boiler. Each PA Fan
is designed to meet 60% MCR condition of the boiler. Details are given
below:]
Description
Units
Design Parameters
..
[.]
Type of Fans
..
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
[.]
Motor Rating
kW
[.]
[.]
k) Forced Draft Fans

supply combustion air to the boiler, mill air through PA Fans and tempering
air to control the classifier temperature of the mills. Details are given below:]
Description
Units
Design Parameters
..
Type of Fans
..
[.]
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
Temperature of Air
[.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[9]
25.09.2014
Power Plant]
Description
Units
[Logo of
Utility]
Design Parameters
Motor Rating
kW
[.]
[.]
l) Induced Draft Fans

evacuates flue gases through two parallel paths of ESP and discharge them
into stack through separate ducting. Details are given below:]
Description
Units
Design Parameters
..
Type of Fans
[.]
..
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
[.]
Motor Rating
kW
[.]
[.]

[Wall Blowers [.numbers] and Long Retractable Soot Blowers (LRSBs)
[.numbers] are being used for cleaning the soot deposited on the heating
surfaces of the water walls and super heaters respectively. Manual soot
blowing system has been provided. Details are given below:]
Description
Units
Design Parameters
Wall Blowers
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
..
Description
[]
Page
No.
Date of Issue
[10]
25.09.2014
Power Plant]
Description
[Logo of
Utility]
Units
Design Parameters

water walls
Nos.
[.]

walls
..
[.]
[.]

Nos.
[.]

[.]

pass tube banks
Nos.
[.]

[.]
LRSBs
n) ESP
[An Electrostatic Precipitator (ESP) has been installed on the cold end side of
the Air Pre-heater to remove the particulate matter from the flue gases. The
ESP has been provided with Gas Distribution System, Collecting Electrodes,
Discharge
Electrodes,
Transformer
Rectifier
Sets
and
[electrically/mechanically] operated rapping system. The hoppers of ESP have
been provided with [capacitance] type level indicators and thermostatically
controlled heating elements. Details are given below:]
Description
Units
Design Parameters
[.]
Nos.
[.]
Nos.
[.]
Number of ESP Hoppers
Nos.
[.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[11]
25.09.2014
Power Plant]
Description
Units
mg/Nm3
[.]
Type of Control
[.]
Gas Velocity in ESP
m/sec
[.]
m2/m3/sec
[.]
..
[.]
cm/sec
[.]
Numbers of TR Sets
..
[.]
Rating of TR Sets
..
[.]
[.]
m2/TR
Set
hrs
Pressure Drop
mmwc
[.]

fields in operation
[.]
Plate Area/TR Set
3.2
Design Parameters
Aspect Ratio
[Logo of
Utility]
[.]

a)
Steam Turbine

water cycle. The LP stage of turbine is designed with Bauman exhaust. The
turbine is provided with HP/LP bypass system of 60% capacity of Boiler
MCR. The turbine is provided with an electro - hydraulic control system,
automatic turbine run up system and turbo supervisory instrumentation. The
condensing system consists of a surface condenser of single shell and two
pass, divided water box construction. Cooling water being supplied to the
condenser is of raw water/ clarified water quality. The design parameters of
the steam turbine are furnished below]
Description
Units

HPT
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Design Parameters
kg/cm2
Description
[.]
Page
No.
Date of Issue
[12]
25.09.2014
Power Plant]
Description
Units
[Logo of
Utility]
Design Parameters

ESV of HPT

Steam
Steam
kg/cm2
[.]
[.]
[.]
kg/cm2
[.]

Steam
[.]
kg/cm2
[.]

Turbine
[.]
b) Condenser
integral air cooling section designed to maintain a pressure of 76 mm of Hg
at turbine exhaust with a cooling water temperature of [] deg C and an
outlet temp of [] deg C. The condenser is capable of operation with []
tubes plugged and has hot well storage capacity of [] minutes
Description
Units
Design Parameters
Make and Model
[.]
Type of Condenser
[.]
m2
[.]
..
[.]
Material of Tubes
..
[.]
mmxmm
[.]

Condenser
inlet to Condenser
m3/h
[.]
[.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[13]
25.09.2014
Power Plant]
Description
Units
Condenser Vacuum
[Logo of
Utility]
Design Parameters
mm Hg
[.]
c) Ejectors
[The Condenser is provided with two quick starting ejectors which operate in
parallel to remove large volumes of air for raising the initial vacuum during
the starting of the Unit. Two main ejectors of 100% capacity each have
been provided remove air and non condensable gases from the condenser to
maintain the required vacuum in the condenser during the normal operation
of the unit.]
[Condensate extraction pumps are of vertical, multistage, centrifugal pumps of
canister type.]
Description
Units
Design Parameters
Make and Model
[.]
Type
[.]
Capacity
m3/h
[.]
TDH
mwc
[.]
Speed
rpm
[.]
Motor Rating
kW
[.]

[A Gland Steam Cooler has been provided to condensate the leak-off steam
from intermediate chambers of end sealings of HP and IP turbine, thereby
heating the main condensate water. The Gland Steam Cooler consists of
shell, tube bundle and removable water box.]
[Each steam turbine is provided with four numbers of low pressure heaters to
increase the temperature of the condensate in stages. LP Heater -1 consists
of two halves and is installed in neck of the condenser. The remaining LP
Heaters are of shell and tube design and have been placed vertically. An
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[14]
25.09.2014
Power Plant]
[Logo of
Utility]
integral drain cooling section is provided in each LP Heater. The design

details of LP Heaters are furnished in the table below.]
Heater No.
Extraction
[...] stage of [...] stage of [...] stage of [...] stage of
Steam
taken IP turbine
IP turbine
IP turbine
IP turbine
from
Bled
Steam
Pressure
(kg/cm2))
[...]
[...]
[...]
[...]
Bled
Steam
Temperature
(deg C)
[...]
[...]
[...]
[...]
g) Deaerator
liter. The feed water storage tank has a capacity of [] minutes feed water
requirement of the boiler corresponding to TMCR Heat Balance]
h)
Boiler Feed Pumps
barrel type, motor driven pumps with hydraulic coupling taking the suction
from the deaerator. The boiler feed pumps discharge feed water through HP
heaters to the economizer of the boiler.]
Description
Units
Design Parameters
Make and Model
..
[.]
Type
...
[.]
No of stages
Nos.
[.]
Capacity
m3/h
[.]
Head
mwc
[.]
Feed water temp
[.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[15]
25.09.2014
Power Plant]
Description
[Logo of
Utility]
Units
Design Parameters
[.]
Minimum flow
m3/h
[.]
[.]
[.]
mwc
[.]
Motor Rating
kW
[.]
i)
HP Heaters
[Each steam turbine is provided with three numbers of high pressure heaters
to increase the temperature of the feed water in stages. The Heaters are of
shell and tube design and have been placed vertically. The design details of
HP Heaters are furnished in the table below.]
Heater No.
Extraction
[...] stage of [...] stage
Steam
taken HP turbine
turbine
from
of
HP [...] stage of HP
turbine
Bled
Steam
Pressure
(kg/cm2))
[...]
[...]
[...]
Bled
Steam
Temperature
(deg C)
[...]
[...]
[...]
j)
HP/ LP Bypass

between the Hot Reheat Line and the Condenser. HP bypass water spray has
been taken from the discharge of Boiler Feed Pumps. LP bypass water spray
has been provided from the discharge of Condensate Extraction Pumps.
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[16]
25.09.2014
Power Plant]
[Logo of
Utility]

from the generator. The system is provided with a quick closing Emergency
Stop Valve (ESV), to interrupt the supply of steam from the boiler and stop
the turbine under emergency conditions. The turbine governing system
includes, speed governor,]
l) Lube Oil System
[The lube oil system consists of Main Oil Tank, Turbine driven main oil pump,
AC driven bearing oil pump, DC driven emergency oil pump, AC driven
jacking oil pump and oil coolers of 3x50% capacity, Lube oil is being purified
by means of a centrifuge. Oil storage tanks consisting of Clean Oil Tank and
Dirty Oil Tank have been provided.]
3.3
Electrical System
a) Generator
[The Generator is a 15.75 kV, 50 Hz, 0.85 power factor machine, directly
coupled with steam turbine operating at 3000 rpm, withtype of
excitation system and digital programmable voltage regulator. The Generator
has direct water cooled stator winding and direct hydrogen cooled rotor
winding. The stator winding cooling water is cooled in a closed cycle
cooling system using DM water, while the hydrogen in the machine is
cooled in gas to water hydrogen coolers mounted inside the machine. The
Parameters of the Generator are briefly mentioned below.]
Description
Units
Design Parameters
Rated MW Capacity
MW
[.]
Rated MVA Capacity
MVA
[.]
kV
[.]
Rated Power Factor
..
[.]
kA
[.]
Rated Speed
rpm
[.]
Description
Page
No.
Date of Issue
[17]
25.09.2014
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Power Plant]
Description
Units
Design Parameters
Rated Frequency
Hz
[.]

Rated Power Factor
[.]
Excitation Current
kA
[.]

Short Circuit Ratio
kV
[.]
..
[.]
Amp
[.]
Phase Connection
[.]
Type of Excitation
[.]
[.]
[.]
kg/cm2
[.]
b)
[Logo of
Utility]
Station Transformer

[common] auxiliary loads of the power plant. The Station Transformers have
been provided with on-load tap changers to keep the station 6.6 kV voltage
constant. Cooling of this transformer is ONAN/ONAF/OFAF and has 2x50 %
separately mounted radiators and 2x50% oil pumps. The Parameters of the
Station Transformers are briefly mentioned below]
Description
Units
Design Parameters
Make
[.]
Capacity / Rating
MVA
[.]
Voltage Ratio
[.]
Type of Cooling
[.]
Quantity
Nos.
[.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[18]
25.09.2014
Power Plant]
c)
[Logo of
Utility]
[The power output from each Generator is being stepped up to 220/400 kV

through a 240 MVA step up Generator Transformer. It has 3x50% coolers
and 3x50% oil pumps. The Parameters of the Generator Transformer are
Description
Units
Design Parameters
Make
[.]
Capacity
MVA
[.]
Voltage Ratio
[.]
Type of Cooling
[.]
d)
meeting all unit auxiliary loads. These transformers have been provided onload tap changers. The Parameters of unit auxiliary transformers are briefly
mentioned below]
Description
Units
Design Parameters
Make
..
[.]
Capacity
MVA
[.]
Voltage Ratio
..
[.]
Type of Cooling
..
[.]
Quantity
Nos.
[.]

[Unit auxiliaries receive their normal power supplies at 6.6 kV through two
(2) nos. unit transformers. For lower rating drives, 6.6 kV is further stepped
down to 415 V by two (2) nos. unit service transformers. The 415 V
distribution system feeds a number of Motor Control Centers (MCCs) for
running 415 V drives. 6.6 kV unit switchgears are connected to station
switchgear for start up and emergency power supply. The details are
mentioned below]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[19]
25.09.2014
Power Plant]
Description
Units
[Logo of
Utility]
Design Parameters
Voltage Level
kV
[.]
Type of Breakers
[.]
Type of Grounding
[.]
Type of Protection
[.]
f) DC System
[Each unit has its own DC system located in the BC bay at ground floor of
the Power House. Separate DC systems have been provided in switchyard
control room, intake pump house and DM plant for controlling the systems.
Each DC system comprises of the Storage Battery, the Battery charger and
the distribution boards. The details are mentioned below]
Description
Units
Design Parameters
Make
[.]
Capacity / Rating
[.]
[.]
Type of Charger
..
[.]
Area of Application
..
[.]
Voltage

[Diesel generating sets are installed for meeting the power requirements of
essential auxiliaries (viz. jacking oil pumps, AC lube oil pump, hydrogen seal
oil pump, float charger for DC battery, emergency lighting, scanner air fan
and stator cooling water pump) during total failure of AC Power Supply in
the power station. Diesel generating sets are located in the CD bay at the
ground floor. The details are mentioned below]
Description
Units
Design Parameters
Make of DG Sets
[.]
Rating of DG Sets
kVA
[.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[20]
25.09.2014
Power Plant]
Description
Quantity
h)
[Logo of
Utility]
Units
Design Parameters
Nos.
[.]
Public Address System
system facilitates paging, communication and also private conversation as on
conventional telephone.]
i)
Illumination System

fixtures have been provided. For high bay areas and outdoor application,
fixtures have been installed. Aviation type fixtures have been installed at the
Chimney]
3.4

[The existing control and instrumentation system generally is an old analogue
based system and requires large scale replacement owing to obsolescence of
the existing equipments. Furnace Supervisory Safeguard System (FSSS) is of
obsolete design for which, no spares are available. Soot blowers are of
manual type. No online Boiler Tube Leakage detection system has been
provided. The turbine is equipped with an electro-hydraulic system of
automatic governing for the smooth and stable operation of turbo-set under
all conditions of operation. Turbine Supervisory system is of electromagnetic
type. No continuous monitoring system has been provided for observing the
health of the turbine. HP- LP bypass system is in the form of standalone
control panel. Integrated microprocessor based closed loop control, open
loop control, sequential control and bulk data acquisition system for SG &
auxiliaries, TG & auxiliaries, station C&I including auxiliaries in hierarchical
levels and integrated unit monitoring and station monitoring systems in the
upper level are therefore to be envisaged for the plant.]
3.5
Balance of Plant
[Coal Handling Plant is a common facility which is feeding all the units of the
power plant having a total installed capacity ofx..MW. Coal to the power
plant is brought through railways by Box N /BOBR wagons and is
unloaded by wagon tipplers / track hoppers. One crusher has been provided
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[21]
25.09.2014
Power Plant]
[Logo of
Utility]
for crushing the coal from 250 mm size to 25 mm size. The plant is provided
with one stacker reclaimer to stock the crushed coal. The coal stock yard
has a storage capacity of 20 days. For feeding the coal to the bunkers of all
the units, two streams of conveyors having a capacity of .TPH have
been provided. The coal handling plant operates for 16 hrs a day.]
Description
Units
Design Parameters
Nos.
[.]
T/hr
[.]
Length of Track Hopper
[.]
Nos.
[.]
T/hr
[.]
Type of Crushers
[.]
Number of Crushers
Nos.
[.]
T/ hr
[.]
Nos.
[.]
Stacking Capacity
TPH
[.]
Reclaiming Capacity
TPH
[.]
days
[.]

The ash is removed with the help of submerged Scrapper Chain Conveyors.
The ash from the air pre-heater and economizer hoppers is being disposed off
along with bottom ash. The ash in the form of ash slurry is conveyed
through sluice channels to the ash slurry pump house with the help of high
pressure jets, from where, it is pumped to the ash pond located the distance
of [] km. [] The ash slurry pump house is provided with [] numbers of
ash slurry pumps of rating [], out of which [] pumps are normally
working. The ash slurry disposal system is having [].numbers of identical
streams of ash slurry pumps connected to [] numbers of ash slurry
pipelines going to the ash pond. Fly ash is collected in dry form below the
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[22]
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Power Plant]
[Logo of
Utility]
ESP hoppers and the same is then conveyed by vacuum system to surge
hoppers from where it is either conveyed through pressurized system to dry
fly ash silos or is sent to ash pond in the form of slurry. From the dry fly ash
silos, the ash is disposed off through the covered trucks.]
c) Raw Water System
[The consumptive water for the plant is sourced from [] river/sea located
at a distance of [] km from the plant boundary. The intake water pump
house is installed with [] intake pumps of capacity [] m3/hr, out of which
[] pumps are normally working and the remaining [] pumps are standby.
The raw water is pumped from the intake water pump house to the in-plant
raw water reservoir, which has a storage capacity of [] days.]
[CW system for the power plant works on re-circulating system with induced
draft cooling towers. The CW system uses raw/clarified quality of water and
is working on [] cycles of concentration. CW pump house is a common
facility for all the units of the power plant. There are two CW pumps of
capacity [] m3/hr provided for each unit. In addition, there are two standby
CW pumps common to all the units. The requirement of ACW system is
being tapped from the cold CW header feeding the condenser. The hot return
ACW water after cooling the auxiliaries of boiler and turbine joins the hot
CW header and is sent to the cooling towers for cooling. The cold water
from the cooling water flows to the fore bay of CW Pump House for
recirculation into the system. One induced draft cooling tower (IDCT) has
been provided for each unit. The cooling tower cools the water from [] deg
C to [] deg C. The cooling tower has been designed for an inlet wet bulb
temperature of [] deg C].
[Water Pre-Treatment Plant is a common facility for all the units of the power
plant. Pre-treatment plant supplies clarified water to DM plant, cooling water
to the auxiliaries of BOP system, coal handling plant dust suppression and to
the drinking water system. There are two numbers of clarifiers of [].m3/hr
capacity to meet all the clarified water requirements of the whole plant,
except DM plant. The clarified water requirement for DM plant is met by a
separate clarifier of capacity [] m3/hr.]
f) DM Plant
[DM plant consists of three streams, each of [] m3/hr capacity. There are
two DM water tanks of [].m3 capacity. A common regeneration system has
been provided for all the three streams.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[23]
25.09.2014
Power Plant]
[Logo of
Utility]
G) Air-Conditioning and Ventilation System

[The central control room, switchyard control room, ESP controls room and
selected areas of service building have been provided with centralized airconditioning system. The central air-conditioning system of chilled water
type has been provided for various control rooms and DX type of plant has
been provided for ESP control room, switchyard control room and other
areas in the service building. Packaged type of air-conditioners has been
provided for water treatment plant control room. Evaporative ventilation
system has been provided for TG building along with roof extractors. Other
system has been provided for power transformers, turbine oil tanks and lube
oil system equipments. Medium velocity sprinkler system has been provided
for cable galleries and coal conveyor galleries. Portable types of fire
extinguishers have been provided throughout the plant for fighting small and
localized fires.]
i)
[Plant and instrument air system is a common facility for all the units of the
plant. For meeting the instrument air requirement, [] number of oil free
screw compressors [] working and [] standby, each of [] m3/hr
capacity and discharge pressure of [] kg/cm (g) have been provided along
with dryers. Equal number of air compressors of similar rating has been
provided to meet the requirement of plant air system. The air drying plant for
the instrument air has been provided to achieve a dew point of (-) 40oC at
atmospheric pressure.]
j)
Fuel Oil System
[The fuel oil system has been designed for the use of Light Diesel Oil (LDO)
for start- up and Heavy Fuel Oil (HFO) for load carrying and flame
stabilization purposes. Two tanks of [] kl each have been provided for the
storage of HFO and two tanks of [] kl each have been provided for the
storage of LDO. The system has been provided with unloading, transferring
and pressurization pumps along with necessary filters. Fuel oil system has
been provided with steam / electric tracing.]
k) Cranes/Hoists
[For the maintenance of various equipments, manually /electrically operated
cranes and hoists have been provided.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[24]
25.09.2014
Power Plant]
3.6
[Logo of
Utility]
Civil Works
Major civil work facilities consist of the following:
(a)
[A common Power House Building has been provided to house [3x200 MW]
units which are placed side by side. Centre to centre placing of units is [67.5
m.] The railway entry has been provided from the rear side of Power House
Building. Turbine Generator (TG) Sets have been placed between AB rows of
columns are laid out longitudinally. The TG bay, also houses, the Boiler Feed
Pumps, Regenerative Heaters, Lube Oil System and other TG accessories.
The total length of TG bay for 3x210 MW units is [276 m] and width [30
m]. The spacing of the column is at [7.5 m]. TG bay is provided with 2 Nos.
of overhead EOT Cranes. In order to make the handling facilities of the
cranes available to the heat exchangers, boiler feed pumps and other
equipments, removable chequered plates have been provided at appropriate
locations.
suitably connected and provided with a common sump for drainage
purposes.
Three stairs for approaching the operating floor level at [+10 m] have been
provided in this bay adjacent to B row columns. In addition, there are stairs
for providing access to various equipments at intermediate platforms and sub
zero pits.
Switchgear and Control Room bay has been provided in the BC bay which is
[12 m] wide. The length of the bay is [249.0 m]. A common Control Room
for all the three units is provided at [10 m] floor. In BC bay at [16 m]
elevation, equipments for chemical dosing, air handling and MCC for soot
blowers etc have been located. The deaerator is placed at an elevation of
[23.0 m]. Air washer units and cooling water tanks are also located at [23.0
m] floor.
vertical mills at Zero m and has space for collection of disposal of mill rejects
at sub zero levels adjacent to D row. A stair to connect operating floor at
[16.0 & 23.0 m] of BC & CD bay has been provided.]
(b)
Boiler Area
(c)
Chimney

Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[25]
25.09.2014
Power Plant]
(d)
[Logo of
Utility]
Transformer Yard
transformer yard houses station transformer, unit auxiliary transformers and
generator transformers along with oil pits etc. To facilitating erection and
maintenance of transformers, the area has been provided with rail tracks
parallel to A row at a distance of [45 m] from A row which is further
connected through cross tracks. In addition, space has been provided for
laying the CW pipelines and locating the butterfly valve chambers.]
(e)
Service building
level.]
(f)
[Besides the above, miscellaneous buildings like administrative building, CW

Pump House, Fire Water Pump House, CHP Control Room, ESP Control
Room, DM Plant Building, Chemical House and Ash Silos have been
provided.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[26]
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Power Plant]
4.1
Performance Parameters of the Unit
[Logo of
Utility]

Capacity of [210 MW] was commissioned in the year [..]. The boiler is
of [] design and the turbine is of [LMZ/KWU] design. Though the
boiler was originally designed for coal with Gross Calorific Value (GCV) of
[.kCal/kg], it presently operates on coal supplied with GCV of about
[..kCal/kg]. The deterioration experienced over the years in Plants
performance parameters is shown in Table 4.1.
Table 4.1- Units Performance Parameters over the life
Years after
Installation
PLF
(%)
Availability
(%)
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross Heat
Rate
(kCal/kWh)
[]
[]
[]
[]
[]
[]
[]
10
[]
[]
[]
[]
[]
[]
[]
15
[]
[]
[]
[]
[]
[]
[]
20
[]
[]
[]
[]
[]
[]
[]
25
[]
[]
[]
[]
[]
[]
[]
Table 4.2 indicated below, illustrates variations over the last five years in the
performance parameters.
{Furnish in the Table 4.2 below, the Average Values for the last three years,
Maximum & Minimum values for Current year and the readings on the last
day.}
Table 4.2
Units Performance Parameters during the Last Three Years
Period
Average
value for
the last
Three
Years
PLF
(%)
Availability
(%)
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross
Heat Rate
(kCal/kW
h)
[]
[]
[]
[]
[]
[]
[]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[27]
25.09.2014
Power Plant]
4.2
[Logo of
Utility]
Period
PLF
(%)
Availability
(%)
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross
Heat Rate
(kCal/kW
h)
Average
value for
the last
Two Years
[]
[]
[]
[]
[]
[]
[]
Average
value for
the last
one Year.
[]
[]
[]
[]
[]
[]
[]
Maximum
&
Minimum
values for
Current
year.
[]
[]
[]
[]
[]
[]
[]
Reading as
on the last
day.
[]
[]
[]
[]
[]
[]
[]

The Project has been regularly monitoring the environmental parameters such
as stack monitoring, ambient air quality (AAQ), noise pollution and liquid
waste pollution by employing an agency approved by State Pollution Control
Board and in accordance with applicable norms.
{Indicate the environmental data of the unit for the past three years against
the limits specified for different pollutants. Furnish the information for each
year as per the table 4.3 below. Also provide the map(s) showing the
locations for various measurements as Annexure to the Detailed Project
Report.}
Table 4.3
Environmental
Aspects
State Pollution and
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Parameters
Achieved
Description
No. of
locations for
measurement
Frequency
of
Sampling.
Page
No.
Date of Issue
[28]
25.09.2014
Power Plant]
Environmental
Aspects
Stack
Emissions
State Pollution and
SPM
(mg/Nm3)
Ambient Air
Quality
SPM
Parameters
Achieved
Not to exceed
[]
On
24
Hrs
Basis
On
Annual
Basis
[]
[]
[]
On
24
Hrs
Basis
On
Annual
Basis
[]
[]
(g/m3)
RPM
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[Logo of
Utility]
No. of
locations for
measurement
Frequency
of
Sampling.
[]
[]
[]
[]
[]
[]
(g/m3)
SO2
(g/m3)
NOX
(g/m3)
Process
Effluent
Leaving the
Plant Boundary

pH
[]
[]
Colour
[]
[]
Odour
[]
[]
Tempera
ture
[]
[]
TSS
(mg/l)
[]
[]
Oil &
grease
(mg/l)
[]
[]
COD
(mg/l)
[]
[]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[29]
25.09.2014
Power Plant]
Environmental
Aspects
State Pollution and
Parameters
Achieved
[Logo of
Utility]
No. of
locations for
measurement
Frequency
of
Sampling.
(mg/l)
4.3
BOD
(mg/l)
[]
[]
Chloride
(mg/l)
[]
[]
Sulphate
(mg/l)
[]
[]
TDS
(mg/l)
[]
[]
Zinc
(mg/l)
[]
[]
Fluoride
(mg/l)
[]
[]
Mercury
(mg/l)
[]
[]

{Indicate in the table below the tripping and maintenance record for the past
three years.}
Table 4.4
Year
Total Trippings
Two
Years
Back
[]
[]
[]
One Year
Back
[]
[]
[]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
No. of Trippings
due to Boiler
Tube Leakages
Other Major
Causes of
Trippings
Description
Maintenance
Carried Out
Page
No.
Date of Issue
[30]
25.09.2014
Power Plant]
Year
Total Trippings
Current
Year
4.4
No. of Trippings
due to Boiler
Tube Leakages
[]
Other Major
Causes of
Trippings
[Logo of
Utility]
Maintenance
Carried Out
[]
[]
Maximum Achievable Load Due To Performance Constraint of ESP

[Due to ESPs performance constraint, the maximum generation from the
unit is restricted to [...] MW, in order to keep SPM emission within the
statutory limit of 50 mg/Nm3. The operational data at the above maximum
load is indicated in the table below.]
Table 4.5
Nature of
constraint
4.5
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units Gross
Efficiency
(%)
Units Gross
Heat Rate
(kCal/kWh)
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]

[The record of reportable accidents for the past three years, is mentioned in
the Table below]
Table 4.6
Year
Man hours lost

due to
accidents
No. of Fatal
Accidents
No. of Accidents
leading to
Permanent
Disablement
Actions taken to
reduce the
number of
accidents
Two
Years
Back
[]
[]
[]
[]
One Year
Back
[]
[]
[]
[]
Current
[]
[]
[]
[]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[31]
25.09.2014
Power Plant]
Year
Man hours lost

due to
accidents
No. of Fatal
Accidents
No. of Accidents
leading to
Permanent
Disablement
[Logo of
Utility]
Actions taken to
reduce the
number of
accidents
Year
4.6
Operation & Maintenance Difficulties Due To Plant Limitations

[Difficulties are being experienced in day to day maintenance of the plant due
to design deficiency, layout of the plant, obsolescence of equipment and non
availability of spare parts etc. These are mentioned in the Table below]
Table 4.7
Nature of Difficulties in O&M of the Unit
S.No.
NATURE OF DIFFICULTY
SPECIFIC REASON
(Design deficiency/ layout of the plant /
obsolescence of equipment / non availability of
spare parts etc)
4.7
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Operating Data Collected During Hot Walk Down Survey

Major Operating Parameters of the Plant as noted during the Hot Walk Down
Survey are indicated in the Table 4.8 below:
Table 4.8
Operating Parameters of the Plant as per Hot Walk Down Survey
Description
Units
Design
Parameters
Operating
Parameters
Load
MW
[..]
[..]
GCV
kCal/kg
[..]
[..]
Water & Steam Parameters
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[32]
25.09.2014
Power Plant]
Description
Units
Main Steam Flow
[Logo of
Utility]
Design
Parameters
Operating
Parameters
T/h
[..]
[..]
Main Steam Temp.
Deg C
[..]
[..]
Main Steam Pressure
kg/cm2
[..]
[..]
Cold Reheat Steam Pressure
kg/cm2
[..]
[..]
Hot Reheat Steam Pressure
kg/cm2
[..]
[..]
Hot Reheat Steam Temp (Left

and Right)
Deg C
[..]
[..]
Cold Reheat Steam Temp (Left

and Right)
Deg C
[..]
[..]
IP Turbine Exhaust Steam

Temp (Left and Right)
Deg C
[..]
[..]
IP Turbine Exhaust Pressure
kg/cm2
[..]
[..]
Turbine Exhaust Hood

Temperature.
Deg C
[..]
[..]
Hot Well T Temperature.
Deg C
[..]
[..]
Condenser Vacuum
mmHg
[..]
[..]
C.W. Water flow
T/h
[..]
[..]
C.W. Inlet Temperature (L and

R)
Deg C
[..]
[..]
C.W. Outlet Temperature (L

and R)
Deg C
[..]
[..]
Drum pressure
kg/cm2
[..]
[..]
Feed water flow
T/h
[..]
[..]
Feed water inlet temp to ECO
Deg C
[..]
[..]
Feed Water Pressure
kg/cm2
[..]
[..]
Super Heater Spray
T/h
[..]
[..]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[33]
25.09.2014
Power Plant]
Description
Units
Reheater Spray
[Logo of
Utility]
Design
Parameters
Operating
Parameters
T/h
[..]
[..]
Air temperature at Air PreHeater Inlet.
Deg C
[..]
[..]
Primary Air temperature at Air

Pre-Heater Outlet.
Deg C
[..]
[..]
Secondary Air temperature at

Air Pre-Heater Outlet.
Deg C
[..]
[..]
Total Quantity of Air
T/h
[..]
[..]

Pre-Heater Inlet.
Deg C
[..]
[..]

Pre-Heater Outlet.
Deg C
[..]
[..]
CO2 in Flue Gas
[..]
[..]
CO2 at Inlet of Air Pre-Heater
[..]
[..]
CO2 at Air Pre-Heater Outlet
[..]
[..]
CO2 in Flue Gas Air PreHeater Outlet
[..]
[..]
CO2 in Flue Gas Air PreHeater Inlet
[..]
[..]
% of Excess Air in Flue Gas at

ID fan Outlet
[..]
[..]
No. of Mills in operation for full

load.
Nos
[..]
[..]
Wind box Differential Pressure

(Left and Right)
mmwc
[..]
[..]
Air Temperature
Deg C
[..]
[..]
Furnace Draft
mmwc
[..]
[..]
ID Fan margin
[..]
[..]
Air and Flue Gas Parameters
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[34]
25.09.2014
Power Plant]
Description
Units
[Logo of
Utility]
Design
Parameters
Operating
Parameters
HP Heaters Parameters
Extraction Steam Pressure HP
Heater (HPH) No.7 at Heater
End
kg/cm2
[..]
[..]

kg/cm2
[..]
[..]

kg/cm2
[..]
[..]
Feed Water (FW) Pressure

Entering HPH-5
kg/cm2
[..]
[..]
kg/cm2
[..]
[..]
kg/cm2
[..]
[..]
F.W. Pressure Common Outlet

of HPH
kg/cm2
[..]
[..]

HPH-5
Deg C
[..]
[..]

HPH-5
Deg C
[..]
[..]

HPH-6
Deg C
[..]
[..]

HPH-6
Deg C
[..]
[..]

HPH-7
Deg C
[..]
[..]
F.W. Temperature Common

Outlet of HPH
Deg C
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Deg C
[..]
[..]
Extraction Steam Temperature

HPH-5 (Heater end)
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[35]
25.09.2014
Power Plant]
[Logo of
Utility]
Description
Units
Design
Parameters
Operating
Parameters
Extn. Steam Temp. HPH-6

(Heater end)
Deg C
[..]
[..]
Extraction Steam Temp. HPH-7 Deg C

(Heater end)
[..]
[..]
Deaerator Pressure
kg/cm2
[..]
[..]
Gauge Glass on HPH-5, 6 and

7
mmwc
[..]
[..]
Level indication in UCB for

HPH-5, 6 and 7
mmwc
[..]
[..]
Relative humidity
[..]
[..]
Oxygen in fuel
[..]
[..]
Distribution of fly ash
[..]
[..]
Distribution of bottom ash
[..]
[..]
Distribution of duct ash
[..]
[..]
Distribution of air heater ash
[..]
[..]
Secondary Fuel Oil

Consumption
ml/ kWh
[..]
[..]
Other Information
Currents Drawn by Auxiliary Equipments

Boiler Feed Pump Current
Amp
[..]
[..]
Mills Motor Current
Amp
[..]
[..]
ID Fan Motor Current
Amp
[..]
[..]
FD Fan Motor Current
Amp
[..]
[..]
PA Fan Motor Current
Amp
[..]
[..]
CEP Motor Current
Amp
[..]
[..]
CW Pumps Motor Current
Amp
[..]
[..]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[36]
25.09.2014
Power Plant]
SELECTION OF R&M OPTION TO BE IMPLEMENTED
5.1
[Logo of
Utility]
[A detailed Feasibility Study was carried out to arrive at the most cost
effective and feasible solution for implementing the Renovation &
Modernization activities of the unit. Existing conditions of the unit were
assessed on the basis of the results of RLA/CA & EA Studies. Based on the
recommendations of RLA/CA & EA Studies, review of the performance data
and discussions with the plant engineers, five R&M options were formulated.
All the R&M options were aimed at achieving the following minimum
objectives:
i) Redesigning the boiler to suit the average coal quality likely to be available
for the next 20 years.
ii) Restoring the performance parameters to the original design values.
iii) Extending the life of the unit by a minimum of 20 years.
iv) Replacing the existing obsolete technology.
v) Meeting the revised statutory emission standards.
vi) Increasing Efficiency.
vii) Reducing Auxiliary Power Consumption
The first option considered for R&M was for the case, in which the
objectives were restricted to the bare minimum for restoring design output,
design heat rate and Auxiliary Power Consumption of the unit and to extend
the unit life by 20 years. Other options were formulated for not only the life
extension of the unit but also for further improving its output, heat rate and
auxiliary power consumption from the original design values, as discussed in
the Table 5.1 below.]
Table 5.1- R&M Options Considered for Cost Benefit Analysis
Option

R&M
i)
[Designing boiler to suit average coal

quality likely to be available for the next
20 Years.]
Shut
Down
Period
[]
ii) [Increasing the output of the unit to

215 MW from (200/210MW) by
retrofitting the LP turbine without
retrofitting Generator. Improving heat
rate beyond the original design heat
rate and restoring the Auxiliary Power
Consumption to the original design
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Major
Performance
Parameters
[Life
Extension
.. Years]
[Output
..MW]
[Heat Rate
Page
No.
Date of Issue
[37]
25.09.2014
Power Plant]
Option

R&M
Shut
Down
Period
values.]
[Logo of
Utility]
Major
Performance
Parameters
kCal/kWh]
iii) [Replacing
the
technology.]
existing
obsolete
[Aux. Power
Consumption
iv) [Meeting the revised statutory emission

standards].
..%]
v) [Extending the life of the unit by a

minimum of 20 years].
II
i)

20 Years].
[]

215 MW from (200/210MW) by
retrofitting the LP and HP turbines
without
retrofitting
Generator.
design heat rate and restoring the
Auxiliary Power Consumption to the
original design values.]
iii) [Replacing
the
technology.]
III
existing
[Life
Extension
.. Years]
[Output
MW]
[Heat Rate
kCal/kWh]
obsolete

standards.]
[Aux. Power
Consumption

minimum of 20 years.]
..%]
i)
[Life
Extension
.. Years]

20 Years].
[]

215 MW by retrofitting complete new
energy
efficient
turbine
without
retrofitting Generator. Improving heat
rate beyond the heat rate of option II
and restoring the Auxiliary Power
Consumption to the original design
values.]
iii) [Replacing
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
the
existing
Output
MW]
[Heat Rate
kCal/kWh]
obsolete
Description
Page
No.
Date of Issue
[38]
25.09.2014
Power Plant]
Option

R&M
Shut
Down
Period
[Logo of
Utility]
Major
Performance
Parameters
technology.]
standards.]
Aux. Power
Consumption

IV
i)

20 Years.]
..%]
[]
ii) [Increasing the Output to 220 MW by

retrofitting
complete new
energy
efficient turbine along with new
Generator, Generator Transformer and
new
static
Excitation
System.
Improving heat rate better than the level
of option III and restoring the Auxiliary
Power Consumption to the original
design values.]
iii) [Replacing
the
technology.]
existing
Output
MW]
[Heat Rate
kCal/kWh]
obsolete
Aux. Power
Consumption

standards.]
..%]

V
i)
[In situ major replacement of boiler on

the existing foundations, retrofitting
complete new energy efficient turbine
along with new Generator, Generator
Transformer and new static Excitation
System. Designing the boiler to suit the
average coal quality likely to be
available for the next 25 years.]
[Life
Extension
.. Years]
[]
Output
MW]
ii) [Increasing the Output to 250/300 MW.

Achieving heat rate and Auxiliary
Power Consumption better than Options
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
[Life
Extension
.. Years]
Description
[Heat Rate
kCal/kWh]
Page
No.
Date of Issue
[39]
25.09.2014
Power Plant]
Option

R&M
Shut
Down
Period
[Logo of
Utility]
Major
Performance
Parameters
III & IV.]

iii) [Replacing
the
technology.]
existing
obsolete
Aux. Power
Consumption

standards.]
..%]

{This option is advised only when the unit
to be renovated is either the first or last
unit of the power plant, since intermediate
units are likely to have space constraint for
installation of new Boiler and TG.}
{While evaluating the options, the utilities are advised to also check the
residual life of the switchyard, the Balance of Plant and the Material Handling
System. Further, the utilities should note that if the proposed calorific value
of coal is inferior to the original calorific value for which the boiler was
designed, then the boiler will require re-engineering.}
Estimated cost for each option was worked out after taking into account the
scope of R&M measures to be implemented for each option. Cost Benefit
analysis of each option was then performed. After cost-benefit analysis of
[Five] options mentioned above, option [...] has been identified as most
appropriate option for implementation. Cost-benefit analysis of all options is
discussed in Section 6.0.
5.2

Based upon the cost benefit exercise carried out and details furnished in the
Feasibility Report for various R&M options, Option [...] has been selected for
implementation. This is expected to bring out the following improvements:
Table 5.2
Improvements Expected after R&M of the Unit
S.No.
Parameters
1.
Residual Plant Life
2.
Capacity
3.
Plant Load Factor
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Units
Years
MW
%
Before R&M
After R&M
[.]
[.]
[.]
[.]
[.]
[.]
Description
Page
No.
Date of Issue
[40]
25.09.2014
Power Plant]
S.No.
Parameters
Units
Before R&M
After R&M
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
4.
Heat Rate
5.
Auxiliary
Consumption
6.
Specific Oil Consumption
ml/kwh
7.
Specific
Consumption
Coal
kg/kWh
8.
Emission of SPM fro stack
mg/Nm3
[.]
[.]
9.
Sox(Ground
Concentration)
Level
g/m3
[.]
[.]
10.
Nox(Ground
Concentration)
Level
g/m3
[.]
[.]
11.

[.]
[.]
12

[.]
[.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
kCal/
kWh
[Logo of
Utility]
Power
Description
Page
No.
Date of Issue
[41]
25.09.2014
Power Plant]
[Logo of
Utility]
DETAILED SCOPE OF R&M WORK

Detailed scope and quantum of work to be carried out for the R&M of the
unit has been worked out on the basis of the R&M option finally selected for
implementation. Detailed scope of work, system and equipment wise, is
furnished in the tables below.
6.1

Justification
Estimated
Cost
[..]
[..]
[]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Low
Temperature
Super
Heater
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Platen Super
Heater
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Pendant
Super
Heater
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Ceiling
Super
Heater
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Steam
Header
[..]
[..]
[..]
[..]
[]
Steam Pipes
[..]
[..]
[..]
[..]
[]
Reheater-
[..]
[..]
[..]
[..]
[]
Equipment
Drum
Water Walls
Unique
Tag
Number
Scope of
Work
Tentative Quantity
[..]
[..]
[..]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[42]
25.09.2014
Power Plant]
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Front
Assembly
[..]
[..]
ReheaterRear
Assembly
[..]
Economiser
[Logo of
Utility]
Justification
Estimated
Cost
[..]
[..]
[]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
RC Header
[..]
[..]
[..]
[..]
[]
Coal Burners
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Equipment
Air PreHeater
Oil Burners
Igniters
Refractory
Insulation
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[43]
25.09.2014
Power Plant]
Equipment
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Buckstays
[..]
[..]
[..]
[Logo of
Utility]
Justification
Estimated
Cost
[..]
[..]
[]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Wall
Blowers /
LRSBs
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Pent House
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Attemperato
rs
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Bottom Ash
Hoppers
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Ducting
Coal Mills
PA Fans
ID Fans
FD Fans
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[44]
25.09.2014
Power Plant]
Justification
Estimated
Cost
[..]
[..]
[]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Fly Ash
Hoppers
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Replacement
and
Retrofitting
of Valves
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Replacement
and
Retrofitting
of Water
Headers
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Replacement
and
Retrofitting
of Dampers/
Expansion
Joints
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Replacement
and
Retrofitting
of Motors
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Replacement
and
Retrofitting
of Pipe
Hangers
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Equipment
ESP
Unique
Tag
Number
Scope of
Work
Tentative Quantity
[..]
[..]
[..]
[Logo of
Utility]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[45]
25.09.2014
Power Plant]
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Equipment
Cooling
Water
System
[..]
[..]
[..]
Misc. valves
Any other
systems
Equipment
6.2
[Logo of
Utility]
Justification
Estimated
Cost
[..]
[..]
[]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Steam Turbine and Auxiliaries

Equipment
Steam
Turbine
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Lube Oil
System
[..]
[]
[..]
[]
Condenser
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Condensate
Extraction
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[46]
25.09.2014
Power Plant]
Equipment
[Logo of
Utility]
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
Pumps
[..]
[..]
[..]
[..]
[]
Deaerator
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Boiler Feed
Pumps
LP Heaters
HP Heaters
Critical
Piping
Control
Valves
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[47]
25.09.2014
Power Plant]
6.3
Scope of
Work
[Logo of
Utility]
Equipment
Unique
Tag
Number
Tentative Quantity
Justification
Estimated
Cost
Replacement
and
Retrofitting
of Pipe
Hangers
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Equipment
Cooling
Water
System
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Misc. valves
[..]
[..]
[..]
[..]
[]
Any other
equipment
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Balance of Plant
Equipment
Coal
Handling
Plant
Ash
Handling
Plant
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[48]
25.09.2014
Power Plant]
[Logo of
Utility]
Equipment
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
Raw Water
System&
Pretreatment
Plant
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
CoolingTow
er
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Fire Fighting
System
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Compressed
Air System
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Air
Conditioning
&
Ventilation
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
DM Plant
CW System
Fuel Oil
Handling
System
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[49]
25.09.2014
Power Plant]
Equipment
[Logo of
Utility]
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
Effluent
Treatment
Plant
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Any other
system/
equipment
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
System
6.4
Electrical System
Equipment
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
Generator
Stator
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Generator
Rotor
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Generator
Cooling
Water
System
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Hydrogen
Coolers
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Excitation
System
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Automatic /
[..]
[..]
[..]
[..]
[]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[50]
25.09.2014
Power Plant]
[Logo of
Utility]
Equipment
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
Digital
Voltage
Regulator
[..]
[..]
[..]
[..]
[]
Seal Oil
System
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Generator
Transformer
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Unit
Auxiliary
Transformer
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Station
Transformer
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
HT
Switchgear
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
6.6 kV
System
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
415 V
System
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
HT & LT
motors
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
DC System
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[51]
25.09.2014
Power Plant]
Equipment
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Public
Address
System
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Illumination
System
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
DG Sets
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Any other
System or
Equipment
6.5
[Logo of
Utility]
Instrumentation and Control

Equipment
DDCMIS
SOOT
BLOWER
Burner Tilt
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[52]
25.09.2014
Power Plant]
Equipment
[Logo of
Utility]
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Boiler
Temperature
MI
Thermocoup
le ( K-Type)
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Boiler
Protections
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Turbine
Protection
Turbine
Controls EHC
Turbine ATRS
Turbine
Supervisory
System
Machine
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[53]
25.09.2014
Power Plant]
[Logo of
Utility]
Equipment
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
Condition
Monitoring
System
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Automatic
Turbine
Testing
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Turbine
Stress
Evaluator (
TSE)
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
HP LP
Bypass ,
PRDS
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Gland Steam
Pressure
Control
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Control
Valves/
Dampers
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Furnace
Draft
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Total Air
Flow
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Mill
Temperature
Indications
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[54]
25.09.2014
Power Plant]
[Logo of
Utility]
Equipment
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
Super
Heater
Steam
Temperature
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Re-Heater
Steam
Temperature
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
DRUM Level
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
BFP Scoop
Tube
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Deaerator
level
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Deaerator
Pressure
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Hot well
level
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
HP Heaters
Levels
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
LP heaters
Levels
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
BFP
Recirculation
valve
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[55]
25.09.2014
Power Plant]
[Logo of
Utility]
Equipment
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
Feed Water
Control
Valve
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Transmitters
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Pressure /
DP Gauges
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Temperature
Gauges
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Pressure /
DP Switches
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Temperature
Switches
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
RTD / TC s
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Flow
Measuremen
t & Primary
Flow
Sensors
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Fuel Flow
[..]
[..]
[..]
[..]
[]
Thermowells
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Equipment
Unique
Tag
Number
Scope of
Work
Tentative Quantity
Justification
Estimated
Cost
Measuremen
t
[..]
[..]
[..]
[..]
[]
Analyzers
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Impulse
Pipeline
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Any other
systems
[..]
[..]
[..]
[..]
[]
Tentative Quantity
Justification
Estimated
Cost
UPS
6.6
[Logo of
Utility]
Civil Works
Equipment
Boiler
TG Building
Chimney
Unique
Tag
Number
Scope of
Work
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
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Equipment
Unique
Tag
Number
Scope of
Work
[Logo of
Utility]
Tentative Quantity
Justification
Estimated
Cost
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
CW Pump
House
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Cooling
Towers
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Miscellaneo
us Works
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
[..]
[..]
[..]
[..]
[]
Coal
Handling
Plant
Ash
Handling
Plant
Water
Treatment
Plant
Any other
Systems
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PROJECT COST AND COST BENEFIT ANALYSIS
7.1
Introduction
[Logo of
Utility]
The objective of the financial analysis during feasibility study was to make a
comparative analysis of the financial implications of the [five R&M options]
as well as the base case option of not undertaking any R&M project at all.
On the basis of the financial analysis of the R&M options, R&M option []
was chosen for implementation. In this chapter, a detailed cost-benefit
analysis of the selected R&M option is carried out.
7.2
Capital Expenditure for the selected R&M option

The estimate of capital expenditure likely to be incurred for the selected
R&M option comprises dismantling cost, supply cost, construction /erection
/commissioning cost, taxes/duties, interest during construction, financing
cost and contingency. As a discussed in Chapter-6, the detailed scope of
Renovation & Modernization work for the different systems and subsystems
of the power plant was decided. The cost for different constituent parts of
the project (i.e. systems and subsystems) was estimated on the basis of past
cost data for similar work wherever available and/or budgetary quotes.
The R&M project work is split into [six] packages to be executed through
[six] different contracts. The Engineering, Procurement and Construction cost
of each of the packages is determined by summing up the cost of the
constituent works covered in the scope of work of the package. The total
Cost of the R&M project is sum of the Engineering, Procurement and
Construction cost of individual packages and other costs such as
taxes/duties, Pre-commissioning costs, interest during construction,
financing cost and contingency.
The estimated capital cost of the selected R&M option is summarized at
Annexure 7.1.
7.3
Cost Estimate for R&M Contract Packages

Package wise Cost Estimate is summarized at Annexure 7.2.
7.4
Impact on Tariff
[The tariff for electricity sent out from this power plant is determined by
Tariff Norms of appropriate Electricity Regulator]. Capitalization of capital
expenditure incurred for the project will affect cost of generation.
Capitalization increases Capacity Charge (Fixed Charge) whereas
improvement in plant heat rate brings down Energy Charge (Variable
Charge). Owner will have to take up with the regulatory commission for
acceptance of the revised tariff. The estimated Cost of Generation for
selected R&M options is shown in Annexure 7.3.
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7.5
[Logo of
Utility]
Financial Impact
Net Present Value (NPV) and Internal Rate of Return (IRR) have been used to
assess the financial merit of selected R&M option. Net Present Value is the
sum of present value of all the project cash outflows and inflows using an
appropriate discount rate. All the future cash flows are discounted suitably
to arrive at their present day value considering time value of money. IRR is
another metric used to assess the financial attractiveness of the selected
R&M option. IRR is the discount rate that makes the project NPV zero. It is
the discount rate at which the present value of all future cash flows
becomes equal to the initial investment. IRR is used in capital budgeting to
compare the profitability of different investment options. The higher the IRR,
the more profitable an investment is. For a project to create value for the
proponent, the IRR should be higher than the cost of fund.
The revenue stream of the selected R&M options has been calculated on the
basis of a single indicative tariff per kWh of electricity for each year. The
indicative tariff is the same as that used for comparing different R&M
options during feasibility study. Assuming that the regulator will prefer
minimum tariff, the indicative tariff per unit of electricity for a year has been
taken to be the minimum value among the calculated Costs of Generation
(COG) as per Regulatory Norms for Tariff of Thermal Power Projects for the
different R&M options and base case tariff for that year. The estimated
capital cost of each R&M option is used for calculation of Return on Equity
and Depreciation. Normative Debt Equity ratio and depreciation rates are as
per Tariff Regulation of appropriate Electricity Regulator. The revenue from
electricity generation during a year in which plant is shut down is calculated
considering normative availability/plant load factor. The loss of generation
due to shut down for R&M is accounted for by considering that equivalent
amount of electricity will have to be procured from the grid/market at the
prevailing tariff. Therefore, the tariff at which power will be procured during
shut down also affects the financial analysis. The negative cash flow due to
shut down is calculated as the product of loss of generation and average
tariff at which power will be procured from the grid net of variable cost .
7.6
Cost of Generation calculation is done as per Tariff norms of appropriate

Electricity Regulator
O&M cost is taken as per Tariff norms of appropriate Electricity Regulator
Average annual Availability/PLF of [85%] is considered for financial
analysis. This is in line with Normative Availability Factor prescribed by
Electricity Regulator.
In line with the approach followed in Tariff Norms of Electricity
Regulators, single value is considered for Plant Gross Heat Rate for
financial analysis over the plant life after R&M. This single value of Heat
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[Logo of
Utility]
Rate includes suitable operating margin over Design Heat Rate. Similarly,
single value of auxiliary power consumption and specific oil consumption
is considered over the entire plant life after R&M for financial analysis.
[For calculating the financial quantities, the design/guaranteed heat rate
with operating margin of [6.5%] is considered the plant Heat Rate for all
the years during the economic life after Renovation & Modernization.]
Specific oil consumption is considered [1 ml/kWh] after R&M.
Present coal price and fuel oil prices are considered to be equal to the
actual coal price and fuel oil prices for the unit.
The discount factor and coal price escalation rate are taken to be [that
notified by appropriate Electricity Regulator].
The main factors for financial analysis are given in Table 7.1.
Table- 7.1
Factors for Financial Analysis
Description
Value of Factors
Escalation rate for domestic coal
[.]
Discount Rate
[.]
Return on Equity
[.]
Interest Rate on Rupee Term Loan
[.]
Interest Rate on Forex Loan plus cost of Forex

Rate Coverage
[.]
{The value of factors indicated in the above table is to be taken from Norms
of Regulator applicable as on the date of analysis. The values indicated in the
table are for illustration only.}
7.7
Inputs for Financial Analysis

Table 7.2
Inputs for Options
Description
Value for Selected R&M

Option
Capacity (MW)
[.]
Operating Life (Years)
[.]
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Description
Value for Selected R&M

Option
Shutdown for R&M(Months)
[.]
Project Implementation Period (Months)
[.]
Gross Heat Rate (kCal/kWh)
[]
Operating Margin on Heat Rate
[6.5%]
Annual Degradation of Heat Rate
7.8
[Logo of
Utility]
[]
Project Cost
[]
Financial Impact of Selected R&M Option

The NPV, IRR and Payback Period calculation for selected R&M options is
placed at Annexure-7.4. The economic impacts are summarized at Table
7.3.
Table 7.3
Financial Evaluation of Selected R&M Options
7.9
Levelized COG
(Rs/kWh)
IRR (%)
NPV
(Rs Million)
Payback Period
(Years)
[.]
[.]
[.]
[.]
Other Benefits
The economic benefit of Renovation & Modernization has been described
above. Apart from the direct economic benefits, R&M of old coal fired
thermal power plants has many other benefits. Some of such benefits are
briefly discussed below:
R&M increases the residual life of ageing power plants and
restores/enhances their capacity. This is a low cost and quicker
method of increasing Indias electricity generation capacity. This is
very important in the present precarious demand-supply scenario of
India marked by both energy shortage and peak shortage.
R&M reduces the downtime of the power plant and increase the plant
availability. This enhances the reliability of electricity supply from the
plant.
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7.10
[Logo of
Utility]
R&M of coal fired power plants is the low hanging fruit for rapidly
ramping up the electricity generation capacity. Not only R&M adds
capacity with at lower capital expenditure and shorter gestation
period, but also enables us to sidetrack complex project
implementation challenges such as land acquisition, resettlement &
Rehabilitation, environmental clearance etc.
As the environmental norms for thermal power plants gets stricter,
R&M is the only way for old power plants to meet the evolving
environmental norms. This is particularly relevant for SPM emissions
as many old coal fired power plants have SPM emission levels far in
excess of what is acceptable my present day environmental
regulation.
Renovation and Modernization is necessary to restore design output
level of power plants receiving coal with calorific values much poorer
than coal considered for boiler design.
R&M leads to lower plant heat rate and lower auxiliary power
consumption thereby reducing specific coal consumption for each unit
of electricity sent out of the power plant. This helps to reduce CO2
emission and emission of other polluting gases. Further, lower coal
and oil consumption helps to decelerate the depletion of fossil fuel
reserves.
R&M may increase the plant rated capacity beyond the original design
capacity and reduce plant heat rate below original design heat rate.

R&M projects are complex in nature and are associated with many
uncertainties. The cost and time for execution of the project may overshoot
estimates and the project may fall short of achieving its objectives. The
financial viability of the selected R&M option should have some level of
tolerance for such uncertainties.
Renovation & Modernization projects are associated with high risk of Time
overrun and cost overrun due to unique nature of each project and also due
to the complexities and uncertainties associated with retrofitting work. The
reasons for Time/Cost overrun are discussed in the Chapter on Risks
(Chapter-14). Time overrun itself is a reason for Cost Overrun due escalation
of hard cost, increase in overheads and increase in interest during
construction. Therefore, R&M projects very often run into time overrun and
cost overrun simultaneously. Time and/or cost overrun adversely affect the
financial viability/attractiveness of R&M projects by negatively affecting Net
Present Value and Internal Rate of Return of the project.
The three prime objectives of any R&M project are Heat Rate improvement,
Electricity Output restoration/up rating and Plant Availability/Reliability
enhancement with concomitant adverse impact on project financials . R&M
projects are associated with the risk of partially or fully failing to achieve
these objectives. Failure to achieve the desired Heat Rate may itself
contribute to less than targeted electrical output. Therefore, in many cases,
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[Logo of
Utility]
R&M projects are likely to miss Heat Rate and Output objectives
simultaneously.
The financial impact of certain level of cost overrun, time overrun and
shortfall in performance is depicted in Table-7.4.
Table 7.4
Impact of Adverse Scenarios on Selected R&M Option
Scenario
Levelized
COG
(Rs/kWh)
IRR (%)
NPV
(Rs Million)
Differential
NPV w.r.t
Base Case
(Rs Million)
Cost Overrun
(+10%)
[.]
[.]
[.]
[.]
Cost Overrun
(+15%)
[.]
[.]
[.]
[.]
Time overrun (+6

months)
[.]
[.]
[.]
[.]
Time overrun
(+12months)
[.]
[.]
[.]
[.]
Time overrun
(+18months)
[.]
[.]
[.]
[.]
Cost Overrun
(+10%) and Time
overrun (+6
months)
[.]
[.]
[.]
[.]
Cost Overrun
(+15%) and Time
overrun (+12
months)
[.]
[.]
[.]
[.]
Cost Overrun
(+20%) and Time
overrun (+18
months)
[.]
[.]
[.]
[.]
Cost Overrun
(+20%)
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NPV
(Rs Million)
[Logo of
Utility]
Scenario
Levelized
COG
(Rs/kWh)
IRR (%)
Differential
NPV w.r.t
Base Case
(Rs Million)
Capacity shortfall(2 MW)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Heat Rate Increase

(+1%)
[.]
[.]
[.]
[.]
Heat Rate Increase

(+2%)
[.]
[.]
[.]
[.]
Heat Rate Increase

(+4%)
[.]
[.]
[.]
[.]
Capacity shortfall
(-2 MW) and Heat
Rate Increase
(+1%)
[.]
[.]
[.]
[.]
Capacity shortfall
(-4 MW) and Heat
Rate Increase
(+2%)
[.]
[.]
[.]
[.]
Capacity shortfall
(-8 MW) and Heat
Rate Increase
(+4%)
[.]
[.]
[.]
[.]
Availability
variation (-3%)
[.]
[.]
[.]
[.]
Availability
variation (-5%)
[.]
[.]
[.]
[.]
{Note: Identify the scenarios for which the NPV of chosen R&M option
becomes negative and analyze them in detail. Discuss the likelihood of
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[Logo of
Utility]
occurrence of each such negative NPV scenarios. If a negative NPV scenario

appears to be highly unlikely or remote possibility, then it may be neglected.
However, in case a negative NPV scenario has a fair chance of becoming a
reality, the impact of such a scenario on the owner utility may be deliberated
upon and accordingly decide whether to go ahead with the implementation
of the chosen R&M option.}
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[Logo of
Utility]

[With growing worldwide concern regarding carbon emission and depletion of
energy resources, governments and international bodies are trying to put in
place incentive mechanisms to encourage reduction in carbon intensity of
economic activities and promote energy efficiencies. The various initiatives in
this regard are evolving both nationally and internationally. Projects that lead
to carbon emission reduction and energy efficiency improvement have the
potential to earn carbon credit and energy efficiency credit that can be sold
and serve as an additional revenue stream.
The R&M project will increase plant efficiency and reduce plant heat rate and
specific coal consumption. This in turn, will result in reduction of emissions
of Green House Gas carbon dioxide (CO2) per unit of electricity generated.
The selected R&M option envisages change in plant design (particularly
change in turbine) so as to increase its efficiency beyond the original design
efficiency and involves additional investment on this account. This R&M
project may qualify for carbon credit benefits. Further, implementation of this
energy efficient R&M project involves overcoming technological barriers as
infrastructure for this kind of project implementation is not well established
in India. Carbon Credit benefit will help make this project viable which is as
such a challenging project from financial and technological stand point.]
{There are various mechanisms such as Clean Development Mechanism
under Kyoto Protocol, Verified Carbon Standard, National Action Plan on
Climate Change(PAT mechanism under National Mission on Enhanced Energy
Efficiency) etc. that can be explored to have financial benefit on account of
reduction in carbon emission and enhancement of energy efficiency.
Improvement in combustion process and burners due to R&M may reduce
NOx emission as well. However, success in securing any benefit under
these schemes will be project specific.}
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FINANCING OF R&M PROJECT
9.1
Financial Performance of Utility
[Logo of
Utility]
The balance sheet and income statement information of Utility for the last 3
financial years is summarized below:
Table 9.1
Balance Sheet and Income Statement
FY .
Amount in Rs
Crores
FY .
Amount in Rs
Crores
FY .
Amount in Rs
Crores
Income from Sale of Power
[.]
[.]
[.]
Other Income
[.]
[.]
[.]
Total Income
[.]
[.]
[.]
Fuel Cost
[.]
[.]
[.]
Employee Expenses
[.]
[.]
[.]
Other Expense
[.]
[.]
[.]
PBDIT (Profit Before

Depreciation, Interest and
Tax)
[.]
[.]
[.]
Depreciation and
Amortization
[.]
[.]
[.]
PBIT (Profit Before Interest

and Tax)
[.]
[.]
[.]
Interest Expense
[.]
[.]
[.]
PBT (Profit Before Tax)
[.]
[.]
[.]
Tax
[.]
[.]
[.]
PAT (Profit After Tax)
[.]
[.]
[.]
[.]
[.]
[.]
Profit and Loss Statement

Particulars
Balance Sheet Particulars

Fixed Asset/Capital Work in
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[Logo of
Utility]
Progress
9.2
Less Accumulated
Depreciation
[.]
[.]
[.]
Net Fixed Asset
[.]
[.]
[.]
Investments
[.]
[.]
[.]
Current Assets excluding

cash
[.]
[.]
[.]
Cash
[.]
[.]
[.]
Total Asset
[.]
[.]
[.]
Long Term Loan
[.]
[.]
[.]
Working capital Loan
[.]
[.]
[.]
Equity Share Capital
[.]
[.]
[.]
Reserves and Surplus
[.]
[.]
[.]
Total Liability
[.]
[.]
[.]
Means of Finance
[Utility is funding the R&M project by a combination of equity and debt.
The cost of the Project is estimated to be Rs. [] million. Utility plans to
fund it at a debt-equity ratio of 70:30, which is same as the normative debt
equity ratio for financing of generation projects specified by Regulator in
Tariff Regulation. The debt and equity requirement for the Project works out
to approximately Rs. [] million and Rs. [] million respectively.
Utility plans to fund the equity component from internal accruals/fresh equity
infusion. Utility needs to infuse fresh equity of [Rs. Crore] to meet the equity
requirement of the R&M Project. Utility is planning to raise the necessary
debt for the R&M project by leveraging its balance sheet. At present the
Company has a debt equity ratio of , which is being leveraged further to
finance various projects including this R&M project.
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[Logo of
Utility]
Utility plans to raise the debt component of the Project cost through a
combination of rupee term loan and foreign currency loan as given in Table
9.2]:
Table 9.2
Means of Financing
Means of Financing
Amount
Equity
[.]
Debt:
[.]
Rupee Term Loan
[ .]
Foreign Currency Loan
[.]
Total
[.]
[Given the balance sheet, the utility can support this kind of financing
arrangement.]
The likely year wise phasing of the debt and equity requirement for this R&M
project is as follows:
Table 9.3
Year Wise Debt & Equity Requirement
Year No
-2
-1
Capex (Rs Cr)
[.]
[.]
[.]
[.]
[.]
Equity (Rs Cr)
[.]
[.]
[.]
[.]
[.]
Debt (Rs Cr)
[.]
[.]
[.]
[.]
[.]
Note: Year 1 is the year in which plant is shut down and R&M work is
implemented.
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10
[Logo of
Utility]

[The scope of R&M works was decided on the basis of the most attractive
option which was selected after the cost-benefit analysis and detailed study
of various options recommended by R&M Consultant. For implementing the
R&M Project, the total work will be divided in suitable number of packages.
A PERT Chart is attached with this Report highlighting the various timelines,
parallel activities and critical paths for the implementation of the R&M
project. For the selection of R&M Contractors, the tendering procedure and
bidding norms will be designed to ensure a fair and transparent competition.]
10.1
Project Team
[
]
{Explain the organization structure of the Project Team along with the
Organization Chart}
10.2
Project Schedule
[
]
{Discuss the project completion schedule along with the schedule of
completion of critical activities including planning for shutdowns. Refer
Annexure 9.1}
10.3
Project Management
[
]
{Discuss the various aspects of Project Management like, Contracting,
Engineering, Procurement, Construction, Erection and Commissioning so as
to ensure that the quality of work conforms to relevant codes / standards
and statutory requirements.}
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10.4
[Logo of
Utility]
Project Monitoring
[
]
{Discuss the methods to be used for regular monitoring the progress of R&M
activities, holding of progress review meetings etc to ensure the timely and
successful completion of Project.}
10.5

[
]
{Discuss the role of the R&M Consultant to carry out the activities from
initial study stage up to the stage of finalizing the R&M contract and to
facilitate approval from regulatory agencies if required.}
10.6
Role of the Implementation Support Consultant

[
]
{Discuss the role of the Implementation Support Consultant for the review of
design documents & drawings to ensure compliance with the spirit, intent &
contents of the EPC contract, inspection & testing, site supervision and
witnessing of Performance Guarantee tests of the equipments.}
10.7
Quality Management
[
]
{Discuss the aspects of field quality plans to ensure that the work performed
by the contractor is as per the relevant codes / standards and statutory
requirements.}
10.8

After the commissioning of the unit post completion of R&M works, the unit
shall be tested to demonstrate the following Guaranteed Parameters as per
the provisions of the R&M Contract.
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[72]
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S. No.
Table 10.1
Performance Guarantee Parameters
[Logo of
Utility]
Value
1.0
Gross Output for the unit at Generator

[]
terminals at 100% TMCR
2.0
Steam Turbine Heat Rate for the unit
[]
at100% TMCR conditions with 0%
makeup.
3.0
[]
conditions while firing design coal
4.0
Auxiliary Power Consumption@ 100%
[]
TMCR while firing design coal
5.0
Emissions of SPM @ 100% TMCR
[]
while firing worst coal
6.0
Noise Level during day time at plant
[]
boundary.
7.0
Noise Level during night time at plant
[]
boundary.
The tests shall be conducted according to the applicable codes and agreed
procedure.
10.9
Liquidated Damages
The R&M Contract shall have provisions of levying Liquidated Damages (LD)
for:
a) Delay in Completion of the Project and
b) Shortfall in Performance.
LD for delay in shall accrue at a rate of Rs. [] per MW per day for each day
of delay up to [] days of delay and Rs. [] per MW per day for each day of
delay beyond [] days of delay. LD for shortfall in performance of the Unit
shall be as per the values given in the following table.
Table 10.2
LD for shortfall in performance
Parameter
Condition
Sl. No.
1.0
2.0
3.0
4.0
LD Amount
Gross Output
For
each
kW
of
shortfall.
Turbine
Heat For each 1 kCal/kWh of
Rate
increase
Boiler Efficiency
For every 0.1% short
fall in efficiency
Auxiliary Power For each 1 kW of
Consumption
increase
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
[]
[]
[]
[]
Page
No.
Date of Issue
[73]
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10.10
[Logo of
Utility]

[
]
{Discuss the steps to be taken for the maintenance of healthy and safe
working environment with the aim to complete the project without any
accident and any adverse effect on the health of manpower. Discuss also the
implementation of HSE Plan by the EPC contractor.}
10.11
Supply of Spares and Special tools and tackles

[
]
{Discuss the R&M Contractors scope to include the supply of spares and
special tools & tackles.}
10.12
Training
[
]
{Discuss the R&M Contractors scope to impart training to the O&M staff of
the utility for the required up-gradation in their skills.}
10.13
O&M Manuals
[
]
{Discuss the R&M Contractors scope to prepare and submit sufficient
number of O&M Manuals, technical diaries indicating various equipment
specifications, process parameters and key schematic diagrams.}
10.14

[
]
{Discuss the O&M Philosophy of the utility to carry out safe, efficient and
reliable plant operation of the plant in compliance with environmental
legislation.}
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[74]
25.09.2014
Power Plant]
11
SELECTION OF R&M CONTRACTOR
11.1
Introduction
[Logo of
Utility]
[The salient features of the tendering procedure for selecting R&M

Contractor have been discussed in this chapter. It is proposed to carry out a
pre-qualification process to identify qualified bidders. The RFP document/
Tender Document will be issued to only those interested bidders that are
found to be qualified in the pre-qualification process. The bidders will be
asked to submit Techno-commercial proposal and price bid in separate
envelopes. First the techno-commercial proposal will be opened and
evaluated for techno-commercial responsiveness. Price bid of only those
bidders, whose techno-commercial proposal is found to be responsive, will
be opened.]
{The utilities may refer the Standard Document on Tendering Procedure for
R&M Contractor, which is being issued separately.}
11.2
Bidding Process
11.2.1
Qualification of Bidders
[The R&M work is technologically complex and challenging in terms of
execution. It is important to ascertain the availability and willingness of
capable and qualified bidders through a pre qualification process before
inviting tenders. Further, evaluating tenders from large number of bidders,
both qualified and unqualified, will make the tendering process time
consuming. Therefore, only parties qualified in a pre-qualification process will
be issued Tender Documents and will be allowed to participate in the
Tendering process. For all the packages, bids will be invited after conducting
a pre-qualification process to shortlist qualified bidders.]
11.2.2
Stages of Bidding Process

[Each R&M project is unique and associated with many complexities
regarding assessment of the quantum and nature of retrofit and replacement
to be carried out. It is important to firm up the technical contours of the
contract before opening price quotations so that all the bidders and the
owner have agreement and clarity about the nature and scope of the work
on which the price bids are based. Therefore, it is envisaged to invite bid in
two parts. The bidder will submit Part-I and Part-II of the bid together. The
Part-I bid will comprise the techno-commercial bid and the Part-II bid will
comprise quotations for price and performance guarantee parameters. First
the Part-I bid (techno commercial offer without price) will be opened and
evaluated for techno commercial responsiveness. Part-II bid (price bid along
with guaranteed parameters) of only parties whose techno-commercial offers
are found to be responsive to tender documents and conditions during
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[75]
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Power Plant]
[Logo of
Utility]
evaluation of Part-I bids will be opened. The rationale behind asking bidders
to submit Part-II bid along with Part-I bid is that bidders will make their
quotes before the number of responsive techno commercial bids is known.
This will encourage competitive price quotes. However in case a bidder is
asked to make changes in its techno commercial offer that have price
implications, the bidder may be allowed to submit supplementary price
against such changes before opening of PartII bid (price bid). The broad
sequence and tentative timelines for the tendering procedure is described in
the Table-10.1.]
Table-11.1
Broad Outline of Tendering Procedure
Activity
Tentative Timeline
(a)
Publication of RFQ and start of issue of

RFQ document
Zero Date
(b)
Last date for issue of RFQ document
15th Day from zero date
(c)
Last date for submission of response to

RFQ
(d)
Short listing based on response to RFQ
(a)
Issue of RFP
(b)
Site Visit and O&M Document Review
Before Pre-Bid Discussion
(b)
Pre - Bid Discussion
(c)
Last date for submission of Both Part I

and Part II Bid and Opening of Part-I
(Techno-commercial) Bid
(d)
Techno Commercial Discussion
(e)
Completion of Evaluation of TechnoCommercial Bids
(f)
Date of Opening of Price Bids
(g)
Selection of Successful Bidder and

Placement of LoI
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[76]
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11.3
Pre-Qualification
11.3.1
Objective
[Logo of
Utility]
[The objective of the pre-qualification is to allow only capable and qualified

bidders having requisite technical expertise, relevant experience, project
execution capability and financial resources to participate in the tendering
process. The pre-qualification document will specify the qualification criteria
to be met by the prospective bidders to be eligible to participate in the
tendering process. The prequalification is not intended to limit competition
to a predetermined number of potential bidders. All the interested parties
meeting the specified criteria will be issued tender documents and allowed to
submit bid.]
11.3.2
Qualification Requirement
[The Qualification Requirement will include Technical Qualification
Requirement, Financial Qualification Requirement and Reasons for Exclusion
if any. The Technical Qualification Requirement will include technological and
execution capabilities and experience in the execution of comparable
projects.
Financial Qualification Requirement will include evidence of
financial soundness; past experience in executing projects of similar
magnitude and ability to mobilize financial resources for executing the
project. The reasons of exclusion are aimed at excluding parties that may
have unfair advantage over other parties or that have past record of
wrongdoing. Any bidder who is or was involved as a consultant in the
preparation or implementation of the project or whose associate or
affiliate is or was involved as a consultant in the preparation or
implementation of the project is to be excluded. Any b i d d e r w h o is
legally barred from the procurement process in India on the grounds of
previous violations of regulations on fraud and corruption is to be
excluded.
The specified Technical and Financial Qualification Requirement will
balance the twin objectives of restricting participation in the
tendering process to capable and experience bidders with ability to
successfully undertake the Renovation & Modernization work and
ensuring participation by adequate number of interested parties to
encourage competitive bids.
Bidders may meet the Qualification Requirements jointly with
associates or consortium partners. In such cases, bidders and his
associates and/or consortium partners will have to furnish joint
undertaking in the prescribed format to discharge their obligations. The
bidder can be a Joint Venture Company as well. In all cases of qualification
through Consortium/Associate/JV, all the parties will be jointly and severally
liable to the employer to discharge all contractual obligations.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[77]
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11.3.3
[Logo of
Utility]
Documentary Evidence for Qualification

[The intending Bidders will be required to furnish documentary evidence and
performance certificates in support of their qualification credentials along
with their response to Request for Qualification. The documentary evidence
will include inter alia list of orders executed along with copies of orders,
Performance Certificates indicating date of completion, documents of
company profile incorporating information about technical man power,
financial strength, resources, organization and experience to undertake such
jobs, copy of audited accounts for last three years along with copy of latest
income tax return etc.]
11.4
Request for Proposal and Selection of Successful Bidder

[The bids for the Renovation and modernization work will be submitted in
two parts. Both the parts will be submitted together.]
11.4.1
Techno-Commercial Bid (Stage-I)

[The Part-I bid will comprise the techno-commercial bid without prices. The
main components of the techno-commercial bid will be Bid Guarantee, scope,
technical descriptions/details, technical data sheets, list of Tools & Tackles,
deviations to technical and commercial specifications/conditions, overall
time schedule & L-1 Network Schedule, resource deployment schedule, detail
of
Sub-Contractors/Sub-Suppliers/Sub-Vendors,
spares
list,
Quality
Assurance Programme, Details of the present commitments of the bidder &
details of contracts in hand, Indices and Coefficients for Price Variation etc.
After evaluation of the techno-commercial (Part-I) bids, each bidder who
has submitted a broadly responsive Part-I bid will be invited for technocommercial discussion, during which all the required amendments,
additions, deletions and other adjustments will be noted and recorded in
a Memorandum. P a r t - I I b i d ( P r i c e B i d ) o f o n l y those bidders
whose Part-I bi d is found to be responsive to tender
specifications and conditions will be opened.]
11.4.2
Price Bid (Part-II)

[The P a r t -II bid will comprise quote for Prices and the Performance
Guarantee parameters. The bidders will be asked to submit filled up Schedule
of Prices and Schedule of Performance Guarantees.
After evaluation of Part-I bid (techno-commercial bid) and before opening of
Part-II (Price Bid), However in case a bidder is asked to make changes in its
techno commercial offer that have price implications, the bidder may be
allowed to submit supplementary price against such changes before opening
of PartII bid (price bid
A comparative evaluation of the price bids will be carried out to identify the
techno-commercial responsive and qualified bidder with Lowest Overall
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[78]
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[Logo of
Utility]
Evaluated Price after taking into account adjustment for differential quote for
Performance Guarantee parameters using adjustment factors specified in the
Tender Documents (adjustment to price of bids with quoted Performance
Guarantee figure inferior to the value quoted in the responsive bid with most
competitive quote for that Performance Guarantee parameter) and cost
compensation if any arising from evaluation of techno-commercial bids.
However, bids with quote for any Performance Guarantee Parameter inferior
to the minimum or maximum value for the parameter specified in the tender
conditions will be rejected.
The qualified and techno-commercially responsive bidder with the lowest
evaluated price will be selected as contractor for carrying out the R&M work.
In case the lowest price quoted is higher or lower than the estimated
reasonable cost for the work by a very large amount, further investigation
will be made regarding the reasonableness of the quoted price.]
11.5
Packaging and Contracting Concept
11.5.1
Packaging
[Implementing the Renovation and Modernization of the entire plant as a
single package by a single contractor makes the tendering and execution
process simple for the owner as it obviates the need to split the work into
different packages, to ensure interface between different packages during
design and execution, and to properly align the completion schedule of
different packages. Further, single package allows owner to fix single point
responsibility and avoids contractual disputes arising out of acts of omission
of one contractor affecting other contractors. However, Renovation and
Modernization of different systems of the plant need different expertise and
experience. There will be very few contractors, if any, who have in house
expertise and experience to carry out the R&M of all areas of a coal fired
power plant. A single EPC bid for R&M work will thus restrict number of
qualified bidders, which will also increase the cost of R&M. In order to
balance the conflicting needs of minimizing project/contract management
complexities and having adequate number of eligible and willing bidders
having relevant expertise and experience to carry out the R&M work under a
package, it is proposed to split the R&M work into the following packages:
1. Boiler & Auxiliaries (including but not limited to Pulverizes, Feeders,
PA Fans, FD Fans, ID Fans), ESP, Auxiliary Steam system and MS,
HRH, CRH, HPBP & LPBP piping and associated Electrical, C&I and
civil works.
2. Turbo-Generator & Auxiliaries (including but not limited to Heaters,
Deaerator, Condenser, BFP, CEP), TG Cycle piping including Boiler
Feed piping and associated Electrical, C&I and civil works. . This
package will also including R&M of C&I system common to both SG
and TG.
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[79]
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[Logo of
Utility]
3. Coal Handling Plant and associated Electrical, C&I and civil works.
4. Ash Handling system and associated Electrical, C&I and civil works.
5. Mechanical Balance of Plant (BOP) systems which includes Plant
Water System (Raw water treatment system, CW System, ACW
system and other water systems), Compressed Air system, Fuel Oil
system, Fire Fighting system and Miscellaneous balance mechanical
systems.
6. Electrical BoP including inter alia switchyard, power transformers.]
11.5.2
Contracting
[R&M of BTG, BTG auxiliaries, Power Transformers and switchyard are likely
to be technologically complex & involve higher value contracts and hence
likely to evoke response from many reputed international bidders. Hence
packages covering these systems will be tendered on International
Competitive Bidding basis. However, R&M of other BoP packages are not
likely to see participation by many reputed international bidders and hence
will be tendered on Domestic Competitive Bidding basis.]
Table-11.2
Nature of Bidding
Sl No
1
Package
Nature of Bidding
[Boiler & Auxiliaries (including but not limited

to Pulverizes, Feeders, PA Fans, FD Fans, ID
Fans), ESP, Auxiliary Steam system and MS,
HRH, CRH, HPBP & LPBP piping and
associated Electrical, C&I and civil works.]
[Turbo-Generator & Auxiliaries (including but
not limited to Heaters, Deaerator,
Condenser, BFP, CEP), TG Cycle piping
including Boiler Feed piping and associated
Electrical, C&I, and civil works. This package
will also including R&M of C&I system
common to both SG and TG.]
[ICB]
[Coal Handling Plant and associated

Electrical, C&I, and civil works.]
[DCB]
[Ash Handling System and associated

Electrical, C&I and civil works.]
[DCB]
[Mechanical Balance of Plant (BOP) systems

which includes Plant Water System (Raw
water treatment system, CW System, ACW
system
and
other
water
systems),
[DCB]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
[ICB]
Description
Page
No.
Date of Issue
[80]
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Sl No
Package
[Logo of
Utility]
Nature of Bidding
Compressed Air system, Fuel Oil system,

Fire Fighting system and Miscellaneous
balance mechanical systems]
[Electrical BoP including inter alia
switchyard, power transformers]
[ICB]
[Each package will be awarded on lump sum EPC contract basis. The scope
of work for each package will consists of design, engineering, manufacture,
supply, inspection & testing at suppliers works, packing, forwarding to site,
transportation, unloading, storage, handling at site, steel structures, civil
works, insurance, erection, painting, start-up, trial operation, testing,
commissioning and performance guarantee testing, guarantee & warranty
and handing over on turnkey contract basis.
The price of the contract will be on lump sum price basis for the entire scope
covered in the contract. The contract price will be subject to adjustment
during the contract period to reflect change in labour and material price
levels as per price variation formula specified in the tender document. The
adjustment in price to reflect in change in labour and material price levels as
per price variation formula will be subject to limits specified in the tender
specification.
Appropriate change order clause will be built into the contract to deal with
the need to change the scope of the contract due to surprises encountered
during the execution of the R&M work
The selected contractor will be required to furnish Contract Performance
Bank Guarantee equivalent to 10% (ten percent) of contract price. The
contractor will be required to furnish Advance Payment Bank Guarantee
equivalent to the advance payment made to it. Progressive payment will be
made to the contractor against supply and erection/construction. Last 10%
of the payment will be made on completion of the facilities by the
contractor.
The contractor will be required to pay Liquidated Damages for delay in
completion of R&M work. The aggregate liability for delay will be limited to
10% of contract price.
The contractor will be required to pay Liquidated Damages for shortfall in
achieving guaranteed performance parameters. The aggregate liability for
shortfall in performance guarantee parameters will be limited to 10% of
contract price.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[81]
25.09.2014
Power Plant]
12
[Logo of
Utility]
RISKS
Renovation and Modernization projects are very complex in nature and
associated with high level of uncertainty. The various risk factors along with
mitigation measures are discussed below.
12.1

[Information and inference flowing from Condition Assessment, Residual Life
Assessment and Life Extension studies forms the basis of planning,
designing, costing and tendering of R&M projects. However, these reports
may not give the accurate idea about actual state of the plant and
equipment. Similarly, the rehabilitation and retrofitting programme may not
lead to the intended life, reliability and performance of the plant. In some
cases serious damage might be detected for plant and equipment during the
implementation stage which could not be detected during the CA studies.
Such surprises may send the cost estimate and schedule for a toss.
The probability and impact of such risks may be moderated by designing
proper condition assessment plans. Further, contingencies may be built into
cost estimates and contractual clauses may be suitably designed to take care
of such surprises.]
12.2
Regulatory Risk
[The capital expenditure incurred for the R&M project has to be serviced by
suitable electricity tariff. If the concerned Electricity Regulatory Commission
does not allow adequate
tariff to cover the expenses incurred, it will
adversely affect the cash flow and net worth of the owner.
The regulatory risk may be mitigated by designing and implementing the
R&M Project in compliance and in sync with the extant regulatory regime.]
12.3

[There is limited availability of competent contractors and personnel for
carrying out R&M works. There is dearth of contractors and personnel with
expertise and experience in implementation of energy efficient R&M works.
Government and industry bodies can play big role in mitigating this risk by
taking initiative expands contractor base and talent pool. Owner on its part
can somewhat mitigate this risk by designing tendering process and
contracts that encourages better participation by available contractors.]
12.4
Risk of too weak or too stringent QR for R&M Contractor

[Too weak qualification requirements may lead to entry of incompetent
bidders with lower price quotes. Awarding the R&M Contract to an incapable
Contractor may severely jeopardize the R&M programme. Similarly, too
stringent qualification requirement may restrict the number of eligible bidders
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[82]
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[Logo of
Utility]
to a few thereby restricting competition and this may lead to higher price
quotes.
Due care should be taken to frame appropriate qualification requirement (QR)
to ensure adequate participation of competent bidders. While framing the
QR, information should be collected from prospective bidders regarding their
experience and capability. ]
12.5
Risk of Non-availability of Spares

[As the unit is very old, there may be difficulty in sourcing many spare parts.
This risk may be obviated in some cases by devising suitable sourcing
strategy or design modifications or reverse engineering.]
12.6

[As R&M of the complete plant calls for shutdown for considerable time and
there is acute shortage of electricity, the grid condition may not permit
shutdown period. This risk may be mitigated by proper planning and taking
all stakeholders into confidence during the planning phase and adhering to
the planned schedule.]
12.7
Financing Risk
[The owner may find it difficult to arrange equity and debt financing for the
R&M project. This risk may be mitigated by proper financial planning.
Similarly, the R&M contractor may face cash flow problem. This risk may be
mitigated by specifying suitable financial qualification criteria in tender
specification and incorporating suitable payment term in the contract.]
12.8
Implementation Risk
[Poor implementation of project may lead to cost and/or time overrun and
deficiency in quality. This risk may be mitigated by efficient Project
Management set up and selection of reliable R&M contractor.
Aligning the timeline of tendering and execution of different packages and
interfacing among different packages when R&M is being implemented in
multiple packages is essential for smooth and timely execution of the R&M
project. This risk may be mitigated by proper planning of tendering and
execution of R&M project and employing suitable Project Management /
Coordination team.]
12.9

[The renovated plant and equipment may not perform as envisaged due
deficiency in design, manufacturing and O&M practices. The risk
underperformance due to design and manufacturing shortcomings may
managed by selecting reliable contractor and incorporating appropriate
clause in the contract. The risk of O&M deficiency can be mitigated
proper training of O&M personnel.]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
do
of
be
LD
by
Page
No.
Date of Issue
[83]
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13
[Logo of
Utility]

{Discuss in this chapter, the need of compliance to the conditions prescribed
by MOEF and State Pollution Control Board (SPCB)}
13.1

[
]
{Discuss the role of Environment Monitoring Cell established at the project.
Discuss the steps to be taken for strengthening the above cell to monitor and
control the environmental impacts from the renovated plant, as per the
revised stringent norms prescribed by the regulating authorities.}
13.2
Stack Emissions
[
]
{Discuss the present levels of emissions of SPM, SO2, NOx and NH3 from the
stack, levels of Ground Level concentrations and the pollutants in the liquid
effluents with respect to the statutory norms vis a vis the levels of emissions
after the implementation of R&M Project. Discuss the methods and
frequency to be adopted by the utility for monitoring and controlling these
emissions as per the revised conditions prescribed by the regulating
authorities.}
13.3

[
]
{Discuss the National Ambient Air Quality Standards prescribed by MOEF and
SPCB. Discuss the methods and frequency to be adopted by the utility for
monitoring and controlling the Ground Level Concentrations (GLC).}
13.4
Liquid Effluents
[
]
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[84]
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[Logo of
Utility]
{Discuss the quality of liquid effluents permitted by SPCB from different

systems of the plant like, effluent from Water Treatment Plant, Boiler Blow
down, Cooling Tower Blow down, recycled water from ash pond and sewage
disposal from plant and colony. Discuss the recycling of ash water from ash
pond and reuse of Cooling Tower Blow down for ash handling and coal dust
suppression. Discuss the proposal of zero discharge, if applicable to your
project.}
13.5
Ambient Noise
[
]
{Discuss the noise level permitted during day and night and methods
proposed to contain the noise level produced from power plant equipment
within the limits imposed.}
13.6
Ash Utilization
[
]
{Discuss the norms for the utilization of ash from the thermal power plants
as per the latest notification from MOEF. Discuss the quantum of fly ash &
bottom ash to be produced from the plant and implementation of ash
utilization plan by the utility, after the completion of R&M project. Please
note that as per MoEF notification dated 3rd November 2009, all the coal and
lignite based thermal power stations operating before the date of the above
notification are required to achieve the target of 100% utilization of fly ash
before the expiry of a period of five years from the date of issue of the said
notification.}
Document Number
Rev
No.
LII-GETS12021-G-00100-004
04
Description
Page
No.
Date of Issue
[85]
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ANNEXURE-7.1
SUMMARY OF CAPITAL COST FOR SELECTED R&M OPTION
Sl. No.
Item
FC
IC
Total
Equiv. Rs.
Rs.
Rs.
1.0
Plant & Equipment
1.1
[...]
[...]
[...]
1.2
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Project Engineering and

Management
[...]
[...]
[...]
Taxes and Duties
[...]
[...]
[...]
Project Cost excluding IDC and FC

(1.0 to 5.0)
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Contingency
[...]
[...]
[...]
Project Cost incl. IDC &FC and

Contingency (1.0 to 8.0)
[...]
[...]
[...]
1.3
1.4
C&I Equipment
Miscellaneous Equipment
Sub-Total (1.0)
2.0
3.0
4.0
5.0
Civil Works
Pre Commissioning Expenses
6.0
Financing Charges
7.0
Interest During Construction (IDC)
IDC + Financing Charges
8.0
Document Number
Rev
No.
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Description
Page
No.
Date of Issue
[86]
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[Logo of
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ANNEXURE-7.2
SUMMARY OF COST ESTIMATE FOR EACH R&M PACKAGE
Name of the Package:
Sl. No.
Item
FC
IC
Total
Equiv. Rs.
Rs.
Rs.
1.0
Onshore Supply
[...]
[...]
[...]
2.0
Offshore Supply
[...]
[...]
[...]
Civil and Structural Works
[...]
[...]
[...]
Installation, Transportation and

other Services
[...]
[...]
[...]
Taxes and Duties
[...]
[...]
[...]
3.0
4.0
5.0
5.1
Taxes and Duties on Onshore

Supply
Taxes and Duties on Offshore
Supply
[...]
[...]
[...]
5.2
[...]
[...]
[...]
5.3
Taxes and Duties on Civil and

Structural Works
Taxes and Duties on Installation,
Transportation and Other Services
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
5.4
6.0
Sub-Total (5.0)
Total Package Cost (Sum of 1.0 to
5.0)
{Note: Cost Estimate Summary for each of the R&M package is to be attached.}
Document Number
Rev
No.
LII-GETS12021-G-00100-004
03
Description
Page
No.
Date of Issue
[87]
25.09.2014
Detailed Project Report For R&M of Unit No.[..] Capacity []of [Name of the
Power Plant]
[Logo of Utility]
ANNEXURE 7.3
COST OF GENERATION (COG) CALCULATION FOR PROPOSED R&M OPTIONS
Year
..
..
..
..
..
16
17
18
19
20
Capacity (MW)
[....]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
PLF (%)
[....]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Heat Rate
(kCal/kWh)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Secondary Fuel
(Oil) Consumption
(ml/kWh)
[....]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Landed Cost of
Coal (Rs/tonne)
[....]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Landed Cost of
Secondary Fuel
(Oil) (Rs/kl)
[....]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Auxiliary Power
Consumption (%)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Energy Generated
(MU)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Energy Sent Out
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Document Number
Rev
No.
Description
Page No.
Date of Issue
LII-GETS12021-G-00100-004
04
[88]
25.09.2014
Power Plant]
Year
..
..
..
[Logo of Utility]
..
..
16
17
18
19
20
[....]
[.]
[.]
[.]
[.]
(MU)
Energy Charges:
Annual Energy
Charge (Rs
Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Energy Charge
per Unit (Rs/kWh)
[....]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Capacity Charge:
[....]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Return on Equity
(Rs Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Interest on Loan
Capital (Rs
Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Interest on
Working Capital
(Rs Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Depreciation (Rs
Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
O&M Charge (Rs
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Document Number
Rev
No.
Description
Page No.
Date of Issue
LII-GETS12021-G-00100-004
04
[89]
25.09.2014
Power Plant]
Year
[Logo of Utility]
..
..
..
..
..
16
17
18
19
20
Million)
Secondary Fuel
(Oil) Charge (Rs
Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Annual Capacity
Charge (Rs
Million)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Capacity Charge
per Unit (Rs/kWh)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Cost of
Generation
(Rs/kWh)
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Discounting
Factor
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[....]
[.]
[.]
[.]
[.]
Levelized Cost of
Generation
(Rs/kWh)
Note: Year 1 is the year in which plant is shut down and R&M work is implemented
{Note: The number of years in the above table is indicative only. The CoG calculation will be done for the number of years
spanning the economic plant life after R&M.}
Document Number
Rev
No.
Description
Page No.
Date of Issue
LII-GETS12021-G-00100-004
04
[90]
25.09.2014
Power Plant]
[Logo of Utility]
ANNEXURE-7.4
CASH FLOW AND RETURN ANALYSIS FOR PROPOSED R&M OPTIONS
Year
-2
-1
..
..
..
..
..
16
17
18
19
20
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Average Heat Rate

(kCal/kWh)
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Auxiliary
Consumption (%)
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Normative Energy
Generated (MU)
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Energy Sent Out

(MU)
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Loss of generation
due to shut down
for R&M (MU)
[...]
[...]
Landed Cost of
Coal (Rs/tonne)
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Landed Cost of
Secondary Fuel
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
PLF (%)
(Normative PLF)
Document Number
Rev
No.
Description
Page No.
Date of Issue
LII-GETS12021-G-00100-004
04
[91]
25.09.2014
Power Plant]
Year
-2
-1
[Logo of Utility]
..
..
..
..
..
16
17
18
19
20
Indicative Tariff
(Rs/kWh)
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Cost of Purchasing
Power from Grid
net of variable
charge (Rs/kWh)
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Annual Coal Cost

(Rs Million)
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Annual Oil Cost

(Rs Million)
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Annual O&M Cost

(Rs Million)
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Cost of Loss of
Generation due to
shut down for
[...]
[...]
(Rs/kl)
Cash Inflow:
Annual Revenue
(Rs Million)
Cash Outflow
Document Number
Rev
No.
Description
Page No.
Date of Issue
LII-GETS12021-G-00100-004
04
[92]
25.09.2014
Power Plant]
Year
-2
-1
[...]
[...]
[...]
Interest Payment
(Rs Million)
[...]
Principal
Repayment (Rs
Million)
[Logo of Utility]
..
..
..
..
..
16
17
18
19
20
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
R&M (Rs Million)

Capex (Rs Million)
[...] [...]
Net Cash Flow (Rs

Million)
[...] [...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Discount Factor
[...] [...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Net Present Value

of Cash Flows (Rs
Million)
IRR (%)
Payback Period
(Years)
Note: Year 1 is the year in which plant is shut down and R&M work is implemented
Document Number
Rev
No.
Description
Page No.
Date of Issue
LII-GETS12021-G-00100-004
04
[93]
25.09.2014
Power Plant]
[Logo of Utility]
{Note: Cash Flow and Return analysis for each of the R&M option and base case to be attached.
The number of years in the above table is indicative only. The analysis will be done for the number of years spanning the
economic plant life after R&M.}
Document Number
Rev
No.
Description
Page No.
Date of Issue
LII-GETS12021-G-00100-004
04
[94]
25.09.2014
Detailed Project Report For R&M of Unit No.[..] Capacity [] of [Name of the
Power Plant]
[Logo of Utility]
ANNEXURE 10.1
PROJECT MILESTONE SCHEDULE FOR R&M CONTRACT
Milestones
Zero Date
[..]
[..]
Site Office Development
[..]
[..]
Site visit and assessment of

Equipment & System
[..]
[..]
Re-Engineering and
Development
[..]
[..]
Supply of Equipment
[..]
[..]
Unit Shut-down
[..]
[..]
Dismantling Activities
[..]
[..]
Erection activities
[..]
[..]
Boiler Erection
[..]
[..]
Turbine Erection
[..]
[..]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00100-004
04
[95]
25.09.2014
Detailed Project Report For R&M of Unit No.[..] Capacity [] of [Name of the
Power Plant]
Milestones
[Logo of Utility]
Erection of Balance of Plant
[..]
[..]
Erection of Electrical
Equipment
[..]
[..]
Erection of C&I Equipment
[..]
[..]
Testing & Commissioning
[..]
[..]
Commercial Operation
[..]
[..]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00100-004
04
[96]
25.09.2014

OF
MODEL ENERGY AUDIT REPORT
PREPARED BY

LII-GETS12021-G-00100-005 R02
September 2013
Model Energy Audit Report For R&M of Unit No.[..] of [Name of the Power Plant]
[LOGO OF
UTILITY]
Revision No.
Date
Prepared /Revised
by
R00
15.03.2013
R.K.Soni (RKS)
R01
03.07.2013
RKS
Report finalized based on the

comments of the Task Force
2013.
R02
26.09.2013
RKS
Revisions carried out as per

discussions held in CEA on 24th July
2013.
Document Number
LII-GETS12021-G-00100-005
Description
Rev
No.
Description
Page
No.
Date of Issue
02
[i]
26.09.2013
[LOGO OF
UTILITY]
BACKGROUND
India. Thermal Power Stations are designed for an economical and stable life span of
25 years, after which, the level of performance starts deteriorating as a result of
degradation of its equipments, components and materials. Deterioration may also take
place before the completion of useful life of 25 years, if the units are not operated and
maintained properly. Deterioration in performance is reflected in frequent forced
outages, reduced outputs, decreased efficiency and increased cost of generation. This
results in costly repair and loss of revenue. Renovations & Modernization (R&M) and
Life Extension (LE) Programme of thermal power station is an activity of carrying out
repairs, refurbishments and replacement of defective equipments & components so as
to extend the life of the power plant by at least 20 years and to restore the
performance parameters to equal or better than the original design parameters.
Need of R&M
In spite of new capacity additions, India continues to face shortages of varying degree
in the supply of energy and peaking power. Implementation of fresh capacity additions
for bridging the demand supply gap involves huge investments and long gestation
periods primarily due to the process of land acquisition and getting the required fuel and
water allocations, permits & clearances, particularly, the environmental clearance.
technologies.
As per the Guidelines issued by Central Electricity Authority (CEA) the following should
be the objectives of R&M and R&M/LE Programmes.
To restore rated capacity and design parameters such as Heat Rate, Auxiliary
Power Consumption and Secondary Oil Consumption etc.
technology.
To improve the performance parameters in terms of Plant Load Factor,

Efficiency, Forced Outages, Availability and Reliability.
Compliance of stringent environmental norms, safety and other statutory

requirements.
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[ii]
26.09.2013
[LOGO OF
UTILITY]

As per the Guidelines issued by Central Electricity Authority (CEA) the following criteria
is to be adopted for considering the R&M and R&M/LE Programmes.
cost of new unit.

Based on the discussions held with Ministry of Power, various utilities, PFC and BHEL,
CEA prepared a document on National Perspective Plan for Renovation &
Modernization and Life Extension and Up-rating (LE&U) of thermal power stations up to
the year 2016-17. This document which also includes revised guidelines for
Renovation & Modernization / Life Extension works on coal/lignite based thermal power
stations was released by Honourable Minister of Power on 14th December 2009. Planwise Achievements of R&M and R&M/LE Programmes starting from 7th Five Year Plan
till 11th Five Year Plan is furnished below:
S.No.
Plan
7th Plan
and Two
Annual
Plans
Year
85-86 to 8990 & 90-91,

91-92
Document Number
LII-GETS12021-G-00100-005
No. of TPS /
No. of Units
Capacity
(MW)
34 / 163
13570
Additional
Generation
Achieved
MU/
Annum
10000
Equivalent
MW
2000
Rev
No.
Description
Page
No.
Date of Issue
02
[iii]
26.09.2013
S.No.
Plan
Year
8th Plan
(R&M)
(LEP)
92-93
to
96-97
9th Plan
(R&M)
(LEP)
97-98
to
2001-02
10th Plan
(R&M)
(LEP)
2002-03 to
2006-07
No. of TPS /
No. of Units
Capacity
(MW)
44 / 198
43/(194)
1/ (4)
20869
(20569)
(300)
37 / 152
29/ (127)
8/ (25)
9/ 25
(14 out of
57 planned )
(11 out of
106 )
[LOGO OF
UTILITY]
Additional
Generation
Achieved
MU/
Annum
5085
Equivalent
MW
18991
(17306)
(1685)
14500
2200
3445
(2460)
(985)
2000
300
763
Life Extension
Programme (LEP)
R&M Programme
Total
Programme
(MW)
Achievement
(MW)
7318
(53 units)
18965
(76 units)
26383
(129 units)
1291
(13 Units)
14855
(59 units)
16146
(72 units)
investigation to identify the R&M works to be carried out and preparation of technical
bid documents based on the investigation was not done. This resulted in unsystematic
and additional work during execution phase and uncertainty about costs resulting in
excessive implementation time, long shutdown periods of plants and cost overruns. In
the absence of standard commercial rules and policies, suppliers showed little interest
in R&M work. Therefore a strong need was felt for providing standardized bidding
procedures as well as model contracts, formats and specifications etc. to the utilities.
Standardization will harmonize the requirements of all the stakeholders and will lead to
their increased participation.
discuss energy related issues of mutual interest. The first meeting of the ad-hoc subgroup on energy efficiency in thermal power stations, constituted as per decision of
meeting of IGEF in December 2007, was held under the chairmanship of Joint Secretary
(Thermal), Ministry of Power on 12th March, 2008 in which preparation of standard
tendering document for the purpose of R&M activities was, inter-alia, identified as an
area of the activities. The scope of the assignment was divided in two parts as under:-
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[iv]
26.09.2013
[LOGO OF
UTILITY]
Phase-I Activity:
Phase-I activity comprised an assessment of tendering procedures currently being
followed by public utilities in India and a review of documents used for standard R&M
projects and the documents which have already been developed for energy efficient
R&M projects financed by particularly World Bank. This activity was carried out by M/s
Evonik (India) under the grant provided by GTZ. M/s Evonik (India) submitted the report
in September 2009.
Phase-II Activity
November 2009, KfW proposed to finance and carryout the work programme of phaseII Activity, on behalf of CEA & in consultation with the Task Force. In a meeting held in
MOP on 17th December 2009, chaired by Joint Secretary (Thermal), MOP, the
representative of KfW suggested that CEA may act as Project Executing Agency for
the phase-II activity. Accordingly Ministry of Power, Govt. of India have entrusted the
task of Project Executing Agency to CEA for implementing Phase-II activity. Under
Indo-German Energy Forum (IGEF) assisted programme, M/s Lahmeyer International
(India) was appointed on16th March 2012 to provide the consultancy services for
Development of tendering procedures and model contract document for R&M of Fossil
Fuel Based Power Plants in India. The scope of consultancy services included the
preparation of the following model documents:
I)

Contractor.

VI) Request for Qualification (RFQ) & (RFP) Documents for R&M Consultants and
R&M Contractors.


MAHAGENCO.
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[v]
26.09.2013
[LOGO OF
UTILITY]
Tender document for Supply, Erection, Testing and Commissioning of Air

Preheater for Unit 5 & 6 Koradi TPS, MAHAGENCO.
Tender document for replacement of 6.6 KV station transformer incoming
breaker & Tie breaker of Koradi TPS, MAHAGENCO.
Commissioning of Rotary Air Preheter for Units 4 & 5, Nasik TPS of
MAHAGENCO.

KfW Documents


Installation.
**************
This Energy Audit Report has been prepared to conceptualize the systematic methods
and procedures to be implemented for carrying out R&M works for the Thermal
Power Plants, taking into account the different practices followed in the past, the
practices and methodologies being adopted in the Industry including the Projects
funded by KfW and World Bank, as indicated in the various documents indicated
above. Detailed standard documents like DPR, RFP & RFQ documents to carry out
R&M works for the Thermal Power Plants shall take into account the findings of
Energy Audit of the Project.
The utilities are advised to refer to the guidelines of the standard documents for the
preparation of the project specific documents for their project.
**************
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[vi]
26.09.2013
[LOGO OF
UTILITY]
NOTES & GUIDELINES FOR USING THE MODEL ENERGY AUDIT REPORT
Central Electricity Authority (CEA), the Project Executing Agency / Employer has
appointed Lahmeyer International India Pvt. Ltd. (LII), the Consultant to Develop
Standard Procedures and Model Documents for the Renovation and Modernization
(R&M) of Fossil Fuel based Power Plants in India. The above assignment is being
financed by KfW Entwicklungsbank. Accordingly, this Model Energy Audit Report has
been prepared for the guidance of Project Authorities, who may decide to carryout R&M
of their old Coal based Power Plants so as to extend the life of their plants and make
them energy efficient, while ensuring that the plants are in compliance with the revised
statutory emission standards.
The purpose of this model document is to standardize the style and contents of the
Energy Audit Report for R&M works. Since a large fleet of 200/210 MW units are
potential candidates for consideration of Renovation as they have crossed 20 to 25
years of useful life, the Model Energy Audit Report has been prepared keeping those
200 MW/210 MW units in view. Since in due course of time, many 500 MW units will
also become due for R&M, the Utilities are advised to suitably modify this document for
its application to 500 MW units.
The Model Energy Audit Report contains two kinds of texts written in black and in blue
colours. The text in blue colour written in italics and enclosed in square bracket
represents variable information which may vary from project to project. The data in blue
colour indicates typical data and values for typical coal fired power plants. The Project
Authorities and their Consultants, carrying out R&M and LE of a particular plant/project,
should review this data in respect of their plant/project and modify these data with the
ones as may be applicable to their specific Project. A few guidelines for carrying out the
energy audit of the power plant equipment have also been provided in blue italics
enclosed within red curly brackets ({}), wherever applicable.
A variety of performance tests and energy measurement tests are required to be carried
out for arriving at decisions for the retrofitting/replacement of the equipments. While
discussing the need, importance and methodology of conducting these tests and
measuring the energy consumption, the Model Energy Audit Report also provides the
templates for the formats for reporting the results of such tests and measurements.
Formats for reporting the results of Energy Audit have been appended at the end of this
Model Document. The Formats provided for a particular kind of test described for any
equipment may be used for similar remaining Equipments.
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[vii]
26.09.2013
[LOGO OF
UTILITY]

FOR
OF
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[viii]
26.09.2013
[LOGO OF
UTILITY]
TABLE OF CONTENT
1
EXECUTIVE SUMMARY
INTRODUCTION
2.1
2.2
3
Objectives of Energy Audit

Methodology adopted for Energy Audit
DESCRIPTION AND SALIENT FEATURES OF THE UNIT

3.1
3.2
6
13
17
20
21
24
26
General
Major Replacements in the last ten years
26
27
28
5.3
5.4
5.5
30
General
Operating Parameters of Boiler and Auxiliaries
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
30
30
Operating Parameters of the Boiler

Operating Parameters of Economiser
Operational Parameters of Air Pre-heater
Temperature Profile of Flue Gas
Feed Water and Boiler Water Quality
Mill Performance Data
Heat Losses and Efficiency of the Boiler
30
31
32
32
33
34
34
Action Plan for Reducing the Energy Consumption

Sankey Diagram for the Efficiency of the Boiler
Schematic Diagrams of the Boiler & Auxiliaries
35
37
37
STEAM TURBINE GENERATOR AND AUXILIARIES

6.1
6.2
6.3
6.4
38
General
6.1.1
6.1.2
6.1.3
6.1.4

Electrical System
Balance of Plant
Civil Works

5.1
5.2
6
6
OPERATIONAL HISTORY OF THE PLANT

4.1
4.2
4.3
General
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
4
5
Operating
Operating
Operating
Operating
38
Parameters
Parameters
Parameters
Parameters
of
of
of
of
Steam Turbine
Condenser
LP Heaters
HP Heaters
38
39
39
40
Action Plan to Reduce Energy Consumption

Sankey diagram for the Efficiency of Turbine & Auxiliaries
Schematic Diagram of the Steam Turbine Generator
41
43
43
BALANCE OF PLANT SYSTEMS

7.1
44
General
Document Number
LII-GETS12021-G-00100-005
44
Rev
No.
Description
Page
No.
Date of Issue
02
[ix]
26.09.2013
7.2
8
44
THERMAL INSULATION
8.1
8.2
48
General
Action Plan for Reducing the Heat Loss
48
48
ILLUMINATION SYSTEM
9.1
9.2
10
11
50
General
Action Plan for Reducing the Energy Loss
50
50
COST BENEFIT ANALYSIS
10.1
10.2
[LOGO OF
UTILITY]
52
Illustration-1 on the basis of efficiency monitoring.

IIlustration-2 on the basis of power consumption for any equipment
SUMMARY OF THE RECOMMENDATION OF ENERGY AUDIT
52
52
54
LIST OF APPENDICES
APPENDIX NO.
DESCRIPTION
Appendix-1
Energy Audit Report for Boiler
92
Appendix-2
Energy Audit Report for Air Preheater
94
Appendix-3
Energy Audit Report for PA Fan
96
Appendix-4
Energy Audit Report for FD Fan
98
Appendix-5
Energy Audit Report for ID Fan
100
Appendix-6
Energy Audit Report for Mills
102
Appendix-7
Energy Audit Report for Steam Turbine
104
Appendix-8
Energy Audit Report for Condenser
106
Appendix-9
Energy Audit Report for LP Heaters
108
Appendix-10
Energy Audit Report for HP Heaters
110
Appendix-11
Energy Audit Report for Boiler Feed Pumps
112
Appendix-12
Energy Audit Report for Condensate Extraction

Pumps
114
Appendix-13
Energy Audit Report for CW Pumps
116
Appendix-14
Energy Audit Report for Cooling Tower
117
Appendix-15
Energy Audit Report for Plant Air Compressors
119
Appendix-16
Energy Audit Report for Instrument Air Compressors
121
Appendix-17
Energy Audit Report for Thermal Insulation
123
Appendix-18
Energy Audit Report for Illumination System
125
Document Number
LII-GETS12021-G-00100-005
PAGE NO.
Rev
No.
Description
Page
No.
Date of Issue
02
[x]
26.09.2013
[LOGO OF
UTILITY]
LIST OF ABBREVIATIONS
Energy Audit Report for their power plant.}
AHP
Ash Handling Plant
AHU
Air Handling Unit
BFP
BOP
Balance of Plant
CA
Condition Assessment
CEA
CFBC
Circulating Fluidized Bed Consumption
CHP
Coal Handling Plant
DM
Demineralization
EA
Energy Audit
ECO
Economizer
ESP
FO
Fuel Oil
GCV
GT
HP
High Pressure
HT
High Tension
HVAC
Heating Ventilation Air Conditioning
IPT
LDO
Light Diesel Oil
LE
Life Extension
LPT
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[xi]
26.09.2013
LT
Low Tension
LTSH
PA
Primary Air
PF
Pulverised Fuel
RLA
PLF
Plant Load Factor
R&M
RH
Reheater
SH
Super Heater
TPH; T/h
Tons per hour
TPS
TR
Document Number
LII-GETS12021-G-00100-005
[LOGO OF
UTILITY]
Rev
No.
Description
Page
No.
Date of Issue
02
[xii]
26.09.2013
[LOGO OF
UTILITY]
LIST OF ANNEXURE TO BE ATTACHED WITH THE ENERGY AUDIT REPORT

{The utilities are advised to attach the following Annexure with their Energy Audit
Report}
S,No.
Description
Schematic Diagram of the Boiler indicating the locations of measuring

instruments.
Schematic Diagram of the Steam Turbine Generator indicating the locations

of measuring instruments.
Schematic Diagrams for Coal Handling Plant, Ash Handling Plant, CW &
ACW System, Pre-treatment Plant, DM Plant, Compressed Air System, Fuel
Oil Handling System, HVAC System etc.
List of Measuring Instruments used in testing along with their latest

Calibration Certificates.
Energy Audit Reports in the prescribed formats for all the Systems and
Major Equipments.
Calculations for the Cost Benefit Analysis for all the Systems and Major
Equipments.
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[xiii]
26.09.2013
[LOGO OF
UTILITY]
EXECUTIVE SUMMARY
This Energy Audit Report has been prepared for carrying out the
Renovation & Modernization (R&M) / Life Extension (LE) of Unit No [...] of
[...] Thermal Power Plant, located at [.], in District [.] in the State of
[.] and having a configuration of [xMW].
The unit no. [...] was first commissioned in the year [.]. After [.]
years of operation, the performance of the unit has gradually deteriorated
resulting in reduced outputs, decreased efficiency and increased cost of
generation. To verify the actual energy consumption of the power plant
equipments and to work out action plans for improving the efficiency of
the unit, an energy audit was carried out during the period [..].
To determine the operating efficiency and energy consumption of various
components and systems of the plant, performance tests were carried out
on all continuously operating equipments of Boiler & Auxiliaries, Steam
Turbine & Auxiliaries and Balance of Plant. The actual values of operating
efficiency and power consumption were compared with the
corresponding design values and reasons for deterioration in efficiency or
excess power consumption were established.
In addition, energy losses due to poor condition of thermal insulation of
the equipments and the excess energy consumption by the lighting &
illuminating fixtures were also analyzed.
The recommendations made in this energy audit report are based upon
the analysis of the operation data of the unit, evaluation of the of the
performance test results of various equipments, as well as, the detailed
discussions held with the project authorities and operating personnel.
After the overall analysis, suitable solutions and energy saving measures
have been recommended which are also found to be attractive from the
perspective of cost benefit analysis. Summary of these recommendations
are furnished below:
Equipment/
Systems
Summary of the
Recommended Action Plans
Cost Impact
[.]
[...]
Steam Turbine
Generator and
Auxiliaries
[.]
[...]
Balance of Plant and

Systems
[.]
[...]
Thermal Insulation
[.]
[...]
Illumination System
[.]
[...]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[1]
26.09.2013
Equipment/
Systems
Any other System
[LOGO OF
UTILITY]
Summary of the
Cost Impact
[.]
[...]
Total Cost Impact
[......]
Sankey Diagrams indicating the scenarios for the heat energy input,
break-up of various losses and net electrical output from the unit before
R&M and as expected after R&M are shown below.
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[2]
26.09.2013
[LOGO OF
UTILITY]
These recommendations are being hereby submitted to the Project

Authorities for minimizing the energy consumption and reducing the cost
of generation. These recommendations should be considered along with
the recommendations of RLA/CA studies while evolving various options
for Renovation and Modernization of the Unit.
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[3]
26.09.2013
[LOGO OF
UTILITY]
INTRODUCTION
[Unit No..of Thermal Power Station was first synchronized
on [.]. The Unit has been operating for more than [.] and its
performance has deteriorated gradually over the years. Extending the life
of the unit and increasing its efficiency and output appears feasible by
carrying out Renovation and Modernization of the Unit. This Energy Audit
(EA) Report has identified those equipment and components of the Unit
which need to be rehabilitated to prevent excess power consumption,
improve efficiency and enable the unit to produce power according to
prevailing norms of operation and the current statutory environmental
regulations in force.
This report is based upon the analysis of the operation data of the unit,
evaluation of the of the performance test results of various equipment of
the power plant, as well as, detailed discussions held with the project
authorities and operating personnel.
The recommendations of the energy audit have been discussed in detail in
Sections 5.0 to 9.0. These recommendations are being hereby submitted
to the Project Authorities for minimizing the energy consumption and
reducing the cost of generation. These recommendations should be
considered along with the recommendations of RLA/CA studies while
evolving various options for Renovation and Modernization of the Unit.
As per the Energy Conservation Act of 2001 (BEE 2008), an energy audit
is defined as:
"The verification, monitoring and analysis of the use of energy and
submission of technical report containing recommendations for improving
energy efficiency with cost-benefit analysis and an action plan to reduce
energy consumption."
The Energy Audit Report has been prepared keeping in view the above
spirit of Energy Conservation Act.
2.1
Objectives of Energy Audit

[The purpose of Energy Audit is to provide recommendation for achieving
the following objectives.
Increasing the Boiler Efficiency by effective utilization of Heat
Energy of fuel through its effective combustion in the Boiler.
Decreasing the Turbine Heat Rate by increasing the effective
utilization of Heat Energy of Steam through Steam Turbine.
Enhancing the performance parameters of power plant equipment
and their auxiliaries.
Minimizing the auxiliary power consumption of electrically driven
equipment.
Increasing the quantum of power generation.
Reducing the cost of generation.
Achieving reduction in the release of green house gases.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[4]
26.09.2013
2.2
[LOGO OF
UTILITY]
Methodology adopted for Energy Audit

[Following steps were followed for carrying out the Energy Audit.
Study of Plant
Design Data
Review of the present

Performance Parameters
Study of Boiler & TG Cycle

Layout, SLD & P&IDs
Review of PG Test and Energy

Audit Reports carried out earlier
Discussion with the Plant

Engineers
Conducting the Energy

Audit of the Unit
Submission of Energy
Audit Report
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[5]
26.09.2013
DESCRIPTION AND SALIENT FEATURES OF THE UNIT
3.1
General
[LOGO OF
UTILITY]
The Power Plant, having a configuration of [xMW] is located at [.],

in District [.] in the state of [.].The Unit no. [.] of the power plant,
which is proposed to be taken up for Renovation and Modernization was
first commissioned in the year [.]. For the above unit, M/s [..] and
M/s [.] are the Original Equipment Manufacturers (OEMs) for the Boiler
and Turbo-Generator respectively. The boiler is of [natural circulation, two
pass, reheat, dry bottom, balance draft, tangentially fired furnace having
PF/CFBC design]. The boiler is provided with [front/front & rear/
corner/down shot firing] system. The Steam Turbine consists of HP
Turbine having [] stages, IP Turbine having [] stages and LP Turbine
having [] stages. [LP stage of Turbine is designed with [bauman
exhaust]. Condenser cooling system of the unit is designed on [once
through / re-circulation system] with [NDCT/IDCT] Cooling Towers. Power
generated from the unit is being supplied to [...State/Central grid]. Power
is being evacuated through [.numbers of 220/400kV Double/Single
to
[.
substation.]
The
primary
fuel
is
Circuit
lines]
[domestic/imported/blended] [coal/lignite] fuel being sourced from
[..&] coal mines. The consumptive water for the power plant is
being sourced from [.river /sea].
3.2

{Indicate in the paragraphs below the salient features and other specific
technical details of the Project. The description given below is of
indicative nature only.}
3.2.1

a)
Boiler
[The Boiler is of natural circulation, pulverized fuel fired, dry bottom,

balanced draft using direct firing system. The design parameters of the
Boiler are furnished below]
Description
Units
Design
Parameters
[.]
T / hr
kg/cm2
[.]
[.]
Re-heater Flow
T / hr
[.]
kg/cm2
[.]
[.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[6]
26.09.2013
Description
Units
Design
Parameters
[.]
Feed Water Flow
T / hr

Economiser
Economiser.
kg/cm2
[.]
[.]
b)
[LOGO OF
UTILITY]
Furnace
fusion welded membrane wall construction. It is equipped
with..numbers of coal burners andnumbers of oil burners located at
numbers of elevations. The design parameters of the Furnace are
furnished below.]
Description
Units
........
Type of Firing
Combustion Chamber Volume
m3
Furnace Dimensions (Width x Depth x

Height)
[..............]
[..............]
[..............]
[..............]

m2
[..............]
ii) Superheaters
m2
[..............]
iii) Reheaters
m2
[..............]
iv) Economiser
m2
[..............]
v) Air Heater
m2
[..............]
vi) Steam Coil Air Heater
m2
[..............]
vii) Temperature Measurement of

Super-heater tubes
Yes / No
viii) Temperature Measurement of

Re-heater tubes
Yes / No
i)
c)
Design Parameters
Water Walls
[..............]
[..............]

pendant section, a rear low temperature section and a steam cooled wall
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[7]
26.09.2013
[LOGO OF
UTILITY]
& roof section. The Re-heater consists of two sections, the front pendant
and the rear pendant sections. The details are given below:]
Description
No. of coils
/ tubes
Pitch
(mm)
Dia.x Thickness
(mm)
Heating
Surface (m2)
Material
Low
Temperature
Super Heater
[.]
[.]
[.]
[.]
[.]
Platen Super
Heater
[.]
[.]
[.]
[.]
[.]
Pendant
Super Heater
[.]
[.]
[.]
[.]
[.]
Ceiling and
Enclosure
Super Heater
[.]
[.]
[.]
[.]
[.]
ReheaterFront
Assembly
[.]
[.]
[.]
[.]
[.]
ReheaterRear
Assembly
[.]
[.]
[.]
[.]
[.]
d)
Economiser
[The Economizer is of a single stage, continuous plane tube and

horizontal, mixed flow type, located in the second pass of the boiler]
e)
Air Pre-Heater

between air and gas sides. Adjustable sector plates have also been
provided to prevent the leakage during expansion. The heating surfaces of
the air pre-heater have been provided with two types of cleaning
systems, soot blowing and water washing system. ]
f)
Raw Coal Bunkers
[Each boiler is provided with [] raw coal bunkers. The total capacity of
the bunkers is to meet [] hours requirement at maximum mills capacity
of the unit. The upper portion of the bunkers is of cylindrical shape made
of carbon steel plate, while the conical portion is made of stainless steel
plate. Each outlet of the bunker is provided with an isolation gate which
is motor operated. In addition to the isolation gates, rod gates have been
provided to control the flow of coal from the bunkers]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[8]
26.09.2013
g)
[LOGO OF
UTILITY]
Raw Coal Feeders
controls with variable frequency drive. The feeders have been provided
with dual independently measuring load cells. All parts of the feeders
coming in contact with coal, except the belt, are made of stainless steel]
h)
Fuel Firing System
[The boiler is working on a direct firing system. The pulverized coal is

being dried and transported to the coal burners by means of hot primary
air being supplied by two primary air fans. The boiler is having [front and
rear/corner/down shot] firing system. There are [] pulverized coal
burners and [] oil burners. The burners are located at [] floors.
i)
Coal Mills
[The unit is provided with . numbers of [BHEL] Make [XRP-783] bowl

type mills, out of which mills are designed to work with designed
coal and ..numbers of mills are standby . The rated capacity of each
mill is ..T/h.]
Description
Units
Design Parameters
..
[.]
Type of Mills
..
[.]
Capacity of Mills
T/h
[.]
Nos.
[.]

Nos.
[.]
Motor Rating
kW
[.]
j)
Primary Air Fans
[Two Primary Air (PA) Fans have been provided for each boiler. Each PA
Fan is designed to meet 60% MCR condition of the boiler. The PA Fans
are Hot PA Fans. Details are given below:]
Description
Units

Type of Fans
..
LII-GETS12021-G-00100-005
[.]
[.]
Nos.
[.]
Rev
No.
Description
Page
No.
Date of Issue
02
[9]
26.09.2013
Document Number
..
Design Parameters
Description
Units
Design Parameters
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
[.]
Motor Rating
kW
[.]
[.]
k)
[LOGO OF
UTILITY]
Forced Draft Fans
supply combustion air to the boiler, mill air through PA Fans and
tempering air to control the classifier temperature of the mills. Details are
given below:]
Description
Units
..
Type of Fans
..
Design Parameters
[.]
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
Temperature of Air
[.]
Motor Rating
kW
[.]
[.]
l)
Induced Draft Fans
evacuates flue gases through two parallel paths of ESP and discharge
them into stack through separate ducting. Details are given below:]
Description
Units
Document Number
LII-GETS12021-G-00100-005
..
Design Parameters
[.]
Rev
No.
Description
Page
No.
Date of Issue
02
[10]
26.09.2013
Description
Units
Type of Fans
..
[LOGO OF
UTILITY]
Design Parameters
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
[.]
Motor Rating
kW
[.]
[.]

[Adequate number of Wall Blowers and Long Retractable Soot Blowers
(LRSBs) are being used for cleaning the soot deposited on the heating
surfaces of the water walls and super heaters respectively. Manually
operated soot blowing system has been provided. Details are given
below:]
Description
Units
Design Parameters
Wall Blowers
..
[]

water walls
Nos.
[.]

walls
..
[.]
[.]

Nos.
[.]

[.]

pass tube banks
Nos.
[.]
LRSBs
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[11]
26.09.2013
[LOGO OF
UTILITY]
Description
Units
Design Parameters

[.]
n)
ESP
[An Electrostatic Precipitator (ESP) has been installed on the cold end side
of the Air Pre-heater to remove the particulate matter from the flue gases.
The ESP has been provided with Gas Distribution System, Collecting
Electrodes, Discharge Electrodes, Transformer Rectifier Sets and
[electrically/mechanically] operated rapping system. The hoppers of ESP
have been provided with [capacitance] type level indicators and
Description
Units
Design Parameters
[.]
Nos.
[.]
Nos.
[.]
mg/Nm3
[.]
Type of Control
[.]
Gas Velocity in ESP
m/sec
[.]
m2/m3/sec
[.]
Aspect Ratio
..
[.]
cm/sec
[.]
Numbers of TR Sets
..
[.]
Rating of TR Sets
..
[.]
[.]
m2/TR
Set
hrs
Pressure Drop
mmwc
[.]
Dust Collection Efficiency with (N1) fields in operation
[.]
Plate Area/TR Set
Document Number
LII-GETS12021-G-00100-005
[.]
Rev
No.
Description
Page
No.
Date of Issue
02
[12]
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3.2.2
[LOGO OF
UTILITY]

a) Steam Turbine
water cycle. The LP stage of turbine is designed with Bauman exhaust.
The turbine is provided with HP/LP bypass system of 60% capacity of
Boiler MCR. The turbine is provided with an electro - hydraulic control
system, automatic turbine run up system and turbo supervisory
instrumentation. The condensing system consists of a surface condenser
of single shell and two pass, divided water box construction. Cooling
water being supplied to the condenser is of raw water/ clarified water
quality. The design parameters of the steam turbine are furnished below]
Description
Units
Design Parameters

HPT
kg/cm2
[.]

ESV of HPT
[.]

Steam
Steam
kg/cm2
[.]
[.]
kg/cm2
[.]

Steam
[.]
kg/cm2
[.]

Turbine
[.]
b) Condenser
integral air cooling section designed to maintain a pressure of 76 mm of
Hg at turbine exhaust with a cooling water temperature of [] deg C and
an outlet temp of [] deg C. The condenser is capable of operation with
[] tubes plugged and has hot well storage capacity of [] minutes
Description
Units
Design Parameters
Make and Model
[.]
Type of Condenser
[.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[13]
26.09.2013
Description
Units
Design Parameters
m2
[.]
..
[.]
Material of Tubes
..
[.]
mmxmm
[.]

Condenser
inlet to Condenser
Condenser Vacuum
m3/h
[.]
[.]
mm Hg
[LOGO OF
UTILITY]
[.]
c) Ejectors
[The Condenser is provided with two quick starting ejectors which
operate in parallel to remove large volumes of air for raising the initial
vacuum during the starting of the Unit. Two main ejectors of 100%
capacity each have been provided remove air and non condensable gases
from the condenser to maintain the required vacuum in the condenser
during the normal operation of the unit.]
[Condensate extraction pumps are of vertical, multistage, centrifugal
pumps of canister type.]
Description
Units
Design Parameters
Make and Model
[.]
Type
[.]
Capacity
m3/h
[.]
TDH
mwc
[.]
Speed
rpm
[.]
Motor Rating
kW
[.]

[A Gland Steam Cooler has been provided to condensate the leak-off
steam from intermediate chambers of end sealings of HP and IP turbine,
thereby heating the main condensate water. The Gland Steam Cooler
consists of shell, tube bundle and removable water box.] .
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[14]
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[LOGO OF
UTILITY]

[Each steam turbine is provided with four numbers of low pressure
heaters to increase the temperature of the condensate in stages. LP
Heater -1 consists of two halves and is installed in neck of the condenser.
The remaining LP Heaters are of shell and tube design and have been
placed vertically. An integral drain cooling section is provided in each LP
Heater. The design details of LP Heaters are furnished in the table below.]
Heater No.
Extraction Steam
taken from
[...] stage
of IP
turbine
[...] stage of
IP turbine
[...] stage
of IP
turbine
[...] stage
of IP
turbine
Bled Steam
Pressure (kg/cm2))
[...]
[...]
[...]
[...]
Bled Steam
Temperature (deg
C)
[...]
[...]
[...]
[...]
g) Deaerator
liter. The feed water storage tank has a capacity of [] minutes feed
water requirement of the boiler corresponding to TMCR Heat Balance]
h) Boiler Feed Pumps
barrel type, motor driven pumps coupled with hydraulic coupling, taking
the suction from the deaerator. The boiler feed pumps discharge feed
water through HP heaters to the economizer of the boiler.]
Description
Units
Design Parameters
Make and Model
..
[.]
Type
...
[.]
No of stages
Nos.
[.]
Capacity
m3/h
[.]
Head
mwc
[.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[15]
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Description
Units
Design Parameters
Feed water temp
[.]
..
[.]
Minimum flow
m3/h
[.]
..
[.]
[.]
mwc
[.]
Motor Rating
kW
[.]
i)
[LOGO OF
UTILITY]
HP Heaters
[Each steam turbine is provided with three numbers of high pressure

heaters to increase the temperature of the feed water in stages. The
Heaters are of shell and tube design and have been placed vertically. The
design details of HP Heaters are furnished in the table below.]
Heater No.
Extraction
Steam taken
from
[...] stage of HP
turbine
[...] stage of HP
turbine
[...] stage of HP
turbine
Bled Steam
Pressure
(kg/cm2))
[...]
[...]
[...]
Bled Steam
Temperature
(deg C)
[...]
[...]
[...]
j)
HP/ LP Bypass

Continuous Rating). HP bypass system has been provided between the
Main Steam Line and Cold Reheat Line. LP bypass system has been
provided between the Hot Reheat Line and the Condenser. HP bypass
water spray has been taken from the discharge of Boiler Feed Pumps. LP
bypass water spray has been provided from the discharge of Condensate
Extraction Pumps.
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[16]
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[LOGO OF
UTILITY]

from the generator. The system is provided with a quick closing
Emergency Stop Valve (ESV), to interrupt the supply of steam from the
boiler and stop the turbine under emergency conditions. The turbine
governing system includes, speed governor.]
l)
Lube Oil System
[The lube oil system consists of Main Oil Tank, Turbine driven main oil
pump, AC driven bearing oil pump, DC driven emergency oil pump, AC
driven jacking oil pump and oil coolers of 3x50% capacity, Lube oil is
being purified by means of a centrifuge. Oil storage tanks consisting of
Clean Oil Tank and Dirty Oil Tank have been provided.]
3.2.3
Electrical System
a) Generator
[The Generator is a 15.75 kV, 50 Hz, 0.85 power factor machine,
directly coupled with steam turbine operating at 3000 rpm, withtype
of excitation system and digital programmable voltage regulator. The
Generator has direct water cooled stator winding and direct hydrogen
cooled rotor winding. The stator winding cooling water is cooled in a
closed cycle cooling system using DM water, while the hydrogen in the
machine is cooled in gas to water hydrogen coolers mounted inside the
machine. The Parameters of the Generator are briefly mentioned below.]
Description
Units
Design Parameters
Rated MW Capacity
MW
[.]
Rated MVA Capacity
MVA
[.]
kV
[.]
Rated Power Factor
..
[.]
kA
[.]
Rated Speed
rpm
[.]
Rated Frequency
Hz
[.]
Efficiency at Rated Power Output

and Rated Power Factor
[.]
Excitation Current
kA
[.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[17]
26.09.2013
Description
Units
Design Parameters

Short Circuit Ratio
kV
[.]
..
[.]
Amp
[.]
Phase Connection
[.]
Type of Excitation
[.]
[.]
[.]
kg/cm2
[.]
b)
[LOGO OF
UTILITY]
Station Transformer

[common] auxiliary loads of the power plant. The Station Transformers
have been provided with on-load tap changers to keep the station 6.6 kV
voltage constant. Cooling of this transformer is ONAN/ONAF/OFAF and
has 2x50 % separately mounted radiators and 2x50% oil pumps. The
Parameters of the Station Transformers are briefly mentioned below]
Description
Units
Design Parameters
Make
[.]
Capacity / Rating
MVA
[.]
Voltage Ratio
[.]
Type of Cooling
[.]
Quantity
Nos.
[.]
c)
[The power output from each Generator is being stepped up to 220/400

kV through a 240 MVA step up Generator Transformer. It has 3x50%
coolers and 3x50% oil pumps. The Parameters of the Generator
Transformer are briefly mentioned below]
Description
Units
Design Parameters
[.]
Rev
No.
Description
Page
No.
Date of Issue
02
[18]
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Make
Document Number
LII-GETS12021-G-00100-005
Capacity
MVA
[.]
Voltage Ratio
[.]
Type of Cooling
[.]
d)
[LOGO OF
UTILITY]
meeting all unit auxiliary loads. These transformers have been provided
on-load tap changers. The Parameters of unit auxiliary transformers are
Description
Units
Design Parameters
Make
..
[.]
Capacity
MVA
[.]
Voltage Ratio
..
[.]
Type of Cooling
..
[.]
Quantity
Nos.
[.]

[Unit auxiliaries receive their normal power supplies at 6.6 kV through
two (2) nos. unit transformers. For lower rating drives, 6.6 kV is further
stepped down to 415 V by two (2) nos. unit service transformers. The
415 V distribution system feeds a number of Motor Control Centers
(MCCs) for running 415 V drives. 6.6 kV unit switchgears are connected
to station switchgear for start up and emergency power supply. The
details are mentioned below]
Description
Units
Design Parameters
Voltage Level
kV
[.]
Type of Breaker
[.]
Type of Grounding
[.]
Type of Protection
[.]
f) DC System
[Each unit has its own DC system located in the BC bay at ground floor
of the Power House. Separate DC systems have been provided in
switchyard control room, intake pump house and DM plant for controlling
the systems. Each DC system comprises of the Storage Battery, the
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[19]
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[LOGO OF
UTILITY]
Battery charger and the distribution boards. The details are mentioned
below]
Description
Units
Design Parameters
Make
[.]
Capacity /Rating
[.]
[.]
Type of Charger
..
[.]
Area of Application
..
[.]
Voltage

[Diesel generating sets are installed for meeting the power requirements
of essential auxiliaries (viz. jacking oil pumps, AC lube oil pump, hydrogen
seal oil pump, float charger for DC battery, emergency lighting, scanner
air fan and stator cooling water pump) during total failure of AC Power
Supply in the power station. Diesel generating sets are located in the CD
bay at the ground floor. The details are mentioned below]
Description
Units
Design Parameters
Make of DG Sets
[.]
Rating of DG Sets
kVA
[.]
Quantity
Nos.
[.]
h) Public Address System

system facilitates paging, communication and also private conversation as
on conventional telephone.]
i)
Illumination System

fixtures have been provided. For high bay areas and outdoorapplication,
fixtures have been installed. Aviation type fixtures have been installed at
the Chimney]
3.2.4

[The existing control and instrumentation system generally is an old
analogue based system and requires large scale replacement owing to
obsolescence of the existing equipments. Furnace Supervisory Safeguard
System (FSSS) is of obsolete design for which, no spares are available.
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[20]
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[LOGO OF
UTILITY]
Soot blowers are of manual type. No online Boiler Tube Leakage detection
system has been provided. The turbine is equipped with an electrohydraulic system of automatic governing for the smooth and stable
operation of turbo-set under all conditions of operation. Turbine
Supervisory system is of electromagnetic type. No continuous monitoring
system has been provided for observing the health of the turbine. HP- LP
bypass system is in the form of standalone control panel. Integrated
microprocessor based closed loop control, open loop control, sequential
control and bulk data acquisition system for SG & auxiliaries, TG &
auxiliaries, station C&I including auxiliaries in hierarchical levels and
integrated unit monitoring and station monitoring systems in the upper
level are therefore to be envisaged for the plant.]
3.2.5
Balance of Plant
[Coal Handling Plant is a common facility which is feeding all the units of
the power plant having a total installed capacity ofx..MW. Coal to the
power plant is brought through railways by Box N /BOBR wagons and
is unloaded by wagon tipplers/ track hopper. One crusher has been
provided for crushing the coal from 250 mm size to 25 mm size. The
plant is provided with one stacker reclaimer to stock the crushed coal.
The coal stock yard has a storage capacity of 20 days. For feeding the
coal to the bunkers of all the units, two streams of conveyors having a
capacity of .TPH have been provided. The coal handling plant
operates for 16 hrs a day.]
Description
Units
Design Parameters
Nos.
[.]
T/h
[.]
Length of the Track Hopper
[.]
Nos.
[.]
T/h
[.]
Type of Crushers
Nos.
[.]
Number of Crushers
Nos.
[.]
T/ hr
[.]
Nos.
[.]
Stacking Capacity
TPH
[.]
Reclaiming Capacity
TPH
[.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[21]
26.09.2013
Description
[LOGO OF
UTILITY]
Units
Design Parameters
days
[.]

The ash is removed with the help of submerged Scrapper Chain
Conveyors. The ash from the air pre-heater and economizer hoppers is
being disposed off along with bottom ash. The ash in the form of ash
slurry is conveyed through sluice channels to the ash slurry pump house
with the help of high pressure jets, from where, it is pumped to the ash
pond located the distance of [] km. [] The ash slurry pump house is
provided with [] numbers of ash slurry pumps of rating [], out of
which [] pumps are normally working. The ash slurry disposal system
is having [].numbers of identical streams of ash slurry pumps connected
to [] numbers of ash slurry pipelines going to the ash pond. Fly ash is
collected in dry form below the ESP hoppers and the same is then
conveyed by vacuum system to surge hoppers from where it is either
conveyed through pressurized system to dry fly ash silos or is sent to ash
pond in the form of slurry. From the dry fly ash silos, the ash is disposed
off through the covered trucks.]
c) Raw Water System
[The consumptive water for the plant is sourced from [] river/sea
located at a distance of [] km from the plant boundary. The intake
water pump house is installed with [] intake pumps of capacity []
m3/hr, out of which [] pumps are normally working and the remaining
[] pumps are standby. The raw water is pumped from the intake water
pump house to the in-plant raw water reservoir, which has a storage
capacity of [] days.]
[CW system for the power plant works on re-circulating system with
induced draft cooling towers. The CW system uses raw/clarified quality
of water and is working on [] cycles of concentration. CW pump house
is a common facility for all the units of the power plant. There are two
CW pumps of capacity [] m3/hr provided for each unit. In addition,
there are two standby CW pumps common to all the units. The
requirement of ACW system is being tapped from the cold CW header
feeding the condenser. The hot return ACW water after cooling the
auxiliaries of boiler and turbine joins the hot CW header and is sent to the
cooling towers for cooling. The cold water from the cooling water flows
to the fore bay of CW Pump House for recirculation into the system. One
induced draft cooling tower (IDCT) has been provided for each unit. The
cooling tower cools the water from [] deg C to [] deg C. The cooling
tower has been designed for an inlet wet bulb temperature of [] deg C].
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[22]
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[LOGO OF
UTILITY]

[Water Pre-Treatment Plant is a common facility for all the units of the
power plant. Pre-treatment plant supplies clarified water to DM plant,
cooling water to the auxiliaries of BOP system, coal handling plant dust
suppression and to the drinking water system. There are two numbers of
clarifiers of [].m3/hr capacity to meet all the clarified water
requirements of the whole plant, except DM plant. The clarified water
requirement for DM plant is met by a separate clarifier of capacity []
m3/hr.]
f) DM Plant
[DM plant consists of three streams, each of [] m3/hr capacity. There
are two DM water tanks of [].m3 capacity. A common regeneration
system has been provided for all the three streams. DM plant operates on
semi-automatic system with PLC controls.]
[The central control room, switchyard control room, ESP controls room
and selected areas of service building have been provided with centralized
air-conditioning system. The central air-conditioning system of chilled
water type has been provided for various control rooms and DX type of
plant has been provided for ESP control room, switchyard control room
and other areas in the service building. Packaged type of air-conditioners
has been provided for water treatment plant control room. Evaporative
ventilation system has been provided for TG building along with roof
extractors. Other areas are ventilated by a combination of exhaust and
supply air fans].
system has been provided for power transformers, turbine oil tanks and
lube oil system equipments. Medium velocity sprinkler system has been
provided for cable galleries and coal conveyor galleries. Portable types of
fire extinguishers have been provided throughout the plant for fighting
small and localized fires.]
i)
[Plant and instrument air system is a common facility for all the units of
the plant. For meeting the instrument air requirement, [] number of oil
free screw compressors [] working and [] standby, each of [] m3/hr
capacity and discharge pressure of [] kg/cm (g) have been provided
along with dryers. Equal number of air compressors of similar rating has
been provided to meet the requirement of plant air system. The air drying
plant for the instrument air has been provided to achieve a dew point of
(-) 40oC at atmospheric pressure.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[23]
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j)
[LOGO OF
UTILITY]
Fuel Oil System
[The fuel oil system has been designed for the use of Light Diesel Oil
(LDO) for start- up and Heavy Fuel Oil (HFO) for load carrying and flame
stabilization purposes. Two tanks of [] kl each have been provided for
the storage of HFO and two tanks of [] kl each have been provided for
the storage of LDO. The system has been provided with unloading,
transferring and pressurization pumps along with necessary filters and
heating arrangement.]
k) Cranes/Hoists
[For the maintenance of various equipments, manually /electrically
operated cranes and hoists have been provided.]
3.2.6
Civil Works
Major civil works of the unit consist of the following:
(a)
[A common Power House Building has been provided to house [3x200

MW] units which are placed side by side. Centre to centre placing of units
is [67.5 m.] The railway entry has been provided from the rear side of
Power House Building. Turbine Generator (TG) Sets have been placed
between AB rows of columns are laid out longitudinally. The TG bay, also
houses, the Boiler Feed Pumps, Regenerative Heaters, Lube Oil System
and other TG accessories. The total length of TG bay for 3x210 MW
units is [276 m] and width [30 m]. The spacing of the column is at [7.5
m]. TG bay is provided with 2 Nos. of overhead EOT Cranes. In order to
make the handling facilities of the cranes available to the heat
exchangers, boiler feed pumps and other equipments, removable
chequered plates have been provided at appropriate locations.
A sub zero floor has been avoided except for the localized pits required
for Condensate Pump, pipe channels and HP Heaters etc. This sub zero
pits are suitably connected and provided with a common sump for
drainage purposes.
Three stairs for approaching the operating floor level at [+10 m] have
been provided in this bay adjacent to B row columns. In addition, there
are stairs for providing access to various equipments at intermediate
platforms and sub zero pits.
Switchgear and Control Room bay has been provided in the BC bay which
is [12 m] wide. The length of the bay is [249.0 m]. A common Control
Room for all the three units is provided at [10 m] floor. In BC bay at [16
m] elevation, equipments for chemical dosing, air handling and MCC for
soot blowers etc have been located. The deaerator is placed at an
elevation of [23.0 m]. Air washer units and cooling water tanks are also
located at [23.0 m] floor.
accommodates coal bunkers, coal feeders and coal mills. CD bay houses
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
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[LOGO OF
UTILITY]
the vertical mills at Zero m and has space for collection of disposal of mill
rejects at sub zero levels adjacent to D row. A stair to connect operating
floor at [16.0 & 23.0 m] of BC & CD bay has been provided.]
(b)
Boiler Area
(c)
Chimney

(d)
Transformer Yard
transformer yard houses station transformer, unit auxiliary transformers
and generator transformers along with oil pits etc. To facilitating erection
and maintenance of transformers, the area has been provided with rail
tracks parallel to A row at a distance of [45 m] from A row which is
further connected through cross tracks. In addition, space has been
provided for laying the CW pipelines and locating the butterfly valve
chambers.]
(e)
Service building
level.]
(f)
[Besides the above, miscellaneous buildings like administrative building,

CW Pump House, Fire Water Pump House, CHP Control Room, ESP
Control Room, Chimney, DM Plant Building, Chemical House and Ash
Silos have been provided.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[25]
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OPERATIONAL HISTORY OF THE PLANT
4.1
General
[LOGO OF
UTILITY]
Unit No [] of [] Thermal Power Station having a

Generating Capacity of [210 MW] was commissioned in the year [..].
The boiler is of [] design and the turbine is of [LMZ] design.
Though the boiler was originally designed for coal with Gross Calorific
Value (GCV) of [.kCal/kg], it presently operates on coal supplied with
GCV of about [..kCal/kg]. The Average Performance Parameters of the
unit over the past 25 years are shown in Table 4.1.
Table 4.1
Units Average Performance Parameters over the life
Years after
Installation
PLF
(%)
Availability
(%)
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross Heat
Rate
(kCal/kWh)
[]
[]
[]
[]
[]
[]
[]
10
[]
[]
[]
[]
[]
[]
[]
15
[]
[]
[]
[]
[]
[]
[]
20
[]
[]
[]
[]
[]
[]
[]
25
[]
[]
[]
[]
[]
[]
[]
Table 4.2 indicated below, illustrates variations over the last five years in
the performance parameters.
{Furnish in the Table 4.2 below, the Average Values for the last five
years. However, for the Parameters in respect of One Year back and
Current Year, furnish the Maximum, the Minimum and the Average
Values.}
Table 4.2
Units Performance Parameters during the Last Five Years
Period
Four Years
back
Three
Years back
PLF
(%)
Availability
(%)
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross Heat
Rate
(kCal/kWh)
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[26]
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4.2
[LOGO OF
UTILITY]
Period
PLF
(%)
Availability
(%)
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross Heat
Rate
(kCal/kWh)
Two Years
back
[]
[]
[]
[]
[]
[]
[]
One Year
back
[]
[]
[]
[]
[]
[]
[]
Current
year
[]
[]
[]
[]
[]
[]
[]

The Project has been regularly monitoring the environmental parameters
such as stack monitoring, ambient air quality (AAQ), noise pollution and
liquid waste pollution in accordance with applicable norms by employing
[M/s., an agency approved by State Pollution Control Board].
The existing environmental data and the limits specified for different
pollutants, the locations of their measurements and the frequency of
monitoring are given in the table below.
Table 4.3
Environmental
Aspects
Stack
Emissions
State Pollution and
SPM
(mg/Nm3)
Ambient Air
Quality
SPM
Parameters
Achieved
Not to exceed
[]
On
24
Hrs
Basis
On
Annual
Basis
[]
[]
[]
On
24
Hrs
Basis
On
Annual
Basis
[]
[]
(g/m3)
RPM
[]
[]
[]
[]
[]
[]
[]
[]
No. of
locations for
measurement
Frequency
of
Sampling.
[]
[]
[]
[]
(g/m3)
SO2
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[27]
26.09.2013
Environmental
Aspects
State Pollution and
Parameters
Achieved
[LOGO OF
UTILITY]
No. of
locations for
measurement
Frequency
of
Sampling.
(g/m3)
NOX
[]
[]
[]
[]
(g/m3)
Process
Effluent
Boiler Blow Down

SS (mg/l)
[]
[]
Oil &
grease
[]
[]
Cu (mg/l)
[]
[]
Fe (mg/l)
[]
[]
(mg/l)
Cooling Tower Blow Down
4.3
[]
Free Cl2
(mg/l)
[]
[]
Zn (mg/l)
[]
[]
Cr (mg/l)
[]
[]
PO4
(mg/l)
[]
[]
pH
[]
[]
Oil &
grease
(mg/l)
[]
[]
BOD
(mg/l)
[]
[]
[]
Major Replacements in the last ten years

[Major replacements of equipment and systems in the Power Project and
capital expenditures in the last 10 years fromto are indicated in
the table 4.4 below]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[28]
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[LOGO OF
UTILITY]
Table 4.4
Major Replacements & Capital Expenditure done during the last 10 years
Reason for
Capital
S.No.
Name of the Equipment
replacement
Expenditure
1
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
10
[]
[]
[]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[29]
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5.1
General
[LOGO OF
UTILITY]
{Discuss in this section, the actual operating parameters with respect to

the design parameters and the action plan recommended to reduce the
energy consumption of the Boiler and its Auxiliaries based upon the
findings of Performance and Efficiency Test. Discuss the
recommendations based upon the Cost Benefit Analysis and the results
of the Energy Audit carried out on the Boiler, Air Pre-Heater, Mills,
ID/FD/PA Fans and ESP etc.
Guidelines for carrying out the Energy Audit for various equipments are
appended at the end of this model document, for general reference.}
5.2
Operating Parameters of Boiler and Auxiliaries

{Discuss below the Design Parameters and Actual Operating Parameters
of the Boiler}.
5.2.1
Operating Parameters of the Boiler

Design and Actual Operating Parameters of the Boiler are given in the
Tables below:
Description
Table 5.1
Design and Operating Parameters of the Boiler
Units
Design
Parameter
tph
[.....]
Actual
Operating
Parameter
[.....]
kg/cm2
[.....]
[.....]
Main steam temperature
[.....]
[.....]
Reheater outlet flow
tph
[.....]
[.....]
Steam temperature at reheater inlet
[.....]
[.....]
Steam temperature at reheater outlet
[.....]
[.....]
Steam pressure at re -heater inlet
kg/cm2
[.....]
[.....]
Steam pressure at re -heater outlet
kg/cm2
[.....]
[.....]
Steam temperature at LTSH outlet
[.....]
[.....]
Saturated steam temperature in drum
[.....]
[.....]
Super heater platen outlet temperature
[.....]
[.....]
Main Steam flow

Main steam pressure
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
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Description
Units
Design
Parameter
kg/cm2
[.....]
Actual
Operating
Parameter
[.....]
Economizer inlet temperature
[.....]
[.....]
Super heater spray
tph
[.....]
[.....]
Re heater spray
tph
[.....]
[.....]
Ambient temperature
[.....]
[.....]
Coal consumption
tph
[.....]
[.....]
kCal/kg
[.....]
[.....]
Pressure drop in reheater
GCV of Coal
5.2.2
[LOGO OF
UTILITY]
Operating Parameters of Economiser

Design and Actual Operating Parameters of the Economiser are given in
the Tables below:
Table 5.2
Design and Operating Parameters of Economiser
Description
Unit
Design
Actual
Parameter Operating
Parameter
2
Feed water pressure at the inlet
kg/cm
[.....]
[.....]
kg/cm2
[.....]
[.....]
Feed water flow
tph
[.....]
[.....]
Feed water temperature at the inlet
[.....]
[.....]
Feed water temperature at the outlet
[.....]
[.....]
Oxygen content in flue gas before

economizer
Excess air % in flue gas before
economizer
[.....]
[.....]
[.....]
[.....]
Flue gas inlet temperature
[.....]
[.....]
Flue gas outlet temperature
[.....]
[.....]
Feed water pressure at the outlet
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
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5.2.3
[LOGO OF
UTILITY]
Operational Parameters of Air Pre-heater

Design and operational parameters of Air Pre-heater are given in the table
below:
Table 5.3
Design and Operating Parameters of AIR Pre-heater
Description
Units
Design
Actual
Parameter Operating
Parameter
Air quantity at APH outlet (Primary)
tph
[.....]
[.....]
5.2.4
Air Quantity at APH outlet (Secondary)
tph
[.....]
[.....]
Air temperature at APH inlet
[.....]
[.....]
Air outlet temperature of APH primary

Air outlet temperature of APH
secondary
Oxygen content in flue gas before APH
[.....]
[.....]
[.....]
[.....]
[.....]
[.....]
Oxygen content in flue gas before APH
[.....]
[.....]
Excess air % in flue gas before APH
[.....]
[.....]
Flue gas inlet temperature
[.....]
[.....]
Flue gas outlet temperature
[.....]
[.....]
Flue gas quantity
tph
[.....]
[.....]
Others
---
[.....]
[.....]
Temperature Profile of Flue Gas

Design and actual profile of flue gas is given in the table below:
Table 5.4
Design and Actual Profile of Flue Gas
Description
Units
Super heater platen outlet
Design
Value
[.....]
Front RH inlet
[.....]
[.....]
Rear RH inlet
[.....]
[.....]
Final SH inlet
[.....]
[.....]
Document Number
LII-GETS12021-G-00100-005
Actual
Value
[.....]
Rev
No.
Description
Page
No.
Date of Issue
02
[32]
26.09.2013
5.2.5
Description
Units
LTSH inlet
[LOGO OF
UTILITY]
Design
Value
[.....]
Actual
Value
[.....]
Economizer inlet
[.....]
[.....]
APH inlet
[.....]
[.....]
APH outlet
[.....]
[.....]
ID fan inlet
[.....]
[.....]
ID fan outlet
[.....]
[.....]
Feed Water and Boiler Water Quality

Design and actual quality of the Boiler Water and Feed Water is given
below:
Table 5.5
Design and Actual values of Boiler Water and Feed Water
Description
Unit
Feed Water
Boilers Water
Design
Actual
Design
Actual
Hardness
ppm
[.....]
[.....]
[.....]
[.....]
pH at 25C
Oxygen
maximum
Total iron
maximum
Total silica maximum
Conductivity at
25C
Hydrazine residual
Total solids
maximum
Chlorides
Copper
maximum
Oil
Document Number
LII-GETS12021-G-00100-005
pH
[.....]
[.....]
[.....]
[.....]
ppm
[.....]
[.....]
[.....]
[.....]
ppm
[.....]
[.....]
[.....]
[.....]
ppm
[.....]
[.....]
[.....]
[.....]
/cm
[.....]
[.....]
[.....]
[.....]
ppm
[.....]
[.....]
[.....]
[.....]
ppb
[.....]
[.....]
[.....]
[.....]
ppm
[.....]
[.....]
[.....]
[.....]
ppm
[.....]
[.....]
[.....]
[.....]
ppm
[.....]
[.....]
[.....]
[.....]
Rev
No.
Description
Page
No.
Date of Issue
02
[33]
26.09.2013
5.2.6
[LOGO OF
UTILITY]
Mill Performance Data

Design and Actual Performance Data of the Mills is furnished below:
Table 5.6
Design and Actual Performance Data of Mills
Description
Design
Actual Operating Value
Value Mill-1 Mill-2 Mill-3 Mill-4 Mill-5
Mill inlet coal
[.....]
[.....] [.....] [.....] [.....] [.....]
flow (tph)
Mill inlet temp.
[.....]
[.....] [.....] [.....] [.....] [.....]
(C)
Mill outlet temp.
[.....]
[.....] [.....] [.....] [.....] [.....]
(C)
Mill differential
[.....]
[.....] [.....] [.....] [.....] [.....]
pressure.
(mmwc)
Air flow to mill
[.....]
[.....] [.....] [.....] [.....] [.....]
(tph)
PA common
[.....]
[.....] [.....] [.....] [.....] [.....]
header pressure
(mmwc)
Coal Fineness
[.....]
[.....] [.....] [.....] [.....] [.....]
Passing through
200 mesh(%)
Mill reject, kg/hr.
[.....]
[.....] [.....] [.....] [.....] [.....]
[.....]
Specific energy
consumption
kWh/ton of Coal.
5.2.7
[.....]
[.....]
[.....]
[.....]
[.....]
Mill-6
[.....]
[.....]
[.....]
[.....]
[.....]
[.....]
[.....]
[.....]
[.....]
Heat Losses and Efficiency of the Boiler

Break up of Heat Losses as well as Design and Actual Values of Boiler
Efficiency are given below:
Table 5.7
Heat Balance of the Boiler
Description
Ambient Temp
--
Design
Value
[.....]
Excess Air
--
[.....]
[.....]
Unburnt Carbon Loss
Z1
[.....]
[.....]
Document Number
LII-GETS12021-G-00100-005
Symbol
Unit
Actual
Value
[.....]
Rev
No.
Description
Page
No.
Date of Issue
02
[34]
26.09.2013
Description
5.3
Symbol
Unit
Dry Gas Loss
Z2
Loss due to Moisture in Fuel
[LOGO OF
UTILITY]
Design
Value
[.....]
Actual
Value
[.....]
Z3
[.....]
[.....]
Loss due to Hydrogen in Fuel
Z4
[.....]
[.....]
Loss due to Moisture in Air
Z5
[.....]
[.....]
Loss due to Carbon Monoxide
Z6
[.....]
[.....]
Sensible heat loss in fly ash
Z7
[.....]
[.....]
Sensible heat loss in bottom ash
Z8
[.....]
[.....]
Radiation loss
Z9
[.....]
[.....]
[.....]
[.....]
Total losses
Z=Z1+Z2+Z3+Z4+Z5+Z6+
Z7+Z8+Z9
Actual Boiler Efficiency
Effa
[.....]
[.....]
Design Boiler Efficiency
Effd
[.....]
[.....]

{Discuss in the Table below, one by one, all the equipment for which the
action is recommended to be taken for improving the efficiency and
reducing the power consumption in the light of energy audit and cost
benefit analysis of the recommendations. Discuss the presently operating
parameters/ efficiency / power consumption of the equipment at rated
performance parameters in comparison to the corresponding values as per
design. Target values indicated in the table should be equal or better than
the design values. Also attach the results of Energy Audit for the
equipments in the form of Annexure. Formats for reporting the results of
Energy Audit have been appended at the end of this Model Document for
reference. The Formats provided for a particular kind of equipment may
be used for similar remaining Equipment.}
Table-5.8
Summary of Action Plan for Boiler and Auxiliaries
Description
Design
Value
[]
Efficiency of
Boiler
Document Number
LII-GETS12021-G-00100-005
Operating
Value
[...]
Target
Value
Recommended
Action Plan
Cost
Impact
[]
[....]
[]
Rev
No.
Description
Page
No.
Date of Issue
02
[35]
26.09.2013
Description
Design
Value
Operating
Value
Air Pre Heater

Cold end
Temperature
[]
Air Pre Heater Air Leakage
[LOGO OF
UTILITY]
Target
Value
Recommended
Action Plan
Cost
Impact
[...]
[]
[....]
[]
[]
[...]
[]
[....]
[]
Air Pre Heater Gas Side

Efficiency
[]
[...]
[]
[....]
[]
Power
Consumption of
Mill A (as per
full loading of
the mill)
[]
[...]
[]
[....]
[]
Power
Consumption of
Mill B (as per full
loading of the
mill)
[]
[...]
[]
[....]
[]
Power
Consumption of
Mill C (as per
full loading of
the mill)
[]
[...]
[]
[....]
[]
Power
Consumption of
Mill D (as per
full loading of
the mill)
[]
[...]
[]
[....]
[]
Power
Consumption of
Mill E (as per full
loading of the
mill)
[]
[...]
[]
[....]
[]
Power
Consumption of
Mill F (as per full
loading of the
mill)
[]
[...]
[]
[....]
[]
Efficiency of ID
Fan A
[]
[...]
[]
[....]
[]
Efficiency of ID
[]
[...]
[]
[....]
[]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[36]
26.09.2013
Description
Design
Value
Operating
Value
Efficiency of FD
Fan A
[]
[...]
Efficiency of FD
Fan B
[]
Efficiency of PA
Fan A
Target
Value
[LOGO OF
UTILITY]
Recommended
Action Plan
Cost
Impact
[]
[....]
[]
[...]
[]
[....]
[]
[]
[...]
[]
[....]
[]
Efficiency of PA
Fan B
[]
[...]
[]
[....]
[]
ESP Efficiency
[]
[...]
[]
[....]
[]
ESP- Emission of
SPM
[]
[...]
[]
[....]
[]
Fan B
Total Cost Impact
[]
Energy Audit Results of Boiler and Auxiliaries are attached at Annexure

[.] to [] of the Report.
5.4
Sankey Diagram for the Efficiency of the Boiler

{Insert a Sankey diagram for the energy input, output and different
losses with range of values being presently achieved, as well as, those
expected after the implementation of recommendations for R&M. A
suggestive diagram is given below.}
5.5
Schematic Diagrams of the Boiler & Auxiliaries

Schematic Diagrams of the Boiler & Auxiliaries indicating the locations of
measuring instruments used during the test are attached at Annexure
[..].
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[37]
26.09.2013
STEAM TURBINE GENERATOR AND AUXILIARIES
6.1
General
[LOGO OF
UTILITY]
{Discuss in this section, the actual operating parameters with respect to

the design parameters and the action plan recommended to reduce the
energy consumption of Steam Turbine Generator and its Auxiliaries,
based upon the findings of Turbine Heat Rate. Discuss the
recommendations based upon the Cost Benefit Analysis and the results
of the Energy Audit carried out on Steam Turbine Generator, Condenser,
CEPs, BFPs and Water Heaters.
6.1.1
Operating Parameters of Steam Turbine

S.No. Parameters
Units
Operating
Value
[........]
Deviation
MW
Design
Value
[........]
Load
MW
[........]
[........]
[........]
Main Steam Pressure kg/cm2

Before ESV
[........]
[........]
[........]
Main Steam
Before ESV
[........]
[........]
[........]
CRH Pressure
[........]
[........]
[........]
CRH Temperature
[........]
[........]
[........]
HRH Pressure
kg/cm2
[........]
[........]
[........]
HRH Temperature
[........]
[........]
[........]
IPT exhaust Temp.
[........]
[........]
[........]
10
Turbine exhaust Temp.
[........]
[........]
[........]
11
Condenser
pressure
back kg/cm2
[........]
[........]
[........]
12
SH Spray Flow
TPH
[........]
[........]
[........]
13
RH Spray Flow
TPH
[........]
[........]
[........]
14
Feed water flow
TPH
[........]
[........]
[........]
15
Feed water Temp.
[........]
[........]
[........]
Document Number
LII-GETS12021-G-00100-005
Temp.
C
C
C
C
C
[........]
Rev
No.
Description
Page
No.
Date of Issue
02
[38]
26.09.2013
S.No. Parameters
Design
Value
[........]
Operating
Value
[........]
Deviation
[........]
16
Soot Blowing Steam TPH

Flow
17
HP Turbine Efficiency
[........]
[........]
[........]
18
IP Turbine Efficiency
[........]
[........]
[........]
19
LP Turbine Efficiency
[........]
[........]
[........]
20
Turbine Heat Rate
kcal/kWh
[........]
[........]
[........]
21
Gross Heat Rate
kcal/kWh
[........]
[........]
[........]
Operating
Value
Deviation
6.1.2
Operating Parameters of Condenser

S.No.
Description
Unit
CW inlet temp
[........]
[........]
[........]
CW outlet temp (L)
[........]
[........]
[........]
CW outlet temp (R)
[........]
[........]
[........]
6.1.3
Units
[LOGO OF
UTILITY]
Design
Value
C
C
C
2
Condenser back
pressure
kg/cm
[........]
[........]
[........]
Saturation temp
[........]
[........]
[........]
TTD
[........]
[........]
[........]
Rise in temp of cooling

water
[........]
[........]
[........]
Condenser heat load
kW
[........]
[........]
[........]
Condenser LMTD
[........]
[........]
[........]
10
Condenser efficiency
[........]
[........]
[........]
11
DP across condenser
mmwc
[........]
[........]
[........]
C
C
Operating Parameters of LP Heaters

Units
Parameters
Feed water
inlet temp.
Feed water
outlet
temp.
Feed water
LPH1
Design
Value
LPH2
Actual
Value
Design
Value
Actual
Value
LPH3
Design
Value
LPH4
Actual
Value
Design
Value
Actual
Value
kg/cm2
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[39]
26.09.2013
Units
Parameters
inlet
pressure
Feed water
outlet
pressure
Extraction
steam
temp.
Extraction
steam
pressure
Drip temp.
Saturation
temp. at
heater shell
pressure.
Shell
pressure.
TTD
DCA
LMTD
6.1.4
LPH1
Design
Value
LPH2
Actual
Value
Design
Value
LPH3
Actual
Value
Design
Value
[LOGO OF
UTILITY]
LPH4
Actual
Value
Design
Value
Actual
Value
kg/cm2
kg/cm2
C
C
kg/cm2
o
C
C
o
C
o
Operating Parameters of HP Heaters

Units
HPH 5
HPH 6
HPH 7
Design
Actual
Design
Actual
Design
Actual
Load
MW
[........]
[........]
[........]
[........]
[........]
[.......]
Feed water inlet

temp.
Feed water
outlet temp.
Feed water inlet
pressure
Feed water
outlet pressure
Extraction
steam temp.
Extraction
steam pressure
[........]
[........]
[........]
[........]
[........]
[.......]
[........]
[........]
[........]
[........]
[........]
[.......]
kg/cm2
[........]
[........]
[........]
[........]
[........]
[.......]
kg/cm2
[........]
[........]
[........]
[........]
[........]
[.......]
[........]
[........]
[........]
[........]
[........]
[.......]
kg/cm2
[........]
[........]
[........]
[........]
[........]
[.......]
C
C
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[40]
26.09.2013
Units
6.2
HPH 5
[LOGO OF
UTILITY]
HPH 6
HPH 7
Design
Actual
Design
Actual
Design
Actual
Drip temp.
[........]
[........]
[........]
[........]
[........]
[.......]
Saturation
temp. at heater
shell pressure
Shell p ressure
[........]
[........]
[........]
[........]
[........]
[.......]
kg/cm2
[........]
[........]
[........]
[........]
[........]
[.......]
TTD
[........]
[........]
[........]
[........]
[........]
[.......]
DCA
[........]
[........]
[........]
[........]
[........]
[.......]
LMTD
[........]
[........]
[........]
[........]
[........]
[.......]
C
C
C
C
C
Action Plan to Reduce Energy Consumption

{Discuss in the Table below, one by one, all the equipment for which
the action is recommended to be taken for improving the efficiency and
reducing the power consumption as per the cost benefit analysis of
energy audit carried out. Discuss the presently operating Heat Rate /
efficiency / power consumption and other parameters of the equipment
at rated performance parameters in comparison to the corresponding
values as per design. Target values indicated in the table should be
equal or better than the design values. Also attach the results of Energy
Audit for the equipments in the form of Annexure.
Formats for reporting the results of Energy Audit have been appended at
the end of this Model Document for reference. The Formats provided for
a particular kind of equipment may be used for similar remaining
Equipment.}
Table-6.1
Summary of Action Plan for Steam Turbine Generator and Auxiliaries
Description
Design
Value
Operating
Value
Target
Value
Recommended
Action Plan
Cost
Impact
Turbine Heat
Rate
[..]
[...]
[..]
[....]
[..]
Efficiency of
HP Cylinder
[..]
[...]
[..]
[....]
[..]
Efficiency of IP
Cylinder
[..]
[...]
[..]
[....]
[..]
Efficiency of LP
Cylinder
[..]
[...]
[..]
[....]
[..]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[41]
26.09.2013
[LOGO OF
UTILITY]
Description
Design
Value
Operating
Value
Target
Value
Recommended
Action Plan
Cost
Impact
Condenser TTD
[..]
[...]
[..]
[....]
[..]
Condenser
Efficiency
[..]
[...]
[..]
[....]
[..]
Efficiency of
CEP-A
[..]
[...]
[..]
[....]
[..]
Efficiency of
CEP-B
[..]
[...]
[..]
[....]
[..]
Efficiency of
CEP-C
[..]
[...]
[..]
[....]
[..]
LP Heater-1
TTD
[..]
[...]
[..]
[....]
[..]
LP Heater-2 TTD
[..]
[...]
[..]
[....]
[..]
LP Heater-3 TTD
[..]
[...]
[..]
[....]
[..]
LP Heater-4 TTD
[..]
[...]
[..]
[....]
[..]
LP Heater-1
DCA
[..]
[...]
[..]
[....]
[..]
LP Heater-2
DCA
[..]
[...]
[..]
[....]
[..]
LP Heater-3
DCA
[..]
[...]
[..]
[....]
[..]
LP Heater-4
DCA
[..]
[...]
[..]
[....]
[..]
Efficiency of
BFP-A
[..]
[...]
[..]
[....]
[..]
Efficiency of
BFP-B
[..]
[...]
[..]
[....]
[..]
Efficiency of
BFP-C
[..]
[...]
[..]
[....]
[..]
HP Heater-1
TTD
[..]
[...]
[..]
[....]
[..]
HP Heater-2
TTD
[..]
[...]
[..]
[....]
[..]
HP Heater-3
TTD
[..]
[...]
[..]
[....]
[..]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[42]
26.09.2013
Description
[LOGO OF
UTILITY]
Design
Value
Operating
Value
Target
Value
Recommended
Action Plan
Cost
Impact
HP Heater-1
DCA
[..]
[...]
[..]
[....]
[..]
HP Heater-2
DCA
[..]
[...]
[..]
[....]
[..]
HP Heater-3
DCA
[..]
[...]
[..]
[....]
[..]
Efficiency of
Generator
[..]
[...]
[..]
[....]
[..]
Total Cost Impact
[..]
Energy Audit Results of Steam Turbine and Auxiliaries are attached at

Annexure [.] to [] of the Report.
6.3
Sankey diagram for the Efficiency of Turbine & Auxiliaries

{Insert a Sankey diagram for the energy input, output and different
losses with range of values being presently achieved, as well as, those
expected after the implementation of recommendations for R&M. A
suggestive diagram is given below.}
6.4
Schematic Diagram of the Steam Turbine Generator

Schematic Diagram of the Steam Turbine Generator indicating the
locations of measuring instruments is attached at Annexure [..].
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[43]
26.09.2013
BALANCE OF PLANT SYSTEMS
7.1
General
[LOGO OF
UTILITY]
{Discuss in this section, the action plan recommended to reduce the

energy consumption of Balance of Plant, based upon the findings of
Performance Test and Measurement of Energy Consumption of Intake
Water Pumps, CW & ACW Pumps, Ash Handling Systems and Pumps,
Induced Draft Cooling Towers, Pre-Treatment and DM Plant, Coal
Handling Plant Equipment, Fuel Oil Handling Pumps, Compressed Air
System, HVAC System etc. Discuss the recommendations based upon
the Cost Benefit Analysis.
appended at the end of this document for general reference.}
7.2

{Discuss in the Table below, one by one all the equipment for which the
action is recommended to be taken for improving the efficiency and
reducing the power consumption as per the cost benefit analysis of
energy audit carried out. Discuss the presently operating
parameters/efficiency / power consumption of the equipment at rated
performance parameters in comparison to the corresponding parameters
as per design. Target parameters indicated in the table should be equal
or better than the design parameters. Also attach the results of Energy
Audit for the equipment in the form of Annexure.
the end of this Model Document for reference. The Formats provided for
a particular kind of equipment may be used for similar remaining
Equipment.}
Table- 7.1
Summary of Action Plan for Balance of Plant and Auxiliaries
Description
Design
Parameters
Operating
Parameters
Target
Parameters
Recommended
Action Plan
Cost
Impact
Water Intake
Pumps
[.]
[...]
[...]
[....]
[ .]
CW Pump-1
[.]
[...]
[...]
[....]
[ .]
CW Pump-2
[.]
[...]
[...]
[....]
[ .]
CW Pump-3
[.]
[...]
[...]
[....]
[ .]
ACW Pump-1
[.]
[...]
[...]
[....]
[ .]
ACW Pump-2
[.]
[...]
[...]
[....]
[ .]
ACW Pump-3
[.]
[...]
[...]
[....]
[ .]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[44]
26.09.2013
Description
[LOGO OF
UTILITY]
Design
Parameters
Operating
Parameters
Target
Parameters
Recommended
Action Plan
Clariflocculator
-1
[.]
[...]
[...]
[....]
[ .]
Clariflocculator
-2
[.]
[...]
[...]
[....]
[ .]
Clarified Water
Pump-1
[.]
[...]
[...]
[....]
[ .]
Clarified Water
Pump-1
[.]
[...]
[...]
[....]
[ .]
DM Water
Make up Pump1
[.]
[...]
[...]
[....]
[ .]
DM Water
Make up Pump1
[.]
[...]
[...]
[....]
[ .]
Cooling Tower
Fans
[.]
[...]
[...]
[....]
[ .]
Clinker Grinder1
[.]
[...]
[...]
[....]
[ .]
Clinker Grinder2
[.]
[...]
[...]
[....]
[ .]
Ash Water
Pump-1
[.]
[...]
[...]
[....]
[ .]
Ash Water
Pump-2
[.]
[...]
[...]
[....]
[ .]
Ash Water
Pump-3
[.]
[...]
[...]
[....]
[ .]
Ash Slurry
Pump-1
[.]
[...]
[...]
[....]
[ .]
Ash Slurry
Pump-2
[.]
[...]
[...]
[....]
[ .]
Ash Slurry
Pump-3
[.]
[...]
[...]
[....]
[ .]
Wagon Tippler
[.]
[...]
[...]
[...]
[ .]
Apron Feeder-1
[.]
[...]
[...]
[...]
[ .]
Apron Feeder-2
[.]
[...]
[...]
[...]
[ .]
Document Number
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Cost
Impact
Rev
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Description
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No.
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Description
[LOGO OF
UTILITY]
Design
Parameters
Operating
Parameters
Target
Parameters
Recommended
Action Plan
Cost
Impact
Primary
Crusher-1
[.]
[...]
[...]
[....]
[ .]
Primary
Crusher-2
[.]
[...]
[...]
[....]
[ .]
Secondary
Crusher-1
[.]
[...]
[...]
[....]
[ .]
Secondary
Crusher-1
[.]
[...]
[...]
[....]
[ .]
Heavy Duty
Conveyor-1
[.]
[...]
[...]
[....]
[ .]
Heavy Duty
Conveyor-2
[.]
[...]
[...]
[....]
[ .]
Plant Air
Compressor-1
[.]
[...]
[...]
[....]
[ .]
Plant Air
Compressor-2
[.]
[...]
[...]
[....]
[ .]
Instrument Air
Compressor -1
[.]
[...]
[...]
[....]
[ .]
Instrument Air
Compressor -2
[.]
[...]
[...]
[....]
[ .]
Fuel Oil
Forwarding
Pump-1
[.]
[...]
[...]
[....]
[ .]
Fuel Oil
Forwarding
Pump-2
[.]
[...]
[...]
[....]
[ .]
HVAC System
[.]
[...]
[...]
[....]
[ .]
Any other
Equipment
consuming
more than 50
kW
[.]
[...]
[...]
[....]
[ .]
Total Cost Impact
[ .]
Audit Results of Balance of Plant Equipments are attached at Annexure

Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
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No.
Date of Issue
02
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[LOGO OF
UTILITY]
{Numbers of equipment indicated in Table above are indicative only. The

number of different equipment should be based on actual number of
equipment of the Power Project, for which Energy Audit is to be carried
out.}
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
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THERMAL INSULATION
8.1
General
[LOGO OF
UTILITY]
{Discuss in this section, the action plan recommended to reduce the

heat loss due to poor or damaged condition of thermal insulation based
upon the findings of Energy Audit. Guidelines for carrying out the Energy
Audit for various equipments are appended at the end of this model
document for general reference.}
8.2
Action Plan for Reducing the Heat Loss

{Discuss in the Table below, one by one, all the equipment for which
the action is recommended to be taken to reduce the heat loss due to
poor or damaged condition of thermal insulation, as per the cost benefit
analysis of energy audit carried out. A few important locations are given
below for reference Discuss the present heat loss, the estimated cost
impact of the action plan against the expected saving in the fuel cost
and payback period. Also attach the results of Energy Audit for the
equipments in the form of Annexure.
the end of this Model Document for reference.}
Table 8.1
Description of
Piping/ Body of
Equipment
Status of
Insulation
Recommended
Action Plan
[Near Boiler
Safety
Valve]
[...]
[....]
[Top of the
down comer
from boiler]
[...]
[....]
[Entry to
Turbine ESV]
[...]
[....]
[]
[Cold Re-heat
Pipe]
[Adjoining
NRV]
[...]
[....]
[]
[Hot Re-heat
Pipe]
[Near Safety
Valve]
[...]
[....]
[]
[Near LP
Bypass]
[...]
[....]
[]
[Deaerator]
[...]
[....]
[]
[Main Steam
Piping[
[Man Hole
Document Number
LII-GETS12021-G-00100-005
Location
Cost
Impact
[]
[]
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Description of
Piping/ Body of
Equipment
Status of
Insulation
Recommended
Action Plan
[HP Heaters]
[...]
[....]
[]
[LP Heaters]
[...]
[....]
[]
[Between
Boiler and
Turbine
House]
[...]
[....]
[]
[Deaerator
Floor]
[...]
[....]
[]
[Hanger locations
on steam piping]
[]
[...]
[....]
[]
[Insulation of
Boiler Shell]
[All burner
floors]
[...]
[....]
[]
[Auxiliary Steam
Headers]
[22 ata]
[...]
[....]
[]
[16 ata]
[...]
[....]
[]
[3 ata]
[...]
[....]
[]
[Level gauge
connections]
[...]
[....]
[]
Covers]
[Outdoor Steam
Piping]
HP/LP Heaters
Location
[LOGO OF
UTILITY]
Cost
Impact
[Drain
connections]
[Boiler Feed
Discharge Piping]
Control
Station
[Steam Turbine]
Lower Half
Casing
[HFO System]
Tank Shells
Heat tracing
of pipes
Total Cost Impact
[]
Energy Audit Results of Thermal Insulation are attached at Annexure [.]

to [] of the Report.
Document Number
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No.
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ILLUMINATION SYSTEM
9.1
General
[LOGO OF
UTILITY]
{Discuss the methodology adopted for conducting the illumination

survey and for identifying the illumination deficient areas and the areas
where energy loss is taking place due to the inefficient luminaries and
lighting fixtures presently installed.
Recommended lux levels for various areas of the power plant and the
Guidelines for carrying out the Energy Audit and working out the energy
loss are appended at the end of this model document for reference.}
9.2
Action Plan for Reducing the Energy Loss

{Discuss in the Table below, one by one, all the areas where inefficient
luminaries and lighting fixtures are recommended to be replaced with the
efficient ones as per the cost benefit analysis of energy audit carried out
Some areas have been indicated for reference. Discuss the cost impact of
implementing the improvements recommended and the energy loss which
can be prevented on annual basis. Support your recommendation with the
details of the illumination survey and Cost Benefit Analysis carried out.
the end of this Model Document for reference.}
Table 9.1
Specific
Location of
Power Plant
Description
of lighting
fixture to be
replaced
Description
of lighting
fixture to be
installed
[Control
Room]
[...]
[...]
[...]
[]
[Administrative
Office]
[...]
[...]
[...]
[]
[Conference
Rooms]
[...]
[...]
[...]
[]
[Crusher
House]
[...]
[...]
[...]
[]
[Coal Stock
areas]
[...]
[...]
[...]
[]
[Switch Yard
area]
[...]
[...]
[...]
[]
[Hazardous
[...]
[...]
[...]
[]
Document Number
LII-GETS12021-G-00100-005
Reason for
Replacement
Cost
Impact
Rev
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No.
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Specific
Location of
Power Plant
Reason for
Replacement
[LOGO OF
UTILITY]
Description
of lighting
fixture to be
replaced
Description
of lighting
fixture to be
installed
Cost
Impact
[Ash Slurry
Pump House]
[...]
[...]
[...]
[]
[Passages
inside the
buildings]
[...]
[...]
[...]
[]
[Periphery
lighting around
the buildings]
[...]
[...]
[...]
[]
[Indoor stair
cases]
[...]
[...]
[...]
[]
[Roads in side
boundary
walls]
[...]
[...]
[...]
[]
[Open- Water
Reservoirs ]
[...]
[...]
[...]
[]
[Toilets]
[...]
[...]
[...]
[]
Area within
Fuel Oil
Storage Dyke]
Total Cost Impact
[]
Energy Audit Results of Illumination System are attached at Annexure

Document Number
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Description
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No.
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10
[LOGO OF
UTILITY]
COST BENEFIT ANALYSIS

[During the Energy Audit, the Performance Test was conducted on all the
continuous operating equipments to first verify the actual operating
efficiency/power consumption of each equipment and compare the same
with the corresponding value as per design. The reason for deterioration
in the efficiency/excess power consumption, if any, was identified.
Recommendations made by R&M Consultant to refurbish the power
consuming equipments for increasing efficiency/reducing the energy
consumption were examined with respect to the actual expenditure
involved for replacing/refurbishing such equipments including cost of
training if any, vis--vis the expected benefits in power consumption.
Cost benefit calculation were made on the basis of simple payback period
as per illustrations given below. The payback period of 5 to 7 years was
considered good criteria for deciding to implement the recommendation of
R&M Consultant.]
10.1
Illustration-1 on the basis of efficiency monitoring.

[(Let us say Boiler Efficiency).]
Let
IC be the Installed Capacity in MW,
a , the Actual Boiler Efficiency before R&M and
e, the Expected Boiler Efficiency after R&M. Then,
Annual fuel consumption before R&M =
IC*8760*PLF*TGHR*1000
kCal/annum
Where,
PLF
= Plant Load Factor
TGHR = Turbine Heat Rate

Annual fuel consumption after R&M =
IC*8760*PLF*TGHR*1000
kCal/annum
Expected annual saving in fuel (in kCal/annum) is therefore,

Expected annual saving in fuel= IC*8760*PLF*TGHR*1000
1
a
1
e
Annual fuel cost saving= Annual saving in Fuel* Fuel Cost

Pay Back Period in Years =
10.2
Capital Expenditure
Annual fuel cost saving
IIlustration-2 on the basis of power consumption for any equipment

[(Let us Say - a Motor Driven Boiler Feed Pump)]
Let, IC be the Installed Capacity in MW,
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[LOGO OF
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Pa, the actual power consumption of the equipment in kilowatt before

R&M and
Pe, the Expected power consumption of the equipment in kilowatt after
R&M
Then Saving in power consumption = Pe Pa
Annual cost of power saving = Power saving (kW)*8760*DF*COG
Where,
DF = Duty factor for equipment in percentage (%).
COG = Cost of Generation (Rs/kWh)
Pay Back Period in Years=
Document Number
LII-GETS12021-G-00100-005
Capital Expenditure
Annual Cost of Power Saving
Rev
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11
[LOGO OF
UTILITY]
SUMMARY OF THE RECOMMENDATION OF ENERGY AUDIT

Based upon the recommendations of energy audit reports of various
systems, the action plans for improving the efficiency and reducing the
power consumption of various plants and equipments have been
discussed in sections 5.0 to 9.0. An overall summary of the
recommended action plans is furnished in the table below.
Table11.1
Summary of the Recommended Action Plans
Equipment/
Summary of the
Cost Impact
Systems
[.]
[...]
Steam Turbine
Generator and
Auxiliaries
[.]
[...]
Balance of Plant and

Systems
[.]
[...]
Thermal Insulation
[.]
[...]
Illumination System
[.]
[...]
Any other System
[.]
[...]
Total Cost Impact
Document Number
LII-GETS12021-G-00100-005
[......]
Rev
No.
Description
Page
No.
Date of Issue
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[LOGO OF
UTILITY]
{GUIDELINES FOR ENERGY AUDIT OF BOILER AND AUXILIARIES}

DETERMINATION OF BOILER EFFICIENCY
Efficiency of the Boiler should be determined by Heat Loss Method.
Guidelines as per the ASME Code PTC 4 provide a more detailed method
of determining the heat losses, whereas Bureau of Energy Efficiency (BEE)
Guidelines provide a relatively simple method of determining the heat
losses. Both the Guidelines are discussed below.
ASME Code PTC 4 Guidelines
As per the above code, Net Heat Loss should be worked out by deducting
the total heat credits from the total heat loss, i.e,
Net Heat Loss = Total Heat Loss Total Heat Credits
As per the above Code, Total Heat Loss consists of the following items:
i)
Heat Loss due to dry flue gases.
ii)
Heat Loss due to evaporation of moisture in fuel.
iii)
Heat Loss due to hydrogen in fuel.
iv)
Heat Loss due to moisture in Air.
v)
Heat Loss due to incomplete combustion to CO.
vi)
Heat Loss due to un-burnt carbon.
vii)
Heat Loss due to mill (pulveriser) rejects.
viii)
Heat Loss due to Radiation and convection (Difficult to evaluate.

Hence Design Value [normally 0.18%] should be considered.)
Total Heat Credit consists of the following items:

i)
Heat Credit due to entering dry air.
ii)
Heat Credit due to moisture in entering air.
iii)
Heat Credit due to sensible heat in fuel.
iv)
Energy Credit due to Auxiliary Equipment within the Boiler

Envelope as per ASME Code PTC - 4.
As per ASME Code PTC 4, Efficiency of Boiler is to be worked out by

the following equation.
Efficiency = 100 - % Net Losses of Heat Input.
Where,
Net Losses of Heat Input = Total Heat Losses Total Heat Credits
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[LOGO OF
UTILITY]
BEE Guidelines
As per BEE Guidelines, both (i) the heat credits and (ii) the losses due to
mill rejects are neglected. As per BEE Guidelines, the following formulae
are to be used for estimating the losses for calculating the efficiency :
i)
Heat loss due to dry flue gases Ldfg:

(11.6 * C) + 34.8 * H2 O2/8) +
100
100
Stochiometric air, kg / kg of fuel =
O2 %
21 O2%
Excess Air Supplied, EA % =
4.35 * S
100
* 100
Whereas O2 = Oxygen Component measured in Flue Gas

1+EA%
Stochiometric air
100 *
Actual Air Supplied (AAS), kg of air/kg of fuel =
Dry flue gas quantity (Wd), kg/kg of fuel =

100
%C
*
12* (CO2% + CO%)
100
Dry flue gas Ldfg % =
%S
267
- %C of BA * Bash 100
C% FA * Fash
100
Dry flue gas quantity Kg/kg of fuel* Specific heat kCal/kg oC * (FGT oC ABT oC)
* 100
GCV of Fuel kCal/kg
Where,
C % BA = % of carbon in bottom ash
C % FA = % of carbon in fly ash
Bash
= Bottom ash quantity in kg/kg
Fash
= Fly ash quantity in kg/kg
FGT
= Flue gas temperature at APH outlet in oC
ABT
= Ambient dry bulb temperature in oC
Cp
= Specific heat of flue gas in kCal/kg oC = 0.23
ii) Heat Loss due to evaporation of moisture in fuel, Lmf
Loss due to moisture in fuel, Lmf =
[(0.45 * (FGT ABT) + 584] * 100

GCV
Where, M is kg of Moisture in 1 kg of fuel

iii) Heat Loss due to Hydrogen in fuel, Lhf
Loss due to hydrogen in fuel, Lhf =
9 * H2 *[(0.45
(FGT ABT) + 584]*

GCV
100
Where,H2 is kg of H2 in 1 kg of fuel
iv)
Heat Loss due to moisture in air, Lma
Loss due to moisture in air, Lma =AAS * humidity * 0.45 * (FGT-ABT) * 100
GCV
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[LOGO OF
UTILITY]
Where, AAS = Actual mass of air supplied

Humidity = humidity of air in kg/kg of dry air
v)
Heat Loss due to incomplete combustion to carbon monoxide, Lco

CO%*C
*
CO%+CO2%
Loss due to carbon monoxide, Lco =
5744 *100
GCV
During the flue gas analysis when CO is obtained in ppm, then losses can
be obtained
Loss due to carbon monoxide, Lco
= CO in ppm * 10-6 * fuel consumption in kg/h * 28 * 5744 * 100
GCV
vi)
Heat Loss due to un-burnt carbon in ash, Luca
Loss due to un-burnt carbon in ash, Luca =

Calorific value of carbon in kCal/kg
GCV of fuel kCal/kg
vii)
* [(C%FA * Fash + (C%BA * Bash)]
Heat Loss due to Radiation and convection.
These losses are taken as per design documents. As per BEE Guidelines,
typical value for 210-500 MW is 0.4%-1.0% of GCV.
As per BEE Guidelines,
Boiler Efficiency = 100 % Sum of Losses mentioned above.
Locations of Measuring Instruments:
For conducting the Boiler Efficiency Test, following locations should be
used for installing the measuring instruments and for collecting the
samples:
Flue Gas Analyzers / Orsat Apparatus at the inlet and outlet of Air PreHeater for measuring O2, CO & CO2.
Thermocouples for measuring the temperature of flue gas at Air PreHeater inlet and outlet.
Fly ash sampling at Economiser outlet and ESP Hoppers for unburnt
carbon in fly ash.
Dry Bulb and Wet Bulb Thermometer.
Sampling of bottom ash from hopper or scrapper.
Sampling of raw coal from RC feeder of the mill for proximate and
ultimate analysis of fuel and finding its Gross Calorific Value (GCV).
Pulverised coal samples from each mill for sieve analysis.
Sampling of mill rejects for finding GCV.
Notes:
(i)
Before the Efficiency Test is conducted, the contractor will submit

a detailed procedure for conducting the test which will be subject
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(ii)
[LOGO OF
UTILITY]
to the approval of the owner. Among other things, the procedure

will also include the type of instruments to be used and the
locations of various measuring instruments and sampling points.
During the Efficiency Test, the Boiler blow downs and the use of
auxiliary steam for purposes like soot blowing should be stopped,
since, accurate evaluation of heat loss due to these items is
difficult.
(iii)
Test Instruments should have 0.5% accuracy. Calibration of the

instruments should not be more than six months old. Instruments
calibration should be certified by Govt. Accredited Laboratories i.e.
NABL approved laboratories.
(iv)
During the test, the operating parameters should be kept stable

and close to design parameters.
(v)
During the Boiler Efficiency Test, quality of fuel to be used should

be as close as possible of the design quality.
(vi)
All loss components should be thoroughly examined for the

deviations, since in most of the plants, the actual GCV of the fuel
and composition of the fuel does not match with design
specifications and the above losses need to be corrected for the
actual quality of fuel.
***************************
Document Number
LII-GETS12021-G-00100-005
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No.
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[LOGO OF
UTILITY]
{PERFORMANCE TEST OF AIR PRE-HEATERS (APH)}

Air Pre-heater is the last heat exchanger in the path of flue gases.
Extracting maximum heat from the outgoing gases helps in improving the
efficiency of the Boiler by reducing the heat loss due to dry flue gas. It
also helps in limiting the cold end temperature of the Air Pre-Heater as
well as the stack temperature.
APH leakage and APH gas side efficiency has to be checked to assess the
performance of APH.
Determination of APH Leakage
The static air pressure on the side of incoming air is much higher than
that of the flue gas side. Unfortunately, this leads to significant air bypass
to flue gas side and consumes unnecessary fan power. When the
incoming air bypasses to the flue gas side, the flue gas temperature
decreases. The lower stack temperature due to air leakage gives a false
indication that the Boiler is operating efficiently. The air leakage therefore
needs to be measured and minimized by improving the sealing
arrangement.
Air heater leakage in APH is the weight of air passing from the air side to
the gas side of the APH. This is an indicator of the condition of the air
heaters seals. As the air heater seals wear, air heater leakage increases.
The increase in the air heater leakage increases the power requirement of
the draft fans, increasing the unit heat rate and possibly limiting the unit
loading.
The air leakage can be determined by measuring the O2 component in
the flue gases before and after the APH. Isokinetic Sampling (Grid
Measurement) should be taken before and after the APH for measuring
the O2 component and Flue Gas temperature.
Air Leakage AL % =
O2% in the gas leaving APH- O2% in the gas entering APH
21 O2% in the gas leaving APH
* 100
Determination of APH Efficiency

The performance of APH can also be checked by finding the operating
gas side efficiency. Gas side efficiency is the ratio of gas temperature
drop (at no leakage) to the temperature Head expressed as a percentage..
Temperature Head is the gas inlet temperature minus the air inlet
temperature.
Gas Side Efficiency = (Tgnl Tge) / (Tae-Tge).
The corrected gas outlet temperature Tgnl is defined as the outlet gas
temperature for no air leakage and is given by the following formula:
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Tgnl =
AL* Cpa (Tgl Tae)

100 * Cpg
[LOGO OF
UTILITY]
+ Tgl
Where,
AL
Tgnl
Cpa
Tae
Tal
Tgl
Cpg
Tge
:
:
:
:
:
:
:
:
Air leakage into APH system, in %

Gas outlet temperature corrected for no leakage, in oC
Mean specific heat of air between Tac and Tgl, in kCal/kg/ oC
Temperature of the air entering the APH, in oC
Temperature of the air leaving the APH, in oC
Temperature of the gas leaving the APH, in oC
Mean specific heat of gas between Tgl and Tgnl, in kCal/kg/ oC
Temperature of gas entering the APH, in oC
{PERFORMANCE TEST OF MILLS}
The energy audit of coal mills has to be conducted after obtaining an

overview of system which includes mills, RC feeders, PA fans, seal air
fans, mill reject handling system and associated ducts, piping, valves and
dampers, lubrication system, thermal insulation status of mills/PA fans
ducts/piping etc. While monitoring the general health of various
installations, noticeable leakages of coal, air, oil and condition of thermal
insulation should be checked.
Coal Mills are designed with a particular fuel grinding capacity or
throughput at a certain Hardgrove Grindability Index (HGI) based on a
definite raw coal size, moisture content and desired fineness level. Since
these factors are significant, the coal to be used for testing the
performance of mills should preferably be close to the design coal quality.
Testing Methods
For checking the performance of mills, following two tests should be
done.
i) Clean Air Pitot Tube Test.
ii) Dirty Pitot Tube Test.
In clean air pitot tube test, no coal is injected into the mills and only
primary air from the PA Fans is supplied to the mills to check any
unbalance of flow of primary air in the coal lines. Flow of air is checked
by measuring the velocity of air with the help of pitot tubes.
In dirty pitot tube test, mills are operated by injecting coal and
measurements are taken on all pulverized coal lines to check any
unbalance of flow of pulverized coal in coal lines / choking of the lines
etc. Samples are taken from each coal line to determine the coal fineness
of each supply conduit of the mills. During the test, coal integrator
readings of individual raw coal feeder should be compared with the
overall coal integrator reading. Quantity and GCV of rejects produced by
each mill should be measured.
As explained above, Performance of all the mills should be checked with
respect to the following design parameters:
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(i)
(ii)
(iii)
(iv)
(v)
[LOGO OF
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Throughput (tons/hour),
Fineness for each supply conduit (% passing through 200 mesh)
Air to coal ratio of mills (tons of air per ton of coal)
Calorific value of Mill rejects and
Power Consumption (kWh/ton of coal).
Measuring instruments to be used

(i)
(ii)
(iii)
(iv)
(v)
Calibrated Pitot tubes.

Gravimetric Feeders.
Standard Sieves.
Stroboscope.
Power Analyzers for measuring electrical parameters like kW, kVA,
pf, V, A and Hz.
***************************
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[LOGO OF
UTILITY]
{Performance Test of ID Fans, FD Fans and PA Fans}

ID, FD and PA Fans generate pressure to move air or flue gases against
air or gases against a resistance caused by ducts, elbows and dampers
etc in the system. Fans being constant volume machines, volume of air or
gases moved through the fans remain constant regardless of density.
Pressure and power requirements however change proportionately with
density.
For doing the energy audit of the ID Fans, FD Fans and PA Fans,
Performance parameters of these fans should be checked with respect to
the design parameters of total pressure developed, the volume of air / flue
gas discharged, power consumption and efficiency of the fans.
Total pressure developed by a fan is the sum of static pressure and the
average velocity pressure. Measurements of static and velocity pressure
are done both at the suction and discharge of the fans by using a
combination of pitot tube and manometer.
Since the velocity pressure in a duct or pipe varies across its cross
section, its measurements are taken at various points by traversing the
pitot tube across the cross-section. Average velocity of air/flue gas in a
duct is determined from the average value of the velocity pressures
measured across the cross-section of the duct. Flow through the duct is
then determined by the product of the average velocity and the area of
cross-section.
Measuring Instruments to be used:
Pitot tubes.
Manometer of suitable range.
Power Analyzer for measuring electrical parameters such as kW, kVA,
PF, V, A and Hz.
Stroboscope for measuring the speed.
Temperature indicator and probe
Hygrometer for measuring the relative humidity.
Evaluation of Results:
Following equations may be used for evaluating the performance and
efficiency of Fans.
Total pressure
developed by a fan
Sum of static pressure and the average

velocity pressure.
Static pressure
developed by the fan.
Difference of static pressure at discharge

and static pressure at suction.
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Velocity pressure
Difference of velocity pressure at discharge

and velocity pressure at suction.
Total pressure
Difference of total pressure at discharge

and total pressure at suction.
Velocity (m/sec) =Cp*(2*9.81*velocity pressure developed (mm wc)*)
Where,
Cp = Pitot tube constant, as given by the manufacturer
= Density of air or gas at test condition in kg/m3
Flow Rate (m3/sec) = Area of Cross-section (m2)*Velocity (m/sec)
PA/FD Fan total kW = Q in m3/s*total pressure developed by fan (mmwc)
102
PA/FD Fan Mechanical Efficiency (%) =
Fan total kW*100
Input kW to motor* m
Where Fan total kW = Total power consumption of the fan in kW
Input kW to motor
m
= Measured power consumption of the motor in kW
= Motor Efficiency
Corrected air density =
273 * 1.293
273+Air temperature (C)
ID Fan total kW = Q in m3/s*total pressure developed by fan (mmwc)*fg

102*1.293
ID Fan Mechanical Efficiency (%) = Fan total kW*100*fg
1.293*Input kW to motor* m
Where fg - Density of flue gas at test condition in kg/m3
As per the basic principles, the combined efficiency of fan and motor can
be determined by the following formula
Combined Efficiency (Fan & Motor) = Pi = dp*q
P
P
Where, Pi
Document Number
LII-GETS12021-G-00100-005
Ideal Power Consumption in Watts.

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P
dp
q
=
=
=
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Actual Power Consumption in Watts.

Total pressure developed by the Fan (N/m2 or Pa)
Flow of air/ flue gas (m3/sec)
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{PERFORMANCE TESTS OF ELECTROSTATIC PRECIPITATOR}

Determination of Efficiency of Electrostatic Precipitator
For measuring the efficiency of Electrostatic Precipitator (ESP), the
volume of the gas flowing through ESP is measured as well as samples
of the dust burden are collected and weighed, both at the inlet as well as
the outlet of all the streams / passes of the ESP.
(i)
(ii)
(iii)
(iv)
Stack Monitoring Kit (For Gas Flow and Dust Loading).

On-line Instruments.
Power Analyzers for measuring electrical parameters like kW, kVA,
pf, V, A and Hz.
Temperature Indicator.
The Efficiency of ESP is then calculated as per the following formula:

(Di-Do)
= -------------------*100%
Di
Em
Where,
Em = The measured test efficiency.

Di = Weighted mean of dust burdens at the inlet of ESP (mg/NM3)
Do= Weighted mean of dust burdens at the outlet of ESP (mg/NM3)
Di =
{(Vm1*Di1)+(Vm2*Di2)+(Vm3*Di3)+(Vm4*Di4)}
(Vm1+ Vm2 + Vm3 + Vm4)
Do=
{(Vm1*Do1)+(Vm2*Do2)+(Vm3*Do3)+(Vm4*Do4)}
(Vm1+ Vm2 + Vm3 + Vm4)
Vm= Volume of Gas flow Measured at various passes/streams of ESP.

(Suffix 1, 2, 3 & 4 represents four gas streams.)
Measurement of Solid Particulate Matter (SPM):
The test is done by method 17 of Environment Protection Agency (EPA)
of US. This involves determination of mass concentration and volumetric
flows. The method involves collection of a representative sample of flue
gas from all the streams / passes at the ESPs outlet and finding out mass
concentration of particulates from this sample.
In sampling, it is to be ensured that a representative sample of flue gas is
obtained. To ensure this, isokinetic sampling is done by grid method such
that velocity and direction of the gas entering the probe is the same as
the gas in the duct at the sampling point. The test is done for a period of
at least one hour and sampling from each grid point is done for two
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minutes. The dust particulates are collected on the filters. The filters are
dried in the oven and the weight of the dust particulates is found by
deducting the weight of net filter from the gross filter weight. The actual
sampling volume of dry gas is measured by the gas meter which is
converted into volume at standard conditions of temperature and
pressure. The solid particulate emission is then worked out by dividing
the dried mass of solids by the corresponding volume of gas at standard
temperature and pressure.
Do
SPM = -------------------*100%
Vs
Where,
Do= Weighted mean of dust burdens at the outlet of ESP (mg/NM3)
Vs = Volume of Dry Flue Gas at standard temperature and pressure.
***************************
Document Number
LII-GETS12021-G-00100-005
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{GUIDELINES FOR ENERGY AUDIT OF STEAM TURBINE GENERATOR

AND AUXILIARIES}
Performance Testing of Steam Turbine Generator
Performance Test of a Steam Turbine Generator (STG) should be
conducted in accordance with Standard Test Codes ASME PTC-6.
The performance of a STG is judged by the Net Heat Rate which is a ratio
of Heat given to the STG cycle to The Gross Electrical Output. Turbine
Heat Rate (HR) is expressed by the following equation:
Turbine Heat Rate = Heat Given to the Cycle/ Gross Electrical Output
Heat given to the cycle is calculated by adding the Enthalpy additions
made to the feed water as well as to the Cold Reheat Steam and by
making correction due to the enthalpy of de-superheating water injected
to the super heated/ reheated steam. Net Electrical Output is measured
at the terminals of Generator.
Turbine Heat Rate is given by:
Turbine Heat Rate (kCal/kWh) =
Q1*(H1-h2)+Q2*(H3-H2)
Gross Generator Output
Where:
Units
Q1
Main steam flow
kg/ hr
H1
Main steam enthalpy
kCal/kg
h2
Feed water enthalpy
kCal/kg
H3
Hot reheat enthalpy
kCal/kg
H2
Cold reheat enthalpy
kCal/kg
Q2
Reheat steam flow
kg/ hr
Turbine Cycle Efficiency % =
860
Turbine Heat Rate
* 100
Measurement of Steam Flow Rate:The installation and calibration of flow measuring devices for determining
the steam flow rate to higher pressure, high temperature turbines is
inherently difficult. ASME Code PTC-6 therefore recommends the use of
flow measuring devices in the low temperature portion of the water
cycle, i.e. either for the condensate flow or the feed water flow.
The measurement of condensate or feed water flow should be done by
measuring the differential pressure across the calibrated flow nozzle built
to the design and dimensions given in the ASME code.
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Main Steam flow rate can be worked out from the measured value of
condensate flow by adding the flow from the HP Water Heaters
calculated through Heat Mass Balance, by adjusting to the equivalent
flow corresponding to the level changes in the deaerator, by subtracting
un-accounted leakage of maximum allowable value 0.1% and by
deducting the amount of water taken for sampling. A typical example of
calculating the Main Steam Flow and Reheat Flows is discussed below.
However, it is to be noted that the method of computation for any project
will actually depend upon the project specific scheme of the Steam
Turbine and its auxiliaries.
EXAMPLE:
Let,
MF1 be the Condensate flow to deaerator,
MF4 be the Ejector steam flow from deaerator,
Mfw be the feed water at the out of deaerator,
H7, H6, H5, H4 be the enthalpies of water after HP Heaters, HP7, HP6,
HP5 & LP heater LP4 respectively,
Hfw be the enthalpy of Feed Water at deaerator outlet and
Mext7, Mext6, Mext5, Mext4 be the extraction steam flow of Ext 7, 6, 5
& 4 respectively.
Then, from Heat Balance of HPH - 7, HPH-6 and HPH-5, we have,
Mfw * (H7- H6) = Mext7*(Hex7- Hdrip7) - Eq. (1)
Mfw * (H6 H5) = Mext6 * (Hext6 Hdrip6) + Mext7 * (Hdrip7- Hdrip6) - Eq.(2)
Mfw (H5Hfw)= Mext5 (Hext5- Hdrip5)+ [(Mext7+ Mext6)*(Hdrip6
drip
5)] - Eq.(3)
Similarly from Heat Balance and Mass Balance of Deaerator, we have,

Mfw*Hfw=Mext4*Hext4+MF1*H4+(Mext7+Mext6+Mext5)*Hdrip5MF4*H ------Eq.(4)
Mfw= Mext7 + Mext6 + Mext5 + Mext4 + MF1 Mej Eq. (5)
After four unknown quantities of Mext7, Mext6, Mext5 and Mext4 from
above five equations are determined by solving above equations, then
Feed water flow at the outlet of Deaerator can be worked out from
equation-5 above. Main Steam Flow (Q1) can then be established as
explained below.
Q1= Mfw+Mdl-Ms-Mlk
Where,
Mdl = Equivalent flow corresponding to decrease in the level of deaerator.
Ms = Amount of water taken for sampling if any.
Mlk = Un-accounted leakage. (Maximum allowable value is 0.1%)
Reheat steam flow Q2 is evaluated by subtracting steam extraction to last
two HP Heaters (as per the heat balance across these heaters) & HP
Turbine Leak off flows from the main steam flow Q1and by adding sprays
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for the attemprations. Leak off flows shall either be taken as per the
design values or evaluated from the collected data.
Thus Q2 = Q1 Extraction from last 2 HP Heaters - (HPT leaks)
As already stated, Turbine Heat Rate can be worked out as follows.
Turbine Heat Rate (kCal/kWh) =
Q1*(H1-h2)+Q2*(H3-H2)
Gross Generator Output

Temperature Indicators and Sensors.
Pressure Gauges.
Water Flow Measuring Instruments (Calibrated Flow Nozzles,
Ultrasonic Devices)
Helium Leak Detectors for Condensers.
(i)
(ii)
(iii)
(iv)
Notes:
(I)
To ensure the accuracy of the test, extraneous flows like, Make up

to the cycle, bypass lines and drain lines are isolated from the
cycle.
(II)

calibration should be certified by Govt. Accredited Laboratories i.e.
NABL approved laboratories.
(III)
At the beginning of the test, Deaerator and Hot well levels should
be kept at high water level.
(IV)
During the test, the operating parameters should be kept stable

and close to design parameters.
Determination of Efficiency of Individual Turbine Cylinders

Efficiency of Individual HP, IP and LP Turbine Cylinders can be determined
by first calculating the energy extracted from each kg of steam passing
through a particular cylinder (HP, IP or LP) by subtracting the exhaust
enthalpy (Hout act) from the inlet enthalpy (Hin act). Dividing this
quantity by the amount of energy that would have been extracted, if the
process was isentropic or ideal, gives the efficiency of the particular
Turbine Cylinder. The energy extraction through isentropic process can be
determined from the Mollier Chart:
Where, Hin act = The actual inlet enthalpy of the steam.

Hout act = The actual exhaust enthalpy of the steam.
Hout ideal = The ideal exhaust enthalpy of the steam.
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{PERFORMANCE TEST OF CONDENSERS}

Since the performance of the condenser depends upon the cooling water
flow and inlet cooling water temperature, it is often cost effective to
conduct the performance test of the condenser along with the testing of
CW Pumps and Cooling Tower.
Objective of the condenser performance test is to find out whether
condenser is performing as per the design expectations or not. Analysis
of the condenser performance is based on the following parameters:
CW Inlet Temperature.
CW Outlet Temperature.
Flow Quantity of Cooling Water.
Turbine exhausts hood temperature.
Terminal temperature difference (TTD.)
Log Mean Temperature Difference (LMTD)
Back Pressure.
The above parameters most importantly the TTD, (LMTD) and Back
Pressure are compared with the design /expected parameters and actions
are required to be planned to correct the deviations.
Notes:
Before conducting the test, it should be ensured that,
(i)
The condenser tubes are cleaned and
Air leakage into the condenser has been tested with the help of
(ii)
Helium leak detection system.
Parameters to be checked
The following parameters need to be checked:
(i)
Condenser heat load
Condenser heat load (kCal/h) = Q x T x Cp

Where,
Q
= Water flow rate in (kg/h)
T
= Average CW temperature rise in oC
Cp = Specific heat in kCal/kg oC
(ii)
Condenser Vacuum
Expected condenser vacuum can be calculated from the performance

curves of condenser as given by the manufacturer.
Calculated condenser vacuum
Calculated condenser vacuum = atmospheric pressure Condenser back pr.
Deviation in condenser vacuum

Deviation in vacuum=Expected condenser vacuum Measured condenser vacuum
(iii)
Condenser TTD
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Condenser TTD = Saturation temperature Cooling water outlet temperature
(iv)
Condenser Effectiveness
Condenser effectiveness =
(v)
Rise in cooling water temperature

Saturation temperature Cooling water inlet temperature
Determination of actual LMTD
Actual LMTD is given by:
Tout - Tin
Tsat Tin
Tsat - Tout
LMTD =
Ln
Where
LMTD = Log Mean Temperature Difference
Tsat
= Saturation temperature (oC) corresponding to back pressure.
Tin
= Cooling water inlet temperature (oC)
Tout
= Cooling water outlet let temperature (oC)
Establishing the reasons for loss/gain in condenser vacuum:

After diagnosis, the loss/gain in condenser vacuum should be categorized
into the following factors in order to find optimum solutions:
i)
ii)
iii)
iv)
Due
Due
Due
Due
to
to
to
to
CW inlet Temp.:
CW inlet flow:
air ingress:
dirty tubes :
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{PERFORMANCE TEST OF LP & HP FEED WATER HEATERS}

Performance of the LP & HP feed Water heaters is to be checked from the
following indices:
Terminal Temperature Difference (TTD)

Drain Cooler Approach (DCA)
Temperature Rise across the heaters.(TR)
Formulae to be used are given below

Terminal temperature difference, TTD = tsat tfw out
Where,
TTD
= Terminal temperature difference (oC)
Tsat
= Saturation temperature taken at the heater shell pressure (0C)
Tfw out = Temperature of feed water leaving the heater (oC)
Drain Cooler Approach temperature, DCA = Tdrains Tfwin

Where,
DCA = Drain cooler approach temperature (oC)
Tdrains = Temperature of the drains leaving the heater (oC)
Tfw in = Temperature of feed water entering the heater (oC)
Temperature Rise, TR = Tfw out Tfw in

Where,
TR
= Feed water temperature rise across the heater (oC)
Tfw in
= Temperature of feed water entering the heater (oC)
Tfw out = Temperature of feed water leaving the heater (oC)
The above parameters are compared with the design /expected

parameters and actions are required to be planned to correct the
deviations.
***************************
{PERFORMANCE TEST OF CEPs AND BFPs}
For the performance test of CEPs and BFPs, please refer to the
Guidelines for Testing Centrifugal Pumps appended after the section on
Balance of Plant.
***************************
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{GUIDELINES FOR ENERGY AUDIT OF BALANCE OF PLANT SYSTEMS}

Performance Testing of Centrifugal Pumps
All kinds of centrifugal pumps namely the Boiler Feed Pumps, Condensate
Extraction Pumps, CW Pumps, ACW Pumps, Raw Water Intake Pumps,
Ash Water Pumps, DM Water Pumps, Ash Slurry Pumps and
Miscellaneous pumps can be tested by the method explained below.
The primary factors affecting the operation of the pumps are the inlet
condition at suction side, outlet condition on the discharge side and the
operating speed of the pump. The secondary factors are physical and
climatic variables, such as the temperature, viscosity, specific weight and
turbidity of the liquid being pumped and the elevation of the pumping
system above the sea level.
During the test, the following instruments are required.
(i)
(ii)
(iii)
(iv)
Venturi meters / flow nozzles / orifice meters / pitot tubes for

measuring the Discharge,
Bourden type pressure gauges for measuring suction and
discharge Head
Stroboscobe for measuring Operating Speed.
Power Analyzers for measuring electrical parameters like kW,
kVA, pf, V, A and Hz.
Measurement of Discharge:Discharge or flow can be measured by installing calibrated devices like

venturi meters, flow nozzles, orifice meters and pitot tubes etc.
When the flow is measured by the venturi meter, the flow nozzle or
orifice meter, its quantity can be calculated by the following equation:
Where,
Q
C
A2
g
=
=
=
=
Rate of flow (m3/sec)

Coefficient of discharge for venturi meter, flow nozzle or
orifice meter as the case may be.
Area of throat in case of venturi meter /flow nozzle or area
of orifice in case of orifice meter, as the case may be (m2).
Acceleration due to gravity (9.81 m/sec2)
Differential head of liquid between meter inlet and throat in

case of venture meter or head across the flow nozzle or
orifice meter as the case may be.(m)
Ratio of throat to inlet diameter in case of venturi meter/

flow nozzle or orifice meter as the case may be.
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When the Discharge or Flow is measured by the pitot tube, its quantity
can be calculated by the following equation:
Where,
Q = Flow in m3/sec
A = Area of cross section of flow, where pilot tube is installed (m2)
g = Acceleration due to gravity (9.81 m/sec2)
h= Height of rise of water column above the surface of water (m)

Measurement of Total Dynamic Head (TDH):For measuring the TDH, measurements are required to be taken both on
the suction as well as Discharge side of the pumps. Instruments to be
used could be either the direct reading liquid manometers, converted
mercury manometers or calibrated bourden pressure gauges.
The TDH is given by the algebraic difference of the total discharge head
(hd) and the total suction head (hs) i.e.
H = hd hs
The values of hd and hs are calculated by the following equations:
and
Where,
hgd
=
hgs
=
Zd
=
Zs
=
Vd
=
Vs
=
discharge gauge reading in metres of liquid.

suction gauge reading in metres of liquid.
elevation of discharge gauge above datum elevation.
elevation of suction gauge above datum elevation.
Velocity in discharge pipe (m/s)
Velocity in suction pipe (m/s)
Measurement of Power Consumption:The power consumption (kW) should be measured at the terminals of the
drive motor (in case of motor driven pumps) to exclude any line losses
that may occur between the switchboard and the driver.
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Measurement of Speed:The speed of the pump can be measured by revolution counter (manual or
automatic), tachometer, stroboscopic device or an electronic counter.
Power Output of Pump:Power output of the pump in kW can be determined by the following
relationship:
Liquid Power Output (kW)
Q* H* * g
1000
Where,
Q = Flow rate of liquid (m3/sec)
H = Total Dynamic Head (m)
= Density of Liquid / Ash Slurry (kg/m3)
g = Acceleration due to gravity (9.81 m/sec2)
Pump Efficiency:Mechanical Efficiency of the Pump is given by the following relationship:
Mechanical Efficiency % =
Liquid Power Output (kW)

x100
Power Input to the shaft (kW)
Overall Efficiency of the Motor Driven Pump including motor is given by

the following equation:
x 100
Adjustments due to change in pump speed;If the frequency of electrical supply of power is other than 50 Hz, the
actual speed of the pump during the test will be somewhat different from
the rated speed. Adjustments are therefore required to be made in the
measured values of Discharge, TDH and Electric Power Consumption, to
convert these parameters corresponding to the rated speed of the pump.
This can be done by using the following equations:
x
Where,
Qr
Qt
Hr
Ht
=
=
=
=
Discharge Capacity at Rated speed

Discharge Capacity at Tested Speed
TDH at Rated Speed
TDH at Tested Speed
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Pr
Pt
Nr
Nt
=
=
=
=
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Power Consumption at Rated Speed

Power Consumption at Tested Speed
Rated Speed
Test Speed
****************************
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{COOLING TOWER PERFORMANCE TEST}

There are a number of variables, which influence the performance of
cooling towers. The various test codes namely CTI Code ATC-105, ASME
Code PTC-23 and BS 4485 Part 2 prescribe certain permissible limits for
these variables. The permissible limits recommended by CTI Code ATC105 are given below:S.No. Parameter
Permissible Variation
from the Design value
Water Rate
10%
Cooling Range
20%
Heat Load
20%
Wet Bulb Temperature
10o F
Dry Bulb Temperature
20o F
Wind velocity
10%
Fan Power
10%
The Wet Bulb Temperature in case of Induced Draft Towers and Wet &
Dry Bulb Temperatures in case of Natural Draft Towers are the basic
weather conditions on which the cooling towers are designed. The date
of conducting the performance test of the Cooling Towers should
therefore be chosen considering the trend of the weather conditions so
that the above temperatures are as close as possible to the design values.
Testing Method:
The test is conducted for a minimum period of one hour during which
time, readings for all the following parameters are taken at an interval of
5 minutes.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Wind Velocity.
Ambient Wet & Dry Bulb Temperatures.
Inlet Wet Bulb Temperature.
Hot Water Flow to the Cooling Tower.
Temperature of Hot Water.
Re-cooled Water Temperature.
Fan Power Consumption in case of Induced Draft Cooling Towers.
Instruments Required
(i)
Mechanically aspirated psychrometer for measuring Wet Bulb

Temperature.
(ii)
Dry Bulb Thermometers.
(iii)
Anemometer for measuring wind speed and Cooling Tower Air

Flow.
(iv)
Pitot Tube for measuring water velocity to determine Water flow.
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(v)
Mercury in Glass Thermometers or RTDs for measuring hot and

cold water temperatures.
(vi)
Watt meter for measuring power consumed by the Fan Motor.
Following relationships are used for determining important parameters:

Cooling Range = Hot Water Temperature at Inlet Cold Water Temperature at Outlet.
Cooling Tower Approach = Cold Water Temperature at Outlet Wet Bulb Temperature.
Range
Range +Approach
Effectiveness % =
Fan Air Flow Actual (NM3/h) Per Cell =
x100
Rated Fan Flow (Nm3/h)x (Fan Input kW Actual)1/3

(Fan Input Rated)1/3
Air Mass Flow Per Cell = Air Flow x Density of Air
L/G Ratio =
Water Flow in kg/h

Air Flow in kg/h
Evaporation Loss =
Cooling Water Flow (m3/h)x Cooling Tower Range in 0C

675
Based upon the actual test data, the predicted re-cooled water
temperature is determined from the performance curves provided by the
manufacturer. The deviation is analyzed and corrective action is planned
to remove the deviation.
Note:
To simplify the evaluation of test results and to minimize the chances of
errors, blow down and make up is stopped during the time of testing.
Document Number
LII-GETS12021-G-00100-005
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{PERFORMANCE TEST OF COMPRESSED AIR SYSTEM}

Performance of air compressors and compressed air system deteriorates
with the passage of time. During the Energy Audit, the capacity of the air
compressor as well as the leakages in the system should be checked.
FREE AIR DELIVERY (FAD) TEST
This test is to be conducted to assess the actual output of the
compressor. The procedure of conducting the test is as follows:
Isolate the compressor along with its individual receiver being

taken for test from main compressed air system by tightly closing
the isolation valve or blanking the receiver outlet. Ensure that the
valves are closed completely.
Check the pressure gauge and the temperature gauge installed for
the air receiver for calibration and working status.
Open water trap drain outlet and empty the receiver and the
pipeline. Make sure that water trap line is tightly closed once again
to start the test.
Start the compressor and activate the stopwatch
Note the time to attain the normal generated pressure P2 (in the
receiver) from initial pressure P1.
Measure the temperature of ambient and compressed air (receiver)

Calculate the capacity as per the formula given below:
Actual Free Air Discharge:
Q =
Where,
Q
:
P2
:
P1
:
:
P0
V
:
T
:
(P2 P1)
P0
V
T
Actual free air discharge (m3/min)

Final pressure after filling (kg/cm2a)
Initial pressure (kg/cm2a) after bleeding
Atmospheric pressure (kg/cm2a)
Receiver and connected pipe volume in m3
Time taken to build up pressure to P2 in minutes
The above equation is relevant where the compressed air temperature is

same as the ambient air temperature, i.e. perfect isothermal compression.
In case the actual compressed air temperature at discharge, say t2 0C is
higher than ambient air temperature say t1 0C (as is the usual case), the
FAD is to be corrected by a factor (273 + t1) / (273 + t2).
Once the actual output is assessed, then it should be compared with
rated output. If any deviation is found then the various factors causing
deviation should be investigated to arrive at the remedial measures to
improve the performance.
Efficiency Calculation
Calculate the ideal kW as per formula given below:
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[79]
26.09.2013
Ideal Power kW=
Where,
N
:
K
:
Ps
:
Pd
:
Q
:
NK
K-1
Q * Ps
0.612
Pd
Ps
[LOGO OF
UTILITY]
K
(K-1)/NK
-1
No. of stages
Ratio of Specific Heat (1.35 for air)
Suction Pressure in kg / cm2g
Discharge pressure in kg / cm2g
Actual fir flow (m3/min)
Measure the actual kW during steady state load condition.

Calculate the actual efficiency
Ideal kW
=
Actual kW
Compare the actual with the design efficiency. If any deviation is found
then the various factors causing deviation should be investigated to arrive
at the remedial measures to improve the efficiency.
Method of checking the leakages in the System:
Loud leaks can be spotted without the aid of an ultrasonic leak detector
while walking across the route of compressed air pipelines. Check the rags
placed over the pipes to reduce the noise level of large scale leaks. Check
all the drain traps. Small leaks can be traced with the help of ultrasonic
leak detector.
For checking the rate of leakage in a given system, all the isolating valves
at supply points and the drain traps should be closed. The normal
operating pressure should be established in the air receiver and the
compressor should be stopped. The fall in the air pressure of the receiver
should be monitored over a period of time. The rate of leakage in the
system can be worked out by the following formula.
*
****************************
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[80]
26.09.2013
[LOGO OF
UTILITY]
{Performance Test of Air Conditioning System}

Evaluation of net refrigeration capacity and specific energy consumption
The test shall include a measurement of the net heat removed from the
water as it passes through the evaporator by determination of the
following:
1.
Water flow rate
2.
Temperature difference between entering and leaving water
The heat removed from the chilled water is equal to the product of the
chilled water flow rate, the water temperature difference, and the specific
heat of the water.
The net refrigeration capacity in tons shall be obtained by the following
equation:
m x cp x (Tin-Tout)
3024
Net refrigeration capacity (TR) =
Where
m
- Mass flow rate of chilled water, m3/hr
Cp
- Specific heat, kcal/kg oC
Tin
- Chilled water temperature at evaporator inlet oC
Tout
- Chilled water temperature at evaporator outlet oC
The accurate temperature measurement is very vital in refrigeration and

air conditioning and therefore least count of temperature measured should
be at least to one decimal place.
After arriving at net refrigerating capacity, the specific energy
consumption can be arrived at by measuring power consumption.
kW input to the motor
Net refrigeration effect in TR
Specific power consumption , kW/TR =
The compressor power can be measured by a portable power analyzer,

which would give reading directly in kW.
Other specific energy parameter is,
Co-efficient of Performance COP=
Refrigeration effect in kW
Motor input power
Performance evaluation of Air Handling Units (AHU)

Performance of air handling units needs to be evaluated for the following:
TR of AHU (Heat load)
No of air changes of fresh air supply
Air flow rate
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[81]
26.09.2013
[LOGO OF
UTILITY]
Operating parameters
For centralized air conditioning systems the airflow at the air-handling unit
(AHU) can be measured with an anemometer. The dry bulb and RH can
be measured at the AHU inlet and outlet by using thermal hygrometer.
The data can be used along with a psychrometric chart (now a software
is available) to determine the enthalpy (heat content of air at the AHU
inlet and outlet).
Heat load (TR) =
m x (hin hout)
4.18x3024
Where:
m
- Mass flow rate of air, kg/hr
hin
- Enthalpy of inlet air at AHU, kj/kg
hout
- Enthalpy of outlet air at AHU, kj/kg
Power Consumption of Auxiliaries:

Measure all electrical parameters of air conditioning auxiliaries such as
pumps, fans and blowers.
Tabulate the measured parameters
Evaluate specific energy consumption
Compare above measurement with respective design / best achieved
values.
****************************
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[82]
26.09.2013
[LOGO OF
UTILITY]
{AUDIT OF WATER CONSUMPTION}

In thermal power stations, monitoring and auditing of specific water
consumption (litres/kwh) should also be done similar to the monitoring of
specific coal consumption or specific oil consumption.
Requirement of water in a thermal power station is mainly for the
following areas:i)
Water requirement for Boiler make up.
ii)
Cooling water for Condenser and Heat Exchangers etc.
iii) Make up water for evaporation and blow down loss from cooling
tower.
iv) Water requirement for ash disposal.
v)
Water requirement for coal dust suppression.
vi) Service water for washing and cleaning purposes.

vii) Drinking water supply.
Auditing of Water Consumption
Auditing of water consumption should be carried out periodically and as
frequently as possible for each of the systems covered in the water
balance diagram. Effort should be made to conserve the usage of water.
Guidelines for conserving water
A few guidelines are mentioned below for minimizing specific water
consumption in the power plants:
i)
Increasing the Cycle of Concentration (COC) in Condenser cooling

water system in closed cycle.
ii)
Increasing the ash concentration in the wet ash disposal system.
iii)
Recycling of water from the wet ash disposal system.
iv)
Adopting of dry fog dust suppression system for coal handling plant.
v)
Checking of leakages from water pipe joints and water taps.
vi)
Treatment and recycling of waste water.
vii)
Rain water harvesting
viii) Adopting zero discharge system.
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[83]
26.09.2013
[LOGO OF
UTILITY]
{Guidelines for the Energy Audit of Thermal Insulation}

In thermal power plants, thermal insulation is provided for the following
purposes;
To minimize the heat loss to environment from the hot surfaces of
pipes and equipment specially carrying steam and hot water.
To minimize heat gain from environment to the cold surfaces of Air
Conditioning System.
To protect the working personnel.
Thermal insulation is normally provided for the following systems in the
thermal power plants:
Piping and equipment carrying steam and hot water e.g. Boiler &
Auxiliaries, Steam Turbine & Auxiliaries and Feed Water System.
Heat tracings for Fuel Oil Systems.
Chimney.
Air Conditioning System.
Generally, it is the avoidable heat loss from the damaged insulation of hot
surfaces, which matters most in the thermal power plants. For carrying
out energy audit for the thermal insulation system, the condition of the
insulation should be inspected and surface temperatures of hot spot areas
having damaged insulation, should be measured with the help of infrared
temperature indicator. Where the surface temperature is more than 600 C,
the estimated heat loss should be calculated. The formula for calculating
the Heat Loss or gain from the bare and un-insulated surfaces is indicated
below.
H = h x A x (ThTa)
Where,
H
A
h
Th
= Heat loss/ Heat gain in Watts.

= Outside Area in m2.
= Heat transfer coefficient, W/m2K
= Hot surface temperature (for hot fluid piping) & Cold surface
temperature for cold fluids piping in C.
Ta = Average ambient temperature, C
For horizontal pipes, heat transfer coefficient can be calculated by:

h = (B + 0.005 (Th Ta)) 10 W/m2-K
For vertical pipes, heat transfer coefficient can be calculated by:
h = (C+ 0.009 (Th Ta)) 10 W/m2-K
The values of the coefficients B & C are given in the table below.
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[84]
26.09.2013
Surface
Aluminum, Bright Rolled.
0.25
0.27
Aluminum, Oxidized.
0.31
0.33
Steel
0.32
0.34
Galvanized Sheet Metal
0.53
0.55
Non Metallic Surfaces
0.85
0.87
[LOGO OF
UTILITY]
The material and thickness of appropriate Insulation material has to be

worked out so that after the application of insulation, the surface
temperature does not exceed 600C.
The potential saving in heat loss can be worked out by calculating the
heat loss with surface temperature as 600C and subtracting it from the
Heat Loss from the bare and un-insulated surface calculated above.
The cost of replacing the damaged insulation should then be compared
with the expected savings in the cost of fuel, to work out the payback
period
****************************
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[85]
26.09.2013
[LOGO OF
UTILITY]
{Guidelines for the Energy Audit of illumination System}

The illumination System is provided in various areas of the Power Plant
for rendering comfortable working environment. The primary objective
should be to provide the required intensity of lighting at the lowest power
consumption.
Annexure -A indicates the recommended average illumination levels (lux
level) for different areas of the power plant as well as the suggested type
of luminaries to be used.
The purpose of energy audit of any illumination system, therefore, is to
identify the illumination deficient areas and the areas where energy loss is
taking place due to the usage of inefficient luminaries and to recommend
the improvement option.
Measuring Instruments Required
Power Analyzer for measuring electrical parameters such as kW,

kVA, pf, V, A and Hz .
LUX meters.
Measuring tape.
On line energy metering instruments (calibrated)
Method of Energy Audit

For the determination of the number of measurement points and their
locations, first of all Room Index (RI) is calculated for each area, by using
the expression:
RI = L x W
Hm (L+W)
Where,
L = length of interior;
W = width of interior;
Hm = the mounting height of the lighting fittings above the horizontal
working plane.
Depending upon the Room Index (RI), the number of measuring points in
the given area is determined from the values given in the Table-1 below.
Table-1
Number of Measuring Points
Room Index (RI)

Below 1
Between 1&2
Document Number
LII-GETS12021-G-00100-005
16
Rev
No.
Description
Page
No.
Date of Issue
02
[86]
26.09.2013
Between 2&3
25
3 and above
36
[LOGO OF
UTILITY]
Depending upon the number of measuring points, the interior is divided

into a number of equal areas, which should be as square as possible. The
illumination at the centre of each area is measured with lux meter and the
mean value is calculated. By also measuring the power consumed,
Installed Load Efficacy (ILE) of the system can be worked out in terms of
lux/watt/m2. This gives an estimate of the actual illumination on the
horizontal working plane. The working plane is usually assumed to be
0.75m above the floor in the offices and at 0.85m above floor level in
equipment areas.
The ratio of ILE to the target value of lux/watt/m is defined as the
Installed Load Efficacy Ratio (ILER).
i.e. ILER = Actual lux/watt/m2
Target lux/watt/m2
The target values of lux/watt/m2 may be taken from the values given in
the Table - 2 which are based on the advanced type of luminaries being
used in the industry.
Table - 2
Room Index (RI)
Target lux/watt/m2
5
53
52
50
2.5
48
46
1.5
43
1.25
40
36
Annual energy loss of any illumination system can then be worked out by
the following expression.
Annual energy loss (kWh) = (1 - ILER) x watts consumed x no. of operating hrs / year.
1000
The above method is summarized below in the form of steps.
STEP -1: Measure the floor area of the interior in m2.
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[87]
26.09.2013
[LOGO OF
UTILITY]
STEP- 2: Calculate the Room Index (RI)

STEP-3: Determine the total circuit watts of the installation by a power
meter if a separate feeder for lighting is available. If a separate
feeder for lighting is not available, a reasonable approximation
can be obtained by totaling up the lamp wattages including the
ballasts.
STEP-4: Calculate Watts consumed per square metres (W/m) by
dividing the Value of Step 3 by the value of Step 1.
STEP -5: Ascertain the average maintained lux level, by using lux meter.
STEP-6: Divide the Value of step 5 by the Value of step 4 to calculate
Actual value of Lux/W/m.
STEP-7: Obtain Target value of Lux/W/m for the given RI from the
values given in the Table-2 above.
STEP-8: Calculate Installed Load Efficacy Ratio (ILER) by Dividing the
Value of step 6 by the value of step 7.
STEP -9: Calculate the Annual Energy Loss.
****************************
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[88]
26.09.2013
[LOGO OF
UTILITY]
ANNEXURE-A
THE AREA-WISE AVERAGE ILLUMINATION LEVELS AND TYPE OF LUMINARIES
S. NO.
1.
LOCATION
Control Rooms /
Conference Room
AVERAGE
LUX LEVEL
LIGHTING FIXTURE TYPE
Energy Efficient FTL in Decorative fittings 500

with wide angle mirror optic antiglare
reflector.
OR
Decorative Compact fluorescent tube
(CFL) fitting with internal mirror reflector
with mounting bracket suitable for
1x18W/ 1 x 22W/ 1x25W lamps.
2.
Office / Conference
room
Decorative recessed type energy efficient

2 x 40 FTL with mirror reflector.
300
OR
1x18W/ 1 x 22W/ 1x25W lamps.
For rooms without false ceiling, surface
mounted fixtures shall be used.
3.
Testing
Laboratories
Energy Efficient FTL in Decorative fittings 400

with wide angle mirror optic antiglare
reflector.
OR
1x18W/ 1 x 22W/ 1x25W lamps.
4.
Work shop Building
High fittings 150W/250W HPSV
300
5.
Transformer area,
Switchyard area,
outdoor yard area
Dust & weather proof 70 W HPSV well

glass fitting with reflector and integral
mounted control gear.
50
6.
Indoor GIS
Buildings
High Bay fittings 400W/250W HPSV
300
7.
Air Compressor
Energy efficient 2x40 W FTL industrial
200
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[89]
26.09.2013
S. NO.
LOCATION
AVERAGE
LUX LEVEL
Plant
type with vitreous enamel finish (pendant

/ bracket mounting
8.
Silo surrounding
areas, Silo
Platforms
Dust and weather proof 70W HPSV well

100
9.
Pump Houses
High / medium Bay fittings - 250/400W

HPSV
200
10.
Battery Room
Energy efficient 2X40 W FTL industrial

type Corrosion proof with vitreous
enamel finish (pendant / bracket
mounting (Explosion Protected)
150
11.
Air Conditioning
Plant Room

/ bracket mounting
200
12.
AHU Room

/ bracket mounting
200
13.
Switchgear/MCC/El Energy efficient 2x40 W FTL industrial

ectrical & Electronic type with vitreous enamel finish (pendant
equipment Rooms
/ bracket mounting
200
14.
Elevator M/C Room

/ bracket mounting
100
15.
Cable spreader
Area

type with vitreous enamel finish
100
16.
Chlorination
Building /
Chlorinator Room
Acid/ Corrosion proof CFL light fixture
200
17.
Chemical storage
Room
18.
Conveyors
(exposed)
70 W HPSV lamps Dust & Vapour proof

increased safety well glass with reflector
wire guard, integral mounted control gear
50
19.
Conveyors
(enclosed)
150 W HPSV lamps Dust & Vapour proof

100
Document Number
LII-GETS12021-G-00100-005
[LOGO OF
UTILITY]
150
Acid/ Corrosion proof CFL light fixture
Rev
No.
Description
Page
No.
Date of Issue
02
[90]
26.09.2013
S. NO.
LOCATION
[LOGO OF
UTILITY]
AVERAGE
LUX LEVEL

20.
Crusher House
Screen Houses
Junction towers
70 / 150W HPSV - Dust & Vapour proof

200
1 X 400W HPSV - General Purpose

Flood Light
20
21.
Coal / Lignite stock

Yard (open Area)
22.
Coal / Lignite stock 1 X 400W HPSV - MH General Purpose

yard (covered
Flood light Medium beam
Area), stacker and
reclaimer
25-50
23.
Oil Room and

indoor hazardous
areas
1 x 70 W HPMV Flame proof well glass

fixture
150
24.
Passage, Indoor
Stair case , Toilet
etc
Energy efficient 2x20/40 W FTL

industrial type with vitreous enamel
finish
100-150
25.
Outdoor/Semi
outdoor stairs
Dust & weather proof 70 W HPSV well

70
26.
Street / roads &

periphery lighting
150W/250W HPSV street / roads light

fittings
20
27.
Building periphery
lighting
150W/250W HPSV Outdoor/building

periphery light fitting with integral
mounted control gear/industrial bulk head
with integral mounted control gear/ flood
light fittings
100
28.
Approach roads
150 W HPSV Street / roads light fitting

with clear acrylic cut off type with
integral mounted control gear
50
29.
Hydrogen Plant
Indoor hazardous
areas
Document Number
LII-GETS12021-G-00100-005
1 x 70 W HPMV Flame proof well glass

fixture
150
Rev
No.
Description
Page
No.
Date of Issue
02
[91]
26.09.2013
[LOGO OF
UTILITY]
Appendix-1
ENERGY AUDIT REPORT FOR BOILER
S.No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Type
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
MW
[]
[]
[]
kg/cm2
[]
[]
[]
Unit Load
Main Steam Pressure
3.
Main Steam
Temperature
[]
[]
[]
4.
Re-heat Temperature
[]
[]
[]
5.
Oxygen in flue gas
[]
[]
[]
Air preheater flue

gas outlet
temperature
[]
[]
[]
Main Steam Flow
TPH
[]
[]
[]
Economizer Inlet
Feed Water
Temperature
[]
[]
[]
Calorific Value
GCV
kCal/Kg
[]
[]
[]
10
Number of Mills in
Operation
Nos
[]
[]
[]
11
ID Fan Margin
[]
[]
[]
12
Furnace Draft
mmwc
[]
[]
[]
13
Superheater Spray
TPH
[]
[]
[]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[92]
26.09.2013
S.No.
Description
[LOGO OF
UTILITY]
Unit
Design
Value
Operating
Value
Deviation
(%)
TPH
[]
[]
[]
14
Reheater Spray
15
Type of Mills
[]
16
Type of Feeder
[]
17
No.of ESP fields

working
[]
18
Dry Flue Gas Loss
[]
[]
[]
19
Loss due to
Hydrogen in Fuel
[]
[]
[]
20
Loss due to Moisture

in Fuel
[]
[]
[]
21
Loss Due to Unburnt Carbon
[]
[]
[]
22
Radiation Loss
[]
[]
[]
23
Total Loss
[]
[]
[]
24
Efficiency
[]
[]
[]
Observations:
[
]
Recommendations:
[
.]
Cost Benefit Analysis:
[Calculations for the cost benefit analysis are attached. The results of analysis are
Estimated Investment (Rs.)
Estimated Increase in Efficiency

(%)
[]
[]
Payback Period (Years)

[]
[Based on the cost benefit analysis, it is recommended to take up the R&M Measures]
[Signature ]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[93]
26.09.2013
[LOGO OF
UTILITY]
Appendix-2
ENERGY AUDIT REPORT FOR AIR PREHEATER (A/B)
S.No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Type
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
Ambient
Temperature
[]
[]
[]
Temperature of Air
entering the air
heater
[]
[]
[]
Temperature of gas
entering the air
heater
[]
[]
[]
Temperature of gas
leaving the air heater
[]
[]
[]
Percent O2 in flue
gas entering air
heater
[]
[]
[]
Percent O2 in flue
gas leaving air
heater
[]
[]
[]
Air preheater
Leakage
[]
[]
[]
Gas Side Efficiency
[]
[]
[]
Observations:
[
.]
Recommendations:
[
]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[94]
26.09.2013
[LOGO OF
UTILITY]

(%)
[]
[]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[95]
26.09.2013
[LOGO OF
UTILITY]
Appendix-3
ENERGY AUDIT REPORT FOR PA FAN (A/B)
S.No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Control
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
MW
[..]
[..]
[..]
m3/sec
[..]
[..]
[..]
Pa
[..]
[..]
[..]
Load
Flow Rate
Discharge Pressure
Current
Amps
[..]
[..]
[..]
Speed
RPM
[..]
[..]
[..]
Power consumption
KW
[..]
[..]
[..]
Mechanical
Efficiency
[..]
[..]
[..]
Combined Efficiency
of Fan & Motor
[..]
[..]
[..]
Observations:
[
.]
Recommendations:
[
.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[96]
26.09.2013
[LOGO OF
UTILITY]


(%)
[]
[]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[97]
26.09.2013
[LOGO OF
UTILITY]
Appendix-4
ENERGY AUDIT REPORT FOR FD FAN (A/B)
S.No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Control
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
MW
[]
[]
[]
Pa
[]
[]
[]
m3/sec
[]
[]
[]
Load
Furnace Draft
Flow
Suction Pressure
Pa
[]
[]
[]
Discharge Pressure
Pa
[]
[]
[]
Total Head
Developed
Pa
[]
[]
[]
Discharge Air
Temperature
[]
[]
[]
Current
Amps
[]
[]
[]
Speed
RPM
[]
[]
[]
10
Power consumption
kW
[]
[]
[]
11
Efficiency
[]
[]
[]
Observations:
[
.]
Recommendations:
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[98]
26.09.2013
[LOGO OF
UTILITY]
]

(%)
[]
[]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[99]
26.09.2013
[LOGO OF
UTILITY]
Appendix-5
ENERGY AUDIT REPORT FOR ID FAN (A/B/C)
S.No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Control
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
MW
[]
[]
[]
Pa
[]
[]
[]
m3/sec
[]
[]
[]
Load
Furnace Draft
Flow
Suction Pressure
Pa
[]
[]
[]
Discharge Pressure
Pa
[]
[]
[]
Discharge Flue Gas

Temperature
[]
[]
[]
Current
Amps
[]
[]
[]
Speed
RPM
[]
[]
[]
Power consumption
kW
[]
[]
[]
10
Efficiency
[]
[]
[]
Observations:
[
.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[100]
26.09.2013
[LOGO OF
UTILITY]
Recommendations:
[
.]

(%)
[]
[]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[101]
26.09.2013
[LOGO OF
UTILITY]
Appendix-6
ENERGY AUDIT REPORT FOR MILL (A/B/C/D/E/F/G/H)
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Type (Ball, Bowl, Ball&Race)[..]
S.No.
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
Unit Load
MW
[]
[]
[]
Frequency
Hz
[]
[]
[]
TPH
[]
[]
[]
Mill Capacity/
Throughput
Furnace Draft
mmwc
[]
[]
[]
Mill Motor Speed
RPM
[]
[]
[]
Mill Differential
Pressure
mmwc
[]
[]
[]
Mill Current
Amps
[]
[]
[]
Mill Power
Consumption / ton
of coal
kW/ton
[]
[]
[]
Calorific Value of
Mill reject
kCal/kg
[]
[]
[]
10
Classifier Position
[]
[]
[]
11
Air to Coal ratio
Fineness
Analysis
Delivery Port-1
Tons/Tons
Delivery Port-2
Delivery Port-3
Delivery Port-4
+50 Mesh
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[102]
26.09.2013
Fineness
Analysis
Delivery Port-1
Delivery Port-2
Delivery Port-3
[LOGO OF
UTILITY]
Delivery Port-4
200 Mesh
Observations:
[
.]
Recommendations:
[
.]

(%)
[]
[]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[103]
26.09.2013
[LOGO OF
UTILITY]
Appendix-7
ENERGY AUDIT REPORT FOR TURBINE
S.No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Type
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
Load
MW
[]
[]
[]
Auxiliary
Consumption
MW
[]
[]
[]
Main Steam
Pressure Before ESV
kg/cm2
[]
[]
[]
Main Steam
Temperature before
ESV
[]
[]
[]
CRH Pressure
[]
[]
[]
CRH Temperature
[]
[]
[]
HRH Pressure
kg/cm2
[]
[]
[]
HRH Temperature
[]
[]
[]
IPT Exhaust
Temperature
[]
[]
[]
10
Turbine Exhaust
Temperature
[]
[]
[]
11
Condenser back
pressure
[]
[]
[]
12
SH Spray Flow
TPH
[]
[]
[]
13
RH Spray Flow
TPH
[]
[]
[]
14
Feed Water Flow
TPH
[]
[]
[]
Document Number
LII-GETS12021-G-00100-005
kg/cm2
kg/cm2
Rev
No.
Description
Page
No.
Date of Issue
02
[104]
26.09.2013
15
Feed Water
Temperature
16
Soot Blowing Steam

Flow
17
[LOGO OF
UTILITY]
[]
[]
[]
TPH
[]
[]
[]
HP Turbine
Efficiency
[]
[]
[]
18
[]
[]
[]
19
LP Turbine
Efficiency
[]
[]
[]
20
Turbine Heat Rate
kCal/Kwh
[]
[]
[]
21
Gross Heat Rate
kCal/Kwh
[]
[]
[]
Observations:
[
.]
Recommendations:
[
.]

(%)
[]
[]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[105]
26.09.2013
[LOGO OF
UTILITY]
Appendix-8
ENERGY AUDIT REPORT FOR CONDENSER (A/B)
S.No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Type
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
Number of cooling
tubes
Nos
[]
[]
[]
Cooling surface area
M2
[]
[]
[]
Cooling water flow
TPH
[]
[]
[]
CW I/L temperature
[]
[]
[]
CW O/L temperature
[]
[]
[]
Back Pressure
kg/cm2
[]
[]
[]
Hot well
Temperature
[]
[]
[]
Length of cooling
tubes
MM
[]
[]
[]
Diameter of cooling
tubes
MM
[]
[]
[]
10
Turbine exhaust
hood temperature
[]
[]
[]
11
Condenser TTD
[]
[]
[]
12
LMTD
[]
[]
[]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[106]
26.09.2013
[LOGO OF
UTILITY]
Observations:
[
.]
Recommendations:
[
.]

(%)
[]
[]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[107]
26.09.2013
[LOGO OF
UTILITY]
Appendix-9
ENERGY AUDIT REPORT FOR LP HEATERS (No.1/2/3/4/5)
S.No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Type
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
Saturation
temperature of
extraction steam
[]
[]
[]
Temp of feed water

at Heater Outlet
[]
[]
[]
Temperature of
heater drip
[]
[]
[]
Temp of feed water

at Heater Inlet
[]
[]
[]
TTD of heater
[]
[]
[]
DCA of heater
[]
[]
[]
Observations:
[
.]
Recommendations:
[
.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[108]
26.09.2013

(%)
[]
[]
[LOGO OF
UTILITY]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[109]
26.09.2013
[LOGO OF
UTILITY]
Appendix-10
ENERGY AUDIT REPORT FOR HP HEATERS (No.5/6/7)
S.No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Type
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
Saturation
temperature of
extraction steam
[]
[]
[]
Temp of feed water

at Heater Outlet
[]
[]
[]
Temperature of
heater drip
[]
[]
[]
Temp of feed water

at Heater Inlet
[]
[]
[]
TTD of heater
[]
[]
[]
DCA of heater
[]
[]
[]
Observations:
[
.]
Recommendations:
[
.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[110]
26.09.2013

(%)
[]
[]
[LOGO OF
UTILITY]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[111]
26.09.2013
[LOGO OF
UTILITY]
Appendix-11
ENERGY AUDIT REPORT FOR BOILER FEED PUMP (No.1/2/3)
S.No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Type
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
Load
MW
[]
[]
[]
Feed water
temperature to BFP
Inlet
[]
[]
[]
Feed water
temperature to BFP
Outlet
[]
[]
[]
Feed water pressure

to BFP inlet
kg/cm2
[]
[]
[]
Feed water pressure

to BFP outlet
kg/cm2
[]
[]
[]
Speed
RPM
[]
[]
[]
Current
Amps
[]
[]
[]
Power
kW
[]
[]
[]
Capacity
TPH
[]
[]
[]
10
Efficiency
[]
[]
[]
Observations:
[
.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[112]
26.09.2013
[LOGO OF
UTILITY]
Recommendations:
[
.]

(%)
[]
[]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[113]
26.09.2013
[LOGO OF
UTILITY]
Appendix-12
ENERGY AUDIT REPORT FOR CONDENSATE EXTRACTION PUMP (No.1/2/3)
S.No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Type
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
Load
MW
[]
[]
[]
Feed water
temperature to CEP
Inlet
[]
[]
[]
Feed water
temperature to CEP
Outlet
[]
[]
[]
Feed water pressure

to CEP inlet
kg/cm2
[]
[]
[]
Feed water pressure

to CEP outlet
kg/cm2
[]
[]
[]
RPM
RPM
[]
[]
[]
Current
Amps
[]
[]
[]
Power
kW
[]
[]
[]
12
Capacity
TPH
[]
[]
[]
13
Minimum flow
recommended
TPH
[]
[]
[]
15
Efficiency
[]
[]
[]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[114]
26.09.2013
[LOGO OF
UTILITY]
Observations:
[
]
Recommendations:
[
.]

(%)
[]
[]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[115]
26.09.2013
[LOGO OF
UTILITY]
Appendix-13
ENERGY AUDIT REPORT FOR CW PUMP (No.1/2/3)
S.No.
Equipment
[..]
Plant Name
[..]
Capacity
[..]
Owner
[..]
Date
[..]
Time
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
Capacity
TPH
[]
[]
[]
Total dynamic head
mwc
[]
[]
[]
Speed
RPM
[]
[]
[]
Current
Amps
[]
[]
[]
Power
kW
[]
[]
[]
[]
[]
[]
Efficiency
Observations:
[
]
Recommendations:
[
.]

(%)
[]
[]

[]
[Based on the cost benefit analysis, it is recommended / not recommended to take up

the R&M Measures]
[Signature ]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[116]
26.09.2013
[LOGO OF
UTILITY]
Appendix-14
ENERGY AUDIT REPORT FOR COOLING TOWER
S.No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Type
[..]
Description
Unit
Design
Value
Operating
Value
Deviation
(%)
Ambient Wet Bulb

Temp
[]
[]
[]
Ambient Dry Bulb

Temp
[]
[]
[]
Inlet Wet Bulb Temp
[]
[]
[]
Flow
m3/hr
[]
[]
[]
Hot Water Temp
[]
[]
[]
Recooled Water
Temp
[]
[]
[]
Power Consumption
kW
[]
[]
[]
[]
[]
[]
Efficiency
Observations:
[
.]
Recommendations:
[
.]

Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[117]
26.09.2013
[LOGO OF
UTILITY]

(%)
[]
[]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[118]
26.09.2013
[LOGO OF
UTILITY]
Appendix-15
ENERGY AUDIT REPORT FOR PLANT AIR COMPRESSOR (No.1/2/3)
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Type
[..]
S.No.
Description
Units
Design
Values
Operating
Value
Deviation
(%)
.
1
Atmospheric
pressure
Bar
[]
[]
[]
Relative
humidity
[]
[]
[]
Dry bulb
temperature
[]
[]
[]
Saturated
vapour
pressure
kg/cm2
[]
[]
[]
Partial vapour
pressure
kg/cm2
[]
[]
[]
Suction
pressure
kg/cm2
[]
[]
[]
Pressure
reading at start
kg/cm2
[]
[]
[]
Pressure
reading at finish
kg/cm2
[]
[]
[]
Final
temperature
[]
[]
[]
10
Volume of
receiver
m3
[]
[]
[]
11
Volume of pipes
m3
[]
[]
[]
12
Total volume
m3
[]
[]
[]
13
Time of filling
Sec
[]
[]
[]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[119]
26.09.2013
S.No.
[LOGO OF
UTILITY]
Description
Units
Design
Values
Operating
Value
Deviation
(%)
14
Free air delivery
m3/hr
[]
[]
[]
15
Measured
capacity
Nm3/hr
[]
[]
[]
16
Power
consumption
kW
[]
[]
[]
17
KW rating
kW
[]
[]
[]
Observations:
[
.]
Recommendations:
[
.]

(%)
[]
[]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[120]
26.09.2013
[LOGO OF
UTILITY]
Appendix-16
ENERGY AUDIT REPORT FOR INSTRUMENT AIR COMPRESSOR (No.1/2/3)
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Make
[..]
Type
[..]
S.No.
Description
Units
Design
Values
Operating
Value
Deviation
(%)
.
1
Atmospheric
pressure
Bar
[]
[]
[]
Relative
humidity
[]
[]
[]
Dry bulb
temperature
[]
[]
[]
Saturated
vapour
pressure
kg/cm2
[]
[]
[]
Partial vapour
pressure
kg/cm2
[]
[]
[]
Suction
pressure
kg/cm2
[]
[]
[]
Pressure
reading at start
kg/cm2
[]
[]
[]
Pressure
reading at finish
kg/cm2
[]
[]
[]
Final
temperature
[]
[]
[]
10
Volume of
receiver
m3
[]
[]
[]
11
Volume of pipes
m3
[]
[]
[]
12
Total volume
m3
[]
[]
[]
13
Time of filling
Sec
[]
[]
[]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[121]
26.09.2013
S.No.
[LOGO OF
UTILITY]
Description
Units
Design
Values
Operating
Value
Deviation
(%)
14
Free air delivery
m3/hr
[]
[]
[]
15
Measured
capacity
Nm3/hr
[]
[]
[]
16
Power
consumption
kW
[]
[]
[]
17
kW rating
kW
[]
[]
[]
Observations:
[
.]
Recommendations:
[
.]

(%)
[]
[]

[]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[122]
26.09.2013
[LOGO OF
UTILITY]
Appendix-17
ENERGY AUDIT REPORT FOR THERMAL INSULATION
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
S.No.
Description
of Piping/
Equipment
Body
Surface
Temperature
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
10
[.]
[.]
[.]
[.]
[.]
11
[.]
[.]
[.]
[.]
[.]
12
[.]
[.]
[.]
[.]
[.]
13
[.]
[.]
[.]
[.]
[.]
14
[.]
[.]
[.]
[.]
[.]
15
[.]
[.]
[.]
[.]
[.]
16
[.]
[.]
[.]
[.]
[.]
Document Number
LII-GETS12021-G-00100-005
(0C)
Heat Saving
Potential
Cost Impact
Payback
Period
(Watts/m2)
Rev
No.
Description
Page
No.
Date of Issue
02
[123]
26.09.2013
S.No.
Description
of Piping/
Equipment
Body
Surface
Temperature
17
[.]
[.]
[.]
[.]
[.]
18
[.]
[.]
[.]
[.]
[.]
19
[.]
[.]
[.]
[.]
[.]
20
[.]
[.]
[.]
[.]
[.]
(0C)
Heat Saving
Potential
Cost Impact
[LOGO OF
UTILITY]
Payback
Period
(Watts/m2)
Observations:
[
.]
Recommendations:
[
.]
[Calculations for the cost benefit analysis for each of the recommended improvement
options are attached.]
[Signature]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[124]
26.09.2013
[LOGO OF
UTILITY]
Appendix-18
ENERGY AUDIT REPORT FOR ILLUMINATION SYSTEM
S. No.
Plant Name
[..]
Work Order Number
[..]
Test Report Number
[..]
Owner
[..]
Unit Number
[..]
Unit Capacity
[..]
Date
[..]
Location
Actual
lux/W/m2
Target
lux/W/m2
Energy Loss
Saving
Potential
kWh/Annum
Cost
Impact
Payback
Period
1.
Control Room.
[..]
[..]
[..]
[.]
[.]
2.
Conference Room
[..]
[..]
[..]
[.]
[.]
3.
Administrative
Office
[..]
[..]
[..]
[.]
[.]
4.
Conference room
[..]
[..]
[..]
[.]
[.]
5.
Testing Laboratory
[..]
[..]
[..]
[.]
[.]
6.
Work shop Building
[..]
[..]
[..]
[.]
[.]
7.
Transformer area,
[..]
[..]
[..]
[.]
[.]
8.
Switchyard area
[..]
[..]
[..]
[.]
[.]
9.
Outdoor yard area
[..]
[..]
[..]
[.]
[.]
10.
Indoor GIS
Buildings
[..]
[..]
[..]
[.]
[.]
11.
Air Compressor
Plant
[..]
[..]
[..]
[.]
[.]
12.
Silo surrounding
areas
[..]
[..]
[..]
[.]
[.]
13.
Silo Platforms
[..]
[..]
[..]
[.]
[.]
Document Number
LII-GETS12021-G-00100-005
Rev
No.
Description
Page
No.
Date of Issue
02
[125]
26.09.2013
S. No.
Location
Actual
lux/W/m2
Target
lux/W/m2
[LOGO OF
UTILITY]
Energy Loss
Saving
Potential
kWh/Annum
Cost
Impact
Payback
Period
14.
CW Pump House
[..]
[..]
[..]
[.]
[.]
15.
Battery Room
[..]
[..]
[..]
[.]
[.]
16.
Air Conditioning
Plant Room
[..]
[..]
[..]
[.]
[.]
17.
AHU Room
[..]
[..]
[..]
[.]
[.]
18.
Switchgear Room
[..]
[..]
[..]
[.]
[.]
19.
Electrical &
Electronic
equipment Room
[..]
[..]
[..]
[.]
[.]
20.
Elevator M/C Room
[..]
[..]
[..]
[.]
[.]
21.
Cable spreader
Area
[..]
[..]
[..]
[.]
[.]
22.
Chlorination
Building
[..]
[..]
[..]
[.]
[.]
23.
Chlorinator Room
[..]
[..]
[..]
[.]
[.]
24.
Chemical storage
Room
[..]
[..]
[..]
[.]
[.]
25.
Conveyors
(exposed)
[..]
[..]
[..]
[.]
[.]
26.
Conveyors
(enclosed)
[..]
[..]
[..]
[.]
[.]
27.
Crusher House
[..]
[..]
[..]
[.]
[.]
28.
Screen Houses
[..]
[..]
[..]
[.]
[.]
29.
Junction Towers
[..]
[..]
[..]
[.]
[.]
30.
Coal / Lignite Stock

Yard (open Area)
[..]
[..]
[..]
[.]
[.]
31.
Coal / Lignite
stock yard
(covered Area)
[..]
[..]
[..]
[.]
[.]
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S. No.
Location
Actual
lux/W/m2
Target
lux/W/m2
[LOGO OF
UTILITY]
Energy Loss
Saving
Potential
kWh/Annum
Cost
Impact
Payback
Period
32.
Stacker and
Reclaimer area
[..]
[..]
[..]
[.]
[.]
33.
Fuel Oil Pump

House
[..]
[..]
[..]
[.]
[.]
34.
Hazardous Area
within Fuel Oil
Storage Dyke Area
[..]
[..]
[..]
[.]
[.]
35.
Passages
[..]
[..]
[..]
[.]
[.]
36.
Indoor Stair Cases
[..]
[..]
[..]
[.]
[.]
37.
Outdoor Stair
Cases
[..]
[..]
[..]
[.]
[.]
38.
Semi Outdoor
stairs
[..]
[..]
[..]
[.]
[.]
39.
Toilets
[..]
[..]
[..]
[.]
[.]
40.
Roads inside the

Boundary Wall
[..]
[..]
[..]
[.]
[.]
41.
Periphery lighting
around the
Buildings
[..]
[..]
[..]
[.]
[.]
42.
Approach roads
[..]
[..]
[..]
[.]
[.]
43.
Hydrogen Plant
hazardous areas
[..]
[..]
[..]
[.]
[.]
Observations:
[
.]
Recommendations:
[
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[LOGO OF
UTILITY]

[Calculations for the cost benefit analysis for each of the recommended improvement
options are attached.]
[Signature]
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OF
MODEL TENDERING PROCEDURE FOR SELECTION OF

R&M CONTRACTORS AND CONSULTANTS
PREPARED BY

THE CONSULTANT
LII-GETS12021-G-00119-006 R01
September 2014
Model Tendering Procedure for Selection of R&M Contractors and

Consultants
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BACKGROUND
India. Thermal Power Stations are designed for an economical and stable life span of
25 years, after which, the level of performance starts deteriorating as a result of
degradation of its equipments, components and materials. Deterioration in performance
is reflected in frequent forced outages, reduced outputs, decreased efficiency and
increased cost of generation. This results in costly repair and loss of revenue.
Renovations & Modernization (R&M) of thermal power station is an activity of carrying
out repairs, refurbishments and replacement of defective equipments & components so
as to extend the life of the power plant by at least 15-20 years, to restore the
performance parameters to equal or better than the original design parameters and to
ensure that the renovated plant complies with the revised statutory emission standards.
Need of R&M
In spite of new capacity additions, India continues to face shortages of varying degree
in the supply of energy and peaking power. Implementation of fresh capacity additions
for bridging the demand supply gap involves huge investments and long gestation
periods primarily due to the process of land acquisition and getting the required fuel and
water allocations, permits & clearances, particularly, the environmental clearance.
technologies.
Need of preparation of Model R&M Documents
Based on the discussions held with Ministry of Power, various utilities, PFC and BHEL,
CEA prepared a document on National Perspective Plan for Renovation &
Modernization and Life Extension and Up-rating (LE&U) of thermal power stations up to
the year 2016-17. This document which also includes revised guidelines for
Renovation & Modernization / Life Extension works on coal/lignite based thermal power
stations was released by Honourable Minister of Power on 14th December 2009. In the
Perspective Plan, 53 units (7318 MW) for LE works and 76 units (18965 MW) for R&M
works were identified for 11th Plan and 72 units (16532 MW) for LE works and 23 units
(4871 MW) for R&M works were identified for 12th Plan.
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investigation to identify the R&M works to be carried out and preparation of technical
bid documents based on the investigation was not done. This resulted in unsystematic
and additional work during execution phase and uncertainty about costs resulting in
excessive implementation time, long shutdown periods of plants and cost overruns. In
the absence of standard commercial rules and policies, suppliers showed little interest
in R&M work. Therefore a strong need was felt for providing standardized bidding
procedures as well as model contracts, formats and specifications etc. to the utilities.
Standardization will harmonize the requirements of all the stakeholders and will lead to
their increased participation.
discuss energy related issues of mutual interest. The first meeting of the ad-hoc subgroup on energy efficiency in thermal power stations, constituted as per decision of
meeting of IGEF in December 2007, was held under the chairmanship of Joint Secretary
(Thermal), Ministry of Power on 12th March, 2008 in which preparation of standard
tendering document for the purpose of R&M activities was, inter-alia, identified as an
area of the activities. The scope of the assignment was divided in two parts as under:Phase-I Activity:
Phase-I activity comprised an assessment of tendering procedures currently being
followed by public utilities in India and a review of documents used for standard R&M
projects and the documents which have already been developed for energy efficient
R&M projects, financed particularly by World Bank. This activity was carried out by M/s
Evonik under the grant provided by GTZ.
Phase-II Activity
November 2009, KfW proposed to finance and carryout the work programme of phaseII Activity, on behalf of CEA & in consultation with the Task Force. In a meeting held in
MOP on 17th December 2009, chaired by Joint Secretary (Thermal), MOP, the
representative of KfW suggested that CEA may act as Project Executing Agency for
the phase-II activity. Accordingly Ministry of Power, Govt. of India have entrusted the
task of Project Executing Agency to CEA for implementing Phase-II activity. Under
Indo-German Energy Forum (IGEF) assisted programme, M/s Lahmeyer International
(India) was appointed on16th March 2012 to provide the consultancy services for
Development of tendering procedures and model contract document for R&M of Fossil
Fuel Based Power Plants in India.
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Documents of the Power Plants where LII was associated with R&M activities
R&M and LE of Units 1 & 2 of Ukai TPS (2x120 MW) of GSECL.

R&M of Units 1 & 2 of Kutch Lignite TPS (2x70 MW) of GSECL.
Refurbishment & Up-gradation of 240 TPH Blast Gas Fired Boiler of Ispat Energy
Ltd.
Detailed design for the Balance of Plant for the R&M of OBRA A & B Thermal
Power Station.
RFP document for the R&M Unit 1, 3, & 4 (3x50 MW) of Patratu TPS of JSEB.
R&M crash programme document for Units III & IV of Panki Thermal Power
Station (2x105 MW).
Documents provided by CEA

MAHAGENCO.
Tender document for Supply, Erection, Testing and Commissioning of Air
Preheater for Unit 5 & 6 Koradi TPS, MAHAGENCO.
Tender document for replacement of 6.6 KV station transformer incoming
breaker & Tie breaker of Koradi TPS, MAHAGENCO.
Commissioning of Rotary Air Preheter for Units 4 & 5, Nasik TPS of
MAHAGENCO.
Documents provided by WBPDCL

KfW Documents


Installation.
Standard Request for Proposal for the Selection of Consultants.
**************
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OBJECTIVE OF THE MODEL TENDERING PROCEDURE DOCUMENT

Central Electricity Authority (CEA), the Project Executing Agency / Employer has
appointed Lahmeyer International India Pvt. Ltd. (LII), the Consultant to Develop
Standard Procedures and Model Documents for the Renovation and
Modernization (R&M) of Fossil Fuel based Power Plants in India. The above
assignment is being financed by KfW Entwicklungsbank. Development of Model
Tendering Procedure for Selection of R&M Contractors and Consultants is one of
the tasks under this assignment. Accordingly, this Tendering Procedure for
Selection of R&M Contractors and CXonsultants has been prepared for the
guidance of Project Authorities who may decide to carryout R&M of their old
Coal based Power Plants so as to extend the life of their plants and make them
energy efficient in compliance with statutory norms. The utilities are advised to
refer to the guidelines of the standard documents for the preparation of the
project specific documents for their project.
**************
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TABLE OF CONTENTS
1
INTRODUCTION ............................................................................................... 1
1.1
Guiding Principles ....................................................................................... 1
1.2
Applicability ............................................................................................... 1
OVERALL TENDERING PROCESS FOR CONTRACTORS .......................................... 2

2.1
2.1.1
Pre-Qualification vs. Post Qualification ..................................................... 2
2.1.2
Qualification Requirement ...................................................................... 3
2.1.3
Qualification Document ......................................................................... 3
2.2
Stages of Tendering Process ........................................................................ 4
2.2.1
Single Stage Single Envelope Bidding ....................................................... 4
2.2.2
Single Stage Two Envelope Bidding ......................................................... 4
2.2.3
Two Stage Bidding ............................................................................... 5
2.2.4
Recommended Tendering Process ........................................................... 5
2.3
3
Qualification of Bidders ............................................................................... 2
Recommended Timeline of Tendering Process ................................................. 6
PACKAGING CONCEPT FOR R&M WORK .......................................................... 10

3.1
Single Package R&M vs Multiple Package R&M ............................................. 10
3.2
Recommended Package List ....................................................................... 11
CONTRACTING CONCEPT FOR R&M WORK (CONTRACTORS) ............................. 12

4.1
International Competitive Bidding vs Domestic Competitive Bidding .................. 12
4.2
Lump sum Price vs Unit Rate ...................................................................... 13
4.3
Scope Change.......................................................................................... 13
4.4
Price Basis & Price Variation....................................................................... 14
4.4.1
Scope ............................................................................................... 14
4.4.2
Taxation............................................................................................ 14
4.4.3
Insurance .......................................................................................... 14
4.5
Terms and Methods of Payment ................................................................. 14
4.6
Splitting of Contract ................................................................................. 15
4.7
Assignee ................................................................................................. 15
4.8
Sub contractors and Sub vendors ............................................................... 15
4.9
Performance Guarantee ............................................................................. 15
4.10 Liquidated Damage ................................................................................... 16

4.11 Advance Payment Security ........................................................................ 16
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4.12 Contract Performance Security ................................................................... 16

4.13 Retention Money ...................................................................................... 16
4.14 Force Majeure .......................................................................................... 16
4.15 Applicable Law ........................................................................................ 16
4.16 Dispute Resolution .................................................................................... 16
5
TENDERING FOR SELECTION OF R&M CONTRACTORS ....................................... 17

5.1
Invitation for Bid....................................................................................... 17
5.2
Clarification and Amendment...................................................................... 17
5.3
Time frame .............................................................................................. 17
5.4
Language of Bid and Tender Document ........................................................ 17
5.5
Currency of Bid and Currency Conversion..................................................... 17
5.6
Validity of Bid .......................................................................................... 17
5.7
Bid Security ............................................................................................. 18
5.8
Integrity Pact ........................................................................................... 18
5.9
Components of Bid ................................................................................... 18
5.9.1
Techno-Commercial Bid ....................................................................... 18
5.9.2
Price Bid............................................................................................ 18
BID EVALUATION AND AWARD OF CONTRACT FOR R&M WORKS ...................... 19

6.1
Bid Submission and Bid Opening ................................................................. 19
6.2
Completeness of Bid ................................................................................. 19
6.3
Evaluation of Techno-Commercial Bids ......................................................... 19
6.4
Evaluation of Part-II Bids ............................................................................ 20
6.4.1
Price preference ................................................................................. 21
6.4.2
Cost Compensation for Deviation .......................................................... 21
6.4.3
Differential Loading for Quoted Performance Guarantee Parameters............ 21
6.5
Letter of Award and Signing of Contract ...................................................... 21
6.6
Inadequate Participation by Bidders ............................................................. 21
6.7
Unreasonable Price Quote .......................................................................... 22
6.8
Rejection of all Bids and Retendering ........................................................... 22
TENDERING PROCEDURE FOR SELECTION OF CONSULTANTS ............................. 23

7.1
Types of Consultant.................................................................................. 23
7.2
Role and Responsibility of Consultants ......................................................... 23
7.2.1
Role of R&M Consultant ...................................................................... 23
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7.2.2
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Role of Implementation Support Consultant ............................................ 24
7.3
Tendering for R&M Consultant & Implementation Support Consultant ............... 25
7.4
Request for Qualification for Consultants (R&M Consultant and ISC) ................ 26
7.5
Pre-qualification Documents ....................................................................... 26
7.6
Request for Proposal for Consultants (R&M Consultant & ISC) ........................ 27
7.7
Evaluation Criteria for Consultants (R&M Consultant and ISC) ......................... 28
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INTRODUCTION
1.1
Guiding Principles
Logo of Utility
This Tendering Procedure has been prepared to provide the guidelines for the
methodology to be adopted for selection of R&M Contractors and Consultants in
a fair and transparent manner with an objective to carry out the Energy Efficient
Renovation & Modernization work by adhering to acceptable standards of quality
and cost competitiveness. The prescribed methodology aims at employing
capable and competent contractors from any part of the world to best achieve
Life Extension, Reliability improvement and Performance Restoration/
Enhancement objectives of R&M Projects. While developing the procedure, the
tendering practices prescribed by international development banks and practices
followed by public sector undertakings of India were reviewed.
1.2
Applicability
This Tendering Procedure may be used by utilities as a guideline for designing a
Tendering Process for selection of Contractors and Consultants for Renovation &
Modernization work for coal fired thermal power plants in India.
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OVERALL TENDERING PROCESS FOR CONTRACTORS
2.1
Qualification of Bidders
Logo of Utility
2.1.1 Pre-Qualification vs. Post Qualification

Pre-qualification is carried out to assess whether or not the interested bidders
are capable of properly delivering as per the contractual scope of work. The
capability of the bidders is assessed on the basis of qualification documents
submitted as part of the pre-qualification exercise. Only such bidders who are
found qualified in the pre-qualification stage are issued the tender documents
and are allowed to submit the bid for the R&M work.
In tendering process with post-qualification, the qualification documents and the
actual bids are submitted simultaneously.
Advantages of pre-qualification:In pre-qualification route, bidders have a fair idea whether or not they are
qualified to be considered as prospective contractor for the work being tendered,
before spending considerable time and expenses for preparing a detailed bid.
Further, prequalification gives the Owner some idea about the qualified bidders
who are likely to submit the bid. In case it turns out that inadequate number of
prospective bidders are qualified to bid; the owner may explore ways to increase
participation of qualified bidders.
Advantages of post-qualification:Post-qualification route obviates the need for a separate pre-qualification
exercise before submission of proposal. Further, as the qualification documents
are submitted along with proposal, latest qualification data/status as on the date
of submission of proposal can be used for qualification.
Recommended Qualification Procedure for R&M Work:Pre-qualification route is more suitable for large or complex work that involves
considerable time and effort for preparation of detailed bid/proposal.
The Energy Efficient R&M work is technologically complex and challenging in
terms of execution. It is important to ascertain the availability and willingness of
capable and qualified bidders through a pre qualification process before inviting
tenders. Further, evaluating tenders from a large number of bidders, both
qualified and unqualified, will make the tendering process time consuming.
Therefore, only parties qualified in a pre-qualification process should be issued
Tender Documents and should be allowed to participate in the Tendering
process. For all the packages, bids should be invited after conducting a prequalification process to shortlist qualified bidders
The objective of the pre-qualification is to allow only the capable and qualified
bidders having requisite technical expertise, relevant experience, project
execution capability and financial resources to participate in the tendering
process. The pre-qualification document should specify the qualification criteria
to be met by the prospective bidders to become eligible for participating in the
tendering process. The prequalification route is not intended to limit the
competition to a predetermined number of potential bidders. While following this
route, all the interested parties meeting the specified criteria will be issued
tender documents and allowed to submit bid.
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2.1.2 Qualification Requirement

Due care should be taken to frame appropriate Qualification Requirement (QR) to
ensure adequate participation of competent bidders. While framing the QR,
detailed information should be collected from prospective bidders regarding their
experience and capability.
The Qualification Requirement should include Technical Qualification
Requirement, Financial Qualification Requirement and should cover Reasons for
Exclusion if any. The Technical Qualification Requirement should call for
technological & execution capabilities and experience in the execution of
comparable projects.
Financial Qualification Requirement should call for
evidence of financial soundness; past experience in executing projects of similar
magnitude and ability to mobilize financial resources for executing the project.
The reasons of exclusion are aimed at excluding parties that may have unfair
advantage over other parties or may have past record of wrongdoing. Any bidder
who is or was involved as a consultant in the preparation or implementation of
the project or whose associate or affiliate is or was involved as a consultant in
the preparation or implementation of the project is to be excluded. Any bidder
who is legally barred from the procurement process in India on the grounds of
previous violations of regulations on fraud and corruption is to be excluded.
Too weak a qualification requirement may lead to the entry of incompetent
bidders with lower price quotes. Awarding the R&M Contract to an incapable
bidder may severely jeopardize the R&M programme. Similarly, too stringent a
qualification requirement may restrict the number of eligible bidders to only a
few, thereby restricting competition which may lead to higher price quotes.
The specified Technical and Financial Qualification Requirement should balance
the twin objectives of restricting participation in the tendering process to capable
and experience bidders with ability to successfully undertake the Renovation &
Modernization work and ensuring participation by adequate number of interested
parties to encourage competitive bids.
Bidders should be entitled to meet the Qualification Requirements jointly with
their associates or consortium partners. In such cases, bidders and their
associates and/or consortium partners should be asked to furnish a joint
undertaking in the prescribed format to discharge their obligations. A bidder can
be a Joint Venture Company as well. In all cases of qualification through
Consortium/Associate/JV, all the parties will be jointly and severally liable to the
Owner to discharge all contractual obligations.
2.1.3 Qualification Document
The intending Bidders should be asked to furnish documentary evidence and
performance certificates in support of their qualification credentials along with
their response to Request for Qualification. The documentary evidence should
include inter alia list of orders executed along with copies of orders, Performance
Certificates indicating date of completion as well as documents of company
profile incorporating information about technical man power, financial strength,
resources, organization, experience to undertake such jobs and certificates of
audited accounts for last three years along with copies of latest income tax
return etc.
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2.2
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Stages of Tendering Process

The bid/proposal for the Renovation and Modernization work comprises (i)
Techno-Commercial proposal/bid (without price) and (ii) Price/Financial Bid. The
owner/processor has the option of inviting these two components of the bid
simultaneously or in stages/in bids.
2.2.1 Single Stage Single Envelope Bidding

In this method of bidding, the bidder is asked to submit the techno-commercial
bid along with price bid, which are are opened simultaneously. The quoted prices
of the bidders are thus known before the evaluation of techno-commercial
proposals of the bidders to assess their techno-commercial responsiveness and
before any discussion with the bidders regarding deviation in bids with respect
to the tender conditions. The advantage with this method is that in case of large
number of bids, detailed evaluation of bids can be restricted to the lowest bid
and the bids with price quote close to the lowest bid. However, it has two
disadvantages. Firstly, in case the bid with lowest price quote turns out to be
techno-commercially non-responsive, it becomes a tough call to reject the lowest
price bid and accept a bid with higher price quote. Secondly, this method has no
provision of inviting supplementary price quotes, in case; the purchaser wants to
introduce some changes in the specifications on the basis of post-bid
discussions.
2.2.2 Single Stage Two Envelope Bidding
In this method, the bids for the Renovation and modernization work are
submitted in two parts. Both the parts are submitted together.
The Part-I bid comprises the techno-commercial bid without prices. The main
components of the techno-commercial bid are Bid Guarantee, Scope of Work &
Terminal Points, Technical descriptions/details, Technical data sheets, List of
Tools
&
Tackles,
Deviations
to
technical
and
commercial
specifications/conditions, Overall completion period & L-1 Network Schedule,
Resource deployment schedule, Detail of Sub-Contractors/Sub-Suppliers/SubVendors, Spares list, Quality Assurance Programme, Details of the present
commitments & details of contracts in hand, Indices and Coefficients for Price
Variation etc. Part -II Bid will comprise quoted price and Performance Guarantee
Parameters. Initially, only the Part-I bid is opened and Part-II bid is kept in safe
custody.
After evaluation of the techno-commercial (Part-I) bids, each bidder who has
submitted a broadly responsive Part-I bid, is invited for techno-commercial
discussion, during which, all the required amendments, additions, deletions and
other adjustments are noted and recorded in a Memorandum. Part-II bid (Price
Bid) of only those bidders is opened, whose Part-I bid is found to be responsive
to tender specifications and conditions.]
The Part-II bid comprises quote for Prices and the Performance Guarantee
parameters in the form of filled up Schedules of Prices and Performance
Guarantees.
However, after the evaluation of Part-I bids (techno-commercial bids) and before
opening of Part-II bids (Price Bids), in case a particular bidder is asked to make
changes in his techno commercial offer that may have price implications, then
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that bidder is allowed to submit supplementary price against such changes

before the opening of PartII bids (Price Bids).
This tendering method has the advantage that the evaluation of technocommercial bid and techno-commercial discussion is carried out without any
influence of price quotes. The price-bid of techno-commercially non-responsive
bid is not opened at all. Further, in case any bidder is asked to change his
proposal during techno-commercial discussions for conformance to tender
conditions, the bidder is given an opportunity to submit supplementary price
corresponding to that change. However, in this tendering method, technocommercial bids of all the participating bidders need to be evaluated in detail.
This may consume a lot of time and effort when quite a large number of bids are
received.
2.2.3 Two Stage Bidding
In this tendering method, in the first stage, the bidders are asked to submit only
the techno-commercial bid without any price quote and guaranteed performance
parameters. The techno-commercial bids are evaluated to assess the technocommercial responsiveness of the bid. Techno-commercial discussion is carried
out to freeze the techno-commercial conditions of the contact. In the second
stage, only the bidders whose techno-commercial bids are found to be
responsive, are asked to submit price bids comprising quoted price and quoted
performance guarantee parameters. The biggest advantage of this tendering
method is that the bidders know the final techno-commercial contours of the
tender before submitting any price bid. Therefore, they get the opportunity to
base their price quotes on the final agreed techno-commercial conditions of the
contract. However, the flip side is, that the bidders know who are the bidders,
whose techno-commercial bids have been evaluated to be responsive, before
making the price quotes. This may lead to uncompetitive price quotes in case
where the number of responsive bidders is low (i.e. one/two). Further, in case
only one bid is found to be responsive, the bidder is likely to quote largely
inflated price to take advantage of the situation. Further, contracts/procurement
norms of Government undertakings may not allow inviting price quotes from only
one bidder.
2.2.4 Recommended Tendering Process
Each R&M project is unique and associated with many complexities regarding
assessment of the quantum and nature of retrofit and replacement to be carried
out. It is therefore important to firm up the technical contours of the contract
before opening price quotations so that all the bidders and the owner have
agreement and clarity about the nature and scope of the work on which the
price bids are to be based. Considering the complexities of R&M Projects, it is
recommended to invite the bids in two parts in single stage, as discussed in Para
2.2.2 above. The rationale behind inviting Part-II bid along with Part-I bid is that
bidders will make their quotes before the number of responsive techno
commercial bids is known. This will encourage competitive price quotes.
However in case a bidder is asked to make changes in its techno commercial
offer that may have price implications, that bidder may be allowed to submit
supplementary price against such changes before opening of PartII bids (Price
Bids).
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2.3
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Recommended Timeline of Tendering Process

The recommended sequence and timelines for the tendering process are
described in the Table-2.1 and Figure-1 below:
Table-2.1
Broad Outline of Tendering Procedure
Activity
Tentative Timeline
(a)
Publication of RFQ and start of issue of

RFQ document
Zero Date
(b)
(c)
Last date for submission of response to

RFQ
(d)
Short listing based on response to RFQ
(a)
Issue of RFP
(b)
Pre - Bid Discussion
(c)
Last date for submission of Both Part I

and Part II Bid and Opening of Part-I
(Techno-commercial) Bid
Techno Commercial Discussion
Completion of Evaluation of
Commercial Bids
Date of Opening of Price Bids
(d)
(e)
(f)
(g)
Techno-
Selection of Successful Bidder and

Placement of LoI
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Figure-1: Tendering Procedure
PREQUALIFICATION
Request for Qualification is
advertized by Owner
Prospective Bidders respond to

RFQ
Owner examines Qualification

Documents and intimates the
Qualified Bidders about Qualification
TENDERING
Owner issues Tender Documents to
Pre-qualified Bidders
Pre-Bid Clarification Meeting Bidders
Bidders submit two-part BidsPart-1

Un-priced Techno-Commercial Offer
Part-2 Price Bid with Performance
Guaranteed Parameters
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EVALUATION OF PART-I BID

Part-I -Techno-Commercial Bids are
opened and Part-II Bids are kept in
safe custody
Preliminary Evaluation of Part-I Bids
Post Bid Clarification Meeting &

Techno-Commercial Discussion with
Bidders
Part-I Bids are evaluated for

completeness & responsiveness
Owner intimates the date and time

for opening of Price Bids to Bidders
whose Techno-Commercial (Part-I)
Bids were found responsive
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EVALUATION OF PART-II BID
Price Bid of Bidders whose Part-I

Bid was evaluated to be responsive
is opened.
Part-II Bids are evaluated to identify
Bidder with Lowest Evaluate Price
as successful Bidder
Employer notifies successful Bidder.

Successful Bidder submits Contract
Performance Security and Contract
is signed
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PACKAGING CONCEPT FOR R&M WORK
3.1
Single Package R&M vs Multiple Package R&M
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Aligning the timeline of tendering process and execution of different packages

and interfacing among different packages when R&M is being implemented in
multiple packages is essential for smooth and timely execution of the R&M
project. This risk may be mitigated by proper planning of tendering and
execution of R&M project and employing suitable Project Management /
Coordination team.
When a utility is planning to carry out renovation and modernization of the entire
plant covering a number of major equipment and systems, it has the option of do
it as a single package by a single contractor or split it into a number of packages
each covering a major part of the plant /system and awarding these packages to
separate contractors.
The advantages and disadvantages of single package R&M and multi-package
R&M are listed in table 3.1.
Table 3.1
Single Package R&M Vs Multi-package R&M
Single Package
Multiple Package
Advantages
Advantages
An all inclusive scope of work can

minimize the need for changes in scope
of work during execution and minimize
disputes pertaining to scope of work.
Lower contract price and better

control on progress based payment.
Single point responsibility of one R&M

Contractor.
For delay in any part, liquidated
damages will be paid by the Contractor
based on total contract value.
Better suppliers/vendors for each

package
specialized
in
their
respective area.
Owner can better monitor and
control he work at more granular
level.
In case of deficiency in performance,

liquidated damages will be paid by
Contractor based on total contract
value.
Less time and effort
selection of contractor.
required
in
Disadvantages
Disadvantages
Higher contract price.
No
single
point
responsibility. Owner
for overall R&M work.
Selection of suppliers/vendors for

different sub packages at the discretion
of the main contractor.
Less transparency in project execution
information flow.
No of competent Contractors available
to execute such big R&M Contract is
limited
which
leads
to
limited
competition.
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contractor
responsible
Scope of work, terminal points and

interface requirements for different
Contractors need to be defined
properly to ensure there is no
mismatch
and
no
system/equipment is missed.
Liquidated damage for delay is paid
by individual contractor linked to
his contract value though delay in
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single package
whole project.
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may
delay
the
More time and effort required for

selection of contractors.
3.2
Recommended Package List

Implementing the Renovation and Modernization of the entire plant as a single
package by a single contractor makes the tendering and execution process
simple for the owner as it obviates the need to split the work into different
packages, to ensure interface between different packages during design and
execution and to properly align the completion schedule of different packages.
Further, single package allows owner to fix single point responsibility and avoids
contractual disputes arising out of acts of omission of one contractor affecting
other contractors. However, Renovation and Modernization of different systems
of the plant need different expertise and experience. There will be very few
contractors, if any, who have in-house expertise and experience to carry out the
R&M of all areas of a coal fired power plant. A single EPC bid for R&M work will
thus restrict number of qualified bidders, which will also increase the cost of
R&M. In order to balance the conflicting needs of minimizing project/contract
management complexities and having adequate number of eligible and willing
bidders having relevant expertise and experience to carry out the R&M work
under a package, it is recommended to split the R&M work into the following
packages:
1. Boiler & Auxiliaries (including but not limited to Pulverizes, Feeders, PA
Fans, FD Fans, ID Fans), ESP, Auxiliary Steam system and MS, HRH,
CRH, HPBP & LPBP piping and associated Electrical, C&I and Civil Works.
2. Turbo-Generator & Auxiliaries (including but not limited to Heaters,
Deaerator, Condenser, BFPs, CEPs), TG Cycle piping including Boiler Feed
piping and associated Electrical, C&I and Civil Works. This package will
also including R&M of C&I system common to both SG and TG.
3. Coal Handling Plant and associated Electrical, C&I and Civil Works.
4. Ash Handling System and associated Electrical, C&I and civil works.
5. Mechanical Balance of Plant (BOP) System which includes Plant Water
System (Raw water intake system, Pre-treatment Plant, D.M.Plant, CW
Systemincluding Cooling Towers, ACW & CCW System), Compressed Air
System, Fuel Oil System, Fire Fighting System and Miscellaneous balance
mechanical systems.
6. Electrical BoP including inter alia Switchyard, Power Transformers and
Switchgears.
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CONTRACTING CONCEPT FOR R&M WORK (CONTRACTORS)

The utility should adopt a fair and transparency bidding process that provides
equal opportunity to all eligible bidders to participate in the tendering process.
The objective of the tendering process is to select a contractor that is likely to
execute the scope of renovation and modernization work satisfactorily adhering
to envisaged completion schedule and acceptable quality standards at
competitive prices.
4.1
International Competitive Bidding vs Domestic Competitive Bidding

International Competitive Bidding (ICB) process will be followed for high value
contracts and contracts that are complex in terms of engineering and execution
skills to achieve the best possible supply and services at competitive prices.
R&M of BTG, BTG auxiliaries, Power Transformers and Switchyard are likely to
be technologically complex & involve higher value contracts and hence likely to
evoke response from many reputed international bidders. Hence packages
covering these systems may be tendered on International Competitive Bidding
(ICB) basis. However, R&M of other BoP packages are not likely to see
participation by many reputed international bidders and hence may be tendered
on Domestic Competitive Bidding (DCB) basis.
Recommended list of packages and suggested nature of bidding is given at Table
4.1 below:
Table-4.1
Nature of Bidding
S. No
1
Package
Nature of Bidding
Boiler & Auxiliaries (including but not ICB

limited to Pulverizes, Feeders, PA
Fans, FD Fans, ID Fans), ESP, Auxiliary
Steam system and MS, HRH, CRH,
HPBP & LPBP piping and associated
Electrical, C&I and Civil Works.
Turbo-Generator
&
Auxiliaries ICB
(including but not limited to Heaters,
Deaerator, Condenser, BFPs, CEPs),
TG Cycle piping including Boiler Feed
piping and associated Electrical, C&I,
and Civil Works. This package will also
including R&M of C&I system common
to both SG and TG.
Coal Handling Plant and associated DCB

Electrical, C&I, and civil works.
Ash Handling system and associated DCB

Electrical, C&I and civil works.
Mechanical Balance of Plant (BOP) DCB

systems which includes Plant Water
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S. No
4.2
Package
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Nature of Bidding
System (Raw water intake system,

Pre-treatment Plant, D.M.Plant, CW
System including Cooling Towers,
ACW & CCW System), Compressed
Air System, Fuel Oil System, Fire
Fighting System and Miscellaneous
balance mechanical Systems
Electrical BoP including inter alia ICB
switchyard, power transformers and
Switchgears
Lump sum Price vs Unit Rate

In a lump sum price contract, the entire scope of supply and services is grouped
into a single overall contract price for the contractors to quote their price
against. During execution of work, phasing of payment is done against progress
of supply and services, but the sum of total of all the payments is the contracted
price and it remains unchanged irrespective of the quantity of supply and service
required to complete the contracted scope of work. The payments are linked to
contractual milestones.
The bidder quoting the lowest lump sum price for the overall contract scope of
work is treated as the lowest price bidder.
For unit rate contract, the bidders quote the unit rates for each supply and
service against an estimated bill of quantity. The bidder with lowest total price
for the estimated BOQ is treated as the lowest price bidder. During execution,
payment is made based on actual quantity of each item/type of supply and
service.
Given the nature of renovation and modernization work, it is difficult to
exhaustively indentify all the types/items of supply and service required and
estimate quantities for them. Therefore, unit rate contract is difficult to design
for renovation and modernization work. It is more practical to contract R&M
work on lump sum price basis for the entire scope of plant, equipment,
machinery, material, parts and including design, engineering, procurement,
supply, assembly, construction, erection, testing & commissioning.
Each package therefore should be awarded on lump sum EPC contract basis
based on the Scope and Terminal Points identified in the Bid Documents of the
corresponding package.
4.3
Scope Change
The scope of Renovation & Modernization is defined in the bid documents of
different packages on the basis of Residual Life Assessment / Condition
Assessment and Energy Audit. During execution, in case there arises a need for
any change in scope of work, change order should be issued. The contract
should include procedure to deal with such change order.
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Appropriate change order clause will be built into the contract to deal with the
need to change the scope of the contract due to surprises encountered during
the execution of the R&M work.
4.4
Price Basis & Price Variation

The Contract Price should include price of executing whole scope of work
specified in the Contract. The price of the contract should be on lump sum price
basis for the entire scope covered in the contract. The contract price should be
subject to adjustment during the contract period to reflect change in labour and
material price levels as per price variation formula specified in the tender
document, which is subject to limits specified in the tender specification.
For adjustment in contract price, bidding document should specify base date for
contract price and price variation formula. The price variation formula should
break down the total price into components that are not adjustable and
components that are adjustable by indices specified for the various components.
The bidders may be asked to indicate the coefficients (in the techno-commercial
bid) to distribute the adjustable price into different components.
4.4.1 Scope
The scope of work for each package should consists of design, engineering,
manufacture, supply, inspection & testing at suppliers works, packing,
forwarding to site, transportation, unloading, storage, handling at site, steel
structures, civil works, insurance, erection, painting, start-up, trial operation,
testing, commissioning and performance guarantee testing, guarantee &
warranty and handing over on turnkey contract basis.
4.4.2 Taxation
The tender specification should explicitly indicate the taxes and duties that will
be reimbursed to the contractor by the Owner. Usually custom duty, excise
duty, VAT, sales tax, GST is reimbursed by the Owner on actual for direct
transactions between Owner and Contractor. All other taxes (i.e. taxes other
than specifically mentioned in the contract for reimbursement) levied on the
contractor in connection with the contract work, are borne and paid by the
Contractor. Such taxes are to be included by the bidders in the quoted contract
price. Cost of transportation of material, equipment, tools & tackles are to be
included in the quoted contract price.
4.4.3 Insurance
Bidding document should include clauses that require contractor to bear the cost
of insurance. Bidding document should specify the types and terms of insurance
to be bought by the contractor. Usually, all risk type of policy is specified.
4.5
Terms and Methods of Payment

The payment for the supplies and services should be made progressively as the
project execution progresses. Payments should be made in currencies agreed
between Owner and Contractor in the Contract. The Bidders should be asked to
prepare and submit to the Owner item-wise breakup of the Contract price in the
currencies of the Contract. The contract price break up should be linked to the
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detailed PERT network of the contract. Owner may pay 10% of the contract
price as initial interest free amount. Major part of the payment for supply items
should be linked to dispatch and receipt of item. A part of the contract price for
supply and service should be linked to commissioning/completion
equipment/facilities. Payment should be made through Letter of Credit and
Electronic Transfer.
4.6
Splitting of Contract
For each package of the renovation & modernization work, there should be a
contract encompassing the entire scope of the work and the principal bidder
should be made responsible for executing the entire scope of work. However,
this contract may be split into two or more independent component contracts for
offshore supply, onshore supply, transportation & port clearance, erection &
installation services etc. All the independent component contracts should contain
a cross-fall breach clause specifying that breech of one contract will constitute
breech of the other contracts.
4.7
Assignee
Any foreign bidder should have the option to propose an Assignee in its bid to
execute the Indian supply & services part of the contract. The Assignee should
have acquired capability and relevant experience to perform his scope of work.
4.8
Sub contractors and Sub vendors

The contractor may subcontract parts of supply and service to subcontractor/sub-vendors approved by the Owner. However, the successful bidder
should not be permitted to subcontract the entire work on back to back basis or
otherwise.
4.9
Performance Guarantee
The bidding documents should specify the performance parameters, the bidder is
required to guarantee. Against each specified parameter, the bidding document
should specify the minimum performance level that the bidder is required to
guarantee. The bidding documents should stipulate performance test procedures
to measure actual value of performance parameters. If the measured
performance parameters fall short of guaranteed or specified value, and the
contractors fail to bring it to acceptable levels through repair and rectification
within a stipulated period, the executed plant equipment may be rejected and
payments already made may be recovered. For shortfall in performance
parameters that have economic consequences, if the quantum of shortfall is
within certain limits specified in tender specification, the plant and equipment
may be accepted after levying liquidated damages. If the shortfall in performance
level is beyond the limits specified in tender specification, the plant and
equipment will be rejected and payments already made will be recovered.
Shortfall in functional parameters pertaining to safety or statutory environmental
requirements, the plant and equipment will be rejected and payments already
made will be recovered.
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4.10
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Liquidated Damage
The contractor should be made responsible to pay Liquidated Damages for delay
in completion of R&M work. The aggregate liability for delay may be limited to
10% of contract price.
The contractor should be made responsible to pay Liquidated Damages for
shortfall in achieving guaranteed performance parameters. The aggregate liability
for shortfall in performance guarantee parameters may be limited to 10% of
contract price.
4.11
Advance Payment Security

The contractor should be made responsible to furnish unconditional Bank
Guarantee equivalent to advance payment made to him. The value of advance
payment security may be reduced at regular intervals on prorata based on the
value of the equipments/service/facilities received.
4.12
Contract Performance Security

The bidding document should specify contract performance security to be
furnished by the contractor to protect the Owner in case of breach of contract
by the contractor. The contract performance security may be of 10% of the
contract price for all the contracts and may be valid till three months beyond the
defect liability period.
4.13
Retention Money
10% of price of each item of supply and service should be held as retention
money until final acceptance of contractors work. After provisional acceptable,
contractor may be allowed to take the retention money by furnishing retention
money security guarantee of equivalent amount.
4.14
Force Majeure
The bidding document should incorporate appropriate force majeure clause to
cover any event beyond the reasonable control of the Owner or Contractor and
which cannot be avoided notwithstanding reasonable care by the affected party.
No delay or non-performance by either party caused by an event of force
majeure will constitute a default or breach of contract. The bidding document
should specify procedure to deal with the consequences of an event of force
majeure.
4.15
Applicable Law
The contract for renovation & modernization work should be governed and
interpreted in accordance with laws in force in India.
4.16
Dispute Resolution
The bidding document should specify dispute settlement mechanisms such as
Adjudication and Arbitration.
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TENDERING FOR SELECTION OF R&M CONTRACTORS
5.1
Invitation for Bid
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Tender documents should be issued to parties qualified in pre-qualification stage.

The bidding document should comprise the following main components:
5.2
Invitation for Bid
General Project Information
Instruction to Bidders
General Conditions of Contract.
Particular Condition of Contract.
Technical specification & tender drawings.
Bid forms & other formats
Bid Datasheets
Format for Price Schedules.
Clarification and Amendment

All clarifications/corrigendum/Addendum/Amendment to the Tender Documents
should notified to all the Bidders
5.3
Time frame
Adequate time should be allowed to the bidders for preparation and submission
of Bid.
5.4
Language of Bid and Tender Document

The bid submitted by the bidders should be in English language. Any document /
literature furnished by the Bidder in any other language should be accompanied
by authentic English translation. The English translation should be used for
interpretation of the bid. The tender documents issued to the bidders should be
in English language.
5.5
Currency of Bid and Currency Conversion

The bidders should be allowed to quote prices of supply item in any currency.
However, the number of foreign currencies used should be limited to some
number specified in tender document.
Indian bidders quoting in foreign currencies should be asked to comply with
relevant government regulation. The prices of local (Indian) services such as local
transportation, installation, construction etc should be quoted in Indian currency.
5.6
Validity of Bid
The Techno-Commercial bid and price bid submitted by the bidders should be
valid for sufficient period to allow ample time for bid evaluation, post-bid
discussion, internal processing and award.
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5.7
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Bid Security
Every bidder should furnish, as part of the techno-commercial bid, a Bid Security
for an amount to be specified in Tender Documents. The bid security will be
forfeited in case (1) the bidder withdraws or modifies the bid during validity of
bid or fails to sign the contract document or deposit contract performance
security when selected as the successful bidder or (2) commits any fraud.
5.8
Integrity Pact
The Tender Documents should include a format for Integrity Pact. The Owner
and Bidder will enter into an integrity pact before the bidders bid is considered
by the Owner.
5.9
Components of Bid
5.9.1 Techno-Commercial Bid

The Techno-Commercial Bid should comprise of the following main components:
1. Bid Security.
2. Filled up and signed form of bid.
3. Authorization in favour of a person signing the bid.
4. Overall project completion schedule.
5. Contractors Resource Deployment schedule.
6. Requirements of the contractor at site.
7. Technical details and Quality Assurance Programme.
8. List of mandatory and recommended spares.
9. Deviation to Technical Specifications.
10. Deviation to commercial conditions.
5.9.2 Price Bid
The price bid should comprise of the following main components:
1. Filled up form of Bid.
2. Filled in schedule of Prices.
3. Filled in schedule of Guaranteed Performance Parameters.
Prices of Indian supply items should be quoted in Ex-works basis including
packing and forwarding. Prices of Foreign Supply items should be quoted on CIF
Indian Port basis. Cost of inland transportation and insurance should be indicated
separately. Taxes & duties on all direct transaction between Owner and
Contractor should be indicated separately.
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BID EVALUATION AND AWARD OF CONTRACT FOR R&M WORKS

A comparative evaluation of the price bids should be carried out to identify the
techno-commercial responsive and qualified bidder with Lowest Overall
Evaluated Price after taking into account, adjustment for differential quote for
Performance Guarantee Parameters using adjustment factors specified in the
Tender Documents (adjustment to price of bids with quoted Performance
Guarantee Figure inferior to the value quoted in the responsive bid with most
competitive quote for that Performance Guarantee Parameter) and cost
compensation if any arising from evaluation of techno-commercial bids.
However, bids with quote for any Performance Guarantee Parameter inferior to
the minimum or maximum value for the parameter specified in the tender
conditions should be rejected.
The qualified and techno-commercially responsive bidder with the lowest
evaluated price should be selected as contractor for carrying out the R&M work.
In case the lowest price quoted is higher or lower than the estimated reasonable
cost for the work by a very large amount, further investigation should be made
regarding the reasonableness of the quoted price.
6.1
Bid Submission and Bid Opening

The date of bid opening of Part-I (Techno-Commercial) should be same as the
last date of bid submission. The Techno-Commercial Bids should be opened
promptly after the deadline for receipt of bids. The date and exact time of
opening of Techno-Commercial Bid should be specified in the Tender
Documents. The date and time of opening of Price Bid should be communicated
to the bidders after evaluation of the techno-commercial bid. Bidders or their
representatives should be allowed to be present during opening of Part-II and
Part-I bid.
6.2
Completeness of Bid
Each of the techno-commercial bid should be first examined to ascertain whether
the required bid security has been furnished, all the required components have
been submitted and the bids/attached documents have been properly signed.
6.3
Evaluation of Techno-Commercial Bids

The techno commercial bids should be evaluated to ensure that:
(1) The proposals are in line with the intended scope, quality and performance of
the contract;
(2) The proposals do not adversely affect the rights of Owner and obligations of
contractor envisaged in the tender conditions;
(3) The proposals are in line with and are complete as per technical specification
and commercial conditions.
(4) The proposals conform to completion schedule specified in the tender
documents;
(5) The proposals meet the performance guarantee requirements specified in
tender documents.
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The techno-commercial bids from pre-qualified bidders meeting above criteria

during evaluation should be considered techno-commercially responsive to tender
conditions. The Owner may invite any bidder(s) for a meeting during the
evaluation stage for the purpose of seeking some clarifications..
The Owner may issue amendments to the tender documents, if considered
necessary by Owner, based upon evaluation of techno-commercial evaluation
and post-bid clarification meeting.
The bidders may be asked to withdraw some deviations to tender conditions and
technical specifications to make the bid compliant with the tender specifications.
If any amendment to the tender documents or any withdrawal of deviation by a
bidder may have cost implication, that bidder may be allowed to furnish
supplementary price quotes against such amendments /withdraw of deviations,
before opening of the Part-II Bid (Price Bid).
The bidders of the techno-commercially responsive offers should be intimated
the date and time of Part-II Bid (Price Bid). The price bids of such technocommercially responsive bids should be opened on the scheduled date and time
in the presence of bidders or their representatives who want to be present during
opening of Price Bid. The bidders of techno-commercially non-responsive bids
should be intimated about such finding and their bid security should be returned.
6.4
Evaluation of Part-II Bids

After opening, the price bids should be examined to ensure that
(i)
The bids are complete and signed. The price schedules and performance
guarantee schedules are filled up. Incomplete and improperly filled bids
should be rejected.
(ii)
There is no arithmetic error in price quotes.
The tender document should elaborate a method for dealing with arithmetic
errors.
To facilitate comparison of quoted prices, the bid prices expressed in different
currencies may be converted to a single currency. The tender documents should
explicitly specify the currency and source and date of exchange note to be used
for converting bid prices to a common currency.
For comparison of price bids, the following should be added to the arithmetically
corrected quoted price:
(1) Adjustments for quoted performance guarantee parameters.
(2) Cost compensation for deviations.
(3) Any price preference to domestic bidders as per Govt. Policy.
The prices arrived at after adding these values to quoted price will be the
evaluated prices of the techno-commercially responsive qualified bids. Bidder
with the lowest evaluated price bid should be selected as successful bidder for
award for the R&M Contract. The evaluated price arrived at as above will be
used for comparison of price bid only. The arithmetically corrected quoted price
will be the contract price.
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The taxes, duties & levies that are to be reimbursed by the Owner on actual
basis as per stipulation of tender documents will not be considered for
comparison of price bid.
The escalation in prices due to change in material and labour index during
execution will not be considered in price bid evaluation.
6.4.1 Price preference
In case Government Rules mandate any price preference to domestic bidders,
the same should be clearly brought out in the tendering documents along with
an unambiguous procedure for applying the price preference.
6.4.2 Cost Compensation for Deviation
In case the bidder has taken any deviation to technical specification or tender
condition and after evaluation of techno-commercial deviation, Owner decides to
allow the bidder to retain the deviation, the cost implication, if any, of such
deviation will be added to the quoted bid price for evaluation of price bid.
6.4.3 Differential Loading for Quoted Performance Guarantee Parameters
Bidders should be asked to quote guaranteed value of performance guarantee
parameters of the retrofitted plant and facilities on the prescribed performance
guarantee schedule as part of the price bid. The tender documents should
indicate adjustment factors or bid evaluation factors for performance guarantee
parameters having financial implication. For evaluation purpose, for every such
performance parameter, the most favourable quoted value for the parameter
should be taken as the base value and the difference between quoted value of
any other bidder and base value should be multiplied with the indicated
adjustment factor for loading the price bid of the bidder with the performance
parameter inferior to the base value.
6.5
Letter of Award and Signing of Contract

The successful bidder should be notified within the bid validity period in writing
that his bid has been accepted. Once the successful bidder submits contract
performance security, the unsuccessful bidders will be intimated that they have
not been successful and their bid security will be released.
After the deposition of contract performance security and other required
details/documents by the successful bidder, the contract will be signed without
any delay and the bid security of successful bidder will be released.
6.6
Inadequate Participation by Bidders

To promote competitive price quotes, efforts should be made to ensure that
adequate number of prospective bidders participate in the pre-qualification and
subsequent bidding process. In case the number of parties qualified in prequalification process is less than three, the reasons of non-participation by
capable/eligible entities should be analyzed. Similarly, whether the specified
qualifying requirements are stringent should be examined. Preferably three or
more (at least two) qualified bidders should submit the bid for the R&M work.
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6.7
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Unreasonable Price Quote

If the bid price of bidder with the lowest evaluated price is too low or too high
as compared to the updated cost estimate for the R&M work, all the possible
reasons for the same should be analyzed. If the quoted price is too high, it
should be examined whether or not the tendering process encourages
competitive price quotes. If the quoted price is too low, then the
seriousness/competence of the bidder should be looked into.
6.8
Rejection of all Bids and Retendering

The tender document should include a clause empowering the Owner to reject all
bids, if so required. However rejection of all bids and retendering should be
considered only as an extreme measure due to any or combination of the
following reasons:1. There is lack of adequate and effective competitive competition among the
bidders.
2. All the bids are found to be techno-commercially non-responsive or defective.
3. The bid price of lowest evaluated bidder is high as compared to updated
estimate of the Owner.
4. Fraud and unfair practices by bidders.
Inadequate participation of bidders in prequalification process or proposal/bid
process and inadequate number of techno-commercial bids should trigger review
and analysis of the tendering process. However, less number of bidders is not
the sole criteria for annulment of tendering process and retender. If it is
established that appropriate prequalification and tendering process have been
followed, the Owner may persist with the tendering process even if there is only
one techno-commercially responsive bid. If the evaluated price of the sole
techno-commercially responsive bid is comparable with or within the Owners
estimate and prevalent market prices, such as bidder may be selected as the
successful bidder. Similarly, the qualification requirements should be changed
only if they are found to be too stringent and that appears to be the reason for
inadequate participation/competition among prospective bidders.
If all the bids are rejected and retendering is required to be carried out, the
tender documents should be thoroughly reviewed with regard to scope, technical
specification, commercial conditions, risk allocating between Owner and
contractor and other influencing factors before issue of the retender.
If rejection of all the bids is due to the reason that all the bids are technocommercially non-responsive, fresh prequalification and retendering may
substantially delay R&M project and in case, new capable bidders other than
already participating bidders are not likely to participate in the fresh qualification
and retendering, new bids may be invited from the already qualified bidders with
the original or modified tender documents. If the lowest evaluated price of the
responsive bids is substantially higher than the Owners estimate in spite of
adequate participation by the potential bidders, negotiations may be carried out
with the bidder with the lowest evaluated price, for reduction in contract price to
a reasonable level.
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TENDERING PROCEDURE FOR SELECTION OF CONSULTANTS
7.1
Types of Consultant
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Renovation and Modernization of old Thermal Power Projects involves in-depth

study of the power plant equipment, assessment of their health condition,
identification of the root causes of the equipments for deficit performance,
determination of the residual life of critical components, auditing of auxiliary
power consumption of various equipments, finding solutions to various
operational problems in terms of Run/ Retrofit/ Replacement options etc. This
requires special knowledge, skill and experience which is normally not available
with the Operating and Maintenance Engineers of the Power plants. Power
plants therefore require the services of consultants who are specialized in the
field of conducting various investigative studies and can deliver the services of
this nature.
Support of consultants is also needed to review the design and engineering work
done by the R&M Contractors, to monitor the progress of R&M works at the site
and to evaluate the results of the Performance Guarantee Tests etc. The job of
site supervision requires adequate experience of erection and construction
activities which is not always available with O&M engineers of the power plants.
Two types of Consultants have been suggested namely, R&M Consultantsand
Implementation Support Consultants(ISC). The consultancy work is initiated by
the R&M Consultant who does all the investigative studies like RLA/CA and EA
studies, provides the solutions to various operating problems in the form of
formulation of R&M options, selects the most attractive R&M option to be
implemented, prepares the DPR (Detailed Project Report), assists the utility in
getting the approval of appropriate Regulatory Commission, prepares the Bidding
Documents as well as appointment of R&M Contractor(s). Implementation of
R&M works is finally done with the help of Implementation Support Consultant
(ISC).
7.2
Role and Responsibility of Consultants
7.2.1 Role of R&M Consultant

The consultant to be selected for the role of R&M Consultant should have
requisite experience of conducting the plant studies as well as for the
preparation and evaluation of bidding documents. Role of R&M Consultant
consists of the following activities:
i.
Conducting of Cold Walk-down and Hot Walk-down Survey.
ii. Review of the operational history of the power plant.

iii. Discussion with the Plant Engineers.
iv. Carrying out of technical studies namely, the Residual Life Assessment
(RLA) and Condition assessment (CA) of BTG and BOP of the power
plant.
v. Carrying out Energy Audit of BTG and BOP to identify the reasons and
sources of excess power consumption.
vi. Reviewing the results of studies mentioned at v) & vi) above.
vii. Identification of the equipments needing retrofitting / replacement.
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viii.Studying the variations in the present quality of coal from the quality
considered at the time of original design of the plant.
ix. Studying the average quality of coal likely to be available during the next
twenty years.
x. Studying the latest environment standards prescribed by the regulating
agencies at the national and state level.
xi. Formulating alternative options including the cost impact for the
refurbishment / replacement of specific plant equipments for enhancing
their performance and extending their life.
xii. Preparing a matrix of R&M options for the plant as a whole for extending
the useful life by minimum 20 years by either restoring the performance
parameters to the original level or for achieving better parameters than
the original design.
xiii. Carrying out detailed economic evaluation of each of the R&M options
proposed in the matrix.
xiv. Discussions with Plant Management.
xv. Selection of R&M option to be implemented.
xvi. Finalizing the scope of R&M Works.
xvii. Preparation of Detailed Project Report.
xviii. Obtaining approval from appropriate Regulatory Commission.
xix. Preparation of Bidding Documents for the appointment of R&M
Contractors.
xx. Evaluation of Bids of R&M Contractors.
7.2.2 Role of Implementation Support Consultant
The consultant to be selected for supporting the utilities for implementing the
R&M works should have adequate experience of executing the projects of similar
nature. The role of the Implementation Support Consultant consists of the
following activities:
i.
Reviewing of design documents & drawings of the R&M contractors to

ensure compliance of scope of works.
ii. Site supervision and monitoring the progress of works.

iii. Checking the quality of construction and erection.
iv. Holding review meetings with the contractor(s).
v. Coordination between the Plant head and the R&M Contractor.
vi. Shop Testing at suppliers works and inspection at site.
vii. Supervising the commissioning activities.
viii.Witnessing and evaluation of Performance Guarantee Tests.
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7.3
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Tendering for R&M Consultant & Implementation Support Consultant

The Bidding procedure for appointment of R&M Consultant has been
standardized. For hiring of Consultants, a two step process comprising Request
for Qualification and Request for Proposal is recommended. For the Request for
Proposal for selecting R&M Consultant and Implementation Support Consultant
(ISC), a Single stage Two Envelope method has been specified since the
consultants to be engaged for R&M services must be specialized in their
respective fields and must have requisite experience of similar nature.
Following documents were studied to analyze the process of hiring consultants:
i.
World Bank Guideline (January 2011) for Selection and Employment of

Consultants
ii. KfW Guidelines for Assignment of Consultants in Financial Cooperation

with developing countries.
iii. Model Request for Proposal for Selection of Technical Consultants
published by Planning Commission, Government of India
iv. Request for Tender for Selection of Consultant for Feasibility Study for
Renovation & Modernization of Unit-4 of Nasik Thermal Power Station.
The recommended Selection Criteria for R&M Consultant and Implementation

Support Consultant broadly conforms to the Quality and Cost Based selection
process of World Bank guidelines and Two-Stage selection process with preselection as per KfW Guideline. However, it is recommended that the first stage
or pre-qualification stage will be Pass / No-Pass type without any limitation on
number of consultants to be pre-qualified for quality and cost based competition
in second stage. The evaluation criteria are in line with the Model RFP for
Technical Consultants published by Planning Commission.
Only Applicants found pre-qualified on the evaluation of qualification documents
submitted in response to the RFQ will be issued RFP documents for the
Consultancy work and will be eligible to submit Bid Proposal. The RFQ
Documents specify the qualification criteria to be met by the prospective bidders
to become eligible for participating in the tendering process. The bidders are
required to submit evidence of their technical expertise, relevant past
experience, competence of key personnel, project execution capability and
financial resources to discharge the scope of service.
Single Stage Two Part Bidding Procedure will be followed for RFP stage.
The bidders are required to submit, the bids for the Consultancy Services in two
parts. Both the parts are to be submitted together before the indicated Bid
submission Time & Dates.
The Part-I Bid comprises the techno-commercial bid without prices. The main
components of the Techno-Commercial Bid are Bid Guarantee, Methodology &
Work Plan for discharging the consultancy services as per Terms of Reference,
Details of Key Personnel along with their Curriculum Vitae, Deviations to Terms
of Reference, Deviation to commercial Conditions, Overall Completion Time
Period & Network Schedule, Resource Deployment Schedule, Detail of SubConsultants, Details of the present commitments & details of contracts in hand
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etc. Part-II Bid will comprise Quoted Price. Initially, only the Part-I Bid will be
opened and Part-II Bid will be kept in safe custody.
The Part-I Bid will be checked for responsiveness to techno-commercial
conditions and a detailed Technical Evaluation will be carried out to assign a
Technical Score to each Bid. Part-II Bid (Price Bid) of only those Bidders will be
opened, whose Part-I Bid is found to be responsive to Tender Specifications and
Conditions and Technical Score is above a specified level.
7.4
Request for Qualification for Consultants (R&M Consultant and ISC)

The RFQ document for selection of Consultants has been standardized. The
Standard RFQ covers the following aspects:
1. The scope of works for R&M Consultant
2. The RFQ details regarding the
i.
ii.
iii.
iv.
v.
3.
4.
5.
6.
Participation fee
Publication date of RFQ
Last date and time for receipt of RFQ applications
Date for selection of qualified consultancy Firm
List of Qualification Document
Instruction to Applicants
Standard Application Forms and Data Sheets
The following Forms and Data Sheets have been standardized

1.
2.
3.
4.
Format for the Pre qualification Application

Letter of Consent to be Furnished by the Associate
Letter of Consent to be Furnished by the Consortium Partners
Sample format for Data sheet regarding Technical Qualification
Requirement
5. Sample format for Data sheet regarding Financial Qualification
Requirement
7.5
Pre-qualification Documents
The pre-qualification documents requirement for consultants has been
standardized. These include the following:
(i)
(ii)
(iii)
(iv)
List of orders executed by them, their Consortium Partners /

Associates along with copies of orders to prove their qualifications.
Past Performance Certificates from the previous employers in respect
of such completed consultancy assignment(s) clearly indicating scope
of and date of completion for each assignment.
Names of proposed Associates or Consortium member if any, along
with Letters of Consent from each Associate / Consortium Partner.
Particulars of Key Personnel that must include inter alia their names,
details regarding qualification, areas of expertise, professional
experience and names of relevant projects.
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(v)
Documents of company profile incorporating details of technical man

power, financial strength, resources, organization and experience to
undertake such jobs as an evidence of their capacity for the
satisfaction of Employer.
(vi) Firms audited accounts for last three (3) years along with a copy of
latest income tax return filed.
(vii) Consultancy Assignments in hand / pending jobs and their status along
with value.
(viii) Pending legal cases, if any.
7.6
Request for Proposal for Consultants (R&M Consultant & ISC)

The Standard Request for Proposal for consultants comprises the sections as
indicated in the Table below:
Table: 7.1
Structure of Request for Proposal for Consultants
Section
Description
Commercial
1. Invitation For Bid
2. Instruction to Bidder
3. General Project Information
Section-I
4. General Condition of Contract (GCC)
5. Special Condition of Contract (SCC)
6. Forms and Schedules
Section-II Terms of Reference
General Conditions of Contract (GCC)
The GCC contains the Contracting Concept, the scope of the Contractor, the
precedence of the Contract Documents, definitions and Acronyms used in
the Contract Document, the severability of the Contract, the governing laws
to the Contract, methods for settlement of disputes, Time of commencement
and completion of the contract, Contractors Responsibilities, Owners
Responsibilities, Taxes and Duties applicable, Confidential Clause. It also
covers the Defect Liabilities, Completion Time and Liquidated damages,
Conditions to Performance Guarantees, Limitations of Liability, Transfer of
Ownership, Insurance, Force Majeure Conditions and Termination of the
Contract.
Special Conditions of Contract (SCC)
i. Effective date: The Owner shall inform the successful Bidder of its
acceptance of the Tender by a formal Letter of Acceptance. The date of
this Letter of Acceptance will be the Effective Date for determining the
Time for Completion of the milestones for Consultancy work as per the
scope of work. The Owner will make the advance payment promptly once
Contractor has fulfilled the necessary conditions specified in Terms of
Payment. If payment of Advance is delayed beyond two months from the
date of Letter of acceptance for reasons attributable to the Owner, the
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date of payment of advance shall be the effective date for determining the
time for completion of facilities. However, failure of the contractor to
provide all the required Bonds/Guarantees within the prescribed period will
cause the Bid Security to be forfeited.
ii.
iii.
Time of Commencement and Completion: The Time Schedule for the

execution of the scope of work by the Consultant is to be specified.
Contract Securities
a) Advance Payment Security: The Contractor shall, provide a security for
an amount equal to the advance payment, and in the same currency or
currencies, with validity of up to ninety (90) days beyond the date of
the Scheduled Completion Date for R&M Consultancy Services.
b) Performance Security: The Contractor shall provide a security for the
due performance of the Contract for five percent (5%) of the Contract
Price with an initial validity up to ninety (90) days beyond the the
Scheduled Completion Date for R&M Consultancy Services.
7.7
Evaluation Criteria for Consultants (R&M Consultant and ISC)

The selection of the successful Bidder for award of the R&M Consultancy
Services Contract and Implementation Support Consultancy (ISC) contract
will be based on both Quality of the Technical Proposal and Price quoted by
the Bidder for the entire scope of work. The selection process will comprise
the following steps:
1. First, Techno-Commercial offer will be assessed for completeness and
responsiveness to commercial/contractual conditions. Bidders qualifying
the criteria would be considered for further evaluation on the basis of
Quality and Price.
2. The Bidders proposed methodology and Work Plan for discharging the
Consultancy Assignment, experience of the Bidder and the experience &
expertise of Key Personnel will be assigned a Technical Score St. Only
those Bidders whose Technical Proposals get a Technical Score of 70
marks or more out of 100 shall qualify for further consideration.
The Technical score of each Bidder will be equal to the weighted sum scores
on three elements with indicated weights
St = 0.2 x St-1 + 0.3 x St-2 + 0.5 x St-3
Where:
a. St Technical score
b. St-1 should be less than or equal to 100 points, depending on the
clarity, completeness, soundness of methodology and scope of work. The
Bidder with the best submission will be assigned a score of 100 (St-1 =
100). Other Bidders will be assigned scores below 100 considering the
relative quality of the submission with respect to the best submission.
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c. St-2 should be less than or equal to 100 points, depending on the

Bidders experience on the grounds of size, nature & complexity of scope
and similarity with the subject R&M Consultancy Service /
Implementation Support Consultancy Service for at least 5 projects.
d. St-3 should be less than or equal to 100 points, depending on the
experience list of at least a specified number of personnel who would be
associated with the R&M Project.
3. The Price Proposal of each qualified Technical Bidder will be assigned a
Financial Score (Sf) on the basis of its cost competitiveness.
Sf = 100 x (Lowest Quoted Total Price /Total Price quoted by the Bidder)
4. Each bidder will be assigned a Composite Score (Sc) equal to the weighted
sum of Technical Score and Financial Score. Finally, the bidder with the
highest Composite Score will be selected as R&M Consultant for the
subject R&M Consultancy Services Contract or Implementation Support
Consultancy (ISC) contract.
For selection of successful Bidder, the Technical Score will be a weight of
70% and Financial Score will be given a weight of 30%. For each Bidder, the
Composite Score Sc will be computed as follows:
Sc = 0.7 x St + 0.3 x Sf
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MODEL REQUEST FOR QUALIFICATION

FOR
SELECTION OF CONTRACTOR
FOR
OF
PREPARED BY

THE CONSULTANT
LII-GETS12021-G-00100-006 R02
September 2014
Request for Qualification for the Selection of Contractor for R&M of Boiler of
Unit No.[..] Capacity [..] of [Name of the Power Plant]
[LOGO OF
UTILITY]
TABLE OF CONTENTS
1
INVITATION FOR QUALIFICATION .................................................................. 1

1.1
1.2
1.3
1.4
1.5
Introduction .......................................................................................... 1
INVITATION .......................................................................................... 1
Brief Scope of Work ............................................................................... 1
RFQ Details........................................................................................... 1
Objective of Request for Qualification ....................................................... 2
QUALIFICATION REQUIREMENT ..................................................................... 3

2.1 Qualification Requirement ....................................................................... 3
2.1.1 Technical Qualification Requirement ...................................................... 3
2.1.2 Financial Qualification Requirement ....................................................... 3
2.1.3 Other Criteria ..................................................................................... 4
2.2 Qualification Documents ......................................................................... 4
2.2.1 Documents to be submitted (Pre-qualification)......................................... 4
INSTRUCTION TO APPLICANTS ..................................................................... 6
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[i]
25.09.2014
[LOGO OF
UTILITY]
S.No
List of Formats & Data Sheets

Description
Format/ Data Sheet No.
1.0
Format for Pre-qualification Bid
Annexure-1
2.0
Format for Letter of Undertaking by JV Annexure-2

Partner / Holding Company / Consortium
Partner
pledging
unconditional
&
irrevocable support to the bidder for the
execution of R&M work.
Format for Letter of Consent to be Annexure-3
furnished by the Consortium Partners
Data Sheet-1
Sample format for Data sheet regarding
Technical Qualification Requirement at
Clause No. 2.1.1 (a).
3.0
4.0
5.0
6.0
7.0
8.0
9.0

Clause No. 2.1.1 (b).
Sample Format for Data Sheet regarding
Turnover requirement stipulated at RFQ
clause 2.1.2 (a)
Net worth requirement specified at RFQ
clause 2.1.2 (b)
Turnover & Net Worth requirement
when Bidder does not meet RFQ clause
2.1.2 (a) & 2.1.2 (b) on its own &
Holding/ Partner Company meet the
financial QR
utilized credit line & Bank balances as
per requirement at clause 2.1.2 (c) of
RFQ document
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Data Sheet-2
Data Sheet-3
Datasheet-4
Data Sheet-5
Data Sheet-6
Description
Page No.
Date of Issue
RFQ for Contractor
[ii]
25.09.2014
INVITATION FOR QUALIFICATION
1.1
Introduction
[LOGO OF
UTILITY]
[Give brief introduction about the name, location and details of the Power
Plant of the utility inviting tender for R & M work]
[XXX is undertaking renovation & modernization of XXX MW Unit no.-XX -------- of the Power Plant]
1.2
INVITATION
[Name of The Utility], hereinafter referred to as Employer / Owner /
Purchaser, is undertaking Renovation & Modernization project of Unit
No.[XXX] of the [XXX] Power Plant. Under this project, [Name of The Utility]
invites sealed Pre-Qualification Tenders from experienced and interested
bidders for the Renovation & Modernization Work of [Boiler & Auxiliaries]
package of Unit No.[XXX] of the [XXX] Power Plant on International
Competitive Bidding (ICB).
Interested bidders may collect the RFQ documents in person from [Name and
Contact Details of Designated Official.]. The RFQ documents can
be collected between [---] hrs to [---] hrs on all working days from
[.] to [.]. Alternatively, the RFQ document can
be downloaded from [Name of The Utility] website [..].
The Pre-Qualification Tender in the form and manner specified in the RFQ
document along with necessary attachments and stipulated participation fee
should be submitted to [Name and Contact Details of Designated
Official.] by [Date and Time ].
1.3
Brief Scope of Work

The scope of work under this R&M package involves disassembly and
replacement of specified existing equipments / systems by supplying new
equipments/ systems including supply of assembly materials, inspection &
testing at suppliers works, supply of mandatory spares, packing & forwarding,
transportation & insurance, receipt at site, unloading, handling & storage at
site, pre-assembly, fabrication, repair, servicing/ overhauling, erection, carrying
out of all associated civil works including supply of cement & steel etc., testing
& commissioning and successful completion of trial operation & Performance
guarantee tests for [Boiler & Auxiliaries] package of Unit no. [XXX] of [XXX]
Power Plant.
1.4
RFQ Details
(a)
Participation Fee
: INR [---]/ USD [---]/ EUR [---]
(b)
[----------------------------]
(c)
Last date for issue of

RFQ document
[----------------------------]
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
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Date of Issue
RFQ for Contractor
[1]
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(d)
Last Date & Time of

Receipt of PreQualification Bids and
Date &Time for
Opening of
Prequalification Bids
[----------------------------]
(e)
Date for identification

of Qualified Bidders and
Issuance of RFP
[----------------------------]
[LOGO OF
UTILITY]
If any of the date happens to be a public holiday, the deadline will be the next
working day.
1.5
Objective of Request for Qualification

[Name of the Utility] is carrying out this Pre-Qualification Process to identify
qualified bidders for the issuance of RFP Documents for the Tender of
Renovation & Modernization work of [Boiler & Auxiliaries] package of Unit no.
[XXX] of [XXX] Power Plant. The objective of the pre-qualification is to allow
only the capable and qualified bidders having requisite technical expertise,
relevant experience, project execution capability and financial resources to
participate in the tendering process.
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
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[2]
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QUALIFICATION REQUIREMENT
2.1
[LOGO OF
UTILITY]
To be pre-qualified for participation in tendering process for the subject

Renovation & Modernization work for [Boiler & Auxiliaries] package, the
bidder must meet the Technical Qualification Requirement specified at clause
2.1.1 and Financial Qualification Requirement specified at clause 2.1.2 below.
Further, the eligibility of the Bidders to participate in the Tendering process is
subject to other criteria specified at clause no 2.1.3.
2.1.1
Technical Qualification Requirement

(a)
The Bidder, during the last 10 years preceding the scheduled date for
submission of Pre-Qualification Tenders indicated in row (d) in section
1.4 above, should have designed, engineered, manufactured, supplied,
erected/ supervised erection and commissioned / supervised
commissioning of one (1) unit of reheat type coal/lignite fired Boiler for a
power plant unit of 200 MW or above capacity which should have
completed satisfactory operation for a period of not less than One (1)
years as on the date of opening of Pre-Qualification Bid.
And
2.1.2
(b)
The bidder, during the last 10 years preceding the scheduled date for
1.4 above, should have successfully completed execution of Renovation
& Modernization of one (1) unit of coal/ lignite fired Boiler for a power
plant unit of 50 MW or above capacity.
(c)
The bidder can be a Joint Venture of two firms who collectively meet
the Qualification Requirement specified at (a) and (b) above. Each of the
JV partner must have at least 26% equity in the JV and in case of
award of contract, must maintain JV arrangement till the successful
completion of the R&M work. In such a case, parts and components of
boiler has to be sourced from the partner who satisfies the Qualification
Requirement specified at (a).
(d)
The bidder can be a Consortium of two firms who collectively meet the
Qualification Requirement specified at (a) and (b) above. The Consortium
members shall designate one member as the Leader of the Consortium
with whom the Contract will be entered into in case the Consortium
emerges as the successful bidder. In such a case, parts and components
of boiler has to be sourced from the Consortium member who satisfies
the Qualification Requirement specified at (a).
Financial Qualification Requirement

(a)
The average annual turnover of the Bidder should be at least [Indian

Rupees ] millions or equivalent foreign currency as per audited
annual accounts during the preceding three consecutive years [FY
.], [FY ] and [FY ...] For the purpose of conversion of
foreign currency to Indian Rupees, the TT Buying rate of State Bank of
India as on 30 days prior to the date of submission of Bid will be
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[3]
25.09.2014
[LOGO OF
UTILITY]
considered. Other income will not be considered for arriving at the

annual turnover.
(b)
The Net Worth of the Bidder as on the last date of preceding Financial
Year shall be positive.
(c)
The sum of bank balances (including fixed deposits) and available

unutilized credit line of the bidder (including non fund based credit lines)
should not be less than [INR.] as on not more than 30 days prior
to the scheduled last date of submission of Pre-qualification Bid
(d)
In case the Bidder/Consortium Leader does not satisfy the Financial

Criteria stipulated in the above clauses (a) and (b) on its own and the JV
Partner in case the Bidder a Joint Venture of two firms or Holding
Company having controlling interest in the Bidder / Consortium Partner
Company, as the case may be, meets the stipulated turn-over
requirements at Clause (a), then Financial Criteria stipulated in the above
clauses (a) and (b) will be deemed to have been met, provided that the
Net worth of such Holding Company / Partner Company, as the case
may be, as on the last day of the preceding financial year is at least
equal to or more than [..]. In such a case, the Bidder /
Consortium Leader has to submit a Letter of Undertaking from the JV
Partner Company/ Holding Company/ Consortium Partner company
pledging unconditional and irrevocable financial support to the bidder for
execution of the Contract.
To establish the financial capacity for performance of the contractual
obligations, the Bidder shall furnish documentary proof of their audited
annual turnover and net worth for the last three (3) financial years [FY
.], [FY ] & [FY ..].
2.1.3
Other Criteria
(a)
Any firm who is or was involved as a Consultant in the preparation for

this R&M Project for activities such as Feasibility Study or RLA/CA Study
or Energy Audit or preparation of DPR/Tender Document or any other
preparatory activity or any firm who is or was involved as a consultant
for implementation of this R&M project or whose associate or affiliate is
or was involved as a consultant in the preparation or implementation of
this R&M project cannot participate as a bidder for this R&M Tender.
(b)
Any bidder who is legally barred from the procurement process of [name
of Utility] on the grounds of previous violations of rules/regulations on
fraud and corruption or any other reason cannot participate as a bidder
for this R&M Tender.
(c)
Any firm or its associate company or parent company cannot participate

as Bidder or JV Partner or Consortium Member in more than one Bid
under this tender.
2.2
Qualification Documents
2.2.1
Documents to be submitted (Pre-qualification)
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[4]
25.09.2014
[LOGO OF
UTILITY]
Bidders are required to furnish following documents for pre-qualification in

[five (5)] copies and an application with requisite participation fee along with
their Pre-Qualification Bid.
(i)
List of orders executed by them along with copies of orders to
demonstrate their qualifications.
(ii)
Past Performance Certificates clearly indicating date of completion from
the facility owner in respect of such completed contract(s).
(iii) Name of any proposed JV partner or Consortium member along with
details of equity participation of JV partner or letter of consent of
consortium partner.
(iv) Documents of company profile incorporating technical man power,
financial strength, resources, organization and experience to undertake
such jobs as an evidence of their capacity to the satisfaction of
Employer. Firms audited accounts for last three years along with copy
of latest income tax return filed.
(v) Contracts in hand / pending jobs and their status along with value.
(vi) Major pending legal cases.
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[5]
25.09.2014
[LOGO OF
UTILITY]
INSTRUCTION TO APPLICANTS
3.1.
Only bidders pre-qualified on the evaluation of qualification documents

submitted in response to the RFQ will be issued RFP documents for the R&M
work of [Boiler & Auxiliaries] package and will be eligible to submit Bid
Proposal for R&M work. The RFQ Documents specify the qualification criteria
tendering process. The bidders are required to submit evidence of their
technical expertise, relevant past experience, project execution capability and
financial resources to discharge the scope of service
3.2.
[Name of Utility] is committed to have most ethical business dealing with the
Vendors, Bidders and Contractors of goods and services and deal with them
in a transparent manner with Equity and Fairness. In case,
certificate(s)/document(s) submitted by the Bidder or JV Partner or
Consortium leader or Consortium partner is found to be factually incorrect or
manipulated, the Bidder or JV Partner or Consortium leader or Consortium
partner as the case may be, will be disqualified for the tender and will be
liable to be blacklisted / debarred by the Employer for future tenders.
3.3.
The Scope of work of the Bidder shall be on the basis of single bidder
responsibility. The contract will be entered into only with the successful
Bidder / Consortium leader. Thus the bidder / Consortium leader shall be solely
responsible and liable for all the technical, management and all other services
required for completing the entire scope of work.
3.4.
The Bidder / Consortium leader and Consortium partner shall not Sub-contract
the entire scope of work, back to back or otherwise, for the performance of
this contract.
3.5.
The bidder meeting the Qualifying Requirement on the strength of the JV

partners should enclose details of equity holding of the JV partners. However,
in the event, the bidder is found pre-qualified and issued RFP document, while
submitting the techno-commercial Bid Proposal for R&M work, the bidder shall
furnish a copy of the Joint Venture Agreement. Further, while submitting the
techno-commercial Bid Proposal for R&M work, the JV partners shall furnish a
joint undertaking towards joint and several liability to the employer for the
successful performance of the Contract. The undertaking shall be furnished as
per the format to be specified in the RFP document.
3.6.
The bidder meeting the Qualifying Requirement as a Consortium should

enclose the Letter of Consent (as per the prescribed format) from the
consortium Partner along with the Pre-Qualification Bid signed by the
Consortium Partners indicating the scope of work. However, in the event, the
bidder is found pre-qualified and issued RFP document, while submitting the
techno-commercial Bid Proposal for R&M work, the bidder (consortium leader)
shall furnish a Consortium Agreement with the other Consortium member. No
new consortium partner, (other than those qualified at Pre-qualification stage)
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[6]
25.09.2014
[LOGO OF
UTILITY]
will be permitted at the time of submitting the Techno commercial Bid.

Further, while submitting the techno-commercial Bid Proposal for R&M work,
the Consortium leader and Consortium member will furnish a joint undertaking
regarding diligent performance of their respective scope of work and towards
joint and several liability to the employer for the successful performance of
the Contract. The undertaking shall be furnished as per the format to be
specified in the RFP document.
3.7.
As a Contract security, the successful Bidder, to whom the work is awarded,

shall be required to furnish a Contract Performance Guarantee (CPG) in the
Format to be specified in RFP document, in favour of the Owner within 30
days from the date of issue of Letter of Award (LOA). The guarantee amount
shall be equal to ten percent (10%) of the Contract Price and it shall
guarantee the faithful performance of the Contract in accordance with the
terms and conditions specified in the documents and specifications. The CPG
shall be valid till the end of Warranty Period plus Ninety (90) days grace
period.
If the bidder is a joint venture of two firms who collectively meet the
Qualifying Requirement, in addition to the Contract Performance Guarantee
(CPG) of 10% furnished by the bidder, each of the JV partner shall furnish
Additional Contract Performance Guarantee equal to 1% of Contract Price.
If the bidder is a Consortium of two firms, in addition to the Contract
Performance Guarantee (CPG) of 10% furnished by the Consortium Leader,
the other consortium member will furnish Additional Contract Performance
Guarantee equal to 2% of Contract Price
The Bidder shall provide satisfactory evidence that he and / or, where
applicable, the consortium leader and consortium partners have adequate
capability and capacity to perform the work properly and expeditiously within
the time period specified. The evidence shall specifically cover, with written
details, the installed manufacturing and / or fabrication capacities to meet the
requirements appropriate to the works covered in his bid have an adequate
field service organization to provide the necessary field erection and
management services required to successfully erect, test and commission the
equipment / system as required by the bidding documents. Pre-Qualification
Bid submitted without the proper documentary evidence to substantiate
fulfilment of the qualifying requirements as specified are liable for rejection
without assigning any reason.
3.8.
The Bidder shall provide satisfactory evidence that he has adequate capability and
capacity to perform the work properly and expeditiously within the time period specified.
The evidence shall specifically cover, with written details, the installed manufacturing and
/ or fabrication capacities to meet the requirements appropriate to the works covered in
his bid and adequate field service organization to provide the necessary field erection and
management services required to successfully erect, test and commission the equipment
/ system as required by the bidding documents. Pre-Qualification Bid submitted without
the proper documentary evidence to substantiate fulfillment of the qualifying
requirements as specified are liable for rejection without assigning any reason.
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[7]
25.09.2014
[LOGO OF
UTILITY]
3.9.
Notwithstanding anything stated above, [Name of Utility] reserves the right

to verify independently all statements / information submitted to confirm the
bidders / Consortium leaders & Consortium Partners claim on experience
and to assess the Bidders / Consortium leaders & Consortium Partners
capability and capacity to perform the contract, should the circumstances
warrant such an assessment in the overall interest of the project.
3.10.
[Name of Utility] reserves the right to reject any or all Pre-Qualification Bids
or cancel / withdraw the Request for Qualification without assigning any
reason whatsoever and in such case no bidder / intending bidder shall have
any claim arising out of such action.
3.11.
Participation Fee for an amount of [INR..] or [USD..] or

[Euro.] in the form of Demand Draft drawn in favour of [Name of
Utility], payable at [XXXXX] is to be submitted along with the PreQualification Bid. Pre-Qualification Bid received without the Participation Fee
will be rejected. Participation Fee is non-refundable.
3.12.
Language of Bid
The Bid submitted by the Bidder and all correspondences and documents
relating to the Bid exchanged by the bidder and [Name of Utility] shall be
written in English language. Any printed literature / material furnished by the
bidder in any other language shall be accompanied by an authentic English
translation of all the pertinent points. For purpose of interpretation of the bid,
the English translation shall govern.
3.13.
Signature on Pre-Qualification Bid

The Pre-Qualification Bid must contain the name and place of business of the
Bidder and each page of the EOI must be signed and sealed by the authorized
person(s) of the Bidder / Consortium leader with his usual signature. The
name of all persons signing should be typed or printed below the signature.
Satisfactory evidences of authority of the person signing on behalf of the
bidder / Consortium leader shall be furnished with the Bid.
The Bidder / Consortium leaders name stated on the Pre-Qualification Bid
shall be the exact legal name of the firm.
3.14.
Method of Submission of Pre-Qualification Bid

The Pre-Qualification Bid shall be submitted in one (1) original and five (5)
identical copies indicating clearly as original and copy along with a soft
copy in PDF format. The cover shall be pasted properly before applying the
official seal. Failure to do so would result in rejection of The Pre-Qualification
Bid.
The outside of the covers should indicate clearly the name of the Bidder /
Consortium leader and his address. In addition, the envelope or container
should indicate the "Tender No. and Name of the work for which the PreQualification Bid is submitted ". Pre-Qualification Bid with no indication given
on the outside of the envelope that it is a Pre-Qualification Bid which
therefore gets opened before the due date shall be liable to be disqualified. All
the pages of the Pre-Qualification Bid shall be serially numbered.
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[8]
25.09.2014
[LOGO OF
UTILITY]
The Pre-Qualification Bid, complete in all respects, must be submitted to the

official and address mentioned below.
[XXXXX]
[XXXXX] [XXXXX]
Submission of Pre-Qualification Bid through Fax, Telex, E-Mail will not be
accepted.
[Name of Utility], takes no responsibility for delay, loss or non-receipt of
documents or any letter sent by post either way.
Pre-Qualification Bids must reach the above office on or before [XXXXX]
Hours (IST) on [XXXXX]. Any Pre-Qualification Bid received after the expiry
of the time specified is liable for rejection.
3.15.
Opening of Pre-Qualification Bid

The Pre-Qualification Bids received from the bidders as above will be opened
at [Place XXXXX] on Date and at Time indicated in row (d) in section 1.4
above.
The Pre-Qualification Bids shall be opened in the presence of such bidders
who may be present. The bidders are at liberty to be present or authorise their
representatives (not more than two per Bidder) to be present at the time of
opening of Pre-Qualification Bids.
Accredited Agents / representatives of foreign bidders in India are also
permitted to submit the Pre-Qualification Bids on behalf of the foreign bidders
with due Authorisation Letter.
Clarification request regarding the content of RFQ Document and RFQ
process, if any, should reach at least [15 (Fifteen) days] before the date
stipulated for opening of Pre-Qualification Bid. Requests for clarification
received after this will not be entertained. [Name of Utility] will issue
interpretations and clarifications as it may deem fit.
3.16.
Application Data Sheets and Forms

The Pre-Qualification Bid is to be submitted as per the Format at Annexure-1.
The following sample formats are to be used for the various attachments to
be submitted with the Pre-Qualification Bid. Wherever no sample format has
been specified, Bidder is required to use any appropriate format as per
prevalent practice in conformity with the requirement stipulated in RFQ
document.
Sl No
1.0
2.0
3.0
Description
Format for Letter of Undertaking by JV
Partner / Holding Company / Consortium
Partner
pledging
unconditional
&
Format for Letter of Consent to be
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02

Annexure-1
Annexure-2
Annexure-3
Description
Page No.
Date of Issue
RFQ for Contractor
[9]
25.09.2014
Sl No
4.0
5.0
6.0
7.0
8.0
9.0
Description
clause 2.1.2 (a)
clause 2.1.2 (b)
2.1.2 (a) & 2.1.2 (b) on its own &
Holding/ Partner Company meets the
financial QR
RFQ document
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
[LOGO OF
UTILITY]

Data Sheet-1
Data Sheet-2
Data Sheet-3
Datasheet-4
Data Sheet-5
Data Sheet-6
Description
Page No.
Date of Issue
RFQ for Contractor
[10]
25.09.2014
Unit No. [..] Capacity [..] of [Name of the Power Plant]
[LOGO OF
UTILITY]
Annexure-1
Format for Pre-Qualification Bid

Date: - [XXXXX]
RFQ No. [XXXXX]
Name of Package: Renovation & Modernization of [..] Package for Unit No.
[XXXXX] of [XXXXX] power plant of [XXXXX].
To,
[Designated Officer XXXXX]
[Address XXXXX]
Dear Sir /Madam

1.0
Having examined the RFQ Document No. [XXXXX], we the undersigned intend to
participate in the pre-qualification process for selection of qualified bidders for
Renovation & Modernization of [Boiler & Auxiliaries] Package for unit [XXXXX] of
[XXXXX] power plant of [XXXXX]. Towards this end we submit the following details &
documents for prequalification.
2.0
Name of the Bidder/Leader of Consortium with name & designation of person
authorized to submit the pre-qualification bid:
Name of Bidder/ Leader of Consortium: []
Name & Designation of Authorized Person: []
3.0
We meet the Qualification Requirement stipulated at clause no.2.1.1 & 2.1.2 of
RFQ document on our own/ on the strength of the parent JV partner [XXXXX] &
[XXXXX] / in association with our Consortium Partner [XXXXX].(Bidder to strike off
whichever is not applicable).
(The bidder is required to give a detailed description indicating the specific part of the
qualification requirement which is met by the Bidder/JV Partner/ Consortium Members.
Bidder is also required to furnish the relationship between the Bidder & others on whose
strength Qualification Requirement is met.)
4.0
We confirm that neither we nor any of our parent JV Partners/ Our Consortium
Members/ Our associates/ affiliates are liable for exclusion from participation in tendering
process under other criteria stipulated under clause no.2.1.3 of RFQ document.
5.0
We are enclosing the following attachments as integral part of our PreQualification Bid
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[11]
25. 09.2014
[LOGO OF
UTILITY]
(i)
Covering Letter
(ii)
Power of Attorney in favor of persons signing on behalf of Bidder,

Consortium members, Parent JV Partner and Holding Company as
applicable.
(iii)
Data Sheet regarding Technical Qualification Requirement at clause 2.1.1

(a)
(iv)

(b)
(v)
Data Sheet regarding turnover requirement at RFQ clause no. 2.2.1 (a)
(vi)
Data Sheet regarding net worth requirement at RFQ at clause 2.2.1 (b)
(vii)
Data Sheet regarding bank balances & available unutilized credit line.
(viii)
Letter of Undertaking pledging unconditional & irrevocable financial

support to the bidder for execution of the contract.(In case of financial QR
is met on the strength of Holding Company/ Partner Company.)
(ix)
(x)
Letter of Consent of Consortium partner in case of Consortium

Details of equity holding of JV partners for Joint Ventures.
6.0
We are submitting the following supporting documents to demonstrate our
qualifications & capability to execute the subject R&M work:(i)
List of order executed
(ii)
Copies of order
(iii)
Past performance certificate.
(iv)
Contracts in hands/pending jobs along with value
(v)
Documents regarding company profile, technical manpower, financial

strength, resources, construction equipment.
(vi)
Copies of last 3 year audited financial statement.
(vii)
List of major litigations/disputes.
(viii)
Any other document.
7.0
We hereby attach participation fee of [INR-----------] in the form of demand draft in
favor of [XXXXX] payable at [XXXXX].
8.0
We certify that all the information and documents furnished with this PreQualification Bid are true and genuine to the best of our knowledge & belief.
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[12]
25. 09.2014
[LOGO OF
UTILITY]
Dated this [XXXXX] day of [XXXXX] 20XX

Yours Faithfully,
Signature [XXXXX]
Full Name [XXXXX]
Designation [XXXXX]
Company Seal [XXXXX]
Business Address: [XXXXX]
Country & province of Incorporation [XXXXX]
Contact details [XXXXX]
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[13]
25. 09.2014
[LOGO OF
UTILITY]
Annexure-2
Format for Letter of Undertaking by Holding Company / JV Partner /
Consortium Partner pledging unconditional & irrevocable support to the Bidder
for the execution of R&M work.
Ref.: [XXXXX]
Date: [XXXXX]
To,
[Designated Official of Utility XXXXX]
[Name & Address XXXXX]
Dear Sir/ Madam,

*We, M/s.................. (Name and Complete address of the Holding Company)
hereby declare that we have controlling interest in ..(Name of the
Bidder) who is submitting Prequalification bid for R&M of Boiler Package for
Unit No. [.] of [] Plant of [].
M/s..(Name of the Bidder) have sought financial strength and support
from us for meeting the stipulated Financial Qualifying Requirement as per
Clause 2.1.2 (a) & (b) of RFQ document./
*We have formed a Joint Venture with (name of other JV Partner) and the
Joint Venture (Name of JV) is submitting Prequalification bid for R&M of
Boiler Package for Unit No. [.] of [] Plant of
[]. M/s..(Name of JV) have sought financial strength and
support from us for meeting the stipulated Financial Qualifying Requirement as
per Clause 2.1.2 (a) & (b) of RFQ document. /
*We, M/s.................. (Name and Complete address of the Consortium
Partner) hereby declare that we have agreed to associate with ..(Name
and Complete address of the Bidder/Consortium Leader) for part scope of
work of for the package ............................. (Name of the package) for Unit
No. [XXXXX] of [XXXXX] power plant of [XXXXX] under RFQ
no.......................... dated ..................... and M/s..(Name of the
Bidder/Consortium Leader) have sought financial strength and support from us
for meeting the stipulated Financial Qualifying Requirement as per Clause
2.1.2 (a) & (b) of RFQ document.
We hereby undertake to pledge our unconditional & irrevocable financial
support
for
the
execution
of
the
said
package
to
M/s........................................ (Name of the Bidder), for the execution of
the Contract, in case they are awarded the Contract for the said package at
the end of the bidding process. We further agree that this undertaking shall be
without prejudice to the various liabilities that M/s....................................
(Name of Bidder) would be required to undertake in terms of the Contract
including the Performance Security as well as other obligations of the
Bidder/Contractor.
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[14]
25. 09.2014
[LOGO OF
UTILITY]
This undertaking is irrevocable and unconditional, and shall remain in force till
the successful execution and performance of the entire contract and/or till it is
discharged by Employer.
Yours faithfully,
(Signature of Authorized
Signatory) on behalf of the
Holding Company)
Name & Designation........................................
Date:
Place:
Name of the Holding Company..............................

Seal of the Holding Company.................................
1.
*Strike off whichever is not applicable
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[15]
25. 09.2014
[LOGO OF
UTILITY]
Annexure-3
Letter Of Consent To Be Furnished By The Consortium Partners
We hereby declare that the undersigned firm (Name and Complete
address of the Consortium Partner) hereby agrees to associate with ..
(Name and Complete address of the Bidder/Consortium Leader) for the
successful completion of part scope of work as enclosed in the attachment
(authenticated by the Consortium Partner) of [XXXXX] Package for the Unit
no.[XXXXX] of .[XXXXX] plant in the state of [XXXXX] for [XXXXX], India.
We also hereby undertake to ensure the quality of manufacture, timely delivery
and the successful performance of the equipment/system covered in our scope
of. [XXXXX] , fully meeting the guarantee and also depute our technical
experts from time to time for advice on procedures and guidance during design,
engineering, manufacture, erection, testing and commissioning, as applicable to
the place of work / Employers Project site.
On award of LOA, we the Consortium Partner agrees to furnish on demand a
back up bank guarantee for 2 % of Contract Price.
1.
WITNESS
For Consortium Partner
Signature:
(Signature of the Authorized Signatory)
Name
Name
Designation:
Designation:
Office Address
2.
Seal of the Company
WITNESS
Signature:
For Bidder
Name
Name
Designation:
Designation:
Office Address
Seal of the Company
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[16]
25. 09.2014
[LOGO OF
UTILITY]
Data Sheet-1
Sample format for Data Sheet regarding Technical Qualification Requirement at Clause
No. 2.1.1 (a):
To,
Bidder/Consortium
Partner/JV Partners Name
and Address:-
[Designated Official]
[Name of Utility]
[Address]
*We are submitting the Prequalification Bid for R&M of [Boiler & Auxiliaries] Package for
Unit No. [..] of [] Plant of [.]. /
*We are associated with (Name of Consortium Leader) as Consortium Partner for R&M
of Boiler Package for Unit [] of [] Plant of
[..] / *We have formed a Joint Venture with (name of other JV Partner)
and the Joint Venture (Name of JV) is submitting Prequalification bid for R&M of Boiler
Package for Unit No. [.] of [] Plant of [].
We have designed, engineered, manufactured, supplied, erected/supervised erection and

commissioned/supervised commissioning of at least one (1) unit of reheat type coal fired
Boiler for a power plant unit of 200 MW or above capacity which has completed
satisfactory operation for a period of not less than two (2) years as on the scheduled
date of opening of Prequalification Bid as per stipulated requirement at Clause No. 2.1.1
(a) of RFQ document. The details of the same are given below:
Sl.
Description
Installation
No.1
1.
Name of the Thermal Power

Station and its Location
2.
Client Name and its Address,

Fax & Tel. No.
Installation
No.2
Installation
No.3
- Email ID
- Web site address
3.
Name and Designation of the

responsible person in Clients
organization.
4.
No. of Boiler & Auxiliaries Sets

supplied to the Station
5.
Contact No. & Date
6.
Capacity in MW of unit
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[17]
25. 09.2014
Sl.
Description
[LOGO OF
UTILITY]
Installation
No.1
Installation
No.2
Installation
No.3
7.
Starting Date of the Project
8.
Schedule Date of Completion
9.
Actual Date of Completion
10.
Date of Commencement
Successful Operation
11.
(a) Whether the Plant is coal

fired thermal power station
Yes*/No*
Yes*/No*
Yes*/No*
(b) Whether the

reheat type
Yes*/No*
Yes*/No*
Yes*/No*
(i) Designed
Yes*/No*
Yes*/No*
Yes*/No*
(ii) Engineered
Yes*/No*
Yes*/No*
Yes*/No*
(iii) Manufactured
Yes*/No*
Yes*/No*
Yes*/No*
*Supervised
Yes*/No*
Yes*/No*
Yes*/No*
(v) *Commissioned
/
*Supervised Commissioning
Yes*/No*
Yes*/No*
Yes*/No*
12.
is
of
Scope of Work executed for the

aforesaid Boiler & Auxiliaries
includes the following:
(iv) *Erected
Erection
13.
Boiler
of
Details of Boiler & Auxiliaries

Is this Steam Generator of the Yes*/No*
similar type as per reference
package
Yes*/No*
Yes*/No*
Type of Boiler [*Drum type with

*single pass (Tower type) /
*Two pass arrangement or
*once through type with* single
pass (Tower Type) / *Two pass
arrangement]
Boiler Superheated steam flow
capacity (T/Hr)
Main Steam Temperature (C)
Main Steam Pressure {kg/cm
(a)}
Reheat Steam flow (T/Hr)
Reheat outlet pressure
{kg/cm(a)} and temperature
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[18]
25. 09.2014
Sl.
Description
Installation
No.1
Installation
No.2
[LOGO OF
UTILITY]
Installation
No.3
(C)
Whether balanced draft type or
not
Type of start up/ circulation
system
Details of water wall tube
(i) Type of water wall tubes
(Inclined, Wrap around or
vertical plain, ribbed or
vertical rifled)
(ii) Tube outer dia & thickness
(mm)
(iii) Width of fins in the
membrane wall (mm)
Mass flow through the water
wall tubes in the burner zone
(Kg/m-sec) (applicable for
bidders offering drum type
Steam Generator)
a)Maximum
b)Minimum
Minimum load at which
separator runs dry (%)
(applicable for bidders offering
once through type Steam
Generator Unit)
Type of coal used
i)
Max. HHV (kCal/kg)
ii)
Min.HHV (kCal/kg)
iii)
Max. Ash content (%)
iv)
Max. total moisture

content (%)
v)
Volatile matter
content (%)
Type of oil used for Start up/low

load operation
i)
HHV (Kcal/Kg)
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[19]
25. 09.2014
Sl.
Description
Installation
No.1
ii)
Sulphur content (%)
iii)
Viscosity in
centistokes at 50C
(Max.)
iv)
Pour point (C)
v)
Flash point (C)
Installation
No.2
[LOGO OF
UTILITY]
Installation
No.3
Any other Type of fuel(s) used

Firing rate (T/hr.)
Type of
firing(Corner/Wall/Downshot etc)
Calorific value of fuel (kCal/kg)
Designed Boiler efficiency and
corresponding GCV
Tested boiler efficiency and
corresponding GCV
Tested boiler efficiency
corrected to design conditions
and corresponding GCV
a) Whether used for two shift
operation
b) If yes, number of such
operations it has been designed
for
c) No. of actual two shift cycles
it has actually operated till date
Minimum start-up time achieved
i)
Cold (after 72 hrs of
unit shut down)
ii)
Warm (after 36 hrs of

unit shut down)
iii)
Hot (after 8 hrs of

unit shut down)
Availability of Steam Generator

for last two years
Maximum Total NOx emmission
(from thermal as well as fuel)
from Steam Generator at rated
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[20]
25. 09.2014
Sl.
Description
Installation
No.1
Installation
No.2
[LOGO OF
UTILITY]
Installation
No.3
load with coal firing gm / Giga

joules of Heat input
14.
Certificate(s) from the Client

is/are enclosed along with the
bid at Annexureto this
Attachment
Date
:
(Signature.)
Place :
(Full Name)
(Designation)
(Company Seal)
1. If required, continuation sheets may be used.

2. *Strike off whichever is not applicable
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[21]
25. 09.2014
[LOGO OF
UTILITY]
Data Sheet -2
No. 2.1.1 (b):
To,
Bidder/Consortium
and Address:-
[Name of Utility]
[Address]
*We are submitting the Prequalification Bid for R&M of [Boiler & Auxiliaries] Package for
Unit No. [..] of [] Plant of [.]. /
*We are associated with (Name of Consortium Leader) as Consortium Partner for R&M
of Boiler Package for Unit [] of [] Plant of
[..] / *We have formed a Joint Venture with (name of other JV Partner)
and the Joint Venture (Name of JV) is submitting Prequalification bid for R&M of Boiler
We have successfully completed execution of Renovation & Modernization of at least
one coal fired Boiler for a power plant unit of 50 MW or above capacity. The details of
the same are given below:
Sl.
Description
1.

2.

Fax and Tel. Nos.
Installation
No.1
Installation
No.2
Installation
No.3
Yes*/No*
Yes*/No*
Yes*/No*
- Email ID
- Web site address
3.

organization.
4.
No. of Steam Generator sets

retrofitted by us for the station
5.
Capacity in MW of Unit
6.
Starting date of Project
7.
Scheduled date of completion
8.
Actual date of completion
9.
Date of commencement
successful Operation
10.
Whether the Plant is coal fired
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
of
Description
Page No.
Date of Issue
RFQ for Contractor
[22]
25. 09.2014
Sl.
Description
[LOGO OF
UTILITY]
Installation
No.1
Installation
No.2
Installation
No.3
Designed
Yes*/No*
Yes*/No*
Yes*/No*
Engineered
Yes*/No*
Yes*/No*
Yes*/No*
Manufactured
Yes*/No*
Yes*/No*
Yes*/No*
*Erected / *Supervised Erection
Yes*/No*
Yes*/No*
Yes*/No*
*Commissioned / *Supervised
Commissioning
Yes*/No*
Yes*/No*
Yes*/No*

11.
Details of Steam Generator for

which R&M work had been done
by us:
Brief scope of R&M work carried
out
Scope of work executed by us
for
the
aforesaid
Steam
Generator
and
associated/
auxiliaries includes the following
:
List of major parts/equipment

renovated / retrofitted and type
of
work
for
such
parts/equipment
(repair
/
replacement / modification etc.)
Is this Steam Generator of the Yes*/No*
package
Yes*/No*
Yes*/No*
Type of Steam Generator

[*Drum type with *single pass
(Tower type) / *Two pass
arrangement or *once through
type with* single pass (Tower
Type) / *Two pass arrangement]
Steam Generator Superheated
steam flow capacity (T/Hr)
Main Steam Temperature (C)
Main Steam Pressure {Kg/cm
(a)}
Reheat Steam flow (T/Hr) if
applicable
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[23]
25. 09.2014
Sl.
Description
Installation
No.1
Installation
No.2
[LOGO OF
UTILITY]
Installation
No.3
Reheat outlet pressure

{Kg/cm(a)} and temperature
(C) if applicable
Whether balanced draft type or
not
Type of start up/ circulation
system
Details of water wall tube
(iv) Type of water wall tubes
(Inclined, Wrap around or
vertical plain, ribbed or
vertical rifled)
(v) Tube outer dia & thickness
(mm)
(vi) Width of fins in the
membrane wall (mm)
Type of coal used
vi)
Max. HHV (kCal/kg)
vii)
Min.HHV (kCal/kg)
viii)
Max. Ash content (%)
ix)
Max. total moisture

content (%)
x)
Volatile matter
content (%)
Type of oil used for Start up/low

load operation
vi)
HHV (kCal/kg)
vii)
Sulphur content (%)
viii)
Viscosity in
centistokes at 50C
(Max.)
ix)
Pour point (C)
x)
Flash point (C)
Any other Type of fuel(s) used

Firing rate (T/hr.)
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[24]
25. 09.2014
Sl.
Description
Installation
No.1
Installation
No.2
[LOGO OF
UTILITY]
Installation
No.3
Type of firing
(Corner/Wall/Downshot etc)
Calorific value of fuel (kCal/kg.)
Designed Boiler efficiency and
corresponding GCV
Boiler efficiency before R&M and
corresponding GCV
Tested boiler efficiency after
R&M and corresponding GCV
Tested boiler efficiency after
R&M corrected to design
conditions and corresponding
GCV
Boiler capacity before R&M
(T/hr)
Boiler capacity after R&M (T/hr)
operation
for
iv)
unit shut down)
v)

unit shut down)
vi)
Hot (after 8 hrs of

unit shut down)
Availability of Steam Generator

for last two years
Maximum Total NOx emmission
(from thermal as well as fuel)
from Steam Generator at rated
load with coal firing gm / Giga
joules of Heat input
Extended life after R&M (years)
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[25]
25. 09.2014
Sl.
Description
Installation
No.1
12.

bid at Annexure [] to this
Attachment
Date
Installation
No.2
[LOGO OF
UTILITY]
Installation
No.3
(Signature.)
Place :
(Printed Name)
(Designation)
(Company Seal)
1.
If required, continuation sheets may be used.
2.
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[26]
25. 09.2014
[LOGO OF
UTILITY]
Data Sheet-3
Sample Format for Data Sheet regarding Turnover requirement stipulated at RFQ clause
2.1.2 (a):
To,
Bidder/Consortium
and Address
[Name of Utility]
[Address]
We are submitting the Prequalification Bid for R&M of [Boiler Auxiliaries] Package for
Unit No. [..] of [] Plant of [.].
In line with RFQ Document clause 2.1.2(a) , we confirm that our average annual
turnover during the preceding three financial years as on date of bid opening is not less
than [XXXXX] or in equivalent foreign currency. In support of above, we are enclosing
Balance Sheets and Profit & Loss Account duly certified by a Chartered Accountant.
Sl. No.
1
2
3
4
Financial Year
Amt. of Bidders
Currency
Amt. in Rs.
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Financial Years.
We have enclosed
Balance Sheets and
Profit & Loss Account
duly certified by
Chartered Accountant
Date:
Place:
Exchange rate
as on 30 days
prior to the
schedule date
of bid opening
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[27]
25. 09.2014
[LOGO OF
UTILITY]
Data Sheet-4
Sample Format for Data Sheet regarding Net worth requirement specified at RFQ
clause 2.1.2 (b):
To,
Bidder/Consortium
and Address:-
[Name of Utility]
[Address]
We are submitting the Prequalification Bid for R&M of [Boiler & Auxiliaries] Package
for
Unit
No.
[..]
of
[]
Plant
of
[.].
We hereby confirm that net worth of our company as on the last day of the
preceding financial year is positive.
The Details are as under:
Sl. No.
1
3
Description
Net worth on last date of preceding financial
year.
We have enclosed Balance Sheets and Profit
& Loss Account duly certified by Chartered
Accountant
Date:
Place:
As on last day of the

preceding financial year
------*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[28]
25. 09.2014
[LOGO OF
UTILITY]
Data Sheet-5
Sample Format for Data Sheet regarding Turnover & Net Worth requirement when Bidder
does not meet RFQ clause 2.1.2 (a) & 2.1.2 (b) on its own & JV Partner / Holding
Company / Consortium Partner Company meets the financial QR:
To,
Bidder/Consortium
and Address:-
[Name of Utility]
[Address]
We are submitting the Prequalification Bid for R&M of [Boiler & Auxiliaries] Package for
Since we do not meet Financial QR on own, we give the following details of JV Partner /
Holding Company/ Consortium Partner:Name and Address of the Holding/Partner Company: ...........................................
Turnover of the JV Partner / Holding Company / Partner Company with following details:
Sl. No.
1
2
3
4
Financial Year
Amt. of Bidders
Currency
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Financial Years as on
date of Bid Opening.
Net worth of Holding/
Partner Company on
last day of preceding
financial year
We have enclosed
Balance Sheets and
of Holding/ Partner
Company duly certified
by Chartered
Accountant
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Amt. in Rs.
Exchange rate
as on 30 days
prior to the
schedule date
of bid opening
*Yes/*No
Description
Page No.
Date of Issue
RFQ for Contractor
[29]
25. 09.2014
We are enclosing a
Letter of Undertaking
from the
Holding/Partner
Company, pledging
unconditional and
irrevocable financial
support for execution
of the contract by the
bidder in case of award
is enclosed
Date:
Place:
[LOGO OF
UTILITY]
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[30]
25. 09.2014
[LOGO OF
UTILITY]
Data Sheet -6
Sample Format for Data Sheet regarding utilized credit line & Bank balances as per
requirement at clause 2.1.2 (c) of RFQ document:
To,
Bidder/Consortium
and Address
[Name of Utility]
[Address]
We are submitting the Prequalification Bid for R&M of [Boiler & Auxiliaries] Package for
We hereby confirm that the sum of unutilised line of credit for fund based and non fund
based limits & cash & bank balances including fixed deposits of our company, duly
certified by the bankers as on not more than 30 days prior to the schedule date of bid
opening, is not less than INR [XXXXX] or in equivalent foreign currency.The details are
as under:
Sl. No.
Description
Amount in Indian Rupees

or equivalent in foreign
currency* as on a date
not earlier than 30 days
prior to the date of bid
opening
Sanctioned Line of credit
Unutilized Line of credit for fund based and

non-fund based limits
Cash and bank balances including fixed

deposits
We are enclosing Certificate from the

Bankers in respect of unutilized Line of credit
& bank balances as on (date)
Date:
Place:
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Note: In case certificates from more than one bank are submitted, the certified unutilized
limit shall be of the same date from all such banks.
Document Number
LII-GETS12021-G-00100-006
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[31]
25. 09.2014

FOR
FOR
OF
TURBO GENERATOR & AUXILIARIES
PREPARED BY

THE CONSULTANT
LII-GETS12021-G-00100-007 R02
September 2014
Request for Qualification for the Selection of Contractor for R&M of Turbo
Generator of Unit No. [..] Capacity [..] of [Name of the Power Plant]
[LOGO OF
UTILITY]
TABLE OF CONTENTS
1

1.1
1.2
1.3
1.4
1.5
Introduction .......................................................................................... 1
INVITATION .......................................................................................... 1
RFQ Details........................................................................................... 1

2.1.3 Other Criteria ..................................................................................... 4
Document Number
LII-GETS12021-G-00100-007
Rev. No.
02
Description
RFQ for Contractor
Page No.
Date of Issue
[i]
25.09.2014
S.No
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
Document Number
LII-GETS12021-G-00100-007

Description
[LOGO OF
UTILITY]

Annexure-1
Partner/Holding Company/ Consortium
Partner
pledging
unconditional
&
Data Sheet-1
clause 2.1.2 (a)
clause 2.1.2 (b)
2.1.2 (a) & 2.1.2 (b) on its own &
Holding/ Partner Company meet the
financial QR
RFQ document
Rev. No.
02
Description
RFQ for Contractor
Data Sheet-2
Data Sheet-3
Datasheet-4
Data Sheet-5
Data Sheet-6
Page No.
Date of Issue
[ii]
25.09.2014
1.1
Introduction
[LOGO OF
UTILITY]
1.2
INVITATION
invites sealed Pre-Qualification Tender from experienced and interested
bidders for the Renovation & Modernization Work of [Turbo Generator &
Auxiliaries] package of Unit No.[XXX] of the [XXX] Power Plant on
International Competitive Bidding (ICB).
[.]to [.]. Alternatively, the RFQ document can be
downloaded from [Name of the Utility] website [..].
1.3
Brief Scope of Work

replacement/refurbishment of specified existing equipments / systems by
supplying new equipments/ systems including supply of assembly materials,
inspection & testing at suppliers works, supply of mandatory spares, packing
& forwarding, transportation & insurance, receipt at site, unloading, handling
& storage at site, pre-assembly, fabrication, repair, servicing/ overhauling,
erection, carrying out of all associated civil works including supply of cement,
steel etc., testing & commissioning and successful completion of trial
operation & performance guarantee tests for [Turbo Generator & Auxiliaries]
package of Unit no. [XXX] of [XXX] Power Plant.
1.4
RFQ Details
(a)
Participation Fee
: INR [---]/ USD [---]/ EUR [---]
(b)
: [----------------------------]
Document Number
LII-GETS12021-G-00100-007
Rev. No.
02
Description
RFQ for Contractor
Page No.
Date of Issue
[1]
25.09.2014
(c)

RFQ document
: [----------------------------]
(d)
Last Date & Time of

Date & Time of
Opening of
: [----------------------------]
(e)

Issuance of RFP
: [----------------------------]
[LOGO OF
UTILITY]
working day.
1.5

[Name of The Utility] is carrying out this Pre-Qualification Process to identify
Renovation & Modernization work of [Turbo Generator & Auxiliaries] package
of Unit no. [XXX] of [XXX] Power Plant. The objective of the pre-qualification
is to allow only the capable and qualified bidders having requisite technical
expertise, relevant experience, project execution capability and financial
resources to participate in the tendering process.
Document Number
LII-GETS12021-G-00100-007
Rev. No.
02
Description
RFQ for Contractor
Page No.
Date of Issue
[2]
25.09.2014
2.1
[LOGO OF
UTILITY]

Renovation & Modernization work for [Turbo Generator & Auxiliaries]
package, the bidder must meet the Technical Qualification Requirement
specified at clause 2.1.1 and Financial Qualification Requirement specified at
clause 2.1.2. Further, the eligibility of the Bidders to participate in the
Tendering process is subject to other criteria specified at clause no. 2.1.3.
2.1.1

(a)
The Bidder during the last 10 years preceding the scheduled date for
1.4 above, should have designed, engineered, manufactured, supplied,
erected/ supervised erection and commissioned / supervised
commissioning of one (1) unit of reheat type Steam Turbine Set of 200
MW or above capacity for a coal fired power plant which should have
completed satisfactory operation for a period of not less than One (1)
years as on the scheduled date for submission of Pre-Qualification
Tenders indicated in row (d) in section 1.4 above.
And
2.1.2
(b)
The bidder, during the last 10 years preceding the scheduled date for
1.4 above,
should have successfully completed execution of
Renovation & Modernization of Steam Turbine Set of 50 MW or above
capacity for a coal fired power plant.
(c)
The bidder can be a Joint Venture of two firms who collectively meet
the Qualification Requirement specified at (a) and (b) above. Each of the
JV partner must have at least 26% equity in the JV and in case of
award of contract, must maintain JV arrangement till the successful
completion of the R&M work. In such a case, parts and components of
turbine set has to be sourced from the partner who satisfies the
Qualification Requirement specified at (a).
(d)
The bidder can be a Consortium of two firms who collectively meet the
Qualification Requirement specified at (a) and (b) above. The Consortium
members shall designate one member as the Leader of the Consortium
with whom the Contract will be entered into in case the Consortium
emerges as the successful bidder. In such a case, parts and components
of turbine set has to be sourced from the Consortium member who
satisfies the Qualification Requirement specified at (a).

(a)

.], FY [] and FY [...]. For the purpose of conversion of
Document Number
LII-GETS12021-G-00100-007
Rev. No.
02
Description
RFQ for Contractor
Page No.
Date of Issue
[3]
25.09.2014
[LOGO OF
UTILITY]

annual turnover.
(b)
(c)

(d)

Criteria stipulated in the above clauses (a) and (b) on its own and the JV
Partner in case the Bidder a Joint Venture of two firms or Holding
Company having controlling interest in the Bidder / Consortium Partner
Company, as the case may be, meets the stipulated turn-over
equal to or more than [..]. In such a case, the Bidder /
Consortium Leader has to submit a Letter of Undertaking from the JV
Partner Company/ Holding Company/ Consortium Partner company
pledging unconditional and irrevocable financial support to the bidder for
] , [FY ] & [FY ..].
2.1.3
Other Criteria
(a)

(b)
(c)

as Bidder or JV Partner or Consortium Member in more than one Bid
under this tender.
Document Number
LII-GETS12021-G-00100-007
Rev. No.
02
Description
RFQ for Contractor
Page No.
Date of Issue
[4]
25.09.2014
2.2
2.2.1
[LOGO OF
UTILITY]

(i)
List of orders executed by them along with copies of orders to prove
their qualifications.
(ii)
(iii) Name of any proposed JV partner or Consortium member along with
details of equity participation of JV partner or letter of consent of
consortium partner.
(v) Contracts in hand / pending jobs and their status along with value.
Document Number
LII-GETS12021-G-00100-007
Rev. No.
02
Description
RFQ for Contractor
Page No.
Date of Issue
[5]
25.09.2014
[LOGO OF
UTILITY]
3.1.

work of [Turbo Generator & Auxiliaries] package and will be eligible to submit
Bid Proposal for R&M work. The RFQ Documents specify the qualification
criteria to be met by the prospective bidders to become eligible for
participating in the tendering process. The bidders are required to submit
evidence of their technical expertise, relevant past experience, project
execution capability and financial resources to discharge the scope of service
certificate(s)/document(s) submitted by the Bidder or JV Partner or
manipulated, the Bidder or JV Partner or Consortium leader or Consortium
3.2.
3.3.
3.4.
this contract.
3.5.
The bidder meeting the Qualifying Requirement on the strength of the JV

partners should enclose details of equity holding of the JV partners. However,
in the event, the bidder is found pre-qualified and issued RFP document, while
submitting the techno-commercial Bid Proposal for R&M work, the bidder shall
furnish a copy of the Joint Venture Agreement. Further, while submitting the
techno-commercial Bid Proposal for R&M work, the JV partners shall furnish a
joint undertaking towards joint and several liability to the employer for the
successful performance of the Contract. The undertaking shall be furnished as
per the format to be specified in the RFP document.
consortium Partner along with the Pre-Qualification Bid signed by the
will be permitted at the time of submitting the Techno commercial Bid.
Further, while submitting the techno-commercial Bid Proposal for R&M work,
3.6.
Document Number
LII-GETS12021-G-00100-007
Rev. No.
02
Description
RFQ for Contractor
Page No.
Date of Issue
[6]
25.09.2014
[LOGO OF
UTILITY]
the Consortium leader and Consortium member will furnish a joint undertaking
regarding diligent performance of their respective scope of work and towards
joint and several liability to the employer for the successful performance of
the Contract. The undertaking shall be furnished as per the format to be
specified in the RFP document.
3.7.

shall be valid till the end of Warranty Period plus Ninety (90) days grace
period.
If the bidder is a joint venture of two firms who collectively meet the
Qualifying Requirement, in addition to the Contract Performance Guarantee
(CPG) of 10% furnished by the bidder, each of the JV partner shall furnish
Additional Contract Performance Guarantee equal to 1% of Contract Price.
If the bidder is a Consortium of two firms, in addition to the Contract
Performance Guarantee (CPG) of 10% furnished by the Consortium Leader,
the other consortium member will furnish Additional Contract Performance
Guarantee equal to 2% of Contract Price
equipment / system as required by the bidding documents. Pre-Qualification Bid
submitted without the proper documentary evidence to substantiate fulfilment
of the qualifying requirements as specified are liable for rejection without
assigning any reason.
3.8.
The Bidder shall provide satisfactory evidence that he has adequate capability and
capacity to perform the work properly and expeditiously within the time period specified.
The evidence shall specifically cover, with written details, the installed manufacturing and
/ or fabrication capacities to meet the requirements appropriate to the works covered in
his bid and adequate field service organization to provide the necessary field erection and
management services required to successfully erect, test and commission the equipment
/ system as required by the bidding documents. Pre-Qualification Bid submitted without
the proper documentary evidence to substantiate fulfillment of the qualifying
3.9.

Document Number
LII-GETS12021-G-00100-007
Rev. No.
02
Description
RFQ for Contractor
Page No.
Date of Issue
[7]
25.09.2014
[LOGO OF
UTILITY]

3.10.
3.11.
3.12.
Language of Bid
3.13.

person(s) of the Bidder / Consortium leader with his usual signature. The
name of all persons signing should be typed or printed below the signature.
3.14.

Bid.
Document Number
LII-GETS12021-G-00100-007
Rev. No.
02
Description
RFQ for Contractor
Page No.
Date of Issue
[8]
25.09.2014
[LOGO OF
UTILITY]

[XXXXX]
[XXXXX] [XXXXX]
accepted.
3.15.

above.
3.16.

document.
S.No
Description
1.0
Annexure-1
2.0

Partner/ Holding Company/ Consortium
Partner
pledging
unconditional
&
Document Number
LII-GETS12021-G-00100-007
Rev. No.
02
Description
RFQ for Contractor
Page No.
Date of Issue
[9]
25.09.2014
S.No
Description
3.0

Data Sheet-1
4.0
5.0
6.0
7.0
8.0
9.0
Document Number
LII-GETS12021-G-00100-007

clause 2.1.2 (a)
clause 2.1.2 (b)
2.1.2 (a) & 2.1.2 (b) on its own &
Holding/ Partner Company meets the
financial QR
RFQ document
Rev. No.
02
[LOGO OF
UTILITY]
Description
RFQ for Contractor
Data Sheet-2
Data Sheet-3
Datasheet-4
Data Sheet-5
Data Sheet-6
Page No.
Date of Issue
[10]
25.09.2014
[LOGO OF UTILITY]
Annexure-1

Date: - [XXXXX]
RFQ No. [XXXXX]
To,
[Address XXXXX]
Dear Sir /Madam

1.0
Renovation & Modernization of [Turbo Generator & Auxiliaries] Package for unit
[XXXXX] of [XXXXX] power plant of [XXXXX]. Towards this end we submit the
following details & documents for prequalification.
2.0
3.0
RFQ document on our own/ on the strength of the parent JV partner [XXXXX] &
[XXXXX] / in association with our Consortium Partner [XXXXX].(Bidder to strike off
whichever is not applicable).
qualification requirement which is met by the Bidder/JV Partner/ Consortium Members
meet which part of Qualification Requirement. Bidder is also required to the relationship
between the Bidder & others on whose strength Qualification Requirement is met.)
4.0
We confirm that neither we nor any of our parent JV Partners/ our Consortium
Members/our associates/ affiliates are liable for exclusion from participation in tendering
process under other criteria stipulated under clause no.2.1.3 of RFQ document.
5.0
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[11]
18.09.2014
6.0
[LOGO OF UTILITY]
(i)
Covering Letter
(ii)

Consortium members, Parent JV Partner and Holding Company, as
applicable.
(iii)

(a)
(iv)

(b)
(v)
(vi)
(vii)
(viii)

support to the bidder for execution of the contract. (In case of financial
QR is met on the strength of Holding Company/ Partner Company).
(ix)
Letter of Consent of Consortium Partner in case of Consortium
(x)
Details of equity holding of JV partners for Joint Ventures.

(ii)
Copies of order
(iii)
(iv)
(v)

(vi)
(vii)
(viii)
Any other document.
7.0

8.0
We certify that all the information and documents furnished with this PreQualification Bid are true and genuine to our best of the knowledge & belief.
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[12]
18.09.2014
[LOGO OF UTILITY]

Yours Faithfully,
Signature [XXXXX]
Full Name [XXXXX]
Designation [XXXXX]
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[13]
18.09.2014
[LOGO OF UTILITY]
Annexure-2
Format for Letter of Undertaking by Holding Company/ JV Partner/
Consortium Partner pledging unconditional & irrevocable support to the Bidder
for the execution of R&M work.
Ref.: [XXXXX]
Date : [XXXXX]
To,
Dear Sir/ Madam,
*We, M/s.................. (Name and Complete address of the Holding Company)
hereby declare that we have controlling interest in ..(Name of the
Bidder) who is submitting Prequalification bid for R&M of Turbo Generator
Clause 2.1.2 (a) & (b) of RFQ document./
*We have formed a Joint Venture with (name of other JV Partner) and the
Joint Venture (Name of JV) is submitting Prequalification bid for R&M of
Turbo Generator Package for Unit No. [.] of [] Plant of
[]. M/s..(Name of JV) have sought financial strength and
support from us for meeting the stipulated Financial Qualifying Requirement as
per Clause 2.1.2 (a) & (b) of RFQ document. /
* We, M/s.................. declare that we are the holding company of
M/s................... (Name of the Bidder) and have controlling interest therein.
* We, M/s.................. (Name and Complete address of the Consortium
Partner) hereby declare that we have agreed to associate with .. (Name
and Complete address of the Bidder/Consortium Leader) for part scope of
work of for the package............................. (Name of the package) for Unit
No. [XXXXX] of [XXXXX] power plant of [XXXXX] under RFQ
no.......................... dated ..................... and M/s..(Name of the
Bidder/Consortium Leader) have sought financial strength and support from us
for meeting the stipulated Financial Qualifying Requirement as per Clause
2.1.2 (a) & (b) of RFQ document.
We hereby undertake that we hereby pledge our unconditional & irrevocable
financial support for the execution of the said package to
Bidder/Contractor.
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[14]
18.09.2014
[LOGO OF UTILITY]
Yours faithfully,
Holding Company)
Date:
Place:

1.
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[15]
18.09.2014
[LOGO OF UTILITY]
Annexure-3
(Name and Complete address of the Bidder/Consortium Leader) for the
successful completion of part scope of work as enclosed in the attachment
(authenticated by the Consortium Partner) of [XXXXX] Package for the Unit
no.[XXXXX] of .[XXXXX] plant in the state of [XXXXX] for [XXXXX], India.
We also hereby undertake to ensure the quality of manufacture, timely delivery
and the successful performance of the equipment/system covered in our scope
of. [XXXXX] , fully meeting the guarantee and also depute our technical
experts from time to time for advice on procedures and guidance during design,
On award of LOA, we the Consortium Partner agrees to furnish on demand
1.
Witness
Signature:
Name
Name
Designation:
Designation:
Office Address
Seal of the Company
2.
Witness
For Bidder
Signature:
Name
Name
Designation:
Designation:
Office Address
Seal of the Company
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[16]
18.09.2014
[LOGO OF UTILITY]
Data Sheet-1
No. 2.1.1 (a):
To,
Bidder/Consortium
and Address:-
[Name of Utility]
[Address]
*We are submitting the Prequalification Bid for R&M of [Turbo Generator & Auxiliaries]
Package for Unit No. [..] of [] Plant of
[.]. / *We are associated with (Name of Consortium Leader) as
Consortium Partner for R&M of Turbine & Generator Package for Unit [] of
[] Plant of [..] / *We have formed a Joint Venture with
(name of other JV Partner) and the Joint Venture (Name of JV) is submitting
Prequalification bid for R&M of Turbine & Generator Package for Unit No. [.]
of [] Plant of [].
We have designed, engineered, manufactured, supplied, erected/supervised erection and

commissioned/supervised commissioning of at least one (1) unit of reheat type steam
Turbine set of 200 MW or above capacity for a coal fired power plant which has
completed satisfactory operation for a period of not less than two (2) years as on the
scheduled date of opening of Prequalification Bid as per stipulated requirement at Clause
No. 2.1.1 (a) of RFQ document. The details of the same are given below:
Sl.
Description
1.

2.

Fax and Tel. Nos.
3.

organization.
4.
No. of Turbine set supplied to

the Thermal Power Station.
5.
Contact No. & Date
6.
Turbine Set Capacity in MW
7.
Document Number
LII-GETS12021-G-00100-007
Installation
No.1
Rev
No.
02
Installation
No.2
Installation
No.3
Description
Page No.
Date of Issue
RFQ for Contractor
[17]
18.09.2014
Sl.
Description
[LOGO OF UTILITY]
Installation
No.1
Installation
No.2
Installation
No.3
8.
9.
10.
11.
(a) Whether the Plant is coal

fired thermal power station
Yes*/No*
Yes*/No*
Yes*/No*
(b) Whether the Turbine Set is

reheat type
Yes*/No*
Yes*/No*
Yes*/No*
(i) Designed
Yes*/No*
Yes*/No*
Yes*/No*
(ii) Engineered
Yes*/No*
Yes*/No*
Yes*/No*
(iii) Manufactured
Yes*/No*
Yes*/No*
Yes*/No*
*Supervised
Yes*/No*
Yes*/No*
Yes*/No*
(v) *Commissioned
/
*Supervised Commissioning
Yes*/No*
Yes*/No*
Yes*/No*
12.

aforesaid Steam Turbine set
(iv) *Erected
Erection
13.
of
Details of Steam Turbine

Steam Turbine Make
*Tandem Compound / *Cross
Compound
No. of Reheat
No. of Cylinders
(i) HP
(ii) IP
(iii) Combined HP & IP
(iv) LP
Module No.
(i) HP Turbine
(ii) IP Turbine
(iii) LP Turbine
(iv) Combined HP & LP
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[18]
18.09.2014
Sl.
Description
[LOGO OF UTILITY]
Installation
No.1
Installation
No.2
Installation
No.3
*Condensing /
*NonCondensing
*Condensing /
*NonCondensing
*Condensing /
*NonCondensing
Whether Steam Turbine and

Generator directly coupled
Yes*/No*
Yes*/No*
Yes*/No*
Installation
*Indoor /
*Outdoor
Indoor /
*Outdoor
Indoor /
*Outdoor
Whether HP & IP Combined or

Separate
Initial Pressure (ata)
Initial Temperature (deg C)
Reheat Temperature (deg C)
Exhaust Pressure (ata)
Type of Turbine
Rated Speed (rpm) and

Operating Frequency range (Hz)
No. of Steam Extractions for
regeneration
14.

Attachment
Date
:
(Signature.)
Place :
(Full Name)
(Designation)
(Company Seal)
1.
2.

Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[19]
18.09.2014
[LOGO OF UTILITY]
Data Sheet -2
No. 2.1.1 (b):
To,
Bidder/Consortium
and Address:-
[Name of Utility]
[Address]
*We are submitting the Prequalification Bid for R&M of [Turbo Generator & Auxiliaries]
[.]. / *We are associated with (Name of Consortium Leader) as
Consortium Partner for R&M of Turbine & Generator Package for Unit [] of
[] Plant of [..] / *We have formed a Joint Venture with
(name of other JV Partner) and the Joint Venture (Name of JV) is submitting
Prequalification bid for R&M of Turbine & Generator Package for Unit No. [.]
of [] Plant of [].
We have successfully completed execution of Renovation & Modernization of at least
one Steam Turbine set of 50 MW or above capacity for a coal fired power plant. The
details of the same are given below:
Sl.
Description
Installation
No.1
1.

2.

Fax and Tel. Nos.
Installation
No.2
Installation
No.3
- Email ID
- Web site address
3.

organization.
4.
No. of Turbine Generator sets

retrofitted by us for the station
5.
6.
7.
8.
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[20]
18.09.2014
Sl.
Description
9.
10.
Whether the Plant is coal fired

11.
Details of Turbine Generators for

which R&M work had been done
by us:
[LOGO OF UTILITY]
Installation
No.1
Installation
No.2
Installation
No.3
Yes*/No*
Yes*/No*
Yes*/No*
of

out
Steam Turbine Make
*Tandem Compound / *Cross
Compound
No. of Reheat
No. of Cylinders
HP
IP
Combined HP & IP
LP
Module No.
HP Turbine
IP Turbine
LP Turbine
Combined HP & LP
Whether HP & IP Combined or
Separate
Initial Pressure (ata)
Initial Temperature (deg C)
Reheat Temperature (deg C)
Exhaust Pressure (ata)
Type of Turbine
*Condensing / *Condensing / *Condensing /

*Non*Non*NonCondensing
Condensing
Condensing
Rated
Speed
(rpm)
and
Operating Frequency range (Hz)
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[21]
18.09.2014
[LOGO OF UTILITY]
Sl.
Description
Installation
No.1
Installation
No.2
Installation
No.3
No. of Steam Extractions for

regeneration
Whether Steam Turbine
Generator directly coupled
and Yes*/No*
Yes*/No*
Yes*/No*
*Indoor
*Outdoor
/ Indoor
*Outdoor
/ Indoor
*Outdoor
Installation
bid at Annexure [..]
out
Scope of work executed by us
for
the
aforesaid
Turbine
Generator
and
associated/
auxiliaries includes the following
:
Designed
Yes*/No*
Yes*/No*
Yes*/No*
Engineered
Yes*/No*
Yes*/No*
Yes*/No*
Manufactured
Yes*/No*
Yes*/No*
Yes*/No*
*Erected / *Supervised Erection
Yes*/No*
Yes*/No*
Yes*/No*
*Commissioned / *Supervised
Commissioning
Yes*/No*
Yes*/No*
Yes*/No*
List of major parts/equipment

renovated / retrofitted and type
of
work
for
such
parts/equipment
(repair
/
replacement / modification etc.)
Is this Turbine Generator of the Yes*/No*
package
Yes*/No*
Yes*/No*
Designed TG Heat rate

TG Heat rate before R&M
Tested heat rate after R&M
Tested heat rate after R&M
corrected to design conditions
TG Output before R&M
TG Output after R&M
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[22]
18.09.2014
Sl.
Description
Installation
No.1
[LOGO OF UTILITY]
Installation
No.2
Installation
No.3

operation
for
i)
unit shut down)
ii)

unit shut down)
iii)
Hot (after 8 hrs of

unit shut down)
Availability of Turbo Generator

for last two years
Extended life after R&M (years)
12.

bid at Annexure [] to this
Attachment
Date
:
(Signature.)
Place :
(Printed Name)
(Designation)
(Company Seal)
1.
2.

Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[23]
18.09.2014
[LOGO OF UTILITY]
Data Sheet-3
2.1.2 (a):
To,
Bidder/Consortium
and Address
[Name of Utility]
[Address]
We are submitting the Prequalification Bid for R&M of [Turbo Generator & Auxiliaries]
[.].
Sl. No.
1
2
3
4
Financial Year
Amt. of Bidders
Currency
Amt. in Rs.
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Financial Years.
We have enclosed
Balance Sheets and
duly certified by
Date:
Place:
Exchange rate
as on 30 days
prior to the
schedule date
of bid opening
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
1. *Strike off whichever is not applicable.

Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[24]
18.09.2014
[LOGO OF UTILITY]
Data Sheet-4
clause 2.1.2 (b):
To,
Bidder/Consortium
and Address:-
[Name of Utility]
[Address]
We are submitting the Prequalification Bid for R&M of [Turbo Generator &
Auxiliaries] Package for Unit No. [..] of [] Plant of
[.].
Sl. No.
1
3
Description
year.
Accountant
Date:
Place:

------*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[25]
18.09.2014
[LOGO OF UTILITY]
Data Sheet-5
does not meet RFQ clause 2.1.2 (a) & 2.1.2 (b) on its own & JV Partner / Holding
Company / Consortium Partner Company meets the financial QR:
To,
Bidder/Consortium
and Address:-
[Name of Utility]
[Address]
[.].
Since we do not meet Financial QR on own, we give the following details of JV Partner
Company/ Holding Company/Consortium Partner:Name and Address of the Holding/Partner Company: ...........................................
Turnover of the Holding JV Partner/ Holding Company/ Partner Company with following
details:
Sl. No.
1
2
3
4
Financial Year
Amt. of Bidders
Currency
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Net worth of Holding/
Partner Company on
last day of preceding
financial year
We have enclosed
Balance Sheets and
of Holding/ Partner
Company duly certified
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Amt. in Rs.
Exchange rate
as on 30 days
prior to the
schedule date
of bid opening
*Yes/*No
Description
Page No.
Date of Issue
RFQ for Contractor
[26]
18.09.2014
by Chartered
Accountant
We are enclosing a
from the
Holding/Partner
Company, pledging
unconditional and
is enclosed
Date:
Place:
[LOGO OF UTILITY]
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[27]
18.09.2014
[LOGO OF UTILITY]
Data Sheet -6
To,
Bidder/Consortium
and Address
[Name of Utility]
[Address]
[.].
opening, is not less than INR [XXXXX] or in equivalent foreign currency.
The details are as under:

Sl. No.
Description

opening


deposits

Date:
Place:
Document Number
LII-GETS12021-G-00100-007
*Yes/*No
(Signature)..........................................
(Full Name)....................................
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[28]
18.09.2014
[LOGO OF UTILITY]
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-007
Rev
No.
02
Description
Page No.
Date of Issue
RFQ for Contractor
[29]
18.09.2014

FOR
FOR
OF
COAL HANDLING PLANT
PREPARED BY

THE CONSULTANT
LII-GETS12021-G-00100-008 R01
September 2014
Request for Qualification For R&M of Coal Handling Plant of Unit No.[..]
Capacity [] of [Name of the Power Plant]
[LOGO OF
UTILITY]
TABLE OF CONTENTS
1
INVITATION FOR QUALIFICATION ................................................................... 1

1.1
1.2
1.3
1.4
1.5
Introduction .......................................................................................... 1
Invitation .............................................................................................. 1
RFQ Details........................................................................................... 1

2.1.3 Other Criteria ..................................................................................... 4
Document Number
LII-GETS12021-G-00100-008
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[i]
25.09.2014

Description
S.No
1.0
2.0
Format for Letter of Undertaking by

Holding Company pledging unconditional Annexure-2
& irrevocable support to the bidder for
the execution of R&M work.
3.0
4.0
5.0
6.0
7.0

Clause No. 2.1.1.
clause 2.1.2 (a)
clause 2.1.2 (b)
[LOGO OF
UTILITY]
Annexure-1
Data Sheet-1
Data Sheet-2
Datasheet-3

Data Sheet-4
2.1.2 (a) & 2.1.2 (b) on its own &
Holding Company meets the financial QR
RFQ document
Document Number
LII-GETS12021-G-00100-008
Rev
No.
01
Data Sheet-5
Description
Page No.
Date of Issue
RFQ for Contractor
[ii]
25.09.2014
1.1
Introduction
[LOGO OF
UTILITY]
1.2
Invitation
bidders from India for the Renovation & Modernization Work of [Coal Handling
Plant] package of Unit No.[XXX] of the [XXX] Power Plant on Domestic
Competitive Bidding (DCB).
Interested bidders from India may collect the RFQ documents in person from
[Name and Contact Details of Designated Official.]. The RFQ
documents can be collected between [---] hrs to [---] hrs on all working days
from [.]to [.]. Alternatively, the RFQ document
can be downloaded from [Name of the Utility] website [..].
1.3
Brief Scope of Work

operation & performance guarantee tests for [Coal Handling Plant] package of
Unit no. [XXX] of [XXX] Power Plant.
1.4
RFQ Details
(a)
Participation Fee
INR [---]
(b)
[----------------------------]
(c)

RFQ document
[----------------------------]
Document Number
LII-GETS12021-G-00100-008
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[1]
25.09.2014
(d)
Last Date & Time of

Date & Time of
Opening of
[----------------------------]
(e)

Issuance of RFP
[----------------------------]
[LOGO OF
UTILITY]
working day.
1.5

Renovation & Modernization work of [Coal Handling Plant] package of Unit no.
Document Number
LII-GETS12021-G-00100-008
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[2]
25.09.2014
2.1
[LOGO OF
UTILITY]

Renovation & Modernization work for [Coal Handling Plant] package, the
2.1.1 and Financial Qualification Requirement specified at clause 2.1.2.
subject to other criteria specified at clause no. 2.1.3.
2.1.1

[The Bidder , during the last 10 years preceding the scheduled date for
submission of Pre-Qualification Bids indicated in row (d) in section 1.4 above,
should have designed, engineered, manufactured, erected and commissioned
[at least one coal Handling Plants of capacity .TPH] comprising (Track
Hopper/Wagon Tippler) Belt Conveying System, Stacker Reclaimer, Inline
Magnetic Separators, Metal Detectors, Coal Crusher, Transfer Points,
Traveling Trippers, Dust Extraction & Dust Suppression System complete with
associated Electrical and PLC based Instrument and Control System for entire
Coal Handling Plant which should have completed satisfactory operation for a
period of not less than One (1) year as on the scheduled date for submission
of Pre-Qualification Bids indicated in row (d) in section 1.4 above.]
2.1.2

(a)

Rupees ] millions as per audited annual accounts during the
preceding three consecutive years [FY .], FY [] and FY
[...].Other income will not be considered for arriving at the annual
turnover.
(b)
(c)

(d)
In case the Bidder does not satisfy the Financial Criteria stipulated in the
above clauses (a) and (b) on its own and the Holding Company having
controlling interest in the Bidder, meets the stipulated turn-over
Net worth of such Holding Company as on the last day of the preceding
financial year is at least equal to or more than [..]. In such a
case, the Bidder has to submit a Letter of Undertaking from the Holding
Company pledging unconditional and irrevocable financial support to the
bidder for execution of the Contract.
Document Number
LII-GETS12021-G-00100-008
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[3]
25.09.2014
[LOGO OF
UTILITY]

] , [FY ] & [FY ..].
2.1.3
Other Criteria
(a)

(b)
(c)

as Bidder in more than one Bid under this tender.
2.2
2.2.1

(i)
(ii)
(iii) Documents of company profile incorporating technical man power,
(iv) Contracts in hand / pending jobs and their status along with value.
(v)
Major pending legal cases.
Document Number
LII-GETS12021-G-00100-008
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[4]
25.09.2014
[LOGO OF
UTILITY]
3.1.

work of [Coal Handling Plant] package and will be eligible to submit Bid
3.2.
certificate(s)/document(s) submitted by the Bidder is found to be factually
incorrect or manipulated, the Bidder will be disqualified for the tender and will
be liable to be blacklisted / debarred by the Employer for future tenders.
3.3.
Bidder. Thus the bidder shall be solely responsible and liable for all the
technical, management and all other services required for completing the
entire scope of work.
3.4.
The Bidder shall not Sub-contract the entire scope of work, back to back or
otherwise, for the performance of this contract.
3.5.

shall be valid till the end of Warranty Period plus ninety (90) days grace
period.
The Bidder shall provide satisfactory evidence that he has adequate capability
and capacity to perform the work properly and expeditiously within the time
period specified. The evidence shall specifically cover, with written details,
the installed manufacturing and / or fabrication capacities to meet the
requirements appropriate to the works covered in his bid and adequate field
service organization to provide the necessary field erection and management
services required to successfully erect, test and commission the equipment /
system as required by the bidding documents. Pre-Qualification Bid submitted
without the proper documentary evidence to substantiate fulfilment of the
qualifying requirements as specified are liable for rejection without assigning
any reason.
3.6.
Document Number
LII-GETS12021-G-00100-008
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[5]
25.09.2014
[LOGO OF
UTILITY]
3.7.

bidders claim on experience and to assess the Bidders capability and
capacity to perform the contract, should the circumstances warrant such an
assessment in the overall interest of the project.
3.8.
3.9.
Participation Fee for an amount of [INR..] in the form of Demand Draft

drawn in favour of [Name of Utility], payable at [XXXXX] is to be submitted
along with the Pre-Qualification Bid. Pre-Qualification Bid received without
the Participation Fee will be rejected. Participation Fee is non-refundable.
3.10.
Language of Bid
3.11.

person(s) of the Bidder with his usual signature. The name of all persons
signing should be typed or printed below the signature.
bidder shall be furnished with the Bid.
The Bidders name stated on the Pre-Qualification Bid shall be the exact legal
name of the firm.
3.12.

Bid.
The outside of the covers should indicate clearly the name of the Bidder and
his address. In addition, the envelope or container should indicate the "Tender
No. and Name of the work for which the Pre-Qualification Bid is submitted ".
Pre-Qualification Bid with no indication given on the outside of the envelope
that it is a Pre-Qualification Bid which therefore gets opened before the due
Document Number
LII-GETS12021-G-00100-008
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[6]
25.09.2014
[LOGO OF
UTILITY]
date shall be liable to be disqualified. All the pages of the Pre-Qualification Bid
shall be serially numbered.
[XXXXX]
[XXXXX] [XXXXX]
accepted.
3.13.

above.
3.14.

document.
S.No
Description
1.0
Annexure-1
2.0

Document Number
LII-GETS12021-G-00100-008
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[7]
25.09.2014
S.No
3.0
4.0
5.0
6.0
7.0
Description

Clause No. 2.1.1.
clause 2.1.2 (a)
clause 2.1.2 (b)
2.1.2 (a) & 2.1.2 (b) on its own &
RFQ document
Document Number
LII-GETS12021-G-00100-008
Rev
No.
01
[LOGO OF
UTILITY]
Data Sheet-1
Data Sheet-2
Datasheet-3
Data Sheet-4
Data Sheet-5
Description
Page No.
Date of Issue
RFQ for Contractor
[8]
25.09.2014
[LOGO OF
UTILITY]
Annexure-1

Date: - [XXXXX]
RFQ No. [XXXXX]
To,
[Address XXXXX]
Dear Sir /Madam

1.0
Renovation & Modernization of [Coal Handling Plant] Package for unit [XXXXX] of
2.0
Name of the Bidder with name & designation of person authorized to submit the
pre-qualification bid:
Name of Bidder: []
3.0
RFQ document.
4.0
We confirm that neither we nor any of our associates/ affiliates are liable for
exclusion from participation in tendering process under other criteria stipulated under
clause no.2.1.3 of RFQ document.
5.0
(i)
Covering Letter
(ii)
Power of Attorney in favor of persons signing on behalf of Bidder and

Holding Company, as applicable.
(iii)
(iv)
Document Number
LII-GETS12021-G-00100-008
Rev No.
Description
Page No.
Date of Issue
00
RFQ for Contractor
[9]
16.10.2013
6.0
[LOGO OF
UTILITY]
(v)
(vi)
(vii)

QR is met on the strength of Holding Company).

qualifications & capability to execute the subject R&M work:
(i)
(ii)
Copies of order
(iii)
(iv)
(v)

(vi)
Copies of last 3 years audited financial statement.
(vii)
(viii)
Any other document.
7.0

8.0

Yours Faithfully,
Signature [XXXXX]
Full Name [XXXXX]
Designation [XXXXX]
Document Number
LII-GETS12021-G-00100-008
Rev No.
Description
Page No.
Date of Issue
00
RFQ for Contractor
[10]
16.10.2013
[LOGO OF
UTILITY]
Annexure-2
Format for Letter of Undertaking by Holding Company pledging unconditional
& irrevocable support to the Bidder for the execution of R&M work.
Ref.: [XXXXX]
Date : [XXXXX]
To,
Dear Sir/ Madam,
We, M/s.................. declare that we are the holding company of
Clause 2.1.2 (a) & (b) of RFQ document for the package.............................
(Name of the package) for Unit No. [XXXXX] of [XXXXX] power plant of
[XXXXX] under RFQ no.......................... dated ......................
Bidder/Contractor.
Date:
Place:
Yours faithfully,
Holding Company)
Document Number
LII-GETS12021-G-00100-008
Rev No.
Description
Page No.
Date of Issue
00
RFQ for Contractor
[11]
16.10.2013
[LOGO OF
UTILITY]
Data Sheet-1
No. 2.1.1:
To,
Bidderss
Name
and Address:-
[Name of Utility]
[Address]
We are submitting the Prequalification Bid for R&M of [Coal Handling Plant] Package for
[We have designed, engineered, manufactured, erected and commissioned [ Coal
Handling Plants of capacity .TPH] comprising (Track Hopper/Wagon Tippler) Belt
Conveying System, Stacker Reclaimer, Inline Magnetic Separators, Metal Detectors, Coal
Crusher, Transfer Points, Traveling Trippers, Dust Extraction & Dust Suppression System
complete with associated Electrical and PLC based Instrument and Control System for
entire Coal Handling Plant which have completed satisfactory operation for a period of
not less than two (2) years as on the date of opening of Pre-Qualification Bid.] The
details of the same are given below:
Sl.
Description
1.

2.

Fax and Tel. Nos.
3.

organization.
4.
Contact No. & Date
5.
6.
7.
8.
9.

aforesaid Coal Handling Plant.
Document Number
LII-GETS12021-G-00100-008
Installation
No.1
Installation
No.2
Installation
No.3
of
Rev No.
Description
Page No.
Date of Issue
00
RFQ for Contractor
[12]
16.10.2013
Sl.
Description
Installation
No.1
Installation
No.2
[LOGO OF
UTILITY]
Installation
No.3
10. Details of the Plant/Systems executed

- Capacity of Coal Handling
Plant (TPH)
- Inlet Coal lump size at Wagon
Tippler/Track Hopper (mm)
- Coal size at the outlet of
Crusher (mm)
- Hours of operation per day
- No. of tips/hour. (in case of
Wagon Tippler)
- Capacity of Paddle/Plough
Feeders. (in case of Track
Hopper)
Belt Conveyors
- Belt material
- Belt width (mm)
- Belt speed (m/sec)
- Troughing angle (oC)
- Belt Protection Switches (Pull
Cord, Belt Sway & Zero
Speed Switches)
- Type
of
Tensioning
Arrangement provided
Pulleys
- Pulleys width
- Material of construction
- Material of lagging
- Type of bearings
Idlers
- Material
- Type of Bearing
Gear Boxes
- Type of Prime Mover
- Type of High Speed Coupling
Document Number
LII-GETS12021-G-00100-008
Rev No.
Description
Page No.
Date of Issue
00
RFQ for Contractor
[13]
16.10.2013
Sl.
Description
Installation
No.1
Installation
No.2
[LOGO OF
UTILITY]
Installation
No.3
- Type of Low Speed Coupling

Belt Weigher
- Type of sensing
- Type of indication
Magnetic Separator
- Type
- Operating gap (mm)
- Supply voltage
- Method
of
transformer
cooling
the
Vibrating Screens before Crusher

- Capacity
- Screening size
- Efficiency of screening
Crushers
- Type
- Capacity of Crushers (TPH)
- Capacity of Drive Motor (KW)
- Type of Coupling
Stacker Cum Reclaimer
- Type
- Quantity
- Boom length
- Length of Travel (m)
Coal Storage Bunkers
- Type / Shape
- Capacity
- Quantity
- Material of Construction
- Type of level indicator
Dust Extraction System
Document Number
LII-GETS12021-G-00100-008
Rev No.
Description
Page No.
Date of Issue
00
RFQ for Contractor
[14]
16.10.2013
Sl.
Description
Installation
No.1
Installation
No.2
[LOGO OF
UTILITY]
Installation
No.3
- Type of System
- Locations
- Dust level achieved during
operation (mg/Nm3)
Dust Suppression System
- Type of System
- Locations
- Dust level achieved during
operation (mg/Nm3)
Date
:
(Signature.)
Place :
(Full Name)
(Designation)
(Company Seal)
1.
Document Number
LII-GETS12021-G-00100-008
Rev No.
Description
Page No.
Date of Issue
00
RFQ for Contractor
[15]
16.10.2013
[LOGO OF
UTILITY]
Data Sheet-2
2.1.2 (a):
To,
Bidders Name
[Name of Utility]
[Address]
and Address
Sl. No.
1
2
3
4
Financial Year
Amt. of Bidders
Currency
Amt. in Rs.
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Financial Years.
We have enclosed
Balance Sheets and
duly certified by
Exchange rate
as on 30 days
prior to the
schedule date
of bid opening
*Yes/*No
Date:
Place:
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-008
Rev No.
Description
Page No.
Date of Issue
00
RFQ for Contractor
[16]
16.10.2013
[LOGO OF
UTILITY]
Data Sheet-3
clause 2.1.2 (b):
To,
Bidders Name
[Name of Utility]
[Address]
and Address:-
We are submitting the Prequalification Bid for R&M of [Coal Handling Plant] Package
for
Unit
No.
[..]
of
[]
Plant
of
[.].
Sl. No.
1
3
Description
year.
Accountant
Date:
Place:

------*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-008
Rev No.
Description
Page No.
Date of Issue
00
RFQ for Contractor
[17]
16.10.2013
[LOGO OF
UTILITY]
Data Sheet-4
does not meet RFQ clause 2.1.2 (a) & 2.1.2 (b) on its own & Holding Company meet
the financial QR:
To,
Bidder, Name
and Address:-
[Name of Utility]
[Address]
Since we do not meet Financial QR on own, we give the following details of Holding
Company:Name and Address of the Holding Company: ...........................................
Turnover of the Holding Company with following details:
Sl. No.
1
2
3
4
Financial Year
Amt. of Bidders
Currency
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Net worth of Holding
Company on last day
of preceding financial
year
We have enclosed
Balance Sheets and
of Holding duly
certified by Chartered
Accountant
Document Number
LII-GETS12021-G-00100-008
Amt. in Rs.
Exchange rate
as on 30 days
prior to the
schedule date
of bid opening
*Yes/*No
Rev No.
Description
Page No.
Date of Issue
00
RFQ for Contractor
[18]
16.10.2013
We are enclosing a
from the Holding
Company, pledging
unconditional and
is enclosed
Date:
Place:
[LOGO OF
UTILITY]
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-008
Rev No.
Description
Page No.
Date of Issue
00
RFQ for Contractor
[19]
16.10.2013
[LOGO OF
UTILITY]
Data Sheet -5
To,
Bidders Name
[Name of Utility]
[Address]
and Address
opening, is not less than INR [XXXXX] or in equivalent foreign currency. The details are
as under:
Sl. No.
Description

opening


deposits

Date:
Place:
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-008
Rev No.
Description
Page No.
Date of Issue
00
RFQ for Contractor
[20]
16.10.2013

FOR
FOR
OF
ASH HANDLING PLANT
PREPARED BY

THE CONSULTANT
LII-GETS12021-G-00100-009 R01
September 2014
[LOGO OF UTILITY]
Request for Qualification For R&M of Ash Handling Plant of Unit No. [..]
Capacity [..] of [Name of the Power Plant]
TABLE OF CONTENTS
1
INVITATION FOR QUALIFICATION ................................................................... 1

1.1
1.2
1.3
1.4
1.5
Introduction ........................................................................................... 1
Invitation ............................................................................................... 1
Brief Scope of Work ................................................................................ 1
RFQ Details............................................................................................ 1
Objective of Request for Qualification ........................................................ 2
QUALIFICATION REQUIREMENT ...................................................................... 3

2.1 Qualification Requirement ........................................................................ 3
2.1.3 Other Criteria ..................................................................................... 4
2.2 Qualification Documents .......................................................................... 4
INSTRUCTION TO APPLICANTS ...................................................................... 5
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[i]
25.09.2014
[LOGO OF UTILITY]
S.No

Description
1.0
Annexure-1
2.0
Format for Letter of Undertaking by Annexure-2

Holding Company pledging unconditional
Data Sheet-1
Clause No. 2.1.1.
3.0
4.0
5.0
6.0
7.0
Document Number
LII-GETS12021-G-00100-009

clause 2.1.2 (a)
clause 2.1.2 (b)
2.1.2 (a) & 2.1.2 (b) on its own &
RFQ document
Rev
No.
01
Data Sheet-2
Datasheet-3
Data Sheet-4
Data Sheet-5
Description
Page No.
Date of Issue
RFQ for Contractor
[ii]
25.09.2014
[LOGO OF UTILITY]
1.1
Introduction
1.2
Invitation
No.[XXX] of the [XXX] Power Plant. Under this project, [Name of the Utility]
bidders from India for the Renovation & Modernization Work of [Ash Handling
Plant] package of Unit No. [XXX] of the [XXX] Power Plant on Domestic
Competitive Bidding (DCB).
Interested bidders from India may collect the RFQ documents in person from
from [.] to [.]. Alternatively, the RFQ document
1.3
Brief Scope of Work

operation & performance guarantee tests for [Ash Handling Plant] package of
Unit no. [XXX] of [XXX] Power Plant.
1.4
RFQ Details
(a) Participation Fee
INR [---]
(b) Publication date of RFQ
[----------------------------]
(c) Last date for issue of

RFQ document
[----------------------------]
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[1]
25.09.2014
[LOGO OF UTILITY]
(d) Last Date & Time of

Date & Time of
Opening of
[----------------------------]
(e) Date for identification

Issuance of RFP
[----------------------------]
working day.
1.5

Renovation & Modernization work of [Ash Handling Plant] package of Unit no.
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[2]
25.09.2014
[LOGO OF UTILITY]
2.1
Renovation & Modernization work for [Ash Handling Plant] package, the
2.1.1 and Financial Qualification Requirement specified at clause 2.1.2.
2.1.1
[The Bidder, during the last 10 years preceding the scheduled date for
should have designed, engineered, manufactured, erected and commissioned
at least One Ash Handling Plants for Thermal Power Plants of capacity 200
MW or above comprising, a) Lean Slurry/High Concentration Slurry Disposal
System) for Bottom & Coarse Ash; b) Dry Handling & Disposal System for Fly
Ash and c) Ash Water Recycling System, complete with associated Electrical
and PLC based Instrumentation & Control Systems for the entire Ash Handling
Plant which should have completed satisfactory operation for a period of not
less than One (1) years as on the scheduled date for submission of PreQualification Bids indicated in row (d) in section 1.4 above.
2.1.2

(a)

Rupees ] millions as per audited annual accounts during the
[...]. Other income will not be considered for arriving at the annual
turnover.
(b)
(c)

(d)
controlling interest in the Bidder, meets the stipulated turn-over
equal to or more than [..]. In such a case, the Bidder has to
submit a Letter of Undertaking from the Holding Company pledging
unconditional and irrevocable financial support to the bidder for
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[3]
25.09.2014
[LOGO OF UTILITY]

] , [FY ] & [FY ..].
2.1.3
Other Criteria
(a)

(b)
(c)

as Bidder in more than one Bid under this tender.
2.2
2.2.1

(i)
(ii)
(v)
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[4]
25.09.2014
[LOGO OF UTILITY]
3.1.

work of [Ash Handling Plant] package and will be eligible to submit Bid
3.2.
incorrect or manipulated, the Bidder will be disqualified for the tender and will
be liable to be blacklisted / debarred by the Employer for future tenders.
3.3.
3.4.
3.5.

period.
requirements appropriate to the works covered in his bid and adequate field
service organization to provide the necessary field erection and management
services required to successfully erect, test and commission the equipment /
system as required by the bidding documents. Pre-Qualification Bid submitted
without the proper documentary evidence to substantiate fulfilment of the
qualifying requirements as specified are liable for rejection without assigning
any reason.
3.6.
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[5]
25.09.2014
[LOGO OF UTILITY]
3.7.
Notwithstanding anything stated above, [Name of Utility] reserves the right to

verify independently all statements / information submitted to confirm the
3.8.
3.9.
Participation Fee for an amount of [INR] in the form of Demand Draft

3.10.
Language of Bid
3.11.

The Bidders name stated on the Pre-Qualification Bid shall be the exact legal
name of the firm.
3.12.

Bid.
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[6]
25.09.2014
[LOGO OF UTILITY]
[XXXXX]
[XXXXX] [XXXXX]
accepted.
3.13.

above.
3.14.

document.
S.No
Description
1.0
Annexure-1
2.0

Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[7]
25.09.2014
[LOGO OF UTILITY]
S.No
Description

3.0
4.0
5.0
6.0
7.0
Document Number
LII-GETS12021-G-00100-009

Data Sheet-1
Clause No. 2.1.1.
Data Sheet-2
clause 2.1.2 (a)
Datasheet-3
clause 2.1.2 (b)
Data Sheet-4
2.1.2 (a) & 2.1.2 (b) on its own &
RFQ document
Rev
No.
01
Data Sheet-5
Description
Page No.
Date of Issue
RFQ for Contractor
[8]
25.09.2014
[LOGO OF
UTILITY]
Annexure-1
Date: - [XXXXX]
RFQ No. [XXXXX]
To,
[Address XXXXX]
Dear Sir /Madam

1.0
Renovation & Modernization of [Ash Handling Plant] Package for unit [XXXXX] of
2.0
Name of Bidder: []
3.0
RFQ document.
4.0
We confirm that neither we nor any of our associates/ affiliates is liable for
5.0
(i)
Covering Letter
(ii)

(iii)
(iv)
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[9]
25.09.2014
6.0
[LOGO OF
UTILITY]
(v)
(vi)
(vii)
Letter of undertaking pledging unconditional & irrevocable financial support

to the bidder for execution of the contract. (In case of financial QR is met
on the strength of Holding Company).

(i)
(ii)
Copies of order
(iii)
(iv)
(v)

(vi)
(vii)
(viii)
Any other document.
7.0

8.0

Yours Faithfully,
Signature [XXXXX]
Full Name [XXXXX]
Designation [XXXXX]
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[10]
25.09.2014
[LOGO OF
UTILITY]
Annexure-2
Ref.: [XXXXX]
Date : [XXXXX]
To,
Dear Sir/ Madam,
Bidder/Contractor.
Yours faithfully,
Holding Company)
Date:
Place:

Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[11]
25.09.2014
[LOGO OF
UTILITY]
Data Sheet-1
No. 2.1.1:
To,
Bidderss
Name
and Address:-
[Name of Utility]
[Address]
We are submitting the Prequalification Bid for R&M of [Ash Handling Plant] Package for
[We have designed, engineered, manufactured, erected and commissioned Ash
Handling Plants for Thermal Power Plants of capacity 200 MW or above comprising, a)
Lean Slurry/High Concentration Slurry Disposal System) for Bottom & Coarse Ash; b)
Dry Handling & Disposal System for Fly Ash and c) Ash Water Recycling System,
complete with associated Electrical and PLC based Instrumentation & Control Systems
for the entire Ash Handling Plant which have completed satisfactory operation for a
period of not less than two (2) years as on the date of opening of Pre-Qualification Bid.]
The details of the same are given below:
Sl.
Description
Installation
No.1
1.

2.

Fax and Tel. Nos.
3.

organization.
4.
Contact No. & Date
5.
6.
7.
8.
9.

aforesaid Ash Handling Plant.
Installation
No.2
Installation
No.3
of

Bottom Ash Handling System
- Type
Document Number
LII-GETS12021-G-00100-009
of
collection
Rev
No.
01
system
Description
RFQ for Contractor
Page No.
Date of Issue
[12]
25.09.2014
Sl.
Description
Installation
No.1
Installation
No.2
[LOGO OF
UTILITY]
Installation
No.3
(Submerged
Scrapper
Chain
Conveyor System / W-Shaped
Water Impounded Hopper)
- Capacity (TPH)
- Type of wet disposal system
(Lean Slurry/High Concentration
Slurry Disposal System (HCSD)
- Ash to Water Ratio
Coarse Ash Handling System
- Type of collection system
- Capacity (TPH)
- Type of Disposal System.
- Ash to Water Ratio.
Fly Ash Handling System
- Type of System adopted for
collection & conveying dry fly
ash from ESP Hoppers to Surge
Hoppers (Vacuum / Pressurized
System)
- Type of System adopted for
conveying dry fly ash from
Surge Hopper to Fly Ash Storage
Silos.
- Capacity of Fly Ash Storage
Silos.
Ash Water Recycling System
- Percentage
recycled.
of
ash
water
- Type of treatment provided for

the recycled ash water
Date
:
(Signature.)
Place :
(Full Name)
(Designation)
(Company Seal)
1.
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[13]
25.09.2014
[LOGO OF
UTILITY]
Data Sheet-2
2.1.2 (a):
To,
Bidders Name
[Name of Utility]
[Address]
and Address
Sl. No.
1
2
3
4
Financial Year
Amt. of Bidders
Currency
Amt. in Rs.
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Financial Years.
We have enclosed
Balance Sheets and
duly certified by
Date:
Place:
Exchange rate
as on 30 days
prior to the
schedule date
of bid opening
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[14]
25.09.2014
[LOGO OF
UTILITY]
Data Sheet-3
clause 2.1.2 (b):
To,
Bidders Name
[Name of Utility]
[Address]
and Address:-
We are submitting the Prequalification Bid for R&M of [Ash Handling Plant] Package
[..]
of
[]
Plant
of
for
Unit
No.
[.].
Sl. No.
1
3
Description
year.
Accountant
Date:
Place:

------*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[15]
25.09.2014
[LOGO OF
UTILITY]
Data Sheet-4
the financial QR:
To,
Bidder, Name
and Address:-
[Name of Utility]
[Address]
Sl. No.
1
2
3
4
Financial Year
Amt. of Bidders
Currency
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Company on last day
year
We have enclosed
Balance Sheets and
of Holding duly
Accountant
We are enclosing a
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Amt. in Rs.
Exchange rate
as on 30 days
prior to the
schedule date
of bid opening
*Yes/*No
*Yes/*No
Description
RFQ for Contractor
Page No.
Date of Issue
[16]
25.09.2014
[LOGO OF
UTILITY]
from the Holding

Company pledging
unconditional and
is enclosed
Date:
Place:
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[17]
25.09.2014
[LOGO OF
UTILITY]
Data Sheet -5
To,
Bidders Name
[Name of Utility]
[Address]
and Address

Sl. No.
Description

opening


deposits

Date:
Place:
Document Number
LII-GETS12021-G-00100-009
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Rev
No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[18]
25.09.2014
[LOGO OF
UTILITY]
Document Number
LII-GETS12021-G-00100-009
Rev
No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[19]
25.09.2014

FOR
FOR
OF
BALANCE OF PLANT (BOP)
PREPARED BY

THE CONSULTANT
LII-GETS12021-G-00100-010 R0
September 2014
Request for Qualification for the Selection of Contractor for R&M of Balance of
Plant of Unit No.[..] Capacity [..] of [Name of the Power Plant]
[LOGO OF
UTILITY]
TABLE OF CONTENTS
1

1.1
1.2
1.3
1.4
1.5
Introduction .......................................................................................... 1
INVITATION .......................................................................................... 1
RFQ Details........................................................................................... 1

2.1.1 Technical Qualification Requirement for Bidder ........................................ 3
2.1.2 Technical Qualification Requirement for BoP Systems .............................. 4
2.1.4 Other Criteria ..................................................................................... 6
Document Number
LII-GETS12021-G-00100-010
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[i]
25.09.2014
S.No

Description
1.0
2.0

furnished by the Consortium Partners.
3.0
4.0
5.0
6.0
7.0
8.0
9.0
Document Number
LII-GETS12021-G-00100-010
[LOGO OF
UTILITY]

Annexure-1
Annexure-2
Annexure-3
Sample format for Data Sheet regarding

Clause No. 2.1.1
Data Sheet-1

Clause No. 2.1.2.
Data Sheet-2

clause 2.1.3 (a)
Data Sheet-3

clause 2.1.3 (b)
Datasheet-4

2.1.3 (a) & 2.1.3 (b) on its own &
Holding Company meet the financial QR
Data Sheet-5

RFQ document
Data Sheet-6
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[ii]
25.09.2014
1.1
Introduction
[LOGO OF
UTILITY]
1.2
INVITATION
invites sealed Pre-Qualification Tender from experienced and interested Indian
bidders for the Renovation & Modernization Work of [Balance of Plant]
package of Unit No.[XXX] of the [XXX] Power Plant on Domestic Competitive
Bidding (DCB).
[.] to [.]. Alternatively, the RFQ document can
be downloaded from [Name of the Utility] website [..].
1.3
Brief Scope of Work

operation & performance guarantee tests for [Balance of Plant] package of
Unit no. [XXX] of [XXX] Power Plant comprising [] systems.
1.4
RFQ Details
(a)
Participation Fee
INR [---]
(b)
Publication date of
[----------------------------]
Document Number
LII-GETS12021-G-00100-010
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[1]
25.09.2014
[LOGO OF
UTILITY]
RFQ
(c)

RFQ document
[----------------------------]
(d)
Last Date & Time of

Date & Time of
Opening of
[----------------------------]
(e)

of Qualified Bidders
and Issuance of RFP
[----------------------------]
working day.
1.5

Renovation & Modernization work of [Balance of Plant] package of Unit no.
Document Number
LII-GETS12021-G-00100-010
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[2]
25.09.2014
2.1
[LOGO OF
UTILITY]

Renovation & Modernization work for [Balance of Plant] package, the bidder
must meet the Technical Qualification Requirement specified at clause 2.1.1
and Financial Qualification Requirement specified at clause 2.1.3. As per the
stipulation in Clause 2.1.1, the Bidder/Consortium Leader/Consortium
Member(s)/Sub-Contractor(s), as the case may be, must meet the
Qualification Requirements for BoP systems stipulated at Clause 2.1.2.
2.1.1
Technical Qualification Requirement for Bidder

The Bidder must meet Qualification Requirement stipulated at (a) or (b) or (c)
below:
(a)
The bidder should have executed contract(s) on Engineering,

Procurement and Construction (EPC) basis for at least one number of
coal based / lignite based / gas based combined cycle power plant of
installed capacity not less than 100 MW which has been commissioned
during the last 10 years preceding the scheduled date for submission of
Pre-Qualification Bids indicated in row (d) in section 1.4 above and has
been in satisfactory operation for a period of not less than one year as
on the original scheduled date of submission of Pre-Qualification Bids
indicated in row (d) in section 1.4 above. The scope of work of such
Contract(s) must have included Engineering, Supply, installation (with all
associated Mechanical, Electrical, Civil & Structural Works), testing and
commissioning of Main power plant equipment (BoilerTurbine-generator
or Gas Turbine - HRSG - STG) with all associated integral auxiliaries.
In addition, the Bidder should meet the Qualification Requirement
stipulated at clause 2.1.2 for the four BoP systems listed therein. If the
Bidder does not meet the Qualification Requirement for some or all
systems listed at Clause 2.1.2, he can employ Sub-Contractor(s) who
meet Qualification Requirement stipulated for such system.
or
(b)
The bidder should have executed contract(s) on Engineering,

Procurement and Construction (EPC) basis for Balance of Plant of at
least one number of coal based / lignite based / gas based combined
cycle power plant of installed capacity not less than 100 MW which has
been commissioned during the last 10 years preceding the scheduled
date for submission of Pre-Qualification Bids indicated in row (d) in
section 1.4 above and has been in satisfactory operation for a period of
not less than one year as on the original scheduled date of submission of
Pre-Qualification Bids indicated in row (d) in section 1.4 above. The
scope of work of such Contract(s) must have included Engineering,
Supply, installation (with all associated Mechanical, Electrical, Civil &
Document Number
LII-GETS12021-G-00100-010
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[3]
25.09.2014
[LOGO OF
UTILITY]
Structural Works), testing and commissioning of at least the following

four systems with all associated integral auxiliaries:
1. Cooling Tower
2. CW Pumps for Condenser Cooling
3. Water Pre-treatment Plant and/or Liquid Effluent Treatment Plant
4. Demineralization (DM) Plant
In addition, the Bidder should meet the Qualification Requirement
stipulated at clause 2.1.2 for the four BoP systems listed therein. If the
Bidder does not meet the Qualification Requirement for some or all
systems listed at Clause 2.1.2, he can employ Sub-Contractor(s) who
meet Qualification Requirement stipulated for such system (s).
or
(c)
The bidder can be a Consortium of firms who collectively meet the

Qualification Requirement specified at Clause 2.1.2 for the four systems
listed therein. The Consortium members shall designate one member as
the Leader of the Consortium with whom the Contract will be entered
into in case the Consortium emerges as the successful bidder. The
maximum number of Consortium members shall be limited to four. Each
of the Consortium Member, including Consortium Leader, must meet
Qualification Requirement for at least one of the four stipulated systems.
In such a case, each of the listed systems will be executed by the
Consortium Partner who meets the Qualification Requirement stipulated
for that system.
2.1.2
Technical Qualification Requirement for BoP Systems
2.1.2.1
Qualification Requirement for Cooling Tower

The bidder , during the last 10 years preceding the scheduled date for
should have designed, constructed and commissioned at least one (1) number
of [Natural Draft/Induced Draft Cooling tower] with [splash type / film type
fill], of capacity not less than {Insert the design Capacity of Existing Cooling
Tower in m3/h} which is in successful operation for at least one (1) year as on
the scheduled date for submission of Pre-Qualification Bids indicated in row
(d) in section 1.4 above.
2.1.2.2
Qualification Requirement for CW Pumps for Condenser Cooling

should have designed, manufactured, supplied, erected/ supervised erection,
and commissioned/ supervised commissioning of at least one (1) nos. of
vertical wet pit pumps for condenser cooling water application/ comparable
duty, of capacity not less than {Insert the design Capacity of Existing CW
pump in m3/h}, having specific speed in the range of [40007000 (US units)]
which are in successful operation for at least one (1) year as on the scheduled
Document Number
LII-GETS12021-G-00100-010
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[4]
25.09.2014
[LOGO OF
UTILITY]
date for submission of Pre-Qualification Bids indicated in row (d) in section

1.4 above.
2.1.2.3
Qualification Requirement for Water Pre-treatment Plant and/or Liquid Effluent

Treatment Plant
should have designed, supplied, erected and commissioned at least one (1)
numbers of water/waste water treatment plants, each with a total capacity of
{Insert the design Capacity of Existing stream in m3/h} (minimum), comprising
of clarifiers/tube settlers/ thickeners or a combination thereof. The plants
should be in successful operation for at least One (1) years as on the
scheduled date for submission of Pre-Qualification Bids indicated in row (d) in
section 1.4 above.
2.1.2.4
Qualification Requirement for Demineralization (DM) Plant

should have designed, supplied, erected and commissioned at least one (1)
number of ion exchange based demineralising plant, consisting of at least two
(2) streams of minimum {Insert the design Capacity of Existing stream in
m3/h} capacity, capable of producing outlet water quality of silica and
conductivity not more than 0.02 ppm as SiO2 and 0.2 micro mho/cm
respectively, which are in successful operation for at least one (1) year as on
the scheduled date for submission of Pre-Qualification Bids indicated in row
(d) in section 1.4 above.
2.1.3

(a)
The average annual turnover of the Bidder or Consortium Leader, as the

case may be, should be at least [Indian Rupees ] millions or
equivalent foreign currency as per audited annual accounts during the
[...]. For the purpose of conversion of foreign currency to Indian
Rupees, the TT Buying rate of State Bank of India as on 30 days prior to
the date of submission of Bid will be considered. Other income will not
be considered for arriving at the annual turnover.
(b)
The Net Worth of the Bidder or Consortium Leader, as the case may be,
as on the last date of preceding Financial Year shall be positive.
(c)

unutilized credit line of the bidder or Consortium Leader, as the case may
be, (including non fund based credit lines) should not be less than
[INR.] as on not more than 30 days prior to the scheduled last
date of submission of Pre-qualification Bid
(d)

Criteria stipulated in the above clauses (a) and (b) on its own and the
Holding Company having controlling interest in the Bidder / Consortium
Leader, as the case may be, meets the stipulated turn-over requirements
Document Number
LII-GETS12021-G-00100-010
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[5]
25.09.2014
[LOGO OF
UTILITY]
at Clause (a), then Financial Criteria stipulated in the above clauses (a)
and (b) will be deemed to have been met, provided that the Net worth of
such Holding Company as on the last day of the preceding financial year
is at least equal to or more than [..]. In such a case, the Bidder /
Consortium Leader has to submit a Letter of Undertaking from the
Holding Company
pledging unconditional and irrevocable financial
support to the bidder for execution of the Contract.
] , [FY ] & [FY ..].
2.1.4
Other Criteria
(a)

(b)
Any Bidder who is legally barred from the procurement process of [name
(c)

as Bidder or Consortium Member in more than one Bid under this tender.
2.2
2.2.1

(i)
(ii)
(iii) Name of any proposed Consortium member (s) along with letter of
consent of consortium member.
(v)
Contracts in hand / pending jobs and their status along with value.
Document Number
LII-GETS12021-G-00100-010
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[6]
25.09.2014
[LOGO OF
UTILITY]
3.1.

work of [Balance of Plant] package and will be eligible to submit Bid Proposal
for R&M work. The RFQ Documents specify the qualification criteria to be met
by the prospective bidders to become eligible for participating in the tendering
process. The bidders are required to submit evidence of their technical
expertise, relevant past experience, project execution capability and financial
resources to discharge the scope of service.
3.2.
certificate(s)/document(s) submitted by the Bidder or Consortium leader or
Consortium partner is found to be factually incorrect or manipulated, the
Bidder or Consortium leader or Consortium partner as the case may be, will be
disqualified for the tender and will be liable to be blacklisted / debarred by the
Employer for future tenders.
3.3.
3.4.
this contract.
3.5.

consortium Partner (s) along with the Pre-Qualification Bid signed by the
will be permitted at the time of submitting the Techno commercial Bid. The
Consortium Agreement must include but not limited to (1) Scope of Service of
each Consortium Member, (2) Authorization in favour of Consortium Leader to
Bid and act on behalf of the Consortium Members during tendering and
execution stage, (3) Joint and several liability of all consortium members for
the entire scope of service, (4) Undertaking that any dispute among
Consortium Members will not relieve any Member from its obligations towards
the Owner under this Contract, (5) Undertaking by each member for providing
expertise, man power and other technical support for successful completion
of the respective Scope of Service and (6) Undertaking that each Member
Document Number
LII-GETS12021-G-00100-010
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[7]
25.09.2014
[LOGO OF
UTILITY]
will provide Additional Contract Performance Security in addition to the

Contract Performance Security to be furnished by Consortium Leader.
3.6.
3.7.

period.
If the bidder is a Consortium of firms, in addition to the Contract Performance
Guarantee (CPG) of 10% furnished by the Consortium Leader, each other
consortium member will furnish Additional Contract Performance Guarantee
equal to 1% of the Contract Price.
3.8.

3.9.
3.10.

3.11.
Language of Bid
Document Number
LII-GETS12021-G-00100-010
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[8]
25.09.2014
[LOGO OF
UTILITY]

3.12.

Bidder and each page of the Pre-Qualification Bid must be signed and sealed
by the authorized person(s) of the Bidder / Consortium leader with his usual
signature. The name of all persons signing should be typed or printed below
the signature.
3.13.

Bid.
[XXXXX]
[XXXXX] [XXXXX]
accepted.
3.14.

above.
The Pre-Qualification Bids shall be opened in the presence of such Bidders
Document Number
LII-GETS12021-G-00100-010
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[9]
25.09.2014
[LOGO OF
UTILITY]
process, if any, should reach at least [15 (Fifteen) days)] before the date
3.15.

document.
S.No

Description
1.0
2.0

3.0
4.0
5.0
6.0
7.0
8.0
Document Number
LII-GETS12021-G-00100-010

furnished by the Consortium Partners.

Annexure-1
Annexure-2
Annexure-3

Clause No. 2.1.1.
Data Sheet-1

Clause No. 2.1.2.
Data Sheet-2

clause 2.1.3 (a)
Data Sheet-3

clause 2.1.3 (b)
Datasheet-4

Data Sheet-5
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[10]
25.09.2014
S.No

Description
[LOGO OF
UTILITY]
2.1.3 (a) & 2.1.3 (b) on its own &

Holding Company meet the financial QR
9.0
Document Number
LII-GETS12021-G-00100-010

RFQ document
Rev. No.
01
Description
RFQ for Contractor
Data Sheet-6
Page No.
Date of Issue
[11]
25.09.2014
[LOGO OF UTILITY]
Annexure-1

Date: - [XXXXX]
RFQ No. [XXXXX]
To,
[Address XXXXX]
Dear Sir /Madam
1.0
Renovation & Modernization of [Balance of Plant] Package for unit [XXXXX] of [XXXXX]
power plant of [XXXXX]. Towards this end we submit the following details &
2.0
3.0
We meet the Qualification Requirement stipulated at clause no.2.1.1 of RFQ
document *on our own / *in association with our Consortium Partner(s) [XXXXX].
*We on our own meet the Qualification Requirement at Clause 2.1.2.1 of RFQ / *We in
association with our Consortium Partner(s) () meet the Qualification
Requirement at Clause 2.1.2.1 of RFQ / *We will employ Sub-Contractor who will meet
Qualification Requirement at 2.1.2.1.
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[12]
25.09.2014
[LOGO OF UTILITY]
*We on our own meet the Qualification Requirement at Clause 2.1.3 of RFQ / *We on
the strength of our Holding Company () meet the Qualification Requirement at
Clause 2.1.3 of RFQ.
qualification requirement, which is met by the Bidder/ Consortium Member(s) meet
which part of Qualification Requirement and which part of the Qualification Requirement
will be met by Sub-Contractor(s). Bidder is also required to the relationship between the
Bidder & others on whose strength Qualification Requirement is met.)
4.0
We confirm that neither we nor any of our Consortium Members/our associates/
affiliates are liable for exclusion from participation in tendering process under other
criteria stipulated under clause no.2.1.4 of RFQ document.
5.0
(i)
Covering Letter
(ii)

Consortium members, and Holding Company, as applicable.
(iii)
(iv)
(v)
(vi)
(vii)
(viii)

(ix)
6.0
Letter of Consent of Consortium Partner in case of Consortium

(ii)
Copies of order
(iii)
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[13]
25.09.2014
[LOGO OF UTILITY]
(iv)
(v)

(vi)
(vii)
(viii)
Any other document.
7.0

8.0

Yours Faithfully,
Signature [XXXXX]
Full Name [XXXXX]
Designation [XXXXX]
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[14]
25.09.2014
[LOGO OF UTILITY]
Annexure-2
Ref.: [XXXXX]
Date : [XXXXX]
To,
Dear Sir/ Madam,
M/s................... (Name of the Bidder/Consortium Leader) and have
controlling interest therein.
M/s..(Name of the Bidder/Consortium Leader) have sought financial
strength and support from us for meeting the stipulated Financial Qualifying
Requirement as per Clause 2.1.3 (a) & (b) of RFQ document.
M/s........................................ (Name of the Bidder//Consortium Leader), for
the execution of the Contract, in case they are awarded the Contract for the
said package at the end of the bidding process. We further agree that this
undertaking shall be without prejudice to the various liabilities that
M/s.................................... (Name of Bidder) would be required to
undertake in terms of the Contract including the Performance Security as well
as other obligations of the Bidder/Contractor.
Yours faithfully,
Holding Company)
Date:
Place:

1.
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[15]
25.09.2014
[LOGO OF UTILITY]
Annexure-3
(Name and Complete address of the Consortium Leader) for the successful
completion of part scope of work as enclosed in the attachment (authenticated
by the Consortium Partner) of [XXXXX] Package for the Unit no.[XXXXX] of.
[XXXXX] plant in the state of [XXXXX] for [XXXXX], India. We also hereby
undertake to ensure the quality of manufacture, timely delivery and the
successful performance of the equipment/system covered in our scope of.
[XXXXX] , fully meeting the guarantee and also depute our technical experts
from time to time for advice on procedures and guidance during design,
back up bank guarantee for 5 % of Contract Price for our Scope of Work.
1.
Witness
Signature:
Name
Name
Designation:
Designation:
Office Address
Seal of the Company
2.
Witness
For Bidder (Consortium Leader)
Signature:
Name
Name
Designation:
Designation:
Office Address
Seal of the Company
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[16]
25.09.2014
[LOGO OF UTILITY]
Data Sheet-1
No. 2.1.1 :
To,
Bidder/Consortium
and Address:-
[Name of Utility]
[Address]
We are submitting the Prequalification Bid for R&M of [Balance of Plant] Package for
*We have executed contract(s) on Engineering, Procurement and Construction (EPC)
basis for at least one number of coal based / lignite based / gas based combined cycle
power plant of installed capacity not less than 100 MW which has been commissioned
during the last 10 years preceding the original scheduled date for submission of PreQualification Bids and has been in satisfactory operation for a period of not less than one
year as on the original scheduled date of Pre-Qualification Bid opening. The scope of
work of such Contract(s) included Engineering, Supply, installation (with all associated
Mechanical, Electrical, Civil & Structural Works), testing and commissioning of Main
power plant equipment (BoilerTurbine-generator or Gas Turbine - HRSG - STG) with all
associated integral auxiliaries. The details of the same are given below. We meet
Qualification Requirement stipulated at Clause 2.1.1 (a). / *We have executed
contract(s) on Engineering, Procurement and Construction (EPC) basis for Balance of
Plant of at least one number of coal based / lignite based / gas based combined cycle
power plant of installed capacity not less than 100 MW which has been commissioned
during the last 10 years preceding the original scheduled date for submission of PreQualification Bids and has been in satisfactory operation for a period of not less than
one year as on the original scheduled date of Pre-Qualification Bid opening. The scope of
work of such Contract(s) included Engineering, Supply, installation (with all associated
Mechanical, Electrical, Civil & Structural Works), testing and commissioning of at least
the following four systems with all associated integral auxiliaries:
1.
Cooling Tower
2.
CW Pumps for Condenser Cooling
3.
Water Pre-treatment Plant and/or Liquid Effluent Treatment Plant
4.
Demineralization (DM) Plant
The details of the same are given below. We meet Qualification Requirement stipulated
at Clause 2.1.1 (b).
Sl.
Description
1.

Document Number
LII-GETS12021-G-00100-010
Installation
No.1
Rev
No.
01
Installation
No.2
Installation
No.3
Description
Page No.
Date of Issue
RFQ for Contractor
[17]
25.09.2014
[LOGO OF UTILITY]
Sl.
Description
Installation
No.1
Installation
No.2
Installation
No.3
2.

Fax and Tel. Nos.
3.

organization.
4.
Type of Power Plant (Coal Fired

/ Lignite Fired/ Combined Cycle)
5.
Contact No. & Date
6.
Plant Capacity in MW
7.
8.
9.
10.
11.

aforesaid Contract set includes
the following:
(i) Engineering
Yes*/No*
Yes*/No*
Yes*/No*
(ii) Procurement
Yes*/No*
Yes*/No*
Yes*/No*
(iii) Construction
Yes*/No*
Yes*/No*
Yes*/No*
(iv) Commissioning and Testing
Yes*/No*
Yes*/No*
Yes*/No*
(v) Project Management
Yes*/No*
Yes*/No*
Yes*/No*
of
12.
Detail scope of Work
13.

Attachment
Date
:
(Signature.)
Place :
(Full Name)
(Designation)
(Company Seal)
1.
2.

Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[18]
25.09.2014
[LOGO OF UTILITY]
Data Sheet -2
No. 2.1.2 :
To,
Bidder/Consortium
and Address:-
[Name of Utility]
[Address]
*We are (Name of Bidder/Consortium Partner) submitting the Prequalification Bid for
R&M of [Balance of Plant] Package for Unit No. [..] of
[] Plant of [.]. / *We are associated with
(Name of Consortium Leader) as Consortium Partner for R&M of Balance of Plant
Package for Unit [] of [] Plant of [..]
We meet the Qualification Requirements at Clauses *2.1.2.1, *2.1.2.2, *2.1.2.3 and
*2.1.2.4 The details of the same are given below:
Sl.
Description
1.
Name of the Station and its

Location
2.

Fax and Tel. Nos.
Installation
Installation
Installation
No.1
No.2
No.3
- Email ID
- Web site address
3.

organization.
4.
5.
6.
7.
8.
9.
Type of Power Plant (Coal Fired

/ Lignite Fired/ Combined
Cycle)
14.
Detail scope of Work
15.

Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
of
Description
Page No.
Date of Issue
RFQ for Contractor
[19]
25.09.2014
[LOGO OF UTILITY]
Sl.
Description
Installation
Installation
Installation
No.1
No.2
No.3
(vi) Designed
Yes*/No*
Yes*/No*
Yes*/No*
(vii)Engineered
Yes*/No*
Yes*/No*
Yes*/No*
(viii)
Yes*/No*
Yes*/No*
Yes*/No*
*Supervised
Yes*/No*
Yes*/No*
Yes*/No*
(x) *Commissioned / *Supervised

Commissioning
Yes*/No*
Yes*/No*
Yes*/No*
bid at Annexureto
Attachment
12.

aforesaid Balance of Plant Package
Manufactured
(ix) *Erected
Erection
13.
13.1
13.2
this
Details of Balance of Plant

Yes*/No*
Raw Water System

i
Number of Intake pumps
ii
Type of Pump
iii
Rated Flow
iv
Rated Speed
Total Developed Head
vi
Range of operation
vii
Maximum efficiency of the

pump at design point
viii
Intake well diameter
ix
Intake well finished bed

level
Pump house inside clear

plan dimension

Aerator
i
No. of Aerator
ii
Type of Aerator
iii
Design Flow
iv
% of Sludge
Stilling Chamber
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[20]
25.09.2014
[LOGO OF UTILITY]
Sl.
Description
i
Number
ii
Capacity (Retention Time)
Installation
Installation
Installation
No.1
No.2
No.3
Flash Mixer
i
Number
ii
Type
iii
Agitator Type
iv
Agitator Number
Capacity of each Agitator

(Retention Time)
Flocculator
13.3
13.4
Type
ii
Material of Construction
iii
Rated net output capacity
iv
Retention time (minimum)
CW System
i
Number of CW pumps
ii
Type of Pump
iii
Rated Flow
iv
Rated Speed
vi
Range of operation
vii
Maximum efficiency of the

pump at design point
viii
Intake well diameter
ix
Intake well finished bed

level
Pump house inside clear

plan dimension
xi
Size of CW Pipe in mm
xii
Wall thickness of CW pipe

in mm
Cooling Tower
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[21]
25.09.2014
[LOGO OF UTILITY]
Sl.
13.5
Description
i
Type of Cooling Tower
ii
Rated water flow per tower
iii
Design wet bulb

temperature
iv
Approach
Cooling range at rated flow
vi
Design ambient relative

humidity (average)
vii
Evaporation loss (maximum)
viii
Drift loss (maximum)
ix
Draft loss
Installation
Installation
Installation
No.1
No.2
No.3
SAC, WAC [.]
SAC, WAC [.]
SAC, WAC [.]
SBA, WBA [.]
SBA, WBA [.]
SBA, WBA [.]
DM Plant
i
No. of DM Streams
ii
No. of working streams
iii
No. of standby streams
iv
Water source
Net permeate water output
vi
Period between successive

regenerations
vii
Pressure Vessels Type
viii
Number of Pressure Vessels

(For Each type i.e. Strongly
acidic cation exchanger
(SAC), Weak Acid Cation
exchanger (WAC), Strongly
basic anion exchanger
(SBA), Weak Base Anion
exchanger (WBA), Mixed
bed exchanger (MB)
ix
Net outflow/unit
MB - [.]
x
Design surface flow rate
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
SAC, WAC -
MB - [.]
MB - [.]
SAC, WAC -
SAC, WAC -
Description
Page No.
Date of Issue
RFQ for Contractor
[22]
25.09.2014
[LOGO OF UTILITY]
Sl.
Description
Installation
Installation
Installation
No.1
No.2
No.3
[.]
[.]
[.]
SBA, WBA [.]
SBA, WBA [.]
SBA, WBA [.]
MB - [.]
i
Date
MB - [.]
MB - [.]
Duty classification
:
(Signature.)
Place :
(Printed Name)
(Designation)
(Company Seal)
1.
2.

3.
Separate Data Sheet to be furnished for Bidder/Consortium Member (s)
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[23]
25.09.2014
[LOGO OF UTILITY]
Data Sheet-3
2.1.3 (a):
To,
Bidder/Consortium
Partners Name
and Address
[Name of Utility]
[Address]
In line with RFQ Document clause 2.1.3(a) ), we confirm that our average annual
Sl. No.
1
2
3
4
Financial Year
Amt. of Bidders
Currency
Amt. in Rs.
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Financial Years.
We have enclosed
Balance Sheets and
duly certified by
Date:
Place:
Exchange rate
as on 30 days
prior to the
schedule date
of bid opening
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[24]
25.09.2014
[LOGO OF UTILITY]
Data Sheet-4
clause 2.1.3 (b):
To,
Bidder/Consortium
Partners Name
and Address:-
[Name of Utility]
[Address]
Unit
No.
[..]
of
[]
Plant
of
[.].
Sl. No.
1
3
Description
year.
Accountant
Date:
Place:

------*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[25]
25.09.2014
[LOGO OF UTILITY]
Data Sheet-5
the financial QR:
To,
Bidder/Consortium
Leaders Name
and Address:-
[Name of Utility]
[Address]
Since we do not meet Financial QR on own, we give the following details of Holding:Name and Address of the Holding Company: ...........................................
Turnover and Networth details of Holding Company folllows:
Sl. No.
1
2
3
4
Financial Year
Amt. of Bidders
Currency
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Company on last day
year
We have enclosed
Balance Sheets and
of Holding Company
duly certified by
We are enclosing a
from the Holding
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Amt. in Rs.
Exchange rate
as on 30 days
prior to the
schedule date
of bid opening
*Yes/*No
*Yes/*No
Description
Page No.
Date of Issue
RFQ for Contractor
[26]
25.09.2014
[LOGO OF UTILITY]
Company, pledging
unconditional and
is enclosed
Date:
Place:
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[27]
25.09.2014
[LOGO OF UTILITY]
Data Sheet -6
To,
Bidder/Consortium
Partners Name
and Address
[Name of Utility]
[Address]
Sl. No.
Description

opening


deposits

Date:
Place:
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-010
Rev
No.
01
Description
Page No.
Date of Issue
RFQ for Contractor
[28]
25.09.2014

FOR
FOR
OF
ELECTRICAL BALANCE OF PLANT (eBOP)
PREPARED BY

THE CONSULTANT
LII-GETS12021-G-00100-011 R01
September 2014
Request for Qualification for the Selection of Contractor for R&M of Electrical
Balance of Plant of Unit No.[..] Capacity [..] of [Name of the Power Plant]
[LOGO OF
UTILITY]
TABLE OF CONTENTS
1

1.1
1.2
1.3
1.4
1.5
Introduction .......................................................................................... 1
INVITATION .......................................................................................... 1
RFQ Details........................................................................................... 1

2.1.3 Other Criteria ..................................................................................... 4
Document Number
LII-GETS12021-G-00100-011
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[i]
25.09.2014
List of Annexure & Data Sheets

S.No
Description
[LOGO OF
UTILITY]
1.0
Annexure-1
2.0

Annexure-2

Clause No. 2.1.1.
Data Sheet-1

clause 2.1.2 (a)
Data Sheet-2

clause 2.1.2 (b)
Datasheet-3

2.1.2 (a) & 2.1.2 (b) on its own &
Data Sheet-4

RFQ document
Data Sheet-5
3.0
4.0
5.0
6.0
7.0
Document Number
LII-GETS12021-G-00100-011
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[ii]
25.09.2014
1.1
Introduction
[LOGO OF
UTILITY]
1.2
INVITATION
invites sealed Pre-Qualification Tender from experienced and interested
bidders for the Renovation & Modernization Work of [Electrical Balance of
Plant] package of Unit No.[XXX] of the [XXX] Power Plant on International
Competitive Bidding (ICB).
[.]to [.]. Alternatively, the RFQ document can be
downloaded from [Name of the Utility] website [..].
1.3
Brief Scope of Work

operation & performance guarantee tests for [Electrical Balance of Plant]
package of Unit no. [XXX] of [XXX] Power Plant.
1.4
RFQ Details
(a)
Participation Fee
INR [---]
(b)
Publication date of
RFQ
[----------------------------]
Document Number
LII-GETS12021-G-00100-011
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[1]
25.09.2014
(c)

RFQ document
[----------------------------]
(d)
Last Date & Time of

Date & Time of
Opening of
[----------------------------]
(e)

of Qualified Bidders
and Issuance of RFP
[----------------------------]
[LOGO OF
UTILITY]
working day.
1.5

Renovation & Modernization work of [Electrical Balance of Plant] package of
Unit no. [XXX] of [XXX] Power Plant. The objective of the pre-qualification is
to allow only the capable and qualified bidders having requisite technical
expertise, relevant experience, project execution capability and financial
resources to participate in the tendering process.
Document Number
LII-GETS12021-G-00100-011
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[2]
25.09.2014
2.1
[LOGO OF
UTILITY]

Renovation & Modernization work for [Electrical Balance of Plant] package,
the bidder must meet the Technical Qualification Requirement specified at
clause 2.1.1 and Financial Qualification Requirement specified at clause 2.1.2.
2.1.1

[The Bidder, during the last 10 years preceding the scheduled date for
should have designed, engineered, supplied, erected, tested and
commissioned at least two E-BOP (Electrical Balance of Plant) packages of
Thermal Power Plants of unit size 200 MW or above comprising Air Insulated
Switchyard, Switchyard Automation System and Power Transformers which
should have completed satisfactory operation for a period of not less than two
(2) years as on the date of opening of Pre-Qualification Bid. Bidders should
have experience of manufacturing, supply, erection, testing, commissioning of
Power Transformers for Thermal Power Plants of unit size 200 MW or above
which are in successful operation for the last minimum two years. In case,
the bidder is not a manufacturer of 400/220 kV Air Insulated Switchyard and
Switchyard Automation System, the bidder can source these equipments from
the original Equipment Manufacturers who have supplied such equipments to
Thermal Power Plants of unit size 200 MW or above which are in successful
operation for the last minimum one year as on the original scheduled date of
submission of Pre-Qualification Bids indicated in row (d) in section 1.4 above.
However, the Bidder shall be fully responsible for the successful performance
of all such bought out equipments as per the requirements of the contract. ]
2.1.2

(a)

annual turnover.
(b)
(c)

Document Number
LII-GETS12021-G-00100-011
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[3]
25.09.2014
(d)
[LOGO OF
UTILITY]
controlling interest in the Bidder meets the stipulated turn-over
Net worth of such Holding Company as on the last day of the preceding
financial year is at least equal to or more than [..]. In such a
case, the Bidder has to submit a Letter of Undertaking from the Holding
Company pledging unconditional and irrevocable financial support to the
bidder for execution of the Contract.
] , [FY ] & [FY ..].
2.1.3
Other Criteria
(a)

(b)
(c)
Any firm cannot participate as Bidder in more than one Bid under this
tender.
2.2
2.2.1

(i)
(ii)
(v)
Document Number
LII-GETS12021-G-00100-011
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[4]
25.09.2014
[LOGO OF
UTILITY]
3.1.

work of [Electrical Balance of Plant] package and will be eligible to submit Bid
financial resources to discharge the scope of service
incorrect or manipulated, the Bidder as the case may be, will be disqualified
for the tender and will be liable to be blacklisted / debarred by the Employer
for future tenders.
3.2.
3.3.
3.4.
3.5.

shall be valid till the end of Warranty Period plus three (3) months grace
period.
Document Number
LII-GETS12021-G-00100-011
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[5]
25.09.2014
[LOGO OF
UTILITY]
3.6.

3.7.
3.8.
3.9.
Language of Bid
3.10.

The Bidder name stated on the Pre-Qualification Bid shall be the exact legal
name of the firm.
3.11.

official seal. Failure to do so would result in rejection of the Pre-Qualification
Bid.
Document Number
LII-GETS12021-G-00100-011
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[6]
25.09.2014
[LOGO OF
UTILITY]

[XXXXX]
[XXXXX] [XXXXX]
accepted.
3.12.

above.
3.13.

document.
S.No
Description
1.0
Annexure-1
2.0

Annexure-2
Document Number
LII-GETS12021-G-00100-011
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[7]
25.09.2014
S.No
3.0
4.0
5.0
6.0
7.0
Document Number
LII-GETS12021-G-00100-011
Description
[LOGO OF
UTILITY]

Clause No. 2.1.1.
Data Sheet-1

clause 2.1.2 (a)
Data Sheet-2

clause 2.1.2 (b)
Datasheet-3

2.1.2 (a) & 2.1.2 (b) on its own &
Data Sheet-4

RFQ document
Data Sheet-5
Rev. No.
01
Description
RFQ for Contractor
Page No.
Date of Issue
[8]
25.09.2014
Request for Qualification For R&M of Electrical Balance of Plant of Unit

No.[..] Capacity [] of [Name of the Power Plant]
[LOGO OF
UTILITY]
Annexure-1
Date: - [XXXXX]
RFQ No. [XXXXX]
To,
[Address XXXXX]
Dear Sir /Madam
1.0
Renovation & Modernization of [Electrical Balance of Plant] Package for unit [XXXXX] of
2.0
Name of Bidder: []
3.0
RFQ document.
4.0
We confirm that neither we nor any of our associates/ affiliates are liable for
5.0
(i)
Covering Letter
(ii)

(iii)
(iv)
(v)
Document Number
LII-GETS12021-G-00100-011
Rev No.
Description
Page No.
Date of Issue
01
RFQ for Contractor
[9]
25.09.2014

6.0
[LOGO OF
UTILITY]
(vi)
(vii)


(i)
(ii)
Copies of order
(iii)
(iv)
(v)

(vi)
(vii)
(viii)
Any other document.
7.0

8.0

Yours Faithfully,
Signature [XXXXX]
Full Name [XXXXX]
Designation [XXXXX]
Document Number
LII-GETS12021-G-00100-011
Rev No.
Description
Page No.
Date of Issue
01
RFQ for Contractor
[10]
25.09.2014

[LOGO OF
UTILITY]
Annexure-2
Ref.: [XXXXX]
Date : [XXXXX]
To,
Dear Sir/ Madam,
Bidder/Contractor.
Date:
Place:
Yours faithfully,
Holding Company)
Document Number
LII-GETS12021-G-00100-011
Rev No.
Description
Page No.
Date of Issue
01
RFQ for Contractor
[11]
25.09.2014

[LOGO OF
UTILITY]
Data Sheet-1
No. 2.1.1:
To,
Bidderss
Name
and Address:-
[Name of Utility]
[Address]
We are submitting the Prequalification Bid for R&M of [Electrical Balance of Plant]
[.].
[We have designed, engineered, supplied, erected, tested and commissioned at least two
E-BOP (Electrical Balance of Plant) packages of Thermal Power Plants of unit size 200
MW or above comprising 400/220 kV Air Insulated Switchyard, Switchyard Automation
System and Power Transformers, which have completed satisfactory operation for a
period of not less than two (2) years as on the date of opening of Pre-Qualification Bid.
We have experience of manufacturing, supply, erection, testing, commissioning of
Power Transformers for Thermal Power Plants of unit size 200 MW or above which are
in successful operation for at least two years.] The details of the same are given below:
Sl.
Description
Installation
No.1
1.

2.

Fax and Tel. Nos.
3.

organization.
4.
Contact No. & Date
5.
6.
7.
8.
9.

aforesaid Electrical Balance of
Plant.
Installation
No.2
Installation
No.3
of
Document Number
LII-GETS12021-G-00100-011
Rev No.
Description
Page No.
Date of Issue
01
RFQ for Contractor
[12]
25.09.2014

Sl.
Description
Installation
No.1
Installation
No.2
[LOGO OF
UTILITY]
Installation
No.3
- Details
of 400/220 kV Air
Insulated Switchyard executed
- Model
- Make
- Reference Standard
- Voltage
- Switchyard Automation System

- Make
- Model
- Communication
Supported
Protocols
- Protocol
for
Synchronization
Time
- Power Transformer
- Application
- Name of the manufacturer
- Rating (MVA)
arrangement
with
cooling
- Rated no load voltage

HV winding
LV winding
Date
:
(Signature.)
Place :
(Full Name)
(Designation)
(Company Seal)
1.
Document Number
LII-GETS12021-G-00100-011
Rev No.
Description
Page No.
Date of Issue
01
RFQ for Contractor
[13]
25.09.2014
[LOGO OF
UTILITY]

Data Sheet-2
2.1.2 (a):
To,
Bidders Name
[Name of Utility]
[Address]
and Address
[.].
Sl. No.
1
2
3
4
Financial Year
Amt. of Bidders
Currency
Amt. in Rs.
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Financial Years.
We have enclosed
Balance Sheets and
duly certified by
Exchange rate
as on 30 days
prior to the
schedule date
of bid opening
*Yes/*No
Date:
Place:
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-011
Rev No.
Description
Page No.
Date of Issue
01
RFQ for Contractor
[14]
25.09.2014

[LOGO OF
UTILITY]
Data Sheet-3
clause 2.1.2 (b):
To,
Bidders Name
[Name of Utility]
[Address]
and Address:-
[.].
Sl. No.
1
3
Description
year.
Accountant
Date:
Place:

------*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-011
Rev No.
Description
Page No.
Date of Issue
01
RFQ for Contractor
[15]
25.09.2014
[LOGO OF
UTILITY]

Data Sheet-4
does not meet RFQ clause 2.1.2 (a) & 2.1.2 (b) on its own & Holding Company
meetsthe financial QR:
To,
Bidder, Name
and Address:-
[Name of Utility]
[Address]
[.].
Sl. No.
1
2
3
4
Financial Year
Amt. of Bidders
Currency
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Company on last day
year
We have enclosed
Balance Sheets and
of Holding duly
Document Number
LII-GETS12021-G-00100-011
Amt. in Rs.
Exchange rate
as on 30 days
prior to the
schedule date
of bid opening
*Yes/*No
Rev No.
Description
Page No.
Date of Issue
01
RFQ for Contractor
[16]
25.09.2014

Accountant
We are enclosing a
from the Holding
Company, pledging
unconditional and
is enclosed
Date:
Place:
[LOGO OF
UTILITY]
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-011
Rev No.
Description
Page No.
Date of Issue
01
RFQ for Contractor
[17]
25.09.2014

[LOGO OF
UTILITY]
Data Sheet -5
To,
Bidders Name
[Name of Utility]
[Address]
and Address
[.].
opening, is not less than INR [XXXXX] or in equivalent foreign currency. The details are
as under:
Sl. No.
Description

opening


deposits

Date:
Place:
Document Number
LII-GETS12021-G-00100-011
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Rev No.
Description
Page No.
Date of Issue
01
RFQ for Contractor
[18]
25.09.2014

[LOGO OF
UTILITY]
Document Number
LII-GETS12021-G-00100-011
Rev No.
Description
Page No.
Date of Issue
01
RFQ for Contractor
[19]
25.09.2014

OF

FOR
SELECTION OF CONSULTANT
FOR
PREPARED BY

THE CONSULTANT
LII-GETS12021-G-00100-012 R01
September 2014
Request for Qualification for Selection of Consultant for Renovation &

Modernization of Unit No.[..] Capacity [...] of [Name of the Power Plant]
[LOGO OF UTILITY]
TABLE OF CONTENTS
1

1.1
1.2
1.3
1.4
1.5
Introduction .......................................................................................... 1
Invitation .............................................................................................. 1
RFQ Details........................................................................................... 2

2.1.1 Technical Qualification Requirement-1 ................................................... 4
2.1.2 Technical Qualification Requirement-2 ................................................... 4
2.1.4 Other Criteria ..................................................................................... 5
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
Model RFQ for R&M Consultant
[i]
25.09.2014

S.No

Description
1.0
Format for Pre-qualification Application
2.0
Letter Of Consent To Be Furnished By

The Associate
The Consortium Partners
3.0
4.0
5.0
6.0
7.0
Document Number
LII-GETS12021-G-00100-012
[LOGO OF UTILITY]

Annexure-1
Annexure-2
Annexure-3

Clause No. 2.1.1
Data Sheet-1

Clause No. 2.1.2
Data Sheet-2

clause 2.1.3 (a)
Data Sheet-3

clause 2.1.3 (b)
Data Sheet-4
Rev
No.
01
Description
Page No.
Date of Issue
[ii]
25.09.2014

1.1
Introduction
[LOGO OF UTILITY]
{Give brief introduction about the name, location and details of the Power
Plant for which the utility proposes to appoint a consultant for advising about
the Renovation & Modernization and Life extension (R & M and LE) work for
any of the identified units.}
1.2
Invitation
[Name of The Utility], hereinafter referred to as Employer, plans to
undertake Renovation & Modernization of Unit No.[XX] of the [XXX] [Coal /
Lignite] based Power Plant and desires to appoint a Renovation &
Modernization Consultant (R&M Consultant) for a) Carrying out investigation
studies such as Hot and Cold Walk down Studies, Residual Life Assessment /
Condition Assessment (RLA/CA) Studies and Energy Audit (EA) Studies, b)
Preparing Feasibility Report and Detailed Project Report, c) Providing
assistance in obtaining Regulatory approval, d) Preparing Tender Documents
and d) Providing support in Tendering and Bid evaluation process to appoint
R&M Contractor(s). Towards this end, [Name of The Utility] invites sealed
Pre-Qualification Tenders from experienced and interested Consultancy Firms
for providing Consultancy Services for Renovation & Modernization of Unit
No.[XX] of the [XXX] Thermal Power Plant. Consultancy Firms both from
India and abroad are eligible to participate in the Pre-Qualification Process and
subsequent Request for Proposal process, if found eligible during PreQualification process.
Interested Consultancy Firms may collect the RFQ documents in person from
[Name and Contact Details of Designated Official]. The RFQ documents can
[.] to [.]. Alternatively, the RFQ documents can
be downloaded from [Name of the Utility] website [..].
should be submitted to [Name and Contact Details of Designated Official] by
[Date and Time].
1.3
Brief Scope of Work

The Scope of work of the R&M Consultant shall be divided in two Phases.
First Phase shall cover scope up to obtaining regulatory approval for R&M
works and Second Phase shall cover preparation of tender documents and bid
evaluation for the selection of R&M Contractor(s) as described below.
Phase-I
i)
Document Number
LII-GETS12021-G-00100-012
Review and Analysis of Operational Data and Trip Reports provided by

Employer.
Rev
No.
01
Description
Page No.
Date of Issue
[1]
25.09.2014

[LOGO OF UTILITY]
ii) Hot Walk Down Survey

iii) Cold Walk Down Survey
iv) Review of previous RLA/CA and EA Studies, if any.
v) Conducting Residual Life Assessment (RLA) / Condition Assessment
(CA) of the Equipments / Systems of complete Power Plant
vi) Conducting Energy Audit and Performance Testing of major
Equipments/ Systems of the Power Plant
vii) Working out of various R& M Options for improving the Performance
Parameters and extending the life of the Unit.
viii) Finalizing the most cost effective option for R&M and LE of the unit.
ix) Preparation of Feasibility Report (FR).
x) Preparation of Detailed Project Report (DPR).
xi) Providing Assistance to the Employer in obtaining necessary approvals
from statutory / regulatory authorities.
Phase-II
i) Basic Design & Engineering and Preparation of Tender Documents.
ii) Support for bid evaluation for the selection of R&M Contractor(s), up to
the placement of Letter of Award.
Note: Phase-II shall commence only after obtaining necessary approvals
from statutory / regulatory authorities and after obtaining the Notice to
Proceed from the Employer.
1.4
RFQ Details
(a)
Participation Fee
INR [---]
(b)
Publication date of
RFQ
[----------------------------]
(c)
Last date for issue

of RFQ document
[----------------------------]
(d)
Last Date & Time of

Receipt of PreQualification
Applications
[----------------------------]
(e)
Date for
[----------------------------]
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[2]
25.09.2014

[LOGO OF UTILITY]
identification of
Qualified
Consultancy Firms
Issuance of RFP
working day.
1.5

qualified Consultancy Firms for the issuance of RFP Documents for selection
of R&M Consultant for the Renovation & Modernization of Unit no. [XX] of
[XXX] Power Plant. The objective of the pre-qualification is to allow only the
capable and qualified Consultancy Firms having requisite technical expertise,
relevant experience supported by adequate number of competent manpower
and having adequate financial resources to fulfill their obligations.
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[3]
25.09.2014

2.1
[LOGO OF UTILITY]
To be pre-qualified for participation in the RFP process for selection of the

R&M Consultant for Renovation & Modernization of Unit no [.] of
[..........] thermal power plant, the Applicant must meet the two Technical
Qualification Requirements specified at clause 2.1.1 and 2.1.2 below. If an
Applicant meets only one of the two Technical Qualification Requirements
(either Technical Qualification Requirement-1 at 2.1.1 or Technical
Qualification Requirement -2 at clause 2.1.2) and does not meet the other, it
can associate with another engineering consultancy firm that meets the other
Technical Qualification Requirement. The Applicant can also be a Consortium
of 2 (two) engineering consultancy firms who collectively meet the two
Technical Qualification Requirements specified at clause 2.1.1 and 2.1.2
below.
In addition to meeting Technical Qualification Requirement, the Applicant
must meet Financial Qualification Requirement at Clause 2.1.3 below. Further,
the eligibility of the Bidders to participate in the Tendering process is subject
to other criteria specified at clause no. 2.1.4.
2.1.1
Technical Qualification Requirement-1

The Applicant should be an engineering consultancy firm that has successfully
completed at least 2 (two) number of technical consultancy assignments
including DPR, Specifications, Bid Evaluation and Review of Vendor Drawings
for coal/lignite fired thermal power plants of capacity 200 MW or more as on
the date of submission of Pre-Qualification Application.
2.1.2
Technical Qualification Requirement-2

The Applicant during the last [10] years, must have successfully completed at
least (1) one technical consultancy assignment for Renovation and
Modernization of coal/lignite fired thermal power plant of 100 MW capacity or
above comprising, a) Carrying out of investigation studies such as Hot and
Cold Walk down Studies, Residual Life Assessment / Condition Assessment
(RLA/CA) Studies and Energy Audit (EA) Studies, b) Preparation of the
Feasibility Report and the Detailed Project Report, c) Preparation of the Tender
Documents and d) Preparation of Tendering Documents and Bid evaluation to
appoint R&M Contractor(s), as on the date of submission of Pre-Qualification
Application.
Consultancy organizations which do not possess the requisite qualification of
carrying out of investigation studies mentioned at a) above, may associate
with such organizations which meet the required qualification, in the form of a
joint venture or a sub-consultancy agreement.
2.1.3

(a)
The average annual turnover of the Applicant should be at least [Indian

Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[4]
25.09.2014

[LOGO OF UTILITY]

annual turnover.
(b) The Net Worth of the Bidder as on the last date of preceding
Financial Year shall be positive.
2.1.4
Other Criteria
(a)
Any entity that is legally barred from participation in Consultancy

assignments of [name of Utility] on the grounds of previous violations of
rules/regulations on fraud and corruption or any other reason cannot
participate as an applicant or associate or consortium member for this
R&M Consultancy Tender.
(b)
Any firm or its associate company cannot participate as Applicant or

Associate or Consortium Member for more than one RFQ application
under this R&M Consultancy Tender.
2.2
2.2.1

Applicants/Consortium Leaders are required to furnish following documents
for pre-qualification in [five (5)] copies and an application with requisite
participation fee along with their Pre-Qualification Bid.
(i)
List of orders executed by them, their Consortium Partners / Associates
along with copies of orders to prove their qualifications.
(ii)
Past Performance Certificates from the previous employers in respect of
such completed consultancy assignment(s) clearly indicating scope of
and date of completion for each assignment.
(iii) Names of proposed Associates or Consortium member if any, along
with Letters of Consent from each Associate / Consortium Partner.
(iv) Particulars of Key Personnel that must include inter alia their names,
details regarding qualification, areas of expertise, professional
experience and names of relevant projects.
(v)
Documents of company profile incorporating details of technical man
power, financial strength, resources, organization and experience to
undertake such jobs as an evidence of their capacity for the satisfaction
of Employer.
(vi) Firms audited accounts for last three (3) years along with a copy of
latest income tax return filed.
(vii) Consultancy Assignments in hand / pending jobs and their status along
with value.
(viii) Pending legal cases, if any.
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[5]
25.09.2014

[LOGO OF UTILITY]
3.1.
Only Applicants found pre-qualified on the evaluation of qualification

documents submitted in response to the RFQ will be issued RFP documents
for the subject R&M Consultancy work and will be eligible to submit Bid
technical expertise, relevant past experience, competence of key personnel,
project execution capability and financial resources to discharge the scope of
service.
3.2.
certificate(s)/document(s) submitted by the Applicant or Associate or
manipulated, the Applicant or Associate or Consortium leader or Consortium
3.3.
The Scope of work of the R&M Consultant shall be on the basis of single
bidder responsibility. The Consultancy Contract will be entered into only with
the successful Bidder (Sole Bidder or Principal Consultant or Consortium
leader as the case may be). Thus the Bidder / Principal Consultant/
Consortium leader shall be solely responsible and liable for all the technical,
management and all other services required for completing the entire scope of
work.
3.4.
The Bidder, Bidders Associate, Consortium leader and Consortium partner

shall not subcontract the entire scope of work, back to back or otherwise, for
the performance of the subject Consultancy Contract.
3.5.
The Applicant, meeting the Qualifying Requirement on the strength of

Associate (s), should enclose the Letter (s) of Association (as per the
prescribed format) from the Associate (s) signed by the Associate (s)
indicating the scope of work along with the Pre-Qualification Application. For
each such Associate, while submitting the techno-commercial Bid Proposal for
R&M Consultancy work, the Associate and Bidder (Principal Consultant) shall
furnish a joint undertaking towards joint and several liability to the employer
for the successful performance of Associates Scope of Work. The
undertaking shall be furnished as per the format to be specified in the RFP
document.
3.6.

enclose the Letter of Association (as per the prescribed format) from the
consortium Partner along with the Pre-Qualification Application signed by the
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[6]
25.09.2014

[LOGO OF UTILITY]
bidder is found pre-qualified and is issued RFP document, while submitting the
techno-commercial Bid Proposal for R&M Consultancy work, the bidder
(consortium leader) shall furnish a Consortium Agreement with the other
Consortium member. No new consortium partner, (other than those qualified
at Pre-qualification stage) will be permitted at the time of submitting the
Techno commercial Proposal. Further, while submitting the techno-commercial
Bid Proposal for R&M work, the Consortium leader and Consortium members
will furnish a joint undertaking towards diligent performance of their
respective scope of work and towards joint and several liability to the
employer for the successful performance of the Consultancy Contract. The
undertaking shall be furnished as per the format to be specified in the RFP
document.
3.7.

Format to be specified in RFP document, in favour of the Employer within 30
shall be equal to five percent (5%) of the Contract Price and it shall
shall be valid till the scheduled date of completion of R&M Consultants work
plus three (3) months grace period.
If the bidder is a Consortium of Consultancy firms, in addition to the Contract
Performance Guarantee (CPG) of 5% furnished by the Consortium Leader, the
other consortium members shall furnish Additional Contract Performance
Guarantee equal to 2% of Contract Price.
If the Bidder meets Qualification Requirement on the strength of Associate (s),
in addition to the Contract Performance Guarantee (CPG) of 5% furnished by
the Bidder (Principal Consultant), each Associate shall furnish Additional
Contract Performance Guarantee equal to 2% of Contract Price.
3.8.
The Applicant/Consortium Leader shall provide satisfactory evidence that the

applicant and / or, where applicable, the Associate (s)/ consortium partners
have adequate capability and capacity to deliver the consultancy services
properly and expeditiously within the time period specified. The evidence shall
specifically cover, with written details, the expertise, the number of experts
and other supporting consultants, to meet the requirements appropriate to the
works covered in his bid. Pre-Qualification Application submitted without the
proper documentary evidence to substantiate fulfilment of the qualifying
3.9.

to verify independently all statements / information submitted to verify the
Applicants / Consortium leaders, Associates and Consortium Partners
claim on experience and to assess the Applicants / Consortium leaders,
Associates and Consortium Partners capability and capacity to execute the
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[7]
25.09.2014

[LOGO OF UTILITY]
subject R&M Consultancy contract, should the circumstances warrant such an

assessment in the overall interest of the R&M project.
3.10.
[Name of Utility] reserves the right to reject any or all Pre-Qualification

Applications or cancel / withdraw the Request for Qualification without
assigning any reason whatsoever and in such case no Applicant / intending
Applicant shall have any claim arising out of such action.
3.11.

along with the Pre-Qualification Application. Pre-Qualification Application
received without the Participation Fee will be rejected. Participation Fee is
non-refundable.
3.12.
Language of Bid
The Pre-Qualification Application submitted by the Applicant and all
correspondences and documents relating to the Application exchanged by the
Applicant and [Name of Utility] shall be written in English language. Any
printed literature / material furnished by the bidder in any other language shall
be accompanied by an authentic English translation of all the pertinent points.
For purpose of interpretation of the bid, the English translation shall govern.
3.13.

The Pre-Qualification Application must contain the name and place of
business of the Application and each page of the Application must be signed
and sealed by the authorized person(s) of the Applicant / Consortium leader
with his usual signature. The name of all persons signing should be typed or
printed below the signature.
Applicant / Consortium leader shall be furnished with the Application.
The Applicant / Consortium leaders name stated on the Pre-Qualification
Application shall be the exact legal name of the firm.
3.14.

The Pre-Qualification Application shall be submitted in one (1) original and five
(5) identical copies indicating clearly as original and copy along with a soft
Application.
The outside of the covers should indicate clearly the name of the Applicant /
should indicate the "Tender No. and Name of the work for which the PreQualification Application is submitted ". Pre-Qualification Application with no
indication given on the outside of the envelope that it is a Pre-Qualification
Application which therefore gets opened before the due date shall be liable to
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[8]
25.09.2014

[LOGO OF UTILITY]
be disqualified. All the pages of the Pre-Qualification Application shall be

serially numbered.
The Pre-Qualification Application, complete in all respects, must be submitted
to the official and address mentioned below or may be sent by Courier or
Registered Post the address mentioned below.
[XXXXX]
[XXXXX] [XXXXX]
Submission of Pre-Qualification Application through Fax, Telex, E-Mail will not
be accepted.
documents or any letter sent by post or courier either way.
Pre-Qualification Applications must reach the above office on or before
[XXXXX] Hours (IST) on [XXXXX]. Any Pre-Qualification Application
received after the expiry of the time specified is liable for rejection.
3.15.

at [Place XXXXX] on [Date XXXXX] at [Time XXXXX] Hours (IST).
3.16.

The Pre-Qualification Application is to be submitted as per the Format at
Annexure-1.
be submitted with the Pre-Qualification Application. Wherever no sample
format has been specified, Bidder is required to use any appropriate format as
per prevalent practice in conformity with the requirement stipulated in RFQ
document.
S.No
Description
1.0
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Annexure-1
Description
Page No.
Date of Issue
[9]
25.09.2014

2.0
3.0
4.0
5.0
6.0
7.0
Document Number
LII-GETS12021-G-00100-012

The Associate
The Consortium Partners
[LOGO OF UTILITY]
Annexure-2
Annexure-3

Clause No. 2.1.1
Data Sheet-1

Clause No. 2.1.2
Data Sheet-2

clause 2.1.3 (a)
Data Sheet-3

clause 2.1.3 (b)
Data Sheet-4
Rev
No.
01
Description
Page No.
Date of Issue
[10]
25.09.2014
Request for Qualification for R&M Consultancy Services for Unit No. [..] Capacity
[..] of [Name of the Power Plant]
[LOGO OF UTILITY]
Annexure-1
Format for Pre-Qualification Application
Date: - [XXXXX]
RFQ No. [XXXXX]
Name of Package: Renovation & Modernization Consultancy Services for [..]
Package for Unit No. [XXXXX] of [XXXXX] thermal power plant.
[Address XXXXX]
Dear Sir /Madam

1.0
participate in the pre-qualification process for selection of qualified Consultants for
Renovation & Modernization Consultancy work for unit [XXXXX] of [XXXXX] power
plant of [XXXXX]. Towards this end we submit the following details & documents for
prequalification.
2.0
Name of the Applicant/Leader of Consortium with name & designation of person
authorized to submit the pre-qualification Application:
Name of Applicant/ Leader of Consortium: []
3.0
We meet the Qualification Requirement stipulated at clause no.2.1.1, 2.1.2 &
2.1.3 of RFQ document on our own/ in association with our Associate (s) [XXXXX] / in
association with our Consortium Partner(s) [XXXXX].(Applicant to strike off whichever is
not applicable).
(The Applicant is required to give a detailed description indicating the specific part of the
qualification requirement which is met by the Applicant/Associate(s)/ Consortium
Member(s). Applicant is also required to give detailed description of the relationship
between the Applicant & others on whose strength Qualification Requirement is stated
to have met.)
4.0
We confirm that neither we nor any of our Associate (s) / our Consortium
Members are liable for exclusion from participation in Pre-Qualification process under
other criteria stipulated under clause no.2.1.4 of RFQ document.
5.0
(i)
Covering Letter
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[11]
25.09.2014
6.0
[LOGO OF UTILITY]
(ii)
Power of Attorney in favor of persons signing on behalf of Applicant,

Associate (s) and Consortium member (s) as applicable.
(iii)
Data Sheet regarding Technical Qualification Requirement at clause 2.1.1.
(iv)
Data Sheet regarding Technical Qualification Requirement at clause 2.1.2.
(v)
(vi)
(vii)
Letter of Association of Consortium Partner(s) in case of Consortium
(viii)
Letter of Association of Associate(s) if applicable

List of orders executed
(ii)
Copies of orders
(iii)
(iv)
(v)

(vi)
(vii)
List of pending litigations/disputes.
(viii)
Any other document.
7.0
We hereby attach participation fee of [INR-----------] in the form of demand draft

No.dated. in favor of [XXXXX] payable at [XXXXX].
8.0

Yours Faithfully,
Signature [XXXXX]
Full Name [XXXXX]
Designation [XXXXX]
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[12]
25.09.2014
[LOGO OF UTILITY]

Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[13]
25.09.2014
[LOGO OF UTILITY]
Annexure-2
Letter Of Association To Be Furnished By The Associate
[Name and Complete Address of Applicant] is submitting the Prequalification
Application for R&M Consultancy work for Unit No. [..] of
[] Plant of [.].
We hereby declare that the undersigned firm [Name and Complete
address of the Associate] hereby agrees to associate with .. [Name and
Complete address of the applicant] for the successful completion of part scope
of work as enclosed in the attachment (authenticated by the Associate) for
R&M Consultancy services for the Unit no.[XXXXX] of .[XXXXX] plant in the
state of [XXXXX], India. We also hereby undertake to ensure the diligent and
timely completion of Consultancy Work covered in our scope of work adhering
to high professional standard and also to depute our technical experts from
time to time to the place of work / Employers Project site as per requirement.
On award of LOA, we, the Associate, agrees to furnish on demand additional
performance Security bank guarantee for 2 % of Contract Price.
1.
Witness
For Associate
Signature:
Name
Name
Designation:
Designation:
Office Address
Seal of the Company
2.
Witness
For Applicant
Signature:
Name
Name
Designation:
Designation:
Office Address
Seal of the Company
************
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[14]
25.09.2014
[LOGO OF UTILITY]
Annexure-3
Letter Of Association To Be Furnished By The Consortium Partners
(Name and Complete address of the Applicant/Consortium Leader) as
Consortium Partner to form Consortium to Bid for R&M Consultancy Work
under Tender No.[.] and for the successful completion of part scope of
work as enclosed in the attachment (authenticated by the Consortium Partner)
of R&M Consultancy work for the Unit no.[XXXXX] of .[XXXXX] Thermal
Power Plant in the state of [XXXXX] for [XXXXX], India. We also hereby
undertake to ensure the diligent and timely completion of Consultancy Work
covered in our scope of work adhering to high professional standard and also to
depute our technical experts from time to time to the place of work /
Employers Project site as per requirement.
1.
Witness
Signature:
Name
Name
Designation:
Designation:
Office Address
Seal of the Company
2.
Witness
For Applicant
Signature:
Name
Name
Designation:
Designation:
Office Address
Seal of the Company
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[15]
25.09.2014
[LOGO OF UTILITY]
Data Sheet-1
No. 2.1.1:
To,
Applicant/Consortium
Partner/Associates Name
and Address:-
[Name of Utility]
[Address]
*We are submitting the Pre-Qualification Application for R&M Consultancy work for Unit
No. [..] of [] Plant of [.]. / *We
are associated with (Name of Applicant) as Associate for R&M Consultancy work for
Unit No. [..] of [] Plant of [..] / * We are
associated with (Name of Consortium Leader) as Consortium Partner for R&M
Consultancy work for Unit No. [..] of [] Plant of
[..].
We meet the Qualification Requirement stipulated at Clause No. 2.1.1 of RFQ document.
The details of relevant experience are given below:
Sl.
Description
1.

2.

Fax and Tel. Nos.
3.

organization.
4.
Contact No. & Date
5.
Starting Date of the Technical

Consultancy Work
6.
Schedule Date of Completion of

the
Technical
Consultancy
Work
7.
Actual Date of Completion of

the
Technical
Consultancy
Work
8.
Whether
the
Plant
is
coal/Lignite fired thermal power
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Installation
No.1
Installation
No.2
Installation
No.3
Yes*/No*
Yes*/No*
Yes*/No*
Description
Page No.
Date of Issue
[16]
25.09.2014
Sl.
Description
Installation
No.1
[LOGO OF UTILITY]
Installation
No.2
Installation
No.3
station
9.

aforesaid Technical Consultancy
Work
10.
Original order value of the

contract aforesaid Technical
Consultancy Work
11.
Completed order value of the

Consultancy Work
12.

Application at Annexureto
this Data Sheet
Date
:
(Signature.)
Place :
(Full Name)
(Designation)
(Company Seal)
1.
1.

Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[17]
25.09.2014
[LOGO OF UTILITY]
Data Sheet-2
No. 2.1.2:
To,
Applicant/Consortium
Partner/Associates Name
and Address:-
[Name of Utility]
[Address]
No. [..] of [] Plant of [.]. / *We
are associated with (Name of Applicant) as Associate for R&M Consultancy work for
Unit No. [..] of [] Plant of [..] / * We are
associated with (Name of Consortium Leader) as Consortium Partner for R&M
Consultancy work for Unit No. [..] of [] Plant of
[..].
We meet the Qualification Requirement stipulated at Clause No. 2.1.1 of RFQ document.
The details of relevant experience are given below:
Sl.
Description
Installation
No.1
Installation
No.2
Installation
No.3
Yes*/No*
Yes*/No*
Yes*/No*
1. Name of the Thermal Power

2.

Fax and Tel. Nos.
3.

organization.
4.
Contact No. & Date
5.
Starting
Date
of
Consultancy Assignment
6.

the Consultancy Assignment
7.

8.
Whether
the
Plant
is
station
9.
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
the
Description
Page No.
Date of Issue
[18]
25.09.2014
Sl.
Description
aforesaid
the
Assignment.
Installation
No.1
Installation
No.2
Installation
No.3
Consultancy
10.

Consultancy Work
11.

Consultancy Work
12.

this Data Sheet
Date
[LOGO OF UTILITY]
:
(Signature.)
Place :
(Full Name)
(Designation)
(Company Seal)
1.
2.

Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[19]
25.09.2014
[LOGO OF UTILITY]
Data Sheet-3
2.1.3 (a):
To,
Applicants Name
and Address
[Name of Utility]
[Address]
No. [..] of [] Plant of [.] under
Tender No. [..].
Sl. No.
1
2
3
4
Financial Year
Amt. of
Applicants
Currency
Amt. in
Rs.
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Financial Years.
We have enclosed
Balance Sheets and
duly certified by
Date:
Place:
Exchange rate as on
30 days prior to the
schedule date of PreQualification
Application opening
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[20]
25.09.2014
[LOGO OF UTILITY]
Data Sheet-4
clause 2.1.3 (b):
To,
Applicants Name
and Address
[Name of Utility]
[Address]
*We are submitting the Pre-Qualification Application for R&M Consultancy work for
Unit No. [..] of [] Plant of
[.] under Tender No. [..].
Sl. No.
1
3
Description
year.
Accountant
Date:
Place:

------*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-012
Rev
No.
01
Description
Page No.
Date of Issue
[21]
25.09.2014

OF

FOR
SELECTION OF
IMPLEMENTATION SUPPORT CONSULTANT
FOR
RENOVATION & MODERNIZATION
PREPARED BY

THE CONSULTANT
LII-GETS12021-G-00100-013 R01
September 2014
Request for Qualification for Selection of Implementation Support Consultant for

Renovation & Modernization of Unit No. [..] Capacity [...] of [Name of the Power
Plant]
[LOGO OF UTILITY]
TABLE OF CONTENTS
1

1.1
1.2
1.3
1.4
1.5
Introduction .......................................................................................... 1
INVITATION .......................................................................................... 1
RFQ Details........................................................................................... 2

2.1.3 Other Criteria ..................................................................................... 3
2.2.1.
3
DOCUMENTS TO BE SUBMITTED (PRE-QUALIFICATION) ............................ 4
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue
Model RFQ for Implementation

Support Consultant
[i]
25.09 2014

Plant]
S.No

Description
1.0
2.0
3.0
4.0
Document Number
LII-GETS12021-G-00100-013
[LOGO OF UTILITY]

Annexure-1

Clause No. 2.1.1
Data Sheet-1

clause 2.1.2 (a)
Data Sheet-2

clause 2.1.2 (b)
Data Sheet-3
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[ii]
25.09 2014

Plant]
1.1
Introduction
[LOGO OF UTILITY]
{Give brief introduction about the name, location and details of the Power
Plant for which the utility is proposing to appoint an Implementation Support
Consultant for R & M works.}
1.2
INVITATION
[Name of The Utility], hereinafter referred to as Employer, is planning to
undertake Renovation & Modernization of Unit No.[XX] of the [XXX] Power
Plant and desires to appoint a Implementation Support Consultant (IS
Consultant). Towards this end, [Name of the Utility] invites sealed PreQualification Tenders from experienced and interested Consultancy Firms for
Implementation Support Consultancy Services for Renovation & Modernization
of Unit No. [XX] of the [XXX] Power Plant. Consultancy Firms from both India
and abroad are eligible to participate in the Pre-Qualification Process and
subsequent Request for Proposal process if found eligible during preQualification process.
Interested Consultancy Firms may collect the RFQ documents in person from
from [.] to [.]. Alternatively, the RFQ document
1.3
Brief Scope of Work

Scope of work of the Implementation Support Consultant shall include:
Document Number
LII-GETS12021-G-00100-013
To provide support to [Name of the Utility] during detailed engineering,

supply, implementation and commissioning of R&M works.
To review the detailed engineering drawings/design calculations,
schedule planned for execution and commissioning of all the works in
line with the broad parameters of accepted design.
Preparation of work schedules and monitoring the progress of R&M
works through close involvement with the Contractors and other
agencies on behalf of Employer.
Assistance to Employer in decisions making and in taking timely
actions to ensure schedule adherence during the tenure of R&M
project.
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[1]
25.09 2014

Plant]
[LOGO OF UTILITY]
To flag critical problems as and when arises during the tenure of R&M
project to Employer and suggest suitable remedial measures to control
the situation.
To provide assistance to the Employer in addressing any techno
commercial / contractual and regulatory issues as and when these may
arise during the course of the R&M project.
The detailed Scope of Work will be indicated in the Request for Proposal
(RFP) that will be issued to pre-qualified applicants.
1.4
RFQ Details
(a)
Participation Fee
INR [---]/ USD [---]/ EUR [---]
(b)
[----------------------------]
(c)

RFQ document
[----------------------------]
(d)
Last Date & Time of

Receipt of PreQualification
Applications
[----------------------------]
(e)

of Qualified
Consultancy Firms for
Issuance of RFP
[----------------------------]
working day.
1.5

qualified Consultancy Firms for the issuance of RFP Documents for selection
of Implementation Support Consultant for Renovation & Modernization of Unit
no. [XX] of [XXX] Power Plant. The objective of the pre-qualification is to
allow only the capable and qualified Consultancy Firms having requisite
technical expertise, relevant experience, associated with adequate number of
competent personnel and financial resources to participate in the selection
process.
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[2]
25.09 2014

Plant]
2.1
[LOGO OF UTILITY]
To be pre-qualified for participation in the RFP process for selection of the

Implementation Support Consultant for Renovation & Modernization of Unit no
[.] of [..........] power plant, the Applicant must meet the Qualification
Requirements specified at clause 2.1.1 and 2.1.2. Further, the eligibility of the
Bidders to participate in the Tendering process is subject to other criteria
specified at clause no. 2.1.3.
2.1.1

The Applicant should be an engineering consultancy firm that must have
successfully completed during the last [10] years at least 2 (two) number of
engineering consultancy assignments pertaining to coal/lignite fired thermal
power plants of unit size 200 MW or above as on the date of Pre-Qualification
Bid opening. The Consultancy assignments may be for either green field
power projects or Renovation & Modernization Power Project. The scope of
work for each of the two reference consultancy assignments must have
included the following:
1. Review & Approval of Vendor Drawings & Documents
2. Field Services (Assistance in Construction Supervision, Start up,
Commissioning and Testing)
2.1.2
2.1.3

(a)
The average annual turnover of the Applicant should be at least [Indian

annual turnover.
(b)
Other Criteria
(a)
Any Applicant who is legally barred from participation in Consultancy

assignments of [name of Utility] on the grounds of previous violations of
rules/regulations on fraud and corruption or any other reason cannot
participate as an applicant for this Implementation Support Consultancy
Tender.
(b)
Any firm or its associate company cannot participate as Applicant in

more than one Bid under this Implementation Support Consultancy
Tender.
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[3]
25.09 2014

Plant]
2.2
2.2.1.
[LOGO OF UTILITY]

(i)
(ii)
the employer in respect of such completed consultancy assignment(s).
(iii) Particular of Key Personnel that must include inter alia name, details
regarding qualification, area of expertise, professional experience and
name of relevant projects.
Employer.
(v)
Firms audited accounts for last three years along with copy of latest
income tax return filed.
(vi) Consultancy Assignments in hand / pending jobs and their status along
with value.
(vii) Major pending legal cases.
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[4]
25.09 2014

Plant]
[LOGO OF UTILITY]
3.1.
Only Applicants pre-qualified on the evaluation of qualification documents

submitted in response to the RFQ will be issued RFP documents for the
subject Implementation Support Consultancy Services Contract and will be
eligible to submit Bid Proposal. The RFQ Documents specify the qualification
criteria to be met by the prospective bidders to become eligible for
participating in the tendering process. The bidders are required to submit
evidence of their technical expertise, relevant past experience, competence of
key personnel, project execution capability and financial resources to
discharge the scope of service.
3.2.
certificate(s)/document(s) submitted by the Applicant is found to be factually
incorrect or manipulated, the Applicant will be disqualified for the tender and
will be liable to be blacklisted / debarred by the Employer for future tenders.
3.3.
The Scope of work of the Implementation Support Consultant shall be on the

basis of single bidder responsibility. The Consultancy Contract will be entered
into only with the successful Bidder. Thus, the Bidder shall be solely
3.4.
otherwise, for the performance of the subject Consultancy Contract.
3.5.

Format to be specified in RFP document, in favour of the Employer within 30
shall be equal to five percent (5%) of the Contract Price and it shall
shall be valid till the scheduled date of completion of Implementation Support
Consultants work plus three (3) months grace period.
3.6.
The Applicant shall provide satisfactory evidence that he has adequate

capability and capacity to perform the consultancy work properly and
expeditiously within the time period specified. The evidence shall specifically
cover, with written details, the expertise and number of experts and other
support staff, to meet the requirements appropriate to the works covered in
his bid.
Pre-Qualification Application submitted without the proper
documentary evidence to substantiate fulfilment of the qualifying
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[5]
25.09 2014

Plant]
[LOGO OF UTILITY]
3.7.
Notwithstanding anything stated above, [Name of Utility] reserves the right to

verify independently all statements / information submitted to confirm the
Applicants claim on experience and to assess the Applicants capability and
capacity to perform the subject Implementation Support Consultancy
contract, should the circumstances warrant such an assessment in the overall
interest of the R&M project.
3.8.
[Name of Utility] reserves the right to reject any or all Pre-Qualification

Applications or cancel / withdraw the Request for Qualification without
assigning any reason whatsoever and in such case no Applicant / intending
Applicant shall have any claim arising out of such action.
Utility], payable at [XXXXX] is to be submitted along with the PreQualification Application. Pre-Qualification Application received without the
Participation Fee will be rejected. Participation Fee is non-refundable.
3.9.
3.10.
3.11.
Language of Bid
The Pre-Qualification Application submitted by the Applicant and all
correspondences and documents relating to the Application exchanged by the
Applicant and [Name of Utility] shall be written in English language. Any
printed literature / material furnished by the bidder in any other language shall
be accompanied by an authentic English translation of all the pertinent points.
For purpose of interpretation of the bid, the English translation shall govern.
The Pre-Qualification Application must contain the name and place of
business of the Application and each page of the Application must be signed
and sealed by the authorized person(s) of the Applicant with his usual
signature. The name of all persons signing should be typed or printed below
the signature.
Applicant shall be furnished with the Application.
The Applicant name stated on the Pre-Qualification Application shall be the
exact legal name of the firm.
3.12.

The Pre-Qualification Application shall be submitted in one (1) original and five
(5) identical copies indicating clearly as original and copy along with a soft
Application.
The outside of the covers should indicate clearly the name of the Applicant
and his address. In addition, the envelope or container should indicate the
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[6]
25.09 2014

Plant]
[LOGO OF UTILITY]
"Tender No. and Name of the work for which the Pre-Qualification Application
is submitted ". Pre-Qualification Application with no indication given on the
outside of the envelope that it is a Pre-Qualification Application which
the pages of the Pre-Qualification Application shall be serially numbered.
The Pre-Qualification Application, complete in all respects, must be submitted
to the official and address mentioned below or may be sent by Courier or
Registered Post to the address mentioned below.
[XXXXX]
[XXXXX] [XXXXX]
Submission of Pre-Qualification Application through Fax, Telex, E-Mail will not
be accepted.
documents or any letter sent by post or courier either way.
Pre-Qualification Applications must reach the above office on or before
[XXXXX] Hours (IST) on [XXXXX]. Any Pre-Qualification Application
received after the expiry of the time specified is liable for rejection.
3.13.

at [Place XXXXX] on [Date XXXXX] at [Time XXXXX] Hours (IST).
3.14.

The Pre-Qualification Application is to be submitted as per the Format at
Annexure-1.
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[7]
25.09 2014

Plant]
[LOGO OF UTILITY]
be submitted with the Pre-Qualification Application. Wherever no sample
format has been specified, Bidder is required to use any appropriate format as
per prevalent practice in conformity with the requirement stipulated in RFQ
document.
S.No

Description
1.0
2.0
3.0
4.0
Document Number
LII-GETS12021-G-00100-013

Annexure-1

Clause No. 2.1.1
Data Sheet-1

clause 2.1.2 (a)
Data Sheet-2

clause 2.1.2 (b)
Data Sheet-3
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[8]
25.09 2014

Renovation & Modernization of Unit No [..] Capacity [..] of [Name of the Power
Plant]
[LOGO OF UTILITY]
Annexure-1
Format for Pre-Qualification Application
Date: - [XXXXX]
RFQ No. [XXXXX]
Name of Package: Implementation Support Consultancy Services for Renovation &
Modernization of Unit No. [XXXXX] of [XXXXX] Thermal power plant.
To,
[Address XXXXX]
Dear Sir /Madam
1.0
participate in the pre-qualification process for selection of qualified Consultants for
Implementation Support Consultancy services for unit [XXXXX] of [XXXXX] power plant
of [XXXXX]. Towards this end we submit the following details & documents for
prequalification.
2.0
Name of the Applicant with name & designation of person authorized to submit
the pre-qualification Application:
Name of Applicant: []
3.0
We meet the Qualification Requirement stipulated at clause no.2.1.1, 2.1.2 &
2.1.3 of RFQ document.
4.0
We confirm that neither we nor any of our Associate (s)/Affiliate (s) are liable for
exclusion from participation in Pre-Qualification process under other criteria stipulated
under clause no.2.1.4 of RFQ document.
5.0
(i)
Covering Letter
(ii)
Power of Attorney in favor of persons signing on behalf of Applicant,

Associate (s) and Consortium member (s) as applicable.
(iii)
(iv)
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[9]
25.09.2014

Plant]
(v)
6.0
[LOGO OF UTILITY]

(ii)
Copies of order
(iii)
(iv)
(v)

(vi)
(vii)
List of pending litigations/disputes.
(viii)
Any other document.
7.0

8.0

Yours Faithfully,
Signature [XXXXX]
Full Name [XXXXX]
Designation [XXXXX]
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[10]
25.09.2014

Plant]
[LOGO OF UTILITY]
Data Sheet-1
No. 2.1.1:
To,
[Name of Utility]
[Address]
Applicants Name
and Address:-
We are submitting the Pre-Qualification Application for Implementation Support

Consultancy Services Contract for R&M of Unit No. [..] of
[] Plant of [.].
We are an engineering consultancy firm and we have successfully completed at least 2
(two) number of engineering consultancy assignments pertaining to coal/lignite fire
thermal power plants of unit size 200 MW or above during the last 5 (five) years. As
per stipulated requirement at Clause No. 2.1.1 of RFQ document, the scope of work for
each of the three reference consultancy assignments included the following:
1.
Review & Approval of Vendor Drawings & Documents
2.
Field Services (Assistance in Construction Supervision, Start up, Commissioning

and Testing)
The details of the same are given below:

Sl.
Description
1.

2.

Fax and Tel. Nos.
3.

organization.
4.
Contact No. & Date
5.
Starting
Date
of
6.

7.

8.
Whether
Document Number
LII-GETS12021-G-00100-013
the
Plant
Rev
No.
01
Installation
No.1
Installation
No.2
Installation
No.3
Yes*/No*
Yes*/No*
Yes*/No*
the
is
Description
Page No.
Date of Issue

Support Consultant
[11]
25.09.2014

Plant]
Sl.
Description
[LOGO OF UTILITY]
Installation
No.1
Installation
No.2
Installation
No.3

station
9.
The Consultancy Assignment

was for a Green Field Power
Project
Yes*/No*
Yes*/No*
Yes*/No*
10.
The Consultancy Assignment

was for R&M of a Power
Project
Yes*/No*
Yes*/No*
Yes*/No*
11.
The Scope of Work for the

aforesaid
Consultancy
Assignment included:
(a) Review & Approval of
Vendor Drawings & Documents
Yes*/No*
Yes*/No*
Yes*/No*
(b) Field Services (Assistance in

Construction Supervision, Start
up, Commissioning and Testing)
Yes*/No*
Yes*/No*
Yes*/No*
12.

aforesaid
Consultancy
Assignment
13.

contract aforesaid Consultancy
Assignment
14.

contract aforesaid Consultancy
Assignment
15.

this Data Sheet
Date
:
(Signature.)
Place :
(Full Name)
(Designation)
(Company Seal)
1.
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[12]
25.09.2014

Plant]
1.
[LOGO OF UTILITY]
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[13]
25.09.2014

Plant]
[LOGO OF UTILITY]
Data Sheet-3
2.1.2 (a):
To,
Applicants Name
and Address
[Name of Utility]
[Address]

[] Plant of [.].
Sl. No.
1
2
3
4
Financial Year
Amt. of
Applicants
Currency
Amt. in
Rs.
[XXXXX]
[XXXXX]
[XXXXX]
Average Annual
Turnover for the
preceding three (3)
Financial Years.
We have enclosed
Balance Sheets and
duly certified by
Date:
Place:
Exchange rate as on
30 days prior to the
schedule date of PreQualification
Application opening
*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[14]
25.09.2014

Plant]
[LOGO OF UTILITY]
Data Sheet-4
clause 2.1.2 (b):
To,
Applicants Name
and Address
:-
[Name of Utility]
[Address]

[] Plant of [.].
Sl. No.
1
3
Description
year.
Accountant
Date:
Place:

------*Yes/*No
(Signature)..........................................
(Full Name)....................................
(Designation)......................................
(Company seal)...................................
Document Number
LII-GETS12021-G-00100-013
Rev
No.
01
Description
Page No.
Date of Issue

Support Consultant
[15]
25.09.2014

OF
MODEL TENDER DOCUMENT FOR SELECTION OF

R&M CONSULTANT
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-007 R01
September 2014
Tender Document for Selection of R&M Consultant for Unit No. [..]
[Logo of Utility]
INDEX
Section
Description
Section-I
Commercial
Section-II
Terms of Reference
Document Number
LII-GETS12021-G-00129-007
Rev No
01
Description
Tender Document for Selection of R&M
Consultant
Section-I
Page No. Date of Issue

[i]
25.09.2014
[Logo of Utility]
SECTION-I: COMMERCIAL
1.
Invitation For Bid
2.
Instruction to Bidder
3.
4.
General Condition of Contract (GCC)
5.
Special Condition of Contract (SCC)
6.
Forms and Schedules
*****
Document Number
LII-GETS12021-G-00129-007
Rev No
01
Description
Consultant
Section-I

[ii]
25.09.2014
[Logo of Utility]

R&M CONSULTANT

OF
SECTION-I
Document Number
LII-GETS12021-G-00129-007
Rev No
01
Description
Consultant
Section-I

[iii]
25.09.2014
[Logo of Utility]
TABLE OF CONTENTS
1.0 INVITATION FOR BID ................................................................................... 1
1.1
1.2
1.3
1.4
1.5
1.6
2
Introduction .......................................................................................... 1
Invitation .............................................................................................. 1
Tender Details ....................................................................................... 2
Time Schedule ...................................................................................... 2
Bid Submission...................................................................................... 2
INSTRUCTIONS TO BIDDERS......................................................................... 4
2.1 Introduction .......................................................................................... 4
2.2 Address and Contact Details of Employer .................................................. 4
2.3 General Project Information ..................................................................... 4
2.4 Cost of Bidding ..................................................................................... 4
2.5 Non-Transferability of Bid document ......................................................... 4
2.6 Scope of Work & Single Bidder Responsibility ............................................ 4
2.7 Time Schedule ...................................................................................... 4
2.8 Tender Documents ................................................................................ 4
2.9 Preparation of Bids ................................................................................ 5
2.9.1 Language of Bid ............................................................................... 5
2.9.2 Bidding Procedure ............................................................................ 6
2.9.3 Bid Submission ................................................................................ 6
2.9.4 Bid Guarantee .................................................................................. 7
2.9.5 Bid Opening ..................................................................................... 8
2.10 Composition of Techno Commercial Bid (Part-I Bid) ..................................... 8
2.11 Composition of Price Bid (Part-II Bid) ........................................................ 9
2.12 Bid Prices ........................................................................................... 10
2.13 Signature of Bids ................................................................................. 10
2.14 Clarifications/Corrigendum/ Amendment of Tender Specifications ............... 10
2.15 Modification of Bids ............................................................................. 10
2.16 Policy of Bids under Consideration ......................................................... 11
2.17 Validity of Bid ..................................................................................... 11
2.18 Understanding & Clarification on Documents & Specifications .................... 11
2.19 Latest Hour for Receipt of Bids .............................................................. 12
2.20 No Claim for Compensation for Submission of Bid .................................... 12
2.21 Evaluation of Bid ................................................................................. 12
2.21.1 Evaluation of Technical Proposal .................................................... 13
2.21.2 Evaluation of Price Bid .................................................................. 14
2.21.3 Composite Score ......................................................................... 14
2.21.4 Other Evaluation Conditions .......................................................... 14
2.22 Deviations .......................................................................................... 14
2.23 Blacklisting/Debarring ........................................................................... 15
2.24 Award of Contract ............................................................................... 15
2.25 Contract Performance Bank Guarantee (CPBG) ......................................... 16
Document Number
LII-GETS12021-G-00129-007
Rev No
01
Description
Consultant
Section-I

[iv]
25.09.2014
[Logo of Utility]
2.26 Vital Clauses....................................................................................... 17

3
GENERAL PROJECT INFORMATION .............................................................. 18

3.1
Project & Site Information ..................................................................... 18
GENERAL CONDITIONS OF CONTRACT (GCC) ............................................... 19

4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.27
4.28
4.29
4.30
4.31
4.32
4.33
4.34
4.35
4.36
4.37
4.38
Definitions .......................................................................................... 19
Contract Documents ............................................................................ 21
Order of Precedence of Contract Documents ........................................... 22
Interpretation ...................................................................................... 22
Independent Consultant ........................................................................ 22
Joint Venture or Consortium ................................................................. 22
Non-Waiver ........................................................................................ 23
Severability......................................................................................... 23
Origin ................................................................................................ 23
Notices .............................................................................................. 23
Governing Laws .................................................................................. 23
Settlement of Disputes ......................................................................... 23
Scope of Services ............................................................................... 24
Time for Commencement and Completion ............................................... 24
Consultants Responsibilities ................................................................. 25
Owners Responsibilities ....................................................................... 25
Taxes & Duties ................................................................................... 26
Intellectual Property ............................................................................. 26
Confidential Information ....................................................................... 26
Conflict of Interest............................................................................... 27
Representatives ................................................................................... 27
Work Program ..................................................................................... 28
Substitution of Key Personnel ................................................................ 29
Sub-Consultant ................................................................................... 30
Completion Time ................................................................................. 30
Patents Indemnity ................................................................................ 30
Accuracy of Data and Document ........................................................... 30
Liability of R&M Consultant ................................................................... 30
Equipment and Material provided by the Owner ........................................ 31
Loss of or Damage to Property; Accident or Injury; Indemnification ............. 31
Insurance ........................................................................................... 31
Owners Prior Approval ........................................................................ 32
Ownership of Documents Prepared by Consultant (R&M Consultant) ........... 32
Change in Laws & Regulation ................................................................ 33
Force majeure ..................................................................................... 33
Change in the Scope of Services ............................................................ 34
Extension of Time for Completion .......................................................... 34
Termination ........................................................................................ 34
Document Number
LII-GETS12021-G-00129-007
Rev No
01
Description
Consultant
Section-I

[v]
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4.39 Assignment ........................................................................................ 38

5
SPECIAL CONDITIONS OF CONTRACT (SCC) ................................................ 39

5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
Contract Details .................................................................................. 39

Effective Date ..................................................................................... 39
NOT USED ......................................................................................... 41
NOT USED ......................................................................................... 41
Contract Price ..................................................................................... 41
Terms of Payment ............................................................................... 41
Contract Securities .............................................................................. 41
FORMS AND SCHEDULES ........................................................................... 43
Document Number
LII-GETS12021-G-00129-007
Rev No
01
Description
Consultant
Section-I

[vi]
25.09.2014
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1.0
INVITATION FOR BID

Tender No
1.1
[ ---------------------------------------------------------------------------]
Introduction
{Give brief introduction about the name, ownership, business & Power Projects of
the utility inviting bid proposal for R & M Consultancy work}
1.2
Invitation
[Name of The Utility], hereinafter referred to as Employer, is planning to
undertake Renovation & Modernization of Unit No.[XX] of the [XXX] Thermal
Power Plant and desires to appoint a Renovation & Modernization Consultant
(R&M Consultant) to carry out preparatory work for Renovation & Modernization
such as Residual Life Assessment (RLA) Study, Energy Audit (EA), Preparation of
Feasibility Report (FR) and Detailed Project Report (DPR), providing assistance in
obtaining Statutory & Regulatory approvals. [Name of The Utility], hereinafter
referred to as Employer / Owner / Purchaser, invites sealed Bid Proposals in
English language from Prequalified Applicants for the Renovation & Modernization
Consultancy Services for Unit No.[XX] of [XXX] Power Plant as per scope of work
Section-II.
1.3
Brief Scope of Work

The Scope of work of the R&M Consultant shall be divided in two Phases. First
Phase shall cover scope up to obtaining regulatory approval for R&M works and
Second Phase shall cover preparation of tender documents and bid evaluation for
the selection of R&M Contractor(s) as described below.
Phase-I
i)
Review and Analysis of Operational Data and Trip Reports provided by

Employer.
ii) Hot Walk Down Survey

iii) Cold Walk Down Survey
iv) Review of previous RLA/CA and EA Studies, if any.
v) Conducting Residual Life Assessment (RLA) / Condition Assessment (CA)
of the Equipments / Systems of complete Power Plant
vi) Conducting Energy Audit and Performance Testing of major Equipments/
Systems of the Power Plant
vii) Working out of various R& M Options for improving the Performance
Parameters and extending the life of the Unit.
Document Number
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Rev No.
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Description
Consultant
Section-I
Page No.
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viii) Finalizing the most cost effective option for R&M and LE of the unit.
ix) Preparation of Feasibility Report (FR).
x) Preparation of Detailed Project Report (DPR).
xi) Providing Assistance to the Employer in obtaining necessary approvals
from statutory / regulatory authorities.
Phase-II
i) Basic Design & Engineering and Preparation of Tender Documents.
ii) Support for bid evaluation for the selection of R&M Contractor(s), up to
the placement of Letter of Award.
Note: Phase-II shall commence only after obtaining necessary approvals
from statutory / regulatory authorities and after obtaining the Notice to
Proceed from the Employer.
The detailed scope of work is given in Terms of Reference Section-II.
1.4
1.5
Tender Details
(a)
Cost of Tender
Documents
: INR [---]
(b)
Bid Guarantee Amount
: INR [--------]
(c)
Date of issuance of
Tender Document
: [----------------------------]
(d)
Date & Time of pre-Bid

Conference
: [----------------------------]
(e)
Last Date & Time of

Receipt of Bid (Both
Part I & Part II)
: [----------------------------]
(f)
Date & Time of

Opening of Unpriced
Techno-Commercial Bid
(Part-I)
: [----------------------------]
Time Schedule
The time schedule for completion of Consultancy Services shall be as per SCC.
1.6
Bid Submission
(a) The Tender Documents are issued to bidders already qualified in a prequalification process. The Tender documents are not transferable.
Document Number
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Rev No.
01
Description
Consultant
Section-I
Page No.
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(b) The Bid proposals are to be submitted in two parts in separate sealed covers
as follows:
Part I
: Bid Guarantee and Technical & Commercial Proposal without

prices
Part II
: Price Schedule.
(c) All other terms and conditions along with the Terms of Reference, General
Conditions of Contract, Special Conditions of Contract, Time Schedule, Bid
Guarantee details, Validity of Bid and Instructions to Bidders, etc. are
contained in the Tender Documents.
(d) Bidder shall submit the bid on or before the scheduled date and time as
specified. Any offer received after the expiry of the time specified for
receiving the completed bids are liable for rejection. The bid shall be
submitted to:
[Designation, Address and Contact details
------------------------------------------------------------- ]
(e) Issuance of Tender Documents to a Bidder shall not be construed to mean
that such Bidder would be automatically considered.
(f) The Bid Prices must be quoted in Indian Rupees. All payments for the entire
scope will be made in Indian Rupees.
(g) Bids submitted by E-mail, Fax, E-tender etc. will not be accepted.
(h) The Tender Documents are meant for the exclusive purpose of bidding
against the subject Consultancy Services tender and shall not be transferred,
reproduced or otherwise used for purposes other than for which these are
specifically issued.
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-I
Page No.
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[Logo of Utility]
INSTRUCTIONS TO BIDDERS
2.1
Introduction
[Name of Utility], the Employer, intends to carry out the Renovation &
Modernization of [Unit no.-XX --------- of the XXXX Power Plant]. [Name of The
Utility] desires to appoint a Renovation & Modernization Consultant (R&M
Consultant) to carry out preparatory work for Renovation & Modernization.
Under the subject Tender, [name of the Utility] invites bid for Renovation &
Modernization Consultancy Services to be carried out as per the accompanying
Terms of Reference. The Bidder shall submit the offer for complete scope of work
indicated in the Terms of Reference.
2.2
Address and Contact Details of Employer

---------------------------------------------------------------------------------------------------------------------------]
2.3

General information about the plant and R&M project is indicated in section 3.0 on
General Project Information.
2.4
Cost of Bidding
The Bidder shall bear all costs associated with the preparation and submission of
its bid, and the Employer will in no case be responsible or liable for these costs,
regardless of the conduct or outcome of the bidding process.
2.5
Non-Transferability of Bid document

Transfer of Bid documents issued to one intending bidder to another is not
permissible.
2.6
Scope of Work & Single Bidder Responsibility

The scope of the work shall be on the basis of single Bidder responsibility,
covering the complete scope of work specified under these specifications and
documents.
2.7
Time Schedule
The completion Time Schedule for Completion of R&M Consultancy Services shall
be as given in the SCC.
2.8
Tender Documents
The scope of contract, terms of reference, bidding procedures and contract terms
are prescribed in the Tender Documents. The Tender Documents comprise, inter
alia, the following Sections:
Section I
Commercial Conditions
Section I, Chapter-1
Invitation for Bid
Instructions To Bidders
Document Number
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Rev No.
01
Description
Consultant
Section-I
Page No.
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[Logo of Utility]
Forms & Schedules
Section II
Terms of Reference
The Bidder is expected to examine all instructions, forms, terms and specifications
in the Tender Documents including clarifications/corrigendum/amendments for
completeness and obtain clarifications, if any, from the Employer.
Failure to furnish all information required as per the bidding documents or
submission of a bid not substantially responsive to the bidding documents in every
respect will be at the Bidder's risk and may result in rejection of its bid.
A prospective Bidder requiring any clarification to the Tender Documents may
notify the Employer in writing by post or by e-mail followed by postal confirmation
at the Owner's address indicated in ITB. The Employer will respond in writing by
post or by e-mail followed by post confirmation to any request for clarification or
modification of the bidding documents that it receives not later than fifteen (15)
days prior to the deadline for submission of bids prescribed by the Employer.
Employer's response will be sent to all prospective Bidders that have been issued
the Bidding Documents.
The Bidder is advised to visit the plant and obtain on its own responsibility all
information that may be necessary for preparing the bid. The Employer will
facilitate the bidder to collect such information about the plant in the manner that
does not interface with plant operation and does not in any way adversely impact
the interest of the Employer. The costs of visiting the site including engaging any
third party consultant by Bidder, if required as per the assessment of Bidder, shall
be borne by the bidder fully.
The Bidder, its personnel and agents will release and indemnify the Owner and its
personnel and agents from and against all liability during such information
collection and will be responsible for death or personal injury, loss of or damage to
property and any other loss, damage, costs and expenses incurred as a result of
the inspection.
At any time prior to the deadline for submission of bids, the Owner may, for any
reason, whether at its own initiative, or in response to a clarification requested by
a prospective Bidder, amend the Tender Documents.
The amendment will be notified in writing by post or by e-mail followed by post
confirmation to all prospective Bidders that have received the bidding documents
and will be binding on them.
At any time prior to the deadline for submission of bids, the Owner, at its
discretion may extend the deadline for submission of the bids.
2.9
Preparation of Bids
2.9.1
Language of Bid
The bid prepared by the Bidder and all correspondence and documents related to
the bid shall be in English language, provided that any printed literature furnished
by the Bidder may be written in another language, as long as such literature is
Document Number
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Section-I
Page No.
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[Logo of Utility]
accompanied by a translation of its pertinent passages in English language in

which case, for purposes of interpretation of the bid, the translation shall govern.
2.9.2
Bidding Procedure
Single Stage Two Part Bidding Procedure will be followed for this package.
The bidders are required to submit, the bids for the R&M Consultancy Services in
two parts. Both the parts are to be submitted together before the indicated Bid
Details of Key Personnel along with their Curriculum Vitae, Deviations to Terms of
Reference, Deviation to commercial Conditions, Overall Completion Time Period &
Network Schedule, Resource Deployment Schedule, Detail of Sub-Consultants,
Details of the present commitments & details of contracts in hand etc. Part-II Bid
will comprise Quoted Price and Quoted Performance Guarantee Parameters.
Initially, only the Part-I Bid will be opened and Part-II Bid will be kept in safe
custody.
The Part-I Bid will be checked for responsiveness to techno-commercial conditions
and a detailed Technical Evaluation will be carried out to assign a Technical Score
to each Bid. Part-II Bid (Price Bid) of only those Bidders will be opened, whose
Part-I Bid is found to be responsive to Tender Specifications and Conditions and
Technical Score is above a specified level.
2.9.3
Bid Submission
(1). Bid proposals shall be accepted from only those eligible bidders who are
found qualified during the pre-qualification process & are issued Tender
Documents. Unsolicited bids shall not be taken into cognizance.
(2). All Bid proposals shall be prepared and submitted in two parts, part-wise in
separate sealed covers, with all pages serially numbered.
(3). [One original and 3 (three) identical] copies of the original with all enclosures
shall be submitted by each Bidder for Part-I and Part-II, clearly indicating the
original and the number of the copy (i.e., Original, Copy No. 1, Copy
No. 2 and Copy No. 3).
(4). In the event of discrepancy between Original and any copy of the bids, the
hard copy of Original shall prevail.
(5). All these covers shall be individually sealed and put in an outer cover which
also shall be sealed and super scribed as in other covers.
(6). The covers should be pasted properly before applying the wax seal. Failure to
do so may result in rejection of such bids.
(7). The Bidders Bid and the documents attached thereto shall be considered as
forming part of the Contract documents.
(8). The Bid shall be submitted to [---------------------------]. Bid submitted to any
other office of Owner is liable for rejection. Bids submitted by Telefax or email will be rejected
Document Number
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Rev No.
01
Description
Consultant
Section-I
Page No.
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(9). Owner will receive Bids in respect of entire scope of work as set forth in the
accompanying Terms of Reference. All bids shall be prepared and submitted
in accordance with the Tender Documents.
(10). Failure to furnish all information required in the Tender Documents or
submission of a Bid not substantially responsive to the Tender Conditions and
Terms of Reference in every respect or bids received in incomplete shape
shall be liable for rejection. A bid shall be determined as substantially
responsive in every respect, if it conforms to all the terms, conditions and
specifications specified in Tender Documents without material deviations,
objections, conditionality or reservations.
(11). A material deviation, objection, conditionality or reservation is one:
(i). That affects in any substantial way the scope, quality or performance of
the contract;
(ii). That limits in any substantial way, inconsistent with the Tender
Documents, the Owners rights or the successful Bidders obligations
under the contract.
(12). Deviation(s) to vital clauses listed under the Tender Documents shall be
considered to be material deviation(s).
(13). Notwithstanding any information and data, which may be contained in these
Tender Documents, the Bidder has to make independent inquiries and
generally obtain his own information on all matters that may in any way
affect prices, risks and obligations of the Consultant under the Contract.
2.9.4
Bid Guarantee
(1). The Bid shall be accompanied by Bid Guarantee either in the form of Bank
Guarantee valid for [----] days from the scheduled date of opening of the Bids
(Part-I) or Demand Draft of equivalent amount drawn in favour of [-------------] payable at [--------].
(2). The Bank Guarantee shall be from any scheduled commercial Bank in India
authorized by Reserve Bank of India,, to issue such Bank Guarantee on a
non-judicial stamp paper of value not less than Rs. [---]/-.The stamp paper
shall be purchased in the name of the Bank. Foreign Bidders may submit the
Bank Guarantee from any bank in India as above or from any foreign bank
which is in the approved list of RBI.
(3). Unless otherwise expressly stated,
a) The Bid Guarantee shall be executed only on behalf of the Bidder in
whose name the Tender Documents have been issued.
b) The Bid and other documents shall be submitted only by the Bidder in
c) The Bid Guarantee shall be executed only as per the format prescribed by
Owner at ([--------------]). In the event of any deviation in this regard, the
decision of Owner as to whether the same could be accepted or not, will
be final and binding on the Bidder.
d) In case of foreign Bidder, the Bid Guarantee amount shall be in US Dollar /
Euro/ Indian Rupee.
Document Number
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Rev No.
01
Description
Consultant
Section-I
Page No.
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(4). The Bidder shall arrange for extension of validity of Bid and that of the Bid
Guarantee upon request from the Owner.
(5). No interest shall be paid on Bid Guarantee amount. The offer without Bid
Guarantee or with short Bid Guarantee or Bid Guarantee in the form other
than that specified herein above or from banks not specified hereinabove will
be liable for rejection.
(6). Any Bid not accompanied by the Bid Guarantee shall be rejected and the
Bidder shall not be permitted to participate in the tender.
(7). The Bid Guarantee shall be forfeited if the Bidder withdraws / modifies /
changes / impairs / derogates the bid proposal on its own after the Bids are
opened or submits forged/bogus certificates or fails to accept the Letter of
Award issued by Owner or fails to submit Contract Performance Security
(Bank Guarantee).
(8). The Bid Guarantee of all unsuccessful Bidders shall be returned after
selection of the successful Bidder. The Bid Guarantee of the successful
Bidder shall be returned after furnishing of the Contract Performance Bank
Guarantee to the Owner and acceptance thereof.
2.9.5
Bid Opening
1.
2.
3.
2.10
This is a single stage two part tender. On the specified date and time of
opening, Part I Bid containing Bid Guarantee and Technical and Commercial
Proposal without Prices will be opened. At the time of opening of PartI of
the bids, the names of the bidders who submitted their bids shall be read out
and other such details as Owner, at its discretion, may consider appropriate,
shall be read out.
If the Bidder desires to be present at the time of opening of Part-I of bids, it
shall depute its representatives (not more than two persons) in time with due
authorization for participating in the Bid opening.
Owner takes no responsibility for delays, loss or non-receipt of Bid documents
or any letters sent by post/courier either way and also reserve the right to
reject any Bid in part or full without assigning any reasons thereof.
Composition of Techno Commercial Bid (Part-I Bid)
This part shall, inter alia, include the following in the same order as listed
below. One original and 3 (three) identical copies shall be submitted.
(i).
Duly filled in "Form of Bid" (As per Annexure-B of this Section).
(ii).
Bid Guarantee- as per Annexure A.
(iii).
Power of Attorney/Authorization with the seal of the company in favour
of the person signing the Bid.
(iv). Letter of Undertaking as per Annexure-D to be furnished by the Bidder
and Associate (s) regarding joint and several liability for Associates scope
of work if the Bidder has met Qualification Requirement with the help of
Associate (s)
(v).
Consortium Agreement if the Bidder is a Consortium of Consultancy
Firms. The Consortium Agreement must include but not limited to (1)
Scope of Service of each Consortium Member, (2) Authorization in favour
Document Number
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Rev No.
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Description
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Section-I
Page No.
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of Consortium Leader to Bid and act on behalf of the Consortium

Members during tendering and execution stage, (3) Joint and several
liability of all consortium members for the entire scope of service, (4)
Undertaking that any dispute among Consortium Members will not relieve
any Member from its obligations towards the Owner under this Contract,
(5) Undertaking by each member for providing expertise, man power and
other technical support for successful completion of the respective Scope
of Service and (6) Undertaking that each other Consortium Member will
provide Additional Contract Performance Bank Guarantee equivalent to
2% of Contract Price in addition to the Contract Performance Bank
Guarantee equal to 5% of Total Contract Price to be furnished by
Consortium Leader.
(vi). Signed copy of all the corrigendums/amendments/clarifications, if any
issued for the tender
(vii). Overall Time Schedule as per Schedule F2 and Bar chart/PERT Network
schedule to achieve the time schedule
(viii). Deviations to the Commercial Conditions, if any, as per Schedule F3.
(ix). Deviations to Terms of Reference, if any, as per Schedule F4.
(x).
Methodology and Work Plan for completing different tasks under the
Consultancy Assignment. Bidder to indicate the scope of work to be
covered with sufficient details regarding the tasks and subtasks to be
covered.
(xi). Details of Equipment and Instruments to be deployed for RLA
Study/Condition Assessment and Energy Audit
(xii). Details of Key Personnel as per Schedule F5. Bidder to indicate the
minimum number of hours each identified key person will spend on the
(xiii). Curriculum Vitae of each key person as per Schedule-F6
(xiv). Organization Structure and Team Composition (Both Professional Staff
and Support Staff)
(xv). Staffing Schedule describing month-wise deployment of personnel
(xvi). Details of the present commitments of the Bidder, details of contracts in
hand
(xvii). Details of Sub-Consultants, if any
The Part-I Bid shall not contain any Price data.
In addition to the hard copy of Part-I Bid, the Bidder shall submit soft copy the Bid
in a compact disk (CD). However, hard copy alone will be considered as authentic
for evaluation.
2.11
Composition of Price Bid (Part-II Bid)

The Bidders are requested to quote the Prices with break up as per Schedule-F1.
Price given in Part-II Bid should cover the entire scope of work as given in Part-I of
the offer. [One original and 3 (three) identical] copies shall be submitted.
1. The Price Bid shall contain the following :
(i). Duly filled in Form of bid as per Annexure-C
Document Number
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Rev No.
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Description
Consultant
Section-I
Page No.
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[Logo of Utility]
2.
3.
4.
2.12
(ii). Completely filled in Schedule of Prices Schedule F1

The Bidder shall quote his price against each item of the schedules as
indicated in the enclosed format (Price Schedule). The Bidder shall quote the
prices only once after considering all the pros and cons, risks and
contingencies. Rebate percentage etc., if any, should be spelt out by the
Bidder in the first Bid itself.
The amount shall be quoted both in figures and words clearly and legibly. No
overwriting is allowed. All scoring and cancellations should be countersigned
by the Bidder. In case of illegibility, the interpretation of the Owner shall be
final. All entries shall be in English language only.
The Price shall be quoted in Indian Rupees only.
Bid Prices
Bidders shall quote for the entire scope of work on single responsibility basis & the
total bid price covers all the obligations of the Consultant mentioned in Tender
Documents/Terms of Reference or to be reasonably inferred from the Tender
Documents/Terms of Reference.
Bidders are required to quote the price for the entire commercial, contractual and
technical obligations outlined in the tender documents.
Prices quoted by the Bidder shall remain firm for the term of the contract .
2.13
Signature of Bids
Each page of the Bid must be signed and stamped by the Bidder with his usual
signature. The names of all persons signing should also be typed or printed below
the signature. Satisfactory evidences of authority of a person signing on behalf of
the Bidder shall be furnished with the Bid. Erasures or corrections in the Bid
documents if any shall be signed by the person signing the Bid. Printed literature,
it enclosed need not be signed. Bids not conforming to the above requirements are
liable to be treated as non-responsive.
2.14
Clarifications/Corrigendum/ Amendment of Tender Specifications

1. At any time prior to the deadline for submission of Bids, the Owner may, for
any reason, whether at his own initiative or in response to clarification(s)
requested by a prospective Bidder, modify the Tender Documents including
the Terms of Reference by amendment.
2. Clarifications/Corrigendum/Amendment shall be construed to be an integral
part of the Tender Documents. Amendments will be hosted in Owners
website. Bidders are requested to visit Owners website and note
amendments, if any, before submission of bid. Owner shall not be responsible
if any bidder fails to notice any amendment.
3. Amendment shall be numbered serially. Signed copies of amendments &
clarifications shall be enclosed in Part-I of bid by bidder.
2.15
Modification of Bids
The Bidder is not permitted to modify his Bid suo-moto after the Bid
submission.
Document Number
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Rev No.
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Description
Consultant
Section-I
Page No.
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2.16
Policy of Bids under Consideration

Bids shall be deemed to be under consideration immediately after they are
opened. While the Bids are under consideration, Bidders and/or their
representatives or other interested parties are advised to refrain from contacting
by any means, the Owner and/or his employees/ representatives on matters
related to the Bids under consideration. The Owner, if necessary will obtain
clarifications on the Bids by requesting for such information from any or all the
Bidders, in writing as may be necessary.
2.17
Validity of Bid
1.
2.
3.
2.18
The Bid shall be kept valid for acceptance for [120 days] from the schedule
date of opening of the Part-I Bid.
The Bidder will not be permitted to change the substance of the Bid suomoto, after Bid has been opened.
Unilateral revision or withdrawal of offer by the Bidder within the subsistence
of the validity period of offer shall not be permitted. Violation of this
condition shall result in rejection of the Bid without notice, besides forfeiture
of Bid Guarantee. The Bidder shall also be debarred either permanently or for
a fixed period, at the discretion of Owner from participating in any of the
Owners tenders.
Understanding & Clarification on Documents & Specifications

1.
2.
3.
4.
The Bidder is required to carefully examine the specifications and documents

and fully informs himself as to all the conditions and matters which may in
any way affect the Renovation and Modernization Consultancy Services to
be rendered or the cost thereof. Bidders are free to visit the plant. However,
the Bidders visit to site shall be at their cost and risk, without any liability on
part of the Owner.
Bidders may seek clarifications to the prescribed clauses and / or different
part of the Tender Specifications. Such a request for clarifications, if any,
should reach the Owner at least [7 (seven) days] before the date stipulated
for pre-bid meeting. The Owner then will issue interpretations and
clarifications as it may think fit in during the pre-bid meeting. After pre-Bid
meeting, Bidder may seek further clarification till [14 days] prior to schedule
opening date of Part-I Bid. After receipt of such clarifications, the Bidder may
submit its Bid but within the time and date as specified in the Invitation for
Bid or as amended by the Owner. All such clarifications and the relevant
exchange of correspondence between the parties shall be construed to form
part of the tender specifications.
Pre-Bid Conference will be organized and outcome of the pre-bid conference
is binding on all the Bidders. Outcome of the Pre-Bid Conference will be
intimated by the Owner to all the Bidders.
A copy of such clarifications duly signed and stamped shall be enclosed with
the Bid (Part-I). In case any queries remain un-replied, it shall be construed
that in respect of those queries, the respective stipulations of the Tender
Specifications/Conditions shall continue to apply and/or no new stipulations
are made with respect to those queries.
Document Number
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Rev No.
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5.
2.19
No extension of time for submission of Bid will be granted on account of

Bidders request for interpretation/clarifications.
Latest Hour for Receipt of Bids

Bids must reach the designated Office of Owner not later than [------] Hrs, Indian
Standard Time (IST) on the date fixed for receipt of the Bid as indicated in the
Invitation for Bid. Bids delivered / received after the time and date fixed for the
receipt of the bids shall be liable for rejection.
2.20
No Claim for Compensation for Submission of Bid

1.
2.
2.21
The submission of any Bid connected with these documents and

specifications shall constitute an agreement that the Bidder shall have no
cause of action or claim against the Owner for rejection of his Bid.
Regardless of the conduct or outcome of the bidding process, Bidder shall
not be entitled to claim any costs, charges and expenses incidental to or
incurred by him through or in connection with his submission of Bid or its
consideration by the Owner, even though the Owner may elect to
modify/withdraw the Invitation for Bid or does not accept the Bid(s).
Evaluation of Bid
The selection of the successful Bidder for award of the R&M Consultancy Services
Contract will be based on both Quality of the Technical Proposal and Price quoted
by the Bidder for the entire scope of work. The selection process will comprise the
following steps:
1. First, Techno-Commercial offer will be assessed for completeness
and responsiveness to commercial/contractual conditions. Only the
Bids that are determined to be complete in all respects and
responsive to commercial/contractual conditions will be taken up
for further evaluation on the basis of Quality and Price.
2. Technical Proposal of Bidders, whose Bid is determined to be
complete and responsive to commercial/contractual conditions, will
be evaluated on the basis of Bidders proposed methodology and Work
Plan for discharging the Consultancy Assignment, experience of the Bidder
and the experience & expertise of Key Personnel and will be assigned a
Technical Score St. Only those Bidders whose Technical Proposals get a
Technical Score of 70 marks or more out of 100 shall qualify for further
consideration. All the Bidders with Technical Score of 70 or more will be
considered for next stage of evaluation. It is not intended to short list a predetermined number of Bidders on the basis of evaluation of Technical
Proposal.
3. The Price Proposal of each Bidder with Technical Score of 70 or more will
be assigned a Financial Score (Sf) on the basis of its cost competitiveness.
highest Composite Score will be selected as R&M Consultant for the
subject R&M Consultancy Services Contract.
Document Number
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Rev No.
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2.21.1
Evaluation of Technical Proposal

The evaluation of Technical Proposal will have three elements as depicted in Table
below:
Sl
No
Parameter
Weightage
Basis of Evaluation
Methodology and Work

Plan (St-1)
20%
Bidders
understanding
of
Terms
of
Reference and clarity, completeness and
soundness of methodology and work plan to
achieve successful completion of the
objectives of the R&M Consultancy work.
The Bidder with the best submission will be
assigned a score of 100 (St-1 = 100). Other
Bidders will be assigned scores below 100
considering the relative quality of the
submission with respect to the best
submission.
Bidders Experience (St)
40%
Each Bidder has to list up to 5 technical

consultancy projects, pertaining to thermal
power plants of unit size 200 MW or above,
successfully executed by it during the last 10
years. Bidder has to furnish detailed scope of
work executed by it for each listed
consultancy project. Each such Project will
be assigned a score out of 20 on the basis of
size, nature & complexity of scope and
similarity with the subject R&M Consultancy
Service. If any Bidder lists less than 5
projects, a score of zero will be assigned for
the shortfall number of project(s). For each
Bidder, the sum of scores for the five
projects will be the score (St-2) out of 100.
Experience
Expertise
Personnel (St-3)
40%
The Bidder has to list name and other details

of 10 key personnel of specified area of
expertise in Schedule-F5 who are likely to be
substantially associated with this R&M
Consultancy assignment if the Bidder
emerges as successful Bidder for award of
the R&M Consultancy Services Contract. The
Bidder is required to submit detailed
Curriculum Vitae of these key personnel as
per the format at Schedule-F6. Each
identified Key Person will be assigned a score
out of 10 based on their qualification and
nature & quantum of experience in the
specified area of expertise. For each Bidder,
the sum of scores of these 10 key personnel
will be the score (St-3) out of 100.
and
Key
The Technical score of each Bidder will be equal to the weighted sum scores on
three elements with indicated weights.
Document Number
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Rev No.
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St = 0.2 x St-1 + 0.4 x St-2 + 0.4 x St-3

2.21.2 Evaluation of Price Bid
The Price Bid should be complete, unconditional and unqualified. For financial
evaluation, the total Price indicated in the Price Schedule . excluding Service Tax
and associated surcharge & cess will be considered. The price indicated in the
Price Bid shall be deemed as final and reflecting the total Price of the entire scope
of services as per Terms of Reference. Failure by Bidder to include the price of any
item shall not entitle the firm to be compensated and the Consultant shall be liable
to fulfill its obligations as per the TOR. The Bidder with lowest quoted total price
will be assigned a Financial Score (Sf) of 100. The financial score of other Bidders
will computed as follows:
2.21.3 Composite Score
For selection of successful Bidder, the Technical Score will be a weight of 70%
and Financial Score will be given a weight of 30%. For each Bidder, the
Sc = 0.7 x St+ 0.3 x Sf
The Bidder who is determined to secure the highest Composite Score will be
selected for award of the R&M Consultancy Contract.
2.21.4 Other Evaluation Conditions
(1) Arithmetical errors will be rectified on the following basis:
If there is any discrepancy between the unit price and the total price
that is obtained by multiplying the unit price and the quantity, the unit
price shall prevail and the total price will be corrected.
If there is a discrepancy between the total Bid Price and the sum of
total prices, the sum of the total prices shall prevail and the total Bid
Price will be corrected.
If there is discrepancy between the rates in figures and in words, the

rates expressed in words shall only prevail and shall be adopted.
(2). Comparison of Bids will be between main Bids only. Alternative Bids will not
be accepted and evaluated.
(3). All the Sl. Nos. and columns in the Schedules of Prices shall be quoted. If
no prices are envisaged for any of the entries, Nil shall be mentioned. In this
context Nil mentioned against any item shall construe that the Bidder shall
not charge any amount separately for that item from the Owner. If the terms,
such as not applicable ----- or blank are mentioned against any Sl.
Nos./columns, the highest amount quoted for the concerned entry among all
Bidders will be loaded for purposes of evaluating the Price Bids.
2.22
Deviations
1.
Normally, deviations are not permitted in commercial terms & conditions and
Terms of Reference. Nevertheless, if the Bidder takes any deviation, it shall be
clearly indicated in the deviation schedule (Schedule [------] and Schedule- [-----] with a soft copy in MS-Word format in compact disc, with Original of
Part-I of the Bid). Deviation listed elsewhere in the Bid shall be summarily
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2.
3.
2.23
rejected and ignored. Separate printed standard terms and conditions of the
Bidder shall not be taken into cognizance and shall be totally rejected.
No alterations or disfigurement, other than filling in particulars wherever
called for in the formats of the Tender Specifications shall be made in the Bid.
Any changes/modifications made by the Bidder in Bid documents itself shall
not be taken into consideration.
If at any later date, it is found that documents, information, averments and
data submitted by the bidder in the Bid, based on which the Bidder has been
considered eligible or successful or has been awarded the Contract is
incorrect or false to the extent that had the correct or true information been
made available to the Owner at time of tender evaluation, the Bid would have
been declared ineligible or unsuccessful, the Bidder shall be forthwith
disqualified or, as the case may be, the Contract awarded based on such
incorrect or false information shall be cancelled and the Bid Guarantee /
contract performance Guarantees deposited shall be appropriated by the
Owner towards Owners cost, loss and damage to Owner.
Blacklisting/Debarring
In case, certificates submitted by the Bidders are found to be a forged/untrue, the
Bidder will not only be disqualified for this tender but also would be black listed/
debarred by the Owner.
2.24
Award of Contract
1.
2.
3.
4.
Award Criteria
The R&M Consultancy Service Contract will be awarded to the Bidder with
the highest Composite Score as described in clause 2.21.
Owner's Right to Accept Any Bid and to Reject Any or All Bids
The Owner reserves the right to accept or reject any bid, for any reasons
including National defense and security consideration and to annul the bidding
process and to reject all bids at any time prior to award of contract, without
thereby incurring any liability to the affected Bidder or bidders or any
obligation to inform the affected Bidder or bidders of the grounds for the
Owner's action.
Notification of Award
Prior to the expiration of the period of bid validity, the Owner will notify the
successful Bidder in writing by registered letter or by email to be confirmed in
writing by registered letter, that its bid has been accepted. The notification of
award will constitute the formation of the contract.
Upon the successful Bidder's furnishing of the performance securities the
Owner will promptly notify each unsuccessful Bidder and will discharge its bid
security.
Signing the Contract Agreement
At the same time as the Owner notifies the successful Bidder that its bid has
been accepted, the Owner will send to the Bidder the Contract Agreement
provided in the bidding documents, incorporating all agreements between the
parties.
Document Number
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Rev No.
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5.
6.
2.25
Within [twenty-eight (28)] days of receipt of the Contract Agreement, the

successful Bidder shall sign and date the Contract Agreement and return it to
the Owner.
Cost of preparing Contract Agreement shall be borne by the bidder.
Performance Security
Within [thirty (30) days] after receipt of the Notification of Award, the
successful Bidder shall furnish Contract Performance securities as per clause
no 2.25. These Bank Guarantees shall be furnished in the form provided in
the section "Forms and Procedures" of the bidding documents and shall be
initially valid upto [ninety (90)] days after the scheduled date of completion of
R&M Consultancy Service.
Failure of the successful Bidder to submit Contract Performance Security
within stipulated time shall constitute sufficient grounds for the annulment of
the award and forfeiture of his bid security, in which event the Owner may
make the award to the next lowest evaluated Bidder or call for new bids.
Corrupt or Fraudulent Practices
The Owner requires that Bidders, Contractors and Consultants to observe the
highest standard of ethics during the Pre-Qualification, Tendering (Request for
Proposal) process and during the execution of the contracts. The Employer
may reject a Bid Proposal of a successful Bidder if it emerges that the Bidder
recommended for award has engaged in Corrupt or Fraudulent practices in
competing for the subject contract. The Employer may declare a Bidding firm
ineligible for participation in future tenders of the Employer, either indefinitely
or for a stated period of time, if it at any time it emerges that the firm has
engaged in Corrupt or Fraudulent practices in competing for or in executing a
contract of the Owner. Corrupt Practice means the offering, giving, receiving
or soliciting of anything of value to influence the tendering process or contract
execution. Fraudulent practice means a misrepresentation of facts in order to
influence a procurement process or the execution of a contract to the
detriment of the Employer and includes collusive practice among Bidders
designed to establish bid prices at artificial non-competitive levels and to
deprive the Employer of the benefits of free and open competition.
Contract Performance Bank Guarantee (CPBG)

As a Contract security, the successful Bidder, to whom the work is awarded, shall
be required to furnish a Contract Performance Bank Guarantee (CPBG) in the
Format attached as Annexure- G, in favour of the Owner within 30 days from the
date of issue of Letter of Award (LOA). The guarantee amount shall be equal to
five percent (5%) of the Contract Price and it shall guarantee the faithful
performance of the Contract in accordance with the terms and conditions
specified in these documents and specifications. The CPG shall be valid till the
Schedule Completion Time Period for Consultancy Services plus ninety (90) days
grace period.
If the bidder is a Consortium Consultancy firms, in addition to the Contract
Performance Guarantee (CPG) of 5% furnished by the Consortium Leader, each of
the other consortium member shall furnish Additional Contract Performance
Guarantee equal to 2% of Contract Price.
Document Number
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Rev No.
01
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If the Bidder meets Qualification Requirement on the strength of Associate (s), in

addition to the Contract Performance Guarantee (CPG) of 5% furnished by the
Bidder (Principal Consultant), each Associate shall furnish Additional Contract
Performance Guarantee equal to 2% of Contract Price.
2.26
Vital Clauses
The following clauses in the Tender Specification & Form of Contract are
vital. Bidder is advised not to take deviations to these clauses. If deviations
are taken from the stipulations of these clauses, such Bids would be liable for
rejection:
Scope of Work
Time Schedule
Price Basis
Contract Performance Guarantee
Force Majeure
Arbitration
Taxes & Duties
Bid Guarantee
Patents, Indemnity
Validity of Bids
Document Number
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Rev No.
01
Description
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Section-I
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GENERAL PROJECT INFORMATION
3.1
Project & Site Information
Owner / Purchaser
[-------------------------------------------------]
Consultant
[-------------------------------------------------]
Project Title
[-------------------------------------------------]
Location
[-------------------------------------------------]
Latitude
[-------------------------------------------------]
Longitude
[-------------------------------------------------]
Elevation above MSL
[-------------------------------------------------]
Nearest Railway Station
[-------------------------------------------------]
Nearest Sea Port
[-------------------------------------------------]
Nearest Airport
[-------------------------------------------------]
Road Access/Approach to :
Site
[-------------------------------------------------]
For Project & Site related detailed information, refer Terms of Reference Section-II.
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Rev No.
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Section-I
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GENERAL CONDITIONS OF CONTRACT (GCC)
4.1
Definitions
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
"Applicable Laws" means the laws of any national, state, local or

municipal legislature in India, or of any other Competent Authority,
including all laws, acts, judgments, statutes, rules, regulations,
ordinances, orders, decrees, injunctions, governmental authorizations,
requirements of Applicable Permits and any agreements, decisions, acts,
instructions, requirements, directions and notifications of any competent
or other Competent Authority or court or tribunal or arbitrator having
jurisdiction over the matter in question, including those related to taxes,
assessments, expropriation and duties, or authoritative interpretation, as
amended, modified, enacted, reinterpreted or revised from time to time
hereafter.
Applicable Permits" means all permits, licenses, authorizations,
consents, decrees, waivers, privileges, acknowledgements, concessions,
approvals, rulings, decisions and visas from, filings with or applications
submitted to, any Competent Authority or court or tribunal of competent
jurisdiction necessary from time to time for or in relation to the
performance of the Services, including as detailed in this GCC.
"Agreement" means the Contract Agreement (entitled "Contract
Agreement") executed by the parties to which these Conditions are
annexed and also includes supplements & amendments to the Contract.
"Contract" means the Agreement entered into between Owner and
Consultant as per the 'Contract Agreement' signed by the parties,
including contract documents, all attachments and appendices thereto
and all documents incorporated by reference therein.
Contract Documents means the complete documents, which are the
basis of finalization of the contract, including correspondence exchanged
from issue of tender till date of signing the contract. All such documents
shall be listed in the Contract Agreement.
Consultants Equipment means all equipment, machinery, tools,
apparatus, appliances or things of every kind required in or for
discharging the R&M Consultancy Services to be brought to the site by
the Consultant.
Consultant means the person(s), Firm or a Company or Consortium of
Firms whose bid to perform the R&M Consultancy Services Contract has
been accepted by the Owner and shall be named as such in the Contract
Agreement, and includes the legal successors or permitted assigns of the
Consultant.
Contract Price means any sum or sums finally accepted by the Owner
for the execution of this contract, subject to such additions and
adjustments thereto or deductions there from, as may be made pursuant
to the Contract.
Document Number
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Rev No.
01
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ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
xvii.
xviii.
xix.
xx.
xxi.
xxii.
xxiii.
Consultants Representative means any person nominated by the

Consultant & approved by the Owner hereof to perform the duties
delegated by the Consultant.
Completion means the completion of R&M Consultancy Services by
the Consultant (R&M Consultant) covering the entire Scope of Work as
per the Terms of Reference and submission of all the reports and other
deliverables incorporating Owners observation on the draft reports to the
satisfaction of the owner .
Consultancy Services or R&M Consultancy Service or Renovation &
Modernization Consultancy Services means the entire services ancillary
to the completion of entire scope of work as per the Terms of Reference.
Day means calendar day of the Gregorian calendar.
Effective Date means the date from which the Time for Completion of
R&M Consultancy Services and other milestones for execution of the
Renovation & Modernization Consultancy Services as per the scope of
work under this tender by the Consultant shall be determined.
GCC means the General Conditions of Contract hereof.
"Good Industry Practice means the exercise of that degree of skill,
diligence and prudence which would reasonably and ordinarily be
expected from a skilled and experienced Consultant applying the
standards generally adopted by global Engineering/Technical , except in
so far as inconsistent with any applicable Indian law or directive.
"Letter of Intent (LOI)/Letter of Award (LOA)" means the official letter
issued by the Owner notifying the Consultant that its Bid Proposal has
been accepted.
Month means calendar month of the Gregorian calendar.
Owners Acceptance means the Owner has accepted that the
Consultant (R&M Consultant) has successfully discharged the R&M
Consultancy Services covering the entire scope of work as per the ToR
adhering to industry standard and Good Industry Practice and all the
reports & other deliverables submitted by the Consultant as part of the
R&M Consultancy Services .
Owner or Purchaser or Employer shall means the [Name of the
Utility], and includes its legal successors or permitted assignees.
"Person" means any natural person, firm, corporation, company,
voluntary association, partnership, joint venture, trust, and incorporated
organization, unincorporated organization, Competent Authority or other
entity.
Project means the Owners [----------------------------] in respect of which
the Contract has been signed.
Project Manager means the person appointed by the Owner thereof and
named as such, to perform the duties delegated by the Owner.
R&M Consultant or Renovation & Modernization Consultant means
the person(s), Firm or a Company or Consortium of Firms whose bid to
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xxiv.
xxv.
xxvi.
xxvii.
xxviii.
xxix.
xxx.
xxxi.
perform the R&M Consultancy Services Contract has been accepted by

the Owner and is also named Consultant in the Contract Agreement.
R&M Project means the proposed R&M work for Unit [..] of [..]
plant of Owner. The subject R&M Consultancy Services package is being
tendered to appoint an R&M Consultant for carrying out preparatory work
for the R&M Project.
SCC means the Special Conditions of Contract.
Site means the [.] plant of [].
Sub Consultant means any firm or person to whom execution of any
part of the subject R&M Consultancy Services Contract is subcontracted
directly or indirectly by the Consultant, and includes its legal successors
or permitted assignees.
Tender Documents means the document, setting out a description and
specification of the Consultancy services and statement of the technical
and other standards to which the Services are to be performed including
any modifications thereto made in accordance with the Conditions. This
includes the commercial specifications, Terms of Reference and other
Tender Documents forming a part of the Contract and such other
Schedules and drawings as may be mutually agreed upon.
Tenderer"/"Bidder"/Applicant means the Person(s), Firm/Company
who has submitted its Bid Proposal in response to the bid invitation by
the Owner, for the Project.
Time for Completion means the time within which completion of R&M
Consultancy Services by the Consultant (R&M Consultant) covering the
entire Scope of Work as per the Terms of Reference and submission of all
the reports and other deliverables incorporating Owners observation on
the draft reports to the satisfaction of the owner is to be attained in
accordance with the stipulations and provisions of the Contract.
"Writing" or "Written" shall include any manuscript, type-written or
printed statement, under or over signature and/or seal as the case may
be.
When the words "Approved", "Subject to Approval", "Satisfactory", "Equal to",

"Proper", "Requested", "As Directed", "Where Directed", "When Directed",
"Determined by", "Accepted", "Permitted", or words and phrases of similar
importance are used, the approval, judgment, direction, etc., is understood to be a
function of the Owner. Words implying persons or the gender neutral pronoun it,
shall include firms, companies, corporation, associations or body of individuals
whether incorporated or not. Words implying masculine gender or singular number
shall also include the feminine gender and plural number and vice-versa where the
context so requires or permits.
4.2
Contract Documents
a) All documents forming part of the Contract (and all parts thereof) are intended
to be correlative, complementary and mutually explanatory. The Contract shall
be read as a whole.
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b) The Contract will be signed in three originals and the Consultant shall be
provided with one signed original and the rest will be retained by the Owner.
4.3
Order of Precedence of Contract Documents

In case there is any ambiguity of conflict between different contract documents,
the order of precedence shall be as follows:i. The signed Contract Agreement & the annexure/ appendices thereto (highest
precedence)
ii. Notification of award.
iii. Special Condition of Contract
iv. General Condition of Contract
v. The bid & schedules/ attachment submitted by the Consultant.
vi. Terms of Reference
4.4
Interpretation
All Contract Documents, all correspondence and communications to be given,
and all other documentation to be prepared and supplied under the Contract shall
be written in English, and the Contract shall be construed and interpreted in
accordance with English language.
The singular shall include the plural and the plural the singular, except where the
context requires otherwise.
Unless inconsistent with any provision of the Contract, the meaning of any
trade term and the rights and obligations of parties there under shall be as
prescribed by Incoterms. Incoterms means latest edition of International Rules for
Interpreting Trade Terms published by the International Chamber of Commerce
Paris, France.
4.5
Independent Consultant
The Consultant shall be an independent Consultant performing the Contract. The
Contract does not create any agency, partnership, joint venture or other joint
relationship between the parties hereto.
Subject to the provisions of the Contract, the Consultant shall be solely
responsible for the manner in which the Contract is performed. All employees,
representatives or SubConsultants engaged by the Consultant in connection with
the performance of the Contract shall be under the complete control of the
Consultant and shall not be deemed to be employees of the Owner, and nothing
contained in the Contract or in any subcontract awarded by the Consultant shall
be construed to create any contractual relationship between any such employees,
representatives or SubConsultants and the Owner.
4.6
Joint Venture or Consortium

If the Bidder/Consultant is a joint venture or consortium of two or more firms, all
such firms shall be jointly and severally bound to the Owner for the fulfillment of
the provisions of the Contract and the Bidder shall submit a letter of consent to
this effect (with Part-I Bid) signed by all joint venture partners / consortium
members. The joint venture/consortium partners shall designate one of such firms
to act as a leader with authority to bind the joint venture or consortium. The
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composition or the constitution of the joint venture or consortium shall not be

altered without the prior consent of the Owner.
4.7
Non-Waiver
No relaxation, forbearance, delay or indulgence by either party in enforcing any of
the terms and conditions of the Contract or the granting of time by either party to
the other shall prejudice, affect or restrict the rights of that party under the
Contract, nor shall any waiver by either party of any breach of Contract operate as
waiver of any subsequent or continuing breach of Contract. Any waiver of a
partys rights, powers or remedies under the Contract must be in writing, must be
dated and signed by an authorized representative of the party granting such
waiver, and must specify the right and the extent to which it is being waived.
4.8
Severability
If any provision or condition of the Contract is prohibited or rendered invalid or
unenforceable, such prohibition, invalidity or unenforceability shall not affect the
validity or enforceability of any other provisions and conditions of the Contract.
4.9
Origin
Origin means the place where the materials, equipments and other supplies for
the Facilities are mined, grown, produced or manufactured, and from which the
services are provided.
4.10
Notices
All notices to be given under the Contract shall be in writing, and shall be sent by
personal delivery, or post, or special courier, or telefax, or Electronic Data
Interchange (EDI) to the address of the relevant party indicated in the Contract.
Either party may change its postal, telefax number, or EDI address or addressee
for receipt of such notices by ten (10) days notice to the other party in writing
Notices shall be deemed to include any approvals, consents, instructions, orders
and certificates to be given under the Contract.
4.11
Governing Laws
The Contract shall be governed by and interpreted in accordance with laws in
force in India. The Courts of [........] shall have exclusive jurisdiction in all matters
arising under the Contract.
4.12
Settlement of Disputes
a) Mutual Consultation
If any differences/ dispute arises between the Owner and the Consultant in
connection with or arising out of the Contract, before or after the termination,
abandonment or breach of the Contractthe Owner & Consultant shall seek to
resolve any such dispute or difference by mutual consultation. If the parties
fail to resolve such a dispute or difference by mutual consultation, then the
dispute shall be referred in writing by either party to the Arbitrator, with a copy
to the other party.
b) Arbitration
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Either Owner or the Consultant may, of its intention to commence arbitration,

as to the matter in dispute, and no arbitration may be commenced unless such
notice is given.
Any dispute, in respect of which a notice of intention to commence arbitration
has been given, as above shall be finally settled by arbitration. Arbitration may
be commenced prior to or after completion of the Facilities
Any dispute submitted by a party to arbitration shall be heard by an arbitration
panel composed of three arbitrators, in accordance with the provisions set
forth below.
The Owner and the Consultant shall each appoint one arbitrator, and these two
arbitrators shall jointly appoint a third arbitrator, who shall chair the arbitration
panel. If the two arbitrators do not succeed in appointing a third arbitrator
within [twenty eight (28)] days after the latter of the two arbitrators has been
appointed, the third arbitrator shall, at the request of either party, be appointed
by President, Institution of Engineers as the Appointing Authority.
If one party fails to appoint its arbitrator within [forty-two (42)] days after the
other party has named its arbitrator, the party which has named an arbitrator
may request the Appointing Authority to appoint the second arbitrator.
If for any reason an arbitrator is unable to perform its function, the mandate of
the Arbitrator shall terminate in accordance with the provisions of applicable
laws and a substitute shall be appointed in the same manner as the original
arbitrator.
Adjudication/Arbitration proceedings shall be conducted in accordance with
Indian Arbitration and Conciliation Act 1996.
The Place for Arbitration shall be [.], India.
The language of arbitration shall be English.
The decision of a majority of the arbitrators (or of the third arbitrator chairing
the arbitration, if there is no such majority) shall be final and binding and shall
be enforceable in any court of competent jurisdiction as decree of the court.
The parties thereby waive any objections to or claims of immunity from such
enforcement.
Notwithstanding any reference to the arbitration,
4.13
the parties shall continue to perform their respective obligations under the
Contract unless they otherwise agree
The Owner shall pay the consideration Consultant due to the Consultant.
Scope of Services
The Scope of Services shall be as per the Terms of Reference Section-II.
4.14
Time for Commencement and Completion

a) The Consultant shall commence work on the Scope of Services under this
Tender from the date of Letter of Award. Consultant shall thereafter proceed
with the Services in accordance with the time schedule specified in SCC &
detailed network schedule agreed & appended to the contract.
b) The Consultant shall attain Completion of the Consultancy Services (or of a
part where a separate time for Completion of such part is specified in the
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Contract) within the time stated in the SCC subject to time extensions, the
Consultant is entitled under the contract conditions or time extension expressly
granted by the Owner.
4.15
Consultants Responsibilities
a) Before entering into this contract the Consultant is responsible to have
examined the data relating to the plant and facilities provided by the Owner,
and on the basis of information that the Consultant could have obtained from a
visual inspection of the Site and of other data readily available to it relating to
the Plant & Facilities as at one month days prior to bid submission. Any failure
to acquaint itself with all such data and information shall not relieve Consultant
of its responsibility for properly estimating the difficulty or cost of successfully
performing its scope of work under this contract.
b) The Consultant shall acquire in its name all permits, approvals and/or licenses
from all local, state or national government authorities or public service
undertakings in the country where the Site is located that are necessary for the
performance of the Contract, including, without limitation, visas for the
Consultants and SubConsultants personnel and entry permits for all imported
Consultants Equipment.
c) The Consultant shall perform the Services in accordance with the Applicable
Laws and shall take all practicable steps to ensure that any Sub-Consultant, as
well as the Personnel and agents of the Consultant and any Sub-Consultant,
comply with the Applicable Laws. The Consultant shall comply with all laws in
force in India and the place where the facility is located out. The laws will
include all national, provincial, municipal or other laws that affect the
performance of the Contract and bind upon the Consultant. The Consultant
shall indemnify and hold harmless the Owner from and against any and all
liabilities, damages, claims, fines, penalties and expenses of whatever nature
arising or resulting from the violation of such laws by the Consultant.
d) The Consultant shall perform the Services and carry out its obligations under
this Contract with all due diligence, efficiency and economy, in accordance
with generally accepted professional techniques and practices, and shall
observe sound management practices, and employ appropriate advanced
technology and safe and effective equipment, machinery, materials and
methods. The Consultant shall always act, in respect of any matter relating to
this Owner or to the Services, as a faithful advisor to the Owner, and shall at
all times support and safeguard the Owners legitimate interests in any
dealings with Sub-Consultants or Third Parties.
4.16
Owners Responsibilities
a) The Owner shall be responsible for access to the plant and the Site and for
providing possession of and access to all other areas reasonably required for
the proper execution of the Contract.
b) The Owner shall facilitate plant shut down and controlled operation of the
plant reasonably required to enable the Consultant to carry our Residual Life
Assessment/ Condition Assessment studies and Energy Audit
c) The owner shall make available to the Consultant all the plant operation data,
Manufacturers Manual, O&M Manual and other Technical data/information to
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the extent available with the Owner and reasonably required by the Consultant
for discharging Services as per the Terms of Reference
d) The Owner shall acquire and pay for all permits, approvals and/or licenses
undertakings, which such authorities or undertakings require the Owner to
obtain them in the Owners name, are necessary for the execution of the
Contract.
e) If requested by the Consultant, the Owner shall use its best endeavours to
assist the Consultant in obtaining in a timely and expeditious manner all
permits, approvals and/or licenses necessary for the execution of the Contract
undertakings that such authorities or undertakings require the Consultant or
SubConsultants or the personnel of the Consultant or SubConsultants, as the
case may be, to obtain.
4.17
Taxes & Duties

a) The Owner shall bear and promptly pay Service Tax along with applicable
Surcharge and Cess thereon, in respect of direct transaction between the
Owner and the Consultant payable in India as per Indian law. All other Taxes
and Duties will be borne by the Consultant.
b) If any tax exemptions, reductions, allowances or privileges may be available to
the Consultant, the Owner shall use its best endeavours to enable the
Consultant to benefit from any such tax savings to the maximum allowable
extent.
4.18
Intellectual Property
The copyright in all drawings, documents and other materials containing data and
information furnished to the Owner by the Consultant herein shall remain vested in
the Consultant or, if they are furnished to the Owner directly or through the
Consultant by any third party, including suppliers of materials, the copyright in
such materials shall remain vested in such third party. The Owner shall however
be free to reproduce all drawings, documents and other material furnished to the
Owner for the purpose of the contract.
4.19
Confidential Information
a) The Owner and the Consultant shall keep confidential and shall not, without
the written consent of the other party hereto, divulge to any third party any
documents, data or other information furnished directly or indirectly by the
other party hereto in connection with the Contract, whether such information
has been furnished prior to, during or following termination of the Contract.
Notwithstanding the above, the Consultant may furnish to
its
SubConsultant(s) such documents, data and other information it receives from
the Owner to the extent required for the SubConsultant(s) to perform its work
under the Contract, in which event the Consultant shall obtain from such
SubConsultant(s) an undertaking of confidentiality similar to that imposed on
the Consultant.
b) The obligation of a party, shall not apply to that information which
now or hereafter enters the public domain through no fault of that party
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4.20
can be proven to have been possessed by that party at the time of

disclosure and which was not previously obtained, directly or indirectly,
from the other party hereto
Otherwise lawfully becomes available to that party from a third party
that has no obligation of confidentiality.
Conflict of Interest
a) The Consultant shall not have a Conflict of Interest and any breach hereof shall
constitute a breach of the Agreement.
b) During the term of this Contract and after its termination, the Consultant or any
Associate or Consortium Partner thereof and any entity affiliated with the
Consultant, as well as any Sub-Consultant and any entity affiliated with such
Sub-Consultant, shall be disqualified from providing goods, works, services,
loans or equity for any project resulting from or closely related to the Services
and any breach of this obligation shall amount to a Conflict of Interest; provided
that the restriction herein shall not apply after a period of five years from the
completion of this assignment or to consulting assignments granted by banks/
lenders at any time; provided further that this restriction shall not apply to
consultancy/ advisory services provided to the Owner in continuation of this
Consultancy or to any subsequent consultancy/ advisory services provided to the
Owner. For the avoidance of doubt, an entity affiliated with the Consultant shall
include a partner in the Consultants firm or a person who holds more than 5%
(five per cent) of the subscribed and paid up share capital of the Consultant, as
the case may be, and any Associate thereof.
c) The Contract Price provided under the provisions of this Contract shall constitute
the R&M Consultants sole remuneration in connection with this Contract or the
Services and the Consultant shall not accept for its own benefit any trade
commission, discount or similar payment in connection with activities pursuant
to this Contract or to the Services or in the discharge of its obligations
hereunder, and the Consultant shall use its best efforts to ensure that any SubConsultant, as well as the Personnel and agents of either of them, similarly shall
not receive any such additional remuneration.
4.21
Representatives
d) Project Manager
If the Project Manager is not named in the Contract, then within fourteen (14)
days of the Effective Date, the Owner shall appoint and notify the Consultant in
writing of the name of the Project Manager. The Owner may from time to time
appoint some other person as the Project Manager in place of the person
previously so appointed, and shall give a notice of the name of such other
person to the Consultant without delay. The Owner shall take reasonable care
to see that no such appointment is made at such a time or in such a manner as
to impede the progress of work on the Facilities. The Project Manager shall
represent and act for the Owner at all times during the currency of the Contract.
All notices, instructions, orders, certificates, approvals and all other
communications under the Contract shall be given by the Project Manager,
except as herein otherwise provided.
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All notices, instructions, information and other communications given by the

Consultant to the Owner under the Contract shall be given to the Project
Manager, except as herein otherwise provided.
e) Consultants Team Leader
4.22
If the Consultants Team Leader is not named in the Contract, then within
[fourteen (14) days] of the Effective Date, the Consultant shall appoint
the Consultants Team Leader and shall request the Owner in writing to
approve the person so appointed. If the Owner makes no objection to the
appointment within [fourteen (14)] days, the Team Leader shall be
deemed to have been approved. If
the Owner objects to the
appointment within [fourteen (14)] days giving the reason there for, then
the Consultant shall appoint a replacement within [fourteen (14) days] of
such objection.
The Consultants Representative shall represent and act for the
Consultant at all times during the currency of the Contract and shall give
to the Project Manager all the Consultants notices, instructions,
information and all other communications under the Contract. All notices,
instructions, information and all other communications given by the
Owner or the Project Manager to the Consultant under the Contract shall
be given to the Consultants Team Leader or, in its absence, its deputy,
except as herein otherwise provided. The Consultant shall not revoke the
appointment of the Consultants Representative without the Owners
prior written consent, which shall not be unreasonably withheld. If the
Owner consents thereto, the Consultant shall appoint some other person
as the Team Leader.
The Consultants Team Leader may, subject to the approval of the
Owner (which shall not be unreasonably withheld), at any time delegate
to any person any of the powers, functions and authorities vested in him
or her. Any such delegation may be revoked at any time. Any such
delegation or revocation shall be subject to a prior notice signed by the
Consultants Team Leader, and shall specify the powers, functions and
authorities thereby delegated or revoked.
No such delegation or
revocation shall take effect unless and until a copy thereof has been
delivered to the Owner and the Project Manager.
The Owner may by notice to the Consultant object to any representative
or person employed by the Consultant in the execution of the Contract
who, in the reasonable opinion of the Owner, may behave inappropriately,
may be incompetent or negligent, or may commit a serious breach of the
Site regulations. In such cases, the Consultant will arrange suitable
replacement.
Work Program
a) Consultants Organization
The Consultants Organization chart and list of key personnel and Team Leader
identified for the Project will be appended to the Contract Agreement. The
Consultant shall ensure adequate and timely availability of these personnel to
work on this Consultancy Services. Consultant will also ensure availability and
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b)
c)
d)
e)
4.23
services of any additional personnel required for the successful and timely
completion of the Scope of Services as per the Terms of Reference.
Program of Performance
Within [twenty-eight (28)] days after the date of Notification of Award of
Contract, the Consultant shall prepare and submit to the Project Manager a
detailed Program of Performance of the Contract, made in the form specified in
the SCC and showing the sequence in which it proposes to design, supply,
transport, assemble, install and precomissioning the Facilities, as well as the
date by which the Consultant reasonably requires that the Owner shall have
fulfilled its obligations under the Contract so as to enable the Consultant to
execute the Contract in accordance with the program and to achieve Completion
and Acceptance of the Facilities in accordance with the Contract. The program
so submitted by the Consultant shall accord with the Time Schedule included in
Appendix 4 (Time Schedule) to the Form of Contract Agreement and any other
dates and periods specified in the Contract. The Consultant shall update and
revise the program as and when appropriate or when required by the Project
Manager, but without modification in the Times for Completion.
Progress Report
The Progress Report shall be in a form acceptable to the Project Manager and
shall indicate: (a) percentage completion achieved compared with the planned
percentage completion for each activity; and (b) where any activity is behind the
program, giving comments and likely consequences and stating the corrective
action being taken.
Progress of Performance
If at any time the Consultants actual progress falls behind the program, or it
becomes apparent that it will so fall behind, the Consultant shall, at the request
of the Owner or the Project Manager, prepare and submit to the Project Manager
a revised program, taking into account the prevailing circumstances, and shall
notify the Project Manager of the steps being taken to expedite progress so as to
attain Completion of the Facilities within the Time for Completion.
Work Procedures
The Contract shall be executed in accordance with the Contract Documents and
the procedures given in the section on Forms and Procedures of the Contract
Documents.
If agreed between the Owner and the Consultant, the Consultant may execute
the Contract in accordance with its own standard project execution plans and
procedures to the extent that they do not conflict with the provisions contained
in the Contract.
Substitution of Key Personnel

The Owner expects that all the Key Personnel specified in the Bid Proposal shall
be available during the execution of R&M Consultancy Services. The Owner will
not consider any substitution of Key Personnel except under compelling
circumstances beyond the control of the Consultant and the concerned Key
Personnel. Such substitution may be permitted only in exceptional cases subject
to equally or better qualified and experienced personnel being provided to the
satisfaction of the Owner.
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4.24
Sub-Consultant
The R&M Consultant or Consortium Leader or Associate shall not subcontract its
entire scope of work back-to-back or otherwise. In any case, appointment of any
Sub-Consultant to discharge any part of the Scope of Service under this
Contract is subject to Owners prior written approval. Owner may accept or
reject any Sub-Consultant at its discretion.
4.25
Completion Time
The Consultant guarantees that it shall attain Completion of the entire Scope of
Service as per the Terms of Reference or part thereof within the Time for
Completion specified in the SCC.
4.26
Patents Indemnity
The Consultant shall indemnify and hold harmless the Owner and its employees
and officers from and against any and all suits, actions or administrative
proceedings, claims, demands, losses, damages, costs, and expenses of
whatsoever nature, including attorneys fees and expenses, which the Owner
may suffer as a result of any infringement or alleged infringement of any patent,
utility model, registered design, trademark, copyright or other intellectual
property right registered or otherwise existing at the date of the Contract by
reason of: (a) the installation of the Facilities by the Consultant or the use of the
such Facilities.
4.27
Accuracy of Data and Document

The Consultant shall be responsible for accuracy of the data collected by it
directly or procured from other entities, the designs, drawings, estimates and all
other details prepared by it as part of these services. Subject to the GCC
provisions regarding limitation of Consultants liability, the Consultant shall
indemnify the Owner against any inaccuracy in its work which might surface
during implementation of the R&M Project, if such inaccuracy is the result of any
negligence or inadequate due diligence on part of the Consultant or arises out of
its failure to conform to good industry practice. The Consultant shall also be
responsible for promptly correcting, at its own cost and risk, the drawings
including any re-survey / investigations.
4.28
Liability of R&M Consultant

a) The R&M Consultants liability under this Agreement shall be determined by the
Applicable Laws and the provisions hereunder.
b) The Consultant shall, subject to the limitation specified hereunder, be liable to
the Owner for any direct loss or damage accrued or likely to accrue due to
deficiency in Services rendered by it.
c) Except in cases of criminal negligence or wilful misconduct by the Consultant,
the aggregate liability of the Consultant (R&M Consultant) to the Owner,
whether under the Contract, in tort or otherwise, shall not exceed the total
Contract Price, provided that this limitation shall not apply to any obligation of
the Consultant to indemnify the Owner with respect to patent infringement.
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d) Except in cases of criminal negligence or wilful misconduct by the Consultant,

the Consultant shall not be liable to the Owner, whether in contract, tort, or
otherwise, for any indirect or consequential loss or damage, loss of use, loss of
production, or loss of profits or interest costs,.
4.29
Equipment and Material provided by the Owner

Equipment and materials made available to the R&M Consultant by the Owner
shall be the property of the Owner and shall be marked accordingly. Upon
termination or expiration of this Contract Agreement, the Consultant shall furnish
forthwith to the Owner, an inventory of such equipment and materials and shall
return to the owner or otherwise dispose of such equipment and materials in
accordance with the instructions of the Owner. While in possession of such
equipment and materials, the R&M Consultant shall, unless otherwise instructed
by the Owner in writing, insure them in an amount equal to their full replacement
value.
4.30
Loss of or Damage to Property; Accident or Injury; Indemnification

The
Consultant
shall indemnify and hold harmless the Owner and
its
employees and
officers from and against any and all suits, actions
or
administrative proceedings, claims, demands, losses, damages, costs, and
expenses of whatsoever nature, including attorneys fees and expenses, in
respect of the death or injury of any person or loss of or damage to any
property (other than the Facilities whether accepted or not), arising in connection
with Consultancy Services and by reason of the negligence of the Consultant or
its SubConsultants, or their employees, officers or agents, except any injury,
death or property damage caused by the negligence of the Owner, its Consultants,
employees, officers or agents.
4.31
Insurance
a)
b)
c)
The Consultant shall, for the duration of this Contract, take and maintain, and
shall cause any Sub-Consultant to take and maintain, at its (or the SubConsultants, as the case may be) own cost, but on terms and conditions
approved by the Owner, insurance against the risks, and for the coverage, as
specified hereunder and in accordance with good industry practice.
Within 15 (fifteen) days of receiving any insurance policy certificate in respect
of insurances required to be obtained and maintained under this clause, the
Consultant shall furnish to the Owner, copies of such policy certificates, copies
of the insurance policies and evidence that the insurance premia have been
paid in respect of such insurance. No insurance shall be cancelled, modified or
allowed to expire or lapse during the currency of this Contract.
If the Consultant fails to effect and keep in force the aforesaid insurances for
which it is responsible pursuant hereto, the owner shall, apart from having other
recourse available under this Contract, have the option, without prejudice to the
obligations of the Consultant, to take out the aforesaid insurance, to keep in
force any such insurances, and pay such premia and recover the costs
thereof from the Consultant, and the Consultant shall be liable to pay such
amounts on demand by the Owner.
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d)
e)
f)
4.32
Except in case of Third Party liabilities, the insurance policies so procured shall
mention the Owner as the beneficiary of the Consultant and the Consultant
shall procure an undertaking from the insurance company to this effect;
provided that in the event the Consultant has a general insurance policy that
covers the risks specified in this Agreement and the amount of insurance cover
is equivalent to 3 (three) times the cover required hereunder, such insurance
policy may not mention the Owner as the sole beneficiary of the Consultant or
require an undertaking to that effect.
The risks and coverages shall include but not be limited to the following:
i.
Third Party liability insurance as required under Applicable Laws, with a
minimum coverage of [.........].
ii.
Employers liability and workers compensation insurance in respect of
the Personnel of the Consultant and of any Sub-Consultant, in
accordance with Applicable Laws.
iii.
Professional liability insurance for an amount no less than the
Agreement Value.
In case of consortium, the policy should be in the name of Consortium Leader
and not in the name of individual Members of the consortium.
Owners Prior Approval

The Consultant shall obtain the Owners written prior approval in writing before
taking any of the following actions:
a)
Replacing any Key Personnel listed in the Contract Schedule
b)
Discontinuing participation of any Key Personnel in this R&M Consultancy
Services during the currency of the Contract
c)
Any other action that is specified in the Tender Document or Contract
Agreement.
4.33
Ownership of Documents Prepared by Consultant (R&M Consultant)

a)
b)
All plans, drawings, specifications, designs, reports and other documents

(collectively referred to as Consultancy Documents) prepared by the R&M
Consultant (or by the Sub-Consultants or any Third Party) in performing the
Services shall become and remain the property of the Owner, and all
intellectual property rights in such Consultancy Documents shall vest with
the Owner. Any Consultancy Document, of which the ownership or the
intellectual property rights do not vest with the Owner under law, shall
automatically stand assigned to the Owner as and when such Consultancy
Document is created and the Consultant agrees to execute all papers and to
perform such other acts as the Authority may deem necessary to secure its
rights herein assigned by the R&M Consultant.
The R&M Consultant shall, not later than termination or expiration of this
Contract, deliver all Consultancy Documents to the Owner, together with a
detailed inventory thereof. The Consultant may retain a copy of such
Consultancy Documents. The R&M Consultant, its Sub-Consultants or a
Third Party shall not use these Consultancy Documents for purposes
unrelated to this Contract without the prior written approval of the Owner.
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c)
4.34
The Consultant shall hold the Owner harmless and indemnified for any
losses, claims, damages, expenses (including all legal expenses), awards,
penalties or injuries (collectively referred to as claims) which may arise from
or due to any unauthorised use of such Consultancy Documents, or due to
any breach or failure on part of the Consultant or its Sub-Consultants or a
Third Party to perform any of its duties or obligations in relation to securing
the aforementioned rights of the Owner.
Change in Laws & Regulation

If, after the date [seven (7)] days prior to the date of Bid submission, in India,
any law, regulation, ordinance, order or by-law having the force of law is
enacted, promulgated, abrogated or changed (which shall be deemed to include
any change in interpretation or application by the competent authorities) that
subsequently affects the costs and expenses of the Consultant and/or the Time
for Completion, the Contract Price shall be correspondingly increased or
decreased, and/or the Time for Completion shall be reasonably adjusted to the
extent that the Consultant has thereby been affected in the performance of any
of its obligations under the Contract. However, these adjustments would be
restricted to direct transactions between the Owner and the Consultant.
4.35
Force majeure
(a)
Force Majeure shall mean any event beyond the reasonable control of the
Owner or of the Consultant, as the case may be, and which is unavoidable
notwithstanding the reasonable care of the party affected.
(b) If either party is prevented, hindered or delayed from or in performing any of
its obligations under the Contract by an event of Force Majeure, then it shall
notify the other in writing of the occurrence of such event and the
circumstances thereof within [fourteen (14)] days after the occurrence of
such event.
(c) The party who has given such notice shall be excused from the performance
or punctual performance of its obligations under the Contract for so long as
the relevant event of Force Majeure continues and to the extent that such
partys performance is prevented, hindered or delayed.
(d) The party or parties affected by the event of Force Majeure shall use
reasonable efforts to mitigate the effect thereof upon its or their performance
of the Contract and to fulfil its or their obligations under the Contract, but
without prejudice to either partys right.
(e) No delay or non-performance by either party hereto caused by the occurrence
of any event of Force Majeure shall
- constitute a default or breach of the Contract
- to any claim for damages or additional cost or expense occasioned
thereby
if and to the extent that such delay or non-performance is caused by the
occurrence of an event of Force Majeure.
(f) If the performance of the Contract is substantially prevented, hindered or
delayed for a single period of more than [sixty (60)] days or an aggregate
period of more than one hundred and [twenty (120)] days on account of one
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(g)
4.36
or more events of Force Majeure during the currency of the Contract, the
parties will attempt to develop a mutually satisfactory solution.
Force Majeure shall not apply to any obligation of the Owner to make
payments to the Consultant herein.
Change in the Scope of Services

The Owner shall have the right to propose, and subsequently require, the
Consultant during the performance of the Contract to make any change,
modification, addition or deletion to, in or from the Scope of Services, provided
that such Change falls within the general scope of the Services and does not
constitute unrelated work and that it is technically practicable, taking into
account both the state of advancement of the assignment and the technical
feasibility. The parties will agree on the change in Contract Price due Change in
Scope of Services on mutual consultation basis.
4.37
Extension of Time for Completion

(a)
(b)
(c)
4.38
The Time(s) for Completion specified in the SCC shall be extended if the
Consultant is delayed or impeded in the performance of any of its obligations
under the Contract by reason of any of the following:
- Any Change in the Facilities or
- any occurrence of Force Majeure or
- any suspension order given by the Owner or reduction in the rate of
progress or
- any changes in laws and regulations or
- any default or breach of the Contract by the Owner, or any activity, act
or omission of any other Consultants employed by the Owner or
- any other matter specifically mentioned in the Contract;
By such period as shall be fair and reasonable in all the circumstances and
as shall fairly reflect the delay or impediment sustained by the
Consultant.
Except where otherwise specifically provided in the Contract, the Consultant
shall submit to the Project Manager a notice of a claim for an extension of
the Time for Completion, together with particulars of the event or
circumstance justifying such extension as soon as reasonably practicable
after the commencement of such event or circumstance. As soon as
reasonably practicable after receipt of such notice and supporting particulars
of the claim, the Owner and the Consultant shall agree upon the period of
such extension.
The Consultant shall at all times use its reasonable efforts to minimize any
delay in the performance of its obligations under the Contract.
Termination
(a)
Termination for Owners Convenience

The Owner may at any time terminate the Contract for any reason by giving
the Consultant a notice of termination. Upon receipt of the notice of
Document Number
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Rev No.
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[Logo of Utility]
termination, the Consultant shall either immediately or upon the date

specified in the notice of termination
(i)
Cease all further work.
(ii)
terminate all subcontracts, except those to be assigned
(iii)
remove all Consultants Equipments from the Site, repatriate the

Consultants and its SubConsultants personnel from the Site, remove
from the Site any wreckage, rubbish and debris of any kind, and leave
the whole of the Site in a clean and safe condition
(iv) The Consultant, subject to the payment, shall
o
o
deliver to the Owner the data collected during the course of the consultancy
services and study reports prepared up to the date of termination
Deliver to the Owner all non-proprietary drawings, specifications and other
documents prepared by the Consultant or its SubConsultants as at the date of
termination in connection with the Facilities.
o
o
o
o
In the event of termination of the Contract for Owners

convenience, the Owner shall pay to the Consultant the
following amounts
the Contract Price, attributable to the parts of the Services executed by the
Consultant as on the date of termination
the costs reasonably incurred by the Consultant in the removal of the Consultants
Equipment from the Site and in the repatriation of the Consultants and its
SubConsultants personnel
any amounts to be paid by the Consultant to its SubConsultants in connection with
the termination of any subcontracts, including any cancellation charges
the additional cost of satisfying other obligations, commitments and claims that the
Consultant may in good faith have undertaken with third parties in connection with
the Contract.
(b)
Termination for Consultants Default

(i)
The Owner, without prejudice to any other rights or remedies it may

possess, may terminate the Contract forthwith in the following
circumstances by giving a notice of termination and its reasons thereof
to the Consultant:
the Consultant becomes bankrupt or insolvent, has a receiving order
issued against it, compounds with its creditors, or, if the Consultant
is a corporation, a resolution is passed or order is made for its
winding up (other than a voluntary liquidation for the purposes of
amalgamation or reconstruction), a receiver is appointed over any
part of its undertaking or assets, or if the Consultant takes or
suffers any other analogous action in consequence of debt
If the Consultant assigns or transfers the Contract or any right or
interest therein in violation of the provision.
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-I
Page No.
- 35-
Date of Issue
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[Logo of Utility]
If the Consultant, in the judgement of the Owner has engaged in

corrupt or fraudulent practices in competing for or in executing the
Contract.
For the purpose of this Sub Clause:
"corrupt practice" means the offering, giving, receiving or soliciting
of anything of value to influence the action of a public official in the
procurement process or in contract execution.
"fraudulent practice" means a misrepresentation of facts in order to
influence a procurement process or the execution of a contract to
the detriment of the Owner and includes collusive practice among
Bidders (prior to or after bid submission) designed to establish bid
prices at artificial non-competitive levels and to deprive the Owner
of the benefits of free and open competition.
(ii)
If the Consultant
-
(iii)
has abandoned or repudiated the Contract

has without valid reason failed to commence the Consultancy
Services promptly for more than [twenty eight (28)] days after
receiving a written instruction from the Owner to proceed
persistently fails to execute the Contract in accordance with the
Contract or persistently neglects to carry out its obligations under
the Contract without just cause
refuses or is unable to provide sufficient personnel and other
resources to execute the Services in the manner specified in the
program at rates of progress that give reasonable assurance to the
Owner that the Consultant can attain Completion of the Services by
the Time for Completion as extended
then the Owner may, without prejudice to any other rights it may
possess under the Contract, give a notice to the Consultant stating
the nature of the default and requiring the Consultant to remedy the
same. If the Consultant fails to remedy or to take steps to remedy
the same within [fourteen (14)] days of its receipt of such notice,
then the Owner may terminate the Contract forthwith by giving a
notice of termination to the Consultant.
The Consultant shall, either immediately or upon such date as is
specified in the notice of termination,
ease all further work,

terminate all subcontracts, except those to be assigned to the
Owner
deliver to the Owner the data collected during the course of the
consultancy services and study reports prepared up to the date of
termination
Deliver to the Owner all drawings, specifications and other
documents prepared by the Consultant or its SubConsultants as at
the date of termination in connection with the Services.
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-I
Page No.
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Date of Issue
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[Logo of Utility]
(c)

Consultants and its SubConsultants personnel from the Site,
remove from the Site any wreckage, rubbish and debris of any kind,
and leave the whole of the Site in a clean and safe condition
Termination by Consultant
i.
If
-
ii.
If the Contract is terminated, then the Consultant shall immediately

-
(v)
the Owner has failed to pay the Consultant any sum due under the
Contract within the specified period, has failed to approve any
invoice or supporting documents without just cause pursuant to [----------] (Terms and Procedures of Payment) of the Form of Contract
Agreement, or commits a substantial breach of the Contract, the
Consultant may give a notice to the Owner that requires payment of
such sum,
requires approval of such invoice or supporting
documents, or specifies the breach and requires the Owner to
remedy the same, as the case may be. If the Owner fails to pay
such sum, fails to approve such invoice or supporting documents or
give its reasons for withholding such approval, fails to remedy the
breach or take steps to remedy the breach within [fourteen (14)
days] after receipt of the Consultants notice, or
the Consultant is unable to carry out any of its obligations under the
Contract for any reason attributable to the Owner, ,
then the Consultant may give a notice to the Owner thereof, and if
the Owner has failed to pay the outstanding sum, to approve the
invoice or supporting documents, to give its reasons for withholding
such approval, or to remedy the breach within [twenty eight (28)
days] of such notice, or if the Consultant is still unable to carry out
any of its obligations under the Contract for any reason attributable
to the Owner within twenty eight (28) days of the said notice.
If the Owner becomes bankrupt or insolvent, has a receiving order
issued against it, compounds with its creditors, or, being a
corporation, if a resolution is passed or order is made for its winding
up (other than a voluntary liquidation for the purposes of
part of its undertaking or assets, or if the Owner takes or suffers
any other analogous action in consequence of debt.
cease all further work, except for such work as may be necessary
for the purpose of protecting that part of the Facilities already
executed, or any work required to leave the Site in a clean and safe
condition
Owner pursuant to paragraph (d)(ii)
remove all Consultants Equipment from the Site and repatriate the
Consultants and its SubConsultants personnel from the Site
The Consultant, subject to the payment, shall
Document Number
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Rev No.
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Consultant
Section-I
Page No.
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Date of Issue
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[Logo of Utility]
o
o
deliver to the Owner the data collected during the course of the consultancy
services and study reports prepared up to the date of termination
In the event of termination of the Contract for Owners convenience,
the Owner shall pay to the Consultant the following amounts
o
o
o
o
4.39
the costs reasonably incurred by the Consultant in the removal of the
Consultants Equipment from the Site and in the repatriation of the
Consultants and its SubConsultants personnel
any amounts to be paid by the Consultant to its SubConsultants in connection
with the termination of any subcontracts, including any cancellation charges
the additional cost of satisfying other obligations, commitments and claims
that the Consultant may in good faith have undertaken with third parties in
connection with the Contract.
Assignment
The Consultant shall not, without the express prior written consent of the Owner,
assign to any third party the Contract or any part thereof, or any right, benefit,
obligation or interest therein or there under, except that the Consultant shall be
entitled to assign either absolutely or by way of charge any monies due and
payable to it or that may become due and payable to it under the Contract.
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-I
Page No.
- 38-
Date of Issue
25.09.2014
[Logo of Utility]
SPECIAL CONDITIONS OF CONTRACT (SCC)
5.1
Contract Details
Name of Contract: Renovation & Modernization Consultancy Services

for [---------------------------------------]
Bid Document No. :[-------------------------]
The Owner is:

Name of Owner: [-------------------------]
Address of Owner: [-------------------------]
Telephone No. : [-------------------------]
Fax No: [-------------------------]
E-Mail: [-------------------------]
The Project Manager is:

Name of Project Manager: [-------------------------]
Address of Project Manager: [-------------------------]
Telephone No. : [-------------------------]
Fax No: [-------------------------]
E-Mail: [-------------------------]
5.2
Effective Date
The Owner shall inform the successful Bidder of its acceptance of the Tender by a
formal Letter of Acceptance. This Letter of Acceptance will be the Effective Date
for determining the Time for Completion of the facilities and other milestones for
execution of the Renovation & Modernization Consultancy work as per the scope
of work under this tender by the Consultant.
The following three activities will be completed within [two (2)] months from the
date of Letter of Acceptance:
(a) The contract agreement will be executed by the Owner and the Consultant. (b)
The Consultant will submit to the Owner the Contract Performance Security, any
Additional Performance Security associate etc if applicable, and the Advance
Payment Security.
(c) The Owner will pay the Consultant the Advance Payment as per the Terms of
Payment.
(d) The Consultant will submit the Inception Report and incorporate any change
suggested by Owner in the Inception Report
The Owner will make the advance payment promptly once Consultant has fulfilled
the necessary conditions specified in Terms of Payment. If payment of Advance is
delayed beyond two months from the date of Letter of acceptance for reasons
attributable to the Owner, the date of payment of advance shall be the effective
date for determining the time for completion of facilities. However, failure of the
Document Number
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Rev No.
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Section-I
Page No.
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[Logo of Utility]
Consultant to provide all the required Bonds/Guarantees within the prescribed

period will cause the Bid Security to be forfeited.
5.3

The Time Schedule for the execution of the scope of work by the Consultant
under this tender:
Task/Milestone
Time for Completion
Phase-I
1.
[Completion of RLA Study]
[.]from Effective
Date
2.
[Completion of Energy audit]
[.]
3.
[.]
[.]
4.
[Submission of Draft Feasibility Report.]
[.]
5.
[Submission of Final Feasibility Report]
[.]
.
[Submission of Draft Feasibility Report.]
[.]
[Submission of Final Feasibility Report]
[.]
Phase-II
1
[Submission of Draft Tender Document]
[Submission of Final Tender Document]
[..] from Notice to

Proceed for Phase-II activities
[ Submission of Techno-Commercial Bid

Evaluation Report]
[..] from TechnoCommercial Bid Opening

Date
[ Submission of Price Bid Evaluation

Report]
[..] from Price Bid

Opening Date
..
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-I
Page No.
- 40-
Date of Issue
25.09.2014
[Logo of Utility]
5.4
NOT USED
5.5
NOT USED
5.6
Contract Price
a) The Contract Price shall be as (Contract Price and Terms of Payment) of the
Form of Contract Agreement.
b) The Consultant shall be deemed to have satisfied itself as to the correctness
and sufficiency of the Contract Price, which shall, except as otherwise
provided for in the Contract, cover all its obligations under the Contract.
5.7
Terms of Payment
a) The Contract Price shall be paid as Terms and Procedures of Payment to the
b) No payment made by the Owner herein shall be deemed to constitute
acceptance by the Owner of the Services or any part(s) thereof.
c) All the payments will be made in INR.
5.8
Contract Securities
a) The Consultant shall provide the securities specified below in favour of the
Owner at the times, and in the amount, manner and form specified below.
b) Advance Payment Security
The Consultant shall, within [thirty (30)] days of the Notification of Contract
Award, provide a security for an amount equal to the advance payment, and in
the same currency or currencies, with a initial validity of up to [ninety (90)]
days beyond the schedule date of Completion of R&M Consultancy Services.
The security shall be in the form of an Unconditional Bank Guarantee. The
Advance payment Security shall be reduced prorata every three (3) months
after First Running Account Bill/Stage Payment under the Contract based on
the value of Services received. The cumulative amount of reduction at any
point of time shall not exceed ninety percent (90%) of the advance
corresponding to cumulative value of the Services received as per a certificate
issued by the Project Manager and the balance of 10% shall be released on
Completion of R&M Consultancy Services and Owners Acceptance thereof. It
should be clearly understood that reduction in the value of security for advance
shall not in any way dilute the Consultant's responsibility and liabilities under
the Contract including in respect of the Services for which the reduction in the
value of security is allowed.
c) Performance Security (Contract Performance Bank Guarantee)
The Consultant shall, within [thirty (30)] days of the notification of award, provide
a security for the due performance of the Contract for five percent (5%) of the
Contract Price with an initial validity upto [ninety (90)] days beyond the Scheduled
Completion Date for R&M Consultancy Services.
If the bidder is a Consortium of Consultancy firms, in addition to the Contract
Performance Bank Guarantee (CPBG) of 5% furnished by the Consortium Leader,
each of the other consortium member shall furnish Additional Contract
Performance Bank Guarantee equal to 2% of Contract Price.
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-I
Page No.
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Date of Issue
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[Logo of Utility]
If the Bidder meets Qualification Requirement on the strength of Associate (s), in

addition to the Contract Performance Bank Guarantee (CPBG) of 5% furnished by
the Bidder (Principal Consultant), each Associate shall furnish Additional Contract
Performance Bank Guarantee equal to 2% of Contract Price.
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-I
Page No.
- 42-
Date of Issue
25.09.2014
[Logo of Utility]
FORMS AND SCHEDULES

The Tender Document comprises the following Forms and Schedules:
I
Bid Forms and Schedules/Annexure to be submitted with Bid
Annexure-A
Format of Bid Guarantee
Annexure-B
Form of Part-I Bid
Annexure-C
Form of Part-II Bid
Annexure-D
Sample Format for Letter of Consent to be furnished by the

Bidder and Associate
Schedule F1
Price Schedule
Schedule F2
Overall Time Schedule
Schedule F3
Deviation Schedule
Commercial
Schedule F4
Deviation Schedule to Terms of Reference
Schedule F5
Details of Key Personnel
Schedule F6
Format for Curriculum Vitae (CV) of Key Personnel
II
Forms and Contract Scheduless to form part of Contract
Annexure-F
Form of Contract
Contract
Schedule-1
Terms of Payment
Contract
Schedule-2
NOT USED
Contract
Schedule-3
Time Schedule
Contract
Schedule-4
List of Sub-Consultants
Contract
Schedule-5
List of Key Personnel
III
Formats for Contract Securities
Annexure-G
Format for Contract Performance Security
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
to
Tender
Document
Description
Consultant
Section-I
Page No.
- 43-
Section-I
Date of Issue
25.09.2014
Tender Document for R&M of Unit No.[..] Capacity [..] of [Name of the [Logo of Utility]
Power Plant]
ANNEXURES & SCHEDULES
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[1]
25.09.2014
Power Plant]
ANNEXURE - A
FORMAT OF BID GUARANTEE
1. This Guarantee should be furnished by a scheduled commercial Bank in India
authorized by RBI to issue a Bank Guarantee in the same format as given below.
[Name of Utility], reserves its right to reject the Bank Guarantee if the same is not in
the specified format.
2. This Bank Guarantee should be furnished on stamp paper of value not less than
[Rs..]
3. The stamp paper should have been purchased in the Name of the Bank executing
the guarantee.
Ref.:
Bank Guarantee No:

Date
To:
[Details of Designated Official ]
[-Name of Utility]
Dear Sirs,
In accordance with your "Invitation for Bid" under your Tender No [.................
] dated [.................] M/s [Name of
Bidder] hereinafter called the Bidder, having its registered/head office at
[] with the following persons on its Board of
Directors/Partners of the firm:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
wish to participate in the said Bid for [R&M Consultancy Services package for ],
India, as an irrevocable Bank Guarantee against Bid Guarantee for a sum of
[..] (in words and figures) valid for 300 days from
[..] (the date of Bid Opening) is required to be submitted by the Bidder as
a condition precedent for participation in the said bid, which amount is liable to be
forfeited on the happening of any contingencies mentioned in the Bid Documents, we,
the [] Bank at (local address) [] having our
Head Office at [] guarantee and undertake to pay immediately
on
first
demand
by
[Name
of
Utility]the
amount
of
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[2]
25.09.2014
Power Plant]
[.] (in figures and words) to the

said [Name of Utility] without any reservation, protest, demur and recourse. Any such
demand made by [Name of Utility] shall be conclusive and binding on the Bank
irrespective of any dispute or difference raised by the Bidder.
This Guarantee shall be irrevocable and shall remain valid upto [..] If any
further extension of this Guarantee is required, the same shall be extended to such
required period on receiving instructions from M/s [Name of Bidder] on whose behalf
this Guarantee is issued.
IN WITNESS WHEREOF the Bank, through its authorised officer, has set its hand and
stamp on this [] day of [] 201 [.] at []
Signature
Name
Designation
Staff Code No.
Bankers Seal
Date
Witness:
1.
2.
Signature
Full name in block letters
Designation
Address
Signature
Designation
Address
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[3]
25.09.2014
Power Plant]
ANNEXURE - B
FORMAT OF BID
To be submitted by the Bidder in
Part-I [Techno-commercial] Bid
From:
[Bidder Details]
[]
[]
To:
[-Name of Utility] []
Sub
: ___ (Name of Package) []

Tender No. []_____________________________________
Having carefully examined the Tender Specifications issued to us for your Tender No.
[]_dated__________,and its Amendments / Corrigendum / Clarifications
issued till the date of tender opening:
1. We agree to complete the works in conformity with all the terms and conditions
stated in Tender Specifications and its Amendments/Corrigendum/Clarifications
issued till the date of tender opening and as per time schedule given in Tender
Specification.
2. We undertake, in case our Bid is accepted, to commence the work from the date of
Letter of Award and to complete and deliver the whole of the work and
responsibilities comprised in the Contract within as per Time schedule given in SCC
of Tender Specification.
3. We are submitting the Bid Guarantee for a sum of INR_____________ (Indian
Rupees___[..]_only) in the form ________________ as instructed by
you. This Bid Guarantee shall be governed as per the stipulations provided in the
"Instructions to Bidders".
4. We agree to abide by and keep our Bid valid initially for a period of 240 (Two
Hundred Forty) days from the date of opening of bids by Purchaser and it shall
remain binding on us and may be accepted at any time before the expiry of that
period.
5. Should our Bid be accepted, we hereby agree to abide by and fulfill all terms and
conditions of Tender Specification as accepted by us and in default thereof, to
forfeit and pay to [Name of Utility], assignees or authorized nominees such sums of
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[4]
25.09.2014
Power Plant]
money as are stipulated in conditions contained in Tender Specification and agree to

furnish Bank Guarantee for Contract Performance as per the proforma prescribed by
Purchaser and for the sum equal to 5% of the "Contract Price", for the entire scope
of work within 30 days from the date of Letter of Award.
6. We understand that Purchaser is not bound to accept the lowest or any Bids
received and Purchaser has the right to reject any Bid, without assigning any reason
whatsoever.
7. This Bid together with written acceptance thereof shall constitute a binding
Contract between Purchaser and ourselves till a formal Contract is executed.
Signed this __________________ day
of _______________
Signature
Name
Designation
Company
Date
Company Seal
Witness:
1.
2.
Signature
Occupation
Address
Signature
Occupation
Address
*****
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[5]
25.09.2014
Power Plant]
ANNEXURE - C
FORMAT OF BID
Part-II [Price Bid]
Tender No.
[-----------]
Bid No
[------------]
From:
[]
[]
Dated:
[]
To
:
[]
[]
[]
Dear Sirs
Having carefully examined and understood the Tender Specification including the
amendments/Corrigendum/Clarifications issued till the date of Bid Opening, if any:
1.
2.
We hereby agreed to carry out the entire scope of work as described in the Terms
of Reference in conformity with the specifications and Terms of Reference, as per
prices quoted by us in the Schedule of Prices [Schedule .] enclosed herewith
In the event of our proposal being accepted, we agree to furnish a Bank Guarantee
for Contract Performance as per the proforma prescribed by Employer [Name of
Utility ] and for the sum equal to 5% of the "Contract Price". The Bid Guarantee
shall be released only after the Contract Performance Guarantee issued in favour
of Employer is received and accepted by the Employer
Signed this___________ day of____________201[--] _________
Signature
Name
Designation
Company
Date
Company Seal
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[6]
25.09.2014
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Witness:
1.
2.
Signature
Occupation
Address
Signature
Occupation
Address
*****
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[7]
25.09.2014
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ANNEXURE D
(SAMPLE FORMAT)
LETTER OF CONSENT
TO BE FURNISHED BY THE BIDDER and ASSOCIATE/Consortium Member
We hereby declare that the undersigned firm [-------------] (Name and Complete address of
the Associate/Consortium Member hereby agrees to associate with [-------------] (Name and
Complete address of the Bidder) for the successful completion of part scope of service as
enclosed in the attachment (authenticated by the Bidder and Associate/Consortium Member
for [-------------] Package for the [-------------] Project at [-------------] in the state of [------------], India. We also hereby undertake to ensure high professional standard and timely
completion of our scope of services of [-------------] package and also depute our technical
experts from time to time as applicable to the place of work / Owners Project site.
On award of LOA, we the Associate/Consortium Member agree to furnish an on demand
additional bank guarantee for 2% of Contract Price.
1.
Witness
For Associate/Consortium Member
Signature:
Name:
Name:
Designation:
Designation:
Office Address
Seal of the Company
2.
Witness
For Bidder
Signature:
Name:
Name:
Designation:
Designation:
Office Address:
Seal of the Company:
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[8]
25.09.2014
Power Plant]
ATTACHMENT TO THE LETTER OF CONSENT

Scope of Work of the Associate/Consortium Member:
For Associate/Consortium Member
For Bidder
(Signature of the Authorized

Signatory)
Name:
Name:
Designation:
Designation:
Seal of the Company
Seal of the Company

*****
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[9]
25.09.2014
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SCHEDULE F1
PRICE SCHEDULE
S.No.
Description
INR
Price for RLA Study, Condition Assessment Study and LE Study

(On Lump Sum Fixed Price Basis)
Price of Energy Audit (On Lump Sum Fixed Price Basis)
Price of studies for identification of R&M Option and preparation of

Cost Estimate for R&M options (On Lump Sum Fixed Price Basis)
Preparation of Feasibility Report (On Lump Sum Fixed Price Basis)
4
5
Preparation of Detailed Project Report (On Lump Sum Fixed Price

Basis)
Price for providing support for obtaining regulatory approval (On

Lump Sum Fixed Price Basis)
Price for Basic Design & Engineering, Preparation of Tender

Documents and Support for Vendor Selection (On Lump Sum Fixed
Price Basis)
Price of any additional Work/Service that the Bidder feels required
for completing its scopes as per ToR and is not included at sl no. 1
to 6 above. (On Lump Sum Fixed Price Basis)
Bidder to give sufficient detail for such work/service and detailed
break up quoted price.
Total Price excluding Service Tax on Direct Transaction between
the Owner & Consultant (Sum of 1 to 8)
9
10
11
Service Tax on Direct Transaction between the Owner &

Consultant
Total Price including Service Tax on Direct Transaction between
the Owner & Consultant
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[10]
25.09.2014
Power Plant]
SCHEDULE F2
OVER ALL TIME SCHEDULE
(Bidder to fill-in and submit with its Bid)
S.No
Days from Effective

Date
Work Description
Start
Signature
Name
Designation
Company
Date
Finish
Company Seal
*****
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[11]
25.09.2014
Power Plant]
SCHEDULE F3
DEVIATION SCHEDULE TO TENDER DOCUMENT VOL-I (COMMERCIAL)
All deviations to commercial condition (Tender Document Vol-I) shall be filled in by the
Bidder clause by clause in this schedule.
S.No
Clause
Deviation
Reason for Deviation
The Bidder hereby certifies that the above mentioned are the only deviations from the
commercial condition (Tender Document Vol-I) . The Bidder further confirms that in the
event any other data or information presented in the Bidders proposal and accompanying
documents are at variance with the specific requirements laid out in the commercial
condition (Tender Document Vol-I) , then the latter shall govern and shall be binding on
the Bidder for the quoted price.
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[12]
25.09.2014
Power Plant]
SCHEDULE F4
DEVIATION SCHEDULE TO TERMS OF REFERENCE
All deviations from the Technical Specification shall be filled in by the Bidder, clause by
clause, in this Schedule:
S.No
Volume /
Section
Clause
No
Description
Deviation
Purchasers Technical Specifications for this enquiry. The Bidder further confirms that in
the event any other data and information presented in the Bidders proposal and
accompanying documents including drawings, catalogues, etc are at variance with the
specific requirements laid out in the Purchasers Technical Specifications then the latter
shall govern and shall be binding on the Bidder for the quoted price.
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[13]
25.09.2014
Power Plant]
SCHEDULE F5
DETAILS OF KEY PERSONNEL
Sl
Np
Designation
Team
Leader
Boiler
Expert
Turbine
Expert
Mechanical
BoP Expert
Electrical
Expert
C&I Expert
Civil Expert
Name
Educational
Qualification
Professional
Experience
(years)
Present
Employer
Signature
Name
Designation
Company
Date
Employed
with
present
Employer
Since
Minimum
No of Hours
to
be
Deployed
for
this
Consultancy
Assignment
Company Seal
*****
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[14]
25.09.2014
Power Plant]
SCHEDULE F6
1.
Proposed Designation (As per Schedule-F5) :
2.
Name of Key Person:
3.
Date of Birth:
4.
Nationality:
5.
Educational Qualifications:
6.
Employment Record:
(Starting with present position, list in reverse order every employment held.)
7.
List of projects on which the Personnel has worked

Sl No
8.
9.
Name of Project
Description of Responsibilities
Start Date and

End Date of
Association
Other present work commitment

Details of the role in the subject R&M Consultancy Services assignment and the
time duration for which services are required for this assignment.
Certification:
1
I am willing to work on the R&M Consultancy Services assignment for [..]

project of [..] and I will be available for entire duration of the Project
assignment as required.
I, the undersigned, certify that to the best of my knowledge and belief, this CV
correctly describes myself, my qualifications and my experience.
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[15]
25.09.2014
Power Plant]
Place..............................(Signature and name of the Key Personnel)

(Signature and name of the authorized signatory of the Bidder)
Notes:
Use separate form for each Key Personnel
*****
Document Number
LII-GETS12021-G-001129-007
Rev No
Description
01

Consultant

[16]
25.09.2014
Tender Document for R&M Consultancy Services for Unit No. [..] Capacity [Logo of Utility]
Form of Contract Agreement
Document Number
LII-GETS12021-G-00129-007
Rev No
Description
01

Consultant
Volume-I, Annexure & Schedules

[1]
25.09.2014

THIS CONTRACT AGREEMENT is made the_----------------day of_-------, 20---------------.
BETWEEN (1) [Name of Employer], a corporation incorporated under the laws of
[country of Employer] and having its principal place of business at [address of
Employer] (hereinafter called the Employer), and (2) [name of Contractor], a
corporation incorporated under the laws of [country of Contractor] and having its
principal place of business at [address of Contractor] (hereinafter called the
Contractor)
WHEREAS the Employer desires to engage the Contractor to provide R&M
Consultancy
Services
comprising
.
[
..]
(the R&M Consultancy Services) and the Contractor have agreed to such
engagement upon and subject to the terms and conditions hereinafter appearing.
NOW IT IS HEREBY AGREED as follows:
1.1
Contract Documents
a) Contract Documents means this signed Contract agreement and its
annexure/Contract Schedules, and the complete documents, which are the
basis of finalization of the contract, including correspondence exchanged from
issue of tender till date of signing the contract. The following will constitute
the Contract Documents:
i. The signed Contract Agreement & the annexure/ Contract Schedule
thereto (highest precedence)
ii. Letter of award.
v. Terms of Reference.
vi. The bid & its schedules/ attachment submitted by the contractor.
b) All documents forming part of the Contract (and all parts thereof) are intended
to be correlative, complementary and mutually explanatory. The Contract
shall be read as a whole.
c) The Contract will be signed in three originals and the Contractor shall be
provided with one signed original and the rest will be retained by the
Employer.
1.2

precedence)
Document Number
LII-GETS12021-G-00129-007
Rev No
Description
01

Consultant

[2]
25.09.2014
vi. The bid & schedules/ attachment submitted by the contractor.
1.3
Definitions
The Definitions of terms and expressions shall be as per General Conditions of
Contract (GCC).
1.4
Contract Price
The Employer hereby agrees to pay to the Contractor the Contract Price in
consideration of the performance by the Contractor of its obligations hereunder:
[amount in local currency in words], [amount in figures], or such other sums as
may be determined in accordance with the terms and conditions of the Contract.
1.5
Term of Payment
The terms and procedures of payment according to which the Employer will
reimburse the Contractor are given in Contract Schedule 1 (Terms and Procedures
of Payment) hereto.
1.6

The Time Schedule for the execution of the scope of work by the Contractor
under this shall be as follows:
Task/Milestone
Time for Completion
For Phase-I
[..]
By [] months from
Effective Date
[..]
[..]
[..]
By [] months from
Effective Date
[..]
[..]
[..]
For Phase-II
[..]
By [..]weeks from
Phase-II Notice to Proceed
[..]
[..]
[..]
[..]
[..]
[..]
The detailed Time Schedule shall be as per Contract Schedule 2.

Contract Schedules
The Contract Schedules listed in the attached list of Contract Schedules shall be
deemed to form an integral part of this Contract Agreement.
Reference in the Contract to any Contract Schedule shall mean the Contract
Schedules attached hereto, and the Contract shall be read and construed
accordingly.
Document Number
LII-GETS12021-G-00129-007
Rev No
Description
01

Consultant

[3]
25.09.2014
IN WITNESS WHEREOF the Employer and the Contractor have caused this
Agreement to be duly executed by their duly authorized representatives the day and
year first above written.
Signed by for and on behalf of the Employer
_-----------------------------------------------------------------------------[Signature]
_------------------------------------------------------------------------------- [Title]
In the presence of -------------------------------------------------------------------------------_______________________________________
Signed by for and on behalf of the Contractor
_----------------------------------------------------------------------------- [Signature]
_------------------------------------------------------------------------------- [Title]
CONTRACT AGREEMENT
dated the_-----------day of---------------, 20_---------_____
BETWEEN
[The Employer]------------------------------------------------------------------------------------------and
[The Contractor]-------------------------------------------------------------------------------------
Contract Schedules:
Contract
Contract
Contract
Contract
Contract
Schedule
Schedule
Schedule
Schedule
Schedule
Document Number
LII-GETS12021-G-00129-007
1
2
3
4
5
:
:
:
:
:
Terms of Payment
NOT USED
Time Schedule
Rev No
Description
01

Consultant

[4]
25.09.2014
Contract Schedule-1
Terms of Payment
The Employer shall pay the Contractor in the following manner and at the following
times, on the basis of the Price Break down given in the Section on Price
Schedules. Payments will be made in Indian Rupees. Application for payment in
respect of part deliveries may be made by the Contractor as work proceeds.
I.
Terms of Payment for Price for RLA Study, Condition Assessment Study and LE
Study:
1
10% of the Lump Sum Price
3
4

II.
Initial Advance on
(1)Acceptance of Letter of Award by
the Contractor, (2) Signing of Contract
Agreement, (3) Submission of Contract
Performance
Security,
Additional
Contract Performance Security and
Advance
Payment
Security
by
Contractor and (4) Submission of
Inception Report by the Contractor and
Acceptance of the same by Owner
Completion of all tests for Residual Life
Assessment and Condition Assessment
Submission of Draft RLA Study Report
Submission of Final RLA Report and
Owners acceptance thereof
Owners
Acceptance
that
the
Contractor (R&M Consultant) has
successfully and completely discharged
the R&M Consultancy Services and has
submitted all the test data, reports,
recommendation etc. to the Owner
Terms of Payment for Price for Energy Audit:

1
Document Number
LII-GETS12021-G-00129-007
Initial Advance on
Performance
Security,
Additional
Advance
Payment
Security
by
Completion
of
all
tests
and
Rev No
Description
01

Consultant

[5]
25.09.2014
III.
measurement for Energy Audit

Submission of Draft Energy Audit
Report
Submission of Final Energy Audit
Report and Owners acceptance thereof
Owners
Acceptance
that
the
Terms of Payment for Price of studies for identification of R&M Option and
preparation of Cost Estimate for R&M options
1
IV.
Initial Advance on
Performance
Security,
Additional
Advance
Payment
Security
by
Submission
of
details
regarding
identified R&M options and their scope
of work to the Owner
Acceptance of R&M options and their
scope of work by Owner
Submission of details Cost Estimate for
R&M options to the Owner
Acceptance of Cost Estimate for R&M
options by the Owner
Owners
Acceptance
that
the
Terms of Payment for Price of Preparation of Feasibility Report

1
Document Number
LII-GETS12021-G-00129-007
Initial Advance on
Rev No
Description
01

Consultant

[6]
25.09.2014
V.

Performance
Security,
Additional
Advance
Payment
Security
by
Submission of Draft Feasibility Report
to the Owner
Submission of Final Feasibility Report
and Owners acceptance thereof
Owners
Acceptance
that
the
Terms of Payment for Price of Preparation of Detailed Project Report

1
VI.
Initial Advance on
Performance
Security,
Additional
Advance
Payment
Security
by
Submission of Draft Detailed Project
Report to the Owner
Submission of Final Detailed Project
Report and Owners acceptance thereof
Owners
Acceptance
that
the
Terms of Payment for Price for providing support for obtaining regulatory
approval
1
Document Number
LII-GETS12021-G-00129-007
Initial Advance on
Rev No
Description
01

Consultant

[7]
25.09.2014
VII.

Performance
Security,
Additional
Advance
Payment
Security
by
Preparation of application and other
inputs
for
submission
to
Regulator/Statutory Authority
Preparation of replies to all queries
raised by the Regulator and attending
all the required meeting/hearings with
Regulator/Statutory Authority
Owners
Acceptance
that
the
Terms of Payment for Basic Design & Engineering, Preparation of Tender

Documents and Assistance for Vendor Selection
1
[ %] of the Lump Sum Price

Document Number
LII-GETS12021-G-00129-007
Initial Advance on
Performance
Security,
Additional
Advance
Payment
Security
by
[Submission of Draft Tender Documents
for RM Package-1]
[Issue of RFP for R&M Package-1]
[Completion of Techno-Commercial Bid
Evaluation for R&M Package-1]
[Formation of Contract for R&M
Package-1]
[Submission of Draft Tender Documents
for RM Package-2]
[Issue of RFP for R&M Package-2]
[Completion of Techno-Commercial Bid
Evaluation for R&M Package-2]
Rev No
Description
01

Consultant

[8]
25.09.2014

.
.
.
.
.
VIII.
[Formation of Contract for R&M

Package-2]
..
..
..
..
..
Owners
Acceptance
that
the
Terms of Payment for Price of any additional Work/Service

1
IX.
NOT USED
X.
Terms of Payment for Taxes & Duties
Initial Advance on
Performance
Security,
Additional
Advance
Payment
Security
by
Owners
Acceptance
that
the
Any Tax or Duty payable by Employer as per the Terms & Conditions of
Contract and is directly payable to Statutory Authorities/Government as per law
shall be directly paid to the concerned authority or Government by the
Employer. Any other Tax or Duty payable by Employer to the Contractor as per
the Terms & Conditions of Contract shall be reimbursed on production of
evidence of payment by Contractor.
Document Number
LII-GETS12021-G-00129-007
Rev No
Description
01

Consultant

[9]
25.09.2014
XI.
Terms of Payment for Statutory Variation in Taxes & Duties

Any amount towards statutory variation in Taxes & Duties payable by Employer
as per the Terms & Conditions of Contract shall be reimbursed to the Contractor
upon submission of evidence by the Contractor to the Employer as to the
Contractor having paid such variation.
Document Number
LII-GETS12021-G-00129-007
Rev No
Description
01

Consultant

[10]
25.09.2014
Contract Schedule-2
NOT USED
Document Number
LII-GETS12021-G-00129-007
Rev No
Description
01

Consultant

[11]
25.09.2014
Contract Schedule-3
TIME SCHEDULE
[Detailed Time Schedule agreed between Employer and Contractor shall be placed]
Document Number
LII-GETS12021-G-00129-007
Rev No
Description
01

Consultant

[12]
25.09.2014
Contract Schedule-4
LIST OF SUB-CONSULTANTS
[List of approved subcontractors shall be placed]
Document Number
LII-GETS12021-G-00129-007
Rev No
Description
01

Consultant

[13]
25.09.2014
Contract Schedule-5
LIST OF KEY PERSONNEL
Document Number
LII-GETS12021-G-00129-007
Rev No
Description
01

Consultant

[14]
25.09.2014
Tender Document for Selection of R&M Consultant for Unit No. [..] Capacity [Logo of Utility]
ANNEXURE - G
CONTRACT PERFORMANCE BANK GUARANTEE FORMAT
[To be furnished by Consultant]
[Bank Guarantee shall be executed on non-judicial stamp paper of appropriate value]
Place:
Bank Guarantee No:
Date:
To:
[Name & Address of Owner (Utility)
..
]
Dear Sirs,
1
In consideration of the [........................................] hereinafter referred to as the

OWNER, which expression shall, unless repugnant to the context or meaning, thereof
include its successors, representative and assignees, having awarded in favour of
M/s.[Consultants Name] having its
registered
office
at..hereinafter
referred to as the CONSULTANT, which expression shall, unless repugnant to the
context or meaning thereof include its successors, administrators, representatives and
assignees, a Contract, hereinafter referred to as the "CONTRACT" for
theon terms and conditions set out interalia, in the
OWNER's
Contract/Letter
of
Award
No..datedas
well
as
CONTRACT documents, valued at [amount in words], [amount in figures] and the
same having been unequivocally accepted by the CONSULTANT and the
CONSULTANT having agreed to provide a Contract Performance Guarantee for the
faithful performance of the entire CONTRACT under the CONTRACT equivalent to 5%
(five percent) of the said value of the CONTRACT to OWNER amounting to
Rs(Rupeesonly) as Contract
Security in the form of a Bank Guarantee.
We,.[Name & Address of Bank]

and having its Head Office at., hereinafter referred to
as the Bank which expression shall, unless repugnant to the context or meaning
thereof, include its successors, administrators, representatives and assignees do
hereby irrevocably guarantee and undertake to pay the OWNER merely on demand
without any previous notice and without any demur and without referring to any other
source, any and all monies payable by the CONSULTANT by reason of any breach of
the said CONSULTANT of any of the terms and conditions of the said CONTRACT
including non-execution of the CONTRACT AGREEMENT, to the extent of
..(%).
of
the
Contract
price
to
OWNER
amounting
to
Document Number
LII-GETS12021-G-00129-007
Rev No
Description
01

Consultant

[1]
25.09.2014
8
9
Rs(Rupees.only).
Any
such demand made by the OWNER on the Bank shall be conclusive and binding,
absolute and unequivocal notwithstanding any difference between the OWNER and
CONSULTANT or any dispute or disputes raised/ pending before any Court, Tribunal,
Arbitrator or any other authority. The Bank agrees that the guarantee herein contained
shall continue to be enforceable till this sum due to the OWNER is fully paid and claims
satisfied or till the OWNER discharges this Guarantee.
The OWNER shall have the fullest liberty without affecting in any way the liability of
the Bank under this guarantee, from time to time, to extend the time of Performance
by the CONSULTANT. The Bank shall not be released from its liabilities under these
presents by any exercise of the OWNER of the liberty with reference to the matter
aforesaid.
The OWNER shall have the fullest liberty, without affecting this guarantee to postpone
from time to time the exercise of any powers vested in them or of any right which they
might have against the CONSULTANT and to exercise the same at any time in any
manner, and either to enforce or to forbear to enforce any covenants, contained or
implied in the CONTRACT between OWNER and the CONSULTANT or any other
course or remedy or security available to the OWNER and the Bank shall not be
released of its obligations/liabilities under these presents by any exercise by the
OWNER of his liberty with reference to the matters aforesaid or any of them or by
reasons of any other act or forbearance or other acts of omission or commission on the
part of the OWNER or any other indulgence shown by the OWNER or by any other
matter or thing whatsoever which under law would, but for this provision, have the
effect of relieving the Bank Guarantee. The Bank further undertakes not to revoke this
guarantee during its currency without the previous consent of the OWNER.
The Bank further agrees that the decision of the OWNER as to the failure on the part of
the CONSULTANT to fulfill their obligations as aforesaid and/or as to the amount
payable by the Bank to the OWNER hereunder shall be final, conclusive and binding on
the Bank.
The OWNER shall have the fullest liberty to lodge their claim for encashment of the
guaranteed sum either in full or part, in the manner suitable to them. However,
payment made for a sum lesser than the guaranteed amount shall not relieve or
discharge the bank from their obligations guaranteed under the bank guarantee, till the
contractual obligations are fully performed by the Consultant or the Bank Guarantee is
discharged by the OWNER, as the case may be and the Bank Guarantee shall continue
to be in force till such time.
The Bank also agrees that the OWNER shall be entitled at his option to enforce this
guarantee against the Bank as a Principal Debtor, in the first instance notwithstanding
any other security or guarantee that it may have in relation to the CONSULTANT's
liabilities.
This guarantee will not be discharged due to the change in the constitution of the Bank
or the CONSULTANT(S).
Notwithstanding anything contained hereinabove, our liability under this guarantee is
restricted to Rs (Rupees) and
it will remain in force upto and including and shall be extended
Document Number
LII-GETS12021-G-00129-007
Rev No
Description
01

Consultant

[2]
25.09.2014
from time to time for such period as may be desired by [Name

Consultant] on whose behalf this guarantee has been given.
10
Signed atthis..day of..20...
Signature
Name
Designation
Staff Code No
Date
of
Bank Seal
Witness:
1.
2.
Signature
Occupation
Address
Signature
Occupation
Address
:
*****
Document Number
LII-GETS12021-G-00129-007
Rev No
Description
01

Consultant

[3]
25.09.2014

OF

R&M CONSULTANT
SECTION-II TERMS OF REFERENCE
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-007 R01
September 2014
[Logo of Utility]

R&M CONSULTANT

OF
Document Number
LII-GETS12021-G-00129-007
Rev No
01
Description
Consultant
Section-II

[i]
25.9.2014
[Logo of Utility]
TABLE OF CONTENTS
1
GENERAL ................................................................................................... 1
1.1
Project Background ................................................................................ 1
ROLE OF R&M CONSULTANT ........................................................................ 2
SCOPE OF SERVICES ................................................................................... 3

3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
Data Collection...................................................................................... 3
Studies to be carried out:........................................................................ 3
Working out of R&M Options: ................................................................. 4
Cost Benefit Analysis: ............................................................................ 4
Obtaining necessary approval: ................................................................. 4
Selection of R&M Contractor: .................................................................. 4
Schedule For Completion Of Task: ........................................................... 4
Final outputs required of the Consultant: ................................................... 5
FACILITIES TO BE PROVIDED BY THE CLIENT: ................................................ 6
KEY PROFESSIONAL POSITIONS WHOSE CV WOULD BE EVALUATED: .............. 7
Document Number
LII-GETS12021-G-00129-007
Rev No
01
Description
Consultant
Section-II

[ii]
25.9.2014
[Logo of Utility]
GENERAL
{Briefly explain the need and objective of R&M, give reference of the studies carried
out to assess the health of the unit and the progress made till date for the
implementation of R&M}
1.1
Project Background
{Give brief description of the unit and the latest performance parameters in terms of
Average Load during the year, PLF, Availability Auxiliary Power Consumption, Heat
Rate and the average Calorific Value of Coal being presently used in the Boiler.}.
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-II
Page No.
- 1-
Date of Issue
25.9.2014
[Logo of Utility]
ROLE OF R&M CONSULTANT

Role of R&M Consultant shall be as follows:a. To assess the health condition of major systems; equipments and their components.
b. To assess the causes of deterioration in performance and efficiency of the
equipments/systems.
c. To provide solutions for removing the deficiencies in performance and efficiency along
with cost impact.
d. To work out R&M options for improving the performance, output rating, extending the
life of the plant and reducing the levels of emission from the unit.
e. To carry out cost benefit analysis of various options and recommend the most attractive
option for deciding the scope of work for R&M.
f.
To obtain necessary approvals from the concerned Regulatory Commission.
g. Basic Design & Engineering and Preparation of Tender Documents.

h. Support for Vendor Selection (up to placement of Letter of Award).
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-II
Page No.
- 2-
Date of Issue
25.9.2014
[Logo of Utility]
SCOPE OF SERVICES
The detailed scope of services shall be as described below:
3.1
Data Collection
To collect the following data/information from the Employer:
i)
Operation data for the current year and the previous years.
ii) Details of forced outages during the current and the previous years.
iii) Information about the replacements / refurbishments done during the previous years.
iv) Earlier reports of RLC/CA studies and Energy Audit Studies carried out, if any.
v) Coal quality (along with its analysis) to be considered for redesign.
vi) Any other information needed by R&M Consultant like original design specifications and
drawings.
3.2
Studies to be carried out:

The R&M Consultant shall carry out the following studies through his team of experts:i)
Cold walk down survey of the plant covering all major systems/equipments.
ii)
Hot walk down survey of plant covering all major systems/equipments.
iii)
Residual Life Assessment / Condition Assessment of all applicable

systems/equipments, including but not limited to the carrying out of following
tests/studies:
a) Visual examinations
b) Fiberscopic /Boroscopic Inspections
c) Dye Penetration Tests
d) Magnetic Particle Inspection
e) Ultrasonic scanning
f)
Ultrasonic thickness testing
g) Oxide Scale Thickness Measurements

h) In-situ Microstructure Replica Analysis
i)
j)
Dimensional Measurement
k) Steam Path Audit

l)
ELCID Test
m) Recurrent Surge Oscilliograph (RSO) Test

n) Tan Delta Test
o) Destructive Tests to check the mechanical properties like tensile strength, yield
strength, elongation etc.
iv)
Energy Audit:
R&M Consultant shall carry out the Energy Audit / Performance Tests of all major
equipments/systems, including but not limited to the following:
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-II
Page No.
- 3-
Date of Issue
25.9.2014
[Logo of Utility]
a) Boiler Efficiency Test.

b) Performance Test and Energy Audit of Air Pre-heaters.
c) Performance Test and Energy Audit of Mills.
d) Performance Test and Energy Audit of ID Fans, FD Fans and PA Fans.
e) Performance Test of ESP.
f)
Performance Test for determining the Heat Rate of Turbine Generator.
g) Performance Test of Condensers.

h) Performance Test of LP/HP Feed Water Heaters.
i)
Performance Test and Energy Audit of CEPs/BFPs
j)
Performance Testing and Energy Audit of Water Intake Pumps, CW Pumps, RW

Supply Pumps, Clarified Water Supply Pumps, DM Water Supply Pumps and Ash
slurry Pumps.
k) Cooling Tower Performance Test.

l)
Performance Test and Energy Audit of Compressed Air System.
m) Performance Test and Energy Audit of Air Conditioning System.

n) Energy Audit of Thermal Insulation.
o) Energy Audit of Illumination System.
p) Any other system considered important by the Utility.
3.3
Working out of R&M Options:

Working out of R&M options for the unit considering the following:
3.4
i)
Improving the Performance Parameters.
ii)
Increasing the Efficiency of equipments/systems.
iii)
Reducing the level of emissions so as to comply with the statutory norms.
iv)
Increasing the output from the unit.
v)
Extending the life of the unit by 20/25 years.

Carrying out the cost benefit analysis of various options and arriving at the most attractive
solution for the R&M of the unit.
3.5
Obtaining necessary approval:

The Consultant shall assist the Employer in obtaining necessary approval of the concerned
Regulatory Commission.
3.6
Selection of R&M Contractor:

The Consultant will prepare RFQ & RFP for the selection of R&M Contractor. After the
receipt of the Bids, the Consultant will prepare the Bid Evaluation Report.
3.7
Schedule For Completion Of Task:

The Contract will be implemented in accordance with the services indicated. The Consultant
shall prepare and submit well in advance the complete schedule of completion of work and
the schedule of manpower to be deployed.
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-II
Page No.
- 4-
Date of Issue
25.9.2014
[Logo of Utility]
3.8
Final outputs required of the Consultant:

The following outputs are required from the Consultant:
1. Inception report within 30 days of date of effectiveness.
2. Residual Life Assessment / Condition Assessment Report.
3. Energy Audit Report.
4. Feasibility Report indicating various R&M options and their cost impact as well as
selection of R&M option to be implemented.
5. Detailed Project Report.
6. RFQ & RFP for the R&M Contractor.
7. Technical Bid Evaluation Report for the selection of R&M Contractor.
8. Monthly Progress Reports.
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-II
Page No.
- 5-
Date of Issue
25.9.2014
[Logo of Utility]
FACILITIES TO BE PROVIDED BY THE CLIENT:

Facilities which will be provided to the Consultant by the Client will include the following: A. Facility for the visiting Consultant:
-
Lodging in Business Class Hotel or equivalent accommodation.
Local conveyance.
B. Facility for the manpower posted at site:

-
The accommodation will be provided either in the plant colony or in the guest house.
The available Canteen / Mess facility.
Temporary office space with intercom phone connected to PBX. (Outside /

International calls on chargeable basis.)
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-II
Page No.
- 6-
Date of Issue
25.9.2014
[Logo of Utility]
KEY PROFESSIONAL POSITIONS WHOSE CV WOULD BE EVALUATED:

S.
No.
Key Position
Team Leader
Boiler Expert
Design- Engineering /
Production, Project
planning Erection and
Commissioning
Turbine Expert
Production, Project
Commissioning
4.
Mechanical BoP
Expert
Production, Project
Commissioning.
Electrical Expert
Production, Project
Commissioning
Control and
Instrumentation
Expert
DCS Installation and

Commissioning
Document Number
LII-GETS12021-G-00129-007
Area of Specific Expertise

desired
Overall Management
Team of R&M Consultant
Rev No.
01
Minimum Qualification and Professional

Experience Desired
Graduate Engineer with minimum 15
years relevant experience of Boiler /
Turbine
design/erection/commissioning
preferably of 200 MW or above
capacity. Good knowledge of project &
safety aspects. The proposed individual
should also have direct experience of
handling an EPC Project of coal fired
thermal power plant of 200 MW or
above capacity.
Graduate Mechanical Engineer with at
least 5-10 years experience in the
relevant
fields,
including
direct
experience of Boiler design/ erection
/commissioning preferably of 200 MW or
above capacity. Should have knowledge
of relevant International and National
testing code.
least 5- 10 years experience in the
relevant
fields,
including
direct
experience of Turbine design/ erection/
commissioning preferably of 200 MW or
testing code.
relevant
fields,
including
direct
experience of Mechanical BoP of 200
MW or above capacity. Should have
knowledge of relevant International and
National testing code.
Graduate Electrical Engineer in Electrical
Systems with at least 5-10 years
experience in the relevant fields,
including direct experience of design
/erection/commissioning of Electrical
Equipment /systems preferably of 200
Graduate Instrumentation Engineer with
at least 5-10 years experience in the
relevant
fields.
Including
direct
experience
of
design/
erection/
commissioning of electrical systems
preferably of 200 MW or above
capacity.
Description
Consultant
Section-II
Page No.
- 7-
Date of Issue
25.9.2014
[Logo of Utility]
S.
No.
Key Position
Civil Expert
Area of Specific Expertise

desired
Design- Engineering/
Construction of Civil and
Structural works.

Experience Desired
Graduate Civil Engineer with at least 510 years experience in the relevant
fields, including direct experience of
Construction of Civil and Structural
works of 200 MW or above capacity.
Should have knowledge of relevant
International and National testing code.
Note:
After award of the contact the client expects all the proposed key personnel to be available
during implementation of the contract as per the agreed staffing schedule at the time of
negotiation. The Utility expects that Consultant will keep experts same throughout the
contract period. If any replacement is required, the Consultant should ensure that there is a
reasonable overlap between the staff to be replaced, wherever feasible/possible.
Document Number
LII-GETS12021-G-00129-007
Rev No.
01
Description
Consultant
Section-II
Page No.
- 8-
Date of Issue
25.9.2014

OF

IMPLEMENTATION SUPPORT CONSULTANT FOR
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-008 R01
September2014
Tender Document for Selection of Implementation Support Consultant for

[Logo of Utility]
R&M of Unit No. [..] Capacity [..] of [Name of the Power Plant]
INDEX
Section
Description
Section-I
Commercial
Section-II
Terms of Reference
Document Number
LII-GETS12021-G-00129-008
Rev No
01
Description
Tender Document for Selection of Implementation
Support Consultant
Section-I

[i]
25.09.2014

[Logo of Utility]
SECTION-I: COMMERCIAL
1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
*****
Document Number
LII-GETS12021-G-00129-008
Rev No
01
Description
Support Consultant
Section-I

[ii]
25.09.2014

[Logo of Utility]

IMPLEMENTATION SUPPORT CONSULTANT FOR

OF
SECTION-I
Document Number
LII-GETS12021-G-00129-008
Rev No
01
Description
Support Consultant
Section-I

[iii]
25.09.2014

[Logo of Utility]
TABLE OF CONTENTS
1.0 INVITATION FOR BID ................................................................................... 1
1.1
1.2
1.3
1.4
1.5
1.6
2
Introduction .......................................................................................... 1
Invitation .............................................................................................. 1
Tender Details ....................................................................................... 1
Time Schedule ...................................................................................... 2
Bid Submission...................................................................................... 2
INSTRUCTIONS TO BIDDERS......................................................................... 3
2.1 Introduction .......................................................................................... 3
2.2 Address and Contact Details of Emloyer .................................................... 3
2.3 General Project Information ..................................................................... 3
2.4 Cost of Bidding ..................................................................................... 3
2.5 Non-Transferability of Bid document ......................................................... 3
2.6 Scope of Work & Single Bidder Responsibility ............................................ 3
2.7 Time Schedule ...................................................................................... 3
2.8 Tender Documents ................................................................................ 3
2.9 Preparation of Bids ................................................................................ 4
2.9.1 Language of Bid ............................................................................... 4
2.9.2 Bidding Procedure ............................................................................ 5
2.9.3 Bid Submission ................................................................................ 5
2.9.4 Bid Guarantee .................................................................................. 6
2.9.5 Bid Opening ..................................................................................... 7
2.10 Composition of Techno Commercial Bid (Part-I Bid) ..................................... 7
2.11 Composition of Price Bid (Part-II Bid) ........................................................ 8
2.12 Bid Prices ............................................................................................. 8
2.13 Signature of Bids ................................................................................... 9
2.14 Clarifications/Corrigendum/ Amendment of Tender Specifications ................. 9
2.15 Modification of Bids ............................................................................... 9
2.16 Policy of Bids under Consideration ........................................................... 9
2.17 Validity of Bid ....................................................................................... 9
2.18 Understanding & Clarification on Documents & Specifications .................... 10
2.19 Latest Hour for Receipt of Bids .............................................................. 10
2.20 No Claim for Compensation for Submission of Bid .................................... 10
2.21 Evaluation of Bid ................................................................................. 11
2.21.1 Evaluation of Technical Proposal .................................................... 11
2.21.2 Evaluation of Price Bid .................................................................. 12
2.21.3 Composite Score ......................................................................... 12
2.21.4 Other Evaluation Conditions .......................................................... 13
2.22 Deviations .......................................................................................... 13
2.23 Blacklisting/Debarring ........................................................................... 14
2.24 Award of Contract ............................................................................... 14
Document Number
LII-GETS12021-G-00129-008
Rev No
01
Description
Support Consultant
Section-I

[iv]
25.09.2014

[Logo of Utility]
2.25 Contract Performance Bank Guarantee (CPG) ........................................... 15

2.26 Vital Clauses....................................................................................... 15
3
GENERAL PROJECT INFORMATION .............................................................. 16

3.1
Project & Site Information ..................................................................... 16
GENERAL CONDITIONS OF CONTRACT (GCC) ............................................... 17

4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.27
4.28
4.29
4.30
4.31
4.32
4.33
4.34
4.35
4.36
4.37
Definitions .......................................................................................... 17
Contract Documents ............................................................................ 20
Order of Precedence of Contract Documents ........................................... 20
Interpretation ...................................................................................... 20
Independent Consultant ........................................................................ 20
Non-Waiver ........................................................................................ 20
Severability......................................................................................... 21
Origin ................................................................................................ 21
Notices .............................................................................................. 21
Governing Laws .................................................................................. 21
Settlement of Disputes ......................................................................... 21
Scope of Services ............................................................................... 22
Consultants Responsibilities ................................................................. 23
Employers Responsibilities ................................................................... 23
Taxes & Duties ................................................................................... 24
Intellectual Property ............................................................................. 24
Confidential Information ....................................................................... 24
Conflict of Interest............................................................................... 25
Representatives ................................................................................... 25
Work Program ..................................................................................... 26
Substitution of Key Personnel ................................................................ 27
Sub-Consultant ................................................................................... 27
Completion Time ................................................................................. 28
Patents Indemnity ................................................................................ 28
Accuracy of Data and Document ........................................................... 28
Liability of Implementation Support Consultant ......................................... 28
Equipment and Material provided by the Employer .................................... 29
Loss of or Damage to Property; Accident or Injury; Indemnification ............. 29
Insurance ........................................................................................... 29
Employers Prior Approval ..................................................................... 30
Employership of Documents Prepared by Consultant ................................. 30
Change in Laws & Regulation ................................................................ 31
Force majeure ..................................................................................... 31
Change in the Scope of Services ............................................................ 32
Extension of Time for Completion .......................................................... 32
Termination ........................................................................................ 32
Document Number
LII-GETS12021-G-00129-008
Rev No
01
Description
Support Consultant
Section-I

[v]
25.09.2014

[Logo of Utility]
4.38 Assignment ........................................................................................ 36

5
SPECIAL CONDITIONS OF CONTRACT (SCC) ................................................ 37

5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
Contract Details .................................................................................. 37

Effective Date ..................................................................................... 37
NOT USED ......................................................................................... 38
NOT USED ......................................................................................... 38
NOT USED ......................................................................................... 38
Contract Price ..................................................................................... 38
Terms of Payment ............................................................................... 38
Contract Securities .............................................................................. 38
FORMS AND SCHEDULES ........................................................................... 40
Document Number
LII-GETS12021-G-00129-008
Rev No
01
Description
Support Consultant
Section-I

[vi]
25.09.2014

[Logo of Utility]
1.0
INVITATION FOR BID

Tender No
1.1
[ ---------------------------------------------------------------------------]
Introduction
{Give brief introduction about the name, ownership, business & Power Projects of
the utility inviting bid proposal for Implementation Support Consultancy Service}
1.2
Invitation
[Name of The Utility], hereinafter referred to as Employer / Owner / Purchaser, is
planning to undertake Renovation & Modernization of Unit No.[XX] of the [XXX]
Power Plant and desires to appoint a Implementation Support Consultant for the
same. [Name of The Utility], invites sealed Bid Proposals in English language from
Prequalified Applicants for the Implementation Support Consultancy Services for
Renovation & Modernization of Unit No.[XX] of the [XXX] Power Plant as per
scope of work given in Section-II Terms of Reference.
1.3
Brief Scope of Work

Scope of work of the Implementation Support Consultant will include: To provide support to [Name of the Utility] during detailed engineering,
supply, implementation and commissioning of R&M works.
To review the detailed engineering drawings/design calculations,
schedule planned for execution and commissioning of all the works in
line with the broad parameters of accepted design.
Preparation of work schedules and monitoring the progress of R&M
works through close involvement with the Contractors and other
agencies on behalf of Employer.
Assistance to Employer in decisions making and in taking timely actions
to ensure schedule adherence during the tenure of R&M project.
To flag critical problems as and when arises during the tenure of R&M
project to Employer and suggest suitable remedial measures to control
the situation.
To provide assistance to the Employer in addressing any techno commercial /
contractual and regulatory issues as and when these may arise during the course
of the R&M project.The detailed scope of work is given in Terms of Reference
Section-II.
1.4
Tender Details
(a)
Cost of Tender
Documents
: INR [---]
(b)
: INR [---]
(c)
Date of issuance of
Tender Document
: [----------------------------]
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Tender Document for Selection of
Implementation Support Consultant
Section-I
Page No.
- 1-
Date of Issue
25.09.2014

[Logo of Utility]
1.5
(d)

Conference
: [----------------------------]
(e)
Last Date & Time of

Part I & Part II)
: [----------------------------]
(f)
Date & Time of

Opening of Unpriced
Techno-Commercial Bid
(Part-I)
: [----------------------------]
Time Schedule
The time schedule for completion of Consultancy Services shall be as per SCC.
1.6
Bid Submission
(b) The Bid proposals are to be submitted in two parts in separate sealed covers
as follows:
Part I
: Bid Guarantee and Technical & Commercial Proposal without

prices
Part II
: Price Schedule.
(c) All other terms and conditions along with the Terms of Reference, General
Guarantee details, Validity of Bid and Instructions to Bidders, etc. are
contained in the Tender Documents.
(d) Bidder shall submit the bid on or before the scheduled date and time as
specified. Any offer received after the expiry of the time specified for
receiving the completed bids are liable for rejection. The bid shall be
submitted to:
------------------------------------------------------------- ]
(e) Issuance of Tender Documents to a Bidder shall not be construed to mean
that such Bidder would be automatically considered.
(f) The Bid Prices must be quoted in Indian Rupees. All payments for the entire
scope will be made in Indian Rupees.
(h) The Tender Documents are meant for the exclusive purpose of bidding
against the subject Consultancy Services tender and shall not be transferred,
reproduced or otherwise used for purposes other than for which these are
specifically issued.
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
- 2-
Date of Issue
25.09.2014

[Logo of Utility]
2.1
Introduction
[Name of Utility], the Employer, intends to carry out the Renovation &
Modernization of [Unit no.-XX --------- of the XXXX Power Plant]. [Name of The
Utility] desires to appoint a Implementation Support Consultant.
Under the subject Tender, [Utility] invites bid for Implementation Support
Consultancy Services to be carried out as per the accompanying Terms of
Reference. The Bidder shall submit the offer for complete scope of work indicated
in the Terms of Reference.
2.2
Address and Contact Details of Emloyer

---------------------------------------------------------------------------------------------------------------------------]
2.3

2.4
Cost of Bidding
The Bidder shall bear all costs associated with the preparation and submission of
its bid, and the Employer will in no case be responsible or liable for these costs,
regardless of the conduct or outcome of the bidding process.
2.5

Transfer of Bid documents issued to one intending bidder to another is not
permissible.
2.6

The scope of the work shall be on the basis of single Bidder responsibility,
covering the complete scope of work specified under these specifications and
documents.
2.7
Time Schedule
The completion Time Schedule for Completion of Implementation Support
Consultancy Services shall be as given in the SCC.
2.8
Tender Documents
The scope of contract, terms of reference, bidding procedures and contract terms
are prescribed in the Tender Documents. The Tender Documents comprise, inter
alia, the following Sections:
Section I
Commercial Conditions
Invitation for Bid
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
- 3-
Date of Issue
25.09.2014

[Logo of Utility]
Section I, Cahpter-6
Forms & Schedules
Section II
Terms of Reference
The Bidder is expected to examine all instructions, forms, terms and specifications
in the Tender Documents including clarifications/corrigendum/amendments for
completeness and obtain clarifications, if any, from the Employer.
Failure to furnish all information required as per the bidding documents or
submission of a bid not substantially responsive to the bidding documents in every
respect will be at the Bidder's risk and may result in rejection of its bid.
A prospective Bidder requiring any clarification to the Tender Documents may
notify the Employer in writing by post or by e-mail followed by postal confirmation
at the Employer's address indicated in ITB. The Employer will respond in writing
by post or by e-mail followed by post confirmation to any request for clarification
or modification of the bidding documents that it receives not later than fifteen (15)
days prior to the deadline for submission of bids prescribed by the Employer.
Employer's response will be sent to all prospective Bidders that have been issued
the Bidding Documents.
information that may be necessary for preparing the bid. The Employer will
facilitate the bidder to collect such information about the plant in the manner that
does not interface with plant operation and does not in any way adversely impact
the interest of the Employer. The costs of visiting the site including engaging any
third party consultant by Bidder, if required as per the assessment of Bidder, shall
be borne by the bidder fully.
personnel and agents from and against all liability during such information
collection and will be responsible for death or personal injury, loss of or damage to
property and any other loss, damage, costs and expenses incurred as a result of
the inspection.
At any time prior to the deadline for submission of bids, the Employer may, for
any reason, whether at its own initiative, or in response to a clarification
requested by a prospective Bidder, amend the Tender Documents.
confirmation to all prospective Bidders that have received the bidding documents
and will be binding on them.
At any time prior to the deadline for submission of bids, the Owner, at its
discretion may extend the deadline for submission of the bids.
2.9
Preparation of Bids
2.9.1
Language of Bid
The bid prepared by the Bidder and all correspondence and documents related to
the bid shall be in English language, provided that any printed literature furnished
by the Bidder may be written in another language, as long as such literature is
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
- 4-
Date of Issue
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[Logo of Utility]
accompanied by a translation of its pertinent passages in English language in

which case, for purposes of interpretation of the bid, the translation shall govern.
2.9.2
Bidding Procedure
The bidders are required to submit, the bids for the Implementation Support
Consultancy Services in two parts. Both the parts are to be submitted together
before the indicated Bid submission Time & Dates.
Details of Key Personnel along with their Curriculum Vitae, Deviations to Terms
of Reference, Deviation to commercial Conditions, Overall Completion Time Period
& Network Schedule, Resource Deployment Schedule, Detail of Sub-Consultants,
Details of the present commitments & details of contracts in hand etc. Part-II Bid
will comprise Quoted Price. Initially, only the Part-I Bid will be opened and Part-II
Bid will be kept in safe custody.
The Part-I Bid will be checked for responsiveness to techno-commercial conditions
and a detailed Technical Evaluation will be carried out to assign a Technical Score
to each Bid. Part-II Bid (Price Bid) of only those Bidders will be opened, whose
Part-I Bid is found to be responsive to Tender Specifications and Conditions and
Technical Score is above a specified level.
2.9.3
Bid Submission
(1). Bid proposals shall be accepted from only those eligible bidders who are
found qualified during the pre-qualification process & are issued Tender
Documents. Unsolicited bids shall not be taken into cognizance.
separate sealed covers, with all pages serially numbered.
(3). [One original and 3 (three) identical] copies of the original with all enclosures
shall be submitted by each Bidder for Part-I and Part-II, clearly indicating the
original and the number of the copy (i.e., Original, Copy No. 1, Copy
No. 2 and Copy No. 3).
(4). In the event of discrepancy between Original and any copy of the bids, the
hard copy of Original shall prevail.
(5). All these covers shall be individually sealed and put in an outer cover which
also shall be sealed and super scribed as in other covers.
(6). The covers should be pasted properly before applying the wax seal. Failure to
do so may result in rejection of such bids.
(8). The Bid shall be submitted to [---------------------------]. Bid submitted to any
other office of Employer is liable for rejection. Bids submitted by Telefax or email will be rejected
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
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[Logo of Utility]
(9). Employer will receive Bids in respect of entire scope of work as set forth in
the accompanying Terms of Reference. All bids shall be prepared and
submitted in accordance with the Tender Documents.
(10). Failure to furnish all information required in the Tender Documents or
submission of a Bid not substantially responsive to the Tender Conditions and
Terms of Reference in every respect or bids received in incomplete shape
shall be liable for rejection. A bid shall be determined as substantially
responsive in every respect, if it conforms to all the terms, conditions and
specifications specified in Tender Documents without material deviations,
objections, conditionality or reservations.
(i). That affects in any substantial way the scope, quality or performance of
the contract;
(ii). That limits in any substantial way, inconsistent with the Tender
Documents, the Employers rights or the successful Bidders obligations
under the contract.
Tender Documents, the Bidder has to make independent inquiries and
generally obtain his own information on all matters that may in any way
affect prices, risks and obligations of the Contractor under the Contract.
2.9.4
Bid Guarantee
(Part-I) or Demand Draft of equivalent amount drawn in favour of [-------------] payable at [--------].
authorized by Reserve Bank of India,, to issue such Bank Guarantee on a
non-judicial stamp paper of value not less than Rs. [---]/-.The stamp paper
shall be purchased in the name of the Bank. Foreign Bidders may submit the
Bank Guarantee from any bank in India as above or from any foreign bank
which is in the approved list of RBI.
a) The Bid Guarantee shall be executed only on behalf of the Bidder in
b) The Bid and other documents shall be submitted only by the Bidder in
Employer at ([--------------]). In the event of any deviation in this regard, the
decision of Employer as to whether the same could be accepted or not,
will be final and binding on the Bidder.
Guarantee upon request from the Employer.
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
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[Logo of Utility]
Guarantee or with short Bid Guarantee or Bid Guarantee in the form other
than that specified herein above or from banks not specified hereinabove will
be liable for rejection.
(6). Any Bid not accompanied by the Bid Guarantee shall be rejected and the
Bidder shall not be permitted to participate in the tender.
(7). The Bid Guarantee shall be forfeited if the Bidder withdraws / modifies /
changes / impairs / derogates the bid proposal on its own after the Bids are
opened or submits forged/bogus certificates or fails to accept the Letter of
Award issued by Employer or fails to submit Contract Performance Security
(Bank Guarantee).
(8). The Bid Guarantee of all unsuccessful Bidders shall be returned after
selection of the successful Bidder. The Bid Guarantee of the successful
Bidder shall be returned after furnishing of the Contract Performance Bank
Guarantee to the Employer and acceptance thereof.
2.9.5
Bid Opening
1.
2.
3.
2.10
This is a single stage two part tender. On the specified date and time of
opening, Part I Bid containing Bid Guarantee and Technical and Commercial
Proposal without Prices will be opened. At the time of opening of PartI of
the bids, the names of the bidders who submitted their bids shall be read out
and other such details as Employer, at its discretion, may consider
appropriate, shall be read out.
If the Bidder desires to be present at the time of opening of Part-I of bids, it
shall depute its representatives (not more than two persons) in time with due
Employer takes no responsibility for delays, loss or non-receipt of Bid
documents or any letters sent by post/courier either way and also reserve the
right to reject any Bid in part or full without assigning any reasons thereof.
Composition of Techno Commercial Bid (Part-I Bid)
This part shall, inter alia, include the following in the same order as listed
below. One original and 3 (three) identical copies shall be submitted.
(i).
Duly filled in "Form of Bid" (As per Annexure-B of this Section).
(ii).
(iii).
Power of Attorney/Authorization with the seal of the company in favour
of the person signing the Bid.
(iv). Signed copy of all the corrigendums/amendments/clarifications, if any
issued for the tender
(v).
Overall Time Schedule as per Schedule F2 and Bar chart/PERT Network
(vi). Deviations to the Commercial Conditions, if any, as per Schedule F3.
(vii). Deviations to Terms of Reference, if any, as per Schedule F4.
(viii). Methodology and Work Plan for completing different tasks under the
Consultancy Assignment. Bidder to indicate the scope of work to be
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
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[Logo of Utility]
covered with sufficient details regarding the tasks and subtasks to be

covered.
(ix). Details of Key Personnel as per Schedule F5. Bidder to indicate the
minimum number of hours each identified key person will spend on the
(x).
Curriculum Vitae of each key person as per Schedule-F6
(xi). Organization Structure and Team Composition (Both Professional Staff
and Support Staff)
(xii). Staffing Schedule describing month-wise deployment of personnel
(xiii). Details of the present commitments of the Bidder, details of contracts in
hand
(xiv). Details of Sub-Consultants, if any
In addition to the hard copy of Part-I Bid, the Bidder shall submit soft copy the Bid
in a compact disk (CD). However, hard copy alone will be considered as authentic
for evaluation.
2.11

The Bidders are requested to quote the Prices with break up as per Schedule-F1.
Price given in Part-II Bid should cover the entire scope of work as given in Part-I of
the offer. [One original and 3 (three) identical] copies shall be submitted.
1. The Price Bid shall contain the following :
(i). Duly filled in Form of bid as per Annexure-C
(ii). Completely filled in Schedule of Prices Schedule F1
2. The Bidder shall quote his price against each item of the schedules as
indicated in the enclosed format (Price Schedule). The Bidder shall quote the
prices only once after considering all the pros and cons, risks and
contingencies. Rebate percentage etc., if any, should be spelt out by the
Bidder in the first Bid itself.
3. The amount shall be quoted both in figures and words clearly and legibly. No
overwriting is allowed. All scoring and cancellations should be countersigned
by the Bidder. In case of illegibility, the interpretation of the Employer shall be
final. All entries shall be in English language only.
4. The Price shall be quoted in Indian Rupees only.
2.12
Bid Prices
Bidders shall quote for the entire scope of work on single responsibility basis &
the total bid price covers all the obligations of the Consultant mentioned in Tender
Documents/Terms of Reference or to be reasonably inferred from the Tender
Documents/Terms of Reference.
Bidders are required to quote the price for the entire commercial, contractual and
technical obligations outlined in the tender documents.
Prices quoted by the Bidder shall remain firm for the term of the contract.
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2.13
Signature of Bids
signature. The names of all persons signing should also be typed or printed below
the signature. Satisfactory evidences of authority of a person signing on behalf of
the Bidder shall be furnished with the Bid. Erasures or corrections in the Bid
documents if any shall be signed by the person signing the Bid. Printed literature,
it enclosed need not be signed. Bids not conforming to the above requirements are
liable to be treated as non-responsive.
2.14

1. At any time prior to the deadline for submission of Bids, the Employer may,
for any reason, whether at his own initiative or in response to clarification(s)
requested by a prospective Bidder, modify the Tender Documents including
the Terms of Reference by amendment.
2. Clarifications/Corrigendum/Amendment shall be construed to be an integral
part of the Tender Documents. Amendments will be hosted in Employers
website. Bidders are requested to visit Employers website and note
amendments, if any, before submission of bid. Employer shall not be
responsible if any bidder fails to notice any amendment.
2.15
The Bidder is not permitted to modify his Bid suo-moto after the Bid
submission.
2.16

Bids shall be deemed to be under consideration immediately after they are
opened. While the Bids are under consideration, Bidders and/or their
representatives or other interested parties are advised to refrain from contacting
by any means, the Employer and/or his employees/ representatives on matters
related to the Bids under consideration. The Employer, if necessary will obtain
clarifications on the Bids by requesting for such information from any or all the
Bidders, in writing as may be necessary.
2.17
Validity of Bid
1.
2.
3.
The Bid shall be kept valid for acceptance for [120 days] from the schedule
date of opening of the Part-I Bid.
The Bidder will not be permitted to change the substance of the Bid suomoto, after Bid has been opened.
Unilateral revision or withdrawal of offer by the Bidder within the subsistence
of the validity period of offer shall not be permitted. Violation of this
condition shall result in rejection of the Bid without notice, besides forfeiture
of Bid Guarantee. The Bidder shall also be debarred either permanently or for
a fixed period, at the discretion of Employer from participating in any of the
Employers tenders.
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2.18

1.
2.
3.
4.
5.
2.19
The Bidder is required to carefully examine the specifications and documents

and fully informs himself as to all the conditions and matters which may in
any way affect the Implementation Support Consultancy Services to be
rendered or the cost thereof. Bidders are free to visit the plant. However, the
Bidders visit to site shall be at their cost and risk, without any liability on
part of the Employer.
Bidders may seek clarifications to the prescribed clauses and / or different
part of the Tender Specifications. Such a request for clarifications, if any,
should reach the Employer at least [7 (seven) days] before the date
stipulated for pre-bid meeting. The Employer then will issue interpretations
and clarifications as it may think fit in during the pre-bid meeting. After preBid meeting, Bidder may seek further clarification till [14 days] prior to
schedule opening date of Part-I Bid. After receipt of such clarifications, the
Bidder may submit its Bid but within the time and date as specified in the
Invitation for Bid or as amended by the Employer. All such clarifications and
the relevant exchange of correspondence between the parties shall be
construed to form part of the tender specifications.
Pre-Bid Conference will be organized and outcome of the pre-bid conference
is binding on all the Bidders. Outcome of the Pre-Bid Conference will be
intimated by the Employer to all the Bidders.
A copy of such clarifications duly signed and stamped shall be enclosed with
the Bid (Part-I). In case any queries remain un-replied, it shall be construed
that in respect of those queries, the respective stipulations of the Tender
Specifications/Conditions shall continue to apply and/or no new stipulations
are made with respect to those queries.
No extension of time for submission of Bid will be granted on account of
Bidders request for interpretation/clarifications.

Bids must reach the designated Office of Employer not later than [------] Hrs, Indian
Invitation for Bid. Bids delivered / received after the time and date fixed for the
receipt of the bids shall be liable for rejection.
2.20

1.
2.
The submission of any Bid connected with these documents and

specifications shall constitute an agreement that the Bidder shall have no
cause of action or claim against the Employer for rejection of his Bid.
Regardless of the conduct or outcome of the bidding process, Bidder shall
not be entitled to claim any costs, charges and expenses incidental to or
incurred by him through or in connection with his submission of Bid or its
consideration by the Employer, even though the Employer may elect to
modify/withdraw the Invitation for Bid or does not accept the Bid(s).
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2.21
Evaluation of Bid
The selection of the successful Bidder for award of the Implementation Support
Consultancy Services Contract will be based on both Quality of the Technical
Proposal and Price quoted by the Bidder for the entire scope of work. The
selection process will comprise the following steps:
1. First, Techno-Commercial offer will be assessed for completeness
and responsiveness to commercial/contractual conditions. Only the
Bids that are determined to be complete in all respects and
responsive to commercial/contractual conditions will be taken up
for further evaluation on the basis of Quality and Price.
2. Technical Proposal of Bidders, whose Bid is determined to be
complete and responsive to commercial/contractual conditions, will
be evaluated on the basis of Bidders proposed methodology and Work
Plan for discharging the Consultancy Assignment, experience of the Bidder
and the experience & expertise of Key Personnel and will be assigned a
Technical Score St. Only those Bidders whose Technical Proposals get a
Technical Score of 70 marks or more out of 100 shall qualify for further
consideration. All the Bidders with Technical Score of 70 or more will be
considered for next stage of evaluation. It is not intended to short list a predetermined number of Bidders on the basis of evaluation of Technical
Proposal.
3. The Price Proposal of each Bidder with Technical Score of 70 or more will
be assigned a Financial Score (Sf) on the basis of its cost competitiveness.
highest Composite Score will be selected as Implementation Support
Consultant for the subject Implementation Support Consultancy Services
Contract.
2.21.1
Evaluation of Technical Proposal

The evaluation of Technical Proposal will have three elements as depicted in Table
below:
Sl
No
Parameter
Weightage
Basis of Evaluation
Methodology and Work

Plan (St-1)
20%
Bidders
understanding
of
Terms
of
Reference and clarity, completeness and
soundness of methodology and work plan to
achieve successful completion of the
objectives of the Implementation Support
Consultancy work. The Bidder with the best
submission will be assigned a score of 100
(St-1 = 100). Other Bidders will be assigned
scores below 100 considering the relative
quality of the submission with respect to the
best submission.
Bidders Experience (St)
40%
Each Bidder has to list up to 5 technical

consultancy projects, pertaining to thermal
power plants of unit size 200 MW or above,
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successfully executed by it during the last 10

years. Bidder has to furnish detailed scope of
work executed by it for each listed
consultancy project. Each such Project will
be assigned a score out of 20 on the basis of
size, nature & complexity of scope and
similarity with the subject R&M Consultancy
Service. If any Bidder lists less than 5
projects, a score of zero will be assigned for
the shortfall number of project(s). For each
Bidder, the sum of scores for the five
projects will be the score (St-2) out of 100.
3
Experience
Expertise
Personnel (St-3)
and
Key
40%
The Bidder has to list name and other details

of 10 key personnel of specified area of
expertise in Schedule-F5 who are likely to be
substantially
associated
with
this
Implementation
Support
Consultancy
assignment if the Bidder emerges as
successful Bidder for award of the
Implementation Support
Consultancy
Services Contract. The Bidder is required to
submit detailed Curriculum Vitae of these key
personnel as per the format at Schedule-.....
Each identified Key Person will be assigned a
score out of 10 based on their qualification
and nature & quantum of experience in the
specified area of expertise. For each Bidder,
the sum of scores of these 10 key personnel
will be the score (St-3) out of 100.
The Technical score of each Bidder will be equal to the weighted sum scores on
three elements with indicated weights.
St = 0.2 x St-1 + 0.4 x St-2 + 0.4 x St-3
2.21.2 Evaluation of Price Bid
The Price Bid should be complete, unconditional and unqualified. For financial
evaluation, the total Price indicated in the Price Schedule F1 excluding Service Tax
and associated surcharge & cess will be considered. The price indicated in the
Price Bid shall be deemed as final and reflecting the total Price of the entire scope
of services as per Terms of Reference. Failure by Bidder to include the price of any
item shall not entitle the firm to be compensated and the Consultant shall be liable
to fulfill its obligations as per the TOR. The Bidder with lowest quoted total price
will be assigned a Financial Score (Sf) of 100. The financial score of other Bidders
will computed as follows:
2.21.3 Composite Score
For selection of successful Bidder, the Technical Score will be a weight of 70%
and Financial Score will be given a weight of 30%. For each Bidder, the
Sc = 0.7 x St + 0.3 x Sf
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The Bidder who is determined to secure the highest Composite Score will be
selected for award of the Implementation Support Consultancy Contract.
2.21.4 Other Evaluation Conditions
(1) Arithmetical errors will be rectified on the following basis:
If there is any discrepancy between the unit price and the total price
that is obtained by multiplying the unit price and the quantity, the
unit price shall prevail and the total price will be corrected.
total prices, the sum of the total prices shall prevail and the total
Bid Price will be corrected.
If there is discrepancy between the rates in figures and in words,

the rates expressed in words shall only prevail and shall be adopted.
(2). Comparison of Bids will be between main Bids only. Alternative Bids will not
be accepted and evaluated.
no prices are envisaged for any of the entries, Nil shall be mentioned. In this
context Nil mentioned against any item shall construe that the Bidder shall
not charge any amount separately for that item from the Employer. If the
terms, such as not applicable ----- or blank are mentioned against any Sl.
2.22
Deviations
1.
2.
3.
Terms of Reference. Nevertheless, if the Bidder takes any deviation, it shall be
clearly indicated in the deviation schedule (Schedule [------] and Schedule- [-----] with a soft copy in MS-Word format in compact disc, with Original of
Part-I of the Bid). Deviation listed elsewhere in the Bid shall be summarily
rejected and ignored. Separate printed standard terms and conditions of the
Bidder shall not be taken into cognizance and shall be totally rejected.
No alterations or disfigurement, other than filling in particulars wherever
called for in the formats of the Tender Specifications shall be made in the Bid.
Any changes/modifications made by the Bidder in Bid documents itself shall
not be taken into consideration.
If at any later date, it is found that documents, information, averments and
data submitted by the bidder in the Bid, based on which the Bidder has been
considered eligible or successful or has been awarded the Contract is
incorrect or false to the extent that had the correct or true information been
made available to the Employer at time of tender evaluation, the Bid would
have been declared ineligible or unsuccessful, the Bidder shall be forthwith
disqualified or, as the case may be, the Contract awarded based on such
incorrect or false information shall be cancelled and the Bid Guarantee /
contract performance Guarantees deposited shall be appropriated by the
Employer towards Employers cost, loss and damage to Employer.
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2.23
debarred by the Employer.
2.24
Award of Contract
1.
2.
3.
4.
5.
Award Criteria
The Implementation Support Consultancy Service Contract will be awarded
to the Bidder with the highest Composite Score as described in clause 2.21.
Employer's Right to Accept Any Bid and to Reject Any or All Bids
The Employer reserves the right to accept or reject any bid, for any reasons
including National defense and security consideration and to annul the bidding
process and to reject all bids at any time prior to award of contract, without
thereby incurring any liability to the affected Bidder or bidders or any
obligation to inform the affected Bidder or bidders of the grounds for the
Employer's action.
Prior to the expiration of the period of bid validity, the Employer will notify the
successful Bidder in writing by registered letter or by email to be confirmed in
writing by registered letter, that its bid has been accepted. The notification of
award will constitute the formation of the contract.
Upon the successful Bidder's furnishing of the performance securities the
Employer will promptly notify each unsuccessful Bidder and will discharge its
bid security.
At the same time as the Employer notifies the successful Bidder that its bid
has been accepted, the Employer will send to the Bidder the Contract
Agreement provided in the bidding documents, incorporating all agreements
between the parties.
successful Bidder shall sign and date the Contract Agreement and return it to
the Employer.
Cost of preparing Contract Agreement shall be borne by the bidder.
Performance Security
Within [thirty (30) days] after receipt of the Notification of Award, the
successful Bidder shall furnish Contract Performance securities as per clause
no 2.25. These Bank Guarantees shall be furnished in the form provided in
the section "Forms and Procedures" of the bidding documents and shall be
initially valid upto [ninety (90)] days after the scheduled date of completion of
Implementation Support Consultancy Service.
Failure of the successful Bidder to submit Contract Performance Security
within stipulated time shall constitute sufficient grounds for the annulment of
the award and forfeiture of his bid security, in which event the Employer may
make the award to the next lowest evaluated Bidder or call for new bids.
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6.
2.25

The Employer requires that Bidders, Contractors and Consultants to observe
the highest standard of ethics during the Pre-Qualification, Tendering (Request
for Proposal) process and during the execution of the contracts. The Employer
may reject a Bid Proposal of a successful Bidder if it emerges that the Bidder
recommended for award has engaged in Corrupt or Fraudulent practices in
competing for the subject contract. The Employer may declare a Bidding firm
ineligible for participation in future tenders of the Employer, either indefinitely
or for a stated period of time, if it at any time it emerges that the firm has
engaged in Corrupt or Fraudulent practices in competing for or in executing a
contract of the Employer. Corrupt Practice means the offering, giving,
receiving or soliciting of anything of value to influence the tendering process
or contract execution. Fraudulent practice means a misrepresentation of facts
in order to influence a procurement process or the execution of a contract to
the detriment of the Employer and includes collusive practice among Bidders
designed to establish bid prices at artificial non-competitive levels and to
deprive the Employer of the benefits of free and open competition.
Contract Performance Bank Guarantee (CPG)

As a Contract security, the successful Bidder, to whom the work is awarded, shall
be required to furnish a Contract Performance Bank Guarantee (CPBG) in the
Format attached as Annexure- G, in favour of the Employer within 30 days from
the date of issue of Letter of Award (LOA). The guarantee amount shall be equal
to five percent (5%) of the Contract Price and it shall guarantee the faithful
performance of the Contract in accordance with the terms and conditions
specified in these documents and specifications. The CPG shall be valid till the
Schedule Completion Time Period for Consultancy Services plus ninety (90) days
grace period.
2.26
Vital Clauses
The following clauses in the Tender Specification & Draft Contract are vital.
Bidder is advised not to take deviations to these clauses. If deviations are
taken from the stipulations of these clauses, such Bids would be liable for
rejection:
Scope of Work
Time Schedule
Price Basis
Force Majeure
Arbitration
Taxes & Duties
Bid Guarantee
Patents, Indemnity
Validity of Bids
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3.1
Employer / Purchaser
[-------------------------------------------------]
Consultant
[-------------------------------------------------]
Project Title
[-------------------------------------------------]
Location
[-------------------------------------------------]
Latitude
[-------------------------------------------------]
Longitude
[-------------------------------------------------]
Elevation above MSL
[-------------------------------------------------]
[-------------------------------------------------]
Nearest Sea Port
[-------------------------------------------------]
Nearest Airport
[-------------------------------------------------]
Site
[-------------------------------------------------]
For Project & Site related detailed information, refer Terms of Reference Section-II.
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4.1
Definitions
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
"Applicable Laws" means the laws of any national, state, local or

municipal legislature in India, or of any other Competent Authority,
including all laws, acts, judgments, statutes, rules, regulations,
ordinances, orders, decrees, injunctions, governmental authorizations,
requirements of Applicable Permits and any agreements, decisions, acts,
instructions, requirements, directions and notifications of any competent
or other Competent Authority or court or tribunal or arbitrator having
jurisdiction over the matter in question, including those related to taxes,
assessments, expropriation and duties, or authoritative interpretation, as
amended, modified, enacted, reinterpreted or revised from time to time
hereafter.
Applicable Permits" means all permits, licenses, authorizations,
consents, decrees, waivers, privileges, acknowledgements, concessions,
approvals, rulings, decisions and visas from, filings with or applications
submitted to, any Competent Authority or court or tribunal of competent
jurisdiction necessary from time to time for or in relation to the
performance of the Services, including as detailed in this GCC.
"Agreement" means the Contract Agreement (entitled "Contract
Agreement") executed by the parties to which these Conditions are
annexed and also includes supplements & amendments to the Contract.
"Contract" means the Agreement entered into between Employer and
Consultant as per the 'Contract Agreement' signed by the parties,
including contract documents, all attachments and appendices thereto
and all documents incorporated by reference therein.
Contract Documents means the complete documents, which are the
basis of finalization of the contract, including correspondence exchanged
from issue of tender till date of signing the contract. All such documents
shall be listed in the Contract Agreement.
Consultants Equipment means all equipment, machinery, tools,
apparatus, appliances or things of every kind required in or for
discharging the Implementation Support Consultancy Services to be
brought to the site by the Consultant.
Consultant means the person(s), Firm or a Company whose bid to
perform the Implementation Support Consultancy Services Contract has
been accepted by the Employer and shall be named as such in the
Contract Agreement, and includes the legal successors or permitted
assigns of the Consultant.
Contract Price means any sum or sums finally accepted by the
Employer for the execution of this contract, subject to such additions and
adjustments thereto or deductions there from, as may be made pursuant
to the Contract.
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ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
xvii.
xviii.
xix.
xx.
xxi.
xxii.
Consultants Representative means any person nominated by the

Consultant & approved by the Employer hereof to perform the duties
delegated by the Consultant.
Completion means the completion of
Consultancy Services by the Consultant ( Implementation Support
Consultant) covering the entire Scope of Work as per the Terms of
Reference and submission of all the reports and other deliverables
incorporating Employers observation on the draft reports to the
satisfaction of the Employer .
Consultancy Services or Implementation Support Consultancy
Services means the entire services ancillary to the completion of entire
scope of work as per the Terms of Reference.
Effective Date means the date from which the Time for Completion of
Implementation SupportConsultancy Services and other milestones for
execution of the Implementation Support Consultancy Services as per the
scope of work under this tender by the Consultant shall be determined.
diligence and prudence which would reasonably and ordinarily be
expected from a skilled and experienced Consultant applying the
standards generally adopted by global Engineering/Technical , except in
so far as inconsistent with any applicable Indian law or directive.
issued by the Employer notifying the Consultant that its Bid Proposal has
been accepted.
Employers Acceptance means the Employer has accepted that the
Consultant ( Implementation SupportConsultant) has successfully
discharged the Implementation Support Consultancy Services covering
the entire scope of work as per the ToR adhering to industry standard and
Good Industry Practice and all the reports & other deliverables submitted
by the Consultant as part of the Implementation Support Consultancy
Services .
Employer or Purchaser or Employer shall means the [Name of the
Utility], and includes its legal successors or permitted assignees.
"Person" means any natural person, firm, corporation, company,
voluntary association, partnership, joint venture, trust, and incorporated
organization, unincorporated organization, Competent Authority or other
entity.
Project means the Employers [----------------------------] in respect of
which the Contract has been signed.
Project Manager means the person appointed by the Employer thereof
and named as such, to perform the duties delegated by the Employer.
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xxiii.
xxiv.
xxv.
xxvi.
xxvii.
xxviii.
xxix.
xxx.
xxxi.
Implementation Support Consultant or Consultant means the

person(s), Firm or a Company or Consortium of Firms whose bid to
perform the Implementation Support Consultancy Services Contract has
been accepted by the Employer and is also named Consultant in the
Contract Agreement.
R&M Project means the proposed R&M work for Unit [..] of [..]
plant of Employer. The subject Implementation Support Consultancy
Services package is being tendered to appoint an
Implementation
Support Consultant who will assist the Employer in implementation of the
R&M Project.
SCC means the Special Conditions of Contract.
Site means the [.] plant of [].
Sub Consultant means any firm or person to whom execution of any
part of the subject Implementation Support Consultancy Services
Contract is subcontracted directly or indirectly by the Consultant, and
includes its legal successors or permitted assignees.
specification of the Consultancy services and statement of the technical
and other standards to which the Services are to be performed including
any modifications thereto made in accordance with the Conditions. This
includes the commercial specifications, Terms of Reference and other
Tender Documents forming a part of the Contract and such other
Schedules and drawings as may be mutually agreed upon.
Tenderer"/"Bidder"/Applicant means the Person(s), Firm/Company
who has submitted its Bid Proposal in response to the bid invitation by
the Employer, for the Project.
Time for Completion means the time within which completion of
Consultancy Services by the Consultant
(Implementation Support Consultant) covering the entire Scope of Work
as per the Terms of Reference and submission of all the reports and other
deliverables incorporating Employers observation on the draft reports to
the satisfaction of the Employer is to be attained in accordance with the
stipulations and provisions of the Contract.
"Writing" or "Written" shall include any manuscript, type-written or
printed statement, under or over signature and/or seal as the case may
be.
When the words "Approved", "Subject to Approval", "Satisfactory", "Equal to",

"Proper", "Requested", "As Directed", "Where Directed", "When Directed",
"Determined by", "Accepted", "Permitted", or words and phrases of similar
importance are used, the approval, judgment, direction, etc., is understood to be a
function of the Employer. Words implying persons or the gender neutral pronoun
it, shall include firms, companies, corporation, associations or body of individuals
whether incorporated or not. Words implying masculine gender or singular number
shall also include the feminine gender and plural number and vice-versa where the
context so requires or permits.
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4.2
Contract Documents
a) All documents forming part of the Contract (and all parts thereof) are intended
to be correlative, complementary and mutually explanatory. The Contract shall
be read as a whole.
b) The Contract will be signed in three originals and the Consultant shall be
provided with one signed original and the rest will be retained by the Employer.
4.3

precedence)
v. The bid & schedules/ attachment submitted by the Consultant.
vi. Terms of Reference
4.4
Interpretation
All Contract Documents, all correspondence and communications to be given,
and all other documentation to be prepared and supplied under the Contract shall
be written in English, and the Contract shall be construed and interpreted in
accordance with English language.
Unless inconsistent with any provision of the Contract, the meaning of any
trade term and the rights and obligations of parties there under shall be as
prescribed by Incoterms. Incoterms means latest edition of International Rules for
Interpreting Trade Terms published by the International Chamber of Commerce
Paris, France.
4.5
Independent Consultant
The Consultant shall be an independent Consultant performing the Contract. The
Subject to the provisions of the Contract, the Consultant shall be solely
responsible for the manner in which the Contract is performed. All employees,
representatives or SubConsultants engaged by the Consultant in connection with
the performance of the Contract shall be under the complete control of the
Consultant and shall not be deemed to be employees of the Employer, and nothing
contained in the Contract or in any subcontract awarded by the Consultant shall
be construed to create any contractual relationship between any such employees,
representatives or SubConsultants and the Employer.
4.6
Non-Waiver
No relaxation, forbearance, delay or indulgence by either party in enforcing any of
the terms and conditions of the Contract or the granting of time by either party to
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the other shall prejudice, affect or restrict the rights of that party under the
Contract, nor shall any waiver by either party of any breach of Contract operate as
waiver of any subsequent or continuing breach of Contract. Any waiver of a
partys rights, powers or remedies under the Contract must be in writing, must be
dated and signed by an authorized representative of the party granting such
waiver, and must specify the right and the extent to which it is being waived.
4.7
Severability
unenforceable, such prohibition, invalidity or unenforceability shall not affect the
validity or enforceability of any other provisions and conditions of the Contract.
4.8
Origin
Origin means the place where the materials, equipments and other supplies for
the Facilities are mined, grown, produced or manufactured, and from which the
services are provided.
4.9
Notices
personal delivery, or post, or special courier, or telefax, or Electronic Data
Interchange (EDI) to the address of the relevant party indicated in the Contract.
Either party may change its postal, telefax number, or EDI address or addressee
Notices shall be deemed to include any approvals, consents, instructions, orders
and certificates to be given under the Contract.
4.10
Governing Laws
The Contract shall be governed by and interpreted in accordance with laws in
force in India. The Courts of [........] shall have exclusive jurisdiction in all matters
arising under the Contract.
4.11
If any differences/ dispute arises between the Employer and the Consultant in
abandonment or breach of the Contractthe Employer & Consultant shall seek
to resolve any such dispute or difference by mutual consultation. If the parties
fail to resolve such a dispute or difference by mutual consultation, then the
dispute shall be referred in writing by either party to the Arbitrator, with a copy
to the other party.
b) Arbitration
Either Employer or the Consultant may, of its intention to commence
arbitration, as to the matter in dispute, and no arbitration may be commenced
unless such notice is given.
Any dispute, in respect of which a notice of intention to commence arbitration
has been given, as above shall be finally settled by arbitration. Arbitration may
be commenced prior to or after completion of the Facilities
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panel composed of three arbitrators, in accordance with the provisions set
forth below.
The Employer and the Consultant shall each appoint one arbitrator, and these
two arbitrators shall jointly appoint a third arbitrator, who shall chair the
arbitration panel. If the two arbitrators do not succeed in appointing a third
arbitrator within [twenty eight (28)] days after the latter of the two arbitrators
has been appointed, the third arbitrator shall, at the request of either party, be
appointed by President, Institution of Engineers as the Appointing Authority.
If one party fails to appoint its arbitrator within [forty-two (42)] days after the
other party has named its arbitrator, the party which has named an arbitrator
may request the Appointing Authority to appoint the second arbitrator.
If for any reason an arbitrator is unable to perform its function, the mandate of
the Arbitrator shall terminate in accordance with the provisions of applicable
laws and a substitute shall be appointed in the same manner as the original
arbitrator.
Adjudication/Arbitration proceedings shall be conducted in accordance with
Indian Arbitration and Conciliation Act 1996.
The Place for Arbitration shall be [.], India.
The decision of a majority of the arbitrators (or of the third arbitrator chairing
the arbitration, if there is no such majority) shall be final and binding and shall
be enforceable in any court of competent jurisdiction as decree of the court.
The parties thereby waive any objections to or claims of immunity from such
enforcement.
4.12
The Employer shall pay the consideration Consultant due to the
Consultant.
Scope of Services
The Scope of Services shall be as per the Terms of Reference Section-II.
4.13

a) The Consultant shall commence work on the Scope of Services under this
Tender from the date of Letter of Award. Consultant shall thereafter proceed
with the Services in accordance with the time schedule specified in SCC &
detailed network schedule agreed & appended to the contract.
b) The Consultant shall attain Completion of the Consultancy Services (or of a
part where a separate time for Completion of such part is specified in the
Contract) within the time stated in the SCC subject to time extensions, the
Consultant is entitled under the contract conditions or time extension expressly
granted by the Employer.
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4.14
Consultants Responsibilities
a) Before entering into this contract the Consultant is responsible to have
examined the data relating to the plant and facilities provided by the Employer,
and on the basis of information that the Consultant could have obtained from a
visual inspection of the Site and of other data readily available to it relating to
the Plant & Facilities as at one month days prior to bid submission. Any failure
to acquaint itself with all such data and information shall not relieve Consultant
of its responsibility for properly estimating the difficulty or cost of successfully
performing its scope of work under this contract.
b) The Consultant shall acquire in its name all permits, approvals and/or licenses
undertakings in the country where the Site is located that are necessary for the
performance of the Contract, including, without limitation, visas for the
Consultants and SubConsultants personnel and entry permits for all imported
Consultants Equipment.
c) The Consultant shall perform the Services in accordance with the Applicable
Laws and shall take all practicable steps to ensure that any Sub-Consultant, as
well as the Personnel and agents of the Consultant and any Sub-Consultant,
comply with the Applicable Laws. The Consultant shall comply with all laws in
force in India and the place where the facility is located out. The laws will
include all national, provincial, municipal or other laws that affect the
performance of the Contract and bind upon the Consultant. The Consultant
shall indemnify and hold harmless the Employer from and against any and all
liabilities, damages, claims, fines, penalties and expenses of whatever nature
arising or resulting from the violation of such laws by the Consultant.
d) The Consultant shall perform the Services and carry out its obligations under
this Contract with all due diligence, efficiency and economy, in accordance
with generally accepted professional techniques and practices, and shall
observe sound management practices, and employ appropriate advanced
technology and safe and effective equipment, machinery, materials and
methods. The Consultant shall always act, in respect of any matter relating to
this Employer or to the Services, as a faithful advisor to the Employer, and
shall at all times support and safeguard the Employers legitimate interests in
any dealings with Sub-Consultants or Third Parties.
4.15
Employers Responsibilities
a) The Employer shall be responsible for access to the plant and the Site and for
providing possession of and access to all other areas reasonably required for
the proper execution of the Contract.
b) The Employer shall make available to the Consultant all the plant operation
data, Manufacturers Manual, O&M Manual and other Technical
data/information to the extent available with the Employer and reasonably
required by the Consultant for discharging Services as per the Terms of
Reference
c) The Employer shall acquire and pay for all permits, approvals and/or licenses
undertakings, which such authorities or undertakings require the Employer to
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obtain them in the Employers name, are necessary for the execution of the
Contract.
d) If requested by the Consultant, the Employer shall use its best endeavours to
assist the Consultant in obtaining in a timely and expeditious manner all
permits, approvals and/or licenses necessary for the execution of the Contract
undertakings that such authorities or undertakings require the Consultant or
SubConsultants or the personnel of the Consultant or SubConsultants, as the
case may be, to obtain.
4.16
Taxes & Duties

a) The Employer shall bear and promptly pay Service Tax along with applicable
Surcharge and Cess thereon, in respect of direct transaction between the
Employer and the Consultant payable in India as per Indian law. All other Taxes
and Duties will be borne by the Consultant.
b) If any tax exemptions, reductions, allowances or privileges may be available to
the Consultant, the Employer shall use its best endeavours to enable the
Consultant to benefit from any such tax savings to the maximum allowable
extent.
4.17
information furnished to the Employer by the Consultant herein shall remain vested
in the Consultant or, if they are furnished to the Employer directly or through the
Consultant by any third party, including suppliers of materials, the copyright in
such materials shall remain vested in such third party. The Employer shall however
be free to reproduce all drawings, documents and other material furnished to the
Employer for the purpose of the contract.
4.18
a) The Employer and the Consultant shall keep confidential and shall not, without
the written consent of the other party hereto, divulge to any third party any
documents, data or other information furnished directly or indirectly by the
other party hereto in connection with the Contract, whether such information
has been furnished prior to, during or following termination of the Contract.
Notwithstanding the above, the Consultant may furnish to
its
SubConsultant(s) such documents, data and other information it receives from
the Employer to the extent required for the SubConsultant(s) to perform its
work under the Contract, in which event the Consultant shall obtain from such
SubConsultant(s) an undertaking of confidentiality similar to that imposed on
the Consultant.
b) The obligation of a party, shall not apply to that information which
disclosure and which was not previously obtained, directly or indirectly,
from the other party hereto
Otherwise lawfully becomes available to that party from a third party
that has no obligation of confidentiality.
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4.19
Conflict of Interest
a) The Consultant shall not have a Conflict of Interest and any breach hereof shall
constitute a breach of the Agreement.
b) During the term of this Contract and after its termination, the Consultant or any
Associate or Consortium Partner thereof and any entity affiliated with the
Consultant, as well as any Sub-Consultant and any entity affiliated with such
Sub-Consultant, shall be disqualified from providing goods, works, services,
loans or equity for any project resulting from or closely related to the Services
and any breach of this obligation shall amount to a Conflict of Interest; provided
that the restriction herein shall not apply after a period of five years from the
completion of this assignment or to consulting assignments granted by banks/
lenders at any time; provided further that this restriction shall not apply to
consultancy/ advisory services provided to the Employer in continuation of this
Consultancy or to any subsequent consultancy/ advisory services provided to the
Employer. For the avoidance of doubt, an entity affiliated with the Consultant
shall include a partner in the Consultants firm or a person who holds more than
5% (five per cent) of the subscribed and paid up share capital of the Consultant,
as the case may be, and any Associate thereof.
c) The Contract Price provided under the provisions of this Contract shall constitute
the Implementation Support Consultants sole remuneration in connection with
this Contract or the Services and the Consultant shall not accept for its own
benefit any trade commission, discount or similar payment in connection with
activities pursuant to this Contract or to the Services or in the discharge of its
obligations hereunder, and the Consultant shall use its best efforts to ensure that
any Sub-Consultant, as well as the Personnel and agents of either of them,
similarly shall not receive any such additional remuneration.
4.20
Representatives
d) Project Manager
If the Project Manager is not named in the Contract, then within fourteen (14)
days of the Effective Date, the Employer shall appoint and notify the Consultant
in writing of the name of the Project Manager. The Employer may from time to
time appoint some other person as the Project Manager in place of the person
previously so appointed, and shall give a notice of the name of such other
person to the Consultant without delay. The Employer shall take reasonable
care to see that no such appointment is made at such a time or in such a
manner as to impede the progress of work on the Facilities. The Project
Manager shall represent and act for the Employer at all times during the currency
of the Contract. All notices, instructions, orders, certificates, approvals and all
other communications under the Contract shall be given by the Project Manager,
Consultant to the Employer under the Contract shall be given to the Project
Manager, except as herein otherwise provided.
e) Consultants Team Leader
If the Consultants Team Leader is not named in the Contract, then within
[fourteen (14) days] of the Effective Date, the Consultant shall appoint
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4.21
the Consultants Team Leader and shall request the Employer in writing to
approve the person so appointed. If the Employer makes no objection to
the appointment within [fourteen (14)] days, the Team Leader shall be
deemed to have been approved. If
the Employer objects to the
appointment within [fourteen (14)] days giving the reason there for, then
the Consultant shall appoint a replacement within [fourteen (14) days] of
such objection.
The Consultants Representative shall represent and act for the
Consultant at all times during the currency of the Contract and shall give
to the Project Manager all the Consultants notices, instructions,
information and all other communications under the Contract. All notices,
instructions, information and all other communications given by the
Employer or the Project Manager to the Consultant under the Contract
shall be given to the Consultants Team Leader or, in its absence, its
deputy, except as herein otherwise provided. The Consultant shall not
revoke the appointment of the Consultants Representative without the
Employers prior written consent, which shall not be unreasonably
withheld. If the Employer consents thereto, the Consultant shall appoint
some other person as the Team Leader.
The Consultants Team Leader may, subject to the approval of the
Employer (which shall not be unreasonably withheld), at any time
delegate to any person any of the powers, functions and authorities
vested in him or her. Any such delegation may be revoked at any time.
Any such delegation or revocation shall be subject to a prior notice signed
by the Consultants Team Leader, and shall specify the powers,
functions and authorities thereby delegated or revoked.
No such
delegation or revocation shall take effect unless and until a copy thereof
has been delivered to the Employer and the Project Manager.
The Employer may by notice to the Consultant object to any
representative or person employed by the Consultant in the execution of
the Contract who, in the reasonable opinion of the Employer, may behave
inappropriately, may be incompetent or negligent, or may commit a
serious breach of the Site regulations. In such cases, the Consultant will
arrange suitable replacement.
Work Program
a) Consultants Organization
The Consultants Organization chart and list of key personnel and Team Leader
identified for the Project will be appended to the Contract Agreement. The
Consultant shall ensure adequate and timely availability of these personnel to
work on this Consultancy Services. Consultant will also ensure availability and
services of any additional personnel required for the successful and timely
completion of the Scope of Services as per the Terms of Reference.
b) Program of Performance
Within [twenty-eight (28)] days after the date of Notification of Award of
Contract, the Consultant shall prepare and submit to the Project Manager a
detailed Program of Performance of the Contract, made in the form specified in
the SCC and showing the sequence in which it proposes to design, supply,
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transport, assemble, install and precomissioning the Facilities, as well as the

date by which the Consultant reasonably requires that the Employer shall have
fulfilled its obligations under the Contract so as to enable the Consultant to
execute the Contract in accordance with the program and to achieve Completion
and Acceptance of the Facilities in accordance with the Contract. The program
so submitted by the Consultant shall accord with the Time Schedule included in
Appendix 4 (Time Schedule) to the Form of Contract Agreement and any other
dates and periods specified in the Contract. The Consultant shall update and
revise the program as and when appropriate or when required by the Project
Manager, but without modification in the Times for Completion.
c) Progress Report
The Progress Report shall be in a form acceptable to the Project Manager and
shall indicate: (a) percentage completion achieved compared with the planned
percentage completion for each activity; and (b) where any activity is behind the
program, giving comments and likely consequences and stating the corrective
action being taken.
d) Progress of Performance
If at any time the Consultants actual progress falls behind the program, or it
becomes apparent that it will so fall behind, the Consultant shall, at the request
of the Employer or the Project Manager, prepare and submit to the Project
Manager a revised program, taking into account the prevailing circumstances,
and shall notify the Project Manager of the steps being taken to expedite
progress so as to attain Completion of the Facilities within the Time for
Completion.
e) Work Procedures
The Contract shall be executed in accordance with the Contract Documents and
the procedures given in the section on Forms and Procedures of the Contract
Documents.
If agreed between the Employer and the Consultant, the Consultant may execute
the Contract in accordance with its own standard project execution plans and
procedures to the extent that they do not conflict with the provisions contained
in the Contract.
4.22
Substitution of Key Personnel

The Employer expects that all the Key Personnel specified in the Bid Proposal
shall be available during the execution of Implementation Support Consultancy
Services. The Employer will not consider any substitution of Key Personnel
except under compelling circumstances beyond the control of the Consultant and
the concerned Key Personnel. Such substitution may be permitted only in
exceptional cases subject to equally or better qualified and experienced
personnel being provided to the satisfaction of the Employer.
4.23
Sub-Consultant
The R&M Consultant or Consortium Leader or Associate shall not subcontract its
entire scope of work back-to-back or otherwise. In any case, appointment of any
Sub-Consultant to discharge any part of the Scope of Service under this
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Contract is subject to Employers prior written approval. Employer may accept or

reject any Sub-Consultant at its discretion.
4.24
Completion Time
The Consultant guarantees that it shall attain Completion of the entire Scope
of Service as per the Terms of Reference or part thereof within the Time for
Completion specified in the SCC.
4.25
Patents Indemnity
The Consultant shall indemnify and hold harmless the Employer and its
employees and officers from and against any and all suits, actions or
expenses of whatsoever nature, including attorneys fees and expenses, which
the Employer may suffer as a result of any infringement or alleged infringement
of any patent, utility model, registered design, trademark, copyright or other
intellectual property right registered or otherwise existing at the date of the
Contract by reason of: (a) the installation of the Facilities by the Consultant or
the use of the such Facilities.
4.26
Accuracy of Data and Document

The Consultant shall be responsible for accuracy of the data collected by it
directly or procured from other entities, the designs, drawings, estimates and all
other details prepared by it as part of these services. Subject to the GCC
provisions regarding limitation of Consultants liability, the Consultant shall
indemnify the Employer against any inaccuracy in its work which might surface
during implementation of the R&M Project, if such inaccuracy is the result of any
negligence or inadequate due diligence on part of the Consultant or arises out of
its failure to conform to good industry practice. The Consultant shall also be
responsible for promptly correcting, at its own cost and risk, the drawings
including any re-survey / investigations.
4.27
Liability of Implementation Support Consultant

a) The R&M Consultants liability under this Agreement shall be determined by the
Applicable Laws and the provisions hereunder.
b) The Consultant shall, subject to the limitation specified hereunder, be liable to
the Employer for any direct loss or damage accrued or likely to accrue due to
deficiency in Services rendered by it.
c) Except in cases of criminal negligence or wilful misconduct by the Consultant,
the aggregate liability of the Consultant (Implementation Support Consultant) to
the Employer, whether under the Contract, in tort or otherwise, shall not exceed
the total Contract Price, provided that this limitation shall not apply to any
obligation of the Consultant to indemnify the Employer with respect to patent
infringement.
d) Except in cases of criminal negligence or wilful misconduct by the Consultant,
the Consultant shall not be liable to the Employer, whether in contract, tort, or
otherwise, for any indirect or consequential loss or damage, loss of use, loss of
production, or loss of profits or interest costs.
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4.28
Equipment and Material provided by the Employer

Equipment and materials made available to the Implementation Support Consultant
by the Employer shall be the property of the Authority and shall be marked
accordingly. Upon termination or expiration of this Contract Agreement, the
Consultant shall furnish forthwith to the Employer, an inventory of such equipment
and materials and shall return to the Employer or otherwise dispose of such
equipment and materials in accordance with the instructions of the Employer.
While in possession of such equipment and materials, the R&M Consultant shall,
unless otherwise instructed by the Employer in writing, insure them in an amount
equal to their full replacement value.
4.29

The Consultant shall indemnify and hold harmless the Employer and its
employees and
officers from and against any and all suits, actions
or
expenses of whatsoever nature, including attorneys fees and expenses, in
respect of the death or injury of any person or loss of or damage to any
property (other than the Facilities whether accepted or not), arising in connection
with Consultancy Services and by reason of the negligence of the Consultant or
its SubConsultants, or their employees, officers or agents, except any injury,
death or property damage caused by the negligence of the Employer, its
Consultants, employees, officers or agents.
4.30
Insurance
a)
b)
c)
d)
The Consultant shall, for the duration of this Contract, take and maintain, and
shall cause any Sub-Consultant to take and maintain, at its (or the SubConsultants, as the case may be) own cost, but on terms and conditions
approved by the Employer, insurance against the risks, and for the coverage,
as specified hereunder and in accordance with good industry practice.
Within 15 (fifteen) days of receiving any insurance policy certificate in respect
of insurances required to be obtained and maintained under this clause, the
Consultant shall furnish to the Employer, copies of such policy certificates,
copies of the insurance policies and evidence that the insurance premia have
been paid in respect of such insurance. No insurance shall be cancelled,
modified or allowed to expire or lapse during the currency of this Contract.
If the Consultant fails to effect and keep in force the aforesaid insurances for
which it is responsible pursuant hereto, the Employer shall, apart from having
other recourse available under this Contract, have the option, without prejudice
to the obligations of the Consultant, to take out the aforesaid insurance, to
keep in force any such insurances, and pay such premia and recover the
costs thereof from the Consultant, and the Consultant shall be liable to pay
such amounts on demand by the Employer.
Except in case of Third Party liabilities, the insurance policies so procured shall
mention the Employer as the beneficiary of the Consultant and the Consultant
shall procure an undertaking from the insurance company to this effect;
provided that in the event the Consultant has a general insurance policy that
covers the risks specified in this Agreement and the amount of insurance cover
is equivalent to 3 (three) times the cover required hereunder, such insurance
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e)
f)
4.31
policy may not mention the Employer as the sole beneficiary of the Consultant
or require an undertaking to that effect.
The risks and coverages shall include but not be limited to the following:
i.
Third Party liability insurance as required under Applicable Laws, with a
minimum coverage of [.........].
ii.
Employers liability and workers compensation insurance in respect of
the Personnel of the Consultant and of any Sub-Consultant, in
accordance with Applicable Laws.
iii.
Professional liability insurance for an amount no less than the
Agreement Value.
In case of consortium, the policy should be in the name of Consortium Leader
and not in the name of individual Members of the consortium.
Employers Prior Approval

The Consultant shall obtain the Employers written prior approval in writing before
taking any of the following actions:
a)
Replacing any Key Personnel listed in the Contract Schedule
b)
Discontinuing participation of any Key Personnel in this R&M Consultancy
Services during the currency of the Contract
c)
Any other action that is specified in the Tender Document or Contract
Agreement.
4.32
Employership of Documents Prepared by Consultant

a)
b)
c)
All plans, drawings, specifications, designs, reports and other documents

(collectively referred to as Consultancy Documents) prepared by the
Implementation Support Consultant (or by the Sub-Consultants or any Third
Party) in performing the Services shall become and remain the property of
the Employer, and all intellectual property rights in such Consultancy
Documents shall vest with the Employer. Any Consultancy Document, of
which the Employership or the intellectual property rights do not vest with
the Employer under law, shall automatically stand assigned to the Employer
as and when such Consultancy Document is created and the Consultant
agrees to execute all papers and to perform such other acts as the Authority
may deem necessary to secure its rights herein assigned by the
Implementation Support Consultant.
The Implementation Support Consultant shall, not later than termination or
expiration of this Contract, deliver all Consultancy Documents to the
Employer, together with a detailed inventory thereof. The Consultant may
retain a copy of such Consultancy Documents. The Implementation Support
Consultant, its Sub-Consultants or a Third Party shall not use these
Consultancy Documents for purposes unrelated to this Contract without the
prior written approval of the Employer.
The Consultant shall hold the Employer harmless and indemnified for any
losses, claims, damages, expenses (including all legal expenses), awards,
penalties or injuries (collectively referred to as claims) which may arise from
or due to any unauthorised use of such Consultancy Documents, or due to
any breach or failure on part of the Consultant or its Sub-Consultants or a
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Third Party to perform any of its duties or obligations in relation to securing

the aforementioned rights of the Employer.
4.33

any law, regulation, ordinance, order or by-law having the force of law is
enacted, promulgated, abrogated or changed (which shall be deemed to include
any change in interpretation or application by the competent authorities) that
subsequently affects the costs and expenses of the Consultant and/or the Time
extent that the Consultant has thereby been affected in the performance of any
of its obligations under the Contract. However, these adjustments would be
restricted to direct transactions between the Employer and the Consultant.
4.34
Force majeure
(a)
Employer or of the Consultant, as the case may be, and which is unavoidable
(b) If either party is prevented, hindered or delayed from or in performing any of
its obligations under the Contract by an event of Force Majeure, then it shall
notify the other in writing of the occurrence of such event and the
circumstances thereof within [fourteen (14)] days after the occurrence of
such event.
(c) The party who has given such notice shall be excused from the performance
or punctual performance of its obligations under the Contract for so long as
the relevant event of Force Majeure continues and to the extent that such
partys performance is prevented, hindered or delayed.
(d) The party or parties affected by the event of Force Majeure shall use
reasonable efforts to mitigate the effect thereof upon its or their performance
of the Contract and to fulfil its or their obligations under the Contract, but
without prejudice to either partys right.
(e) No delay or non-performance by either party hereto caused by the occurrence
of any event of Force Majeure shall
- to any claim for damages or additional cost or expense occasioned
thereby
if and to the extent that such delay or non-performance is caused by the
occurrence of an event of Force Majeure.
(f) If the performance of the Contract is substantially prevented, hindered or
delayed for a single period of more than [sixty (60)] days or an aggregate
period of more than one hundred and [twenty (120)] days on account of one
or more events of Force Majeure during the currency of the Contract, the
parties will attempt to develop a mutually satisfactory solution.
(g) Force Majeure shall not apply to any obligation of the Employer to make
payments to the Consultant herein.
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4.35
Change in the Scope of Services

The Employer shall have the right to propose, and subsequently require, the
Consultant during the performance of the Contract to make any change,
modification, addition or deletion to, in or from the Scope of Services, provided
that such Change falls within the general scope of the Services and does not
constitute unrelated work and that it is technically practicable, taking into
account both the state of advancement of the assignment and the technical
feasibility. The parties will agree on the change in Contract Price due Change in
Scope of Services on mutual consultation basis.
4.36

(a)
(b)
(c)
4.37
Consultant is delayed or impeded in the performance of any of its obligations
- any suspension order given by the Employer or reduction in the rate of
progress or
- any default or breach of the Contract by the Employer, or any activity,
act or omission of any other Consultants employed by the Employer or
By such period as shall be fair and reasonable in all the circumstances and
as shall fairly reflect the delay or impediment sustained by the
Consultant.
Except where otherwise specifically provided in the Contract, the Consultant
shall submit to the Project Manager a notice of a claim for an extension of
the Time for Completion, together with particulars of the event or
circumstance justifying such extension as soon as reasonably practicable
after the commencement of such event or circumstance. As soon as
reasonably practicable after receipt of such notice and supporting particulars
of the claim, the Employer and the Consultant shall agree upon the period of
such extension.
The Consultant shall at all times use its reasonable efforts to minimize any
delay in the performance of its obligations under the Contract.
Termination
(a)
Termination for Employers Convenience

The Employer may at any time terminate the Contract for any reason by
giving the Consultant a notice of termination. Upon receipt of the notice of
termination, the Consultant shall either immediately or upon the date
specified in the notice of termination
(i)
Cease all further work.
(ii)
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
- 32-
Date of Issue
25.09.2014

[Logo of Utility]
(iii)

Consultants and its SubConsultants personnel from the Site, remove
from the Site any wreckage, rubbish and debris of any kind, and leave
the whole of the Site in a clean and safe condition
(iv) The Consultant, subject to the payment, shall

deliver to the Employer the data collected during the course of the
termination
Deliver to the Employer all non-proprietary drawings, specifications
and other documents prepared by the Consultant or its
SubConsultants as at the date of termination in connection with the
Consultancy services.
In the event of termination of the Contract for Employers convenience,
the Employer shall pay to the Consultant the following amounts
the Contract Price, attributable to the parts of the Services
executed by the Consultant as on the date of termination
the costs reasonably incurred by the Consultant in the removal of
the Consultants Equipment from the Site and in the repatriation of
the Consultants and its SubConsultants personnel
any amounts to be paid by the Consultant to its SubConsultants in
connection with the termination of any subcontracts, including any
cancellation charges
the additional cost of satisfying other obligations, commitments
and claims that the Consultant may in good faith have undertaken
with third parties in connection with the Contract.
(b)
Termination for Consultants Default

(i)
The Employer, without prejudice to any other rights or remedies it may

circumstances by giving a notice of termination and its reasons thereof
to the Consultant:
the Consultant becomes bankrupt or insolvent, has a receiving order
issued against it, compounds with its creditors, or, if the Consultant
is a corporation, a resolution is passed or order is made for its
winding up (other than a voluntary liquidation for the purposes of
part of its undertaking or assets, or if the Consultant takes or
suffers any other analogous action in consequence of debt
If the Consultant assigns or transfers the Contract or any right or
If the Consultant, in the judgement of the Employer has engaged in
Contract.
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
- 33-
Date of Issue
25.09.2014

[Logo of Utility]

the detriment of the Employer and includes collusive practice among
prices at artificial non-competitive levels and to deprive the Employer
of the benefits of free and open competition.
(ii)
If the Consultant
-
(iii)

has without valid reason failed to commence the Consultancy
Services promptly for more than [twenty eight (28)] days after
receiving a written instruction from the Employer to proceed
Contract or persistently neglects to carry out its obligations under
the Contract without just cause
refuses or is unable to provide sufficient personnel and other
resources to execute the Services in the manner specified in the
Employer that the Consultant can attain Completion of the Services
by the Time for Completion as extended
then the Employer may, without prejudice to any other rights it may
possess under the Contract, give a notice to the Consultant stating
the nature of the default and requiring the Consultant to remedy the
same. If the Consultant fails to remedy or to take steps to remedy
the same within [fourteen (14)] days of its receipt of such notice,
then the Employer may terminate the Contract forthwith by giving a
notice of termination to the Consultant.
The Consultant shall, either immediately or upon such date as is
specified in the notice of termination,
ease all further work,

Employer
deliver to the Employer the data collected during the course of the
termination
Deliver to the Employer all drawings, specifications and other
documents prepared by the Consultant or its SubConsultants as at
the date of termination in connection with the Services.
Consultants and its SubConsultants personnel from the Site,
remove from the Site any wreckage, rubbish and debris of any kind,
and leave the whole of the Site in a clean and safe condition
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
- 34-
Date of Issue
25.09.2014

[Logo of Utility]
(c)
Termination by Consultant
i.
If
-
ii.
If the Contract is terminated, then the Consultant shall immediately

-
(v)
o
the Employer has failed to pay the Consultant any sum due under
the Contract within the specified period, has failed to approve any
invoice or supporting documents without just cause pursuant to [----------] (Terms and Procedures of Payment) of the Form of Contract
Consultant may give a notice to the Employer that requires payment
of such sum, requires approval of such invoice or supporting
documents, or specifies the breach and requires the Employer to
remedy the same, as the case may be. If the Employer fails to pay
such sum, fails to approve such invoice or supporting documents or
give its reasons for withholding such approval, fails to remedy the
breach or take steps to remedy the breach within [fourteen (14)
days] after receipt of the Consultants notice, or
the Consultant is unable to carry out any of its obligations under the
Contract for any reason attributable to the Employer, ,
then the Consultant may give a notice to the Employer thereof, and
if the Employer has failed to pay the outstanding sum, to approve
the invoice or supporting documents, to give its reasons for
withholding such approval, or to remedy the breach within [twenty
eight (28) days] of such notice, or if the Consultant is still unable to
carry out any of its obligations under the Contract for any reason
attributable to the Employer within twenty eight (28) days of the
said notice.
If the Employer becomes bankrupt or insolvent, has a receiving order
issued against it, compounds with its creditors, or, being a
corporation, if a resolution is passed or order is made for its winding
up (other than a voluntary liquidation for the purposes of
part of its undertaking or assets, or if the Employer takes or suffers
any other analogous action in consequence of debt.
cease all further work, except for such work as may be necessary
for the purpose of protecting that part of the Facilities already
executed, or any work required to leave the Site in a clean and safe
condition
Employer pursuant to paragraph (d)(ii)
remove all Consultants Equipment from the Site and repatriate the
Consultants and its SubConsultants personnel from the Site
The Consultant, subject to the payment, shall
deliver
to the Employer the data collected during the course of the
consultancy services and study reports prepared up to the date of termination
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
- 35-
Date of Issue
25.09.2014

[Logo of Utility]
Deliver to the Employer all non-proprietary drawings, specifications and other

In the event of termination of the Contract for Employers convenience, the
Employer shall pay to the Consultant the following amounts
o
o
o
o
4.38
the costs reasonably incurred by the Consultant in the removal of the
Consultants Equipment from the Site and in the repatriation of the
Consultants and its SubConsultants personnel
any amounts to be paid by the Consultant to its SubConsultants in connection
with the termination of any subcontracts, including any cancellation charges
the additional cost of satisfying other obligations, commitments and claims
that the Consultant may in good faith have undertaken with third parties in
connection with the Contract.
Assignment
The Consultant shall not, without the express prior written consent of the
Employer, assign to any third party the Contract or any part thereof, or any right,
benefit, obligation or interest therein or there under, except that the Consultant
shall be entitled to assign either absolutely or by way of charge any monies due
and payable to it or that may become due and payable to it under the Contract.
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
- 36-
Date of Issue
25.09.2014

[Logo of Utility]
5.1
Contract Details
Name of Contract: Implementation Support Consultancy Services for

[---------------------------------------]
Bid Document No. :[-------------------------]
The Employer is:

Name of Employer: [-------------------------]
Address of Employer: [-------------------------]
Telephone No. : [-------------------------]
Fax No: [-------------------------]
E-Mail: [-------------------------]

Telephone No. : [-------------------------]
Fax No: [-------------------------]
E-Mail: [-------------------------]
5.2
Effective Date
The Employer shall inform the successful Bidder of its acceptance of the Tender
by a formal Letter of Acceptance. This Letter of Acceptance will be the Effective
Date for determining the Time for Completion of the facilities and other milestones
for execution of the Implementation Support Consultancy work as per the scope
of work under this tender by the Consultant.
The following three activities will be completed within [two (2)] months from the
date of Letter of Acceptance:
(a) The contract agreement will be executed by the Employer and the Consultant.
(b) The Consultant will submit to the Employer the Contract Performance Security,
any Additional Performance Security associate etc if applicable, and the Advance
Payment Security.
(c) The Employer will pay the Consultant the Advance Payment as per the Terms
of Payment.
(d) The Consultant will submit the Inception Report and incorporate any change
suggested by Employer in the Inception Report
The Employer will make the advance payment promptly once Consultant has
fulfilled the necessary conditions specified in Terms of Payment. If payment of
Advance is delayed beyond two months from the date of Letter of acceptance for
reasons attributable to the Employer, the date of payment of advance shall be the
effective date for determining the time for completion of facilities. However,
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
- 37-
Date of Issue
25.09.2014

[Logo of Utility]
failure of the Consultant to provide all the required Bonds/Guarantees within the
prescribed period will cause the Bid Security to be forfeited.
5.3

The Time Schedule for the execution of the scope of work by the Consultant
under this tender shall be as follows:
1.
2.
3.
4.
5.
..
Task/Milestone
[.]
[Finalization
of
Work
Plan.]
[Submission
of
Monthly
Progress Report]
[.]
[Comment/Approval of each
engineering drawing]
[.]
[Approval of Quality Plans]
[.]
5.4
NOT USED
5.5
NOT USED
5.6
NOT USED
5.7
Contract Price
Time for Completion

[.]
[.]from Effective Date
[First week of next month]
[.]
[10 days from the date of submission]
[.]
[.]
[.]
a) The Contract Price shall be as indicated in the Contract Agreement based on

the Total Price quoted by the Bidder in the Price Schedule F1. The Price quoted
by Bidder in the Price Schedule F1 will be deemed to include compensation for
all expenses/costs incurred by the Bidder incidental to rendering all the
Services and discharging all other obligations under this Contract
and
remuneration for rendering all the services as per the Terms of Reference.
b) The Consultant shall be deemed to have satisfied itself as to the correctness
and sufficiency of the Contract Price, which shall, except as otherwise
provided for in the Contract, cover all its obligations under the Contract.
5.8
Terms of Payment
a) The Contract Price shall be paid as Terms and Procedures of Payment to the
b) No payment made by the Employer herein shall be deemed to constitute
acceptance by the Employer of the Services or any part(s) thereof.
c) All the payments will be made in INR.
5.9
Contract Securities
a) The Consultant shall provide the securities specified below in favour of the
Employer at the times, and in the amount, manner and form specified below.
b) Advance Payment Security
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
- 38-
Date of Issue
25.09.2014

[Logo of Utility]
The Consultant shall, within [thirty (30)] days of the Notification of Contract
Award, provide a security for an amount equal to the advance payment, and in
the same currency or currencies, with a initial validity of up to [ninety (90)]
days beyond the schedule date of Completion of R&M Consultancy Services.
Advance payment Security shall be reduced prorata every three (3) months
after First Running Account Bill/Stage Payment under the Contract based on
the value of Services received. The cumulative amount of reduction at any
point of time shall not exceed ninety percent (90%) of the advance
corresponding to cumulative value of the Services received as per a certificate
issued by the Project Manager and the balance of 10% shall be released on
Completion of R&M Consultancy Services and Employers Acceptance thereof.
It should be clearly understood that reduction in the value of security for
advance shall not in any way dilute the Consultant's responsibility and
liabilities under the Contract including in respect of the Services for which the
reduction in the value of security is allowed.
c) Performance Security
The Consultant shall, within [thirty (30)] days of the notification of award, provide
a security for the due performance of the Contract for five percent (5%) of the
Contract Price with an initial validity upto [ninety (90)] days beyond the Scheduled
Completion Date for R&M Consultancy Services.
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Section-I
Page No.
- 39-
Date of Issue
25.09.2014

[Logo of Utility]
FORMS AND SCHEDULES

I
Bid Forms and Schedules/Annexure to be submitted with Bid
Annexure-A
Annexure-B
Form of Part-I Bid
Annexure-C
Form of Part-II Bid
Annexure-D
Not Used
Schedule F1
Price Schedule
Schedule F2
Overall Time Schedule
Schedule F3
Deviation Schedule
Commercial
Schedule F4
Deviation Schedule to Terms of Reference
Schedule F5
Details of Key Personnel
Schedule F6
II
Forms and Contract Scheduless to form part of Contract
Annexure-F
Form of Contract
Contract
Schedule-1
Terms of Payment
Contract
Schedule-2
NOT USED
Contract
Schedule-3
Time Schedule
Contract
Schedule-4
Contract
Schedule-5
III
Annexure-G
Format for Contract Performance Security
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
to
Tender
Description
Section-I
Document
Page No.
- 40-
Section-I
Date of Issue
25.09.2014
Tender Document for Implementation Support Consultant for R&M of Unit [Logo of Utility]
No. [..] Capacity [..] of [Name of the Power Plant]
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[1]
25.09.2014
ANNEXURE - A
1. This Guarantee should be furnished by a scheduled commercial Bank in India
authorized by RBI to issue a Bank Guarantee in the same format as given below.
[Name of Utility], reserves its right to reject the Bank Guarantee if the same is not in
the specified format.
[Rs..]
3. The stamp paper should have been purchased in the Name of the Bank executing
the guarantee.
Ref.:
Bank Guarantee No:

Date
To:
[-Name of Utility]
Dear Sirs,
] dated [.................] M/s [Name of
Bidder] hereinafter called the Bidder, having its registered/head office at
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
wish to participate in the said Bid for [Implementation Support Consultancy Services
package for R&M of ], India, as an irrevocable Bank Guarantee against Bid
Guarantee for a sum of [..] (in words and figures) valid for 300
days from [..] (the date of Bid Opening) is required to be submitted by
the Bidder as a condition precedent for participation in the said bid, which amount is
liable to be forfeited on the happening of any contingencies mentioned in the Bid
Documents, we, the [] Bank at (local address)
[] having our Head Office at [] guarantee
and undertake to pay immediately on first demand by [Name of Utility]the amount of
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[2]
25.09.2014
[.] (in figures and words) to the

said [Name of Utility] without any reservation, protest, demur and recourse. Any such
demand made by [Name of Utility] shall be conclusive and binding on the Bank
irrespective of any dispute or difference raised by the Bidder.
further extension of this Guarantee is required, the same shall be extended to such
required period on receiving instructions from M/s [Name of Bidder] on whose behalf
this Guarantee is issued.
Signature
Name
Designation
Staff Code No.
Bankers Seal
Date
Witness:
1.
2.
Signature
Designation
Address
Signature
Designation
Address
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[3]
25.09.2014
ANNEXURE - B
FORMAT OF BID
From:
[Bidder Details]
[]
[]
To:
Sub

Tender No. []_____________________________________
1. We agree to complete the entire scope of work as per Terms of Reference in
conformity with all the terms and conditions stated in Tender Specifications and its
Amendments/Corrigendum/Clarifications issued till the date of tender opening and
as per time schedule given in Tender Specification.
Letter of Award and to complete and deliver the whole of the work and
responsibilities comprised in the Contract within as per Time schedule given in SCC
of Tender Specification.
Rupees___[..]_only) in the form ________________ as instructed by
you. This Bid Guarantee shall be governed as per the stipulations provided in the
"Instructions to Bidders".
4. We agree to abide by and keep our Bid valid initially for a period of 240 (Two
Hundred Forty) days from the date of opening of bids by Purchaser and it shall
remain binding on us and may be accepted at any time before the expiry of that
period.
conditions of Tender Specification as accepted by us and in default thereof, to
forfeit and pay to [Name of Utility], assignees or authorized nominees such sums of
money as are stipulated in conditions contained in Tender Specification and agree to
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[4]
25.09.2014
furnish Bank Guarantee for Contract Performance as per the proforma prescribed by
Purchaser and for the sum equal to 5% of the "Contract Price", for the entire scope
of work within 30 days from the date of Letter of Award.
6. We understand that Purchaser is not bound to accept the lowest or any Bids
received and Purchaser has the right to reject any Bid, without assigning any reason
whatsoever.
7. This Bid together with written acceptance thereof shall constitute a binding
Contract between Purchaser and ourselves till a formal Contract is executed.
Signed this __________________ day
of _______________
Signature
Name
Designation
Company
Date
Company Seal
Witness:
1.
2.
Signature
Occupation
Address
Signature
Occupation
Address
*****
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[5]
25.09.2014
ANNEXURE - C
FORMAT OF BID
Part-II [Price Bid]
Tender No.
[-----------]
Bid No
[------------]
From:
[]
[]
Dated:
[]
To
:
[]
[]
[]
Dear Sirs
1.
2.
We hereby agreed to carry out the entire scope of work as described in the Terms
of Reference in conformity with the specifications and Terms of Reference, as per
prices quoted by us in the Schedule of Prices [Schedule .] enclosed herewith
In the event of our proposal being accepted, we agree to furnish a Bank Guarantee
for Contract Performance as per the proforma prescribed by Employer [Name of
Utility ] and for the sum equal to 5% of the "Contract Price". The Bid Guarantee
shall be released only after the Contract Performance Guarantee issued in favour
of Employer is received and accepted by the Employer
Signature
Name
Designation
Company
Date
Company Seal
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[6]
25.09.2014
Witness:
1.
2.
Signature
Occupation
Address
Signature
Occupation
Address
*****
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[7]
25.09.2014
SCHEDULE F1
PRICE SCHEDULE
S.No.
Description
INR
Price for the entire scope of work on Lump Sum Fixed Price Basis
Service Tax on Direct Transaction between the Owner &

Consultant
10
Total Price including Service Tax on Direct Transaction between

the Owner & Consultant
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[8]
25.09.2014
SCHEDULE F2
S.No
Days from Effective

Date
Work Description
Start
Signature
Name
Designation
Company
Date
Finish
Company Seal
*****
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[9]
25.09.2014
SCHEDULE F3
All deviations to commercial condition (Tender Document Vol-I) shall be filled in by the
Bidder clause by clause in this schedule.
S.No
Clause
Deviation
commercial condition (Tender Document Vol-I) . The Bidder further confirms that in the
event any other data or information presented in the Bidders proposal and accompanying
documents are at variance with the specific requirements laid out in the commercial
condition (Tender Document Vol-I) , then the latter shall govern and shall be binding on
the Bidder for the quoted price.
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[10]
25.09.2014
SCHEDULE F4
DEVIATION SCHEDULE TO TERMS OF REFERENCE
All deviations from the Technical Specification shall be filled in by the Bidder, clause by
clause, in this Schedule:
S.No
Volume /
Section
Clause
No
Description
Deviation
Purchasers Technical Specifications for this enquiry. The Bidder further confirms that in
the event any other data and information presented in the Bidders proposal and
accompanying documents including drawings, catalogues, etc are at variance with the
specific requirements laid out in the Purchasers Technical Specifications then the latter
shall govern and shall be binding on the Bidder for the quoted price.
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[11]
25.09.2014
SCHEDULE F5
DETAILS OF KEY PERSONNEL
Sl
Np
Designation
Team
Leader
Boiler
Expert
Turbine
Expert
Mechanical
BoP Expert
Electrical
Expert
C&I Expert
Civil Expert
Name
Educational
Qualification
Professional
Experience
(years)
Present
Employer
Signature
Name
Designation
Company
Date
Employed
with
present
Employer
Since
Minimum
No of Hours
to
be
Deployed
for
this
Consultancy
Assignment
Company Seal
*****
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[12]
25.09.2014
SCHEDULE F6
1.
Proposed Designation (As per Schedule-F5) :
2.
Name of Key Person:
3.
Date of Birth:
4.
Nationality:
5.
Educational Qualifications:
6.
Employment Record:
(Starting with present position, list in reverse order every employment held.)
7.
List of projects on which the Personnel has worked

Sl No
8.
9.
Name of Project
Description of Responsibilities
Start Date and

End Date of
Association
Other present work commitment

Details of the role in the subject Implementation Support Consultancy Services
assignment and the time duration for which services are required for this
assignment.
Certification:
1
I am willing to work on the Implementation Support Consultancy Services

assignment for [..] project of [..] and I will be available for entire duration of
the Project assignment as required.
I, the undersigned, certify that to the best of my knowledge and belief, this CV
correctly describes myself, my qualifications and my experience.
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[13]
25.09.2014
Place..............................(Signature and name of the Key Personnel)

(Signature and name of the authorized signatory of the Bidder)
Notes:
Use separate form for each Key Personnel
*****
Document Number
LII-GETS12021-G-001129-008
Rev No
Description
01


[14]
25.09.2014
Tender Document for Implementation Support Consultancy Services for Unit [Logo of Utility]
Document Number
LII-GETS12021-G-00129-008
Rev No
Description
01


[1]
25.09.2014

[country of Employer] and having its principal place of business at [address of
Employer] (hereinafter called the Employer), and (2) [name of Contractor], a
corporation incorporated under the laws of [country of Contractor] and having its
principal place of business at [address of Contractor] (hereinafter called the
Contractor)
WHEREAS the Employer desires to engage the Contractor to provide
Implementation
Support
Consultancy
Services
comprising
.
[
..]
(the Implementation Support Consultancy Services) and the Contractor have
agreed to such engagement upon and subject to the terms and conditions
hereinafter appearing.
1.1
Contract Documents
annexure/Contract Schedules, and the complete documents, which are the
basis of finalization of the contract, including correspondence exchanged from
issue of tender till date of signing the contract. The following will constitute
the Contract Documents:
i. The signed Contract Agreement & the annexure/ Contract Schedule
thereto (highest precedence)
b) All documents forming part of the Contract (and all parts thereof) are intended
to be correlative, complementary and mutually explanatory. The Contract
shall be read as a whole.
c) The Contract will be signed in three originals and the Contractor shall be
provided with one signed original and the rest will be retained by the
Employer.
1.2

precedence)
Document Number
LII-GETS12021-G-00129-008
Rev No
Description
01


[2]
25.09.2014

1.3
Definitions
The Definitions of terms and expressions shall be as per General Conditions of
Contract (GCC).
1.4
Contract Price
The Contract Price shall be:[amount of local currency in words], [amount in
figures], or such other sums as may be determined in accordance with the terms
and conditions of the Contract.
1.5
Term of Payment
The terms and procedures of payment according to which the Employer will
reimburse the Contractor are given in Contract Schedule 1 (Terms and Procedures
of Payment) hereto.
1.6

The Time Schedule for the execution of the scope of work by the Contractor under
this shall be as follows:
Task
Time for Completion
1.
[.]
[.]
2.
[.]
[.]
3.
[.]
[.]
4.
[.]
[.]
5.
[.]
[.]
Contract Schedules
Reference in the Contract to any Contract Schedule shall mean the Contract
Schedules attached hereto, and the Contract shall be read and construed
accordingly.
IN WITNESS WHEREOF the Employer and the Contractor have caused this
Agreement to be duly executed by their duly authorized representatives the day and
year first above written.
_-----------------------------------------------------------------------------[Signature]
_------------------------------------------------------------------------------- [Title]
Document Number
LII-GETS12021-G-00129-008
Rev No
Description
01


[3]
25.09.2014

_----------------------------------------------------------------------------- [Signature]
_------------------------------------------------------------------------------- [Title]
CONTRACT AGREEMENT
dated the_-----------day of---------------, 20_---------_____
BETWEEN
[The Employer]------------------------------------------------------------------------------------------and
[The Contractor]-------------------------------------------------------------------------------------
Contract Schedules:
Contract
Contract
Contract
Contract
Contract
Schedule
Schedule
Schedule
Schedule
Schedule
Document Number
LII-GETS12021-G-00129-008
1
2
3
4
5
:
:
:
:
:
Terms of Payment
Price Adjustment
Time Schedule
Rev No
Description
01


[4]
25.09.2014
Contract Schedule-1
Terms of Payment
times. Payments will be made in Indian Rupees.
I.
Terms of Payment for Contract Price:

1
Initial Advance on
Performance Security and Advance
Payment Security by Contractor and (4)
Submission of Inception Report by the
Contractor and Acceptance of the same
by Owner
[]% of the Lump Sum [Finalization of Work Plan.]
Price
[]% of the Lump Sum
[..]
Price
[]% of the Lump Sum
[Finalization of all quality plans..]
Price
[]% of the Lump Sum
[..]
Price
[]% of the Lump Sum
[..]
Price
..
[..]
..
[..]
.
.
Last
Owners
Acceptance
that
the
Payment
Contractor (Implementation Support
Consultant) has successfully and
completely
discharged
the
Implementation Support Consultancy
Services and has submitted all the test
data, reports, recommendation etc. to
the Owner
II.
NOT USED
III.
Document Number
LII-GETS12021-G-00129-008
Rev No
Description
01


[5]
25.09.2014
IV.
Any Tax or Duty payable by Employer as per the Terms & Conditions of
Contract and is directly payable to Statutory Authorities/Government as per law
shall be directly paid to the concerned authority or Government by the
Employer. Any other Tax or Duty payable by Employer to the Contractor as per
the Terms & Conditions of Contract shall be reimbursed on production of
evidence of payment by Contractor.
Any amount towards statutory variation in Taxes & Duties payable by Employer
as per the Terms & Conditions of Contract shall be reimbursed to the Contractor
upon submission of evidence by the Contractor to the Employer as to the
Contractor having paid such variation.
Document Number
LII-GETS12021-G-00129-008
Rev No
Description
01


[6]
25.09.2014
Contract Schedule-2
NOT USED
Document Number
LII-GETS12021-G-00129-008
Rev No
Description
01


[7]
25.09.2014
Contract Schedule-3
TIME SCHEDULE
Document Number
LII-GETS12021-G-00129-008
Rev No
Description
01


[8]
25.09.2014
Contract Schedule-4
LIST OF SUB-CONSULTANTS
Document Number
LII-GETS12021-G-00129-008
Rev No
Description
01


[9]
25.09.2014
Contract Schedule-5
LIST OF KEY PERSONNEL
Document Number
LII-GETS12021-G-00129-008
Rev No
Description
01


[10]
25.09.2014
Tender Document for Selection of Implementation Support Consultant for [Logo of Utility]
ANNEXURE - G
[To be furnished by Consultant]
Place:
Bank Guarantee No:
Date:
To:
..
]
Dear Sirs,
1
In consideration of the [........................................] hereinafter referred to as the

OWNER, which expression shall, unless repugnant to the context or meaning, thereof
include its successors, representative and assignees, having awarded in favour of
M/s.[Consultants Name] having its
registered
office
at..hereinafter
referred to as the CONSULTANT, which expression shall, unless repugnant to the
context or meaning thereof include its successors, administrators, representatives and
assignees, a Contract, hereinafter referred to as the "CONTRACT" for
theon terms and conditions set out inter alia, in
the
OWNER's
Contract/Letter
of
Award
No..datedas
well
as
CONTRACT documents, valued at [amount in words], [amount in figures] and the
same having been unequivocally accepted by the CONSULTANT and the
CONSULTANT having agreed to provide a Contract Performance Guarantee for the
faithful performance of the entire CONTRACT under the CONTRACT equivalent to 5%
(five percent) of the said value of the CONTRACT to OWNER amounting to

and having its Head Office at., hereinafter referred to
as the Bank which expression shall, unless repugnant to the context or meaning
thereof, include its successors, administrators, representatives and assignees do
hereby irrevocably guarantee and undertake to pay the OWNER merely on demand
without any previous notice and without any demur and without referring to any other
source, any and all monies payable by the CONSULTANT by reason of any breach of
the said CONSULTANT of any of the terms and conditions of the said CONTRACT
including non-execution of the CONTRACT AGREEMENT, to the extent of
..(%).
of
the
Contract
price
to
OWNER
amounting
to
Document Number
LII-GETS12021-G-00129-008
Rev No
Description
01


[1]
25.09.2014
8
9
Rs(Rupees.only).
Any
such demand made by the OWNER on the Bank shall be conclusive and binding,
absolute and unequivocal notwithstanding any difference between the OWNER and
CONSULTANT or any dispute or disputes raised/ pending before any Court, Tribunal,
Arbitrator or any other authority. The Bank agrees that the guarantee herein contained
shall continue to be enforceable till this sum due to the OWNER is fully paid and claims
satisfied or till the OWNER discharges this Guarantee.
The OWNER shall have the fullest liberty without affecting in any way the liability of
the Bank under this guarantee, from time to time, to extend the time of Performance
by the CONSULTANT. The Bank shall not be released from its liabilities under these
presents by any exercise of the OWNER of the liberty with reference to the matter
aforesaid.
The OWNER shall have the fullest liberty, without affecting this guarantee to postpone
from time to time the exercise of any powers vested in them or of any right which they
might have against the CONSULTANT and to exercise the same at any time in any
manner, and either to enforce or to forbear to enforce any covenants, contained or
implied in the CONTRACT between OWNER and the CONSULTANT or any other
course or remedy or security available to the OWNER and the Bank shall not be
released of its obligations/liabilities under these presents by any exercise by the
OWNER of his liberty with reference to the matters aforesaid or any of them or by
reasons of any other act or forbearance or other acts of omission or commission on the
part of the OWNER or any other indulgence shown by the OWNER or by any other
matter or thing whatsoever which under law would, but for this provision, have the
effect of relieving the Bank Guarantee. The Bank further undertakes not to revoke this
guarantee during its currency without the previous consent of the OWNER.
The Bank further agrees that the decision of the OWNER as to the failure on the part of
the CONSULTANT to fulfill their obligations as aforesaid and/or as to the amount
payable by the Bank to the OWNER hereunder shall be final, conclusive and binding on
the Bank.
guaranteed sum either in full or part, in the manner suitable to them. However,
payment made for a sum lesser than the guaranteed amount shall not relieve or
discharge the bank from their obligations guaranteed under the bank guarantee, till the
contractual obligations are fully performed by the Consultant or the Bank Guarantee is
discharged by the OWNER, as the case may be and the Bank Guarantee shall continue
to be in force till such time.
guarantee against the Bank as a Principal Debtor, in the first instance notwithstanding
any other security or guarantee that it may have in relation to the CONSULTANT's
liabilities.
This guarantee will not be discharged due to the change in the constitution of the Bank
or the CONSULTANT(S).
Notwithstanding anything contained hereinabove, our liability under this guarantee is
it will remain in force upto and including and shall be extended
Document Number
LII-GETS12021-G-00129-008
Rev No
Description
01


[2]
25.09.2014
from time to time for such period as may be desired by [Name

Consultant] on whose behalf this guarantee has been given.
10
Signature
Name
Designation
Staff Code No
Date
of
Bank Seal
Witness:
1.
2.
Signature
Occupation
Address
Signature
Occupation
Address
:
*****
Document Number
LII-GETS12021-G-00129-008
Rev No
Description
01


[3]
25.09.2014

OF

PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-008 R01
September 2014
Tender Document for Selection of ISC Consultant for Unit No. [..]
[Logo of Utility]


OF
Document Number
LII-GETS12021-G-00129-008
Rev No
00
Description
Tender Document for Selection of ISC Consultant
Section-II

[i]
25.09.2014
[Logo of Utility]
TABLE OF CONTENTS
1
GENERAL ................................................................................................... 1
1.1
Project Background ................................................................................ 1
ROLE OF IMPLEMENTATION SUPPORT CONSULTANT ...................................... 2
SCOPE OF SERVICES ................................................................................... 3

3.1
3.2
3.3
3.4
3.5
3.6
Data Collection...................................................................................... 3
Detailed Engineering Phase:..................................................................... 3
Supply Phase: ....................................................................................... 3
R&M Implementation Phase: ................................................................... 3
Schedule of Completion of Task: ............................................................. 4
Reports / output to be provided by ISC: .................................................... 4
KEY PROFESSIONAL POSITIONS WHOSE CV WOULD BE EVALUATED: .............. 5
Document Number
LII-GETS12021-G-00129-008
Rev No
00
Description
Tender Document for Selection of ISC Consultant
Section-II

[ii]
25.09.2014
[Logo of Utility]
GENERAL
{Briefly explain the need and objective of R&M, give reference of the studies carried
out to assess the health of the unit and the progress made till date for the
implementation of R&M}
1.1
Project Background
{Give brief description of the unit and the latest performance parameters in terms of
Average Load during the year, PLF, Availability Auxiliary Power Consumption, Heat
Rate and the average Calorific Value of Coal being presently used in the boiler.}
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Tender Document for Selection of ISC
Consultant
Section-II
Page No.
- 1-
Date of Issue
25.09.2014
[Logo of Utility]
ROLE OF IMPLEMENTATION SUPPORT CONSULTANT

Role of the ISC shall as follows:a. To provide assistance to the Utility during detailed engineering, supply, implementation
and commissioning of works.
b. To prepare the work schedule and monitor the progress of works through close
involvement with the Contractors and other agencies on behalf of the Utility.
c. To review the detailed engineering drawings/design calculations, schedule planned for
execution and commissioning of all the works in line with the broad parameters of
accepted design.
d. To assist the Utility in taking various decisions in the course of implementation of project
and in taking timely actions to ensure that the time schedule envisaged for the project is
adhered to.
e. To draw attention of the Utility in case of any problems and suggest suitable remedial
measures to control the situation.
f.
To assist the Utility in addressing any technical / commercial / contractual / legal /

regulatory issues arising during the course of the implementation of the project.
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Consultant
Section-II
Page No.
- 2-
Date of Issue
25.09.2014
[Logo of Utility]
SCOPE OF SERVICES
The detailed scope of services shall be as described below:
3.1
Data Collection
Reports of studies like RLA/CA Reports, Energy Audit Report, Feasibility Report and DPR will
be made available to ISC by the Owner.
3.2
Detailed Engineering Phase:

During Detailed Engineering phase, ISC shalli)
3.3
Co-ordinate between Vendors and Owner.
ii)
Resolve problems arising during all phases.
iii)
Monitor the progress of the work as per approved schedule.
iv)
Approve master list of contractors design drawings along with submission / schedule.
v)
Categorize drawings as for approval and for information only.
vi)
Review and approve contractors drawings / data sheet to ensure conformity to the
technical specification requirements.
vii)
Review design clarification.
viii)
Follow-up with the contractors for expeditious submission of drawings for approval.
ix)
Report any delay to the Owner along with remedial action.
x)
Finalize list of major equipments for which shop performance tests have to be carried
out.
xi)
Finalize delivery schedules for major equipments and sequential supplies to ensure
uninterrupted erection work.
xii)
Prepare overall initial project schedule - L1 network and review of L2 and L3 networks
as submitted by the contractors.
xiii)
Approve PG test procedures.
Supply Phase:
During Supplies phase, ISC shall
i)
Assist the Owner in dealing with statutory authorities such as Boiler Inspectorate
Directorate, Pollution Control Board etc. (if required)
ii) Follow-up with the contractors for expeditious supplies as per approved schedule.
iii) Report any delay to the Owner along with remedial action.
3.4
R&M Implementation Phase:

During R&M Implementation phase, ISC shall
i)
Review the implementation plan, the need of erection machinery, tools and tackles and
availability of trained manpower with the vendor.
ii) Take review of pre-commissioning documents including pre- commissioning check-list.

iii) Take review of O&M manual and write-up instruction relating to initial operation of the
Unit.
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Consultant
Section-II
Page No.
- 3-
Date of Issue
25.09.2014
[Logo of Utility]
iv) Take review and approval of as-built drawings prepared by the contractors based on the
marked-up drawings showing the modifications carried out by them during execution.
v) Ensure overall coordination between various contractors in planning and fixing priority of
construction and installation
vi) Monitor the progress.
vii) Witness the PG Test and evaluate PG Test Reports.

Note: ISC would not be a party for any technical / commercial / legal dispute arising between
the Utility and the manufacturer / vendor / contractor.
3.5
Schedule of Completion of Task:

The Contract will be implemented in accordance with the services indicated. The ISC shall
prepare and submit well in advance the complete schedule of completion of work and the
schedule of manpower to be deployed.
3.6
Reports / output to be provided by ISC:

The following outputs are required from ISC. The ISC may note that the listed reports herein
are minimum requirement only. The reports / reviews to be submitted and tasks to be
fulfilled will be as per requirement of the work to complete the task successfully.
i)
Monthly progress reports.
ii) Report pertaining to the initial Project Schedule L-1 network of each package and
review/finalize L2 and L3 networks.
iii) Approval of Master list of drawing/ Datasheet of all the Contractors of all procurement
packages including submission schedule preferably.
iv) Review Completion report and approval of contractors drawings / data sheet to ensure
conformity to the technical specification requirements
v) Finalization of list of major equipments for which shop performance tests have to be
carried out.
vi) Finalization
units.
of
delivery
schedules
for
major
equipments
from manufacturing
vii) Approval of PG test procedures.

viii) Review and finalization of pre-commissioning documents including pre- commissioning
check-list,
ix) Review and finalization of O&M manuals and write-up instruction relating to other allied
services for initial operation of the equipment and the plant prepared by the contractors.
x) Review and approval of as-built drawings prepared by the contractors based on the
marked-up drawings showing the modifications carried out by them during
construction/erection.
xi)
Furnishing clarifications to specifications and drawings, arrangement for getting

modified drawings, coordination between project site-office and owners head-office as
required during erection of equipment and construction of civil works.
xii) Perusal and monitoring of quality plans and implementation schedules during phases of
implementation.
xiii) PG Test evaluation and acceptance.
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Consultant
Section-II
Page No.
- 4-
Date of Issue
25.09.2014
[Logo of Utility]
KEY PROFESSIONAL POSITIONS WHOSE CV WOULD BE EVALUATED:

S.
No.
1
Key Position

Experience Desired
Graduate Engineer, with minimum 15
Team Leader
years relevant experience in Project
(Project
Management. Good knowledge of project
Management)
safety & legal aspect. The proposed
and Specialist
individual should also have direct
(Boiler/Turbine)
experience of handling an EPC Project of
coal fired thermal power plant of 200 MW
or above capacity.
Specialist
Production, Project
least 5-10 years experience in the
(Boiler)
relevant fields, including direct experience
Commissioning
of Boiler design/ erection /commissioning
preferably of 200 MW or above capacity.
Should have knowledge of relevant
International and National testing code.
Specialist
Production,
Project
(Turbine)
relevant fields, including direct experience
Commissioning
of
Turbine
design/
erection/
commissioning preferably of 200 MW or
testing code.
Graduate Electrical Engineer in Electrical
Specialist/s
Production, Project
Systems with at least 5-10 years
(Electrical)
experience in the relevant fields, including
Commissioning
direct
experience
of
design
/erection/commissioning
of
Electrical
Equipment /systems preferably of 200
DCS Installation and
Graduate Instrumentation Engineer with
Specialist/s
Commissioning
at least 5-10 years experience in the
(Control and
relevant field including direct experience
Instrumentation)
of design/ erection/ commissioning of
electrical systems preferably of 200 MW
or above capacity.
Supervision of civil and
Graduate Civil Engineer with at least 5-10
Specialists - Civil
structural work
years experience in the relevant fields
including direct experience of design/
erection/ commissioning of electrical
systems preferably of 200 MW or above
capacity.
Besides the above mentioned experts, Consultant should appoint sufficient nos. of
commissioning engineers of relevant faculty at site during Commissioning and PG Test.
The owner will provide support staff of relevant faculty who will associate with the
Experts of Consultant during site supervision and field quality monitoring as well as during
preparing required reports.
Document Number
LII-GETS12021-G-00129-008
Area of Specific
Expertise desired
Overall Management of
Project Implementation
Support team.
Rev No.
01
Description
Consultant
Section-II
Page No.
- 5-
Date of Issue
25.09.2014
[Logo of Utility]
Note:
After award of the contact the client expects all the proposed key personnel to be available
during implementation of the contract as per the agreed staffing schedule at the time of
negotiation. The Utility expects that Consultant will keep experts same throughout the
contract period. If any replacement is required, the Consultant should ensure that there is a
reasonable overlap between the staff to be replaced, wherever feasible/possible.
Document Number
LII-GETS12021-G-00129-008
Rev No.
01
Description
Consultant
Section-II
Page No.
- 6-
Date of Issue
25.09.2014

OF

R&M CONTRACTORS

(PACKAGE NUMBER: R&M-SP-01)
VOLUME-I
COMMERCIAL
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R03
September 2015
Tender Document for R&M of Unit No. [..] Capacity [..] of [Name of the
[Logo of Utility]
Power Plant]
MASTER INDEX (ALL VOLUMES)

Volume
Section
Volume-I
Part
Description
---
---
Commercial
Section-I
---
Project Technical Specification
Part-A
Detailed
Technical
Mechanical
Part-B
Detailed Technical Specifications - Electrical
Part-C
Detailed Technical Specifications I&C
Part-D
Detailed Technical Specifications - Civil
---
Part-A
Technical Schedules - Mechanical
---
Part-B
Technical Schedules - Electrical
---
Part-C
Technical Schedules I&C
---
Part-D
Not Used
Volume-II
Specifications
Section-II
Volume-III
*****
Document Number
Rev No
LII-GETS12021-G-00129-001
03
Description
Contractors Boiler & Auxiliaries
Volume-I
Page No.
[i]
Date of Issue
30.09.2015
[Logo of Utility]
Power Plant]
VOLUME-I: COMMERCIAL
1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
*****
Document Number
Rev No
LII-GETS12021-G-00129-001
03
Description
Volume-I
Page No.
Date of Issue
[ii]
30.09.2015
[Logo of Utility]
Power Plant]
VOLUME-II: TECHNICAL SPECIFICATIONS

SECTION-I:
PROJECT TECHNICAL SPECIFICATION
1.
Intent of Specification
2.
Site & Project Specific Information
3.
Existing Plant Details
4.
Scope of Supply & Services
5.
Terminal Points & Exclusions
6.
General Technical Requirements
7.
Layout Consideration
8.
Performance Guarantees
9.
Spare Parts
10.
Annexure
SECTION-II:
DETAILED TECHNICAL SPECIFICATION
1.
Detailed Technical Specification-Mechanical
2.
Detailed Technical Specification-Electrical
3.
Detailed Technical Specification-I&C
4.
Detailed Technical Specification-Civil

*****
Document Number
Rev No
LII-GETS12021-G-00129-001
03
Description
Volume-I
Page No.
[iii]
Date of Issue
30.09.2015
[Logo of Utility]
Power Plant]
VOLUME-III: TECHNICAL SCHEDULES

(TO BE FILLED BY BIDDER)
1.
Technical Schedules-Mechanical
2.
Technical Schedules -Electrical
3.
Technical Schedules -I&C
*****
Document Number
Rev No
LII-GETS12021-G-00129-001
03
Description
Volume-I
Page No.
[iv]
Date of Issue
30.09.2015
[Logo of Utility]
Power Plant]
TABLE OF CONTENTS
1.0 INVITATION FOR BID ................................................................................................... 1
1.1
1.2
1.3
1.4
1.5
1.6
2
Introduction............................................................................................................. 1
Invitation ................................................................................................................. 1
Brief Scope of Work ................................................................................................ 1
Tender Details ........................................................................................................ 1
Time Schedule........................................................................................................ 2
Bid Submission ....................................................................................................... 2
INSTRUCTIONS TO BIDDERS...................................................................................... 3
2.1
Introduction............................................................................................................. 3
2.2
Address and Contact Details of Owner ................................................................... 3
2.3
General Project Information .................................................................................... 3
2.4
Owners Consultant ................................................................................................ 3
2.5
Sources of Fund ..................................................................................................... 3
2.6
Cost of Bidding ....................................................................................................... 3
2.7
Non-Transferability of Bid document ....................................................................... 3
2.8
Scope of Work & Single Bidder Responsibility ........................................................ 3
2.9
Time Schedule........................................................................................................ 4
2.10 Tender Documents ................................................................................................. 4
2.11 Preparation of Bids ................................................................................................. 6
2.11.1
Language of Bid ............................................................................................ 6
2.11.2
Bidding Procedure ......................................................................................... 6
2.11.3
Bid Submission ............................................................................................. 6
2.11.4
Bid Guarantee ............................................................................................... 7
2.11.5
Bid Opening .................................................................................................. 8
2.12 Composition of Techno Commercial Bid (Part-1 Bid) .............................................. 9
2.13 Composition of Price Bid (Part-II Bid) ..................................................................... 9
2.14 Bid Prices ............................................................................................................. 10
2.15 Signature of Bids .................................................................................................. 11
2.16 Clarifications/Corrigendum/ Amendment of Tender Specifications ........................ 11
2.17 Modification of Bids .............................................................................................. 11
2.18 Information to be Furnished with the Bid ............................................................... 11
2.19 Policy of Bids under Consideration ....................................................................... 12
2.20 Validity of Bid ........................................................................................................ 12
2.21 Understanding & Clarification on Documents & Specifications .............................. 12
2.22 Latest Hour for Receipt of Bids ............................................................................. 13
2.23 Single Bidder Responsibility ................................................................................. 13
2.24 No Claim for Compensation for Submission of Bid ............................................... 13
2.25 Deputation of Representatives for Discussion....................................................... 13
2.26 Evaluation of Bid................................................................................................... 13
2.27 Local Conditions ................................................................................................... 15
2.28 Deviations............................................................................................................. 16
2.29 Blacklisting/Debarring ........................................................................................... 16
2.30 Award of Contract ................................................................................................. 16
2.31 Agency Commission ............................................................................................. 18
Document Number
Rev No
LII-GETS12021-G-00129-001
03
Description
Volume-I
Page No.
[v]
Date of Issue
30.09.2015
[Logo of Utility]
Power Plant]
2.32
2.33
2.34
2.35
3
GENERAL PROJECT INFORMATION ........................................................................ 20

3.1
Contract Performance Bank Guarantee (CPBG)................................................... 18

Contract Quality Assurance .................................................................................. 18
Codes & Standards ............................................................................................... 18
Vital Clauses......................................................................................................... 19
Project & Site Information ..................................................................................... 20
GENERAL CONDITIONS OF CONTRACT (GCC)....................................................... 21

4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.27
4.28
4.29
4.30
4.31
4.32
4.33
4.34
4.35
4.36
4.37
4.38
Definitions............................................................................................................. 21
Contract Documents ............................................................................................. 25
Order of Precedence of Contract Documents ....................................................... 25
Interpretation ........................................................................................................ 25
Construction of the Contract ................................................................................. 25
Independent Contractor ........................................................................................ 26
Joint Venture or Consortium ................................................................................. 27
Non-Waiver .......................................................................................................... 27
Severability ........................................................................................................... 27
Origin.................................................................................................................... 27
Notices ................................................................................................................. 27
Governing Laws.................................................................................................... 27
Settlement Of Disputes ......................................................................................... 28
Scope of Facilities ................................................................................................ 29
Time for Commencement and Completion............................................................ 29
Spare Parts .......................................................................................................... 29
Contractors Responsibilities................................................................................. 31
Owners Responsibilities ....................................................................................... 32
Taxes & Duties ..................................................................................................... 32
Intellectual Property .............................................................................................. 33
Confidential Information ........................................................................................ 33
Representatives.................................................................................................... 34
Work Program ...................................................................................................... 35
Subcontracting ..................................................................................................... 36
Design and Engineering ....................................................................................... 36
Procurement ......................................................................................................... 37
Installation ............................................................................................................ 38
Testing & Inspections ........................................................................................... 40
Completion of the Facilities ................................................................................... 41
Commissioning & Operation Acceptance .............................................................. 42
Completion Time and Liquidated Damage ............................................................ 43
Defects Liability .................................................................................................... 43
Functional Guarantees ......................................................................................... 44
Patents Indemnity ................................................................................................. 44
Limitation of liability .............................................................................................. 44
Transfer of Ownership .......................................................................................... 45
Care of Facilities ................................................................................................... 45
Loss of or Damage to Property; Accident or Injury; Indemnification ...................... 45
Document Number
Rev No
LII-GETS12021-G-00129-001
03
Description
Volume-I
Page No.
[vi]
Date of Issue
30.09.2015
[Logo of Utility]
Power Plant]
4.39
4.40
4.41
4.42
4.43
4.44
4.45
4.46
5
SPECIAL CONDITIONS OF CONTRACT (SCC) ......................................................... 57

5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
Insurance.............................................................................................................. 45
Change in Laws & Regulation............................................................................... 47
Force Majeure ...................................................................................................... 48
Change in the Facilities ........................................................................................ 48
Extension of Time for Completion ......................................................................... 50
Suspension........................................................................................................... 50
Termination .......................................................................................................... 51
Assignment........................................................................................................... 56
Contract Details .................................................................................................... 57
Effective Date ....................................................................................................... 57
Liquidated Damage for Delay ............................................................................... 58
Rate of Liquidated Damage for Delay ................................................................... 58
Liquidated Damage for Non-fulfilment of Functional Guarantees .......................... 58
Maximum Leviable Liquidated Damages .............................................................. 59
Payment of Liquidated Damages .......................................................................... 59
Contract Price ....................................................................................................... 60
Terms of Payment ................................................................................................ 60
Contract Securities (Bank Guarantees) ................................................................ 60
Sequential Supply................................................................................................. 61
FORMS AND SCHEDULES ......................................................................................... 62
Document Number
Rev No
LII-GETS12021-G-00129-001
03
Description
Volume-I
Page No.
[vii]
Date of Issue
30.09.2015
[Logo of Utility]
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List of Acronym
CIF
: Cost Insurance Freight
CPBG
Contract Performance Bank Guarantee
CST
Central Sales Tax
EDI
Electronic Data Interchange
EUR
Euro
FOB
Free on Board
GCC
General Conditions of Contract
GOI
Government of India
GST
Goods & Service tax
ICB
INR
Indian Rupees
I&C
Instrumentation & Control
ITB
JV
Joint Venture
LOA
Letter of Award
LOI
Letter of Intent
MoEF
Ministry of Environment and Forests
MSL
Mean Sea Level
PERT
Program evaluation and review technique
RBI
Reserve Bank of India
R&M
Renovation and Modernization
SCC
Special Conditions of Contract
TMCR
UNCITRAL
United Nations Commission on International Trade Law
USD
US Dollar
VAT
Value added Tax
Document Number
Rev No
LII-GETS12021-G-00129-001
03
Description
Volume-I
Page No.
Date of Issue
[viii]
30.09.2015
[Logo of Utility]
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1.0
INVITATION FOR BID

Tender No
1.1
[ ---------------------------------------------------------------------------]
Introduction
[Give brief introduction about the name, ownership, business & Power Projects of the
utility inviting tender for R & M work]
[XXX is undertaking renovation & modernization of XXX MW Unit no.-XX --------- of the
Power Plant]
1.2
Invitation
[Name of The Utility], hereinafter referred to as Employer / Owner / Purchaser, invites
sealed Tenders in English language from Prequalified Bidders for the Renovation &
Modernization of Boiler & Auxiliaries package of Unit No.[XXX] of the [XXX] Power
Plant on International Competitive Bidding (ICB) basis as per the scope of work given
Technical Specification Volume-II.
1.3
Brief Scope of Work

The scope of work under this R&M package involves disassembly of existing
equipment / systems, replacement of specified equipments / systems by supplying new
equipments/ systems including supply of assembly materials, inspection & testing at
suppliers works, supply of mandatory spares, packing and forwarding, transportation &
insurance, receipt at site, unloading, handling & storage at site, pre-assembly,
fabrication, repair, servicing/ overhauling, erection, all associated civil works including
supply of cement, steel etc., testing & commissioning, successful completion of trial
operation and guarantee tests for [XXX] package of Unit no. [XXX] of [XXX] Power
Plant. The detailed scope of work is given in technical specification Vol. II.
The brief scope of work is given below: [-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------]
For detailed Scope of Work & Services, refer Section-I of Volume-II of this
Specification.
1.4
Tender Details
(a)
Cost of Tender
Documents
: INR [---]/ USD [---]/ EUR [---]
(b)
: INR [--------]/ USD [--------]/ Euro [--------]
(c)
Date of issuance of
Tender Document
: [----------------------------]
(d)

Conference
: [----------------------------]
(e)
Last Date & Time of
: [----------------------------]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 1-
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Part I & Part II)
(f)
1.5
Date & Time of

Opening of Unpriced
Techno-Commercial
Bid (Part-I)
: [----------------------------]
Time Schedule
The time schedule for completion of facilities and performance guarantee test shall be
as per SCC.
1.6
Bid Submission
(b) The Bid proposals are to be submitted in two parts in separate sealed covers as
follows:
Part I
Bid Guarantee and Technical & Commercial Proposal without

prices
Part II
Price Schedule and Schedule

parameters with values.
of
Functional
Guarantee
(c) All other terms and conditions along with the Technical Specifications, General
Guarantee details, Validity of Bid and Instructions to Bidders, etc. are contained
in the Tender Documents.
(d) Bidder shall submit the bid on or before the scheduled date and time as specified.
Any offer received after the expiry of the time specified for receiving the
completed bids are liable for rejection. The bid shall be submitted to:
---------------------------------------------------------------------------------------------------------------------------]
(e) Issuance of Tender Documents to a Bidder shall not be construed to mean that
such Bidder would be automatically considered.
(f) The Bid may be made in Indian Rupees as well as in Foreign Currencies
(maximum three foreign currencies) and all payments for the entire scope will be
made in Indian Rupees as well as in the respective quoted Foreign Currencies.
(h) The Tender Documents are meant for the exclusive purpose of bidding against
the subject package and shall not be transferred, reproduced or otherwise used
for purposes other than for which these are specifically issued.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
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[Logo of Utility]
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2.1
Introduction
[Name of Utility], the Owner, intends to carry out the Renovation & Modernization of
[Unit no.-XX --------- of the XXXX Power Plant].
Under the subject Tender, [Utility] invites bid for Renovation & Modernization of Boiler
& Auxiliaries package of the said Renovation & Modernization work to be carried out as
per the accompanying Technical Specifications. The Bidder shall submit the offer for
complete scope of work indicated in the Technical Specification.
2.2
Address and Contact Details of Owner

---------------------------------------------------------------------------------------------------------------------------]
2.3

2.4
Owners Consultant
[------------------------------------------], hereinafter referred to as Consultant is the
Consulting Engineer for the project, appointed by the Owner, [---------------------], to
provide project consultancy services.
2.5
Sources of Fund
[Utility] intends to finance the subject Package of the said renovation & modernization
work, through Internal and other sources & External/ Domestic Commercial/ Borrowing
from international development funding agencies. [Utility] has tied up the required fund
for this package.
2.6
Cost of Bidding
The Bidder shall bear all costs associated with the preparation and submission of its
bid, and the Owner will in no case be responsible or liable for these costs, regardless
of the conduct or outcome of the bidding process.
2.7

Transfer of Bid documents issued to one intending bidder to another is not permissible.
2.8

The scope of the work shall be on the basis of single Bidder responsibility, covering the
complete scope of work specified under these specifications and documents. It shall
include the following:
(a) Disassembly of existing equipment/ systems as required.
(b) Detailed design of the systems/equipment covering all Mechanical, Electrical,
Control & Instrumentation, Civil and Structural works.
(c) Complete manufacture, including shop inspection and testing.
(d) Providing engineering drawings, data, operational & maintenance manuals, etc.,
for the Owners review/ approval.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
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(e) Packing, forwarding and transportation including insurance from the

manufacturers works to plant site and transportation from storage yard to
erection site.
(f) Receipt, storage, preservation and conservation of system/equipment at site
including construction of storage facility viz. covered, semi-covered, airconditioned, open yard at the space allocated at site by Owner including storagecum-erection and all other specified & statutorily required insurance.
(g) Pre-assembly, if any, erection, testing, commissioning, completion of plant and
equipment/ system, conducting trial operation, performance guarantee test and
handing over of all the plant and equipment/ system covered under this
specification.
(h) Carry out all related civil and structural works at site including construction of
foundations, buildings, structures etc. Including supply of cement and steel and
all other required materials.
(i) Supply of mandatory spares and tools & tackles.
(j) Training of Owners personnel.
Detailed scope is provided in Volume-II of the Technical Specifications.
Bids not covering the entire scope mentioned hereinabove may be treated as
incomplete and hence are liable for rejection.
2.9
Time Schedule
The completion Time Schedule for Completion of R&M work and Performance
Guarantee Tests shall be as given in the SCC.
2.10
Tender Documents
The scope of contract, technical specification, bidding procedures and contract terms
are prescribed in the Tender Documents. The Tender Documents comprise, inter alia,
the following volumes:
Volume I
Commercial
Volume I
Chapter-1
Invitation for Bid
Volume I
Chapter-2
Volume I
Chapter-3
Volume I
Chapter-4
Volume I
Chapter-5
Volume I
Cahpter-6
Forms & Schedules
Volume II
Technical Specifications
Volume II
Section-I
Volume II
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
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Section-II, PartA
:
Volume II
Section-II, PartB
:
Volume II
Section-II,
Part-C
Volume II
Section-II,
Part-D
Volume III
Technical Schedules
Volume III,
Part-A
Technical Schedule-Mechanical
Volume III,
Part-A
Technical Schedule-Electrical
Volume III,
Part-A
Technical Schedule-I&C
The Bidder is expected to examine all instructions, forms, terms and specifications in
the Tender Documents including clarifications/corrigendum/amendments for
completeness and obtain clarifications, if any, from the Owner.
The Bidder is expected to examine all instructions, forms, terms, conditions,
specifications and other information in the bidding documents. Failure to furnish all
information required as per the bidding documents or submission of a bid not
substantially responsive to the bidding documents in every respect will be at the
Bidder's risk and may result in rejection of its bid.
A prospective Bidder requiring any clarification to the Tender Documents may notify the
Owner in writing by post or by e-mail followed by postal confirmation at the Owner's
address indicated in ITB. The Owner will respond in writing by post or by e-mail
followed by post confirmation to any request for clarification or modification of the
bidding documents that it receives not later than twenty-one (21) days prior to the
deadline for submission of bids prescribed by the Owner. Owner's response will be
sent to all prospective Bidders that have been issued the Bidding Documents.
information that may be necessary for preparing the bid. The Owner will facilitate the
bidder to collect such information about the plant in the manner that does not interface
with plant operational and does not any way adversely impact the interest of the
Owner. The costs of visiting the site including engaging any third party consultant by
Bidder, if required as per the assessment of Bidder, shall be borne by the bidder fully.
personnel and agents from and against all liability during such information collection
and will be responsible for death or personal injury, loss of or damage to property and
any other loss, damage, costs and expenses incurred as a result of the inspection.
At any time prior to the deadline for submission of bids, the Owner may, for any reason,
whether at its own initiative, or in response to a clarification requested by a prospective
Bidder, amend the bidding documents.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
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confirmation to all prospective Bidders that have received the bidding documents and
will be binding on them.
At any time prior to the deadline for submission of bids, the Owner, at its discretion may
extend the deadline for submission of the bids.
2.11
Preparation of Bids
2.11.1
Language of Bid
The bid prepared by the Bidder and all correspondence and documents related to the
bid shall be in English language, provided that any printed literature furnished by the
Bidder may be written in another language, as long as such literature is accompanied
by a translation of its pertinent passages in English language in which case, for
purposes of interpretation of the bid, the translation shall govern.
2.11.2
Bidding Procedure
The bidders are required to submit, the bids for the Renovation and Modernization
work in two parts. Both the parts are to be submitted together before the indicated Bid
components of the Techno-Commercial Bid are Bid Guarantee, Scope of Work &
Terminal Points, Technical descriptions/details, Technical Data Sheets, List of Tools &
Tackles, Deviations to Technical and Commercial Specifications/Conditions, Overall
Completion Time Period & L-1 Network Schedule, Resource Deployment Schedule,
Detail of Sub-Contractors/Sub-Suppliers/Sub-Vendors, Spares list, Quality Assurance
Programme, Details of the present commitments & details of contracts in hand, Indices
and Coefficients for Price Variation etc. Part-II Bid will comprise Quoted Price and
Quoted Performance Guarantee Parameters. Initially, only the Part-I Bid will be opened
and Part-II Bid is kept in safe custody.
After evaluation of the Techno-Commercial (Part-I) Bids, each Bidder who has
submitted a broadly responsive Part-I Bid, will be invited for Techno-Commercial
Discussion, during which, all the required amendments, additions, deletions and other
adjustments are noted and recorded in a memorandum. Part-II Bid (Price Bid) of only
those Bidders will be opened, whose Part-I Bid is found to be responsive to Tender
Specifications and Conditions. The date & time for opening of Price Bid will be
intimated separately.
Techno-Commercial Bid should not contain any price data.
Price Bid should not contain any matter in respect of Technical and / or Commercial
aspects other than the details specifically sought by the Owner.
2.11.3
Bid Submission
(1). Bid proposals shall be accepted from only those eligible bidders who are found
qualified during the pre-qualification process & are issued Tender Documents.
Unsolicited bids shall not be taken into cognizance.
separate sealed covers, with all pages serially numbered. All bids shall be
prepared in the English language only, by typing or printing.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
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(3). [One original and 9 (nine) identical] copies of the original with all enclosures shall
be submitted by each Bidder for Part-I and Part-II, clearly indicating the original
and the number of the copy (i.e., Original, Copy No. 1, Copy No. 2 etc.).
(4). All these covers shall be individually sealed and put in an outer cover which also
shall be sealed and super scribed as in other covers.
(5). The covers should be pasted properly before applying the wax seal. Failure to do
so may result in rejection of such bids.
(7). In the event of discrepancy between Original and any copy of the bids, the hard
copy of Original shall prevail.
(8). The Bid shall be submitted to [---------------------------]. Bid submitted to any other
office of Owner is liable for rejection. Bids submitted by Telefax or e-mail will be
rejected
(9). Owner will receive Bids in respect of all the equipment/systems and scope of
work as set forth in the accompanying Technical Specifications. All bids shall be
prepared and submitted in accordance with the Tender Documents.
(10). Failure to furnish all information required in the Tender Documents or submission
of a Bid not substantially responsive to the Tender Conditions and Technical
Specifications in every respect or bids received in incomplete shape shall be
liable for rejection. A bid shall be determined as substantially responsive in every
respect, if it conforms to all the terms, conditions and specifications specified in
Tender Documents without material deviations, objections, conditionality or
reservations.
(i). That affects in any substantial way the scope, quality or performance of the
contract;
(ii). That limits in any substantial way, inconsistent with the Tender Documents,
the Owners rights or the successful Bidders obligations under the contract.
Tender Documents, the Bidder has to make independent inquiries and generally
obtain his own information on all matters that may in any way affect prices, risks
and obligations of the Contractor under the Contract.
(14). Either the Indian agent or the foreign Principal directly could bid in a tender, but
not both. The same applies to an Indian agent/dealer representing and Indian
manufacturer. In case both submit the tenders, the tender of the manufacture will
alone be considered.
(15). An agent representing one manufacturer in a tender will not be allowed to quote
on behalf of another manufacturer along with previous manufacturer in a
subsequent / parallel tender for the same item.
2.11.4
Bid Guarantee
(Part-I) or Demand Draft of equivalent amount drawn in favour of [--------------]
payable at [--------].
Document Number
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Rev
No.
03
Description
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Page No.
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authorized by Reserve Bank of India,, to issue such Bank Guarantee on a nonjudicial stamp paper of value not less than Rs. [---]/-.The stamp paper shall be
purchased in the name of the Bank. Foreign Bidders may submit the Bank
Guarantee from any bank in India as above or from any foreign bank which is in
the approved list of RBI.
a) The Bid Guarantee shall be executed only on behalf of the Bidder in whose
name the Tender Documents have been issued.
b) The Bid and other documents shall be submitted only by the Bidder in whose
Owner (at [--------------]). In the event of any deviation in this regard, the
decision of Owner as to whether the same could be accepted or not, is final
and binding on the Bidder.
Euro/ Indian Rupee.
Guarantee or with short Bid Guarantee or Bid Guarantee in the form other than
that specified here in above or from banks not specified hereinabove will be liable
for rejection.
(6). Any Bid not accompanied by the Bid Guarantee shall be rejected and the Bidder
shall not be permitted to participate in the tender.
(7). The Bid Guarantee shall be forfeited if the Bidder withdraws / modifies / changes
/ impairs / derogates the bid proposal on its own after the Bids are opened or
submits forged/bogus certificates or fails to accept the Letter of Award issued by
Owner or fails to submit Contract Performance Guarantee
(8). The Bid Guarantee of all unsuccessful Bidders shall be returned after price cover
opening and price evaluation. The Bid Guarantee of the successful Bidder shall
be returned after furnishing of the Contract Performance Bank Guarantee to the
Owner and acceptance thereof.
2.11.5
Bid Opening
1.
2.
This is a single stage two part tender. On the specified date and time of opening,
Part I Bid containing Bid Guarantee and Technical and Commercial Proposal
without Prices will be opened. At the time of opening of PartI of the bids, the
names of the bidders who submitted their bids shall be read out and other such
details as Owner, at its discretion, may consider appropriate, shall be read out.
The Part II (Price Bid) will be lodged and opening of the same will be intimated
separately to those Bidders whose Part-I Bid willd be determined to be
substantially responsive to Tender Conditions and Technical specifications in all
respects.
If the Bidder desires to be present at the time of opening of Part-I of bids, it shall
depute its representatives (not more than two persons) in time with due
Document Number
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Rev
No.
03
Description
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Page No.
Date of Issue
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3.
2.12
Owner takes no responsibility for delays, loss or non-receipt of Bid documents or

any letters sent by post/courier either way and also reserve the right to reject any
Bid in part or full without assigning any reasons thereof.
Composition of Techno Commercial Bid (Part-1 Bid)
This part shall, inter alia, include the following in the same order as listed below.
One original and 9 (nine) identical copies shall be submitted.
(i).
Duly filled in "Form of Bid" (As per Annexure-B of this Volume).
(ii).
Power of Attorney/Authorization with the seal of the company in favour of the
person signing the Bid.
(iii).
Letter of consent: To be furnished by the Bidder Consortium
Partners/Individual Companies of the Group (as the case may be)- as per
AnnexureD of this Volume
(iv).
Letter of Unequivocal Consent to be furnished by the Bidder and Assignee as
per Annexure-E of this Volume
(v).
(vi).
Schedule of Prices as per Schedule F1 (Table 1 to Table-7) with the word
Quoted in lieu of Price data and all other details except price data.
(vii). Mandatory spares as per Technical Specifications (with the word Quoted in
lieu of Price data)
(viii). Recommended spares (with the word Quoted in lieu of Price data)
(ix).
Tools & Tackles as per Technical Specifications (with the word Quoted in
lieu of Price data)
(x).
Schedule of Performance Guarantees- as per Schedule F1 (Table-8) with
the word Quoted in lieu of Performance Guarantee parameters
(xi).
Signed copy of all the corrigendums/amendments/clarifications, if any issued
for the tender
(xii). Overall Time Schedule as per Schedule F2 and Bar chart/PERT Network
(xiii). Deviations to the Commercial specification, if any, as per Schedule F3.
(xiv). Deviations to Technical Specifications, if any, as per Schedule F4.
(xv). Requirements of the Contractor at site, as per Schedule F5.
(xvi). Resource deployment schedule as per Schedule F6
(xvii). Details of the present commitments of the Bidder, details of contracts in hand
(xviii). Details of Sub-Contractors/Sub-Suppliers/Sub-Vendors, if any
(xix). Quality Assurance Programme
(xx). Technical Details to be furnished with the Bid as called for in the Technical
Specification Vol-II and Technical Bid Data Sheet Vol-III.
(xxi). Schedule of weights and dimensions
(xxii). Coefficients and indices for price variation formula
2.13

The Bidders are requested to quote the Prices and the Performance Guarantee
parameters only in the specified format. Price given in Part-II should cover the entire
Document Number
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Description
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scope of work as given in Part-I of the offer including list of mandatory spares and
Tools & tackles with itemized price and should be as per Schedule of Price enclosed.
[One original and 9 (Nine) identical] copies shall be submitted.
1.
The Price Bid shall contain the following :
(i). Duly filled in Form of bid as per Annexure-B & Annexure-C
(ii). Completely filled in Schedule of Prices Schedule F1 (Table 1 to Table-7)
(iii). Completely filled in Schedule of Performance Guarantees Schedule F1
(Table-8).
2. The Bidder shall quote his price against each item of the schedules as indicated in
the enclosed formats. The Bidder shall quote the prices only once after
considering all the pros and cons, risks and contingencies. Rebate percentage
etc., if any, should be spelt out by the Bidder in the first Bid itself.
overwriting is allowed. All scoring and cancellations should be countersigned by
the Bidder. In case of illegibility, the interpretation of the Owner shall be final. All
entries shall be in English language only.
4. The Bid may be made in Indian Rupees as well as in Foreign Currencies
made in Indian Rupees as well as in the quoted Foreign Currencies.
5. Prices in Indian supply shall be quoted on Ex-works supply of plant & equipment
basis including Packing & forwarding. Inland transportation, Insurance charges,
etc. shall be indicated separately.
6. Prices of imported supply of plant & equipment directly consigned to site shall be
quoted on CIF Indian port of entry basis. The bidder shall also quote separately for
FOB port of shipment price for ocean freight for Marine insurance, all port charges
including customs clearance and inland transport charges from port of destination
to Owners site.
7. Custom Duty, Excize Duty, Central sales tax (CST), service tax, Value Added Tax
(VAT), VAT on Works Contract, other applicable taxes, duties and Cess shall be
clearly indicated by the bidder in the price schedules and these taxes shall be
considered for bid evaluation.
2.14
Bid Prices
total bid price covers all the Contractor's obligations mentioned in tender document
specification or to be reasonably inferred from the tender documents/ specification in
respect of the disassembly/ dismantling of existing equipment facility as specified,
design, manufacture, including procurement and subcontracting (if any), delivery,
construction, installation, commissioning, completion of the facilities and conductance
of Performance Guarantee tests for the facilities including supply of mandatory spares,
recommended spare & tools/ tackles (if any). This includes all requirements under the
Contractor's responsibilities for testing, pre-commissioning and commissioning of the
facilities, conducting Guarantee tests and, where so required by the tender documents,
the acquisition of all permits, approvals and licenses, etc.; the operation, maintenance
and training services and such other items and services as may be specified in the
tender documents, all in accordance with the requirements of the Conditions of
Contract and Technical Specifications.
Bidders are required to quote the price for the commercial, contractual and technical
obligations outlined in the tender documents.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
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Prices quoted by the Bidder shall be subject to adjustment during performance of the
Contract to reflect changes in the cost of labour, material, etc. Bidder A bid submitted
with a fixed price quotation will not be rejected, but the price adjustment will be treated
as zero. The price adjustment provision will not be taken into consideration in bid
evaluation.
2.15
Signature of Bids
signature. The names of all persons signing should also be typed or printed below the
signature. Satisfactory evidences of authority of a person signing on behalf of the
Bidder shall be furnished with the Bid. Erasures or corrections in the Bid documents if
any shall be signed by the person signing the Bid. Printed literature, it enclosed need
not be signed. Bids not conforming to the above requirements are liable to be treated
as non-responsive.
2.16

1. At any time prior to the deadline for submission of Bids, the Owner may, for any
reason, whether at his own initiative or in response to clarification(s) requested by
a prospective Bidder, modify the Tender Specifications by amendment.
2. Clarifications/Corrigendum/Amendment shall be construed to be an integral part of
the Tender Specifications, which will be notified. Amendments will be hosted in
Owners website. Bidders are requested to visit Owners website and note
amendments, if any, before submission of bid. Owner shall not be responsible if
any bidder fails to notice any amendment.
2.17
The Bidder is not permitted to modify his Bid suo-moto after the Bid submission.
2.18
Information to be Furnished with the Bid

1.
2.
3.
4.
The Bid (Part-I) must clearly indicate the name of the manufacturer, the type or
model of each principal item of equipment proposed to be supplied and erected.
The Bid should also contain drawings and descriptive materials indicating general
dimensions, material from which the parts are manufactured, principles of
operation and the extent of pre-assembly involved, major erection equipment
required to be deployed, method of erection and the proposed erection
Organization structure.
The above information shall be provided by the Bidder in the form of separate
sheets, drawings, catalogues, etc.
Any Bid not containing sufficient descriptive material to describe accurately the
system / equipment proposed may be treated as incomplete and hence rejected.
Such descriptive materials and drawings submitted by the Bidder will be retained
by the Owner. Any major departure from these drawings and descriptive material
submitted will not be permitted during the execution of the Contract without
specific written permission of the Owner.
Oral statements made by the Bidder at any time regarding quality, quantity or
arrangement of the equipment or any other matter will not be considered.
Document Number
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No.
03
Description
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5.
6.
2.19
Standard catalogue pages and other documents of the Bidder may be used in the
Bid to provide additional information and data as deemed necessary by the
Bidder.
In addition to the hard copy of Part-I Bid, the Bidder shall submit soft copy of all
data sheets, Schedule, List of Mandatory spares, tools & tackles and Bar
Chart/PERT as well as deviation tables in a compact disk (CD). However, hard
copy alone will be considered as authentic for evaluation. Bidder shall submit all
the filled in datasheet also in soft copy. Bidder shall also furnish soft copies and
hard copies of Data Sheet with filled in details wherever details are required to be
indicated by the Bidder.

Bids shall be deemed to be under consideration immediately after they are opened.
While the Bids are under consideration, Bidders and/or their representatives or other
interested parties are advised to refrain from contacting by any means, the Owner
and/or his employees/ representatives on matters related to the Bids under
consideration. The Owner, if necessary will obtain clarifications on the Bids by
requesting for such information from any or all the Bidders, in writing as may be
necessary.
2.20
Validity of Bid
1.
2.
3.
2.21
The Bid shall be kept valid for acceptance for [180 days] from the schedule date
of opening of the Part-I Bid.
The Bidder will not be permitted to change the substance of the Bid suo-moto,
after Bid has been opened.
Unilateral revision or withdrawal of offer by the Bidder within the subsistence of
the validity period of offer shall not be permitted. Violation of this condition shall
result in rejection of the Bid without notice, besides forfeiture of Bid Guarantee.
The Bidder shall also be debarred either permanently or for a fixed period, at the
discretion of Owner from participating in any of the Owners tenders.

1.
2.
The Bidder is required to carefully examine the specifications and documents and
fully informs himself as to all the conditions and matters which may in any way
affect the Renovation and Modernization work to be carried out or the cost
thereof. Bidders are required to visit the plant to get familiarized with local
conditions. However, the Bidders visit to site shall be at their cost and risk,
without any liability on part of the Owner.
Bidders may seek clarifications to the prescribed clauses and / or different part of
the Tender Specifications. Such a request for clarifications, if any, should reach
the Owner at least [7 (seven) days] before the date stipulated for pre-bid meeting.
The Owner then will issue interpretations and clarifications as it may think fit in
during the pre-bid meeting. After pre-Bid meeting, Bidder may seek further
clarification till [21 days] prior to schedule opening date of Part-I Bid. After receipt
of such clarifications, the Bidder may submit its Bid but within the time and date
as specified in the Invitation for Bid or as amended by the Owner. All such
clarifications and the relevant exchange of correspondence between the parties
shall be construed to form part of the tender specifications.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 12-
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3.
4.
5.
2.22
Pre-Bid Conference will be organized and outcome of the pre-bid conference is

binding on all the Bidders. Outcome of the Pre-Bid Conference will be intimated
by the Owner to all the Bidders.
A copy of such clarifications duly signed and stamped shall be enclosed with the
Bid (Part-I). In case any queries remain un-replied, it shall be construed that in
respect of those queries, the respective stipulations of the Tender
Specifications/Conditions shall continue to apply and/or no new stipulations are
made with respect to those queries.
No extension of time for submission of Bid will be granted on account of Bidders
request for interpretation/clarifications.

Invitation for Bid. Bids delivered / received after the time and date fixed for the receipt
of the bids shall be liable for rejection.
2.23
Single Bidder Responsibility

1.
2.
2.24

1.
2.
2.25
The scope of supply and services shall be under single Bidder responsibility.
The successful Bidder should not sub contract the entire work on back to back
basis or otherwise.
The submission of any Bid connected with these documents and specifications
shall constitute an agreement that the Bidder shall have no cause of action or
claim against the Owner for rejection of his Bid.
Regardless of the conduct or outcome of the bidding process, Bidder shall not be
entitled to claim any costs, charges and expenses incidental to or incurred by him
through or in connection with his submission of Bid or its consideration by the
Owner, even though the Owner may elect to modify/withdraw the Invitation for
Bid or does not accept the Bid(s).
Deputation of Representatives for Discussion
After opening of the Bid, if the Owner desires to have techno-commercial

discussion on the Bid, the Bidder shall be in a position to depute his competent
representatives of various disciplines at short notice with full authority for finalising
technical parameters as well as Commercial Terms and Conditions of the Tender.
2.26
Evaluation of Bid
1.
2.
For evaluation and comparison of price bid, the prices indicated at [------]
summary of Prices as per Schedule [------] will be considered. The Bids received
will be evaluated by the Owner to ascertain the lowest evaluated substantially
responsive Bid vis--vis the Tender Specifications. The Bidder has to satisfy
himself that full information is furnished as required in the specifications. Lack of
particulars or incomplete information furnished will run the risk of rejection of the
bid. The following major procedures would be followed for evaluation of bids.
All the Bidders would be brought on par with reference to Technical Specification,
Commercial Condition, Instructions to Bidders and subsequent technocommercial discussions/ clarifications.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 13-
30.09.2015
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3.
After the evaluation of Part-I bids (techno-commercial bids) and before opening of
Part-II bids (Price Bids), in case the bidders are asked to make changes to their
techno commercial offer that may have price implications, Owner may give the
bidders opportunity to submit addendum to price bid covering the price
implication only against such changes before the opening of PartII bids (Price
Bids). All the bidders will be notified, at least 15 days before the Price Bid
opening date, about such changes against which they can submit addendum to
Price Bid.
4.
Commercial loading would be done for non-compliance of commercial terms and

conditions of the Tender Specifications other than the vital clauses, as the case
may be.
To facilitate evaluation and comparison, the Owner will convert all bid prices
expressed in foreign currencies into Indian Rupee at State Bank of India Bills
Selling exchange rates prevailing on the date of opening of the price bid.
The Bidder is eligible for a price variation as per Tender Condition. However
Price variation shall not be considered for Bid evaluation.
Technical loading will be done for omission of price data in respect of
equipment/facilities, spares, tools & tackles, etc. The highest quoted
corresponding price will be loaded against such omission. If no quoted price is
available, the loading will be done as per the corresponding price as estimated by
the Owner.
The Bidder has to meet the minimum functional performance levels indicated in
Volume-II Technical Specification for all categories of Guarantees. If one or more
of Functional Performance Parameters offered by the Bidder is inferior to the
minimum functional performance level (i.e. higher or lower than maximum or
minimum value specified in Technical Specification), then such bid will be
considered non-responsive and rejected.
The quoted values for Performance Guaranteed Parameters given in Table below
would be evaluated using evaluation factors specified. The evaluation factors
shall be applicable to the differential values calculated from among the Bidders of
corresponding item with appropriate highest or lowest value (i.e., the best quoted
value) as the base. The evaluation will be based on the guarantee parameters
inclusive of all tolerance furnished at the Guaranteed Condition. Bidders to note
that the values indicated in the Schedule of Performance Guarantees shall be
inclusive of all tolerances including measurement uncertainty.
Table-Bid Evaluation Factors
5.
6.
7.
8.
9.
Sl. No.
Functional Performance Parameter
1.
BOILER Efficiency at 100% TMCR

(At rated steam parameters)
2.
Auxiliary Power
Evaluation Factor Rate
[------] INR per 0.01%

difference in efficiency
[------]INR per kW
The evaluation factors rate shall be prorated for any fractions of the
specified value.
(1). Arithmetical errors will be rectified on the following basis:
If there is any discrepancy between the unit price and the total
price that is obtained by multiplying the unit price and the quantity,
the unit price shall prevail and the total price will be corrected.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 14-
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the rates expressed in words shall only prevail and shall be
adopted.
no prices are envisaged for any of the entries, Nil shall be mentioned. In
this context Nil mentioned against any item shall construe that the Bidder
shall not charge any amount separately for that item from the Owner. If the
2.27
Local Conditions
1.
2.
The Bidder shall inspect the site and shall satisfy himself of the site conditions
and shall apprise himself of the procedure for engagement of agencies/labour
and shall collect any other information, which may be required before submitting
the Bid.
Wages not less than Minimum wages for Contract labour shall be paid as
applicable in this region from time to time. Claims and objections due to
ignorance of site conditions will not be considered after submission of Bid.
(i). The Bidder is required to carefully examine the Technical & General
Specification, commercial Terms and Conditions, drawings and other details
relating to work given in the Tender Specification and get fully acquainted
as to all conditions and matters which may in any way affect the work or the
cost thereof.
(ii). The Bidder shall be deemed to have exhaustively examined the Tender
Specifications including the Form of Contract, to have obtained all
information and clarifications on all matters whatsoever that might affect the
carrying out of the work and to have satisfied himself as to the adequacy of
his Bid. He is deemed to have known the scope, nature and magnitude of
the work and the requirements of materials and labour involved etc. and as
to all work he has to complete in accordance with the Contract for the
adequacy of his Bid.
(iii). The Bidder shall be deemed to have visited and carefully examined the
plant/ site and surroundings, to have satisfied himself about the nature and
details of all existing structures, if any, and also as to the nature and
conditions of the railways, roads, bridges and culverts, means of transport
and communications, whether by land, water or air and as to possible
interruptions thereto and the access to and from the site, to have made
independent enquiries, examined and satisfied himself as to the sources for
obtaining earth, gravel, sand, stones, bricks and all other construction
materials, the site for disposal of surplus earth and debris, the available
accommodation, underground existing services, sub-soil water conditions,
storms, prevailing winds, climatic conditions and all other similar matters
which may affect the work.
(iv). The Bidder shall be deemed to have acquainted himself with the Indian
Income tax Act, 1961, Indian Companies Act, 1956, Indian Customs Act,
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 15-
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(v).
2.28
Deviations
1.
2.
3.
2.29
1962, Indian Central Excise Act, Value Added Tax, Indian Sales Tax Act,
Indian Electricity Act, Central Electricity Authority Regulations, Indian Boiler
Regulations, Factories Act, Pollution Control Regulations and other related
Acts & Laws prevalent in the State of [-------------] and in India and as
amended from time to time. The Owner shall not entertain any request for
clarifications from the Bidders regarding such local conditions.
Any neglect or omission or failure on the part of the bidder in obtaining
necessary and reliable information as stated above or on any other matter
affecting the Bidder shall not relieve him from any risk or liabilities or the
entire responsibility for completion of the work in accordance with the
Tender Specifications.
technical specification. Nevertheless, if the Bidder takes any deviation, it shall be
clearly indicated in the deviation schedule (Schedule [------] and Schedule- [------]
with a soft copy in MS-Word format in compact disc, with Original of Part-I of the
Bid). Deviation listed elsewhere in the Bid shall be summarily rejected and
ignored. Separate printed standard terms and conditions of the Bidder shall not be
taken into cognizance and shall be totally rejected.
No alterations or disfigurement, other than filling in particulars wherever called for
in the formats of the Tender Specifications shall be made in the Bid. Any
changes/modifications made by the Bidder in Bid documents itself shall not be
taken into consideration.
If at any later date, it is found that documents, information, averments and data
submitted by the bidder in the Bid, based on which the Bidder has been
considered eligible or successful or has been awarded the Contract is incorrect or
false to the extent that had the correct or true information been made available to
the Owner at time of tender evaluation, the Bid would have been declared
ineligible or unsuccessful, the Bidder shall be forthwith disqualified or, as the case
may be, the Contract awarded based on such incorrect or false information shall
be cancelled and the Bid Guarantee / contract performance Guarantees deposited
shall be appropriated by the Owner towards Owners cost, loss and damage to
Owner.
debarred by the Owner.
2.30
Award of Contract
1.
2.
Award Criteria
The Owner will award the contract to the successful Bidder whose Technocommercial bid has been determined to be substantially responsive and
Price Bid to be the lowest evaluated bid, further provided that the Bidder is
determined to be qualified to perform the contract satisfactorily.
The Owner reserves the right to vary the quantity of any of the Items /
Spares and / or delete any Item / Spares altogether at the time of Award of
Contract.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 16-
30.09.2015
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3.
4.
5.
6.
The Owner reserves the right to accept or reject any bid, for any reasons including
National defense and security consideration and to annul the bidding process and
to reject all bids at any time prior to award of contract, without thereby incurring
any liability to the affected Bidder or bidders or any obligation to inform the
affected Bidder or bidders of the grounds for the Owner's action.
successful Bidder in writing by registered letter (Letter of Award or LOA) or by
email to be confirmed in writing by registered letter, that its bid has been accepted.
The notification of award will constitute the formation of the contract.
Upon the successful Bidder's furnishing of the performance securities the Owner
will promptly notify each unsuccessful Bidder and will discharge its bid security.
At the same time as the Owner notifies the successful Bidder that its bid has been
accepted, the Owner will send to the Bidder the Contract Agreement provided in
the bidding documents, incorporating all agreements between the parties.
successful Bidder / assignee of foreign bidder (if applicable) shall sign and date
the Contract Agreement and return it to the Owner.
The Owner requires that Bidders, Contractors and Suppliers observe the highest
standard of ethics during the procurement and execution of the contracts. In
pursuance of this policy, the Owner:
The Owner requires that Bidders, Contractors and Suppliers observe the
highest standard of ethics during the procurement and execution of the
contracts. In pursuance of this policy, the Owner :
procurement process or in contract execution; and
the detriment of the Owner, and includes collusive practice among
of the benefits of free and open competition;
will reject a proposal for award if it determines that the Bidder
recommended for award has engaged in corrupt or fraudulent practices in
competing for the contract in question;
Will declare a firm ineligible, either indefinitely or for a stated period of
time, to be awarded a contract if it at any time determines that the firm has
engaged in corrupt or fraudulent practices in competing for or in executing
a contract of the Owner.
Fraud Prevention Policy
The Bidder along with its associate/collaborator/sub-contractors/sub-vendors/
consultants/service providers shall strictly adhere to the Fraud Prevention Policy
of Owner displayed on its tender website and shall immediately apprise the Owner
about any fraud or suspected fraud as soon as it comes to their notice. A
certificate to this effect shall be furnished by the bidder along with his bid.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 17-
30.09.2015
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2.31
Agency Commission
No Agency commission shall be payable under the Contract.

2.32

As a Contract security, the successful Bidder, to whom the work is awarded, shall be
required to furnish a Contract Performance Bank Guarantee (CPBG) in the Format
attached as Annexure- G, in favour of the Owner within 30 days from the date of issue
of Letter of Award (LOA). The guarantee amount shall be equal to ten percent (10%) of
the Contract Price and it shall guarantee the faithful performance of the Contract in
accordance with the terms and conditions specified in these documents and
specifications. The CPG shall be valid till the end of Warranty Period plus Ninety (90)
days grace period. If the contract price is in more than one currency, CPBG shall be
10% of respective currency.
If the bidder is a joint venture of two firms who collectively meet the Qualifying
Requirement, in addition to the Contract Performance Guarantee (CPBG) of 10%
furnished by the bidder, each of the JV partner shall furnish Additional Contract
Performance Guarantee equal to 1% of Contract Price. To clarify further, in such a
case, the value of Contract Performance Bank Guarantee furnished by the Bidder and
Additional Contract Performance Bank Guarantee furnished by the JV partners taken
together shall be 12% of the Contract Price.
If the bidder is a Consortium of two firms, in addition to the Contract Performance
Guarantee (CPBG) of 10% furnished by the Consortium Leader, the other consortium
member will furnish Additional Contract Performance Bank Guarantee equal to 2% of
Contract Price. To clarify further, in such a case, the value of Contract Performance
Bank Guarantee furnished by the Bidder (Consortium Leader) and Additional Contract
Performance Bank Guarantee furnished by the other consortium member taken
In case of a successful foreign bidder, if the Owner accepts to enter into the Second
Contract and / or Third Contract with the assignee, then, within Thirty (30) days after
receipt of Letter of Award, the assignee shall furnish an additional Contract
Performance Bank Guarantee for five percent (5%) of the value of the Contract entered
into with the assignee (i.e. for five percent of aggregate value of component
Contract(s) entered into with the assignee).
2.33
Contract Quality Assurance

1. The Bidder shall include in his Bid a detailed Quality Assurance Programme
containing the overall quality, management and procedures which he proposes to
follow in the performance of the Works during various phases.
2. After Letter of Award (LOA) the detailed Quality Assurance Programme to be
followed for the execution of the Contract will be mutually discussed and agreed to
and such agreed Programme shall form a part of the Contract.
2.34
Codes & Standards
Specifications give reference to Indian or internationally accepted Standards.

However, equipment or materials meeting other recognized National or
International Standards, which ensure an equal or superior quality than Standards
specified, will also be accepted. For details of codes and standards refer Technical
specification, Volume-II.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 18-
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2.35
Vital Clauses
The following clauses in the Tender Specification & Draft Contract are vital. Bidder
is advised not to take deviations to these clauses. If deviations are taken from the
stipulations of these clauses, such Bids would be liable for rejection:
Scope of Work
Time Schedule
Price Basis
Warranty
Liquidated Damages
Force Majeure
Arbitration
Taxes & Duties
Bid Guarantee
Patents, Indemnity
Validity of Bids
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
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3.1
Owner / Purchaser
[-------------------------------------------------]
Consultant
[-------------------------------------------------]
Project Title
[-------------------------------------------------]
Location
[-------------------------------------------------]
Latitude
[-------------------------------------------------]
Longitude
Elevation above MSL
:
:
[-------------------------------------------------]
[-------------------------------------------------]
[-------------------------------------------------]
Nearest Sea Port
[-------------------------------------------------]
Nearest Airport
:
Site
[-------------------------------------------------]
[-------------------------------------------------]
For Project & Site related detailed information, refer Clause No. 2 of Section-I of
Volume-II.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 20-
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4.1
Definitions
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
"Applicable Laws" means the laws of any national, state, local or municipal
legislature in India, or of any other Competent Authority, including all laws,
acts, judgments, statutes, rules, regulations, ordinances, orders, decrees,
injunctions, governmental authorizations, requirements of Applicable Permits
and any agreements, decisions, acts, instructions, requirements, directions
and notifications of any competent or other Competent Authority or court or
tribunal or arbitrator having jurisdiction over the matter in question, including
those related to taxes, assessments, expropriation and duties, or authoritative
interpretation, as amended, modified, enacted, reinterpreted or revised from
time to time hereafter.
Applicable Permits" means all permits, licenses, authorizations, consents,
decrees, waivers, privileges, acknowledgements, concessions, approvals,
rulings, decisions and visas from, filings with or applications submitted to, any
Competent Authority or court or tribunal of competent jurisdiction necessary
from time to time for or in relation to the performance of the Works, including
as detailed in this GCC.
"Agreement" means the Contract Agreement (entitled "Contract Agreement")
executed by the parties to which these Conditions are annexed and also
includes supplements & amendments to the Contract Agreement.
Contractor as per the 'Contract Agreement' signed by the parties, including
contract documents, contract schedule, all attachments and appendices
thereto and all documents incorporated by reference therein.
Contract Documents means the complete documents, which are the basis
of finalization of the contract, including correspondence exchanged from issue
of tender till date of signing the contract. All such documents shall be listed in
the Contract Agreement.
Contractors Equipment means all plant, facilities, equipment, machinery,
tools, apparatus, appliances or things of every kind required in or for
installation, completion and maintenance of Facilities that are to be provided
by the Contractor, but does not include Plant and Equipment, or other things
intended to form or forming part of the Facilities.
Contractor means the person(s), Firm or a Company whose bid to perform
the Contract has been accepted by the Owner and shall be named as such in
the Contract Agreement, and includes the legal successors or permitted
assigns of the Contractor.
Contract Price means any sum or sums finally accepted by the Owner for
the execution of this contract, subject to such additions and adjustments
thereto or deductions there from, as may be made pursuant to the Contract.
Contractors Representative means any person nominated by the
Contractor & approved by the Owner hereof to perform the duties delegated
by the Contractor.
Consulting Engineer means Owners Engineer appointed by the Owner.
Also refers to any other firm(s) or person(s) as may be appointed by the
Owner from time to time.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 21-
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xi.
xii.
xiii.
xiv.
xv.
xvi.
xvii.
xviii.
xix.
xx.
xxi.
xxii.
Commissioning means the construction of plant and equipment for

operation of the Facility at rated capacity are complete and the plant and
equipment achieves the designated full load/full capacity, at designated
fuel/input.
Completion means that the Facilities (or a specific part thereof where
specific parts are agreed) have been completed operationally and structurally
and put in a tight and clean condition, and that all work in respect of precommissioning of the Facilities or such specific part thereof has been
completed and commissioning has been attained as per Technical
Specifications.
"Competent Authority means any agency, authority, department,
inspectorate, ministry or statutory person (whether autonomous or not) of
GOI, [Name of the State], Ministry of Environment and Forests (MoEF) any
other State of the Republic of India or any local authority.
Defect Liability Period means the period of validity of the warranties given
by the Contractor, commencing at completion of the Facilities or a part
thereof, during which the Contractor is responsible for defects with respect to
the Facilities.
Effective Date means the date from which the Time for Completion of the
facilities and other milestones for execution of the Renovation &
Modernization work as per the scope of work under this tender by the
Contractor shall be determined.
Erection Services means those entire services ancillary to the supply of
the plant and equipment for the Facilities, to be provided by the Contractor
under the Contract. e.g. transportation and provision of marine or other similar
insurance, inspection, expediting, site preparation works (including the
provision and use of Contractors Equipment and the supply of all
construction materials required), installation, testing, Pre-commissioning,
commissioning, operations, maintenance, the provision of operations and
maintenance manuals, training of Owners Personnel etc.
Facilities means the plant and equipment to be supplied and installed, as
well as all the Installation Services to be carried out by the Contractor under
the Contract.
Force Majeure means mean any event beyond the reasonable control of
the Owner or of the Contractor, as the case may be, and which is unavoidable
diligence and prudence which would reasonably and ordinarily be expected
from a skilled and experienced Contractor, equipment manufacturer or
operator applying the standards generally adopted by global Contractors,
global equipment manufacturers and operators in the construction or
operation of power generation facilities or the manufacture of equipment
therefore, except in so far as inconsistent with any applicable Indian law or
directive.
Guarantee Test(s) means the test(s) specified in the Technical
Specifications to be carried out to ascertain whether the Facilities or a
Document Number
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No.
03
Description
Volume-I
Page No.
Date of Issue
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xxiii.
xxiv.
xxv.
xxvi.
xxvii.
xxviii.
xxix.
xxx.
xxxi.
xxxii.
xxxiii.
xxxiv.
xxxv.
xxxvi.
xxxvii.
specified part thereof is able to attain the Functional/Performance Guarantees

specified in the Technical Specification.
Incoterms means International rules for interpreting trade terms published
by the International Chamber of Commerce (latest edition), Paris (France).
Unless inconsistent with any provisions of the contract, the meaning of any
trade term and the rights and obligations of the parties there under shall be as
prescribed by Incoterms.
"Inspector/Inspecting Engineer" means the Owner or any person
nominated by the Owner from time to time, to inspect the equipment of works
under the contract and/or the duly authorized representative of the Owner.
"Latent Defect" means the defects inherent in the material or arising out of
design deficiency which does not manifest itself during the Warranty
Period/Defect Liability Period, as described in this GCC.
issued by the Owner notifying the Contractor that its Bid Proposal has been
accepted.
Manufacturer's Works or "Contractor's Works" means the place used
by the Contractor, its manufacturer, supplier, collaborators or subcontractors/vendors/sub-vendors for the performance of the works.
Operational Acceptance means the acceptance by the Owner of the
Facilities (or any part of the Facilities where the Contract provides for
acceptance of the Facilities in parts), which certifies the Contractors
fulfillment of the Contract in respect of performance guarantees of the
Facilities.
Owner or Purchaser shall means the [Name of the Utility], , and
includes its legal successors or permitted assignees.
"Person" means any natural person, firm, corporation, company, voluntary
association, partnership, joint venture, trust, and incorporated organization,
unincorporated organization, Competent Authority or other entity.
Pre-commissioning means the testing, checking and other requirements
specified in the Technical specifications that are to be carried out by the
Contractor in preparation for commissioning.
Project means the Owners [----------------------------] in respect of which the
Contract has been signed.
Project Consultant or Owners Consultant means the engineering firm
or person(s) appointed by the Owner to render engineering project
consultancy services for the project.
Plant and Equipment means permanent plant, equipment, systems,
machinery, apparatus, articles and things of all kinds to be provided and
incorporated in the Facilities by the Contractor under the Contract (including
the spare parts to be supplied by the Contractor under the Contract
Agreement), but does not include Contractors Equipment.
SCC means the Special Conditions of Contract hereof.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 23-
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xxxviii.
xxxix.
xl.
xli.
xlii.
xliii.
xliv.
xlv.
Site means the land and other places upon which the Facilities are to be
installed, and such other lands or places as may be specified in the Contract
as forming part of the Site.
Sub Contractor, including Vendors/Sub-Vendors, means any firm or
person to whom execution of any part of the Facilities, including preparation
of any design or supply of any plant and equipment is subcontracted directly
or indirectly by the Contractor, and includes its legal successors or permitted
assignees.
specification of the Works and statement of the technical and other standards
to which the Works are to be performed including any modifications thereto
made in accordance with the Conditions. This includes the technical &
commercial specifications and other Tender Documents forming a part of the
Contract and such other Schedules and drawings as may be mutually agreed
upon.
Tenderer"/"Bidder" means the Person(s), Firm/Company who has
submitted its Bid Proposal in response to the bid invitation by the Owner, for
the Project.
Time for Completion means the time within which completion of the
Facilities as a whole (or of a part of the Facilities where a separate time for
completion of such part has been specified) is to be attained in accordance
with the stipulations and provisions of the Contract.
"Warranty Period" or Defect Liability Period means the period during
which the Contractor shall remain liable for repair or replacement of any
defective part of the works performed under the contract, free of cost.
"Work(s)" means and includes the tasks of furnishing of equipment, labour &
services, transport, handling, unloading and storage at site, civil construction
and complete erection, testing, commissioning putting into satisfactory
operation and completion of successful performance tests, reliability tests and
any other guaranteed parameters as defined in the Contract, replacement,
modification, repair of defective parts or equipment during warranty period
and rectification of latent defects during latent defect period.
"Writing" or "Written" shall include any manuscript, type-written or printed
statement, under or over signature and/or seal as the case may be.
When the words "Approved", "Subject to Approval", "Satisfactory", "Equal to", "Proper",
"Requested", "As Directed", "Where Directed", "When Directed", "Determined by",
"Accepted", "Permitted", or words and phrases of similar importance are used, the
approval, judgment, direction, etc., is understood to be a function of the Owner. Words
implying persons or the gender neutral pronoun it, shall include firms, companies,
corporation, associations or body of individuals whether incorporated or not. Words
implying masculine gender or singular number shall also include the feminine gender
and plural number and vice-versa where the context so requires or permits.
Terms and expressions not herein defined shall have the same meaning as are
assigned to them in the Indian Sale of Goods Act (1930), failing that in the Indian
Contract Act (1872) and failing that in the General Clauses Act (1897) including
amendments thereof, if any.
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4.2
Contract Documents
a) All documents forming part of the Contract (and all parts thereof) are intended to be
correlative, complementary and mutually explanatory. The Contract shall be read
as a whole.
b) The Contract will be signed in three originals and the Contractor shall be provided
with one signed original and the rest will be retained by the Owner.
4.3

In case there is any ambiguity of conflict between different contract documents, the
order of precedence shall be as follows:i. The signed Contract Agreement & the annexure/ appendices thereto (highest
precedence)
v. Technical specification & Tender Drawing submitted by the contractor.
vi. The bid & schedules/ attachment.
4.4
Interpretation
All Contract Documents, all correspondence and communications to be given, and
all other documentation to be prepared and supplied under the Contract shall be
written in English, and the Contract shall be construed and interpreted in accordance
with English language.
Unless inconsistent with any provision of the Contract, the meaning of any trade
term and the rights and obligations of parties there under shall be as prescribed by
Incoterms. Incoterms means latest edition of International Rules for Interpreting Trade
Terms published by the International Chamber of Commerce Paris, France.
4.5
Construction of the Contract

The Contracts to be entered between the Owner and the Contractor shall be as under:
'First Contract' for CIF Supply of all Offshore Plant and Equipments and
Materials including Mandatory Spares to be supplied from abroad.
'Second Contract" for Ex-Works Supply of all Plant and Equipments and
Materials including Mandatory Spares of Indian origin.
Third Contract for providing all services i.e. Port Handling, Port Clearance and Port
Charges for the imported goods, further Loading and Inland Transportation for Delivery
at Site, Unloading, Storage, Handling at Site, Installation, Insurance, Testing and
Commissioning including carrying out Guarantee Tests for all the Equipments supplied
under the First Contract and the Second Contract and all other services specified in the
Tender Documents. All the above Contracts will contain a cross-fall breach clause
specifying that breach of one Contract will constitute breach of the other Contracts
which will confer a right on the Owner to terminate the other Contracts also at the risk
and the cost of the Contractor.
The foreign bidder, however, has the option, to be exercised as a part of its bid
proposal, to propose an Assignee in its bid to execute the Second Contract and/or the
Third Contract. Such foreign bidder shall furnish a written unequivocal consent (with
Part-I Bid) of the proposed Assignee to work as independent Contractor on the terms
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and conditions offered by the bidder For the scope of work envisaged by the foreign
bidder, in its bid, to be executed by Assignee, the Assignee should have
relevant/required capacity and experience of executing similar job. The bidder shall
substantiate with relevant/required documents in the bid to establish capacity and
experience of the Assignee.
If the foreign bidder has proposed an Assignee in its bid to execute the Second
Contract and/or the Third Contract and has also furnished written unequivocal consent
of the proposed Assignee to work as an independent Contractor on the terms and
conditions offered by the bidder and if the Owner is satisfied with the capacity and
experience of the Assignee proposed in the bid, the Owner will enter into the Second
Contract and/or the Third Contract with the Assignee. However, if the Owner in its
judgment does not find acceptable the Assignee proposed in the bid as its Contractor,
then on the request of the Owner, the Bidder shall have option to propose an alternate
Assignee on the same terms and conditions and cost as offered in its bid. In case the
Assignee option is not exercised by the Bidder or if the Assignee fails to enter into
Contract(s) with the Owner or if the Owner in its judgment does not find acceptance of
the Assignee as its Contractor, then the foreign bidder shall be obliged to enter into
and execute all the contracts envisaged to be entered upon this Tender with the Owner
covering the entire scope of work envisaged in the Tender Documents on the same
terms and conditions and cost as offered in its Bid.
If any foreign bidder has proposed an Assignee in his bid to execute the Second
of the proposed Assignee to work as independent Contractor on the terms and
conditions offered by the bidder and if the Owner is satisfied with capacity and
experience of the Assignee, the Owner will enter into the Second Contract and/or
Third Contract with the said Assignee. In case no Assignee has been proposed by the
foreign bidder in his bid or if the Assignee fails to enter into the Second Contract and/or
Third Contract with the Owner or if the Owner in its judgment does not find acceptance
of the proposed Assignee as its Contractor, then the foreign bidder shall be obliged to
enter into and execute all the three Contracts with the Owner.
If the Owner accepts to enter into Second Contract and/or Third Contract with the
Assignee of foreign bidder, the said Assignee, in addition to the Contract Performance
Securities to be provided by the foreign Contractor shall provide within [twenty eight
(28)] days of Notification of Award, separate Contract Performance Bank Guarantee
equivalent to ten percent (5%) of the value of the Contract(s) entered into with the
Assignee for the due performance of the Contract, with an initial validity upto [ninety
(90) days] beyond the scheduled Defects Liability Period.
The award of the separate Contracts shall not in any way dilute the responsibility of the
Contractor for the successful completion of the Facilities as per Contract Documents
and a breach in one Contract shall automatically be construed as a breach of the other
Contract(s) which will confer a right on the Owner to terminate the other Contract(s)
also at the risk and the cost of the Contractor.
4.6
Independent Contractor
The Contractor shall be an independent contractor performing the Contract. The
Subject to the provisions of the Contract, the Contractor shall be solely responsible for
the manner in which the Contract is performed. All employees, representatives or
Subcontractors engaged by the Contractor in connection with the performance of the
Contract shall be under the complete control of the Contractor and shall not be
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deemed to be employees of the Owner, and nothing contained in the Contract or in any
subcontract awarded by the Contractor shall be construed to create any contractual
relationship between any such employees, representatives or Subcontractors and the
Owner.
4.7

If the Bidder/Contractor is a joint venture or consortium of two or more firms, all such
firms shall be jointly and severally bound to the Owner for the fulfillment of the
provisions of the Contract and the Bidder shall submit a letter of consent to this effect
(with Part-I Bid) signed by all joint venture partners / consortium members. The joint
venture/consortium partners shall designate one of such firms to act as a leader with
authority to bind the joint venture or consortium. The composition or the constitution of
the joint venture or consortium shall not be altered without the prior consent of the
Owner.
4.8
Non-Waiver
No relaxation, forbearance, delay or indulgence by either party in enforcing any of the
terms and conditions of the Contract or the granting of time by either party to the other
shall prejudice, affect or restrict the rights of that party under the Contract, nor shall
any waiver by either party of any breach of Contract operate as waiver of any
subsequent or continuing breach of Contract. Any waiver of a partys rights, powers or
remedies under the Contract must be in writing, must be dated and signed by an
authorized representative of the party granting such waiver, and must specify the right
and the extent to which it is being waived.
4.9
Severability
unenforceable, such prohibition, invalidity or unenforceability shall not affect the validity
or enforceability of any other provisions and conditions of the Contract.
4.10
Origin
Origin means the place where the materials, equipments and other supplies for the
Facilities are mined, grown, produced or manufactured, and from which the services
are provided.
4.11
Notices
personal delivery, or post, or special courier, or telefax, or E-mail to the address of the
relevant party indicated in the Contract.
Either party may change its postal address, telefax number, or E-mail address or
addressee for receipt of such notices by ten (10) days notice to the other party in
writing
Notices shall be deemed to include any approvals, consents, instructions, orders and
certificates to be given under the Contract.
4.12
Governing Laws
The Contract shall be governed by and interpreted in accordance with laws in force in
India. The Courts of [........] shall have exclusive jurisdiction in all matters arising under
the Contract.
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4.13
Settlement Of Disputes
If any differences/ dispute arises between the Owner and the Contractor in
abandonment or breach of the Contractthe Owner & Contractor shall seek to
resolve any such dispute or difference by mutual consultation. If the parties fail to
resolve such a dispute or difference by mutual consultation, then the dispute shall
be referred in writing by either party to the Arbitrator, with a copy to the other party.
b) Arbitration
Either Owner or the Contractor may, of its intention to commence arbitration, as to
the matter in dispute, and no arbitration may be commenced unless such notice is
given.
Any dispute, in respect of which a notice of intention to commence arbitration has
been given, as above shall be finally settled by arbitration. Arbitration may be
commenced prior to or after completion of the Facilities
panel composed of three arbitrators, in accordance with the provisions set forth
below.
The Owner and the Contractor shall each appoint one arbitrator, and these two
panel. If the two arbitrators do not succeed in appointing a third arbitrator within
[twenty eight (28)] days after the latter of the two arbitrators has been appointed,
the third arbitrator shall, at the request of either party, be appointed by the
Appointing Authority for arbitrator is given below.
Appointing Authority for Arbitrator:
President, Institution of Engineers in case of an Indian Contractor.
President, International Chambers of Commerce, Paris in case of a Foreign
Contractor.
If one party fails to appoint its arbitrator within [forty-two (42)] days after the other
party has named its arbitrator, the party which has named an arbitrator may
request the Appointing Authority to appoint the second arbitrator.
If for any reason an arbitrator is unable to perform its function, the mandate of the
Arbitrator shall terminate in accordance with the provisions of applicable laws and a
substitute shall be appointed in the same manner as the original arbitrator.
Arbitration proceedings as follows: In case of a foreign contractor the arbitration proceeding shall be conducted
in accordance with the United Nations Commission on International Trade
Law (UNCITRAL) Arbitration Rules of 1976.
In case of an Indian Contractor Adjudication/Arbitration proceedings shall
be conducted in accordance with Indian Arbitration and Conciliation Act
1996
In case of a foreign associate of the contractor, the arbitration proceedings
shall be conducted in accordance with the United Nation Commission on
International Trade Law (UNCITRAL) Arbitration Rules of 1976.
The Place for Arbitration shall be: [New Delhi], India.
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The decision of a majority of the arbitrators (or of the third arbitrator chairing the
arbitration, if there is no such majority) shall be final and binding and shall be
enforceable in any court of competent jurisdiction as decree of the court. The
parties thereby waive any objections to or claims of immunity from such
enforcement.
The Owner shall pay the Contractor consideration due to the Contractor.
4.14
Scope of Facilities
a) Unless otherwise expressly limited in the Technical Specifications, Facilities the
Contractors obligations cover the provision of all Plant and Equipments including
spares and the performance of all Services required for design, manufacture
(including procurement, quality assurance, construction, installation, associated
civil works, Structural and others construction works, precomissioning and delivery)
of the Plant and Equipment and the installation, commissioning, completion of
facilities and performance testing of the Facilities in accordance with the plans,
procedures, specifications, drawings, codes and any other documents as specified
in the Technical Specifications. Such specifications include, but are not limited to,
the provision of supervision and engineering services; the supply of labour,
materials, equipment, spare parts and accessories; Contractors Equipments;
construction utilities and supplies; temporary materials, structures and facilities;
transportation loading & unloading.
b) The Contractor shall, unless specifically excluded in the Contract, perform all such
work and/or supply all such items and materials not specifically mentioned in the
Contract but that can be reasonably inferred from the Contract as being required
for attaining Completion of the Facilities.
4.15

a) The Contractor shall commence work on the scope of work under this Tender from
the date of Letter of Award. Contractor shall thereafter proceed with the Facilities in
accordance with the time schedule specified in SCC & detailed network schedule
agreed & appended to the contract.
b) The Contractor shall attain Completion of the Facilities (or of a part where a
separate time for Completion of such part is specified in the Contract) within the
time stated in the SCC subject to time extensions, the contractor is entitled under
the contract conditions or time extension expressly grouted by the Owner.
4.16
Spare Parts
In addition to the supply of Mandatory Spare Parts included in the Contract, the
Contractor agrees to supply other spare parts (recommended spares) required for the
operation and maintenance of the Facilities for 3 years. However, the identity,
specifications and quantities of such spare parts and the terms and conditions relating
to the supply thereof are to be agreed between the Owner and the Contractor, and the
price of such spare parts shall be that given in Price Schedule for recommended
spares. The price of such spare parts shall include the purchase price therefor and
other costs and expenses (including the Contractors fees) relating to the supply of
spare parts. The prices of recommended spares covered in price schedule shall be
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valid for a period of six months after the date of Notification of Award of Main
Equipment and Mandatory Spares.
The Contractor shall supply the recommended spares at the same terms and
conditions as are otherwise applicable to this Contract.
All the spares for the equipment under the Contract will strictly conform to the
Specification and other relevant documents and will be identical to the
corresponding main equipment/components supplied under the Contract and
shall be fully interchangeable.
All the Mandatory Spares covered under the Contract shall be manufactured
along with the main equipments as a continuous operation and the delivery of
the spares will be affected along with the main equipments in a phased
manner and the delivery would be completed by the respective dates for the
various categories of equipment as per the agreed schedule. If order for the
Recommended Spares has been placed with the Contractor prior to
commencement of manufacture of the main equipment this shall be
applicable for manufacturer of recommended spares as well.
The Contractor will provide the Owner with the manufacturing drawings,
catalogues, assembly drawings and any other document required by the for
the recommended spares. Such details will be furnished to the Owner as
soon as they are prepared but in any case not later than six months prior to
commencement of manufacture of the corresponding main equipment.
In addition to the spares recommended by the Contractor, if the Owner
further identifies certain particular items of spares, the Contractor will submit
the prices and delivery quotation for such spares within [30] days of receipt of
such request with a validity period of 6 months for consideration by the Owner
and placement of order for additional spares, if the Owner so desires.
The quality plan and the inspection requirement finalised for the main
equipment will also be applicable to the corresponding spares.
The Contractor will provide the Owner with all the addresses and particulars
of his sub-suppliers while placing the order on vendors for items/components/
equipment covered under the Contract and will further ensure with his
vendors that the Owner, if so desires, will have the right to place order for
spares directly on them on mutually agreed terms based on offers of such
vendors.
The Contractor shall guarantee the long term availability of spares to the
Owner for the full life of the equipment covered under the Contract. The same
provision will also be applicable to spares supplied by Sub-contractors.
For the first 6 years from the schedule date of completion of facilities the
prices will be derived from the corresponding Ex-Works Price at which the
order for such spares have been placed by Owner as a part of Mandatory
Spares or Recommended Spares, or from the rates of Mandatory Spares or
Recommended Spares as quoted by/negotiated with the Contractor. ExWorks order price of future spares shall be computed in accordance with the
price adjustment provisions covered under the main Contract excepting that
the base indices will be counted from the scheduled date of Commissioning of
the last equipment under the main project. The Contractor will indicate in
advance the delivery period of the items of spares, which the Owner may
procure in accordance with this clause. In case of emergent requirements of
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spares, the Contractor would make every effort to expedite the manufacture
and delivery of such spares on the basis of mutually agreed time schedule.
In case the Contractor fails to supply the mandatory or recommended spares
in the terms stipulated above, the Owner shall be entitled to purchase the
same from the alternate sources at the risk and the cost of the Contractor and
recover from the Contractor, the excess amount paid by the Owner over the
rates worked on the above basis. In the event of such risk purchase by the
Owner, the purchases will be as per the Works and Procurement Policy of the
Owner prevalent at the time of such purchases and the Owner at his option
may include a representative from the Contractor in finalising the purchases.
It is expressly understood that the final settlement between the parties in
terms of relevant clauses of the Contract Documents shall not relieve the
Contractor of any of his obligations under the provision of long term
availability of spares and such provisions shall continue to be enforced till the
expiry of 6 years period reckoned from the scheduled date of Commissioning
of the Plant and Equipment unless otherwise discharged expressly in writing
by the Owner.
The Contractor shall warrant that all spares supplied will be new and in
accordance with the Contract Documents and will be free from defects in
design, material and workmanship. The defects liability period for spares shall
be 12 months from the date it is put to use. In case of failure of any spare part
due to fault in design material or workmanship the same part will be replaced
by the contractor without any extra cost of the Owner.
In case of any failure in the original component/equipments due to faulty designs,
materials and workmanship, the corresponding spare parts, if any, supplied will be
replaced without any extra cost to the Owner unless a joint examination and analysis
by the Owner and the Contractor of such spare parts prove that the defect found in the
original part that failed, can safely be assumed not to be present in spare parts. Any
replaced spare parts will have the Defects Liability period of 12 months from the date it
is put in use. The discarded spare parts will become the property of the Contractor as
soon as they have been replaced by the Contractor. In any case the defect liability of
spares will expire at the end of 48 months from the date of their receipt at site
The Defects Liability of spares that are not used within 18 months from the respective
date of the delivery at Site will, be subject to condition that all such spares are stored in
accordance with Contractor's standard recommended practice, if any, and the same
has been furnished to the Owner.
4.17
Contractors Responsibilities
a) The Contractor shall design, manufacture (including associated purchases and/or
subcontracting), disassemble/dismantle wherever required, install, commission and
complete the Facilities and carryout the Guarantee tests with due care and
diligence in accordance with the Contract.
b) Before entering into this contract the Contractor is responsible to have examined
the data relating to the Facilities provided by the Owner, and on the basis of
information that the Contractor could have obtained from a visual inspection of the
Site and of other data readily available to it relating to the Facilities as at one month
days prior to bid submission. Any failure to acquaint itself with all such data and
information shall not relieve contractor of its responsibility for properly estimating
the difficulty or cost of successfully performing its scope of work under this contract.
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c) The Contractor shall acquire in its name all permits, approvals and/or licenses from
all local, state or national government authorities or public service undertakings in
the country where the Site is located that are necessary for the performance of the
Contract, including, without limitation, visas for the Contractors and
Subcontractors personnel and entry permits for all imported Contractors
Equipment.
d) The Contractor shall comply with all laws in force in India and the place where the
facility is located out. The laws will include all national, provincial, municipal or
other laws that affect the performance of the Contract and bind upon the
Contractor. The Contractor shall indemnify and hold harmless the Owner from and
against any and all liabilities, damages, claims, fines, penalties and expenses of
whatever nature arising or resulting from the violation of such laws by the
Contractor.
4.18
a) The Owner shall be responsible for acquiring and providing legal and physical
possession of the Site and access thereto, and for providing possession of and
access to all other areas reasonably required for the proper execution of the
Contract, including all requisite rights of way.
b) The Owner shall acquire and pay for all permits, approvals and/or licenses from
all local, state or national government authorities or public service undertakings,
which such authorities or undertakings require the Owner to obtain them in the
Owners name, are necessary for the execution of the Contract.
c) If requested by the Contractor, the Owner shall use its best endeavours to assist
the Contractor in obtaining in a timely and expeditious manner all permits,
approvals and/or licenses necessary for the execution of the Contract from all local,
state or national government authorities or public service undertakings that such
authorities or undertakings require the Contractor or Subcontractors or the
personnel of the Contractor or Subcontractors, as the case may be, to obtain.
d) The Owner shall be responsible for the continued operation of the Facilities after
Completion.
4.19
Taxes & Duties

a) Custom Duty, Excise Duty, Central sales tax (CST), service tax, Value Added Tax
considered for bid evaluation. The reimbursement of these taxes shall be on actual
subject to the quoted value of these taxes as ceiling corresponding to the base
price. Additional liability of taxes and duties arising out of price variation shall be
reimbursed against documentary evidence over and above the ceiling (quoted
value). Statutory variation in Indian taxes and duties will be dealt with as per the
relevant stipulations of the specification. Except as otherwise specifically provided
in the Contract, the Contractor shall bear and pay all Taxes, Duties, Levies and
Charges including Entry Tax, Service Tax, if applicable in connection with the
Facilities in India and outside India. All taxes, duties & levies on works contract, if
any, shall be to the Contractor's account and no separate claim in this regard will
be entertained by the Owner.
b) All taxes, duties and levies including entry tax/octroi (if any) in respect of all
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vendor's works to site shall be to the Contractor's account and no separate claim in
this regard will be entertained by the Owner.
c) In case there is introduction of GST or any other tax in lieu of existing Excize
Duty/Service Tax and VAT/ Sales Tax, the contract price will be adjusted for the
impact of any differential tax liability subject to documentary evidence. This will be
restricted to direct transaction between the owner and contractor, and bought out
items directly dispatched from sub-vendor's works to project site.
d) Further all taxes, duties and levies including sales tax on works contract, Entry Tax,
if any, in respect of civil construction works, erection & commissioning if any and
custom duty/sales tax as applicable on the materials used for such construction
works shall be to the contractor's account and no separate claim in this regard will
be entertained by the Owner. Incidence of Service Tax & cess on any component
of the Bid Price shall be to the Contractor's account and bidders shall include
Service Tax as applicable at the date seven (7) days prior to the date of bid submission in the bid price. The Contract Price will be adjusted for impact of any
change in the rate of service tax or cess on service tax subsequent to this date for
direct transactions between the Owner and the Contractor.
e) If any tax exemptions, reductions, allowances or privileges may be available to the
Contractor, the Owner shall use its best endeavours to enable the Contractor to
benefit from any such tax savings to the maximum allowable extent.
4.20
information furnished to the Owner by the Contractor herein shall remain vested in the
Contractor or, if they are furnished to the Owner directly or through the Contractor by
any third party, including suppliers of materials, the copyright in such materials shall
remain vested in such third party. The Owner shall however be free to reproduce all
drawings, documents and other material furnished to the Owner for the purpose of the
contract including, if required, for operation and maintenance.
4.21
a) The Owner and the Contractor shall keep confidential and shall not, without the
written consent of the other party hereto, divulge to any third party any documents,
data or other information furnished directly or indirectly by the other party hereto in
connection with the Contract, whether such information has been furnished prior
to, during or following termination of the Contract. Notwithstanding the above, the
Contractor may furnish to its Subcontractor(s) such documents, data and other
information it receives from the Owner to the extent required for the
Subcontractor(s) to perform its work under the Contract, in which event the
Contractor shall obtain from such Subcontractor(s) an undertaking of confidentiality
similar to that imposed on the Contractor.
b) The Owner shall not use such documents, data and other information received
from the Contractor for any purpose other than the operation and maintenance of
the Facilities. Similarly, the Contractor shall not use such documents, data and
other information received from the Owner for any purpose other than the design,
procurement of Plant and Equipments, construction or such other work and
services as are required for the performance of the Contract.
c) The obligation of a party, shall not apply to that information which
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4.22

disclosure and which was not previously obtained, directly or indirectly, from
the other party hereto
Otherwise lawfully becomes available to that party from a third party that
has no obligation of confidentiality.
Representatives
a) Project Manager
If the Project Manager is not named in the Contract, then within fourteen (14) days of
the Effective Date, the Owner shall appoint and notify the Contractor in writing of the
name of the Project Manager. The Owner may from time to time appoint some other
person as the Project Manager in place of the person previously so appointed, and
shall give a notice of the name of such other person to the Contractor without delay.
The Owner shall take reasonable care to see that no such appointment is made at
such a time or in such a manner as to impede the progress of work on the
Facilities. The Project Manager shall represent and act for the Owner at all times
during the currency of the Contract. All notices, instructions, orders, certificates,
approvals and all other communications under the Contract shall be given by the
Project Manager, except as herein otherwise provided.
Contractor to the Owner under the Contract shall be given to the Project Manager,
b) Contractors Representative & Construction Manager
If the Contractors Representative is not named in the Contract, then within
[fourteen (14) days] of the Effective Date, the Contractor shall appoint the
Contractors Representative and shall request the Owner in writing to approve
the person so appointed. If the Owner makes no objection to the appointment
within [fourteen (14)] days, the Contractors Representative shall be deemed
to have been approved. If the Owner objects to the appointment within
[fourteen (14)] days giving the reason there for, then the Contractor shall
appoint a replacement within [fourteen (14) days] of such objection.
The Contractors Representative shall represent and act for the Contractor at
all times during the currency of the Contract and shall give to the Project
Manager all the Contractors notices, instructions, information and all other
communications under the Contract. All notices, instructions, information and
all other communications given by the Owner or the Project Manager to the
Contractor under the Contract shall be given to the Contractors
Representative or, in its absence, its deputy, except as herein otherwise
provided. The Contractor shall not revoke the appointment of the Contractors
Representative without the Owners prior written consent, which shall not be
unreasonably withheld. If the Owner consents thereto, the Contractor shall
appoint some other person as the Contractors Representative.
The Contractors Representative may, subject to the approval of the Owner
(which shall not be unreasonably withheld), at any time delegate to any
person any of the powers, functions and authorities vested in him or her. Any
such delegation may be revoked at any time. Any such delegation or
revocation shall be subject to a prior notice signed by the Contractors
Representative, and shall specify the powers, functions and authorities
thereby delegated or revoked. No such delegation or revocation shall take
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4.23
effect unless and until a copy thereof has been delivered to the Owner and
the Project Manager.
From the commencement of installation of the Facilities at the Site until
Operational Acceptance, the Contractors Representative shall appoint a
suitable person as the construction manager (hereinafter referred to as the
Construction Manager). The Construction Manager shall supervise all work
done at the Site by the Contractor and shall be present at the Site throughout
normal working hours except when on leave, sick or absent for reasons
connected with the proper performance of the Contract. Whenever the
Construction Manager is absent from the Site, a suitable person shall be
appointed to act as his or her deputy.
The Owner may by notice to the Contractor object to any representative or
person employed by the Contractor in the execution of the Contract who, in
the reasonable opinion of the Owner, may behave inappropriately, may be
incompetent or negligent, or may commit a serious breach of the Site
regulations.
If any representative or person employed by the Contractor is removed.
Work Program
a) Contractors Organization
The Contractor shall supply to the Owner and the Project Manager a chart showing
the proposed organization to be established by the Contractor for carrying out work
on the Facilities. The chart shall include the identities of the key personnel together
with the curricula vitae of such key personnel to be employed within [twenty one (21)]
days of the Effective Date. The Contractor shall promptly inform the Owner and the
Project Manager in writing of any revision or alteration of such an organization chart.
Within [twenty-eight (28)] days after the date of Notification of Award of Contract,
the Contractor shall prepare and submit to the Project Manager a detailed Program
of Performance of the Contract, made in the form specified in the SCC and showing
the sequence in which it proposes to design, supply, transport, assemble, install and
precomissioning the Facilities, as well as the date by which the Contractor
reasonably requires that the Owner shall have fulfilled its obligations under the
Contract so as to enable the Contractor to execute the Contract in accordance with
the program and to achieve Completion and Acceptance of the Facilities in
accordance with the Contract. The program so submitted by the Contractor shall
accord with the Time Schedule included in Appendix 4 (Time Schedule) to the Form
of Contract Agreement and any other dates and periods specified in the Contract.
The Contractor shall update and revise the program as and when appropriate or
when required by the Project Manager, but without modification in the Times for
Completion.
c) Progress Report
The Progress Report shall be in a form acceptable to the Project Manager and shall
indicate: (a) percentage completion achieved compared with the planned percentage
completion for each activity; and (b) where any activity is behind the program, giving
comments and likely consequences and stating the corrective action being taken.
If at any time the Contractors actual progress falls behind the program, or it becomes
apparent that it will so fall behind, the Contractor shall, at the request of the Owner or
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the Project Manager, prepare and submit to the Project Manager a revised program,
taking into account the prevailing circumstances, and shall notify the Project Manager
of the steps being taken to expedite progress so as to attain Completion of the
Facilities within the Time for Completion.
e) Work Procedures
The Contract shall be executed in accordance with the Contract Documents and the
procedures given in the section on Forms and Procedures of the Contract
Documents.
If agreed between the Owner and the Contractor, the Contractor may execute the
Contract in accordance with its own standard project execution plans and procedures
to the extent that they do not conflict with the provisions contained in the Contract.
4.24
Subcontracting
a) The Contract Agreement specifies major items of supply or services and a list of
approved Subcontractors against each item, including vendors. Insofar as no
Subcontractors are listed against any such item, the Contractor shall prepare a list of
Subcontractors for such item for inclusion in such list. The Contractor may from time
to time propose any addition to or deletion from any such list. The Contractor shall
submit any such list or any modification thereto to the Owner for its approval in
sufficient time so as not to impede the progress of work on the Facilities. Such
approval by the Owner for any of the Subcontractors shall not relieve the Contractor
from any of its obligations, duties or responsibilities under the Contract.
b) The Contractor shall select and employ its Subcontractors/Subvendors for such
major items from those listed.
4.25
Design and Engineering

a) Specifications and Drawings
The Contractor shall execute the basic and detailed design and the engineering work
in compliance with the provisions of the Contract, or where not so specified, in
accordance with good engineering practice. The Contractor shall be responsible for
any discrepancies, errors or omissions in the specifications, drawings and other
technical documents that it has prepared, whether such specifications, drawings and
other documents have been approved by the Project Manager or not, provided that
such discrepancies, errors or omissions are not because of inaccurate information
furnished in writing to the Contractor by or on behalf of the Owner.
b) Codes and Standards
Wherever references are made in the Contract to codes and standards in
accordance with which the Contract shall be executed, the edition or the revised
version of such codes and standards current at the date [twenty eight (28)] days prior
to date of bid submission shall apply unless otherwise specified. During Contract
execution, any changes in such codes and standards shall be applied after approval
by the Owner.
c) Approval/Review of Technical Documents by Project Manager
The Contractor shall prepare (or cause its Subcontractors to prepare) and furnish to
the Project Manager the documents for its approval Any part of the Facilities covered
by or related to the documents to be approved by the Project Manager shall be
executed only after the Project Managers approval thereof.
Project Manager shall either return one copy thereof to the Contractor with its
approval endorsed thereon or shall notify the Contractor in writing of its disapproval
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thereof and the reasons there for and the modifications that the Project Manager
proposes. The Project Manager shall not disapprove any document, except on the
grounds that the document does not comply with some specified provision of the
Contract or that it is contrary to good engineering practice. The procedure for
submission of the documents by the Contractor and their approval by the Project
Manager shall be discussed and finalised with the Contractor.
If any dispute or difference occurs between the Owner and the Contractor in
connection with or arising out of the disapproval by the Project Manager of any
document and/or any modification(s) thereto that cannot be settled between the
parties within a reasonable period, then such dispute or difference may be referred to
an Adjudicator. If such dispute or difference is referred to an Adjudicator, the Project
Manager shall give instructions as to whether and if so, how, performance of the
Contract is to proceed. The Contractor shall proceed with the Contract in
accordance with the Project Managers instructions, provided that if the Adjudicator
upholds the Contractors view on the dispute, then the Contractor shall be
reimbursed by the Owner for any additional costs incurred by reason of such
instructions and shall be relieved of such responsibility or liability in connection with
the dispute and the execution of the instructions as the Adjudicator shall decide, and
the Time for Completion shall be extended accordingly.
The Project Managers approval, with or without modification of the document
furnished by the Contractor, shall not relieve the Contractor of any responsibility or
liability imposed upon it by any provisions of the Contract except to the extent that
any subsequent failure results from modifications required by the Project Manager.
4.26
Procurement
a) Plant and Equipment
The Contractor shall manufacture or procure and transport all the Plant and
Equipments in an expeditious and orderly manner to the Site.
b) Transportation
The Contractor shall at its own risk and expense transport all the Plant and
Equipments and the Contractors Equipments to the Site by the mode of transport
that the Contractor judges most suitable under all the circumstances. Unless
otherwise provided in the Contract, the Contractor shall be entitled to select any safe
mode of transport operated by any person to carry the Plant and Equipments and the
Contractors Equipment. Upon dispatch of each shipment of the Plant and
Equipments and the Contractors Equipments, the Contractor shall notify the Owner
by telex, cable, telefax, facsimile or Electronic Data Interchange (EDI) of the
description of the Plant and Equipments and of the Contractors Equipments, the
point and means of dispatch, and the estimated time and point of arrival in the
country where the Site is located, if applicable, and at the Site. The Contractor shall
furnish the Owner with relevant shipping documents to be agreed upon between the
parties.
The Contractor shall be responsible for obtaining, if necessary, approvals from the
authorities for transportation of the Plant and Equipments and the Contractors
Equipments to the Site. The Owner shall use its best endeavours in a timely and
expeditious manner to assist the Contractor in obtaining such approvals, if requested
by the Contractor. The Contractor shall indemnify and hold harmless the Owner from
and against any claim for damage to roads, bridges or any other traffic facilities that
may be caused by the transport of the Plant and Equipments and the Contractors
Equipments to the Site.
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c) The Contractor shall, at its own expense, handle all imported Plant and Equipments
and spares and Contractors Equipments at the point(s) of import and shall handle
any formalities for customs clearance
4.27
Installation
a) Setting Out/Supervision/Labor
Bench Mark: The Contractor shall be responsible for the true and proper setting-out
of the Facilities in relation to bench marks, reference marks and lines provided to it in
writing by or on behalf of the Owner.
If, at any time during the progress of installation of the Facilities, any error shall
appear in the position, level or alignment of the Facilities, the Contractor shall
forthwith notify the Project Manager of such error and, at its own expense,
immediately rectify such error to the reasonable satisfaction of the Project Manager.
If such error is based on incorrect data provided in writing by or on behalf of the
Owner, the expense of rectifying the same shall be borne by the Owner.
Contractors Supervision: The Contractor shall give or provide all necessary
superintendence during the installation of the Facilities, and the Construction
Manager or its deputy shall be constantly on the Site to provide full time
superintendence of the installation. The Contractor shall provide and employ only
technical personnel who are skilled and experienced in their respective callings and
supervisory staff who are competent to adequately supervise the work at hand.
The Contractor shall provide and employ on the Site in the installation of the Facilities
such skilled, semi-skilled and unskilled labor as is necessary for the proper and
timely execution of the Contract. The Contractor is encouraged to use local labour
that has the necessary skills. Unless otherwise provided in the Contract, the
Contractor shall be responsible for the recruitment, transportation, accommodation
and catering of all labour, local or expatriate, required for the execution of the
Contract and for all payments in connection therewith.
The Contractor shall at its own expense provide the means of repatriation to all of its
and its Subcontractors personnel employed on the Contract at the Site to their
various home countries. It shall also provide suitable temporary maintenance of all
such persons from the cessation of their employment on the Contract to the date
programmed for their departure. In the event that the Contractor defaults in providing
such means of transportation and temporary maintenance, the Owner may provide
the same to such personnel and recover the cost of doing so from the Contractor.
The Contractor shall, in all dealings with its labour and the
labor of its
Subcontractors currently employed on or connected with the Contract, pay due
regard to all recognized festivals, official holidays, religious or other customs and all
local laws and regulations pertaining to the employment of labor.
b) Contractors Equipments
All Contractors Equipments brought by the Contractor onto the Site shall be deemed
to be intended to be used exclusively for the execution of the Contract. The
Contractor shall not remove the same from the Site without the Project Managers
consent that such Contractors Equipments are no longer required for the execution
of the Contract. Unless otherwise specified in the Contract, upon completion of the
Facilities, the Contractor shall remove from the Site all Equipments brought by the
Contractor onto the Site and any surplus materials remaining thereon.
The Owner will, if requested, use its best endeavours to assist the Contractor in
obtaining any local, state or national government permission required by the
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Contractor for the export of the Contractors Equipments imported by the Contractor
for use in the execution of the Contract that is no longer required for the execution of
the Contract.
c) Site Regulations and Safety
The Owner and the Contractor shall establish Site regulations setting out the rules to
be observed in the execution of the Contract at the Site and shall comply therewith.
The Contractor shall prepare and submit to the Owner, with a copy to the Project
Manager, proposed Site regulations for the Owners approval, which approval shall
not be unreasonably withheld.
Such Site regulations shall include, but shall not be limited to, rules in respect of
security, safety of the Facilities, gate control, sanitation, medical care, and fire
prevention.
d) Opportunities for Other Contractors
The Contractor shall, upon written request from the Owner or the Project Manager,
give all reasonable opportunities for carrying out the work to any other contractors
employed by the Owner on or near the Site. If the Contractor, upon written request
from the Owner or the Project Manager, makes available to other contractors any
roads or ways the maintenance for which the Contractor is responsible, permits the
use by such other contractors of the Contractors Equipments, or provides any other
service of whatsoever nature for such other contractors, the Owner shall fully
compensate the Contractor for any loss or damage caused or occasioned by such
other contractors in respect of any such use or service, and shall pay to the
Contractor reasonable remuneration for the use of such equipments or the provision
of such services.
The Contractor shall also so arrange to perform its work as to minimize, to the extent
possible, interference with the work of other contractors. The Project Manager shall
determine the resolution of any difference or conflict that may arise between the
Contractor and other contractors and the workers of the Owner in regard to their
work.
The Contractor shall notify the Project Manager promptly of any defects in the other
Contractors work that come to its notice, and that could affect the Contractors work.
The Project Manager shall determine the corrective measures, if any, required to
rectify the situation after inspection of the Facilities. Decisions made by the Project
Manager shall be binding on the Contractor.
e) Emergency Work
If, by reason of an emergency arising in connection with and during the execution of
the Contract, any protective or remedial work is necessary as a matter of urgency to
prevent damage to the Facilities, the Contractor shall immediately carry out such
work.
If the Contractor is unable or unwilling to do such work immediately, the Owner may
do or cause such work to be done as the Owner may determine is necessary in order
to prevent damage to the Facilities. In such event the Owner shall, as soon as
practicable after the occurrence of any such emergency, notify the Contractor in
writing of such emergency, the work done and the reasons there for. If the work done
or caused to be done by the Owner is work that the Contractor was liable to do at its
own expense under the Contract, the reasonable costs incurred by the Owner in
connection therewith shall be paid by the Contractor to the Owner. Otherwise, the
cost of such remedial work shall be borne by the Owner.
f) Site Clearance
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Site Clearance in Course of Performance: In the course of carrying out the Contract,
the Contractor shall keep the Site reasonably free from all unnecessary obstruction,
store or remove any surplus materials, clear away any wreckage, rubbish or
temporary works from the Site, and remove any Contractors Equipments no longer
required for execution of the Contract. Clearance of Site after Completion: After
Completion of all parts of the Facilities, the Contractor shall clear away and remove
all wreckage, rubbish and debris of any kind from the Site, and shall leave the Site
and Facilities clean and safe.
g) Watching and Lighting
The Contractor shall provide and maintain at its own expense all lighting, fencing,
and watching when and where necessary for the proper execution and the protection
of the Facilities, or for the safety of the owners and occupiers of adjacent property
and for the safety of the public as per specification.
4.28
Testing & Inspections

a) The Contractor shall at its own expense carry out at the place of manufacture and/or
on the Site all such tests and/or inspections of the Plant and Equipments and any
part of the Facilities as are specified in the Contract.
b) The Owner and the Project Manager or their designated representatives shall be
entitled to attend the aforesaid test and/ or inspection, provided that the Owner shall
bear all costs and expenses incurred in connection with such attendance including,
but not limited to, all travelling and board and lodging expenses.
c) Whenever the Contractor is ready to carry out any such test and/or inspection, the
Contractor shall give a reasonable advance notice of such test and/or inspection and
of the place and time thereof to the Project Manager. The Contractor shall obtain
from any relevant third party or manufacturer any necessary permission or consent to
enable the Owner and the Project Manager (or their designated representatives) to
attend the test and/or inspection.
d) The Contractor shall provide the Project Manager with a certified report of the results
of any such test and/or inspection. If the Owner or Project Manager (or their
designated representatives) fails to attend the test and/or inspection, or if it is agreed
between the parties that such persons shall not do so, then the Contractor may
proceed with the test and/or inspection in the absence of such persons, and may
provide the Project Manager with a certified report of the results thereof.
e) The Project Manager may require the Contractor to carry out any test and/or
inspection not required by the Contract, provided that the Contractors reasonable
costs and expenses incurred in the carrying out of such test and/or inspection shall
be added to the Contract Price. Further, if such test and/or inspection impede the
progress of work on the Facilities and/or the Contractors performance of its other
obligations under the Contract, due allowance will be made in respect of the Time for
Completion and the other obligations so affected.
f) If any Plant and Equipment or any part of the Facilities fails to pass any test and/or
inspection, the Contractor shall either rectify or replace such Plant and Equipment or
part of the Facilities and shall repeat the test and/or inspection upon giving a notice.
g) If any dispute or difference of opinion shall arise between the parties in connection
with or arising out of the test and/or inspection of the Plant and Equipments or part of
the Facilities that cannot be settled between the parties within a reasonable period of
time, it may be referred to the Adjudicator.
h) The Contractor shall afford the Owner and the Project Manager, at the Owners
expense, access at any reasonable time to any place where the Plant and
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Equipments are being manufactured or the Facilities are being installed, in order to
inspect the progress and the manner of manufacture or installation, provided that the
Project Manager shall give the Contractor a reasonable prior notice.
i) The Contractor agrees that neither the execution of a test and/ or inspection of Plant
and Equipments or any part of the Facilities, nor the witnessing of any test by the
Owner, nor the issuance of any test certificate shall relieve the Contractor of any
obligation under this Contract.
j) No part of the Facilities or foundations shall be covered up on the Site without the
Contractor carrying out any test and/or inspection required under the Contract. The
Contractor shall give a reasonable notice to the Project Manager whenever any such
part of the Facilities or foundations is ready or about to be ready for test and/or
inspection; such test and/or inspection and notice thereof shall be subject to the
requirements of the Contract.
k) The Contractor shall uncover any part of the Facilities or foundations, or shall make
openings in or through the same as the Project Manager may from time to time
require at the Site, and shall reinstate and make good such part or parts.
4.29
Completion of the Facilities

a) As soon as the Facilities or any part thereof has, in the opinion of the Contractor,
been completed operationally and structurally and put in a tight and clean condition
as specified in the Technical Specifications, excluding minor items not materially
affecting the operation or safety of the Facilities, the Contractor shall so notify the
Owner in writing.
b) The Owner shall supply the operating and maintenance personnel as specified in the
Contract for Precomissioning of the Facilities or any part thereof.
c) As soon as all works in respect of Precomissioning are completed and, in the opinion
of the Contractor, the Facilities or any part thereof is ready for Commissioning, the
Contractor shall commence Commissioning as per procedures stipulated in
Technical Specifications, and as soon as Commissioning is satisfactorily completed,
the Contractor shall so notify the Project Manager in writing.
d) If the Project Manager notifies the Contractor of any defects and/ or deficiencies, the
Contractor shall then correct such defects and/or deficiencies.
If the Project Manager is satisfied that the Facilities or that part thereof have reached
Completion, the Project Manager shall, within [seven (7)] days after receipt of the
Contractors notice, issue a Completion Certificate stating that the Facilities or that
part thereof have reached Completion as at the date of the Contractors notice.
If the Project Manager is not so satisfied, then it shall notify the Contractor in writing
of any defects and/or deficiencies within [seven (7)] days after receipt of the
Contractors notice, and the above procedure shall be repeated.
e) If the Project Manager fails to issue the Completion Certificate and fails to inform
the Contractor of any defects and/or deficiencies within [seven (7)] days after receipt
of the Contractors notice, or if the Owner makes use of the Facilities or part thereof,
then the Facilities or that part thereof shall be deemed to have reached Completion
as of the date of the Contractors notice, or as of the Owners use of the Facilities, as
the case may be.
f) As soon as possible after Completion, the Contractor shall complete all outstanding
minor items so that the Facilities are fully in accordance with the requirements of the
Contract, failing which the Owner will undertake such completion and deduct the
costs thereof from any monies owing to the Contractor.
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g) Upon Completion, the Owner shall be responsible for the care and custody of the
Facilities or the relevant part thereof, together with the risk of loss or damage thereto,
and shall thereafter take over the Facilities or the relevant part thereof.
4.30
Commissioning & Operation Acceptance

a)
b)
c)
d)
Commissioning
Commissioning of the Facilities or any part thereof Acceptance shall be
completed by the Contractor as per procedures detailed in the Technical
Specifications. The Contractor shall, unless otherwise specified in Contract/
Tender Specifications, supply the utilities, lubricants, chemicals, catalysts,
facilities, services and other matters required for Commissioning.
Guarantee Test
The Guarantee Tests (and repeats thereof) shall be conducted by the Contractor
after Commissioning of the Facilities or the relevant part thereof to ascertain
whether the Facilities or the relevant part can attain the Functional Guarantees
specified in the Contract Documents. The Contractors and Project Managers
advisory personnel shall attend the Guarantee Test. The Owner shall promptly
provide the Contractor with such information as the Contractor may reasonably
require in relation to the conduct and results of the Guarantee Tests (and any
repeats thereof). If for reasons not attributable to the Contractor, the Guarantee
Tests of the Facilities or the relevant part thereof cannot be successfully
completed within the period from the date of Completion, specified in the SCC or
any other period agreed upon by the Owner and the Contractor, the Contractor
shall be deemed to have fulfilled its obligations with respect to the Functional
Guarantees.
Operational Acceptance
Operational Acceptance shall occur in respect of the Facilities or any part thereof
when
the Guarantee Tests have been successfully completed and the Functional
Guarantees are met; or
The Guarantee Tests have not been successfully completed or has not
been carried out for reasons not attributable to the Contractor within the
period from the date of Completion specified in the SCC or any other
agreed upon period as specified in GCC.
The Contractor may give a notice to the Project Manager requesting the
issue of an Operational Acceptance Certificate in respect of the Facilities or
the part thereof specified in such notice as at the date of such notice.
The Project Manager shall, after consultation with the Owner, and within
forty five (45) days after receipt of the Contractors notice, issue an
Operational Acceptance Certificate. If within [forty five (45)] days after
receipt of the Contractors notice, the Project Manager fails to issue the
Operational Acceptance Certificate or fails to inform the Contractor in
writing of the justifiable reasons why the Project Manager has not issued
the Operational Acceptance Certificate, the Facilities or the relevant part
thereof shall be deemed to have been accepted as at the date of the
Contractors said notice.
Partial Acceptance
If the Contract specifies that Completion, Commissioning and Guarantee Tests
shall be carried out in respect of parts of the Facilities, the provisions relating to
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Completion and Commissioning including the Guarantee Tests shall apply to

each such part of the Facilities individually, and the Operational Acceptance
Certificate shall be issued accordingly for each such part of the Facilities. If a part
of the Facilities comprises facilities such as buildings, for which no
Commissioning or Guarantee Tests are required, then the Project Manager shall
issue the Operational Acceptance Certificate for such facility when it attains
Completion, provided that the Contractor shall thereafter complete any
outstanding minor items that are listed in the Operational Acceptance Certificate.
4.31
Completion Time and Liquidated Damage

a)
b)
c)
4.32
Completion Time Period

The Contractor guarantees that it shall attain Completion of the Facilities (or a
part for which a separate time for completion is specified in the SCC) within the
Time for Completion specified in the SCC.
If the Contractor fails to attain Completion of the Facilities or any part thereof
within the Time for Completion, the Contractor shall pay to the Owner liquidated
damages in the amount computed at the rates specified in the SCC. The
aggregate amount of such liquidated damages shall in no event exceed the
amount specified as Maximum in the SCC.
However, the payment of liquidated damages shall not in any way relieve the
Contractor from any of its obligations to complete the Facilities or from any other
obligations and liabilities of the Contractor under the Contract.
No bonus will be given for earlier completion of the facilities or part there of.
Defects Liability
a) The Contractor warrants that the Facilities or any part thereof shall be free from
defects in the design, engineering, materials and workmanship of the Plant and
Equipments supplied and of the work executed.
b) The Defects Liability Period shall be [eighteen (18)] months from the date of
Completion of the Facilities (or any part thereof) or [twelve (12)] months from the
date of Operational Acceptance of the Facilities (or any part thereof).
If during the Defects Liability Period any defect should be found in the design,
engineering, materials and workmanship of the Plant and Equipments supplied or
of the work executed by the Contractor, the Contractor shall promptly, in
consultation and agreement with the Owner regarding appropriate remedying of the
defects, and at its cost, repair, replace or otherwise make good (as the Contractor
shall, at its discretion, determine) such defect as well as any damage to the
Facilities caused by such defect. The Contractor shall not be responsible for the
repair, replacement or making good of any defect or of any damage to the Facilities
arising out of or resulting from any of the following causes:
improper operation or maintenance of the Facilities by the Owner
operation of the Facilities outside specifications provided in the Contract
Normal wear and tear.
c) The Owner shall give the Contractor a notice stating the nature of any such defect
together with all available evidence thereof, promptly following the discovery
thereof. The Owner shall afford all reasonable opportunity for the Contractor to
inspect any such defect.
d) The Owner shall afford the Contractor all necessary access to the Facilities and the
Site to enable the Contractor to perform its obligations.
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e) If the repair, replacement or making good is of such a character that it may affect
the efficiency of the Facilities or any part thereof, the Owner may give to the
Contractor a notice requiring that tests of the defective part of the Facilities shall be
made by the Contractor immediately upon completion of such remedial work,
whereupon the Contractor shall carry out such tests.
f) If the Contractor fails to commence the work necessary to remedy such defect or
any damage to the Facilities caused by such defect within a reasonable time (which
shall in no event be considered to be less than fifteen (15) days), the Owner may,
following notice to the Contractor, proceed to do such work, and the reasonable
costs incurred by the Owner in connection therewith shall be paid to the Owner by
the Contractor or may be deducted by the Owner from any monies due to the
Contractor or claimed under the Performance Security.
If the Facilities or any part thereof cannot be used by reason of such defect and/or
making good of such defect, the Defects Liability Period of the Facilities or such
part, as the case may be, shall be extended by a period equal to the period during
which the Facilities or such part cannot be used by the Owner because of any of
the aforesaid reasons. Upon correction of the defects in the Facilities or any part
thereof by repair/replacement, such repair/replacement shall have the Defects
Liability Period extended by a period of [twelve (12) month] from the time such
replacement/repair of the Facilities or any part therof.
4.33
Functional Guarantees
The Contractor guarantees that during the Guarantee Tests, the Facilities and all parts
thereof shall attain the Functional Guarantees as per the Contract. If, for reasons
attributable to the Contractor, Functional Guarantees are not met either in whole or in
part, the Contractor shall, within a mutually agreed time, at its cost and expense make
such changes, modifications and/or additions to the Plant or any part thereof as may
be necessary to meet such Guarantees. The Contractor shall notify the Owner upon
completion of the necessary changes, modifications and/or additions, and shall seek
the Owner's consent to repeat the Guarantee Test. If the specified Functional
Guarantees are not established even during the repeat of the Guarantee Tests, the
Owner may at its option, either reject the plant and equipment and recover from the
Contractor payments already made or Accept the equipment/system/plant after levying
Liquidated Damages as specified.
4.34
Patents Indemnity
The Contractor shall indemnify and hold harmless the Owner and its employees and
officers from and against any and all suits, actions or administrative proceedings,
claims, demands, losses, damages, costs, and expenses of whatsoever nature,
including attorneys fees and expenses, which the Owner may suffer as a result of any
infringement or alleged infringement of any patent, utility model, registered design,
trademark, copyright or other intellectual property right registered or otherwise existing
at the date of the Contract by reason of: (a) the installation of the Facilities by the
Contractor or the use of the such Facilities.
4.35
Limitation of liability
Except in cases of criminal negligence or wilful misconduct by the Contractor , the
aggregate liability of the Contractor to the Owner, whether under the Contract, in tort or
otherwise, shall not exceed the total Contract Price, provided that this limitation shall
not apply to any obligation of the Contractor to indemnify the Owner with respect to
patent infringement.
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Except in cases of criminal negligence or wilful misconduct by the Contractor,

the Contractor shall not be liable to the Owner, whether in contract, tort, or otherwise,
for any indirect or consequential loss or damage, loss of use, loss of production, or
loss of profits or interest costs, provided that this exclusion shall not apply to any
obligation of the Contractor to pay liquidated damages to the Owner.
4.36
Transfer of Ownership
Ownership of the Plant and Equipments (including spare parts) to be imported into
India shall be transferred to the Owner upon loading on to the mode of transport to be
used to convey the Plant and Equipments from the country of origin to that country.
Ownership of the Plant and Equipments (including spare parts) procured from within
India shall be transferred to the Owner when the Plant and Equipments including
spares are loaded on to the mode of transport to be used to convey the Plant and
Equipments including spares from the works to the site and upon endorsement of the
despatch documents in favour of the Owner. Ownership of the Contractors
Equipments used by the Contractor and its Subcontractors in connection with the
Contract shall remain with the Contractor or its Subcontractors. Ownership of any Plant
and Equipments in excess of the requirements for the Facilities shall revert to the
Contractor upon Completion of the Facilities or at such earlier time when the Owner
and the Contractor agree that the Plant and Equipments in question are no longer
required for the Facilities, provided quantity of any Plant and Equipments specifically
stipulated in the Contract shall be the property of the Owner whether or not
incorporated in the Facilities. Notwithstanding the transfer of ownership of the Plant
and Equipments, the responsibility for care and custody thereof together with the risk
of loss or damage shall remain with the Contractor until Completion of the Facilities.
4.37
Care of Facilities
The Contractor shall be responsible for the care and custody of the Facilities or any
part thereof until the date of Completion of the Facilities, where the Contract provides
for Completion of the Facilities in parts, until the date of Completion of the relevant
part, and shall make good at its own cost any loss or damage that may occur to the
Facilities or the relevant part thereof from any cause whatsoever during such period.
The Contractor shall also be responsible for any loss or damage to the Facilities
caused by the Contractor or its Subcontractors in the course of any work carried out.
4.38

The Contractor shall indemnify and hold harmless the Owner and its employees
and officers from and against any and all suits, actions or administrative proceedings,
including attorneys fees and expenses, in respect of the death or injury of any
person or loss of or damage to any property (other than the Facilities whether
accepted or not), arising in connection with the supply and installation of the Facilities
and by reason of the negligence of the Contractor or its Subcontractors, or their
employees, officers or agents, except any injury, death or property damage caused by
the negligence of the Owner, its contractors, employees, officers or agents.
4.39
Insurance
a)
The Contractor shall at its expense take out and maintain in effect, or cause to be
taken out and maintained in effect, during the performance of the Contract, the
insurances set forth below in the sums and with the deductibles and other
conditions as specified. The identity of the insurers and the form of the policies
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b)
c)
d)
e)
f)
shall be subject to the approval of the Owner, who should not unreasonably
withhold such approval.
Cargo Insurance during Transport:-Covering loss or damage occurring while in
transit from the Contractors or Subcontractors works or stores until arrival at
the Site, to the Plant and Equipments (including spare parts therefor) and to the
Contractors Equipments.
Installation All Risks Insurance:-Covering physical loss or damage to the
Facilities at the Site, occurring prior to Completion of the Facilities, with an
extended maintenance coverage for the Contractors liability in respect of any
loss or damage occurring during the Defects Liability Period while the
Contractor is on the Site for the purpose of performing its obligations during the
Defects Liability Period.
Third Party Liability Insurance: - Covering bodily injury or death suffered by third
parties (including the Owners personnel) and loss of or damage to property
occurring in connection with the supply and installation of the Facilities.
Automobile Liability Insurance:-Covering use of all vehicles used by the
Contractor or its Subcontractors (whether or not owned by them) in connection
with the execution of the Contract.
Workers Compensation:-In accordance with the statutory requirements
applicable in any country where the Contract or any part thereof is executed.
Owners Liability: - In accordance with the statutory requirements applicable in
any country where the Contract or any part thereof is executed.
Other Insurances Such other insurances as may be specifically agreed upon by
the parties.
The Owner shall be named as co-insured under all insurance policies taken out by
the Contractor pursuant except for the Third Party Liability, Workers
Compensation and Owners Liability Insurances, and the Contractors
Subcontractors shall be named as co-insureds under all insurance policies taken
out by the Contractor except for the Cargo Insurance During Transport, Workers
Compensation and Owners Liability Insurances. All insurers rights of subrogation
against such co-insureds for losses or claims arising out of the performance of the
Contract shall be waived under such policies.
The Form of Contract Agreement, deliver to the Owner certificates of insurance (or
copies of the insurance policies) as evidence that the required policies are in full
force and effect. The certificates shall provide that no less than twenty one (21)
days notice shall be given to the Owner by insurers prior to cancellation or
material modification of a policy.
The Contractor shall ensure that, where applicable, its Subcontractor(s) shall take
out and maintain in effect adequate insurance policies for their personnel and
vehicles and for work executed by them under the Contract, unless such
Subcontractors are covered by the policies taken out by the Contractor.
The Owner shall at its expense take out and maintain in effect during the
performance of the Contract those insurances specified.
the Owner may take out and maintain in effect any such insurances and may from
time to time deduct from any amount due the Contractor under the Contract any
premium that the Owner shall have paid to the insurer, or may otherwise recover
such amount as a debt due from the Contractor. If the Owner fails to take out
and/or maintain in effect the insurances the Contractor may take out and maintain
in effect any such insurances and may from time to time deduct from any amount
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g)
h)
i)
4.40
due the Owner under the Contract any premium that the Contractor shall have
paid to the insurer, or may otherwise recover such amount as a debt due from the
Owner. If the Contractor fails to or is unable to take out and maintain in effect any
such insurances, the Contractor shall nevertheless have no liability or
responsibility towards the Owner, and the Contractor shall have full recourse
against the Owner for any and all liabilities of the Owner herein.
The Owner shall give to the Contractor all such reasonable assistance as may be
required by the Contractor. With respect to insurance claims in which the Owners
interest is involved, the Contractor shall not give any release or make any
compromise with the insurer without the prior written consent of the Owner. With
respect to insurance claims in which the Contractors interest is involved, the
Owner shall not give any release or make any compromise with the insurer without
the prior written consent of the Contractor.
Wherever total damages/loss of equipments/materials, would occur, the
Contractor will be entitled to payment of all payments received from the
underwriters except the following amounts:
The amount paid to the Contractor under the Contract in respect of
equipments/materials damaged/lost (excluding the pro-rata initial advance)
but including the entire amount of escalation, if any, already paid to the
Contractor.
Custom Duties and taxes which have already been paid by the Owner.
In case of damage to any equipments/materials during any stage, the
Contractor upon rectification of the damaged equipment to the satisfaction of
the Owner shall be paid to the extent of full claims settled by the underwriters.
All the Plants & Equipment being supplied by the Owner free of cost for installation
of the equipment, cabling, earthing and lightning protection etc. by the Contractor,
covered by this specification shall be kept insured by the Contractor against loss,
damage, theft, pilferage, fire etc. from the point of unloading at Site upto the time
of taking over by the Owner including handling, in plant transportation, storage,
installation, testing and commissioning, etc. and the Contractor shall be fully
responsible for making good of any loss or damage at his own cost within a
reasonable time as mutually agreed upon by the Owner and the Contractor. Any
loss/damage shall be brought to the Owner's notice immediately. The premium
paid by the Contractor to the Insurance Company for such insurance shall be
reimbursed by the Owner to the Contractor at actual against documentary proof to
be furnished by the Contractor. The Contractor shall obtain competitive quotation
for such insurance and shall take prior approval from the Owner before taking the
insurance. The insurable value of the equipment being procured by the Owner will
be intimated to the Contractor for the purpose of insurance.
It will be the responsibility of the Contractor to lodge, pursue and settle all
claims with the Insurance Company in case of any damage, loss, theft,
pilferage, fire, etc. and the Owner shall be kept informed about it. The losses,
if any, will have to be borne by the Contractor, if the claims are not lodged
and pursued properly or in the time or if the same are not settled by the
Insurance Company.

a)
any law, regulation, ordinance, order or by-law having the force of law is enacted,
promulgated, abrogated or changed (which shall be deemed to include any
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change in interpretation or application by the competent authorities) that

subsequently affects the costs and expenses of the Contractor and/or the Time
extent that the Contractor has thereby been affected in the performance of any of
its obligations under the Contract. However, these adjustments would be
restricted to direct transactions between the Owner and the Contractor and not
on procurement of raw materials, intermediary components etc. by the
Contractor. Notwithstanding the foregoing, such additional or reduced costs shall
not be separately paid or credited if the same has already been accounted for in
the price adjustment provisions wherever applicable.
4.41
Force Majeure
(a)
Owner or of the Contractor, as the case may be, and which is unavoidable
notwithstanding the reasonable care of the party affected. Force Majeure events
include Acts of God, Acts of Government, war, sabotage, riots, civil commotion,
revolution, flood, earthquake, cyclone, fire, epidemic etc.
(b) If either party is prevented, hindered or delayed from or in performing any of its
obligations under the Contract by an event of Force Majeure, then it shall notify
the other in writing of the occurrence of such event and the circumstances thereof
within [fourteen (14)] days after the occurrence of such event.
(c) The party who has given such notice shall be excused from the performance or
punctual performance of its obligations under the Contract for so long as the
relevant event of Force Majeure continues and to the extent that such partys
performance is prevented, hindered or delayed.
(d) The party or parties affected by the event of Force Majeure shall use reasonable
efforts to mitigate the effect thereof upon its or their performance of the Contract
and to fulfill its or their obligations under the Contract, but without prejudice to
either partys right.
(e) No delay or non-performance by either party hereto caused by the occurrence of
any event of Force Majeure shall
- to any claim for damages or additional cost or expense occasioned thereby
if and to the extent that such delay or non-performance is caused by the occurrence of
an event of Force Majeure.
(f) If the performance of the Contract is substantially prevented, hindered or delayed
for a single period of more than [sixty (60)] days or an aggregate period of more
than one hundred and [twenty (120)] days on account of one or more events of
Force Majeure during the currency of the Contract, the parties will attempt to
develop a mutually satisfactory solution.
(g) Force Majeure shall not apply to any obligation of the Owner to make payments
to the Contractor herein.
4.42
Change in the Facilities

(a)
Introducing a Change
-
Contractor during the performance of the Contract to make any change,
modification, addition or deletion to, in or from the Facilities (hereinafter called
Change), provided that such Change falls within the general scope of the
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(b)
Facilities and does not constitute unrelated work and that it is technically
practicable, taking into account both the state of advancement of the Facilities
and the technical compatibility of the Change envisaged with the nature of
the Facilities as specified in the Contract.
The Contractor may from time to time during its performance of the Contract
propose to the Owner (with a copy to the Project Manager) any Change that
the Contractor considers necessary or desirable to improve the quality,
efficiency or safety of the Facilities. This includes any additional scope of
work that the contractor thinks is essential for achieving the minimum
performance level specified in the SCC or the Contract.The Owner may at its
discretion approve or reject any Change proposed by the Contractor.
No change made necessary because of any default of the Contractor in the
performance of its obligations under the Contract shall be deemed to be a
Change, and such change shall not result in any adjustment of the Contract
Price or the Time for Completion.
Changes Originating from Owner

-
If the Owner proposes a Change, it shall send to the Contractor a Request

for Change Proposal, requiring the Contractor to prepare and furnish to the
Project Manager as soon as reasonably practicable a Change Proposal,
which shall include the following:
brief description of the Change
effect on the Time for Completion
estimated Cost of the Change
effect on Functional Guarantees (if any)
effect on any other provisions of the Contract.
The pricing of any Change shall, as far as practicable, be calculated in
accordance with the rates and prices included in the Contract. If the rates
and prices of any change are not available in the Contract, the parties thereto
shall agree on specific rates for the valuation of the Change.
If before or during the preparation of the Change Proposal it becomes
apparent that the aggregate effect of compliance therewith and with all other
Change Orders that have already become binding upon the Contractor to
increase or decrease the Contract Price as originally set forth in the Contract
Agreement by more than fifteen (15) percent, the Contractor may give a
written notice of objection thereto prior to furnishing the Change Proposal as
aforesaid. If the Owner accepts the Contractors objection, the Owner and
the Contractor shall agree on specific rates for valuation of the change.
Upon receipt of the Change Proposal, the Owner and the Contractor shall
mutually agree upon all matters therein contained including agreement on
rates if such rates are not available in the Contract or if the limit of 15% set
forth has been exceeded. Within [fourteen (14)] days after such agreement,
the Owner shall, if it intends to proceed with the Change, issue the Contractor
with a Change Order.
If the Owner is unable to reach a decision within [fourteen (14)] days, it shall
notify the Contractor with details of when the Contractor can expect a
decision.
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If the Owner decides not to proceed with the Change for whatever reason, it
shall, within the said period of [fourteen (14)] days, notify the Contractor
accordingly.
- If the Owner and the Contractor cannot reach agreement on the price for the
Change, an equitable adjustment to the Time for Completion, or any other
matters identified in the Change Proposal, the Owner may nevertheless
instruct the Contractor to proceed with the Change by issue of a Pending
Agreement Change Order.
Upon receipt of a Pending Agreement Change Order, the Contractor shall
immediately proceed with effecting the Changes covered by such Order. The
parties shall thereafter attempt to reach agreement on the outstanding issues
under the Change Proposal.
(c)
Changes Originating from Contractor

-
4.43

(a)
(b)
(c)
4.44
The Contractor shall submit to the Project Manager a written Application for
Change Proposal, giving reasons for the proposed Change and including the
information. Upon receipt of the Application for Change Proposal, the parties
shall follow the procedures indicated above for Request for Change
Proposal.
Contractor is delayed or impeded in the performance of any of its obligations
- any suspension order given by the Owner or reduction in the rate of progress
or
- any default or breach of the Contract by the Owner, or any activity, act or
omission of any other contractors employed by the Owner or
By such period as shall be fair and reasonable in all the circumstances and as
shall fairly reflect the delay or impediment sustained by the Contractor.
Except where otherwise specifically provided in the Contract, the Contractor shall
submit to the Project Manager a notice of a claim for an extension of the Time for
Completion, together with particulars of the event or circumstance justifying such
extension as soon as reasonably practicable after the commencement of such
event or circumstance. As soon as reasonably practicable after receipt of such
notice and supporting particulars of the claim, the Owner and the Contractor shall
agree upon the period of such extension.
The Contractor shall at all times use its reasonable efforts to minimize any delay
in the performance of its obligations under the Contract.
Suspension
(a)
The Owner/ Project Manager may, by notice to the Contractor, order the
Contractor to suspend performance of any or all of its obligations under the
Contract. Such notice shall specify the obligation of which performance is to be
suspended, the effective date of the suspension and the reasons therefor. The
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(b)
(c)
4.45
Contractor shall thereupon suspend performance of such obligation (except those

obligations necessary for the care or preservation of the Facilities) until ordered in
writing to resume such performance by the Project Manager/ Owner.
If, by virtue of a suspension order given by the Project Manager/ Owner, other
than by reason of the Contractors default or breach of the Contract, the
Contractors performance of any of its obligations is suspended for an aggregate
period of more than [ninety (90)] days, then at any time thereafter and provided
that at that time such performance is still suspended, the Contractor may give a
notice to the Project Manager requiring that the Owner shall, within [twenty eight
(28)] days of receipt of the notice, order the resumption of such performance or
request and subsequently order a change, excluding the performance of the
suspended obligations from the Contract.
If the Contractor is unable to carry out any of its obligations under the Contract for
any reason attributable to the Owner, including but not limited to the Owners
failure to provide possession of or access to the Site or other areas;
Then the Contractor may by [fourteen (14)] days notice to the Owner suspend
performance of all or any of its obligations under the Contract, or reduce the rate
of progress. If the Contractors performance of its obligations is suspended or the
rate of progress is reduced, then the Time for Completion shall be extended, and
any and all additional costs or expenses incurred by the Contractor as a result
of such suspension or reduction shall be paid by the Owner to the Contractor in
addition to the Contract Price, except in the case of suspension order or
reduction in the rate of progress by reason of the Contractors default or breach
of the Contract.
During the period of suspension, the Contractor shall not remove from the Site
any Plant and Equipment, any part of the Facilities or any Contractors
Equipment, without the prior written consent of the Owner.
Termination
(a)

The Owner may at any time terminate the Contract for any reason by giving the
Contractor a notice of termination. Upon receipt of the notice of termination, the
Contractor shall either immediately or upon the date specified in the notice of
termination
(i)
cease all further work, except for such work as the Owner may specify in
the notice of termination for the sole purpose of protecting that part of the
Facilities already executed, or any work required to leave the Site in a clean
and safe condition.
(ii)
(iii)
remove all Contractors Equipments from the Site, repatriate the

Contractors and its Subcontractors personnel from the Site, remove from
the Site any wreckage, rubbish and debris of any kind, and leave the whole
of the Site in a clean and safe condition
(iv)
The Contractor, subject to the payment, shall

deliver to the Owner the parts of the Facilities executed by the Contractor
up to the date of termination
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to the extent legally possible, assign to the Owner all right, title and
benefit of the Contractor to the Facilities and to the Plant and Equipments
as at the date of termination, and, as may be required by the Owner, in
any subcontracts concluded between the Contractor and its
Subcontractors
documents prepared by the Contractor or its Subcontractors as at the
date of termination in connection with the Facilities.
In the event of termination of the Contract for Owners convenience, the
Owner shall pay to the Contractor the following amounts
the Contract Price, attributable to the parts of the Facilities executed
by the Contractor as on the date of termination
the costs reasonably incurred by the Contractor in the removal of the
Contractors Equipment from the Site and in the repatriation of the
Contractors and its Subcontractors personnel
any amounts to be paid by the Contractor to its Subcontractors in
costs incurred by the Contractor in protecting the Facilities and leaving
the Site in a clean and safe condition
the additional cost of satisfying other obligations, commitments and
claims that the Contractor may in good faith have undertaken with
third parties in connection with the Contract.
(b)
Termination for Contractors Default

(i)

circumstances by giving a notice of termination and its reasons therefor to
the Contractor:
If the Contractor becomes bankrupt or insolvent, has a receiving order
issued against it, compounds with its creditors, or, if the Contractor is a
corporation, a resolution is passed or order is made for its winding up
(other than a voluntary liquidation for the purposes of amalgamation or
reconstruction), a receiver is appointed over any part of its undertaking
or assets, or if the Contractor takes or suffers any other analogous
action in consequence of debt
If the Contractor assigns or transfers the Contract or any right or interest
therein in violation of the provision.
If the Contractor, in the judgement of the Owner has engaged in corrupt
or fraudulent practices in competing for or in executing the Contract.
"corrupt practice" means the offering, giving, receiving or soliciting of
anything of value to influence the action of a public official in the
detriment of the Owner and includes collusive practice among Bidders
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(prior to or after bid submission) designed to establish bid prices at

artificial non-competitive levels and to deprive the Owner of the benefits
of free and open competition.
(ii)
If the Contractor
-

has without valid reason failed to commence work on the Facilities
promptly the progress of Contract performance for more than [twenty
eight (28)] days after receiving a written instruction from the Owner to
proceed
Contract or persistently neglects to carry out its obligations under the
Contract without just cause
refuses or is unable to provide sufficient materials, services or labor to
execute and complete the Facilities in the manner specified in the
Owner that the Contractor can attain Completion of the Facilities by the
Time for Completion as extended
then the Owner may, without prejudice to any other rights it may possess
under the Contract, give a notice to the Contractor stating the nature of the
default and requiring the Contractor to remedy the same. If the Contractor
fails to remedy or to take steps to remedy the same within [fourteen (14)]
days of its receipt of such notice, then the Owner may terminate the Contract
forthwith by giving a notice of termination to the Contractor.
(iii)
The Contractor shall, either immediately or upon such date as is specified

in the notice of termination,
-
cease all further work, except for such work as the Owner may specify
in the notice of termination for the sole purpose of protecting that
part of the Facilities already executed, or any work required to leave the
Site in a clean and safe condition
terminate all subcontracts, except those to be assigned to the Owner
pursuant to paragraph (d) below
deliver to the Owner the parts of the Facilities executed by the
Contractor up to the date of termination
benefit of the Contractor to the Works and to the Plant and Equipment
Subcontractors
Deliver to the Owner all drawings, specifications and other documents
prepared by the Contractor or its Subcontractors as at the date of
(iv)
The Owner may enter upon the Site, expel the Contractor, and complete
the Facilities itself or by employing any third party. The Owner may, to the
exclusion of any right of the Contractor over the same, take over and use
with the payment of a fair rental rate to the Contractor, with all the
maintenance costs to the account of the Owner and with an indemnification
by the Owner for all liability including damage or injury to persons arising
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out of the Owners use of such equipment, any Contractors Equipments

owned by the Contractor and on the Site in connection with the Facilities
for such reasonable period as the Owner considers expedient for the
supply and installation of the Facilities.
Upon completion of the Facilities or at such earlier date as the Owner
thinks appropriate, the Owner shall give notice to the Contractor that such
Contractors Equipment will be returned to the Contractor at or near the
Site and shall return such Contractors Equipments to the Contractor in
accordance with such notice. The Contractor shall thereafter without delay
and at its cost remove or arrange removal of the same from the Site.
(v)
The Contractor shall be entitled to be paid the Contract Price attributable

to the Facilities executed as at the date of termination, the value of any
unused or partially used Plant and Equipments on the Site, and the costs,
if any, incurred in protecting the Facilities and in leaving the Site in a clean
and safe condition. Any sums due to the Owner from the Contractor
accruing prior to the date of termination shall be deducted from the amount
to be paid to the Contractor under this Contract.
(vi)
If the Owner completes the Facilities, the cost of completing the Facilities
by the Owner shall be determined.
If the sum that the Contractor is entitled to be paid, plus the reasonable
costs incurred by the Owner in completing the Facilities, exceeds the
Contract Price, the Contractor shall be liable for such excess.
The Owner and the Contractor shall agree, in writing, on the computation
described above and the manner in which any sums shall be paid.
(c)
Termination by Contractor
i.
If
-
the Owner has failed to pay the Contractor any sum due under the
Contract within the specified period, has failed to approve any invoice
or supporting documents without just cause pursuant to [-----------]
(Terms and Procedures of Payment) of the Form of Contract
Contractor may give a notice to the Owner that requires payment of
such sum, requires approval of such invoice or supporting documents,
or specifies the breach and requires the Owner to remedy the same, as
the case may be. If the Owner fails to pay such sum, fails to approve
such invoice or supporting documents or give its reasons for withholding
such approval, fails to remedy the breach or take steps to remedy the
breach within [fourteen (14) days] after receipt of the Contractors
notice, or
the Contractor is unable to carry out any of its obligations under the
Contract for any reason attributable to the Owner, including but not
limited to the Owners failure to provide possession of or access to the
Site or other areas or failure to obtain any governmental permit
necessary for the execution and/or completion of the Facilities which the
Owner is required to obtain as per provision of the Contract or as per
relevant applicable laws of the country,
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
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[Logo of Utility]
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then the Contractor may give a notice to the Owner thereof, and if the
Owner has failed to pay the outstanding sum, to approve the invoice or
supporting documents, to give its reasons for withholding such approval,
or to remedy the breach within [twenty eight (28) days] of such notice, or
if the Contractor is still unable to carry out any of its obligations under
the Contract for any reason attributable to the Owner within twenty eight
(28) days of the said notice, then the Contractor may terminate the
Contract forthwith by giving a notice of termination to the Owner.
ii.
If the Owner becomes bankrupt or insolvent, has a receiving order issued

against it, compounds with its creditors, or, being a corporation, if a
resolution is passed or order is made for its winding up (other than a
voluntary liquidation for the purposes of amalgamation or reconstruction), a
receiver is appointed over any part of its undertaking or assets, or if the
Owner takes or suffers any other analogous action in consequence of debt,
then the Contractor may terminate the Contract forthwith by giving a notice
of termination to the Owner.
iii.
If the Contract is terminated, then the Contractor shall immediately

-
cease all further work, except for such work as may be necessary for
the purpose of protecting that part of the Facilities already executed, or
any work required to leave the Site in a clean and safe condition
pursuant to paragraph (d)(ii)
remove all Contractors Equipment from the Site and repatriate the
Contractors and its Subcontractors personnel from the Site
In addition, the Contractor, subject to the payment, shall
benefit of the Contractor to the Facilities and to the Plant and
Equipments as of the date of termination, and, as may be required
by the Owner, in any subcontracts concluded between the
Contractor and its Subcontractors
documents prepared by the Contractor or its Subcontractors as of
the date of termination in connection with the Facilities.
iv.
If the Contract is terminated, the Owner shall pay to the Contractor all
payments, and reasonable compensation for all loss or damage sustained
by the Contractor arising out of, in connection with or in consequence of
such termination.
(d)
The expression Facilities executed shall include all work executed, Erection
Services provided, any all Plant and Equipments acquired (or subject to a legally
binding obligation to purchase) by the Contractor and used or intended to be
used for the purpose of the Facilities, up to and including the date of termination.
(e)
In calculating any payment due from the Owner to the Contractor, account shall
be taken of any sum previously paid by the Owner to the Contractor under the
Contract, including any advance payment paid.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 55-
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[Logo of Utility]
Power Plant]
4.46
Assignment
The Contractor shall not, without the express prior written consent of the Owner,
obligation or interest therein or there under, except that the Contractor shall be entitled
to assign either absolutely or by way of charge any monies due and payable to it or
that may become due and payable to it under the Contract
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 56-
30.09.2015
[Logo of Utility]
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5.1
Contract Details
Name of Contract: Renovation & Modernization of Boiler & Auxiliaries

Package for [---------------------------------------]
Bid Document No. :[-------------------------]
The Owner is:

Name of Owner: [-------------------------]
Address of Owner: [-------------------------]
Telephone No. : [-------------------------]
Fax No: [-------------------------]
E-Mail: [-------------------------]

Telephone No. : [-------------------------]
Fax No: [-------------------------]
E-Mail: [-------------------------]
5.2
Effective Date
formal Letter of Acceptance. This Letter of Acceptance will be the Effective Date for
determining the Time for Completion of the facilities and other milestones for execution
of the Renovation & Modernization work as per the scope of work under this tender by
the Contractor.
The following three activities will be completed within [two (2)] months from the date of
Letter of Acceptance:
(a) The contract agreement will be executed by the Owner and the Contractor. (b) The
Contractor will submit to the Owner the Contract Performance Bank |Guarantee, any
Additional Contract Performance Bank Guarantee by assignee, JV Partner,
Consortium Member etc if applicable, and the Advance Payment Bank Guarantee.
(c) The Owner will pay the Contractor the Advance Payment as per the Terms of
Payment.
The Owner will make the advance payment promptly once Contractor has fulfilled the
necessary conditions specified in Terms of Payment. If payment of Advance is delayed
beyond two months from the date of Letter of acceptance for reasons attributable to
the Owner, the date of payment of advance shall be the effective date for determining
the time for completion of facilities. However, failure of the contractor to provide all the
required Bonds/Guarantees within the prescribed period will cause the Bid Security to
be forfeited.
5.3

The Time Schedule for the execution of the scope of work by the Contractor under this
tender and commencement of unit shut down by Owner shall be as follows:
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
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[Logo of Utility]
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1.
2.
3.
4.
Time for completion (by Contractor) of

Engineering and Supply activities and other
resources mobilization that are required to
be completed before unit shut down as per
L-2 network
Time for Commencement (by Owner) of
Unit Shut Down.
(Note: In case Contractor fails to complete
the engineering, supply and mobilization
activities as at serial no.1, Owner may, at
its discretion, reschedule commencement
of unit shut down
Time for Completion of all R&M activities
that are to be carried out under unit shut
down and subsequent commissioning
activities including trial operation as per the
scope of work under this tender
Performance
Guarantee
Test
(By
Contractor)
5.4
Liquidated Damage for Delay
5.5
Rate of Liquidated Damage for Delay
By []
Effective Date
months from
By []
Effective Date
months from
By [..] days from start

of unit shut down
By [] months from
the
completion
of
trial
operation after completion of
R&M activities
If the Contractor fails to successfully achieve completion of R&M activities and

commissioning of the retrofitted facilities as per the scope of work within the time
period specified in SCC, the Contractor shall pay to the Owner amount calculated as
per the rates given in the following table as Liquidated Damage and not as penalty.
1.
Delay in completion (by Contractor) of Liquidated Damage payable at

Engineering and Supply activities and other the rate Rs.[] for each
resources mobilization that are required to week of delay
L-2 network
2.
Delay in Completion of all R&M activities Liquidated Damage payable at
that are to be carried out under unit shut the rate Rs [..] for
down and subsequent commissioning each day of delay
The Liquidated Damage for Delay in completion (by Contractor) of Engineering and
Supply activities and other resources mobilization that are required to be completed
before unit shut down as per L-2 network and Liquidated Damage for Delay in
Completion of all R&M activities that are to be carried out under unit shut down and
subsequent commissioning activities including trial operation as per the scope of work
under this tender are independent and shall be applied separately.
5.6
Liquidated Damage for Non-fulfilment of Functional Guarantees

If the Contractor fails to successfully achieve the Functional Guarantees during
Performance Guarantee Test as per the Tender Specification, the Contractor shall pay
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
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[Logo of Utility]
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to the Owner amount calculated as per the rates given in the following table as
Liquidated Damage and not as penalty.
Sl. No.
Functional Guarantee Parameter
Rate of Liquidated
Damage
Boiler Capacity in TPH at rated parameters at

superheater outlet, the coal being fired from the
range specified.
[..] INR
perTonnes/Hr. shortfall
[..] INR per 0.01%
decrease
3
Auxiliary Power in kW
[..] INR per kW
increase
The reference condition for Performance Guarantee Parameters shall be as per

Volume-II Technical Specification.
The Liquidated Damage for non-fulfillment of the different Functional Guarantee
Parameters are independent of one another and shall be applied separately.
{Note: The rate of LD for any Functional Guarantee Parameter shall be at least 1.5
times the corresponding Bid Evaluation Factor}
5.7
Maximum Leviable Liquidated Damages

The amount of Liquidated Damage for delay shall be limited to a maximum of 10 % of
the total contracts price (i.e. sum of Ist, IInd and IIIrd )contracts, as applicable) price
including price variation as per the provisions of the contract and excluding price of
Mandatory Spares. This limit is applicable for the Liquidated Damage for Delay in
completion (by Contractor) of Engineering and Supply activities and other resources
mobilization that are required to be completed before unit shut down as per L-2
network and Liquidated Damage for Delay in Completion of all R&M activities that are
to be carried out under unit shut down and subsequent commissioning activities
including trial operation as per the scope of work under this tender taken together.
The aggregate amount of Liquidated Damage for non-fulfillment of functional
guarantee shall be limited to a maximum of 10 % of the total contracts price (i.e. sum
of Ist, IInd and IIIrd )contracts, as applicable) price including price variation as per the
provisions of the contract and excluding price of Mandatory Spares.
The limit on maximum leviable Liquidated Damage for Delay and maximum leviable
Liquidated Damage for non-fulfillment of functional guarantee are independent of each
other and shall apply separately.
5.8
Payment of Liquidated Damages

Contractor shall pay to the owner any Liquidated Damages that are payable as per the
provisions of the Contact within thirty (30) days of receipt of Owners invoice setting
forth amount of Liquidated Damages that are then due and payable. If Contractor
delays payment of Liquidated Damages that are payable under the provisions of the
Contract beyond thirty (30) days, Owner, at its discretion, shall be entitled to recover
such amounts by either setting off the relevant unpaid amount against any payment(s)
due to the Contractor or by making a demand under Contract Performance Bank
Guarantee.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 59-
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[Logo of Utility]
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5.9
Contract Price
a) The Contract Price shall be as (Contract Price and Terms of Payment) of the Form
of Contract Agreement.
b) The Contractor shall be deemed to have satisfied itself as to the correctness and
sufficiency of the Contract Price, which shall, except as otherwise provided for in
the Contract, cover all its obligations under the Contract.
5.10
Terms of Payment
a) The Contract Price shall be paid as Terms and Procedures of Payment to the Form
of Contract Agreement. The procedures to be followed in making application.
b) No payment made by the Owner herein shall be deemed to constitute acceptance
by the Owner of the Facilities or any part(s) thereof.
c) The currency or currencies in which payments are made to the Contractor under
this Contract to the Form of Contract Agreement, subject to the general principle
that payments will be made in the currency or currencies in which the Contract
Price has been stated in the Contractors bid.
5.11
Contract Securities (Bank Guarantees)

a) The Contractor shall provide the Bank Guarantees specified below in favour of the
b) Advance Payment Bank Guarantee
The Contractor shall, within [thirty (30)] days of the Notification of Contract Award,
provide a security for an amount equal to the advance payment, and in the same
currency or currencies, with a initial validity of up to [ninety (90)] days beyond the
date of Completion of Facilities.
Advance payment Bank Guarantee shall be reduced prorata every three (3)
months after First Running Account Bill/Stage Payment under the Contract based
on the value of equipment/facilities received. The cumulative amount of reduction
at any point of time shall not exceed ninety percent (90%) of the advance
corresponding to cumulative value of the Facilities supplied and received as per a
certificate issued by the Project Manager and the balance of 10% shall be released
on Completion of those Facilities. It should be clearly understood that reduction in
the value of security for advance shall not in any way dilute the Contractor's
responsibility and liabilities under the Contract including in respect of the Facilities
for which the reduction in the value of security is allowed.
c) Performance Bank Guarantee
The Contractor shall, within [thirty (30)] days of the notification of award, provide a
Bank Guarantee for the due performance of the Contract for ten percent (10%) of
the Contract Price with an initial validity upto [ninety (90)] days beyond the Defects
Liability Period. If the Owner enters into the Contract with the Assignee of a foreign
Contractor, the said Assignee, in addition to the Contract Performance Bank
Guarantee to be provided by the Contractor for ten percent (10%) of the value of all
the Contracts shall provide within [thirty (30)] days of the Notification of Award, a
separate Contract Performance Bank Guarantee equivalent to five percent (5%) of
the value of Contract entered into with the assignee, (i.e. five percent of the
aggregate value of the component Contracts entered to with the Assignee) for the
due performance of Contract with an initial validity up to [Ninety (90)] days beyond
the Defects Liability Period.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 60-
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[Logo of Utility]
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case, the value of Contract Performance Bank Guarantee furnished by the Bidder
and Additional Contract Performance Bank Guarantee furnished by the JV partners
taken together shall be 12% of the Contract Price.
Guarantee (CPBG) of 10% furnished by the Consortium Leader, the other
consortium member will furnish Additional Contract Performance Bank Guarantee
equal to 2% of Contract Price. To clarify further, in such a case, the value of
Contract Performance Bank Guarantee furnished by the Bidder (Consortium
Leader) and Additional Contract Performance Bank Guarantee furnished by the
other consortium member taken together shall be 12% of the Contract Price.
d) The performance Bank Guarantees shall be denominated in the currency or

currencies of the Contract, or in a freely convertible currency acceptable to the
Owner.
5.12
Sequential Supply
The Contractor is required to supply the material and equipment under the Contract in
a sequential manner as per the requirement at site for erection. If Contractor supplies
any material/equipment ahead of the requirement as per the agreed Detailed Time
Schedule, the Owner, at its discretion, may withhold progressive payment for such
material/equipment till the time it is due for supply as per the agreed Detailed Time
Schedule.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 61-
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[Logo of Utility]
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FORMS AND SCHEDULES

I
Bid Forms and Schedules/Annexure to be submitted with

Bid
Annexure-A
Annexure-B
Form of Part-I Bid
Annexure-C
Form of Part-II Bid
Annexure-D
Sample Format for Letter of Consent to be furnished by The

Bidder And / Consortium Partners / Individual Companies of the
Group
Annexure-E
Sample Format
Letter Of Unequivocal Consent To Be Furnished By The Bidder
and The Assignee
Schedule F1
Table-1
Summary Of Price Schedule
Schedule F1
Table-2
Price Schedule For Supply Of Plant And Equipment Including

Packing And Forwarding Charges
Schedule F1
Table-3A
Price Schedule For Mandatory Spares
Schedule F1
Table-3B
Price Schedule For Recommended Spares
Schedule F1
Table-4
Price Schedule For Tools & Tackles

.
Schedule F1
Table-5
Price Schedule For Unloading, Handling, Storage, Preservation

At Site, Erection, Testing, Commissioning And Performance
Guarantee Tests Of Plant And Equipment
Schedule F1
Table-6
Price Schedule For Civil works
Schedule F1
Table-7
Price Schedule For Training Charges
Schedule F1
Table-8
Schedule Of Performance Guarantee Parameters
Schedule F2
Over All Time Schedule
Schedule F3
Deviation Schedule To Tender Document Vol-I Commercial
Schedule F4
Deviation Schedule To Technical Specification
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 62-
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[Logo of Utility]
Power Plant]
Schedule F5
Requirements Of The Contractor At Site
Schedule F6
Contractors Resource Deployment Schedule
Schedule F9
Coefficients And Indices for Price Variation Formula
II
Forms and Appendices to form part of Contract
Annexure-F
Contract
Schedule-1
Terms of Payment
Contract
Schedule-2
Price Adjustment
Contract
Schedule-3
Time Schedule
Contract
Schedule-4
List of Approved Subcontractors
Contract
Schedule-5
Scope of Works and Supply by the Owner
Contract
Schedule-6
III
Annexure-G
Format for Contract Performance Bank Guarantees
Document Number
LII-GETS12021-G-00129-001
Rev
No.
03
Description
Volume-I
Page No.
Date of Issue
- 63-
30.09.2015
Tender Document for R&M of Unit No. [..] Capacity [..] of [Name of the [Logo of Utility]
Power Plant]
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description
Volume-I, Annexure & Schedules-1

[1]
30.09.2015
Power Plant]
ANNEXURE - A
1. This Guarantee should be furnished by a scheduled commercial Bank in India authorized
by RBI to issue a Bank Guarantee in the same format as given below. [Name of Utility],
reserves its right to reject the Bank Guarantee if the same is not in the specified format.
[Rs..]
3. The stamp paper should have been purchased in the Name of the Bank executing the
guarantee.
Ref.:
Bank Guarantee No:

Date
To:
[-Name of Utility]
Dear Sirs,
] dated [.................] M/s [Name of Bidder]
hereinafter
called
the
Bidder,
having
its
registered/head
office
at
1.
2.
3.
5.
4.
6.
7.
8.
9.
10.
wish to participate in the said Bid for [Name of package and R&M project], India, as an
irrevocable Bank Guarantee against Bid Guarantee for a sum of [..]
(in words and figures) valid for 300 days from [..] (the date of Bid Opening) is
required to be submitted by the Bidder as a condition precedent for participation in the said
bid, which amount is liable to be forfeited on the happening of any contingencies mentioned
in the Bid Documents, we, the [] Bank at (local address)
[] having our Head Office at [] guarantee and
undertake to pay immediately on first demand by [Name of Utility]the amount of
[.] (in figures and words) to the said
[Name of Utility] without any reservation, protest, demur and recourse. Any such demand
made by [Name of Utility] shall be conclusive and binding on the Bank irrespective of any
dispute or difference raised by the Bidder.
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[2]
30.09.2015
Power Plant]
further extension of this Guarantee is required, the same shall be extended to such required
period on receiving instructions from M/s [Name of Bidder] on whose behalf this Guarantee
is issued.
Signature
Name
Designation
Staff Code No.
Bankers Seal
Date
Witness:
1.
2.
Signature
Designation
Address
Signature
Designation
Address
:
:
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[3]
30.09.2015
Power Plant]
ANNEXURE - B
FORMAT OF BID
From:
[Bidder Details]
[]
[]
To:
Sub

Tender
[]_____________________________________
No.
1. We agree to complete the works in conformity with all the terms and conditions stated in
Tender Specifications and its Amendments/Corrigendum/Clarifications issued till the date
of tender opening and as per time schedule given in Tender Specification. The plant,
equipment and systems offered are of the best and latest technology and of international
standards.
Letter of Award and to complete and deliver the whole of the work and responsibilities
comprised in the Contract within as per Time schedule given in SCC of Tender
Specification.
Rupees___[..]_only)/US$__
(US
Dollars________
[-------]
_
_________________only)/Euro___________
(Euro__________
[-------]
_
____________________only) in the form ________________ as instructed by you. This
Bid Guarantee shall be governed as per the stipulations provided in the "Instructions to
Bidders".
4. We agree to abide by and keep our Bid valid initially for a period of 180 (One Hundred
and Eighty) days from the date of opening of bids by Purchaser and it shall remain
binding on us and may be accepted at any time before the expiry of that period.
conditions of Tender Specification as accepted by us and in default thereof, to forfeit
and pay to [Name of Utility], assignees or authorized nominees such sums of money as
are stipulated in conditions contained in Tender Specification and agree to furnish Bank
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[4]
30.09.2015
Power Plant]
Guarantee for Contract Performance as per the proforma prescribed by Purchaser and
for the sum equal to 10% of the "Contract Price", for the entire scope of work within 30
days from the date of Letter of Award.
6. We understand that Purchaser is not bound to accept the lowest or any Bids received
and Purchaser has the right to reject any Bid, without assigning any reason whatsoever.
7. This Bid together with written acceptance thereof shall constitute a binding Contract
between Purchaser and ourselves till a formal Contract is executed.
Signed this __________________ day
of _______________
Signature
Name
Designation
Company
Date
Company Seal
Witness:
1.
2.
Signature
Occupation
Address
:
:
Signature
Occupation
Address
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[5]
30.09.2015
Power Plant]
ANNEXURE - C
FORMAT OF BID
Part-II [Price Bid]
Tender No.
[-----------]
Bid No
[------------]
From:
[]
[]
Dated:
[]
To :
[]
[]
[]
Dear Sirs
1.
2.
We hereby agreed to carry out the entire works as described in the specifications in
conformity with the specifications and Tender Specifications, as per prices quoted by
us in the Schedule of Prices and Schedule of Performance Guarantees [Schedule .]
enclosed herewith
In the event of our proposal being accepted, we agree to furnish a Bank Guarantee for
Contract Performance as per the proforma prescribed by Employer [Name of Utility ]
and for the sum equal to 10% of the "Contract Price". The Bid Guarantee shall be
released only after the Contract Performance Guarantee issued in favour of Employer
is received and accepted by the Employer
Signature
Name
Designation
Company
Date
Company Seal
Witness:
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[6]
30.09.2015
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1.
2.
Signature
Occupation
Address
Signature
Occupation
Address
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[7]
30.09.2015
Power Plant]
ANNEXURE D
(SAMPLE FORMAT)
LETTER OF CONSENT
TO BE FURNISHED BY THE BIDDER and CONSORTIUM PARTNERS
We hereby declare that the undersigned firm [-------------] (Name and Complete address of the
Consortium Partners) hereby agrees to associate with [-------------] (Name and Complete address
of the Bidder) for the successful completion of part scope of work as enclosed in the attachment
(authenticated by the Bidder and Consortium Partner [-------------] Package for the [-------------]
Project at [-------------] in the state of [-------------], India. We also hereby undertake to ensure the
quality of manufacture, timely delivery and the successful performance of the equipment/system
covered in our scope of [-------------] package, fully meeting the guarantee and also depute our
technical experts from time to time for advice on procedures and guidance during design,
engineering, manufacture, erection, testing and commissioning, as applicable to the place of
work / Owners Project site.
On award of LOA, we the Consortium Partner agree to furnish an on demand back up bank
guarantee for 2 % of Contract Price.
1.
Witness
Signature:
Name:
Name:
Designation:
Designation:
Office Address
Seal of the Company
2.
Witness
For Bidder
Signature:
Name:
Name:
Designation:
Designation:
Office Address:
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[8]
30.09.2015
Power Plant]

Scope of Work of the Each Consortium Partner:
For Each Consortium Partner
For Bidder
Name:
Name:
Designation:
Designation:
Seal of the Company
Seal of the Company

*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[9]
30.09.2015
Power Plant]
ANNEXURE E
SAMPLE FORMAT
LETTER OF UNEQUIVOCAL CONSENT TO BE FURNISHED BY THE BIDDER AND THE
ASSIGNEE
Assignee) hereby agree to act as a Assignee to the Firm [-------------] (Name and Complete
address of the Bidder) for the successful completion of part scope of work as enclosed in the
attachment (authenticated by the Bidder and the Nominee) of [-------------] Package for the [------------] Project at [-------------] in the state of [-------------], India. We also hereby undertake to ensure
the quality of manufacture, timely delivery and the successful performance of the
equipment/system covered in our scope of [-------------] package, fully meeting the guarantee and
also depute our technical experts from time to time for advice on procedures and guidance
during design, engineering, manufacture, erection, testing and commissioning, as applicable to
the place of work / Owners Project site.
We, the Assignee, agree to work as an independent contractor, with respect to the 2nd/3rd
Contract or both, on such additional terms and conditions, as may be agreed to, between the
Owner and the Foreign Bidder.
On award of LOA, we the ASSIGNEE agree to furnish an additional Contract Performance Bank
Guarantee for 5%, of the aggregate value of the component contracts entered in to with us.
1.
Witness
For Assignee
Signature:
Name:
Name:
Designation:
Designation:
Office Address
Seal of the Company
2.
Witness
For Bidder
Signature:
Name:
Name:
Designation:
Designation:
Office Address:
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[10]
30.09.2015
Power Plant]
ATTACHMENT TO THE LETTER OF UNEQUIVOCAL CONSENT

1
Scope of Work of the Assignee:
For Bidder
For Assignee
Name:
Name:
Designation:
Designation:
Seal of the Company
Seal of the Company
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[11]
30.09.2015
Power Plant]
SCHEDULE F1: TABLE - 1

SUMMARY OF PRICE SCHEDULE
(In Figures and Words)
S.No.
Foreign
Currency
Description
1.1
Supply of imported Plant & equipment including

technological and misc. structures with all accessories
(FOB) including design, engineering, manufacturing, shop
testing, packing and forwarding charges on lumpsum and
firm price basis.
1.2
Ocean freight on lumpsum and firm price basis for 1.1

above.
1.3
Marine insurance on lumpsum and firm price basis for 1.1

above.
1.4
CIF Cost (1.1+1.2+1.3)
2.
All port charges including port handling, port rent, and port
clearance on lumpsum and firm price basis.
3.
Supply of indigenous Plant & Equipment including

Technological and misc. structures with all accessories
(Ex-Works) including design, engineering, manufacturing,
shop testing, packing and forwarding charges on lumpsum
price basis.
4.
Sales Tax Payable on Indigenous equipment - on Ceiling

basis.
(a) VAT
(b) Central Sales Tax (CST)
5.
(a) Inland transport of imported plant & equipment on

lumpsum and firm price basis.
INR
(b) Inland transport of Indigenous plant & equipment on

lumpsum and firm price basis
6.
Lumpsum price for Civil Works including, supplies such

as cement, reinforcement steel, all foundation bolts etc.at
site cost, including Design & Engineering and Construction
of entire Civil works.
7.
Erection services including dismantling/disassembly.

unloading, handling, storage and preservation at site,
Erection, testing, commissioning and PG tests of plant &
equipment on lumpsum price basis
8.
Marine cum erection insurance on lumpsum and firm price

basis (excluding marine insurance indicated in Sl. No. 1.3
above)
9.
Foreign supervision charges in India during erection,

commissioning & PG test on firm price basis with ceiling.
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[12]
30.09.2015
Power Plant]

S.No.
Foreign
Currency
Description
10.
Training charges on firm price basis with ceiling.
11.
VAT on Works Contract on ceiling basis
12.
Service Tax including Education Cess on Ceiling basis
13.
Others, if any (Please specify),
14.
Total price of package (excluding mandatory spares and

Tools & Tackles.
(Total of Sl.Nos.1.4 + 2 to 13).
15.
Mandatory Spares on lumpsum and firm price basis.

(Landed cost at site) (Breakup to be indicated in Table-3)
16.
Tools & Tackles on lumpsum and firm price basis.

17.
Grand total price of package including Mandatory Spares

and Tools & Tackles.
(Total of Sl Nos 14+15+16).
Signature
Name
:
:
Designation
Company
Date
INR
Company Seal
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[13]
30.09.2015
Power Plant]

PRICE SCHEDULE FOR SUPPLY OF PLANT AND EQUIPMENT INCLUDING
PACKING AND FORWARDING CHARGES
S.No.
Description
Foreign Supply
Indigenous Supply
FOB Price in
Foreign Currency
Supply
Ex-works
price
including
packing
and
forwarding in INR
1.1
1.2
Sub Total (1)
2.
2.1
2.2
Sub Total (2)

3
Control & Instrumentation Equipment
3.1
3.2
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[14]
30.09.2015
Power Plant]
S.No.
Description
Foreign Supply
Indigenous Supply
FOB Price in
Foreign Currency
Supply
Ex-works
price
including
packing
and
forwarding in INR
---Sub Total (3)

4
Total (1 + 2 + 3)
Signature
Name
:
:
Designation
Company
Date
Company Seal
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[15]
30.09.2015
Power Plant]
SCHEDULE F1: TABLE 3A

PRICE SCHEDULE FOR MANDATORY SPARES
Foreign Price
In
Foreign
Currency
S. No.
Description
1.1
1.2
Supply (FOB) of Mandatory Spares including Packing

and Forwarding on lumpsum and firm Price
Ocean freight on lumpsum and firm price
1.3
Marine insurance on lumpsum and firm price
1.4
CIF Cost (1.1 +1.2+1.3)
All port charges including port rent, port handling

charges, port clearance on lumpsum and firm price
Supply (Ex-works) of Mandatory Spares including

Packing and Forwarding on lumpsum and Firm Price
a) Inland transport for Imported items on lumpsum and
firm price basis.
4.
Indigenous
Price in INR
b) Inland transport for indigenous items on lumpsum

and firm price basis.
5
6
Insurance excluding 1.3 above (Lumpsum and firm

price basis)
Sales Tax on Indigenous Spares on Ceiling basis
a) VAT
b) CST
Total price of Mandatory Spares (landed cost at site).
(Total of Sl. Nos 1.4 + 2 to 6)
Signature
Name
Designation
Company
:
:
:
:
Date
Company Seal
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[16]
30.09.2015
Power Plant]
SCHEDULE F1: TABLE 3B

PRICE SCHEDULE FOR RECOMMENDED SPARES
Foreign Price
In
Foreign
Currency
S. No.
Description
1.1
1.2
Supply (FOB) of Recommended Spares including

Packing and Forwarding on lumpsum and firm Price
1.3
1.4
CIF Cost (1.1 +1.2+1.3)

Supply (Ex-works) of Recommended Spares including

firm price basis.
4.
Indigenous
Price in INR

5
6

price basis)
a) VAT
b) CST
Total price of Recommended Spares (landed cost at
site).
Signature
Name
Designation
Company
:
:
:
:
Date
Company Seal
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[17]
30.09.2015
Power Plant]
SCHEDULE F1: TABLE-4

PRICE SCHEDULE FOR TOOLS & TACKLES
Foreign Price
in
Foreign
Currency
S. No
Description
1.1
1.2
Supply (FOB) of Tools and Tackles including Packing and

Forwarding on Lumpsum and Firm Price
1.3
1.4
C.I.F Cost (1.1 +1.2+1.3)
2.
All port charges including port rent, port handling charges,

port clearance on Lumpsum and firm price
3.
Supply (Ex-works) of Tools and Tackles including Packing

and Forwarding on Lumpsum and firm Price
4.
a) Inland transport for imported items on lumpsum and firm

price basis.
b) Inland transport for indigenous items on lumpsum and
firm price basis.
Insurance excluding 1.3 above (lumpsum and firm price
basis)
a) VAT
b) CST
5.
6.
7.
Indigenous
Price in INR
Total price of Tools and Tackles (landed cost at site).

Signature
Name
Designation
:
:
Company
Date
Company Seal
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[18]
30.09.2015
Power Plant]

PRICE SCHEDULE FOR ERECTION SERVICES INCLUDING
DISMANTLING/DIASSEMBLY, UNLOADING, HANDLING, STORAGE,
PRESERVATION AT SITE, ERECTION, TESTING, COMMISSIONING AND
PERFORMANCE GUARANTEE TESTS OF PLANT AND EQUIPMENT
Total Price for complete work at Site in
Indian Rupees
S.No.
Description
1.1
1.2
Sub Total (1)
2.
2.1
2.2
Sub Total (2)

3
3.1
3.2
Sub Total (3)

4
Total (1 + 2 + 3)
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[19]
30.09.2015
Power Plant]
Sign
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[20]
30.09.2015
Power Plant]

PRICE SCHEDULE FOR CIVIL WORKS
S.No.
Foreign Currency
Description
INR
1.
2
3
4
5
..
Total
Signature
Name
Designation
:
:
Company
Date
Company Seal

PRICE SCHEDULE FOR TRAINING CHARGES
S.No.
Man-Months
Description
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Foreign
Currency
Description
INR

[21]
30.09.2015
Power Plant]
1.
2
3
4
5
..
Total
Signature
Name
Designation
:
:
Company
Date
Company Seal
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[22]
30.09.2015
Power Plant]

SCHEDULE OF PERFORMANCE GUARANTEE PARAMETERS
The Biddewr shall furnish performance guarantee of the Package in respect of all items listed
below.
Category I: Performance Guarantees under Liquidated Damages [L.D]
S. No
Particulars
Unit
Value inclusive of design,

manufacture and all other
Tolerances including
measurement uncertainty
..
Category II: Mandatory Performance Guarantees

S. No
Particulars
Unit
Value Inclusive of design, manufacture and all

other tolerances including
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[23]
30.09.2015
Power Plant]
S. No
Particulars

Unit
..
Category -III: Requirement under Demonstration Category
S. No
Particulars
Unit
Value
Inclusive
of
design,
manufacture
and
all
other
tolerances
including
measurement uncertainity
1
2
3
.
Signature
Name
Designation
Company
Date
Company Seal
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[24]
30.09.2015
Power Plant]
SCHEDULE F2
S.No
Days from Effective Date
Work Description
Start
1
Design & Engineering
Manufacture of Plant/Equipment
Finish
(a)
(b)
(c)
....
......
3
Delivery of Plant/Equipment & Systems

(a)
(b)
(c)
....
......
Dismantling/Disassembly of Plant/Equipment &

Systems
(a)
(b)
(c)
....
......
Civil work at Site
Erection of of Plant/Equipment & Systems

(a)
(b)
(c)
....
......
Trial Operation & Provisional Take Over
Performance Guarantee tests Completion and Final

Take Over
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[25]
30.09.2015
Power Plant]
Signature
Name
:
:
Designation
Company
Company Seal
Date
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[26]
30.09.2015
Power Plant]
SCHEDULE F3
All deviations to commercial condition (Tender Document Vol-I) shall be filled in by the Bidder
clause by clause in this schedule.
S.No
Clause
Deviation
commercial condition (Tender Document Vol-I) . The Bidder further confirms that in the event
any other data or information presented in the Bidders proposal and accompanying documents
are at variance with the specific requirements laid out in the commercial condition (Tender
Document Vol-I) , then the latter shall govern and shall be binding on the Bidder for the quoted
price.
Signature
Name
Designation
:
:
Company
Date
Company Seal
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[27]
30.09.2015
Power Plant]
SCHEDULE F4
DEVIATION SCHEDULE TO TECHNICAL SPECIFICATION
All deviations from the Technical Specification shall be filled in by the Bidder, clause by clause,
in this Schedule:
S.No
Volume /
Section
Clause
No
Description
Deviation
Purchasers Technical Specifications for this enquiry. The Bidder further confirms that in the
event any other data and information presented in the Bidders proposal and accompanying
documents including drawings, catalogues, etc are at variance with the specific requirements
laid out in the Purchasers Technical Specifications then the latter shall govern and shall be
binding on the Bidder for the quoted price.
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[28]
30.09.2015
Power Plant]
SCHEDULE F5
REQUIREMENTS OF THE CONTRACTOR AT SITE
(Bidder to fill-in and return with its Bid)
The Bidder shall state his requirements against each of the following including the basis of
requirements:
A.
Requirements Description
Quantity
Signature
Name
Designation
:
:
Company
Date
Company Seal
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[29]
30.09.2015
Power Plant]
SCHEDULE - F6
CONTRACTORS RESOURCE DEPLOYMENT SCHEDULE
A) Construction Equipment
The Bidder shall indicate the schedule of construction equipment, proposed to be deployed
at the site for executing the works as per the pro-forma below:
S. No.
Type of Resource
Months
1
2
3
B) Resource Deployment Schedule

The Bidder shall indicate the schedule of manpower resources proposed to be deployed at
the site for executing the works as per the pro-forma below:
S. No.
Type of Resource
Months
2.
Human Resources
2.1
Engineering Category
2.1.1
Project Engineers
2.1.2
Mechanical Engineers
2.1.3
Electrical Engineers
2.1.4
Civil Engineers
2.1.5
C&I Engineers
2.1.6
Commissioning Engineers
2.1.7
Structural Engineers
2.1.8
Others (bidder shall indicate) as applicable for the work
2.2
Supervisory Category
2.2.1
Const. Manager
2.2.2
Electrical Supervisors
2.2.3
Mechanical Supervisors
2.2.4
C&I Supervisors
2.2.5
Civil Supervisors
2.2.6
Purchase Officer (s)
2.2.7
Finance/Site Office
2.2.8
Inspection/Quality Control
2.2.9
Others (Bidder shall indicate) as applicable for the work
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[30]
30.09.2015
Power Plant]
S. No.
Type of Resource
Months
2.3
Labour Category
2.3.1
Welder
2.3.2
Fitter
2.3.3
Rigger
2.3.4
Un-skilled labour
2.3.5
Signature
Name
Designation
Company
Date
Company Seal
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[31]
30.09.2015
Power Plant]
SCHEDULE F9
COEFFICIENTS AND INDICES FOR PRICE VARIATION FORMULA
Sl No
Component of Contract Price
a=
Ex-Works/FOB price
component of Plant and
b=
Equipment excluding mandatory
c
spares
A=
Lb
L=
2
3
Coefficients
Indices
B=
C=
Erection Services Component
EF=
Civil Works Component
a=
MI=
b=
LI=
c=
FI=
d=
SI=
e=
CI=
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
Rev No
LII-GETS12021-G-001129-001
03
Description

[32]
30.09.2015
Power Plant]
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[1]
30.09.2015
Power Plant]

[country of Employer] and having its principal place of business at [address of Employer]
(hereinafter called the Employer), and (2) [name of Contractor], a corporation
incorporated under the laws of [country of Contractor] and having its principal place of
business at [address of Contractor] (hereinafter called the Contractor)
WHEREAS the Employer desires to engage the Contractor to dismantle/disassemble,
design, manufacture, test, deliver, install, complete and commission certain Facilities,
viz.
[
..]
(the Facilities) and the Contractor have agreed to such engagement upon and subject
to the terms and conditions hereinafter appearing.
1.1
Contract Documents
annexure/appendices, and the complete documents, which are the basis of
finalization of the contract, including correspondence exchanged from issue of
tender till date of signing the contract. The following will constitute the Contract
Documents:
i. The signed Contract Agreement & the annexure/ appendices thereto (highest
precedence)
v. Technical specification & Tender Drawing.
a) All documents forming part of the Contract (and all parts thereof) are intended to
be correlative, complementary and mutually explanatory. The Contract shall be
read as a whole.
with one signed original and the rest will be retained by the Employer.
1.2

precedence)
v. Technical specification & Tender Drawing.
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[2]
30.09.2015
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1.3
Definitions
" The Definitions of terms and expressions shall be as per GCC clause 4.1.
Terms and expressions not defined in GCC shall have the same meaning as are
1.4
Contract Price
The Contract Price shall be the aggregate of: [amount of foreign currency in words],
[amount in figures], and [amount of local currency in words], [amount in figures], or such
other sums as may be determined in accordance with the terms and conditions of the
Contract.
1.5
Term of Payment
The terms and procedures of payment according to which the Employer will reimburse
the Contractor are given in Contract Schedule 1 (Terms and Procedures of Payment)
hereto.
1.6

tender and commencement of unit shut down by Employer shall be as follows:
1.
Time for completion (by Contractor) of By [] months from
Engineering and Supply activities and other Effective Date
L-2 network
2.
Time for Commencement (by Employer) of By [] months from
Unit Shut Down.
Effective Date
activities as at serial no.1, Employer may,
at
its
discretion,
reschedule
commencement of unit shut down
3.
Time for Completion of all R&M activities By [..] days from start
that are to be carried out under unit shut of unit shut down
4.
Performance
Guarantee
Test
(By By [] months from
Contractor)
the
completion
of
trial
R&M activities
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[3]
30.09.2015
Power Plant]
Contract Schedules
Reference in the Contract to any Contract Schedule shall mean the Contract Schedules
attached hereto, and the Contract shall be read and construed accordingly.
IN WITNESS WHEREOF the Employer and the Contractor have caused this Agreement
to be duly executed by their duly authorized representatives the day and year first above
written.
_-----------------------------------------------------------------------------[Signature]
_------------------------------------------------------------------------------- [Title]
_----------------------------------------------------------------------------- [Signature]
_------------------------------------------------------------------------------- [Title]
CONTRACT AGREEMENT
dated the_-----------day of---------------, 20_---------_____
BETWEEN
[The Employer]------------------------------------------------------------------------------------------and
[The Contractor]------------------------------------------------------------------------------------Contract Schedules:
Contract Schedule 1
Contract Schedule 2
Contract Schedule 3
Contract Schedule 4
Contract Schedule 5
Contract Schedule 6
Document Number
LII-GETS12021-G-00129-001
:
:
:
:
:
:
Terms of Payment
Price Adjustment
Time Schedule
Scope of Works and Supply by the Employer
Rev No
Description
03


[4]
30.09.2015
Power Plant]
Contract Schedule-1
Terms of Payment
The Owner shall pay the Contractor in the following manner and at the following times,
on the basis of the Price Break down given in the Section on Price Schedules.
Payments will be made in the currencies quoted by the Bidder unless otherwise agreed
between the parties. Application for payment in respect of part deliveries may be made
by the Contractor as work proceeds.
I.
Terms of Payment for Supply of Plant and Equipment (excluding Mandatory

Spares and Recommended Spares) supplied from Abroad:
1
10% of the total FOB price
50% of FOB price for each

identified
equipment
as
progressive payment and 100%
of Ocean Freight and Marine
Insurance Charges pro-rata to
the value of the equipment
15% of FOB price for each On receipt of equipment at site and
identified equipment
physical verification and certification by
the Employer
On Completion of Facilities
Successful completion of Performance
Guarantee Test
4
5
II.
Initial Advance on Acceptance of Letter of

Award by the Contractor, Signing of
Contract Agreement and submission of
Contract Performance Bank Guarantee,
Additional Contract Performance Bank
Guarantee and Advance Payment Bank
Guarantee by Contractor
Upon dispatch of the identified equipment
after dispatch clearance by employer on
raising of Invoice by the Contractor and
submission of evidence of shipment

Spares and Recommended Spares) supplied from within India:
1
10% of the total Ex-Works Initial Advance on Acceptance of Letter of

price
50% of Ex-Works price for each Upon dispatch of the identified equipment
identified
equipment
as after dispatch clearance by employer on
progressive payment
15% of Ex-Works price for each On receipt of equipment at site and
the Employer
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[5]
30.09.2015
Power Plant]
4
5
III.
20% of the total Ex-Works price

Guarantee Test
Terms of Payment for Supply of Mandatory Spares and Recommended Spares

1
70% of the CIF Price of each

Spare from Abroad or 70% of
the Ex-Works Price of each
Spare from within India
IV.
Upon dispatch of the identified Spare

raising of invoice by the Contractor and
On receipt of Spare at site and physical
verification and certification by the
Employer
Terms of Payment for Local Transportation, Inland Transit Insurance and port
clearance charges & port charges
V.
For Plant & Equipment except Spares

100% of Local Transportation, Inland
Transit Insurance and Port Clearance &
Port Charges pro-rata to value of the
equipment
For Spares
Port Charges pro-rata to value of Spare
On receipt of Equipment at site and

upon raising of Invoice by the
Contractor
On receipt of Spare at site and upon

raising of Invoice by the Contractor
Terms of Payment for Erection of Plant & Equipment

1
3
4
10% of Total Price for Erection of Plant Initial Advance on Acceptance of Letter
& Equipment
of Award by the Contractor, Signing of
Contract
Performance
Bank
Guarantee,
Additional
Contract
Performance Bank Guarantee and
Advance Payment Bank Guarantee by
Contractor
75% of Price for Erection of Plant & On certification by Employer of
Equipment as progressive payment pro- successful erection of plant &
rata to value of plant & equipment equipment and successfully passing of
erected
quality checks
10% of Total Price for Erection of Plant On Completion of Facilities
& Equipment
5% of Total Price for Erection of Plant & Successful completion of Performance
Equipment
Guarantee Test
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[6]
30.09.2015
Power Plant]
VI.
Terms of Payment for Civil Works

1
3
4
VII.
10% of Total Price for Civil Works
Initial Advance on Acceptance of Letter

Contract
Performance
Bank
Guarantee,
Additional
Contract
Contractor
75% of
Price for Civil Works as On certification by Employer regarding
progressive payment
value of work completed & successfully
passing of quality checks
Guarantee Test
Terms of Payment for Price Adjustment Amount
Any increase in the Price of any component Contract shall be paid as per the Terms
of Payment for base price. The initial 10% advance payment pertaining to increase
in price shall be paid along with progressive payment of that equipment. Reduction
to the Contract Price, if any, due to price adjustment provisions, shall be effected by
recovering 100% of the reduction amount (including advance) from any of the
Contractor's bills falling immediately due for payment.
VIII.
IX.

Any Tax or Duty payable by Employer as per the Terms & Conditions of Contract
and is directly payable to Statutory Authorities/Government as per law shall be
directly paid to the concerned authority or Government by the Employer. Any other
Tax or Duty payable by Employer as per the Terms & Conditions of Contract shall
be reimbursed to the Contractor/Assignee upon receipt of corresponding Plant &
Equipment or Spare at site and submission of evidence by the Contractor/Assignee
to the Employer as to the Contractor/Assignee having paid such Taxes & Duties.
Any amount towards statutory variation in Taxes & Duties payable by Employer as
per the Terms & Conditions of Contract shall be reimbursed to the
Contractor/Assignee upon submission of evidence by the Contractor/Assignee to the
Employer as to the Contractor/Assignee having paid such variation.
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[7]
30.09.2015
Power Plant]
Contract Schedule-2
PRICE ADJUSTMENT
(i)
The Contract Price shall be subject to price adjustment during performance of the
Contract to reflect changes in the cost of labour and material in accordance with the
provisions described below.
(ii)
Only following components of the Contract Price will be subject to Price adjustment :
(a)
Ex-Works (India) price of plant and equipment excluding Mandatory Spares

manufactured within India and FOB price component for plant and equipment
excluding Mandatory spares supplied from abroad. The price adjustment amounts
towards these price components shall be without any ceiling.
(b)
Erection Services component of the Contract Price. The price adjustment amounts
towards this price component shall be without any ceiling.
(c)
Civil Works component of the Contract Price. The price adjustment amounts
(iii)
Price adjustment amounts towards aforesaid components of Contract Price shall be paid
in the respective currencies of Contract.
(iv)
The indices for price adjustment shall necessarily be of the country of origin of
goods/labour and shall be well established and nationally recognized in that country.
Preferably Government indices shall be used.
(v)
The price adjustment formula for the components of the Contract Price above shall be as
stipulated hereinafter.
(vi)
Ex-Works/FOB price component of Plant and Equipment excluding mandatory

spares
The price component of the equipment for any shipment/ dispatch comprises of a fixed
portion (designated as 'F' and the value of which is specified hereunder) and a variable
portion linked with the indices for various materials and labour.
The amount of price adjustment towards variable portion payable/recoverable on each
shipment/dispatch shall be computed as under:
ES = ES1 - ES0
ES1 will be computed as follows:
ES1 = ES0 {F + a x
Where
A1
A0
x f1 + b x
B1
B0
x f2 + c x
C1
CO
x f3 + Lb x
L1
L0
x flb }
ES
Adjustment to Ex-Works/FOB price component expressed in the currency

of the Contract payable to the contractor for each shipment/dispatch
ES1
Adjusted amount of Ex-works/FOB price component expressed in the
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[8]
30.09.2015
Power Plant]
currency of the
shipment/dispatch
ES0
payable
to
the
Contractor
for
each
Ex-works/FOB price for the plant and equipment in the currency of the
Contract, shipment/dispatch wise.
The fixed portion of the ex-works/FOB component of the Contract Price

(F) shall be 0.15.
a, b,c etc. shall be co-efficient of major materials/items involved in the exworks/FOB component of the Contract Price. The sum of these coefficient shall be between 0.50 to 0.60.
f1, f2, f3,

flb etc
Contract
A, B, C etc. shall be published price indices of corresponding major

materials/items. Such indices shall necessarily be of the country of origin
of goods.
'Lb" shall be co-efficient for labour component in the ex-works/ FOB
component of the Contract Price which shall be between 0.25 to 0.35.
'L' shall be labour index.
Sum of all the material co-efficient and the labour co-efficient shall be
0.85.
f1, f2, f3 etc. are Exchange rate correction factors for the respective
materials and flb is the exchange rate correction factor for labour with
reference to the currency of the country of origin of index and the
respective contract currency, such that
f=
Z0
Z1
where Z is the no. of units of the currency of the country of the origin of index, which is
equivalent to one unit of the respective contract currency. The exchange rates to be used
for calculation of factor 'f' shall be as per State Bank of India Bills Selling Exchange Rates.
For the indices(A, B, C etc.), subscript 'o' refers to indices as on 30 days prior to original
scheduled date for opening of Part-I Bid.. For 'Z0, subscript o refers to value as on the
date of opening of Part-I Bid.
Subscript '1' refers to indices/exchange rates as of:
(a) three months prior to the date of shipment/dispatch for labour, and
(b) six months prior to the date of shipment/dispatch for material.
In case of shipments/dispatches which are delayed beyond the schedule date of
shipment/dispatch for reasons attributable to the Contractor, the price adjustment
provision shall not be applicable for the period of time between the schedule date of
shipment/dispatch and the actual date of shipment/dispatch.
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[9]
30.09.2015
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The above formula for price adjustment will be applicable if the currency in which the
contract price is expressed is different from the currency of the country of origin of labour
and material indices. In other case, formula shall be applied without the exchange rate
correction factor 'f'.
(vii) Erection Services Component
The price component for erection services comprises of a fixed portion and a variable
portion linked with the index of labour.
The monthly price adjustment amount for the erection services component of the Contract
Price will be computed separately for Indian currency and for foreign currency part, if any,
related to expatriate supervision/labour as per the formula given below:
(a) Indian Rupee part of the Erection Services
ER = ER1 - ERo
ER1 will be computed as follows:
ER1 = ER0 (0.15 + 0.85
Where:
FL1
FL0
ER
Adjustment to erection services component of contract price expressed in

Indian Rupees payable to the contractor for each billing.
ER1
Adjusted amount of erection services component of Contract Price

expressed in Indian Rupees payable to the Contractor.
ER0
Value of the Erection work done in the billing period (month)
FL
.
=
Indian field labour index namely, All India Consumer Price Index for
Industrial Workers (All India Monthly Average) as published by Labour
Bureau, Simla, Government of India.
(b) Foreign Currency portion of the Erection Services

EE = EE1 - EE0
EE1 will be computed as follows:
EE1 = EE0 (0.15 + 0.85
Where:
EF1
EF0
x f)
EE
Adjustment to erection services component of Contract Price expressed in

foreign currency payable to the contractor for each billing.
EE1

expressed in foreign currency payable to the contractor for each billing.
EE0
Value of foreign currency portion of Erection work done in the billing

period (month)
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[10]
30.09.2015
Power Plant]
EF
Index for Expatriate field labour component of the Erection Price of

Installation work. Such index shall necessarily be of the country of
nationality of the labour.
Exchange rate correction factor for expatriate labour with reference to

currency of country of origin of index for expatriate labour and the
Z0
Z1
where Z is the no. of units of the currency of the country of origin of index,
which is equivalent to one unit of the respective contract currency. The
ex-change rates to be used for calculation of factor 'f' shall be as per State
Bank of India Bills Selling Exchange.
f=
For the indices, subscript 'o' refers to indices as on 30 days prior to date
set for opening of bids. For 'Z0 ', subscript 'o' refers to value as on the
For the indices, subscript '1' refers to the indices as applicable for the
month of execution of the erection work. For the exchange rates,
subscript '1' refers to the exchange rates as applicable on the last day of
the month of execution of the erection work.
In case of erection activities which are delayed beyond the schedule date
for reasons attributable to the contractor, the price adjustment provision
shall not be applicable for the period of time between the schedule date of
completion and actual date of completion of the respective erection
activity.
(viii) The following components of the contract price shall not be subject to price adjustment
and shall remain firm during the execution of the contract :
(1) Ocean Freight and Marine Insurance for Plant and Equipment, mandatory spares and
recommended spares.
(2) Ex-works/FOB price component for Mandatory spares & Recommended Spares.
(3) Inland Transportation charges (including Inland Transit Insurance, port clearance, port
handling & port charges) for plant & equipment and Spare Parts.
(ix) Civil Works Component
The Price of Civil Works for any month comprises a fixed part designated as F and
variable parts linked to indices for labour, steel, cement, other commodities and Fuel &
Power. The monthly price adjustment amount for the civil works component of the
Contract Price will be computed as per the formula given below:
EC = EC1 - EC0
EC1 will be computed as follows:
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[11]
30.09.2015
Power Plant]
EC1 = EC0 {F + a x
Where
MI1
MI0
+bx
LI1
LI0
+cx
FI1
FIO
+dx
SI1
SIO
+ex
CI1
CIO
EC
Adjustment to Civil Works price component expressed in the currency of

the Contract payable to the contractor for each month
EC1
Adjusted amount of Civil Works price component expressed in the

currency of the Contract payable to the Contractor for each month
Value of Civil Works done expressed in the currency of the Contract for
the billing period (month).
The fixed portion (F) of the Civil Works component of the Contract Price
shall be 0.15.
a is the coefficient for material cost other than cement and steel involved
in the Civil Works component of the Contract Price and it shall be 0.15.
b is the coefficient for labour cost involved in the Civil Works component
of the Contract Price and it shall be 0.3.
c is the coefficient for Fuel & Power cost involved in the Civil Works
component of the Contract Price and it shall be 0.05.
d is the coefficient for steel cost involved in the Civil Works component of
the Contract Price and it shall be 0.25.
e is the coefficient for cement cost involved in the Civil Works component
EC0
MI shall be All India Whole Sale Price Index for all commodities as
published by the Economic Adviser to Government of India, Ministry of
Commerce & Industry.
LI shall be All India Consumer Price Index for industrial labour as
published by Labour Bureau, Government of India
FI shall Index Number of Wholesale Price for group Fuel & Power as
Commerce & Industry
SI shall Index Number of Wholesale Price for Steel as published by the
Economic Adviser to Government of India, Ministry of Commerce &
Industry
CI shall Index Number of Wholesale Price for Cement as published by
the Economic Adviser to Government of India, Ministry of Commerce &
Industry
For the indices(MI, LI,FI, SI and CI), subscript 'o' refers to indices as on 30 days prior to
original scheduled date for opening of Part-I Bid. Subscript '1' refers to indices as of one
prior to the month for which Civil Works is being billed.
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[12]
30.09.2015
Power Plant]
Contract Schedule-3
TIME SCHEDULE
Sl No.
Work Description
Start
Finish
(Months from
Effective Date)
(Months from
Effective Date)
1
2
Note: Detailed PERT network agreed between Owner and Contractor to be placed below above
table.
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[13]
30.09.2015
Power Plant]
Contract Schedule-4
LIST OF SUB-CONTRACTORS
Sl No.
Equipment / Work Description
Approved Sub-Vendor / Sub-Contractor
1.
2.
3
4
5
1.
2.
3
4
5
1.
2.
3
4
5
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[14]
30.09.2015
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Contract Schedule-5
SCOPE OF WORKS AND SUPPLY BY THE EMPLOYER
[Scope of Works and Supply by the Employer shall be placed]
Sl No.
Description of Works/Supply by Employer
1
2
3
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[15]
30.09.2015
Power Plant]
Contract Schedule-6
FUNCTIONAL GUARANTEES
[Functional Guarantees shall be placed]
Sl No.
Unit
Guaranteed Value
Category-I Performance Guarantee

1
2
3
4
.
Category-II Performance Guarantee
1
2
3
4
.
Category-III Performance Guarantee
1
2
3
4
.
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
03


[16]
30.09.2015
Power Plant]
ANNEXURE - G
[To be furnished by Contractor]
Place:
Bank Guarantee No:
Date:
To:
..
]
Dear Sirs,
1
In consideration of the [........................................] hereinafter referred to as the OWNER,

which expression shall, unless repugnant to the context or meaning, thereof include its
successors, representative and assignees, having awarded in favour of
M/s.[Contractors Name] having its
registered office at..hereinafter referred
to as the CONTRACTOR, which expression shall, unless repugnant to the context or
meaning thereof include its successors, administrators, representatives and assignees, a
Contract,
hereinafter
referred
to
as
the
"CONTRACT"
for
OWNER's
Contract/Letter
of
Award
No..datedas
well
as
CONTRACT documents, valued at [amount of foreign currency in words], [amount in
figures], and [amount of local currency in words], [amount in figures] and the same having
been unequivocally accepted by the CONTRACTOR and the CONTRACTOR having
agreed to provide a Contract Performance Bank Guarantee for the faithful performance of
the entire CONTRACT including the Warranty Obligations /Liabilities under the CONTRACT
equivalent to 10% (ten percent) of the said value of the CONTRACT to OWNER amounting
to Rs(Rupeesonly) as Contract

and having its Head Office at., hereinafter referred to as
the Bank which expression shall, unless repugnant to the context or meaning thereof,
include its successors, administrators, representatives and assignees do hereby irrevocably
guarantee and undertake to pay the OWNER merely on demand without any previous
notice and without any demur and without referring to any other source, any and all monies
payable by the CONTRACTOR by reason of any breach of the said CONTRACTOR of any
of the terms and conditions of the said CONTRACT including non-execution of the
CONTRACT AGREEMENT, to the extent of ..(%). of the Contract price to
OWNER
amounting
to
Rs(Rupees.only).
Any
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
02


[1]
25.09.2014
Power Plant]
such demand made by the OWNER on the Bank shall be conclusive and binding, absolute
and unequivocal notwithstanding any difference between the OWNER and CONTRACTOR
or any dispute or disputes raised/ pending before any Court, Tribunal, Arbitrator or any other
authority. The Bank agrees that the guarantee herein contained shall continue to be
enforceable till this sum due to the OWNER is fully paid and claims satisfied or till the
OWNER discharges this Guarantee.
The Bank further irrevocably guarantees and undertakes to pay any amount due and
payable by the CONTRACTOR by reasons of non-fulfilment of any of the following
obligations of the Contractor:
(a) Successful and satisfactory operation of the plant & equipment supplied and erected
under the said Contract as per the Technical Specifications and other Tender/Contract
documents.
(b) That the equipment installed under the said Contract shall be new and in accordance
with Contract Documents and be free from all defects in design, engineering, material
workmanship and performance for a period of 12 calendar months after final takeover
of the equipment by the OWNER and that upon written notice from the OWNER, the
CONTRACTOR shall remedy free of any expense to the OWNER, such defects as
noticed and developed under the normal use of the said plant & equipment, within the
said guarantee period.
The OWNER shall have the fullest liberty without affecting in any way the liability of the
Bank under this guarantee, from time to time, to extend the time of Performance by the
CONTRACTOR. The Bank shall not be released from its liabilities under these presents by
any exercise of the OWNER of the liberty with reference to the matter aforesaid.
The OWNER shall have the fullest liberty, without affecting this guarantee to postpone from
time to time the exercise of any powers vested in them or of any right which they might have
against the CONTRACTOR and to exercise the same at any time in any manner, and either
to enforce or to forbear to enforce any covenants, contained or implied in the CONTRACT
between OWNER and the CONTRACTOR or any other course or remedy or security
available to the OWNER and the Bank shall not be released of its obligations/liabilities
under these presents by any exercise by the OWNER of his liberty with reference to the
matters aforesaid or any of them or by reasons of any other act or forbearance or other acts
of omission or commission on the part of the OWNER or any other indulgence shown by the
OWNER or by any other matter or thing whatsoever which under law would, but for this
provision, have the effect of relieving the Bank Guarantee. The Bank further undertakes not
to revoke this guarantee during its currency without the previous consent of the OWNER.
The Bank further agrees that the decision of the OWNER as to the failure on the part of the
CONTRACTOR to fulfill their obligations as aforesaid and/or as to the amount payable by
the Bank to the OWNER hereunder shall be final, conclusive and binding on the Bank.
guaranteed sum either in full or part, in the manner suitable to them. However, payment
made for a sum lesser than the guaranteed amount shall not relieve or discharge the bank
from their obligations guaranteed under the bank guarantee, till the contractual obligations
are fully performed by the Contractor or the Bank Guarantee is discharged by the OWNER,
as the case may be and the Bank Guarantee shall continue to be in force till such time.
guarantee against the Bank as a Principal Debtor, in the first instance notwithstanding any
other security or guarantee that it may have in relation to the CONTRACTOR's liabilities.
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
02


[2]
25.09.2014
Power Plant]
This guarantee will not be discharged due to the change in the constitution of the Bank or
the CONTRACTOR(S).
10 Notwithstanding anything contained hereinabove, our liability under this guarantee is
it will remain in force upto and including and shall be extended from
time to time for such period as may be desired by [Name of Contractor]
on whose behalf this guarantee has been given.
11
Signature
Name
Designation
Staff Code No
Date
Bank Seal
Witness:
1.
2.
Signature
Occupation
Address
Signature
Occupation
Address
:
*****
Document Number
LII-GETS12021-G-00129-001
Rev No
Description
02


[3]
25.09.2014

OF

R&M CONTRACTORS

VOLUME-II
SECTION-I
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R04
January 2016
Tender Document for R&M of Unit No. [..] Capacity [...] of [Name of the
Power Plant]
[Logo of Utility]

Volume
Section
Part
Description
Volume-I
---
---
Commercial
Section-I
---
Part-A
Detailed Technical Specifications - Mechanical
Part-B
Part-C
Part-D
---
Part-A
---
Part-B
---
Part-C
---
Part-D
Not Used
Volume-II
Section-II
Volume-III
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-II, Section-I
[i]
15.01.2016
Power Plant]
[Logo of Utility]
1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[ii]
15.01.2016
Power Plant]
[Logo of Utility]

SECTION-I: PROJECT TECHNICAL SPECIFICATION
1.
2.
3.
4.
5.
6.
7.
8.
9.
Spare Parts
10.
Annexure
SECTION-II:
1.
2.
3.
4.
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[iii]
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Power Plant]
[Logo of Utility]

1.
2.
3.
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[iv]
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[Logo of Utility]
TABLE OF CONTENT
1
INTENT OF SPECIFICATION............................................................................................. 1
SITE & PROJECT SPECIFIC INFORMTION ...................................................................... 6
2.1
Project Name ............................................................................................................... 6
2.2
Project Location ........................................................................................................... 6
2.3
Climatological Data ...................................................................................................... 6
2.4
Fuel ............................................................................................................................. 7
2.5
Water Analysis ............................................................................................................12
EXISTING PLANT DETAILS .............................................................................................15

3.1
Operational Background .............................................................................................15
3.2
Salient Technical Feature of Boiler & its Auxiliaries.....................................................22
SCOPE OF SUPPLY & SERVICES ...................................................................................69

4.1
The scope of supply and services ...............................................................................69
4.2
Tools & Tackles ..........................................................................................................72
4.3
Safety .........................................................................................................................73
4.4
Training Requirements ................................................................................................73
4.5
Detail Scope of Work: .................................................................................................73
TERMINAL POINTS & EXCLUSSIONS ..........................................................................108

5.1
Terminal Points .........................................................................................................108
5.2
Exclusions ................................................................................................................110
GENERAL TECHNICAL REQUIREMENTS ....................................................................111

6.1
Codes & Standards ...................................................................................................111
6.2
Name Plates .............................................................................................................112
6.3
Guards and Fences ..................................................................................................113
6.4
Operation, Maintenance & Availability .......................................................................113
6.5
Materials ...................................................................................................................113
6.6
Lubricants, Control Fluids and Chemicals .................................................................113
6.7
Plant Life and Modes of Operation ............................................................................114
6.8
Packaging & Marking ................................................................................................114
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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[Logo of Utility]
6.9
Protection .................................................................................................................115
6.10
Painting.....................................................................................................................115
6.11
Environment Protection .............................................................................................117
6.12
Inspection and Testing ..............................................................................................118
LAYOUT CONSIDERATION ...........................................................................................121
PERFORMANCE GUARANTEES ...................................................................................123

8.1
General Requirements ..............................................................................................123
8.2
Performance Guarantees under Category-I ..............................................................125
8.3
Guarantees under Category-II ..................................................................................131
8.4
Guarantees under Category-III..................................................................................133
SPARE PARTS ...............................................................................................................140

9.1
Mandatory Spares.....................................................................................................140
9.2
Recommended Spares .............................................................................................140
9.3
Start-up & Commissioning Spares ............................................................................141
9.4
10
ANNEXURE .................................................................................................................143
10.1
Annexure-I (List of Existing Drawing) ........................................................................143
10.2
Annexure-II (Mandatory Spares) ...............................................................................143
10.3
Annexure-III (List of Sub-Vendor)..............................................................................143
10.4
RLA/CA Study Report ...............................................................................................143
10.5
EA Study Report .......................................................................................................143
10.6
Baseline Study Report ..............................................................................................143
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[vi]
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Power Plant]
[Logo of Utility]
ABBREVIATIONS
{The utilities are advised to use the following standard abbreviations while preparing Model
Tender Document for their power plant.}
AAQ
Ambient Air Quality
AC
Alternating Current
ACB
Air Circuit Breaker
ACDB
AC Distribution Board
ACG
AHP
Ash Handling Plant
AHU
Air Handling Unit
ASME
ATRS
ATT
AVR
BHEL
Bharat Heavy Electricals Ltd.
BFP
BMCR
BOD
Biochemical Oxygen Demand
BOP
Balance of Plant
BTD
Bearing Temperature Detector
CA
CAVT
CBD
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[vii]
15.01.2016
Power Plant]
[Logo of Utility]
CCTV
CEA
CEMS
CERC
CFBC
CHP
Coal Handling Plant
CRH
Cold Re-Heat
CRT
Cathode Ray Tube
CLCS
CMMS
Computerized Maintenance Management System
COC
COD
Chemical Oxygen Demand
CT
Cooling Tower, Current Transformer
CV
Control Valve
CW
Cooling Water
DB
Distribution Board
DC
Direct Current
DCDB
DCS
Distributed Control System
DDCMIS
Digital Distributed Control Monitoring Information System
DG
Diesel Generator
DGA
DM
Demineralization
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[viii]
15.01.2016
Power Plant]
DMCW
Demineralized Cooling Water
DP
Earthed
ECO
Economizer
EHC
ELCID
EOT
ESP
ESV
ETP
EWS
FD
Forced Draft
FO
Fuel Oil
FOPH
Fuel Oil Pump House
FSSS
GC
Gland Condenser
GCV
GA
General Arrangement
GT
HCA
HFO
Heavy Fuel Oil
HPS
Heavy Petroleum Stock
HPTB
High Pressure Turbine Bypass
Document Number
LII-GETS12021-G-00129-001
[Logo of Utility]
Rev
No.
Description
Page
No.
Date of Issue
04

[ix]
15.01.2016
Power Plant]
HMI
HP
High Pressure
HRH
Hot Re-Heat
HT
High Tension
HV
High Voltage
HVAC
HVWS
IBD
IBR
Indian Boiler Regulations
I&C
ICB
ID
Induced Draft
IGV
Inlet Guide Vane
I/O
Input / Output
IPT
IPR
Inter Posing Relay
ISA
Indian Standard Angle
ISMB
ISMC
Indian Standard Medium Channel
IV
Interceptive Valve
LAN
Local Area Network
LDB
Lighting Distribution Board
LDO
Light Diesel Oil
Document Number
LII-GETS12021-G-00129-001
[Logo of Utility]
Rev
No.
Description
Page
No.
Date of Issue
04

[x]
15.01.2016
Power Plant]
[Logo of Utility]
LE
Life Extension
LP
Low Pressure
LP
Lighting Panel
LPA
LPT
LPTB
Low Pressure Turbine Bypass
LRSB
LSHS
Low Sulfur High Stock
LT
Low Tension
LTSH
LVS
Large Video Screen
MCC
Motor Control Centre
MCCB
MHVT
Multi High Velocity Thermocouple
MOCB
MoEF
MS
Main Steam
MSSV
NDT
Non Destructive Test
NABL
National Accreditation Board for Testing and Calibration Laboratories
NSPBD
Non Segregated Phase Bus Duct
O&M
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[xi]
15.01.2016
Power Plant]
OEM
Original Equipment Manufacturer
OPC
OWS
PA
Primary Air
PDB
Power Distribution Board
PLF
Plant Load Factor
PCC
Power Control Centre
PMCC
Power cum Motor Control Centre
PRDS
PLC
R&M
RfP
RfQ
RH
Reheater
RLA
RO
Reverse Osmosis
RPM
Respirable Particulate Matter
rpm
Revolutions Per Minute
RMS/ rms
Root Mean Square Value
RSO
RTD
SADC
SG
Steam Generator
Document Number
LII-GETS12021-G-00129-001
[Logo of Utility]
Rev
No.
Description
Page
No.
Date of Issue
04

[xii]
15.01.2016
Power Plant]
SH
Super Heater
SPM
Suspended Particulate Matter
STMS
Smart Transmitter Monitoring System
SWAS
TFT
TG
Turbo Generator
TMCR
TPS
TR
TC
Thermocouple
TSE
TSI
TSS
Total Suspended Solids
UCR
Unit Control Room
UE
Unearthed
UPS
VT
Voltage Transformer
VFD
Variable Frequency Drive
VVVFD
Document Number
LII-GETS12021-G-00129-001
[Logo of Utility]
Rev
No.
Description
Page
No.
Date of Issue
04

[xiii]
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[Logo of Utility]
INTENT OF SPECIFICATION
1.1
The intent of this Specification is to Renovate and Modernize various equipment

& systems of Boiler and its auxiliaries including but not limited to [Coal Mills,
Coal Feeders, Primary Air fans, Forced Draft fans, Induced Draft fans, Electro
Static Precipitator, Main steam piping, Cold reheat piping, Hot reheat piping,
Upstream & downstream piping of HP & LP Turbine bypass valve, Auxiliary
Steam System, Valves and all associated Electrical system, Control &
Instrumentation systems and associated Civil & Structural work]. The renovated
Boiler shall be capable of operating with the following parameters to feed the
Turbo-Generator which is being renovated to give the output of
[210/215/220/250] MW. Steam Parameters at the outlet of HP turbine and Feed
Water parameters at the inlet of Economiser under the scope of Turbo Generator
Package are also given below:
Table: 1.1
Description
Units
[.]
T / hr
Steam Pressure at ESV inlet
[.]
kg/cm2
Steam Temperature at ESV inlet
[.]
deg C
Re-heater Flow
[.]
T / hr
Steam Pressure at HPT outlet
[.]
kg/cm2
Steam Temperature at HPT outlet

Steam Pressure at IV inlet
[.]
deg C
[.]
kg/cm2
Steam Temperature at IV inlet
[.]
deg C
Feed Water Flow
[.]
T / hr

Economiser
Economiser.
1.2
Design Parameters
[.]
kg/cm2
[.]
deg C
The Bidder shall carry out the required replacement / refurbishment / retrofitting
of the Boiler & its Auxiliaries as per the requirements of his design so as to make
the same capable of operating for an extended life of [20/25] years and
producing the steam at the desired parameters mentioned in Table-1.1 in order
to be compatible with the requirement of Turbo-Generator package. The scope
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of replacement / refurbishment / retrofitting shall include but shall not be limited to

the scope of work mentioned at clause 4.6 which is based on the
recommendation of RLA/CA and EA studies conducted during [..]. However,
any other items/systems which have not been specifically mentioned but are
considered necessary by the Bidder for giving the intended performance of Boiler
& its Auxiliaries, shall also be included in the scope of Bidder and shall be
separately highlighted by the Bidder in his proposal.
1.3
Bidders are required to quote the performance guarantee values for Boiler
output, Boiler efficiency, ESP outlet emission and the Auxiliary power
consumption in response to the minimum/maximum performance parameters
specified in the Table 1.2 below.
Table: 1.2
S.No.
Parameter
Performance Guarantee Values
Boiler Output/Capacity in TPH at

BMCR
Condition
(at
rated
parameters at superheater outlet,
the coal being fired from the range
specified)
[.]
Boiler Efficiency at 100% TMCR (%)
[.]
Maximum
Auxiliary
Consumption (kW)
[.]
ESP Outlet
(mg/Nm3)
Dust
Power
Emission
[.]
Bidders to note that in case performance guarantee values quoted for Boiler
output and ESP outlet emission are inferior to the minimum/maximum specified
values, the bids will be considered as non responsive. In case of Boiler efficiency
and Auxiliary power consumption, the best quoted value shall be considered as
base parameter and other bids shall be cost loaded as per difference between
base parameter and respective quoted guaranteed parameter multiplied by
evaluation factors specified in the Commercial Volume (Volume-I).
1.4
The modified/replaced/retrofitted equipment will conform to the requirements of

the Specification prescribed in Section-II of Volume-II. The relevant technical
details like OEMs Specifications and Drawings for the existing equipment
required to be modified / replaced / retrofitted have also been provided in
Volume-II, Section-II for the reference of the Bidders.
1.5
Bidders are required to carry out necessary modifications / replacement in the

existing mechanical / electrical equipment or systems including related
civil/structural works as per Specification requirement and also based on their
own assessment.
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1.6
[Logo of Utility]
The scope of work for R&M shall include designing / re-designing, basic and
detailed engineering, re-engineering, refurbishing / retrofitting, supply, inspection
and testing at supplier's works, packing, forwarding to site, forwarding from site to
Bidder's facilities, unloading and storage at site, pre-assembly, machining if
required, site fabrication, erection, replacing of various equipment and systems,
application of thermal insulation, carrying out all pre-commissioning checks/ tests
and any other work required to complete the system, commissioning and trial
operation, performance tests of various equipment and systems covered under
this Specification. Bidders scope shall also include dismantling of the existing
equipment/ facilities, including unloading & transportation to designated storage /
disposal yard, wherever required as a result of augmentation of existing
mechanical, electrical, I&C and civil/structural/ architectural works. The Bidder
shall restore the equipment/ facilities, whenever applicable, after carrying out
necessary renovations/modifications under the scope of R&M works.
All the tools & tackles, labour and other facilities required for dismantling and
restoration shall also be in the scope of the Bidder.
Bidder shall also put back into service all the systems/equipment of the units
after completion of R&M works, whether any modification is carried out on the
same or not. All necessary tools, tackles, labour, instruments, spares,
consumables etc. required for putting back into operation shall also be provided
by the Bidder.
1.7
It is not the intent to specify completely herein all aspects of services and
equipment to be provided by the Bidder who in any case shall be responsible for
fulfillment of the intent of Specification. Irrespective of whether specifically
mentioned or not, the services, equipment and systems to be provided in
accordance with this Specification shall also form a part of the scope of work and
shall conform in all respects to the highest standard of engineering, design,
quality and workmanship so that after completion of R&M work by the Bidder, the
plant shall be capable of performing completely in a safe, reliable and sustained
manner as acceptable to the Owner.
1.8
Unless otherwise specifically clarified by the Owner, interpretation by the Owner

in respect of scope of supplies & services and the meaning of the Specifications,
drawings, requirements of operation, maintenance, redundancy etc., shall be
final and binding on the Bidder. Owner shall have the right to reject or accept any
work or material which in his assessment is not technically complete and proven
to meet the requirements of this Specifications and/or applicable National and
International Codes & Standards mentioned elsewhere in this Specification.
1.9
The requirements, conditions, appendices etc, given in various parts/ sections of

technical Specifications shall form integral part of this Specification. Bidder is
required to carefully examine and understand the Specifications and seek
clarifications, if required, to ensure that he has understood the Specifications as
intended by the Owner. In the absence of any specific clarifications made to the
Owner during Bidding stage, the interpretation of Owner shall be final. The
Document Number
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Bidder's offer should not carry any sections like clarifications, interpretations
and/or assumptions. All such points are required to be clarified & resolved during
Bidding stage.
1.10
Any deviation or variation from the scope of supply and services or the intent of
the Specification shall be clearly brought out under the schedule of Technical /
Commercial deviations, irrespective of the fact that such deviation / variation may
be standard practice or possible interpretation of the Specifications by the Bidder.
In case, no clear and specific deviation is taken by the Bidder in the relevant
schedule of Bid Proposal Sheet while making his Bid proposal, it will be
construed that the Bidder shall comply with the stipulations of the Specification
fully with regard to scope of services and supplies to be provided by him to
achieve the objective of R&M. Further, unless otherwise specifically clarified by
the Owner, the interpretation by the Owner in respect of scope of supplies and
services to be performed by the Bidder shall be final and binding.
1.11
If the Bidder feels that, in his opinion certain features brought out in his offer are
superior to what has been specified, these may be highlighted separately in the
Bid. The Bidder at his own discretion may also make Alternate offers, which in
his opinion are of superior technology, material etc. to the specified requirements
leading to better performance like efficiency / output etc. of the units after
renovation. In such case, the Bidder shall carry out a comprehensive study and
clearly identify the scope of offer in his alternate proposal. The Bidder shall
furnish that detailed study to Owner along with the Bid where the Bidder shall
bring out in detail the scope of modifications required to be carried out by him in
the various systems and equipment including but not limited to [Boiler &
auxiliaries, Coal Mills, Coal Feeders, Primary Air fans, Forced Draft fans, Induced
Draft fans, Electro Static Precipitator, Main steam piping, Cold reheat piping, Hot
reheat piping, Upstream & downstream piping of HP & LP Turbine bypass valve,
Auxiliary Steam System, valves and all associated Electrical system, Control &
Instrumentation systems and associated Civil & Structural work etc].
Such Alternate proposals shall be supplemented with sufficient amount of
information like specified design standards and performance requirements,
Bidder's experience, operating feedback, provenness, etc. for justifying such
proposals. Implications of such Alternate offers on the performance, output,
efficiency, auxiliary power consumption, etc. shall be clearly brought out in the
Bid to enable the Owner to determine the advantages, superiority and
acceptability of the proposals.
However the Bidder's Base offer shall necessarily be in line with the Specification
requirements. Under no circumstances the equipment and services as specified
shall be brought out as an Alternate offer.
The Base offers will be evaluated as per procedure outlined in the Bid documents
and the Alternate Offers of the lowest evaluated Bidder will only be considered
for acceptance or otherwise. Owner may reject alternative proposals submitted
by the Bidder at his sole discretion, without assigning any reason what so ever.
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1.12
In the event of conflict between requirements of any two clauses of the

Specification documents or requirements of different Codes/ Standards specified,
the more stringent requirement as per the interpretation of the Owner shall apply,
unless confirmed otherwise by the Owner in writing.
1.13
The General technical conditions pursuant to the Contract, placed separately in

this Specification, shall form an integral part of the Specification. These
conditions shall supplement all the detailed technical Specification and
requirement identified in this Specification.
1.14
Out of complete unit comprising of mechanical, electrical, C&I systems and

equipment, some components/systems are envisaged to be replaced with new
ones having better design features while some of the other components are to be
refurbished / upgraded by the Bidder under present R&M Work. It shall be the
responsibility of the Bidder to ensure that components/ equipment/ systems
being supplied new OR components/ equipment/ systems being refurbished /
upgraded by him are fully compatible and integrated with the existing equipment /
systems so as to give safe, reliable and sustained operation of the complete unit.
Modifications needed on the assembled equipment to ensure complete
integration are to be brought out by the Bidder in the Bid and such modifications,
if any, after Owner's approval shall be carried out by the Bidder to the satisfaction
of the Owner.
1.15
The unit shall be designed to operate continuously in base load and cyclic load
operation. The systems shall operate without any restriction over the entire range
of operating conditions. The Bidder shall ensure that after R&M there are no
restrictions/ alterations in modes of operations of this unit, as per the
original/existing plant operation philosophy, including achieving base load, peak
load and cyclic load operation.
1.16
As the various equipment/ systems/ components are to be fitted in the unit,

Bidder is advised to visit the plant site to get fully conversant with the job, site
conditions, and constraints, and collect all the information as required and as
available before quoting against this Specification.
1.17
A brief extract of the existing unit, the original design details/ performance
parameters along with plant details, operating history and known problem areas;
wherever possible are brought out in the successive section of this Specification.
Relevant plant layout drawings and certain key schematic drawings, as available,
have also been provided in Annexure-I of this section of the specification for the
purpose of familiarization & guidance only. The successful Bidder shall prepare
and provide the additional drawings and documents describing the design and
engineering details and the manuals for carrying out erection, commissioning and
operation of the renovated unit.
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SITE & PROJECT SPECIFIC INFORMTION
2.1
Project Name
[Logo of Utility]
Project Title: []
Existing Capacity: [X x ..MW]
2.2
Project Location
The proposed project site is located at [.], in District [.] in the state of [.]. The
location details of the project site are as indicated below:
Table: 2.1
Particulars
2.3
Latitude
[.. ....] N
Longitude
[.. ....] E
Height above mean sea level
[.] m
Seismic Zone
Zone - [.]
Distance from [. ] town
[.] km
Distance from national highway No. [.]
[.] km
Distance from state highway No. [.]
[.] km
Distance of nearest airport [.]
[.] km
Distance of nearest seaport [.]
[.] km
Climatological Data
Table: 2.2
Particulars
Highest monthly
temperature
mean
of
daily
maximum
[.] deg C
Lowest monthly
temperature
mean
of
daily
maximum
[.] deg C
Highest monthly
temperature
mean
of
daily
minimum
[.] deg C
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Particulars
Lowest monthly
temperature
mean
of
daily
minimum
[.] deg C
Annual mean of daily maximum temperature
[.] deg C
Annual mean of daily minimum temperature
[.] degC
Extreme highest temperature
[.] deg C
Extreme lowest temperature
[.] deg C
Design ambient temperature (unless specified

otherwise)
{50} deg C
Relative Humidity: Maximum
[.] %
Minimum
[.] %
Average annual rainfall
[.] cm
Heaviest rainfall in 24 hours so far
[.] cm
Number of rainy days in a year
[. ]
Highest monthly mean of wind speed
[.] km/h
Lowest monthly mean of wind speed
[.] km/h
Maximum wind speed
[.] km/h
Table: 2.3
Season
2.4
Dry bulb temperature
Wet bulb temperature
Summer
[.] DegC
[.] deg C
Monsoon
[.] DegC
[.] degC
Winter
[.] DegC
[.] deg C
Fuel
At present the power station is sourcing coal from [..] coal mines. The coal is
being transported to the project site by [Indian Railways/ MGR system/ cross country
conveyor]. Proximity of Railway line to site from . Railway Station is about
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[.] km. The railway link shall also be used for transportation of heavy equipment
to site during construction phase and to bring main and secondary fuel to the power
plant during operation of plant.
2.4.1
Coal and Ash Analysis

a.
Proximate and ultimate analysis of coal (on as received basis)

Table: 2.4
Sl. No.
Particulars
Unit
Performance
Coal
Worst
Coal
Best
Coal
(i)
Proximate Analysis
Moisture
[. ]
[. ]
[. ]
Ash
[. ]
[. ]
[. ]
Volatile Matter
[. ]
[. ]
[. ]
Fixed Carbon
[. ]
[. ]
[. ]
Total
100
100
100
(ii)
Gross calorific value
kCal/kg
[. ]
[. ]
[. ]
(iii)
Grindability index
HGI
[. ]
[. ]
[. ]
(iv)
Ultimate analysis
Carbon
[. ]
[. ]
[. ]
Hydrogen
[. ]
[. ]
[. ]
Sulphur
[. ]
[. ]
[. ]
Nitrogen
[. ]
[. ]
[. ]
Oxygen
difference)
[. ]
[. ]
[. ]
Moisture
[. ]
[. ]
[. ]
Ash
[. ]
[. ]
[. ]
Total
100
100
100
Document Number
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b.
[Logo of Utility]
Ash analysis
Table: 2.5
2.4.2
Characteristics
Unit
Range/ value
SiO2
[. / . ]
Al2O3
[. / . ]
Fe2O3
[. / . ]
TiO2
[. / . ]
CaO
[. / . ]
MgO
[. / . ]
Chloride as Cl
[. / . ]
Sulphate as SO4
[. / . ]
Alkalies as NaOH
mg/kg
[. / . ]
Chromium as Cr
mg/kg
[. / . ]
Mercury as Hg
mg/kg
[. / . ]
Lead as Pb
mg/kg
[. / . ]
Cadmium as Cd
mg/kg
[. / . ]
Nickel as Ni
mg/kg
[. / . ]
Zink as Zn
mg/kg
[. / . ]
Copper as Cu
mg/kg
[. / . ]
Secondary Liquid Fuels

[Analysis of Heavy Fuel Oil (HFO/HPS/LSHS as applicable) & Light Diesel Oil (LDO)]:
{Analysis of Heavy fuel oil (HFO/HPS/LSHS as applicable) and Light diesel oil (LDO)
which is being used in the existing Boiler for start-up, coal flame stabilization and low
load operation shall be specified in the table given below:}
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Table: 2.6
SL. No.
Particulars
(A)
Analysis of heavy furnace oil (HFO)
i)
Specification
[Furnace oil conforming to

IS:1593, heavy grade]
ii)
Average gross calorific value
[. / . ] kCa1/kg
iii)
Flash point
[. / . ] deg C
iv)
Pour point
[. / . ] deg C
v)
Kinematic viscosity at 50 C
[. / . ] centistokes
vi)
Specific heat
[. / . ] kcal/kg/DegC
vii)
Ash
[. / . ] % by weight
viii)
Sediment
ix)
Sulphur
x)
Water content
[. / . ] % by volume
xi)
Acidity
[. / . ]
xii)
Specific gravity
[. / . ]
(B)
Analysis of heavy petroleum stock (HPS)
i)
Calorific value
[. / . ] kCa1/kg
ii)
Acidity inorganic
[. / . ]
iii)
Flash point
[. / . ] deg C
iv)
Pour point
[. / . ] deg C
v)
Kinematic viscosity in cst at 50C
[. / . ] cst
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LII-GETS12021-G-00129-001
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SL. No.
Particulars
Range/ value
vi)
Kinematic viscosity in cst at 100 C
[. / . ] cst
vii)
Sediment
viii)
Ash
ix)
Sulphur
x)
water content
[. / . ]% by Volume
(C)
Analysis for low sulphur heavy stock (LSHS) fuel oil
i)
Gross calorific value
[. / . ] kCal/kg
ii)
Flash point
[. / . ] deg C
iii)
Pour point
[. / . ] deg C
iv)
Ash content
v)
Total sulphur
vi)
Sediment
vii)
Water content
[. / . ] % by Volume
viii)
Viscosity (maximum)
At 38 deg C - [. / . ] cst
At 50 deg C - [. / . ] cst
At 60 deg C - [. / . ] cst
At 70 deg C - [. / . ] cst
At 80 deg C - [. / . ] cst
At 90 degC - [. / . ] cst
At 99 degC - [. / . ] cst
At 100degC - [. / . ] cst
At 110degC - [. / . ] cst
ix)
Specific gravity
Document Number
LII-GETS12021-G-00129-001
[. / . ]
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2.5
[Logo of Utility]
SL. No.
Particulars
Range/ value
x)
Specific heat
[. / . ] kCal/kg/degC
(D)
Light Diesel Oil (LDO)
[As per IS:1460 (latest)]
Water Analysis
[Describe the source of consumptive and / or cooling water (name of river or sea or
bore well) and the type of condenser cooling system being adopted for the unit.]
Chemical analysis of water which is used for this project is indicated as below:
Table: 2.7
Sl.
No.
Constituents/Parameters
Units
Concentration
(Range/Value)
Raw Water Analysis
Calcium
mg/l
[.]
Magnesium
mg/l
[.]
Sodium
mg/l
[.]
Potassium
mg/l
[.]
Total Cations
meq/l
[.]
Bicarbonates
mg/l
[.]
Carbonates
mg/l
[.]
Nitrate
mg/l
[.]
Chloride
mg/l
[.]
10
Sulphate
mg/l
[.]
11
Total Anions
meq/l
[.]
12
Silica
mg/l
[.]
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Sl.
No.
Units
Concentration
(Range/Value)
13
Iron Fe
mg/l
[.]
14
pH value
..
[.]
15
Turbidity
NTU
[.]
16
Total Dissolved Solids
mg/l
[.]
17
Organic Matter (Oxygen

absorbed from Acid
Permanganate in 4 hr)
mg/l
[.]
18
BOD
mg/l
[.]
19
COD
mg/l
[.]
Clarified Water Analysis
Calcium
mg/l
[.]
Magnesium
mg/l
[.]
Sodium
mg/l
[.]
Potassium
mg/l
[.]
Total Cations
meq/l
[.]
Bicarbonates
mg/l
[.]
Carbonates
mg/l
[.]
Nitrate
mg/l
[.]
Chloride
mg/l
[.]
10
Sulphate
mg/l
[.]
11
Total Anions
meq/l
[.]
12
Silica
mg/l
[.]
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Sl.
No.
Units
Concentration
(Range/Value)
13
Iron Fe
mg/l
[.]
14
pH value
..
[.]
15
Turbidity
NTU
[.]
16
mg/l
[.]
17

absorbed from Acid
mg/l
[.]
Demineralised Water for Power Cycle Make up
The quality parameters of demineralised water is in use for make up to the

condenser hotwell and make up to the closed cycle equipment cooling water (ECW)
system is as below:
1
pH
..
{6.8 7.2}
Silica, as SiO2
ppm
{0.01}
Conductivity
micro mho/cm
{0.1}
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EXISTING PLANT DETAILS

The Power Plant, is of the configuration of [xMW]. The Unit no. [.] of the power
plant, which is proposed to be taken up for Renovation and Modernization was first
commissioned in the year [.]. For the above unit, M/s [..] and M/s [.] are the
Original Equipment Manufacturers (OEMs) for the Boiler and Turbo-Generator,
respectively. The boiler for the unit is of [PF/CFBC] design. The boiler is provided with
[front & rear/ corner/down shot] firing system. LP stage of Turbine is designed with
[Bauman] exhaust. Condenser cooling system of the unit is designed on [once through
/ re-circulation system]. Power generated from the unit is being supplied to
[...State/Central grid]. Power is being evacuated through [.numbers of 220/400kV
Double/Single Circuit lines] to [. substation.] The primary fuel is
[domestic/imported/blended] [coal/lignite] fuel being sourced from [..&] coal
mines. The consumptive water for the power plant is being sourced from [.river
/sea].
3.1
Unit No [] of [] Thermal Power Station having a Generating Capacity
of [210 MW] was commissioned in the year [..]. The boiler is of [] design
and the turbine is of [LMZ] design. Though the boiler was originally designed for coal
with Gross Calorific Value (GCV) of [.kCal/kg], it presently operates on coal supplied
with GCV of about [..kCal/kg]. The deterioration experienced over the years in
Plants Average Performance Parameters is shown in Table 3.1.
{Furnish in the Table 3.1 below, the Average Values over the life (say 25 years)}
Table: 3.1
Units Average Performance Parameters over the Life
Years after
Installatio
n
PLF
(%)
Availabilit
y (%)
Output
(MW)
Aux. Power
Consumptio
n (%)
Specific Oil
Consumptio
n (ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross
Heat Rate
(kCal/kWh)
[]
[]
[]
[]
[]
[]
[]
10
[]
[]
[]
[]
[]
[]
[]
15
[]
[]
[]
[]
[]
[]
[]
20
[]
[]
[]
[]
[]
[]
[]
25
[]
[]
[]
[]
[]
[]
[]
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{Furnish in the Table 3.2 below, the Average Values for the last five years. However,
for the Parameters in respect of One Year back and Current Year, furnish the
Maximum, the Minimum and the Average Values.}
Table: 3.2
Units Performance Parameters during the Last Five Years
Period
PLF
(%)
Availabilit
y (%)
Output
(MW)
Aux. Power
Consumptio
n (%)
Specific Oil
Consumptio
n (ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross
Heat Rate
(kCal/kWh)
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Two Years
back
[]
[]
[]
[]
[]
[]
[]
One Year
back
[]
[]
[]
[]
[]
[]
[]
Current
year
[]
[]
[]
[]
[]
[]
[]
Four Years
back
Three
Years back
3.1.1
Auxiliary Power Consumption of Boiler & Auxiliaries

Table-3.3
Sl. No.
Equipment/System
Mills
PA Fans
FD Fans
ID Fans
Air Heaters
Coal Feeders
Boiler Start up drain Recirculation Pump (If

applicable)
Seal Air Fan
Document Number
LII-GETS12021-G-00129-001
Units
Power Consumption
kW
[.]
kW
[.]
kW
[.]
kW
[.]
kW
[.]
kW
[.]
kW
[.]
kW
[.]
Rev
No.
Description
Page
No.
Date of Issue
04

[16]
15.01.2016
Power Plant]
Sl. No.
Equipment/System
Units
Power Consumption
Lube Oil Pumps for Fans/Air Heaters/Mill

System etc.
kW
[.]
10
Scanner Air Fans
kW
[.]
11
Electrostatic Precipitator
kW
[.]
12
Gas Recirculation Fan (If applicable)
kW
[.]
kW
[.]
kW
[.]
kW
[.]
kW
[.]
13
14
3.1.2
[Logo of Utility]
DM Cooling Water Pump for Boiler &

Auxiliaries
Auxiliary Cooling Water Pumps (If applicable
within Boiler & Auxiliaries Package)
15
Any other continuous running loads
16
Total Auxiliary Power Consumption of Boiler

and Auxiliaries

The Project has been regularly monitoring the environmental parameters such as
stack monitoring, ambient air quality (AAQ), noise pollution and liquid waste pollution
in accordance with applicable norms by employing [M/s., which is an agency
approved by State Pollution Control Board].
The existing environmental data and the limits specified for different pollutants, the
locations of their measurements and the frequency of monitoring are given in the table
below.
Table 3.3
Environmental
Aspects
State Pollution and
Stack
Emissions
SPM
3
(mg/Nm )
Ambient Air
Quality
SPM
Document Number
LII-GETS12021-G-00129-001
Parameters
Achieved
Not to exceed
[]
On
24
Hrs
Basis
On
Annual
Basis
[]
[]
No. of
locations for
measurement
[]
[]
On
24
Hrs
Basis
On
Annual
Basis
[]
[]
Frequency
of
Sampling.
[]
Rev
No.
Description
Page
No.
Date of Issue
04

[17]
15.01.2016
Power Plant]
Environmental
Aspects
State Pollution and
Parameters
Achieved
[Logo of Utility]
No. of
locations for
measurement
Frequency
of
Sampling.
(g/m )
RPM
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
(g/m )
SO2
3
(g/m )
NOX
3
(g/m )
Process
Effluent
Leaving the
Plant Boundary
Document Number
LII-GETS12021-G-00129-001

pH
[]
[]
Colour
[]
[]
Odour
[]
[]
Temperat
ure
[]
[]
TSS
(mg/l)
[]
[]
Oil &
grease
(mg/l)
[]
[]
COD
(mg/l)
(mg/l)
[]
[]
BOD
(mg/l)
[]
[]
Chloride
(mg/l)
[]
[]
Sulphate
(mg/l)
[]
[]
Rev
No.
Description
Page
No.
Date of Issue
04

[18]
15.01.2016
Power Plant]
Environmental
Aspects
3.1.3
State Pollution and
Parameters
Achieved
TDS
(mg/l)
[]
[]
Zinc
(mg/l)
[]
[]
Fluoride
(mg/l)
[]
[]
Mercury
(mg/l)
[]
[]
[Logo of Utility]
No. of
locations for
measurement
Frequency
of
Sampling.

Detailed discussions were held with the Plant operators who provided the feedback
about the design and operation related problems of various systems. These are listed
in the Table 3.4 below.
S. No.
Table 3.4
Name of the
Type of Problem
Probable Solution
System/Equipment
as per the
Operators
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[19]
15.01.2016
Power Plant]
S. No.
Name of the
System/Equipment
3.1.4
Type of Problem
[]
[Logo of Utility]
Probable Solution
as per the
Operators
[]
[]

{Indicate in the table below the tripping and maintenance record for the past three
years.}
Table: 3.5
Year
3.1.5
Total
Trippings
No. of Trippings
due to Boiler
Tube Leakages
Other Major
Causes of
Trippings
Maintenance
carried out
[]
Two
Years
Back
[]
[]
One
Year
Back
[]
[]
Current
Year
[]
[]
[]
[]
[]
[]
[]
Maximum Achievable Load due to performance constraint

[Due to performance constraint of various equipment of Boiler & Auxiliaries including
ESP, the maximum generation from the unit is restricted to [] MW. The operational
data at the above maximum load is indicated in the table below.]
Table: 3.6
Nature of
constraint
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units Gross
Efficiency
(%)
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00129-001
Units Gross
Heat Rate
(kCal/kWh)
Rev
No.
Description
Page
No.
Date of Issue
04

[20]
15.01.2016
Power Plant]
3.1.6
[Logo of Utility]

[The record of reportable accidents for the past three years, is mentioned in the Table
below]
Table: 3.7
Year
3.1.7
Man hours lost

due to
accidents
No. of Fatal
Accidents
No. of Accidents
leading to
Permanent
Disablement
Actions taken to
reduce the
number of
accidents
Two
Years
Back
[]
[]
[]
[]
One Year
Back
[]
[]
[]
[]
Current
Year
[]
[]
[]
[]

design deficiency, layout of the plant, obsolescence of equipment and non availability
of spare parts etc. These are mentioned in the Table below]
Table: 3.8
S.No.
Specific Reason
(Design deficiency/ layout of the plant / obsolescence
of equipment / non availability of spare parts etc)
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[21]
15.01.2016
Power Plant]
3.2
[Logo of Utility]
Salient Technical Feature of Boiler & its Auxiliaries

{Describe in this sub-section, the Design Parameters and Salient Features of all the
important Equipment and Systems of Pulverized Fuel (PF) Boiler & Auxiliaries or
Circulating Fluidized Bed Combustion Boilers(CFBC), as applicable and as mentioned
below.}
3.2.1
PF Boiler & Auxiliaries

a)
PF Boiler
[The Boiler is of natural circulation, pulverized fuel fired, dry bottom, balanced draft
using direct firing system. The design parameters of the Boiler are furnished below]
Table: 3.9
Description
b)
Units
Design Parameters
T / hr
[.]
kg/cm2
[.]
deg C
[.]
Re-heater Flow
T / hr
[.]
kg/cm2
[.]
deg C
[.]
Feed Water Flow
T / hr
[.]

Economiser
Economiser.
kg/cm2
[.]
deg C
[.]
Furnace
[The boiler is equipped with a water cooled furnace of balanced draft and fusion
welded membrane wall construction. It is equipped with..numbers of coal burners
andnumbers of oil burners located at numbers of elevations. The design
parameters of the Furnace are furnished below.]
Table: 3.10
Description
Units
Type of Firing
Document Number
LII-GETS12021-G-00129-001
Design Parameters
.............
[...........]
Rev
No.
Description
Page
No.
Date of Issue
04

[22]
15.01.2016
Power Plant]
Description
Units
Combustion Chamber
Volume
m3
Furnace Dimensions
[Logo of Utility]
Design Parameters
[...........]

[...........]
m2
[..............]
ii) Superheaters
m2
[...........]
iii) Reheaters
m2
[..............]
iv) Economiser
m2
[..............]
v) Air Heater
m2
[..............]
vi) Steam Coil Air

Heater
m2
[..............]
vii) Temperature
Measurement of
Super-heater
tubes, whether
provided.
Yes / No
[..............]
viii) Temperature
Measurement of
Re-heater tubes,
whether provided.
Yes / No
[..............]
i)
c)
[...........]
Water Walls

are given below:]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[23]
15.01.2016
Power Plant]
[Logo of Utility]
Table: 3.11
Description
d)
No. of coils
/ tubes
Pitch
(mm)

(mm)
Surface (m2)
Material
Low
Temperature
Super Heater
[.]
[.]
[.]
[.]
[.]
Platen Super
Heater
[.]
[.]
[.]
[.]
[.]
Pendant
Super Heater
[.]
[.]
[.]
[.]
[.]
Ceiling and
Enclosure
Super Heater
[.]
[.]
[.]
[.]
[.]
ReheaterFront
Assembly
[.]
[.]
[.]
[.]
[.]
ReheaterRear
Assembly
[.]
[.]
[.]
[.]
[.]
Economiser
[The Economizer is of a single stage, continuous plane tube and horizontal, mixed flow
type, located in the second pass of the boiler]
Table: 3.12
Description
Economiser
e)
No. of coils Pitch

/ tubes
(mm)
[.]

(mm)
Surface (m2)
[.]
[.]
[.]
Material
[.]
Steam Coil Air Pre-Heater

[Steam Coil Air Pre-heater is being used during initial and low load operation.the
details are given below]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[24]
15.01.2016
Power Plant]
[Logo of Utility]
Table: 3.13
Description
Units
Design Parameters
Type
..
[.]
No. per Boiler
..
[.]
Medium
..
[.]
Heating surface in
m2
[.]
f)
Air Pre-Heater
The air pre-heater is of regenerative rotary type. Special sealing arrangements have
been provided in the air pre-heater to prevent leakage between air and gas sides.
Adjustable sector plates have also been provided to prevent the leakage during
expansion. The heating surfaces of the air pre-heater have been provided with two
types of cleaning systems, soot blowing and water washing system. ]
Table: 3.14
Description
Units
Design Parameters
Type
..
[.]
No. per Boiler
..
[.]
Medium
..
Re- Generative Air Pre-Heater
Primary Air
Secondary Air
Flue gas
m2
[.]
Hot layer (Open hearth steel)
mm
[.]
Intermediate Layer (open

hearth steel)
mm
[.]
Cold layer-corten A steel
mm
[.]
HP
[.]
Heating surface
Heating Element Layer Depth
Rotor Drive
Motor
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[25]
15.01.2016
Power Plant]
[Logo of Utility]
Description
Units
Design Parameters
Voltage
[.]
Speed
rpm
[.]
Motor
HP
[.]
Speed reducer
..
[Reduction Ratio.]
Motor
HP
[.]
Air Pressure
kg/cm2
[.]
Speed
rpm
[.]
Type
[.]
Oil Capacity
Liter
[.]
Motor rating
HP
[.]
Type
[.]
Lubrication
[.]
Oil capacity
Liter
[.]
Motor rating
HP
[.]
Flue Gas Temperature at APH C

outlet (Corrected to 0% air
leakage)
[.]
Cleaning Device
Auxiliary air motor
Guide bearing
Supporting bearing
{In Case of vertical Tubular type following shall be provided}

Description
Units
Number per Boiler
Design Parameters
Details of each Air heater
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[26]
15.01.2016
Power Plant]
[Logo of Utility]
Description
Units
Design Parameters
Type
[.]
No. of gas passes
[.through the tubes]
No. of air passes
[.across the tubes]
Flow
[Counter flow]
Number of bank in the main .

section
[.]
Number of bank in the cold end .

section
[.]
Details of Each Bank:

Tube outside diameter
mm
[.]
Tube thickness
mm
[.]
Tube material
[.]
Tube arrangement
[.]
Tube length
[.]
No. of tubes across air flow
[.]
No. of tubes with air flow
[.]
Tube pitch with air flow
mm
[.]
No. of tubes
[.]
Hating surface
m2
[.]
Total heating surface per Air

heater
m2
[.]
Total Air-heater heating surface

per boiler
m2
[.]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[27]
15.01.2016
Power Plant]
a)
[Logo of Utility]
Raw Coal Bunkers

[Each boiler is provided with [] raw coal bunkers. The total capacity of the bunkers is
to meet [] hours requirement at maximum mills capacity of the unit. The upper
portion of the bunkers is of cylindrical shape made of carbon steel plate, while the
conical portion is made of stainless steel plate. Each outlet of the bunker is provided
with an isolation gate which is motor operated. In addition to the isolation gates, rod
gates have been provided to control the flow of coal from the bunkers]
b)
Raw Coal Feeders

[One gravimetric type of raw coal feeder has been provided for each coal mill. The coal
feeders have been provided with micro-processor based controls with variable
frequency drive. The feeders have been provided with dual independently measuring
load cells. All parts of the feeders coming in contact with coal, except the belt, are
made of stainless steel]
Table: 3.15
Description
Units
Design Parameters
Type
[.]
Number
[.]
Rated capacity each
tones/hr [.]
Required capacity
tones/hr [.]
Motor power required.
BHP
[.]
Motor speed
rpm
[.]
Speed Variation
[.]
Width of feeder
mm
[.]
outlet mm
[.]
Centre line distance between feeder mm

inlet and mill inlet connections (approx.)
[.]
Depth of Coal bed
[.]
Length between inlet

connections (approx.)
Document Number
LII-GETS12021-G-00129-001
and
mm
Rev
No.
Description
Page
No.
Date of Issue
04

[28]
15.01.2016
Power Plant]
c)
[Logo of Utility]
Fuel Firing System

[The boiler is working on a direct firing system. The pulverized coal is being dried and
transported to the coal burners by means of hot primary air being supplied by two
primary air fans. The boiler is having [front and rear/corner/down shot] firing system.
There are [] pulverized coal burners and [] oil burners. The burners are located at
[] floors.
d)
Coal Mills
[The unit is provided with . numbers of [BHEL] Make [XRP-783] bowl type mills, out
of which mills are designed to work with designed coal and ..numbers of mills
are standby . The rated capacity of each mill is ..T/h.]
Table: 3.16
Description
Units
Design Parameters
..
[.]
Capacity of Mills
T/hr
[.]
Size of raw coal (max.)
mm
[.]
Nos.
[.]
Number of Mills to work per boiler with

design coal quality
Nos.
[.]
Motor Rating
kW
[.]
Airflow per mill
T/h
[.]
Air temperature at Mill inlet
[.]
Mill outlet temperature
[.]
Fineness
%Thru
200 Mesh
[.]
Rating
kW
[.]
Voltage
kV
[.]
Frequency
Hz
[.]
Motor
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[29]
15.01.2016
Power Plant]
Description
Units
Speed
e)
[Logo of Utility]
Design Parameters
rpm
[.]
Primary Air Fans

Table: 3.17
Description
Units
Type
[.]
..
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Speed
rpm
[.]
Discharge Pressure
mmwc
[.]
[.]
Motor Rating
kW
[.]
[.]
wk2 of runner & shaft
kg-m2
Bearings
f)
Design Parameters
[2 spherically seated, H.S.

ring
lubricated,
with
assisted lubrication water
cooled. In board bearing
on base plate, outboard
bearing on pedestal.]
Forced Draft Fans

[Two Forced Draft (FD) Fans have been provided for each boiler. Each FD Fan is
designed to meet 60% MCR condition of the boiler. The FD Fans supply combustion
air to the boiler, mill air through PA Fans and tempering air to control the classifier
temperature of the mills. Details are given below:]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[30]
15.01.2016
Power Plant]
[Logo of Utility]
Table: 3.18
Description
Units
Type
..
[.]
..
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
Temperature of Air
[.]
Runner Diameter
mm
[.]
kg-m2
[.]
Speed
rpm
[.]
Motor Rating
kW
[.]
[.]
Bearing
[Two spherically seated

high
speed
pressure
lubricated. The outboard
bearing supported on
pedestal, the inboard on
base plate.]
Power Coupling
g)
Design Parameters
..
[.]
Induced Draft Fans

Table: 3.19
Description
Units
Type
Document Number
LII-GETS12021-G-00129-001
..
Design Parameters
[.]
Rev
No.
Description
Page
No.
Date of Issue
04

[31]
15.01.2016
Power Plant]
Description
Units
Design Parameters
..
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
[.]
Runner Diameter
mm
[.]
kg m2
[.]
Motor Rating
kW
[.]
[.]
Bearing
[Logo of Utility]

high
speed
pressure
base plate]
Power coupling
h)
Wall Blowers and Long Retractable Soot Blowers (LRSBs)

[Adequate number of Wall Blowers and Long Retractable Soot Blowers (LRSBs) are
being used for cleaning the soot deposited on the heating surfaces of the water walls
and super heaters respectively. Manually operated soot blowing system has been
provided. Details are given below:]
Table: 3.20
Description
Units
Design Parameters
Wall Blowers
..
[]
No. of Wall Blowers per boiler at water

walls
Nos.
[.]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[32]
15.01.2016
Power Plant]
[Logo of Utility]
Description
Units
Design Parameters
Medium of soot blowing at water walls
..
[.]
[.]

Nos.
[.]

[.]

pass tube banks
Nos.
[.]
Medium of soot blowing at convection

pass tube banks
[.]
LRSBs
i)
ESP
The hoppers of ESP have been provided with [capacitance] type level indicators and
Table: 3.21
Description
Units
Design Parameters
[.]
Nos.
[.]
Nos.
[.]
Gas Flow
m3/sec
[.]
Inlet dust concentration
mg/Nm3
[.]
Gas Temperature at ESP Inlet
deg C
[.]
mg/Nm3
[.]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[33]
15.01.2016
Power Plant]
Description
j)
[Logo of Utility]
Units
Design Parameters
Type of Electrodes
[.]
Spacing between the Collecting

Plates
Voltage Level
mm
[.]
kV
[.]
Type of Control
[.]
Gas Velocity in ESP
m/sec
[.]
m2/m3/sec
[.]
Aspect Ratio
..
[.]
cm/sec
[.]
Numbers of TR Sets
..
[.]
Rating of TR Sets
..
[.]
Plate Area/TR Set
m2/TR Set
[.]
hrs
[.]
Pressure Drop
mmwc
[.]

fields in operation
Corona Power per unit of effective
collection area
[.]
Watts/m2
[.]
Main steam piping, Cold reheat piping, Hot reheat piping & Auxiliary Steam
Piping
Table: 3.22
Description
Units
Design Parameters
Main Steam Line

Flow
T/hr
Velocity
m/s
Schedule/Thickness
Document Number
LII-GETS12021-G-00129-001
[.]
[.]
Rev
No.
Description
Page
No.
Date of Issue
04

[34]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Upstream of HP turbine bypass valve
Downstream of HP turbine bypass valve

Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Cold Reheat Line
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[35]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Hot Reheat Line
Upstream of LP turbine bypass valve
Downstream of LP turbine bypass valve

Flow
T/hr
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Document Number
LII-GETS12021-G-00129-001
[.]
Rev
No.
Description
Page
No.
Date of Issue
04

[36]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Class
Auxiliary Steam Piping
Other LP Piping
3.2.2
a)
CFBC Boiler and Auxiliaries

CFBC Boiler
[The Boiler is of natural circulation, circulating fuel bed combustion, single drum, dry
bottom, balanced draft using limestone /dolomite as absorbent The boiler is provided
with water cooled/ steam cooled Cyclone Separator(s) to remove coarser entrained
sold particles from the flue gases which are returned to the combustor bed via loop
seal. An External Fluidized Bed Heat Exchanger (EFBHE) has also been provided to
extract heat from a part of the solids before their return to the combustor bed. The
design parameters of the Boiler are furnished below.]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[37]
15.01.2016
Power Plant]
[Logo of Utility]
Table: 3.23
Description
b)
Units
Design Parameters
T / hr
[.]
kg/cm2
[.]
deg C
[.]
Re-heater Flow
T / hr
[.]
kg/cm2
[.]
deg C
[.]
Feed Water Flow
T / hr
[.]

Economiser
Economiser.
kg/cm2
[.]
deg C
[.]
Furnace
[The furnace consists of membrane type water walls to provide most of evaporative
boiler surface. The fuel for the boiler is (coal/lignite). The combustor bed material for
the boiler is composed of (ash, sand and sorbent). Lower zone of the furnace is lined
with refractory. Staged combustion is achieved by injecting the primary air under the
bed and the secondary air above the refractory zone. The bottom of the furnace is
provided with a fluidizing air distributor grid. Stainless steel air nozzles are mounted
on the distributor grid to supply the primary air. Design Parameters of the furnace are
furnished below.]
Table: 3.24
Description
Units
Design Parameters
Furnace Volume
m3
[..............]
Dimensions of Furnace
[..............]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[38]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Height of Refractory
lined lower zone
[..............]
Elevation of Fuel
Injection
[..............]
Elevation of Sorbent
Injection
[..............]
Elevation of Secondary
Air Injection
[..............]
Minimum fluidization
velocity
m/s
[..............]
Superficial velocity
m/s
[..............]
Bed Temperature
deg C
[...........]
Coal / Lignite Feed

Particle Size
[] to []mm
[...........]
Type of Sorbent Used
[..............]
Sorbent Feed Particle

Size
microns
[...........]
Calcium/Sulfur Ratio
[..............]
Sulfur Removal
Efficiency
[..............]
Combustion Efficiency
[..............]
m2
[..............]
ii) Superheaters
m2
[..............]
iii) Reheaters
m2
[..............]

i)
Water Walls
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[39]
15.01.2016
Power Plant]
Description
Design Parameters
iv) Economiser
m2
[..............]
v) Air Heater
m2
[..............]
Air m2
[..............]
vi) Steam
Heater
c)
Units
Coil
vii) Temperature
Yes / No
Measurement
of
Super-heater tubes,
whether provided.
[..............]
viii)Temperature
Yes / No
Measurement of
Re-heater
tubes,
whether provided.
[..............]
Cyclone(s)
Description
d)
[Logo of Utility]
Units
Design Parameters
Number of Cyclones
[.]
Type of Cyclones
[.]
Method of Cooling( Water Cooled /

Steam Cooled)
----
[.]
Inlet gas velocity
m/s
[.]
Concentration of solids at the inlet
kg/m3
[.]
Particle Size Range
[to ] m
[.]
Pressure drop
mmwc
[.]
Units
Design Parameters
Loop Seal
Description
Type of Loop Seal
[.]
Arrangement of fuel feeding
..
[.]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[40]
15.01.2016
Power Plant]
Description
e)
Units
[Logo of Utility]
Design Parameters
Arrangement of sorbent feeding
..
[.]
Number of Blowers
----
[.]
Capacity of Blowers
m3/s
[.]
Discharge Pressure of Blowers
mmwc
[.]
External Fluidized Bed Heat Exchanger (If provided in the existing system)
Description
Units
Design Parameters
Material of Heat Exchanger tubes
[.]
Surface Area of Heat Exchanger tubes
[.]
Number of Blowers
----
[.]
Capacity of Blowers
m/s
[.]
Discharge Pressure of Blowers
mmwc
[.]
Arrangement of fuel feeding

Arrangement of sorbent feeding
f)
Bottom Ash Removal System

{Describe the type of bottom ash removal system provided to remove bed ash to
maintain bed height, to remove oversize particles, to maintain bed pressure drop and
to avoid accumulation & consequent de-fluidization}.
g)
Bottom Ash Cooling System

{Describe the type of bottom ash cooling system provided, the medium of cooling the
bottom ash and the design temperature of the cooled bottom ash}
h)

Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[41]
15.01.2016
Power Plant]
[Logo of Utility]
are given below:]
Table: 3.25
Description
i)
No. of coils
/ tubes
Pitch
(mm)

(mm)
Surface (m2)
Material
Low
Temperature
Super Heater
[.]
[.]
[.]
[.]
[.]
Platen Super
Heater
[.]
[.]
[.]
[.]
[.]
Pendant
Super Heater
[.]
[.]
[.]
[.]
[.]
Ceiling and
Enclosure
Super Heater
[.]
[.]
[.]
[.]
[.]
ReheaterFront
Assembly
[.]
[.]
[.]
[.]
[.]
ReheaterRear
Assembly
[.]
[.]
[.]
[.]
[.]
Economiser
[The Economizer is of a single stage, continuous plane tube and horizontal, mixed flow
type, located in the second pass of the boiler]
Table: 3.26
Description
Economiser
j)
No. of coils Pitch

/ tubes
(mm)
[.]

(mm)
Surface (m2)
[.]
[.]
[.]
Material
[.]

[Steam Coil Air Pre-heater is being used during initial and low load operation. The
details are given below]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[42]
15.01.2016
Power Plant]
[Logo of Utility]
Table: 3.27
Description
Units
Design Parameters
Type
..
[.]
No. per Boiler
..
[.]
Medium
..
[.]
m2
[.]
k)
Heating surface in
Air Pre-Heater
[The air pre-heater is of vertical Tubular type. The details are given below]
Table: 3.28
Description
Units
Design Parameters
Number per Boiler
[.]
[.]
Type
[.]
No. of gas passes
[.through the tubes]
No. of air passes
[.across the tubes]
Flow
[Counter flow]
Number of bank in the main .

section
[.]
Number of bank in the cold end .

section
[.]

Tube outside diameter
mm
[.]
Tube thickness
mm
[.]
Tube material
[.]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[43]
15.01.2016
Power Plant]
l)
Description
Units
Design Parameters
Tube arrangement
[.]
Tube length
[.]
[.]
[.]
Tube pitch with air flow
mm
[.]
No. of tubes
[.]
Hating surface
m2
[.]

heater
m2
[.]

per boiler
m2
[.]
[Logo of Utility]
Fuel Bunkers
[The boiler is provided with [...] bunkers of fuel (coal/lignite). The capacity of each
bunker is to meet [] hours requirement of the boiler. The conical hopper portions of
the bunker are lined with stainless steel.]
m)
Fuel Feeding System

[From the bunkers, fuel flows down a vertical chute to individual extraction feeders
placed under each conical hoppers, which are of drag chain type. These feeders are
provided with variable frequency drives (VFDs) so that fuel feed rate can be controlled
by varying the speed of the feeders. Fuel from these box feeders is again fed to
common main drag chain feeders from where the fuel is conveyed to the combustor
bed of the furnace.]
n)
Sorbent Bunker
[The boiler is provided with [] sorbent bunkers of Limestone/ dolomite. The capacity
of each bunker is to meet [] hours requirement of the boiler. Flow of sorbent is
controlled with gravimetric feeders]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[44]
15.01.2016
Power Plant]
o)
[Logo of Utility]
Start up Burners
[Start up burners using LDO have been provided to raise the temperature of the
combustor bed to the auto ignition temperature of the fuel. For this purpose,
[] burners have been placed in the primary air duct leading to the combustor bed]
p)
Primary Air Fans

Table: 3.29
Description
Units
Type
..
[.]
..
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Speed
rpm
[.]
Discharge Pressure
mmwc
[.]
[.]
Motor Rating
kW
[.]
[.]
kg-m2
Bearings
q)
Design Parameters
[2 spherically seated, H.S.

ring
lubricated,
with
assisted lubrication water
cooled. In board bearing
on base plate, outboard
bearing on pedestal.]
Secondary Air Fans

[Two Secondary Air (SA) Fans have been provided for each boiler. Each SA Fan is
designed to meet 60% MCR condition of the boiler. The SA Fans supply secondary air
to the combustor. Details are given below:]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[45]
15.01.2016
Power Plant]
[Logo of Utility]
Table: 3.30
Description
Units
Type
..
[.]
..
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
Temperature of Air
[.]
Runner Diameter
mm
[.]
kg-m2
[.]
Speed
rpm
[.]
Motor Rating
kW
[.]
[.]
Bearing

high
speed
pressure
base plate.]
Power Coupling
r)
Design Parameters
..
[.]
Induced Draft Fans

Table: 3.31
Description
Units
Type
Document Number
LII-GETS12021-G-00129-001
..
Design Parameters
[.]
Rev
No.
Description
Page
No.
Date of Issue
04

[46]
15.01.2016
Power Plant]
Description
Units
..
[.]
Nos.
[.]
Capacity
m3/sec
[.]
Discharge Pressure
mmwc
[.]
[.]
Runner Diameter
mm
[.]
kg m2
[.]
Motor Rating
kW
[.]
[.]
high
speed
pressure
base plate]
Power coupling
s)
Design Parameters
Bearing
[Logo of Utility]
[.]
Soot Blowers
{Please indicate in the table below, the type, the location and number of soot blowers
provided in the existing CFBC Boiler.}
Table: 3.32
Description
Units
Make and Model of Soot Blowers

provided.
..
[]
No. of Soot Blowers per boiler.
Nos.
[.]
Location of Soot Blowers
..
[.]
Medium of soot blowing.
..
[.]
Document Number
LII-GETS12021-G-00129-001
Design Parameters
Rev
No.
Description
Page
No.
Date of Issue
04

[47]
15.01.2016
Power Plant]
[Logo of Utility]
t) ESP
The hoppers of ESP have been provided with [capacitance] type level indicators and
Table: 3.33
Description
Units
Design Parameters
[.]
Nos.
[.]
Nos.
[.]
mg/Nm3
[.]
Type of Control
[.]
Gas Velocity in ESP
m/sec
[.]
m2/m3/sec
[.]
Aspect Ratio
..
[.]
cm/sec
[.]
Numbers of TR Sets
..
[.]
Rating of TR Sets
..
[.]
Plate Area/TR Set
m2/TR Set
[.]
hrs
[.]
Pressure Drop
mmwc
[.]

fields in operation
[.]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[48]
15.01.2016
Power Plant]
[Logo of Utility]
u) Main steam piping, Cold reheat piping, Hot reheat piping & Auxiliary Steam Piping
Table: 3.34
Description
Units
Design Parameters
Main Steam Line

Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Upstream of HP turbine bypass valve
Downstream of HP turbine bypass valve

Flow
T/hr
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Document Number
LII-GETS12021-G-00129-001
[.]
Rev
No.
Description
Page
No.
Date of Issue
04

[49]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Class
Cold Reheat Line
Hot Reheat Line
Upstream of LP turbine bypass valve
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[50]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Downstream of LP turbine bypass valve

Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Auxiliary Steam Piping
Other LP Piping
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[51]
15.01.2016
Power Plant]
3.2.3
[Logo of Utility]
Electrical System
a)
General Technical Parameters

[The Major design parameters of the electrical systems/Equipment are furnished
below:]
Table: 3.35
Description
Units
Design Parameters
Make/Manufacturer
[.]
Model No
[If applicable]
Installation
[.]
6
. Nominal voltage
6
kV
[.]
Highest System voltage
kV
[.]
Short circuit current
kA
[.]
kV (Peak)
[.]
/
0
. Impulse withstand voltage
4
3One minute power frequency withstand
3voltage
kReference ambient temperature
V
Rated Current
kV (rms)
[.]
[.]
Amp
[.]
b
6.6/0.433 kV Transformer
[The 6.6 / 0.433 kV transformer is designed to cater 100% of Power plant auxiliary load
of respective system like Boiler auxiliary, HVAC etc, with 2 x100% configuration is
followed. For ESP system electrical scope of work shall start from 6.6 kV Unit
switchgear outgoing and shall include HV cable termination, HV cable, LT transformer,
NSPBD, LV switchgear and further distribution. The design parameters of the 6.6 /
0.433 kV transformer are furnished below:]
Table: 3.36
Description
Units
Design Parameters
Make/Manufacturer
[..............]
Type
[Oil/Dry.......]
Transformer application
[..Service ..........]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[52]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
[Indoor/Outdoor.]
Installation
Rating of transformer
MVA
[..............]
No load voltage ratio at

principal tap HV/LV
kV
[..............]
Impedance value at
principal tap on rated MVA
base.
[..............]
Tolerance on impedance at
nominal tap
Rated frequency
[..............]
[..............]
Hz
[..............]
Winding connection and

vector group
System fault level
kA
Impulse withstand voltage /

Power frequency withstand
voltage of windings
kV
[HV.........]; [LV.........]
[..............]
System earthing
[..............]
(a) HV
(b) LV
[..............]
[..............]
Type of tap changer

Guaranteed no load loss
kW
[..............]
Guaranteed load loss
kW
[..............]
Guaranteed efficiency at
[..............]
No & %
[..............]
a) Full load
b) 75% load
No of Cooler Bank and
Capacity (If applicable)
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[53]
15.01.2016
Power Plant]
Description
b)
Units
[Logo of Utility]
Design Parameters
LV Switchgear (PMCC/MCC)
[The LV Switchgear is provided with two incomers and bus coupler with outgoing
feeders intend for specific Auxiliary services. All the MCC/PMCC to feed the boiler
auxiliary like ESP PCC/PMCC/MCC, FOPH PCC/PMCC/MCC, Boiler MCC, Boiler
Valve MCC, Soot Blower MCC, Bottom Ash Handling System MCC, Emergency
MCCs, AC ventilation MCC, PDBs, ACDBs, etc. are the part of Boiler package. The
design parameters of the LV Switchgear are furnished below:]
Table: 3.37
Description
Units
Design Parameters
Make/Manufacturer
Rated voltage, phases &
frequency
[.........]
V, Hz
[...]
System neutral earthing

Maximum system
voltage
[.........]
V
[.........]
[.........]
One minute power

frequency
Voltage
(a) Power circuits
[.........]
(b) Control Circuits
[.........]
Continuous current
rating of bus bars
[.........]
Short Circuit rating of

Bus bar with duration
kA & sec
Bus bar Material
Al/Cu
[.........]
Type- Fully Draw

out/Fixed
Document Number
LII-GETS12021-G-00129-001
[.........]
[.........]
Rev
No.
Description
Page
No.
Date of Issue
04

[54]
15.01.2016
Power Plant]
c)
[Logo of Utility]
Non Segregated Phase Bus Duct (NSPBD)

[Diesel generating sets are installed for meeting the power requirements of essential
auxiliaries (viz. jacking oil pumps, AC lube oil pump, hydrogen seal oil pump, float
charger for DC battery, emergency lighting, scanner air fan and stator cooling water
pump) during total failure of AC Power Supply in the power station. Diesel generating
sets are located in the CD bay at the ground floor. The details are mentioned below]
[The NSPBD which connects 6.6 / 0.433 kV transformer to LV Switchgear required for
boiler auxiliaries and associated equipment. The design parameters of the NSPBD are
furnished below:
Table: 3.38
Description
Units
Design Parameters
Make/Manufacturer
[.........]
Type of bus duct
[.........]
Rated voltage and No. of

phase
[.........]
Material of Bus bar and

Enclosure
[.........]
Rated Current
[.........]
Designation
(From and To)
[.........]
Type of cooling (NSPBD)
[.........]
Maximum temperature oC
rise of conductor over
50oC ambient
[.........]
[.........]
power KV (RMS)
voltage
[.........]
Maximum temperature
rise of enclosure over
50oC ambient
One
minute
frequency
withstand
Continuous
current A
rating at 50oC design
Document Number
LII-GETS12021-G-00129-001
[.........]
Rev
No.
Description
Page
No.
Date of Issue
04

[55]
15.01.2016
Power Plant]
Description
Units
Design Parameters
One second short circuit

withstand rating
KA (RMS)
[.........]
Momentary short circuit

withstand current
KA (Peak)
[.........]
[Logo of Utility]
ambient air temperature
d)
HV Cables
[The HV cables of 6.6kV UE Voltage grade is used for feeding 6.6kV motors as well as
6.6 / 0.433 kV transformers (under boiler package) from 6.6 kV Unit or station
switchgear. HV cable termination at both the end shall be in boiler package. The
design parameters of the HV Cables are furnished below:]
Table: 3.39
Description
Units
Design Parameters
Make/Manufacturer
[.........]
Voltage Grade
[.........]
Nominal Power System

Voltage
kV
Maximum System
Voltage
kV
[.........]
[.........]
System Neutral Earthing
[.........]
No. of Cores
[.........]
Conductor Material
[.........]
Conductor
(stranded/solid)
[.........]
Conductor Screen
[.........]
Insulation
[.........]
Insulation Screen
[.........]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[56]
15.01.2016
Power Plant]
Description
e)
Units
[Logo of Utility]
Design Parameters
Inner Sheath
[.........]
Outer Sheath
[.........]
Armoured/Unarmoured
[.........]
Material of cable drum
[.........]
Type of End Sealing
[.........]
LV Cables
[The LV cables of 1.1kV Voltage grade are used for feeding LV motors as well as for
sub distribution system boards/MCC/PMCC/ACDB/DBs etc. The design parameters of
the LV Cables are furnished below:
Table: 3.40
Description
Units
Design Parameters
Make/Manufacturer
[.........]
Voltage Grade
[.........]

Voltage
kV
Maximum System
Voltage
kV
[.........]
[.........]
[.........]
No. of Cores
[.........]
Conductor Material
[.........]
Conductor
(stranded/solid)
[.........]
Conductor Screen
[.........]
Insulation
[.........]
Insulation Screen
[.........]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[57]
15.01.2016
Power Plant]
Description
f)
Units
[Logo of Utility]
Design Parameters
Inner Sheath
[.........]
Outer Sheath
[.........]
Armoured/Unarmoured
[.........]
[.........]
Type of End Sealing
[.........]
Control (Core) Cables

[The Control cables of 1.1kV Voltage grade are used for Protection, CT, VT connection
and feedback/interlock signals. The design parameters of the LV Cables are furnished
below:
Table: 3.41
Description
Units
Design Parameters
Make/Manufacturer
[.........]
Voltage Grade
[.........]

Voltage
kV
Maximum System
Voltage
kV
[.........]
[.........]
[.........]
No. of Cores
[.........]
Conductor Material
[.........]
Conductor
(stranded/solid)
[.........]
Conductor Screen
[.........]
Insulation
[.........]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[58]
15.01.2016
Power Plant]
Description
g)
Units
[Logo of Utility]
Design Parameters
Insulation Screen
[.........]
Inner Sheath
[.........]
Outer Sheath
[.........]
Armoured/Unarmoured
[.........]
[.........]
Type of End Sealing
[.........]
6.6 kV Motor
[All the 6.6kV motor in boiler packages shall be directly fed from the 6.6kV Unit/station
switchgear. 6.6kV Unit and station switchgear shall be part of TG package. The
provision of Nos of outgoing feeder shall be kept in 6.6kV switchgear in co-ordination
with the boiler package Bidder. The design parameters of 6.6 kV motors used in Boiler
package are furnished below]:
Table: 3.42
Description
Units
Design Parameters
Make/Manufacturer
[.........]
Application
[.........](For each application )
Rating
kW
Rated Voltage, Phase,

Frequency
kV, Hz
[.........]
[.........]
Frame Size
[.........]
Type of Cooling
[.........]
Installation
[.........]
Duty Type
[.........]
Load Factor
[.........]
Full load current
[.........]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[59]
15.01.2016
Power Plant]
Description
h)
Units
Design Parameters
Starting current &

Starting PF
Times Normal
current
[.........]
Winding connection
Star/Delta
[.........]
Full load speed
[.........]
Power factor and

Efficiency
[.........]
Class of insulation
[.........]
Method of starting
:
[.........]
Main terminal box details
[.........]
Space Heater Details
[......]
CT details if provided
with differential
protection
[......]
RTD/BTD Details
[......]
[Logo of Utility]
LV Motor
[All the LV motor in boiler package shall be feeded from the MCC/PMCC of this
package. The design parameters of LV motors used for Boiler package are furnished
below]:
Table: 3.43
Description
Units
Design Parameters
Make/Manufacturer
[.........]
Application
Rating
kW

Frequency
kV, Hz
Document Number
LII-GETS12021-G-00129-001
[.........]
[.........]
Rev
No.
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Description
i)
Units
[Logo of Utility]
Design Parameters
Frame Size
[.........]
Type of Cooling
[.........]
Installation
[.........]
Duty Type
[.........]
Load Factor
[.........]
Full load current
[.........]
Starting current &

Starting PF
Times Normal
current
[.........]
Winding connection
Star/Delta
[.........]
Full load speed
[.........]
Power factor and

Efficiency
[.........]
Class of insulation
[.........]
Method of starting
:
[.........]
[.........]
[......]
RTD/BTD Details
[......]
Electrical Actuators
[The design parameters of Electrical Actuators used for Boiler package are furnished
below]:
Table: 3.44
Description
Units
Design Parameters
Make/Manufacturer
Document Number
LII-GETS12021-G-00129-001
[.........]
Rev
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Description
Units
Design Parameters
Application
j)
[Logo of Utility]
Rating
kW
[.........]

Frequency
kV, Hz
[.........]
Installation
[.........]
Duty Type
[.........]
Load Factor
[.........]
Type
[ Integral/Non Integral.........]
Class of Insulation
[.........]
Illumination System
[The illumination system of Unit No. [..] of [Name of the Power Plant] is categorized
mainly as Normal, Emergency and DC lighting. The illumination system of indoor
area/Building (under the scope of Boiler package), Outdoor area are covered in this
Boiler Package. Lighting system for other area are covered respective packages.
Lighting Distribution Board (LDB) is normally getting supply from 415V PMCC. Each
LDB is provided with lighting transformer for isolation of lighting circuit from power
circuit and also for limiting short time current rating. Outgoing circuits of LDB will feed
Lighting panels which is placed local to fixtures. It is envisaged that separate LDB for
indoor as well as for outdoor area. Emergency Lighting system is same as normal
system however it will get supply from Emergency 41V PMCC backed up with DG set.
The Design parameters of Illumination System and its major components comprising
of LDB with transformer, Lighting Panel, Lighting Fixtures, Lighting wires and Lighting
Poles are furnished below]:
Table: 3.45
Description
Units
Design Parameters
Lighting System:
Voltage
a)AC system
Rated Voltage
Document Number
LII-GETS12021-G-00129-001
[.........]
Rev
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Description
Units
Maximum Voltage
[Logo of Utility]
Design Parameters
V
[.........]
Rated Voltage
[.........]
Maximum Voltage
[.........]
One Minute Withstand

Voltage
[.........]
a) 415V AC
kA(rms)
[.........]
b) 220V DC
kA(DC)
[.........]
b)DC system
System Short-Circuit
Level
LDB/LP:
Manufacturer Name
[.........]
Mounting
a)LDB
[Floor.........]
b) LP
[.Wall........]
Installation
[.........](For each application i.e.

for Indoor/Outdoor and area )
Type, No of
Circuits/Feeder rating
[.........]
Lighting Transformer:
Make of Transformer
[.........]
Type of Transformer
[.Dry........]
Rating
kVA
[.........]
Voltage Ratio
Document Number
LII-GETS12021-G-00129-001
[.........]
Rev
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Description
Impedance
Units
Design Parameters
[.........]
[Logo of Utility]
Lighting Wires:
Make
[.........]
Voltage Grade
[.........]
Conductor Material
Cu/Al
[.........]
Size
Sq.mm
[.........]
Lighting Fixtures:
Make
[.........]
Type of Luminaries
[.........]
Ballast Type
[.........]
Lighting Poles:
Make
Type of Poles
k)
Cable Carrier System

[The Cable Carrier system of Unit No. [..] of [Name of the Power Plant] is described as
below: Indoor Buildings are provided with Cable cellar/Trench and outdoor areas are
provided with Pipe cum cable rack/Duct bank/Trench. Separate Tray is envisaged for
HV cables. LV cables, Control cables and Instrumentation cables in the order that HV
cables Tray at the top followed by LV, Control and Instrumentation Tray. Ladder type
tray is used for HV, LV and Control cables, however Perforated Tray to be used for
Instrumentation cables. The Cable carrier system of indoor area/Building (under the
Boiler package), Outdoor area are covered in this Boiler Package. Cable carrier
system for other area are covered in respective packages. However if any cable of
other package comes under the boiler area, Boiler package Bidder has to provide
sufficient space in their cable carrier system to accommodate other package cables.
Similarly if Boiler package cable run though any other package area, they will keep the
provision of sufficient space in their cable carrier system to accommodate the boiler
package cables. The Design parameters of Cable Carrier System are furnished
below]:
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
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[Logo of Utility]
Table: 3.46
Description
Units
Design Parameters
Make/Manufacturer
[.........]
Size of Tray
mm
[.........]
Material
[.........]
Application
[.........] (I.e. HV/LV/Control/Inst.)
Type of Tray
[.........] (i.e.Ladder/Perforated)
Thickness of Tray
mm
[.........]
Thickness of
Galvanization
mm
Tray Cover Size
mm
[.........]
Tee
mm
[.........] {List out all size}
Cross
mm
[.........]{List out all size}
Bends
Deg
mm
[.........] to [.........]{List out all

size}
mm
[.........]
Cable Tray
Accessories
Reducer
Steel Supports
a) ISMC
b) ISA
l)
Earthing and Lightning System

[The Earthing & Lightning System of Unit No. [..] of [Name of the Power Plant] is
described as below:
All above ground earthing of boiler auxiliaries / structure /equipments / skids / pipes
/column etc are under the boiler package. Earth point/earth pad of the each equipment
shall be connected to the main earth grid via risers. Provision of Sufficient nos. of riser
shall be kept in the BOP package. Sizes of the earth flat/bar/wire shall be depending
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
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No.
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upon the rating of equipment and earth fault current is to be carried during fault
condition. The Design parameters of Earthing and Lightning System are furnished
below]:
Table: 3.47
Description
Units
Design Parameters
Earthing System:
Make/Manufacturer
[.........]
Main Earthing Conductor

a)
Material
[.........]
b)
Dia
[.........]
Treated Earth Pit/Earth

Rod(Dia and Length)
mm & m
[.........]
Size of Earth Conductor
[.........]{List out size of Flat Earth

conductor used for different
equipments of Power plant and no
of points }
a)
6.6kV Switchgear
b)
LV Switchgear
c)
6.6kV Motors
d)
LV Motors {List out KW

rating wise}
e)
Control
etc.
f)
Transformer Body
g)
Transformer
Neutral
{List out Transformer
wise}
h)
Any
other
panel/Equipments
Document Number
LII-GETS12021-G-00129-001
panel,
LPBS
mm x mm
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Description
Units
[Logo of Utility]
Design Parameters
Lightning System:
Air Termination Rod
[.........]
a) Dia & Length
[.........]
b) Material
Down comer
[.........]
a) Material
[.........]
b) Size
Lightning Electrode with test
link
[.........]
[.........]
a) Material
b) Dimension(Length
and Dia)
3.2.4

[The existing control and instrumentation system generally is an old analogue based
system and requires large scale replacement owing to obsolescence of the existing
equipment. Furnace Supervisory Safeguard System (FSSS) is of obsolete design for
which, no spares are available. Soot blowers are of manual type. No online Boiler
Tube Leakage detection system has been provided. HP- LP bypass system is in the
form of standalone control panel. Integrated microprocessor based closed loop control,
open loop control, sequential control and bulk data acquisition system for Boiler &
auxiliaries, TG & auxiliaries, station C&I including auxiliaries in hierarchical levels and
integrated unit monitoring and station monitoring systems in the upper level are
therefore to be envisaged for the plant.]
3.2.5
Civil Works
Bidder shall go through the details of the existing Buildings / Structures / Foundations /
Facilities mentioned hereunder (but not limited to) for the thorough understanding of
conditions of the same. In order to assess the quantum of Civil / Structural /
Architectural R&M work within the package, Bidder shall also carry out a brief or
detailed survey (as required) of the site to acknowledge and obtain any other
information/data about present conditions at site and identification of modification
requirements in any other structure or foundation not included here. Conditional details
of important buildings / structures / foundations / facilities which require major
modifications have been described below:
Document Number
LII-GETS12021-G-00129-001
Rev
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[Logo of Utility]
{Details of the existing foundations in the boiler area, with its auxiliaries like PA fan, FD
fan, ID fan as well as Electrostatic Precipitator shall be indicated in this section. Also
the available GA/Construction Drawing including Load Data shall also be provided.}
Document Number
LII-GETS12021-G-00129-001
Rev
No.
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SCOPE OF SUPPLY & SERVICES
4.1
The scope of supply and services
[Logo of Utility]
The scope of supply and services to be provided by the Bidder shall include all such
activities as required to meet the target and intent of this Specification. The scope for
each unit shall generally cover, but will not be limited to the following:
(i)
Replacement of some of the existing components with new components of improved

and better design.
(ii)
Incorporation of new systems / components wherever required in line with the

Specification.
(iii)
Refurbishing / Retrofitting
equipment/system.
(iv)
All types of civil/structural works like modification and strengthening of foundation of

existing and upgraded equipment, making new structures or foundations (if
applicable), dismantling, restoration, supply and erection of any temporary supports or
any other construction work required for implementation of renovation work.
of
some
of
the
components
in
the
existing
All structural modifications/strengthening of existing structure of building, Boiler, Fans,

ESP etc. including supply, fabrication and erection of any new structure and provision
of any additional platform if required for access to new equipment or existing
equipment as specified.
Supply of all materials, equipments, machinery and manpower required for
civil/structural R&M works.
Site enabling works as per the requirements to support civil/structural R&M works.
(v)
Design, engineering, submission of design calculations for review and approval,

manufacturing, inspection and testing at suppliers works, packing, forwarding to site,
unloading, erection, supervision, pre-commissioning, testing and commissioning and
performance testing of the equipment / systems and works indicated in clause No. 4.5
of this technical Specification.
(vi)
Mandatory spares, start-up and commissioning spares. The general requirements in

respect of various types of spares are given in Clause 9 of this section of Technical
Specification.
(vii)
Packing, transportation and transit insurance of all materials required for renovation /
replacement work as per this Specification from the supplier's/sub supplier's works to
[Name of the Plant], unloading, preservation and storage at site. Packing,
transportation, transit insurance, clearance from all concerned agencies etc. of all
components/materials required to be forwarded from [Name of the Plant] to Bidder's
facilities and back to [Name of the Plant].
(viii)
Dismantling of the systems, handling and storage of dismantled equipment,

reassembly and re-erection / reinstallation along with associated inspection, testing,
Document Number
LII-GETS12021-G-00129-001
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commissioning and trial run of equipment individually as well integrated with the
overall plant trial operation.
(ix)
Materials which are removed from the existing machines but are not re-used during
the re-assembly of the machines as well as those components which are found to be
beyond refurbishment shall be the property of Owner and shall be deposited at
Owner's designated stores. Bidder shall prepare a record of all such dismantled
material and hand it over to the Owner.
(x)
Loading, transportation, unloading and disposal of scrap to the designated

storage/disposal yard.
(xi)
It shall be responsibility of the Bidder to obtain on behalf of the Owner the necessary
approvals of Inspection Authority / Chief Inspector of Boilers as may be required for
design and design calculations, manufacturing, erection procedure renovation as
called for under the IBR. Bidder shall also be responsible for obtaining approval from
the other statutory authorities in India, as may be required, for other plants and
systems supplied by him. All such documentation submitted to statutory authorities
shall also be submitted to the Owner for his review.
Handling of materials at site including handling / transportation as required to take
equipment components to the workshop for carrying out the modification work and to
bring it back for installation. All arrangement for such activities is to be done by the
Bidder.
(xii)
Erection of all material supplied new for renovation (including erection of components,
replacing old components). Re-erection of any component / equipment removed for
modification so as to make complete unit consisting of Boiler and related auxiliaries
including electrical & control and instrumentation equipment /system ready for
commissioning.
(xiii)
All gas cutting / dismantling, edge preparation, welding, bolting etc. and conductance
of all NDTs like radiography, ultrasonic testing, MPI, die penetration testing etc. Any
new matching pieces, piping, hangers & supports etc. required for assembly of
equipment/ systems, as per system requirements shall also be included in the scope
of the Bidder.
(xiv)
All Pre-commissioning activities as may be required such as hydraulic testing, air &
gas tightness test, steam blowing, floating of safety valves, oil flushing etc. including
erection and dismantling of all temporary systems like piping / tanks etc. and
Conductance of all demonstration tests including performance test.
(xv)
Assisting and coordinating with Owner in tuning various control loops finalizing
protection and control requirements of all boiler auxiliaries.
(xvi)
Insurance for all items / activities in line with the provisions of General Condition of
Contract of Volume-I.
(xvii)
Civil / Mechanical work (such as grouting, cutting, welding etc.) related to mounting of
New Cabinets, CRT / Keyboards, laying & termination of associated Cables.
Document Number
LII-GETS12021-G-00129-001
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(xviii)
Supply of all necessary tools, tackles, commissioning spares, test instruments and
deputing of experienced personnel for completion of the above erection, testing and
commissioning work.
(xix)
Dismantling of existing C&I cabinets along with associated cabling, for Boiler &
Auxiliaries related to the unit for retrofitting the new C&I systems, based on
requirement as described in clause No. 4.5.
(xx)
Providing all site execution and supervision by qualified and experienced engineering
personnel during execution of all works under the scope of Bidder. Also providing all
facilities and qualified personnel for implementing the approved quality assurance
programme.
(xxi)
Dismantling of the existing Instrumentation Cables and relaying of new cables as may
be required.
(xxii)
The Bidder shall conduct all shop and site tests as per the requirements of this
Specification and Owner approved "Quality Assurance Program" to be finalised before
the award of this Contract. Facilitating inspection, witness of shop and site tests by the
representatives of Owner shall be in the scope of the Bidder.
(xxiii)
Performance Guarantee tests after successful completion of initial operation.
(xxiv)
Electrical
The scope of electrical system of Boiler and auxiliarys package will include all
electrical equipment listed below (if applicable).
[Note: Scope of work of auxiliary system for SG shall be suitably modified with respect
to specific project and accordingly list of attachments as given in Volume-II, Section-II,
Part B shall be enclosed]
a) [All 415 V MCCs for SG package (Boiler. MCC, Boiler valve MCC etc.) as required
and ACDBs/PDBs and DCDBs for drives and equipment covered in SG package.
b) 6.6 / 0.433 kV transformers, 415 V non segregated phase bus ducts.
c) Welding sockets in SG area with necessary Welding DBs.
d) Control stations / Local Push Button stations.
e) HV/LV A.C. motors and actuators for all the drives in the scope of SG package and
DC Motors and DC starters as required in SG area.
f) Installation, Interconnection laying and termination of all Bidder supplied HV/LV
power and control cables with termination kits for all auxiliaries in TG area.
g) Illumination System including Lighting Transformers, MLDBs, Lighting DBs/
Lighting Panels for the Steam Generator Island.
h) Grounding system for the SG Island and grounding connection to all equipment in
SG area. Making arrangement for proper electrical grounding of all systems,
supplied by him as required by the system design. All required accessories
including grounding cables.
Document Number
LII-GETS12021-G-00129-001
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i)
Lightning Protection system for SG Building and other equipment/building covered

in SG Island.
j) Complete cable racks with necessary supporting structures and foundations within
SG area, cable Trays with support system, cable trenches and accessories in SG
area. Fire proof sealing system in SG area.
k) Variable frequency drives for HV and LV system of SG package].
(xxv)
Construction Water:
[Construction water shall be made available to Bidder at a single point in a suitable
location. The Bidder shall arrange at his own cost the required pumps, distribution pipe
line network for further distribution as required to carry out construction work.]
(xxvi)
Construction Power
[Construction power shall be made available to bidder at single point at [.] kV level.
Further distribution as required to carry out the construction work shall be carried out
by Bidder at his own cost.]
(xxvii)
4.2
Providing all other services necessary for meeting the intent and requirement of this
Specification. This shall include but not limited to system engineering, furnishing
drawings, data, information for Owner's review, participation in meeting & reviews,
System warranty, revision of O&M Manuals etc.
Tools & Tackles
One (1) set of special tools and tackles required for the maintenance of
equipment/systems have to be supplied by the Bidder. These tools and tackles shall
be separately packed and brought to site. These shall not be used for
erection/commissioning purposes and shall be in an unused and new condition, when
they are handed over to the Owner. A list of all such special tools and tackles shall be
submitted along with the offer.
For C&I system, Bidder shall supply one set for each unit of special non standard
tools, module testing kit, cables, and any other equipment required for erection
commissioning, testing, trouble shooting, calibration, maintenance and inspection of all
systems / equipment provided. Any tools required to make changes (DIP shunt cutter,
soldering irons, tips, wire wrap guns and bit unwrapping tools, strippers, terminal
guard, connector repair tool, dies etc.) shall also be supplied.
Bidder's scope shall also include supply of all Cranes, welding sets and NDT testing
equipment, scaffolding, special tools and tackles, jigs and fixtures as may be required
during modification / erection and commissioning. Those items specifically brought to
site solely for erection / modification purpose and if no more needed for regular
maintenance of the equipment, can however, be taken back by the Bidder after
completion of the work at site, subject to the approval of Owner.
Document Number
LII-GETS12021-G-00129-001
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No.
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4.3
Safety
4.3.1
The design of the equipment shall incorporate every reasonable precaution and
provision for the safety of all personnel and for the safety and security of all persons
and property. The design shall comply with all appropriate statutory regulations
relating to safety.
Newly constructed structures and equipment shall be designed and constructed to
withstand every foreseeable static and dynamic loading condition, including loading
under earthquake conditions, with an adequate margin of safety.
Ready and safe access with clear head room shall be provided to all the newly
supplied parts of the plant for operation, inspection, cleaning and maintenance.
4.3.2
While carrying out the R&M work as per this Specification, the Bidder may have to
modify the existing equipment foundations, or do the excavation work and make new
foundations. The Bidder may also have to make new supporting arrangements with /
without modified loads for the items/ equipment supplied by him. Under all such
conditions Bidder shall be solely responsible for ensuring the safety of the adjacent
equipment / foundations and of the existing supporting structures. The R&M work by
the Bidder shall be carried out in such a manner that no damage is caused to existing
equipment / foundations / structure and all precautions, including strengthening of
existing structures, as may be necessary, shall be taken by the Bidder to ensure safety
of existing plant / equipment / foundation / structures.
4.4
Training Requirements
Bidder shall include in his offer the training programme for Owner's Operation &
Maintenance staff in view of introduction of new systems/ equipment. This training
shall be organized before handing over the unit.
In case there is any difference in scope of work and services as described in this
section of the Specifications and individual Specification volumes, then more stringent
of the Scope of work and services shall prevail.
4.5
Detail Scope of Work:
4.5.1
Boiler & Its Auxiliary System

{Describe in this chapter, all the equipment/components which need to be
replaced/refurbished/retrofitted as finalized in the DPR on the basis of RLA/CA and EA
report. Scope with regard to Civil, structural and architectural work as required for the
Power Plant due to incorporation of new equipment/components shall also be
incorporated in this chapter.
Generally there is a considerable time elapsed between the RLA/CA & EA Studies
and the Award of R&M Contract. Due to this time gap, the unit suffers further
deterioration which is not factored into the bidding document. To ensure that the
Renovation & Modernization Project goals are successfully achieved, it is advisable to
convey to the bidders the real health condition of the unit, while issuing the bidding
documents. The utilities are therefore advised to get a Baseline Test conducted before
Document Number
LII-GETS12021-G-00129-001
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[Logo of Utility]
issuing the bidding documents. Such Baseline Test may be conducted through an
Independent Consultant for the Performance Evaluation of Boiler, TG and the Major
BOPs of the Unit. Parameters to be evaluated during the Baseline Test are being
enclosed separately.}
The Bidder shall include in his scope the following works for the R&M of the Unit,
which are based on RLA/CA and EA studies. The overall scope of work shall include
but shall not be limited to the scope of work mentioned below. DCS & other common
system/items, if applicable, procured by owner separately, shall not be considered
under SG package. Any other items not specifically mentioned but considered
necessary by the Bidder for carrying out the R&M work, shall also be included in his
scope so as to meet the intended performance of Boiler & Auxiliaries as specified in
Clause No. 1.1
Table: 4.1
Equipment
Scope of Work
Quantity
PF Boiler/ CFBC Boiler

{The template provided below is common for PF Boiler as well as CFBC Boiler.
Typical Equipments/Components which are applicable only for one kind of boiler and
not for the other type of boiler have been specifically highlighted. }
[Drum]
[..]
[..]
[Water Walls]
[Low Temperature
Super Heater]
[Platen Super Heater]
[Pendant Super
Heater]
[Ceiling Super Heater]
Document Number
LII-GETS12021-G-00129-001
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
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Equipment
Scope of Work
[Reheater-Front
Assembly]
[Reheater-Rear
Assembly]
[Economiser]
[Wind Box]
[Oil Burners]
[Low NOx Burners]

{Applicable only for PF
Boilers}
[Igniters]
[Refractory]
[Insulation]
Document Number
LII-GETS12021-G-00129-001
[Logo of Utility]
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
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Equipment
Scope of Work
[Buckstays]
[Logo of Utility]
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Wall Blowers / LRSBs]
[..]
[..]
[Pent House]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Ducting]
[Attemperators]
[Any other systems]
Air Pre-Heater
[Air Pre- Heater Tubes
for tubular Air Heaters]
[..]
[..]
[Air Pre- Heater Tube

Plates for tubular Air
Heaters]
[..]
[..]
[Sector Plates for

regenerating air Preheater]
Boilers}
[Rubber Seals for
regenerating air Preheater]
Boilers}
[..]
[..]
[..]
[..]
Document Number
LII-GETS12021-G-00129-001
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Equipment
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
Coal Feeders
Boilers}
[..]
[..]
Fuel Feeding System
[..]
[..]
[Any other Component]
(As applicable for

specific CFBC Boiler)
Coal Mills
{Coal Mills and their components indicated below are applicable for PF Boilers only}
[Enhancement of Mill
[..]
[..]
(Model No.)]
[..]
[..]
[Mill Classifier]
[Grinding Elements]
[Rotary Throat &

Ventury]
[Loading Cylinder]
[Mill Inner Cone]
Document Number
LII-GETS12021-G-00129-001
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page
No.
Date of Issue
04

[77]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[Drive Motor, Gear

Box, Lubrication
System etc].
[..]
[..]
[..]
[..]
[Pulverized Fuel Piping

System]
[..]
[..]
[..]
[..]
[..]
[..]
Combustor Bed
{Combustor bed components indicated below are applicable for CFBC Boilers only}
[Distribution Grid]
[..]
[..]
[Air Fluidizing Nozzles]
[..]
[..]
[Combustor Refractory]
[..]
[..]
[Bed Drains]
[..]
[..]
Cyclones
{Cyclones and its components indicated below are applicable for CFBC Boilers only}
[Cyclone Tubes]
[..]
[..]
[Erosion Protection
Refractory]
[Insulation]
[..]
[..]
[..]
[..]
[Lagging]
[..]
[..]
LOOP SEAL
{Loop Seal and its components indicated below are applicable for CFBC Boilers
only}
Stand Pipe
[..]
[..]
Loop Seal bed
[..]
[..]
Fluidizing Air Nozzles
[..]
[..]
Loop Seal Blower
[..]
[..]
External Fluidized Bed Heat Exchanger

Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[78]
15.01.2016
Power Plant]
Equipment
Scope of Work
[Logo of Utility]
Quantity
{External Fluidized Bed Heat Exchanger and its components indicated below are
applicable only for CFBC Boilers only}
Heat Exchanger Tubes
[..]
[..]
Distribution Grid
[..]
[..]
Fluidizing Air Nozzles
[..]
[..]
Heat Exchanger
Blower
Primary Air Fan
[..]
[..]
[Impellers]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Drive Motor]
Induced Draft Fan

[Impellers]
[Hydraulic Coupling]
[Drive Motor]
[Lubrication Systems]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[79]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Forced Draft Fan

[Impeller]
[Drive Motor]
[Lubrication Systems]
[Seal Air Fan]

[ESP Retrofitting]
[ESP controller & HV

Rectifier Transformer]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[80]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Equipment Cooling
Water Pumps & its
associated system for
Boiler]
[..]
[..]
[..]
[..]
[Replacement and
Retrofitting of Motors]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Insulation & Metal

Cladding]
[Ammonia injection
system]
[Fly Ash Hoppers]
[Any other
Components]
[Any other systems]
[High Pressure & Low Pressure Piping and Fittings]

Tag
Description
Document Number
LII-GETS12021-G-00129-001
Flui
Size
Schedule /
Class
Material
Qty
Rev
No.
Description
Page
No.
Date of Issue
04

[81]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
No.
Quantity
Thickness
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[Pneumatic Dampers]
Tag
No.
Description
Drive
Type
Design
Torque
Lever
Radius
Duct
Size
Angular
Movement
(Degree)
Qty
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[Electric Actuators Operated Dampers]

Tag
No.
Description
Drive
Type
Design
Torque
Lever
Radius
Duct
Size
Angular
Movement
(Degree)
Qty
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[Expansion Joints]
Sl. No. / Tag No.
Document Number
LII-GETS12021-G-00129-001
Service Description
Location
Size
Qty
Rev
No.
Description
Page
No.
Date of Issue
04

[82]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[Motorized Valves ]
Tag
No.
Service
Description
Size/
Type
Clas
s
End Conn.
Travel
time
Drg. No.
Qty
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[Manually Operated Valves]

Tag
No.
Service Description
Size/
Type
Class
End
Conn.
Material
Qty
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[Non Return Valves]

Tag
No.
Service Description
Size/
Type
[...]
[...]
[...]
Document Number
LII-GETS12021-G-00129-001
Class
[...]
End
Conn.
[...]
Material
[...]
Qty
[...]
Rev
No.
Description
Page
No.
Date of Issue
04

[83]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Service Description
Size/
Type
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[Relief Valve]
Tag
No.
Class
End
Conn.
Material
Qty
[Electric Actuator for Valve]

Tag
No.
Description & Service
Torque (Nm)
Wattage (W)
Qty
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[Control Valve]
Replacement/
Retrofitting of Control
Valves
[..]
[..]
[..]
[..]
[..]
[..]
[Electrical Works]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[84]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
HV & LV motors
[Motor terminals box]
[Motor stator winding]
[Motor Rotor winding]
[Motor enclosure]
[Motor cooling system]
[Bearings]
[Any other part/system

of motors]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[85]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Motorized Actuator]
[Motor]
[Position
indicator/Transmitter]
[Bearing]
[Limit switches]
[space heater]

of motor actuators]
[LT Transformers]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[86]
15.01.2016
Power Plant]
Equipment
[Transformer HV/LV
coil]
[Tap changer]
[Bushing]
[Marshalling box]
[Transformer oil]

of 6.6 / 0.433 kV
transformers(oil
type/dry type]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[415V NSPBD]
[Bus duct enclosure]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[87]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Bus duct conductor]
[Support insulators]
[Disconnecting
link/flexible]
[support structure]

of NSPBD]
[415V LV Switchgear (PMCC/MCC)]

[Air circuit
breaker/MCCB/SFU/M
CB]
[CT/PT]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[88]
15.01.2016
Power Plant]
Equipment
[Numerical relay]
[AC/DC Starters]
[Electronic over load

relay]
[Transducers]
[Ground bus]
[space heater]
[Switch socket]
Document Number
LII-GETS12021-G-00129-001
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page
No.
Date of Issue
04

[89]
15.01.2016
Power Plant]
Equipment
[Push button station]
[Terminal block]

of LV Switchgear
(PMCC/MCC)]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[HV Cables]
[Joint and termination
kit]

of NSPBD]
[LV Power & Control cables]

[Lugs and Glands]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[90]
15.01.2016
Power Plant]
Equipment

of 415V NSPBD
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Illumination]
[Distribution boards]
[Lighting transformer]
[Aviation warning light

system]
[Emergency light with

self contained
batteries]
[Lamps and fixtures]
[Industrial socket
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[91]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
outlet]
[Fan and regulators]
[Switches and
switchboards]
[Street or road light

poles]
[High mast tower]
[Lighting junction box

and conduits]

of lighting system]
[Grounding & Lightning Protection]

Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[92]
15.01.2016
Power Plant]
[Logo of Utility]
Equipment
Scope of Work
Quantity
[Electrode]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[GI flat/wire]
[Air terminals]
[Clamp/test links]
[Shielding mast]

of earthing and
lightning protection]
Control & Instrumentation Works

[Soot
Blower
Instrumentation]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[93]
15.01.2016
Power Plant]
Equipment
[SADC & Burner TILT]
[Boiler
Temperature
MI Thermocouple ( KType)]
[Combustion Controls
(Coal & Oil)]
[Flame Monitoring and

furnace temperature]
[Boiler Protections]
[Air and
dampers]
Flue
[Furnace
Instrumentation]
Document Number
LII-GETS12021-G-00129-001
gas
Draft
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page
No.
Date of Issue
04

[94]
15.01.2016
Power Plant]
Equipment
[Air Flow Elements (
Venturi or Aerofoil)]
[Acoustic Steam Leak

Detector (ASLD)]
[Mill and Fans Lube oil

instruments]
[Super Heater Steam

Temperature]
[Re-Heater
Temperature]
Steam
[Drum Level Gauges

and Electronic Water
Level indicator (EWLI)]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Junction Boxes/ LIE/

LIRs]
[Pressure/
Document Number
LII-GETS12021-G-00129-001
Diff.
Rev
No.
Description
Page
No.
Date of Issue
04

[95]
15.01.2016
Power Plant]
Equipment
Pressure Transmitters]
[Pressure
Gauges]
DP
[Temperature Gauges]
[Pressure
Switches]
DP
[Temperature
Switches]
[RTD / TC s]
[Instrumentation
Control Cables]
and
[Flow Measurement &

Primary Flow Sensors]
Document Number
LII-GETS12021-G-00129-001
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page
No.
Date of Issue
04

[96]
15.01.2016
Power Plant]
Equipment
[Fuel
Measurement]
Flow
[Flue Gas Analyzers

(O2 and CO)]
[Control Panels (Soot

blowers/ FSSS)]
[Impulse Pipeline and

Fittings]
[Any other systems]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Station C&I (if applicable)

[DCS]
[Station LAN]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[97]
15.01.2016
Power Plant]
Equipment
[Master Clock]
[Panel Earthing /
Grounding]
[PLC System]
[CMMS]
[STMS]
[SWAS]
[Machine Condition
Monitoring System]
Document Number
LII-GETS12021-G-00129-001
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
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Equipment
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Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
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Civil Works
[Boiler Superstructure]
[Boiler Foundation]
[Bunker Building / Bay]
[Coal Mill Foundation]
[PA Fan Foundation]
[FD Fan Foundation]
[ID Fan Foundation]
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Equipment
[ESP Structure]
[ESP Foundation]
[Any other Civil

Structural Work]
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Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
In addition to the above listed works, scope of civil / structural / architectural works and
supplies shall be as detailed below.
Bidder shall carry out a brief or detailed survey (as required) of the site to acknowledge
and obtain any other information/data about present conditions of the buildings,
structures, foundations & facilities mentioned in this Specification and identification of
modification requirements in any other structure or foundation not included here.
Subsequently Bidder shall prepare and submit for approval by Owner, a detailed
scheme including methods techniques, requirements etc. for carrying out
civil/structural/architectural R&M works to executed in the plant.
Bidder shall be provided with the existing drawings and documents as listed in
Annexure-I by the Owner to facilitate the civil / structural / architectural refurbishment
and replacement works.
The scope of Civil / Structural / Architectural works to be carried out by the Bidder
under this package shall generally cover the following:
Inspection and checking the design adequacy of the existing structure foundations like
[boiler, ESP, bunker bay/building, fans and mill foundations, flue gas duct support
foundations etc.] for all the applicable loads and construction of new foundations /
modification of existing, wherever required.
Inspection and checking the design adequacy of existing structures [such as boiler
structures, ESP structures, duct support structures, bunker bay / building structures,
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pipe & cable racks etc.] for any corrosion/damage and rectification / strengthening of
the same.
Carrying out all interior / exterior architectural replacement works [such as flooring,
painting, plastering, door/windows, roof finishing, water proofing, new false ceiling,
glass partitions, lighting works replacement or modification of AC duct where ever
applicable] is also included in Bidders scope. etc.
Any other civil related work required in buildings / structures of the package from
aesthetics ambience & ease of operation point of view.
In addition to this any other modification/alteration to existing nearby
foundation/structural steel/concrete/underground pipes work if required for satisfactory
execution of intended work covered under this Specification shall be carried out by the
Bidder. Supply of all material required for the above work is included in Bidders scope
Supplies for Civil/Structural Work
The Bidder shall supply all material needed for completion of all civil, structural and
Architectural works as per this Specification. The Bidder's scope of supply generally
includes but is not limited to the following:
Supply of cement, steel (for reinforcement as well as for any other use), grout,
admixture for RCC work, sand and all other construction/architectural / building
materials as may be required for any modification of existing civil works / foundation or
for construction of new foundation / civil works.
Supply of structural steel for all structural erection / modification / strengthening.
Supply of all foundation bolts, and nuts base plates, embedments with lugs,
miscellaneous steel where ever needed
Supply of steel helical springs and viscous dampers for new equipment (if any).
Construction Enabling Works
Following facilities shall be made available / constructed as per the requirements for
successful completion of the R&M works.
a) Temporary Site Buildings

The Bidder shall provide at his cost the following buildings/facilities for proper
execution and quality control of the job, while meeting the provision stipulated by
Factory Rules regarding staff welfare facilities. All these buildings shall have brick /
metal cladding. GI/Colour coated metal sheet roofing over steel structure with cement
concrete flooring and false ceiling with air conditioning, as required.
Temporary Stores
A covered store shall be provided with brick cladding and / or GI/Colour coated metal
sheeting to store at least one-month requirement of cement. Cement in bags shall be
stored on a raised floor well away from outer walls and insulated from the floor to avoid
moisture. Not more than 15 bags shall be stacked in any tier. Each consignment of
cement shall be stored separately and consumed in its order of receipt.
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Covered storage area may also be provided to store other construction material, which
will be affected on exposure to wind, sun and rain.
Reinforcement shall be stacked on top of timber sleepers to avoid contact with ground
/ water.
Suitable paving / flooring shall be provided in storage yard for storage of material.
Proper lighting arrangement shall also be provided for the store complex. Proper
fencing and security arrangement shall be provided for the stores complex.
Temporary Workshop and Garage

The Bidder shall provide for a temporary workshop and garage to attend to routine
maintenance and repair of the construction equipment as well as his fleet of vehicles
used for construction activities.
b) Fabrication Yard
Depending on the extent of fabrication envisaged at site, the Bidder shall establish a
full fledged structural fabrication yard with adequate handling facility during and after
the fabrication. A fully equipped testing laboratory providing radiography, ultrasonic,
dye penetration, magnetic particle test facilities shall be ensured adjacent to the
fabrication yard to enforce strict quality control. Portion of the yard shall have covered
shed with H.O.T / E.O.T cranes so that fabrication work can proceed even during
inclement weather.
c) Quality Control Laboratory

A fully equipped quality control laboratory shall be established at site with qualified
personnel to conduct acceptance test on all construction material, weldments,
concrete cubes etc. This laboratory shall be housed in a covered building with A/C
facility as required by the testing facility. All testing equipment shall be periodically
calibrated to the satisfaction of the Owner.
d) Fuel Storage area

The Bidder shall obtain necessary permission from competent authorities and
establish and operate a POL outlet with proper storage, dispensing and adequate fire
fighting facility.
e) Staff Welfare facility

The Bidder shall provide adequate facility for his staff inside the plant boundary such
as toilets for both gents and ladies, canteens, drinking water facility, rest places,
creches etc.
The Bidder shall also provide for proper disposal of sewage and other wastewater
arising from his construction team and his other temporary facilities, to meet with the
requirement of Pollution Control Board.
The Bidder shall identify sufficient area inside the plant boundary to locate his staff and
labour colony. Construction and maintenance of the staff and labour colony to satisfy
all statutory requirement is the sole responsibility of the Bidder.
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The Bidder shall be preliminary responsible for all statutory deductions and
contributions on account of CPF/EPF as per rules/act in force and subsequent
amendments during Contract period.
f) Construction Tools & Materials Supplied By the Bidder

The Bidder shall provide and maintain at the site necessary number and type of
machinery and equipment including survey instruments in good working condition for
proper setting out and timely completion of the various works covered under this
Specification and scope of the work. All arrangements for transporting the equipment
to and from the site shall be done by the Bidder at his own expense. No claim shall be
entertained for mobilizing additional equipment and / or personnel to complete the
work within the stipulated time.
The Bidder shall provide all fuels and lubricants required for the operation and
maintenance of construction machinery and equipment as well as his transport
vehicles at his own cost.
It shall be ensured by the Bidder that work shall proceed uninterrupted even in the
event of power failure. As such, adequate number of liquid fuel operated power
generating equipments shall be provided by the Bidder at his own cost as an
alternative arrangement.
The Bidder shall ensure continuous supply of coarse and fine aggregate conforming to
the Specification.
All materials supplied by the Bidder shall be of the best quality and shall conform to the
given Specifications. Approval in writing shall be obtained from the Owner before any
alternative or equivalent material is used other than what is specifically mentioned in
the drawings / Specification / Bid document.
The Bidder shall furnish manufacturer's test certificate for all the manufactured items
supplied by him. Representative specimens of the material shall also be submitted to
the Owner and shall be tested at a recognised testing laboratory at the Bidder's cost in
case Owner so desire.
The Owner reserves the right to get any construction material supplied by the Bidder
tested in a recognized testing laboratory at the Bidder's cost. In case the sample
materials do not meet the Specification requirements, he shall replace the defective
material at his own cost.
g) Work Execution and Supervision:

The Bidder shall have at the site accredited and qualified engineers and foremen /
supervisors with adequate number of years of experience in execution of similar works
and also operators of machinery and equipment, for satisfactory progress and timely
completion of the works.
The Bidder's Engineer-in-charge of the work at site shall be capable of interpreting the
Specification and drawings and make adequate site decisions as and when required.
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He shall also take instructions from the Owner and be responsible for carrying out the
instructions.
The Bidder shall be fully responsible for the correctness and accuracy of the tests
performed, results obtained / tabulated, interpretation of test results and
recommendations made. The work shall be executed in a professional manner with full
understanding of the importance of work for a R&M project of this magnitude.
In the event of occurrence of any accidents at / near the site of the work or in
connection with execution of the work, a report shall be made immediately to the
Owner, giving full details of the accident. He shall also report such accidents to all the
competent authorities wherever such reports are required by those authorities.
Owner reserves the right to order in writing, from time to time, during the progress of
the work, removal and re-execution of any work which in the opinion of the Owner is
not in accordance with the Specification / Bid document.
During inclement weather, rains etc., the Bidder shall suspend all works for such time
as the Owner may direct and shall protect from damage all works already in progress
or completed just then. All such temporary protective measures shall be at the Bidder's
cost and any damage to works shall be made good by the Bidder at his own expense.
During the course of the Bidder's work, other works, either by the Owner or by other
Bidders or by both simultaneously will be in progress within the Plant area. The Bidder
shall make his best effort to work in harmony with others in the best overall interest of
the project and towards its speedy completion.
h) Mobilisation
All mobilisation costs shall be the Bidder's responsibility and shall include all activities
as described below.
Areas Allocated for the Bidder

The Owner will provide the Bidder with uncovered area at the site for the storage of
plant equipment and materials. The Bidder shall be responsible for preparation of the
site to suit the required purposes.
The areas allocated to the Bidder shall be used solely for construction purposes such
as site offices, prefabrication, maintenance, storage or similar activities. The Bidder
shall not erect in these areas any form of residential or messing facilities.
Transport Conditions
It is the Bidder's responsibility to ensure safe delivery of material upto the worksite.
The Bidder shall make good all damages caused to public, private or government
property e.g. roads etc. caused while transporting equipment etc. up to the work-site.
Temporary Site Services

Prior to erecting any temporary facilities, the Bidder shall submit the detailed drawings
of the proposed temporary facilities and the number of personnel using these facilities,
to the Owner, for approval.
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The Owner shall then decide as to whether the Bidder's proposals comply with the
Owner's requirements.
Communications at Site
Telefax, E-mail and Telephone:

The Bidder shall make his own arrangements for installation of telefax, email and
telephone facility at the Site office and temporary facilities. Where possible, the
Owner's representative may assist the Bidder in obtaining suitable connection. The
Bidder shall pay all associated bills and costs.
Signboards
The signboards shall be approved by the Owner and shall be in Hindi and English. The
signboards shall be removed upon demobilisation.
Medical Facilities
The Bidder shall, within a period of 14 days after mobilisation at work site, provide and
maintain first aid facilities for emergency treatment. The Bidder shall also arrange with
nearby hospital for dealing with emergency cases. The Bidder's staff shall be made
aware of the available first aid facilities and emergency treatment arrangements.
Maintenance
The Bidder shall be responsible for the proper maintenance of all temporary facilities
erected within the allocated areas including the fences, gates, generators, access
roads, etc. constructed by the Bidder. The Bidder shall be responsible for preventing
dust from affecting the existing facilities.
i) Demobilisation of Temporary Facilities:

The Bidder shall demobilise all Bidder's site facilities including, but not limited to, office
buildings, covered areas, workshops, prefabrication shops, storage facilities, toilet
facilities, electrical and water distribution systems, camping upon the completion of
work after intimating the Owner in advance. The Bidder shall reinstate the area to a
clean and tidy condition to the satisfaction of the Owner. The Bidder shall demobiIise
within a reasonable period when advised by the Owner.
Safety of Adjacent Plant/Equipment and Civil Structure
While carrying out the R&M work as per this Specification, the Bidder may have to
modify the existing equipment foundations, or do the excavation work and make new
foundations. The Bidder may also have to make new supporting arrangements with /
without modified loads for the items / equipments supplied by him. Under all such
conditions Bidder shall be solely responsible for ensuring the safety of the adjacent
equipments / foundations and of the existing supporting structures. The R&M work by
the Bidder shall be carried out in such a manner that no damage is caused to existing
equipments / foundations / structures and all precautions, including strengthening of
existing structures, as may be necessary, shall be taken by the Bidder to ensure safety
of existing plant / equipment / foundation / structures.
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4.5.2
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Spares
All spares as specified in Annexure-II of this Specification in accordance with Clause
No. 9.
4.5.3
Consumable, Oil & Lubricants

All the first fill and consumables such as greases, oil, lubricants, servo fluids/control
fluids, gases and essential chemicals etc. as required up to the complete
commissioning of the Boiler & Auxiliaries, are covered in the scope of Bidder. Suitable
standard lubricants as available in India are preferable. Efforts should be made to limit
the variety of lubricants to minimum.
4.5.4
Embedded Parts & Fixture

All fixtures, embedded parts, steel embedment including fixing lugs and welding
between them, foundation plates, grouting, nuts, bolts etc. for fixing all the equipment,
piping on civil works shall be included in scope work of this package. All structures
which would be required by the Bidder for supporting the piping shall also be included
in scope of work of this package.
4.5.5
Other Services
The scope of Erection, Commissioning and Testing shall include the following:
a) Complete pre-commissioning work including tests of facilities such as line flushing,
hydraulic testing of Boiler pressure parts, air and gas tightness tests of Boiler
enclosure, electrostatic precipitators and duct work, chemical cleaning of pressure
parts, steam blowing, gas distribution tests of electrostatic precipitators etc. and all
other tests as mutually agreed in the Bidders quality assurance programme as well as
those identified in the Specification.
b) Supply of all consumables (except coal and fuel oil for firing) like chemicals for
chemical cleaning, passivation, inhibition etc., oil for line flushing, nitrogen for
blanketing, consumables for air/gas tightness tests and any other consumable as
required for above pre-commissioning/ commissioning activities.
c) Necessary arrangement as requires for the start up of Boiler & Auxiliaries. However,
Owner will arrange start up power, coal & fuel oil, instrument & service air and DM
water as required for the star up purpose of the Boiler & Auxiliaries system.
d) Supply of all temporary equipment such as tanks, piping, including supports, valves,
nitrogen blanketing equipment including nitrogen cylinders, pumps and all necessary
instrumentation for successful conductance of pre-commissioning and commissioning
activities. All temporary equipment and instruments shall be clearly listed out in the
Bid.
e) Providing safety barricades and signage during dismantling, erection and testing etc.
f)
Supply of all labour, skilled/semi skilled supervisors, engineers and any other
manpower.
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g) All the erection materials and consumables like shims, welding rods, soldering and
brazing alloys, industrial gases, insulating tapes, compounds, chemicals etc. required
for the erection and commissioning works.
Note: The temporary equipment specifically brought by the Bidder solely for the precommissioning and commissioning work shall, on completion of these activities,
remain the property of the Bidder. Nitrogen blanketing equipment including nitrogen
cylinders shall get included in the Bidders permanent scope of supply and become
property of the Owner.
The selection of material of all the temporary equipment/instruments shall be
compatible with the service conditions expected during pre-commissioning/
commissioning activities.
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TERMINAL POINTS & EXCLUSSIONS
5.1
Terminal Points
[Logo of Utility]
{Terminal points are project specific}

For all terminal points, scope of this Contract shall include supply of matching flanges,
gaskets, bolts, nuts etc including any isolation valve. Terminal Points mean
Engineering, Procurement and Erection in entirety. The terminal points of the complete
package to be supplied shall be as follows.
(a)
Steam & Feed water System
(i)
[Main Steam: Inlet of Main Steam Stop Valve at Turbine hall]
(ii)
[Cold Reheat: Outlet of HP turbine]
(iii)
[Hot Reheat: Inlet of Reheat Steam Stop Valve.]
(iv)
[HP/LP turbine Bypass: Inlet of HP Turbine Bypass Valve and Outlet of HP Turbine
Bypass Valve (Entire upstream and downstream piping of HPTB & LPTB Valve is in
the scope of Bidder).]
(v)
[Blow Down: Boiler blow down tank outlet up to drain pit.]
(vi)
[Feed Water: At Economiser Inlet stop valve.]
(b)
Fuel Firing System:

[Coal-Raw Coal Bunker Inlet Flange, Fuel Oil-20 m from Discharge Flange of
pressurizing pump]
(c)
Mill Reject Handling System:

[Outlet Flange of Mill Spout.]
(d)
Flue Gas Duct

[Inlet Flange of Chimney Flue]
(e)
Ash Handling System:

[Up to Furnace Bottom Ash Hopper, Economiser, Air preheater and ESP Hopper outlet
flanges.]
(f)
Electrical
(i)
[6.6 kV Supply: At the terminal of 6.6kV Unit/Station switchgears for power supply to
6.6 / 0.433 kV transformers and 6.6kV Motors of Boiler package. All Power and control
cables from the terminals of 6.6 kV Unit/Station Switchgears are included in the scope
of Boiler package. 6.6kV Unit/Station Switchgear is in scope of TG package. ]
(ii)
[ESP system terminal point is the outgoing at 6.6 kV Unit switchgear: For ESP system
electrical scope of work shall start from 6.6k V Unit switchgear outgoing and shall
include HV cable termination, HV cable, LV transformer,415 V NSPBD, 415 V LV
switchgear and further distribution]
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(iii)
[Power Supply to Boiler MCC, Boiler Valve MCC, Soot Blower MCC, Boiler Emergency
MCC, Boiler ACDB: Power supply at 415 V level at the outgoing terminals of 415 V
Unit Service Switchgear / 415 V Unit Emergency Switchboard. All cables from the
above terminal points are included in the scope of Boiler package. 415 V Unit Service
Switchgear and 415 V Unit Emergency Switchboard are in the scope of TG package.]
(iv)
[Power Supply to Illumination System of Boiler area: Power supply at 415 V level at the
outgoing terminals of 415 V LV Switchgear. All cables from the above terminal points
are included in the scope of Boiler package. Main Lighting Distribution Board (MLDB)
and further distribution up to and including lighting fixtures is in the scope of TG
Package.]
(v)
[Power Supply to Welding System of Boiler area: Power supply at 415 V level at the
outgoing terminals of 415 V Welding Service Switchgear. All cables from the above
terminal points are included in the scope of Boiler package. Welding Service
switchgear is in the scope of TG Package.]
(vi)
[Power Supply to Bottom Ash Handling System MCC: Power supply at 415V level at
the outgoing terminals of 415 V Ash Handling Service Switchgear. All cables from the
above terminal points are included in the scope of Boiler package. Ash Handling
Service switchgear is in the scope of BOP Package.]
(vii)
[Grounding: Above grounding earthing from riser up to all the equipment under the
scope of Boiler package in scope of Boiler package. Main ground grid and grounding
conductor ring along with two test link at opposite corner of the Boiler switchgear
building/structure shall be in BOP package. Suitable nos. of riser shall be provided by
Bidder.]
(viii)
[For all the inputs required by Boiler Bidder from other packages, the required relay
contacts (1 NO/1 NC) will be provided by the other package Bidder. The required
auxiliary relays, control cables including their laying & termination shall be in the scope
of Boiler package Bidder. Similarly, necessary contact (1 NO/1 NC) required by other
package Bidders shall be provided by Boiler package Bidder.]
(ix)
[Wherever Power is tapped from Owners board or any other package boards, Bidders
scope starts from the outgoing terminals of the respective board. Bidder has to include
all necessary termination materials, cables, trays, conduits, supporting structure,
terminations, and necessary earthing accessories in his scope.]
(g)
(i)
[Inst. & Control Cabling: Up to BMS/FSSS panel for SG integral control systems and
for rest up to Junction Boxes.]
(ii)
[Instruments upto HP turbine Inlet & Outlet (MS & CRH line), IP turbine Inlet (HRH
Line) and HP-LP Bypass systems instruments.]
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5.2
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Exclusions
Following are to be excluded from the scope of work under R&M Works for Boiler &
Auxiliaries:
(a)
[Turbine Generator & Its Auxiliary Equipment including HPTB & LPTB Valve and all
Feed Cycle Equipment]
(b)
[Turbine Extraction piping and Feed Water Piping]
(c)
[Plant Water System including DM plant]
(d)
[Air Conditioning System]
(e)
[Fuel Oil Unloading, Storage & Forwarding System]
(f)
[Compressed Air System]
(g)
[Coal Handling System]
(h)
[Ash Handling System]
(i)
[Distributed Control System (DCS)]
(j)
[Vibration Monitoring System.]
(k)
[6.6kV Unit / Station Switchgears & Unit Auxiliary Switchgears]
(l)
[6.6kV/ 433 V Unit Transformers and 415 V Unit Service Switchgears.]
(m)
[6.6kV / 433 V Lighting Transformers and 415 V Switchgears for lighting]
(n)
[6.6kV / 433 V Welding Transformers and 415 V Welding Service Switchgear.]
(o)
[415 V Ash Handling Service Switchgear]
(p)
[220 V Battery, Battery Charger and Unit DCDB.]
(q)
[Unit UPS and its ACDBs.]
(r)
[Emergency DG sets and 415 V Unit Emergency Switchboard.]
(s)
[Plant communication system]
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GENERAL TECHNICAL REQUIREMENTS
6.1
Codes & Standards
6.1.1
Apart from some specific application, the proposed R&M equipment shall comply with
the appropriate Indian Standard / DIN or equivalent international Standard.
Specification as listed below in this section and mentioned in detailed Specifications,
each incorporating the latest revisions at the time of tendering.
6.1.2
Wherever specified or required the Plant & Equipment shall conform to various
statutory regulations such as Indian Boiler Regulations, Indian Electricity Rules/Act,
Factories Act, etc.
6.1.3
In the event of any conflict between the codes and standards referred above, and the
requirements of this Specification, the requirements, which are more stringent, shall
govern.
6.1.4
In case of any change of code, standards and regulations between the date of
purchase order and the date, the Bidder proceeds with manufacturing, the Owner shall
have the option to incorporate the changed requirements.
6.1.5
List of Reference Codes/Standard

a)
American Society of Mechanical Engineers (ASME).
b)
American National Standards Institute (ANSI).
c)
American Society for Testing and Materials (ASTM).
d)
American Institute of Steel Construction (AISC).
e)
American Welding Society (AWS).
f)
Architecture Institute of Japan (AIJ).
g)
Bureau of Indian Standards Institution (BIS).
h)
British Standards (BS)
i)
Central Board of Irrigation and Power (CBIP) Publications.
j)
Deutsches Institut fr Normung (DIN).
k)
Electric Power Research Institute (EPRI).
l)
Electricity Act 2003.
m)
Emission regulation of Central Pollution Control Board (CPCB)
n)
Federal Occupational Safety and Health Regulations (OSHA)
o)
Heat Exchanger Institute (HEI).
p)
Hydraulic Institute (HIS).
q)
Indian Electricity Rules.
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r)
Indian Boiler Regulations (IBR).
s)
Indian Explosives Act.
t)
Indian Factories Act.
u)
Institute of Electrical and Electronics Engineers (IEEE).
v)
International Electro-Technical Commission Publications.
w)
Instrument Society of America (ISA).
x)
International Organization for Standardization (ISO).
y)
International Electro-technical Commission (IEC).
z)
Japanese Standards (JIS).
aa)
Japanese Electro-technical Committee (JEC).
[Logo of Utility]
bb) National Fire Protection Association (NFPA).

cc)
National Electrical Manufacturer's Association (NEMA).
dd) National Electric Code (NEC).

ee)
Power Test Code for Steam Turbines (PTC).
ff)
Pollution Control regulations of Dept. of Environment, Govt. of India
gg) Regulations of CEA.

hh) Standards of Manufacturer's Standardization Society (MSS).
ii)
Tariff Advisory Committee (TAC) rules.
jj)
Tubular Exchanger Manufacturer's Association (TEMA).
6.2
Name Plates
6.2.1
Instruction plates, nameplates or labels shall be permanently attached to each main

and auxiliary item of plant in a conspicuous position. These plates shall be engraved
with the identifying name, type and manufacturers serial number, together with the
loading conditions under which the item of plant has been designed to operate.
6.2.2
Items such as valves, which are subject to hand operation, shall be provided with
nameplates so constructed as to remain clearly legible throughout the life of the plant
giving due consideration to the difficult climatic conditions to be encountered.
Nameplates shall be securely mounted where they will not be obscured in service by
insulation, cladding, actuators or other equipment. Direction of flow is also to be
engraved.
6.2.3
All trade nameplates and labels shall be in Bilingual language. All measurements shall
be in M.K.S. Units.
6.2.4
The size and location of nameplates shall be subject to Approval of the Owner.
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6.3
Guards and Fences
6.3.1
Effective guards and fences must be provided to prevent injury to operators.
6.3.2
Mesh guards which allow visual inspection of equipment with the guard in place are
generally preferable. The guards shall be constructed of mesh attached to a rigid
framework of mild steel rod, tube, or angle and the whole galvanized to prevent loss of
strength by rusting or corrosion. The guards shall be designed to facilitate removal
and replacement during maintenance.
6.3.3
Guards for couplings and rotating shafts shall be in accordance with BS 5304-1975 or
similar approved standard. All rotating shafts and parts of shafts must be covered.
6.4
Operation, Maintenance & Availability
6.4.1
Equipment/works offered shall be designed for high availability, high reliability, low
maintenance and ease of operation & maintenance. The Bidder shall specifically state
the design features incorporated to achieve high degree of reliability, availability,
operability and ease of maintenance. He shall also furnish details of availability records
in plants stated in his experience list.
6.4.2
Wherever required platforms and walkways with access ladders having hand rails shall
be provided to facilitate operation and maintenance.
6.5
Materials
6.5.1
In selecting materials of construction of equipment, the Bidder shall pay particular

attention to the atmospheric conditions existing at the Site and the nature of
material/fluid handled. Wherever deviations are taken in respect of materials
specified, the reasons shall be spelt out clearly in the proposal.
All materials shall be new, and shall be of the quality most suited to the proposed
application.
6.5.2
As far as possible; materials shall be in accordance with Indian or international

standard Specifications.
Where such standards are not available, sufficient
information shall be provided to allow the Owner to assess the suitability of the
material for the particular application.
All materials used shall have performed lengthy satisfactory service in similar or more
arduous conditions to those proposed by the Bidder.
6.5.3
All parts which could deteriorate or corrode under the influence of the atmospheric,
meteorological or soil conditions at the Site, or under the influence of the working
conditions shall be suitably and effectively protected so that such deterioration or
corrosion is a minimum over the life of the plant.
6.6
Lubricants, Control Fluids and Chemicals
6.6.1
Provision shall be made for suitable efficient lubrication where necessary to ensure
smooth operation free from undue wear.
6.6.2
Non ferrous capillary tubing shall be used throughout.
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6.6.3
Oil baths shall be provided with filling and drain plugs, both of adequate size. An
approved means of oil indication including level switches and temperature indication
shall be provided.
6.6.4
Lubrication points shall be conveniently situated for maintenance purposes. It must be

possible to carry out lubrication from a gangway or landing and without the removal of
guarding or having to insert the hand into it. Where accessibility to a bearing for oiling
purposes would be difficult a method of remote lubrication shall be fitted.
6.6.5
The Bidder shall provide a detailed and comprehensive Specification for all lubricating
oils, greases and control fluids required for Boiler & Auxiliaries. A sufficient supply of
these shall be provided by the Bidder for initial commissioning, first fill and till handing
over of the unit.
6.6.6
Chemicals for Boiler Water conditioning for operation of the Boiler shall be provided by
the Owner. However, chemicals for Boiler cleaning shall be arranged by Bidder.
6.6.7
The Bidder shall supply a detailed schedule giving the lubricant testing, cleaning and
replacement procedures. All equipment and facilities necessary for the testing,
cleaning and changing of lubricants and control fluids shall be provided. The Bidder
shall endeavour to reduce the varieties and grades of required lubricants, chemicals
and control fluids to a minimum, matching them where possible to those already in use
in the generating station in order to simplify procurement and minimize storage
requirements. All lubricants, chemicals and control fluids shall be of internationally
recognized standards and shall be easily obtainable from a large number of Indian
suppliers. Bidder shall also indicate the equivalent Indian Standard for the above for
easy procurement in future.
6.6.8
No lubricant or control fluid shall have toxic or other harmful effects on personnel or on
the environment.
6.7
Plant Life and Modes of Operation
6.7.1
On completion of the R&M project, the plant/equipment and systems individually and
collectively shall be possible to operate continuously with routine maintenance and
overhauls for an economic service life of not less than [20/25 years] under the
prevailing site conditions and for the type of duty intended.
6.7.2
After R&M of Boiler and associated auxiliaries, the unit shall be able to operate to its
rated capacity continuously and there shall be no restriction of the operation of the unit
during Base Load, Peak Load & Cyclic Load operation.
6.7.3
The capability of the unit operations including Cold, Hot & Warm Startups shall be in
no way inferior to its original design capabilities. Accordingly, Bidder shall indicate the
operation capabilities in various regime of operation in his Bid.
6.8
Packaging & Marking

All the equipment shall be suitably protected, coated, covered or boxed and crated to
prevent damage or deterioration during transit, handling and storage at site till the time
of erection. While packing all the materials, the limitations from the point of view of
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availability of railway wagon sizes in India should be taken account of. The details of
various wagons normally available with Indian Railways for transportation of heavy
equipment shall be considered by the Bidder. The Bidder shall be responsible for all
loss or damage during transportation, handling and storage due to improper packing.
The identification marking indicating the name and address of the consignee shall be
clearly marked in indelible ink on two opposite sides and top of each of the packages.
In addition the Bidder shall include in the marking gross and net weight, outer
dimension and cubic measurement. Each package shall be accompanied by a packing
note (in weather proof paper) quoting specifically the name of the Bidder, the number
and date of Contract and names of the office placing the Contract, nomenclature of
contents and Bill of Material.
6.9
Protection
Equipment having antifriction or sleeve bearings shall be protected by weather-tight
enclosures. Coated surfaces shall be protected against impact, abrasion, discoloration
and other damages. Surfaces that are damaged shall be repainted.
Electrical and C&I equipment shall be protected against moisture and water damages.
All external gasket surfaces and flange faces, couplings, rotating equipment shafts,
bearings and like items shall be thoroughly cleaned and coated with rust preventive
compound as specified above and protected with suitable wood, metal or other
substantial type covering to ensure their full protection. All exposed threaded parts
shall be greased and protected with metallic or other substantial type protectors.
All piping, tubing and conduit connections on equipment and other equipment
openings shall be closed with rough usage covers or plugs. Male threaded openings
shall be closed with rough usage covers or plugs. Female threaded openings shall be
closed with forged steel plugs. The closures shall be taped to seal the interior of the
equipment. Open ends of piping, tubing and conduit shall be sealed and taped.
Returnable containers and special shipping devices shall be returned by the
manufacturer's field representative at the Bidder's expense.
6.10
Painting
6.10.1
General
All exposed metallic surfaces subject to corrosion shall be protected by shop
application of suitable coatings. Surfaces not easily accessible after shop assembly
shall be treated before-hand and protected for life of the equipment. Surfaces to be
finish painted after installation shall be shop painted with at least two (2) coats of
primer. Steel surfaces, which are not to be painted, shall be coated with suitable rust
preventive compound subject to the approval of the Owner.
All paints shall be used in accordance with the manufacturer's instructions. No thinners
or other substance shall be added to the coating material without the approval of the
Owner. The quality and vendor of the paints shall require approval of the Owner.
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All paints, when applied in a normal full coat, shall be free from runs, sags, wrinkles,
patchiness, brush marks or other defects.
All primers shall be well marked into the surface, particularly in areas where pitting is
evident, and the first priming coat shall be applied as soon as possible after cleaning,
within four hours maximum. If the drying interval between successive coats, which
should not exceed one week, has been so long as to endanger the adhesion of the
following coat, the paint already applied shall be lightly rubbed down with fine abrasive
paper before putting on the next coat.
Paint spraying on large surfaces shall not normally be done indoors, except with the
approval of the Owner. Spray guns shall not be used outdoors in windy weather or
near unprotected surfaces of a contrasting colour and under no circumstances shall
spray guns be used where spray may be carried into or onto exposed electrical
equipment.
Paint containers shall not be opened until required and the paint shall be mechanically
mixed thoroughly before use, and agitated occasionally during use.
Electrical equipment shall be shop finished with one or more coats of primer and two
coats of high-grade oil resistant enamel. The interior of all panels cabinets and
enclosures shall be finished with gloss white enamel.
The Bidder shall furnish sufficient touch up paint for one complete finish coat on all
exterior factory surfaces of each item of equipment. The touch up paint shall be of the
same type and colour as the factory applied paint and shall be carefully packed to
avoid damage during shipment. Complete painting instructions shall be furnished.
Shop primer for steel and iron surfaces which will have a continuous operating
temperature below 35 C shall be selected by the Bidder, in accordance to the
relevant standard. Special high temperature primer shall be used on surface exposed
to operating temperature above 35 C.
The colour scheme shall be submitted during execution of Contract for approval by the
Owner.
6.10.2
Preparation
Oil and grease shall be removed from the surface by washing with a suitable
detergent, rinsing with clean water, and drying.
Surfaces to be shot blasted shall be cleaned to Swedish Standard SA 2.5 or
equivalent, and all dust remaining after cleaning shall be removed.
The priming coat shall be applied without delay.
6.10.3
Damaged Paintwork
Any damaged paintwork shall be corrected / modified as follows:
a)
The damaged area, together with an area extending 25mm around its
boundary, shall be cleaned down to bare metal.
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6.10.4
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b)
A priming coat shall be immediately applied, followed by a full paint finish equal
to that originally applied and extending 50mm around the perimeter of the
original damage.
c)
The repainted surface shall present a smooth surface. This shall be obtained
by carefully chamfering the paint edges before and after priming.
Painting Systems
The requirements for the dry film thickness (DFT) of paint and the materials to be used
shall be as stated below, unless otherwise specified elsewhere in this Specification.
a) Surfaces Subject to Weathering
All surfaces shall have a minimum of four coats of paint made up as follows:
Primer coat
35 micron DFT
Tie coat
35 micron DFT
Finishing coat (2 Nos.)
35 micron DFT per coat
The total minimum DFT shall be 140 micron.

b) Surfaces Inside Buildings
Primer coat
35 micron DFT
Tie coat
35 micron DFT

The type and colour of primer & finish coat shall be selected by the Bidder after
approval by the Owner.
6.11
Environment Protection
6.11.1
The plant & equipment under this R&M project shall be designed for installation and
operation in harmony with the surrounding environment and all measures of pollution
control shall be ensured by the Bidder to restrict pollution from the liquid effluent and
stack emission within the limits as given below with due consideration of Environment
(Protection) Rules.
6.11.2
For Liquid Effluent

During construction activities, Bidder shall maintain the statuary compliance of State
Pollution Control Board and MoEF in respect of pollution control and environmental
protection within and around plant boundary. Any specific requirement of State
Pollution Authorities over and above shall be maintained.
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6.11.3
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For Air Quality

{Utilities to mention the Limit for SPM and NOx at Stack emission and Ground level
concentration for SOx, NOx, SPM, RPM as stipulated by State Pollution Control
Board.}
a)
Suspended Particulate Matter i.e. dust burden at chimney outlet Maximum []

mg/Nm3 (with worst coal and one field out in each path).
b)
NOx - Shall not exceed [] gm/GJ at 6% excess O2 dry at chimney outlet.

In absence of Indian Standard for emission from power plants as on date, for certain
gaseous effluents, the internationally accepted World Bank Standard is to be followed.
6.11.4
Noise Level Requirement

The plant & equipment under this R&M project will be designed, constructed and
provided with suitable acoustic measures to ensure the noise level criteria as per the
following stipulations of MoEF & State Pollution Control Board.
a) Maximum noise level shall not exceed 85 dB (A) when measured at 1.0 m away from
the noise emission source.
b)
Maximum noise level from its source within the premises shall not exceed 70 dB (A) as
per Environment (Protection) Rules 1986, Schedule-III, Àmbient Air Quality
Standards in respect of noise.
c)
Any statutory changes in stipulations regarding noise limitation that may occur in future
according to State Pollution Control Board or Central pollution Control Board or
Ministry of Environment & Forest regulation during tenure of the Contract, the Bidder
shall comply with the updated/amended requirement.
An exception will be made for the plant at startup operations of other big pressure
reducing devices operating during emergency periods and for the safety valves.
6.12
Inspection and Testing
6.12.1
Inspection and Tests during Manufacture
6.12.1.1
The method and techniques to be used by the Bidder for the control of quality during
manufacture of all plant and equipment shall be agreed with the Owner prior to the
Award of Contract.
6.12.1.2
The Owners general requirements on quality control and shop tests as mentioned in
Section II of Volume-II.
6.12.1.3
Owner shall be informed for witnessing the shop tests of any item of the plant or
equipment for checking the compliance with the Specification requirement and or
related standards prior to leave place of manufacturing.
6.12.1.4
Advance notice shall be given to the Owner as agreed in the Contract, prior to the
stage of manufacture being reached, and the piece of plant must be held at this stage
until the Owner has inspected the piece, or has advised in writing that inspection is
waived. If having consulted the Owner and given reasonable notice in writing of the
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date on which the piece of plant will be available for inspection, the Owner does not
attend, the Bidder may proceed with manufacture having forwarded to the Owner duly
certified copies of his own inspection and test results.
6.12.1.5
The Bidder shall forthwith forward to the Owner the Test Certificates in [] copies for
approval..
6.12.1.6
Under no circumstances any repair or welding of castings be carried out without the
consent of the Owner. Proof of the effectiveness of each repair by radiographic and/or
other non destructive testing technique, shall be provided to the Owner.
6.12.1.7
All the individual and assembled rotating parts shall be statically and dynamically
balanced in the works.
6.12.1.8
Where accurate alignment is necessary for component parts of machinery normally

assembled on site, the Bidder shall allow for trial assembly prior to dispatch from place
of manufacture.
6.12.1.9
All materials used for the manufacture of equipment covered under this Specification
shall be of tested quality. Relevant test certificates shall be made available to the
Owner. The certificates shall include tests for mechanical properties and chemical
analysis of representative material.
6.12.1.10
All pressure parts connected to pumping main shall be subjected to hydraulic testing at
a pressure of 150% of design pressure. The duration of the pressure tests shall be
sufficient, as approved by the Owner, to show any leakage paths and to permit a
thorough examination of the component whilst under pressure.
6.12.1.11
All necessary non destructive examinations shall be performed to meet the applicable
code requirements.
6.12.1.12
All welding procedures adopted for performing welding work shall be qualified in
accordance with the requirements of Section-IX of ASME code or IBR as applicable.
All welded joints for pressure parts shall be tested by liquid penetrant examination
according to the method outlined in ASME Boiler and Pressure Vessel code.
Radiography, magnetic particle examination magnuflux and ultrasonic testing shall be
employed wherever necessary/ recommended by the applicable code. At least 10% of
all major butt welding joints shall be radio graphed. Payments in respect of IBR
approvals including inspection shall be made by Owner. Bidder scope shall be limited
to preparation of all necessary documents, coordination and follow up for above
approvals.
6.12.1.13
The Bidder shall furnish the quality procedures to be adopted for assuring quality from
the receipt of material at site, during storage, erection, pre-commissioning to tests on
completion and commissioning of the complete system/equipment.
6.12.2
Performance Tests at Site
6.12.2.1
The full requirements for testing the system shall be agreed between the Owner and
the Bidder prior to Award of Contract. The completely erected System shall be tested
by the Bidder on site under normal operating conditions. The Bidder shall also ensure
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the correct performance of the System under abnormal conditions, i.e. the correct
working of the various emergency and safety devices, interlocks, etc.
6.12.2.2
The Bidder shall provide complete details of his normal procedures for testing, for the
quality of erection and for the performance of the erected plant. These tests shall
include site pressure test on all erected pipe work to demonstrate the quality of the
piping and the adequacy of joints made at site.
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LAYOUT CONSIDERATION
{Effort should be given to keep the Layout of the newly equipped system / packages
under the R&M project unchanged to the extent possible with respect to existing layout
to avoid disturbance to the existing equipment & facilities for which any
modification/changes are not envisaged based on RLA/LA and EA assessment.
However general guidelines, which need to be followed, as required, are given below :}
The broad salient features of the existing and expected layout arrangements of various
equipment in the main plant building housing the turbine generator and its auxiliaries
and Boiler area are given as hereunder:
7.1
The arrangement of the turbine- generator in the main plant building is of [longitudinal
type]. The boiler centre line is in the [same as that of TG condenser]. Unit pitching
distance between centre lines of two boilers is [approximately 120m]. The column
spacing of main plant building is [about 10 m].
7.2
[The conventional arrangement of AB, BC and CD longitudinal bays with D row as first
row of boiler columns is adopted with their respective widths of about 30m, 10m and
11m. The mill bunker buildings shall be about 12m wide on each side of the boiler].
7.3
[Two transverse bays at 0.0 m elevation equivalent to minimum area of .m2 has
been provided for unloading and maintenance at one end of main plant building].
7.4
[The location of control room (common for two units) is in BC bay at the operating floor
level. Adjoining the control room, there is a control tower which accommodates control
equipment room, AC plant room, battery room and UPS for C&I system, cable vault
etc. at its different floor levels].
7.5
The local pits/trenches in main plant building/ mill bunker bay building/ boiler/ ESP
area is to be avoided as far as possible.
7.6
Clear walk ways of minimum 1.5 m width at all the levels shall be provided in the main
plant building. Adequate fire escape staircases shall be provided with fire doors at
each landing.
7.7
[Interconnecting walkways (minimum 2.0 m clear) shall be provided between main

plant building and boiler on either side of boiler at three elevations viz. mezzanine,
operating and deaerator floor levels. Two nos. walkways each shall be provided on
either side of the boiler between boiler and mill bunker building at feeder floor level,
tripper floor level and roof of mill bay].
7.8
[The layout arrangement of critical piping connecting the Boiler and steam turbine shall
be developed in such a way as to optimize the use of materials and resulting in
minimum pressure losses in the steam flow].
7.9
In the boiler area, facility of crane/ chain pulley block/ monorail hoist etc. shall be
provided along with provision of space for maintenance/ overhauling of equipment
such as mills, coal feeders, boiler circulation pumps, fans, motors, and handling of
APH baskets and coils of economizer and SCAPH etc.
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7.10
Clear approach width of minimum 10m with 8m clear height shall be maintained at the
front and rear of ESP.
7.11
[The VFD control equipment and transformers for radial type ID fans, if provided, shall
be located along with the ESP control equipment in the ESP control room].
7.12
Trestles to be provided for routing of cables, pipes etc. shall have a clear height of
8.0m at road crossings so as to clear the road spaces, approach to maintenance bays
of different equipment. A walkway with hand rails and toe guards of 750mm (minimum)
width shall be provided all along length of the trestle for maintenance of cables and
pipes. Ladders for approach to these platforms shall be provided near roads, passage
ways.
7.13
Floor drains shall be provided at all floors and drain discharge pipes shall be properly
sized taking into account the fire water sprinkler system wherever provided.
7.14
Valves shall be located in accessible positions. All piping shall be routed at a clear
height of minimum 2.5 m from the nearest access level for clear man movement. Best
engineering practices shall be adopted for keeping the minimum clear working space
around equipment and clear headroom within main structures and cable trays etc.
7.15
Fire water pipes in main plant area may be routed in trenches filled with sand and
covered with pre-cast RCC covers.
7.16
The safety requirements as per the Factories Act, Indian Electricity Rules and other
applicable codes/standards etc. shall be observed while developing the layout.
7.17
The available existing layout details of the plant are indicated in the enclosed drawings
as Annexure-I. However, Bidder to suggest his own modified layout arrangement
which shall be subject to approval of the Owner.
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PERFORMANCE GUARANTEES
The term "Performance Guarantees" wherever appears in this Section shall have
the same meaning and shall be synonymous to "Functional Guarantees".
Similarly the term "Performance Tests" wherever appears in this Section shall
have the same meaning and shall be synonymous to "Guarantee Test(s)".
The term BMCR (Boiler Maximum Continuous Rating) appearing in the
Technical Specification shall mean the maximum continuous steam output at
super heater outlet of Boiler at rated parameters.
The term "TMCR" (Turbine maximum continuous rating) appearing in the
Technical Specification shall mean [210/215/220/250] MW electrical power
output at generator terminals under 0% cycle make-up and [76] mm Hg (abs)
condenser pressure, unless used in conjunction with a different cycle make-up.
8.1
General Requirements
8.1.1
The Bidder shall guarantee that the equipment offered shall meet the ratings and
performance requirements stipulated for various equipment covered in this
technical Specifications.
8.1.2
The guaranteed performance parameters furnished by the Bidder in the Bid

proposal, shall be without any tolerance values and all margins required for
instrument inaccuracies and other uncertainties shall be deemed to have been
included in the guaranteed figures.
8.1.3
The Bidder shall demonstrate all the guarantees covered herein under Category
I, II & III during functional guarantee / acceptance test. The various tests which
are to be carried out during performance guarantee/acceptance test are listed
elsewhere in this -Section. The guarantee tests shall be conducted by the Bidder
at site in presence of Owner on the unit.
8.1.4
All costs associated with the tests including the cost associated with the supply,
calibration, installation and removal of test instrumentation shall be included in
the price offered by Bidder.
8.1.5
At all times during the Performance Tests the emissions and effluents from the
Plant shall not exceed the Guaranteed Emission and Effluent Limits.
8.1.6
It shall be the responsibility of the Bidder to make the plant ready for the
performance guarantee tests.
8.1.7
All instruments required for performance testing shall be of the type and accuracy
required by the code and prior to the test, the Bidder shall get these instruments
calibrated in an independent test institute approved by the Owner. All test
instrumentation required for performance tests shall be supplied by the Bidder
and shall be retained by him upon satisfactory completion of all such tests at site.
All calibration procedures and standards shall be subjected to the approval of the
Owner. The protecting tubes, pressure connections and other test connections
required for conducting guarantee test shall conform to the relevant codes.
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8.1.8
Tools and tackles, thermo wells (both screwed and welded) instruments/devices
including flow devices, matching flanges, impulse piping & valves etc. and any
special equipment, required for the successful completion of the tests, shall be
provided by the Bidder free of cost.
8.1.9
The Performance/ Acceptance test shall be carried out as per the agreed
procedure. The PG test procedure including demonstration tests shall be
submitted within [90 days] of the date of Notification of Award and finalization of
the PG test procedure shall be done within [180 days] from the date of
Notification of Award. After the conductance of Performance test, the Bidder shall
submit the test evaluation report of Performance test results to Owner promptly
but not later than one month from the date of conductance of Performance test.
However, preliminary test reports shall be submitted to the Owner after
completing each test run.
8.1.10
The PG test procedures shall be submitted for equipment/ system & subsystem
under Bidder's scope for all Guarantees under category I, II & Ill as mentioned
below, as per latest International codes & standard including correction curves,
meeting the Specification requirements along with sample calculations & detailed
activity plan of preparation (including test instrumentation), conductance and
evaluation of Guarantees.
8.1.11
The Bidder shall submit for Owner's approval the detailed Performance Test
procedure containing the following:
8.1.12
Objective of the test.
Various guaranteed parameters & tests as per Contract.
Method of conductance of test and test code.
Duration of test, frequency of readings & number of test runs.
Method of calculation.
Correction curves.
Instrument list consisting of range, accuracy, least count, and location of

instruments.
Scheme showing measurement points.
Sample calculation.
Acceptance criteria.
Any other information required for conducting the test.
In case, during performance guarantee tests, it is found that the

equipment/systems has failed to meet the guarantees, the Bidder shall carry out
all necessary modifications and/or replacements to make the equipment/system
comply with the guaranteed requirements at no extra cost to the Owner.
However, if the Bidder is not able to demonstrate the guarantees, even after the
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above modifications/replacements within [ninety (90) days] or a reasonable

period allowed by the Owner after the initial performance guarantee tests have
been completed, the Owner will have the right to impose the stipulated clauses
under Guarantee Category I, II & III as specified in this Specification:
For Category-I Guarantees
8.1.13
Reject the equipment/system/plant and recover from the Contractor payments already
made.
(OR)
Accept the equipment/system/plant after levying Liquidated Damages (LD) as
specified in Clause No. 5.6 of Volume I. The LDs shall be prorated for the fractional
parts of the deficiencies.
For Category-II Guarantees
8.1.14
Reject the equipment/plant/system and recover, from the Contractor, the payments
already made. Conformance to the performance requirements under Category-II is
mandatory.
For Category-III Guarantees
8.1.15
Reject the equipment/system/plant & recover, from the Contractor, the payments
already made.
(OR)
Accept the equipment/system after assessing the deficiency in respect of the various
ratings, performance parameters and capabilities and recover from the Contract price
an amount equivalent to the damages as determined by the Owner. Such damages
shall however be limited to the cost of replacement of the equipment/systems
replacement of which shall remove the deficiency so as to achieve the guaranteed
performance.
8.2
Performance Guarantees under Category-I

The performance guarantees which will attract liquidated damages shall be as follows:
(i)
Boiler steaming capacity in Tons per Hour (TPH) of steam at 100% BMCR at rated
steam parameters at superheater outlet and at rated steam temperature at reheater
outlet (with any combination of mills working as per Owners discretion) with the coal
being fired from within the range specified in the Technical Specifications.
(ii)
Efficiency of the Boiler at 100%TMCR unit load at 0% Make-up with site design
ambient condition, while firing the design coal, at rated steam parameters at
superheater outlet and at rated steam temperature at reheater outlet, and rated
excess air.
(iii)
Auxiliary Power Consumption for Boiler & its Auxiliaries at 100% TMCR unit load at
condenser pressure of [76] mm Hg (abs) with 0% make-up and with design ambient air
condition.
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Note: Power consumption of each of the pump/fan/compressors etc. wherever

mentioned shall be measured with its own drive.
8.2.1
Limit of Technical Parameters under Liquidated Damages Applicable For

Category-I Guarantees:
Table: 8.1
S.No.
Performance Limit
Boiler Capacity in TPH at rated

Shortfall beyond [1%] of guaranteed
parameters
at
superheater
value
outlet, the coal being fired from
[(i.e. 1.0 %)]
the range specified.
Shortfall beyond [0.5%] of guaranteed

value
[(i.e. 0.5 %)]
Auxiliary Power
Increase beyond [5%] of guaranteed

value/.
[(i.e. + 5.0 %)]
8.2.2
Parameter
Specific and Limiting Requirements For Boiler Efficiency

{Efficiency of the Boiler should be determined by Heat Loss Method as per the
ASME Code PTC 4 discussed below.}
The efficiency quoted by the Bidder shall comply with following limiting
parameters with design coal firing:
Table: 8.2
S.No
Detail
Description
1.
Excess air at economizer [20%] (min.)

outlet at [105% & 100%
TMCR load]
2.
Corrected
flue
gas [135 degree C] or as predicted by
temperature at air preheater the Bidder whichever is higher
outlet at [105% & 100%
TMCR]
3.
Boiler Efficiency Loss due to [1.0%] (min.)

unburnt carbon
Bidder to note that no credit shall be given in the Bid evaluation

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evaluation of the results of the guarantee tests for performance predictions/

guarantees etc. if the values considered by the Bidder for parameters indicated
above are lower than those specified above.
For the purposes of guarantees the ambient air temperature and relative humidity
shall be taken as [27 degree Celsius and 60%] respectively.
Unless otherwise specified, the guarantees shall be based on design coal firing
with coal/ ash analysis as given with this Technical Specification.
The performance guarantee test will be carried out within three months after the
successful completion of Initial Operation of facilities or as per the time frame
specified for a particular equipment/ plant/ system in the Technical
Specifications. Delay in conductance of the test beyond this period will not be
normally permitted by the Owner. In the event of Owner agreeing to conductance
of such tests after three months, for reasons not attributable to the Owner, as
assessed by the Owner, no factor for ageing shall be considered for computing
performance of the equipment.
Note: In addition to above, major requirements/ method of Boiler Efficiency Tests
i)
Ambient air condition :
[27 degree Celsius temperature (Dry bulb)

and 60% relative humidity]. The reference air
temperature for the Boiler efficiency
guarantee / testing shall be taken as the
temperature of air (i.e. [27 degree Celsius])
entering PA and FD fans.
ii)
No. of readings
Two sets of consistent readings for each of

test loads. Average of the test efficiencies
based on above two readings for each load
shall be considered for Boiler efficiency.
iii)
Measurement and computation of heat losses will include but not be limited to
the following:
A.
ASME Code PTC 4 Guidelines

Boiler Efficiency should be worked out by determining the total heat loss.
Total Heat Loss consists of the following items:
i)
Heat Loss due to dry flue gases.
ii)
Heat Loss due to evaporation of moisture in fuel.
iii)
Heat Loss due to hydrogen in fuel.
iv)
Heat Loss due to moisture in Air.
v)
Heat Loss due to incomplete combustion to CO.
vi)
Heat Loss due to un-burnt carbon.
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vii)
Heat Loss due to mill (pulveriser) rejects.
viii)
Heat Loss due to Radiation and convection (Difficult to evaluate. Hence

Design Value [normally 0.18%] should be considered.)
The Efficiency of Steam Generator should be worked out by the following equation.
Efficiency = 100 - % Losses of Heat Input.
Locations of Installing Measuring Instruments:
For conducting the Boiler Efficiency Test, following locations should be used for
the measuring instruments and for collecting the samples:
installing
Flue gas analysis at the air pre-heater inlet and outlet for measuring O2, CO & CO2.
Temperature of flue gas at air pre-heater inlet and outlet.
Fly ash sampling at Economizer outlet and ESP Hoppers for unburnt carbon in fly ash.
Sampling of bottom ash from hopper or scrapper.
Sampling of raw coal from RC feeder of the mill for proximate and ultimate analysis of
fuel and finding its Gross Calorific Value (GCV).
Pulverised coal samples from each mill for sieve analysis.
Sample of mill rejects for finding GCV.
Notes:
(i)
(ii)
iv)
Before the Efficiency Test is conducted, the contractor will submit a

detailed procedure for conducting the test which will be subject to the
approval of the owner. Among other things, the procedure will also
include the type of instruments to be used and the locations of various
measuring instruments and sampling points.
During the Efficiency Test, the Steam Generator blow downs and the use
of auxiliary steam for purposes like soot blowing should be stopped,
since, accurate evaluation of heat loss due to these items is difficult.
(iii)

calibration should be certified by Govt. Accredited Laboratories i.e. NABL
approved laboratories.
(iv)
During the test, the operating parameters should be kept stable and close
to design parameters.
(v)
During the Boiler Efficiency Test, quality of fuel to be used should be as

close as possible of the design quality.
Correction to tested efficiency shall be applicable for variation in following

parameter only:
Ambient air temperature.
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8.2.3
Relative humidity of ambient air.
Hydrogen in coal.
Moisture in coal.
GCV of coal.
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Auxiliary Power Consumption

The respective auxiliary power consumption as is illustrated hereunder:
a) Auxiliary Power Consumption
The auxiliary power consumption shall be calculated using the following
relationship.
Pau
Pu
Pau= Guaranteed Unit Auxiliary Power Consumption.

Pu= Power consumed by each of the continuously running equipment of Boiler &
Auxiliaries.
While guaranteeing the auxiliary power consumption, the Bidder shall necessarily
include all continuously operating equipment of Boiler & auxiliaries. The
auxiliaries to be considered shall include but not be limited to the following:
a)
Mills (Number of Mills to be considered in operation will correspond to the

number of mills required to be operated for design coal).
b)
PA Fans
c)
FD Fans.
d)
ID Fans.
e)
Air Heaters.
f)
Coal Feeders.
g)
Boiler Start up drain recirculation Pumps (If applicable).
h)
Seal Air Fans.
i)
Lube oil pumps for fans/ Air heaters & mill system etc.
j)
Scanner air fans.
k)
Electrostatic Precipitator with all ESP fields of all ESP passes working and
rapping system in normal operation (as measured at the input terminals of the TR
set. Refer Note 3 below).
l)
Gas Recirculation Fan (if applicable)
m)
DM Cooling (normally working) Water pumps to supply cooling water on the

primary (DM) side of the plate type heat exchangers in the closed loop
Equipment cooling dedicated to Boiler & Auxiliaries.
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n)
Auxiliary Cooling (normally working) water pumps to supply cooling water on the
secondary side of the plate type heat exchangers in the closed loop Equipment
cooling dedicated to Boiler & Auxiliaries.
o)
Power consumption of any other continuously operating auxiliary for Boiler and
its Auxiliaries operation at 100% TMCR.
Note:
1.
The Bidder shall furnish a list of equipment to be covered under Unit auxiliary
power consumption, which shall be subject to Owner's approval.
2.
The Bidder shall ensure that power supply to all such equipment to be covered
under auxiliary power consumption is fed from unit board.
3.
Method of Computation of Auxiliary Power consumption for ESP:For guarantee purpose, total maximum continuous Auxiliary power consumption
will be the power consumption of corona power (excluding power consumption by
hopper heaters, insulator heaters, rapping system, ventilation fans etc.) of all
fields of all passes of ESPs for one unit. Corona power of TR sets will be
computed at the input terminals of the TR sets when all ESP fields of all ESP
passes are working and rapping system is in normal operation at the guarantee
point condition. The measurement for guaranteed auxiliary power consumption
shall be carried out during ESP collection efficiency test. The method for
computing the corona power shall be as described below:a) Power consumption of TR sets will be measured pass wise and for one pass
(Say ESP-A) at a time with the help of energy meter in ESP MCC.
b) Energy meter reading will be taken before starting the collection efficiency test
and after completion of collection efficiency test.
c) Before starting collection efficiency test, switch off all the TR sets serving to
one pass (ESP-A) temporally and note down energy meter readings for period
t1 i.e. E1. Power consumed by hopper heaters, shaft and support insulator
heaters and rapping systems shall be W1 = E1/t1.The time period t1 shall be
minimum 4 hours.
d) During the collection efficiency test the total energy fed in to ESP MCC of one
pass (say ESP-A) will be measured during entire period of collection efficiency
test i.e. E2. Total time period (t2) of test shall be noted. The power
consumption shall be W2=E2/t2. During this period, no change in the status of
hopper heaters, insulator heaters, rapping system, ventilation fans etc. will be
allowed w.r.t. the condition at clause c) above. In case there is any change in
the status of hopper heaters, insulator heaters, rapping system, ventilation fans
etc., then auxiliary power consumption test will be repeated again.
e) Measured corona power consumption for one pass (say ESP-A)=(W2-W1)
f)
Measured corona power of one unit= Corona power of (ESP-A + ESP-8 + ESPC +ESP-D + ESP-E + ESP-F).
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8.3
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Guarantees under Category-II

The Performance Guarantees, conformance to which is mandatory are as
follows:
i.
Particulate Emission/ ESP Efficiency

Maximum [] mg/Nm3] (With worst coal and one field out in each path)
The performance test on electrostatic precipitator will commence after a
minimum period of fifteen hundred (1500) hours of continuous operation after
completion of initial operation. During the interval between the commencement
of initial operation and the commencement of performance test only routine
maintenance shall be carried out. No physical or chemical cleaning of ESP
shall be permitted during this period or immediately before the conductance of
the performance tests.
The test efficiency shall be based on the overall performance of the
electrostatic precipitator over a mutually agreed period of operation under the
conditions given in this Specification and allowing the normal operation of the
unit including rapping and normal soot blowing and/or when fuel oil is being
fired in the igniters and/or warm up guns.
The overall test efficiency and test temperature/inlet dust burden for one set of
ESP passes (streams) serving one Boiler shall be worked out as follows:-
a) Vm (guarantee point test flow) shall be the total of inlet gas flows to, say six
gas streams at the time of test.
b) Test inlet dust burden (Di) shall be weighted mean of the inlet dust burdens for
the individual streams i.e.:
{(Vm1*Di1)+(Vm2*Di2) + (Vm3*Di3)+(Vm4*Di4)+(Vm5xDi5)+(Vm6*Di6)}
Di =--------------------------------------------------------------------------------------------------------------(Vm1+ Vm2 + Vm3 + Vm4+ Vm5 + Vm6)
Where suffix 1, 2,3,4,5 & 6 represents the six gas streams.
Similarly the test outlet dust burden (Do) will be calculated based on outlet gas
flow.
c) The weighted test inlet gas temperature (Ti) shall also be worked out in a
similar manner i.e.
(Ti1*Vm1)+(Ti2*Vm2)+(Ti3*Vm3)+(Ti4*Vm4)+(Ti5*Vm5)+(Ti6*Vm6)
Ti =-----------------------------------------------------------------------------------------------------------------(Vm1+ Vm2 + Vm3 + Vm4 + Vm5 + Vm6)
d) The measured test efficiency shall be :
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(Di-Do)
Em
= -------------------
x100%
Di
e) The corrections for the flue gas flow and ESP inlet flue gas temperature in
excess of the values for these parameters under guarantee point conditions,
shall be allowed only in case and to the extent such variations are caused
solely due to changes in specified coal properties and ambient conditions.
Further, the corrections for the flue gas flow and temperature lower than the
guarantee point values shall be applied based on actually measured test
values. Subject to the above, the corrections for the variation in flue gas flow,
inlet dust burden and ESP inlet flue gas temperature shall be based on the
above computed test values and the procedure given below:
f) At the time of performance testing if the inlet flue gas conditions are not
consistent with the specified conditions, due to variation in coal characteristics
from the design coal and boiler operating conditions the precipitator
performance conforming to this Specification, shall be determined using
performance curves and correction factors accepted at the time of award of
Contract. However, the test efficiency shall be corrected to the guarantee point
conditions in the following manner:
1.
Ec = 1-eZ
Where Ec = Corrected test efficiency to guarantee point conditions.
Z = C Ln (1-Eg)
1
and C =------------------------Ca. Cb. Cc. etc.
Ca.Cb.Cc etc. are Correction factors for flue gas at temperature, moisture
content in flue gas, ESP inlet dust loading, sulphur and sodium contents of coal
ash based on correction curves furnished by the Bidder and approved by the
Owner.
2.
Eg = 1 - eY
Where Y = {(Vm/Vg) Ô.5}* Ln (1-Em)
Eg =
Measured test efficiency corrected to the specified guarantee

point flow
Vg =
Specified Guarantee point gas flow (m3/sec)
Vm = Measured gas flow (m3/sec)

Em = Measured test efficiency
Ln =
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The correction curves should be realistic for expected range of operation and
variation in characteristics specified.
The test efficiency shall be the average of at least three corrected test
efficiencies.
The Performance tests shall be carried out in accordance with method-17 of
EPA (Environmental Protection Agency of USA) code. The details of the test
shall, however be mutually agreed upon between the Owner and the Bidder.
Further, during the performance test of the Electrostatic Precipitator, if the
Bidder establishes that the average of three tested outlet dust burden (Do)
values (uncorrected) are either equal to or less than [] mg/Nm3], then the
Bidder shall also be deemed to have successfully met the guaranteed ESP
efficiency.
ii.
Liquid Effluent
Liquid Effluent discharge to an outside body, from the plant battery limit, shall
meet statutory requirements State Pollution Control Board.
8.4
Guarantees under Category-III

The parameters/capabilities to be demonstrated for various systems/ equipment
shall include but not be limited to the following:
8.4.1
Noise
All the plant, equipment and systems covered under this Specification shall
perform continuously without exceeding the noise level over the entire range of
output and operating frequency specified.
Noise level measurement shall be carried out using applicable and internationally
acceptable standards. The measurement shall be carried out with a calibrated
integrating sound level meter meeting the requirement of IEC 651 or BS 5969 or
IS 9779.
Equivalent A weighted Sound pressure shall be measured all around the
equipment at a distance of 1.0 m from the Noise emitting source.
A minimum of 6 points around each equipment shall be covered for
measurement. Additional measurement points shall be considered based on the
applicable standards and the size of the equipment. The measurement shall be
done with slow response on the A - weighting scale. The average of A-weighted
sound pressure level measurements expressed in decibels to a reference of
0.0002 micro bar shall not exceed the guaranteed value. Corrections for
background noise shall be considered in line with the applicable standards. All
the necessary data for determining these corrections, in line with the applicable
standards, shall be collected during the tests.
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If the noise level recorded is beyond the limits specified above, the Bidder should
provide suitable acoustic cladding to mitigate the noise level to within allowable
limits.
8.4.2
Start-up, loading, Unloading and Shutdown Capabilities

a) Boiler Start-up
Start-up time (up to full load), and loading capabilities for the Boiler for cold start
conditions [(greater than 36 hours shutdown)], warm start conditions [(between 8 and
36 hours shutdown)] and hot start conditions [(less than 8 hours shutdown)] as
indicated by the Bidder in the offer and accepted by the Owner shall be demonstrated,
ensuring various parameters like tube metal temperature, excess air level etc is within
design limits.
b) Sudden Total Loss of External Load
When the steam turbine generator unit experiences sudden total loss of all external
load, the steam turbine generator unit shall not trip on over speed but shall continue to
be in operation (house-load conditions) under the control of its speed governor to
supply power for the plant auxiliary load and during such condition Boiler shall be
capable of producing steam as per the requirement of Turbo Generator. The same
shall be demonstrated.
8.4.3
Other Parameters for Boiler and Auxiliaries

a) Mill Capacity at Rated Fineness {Applicable for PF Boilers but not for CFBC
Boilers}
Performance testing shall be done on each mill towards establishing its capacity
specified at the rated fineness, applying corrections for the variation in coal
characteristics i.e. HGI & total moisture. The Bidder shall guarantee the capacity output
not less than the offered value for each mill with following conditions occurring
simultaneously during testing with the available coal from the specified range:
Coal fineness: Not less than [70% through 200 mesh] and not less than [99%
through 50 mesh] screen.
Mill loading: Not to exceed [90%] of maximum load for worst coal.
The Bidder shall guarantee that the above capacity shall be maintained and
demonstrated with the installed grinding elements in nearly worn-out condition as
mutually agreed for the purpose of ascertaining wear life of any of the wear parts. During
the above mentioned operating period of the mill, manufacturer's operating instructions
shall be followed and mill shall be operated with the specified range of coals without any
such readjustment that requires a shutdown of the mill or reduction of the load and/or
any replacement of any mill wear parts.
For the purpose of testing to demonstrate the capacity, if HGI and total moisture vary
from those given in coal characteristics, the above pulverizer measured capacity shall
be corrected using the capacity correction curves furnished by the Bidder and approved
by the Owner. HGI versus mill capacity curve shall be furnished for HGI variation up to a
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value above which the capacity remain constant. Capacity guarantee shall be conducted
and demonstrated on each coal pulverizer individually.
b) Coal Mill Wear Parts Warranty {Applicable for PF Boilers but not for CFBC
Boilers}
Life of mill wear parts, in hours of operation, for the entire range of coal characteristics
specified.
The Bidder shall warrant the wear life of all wear parts of the pulveriser when grinding
the specified range of coal. Pulveriser wear parts are defined as those parts of the
pulveriser which are in contact with coal or coal dust and are likely to wear out during the
operation of the pulveriser. The guarantee/warrantee shall be demonstrated on each
pulveriser during the Guarantee Trial Period commencing after establishing successful
operation of the pulveriser continuously for a period of not less than [24 (twenty four)]
hours, at or near its warranty rated capacity. The Guarantee Trial Period for the
respective wear part(s) shall be at least three years or the wear life of any wear part that
wear part(s), whichever occurs later. The establishment of the warranty will be based on
actual total hours of operation of the pulveriser, regardless of the specified fuel or fuel
loading of the pulveriser. The wear parts shall be considered to have passed their
warranted operating life when they have successfully demonstrated their capability to
meet the full load rated capacity of the pulveriser during the guaranteed life of the wear
part. In case any of the wear part has worn out to such an extent that either the normal
or safe operation of the pulveriser is jeopardised if this part is not replaced/repaired, or
continuous use with this part may lead to exposure or wear of other parts which are not
meant for the purpose of checking the shortfall in wear life, even if there is no reduction
in pulveriser rated capacity, then the part shall be deemed to have outlived its wear life.
The rated capacity of pulveriser is as per manufacturer standard supplied mills. If any of
the wear parts fail to meet the warranted life, additional quantities of these wear parts
shall be supplied on prorata basis.
Pulveriser Warranty Shortfall Settlement Procedure (With Example)
For all wear parts of each pulveriser:
Table: 8.4
S.No. Description
Example
Guaranteed wear life

of the part is (say=Y)
15,000 hrs
Actual wear life

achieved by failed part
with replacement is
(say Y1 &Y2)
13,000 and 11,000 hrs
Average wear life of

failed wear parts
is(AWL)
= (Y1+Y2)/2
=12000
Document Number
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Remarks
Life of wear part

replaced during 5
year guarantee trial
period
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S.No. Description
Example
Total shortfall in hours

for wear part during 5
years of guarantee
trial period is S
= (Y-Y1)+(Y-Y2)
= 2000+4000
Shortfall settlement
= [S/AWL] x [(20-GTP)/ If the value works

(guarantee trial period)] out to 1.6, then in
that case the same
= 2.0
can be rounded off
to the next higher
whole number.
Remarks
= 6000
The Bidder shall provide to Owner either the wear parts of original or better
quality/material number equivalent to one and a half times the quantity worked out
based on the method explained in the above example so as to compensate for the
shortfall in wear life for a extended plant life of [20/25] years as has been established
above, or the cost of such number (i.e., one and a half time the quantity worked out as
per the above example) of wear parts based on the prices agreed for mandatory spares.
The final mode of compensation for such shortfall viz., by means of additional quantities
of spares worked out or by cost thereof shall be as per Owners discretion. The total cost
of such replacements shall be without any limit to the maximum amount recoverable.
Average Wear Life (AWL) during guarantee trial period, to be considered for pulveriser
wear part warranty shall be as arrived at from the station record for each pulveriser, and
as corrected for variation in YGP index of the coal being fired during guarantee trial
period. For this purpose the coal YGP shall be the average tested value during
guarantee trial period. The Bidder shall collect the coal samples and get them tested for
YGP index at recognised, Owners approved test lab, periodically. (The frequency of
sampling and testing shall be mutually agreed between Bidder & Owner). The YGP
index testing shall be done as per the BS Standard specified. A jointly signed record
shall be maintained during guarantee trial period.
c) Furnace Exit Gas Temperature (FEGT) {Applicable for PF Boilers but not for
CFBC Boilers }
The Bidder shall conduct a comprehensive thermal performance test (TPT). Through
such TPT the Bidder, by indirect measurement, shall demonstrate that the Furnace
Exit Gas Temperature (FEGT) does not exceed the specified maximum temperature
limit, with coal pulverizer combinations to Owner's choice and all other requirement in
line with Specification requirements. The demonstration shall be done by backward
calculations method, after having measured/tested/calculated the economizer outlet
gas temperature (average), excess air (average), unit heat load (based on turbine flow
and reheater flow), characteristics of coal being actually fired during testing, heat
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absorption in different stages of heat transfer equipment (based on steam/water

temperature and pressure measurements) etc. FEGT for the specified design and
worst coals shall be calculated using the measured FEGT (with test coal) as above
and using computer modeling technique for necessary conversion of the results to the
specified design and worst coals. The FEGT demonstration using computer modeling
technique shall involve following steps:
Development of a computer field model (FM) (backward) using above
measured/computed field data. This will be used to calculate the surface effectiveness
factor (SEF) for each of heat transfer banks including furnace water walls with test
coal.
The above field model shall have to be validated by various tests (loads, coal
pulverizer combination etc. with test coal) to ensure SEFs for each bank are consistent
(within: 1.5%) for all tests.
Using above SEFs, for each heat transfer bank Bidder's original boiler design model
will be changed.
The validity of the above model shall be checked for each test by feeding the test coal
both from backward direction FM and the calibrated Unit Specific model as per step-(c)
above. The model validity is established if the results for flue gas temperature profile
in the boiler, zonal assumptions etc are identical in both the 'BACKWARD' and
'FORWARD DIRECTION'.
The validated Unit Specific model shall have "Fuel Switching" capability i.e. it shall be
able to appropriately vary the furnace absorption with changes in the coal properties.
Validation of the above fuel switching capability will also have to be established to the
satisfaction of Owner.
Having established and demonstrated FUEL SWITCHING capability, the Contractual
FEGT can be demonstrated by using the SITE SPECIFC calibrated model as per step(d) and plugging in the specified coal(s).
The detailed procedure and the correction curves for the above test shall be to
Owner's approval.
The Bidder through thermal performance test (TPT) as per above shall also
demonstrate that the flue gas temperature (Actual/MHVT values) at the entry and exit
of various boiler heating surfaces and also the variations across the cross section
perpendicular to gas flow do not exceed the values indicated in the data sheets for
100% TMCR Load.
d) Flue gas Temperature (Actual/MHVT)
The Bidder shall also demonstrate that the flue gas temperature at the entry and exit
of Boiler heating surfaces and also the variations across the cross section
perpendicular to gas flow do not exceed the values indicated in the Technical
Specification Section-II of Volume-II at 100% TMCR load.
e) Fuel Oil Support [(Not above 30% BMCR)] {Applicable for PF Boilers but not
for CFBC Boilers}
The Bidder shall demonstrate that with any combination of mills in service (to Owners
choice) the Boiler does not require any oil firing for stable and efficient Boiler operation
at and above [30% BMCR load].
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
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Power Plant]
[Logo of Utility]
f) Steam Temperature Imbalance

The Bidder shall demonstrate that at SH and RH outlets (in case of more than one
outlet) the temperature imbalance between the outlets does not [exceed 5C]
under all loads including transients.
Also Bidder to demonstrate the rated temperature at ESV & ICV of HP turbine &
HP turbine respectively.
g) Rated SH/RH Imbalance
The Bidder shall demonstrate the Boiler capability to operate on continuous basis
with rated SH/RH outlet steam temperature within the complete control range of
the Boiler and with the whole range of specified coal(s). This demonstration test
shall be conducted for at least 72 (seventy-two) hours and the metal temperature
and various operating parameters of Boiler such as excess air etc shall not exceed
their design/predicted values.
h) SH/RH attemperation System
The Bidder shall demonstrate that for all Boiler loads, the spray water flow for SH
attemporation system does not exceed [8% of main steam flow], at superheater
outlet and spray water flow for RH attemporation system does not exceed [3% of
reheat flow] at reheater outlet, while firing any coal from within the range specified
with HP heaters in service (to be indicated in the Bid) while maintaining the rated
SH/RH steam temperatures at all loads within the control range of the Boiler up to
an including BMCR.
i)
Fans & Drives
j)
- Satisfactory operation without undue noise and vibration while operating in isolation as
well as parallel operation shall be demonstrated.
- Each Fan Set shall be capable of operating within the entire range i.e. from minimum
flow to the design head-capacity point.
Air Heater Leakages
The Bidder shall demonstrate that the air heater air-in-leakage and maximum drift
in air leakage do not exceed the guaranteed or specified value as per technical
Specification. Above requirement needs to be combined even with recirculation of
flue gas from downstream of ESP.
k) Boiler Capability with HP Heater out of service

The Bidder shall demonstrate steam generating capacity of Boiler when one and/or
both or all strings of HP heaters are out of service, as offered. The metal
temperature margins over the design value shall also be demonstrated for the
most adverse operating conditions.
l)
Integration among Boiler C&I and Turbo Generator C &I and BOP C&I
Boiler and its auxiliaries along with its control system (BOILER C&I), TG and its
auxiliaries along with its control system (TG C&I) when integrated with Balance of
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
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[138]
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Power Plant]
[Logo of Utility]
Plant (BOP) C&I systems shall meet the permissible limits for important
parameters, under various operating conditions specified.
m) ESP air leakage
ESP air-in leakage shall not be more than 1% of total gas flow at ESP inlet at the
guarantee point condition.
n) ESP Test
Test to demonstrate for pressure drop across ESP not to exceed the applicable
value.
8.4.4
Auxiliary Water System Pumps

Capacity and head and power consumption of all the pumps dedicated to Boiler
& its Auxiliaries at the rated duty point (to be demonstrated and proved at shop
with the respective job motors).
Vibration, noise level and parallel operation of all the pumps at the rated duty
point shall be demonstrated at site.
8.4.5
Power Cycle Piping

Actual hanger readings, under cold and hot condition (at rated parameters) to
match with those of design cold and hot hanger readings for MS/CRH/HRH / HP
& LP by pass piping system.
8.4.6
Equipment Cooling Water System

Following parameters for ECW pumps dedicated to Boiler and its Auxiliaries:
a) Parallel operation of pumps to be demonstrated at site
b) Further pressure drop across the heat exchanger on the primary & secondary
water circuit to be demonstrated at site.
Note: The Bidder needs to demonstrate performance parameters for the above
auxiliaries, only if, any replacement / refurbishment / retrofitting are carried out
by the Bidder in the respective Equipment/Systems in line with the scope of
work. Nevertheless, Bidder shall demonstrate performance of Boiler &
Auxiliaries closest to the predicted performance and within the safe limit of
parameters.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[139]
15.01.2016
Tender Document for R&M of Unit No.[..] of [Name of the Power Plant]
[Logo of Utility]
SPARE PARTS
The Bidder shall include in his scope of supply all the necessary mandatory
spares, start up and commissioning spares and recommended spares and
indicate these in the relevant schedules. The general requirements pertaining to
the supply of these spares is given below:
9.1
Mandatory Spares
The list of mandatory spares considered essential by the Owner is enclosed in
Annexure-II of this Specification. The Bidder shall indicate the prices for each
and every item (except for items not applicable to the Bidders design) in the
Schedule of mandatory spares whether or not he considers it necessary for the
Owner to have such spares. If the Bidder fails to comply with the above, the cost
of such spares shall be deemed to be included in the Contract price. The Bidder
shall furnish the population per unit of each item in the relevant Schedules.
Whenever the quantity is mentioned in sets the Bidder has to give the item
details and prices of each item.
Whenever the quantity is indicated as a percentage, it shall mean percentage of
total population of that item in the R&M Contract unless specified otherwise, and
the fraction will be rounded off to the next higher whole number. Wherever the
requirement has been specified as a set, it will mean as applicable for one
complete Unit or each type & size of the Equipment being taken up for
refurbishment or replacement. Also the set would include all components
required to replace the item; for example, a set of bearings shall include all
hardware normally required while replacing the bearings.
All mandatory spares shall be delivered at site at least two months before
scheduled date of initial operation of the first unit. However, spares shall not be
dispatched before dispatch of corresponding main equipment.
Wherever quantity is specified both as a percentage and a value, the Bidder has
to supply the higher quantity until and unless specified otherwise. Price of
mandatory spare parts will also be evaluated.
9.2
Recommended Spares
In addition to the mandatory spare parts mentioned above, the Bidder shall also
provide a list of recommended spares for [five (5)] years of normal operation of
the plant and indicate the list and total prices in relevant schedule. The list shall
take into consideration the mandatory spares specified and should be
independent of the list of the mandatory spares. The Owner reserves the right to
buy any or all of the recommended spares. The recommended spares shall be
delivered at project site at least two months before the scheduled date of initial
operation of first unit. However, the spares shall not be dispatched before the
dispatch of the main equipment.
Prices of recommended spares will not be used for evaluation of the Bids. The
price of these spares will remain valid upto execution of the Contract. However,
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
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No.
Date of Issue
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[Logo of Utility]
the Bidder shall be liable to provide necessary justification for the quoted prices
for these spares as desired by the Owner.
9.3
Start-up & Commissioning Spares

Start up and commissioning spares are those spares which may be required
during the start-up and commissioning of the equipment/system till the handing
over of the Plant. The Bidder shall provide all such start up and commissioning
spares and keep an adequate stock of the same to be brought by him to the site
for the plant erection and commissioning. These must be available at site before
the equipment are energized. The unused spares, if any, should be removed
from there, only after handing over of the plant. All start up spares which remain
unused at the time shall remain the property of the Bidder.
9.4
The Bidder shall indicate the service expectancy period for the spares parts (both
mandatory and recommended) under normal operating conditions before
replacement is necessary.
All spares supplied under this Contract shall be strictly inter-changeable with the
parts for which they are intended for replacements. The spares shall be treated
and packed for long storage under the climatic conditions prevailing at the site
e.g. small items shall be packed in sealed transparent plastic with desiccators
packs as necessary.
All the spares (both mandatory and recommended) shall be manufactured along
with the main equipment components as a continuous operation as per same
Specification and quality plan.
The Bidder will provide Owner with cross-sectional drawings, catalogues,
assembly drawings and other relevant documents so as to enable the Owner to
identify and finalize order for recommended spares.
Each spare part shall be clearly marked or labeled on the outside of the packing
with its description. When more than one spare part is packed in a single case, a
general description of the content shall be shown on the outside of such case
and a detailed list enclosed. All cases, containers and other packages must be
suitably marked and numbered for the purposes of identification.
All cases, containers or other packages are to be opened for such examination
as may be considered necessary by the Owner.
The Bidder will provide the Owner with all the addresses and particulars of his
sub-suppliers while placing the order on Vendors for items/ components/
equipment covered under Contract and will further ensure with his Vendors that
the Owner, if so desires, will have the right to place order for spares directly on
them on mutually agreed terms based on offers of such Vendors.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
03

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[Logo of Utility]
The Bidder shall warrant that all spares supplied will be new and in accordance
with the Contract documents and will be free from defects in design, material and
workmanship.
In addition to the recommended spares listed by the Bidder, if the Owner further
identifies certain particular items of spares, the Bidder shall submit the prices and
delivery quotation for such spares within 30 days of receipt of such request for
consideration by the Owner and placement of order for additional spares if the
Owner so desires.
The Bidder shall guarantee the long term availability of spares to the Owner for
the full life of the equipment covered in the Contract. The Bidder shall guarantee
that before going out of production of spare parts of the equipment covered
under the Contract, he shall give the Owner at least 2 years advance notice so
that the latter may order his bulk requirement of spares, if he so desires. The
same provision will also be applicable to Sub-Bidders. Further, in case of
discontinuance of manufacture of any spares by the Bidder and/or his subBidders, Bidder will provide the Owner, two years in advance, with full
manufacturing drawings, material Specifications and technical information
including information on alternative equipment makes required by the Owner for
the purpose of manufacture/procurement of such items.
The prices of all future requirements of spares beyond [five (5)] years shall be
derived from the corresponding FOB/Ex-works price at which the order for such
spares have been placed by the Owner as a part of the mandatory spares or
recommended spares. FOB/Ex-works order price of future spares shall be
computed in accordance with the price escalation formula to be furnished by
Bidder indicating base price reference variation indices for material, labour etc.
Based on the formula and considering escalation indices prevailing at the time of
order of spares, order price shall be worked out. The base indices will be counted
from the scheduled date of successful completion of trial operation of the last
plant/equipment under the project. The above option for procuring future
recommended spares by the Owner shall remain valid for the period of fifteen
[fifteen (15)] years from the date of successful completion of trial operation of the
last plant/equipment. In case the spare parts from the same sub-Vendor are not
available due to obsolescence or any other reason, the Bidder shall supply the
spares for a period of [fifteen (15)] years from an alternative source.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
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No.
Date of Issue
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[142]
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10
ANNEXURE
10.1
Annexure-I (List of Existing Drawing)
[Logo of Utility]
{Available as Build/RFC drawing of the Existing Unit shall be provided to the

Bidder as per the list mentioned in Annexure-I for their information &
familiarization of the existing Unit}
10.2
Annexure-II (Mandatory Spares)

{Applicable Mandatory Spares tor the equipment system to be replaced /
refurbished / retrofitted under the scope of this R&M Tender shall be provided as
detailed in Annexure-II}
10.3
Annexure-III (List of Sub-Vendor)

{List of Sub-vendor for the equipment system to be replaced / refurbished /
retrofitted under the scope of this R&M Tender shall be provided as per the
format in Annexure-III}
10.4
RLA/CA Study Report

{Not attached with this document. This is to be provided by Utilities}
10.5
EA Study Report
10.6
Baseline Study Report

Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
03

[143]
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OF

R&M CONTRACTORS

VOLUME-II
SECTION-I, ANNEXURE-I
LIST OF EXIXTING DRAWING
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-I
List of Existing Drawing

Bidder as per the list mentioned below for their information & familiarization of the
existing Unit.}
i)
MECHANICAL
S.No.
Drawing/Document No.
Title
[]
[General Layout (Plot Plan)]
[]
[Main plant Layout at + 0.00 M]
[]
[Main Plant Equipment Layout Plan at Different

Elevations]
[]
[Main plant Layout Cross Section]
[]
[General layout battery limit]
[]
[Symbol /Legends]
[]
[P&ID for Main Steam, CRH & HRH Steam System]
[]
[Flow Diagram for Boiler Proper]
[]
[Flow Diagram Air and Flue gas path]
10
[]
[Flow Diagram Fuel oil System]
11
[]
[Flow Diagram Chemical feed system]
12
[]
[Flow Diagram Auxiliary Steam System]
13
[]
[Flow Diagram DM Cooling Water System]
14
[]
[Flow Diagram Compressed Air System]
15
[]
[Arrangement of Bunker Bay Section]
16
[]
[Boiler Sectional Drawing]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

Volume-II, Section-I, Annexure-I
[2]
25.09.2013
Power Plant]
S.No.
Title
17
[]
[Boiler Plan/Foot Print]
18
[]
[ESP Elevation].
19
[]
[ESP Foot Print]
ii)
[Logo of Utility]
ELECTRICAL
S.No.
[]
iii)
Title
[Key Single line diagram]
CONTROL & INSTRUMENTATION

S.No.
[]
[Plant DCS Configuration Drawing]
[]
[SG Integral Control System Configuration Drawing]
[]
[Instrument Installation Diagram (Pressure Transmitter)]
[]
[Instrument Installation Diagram (Flow Measurement)]
[]
[Instrument Installation Diagram (Pressure Gauge)]
[]
[Instrument Installation Diagram (DP Measurement)]
[]
[Instrument Installation Diagram (Level Measurement

using gauge & switch)]
[]

using DP Transmitter & Displacer type Transmitter]
[]

for Open/Close Vessels)]
10
[]
[Instrument Source Connection Details Pressure

Measurement on Pipe]
11
[]

Measurement on Duct]
Document Number
LII-GETS12021-G-00129-001
Title
Rev
No.
Description
Page
No.
Date of Issue
02

[3]
25.09.2013
Power Plant]
[Logo of Utility]
S.No.
12
[]
[Instrument Source Connection Details Temperature

13
[]

Measurement on Duct]
14
[]
[Instrument Source Connection Details Flow

Measurement]
15
[]
[Instrument Source Connection Details Flow

Measurement]
16
[]
[Instrument Source Connection Details Level

Measurement]
17
[]
[Instrument Source Connection Details Level

Measurement]
22
[]
[Grounding Scheme for Cabinets/Panels]
23
[]
[C&I Power Supply distribution cabling Philosophy &

Scope Diagram]
24
[]
[C&I Instrumentation cabling Philosophy & Scope

Diagram]
25
[]
[Typical PLC based Control System Configuration

Diagram]
26
[]
[Boiler Protection System Configuration Diagram]
27
[]
[Drive Control Philosophy-Bidirectional drive (ON-OFF

Type MOV)]
28
[]
[Drive Control Philosophy-Bidirectional drive (Inching

Type MOV)]
29
[]
[Drive Control Philosophy- LT drive]
30
[]
[Drive Control Philosophy- HT drive]
31
[]
[Drive Control Philosophy-Solenoid Valve]
32
[]
[Typical Block Diagram for Furnace Flame Viewing

System]
33
[]
[Drive Control Philosophy- VFD]
Document Number
LII-GETS12021-G-00129-001
Title
Rev
No.
Description
Page
No.
Date of Issue
02

[4]
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Power Plant]
iv)
[Logo of Utility]
CIVIL
S.No.
Drawing No.
[]
[Geotechnical Investigation Report of the site]
[]
[Road, drains, trench layouts etc., as available]
[]
[Design documents of the existing structures]
[]
[Drawings for loading data of the existing structures &

foundations]
Document Number
LII-GETS12021-G-00129-001
Description
Rev
No.
Description
Page
No.
Date of Issue
02

[5]
25.09.2013

OF

R&M CONTRACTORS

VOLUME-II
SECTION-I, ANNEXURE-II
MANDATORY SPARES
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-II
Mandatory Spares
{Applicable Mandatory Spares for the equipment system to be replaced / refurbished /
retrofitted under the scope of this R&M Tender shall be provided as detailed in
Annexure-II. Available Mandatory spares of the existing Unit, which can be used after
completion of R&M work, shall also be verified before finalization of the below
mentioned Spare List. Mandatory Spares shall be defined as for each Unit. The unit,
set, indicated in the table below will mean as applicable for one complete Unit or each
type & size of the Equipment being taken up for refurbishment or replacement.}
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

Volume-II, Section-I, Annexure-II
[2]
25.09.2014
Power Plant]
1.
MECHANICAL
1.1
[Boiler and Auxiliaries Mechanical Spares
1.2.1
Pressure Parts
[Logo of Utility]
A. Economiser
i)
Straight tube
200m for each size, type,

thickness and material
ii) Coil end bends
50 nos. of each size, type,

,radius and material.
B. Water wall
i)
Straight tube and spiral tube
200m quantity for each

thickness, size and material.
ii) Bends for burner elevation
20 nos. for each size, type,

thickness, radius and material.
iii) Bends for Furnace opening
10 nos. for each size, type,

thickness, radius & material.
C. Low temperature super heater (LTSH)

i)
Straight tube of 8-10 m length :
ii) Bends
300m length for each size,

thickness, and material.
20 nos. of each size, type,

thickness, radius and material.
iii) bends/offsets for supply tubes
20 nos. each
D. Intermediate temperature superheater

(ITSH)/ Platen superheater
i)
Straight tube
ii) Bends
60 m length of each size,

10 nos. of each size, thickness,

radius, type and material.
75m length of each size,


type, radius and material
E. High temperature superheater/

Final superheater
i)
Straight tube
ii) Bends
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[3]
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Power Plant]
iii)
[Logo of Utility]
Dissimilar metal weld joint spot piece : 25 nos. of each size, radius and
thickness, types & materials
F. Reheater
i)
Straight tube
ii) Bends
100m length of each size,

type and material

type, radius and material
iii) Dissimilar metal weld joint spot piece : 25 nos. of each size, radius and
thickness, types & materials
1.2.2
Headers
A. Water wall headers
i) Hand hole plate
ii) Yoke plate with fasteners
:
:
4 nos.
4 sets
B. Superheater headers
i)
i)
Hand hole plate assembly

Radiographic plug
2 nos. of each type

6 nos.
2 nos. of each type

6 nos.
C. Reheater headers
i) Hand hole plate assembly
ii) Radiographic plug
1.2.3
Superheater and Reheater Attemperation System

Desuperheater liners
1.2.4
:
:
2 sets of each type
Steam Drum (if applicable)

i) Manhole gasket for drum
ii) Local water level gauge
glass assembly
:
:
12 nos.
1 set
iii) Spares for direct water

level gauge
1 set
(such as port assembly,

glass strip lamps spring cones, gaskets etc.)
iv) Spares for remote level indicator
(such as seal ring bull deflector
plate, gasket and diaphragm)
Document Number
LII-GETS12021-G-00129-001
1 set
Rev
No.
Description
Page
No.
Date of Issue
02

[4]
25.09.2014
Power Plant]
v) Spare isolating valve assembly for

above gauge glass
:
[Logo of Utility]
1 set
For separator (if applicable) spares list to be furnished by the bidder along with the
bid document.
1.2.5
Boiler Water Forced Circulation Pumps

i)
ii)
iii)
iv)
v)
vi)
vii)
Complete pump and motor

assembly
Motor stator winding

Journal bearing
Thrust bearing
Casing wear rings
Impeller wear rings
Set of gaskets
(All gaskets including
1 no.
:
:
:
:
:
:
1 no.
2 no
2 no
2 no
3 no
5 sets
5 sets
5 sets
1 set
1 set
1 set
1 set
1 set
heat exchanger)
viii) Set of O rings
ix) Gland packings
x) Motor heat exchanger
xi) Thermocouples
xii) Temperature switches
xiii) Pressure switches
xiv) Flow switches
1.2.6
:
:
:
:
:
:
Fans
A. ID Fans
i)
Radial/Axial type (as applicable)

a)
b)
c)
d)
e)
f)
g)
Fan rotating element (complete assembly) :

Impeller liners
Casing liners
:
Motor bearings
Fan bearings
Bearing Housing
Seals, O rings oil rings for
all the fan bearings
1 set
:
2 set
:
:
:
:
2 sets
2 sets
2 sets
1 No
6 sets
h) Lube oil system

Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[5]
25.09.2014
Power Plant]
Pump assembly
Pressure regulator
Filters
Coupling between oil pump
and motor
Coolers
i) Inlet guide vanes (IGV)if applicable
j) Fan blades
k) Spares for blade bearing assembly
i)
Bearing
ii)
O rings
iii)
Bushes
iv)
Metallic rings
v)
Intermediate piece (if applicable
vi)
Hydraulic servomotor
vii)
Fan Bearing Housing
l) ID Fan Motor complete
:
:
:
:
1 no.
2 nos.
8 nos.
2 nos.
:
1 set
:
1 set
:
:
:
:
:
:
:
:
2 sets
2 sets
2 sets
2 sets
2 sets
2nos
1 set
1 no.
[Logo of Utility]
1 set
B. FD fans
i)
Fan rotor complete (including

impeller and shaft)
ii)
iii)
iv)
v)
vi)
Fan bearings
Bearing Housing
:
Motor bearings
Fan blades
Spares for blade bearing assembly
a) Bearings
b) O rings
c) Bushes
d) Metallic rings
e) Intermediate piece
vii) Lube oil system
a) Pump assembly
b) Pressure regulator
c) Filters
d) Coupling between oil pump
and motor
e) Coolers
viii) Couplings between fan
Document Number
LII-GETS12021-G-00129-001
:
1 no
:
:
1 no.
1 set
1 set
2 sets
:
:
:
:
:
2 sets
2 sets
2 sets
2 sets
3 sets
:
:
:
:
1 no.
3 nos.
8 nos.
2 nos.
1 set
Rev
No.
Description
Page
No.
Date of Issue
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[6]
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Power Plant]
and motor
ix) Hydraulic servomotor
x) FD fan Motor complete
1.2.7
2 nos.
:
:
2 nos.
1 no.
[Logo of Utility]
Coal Pulverizers
i)
Grinding elements
Rollers/ tyres/ grinding balls
Bull ring segments/ bowl/ rings
:
:
2 sets
1 set
Note: One set of grinding element above is defined as under

1 set = (Grinding elements needed for complete replacement of one mill) x A
Where
A = [(8000 x N)/ GWL. Rounded off to nearest whole number]
GWL = Guaranteed wear life of grinding element as offered by Bidder
N = Number of mills installed for one Boiler unit
ii) Gear box internals (expect bearings and seals)
iii) Mill motor complete
iv) Mill motor bearing
v) Complete gear box
vi) Bearings for mills
vii) Seals and rings for gear box
viii) Liners with brackets & fasteners
ix) Discharge valve assembly
x) Multiport outlet & liners
xi) Mill main shaft/ yoke
xii) Journal & Spring
xiii) Hydraulic loading cylinder
:
3nos.
xiv) Filter cartridges
xv) Actuators (pneumatic/hydraulic) (complete) :
xvi) Actuators (pneumatic/ hydraulic) spare kits :
xvii) Mill bottom
xviii) Bowl hub assembly/Ring seat
xix) Lube oil system
Document Number
LII-GETS12021-G-00129-001
:
:
:
:
:
:
:
:
:
:
:
1 sets*
1no
1 set
2 sets*
2 sets*
2 sets*
3 sets*
2 sets*
2 sets
1no.
2nos.
:
6nos.
1no. of each type
1 set of each type
:
2nos.
:
1nos.
Rev
No.
Description
Page
No.
Date of Issue
02

[7]
25.09.2014
Power Plant]
a)
b)
c)
d)
e)
Pump and motor coupling

Pump assembly
Motor assembly
Filters
Pressure regulator
:
:
:
:
:
xx) Oil cooler assembly for coal mills

xxi) Bearings for gear box
*One set means complete replacement of one mill
1.2.8
3nos.
2nos.
2nos.
12 nos.
2nos.
2 nos.
Feeders
i) Belt
ii) Belt drive feeder motor
iii) Belt drive reducer
iv) Clean out conveyor motor
v) Clean out conveyor reducer
vi) Counter assembly (complete) :
vii) Head pulley assembly (complete)
viii) Weight sensing system
a) Weighing oil
b) Weighing spare roller assembly
c) Drag link assembly
ix) Tension roll
x) Worm
xi) Worm wheel
xii) Feeder gate
xiii) Actuator
1.2.9
:
3 sets*
[Logo of Utility]
:
:
:
:
:
2nos.
:
6 sets*
2nos.
2nos.
2nos.
2nos.
:
:
:
2nos.
2nos.
2nos.
:
:
:
:
:
2nos.
2nos.
2nos.
2nos.
1no. of each type
2nos.
Coal Burners and Coal Pipe Bends

Bidder to provide the complete list of spares as required.
1.2.10
Seal Air Fan

i) Impeller with shaft
:
ii) Bearings and seals
:
iii) Motor bearings
:
iv) Seal Air Fan Motor complete
:
* One set means complete replacement of one fan
Document Number
LII-GETS12021-G-00129-001
1 no.
2 sets
2 sets
1 no.
Rev
No.
Description
Page
No.
Date of Issue
02

[8]
25.09.2014
Power Plant]
1.2.11
[Logo of Utility]
Regenerative Air Preheaters (RAPH)

i) Support bearing
:
ii) Guide bearing
:
iii) Lubricating system of support and guide bearing
a) Pump assembly
:
b) Pressure regulator
:
c) Filters
:
d) Pump motor coupling
:
e) Coolers
:
iv) Radial seals
:
v) Axial seals
:
vi) Circumferential or bypass seals
:
vii) Rotor post seals
:
viii) Speed reducer
a) Complete speed reducer(gear box)
:
b) Speed reducer gears, pinions
:
and shaft
2 nos.
2 nos.
1 no.
1 no.
6 nos.
3 nos.
1 set
4sets
4 sets
2 sets
4 sets
1 set
1 set
c) Speed reducer bearings

d) Speed reducer seals and
gaskets
1 set
2 sets
e) Speed reducer clutch

assembly
2 nos.
ix) Fluid coupling 3 nos.

x) Other couplings with inserts
and fasteners
xi) Solenoid valves

xii) Spare kit for rotor stoppage
alarm
2 nos.
:
2 nos.
1 set
1 set
b) Coupling
c) Bearing and seals for speed
reducer
1 set
1 set
d) Bearing for cleaning device
2 sets
xiii) Spare kit for fire sensing device 1 set

xiv) Spares for cleaning device
a) Worm and worm wheel for
gear reducer
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[9]
25.09.2014
Power Plant]
xv) Bushings for worm gear reducer

xvi) Actuators
for isolation dampers
xvii) Cold, intermediate and hot
end baskets
[Logo of Utility]
:
:
1 set
2 no.
1set for each type and size
xviii) RAPH motor complete

:
1 no. of each type
*One set means complete replacement for one APH
1.2.12
Fuel Oil System

A. Heavy fuel oil system
i) Fuel oil guns
ii) Oil gun nozzle (with back plate,
mixing plate and cap nut)
2nos
:
4 sets
iii) Oil gun flexible hoses (including

for guide pipe, air line)
4 sets
iv) Burner isolation valves

a) Isolation valves
12 nos. or 10%
whichever is higher
2 sets
2 sets
1 no.
each 1 no
vii) Oil shut off valve of each type, size

& model
1 no
viii) Check valve of each type, size

& model
1 no
ix) Limit switches for the displacement :

device
2 nos
x) Steam traps
xi) Heavy oil temperature control
valve
4 nos
b) Gaskets for above valves

c) Gland packings for above
valves
v) Atomizing steam pressure
reducing valve
vi) Electro pneumatic quick closing
valves used in oil burner area,
each type size & model ( complete
valve with servo motors, solenoid
& its limit switches for ol, air, steam
Document Number
LII-GETS12021-G-00129-001
:
:
1 no.
Rev
No.
Description
Page
No.
Date of Issue
02

[10]
25.09.2014
Power Plant]
xii) Actuators of above valves

1.2.13
1 no. of each type

and rating
Light oil system

i) Light oil gun
ii) Oil gun nozzle (with back plate,
mixing plate and cap nut)
iii) Burner isolation valves
a) Isolation valves
b) Gaskets for above valves
c) Gland packings for above valves
iv) Light oil pressure control valve
v) Light oil main trip valve complete
1.2.14
[Logo of Utility]
1 set
2 sets
:
:
:
1 no.
:
4nos
2 sets
2 sets
1 no.
HEA Igniters
i) HEA retractor
:
2 sets
ii) HEA spark rod
:
2 sets
iii) HEA spark tip
:
2 sets
iv) HEA exciter
:
4 nos. of each type and rating
v) Solenoid valves
:
vi) Limit switch
:
vii) Solenoid valve coil
:
viii) HEA spark gap
:
8 nos.
ix) HEA transformer
:
8 nos.
x) HEA rectifier
:
8 nos.
xi) HEA inductor
:
8 nos.
xii) Resistor
:
xiii) Capacitor
:
* One set means one complete replacement of one HEA igniter
1.2.15
Soot Blowers
i)
Complete assembly of water wall

Deslaggers (water lances)
ii) Motor for water wall deslaggers

a) For each drive
iii) Complete valve assembly for water
wall deslaggers
Document Number
LII-GETS12021-G-00129-001
2 nos.
3 nos.
4 nos.
Rev
No.
Description
Page
No.
Date of Issue
02

[11]
25.09.2014
Power Plant]
[Logo of Utility]
iv) Motor for long travel retractable soot blower(Steam soot blowers in convective
pass)
a) For rotary motion
:
2 nos.
b) For traverse motion
:
2 nos.
v) Complete valve assembly for long
retractable soot blower
:
2 nos.
vi) motors for air preheater
soot blower
1 no. of each type
vii) Reduction gear box and motor for

air preheater soot blower oscillation
1 no of each type
viii) Complete valve assembly for air

preheater soot blower
1 no. of each type
:
:
2 sets
3 sets
1 no.
1 no.
:
:
:
:
2 sets
6 sets
4 sets
2 sets
1 no. of each type
ix) Bearing and oil seals for

a) Long retractable soot blower
b) Water wall deslagger
x) Complete steam safety
valve assembly for soot blowing system
xi) Steam pressure control valve assembly
xii) Steam pressure control valve spares
a) Stem and disc assembly
b) Gaskets
c) Gland packings
d) Seat rings
xiii) Long retractable soot blower
assemblies complete
xiv) Limit switches
:
xv) Complete power pack assembly
for long retractable soot blower
xvi) Spare set of rotary and transverse chain
for long retractable soot blowers
xvii) Spares for rack gear assembly
a) Set of gears and shaft
(Spur and worm)
b) Rack and pinion
xviii) Thermocouples for temperature
probes
Document Number
LII-GETS12021-G-00129-001

:
2 nos. (1 no. for rotary
no. for transverse)
:
1 no. of each type and size
1 set
1 set
1 no. of each type and size
Rev
No.
Description
Page
No.
Date of Issue
02

[12]
25.09.2014
Power Plant]
xix) Soot blower nozzle

xx) Soot blower lance tube
1.2.16
[Logo of Utility]
:
:
10 % of populaaton
10 % of population
:
:
:
:
:
:
:
2 nos. of each type

2 nos. of each type
2 nos. of each type
2 nos. of each type
1 no.
2 nos.
1 no.
:
:
:
:
:
:
2 nos. of each type

2 nos.
:
2 nos.
1 no.
2 sets of each type
1 no. of each type
2 sets of each type
:
:
:
:
:
:
:
1 no. of each type

1 no. of each type
1 no. of each type
1 no. of each type
1 set of each type
1 no. of each type
1 no. of each type
:
:
:
:
:
:
:
1 no. of each type

1 no. of each type
1 no. of each type
1 no. of each type
1 set of each type
1 set of each type
1 set
1 no. of each type
Valves
A.
i)
ii)
iii)
iv)
v)
vi)
vii)
B.
i)
ii)
iii)
iv)
v)
vi)
vii)
C.
i)
ii)
iii)
iv)
v)
vi)
vii)
D.
i)
ii)
iii)
iv)
v)
vi)
vii)
E.
i)
Steam drum (if applicable ) safety valves

Upper adjusting ring
Lower adjusting ring
Locking pin set
Safety valve disc
Safety valve stem
Valve spindle
Guide
SH safety valves
Disc
Valve spindle
Set of washers
Guide
Set of locking pins
Hot RH safety valves
Disc
Valve spindle
Set of washers
Set of pins
Guide
Cold RH safety valves
Disc
Valve spindle
Locking pin set
Guide
Set of washers
Electromatic relief valve
Complete electromatic relief valve
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[13]
25.09.2014
Power Plant]
ii) Spares for above:

a) Disc for main valve
b) Spring for main valve
c) Seal rings for main valve
d) Seal bushing for main valve
e) Disc and steam assembly
for pilot valve
[Logo of Utility]
:
2 nos. of each type
:
2 nos. of each type
:
2 nos. of each type
2 nos. of each type
2 nos. of each type
f) Bushing for pilot valve

:
2 nos. of each type
g) Spring for pilot valve
:
2 nos. of each type
h) Seal ring
:
2 nos. of each type If air assisted safety valves are envisaged, necessary spares to be added..
F. Superheater spray control valve
i) Complete superheater spray
control valve
ii) Spares for the above:
a) Gland packings set
b) Pressure seal gasket
c) Stem
d) Plug valve
G. Reheater spray control valve
i) Complete reheater spray
control valve
ii) Spares for the above:
a) Gland packings set
b) Pressure seal gasket
c) Stem
d) Plug valve
H. Superheater Spray Block Valve
i) Gland packing set
ii) Pressure seal gasket
iii) Stem
iv) Valve plug
I. Reheater Spray Block Valve
i) Gland packing set
ii) Pressure seal gasket
iii) Stem
Document Number
LII-GETS12021-G-00129-001
1 nos. of each size and type
:
:
:
:
4 sets
4 sets
2 nos.
2 nos.
:
:
:
:
6 sets
6 sets
2 nos.
2 nos
:
:
:
:
2 sets of each type

2 nos. of each type
2 nos. of each type
2 nos. of each type
:
:
:
2 sets of each type

2 nos. of each type
2 nos. of each type
Rev
No.
Description
Page
No.
Date of Issue
02

[14]
25.09.2014
Power Plant]
iv) Valve plug

1.2.17
[Logo of Utility]
2 nos. of each type
:
:
:
6 sets
8 nos.
1 no. of each type (1 no. for
main valve and 1 no. for integral
Boiler Main Steam Stop Valve

i) Set of gland packings
ii) Pressure seal gaskets
iii) Stem
bypass valve)
iv) Disc
v) Seat rings
vi) Fasteners
vii) Actuator
1.2.18
Stem
Disc
Body seat rings
Gland packings
Pressure seal rings
Fasteners
:
:
:
:
:
:
1 no.
1 no.
2 sets
3 sets
3 nos.
1 set
:
:
:
:
:
1 no.
1 no.
1 set
2 sets
2 sets.
:
:
:
:
:
2 nos.
2 nos.
2 nos.
4 sets
1 set
Economiser Recirculation Valve

i) Valve Stem
ii) Disc
iii) Body seat rings
iv) Gland packings
v) Pressure seal rings
vi) Boiler Feed Check Valve
(i) Body seat rings
(ii) Flap
(iii) Pressure seal ring
(iv) Gland packings
(v) Fasteners
1.2.20
-do-do-do-do-
Start Up Vent Valves

i)
ii)
iii)
iv)
v)
vi)
1.2.19
:
:
:
:
Auxiliary Steam Pressure Reducing and Desuperheating (PRDS) System

A. High capacity PRDS system (MS)
i) Desuperheater liners
:
1 set
ii) Pressure reducing cum desuperheating valves
a) Stem
:
1 no.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[15]
25.09.2014
Power Plant]
[Logo of Utility]
b) Disc
c) Body seat rings
:
:
1 no.
2 nos. for each type, size and
rating of valves
d) Gland packings

rating of valves
:
:
3 nos.
3 nos.
1 no. for each size, type and
e) Pressure seal ring

f) Gasket
iii) Spray water line control valves
Valve trim including cage
plug, stem, seat rings, guide
rating of valves
bushings, stem packing

B. Low capacity PRDS system (CRH)
i) Desuperheater liners 1 set
ii) Pressure reducing cum desuperheating valves
a) Stem
:
1 no.
b) Disc
:
1 no.
c) Body seat rings
:
rating of valves
d) Gland packings
e) Pressure seal ring
f) Gasket
iii) Spray water line control valves
Valve trim including cage

rating of valves
:
:
3 nos.
3 nos.
1 no. for each size, type and
rating of valves
bushings, stem packing

1.2.21
Bottom ash removal system

1. Furnace bottom ash removal system
a. Wet type slag removal equipment
i) Round chain
:
ii) Nylon rings
:
iii) Shaft seals
:
iv) Round core packing
:
v) PIV Spare chains
:
vi) Roller chain between gearing
Document Number
LII-GETS12021-G-00129-001
2 sets
8 sets
8 sets
8 sets
1 no.
Rev
No.
Description
Page
No.
Date of Issue
02

[16]
25.09.2014
Power Plant]
and driving shafts

vii) Bearings of various type
viii) Drive motor
ix) Wear plates
x) Tension pulley with bearing
xi) Deflection station
xii) Central sprocket wheel discs
xiii) Water proof bin assembly
1.2.22
:
:
:
:
:
:
:
2 nos. of each type

1 no. of each type
1 set
1 no.
1 no.
1 no.
8 nos.
1 no.
:
:
:
:
:
:
:
1no.
:
:
:
:
3 nos.
1no.
1no.
3 nos.
1no.
1no.
1no.
1no.
2nos.
2nos.
1no.
Scanner (Cooling air fans)

i)
ii)
iii)
iv)
v)
1.2.24
1 set
Chemical dosing system(if applicable)

1. HP chemical dosing system
i)
Drive shaft cum worm
:
ii)
Drive worm wheel
iii)
Connecting rod plate
iv)
Cross head
v)
Cross head guide bush
vi)
Plunger
vii)
Discharge NRV
viii)
Plug
ix)
Oil seal
:
x)
Suction NRV
xi)
Washer
xii)
Gland nut
xiii)
HP dosing pump assembly
1.2.23
[Logo of Utility]
Filter screens for cooling air fans

Fan impeller
Motor AC
Seal
Bearings
:
:
:
:
:
1 no
1 no
1 no
2 nos. of each type
1 no. of each type
500mm NB
5% of each type & size per unit.
Spare set of gland packings of

all the gate valves for all sizes
-do-
Power Cycle Piping

i)
ii)
Spare gasket for all the gate

valves of sizes 15mm NB to
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[17]
25.09.2014
Power Plant]
iii)
Spare gasket for all the globe

valves for sizes 15mm NB to 500
mm NB
iv)
[Logo of Utility]
-do-
Spare set of gland packings of all

the globe valves for all sizes
-do-
Spare gaskets for NRV for all the

valves
-do-
Spare set of gaskets for safety

relief valves for all sizes
-do-
Complete gate valves assembly

upto the size of 50NB
:
-do-
Complete angle valves upto the

size of 50 NB
-do-
Complete globe valves upto the

size of 50 NB
-do-
Complete NRVs upto the size of

50 NB
-do-
Complete needle valves upto the

size of 50 NB
-do-
xii)
Spring hangers
5% of each type & stiffness of

quality
xiii)
Gasket for each flanged connection

on HP steam and feed line, jacking
oil lines
2 nos.
Steam traps and Y-strainers for

each size, type and rating
10% of total population
:
:
1no.
1no.
1no.
10% or 2nos. whichever is lesser
v)
vi)
vii)
viii)
ix)
x)
xi)
xiv)
xv)
xvi)
xvii)
SH spray valve (control)

RH spray valve (control)
Other valves
Each type, size & class
100mm below
xviii)
Each type, size & class

100mm above
Critical piping
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[18]
25.09.2014
Power Plant]
[Logo of Utility]
For MS, HRH, CRH, BFD, HP-LP Bypass, Aux PRDS Systems, Spray Water and
all Miscellaneous Piping including Drains (of boiler scope) as follows:
Pipes of dimension 100Nb and
above with IBR certification in
6 meters
6 meters
form IIIA
Pipes of dimension below
100 NB with IBR certification
in Form III B.
Gaskets for the system including
all types of metal gaskets, grafoil :
1.2.25
10%
After Burning Grate (ABG)

ABG (1 set = requirement of one ABG)
i)
Drive shaft
2 nos.
ii) Return shaft
2 nos.
iii) Louvre plates
1 set
iv) Side supports
1 set
v) Intermediate supports
1 sets
vi) Rollers
1 set
vii) Lower support bar
1 set
viii) PIV Gear box
1 no
ix) Constant speed Gear box
1no
x) Clutch assembly
1no
xi) Coupling motor to PIV
xii) PIV chain assembly
4 nos
:
4 nos.
a) For drive shaft
2 nos.
b) For return shaft
2 nos.
xiii) Plummer block with bearing-
xiv) Drive sprocket
1.2.26
1 set
xv) Return shaft pulley
1 set
xvi) ABG Motor complete
1 no.
6 nos.
Electrostatic Precipitator (ESP)

i)
Support insulator
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[19]
25.09.2014
Power Plant]
ii) Shaft insulator

iii) Bushing insulators assembly
iv) Emitting electrodes
a) Helical wire type
[Logo of Utility]
:
:
6 nos.
4 nos.
5% of the installed quantity in

one ESP
b) Wire pipe in rigid frame

one ESP
c) Mast type

one ESP
v) Collecting electrode

one ESP
vi) Inner arm assembly
20 nos. each for collecting and

emitting system
vii) Outer arm assembly
10 nos. each for collecting and

emitting system
viii) Plain bearing

ix) Shock bar/ anvil
:
x) Rappers
a) For electric rappers
Assembled rapper/ drop rods
Coil assembly along with
sleeve
:
20 nos. of each type and size
60 nos. of each type and size
Casing
Gaskets and packing
b) For tumbling rappers
Hammers
Bearing components
Shafts
Gear motors
xi) Transformer rectifier set
a) Complete set
b) High voltage insulator
c) Switches and gaskets
4 nos.
:
:
4 nos.
:
:
:
:

4 nos.
4 nos.
4 nos.
:
:
:
2 nos.
4 nos.
1 set
(One set means one complete
replacement for all the TR sets
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[20]
25.09.2014
Power Plant]
[Logo of Utility]
of one ESP)
xii) Control system
a) Transformer-rectifier set controller: 2 nos.
b) Rapper controller complete :
2 nos.
c) Communication controller
complete
:
2 nos.
d) Electronic cards
For rapper controller and
ESP management system
For transformer rectifier

controller
e) Display unit
f) Keyboard
g) Push buttons for:
TR set controller:
h) Indicator lamps
i) Control fuse
j) Power fuse
k) Thyristor fuse
l) Thyristor of transformer
rectifier controller
xiii) Rapping motor complete
1 set
2 sets
:
:
2 nos. of each type

2 nos. of each type
2 sets
:
:
:
:
1 set
1 set
1 set
1 set
2 sets
5 nos. of each type and rating]
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[21]
25.09.2014
Power Plant]
2.
[Logo of Utility]
ELECTRICAL
S.No /
Cl. No.
2.1
Item
Quantity
Remarks
General (VENTILATION & AIR CONDITIONING) (To be repeated for each type & rating)
Contactors
Min. 1 no. of each type
2.1.2
Over load relay
2 nos. of each type
2.1.3
Relay/ Timers
3 nos. of each type
2.1.4
Fan motor
30 % of each rating
2.1.5
Switch fuse unit/MCCB/ELCB
2 nos. of each rating
2.1.6
Blower motor
30% of each rating
2.1.1
VFD System (To be repeated for each type & rating)

2.1.7
Electrical Cards
2.1.8
Control modules
1 No of each type & rating
2.1.9
I/o modules
2 Nos. of each type & rating
2.1.10
Power supply modules
2 Nos. of each type & rating
2.1.11
Thyristor gate module including gate 10% of installed quantity

transformer
2.1.12
Exciter module
1 No.
2.1.13
Thyristor bridge leg
10%
2.1.14
Over voltage limiter

suppressor network
2.1.15
Power & Control fuse
100% of installed quantity
2.1.16
Control transformer
1 no. of each type & rating
2.1.17
Contractor/load break switch
1 No.
2.1.18
CT/VT
1 No. of each type & rating
Document Number
LII-GETS12021-G-00129-001
and
surge 1 set
Rev
No.
Description
Page
No.
Date of Issue
02

[22]
25.09.2014
Power Plant]
S.No /
Cl. No.
Item
[Logo of Utility]
Quantity
Remarks
2.1.19
Indicating lamps
2.1.20
Auxiliary contractors & relays
2.1.21
Panel mounted meters
1 No. of each type & rating
2.1.22
Panel mounted printer
1 No.
2.1.23
Hand held unit
2 Nos.
415 V NON-SEGREGATED PHASE BUS DUCT (To be repeated for each type & rating)
2.1.24
Bus support Insulator
15 Nos. each type and rating
2.1.25
Rigid joint
5 Nos. each type and rating
2.1.26
Copper/Aluminum flexible for main run 1 Set of each type and rating
and tap offs bus ducts
per phase
2.1.27
Seal of bushing for main run and tap 1 Set of each type and rating
offs bus ducts
per phase
2.1.28
Jumpers, if any
2 No. of each type
2.1.29
Drain Plugs with cap
3 Nos.
2.1.30
Gaskets
3 sets of each type and rating
2.1.31
Rubber bellow for main run and tap offs 1 Set of each type and rating
bus ducts
per phase
2.1.32
Belleville washers
5 Nos.
2.1.33
Densal or equivalent compound
1 kg.
2.1.34
Space Heaters
1 set
2.1.35
Silica gel breather
1 No.
TRANSFORMER (Dry Type) (To be repeated for each type & rating)
2.1.36
Complete winding temperature

equipment
1 set
2.1.37
CTs of each type and rating
1 set
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[23]
25.09.2014
Power Plant]
S.No /
Cl. No.
Item
Quantity
2.1.38
Thermistor
2 sets
2.1.39
Temperature surveillance unit
2 nos.
2.1.40
Tap changer contact
1 set
2.1.41
Set of gaskets (other than that with the 1 No.

bushing)
2.1.42
PRV
1 No.
2.1.43
Support insulators
2 sets
[Logo of Utility]
Remarks
TRANSFORMERS (ONAN) (If applicable for VFD drives) (To be repeated for each type & rating)
2.1.44
HV bushing
4 nos.
2.1.45
LV Bushing
4 Nos.
2.1.46
LV Neutral Bushing
2 nos.
2.1.47
Bushing CT (LV) of each rating
2 nos.
2.1.48
Complete set of gaskets
2 sets
2.1.49
Valve of each type
4 nos.
2.1.50
Magnetic oil level indicator
2 nos.
2.1.51
Buchholz Relay
1 no.
2.1.52
Winding temperature indicator
2 nos.
2.1.53
Dial type oil temperature indicator
2 nos.
2.1.54
Silica gel breather
2 nos.
2.1.55
Buchholz Relays
2 nos.
2.1.56
Radiator unit
1 no.
2.1.57
Pressure relief device
2 nos.
2.1.58
Tap changer contact
1 set
415 V Switchgear (To be repeated for each type & rating)

2.1.59
Busbar support insulators
10 Nos. of each type
2.1.60
Current transformers
1No. of each type & rating
2.1.61
Potential transformers 415/110V
1 No.
2.1.62
Male contact of ACB (main and aux.)
1 set
2.1.63
Female contact of ACB (main and aux.)
1 set
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[24]
25.09.2014
Power Plant]
S.No /
Cl. No.
Item
[Logo of Utility]
Quantity
2.1.64
Limit switch of ACB
3 Nos.
2.1.65
Spring charging motor of ACB
3 Nos.
2.1.66
Closing coil of ACB
2 Nos.
2.1.67
Tripping coil of ACB
2 Nos.
2.1.68
Breaker control switch
2 Nos.
2.1.69
Protection Relays
1No. of each type
2.1.70
Electronic overload relays with single 1 no. of each type

phase preventers
2.1.71
Relays of each type and rating
1 no.
2.1.72
Auxiliary relay
2 Nos. of each type
2.1.73
Load break switch
1 no. of each type
2.1.74
Auxiliary contact assembly of breaker
Remarks
i) Test position
3 sets of each type
ii) Service position
3 sets of each type
2.1.75
Arc chute for CBs
5 nos. of each type
2.1.76
Arching contacts (for fixed)
3 nos.of each rating
2.1.77
Arching contacts (for moving)
3 nos.of each rating
2.1.78
Check synchronizing relay
1no
2.1.79
MCB/MCCB
1no. of each rating
2.1.80
Timers
2 nos. of each type per board
2.1.81
Fuse base
10 nos of each type
2.1.82
Switch Fuse Assembly
1 no. of each type and rating
2.1.83
Power and control circuit fuses
2.1.84
Selector switch
5 nos. of each type
2.1.85
Voltmeter selector switch
5 nos. of each type
2.1.86
Ammeter selector switch
5 nos. of each type
2.1.87
Local-Remote selector switch
3 nos. of each type
2.1.88
Terminal blocks
10 sets
2.1.89
Aux & Power Contactors
5 nos of each type
2.1.90
Indicating Lamp assembly (LED LVGP 10 Nos. of each type & colour
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[25]
25.09.2014
Power Plant]
S.No /
Cl. No.
Item
[Logo of Utility]
Quantity
Remarks
type)
2.1.91
Phase sequence meter
2 Nos.
2.1.92
MPCB
1no of each type and rating
2.1.93
MCCB
1no of each type and rating
2.1.94
Single phase control transformer

(415/110V)
1 no. of each type
2.1.95
Interposing relay
1 no. of each type
2.1.96
Push button with contact element
1 no. of each type
2.1.97
Meters
1 no. of each type
2.1.98
Intelligent control modules
2 nos of each type.
MOTORS (To be repeated for each type & rating)

2.1.99
Bearing (driving end)
1 No. of each type
2.1.100
Bearing (Non-driving end)
1 No. of each type
2.1.101
End shield (DE and NDE)
1 set of each type
2.1.102
Cooling fan of motors
1 No. of each type
2.1.103
Fan cover
1 No. of each type
2.1.104
Lubrication oil pump motor
1 No. of each type and rating
2.1.105
Bearing puller
1 Nos. of each type
2.1.106
Grease gun
2 Nos.
2.1.107
Special spanners/tools
1 Set
ELECTRICAL MOTORIZED ACTUATORS (To be repeated for each type & rating)
2.1.108
Actuator motor
2.1.109
Torque
contact
2.1.110
Limit switch with potential free contact
2 Nos. of each type
2.1.111
Mechanical position indicator
1 No.
switch
Document Number
LII-GETS12021-G-00129-001
1 No. of each type and rating

with
potential
free 2 Nos. of each type
Rev
No.
Description
Page
No.
Date of Issue
02

[26]
25.09.2014
Power Plant]
S.No /
Cl. No.
2.1.112
Item
Quantity
Hand wheel for manual operation
[Logo of Utility]
Remarks
1 No.
ACDB/PDB/LDB/SLDB/AUX. PDB/ DISTRIBUTION PANELS(To be repeated for each type &

rating)
2.1.113
Busbar support insulators
3 Nos. of each type
2.1.114
MCCB / SFU
2 Nos. of each rating
2.1.115
MCB
2 Nos. of each rating
2.1.116
Control switch
2 Nos. of each type
ILLUMINATION
2.1.117
Lamps
2.1.118
Fittings
2 Sets of each type
2.1.119
Control gear box complete
5 Sets of each type
2.1.120
Timer/photo cell (wherever applicable)
2 Nos.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[27]
25.09.2014
Power Plant]
3.
[Logo of Utility]
S.No
3.1
Item
Quantity / Unit
Remarks
Boiler Integral Control System
Power Supply module/Cards
10% of each type &

model no.
Network modules
10% of each type &

model no.
Communication
modules
Input/Output modules
10% of each type &

model no.
Controller module
10% of each type &

model no.
SOE Module
10% of each type &

model no.
Net work components like

switch/repeaters/hubs etc
10% of each type &

model no.
Printer Paper
1000 sheets of each

type
Printer Cartridge
Data Bus Cable
1 no. of each type &

Length
Fibre Optic Patch Cords (if 1 no. of each type &

applicable)
Length
Prefab interconnecting cables 1 no. of each type &

with connectors
Length
Interface
System
bus
connectors
Loose Connectors
Batteries used
backup of RAMs
Panel/Cabinet cooling fans
10% of each type &

model
Fuses
200% of each type &

rating
Relays
20% of each type
Document Number
LII-GETS12021-G-00129-001
cable
with
10% of each type &

model no.

Length
5 nos. (set) of each
type
for
battery
10%
Rev
No.
Description
Page
No.
Date of Issue
02

[28]
25.09.2014
Power Plant]
S.No
Item
Quantity / Unit
3.2
Boiler Related Instruments
Flame Monitoring System
a1
Complete
Flame
Assembly including
head
assembly,
housing and cables
a2
Flame scanner lens
a3
Flame
unit
a4
Power Supply modules/unit
Lignite Feeders
b1
Motion
Monitor/Speed 10% of each type &
transmitter/switch
model no.
b2
Speed pick-up
10% of each type &

model no.
b3
Torque Switch
10% of each type &

model no.
b4
Load Cell
10% of each type &

model no.
Scanner
scanner
scanner
2 nos. each/2 sets
electronic
2 nos. of each type &

model no.
model no
b5
Electronics cards and power 10% of each type &

supply cards
model no.
b6
Limit Switch assembly
10% of each type &

model no.
Not used
Not used
Acoustic Pyrometer
e1
Electronic
cards/PCBs/modules

model no.
e2
Sensors & transceivers
20% of each type &

Model no.
Furnace
System
Flame
f1
Flame Camera
1 No. of each type &

Model
f2
Electronic Modules/PCBs
2 Nos. of each type &
Document Number
LII-GETS12021-G-00129-001
Remarks
10 nos.
monitoring
&
[Logo of Utility]
Viewing
Rev
No.
Description
Page
No.
Date of Issue
02

[29]
25.09.2014
Power Plant]
S.No
Item
Quantity / Unit
[Logo of Utility]
Remarks
model
g
Mill & Air heater Fire detection

system
g1
Thermocouples
10% of each type &

Length
g2
Process actuated switch
10% of each type
Electronic Drum Level Indicator
h1
Probes
20%
h2
Electronic Cards
20% of each type
h3
Display indicator for local &

remote including cables
1 nos. each
3.3
Local Measuring Instruments
Electronic Transmitter
a1
Transmitters of all types, range

and model no. (for the
10% of each type &
measurement
of
pressure,
model
differential pressure, flow, level
etc.)
a2
Electronic cards / PCB's for

each
type and model of transmitters
Complete RTD assembly along 10% of each type &

length
with thermowell
Complete
Thermocouple 10% of each type &
assembly along with thermowell length
Metal
Thermocouple
Proximity switch along with

sensor
10% of each type
Temperature Transmitter
10% of each type
Gauges
(Pressure,
Temperature)
Switch
(Pressure,
DP, 10% of each type &
Temperature, Level, Flow)
Range
Ultrasonic Level Transmitter 1 no. of each type &

(Complete assembly)
model
Document Number
LII-GETS12021-G-00129-001
Temperature
DP,
10%
10% of each type &

length
10% of each type &

Range
Rev
No.
Description
Page
No.
Date of Issue
02

[30]
25.09.2014
Power Plant]
S.No
Item
Quantity / Unit
Radar Type Level Transmitter 1 no. of each type &

(Complete assembly)
model
Rotameters

model
Coriolis Flow Meter

model
Oxygen Analyzer
p1
Standard gas for Zero & Span
2
Cylinders
with
Pressure regulator &
Connector
p2
Complete Probe assembly
1 no. for each type &

model no.
p3
Complete Electronic unit

model no
p4
Sensing
gaskets,

model no
p5
Heating Element & filter
CO Analyzer
q1
Standard gas for Zero & Span
2
Cylinders
with
Pressure regulator &
Connector
q2
Complete Probe assembly

model no.
q3
Complete Electronic unit

model no
q4
Sensing
gaskets,

model no
3.4
Control Valves, Actuators & Accessories
element,
O-rings,
element,
O-rings,
Valve trim (including cage,

1 set for each type of
control valve
bushings etc)
Packing & Gasket
5 no. of each type
Actuator Diaphragm
1 no. of each type
O-rings
5 nos. of each type for

each positioner
LII-GETS12021-G-00129-001
Remarks

model no
Document Number
[Logo of Utility]
Rev
No.
Description
Page
No.
Date of Issue
02

[31]
25.09.2014
Power Plant]
S.No
Item
Quantity / Unit
Feedback linkage
1 no. of each type
Pressure gauges of all types,

range, make, rating etc
10%
Air Filter Regulator
10% of each type &

Range
I-to-P Converter
10% of each type &

Range
Position transmitter
10% of each type &

Range
Limit Switch
10% of each type &

model no.
Solenoid Valves assembly with 10% of each type &

model no.
coil
Not used
Air lock relay
10% of each type &

model no.
Smart Positioner
10% of each type &

model no.
Not used
Pneumatic Power Cylinder
1 complete set of each

type & model no.
p1
Feedback linkage
1 no. of each type
p2
Packing & gaskets
1 no. of each type
p3
O-rings
5 nos. of each type for

each positioner
3.5
Process connection Piping
2 way, 3 way Valves

instruments
Fittings
10 Nos. of each type,

rating, material & size
Valve manifolds
10 % of each type,
rating & model no.
Air Filter regulator
10 % of each type,
rating & model no.
Impulse piping & tubing
5 nos. of standard
Document Number
LII-GETS12021-G-00129-001
for
[Logo of Utility]
Remarks
10% of each type,

size, rating, class,
material & model no.
Rev
No.
Description
Page
No.
Date of Issue
02

[32]
25.09.2014
Power Plant]
S.No
Item
Quantity / Unit
[Logo of Utility]
Remarks
Length of each size,

rating & material
3.6
3.7
Instrumentation cables & Accessories

5% of total installed
Length (In running
meter) of each type,
pair & size (if total
Cables
(including
installed length < 500
compensating cable)
mtrs.), 1 no. of 500
mtr. Drum (if total
installed length > 500
mtrs.)
Cabinets, Panels & Junction Box
Terminal Blocks

& rating ( for type
exceeding 100 nos.)
MCBs
10% of each type &

rating
Fuse

rating
Junction box
1 no. of each size &

material
LED Indicators
10% of each type &

Colour
3.8
Programmable Logic controller (PLC)
Power Supply Unit/Module

Model
Input/ Output modules
10 % of each type &

Model
Central processor Unit

Model
Interface Units/ Communication 1 no. of each type &

module
Model
Interconnecting Cables
1 no. of each type
Batteries for RAM battery backup
1 set of each type
3.9
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[33]
25.09.2014
Power Plant]
S.No
Item
Quantity / Unit
Complete control unit

display/operating unit
Interface/communication
hardware for interfacing with
Model
other control systems
Local instruments including 1 no. of each type,

gauge, switch, transmitter etc.
range & model
Document Number
LII-GETS12021-G-00129-001
with
[Logo of Utility]
Remarks

Model
Rev
No.
Description
Page
No.
Date of Issue
02

[34]
25.09.2014

OF

R&M CONTRACTORS

VOLUME-II
SECTION-I, ANNEXURE-III
LIST OF SUB-VENDOR
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-III
List of Sub-vendor
{List of approved vendor for the equipment system to be replaced / refurbished /
retrofitted under the scope of this R&M Tender shall be provided as in the given
format.}
A.
MECHANICAL
Sl. No
B.
Item/Equipment Description
Sub Vendors
1.
[]
[]
2.
[]
[]
3.
[]
[]
4.
[]
[]
5.
[]
[]
[]
[]
ELECTRICAL
Sl. No
Sub Vendors
1.
[]
[]
2.
[]
[]
3.
[]
[]
4.
[]
[]
5.
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

Volume-II, Section-I, Annexure-III
[2]
25.09.2014
Power Plant]
C.

Sl. No
D.
[Logo of Utility]
Sub Vendors
1.
[]
[]
2.
[]
[]
3.
[]
[]
4.
[]
[]
5.
[]
[]
[]
[]
CIVIL
Sl. No
Sub Vendors
1.
[]
[]
2.
[]
[]
3.
[]
[]
4.
[]
[]
5.
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
02

[3]
25.09.2014

OF

R&M CONTRACTORS

VOLUME-II
SECTION-II, PART-A
DETAILED TECHNICAL SPECIFICATIONMECHANICAL
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R04
January 2016
Tender Document for R&M of Unit No. [..] Capacity [] of [Name of the
Power Plant]
[Logo of Utility]

Volume
Section
Part
Description
Volume-I
---
---
Commercial
Section-I
---
Part-A
Part-B
Part-C
Part-D
---
Part-A
---
Part-B
---
Part-C
---
Part-D
Not Used
Volume-II
Section-II
Volume-III
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-II, Section-II, Part-A
[i]
15.01.2016
Power Plant]
[Logo of Utility]
1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[ii]
15.01.2016
Power Plant]
[Logo of Utility]

1.
2.
3.
4.
5.
6.
7.
8.
9.
Spare Parts
10.
Annexure
SECTION-II:
1.
2.
3.
4.
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[iii]
15.01.2016
Power Plant]
[Logo of Utility]

1.
2.
Technical Schedules-Electrical
3.
Technical Schedules-I&C
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[iv]
15.01.2016
Power Plant]
[Logo of Utility]
TABLE OF CONTENT
1
DESIGN AND SIZING OF BOILER & AUXILIARIES.......................................................... 1

1.1
General ........................................................................................................................ 1
1.2
Codes & Standards ...................................................................................................... 1
1.3
Specific Design Criteria of Boiler & Auxiliaries ............................................................. 1
1.4
System Description .....................................................................................................16
DESIGN AND SIZING OF POWER CYCLE PIPING .........................................................54

2.1
Codes & Standards .....................................................................................................54
2.2
Design Basis ...............................................................................................................56
2.3
Piping Design..............................................................................................................59
2.4
Stress Analysis ...........................................................................................................60
2.5
Statutory Approvals.....................................................................................................62
2.6
Installation ..................................................................................................................62
2.7
Inspection and Testing ................................................................................................63
2.8
Low Pressure Piping, Valves and Fittings ...................................................................64
2.9
Piping Materials and Sizes ..........................................................................................64
2.10
Wall Thickness............................................................................................................65
2.11
Fittings ........................................................................................................................65
2.12
Piping Layout ..............................................................................................................67
2.13
Valves .........................................................................................................................69
2.14
Cleaning .....................................................................................................................73
2.15
Inspection and Tests ...................................................................................................73
2.16
Painting and Corrosion Protection...............................................................................74
2.17
Material Specification for Piping and Fittings ...............................................................74
2.18
Gates (if applicable) ....................................................................................................77
2.19
Strainers .....................................................................................................................77
2.20
Steam Traps ...............................................................................................................78
2.21
Instrument Connections ..............................................................................................78
2.22
Welding and Heat Treatment ......................................................................................78
2.23
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[v]
15.01.2016
Power Plant]
[Logo of Utility]
2.24
Underground Protection ..............................................................................................79
2.25
Non destructive examination .......................................................................................79
2.26
Hydrostatic Test Pressure ...........................................................................................79
THERMAL INSULATION...................................................................................................81
3.1
Genaral .......................................................................................................................81
3.2
Design Criteria ............................................................................................................81
3.3
General Requirements ................................................................................................81
3.4
Testing of Insulation ....................................................................................................84
3.5
Refractories ................................................................................................................85
QUALITY ASSURANCE ....................................................................................................86

4.1
Introduction .................................................................................................................86
4.2
Boiler and Auxiliaries ..................................................................................................86
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[vi]
15.01.2016
Power Plant]
[Logo of Utility]
ABBREVIATIONS
AAQ
Ambient Air Quality
AC
Alternating Current
ACB
Air Circuit Breaker
ACDB
AC Distribution Board
ACG
AHP
Ash Handling Plant
AHU
Air Handling Unit
ASME
ATRS
ATT
AVR
BHEL
Bharat Heavy Electricals Ltd.
BFP
BMCR
BOD
BOP
Balance of Plant
BTD
Bearing Temperature Detector
CA
CAVT
CBD
CCTV
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[vii]
15.01.2016
Power Plant]
[Logo of Utility]
CEA
CEMS
CERC
CFBC
CHP
Coal Handling Plant
CRH
Cold Re-Heat
CRT
Cathode Ray Tube
CLCS
CMMS
COC
COD
CT
Cooling Tower, Current Transformer
CV
Control Valve
CW
Cooling Water
DB
Distribution Board
DC
Direct Current
DCDB
DCS
Distributed Control System
DDCMIS
DG
Diesel Generator
DGA
DM
Demineralization
DMCW
DP
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[viii]
15.01.2016
Power Plant]
Earthed
ECO
Economizer
EHC
ELCID
EOT
ESP
ESV
ETP
EWS
FD
Forced Draft
FEGT
Furnace Exit Gas Temperature
FO
Fuel Oil
FOPH
Fuel Oil Pump House
FSSS
GC
Gland Condenser
GCV
GA
General Arrangement
GT
HCA
HFO
Heavy Fuel Oil
HPS
Heavy Petroleum Stock
HPTB
High Pressure Turbine Bypass
HMI
HP
High Pressure
Document Number
LII-GETS12021-G-00129-001
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HRH
Hot Re-Heat
HT
High Tension
HV
High Voltage
HVAC
HVDC
High Voltage Direct Current
HVWS
IBD
IBR
Indian Boiler Regulations
I&C
ICB
ID
Induced Draft
IGV
Inlet Guide Vane
I/O
Input / Output
IPT
IPR
Inter Posing Relay
ISA
Indian Standard Angle
ISMB
ISMC
Indian Standard Medium Channel
IV
Interceptive Valve
LAN
Local Area Network
LDB
Lighting Distribution Board
LDO
Light Diesel Oil
LE
Life Extension
LP
Low Pressure
Document Number
LII-GETS12021-G-00129-001
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LP
Lighting Panel
LPA
LPT
LPTB
Low Pressure Turbine Bypass
LRSB
LSHS
Low Sulfur High Stock
LT
Low Tension
LTSH
LVS
Large Video Screen
MCC
MCCB
MHVT
Multi High Velocity Thermocouple
MOCB
MoEF
MS
Main Steam
MSSV
NDT
Non Destructive Test
NABL
National Accreditation Board for Testing and Calibration Laboratories
NSPBD
Non Segregated Phase Bus Duct
O&M
OEM
Original Equipment Manufacturer
OPC
OWS
Document Number
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PA
Primary Air
PDB
Power Distribution Board
PLF
Plant Load Factor
PCC
Power Control Centre
ppm
Parts Per Million
PLC
PMCC
Power cum Motor Control Centre
PRDS
PTFE
Polytetrafluoroethylene
PVDF
Polyinylidene Fluoride
R&M
RfP
RfQ
RH
Reheater
RLA
RO
Reverse Osmosis
RPM
Respirable Particulate Matter
rpm
Revolutions Per Minute
RMS/ rms
Root Mean Square Value
RSO
RTD
SADC
SG
Steam Generator
SH
Super Heater
Document Number
LII-GETS12021-G-00129-001
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SPM
Suspended Particulate Matter
STMS
Smart Transmitter Monitoring System
SWAS
TFT
TG
Turbo Generator
TMCR
TPS
TR
TC
Thermocouple
TSE
TSI
TSS
Total Suspended Solids
UCR
Unit Control Room
UE
Unearthed
UPS
VT
Voltage Transformer
VFD
Variable Frequency Drive
VVVFD
Document Number
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DESIGN AND SIZING OF BOILER & AUXILIARIES
1.1
General
[Logo of Utility]
[The Boilers shall be drum or once through type unit, sub - critical, either a single
pass (tower type) or two pass type gas path arrangement, dry bottom, balanced
draft, natural or assisted circulation semi-outdoor type, top supported, pulverized
coal fired, single reheat type with all auxiliaries. The Boiler shall have the super
heater and reheat outlet indicative parameters as mentioned below in the table
1.1.]
[For CFBC Boiler & Auxiliaries, refer Annexure-M1]
1.2
Codes & Standards

The design, manufacture, erection, inspection and testing and materials of the
Boilers shall comply with the Indian Boiler Regulations (IBR) and any other
standards that are permitted by the IBR and are acceptable to the Chief
Inspector of Boilers.
The Boilers shall also comply with those specification requirements that are in
addition to those specified in IBR.
International Standards other than IBR that are considered to be equivalent or
superior to the IBR shall also be acceptable subject to the approval of the Chief
Inspector of Boilers. However, in the event of any conflict between the
requirements of the equivalent codes and standards, and the requirements of the
Indian Standards/ Regulations, the latter shall govern, unless, specified
otherwise in this Specification.
It shall be responsibility of the Bidder to obtain such approvals of the Inspection
Authority and Chief Inspector of Boilers on behalf of the Owner, as may be
required for designing, manufacturing and erecting, and testing as required by
the IBR. All such documentation submitted to statutory authorities shall also be
submitted to the Owner/Consultant for his review. It shall also be the
responsibility of the Bidder to furnish the requisite documentation as required by
the Owner for registering the boiler under IBR.
1.3
Specific Design Criteria of Boiler & Auxiliaries

Table 1.1
Boiler Rating (Tentative Indicative Parameters)
S.No.
1
Description
Steam flow at superheater
outlet at boiler maximum
continuous rating (BMCR)
when firing the worst coal
Steam temperature
a) At superheater (SH)
outlet
Document Number
LII-GETS12021-G-00129-001
Unit
%
Rated Parameter
[1.02 times
the steam flow
at
turbine
VWO
condition
plus
continuous
auxiliary
steam
requirement of unit at TMCR
condition.]
[540 (Correspond to HP turbine inlet
parameters of 537C)
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S.No.
b)
3
Description
At re-heater (RH) outlet
Unit
C
Rated Parameter
540 (Correspond to IP turbine inlet

temperature of 537C)]
[247 C.]
Feed water temperature at

economizer inlet
Steam pressure at
superheater outlet
Boiler control range
kg/cm
(abs)
[Logo of Utility]
The Boiler shall also be suitable for

accepting
feed
water
at
lower
temperature corresponding to HP
heaters out of service condition without
exceeding any design limits including
the design metal temperature.
[137 kg/cm2 (a)] [corresponding to
turbine throttle steam pressure [130
kg/cm2 (a)] at 100% TMCR]
[50%
TMCR
to
100%
BMCR].
However, the bidder to specify the

feasible mill combinations below 60%
TMCR
The above parameter shall be in line with finalized TG parameters (TG

specification.
Note!
Pressure drop in reheater should not exceed [2.5 kg/cm2] under all operating
conditions.
1.3.1
Limiting Parameters for Boiler Design

The Boiler design shall comply with the following limiting parameters with design
coal firing, under stipulated air condition [i.e. 27C temperature and 60% relative
humidity].
1.3.2
Excess air at economiser outlet at TMCR load: [20%] if (i) quoted (ii) actual
value during the PG test is higher than [20%] the higher value shall be taken.
Flue gas temperature at air heater outlet at TMCR: [135-150C] (minimum)
The Boiler guarantees shall however be as per the conditions stipulated in
relevant section of the specification.
Quality Parameters of Steam
The quality parameters of steam shall be as per the requirement of the turbine
manufacturer. However, the same shall not be inferior to the following under all
operating conditions:
a. [Silica as SiO2 :<20ppb]
b. [Sodium + Potassium as Na + K :<10ppb]
c. [Copper as Cu :<3ppb]
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d. [Iron as Fe :<20ppb]
e. [Conductivity at 25 deg C :<0.3 S/cm]
1.3.3
Boiler Water Quality

The quality parameters of the boiler water shall not be inferior to the following
limits:
a) [Phosphate ions : 0.5 to 3 ppm]
b) [Silica_
c) [TDS_
: 0.25 ppm]
: 0.20 ppm]
d) [Conductivity at 25 deg C: 50 S/cm]

e) [pH at 25 deg C : 9.2 to 9.4]
1.3.4
Minimum Load without Oil support for Flame Stabilization

The design of Boiler shall be such that it does not call for any oil support for
flame stabilization [beyond 30% BMCR] load when firing any coal from the range
specified, with adjacent mills in service and mill load not less than 50% of its
capacity. This shall be guaranteed and demonstrated by the bidder.
1.3.5
Cyclic Load Capability and Adoptability for Sudden Load Changes/ Load
Throw Off
i)
To match the desired plant operating capabilities, the Boiler shall also be
designed for regular cyclic/ two shift operation. The total number of start-ups
shall be as under
a
Hot starts [(less than 8 hrs*)]
[4000]
Warm starts [(between 8 and 36 hrs*)]
[1000]
Cold starts [(greater than 36 hrs*)]
[150]
* The time specified is with respect to hours of unit shutdown.

ii)
Under the above conditions, no portion of the Boiler and the associated systems
shall be stressed beyond acceptable safe stress and fatigue levels and the
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design of Boiler and its pressure parts shall take care of above without affecting
the life of equipment and pressure parts adversely.
1.3.6
iii)
Boiler shall also be capable of satisfactory, stable and safe operation in case of
rapid load changes in downward direction due to external disturbances or
equipment malfunction. Under such conditions, the system shall stabilize itself
through proven concepts and controls within the recommendation of National
Fire Protection Association, USA (NFPA), and sections 85C, 8502 and 8503.
iv)
In case of sudden load throw off, in worst case from 100% TMCR, the Boiler shall
be capable of automatically bringing down the steam generating capacity to
match with HP-LP bypass capacity of [60% BMCR]. The bidder to indicate
minimum load of Boiler to which it can be brought down under such condition,
during short turbine outages or export load rejection, with a view to save fuel and
reduce heat losses. The unit shall be capable of operating at house load
conditions.
v)
In line with automatic run back capability of the unit load on loss of critical
auxiliary equipments, the Boiler equipment and systems shall also ensure
smooth and stable runback operation.
Operation without HP Heaters in Service
Boiler shall be designed for continuous operation with HP heaters out of
operation. The Boiler heat output with HP heaters out of service shall be not less
than that at 100% BMCR with all HP heaters in service. Under this condition the
superheater and reheater outlet steam temperature shall be maintained at rated
values within the whole control range of Boiler load. Further, during such
operation the metal temperature of various pressure parts shall not exceed the
limits stipulated in their design/ selection.
1.3.7
Operation with/ without Turbine HP- LP Bypass System

i)
As specified elsewhere, when unit trips under full load, HP-LP by-pass
system shall come into service. This will call for boiler operation in HP-LP
bypass mode, with SH flow of [60% BMCR] capacity and feed water
temperature of [140C] at economiser inlet. For such condition the
economiser shall be suitably designed to take a thermal shock of sudden
change of feed water temperature from the rated value to approx [140C].
The superheater and reheater outlet steam temperatures, during such
operation shall be maintained at the rated value without the metal
temperature for various pressure parts exceeding the safe limits stipulated for
their design/ operation.
ii) Irrespective of the fact that HP-LP bypass system is provided for smooth
start-up, fast loading and house load operation of the unit; the Boiler shall
also be capable of start up without HP-LP bypass system in service, except in
case of hot start-up.
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1.3.8
[Logo of Utility]
Mode of Boiler Operation and Rate of Loading

i) In line with the plant operating capability requirements, the Boilers shall be
designed for [both constant as well as variable pressure operation]. Thermal
design of Boiler and the selection of materials shall be suitable for both the
operational modes.
ii) The Boilers shall be designed for minimum rate of loading/ unloading
mentioned below from 50% to 100% (TMCR) loads without compromising on
design life of pressure parts.
a. Step load change
: Minimum 10% per minute.
b. Ramp rate : Minimum 2% per min (30% to 50% TMCR Load)

: Minimum 4% per min (50% to 100% TMCR Load)
Bidder shall clearly bring out the max. rates of loading/ unloading achievable with
steam generator offered and the corresponding limiting variations (+ %) of boiler
parameters such as throttle pressure, oxygen in flue gas, drum level, SH steam
temperature, RH steam temperature, furnace draft, etc.
1.3.9
Furnace
Furnace shall comply with following requirements at 100% BMCR with or without
HP heaters out of service and with range of specified coal, under most stringent
combination of operating conditions.
i)
ii)
iii)
iv)
v)
vi)
Max heat input (NHI) per

Unit plan area of furnace
Max heat liberation rate
(Volumetric Loading)
Max burner zone heat release rate
Max heat input per burner
Max furnace cooling factor
Max furnace exit gas temp(FEGT) :
vii) Minimum furnace residence time

viii) Pressure withstanding capability :
ix)
No. of coal burner elevation to

be fed from one mill
Document Number
LII-GETS12021-G-00129-001
:
:
4-5x106 kCal/hr/m2
110000 kCal/hr/m3
:
:
:
Bidder to furnish kCal/hr/m3

60C
below
minimum
initial
deformation temperature (IDT) of
ash
(FEGT
measured
at
downstream of first stage Platen SH)
[1.8-2.0 seconds.(Coal specific)]
Minimum 660 mmwc at 67% yield
strength or maximum conceivable
head of fans, whichever is higher.
Bidder to specify
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x)
Buckstay spacing
xi)
Buckstay support
1.3.10
[Logo of Utility]
To ensure that its natural frequency

is sufficiently away from the flame
pulsation frequency.
Self support from furnace walls with
no interconnection from the flame
pulsation frequency.
Pressure parts
i)
The design of all pressure parts (tubes, headers, vessels etc.) shall be as per
IBR or other international codes with the approval of the Owner.
ii)
Design pressure of the boiler pressure parts shall be at least 1.05 times the
maximum operating pressure, or as required by IBR/ other international codes,
whichever is higher. For boiler drum, the design pressure shall be higher of the
value as per (i) above or lowest drum safety valve set pressure for full discharge.
iii)
The thickness of the pressure parts (steam and water tubes/ headers, pressure
vessel etc.) shall be calculated using IBR formulae/factor of safety etc (or as per
codes/ formulae acceptable to IBR). Such thickness as per IBR formulae shall be
arrived at after allowing for tube bend thinning, where ever applicable as per
IBR/international codes. Additional erosion allowance on the calculated tube
thickness shall be provided at specific locations as specified in this specification.
iv)
In line with IBR, the maximum permissible temperature/ metal temperature for
design of different components of the boiler shall be considered as below:
Table 1.2
Design temperature values for different components
S.No
Components
Designed values
Economiser tubes
Maximum working water temperature plus 11

deg C
Furnace and boiler tubes
Saturation temperature corresponding

maximum working pressure plus 28 deg C
Superheater and reheater

tubes in convection path
Maximum working steam temperature plus 39

deg C
Superheater and reheater

tubes in radiation path
Maximum working steam temperature plus 50

deg C
to
Material for Design Metal Temperature is given below

Design Metal Temperature
Upto & including 400C
Document Number
LII-GETS12021-G-00129-001
Material
Carbon steel to ASME SA-106 Gr. B/C or SA 209 T1 or
SA 210 Gr-A1 or approved equivalent
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Design Metal Temperature
1.3.11
[Logo of Utility]
Material
Upto & including 550C
Alloy steel to ASME SA-335: P-11/P-12/P-22; ASME

SA213: T-11/T-22 or approved equivalent.
Material above 550 C & up

to 600C
Alloy steel ASME SA-335/213:P91/T-91 or approved

equivalent
Superheaters and Reheaters

Table 1.3
Superheaters and Reheaters Design Criteria
S.No
Components
Designed values
Maximum average flue gas

velocity in section/ tube banks
with transverse tube pitching
600 mm or less and with 20%
excess air at economizer outlet
Means of temperature control
10 m/s (The maximum localized velocity

across the cross section shall not exceed
12 m/sec)
Super heater
Spray water attemperation shall be tapped

off from a suitable source upstream of HP
heaters (from BFP discharge or Kicker
stage outlet). The bidder can also tap off
the spray water
from a suitable location
downstream side of HP heaters, provided
bidder is having experience of such
tapping, details of which shall be provided
to Owner/Consultant.
Reheater
Spray water attemperation (utilizing water

tapped off from inter-stage of BFP)
Maximum allowable spray water

flow
For Superheater: 8% of TMCR flow,

however the valve sizing shall be
considered 12% of BMCR flow.
For Reheater: 3% of RH flow at TMCR
(However, the control valve shall be sized
for 6% of the BMCR flow.
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1.3.12
[Logo of Utility]
Economiser
Table 1.4
Economiser Design Criteria
S.No
1.3.13
Description
Design basis
Type
Non steaming type, with parallel cross flow

or counter cross flow arrangement
Feed Water Approach temperature
17 deg C (min.) at BMCR load. However,

there shall be no steaming at part load
and/ sliding pressure operation
Maximum average flue gas velocity

through inter-tube space of the
economizer banks (the gas velocity
shall be calculated
considering
17% excess air at economiser
outlet)
10 m/s (maximum localized velocities shall

not exceed 12m/s)
Air Pre Heaters

Table 1.5
Air Pre Heaters Design Criteria
S.No.
a
Description
Design basis
[Regenerative type Tri-sector air pre heaters with facility
of steam coil heating on secondary air side to guard
against low cold end temperature.]
Type
OR
[Tubular type air pre heaters with facility of steam coil
heating to guard against low cold end temperature.]
b
Design ambient air
[27C and 60% RH]
Boiler load to be
60% BMCR with worst coal and maximum moisture

[with one APH in service, as applicable for
Regenerative type Tri-sector air pre heaters]
Minimum average cold- end

temperature at100% BMCR
(with SCAPHs out of service)
Bidder to calculate and specify.
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S.No.
Description
[Logo of Utility]
Design basis
APH sizing shall also

ensure following (for whole
range of specified fuels)
-Minimum
flue
gas
temperature (corrected) at
APH exit at 100% TMCR
load with design coal firing
- Air leakage
[135-150 deg C]
Max 10% of the TMCR flue gas weight entering airheater [as applicable for Regenerative type Tri-sector
air pre heaters].
Minimum
flue
temperature at all loads
gas
10 deg C above acid dew point of flue gas
Sizing of air-preheater(s) shall also ensure that there is no need for economiser
bypass to get the desired mill outlet temperature, for the whole range of specified
coal.
1.3.14
Steam Coil Air preheater (SCAPH)

SCAPH shall be designed and sized to increase the air heater inlet temperature
based on following criteria
i)
Design ambient temperature
[27 deg C]
ii)
Number of SCAPHs
One (1) per [tri-sector type] APH
iii)
Air temperature at the inlet of
To keep average cold end metal
each air preheater (throughout
temperature minimum 10 deg C
boiler control range)
above the acid dew point for

flue gases.
iv)
1.3.15
Design SCAPH and connected duct work suitable to handle flows corresponding
to 30% BMCR loads without any undue noise/vibration.
Auxiliary Steam PRDS
The sizing of the auxiliary steam PRDS shall be based on the following:
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Table 1.6
Auxiliary Steam PRDS - Particulars
S.No.
Description
High capacity
auxiliary PRDS
Low capacity
auxiliary PRDS
No. of aux. PRDS unit
Source of steam
Main steam line
Capacity
Bidder to specify Bidder to specify

depending
on depending
on
requirement as per requirement
as
Note-1
per Note- 2
Indicative parameters of steam on [16 kg/cm2 (abs.) [16 kg/cm2 (abs.)

and 210 deg C]
and 310 deg C]
downstream sides
Cold
reheat
steam line
Note-1: The high capacity PRDS shall be sized for auxiliary steam requirement of
the equipment specified in the bidders scope of supply with the normal unit
running at TMCR rating [plus start-up auxiliary requirement of another unit, if any]
plus the auxiliary steam requirement of equipments in Owners scope.
Note-2: The low capacity PRDS shall be sized for auxiliary steam requirement of
the equipment specified in the bidders scope of supply with the normal unit
running at TMCR rating plus the auxiliary steam requirement of equipments in
Owners scope.
1.3.16
Coal Firing System

a) Coal Mill
Type - Vertical spindle mills type [(like pressurized type bowl mills, ball and race
mills, MPS type roller mills or approved equivalent)]
Input coal size: 20-25 mm with excursion of 50 mm up to 15%
Maximum loading of the mill with worst coal and design coal (for sizing whichever
is higher) - 90% or mill loading achievable corresponding to near wear out
condition of mill grinding loss whichever is less for the range of specified coals.
Expected Mill out-put: 99% thru 50 mesh (300 microns) and 70% through 200
mesh (75 microns)
No. of Mills:
At 100% BMCR worst coal firing [N+1]

At 100% BMCR design coal firing [N+2]
At 100% TMCR worst coal firing [N+2]
(Where N is no. of Working Mills)
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Guaranteed life of different mill components:

Seals: 20000 hours
Grinding elements (Rolls/Balls and Rings/Race): 7200 hours
Mill Discharge Valves: 15000 hours
Classifier Cone and other ceramic lined components: 25000 hours
Classifier vane: 25000 hours
b) Coal pipes
S.No
1
Detail
Description
Minimum 15m/s
Velocity in coal pipe
Maximum 28m/s
2
Continuous
operating
temperature for pipe design
110 deg C (Minimum)
Special erosion protection
Ceramic lining/wear plate liner
(on identified areas)

4
Design Pressure
3.5 kg/cm (minimum) as per NFPA

requirement
c) Raw Coal Feeders

S.No
Detail
Description
Type
Gravimetric type.
Maximum moisture
As per specified coal
Feeder capacity
Minimum 20% spare capacity over maximum

mill capacity
Environment
withstand
capability as per NFPA
norms
a) Operating pressure of 0.14 kg/cm

2
b) Explosion pressure of 3.5 kg/cm (minimum)
c) Ambient temperature 70 deg C Other
environmental conditions envisaged
d) Coal burners
S.No
Detail
Description
Capacity
a) To be cater to 100% BMCR load

b) To ensure stable operation at BMCR
with coal having lowest volatile matter
without oil support.
Turn down ratio of each set from

one mill
To be decided by bidder as per stable

operation criteria detailed above subject
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to minimum of 2.5:1.
1.3.17
Special feature
a) Low NOx design.

b) Total NOx emission (fuel as well as
thermal NOx shall not exceed
260gms/giga joule of heat input to the
boiler)
Control
Centralized automatic control with flame

scanner and safety precautions.
Operation
Conforming to NFPA guidelines.
Fuel oil preparation and Firing System

i)
Type of fuel oil

Startup fuel for cold start
LDO
Startup fuel for normal start up,
HFO
low load operation, coal flame

stabilization
ii)
iii)
Minimum fuel oil firing capacity

For LDO
[7.5% BMCR heat input capacity]
For HFO
[30%BMCR heat input capacity]
Steam/air atomized with HEA igniters
Oil burners
Type
Atomization medium :
Air for LDO and steam for HFO
Capacity
> To cater for [30% BMCR] heat input with HFO for
load carrying and as oil support.
>To cater for [7.5% BMCR] heat input with LDO for
startup at cold start conditions.
iv)
Turndown ratio
v)
1.3.18
Control
:
:
4:1.
Centralized automatic scanner with flame scanner
and safety protection.
Draft System
The forced draft (FD) fans and induced draft (ID) fans shall be capable of
maintaining balance draft conditions in the furnace over the entire load range
with any one or both FD fans and any one or both ID fans in operation while
burning the specified range of fuels.
Document Number
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Table 1.7
Draft System - Particulars
S. No.
Description
FD fans
ID fans
i)
Type of fans
Constant speed axial fans
Variable speed radial fans

or constant speed axial fans
with variable blade pitch
control
ii)
Fan sizing criteria

with all the following
conditions occurring
together
Each fan to be sized for 60%

BMCR flow (one stream in
operation) calculated taking into
account
following
factors
occurring together.
Each fan to be sized for

60% BMCR flow (one
stream
in
operation)
calculated
taking
into
account following factors
occurring together.
a) Type of coal firing
Design/best/worst coal whichever

gives maximum FD fan air
requirement
Design/best/worst
coal
whichever gives maximum
flue gas flow.
b) Power
frequency
47.5 Hz
47.5 Hz
supply
c) Excess air
20% over
requirement
d) Fan inlet air/ flue

gas temperature
[27 deg C with 60% RH]
e) Air heater air-in

leakage
10%
or
guaranteed
whichever is higher
f) Pressure
through ESP
drop
Not applicable
[25 mmwc]
g) Air-in
leakage
through ESP
Not applicable
1% through ESP and 2%

through duct or actual
whichever is higher
h) Pressure required
at chimney inlet
Not applicable
+ 10 mmwc
i) Air
Not applicable
+2%
in
Document Number
LII-GETS12021-G-00129-001
leakage
stoichiometric
air
20% over stoichiometric air

requirement
150 deg C or actual which
ever
is
higher,
corresponding to ambient
air temperature of [27 deg C
with 60% RH]
value
Based on minimum 15%

leakage from primary air
and minimum 10% leakage
from secondary air.
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FD fans
ID fans
through duct
iii)
j) Operating
medium
atmospheric air
Flue gas
The fan shall also

fulfil following sizing
criteria in addition to
that
mentioned
above (with both
fans working):
Taking into account following

conditions taken together:
Taking
into
account
following conditions taken
together:
a) Margin
over
100% BMCR flow
20%
20%
b) Margin
100%
pressure
44%
44%
over
BMCR
(The sizing criteria specified above shall consider air heater and ducts in normally fouled up
condition. The static pressure requirements only shall be considered without any credit for
velocity pressure recovery.)
Additional Points needs to be considered in design:
Suction effect of the chimney to be neglected.
Pressure and temperature drop across ESP has to be considered.
Minimum efficiency of the ESP has to be considered.
Deterioration in the capacity of the fan due to wear on account of extended period of service.
1.3.19
Flue Gas Duct and Air Ducts

All necessary flue gas and air ducts shall be provided. Supply of the flue gas and
air ducts shall include all access doors, inspection ports, test points and thermal
insulation. The bidder shall supply all steelwork for supporting the ductwork
together with all expansion joints and special supports necessary to
accommodate thermal expansion. Expansion joints shall be designed so that
dust or water cannot accumulate in them.
All necessary drains shall be provided to ensure complete draining of wash
water. The duct design shall ensure that wash water does not accumulate on
duct surfaces and cause off load corrosion. All ducts shall be designed for the
most severe pressures.
i)
Maximum allowable flue gas velocity:
13 m/s (before ESP)

16 m/s (after ESP)
ii)
Maximum allowable air velocity
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16 m/s
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iii)
Design Pressure
660 mmwc at 67% yield strength

or maximum conceivable pressure of
the relevant fans, whichever is
higher.
iv)
Type of damper
a) Control damper: pneumatic

b)
Isolation:
Electric/pneumatic,
where fast closing is desirable from
process point of view.
v)
Duct Plate material
a) Minimum thickness 6 mm in the

flue gas ducts. However, duct pate
thickness of 5 mm can be
considered, provided the duct
stresses remain in normal range.
b) Minimum thickness of 5 mm in the
air ducts.
c) A corrosion allowance of 1.5 mm
shall be considered for
stress
calculation for gas ducts.
d) Resistance to flow is to be kept at
an economically low value.
e) Equal distribution of flow to
various portions of the unit is to be
ensured.
f)
Dust
accumulation
prevented/minimized.
is
g) Wind load, dead weight and

weight of insulation, lagging and
cladding.
h) Proper drainage of ducts.
i) Extra thickness of flue gas duct
plate at the portion where
flue
gas changes direction.
j) Adequate provision of access by
providing gas tight access
doors
with bolted and hinged covers and
ladders / platforms staging, etc for
carrying out maintenance.
k) Provision of ash/dust hopper in
the flue gas ducts, as may be
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required, especially in vertical

portions or at the place where flue
gas changes direction.
l) Suitable load factors shall be
applied to the design loads to care of
the higher temps.
m) Vibration aspects of ducts and
respective fans so thatresonance
does not occur under any condition.
1.4
System Description
1.4.1
Boiler
Boiler shall be designed to produce maximum continuous output power with
steam parameters of [137 kg/cm2 (a)] pressure and [540 deg C / 540 deg C]
temperature at the SH outlet. The power plant shall be designed to operate on
unit basis [having no interconnection with other units either on the boiler feed
water side or main steam side. Each generator shall be connected to its own
generator transformer].
Table 1.8
BOILER Parameters
S.No
Unit
Value
1.
Main Steam Flow at BMCR
Parameter
TPH
[..]
2.
Main Steam Flow at TMCR
TPH
[..]
kg/cm (a)
[137]
deg C
[540]
3.
Main Steam pressure at SH Outlet,
4.
Main Steam temperature at SH Outlet
kg/cm (a)
[130]
Main Steam Temperature at HP Turbine inlet
deg C
[537]
Hot Reheat inlet Temperature at IP Turbine
deg C
[537]
5.
Main Steam Pressure at HP Turbine inlet
6.
7.
The above parameters are indicative only and the bidder has to size the Boiler as
per their proven standard practice for optimized and efficient [210/215/220/250]
MW units.
a) Considerations for Boiler Design
The Boiler design parameters shall comply with the following limiting parameters
with design coal firing. The Boiler shall be designed to operate as a base load
unit. However, continuous operation under two shift and cyclic modes during
certain periods of the year is also envisaged. The design should cover adequate
provision for quick startup and loading of the unit to full load at a fast rate and
apart from constant pressure operation would also have the facility for sliding
pressure operation.
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1. The Boiler design shall be such that the rated Reheater outlet temperature is
achievable for the entire range of operation while firing the specified range of
coal and under all the specified operating conditions of operation of Boiler
with reduced feed water inlet temperature during the conditions of HP heaters
out of operation and/or HP/LP bypass operation, at 100% TMCR load.
2. The unit and the auxiliaries shall be designed for maximum reliability and
availability; operability and maintainability. The bidder shall specifically state
the design features incorporated to achieve the high degree of reliability and
availability.
3. The unit shall be suitably designed and provided with necessary
instrumentation for rapid starting, loading and unloading without causing
undue vibration, distortion, differential expansion or producing excessive
thermal stresses. The design of the control system and relevant equipment
shall adhere to the fail safe operation at all system conditions. The fail safe
operation signifies that loss of signal/air/power supply, loss of excitation or
failure of any component shall not cause hazardous conditions and at the
same time prevent occurrence of false trips.
4. The work falling under the purview of Indian Boiler Regulations (IBR) shall
completely meet or exceed all the requirements of the latest edition of IBR.
Any other standard acceptable to IBR can also be considered, provided the
requirements of that standard are equivalent or exceed IBR requirements.
5. It shall be the responsibility of the Bidder to furnish the requisite
documentation as required by the Owner/consultant for ascertaining the
adequacy of the design/soundness of the materials of construction
/manufacturing methods adopted etc.
6. All materials used for the construction of the equipment shall be new and
shall be in accordance with the requirements of this specification. Materials
utilised for various components shall be those which have been established
for use in such applications. It would be the responsibility of the bidder to
furnish the relevant information in this regard, as required, at the time of
detailed engineering.
7. All heavy parts of the plant must be provided with some convenient
arrangement for aligning and for handling during erection and overhaul. Any
item of plant required be stripping or lifting during period of maintenance and
weighing one tonne or more shall be marked with its approximate weight. All
equipment shall be designed to run satisfactorily without any undue noise and
vibrations. Corresponding parts throughout shall be made to gauge and shall
be interchangeable wherever possible. No welding, filling or plugging of
defective parts shall be allowed without the permission in writing to the
Owner.
8. The Boilers shall be supplied with all equipment and software necessary to
monitor and record the fatigue and creep life usage (as appropriate) of major
pressures parts which shall include but not limited to the drum, main steam
and reheater outlet pipes and the superheater and reheater outlet headers.
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1.4.1.1
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Boiler Furnace
i.
The furnace shall be designed to burn the specified fuels under all loads up to
BMCR.
ii. The furnace volume and residence time shall be sufficient to maintain efficient
combustion at all loads without incurring any damage and there shall be no flame
impingement on any part of the furnace walls, superheater or reheater, and no
accumulation of slag or ash on the walls, tubes or hoppers that shall interfere
with the continuous operation of the boiler or the easy removal of ash from the
furnace hopper.
iii. The thermal ratings of the furnace shall be selected based on previous
successful operating experience with coal having similar slagging, fouling,
combustion and erosion characteristics to those specified.
iv. The design metal temperature for the boiler tubes shall not be less than the
saturation temperature of the steam at the maximum allowable working pressure
plus the following temperature margins:a. 39C for tubes mainly subject to convective heat.
b. 50C for tubes mainly subject to radiant heat.
Test ports shall be provided throughout the boiler for measuring temperatures,
gas pressures and for gas sampling using portable instruments.
1.4.1.2
Boiler Casing
1. The furnace, superheater, reheater, convection passes and economiser shall
be enclosed within a completely gas tight casing. The enclosure shall be
formed using welded wall construction only. Where use of refractory is
unavoidable, 4mm thick steel plate behind refractory shall be provided to form
enclosure and any penetration(s) into the Boiler enclosure shall be sealed for
gas tight integrity.
2. The boiler casing shall be designed and constructed to withstand the
maximum internal positive or negative pressures produced by draught plant
control, or explosion, and complete combustion trips. In addition, the furnace
structural design pressures shall not be less severe than that required by
NFPA 85.
3. Leak tests shall be carried out before commissioning the boiler and before
fixing of external insulation. These tests shall prove the gas tightness of the
boiler casings, associated fittings and flues. Defects shown by this test shall
be made good and proved by a further test, at the bidders expense before
lagging.
4. No Dissimilar Metal Welds (DMW) between austenitic and ferritic steels,
martensitic and austenitic steels, martensitic and ferritic steel shall be allowed
inside the Boiler at site for the pressure parts which are exposed to hot flue
gases.
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5. The casing/pent house and its supporting system shall be capable of taking
additional loads due to accumulation of ash (300 mm thick) expected in
between two overhauls of the units. This additional load is over and above
the other loads considered for casing design.
1.4.1.3
Water Walls
Water/steam walls shall be of membrane wall construction and shall be made of
seamless tubes.
A minimum allowance of 0.6 mm over and above the calculated thickness as per
IBR shall be provided for entire water wall. An additional tube thickness of 1.0
mm over and above the tube thickness of water wall tubes calculated as per
above shall be provided on all water wall tubes coming within a radius of one
meter around each wall blower to guard against premature tube failure due to
soot blowing steam erosion, if the soot blowing arrangement is so designed that
there may be impingement of soot blowing medium on the water wall tubes.
Provide adequate nos. of furnace observation and tapping points for local
instruments, gauges, switches, test pockets etc. Incase water wall orifice are
provided, these should be supplied with indexing holes and index pins
Important features of water walls shall be as given below:
1. Water walls made of seamless steel tubes with membrane welded construction.
2. Minimum refractory construction. Arrangement to ensure that there is no exposed
refractory in the furnace except at the burner throat.
3. Water wall headers shall be sized generously and shall be located outside the
gas path. These shall be provided with suitable openings with forged weld on
caps for inspection and chemical cleaning. If under unavoidable circumstances it is
required to locate the headers in the gas path, they shall be suitably shielded and
protected from erosion due to ash impingement.
4. Water wall headers shall be completely drainable and shall be fed through down
comers.
5. The water wall tubes and headers shall be provided with supports, stiffeners, etc.
for carrying load, for permitting proper expansion / contraction and for protection
against vibrations.
Lowest water wall header shall be at sufficient height to facilitate installation and
easy access for maintenance of ash hoppers and bottom ash handling
equipment. All bottom ash handling equipment shall be installed above ground
level. Elevation of Furnace Bottom ring header shall be so chosen to
accommodate all ash handling equipment like the Scraper Chain Conveyor and
clinker grinder & bed ash transfer conveyor system equipments (by other bidder)
below the header.
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In case of tower type design of the Boilers, necessary leak proof expansion joints
shall be provided between the water walls enclosure and the flue gas duct to take
care of any differential expansion.
1.4.1.4
Boiler Drum
The drum shall be provided with all necessary internals, mountings and fittings
including but not limited to the following:
i)
Steam water separators
ii)
Moisture eliminators
iii)
Feed water distribution system
iv)
Chemical feed pipe
v)
Intermittent and continuous blow down pipes and vessels,
vi)
Saturated steam and water sampling probes
vii)
Nitrogen connections
viii)
Gauge Glass
ix)
Safety valves.
x)
All steam drum integral piping and associated fittings

The dissolved solids in the saturated steam shall not exceed 0.02 ppm when
the total dissolved solids in the Boiler water are not greater than 15 ppm. The
dryness fraction of steam leaving the drum shall not be less than 0.999
Adequate steam separators shall be provided together with a single drain
collection vessel. The separators and drain collection vessel shall be of
welded construction with all necessary internals, valves, mountings, fittings
and accessories.
The drum dished ends shall be provided with properly sized manholes and
hinged manhole covers of forged steel secured by forged steel yokes and
bolts. Suitable sampling connections shall be provided to facilitate collection
of representative samples of Boiler water from drum and of condensed steam
from the saturated steam outlets.
The storage capacity of the drum shall be adequate so as not to cause trip
out of the unit on low drum level, in case of tripping of a running boiler feed
pump and cutting in of the standby pump automatically in 15 seconds.
Storage capacity of drum shall also be adequate considering duration of 10
seconds to reach trip level in Boiler drum from the normal drum level at
BMCR draw off condition with no inlet flow to drum.
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1.4.1.5
[Logo of Utility]
Superheater and Reheater

In the design of the superheaters and reheaters, due account shall be taken of
the inaccuracies of predicting furnace exit gas temperatures to ensure that
adequate surface area is provided in the superheaters and reheaters and that
tube metal temperatures in excess of design are not encountered. Due account
shall also be taken of the variations which shall occur in the characteristics of the
specified fuels.
Measures shall be taken to prevent magnetite exfoliation of the internal surfaces
of superheater and reheater tubes.
The transverse spaces between superheater and reheater elements shall be
selected based on previous successful operating experience with coal having
similar slagging, fouling, combustion and erosion characteristics to those
specified. Bidder to ensure that the furnace exit gas temperature shall be at least
60 C below the minimum ash deformation temperature in reducing conditions for
any specified coal for all loads up to & including BMCR.
Spacing of superheater/reheater elements shall be selected with specific
reference to ash quality in coal particularly in high temperature sections and
accordingly the spacing shall be large. The transverse pitch of elements in
heating surface meeting highest flue gas temperature region shall not be less
than 800 mm and that of lowest flue gas temperature region shall not be less
than 100 mm.
Design of the superheater elements shall be such that any individual tube or
element can be easily repaired & replaced with or without removing it from the
Boiler. Design / spacing shall also permit increase of surface area, if necessary.
A minimum spacing of 1.2 m shall be provided between any two sections of
super heater and reheater and between any horizontal tube banks of heat
exchangers to allow personnel access for maintenance. For vertical surfaces,
minimum clearance between two banks shall be 600 mm.
All the horizontal heat transfer surfaces shall be suitably supported using steam
cooled tubes. The support tubes shall be designed to withstand direct radiation
and shall not be subjected to distortion, erosion, corrosion and creep. The joint
between the supporting tubes and the heating surfaces shall be designed so as
so to permit free thermal expansion of both the supporting tubes and the heating
surfaces. Necessary shielding shall be provided to prevent direct impingement of
flue gases.
Necessary safety valves as per IBR shall be provided for superheater and
reheater system. Test pressure gauges shall be provided on the super heater
outlet pipes and the reheater inlet pipes to facilitate adjustment of the setting of
safety valves.
The reheater shall be provided with isolators both at inlet and outlet to facilitate
isolation of reheater during hydraulic tests. Reheater isolating devices shall be
provided on cold reheat and hot reheat lines at Boiler outlet. Isolating device shall
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consist of a robust cast steel body with carbon steel (ASTM A216 GR WCB)
material for cold reheat application and alloy steel (ASTM A217 GR WC 9) for hot
reheat application suitable for pressure and temperature condition to which they
shall be subjected. Isolating device shall be of welded type construction and will
form part of the pipe line during normal operation without any leakage. Before
hydrostatic test top cover and bonnets are removed and a separate test closure
assembly with sealing rings are inserted to close the flow path. Drains shall be
provided on both side of the device.
For superheater and reheater tubes, erosion allowance of one (1) mm shall be
provided over and above the calculated thickness as per the IBR formula. In
addition to the above, +10% minimum thinning allowance on bends shall be
provided. Erosion shields for the tubes shall be provided for critical zones likely to
encounter erosion due to ash or due to soot blower steam. The maximum
average flue gas velocity in the convection pass shall be limited to 10 m/sec,
however localized velocity of flue gas shall not be allowed to exceed 12 m/sec
due to installation of such shields.
The maximum skin temperature to which the tubes shall be subjected shall be 40
deg C below the oxidation limit as applicable to the material.
1.4.1.6
Arrangement of Headers
Headers shall be located outside of the gas path and shall be fully drainable. If
locating the headers in the gas path is unavoidable, then such headers shall be
suitably protected with erosion shields. All headers shall be seamless and shall
be provided with inspection and cleaning openings. All such openings shall be
readily accessible and permit the convenient internal inspection by video-scope
without removal of Boiler enclosure walls or nearby headers and tubes. The
topmost header shall be provided with suitable stubs for nitrogen capping. It shall
be ensured that the maximum steam side header unbalance is 6%
1.4.1.7
Economiser
An inline, bare tube economizer shall be provided with vents, recirculation
system, drains and sampling connections etc. The support structure and hanger
designs shall be suitable for loads due to these additional surfaces. The
economiser shall be of the non steaming type.
The economizer shall be so designed as to keep the feed water temp. in all
sections at least 17 deg C below the saturation temperature, under all conditions
of Boiler operation.
In case of tower type Boilers, economiser shall be arranged for parallel cross flow
of feed water and flue gases. In case of two pass design of Boilers, it shall be
arranged for counter cross flow of feed water and flue gases.
Provision for recirculation of water (economiser recirculation system) while
starting shall be provided.
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The maximum average flue gas velocity through economiser section (with 20%
excess air at economizer outlet) shall not exceed 10 m/s. However; the maximum
localized velocities across the cross-section shall not exceed 12m/sec. The
economiser tubes shall be arranged to permit the installation of soot blowers.
The design shall ensure elimination of water hammering in economiser and feed
line during cold start-up. Maximum skin temperature to which the tubes shall be
subjected shall not exceed the oxidation limit as applicable to the material.
The erosion shields for leading tubes of each tube bank of economiser shall be
provided. In addition sturdy cassette baffles shall be provided for all front side
and rear side bends of economizer banks. The tube thickness erosion allowance
of 0.5 mm over and above design tube thickness considering normal erosion
allowance.
If the Boiler has the flue gas down flow section with horizontal economiser tube
banks, the top most row shall be shielded to reduce erosion.
1.4.1.8
Furnace Sizing
Bidder shall furnish the details of their standard design practices for sizing
furnaces which shall include but not be limited to the following:
1.4.1.9
Maximum net heat input (NHI) per unit plan area of furnace
Maximum heat liberation Rate
Maximum burner zone heat release rate
Maximum heat input per burner, maximum furnace cooling factor
Maximum furnace exit gas temperature
Minimum furnace residence time
Steam Temperature Control

1.
The Boiler design shall ensure that rated superheater and reheater outlet
temperatures are achieved for the entire control ranges while firing any coal
within the specified range and all the operating conditions such as the
following:
Operation of the Boiler with HP heaters out of service
Turbine bypass operation
Mills operating with all combinations
2.
During steady operation the superheater and reheater outlet steam

temperatures shall be maintained constant at all loads above 65% BMCR
when operating in modified sliding pressure mode and shall be within the
permissible limits stated in IEC 60045-Part 1, clause 6.2(b). The superheater
outlet pressure shall be within 1% of the set point.
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1.4.1.10
[Logo of Utility]
3.
During major load changes and during start up when the Boiler is above 60%
BMCR the superheater and reheater outlet temperatures shall be within the
permissible limits stated in IEC 60045-Part 1, clause 6.2(b) and the outlet
pressure within 3% of the set point.
4.
The permissible variations in temperature and pressure shall apply when the
Boiler is operated in both modified sliding pressure and constant pressure
modes.
5.
Superheater de-superheating shall be provided by spray type attemperators.

The spray water shall be from a location on the feed system selected in after
the HP Heaters outlet accordance with the bidders experience.
6.
Each superheater and reheater spray system shall be provided with all
necessary valves and fitting.
Supporting & Enclosing Structure, Galleries, Walkways, Roofing, Platforms

1. Boiler supporting structure complete with girders, beam column base plates,
foundation bolts, shims etc.
Galleries, walkways, platforms, hand rails, ladders, auxiliary steel for piping
supports shall include base plates, foundation bolts, nuts, washers, U bolts and
hangers for Drum (if applicable), superheaters, reheaters, furnace rear pass tubes
(if applicable) and grating.
2. Stair cases/platforms of minimum 1000 mm width with handrails 100 cm high and
2(two) rail safety handrails of 40 mm galvanised iron (GI) pipe, on either side of
Boiler from 0 ML to the roof.
3. The interconnecting platforms between the Boiler (operating floor) and main station
building at 4 elevations (excluding ground floor) at two places per Boiler.
4. Storage platforms for storing of scaffoldings, APH baskets and other maintenance
item during overhaul of Boiler. Platforms for removal, handling & storage of
Economiser and Reheater/Superheater sections (all horizontal heating surfaces).
The above provision shall include but shall not be limited to the following locations:
a)
Bunker outlet gate.
b)
All maintenance hoist levels.
c)
All dampers and their drives.
d)
Furnace seal trough level.
e)
All fans and associated motors.
(Continuous platforms shall be provided around the fans and their
corresponding motors).
f)
g)
h)
i)
SCAPHs
Air preheaters
All valves.
All observation ports, access manholes etc.
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j)
k)
l)
m)
[Logo of Utility]
All soot blowers and water lancers.

All Burner levels
All Control Stations
PRDS area
5. Access platforms, staircases and walkways for sootblowers, man holes/inspection

doors, dampers/damper drives, valves of critical services, ID fans, FD fans, air
preheater, transmitter racks, junction boxes etc.
6. Boiler roof shall be provided with an approach ladders and all round hand railings
7. All Operating platforms and main access walkways in boiler area shall have
minimum width of 1200 mm. All interconnecting platforms (with side coverings and
roof) between boiler galleries and elevators landings shall also have a minimum
width of 2000 mm. In case it is not possible to provide width of the platforms /
walkways as mentioned above due to layout constraints, lesser widths, in
exceptional cases, may be accepted subject to Owners /Consultants approval.
All Maintenance access walkways in boiler area shall have a minimum width of
1000 mm. The gap between the equipment / furnace casing and walkways shall
not exceed 150 mm.
All other walkways shall have a minimum width of 800 mm.
8. Floor Grating
Floor grating for floors, platforms, stair landings, any other locations shall have
minimum 5 mm thick bearing bars on 40 mm centers, 32 mm deep. Cross bars
shall be spaced 100 mm on centers and electro-forged into the bearing bars to
provide a non-slip surface. The gratings shall be made of steel conforming to IS:
2062 and hot dip galvanized. Galvanization shall be done as per IS: 2629 and IS:
4759. Weight of galvanization shall not be less than 610 gm/m2. Grating shall
also be designed for a minimum live load of 500 kg/m2.
Floor grating shall be neatly cut and banded around all openings. Unless
otherwise indicated, banding shall from a 100 mm high curb. Grating to head of
stair runs shall have an applied chequered plate or cast iron abrasive surfaced
nosing similar to that specified for stair treads.
Grating panel shall be removable type and shall have the bars of adjacent panels
aligned.
Grating shall be anchored to support with bent clip fasteners secured to threaded
stud field welded to supporting members. Two clips at each end of each panel
and one clip (staggered) at each intermediate support shall be provided.
Penetrations through grating and floor plates that are not shop fabricated
(generally opening under 500 mm in nominal size pipes and for conduits etc.) are
to be cut in the field as required. Such opening shall be neatly trimmed,
concentric with penetration or as required for movements. Generally 50 mm
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clearance shall be left over insulation and 25 mm clearance at bare metal.

Openings may be ganged where accepted by the Purchaser / Consultant.
Openings less than 150 mm in maximum dimension may be squared off. Large
openings shall be suitably shaped. All grating opening shall be kick plates or
banded to match the shop fabricated work. All grating for a given area shall be
positioned and aligned before the stud bolts are located and welded to the
supporting members.
1.4.1.11
Pipe & Cable Racks

The pipe and cable rack and support structure shall be provided for the pipes /
cable racks with access and adequate working platform, crossovers for erection
and maintenance. Certain portions of these pipe racks shall have to
accommodate Purchasers pipes /cables also, the details of which shall be
furnished to the Bidder during detailed engineering of cable racks:
All other safety requirements as per the factories act, explosives act, etc. shall be
observed while developing the layout.
No cable trenches, under-ground cable vaults are acceptable in main plant as
well as interplant cable routing. In case it is unavoidable, it shall be provided only
with prior written approval by the Purchaser / Consultant. In that case, trenches
shall be finished to surrounding floor levels/ paved area.
To the extent possible, Bidder shall route all the cablings from the Boiler house to
control rooms, MCC/PMCC only at the sideways. Care shall be taken not to route
/ pass the same through Boiler house area.
Bidder shall ensure that in the lay out, no C&I provisions shall be installed below
any of the fire hydrant provision and is suggested that routes for A.C. &
ventilation ducts, piping, cables, etc. be conceptualized at initial stage to avoid or
to minimize any interference during execution / actual installation.
1.4.1.12
Maintenance
The Bidder shall provide adequate handling facilities & approach as for carrying
out on-line and off-line maintenance of the Boiler and its auxiliaries. In order to
carry out on-line maintenance, it shall be possible to readily disassemble, repair
and reassemble the equipment supplied in the shortest period. A minimum of
four accesses and clean out doors in each area shall be provided to permit
access to the furnace, superheater, reheater, the area between tube bank,
economiser and any other area requiring maintenance.
A vertical & straight chute of minimum 500 mm dia and made from minimum 10
mm thick mild steel pipe shall be provided for Boiler, from pent house level to
ground level for disposal of debris & scrap generated during erection, operation
and maintenance. The chute shall be provided with branch connections with
doors and suitable access to the doors at all platform levels. Garbage collection
trolleys shall also be provided at the ground level.
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1.4.1.13
[Logo of Utility]
Valves
The Boiler valves shall include all necessary isolating, control, regulating, check
and relief valves and/or pneumatic valves, motorized valves including main
steam stop valves, vent valves, drain valves, root valves, safety valves,
mountings required for the safe, efficient, and reliable operation of the Boiler.
Valves and accessories shall comply with all the requirements of the applicable
standards. The Boiler drain system shall include emergency drain valves and
appropriate noise reducing measures on the blowdown pipes and tanks. Any
other valves not mentioned specifically but needed to complete the system with
drives, wherever required shall be provided
1.4.1.14
Internal Cleaning of Boiler and Associated Pipe work

1. During the construction and commissioning, the bidder shall be responsible for the
internal cleaning of the Boiler.
2. On completion of erection, and after the commissioning of all the auxiliary plant
associated with the Boiler, Boiler shall undergo a chemical cleaning process
throughout the economiser, and the water circulating spaces. The superheaters
and reheaters shall be subject to thorough water flushing or blowing out procedure.
In addition, the superheaters and reheaters and steam pipes connecting the
superheaters and reheaters shall be steam purged to ensure all foreign debris is
removed. The procedure for steam purging, including the target plate acceptance
criteria shall be reviewed by the steam turbine supplier and the Owner/consultant.
3. All the necessary temporary equipment, pipes, connections and valves, together
with chemicals, inhibitors and reagents necessary for the monitoring of the
effectiveness of the process shall be provided by the bidder.
4. The method adopted for the chemical cleaning process shall be to the approval of
the Owner/Consultant, including the disposal of any effluent. The bidder shall be
responsible for the disposal of the effluent to a suitable site.
5. The procedures for chemical cleaning and steam purging shall be in accordance
with VGB-R 513, "Internal Cleaning of Water-Tube Steam Generating Plants and
Associated Pipe work".
6. Bidder shall be responsible for the monitoring and supervision of all stages of the
process.
1.4.1.15
Fly Ash Hopper

Bidder to furnish all necessary boiler, air heater, fly ash hoppers including ESP
hoppers as required. The capacity of each hopper shall not be less than 8 hrs of
storage capacity when the boiler is steaming at 100% BMCR while firing the
worst coal. All hoppers shall be equipped with proper flanged pipe connection
including matching counter flanges for attaching to fly ash removal system. The
outlet of the fly ash hoppers shall be at a height of 3.5 meters minimum above
the floor level.
1.4.1.16
Soot Blowing System & Water Lancers
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Bidder to supply the fully automatic sequentially controlled micro-processor

based steam soot blowers for the superheaters, reheaters, economizer and
airheaters complete with all pipings and accessories, including valves, controls,
control panels, motor control centre complete with starter and wiring. System
offered shall be for long retractable soot blowers & water lancers for the boiler
furnace.
Water Lancers for furnace shall be of proven design & reliability. 2 x 100%
capacity high pressure pumps and drives complete with necessary valves,
instruments & piping for supplying water to the water lancers and control
systems. All control & interlocks necessary for sequential operation of water
lancers (for deslagging of the furnace zone) shall be incorporated by the bidder in
the soot blowing control panel.
For detailed control and operation philosophy of soot blowing and water lance
system refer respective instrumentation system.
1.
2.
3.
4.
5.
6.
1.4.1.17
The steam used for the blowing should be taken from the appropriate auxiliary
steam header or from saturated/superheater steam header directly.
For air heater blowing additional provision shall be provided to tap off the steam
from auxiliary steam header to clean the elements during startup when steam may
not be available from the main source.
Adequate no of motorised drain valves shall be provided to facilitate warmup the
complete piping before starting the soot blowing operation. Suitable by-pass with
orifice shall also be provided. Temperature detectors with drain valves shall also
be part of the complete system.
The retractable blowers shall be located on both sidewalls of the boiler and each
shall cover little more than half the effective width of the boiler, when fully extended
in order to ensure through deslagging/cleaning. Provision of retracting back the
blowers during emergencies like drop in steam pressure, low steam etc, shall also
be provided.
Platform/galleries shall be provided around all the soot blowers to facilitate access
and maintenance.
Provision shall also be kept for additional installation of blowers/lances in the
boiler. Provision shall also be kept in the control panel, if required to be installed in
future.
[Boiler Startup Circulation Pumps (If applicable)]
Assisted circulation, if applicable, shall ensure adequate circulation during startup, normal operation and sudden load changes to prevent overheating of tubes.
The design shall ensure that with the circulation pumps in operation, all duty of
the boiler can be met under all operating conditions. The design should envisage
adequate stand by pumps or in case assisted circulation is not envisaged, and if
as per the bidders design only one pump (1 x 100%) is envisaged during start up
and low load only, the Boiler design shall ensure adequate circulation during
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normal operation and sudden load changes to prevent overheating of boiler

tubes.
Circulating water pump shall be hermetically sealed glandless type without
requiring any external sealing arrangement. The pump and motor shall be
submerged in boiler water and shall be mounted on the Boiler circulating system.
The entire pump and motor shall be enclosed in the pressure tight casing, motor
being protected from the high temperature fluid inside the pump casing by a
suitably designed thermal throttle. The motor shall be of wet stator construction.
The liquid inside the motor shall be circulated by an impeller mounted on the
motor shaft in a closed cycle network and shall be cooled by indirect water/water
heat exchanger. Cooling water for the heat exchanger shall be tapped off from
cooling water system. The power and instrumentation leads shall be taken out of
the motor through properly sealed glands with adequate provisions of differential
expansion of pump body and conductor.
Pump design and installation shall be so as to ensure adequate NPSH under all
operating condition of the boiler including cold start. The circulating water pumps
shall be suitable for parallel operation throughout the entire operating range.
Adequately sized Journal and thrust bearings shall be provided for the common
shaft of pump and motor assembly. Guide bearings shall be spherically seated
journal guide bearings and thrust bearings shall be spherically seated tiling pad
type double action thrust bearings. All bearings shall be lubricated by the liquid in
the motor cavity. Bearing material shall preferably be Ferrobestos and leaded
bronze impregnated with polytetra fluoro ethylene or FRP.
The material of construction of pumps & motors shall be suitable for continuous
operation with chemically conditioned boiler quality water normally encountered
in such service and shall ensure long service life. The circulation system shall be
so designed that the boiler shall be capable of operating at 100% BMCR
uninterruptedly when any one of the operating pumps undergoes sudden trip out.
Suitable isolating valves shall be provided in the circulating pipings so as to
enable operation of Boiler with remaining pumps. Control valve shall be provided
to ensure appropriate flow distribution/to prevent zonal overheating in the water
walls.
Automatic cutting in feature of stand-by circulation water pump shall be provided
by the bidder. Bidder shall indicate the safety protections and interlock scheme
provided for the circulation water pumps.
1.4.1.18
Boiler Integral Piping

The integral piping shall comply with the Indian Boiler Regulations (IBR) and the
requirements of the Boiler Specifications.
2. The scope shall include all necessary super heater outlet including the Main Steam
Stop Valve (by-pass arrangement including valves and piping), HRH and CRH
piping, HP- LP bypass system piping, complete drain collection piping from various
headers and equipments, drum, safety valves, down comers, drain collection
1.
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headers, all piping downstream of and including the NRV on the feed water piping
at economizer inlet. All auxiliary steam piping to SCAPH, fuel oil atomisation, mill
fire fighting etc. All vent pipes and safety valves escape pipes shall be taken to a
level above boiler house roof. The vents on the headers and links shall be provided
with drain lines connected to a common trough and further terminated at the drain
trench at the ground level.
3. All hangers and supports shall be provided with auxiliary steel structure, including
columns and beams, base plates, foundation bolts, nuts and washers.
4. All the above piping systems shall be complete with valves, specialities, stubs
including instrument stubs pipe reducers/expanders, matching flanges and suitable
gaskets, nuts and bolts.
5. Bidder to provide tapping points with root/isolation valve for sample points for
SWAS.
1.4.2
Draft Plant
Complete draft plant for the balanced draft system shall be tested in accordance
with ASME PTC11.
a) Forced Draft (FD) Fans
Two FD fans (2 x 60%) of the axial, variable pitch type shall be provided with
necessary ancillary equipment and VIS foundation.
Each fan shall be provided with bearing lubrication and hydraulic blade pitch
control unit each consisting of 2 x 100% oil pumps, oil coolers and filters On-line
bearing temperature and vibration monitoring shall be provided.
Blade material for FD fans shall be high strength aluminium alloy having
minimum hardness of 75 BHN. The material of construction of fans, the blade
thickness, liner thickness etc. for fans as per manufacturers recommendation is
also acceptable.
For FD fans, for limiting the noise level, silencers shall be provided at the suction
of the fans to limit the noise level On-line bearing temperature and vibration
monitoring shall be provided.
b) Induced Draft (ID) Fans
Two ID fans (2 x 60%) shall be provided and they shall be of the radial backward
curved type with renewable liners and variable frequency drive with VIS
foundation or constant speed axial type with blade pitch control with VIS
foundation . The blade material of ID fan shall be minimum of 25 mm thick and
provided with renewable liners of wear resistant material having a minimum
thickness of 10 mm. These shall be designed to withstand high bending and axial
load and a temperature upto 200C. However, the material of construction of
fans, the blade thickness, liner thickness etc. for fans as per manufacturers
recommendation is also acceptable.
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Each ID fan shall be provided with bearing lubrication and inlet vane control each
consisting of 2 x 100% redundancy for oil pumps, oil coolers, filters. On-line
bearing temperature and vibration monitoring shall be provided
1.4.3
Regenerative Air Pre-Heater (RAPH)

1. Ljungstrom regenerative type air heater with vertical axis of rotation for
secondary air heating. Each boiler shall be provided with 2 x 60% regenerative
air heater to reduce the diluted flue gas temperature to not less than the acid
dew point when firing the specified fuels, under all boiler operating conditions.
There shall be adequate margin between the sulphuric acid dew point and the
temperatures of the flue gases to the electrostatic precipitators and the flue
gas desulphurization equipment (if applicable) under all operating conditions.
These operating conditions shall include start ups and shutdowns.
2. Each regenerative air preheater shall have 2 x 100% AC drive (1 W + 1S) and
lube oil pump.
3. Each air heater shall be performance tested in accordance with ASME PTC
4.3.The air heater design and construction shall ensure that the leakage from
the air space to the gas space shall not be greater than 10% of the inlet gas
flow after 8760 hours of operation.
4. Air heaters shall be provided with forced lubrication system for bearing 2 x
100% oil coolers, pressure & temperature indicators, complete piping valves,
pressure switch and all the bearings shall be provided with temperature
sensing elements for local as well as remote measurement.
5. The air heater shall be equipped with an approved means of internal fire
detection and fire fighting water supplied from the station fire hydrant system.
The equipment shall be complete with all the necessary probes, scanners and
controllers etc., to operate in conjunction with the station alarm system.
6. Steam soot blowers, complete with the necessary pipe work, valves and
fittings, shall be provided to enable effective on load cleaning and cleaning
during the start-up period of the air heater.
7. Air heater housing shall be provided with suitable access doors for inspection,
cleaning and maintenance. It shall be possible to replace the cold end
elements without dismantling the RAPH. Inspection ports in the air inlet duct
for rotor inspection shall be provided with glass windows and vapor proof
lights. Suitable water washing arrangement shall be provided which includes
necessary pumps, pipes, valves, fittings & drains. The drains shall be
connected to the slag flush channel.
8. The handling arrangement for RAPH shall include hoist for
Basket removal operating floor to ground level (1 no common for two

RAPH)
From Air heater top to operating floor (one number for one RAPH)
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1.4.4
[Logo of Utility]
Steam Coil Air Pre-Heaters (SCAPH)

Steam coil air preheaters shall be provided in FD fan outlets with necessary
dampers, condensate collection flash tank, along with drain pipe up to flash tank
and from flash tank up to condenser, auxiliary steam piping to supply heating
steam to each SCAPH from the auxiliary steam system during start up along with
individual temperature control valves.
SCAPH of modular construction shall be provided by the Bidder for start up, for
low load operation of the boiler or at any abnormal condition when an increased
air inlet temperature is considered desirable. SCAPHs shall be adequate to
maintain cold end metal temperature 10 deg.C. above acid dew point throughout
the load range i.e. 60%TMCR to 100% BMCR with a minimum ambient
temperature specified. These shall not be used under normal operating
conditions for the whole range of fuel specified.
Each SCAPH and connected air ducts to handle flows shall be designed for 30%
BMCR load.
Air temperature at SCAPH outlet (with best Coal firing) shall be as below:
At 30% BMCR - 100C (minimum)
SCAPHs shall be provided on the outlet of each FD fan in a bypass duct with
necessary shut off and control dampers so that the SCAPH can be completely
isolated from the service line, whenever it is not required. Steam supply
arrangement for SCAPH shall be complete with necessary valves, power
operated control valves, motor operated isolating valves, steam piping, steam
traps etc. Steam for SCAPH shall be taken from auxiliary steam header of the
boiler. Each SCAPH shall be provided with its own drain and the drain
condensate from SCAPH shall be directed to IBD tank.
1.4.5
Coal Mills
The coal Mills shall be vertical spindle type (like pressurised type bowl mills, ball
and race mills, roller mills or the approved equivalent. The number of coal
pulverisers to be provided shall conform to sizing /standby requirement. Each Mill
shall be complete with all wear parts/ grinding elements and shall be provided
with platforms around the Mill, lubrication systems (comprising of [2x100%
pumps, 2x100% cooler and 2x100% filters] for each pulveriser) drive motors,
auxiliary gear, instrument tapping points and any other equipment necessary for
safe and efficient operation of Mill. The Mill shall also include static classifier and
all the automatic auxiliary equipment necessary to make the Mill self contained.
Adequate number of temperature sensors, temperature transmitters, local
indicators and signaling contacts for bearings and lube oil systems shall be
provided as per standard practice of Bidder. Independent purge meters, air filter
cum regulator sets, local pressure indicators, instruments and sensing device for
milling system including the instrument requirements shall be provided. Primary
airflow measuring devices shall be provided at air inlet of each coal pulveriser.
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Adequate number of thermocouple type fire detection system with temperature

transmitters as a composite & complete unit with all required accessories with
adequate redundancy shall be provided.
Proven fire detection and fire extinguishing systems in line with the standard
practice of the manufacturer shall be provided. In case of CO2/N2 based system,
the scope of supply shall also include the required cylinder/piping and valves
network etc. In case, the proposed type of mill requires inerting during start-up/
shut-down of the mill to ensure safety of operation, suitable system along with all
piping, valves, instrumentation, interlock system etc. shall also be provided.
The bidder shall provide the necessary interlocking features for the coal mills for
safe operation of the Boiler.
Bidder to ensure the sufficient access is provided for removal of mill components
as well as from maintenance consideration. Dismantling of any duct, platforms,
structural steel, coal pipes shall not be required to remove beater mill internals.
Bidder shall take care of over load imbalance in the mill and shall not be
transferred to the boiler main structure.
1.4.6
Seal Air Fans

2x100% centrifugal seal air fans common for all the mills of one Boiler unit shall
be provided. Seal air catered through FD Fans discharge is also acceptable
provided adequate size and capacity of FD fan /Ducts is taken care of by the
bidder. The sealing system shall prevent ingress of any dust into the bearings
and cold air leakage in to the Mill from atmosphere.
Following margins shall be provided for each fan over and above the calculated
values under maximum duty conditions are:
Margin on flow
25%
Margin on pressure
30%
The above margins shall be based on an ambient temperature of 27 deg C,

relative humidity of 60 % and system leakages with mill operation at maximum
duty.
1.4.7
Coal Burners
i.
Number and arrangement of the coal burners shall be such that there is
stable firing and efficient total combustion in the furnace while firing the
specified fuel and operating with any combination of pulverisers. The basic
criteria for selection of firing system shall be:
ii.
Stable flame over entire operating range of the furnace.
iii.
Complete burn out at furnace exit.
iv.
Avoiding contact between flame and furnace wall.
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v.
More number of burner with less heat release rate in order to ensure better
turn down than few larger rates.
vi.
Selection of heat release rate for furnace & burners that will prevent
inadmissible fouling in particular within the burner area.
vii.
Burner design shall be such as to minimize NOx generation. Bidder to

furnish the detail of the design to keep the NOx level with in permissible
values
Pulverised coal coming out of mill goes to the vertical coal burners through
pulverised piping. Each coal burner has an inclination of 10 Deg
downstream. Secondary hot air is fed through proper air duct to the coal
burners. Pulveriser coal velocity shall be in the range of 15-28m/sec.
The air / fuel ratio around the burner shall be optimized to ensure low
emission of NOx which shall not exceed [260] grams / gigajoule of heat
input of the boiler.
1.4.8
Oil Burners
Oil Burner design basis shall be as follows:
Table 1.10
S.No
1.4.9
Particulars
HFO Firing System
LDO Firing System
Type of burner
Steam atomised ( steam to

tap off from the auxiliary
steam header)
Air atomised( to draw from

the compressed air system)
Burner cooling
medium
Steam or air
Air
Burner tip material
Resistant to corrosion
Resistant to corrosion
Minimum life of burner

tip before needed any
maintenance
16000 hours
16000 hours
Hardness of atomizer
(hardness retained
even at 400C)
Type of oil igniters
High Energy Arc Igniters
High Energy Arc Igniters
Oil burner turndown
4:1
4:1
Minimum vickers hardness 400
Dampers
Isolation dampers with electric drives on all cold air, hot air, seal air, and flue
gas ducting before and after equipment.
Electrically operated guillotine type gas tight isolators at inlet and outlet of
each ID fan and electrically operated dampers at inlet and outlet of each
RAPH where ever required for local/remote operation
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1.4.10
[Logo of Utility]
Regulating dampers with pneumatic drives, supporting structure for all

damper drives.
Air registers with drives at various elevations
ESP
i.
For designing ESP ash % of the coal shall be considered as [%] as

per worst coal analysis.
ii.
The Electrostatic Precipitators shall be of outdoor type and installed on

the cold end side of regenerative air pre heaters. The flue gas shall be
drawn from air pre heater outlets of the balanced draft, pulverized coal
fired Boiler and guided through adequately sized duct work into the
specified number of independent gas streams of the Electrostatic
precipitators. Similarly, the flue gas after the Electrostatic Precipitators
shall be led to the suction of the induced draft fans. The flue gas
temperature may approach the economiser outlet temperature of about
300 deg C in case the regenerative air pre heaters fail to operate. The
Bidder shall take these aspects into account while designing the
precipitator.
iii.
[4 Nos.]. ESPs per boiler (i.e. [four Nos. gas paths per boiler housed in
four independent casings]) have been envisaged. The capacity of each
ESP shall be designed for a gas flow of [30% BMCR].
iv.
The Boilers are designed to burn HFO (Heavy furnace oil) and LDO in
conjunction with pulverized coal during startup and at low loads for warm
up and flame stabilization. Further, the frequency and duration for startup
and low loads operation may be quite long during the first year of unit
commissioning and operation after R&M. The Bidder shall take into
account the entire characteristics of expected combination of fuels to be
fired and shall clearly bring out in his proposal the recommendations on
preventive measures or equipment to be provided by him to minimize the
possibility of fires in the Electrostatic Precipitators and the
features/materials provided to avoid the corrosion of ESP
components/surfaces.
v.
The Bidder shall offer the best design to accommodate the Electrostatic
precipitator and accessories within the confines of the space available.
The design shall permit satisfactory duct layout before and after the ESP
terminal flanges.
vi.
ESP control room (Individual for each unit) located at grade elevation
adjacent to ESP shall house the control cubicles. Man Machine Interface
(MMI) to be provided to enable UCB operator to access the ESP controls
for control, monitoring and data acquisition functions. The MMI may be
suitably located in UCB .Necessary provision shall be provided for
integration of ESP with plant DCS for effective monitoring.
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vii.
Bidder to furnish the ESP control room AC, ventilation system and
passenger lift (if control room building is having more than 2 floors)
arrangement details in the offer.
viii.
The design of the precipitators shall allow adequate space above and
between the adjacent fields to carryout necessary inspection and
maintenance. A permanent walkway shall be provided at each rapper
level both for the discharge and collecting electrodes.
Minimum
3.0m wide platforms shall be provided between the two casings of the
ESPs to facilitate maintenance work. The protection for the platform and
the rapping motors from exposure to rain shall also be provided.
ix.
Staircases as per the requirements shall be provided from ground to the

roof of the ESPs with landings connected to all platforms. Further, the
platforms between all the ESP casings shall be interconnected at least at
three intermediate elevation. Stair cases and handrails shall be of 40mm
GI pipes etc.
x.
A monorail system with movable trolley and an electrically operated hoist

mounted on the precipitators roof shall be provided for handling and
maintenance of HVRT, rapper motors, fans (if applicable) etc.
xi.
Collecting electrodes shall be designed for dimensional stability and to

maintain the collection efficiency at the specified level. Minimum Specific
Collection Area (sca) with one series electric field out of operation shall
not be less than [180 m/m/sec] for a maximum collecting plate spacing
of [400 mm] and shall not be less than [240 m/m/sec] for a maximum
collecting plate spacing of [300 mm].
xii.
The plate spacing shall be either 300mm or 400 mm, and the specific
collecting area and the plate spacing shall be so chosen to achieve the
required dust concentration of less than 50mg/Nm.
xiii.
The high tension discharge electrodes shall be of rigid frame type

design, located mid-way between the collecting electrodes. The
electrodes shall be self tensioned, or restrained in pipe frames. They
shall be constructed from durable, corrosion and erosion resistant
material, helical wires, spiral of SS material to ensure uniform current
distribution. In case spiral type discharge electrodes are being offered,
the material for the same shall be high tension discharge electrode of
durable, corrosion and erosion resistant material like stainless steel.
Vertical and horizontal members shall be rigid enough to maintain the
alignment of the system without warping or distortion even at elevated
temperatures. Provisions made to maintain alignment of electrodes
during normal operation, including rapping and thermal transients, shall
be clearly brought out in the offer. However, no anti-sway insulators shall
be used at the bottom of the discharge electrodes frame to accomplish
the above
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xiv.
Independent rapping system shall be provided for discharge and

collecting electrodes with control systems as per the requirement
specified in Electrical Sub-Section (Part-B, Section-II, Volume-II). The
rapping mechanism shall be of either electric impact type or tumbling
hammer type. This shall be adjustable in frequency, intensity (for electric
impact type only) and duration (for tumbling hammer type) to provide an
efficient cleaning rate. Separate rapping equipment, shall be provided for
the discharge and collecting electrodes served by one HVRT so that
each mechanism can be suitably adjusted when required. It shall be so
arranged that the rapping frequency can be independently set from the
control room in accordance with the operating requirements. The rapping
frequency range shall be adjustable in wide range from 0 to a minimum
of 24 hours, and this facility shall be such that it does not require any
stoppage of rapper operation. Sufficient number of rappers and rapper
drives shall be provided so that minimum collection area and discharge
electrode lengths are rapped at a time, which shall not be more than
4.33% of the total collection area for at least the last two fields/discharge
electrode length of each field served by one HVRT. The Bidder shall
provide necessary calculations in support of fulfilling the above
requirements along with the offer. The rapping system shall be designed
for continuous sequential rapping to prevent puffing under any conditions
of precipitator operation.
xv.
All internal parts of the rapping mechanism shall be accessible for

inspection and they shall be placed on wide access passages and shall
be easily accessible for operational and maintenance purposes. Major
part of the rapping mechanism shall be located external to the
precipitator. Necessary lubrication system shall be provided for the
rapping mechanism.
xvi.
The perforated plates and/or guide vanes furnished for gas distribution
system shall also be provided with rapping systems.
xvii.
Dust hoppers shall be of pyramidal type, each having a storage capacity

of minimum of eight (8) hours corresponding to the maximum ash
collection rate of the field under which the hopper is being provided when
two preceding fields are de-energized. The ash carry-over to ESP shall
be taken as 90% of total ash produced while burning worst coal having
maximum ash content. The hopper capacity shall be based on the inlet
dust burden, gas flow rate and gas temperature indicated in ESP sizing
criteria for the design point condition while firing the maximum ash coal.
Storage shall be up to a level which will not reduce the overall efficiency
of the precipitator due to re-entrainment. Ash storage capacity shall be at
least 10% higher than the ash storage capacity theoretically required for
each dust hopper. Specific weight of ash shall be assumed as 600 kg/m
for calculating storage capacity and 1600 kg/m for structural design.
Further for hopper strength and ESP structural calculations the level of
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ash in ESP shall be considered at least up to the top of hopper partition

plane or the bottom of electrodes (whichever is more) plus the angle of
repose from the 3rd field backward i.e. towards ESP inlet. In case a
bidder desires to adopt any level higher than that calculated as above,
this higher level may be adopted. Necessary calculations supporting the
same shall be furnished along with the bid. The number and
arrangement of dust hoppers shall be such that there is at least one dust
hopper per HVRT. Further, an arrangement with one hopper being
shared by more than one HVRT set is not acceptable. The hoppers for
all fields shall be identical in shape and size.
xviii.
Hoppers shall be in welded steel plate construction. The lower 1.5

meters of each hopper shall be lined with 16 gauge or heavier, type 304
stainless steel. All hopper internal sloping corners shall have 100 mm
radius. Hopper valley angle to the horizontal shall not be less than sixtyfive (65) degrees. Hopper outlet flanges shall be terminated at 3.5 m
height above the ground level to facilitate installation of fly ash removal
system.
xix.
The dust hoppers shall be electrically heated up to a minimum of lower

one third (1/3) of the dust hopper height but not less than 1.5 meter in
height by thermostatically controlled panel type heating elements to
prevent ash bridge formation. All heaters on each level shall have same
wattage and be capable of maintaining internal hoppers temperature in
excess of 150C and capacity selection of these heaters shall be as per
Owner approval. The heater arrangement shall be such not to produce
any localized hot spot causing self burning of heaters. This temperature
must be maintained even when there is no flow of flue gases through the
precipitator. Maximum excursion of flue gas temperature up to 350 deg
C, while the air heaters are out also shall be considered for heater
mechanical design. They shall be arranged in at least three groups i.e.
for the lower, middle and upper half of the heated height. The heating
system shall be of low watt density, panel type to avoid hot spots and to
have more uniform distribution of heat having the heating capacity not
less than 10 kW per hopper, or approved equivalent and shall be
complete with local junction box, indicating lamps and test lamps. The
Minimum heat input shall in no case be less than 500 Watts/m of hopper
surface area. Each hopper shall be provided with separate thermostats.
External surface of the hoppers shall be properly insulated.
xx.
Each hopper shall be provided with two (2) nos. of hundred (100) mm dia
poke hole in mutually perpendicular directions, with threaded caps. The
caps shall have flat iron bars suitable for striking with a hammer, to
assist in breaking free any seized threads. The hoppers shall also be
provided with suitably designed and located rapping anvils for loosening
the fly ash by striking with sledgehammer.
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xxi.
Hopper baffles shall be designed to be capable of withstanding the

unbalance of pressure created when one side of the hopper is filled with
fly ash and the other side is empty. All bracing and stiffening shall be on
the external side of the hoppers. Internal bracing, stiffening etc., shall not
be accepted.
xxii.
Each dust hopper shall be provided with a high level, high-high level and
a low level monitor operating on proven Radiofrequency measurement
principle. The level monitoring system shall incorporate all the necessary
accessories including three nos. level switches per hopper (one each for
high, high high and other for low level), each with 2 NO + 2 NC contacts,
local and remote signaling lamps and high and low level alarms. The
high level ash switch shall provide contact closure and activate the alarm
when the ash level reaches a level high enough to cause deterioration of
ESP performance and possibility of damage to ESP structure if not
corrected. After a preset time elapses with the ash under high alarm
activated, the logic shall have provisions to de-energies the HVRT of the
particular field of the affected ash hopper. The level control device shall
be unaffected by ash build up, due to moisture or charged ash on either
the hopper walls or on the probe itself. The high level switches shall be
used for operation of ash evacuation systems.
xxiii.
The structural rigidity & strength of the ESP should be able to withstand
the load of all hoppers fully filled with ash.
xxiv.
Each hopper shall be provided with a quick opening access door of not
less than 600 mm dia, if round or not less than 450 mm x 600 mm, if
rectangular. Access doors shall be hinged vertically and provided with a
safety chain and grounding strap. Suitable access ladders shall be
provided from the walkway beneath the hoppers to facilitate approach to
the access doors.
xxv.
Thermal Insulation along with G. I. / Aluminium cladding shall be

provided for ESP surfaces and hoppers having skin temperature more
than 60 degree Celsius. Weather proof enclosure for insulator
compartment complete with heaters, air blowers, filters, controls etc.
xxvi.
ESP shall be provided with pent house on roof top. ESP pent house shall
be covered continuously with corrugated coloured metapoly sheet of min
0.6 mm thickness
xxvii.
Lower portion of each fly ash hopper shall have SS 304 liner plates. The
outlet flanges shall be standard size and shall be located at a height of
minimum 3.5m above the ground floor level. Suitable opening shall be
provided on both sides in the lower portion of the hopper for providing
fluidizing pads by others. The sizes and location of the opening shall be
finalized during detailed engineering.
xxviii.
Transformer Rectifier Unit
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a)
b)
c)
d)
e)
[Logo of Utility]
Adequate number of roof mounted transformer-rectifier (TR) sets,

mounted on ESP roof top, for supplying HVDC to the ESPs shall be
provided by the Bidder. Minimum one no. of TR set per stream per series
electrical field shall be provided. Each leg of the TR set shall not be
connected to more than one bus section. Protection against surge,
excess temperature rise and under voltage, etc. shall be provided for the
TR units. Ambient temperature for design of TR units shall be taken as
50C. Transformers shall be mineral insulated oil filled type class ONAN
cooling type. The transformers and its associated equipment shall
conform to IS or other approved international standards (like BS / DIN/JIS
etc.) Each field of each section shall be provided with one TR set.
Relays and local instruments, such as, Buchholz relay, local oil level
gauge, dial type thermometer with alarm & trip contact, pressure relief
valve etc. and two nos. marshalling box, one for power and other for
protection & control cable entry shall be provided by the Bidder.
Clear indication for ON & OFF for the transformers shall be provided.
Dedicated key shall be provided in each rectifier panel and corresponding
transformer for maintenance purpose so that in no case running
transformer can be taken for maintenance. Provision for switching off
each TR set from control room shall be provided.
Silicon diode type rectifiers with proven service record and conforming to
relevant IS or other approved international standards shall be provided by
the Bidder. The rectifier units shall be suitably arranged to give
satisfactory operation at all loads with arrangement to take any one unit
off the system without affecting operation of the precipitator. Each TR set
shall be placed on a metal tray to collect leakage/spillage oil. All such
trays shall be connected to common drain pipe which shall be extended
up to ground level with necessary valves. The TR set shall be of approved
make having adequate proven experience of use and subject to approval
of the Purchaser. The HV Rectifier set shall preferably be located in a
separate chamber, other than the transformer tank, in order to facilitate
replacement / maintenance of the diodes. However, designs having HV
rectifier integral to transformer tanks are also acceptable. Over current
protection shall be provided in case of failure of diodes. Each TR panel
shall have a provision of interfacing with ESP control room PC for ON
OFF, data logging, alarm and display, etc. During normal operation, if
power fails, the system can be restarted from PC after revival of power.
HV side of the TR set shall be provided with isolator and earthing switch
that can be operated from outside the HV enclosure.
xxix.
Control Panel,
annunciation
a)
Control Panel
Document Number
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Microprocessor based semi pulse control system shall be provided. Bidder

shall make a separate ESP cum VFD control building, which shall house
LT transformers, Power Control Centers (PCC), MCC, auxiliary control
panels and rectifier control cubicles. One no. Each unit ESP PLC shall be
suitably interfaced with Plant DCS through suitable protocol located in unit
control room. With this various parameters of the ESP shall be monitored
and controlled from unit control room. The incomer and bus coupler status
of LT main switch board, transformer troubles, indication, metering
annunciation etc. of breakers, etc. shall also be monitored at DCS through
hard wiring.
b)
Auxiliary Control Panel

For control / regulation of operation of auxiliaries (rapping system, heating
elements, etc.) auxiliary control panels for each horizontal pass of the ESP
shall be provided. Each aux. control panel shall consist of necessary
relays, Electronic master-controllers, timers, switches, indicating lamps
etc. for the efficient operation and control of individual / group tapping
mechanism and heating elements. Master controller and timer shall be
designed to control the sequence and frequency of the operation of
rapping mechanism of the collecting and discharge system of the different
fields of the precipitators. Signal lamps shall indicate overload tripping of
the rapping motors.
c)
Rectifier Control Cubicle

Control cubicles for the TR unit shall incorporate protections for abnormal
condition such as under-voltage protection and protection for excessive
temperature rise and internal short circuit of the transformer winding. It
shall also include devices like arc suppression unit. The panel shall be
complete in all respects with DC and AC ammeters, voltmeters, circuit
breaking devices, pulse rate controller, L.T. bus bar, control/ switches,
indicators, visual and audio alarm overload and earth fault protection,
current limiting relays, polarity switch (if applicable) and all necessary
relays. The panel shall also provide all necessary interlocks, automatic
regulator and other protective devices for safe and efficient operation of
the precipitator and safety for operating personnel. DC voltage and current
measurement must be directly from DC side.
d)
Annunciation
Annunciation in the unit control room shall include.

ESP rectifier faulty
Electric supply to ESP failed
Rapping mechanism trip
Outlet dust emission level high
Under voltage
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The annunciations shall be suitably made available in the HMI of ESP

PLC.
xxx.
a)
b)
xxxi.
a)
b)
xxxii.
a)
xxxiii.
a)
415V Power cum motor control center / PCC/PMCC

415 V power control center shall have two incomers and one bus coupler
(all electrically operated ACB controlled). This PCC / PMCC shall have
sufficient active / spare feeders for feeding the ESP MCCs, ESP control
panels, etc. ESP MCCs shall have required no. of active and spare
feeders for feeding all loads of ESP. Required number of active and spare
outgoing feeders for control of various ESP drives and loads (including
ESP, control building lighting, air conditioning & ventilation system and
hoist loads) shall be provided for each unit. Electrical panels (PCC, MCC,
etc.) shall be housed in a pressure ventilated room and ESP control
panels shall be housed in air conditioned room.
Each ESP PMCC / PCC shall be fed from 11 KV unit switchgears located
in Power House building via a pair of dry type L.T. transformers to be
installed adjacent to ESP PMCC / PCC within ESP cum VFD control
building. LT transformers located near the ESP switchgear shall be
connected to ESP PMCC / PCC by non-segregated phase, L.T. bus duct.
Cables and cabling
All power and control cables including special cables as required for inter
connection of L.T. PCC & MCC, control cubicles, auxiliary control panel,
TR units, heaters and rapping mechanism motors, remote signaling
devices etc. of ESP system and AC & Ventilation equipment shall also be
provided by the Bidder.
Supply and installation of power and control cables including termination
at both ends is included in the scope. Cable trays, supporting structures,
cable trestle / tunnel / trench, etc. all accessories like cable lugs, glands,
clamps, etc. are also included. Cabling shall be complete with cable
numbering tags, core ferrules, indicating termination and destination at
both ends, cable glands, supports and accessories. Connection between
the TR units and the discharge system shall be provided by bus bar in
ducting by the Bidder.
Earthing and Shielding
All electrical equipment shall be properly protected and two terminals shall
be provided for earthing of each equipment. Earthing of electrical
equipment shall be done as detailed elsewhere. Special electronic type
earthing shall be envisaged for PLC/microprocessor based control system.
Safety Interlocks
Safety sequential interlocks with mechanical key exchange boxes shall be
provided to prevent access to interior of precipitator or hoppers unless all
transformer rectifier sets are de-energised and grounded. This should be
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achieved by key interlock between the rectifier feeder circuit breakers and
the door lock of the precipitator hoppers and roof doors.
xxxiv.
a)
xxxv.
Power Supply
11 kV power shall be fed to ESP L.T. transformer by cables and 415V, 3
phase, 4 wire 50 Hz power from secondary of the L.T. transformer shall be
received at 415 V ESP PMCC / PCC through LT bus duct. Other power
supply requirement if any shall be derived from this supply by Bidder
Routine, Acceptance and Type Tests
Routine and Acceptance Tests
All acceptance and routine tests as per the specification and relevant
standards shall be carried out in the presence of the Purchaser.
Type Test
The Bidder shall submit type test certificates of similar type of the
equipment for the tests indicated below.
a) TR Set
1). Temperature rise test at rated DC current at 1:1 charge ratio
2). Lightning Impulse voltage test
3). Jacking test on Transformer load bearing member
4). Measurement of harmonic current in no load current
5). PRD operation test
6). Short Circuit Test (To be conducted as described below)
This short circuit test shall be performed on TR set along with
the TR panel and controller with a spark gap connected across
the output. The gap is adjusted to get the spark at kVp as
applicable which is the short circuit condition and the controller
shall control the voltage to quench the spark.
7). Oil leakage test for 24 hours
8). Vacuum test on tank
9). Pressure test on tank
10). Induced over voltage test
11). Measurement of no load losses and current
12). Measurement of impedance voltage/ short circuit Impedance
and losses
13). Measurement of IR
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14). Measurement of acoustic sound level

15). Degree of protection test
16). Measurement of capacitance and tan delta
b). Insulators
1). Compression test on support insulator
2). Torsion test on shaft insulator
3). Lightning impulse test and one minute dry power frequency test
on each type of insulators.
c). Disconnecting Switch
1). Lightning impulse test and one minute dry power frequency test
In case the bidder is not able to submit report of the type test(s) conducted
or in the case of type test report(s) are not found to be meeting the
specification requirements, the bidder shall conduct all such tests without
cost implication in the presence of the Purchaser and submit the reports
for approval.
However, in spite of availability of valid type test certificate following
minimum tests shall have to be performed in presence of Owner / Owners
representative as per IS/IEC Standards:
Impulse test on any one transformer of each type selected by the
Owner.
Heat run (Temperature rise) Test on any one transformer of each
type selected by the Owner.
xxxvi.
Model Study
a. The Bidder shall conduct computer based model study using CFD
technique to achieve optimum size and layout of the ducting, uniform flue
gas distribution, maximum particulate collection, minimum draft loss,
minimum dust drop out and build up and minimum re-entrainment from
within the precipitator.
b. The model study shall include the design of all connecting duct work
from the air preheater gas outlets to the induced draft fans inlets,
induced draft fan outlet to chimney flue inlet including the inlet duct
transition piece, including all dampers, turning vanes and distribution
devices. Based on the model test studies, the Bidder shall finalize the
design of the duct work, guide vanes, flow splitters etc. The model study
shall also include a gas distribution study for the duct system around
ESP to find out the effect of isolation of one stream of the ESP.
c. The report of CFD model study shall be furnished to the Owner. CFD
model study for the ESP may not be needed in case the bidder has
earlier carried out the CFD modeling for similar size and type of the ESP.
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The report of CFD model study earlier carried out by bidder for similar
size and type of the ESP shall be furnished to the Owner.
1.4.11
Fuel Oil System

Fuel Oil System under Boiler & Auxiliaries package is envisaged from the
terminal points onwards, as mentioned in Clause No. 5.1 of Section-I of VolumeII.
i.
HFO Transfer System

HFO will be sent to the steam generator by means of positive displacement
screw type supply pumps located in Fuel Oil Pump House. The HFO pumps shall
deliver filtered heavy fuel oil in a common header kept at the correct pressure by
means of a pressure control station on a recirculation line to the storage tanks;
the pressure holders / accumulators if applicable, shall be installed to assure the
minimum pressure required by the burners during trip of one pump and start up
of the stand-by pump. Steam tracing is envisaged for all the heavy fuel oil lines to
maintain required flow ability. Fuel oil burners shall be provided complete with
diffusers, tips extension pipes, atomizers, burner shut off valves, flexible hoses
and all other ancillaries. Oil connections to each burner from ring main shall be
provided complete with fine filters as near as possible to each burner and means
for determination of oil flow to each burner. Complete Piping along with auxiliary
steam piping, oil drain piping, vent piping, tracing steam piping and recirculation
piping shall be provided complete with all protection & instrumentation controls,
suitable hangers, support, pipe trestles, etc.
ii.
LDO Transfer System

LDO will be sent to the steam generator from by beans of horizontal screw type
LDO supply pumps complete located in Fuel Oil Pump House. A common recirculating line with a pneumatic control valve is foreseen to re-circulate the light
fuel oil to the LDO storage tanks. One pressure holder is envisaged to assure the
minimum pressure required by the burners in case of trip of one pump. The light
fuel oil system will have the following design features:
Relief valves will be provided on larger section of fuel oil pipes, which can be
isolated. Isolation valves will be provided both on upstream and downstream
sides for all in-line items like pumps, heaters, flow meters, filters, control valves
etc., which are required to be taken out for maintenance. For LDO handling
system, steam flushing system will be provided for cleaning during
commissioning. Adequately sized pressure accumulators will be provided on fuel
oil lines to individual Steam Generator for maintaining constant oil pressure.
Each accumulator will be complete with a pressure gauge, stop cock and
isolation valves to ensure maintainability of nitrogen pressure.
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iii.
[Logo of Utility]
Pipings, Valves, Fittings, Pipe Support, etc.

The layout of oil piping, valves, flanges, steam traps, fittings and supports etc.
shall be such as to facilitate maximum flexibility of interconnection of pumps,
heaters, strainers. All HFO lines shall be steam traced and properly lagged. All
lines carrying steam and oil shall be provided with adequate drain and vent
connection. All fuel oil lines and filters shall be provided with steam flushing
points at suitable locations. All steam and condensate piping handling fluid of
pressure below 20kg/Sq.cm.g shall conform to the latest edition of IS: 1239
(Heavy grade) or ASTM-A-106 Gr. B or other approved equivalent standards. Oil
pipelines from discharge of pressurising pump to boilers shall conform to IS:
1978 or other approved equivalent standard with latest amendments. Double
isolation valves shall be provided from the discharge of the pressurizing pumps,
for inline items that are to be removed for maintenance. This applies to flow
meters, filters, isolation valves and the pressure maintaining valves etc. Larger
lengths of piping that can be isolated shall be provided with thermal relief valves.
Between the pressure oil line and the return oil line, an interconnecting line shall
be provided with automatic pressure control system to maintain the pressure of
oil to the Boiler at a predetermined value. The interconnecting line shall also
serve to divert the fuel oil to the return line under conditions when oil supply to
the burners is to be cut off or reduced. Suitable non-return valves shall be
provided on the return oil lines from the Boilers to prevent pressurized fuel oil
from going back into the burners in the reverse direction when the quick acting
valve closes. The fuel oil lines to individual boilers shall be provided with
pressure accumulators of adequate size (if warranted by design) to maintain the
oil pressure at a constant value.
All flanges shall conform to IS: 6392 or equivalent. The nominal pressure and
temperature ratings of flanges shall be such as to withstand the design condition
of the respective pipe/equipment to which they are attached. Matching counter
flanges with nuts, bolts and gaskets shall be provided for all the system terminal
points on oil, steam/condensate and air lines.
All high pressure pipe fitting shall be of butt welded construction, wherever
possible and shall conform to ASTM-A-234 (carbon steel)or other approved
equivalent.
All valves on oil, steam and condensate lines shall have cast steel body. Valves
for oil service shall be fire safe ball valves type, easy to operate, less
maintenance prone, leak proof, and self-lubricating type. The valve internals shall
be chrome-steel for oil, steam / condensate lines. The drain valves shall be
located at the lowest points in the system to ensure complete draining of the
system.
Suitable supports / hangers shall be provided for all the piping covered under fuel
oil facilities. Piping in the boiler area shall be designed with laying up on trestle
supports as far as possible. The pipes crossing roads/rails shall also be
trestle-supported. Dead zones in pipes shall be avoided as much as possible.
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The high temperature piping / heat traced piping shall be provided with
expansion loops to take care of thermal expansion.
The steam traps shall be of proven design and provided with integral/separate
strainers. The trap body shall be of carbon steel and the internals including
strainer screen shall be of stainless steel conforming to AISI-316.
iv.
Steam Heat Tracing and Insulation

The entire HFO pipeline shall be steam heat traced and insulated with slag wool
to maintain heavy oil temperature in the system at 85 deg C 5 deg C. The
insulation shall be fixed with wire netting & external protection given by 22SWG
thick aluminium sheets. Insulation shall be carried out as per IS: 7413.
v.
Condensate Flash Tank
Bidder shall provide all necessary arrangement to bring all the steam condensate
drains of the fuel oil system to a common condensate flash tank.
Condensate flash tank of adequate capacity one per boiler shall be provided in
the Boiler area. The drains from these tanks shall also be led to the guard pond
in effluent treatment plant
1.4.12
HP Chemical Dosing System

Phosphate Dosing System (Drum type Boiler)
High pressure chemical dosing system to be supplied shall be complete with
solution preparation tanks, metering tanks, dosing pumps with motors, actuators
and all accessories for pump stroke control including instrumentation, connected
piping as required and all necessary relief, isolation and non-return valves,
strainers and fittings, DM and condensate water supply piping as required for
dosing system. The tank shall be provided as per IS:4682 and the tank shall be
provided with 4.5mm thick rubber lining.
(i).
(ii).
2 x 100% capacity HP dosing pump shall be furnished for each boiler.

Dosing pump shall be of positive displacement type, all stainless steel
construction, adjustable stroke, complete with built-in recirculation type safety
valve, drive motor, base plate etc. the discharge pressure of the pump shall be
as per the requirement of the HP dosing system.
(iii). On line self cleaning type filter shall be provided after the tank for removing the
suspended particles.
(iv). All piping, valves & fittings shall be as per ASTM SA 210 Gr.Al or equivalent.
All Volatile Treatment (AVT) For Once through Boiler
Bidder to consider an appropriate dosing system for the once through boilers as
per the requirement.
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1.4.13
[Logo of Utility]
Auxiliary Steam System

The auxiliary steam system (Aux. PRDS) shall include the high capacity and low
capacity pressure reducing stations to meet the continuous and start-up auxiliary
steam requirements of the boiler turbine units. The steam source for high
capacity PRDS shall be the main steam pipes and that for the low capacity
PRDS shall be the cold reheat (CRH) pipes.
A high temperature unit auxiliary steam header operating at [16 kg/cm2 (a) and
310 deg C] taking steam from the above PRDS stations and also a low
temperature unit auxiliary steam header operating at [16 kg/cm2 (a) and 210 deg
C] shall be provided.
The auxiliary steam systems of the units shall be interconnected through the
station auxiliary steam headers.
Bidder shall provide auxiliary steam system for meeting internal auxiliary steam
requirement for the following services:
i)
Steam coil air pre-heater
ii)
Burner atomizing steam
iii)
Fuel oil heaters
iv)
Steam tracing of fuel oil system
v)
RAPH soot blower
vi)
Systems of TG sets & auxiliaries, vapor absorption air conditioning machine.
vii)
Besides above, spare tappings with isolating valves shall also be provided.
System provided shall be complete with pressure reducing desuperheating
stations, valves, piping, headers, spray water system, supports and
necessary instrumentation and controls.
Each Boiler shall be provided with a suitable capacity High Capacity PRDS
(HCPRDS), one no. Low Capacity PRDS (LCPRDS). For the HCPRDS, steam
shall be tapped off from Main Steam Line and for the LCPRDS, steam shall be
tapped off from Cold Reheat Line.
Suitable interconnection between the headers shall be provided generally and

shall be subject to approval of the Owner / consultant. All interconnections shall
be through motorized isolation valves. Besides normal tappings shown in the
tender drawing. 2 nos. spare tappings with isolation valves shall also be provided
on each of the headers indicated above. All stub connections on the unit / station
aux. PRDS headers shall be provided with isolation valves.
Isolation valves with blank flanges shall be provided on both low temperature as
well as high temperature station headers for future interconnection.
Auxiliary steam tapping from the boiler shall be provided with a root valve and a
non return valve. Main PRDS station shall be complete with pneumatic control
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valve, facilities for automatic control with remote manual operation feature from
fireman's panel.
High temperature unit aux. headers shall receive steam from the above
mentioned PRDS units. Low temperature unit aux. steam header shall receive
steam by connecting it to high temperature header through a desuperheater.
Station headers shall receive steam from respective unit auxiliary headers of
both the units.
The PRDS station shall be located at a suitable location in the boiler area.
Tentative location of these low temperature header(s) & high temperature
header(s) shall be in main turbine building (under the scope of TG package) [at
32 m level in BC bay along C row columns]. Exact location shall be intimated to
the successful Bidder after award of contract.
The LCPRDS shall meet normal auxiliary steam requirements, whereas the
HCPRDS shall meet the increased intermittent requirements of the unit and
station. [During cold start up auxiliary steam shall be supplied by the auxiliary
boiler]. Subsequently, when the MS pressure is more than 60kg/cm and the
CRH steam pressure is inadequate, the LCPRDS shall be inoperative and the
auxiliary steam requirements shall be catered only by the HCPRDS. The same
operation philosophy shall be adopted during hot start up also when there is
adequate main steam available in the boiler and the CRH steam pressure is not
adequate. Once the CRH steam pressure become adequate, LCPRDS shall
become operative while the HCPRDS shall close down. Further, when the
auxiliary steam requirement increases beyond the capacity of the LCPRDS, the
HCPRDS shall open to meet the steam demand. However, in this case the
LCPRDS shall be kept fully open and the auxiliary steam flow shall be controlled
by the HCPRDS only. Thus the staggered opening of the HCPRDS shall allow
parallel operation of both high and low capacity PRDS so as to meet the
increased auxiliary steam demand. When the aux. Steam demand decreases
within the capacity of the LCPRDS, the control shall be transferred back to the
LCPRDS and the HCPRDS shall close fully. Changeover of control from
HCPRDS to LCPRDS and vice versa shall be automatic with facility of manual
override by the operator. Design shall ensure that changeover is bump less and
smooth. Throughout the range of operation of the auxiliary PRDS, the steam flow
shall be controlled either by LCPRDS or HCPRDS depending on the unit
condition and steam demand. Load sharing between the two stations is not
envisaged
High Capacity PRDS shall supply steam for the following
i)
Auxiliary steam requirement for air heater soot blowing,
ii)
Pulveriser fire fighting etc.
iii)
Intermittent requirements of Unit and Station
iv)
Turbine driven Boiler Feed Pump
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v)
Start up requirement of other units
vi)
As stand by to Low Capacity PRDS station
vii)
Capable of delivering at least 20 T/Hr steam to Low Temperature Auxiliary

steam station header.
The exact quantity of minimum and maximum aux. steam required under
different startup and operating condition shall be furnished by the Bidder along
with the sizing and arrangement of PRDS units proposed by him.
Low Capacity PRDS shall supply steam for normal requirements of its own unit
Adequate capacity safety relief valves and escape pipes shall be provided at
auxiliary steam headers at suitable locations as per applicable codes to protect
the equipment situated downstream of the pressure reducing stations.
If steam for the Boiler unit auxiliaries is required at pressure/temperature other

than that of the auxiliary steam header, suitable arrangements shall be made by
the Bidder in the design of the Boiler to meet such requirements.
All control valves used in the system shall be pneumatically operated.
The HCPRDS system shall comprise of steam pressure reducing cum

desuperheating valve, motorized isolation valve with integral bypass valve
(motorised), separate stream temperature and pressure control valves, etc. as
follows:
i)
One number angular type electro pneumatically operated combined pressure

reducing cum desuperheating valve rated for full duty.
ii)
One number motorized isolation valve with motor operated integral bypass at the
upstream of the pressure reducing and desuperheating valve.
iii)
2 nos. desuperheating spray water lines ( one main and one 100% bypass line)
each having one number pressure control valve and one no. temperarture
control valves (electrohydraulically / electropneumatically operated). These two
lines shall be interconnected and a common line shall be led up to the combined
HCPRDS.
iv)
One number motorized isolation valve at the inlet of pressure and temperature
control valves on each desuperheating spray water line.
v)
One no. non return valve (NRV) and one number manual isolation valve at the
downstream of combined HCPRDS station.
vi)
One no. manual isolation valve on each spray water line downstream of pressure
and temperature control valves. One no. NRV on common spray water line going
to HCPRDS.
The LCPRDS system shall include steam pressure control valve, motorized
isolation valves, motorized bypass control valves, separate pressure and
temperature control valves, etc as follows:
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i)
One number electro pneumatically operated pressure reducing valve rated for full
duty.
ii)
One number of motor operated pressure reducing valve rated for full duty on the
bypass line to the main pressure reducing valve.
iii)
One number motorized isolation valve at the inlet of main pressure reducing
valve.
iv)
One number motorized isolation valve at the inlet of the motor operated pressure
reducing valve on the bypass line.
v)
One number desuperheater downstream of the pressure reducing valve.
vi)
2 nos. desuperheating spray water lines ( one main and one 100% bypass line)
each having one number pressure control valve and one no. temperarture
control valves (electrohydraulically / electropneumatically operated). These two
lines shall be interconnected and a common line shall be led up to the
desuperheater.
vii)
One number motorized isolation valve at the inlet of pressure and temperature
control valves on each desuperheating spray water line.
viii) One no. manual isolation valve on each spray water line down stream of
pressure and temperature control valves. One no. NRV on common spray water
line going to desuperheater.
ix)
One number motorized isolation valve on the steam line, upstream of the
desupereater.
x)
One number NRV and one number manual isolation valve on the downstream of
the desuperheater.
The control system for Auxiliary PRDS system shall be microprocessor based
with facility of TFT/KBD operation as well as through the back up push button
station etc.
For pneumatic actuation system envisaged for the control valves, positioners with
complete set of feedback cams, position transmitters , smart positioners, air filter
regulator sets, with inlet and outlet pressure gauges, solenoid valves, air lock(if
required), limit switches and other accessories to make the system complete
shall be provided.
All local sensors and gauges for pressure /temperature and process suitable
devices as per the process requirements.
Complete control system inclusive of control system components, control

cabinets, console inserts, transmitters, sensors, interlocks, prefabricated cables,
interconnecting special cables, etc. and all required accessories shall be
provided.
For meeting auxiliary steam requirement of the facilities falling under the battery
limit of this package, entire auxiliary steam piping from the headers up to the
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consumer points along with all valves, supports, fittings and specialty shall be
1.4.14
Blow Down Tanks

Blowdown vessel shall receive blow down from the drum, water walls drain
header & attemperator haeders. Blowdown vessel shall be designed as per IS2825 or approved equivalents. All the inlet connection to the tanks shall be
tangential and wear plate shall be provided to take of the erosion.
Two number blowdowns tanks shall be provided for each Boiler, one intermittent
blow down (IBD) tank and other continuous blow down (CBD) tank. The IBD shall
be sized to receive the following:
(i).
All blow down and drains from Boiler.
(ii).
Drain from water wall headers, attemperators headers and CBD tank.
(iii). Alternate drains from main steam lines, CRH lines, HRH lines and SCAPH
drains.
(iv). Other drains from power cycle piping.
The CBD tank shall receive the continuous blow down from the Boiler drum. CBD
system shall be designed for maximum blow down of 5% BMCR load. Facility for
complete bypass of CBD tank shall also be provided. The flashed vapour from
CBD vessel shall be led to the deaerator.
The IBD tank shall be located at ground level near Boiler and CBD tank shall be
located at deaerator floor.
Tank design shall not allow discharge of any free water from vent. The steam
velocity through the vent pipe shall not exceed 90 m/s. Vent pipe size shall be so
selected that no pressurisation takes place in the blow down tank.
Drain valve & drain piping shall be provided with a suitable loop pipe
arrangement so as to maintain a minimum water level inside the tanks. The drain
shall be cooled and the cold discharge shall be connected to guard pond in the
effluent treatment plant.
Blowdown tank shall include level gauges, local pneumatic level controllers,
redundant level transmitters for remote level control through Boiler C&I system,
control valves, safety valves, vents, drains. All other local instruments like gauge
glass, level switch, high/low level alarms and pressure/temperature
instrumentation shall also be provided.
1.4.17.1
Tank Constructional Features

1. Tanks shall be designed and fabricated as per requirements of IS 2825/ BS 806.
2. All drain connection to the tanks shall be tangential, and wear plates shall be
provide to prevent erosion due to high pressure and high velocity drains.
3. Matching flanges shall be provided for level switches and other instruments.
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4. Drain valves and drain piping shall be provided at the bottom of the BDT. All
drains from BDT shall be cooled to a temperature not exceeding 60C.
5. Manholes on BDT shall be provided with hung on hinged type bolted doors.
6. IBD Tank drain shall be connected to guard pond provided by purchaser and the
vent shall be routed to above boiler roof.
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DESIGN AND SIZING OF POWER CYCLE PIPING
2.1
Codes & Standards
[Logo of Utility]
The Design, manufacture, shop testing, erection, testing and commissioning of piping
and valves shall conform to the latest revisions of the following codes and Indian
Standards or equivalent international codes, in addition to other standards mentioned
in the tender documents subject to any modification and requirement as specified
hereinafter.
IS: 778
Gunmetal gate, globe and check valves for general purpose.
IS: 780
Sluice valves for water purpose (50 to 300 mm).
IS: 1239
Mild steel tubes and fittings - Part I & II, ERW pipe upto 8 diameter.
IS: 1536
Centrifugally cast (spun) iron pipes for water, gas and sewage.
IS: 8329
Centrifugally cast (Spun) Ductile Iron Pressure Pipe for water, gas and
sewage
IS: 1537
Vertically cast iron pressure pipe for water, gas and sewage.
IS: 1538
Cast iron fittings for pressure pipes for water, gas and sewage.
IS: 1703
Ball valves (horizontal) plunger type including floats for water supply
purposes.
IS: 2379
Colour for the identification of pipe line.
IS: 2685
Code of practice for erection, installation, and maintenance of sluice

valves.
IS: 2906
Sluice valve for water works purposes (350 to 1200 mm).
IS: 3042
Single faced sluice gates (200 to 1200 mm).
IS: 3589
Electrically welded steel pipes for Water gas & sewage (200 to 2000
mm).
IS: 4038
Foot valve for water works purposes.
IS: 4984
High Density polyethylene pipes.
IS: 4985
Unplasticised PVC Pipes.
IS: 5312
Swing check type reflux (non-return) valve Part-I.
IS: 458
Concrete pipes (with and without reinforcement).
IS: 3952
Cast Iron butterfly valves for general purposes.
ASTM-A 106
Gr.C Seamless carbon steel pipe.
ASTM 53
Seamless carbon steel.
AWWA-C-504
Standard for butterfly valve.
BS: 5156
Standard for Diaphragm valve.
IS: 554
Pipe thread for pressure tight joints.
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IS : 1363
Black hexagon bolts, nuts and lock nuts.
IS: 1364
Precision and semi-precision hexagon bolts, screws, nuts and lock

nuts.
IS: 2062
Structural steel fusion welding quality.
IS: 4736
Hot dip zinc coating on steel tubes.
IS: 2825
Code of unfired pressure vessels.
IS: 2712
Gaskets.
IS: 4192
Part-I Rubber lining.
IS: 9523
Specification for Ductile Iron fittings for pressure pipes for water, gas
and sewage
IS: 3006
Acid resistant SWG Pipe.
IS: 783
Code of practice for laying RCC pipes.
IS: 3114
Code of practice for CI Pipes.
BS: 5142
Cl globe valve.
ANSI:B 16.5
Steel pipe flanges and flanged fittings.
ANSI:B 31.1
Power Piping code.
ANSI B 16.34
Valves-Flanged, threaded and welding ends
ASME Sec VIII,

Div 1
Boiler and pressure vessels code
ASME B 16.21
Non metallic gaskets for flange
ASME B 16.20
Metallic gaskets for flange
ASME B 16.11
Screwed joints
ASME B 16.25
Welded joints
ASTM A 106, Gr.

C
Schedule 80 - Seamless carbon steel pipe
ASTM
A
312
Grade TP-316
Schedule 40s - Stainless Steel pipes
IS:4984- Class-5
High density polyethylene pipes
IS:4985- Class-4
PVC Pipes.
ASTM D 3517 /
4024
GRP pipes
ASTM A 105
Standard specification for carbon steel forgings for piping application.
ASTM A 182
Standard specification for forged or rolled alloy and stainless steel,

pipe flanges, forged fittings and valves and parts for high temperature
service.
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ASTM A 216
Standard specification steel casting suitable for fusion welding for high
temperature service.
ASTM A 217
Standard specification for steel castings martensitic stainless and alloy

for pressure containing parts suitable for high temperature service.
ASTM A 234
Standard specification for pipe fittings of wrought carbon steel and

alloy steel for moderate and high temperature service.
ASTM A 312
Standard specification for seamless welded and heavily cold worked

austenitic stainless steel pipe.
ASTM A 335
Standard specification for seamless ferritic alloy steel pipe for high
ASTM A 403
Standard specification for wrought austenitic stainless steel pipe

fittings.
MSS SP-58
Pipe hangers and supports- Materials, designs and manufacture
MSS SP-69
Pipe hangers and support Selection and application
API-6D
Specification for pipe line valves
API-607
Fire teat for soft seated ball valves
API-598
Valve inspection test
API-594
Standard for dual check valve
ASTM A-193-194
Specification of alloy steel and stainless steel bolting material;/ nuts for
high temperature services
Design Basis
1.
2.
3.
4.
5.
6.
Design, fabrication, testing & erection of Power Cycle Piping, valves & specialties for
critical piping system under purview of IBR, shall satisfy IBR, and ANSI/ASME B31.1
latest code.
Design, fabrication, testing & erection of Power Cycle Piping, valves & specialties for
non-critical piping system which are not purview of IBR, shall satisfy ANSI/ ASME
B31.1 latest code.
Sizing, design and installation of safety valves shall conform to IBR and the nonmandatory rules for the design of safety valve installation of ANSI/ ASME B31.1.
Piping Flexibility analysis shall be carried-out for all piping having sizes equal to or
above 50 mm NB & design temperature 100C and more, according to ANSI/ASME B31.1 latest & also satisfying IBR latest.
Design pressure and temperature shall be as per IBR. Wherever not clearly stipulated
in IBR, criteria stipulated in ASME/ ANSI B31.1 for selecting design pressure &
temperature shall be followed.
Material of construction of piping, valves & specialties shall conform to relevant ASME
/ ASTM / BS / IS or equivalent codes/standards. In case materials not approved by IBR
are used, it is the Bidders responsibility to obtain IBR approval, without affecting the
Construction schedule.
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7.
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Type of Hangers, supports etc. shall be selected as per the following criteria:
a) Variable spring hangers
(i). Where the variation in supporting effort between hot and cold condition does
not exceed 20% of the higher of the operating load and cold setting load.
(ii). The resulting effect of load take-up/ release by a group of hangers in a span
does not overstress the piping span or cause overloading at equipment
terminals.
(iii). Thermal deflection between hot & cold conditions does not exceed 40 mm.
b) Constant load hangers
When thermal deflection between hot and cold conditions exceeding 40mm, these
are used.
c) Spring hangers
These should not be loaded more than 80% of the spring travel range.
d) Rigid hangers & restraints
To be judiciously selected, without exceeding the stipulated limits of terminal forces
& moments and stress level. Struts shall be considered where compressive load is
expected.
8.
9.
Design Requirement of Hangers & Supports:In order to minimize any horizontal force components of the dead weight or any
binding of the pin or rocker joints used on the hangers, the hanger rods should be as
long as possible. In critical piping systems, the length of the hanger assembly capable
of swinging shall not be less than 20 times the maximum expected pipe movement in
the horizontal plane at the hanger location. It is recommended in case of main steam
piping to provide for a hanger rod length of at least 5-6 meters wherever feasible.
Constant support type of hangers shall be adopted at all locations on critical piping
excepting where the smaller of vertical movements of pipe justifies the use of variable
spring hangers.
As far as practicable, connections of hangers to supporting structure shall be achieved
without welding to structural members. If welding is inevitable, adequate factor of
safety shall be considered in the design and specification of the weld.
The attachment of support brackets to brick walls shall be avoided as far as possible
and where this is not possible, details of the attachment shall be furnished to the
consultant for his approval. Under unavoidable circumstances, when medium or heavy
brackets are bolted to walls, back plates of adequate size and thickness shall be
furnished to distribute the load against the wall. Where the use of a back plate is not
practical, the brackets shall, be fastened to the wall in an approved manner.
Diameter of hanger rods for piping NB 50 mm and smaller shall not be less than 10
mm and for piping with size NB 65 mm and larger shall not be less than 13 mm.
All components for hangers such as turn buckles, clamps, etc. shall be of forged steel.
Snubbers, dampers etc.
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10.
11.
12.
13.
14.
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To take seismic / dynamic loads, thrust due to safety valve discharge. Effort shall be
made to limit its use by judicious placement of rigid hangers. Bottom support spring
hangers are to be avoided as far as possible.
Design, materials, fabrication, testing and erection of hangers, supports, anchors,
guides etc. shall be as per ANSI/ASME B31.1 latest code. Material of support packing
used for alloy steel piping shall be same or better than the parent pipe material.
Hanger suspension rods, tie-rods/ struts should have proper arrangement & adequate
length, so that thermal movements in direction which are free are not constrained and
should not make an angle more than 4 degree with vertical due to horizontal pipe
movement.
Pipe Thickness calculations shall be made on the basis of procedure and formula
given in ANSI B31.1. Stress values of piping material for calculation shall be selected
from tables given in ANSI B31.1. Thickness, thus calculated shall be checked as per
the formula of IBR and the more stringent of the two shall then be selected. If it is seen
that sizes arrived at for main steam and hot reheat pipes are not in the standard range
of the manufacturers, ID controlled piping, shall then be selected for these piping
systems.
Pipe sizing and piping system design shall conform to the requirements of power
piping code ANSI B31.1. Statutory requirements as laid down in Indian Boiler
Regulations (latest edition) shall also be taken care in pipe system designs. Pipe wall
thickness as calculated by ANSI Code formula shall also be checked for IBR
requirements for piping systems falling under IBR purview.
Inside diameters of piping shall first be calculated for the flow requirement of various
systems. The velocity limits for calculating the inside diameters are listed below used
to determine line size if dictated by considerations of pressure drop, NPSH, surges,
water hammer, etc.
a) Steam
i) Main Steam hot and cold reheat pipes :
75 m/sec.
ii) Saturation steam
:
40 m/sec
iii) Auxiliary steam
:
30 m/sec.
(Aux. steam to take care of various design flows)
b) Feed Water
i) Suction
ii) Discharge
c) HP bypass
i) Upstream
ii) Downstream
d) LP bypass
i) Upstream
ii) Downstream
e) Extraction steam
Document Number
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:
:
:
2.0 m/sec.
5.0m/sec.
:
:
75 m/sec.
100 m/sec.
:
:
75 m/sec.
100 m/sec.
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i) Superheated steam
:
60 m/sec.
ii) Saturated steam
:
30 m/sec.
f) Condensate
i) Discharge
:
3.4 m/sec.
ii) Suction
:
1.5 m/sec.
g) Heater vents
:
25m/sec.
h) Heater drains
:
1.5m/sec.
15. Other piping - As per good engineering practice.
16. Drains shall be provided, at all low points and vents at all high points as per actual
layout regardless of whether the same have been shown in the flow diagrams or not.
Pipelines shall be sloped towards the drain points. For operating temperatures of
greater than 400 deg C, drip leg with drains, operated by a motor operated valve shall
be provided. At all other drain locations (operating temperatures less than 400 deg C)
traps shall be provided. All traps shall be provided with strainers, isolating, bypass and
free blow valves. Traps shall be thermodynamic type
2.3
Piping Design
1.
2.
3.
4.
5.
6.
Complete design, engineering, etc. for the power cycle piping systems and other
piping systems shall be the responsibility of the Bidder. Owner's/Consultant
responsibility/ function in this connection shall be limited to review and approval of
Bidder's design/ calculation, engineering, drawings, documents. Bidder's scope of
services for complete engineering of the piping systems shall include but not be limited
to the following:
Preparation of engineering piping diagram indicating flow schematic, flow parameter,
pipe sizes, line designations and tag nos. of various components etc.
Design parameter selection, pipe sizing calculation, pipe schedule, valve schedule,
insulation schedule, specialties schedule and hanger schedule for the systems.
Preparation of preliminary as well as final composite piping layout drawings of pipe
size 65mm NB & above.
Design in detail all piping supports including restraints, guides, stops etc., after
deciding the final location of hangers and supports and based on final stress analysis
and hanger/ support load data.
Prepare separate sketches for each hanger/ support, restraint, anchor, etc. These
sketches shall include the location with reference to column co-ordinates, identification
number, bills of material, design loads, operating load, spring stiffness, amount of
spring pre-compression etc., the method of attachment to the pipe and steel structure.
Additionally the sketches shall show a key plan referenced to plant north and centre
line elevation of the pipe at the point of attachment for cold and hot conditions.
Preparation of fabrication and erection isometric (with material take off) drawings for
shop fabricated piping which are of size 65 mm NB and above.
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7.
2.4
[Logo of Utility]
High pressure piping shall be manufactured from hot or cold finished, seamless steel
tubes. Bosses shall be provided for the purpose of creep checking. Zero
measurements shall be taken and recorded before the plant goes into service.
Stress Analysis
The Bidder shall carryout stress analysis of piping system using proven and validated
software and shall submit for Owners/Consultant approval.
(a)
Following loading conditions shall be considered for stress analysis:
i)
Internal pressure
ii)
Thermal loads due to (i) Piping thermal expansion and (ii) Anchor displacement due
to thermal movements of piping anchors.
iii)
Piping weight consisting of weight of piping, valves, bends, fittings, insulation etc. as
well as weight of support components like clamps, shoes, suspension rods, trapeze
etc. & weight of contained fluid.
iv) Test or cleaning fluid load

v)
Equivalent static loads due to discharge of safety valve (SV), Electromatic relief valve
(ERV), simultaneous discharge of SV & ERV where applicable.
vi) Dynamic load due to steam hammer (if applicable)

vii) Seismic loads due to
Equivalent static load due to seismic inertia effect and
Equivalent static load due to seismic anchor displacement
viii) Wind load where applicable
(b)
Loading combination Design load for supports, restraints, anchors & supporting
structures shall be obtained by proper selection of one or combination of two or more
of the loads as above based on the possibility of independent or simultaneous
occurrence. Loads imposed due to hydrostatic tests shall also be taken into
consideration for the design of supports.
(c)
Bidder shall clearly indicate the basis of his judicious selection or loading combination
for support, restraints and anchor design. Component of thermal expansion reaction
range expected to appear at cold condition, as per equation 9 & 10 of ANSI/ASME
B31.1 shall be considered in loading combinations. As overload factor of 1.30 shall be
considered over the computed loads except occasional loads before combining them.
Bidder shall justify with reasoning in case any one of the specified loads is not
considered in analysis.
(d)
Combination of Stresses the computed stress under different loading conditions shall
be combined as per equation 11, 12 & 13 of ANSI/ASME B31.1 & the stress shall be
within allowable limits.
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(e)
Allowable stress values for piping materials other than ASME/ASTM materials, values
shall be derived as per the criteria defined in Appendix-P of ASME Boiler & Pressure
Vessel Code, Section-VIII, and Division 1 while computing pipe wall thickness and
flexibility analysis shall be conducted as per ANSI/ASME B31.1. However, higher of
pipe wall thicknesses derived between IBR regulation & ANSI/ ASME B31.1 code shall
be considered.
(f)
Factor to be considered in flexibility analysis.
i)
Cyclic load operation of the Unit. Bidder shall consider value of stress range reduction
factor f for cyclic conditions due to temperature reversals equal to ONE.
ii)
Stress intensification factor at all transitions, fittings & all branches as per ANSI/ASME
B31.1.
iii)
Variation in supporting effort by variable spring due to pipe movements
(g)
Piping Flexibility analysis is to be conducted as per the piping layout in case any
modification of piping layout is felt essential to maintain stresses & terminal reactions
within allowable ranges, same are to be carried out by the Bidder after discussion with
Owner/Consultant.
The following piping systems shall be analyzed:
i)
Pipelines with a maximum operating temperature equal to or greater than 100 deg C
having size 50NB or above.
ii)
A write up on the stress analysis including codes used and design conditions
considered.
iii)
A copy of the computer print out for input data for the various design conditions
considered for stress analysis along with the stress diagram (piping isometric marked
with node points marked.)
iv) A copy of flexibility analysis software soft copy shall also be submitted for Owner/
Consultant approval.
v)
Analysis results in tabular form giving calculated and allowable reactions / forces /
moments on equipment nozzles/terminals for the various design conditions considered
for analysis.
vi) Allowable and calculated code stresses at various node points in the piping for the
design conditions considered based on code requirements for analysis.
vii) Analysis results giving calculated forces and moments and movements at various
hanger / support / restraint / anchor points from the static analysis corresponding to
various thermal / operating conditions, sustained load case, hydro load case (other
than water lines) and occasional loads, as applicable, for each piping system
analyzed.
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2.5
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Statutory Approvals
(a)
It is the sole responsibility of the Bidder to identify and obtain all necessary approvals
from various Government agencies / statutory authorities including IBR, CCoE, etc., as
applicable for the design, manufacture and testing of pipes, valves, fittings, specialties
etc.
(b)
The Bidder shall also identify and obtain all necessary

approvals from the IBR
authority in the state where the plant is being installed, for the erection / testing /
commissioning and any other requirement as required by IBR.
(c)
It is also the responsibility of the Bidder to get approval(s) from any other statutory
authority in other countries from where the supplies are made, as applicable and
acceptable to IBR for the design/manufacture/testing etc. for the piping / fittings /
valves / specialties etc.
(d)
In order to obtain the above approvals, all necessary documentation etc. required shall
be arranged and furnished by the Bidder to the statutory authorities.
2.6
Installation
(a)
Cleaning including chemical cleaning of all systems as specified herein and installation
of temporary pipe work for the same. All hot bent, forged formed, fabricated and
straight pipes shall be chemically cleaned, pickled or wire brushed and purged with air
blast or shot/grit blast to remove all sand and scale from the inner surface as
applicable.
(b)
Making temporary closures/ stubs on piping system as required for hydrostatic testing
and performing hydrostatic test on all piping. All pipes shall be hydro tested at shops
for pressures as per standards and all erected piping shall be tested 1.5 times the
design pressure.
The Bidder shall carryout the following cleaning after hydro test.
i)
All piping shall be mass flushed, in addition to the specific cleaning operations as
described below, as required.
ii)
Main steam, cold and hot reheat piping and HP & LP bypass piping shall be steam
blown.
iii)
Auxiliary steam piping and associated steam lines, heavy fuel oil/ LDO piping shall be
steam blown.
(c)
Making interface piping connections at TP with equipment/piping etc. as applicable.
(d)
Apart from carrying out chemical cleaning, the work shall include neutralization
disposal of water, clean up, reinstatement of the cleaned piping system, dismantling
and removal all temporary piping, equipment and materials from site.
(e)
Painting of piping system shall be in accordance with the stipulations laid down
elsewhere in this specification.
(f)
Weather hood for pipes crossing ceilings and walls.
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2.7.1
[Logo of Utility]
Checks after Installation

In order to ensure that all supporting elements, anchor and restraints have been
installed and adjusted in accordance with design documentation, the Bidder shall
inspect and log the hanger readings for the hangers associated with the power cycle
piping system as follows:
(a)
After hydrostatic test with the piping in the cold position, with all travel stops removed,
with the pipe completely insulated and in all respect ready for start-up.
(b)
Piping in hot position (rated parameter condition) after six (6) months of operation.
(c)
Piping in cold position during the first complete shutdown after at least six (6) months
of operation.
(d)
After steam blowing, in case steam blowing is applicable for the line.
(e)
At the time of each inspection, the Bidder shall determine the necessity for revision,
adjustment or replacement of pipe supporting elements, restraints and anchors. Any
changes proposed shall be subject to the concurrence of the Owner/Consultant. The
changes shall be incorporated by the Bidder after Owner's/Consultant concurrence.
2.7

All shop tests as required by the applicable codes, ANSI Standards, IBR and other
standards specified.
(a)
Obtaining approval from Chief Inspector of Boiler as per latest Indian Boiler
Regulations (IBR) is the responsibility of the Bidder. This shall include furnishing all
necessary certificates for design, manufacture and testing for pipe, valves, fittings,
specialties, tanks, vessels certificate of manufacture and test for each erected entity in
the relevant formats to the Chief Inspector of Boilers, obtaining his approval and
furnishing the same to the Owner/Consultant.
(b)
The Bidder shall also identify and satisfy all other statutory code requirements as may
be required for the piping systems covered in this specification.
(c)
Certified copies of test reports for all tests and examinations specified in the
specification and for the mandatory test and analysis required by ASME/ ASTM
material specification, for the materials used for piping, shall be furnished to
Owner/Consultant.
(d)
Provide complete interface engineering with the suppliers of other equipment and
piping with which the piping systems in the Bidder's scope are connected.
(e)
Performing all tests and implementing all quality control procedures as specified herein
including provision of testing equipment, stress relieving equipment, radiography
equipment and any other equipment necessary to meet the requirements of the
specification.
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2.8
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Low Pressure Piping, Valves and Fittings

This section of specification covers all low pressure piping within the battery limits
handling fluids HFO, LDO, etc.
Low Pressure (LP) piping shall, basically, cover piping systems for the following
services:
i)
Boiler fill system.
ii)
Fuel oil (LDO / HFO) Systems.
iii)
Chemical feed lines
iv) Auxiliary cooling water system

v)
Drain piping system for the piping\equipment etc.
vi) Re-circulation pipes along with valves, break-down orifices etc., wherever required.
vii) DM, Potable and service water distribution
viii) Compressed air piping
ix) Laying of AC/Ventilation ducting within the battery limits.
x)
Any other piping system required to make the Low Pressure (LP) piping systems
complete.
All the piping systems be designed to operate without replacement and with normal
maintenance for a plant service life of [20-25] years, and shall withstand the operating
parameter fluctuations and cycling which can be normally expected during this period.
2.9
Piping Materials and Sizes

All piping system shall be capable of withstanding the maximum pressure and
temperature in the corresponding line. The pressure rating of individual piping system
component such as valves, flanges etc shall however be not less than that specified.
Nominal pipes sizes and pipe outside diameters shall generally be as per ANSI
B36.10. In case of deviation Bidder shall bring it to the specific attention of
Owner/Consultant for prior approval stating reasons for the deviation.
The Steel pipes (Welded type) for the services of water/clarified water/Filtered water
shall conform to the following standards or codes.
i)
a)
Pipes upto 150 NB

IS:1239 Part-I
b)
ASTM-A-53 Grade B (Welded)
(Heavy grade-Black)
Sch 80 up to
size(Minimum)
inch
nominal
Sch 40 above 2 inch nominal size

(Minimum).
ii)
Pipes 200 NB and above
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a)
b)
2.10
IS:3589 Grade 410

ASTM A53 Grade B (Welded)
[Logo of Utility]
Sch. 40 (Minimum)
Wall Thickness
The calculation of wall thickness required for pipelines subject to internal and/or
external pressure shall be based on the formulae and recommendations as given in
the applicable codes. Adequate allowances shall be made towards thinning due to
bending, weakening at branch connections, threading, commercial tolerances on pipe
wall thickness, corrosion and erosion, etc. and the same shall be subject to approval
by consultant. In any case a minimum corrosion allowance of 1.0 mm shall be
considered while selecting the thickness.
In case of carbon steel materials, the nominal wall thickness of pipeline shall be not
less than the minimum acceptable values given below:
-------------------------------------------------------------------------------------------------------------------NB mm
(inch)
15
20
(1/2) (3/4)
25
32
40
(1) (1 1/4) (1.5)
50
65
80
100
125
(2)
(2.5)
(3)
(4)
(5)
-------------------------------------------------------------------------------------------------------------------Min.
3.2
3.2
3.6
3.6
3.6
3.6
3.6
4.0
4.5
5.4
thickness, mm
--------------------------------------------------------------------------------------------------------------------NB mm
(inch)
150
(6)
200
250
300
350
400
(8)
(10)
(12)
(14)
(16)
450
(18)
500
600
(20)
(24)
--------------------------------------------------------------------------------------------------------------------Min.
5.4 6.35
6.35
6.35
7.1
7.1
7.1
8.0 8.0
thickness, mm
--------------------------------------------------------------------------------------------------------------------> NB 600 mm to NB 950 mm - 10.00 mm
> NB 950 mm to NB 1200 mm - 12.00 mm
2.11
Fittings
Fittings to be used with carbon steel pipes shall conform to IS: 1239 Part-II (Heavy
grade) or ASTM A 234 Gr. WPB. for sizes upto 150 NB.
For sizes 200 NB & above steel fittings shall conform to ASTM A 234 Gr. WPB.
However for sizes above 300 NB fabricated fittings (mitre bends etc) may be used.
Wherever regular pipe bends are employed for change of direction the same shall be
to a radius of 5 times the pipe diameter. Mitre bends shall be 1.5D radius.
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Inside surface of all the fittings used for the rubber lined application shall be de beaded
and made suitable for rubber lining.
Galvanized pipe application all the fittings shall be galvanized as per IS: 4736. Fittings
to be used in other type of piping shall conform to relevant IS/BS ANSI Standards and
in conformity with the parent pipe standard.
Branch connections in piping shall be made by the use of wrought or forged seamless
fittings such as tees, laterals and crosses. Small stubs as may be required for
instrument, drain and vent connection may be provided in the form of weld outlet
fittings or forged couplings. Intersection welds are acceptable only in the event of nonavailability of fittings.
2.12.1
Design and Construction

(a)
Pipes, valves and Fittings

Following items shall be included for piping:
i)
Pipes, bends, elbows, tees, branches laterals, crosses, reducing unions, couplings,
cap, expansion joints, flanges, blank flanges, saddles, shoes, sampling connections
etc. necessary for making a reliable piping system.
ii)
Valve, gates, dampers, etc.
iii)
Strainers and filters.
iv) Instrument tapping connection, stubs and thermo-wells, root valves.

v)
Matching flanges, pipe spools and matching pipes to connect to equipment,

instruments, etc. as necessary.
vi) Gaskets, ring joint, bracing rings, jointing material etc. as required.
vii) Bolts, nuts, fasteners as required for interconnecting piping, valves and fitting as well
as for terminal points.
viii) Pipe supports like pedestals, Anchor blocks (for buried / over ground piping), brackets,
hangers, clamps, trestles, etc.
ix) Secondary steel for pipe supports and embedded steel. Also pipe supports and
necessary embedment required to be embedded in concrete for underground/above
ground pipes.
x)
(b)
Painting, anti-corrosive coatings, wrapping and coating, thermal insulation, etc. inside
and outside of pipes as necessary.
End connections
Unless otherwise specified, following types of end connections shall be used:
Pipes 50 NB and smaller shall have socket welded joints for chlorine line. For water,
air and other services where steel pipes are used, joints of this size range shall be
Socket welded/screwed/flanged type (For rubber lined pipes).
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All unlined steel pipes 65 NB and above (other than CI pipes and air service pipes)
shall be jointed by butt welding. All rubber lined pipes shall have flanged joints.
Butt welding edge preparation shall be done as per ANSI B 16.25.The Bidder shall
furnish details/specifications for all welding electrodes and welding rods including
special ones, if any for approval.
Steel pipe flanges shall be generally slipped on flat face type. Weld neck flanges shall
be used when flange follows immediately after a butt welding or where it is required
with respect to service conditions. Slip-on type of flanges may be only up to a
maximum pressure rating of ANSI 300 lbs. In case of higher pressure ratings, weldneck type of flanges shall be employed. When weld neck or socket weld flanges are
used, their bore must be made the same as that of the pipe being welded to. Socket
welded or threaded flanges may be used, with the appropriate piping system for
connection of pipe to the flanged equipment.
All the piping flanges and counter flanges shall conform to ANSI B 16.5 Cl. 150
(minimum). However wherever the interferences is involved with the Owners pipe, the
flange/interconnection details shall be designed to match the piping and the details of
which will be intimated later.
For easy handling & removal of equipments, valves etc. and for maintenance purpose,
break up flanges for 65 NB and above sizes and suitable type of compression flexible
coupling for flanged joints of 50 NB and below size shall be provided. The over ground
piping wherever routed inside building, shall have a clear head room of minimum 2.1
metre from operating floor/walk ways.
2.12
Piping Layout
(a)
Pipes shall be generally routed above ground but where specifically indicated/specified
the pipe may be laid in trenches or buried. Buried piping shall be generally installed so
that the top of pipe is 1.0 meter below the ground level unless otherwise specifically
mentioned. Full length of buried piping shall be provided with 100 mm thick sand bed.
(b)
Complete supporting system for the pipe line shall be designed, fabricated and
supplied by the Bidder. Inside the building, the overhead portion of the pipe line may
be supported from the building structures. No support shall be taken from the brick
wall. Outdoor, pipes other than buried pipes shall run on steel trestles. Crossing of
the road shall be on a pipe bridge with a clear height of at least 8.0 meters (minimum)
over the road surface. All the steel structure for the pipe bridge and the supporting
posts/trestles along with all necessary hangers clamps, connecting steel, fixing bolts,
nuts etc. shall be supplied and erected by the Bidder. All pipe rack shall be provided
with 750 mm (Minimum) clear width walkways.
(c)
Hangers and supports shall be capable of carrying the sum of all concurrently acting
loads. They shall be designed to provide the required supporting effects and allow
pipe line movements as necessary. All guides, anchors, braces, dampener, expansion
joint and structural steel to be attached to the building/structure, trenches etc. shall be
provided.
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(d)
Mitre bends shall not be accepted for steel pipes of 250 NB and below. For sizes
above 250 NB, the mitre bends shall conform to BS: 534.
(e)
For rubber lined pipe of acid service, lining should be applied in two (2) layers, giving a
total thickness not less than 3 mm.
(f)
Pipe coming under purview of IBR should meet its requirements and getting the IBR
approval shall be under Bidders scope.
(g)
A commercial grade of E type glass fibre should be used conforming to IS: 113201985 IS: 11273-1985 IS: 11551-1986 for Glass Fibre Reinforced Plastic Pipes (GRP
pipe). The resin shall be either isopthalic or bisphenol. No glass fibre reinforcement
shall penetrate the interior surface of pipe line. Each pipe length shall have sufficient
strength to withstand class AA type vehicular loading in addition to the overburden of
backfill load. The pipeline shall be designed for 2500 N/M stiffness class (min.).
(h)
Anti corrosive protection shall be provided for all buried piping including galvanised
steel piping. In case of buried pipes of size 1000 mm NB and above, the Bidder shall
stiffen them and/or increase the thickness of pipe adequately against ovality formation
in use.
(i)
Flexibility analysis for piping systems wherever required. Whenever, straight run of the
above ground yard pipes are more than 50 metres, flexibility analysis shall be
conducted by the Bidder to identify the requirement of loops, type of supports etc.
(j)
The Bidder shall prepare the flow diagrams, detailed dimensional piping layout/
Isometric/ fabrication/ as built drawings of all the systems along with Cross sectional
drawings, showing all supports and equipment as required.
(k)
All pipelines with size greater than NB 50 mm are considered as shop fabricated piping
and detailed piping layout drawings shall be prepared for all such pipelines. The
drawings shall be to scale and shall be prepared as plan & sections and shall carry the
following minimum details:
i)
Fully dimensioned layout with locating dimensions referred to plant axes and
coordinates
ii)
Details of all stub connections and other welded attachments as required for anchors,
restraints, hangers supports, etc.
iii)
Slope, drains and vents
iv) Edge preparation details of weld ends

v)
Mounting and orientation of valves and specialties and maintenance space

requirements
vi) Location and tag numbers of hangers, supports, restraints, anchors, etc.
vii) Location and magnitude of cold cuts, if any
viii) Pipe sizes, materials, design parameters, shop and field test requirements
ix) Insulation details
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x)
[Logo of Utility]
Tolerances, if any
xi) Any specific requirements on shop fabrication and/or field erection

xii) Any other detail considered necessary by the Owner/Consultant.
(l)
Bidder shall carry-out Transient/surge analysis for long (1 kilometer or more) pipe
lines, and/or large diameter (i.e. large volume) pipe lines. Bidder shall also furnish
calculation to establish adequacy of size and provision of Air Release Valves in a
piping system etc. These calculations are subject to Owners/Consultant approval.
(m)
The piping shall be arranged to provide clearance for the removal of equipment
requiring maintenance and for easy access to valves and other piping accessories
required for operation and maintenance. Layout drawings shall indicate valve
orientations and availability of access to valves and specialties. Layout of all piping
shall ensure that all valves including motor operated valves are located as to be
accessible conveniently for operation. Valves for operation and maintenance shall
have 1.0 m clear approach space. If any of the valves are not accessible, suitable
access platform shall be provided by the Bidder.
(n)
All drains & vents lies in piping system (both water and steam) with design pressure 40
KSC & above shall be provided with two valves.
(o)
The piping routing shall be such that a clear head room of not less than 2.1 m above
the walkways/working areas is available.
(p)
Provision shall be made while preparing piping layout to accept control valves, flow
measurement element and any other on-line specialty or equipment. Sufficient
upstream and downstream lengths shall be provided for flow measuring devices,
control valves, desuperheaters and other specialties as required by the respective
equipment manufacturer.
2.13
Valves
(a)
All valves shall be suitable for service conditions i.e. flow, temperature and pressure
under which they are required. The valves shall be of standard pressure rating as per
the relevant code/ standard.
(b)
Either Butterfly type or sluice/gate valves shall be used for isolation purposes in raw
water, Clarified & Filtered water application. Butterfly valves shall be of double flanged
or lugged wafer type of low leakage rate conforming to AWWA-C-504 class 150 or EN593 Class 150.
(c)
Manually operated valves shall be provided with reduction gear unit for valves of size
200 NB and above. Valve provided with motorized or pneumatic actuator shall be
provided with a hand wheel for manual operation.
(d)
All the valves shall be equipped with adjustable mechanical stop-limiting devices to
prevent over travel of the valve disc in the open and closed positions. The valve
operators (Hand wheel or Gear reduction unit or Motor actuator etc.) shall be designed
as per relevant International Standard.
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(e)
Ball valves or Globe Valves may also be provided for the application of Raw/ Clarified /
Filtered water services for sizes 50 NB and below.
(f)
Butterfly valves or proven patented diaphragm valves shall be used for the services of
demineralised water application for isolation purposes.
(g)
Sluice valve/knife edge type slide valves shall be used in the sludge and drain pipe
line.
(h)
For Air services, globe valves or Ball valves may be used for sizes 50 NB and below.
For sizes higher than 50 NB, either Butterfly valve or Ball valves shall be used.
(i)
Check valves for Raw / Clarified / Filtered water may be offered in Gun metal
construction and with threaded ends for sizes 50 NB and below conforming to IS: 778
or Equivalent.
(j)
The safety valves / relief valves at the downstream of positive displacement type
metering pumps shall be of the standard type manufactured by the pump manufacturer
and the material of construction shall suit to the fluid handled.
(k)
Safety valve
i)
Number, size, location and setting of safety valves on Superheater, reheater and drum
(if applicable) shall conform to the requirement of IBR. Relieving capacity of all the
safety valves on the Drum and the superheater taken together (excluding power
operated impulse safety valve) shall be at least 105% of the BMCR.
ii)
The escape pipes of safety valves shall lead to the nearest convenient point above the
boiler house roof.
iii)
Noise level during lifting of the safety valves shall not exceed 115 dBA. Silencers for
the lowest set pressure safety valve on Drum, superheater and reheater separately
shall be provided by the Bidder.
iv) Power operated impulse safety valves with isolating valves and silencer at superheater
outlet shall be provided. Associated solenoid valve assembly, pressure sensing
devices, controller relays, indicating lamps, impulse piping, accessories, control
station, etc. shall also be provided. Relieving capacity of this valve shall be 30% of
BMCR.
v)
(l)
Power operated impulse safety valves with capacity equal to minimum 30% of reheater
flow at BMCR shall also be provided at reheater outlet. This shall also be provided with
all accessories as shall be provided for SH outlet impulse safety valve.
The butterfly valves for DM water application shall conform to the following
requirements:
i)
Body shall be lined (minimum 3 mm) with natural rubber, ebonite, polypropylene or
PVDF.
ii)
Disc shall be lined with PVDF, polypropylene, or natural rubber.
iii)
Seat rings shall be of Nitrile rubber or Hypalon
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(m)
Valves for Acid & Alkali Services (if applicable) shall be proven patented diaphragm
type. Diaphragm shall be of reinforced teflon, EPDM/Black Butile/appd. eqv. For acid
services and reinforced Neoprene/Hypalon/app eqv for alkali services.
(n)
For air application, Body material of Ball valves shall be leaded Tin Bronze (IS: 318
Gr.2) or stainless steel (AISI: 304/316). Body & Disc of Butterfly valves shall be either
cast iron lined with elastomer such as PVDF or PTFE or stainless steel construction
(AISI 304/316).
(o)
For the application of alum, lime, coagulant aid solution, DM water and air, the body,
cover & Disc of Non return valves shall be lined with natural Rubber, PTFE or Viton.
(p)
Motor operated valves:

Motor operated valves shall be fitted with both hand and motor operating gear and
where a bypass valve is provided this also shall be provided with both hand and motor
operating gear and interlocked to ensure that the bypass valve is opened before the
main valve. Each valve gate has reached the `full open' or `full closed' position (with a
minimum increase in the torque). The motor shall be placed in such a position relative
to the valve that there is no possibility of leakage of liquid, steam or corrosive gas from
valve joints on to the motor or control equipment.
The hand operating and motor operating mechanism shall be so interlocked that the
hand operating mechanism is disconnected before the motor is started. Valves shall
be provided with seating control and except where specifically approved by the
Owner/Consultant for small valves, a slipping clutch or other torque-limiting device
shall be incorporated in the motor drive. The operation of opening or closing the valve
shall be controlled by means of push buttons labeled respectively Òpen' & `Stop'. The
control shall be so arranged that the motor can be stopped with the valve in any
position by means of `stop' push button and after having been stopped can be
restarted either direction by the òpen' or `close' push buttons.
Necessary positioning indicators for valves closely connected with the operation of
main units and need continuous and repeated monitoring shall be provided in plant
control room/control pulpits
2.14.1
Design and Construction Features

The following design and construction features of valves shall be complied with.
All gate and globe valves shall be of rising stem, outside screw and yoke type. The
design of valves shall ensure a streamlined passage and gate valves shall have low
pressure drop. The seats and discs shall be easily renewable and/or shall be suitable
for easy refacing and grinding. Valve discs shall be of such design as to keep the
seats tight when the valve body is subjected to pressure, temperature variations and
piping stresses. Gate valves shall close in both flow directions.
All globe valves shall be capable of being closed against pressure.
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In the case of all end-welded valves, the stub ends of the valves shall project from the
valve body a sufficient amount to ensure that the welding process shall not distort the
valve body and internal parts.
Valves for regulating duties shall be of the globe type with tapered plug type disc.
Hardness of seating surfaces shall be a minimum of 350 BHN and a minimum
differential hardness of 50 BHN shall be provided between seats to prevent galling.
This is not applicable for stellited seats.
Check valves of sizes 400 mm NB and larger shall have dash pot arrangement.
All gate and globe valves shall have back-seating arrangement to facilitate easy
replacement of packing with the valve in service.
All valves shall be so designed that the hand-wheel moves in a clockwise direction to
close the valve. The face of the hand-wheel shall be clearly marked with the words
'OPEN' and 'CLOSE' and an arrow to indicate the direction for opening. All handwheels shall be fitted with name plate. All globe valves shall be provided with position
indicator.
Piston lift check valves shall have accurately guided pistons so that the pistons are
cushioned in their cylinders as they move up.
All gate, globe, Y-type and angle valves intended for manual operation and falling
under the following categories shall be equipped with a gear operator for ease of
operation and to ensure fast and tight closure:
ANSI Pressure Rating
Valve Sizes
--------------------------------------------------------------------------------------------------Class 300 and below
350 mm and larger
Class 600 and above
200 mm and larger
--------------------------------------------------------------------------------------------------All gate valves falling in the following categories shall be provided with integral bypass
valve. Bypass size shall conform to MSS-SP-45 as a minimum standard. The bypass
valve shall be hand operated unless otherwise. Pipe for bypass shall be at least
schedule 80 seamless and of a material of the same nominal chemical composition
and physical properties as that used for the main line. Orientation of bypass
arrangement shall be subject to the approval of Owner/Consultant.
ANSI Pressure Rating
Valve Sizes for which Bypass is required
-------------------------------------------------------------------------------------------------------Class 600 and over

Class 300 & 150
200 mm and larger

350 mm and larger
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All gate valves of ANSI pressure rating class 150 and 300 shall have solid or flexible
wedge and ANSI pressure rating class 600 and above shall have flexible or parallel
slide type of wedge.
Valves with flexible wedge shall have provision for relieving the pressure in the neck of
the valve when the valve is in the closed position.
All valves of ANSI pressure rating up to class 600 shall have bolted bonnet
construction and class 900 and above shall have bonnet construction of the pressure
seal type. Pressure seal valves shall have stainless steel inlay in the gasket area and
silver-plated gaskets or other acceptable proven features.
All carbon steel valves of ANSI pressure rating up to class 150 and 300 shall have
stainless steel trim (13% Cr) and ANSI pressure rating class 600 and above shall have
stellited trim.
All alloy steel valves shall have stellited seats.
All valves of ANSI pressure rating up to class 900 and higher shall have yoke with antifriction bearing arrangement.
Valves that are to be kept in full 'OPEN'/'CLOSE' position shall be provided with a nondetachable locking arrangement. The locking arrangement provided shall be subject
to approval by the Owner/Consultant.
Valves operating under vacuum conditions shall have glands with water sealing. The
inlet and outlet connections shall be NB 15mm. The Bidder shall indicate the
maximum and minimum sealing water pressure and the required flow rate.
Motor actuators for motor operated valves shall meet requirements mentioned in the
specification.
2.14
Cleaning
Prior to factory inspection, all manufacturing waste, such as metal chips and filings,
welding rods and stubs, rags, debris and all other foreign matter shall be removed from
the interior of each valve. All mill scale, rust, oil, grease, chalk, crayon, paint marks
and other deleterious material shall be removed from the interior and exterior surfaces.
At the time of shipment, valves shall be clean inside and outside.
2.15
Inspection and Tests

Inspection and tests for piping systems which are under the purview of IBR shall be
tested at manufacturers work and site as per the requirement of IBR as a minimum.
Defects in excess of acceptance standards shall be removed by suitable means. If
removal of surface defects does not result in reduction in wall thickness below 5% of
intended thickness of metal at that location, the area shall be blended smoothly into
the surrounding surface. Where defect removal results in a wall thickness less than the
above resultant cavity may be repaired by welding. The procedure and operator shall
be qualified as per applicable standards. Major weld repairs shall be stress relieved or
heat treated in accordance with ASME Section VIII Division I-UCS 56.
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The required area shall be re-examined and the acceptance standards shall be as in
the original examination.
Weld repairs made as a result of radiographic examination shall be radiographed after
welding. Repairing a particular area more than 2 times is not permitted and the
component shall be rejected. The acceptance standards for welds shall be as per
ASME Boiler and Pressure Vessel Code, Section VIII, Division I, UW - 51.
Prior approval shall be obtained from the Owner/Consultant before taking up major
weld repairs (major weld repair - when depth of repair exceeds 20% of thickness or 1
inch whichever is smaller). Mapping of major weld repairs is also required.
All valves shall be tested hydrostatically for strength, tightness of seats and tightness
of back seating at the pressures, in accordance with MSS-SP 61, "Hydrostatic Testing
of Steel Valves". Water used for hydrostatic testing of valves with stainless steel
components shall not have chloride content exceeding 20 ppm. Clean potable water
may be used for testing of all other valves.
All valves except check valves shall be tested for seat tightness by air at a pressure of
6 bar (g) on both sides of seat.
All check valves shall also be hydro tested at 125% of the seat hydro test pressure.
All valves shall be checked for correctness in respect of specified end details as per
applicable standards.
2.16
Painting and Corrosion Protection

Two coats of primer of thickness 35 microns for each coat shall be applied to all steel
and cast iron exposed surfaces as required to prevent corrosion, after release has
been given for painting and before dispatch. The use of grease or oil, other than light
grade mineral oil, for corrosion protection is prohibited. Bores of all valves shall be
covered immediately after testing, draining and drying with suitable plastic end covers
to avoid ingress of foreign materials. Also refer section-XI for painting.
2.17
Material Specification for Piping and Fittings
2.18.1
Materials for Boiler Components

The material used for Boiler components like piping, valves & fittings etc. and other
components shall be equal to or better than the following unless specified otherwise:
The temperature range indicated below is design metal temperature.
i)
Up to & including 400 deg C Carbon steel to ASME SA-106Gr. B/C, SA 210 C or SA
210 Gr A1 or approved equivalent.
ii)
Up to & including 550 deg C: Alloy steel to ASME SA-335: P-11/P-12/P-22/; ASME
SA213: T-11/T-22 or approved equivalent.
iii)
Up to & including 600 deg C: Alloy steel ASME SA-335/213: P 91 /T-91, or approved
equivalent.
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Service
[Logo of Utility]
Pipes
Fittings
Flanges
A 335 P91/ A335P22
A234
A182 F91/ A182

F22
Main steam
65 NB & above
WP91/ A234
WP22
50 NB & below
A 335 P91
A182 F91 or Gr
F22/ASTM 105A
A182 F91
65 NB & above
A106 Gr. C
A 234 WPC
A 105
50 NB & below
A106 Gr .C
A 105
A 105
65 NB & above
A 335 P91
A234 WP91
A182 F91
50 NB & below
A 335 P91/ A 335 P22
A182 F91/ A182

F22
A182 F91/ A182

F22
65 NB & above
A106 Gr. B/ Gr. C
A 234 WPB
A 105
50 NB & below
A106 Gr. B/ Gr. C
A 105
A 105
Cold reheat
Hot reheat
Aux. Steam/boiler
feed /condensate/fuel
oil
2.18.2
Specific Requirement for Valves
Service
Size
Body/ bonnet
Disc
Stem
Hand wheel
Valve ends
Steam lines (temp

> 400C) except
for main steam and
hot-reheat
> 65NB
ASTM
A217
WC-6/WC-9
ASTM
A182
Gr.F-11/Gr.F22
ASTM A217
WC-6/WC-9
ASTM
A182
Gr.F-11/Gr.F22
ASTM A182
Gr. F6a
ASTM A47 G
Gr. 32510
ASTM A97
Gr.32510
Butt welded.
Steam lines (temp

< 400 C), feed
water,
Condensate blow
down, steam
tracing
>65NB
ASTM A216
Gr WCB
ASTM A182
Gr F6a
ASTM A47
Gr 32510
Butt welded
ASTM A182
Gr F6a
ASTM A182
Gr F6a
ASTM A47
Gr 32510
Socket
welded
< 50 NB
ASTM A216
Gr WCB
ASTMA105
< 50 NB
Document Number
LII-GETS12021-G-00129-001
ASTM A182
Gr.F6a
Socket
Weld
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Service
Size
Body/ bonnet
Disc
Stem
Hand wheel
Valve ends
HFO, LDO, lube

oil, oily water drain
>65NB
ASTM A216
Gr WCB
ASTMA105
ASTM A216
Gr WCB
ASTM A182
Gr F6a
ASTM A47
Gr 32510
Butt welded
ASTM A182
Gr F6a
ASTM A182
Gr F6a
ASTM A47
Gr 32510
Socket
welded
< 50 NB
Boiler feed system
Cooling water
system
Service
ASTM A216
Gr.
WCB/WCC
ASTM A 216
Gr.
WCB/WCC
ASTM A 182
Gr. F6a
ASTM 417
Gr. 32510
BW
<50NB
A105
ASTM A 182
Gr.F6a
ASTM A 182
Gr.F6a
ASTM 417
Gr. 32510
SW
BFV
AWWA C-504; flanged or long body wafer type; Body A 216

WCB;SHAFT A 182 304; seal & O ring: EPT/ BUNA N /
Neoprene
Size
Instrument
air
system, potable
water system
>65NB
Body/ bonnet
ASTMB62 /
IS318 Gr.2
air
(ball
>65NB
< 50 NB
ASTM B62 /
IS:318 Gr.2
ASTM A216 ASTM A216

Gr WCB
Gr WCB
ASTM A105 ASTM A182
Gr F6a
FL
Stem
Hand
Wheel
ASTM A182
Gr F6a
ASTM A47
Gr 32510
ASTM B312
Gr A / IS320
HT2
ASTM A47
Gr 32510
ASTM A182
Gr F6a
ASTM A47
Gr 32510
Butt welded
ASTM A182
Gr F6a
ASTM A47
Gr 32510
Socket
welded
Disc
ASTM A216 ASTM A216

Gr WCB
Gr WCB
< 50 NB
(ball valves)
Service
system,
valves)
65NB
Valve ends
Flanged
Screw type
Note:
1.
Testing of body, seat and back seat shall be as per ANSI B16.34
2.
For water system with sizes greater than NB200 butterfly valves shall be used and
shall conform to AWWA C-504.
3.
Butterfly valves for main cooling water lines shall be hydraulically operated with oil
pack.
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2.18
[Logo of Utility]
Gates (if applicable)

Design standard for gates shall be IS: 3042 or equivalent. The gates shall be
rectangular or square sluice, rising spindle type conforming to class-1 of IS: 3042. The
Material of Construction shall be as follows:
i)
Frame and Door
Cast Iron IS:210 Gr. 260
ii)
Spindles, bolts & nuts
ASTM A 182 Gr. F6A
iii)
Face & seat rings
Gun metal (as per IS: 3042).
All the parts of gates shall be applied with the coats of heavy duty bitumastic paint.
2.19
Strainers
(a)
Basket Type Strainers

Basket strainers of simplex design shall have the following materials of construction for
raw/clarified/filtered water application.
i)
Body
Fabricated mild steel : IS:2062 (Tested quality)
ii)
Strainers
Wire shall be stainless steel (AISI: 316 30 mesh

suitably reinforced. Reinforcement material shall
also be of stainless steel construction)
iii)
Drain Plug/Nuts
Gun metal
Screen (strainer) flow area shall be at least four times pipe sectional area. Flow area in
any portion of Basket strainer assembly shall not be less than the pipe cross sectional
area. Pressure drop in clean condition shall not be more than 1.0 MWC.
Basket Strainer shall be provided with lifting lugs and suitable mounting arrangement.
Suitable Vent and drain valves shall be provided for the strainers.
For DM water service, body shall be rubber lined to minimum 4.5 mm thickness (soft
rubber of shore Hardness 65 5 Deg A).
(b)
Y-Type Strainers
Y-Type strainer for water application shall be constructed of following materials
i)
Body :
Cast Iron IS: 210 Gr. FG 260
ii)
Strainers:
Wires of stainless steel AISI-316, 30 mesh suitably reinforced.
Reinforcement material shall also be of stainless steel construction.
iii)
Drain Plugs:
Gun metal (threaded construction)
Body of the Y-type strainers of alkali, and demineralised water shall be of Cast Iron
(IS: 210, Gr.FG 260) and lined with soft or hard rubber to a thickness of 4.5 mm.
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For acid services, apart from the rubber lined body material, the screen material shall
be Polypropylene or HDPE wire cloth of suitable mesh and thickness.
2.20
Steam Traps
(a)
The steam traps shall be inverted bucket or thermodynamic type complete with integral
or separate strainers.
(b)
The internal components of traps shall be of AISI- 316 stainless steel construction.
Material of construction of the body shall be selected by the Bidder based on the
service conditions stipulated.
(c)
All Y-type strainers, wherever provided with steam traps or otherwise, shall have
AISI-316 stainless steel screen of not more than 20 mesh size. Screen open area shall
be at least three (4) times the pipe internal cross-sectional area. The strainer shall
have a screwed blow-off connection with a removable plug. Material of construction of
the body shall be selected by the Bidder based on the duty conditions specified.
(d)
All traps and strainers shall have socket weld ends as per ANSI B16.11 for size NB 50
mm and smaller and butt weld ends as per B 16.25 for size NB 65 mm and above.
Steam drain traps shall be provided with strainers, inlet and discharge valves and
by-passes and test cocks as schematically indicated in the enclosed drawing.
Materials and other details of these valves shall meet the specified requirement.
General
Note: The specification furnished above shall be considered as broad requirement.
The Bidder shall consider compatible material and specification for all piping
components as well as specialties for the corresponding service applications.
2.21
Instrument Connections
Unless otherwise called for by Owner, all thermo well stubs shall have an internal
threading to M33 x 2.
All stubs for pressure or flow measurement for pipelines with a maximum working
pressure equal to or above 42 bar(g) or with a maximum working temperature equal to
or above 350 deg C shall be NPS 25 mm and double root valves shall be used.
Stubs for pressure or flow measurement on pipelines with a maximum working
pressure less than 42 bar(g) and a maximum working temperature less than 350C
shall be of NPS 15 mm size and single root valves can be used.
Measurement stubs on fuel oil lines shall be of NPS 25 mm size and provided with two
root valves.
2.22
Welding and Heat Treatment

All heat treatment, welding, post and pre weld temperatures shall be as per the code
ASME B31.1.
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2.23
[Logo of Utility]

All uninsulated piping systems, hangers and supports shall have two coats of red oxide
Zinc Chromate primer (conforming to IS 2074) with minimum dry film thickness (DFT)
of 25 microns per coat and two coats of finish paints using enamel paint to give a
minimum total DFT of 100 microns (after two coats of primer and two coats of finish
paint). Shades shall be as per IS 5 or as indicated by Owner. Service of the pipe/line
designations shall be painted on all pipes at visible locations.
Before application of paint, Bidder shall clean the pipes of all mill scale, dirt dust, soot,
grease, rust etc.
All pipe lines, piping components shall be adequately protected against corrosion
during manufacture, fabrication, shipment and storage by appropriate protective paint.
2.24
Underground Protection
Where pipelines are buried, underground protection shall be provided for the piping
system as indicated any one of the methods given below:
(a)
Coal tar primer, coal tar enamel, inner wrap of fiber glass, final outer wrap of enamel
impregnated fiber glass. Total thickness of coating shall not be less than 4.0 mm.
(b)
With anti-corrosive tape of 4 mm thick conforming to IS-10221 and AWWA C 203-93.

Pipe surfaces shall be cleaned by shot or sand blasting before application. Slag
blasting may also be considered.
Tests to be carried out after application
(c)
Bond/Adhesion test
(d)
Holiday test
2.25
Non destructive examination

(a)
Mandatory as per ASME B31.1 & Regulation 360(d) of IBR.
(b)
Special requirements
i)
100% UT/RT & MPI and 3% hardness testing on butt welds of P22, P12, and P11
materials.
ii)
100% UT/RT & MPI and 100% hardness testing on butt welds of P91, and X20
materials.
iii)
100% MPI on butt welds of carbon steel materials.
iv) 100% UT/RT for fittings of 200NB & above for X20 & P91, material.
v)
2.26
100% UT/RT for fittings of all other piping of size OD 508mm & above.
Hydrostatic Test Pressure
(a)
Piping system under IBR purview:
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i)
At Shop All piping including fabricated piping shall be hydro tested at 1.5 times the
design pressure subject to regulation 374 of IBR. However, non-destructive testing in
lieu of hydro test is also acceptable subject to regulation 343 (3) of IBR
ii)
After Erection all piping systems shall be hydro tested at 1.5 times the design pressure
subject to regulation of 374 IBR. However, for such systems where it is practically not
possible to do hydro tests, the tests as called for in ANSI B31.1& IBR in lieu of hydro
test shall also be acceptable.
(b)
Non-IBR Piping Systems:-
i)
At Shop All piping including fabricated piping shall be hydro tested at 1.5 times the
design pressure.
ii)
After Erection All piping systems shall be hydro tested at 1.5 times the design pressure
subject.
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THERMAL INSULATION
3.1
Genaral
[Logo of Utility]
All equipment / pipes / ducts whose surface temperature is higher than 60 deg C,
shall be provided thermal insulation along with aluminum cladding for personnel
protection and heat conservation. The insulation material shall be chemically
inert, non-combustible and shall be harmless. Outer surface of the insulation
shall be covered with aluminium cladding.
3.2
Design Criteria
Thermal insulation to be provided for:
i)
Piping & equipment having rated operating temperature exceeding 60 deg C.
ii)
For insulation thickness calculation ambient temperature shall be [45 deg C] or as

per ASTM C 650 or equivalent.
iii)
Wind velocity = 0.25 m/sec for outside the plant building and 0.5 m/sec for inside
the plant building.
iv)
Thermal conductivity = Not less than values given in IS-8183
v)
Emissivity = 0.2
3.3
3.3.1
a)
Insulation Material
Material and application of insulation material, protective cladding, wire mesh etc.
shall be conforming to latest edition of following Codes:
i)
IS:8183 - Bonded mineral wool
ii)
IS:3677 - Unbonded Rockwool/Mineral Wool
iii)
IS:3144 - Methods of test for mineral wool thermal insulation materials
iv)
IS: 14164 Thermal insulation of cold services
v)
IS:280 - Mild Steel Wire for General Engineering Purposes
vi)
ASTM-B 209 - Standard Specification for Aluminum and Aluminum-Alloy Sheet and
Plate
vii)
IS 4412 Copper wires for general engineering purposes
viii)
IS 7413 Code of practice for thermal industrial application and finishing of thermal
insulating materials
ix)
IS 9843 Code Of Practice For Use Of Adhesives For Packaging
x)
IS 737 Wrought aluminium and aluminium alloy sheet and strip for general
engineering purposes
b)
Other equipment or better international codes/ standard shall also be acceptable.

Insulation material for all equipments, piping, ducting, etc. shall conform to following
requirements:
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i)
Material Lightly resin bonded mineral wool of best grade conforming to IS: 8183.
(Hand made mattresses are not acceptable). Material shall be rock wool only. Slag
wool or slag wool inclusion shall not be accepted. Lightly resin bonded glass wool
mattress, having density 64 kg/m (min.), self stitched in shop can also be accepted
for temperature less than 400 deg C.
ii)
Bulk density of lightly resin bonded mineral wool mattresses shall be 100 kg/m for
use up to 400 deg C and 150 kg/mfor use above 400 deg C.
c)
d)
The Insulation mattress shall be rated incombustible when tested by the method
prescribed in clause 15 of IS:3144 and shall meet the requirement of the Mercantile
Marine department, Lloyd's Register of shipping, underwriter, fire hazards codes
and other International standards.
Insulation material (and protective covering) shall:
i)
Be fresh, incombustible, rust proof, non hygroscopic,
ii)
Be capable of withstanding continuously and without deterioration the maximum

temperature to which they shall be subjected.
iii)
Not react chemically, either to itself or with other components.
iv)
Not sustain any fungi or vermin and must not pose health hazards.
e)
The use of insulation of finishing materials containing asbestos in any form is not
permitted.
Insulation mattress/section shall be supplied in thickness of 25, 40, 50 and 75 mm.
Insulation of higher thickness shall be made up in multiple layers using
mattress/slabs of thickness specified above. However, if the required thickness is
such that by using above mattress/slabs the calculated thickness is not achieved,
the mattress/slabs in increment of 5 mm shall be acceptable for outer layers. The
min. thickness however, shall not be less than 25 mm and number of layers shall be
minimum and innermost layer shall be thickest.
f)
3.3.2
Sheathing Material
a)
b)
3.3.3
Sheathing material for all insulated surfaces, equipments, piping etc. confirming
to ASTM B-209-1060 temper H-14 or IS: 737 Gr. 19000/H2 shall be provided as
per following:
For dia of insulated surfaces of 450 mm & above - 16 SWG and for flat surfaces
For dia of insulated surfaces less than 450 mm - 20 SWG
For Boiler outer casing ribbed Aluminium - 16 SWG
Binding and Lacing Wires
a)
b)
3.3.4
Binding and lacing wires shall be provided in line with following:

Up to 400 deg C - Galvanised Steel of 20 SWG dia.
Above 400 deg C - Stainless Steel of 20 SWG dia.
Straps and Bands
a)
Straps and bands shall conform to materials as under:

Up to 400 deg C - Galvanised Steel
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b)
3.3.5
[Logo of Utility]
Above 400 deg C

- Stainless Steel
Bands shall be 20 mm wide and 0.6 mm thick
For securing Aluminium sheathing material, stainless steel or anodised
aluminium bands shall be used.
Screws shall be of galvanised steel, check headed, self tapping type. Above 400
deg C temperature, screws shall be stainless steel.
Non metallic components like 3 mm thick mill board, aluminium pigment sealant,
white glass cloth, insulating cement, neoprene washer shall be provided.
Application of Insulation
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
All surfaces to be insulated shall be cleaned of all foreign materials such as dirt,
grease, rust etc. and shall be dry before the application of insulation.
Before applying the insulation the Bidder shall check that all instrument tapping,
clamps, lugs and other connections on the surface to be insulated have been
properly installed as per the relevant erection drawing.
All flanged joints shall be insulated only after the final tightening and testing.
The insulation shall be applied to all surfaces when they are at ambient temp.
Ample provision shall be made for the maximum possible thermal movement and
the insulation shall be applied so as to avoid breaking/telescoping due to alternate
periods of expansion and contraction.
All cracks voids and depressions shall be filled with finishing cement, suitable for
the equipment operating temperature so as to form a smooth base for the
application of cladding.
All vertical pipes shall be provided with the suitable insulation supports to prevent
collapsing/crushing of insulation due to its self weight. Support rings shall be
provided on all vertical piping with a difference in elevation of 4 m or above, and
there shall not be more than 3 m straight length between support rings.
joints of insulation mattress sections of horizontal piping shall be on the bottom or at
the sides of the pipe.
When more than one layer of insulation mattress/section is required on piping the
circumferential joints on adjacent layers shall be staggered by at least 150 mm and
longitudinal joints shall be staggered by at least 50 mm.
The mattress type insulation shall be formed to fit the pipe and applied with the
mattress edges drawn together at the longitudinal joints and secured by lacing wire.
Pipe section insulation shall be fitted on pipe using binding wires.
Where insulation is applied in two or more layers each layer of mattress shall be
backed with hexagonal wire mesh. For the first layer of insulation and in case of
single layer insulation, hexagonal wire mesh shall be provided on both the surface
of the mattress. For pipe sections, the sections shall be held in place by binding
wires without any wire mesh.
The ends of all wire loops shall be firmly twisted together with pliers, bent over and
carefully pressed into the surface of the insulation. Any gap in the insulation shall
be filled with loose mineral wool or finishing cement.
Insulation mattress/section ends shall be terminated at a sufficient distance from the
flanges to facilitate removal of bolts.
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m)
n)
o)
p)
q)
r)
s)
t)
u)
v)
w)
3.4
[Logo of Utility]
The insulation shall be held in place by fastening over with binding wire for
insulation surface with diameter up to and including 550 mm and with metal bends
for insulation surfaces with diameter over 550 mm. The fastening shall be done at
intervals of 250 mm except where specified otherwise. The ends of the binding
wires shall be hooked and embedded in the insulation. The straps shall be
mechanically stretched and fastened with metallic clamping seals of the same
materials as the strap.
Insulation for application on bends and elbows shall be cut into mitred segments,
sufficiently short to form a reasonably smooth internal surface. After the application
of insulation material place, insulating cement shall be applied as required to obtain
a smooth surface.
Weather hoods shall be provided for insulated piping passing through floors/walls.
All pipe attachments coming on horizontal pipes, inclined pipes and bends shall be
insulated along with pipe such that there shall be no insulation applied to hanger
rod and the component connecting hanger rod to pipe attachment. All pipe
attachments exposed to weather shall be provided with weather proof covering.
Upstream of all drain lines and the lines connected to steam traps, shall be
insulated up to and including first isolating valve for heat conservation. Rest of such
lines such as downstream of the drain valves, traps etc. and other lines such as
safety valve discharges, vents, etc. shall be insulated for personnel protection.
All valves fittings and specialties shall be insulated with the same type and
thickness of insulation as specified for the connected piping with the special
provisions and or exceptions as given below.
All valves fittings and specialties shall be insulated with the same type and
thickness of insulation as specified for the connected piping with the special
provisions and or exceptions as given below.
All valves and flanges shall be provided with removable box type of insulation
covered with box fabricated from aluminium sheets of thickness same as the
connected pipe cladding. Adjoining pipe insulation shall be bevelled back to permit
removal bolts and nuts or bands. The portion of the valve which can not be
covered by box type insulation shall be filled by loose insulating material of packing
density at least equal to that of the insulating material of adjoining pipe. The
insulation for valves/flanges shall be applied after the finishing has been applied
over the connected piping. The cladding shall be applied in such a manner that the
bonnet flange can be exposed easily without disturbing the complete insulation and
cladding.
Union shall not be insulated. Expansion joints, metallic or rubber, shall not be
insulated unless otherwise specifically indicated.
Safety valves shall be insulated.
Sampling of steam, feed water lines at high temperatures shall be insulated.
Testing of Insulation
a)
All tests, as per the applicable material standards and as specified shall be carried
out in accordance with the methods prescribed. Owner/Consultant shall have the
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b)
3.5
[Logo of Utility]
right to witness any or all of the tests conducted by the Bidder at the shop or
laboratory.
The Bidder shall guarantee that if on actual measurement the specified maximum
insulation surface temperatures are exceeded, if the Bidder shall either replace the
insulation with a superior material or provide additional insulation thickness at no
extra cost.
Refractories
The refractory material shall comply with relevant Indian Standards. The
refractory selected shall ensure perfect sealing, and shall have good thermal
cycling properties allowing quick startup/shut down of Boilers.
3.5.1
Materials
a)
b)
c)
d)
e)
3.5.2
The refractory material shall

Have high bulk density and minimum moisture content,
Be capable of withstanding service temperature of 1700 degree Celsius.
Be resistant to slagging products due to coal, and to impurities of oil like V2O5,
Fe2O3, K2O2, Na2O etc. and to erosion due to fly ash.
Be chemically inactive towards alkalis, iron, silica etc. shall pose no health hazard to
working personnel, and shall not have any explosive properties.
Have sufficient strength to withstand forces generated in boiler, without any rupture
or damage.
Application
a)
b)
c)
d)
Application of refractory shall be such that:

To ensure perfect sealing, easy maintenance, minimum time for application.
To ensure minimum number of joints. All the joints to be filled and tightly packed
with loose powder of same material.
Selection of Refractory shall consider the applied stress, stress distribution and
expansion allowance.
Refractory shall have good thermal cycling properties to ensure quick start up and
shut down of Boilers.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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QUALITY ASSURANCE
4.1
Introduction
[Logo of Utility]
All materials, components and equipment covered under the scope of supply
shall be procured, manufactured, erected and tested at all stages as per the
comprehensive Quality Assurance (QA) programme. The QA document
indicating the specific inspection and testing requirements to be followed shall be
subject to the approval of the Owner/Consultant. The Bidder shall submit his
quality assurance programme for review by Owner/Consultant and shall
generally cover the following:
a)
Organizational structure for management and implementation of the proposed
quality assurance programme.
b)
Quality system manual.
c)
Documentation control system.
d)
Qualification and experience data of Bidder's key personnel.
e)
The procedure for procurement of materials, parts, components and
equipment.
f)
Procedure for inspection at source, inspection of incoming raw-materials/
parts/ components & verification of materials purchased.
g)
System for shop manufacturing including process controls, fabrication and
assembly controls, and procedure for product identification & traceability.
h)
System for inspection and testing during manufacture, processing, fabrication,
welding, assembly and other activities.
i)
The reference documents, plant standards, acceptance norms, test and
inspection procedure etc.
j)
Control of calibration and testing of measuring and testing equipments.
k)
System for quality audits, documentation to indicate conformance or
nonconformance of the product to the specification and testing and inspection
requirements; review and control of non- conforming items and system for
corrective actions.
l)
System for indication and appraisal of inspection status.
m) System for authorizing release of manufactured product to the Owner.
n)
System for packaging, handling, transportation, storage and delivery.
o)
System for generation and maintenance of inspection and test records.
4.2

Testing and inspection requirements of major equipment over and above the
respective codes / standards requirement are given hereunder:
4.2.1
Pressure Parts
Only those materials shall be used in the manufacture of pressure parts which
can be identified against mill sheet or manufacturer test certificates. Material
shall meet all the mandatory requirements (and supplementary checks, if asked
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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Power Plant]
[Logo of Utility]
for) of specified specification, Indian Boiler Regulations (IBR), and relevant

code/standard. All non destructive testing as detailed against relevant equipment
shall meet the requirement of ASTM section 3 Vol. 3.03 or equivalent BIS
standard.
A.
Drum
i)
Each plate shall be subjected to a 100 % normal and shear ultrasonic at the mill to
meet the minimum requirements of BS: 5996 grade LC3/ ASTM or equivalent
standards. Elevated temperature tensile tests shall also be carried out on plate
material for each heat.
ii)
After cutting to size and removal of cut outs, the plates shall be subjected to
magnetic particle examination (MPE) along the edges of the plate and on areas
adjacent to the cutouts.
iii)
All forged connections shall be examined by 100% ultrasonic testing (UT) before
machining.
iv)
Fully machined connecting pieces of internal diameter 100mm and above, except
for forgings, shall be subjected to MPE.
v)
Mechanical tests shall be carried out on specimens prepared from the production
control test plates of the longitudinal welds.
vi)
Mechanical tests shall be conducted on the specimens from manhole cutouts of

dished ends.
vii)
All butt welds shall be subjected to 100% radiographic test (RT) before stress
relieving.
viii)
On completion of welding, the entire drum shall be subjected to stress relieving in

the furnace.
ix)
All butt welds shall be subjected to 100% ultrasonic test and magnetic particle
examination after stress relieving.
x)
All full penetration welds shall be subjected to ultrasonic examination after stress
relief.
xi)
After stress relieving, all welds shall be examined by magnetic particle examination
(MPE) methods depending on size and accessibility.
xii)
Complete drum shall be subjected to hydraulic pressure test and all compensating
pads shall be pneumatically tested.
B.
Headers
i)
Raw material for headers shall be subjected to UT prior to fabrication.
ii)
All butt welds shall be subjected to MPE and radiographic examination before
stress relieving.
iii)
All full penetration nozzle and attachment welds shall be subjected to UT prior to
stress relieving.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[87]
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[Logo of Utility]
iv)
All nozzles, branches, stubs and load bearing attachment shall be examined by
MPE techniques after the toes of the weld have been ground smooth and stress
relieved.
v)
Non-load bearing welds shall be examined by MPE techniques after the toes of the
welds have been ground smooth and stress relieved.
vi)
Completed closed end headers shall be subjected to hydraulic pressure tests and
all compensating pads shall be pneumatically tested.
C.
Tubes and tube elements
i)
Raw material for tubes for water wall, superheater, reheater, economiser, riser,
supply and connecting tubes including nozzle/stubs, connections for drum, headers,
pipe work etc., shall be subjected to 100% UT prior to fabrication as per IBR or
ASME E 213 or equivalent with the longitudinal calibration notch of depth 5% of wall
thickness (0.3mm minimum and 1.5mm maximum).
ii)
All bent tubes, stubs shall be checked for ovality and thinning by ultrasonic method
on first off lot and random checks on subsequent pieces.
iii)
All tubes, stubs, panels, coils shall be checked for clearance by steel ball test and
for cleanliness by sponge passage.
iv)
Finished butt welds shall be subjected to RT and UT. Wherever the

code/standard/process specifies random sampling, the same shall be minimum
20%. All fillet welds shall be subjected to MPE or dye penetration test (DPT).
v)
Tubes and fabricated panels, coils shall be subjected to hydraulic pressure test
excluding water wall panels and loose tubes but including burner panels, reheaters,
superheaters and economizers.
D.
Integral piping and fittings
i)
All pipe lengths shall be subjected to 100 % ultrasonic examination as per ASME
E213 or equivalent, with longitudinal calibration notch of depth 5% of wall thickness
(0.3mm minimum and 1.5mm maximum) or hydraulic tests and UT or RT on
longitudinal welds at the tube mill.
ii)
All mother pipes shall be subjected to 100% UT prior to fabrication as per ASME E
213 or equivalent with longitudinal calibration notch of depth 5% of wall thickness
(0.3mm minimum and 1.5mm maximum).
iii)
All forged fittings shall be checked by UT and formed fittings shall be checked by
MPE.
iv)
All pressure parts shall be 100 % UT tested. All welded, cast alloy steel and carbon
steel fittings for use above 71 bar design conditions shall be 100 % RT tested.
However, wherever the code/standard/process specifies random sampling, the
same shall be minimum 20%.
v)
10% of each lot of bent pipes shall be checked for quality and thinning by UT on
first off lot and on random samples for subsequent pieces. Outer surface of bends
shall be subjected to MPE or DPT.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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[Logo of Utility]
vi)
The edge preparation for shop and site welds in stainless steel and alloy steel shall
be subjected to dye penetration check. Non-destructive examination of welds shall
be carried out after post weld heat treatment, if any.
vii)
All butt welds shall be subjected to UT or RT and MPE. For weld on alloy steel
piping, UT or RT shall be done after stress relieving. Wherever the code/ standard/
process specifies random sampling, the same shall be minimum 20 %.
viii)
All butt welds in alloy steel piping of P91, X20 and X 22 shall be checked for RT or
UT and MPE after stress relieving (SR). UT shall be of digital recordable type.
ix)
All weld joints in alloy steel piping of P 91, X20 and X22 shall be checked for
hardness. For preheating and post weld heat treatment (PWHT) induction heating
shall be deployed. However, PWHT can be done in furnace also. 3% hardness
check shall be carried out on welds of other alloy steel piping.
x)
All load-bearing attachment welds shall be subjected to MPE after stress relieving.
xi)
For HP piping, non-destructive examination of welds shall be carried out in

accordance with the relevant design/manufacturing codes. However, apart from
above, the following requirements shall be met. Further statutory requirement,
wherever applicable shall also be complied with the following:
a. Temperature > 400 deg C and/ or pressure exceeding 71 bar
100% RT or UT on butt welds and full penetration branch welds.
100% MPE.
b. Temperature > 175 deg C up to 400 deg C and/or pressure exceeding 17
bar and up to 71 bar
100% RT or UT on butt welds and full penetration branch welds for pipe
diameter more than 100NB.
10% RT or UT on butt welds and full penetration branch welds for pipe
diameter up to 100NB.
100% MPE.
c. All other pipes not covered above shall be subjected to 100% MPE or DPT
in case of underground pipes and 10% MPE or DPT in case of piping above
the ground. Further, 10% of butt welds of underground piping shall be
subjected to RT.
E.
Valves
i)
Pressure retaining parts of valves shall be subjected to NDT as per Table 4.1.
ii)
Hardened and stellited valve disc and seat shall be subjected to DPT and hardness
check.
iii)
Color matching of valve disc/plug and seat shall be carried out to ensure minimum
80% contact and no through passage.
iv)
Hydraulic pressure test and seat leak test shall be carried out as per ANSI 16.34 or
IBR.
v)
Air seat leak test shall be carried out as per applicable standards or codes.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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[Logo of Utility]
vi)
Functional tests shall be carried out on each valve to check the following as per the
approved valve data sheet
vii)
Smooth operation.
viii)
Valve travel, closing and opening time.
ix)
Current drawn by actuators.
x)
Springs for safety valves shall be tested with suitable NDT and for spring stiffness
rate.
xi)
Safety relief valves shall be tested for performance.

Table 4.1
NDT requirements for pressure retaining components of valves
S.No.
Valve size NB
(mm)
ANSI Class
upto 300
ANSI Class
above 300
upto 600
Less than 50
Visual
Visual
ANSI Class
above 600
below 900
ANSI Class 900

and above but
below 4500
Visual
MPE (for special

class valves)
50 & above but
Visual
Visual
below100
MPE (for
special
class valves)
MPE and RT on
10%of valves on
100% area
100 & above but

less than 300
Visual
MPE
MPE and RT on
10% of valves
on change of
section and
weld ends
MPE and RT on
100% area
300 and above
MPE
MPE
MPE and RT on
change of
sections and
weld ends
MPE and RT on
100% area
Note:
a. For body and bonnet forgings, UT with MPE may be adopted in place of RT.
b. For austenitic steel, MPE may be replaced by DPT.
F.
Non pressure bearing attachments

Load bearing welds shall be subjected to UT and MPE after stress relieving. Non
load bearing welds shall be subjected to MPE after stress relief. The toes of the
welds adjoining the drum shall be ground smooth prior to stress relieving before
carrying out this examination.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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[Logo of Utility]
G.
Hydraulic test
i)
The drum and all components which are to be subjected to fluid pressure shall be
tested to minimum of 150% of the design pressure. The duration of the pressure
tests shall be sufficient, as approved by the Owner/Consultant, to show any leakage
paths and to permit a thorough examination of the component whilst under
pressure.
ii)
The temperature of the fluid used for the pressure test shall be such as to avoid any
possibility of brittle fracture at a low temperature and the same shall be modified
and submitted to the Owner/Consultant for approval, before commencing the test.
iii)
The fluid used shall be of a sufficient purity and where relevant, suitable inhibits
shall be used to avoid excessive corrosion and /or damage to temporary parts
either during the test or prior to drying and cleaning.
H.
Pneumatic test of compensating pads

All compensating pads shall be provided with two-threaded weep holes to test
welds at 0.5 kg/cm2 (g) with soap solution and no leakage shall be ensured.
4.2.2
Air Preheaters, Steam Coil Air Pre-Heater and Fuel Oil Heaters
A.
Air Preheaters
i)
Forged shafts for air preheater like stub shaft, main rotor forging, housing hub shall
be subjected to 100% UT at mill and magnetic particle examination after machining.
ii)
For non-modular design, trial assembly shall be carried out at shop prior to dispatch
to site.
iii)
Critical welds of rotor post shall be subjected to radiographic examination.
B.
Steam coil air pre-heater and fuel oil heaters

Hydraulic pressure test shall be carried out on the heating coils. All pipes, valves,
steam traps and mountings shall be subjected to hydraulic test as called for
under IBR, BS or other approved codes.
4.2.3
Soot Blowers
i)
Butt weld between nozzle and lance tube shall be subjected to 100 % radiography
tests.
ii)
Soot blower shall be subjected to operational checks as below:

a) Smooth operation
b) Long tube travel, closing and opening time.
c) Current drawn.
4.2.4
ID and FD fans
i)
Rotor components shall be subjected to ultrasonic test at mill and magnetic particle
examination/dye penetration examination after rough machining.
ii)
Butt welds in rotor components shall be subjected to 100% UT and all welds shall
be subjected to MPE or DPT after stress relieving.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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[Logo of Utility]
iii)
All rotating components of fans shall be dynamically balanced to quality grade 2.5
of ISO 1940.
iv)
Test for natural frequency of all fan components, including fan blades shall be
carried out for the fans.
v)
Full range performance test shall be carried out on one fan of each type and size as
per BS 848, Part-1.
vi)
ID fan shall be checked for string test i.e., operational check of one fan assembly to
check temperature rise, smooth operation, vibration and noise level. Dry run test
shall preferably be carried out during string test.
4.2.5
Coal Mills, Pulverised Coal Piping and Burners

i)
Raw material for shaft, coupling, gears and pinions, top and bottom races and other
rotating components shall be subjected to UT. MPE or DPT shall be carried out to
check surface soundness.
ii)
Wear-resistant parts shall be subjected to UT or RT to check soundness after

suitable heat treatment. Check for chemical composition and hardness shall be
carried out. For ceramic materials check for various properties including hardness,
density, wear rate and composition shall be carried out.
iii)
Butt welds in the body casing and separator of the mill shall be tested by RT and
MPE. All other welds shall be tested by MPE or DPT for acceptance.
iv)
All gearboxes shall be run tested for adequate duration to check rise in oil
temperature, noise level and vibration. Check for leak tightness of gear case also
shall be performed.
v)
Fabricated pipe welds shall be examined by MPE.
vi)
Ceramic/basalt lined piping and bends etc. shall be checked for proper layout.
vii)
Weldments on burner components shall be checked with suitable NDT. The burner
assembles shall be tested for operation at shop.
viii)
All rotating components shall be dynamically balanced.
4.2.6
Coal Feeders
i)
Type tests including degree of protection and routine tests shall be done as per
relevant Indian Standards or equivalent International Standards.
ii)
All major items like plates for casings, head pulley, tail pulley, pulley shaft and major
castings shall be procured with respective material test certificates.
iii)
Explosion proof test at 50 psi as per NFPA code shall be done as type test. Leak
tightness test shall be done on apron feeder casing. Endurance test for load cell
shall be carried out.
iv)
Test for weighing accuracy, calibration and repeatability shall be carried out at
various speeds by coal flow on one feeder.
v)
Calibration check shall be carried out on all feeder cabinet and assemblies prior to
dispatch.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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4.2.7
[Logo of Utility]
Boiler structure, ducts, hoppers, dampers etc.

i)
Only those materials which have been identified against mill sheet or test
certificates shall be used for construction. Structural steel and built up plate girders
for main boiler shall be as per approved Indian / international standards. All plates
of tension and compression flanges and connection material and plates above
40mm thickness shall be 100% ultrasonically tested.
ii)
Visual inspection of all welds shall be performed in accordance with AWS D.1.1.
Also the butt and fillet welds for built up plate girders shall be inspected 100% by
magnetic particle examination.
iii)
RT or UT shall be performed on all butt welds of thickness 32mm and above. For
thickness below 32mm and upto 25mm, 100% MPE shall be carried out and for
thickness below 25mm 10% MPE or DPT shall be performed. Edge preparations for
field welding shall be examined by MPE for plate thickness 32mm and above. Field
welds ends in ceiling girder shall be subjected to Ultrasonic examination for 100mm
depth from the edges.
iv)
Ceiling girders, columns, ducts hoppers and tunnels shall be trial assembled and
match marked prior to dispatch/erection. At least two consecutive girders along with
cross member shall be assembled at a time.
v)
Drum sling rods

a) Sling rods forging shall be subjected to ultrasonic examination.
b) Welds shall be examined by UT and MPE after stress relief.
c) Trial fitment of the rods with the drum shell shall be carried out to ensure proper
contact.
d) Screw thread of the rods shall be suitably protected to avoid damage during
handling and transport.
vi)
Dampers
a) All the dampers shall be subjected to operational test/checks.
b) Gas tight dampers shall be subjected to shop leakage test to demonstrate the
guaranteed tightness (minimum one damper of each type and size offered). In
case such type test is already done, the reports of the same shall be submitted
for review.
a) All dampers shall be checked for sealing dimensions to establish guaranteed
tightness.
4.2.8
Electro- Static Precipitators (ESPs)

A.
Discharge and collecting electrodes
i)
Work tests for discharge electrodes shall include the following (for the wire type
electrodes):
a) Chemical and tensile tests.
b) Metallographic examination-longitudinal and transverse (250X)
c) Surface finish and surface purity from chloride ions.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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[Logo of Utility]
d) Spring back and surface finish after coiling (applicable to helical discharge
electrodes
ii)
Work tests for collecting electrodes and rigid discharges electrode shall include the
following:
a)
b)
c)
d)
Chemical and mechanical properties.

Check for profile and straightness.
Check for surface finish and dimensional accuracy.
Cupping test for deep drawn sheets.
B.
ESP structure
i)
Visual inspection of all welds shall be performed in accordance with AWS D1.1.
ii)
Also the butt and fillet welds for built up plates and columns shall be inspected by
100% MPI.
iii)
Radiographic examination shall be performed on butt welds as per AWS D1.1.

100% radiography on tension flange (bottom flange) welds and spot radiography on
all joints in compression flange (top flange) of all beams and columns shall be
carried out. The minimum length of welds for spot radiography and acceptance
criterion shall be as per AWS D 1.1.
iv)
Edge preparation for field welding shall be examined by MPI.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[94]
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OF

R&M CONTRACTORS

VOLUME-II
SECTION-II, PART-B
DETAILED TECHNICAL SPECIFICATION-ELECTRICAL
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Tender Document For R&M of Unit No. [..] Capacity [..] of [Name of the
Power Plant]
[Logo of Utility]

Volume
Section
Part
Description
Volume-I
---
---
Commercial
Section-I
---
Part-A
Part-B
Part-C
Part-D
---
Part-A
---
Part-B
---
Part-C
---
Part-D
Not Used
Volume-II
Section-II
Volume-III
*****
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-II, Section-II, Part-B
[i]
25.09.2014
Power Plant]
[Logo of Utility]
1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
*****
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[ii]
25.09.2014
Power Plant]
[Logo of Utility]

1.
2.
3.
4.
5.
6.
7.
8.
9.
Spare Parts
10.
Annexure
SECTION-II:DETAILED TECHNICAL SPECIFICATION

1.
2.
3.
4.
*****
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[iii]
25.09.2014
Power Plant]
[Logo of Utility]

1.
2.
3.
*****
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[iv]
25.09.2014
Power Plant]
[Logo of Utility]

R&M CONTRACTORS

VOLUME-II,
SECTION-II, PART-B
DETAILED TECHNICAL SPECIFICATION- ELECTRICAL

OF
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[v]
25.09.2014
Power Plant]
[Logo of Utility]
TABLE OF CONTENT
1.
GENERAL ........................................................................................................ 1
2.
LIST OF ATTACHMENTS ................................................................................... 2
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[vi]
25.09.2014
Power Plant]
1.
[Logo of Utility]
GENERAL
This specification is intended to cover the [design, engineering,
manufacture, assembly, testing at manufacturer's works, supply in
properly packed condition for transport to site, erection, site testing and
commissioning] of Boiler complete with all accessories for efficient and
trouble-free operation of R&M of Unit No. [..] Of [Name of the Power
Plant] at [District], [State] for [Name of the Client].
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[1]
25.09.2014
Power Plant]
2.
[Logo of Utility]
LIST OF ATTACHMENTS
The following
specification.
List
of
attachments
is
enclosed
along
with this
[Note: List of attachments is depends on specific project scope of work.

R & M consultant may attach the attachments as per project specific
scope of work. For reference all attachments are considered in this
package as per scope of work considered]
Legend: O: USE, X: NOT USE
Sl.No
1
2
3
Attachment
Number
E1
E2
E3
E4
E5
6
7
8
9
10
11
E6
E7
E8
E9
E10
E11
12
13
14
E12
E13
E14
Table: 1.1
Description
Motor
Motorized Actuators
LV Transformers(Dry
type/Oil type)
415V Switchgear, MCC
and DBs
415V Non Segregated Bus
Duct
220V DC system
HV Cables
LV Cables
Illumination system
Cable Carrier System
Earthing and Lightning
Protection system
6.6kV Switchgear
Variable Frequency Drives
6.6kV Segregated Phase
Bus Duct
Rev
No
R1
R1
R1
Application
R1
R1
R1
R1
R1
R1
R1
R1
X
O
O
O
O
O
R1
R1
R1
X
O
X
O
O
O
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[2]
25.09.2014

OF

R&M CONTRACTORS
VOLUME-II
SECTION-II, PART-B, ANNEXURE-E1
TECHNICAL SPECIFICATION FOR MOTORS
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-E1
1.0
MOTOR
1.1
General
This specification is intended to cover the [design, Engineering, manufacture,
assembly, testing at manufacturer's works, supply in properly packed
condition for transport to site, Erection, site testing and commissioning] of
Electric Motor complete with all accessories for efficient and trouble-free
operation of R&M of Unit No. [..] of [Name of the Power Plant] at [District],
[State] for [Name of the Client].
1.2
Codes & Standards

All equipment and materials shall be designed, manufactured and tested in
accordance with the latest applicable Indian Standards (IS) / IEC as given
below except where modified and/or supplemented by this specification.
Table: 1.0
IS : 325
Specification for three phase induction motor.
IS :
900
Code of Practice for installation and maintenance of

induction motors
IS :
996
Single phase AC motors
IS : 1231
Dimensions of three-phase foot-mounted induction motors
IS : 1271
Thermal evaluation
insulation.
IS : 2223
Dimensions of flange mounted ac induction motors.
IS : 2254
Dimensions of vertical shaft motors for pumps
IS : 3177
Crane duty motors
IS : 4029
Guide for testing three phase induction motors.
IS : 4691
Degree of protection for enclosures of rotating electrical

machinery.
IS : 4722
Specification for rotating electrical machinery.
and
classification
of
electrical
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-II, Section-II, Part-B,Annexure-E1
[1]
25.09.2014
Power Plant]
[Logo of Utility]
IS : 4728
Terminal marking and direction of rotation for rotating

electrical machinery.
IS : 4889
Methods of determination
electrical machines.
IS : 5571
Guide for selection of electrical equipment for hazardous

areas.
IS : 6362
Designation of Method of Cooling of Rotating electrical

machines.
IS : 8223
Dimensions and output ratings for foot mounted rotating

electrical machines with frame numbers 355 to 1000.
IS : 8789
Values of performance characteristics for three phase

induction motors.
IS : 12065
Noise level of motors.
IS : 12075
Measurement and evaluation of vibration of rotating

electrical machines.
IS : 12615
Induction motors - Energy efficient, three-phase, squirrel

cage - Specification
IS : 12802
Temperature
machines
IS : 12824
Type of duty and classes of rating assigned.
IS : 14222
Requirements and method of Impulse withstand test
CEA
CEA Regulations
CEA
Standard Technical Specifications For Main Plant Package
IEC: 60034
Rotating electrical machines.
NEMA, MG-1
Motors and Generators
ISO : 1940-1
Mechanical vibration
residual unbalance
rise
of
measurement
efficiency
of
of
rotating
Determination
of
rotating
electrical
permissible
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
Equipment and material conforming to any other standard, which ensures

equal or better quality, may be accepted. In such case, copies of the English
version of the standard adopted shall be submitted along with the bid.
The electrical installation shall meet the requirements of Indian Electricity
Rules as amended up to date and relevant IS Code of Practice. In addition,
other rules and regulations applicable to the work shall be followed.
1.3
Design Criteria
a. All motors shall be suitable for an ambient temperature of 50 C and
relative humidity of 95%. The motors shall be suitable for operation in a
highly polluted environment.
b. AC Motors shall be of [constant speed, squirrel cage, three/ single phase,
induction type.] Motors shall be rated for [continuous duty/intermittent
duty]. They shall also be suitable for long period of inactivity. They shall
also be suitable for direct online starting (DOL starting).
c. DC motors provided for emergency service shall be shunt / compound
wound type. Motor shall be sized for operation with fixed resistance
starter for maximum reliability.
d. Power supply for AC motors shall be as follows:
Table: 2.0
1. [Below 0.22 kW]
: 240V, 1 Phase, 50Hz
2. [From 0.22 kW up to & including 160
415V, 3 Phase, 50Hz
6.6kV, 3 Phase, 50Hz
kW]
3. [Above 160 kW]
e. All AC motors shall be suited for the following range of frequency and
voltage variations:
i.
Voltage Variation
+/-10%
ii.
Frequency Variation
50Hz (+)3% to (-)5%
iii.
Combined
Variation
Voltage & Frequency
of :
10% (absolute sum)
f. DC motors shall be rated for 220V DC supply with voltage variation of

-15% to +10%.
g. The motor characteristics shall match the requirements of the driven
equipment so that adequate starting, accelerating, pull up, break down
and full load torques are available for the intended service.
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No.
Description
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Date of Issue
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[Logo of Utility]
h. Moreover, motors shall be so designed that maximum inrush currents and

locked rotor and pullout torque developed by them at extreme voltage
and frequency variations do not endanger the motor and driven
equipment.
i. Motors shall be capable of developing the rated full load torque even if
the supply drops to 70% of the rated voltage.
j. For 6.6kV motors, locked rotor current not to exceed [600%] of full load
current, including positive tolerance, except for BFP. For BFP the starting
current shall be [450%] of FLC. For 415 V motors Locked rotor current
not to exceed [600%] of full load current with IS tolerance.]
k. For DC motors, the starters shall be provided to limit the starting current
to [2] times of the full load current.
l. Maximum continuous motor ratings shall be at least [10%] above the
maximum load demand of the driven equipment under entire operating
range including voltage and frequency variations.
m. Accelerating torque at any speed with the lowest permissible starting
voltage shall be at least [10%] motor full load torque. Pull out torque at
rated voltage shall not be less than 205% of full load torque. It shall be
275% for crane duty motors.
n. The motors shall be suitable for bus transfer schemes provided on the
6.6kV and 415V systems without any injurious effect on its life. If
motors are connected to an automatic bus transfer system, they may be
subjected to 150% of the nominal voltage during changeover of buses
due to the phase difference between the incoming voltage and motor
residual voltage. In such cases, motors shall be capable of restarting
under full load after momentary loss of voltage.
o. Motors shall be of [energy efficient of type Eff-2] as per IS:
12615/equivalent IEC/ International Standards.
p. Motor shall be designed to keep torsional and rotational natural
frequencies of vibration of the motor and driven equipment at least 25%
above the motor operating speed range.
1.3.1
System Grounding
Table: 3.0
(a)
6.6 kV
Low Resistance Grounded to limit the

earth fault current to [300 Amps]
(b)
415 V
Solidly Grounded
(c)
220V DC
Ungrounded
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1.3.2
[Logo of Utility]
Fault Level
Table: 4.0
1.3.3
(a)
6.6 kV
[40 kA for 1 second]
(b)
415 V
(c)
220V DC
Degree of Protection
Table: 5.0
1.3.4
(a)
Indoor Motors
[IP 54]
(b)
Outdoor Motors
[IPW 55]
(c)
Cable Box located in Indoor Area
[IP 54]
(d)
Cable Box located in Outdoor Area
[IPW 55]
Winding Insulation
Table: 6.0
1.3.5
(a)
For 6.6 kV AC Motors
[Class F]
(b)
For 415V AC Motors
[Class B]
(c)
For 220V DC Motors
[Class B]
Winding Conductor Material

Table: 7.0
1.3.6
(a)
For 6.6 kV AC Motors
Copper
(b)
For 415V AC Motors
Copper
(c)
For 220V DC Motors
Copper
Bearing
Table: 8.0
(a)
For Drive End
[Roller]
(b)
For Non Drive End
[Roller / Ball]
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1.3.7
[Logo of Utility]
Temperature Rise
Table: 9.0
(a)
For Air Cooled Motors
[70 C] over ambient temperature

[Class B]
(b)
1.3.8
For Water Cooled Motors
[80C]
over
inlet
temperature [Class B]
cooling
water
Motor Earthing
Table: 10.0
1.3.9
(a)
Motors above 90 kW
[50 x 6 mm GI Flat]
(b)
Motors above 30 kW and up to 90 kW
[25 x 6 mm GI Flat]
(c)
Motors above 5 kW and up to 30 kW
[25 x 3 mm GI Flat]
(d)
Motors up to 5 kW
[8 SWG GI Wire]
(e)
Terminal Box
[8 SWG GI Wire]
Space Heater
Table: 11
(a)
For Motors 30 kW rating and

above
Space heater suitable for 1Phase,

240V AC, 50 Hz supply
(b)
For Motors below 30 kW rating
No Space heater provided.
1.3.10 Painting
Table: 12
a)
Paint Type
Epoxy based with approved class
b)
Paint Thickness
[Within 100 to 150 micron.]
c)
Paint Shade
[RAL5012 BLUE]
1.4
Specific Requirements
1.4.1
Locked Rotor Withstand Time

a) The starting time of the motor shall be at the minimum permissible
voltage.
b) For motors with starting time up to 20 seconds at minimum permissible
voltage during starting, the locked rotor withstand time under hot
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condition at highest voltage limit shall be at least 2.5 second more than
starting time.
c) For motors with starting time more than 20 second and up to 45 seconds
at minimum permissible voltage during starting, the locked rotor
withstand time under hot condition at highest voltage limit shall be at
least 5 second more than starting time.
d) For motors with starting time more than 45 seconds at minimum
permissible voltage during starting, the locked rotor withstand time under
hot condition at highest voltage limit shall be more than starting time by
at least 10% of the starting time.
e) Speed switches mounted on the motor shaft shall be provided in cases
where above requirements are not met.
1.4.2
Starting Voltage Requirement

I.
All motors (except mill motors):
a)
[85% of rated voltage for motors up to 4000 kW]
b)
[75% of voltage for motors above 4000 kW]
II.
For mill motors:
a)
[85% of rated voltage for motors above 1000 kW]
b)
[90% of rated voltage for motors below 1000 kW]
The motor shall be capable of withstanding the stresses imposed if started at

110% rated voltage.
Pump motor subject to reverse rotation shall be designed to withstand the
stresses encountered when starting with non-energized shaft rotating at
[125%] rated speed in reverse direction.
The motor may be subjected to sudden application of 150% rated voltage
during bus transfer, due to the phase difference between the incoming
voltage and motor residual voltage.
1.4.3
Winding and Insulation

a)
6.6 kV
motors
AC
Winding material shall be of copper. Insulation shall be of
[Class F with winding temperature rise limited to

Class B]. They shall withstand 1.2/50 microsecond
switching surges of 4U+5 KV (U=Line voltage in KV).
The coil inter-turn insulation shall be suitable for 0.3/3
micro second surge of 32 / 12 KV followed by 1 min
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No.
Description
Page
No.
Date of Issue
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power frequency high voltage test of appropriate voltage

on inter turn insulation.
b)
415V AC &
220V
DC
motors
c)
1.4.4
Conveyor
motors
Winding material shall be of copper. Insulation shall be of
[Class B with temperature rise limited to Class B.]

Short circuit rings of conveyor motors shall be either joint
less or welded type. Brazed joint is not acceptable.
Motor Control
(a) For HV Motors
i.
Motors of rating above [160 kW] shall be suitable for 6.6 KV

voltage
ii.
Frequent starting motors of rating above [160 kW] shall be

suitable to be controlled by vacuum contactors
(b) For LV Motors

i.
ii.
iii.
1.4.5
Motors of rating less than [132 kW] shall be operated by Contactor

from respective MCCs. Motors of rating up to [18.5 KW] shall be
provided with MPCBs and Electronic overload relays. Motors of
rating above [18.5 KW] and below [45 KW] shall be provided with
MCCBs and Electronic overload relays. Motors of rating [45 KW]
and above but less than [132 KW] shall be provided with MCCBs
and CT operated Electronic over load relays.
Motors of rating [132 KW] and up to [160 KW] shall be suitable to
be controlled by Air circuit breakers from switchgear, PMCCs and
shall be provided with comprehensive numerical motor protection
relays.
Only for firefighting system, motor rated [upto 200kW] shall be fed
from 415V switch board.
Starting duty
Motors shall be suitable for [3 nos. consecutive Cold starts ups and 2 nos.
consecutive Hot starts ups.] Motors shall be suitable for three equally spread
starts per hour when the motor is under normal service condition.
1.4.6
Bearings
a) Anti-friction type radial and thrust bearings (ball, roller) and sleeve
bearing shall be rated for minimum standard life of 40,000 hours taking
bearing and driven equipment loads (in case the drive is not having
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b)
c)
d)
e)
f)
g)
h)
1.4.7
[Logo of Utility]
separate thrust bearing) into account. If bearings are lubricated, loss of

grease shall be scarce and it shall not creep along shaft into motor
housing. Facility of removal of excess grease shall also be provided for
grease lubricated bearings.
Vertical shaft motors shall be provided with thrust and guide bearings.
Thrust bearing of tilting pad type is preferred. However, if Anti-friction
bearings can take vertical thrust, thrust & guide bearings are not
required.
Bearing shall be effectively sealed against dust ingress and shall be
pressure grease gun lubricated. The bearing and housing shall be so
designed that greasing shall be possible while the motor is running,
without removal of covers.
Where bearing supports are attached to the motor casing, adequate
bracing shall be provided on these supports to reduce vibrations and
ensure life of bearings.
If the bearings are oil lubricated, a drain plug shall be provided for
draining residual oil and oil level gauge shall be provided to show
precisely oil level required under standstill and running conditions.
Unless otherwise approved, bearing lubricating system shall be such that
no external forced oil or water is necessary to maintain required oil
supply to keep bearing temperature within design limits.
Lubricants shall be selected for prolonged storage and normal use of
motors in tropical climate and shall contain corrosion and oxidation
inhibitors. Greases shall have suitable bleeding characteristics to minimize
setting. The selected lubricants shall be indigenously available.
Motors rated above 1000 kW shall have insulated bearings to prevent
flow of shaft currents.
Temperature Rise
a) For Air Cooled Motors, temperature rise of insulation should be limited to
[70 C] over ambient temperature by resistance method.
b) For Water Cooled Motors, temperature rise of insulation should be limited
to [80 C] over inlet cooling water temperature mentioned elsewhere, by
resistance method.
1.4.8
Cooling
[All motors shall be either Totally Enclosed Fan Cooled (TEFC) or Totally
Enclosed Tube Ventilated (TETV) or Closed Air Circuit Air Cooled (CACA)
type. However, motors rated 3000 kW or above can be Closed Air Circuit
Water Cooled (CACW)]
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Date of Issue
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1.4.9
[Logo of Utility]
Enclosure
a) All motor enclosures shall conform to the degree of protection of
[IP54] for indoor and IPW-55 for outdoor installation unless otherwise
specified. Motor for outdoor or semi outdoor service shall be of weather
proof construction. Motors of large output rating located indoor could
have screen protected drip proof (SPDP) enclosure conforming to [IP-23.]
b) For motors located in outdoor & corrosive locations, FRP canopy shall be
provided. In case steel canopy is provided, the same shall be epoxy
painted to meet the surrounding atmosphere. Motors located in
hazardous areas such as Hydrogen plant shall have flame proof
enclosures of Group IIB conforming to IS: 2148.
c) For hazardous locations such as fuel oil facilities area, the enclosure of
motor shall have flame proof construction conforming to IS 2148.
1.4.10
Noise Level and Vibration

Noise level shall be limited to 85 dB (A) at 1.5 meters from the motor.
However the same shall be as per IS: 12065 unless otherwise specified. The
peak amplitude of vibration shall be within the specified limits laid down in
IS: 12075. Motors shall withstand vibrations produced by driven equipment.
HV motor bearing housings shall have flats in both X and Y directions
suitable for mounting 80mmX80mm vibration pads. Vibration pads with
screwed holes for mounting vibration probes shall be provided at both DE
and NDE.
1.4.11
Temperature Monitoring
[In HV motors, at least four numbers simplex/ two numbers duplex platinum
resistance type temperature detectors shall be provided for each phase of
stator winding]. Each bearing shall be provided with dial type thermometer
with adjustable alarm contact and two numbers duplex Platinum resistance
type temperature detector (3 wire, 100 ohm at zero C). In case of CACA
and CACW motors dial type temperature indicator shall be provided (one
each for hot and cold air temperature monitoring for CACA and CACW and
one each for inlet and outlet water temperature monitoring for CACW). If
alarm and trip are required for cooling air temperature, temperature switch
shall be provided. The contact rating shall be minimum 0.5A at 220V DC and
5A at 240V AC. Flow switches shall be provided for monitoring cooling
water flow of CACW motor and oil flow of forced lubrication bearing. Low
voltage motors rated 100 kW and above shall be provided with two PT100
RTDs per phase of winding.
1.4.12
Earthing
Motor body shall have two earthing points on opposite sides. Motor terminal
boxes shall also have separate grounding terminals.
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1.4.13
[Logo of Utility]
Termination
a) HV motors can be offered with either Elastimold termination or dust tight
phase segregated double walled (metallic as well as with insulated
barrier) cable boxes. In case Elastimold terminations are offered, then
protective cover and trifurcating sleeves shall also be provided.
Removable gland plates of thickness 3 mm (hot/cold rolled sheet steel) or
4 mm (non magnetic material for single core cables) shall be provided in
case of cable boxes. The main cable box / terminal box shall withstand [a
fault current up to 40 kA for 0.25 seconds for HV motors and 50 kA for
0.25 seconds for LV motors]. Separate terminal boxes shall be provided
for space heaters and RTDs and NCT (if applicable).
b) [All terminal boxes shall be capable of being turned through 360 degrees
in steps of 90 degrees unless otherwise specified.]
c) For HV motors the distance between gland plate and the terminal studs
shall not be less than 500 mm.
1.4.14
Differential Protection
For motors rated 6.6kV, [2000 KW & above,] neutral current transformers of
PS class shall be provided on each phase in a separate neutral terminal box
for differential protection.
1.4.15
Tropical Protection
(a) All motors shall have fungus protection involving special treatment of
insulation and metal against fungus, insects and corrosion.
(b) All fittings and hardware shall be corrosion resistant.
(c) Space Heater
(d) Suitable single phase space heaters operated at 240V, 50Hz, 1Phase AC
supply shall be provided on motors rated for 30KW and above to
maintain windings in dry condition when motor is standstill. Separate
terminal box for space heaters & RTDs shall be provided.
(e) The space heater shall be sized to maintain the motor internal
temperature above dew point when the motor is in idle condition.
1.4.16
Rating Plate
Motor shall have Stainless steel nameplate(s) showing diagram of
connections, all particulars as per IS: 325 / NEMA-MG-1 and following
additional information:
(a) Type of bearing and recommended lubricants along with location of
insulated bearing.
(b) Temperature rise under normal/abnormal conditions.
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No.
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(c) In addition to above, an arrow block shall be screwed on to the body of

motor on the non-driving end to indicate normal direction of rotation of
motor.
(d) Year of Manufacture
1.4.17
Drain Plug
Motor shall have drain plugs so located that they shall drain the water,
resulting from the condensation or other causes from all pockets of the
motor casing.
1.4.18
Dowel Pins
Motor shall be designed to permit easy access for drilling holes through
motor feet or mounting flange for installation of dowel pins after assembling
the motor and driven equipment.
1.4.19
Painting
The complete motor assembly including fan shall be painted with corrosion
proof paints of approved class.
1.4.20
Lifting provision
Motor weighing 25 Kg or more shall be provided with eyebolt or other
adequate provision of lifting.
1.4.21
Local Push Button Station (LPBS)

a) Each motor shall be provided with push button station as per process
requirement i.e. Start/Stop or Emergency Stop.
b) The degree of protection of LPBs shall be IPW 55 for outdoor and IP 54
for indoor applications.
c) All Push Buttons shall be push to actuate type and stop Push Button shall
be lockable in off position as per the scheme requirement.
d) The Emergency local stop push button of Stay put type shall be provided
with Press to lock & turn to release keyless mechanism.
e) All PBs shall be provided with 2 numbers NO and 2 numbers NC contacts
for various interlocking purposes. One contact of stop PB shall be directly
wired to switchgear module for direct tripping and another contact to
control system.
f) Terminals to be suitable for 2 cores of 2.5 Sq.mm. cable with 20% spare
terminals.
g) All LPBS shall be of Poly Carbonate /FRP / Die Cast Aluminium material.
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No.
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I)
[Logo of Utility]
TestsType Test
For each type & rating of HV and LV motors of rating above [50 kW], the
Bidder shall submit for Owners approval the reports of all the type tests as
per relevant standards and carried out within last[five] years from the date
of bid opening. These reports should be for the tests conducted on the
equipment similar to those proposed to be supplied under this contract and
the test(s) should have been conducted at an independent laboratory.
In case the Bidder is not able to submit report of the type test(s) conducted
within last [five] years from the date of bid opening, or in case the type test
report(s) are not found to be meeting the specification requirements, the
Bidder shall conduct all such tests under this contract free of cost to the
Owner and submit the reports for approval.
The following shall constitute the type tests:
(a) Visual and dimensional check
(b) Winding resistance measurement
(c) No load test
(d) Mechanical vibration
(e) Direction of rotation versus phase sequence
(f) Insulation resistance measurement
(g) High potential test
(h) Locked rotor test
(i) Speed/torque test
(j) Over speed test
(k) Temperature rise test
(l) Determination of characteristic
(m) Degree of protection test for the enclosure.
(n) Noise level
(o) Shaft current and bearing insulation test (Applicable for HV motors)
II)
Routine Test
All equipment shall be completely assembled, wired, adjusted and routine

tested as per relevant IS / IEC Standards at manufacturer's works in the
presence of consultant /purchaser or his representative.
III)
Test Witness
[The tests shall be carried out in presence of the Owners representative, for
which a minimum 7 days notice shall be given by the Bidder. The Bidder shall
obtain the Owners approval for the type test procedure before conducting
the type test. The test procedure shall clearly specify the test set-up,
instruments to be used, procedure, acceptance norms, recording of different
parameters, interval of recording, precautions to be taken etc. for the type
test(s) to be carried out.]
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No.
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No.
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IV) Test Certificates
a) Certified copies of all tests carried out at works and at site shall be
furnished in requisite no. of copies for approval of the Owner.
b) The equipment shall be dispatched from works only after receipt of
Owner's written approval of shop test reports.
1.5
Drawings, Data & Manuals

Drawings, data & manuals for the motors shall be submitted as indicated
below:
Dimensional General Arrangement drawing
a) [Motor sizing calculation
b) Foundation Plan & Loading
c) Cable end box details
d) Space requirement for rotor removal
e) Thermal withstand curves hot & cold
f) Starting and speed torque characteristics at 80% & 100% voltage
g) Complete motor data
h) Erection & Maintenance Manual
i) Test reports
j) QAP]
1.6
Rating and Requirements

Major technical parameters of motor are listed below. However, Bidder may
also refer to Volume-III, technical schedule in order to submit technical data
of equipment along with their technical proposal.
S. No.
Technical Particulars
Unit
Motor application
Rated Output, kW
kW
Maximum continuous
kW obtainable
without exceeding
specified
temperature rise
kW
Motor type
Duty Cycle (IEC

60034-1)
Parameters
[As per
requirement]
[As per
requirement]
Remarks
[By Bidder]
Squirrel cage
induction motor
[S1]
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No.
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S. No.
Unit
Rated voltage
kV
Phase/frequency
Allowable variation in
supply conditions
Voltage
Frequency
Combined
Method of starting
Hz
8
a)
b)
c)
9
DOL
CT details for
differential protection
11
Full load amperes
12
Locked rotor current

amperes
13
Method of Cooling
(IC code)
14
Enclosure (IP Code)
15
16
Remarks
6.6 kV
50
10
Construction
(horizontal or
vertical)
Max. temperature,
by resistance method
Parameters
6.6 kV for HV
motors
415 V for LV
motors
220V DC for DC
motors
50
[Logo of Utility]
Yes/No
For motors of
rating > 2000kW
[By Bidder]
HV(Except BFP):
6 times without
tolerance
BFP: 4.5 times
without tolerance
LV: 6 times with
IS specified
tolerance
DC : 2 times with
no positive
tolerance at rated
terminal voltage.
[As per
requirement]
Indoor : IP54
Outdoor : IPW55
[As per
requirement]
Deg C
120 deg
(Class B)
Document Number
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No.
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S. No.
17
Unit
Parameters
HV: Class F
LV: Class B
Insulation class
18
19
a)
b)
c)
20
Motor insulation
system (describe
material used)
Bearings
Type
Quantity
Lubrication system
pressure and flow
Temperature
detector (type &
quantity)
a)
Winding
b)
Bearing
21
b
22
23
a)
b)
c)
d)
24
a)
b)
c)
25
a)
b)
Remarks
[By Bidder]
[By Bidder]
[As per
requirement]
[As per
requirement]
Space heaters
a
[Logo of Utility]
30 kW and above
Watts
(Rating/Operating)
Volts
(Rating/Operating)
GD2 of motor
Power factor
Full load
3/4 load
1/2 load
No load
Efficiency
Full load
3/4 load
1/2 load
Impedance data
locked rotor
reactance per phase
Rotor resistance per
phase
[By Bidder]
[By Bidder]
[By Bidder]
[By Bidder]
p.u
p.u
p.u
p.u
[By Bidder]
%
%
%
[By Bidder]
Ohm
Ohm
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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S. No.
c)
26
27
28
29
30
stator resistance per
phase
Net motor weight
Terminal box
dimensions H/W/D
Rotor removal
clearance
Winding connection
(star or delta)
Noise Level
Unit
Parameters
[Logo of Utility]
Remarks
Ohm
Kg
[By Bidder]
Mm
[By Bidder]
mm
[By Bidder]
dB(A)
HV: Star
LV: Delta
[As per
requirement]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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OF

R&M CONTRACTORS
VOLUME-II
TECHNICAL SPECIFICATION FOR MOTORIZED
ACTUATORS
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-E2
1.0
MOTORIZED ACTUATORS
1.1
General
This specification is intended to cover the
[design, Engineering,
manufacture, assembly, testing at manufacturer's works, supply in properly
packed condition for transport to site, Erection, site testing and
commissioning] of Motor Operated Actuator complete with all accessories
for efficient and trouble-free operation of valves, dampers and gates for
R&M of Unit No. [..] of [Name of the Power Plant] at [District], [State] for
[Name of the Client]..
1.2
Codes & Standards

Table 1.0
IS :
325
Specification for three phase induction motor.
IS :
900
Code of Practice for installation and maintenance of induction

motors
IS :
996
Single phase AC motors
IS : 1271
Thermal evaluation and classification of electrical insulation.
IS : 2223
Dimensions of flange mounted ac induction motors.
IS : 4029
Guide for testing three phase induction motors.
IS : 4691
Degree of protection for enclosures of rotating electrical

machinery.
IS : 4722
Specification for rotating electrical machinery.
IS : 4728
Terminal marking and direction of rotation for rotating electrical

machinery.
IS : 4889
Methods of determination of efficiency of rotating electrical

machines.
IS : 5571
Guide for selection of electrical equipment for hazardous areas.
IS : 6362
Designation
machines.
of
Method
of
Cooling
of
Rotating
electrical
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
IS : 8789
Values of performance characteristics for three phase induction

motors.
IS :
Electrical Motor Operated Actuators.
9334
IS : 12065
Noise level of motors.
IS : 12075
Measurement and evaluation of vibration of rotating electrical

machines.
IS : 12615
Induction motors - Energy efficient, three-phase, squirrel cage Specification
IS : 12802
Temperature rise measurement of rotating electrical machines
IS : 12824
Type of duty and classes of rating assigned.
CEA
CEA Regulations
CEA
IEC:
60034-1
Rotating electrical machines.
NEMA,
MG-1
Motors and Generators

1.3
Design Criteria
a. All motor operated actuators shall be suitable for an ambient temperature
of 50 C and relative humidity of 95%.
b. Depending on the required type of services, the rating of motor operated
actuators shall be selected. For isolating service, the actuator shall be
[rated for three successive open-close operations of the valve/ damper or
15 minutes continuous operation whichever is higher.] Whereas for
regulating service, the actuator shall be suitably [time rated for required
number of duty cycle or 150 start per hour whichever is higher].
c. The actuator shall be accompanied with constant speed, squirrel cage,
three/ single phase, induction motor. The motor shall be designed for high
Document Number
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No.
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No.
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[Logo of Utility]
torque and reversing service. They shall also be suitable for direct online
starting (DOL starting).
d. Motors of actuators shall be suited for the following range of frequency
and voltage variations:
i.
Voltage Variation
+/-10%
ii.
Frequency Variation
50Hz (+)3% to (-)5%
iii.
Combined
Variation
Voltage & Frequency
of :
10% (absolute sum)
e. The motor operated actuator shall be sized for performing open / close
operation at rated speed against designed differential pressure at [90%]
of rated voltage. The motor shall have [10%] design margin on the shaft
design power.
The actuator shall meet the following performance requirements:
i. Open & Close the valve completely and make leak tight valve closure
without jamming.
ii. Attain full speed of operation before valve load is encountered and
impart an unseating blow to start the valve in motion (hammer blow
effect).
iii. The motor reduction gearing shall be sufficient to lock the shaft when
the motor gets de energized and prevent drift from torque switch
spring pressure.
iv. The entire mechanism shall withstand shock resulting from closing
with improper setting of limit switches or from lodging of foreign
matter under the valve seat.
v. The actuator shall be designed for mounting in any position without
any lubricant leakage or operating difficulty.
1.4
1.4.1
Construction
a) The actuator shall essentially comprise of drive motor, limit switches,
gear train, clutch, hand wheel, position indicator/ transmitter, space
heater and internal wiring.
b) The actuator enclosure shall be totally enclosed, dust tight, weather
proof with [IPW 55] degree of protection.
c) All electrical equipment, accessories and wiring shall be provided with
tropical finish to prevent fungus growth.
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No.
Description
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[Logo of Utility]
d) Gear train shall be made of metal (fiber gears are not acceptable). Self
locking feature shall be provided to prevent drift under torque switch
(wherever applicable) spring pressure when motor is de energized.
e) Manual wheel shall disengage automatically during motor operation.
1.4.2
Type
a) The actuators shall have integral starters along with overload relays with
built-in single phase preventer.
b) A 415 V, 3 phase, 3 wire, 50 Hz power supply will be provided from
power plant 415 V switchgear through MCCB. Control voltage of the
starter circuit shall be 110 V AC or depending on manufacturers
practice. But the same shall be derived from incoming 415 V, 3 phase, 3
wire supply.
1.4.3
Motors
a) Type: The drive motor shall be three phase, squirrel cage induction motor
suitable for direct on line starting with starting current limited to six times
the rated current
b) Enclosure: The motor shall be totally enclosed, self ventilated with [IPW
65] degree of protection.
c) Insulation: The motor winding shall be insulated with [Class B]
insulation having temperature rise limited to [Class B].
d) Bearing: The motor bearing shall be [double shielded, grease lubricated
and antifriction type].
e) Earthing: At least two earthing terminals shall be provided for the motor
body. Separate earthing terminal should be provided for terminal box.
f) Protection: The following electrical protections should be provided for the
motor:
i. Single Phasing Protection
ii. Overload Protection
iii. Overheating Protection through thermostat
iv. Wrong Phase Sequence Protection
g) Limit Switches: Each actuator shall be accompanied with following
switches:
i. Four nos. positional limit switches (2 for open & 2 for close), each
adjustable at any position from fully open to fully closed positions
of the valve / damper.
ii. Two torque limit switches, one for each direction of travel, self
blocking & adjustable torque type.
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Rev
No.
Description
Page
No.
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[Logo of Utility]
iii. Four nos. end travel limit switches, two for each direction of
travel.
iv. A single shaft shall actuate all contacts of limit switches at each
position.
h) Interface: Open/close command termination logic with position and
torque limit switches, positioned circuit shall be suitably built in the PCB
inside the actuator.
i. For binary drive, open/close command and status thereof and
disturbance monitoring signal (common contact for overload,
thermostat, control supply failure, L/R selector switch at local,
other protections operated) shall be provided. Interface with the
control system shall be through hardwired signal only. Interposing
relays provided (with coil burden 2.5 VA) in the DCS shall be
energized to initiate opening and closing, by 24V DC signal from
the external control system. Potential free contact provided by the
IPR shall be utilized in the control circuit of the contactor of
motorized actuators.
ii. For modulating drive, the command to actuator shall be in form of
4- 20mA signal. The necessary positioning circuit and motor
protection shall be provided.
iii. Open/close command termination logic shall be suitably built
inside actuator.
i)
Hand Wheel: Each actuator shall be provided with a hand wheel for
emergency manual operation. The hand wheel shall disengage
automatically when the motor is energized.
j)
Position Indicator / Transmitter: The actuator shall have

i. One built in local position indicator for 0 100% travel.
ii. One position transmitter of modulating / inching type for remote
indication suitable to stabilize 4-20mA signal and operated with
[24V DC].
k) Space Heater: Space heater of suitable rating shall be provided. The
power supply shall be derived from main power supply available in the
actuator.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
l)
Wiring: All electrical devices shall be wired up to and terminated in a

terminal box. The internal wiring shall be done with [2.5 sqmm] copper
wires. All wiring shall be well identified at both ends with ferrules.
m) Terminal Box:
i. The terminal box shall be weather proof with removable front
cover and cable glands suitable for cable connection. The
terminals shall be suitable for connection of [2.5 sq.mm copper]
conductor.
ii. Necessary double compression cable glands with nickel coating
and tinned copper lugs for cables shall be provided.
iii. The terminal block shall be suitable for 650V grade power cable.
.
n) Rating Plate : Motor and actuator shall have Stainless steel nameplate(s)
showing all particulars as per relevant IS/ IEC and following additional
information:
i. Type of bearing and recommended lubricants.
ii. Temperature rise under normal/abnormal conditions.
iii. Degree of Protection
iv. In addition to above, an arrow block shall be screwed on to the
body of motor on the non-driving end to indicate normal direction
of rotation of motor.
v. Year of Manufacture
1.5
Tests
The actuator and all components thereof shall be subject to routine factory
tests as per relevant IS standards. In addition, if any special test is called for
in equipment specification, the same shall be performed.
1.5.1
Test Witness
which a minimum [7] days notice shall be given by the Bidder. The Bidder
shall obtain the Owners approval for the type test procedure before
conducting the type test. The test procedure shall clearly specify the test
set-up, instruments to be used, procedure, acceptance norms, recording of
different parameters, interval of recording, precautions to be taken etc.]
1.5.2
Test Certificates
furnished with requisite no. of copies for approval of the Owner.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]

owner's written approval of shop test reports.
1.6
Drawings Data and Manuals

The drawings, data & manuals for the motorized actuators shall be
submitted as indicated below:
1. [Actuator Data Sheet
2. General arrangement drawing
3. Internal wiring Diagram and Control Schematic.
4. Torque switch and Limit switch contacts development.
5. QAP for Test Reports
6. Manufacturers Catalogue.
7. Instruction manuals on Installation methods.]
1.7

S. NO.
1.
2.
3.
DESCRIPTION
UNIT
DATA
Integral
Type
Application
[As per project

specific]
Motor type
Squirrel Cage
Supply voltage
415 V, 3 ph, 3
wire.
5.
Phase, frequency
Hz
3ph, 50 Hz
6.
Motor rated voltage
415V/230 V
7.
Control Voltage
[110 V AC]
8.
Voltage and its variation
10%
9.
Frequency and its variation
10.
Combined V & f variation
4.
Hz
+3 to -5%
10%
Document Number
Rev
No.
Description
Page
No.
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S. NO.
DESCRIPTION
[Logo of Utility]
UNIT
DATA
11.
IPW 65
12.
Winding Insulation
Class B
13.
Temperature Rise (over ambient

temperature)
14.
Painting
15.
Motor Starting
Class B
[RAL 5012]
a) Method
DOL
b) Staring Current
6 times
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
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[8]
25.09.2014

OF

R&M CONTRACTORS
VOLUME-II
TECHNICAL SPECIFICATION FOR LV TRANSFORMERS
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-E3
1.0
LV TRANSFORMER (DRY TYPE/OIL TYPE)
1.1
General
This specification is intended to cover [design, Engineering, manufacture,
LV Transformers (Dry type/Oil type) complete with all accessories for
efficient and trouble free operation for of R&M of Unit No. [..] of [Name of
the Power Plant] at [District], [State] for [Name of the Client]..
1.2
Codes and Standards

Table 1.0
CODE
NAME OF STANDARD
IS:334
Dimensions for porcelain Transformer bushing
IS:335
New insulating oil for transformers and switchgears
IS:1271
Classification of insulating materials for Electrical

Machinery and apparatus in relation to their stability
in service.
IS 2026
Specification for power Transformer (all parts)
IS:2071
Method of high voltage testing
IS:2099
High voltage porcelain bushings
IS:2147
Degree of protection.
IS:2705
Current transformers
IS:3202
Code of practice for Climate proofing of electrical

equipment
IS:3637
Gas operated relays
IS:3639
Fittings and accessories for power Transformers
IS:5561
Electric Power connectors
IS:6600
Guide for loading of oil immersed transformers
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
CODE
NAME OF STANDARD
IS: 11171
Dry type transformers
IS:10028
Code of practice for selection, Installation and

maintenance of transformers Part I, II and III
CBIP
Manual on transformers
IEC60076
Power Transformer
IEC 60214
Tappings
IEC 60726
Dry-type power transformers
IEEE C57.12.01
General Requirements for Dry-Type Distribution and

Power Transformers Including Those with Solid
Cast and / or Resin-Encapsulated Windings
ANSI C57.12.51
Requirements for Ventilated Dry-Type Power

Transformers, 501 KVA and Larger, Three-Phase
with High-Voltage 601 to 34 500 Volts, Low
Voltage 208Y/120 to 4160 Volts
ANSI C57.12.55
Dry-Type Transformers in Unit Installations,

Including Unit Substations Conformance Standard
ANSI/IEEE
Impulse Tests, Guide for Transformer (Appendix to

ANSI/IEEE C57.12.90)
C57.98
ANSI/NFPA 70
National Electrical Code
IEEE C57.12.91
Test Code for Dry-Type Distribution and Power

Transformers
IEEE C57.94
Recommended Practice for Installation, Application,

Operation and Maintenance of Dry-Type General
Purpose Distribution and Power Transformers
IEEE C57.96
Guide for Loading Dry-Type Distribution and Power

Transformers
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
CODE
NAME OF STANDARD
NEMA ST 20
Dry Type Transformers for General Applications
CEA
CEA Regulations
CEA
Standard Technical Specifications For Main Plant

Package

1.3
Design Criteria
a)
b)
c)
d)
e)
f)
g)
The transformers shall be dry type (AN) for indoor location and shall be
oil type (ONAN) for outdoor location.
The oil type transformer shall be installed in hot, humid and tropical
atmosphere with ambient temperature equal to 50oC. All equipment,
accessories and wiring shall be provided with tropical finish to prevent
fungus growth.
The transformer shall be capable of continuous operation at specified
rating under the following condition:
i)
Voltage variation
10%
ii)
Frequency variation
[+3% ,-5%]
iii)
Combined voltage and
frequency variation (absolute sum)
- [10%]
The transformer shall be capable of withstanding the short circuit
stresses due to a terminal fault on one winding with full voltage
maintained on the other winding for minimum period of two (2)
seconds.
The noise level shall be limited to the value specified by NEMA
Standard Publication No. TR-1-1993 when measured in accordance
with conditions outlines in ANSI/IEEE C57.12.90-1999/IS13964/CBIP
publication.
The design shall be such as not to cause any undesirable interference
with radio or communication circuits.
Transformers shall accept without injurious heating, combined voltage
and frequency variation which produce an over fluxing condition of
120% for one (1) minute.
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h)
i)
[Logo of Utility]
Each transformer shall be sized based on actual load with 10% margin
and considering voltage regulation factor. It shall be sized by
considering 100% load connected on the bus considering other
transformer outage. An appropriate load factor of 0.9 for continuous
and 0.2 for intermittent shall be considered.
The impedance of the transformers shall be chosen such that the fault
level on the LV switchgear does not exceed 50kA including the motor
contributions and also voltage dip while starting the motor does not
exceed 15% at motor terminal.
1.4
Specific Requirements of Transformers
1.4.1
Enclosure (for dry type)

a) The encapsulated cast resin transformer shall be housed in naturally
ventilated floor mounted cold rolled sheet steel cubicle with louvers
backed by fine brass wire mesh. The enclosure shall be of bolted type
fabrication and degree of protection shall be at least IP32. The minimum
sheet steel thickness shall be 2 mm.
b) Enclosure shall be provided with lifting lugs and grounding terminals at
both ends. Further the enclosure door shall have pad locking provision.
c) The enclosure door shall be interlocked with service transformer incoming
breaker such that.
The door can be opened only when the service transformer HV side
circuit breaker is in Test/Isolated position.
[6.6] kV side circuit breaker can be closed only when the doors are
closed.
d) Necessary illumination with controls shall be provided in the enclosure.
e) Thermostatically controlled space heater inside the enclosure of suitable
rating shall be provided if necessary.
1.4.2
Tank (for oil type)

a) For LV transformers, the tank shall be of conventional type.
b) Tank shall be made from good commercial grade low carbon steel and
shall be of welded construction.
c) Tank shall be designed to permit lifting, by crane or jacks of the complete
transformer assembly filled with oil. Suitable lugs and bosses shall be
provided for this purpose.
d) Tank together with radiators, coolers, conservator, bushings vessel and
other fittings, shall be designed to withstand full vacuum without
permanent distortion.
e) The transformer top shall be provided with a detachable tank cover with
a bolted flanged gasket joint. Lifting lugs shall be provided for removing
the cover. The surface of the cover shall be suitably sloped so that it
does not retain rain water.
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No.
Description
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No.
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f) The material used for gaskets shall be cork-neoprene or approved

equivalent. Gasketed joints for tank and manhole covers, bushings and
other bolted attachments shall be so designed that the gasket will not be
exposed to the weather. Spare gaskets shall be provided for all openings
as shipping gaskets will not be reused.
g) Tank shall be provided with all necessary valves.
h) Tank shall be provided with a pressure release device which shall operate
at a pressure below the test pressure for the tank and radiators. This
device shall be of sufficient size for rapid release of any pressure that
may be generated in the tank and which may result in damage to the
equipment. The device shall be rain proof after blowing and shall be
provided with a device visible from ground to indicate operation. An
equaliser pipe connecting the pressure relief device to the conservator
shall be supplied. This device shall be provided for all transformers.
Pressure relief device shall be equipped with remote monitoring/alarm
contacts
1.4.3
Core
a) The transformers shall be three phase core type. The core shall be built
up with high grade, non-ageing, low loss, high permeability grain oriented
cold rolled silicon steel laminations especially suitable for core material.
Laminations shall be annealed in a non-oxidizing atmosphere to relieve
stresses and restore the original magnetic properties of CRGO sheets
after the cutting and punching operations.
b) CRGO sheets shall be coated with insulation varnish. Insulation shall be
able to withstand the curing temperature and shall reduce eddy current to
minimum. The core shall be protected from corrosion with a rust-resistant
coating.
c) The core clamping brackets shall be designed to provide an even
distribution of clamping forces to the core, yokes and legs and shall be
rigidly braced to reduce sound levels and losses.
1.4.4
Winding
a) The coils shall be manufactured from electrolytic copper conductor with
sufficient number of radial supports and fully insulated for rated voltage.
b) The insulating material shall conform to Class F. Coils shall be so
insulated that impulse and power frequency voltage stresses are
minimum and shall withstand even the severest of temperature
fluctuations.
c) Coil assembly shall be suitably supported between adjacent sections by
insulating spacers and barriers. The windings shall be arranged to ensure
a free circulation of the air and to reduce the hot spots in the winding.
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No.
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d) All leads from the windings to the terminal board and bushings shall be
rigidly supported to prevent injury from vibration or short circuit stresses.
Guide tube shall be used where practicable.
e) The core and coil assembly shall be securely fixed in position so that no
shifting or deformation occurs during movement of transformer, under
short circuit stresses, switching or other transients.
f) All coils rated 1200V or higher shall be subjected to partial discharge
tests to ensure a properly cured and void free casting.
1.4.5
Encapsulation (for dry type)

a) HV and LV coils shall be separately cast under vacuum in fibre glass
reinforced epoxy resin compound. The insulation shall be fire resistant,
non-inflammable, non-hygroscopic and resistant to temperature
fluctuations.
b) The epoxy shall contain filler material providing characteristics superior to
unfilled epoxy including higher temperature rating, better heat
conductivity, better arc resistance and adhesion to the conductor, plus a
coefficient of expansion closer to that of the conductor material. The
epoxy resin shall be self extinguishing.
c) Encapsulated winding shall be free of internal voids, surface irregularities,
etc. No surface finishing of encapsulated winding shall be undertaken
after the process of encapsulation.
1.4.6
Insulating Oil (for oil type)

a)
b)
c)
d)
e)
f)
The transformer shall be filled with mineral insulating oil suitably

inhibited to prevent sludging.
The quality of oil to be supplied for the transformer shall conform to the
parameter specified in IS: 335 with latest amendments. No inhibitors
shall be used in oil. Prior to filling oil shall be tested as per IS: 335 for
tan delta, specific resistivity, breakdown voltage, moisture content etc.
Transformer shall be dispatched oil filled. 10% excess oil for topping up
shall be supplied in non-returnable container suitable for outdoor
storage.
Oil preservation shall be by means of conservator tank complete with
silica gel breather and oil seal.
Oil preservation shall be by means of bellows/ diaphragm sealed
conservator tank with silica gel breather to avoid direct connection
between atmosphere and transformer oil. It shall be complete with level
gauges, pipes , drain valve etc. The level gauges shall be so placed that
same can be readable standing from ground.
Necessary device shall be kept to provide annunciation in the event of
rupturing of bellow.
Document Number
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No.
Description
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No.
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1.4.7
Tappings (OCTC)
a)
b)
c)
d)
e)
f)
g)
1.4.8
[Logo of Utility]
Off-circuit taps as specified shall be provided on the high voltage

winding.
The transformer shall be capable of operation at its rated KVA on any
tap provided the voltage does not vary by more than 10% of the
rated voltage corresponding to the tap.
The winding including the tapping arrangement shall be designed to
maintain electromagnetic balance between HV and LV windings at all
voltage ratios.
A warning plate indicating that switch shall be operated only when the
transformer is de-energized shall be provided.
Off circuit tap changer switch where provided shall be 3 phase, hand
operated, by an external handle with position markings and pad locking
facility and mechanical stops to prevent over cranking beyond extreme
positions.
Arrangement shall be such that switch can be operated at standing
height from ground level.
The operating handle can be padlocked at any tap position. The design
shall be such that the lock cannot be inserted unless the contacts are
correctly engaged. The mechanism shall be provided with a mechanical
tap position indicator with pad locking facility.
Fittings and Accessories:

The following fittings and accessories shall be provided :
a) Earthing pads: Two earthing pads of copper or other non-corrodible
material shall be welded at the bottom corners of the transformer tank
and supplied with clamp type terminals suitable for the purchasers
earthing conductors. Suitable earthing terminals on cable boxes shall also
be provided.
b) Terminal marking and rating plates shall be as per the specified standard.
c) In case of oil type, the conservator shall be of sufficient volume to
maintain the oil seal from the minimum ambient temperature of 5oC up
to an oil temperature of 100oC, with oil level varying within the minimum
and maximum visible levels with necessary accessories.
d) In case of oil filled type, Valves shall be supplied on the transformer tank
and radiators.
e) Pressure relief device: Pressure relief device shall be provided for
transformers rated 2 MVA and above which shall be of sufficient size for
rapid release of any pressure that may be generated within the tank and
which may result in damage of the equipment
f) Gas and Oil Actuated Relay (Magnetic Reed Type Gas & Oil Relay):
Document Number
Rev
No.
Description
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No.
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[Logo of Utility]
A double float type magnetic reed type gas and oil relay as per applicable
standard shall be provided for all oil filled transformers. All gas evolved
in the transformer shall collect in this relay. The relay shall be provided
with a test cock suitable for a flexible pipe connection for checking its
operation. The device shall be provided with two electrically independent
ungrounded contacts, one for alarm on gas accumulation and the other
for tripping on sudden rise of pressure. These contacts shall be wired up
to the transformer marshalling box. The relay shall be provided with shut
off valves on the conservator side as well as the tank side.
g) Temperature Indicators
i Oil temperature indicator (OTI)
All oil type transformers shall be provided with a 150 mm dial type
thermometer for top oil temperature indication. The thermometer shall
have adjustable, electrically independent ungrounded alarm and trip
contacts, maximum reading pointer and resetting device. The
contacts shall be rated minimum 0.5A making and 0.2A breaking at
220V DC.
ii Winding Temperature Indicator (WTI):
A device for measuring the hot spot temperature of the winding shall
be provided. The accuracy class of winding temperature indicator
shall be 20oC or better.
iii Oil Level Indicator:
A magnetic type oil level indicator shall be provided to indicate oil

level in the tank.
iv RTD/transducers for remote annunciation:
In addition to the above mentioned indicators, the Oil and winding

temperature measurement, RTDs / transducers shall be provided for
remote indication in the DCS. RTDs shall be duplex platinum type
with nominal resistance of 100 ohms at zero degree centigrade.
h) Bushing Current Transformers for stand by earth fault protection shall be
provided in the neutral bushing and lead shall be brought to Marshalling
box.
i) Radiator (oil filled type): Tank mounted radiators banks shall have bolted
flanged connections and pipe extensions to permit withdrawal of
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No.
Description
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No.
Date of Issue
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j)
1.4.9
[Logo of Utility]
transformer tank without disturbing the radiators. Flexible joints shall be

provided in the interconnecting pipes (unless otherwise approved) to
facilitate erection and dismantling and reduce transfer of vibrations from
tank to radiator. The interconnecting pipes shall be provided with drain
plug and air release vents.
Conservator (For oil filled type): The transformers rated below 7.5MVA
shall be provided with conventional single compartment conservator with
dry air filling the space above the oil.
Bushings
a) The bushing shall conform to the requirements of IS:2099 and IS:3347.
b) All transformer bushings shall be of porcelain (for oil filled)/ epoxy (for dry
type).
c)
The neutral terminal of
433V winding shall be brought out on a bushing along with the 433V
phase terminal to forma 4 wire system for the 433V. Neutral CTs shall be
located in the lead coming out of the winding and location of these CTs
shall not be inside the tank.
d)
The neutral terminal of
secondary shall be brought out through an outdoor. Further this neutral
terminal shall be connected by a copper flat of size [50 mm x 6] mm,
which shall be brought down upto 100 mm above ground. The copper
flat shall be insulated and supported from the tank body.
1.4.10
Terminal arrangement
a) Cable boxes
i. Wherever cable connections are specified, suitable cable boxes shall
be provided and shall be air insulated.
ii. Cable boxes shall have drilled gland plate of adequate size to receive
cables and to allow easy termination.
iii. Removable drilled gland planes shall be provided in the cable boxes.
iv. The additional supports for the cable boxes shall be galvanised iron.
v. The contractor shall provide earthing terminals on the cable box, to
suit [50mmx6] mm GI flat.
b) Bus duct
i. Wherever Bus duct termination is specified a flanged throat or
equivalent connection shall be provided for termination of bus duct
enclosure. The winding termination shall be outdoor type bushing.
The material of the bus duct termination arrangement of the
transformer shall be nonmagnetic. The bus duct may be either phasesegregated or non-segregated.
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No.
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ii.
1.4.11
b)
c)
A sheet steel weather, vermin and dust proof marshalling box shall be
furnished. The sheet steel used shall be at least 2.0 mm (CRCA) thick.
The box shall be free standing floor mounted/tank mounted type and
have a sloping roof. The degree of protection shall be IP-55 in
accordance with IS:2147.
The marshalling box shall have a glazed door of suitable size for
convenience of temperature indicators reading.
All incoming cables shall enter the marshalling box from the bottom.
Wiring
a)
b)
c)
d)
e)
1.4.13
Tolerance permissible for the height of terminals and bus duct flange
location specified for bus duct termination over ground level is
5mm. Contractor has to ensure that radiator, conservator and
explosion vent do not obstruct the path of the bus-ducts.
Marshalling box
a)
1.4.12
[Logo of Utility]
All control, alarm and indication devices provided with the transformer
shall be wired up to the terminal blocks.
Wiring shall be done with 650V PVC wires in conduit or PVC armored
cable. [Minimum wire size shall be 1.5 sq.mm stranded copper. Not
more than two wires shall be connected to a terminal. 20% spare
terminals shall be provided.]
Multi-way terminal block complete with mounting channel, binding
screws and washers for wire connections and marking strip for circuit
identification shall be provided for terminating the panel wiring.
[Terminals shall be stud type, suitable for terminating 2 nos. 2.5 mm2
stranded copper conductor and provided with acrylic insulating cover.]
All devices and terminal blocks shall be identified by symbols
corresponding to those used in applicable schematic or wiring diagram.
Each wire shall be identified, at both ends, with interlocking type
permanent markers bearing wire numbers as per Bidder's Wiring
Diagrams. AC / DC wiring shall have separate colour-coding.
Wire termination shall be made with crimping type connectors with
insulating sleeves. Wires shall not be spliced between terminals.
Painting
a)
b)
c)
All steel surfaces shall be thoroughly cleaned by sand blasting and / or

by chemical agents, as required to produce a smooth surface free of
scales, grease and rust.
The external surfaces, after cleaning, shall be given a coat of high
quality red oxide or yellow chromate primer followed by filler coats.
The transformer finished with two coats of epoxy based powder coated
paint. The paints shall be carefully selected to withstand tropical heat,
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d)
e)
1.4.14
[Logo of Utility]
rain etc. The paint shall not scale off or crinkle or be removed by
abrasion due to normal handling.
Painting shade shall be subject to owners approval.
Sufficient quantity of touch-up paint shall be furnished for application at
site.
Name Plate
Nameplates of approved design shall be furnished at each cubicle (one no.
each at front as well as at backside of cubicle) and at each instruments &
device mounted on or inside the cubicle. The material shall be lamicoid or
approved equal, 3 mm thick with white letter on black background. Selftapping screws shall hold the nameplate. [Nameplate size shall be minimum
20 x 75mm for instrument/device and 40 x 150mm for panels. Caution
notice on suitable metal plate shall be affixed at the back of terminal Box.]
1.5
Tests
1.5.1
Type Tests
For each type & rating of LV Transformers, the Bidder shall submit for
Owners approval the reports of all the type tests as per relevant standards
and carried out within [last five] years from the date of bid opening. These
reports should be for the tests conducted on the equipment similar to those
proposed to be supplied under this contract and the test(s) should have been
conducted at an independent laboratory.
within [last five] years from the date of bid opening, or in case the type test
The following shall constitute the type tests:
a) Temperature rise test
b) Dielectric test
1.5.2
Routine Tests
The following tests shall be performed on each transformer as a minimum:
a) After assembly, each core shall be pressure tested for one minute at
2KV (r.m.s.) A.C. between all bolts, side plates, structural steel works
and the core.
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No.
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b)
c)
d)
e)
f)
g)
h)
i)
j)
1.5.3
[Logo of Utility]
The wiring for auxiliary power and control circuitry shall be subjected to
withstand one minute power frequency test with 2.0KV (r.m.s.) to earth
Measurement of winding resistance
Measurement of voltage ratio and check of phase displacement
Measurement of short circuit impedance and load loss
Measurement of no load loss and current
Dielectric routine tests
Excitation loss and current measurements shall be made at 90%, 100%
and 110% of the rated voltage as routine test.
Partial discharge test
Tan delta test
Test Witness
1.5.4
Test Certificates
a)
b)
1.6
Certified copies of all tests carried out at works and at site shall be
The equipment shall be dispatched from works only after receipt of
Drawings/ Data and Manuals

Drawings, data, and manuals for the transformers shall be submitted as
indicated below:
a) [General Arrangement Drawing
b) Dimensioned general arrangement drawing showing enclosure, core coil
assembly, terminal arrangement, marshalling box and various fittings.
c) Transport/shipping dimensions with weights, wheel base detail etc.
d) Foundation plan & loading.
e) Bus duct/cable termination arrangement.
f) Control schematics and wiring diagrams.
g) Test reports and QAP
h) Any other relevant drawing or data necessary for satisfactory installation,
operation and maintenance.
i) Instruction manuals on Transformer and its various fittings The manual
shall clearly indicate method of installation, checkups and tests to be
carried out before commissioning of the equipment.]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
Note: The drawings, data and manuals listed are minimum requirement only.
The Bidder shall ensure that all other necessary write-ups, curves
and
information required to fully describe the equipment offered are submitted.
1.7
Ratings and Requirements

Table 2.0
6.6/0.420 kV LV AUXILIARY TRANSFORMER
Dry Type
Oil Type
1.
Application
[As per project

requirement]
[As per project

requirement]
2.
Location
Indoor
Outdoor
3.
Type
[Dry Type: epoxy cast

resin transformer]
[Oil type transformer]
4.
Reference standard
IS 11171
IS 2026
5.
Rated power (indicative)
[ As per project
requirement]
[ As per project
requirement]
6.
Rated winding voltage

ratio (line to line)
6.6/0.433 kV
6.6/0.433 kV
7.
Number of phases
8.
Winding
9.
Rated frequency
50 Hz
50 Hz
10.
Type of cooling
AN
ONAN
11.
Insulation Class
Class F or Better
Class F or Better
12.
Temperature rise Over

ambient temperature of
50oC
90oC or lower as
permissible for class
55oC
a.
For Winding by
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b.
13.
[Logo of Utility]
resistance method
of insulation offered
For Oil by Thermometer

method
Not Applicable
50 oC
60 KVp/20 kVrms
60 KVp/20 kVrms
Insulation level
( LI/AC)
a.
HV-
(LI/AC)
b.
LV-
(LI/AC)
-KVp/3KVrms
Vp/3KVrms
14.
Vector group
[Dyn11]
[Dyn11]
15.
Short-circuit impedance
on principal tap
[As per project

requirement]
[As per project

requirement]
16.
Parallel operation of
transformer
Momentarily
Momentarily
17.
Type of taps provided
OCTC, full capacity
OCTC, full capacity
18.
Taps provided on
H.V. winding
H.V. winding
Range of taps
[+/- 5 % in steps
of 2.5%]
[+/- 5 % in steps
of 2.5%]
19.
20.
21.
Method of Tap charge

controla.
Manual local
Yes
Yes
b.
Electrical local
No
No
c.
Electrical remote
No
No
d.
Automatic
No
No
System earthing
Document Number
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No.
Description
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a.
b.
22.
[Logo of Utility]
H.V.
Non-effectively
earthed
Non-effectively
earthed
L.V.
Effectively earthed
Effectively earthed
H.V.
6.6kV(UE) Cable/
busduct
6.6kV(UE) Cable/
busduct
L.V.
Non-segregated phase
bus duct
Non-segregated phase
bus duct
Neutral for earthing
GS flat connector
GS flat connector
a.
b.
23.
24.
Same as Dry type

transformer
Transformer bushing
HV
LV
LV - N
25.
Voltage class KV(r.m.s.)
7.2
1.1
1.1
26.
Creepage distance
mm
[As 25mm/kV]
[As 25mm/kV]
27.
Min. Ph-Ph/ Ph-E

clearance mm
As per Standard
As per standard
28.
System fault Level
29.
30.
31.
a.
HV Side
40 KA (r.m.s.)
40 KA (r.m.s.)
b.
LV Side
50KA (r.m.s.)
50KA (r.m.s.)
Max. Noise level
As per NEMA std. TR1
As per NEMA std. TR1
415 V, 3 ph, 3 wire

AC, 50 Hz
415 V, 3 ph 3 wire
AC, 50 Hz
220V +10%, -15% 2

wire DC(if required)
220V +10%, -15% 2

wire DC(if required)
[As per project
[As per project
Auxiliary supply
LV neutral side
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
current transformer
for standby earth fault
protection
requirement]
requirement]
32.
Guaranteed no load
loss (kW)
[By Bidder]
[By Bidder]
33.

(kW)
[By Bidder]
[By Bidder]
34.
Efficiency
a
At full load
[By Bidder]
[By Bidder]
At 75% load
[By Bidder]
[By Bidder]
At 50% load
[By Bidder]
[By Bidder]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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02

[16]
25.09.2014

OF

R&M CONTRACTORS
VOLUME-II
TECHNICAL SPECIFICATION FOR 415V SWITCHGEAR,
MCC & DBs
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-E4
1. 0
415V SWITCHGEAR, MCC AND DB
1.1
General
415V Switchgear MCC and DBs, complete with all accessories for efficient
and trouble-free operation for of R&M of Unit No. [..] of [Name of the Power
Plant] at [District], [State] for [Name of the Client]..
1.2
Codes and Standards

Table 1.0
Codes
Name of Standard
IS : 1248
IS: 2551
Direct acting indicating analogue electrical measuring instruments

and their accessories
Danger notice plates
IS :2705
Current transformers-specification
IS :3156
Voltage transformer specification
IS :3231
Specification for electrical relays for power system protection
IS: 8084
Specification for interconnection busbars for AC voltages above

1kV up to and including 36kV.
Specification for low-voltage switchgear and control gear
assemblies
Specification for static protective relays
IS :8623
IS :8686
IS :10118
IS :12021
IS : 13947
( Part 1)
IS : 13947
( Part 2)
IS : 13947
( Part 4)
Code-of practice for selection installation and maintenance of

switchgear and control gear
Specification for control transformers for switchgear and control
gear for voltages not exceeding 1000 v ac
Specification for low-voltage switchgear and control gear
Specification for low-voltage switchgear and control gear part 2:
circuit breakers
Specification for low-voltage switchgear and control gear -part 4 :
contactors and motor feeders
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[1]
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Power Plant]
[Logo of Utility]
Codes
Name of Standard
IS : 13947
( Part 5)
Low-voltage switchgear and control gear specification

Part 5 : control circuit devices and switching elements
IEC 61439
Low voltage switchgear and control gear assemblies.
CEA
CEA regulations for installation and operation of meters 2006.
CEA
Standard technical specifications for main plant package
Equipment and material conforming to any other standard which ensures

equal or better quality may be accepted. In such case, copies of the English
Rules as amended up to date and relevant IS Codes of Practice. In addition,
1.3
Design Criteria
a) All 415V Switchgear, MCC and DB shall be suitable for an ambient
temperature of 50 C and relative humidity of 95%. The Switchgear shall
be suitable for operation in a highly polluted environment.
b) All 415V Switchgear, MCC and DB shall be suitable for following voltage
& frequency variations as follows:
Voltage Variation
() 10%
Frequency Variation
(+) 3% to (-)5%
Combined Variation of Voltage &

Frequency
10% (absolute sum)
For DC system
-15% to +10%
c) 415 V switchgear & MCCs shall be of indoor /outdoor, double

front/single front [Preferably single front] and fully draw out type. ACB
feeder may be of single tier/two tier configuration depending upon rating.
DBs (ACDB / DCDB) shall be of single / double front [Preferably single
front] and fixed type. These shall be CRCA sheet metal enclosed and
assembled to form a rigid, free-standing floor mounted structure. Vertical
units shall be assembled to form a continuous line up of panels.
Compartmentalized multi-tier configuration shall be provided.
d) All AC motor starters shall be suitable for Direct on Line (DOL) starting.
Motors rated below [132]kW shall be provided with combination starters
consists of MCCB/MPCB, contactors and electronic over load relay and
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e)
f)
g)
h)
i)
j)
k)
l)
m)
[Logo of Utility]
the motor starter shall comply with Type 2 coordination conforming to

relevant code and standards. Motors rated [132] kW and above shall be
breaker controlled and shall be provided with comprehenive motor
protection relay. Motors rated above [160]kW shall be fed from MV
Switchgear [Only for firefighting system Motor rated up to 200kW shall
be fed from 415V switch board].
For 415 V switchgear & MCCs Feeders rated [630A] and above shall be
equipped with Air Circuit Breaker (ACB). Outgoing/Incoming feeders
rating below [630] A shall be MCCBs.
For DBs Incomer rated 630A and above shall be ACB. Incomer below
630A shall be MCCB. Outgoing feeder may be MCCB/MCB depending
upon the bus fault level.
All ACB shall be draw out type & should have Service, test and
disconnected positions with positive indications for service & test
positions. It shall be possible to charge the springs manually, if, required
Local/remote selection shall be provided for all incoming/Outgoing ACB
module. Incoming/Outgoing breaker shall be closed at service position
from remote (DCS) and at test position from Local(Switchgear).
Two out of three breaker logic shall eb considered for switchgear/MCC.
However mechanical interlock shall beconsidered for income of MCCB
operated DBs.
Also, Local/remote selection switch shall be provided for all motor
modules for control from Remote(DCS). Also for breaker operated motor,
breaker shall be closed in Test position from local(Switchgear).
All motors shall be provided with Emergency stop push button.
Control circuits shall operate at suitable voltage of 110V AC or 220V DC.
Necessary control supply transformers having primary and secary
MCcB/MCB shall be provided for each MCC, 2 x 100% per section.
Howeer breaker shall operate on 220V DC. The auxiliary bus bars for
control supply shall be segregated from bus bars. This control supplies
shall be monitored.
All the numerical relays shall have communication on two ports, local
front port communication to laptop and a second port with [IEC 61850
protocol] to communicate with DCS.
1.4
1.4.1
Construction
All 415V switchgear, MCC and DBs shall have following minimum features.
a) All 415V switchgear, MCC and DBs shall be metal enclosed, indoor, floor
mounted and free standing type. The panels shall be suitable for cable
entry at bottom and busduct connection at top.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
b) Between 415V Switchgear and dry type transformers, non segregated

phase bus duct is considered. Hence switchgear shall be suitable for this
connection and necessary flange connection and co ordination with
busduct manufacturer in this regards is covered in this specfication.
c) All frames and load bearing members shall be fabricated using mild steel
structural sections or pressed and shaped cold rolled sheet steel of
thickness not less than 2 mm.
d) Frame shall be enclosed in cold rolled sheet steel of thickness not less
than 2 mm. Doors and covers shall also be of cold rolled sheet steel of
thickness not less than 1.6 mm. Removable gland plates of thickness
3mm (hot/cold rolled sheet steel) or 4 mm (non magnetic material )shall
be provided for all panels. Suitable removable type lifting hooks and / or
jacking pad shall be provided on each panel or shipping section for ease
of lifting of switchgear. These hooks when removed shall not leave any
opening in the panels
e) Each breaker shall be housed in a separate cubicle, complete with an
individual front access door. Each vertical section shall have a removable
back cover.
f) The switchgear enclosure shall confirm to the degree of protection IP-54
(for outdoor). For indoor, enclosure shall confirm to IP52, however for
Busbar chamber of switchboards rated above 1600A, degree of
protection shall be IP-42.
g) Paint shade for complete panels excluding end covers shall be [RAL
9002] and [RAL 5012] for extreme end covers for all board.
h) The switchgear assembly shall comprise a continuous, line-up of single /
multi tier cubicles. The installations of circuit breakers however shall be
limited to the bottom two tiers only. Working height shall be limited to
[250 mm to 1800 mm] from the floor level.
i) Metallic barriers shall be provided between vertical sections and also
between adjacent modules to ensure prevention of accidental contact
with live parts during routine inspection/maintenance of functional units
or cable terminations of one or more functional units when working on
those of adjacent units. These barriers shall have insulating inserts as
necessary for taking the interconnections etc
j) A nameplate with switchgear designation shall be fixed at the top of the
central panel. A separate nameplate giving feeder details shall be
provided for each compartment. A separate nameplate giving details of
bus section shall also be provided for switchgears having more than one
bus section.
k) Name plate shall be provided for each equipment (lamps, push buttons,
switches, relays, auxiliary contactor, etc) mounted on the switchboard.
Special warning plates one each on each feeder of a shipping section
shall be provided on removable covers of doors giving access to cable
Document Number
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No.
Description
Page
No.
Date of Issue
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l)
m)
n)
o)
p)
q)
r)
s)
1.4.2
[Logo of Utility]
terminals and busbars. Name plate size shall be minimum of 20x75 mm

for Instruments/devices and 40x50 mm for panels. Thickness shall be
minimum 3 mm.
For MCC/DB a full height vertical cable chamber with cable supports shall
be provided in each section to facilitate unit wiring.
2x100%, 415V/110V AC control transformer shall be provided for
control, Indication and annunciation supply for contactor operated motor
feeder. All the necessary auxiliary and main contactor shall be provided
suitable for this control supply.
Two 220V DC feeders shall be provided for control, Indication and
annunciation of breaker operated module.
Compartment door shall be interlocked with main power isolating device
for safety with provision for defeating it by authorized person.
Supplier shall provide total 20% or minimum one (1) no. spare feeder of
each type & rating with respect to total requirement of the switchgear.
Motors of rating 30 kW and above shall be provided with anticondensation heaters. Necessary provision for supply of motor space
heating shall be considered in the switchgear.
The incoming connection to transformer of more than 1000kVA and
inter-connecting sections between switchboards shall preferably be of
bus ducts.
It should be possible to carryout maintenance on a feeder with adjacent
feeders alive.
Bus and Bus taps

a) The main buses and connections shall be of high [conductivity Aluminum
/ Copper] alloy sized for specified current ratings with temperature rise
limited [to 40C over ambient temperature of 50C].
b) Silver plating shall be done on copper bar wherever copper to copper and
copper to aluminum contacts are envisaged. All connection hardware
shall be non-magnetic and shall have high corrosion resistance. Adequate
contact pressure shall be ensured by means of two bolts connection with
plain & spring washers and locknuts.Temperature rise shall not exceed
105 degree for siliver plated joints over an ambient temperature of 50
degree.
c) Bus bars and connections shall be fully insulated for working voltage with
adequate phase / ground clearances. Insulating sleeves for bus bars and
shrouds for joints shall be provided.
d) Bus insulators shall be flame-retardant, track resistant type with high
creepage surface. All buses and connections shall be supported and
braced to with stand the stresses due to maximum short-circuit current
and also to take care of thermal expansion.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
e) Bus bars shall be color coded for easy identification and so located that
the sequence R-Y-B shall be from left to right, top to bottom or front to
rear, when viewed from the front to switchgear assembly.
f) Power shall be distributed to each module or compartment by a set of
vertical bus bars. The vertical bus bars shall run behind the modules.
Necessary tee off connectors shall be used for distributing auxiliary
supply to each vertical panel. Rubber grommets shall be used for all wire
entries to make the entries dust and vermin proof.
g) The clearance between the individual bare phase power bus bars and
between the phase and earth bus bars in air shall be not less than [25.4]
mm.
h) Three phase, neutral (with at least [50] % rating of main Bus bar and
continuous earth bus shall be provided. Bus bar and tapping shall be
provided with color coded PVC sleeves.
1.4.3
Air Circuit Breaker

a) All Circuit Breakers for incoming feeders and Bus couplers shall be [four]
poles; single throw, motor operated and air break type. Circuit breaker for
outgoing feeders shall be triple pole, single throw and air break type.
However for supply feeders it shall be [four] pole.
b) Circuit Breakers shall be [draw out type] having Service, Test &
Disconnected positions with positive indication for each position.
c) Circuit breakers of identical rating shall be physically and electrically
interchangeable.
d) Bolted disconnected links shall be provided for all outgoing feeders for
isolation of neutral, if necessary.
e) For motor wound mechanism, spring charging shall take place
automatically after each breaker closing operation. One open close
open operation of the circuit breaker shall be possible after failure of
power supply to the motor when the spring is charged after a closing
operation.
f) Mechanical safety interlock shall be provided to prevent the circuit
breaker from being racked in or out of the service position when the
breaker is closed.
g) Automatic safety shutters shall be provided to fully cover the female
primary disconnects when the breaker is withdrawn.
h) Each breaker shall be provided with an emergency manual trip,
mechanical ON-OFF indicator, an operational counter and mechanism to
indicate spring charge / discharge condition.
i) In addition to the auxiliary contacts required for normal breaker operation
and indication, each breaker shall be provided with followings for
interlocking purpose:i.
Position / cell switch with 4 No + 4 NC contacts.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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[Logo of Utility]
ii.
Limit / auxiliary switches shall be convertible type that is facility

for changing N.O. contact to N.C. and vice-versa.
iii.
Mechanical stopper to prevent accidental falling while withdrawing.
j) Breaker cannot be racked in from isolated to test position with the
door open together with provision for defeat of this interlocking,
however, the door can be closed only when the breaker is brought back
to isolated position. Insertion of breaker into Service position not
possible if the shutters are not free.
k) Door can be opened only when breaker is OFF and is in Isolated
position. Remote closing of breaker not permitted with door open.
l) Anti pumping relay / device to ensure that there can be only one closing
operation for each closing command.
m) Suitable trolley arrangement shall be provided for breaker/starter
modules. Two trolleys per switchgear room shall be provided so that top
most breaker module of all types, sizes and rating can be withdrawn on
trolley and lowered for maintenance purpose.
n) Closing and tripping coil shall operate satisfactorily under the following
conditions.
i.
Closing Coil: 85% to 110% of rated voltage.
ii.
Tripping Coil : 70% to 110% of rated voltage.
1.4.4
Contactors, MCCB and MPCB

a) Incomers for MCCs and DBs rated below 630A shall be MCCB.
b) Incomer and bus coupler rated below 630A shall be mechanically
Interlocked.
c) Motor starter contactors shall be of air break, electromagnetic type.
Suitable for DOL starting of motor, and shall be of utilization category
AC-3 for ordinary and AC-4 for reversing starters. DC contactor shall be
of DC-3 utilization category.
d) The contactors shall be three pole, air break type designed for [duty class
III category A.C. 3 with non-bouncing silver / silver alloy.]
e) Each contactor shall be provided with two (2) normally open and two (2)
normally closed auxiliary contacts unless otherwise specifically stated.
Rating shall be decided by the bidder.
f) Reversing contacts shall be electrically and mechanically interlocked.
g) Contactors with delayed dropout feature shall be provided for some
essential auxiliaries. These contactors shall not dropout on power failure
if the voltage is restored within 3 seconds.
1.4.5
Electronic over load relays

a) Electronic overload relays shall conform to IEC:292-1 and shall be triple
pole, ambient temperature compensated with adjustable setting, inverse
time lag, built in single phase preventer and hand/auto reset type
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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[Logo of Utility]
provided as per requirement along with necessary command, feedback

cable, coupling relays etc.
b) Provided with 1 NO and 1NC contact of rating same as the auxiliary
contact of the contactors.
c) The relay shall be able to withstand prospective short circuit current
without damage or injurious heating till the motor protection
MCCB/MPCB clears the fault.
d) Relays may be direct acting or CT operated, depending on current rating.
CTs shall be included in the scope of supply.
1.4.6
Bus Transfer scheme:

Each switchgear of two incomer and bus coupler shall be provided with the
following provisions.
i) Dead bus closing.
ii) Manual live change over (Momentary paralleling)
iii) Automatic bus transfer scheme.
1.4.7
Current Transformer
a) Current Transformers shall be cast-resin type. All secondary connections
shall be brought out to terminal blocks where wye or delta connection
shall be made.
b) CTs shall have polarity makings indelibly marked on each transformer at
the lead terminations and at the associated terminal block. Facility shall
be provided for short circuiting and grounding the CT secondary at the
terminal blocks. Secondary terminals shall be provided with protective
cap.
c) CT terminal block shall be disconnecting type and suitable for round type
lugs with facility for testing and short circuiting of individual CT.
d) All CTs shall be provided with supports independent of busbars / busbar
supports. The CTs shall be located in such a way that they can be easily
approached for maintenance without necessitating shutdown of adjacent
feeders.
e) CTs shall be provided with disconnected type test links in both secondary
leads for carrying out current and phase angle measurement.
1.4.8
Voltage Transformer
a) Voltage transformers(VT) shall be cast-resin type with an accuracy class
of 1.0 for metering and 3P for protetction.
b) VTs shall be of the single-phase type. VTs shall be protected on their
primary side by MCCBs with interrupting ratings corresponding to breaker
rating and by MCB (with auxiliary contacts) on the secondary sides.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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c)
VTs shall have continuous over voltage factor of 1.2 and short time over
voltage factor of 1.5 for 30 seconds for effectively earthed system
d) It shall be possible to replace VTs without having to de-energise the main
busbars.
e) VTs shall be provided with disconnected type test links in both secondary
leads for carrying out current and phase angle measurement.
1.4.9
Transducer
For all the incoming and the outgoing of 415V Switchgear / MCC/ DB
Feeders requiring remote metering and/or current monitoring shall be
provided with multi-functional transducers. The output shall be 4-20 mA DC
which shall correspond to the normal range.
1.4.10
Secondary Wiring
a) The switchgear shall be fully wired at the factory to ensure proper
functioning of control, protection and interlocking schemes.
b) Fuse /MCB and links shall be provided to permit individual circuit isolation
from bus wires without disturbing other circuits. All spare contacts of
relays, switches and other devices shall be wired up to terminal blocks.
c) Secondary wiring within the switchgear shall be carried out in a neat and
systematic manner and securely held in position (either loomed or run in
conduit / trunking). Wherever wiring passes through compartment, it shall
be run in conduit / trunking, if metallic shall be bonded to the main earth
busbar.
d) Wiring shall be done with flexible, 1.1/0.650kV grade, PVC insulated
switchboard wires with [stranded copper conductors of 2.5 mm2 for CT
& PT circuits and 1.5mm2 for control circuit wiring.]
e) Each wire shall be identified, at both ends, with permanent markers
bearing wire numbers as per bidders wiring diagrams. Wire terminations
shall be made with crimping type connectors with insulating sleeves, wire
shall not be spliced between terminals.
1.4.11
Terminal Blocks
a) Terminal blocks shall be 660V grade box-clamp type with marking strips,
similar to 10 mm2 or equal. Terminals for C.T. secondary leads shall have
provision for shorting.
b) Not more than two wires shall be connected to any terminal. lf more than
two wires at one terminal are required, separate terminals with function
wise shorting links shall be provided. [Spare terminal equal in number to
20% of active terminals shall be furnished.]
c) Terminal blocks shall be located to allow easy access. Wiring shall be so
arranged so that individual wires of an external cable can be connected
to consecutive terminals.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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1.4.12
[Logo of Utility]
Ground bus
a) A ground bus, rated to carry maximum fault current, shall extend full
length of the switchgear. The ground bus shall be provided with two-bolt
drilling with G.I. bolts and nuts at each end to for connection to the
grounding conductor / flat.
b) Each unit shall be connected directly to the ground bus. The frame of
each circuit breaker and draw out V.T. unit shall be grounded through
heavy multiple contacts at all times except when the primary
disconnecting devices are separated by a safe distance.
c) C.T. & V.T. secondary neutrals shall be earthed through removable links
so that earth of one circuit may be removed without disturbing others. All
hinged doors shall be earthed by flexible copper bride.
1.4.13
Space Heater
a) Each vertical section shall be provided with thermostat controlled space
heater 5A, 3 pin socket plug.
b) In addition, motor feeders rated [30 KW and above] shall be wired up for
feeding the motor space heater through suitably rated breaker auxiliary
NC contact and/or contactor.
c) Cubicle heater, Motor heater, and Plug socket circuit shall have individual
switch fuse units/MCB.
1.4.14
AC Distribution Boards (ACDBs)

a) AC Distribution Boards shall have MCCB/MCB at incomer depending upon
the short circuit rating. Distribution Boards may be fed from switchgear
and shall have two incomers. AC distribution Boards shall be of two
types - one with 415V, 4-wire, triple pole and neutral (TPN) outgoing
feeders and the other with 240V, 2-wire, single pole and neutral (SPN)
outgoing feeders.
b) For small loads, MCB boards with TPN MCB as incomer and TPN/SP
MCBs for outgoing may be considered. The feeder rating and quantity
shall be as per requirement.
c) Board shall be single/double front [preferably single front], metal clad,
front matched, dust and vermin proof, fixed type, compartmentalized and
extensible on both sides.
d) Bus bars shall have same cross section throughout the length. Rating of
the neutral bus bar shall be 50% of the main bus bar. Earth bus bar shall
run in bottom chamber throughout the length of the Board.
1.4.15
DC Distribution Boards
DCDBs shall have two incomers and a bus coupler. Incomers and outgoing
feeders of DCDBs shall be MCB/MCCB modules. They shall be fixed type and
floor mounted. Other constructional features shall be similar to ACDB.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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[Logo of Utility]
The feeder rating and quantity shall be as per requirement.

1.4.16
Control & Indication

The circuit breaker shall be wired up for local & remote operation. Each
breaker cubicle shall be equipped with following:
a) Remote selector switch with pistol grip handle and key interlock for
breakers with motor wound spring charging mechanism. In Remote
position, the breaker can be operated in service position with all interlock
and protections. In switchgear position, the breaker shall be operated
from switchgear only in test position with only protection (no interlock).
b) Two (2) heavy duty, oil-tight, push buttons for Trip & Close.
c) Circuit breaker shall be indicated electrically. The following indication
colour shall be used.
Breaker open
GREEN
Breaker closed
RED
Spring Charged -
WHITE
Breaker Auto Trip-
AMBER
d) However, any other indication shall be provided as per owners

requirement.
e) Lamps shall be LED type with resistance for voltage protection. Lamp and
lens shall be replaceable from the front.
f) For all MCCB feeders, trip indication lamp shall be provided on front of
the compartment.
g) For all starters, ON, OFF and trip indication lamps shall be provided on
front of the compartment.
1.4.17
Relays, Protection & Metering

a) The hardware design for protection and associated equipment shall use
latest stateofthe-art technology and shall generally be integrated
numerical/digital, modular in nature. Where design is based on numerical
technology, adequate self testing/monitoring/diagnostic facilities shall be
provided.
b) All numerical relays, auxiliary relays and devices shall be of types, proven
for the application; satisfying requirements specified elsewhere and shall
be subject to Purchaser's approval. Numerical Relays shall have
appropriate setting ranges, accuracy, resetting ratio, transient overreach
and other characteristics to provide required sensitivity to the satisfaction
of the Owner.
c) All protective relays shall be in draw out or plug-in type / modular cases
with proper testing facilities. Necessary test plugs / test handles shall be
supplied loose and shall be included in suppliers scope of supply.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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d) All AC operated relays shall be suitable for operation at 50 Hz. AC

voltage operated relays shall be suitable for 110 Volts VT secondary and
current operated relays for [1 or 5] amp CT secondary. All relays and
timers shall be rated for control supply voltage as mentioned elsewhere
under parameters and shall be capable of satisfactory continuous
operation between 80-120% of the rated voltage. Voltage operated
relays shall have adequate thermal capacity for continuous operation.
e) Energy meters shall be provided for incomer of 415V Switchgear and
MCC and shall able to communicate with DCS. These meters shall be as
per CEA regulation 2006 Installation and operation of meters. Accuracy
class shall not be less than 1.0S.
f) Provision shall be made for easy isolation of trip circuits of each relay for
the purpose of testing and maintenance.
g) All protective relays and alarm relays shall be provided with one extra
isolated pair of contacts wired to terminals exclusively for future use.
h) The relay shall be designed to perform satisfactorily under highly noisy
electrical environment. Sufficient degree of high frequency disturbance
immunity and impulse voltage withstand capacity shall be built into
electronic designs as stipulated in relevant standards.
i) All protections shall be furnished complete with necessary auxiliary,
supervisory, lock out relays. Suitably separate sets of single phase
auxiliary C.T with multiple taps shall be provided with relay whenever
required.
j) Visual and audible alarm annunciation shall be initiated in the event of
operation of protective/supervisory relay.
k) D.C supply shall be supervised by DC supervision relays.
l) Trip circuit shall be supervised by Trip circuit supervision.
m) Tripping shall be done through high speed lock out relays.
n) All meters/ instrument shall be flush mounted on front panel, at least
96mm2 size with 900 linear scales and accuracy class of 2.0.
o) Interposing relays for ON/OFF command or any other command shall be
as per system requirement.
p) For alarm and Indication at DCS end necessary contacts shall be provided
at switchgear end.
q) Metering and protection shall be as per below table
a)
Incomers
Protections
Metering
Time graded short circuit

protection
Local Current (single phase)

indication and remote indication
through transducer.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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ii
Over current protection
Voltage Measurement for all three

phases and remote indication
through transducer.
iii
Earth fault protection
KW, Kwhr
b)
Bus coupler
Protections
Metering
Over current protection(51)
Local Current (single phase)

indication.
ii
IDMT Earth fault protection(51N)
c)
c)
[Logo of Utility]
Contactor controlled motor feeders [90kW and above motor only]

Protections
Metering
Time graded short circuit

protection
Local Current indication and remote

indication through transducer.
ii
Over current protection
[Motor Feeders [of 132KW and above only)]

Protections
Metering
Composite motor protection to

cover a minimum of protections
such as over current, short circuit,
earth fault, locked rotor, Negative
phase sequence, thermal overload
etc.
Local Current indication and remote

indication through transducer.
[Other feeders]
a)
Bus PT / Line PT Modules

Protections
Metering
Under voltage protection
[Voltage phase to phase,]
Fuse failure protection

b)
Motor feeders (MPCB/MCCB with Contractors)

Protections
Metering
Electronic Overload relay (with single

phase preventor), short circuit
protection (through fuse/MCCB/MPCB
as specified)
c)
Incoming feeders for ACDB/DCDB

Protections
Metering
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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Short circuit protection (if MCCB)
[Logo of Utility]
[Voltage (single phase and,

Phase Current (1 Phase)] Local
indication only.
Outgoing feeders of ACDB/DCDB
d)
Protections
Metering
Short circuit protection (through

fuse/MCCB)
1.5
Tests
I)
Type Test
For each type & rating of 415V Switchgear, the Bidder shall submit for
Owners approval the reports of all the type tests as per relevant standards
and carried out within [last five] years from the date of bid opening. These
reports should be for the tests conducted on the switchgear similar to those
within last five years from the date of bid opening, or in case the type test
II)
Routine Test

The minimum tests shall be conducted are as follows:
a) Measurement of insulation resistance of Circuit Breaker in closed and
open positions.
b) Measurement of milli-volt drop across Circuit Breaker main contacts and
other joints.
c) Measurement of Circuit Breaker/Contactor operating time for close &
open at nominal voltage and 80% of rated voltage.
d) Measurement of resistance, IR value and drop-off/pick-up voltage of close
and trip coils.
e) Healthiness of limit switch contacts.
f) Spring charging motor functional checks.
g) Verification of phase sequence and checking of clearances of busbars
between phase to phase and phase to earth.
h) Measurement of milli-volt drop across busbar joints
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
i)
j)
k)
l)
m)
Torque tightness test.

High voltage test on busbar.
Measurement of CT/PT polarity, ratio and knee point voltage.
Electrical and mechanical interlock checks.
Secondary injection of all protection relays by using service settings and
simulation of all protection functions.
n) Secondary injection of all metering circuits.
o) Functional tests to demonstrate the specified control and interlocks
III)
Test Witness
IV) Test Certificates:
Certified copies of all tests carried out at works and at site shall be furnished in
requisite no. of copies for approval of the Owner. The equipment shall be
dispatched from works only after receipt of Owner's written approval of shop
test reports.
1.6
Drawing & Documents

below
a) [General Arrangement drawings and cross-section showing constructional
features & cable entry with bottom view with opening.
b) Bill of Materials.
c) Technical Data sheet and Catalogue.
d) Foundation drawing details with bottom view of switchgear.
e) Descriptive write-ups and literature for the main equipment offered
including relays, meters, etc.
f) Control Schematics & Wiring diagram.
g) Inspection and Test Plan (ITP).
h) Suggestive list of protective relays.
i) Transport/shipping dimensions and weights].
1.7
Ratings & Requirements

415V switchgears, MCC and DB shall comply with the particulars indicated
in the following tables.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
Table- 2.0
S. No.
DESCRIPTION
UNIT
1.0
General
1.1
Name of Manufacturer
1.2
Place & Country of manufacture
1.3
Specifications and Standards
2.0
Switchgear Details
2.1
Rated voltage, phases & frequency
DATA
415 Volts,
3 Phase, 4 wire
50 Hz.
2.2
Solidly earthed
2.3
Voltage & frequency variation
+/-10%, -5%to +3% Hz.
2.4
Rated frequency
Hz
50Hz
One minute power frequency

2.4
a) 2.5kV
Voltage
a) For power Circuits
b) 1.5kV
b) For Control Circuits

2.5
Continuous current rating of

busbars under site reference
ambient temp.
[As per Project

requirement]
2.6
Reference ambient temperature
50C
2.7
Maximum temperature of bus bars

and droppers/connectors under site
conditions specified
900C for busbars having

non-silver plated joints
2.8
1050C for busbars having

silver plated joints
Short circuit current withstand for

busbars and droppers
a
Short time
kA
(rms)
50
Dynamic Rating
kA
(peak)
105
2.9
Whether busbars have been

insulated
Yes
Required
2.10
Type of insulation
[By Bidder]
2.11
Material of bus bar supports
[By Bidder]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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UNIT
[Logo of Utility]
S. No.
DESCRIPTION
DATA
2.12
Switchgear designation
[As per project specific]
2.13
Bus bar material
Cu/Al
2.14
Fully draw out (FD)/ Fixed (F)
FD for Switchgear/MCC;
F for DBs.
2.15
Entry Top (T)/Bottom (B)
Top for busduct, bottom for

cables
2.16
Degree of protection
IP 52
2.17
Colour finish shade
Interior
[Glossy white]
Exterio
r
[RAL 5012]
2.18
Earthing bus
Materi
al
GS
2.19
Minimum clearances in air of live

parts
mm
As per standard
3.0
Starters
3.1
Type
DOL
DOL
3.2
Contactor rated duty
3.3
Single phasing preventer required.
Yes /
no
Yes
3.4
Thermal overload relay reset
Manual
/ Auto
Settable for either to

Manual or Auto
4.0
Circuit breakers
4.1
Makers name
[By bidder]
4.2
Voltage, frequency & no.of phases

, poles
415 V, 50 Hz, 3 Ph, 4

Pole
4.3
Rated operating duty
O-3min-CO- 3min -CO
4.4
Circuit breakers type
ACB
4.5
Short circuit withstand current for 1

sec. Duration
kA
50
4.6
Rated making current
kAp
105
4.7
Rated current at site reference

ambient temp
[By bidder]
AC3 for DOL
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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UNIT
[Logo of Utility]
S. No.
DESCRIPTION
DATA
4.8
Type of operating mechanism
Spring charged motor and

manual
4.9
Minimum no. of auxiliary
6 NO, 6 NC
Contacts for purchasers use

4.10
Control voltage
Fora Spring charging motor

b
4.11
For closing/tripping
V
AC/DC
[220V DC/240V AC]
V
AC/DC
220V DC
Limits of voltage for satisfactory

operation of the following devices
as a % of normal voltage
a
Operating mechanism
As per IS
Closing at normal voltage
As per IS
Trip coil
As per IS
4.12
Power required for closing at normal

voltage
[By bidder]
4.13
Power required for tripping at

normal voltage
[By bidder]
4.14
Spring charging motor details:

a
Rating
kW
[By bidder]
Rated voltage
V,
AC/DC
[By bidder]
Spring charging
Sec.
[By bidder]
Electrical and mechanical antipumping features been provided
Yes/No
Required
5.0
MCCBs/MPCBs
5.1
Voltage, frequency & no. of phases
415 V, 50 Hz & 3 P for

outgoing, 4P for incoming
and supply feeders
5.2
As per IS
5.3
Rated breaking capacity
kA
(rms)
50
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
S. No.
DESCRIPTION
UNIT
DATA
5.4
kA
(Peak)
105
5.5
On/off operation
5.6
Manual
Yes/No
Yes
5.7
Over-load inverse time, short circuit

and earth fault
Yes/No
Yes
5.8
Auxiliary contacts required
Yes/No
6.0
Contactors
6.1
Make
6.2
Rated duty
[By Bidder]
AC3/A
C4
AC3 for DOL

AC4 for RDOL
6.3
No of poles
6.4
Utilization category
[By Bidder]
6.5
Rated voltage of auxiliary contacts
[By Bidder]
6.6
Rated voltage of coil
[By Bidder]
6.7
Factor
of
rated
current
[By Bidder]
6.8
Rated making capacity
Factor
of
rated
current
[By Bidder]
6.9
Limits of operation
As per IS/IEC
Supply voltage variation
[By Bidder]
Supply frequency variation for

closing
[By Bidder]
Drop out voltage
[By Bidder]
6.10
7.0
No of auxiliary contacts:
a
Normally open
Normally closed
Instrumentation transformers
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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S. No.
DESCRIPTION
7.1
Voltage Ratio
[415/sqrt(3)/110/sqrt(3)]
7.2
CT Ratio
Primary current/1A or 5A
7.3
UNIT
[Logo of Utility]
Measuring CTs
DATA
Cl - 1.0 instrument safety

factor 5.0
7.4
Protection CTs
7.5
Measuring VTs
7.6
Protection VTs
8.0
Control transformers
8.1
Make
[By Bidder]
8.2
Type
Dry Type
8.3
Applicable standards
As specified in the
specification
8.4
Ratio
[415/sqrt(3)/110/sqrt(3)]
8.5
Class of insulation
Class-B or Better
8.6
Rated output
9.0
Fuse (if applicable)

a
Type
Voltage rating
Cl 5P20
(min)/phase Cl1.0
Cl 3P
VA
10.0
Instantaneous over current relay
10.1
Application (phase fault or earth

fault)
[By Bidder]
10.2
Make
[By Bidder]
10.3
Type designation
[By Bidder]
10.4
Setting range
[By Bidder]
11.0
Inverse time and thermal

overcurrent relay
11.1
Application
[By Bidder]
11.2
Make
[By Bidder]
11.3
Type
[By Bidder]
11.4
Current setting range
[By Bidder]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
S. No.
DESCRIPTION
UNIT
DATA
11.5
Time setting range at 10 times the

current setting
Sec
[By Bidder]
12.0
Under voltage relay
12.1
Make
[By Bidder]
12.2
Type
[By Bidder]
12.3
Voltage rating
[By Bidder]
12.4
Setting range
[By Bidder]
13.0
Auxiliary relays and timers
13.1
Make
[By Bidder]
13.2
Type
[By Bidder]
13.3
Coil voltage
14.0
Control/selector switch
14.1
Make
[By Bidder]
14.2
Type designation
[By Bidder]
15.0
Meters
15.1
Applicable Standards
As specified in the
specification.
15.3
Accuracy Class
15.4
Make
Class 1.0 or
Better
[By Bidder]
15.5
Type
16.0
Voltmeter
16.1
Make
*[By Bidder]
16.2
Type
Moving coil
16.3
As specified in the
specification.
16.4
Accuracy class
Class 1.0
17.0
Ammeter
[By Bidder]
Multi function
with RS 485 connectivity
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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02

[21]
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Power Plant]
S. No.
DESCRIPTION
17.1
Make
As specified in the
specification.
17.2
Type
Moving coil
17.3
As specified in the
specification.
17.4
Accuracy class
Class 1.0
18.0
Indicating lamps
18.1
Make
As specified in the
specification.
18.2
Type
Clustered Led
18.3
Voltage
18.4
Wattage of lamp
19.0
Push buttons
19.1
Make
19.2
Type designation
19.3
Contact rating
20.0
Space heater
20.1
Make
20.2
Type
20.3
Rated voltage
21.0
Wiring and terminal blocks
21.1
Voltage grade
1.1 kV
21.2
Insulation
[By Bidder]
21.3
Minimum size of conductor for:

a
UNIT
[Logo of Utility]
Power wiring
Sq.mm
DATA
As specified in the
specification.
As specified in the
specification.
As specified in the
specification.
As specified in the
specification.
As specified in the
specification.
As specified in the
specification.
As specified in the
specification.
As specified in the
specification.
2.5 for CT & PT

1.5 for Others
Control wiring
Sq.mm
1.5 for Others
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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Power Plant]
S. No.
DESCRIPTION
21.4
Type of terminal blocks:
21.5
UNIT
[Logo of Utility]
DATA
I) For Withdrawable Type
Sliding type
II) For Fixed Type
Stud & nut type
Minimum current rating of terminal

blocks
10
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[23]
25.09.2014

OF

R&M CONTRACTORS
VOLUME-II
TECHNICAL SPECIFICATION FOR 415V NON
SEGREGATED PHASE BUS DUCTS
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-E5
1.0
415V NON SEGREGATED PHASE BUS DUCT
1.1
General
415V Non Segregated Phase Busduct, complete with all accessories for
efficient and trouble-free operation for of R&M of Unit No. [..] of [Name of
1.2
Codes and Standards

Table: 1.0
IS 8084
Interconnecting Bus bar for AC Voltage above

1KV up to and Including 36kV
IEC 60947
Low Voltage Switchgear and Control gear
ANSI/IEEE C37.20
Metal-Clad and Station-Type Cubicle Switchgear
ANSI/IEEE
Guide for Evaluating the Effect of Solar Radiation

on Outdoor Metal Enclosed Switchgear
C37.24
IEC 60439
Low-voltage
assemblies.
switchgear
and
BS 159:1957
Bus bar and Bus bar connection
CEA
CEA regulations and standards
control
gear
Equipment and material conforming to any other standard which ensures

equal or better quality may be accepted. In such case, copies of the English
1.3
Design Criteria
a) The 415V Non-segregated phase bus duct shall serve as an
interconnection between the 415V Switchgear and 11/0.433kV LV
Transformer. The Non-segregated phase bus duct shall be installed
Document Number
Rev
No.
Description
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No.
Date of Issue
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Power Plant]
b)
c)
d)
e)
f)
g)
h)
[Logo of Utility]
indoor/Outdoor in a hot, humid and tropical atmosphere. All panels

associated with
Non-segregated phase bus duct shall be located
indoors/Outdoors.
Bus duct, associated equipment and wiring shall be provided with tropical
finish to prevent fungus growth. All ventilation openings shall be
screened and drains shall be filtered to prevent entrance of dust and
insects.
For continuous operation at specified ratings, temperature rise of the bus
duct and auxiliary equipment shall be as specified in Clause 1.7 Rating
and requirements.
Bus duct and auxiliary equipment shall be capable of withstanding the
mechanical forces and thermal stresses of the required short-circuit
currents.
The bus ducts and supporting structures shall be designed & constructed
so as to withstand without damage the horizontal / vertical ground
accelerations due to earthquake.
The bus ducts shall be self cooled and shall not be equipped with blower
or any other type of forced ventilation.
The equipment rating shall be based on an ambient temperature. Same
phase disposition shall be maintained throughout the run of the bus duct.
Phase crossover units, if required, shall also be provided inside the
Busduct itself.
Bus ducts shall be suitable for continuous operation at maximum system
voltage and shall be adequately sized to withstand short circuit current.
1.4
1.4.1
General
a) 415V Non Segregated Phase Busduct is provided for connection between
low voltage side of 11/0.433kV cast resin dry type /oil type transformers
and associated 415V Switchgears shall be of TPN (3 phase and neutral)
along with necessary bends, flexible at both transformer & switchgear
ends, flanges, phase crossover chambers (if required), support structures
& accessories including terminations at the equipment ends.
b) The 415V bus duct shall be metal enclosed, non-phase segregated
enclosure type, self cooled and insulated for 1.1kV voltage. The cooling
medium inside the duct shall be air.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[2]
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Power Plant]
[Logo of Utility]
c) All parts and accessories shall have appropriate match mark and part
numbers for easy identification and installation at site.
d) The 415V non-segregated phase bus duct will be installed indoor or
partially indoor & outdoor depending upon the location of equipment
being interconnected in a hot, humid and tropical atmosphere. All panels
associated with LV non-segregated phase bus duct will be located
indoors.
e) The continuous current rating and momentary peak withstand current
rating of the Busduct between transformers & their associated
switchgears shall be same as that of the associated switchgears and as
indicated in the specification.
f) All supporting steel structures shall be hot dip galvanized.
g) The bus ducts shall be provided with space heaters to control moisture.
Slicagel breather if required same shall be provided.
1.4.2
Enclosures
a) The enclosure shall be rectangular and shall be made of [aluminium
alloy/Mild steel] of grade [19000H2] as per IS-5082. The entire bus duct
shall be designed with dust, weather and vermin-proof construction. The
inside of the bus enclosure shall be treated with a matt paint of dark
colour, preferably black to facilitate efficient heat dissipation. The bare
enclosure with above painting shall be designed so as not to exceed the
temperature specified in IS: 8084.
b) [Phases shall be enclosed in a weather-proof, dust-tight, non-magnetic
metal (aluminum alloy) of 3mm for bus rating including and above 3000A
whereas enclosures for normal bus current rating (<3000 A) shall be
sheet steel fabricated type of 2.5mm thick].
c) Enclosures shall be provided with flange ends with drilled dimensions to
suit the flanges at the switchgear and transformer ends.
d) Circumferential neoprene rubber gaskets shall be provided for dust tight
joints with adjacent enclosure section.
h) The bus enclosure shall have extended bellows or equivalent means to
allow for temperature changes and vibrations. Flexible joints shall be
provided in enclosures at all points where the bus duct terminates at
equipment to withstand vibration, expansion / contraction and at suitable
intervals in any straight run of the bus duct where expansion and
contraction would otherwise result in stresses in the supporting
structures.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[3]
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Power Plant]
i)
j)
k)
l)
m)
n)
o)
p)
q)
1.4.3
[Logo of Utility]
All outdoor bus-enclosures shall be so designed & constructed as to

prevent accumulation of rain water on top sheet. Similarly all Gasketed
flanged joints shall be suitably protected against direct splashing of rain
water in case of outdoor runs. The connection flanges shall be
sufficiently stiffened so as not to bend while tightening the bolts.
Outdoor portions of the bus duct, if any, shall have continuous rain hood
of non magnetic material or with suitable arrangement for rainwater
prevention.
Suitable inspection openings shall be provided for access to support
insulators, bus joints, transformer terminals, switch gear terminals etc.
All inspection openings shall have reliable sealing arrangement with
neoprene gaskets.
Seal-off bushings complete with wall-frame and support plates shall be
provided where the bus duct penetrates the building wall. The seal is to
prevent free exchange of air between indoor and outdoor portions of the
bus duct.
In case, the bus duct penetrates the firewall, the wall frame assembly
and the seal shall be designed for the same fire rating as the firewall.
Silica-gel breather shall be provided on both indoor and outdoor portions
of the bus duct. Space Heaters shall be provided in the bus duct.
Filtered drains for drainage of condensate shall be provided at the lowest
points and at such locations where accumulation of condensate can be
expected.
Shipping length of the Busduct shall be not more than three (3) meters in
length.
Minimum Degree of protection of Busduct enclosure shall be IP-52 for
indoor and IPW-55 for outdoor section of the Busduct.
Bus Conductor
a) The bus conductor shall be of high conductivity, [Aluminium alloy /
Aluminium].
b) The bus conductors shall be given a coat of matt black paint to facilitate
heat dissipation. However the sizing of the bus conductor shall consider
the conductor as bare.
c) The bus conductor shall be designed for bolted connections throughout
the run.
d) Flexible connection shall ensure an efficient and trouble-free connection.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[4]
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Power Plant]
[Logo of Utility]
e) Silver plating shall be done on copper bar wherever copper to copper and
copper to aluminium contacts are envisaged. All connection hardware
shall be non-magnetic and shall have high corrosion resistance.
f) The bus conductors and their support insulators shall be designed to
withstand, without damage, the forces developed while carrying the
short circuit current.
g) The bus bar shall be sleeved with FRLS heat shrinkable, colour coded
PVC sleeves at intermittent points for phase identification.
h) The material of the conductor shall be aluminium alloy of grade
[63401WP] as per IS: 5082. The temperature rise of conductor shall be
40 degree over design ambient temperature of 50 degree. Also, the
temperature of the bus shall not exceed 250C while carrying the
specified short circuit current for one second when a fault occurs at the
operating temperature.
1.4.4
Disconnect Link
a) Removable bolted disconnected link shall be provided in the bus for the
purpose of isolation.
b) Disconnect link shall consist of a removable section of conductor and
shall be so constructed as to permit easy removal or reinsertion without
alignment difficulties.
c) The bus on both sides of the link shall be rigidly supported so that the
disconnect link is equal in mechanical strength to any other section of the
bus.
d) A minimum clearance of [300 mm. (12)] shall be provided between the
disconnected bus sections with the link removed.
1.4.5
Insulators
a) The bus conductor supporting insulators shall be flame retardant, nonhygroscopic, high impact and high dielectric strength material with an
anti tracking contour.
b) Material of insulator shall be [Epoxy SMC moulded /FRP].
c) Spacing of the bus support insulators shall be considered by giving due
factor of safety to withstand the forces due to the short circuit current
assigned to the bus duct.
d) Bus support insulators shall be interchangeable, high creepage, high
strength, wet process, fine glazed porcelain. Alternatively good quality
cast resin insulators may be offered.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[5]
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Power Plant]
[Logo of Utility]
e) Insulator shall be mounted in such a way so as to permit easy removal or

replacement without disassembly of the bus. The insulator mounting
plate shall be designed for cantilever loading to withstand the short
circuit.
f) The conductor shall be fastened on the insulator through fixed and slip
joints so as to allow conductor expansion or contraction without straining
the insulator.
g) Space heater shall be provided preferably located near to each insulator
to avoid moisture condensation within bus duct.
1.4.6
Connections & Terminations

a) All matching flanges, seal-off bushings, gaskets, fittings, hardware and
supports required for termination of the Busduct at the switchgear,
transformers and other equipment shall be furnished.
b) In this connection the bidder is required to coordinate with the
switchgear and auxiliary transformers manufacturer with regard to
connection details, mechanical and thermal stresses.
c) Flexible connections both for conductor and enclosure shall be furnished
at all equipment termination to provide for misalignment up to 25 mm in
all directions.
d) The equipment terminal connections shall be readily accessible and shall
provide sufficient air gap for safe isolation of equipment during testing.
1.4.7
Supporting Structures
a) All supporting structures required for hanging and/or supporting the
complete bus duct shall be furnished. These include all members,
indoor/outdoor posts, bolts, shims, base plates, beams, hangers,
brackets, bracings and hardware.
b) All buses shall be adequately supported and braced to successfully
withstand normal operation, vibration, thermal expansion, short circuit
forces and all specified design loads including wind & earthquake forces.
c) Support shall be designed to provide tolerance of 12 mm in the
horizontal and vertical directions.
d) All steel members shall be hot-dip galvanized after fabrication. All
hardware shall be of high strength steel with weather resistant finish.
e) The mounting arrangement of Busduct on the supporting structure shall
be designed to allow movement of the Busduct during expansion and
contraction.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[6]
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Power Plant]
[Logo of Utility]
f) All structure shall be self supporting and in no case rely for support on
equipment to which the busbars are connected.
1.4.8
Ground bus
a) The ground bus of two numbers of separately run [50x10 mm] minimum
GS flat shall be provided along the run of the bus duct. All parts of the
bus enclosure, supporting structures and equipment frames shall be
bonded to above ground bus.
b) Ground bus shall be finally to connected to power plant earth grid at one
end.
1.4.9
Wiring
All wiring for space heaters shall be done with insulated stranded copper
conductor of not less than [ 2.5 mm2 cross-section]. Each wire shall be
identified at both ends with wire designation as per bidders wiring diagram
and shall be brought out to a terminal box outside the bus duct.
Terminal blocks shall be box-clamp type minimum10 mm2 with marking
strips.
At [least 20% spare terminals] shall be furnished in the terminal block.
1.4.10
Name Plate
Suitable name plate shall be furnished with each piece of equipment.
[Materials for name plate shall be plastic / lamicoid, 3 mm thick, using white
letters on black background.]
1.4.11
Space Heater
Thermostatically controlled Space heaters shall be provided in the bus ducts,
wherever the manufacturer considers them necessary and recommends their
provision for preventing harmful moisture condensation. At least one number
space heater with thermostat shall be provided at each transformer and
switchgear end.
The space heaters shall be suitable for continuous operation on single phase
supply, and shall be automatically controlled by thermostats. Necessary
wiring up to junction boxes mounted on bus duct and from junction boxes to
switchboards shall be provided.
1.4.12
Painting and Finish

a) All surfaces to be painted including interior and enclosures and other
metal parts shall be shot or sand blasted or chemically treated to remove
all rust, scale, grease and other adhering foreign matters as far as
Document Number
Rev
No.
Description
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No.
Date of Issue
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[7]
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Power Plant]
b)
c)
d)
e)
f)
g)
h)
i)
1.5
[Logo of Utility]
possible shall be painted with not less than two (2) coats of Acid and
corrosion resistant paint
Steel surfaces, exposed to weather shall be given two (2) coats of zinc
chromate and two (2) coats of an 'approved' Manufacturer's paint of
'approved' colour.
All metal parts not accessible for painting shall be made of corrosion
resistant materials.
All machine finished or bright surfaces shall be
coated with a suitable rust preventive compound and wrapped or
otherwise protected.
Inside of the bus enclosure shall be treated with a matt paint of dark
colour, preferably black to facilitate efficient heat dissipation. The shade
of exterior surface finish shall be [RAL 5012].
The interior surface finish shall be as per manufacturers standard.
Pretreatment consisting of degreasing, de-rusting etc. shall be done on all
fabricated parts before painting or galvanizing.
Paints shall be carefully selected to withstand heat and weather
conditions. The paint shall not scale-off or crinkle or get removed by
abrasion due to normal handling.
Sufficient quantities of all paints and preservatives required for touching
up at sites shall be furnished.
The paint shade shall be subject to owners approval.
Tests
I)
Type Test
For each type & rating of 415V Non segregated phase bus duct, the Bidder
shall submit for Owners approval the reports of all the type tests as per
relevant standards and carried out within last[five] years from the date of
bid opening. These reports should be for the tests conducted on the Busduct
similar to those proposed to be supplied under this contract and the test(s)
should have been conducted at an independent laboratory.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[8]
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Power Plant]
II)
[Logo of Utility]
Routine Test

Some of the specific tests required are listed below.
a) Visual inspection and verification of dimensions
b) Dry power frequency voltage withstand for 1-minute
c) Milli-volt drop test & Water tightness test
1.6
Drawings and Documents

Drawings, data & manuals for the 415V Non segregated phase bud duct
shall be submitted as indicated below:
a) [Dimensional GA drawing
b) Data sheets
c) Typical calculation for arriving at the size of conductor and the insulator
spacing.
d) Type test report (short circuit, temperature rise test) for similar bus duct
manufactured by the proposed manufacturer.
e) Foundation layout and requirements
f) The bidder may note that the drawings, data and manuals listed are
minimum requirement only. The bidder shall ensure that all other
necessary write-ups, curves and information required to fully describe the
equipment offered are submitted with his bid.]
1.7

Major technical parameters of 415V non segregated Bus Duct are listed
below. However, Bidder may also refer to Volume-III, technical schedule in
order to submit technical data of equipment along with their technical
proposal.
Table: 2.0
S. No.
1.
2.
3.
Type of bus duct
Rated voltage and
No. of phase
Unit
Applicable standard
Parameters
Non segregated
phase bus duct
415V, Triple Pole ,
Neutral(3Phase & 4
Wire)
IS 8084
Remarks
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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S. No.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
System Frequency
Unit
Hz
Design ambient
temperature
Rated Current
Degr
ee
A
Designation (from &

to)
Type of cooling
(NSPBD)
Maximum
temperature rise of
conductor over 50oC
ambient
Maximum
temperature rise of
enclosure over 50oC
ambient
One minute power
frequency voltage
withstand
Continuous current
rating at 50oC
design ambient air
temperature
Material
a) Bus bar
b) Enclosure
One second short
circuit withstand
rating
Momentary short
circuit withstand
current
Bus bar Support
Parameters
50
[As per project
Requirement]
[As per project
Requirement]
Natural air
[40]
[30]
KV
(RMS
)
A
2.5
Earthing Conductor
Material
Remarks
50
KA
(RMS
)
KA
(Peak
)
[Logo of Utility]
[As per project

Requirement]
a) [Aluminum
b) Aluminum
alloy/MS]
50
105
[FRP/ SMC]
IP 52 for indoor
IP W55 for outdoor
GS
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[10]
25.09.2014
Power Plant]
S. No.
Heating
Unit
19.
20.
21.
Fittings of silica gel

breather and drain
plug
Finish of Bus
Enclosure
[Logo of Utility]
Parameters
Thermostat
controlled space
heater
Required
Remarks
a) Inside: Matt
Black
b) Outside [RAL
5012]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[11]
25.09.2014

OF

R&M CONTRACTORS
VOLUME-II
TECHNICAL SPECIFICATION FOR HV CABLES
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-E7
1. 0
1.1
HV CABLEs
General
HV cables complete with all accessories for efficient and trouble-free
operation for of R&M of Unit No. [..] of [Name of the Power Plant] at
[District], [State] for [Name of the Client]..
1.2
Codes and Standards

below except where modified or supplemented by this specification.
Table: 1.0
IS: 2982
: Copper conductor in insulated cables and cords.
IS: 3961
: Recommended current ratings for cables.
IS: 3975
: Mild steel wires, strips and tapes for armouring cables
IS: 5609
: Specification for low frequency wirers and cables

with PVC insulation and PVC sheath
IS:5831
: PVC insulation and sheath of electric cables
IS: 6380
: Specification of elastomeric insulation of sheath of

electric cables.
IS:7098(Part II)
IS: 8130
: Conductors for insulated electric cables and flexible

cords
IEC: 60
: High voltage test techniques
IEC: 230
: Impulse tests on cables and their accessories
IEC: 287
: Calculation of the continuous current rating of the
XLPE insulated PVC sheathed cables for working voltage

from 3.3kV up to and including 33kV
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[1]
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Power Plant]
[Logo of Utility]
cables(100% load factor).

IEC: 288
: Nominal cross sectional area and composition of

conductor of insulated cables.
IEC-331
: Fire resisting characteristics of electric cables
IEC: 332-1
: Test on electric cables under fire conditions.
IEEE: 383
: Standard for type test for class IE electric cables,

filled splices and connection for nuclear power
generation station.
IEC: 502
: Extruded solid dielectric insulated power cables for

rated voltages from 1kV upto 30kV.
IEC: 540
: The methods for insulations and sheath of electric

cables and cords(elastomeric and thermoplastic
compounds)
IEC-754-I
: Test method for acid gas generation
NEMA-WC-5
: Thermoplastic insulated wires and cables for

transmission and distribution of electrical energy.
ASTM-D-2843
: Standard test method for density of smoke from

burning/decomposition of plastics.
ASTM-D-2863
: Test for determination of oxygen index.
CEA
CEA Regulations
CEA

equal or better quality, may be accepted subject to approval of the Owner. In
such case, copies of the English version of the standards adopted shall have
to be submitted along with the bid.
Rules as amended upto date and relevant IS Codes of Practice. In addition,
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[2]
25.09.2014
Power Plant]
1.3
[Logo of Utility]
Design Criteria
a) The cables shall be installed in hot, humid tropical atmosphere with
ambient temperature of 50oC.
b) All HV cables shall be suitable for operation under the following voltage &
frequency variations:
Voltage Variation
() 10%
Frequency Variation
(+) 3% to (-)5%
Combined
Frequency
Variation
of
Voltage
& :
10% (absolute sum)
c) The HV power cables shall be 6600V unearthed grade, single/multi core

stranded Aluminum conductor, extruded XLPE insulated with extruded
PVC inner sheath, armoured and overall sheath with extruded Flame
Retardant Low Smoke (FRLS) PVC compound (Type ST-2). These cables
shall conform to IS 7098 (Part II).
d) The continuous and short time current carrying capacity of XLPE
insulated cables shall be based on maximum operating temperature of
90oC and 250oC respectively.
e) HV power cables shall be sized taking into account the following derating
factors:
i. Max Ambient air temperature
ii. Max Ambient ground temperature
iii. Grouping of cables/Method of laying
iv. Depth of laying for cable buried in ground.
v. Soil thermal resistivity for cable buried in ground.
f) HV cables shall be chosen taking into account the following factors:
i. System Fault level.
ii. Maximum time for fault clearance (i.e, operating time of the backup
protection relays plus the time of operation of the circuit breakers).
iii. Full load current of the circuit.
iv. Short circuit current and duration (for breaker protected cables)
v. Installation conditions.
vi. Voltage drop under normal running and starting condition
vii. Voltage drop at motor terminals shall be within permissible limit
during starting & normal running. i.e 5% during steady state and
15% during transient or starting at motor terminal.
viii. The cable should withstand the maximum fault current
corresponding to the particular voltage level for the minimum time
before the fault is cleared.
ix. Consideration shall also be given to limit the cable to the nearest
standard sizes instead of using too many types.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[3]
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Power Plant]
1.4
1.4.1
Type of Cable
[Logo of Utility]
a) HV cables shall be 6600V unearthed grade, heavy duty, stranded

aluminium conductor, XLPE insulated, extruded black FRLS PVC inner
sheathed, armoured and overall FRLS extruded black PVC outer sheathed
(Type ST-2) cables conforming to IS: 7098 part II.
1.4.2
Conductor
The cable conductor shall be made from standard Aluminum to form
compact conductor having a resistance within the limits specified.
1.4.3
Conductor Shield
The conductor having a semi-conducting screen shall ensure perfectly
smooth profile and avoid stress concentration. The conductor screen shall be
provided over the conductor by applying non metallic semi conducting tape
or by extrusion of semi conducting tape or by extrusion of semi-conducting
compound or a combination of the two. The semi conducting polymer shall
be cross linked for XLPE cables.
1.4.4
Insulation
The insulation of the HV cables shall be XLPE type. It shall be designed and
manufactured for the specified system voltage. The manufacturing process
shall ensure that insulation shall be free from voids. The insulation shall
withstand mechanical and thermal stresses under steady state and transient
operating conditions. The extrusion method should give a very smooth
interface between semi conducting screen and insulation. The insulation of
the cables shall be of high standard quality.
1.4.5
Insulation Shield
A non magnetic semi conducting shield shall be put over the insulation to
confine electrical field to the insulation. The XLPE cable insulation shield shall
be strippable.
The metallic layer of the insulation shield shall be grounded at least at one
location in the cables run. In the case of single conductor cable, care should
be taken with regard to ampacity when grounding at more than one point.
For all the cables having insulation shield, it shall have some form of stress
relief measure at every splice at termination. This can be stress cones,
moulded devices, heat shrink or cold shrink kits. All kits must be suitable for
the voltage class and cable size.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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02

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1.4.6
[Logo of Utility]
Inner Sheath
The sheath shall be suitable to withstand the site conditions and the desired
temperature. It shall be of adequate thickness and applied by a continuous
process to produce a sheath of consistent quality free from all defects. PVC
sheath shall be extruded with FRLS properties.
1.4.7
Armour
HV cables shall be provided with galvanized steel wire/strip armouring. The
hard drawn aluminium wire for armour shall be of H4 grade, as per IS-8130
(having tensile strength above 150 N/mm2). The diameter of the aluminium
wire shall be as per the table for the dimensions of the galvanized steel wire
armour given in the relevant standard.
1.4.8
Outer sheath
Outer sheath shall be extruded layer of FRLS PVC compound (ST-1).Sheath
shall be resistant to water, Ultra Violet radiations, fungus, termites and
rodent attacks. The color of the sheath shall be black.
1.4.9
Packing
[Cables shall be supplied in non-returnable drums]. Drum lengths shall be
such so that cable joints are totally avoided. The drums shall be of heavy
construction. [All wooden parts shall be manufactured from seasoned wood.]
All ferrous parts used shall be treated with suitable rust preventive finish or
coating to avoid rusting during transit or storage. [Wooden cable drum shall
be treated by immersing in copper-nitrate solution.]
The ends of each cable length shall be sealed before shipment. Heat
shrinkable cable cap shall be used for this purpose.
[A label shall be securely attached to each end of the reel indicating the
Purchaser's order number, Owners identification mark, length, type, voltage
grade, conductor size and number of cores of the cable.] A tag containing
the same information shall be attached to the leadings end of the cable
inside. An arrow and necessary instructions shall be marked on the drum
indicating the direction in which it should be rolled. Drum numbers are to be
indicated on the cable drums. Drum length shall not be less than 500m or as
per required length.
1.4.10
Identification of cores:
HV power cables shall be identified by color code.
1.4.11
Constructional Requirements
a) Cable shall have suitable filters laid up with the conductors to provide a
substantially circular cross section before the sheath is applied. Fillers
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
shall be suitable for the operating temperature of the cable and

compatible with the insulating material. All materials shall be new,
unused and of finest quality.
b) Workmanship shall be neat, clean and of the highest grade.
c) Special Properties:
All the above cables shall be conforming to the relevant Indian/IEC
standard in general, with the following special properties:
i. Oxygen Index of the outer sheath shall not be less than 29, when
tested as per ASTM-D-2863.
ii. Temperature Index of the outer sheath shall not be less than 250C,
when tested as per ASTM-D-2863.
iii. Halogen acid contents in outer sheath shall not be more than 20%,
when tested as per IEC-60754.
iv. The maximum smoke density in percent light absorption should not
exceed 60% in case of PVC compound and 20% in case of fire
survival cables, when tested as per ASTM-D-2843.
v. Swedish chimney test as per SS-4241475 class F3 and ladder test
for flammability as per IEEE-383.
vi. The cables shall be tested for resistance to Ultraviolet radiation. The
retention values of tensile strength and ultimate elongation after test
shall be minimum 60% of tensile strength.
vii. Outer sheath of cable shall be subject to tests for water absorption.
The methodology shall be as per IS 10810 part 33.
1.4.12
Joints and Terminations

Materials of construction for a joint/termination shall perfectly match with
the dielectric chemical and physical characteristics of the associated cables.
The material and design concepts shall incorporate a high degree of
operating compatibility between the cable and joints. The protective outer
covering (jacket) used on the joints/terminations shall have the same qualities
as that of the cable outer sheath in terms of ambient/operating temperature
withstand capability and resistance to hazardous environments and corrosive
elements. No joints shall be allowed unless the cable drawn length is
exceeded.
1.4.13
Cable Identification
Cable identification shall be provided by embossing the following on the
outer sheath:
a. [Manufacturer's name or trade mark
b. Voltage grade
c. Year of manufacture
d. Type of insulation.
e. Type of outer sheath e.g. "FRLS" etc.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[6]
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f.
g.
h.
i.
1.4.14
[Logo of Utility]
ISI marks
Nominal cross sectional area of the conductor & no of cores
Sequential marking
Owners identification mark]
Fire Proof sealing system

i)
a)
b)
c)
d)
General
Fire proof sealing system shall consist of
Fire-stops/fire-seals for
sealing of cable/cable tray and conduit/pipe penetrations, both
horizontal and vertical, through brick or RCC walls/floors, to prevent
the spread of fire from one area, which is separated from others by
fire-resistant barriers.
Fire-breaks' provided on long runs of cable racks/trays to prevent the
propagation of fire along the cable rack, within a single fire-area or
fire- zone.
The FPS system shall also include all the necessary accessories and
equipment required for supporting, holding in position, fixing and
installation of the fire-stop/fire-break.
The FPS system shall comply in all respects with the requirements of
the codes and standards listed below
IEEE-634 ASTM-E-814
ANSI-IEEE-383 IEC-331
ii)
IEC-332
Fire stop/ seal
The FPS system adopted for cables or cable trays penetrating through walls
and floor constitute a openings, or cables passing through embedded
conduits / pipes / pipe- sleeves, fire stop / seal', which is meant to prevent
spreading of fire between areas separated by fire-resistant barriers.
iii)
Fire Break
The fire proofing system, other than fire-stops, adopted to retard flame
propagation long runs of horizontal or vertical cable trays in the same fire
zone or area, in an event of a fire, shall constitute a `fire-break' and shall be
provided by applying a suitable fire resistance coating on cables and cable
trays for the required length, with or without a fire resistant panel, at the
point of the fire break to obtain the fire-rating specified.
iv)
Application of fire proof sealing system
Fire stops shall be provided for cable penetration openings listed below
The passage of cables/cable trays pipe sleeves/embedded conduits through
walls / floors.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[7]
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[Logo of Utility]
Vertical raceways, which carry cables between successive floors, through

openings provided in the RCC floor slab, shall be sealed by fire stops at each
floor level.
Cable entry through openings in floor slabs below HT/LT switchgear, MCCs,
various Control and relay panels and other bottom entry panels, shall be
effectively sealed by fire stop
Location of fire breaks
Firebreaks shall be provided on both cable rack and trenches at all cable tray
Intersections and tee-offs.
On linear runs of cable trays between fire stops or fire breaks, fire breaks
shall be provided at intervals of 15 metres on horizontal cable runs and 5 m
on vertical cable runs.
Fire breaks in linear runs of cable trenches between intersections and teeoffs shall be provided at intervals of 30 metres.
Bidder shall furnish the test certificates for the fire stops and fire breaks after
award of contract for Owner/Owners Representative review. If the
certificates are not satisfactory all the tests shall be conducted free of cost.
The offered system i.e. fire stops and fire breaks shall be identical (or better)
with the system which is successfully type tested for the specified rating i.e.
the composition density of the material, thickness of coating in case of fire
breaks and any other properties of the material / system offered shall be
identical or better than the tested system and shall be subject to Owner /
Owners Representative.
v)
Test on fire stops
The fire stops shall be subjected to the following type tests:
a. Fire Rating Test
b. Hose Stream Test
Type tests shall be conducted on different fire stop test specimens described
above as per IEEE-634. The sizes of the fire stop test specimens shall be
similar to the largest of the sizes being used in the plant.
Preconditioning of fire stop test specimens before conducting the fire rating
and hose stream tests, each test specimen shall be preconditioned for
thermal ageing, water immersion and vibration.
Test on Fire Stops
During the fire rating test, the transmission of heat through the cable
penetration fire stop shall not raise the temperature on its unexposed surface
above the self ignition temperature of the outer cable covering, the cable
penetration fire stop material, or material in contact with the cable
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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02

[8]
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Power Plant]
[Logo of Utility]
penetration fire stop, with a maximum temperature limit on the unexposed

surface of 200oC.
Tests on fire breaks
Firebreaks shall undergo the following tests as per ANSI-IEEE-383:
Ampacity test
Flame test
1.5
Tests
1.5.1
Type Test
For each type & rating of HV cables, the Bidder shall submit for Owners
approval the reports of all the type tests as per relevant standards and
carried out within [last five] years from the date of bid opening. These
The list of type tests are as follows:
a) Tests on conductor:
i. Annealing test (for copper)
ii. Tensile test (for aluminum)
iii. Wrapping test (for aluminum)
iv. Conductor resistance test.
b) Test for armouring wires/strips
c) Test for thickness of insulation and sheath
d) Physical tests for insulation and outer sheath:
i. Tensile strength and elongation at break
ii. Ageing in air oven
iii. Shrinkage test
iv. Hot deformation
v. Loss of mass in air oven
vi. Heat shock test
vii. Thermal Stability
e) Insulation resistance test
f) High voltage test (water immersion test)
g) High voltage test at room temperature
h) Flammability test
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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02

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1.5.2
[Logo of Utility]
Routine Test
Cables shall be subject to acceptance and routine tests as per IS codes.
Acceptance tests and FRLS test as specified earlier shall be conducted on
cables and the same shall be witnessed by purchaser.
The FRLS test shall be carried out on one cable of each batch of compound
used. Other acceptance tests shall be carried out on drums selected as per
sampling plan as indicated in IS. Test certificates for routine acceptance and
special tests shall be furnished by the Bidder for review and approval of
purchaser.
1.6
Drawings, Data and Manuals

The following drawings/documents and calculation as listed below but not
limited to shall be furnished along with the bid for review
[Cable datasheets and cross sectional drawings]
[Cable sizing calculation]
[QAPs & Test Reports]
[Relevant catalogues]
[Estimated weight of cable and cable drum]
1.7
1.7.1
H.V. Power cable, 6600V unearthed grade

Table: 2.0
S.No.
Technical
Particulars
Unit
1.
System voltage
2.
Voltage Grade
3.
4.
5.
Ambient
Temperature
Maximum
conductor
temperature for
continuous
operation for XLPE
cables
Maximum
conductor
temperature for
Parameters
Remarks
6.6 V
6.6/6.6kV
Unearthed
50oC
90oC
250oC
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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S.No.
Technical
Particulars
Unit
Parameters
[Logo of Utility]
Remarks
short time
operation for
XLPEcables
6.
Conductor
Aluminum
7.
Insulation
XLPE
8.
Inner Sheath
Extruded PVC (ST-1)
9.
Outer sheath
Extruded PVC (ST-1)

with FRLS
characteristic
10.
Armored/ Unarmored
Armoured
11.
System Grounding
Resistance
Grounded
12.
Whether cores
identifications
numbers provided
13.
14.
15.
16.
17.
a)
b)
Whether
incremental running
lengths are marked
on cable.
Short circuit
capability for 1 sec
Maximum overall
diameter of cables
Min. Bending
Radius
To be provided
By Bidder
40 kA
By Bidder
By Bidder
By Bidder
Drum Details:
Length of cables in
Drums and Volume
+ Tolerance
Weight of cable
drum with cables
By Bidder
By Bidder
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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S.No.
Technical
Particulars
Unit
c)
Weight of cable
drum without
cables
d)
Type of end sealing
e)
Marking on cable
drums as per IS
required
Parameters
[Logo of Utility]
Remarks
By Bidder
By Bidder
By Bidder
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[12]
25.09.2014

OF

R&M CONTRACTORS
VOLUME-II
TECHNICAL SPECIFICATION FOR LV CABLES
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-E8
1.0
1.1
LV CABLES
General
LV cables for power & control applications complete with all accessories for
efficient and trouble-free operation for of R&M of Unit No. [..] of [Name of
1.2
Codes and Standards

below except where modified or supplemented by this specification.
Table: 1.0
IS:1554(Part I)
: PVC insulated (heavy duty) electric cables for working

voltage up to and including 1100V
IS: 2982
: Copper conductor in insulated cables and cords.
IS: 3961
: Recommended current ratings for cables.
IS: 3975
: Mild steel wires, strips and tapes for armouring cables
IS: 5609
: Specification for low frequency wirers and cables

with PVC insulation and PVC sheath
IS:5831
: PVC insulation and sheath of electric cables
IS: 6380
: Specification of elastomeric insulation of sheath of

electric cables.
IS:7098(Part I)
IS: 8130
: Conductors for insulated electric cables and flexible

cords
IEC: 60
: High voltage test techniques
XLPE insulated PVC sheathed cables for working voltage

up to 1.1kV
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
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[Logo of Utility]
IEC: 230
: Impulse tests on cables and their accessories
IEC: 287
: Calculation of the continuous current rating of the

cables(100% load factor).
IEC: 288
: Nominal cross sectional area and composition of

conductor of insulated cables.
IEC-331
: Fire resisting characteristics of electric cables
IEC: 332-1
: Test on electric cables under fire conditions.
IEEE: 383
: Standard for type test for class IE electric cables,

filled splices and connection for nuclear power
generation station.
IEC: 502
: Extruded solid dielectric insulated power cables for

rated voltages from 1kV upto 30kV.
IEC: 540
: The methods for insulations and sheath of electric

cables and cords(elastomeric and thermoplastic
compounds)
IEC-754-I
: Test method for acid gas generation
NEMA-WC-5
: Thermoplastic insulated wires and cables for

transmission and distribution of electrical energy.
ASTM-D-2843
: Standard test method for density of smoke from

burning/decomposition of plastics.
ASTM-D-2863
: Test for determination of oxygen index.
CEA
CEA Regulations
CEA

Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]

Rules as amended upto date and relevant IS Codes of Practice. In addition,
1.3
Design Criteria
a) The cables shall be installed in hot, humid tropical atmosphere with
ambient temperature of 50oC.
b) All LV cables shall be suitable for operation under the following voltage &
frequency variations:
Voltage Variation
() 10%
Frequency Variation
(+) 3% to (-)5%
Combined
Frequency
Variation
of
Voltage
& :
10% (absolute sum)
c) The LV power cables shall be 1100V grade, single/multi core stranded

Aluminum conductor, extruded XLPE/PVC insulated with extruded PVC
inner sheath, armoured and overall sheath with extruded Flame Retardant
Low Smoke (FRLS) PVC compound (Type ST-1). These cables shall
conform to IS 7098 (Part I) for XLPE and 1554(part 1) for PVC insulation.
d) The control cables shall be 1100 V grade, multi core, stranded annealed
high conductivity copper with extruded PVC insulated inner sheath,
armoured and overall sheath with extruded Flame Retardant Low Smoke
(FRLS) PVC compound (Type ST-1).
e) The continuous and short time current carrying capacity of XLPE
insulated cables shall be based on maximum operating temperature of
90oC and 250oC respectively.
f) The continuous and short time current carrying capacity of PVC insulated
cables shall be based on maximum operating temperature of 70oC and
160oC respectively.
g) LV power cables shall be sized taking into account the following deraing
factors:
i. Max Ambient air temperature
ii. Max Ambient ground temperature
iii. Grouping of cables/Method of laying
iv. Depth of laying for cable buried in ground.
v. Soil thermal resistivity for cable buried in ground.
h) Power cables shall be chosen taking into account the following factors:
i. System Fault level.
ii. Maximum time for fault clearance (i.e, operating time of the backup
protection relays plus the time of operation of the circuit breakers).
iii. Full load current of the circuit.
iv. Short circuit current and duration (for breaker protected cables)
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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v.
vi.
vii.
viii.
ix.
x.
[Logo of Utility]
Installation conditions.
Voltage drop under normal running and starting condition
Voltage drop at motor terminals shall be within permissible limit
during starting & normal running. i.e 5% during steady state and
15% during transient or starting at motor terminal.
The cable should withstand the maximum fault current
corresponding to the particular voltage level for the minimum time
before the fault is cleared.
Consideration shall also be given to limit the cable to the nearest
standard sizes instead of using too many types.
The minimum size of cables to be used shall be as follow :
Aluminium conductor
:
6 Sq. mm.
Copper conductor
:
2.5 Sq. mm
1.4
1.4.1
Type of Cable
a) LV power cables shall be 1100V grade, heavy duty, stranded aluminium
conductor, XLPE/ PVC insulated, extruded black FRLS PVC inner
sheathed, armoured and overall FRLS extruded black PVC outer sheathed
(Type ST-1) cables conforming to IS: 1554(Part 1) for PVC insulation and
IS 7098(Part 1) for XLPE insulation.
b) Control Cables shall be 1100 V grade, heavy duty with annealed high
conductivity stranded copper conductor, PVC insulated, FRLS PVC inner
sheathed, armoured and FRLS extruded black PVC outer sheathed (Type
ST-1) cables conforming to IS : 1554.
c) LV power cables of size above 35 sq. mm may be provided with XLPE
insulation. Bidder shall clearly indicate the type of insulation provided in
the technical bid.
1.4.2
Conductor
The cable conductor shall be made from standard Aluminum for LV Power
cables and Copper for control cables to form compact conductor having a
resistance within the limits specified. All the cables of size 25mm2 and above
shall have sector shaped conductors.
1.4.3
Insulation
The insulation of the LV power and control cables shall be [XLPE/PVC] type.
It shall be designed and manufactured for the specified system voltage. The
manufacturing process shall ensure that insulation shall be free from voids.
The insulation shall withstand mechanical and thermal stresses under steady
state and transient operating conditions. The extrusion method should give a
very smooth interface between semi conducting screen and insulation. The
insulation of the cables shall be of high standard quality.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[4]
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Power Plant]
1.4.4
[Logo of Utility]
Inner Sheath
The sheath shall be suitable to withstand the site conditions and the desired
temperature. It shall be of adequate thickness and applied by a continuous
process to produce a sheath of consistent quality free from all defects. PVC
sheath shall be extruded with FRLS properties.
1.4.5
Armour
LV power and control cables shall be provided with galvanized steel
wire/strip armouring. The hard drawn aluminium wire for armour shall be of
H4 grade, as per IS-8130 (having tensile strength above 150 N/mm2). The
diameter of the aluminium wire shall be as per the table for the dimensions
of the galvanized steel wire armour given in the relevant standard.
1.4.6
Outer sheath
Outer sheath shall be extruded layer of FRLS PVC compound (ST-1).Sheath
shall be resistant to water, Ultra Violet radiations, fungus, termites and
rodent attacks. The color of the sheath shall be black.
1.4.7
Packing
[Cables shall be supplied in non-returnable drums]. Drum lengths shall be
such so that cable joints are totally avoided. The drums shall be of heavy
construction. [All wooden parts shall be manufactured from seasoned wood.]
All ferrous parts used shall be treated with suitable rust preventive finish or
coating to avoid rusting during transit or storage. [Wooden cable drum shall
be treated by immersing in copper-nitrate solution.]
The ends of each cable length shall be sealed before shipment. Heat
shrinkable cable cap shall be used for this purpose.
[A label shall be securely attached to each end of the reel indicating the
Purchaser's order number, Owners identification mark, length, type, voltage
grade, conductor size and number of cores of the cable.] A tag containing
the same information shall be attached to the leadings end of the cable
inside. An arrow and necessary instructions shall be marked on the drum
indicating the direction in which it should be rolled. Drum numbers are to be
indicated on the cable drums. Drum length shall not be less than the
following:
a) Power cables: 500m
b) Control cables: 1000m
1.4.8
Identification of cores and spares:

LV power cables shall be identified by color code. However LV control cables
shall be identified by the number of its cores.
[Multi-core control cables shall have 20% spare core, minimum one spare.]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[5]
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Power Plant]
1.4.9
[Logo of Utility]
a) Cable shall have suitable filters laid up with the conductors to provide a
substantially circular cross section before the sheath is applied. Fillers
shall be suitable for the operating temperature of the cable and
compatible with the insulating material. All materials shall be new,
unused and of finest quality.
b) Workmanship shall be neat, clean and of the highest grade.
c) Special Properties:
All the above cables shall be conforming to the relevant Indian/IEC
standard in general, with the following special properties:
i. Oxygen Index of the outer sheath shall not be less than 29, when
tested as per ASTM-D-2863.
ii. Temperature Index of the outer sheath shall not be less than 250C,
when tested as per ASTM-D-2863.
iii. Halogen acid contents in outer sheath shall not be more than 20%,
when tested as per IEC-60754.
iv. The maximum smoke density in percent light absorption should not
exceed 60% in case of PVC compound and 20% in case of fire
survival cables, when tested as per ASTM-D-2843.
v. Swedish chimney test as per SS-4241475 class F3 and ladder test
for flammability as per IEEE-383.
vi. The cables shall be tested for resistance to Ultraviolet radiation. The
retention values of tensile strength and ultimate elongation after test
shall be minimum 60% of tensile strength.
vii. Outer sheath of cable shall be subject to tests for water absorption.
The methodology shall be as per IS 10810 part 33.
1.4.10
Joints and Terminations

Materials of construction for a joint/termination shall perfectly match with
the dielectric chemical and physical characteristics of the associated cables.
The material and design concepts shall incorporate a high degree of
operating compatibility between the cable and joints. The protective outer
covering (jacket) used on the joints/terminations shall have the same qualities
as that of the cable outer sheath in terms of ambient/operating temperature
withstand capability and resistance to hazardous environments and corrosive
elements. No joints shall be allowed unless the cable drawn length is
exceeded.
1.4.11
Cable Identification
Cable identification shall be provided by embossing the following on the
outer sheath:
a. [Manufacturer's name or trade mark
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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b.
c.
d.
e.
f.
g.
h.
i.
[Logo of Utility]
Voltage grade
Year of manufacture
Type of insulation.
Type of outer sheath e.g. "FRLS" etc.
ISI marks
Nominal cross sectional area of the conductor & no of cores
Sequential marking
Owners identification mark]
1.5
Tests
1.5.1
Type Test
For each type & rating of LV power and control cables, the Bidder shall
submit for Owners approval the reports of all the type tests as per relevant
standards and carried out within [last five] years from the date of bid
opening. These reports should be for the tests conducted on the equipment
similar to those proposed to be supplied under this contract and the test(s)
should have been conducted at an independent laboratory.
The list of type tests are as follows:
a) Tests on conductor:
i. Annealing test (for copper)
ii. Tensile test (for aluminum)
iii. Wrapping test (for aluminum)
iv. Conductor resistance test.
b) Test for armouring wires/strips
c) Test for thickness of insulation and sheath
d) Physical tests for insulation and outer sheath:
i. Tensile strength and elongation at break
ii. Ageing in air oven
iii. Shrinkage test
iv. Hot deformation
v. Loss of mass in air oven
vi. Heat shock test
vii. Thermal Stability
e) Insulation resistance test
f) High voltage test (water immersion test)
g) High voltage test at room temperature
h) Flammability test
Document Number
Rev
No.
Description
Page
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Power Plant]
1.5.2
[Logo of Utility]
Routine Test
Cables shall be subject to acceptance and routine tests as per IS codes.
Acceptance tests and FRLS test as specified earlier shall be conducted on
cables and the same shall be witnessed by purchaser.
The FRLS test shall be carried out on one cable of each batch of compound
used. Other acceptance tests shall be carried out on drums selected as per
sampling plan as indicated in IS. Test certificates for routine acceptance and
special tests shall be furnished by the Bidder for review and approval of
purchaser.
1.6

The following drawings/documents and calculation as listed below but not
limited to shall be furnished along with the bid for review
[Cable datasheets and cross sectional drawings]
[Cable sizing calculation]
[QAPs & Test Reports]
[Relevant catalogues]
[Estimated weight of cable and cable drum]
1.7
1.7.1
L.V. Power and control cables, 1100 V grade

Table: 2.0
S.No.
Technical
Particulars
Unit
Parameters
1.
System voltage
415 V
2.
Voltage Grade
1.1 kV
Ambient
Temperature
Maximum
conductor
temperature
for
continuous
operation
for
XLPE/PVC cables
50oC
3.
4.
5.
Maximum
conductor
temperature
for
Remarks
For XLPE: 90oC

For PVC: 70oC
For XLPE: 250oC

For PVC: 160oC
Document Number
Rev
No.
Description
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No.
Date of Issue
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Power Plant]
S.No.
Technical
Particulars
Unit
Parameters
[Logo of Utility]
Remarks
short
time
operation
for
XLPE/PVC cables
6.
Conductor
For power cable:

Aluminum
For Control Cable:
Copper
For power cable:
XLPE/PVC
7.
Insulation
For Control Cable:
PVC
8.
Inner Sheath
Extruded PVC (ST-1)
9.
Outer sheath
Extruded PVC (ST-1)

with FRLS
characteristic
For power cable:

Armoured
10.
Armored/ Unarmored
For Control Cable:
Armoured
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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Power Plant]
S.No.
Technical
Particulars
Unit
11.
System
Grounding
12.
Whether cores
identifications
numbers provided
13.
14.
15.
16.
17.
a)
b)
c)
d)
e)
Parameters
[Logo of Utility]
Remarks
415 V system is
solidly grounded.
Whether
incremental
running lengths
are marked on
cable.
Short circuit
capability for 1
sec
Maximum overall
diameter of
cables
Min. Bending
Radius
To be provided
By Bidder
50 kA
By Bidder
By Bidder
By Bidder
Drum Details:
Length of cables
in Drums and
Volume +
Tolerance
Weight of cable
drum with cables
Weight of cable
drum without
cables
Type of end
sealing
Marking on cable
drums as per IS
required
By Bidder
By Bidder
By Bidder
By Bidder
By Bidder
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[10]
25.09.2014

OF

R&M CONTRACTORS
VOLUME-II
TECHNICAL SPECIFICATION FOR ILLUMINATION SYSTEM
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Tender Document for R&M of Unit No. [..] Capacity of [Name of the
Power Plant]
[Logo of Utility]
ANNEXURES-E9
1.0
1.1
ILLUMINATION SYSTEM
General
Illumination System complete with luminaries and all accessories for efficient
and trouble-free operation of R&M of Unit No. [..] of [Name of the Power
1.2
Codes and Standards

Table: 1.0
Code
Name of Standard
IS 1913
Electrical lighting fittings- General and

safety requirements
IS 2418 - Part I
Tubular fluorescent Lamp
IS 3480
Flexible steel conduits for electrical

wiring
IS 3646 (Part I to III)
Code of Practice For Interior

Illumination
IS 4012
Dust proof electric lighting fittings
IS4013
Flame proof enclosure
IS 6665
Code of practice for industrial lighting
IS 5077
Decorative light fittings
IS 9537 - Part II
Rigid steel conduits for electrical

installations
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[1]
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Power Plant]
[Logo of Utility]
IS 9583
Emergency lighting units
IS 9900
High pressure mercury vapor lamp
IS 9974
High pressure sodium vapor lamp
IS 10322
Luminaries for street lighting
CBIP Manual
Substation Equipment, Illumination and

Layouts
IES (Illuminating Engineering

Society of North America)
Application and Reference Volume
IEC 60598
Luminaries
CEA
CEA regulations and standard technical

specification.

Rules as amended up to date and relevant IS Codes of Practice. In addition,
1.3
Design Criteria
a. All illumination systems shall be suitable for an ambient temperature of
50 C and relative humidity of 95%. The illumination systems shall be
suitable for operation in a highly polluted environment.
b. Lighting fixtures shall be suited for the following range of frequency and
voltage variations:
i.
Voltage Variation
10%
ii.
Frequency Variation
50Hz (+)3% to (-)5%
iii.
Combined
Variation
Voltage & Frequency
of :
10% (absolute sum)
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No.
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No.
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[2]
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[Logo of Utility]
c. All emergency DC lighting systems shall be suited for voltage variation

from -15% to +10% of rated voltage.
d. The design of the lighting systems shall be such that it shall ensure
average lux levels specified for different areas.
e. The illumination system shall comprise of the following:
i.
Normal AC lighting
ii.
Normal cum emergency lighting system
iii.
220V DC Emergency lighting system
iv.
Maintenance 24V AC lighting system
v.
Portable emergency lights with self contained battery packs.
1.4
1.4.1
Scope of work
The scope of work shall include design, preparation of Lighting design and
manufacture, supply, unloading at site, storing, laying, fixing,
jointing/termination, erection, testing and commissioning of equipment
associated with Lighting system for following areas Listed below but not
limited to the following:
[Note: With reference to particular package, scope of work shall be
modified.]
a) TG Area:
i) TG Platforms.
ii)TG area Grade Levels Maintenance area.
iii) Switchgear room and cable gallery.
iv) All roads within battery limit.
v) Perimeter and boundary illumination of the above premises.
vi) Any other area/premises not specifically mentioned here, but which
fall under the battery limit of this package is included in the scope.
b) Boiler Area:
i) Boiler Platforms
ii)Boiler Grade Levels covering coal mill and Maintenance area.
iii) ESP Platforms
iv) ESP/FOPH switchgear room and cable gallery.
v) FOPH area.
vi) Transfer towers & Conveyor galleries.
vii) All roads within battery limit.
viii) Perimeter and boundary illumination of the above premises.
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No.
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c)
d)
e)
f)
1.4.2
[Logo of Utility]
ix) Any other area/premises not specifically mentioned here, but which
Balance of plant Area:
i) Lighting system for Mechanical BOP package like Raw water, Water
pre-treatment, Fuel oil, CW / ACW System and Cooling Towers,
AC and ventilation Vacuum Pump House, Silo Area, Compressor
House, Guard Pond, Effluent Treatment Plant, Chimney, Fire water
pump house, Cable galleries, all Switchgear Rooms, Control rooms,
all roads within battery limit etc.
ii)All roads within battery limit.
iii) Perimeter and boundary illumination of the above premises.
iv) Any other area/premises not specifically mentioned here, but which
CHP Area:
i) Switchgear rooms
AHP Area:
i) Switchgear rooms.
Electrical Balance of Plant(Switchyard) Area:
i) Switchyard control room
ii)GIS building (if applicable)
iii) Transformer area
iv) All roads within battery limit.
v) Perimeter and boundary illumination of the above premises.
vi) Any other area/premises not specifically mentioned here, but which
Illumination System Description

The plant illumination system shall comprise of the following categories:
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No.
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No.
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[Logo of Utility]
a. Normal AC lighting
In this system, the lighting circuits shall be fed by the 3 phase, 4 wire
normal AC supply from the normal lighting distribution boards (LDB). All
the lighting fixtures connected to this system shall be available as long as
the 415V station / unit auxiliary service supply is available.
b. Normal cum emergency lighting system
Certain lighting fixtures considered essential shall be connected to this
system. In this system the lighting circuits shall be fed from lighting
distribution board connected to 415V Normal cum Emergency
Switchgear. The lighting fixtures connected to this system shall be
available whenever normal supply is available in the plant and also
whenever DG set supplies the power to 415V Normal emergency
switchgear.
These lighting fixtures will go off for a few seconds when normal supply
fails but will be automatically restored when the emergency AC bus is reenergized by automatic transfer to standby DG supply.
[20% of the total fittings shall be fed from Emergency lighting for areas
such as Switchgear room and control rooms etc.]
c. Emergency 220 V D.C. Lighting
The Emergency DC Lighting System shall be located strategically in
critical operating areas and at emergency exits. Emergency DC lighting
shall also be provided in the Control rooms, Switchgear/ MCC rooms and
other strategically important areas. These fixtures shall be fed from
respective Emergency DC Lighting Panels. The Emergency DC Lighting
Panels (DC ELLP) shall be fed from 220V DC Distribution Boards (DCDB).
These lights shall remain normally OFF but on failure of AC supply these
lights shall be automatically ON. Tube lights with Electronic choke
suitable for 230 V, AC / DC operation or other Energy Efficient Lamps
may be used for DC emergency lighting.
d. Maintenance 24 V AC Lighting System
For lighting facilities comprising portable hand lamps and/or connection of
portable hand tools etc., required during the routine maintenance work,
24V single phase 3 pin sockets with switches shall be provided at
selected points in the areas listed below. Such sockets for routine
maintenance shall be clearly identified by colour coding in order to
distinguish them from the normal 240V power outlets. Necessary outlets
shall be made on the inside walls of the building near equipments.
Document Number
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No.
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No.
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i.
ii.
iii.
iv.
v.
[Logo of Utility]
Boiler area: Near inspection manholes on the boiler platforms and

near boiler drum at different levels on all four sides.
TG building: Near HP & LP heaters, turbine flash tank, blow down
tank, near condenser water box and near bus duct termination of
generator end.
ESP columns: Near inspection manholes
Near de-aerator.
Cable galleries.
Any other areas

engineering.
considered
necessary
identified
during
detailed
e. Portable Emergency Lights

This system shall be provided by portable self-contained battery /
automatic charger / inverter fed compact fluorescent lamps in isolated
buildings / areas where station D.C. supply is not available. These
portable emergency light units shall be switched on automatically on loss
of normal AC supply. [Battery packs for portable emergency lights shall
be rated for minimum 3 hours duty and the battery shall be of Ni-Cd.].
f. Exit lights
Emergency escape signs shall be provided at the exit doors, escape
routes, intersection corridors, at different floor levels/directions,
windowless rooms, toilets , firefighting equipment, lifts, control rooms,
switchgear rooms and the areas considered necessary by bidder. [9W
CFL] lamp shall be used for exit lamps.
The contractor shall design emergency exit lighting system based on
plant layouts and install escape lights at suitable locations considering the
various escape routes. Emergency exit lights will be fed from normalcum-emergency lighting panel, wherever available, [and will be with inbuilt battery (Ni-Cd) back up of 3 hours operation.]
1.4.3
Illumination Calculation
a. Standard Lumen method shall be adopted for interior and exterior lighting
in order to determine the number of lighting fixtures for obtaining the
desired average level of illumination.
b. The coefficient of utilization shall be considered to take care of Lumen
loss due to:
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No.
Description
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No.
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[Logo of Utility]
i.
Effect of room dimensions.
ii.
Absorption of light in luminaries.
iii.
Absorption of light at various room surfaces i.e. ceiling wall etc.
iv.
Floor cavity, ceiling cavity.
v.
Mounting height.
c. Moreover a maintenance factor shall also be considered to account for
the fall of illumination due to aging, pollution like dust deposits etc.
d. Voltage drop at the fixture terminals from the MLDB shall [not exceed
3%]. Circuit loading of each lighting Panel shall be done in such a way
that almost balanced loading in all the phases i.e. R, Y and B is achieved.
At least two sub circuits shall be used for illumination of a particular area.
Sub circuit loading of each lighting panel shall be restricted to 2000
Watts.
e. Design of lighting system shall be such that the average lux level as
specified is achieved. The Bidder shall submit illumination
calculation/layout for the purchasers review.
1.4.4
Lighting Distribution System

a. Separate lighting transformers shall be provided inside the lighting
distribution boards located at required location. Lighting distribution
system shall be distinct and separate from the LV main distribution.
Lighting transformers shall be encapsulated cast resin dry type.
b. AC lighting panels shall have 240V single-phase, 2 wire incomer
controlled by earth leakage circuit breaker and number of single phase
outgoing circuits controlled by MCBs. The lights connected to a circuit or
few circuits shall be ON automatically through photocell for outdoor
lighting. Provision shall be made for switching ON the rest of the lights.
Lighting fixtures in indoor areas shall be controlled from the respective
lighting panels
c. Normal 240 V AC Lighting System
For this system, lighting points shall be supplied at 240 V AC through
415 V, 3-phase, 4-wire, 50 Hz, LDB. The supply shall be derived from
415 V, 3-phase, 4-wire, 50 Hz switchgear through delta/star lighting
transformer. The secondary of lighting transformer shall be connected to
respective 415 V, 3-phase, 4-wire AC lighting distribution board (LDB).
The LDBs shall be provided with number of outgoing circuits controlled
by double pole MCBs to feed the lighting panels distributed in and around
the plant. Different circuits shall be used from different source. The
whole lighting network shall be balanced as far as possible.
d. Normal/Emergency 240V AC System
For these systems, the distribution shall be by 415V, 3-phase, 4-wire, 50
Hz supply. This supply shall be derived from 415 V, 3-phase, 4-wire, 50
Document Number
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No.
Description
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No.
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Power Plant]
[Logo of Utility]
Hz normal emergency switchgear for NE & lighting through delta/star

lighting transformer. The secondary of lighting transformer shall be
connected to respective 415 V, 3-phase, 4-wire AC lighting distribution
board (LDB). The LDBs shall be provided with number of outgoing circuits
controlled by double pole MCBs to feed the lighting panels distributed in
and around the plant.
e. Emergency 220 V DC Lighting System
The power supply shall be obtained from the nearest 220 V DC
switchboard. DC lighting panel will have one (1) incomer controlled by
double pole MCB, Outgoing circuits will be controlled by DP MCB. Upon
failure of the normal-cum-emergency AC supply, emergency DC lighting
fixtures will be made automatically ON. The change over in the reverse
direction shall also be automatic.
f. Maintenance 24V AC Lighting System
24 V AC supply for maintenance purposes (for hand lamps and/or hand
operated tools) shall be supplied from 24 V AC distribution panel, which
receives 240 V power supply from 415 V/240V transformer modules of
N/E switchgear. 24 V AC distribution panel consists of one incomer
controlled by MCB, one 240/26.5 V dry type transformer of adequate
rating and number of outgoing circuits controlled by MCB.
1.4.5
Illumination levels and choice of lighting fixtures

The area-wise distribution of average illumination levels and type of
luminaries shall be as indicated below:
[Note: These are indicative only. However as per specific Existing project,
Bidder may refer section I of this specification for exact details of type of
fixtures.]
Table 2.0
Sl.
Area/Structure Average
Type of Fixture
Type of
No.
Illumination
Luminaries
Level in Lux
ATURBINE GENERATOR BUILDING
1.1
General
200
Industrial well glass 1x70 W/
(auxiliary
fixture, dust & jet 1x150 W
equipment
proof,
die
cast HPSV
areas)
aluminium body, stove lamp
enamel finish, vitreous
enamel
reflector
integral
mounted
control gear/industrial
bulk head with integral
Document Number
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No.
Description
Page
No.
Date of Issue
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Sl.
No.
Area/Structure
1.2
Cable vault
1.3
All switchgear
room area
(including offsite building
control room)
TG Building
operating floor
250
1.5
Unit control
room and
Switchyard
control room
400
1.6
Battery rooms
1.7
TG building
ground,
mezzanine
floor and misc.
floors
Air washer
room and A/C
plant room
Unloading and
maintenance
bay
1.4
1.8
1.9
Average
Illumination
Level in Lux
100
[Logo of Utility]
Type of Fixture
Type of
Luminaries
Industrial type FTL

with vitreous enamel
reflector
Industrial type with
vitreous
enamel
reflector
Energy
Efficient
FTL
Energy
Efficient
FTL
Industrial high bay with

anodized
aluminium
reflector
with
all
accessories including
control gear
Decorative
recessed
with wide angle mirror
optic antiglare type
1x400 W
Metal
Halide
lamp
150
Corrosion-proof
200
Industrial well glass

with integral control
gear
200
Totally enclosed vapor

proof with clear acrylic
cover
Industrial high bay with
anodised
aluminium
reflector
Energy
Efficient
FTL
1x150 W/
1x250W
Metal
Halide
lamp
Energy
Efficient
FTL
250 W
HPSV
lamp (for
mounting
height
>9m)
250
300
Energy
Efficient
FTL
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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Sl.
No.
Area/Structure
1.10
Electrical
laboratory,
chemical
laboratory etc.
(airconditioned)
BOILER AREA
Boiler area and
platforms, ESP
area and
platforms
Feeder floor
areas
B1.1
1.2
[Logo of Utility]
Average
Illumination
Level in Lux
300
Type of Fixture
100
Dust proof / dust tight 70 W

well glass fixture
Metal
Halide
lamp
Dust proof / dust tight 70 W
increased safety well Metal
glass
Halide
lamp
Decorative
recessed Energy
with wide angle mirror Efficient
optic anti-glare type
FTL
150
Decorative
recessed Energy
with wide angle mirror Efficient
optic anti-glare type
FTL
1.3
ESP control
room
C1.1
VARIOUS OFF-SITE BUILDING

Equipment
200
room (pump
vitreous
enamel
house)
reflector
upto
mounting height of 8
M
Switchgear
250
Industrial high bay for
room
mounting
heights
above 8M
Outside
70
Flood light medium
working areas
beam
1.2
1.3
300
Type of
Luminaries
1.4
Stores
100
1.5
Fuel Oil Tank

Farm
50
150 / 250
W HPSV
lamp
Energy
Efficient
FTL
250 W
HPSV
lamp
Industrial type with Energy
vitreous
enamel Efficient
reflector
FTL
General Purpose flood
250 W
light with
HPSV
weatherproof fixture
lamp
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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Sl.
No.
Area/Structure
1.6
Fuel oil
decanting
pump house,
Hydrogen
storage area,
Coal conveyor
areas
GENERAL
Corridors,
walkways,
staircase, etc.
D1.1
1.2
1.3
1.4
Average
Illumination
Level in Lux
150
Type of Fixture
Type of
Luminaries
Flame-proof well glass
1 x 70 W
HPMV
lamp
100

vitreous
enamel
reflectors/channel
mounted box type
Lockers,
toilets, wash
rooms, etc.
Elevator well
100
Channel mounted box

type
50
Industrial bulk head
Building
periphery
lighting
50
Energy
Efficient
FTL/1 x 70
W HPMV
lamp
Energy
Efficient
FTL
1 x 100 W
incandesce
nt lamp
70 W
HPSV
lamp / 400
W HPSV
lamp
Industrial well glass

with integral mounted
control gear/industrial
bulk head with integral
mounted control gear/
flood light fittings with
timer control
Decorative
recessed Energy
type FTL
Efficient
FTL
Flood
light
with 400 / 250
weatherproof
fixture W HPSV
with timer control
lamp
Street
weatherproof 150 / 250
fixture
with
timer W HPSV
control
lamp
Flood
light
with 400 / 250
weatherproof
fixture W HPSV
with timer control
lamp
1.5
Office Rooms
300
1.6
1.7
Transformer
yard and
Switchyard
Street lighting
50 on
equipment,
20 general
20
1.8
Parking area
70
[Logo of Utility]
DC LIGHT FITTINGS
Document Number
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No.
Description
Page
No.
Date of Issue
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1.4.6
Sl.
No.
Area/Structure
1.1
Control room
Average
Illumination
Level in Lux
400
1.2
Other areas
250
[Logo of Utility]
Type of Fixture
Type of
Luminaries
Energy
Efficient CFL lamp
2x40W FTL industrial
type
of
vitreous
enamel finish and with
Electronic
choke
suitable for 220V DC
operation
Energy
Efficient CFL lamp
2x40W FTL industrial
type
of
vitreous
enamel finish and with
Electronic
choke
suitable for 220V DC
operation
Area wise distribution of Lighting system in plant

Area wise lighting distribution shall be as below:
Table: 3.0
Area/building
Percentage Distribution of Lighting

Normal
Normal & 220V DC
Emergency
(all 80%
20%
10%
Turbine Generator Building

the bays)
Control rooms
Boiler Area (Grade level &
Platforms)
Service building
Various pump houses and
electrical switchgear rooms such
as AHP, CHP, FOPH switchgear
room, etc.
Electro static precipitator
Switchyard and Transformer yard
1.4.7
80%
80%
20%
20%
10%
5%
90%
90%
10%
10%
5%
5%
90%
80%
10%
20%
5%
5%
Lighting System Design

The lighting system design shall comply with the acceptable norms and the
best engineering practices. The system design shall consider principles of
Document Number
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No.
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No.
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[Logo of Utility]
lighting specified in following paragraph. The lighting layout shall be

designed to provide uniform illumination with minimum glare. The layout
design shall meet all the statutory requirement, local rules etc.
a. Indoor Lighting
The recommended values of illumination level for various areas in the
plant are indicated in the table above. Lighting layouts shall be designed
such that the ratio of minimum to average illumination shall not be less
than [0.6]. Following factors shall be considered while arriving at the
utilization factor to determine the number of fixtures for each
area/buildings in the plant.
i.
Maintenance Factor:
ii.
Air conditioned clean interiors like office rooms, Laboratories,

Auditoriums : 0.8
Air conditioned clean interiors like office rooms, Laboratories,
Auditoriums : 0.8
Industrial areas with normal interiors such as workshops, stores
: 0.7
Industrial areas with dusty interiors : 0.6
Industrial areas with very dusty interiors such a crusher house
and junction towers : 0.5
Reflection factor for wall/ceiling
White and very light colors
Light colors
:
:
0.7
0.5
Middle tints
:
0.3
Dark colors
:
0.1
iii.
The working plane shall be considered at 0.85 m from the floor
level.
iv.
The value of the ratio of spacing (S) to mounting height (H) shall
be commensurate with the type of fittings selected and uniformity
of illumination. The suspension height for suspended fixtures shall
not exceed 1 meter.
b. Outdoor Lighting
i)
The recommended illumination levels for outdoor areas are indicated

in the above table.
ii)
Mounting height, spacing of flood lights shall be based on lamp

wattage, uniformity of illumination and vertical angles. Ratio of
minimum to average illumination shall not be less than 0.3 and for
minimum to maximum shall not be less than 0.05.
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No.
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No.
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[Logo of Utility]
iii) Maintenance factor shall be generally 0.6 under average conditions.

iv) Flood lights for area lighting shall be mounted on building structures.
For outdoor lighting i.e. around the power plant building and
transformer yard provision to be made with 400W outdoor type
lamps mounted on wall/structures.
v) Automatic switching ON/OFF shall be shall be provided through
timers/photo cells.
vi) For road illumination inside the boundary limit lighting poles shall be
provided and the distance between the poles shall not exceed 30m.
vii) Aviation obstruction lights shall be provided on tall installations
(Chimney, Cooling Towers etc) as per Airports Authority and
international standards. Aviation warning lights shall be high intensity
type-A flashing LED type with varying intensity for day and night.
viii)In an area, the lighting fixtures shall be arranged in different phase /
LPs such that even in case one lighting panel is faulty complete
lighting is not affected. In any location the lighting shall be arranged
from two phases.
c. The circuit loading on each circuit shall be restricted to 80% of the MCB
rating.
d. The voltage drop from LDB and any fixture shall not exceed 3%.
e. All lighting design calculations, layouts, conduit wiring diagrams, LDBs
and LPs drawings and technical data sheets etc shall be furnished for
Owner/ Owners consultants approval.
1.4.8
Lighting system equipment

a. Lighting Distribution Boards (LDB) & Lighting Panels (LP)
i.
The Lighting Distribution board shall be fed through 415V/433V

lighting transformers with off circuit taps 5% in steps of 2.5%.
The lighting transformer shall be cast resin dry type , vector group
of [Dy1], class F insulation with temperature rise limited to class F
and shall be housed in a suitable enclosure. In general, the
transformers shall confirm to the specification covered under
Service transformers. The lighting distribution boards shall consist
of MCCB incomer and required number of double pole MCB
controlled out going feeders to LPs. The LDB shall be designed for
the required short circuit level of [20] kA. All the distribution
boards shall be sheet steel clad, dust and vermin proof, cubicle
type with degree of protection conforming to IP-52. Outdoor
panels shall be weather proof type with IPW-55 protection. The
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[14]
25.09.2014
Power Plant]
[Logo of Utility]
thickness of sheet steel enclosures shall be CRCA, 2 mm

minimum for load bearing and 1.6 mm for other members.
ii.
Number of outgoing feeders in each LDB shall be provided as per
requirement including the minimum 3 nos spare feeders for
Purchaser use. Each outgoing MCB in LDBs shall be of 15 A,
but load to be limited to 2 kW or maximum 10 nos. fittings to be
connected to one MCB
iii.
Individual control in office buildings shall be through single pole
flush type switches/MCBs. In those areas where group controls
are required, rotary switches shall be provided
iv.
External area lighting shall be fed from separate boards located at
suitable places. Automatic switching ON/OFF of these circuits
shall be done through timers/photo cell.
v.
In high bays, walkway shall be provided for maintaining light
fittings. At other places suitable ladder / platform / approach shall
be provided for maintaining / replacement of light fittings.
vi.
Each of the LDBs shall be provided with voltmeter and ammeter
along with selector switches, SUPPLY ON indicating lamps, etc.
The switch boxes, receptacle boxes etc. shall be made up of 18
SWG sheet steel.
vii.
Two ground pads with bolts and nuts shall be provided on each
board for connection to 50x6/25x3 mm GS flat.
b. Lighting Fixtures and Lamps
i)
Fluorescent fixtures with electronic ballast shall be generally

provided for a room height upto 5m. Type of fixture shall be
industrial type with gasket, clear acrylic cover and enamelled
reflector or decorative type to suit the aesthetics. For areas with
false ceiling, recessed mounted decorative fixtures with mirror
optic louvres shall be used. In control room / computer rooms,
decorative mirror optic fluorescent light fittings with antiglare
features shall be provided. The surface finish shall be smooth,
unobtrusive and scratch resistant.
ii)
Reflector shall be of sheet steel or aluminium, minimum 20 SWG

thick and securely fixed by fastening device of captive type.
iii)
Fixture shall be suitable for 19 mm conduit entry and 16 SWG GI

earth wire connection.
iv)
Fixture shall be furnished complete with lamps and integrally

mounted accessories. These shall include holders, ballast,
capacitor, starter, ignitors (separate type) etc.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[15]
25.09.2014
Power Plant]
[Logo of Utility]
v)
For corrosive areas, corrosion proof lighting fixture shall be

provided. For hazardous areas, light fittings, conduits, junction
boxes etc. shall have to meet the corresponding area classification
requirement.
vi)
Medium bay or high bay type of lighting fixtures with HPMV/HPSV

lamps shall be used depending on the mounting heights for indoor
areas having room height more than 5m. Medium/ High bay fixtures
shall be provided with vibration damper wherever required.
vii)
For areas like boiler and outdoor areas such as roads, street,
transformer areas and open yards, weatherproof HPSV flood/ street
lighting fixtures shall be used. For areas like boiler platforms,
weatherproof well glass type HPSV fixtures with wire guards shall
be used.
viii)
All type of fluorescent lamps including Compact Fluorescent Lamp

(CFL) shall be bi-pin rotary type and either cool daylight or white.
ix)
Mercury / Sodium vapour lamp shall be colour corrected type with

screwed cap.
x)
Lamps shall be suitable for use in position and capable of

withstanding small vibrations.
xi)
Ballasts shall be of heavy duty, low loss and polyester-filled type

with copper winding.
xii)
Ballasts for Mercury / Sodium vapour lamps shall be provided with

suitable tappings to set the voltage within range specified.
xiii)
Ballasts shall be free from hum. Ballasts which produce humming

sound shall be replaced, free of cost.
xiv)
In multi-lamp fixture, each lamp shall be provided with individual

ballast.
c. Switches, Receptacles
i.
In the plant areas, the lighting circuits shall be controlled directly
from the MCBs in the lighting panels. Wherever the lighting panel
is not in the same area, separate switches shall be provided. For
cabins, rooms, etc., separate switches shall be provided for each
point. Similarly for entrances, building periphery lighting separate
switches shall be provided
ii.
240V, 50 Hz, 3 pin Power Receptacles (5A, 15A) shall be
provided in all building/areas of the plant. Inside a building,
receptacles shall be provided at interval of 30m or part thereof for
hand tools, water coolers, exhaust fans etc. Inside each cabins at
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[16]
25.09.2014
Power Plant]
[Logo of Utility]
least two receptacles shall be provided and the same shall be

indoor/outdoor/flameproof as per the location. Minimum 2 nos of
5A and 1 no 15A receptacles shall be provided in each room.
Receptacles shall be heavy duty, complete with individual plug
and switch as described below:
Table: 4.0
S.No.
Type
Description
RA
5A, 240V, 2 Pole, 3 Pin with third pin earthed - Suitable for
flush mounting in office areas and control room. The switch
shall also be flush mounting piano type.
RB
15A, 240V, 2 Pole, 3 Pin with third pin earthed - Wall/

column mounted, metal clad gasketed construction, suitable
for 19 mm conduit entry, screwed metal cover tied with metal
chain, weatherproof construction suitable for indoor/outdoor
installation. This shall be provided at an interval of 30m, or
minimum one in each room.
RC
63A, 415V, 3 Phase, 5 pin interlocked plug and switch with

fifth pin earthed.
Wall/column mounted, metal clad gasketed construction
weather proof, suitable for loop in/ loop out connection of 4
Core 35 sq.mm AYWY cable. These receptacles shall be
provided at an interval of 50m throughout the Plant Area.
RD
100A, 415V, 3 phase, 5 Pin interlocked plug and switch with

fifth pin earthed
Wall/column mounted metal clad gasketed construction
weather proof, suitable for loop in/ loop out connection of 3.5
Core, 95 sq.mm AYWY cable.
d. Cables and Wiring

i.
Wiring from lighting DBs/panels to individual fixtures, plug points,
fans, etc. shall be of single core, 2.5sq.mm, 1100 V grade PVC
stranded copper conductors through surface mounted or
concealed medium duty GI conduits confirming to IS 1239 with
earth wire. The wires in the conduits shall not exceed 60% of the
conduit area.
ii.
1100V grade stranded copper conductor, PVC insulated, colour
coded, wires laid in GI conduits shall be used for lighting in nonhazardous area. In the hazardous area, outdoor areas like
transformer yard and road lighting, cabling shall be adopted. The
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[17]
25.09.2014
Power Plant]
[Logo of Utility]
specification of cable shall conform to the details indicated in

Cabling System section.
iii.
Minimum size of wires in case of conduit wiring shall be
2.5sq.mm copper in case of lighting and 4sq.mm copper in case
of receptacle wiring
iv.
Wires of different phases shall be run in separate conduits.
However, wires of same phase but having different circuit nos.
can be run in same conduit.
Wires of lighting and power
receptacles shall be carried out in separate conduits and on
separate circuits. Wires of AC and DC lighting system shall be
carried out in separate conduits
v.
For outdoor lighting, the cable shall be buried at a minimum depth
of 750 mm from ground level or run in cable trays. The buried
cables shall have suitable bedding, protective covers and markers
vi.
Material used for saddles, clamps, JBs, etc. shall be galvanized
vii.
Office buildings, laboratory buildings shall have concealed wiring
with 2.5sq.mm wires using PVC conduits. In heat zones, i.e. in
the areas where ambient temperature is 600 C and above, heat
resistant control cables shall be used in hot dip galvanised rigid
steel surface mounted conduits
e. Fans and Regulators
i.
The fans shall have three well balanced blades, double ball
bearings and shall be reasonably free from noise. Fan motor shall
be totally enclosed type with copper winding and class-E
insulation. Sweep shall be given as 1200 /1400 mm.
ii.
Regulators shall have minimum five steps. Electronic Regulators
with smooth control shall be provided.
f. Flame-Proof Equipment
i.
The enclosure of all flameproof equipment for use in hazardous

areas where gases/vapors of Group I, IIA, IIB are present, shall be
of cast iron/cast aluminum, stove enamel finished. Chemical
corrosion resistant epoxy finish shall be provided in corrosive
areas. The construction shall comply with relevant applicable
standards
ii.
If the enclosures are additionally required to be weather proof,

neoprene gaskets shall be provided to make the enclosure dust
and weather proof providing a degree of protection of IPW 55.
iii.
All ferrous parts, exposed to atmosphere shall be suitably

plated/galvanized
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[18]
25.09.2014
Power Plant]
[Logo of Utility]
iv.
All internal wiring shall be connected to terminal blocks provided

in terminal enclosure on incoming side.
v.
Flameproof cable gland entries shall be provided suitable for the

cable sizes. The number of required cable entries for
junction/terminal boxes as required for branching, terminating of
cables for lighting distribution shall be provided. All unused cable
entries shall be closed by flameproof plugs.
vi.
Flameproof receptacle unit (socket with associated switch/MCB

and plug) shall have interlocking feature such that plug cannot be
inserted or taken out with switch/MCB in ON position.
vii.
Adequate mounting lugs with necessary hardware shall be

provided for mounting the equipment on wall/structure.
viii.
These enclosures shall have inscription warning against opening

the enclosure unless the circuit is isolated. Equipment rating and
ON/OFF positions of switches/MCBs shall also be designated.
ix.
The BIDDER shall indicate that the enclosures have been tested
and certified by relevant statutory authorities for use in hazardous
areas.
g. Lighting poles and towers

i.
Lighting poles for street lights and flood lights shall be of swaged
and welded steel, pole of height 9M/11M and shall conform to
relevant standard. Poles shall be hot dip galvanized internally and
externally after fabrication as per IS 2629 / IS 2633 / IS 4759
standards. The Poles shall be designed to withstand the maximum
wind speed as per IS 875. The steel sheet used to manufacture
steel poles shall be of minimum thickness of 3 mm and shall
conform to relevant standard . Junction boxes shall be provided
with weather proof flush doors and locking facility. Bidder shall
design and furnish the foundation drawings for the poles to
withstand basic wind speed of minimum [50 ]meter/sec.
ii.
The supply of poles/Towers shall be complete with base plate,
foundation bolts, hot dip galvanized brackets / necessary pipe
reducer for fixing the fitting and also include the necessary
associated pole mounted junction boxes.
iii.
Towers for mounting flood lights shall be e of continuously
tapered poly gonal cross section and shall be supplied with all
acesssories. Steel structure for towers shall be made of hot dip
galvanized steel. A steel ladder and platform at the top shall be
provided. The length of each step of the ladder shall be at least
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[19]
25.09.2014
Power Plant]
[Logo of Utility]
300 mm and spacing between two adjacent steps not more than
300 mm. The structure shall be suitable for mounting the required
number of flood lights, weights of maintenance crew and specified
wind pressure. The factor of safety shall be [2] for each part and
section. The Contractors structural design drawings shall be
approved by the Purchaser before fabrication.
1.4.9
Name Plate
Name plates shall be furnished for identification of devices and circuits. All
switches, controls and indications shall be permanently and legibly marked in
English regarding the functions.
1.4.10
Painting
All surfaces shall be sand blasted, pickled and grounded as required to
produce a smooth, clean surface free of scale, grease and rust.
After cleaning, the surfaces shall be given a phosphate coating followed by 2
coats of high quality primer and stoved after each coat.
The equipment shall be finished in approved color shade by owner with two
coats of epoxy based powder coated paint. The coating shall be done electro
statically followed by stoving.
Sufficient quantity of touch-up paint shall be furnished for application at site.
1.5
Tests
I)
Type Test
The Bidder shall submit for Owners approval the reports of all the type tests
as per relevant standards and carried out within last[five] years from the date
II)
Routine Test

tested as per relevant IS / IEC Standards at manufacturer's works/site in the
Tests on Lighting Distribution Boards / Panels shall include:
a. Wiring continuity tests.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[20]
25.09.2014
Power Plant]
[Logo of Utility]
b. High voltage and insulation tests.

c. Operational tests.
III)
Test Witness
1.6

below:
a) Lighting panels & distribution boards.
b) Receptacles & Junction boxes.
c) Street light poles & towers.
d) Lighting fixture complete with lamps and accessories.
e) Non-integral/separate type control gear box for lighting fixtures, as
applicable.
f) Lux level calculations for each area.
g) Data sheets for lighting fixture, lamps, accessories with light distribution
curves, co-efficient of utilization charts etc. Type and routine test
certificates of transformer and cables.
h) Control schematic and wiring diagram of 415V AC/220V DC lighting
panel with automatic changeover from AC to DC and vice-versa, 415V
normal AC Street/area lighting panel with automatic ON/OFF feature.
i)
Technical leaflets and data sheet on each piece of equipment/ device

such as MCB, switch, fuse, receptacle etc. Type and routine test
certificates of transformer and cables.
j)
QAP and relevant test certificates
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[21]
25.09.2014
Power Plant]
[Logo of Utility]
k) Lighting layouts showing the disposition of fixtures, lighting

panels/boards, circuit distributions, conduit & wire routing.
l)
1.7
Key Single Line Diagram for lighting distribution, board wise single line
diagram with feeder loading, cable schedule and interconnection chart,
design calculation for lighting.]

S. No.
DESCRIPTION
UNIT
DATA
1.0
GENERAL
1.1
Normal Supply Voltage, Phase and

Frequency
AC
240V, 1Ph, 50Hz
DC
220V DC
a) Voltage
10
b) Frequency
c) Combined voltage & frequency
10
1.3
Design Ambient Air Temperature
50
1.4
System Short-Circuit Level

a) At 415V AC
kA(rms
)
50KA for 1 sec
b) At 220V DC (For DC LP)
kA(DC)
[10] kA for 1 sec
1.2
Variation in Supply
1.4
Luminaries Earthing Terminal

Suitable for
a
Conductor material
Conductor size
G.I
SWG
12
2.0
Lighting Distribution Board and

Lighting panel
2.1
Manufacturer Name
2.2
Rated Voltage, phase and

Frequency
AC
415V, 3phase, 4 wire,

50Hz
2.3
One Minute Withstand Voltage
2500
2.4
Mounting Type
[By bidder]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[22]
25.09.2014
Power Plant]
S. No.
DESCRIPTION
UNIT
[Logo of Utility]
DATA
a) LDBs
Floor Mounted
b) Single Phase LP
Wall/Structure mounted
2.5
Type and no of circuits & feeder

rating
[As per project

requirement]
2.6
Colour shade
[RAL 5012]
2.7
Lighting Transformer
a) Type
Epoxy cast resin dry

type
b) Voltage Ratio
415/415V
c) Taps
+/-5%
d) Vector Group
[Dyn1]
e) Impedance
[5%]
f)
KVA
[As per project

requirement]
Rating
3.0
Fixture details:
3.1
Name of Manufacturer and

Country
[By Bidder]
3.2
Luminaries
[By Bidder]
a) Fluorescent
b) HPMV
c) HPSV
d) Metal Halide
e) Compact Fluorescent Lamp
f) Flame proof
3.3
Applicable Standards for
[By bidder]
a) Luminaires
b) Accessories
3.4
Manufacturers type and Catalogue

No.
[By bidder]
a) Luminaires
b) Accessories
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[23]
25.09.2014
Power Plant]
UNIT
[Logo of Utility]
S. No.
DESCRIPTION
4.0
Schedule of fitting and Accessories
[As per project

requirement]
5.0
Technical details of luminaries
[By bidder]
5.1
Lamps
a
Maximum permissible supply

voltage variation
Luminous output
c
5.2
i)
After 100 burning hours
Lumen
s
ii)
Lumen
s
Average burning hour life
Hours
[By bidder]
Ballasts & Starters

a
Maximum permissible supply

voltage variation
Power loss at nominal working

voltage
Maximum hot spot temperature of

ballast
Conductor material of ballast
Insulation class of ballast winding
Average life of
5.3
i) Ballast
Hrs.
ii) Starters
Hrs.
Capacitors
a
5.4
[By bidder]
Power factor
[By bidder]
Luminaries
a
Weight of luminaries
Earthing terminal
Kgs
i) Material
DATA
G.I
ii) Suitable upto conductor size
SWG
Internal wiring size
Sq.mm
12
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[24]
25.09.2014
Power Plant]
S. No.
DESCRIPTION
UNIT
Terminal block suitable for

conductor size
Sq.mm
Sheet steel thickness of

i) Housing
SWG
ii) Reflector
SWG
Wire guard thickness
mm
Descriptive catalogues enclosed
Yes/No
[Logo of Utility]
DATA
6.0
Miniature circuit breaker
[By bidder]
6.1
Make
6.2
Type
6.3
Literature enclosed
7.0
Earth leakage circuit breaker
7.1
Make
7.2
Type
7.3
Leakage Current I
7.4
Literature enclosed
8.0
Instrument transformers
CTs VTs
8.1
Make
[By bidder]
8.2
Type
[By bidder]
8.3
Output
8.4
Accuracy Class
8.5
Literature enclosed
9.0
Meters
VOLTMETER AMMETER
WATTMETER
9.1
Make
[By bidder]
9.2
Type
[By bidder]
9.3
Accuracy Class
[By bidder]
9.4
Literature enclosed
10.0
Relays (if any provided)
10.1
Make
Yes/No
[By bidder]
mA
Yes/No
VA
[By bidder]
[By bidder]
Yes/No
Yes/No
[By bidder]
[By bidder]
[By bidder]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[25]
25.09.2014
Power Plant]
S. No.
DESCRIPTION
UNIT
10.2
Type
10.3
Voltage Rating
10.4
Setting Range
10.5
No. of Contacts
[Logo of Utility]
DATA
a)Normally open
b)Normally closed
10.6
Literature enclosed
Yes/No
11.0
11.1
Make
11.2
Suitable for use in hazardous area
[By bidder]
a)Area classification
[Fuel oil pump house,

Main oil tank area]
b)Gases/Vapor group
[By bidder]
11.3
Dimensional Drawings and

Literature of each required
equipment flameproof enclosure
including fixing details enclosed
Yes/No
[By bidder]
11.4
Approval certificates of relevant

statutory authorities enclosed
Yes/No
[By bidder]
12.0
Lighting Control Switches
12.1
Make
12.2
Decorative
12.3
Industrial
12.4
Flame proof
12.5
Literature Enclosed
13.0
Receptacle units
13.1
Make
13.2
Decorative
13.3
Industrial
13.4
Flame proof
13.5
Literature Enclosed
[By Bidder]
Yes/No
[By Bidder]
Yes/No
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[26]
25.09.2014
Power Plant]
UNIT
[Logo of Utility]
S. No.
DESCRIPTION
DATA
14.0
Lighting wires
[By Bidder]
14.1
Make
[Point wiring with

respect to different
length shall be
furnished]
14.2
Applicable Standard
14.3
Voltage Grade
14.4
Conductor Material
Cu/Al
14.5
Size
Sq.mm
14.6
No. of Strands
14.7
Colour Coding
15.0
Conduits
15.1
Make
15.2
Rigid Steel
15.3
Rigid Non-metallic
15.4
Sizes offered and wall thicknesses
15.5
Supply of necessary couplings,

bends, tees, necessary for conduit
routing included
Yes/No
15.6
Literature Enclosed
Yes/No
16.0
Junction boxes
16.1
Make
16.2
Material and Gauge
16.3
Galvanised
16.4
Dimensioned Drawings Enclosed
Yes/No
16.5
Weather Proof Construction

Required
Yes/No
16.6
Flame Proof / Non-flame proof
17.0
Lighting poles/towers
17.1
Make
17.2
Type of Poles/Towers
[By bidder]
Galvanized
[By bidder]
Yes
[By bidder]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[27]
25.09.2014
Power Plant]
S. No.
DESCRIPTION
UNIT
17.3
Dimensioned Drawing/Particulars
of Flood Light Tower enclosed
Yes/No
17.4
Junction Box with Pole
Yes/No
18.0
Ceiling fans
18.1
Make
18.2
Blade Sweep
mm
18.3
Suspension Rod Length
mm
[Logo of Utility]
DATA
[By bidder]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[28]
25.09.2014

OF

R&M CONTRACTORS
VOLUME-II
TECHNICAL SPECIFICATION FOR CABLE CARRIER
SYSTEM
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-E10
1.0
CABLE CARRIER SYSTEM
1.1
General
Cable Carrier system complete with all accessories for efficient and trouble
free operation of R&M of Unit No. [..] of [Name of the Power Plant] at
[District], [State] for [Name of the Client].
1.2
Codes and Standards

Table 1.0
IS 800
Code of Practice for structural Steel
IS 1646
Code of Practice for Fire Safety of buildings
IS2667
Fittings for Rigid steel Conduits
IS 3419
Fittings for Rigid Non Metallic Conduits
IS 3837
Accessories for Rigid Steel Conduits
IS 4649
Adaptors for Flexible Steel Conduits
IS 5216
Guide for Safety Procedures and Practices in electrical Work

Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[1]
25.09.2014
Power Plant]
1.3
[Logo of Utility]
Design Criteria
a) Cable and cable trays shall be installed in an ambient temperature of 50
C and relative humidity of 95%.
b) The cable carrier system shall be designed considering the following:
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
1.
Facility for easy laying of cables.
2.
Access to maintenance.
3.
Neat and aesthetic appearance.
4.
Safety of equipment & personnel.
5.
Ground water seepage.
Cables shall be laid in prefabricated ladder/perforated type trays and in
conduits. Direct burial of cable shall be mostly avoided.
Upper cable trays and all vertical cable trays shall be provided with tray
covers.
Cable filling in the trays or racks shall not exceed 80%. Conduits if used,
the wires in the conduits shall not exceed 40% of the conduit area.
Different voltage grade cables shall be laid in separate trays when trays
are arranged in tiers. H.V cables shall be laid in top trays and cables of
subsequent voltage grade in lower tier of trays. Instrumentation cables
shall be laid at bottom most tray.
At least 300mm clearance shall be provided between HV and LV cables
& LV and control/Instrumentation cables.
Support system for cables shall be prefabricated type.
Single core cables shall be laid in trefoil touching formation. Trefoil clamp
shall be provided in a staggered manner.
1100V grade power cables of [120] mm2 size and above shall normally
be laid in single layer in trays/on racks.
1100V grade power cables below [120] mm2 may be run in double
layers in case of space restrictions.
Control and instrumentation cables can be laid up to a maximum of three
layers in each tray/rack.
1.4
1.4.1
Scope of work:
The scope of work shall include Design, Preparation of Cable Tray,
Trench/Duct bank/Conduit Layout, supply of Cable tray and its Accessories,
unloading at site, storing, laying, fixing, jointing/termination, erection, testing
and commissioning of equipment associated with the Cable Carrier System
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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[Logo of Utility]
for following package. The below list indicates area where cable carrier
system to be provided but not limited to:
modified.]
a) TG Area:
i) TG Platforms.
ii) TG area Grade Levels Maintenance area.
iii) Preparation of Cable schedules and Inter Connection
schedules/Diagram.
iv) Laying and Termination of power & control cables for all the
equipments of TG package.
b) Boiler Area:
i) Boiler Platforms
ii) Boiler Grade Levels covering coal mill and Maintenance area.
iii) ESP Platforms
iv) ESP/FOPH switchgear room.
v) FOPH area.
vi) Preparation of Cable schedules and Inter Connection
schedules/Diagram.
vii) Laying and Termination of power & control cables for all the
equipments of Boiler package.
c) Balance of Plant Area:
i) Cable Carrier System for Mechanical BOP package like Raw water,
Water pre-treatment, Fuel oil, CW / ACW System and Cooling
Towers, AC and ventilation Vacuum Pump House, Silo Area,
Compressor House, Guard Pond, Effluent Treatment Plant,
Chimney, Fire water pump house, Cable galleries, Transformer
area, all Switchgear Rooms, Control rooms, all roads within battery
limit etc.
ii) Laying and Termination of power & control cables for all the
equipments of BOP package.
d) CHP Area:
i) CHP Switchgear room
ii) Conveyor.
iii) Crusher House
iv) Stacker and Reclaimer
v) Any other area covered in this package.
vi) Laying and Termination of power & control cables for all the
equipments of CHP package.
e) AHP Area:
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
i)
ii)
iii)
iv)
f)
g)
h)
i)
1.4.2
AHP Switchgear room.

Silo Area.
Any other area covered in this package.
Laying and Termination of power & control cables for all the
equipments of AHP package.
i) Switchyard
ii) Transformer yard
iii) Inter plant cabling.
iv) Any other area covered in this package.
v) Laying and Termination of power & control cables for all the
equipments of eBOP package.
All civil and structural works necessary for successful installation and
commercial operation of all electrical equipment to be erected under this
specification. Supply of cement, sand, stone etc. required for the
execution of the contract shall be the responsibility of the Bidder.
All other ancillary works in connection with the items of work described
above which are not specifically mentioned but are necessary to
complete the work.
For Terminal Points and Exclusions of Cable Carrier system and Specific
scope of work Bidder may refer section I of this specification.
General Installation Requirements:

a) Cable trays shall be fabricated from 14 gauge mild steel sheets. Cable
trays shall be of hot dip galvanized Steel of ladder/perforated type,
complete with all necessary coupler plates, elbows, tees, bends,
reducers, stiffeners and other accessories and hardware as detailed in the
relevant drawings to be submitted by Bidder. All hardware (i.e. bolts,
nuts, screws, washers, etc.) shall be hot dip galvanized.
b) Constructional details, supporting arrangement and installation details for
cable trays shall be furnished by Bidder.
c) Each 2.5 meter section of all types of cable trays and all elbows, tees,
crosses, etc. shall be provided with two side coupler plates and
associated bolts, nuts and washers.
d) Cable tray covers shall be fabricated from 16 gauge MS sheets. Cable
tray covers shall be hot dip galvanized and same shall be provided for all
outdoor cable trays and vertical raceways/trays. Covers for vertical
raceways shall be in individual, easily removable sections to facilitate
cable maintenance.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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02

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[Logo of Utility]
e) Cable Tray of Standard width of 600mm shall be followed. However,

trays with 450, and 300, 150 mm width may be used in some places
considering the requirement and space restrictions. For instrumentation
and control purpose, some perforated type cable trays of width 150 mm
may be used particularly in Boiler Platform area, and 600, 450, 300 mm
perforated trays may be used depending on site requirement.
f) Cable trays shall be ladder type with maximum rung spacing 250 mm
depth 100 mm and rung width not less than 50 mm.
g) Cable trays in areas subjected to excessive coal dust, or mechanical
damage shall have hot-dip galvanized sheet metal tray cover installed on
front tray in vertical run and inverted `V' type on upper tray in horizontal
run. Where covers are used on trays containing power cables,
consideration should be given to ventilation requirements. Areas where
corrosive chemicals are likely to be handled, cable tray and covers shall
be epoxy painted.
h) Suitable embedded steel inserts shall be provided on wall/floor/ ceiling
surfaces for welding of cable tray bracket in order to make the cable tray
system withstand horizontal / vertical accelerations due to seismic forces
for indoor trays and also wind load for outdoor trays such as on Boiler
platforms in addition to normal tray cable loadings.
i) Cable installation
work shall mean erection of cable trays/racks,
supports, hangers, junction boxes, conduits, laying of cables either in
ground or on trays inside trenches tunnels/overhead trays in conduits etc.
dressing and clamping, jointing and termination inclusive of supply of
necessary jointing/termination kits, lugs, glands, ferrules, tapes etc. and
other accessories, grounding of cable armor. In case of direct laying in
ground, all excavation work, necessary back-filling, supply of bricks and
protective concrete slabs, removal of excess earth shall be part of the
installation work.
j) Erection of cabling work shall be executed keeping in view all necessities
and requirements of fire fighting codes for Generating Stations having an
adverse industrial environment.
1.4.3
Cable Routing/Laying
a) Cables shall generally be laid on ladder type cable trays either in trenches
or overhead supported from building steel/structures except in some
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No.
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b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
[Logo of Utility]
cases cables may have to be laid underground and for short runs in
conduits for protection while crossing roads and other facilities.
For interplant connections, the cables may be routed through an
overhead cable bridge or cable trenches/tunnels selection being
dependent on site constraints.
For underground crossing of railways, roads etc. hume pipes shall be
used and shall be laid at a depth of minimum 1000 mm such that cables
shall not be damaged.
In boiler area, trench shall be avoided as far as practicable. The cable
racks shall be supported from Boiler structure in vertical configuration
with suitable cover to avoid deposition of coal dust as far as practicable.
Different voltage grade cables shall be laid in separate trays when trays
are arranged in tiers. Power cables shall be on top trays and
Control/Instrumentation cables on bottom trays, and it is recommended
that trays for cables of different voltage levels be stacked in descending
order with higher voltage level above.
Cables for redundant equipment/system shall be run in separate trays in
separate route.
Cables from two different services viz. supply from station board and
supply from unit board shall be fully segregated to prevent simultaneous
damage due to fire in one of the services.
Low level signal cables and other special Instrumentation and Control
cables shall run in separate trays. In general, a minimum of 1500 mm
clearance shall be maintained between these cables and noise generating
equipment (large motors, generators, transformers etc.).
The cable spreaders of each unit shall be compartmentalized by provision
of fire proof partition wall and fire proof doors.
The floor of the cable spreader rooms shall have to be made water proof
so that water does not percolate to lower levels in the event of fire
fighting operations. Adequate arrangement for efficient drainage of water
shall be provided. The cable raceways should also be suitably planned to
avoid water entry through this place.
Cables shall generally be laid on cable trays either in concrete trenches or
overhead supported from building steel/structures. Cables shall be run in
concrete trenches in those electrical rooms at ground level, which are
without any spreader room below. In mechanical equipment areas
(Indoor), overhead cable trays shall generally be used.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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l)
1.4.4
[Logo of Utility]
For inter plant connections, the cables shall be routed through an

overhead cable bridge pipe cum Cable Bridge. For isolated but long
outdoor cable route with very few cables of 3/4 nos., the cables may be
directly buried with prior permission from the purchaser.
Installation of Cables
a) The Bidder shall install, terminate and connect up all cables and conduits
with supporting arrangements as per drawings, cable schedules and
interconnection chart/drawings.
b) The HV power cables of 6.6kV shall be laid in trays or racks as follows:
i) In single layer only.
ii) 3 core cables to be laid in touching formation.
iii) Cables in trefoil groups of the same circuit shall be laid as indicated
below so as to ensure balanced current distribution:
Y
R
Y
B
Y
R
Y
B
and so on.
c) 1100V grade power cables shall be laid in single layer in trays depends
on size of cables. Cable of up to 120 sqmm shall be laid in two layers.
Beyond this size single layer will be followed.
d) Control and Instrumentation cables can be laid up to a maximum of three
layers in each tray.
e) The trays shall be run with a vertical spacing of 300 mm for overhead
cable trays as well as inside cable trenches. A minimum of 225 mm
clearance shall be provided between the top of tray and beams, cold
piping, 500 mm clearance for hot piping/object to facilitate installation of
cables in tray.
f) Adequate pull boxes shall be provided in conduit run to facilitate cable
pulling in long runs and also to ensure that there shall not be more than 2
nos. 90 Deg. Bends between pull points.
g) Cable tray/conduit system shall be installed to accommodate cable
manufacturer's recommended maximum pulling tension, minimum
bending radius and no. of bends.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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[Logo of Utility]
h) All openings in the floor and wall for cable access shall be sealed
after installation of the cable system with non-inflammable materials, as
follows :
Fire stop/Penetration seal shall be installed in the cable spreaders
and cable raceways.
Similarly in the trenches fire stop/penetration seals shall be
provided at suitable interval to avoid spread of fire.
For all HV, LV, Relay and Control panels, Control desk,
instrumentation panels, battery charger, D.C. Dist. boards and
other miscellaneous panels, fire-stops should be provided below
base plate.
i) All floor/wall openings for cable entry to the electrical equipment
and accessories shall be sealed with non-inflammable materials, after
completion of cable installation. Thickness of such materials shall be
equal to the thickness of floor/wall unless specified otherwise.
j) The portion of galvanized steel, which, if required, undergoes any
welding at site, shall be coated with two (2) coats of cold galvanizing
anti-corrosive paint after welding.
1.4.5
Cable Termination and Joints (if applicable and not covered in cable
specification)
a) The Bidder shall supply cable termination and jointing kits in requisite
quantity for HV. Power Cables, LV. Power, Control Cables, etc. along
with all accessories & consumables required for making termination and
joints complete . All the materials and components of the
termination/joints shall be suitable and compatible with the type of cables
for which the terminals/joints are intended.
b) The straight through joints of HV. cables shall be heat shrinkable and pre
moulded push on type. The end termination kits for HV. cables shall be of
{Raychem/3M/Elastimold} type. Cable joint or end terminations on
Electrical equipment shall be suitable for Indoor & Outdoor use, as the
case may be.
c) Glands and lugs required for termination of HV, LV. shall be supplied by
the Bidder in required quantity.
d) Cable glands shall be tinned brass gland, double compression type
complete with necessary armour clamp and tapered washer etc. Cable
glands shall match with the sizes of different HV/LV/Control cables.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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[Logo of Utility]
e) Cable lugs shall be suitable for termination of different cross-sections of

L.V./Control cables and shall be of following types:
i. Aluminium tubular terminal end for solderless crimping to aluminium
conductors.
ii. Copper tubular terminal end for solderless crimping to copper
conductors.
iii. Solderless crimping of terminals shall be done by using
corrosion inhibiting compound. The cable lugs shall suit the type of
terminals
provided
on
the
equipment.
Lugs
for
control/instrumentation cables shall be PVC insulated/sleeved type.
iv. Cable lugs for control cable termination shall be insulated. These lugs
shall be pin type/flat type/ring type/U type to suit the terminals
provided in the panels.
v. The terminations shall with tinned copper only.
vi. For mill area, the cable shall be routed through GI pipes embedded in
Ground.
vii. In heat zone areas as far as possible the cables shall be taken away
from the area to avoid heat. If cabling in the heat zones can not be
avoided, the cables shall be terminated in junction box of IP 67
protection class away from the heat zones and small length of
cables may be laid from junction box to the respective equipment
to facilitate easier replacement in case of fire. Bunching of cables in
the heat zones and boiler areas shall be avoided and laid in separate
groups.
1.4.6
Identification
a) The complete cabling system shall be properly identified. Methods for
identification of cabling system will be furnished to the Bidder and the
Bidder shall strictly adhere to the said methods.
b) Each cable and conduit run shall be tagged with numbers that appear in
the cable and conduit schedule.
c) Location of cables laid directly underground shall be clearly indicated with
cable marker made of galvanized iron plate, projected above ground level.
d) Cable tags shall be provided on all cables at each end (just before
entering the equipment enclosure), on both sides of a wall or floor
crossing, on each duct/conduit entry, at each bend and at every thirty
(30) meters in cable tray/trench runs. Cable tags shall also be provided
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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[Logo of Utility]
inside the switchgear, MCC, control & relay panels etc. wherever
required for cable identification, such as where a number of cables enter
together through a gland plate.
1.5
Tests
I)
Type Test
as per relevant standards and carried out within last[five] years from the
date of bid opening. These reports should be for the tests conducted on the
II)
Routine Test

a) Checking of continuity / phasing and IR values for all the cables before
and after HV test
b) Checking of continuity / phasing and IR values for all the cables before
and after HV test.
c) HV test and measurement of leakage current after termination of cable
kits (for HT cables).
d) Checking of earth continuity for armour.
e) Check for mechanical protection of cables.
f) Check for identification (tag number system) distance placement of cable
marker, cable joint etc. as per the cable layout drawing.
g) Check earthing of cable structures.
h) Check safe head room in gallery area
i) Check clearance from ventilation duct and light fittings for cable
structures.
j) Check proper fixing of cable structures.
k) Check for proper drainage and removal of water (if any).
III)
Test Witness
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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[Logo of Utility]
1.6

below:
a) [General arrangement drawing Cable Tray]
b) [Cable Tray Accessories like Tee, Cross, Bends, Coupler, Reducer etc]
c) [Cable Tray support materials]
d) [Technical Data sheets for cable carrier system].
1.7

SL NO.
DESCRIPTION
UNIT
DATA
1.
Make/Manufacturer
2.
Size of Tray
3.
Material
Galvanised Steel
4.
Application
[As per project requirement]
5.
Type of Tray
[Ladder/Prerforated]
6.
Thickness of Tray
7.
Thickness of Galvanization
8.
Tray Cover Size
9.
Cable Tray Accessories
[By bidder]
mm
mm
[600/450/300/150]
2mm
[100 microns]
mm
[As per project requirement]

[By bidder]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
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SL NO.
DESCRIPTION
UNIT
9.1
Tee
mm
9.2
Cross
mm
9.3
Bends
Deg
9.4
Reducer
mm
9.5
Steel Supports
9.6
a) ISMC
mm
[Logo of Utility]
DATA
a) [100]
b) [50x 50 x 6]
b) ISA
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
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OF

R&M CONTRACTORS
VOLUME-II
TECHNICAL SPECIFICATION FOR EARTHING AND
LIGHTNING SYSTEM
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Tender Document for R&M of Unit No. [..] of Capacity [Name of the
Power Plant]
[Logo of Utility]
ANNEXURES-E11
1.0
EARTHING AND LIGHTNING PROTECTION SYSTEM
1.1
General
Earthing and Lightning Protection System complete with all accessories for
efficient and trouble-free operation of R&M of Unit No. [..] of [Name of the
Power Plant] at [District], [State] for [Name of the Client].
1.2
Codes and Standards

Table 1.0
IS:2309
Code of Practice for the protection of building and allied

structures against lightning.
IS:2629
Recommended practice for hot dip galvanizing of iron & steel
IS:2633
Method for testing uniformity of coating on zinc coated articles.
IS:3043
Code of practice for Earthing
IS:9537
Conduits for electrical installation.
IEEE:80
IEEE guide for safety in AC substation grounding
IEEE:142
Grounding of Industrial & commercial power systems
CEA
CEA Regulations and standard technical specification for main

plant package.

Document Number
Rev
No.
Description
Page
No.
Date of Issue
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1.3
[Logo of Utility]
Design Criteria
a) Earthing system design shall consist of earth grids and electrodes buried
in soil in the whole plant area, embedded in concrete inside all the
buildings to which all the electrical equipment, metallic structures are
connected to have earth continuity for safety reasons.
b) The main objectives of earthing system is to:
1. Provide safety to personnel from contact of dangerous potential
caused by ground fault.
2. Ensure sufficient grounding current for effective relaying.
3. Stabilize circuit potential with respect to ground.
c) The earthing conductor shall be designed for fault current of [50 kA] for
duration of 1 second.
d) It is the responsibility of the Bidder to undertake the soil resistivity
measurements at site and select suitable size of conductor based on the
soil resistivity.
e) Ground conductor shall be of galvanized steel for above ground and mild
steel for embedded and below ground earthing.
f) Main earth grid conductor shall be mild steel (MS) of [40] mm dia.
g) Suitable corrosion allowance shall be considered over ground conductor
size depends upon soil resistivity.
h) The main purposes of lightning protection system are to :
1. Provide protection to structures from lightning strokes.
2. Provide a low resistance-conducting path to lightning discharge.
3. Lightning protection shall be provided as per IS: 2309 for Boiler area
and other tall structures within the battery limit.
1.4
Specific requirements
1.4.1
Scope of Work
The scope of work shall include Design, Preparation of Earthing and
Lightning Layout, supply, unloading at site, storing, laying, fixing,
jointing/termination, erection, testing and commissioning of equipment
associated with the safety earthing and Lightning Protection system for
following areas Listed below but not limited to the following:
modified.]
a) TG Area:
i) TG Platforms.
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No.
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No.
Date of Issue
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b)
c)
d)
e)
f)
[Logo of Utility]
ii)TG area Grade Levels Maintenance area.

iii) All equipments, structures etc of TG package.
iv) For all above areas, above ground Earthing and Lightning protection
system shall be provided.
Boiler Area:
i) Boiler Platforms
ii)Boiler Grade Levels covering coal mill and Maintenance area.
iii) ESP Platforms
iv) ESP/FOPH switchgear room.
v) FOPH area.
vi) All equipments, structures etc of Boiler package.
vii) For all above areas, above ground Earthing and Lightning protection
Balance of plant Area:
i) Earthing and lightning protection system for Mechanical BOP package
like Raw water, Water pre-treatment, Fuel oil, CW / ACW System
and Cooling Towers, AC and ventilation Vacuum Pump House, Silo
Area, Compressor House, Guard Pond, Effluent Treatment Plant,
Chimney, Fire water pump house, Cable galleries, Transformer
area, all Switchgear Rooms, Control rooms, all roads within battery
limit etc.
ii)For all above areas, above ground Earthing and Lightning protection
CHP Area:
i) Switchgear rooms
ii)All equipments, structures etc of Boiler package.
iii) For all above areas, above ground Earthing and Lightning protection
AHP Area:
i) Switchgear rooms
ii)All equipments, structures etc of Boiler package.
iii) For all above areas, above ground Earthing and Lightning protection
i) Switchyard, Transformer yard and BTG area are provided with earth
mat of [40] mm dia MS Rod conductor buried below 600mm from
ground level. Areas like AHP, CHP, Boiler and TG, and all other
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
BOP area below grounding system are covered in this eBOP

package and above ground earthing for AHP, CHP, Boiler, TG and
Mechanical BOP are covered in respective package itself. System
Neutrals are earthed through Treated Earth Pit. All areas of power
plant are interconnected to form an integrated single earthing
system. Lightning system for above ground are covered in
respective packages and below ground is covered in this eBOP
package in same way as earthing system.
1.4.2
Earthing system
a) Earthing system shall be designed in accordance with IS 3043 and Indian
Electricity Rules and Acts.
b) Fault current for the earthing system shall be designed for [50] KA for
duration of 1 sec.
c) All electrical equipment, non-current carrying metal parts, structures,
building steel, lightning protection system, transformer neutrals shall be
connected to station ground grid.
d) Treated earth pits including riser shall be provided for transformer neutral
earthing.
e) Connection between the equipment earth lead and the grid conductor
shall be welded. For rust protection, the welds shall be treated with zinc
chromate primer and coated with zinc rich paint.
f) Entire erection of grounding work shall be carried out in such a way as to
be capable of withstanding the intended services of carrying full short
circuit level currents to ground mat without any damage/deformation.
g) All off site area of AHP , CHP etc shall be provide with peripheral
earthing with at least two connection to main station earth grid through
treated earth pit.
1.4.3
Ground Grid Conductor

a) Ground grid conductor of mild steel rod shall be used.
b) [The minimum conductor section is determined on the basis of ground
fault current. This section is then increased by an allowance to account
for the soil corrosion loss of 0.12 mm (on diameter of conductor) per
year over the design life of 40 years.]
c) However bidder shall consider as per CBIP norms Manual on Earth mat
design the corrosion allowance as below:
For soil resistivity greater than 100 ohm-meter: No allowance.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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1.4.4
[Logo of Utility]
For soil resistivity greater than 25- 100 ohm-meter: 15%

allowance.
For soil resistivity less than 25 ohm-meter: 30% allowance.
Underground Grid
a) The ground grid mesh is designed to keep the touch and step voltages within
safe limits as per recommendation of IEEE 80.
b) [The ground grid conductors shall be buried in earth at a depth of 600
mm]. The length of ground conductors below earth shall be sufficient to
ensure a ground resistance less than one (1) ohm.
c) The ground grid conductor shall be so laid as to provide short and direct
connection to building steel and major electrical equipment.
d) Ground rods shall be provided at the points where system neutrals/lightning
protections are connected to the ground grid.
e) All ground grid conductor connections shall be welded type.
f) Ground grid shall be interconnected with the ground grid of neighboring areas
at least at two (2) points for further reducing the ground grid resistance.
g) Suitable pigtails shall be provided and shown in the [layout drawing]
for connection with ground grid of neighboring areas.
h) A minimum earth coverage of [300] mm shall be provided between the
ground grid conductor and the bottom of trenches, tunnels,
underground pipes, foundations, railway tracks etc. The ground grid
conductor shall be re-routed in case it fouls with equipment foundations.
i) In some cases, it may happen that the construction work of cable trench,
foundation and laying of underground pipes are being taken up after the
grounding mat has been laid. It may be required to cut a portion of grounding
conductor to avoid fouling with cable trench, equipment foundations,
underground pipes etc. In this case, the ground conductor shall be properly
rerouted and rejoined/reconnected with the main grounding mat during the
construction/laying of above underground objects and good electrical
continuity of grounding conductor shall be ensured.
j) Grounding conductors crossing the road may have to be laid at greater depth
to suit the site conditions.
k) Grounding conductor around the building shall be buried in earth at a
minimum distance of [1200] mm from the outer boundary of the building.
l) The Bidder shall carryout the grounding of all electrical equipments and
connection to main earth grid.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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1.4.5
[Logo of Utility]
Ground Electrode
Ground electrodes shall be [40] mm dia. and [3] metre long M.S. rod. These
are to be fabricated and driven into the ground by the side of mat
conductors. All connections to the conductors shall be done by arc welding
process.
1.4.6
Above Ground Connections

a) Galvanized steel flats shall be used for all connections above earth.
b) Inside building, ground conductors shall be run for each floor supported on
building steel and/or cable trays. These ground conductors in turn shall be
connected to the station ground grid through riser (at least two) coming up
along building columns/cable shafts.
c) Two separate and distinct ground connections shall be provided for each
electrical equipment in compliance with I.E. Rules.
d) All steel columns and structures shall be connected to the earth mat
through earth leads.
All connections above ground shall be welded type except connection to
equipment/structures which shall be bolted type.
1.4.7
Risers
Risers are required for connecting the equipment and structures with the
ground mat. Risers are to be provided from underground mat to above
ground levels where the ends shall be left free for connecting to the
equipment. Each riser shall be 1 No. [40] mm dia. M.S. rod and shall project
above grade level/concrete floor level by minimum 300 mm. They are to be
clamped or supported along the outer edge of the concrete foundation.
Connection to the ground mat shall be done by arc welding.
1.4.8
Equipment Ground Lead

a) Equipment ground connections shall be sized to carry the ground fault
current. Considerations shall also be given to mechanical ruggedness of the
connections and to limit the number of sizes.
b) The minimum ground conductor sizes for various equipment and structures
are given in below.
Table 2.0
DESCRIPTION
SIZE
MATERIAL
a) Main Grounding Grid Conductor
[40] mm dia Rod
Mild Steel
b) Riser/Pigtail
Grid/Mat
[40]
- Do -
From
Grounding
40 mm dia
Rod
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DESCRIPTION
SIZE
c) Electrode
[40]
[3000]
[Logo of Utility]
MATERIAL
mm dia,
mm long
- Do -
Rod
d) Conductor used for connection of various equipment/structures as listed below
HV motors, Earthing ring, Earthing
lead to earth pits etc.
[50 x 10] mm
Galvanised steel
Structures, Control Panels, Cable

Trays etc.
[50 x 10] mm Flat
- Do -
415V Power Control Centres, Motor

Control Centres, Distribution Boards
etc.
[50 x 10] mm Flat
- Do -
Local Panels, Lighting Panels
[25 x 6] mm Flat
- Do -
Above 90 kW
[50 x 10] mm Flat
Galvanised steel
Above 30 kW Upto 90 kW
[25 x 6] mm Flat
- Do -
Above 5 kW Upto 30 kW
[25 x 3] mm Flat
- Do -
Upto 5 kW
[8] SWG
- Do -
Miscellaneous Items, viz. Push

Button Station, Junction Boxes etc
[8] SWG
- Do -
Motors :
{The Above size of Earth flat is indicative only. Bidder shall refer Volume II
Section I for size of earth flat used for existing plant or as per design.}
1.4.9
Jointing and Connection

a) All ground conductor connections below ground level shall be done by
electric arc welding with low hydrogen content electrode. The contact
surfaces shall be thoroughly cleaned to provide good electrical continuity.
b) The bending of the large diameter ground conductor where necessary shall
be done by gas heating.
c) The projected portion of riser/pigtail above ground shall be coated with two
coats of bitumen paints (anti-corrosive paints) with a minimum thickness of 1
mm after connection.
d) The connections between the riser/pigtail and earthing conductors
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e)
f)
g)
h)
1.4.10
[Logo of Utility]
(galvanized steel flats) and between the earthing conductors above ground
level shall be made by electric arc welding.
The portion of galvanized steel flats, which undergoes welding at site, shall
be coated with two (2) coats of cold galvanizing anti-corrosive paint after
welding.
The earthing connections to equipment grounding pads/terminals and some
removable structures shall be bolted type with GI bolts and nuts. The contact
surfaces shall be thoroughly cleaned (to free from scale, paint, enamel,
grease, rust) before connection to ensure good electrical contact.
Equipment/structures ground connections shall be coated with weather
resistant paints/cold galvanizing paints after proper checking / testing.
Whether specifically shown or not, all conduits, trays, cable armour and
cable end box, electrical equipment such as motors, switchboards, panels,
cabinets, junction boxes, lockout switches, fittings, fixtures, etc. shall
be effectively grounded.
Earthing system installation

a) The spacing between two electrodes shall be at least equivalent to twice the
length of the electrode.
b) Earthing conductor running exposed on column, walls, etc., shall be
supported by suitable cleating, at intervals of 750 mm.
c) The earthing conductor crossing the road / track shall be laid in hume
pipe or laid at a greater depth to avoid damage.
d) When earth conductor passes through floors, walls, etc suitable pipe
sleeves shall be provided and the same shall be sealed after installation.
e) The connection between earthing pads / terminal to the earth grid shall
be made short and direct and shall be free from kinks & splices.
f) Metallic conduits and pipes shall not be used as earth continuity
conductor.
g) Street lighting poles, flood light poles & towers, their junction boxes shall
be connected to the earthing conductor to be run along with supply
cable. This earth conductor shall be in turn connected to earth grid at
two extreme points.
h) The steel columns, metallic stairs, hand-rail etc. of the building where
electrical equipment are located shall be connected to the nearby ground mat
by earthing conductor. Electrical continuity shall be ensured by bonding the
different sections of handrails and metallic stairs.
i) Fence within the ground grid shall be bonded to the plant ground system at
regular interval not exceeding ten [10] metres. Fence gate shall be separately
grounded with flexible connection to permit movement.
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No.
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j)
k)
l)
m)
n)
o)
p)
q)
r)
s)
t)
[Logo of Utility]
[50 x 10] mm galvanized steel flats(minimum size) shall be run as main

earthing conductors above ground along building columns, walls, steel
structure, etc. for equipment and other structures earthing.
These earthing
conductors shall be interconnected between them and to the main ground
grid through risers/pigtail. The connection between earthing conductor and
riser shall be made above ground. Earthing conductors can be embedded in
concrete floor of the building wherever necessary without having direct
contact with the reinforcement rods. At the crossing of building walls, floors
etc. the earthing conductor shall be passed through galvanised conduit
sleeves. Both ends of the sleeve shall be sealed to prevent the passage of
water through the sleeves.
All indoor and outdoor electrical equipment and associated non-current
carrying metal works, supporting structures, building/ boiler columns, fence,
system neutrals, lightning masts/arresters shall be connected to the plant
ground system.
Miscellaneous devices such as junction boxes, pull boxes, pushbutton
stations, lockout switches, cable end boxes, lighting fixtures, receptacles,
switches etc. shall be effectively grounded whether specifically shown or
not.
Metallic conduits and pipes shall not be used as earth continuity conductor.
These shall be grounded at both ends.
A continuous [50 x 10] mm (minimum size) G.S. flat earthing conductor
shall run along the cable trays and supporting structure of all cable routes.
This earthing conductor shall be attached to each section of cable tray/trays
through [50 x 10] mm G.S. flats. The earthing conductor shall be securely
connected to the earth mat at both ends.
Flexible earth conductors shall be provided at expansion joints for
earthing the gates, operating handles, etc.
Equipment bolted connection after being checked and tested shall be
painted with anti-corrosive paint / compound.
Connection between the equipment earth lead and the grid conductor
shall be welded. For rust protection, the welds shall be treated with zinc
chromate primer and coated with zinc rich paint.
The cable sheaths, screens armour shall be earthed at both ends for
multi-core cables. For single core cables the same shall be done at one
end (switchgear end) only.
All bimetallic connections shall be treated with suitable compound to
prevent moisture ingression.
Main plant earth grid and switchyard earth grid shall be interconnected
each other by minimum two numbers of leads.
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Rev
No.
Description
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No.
Date of Issue
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1.4.11
[Logo of Utility]
Lightning Protection System Design

a) Lightning protection design and installation work shall be provided on the
basis of IS 2309 Code of Practice.
b) Lightning protection system shall consist of vertical air termination rods,
horizontal roof conductors, down conductors and pipe electrodes.
c) The need for providing the lightning protection system shall be
established by calculating risk index value for each building structure,
etc., as per procedure given in IS-2309 and any building whose risk index
is more than value specified in IS shall be provided with lightning
protection. However, Boiler areas, station building, switchyard building
shall be provided with lightning protection irrespective of the arrived risk
index.
d) Shielding angle for one vertical air termination shall be 45 degrees. For more
than one rod, shielding angle between the rods shall be taken as 60 Degrees.
e) Down conductors shall run along the outer surfaces of the building and shall
have a test joint about 1500 mm above ground.
f) A Lightning electrode shall be provided at the connection point of the down
conductor with the station ground.
g) Galvanized steel rods and flats shall be generally used for air termination and
connections. All connections shall be welded type.
1.4.12
Air Terminations
a) The vertical air terminal rods shall be installed at the roof of Turbo generator
building, Boiler and chimney etc to protect these objects from lightning
strokes.
b) The projected length of the Air termination rod shall be as required to protect
the object (on which the rod is fixed) from lightning stroke.
c) The air terminal rod shall be properly fixed on the top of the building/structure
to withstand very high wind pressure. In case the air terminal rod is
embedded at the top of roof of building, the portion embedded inside the
concrete shall not touch the reinforcement bars and shall be duly insulated
from them.
d) All the vertical air terminal rods shall be electrically connected together by
means of horizontal conductors of size [50 x 6] mm galvanized steel flats.
e) For chimney air termination, rods interconnected by circumferential
conductors will be provided at the apex of flue and also upon outer shell
of the chimney. The air termination system will be formed by lead coated
copper conductors to prevent melting and corrosion of conductors due to
flue gas.
f) For cooling towers, air termination system will comprise of horizontal
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circumferential conductors at the top

1.4.13
Down Conductors
a) Galvanized steel down conductors of suitable size [25 x 6] shall be
connected with air terminal rod/horizontal conductor at the top of
roof/structure and other end connected to the nearest 40 mm dia. mild
steel rod riser from ground electrode.
b) Each down conductor shall have an independent earth termination. In no
case conductors of the lightning protection system shall be connected
with the conductor of grounding system above ground level.
c) The connection between each down conductor and rod electrode (by
means of 40 mm mild steel rod riser) shall be made by others. However
Bringing down comer with test link at a level of 1500mm approximately
from above ground level shall be boiler contractor scope of work.
d) The down conductor shall be laid straight and sharp bends shall be
avoided as far as practicable. These shall be cleared on outside of the
building wall and column/structure at about 750 mm intervals unless
stated otherwise in the drawing.
e) At all supports for down conductor along the column/wall of the buildings
etc. the portion embedded inside the building concrete should not touch
the reinforcement bars.
f) All exposed metallic parts of the buildings shall be bonded to the
down conductors. Such parts shall include ladders, balconies, conduits
etc.
g) The down conductors shall be protected at the ground level against
mechanical injury by means of non-metallic pipes, viz. PVC pipes filled
with bituminous compound.
1.4.14
Switchyard Lightning protection

a) For switchyard lightning protection shall be provided by lightning masts
and/or shield wires.
b) In case of lightning protection by shield wire, the shield wires provided
shall be of GS wire strung across the pinnacles of the gantry tower
structures. The size of shield wire shall be based on the lightning impulse
current expected and the time duration for which it is likely to flow.
Allowance shall be given in the final size to account for corrosion of the
shield wire during service at rate of [0.03] mm per annum. However,
minimum size of the shield wire shall not be less than [70 ]sq.mm. The
zone of coverage for the shield wire shall be considered as 60 deg
between the two shield wires and 45 deg for end shield wires. The down
conductors from shield wires shall be run along the towers and
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No.
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connected to rod/pipe electrodes.

c) In case of lightning protection by lightning protection masts, the down
conductors from the masts/peaks/shield wires shall be run along the
tower and connected to the test links mounted on the towers at 1500m
from the ground level. Conductors from the test links shall be connected
to the rod/pipe electrodes which in turn are connected to the main earth
grid in the switchyard. Calculations for sizing and determining topography
and number of lightning masts shall be furnished for approval.
1.4.15
Electrodes (for Lightning Protection)

The electrodes shall be [40 mm] diameter [3000 mm] long mild steel rod.
These shall be driven into the ground.
All the electrodes shall be interconnected by means of one (1) [40 mm] dia
mild steel rod which shall be laid under ground at a minimum depth of [600
mm] below finished grade level unless stated otherwise. This ground
mats/electrode in turn shall be connected to main grounding grid.
1.4.16
Riser (for Lightning Protection)

All risers connected to grounding mat shall be [40 mm] mild steel rods and
shall be projected 300 mm above grade level unless stated otherwise.
1.4.17
Jointing & Connection

a) All ground conductor connections below ground level shall be done by
electric are welding with low hydrogen content electrode.
b) The projected portion of riser above ground shall be coated with two (2)
coats of bitumen paints (anti-corrosive paints) with a minimum thickness
of 1 mm after connection.
c) The joints in the lightning conductors shall be kept to a minimum and
there shall be no joint in the underground portions of conductors.
d) All the joints shall be done by arc welding process overlapping of
the conductors at straight joints shall not be less than 150 mm. The
contact surfaces shall be cleaned properly before jointing.
e) The portion of galvanized steel flats, which undergoes welding at site,
shall be coated with two (2) coats of cold galvanizing anti-corrosive paint
after welding.
f) The bolted joint of the test link shall be covered with thick coating of
bitumen paint after successful testing.
g) The air terminal rods and shielding mast shall be coated with weather
resistant anti-corrosive paint (zinc chromate followed by two coats of
aluminium paint).
h) The steel to copper connection shall be brazed type.
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No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
i)
The lightning protection of inflammable liquid storage tanks wherever

required, shall be provided with horizontal conductors strung between tall
poles covering the entire zones or with air terminal rods mounted on top
of poles/structure. These horizontal conductors/vertical air terminal rods
shall be connected to rod electrodes, which in turn shall be connected to
station ground mat.
j) The sizes and materials of earthing conductors to be used in
lightning protection system are listed below :
k) Note: The above sizes are indicative only. Actual size shall be as per
Bidder design or as per existing plant details as provided in Section I in
case of replacement work as called for.
Table 3.0
DESCRIPTION
SIZE
MATERIAL
a) Vertical Air Termination
[20] mm dia Rod
Galvanised steel
b) Horizontal Conductor
[50 x 6] mm flat
------do-----
[ 25 x 6] mm Flat
c) Down Conductors
------do-----
[25 x 6 ] mm Flat
1.5
d) Ground electrode / riser
[40] mm dia Rod
Mild Steel
e) Interconnection with earth

mat
[40 ] mm dia Rod
Mild Steel
Tests
I)
Type Test
as per relevant standards and carried out within last[five] years from the date
Document Number
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No.
Description
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No.
Date of Issue
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[Logo of Utility]
II)
Routine Test

The following test shall be conducted:
a) Measurement of earth resistance for each electrode.
b) Measurement of total earth resistance.
c) Measurement of earth loop resistance for E/F path of biggest LV
drive.
d) Check tightness of all earth connections
e) Check earthing of all metallic equipments, cable trays, bus bar
supporting structures, building column (if steel all elect equipments,
pipe lines etc. as per the drawing / specification)
III)
Test Witness
1.6

below:
a) [Earthing Material like conductor , flat , welding description etc]
b) [Air termination rod and its accessories etc]
c) [Technical Data sheets for Earthing and Lightning system].
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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1.7
[Logo of Utility]

DESCRIPTION
SL
NO.
1.0
EARTHING SYSTEM
1.1
Manufacturer Name
1.2
Main ground grid conductor material & size
1.3
Ground electrode material & size
1.4
Riser material & size
1.5
Grounding installation work carried out as

per pecification
2.0
LIGHTNING PROTECTION SYSTEM
2.1
Manufacturer Name
2.2
Vertical air termination conductor material

& size
2.3
Horizontal air termination conductor

material & size
2.4
Down Conductor material & size
2.5
Electrode material & size
2.6
Riser conductor material & size
2.7
Lightning Protection work carried out as

per specification.
UNIT
DATA
Y/N
Y/N
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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OF

R&M CONTRACTORS
VOLUME-II
TECHNICAL SPECIFICATION FOR VARIABLE FREQUENCY
DRIVES
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-E13
1.0
1.1
VARIABLE FREQUENCY DRIVE

General
Variable Frequency Drives complete with all accessories for efficient and
trouble-free operation of of R&M of Unit No. [..] of [Name of the Power
1.2
Codes and Standards

Table 1.0
IS-3700
Essential ratings and

conductor devices
IS-3715
Letter symbols for semi-conducting devices
IS-4411
Code of designation of semi-conducting devices
IS-5001
Guide for preparation of drawings for semiconductor devices
IS-5469
Code of practice for the use of semi-conductor

junction devices
IS-5621
Hollow Insulators for use in electrical equipment
IS-6209
Methods for partial discharge measurement.
IS-6297
Transformers
equipment
IS-8789
Performance parameters for motors
IS-12729
Switchgear and control gear for voltages exceeding
and
characteristic
indicators
for
of
semi-
electronic
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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Power Plant]
[Logo of Utility]
1000V- General requirements

IS-13408
Code of practice for the selection, installation and

maintenance of electrical apparatus for use in
potentially explosive atmospheres
IEC 146
Semi Conductor converters
IEC 168
Tests on indoor and outdoor post insulators of

ceramic material or glass for systems with nominal
voltages greater than 1000V
IEC 270
Partial discharge measurement
IEC 297
Dimension of panels and racks
IEC 326
General requirements and measuring methods for

printed wiring boards
IEC 352
Solder less wrapped connection
IEC-618003,4&5
EMC requirements and specific test methods
IEC-60664-1
Insulation coordination for equipment within lowvoltage systems
IEC/EN-60204-1
Safety of
machines
IEC/EN-60529
Degrees of Protection Provided by Enclosures (IP

Code)
IEC/EN-61000-312
Electromagnetic compatibility
IEEE 444
Protection standards for converters
IEEE 519
Harmonic control & reactive compensation of

static power converters
machinery-electrical
equipment
of
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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Power Plant]
DIN 41488
[Logo of Utility]
Electrical engineering dimensions

1.3
Design Criteria
a) All VFDs shall be suitable for an ambient temperature of 50 C and
relative humidity of 95%. The VFDs shall be suitable for operation in a
highly polluted environment.
b) All VFDs shall be suited for uninterrupted operation under the following
variations in bus voltage and frequency:
Voltage Variation
: +/-10%
i.
ii.
Frequency Variation
iii.
Combined Variation
Voltage & Frequency
:
of :
50Hz (+)3% to (-)5%

10% (absolute sum)
c) The VFD shall be of modern design for similar applications in power

plants. The system shall be commutated inverter type with minimum [six]
pulse design, [IGBT based] and PWM controlled or better control system.
d) VFD shall consist of Input section (rectifier and filter), control section and
output section (PWM module, base drive circuits).
e) VFD shall include an input filter for limitation of the harmonic current.
General requirements of VFD shall conform to IEC 61800-2 and IEEE519.
f) VFD shall follow EMC directives as specified in IEC-61000.
g) VFD model shall be suitably selected based on actual cable length from
VFD to motor terminals. Shielded cables suitable for VFD applications
shall be provided by the bidder.
h) For [12 pulse] VFD, required 3 winding transformer and necessary cabling
shall be provided by the bidder.
i) Bidder shall provide inverter duty motor to withstand voltage stresses
produced by PWM action
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No.
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Page
No.
Date of Issue
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1.3.1
[Logo of Utility]
Performance requirements:
a) The system shall be energy efficient, designed as standard product and
shall provide very high reliability, high power factor, low harmonic
distortion and low vibration / wear / noise.
b) The system shall be suitable for the load characteristics and the
operational duty of the driven equipment.
c) The drive system shall be designed to operate in one or more of the
following operating modes as to suit characteristics of the driven
equipment:
i. Variable torque changing as a function of speed i.e. speed squared.
ii. Constant torque over a specific speed range.
iii. Constant power over a specific speed range where the torque
decreases when speed increases.
d) The drive controller shall be equipped with microprocessor based digital
regulator with programmable functions. The system shall be designed for
linear continuous speed control from [10% to 100%] of driven
equipments rated speed and shall be of a modern proven design.
e) The total harmonic distortion (THD) of the voltage and current at inverter
output shall be as per IEC 61800-4 and it shall be considered in the
design of the motor.
f) Unless otherwise specified, the overload capacity of the controller shall
be 150% of rated current of motor for one minute for constant torque
applications, and 115% of rated current for one minute for variable
torque applications at rated voltage. If the motor load exceeds the limit,
the drive shall automatically reduce the frequency and voltage to the
motor to guard against overload. If load demands exceed the current limit
for more than one minute, the drive shall shut down to prevent over
heating of the motor and damage to the drive.
g) During operation, the system shall be capable of developing sufficient
torque under all load conditions to respond to a 20% alteration in speed
set point within a time limit up to 60 seconds.
h) The integrator action of the speed set point alteration shall be
independently adjustable for both an upward and a downward alteration.
The minimum time interval between set point adjustments by the
distributed control system shall be considered as 10 seconds.
i) The drive shall trip in case the speed exceeds 105% of the maximum
operational speed or reduces to 95 % of the minimum operational speed
for more than 10 seconds.
j) Maximum noise level of motor shall be measured as per relevant IS
standard.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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k) Variable frequency drive shall be arranged so that it can be operated in an

open circuit mode, disconnected from the motor for startup adjustments
and troubleshooting/ maintenance.
l) Voltage at motor neutral shall be maintained at ground potential for the
total operating condition.
The drive system shall ensure following:
i. VFD induced torque pulsation are limited to maximum 1% (even at

low speed) so there is minimal stress to the equipment
ii. Motor is protected from dv/dt stresses.
iii. No appreciable increase in motor audible noise.
1.3.2
Control requirement:
a) The VFD and motor characteristics shall be suitable for load specific
torque-speed characteristics.
b) Short time voltage dips up to 20% of nominal voltage (e.g. in case of a
large motor start up connected to the same bus as VFD) shall not cause
the control system to stop functioning and shall not trip the drive system.
c) The system shall also be equipped with a facility which shall restart the
system in case of voltage dip over 20% or power interruptions for less
than 2 seconds, with recovery of the voltage to its nominal value. The
drive shall have the facility to block this feature, if required by the
operator. Upon restart the converter shall be capable of synchronizing on
to a rotating motor and develop full acceleration torque within 10
seconds.
d) The power controller shall be controlled to always start the motor in the
forward direction. Logic shall be provided to prevent the motor from
being started in the reverse direction.
e) The drive motor shall be speed controlled corresponding to 4-20 mA
reference input signal unless otherwise specified upon complete loss of
the user's speed reference signal, the drive shall automatically run at
constant speed at the last speed reference available prior to the loss of
signal.
f) It shall be possible to vary the speed of the drive in either manual or auto
mode. Auto/manual selection shall be from VFD panel unless otherwise
specified.
i. With the selector switch in "manual" mode, the operator shall be able
to set the speed through keypad, mounted on front of the drive panel
or from speed increase/decrease push buttons from the field. Motor
operated potentiometer shall be provided as a speed set point device.
ii. With the selector switch in "auto" mode, speed of the motor shall be
controlled from a 4-20 mA signal, from owner's DCS (Process
Control) system. Necessary equipment required for interfacing with
DCS shall also be provided in the drive panel.
Document Number
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No.
Description
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No.
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g) The required provision for the interface with remote I/O (as per
requirement) shall be through hardwired connection (with potential free
contacts and transducers)
h) Drive system shall have provision for interface with upper level
automation such as electrical control system.
i) The closed loop control feedback for the drive system having output
transformer shall be tapped from the secondary side of the output
transformer.
j) Bypass Feature
i. Bypass breaker / contactor-HRC fuse complete with protection,
annunciation and metering shall be provided.
ii. All Variable frequency drives (VFD) having bypass feature shall have
motor protection relay along with necessary control and metering etc.
Switching scheme shall be such that in case of drive mal-operation,
the motor could be taken on bypass control manually, while the drive
could be attended by opening its isolation devices.
iii. Safety interlock between inverter and bypass breaker/contactor shall
be provided such that closing of healthy device is inhibited in case of
external fault.
1.4
1.4.1
a) Panel Construction
i. The panel shall include suitable semi conducting power devices
(Diodes / IGBT) modules with protective devices, reactors (if
required), filters (if required), control circuit, control accessories,
indication and annunciation etc. The construction of the panel shall
provide effective protection against electromagnetic emissions and
shall meet the design requirement of integrated standards.
ii. Upstream breaker nclude suitable semi conducting power devices
(Diodes / IGBT) modules win shall be provided on the front door.
iii. Safety Interlock shall be provided so that power cabinet cannot be
opened unless the upstream breaker is disconnected, safetygrounding switch is closed and DC link capacitor is discharged. Power
source breaker can only be closed once the earthing switch is open
and panel door is closed with lock defeat facility.
iv. The drive shall be suitably housed in sheet steel panels fabricated
with 2 mm thick cold rolled sheet steel. The panel shall be suitable for
indoor installation, if not otherwise specified. The panel shall be free
standing with degree of enclosure protection as IP-31. The maximum
and minimum operating height shall be 1800 mm and 400 mm
respectively.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[6]
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Power Plant]
[Logo of Utility]
v. Bolted un-drilled gland plate shall be provided at bottom. Clamp type

terminals shall be used for connection of all wires up to 10 mm2 and
terminal for higher sizes shall be bolted type suitable for cable lugs.
Minimum space for power cable termination shall be 600 mm clear
from bottom of the cable gland plate.
vi. Bus bars shall be of electrolytic copper, color coded separately for AC
and DC system. All the live parts shall be sleeved / shrouded to
ensure complete safety to personnel intending to carry out routine
inspection by opening the panel doors. All the equipment inside the
panel and on the doors shall be provided with suitable nameplate.
vii. All the switches component and accessories which are essential for
normal and emergency operation shall be mounted on the door and
shall be operable externally. Digital meters shall be preferred.
Analogue instruments, where provided, shall be switchboard type,
back connected, 72x72mm. Scale shall have red mark indicating
maximum permissible operating rating.
viii. All panels shall be of same height so as to form a uniform line-up, to
give good aesthetic appearance.
ix. All the control wiring shall be enclosed in plastic/ metal channel. Each
wire shall be identified at both ends by self-sticking wire marker tapes
or PVC ferrules. Power and control wiring inside the panel shall be
done with PVC insulated, fire retardant, copper conductor wire. 1.5
mm2 size wire shall be used for control circuits, 2.5 sq.mm for CT/PT
circuits and 0.75 mm2 for electronic circuits. The control fuse rating
is 10 Amps or less and 2.5mm2 size for control fuse rating above 16A
for electrical circuits and 0.7 mm2 for electronic circuits. All wires
shall be ferruled and terminals shall be properly numbered. Minimum
20% spare terminals shall be provided.
x. All electronic modules and components shall be accessible from front
of panel only. Modular assemblies for both the system control
electronic equipment and power electronic equipments shall be used.
xi. All low voltage compartment and cabling shall be electrically and
physically separated from the high voltage compartment.
xii. DC link capacitor and pre charging and discharging circuit shall be
preferably mounted in the rear of the panel. Suitable removable type
hooks shall be provided for lifting the panel.
xiii. Drive keypad, operator control panel required for control, monitoring
and measurements shall be supplied and installed outside the panel on
the front door. It shall be accessible for operation without opening the
front door and shall be non-removable type.
xiv. All equipment shall be complete with double compression glands, lugs
etc.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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Power Plant]
[Logo of Utility]
b) Cooling
i. The drive panel shall be naturally cooled or water cooled type as per
manufacturer's standards. However it is preferred to have natural air
cooled system. If unavoidable, forced type-cooling system shall be
provided. Cooling system shall include well-dimensioned panel,
adequate cooling airflow path, module cooling fan and if necessary,
panel cooling fan or water-cooling system shall be considered. Bidder
shall ensure that the panel dimensions and flow paths have been
designed for continuous running at the specified ambient without
overheating. For fan cooled drives, redundant ventilating fans (N + 1)
shall be provided.
ii. Necessary starters shall be provided within the VFD panels for the
ventilation fans, any other auxiliary motor etc.
iii. The system provided shall be interfaced with drive starting and shut
down such that safety interlocks such as start permit from cooling
system to drive and trip signal from cooling system to drive in case of
cooling system failure etc., shall be incorporated in the overall
sequence logic.
iv. MCB for motor space heater, auxiliary power supply if required for
local panel, drive panel space heater etc. shall be included and
mounted in easily accessible location.
1.4.2
Motor
The motor shall be designed, constructed and tested in accordance with the
Specification for high Voltage Induction / Synchronous Motor, in addition to
the following requirements:
a) The motor shall be suitable for VFD control.
b) The motor shall be suitable for the current waveforms produced by the
power supply including the harmonics generated by the drive.
c) The motor shall be designed to operate continuously at any speed in the
operating range for the driven equipment (ie; ID fan / Coal feeder).
d) The permitted voltage variation shall take into account the voltage drop
across the AC drive and all other system components upstream the
motor.
e) Motors required to be transferred to DOL by-pass mode shall be rated for
specified variations in system line voltage and frequency. Starting current
of motor in DOL bypass mode shall be limited to value specified in motor
specifications.
f) The motor shall be constructed to withstand torque pulsations resulting
from harmonics generated by the solid-state power supply.
g) The motor insulation shall be designed to accept the applied voltage
waveform, within the Vpeak and dv/dt limits as per IEC-61800-4.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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Power Plant]
[Logo of Utility]
h) The drive manufacturer shall be solely responsible for proper selection of

the motor for the given load application and the output characteristics of
the drive.
1.4.3
Static Power Converter

a) The static power converter shall consist of a line side converter for
operation as a rectifier and a load side power converter for operation as a
fully controller inverter. Power converter shall be fast switching, most
efficient and low loss type.
b) The converter shall be co-ordinated with the transformers. The converter
shall be able to withstand a three phase short circuit current until
interrupted by normal breaker operation.
c) Adequate short circuit and over voltage protection shall be provided for
the converter and inverter system.
d) All power converter devices shall include protective devices, snubber
networks and dv/dt networks as required.
e) The current rating of the converters semi-conductor components shall not
be less than 120% of the nominal current flowing through the elements
at full load of the VFD through the whole speed range. If the parallel
connection of semi conductor is applied, the above current rating shall
not be less than 140% of the above values.
f) All power diodes shall be of silicon type with minimum VBO rating at 2.5
times the rated operating voltage.
g) The power converter circuit shall be designed so that motor can be
powered at its full nameplate rating continuously without exceeding its
rated temperature rise nor reducing its service factor due to harmonic
currents generated by the inverter operation.
h) The conversion devices and associated heat sinks shall be assembled
such that individual devices can be replaced without requiring the use of
any special precautions / tools.
i) The cooling system of the electronic components, if provided, shall be
monitored and necessary alarms shall be provided to prevent any
consequential damage to the power control devices.
1.4.4
Converter Transformer
a)
The converter transformer, if provided, shall be copper wound dry type.

Insulation class of dry type transformer shall be H with temperature rise
of body limited to 75C. Dry type transformer shall preferably be
mounted inside the drive system panel. The impedances of converter
input transformers with more than one secondary winding for minimum
18 pulse systems shall be selected to ensure equal load / current sharing
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[9]
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Power Plant]
[Logo of Utility]
between the secondary windings, the converters and the motor

windings under all operational conditions including starting and
restarting.
b)
1.4.5
1.4.6
1.4.7
The transformation ratio, impedances, taps and secondary voltage shall

be chosen by the drive vendor to optimize system performance.
DC link reactor
a)
Smoothing reactors for the DC link shall be designed to sufficiently

decouple the rectifier and inverter portion of the converter and to limit
fault currents in this circuit.
b)
Unless otherwise specified, the reactor shall be dry type, air cored, aircooled or fan cooled type located within the panel.
c)
Reactor shall be suitable for withstanding earth fault continuously and

for operation with the non-sinusoidal current wave shapes and DC
components under all operational conditions of the system without
exceeding its temperature limits.
d)
Noise level shall not exceed value specified in NEMA TR-1
Output filter
a)
VFD output current waveform should be inherently sinusoidal at all

speeds, with harmonic limits as specified in this specification. Output
filter shall be provided if required. Output filter capacitors shall be
provided with discharge circuits to ensure that all residual stored charge
is reduced to less than 50 V DC within 300 seconds after a loss of AC
voltage. All capacitor shall be maintenance free and self-healing type.
b)
The VFD system shall inherently protect motor from high voltage dv/dt
stress, independent of cable length to motor. Output filter shall be an
integral part of the VFD system and included within the VFD enclosure.
Protection, Control, Metering, Indication and Annunciation

a)
The Bidder shall provide all the necessary system control, protection,
alarm equipment and metering for the entire drive system and its
auxiliary equipment.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[10]
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Power Plant]
b)
[Logo of Utility]
Automatic sequence control shall include start-up of cooling system,

auxiliary system of the motor, interlock checking, automatic start and
run-up of drive, planned and emergency shutdown. The same shall be
processed through microprocessor-based system.
c)
Protective Relays:
For details on protective relays used, refer to Technical Specifications on
MV Switchgear
d)
Operator Control Panel

i.
Each drive shall be equipped with a front mounted operator control

panel consisting of a backlit alphanumeric display and a keypad with
keys for parameterization and adjusting parameter which shall not be
limited to start/Stop, Local/Remote, auto/manual, Increase/Decrease,
menu navigation and protection and measurement parameter
selection, etc.
ii.
All parameter names, fault messages, warnings and other information

shall be displayed in complete English words or standard English
abbreviations to allow the user to understand what is being displayed
without the use of a manual or cross-reference table. This shall also
be used for the modification of all electrical values, configuration
parameters, drive menu parameters, application and activity function
access, faults, local control, adjustment storage, self test and
diagnostics. Keypad shall be operable with password for changing the
protection setting, safety interlock etc. However the parameters such
as measurements, setting, mode of drive etc. shall be allowed to be
viewed without any password.
iii.
Operator console shall have facility /port to connect external

hardware such as Lap-Top etc. Console shall have facility for upload
and download of all parameter settings from one drive to another
identical drive for start up and operation.
iv.
Drive system control shall also have facility to receive tripping signal
from upstream breaker for tripping and also provision for closing up
stream breaker after all required process parameters are achieved.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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Power Plant]
[Logo of Utility]
v.
User-friendly software for operation and fault diagnostic shall be

loaded in the drive system panel before commissioning.
vi.
Suitable interface with DCS to be provided for control and status

signals of VFD.
e)
Local Motor Control Station

i.
The local motor control station shall be installed near the motor.
Components and accessories that are required in the local motor
control station may be mounted on the local field mounted panel
envisaged for the driven equipment.
ii.
Meters in the local control station shall be suitable for 4-20mA

transducer outputs and shall be calibrated for the actual motor
current. Further, for drives with bypass facility, the meters shall be
capable of reading bypass full load and starting currents, as well as
the drive current.
iii.
Requirement of controls and indications required in the Local Control

Station shall be as specified in the data sheet.
f)
Protective Features:
The system offered shall incorporate adequate protective features,
properly coordinated for the drive control and for motor but not limited to
the following:
i.
Incoming line surge protection
ii.
Under / Over voltage protection
iii.
Phase loss, phase reversal protection.
iv.
Programmable Over current protection and under load protection.
v.
Motor differential protection for motor rated above 1000 kW
vi.
Inverter Fault.
vii.
Over frequency operation.
viii.
Ventilation loss,
ix.
Over temperature of equipment.
x.
Over speed of motor.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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Power Plant]
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xi.
Specific motor protection, including motor winding, bearing

temperatures, over-current, overload, negative phase sequence,
locked rotor and earth fault protections etc.
xii.
System Earth fault protection.
xiii.
Excitation system protection for synchronous motor
xiv.
Over and under frequency, rotor earth fault, field failure protection for
synchronous motor
xv.
Additional protection for drive system
g)
Control features
The following controls shall be provided as a part of the Operator Control
Panel or through separate switches.
i.
Start/Stop
ii.
Speed control (Raise/lower)
iii.
Forward/Reverse(if Specified)
iv.
Auto/Manual /test mode
v.
Local/remote
vi.
Emergency stop
vii.
Start/stop for by pass starter ( where specified)
viii.
Trip-Remote Breaker
ix.
Excitation control system for synchronous motors
x.
Sequential switching of filters
h)
Metering
Digital display of the following parameters shall be as a part of the
Operator Control Panel, selectable by the operator.
i.
Input AC Current
ii.
Input AC voltage
iii.
Input AC frequency
iv.
Output voltage
v.
Output current VFD / Bypass
vi.
Output frequency
vii.
Motor thermal state
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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Power Plant]
viii.
[Logo of Utility]
Drive thermal state
ix.
Motor speed
x.
Motor energy meter
xi.
DC Link voltage
xii.
Hour Run
xiii.
Voltage and current meter for excitation system for synchronous

motor.
xiv.
KVAR, power factor meter for synchronous motors
xv.
Necessary transducer shall be provided with 4-2OmA output for

indicating motor speed and motor current in DCS unless otherwise
specified for other parameters.
i)
Indications
Bidder shall provide indications as required for normal operation and for
easy maintenance, which shall not be limited to the following indications
both at local and at plant DCS.
i.
Motor running
ii.
Motor stopped
iii.
VFD System Fault
iv.
System ready to start
v.
AC mains ON
vi.
Motor over speed
vii.
Rectifier output 'ON'
viii.
Motor zero speed
ix.
Remote breaker trip
x.
Excitation system healthy for synchronous motors
j)
Above indications may be provided as a part of the operator control

panel, i.e., door mounted keypad or through hardwired indicating
lamps/LEDS.
Potential free contacts of items i- iv shall be wired separately for remote
indications in DCS.
Audio-visual annunciations
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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Power Plant]
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i.
The system shall incorporate audio-visual annunciations for

protection, for various fault conditions, for the Drive motor, Supply
cables, DC Reactor and the Converter, output transformer etc.
ii.
Alarms shall also be included for the failure of various auxiliaries

together with identification of the failing unit, loss of cooling system,
various protection devices provided for converter transformer etc.
iii.
Audio-visual window annunciations shall be provided on the front of

the panel All annunciations as required for normal and satisfactorily
operation of the drive system shall be included as per Bidder
standards. These annunciations can be part of operator console panel
or separately mounted type.
iv.
Bidder shall include audio-visual alarm as required for normal operation

and maintenance of the system but not be limited to the following,
k)
Rectifier fuse failure
Main AC failure
Inverter fuse failure
Inverter overload
Inverter high temperature
Cooling system failure
Motor failed to start
Transformer failure
Excitation system failure for synchronous motor
Battery monitoring healthiness
Communication and measurement system un healthy
Motor temperature high
Harmonic filters monitoring
i. Common potential free contacts shall be provided for above

annunciations and these shall be wired up to terminals of DCS I/O
panels for remote alarm and monitoring.
Fault Diagnostic
Fault diagnostic shall be built into the system to supervise the operation
and failure of the system. The information regarding failure of any of the
system including shut down of the system shall be available for a period
of minimum 4 days (96 hours) after a shut down even though no supply
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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Power Plant]
[Logo of Utility]
would be available to the system. The system may be totally deenergized for maintenance or otherwise. It shall be possible to retrieve
the record of events prior to tripping of the system or de-energisation.
Auxiliary supply to the system components or to the electronics
(firmware) for the diagnostics / display shall be taken care by the
manufacturer for this purpose.
1.4.8
External Power supply for auxiliary and Control Circuit

Auxiliary power supply for devices external to VFD module, space heater
supply for Motor, VFD panel space heater, auxiliary power supply for
transformers, cubicle lamps (CFL) etc. shall operate on 240 volts single
phase AC.
All control circuit shall operate at voltage of 110V AC or 220V DC.
Bidder shall include supply of all control transformers, protective devices,
required accessories etc. and any other control supply voltage as required for
the system.
1.4.9
Maintenance features
The controller design shall incorporate the following maintenance features:
a) Modular construction
b) All components shall be easily accessible.
c) Standard diagnostics to aid maintenance personnel. These shall include
LED or alphanumeric displays, test or measurement points.
1.4.10
Painting
a) All metal surfaces shall be thoroughly cleaned and de-greased to remove
mill scale, rust, grease and dirt. Fabricated structures shall be pickled and
then rinsed to remove any trace of acid. The under-surface shall be
prepared by applying a coat of phosphate paint and a coat of yellow zinc
chromate primer. The under-surface shall be made free from all
imperfections before undertaking the finishing coat.
b) After preparation of the under surface, the panel shall be provided with
epoxy based powder coating. The color shade of the final paint shall be
as per manufacturer's standard, unless otherwise specified. Panel finish
shall be free from imperfections like pinholes, orange peels, runoff paint,
etc.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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c) All unpainted steel parts shall be zinc passivated, cadmium plated or

suitably treated to prevent rust and corrosion. If these parts are moving
elements, then these shall be greased.
Final paint shade shall be light gray and dove gray 631 and 632 as per IS-5
for indoor and outdoor equipment respectively unless otherwise specified
1.5
Tests
The Routine and Type Tests to be performed on the drive system in the
presence of the purchaser of consultant shall be as follows:
1.5.1 Type Tests

For each rating and type of VFD, the Bidder shall submit for Owners
approval, the reports of all the type tests as per relevant standards and
carried out within [last five] years from the date of bid opening. These
All type tests shall be conducted as per relevant standards and test
certificates of similar panels conducted within last 5 years shall be furnished.
1.5.2
Routine tests
a)
Visual Inspection
b)
It involves checking of the various equipments/components fault

diagnostic unit, Wiring, Terminals, earthing ratings etc.in line with the
approved drawings and visual inspection shall not be limited to the
following:
c)
Insulation Test
d)
Light Load and Functional Test
e)
Load characteristics test
f)
Load duty test
g)
Checking of Auxiliary Devices
h)
Checking the properties of the control equipment
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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i)
Checking the Protective Devices
j)
Checking of control and functional requirements
k)
High voltage test
l)
Leakage and pressure test for cooling water system where provided
m)
Shaft current/bearing insulation
n)
Automatic restart/re-acceleration
Additional tests on switchgears and dry type transformers shall be carried

out based on the requirement defined in the technical specification.
1.5.3
Test Witness
1.5.4
Test Certificates
1.6

The engineering services scope and the documentation to be issued with the
bid are described hereafter. The list shows the minimum requirements for the
documentation, so that any additional documentation considered as
necessary will be added to this.
a) Engineering, manufacturing, delivering and test schedule
b) Sub-Supplier lists.
c) General arrangement drawings(plan, elevation, section view) with
dimensions
d) Foundation drawing including loading data.
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

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[Logo of Utility]
e) Technical Data sheets.

f) Electrical and control wiring diagram.
g) Terminal arrangement drawing, interconnection wiring diagram.
h) Cross sectional drawing.
1.7
i)
Inspection and test plan.
j)
Manufacturing Quality Plan.
Ratings and requirements

Table 2.0
Sl.
No
Technical Parameters
6.6 kV
415 V
Manufacturer Name
[By Bidder]
[By Bidder]
Model No.
[By Bidder]
[By Bidder]
Application
Quantity
Enclosure Protection
Rating
IP-31
IP-31
Output Current Rating at

ambient temperature
[as per
requirement]
[as per
requirement]
% derating considered for

specific ambient
As per IEC
As per IEC
Rated Voltage (volts) Input
6.6 kV AC
10%, 3-phase
415 V 10%,
3-phase
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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02

[19]
25.09.2014
Power Plant]
Sl.
No
[Logo of Utility]
6.6 kV
415 V
Output Frequency Range

(Hz)
[By Bidder]
[By Bidder]
10
Number of Phases and

Frequency (Hz)
3 Phase, 50 Hz
(+3% to -5%)
3 Phase, 50 Hz
(+3% to -5%)
11
Rectifier type & Design
[6/12/18 Pulse
Diode Bridge]
[6/12/18 Pulse
Diode Bridge]
12
Inverter type & Design
[as per
requirement]
[as per
requirement]
13
Min/Recommended / Max
switching frequencies
(kHz)
[as per
requirement]
[as per
requirement]
14
Filters
[as per
requirement]
[as per
requirement]
Line Side
[as per
requirement]
[as per
requirement]
Load Side
[as per
requirement]
[as per
requirement]
15
Output Modulation
Method
PWM
PWM
16
Speed Accuracy (+/- %)
[as per
requirement]
[as per
requirement]
17
Response time (speed)
<5ms with
nominal Torque
<5ms with
nominal Torque
18
Response time (Torque)
[By Bidder]
[By Bidder]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[20]
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Sl.
No
[Logo of Utility]
6.6 kV
415 V
19
Type of cooling
[Natural/forced/w
ater] cooled
[Natural/forced/
water] cooled
20
Whether VFD is suitable

for outdoor installation
No
No
21
Drive Control Capabilities

Start/Stop Push button
ON/Speed
Increase/Speed
decrease From
DCS
ON/Speed
Increase/Speed
decrease From
DCS
Modbus control
Yes
Yes
Output Frequency (Hz)
[0 to120Hz]
[0 to120Hz]
Full Load current (Amp)
[By Bidder]
[By Bidder]
VFD Heat dissipation (w)
[By Bidder]
[By Bidder]
At Full rated Torque
[Approx 98%
(Only drive)]
[Approx 98%
(Only drive)]
At 75% of full load torque
[By Bidder]
[By Bidder]
[By Bidder]
[By Bidder]
[0.98
(Fundamental)]
[0.98
(Fundamental)]
22
23
24
Load parameters at rated

voltage & frequency
VFD Efficiency
Drive Power factor range

At rated speed, Torque
Document Number
Rev
No.
Description
Page
No.
Date of Issue
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Sl.
No
[Logo of Utility]
6.6 kV
415 V
25
DC Voltage
[1.35 times of
supply voltage]
[1.35 times of
supply voltage]
26
Fundamental power factor
0.98(At
nominal Load)
0.98(At
nominal Load)
27
Switching Frequency
[By Bidder]
[By Bidder]
Drive Dimensions
[By Bidder]
[By Bidder]
Length
[By Bidder]
[By Bidder]
Height
[By Bidder]
[By Bidder]
Depth
[By Bidder]
[By Bidder]
Weight
[By Bidder]
[By Bidder]
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

[22]
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OF

R&M CONTRACTORS

VOLUME-II
SECTION-II, PART-C
DETAILED TECHNICAL SPECIFICATION-I&C
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R03
Sep 2015
Contract Document For R&M of Unit No.[..] of [Name of the Power Plant]
[Logo of Utility]

Volume
Section
Part
Description
Volume-I
---
---
Commercial
Section-I
---
Part-A
Part-B
Part-C
Part-D
---
Part-A
---
Part-B
---
Part-C
---
Part-D
Not Used
Volume-II
Section-II
Volume-III
*****
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Model Tender Document for Selection of
R&M Contractors Boiler & Auxiliaries
Volume-II, Section-II, Part-C
Page
No.
Date of Issue
[i]
02.09.2015
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1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
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1.
2.
3.
4.
5.
6.
7.
8.
9.
Spare Parts
10.
Annexure

1.
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3.
4.
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1.
2.
3.
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TABLE OF CONTENT
CONTROL & INSTRUMENTATION ................................................................... 1
1.1
General ....................................................................................................... 1
SYSTEM DESCRIPTION ................................................................................. 2
DESIGN PHILOSOPHY ................................................................................... 3
DESIGN CRITERIA ........................................................................................ 9
4.1
General Requirements.................................................................................... 9
4.2
Codes & Standards ..................................................................................... 10
4.3
Power Supply............................................................................................. 14
4.4
Standard Ranges of Analog Signals ............................................................... 14
4.5
Contact Ratings.......................................................................................... 14
4.6
Reliability and Availability............................................................................. 15
4.7
Standardization & Uniformity of Hardware ...................................................... 15
4.8
Redundancy ............................................................................................... 15
4.9
Operability & Maintainability ......................................................................... 16
4.10
Metering Bases of Units ............................................................................... 16
4.11
Grounding System ...................................................................................... 17
4.12
Flow Element Selection ............................................................................... 17
4.13
Drive Control Philosophy .............................................................................. 18
4.14
HT drives .................................................................................................. 20
4.15
Variable Frequency Drives (VFD) ................................................................... 21
SG INTEGRAL CONTROL SYSTEM ................................................................ 22
5.1
Control System Requirements ....................................................................... 22
5.2
General Requirements.................................................................................. 29
5.3
Redundancy in Measurements ...................................................................... 43
5.4
Other SG Related System/ Equipments........................................................... 46
5.5
SG Auxiliaries ............................................................................................ 55
6.
DISTRIBUTED CONTROL SYSTEM (DCS) ....................................................... 65
6.1
General Requirements.................................................................................. 65
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6.2
Design Requirements ................................................................................... 66
6.3
System Configuration .................................................................................. 71
6.4
DCS Sub-Systems .................................................................................... 107
6.5
DCS Power Supply Requirements ................................................................ 121
6.6
DCS System Cabinets/Panels...................................................................... 122
6.7
DCS System Response Requirements........................................................... 122
7.
PROGRAMMABLE LOGIC CONTROL (PLC) ................................................... 126
7.1
General Technical & Design Requirements .................................................... 126
7.2
PLC System Configuration ......................................................................... 127
8.
COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM (CMMS)................. 131
8.1
General ................................................................................................... 131
8.2
Functional Requirement ............................................................................. 131
8.3
Design Requirements ................................................................................. 135
9.
SMART TRANSMITTER MAINTENANCE STATION (STMS) ............................. 136
9.1
General ................................................................................................... 136
9.2
9.3
Functional Requirements ............................................................................ 136
10.
STATION WIDE LOCAL AREA NETWORK ..................................................... 138
10.1
General ................................................................................................... 138
10.2
Design & Functional Requirements .............................................................. 139
10.3
Security Features Requirements .................................................................. 140
10.4
Network Monitoring & Management Requirements ......................................... 142
11.
STEAM & WATER ANALYSIS SYSTEM (SWAS) ............................................ 144
11.1
General Requirements................................................................................ 144
11.2
11.3
Sample stream Requirements...................................................................... 145
11.4
Sample Conditioning System ...................................................................... 146
11.5
Sample Pumps ......................................................................................... 149
11.6
Sample Patch Board .................................................................................. 150
11.7
Grab Sample ............................................................................................ 150
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11.8
Sample Sink............................................................................................. 150
11.9
Analyzers ................................................................................................ 150
11.10 SWAS Panels ........................................................................................... 161

11.11 Constructional Features ............................................................................. 162
11.12 Piping, Tubing & Accessories ..................................................................... 162
11.13 Wiring ..................................................................................................... 164
11.14 Power Supply & Grounding ........................................................................ 164
11.15 Lighting & Receptacles .............................................................................. 165
11.16 Control & Monitoring System ..................................................................... 165
12.
CONTINUOUS STACK EMISSION MONITORING SYSTEM ............................... 166
12.1
General ................................................................................................... 166
12.2
12.3
Technical Requirements of Analyzer Shelter .................................................. 167
12.4
Technical Requirements of Analyzers ........................................................... 169
13.
VIBRATION MONITORING SYSTEM............................................................. 172
13.1
General ................................................................................................... 172
13.2
Design & Functional Requirements .............................................................. 172
13.3
Technical Requirements ............................................................................. 173
14.
FIELD INSTRUMENTS & FINAL CONTROL ELEMENTS .................................... 178
14.1
14.2
Pressure / Differential Pressure / Flow / Level Transmitter ............................... 178
14.3
Temperature Transmitter............................................................................ 180
14.4
Thermocouple .......................................................................................... 182
14.5
Resistance Temperature Detector (RTD) ....................................................... 184
14.6
Metal Temperature Thermocouple ............................................................... 185
14.7
Cold junction Compensation (CJC) Boxes ..................................................... 186
14.8
Thermowell for Temperature Elements ......................................................... 187
14.9
Pressure Gauge/ Differential Pressure Gauge/Draft Gauge ............................... 188
14.10 Temperature Gauge .................................................................................. 190

14.11 Level Gauge ............................................................................................. 191
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14.12 Pressure/ Differential Pressure Switch .......................................................... 192

14.13 Conductivity Type Level Switch .................................................................. 194
14.14 Capacitance Type Level Switch .................................................................. 195
14.15 Float/Displacer Type Level Switch ............................................................... 195
14.16 Ultrasonic Level Transmitter ....................................................................... 196
14.17 Guided Wave Radar Type Level Transmitter .................................................. 198
14.18 Flow Switch ............................................................................................ 199
14.19 Rotameter ............................................................................................... 199
14.20 Sight Glass Indicator (Flow Glass) ............................................................... 200
14.21 Flow Elements.......................................................................................... 200
14.22 Oxygen Analyzer ...................................................................................... 203
14.23 Carbon Monoxide Analyzer......................................................................... 204
14.24 Control Valves ......................................................................................... 205
14.25 Solenoid Valves ........................................................................................ 212
14.26 Dew Point Meter ...................................................................................... 212
14.27 Speed Probe ............................................................................................ 213
14.28 Speed Transmitter .................................................................................... 213
14.29 Flow/No Flow Detector Switch ................................................................... 213
15.
PROCESS CONNECTION PIPING ................................................................. 215
15.1
Design Pressure and Temperature ............................................................... 215
15.2
Sizes of Instrument Primary Piping .............................................................. 216
15.3
Materials for Instrument Primary Piping ........................................................ 216
15.4
Insulation of Instrument Primary Piping ........................................................ 216
15.5
Process Connection Size ............................................................................ 216
15.6
Impulse Piping, Tubing, Fittings, Valves & Valve Manifolds ............................. 218
15.7
Air Supply Piping ...................................................................................... 223
16.
INSTRUMENTATION CABLES & ACCESSORIES ............................................ 226
16.1
Specifications of Instrumentation Cables ...................................................... 226
16.2
Specifications of Optical Fibre Cables (OFC) ................................................. 231
16.3
Instrumentation Cable Interconnection & Termination Philosophy ..................... 235
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16.4
Terminal Blocks ........................................................................................ 236
16.5
Internal Panels, Cabinets, System Cabinet Wiring Philosophy ........................... 237
16.6
Cable Installation & Routing ....................................................................... 238
16.7
Cable Laying ............................................................................................ 238
16.8
Cable Accessories..................................................................................... 239
16.9
Cable Conduits ......................................................................................... 240
16.10 Cable Sub Trays & Support ........................................................................ 241

17.
SYSTEM CABINETS, PANELS & JUNCTION BOX .......................................... 243
17.1
17.2
System Cabinets ...................................................................................... 244
17.3
Marshalling Cabinets ................................................................................. 245
17.4
Local Instrument Enclosure & Racks ............................................................ 246
17.5
Local Junction Box ................................................................................... 247
18.
TIME SYNCHRONIZATION SYSTEM (MASTER CLOCK SYSTEM) ..................... 249
18.1
General ................................................................................................... 249
18.2
19.
NINTERRUPTED POWER SUPPLY (UPS) ....................................................... 251
19.1
General ................................................................................................... 251
19.2
Scope of Supply ....................................................................................... 251
19.3
Technical requirements .............................................................................. 251
19.4
Functional requirements ............................................................................. 252
19.5
Normal Operation ..................................................................................... 252
19.6
Emergency operation ................................................................................. 253
19.7
Static inverters and auxiliary equipment ....................................................... 254
19.8
Static transfer switches and auxiliary equipment ........................................... 256
19.9
Battery Charger Auxiliary Equipment ............................................................ 259
19.10 Ground Detector System............................................................................ 260

19.11 UPS Battery ............................................................................................. 260
19.12 Battery Accessories .................................................................................. 261
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1.1
General
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This specification is intended to provide the technical guidelines for the fully
coordinated Control & Instrumentation (C & I) system for the Steam Generators
and its Auxiliaries of [210/215/220/250] MW, Coal fired Subcritical Thermal
Power Plant. DCS & other common systems/items procured under TG package
shall be deleted from SG package.
The Control and Instrumentation system for the plant shall be designed to ensure
safe, efficient and reliable operation of the plant under all regimes of operation
namely start up, shutdown, normal operation, part load operation and under
emergency conditions resulting in cost effective power generation with optimum
fuel consumption and reduced emission levels.
The technical specification shall serve as the guide specification for the
proprietary controls like Boiler & its integral control, Burner Management System,
Furnace Protection System including Master Fuel Trip (MFT), Safety Shutdown
System, etc equipment packages, as also various stand alone system controls
included as part of sub-packages, as in case of plant auxiliaries. It is not the
intent or purpose of this specification to give details of every single item that
might be required for completeness and/or proper integration of the overall
system.
It is to be noted that where equipment or system for the Steam Generating Units
are described, it shall be understood that the quantities described are per unit
basis, i.e., identical sets to be furnished for each of the units. Where equipment
or systems for common facilities are described, it shall be understood that the
quantities described are the total quantities required.
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SYSTEM DESCRIPTION
The plant C&I system is envisaged to be configured by interfacing main plant
control system for Station C&I namely Plant DCS interfaced with SG Integral
control system (Separate Control system or implemented in DCS) and provided
with different special plant monitoring and analysis systems to provide
supervisory and reporting facilities to plant personnel and management.
The plant C&I system is envisaged to permit centralized operation and monitoring
of the power plant from the central control room (CCR). The system shall consist
of a functionally distributed microprocessor based system (DCS) with facility for
VDU (Video Display Unit) / Keyboard & Large Video Screen based operation,
control and monitoring.
SG Integral control system shall include Burner Management System (BMS) &
Boiler protection system and could be an independent microprocessor based
control system. BMS & Boiler Protection system shall be a fail-safe type system
conforming to SIL 3 with certification from authorized agency.
SG Integral Control system (For BMS & Boiler protection system) shall be
interfaced with Plant DCS through redundant bi-directional OPC link with
Ethernet based TCP-I/P protocol or by only Ethernet based TCP-I/P protocol.
The plant C&I system is envisaged to be configured by interfacing main plant
control system namely Plant DCS interfaced with other different plant control
systems namely, TG Integral control system and other utility and auxiliary plant
control systems (unit specific and plant common systems) and provided with
different special plant monitoring and analysis systems to provide supervisory
and reporting facilities to plant personnel and management.
The control requirements of the main power plant comprising SG with associated
auxiliaries (except for SG Integral control systems) to be implemented in
microprocessor based Distributed Control system.
Following PLC based systems shall be interfaced with plant DCS through
redundant unidirectional OPC link with Ethernet based TCP-I/P protocol.
ESP Control System
Auxiliary Boiler Control System (if applicable)
CCR operation / monitoring of equipment/systems under SG Integral control
systems shall be through plant DCS system OS /LCD.
A common time synchronization system is envisaged for time synchronizing of
all programmable control systems like SG Integral control system, TG Integral
Control System plant DCS, PLC control systems etc. for the whole station.
Operation and Monitoring of Plant Electrical 11 kV, 6.6 kV and Downstream
System shall be performed through Plant DCS. Additionally, DCS shall have a
redundant Software link with Substation Automation System (SAS) for
monitoring of 400 KV & 220 KV switchyard systems. Switch yard system
equipments shall be primarily operated from CCR (Operator stations shall be
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provided in CCR by extending the SAS bus) and control/monitored from SAS in
Switchyard. For SOE inputs hardwired signals shall be connected to Plant DCS.
3
DESIGN PHILOSOPHY
This section covers the design philosophy which shall be used for all control &
instrumentation system for steam generator & its auxiliaries.
1. Pressure indicators shall be used wherever indicating type Pressure transmitters
are not envisaged. The applications include:
a) Suction and discharge lines of pumps & fans, including header section, if two
or more pumps are employed for the same service.
b) All input and output lines of process equipments.
c) Inlets and outlets of heat exchangers (both the fluid media) and de-super
heaters.
2. Pressure Switches shall be avoided as far as possible and in place, smart
pressure transmitters with soft limit value monitoring in Plant DCS shall be used.
The applications shall include the following:
a) On all process lines / Equipments where parameter abnormality / status
including pre trips alarms to be communicated to the operator in control
room.
b) For all permissive and protection conditions governed by safety operation of
the equipments. e.g. pressure adequate, pressure very high / very low
conditions.
c) For all interlock conditions, governing starting of standby equipment or
subsequent equipments for safety operation of the system.
d) Inlet and outlet of filters / strainers.
3. Differential Pressure Switches (indicating
filters/strainers for remote monitoring.
type)
shall
be
used
across
4. Smart Pressure Transmitter shall be used for all control applications and as
demand by the process. Pressure stubs with isolating valves shall be used.
5. Differential Pressure Transmitter shall be used for all the requirements of
differential pressure, flow, level measurement. Pressure stubs with isolating
valves shall be used.
6. Temperature indicators (Thermometers) shall be used for following applications
a) On all process lines where local indication is warranted by the system either
for monitoring or testing.
b) On the inlet/outlet of equipments such as desuper-heaters, Heat Exchangers
& Coolers for both the fluid media.
c) Differential temperature indicator shall be used across BFP suction and
discharge service.
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7. Temperature Elements: Thermocouples / RTDs shall be used for casing metal

temperature monitoring and bearing temperature monitoring of HT drives/motors.
a) The elements shall be duplex type with integral thermowell (except for metal
thermocouples). K Type Thermocouples shall be used for all temperature
measurements wherever possible. However, for high temperature flue gas
services R or S type thermocouple shall be used. For metal thermocouples
suitable MS pads, clamps, flexible extension lengths etc. shall be used.
Temperature elements in boiler and air ducts shall be used with protective
tubes. Both the elements of duplex temperature sensors shall be brought to
junction boxes.
b) Compensating cable shall be used with all thermocouples for terminating to
the control system eg. Plant DCS.
c) Six nos. (2 nos. per phase) Resistance temperature detectors (RTDs) shall be
used for all HT motors, for winding temperature monitoring. Each element
shall be 3-wire type, duplex with thermowell assembly. RTDs shall be
terminated in the external terminal box, for connection to Plant DCS system.
d) 1 no. duplex PRT-100 type RTD shall be used for each bearing of HT
equipment and its driving equipment (motor).
e) All RTDs shall be PRT-100 type with each element being 3-wire type, duplex
with thermowell assembly. RTDs shall be terminated in the external terminal
box, for connection to Plant DCS system.
f) For process temperature up to 200 degree C, RTD shall be used. Beyond 200
*C temperature thermocouple to be used.
g) Temperature measurement shall have upscale / down scale protection
features not to cause major process upset in case of sensor failure.
8. Level gauges shall be used on all tanks and the maximum length of one gauge
glass shall not exceed 1 meter. The gauge glasses shall be stacked to cover the
complete height of the tanks including over flow level. There shall be an overlap
of minimum 100mm, when more than one level gauge is required.
9. Level switches: The instrument shall be used for the following applications:
a) On all equipments (storage vessel) where parameter abnormality/status has
to be communicated to the operator in the control room.
b) All permissive, interlock and protection conditions governed by the safe
operation of the equipment.
c) The instrument shall be external cage type with SW connection with isolation
facility for surface mounted tanks and top mounted with still pipe for all
sumps. Still pipes shall be used with adequate supports.
d) Conductivity type level switches shall be used for all heaters and drain pots.
e) Radar type level switches shall be used for bulk material bunkers.
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10. Level Transmitters Stubs with impulse pipes, root valves for mounting Level
transmitters shall be used on process equipments where continuous remote
monitoring and/or control of level is envisaged. Wherever necessary standpipes
or float chambers and also makeup line shall be used for filling up the constant
level vessel.
a) The instrument shall be differential pressure type for boiler drum etc.
b) Radar type level transmitter shall be used for fuel oil storage tanks.
c) Admittance or Radar type shall be for sludge and slurry applications.
11. Flow Glasses shall be used at the outlet of the pipe lines and shall be employed
under the following conditions:
a) Coolers
b) The instrument shall be rotary type with glass mounted for indication
c) Up to 6 inch on-line flow glasses shall be supplied and above 6 inch bypass
type flow glasses shall be used. Sight flow and variable flow indicators shall
be used for low pressure and low temperature applications.
12. Speed Measurement shall be used, where variable speed drives are controlled
from remote (e.g. feeders, ID fans etc). All speed sensors shall be non-contact
type. All speed transmitters shall be microprocessor based. Microprocessor
based speed switches shall be used for zero speed detection, chain cut
detection, locked rotor protection etc. Microprocessor based reverse rotation
switch shall be used for pump protections.
13. Pneumatically Operated Control Valves shall be used for all control application. If
the process demands any other control, then control valves shall be used for
those applications also. Where a single control valve cannot meet the turn down
ratio as dictated by the process, control valves with split range application shall
be used.
a) All bypass valves of control valves shall be motor operated valves suitable for
inching operation provided with position transmitters.
b) All integrated bypass valves shall be motor operated. Electro-pneumatic
positioners shall be used for all pneumatic control valves.
c) Pressure test points & drains shall be used across each control valve
14. The pneumatically operated control valves shall be used with Smart Positioners,
diagnostics and HART compatibility. Control Valve diagnostics shall be
transmitted through this HART Protocol to Plant DCS.
15. Solenoid Valves shall be used for all pneumatic control valves hooked up with
process interlock requirements and where direct tripping is involved. All solenoid
valves shall be uniformly rated for 24V DC or 220V DC. The number of ways for
solenoid valve shall be used as indicated below :
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a) On line two (2) way solenoid valves shall be used, where process line of less
than 2 inch with low pressure & temperature application is involved.
b) Three (3) way solenoid valves shall be used commonly, where the pressure is
admitted or exhausted from a diaphragm valve or single acting cylinder. E.g.:
Pneumatic operated spray water block valve.
c) Four (4) way solenoid valve shall be used for operating double acting
cylinders (If applicable). E.g.: Pneumatically operated on-off type dampers.
d) Dual coil, latch, unlatch type Solenoid valves shall be supplied for equipment
trips/critical applications.
e) Five port solenoid valves shall be used for pneumatic retract/insert
mechanism power cylinders for Oil gun, ignition gun etc.
16. Position Transmitters shall be used for all motorized inching valves. Position
transmitters shall be 24 V DC, 2 wire, non-contact type.
17. Electro-Pneumatic positioners shall be used for all pneumatically operated control
valves, power cylinders etc., for converting controller output of 4-20 mA to
appropriate pneumatic signal.
18. Air Filter Regulators along with gauges shall be used in each of the:
a) Air supply line to valve positioners /power cylinders
b) Air supply line to pneumatic interlocked block valves
19. Interposing relay (To be mounted in Control room cabinet) for interface to the
following:
a) Solenoid valve (if output module cannot directly drive SOV)
contact rating of minimum 2 Amps.
- Relays with
b) DC Starter ((if output module cannot directly drive) - Relays with contact
rating of minimum 0.2 Amps.
c) Hardwired signal exchange as required.
20. For all HT rotating equipment bearings provision for mounting vibration probes
shall be used.
21. Junction Boxes/Field termination cabinet: All JBs /FTCs shall be SS. Junction
Boxes shall be used for:
a) Termination of all sensors located equipment wise.
b) Termination of Duplex Thermocouples / RTDS
c) Termination of limit switch, torque switch, position transmitter and control
demand, independently for each valve.
d) Area wise or Elevation wise bunching of cables.
22. Instrumentation & control cables and Prefabricated Cables with Anti-Rodent
treatment shall be used to:
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a) Connect field instruments to field junction boxes/Local Panels. For switches,

both the SPDT contacts of switches shall be wired up to the J.B.
b) Connect limit switches, torque switches and position transmitters to their
respective field junction boxes.
c) Compensating cable shall be supplied for connection between the element
and the respective junction boxes / system cabinets as per guidelines.
d) Prefabricated cable for connecting between system cabinets, marshalling
cabinet to system cabinet, system cabinet to Relay Rack, system cabinets to
engineering work stations etc.
e) Entire I&C cable within the battery limits.
23. All field instruments including electronics located outside control room areas
shall be tropicalized and shall be designed to work in site specific
atmosphere/climatic conditions and enclosed in dust tight, waterproof and
weatherproof enclosures. In general, transmitters and switches installed at
outdoor location shall be mounted in closed type transmitter enclosure. For other
areas (indoor), open type racks may be used for installation of transmitters and
process switches.
24. Conventional hardwired alarm annunciation system has not been envisaged. All
alarm shall be displayed in the Plant DCS HMI/LVS. However where local panels
are used for local operation/monitoring, PLC/ DCS driven alarm annunciation
system with LED type lamps for local panel shall be used.
25. Pressure, temperature and flow test points shall be used in line with latest
performance test code requirements.
In general, pressure and temperature test points shall be used for the following
services:
a) At the discharge of all pumps and fans
b) At the inlet and outlet of the heat exchangers for the fluid media involved
c) Adequate number at the Combustor at different zones
d) At the inlet and outlet of each control valve
26. The ranges of the instruments shall be selected based on the following
philosophy:
a) For pressure and draft measurements, the maximum operating pressure shall
be within 70 to 80% of the maximum scale range.
b) For temperature measurement, the maximum operating temperature shall be
within 80 to 90% of the maximum scale range.
c) For pressure switches and temperature switches, the set points shall fall
within 40% to 70% of the scale range selected.
d) For level measurement, the maximum of the range shall cover the overflow
point or six inches from the top of the vessel and the minimum of the range
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shall be six inches above the bottom of the vessel. Also, the gauge glasses
shall be stacked with overlap to cover permissive, alarm and trip levels.
e) For flow measurement, the maximum range shall be fixed at about 10 to
15% above the maximum operating flow
f) For electro-chemical measurements (conductivity, pH, dissolved O2, Silica
etc.), the maximum range shall be around 10 to 15% higher than the
recommended alarm settings.
g) For gas analyzers, the maximum range shall be around 10 to 15% higher
than the recommended alarm settings.
27. Individual (one for each transmitter) purging line connected to the impulse line
before the root valve with required accessories shall be used for all Air and Flue
gas transmitters impulse lines.
28. Spring-loaded/ Cage clamp type terminals shall be used for termination of
instrumentation cables at field JBs, FTCs and local panels.
29. Signal Exchange Between Boiler Equipments / System and Plant DCS System
a) All the signals required for interlock / alarm / SER purpose (to be
Implemented in the Plant DCS) shall be hardwired.
b) All binary outputs provided to local panels/sensors for connection from Plant
DCS shall be potential free contacts with a rating of 0.2 amps at 220 V DC
or 2 amps at 24 V DC or 5 amps at 240 V AC. All check backs to Plant DCS
shall only be potential free contacts.
c) All analog outputs provided to local panels/sensors for connection from Plant
DCS shall be isolated 4-20 mA DC.
d) Command outputs from Plant DCS to motorized valve actuator shall be logic
level signal (24 V DC) and necessary interposing relays suitable to accept 24
V DC logic level command signal shall be used in MCC module for MOV
actuator.
e) Push buttons station/panel for safe emergency shutdown of the plant shall be
provided.
30. Flow elements for measurements of secondary airflow to the furnace & Primary
air flow to Pulverizer shall be used along with 3 (three) tappings for
measurement & Control and one tapping for test purpose.
31. Airflow shall be measured by aerofoil or venturi or by any special online
measurement technique with high accuracy (typically better than+/- 2%).
32. All indication lamps shall be LED type.
33. All interposing relays shall be Plug in type with screw type base & LED for status
indication. Relay modules/boards etc. are not acceptable.
34. All Limit Switch shall be Non-Contact type. If there is constraints because of
process conditions/space, mechanical lever actuated Limit switch may be used.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[8]
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DESIGN CRITERIA
4.1
This section covers the general design criteria to be adopted in designing the
Control & Instrumentation system for the SG Package.
Ambient Conditions
Instruments, devices and equipment for location in outdoor / indoor / airconditioned areas shall be designed to suit the environmental conditions
indicated below and shall be suitable for continuous operation in the operating
environment of a coal fired Power plant and also during periods of air
conditioning failure without any loss of function, or departure from the
specification requirements covered under this specification.
Table 4.1
Protection Class Requirement
Ambient
Temperature
(outside
temperature)
Pressure
Relative
Humidity
Required
Protection class of
panels / cabinets /
desks
Atmosphere
Outdoor Location
55 oC max
Atmosphere
100%Max
Air (dirty)
IP 65
4 oC min
Atmosphere
5% Min
Air (dirty)
IP 65
Atmosphere
95% Max
Air
IP 54
Atmosphere
5% Min
Air
IP 54
24 +/- 2 oC
Atmosphere
normal
95% Max
Air
IP 44
50 oC Max.
5 % Min
Air
IP 44
Indoor Location
55 oC max
4
C min.
Air-conditioned Area
Atmosphere
a) For Ventilated enclosures, protection class shall be IP 42.

b) For hazardous areas the protection class shall be in accordance with the
requirements of the relevant NEC code for the location.
c) For PCs, OWS, EWS, Servers, Printers and other peripherals, maximum
temperature limit shall be 35 oC, For LVS the same shall be 25 oC & for
UPS the same shall be 40 oC
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[9]
02.09.2015
4.2
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Codes & Standards

All equipment, system and service covered under this specification shall comply
with the requirements of the latest statutes regulations and safety codes as
applicable in the locality where the equipment/systems shall be installed.
The equipment, systems and services furnished as per this specification shall
conform to the latest edition of codes and standards mentioned in this section.
However in the event of any conflict between the requirements of two standards
or between the requirements of any standard and this specification, the more
stringent requirements shall apply unless confirmed otherwise by the
owner/owners engineer in writing. The decision of the owner shall be final &
binding in all such cases.
All equipments supplied under this specification shall be given tropical treatment
for the climatic conditions prevailing at site as described under project data.
Tropical protection shall confirm to IS-3202 (Climate proofing of electrical
equipments) or any other applicable international standard for protection of
Electrical power equipments against climatic conditions.
Reference Codes and Standards
The design, manufacture, inspection, testing, site calibration and installation of
all equipment and systems covered under this specification shall conform to the
latest editions of codes and standards mentioned below and all other applicable
ANSI, ASME, IEEE, NEC, NEMA, ISA, DIN, VDE and Indian Standards and their
equivalents.
Temperature Measurement
Instrument and apparatus for temperature measurement ASME PTC 19.3
Temperature measurement - Thermocouples ANSI-MC 96.1
Temperature measurement by electrical resistance thermometers IS: 2806.
Thermometer-element-platinum resistance-IS-2848 / DIN 43760/ IEC 751
Pressure Measurement
Instrument and apparatus for pressure measurement - ASME PTC 19.2
Bourdon tube pressure and vacuum gauges - IS 3624
Flow Measurement
Instrument and apparatus for Flow measurement ASME PTC 19.5 Interim
supplement, Part-II
Measurements of Fluid flow in closed conduit BS 1042 / ISO 5167.
Electronic measuring Instruments & Control hardware
Automatic null balancing electrical measuring instruments - ANSI C 39.4 (Rev.)
Safety requirements for electrical and electronic measuring and controlling
instrumentation - ANSI C 39.5.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[10]
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Compatibility of analog signals for electronic industrial process instruments ISA-S 50.1: ANSI MC 12.1.
Dynamic response testing of process control instrumentation - ANSI MC 4.1:
ISA-S26.
Surge withstand capability (SWC) tests - ANSI C 37.90a IEEE Std. 472. IEC 254.1.
Printed circuit boards - IPC TM-650, IEC 326 C
General requirements and tests for printed wiring boards - IS 7405 (Part-I)
Edge socket connectors - IEC 130-11.
Requirements and methods of testing of wire wrap terminations DIN 41611
Part-2.
Dimensions of attachment plugs & receptacles ANSI C73.
Direct acting Electrical Indicating Instruments: IS-1248.
Electronic Cards, Subassemblies & Components
1. Unpackaged
Vibration IEC 68.2.26
Shock IEC 68.2.27
Drop & Topple IEC 68.2.31
2. Packaged
Vibration, Drop & Static Compression NSTA
3. Electromagnetic Compatibility
Electrical Fast Transient IEC 801.4
Surge Withstand IEC 255.4
Radiated Electromagnetic Field IEC 801.3
Electrostatic Discharge IEC 801.2
Electromagnetic Emissions VDE 0871, Class B
Instrument Switches and Contacts
Contact rating - AC services NEMA ICS Part-2 125, A600
Contact rating - DC services NEMA ICS Part-2-125, N600.
Enclosures
Types of enclosures - NEMA Std. ICS-6-110.15 through 110.22 (Type 4 to
13).
Racks, panels, and associated equipment - EIA: RS-310-B (ANSI C83.9)
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[11]
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Protection Class for Enclosure, Cabinets, Control Panels and Desks - IS-13947,
& IEC 529.
Apparatus, enclosures and installation practices in hazardous areas
Classification of hazardous area - NFPA Art. 500, Vol.70.
Electrical Instruments in hazardous dust locations - ISA-RP 12.11
Intrinsically safe apparatus - NFPA Art.493 Vol.4.
Purged and pressurized enclosure for electrical equipment in hazardous location
- NFPA Art. 496.
Sampling System
Stainless steel material of tubing and valves for sampling system - ASTM
A269-82 Gr. TP316.
Submerged helical coil heat exchangers for sample coolers ASTMD 11-92.
Water and Steam in power cycle - ASME PTC 19.11.
Standard methods of sampling system - ASTM D 1066-69.
The system shall be based on established Standard & Codes of Practice, such
as GDCD 234 / 164 / 163, CEGB, UK.
Annunciator
Specifications and guides for the use of general purpose annunciator - ISA RP
19.1.
Surge withstand capability tests - ANSI C.37.90a and IEEE std. 472
Interlocks, Protections
Relays and relay system associated with electric power apparatus - IEEE
std.3.13.
Surges withstand capability tests - ANSI C.37.90a and IEEE Std. 472.
General requirements & tests for switching devices for control and auxiliary
circuits including contactor relays - IS-6875 (Part-I).
Boiler safety interlocks - NFPA Section 85B, 85D, 85E, 85F, 85G.
Control Valves
Flow Equation for Sizing Control Valves ISA S39.2
Control Valve Seat Leakage ANSI / FCI 70.2
Face to face Dimensions of Control Valves ANSI B16.10, ISA S75.03 &
ISA S75.16
Steel Pipe, Flanges & Flanged Fittings ANSI B16.34
Control Valve Capacity Test Procedure ISA S75.02
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[12]
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Industrial Process Control Valves - IEC 534

Process Connection and Piping
Codes for pressure piping power piping ANSI B31.1
Seamless carbon steel pipe ASTM A-106.
Forged and Rolled Alloy steel pipe flanges, forged fittings, valves and parts ASTM A-182.
Material for socket welded fittings - ASTM A-105.
Seamless Ferritic alloy steel pipe - ASTM A-335.
Pipe fittings of wrought carbon steel and alloy steel - ASTM A-234.
Composition bronze or metal castings - ASTM B-62.
Seamless copper tube, bright annealed ASTM B-168.
Seamless copper tube - ASTM B-75.
Dimensions of fittings - ANSI B-16.11
Valves flanged and butt welding ends - ANSI B16.34.
Nomenclature for Instrument tube fittings ISA-RP-42.1.
Instrument Tubing
Seamless carbon steel pipe - ASTM - A106.
Material for socket welds fittings - ASTM - A105.
Dimensions of fittings - ANSI B16.11
Code for pressure piping, welding, hydrostatic testing - ANSI B31.1.
Nomenclature for Instrument Tube Fittings ISA RP 42.1
Seamless Stainless Steel Tubes ASTM A 312 TP 304
Cables
Thermocouple extension wires/cables - ANSI C 96.1.
Colour coding of single or multi-pair cables - ICEA S-61- 402. (Third edition)
NEMA WCS.
Guide for design and installation of cable systems in power generating stations
(insulation, jacket materials) - IEEE Std. 422.
Requirements of vertical tray flame test - IEEE 383.
Standard specification for tinned soft or annealed copper wire for electrical
purpose - ASTM B-33 - 81.
Oxygen index and temperature index test - ASTM D-2863.
Smoke generation test - ASTMD-2843 and ASTME-662.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[13]
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Acid gas generation test - IEC-754-1.

Swedish chimney test - SEN - 4241475 (F3)
Instrumentation cables and internal wiring IS-1554 (Part-I) and IS: 5831.
Mono-mode Fibre ITU-T G.652 for Optical Fibre Cable
IEEE 1138 / IEC 1089 / EIA-455 B for Optical Fibre Cable
Cable Trays, Conduits
Guide for the design and installation of cable systems in power generating
station (cable trays, support systems, conduits) - IEEE Std. 422, NFPA-70.
Guide for the design and installation of cable systems in power generating
station (Cable trays, support systems, conduits) Test Standards, NEMA VE-1.
Galvanizing of Carbon steel cable trays - ASTM A-386-78.
4.3
Power Supply
All instruments and control devices shall be designed to operate on power
supplies as follows:
1. Electric:
a) 230 volts AC, 50 hertz, single-phase for low torque drives with guaranteed
satisfactory operation when equipment is continuously energized at any
voltage from 216VAC to 264VAC.
b) 24V DC for PLC & DCS.
c) 24 VDC, 110VAC or 230 VAC for Field Instruments.
4.4
2. Pneumatic:
Clean, dry, and oil free instrument air at 4.2 to 8.6 bars gauge. All necessary
pressure reducing controls, where required, shall be furnished by the equipment
supplier as specified at some other place under air compressors section.
Standard Ranges of Analog Signals
The ranges of analog signals shall normally be as follows:
a) Electric
--
4 to 20 mA DC.
b) Pneumatic
--
0.2 to 1.0 kg/cm2.
The use of any signal range other than the above shall not be acceptable.
4.5
Contact Ratings
The ratings of all instrument contacts used for alarms and interlocks shall be as
follows:
Table 4.2
Contact Ratings
Voltage Rating (volts)
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Continuous Rating
Description

Switching Rating (break)

Page
No.
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[14]
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4.6
1.
2.
3.
4.
4.7
4.8
1.
2.
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a)
240 AC
480 volt-amperes
1200 volt-amperes
b)
220 DC
60 watts
200 watts
c)
24 DC
12 watts
25 watts
The ratings of all microprocessor-based controller or programmable controller

output contacts shall be as required by the controlled devices. Where necessary
for higher current ratings or isolation, interposing relays shall be used.
Reliability and Availability
Each component and system shall be of established reliability. The minimum target
reliability of each piece of equipment like each electronic module/card, power
supply, peripheral etc. shall be established by considering its failure rate/mean
time between failures (MTBF), meantime to repair (MTTR), such that the
availability of the complete C&I system is assured for 99.7%.
Detailed reliability calculations shall be used for each system/ equipment (with the
help of a schematic of various sub-system connected in series or in parallel as the
case may be and MTBF & MTTR values for the various equipments). Availability
calculation shall be as per IEEE Standard-P1046 or equivalent.
When more than one device uses the same measurement or control signal, the
transmitter and other components/ module shall be fully equipped to provide all
signal requirements. The system shall be arranged so that the failure of any
monitoring device or control components or spurious intermediate grounding in the
signal path shall not open the signal loop nor cause the loss or malfunction of
signal to other devices using the same signal.
To ensure availability, adequate redundancy in system design shall be used at
hardware, software and sensor level to satisfy the availability criteria. For the
protection system, independent sensing device shall be used to ensure adequate
safety of plant equipment.
Standardization & Uniformity of Hardware
To ensure smooth and optimal maintenance, easy interchange ability efficient
spare parts management of various C&I instruments, ensure that all
instruments/devices (Processor modules, input/output modules, power supply
modules etc.) are of the same family of hardware. For example, all 4-20 mA
electronic transducers, control hardware, control valves, actuators instruments/
local devices etc. being furnished shall be boiler manufacturer specific. Take
special care towards selection of SG Integral Control system.
Redundancy
Reliability of the Control System shall be established by judicious incorporation of
redundancy. In general all critical parts shall have hot standby feature to render
the system immune to any single failure.
Measurement system (MS), Closed Loop Control System (CLCS) and Open Loop
Control System (OLCS) shall all be configured with redundancy at processor
modules, communication modules, data bus and power supply modules.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[15]
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4.9
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3. Both CLCS & OLCS shall be configured with I/O channels redundancy for each
sensor/signals. Where redundant sensors are provided redundant I/O channels
shall be used for each sensors/signals.
4. Two out of three measurements philosophy shall be adopted for the control of all
closed and critical open loop variables for reliability of operation. The control
system shall select the median value for the normal control purpose.
Operability & Maintainability
1. The design of the control systems and related equipments shall adhere to the
principle of Fail Safe operation wherever safety of personnel / plant equipment is
involved. Fail Safe operation signifies that the loss of signal or failure of any
component shall not cause a hazardous condition. However, it shall also be
ensured that occurrence of false trips are avoided / minimized.
2. The types of failure which shall be taken into account for ensuring operability of
the plant shall include but not be limited to:
a) Failure of sensor or transmitter,
b) Failure of main and/or redundant controller/other modules,
c) Loss of motive power to final control element,
d) Loss of control power.
e) Loss of instrument air
3. The choice of hardware shall also take into account sound maintainability
principles and techniques. The same shall include but shall not be limited to the
following:
a) Standardization of parts.
b) Grouping of functions.
c) Interchangeability.
d) Malfunction identification facility/self surveillance facility.
e) Easy modular replacement.
f) Fool proof design providing proper identification and other features to
preclude improper mounting and installation.
g) Appropriate derating of electronic components and parts.
4.10
Metering Bases of Units

The following system of units shall be followed throughout the specification
unless otherwise mentioned.
Table 4.3
Metering Bases of Units
S.N
1
2
Parameter
Pressure
Differential pressure
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Unit
Kg/sq. cm
mm of H2O column or Kg/sq. cm
Description
Page
No.
Date of Issue
[16]
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S.N
3
4
Parameter
Draught
Vacuum
Unit
mm of H2O column
mm of Hg
Temperature
Flow (Steam /
Feedwater)
Flow (Air / Gas)
Flow (Oil)
Density
Level
Conductivity
Degree Celsius
6
7
8
9
10
11
4.11
4.12
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Tonnes / hr or Kg/hr
Tonnes / hr or N. Cu. M /hr
Tonnes / hr or Kg/hr
gm / cu.cm
mm or M
Micro-mho/cm
Grounding System
All panels, desks, cabinets shall be used with a continuous bare copper ground
bus. The ground bus shall be bolted to the panel structure on bottom on both
sides. The bolts shall face inside of panels.
The system ground shall be isolated from the panel ground with suitable
isolators. All internal component grounds or common shall be connected to the
system ground, which shall be fabricated of copper flat (size 25 mm x 6 mm
min, length as applicable).
Shield on instrumentation cables shall be grounded on panel side. When shielding
termination is required in cabinets furnished under this specification, suitable
terminals shall be furnished on copper flat forming system ground. System and
shield ground shall be connected to earthing strip at 0.0 meter level using
suitable size of cable.
Flow Element Selection
Table 4.4
Flow Element Selection
Sl.
No.
Type of
Flow
meter
Orifice
Fluid
medium
Water
Plate
(DM
Water)
Orifice
Plate
Steam
Flow
nozzle(AI
SI
Type316
L)
Water
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Pipe sizes
Application
suitable for FE
Type of
connectio
n
As per
process
requirement
For all sizes

Except very
large
diameter pipe
DM Water
Flow To
CST
Flange
For any
condition
< 3
Soot
blowing
steam flow
BW
As per
process
requirement
For all pipe

sizes except
very large
diameter
Pipe
Process
Parameter
Description
(i) FW Flow
to boiler
drum
(ii) SH/RH
Spray water
flow
BW
Page
No.
Date of Issue
[17]
02.09.2015
4.13
Flow
nozzle(AI
SI
Type316
L)
Steam
As per
process
requirement
As per
process
requirement
For all pipe

sizes except
very large
diameter
Pipe
Air foil
Air
All duct sizes
Any
Other
Services
required.
Subject to Owner / Consultants approval.
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AUX. Steam
BW
flow
(i) Primary
air flow
BW
(ii)secondary BW
air flow
Drive Control Philosophy

The Drive control & measurement philosophy for the project is detailed in this
section.
1. Bi-directional drives (inching or open/close)
a) All bi-directional drives shall be operable from Remote i.e. from CCR.
b) Remote manual operation of all drives shall be carried out from OWS.
c) Remote Open/Close commands, generated in control system shall be issued
to MCC module through interposing relays located in respective MCC module
in the MCC room. Latching of commands shall be used in control system
logic which shall be reset by Limit/Torque switch feedback. The Limit/Torque
switch feedback from drive shall be directly wired to Control System.
d) Necessary Electrical protections shall be realized at MCC module whereas
process interlocks & protections shall be realized in Control system.
e) Following signal exchange shall be envisaged between Drive & Control
system:
Open Limit Switch (Both NO & NC contacts)
Close Limit Switch (Both NO & NC contacts)
Open Torque Actuation
Close Torque Actuation
Position feedback (4-20 mA, two wire electronic type) for inching drive
f) Following signal exchange shall be envisaged between MCC & Control
system (Remote I/O cabinet of control system located in/near MCC room):
Switchgear available
Switchgear disturbance
Open Command
Document Number
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No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[18]
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Close Command
2. Unidirectional LT drives
a) Unidirectional LT drives shall be operable only from Remote i.e. from CCR. In
addition, Local pushbutton shall be used only for emergency stopping of
drive. Local start operation of the drive is not envisaged.
c) Remote Start/Stop commands shall be generated in Control system & shall be
issued to MCC module through interposing relays located in respective MCC
modules.
d) Emergency stop of the drive shall be envisaged from the local pushbutton
provided near the drive. The stop push button (Stay put type) shall be used
with a press to lock & turn to release type keyless mechanism. Under locked
position the drive operation is inhibited from remote. The local emergency
stop push button shall be wired directly to MCC.
e) Necessary Electrical protections shall be realized at MCC module whereas
process interlocks & protections shall be realized in Control system.
f)
Current transducer with 4-20 mA type outputs shall be used in the MCC for
monitoring the current in Control System for all Drives greater than 90 KW.
Auxiliary power supply to these transducers shall be from the control supply
of the respective MCC modules.
g) Following signal exchange shall be envisaged between MCC & Control

system(Remote I/O cabinet of control system located in MCC room):
Switchgear available
Switchgear disturbance
On Feedback
Off Feedback
Start Command
Stop Command
h) All Numerical relays/Intelligent controllers for LT drives shall be interfaced to Control
System through IEC 61850 protocol.
3. Solenoid Operated drives
a) Solenoid operated drives shall be operable only from Remote i.e. from CCR.
c) Remote Open/Close commands shall be generated in Control system & shall
be issued to the Solenoid through interposing relays, located in Relay Panel.
d) Necessary process interlocks shall be realized in Control system.
Document Number
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No.
LII-GETS12021-G-00129-001
03
Description
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No.
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e) Following signal exchange shall be envisaged between solenoid drive &

Control system:
Open Limit Position
Close Limit Position
Open Command
Close Command
4.14
HT drives
1. HT drives shall be operable only from Remote i.e. from CCR. In addition, Local
pushbutton shall be used only for emergency stopping of drive. Local start
operation of the drive is not envisaged.
2. Remote manual operation of all drives shall be carried out from OWS.
3. Remote Start/Stop commands shall be generated in Control system & shall be
issued to MCC module through interposing relays located in respective MCC
modules.
4. Emergency stop of the drive shall be envisaged from the local pushbutton
provided near the drive. The stop push button (Stay put type) shall be used with a
press to lock & turn to release type keyless mechanism. Under locked position the
drive operation is inhibited from remote. The local emergency stop push button
shall be wired directly to MCC.
5. Necessary Electrical protections shall be realized at MCC module whereas process
interlocks & protections shall be realized in Control system.
6. Current transducer with 4-20 mA type outputs shall be used in the MCC for
monitoring the current in Control System for all Drives. Auxiliary power supply to
these transducers shall be from the control supply of the respective MCC modules
7. Following signal exchange shall be envisaged between MCC & Control
system(Remote I/O cabinet of control system located in MCC room):
a) Switchgear available
b) Switchgear disturbance
c) Master Trip relay Operated
d) On Feedback
e) Off Feedback
f) Trip Feedback
g) Emergency stop feedback
h) Start Command
i)
Stop Command
j)
Current Feedback
8. All Numerical relays/Intelligent Controllers for HT drives shall be interfaced to

Control System through IEC 61850 protocol.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
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4.15
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Variable Frequency Drives (VFD)

1. VFD shall be operable from Remote i.e. from CCR & from VFD Local Display unit.
In addition, Local pushbutton shall be used only for emergency stopping of drive.
2. Remote manual operation of VFD shall be carried out from OWS.
3. Remote Start/Stop commands shall be generated in Control system & shall be
issued to VFD Panel through interposing relays located in VFD Panel.
4. Emergency stop of the drive shall be envisaged from the local pushbutton
provided in the field. The stop push button (Stay put type) shall be used with a
press to lock & turn to release type keyless mechanism. Under locked position the
drive operation is inhibited from remote. The local emergency stop push button
shall be wired directly to VFD panel.
5. Necessary Electrical protections shall be realized at VFD module whereas process
interlocks & protections shall be realized in Control system.
6. Following signal exchange shall be envisaged between VFD & Control system:
a) Switchgear available
b) Switchgear disturbance
c) On Feedback
d) Off Feedback
e) Trip Feedback
f) Emergency stop feedback
g) Start Command
h) Stop Command
i)
Current Feedback
j)
Speed feedback
k) Speed Setpoint
7. The VFD shall also be interfaced with control system via Modbus soft link.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[21]
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SG INTEGRAL CONTROL SYSTEM

The microprocessor based Control System shall be used for the safe and efficient
operation of Steam Generator Protection in all regimes of operation.
Implementation of all the control, monitoring, interlock and protection schemes
for Steam Generator integral control system which include MFT scheme, Flame
monitoring system, Burner management system, Boiler/Furnace protection,
Furnace Purging etc. PLC or DCS shall be offered to implement the SG integral
control system. The SG integral system shall be interfaced with Plant DCS
through redundant data highway.
For all the OLCS & CLCS for SG and auxiliaries like Coordinated Master control,
furnace draft control, Super heater and Re-heater steam temperature control, fuel
oil flow/ fuel oil pressure control, combustion air flow control, pulveriser coal/ air
temperature control, primary air pressure control, Fans start stop interlocks,
SADC, Soot blower control etc. Control schemes and logics & write ups shall be
provided to the Plant DCS supplier for implementation within Plant DCS system.
5.1
Control System Requirements

1. The SG Integral control system shall consists of the following System controls:
a) Burner Management System (BMS) including SG Protection System, Furnace
Purging & Master Fuel Trip (MFT)
b) Coal Mill & Feeder Control Logics
c) Furnace flame monitoring system
d) Furnace Flame viewing & analysis system
e) Auxiliary Steam System
2. All hardware / software, whether or not specifically indicated in this specification
shall fully meet operational / maintenance / safety requirement as well as
statutory / international standards and proven practices.
3. The Control System shall function reliably under the environmental conditions as
specified in Design Criteria/Philosophy of this specification. It shall be immune
from the interference resulting from disturbance in power supply feeders, signal
lines, inputs, outputs, etc. as experienced in a Power station.
4. The Control System shall have on-line simulation and testing facility. Further, it
shall be possible to on-line configure and tune controllers through engineering
workstation.
5. The system shall have the flexibility to easily reconfigure any controller at any
time without requiring additional hardware or system wiring changes and without
disabling other devices from their normal operation mode. Modifications shall not
require switching off power to any part of the system.
6. Power supply to individual functional group shall be from redundant 24 V DC
feeders with diode auctioneering and further sub-distribution.
Document Number
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7. Independent and dedicated controllers (main and its 100% standby) shall be
used for each of the System except for SG protection system where triple
redundant controllers are to be used as per this specification. All the 100% hot /
redundant backup controllers shall be identical in hardware and software
implementation to their corresponding main controllers and shall be able to
perform all its tasks. The backup controller shall track its corresponding main
controller. There shall be an automatic and bumpless switchover from the main
controller to its corresponding backup controller in case of main controller failure
and vice versa without resulting in any change in control status. In case of
switchover from main controller to the 100% hot backup controller, the back-up
controller shall work as the main controller. Facility shall also be provided for
manual switchover from main to 100% hot back-up controller and vice versa
from the Engineers Work Station.
8. The control system hardware design shall be such that it is able to withstand
power line disturbances.
9. The loop / logic reaction time shall be suitable to match actual process
requirements, subject to minimum requirement wherever specified.
10. The control system design shall ensure compliance of furnace safety related loop
and logic in CLCS & OLCS as per NFPA requirements.
5.1.1
Burner Management System (BMS)

1. Fully proven microprocessor based system, based on hardware and software
specially designed and proven for Burner Management application meeting the
proven-ness criteria shall be used to achieve the Boiler protection action e.g.
Master Fuel Trip (MFT), etc.
2. The BMS shall be used with automatic self-monitoring facility. All modules to be
used in this system shall be of failsafe design. Any single fault either in primary
sensor, I/O modules, multifunction controllers etc shall not result in loss of safety
function. All faults shall be annunciated to the operator right at the time of its
occurrence in the OWS.
3. Triple modular redundancy philosophy (TMR) hardware and software shall be
used for safety tripping of the Boiler. The system shall be fail safe type with
minimum Safety integrity Level 3 as defined in IEC 61508.
4. The MFT functions shall be implemented in a fault tolerant 2 out of 3 triple
redundant configuration. Each of the three independent channels shall have its
own dedicated processors, multifunction controllers, communication controllers,
I/O modules, interface etc. All the primary sensors/instruments for unit / boiler
protection shall be triple redundant. Signal for each trip input shall be time
stamped with 1ms resolution for SOE at the input level itself, without any
processing so as to enable analysis in sequence of event, the exact cause of trip.
5. The acquisition and conditioning of binary and analog protection criteria signals
for MFT shall be carried out in each of the three triple redundant channels. Each
channel shall compute the 2 out of 3 voting logic and issue a trip command. The
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trip signals of the three channels shall be fed to a failsafe 2 out of 3 relay
tripping unit for each drive. The protection criteria for tripping shall be executed
by a program which shall be identical in each of the triple redundant channel.
The check back contact signals of each relay of the 2 out of 3 relay tripping unit
shall be fed back to each of the triple redundant channels and shall be
continuously monitored for equivalence in each of them. In case one of the
independent channels or any of the triple redundant sensors is faulty, the same
shall be alarmed and the balance two channels / sensors shall be operated in 1
out of 2 mode.
6. The BMS shall be designed to :
a) Prevent any fuel firing unless a satisfactory purge sequence has first been
completed.
b) Prevent start-up of individual fuel firing equipment unless permissive interlocks
have first been satisfied.
c) Monitor and control proper equipment sequencing during its start-up and
shutdown.
d) Provide equipment status feedback and annunciator indication to the unit
operator.
e) Provide flame monitoring when fuel-firing equipment is in service and effect a
burner trip or master fuel trip upon warranted firing conditions.
f) Continually monitor boiler conditions and actuate a master fuel trip (MFT)
during adverse operating conditions which could be hazardous to equipment
and personnel.
g) Reliably operate and minimize the number of false trips.
h) Provide a master fuel trip relay independent of processors and I/O modules to
provide a completely independent trip path.
i)
Provide all logic and safety interlocks in accordance with National Fire
Protection Association (NFPA).
j)
Include a first out feature in all controllers to identify the cause of any burner
trip or boiler trip.
k) Provide a complete BMS diagnostic system for the operator to immediately

identify any system module failure.
l)
Allow burners and igniters to be started, stopped and tripped on a burner

basis.
m) Allow the automatic start and stop of burners based on boiler load. The
sequence of which burner shall be started or stopped shall be selected by the
operator from OIU/LVS.
5.1.2
Secondary Air Damper Control System (SADC)

1. SADC system shall be used to achieve the following functions
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a) Control of fuel air flow.

b) Control of auxiliary air flow at the oil elevations.
c) Control of wind box / furnace differential pressure.
d) Limit NOx content in the flue gas by modulation over fire dampers, if
provided
5.1.3
2. In case of tangentially fired boiler, SADC shall modulate fuel air dampers of each
elevations based on the signal that is representative of the Coal feed rate.
Further, the auxiliary air dampers at the oil elevations shall be modulated on fuel
oil pressure signal whereas the auxiliary air dampers at all other elevations shall
be modulated to maintain the wind box to furnace differential pressure.
3. In order to limit the NOX content in flue gas, SADC shall also include the control
of over fire dampers (if provided). The secondary air damper controls and
necessary interlocks to modulate or to open/close shall be incorporated as per
the requirements of the boiler design in plant DCS.
4. The secondary air damper control system shall also be provided even in case
front or front and rear fired boiler.
5. Individual position transmitters are to be provided for each of the secondary air
dampers and the same shall be connected to Plant DCS.
Auxiliary Steam System
1. Auxiliary steam System shall be of integral type pressure reducing and desuperheating stations (PRDS) along with de-super heater getting spray water
from Condensate Extraction Pump discharge.
2. The system shall consist of steam pressure control loop & steam temperature
control loop. Auxiliary steam system shall be implemented through a set of
redundant controller modules, I/O modules, redundant primary sensors etc. &
suitably interface with other SG C&I controls and system shall have control
provision from CCR.
3. Pressure and temperature measurements for control of Auxiliary steam system
shall be in 2/3 voting circuit.
4. The system shall be provided with the pressure gauges, pressure transmitters,
temperature elements and transmitters for monitoring and control purpose.
5.1.4
Binary Controls/ Open Loop Control System (OLCS) Functions

1. The OLCS shall include sequence control, interlock & protection for various plant
auxiliaries/valves /dampers/drives etc. The sequence control shall provide safe
and automatic start up and shut down of plant and of plant items associated
with a plant group. The interlock and protection system shall ensure safe
operation of plant/plant items at all times and shall automatically shut down
plant/plants items when unsafe conditions arise.
2. The OLCS shall be arranged in the hierarchical control structure consisting of unit
level, group level, subgroup level and drive level (as applicable).
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3. It shall be possible to perform automatic unit start up and shutdown by issuing

minimum number of command from OWS / LVS. Thus, the unit level shall control
all the Control System Blocks and issue appropriate start up and shutdown
commands to various blocks of Control System.
4. The group level shall control a set of functional sub-groups of drives. Appropriate
start-up and shut down commands shall be issued to the sub-group control and
various check-backs shall be received from sub-groups of drives. Each sub-group
shall execute the sequential start-up and shut down programs of a set of interrelated drives along with system interlocks and protections related to individual
drive falling under that sub-group. The drive level shall accept commands from
the sub-groups, push buttons (wherever provided) etc., and transmit them to the
respective drive, after taking into account various interlocks and protections and
the safety of that particular drive. For HT drive, first-up logic shall be
incorporated to indicate the cause of protection / trip.
5. A sequence shall be used to move a set of groups and sub-groups from an initial
steady state (for instance 'OFF') to a final steady state (for instance 'ON'). The
sequence initiating command for the unit and group level shall be issued from
OWS/LVS.
6. A sequence shall be made of steps. The steps shall be executed in
predetermined order according to logic criteria and monitoring time consisting of
the interlock & protection requirements and check back of previous step which
shall act as pre-conditions before the sequence control can execute the
command for that step.
7. Each step shall have a "waiting time" implying that the subsequent step would
not be executed unless the specified time elapses. A monitoring time shall also
be defined as the maximum time required in executing the commands of any
step and the time required for appearance of check back signals. In case, this is
not completed within the specified time, a message shall be displayed and
programme shall not proceed further.
8. Manual intervention shall be possible at any stage of operation and the sequence
control shall be able to continue at the correct point in the programme on return
to automatic control. Protection commands shall have priority over manual
commands, and manual commands shall prevail over auto commands.
9. Open or close priority shall be selectable for each drive.
10. The sequence start up mode shall be of the following types:
a) Automatic Mode
In this mode of operation, the sequence shall progress without involving any
action from the operator. The sequence start / stop command shall be issued
from the OWS / LVS.
b) Semi-Automatic Mode
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In this mode of operation, once the sequence is initialized, the step

progressing shall be displayed on the OWS / LVS. But the step execution
command shall be prevented and shall be sent by the operator via the
keyboards. It shall be possible to bypass and / or simulate one or more
criteria to enable the program to proceed. This facility shall allow the program
to be executed even if some criteria are not fulfilled because of defective
switching devices, etc., while the plant condition is satisfactory. All the
criteria bypassed shall be logged and displayed. It shall be possible to put the
system on the Auto-mode after operating it on semi-automatic mode for
some steps or vice-versa, without disturbance to the sequence operation.
c) Operator Guide Mode / Test Mode
It shall be possible to use the sequential control in operator guide mode / test
mode i.e. the complete system runs and receives input from the plant and the
individual push button stations (where provided) / keyboards but its
command output is blocked. The whole programme, in this case shall run in
manual mode. This mode shall allow the operator to practice manual
operation using step and criteria indications. The actual protection should
remain valid during this mode of operation also.
11. The sequence shall be started by putting the sequence on auto and on receipt
of start command from the OWS / LVS or from a higher-level group / protection
action as defined. The sequence shall then progress as per the defined logics. It
should be possible to select alternative operation in the same sequence
depending on certain process / equipment condition. Some step can be
automatically bypassed also based on certain process / equipment condition.
When the expected results of the sequence are reached the sequence is
considered as END. If during sequence initialization or sequence progressing or
during normal running of the drive, a shutdown criterion is present, the sequence
shall be stopped and the shut down sequence initiated.
12. For the drives, the command shall be used through O/P module to MCC / SWGR
/ Actuator as applicable and input (status, SWGR and process) shall be acquired
through input modules. The drive logic shall be implemented in the redundant
controller. The status for the 11 KV, 6.6 KV drives and some other important
drives shall also be wired in parallel to redundant input modules so that on failure
of the single input modules, the information regarding the status of the affected
drive remains available in OLCS.
13. The output modules shall have the feature that ensures that in case of failure, all
the outputs are driven to zero. The 24V DC command outputs to drives for ON /
OPEN, OFF / CLOSE shall be separate and independent and the inverted outputs
shall not be employed. For inching type of drives, position transmitter shall be
used.
14. The termination for ON / OPEN, OFF / CLOSE command for the drive actuator
shall be performed. However ON/OPEN feedback, OFF/CLOSE feedback, Switch
gear disturbance feed back as a minimum shall be monitored in OLCS.
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15. The drive function i.e. basic interlocks and protection logic of the drive shall be
implemented in redundant controllers. The drive function shall ensure that
protection signals for the safety of the drive shall be effective under all
conditions and under all modes of operation. The different commands shall be
performed according to the priority of protection OFF, protection ON, manual
and automatic. The standard functions like running time monitoring, status
signaling, alarm / drive annunciation, etc. shall be performed in drive function.
The drive function shall prevent hunting of the actuator in the presence of both
open and close commands for actuators of the valves and dampers. The drive
function shall be implemented in dedicated standard software functional block
5.1.5
Analog Controls/ Close Loop Control System (CLCS) Functions

1. The CLCS shall continuously act on valves, dampers or other mechanical
modulating devices such as hydraulic coupling etc., which alter the plant
operation conditions. The system shall be designed to give stable control action
in steady state condition and for load changes in step / ramp over the load range
of 60% to 100% MCR with variation or parameters within permissible.
2. The controller capability shall, as a minimum, include (i) P, PI, PD and PID control
functions and their variations (ii) cascade control (iii) feed forward control (iv)
state-variable based predictive control for SH/RH temperature control (v) on-off
control, (vi) ratio and bias control, (vii) logical operation etc. The loop reaction
time (from change of output of the sensor of the transmitter/temperature
element to the corresponding control command output) shall be within 250 ms.
However, for faster loops such as feed water, furnace draft, PA header pressure
control loop etc. the same shall be based on actual process requirement.
3. The loop response time, for conventional I/Os, is the cumulative response time
inclusive of input scan time, Controller Execution time and output card
throughput time (in other words loop response is the time taken by the system
to read a change in field signal at the input card terminal, process the controller
task associated with the input and to make the required change in the control
output at the output terminal of the output card)
4. The control system shall be bumpless transferred to manual on the conditions
such as Control power supply failure, failure of redundant controllers, field input
signal not available, analog input exceeding preset value, etc. as minimum
conditions.
5. Any switch over from auto to manual, manual to auto and switchover from TFT
operation to auto manual station operation and vice versa shall be bumpless and
without resulting in any change in the plant regulations and the same shall be
reported to the operator.
6. Buffered analog output (positioning signal) of 4-20mA DC shall be used from
CLCS to the respective E/P converters. For electrical actuators, pulse type output
(bound less control) shall be preferred. CLCS shall also provide all the necessary
outputs for indicators & recorders with output loop resistance of 500 ohms for
each channel of the output module.
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7. The system being supplied shall be such that when permissible limits are
exceeded, an automatic switchover from an operation governed by maximum
efficiency, to an operation governed by safety and availability is affected.
8. For safety reasons, switchover logics associated with the modulating control
loops shall be performed within the closed loop control equipment.
9. Time supervision facility shall be used to monitor the final control element.
10. It shall be possible to block the controller output on a pre-programmed basis.
11. All controllers shall be freely configurable with respect to requisite control
algorithms.
12. Whenever, alternate measurement is available for a control input the alternate
measurement value shall be automatically substituted in the control loop in case
of loss of control input. All necessary software for switching and reconfiguration
shall be used. In addition, such substitution shall be balance less and bumpless
and shall be reported to the operator.
5.2
The requirements for Control System for SG integral control are indicated on
functional basis in this specification. It is not the intent or purpose of this
specification to specify all individual system components.
The control and automation system and the field instruments and actuators as
well as its support systems, power supplies and data networks shall be immune to
the electromagnetic interference and shall conform to the internationally accepted
standards.
5.2.1
System Configuration
The SG integral control system shall basically consist of:
1. Distributed Processing units (Controllers) for SG Protection & MFT, Burner
management System, Mill & Coal Feeder Logics.
2. I/O modules
3. Data communication system
4. System Programming & Documentation facility (Engineering Work Station)
5. Interfacing with plant DCS
6. Integrated Annunciation functions
5.2.2
System Expandability
Modular System design shall be adopted for SG control system in order to
facilitate easy system expansion. The capability and facility for expansion
through the addition of controller modules, I/O cards etc. shall be provided. The
system shall have the capability to add any new control loops, groups /
subgroups in control system, while the existing system is fully operational. The
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future expansion shall be expandable to allow at least 50% only by addition of

extra modules without removing or modifying any existing hardware.
5.2.3
Online Maintenance
It shall be possible to remove / replace modules online (like I/O module, interface
modules etc.) from its slot for maintenance purpose without switching off power
supply to the corresponding rack. System design shall ensure that while doing
so, undefined signalling and releases do not occur and controller operation is not
affected in any way (including any control loop trip to manual, etc) except that
information related to remove module is not available to controller. Further, it
shall also be possible to remove / replace any of the redundant controller
modules without switching off the power to the corresponding rack and this
shall not result in system disturbance or loss of any controller function for the
other controller. The on-line removal / insertion of controller, I/O modules etc.
shall in no way jeopardize safety of plant and personnel
5.2.4
Fault Diagnostic
The control system shall include on-line self-surveillance, monitoring and
diagnostic facility so that a failure / malfunction can be diagnosed automatically
down to the level of individual channels of modules giving the details of the fault
on the Engineers Work Station (EWS) monitor and printers. The faults to be
reported shall also include faults in main and standby power supplies, sensor
fault, Controller fault, any channel fault in 2V3 channels, failure of links to other
systems. These faults shall be identified by local indication on the faulty channel
/ module and on respective rack / cubicle. The diagnostic system shall ensure
that the faults are detected before any significant change in any controller output
has taken place.
5.2.5
Fault Tolerance & Controllability

1. The control system shall provide safe operation under all plant disturbances and
on component failure so that under no condition the safety of plant, personnel or
equipment is jeopardized. Control System shall be designed to prevent abnormal
swings due to loss of control system power supply, failure of any control system
component, open circuits, instrument air supply failure etc. On any of these
failures the control system output shall either remain in last position before
failure or shall come to fully open / close or on / off state as required for the
safety of plant / personnel / equipment. System shall be designed such that there
shall be no upset when Power is restored.
2. No single failure either of equipment or power source shall be capable of
rendering any part / system / sub-system of control system inoperative to any
degree or loss of generation.
3. The system design shall ensure that no single failure, whatsoever in any part of
Control system result in loss of communication.
4. The controlled variable response rate and controllability shall be limited by the
characteristics of main equipment, which is being controlled, and control system
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shall not impose any limitations in the response rate or controllability. Controlled
process variables shall return to normal values in a stable manner and without
control loop interactions or cycling of generation when generation matches with
load demand.
5.2.6
Signal Exchange
1. All the signal exchange between various functional groups of each control group
shall be implemented through redundant main system bus and local system bus
within a subsystem. It shall be ensured that any single failure in electronics
involved for such communication e.g. communication controllers, bus interface
modules, physical communication media, etc. does not result in loss of such
signal exchange and there is no deterioration in specified system response and
system parametric requirements. In case a controller utilizes some inputs
generated / processed by any other controllers / functional group and the
requirement of controller response time as specified is not met due to inadequate
communication rate / procedure, then provide hardwired signal exchange for
such inputs.
2. Control and Protection signal exchange between SG control system & Plant DCS,
along with any other critical signal exchange shall be hardwired only. Protection
signals like MFT shall necessarily be hardwired even for exchange between the
same sub-systems.
5.2.7
Redundancy
The Following shall be completely redundant:
All the parallel & serial communication buses
All the communication devices
All the Process controllers
All the Power Packs
Critical drives related I/O Modules.
1. The redundant communication buses between the process stations and the
operator supervision stations shall follow different paths. The redundant
processor shall be connected to the same I/Os of the processor that it is
associated to and shall be able to carry out all the operations assigned to this
processor. In the case of a processor failure, the redundant processor shall
become operative within the cycle time, without causing any loss of data or the
interruption of the process control. The switch between the processor being
utilized and the reserve processor shall be bump less and shall be within 20 ms
which shall not cause any interruptions or stopping of the station functions.
Furthermore, this switch must also be signalled by a high priority alarm.
2. The operator station shall be able to perform from any work station. The
operator station electronic units shall be in dual configuration and independently
connected to the system buses. In case of an operator stations failure, the
station shall remain operative without the operator having to carry out any type
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of action. Each operator electronic unit and each process station shall be
powered by redundant power packs those are able to power the entire load. In
case of a failure, the switch between the power packs shall not cause stops or
interruption in the carrying out of the station functions. The switch between the
power packs shall be signalled by a high priority alarm.
3. In order to establish a high degree of system availability, the various control
systems which comprise the overall unit control system shall be configured such
that no single component failure can cause a failure or mal-operation of critical
automatic or manual control functions. The failure of a redundant component
shall be alarmed to the operator to allow on-line removal/replacement or at the
first shutdown opportunity. The system's redundancy schemes shall be designed
such that the transfer from any critical element to its redundant backup shall
occur without upset to normal process control or to system displays, data
collection, or other normal DCS functions within 50 m sec.
4. The signal distribution from sensors which are shared due to process restrictions
between control loops, logics, monitoring purposes shall be as follows:a) In the case of multiple inputs to a card, input cards used shall be restricted to
a maximum of 16 inputs per card for analog input and 32 for digital inputs.
b) In case there is either process redundancy (Left, Right) or transmitter or
switches redundancy, the inputs shall be routed through independent input
cards.
c) No two control loops/interlock loop shall share the inputs (either binary or
analog) wide input cards if process signals are independently available.
d) Protective inputs for two drives shall not be allotted to the same input card.
e) Output cards shall be independent for each control loop.
f) For outputs to HT and LT motors, the following shall be adopted :
Each HT motor and unidirectional drives shall have dedicated output cards. No
other drive shall be combined with HT motor drive output card. However
indication outputs can be driven from this output card for the concerned logic
loop.
Not more than two bidirectional drives shall share one output card.
For unidirectional drives, not more than one drive shall be allotted to one
output card.
g) For signal distribution or fan-out, suitable electronic cards (opto couplers)
shall be used.
h) The processors shall contain the logic required to group individual process
and system alarms into common groups as well as the annunciation
sequence logic.
5. Redundant components and equipment within given systems shall be distributed
among processors and I/O cards to the extent practical.
6. Critical inputs shall be supplied with redundant sensors/transmitters with each
input connected to different input cards. Where redundant inputs exist, the DCS
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shall be configured to automatically reject erroneous data. Where required, oneof-two, two-of-two, two-of-three, or median select schemes shall be utilized to
ensure the integrity of critical inputs.
7. The use of redundant outputs driving the same final element or equipment shall
generally be avoided in favour of failsafe design and redundancy of the plant
equipment.
8. The operator stations shall be identical in capability and independently linked to
the system. Although these stations shall be normally dedicated to a specific
function, any station can replace the function of any other station at any time.
9. All power source and power conditioning equipment in the system shall be
redundant.
5.2.8
System Spare Capacity

1. Following philosophy shall be followed for the spare capacity of the SG Control
system:
a) Twenty (20) percent spare channels in each of the functional groups for each
type of input/output modules fully wired up to marshalling / field termination
cabinet TBs.
b) Ten percent (10%) installed spare I/O modules which may be capable of hot
swapping.
c) Wired-in usable space for 20% modules in each of
the
system
cabinets for mounting electronic modules shall be spared for future use.
Empty slots between individual modules / group or group of modules, kept
for ease in maintenance or for heat dissipation
requirement as standard
practice and shall not be considered as wired-in usable space for I/O
modules. Field Terminal assemblies, PCB / Connectors, corresponding to the
I/O modules shall be used for above mentioned 20% blank space, distributed
proportionally to main population.
d) Each controller shall have 40% spare functional capacity to implement
additional function blocks, over and above implemented logic / loops. Further,
each controller shall have spare capacity to handle minimum 40% additional
inputs / outputs of each type, over and above implemented capacity. Under
worst loading condition, Controller should not be loaded beyond 60%. Each
of the corresponding communication controllers shall also have same spare
capacity as that of controller.
e) The data communication system (including main system Bus and other bus
system) shall have the capacity to handle the additions mentioned above.
f) Each Communication Network Switch shall have 20% spare ports.
g) Twenty (20) percent spare relays of each type and rating mounted and wired
in relay cabinets. All contacts of relays shall be terminated in terminal blocks
of relay cabinets. In each of the relay cabinets 20% spare terminal blocks
shall be used so that additional relays can be mounted and wired.
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h) For power distribution board 20% spare feeder fully wired ready for use with
MCBs fuses, TBs etc. Other hardware such as signal distribution isolation,
trip amplifiers etc. shall be provided with 20% spares wired ready for use.
2. Sufficient and additional software capacity shall be available in the system to
take care of spares requirement as specified above to meet all functional
requirements. The calculation for processor power and memory for all nodes
should be furnished. Also, the dynamic processor load for all nodes either in
terms of idling time or percentage load shall be available in VDU.
3. The spare capacity as specified above shall be uniformly distributed throughout
all functional groups. The system design shall ensure that above mentioned
additions shall not require any additional controller / processor / peripheral drivers
/ cabinets in the system delivered at site. Further, these additions shall not
deteriorate the system parametric requirement like response time / duty cycle
etc. from those stipulated under this specification and shall meet other
redundancy / functional requirement.
5.2.9
System Programming & Documentation facility

1. Programming facility (Engineering Workstation) shall be provided for Control
system and system documentation.
2. The programming tools shall have in-built safety features that shall protect the
system against inadvertent and unauthorized use of these tools. Necessary hard
key locks and software locks, etc. shall be used for this. During on line
programming, external plant / equipment should not be affected.
3. The system shall also have facility to permit the programmer to add text
information at the beginning and end of each program, wherein programmer shall
list out his name, time, date of change which has been made, name of the
person who has authorized the change, etc.
4. Any modification done in Control System shall be suitably logged so that it can
be traced to the user log-in ID and time of change
5. Structuring / configuring and tuning facilities shall be provided for
structuring / modification, storing / loading, testing, tuning, monitoring, etc. of all
the microprocessor based controllers of the control system. The configuration
and tuning unit shall be hooked up with the system bus.
6. It shall be possible to configure the system with ease without any special
knowledge of programming or high level languages. Control strategy shall be
implemented using familiar and conventional automation function blocks
(software implemented). Whenever any change in configuration is done, it shall
be recorded and modified configurations shall be available for printing and
documentation and shall be stored in non-volatile memory. The entire system
configuration, tuning / fixed parameters shall be documented and printed in form
of function diagrams and lists respectively.
7. On-line tuning of the control loops shall be possible without causing any
disturbance in the execution of the control loops. Provision to store and retrieve
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on immediate and long term basis the system configuration, data base etc. on
some device such as DVD shall be included. Facility shall be used to reload /
down-load the system or controller module from the already stored data, on-line.
Table 5.1
Specifications for Engineering Work Station
S.N
1
2
3
4
5
6
7
8
9
10
11
12
13
a
b
c
d
e
f
g
h
5.2.10
Features
Minimum Requirements
Processor
Configuration
Internal Clock
Architecture
Video Card
Intel i5 or better with latest generation

Tower
3.2 GHz
64 Bit
PCI
System Memory
Hard Drive
Cache
CD Drive
Audio Controller
Operating System
4 GB or better
1 TB
2 MB
52X DVD R/RW
16 bit
WIN NT or higher
Graphic Accelerator
Monitor
Type
Screen Diagonal
Display
Resolution
8 MB (minimum)
Power supply
Ambient Temperature
Humidity
IP-30
230 V, 50 Hz
0-50 *C
95% non condensable
TFT Color Monitor

21
XGA or better
1280 X 1024 32 bit color support
Data Communication System

1. The Data Communication System shall include a redundant System Bus for major
subsystems with hot back-up. The data highway shall be high speed digital links
of speed preferable 10/100 M baud. Bus protocols at control levels shall conform
to OPC compliant ISO-7 layer protocol in master less, token ring or token bus (as
per IEEE 802) or any standard proven and acceptable protocol in deterministic
mode. Extensive error checking (CRC-16/12) or error correcting codes shall be
used in these levels to improve the reliability of communication.
2. Redundant communication controllers shall be used to handle the communication
between each functional group of controllers of Control System and the System
Bus. The design shall be such as to minimize interruption of signals. It shall
ensure that a single failure anywhere in the media shall cause no more than a
single message to be disrupted and that message shall automatically be
retransmitted. Any failure or physical removal of any station / module connected
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to the system bus shall not result in loss of any communication function to and
from any other station / module.
5.2.11
Sequence of Event Recording System

1. The DCS system shall perform the SOE functions like stamping of SOE inputs /
points with 1 ms resolution. The SOE function shall be built-in function of DCS.
2. SOE shall be capable of accepting minimum 512 inputs per unit including 10%
spare channels (included in total 512 inputs).
3. The system shall monitor SOE inputs with a resolution of one millisecond at all
times for all inputs including spare inputs. That is, all SOE points entering status
change shall be reported and time tagged within 1 (one) millisecond of their
occurrence. Input card shall be equipped with digital filters with filter delay shall
be such that it should meet SOE time resolution of 1 msec (identical for all
points) to eliminate contact bounce such that field contact which is changing
state must remain in the new state for stipulated time to be reported as one
event. The start of data collection for SOE report shall be reported to OWS
within1 sec of SOE data collection initiation.
4. SOE shall be envisaged as an integral part of DCS with 1 millisecond time
resolution. The SOE data base shall be an integral part of the DCS database and
same shall be made available at all the OWS / EWS resident on the network.
Operator can access the SOE on activation of SOE alarm page. All SOE inputs
shall have real time time-stamping following any tripping of major equipment,
or sub-system or the plant as a whole.
5. The SOE system of Plant DCS shall collect process and report SOE inputs of SG
control system for a consolidated master SOE system. Necessary communication
with required hardware & software at SG control system end and engineering coordination with Plant DCS supplier shall be done for successful implementation
of a consolidated master SOE system. Consolidated master SOE system shall be
used by the Plant DCS supplier.
6. The system shall have provision of rejection of chattering inputs.
7. The system shall have the facility for adding a field adjustable software delay on
as per point basis.
8. The system shall also include provision for historical storage and retrieval of SOE
reports for 3 months period.
9. The SOE report collection shall begin on occurrence of change of status of any
SOE point and shall be printed after an operator selectable time interval of 1 to 3
min. or 100 status changes have taken place after the first event. Adequate
numbers of buffers shall be provided to prevent loss of data before transferring
to HSR.
10. SOE reports shall include a list of major equipment trip in chronological order and
include the points that initiated SOE collection. The inputs for SOE shall include
a. Hardwired inputs in input cards and
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b. Calculated points / generated points of Control System.

11. All the operator initiated actions such as trip inactivation (bypass) & trip
activation (inline) shall form input to SER.
12. All the SOE inputs shall also be available for interlock / protection functions.
13. SOE of other systems (SG/TG integral control systems) shall also be integrated in
this system. The SOE system shall collect process & report SOE inputs of SG &
TG control system for a consolidated master SOE system. Necessary
communication with required hardware & software and necessary engineering
co-ordination with SG & TG Supplier shall be done for successful implementation
of a consolidated master SOE list.
14. SOE time stamping shall occur at I/O level.
15. Self Diagnostic Features like scanner test (a periodic test for communication
between several levels), functional test by simulating abnormal Conditions shall
be provided.
16. One (1) no dedicated SOE viewing station with SOE Log printer shall be
provided.
5.2.12
Historical Storage & Retrieval System

The HSRS of Plant DCS shall collect store and process system data from SG
control system for a consolidated master HSRS system. Necessary
communication with required hardware & software at SG control system end and
engineering co-ordination with Plant DCS supplier shall be done for successful
implementation of a consolidated master HSRS system.
5.2.13
Master & Slave Clock System

A Global Positioning Satellite (GPS) based Master Clock System shall be provided
by the Plant DCS supplier. Necessary signal output for time synchronization from
Master Clock System shall be made available to the SG control system to have
common time reference.
5.2.14
Power Supply & Grounding

1. Redundant UPS power feeder for all 230VAC equipments and/or redundant
feeders for 24 V DC are required for SG control system requirements.
2. Make suitable arrangements with redundant distribution boards for each system
with proper auto change over scheme to change the load from one feeder to
other, in case of one feeder failure.
3. All panels, desks, cabinets shall be used with a continuous bare copper ground
bus. The ground bus shall be bolted/ welded to the panel structure and shall
efficiently ground the entire structure. All individual cabinet grounds shall be
connected to separate earthing riser to be provided for C&I system signal
grounding. The grounding requirements of various parts of the C&I system shall
be properly co-ordinated with design of plant earthing system.
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5.2.15
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System Cabinets/Panels
1. All Control system modules, power supply components, other control devices
(except field mounted sensors/transmitters) which are required for completeness
of the system shall be housed in cabinets. All equipment and dedicated cabinets
required for termination, marshalling and proper interface within the system and
also with other systems shall also be provided.
2. The cabinet mounted equipments shall be fully assembled, installed in mounting
racks, wired and fully tested as per specification requirements and approved
drawings in the manufacturing works of a qualified manufacturer prior to
shipment to the project site. It shall be ensured that the cabinets are complete
and ready for installation before dispatch from manufacturing works. The
installation work at project site for these cabinets should only involve
connections through multi pair cables from marshalling cabinets (wherever
provided) to system cabinets and inter-cabinet.
3. The Control system cabinets shall be grouped into physically separate cabinets
as follows:
a) Control System Cabinets
b) Marshalling cabinets
c) Relay cabinets
However, in case the system design requires the termination cabinet
independent from system cabinet, the marshalling cabinets can be combined
with the termination cabinet. In case, the termination arrangement is part of
the system cabinet, independent marshalling cabinets shall be provided.
4. A special note shall be indicated that termination of field cables directly to
control system cabinets is not acceptable.
5. The Control system cabinets shall house all types of modules / hardware to
achieve all functions of Control System including signal conditioning modules,
controller modules, I/O modules, communication controller modules and all other
requisite hardware for a complete system.
5.2.16
System Software Requirement

1. The system shall be provided with all licensed software packages with media
required by the system for meeting the intent, functional/parametric
requirements and performance requirements of the specification.
2. The system shall utilize a readily upgradeable, public domain software platform
proven for real-time operation environment at the control and monitoring level
overlaid with a relational database program. The desirable features are indicated
below:
a) The software system shall be fully modular.
b) The software shall meet the following general requirements:
Simple, easy-to-learn editing language for editing and on-line operation.
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Wide range of standard and non-standard peripheral support capability by

modular controllers / supervisors.
Effective task scheduling and support of multiple priority structure
including event based interrupt etc.
Effective debugging.
Provision for on-line editing
interrupting on-line functions.
and
program
development
without
Self-diagnostic routines.
Efficient memory management and effective utilization of system time.
Quick start-up and loading.
3.
4.
5.
6.
7.
Support of multiprogramming and multi-user operation.

Industry standard operating system like UNIX/WINDOWS NT etc. to ensure
openness and connectivity with other system in industry standard protocols (TCP
/ IP etc.) shall be used. The system shall have user oriented programming
language & graphic user interface.
All system related software including Real Time Operating System, File
management software, screen editor, database management software, On line
diagnostics / debug software, peripheral drivers software shall be used. Latest
versions of standard PC-based software for database handling, word-processing,
spread sheet, etc. and latest WINDOWS based packages etc. and any other
standard language offered shall be furnished as a minimum. Systems having
program development environments like EWS, Station LAN Server shall have
high level programming support like Microsoft Visual Studio, Oracle, RDBMS etc.
The programming language shall support Relational Data Base Management in a
global and truly distributed Client-Server environment and shall have the
following minimum features:
a) Modern high-level block structures type
b) Powerful, compact syntax
c) Logical organization that facilitates documentation, modification and
maintenance of programs
d) Early detection of errors at compiles and run time
e) Fast debugging
f) Improved program reliability
g) Clearly defined data structure complemented by flexible user-declared data
types
h) Fast execution.
All application software for control system functioning like input scanning, acquisition, conditioning, processing & control along with communication among
various Control System functional blocks shall be used.
The system shall be provided with software locks and passwords to engineers at
site for all operating & application software in order to prevent unauthorized
access and only authorized engineers are able to do modifications at site.
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8. Two sets of all final / latest software on non-rewritable/non-editable media shall

be used as back-up.
9. Software License
Software license shall be used for all software in the Control System. The
software licenses shall be used for the project (e.g. organization or site license)
and shall not be hardware / machine-specific. That is, if any hardware /
machine is upgraded or changed, the same license shall hold good and it shall
not be necessary to seek a new license / renew license due to up-gradation /
change of hardware / machine in control system at site. All licenses shall be
valid for the continuous service life of the plant.
In case the s/w license is dependent on no. of points, then quantity to be
considered is 30% above the finally implemented points.
10.Software Upgrades
The system softwares installed in the plant DCS shall be periodically upgraded
with the new releases, that would be taking place after the system is
commissioned.
5.2.17
Measurement Functions Of Control System

All the signals coming into / going out of the Control System shall be routed
through marshalling cabinets. The input / output modules employed in the
Controls System shall be separated from controller hardware.
5.2.17.1
Analog Signal Conditioning & Processing

1. The conditioning and processing functions to be performed as a minimum for the
analog input coming for control and information purpose are:
a) Galvanic isolation of input signals for which power supply source is other
than the measurement system of the control system.
b) Transmitter power supply with per point fuse protection or current limiting
and power supply monitoring.
c) Transducer / transmitter signal output limit check
d) Implementation of multiple measurement schemes
e) Square root extraction
f) Pressure and temperature compensation.
g) On-line ADC gain and drift monitoring and correction at periodic intervals.
h) Linearization of temperature signals (from thermocouples and RTD through
temperature transmitters).
i) Reasonability checks for all analog inputs.
j) Monitor sensor wire break / open circuit / short circuit and take suitable
actions in logic / loop. (This shall include blocking of trip signals in case of
RTD failure).
k) Rate of rise / fall calculation
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2.
3.
4.
5.
6.
5.2.17.2
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l) LVM generation.
All analog signals for control purpose shall be acquired, validated, processed and
their respective Controller data base updated at a maximum interval of 250 ms
except for some fast-acting control loops for which the above referred time shall
be as per process requirement. The validated analog inputs shall be converted
into engineering units on per point basis. Analog input processing (scanning to
alarm checking) shall be performed once every scan cycle.
The analog 4-20 mA input cards shall have input loop resistance >= 250 ohm
for interfacing transmitters / analyzers giving 4-20 mA DC signals along with
superimposed HART interface signals. 4-20 mA DC signal shall only be used for
control purpose and superimposed HART signal shall be used for configuration,
maintenance, diagnostic and record keeping facility for electronic transmitters
and Analyzers etc.
Triple measurement scheme for analog inputs employing three independent
transmitters connected to separate tapping points shall be employed for the most
critical measurements. The three signals shall be auctioneered to determine the
median / average value, which shall be used for control purpose. In case one
transmitter fails or shows excessive deviation with respect to others, it shall be
removed from computation of median / average value and the average of the
other two transmitter outputs shall be used for controls. The control loop shall
trip to manual when any two of the three transmitter signals fail. The outputs of
the transmitters shall be continuously monitored for excessive deviation which
shall be displayed, logged and alarmed.
Dual measurement scheme for analog inputs employing two independent
transmitters connected to separate tapping points / temperature element shall be
employed for the remaining measurements used for analog control functions. The
output of the redundant transmitters shall be continuously monitored for
excessive deviation. In case the deviation is within limits, the mean value shall
be used for the control loop. If the deviation becomes high (with both
transmitters remaining healthy), the loop shall be automatically transferred to
manual. However, if one transmitter fails and other transmitter remain healthy,
then the output of the healthy transmitter shall be used for control. If the other
transmitter also fails, loop shall trip to manual. The outputs of the transmitters
shall be continuously monitored for excessive deviation which shall be displayed,
logged and alarmed.
Individual transmitter signal, their value and selected value for
control/measurement shall be available in OWS.
Binary Signal Conditioning & Processing
1. The changeover type contacts (i.e. NC + NO together) shall be wired to the

controller system for all the binary inputs required for control purposes, except
for inputs from MCC / SWGR. The binary inputs required for information
purposes only shall be wired to control system in the form of non-changeover
type contacts.
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5.2.18
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binary inputs coming for control and information purposes are:
a) 24 VDC power supply for contact interrogation for all potential free contacts
with per point fuse protection or suitable current limit feature / isolation
through optocoupler.
b) Contact bounce filtering delay time of 15ms. However for SOE inputs, it
shall be 4ms.
c) Facility for automatic pegging of the binary signal to logic one / zero or last
correct value in case of failure of binary input module.
d) Binary signal distribution to different user shall be in such a way so as to
ensures that a short / ground fault on one user is not reflected to the other
user.
e) Implementation of multiple measurement schemes for signals for control
purpose.
f) All binary signals shall be acquired, validated, processed, alarm checked and
their data base updated within one second. In addition to this requirement,
binary signals required for SOE shall have resolution of 1 millisecond.
g) Checking for excessive number of status changes for all binary / contact
inputs and making it off-scan, if the total no. of changes exceeds a limit
within pre-defined time.
h) The non-coincidence monitoring shall be used for binary inputs for all
changeover signals.
Wiring Scheme for Inputs to Control System
1. Each of the triple redundant binary and analog inputs shall be wired to three
separate input modules. In addition, for functions employing 2V3 controllers (e.g.
BMS protection), each of the redundant binary and analog signals shall be wired
to separate input modules associated with each controller. Similarly each of the
dual redundant binary and analog inputs shall be wired to two separate input
modules. These redundant modules shall be placed in different racks, which shall
have separately fused power supply distribution. Implementation of multiple
measurement schemes of these inputs shall be performed in the redundant
hardware. Loss of one input module shall not affect the signal to other modules.
Other channels of these modules can be used by other inputs of the same
functional group.
2. No single failure in any component of the control system shall lead to
unavailability of more than one of dual / triple redundant input signals to control
system. Similarly, no single failure in any component of the control system shall
lead to unavailability of more than one of dual / triple redundant output signal
from the control system.
3. The single (i.e. non-redundant) binary and analog signal required for control
purpose shall be wired as follows:
a) The on-off status of HT drives and Breakers with synchronization provision
shall be wired to two input modules in parallel.
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4.
5.
6.
7.
8.
9.
5.3
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b) All analog and binary inputs including the limit switches of valves / dampers
/ MCC / SWGR, check-backs of all drives, SOE and information related
signals should be wired to single input modules.
It is envisaged to use remote I/O modules in plant areas where it is required from
location point of view. The remote I/O signals shall be connected to the
respective functional groups through redundant extended I/O bus. The hardware
independence of functional groups shall be applicable for remote I/O as well. The
remote input / output modules shall be located in cubicles in respective areas.
Remote input / output modules shall be designed in such a way to work
continuously under the harsh environment expected to be encountered in these
areas (high temp, dust level, humidity etc.). It shall be ensured that extending of
I/O bus of functional group in field does not result in false signalling / noise
pickups. Further, it shall in no way deteriorate the performance of that functional
group and Control System.
Power supply arrangement for these cubicles shall be similar to DCS System
cabinets
The measurement system of control system should be capable of acquiring data
from various equipment and system in digital form through serial port, field bus/
Profibus, Ethernet connection using industry standard protocols. The control
system shall include requisite modules for accepting such signals.
The maximum number of inputs/outputs to be connected to each type of
modules shall be as follows:
a) Analog input module
16
b) Analog output module
08
c) Binary input module
32
d) Binary output module
32
The following requirements shall be met for analog/binary input / output modules
as applicable:
a) Input filters to attenuate noise shall be used
b) All analog / binary inputs and outputs shall be capable of withstanding 500V
DC common mode and 500V AC peak to peak between analog and digital
parts. All analog outputs shall be short circuit proof.
Any single sensor / transducer / transmitter failure alarm shall be used on
Engineers Station monitors for all sensors / transducers / transmitters. Similarly
sensor break alarm for thermocouples etc. shall also be logged and displayed.
Redundancy in Measurements
Minimum redundancy requirement (1 out of 2 or 2 out of 3) of measurements
and controls including compensation are given below. For critical Closed Loop
controls 2 out of 3 sensors / transmitters shall be used including 2 out of 3
signals for compensation signals.
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Table 5.2
Redundancy Requirements
Parameter
Boiler Drum level
Boiler Drum pressure
Feed water Flow
Input Redundancy
2 out of 3 (on each side of drum)
2 out of 3
2 out of 3
Feed water Temperature

SH Spray water flow (Left & Right)
RH Spray water flow (Left & Right)
Main steam Pressure
Main steam Pressure
Main steam Temperature
2
2
2
2
2
2
out
out
out
out
out
out
of
of
of
of
of
of
3
3
3
3 (Left side)
3 (Right side)
3 (Left side)
Main steam Temperature

BFP Suction Flow
DP across feed control
Secondary Air flow
Coal air flow (at each elevation)
Oxygen in Flue Gas
2 out
1 out
2 out
1 out
1 out
2 out
of
of
of
of
of
of
3 (Right side)
2
3
2 (Left & Right)
2
3 (Before Economizer)
Furnace Pressure
P.A. Header Pressure
Mill air flow
Mill outlet Temperature
SH Outlet Steam temperature
RH Outlet Steam Temperature
2
2
1
1
2
2
of
of
of
of
of
of
3
3
2
2
3 (Left& Right)
3 (Left & Right)
Auxiliary Steam temperature

Auxiliary Steam pressure
1 out of 2
1 out of 2
out
out
out
out
out
out
1. For measurement of metal temperature of super-heater, re-heater and boiler

drum, permanent / removable duplex type mineral insulated thermocouples
terminated in junction boxes at boiler platforms shall be used. Super-heater tube
metal thermocouples shall be used on every fourth tube connected to the
intermediate super-heater outlet headers, the intermediate reheat outlet headers
& the final super heater/ reheater outlet header.
2. Bearing temperature of ID, FD, PA Fans, pulverizers and any other equipment
driven by HT motors shall be used with direct mounted dial thermometers for
both driven equipment and motor.
3. Duplex RTDs (PT-100) shall be used both for the driven equipment & HT motor
bearing temperatures- for monitoring and interlocking in Plant DCS. In case RTD
in pulverizer bearing cannot withstand vibration, suitable thermocouple like Jtype thermocouple may be provided.
4. All HT motors windings shall be used with two nos. duplex RTDs (PT-100) per
phase for monitoring and interlocking in Plant DCS.
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5. Redundant non-contact type speed sensors with transmitters shall be used with
each Coal feeder and shall provide an output to the feeder speed control.
6. Monitoring and alarm provisions in the DCS shall be provided for Lube Oil
Pressure and Temperature and other important parameters for subsystems of all
major drives e.g. Pulverizer, ID Fans, PA and FD Fans etc.
7. A non-contact type no-Coal flow detector complete with amplifier and pick-up
located at the outlet of each Coal feeder shall be used to detect no-Coal flow
8. Coal flow measurement with the help of conveyor speed and active load cells
shall be used for each feeder. The Coal flow rate along with the integrator shall
be made available in plant DCS.
9. Coal feeder shall be gravimetric type preferably based on variable voltage &
frequency drive. The coal flow measuring system shall have the output 4-20mA
DC for indication and control purposes. Weighing system of the equipment shall
be based on load cell measurement and shall have the highest resolution by
proper selection of load cell.
10. Measurement and totalization of oil flow shall be used with Coriolis mass flow
measuring type instrument with 4-20mA DC output for Plant DCS indication and
totalization. The Mass flow meter electronics shall have the facility for
configuration to indicate Mass and Volumetric Flow rate.
11. In Coal Bunkers, Load Cell/Strain Gauge/Ultrasonic type level measuring system
is required for displaying bunker level at the control room and generate the
necessary isolated outputs for interlocking with Coal handling Plant for Coal
filling operation.
12. Oxygen measurement in high temperature zones of boiler is required (in APH inlet
& outlet on both side) for combustion control and performance analysis.
13. Temperature measuring devices shall be installed at different zones in the flue
gas path including ID fan inlet and chimney inlet for monitoring at Plant DCS.
14. All motorized bypass valves & Bypass Dampers shall be inching type and shall be
used with non-contact type position Transmitters.
15. Digital speed measurement with proximity pick-up shall be envisaged for the
feeder. The control system shall be microprocessor based with the facility of online diagnosis of the system and integration with DCS through software link for
monitoring facility of various faults and status of the feeder and feeder control
system. Gravimetric feeder shall be controlled by 4-20mA DC signal and other
interlocking signals from DCS. The system shall have facility for gravimetric and
volumetric indications of coal flow as well as totalisation. In addition, separate
instruments shall be provided for coal flow /no coal flow indication in DCS.
Controller shall be provided with following minimum features:
16. Alphanumeric display of feed rate; material density, motor speed, total weight,
automatic and manual calibration of the weighing system and adjustment of
system drift, non volatile memory to store information and program data, alarm
generation capability with date and time stamp, automatic transfer from
gravimetric to volumetric in case of failure of load cell, status LED, keyboard for
configuration. Running indication of clean out conveyor to be displayed in OWS.
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17. For measurement of pulverizer outlet temperature and flue gas temperature
suitable abrasion resistant thermo wells shall be provided.
18. Adequate Pressure and Temperature gauges, depending upon the requirement
shall be provided.
19. For all critical trip interlocks such as furnace pressure high and furnace pressure
low minimum 3 numbers transmitters on each side (for deriving LVM contacts)
shall be provided.
20. For lube oil protection of HT drives wherever applicable, 2 out of 3 logic shall be
provided.
21. All initiating devices for starting and tripping of auxiliaries viz. ID fan lube oil
pump, FD fan lube oil pump, pulverizer lube oil pump etc. shall be provided for
interlock and protection and associated annunciations.
22. Necessary pressure controller of Electromatic safety valve complete with all
accessories like special cables, pressure sensing devices, solenoid valves,
impulse piping etc shall be provided. A miniature electronic control station
suitable for monitoring on the auxiliary control desk shall be furnished with
indicating lights and switches to facilitate auto / remote / manual operation of
the valve. Operation of the valve shall also be interface with DCS.
23. All local instruments related with Steam Generator and Fuel Oil System viz.
pressure and temperature gauges, pressure and temperature switches shall be
mounted on gauge boards located at convenient places.
24. Status of various strainers in the fuel oil line and lube oil line in the boiler area
shall be monitored in DCS.
25. All pilot solenoid/solenoid operated valves, motorized valves, initiating devices
and switches, sensors, transmitters, all flanges, gaskets, nuts, and bolts shall be
provided.
26. All instruments for Performance Guarantee test measurements including tapping
points with root valves for pressure measurement and temperature stubs with
thermo wells are to be provided.
27. Local Stop push button shall be used for all HT and LT drives for emergency
stopping of the drives. The contacts of the push button shall be wired directly to
MCC to initiate trip & this signal shall be made available to Plant DCS/PLC for
alarm annunciation/logging etc.
5.4
5.4.1
Other SG Related System/ Equipments

Steam Generator
1. For measurement of furnace draft using three pressure transmitters across the
furnace, Two out of three logic shall be used.
2. Local measurement of furnace draft using minimum four numbers of draft
gauges.
3. For sensing of high & low furnace draft six number of pressure switches (three
on each side of furnace) shall be used and two out of three logic shall be used
for tripping application.
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5.4.2
5.4.3
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4. Flame sensing and control for each oil and gas burners with flame intensity
indication in control room shall be provided along with necessary interlocks &
protection against flame failure and dull flame.
5. Measurement of differential pressure between furnace and wind box shall be
provided.
6. Measurement of differential pressure between furnace and scanner air pressure
shall be provided along with Separate DP switch for alarm.
7. For measurement of metal temperature of primary and secondary super heater,
adequate number of mineral insulated duplex type chromel-alumel thermocouples
with stainless steel sheathing shall be provided. These shall be routed through
suitable trays and terminated directly to temperature transmitter to be mounted
in convenient and accessible location.
Steam Cycle
1. Measurement of steam pressure after primary super heater, de-superheater and
secondary super heater, redundant pressure transmitters shall be used for the
same.
2. Local measurement of steam pressure after super heater.
3. Measurement of temperature of steam after primary super heater, de-superheater
and secondary super heater. Redundant temperature sensors shall be used for
each application.
4. Local measurement of steam pressure at inlet to each steam coil air preheater.
5. Measurement of steam pressure at inlet to each steam coil air preheater.
6. Measurement and control of atomizing steam pressure to boiler.
Air System
1. Measurement of air pressure after FD fans.
2. Measurement of air pressure before and after air pre-heater.
3. Measurement of pressure of secondary air to burners.
4. Measurement of pressure of compressed air for atomization.
5. Measurement of pressure after PA fans.
6. Measurement of differential pressure across air preheater.
7. Measurement of seal air discharge pressure.
8. Sensing of low and very low air pressure after primary air fans using independent
pressure switches.
9. Sensing of differential pressure between primary air heater and seal air header.
10. Local measurement of air pressure at the discharge of each FD fan. Sensing of
low & very low air pressure after FD fans using independent pressure switches.
11. Local measurement of air pressure after seal air fans. Sensing of low seal air
pressure at the header.
12. Local measurement of pressure at scanner air fan discharge. Sensing of low
pressure at scanner
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5.4.4
5.4.5
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13. Local measurement of differential pressure across all air filters. Sensing of high
differential pressure across all air filters using separate switches.
14. Measurement of both primary air & secondary air temperature before and after
the rotary air preheater.
15. Sensing of low temperature of both primary air & secondary air after air
preheater using independent switches.
16. Measurement of secondary air temperature at outlet of each steam coil air
preheater.
17. Measurement of hot air temperature to each mill.
18. Measurement of flow of air after FD fans using redundant flow transmitters.
19. Measurement of flow of primary air to each mill using redundant flow
transmitters.
20. Local measurement of pressure of instrument air at the header. Sensing of low
pressure for the same using independent pressure switch.
21. Measurement of atomizing air pressure to boiler.
22. Measurement of temperature in air preheater for both gas side as well as air side
using thermocouples connected to a scanner in the control room and also to
Boiler integral control system.
23. Measurement of differential pressure between furnace and wind box.
Flue Gas System
1. Measurement of flue gas pressure before & after super heater.
2. Measurement of flue gas pressure after economizer.
3. Measurement of flue gas pressure after air pre heater.
4. Measurement of flue gas pressure after ESPs.
5. Measurement of flue gas differential pressure across air pre heater.
6. Measurement of flue gas pressure at the discharge of each ID fan.
7. Measurement of flue gas temperature before & after super heater.
8. Measurement of flue gas temperature after economizer.
9. Measurement of flue gas temperature after air Pre heater.
10. Measurement of flue gas temperature after ESPs.
Soot Blowing System
1. Soot blowing control shall be implemented in Plant DCS and operated from
operators console. Soot blowing analog and sequential control logic shall be
implemented in redundant of processors of Plant DCS. However outputs to the
drives of soot blowing system shall be non-redundant.
2. Soot Blower system complete with provision for individual operation of any soot
blower and facility to bypass any soot blower shall be used with following:
a) Automatic starting of each soot blower in the system
b) Cancelling the selection of any soot blower in the system when not required
for operation.
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c) Indication of the soot blower-selected to operate.

d) Capability to monitor all the essential parameter/status of the soot blowing
system.
e) Capability to prevent continued soot blower operation if the system is not
functioning properly.
f) The ability to operate two soot blowers located in opposite walls
simultaneously.
g) Manual over-riding of the automatic operations.
h) To prevent automatic blowing when the parameters of soot blowing system
are beyond permissible limits.
i) Indications of soot blower which has malfunctioned.
j) Control circuit for the retractable blowers shall be so designed as to prevent
insertion of the blowers in to the combustion chamber unless the blowing
medium is available.
k) Limit switches and Torque switches are to be connected to Plant DCS.
3. Soot Blower control system shall also provide controls for:
5.4.6
a) Pressure control of steam.

b) Warm up control of the complete piping system which shall include flow
control, drain temperature control etc.
c) Steam temperature control (if required)
Flame Monitoring System
1. The purpose of the system is to detect the individual burner/ type of flame and
to enhance the boiler/furnace safety, to avoid spurious and unwarranted trips
and to increase operational reliability, availability and efficiency of the Steam
Generator such that the consumption of fuel oil shall be reduced to optimal
minimum.
2. Flame monitoring system shall be microprocessor based, fail safe and easily
maintainable which shall include flame detectors of proven design for the type of
fuel, environmental condition and other conditions, of established reliability at all
loads of the steam generator. It shall be designed to work under all adverse
conditions such as wide variation in fuel/air input ratio, wide variation in fuel
characteristics, variation in operating temperature, and maximum temperature
under interruption of cooling air supply. The system shall conform to NFPA
recommendation and location of detectors as per NEC requirements.
3. Flame detectors shall be working on the dynamic and static properties of primary
combustion zone of each type of fuel and flicker frequency of flame. It shall pick
up only the flame to which it is assigned and shall not respond to the adjacent
and background flame or other radiations generated in the furnace. The design
shall also take into account the absorption by a Coal shroud, recirculated dust or
other deposition on the flame detector head & required protection of lens head
against pitting. The complete system shall provide the discrimination between oil
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and Coal flame. Intensity indicators for main flame shall be used along with
galvanically isolated 4-20 mA DC signals and hooked to the Plant DCS.
4. The system should be easily maintainable and include automatic self test facility
at regular interval.
5. A portable flame detector testing kit shall be used with built in stabilizer, capable
of simulating both oil and Coal flame, and testing of flame detector head unit at
field. The testing kit shall also have facility for testing all type of electronic cards
as being used in the flame monitoring system.
6. In case of tangentially fired boiler, arrange flame detectors in such a manner that
Coal flame detectors are available both above and below each Coal burner and
separate oil flame detectors are provided for each oil burner. In case of
discriminating type flame detectors capable of detecting and discriminating both
oil and Coal flame, with the help of a single scanner, the same can also be
utilized for monitoring both oil and Coal flame. For any other type of firing i.e.
non-tangential type the flame detectors shall be used for each Coal and oil
burner responding only to the flame of its associated burner.
7. In cold start up test, capability of detectors to detect oil flame under varying oil
pressure shall be checked. In load test, the detector shall be able to detect when
only oil is present, only Coal is present and both Coal and oil are present. It shall
be ensured that the detectors are able to detect the proven flame at very low
load with oil guns withdrawn. The above tests shall be performed for every Coal
and oil elevation.
8. Provision of scanner air for cooling the flame detectors by 100% redundant
scanner air fans shall be used. The dampers associated with scanner air fans
shall be pneumatically operated with DC solenoid valves.
5.4.7
Coal Feeders Control & Instrumentation

1. A minimum of two independent speed sensors, pulser units and associated
amplifiers, etc. shall be used for each of the Coal feeders. Output from the speed
sensors shall be used to provide at least four numbers isolated 4-20 mA DC
analog signals corresponding to Coal flow rate in tons per hour and any other
signals that may be required for the control of the Coal feeder. In addition, one
pulser unit shall also be used with two pulse outputs-one for use in control
system and the other for remote integrator.
2. Each Coal feeder shall receive signals from Plant DCS for feeder speed control.
The signal to be provided by Plant DCS shall be in the form of galvanically
isolated 4-20 mA DC. All required power amplifier units/interface devices to
accept this 4-20 mA signal shall be included.
3. All associated electronics like buffer amplifiers, frequency to current converters
etc. shall be used for each raw Coal (RC) feeder with local and remote speed
indicators and integrators. The speed sensors and pulser units shall be totally
enclosed, fire, dust and weather proof, suitable for the service conditions.
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4. The control cabinet shall be used with reset push buttons and individual lights to
signal the individual internal trip conditions.
5. Each feeder shall be used with a four position switch located at the feeder for
remote off, local run (when there is no Coal on conveyor) and calibration
purpose.
6. If there is any electronic modules mounted local to the feeder body then these
shall be suitable for operating in a non-air-conditioned area in a suitable enclosure
to combat the effect of noise, vibration, entry of dust etc.
7. All necessary paddle switches and other detectors to monitor Coal on belt,
feeder discharge plugged etc. should be provided to ensure safe operation of the
feeders.
5.4.8
5.4.9
5.4.10
Electromatic Safety Valve

The Electromatic Safety Valve shall be an automatic electrically actuated
pressure relief valve. It shall be possible to set the value for one percent or less
differential between opening and closing pressure. The Electromatic safety valve
shall be used complete with all accessories like pressure measuring devices,
controller units, local PB station, solenoid assembly, impulse piping etc. Provision
shall also be kept to operate the Electromatic relief valves from the Plant DCS
OWS and miniature PB stations on the Emergency backup panel. The operation
of the valve shall be accomplished by operator command or by means of
pressure sensitive element which shall precisely and automatically relieve the
pressures within very close limits.
Furnace Temperature Probes
Two numbers of furnace temperature probes shall be provided before platen
super heater and / or before Reheater regions and shall be electrically operated,
fully retractable type. The furnace temperature probes shall be furnished with
complete actuating mechanism and all the logics required for the actuating
mechanism. The probes shall be provided with position transmitters, limits
switch & indicator for remote indication. Each temperature probe shall have a
duplex thermocouple suitable for the measurement range. The logics for furnace
temperature probe shall be implemented in the DCS.
Acoustic Pyrometer {TO BE DELETED, IF NOT APPILCABLE.}
1. Acoustic pyrometers shall be provided to determine the average flue gas
temperatures and complete flue gas temperature profile at furnace exit plane (for
FEGT measurements), at economizer outlet & in Super heater (SH) Area.
Minimum eight numbers of acoustic transceivers shall be provided for Furnace
temperature measurement in SH Area.
2. For each temperature measurement plan/section, a PC based system complete
with all required software, comprising of minimum eight nos. of acoustic
transreceivers, signal processor, interface unit, etc. shall be provided. The
system shall be suitably interfaced with DDCMIS.
3. The system shall include all software & interface hardware required for
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4.
5.
6.
7.
5.4.11
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presenting (in the HMI of DDCMIS) visual information on real time or historical
gas temperatures including spatial temperature distribution profiles, individual
path temperatures, temperature trends & average gas temperature within defined
area.
The system shall be able to eliminate the varying high noise environment both in
and out of an operating boiler.
The transit time of each of the associated transmitters/receivers shall be
transmitted to the central processing unit (to be located at CER) for storage and
analysis through suitable interface device. A temperature profile shall then be
determined and displayed by analysing the mean temperature across every
transit section using deconvolution technique. The time interval to take a
complete cycle of eight transceivers should be less than one minute.
The measuring range should be sufficient to cover the entire regime of boiler
operation and shall not be less than 1900C. The mean temperature and profile
temperature accuracy shall be 2%, & 4% of reading respectively or better.
Full colour TFT display and colour printer output shall be provided. The system
shall also provide 4-20mA DC output to DDCMIS.
The transducers shall not be placed directly in the hot gas stream. The system
shall be of proven design and it's performance must be proven using similar type
of fuel. The components to be located at boiler area shall be able to withstand
the stringent environmental condition expected at such locations with operating
boiler.
Furnace & Flame Viewing System
1. The flame cameras shall be suitable for direct online continuous viewing in the
central control room of the Coal and oil flame and condition of the furnace
internals including slagging of the water walls and any other deterioration in the
furnace condition.
2. The flame camera system shall consist of the following facilities/ components as
a minimum: a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
21" High resolution color monitor.

Facility for optical zooming of lens from the monitor
Automatic Electronic shutter control mechanism
Built-in temperature sensor to measure temperature of camera tip.
Proper cooling arrangement (preferably air) and protection against
Cooling medium failure alarm.
Weatherproof local control box for mounting of electronics.
All necessary remote/ local programming tool.
All interconnecting cable and termination device.
Any other accessory to make the system completely operational.
3. The cameras and the total system shall be suitable for the furnace design, the
firing arrangement, the fuel being fired considering the ash content of worst
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Coal. The cameras should be expected to withstand the temperature expected in

the furnace of the boiler but shall not be less than 1600 deg C.
4. The viewing angle of the camera shall be commensurate with the furnace size,
the camera location and the positioning of the burners. The system shall conform
to PAL and number of TV lines shall be adequate for a clear image of the
furnace.
5. The flame camera system shall have a record of trouble free performance of
minimum one (1) year in a Coal-fired boiler of size 210/215/220/250 MW.
6. The system shall be capable of transmitting the image to the Plant DCS system
where it should be possible to display the same on the monitors of operator
workstation & LVS.
5.4.12
Mill & Air heater Fire Detection System

1. Adequate number of thermocouple type fire detection system for each mill and
air heater shall be used as a composite and complete unit with all required
signals and accessories with adequate redundancy.
2. The controls & protection required for the mill fire detection system and air
heater fire detection system shall be implemented in the Plant DCS, using rateof-rise algorithm taking care of manufacturer's recommendation.
5.4.13
Chemical Dosing System

1. Each dosing pump shall be used with glycerin filled type pressure gauge of
proper range on discharge piping with isolation valves, fittings diaphragm seal,
Snubber, etc. Each solution tank shall be used with level gauge glass with
graduated scale. Level switch shall be used for low-level alarm and interlock.
Alarm hooter shall be used for tank level low annunciation in local panel. The
chemical feed system shall be operated and adjusted from the local panel and
also through the Plant DCS from CCR.
2. Minimum field instruments, transmitters, switches etc. shall be used which are
to be connected to the Plant DCS for remote monitoring from CCR.
a) Chemical storage tank level.
b) Dosing Pump Discharge Pressure at downstream of NRV.
c) Open Close indication of all Manual Valves from the Dozing system to the
CTP and DMCW system.
3. Facility shall also be provided for start stop operation of the Agitator motors and
Dozing pumps from the Operator Work Station in the CCR.
4. Dosing Pumps Remote Stroke Control facility from the CCR shall be used.
Necessary local controller, drive unit as required shall be used for this purpose.
5.4.14
Electronic Remote Drum Level Monitoring System

In order to measure and monitor Boiler drum level, Electronic Water level
Indicator working on principle of difference in electrical conductivity between
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steam and water shall be used. The monitoring system shall meet the following
requirements as a minimum.
1. Each end of the drum shall have independent pressure vessels with adequate no.
of electrodes covering the entire range for indication for each end of drum.
Further, independent and separate pressure vessels shall also be used for each
end of drum / vessels along with electrodes to provide validation for very low
trip setting.
2. The sensing electrodes shall be placed in equal pitch. The maximum distance
(gap) between two electrode shall be 50 mm and the electrodes shall be
arranged in such a way that the last and the first electrode shall not be at any
alarm or trip level. For a boiler of 210 MW and above unit, the number of
electrodes shall not be less than 16 for indication and eight for validation.
3. Both indication and validation system shall be supplied with double isolation
valves in water, steam, drain and vent lines with mechanical key interlock
system, that is, the total number of key interlocks shall be four nos. per boiler.
The provision of key interlock system shall ensure a fool proof safety feature and
the details of the same shall be brought out clearly in the offer.
4. The detector unit (if not located locally), logic units, 2 x 100 % redundant power
supply units / packs (to be located in control equipment room) shall be housed in
separate and independent cubicle for pressure vessel on each side of the drum.
The detector units, logic units etc. shall be independent for each pressure vessel.
5. Indication shall be used at field for both indication and validation system. Remote
indication is to be provided for indication system at the CCR.
6. Each cubicle shall be used with 2 x 100% redundant power supply pack
converters to be fed from two feeders of 24 V dc. These two power supplies
shall be internally fused and failure of one power supply shall not affect the
performance of the system. Self monitoring facility to detect and alarm the loss
of power supply shall be used.
7. The pressure vessel shall be constructed in such a way that density level error
between drum and pressure vessel shall not be more than 25 mm. All vent, drain
and isolation valves shall meet 1.5 times the maximum design conditions.
8. Electrode assembly shall have blow out and leakage proof sealing arrangement.
Field proven ceramic / zirconia probe insulation suitable for design pressure and
temperature are to be used.
9. The system design shall be such that it shall ensure that failure of one probe
circuit shall not affect another probe circuit and failure of any electrode shall not
hamper the system function and operation. Further the entire system shall be of
proven fail-safe design.
10. The logic shall be such that the trip and alarm relay circuits shall be independent
for each for low, low-low, high and high-high levels of drum. Monitoring of set
time for trip generation and provision of setting time delay shall be available in
the system. Trip logic shall be independent and separate from fault finding logic.
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Provision shall be there to connect the alarm & trip signals to Plant DCS. Also
the 4-20 mA DC output shall be available for drum level indication (both side) on
Plant DCS.
11. The system shall have fault diagnostic features such as process fault, system
hardware fault, probe failure, circuit board failure, shorted wire etc. Further the
system shall be able to distinguish between a cable fault and an electrode fault.
12. The necessary relays and relay modules for the output contacts shall be of
proven design and each contact shall be rated for 5A, 240 V AC/ 0.25 A, 220 V
DC rating. All these contacts shall be SPDT type.
5.4.15
Acoustic Tube Leak Detection System

A Microprocessor based Acoustic Tube leak detection system with PC & A4 size
Laser printer, working on the principle of Digital sound analysis techniques shall
be provided by the bidder. This system as a minimum shall have the following
features:
1. The system shall be capable of leak identification for the tube leak size of 2mm
diameter.
2. A minimum of 20 sensors should be installed for tube leak detection.
3. Graphical display of audio frequency spectrum capable of displaying the size and
location of detected leak.
4. Mimic display for location of the leak & Trend display to indicate the rate at
which the leak is growing.
5. Alarm bar graph display (Overview of all sensor points) having different colour
displays in case of Normal, Caution, Alarm, Wave guide blockage and system
fault.
6. Alarm outputs which can be wired to DCS for attracting operators attention in
case of initiation of any leak.
7. User friendly MMI for selecting displays, printout in demand / time bases, alarm
accept and audio selection with loud speaker.
8. History record of the previous data for trend analysis.
5.5
SG Auxiliaries
Following are indicative list of requirements for Control & Protection of SG
Auxiliaries. All CLCS, measurement and Data Acquisition of SG auxiliaries
instruments shall be implemented in Plant DCS.
5.5.1
ID Fans
1. Induced draught fan controls shall be implemented in DDCMIS for Induced
draught control. The drive shall be compatible for 4-20 mA DC signals for
regulation. The drive controls shall be blade pitch control with feedbacks to
DDCMIS.
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2. For remote bearing temperature of fan & motor and motor winding temperatures
monitoring, duplex RTDs shall be provided.
3. Vibration monitoring in X & Y directions at DE & NDE shall be provided. All
vibration parameters shall be available in CCR.
4. Required Local instruments such as level, pressure, temperature gauges, Sight
glass, pressure & flow switches etc. shall be provided.
5. Remote monitoring & alarm facility for the following parameters shall be provided
in addition to bidders recommended instruments:
a) Fan speed
b) Lube oil tank level
c) Lube oil pump discharge pressure.
d) DP across lube oil strainer-Alarm
e) Blade pitch angle (If applicable)
f) Fan & Motor bearing temperature
g) Lube oil cooler outlet temperature
h) Cooling water flow Low alarm
5.5.2
FD Fans
1. Inlet guide vane/blade pitch control to be operated by 4-20 mA DC signal from
DDCMIS, complete with pneumatic actuator, I-to-P converter, Position
transmitter etc. for control of Combustion Air Flow shall be provided
vibration parameters shall be monitored from CCR.
in addition to bidders recommended instruments
a) Lube oil tank level
b) Lube oil pump discharge pressure.
c) DP across lube oil strainer-Alarm
d) Pitch control oil pressure (both control & power oil)
e) Fan & Motor bearing temperature
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f) Lube oil cooler outlet temperature

g) Cooling water flow Low alarm
5.5.3
PA Fans
1. Inlet guide vane/blade pitch control to be operated by 4-20 mA DC signal from
DDCMIS, complete with pneumatic actuator, I-to-P converter, Position
transmitter etc. for control of Combustion Air Flow shall be provided
in addition to bidders recommended instruments
a) Lube oil tank level
b) Lube oil pump discharge pressure.
c) DP across lube oil strainer-Alarm
d) Pitch control oil pressure (both control & power oil)
e) Fan & Motor bearing temperature
f) Lube oil cooler outlet temperature
g) Cooling water flow Low alarm.
5.5.4
Seal Air Fans

1. Pneumatic actuator shall be provided for full open/full close dampers complete
with I-to-P converter, Position transmitter, Solenoid valves, AFR etc.
glass, pressure & flow switches etc. shall be provided
5. Remote monitoring and alarm facility for the following parameters shall be
provided in addition to bidders recommended instruments:
a) Seal air fan discharge pressure
b) Motor and fan bearing temperature
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5.5.5
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Coal Mill
1. For remote bearing temperature & motor winding temperatures monitoring,
duplex RTDs shall be provided.
3. Temperature Elements & Gauges for lube oil & bearing temperatures, lube oil
flow switch, Pressure switches for alarm/standby pump auto start, pressure
gauges etc. shall be provided.
provided in addition to Bidders recommended instruments:
a) DP across lube oil strainer Alarm
b) Mill DP
c) Mill outlet temperature
d) Lube oil pressure
e) Lube oil cooler outlet temperature
f)
5.5.6
Cooling water flow Low alarm
Coal Feeder
Remote monitoring and alarm facility for the following parameters shall be used
as a minimum:
1. Coal bunker level
2. Remote operation and Open and Close indication for bunker to feeder isolating
gate
3. Running indication of clean out conveyor
4. No Coal flow
5. Feeder Speed
5.5.7
Air Preheater
1. For emergency operation Air motor shall be provided. Low air pressure switch &
Solenoid valve shall be provided for auto start of Air motor.
2. Support/Guide bearing oil circulation unit shall be provided with local instruments
such as oil pressure switches, temperature switches, temperature elements, flow
switches, local pressure & temperature gauges etc.
3. Thermocouples in Air & gas flow streams for APH fire sensing & RTDs for
bearing temperature monitoring shall be provided.
provided in addition to bidders recommended instruments:
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a) O2 measurements at each of air heater inlet and outlet in addition to the 3

nos. O2 measurement before economiser.
b) Differential Pressure Transmitter across air preheater.
c) Pressure Transmitters and Temperature elements / transmitters at I/L and
O/L on Flue gas path and air path.
5.5.8
SG Controls
1. CLCS controls shall be used through Plant DCS for the following control loops as
minimum for which required sensors, transmitters, control valve & Valve
positioner, damper etc. shall be used for controlling:
1. Combustion control
2. Furnace Draft control
3. Drum Level control
4. SH and RH steam Temperature control
5. Secondary Air Damper control
6. Soot Blower Steam Pressure control
7. Heavy Fuel Oil Pressure & Flow control
8. Light Oil Pressure & Flow control
9. Steam Coil Air-Preheater (SCAPH) Temperature control
10. SCAPH Tank Level control
11. Auxiliary Steam Header Pressure and Temperature Control
12. Mill Outlet Temperature control
13. Primary air (Mill air) header pressure control
14. Total air flow control
15. Primary air flow control
16. Atomizing steam pressure control
17. CBD Level Control
18. Air Heater average cold end temperature control
19. Oil Burner air flow control
The description of the few important closed loop control are indicated below:
a.
Master Pressure Control

The function of this shall be basically to provide combustion demand signal for
fuel and air flow controls, in order to maintain the steam pressure at plant header
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at a constant value during load changes. The output of master pressure control
shall regulate total fuel flow and total air flow and shall work in conjunction with
Burner Management System.
b.
Air Flow Control

The combustion set point signal derived from the master pressure control shall be
compared with total fuel (coal and oil) signal and a fixed signal corresponding to
minimum air flow required for furnace purge and low load operation. The
maximum value selected out of above shall be the set point for the air flow
control. The air flow measurement shall be corrected for temperature and trimmed
for oxygen present in the flue gas. The furnace shall be designed for air LEAD
circuit ensuring air-rich-furnace. The output of air flow controller shall regulate FD
fan inlet dampers. Proper biasing arrangement shall be provided for FD fans for
equal load sharing.
c.
Furnace Draft Control

The furnace pressure shall be controlled by controlling the ID fan blade
pitch/vane. Three furnace pressure transmitters shall be provided and connected
to three separate tap points on the furnace. The average value of the transmitters
shall be compared in the controller with the set point and output of the controller
shall vary ID fan blade pitch/vane position to maintain the desired furnace
pressure. Total air flow may be used as feed forward signal for furnace draft
control. The fan damper interlock shall be so arranged to always provide an open
flow path between FD fan inlet and ID fan discharge under all combinations of
running and idle fans.
The provision for biasing shall be provided for synchronized operation of both the
ID fans.
d.
Super heater Steam Temperature Control

Superheated steam temperature shall be maintained by injecting feed water spray
between 30% MCR and 100% MCR or may be as recommended by the bidder.
Three temperature sensors shall be provided at the outlet of final super heater for
measuring steam temperature. Median value shall provide healthy signal to the
controllers. The final super heater outlet temperature shall be achieved by
regulating Attemperation water flow. All the required feedback signals and other
necessary corrective action shall also be considered to achieve optimum
temperature regulation.
e.
Air Preheater Cold End Temperature Control

The function of this loop is to control cold end temperature of air heater. This
shall be achieved by measuring flue gas temperature at outlet of APH by using
thermocouple and throttling the steam control valve in SCAPH line.
1. Other control loops include the following as a minimum:

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A. Fuel oil Temperature control

The fuel oil temperature control shall maintain the temperature at outlet of
fuel oil heater by regulating steam inlet valve.
B. Atomizing Steam Header Pressure Control
Fuel oil atomizing steam header pressure shall be maintained at desired value
by positioning atomizing steam control valve.
C. Continuous Blow down tank Level Control
The continuous blow down tank level control shall maintain the level in the
tank at the desired valve by modulating a control valve in the line from
continuous blow down to intermittent blow down tank.
D. Fuel Oil Header Pressure Control:
The fuel oil header pressure control shall maintain the pressure at the outlet
of fuel oil heaters by recirculating (bypass) optimum quantity of fuel oil
(before the heaters) back to the storage tank.
2. Typical minimum requirement of Interlock and Protection has been stated below:
a) Boiler Starting Interlock
After ID and FD fans have been started, following condition should be
fulfilled for light up of boiler:
Purging of boiler at predetermined airflow for a predetermined time
Resetting of MFR
Permissive of starting Igniter
b) Purging conditions
Either or both I.D Fans running
Either or both F.D Fans running
MFR in tripped position
Air registers in purge position
Air flow between 25% to 30% MCR
No flame condition is true
All fuel closed
Boiler Tripping
c) Master Fuel Trip conditions
Boiler shall trip automatically through Master Fuel Relay (MFR) if any one of
the following emergencies occurs:
Boiler Drum Level Very High : 2 out of 3
Boiler Drum Level Very Low : 2 out of 3
Furnace Pressure Very High : 2 out of 3
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Furnace Pressure Very Low : 2 out of 3

Both ID Fans tripped
: 2 out of 3
Both FD Fans tripped
: 2 out of 3
Total Flame Failure
: As per manufacturers Recommendation
d) Tripping of MFR shall initiate the followings as minimum:

Tripping of all oil burners
Tripping of all pulverizers and Coal feeders
Tripping of PA Fans
HT supply to ESP
Turbine trip
e) Followings sequence controls have been envisaged as minimum:
Burner sequence
Coal mills group
ID, FD and PA fans
Air Pre-heaters
Coal Feeder Group
Furnace Purging
5.5.9
SG Performance Optimization System

1. Each SG shall be used with a Combustion Control Optimization System to
maximize combustion thermal efficiency and keeping the emission limit within
predetermined limit during all regime of SG operation. The system shall be part
of the Performance Optimization Package of Plant DCS. Functioning of the SG
Combustion Optimization System shall be based on adaptive stochastic model of
combustion process derived from the process inputs like flame intensity, Coal
flow, air flow, Oxygen, Carbon monoxide and NOx. For this all inputs, logics,
equipment design data, complete thermal design model of SG etc which shall be
required for successful implementation of the Boiler Combustion Optimization
System in the Plant DCS. System shall guide the operator in terms of most
optimum air fuel ratio and shall also be capable to generate set point for air flow
controller of combustion control system. System shall also have the capability of
simultaneous firing of different grade of Coal by providing dynamic coordination
of secondary air flow at different burner rows. Means shall be used to interface
the signal with the combustion control system, if desired by the operator.
2. The Combustion Optimization System shall incorporate the complete thermal
design model of the SG capable of both forward and backward calculation of
complete SG thermal performance. The model shall be calibrated and made "Site
Specific" based on series of field trials of thermal performance of the SG during
startup and prior to trial operation. The input for the Combustion Optimization
System shall be based on accurate and continuous on line measurement of the
following:
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a) Flue gas oxygen.

b) Other fluid temperature(s) entering and exiting various heat transfer banks.
c) Coal characteristics
3. The Combustion Optimization System shall be capable for continuous on-line
calculation of the thermal performance of the SG for the operating conditions
indicating performance prediction zonal absorption, metal temperature and shall
have necessarily the following features:
a) Fuel switching capability.
b) "WHAT IF" capability.
c) Selective soot blowing of furnace/super heater based on trends of zonal
absorption.
d) Expert system diagnostics for quick identification of the 'Root Cause' of
deviations from the predicted parameters.
e) The computer modeling and arriving at factors to make it "Site Specific.
4. Following minimum features have been envisaged for the system (the system
shall be part of the PADO System of Plant DCS:
a) Software for stochastic modeling and combustion control optimization.
b) Graphics for monitoring Fuel flow, Air flow, Oxygen, CO and NOx etc.
c) Setting of operator targets like set point for concentration limit of CO, NOx
etc.
d) Validation of calculated variables. Provision for manual and auto bypass in
case signal bad value, bad calculated variable and communication error etc.
e) Trend display for monitoring performance of controller. Graphic comparison
of the actual model curve and curves with the reference model.
f) Initialization software to initialize initial characteristic curves of combustion,
Input and Output configuration and communication link.
5. The System shall also include the following:a) Boiler performance optimization packages including the optimized operation
of soot blowing System.
b) Boiler stress condition analyzer.
Interactive water and gas chemistry management system.
5.5.10
Other Auxiliary System

1. Complete and independent PLC based Control and Instrumentation system with
all accessories & associated equipments and cables for the safe, efficient and
reliable operation of the plant auxiliary systems such as ESP control and Auxiliary
Boiler/ Auxiliary steam system etc.
2. All instruments and control equipments like primary and secondary instruments
etc. which meet the requirements specified on field Instruments. In addition, all
instrument devices like switches/transmitters/ controllers/ analyzers/ solenoid
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valves which are located in the field/hazardous locations shall be used with
explosion proof enclosure suitable for hazardous areas described in National
Electric Code (USA), Article 500, Class-I, Division-I. All field wiring should be
through conduits. All fittings, cable glands etc. shall be strictly as per NEC
recommendation article, 500 to 503.
3. ON/OFF control, indication, annunciation of incomers and bus-coupler are also to
be performed for each of the above system as applicable.
4. Take special care for selecting the PLC for all the sub-systems from same make
to the extent possible.
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6.
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DISTRIBUTED CONTROL SYSTEM (DCS)

{TO BE DELETED, IF ALREADY PROCURED UNDER TG PACKAGE.}
6.1
1. The requirements for Distributed Control System are indicated on functional
basis in this specification. The System shall be state of the art microprocessor
based & of proven design, the performance & high availability having adequately
demonstrated over a substantial period of successful operation.
2. The system shall have distributed intelligence architecture and shall comprise
independent multifunction processors for execution of open loop and closed loop
control and data acquisition functions.
3. If DCS & other common system/items (CMMS, STMS, Station LAN, SWAS,
Master Clock System etc.) have been procured under TG package, then chapter6 for DCS, and other common system/items shall be deleted from SG package.
4. The microprocessor based Distributed Control System shall have following
capabilities:
a) Scan, acquire, validate, time-tag, process, store, update, archive, retrieve and
display all analog and digital data and parameter.
b) Monitor real and calculated variables for multi-level alarm conditions.
c) Accept and execute operators commands and pre-programmed routines and
run-times.
d) Perform all open and closed loop control functions.
e) Display plant mimics, bar-graphs, control templates, point description, trend
graphs (real time & history) in interactive mode with the operator.
f) Prepare and print logs and reports.
g) Perform performance calculation based on real-time and manually entered
data.
h) Dynamically reconfigure itself on command from engineering station.
i) Run its own diagnostics, watch dogs, system checks and consequent
fallback routines.
j) All system information and diagnostic alarm like failure of I/O channel, I/O
card, Multifunction controller, communication modules, node failure, CPU
loading, Network loading, workstation diagnostic etc. shall be annunciated
and displayed at any workstation.
k) Dynamic data exchange (DDE) for communication with other computers
5. When more than one device utilizes the same signal for measurement and
control, signal splitting shall be performed in such a way that disconnecting,
shorting or failure of one receiver device shall not cause any upset at any other
consumer point or cause any change in transmitter calibration.
6. Comprehensive self-diagnostic features shall be provided to facilities easy fault
location and detection of failure without individually checking each module. On-
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line testing facility of control system while the unit is in operation shall be
provided with suitable indication for easy identification of faulty module.
7. DCS offered shall have open system architecture with open connectivity for
viewing at remote locations without virus infection to control network and
employing non-proprietary hardware/software. Latest hardware models &
software versions shall be offered.
8. DCS shall be of distributed architecture type with VDU based operation. The
entire system shall be bus organized and the plant operator shall run the plant
through console consisting of LCD screens, Mouse and Keyboards. All the
screens and key boards for ease of operation shall be of same design and shall
enable the operator to view process data, control outputs, shut down status and
to change all parameters necessary to control the plant.
9. The system software shall be governed by the operating system running in a real
time mode. It shall meet all functional requirements specified in this specification
as a minimum. The latest version of software at the time of SAT shall be
supplied even if it is introduced after Contract finalization.
10. All the inputs shall be galvanically isolated, provided with suitable noise filter and
routed through individual fuse. Isolation shall also be provided between operator
console and related sub-systems connected to it. The digital outputs shall be
routed through interposing relays. Each output shall be short circuit proof and
protected by fuse.
11. The system shall be capable to detect open, short and earth fault conditions. The
open sensor reading shall be either upscale or downscale and it shall depend on
field requirement and shall be programmable from engineering station.
6.2
Design Requirements
6.2.1
System Expandability
Modular System design shall be adopted to facilitate easy system expansion. The
system shall have the capability and facility for expansion through the addition of
controller modules, I/O cards etc. The system shall have the capability to add
any new control loops, groups / subgroups in control system, while the existing
system is fully operational. The system shall be expandable to allow at least
50% future expansion only by addition of extra modules without removing or
modifying any existing hardware.
6.2.2
Online Maintenance
It shall be possible to remove / replace modules online (like I/O module, interface
modules etc.) from its slot for maintenance purpose without switching off power
supply to the corresponding rack. System design shall ensure that while doing
so, undefined signaling and releases do not occur and controller operation is not
affected in any way (including any control loop trip to manual, etc) except that
information related to remove module is not available to controller. Further, it
shall also be possible to remove / replace any of the redundant controller
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modules without switching off the power to the corresponding rack and this
shall not result in system disturbance or loss of any controller function for the
other controller. The on-line removal / insertion of controller, I/O modules etc.
shall in no way jeopardize safety of plant and personnel.
6.2.3
Fault Diagnostic
The control system shall include on-line self-surveillance, monitoring and
diagnostic facility so that a failure / malfunction can be diagnosed automatically
down to the level of individual channels of modules giving the details of the fault
on the Engineers Work Station (EWS) monitor and printers. The faults to be
reported shall also include faults in main and standby power supplies, sensor
fault, Controller fault, any channel fault in 2V3 channels, failure of links to other
systems. These faults shall be identified by local indication on the faulty channel
/ module and on respective rack / cubicle. The diagnostic system shall ensure
that the faults are detected before any significant change in any controller output
has taken place.
6.2.4
Fault Tolerance & Controllability

The control system shall provide safe operation under all plant disturbances and
on component failure so that under no condition the safety of plant, personnel or
equipment is jeopardized. Control System shall be designed to prevent abnormal
swings due to loss of control system power supply, failure of any control system
component, open circuits, instrument air supply failure etc. On any of these
failures the control system output shall either remain in last position before
failure or shall come to fully open / close or on / off state as required for the
safety of plant / personnel / equipment. System shall be designed such that there
shall be no upset when Power is restored.
No single failure either of equipment or power source shall be capable of
rendering any part / system / sub-system of control system inoperative to any
degree or loss of generation.
The system design shall ensure that no single failure, whatsoever in any part of
Control system result in loss of communication.
The controlled variable response rate and controllability shall be limited by the
characteristics of main equipment, which is being controlled, and control system
shall not impose any limitations in the response rate or controllability. Controlled
process variables shall return to normal values in a stable manner and without
control loop interactions or cycling of generation when generation matches with
load demand.
1.
2.
3.
4.
6.2.5
Signal Exchange
1. All the signal exchange between various functional groups of each control group
shall be implemented through redundant main system bus and local system bus
within a subsystem as per standard practice. It shall be ensured that any single
failure in electronics involved for such communication e.g. communication
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controllers, bus interface modules, physical communication media, etc. does not
result in loss of such signal exchange and there is no deterioration in specified
system response and system parametric requirements. In case a controller
utilizes some inputs generated / processed by any other controllers / functional
group and the requirement of controller response time as specified is not met
due to inadequate communication rate / procedure, then the it shall provide
hardwired signal exchange for such inputs.
2. However critical signal exchanges are found required shall be hardwired. Control
and Protection signal exchange between control system of SG/TG and Plant DCS
shall be hardwired only. Protection signals shall necessarily be hardwired even
for exchange between the same sub-systems.
6.2.6
Redundancy
The Following shall be completely redundant:
All the parallel & serial communication buses
All the communication devices
All the Process controllers
Servers (if Server based system)
All the Power Packs
Critical drives related I/O Modules.
1. The redundant communication buses between the process stations and the
operator supervision stations shall follow different paths. The redundant
processor shall be connected to the same I/Os of the processor that it is
associated to and shall be able to carry out all the operations assigned to this
processor. In the case of a processor failure, the redundant processor shall
become operative within the cycle time, without causing any loss of data or the
interruption of the process control. The switch between the processor being
utilized and the reserve processor shall be bump less and shall be within 20 ms
which shall not cause any interruptions or stopping of the station functions.
Furthermore, this switch must also be signalled by a high priority alarm.
2. The operator station shall be able to guarantee, from any work station, the
complete control of the plant. The operator station electronic units shall be in
dual configuration and independently connected to the system buses. In case of
an operator stations failure, the station shall remain operative without the
operator having to carry out any type of action. Each operator electronic unit and
each process station shall be powered by redundant power packs those are able
to power the entire load. In case of a failure, the switch between the power
packs shall not cause stops or interruption in the carrying out of the station
functions. The switch between the power packs shall be signalled by a high
priority alarm.
3. In order to establish a high degree of system availability, the various control
systems which comprise the overall unit control system shall be configured such
that no single component failure can cause a failure or mal-operation of critical
automatic or manual control functions. The failure of a redundant component
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4.
5.
6.
7.
8.
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shall be alarmed to the operator to allow on-line removal/replacement or at the

first shutdown opportunity. The system's redundancy schemes shall be designed
such that the transfer from any critical element to its redundant backup shall
occur without upset to normal process control or to system displays, data
collection, or other normal DCS functions within 50 m sec.
The signal distribution from sensors which are shared due to process restrictions
between control loops, logics, monitoring purposes shall be as follows:a) In the case of multiple inputs to a card, input cards used shall be restricted to
a maximum of 16 inputs per card for analog input and 32 for digital inputs.
b) In case there is either process redundancy (Left, Right) or transmitter or
switches redundancy, the inputs shall be routed through independent input
cards.
c) No two control loops/interlock loop shall share the inputs (either binary or
analog) wide input cards if process signals are independently available.
d) Protective inputs for two drives shall not be allotted to the same input card.
e) Output cards shall be independent for each control loop.
f) For outputs to HT and LT motors, the following shall be adopted :
g) Each HT motor and unidirectional drives shall have dedicated output cards.
No other drive shall be combined with HT motor drive output card. However
indication outputs can be driven from this output card for the concerned logic
loop.
h) Not more than two bidirectional drives shall share one output card.
i) For unidirectional drives, not more than one drive shall be allotted to one
output card.
j) For signal distribution or fan-out, suitable electronic cards (opto couplers)
shall be used.
k) The processors shall contain the logic required to group individual process
and system alarms into common groups as well as the annunciation
sequence logic.
Redundant components and equipment within given systems shall be distributed
among processors and I/O cards to the extent practical.
Critical inputs shall be supplied with redundant sensors/transmitters with each
input connected to different input cards. Where redundant inputs exist, the DCS
shall be configured to automatically reject erroneous data. Where required, oneof-two, two-of-two, two-of-three, or median select schemes shall be utilized to
ensure the integrity of critical inputs.
The use of redundant outputs driving the same final element or equipment shall
generally be avoided in favour of failsafe design and redundancy of the plant
equipment.
The operator stations shall be identical in capability and independently linked to
the system. Although these stations shall be normally dedicated to a specific
function, any station can replace the function of any other station at any time.
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9. All power source and power conditioning equipment in the system shall be
redundant
6.2.7
System Spare Capacity

1. Following philosophy shall be followed for the spare capacity of the Distributed
Control system:
a) Twenty (20) percent spare channels in each of the functional groups for each
type of input/output modules fully wired up to marshalling / field termination
cabinet TBs.
b) Ten percent (10%) installed spare I/O modules which may be capable of hot
swapping.
c) Wired-in usable space for 20% modules in each of
the
system
cabinets for mounting electronic modules shall be provided for future use.
Empty slots between individual modules / group or group of modules, kept
for ease in maintenance or for heat dissipation requirement as per standard
practice, shall not be considered as wired-in usable space for I/O modules.
Field Terminal assemblies, PCB / Connectors (if any in the offered system),
corresponding to the I/O modules shall be provided for above mentioned 20%
blank space, distributed proportionally to main population.
d) Each controller shall have 40% spare functional capacity to implement
additional function blocks, over and above implemented logic / loops. Further,
each controller shall have spare capacity to handle minimum 40% additional
inputs / outputs of each type, over and above implemented capacity. Under
worst loading condition, Controller should not be loaded beyond 60%. Each
of the corresponding communication controllers shall also have same spare
capacity as that of controller.
e) The data communication system (including main system Bus and other bus
system) shall have the capacity to handle the additions mentioned above.
f) Each Communication Network Switch shall have 20% spare ports.
g) Twenty (20) percent spare relays of each type and rating mounted and wired
in relay cabinets. All contacts of relays shall be terminated in terminal blocks
of relay cabinets. In each of the relay cabinets 20% spare terminal blocks
shall be provided so that additional relays can be mounted and wired.
h) For power distribution board 20% spare feeder fully wired ready for use with
MCBs fuses, TBs etc. Other hardware such as signal distribution isolation,
trip amplifiers etc. shall be provided with 20% spares wired ready for use
2. Sufficient and additional software capacity shall be available in the system to
take care of spares requirement as specified above to meet all functional
requirements. The calculation for processor power and memory for all nodes
should be furnished. Also, the dynamic processor load for all nodes either in
terms of idling time or percentage load shall be available in VDU.
3. The spare capacity as specified above shall be uniformly distributed throughout
all functional groups. The system design shall ensure that above mentioned
additions shall not require any additional controller / processor / peripheral drivers
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/ cabinets in the system delivered at site. Further, these additions shall not
deteriorate the system parametric requirement like response time / duty cycle
etc. from those stipulated under this specification and shall meet other
redundancy / functional requirement.
6.3
System Configuration
The Distributed Control System shall basically consist of the following:
Control system including Auto Controls & Interlocks, Protection & Sequential
control system.
Measurement system
Data Communication Bus system for control & communication with Process
Man-Machine Interfacing System
Maintenance Engineers System (Engineering Station)
Software
The basic configuration of Distributed Control System shall be as indicated in the
Drawings.
DCS system shall be independent for units yet connected at network level so
that, even when system for any unit is not in service (in case of long term
shutdown of a unit) or non- functional, the functioning of other unit or plant
common systems shall not be disturbed.
6.3.1
Control System Requirements

The control system shall be broadly divided into SG - C&I, TG - C&I and BOP C&I.
1. The SG- C&I part of DCS system shall perform the following function as
minimum but not limited to:
a) Burner management system (BMS) including control & protection of coal
mills, fuel oil system etc.
b) Analog control functions pertaining to secondary air damper control etc.
c) Soot blower control.
2. The TG- C&I part of DCS system shall perform the following functions:
a) Turbine protection system function (TPS)
b) Turbine governing system for main turbine
c) Turbine stress control system (TSCS)
d) Automatic turbine testing (ATT)
e) Automatic turbine run up system. (ATRS)
f) HP&LP bypass control system
g) Turbine generator control system
h) EHG, interlock & protection for turbine driven BFP
3. The BOP- C&I system shall perform the following functions:
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4.
5.
6.
7.
8.
9.
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a) Analog control functions, other than those covered in SG-C&I and TG-C&I,
like co-ordinated master control, furnace draft control, SH/RH steam
temperature control, FW flow control, heaters/deaerator/condenser level
control, Auxiliary PRDS pressure & temperature control etc.
b) Binary control functions pertaining to main plant auxiliaries like FD/ID/PA
fans, APH, BFP etc., Generator auxiliary systems and electrical breakers etc.
Close Loop Control System (CLCS): Modulating control functions for SG/TG/BOP
system includes the CLCS SADC Control, Air/Fuel oil flow control Drum Level
Control, FW Flow Control, SH/RH Temperature Control, Furnace pressure, wind
box air damper, Auxiliary PRDS Coordinated Master Control, De-aerator Pressure
& Level Control, HP/LP Bypass control, Hotwell Level Control, HP/LP heaters
Level Control, BFP Scoop control, BFP & CEP minimum Recirculation Control &
individual control and operation of modulating drives.
Open Loop Control System (OLCS): Binary control functions pertaining to SG
control system such as Sequence/ Interlock/ Protection of SG Auxiliaries includes
the OLCS for FD Fan, ID Fan, APH, Soot Blowers etc. This includes controls of
all HT drives, LT drives, motor operated valve, solenoid valves, Soot blower
protection & auto-standby of HT & LT drives.
However the binary control functions pertaining to TG & BOP control system
such as Sequence/ Interlock/ Protection of TG Auxiliaries includes the OLCS for
the BFP, CEP, CW, ACW, ECW Drain & Vent Valves etc. and individual control &
protection of Binary drives. This includes controls of all HT drives, LT drives,
motor operated valve, solenoid valves, Electrical breaker, auto-standby of HT &
LT drives.
Time stamping of SOE inputs/points, Integration of BOP PLCs etc.
Other Miscellaneous controls, signal processing etc.
For each of the Functional Groups (FG), separate sets of controllers, I/O
modules, communication controllers, power packs / modules, etc. shall be
provided. Mixing of hardware of two or more FGs shall not be acceptable.
However, splitting of any functional group in more than one FGs due to any
limitation in system (e.g. limitation in handling number of inputs /outputs
including spare capacity, limitation in implementation of number of functional
blocks including, spare blocks etc.) shall be acceptable, subject to Consultants
approval. It may be noted that after splitting of the functional groups, each FG
must have its own set of controllers, I/O modules, communication controllers,
power packs / modules etc. It shall be ensured that failure of any set(s) of
hardware of any FG does not affect other FG(s) and data communication
between other FG(s) and MMI.
The minimum functions to be realized in the Control System shall be as per
requirements specified under subsequent clause of this specification. The system
shall provided with all hardware /software, whether or not specifically indicated
in this specification to fully meet operational / maintenance / safety requirement
as well as statutory /international standards and proven practices.
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6.3.1.1
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10. The Control System shall function reliably under the environmental conditions as
specified in design philosophy & design criteria of this specification. It shall be
immune from the interference resulting from disturbance in power supply
feeders, signal lines, inputs, outputs, etc. as experienced in a power station.
11. The Control System shall have on-line simulation and testing facility. Further, it
shall be possible to on-line configure and tune controllers through Engineering
Station.
12. The system shall have the flexibility to easily reconfigure any controller at any
time without requiring additional hardware or system wiring changes and without
disabling other devices from their normal operation mode. Modifications shall not
require switching off power to any part of the system.
13. Power supply to individual functional group shall be from redundant 24 V feeders
with diode auctioneering and further sub-distribution.
14. The assignment of I/O channels for inputs / outputs, arrangement of modules
within cabinet etc shall be identical. Further uniformity should be maintained for
redundant stream of process equipment within a unit.
15. The application programs for the functional controllers shall be software based
which shall be maintained even during power supply failure. The application
program shall be alterable through the configuration and tuning station for all
configuration and strategy changes, etc. and through the operators console for
set points / bias changes, device selection, etc. Parts replacement or parts
removal shall not be required in order to accomplish changes in application
programs including system tuning.
16. Independent and dedicated controllers (main and its 100% standby) shall be
provided for each of the functional group (FG) of Control System. All the 100%
hot / redundant backup controllers shall be identical in hardware and software
implementation to their corresponding main controllers and shall be able to
perform all its tasks. The backup controller shall track its corresponding main
controller. There shall be an automatic and bumpless switchover from the main
controller to its corresponding backup controller in case of main controller failure
and vice versa without resulting in any change in control status. In case of
switchover from main controller to the 100% hot backup controller, the back-up
controller shall work as the main controller. Facility shall also be provided for
manual switchover from main to 100% hot back-up controller and vice versa
from the Engineering Work Station.
17. The loop / logic reaction time shall be suitable to match actual process
requirements, subject to minimum requirement wherever specified.
Binary Controls/ Open Loop Control System (OLCS) Functions
1. These clauses are applicable for all the Binary controls of Systems for the
systems of SG & TG which are to be implemented in Plant.
2. The OLCS shall include sequence control, interlock & protection for various plant
auxiliaries/valves /dampers/drives etc. The sequence control shall provide safe
and automatic start up and shut down of plant and of plant items associated
with a plant group. The interlock and protection system shall ensure safe
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operation of plant/plant items at all times and shall automatically shut down
plant/plant items when unsafe conditions arise.
3. The OLCS shall be arranged in the hierarchical control structure consisting of unit
level, group level, subgroup level and drive level (as applicable).
4. It shall be possible to perform automatic unit start up and shutdown by issuing
minimum number of command from OWS / LCD. Thus, the unit level shall
control all the Control System Blocks and issue appropriate start up and
shutdown commands to various blocks of Control System.
5. The group level shall control a set of functional sub-groups of drives. Appropriate
start-up and shut down commands shall be issued to the sub-group control and
various check-backs shall be received from sub-groups of drives. Each sub-group
shall execute the sequential start-up and shut down programs of a set of interrelated drives along with system interlocks and protections related to individual
drive falling under that sub-group. The drive level shall accept commands from
the sub-groups, push buttons (wherever provided) etc., and transmit them to the
respective drive, after taking into account various interlocks and protections and
the safety of that particular drive. For HT drive, first-up logic shall be
incorporated to indicate the cause of protection / trip.
6. A sequence shall be used to move a set of groups and sub-groups from an initial
steady state (for instance 'OFF') to a final steady state (for instance 'ON'). The
sequence initiating command for the unit and group level shall be issued from
OWS/LCD.
7. A sequence shall be made of steps. The steps shall be executed in
predetermined order according to logic criteria and monitoring time consisting of
the interlock & protection requirements and check back of previous step which
shall act as pre-conditions before the sequence control can execute the
command for that step.
8. Each step shall have a "waiting time" implying that the subsequent step would
not be executed unless the specified time elapses. A monitoring time shall also
be defined as the maximum time required in executing the commands of any
step and the time required for appearance of check back signals. In case, this is
not completed within the specified time, a message shall be displayed and
programme shall not proceed further.
9. Manual intervention shall be possible at any stage of operation and the sequence
control shall be able to continue at the correct point in the programme on return
to automatic control. Protection commands shall have priority over manual
commands, and manual commands shall prevail over auto commands.
10. Open or close priority shall be selectable for each drive.
11. The sequence start up mode shall be of the following types:
a) Automatic Mode
In this mode of operation, the sequence shall progress without involving any
action from the operator. The sequence start / stop command shall be issued
from the OWS / LCD.
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b) Semi-Automatic Mode
In this mode of operation, once the sequence is initialized, the step
progressing shall be displayed on the OWS / LCD. But the step execution
command shall be prevented and shall be sent by the operator via the
keyboards. It shall be possible to bypass and / or simulate one or more
criteria to enable the program to proceed. This facility shall allow the program
to be executed even if some criteria are not fulfilled because of defective
switching devices, etc., while the plant condition is satisfactory. All the
criteria bypassed shall be logged and displayed. It shall be possible to put the
system on the Auto-mode after operating it on semi-automatic mode for
some steps or vice-versa, without disturbance to the sequence operation.
c) Operator Guide Mode / Test Mode
It shall be possible to use the sequential control in operator guide mode / test
mode i.e. the complete system runs and receives input from the plant and the
individual push button stations (where provided) / keyboards but its
command output is blocked. The whole programme, in this case shall run in
manual mode. This mode shall allow the operator to practice manual
operation using step and criteria indications. The actual protection should
remain valid during this mode of operation also.
12. The sequence shall be started by putting the sequence on auto and on receipt
of start command from the OWS / LCD or from a higher-level group / protection
action as defined. The sequence shall then progress as per the defined logics. It
should be possible to select alternative operation in the same sequence
depending on certain process / equipment condition. Some step can be
automatically bypassed also based on certain process / equipment condition.
When the expected results of the sequence are reached the sequence is
considered as END. If during sequence initialization or sequence progressing or
during normal running of the drive, a shutdown criterion is present, the sequence
shall be stopped and the shut down sequence initiated.
13. For the drives, the command shall be provided through O/P module to MCC /
SWGR / Actuator as applicable and input (status, SWGR and process) shall be
acquired through input modules. The drive logic shall be implemented in the
redundant controller. The status for the 11 KV, 3.3 KV drives and some other
important drives shall also be wired in parallel to redundant input modules so
that on failure of the single input modules, the information regarding the status
of the affected drive remains available in OLCS.
14. The output modules shall have the feature that ensures that in case of failure, all
the outputs are driven to zero. The 24V DC command outputs to drives for ON /
OPEN, OFF / CLOSE shall be separate and independent and the inverted outputs
shall not be employed. For inching type of drives, position transmitter shall be
provided.
15. The termination for ON / OPEN, OFF / CLOSE command for the drive actuator
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6.3.1.2
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shall be performed as specified in Chapter-4 Clause-4.13. However ON/OPEN

feedback, OFF/CLOSE feedback, Switch gear disturbance feed back as a
minimum shall be monitored in OLCS.
16. The drive function i.e. basic interlocks and protection logic of the drive shall be
implemented in redundant controllers. The drive function shall ensure that
protection signals for the safety of the drive shall be effective under all
conditions and under all modes of operation. The different commands shall be
performed according to the priority of protection OFF, protection ON, manual
and automatic. The standard functions like running time monitoring, status
signalling, alarm / drive annunciation, etc. shall be performed in drive function.
The drive function shall prevent hunting of the actuator in the presence of both
open and close commands for actuators of the valves and dampers. The drive
function shall be implemented in dedicated standard software functional block
Analog Controls/ Close Loop Control System (CLCS) Functions
1. These clauses are applicable for all the Analog controls of Systems included in
for the systems of SG & TG which are to be implemented in Plant.
2. The CLCS shall continuously act on valves, dampers or other mechanical
modulating devices such as hydraulic coupling etc., which alter the plant
operation conditions. The system shall be designed to give stable control action
in steady state condition and for load changes in step / ramp over the load range
of 60% to 100% MCR with variation or parameters within permissible limits.
3. The controller capability shall, as a minimum, include (i) P, PI, PD and PID control
functions and their variations (ii) cascade control (iii) feed forward control (iv)
state-variable based predictive control for SH/RH temperature control (v) on-off
control, (vi) ratio and bias control, (vii) logical operation etc. The loop reaction
time (from change of output of the sensor of the transmitter/temperature
element to the corresponding control command output) shall be within 250 ms.
However, for faster loops such as feed water, furnace draft, PA header pressure
control loop etc. the same shall be based on actual process requirement.
4. The loop response time, for conventional I/Os, is the cumulative response time
inclusive of input scan time, Controller Execution time and output card
throughput time (in other words loop response is the time taken by the system
to read a change in field signal at the input card terminal, process the controller
task associated with the input and to make the required change in the control
output at the output terminal of the output card)
5. The control system shall be bumpless transferred to manual on the following
conditions as a minimum. Control power supply failure, failure of redundant
controllers, field input signal not available, analog input exceeding preset value,
etc.
6. Any switch over from auto to manual, manual to auto and vice versa shall be
bumpless and without resulting in any change in the plant regulations and the
same shall be reported to the operator and recorded automatically.
7. Buffered analog output (positioning signal) of 4-20mA DC shall be provided from
CLCS to the respective E/P converters. For electrical actuators, pulse type output
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(bound less control) shall be preferred. CLCS shall also provide all the necessary
outputs for indicators & recorders with output loop resistance of 500 ohms for
each channel of the output module.
8. The functional requirement of the CLCS loops as well as the detailed schemes
shall be subject to purchaser approval.
9. The system being supplied shall be such that when permissible limits are
exceeded, an automatic switchover from an operation governed by maximum
efficiency, to an operation governed by safety and availability is affected.
10. For safety reasons, switchover logics associated with the modulating control
loops shall be performed within the closed loop control equipment.
11. Time supervision facility shall be provided to monitor the final control element.
12. It shall be possible to block the controller output on a pre-programmed basis.
13. All controllers shall be freely configurable with respect to requisite control
algorithms.
14. Whenever, alternate measurement is available for a control input the alternate
measurement value shall be automatically substituted in the control loop in case
of loss of control input. All necessary software for switching and reconfiguration
shall be provided. In addition, such substitution shall be balance less and
bumpless and shall be reported to the operator.
Table 6.1
Specifications for Controller
S.No.
Features
Type
2
3
4
5
6
No. of Loops
Word Length
Register add cycle time
Instruction Cycle time
I/O address capability
Memory
8
9
10
11
12
Redundancy Supported
Fall back transparent
Power Supply
Mounting
Indication
13
Diagnostic
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Microprocessor based, multi loop,
multi
function,
dual
redundant
configuration.
40 (maximum/per controller)
32 bits
1 microsecond (typical)
75 microseconds (maximum)
256 points (minimum)
RAM 12 MB (minimum) with battery
backup
Yes
Yes
24V, 5V DC
Sub-rack
Processor status & fault display
Invalid command checking, Automatic
periodic
Description

illegal
address
detection,
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S.No.
Features
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routine check and memory parity
check,
watch
dog
report
to
engineering terminal, time - out
checking,
6.3.1.3
Guidelines for Functional Grouping of Plant DCS Controllers

The guidelines for functional grouping of controllers in Plant DCS shall be as
described in this clause.
1. Stream wise process redundancy is to be maintained in Plant DCS. That is, if
there is more than one main equipment in a process block, these are to be
allocated in different functional groups. For example, ID fan A & B shall be
allocated to two different functional groups, BFP- A, B & C shall be allocated to
three different functional groups, etc. In the functional groups thus obtained,
main equipment of similar stream shall be allocated. For example, if one
functional group caters to Stream-A main equipments, all main equipments of
Stream A of the same block should be put together e.g. FD fan-A, ID fan-A
should be put together. Further the auxiliaries of main equipment shall be
allocated in the same functional group where corresponding main equipment is
allocated e.g. Lube oil pump-A & Lube oil pump- B of FD fan A should be
allocated with FD fan-A.
2. For different streams of process blocks defined below, separate sets of
functional groups shall be provided. Where different streams of process blocks
are not defined, separate sets functional groups shall be provided for the process
blocks. The functions of two streams/process blocks should not be mixed in any
case.
3. The information signals of respective process areas shall be kept along with the
main equipment.
4. Electrical system of unit shall be a separate process block.
5. The Plant DCS shall be divided into following major sub-systems:
a) BOP SG
b) BOP TG
c) Common System
d) Electrical system
For each of the above major sub-systems, the process blocks, along with major
equipments/control loops in each block shall be as follows:
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A. BOP - SG
Air Block: ID Fans- A & B, FD Fans-A & B, SA Fans A & B, Primary APH
A & B along with flue gas temperature control/fire detection, stack path,
Furnace draft control, Secondary SCAPH A & B, Air Flow Control etc.
Steam & Water Block: SG vents & drains, Main Steam/RH/SH valves
along with temperature control, ECW Pumps- A & B along with DP
control, Chemical Dosing, Feed water valves, SG misc. Drives,
Coordinated Master Control, Feed Water Control, Group Control, RH
Protection, SWAS, BCWP - A, B & C, etc.
Mills & feeder Block: Mills/feeder A, B, C, D, E, F, G & H controls for
outlet temperature, Primary APH A & B along with fire detection &
temperature control, Primary SCAPH A & B, etc.
B. BOP - TG
The BOP- TG shall include the following major equipments/controls:
BFP A, B & C
CEP A, B & C along with recirculation controls
ACWP A, B & C
HP Heaters valves & Level control ( all HP heaters should be kept in same
Functional group)
LP Heaters valves & Level control ( all LP heaters should be kept in same
Functional group)
Hotwell level control
ECW Pumps- A & B along with DP control
TG misc. Valves/drives controls etc.
C. Common system
The Common systems shall include the following major equipments/controls:
Compressed Air System block
CW pumps A, B & C ( CW pumps shall be allocated to three different
functional groups)
LDO/HFO handling system block.
D. Electrical system
All Electrical breakers, bus couplers etc. shall be covered in this sub-system.
6. The major aspects to be considered shall be as follows:
a) Hardware capacity, including spare capacity.
b) Software capacity, including spare capacity.
c) Response time/signal acquisition time requirement of Plant DCS.
d) Parametric Requirement of Plant DCS.
e) Tentative Functional grouping as described in Table 6.1A.
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7. The exact functional grouping shall be subject to approval. The equipments,

logics, controls indicated in the functional grouping are tentative & shall be
dependent on the design, recommended logics & controls of the SG & TG
Vendors.
Table 6.1A
Functional Grouping of Controllers
Functional
S. No.
Functions
Group
FD Fan A, ID Fan A, SA Fan A, Stack Path A &
1
FG-01
B, etc
Furnace Draft Control, RAPH-A, RAPH A
2
FG-02
Temperature Control, SCAPH A, RAPH A fire
detection, etc.
FD Fan B, ID Fan B, SA Fan B, Stack Path C &
3
FG-03
D, etc.
Air flow control, Fuel Flow Control, Coal Feeder
Speed Control, HFO/LDO control, RAPH-B, RAPH- B
4
FG-04
Temperature Control, SCAPH B, RAPH B fire
detection, etc.
SG misc. dives, SG Drains & Vents, SG DMCWP A,
5
FG-05
BSCP-A, Soot Blower Control, SADC, etc.
Coordinated Master Control, Group Control, RH
6
FG-06
protection, Misc. Boiler Controls, etc.
RH temp. Control, SH temp. control, RH/SH spray
7
FG-07
drains & vents, Eco. I/L valves, BSCP-B, Boiler Fill
Pump-A, Aux. PRDS Control, etc.
FW valves, SG DMCWP-B, SG misc. drives, BSCP-C,
8
FG-08
Boiler Fill Pump-B, Dosing system drives, etc.
9
FG-09
CEP-A, CEP-A recirculation system, etc.
Hotwell level control, CEP B, CEP B recirculation
10
FG-10
control, GSC Minimum flow, etc.
ACW A, TG ECW A, TG ECW CLCS, LP heaters
11
FG-11
CLCS, LP Heaters (valve) Drives, etc.
CEP-B, CEP-B recirculation system, HP bypass
12
FG-12
system, etc.
ACW B, TG ECW B, HP heaters CLCS, HP Heaters
13
FG-13
Drives (valves), LP Bypass system, etc.
MDBFP, Deaerator Level control, Deaerator Pressure
Control, Deaerator Overflow Control, Deaerator
14
FG-14
Drives (valves), CEP-C, CEP-C recirculation system,
etc.
15
FG-15
ACW C, TG Misc. Drives, etc.
IA Compressor A , CWP- A, HFO Transfer pump
16
FG-16
A, LDO Transfer pump A, Service Air Compressor
A, LDO System Misc. drives, etc.
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S. No.
6.3.2
Functional
Group
17
FG-17
18
FG-18
19
20
FG-19
FG-20
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Functions
HFO Transfer pump -B Handling system, CWP B,
IA Compressor B, LDO Transfer pump B, Service
Air Compressor C, HFO Misc. drives, etc.
CWP- C, HFO Transfer pump C, IA Compressor C,
LDO Transfer pump C, etc.
Electrical systems, UPS, etc.
Electrical Systems, 24 V DC system, etc.
Measurement System Requirements

All the signals coming into / going out of the Control System shall be routed
through marshalling cabinets. The input / output modules employed in the
Control System shall be separated from controller hardware.
6.3.2.1
Analog Signal Conditioning & Processing

analog input coming for control and information purpose are:
a) Galvanic isolation of input signals for which power supply source is other
than the measurement system of the control system.
b) Transmitter power supply with per point fuse protection or current limiting
and power supply monitoring.
c) Transducer / transmitter signal output limit check
d) Implementation of multiple measurement schemes
e) Square root extraction
f) Pressure and temperature compensation.
g) On-line ADC gain and drift monitoring and correction at periodic intervals.
h) Linearization of temperature signals (from thermocouples and RTD through
temperature transmitters).
i) Reasonability checks for all analog inputs.
j) Monitor sensor wire break / open circuit / short circuit and take suitable
actions in logic / loop. (This shall include blocking of trip signals in case of
RTD failure).
k) Rate of rise / fall calculation
l) LVM generation.
2. All analog signals for control purpose shall be acquired, validated, processed and
their respective Controller data base updated at a maximum interval of 250 ms
except for some fast-acting control loops for which the above referred time shall
be as per process requirement. The validated analog inputs shall be converted
into engineering units on per point basis. Analog input processing (scanning to
alarm checking) shall be performed once every scan cycle.
3. The analog 4-20 mA input cards shall have input loop resistance >= 250 ohm
for interfacing transmitters / analyzers giving 4-20 mA DC signals along with
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superimposed HART interface signals. 4-20 mA DC signal shall only be used for
control purpose and superimposed HART signal shall be used for configuration,
maintenance, diagnostic and record keeping facility for electronic transmitters
and Analysers etc.
4. Triple measurement scheme for analog inputs employing three independent
transmitters connected to separate tapping points shall be employed for the most
critical measurements. The three signals shall be auctioneered to determine the
median / average value, which shall be used for control purpose. In case one
transmitter fails or shows excessive deviation with respect to others, it shall be
removed from computation of median / average value and the average of the
other two transmitter outputs shall be used for controls. The control loop shall
trip to manual when any two of the three transmitter signals fail. The outputs of
the transmitters shall be continuously monitored for excessive deviation which
shall be displayed, logged and alarmed.
5. Dual measurement scheme for analog inputs employing two independent
transmitters connected to separate tapping points / temperature element shall be
employed for the remaining measurements used for analog control functions. The
output of the redundant transmitters shall be continuously monitored for
excessive deviation. In case the deviation is within limits, the mean value shall
be used for the control loop. If the deviation becomes high (with both
transmitters remaining healthy), the loop shall be automatically transferred to
manual. However, if one transmitter fails and other transmitter remain healthy,
then the output of the healthy transmitter shall be used for control. If the other
transmitter also fails, loop shall trip to manual. The outputs of the transmitters
shall be continuously monitored for excessive deviation which shall be displayed,
logged and alarmed.
6. Individual transmitter signal, their value and selected value for
control/measurement shall be available in OWS.
6.3.2.2
Binary Signal Conditioning & Processing

1. The changeover type contacts (i.e. NC + NO together) shall be wired to the
controller system for all the binary inputs required for control purposes. The
binary inputs required for information purposes only shall be wired to control
system in the form of non-changeover type contacts.
binary inputs coming for control and information purposes are:
a) 24 V DC power supply for contact interrogation for all potential free contacts
with per point fuse protection or suitable current limit feature / isolation
through opto-coupler.
b) Contact bounce filtering delay time of 15 ms. However for SOE inputs, it
shall be such that it should meet SOE time resolution of 1 ms.
c) Facility for automatic pegging of the binary signal to logic one / zero or last
correct value in case of failure of binary input module.
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d) Binary signal distribution to different user shall be in such a way so as to

ensures that a short / ground fault on one user is not reflected to the other
user.
e) Implementation of multiple measurement schemes for signals for control
purpose.
f) All binary signals shall be acquired, validated, processed, alarm checked and
their data base updated within one second. In addition to this requirement,
binary signals required for SOE shall have resolution of 1 millisecond.
g) Checking for excessive number of status changes for all binary / contact
inputs and making it off-scan, if the total no. of changes exceeds a limit
within pre-defined time.
h) The non-coincidence monitoring shall be provided for binary inputs for all
changeover signals.
6.3.2.3
1.
2.
3.
4.
Wiring Scheme for Inputs to Control System

Each of the triple redundant binary and analog inputs shall be wired to three
separate input modules. In addition, for functions employing 2V3 controllers,
each of the redundant binary and analog signals shall be wired to separate input
modules associated with each controller. Similarly each of the dual redundant
binary and analog inputs shall be wired to two separate input modules. These
redundant modules shall be placed in different racks, which shall have separately
fused power supply distribution. Implementation of multiple measurement
schemes of these inputs shall be performed in the redundant hardware. Loss of
one input module shall not affect the signal to other modules. Other channels of
these modules can be used by other inputs of the same functional group.
No single failure in any component of the control system shall lead to
unavailability of more than one of dual / triple redundant input signals to control
system. Similarly, no single failure in any component of the control system shall
lead to unavailability of more than one of dual / triple redundant output signal
from the control system.
The single (i.e. non-redundant) binary and analog signal required for control
purpose shall be wired as follows:
a) The on-off status of HT drives and Breakers with synchronization provision
shall be wired to two input modules in parallel.
b) All analog and binary inputs including the limit switches of valves / dampers /
MCC / SWGR, check-backs of all drives, SOE and information related signals
should be wired to single input modules.
It is envisaged to use remote I/O modules in plant areas where it is required from
location point of view. The remote I/O signals shall be connected to the
respective functional groups through redundant extended I/O bus. The hardware
independence of functional groups shall be applicable for remote I/O as well. The
remote input / output modules shall be located in cubicles in respective areas.
Remote input / output modules shall be designed in such a way to work
continuously under the harsh environment expected to be encountered in these
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5.
6.
7.
8.
9.
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areas (high temp, dust level, humidity etc.). It shall be ensured that extending of
I/O bus of functional group in field does not result in false signalling / noise
pickups. Further, it shall in no way deteriorate the performance of that functional
group and Control System.
Power supply arrangement for these cubicles shall be similar to DCS System
cabinets
The measurement system of control system should be capable of acquiring data
from various equipment and system in digital form through serial port, Field bus/
Profibus, Ethernet connection using industry standard protocols. The control
system shall include requisite modules for accepting such signals.
The maximum number of inputs/outputs to be connected to each type of
modules shall be as follows:
a) Analog input module
16
b) Analog output module
08
c) Binary input module
32
d) Binary output module
32
The following requirements shall be met for analog/binary input / output modules
as applicable:
a) Input filters to attenuate noise shall be provided
b) All analog / binary inputs and outputs shall be capable of withstanding 500V
DC common mode and 500V AC peak to peak between analog and digital
parts. All analog outputs shall be short circuit proof.
Any single sensor / transducer / transmitter failure alarm shall be provided on
Engineers Station monitors for all sensors / transducers / transmitters. Similarly
sensor break alarm for thermocouples etc. shall also be logged and displayed.
Table 6.2
Specifications for High Level Analog Input Modules
S.No.
Features
1
2
3
4
5
No. of Inputs/module
Type of Input(Linear)
Accuracy
A/D Converter
Temperature Effect
16
4-20 mA & 1-5 V
0.1% or better
Integrating, 15 bit + Sign or better
0.01%/Deg. C or better
6
7
8
CMRR
NMRR
Stability
Diagnostic
60 dB (at 50 Hz) or better

0.03%/year or better
Limit check
A/D converter fault
Channel fault
Wire break
Short Circuit
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S.No.
Features
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Auto Gain Correction
Table 6.3
Specifications for Low Level Analog Input Modules
S.No.
Features
Type of Input
(Grounded & Un-grounded)
Cold Junction Compensation
4
5
6
7
8
9
Accuracy
A/D Converter
Temperature Effect
CMRR
NMRR
Stability
10
16
Thermocouple (J,K,R,S,T)
RTD (Pt-100)
{Two wire & three wire}
On module/Local RTD
0.1% or better (Linearized)
Integrating, 15 bit + Sign or better
0.01%/Deg. C or better
0.03%/year or better
A/D converter fault
Channel fault
Wire break
Short Circuit
Auto Gain Correction
Diagnostic
Table 6.4
Specifications for Binary Input Modules (Slow Scan)
S.No.
1
Features
Type of Input
Input Current
Diagnostic
32
24 / 48 V DC
NO/NC/Change Over Contacts
5-10 mA
Input Simulation
Wire Break detection
Short Circuit
Table 6.5
Specifications for Binary Input Modules (Fast Scan SOE)
S.No.
Features
Same as Table 6.4 above but resolution 1 milli Second
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Table 6.6
Specifications for Pulse Input Modules
S.No.
Features
Same as Table 6.4 above but, with 16 channels/module (maximum) and Leading/Trailing
edge detection. Minimum Pulse width 1 milli Second.
Table 6.7
Specifications for Analog Output Modules
S.No.
1
2
3
Features
No. of Points/module
Type of Output(Linear)
Accuracy
Load
Diagnostic
08
4-20 mA
0.4% or better
600 Ohms (current)
1000 Ohms (Voltage)
Channel fault
Table 6.8
Specifications for Binary Output Modules
S.No.
1
2
3
4
5
6
6.3.3
Features
No. of Points/module
Type of Output
Contact Rating
Contact Voltage Rating
Switching Frequency
Contact Life
32
Relay with one changeover contact
60VA
60 Volts
2 Hz
1 million operations
Data Communication Bus System Requirements

The System offered shall be an open system and shall conform to Open Industry
Standard (IEEE). A redundant 10 / 100 MBPS Ethernet based high speed
switched fault tolerant Data Communication System shall be deployed that
provides
for
multiple
simultaneous
bi-directional
communications.
Communication shall be full duplex and with TCP-IP protocol. All interfaces links
of controllers, gateways, MMI stations, switches and all other communication
devices on the network shall be dual so that a single point failure shall not lead
to system shutdown. Network shall be capable of handshaking with any third
party system following standard protocol. The primary objective shall be
centralized monitoring, presentation & report of data for information and analysis
of entire plant. All the functional groups shall be connected to a common highspeed data network for global distribution and peer-to-peer data communication.
Any data shall be available at any point on the network as and when required.
The control system shall be modular, expandable and flexible so the expansion of
the system is possible by adding extra stations on the data communication bus.
Comprehensive self-diagnostic features have been envisaged to facilitate easy
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1.
2.
3.
4.
5.
6.
7.
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fault location and detection of hardware and software while the unit is in
operation. It shall be able to direct intelligent routing of messages without the
drawbacks of traffic jamming etc.
The Data Communication System shall include a Redundant System Bus for
major subsystems with hot back-up. The data highway shall be high speed
digital links of speed preferable 10/100 MBPS. Bus protocols at control levels
shall conform to OPC compliant ISO-7 layer protocol in master less, token ring
or token bus (as per IEEE 802) or any standard proven and acceptable protocol
in deterministic mode. Extensive error checking (CRC-16/12) or error correcting
codes shall be used in these levels to improve the reliability of communication.
The Data Communication System shall have following minimum features:
Redundant communication controllers shall be provided to handle the
communication between each functional group of controllers of Control
System and the System Bus. The design shall be such as to minimize
interruption of signals. It shall ensure that a single failure anywhere in the
media shall cause no more than a single message to be disrupted and that
message shall automatically be retransmitted. Any failure or physical removal
of any station / module connected to the system bus shall not result in loss of
any communication function to and from any other station / module.
If the system bus requires a master bus controller philosophy, it shall employ
redundant master bus controller with automatic switchover facility.
Built-in diagnostics shall be provided for easy fault detection. Communication
error detection and correction facility shall be provided at all levels of
communication. Failure of one bus and changeover to the standby system bus
shall be automatic and completely bumpless and the same shall be suitably
alarmed / logged. The above changeover shall not result in any data loss.
The design and installation of the system bus shall take care of the
environmental conditions and hazardous area classification as applicable to
similar services.
Data transmitting speed shall be sufficient to meet the responses of the system
in terms of displays, control etc. plus 50% spare capacity shall be available for
future expansion.
Passive coaxial cables or fibre optic cables shall be employed for System Bus. It
may proposed with other type of cables as per their standard also which shall be
subject to Consultants approval. However the following buses shall be fibreoptic only.
a) System bus connections between Control Room & Control Equipment Room.
b) System bus from locally mounted control system cabinets / OWS to central
location.
c) I/O Bus from remote I/Os to centrally located system cabinets. The redundant
buses shall be physically separate and shall be routed separately.
If UTP / STP cables are used, then it shall routed with flexible conduit.
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8. In case of any distance or other limitation in the Data Communication System,

then it shall be provide with special type of cables like optical fibres with
repeaters as required to make the system fully operational.
9. Serial device interface module shall be capable of providing communication
interface with serial devices. The Modbus interface shall support MODBUS RTU
protocol and use EIA-422/485 multi loop configuration by establishing direct
digital communication. The nominal capacity of a link shall not be less than 5000
digital and 200 analog inputs. The acquired & transmitted data shall integrate
seamlessly with DCS database. The physical medium of communication can be
twisted wire, coaxial or fibre optic cable, depending on transmission distance
and surrounding electrical interference.
10. In redundant network, the communication cables of each network shall be
uniquely colour coded.
6.3.3.1
DCS System Interfacing Requirements

Following Interfacing facility shall be provided for DCS System.
1. One (1) no. independent Redundant Bi-directional OPC/ Soft Link, for monitoring,
operation & effective control of the system (without time delay), with Ethernet
based TCP-IP protocol for SG integral Control System.
2. One (1) no. independent Redundant Bi-directional OPC/Soft Link, for monitoring,
operation & effective control of the system (without time delay), with Ethernet
based TCP-IP protocol for TG integral Control System.
3. One (1) no. independent Redundant Bi-directional OPC Link with Ethernet based
TCP-IP protocol for the Coal Handling Plant Control System.
TCP-IP protocol for the Ash Handling Plant Control System.
TCP-IP protocol for the Water Treatment & Effluent Treatment Plant Control
System.
TCP-IP protocol for the Raw Water Intake Pump house Control System.
TCP-IP protocol for the Hydrogen Generation Plant Control System.
TCP-IP protocol for the Substation Automation System.
TCP-IP protocol for the ESP Control System.
TCP-IP protocol for Water Lance System.
11. One (1) no. independent Redundant Bi-directional OPC/Soft Link with Ethernet
based TCP-IP protocol for the Emergency DG Control System.
12. One (1) no. independent Redundant Uni-directional OPC Link with Ethernet
based TCP-IP protocol for Turbine Supervisory Instrumentation (TSI) System.
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13. One (1) no. independent Redundant Uni-directional OPC Link with Ethernet
based TCP-IP protocol for Online Tube Cleaning System.
14. One (1) no. independent Redundant Uni-directional OPC Link with Ethernet based
TCP-IP protocol for Turbine Lube Oil Purification System.
15. One (1) no. independent Redundant Uni-directional OPC/Soft Link with Ethernet
based TCP-IP protocol for AC & Ventilation Control System.
16. One (1) no. independent Redundant Uni-directional OPC/Soft Link with Ethernet
based TCP-IP protocol for Fire Detection & Protection System.
17. One (1) no. independent Redundant Uni-directional OPC Link with Ethernet based
TCP-IP protocol for MIS system.
TCP-IP protocol for Computerized Maintenance Management System (CMMS).
TCP-IP protocol for PADO system.
20. One (1) no. independent Redundant Bi-directional Communication Link with
Ethernet based TCP-IP protocol for Vibration Monitoring & Analysis System.
21. One (1) no. independent Redundant Uni-directional Communication Link with RS485 Modbus Protocol for interfacing with SWAS.
22. One (1) no. independent Redundant Uni-directional Communication Link with RS485 Modbus Protocol for interfacing with CEMS.
23. One (1) no. independent Redundant Uni-directional Communication Link with RS485 Modbus Protocol for interfacing with Instrument & Service Air Compressors
(NTA-1 Package).
24. Uni-directional Communication Link with IEC 61850 Protocol for interfacing with
Numerical Protection relays.
25. Redundant Bi-Directional Communication Link with RS-485 Modbus Protocol for
interfacing with Variable Frequency Drives.
26. Any other Communication Link as required for proper functioning of Complete
System.
27. Two (2) nos. Redundant Bi-directional communication OPC Link with Ethernet
based TCP-IP protocol as spare provision.
28. Two (2) nos. Redundant Uni-directional communication OPC Link with Ethernet
based TCP-IP protocol as spare provision.
29. Two (2) nos. Uni-directional Communication Link with RS-485 Modbus Protocol
as Spare Provision.
30. Four (4) nos. Uni-directional Communication Link with IEC 61850 Protocol as
Spare Provision.
Man-Machine Interfacing System
1. Man-Machine interface system shall be designed and engineered for safe,
efficient, reliable and convenient operation. MMI shall employ high performance,
non-priority open system architecture to ensure fast access and response time
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3.
6.3.4.1
1.
2.
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and compatibility with other system and portability of third party software. MMI
System shall be used primarily for the following functions:
a) As operator interface for control operation for the plant for accepting data
from and issuing commands to control system etc.
b) To perform plant supervisory, monitoring and information functions.
No single failure in MMI System shall lead to non-availability of more than one
OWS or one LCD or one printer. In such an event i.e. single failure leading to
non-availability of any OWS / LCD, it shall be possible to operate the entire plant
in all regimes of operation including emergency conditions from each of the other
available OWS / LCD.
The Plant data pertaining to one unit shall be available in the MMI of the
respective unit. Data from common system shall be available in the MMI of units.
Further, suitable displays with selection facility shall be provided for common
system drives so that all common system drives can be controlled from any of
the unit.
Operator Interface Requirements
The Operator interface of the MMI system shall consist of TFT Monitor, Mouse,
Keyboards of OWS, LCD, Printers, etc. as follows:
a) Six (6) Nos. OWS with 21 TFT Monitors, Optical Mouse, Keyboard etc. for
Unit Operation.
b) Two (2) Nos. OWS with 21 TFT Monitors, Optical Mouse, Keyboard etc. for
Common system Operation
c) Two (2) Nos. OWS with 21 TFT Monitors, Optical Mouse, Keyboard etc.
for Shift In Charge Engineer.
d) Two (2) Nos. 65 LCD with work station for display control and all other
accessories, for Operation & Monitoring.
e) One (1) No. 65 LCD with work station for display control and all other
accessories, for Operation & Monitoring of Plant Common System.
f) One (1) No. 65 LCD with work station for display control and all other
accessories, for Operation & Monitoring of Plant Electrical System.
g) Two (2) Nos. Dot Matrix Printer (A3 size) for Alarm Printing.
h) Two (2) Nos. Dot Matrix Printer (A3 size) for Log Printing.
i) Two (2) Nos. Color Laser Jet Printer (A3 size) for Hard Copy Printing.
j) One (1) No. Color Laser Jet Printer (A4 size) for Shift In charge Station.
All OWS / LCD of the MMI System shall be fully interchangeable i.e. all operator
functions including control, monitoring and operation of any plant area shall be
possible from any of the OWS / LCD at any point of time without the necessity
of any action like downloading of additional files. Each OWS / LCD shall be able
to access all control information related data under all operating conditions
including a single processor / computer failure in the MMI System. Further,
simultaneous operation of at least two drives of control system shall be possible
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3.
4.
5.
6.
7.
8.
6.3.4.2
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from a single display without calling additional display for multiple drive
operation.
The operator functions for each OWS / LCD shall as a minimum include control
system operation (A/M selection, raise / lower, set point / bias change, on / off,
open / close operation, mode / device selection, bypassing criteria, sequence
auto, start / stop selection, drive auto selection, local-remote / other multiposition selection etc.), alarm acknowledge, call all kind of displays, logs,
summaries, calculation results etc., printing of logs and reports, retrieval of
historical data and any other functions required for smooth operation, control
and management of information.
All frequently called important functions including major displays shall be
assigned to dedicated function keys on a soft keyboard for the convenience of
the operator for quick access to displays and other operator functions.
The display selection process shall be optimized so that the desired display can
be selected with the minimum number of operations. Navigation from one display
to any other should be possible efficiently through paging soft keys as well as
through targets defined on the displays. There should be no limitation on number
of such targets.
The system shall have built-in safety features that shall allow certain functions
and entry fields with a function to be under password control to protect against
inadvertent and unauthorised use of these functions. Assignment of allowable
functions and entry field shall be on the basis of user profile. The system
security shall contain various user levels with specific rights, which shall be
changeable by the programmer.
Set points and other entries made shall be automatically checked for validity of
range.
In addition to the OWS & LCD, minimum amount of conventional instrumentation
(i.e. Push button Stations etc.) shall be provided as per standard practice for safe
shut-down of the unit.
MMI System Functional Requirements
The MMI System shall be designed as an on-line system which shall process,
display and store Information to provide the operator, either automatically or on
demand. The Following functions shall be performed by MMI system as a
minimum:
1. Plant Control Displays

Various displays on the OWS / LCD shall as a minimum include P&ID displays or
mimic, bar chart displays, X-Y and X-T plot (trend) displays, operator guidance
message displays, group displays, plant start-up / shut-down message displays,
system status displays etc. Number of displays and the exact functionality shall
be on as required basis.
Minimum contents and functionality of various types of displays shall be as
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a) Mimic Display
These displays shall depict the process in graphical form and shall cover all
the drives operable from DCS and all process areas being monitored therein.
There shall be two types of mimic display, broadly, i.e. Overview displays
and sub-area / individual displays. Operation of sequences and drives shall
generally be carried out through the sub-area / individual displays.
Facility of adding a user specific symbol to the standard library shall be
possible. It shall be possible to go to a predefined trend display on selecting a
field on any analog point on the displays.
b) Control Tile Display
In this display the drives of a loop shall be displayed with related parameters
such as process value, set point, deviation for the loop along with facility for
any selections (like A/M selection, valve selector etc.) and the command
output, disturbance status and the position feedback signals, for each drive.
It shall be possible to call this display as a Pop-up window from the
controlled drives in main mimics.
c) Trend Display (X-T Plots)
These displays shall show the trend of analog points with respect to time.
These displays shall be continuous curve plot and not point plots. Time spans
of displays shall have operator selectable intervals of 5, 10, 15, 30, 60
minutes, 8, 24 and 72 hours. In addition, zoom in / out, stretching facilities
etc. shall be provided. Sufficient buffer space shall be provided to store data
for minimum 500 points at MMI system scan rate for 72 hours.
d) X-Y Plot Display
There shall be fifteen number of such X-Y plot displays each of one page,
pre-programmed in the system. At any instant of time, this page shall include
up to 3 independent X-Y point Plots (values of X and Y variables) of up to
three equipment typically in the form of a cross X. Operating curves shall be
superimposed over the X-Y plot. Alphanumeric information shall be overlaid
to indicate X and Y scales, point identification, current operation point value
with engineering units, etc. Two or three pairs of X and Y variables having
common operating curves shall be displayed on one display page only. In
such cases distinct symbols shall be used to show operating point for each.
The balance shall be programmable at site.
e) X-Y Plot Display using stored data
This type of display shall show the analog trend of X-axis variable with Y-axis
variable with facility to select time period. Ten numbers of such displays,
each of one page shall be pre-programmed in the system.
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f)
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Sequence Display
Sequence chain displays for each group and sub-group shall be used to trace
the sequence of a control chain as well as to facilitate the operator
interventions and enable mode changes / auto selection. Sequence chain
display shall present complete sequence chain, in functional blocks, steps
being carried out, criteria, running time, monitoring time, waiting time,
operating mode, various parameters with associated engineering units for
each step and criteria. It shall be possible to display a list of missing criteria
for each sequence chain on Operators demand. The sequence chain display
shall automatically move forward when the auto sequence is in operation.
g) Drive Level Display

For each drive (both binary & modulating) a drive level display shall be
provided which shall indicate the value / status of drive related inputs /
outputs, permissive and protection conditions, the drive level logic and other
drive related information including individual drive faults and disturbance
criteria. It should be possible to call these displays as pop-up displays.
h) CLCS Display
The loop schematic for each loop shall be available in a display form which
shall show the individual analog and binary values (input / output and
intermediate) and the loop tuning parameters also.
i)
Group Display
The group display shall present point information including point ID,
description, current value, range, function group, quality tag and engineering
unit of a group of points. (Number of points in a page shall be minimum 20).
j)
Bar Graph Display

Horizontal and vertical bar charts shall be provided for the display of related
points. Number of bars in a display shall be limited only due to visibility and
resolution and no restriction shall be there in the numbers otherwise.
k) Alarm/Fault Analysis Display

In order to guide the operator in case of a process fault / alarm, a fault
analysis display shall be provided so that the cause of the alarm, is presented
to the operator. For each alarm, various reasons for the cause of the alarm
shall be displayed.
l)
Alarm Querying facility

On each display, one icon shall be provided. Clicking this icon shall lead to a
display indicating all the lamp boxes and list of alarms in each box along with
its status. Clicking on the alarm text of a lamp box shall give detailed list
along with status of the individual alarm if it is a group alarm.
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m) Point Detail Display

From any display, i.e. mimic alarm or any other group display, facility shall be
provided to select any point for point detail display. This display shall include
all the database attributes of the point. For field I/Os, the termination and
interconnection details up to field sensors shall additionally be available. In
the point detail display of calculated point, by simple clicking of point or
through soft key it shall be possible to display the calculation used and to get
further details of any other calculated points used in the calculation.
n) LCD Display
In addition, top area of the LCD (around 300mm), shall be reserved for
display of soft replica of Conventional annunciation fascia (for permanent
viewing i.e., not operator changeable). LCD based overview display shall be
provided, which shall be overlaid across all LCD for viewing as video wall.
2. Log/ Summaries/ Reports
The system shall generate three basic types of reports / logs i.e., Event
activated, Time activated and Operator demand log and summaries. The system
shall have the facility for viewing of the logs / summaries on the OWS / LCD as
well as for their copying in formats compatible to be used with MS-Office or
similar tools.
The system shall be designed for automatic printing of all the reports / logs with
a provision of inhibition of the print function for each log separately, with
selectable duration and selectable page / group of each log. Manual printing of
time-actuated log shall also be possible.
Automatic switching of any log function from a pre-selected primary printer to a
pre-selected secondary printer (defined on a per log basis) shall be possible.
However, change in the assignment of the printers shall be possible through
OWS/EWS.
a) Event Activated Logs
Event activated logs shall as a minimum include alarm log, trip analysis log,
start-up log, control related logs and operator action log. All operator actions,
modification in database etc. shall be logged (with historical storage) along
with the username responsible for that action.
The trip analysis log shall record 30-100 pre-trip and 30-100 post-trip
readings, operator selectable at site for the pre-defined parameters (not less
than 250 points), sub-divided in to 25 groups. The data collection rate shall
be of scan rate 2 minutes (operator selectable at site).
The system shall be capable of generating and printing TG start-up logs, the
functionality of which shall be similar to the trip analysis log.
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b) Time Activated Logs

Time activated logs shall include shift log and daily log as a minimum. Each
of these shall provide hourly record of a minimum 250 points sub divided into
25 groups
c) Operator Demand Logs
Operator demand logs shall include, as a minimum, digital trend log,
maintenance data log. Summary log, performance logs and some special
logs.
The system shall be capable of generating and printing trend log for a
minimum of 80 groups of 15 points each.
Maintenance Data Log (MDL) shall provide schedule of preventive
maintenance and routine equipment inspection for 100 numbers of equipment
per unit and for auxiliary plant. The data in MDL shall include current status,
total running time, running time since last maintenance, running time in
current financial year, loss due to downtime etc.
Performance log shall provide results of performance calculations.
d) Various Summaries
Various summaries shall include off scan summary, constants summary,
point quality summary, substituted values summary, peripheral status
summary, alarm annunciation group summary, etc. These summaries shall
also be available process area or sub-area wise, as well as based on any
other data base criterion like functional group number, cabinet number, type
of signal etc.
e) Generated Reports
It shall be possible to generate certain reports in some of the PCs on the
station LAN, which shall constitute partly off-line data entered there-in and
on-line information collected from the system. There shall be provision of
generation of minimum ten (10) such reports per PC on the LAN.
f)
Log Generation Utility

The system shall have a log generation utility to generate a log / report
having following facilities as a minimum:
Define format of the log like header information, time, date etc.
Selection of any point (scanned and calculated) from the data base and
assign it to a log group.
Selection of log data collection process initiating event, collection
intervals (1, 2, 3, 5, 10, 30 & 60 minutes) for each point of a particular
log group. Facility shall also be provided for selection of 100 points at a
collection interval of 1, 2, 3, 5, 10 and 30 seconds.
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Assignment of log printout initiation on event or time including selection

of the printing interval for particular log group and time of printing. (For
time initiated logs).
Assignment of number of samples to be collected for each point.
Select points for which minimum, maximum accumulation over a selected
period, average, etc., values can be printed. Also facility shall be provided
to tag the time at which the parameter passed through maximum /
minimum.
It shall be possible to define 100 log groups of 15 points each. Any log
group can have any point from the database. One log shall include at the
maximum 10 such groups.
3. Alarm Monitoring & Reporting
a) The system shall display history of alarms in chronological order on any of
the OWS. The MMI system shall have the capability to store a minimum of
1000 alarms each with paging features allowing the operator to view any
page. The system shall have all alarm functions and related function keys like
alarm acknowledge, reset, paging, summaries etc. Other design features like
set point / dead band adjustments, provision of alarm priority, manual
inhibition and automatic inhibition based on predefined logic etc., shall be
provided. The alarm display / report format shall be subject to approval.
b) Facility of audio annunciation including voice audio shall be provided in OWS
upon the occurrence of alarms irrespective of whether alarms are displayed
or not. Facility to disable the audio annunciation per OWS shall be provided
under the security level of Maintenance or Administrator.
c) At least four levels of alarm priority shall be available which shall be
displayed in different colour. It shall be possible to display and print alarms of
any of the four levels only on a per OWS basis.
d) Alarm boxes shall be provided in each display to alert the operator about an
alarm when he is viewing some other picture. Number of alarm boxes shall be
for each process area and with priority therein.
e) Features viz. root cause analysis, alarm filtering, alarm cut out and display of
alarms on LCD shall be provided.
4. Calculations
a) All the algebraic / logical calculations related to analog points e.g. sum /
difference / average / maximum / minimum / integration, selection of one
analog point out of two based on status of digital point, duration for which
an analog point is above / below a threshold, digital point (e.g. AND / OR /
COMPARE etc.), transformations , like running average, periodic average,
weighted average, hourly / daily maximum / minimum (or for a specified
duration ) and time of maximum / minimum, flow calculations, time projection
or rate of change calculations, duration in alarm (or duration in a band),
number of transgression of a point in a band etc. shall be provided. All the
calculated values of the plant shall be available in the database and can be
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assigned to all functions just like any scanned point. It should be possible to
add new algorithm for basic calculations to the standard library.
Using one hour average data of process parameters, the system shall have
the capability to calculate present value, expected value and deviations for
parameters like plant heat rate (net and gross), boiler efficiency, major drives
efficiency calculation, auxiliary power consumption. The performance
calculation package shall be based on latest codes & standards as applicable
like ASME, BS & HEI.
Provision shall be made, including all required custom programmed software,
for performing the calculations described in this clause. All calculations shall
use a high level language. Calculations shall be made using floating point
arithmetic. These equations shall be changeable on line at the job site.
An extensive set of steam property subroutines based on the latest ASME
steam tables shall be included. The calculation results shall automatically be
quality coded according to the worst quality of any of the inputs to each
calculation. The results of these calculations shall be available through the
data base, for appropriate logs and operator displays.
Calculation for monitoring the performance of the unit shall be performed.
These calculations are categorized into two classes.
i.
Class I calculations include those calculations that are made every scan
cycle, generally for the purpose of detecting and alarming unit
malfunctions. The following class I calculations shall be included:
b)
c)
d)
e)
Cold reheat steam approach to saturation temperature

Drum Water Saturation Temperature rate of change
First stage superheat outlet temperature approach to saturation
temperature
Turbine steam metal temperature differences
Turbine metal temperature rates of change
Feed water individual heater terminal temperature difference.
Excess air deviation from standard.
Feed water leaving each heater temperatures deviation from standard
Turbine steam supply accounting.
ii.
Metal Temperature differences for SHY , RH Y region and any

specific location.
Class II calculations include those calculations that are made to determine the
performance of individual items of equipment and the overall unit. Class II
calculations shall be performed on-line using averaged data which is accumulated
over a period of time. This time period shall be selectively adjustable from 10 to 30
minutes. The system shall also collect this averaged data. The operator shall be able
to input coal analysis data into the computer for the class II calculations.
Class II turbine performance calculations shall comply with the
recommendations of ASME Performance Test Code Report PTC 6S-
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[97]
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latest, Simplified procedure for Routine Performance Test of Steam

Turbines. The vendor shall be responsible for altering his standard
performance programme to comply with this specification and to conform
to the cycle of these units.
Boiler efficiency shall be computed by the heat loss method and the inputoutput method. Percentage deviation between the two methods shall be
calculated as recommended in the ASME Test Code PTC 4.1-latest as
applicable, Steam Generating Units. If the test codes require measured
data that is not actually available in the process, manually substituted
values shall be used.
The following Class II calculations shall be performed.
Unit heat rate
Boiler Efficiency
Operating Hours
Air Heater Performance
Economizer Performance
Deaerator Performance
HP & LP turbine enthalpy drop efficiency
LP turbine enthalpy drop efficiency (using dry exhaust)
Turbine heat rate
Feed water heater performance
Condenser performance
Plant Load/Availability Factors
Unit Availability Calculations
Deviations from Expected Values for Each Calculations
5. Quality Tags
a) The system shall identify and tag the quality of all data (scanned and
calculated points) in a way that makes all users (control, calculations, logs,
display, etc.) aware of its quality. Quality of data other than good shall be
clearly identified in all printouts and displays by appending quality character
to the value / status of point. The quality tagging shall include good, bad,
substitute, doubtful, missing, etc.
b) Typically 'Good' shall designate variable that satisfies all tests for quality,
'Substitute' designating a value that has been manually substituted, 'missing'
and 'bad' designating an open circuit, transducer limit violation on both upper
& lower side, etc. for analog inputs & open fuses, excessive number of
chattering etc for digital inputs
6. Database
c) The database shall be organized in such a way that searching / querying &
sorting of any field shall be possible. There shall be minimum 10 process
areas and each database point shall have various attributes.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
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d) Based on these attributes & its combinations, the sorting / searching of the
data shall be done.
e) The attributes shall include as a minimum single point ID, additional tag
number, description, current value, quality tag, engineering unit (if
applicable), alarm limits, dead band, alarm cut out point identifier, variable
limit point identifier, conversion constants, electrical signal value & unit,
alarm status, scan status, historical / long term storage frequency, plant area
/ sub area hardware details, reference of logic / loop diagram number & page
etc.
f) All the points i.e. I/Os, OLCS/CLCS, generated signals, computed signals of
calculations, OPC tags, shall be identified by unique tag throughout the
networked DCS system/ sub-systems including station LAN.
7. Messaging System
It shall be possible to send pre-defined messages either periodically or on
occurrence of certain events in the form of
a) Operator guidance message to OWS / LCD.
b) E-mail messages to various clients on the station LAN.
c) Messages to pre selected Mobile numbers
Adequate safety in the system shall be built up to avoid any unauthorized access
to DCS system. All necessary Hardware & Software shall be provided to achieve
the same.
6.3.4.3
1.
2.
3.
4.
5.
6.
MMI System Hardware Requirements

The MMI system shall be based on latest state of the art Workstations and
Servers and technology suitable for industrial application & power plant
environment.
The Workstation / Servers employed for HMIPIS implementation shall be based
on industry standard hardware and software, which shall ensure easy
connectivity with other systems and third party software.
Power Fail auto Restart facility with automatic time update shall be provided.
Necessary hardware and software for quick backup and restore shall be
provided.
Minimum amount of conventional mosaic compatible hardwire devices mounted
on draw out portion of Control Desks.
All the peripherals shall conform to the following minimum requirement but the
exact make & model shall be subject to approval.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[99]
02.09.2015
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A) Operator Workstation
Table 6.9
Specifications for Operator Workstations
Features
Processor
Intel i5 or better /64 bit latest generation
Memory
4 GB RAM expandable to 6 GB
Hard Disk
1 TB
Monitor Support
Dual
CD Drive
52X Read/Write
Power Supply
230 V 50 HZ
Keyboard
ASCII
Pointing Device
Optical Mouse
Monitor
Min 21" TFT Flat Monitor with resolution

of 1600 x 1200 non-interlaced refresh
rate min. 85 Hz
S.No.
B) Servers
Table 6.10
Specifications for Servers
S.No.
Features
1
2
Processor
Memory
Hard Disk
RAID
64 bit latest generation

3 X1 TB ultra wide SCSI/7200 RPM, Hot
swappable
SCSI-channels, hardware RAID level 5
implemented
Monitor Support
Dual
CD Drive
Power Supply
10
11
Removable Bulk storage Drive

No. of Removable bulk storage
media for above
Keyboard
Pointing Device
52X Read/Write
Redundant Hot swappable, 230 V 50Hz 1phase
1 TB minimum
12
Monitor
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
10 nos.
ASCII
Optical Mouse
rate min. 85 Hz
Description
Page
No.
Date of Issue
[100]
02.09.2015
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C) LCD Screen
LCD display complete with control units & associated accessories shall be
supplied as per the following specifications.
Table 6.11
Specifications for LCD
S.No.
Features
1
2
Viewable Picture Area

Resolution
65 inch measured diagonally

1920 X 1080
3
4
5
6
7
8
Aspect Ratio
Display Colors
LCD Panel
Contrast Ratio
Brightness
Viewing Angle
16:9
16.9 million colors
Active matrix TFT LCD
800:1
500 cd/m2, Anti-glare
1780 Horizontal & Vertical both
9
10
11
12
13
Computer Interface
Cabinet Material
Finish
Mounting
Power supply
14
Accessories
VGA, DVI-D, HDMI,

ABS
Black
Fixed Wall Mounting
230 V, 50 Hz, 1-phase
Universal Tilt wall mount stand, IR Remote,
Power cord
Other Features of LCD

1. LCD shall be designed for continuous viewing (24 hours in a day) under
normal room ambient lighting without any need to darken the room.
Suitable darkening of the projection screen for light absorption shall be
provided for this purpose.
2. The screen should be flicker free and there shall not be any screen burnin due to display of same information for a long time.
3. Auto brightness adjustment between each screen shall be provided.
4. The control unit shall interface with the unit LAN. The control units shall
have dual Ethernet connection with the respective Unit LANs and shall be
located in the LCD panel.
5. Suitable facility shall be provided to the Operator for transferring the screens,
without any need of changing of hardware / wiring or software.
6. Master control unit shall be capable of projecting MMI displays over a part of
screen to multiple screens. Any communication of windows shall be
possible. Facility for overlays shall be provided.
7. The LCD Screens shall have additional features to work in association with
multiple numbers of plant cameras also to be supplied under this package.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[101]
02.09.2015
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D) Printers
Table 6.12
Specifications for Dot Matrix Printer
S.No.
1
2
Features
Type
No. of Needles
Printing Speed
4
5
6
Character dimension
Buffer
Local Memory
7
8
Communication Port
Power supply
Paper size
10
11
12
Paper input capacity

Character sets
Transfer distance
13
Print features
14
Reliability
15
16
Noise Level
Ribbon Life
17
Diagnostics
18
No. of Copies
19
Accessories
Heavy duty (at least 50000 pages/month)
24 pin
300 characters per second/ 1000 Lines
per minute
9x8
80 KB (minimum)
RAM with battery backup
Ethernet/RS-232/parallel
230 V, 50 Hz, 1-phase
132
column
continuous
fan
fold
type/A4/A3
continuous
ASCII, IBM, Italics,
200 mtrs. Minimum
Graphic print, Emphasized, double width,
underlined, subscript, superscript, double
strike, backspace, margin etc.
MTBF> 8000 hrs.
Less than 60 dBA
2 million characters
Self diagnostic, LED error code display,
Audio alarm paper exhausted
Minimum Original +3
Printer stand
Table top receiving station
Interface cable
Paper tear box
Ribbon
Table 6.13
Specifications for Laser jet Printer
S.N
1
Features
Type
Printing speed
Printer Memory
Electro-Laser photographic, Table top type
Monochrome : 24 ppm A4
Color
: 6 ppm A4
256 MB (minimum)
4
5
6
7
Resolution
No. of Color (Basic)
Duty cycle
Power supply
1200 X 1200 DPI in color

4 nos.
Monochrome 75000 pages/month
230 V, 50Hz, 1-phase
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[102]
02.09.2015
S.N
8
10
Communication Port
A3/A4
Plain paper, Transparency, Thick stock,
Glossy stock, Envelopes
Ethernet port/ Parallel port
11
12

Others
500 pages
Auto duplex function
6.3.5
1.
2.
3.
4.
5.
6.
Features
Paper size
[Logo of Utility]
Print media
Maintenance Engineer Station (Engineering Work Station)

The system shall be provided with programming facility (Engineering
Workstation) for Control system and system documentation. Three (3) Nos. of
EWS shall be provided on per unit basis placed in Engineering Room. The system
shall be complete with monitor, keyboard & Optical mouse.
The system shall be also provide minimum Two (2) Nos. of Laptop computers
with latest hardware configuration and loaded with suitable operating &
application program as a backup portable programming and configuration station.
Each station shall be equipped with DVD writer for archiving of the
configuration.
EWS shall have all the features of OWS and in addition shall have the following
capabilities as a minimum:
a) To generate control software through logic diagrams without any
programming knowledge
b) To generate graphic display and control displays, facility to change/enter all
the attributes of analog and digital I/O points, calculated and Boolean
variables and constants like scan rate, process range
c) To test, configure/reconfigure process interface modules/cards
d) CLCS tuning
e) To accumulate I&C faults to analyse downtimes and time to repair
f) To run offline system diagnostic programmes
g) On- line fault detection through diagnostics
h) Other maintenance Engineer's functions.
i) Online modification/addition of loops without hampering of smooth operation
of plant. In case of errors in programming at engineering station, same shall
be notified along with suggested corrections by the system itself, before
loading.
The programming tools shall have in-built safety features that shall protect the
system against inadvertent and unauthorized use of these tools. Necessary hard
key locks and software locks, etc. shall be provided for this. During on line
programming, external plant / equipment should not be affected.
The system shall also have facility to permit the programmer to add text
information at the beginning and end of each program, wherein programmer shall
list out his name, time, date of change which has been made, name of the
person who has authorized the change, etc.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[103]
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7. Any modification done in Control System shall be suitably logged so that it can
be traced to the user log-in ID and time of change. Facility for modifications shall
be user friendly
8. Structuring / configuring and tuning facilities shall be provided for
structuring / modification, storing / loading, testing, tuning, monitoring, etc. of all
the microprocessor based controllers of the control system. The configuration
and tuning unit shall be hooked up with the system bus. In case different
hardware is employed for different parts of control systems and it is not possible
to provide structuring/ configuration and tuning of these from the same station,
then the system shall be provided with necessary number of stations for the
purpose.
9. It shall be possible to configure the system with ease without any special
knowledge of programming or high level languages. Control strategy shall be
implemented using familiar and conventional automation function blocks
(software implemented). Whenever any change in configuration is done, it shall
be recorded and modified configurations shall be available for printing and
documentation and shall be stored in non-volatile memory. The entire system
configuration, tuning / fixed parameters shall be documented and printed in form
of function diagrams and lists respectively.
10. On-line tuning of the control loops shall be possible without causing any
disturbance in the execution of the control loops. Provision to store and retrieve
on immediate and long term basis the system configuration, data base etc. on
some device such as DVD shall be included. Facility shall be provided to reload /
down-load the system or controller module from the already stored data, on-line.
11. The Engineering station shall be equipped with system/software to calculate the
tuning constants i.e. P, I & D values of control loops automatically. Facility shall
be provided to conduct open loop tests (i.e. controller in manual mode) and close
loop tests (i.e. controller in auto mode) on control loops through GUI based user
interface. It shall be possible for the user to adjust the step size of disturbance,
sample time and duration of test. Facility shall be provided to choose the type of
process to be tuned i.e. PI, PID etc., controller type i.e. regulating or tracking
and the type of process being controlled i.e. Integrating, non-integrating etc.
Further it shall also be possible to calculate the tuning constants by capturing the
process changes during normal process disturbance (without conducting any
test). The calculation of tuning constants shall follow internationally accepted
tuning procedures.
12. Online system shall be provided for programmed development / modification to
achieve various functions including development, modification and testing of
software of MMI, generation and modification of graphics, logs, and HSRS
functions in an interactive manner, MMI Database modification / creations, down
loading the software with associated data base from the console and other
features necessary for system maintenance. Also facility shall be provided to
print system fault as detected by the online self-diagnostic routine.
13. The system shall have the facility to generate the associated documentation for
both the Control System & MMI. The document, to be generated by the system
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[104]
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shall include P&ID drawings, control loop drawings, sequence drawings, signal
distribution list / drawings, system interconnection drawings, cabinets general
arrangement drawings, measurement list, drive schedule, alarm schedule, system
hardware and functional configuration drawings for displays, logs, trends,
graphics etc. The system shall also include all required software and hardware
tools for creating, modifying and printing CAD drawings to achieve paperless
documentation for DCS.
Table 6.14
Specifications for Engineering Workstations
S.No.
1
2
3
4
5
Features
Processor
Memory
Hard Disk
CD Drive
Power Supply
1 TB
52X DVD Read/Write
230 V 50 HZ 1-phase
6
7
Keyboard
Pointing Device
Monitor
ASCII
Optical Mouse
rate min. 85 Hz
Table 6.15
Specifications for Engineering Laptop
6.3.6
S.No.
Features
Processor
Intel i5 or better latest generation
Memory
4 GB DDR3 SDRAM expandable to 6 GB
3
4
5
Hard Disk
CD Drive
Power Supply
Communication Ports
7
8
Screen
Battery
SATA2/ 1 TB/7200 RPM

52X combo CD/DVD Read/Write
230 V, 50 HZ, 1-Phase
2 Nos. USB
1 No. Ethernet
2 Nos. Serial Port
1 Nos. Parallel port
15.4 TFT LCD screen
6-cell, LI-Ion Battery
Software Requirements
1. The system shall be provided with all licensed software packages with media
required by the system for meeting the intent, functional / parametric
requirements and performance requirements of the specification.
2. The system shall utilize a readily upgradeable, public domain software platform
proven for real-time operation environment at the control and monitoring level
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[105]
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overlaid with a relational database program. The desirable features are

indicated below:
a) The software system shall be fully modular.
b) The software shall meet the following general requirements:
Simple, easy-to-learn editing language for editing and on-line operation.
Wide range of standard and non-standard peripheral support capability
by modular controllers / supervisors.
Effective task scheduling and support of multiple priority structure
including event based interrupt etc.
Effective debugging.
Provision for on-line editing
interrupting on-line functions.
and
program
development
without
Self-diagnostic routines.
Efficient memory management and effective utilization of system time.
Quick start-up and loading.
Support of multiprogramming and multi-user operation.
3. Industry standard operating system like UNIX/WINDOWS NT etc. to ensure
openness and connectivity with other system in industry standard protocols
(TCP / IP etc.) shall be provided. The system shall have user oriented
programming language & graphic user interface.
4. All system related software including Real Time Operating System, File
management software, screen editor, database management software, On line
diagnostics / debug software, peripheral drivers software shall be provided.
Latest versions of standard PC-based software for database handling, wordprocessing, spread sheet, Anti-virus etc. and latest WINDOWS based
packages etc. and any other standard language offered shall be furnished as a
minimum. Systems having program development environments like EWS,
Station LAN Server shall have high level programming support like Microsoft
Visual Studio, Oracle, RDBMS etc.
5. The programming language shall support Relational Data Base Management in
a global and truly distributed Client-Server environment and shall have the
following minimum features:
a) Modern high-level block structures type
b) Powerful, compact syntax
c) Logical organization that
maintenance of programs
facilitates
documentation,
modification
and
d) Early detection of errors at compiles and run time

e) Fast debugging
f) Improved program reliability
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[106]
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g) Clearly defined data structure complemented by flexible user-declared data

types
h) Fast execution.
6. All application software for control system functioning like input scanning,
acquisition, conditioning, processing & control along with communication
among various Control System functional blocks shall be provided.
7. The system shall be provided with software locks and passwords to engineers
at site for all operating & application software in order to prevent
unauthorized access and only authorized engineers are able to do
modifications at site.
8. Two sets of all final / latest software on non-rewritable/non-editable media
shall be provided as back-up.
9. Software License
a) The system shall be provided with software license for all software being
used in the DCS system. The software licenses shall be provided for the
project (e.g. organization or site license) and shall not be hardware / machinespecific. That is, if any hardware / machine is upgraded or changed, the same
license shall hold good / renew license due to up-gradation / change of
hardware / machine in control system at site. All licenses shall be valid for
the continuous service life of the plant.
b) In case the s/w license is dependent on no. of points, then quantity to be
considered is 30% above the finally implemented points.
10.Software Upgrades
The system softwares installed in the plant DCS, shall be periodically upgrades
with the new releases, that would be taking place after the system is
commissioned.
6.4
DCS Sub-Systems
The DCS shall consist of the following broad sub-systems, functionally
independent of each other except for mutual signal exchange.
Sequence of Event Recording System (SOE)
Integrated Annunciation system
Historical storage & Retrieval system (HSRS)
6.4.1
Plant Performance Analysis, Diagnostic & Optimization system (PADO)

Management Information System (MIS)
Sequence Of Event Recording System
1. The DCS system shall also perform the SOE functions like stamping of SOE
inputs / points with 1 ms resolution. The SOE function shall be built-in function
of DCS.
2. SOE shall be capable of accepting minimum 512 inputs per unit including 10%
spare channels (included in total 512 inputs).
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[107]
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3. The system shall monitor SOE inputs with a resolution of one millisecond at all
times for all inputs including spare inputs. That is, all SOE points entering status
change shall be reported and time tagged within 1 (one) millisecond of their
occurrence. Input card shall be equipped with digital filters with filter delay such
that it should meet SOE time resolution of 1msec (identical for all points) to
eliminate contact bounce such that field contact which is changing state must
remain in the new state for stipulated time to be reported as one event. The start
of data collection for SOE report shall be reported to OWS within1 sec of SOE
data collection initiation.
4. SER is envisaged as an integral part of DCS with 1 millisecond time resolution.
The SER data base shall be an integral part of the DCS database and same shall
be made available at all the OWS / EWS resident on the network. Operator can
access the SER on activation of SER alarm page. All SER inputs shall have real
time time-stamping following any tripping of major equipment, or sub-system
or the plant as a whole.
5. The system shall also have provision of rejection of chattering inputs.
6. In addition to above, facility for adding a field adjustable software delay on a per
point basis shall be provided.
7. The system shall also include provision for historical storage and retrieval of SOE
reports for 3 months period.
8. The SOE report collection shall begin on occurrence of change of status of any
SOE point and shall be printed after an operator selectable time interval of 1 to 3
min. or 100 status changes have taken place after the first event. Adequate
numbers of buffers shall be provided to prevent loss of data before transferring
to HSR.
9. The SOE reports shall also include a list of major equipment trip in chronological
order and include the points that initiated SOE collection. The inputs for SOE
shall include
a) Hardwired inputs in input cards and
b) Calculated points / generated points of Control System.
10. Further, all the operator initiated actions such as trip inactivation (bypass) & trip
activation (inline) shall form input to SER.
11. All the SOE inputs shall also be available for interlock / protection functions.
12. SOE of other systems (SG/TG integral control systems) shall also be integrated in
this system. The SOE system shall collect process & report SOE inputs of SG &
TG control system for a consolidated master SOE system. Necessary
co-ordination with SG & TG Supplier shall be done for successful implementation
of a consolidated master SOE list.
13. SOE time stamping shall occur at I/O level.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
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14. Self Diagnostic Features like scanner test (a periodic test for communication
between several levels), functional test by simulating abnormal Conditions shall
be provided.
15. One (1) no dedicated SOE viewing station with SOE Log printer shall be provided
for each unit.
Table 6.16
Specifications for SOE Station
S.No.
1
2
3
4
5
Features
Processor
Configuration
Internal Clock
Memory
Hard disk
Tower
3.2 GHz or better
2 TB/7200 RPM
6
7
CD Drive
Graphic Accelerator
Communication Port
52X Combo CD/DVD read/write

16 MB
2 serial port, 1 parallel port, 4 USB port, dual
100 MBPS Ethernet port
dual
QWERTY 101 keys Keyboard
Optical mouse
rate min. 85 Hz.
9
10
11
Monitor support
Keyboard
Pointing Device
12
Monitor
Table 6.17
Specifications for SOE Log Printer
S.No.
1
2
Features
Type
No. of Needles
Printing Speed
4
5
6
Character dimension
Buffer
Local Memory
7
8
9
10
11
12
Communication Port
Power supply
Paper size
Character sets
Transfer distance
13
Print features
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Heavy duty Dot Matrix Printer
24 pin
300 characters per second/ 1000 Lines per
minute
9x8
80 KB (minimum)
RAM with battery backup
Ethernet/RS-232/parallel
230 V, 50 Hz, 1-phase
132 column continuous fan fold type
continuous
ASCII, IBM, Italics,
200 mtrs. Minimum
Graphic print, Emphasized, double width,
underlined, subscript, superscript, double
strike, backspace, margin etc.
Description

Page
No.
Date of Issue
[109]
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6.4.2
[Logo of Utility]
S.No.
14
15
Features
Reliability
Noise Level
MTBF> 8000 hrs.
Less than 60 dBA
16
Ribbon Life
17
Diagnostics
18
No. of Copies
19
Accessories
2 million characters
Self diagnostic, LED error code display, Audio
alarm paper exhausted
Minimum Original +3
Printer stand
Table top receiving station
Interface cable
Paper tear box
Ribbon
Annunciation System
1. The LCD annunciation shall emulate salient features of conventional hardware
annunciations while presenting more flexibility.
2. The annunciation system shall be implemented as an in built function of DCS.
The field contacts shall be acquired through DCS only. The annunciation points
shall be presented on topmost area of LCD screens. The annunciation area shall
be divided into multiple alarm bands. There shall be 3 nos. of alarm bands in
each LCD screens.
3. The annunciation functionality shall be implemented through the LCD as
described below as a minimum:
a) There shall be one alarm for each alarm window. Group alarms shall be
provided only for pre-defined system/field faults. The alarm text is to be
displayed only when alarm is present. A top up window shall be associated
with each alarm window which shall show tag no. of alarm point when
cursor is brought over the alarm window.
b) Hooters/speakers (not PC Speakers) of different frequencies shall be available
for reporting new alarms & resetting of alarms etc. All flashing windows shall
flash together (synchronized) in any LCD screen. Suitable means shall be
provided to distinguish between new alarms & return to normal message.
c) Annunciation points shall be distributed on various LCD screens based on
process area.
d) No fixed space shall be fixed for any alarm band. Once a particular alarm
band is full the new alarm on this band shall be reported by shifting old alarm
on left side band one by one on FIFO basis. A scroll bar shall be provided to
view older alarms.
e) The hooter alarms sound shall be different for different units.
f) Facility shall be provided by which the operator can view details of the
alarms, acknowledge the alarm, acknowledge the hooter etc. by clicking on
the pop up window options.
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4. The above annunciation features shall also be replicated on all OWS.

6.4.3
1.
2.
3.
4.
5.
6.
7.
Historical Storage & Retrieval System( HSRS)

Historical storage and retrieval facility shall allow collect and store data and
parameters including trends, alarms and events from DCS data base periodically
and automatically to removable data storage devices once every 24 hour for long
term storage and retrieval.
HSRS of other systems (SG integral control systems) shall also be integrated in
this system. The HSR system shall collect, process & report HSR inputs of SG
control system for a Consolidated master HSR system. Necessary
co-ordination with SG Supplier shall be done for successful implementation of a
consolidated master HSRS.
Provision shall be made to notify the operator when the disk is certain
percentage full.
The data to be stored in the system shall include alarm & event list, periodic
plant data, selected logs/trends/reports etc. Exact data/information to be stored
and frequency of data storage & retrieval shall be as possible.
Historical storage should permit trending of all analog inputs with time scale
selectable as 1 sec., 10 sec., 30 sec., 1 min., 5 min., 30 min., 1 hour, 8 hours
& 24 hours. Vertical Range (parameter range) shall be freely programmable. It
shall be possible to map real time & history trend on the same trend group
display. History data shall be for minimum 30 days & after expiry shall
automatically/manually transferred to the external storage device such as DVD
writer or external hard disk.
The system shall provide user-friendly operator functions to retrieve the data
from historical storage. It shall be possible to retrieve the selected data on OWS
/ LCD or printer in form of trend / report by specifying date, time & period
through point IDs / group of points. Further, suitable index files / directories shall
also be provided to facilitate the same.
The System shall store following data as a minimum:
a) Periodic Plant Data
1000 analog points with 1 sec rate
1000 analog points with 5 sec rate
Balance analog points with 30 sec rate
Binary points on status change (with suitable protection against excessive
status change)
b) Logs & Reports
All hourly, shift, daily, monthly, yearly logs
All alarm logs
All control related logs
All event based logs
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Pre-Trip & Post-trip logs

Start up logs
SOE Reports
Maintenance data log
Apart from this other logs comprised of computed data such as running hour
logs of drives, fuel consumption log, water consumption log, Auxiliary power
consumption log, metal temperature logs or calculated values like efficiency
etc.
8. Dedicated Redundant workstation with dot matrix & Laser jet printer shall be
provided (per unit) for historical storage & retrieval system.
9. Provision for export of data to Excel spreadsheet package shall be available.
Table 6.18
Specifications for HSRS Station
S.No.
1
2
3
4
5
Features
Processor
Configuration
Internal Clock
Memory
Hard disk
Intel i5 or better 64 bit latest generation
Tower
3.2 GHz or better
2 TB/7200 RPM
6
7
CD Drive
Graphic Accelerator
Communication Port
52X DVD read/write

16 MB
2 serial port, 1 parallel port, 4 USB port, dual
100 MBPS Ethernet port
Dual
QWERTY 101 keys Keyboard
Optical mouse
rate min. 85 Hz.
9
10
11
Monitor support
Keyboard
Pointing Device
12
Monitor
Table 6.19
Specifications for HSRS Log Printer
S.No. Features
Same as Table 6.17
Table 6.20
Specifications for HSRS Laser Jet Printer
S.N
Features
Same as Table 6.13
Document Number
Rev
No.
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03
Description
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No.
Date of Issue
[112]
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6.4.4
6.4.4.1
1.
2.
3.
4.
6.4.4.2
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Plant Performance Analysis, Diagnostic & Optimization System

General
PADO system shall provide critical analysis of the plant performance and
guidance for optimisation on continuous on-line basis. The system shall analyse
dynamically the status of the process and the equipment of the power
generating units and shall automatically generate the operator guidance
instructions for remedial actions for maintaining the process and the system /
equipment in the plant to their optimum performance.
PADO shall incorporate the complete thermal design model of the plant and shall
use the measured data from the plant DCS acquired through a suitable interface.
The system to be provided shall include all necessary hardware, software,
firmware and interfaces required for implementing a fully functional PADO
system. PADO shall include but not limited to the details specified in subsequent
paragraphs.
PADO system shall be independent for each unit.
Functional Requirements
PADO system shall provide following functional requirements:
Performance analysis and monitoring of systems and components
System and performance diagnosis
System and performance Optimisation
Emission analysis and monitoring
Boiler performance optimisation
Boiler Stress Condition Analysis
Regenerative cycle performance Optimisation

Interactive water and steam chemistry management system
1. Performance Analysis & Monitoring of Systems & Components
Performance analysis and monitoring of systems and components shall involve
and facilitate the following:
a) Computation of thermal performance status of the plant and efficiency of
generation.
b) Computation of all the key system performance indicators at system level
such as heat rate, plant and equipment efficiency, generator output and
controllable losses.
c) Computation of all the key system performance indicators at major
component. This shall include the following:
Assessment of boiler operation based on efficiency, excess air and
cleanliness factors of super heater, re heater and economiser.
Turbine performance evaluation considering efficiency, enthalpies, steam
flow and gland leakage flow estimation.
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Air Pre-heater performance involving efficiency and pressure losses.

Condenser performance based on heat duty and heat transfer co-efficient
and cleanliness factors.
Performance of re-generative heaters by computing extraction flows,
drain flows, terminal temperature difference and drain cooling approach.
d) Analyse the impact of individual component performance on overall losses or
gains in total unit generation along with computation and display of cost of
individual loss/gain.
e) Performing detailed analysis of each component including computation of key
performance indicators such as efficiency, heat transfer co-efficient, TTD,
DCA and fouling factor.
f) Visualisation of individual component efficiencies & performances and display
of the same.
g) Visualisation of impact of incremental change of the major process
parameters including but not limited to the following on boiler efficiency,
turbine heat rate and unit heat rate etc. through What If query facility for
operator:
Main Steam pressure
Super heater Spray flow
Re heater Spray flow
Economiser Inlet Temperature
Excess Air
Coal Analysis
Surface effective for super heater, re heater and economiser
h) Performance computations to be carried out at specified intervals based on
time averaged data during steady state operating conditions.
i)
Computations to be based on process signals, equipment status, design

criteria and manual input data (where ever needed). Raw measured value for
process signals shall be reconciled before usage.
2. Systems & Performance Diagnosis

a) System and performance diagnosis shall involve detection of the
abnormalities and diagnosis of system and component performance
degradation up to component level to pin-pointing root cause of abnormalities
existing in the process and guiding the operating personnel to attend to the
same.
b) Diagnosis function involves the following:
Equipment health diagnosis for high/ low pressure, temperature, level &
vibration etc.
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No.
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Plant performance diagnosis for boiler, turbine, condenser, feed water and
regenerative heating system
Identifying degradation of measuring instrument for important parameters
using data validation checks.
c) Diagnosis based on expert system in the form of Fault Trees / Neural and
Bayesian belief networks etc. Expert systems shall draw inferences based on
knowledge base, on-line measured data and computed performance indices.
d) Diagnosis system shall be capable to provide following helps:
Avoiding a possible trip
Maintaining process parameters within safe limits thereby enhancing the
life of the equipment
Drawing the operators attention to the degradation of the equipment and
instruments
3. Systems & Performance Optimization
System and performance optimisation involves optimisation of set points for
controllable parameters by recommending to the operator the optimum set points
for optimising the given process or activity at the measured operating condition
using state of the art optimisation techniques.
4. Emission Analysis & Optimization
Emission analysis and monitoring functions involves the following:
a) Monitoring, tracking and analysing plant emissions such as SO2, NOX, CO,
CO2 etc. in real time.
b) Monitor and analyse ESP & Stack conditions such as temperature, humidity,
gas flow rate and opacity.
c) Facilitate obtaining lowest emissions by recommending optimal damper
position to minimise the NOX level measured at the stack while maintaining
the CO value and unburnt carbon below desired permissible limits.
d) Facilitate obtaining
efficiency.
lowest
emissions
while
maintaining
combustion
e) Facilitate to set alarms to highlight conditions that violate pre-defined

conditions
5. Boiler Performance Optimization System (BPOS)
BPOS shall enable operating personnel to improve boiler performance and
optimise fuel consumption including optimised operation of Soot Blowing
system. This system shall have following features:
a) Incorporates the complete thermal design model of the boiler capable of both
forward and backward computation of complete boiler thermal performance.
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b) Boiler thermal design model calibrated to made Site- specific based on

series of field trials of thermal performance of the boiler during start up and
prior to trial operation.
c) BPOS to function continuously taking into consideration the performance of
furnace, super heater, economiser, air heater and pulveriser based on the
continuous on-line measurement of the including but not limited to the
following parameters:
Flue gas temperature at ECO I/L
Flue gas oxygen content
Other fluid temperature(s) entering and exiting various heat transfer
surfaces
Coal Characteristics
d) BPOS shall be capable for continuous on-line calculation of the thermal
performance of the boiler for the operating conditions indicating performance
prediction zonal absorption, metal temperature and shall have the following
features:
Fuel switching capability
What If query capability
Selective soot blowing of furnace/Super heater based on trends of zonal
absorption.
e) Expert system diagnostics for quick identification of the Root Cause of
deviations from the predicted parameters.
6. Boiler Stress Condition Analysis (BSCA)
a) BSCA monitors the thermal stresses and assess life exhaustion in thick
walled components like super heater and re heater outlet headers by
estimating the expended life due to low cycle fatigue and creep.
b) BSCA shall guide the operator during start- up and shut down regarding
controlling of rate of heating or cooling of metal within specified limits and
also guides the margins available for the rate of steam generation (for fuel
firing) during start-up.
7. Regenerative Cycle Performance Optimization System (RCPOS)
Regenerative cycle performance optimisation system shall involve the following:
a) Analysis of deviation of performance of the turbine cycle by examining the
deviation of important parameters of the turbine cycle.
b) Analysis of actual efficiency of individual stages of turbine.
c) Evaluation of LPH & HPH performance by comparing current values of TTD/
DCA to the reference values.
d) Heater level evaluation
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No.
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No.
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8. Interactive Steam & Water Chemistry Management System

a) Interactive water and steam chemistry management system shall be capable
of guiding the operator for appropriate chemical dosing to maintain the
chemical balance, optimal blow down and carry out further investigation as
advised by the system.
b) The system shall have following features:
Monitoring of various steam and water parameters at certain predetermined points in the flow cycle and warning the operator about any
distinct aberration and guiding on precautionary as well as corrective
actions to be taken.
The system shall use Decision Trees and Fault Trees or other suitable
methods for each parameter to diagnose deviations in controlled
parameters in order to find the root cause and advise corrective actions.
c) The system shall provide following benefit to the user/operator:
Minimisation of makeup water consumption
Decrease in consumption of dosing chemicals
Prevention of carryover of impurities into the turbine
Decline in degradation of turbine components
Lessening of boiler tube scale formation
Reduction in energy consumption
6.4.4.3
1.
2.
3.
4.
5.
6.
7.
Design Requirements
PADO system shall be based on Client- Server and expert system. The system
shall operate on a commonly used hardware platform and network operating
system.
System shall be suitable for simultaneous use by multiple users.
The system shall be suitable for a wide range of tagging systems and in
particular KKS tagging system.
The system shall be password protected. It shall be possible to organise system
users into groups and each group shall have a separate security profile. It shall
be possible to provide additional personal security settings for individuals within
a group.
The system shall be able to obtain requisite plant system / equipment and
process data from the plant DCS. To meet the above requirement, PADO system
shall be interfaced with Plant DCS through redundant bi-directional
communication link.
The system shall have facility to store bulk data with facility for retrieval of the
same. The system shall have facility to share all the data in the hard disk/back
up media and provide user friendly utilities to retrieve and analyze stored data.
Each PADO system shall include all hardware and software as required for proper
functioning of the system including:
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a) One (1) No. Redundant Server (with monitor, keyboard, Mouse etc.) per unit
b) One (1) No. User Workstation (with monitor, keyboard, mouse, Colour Printer
etc.) per unit.
c) PADO Software with required user Licenses
d) Bulk Data Storage & Retrieval facility
e) Redundant OPC communication Link with all necessary hardware & software.
8. All software licenses shall be valid for entire life of the plant. It shall be possible
to upgrade the installed system with latest available version of the software
model without any additional hardware/software requirements during entire life
of the plant.
Table 6.21
Specifications for PADO Server
S.No.
1
2
Features
Processor
Memory
Hard Disk
RAID
5
6
Monitor Support
CD Drive
Power Supply
10
11
Removable Bulk storage Drive

Removable bulk storage media
for above
Keyboard
Pointing Device
12
Monitor
Intel i5 or better /64 bit latest generation
2X1TB ultra wide SCSI/7200 RPM, Hot
swappable
SCSI-channels, hardware RAID level 5
implemented
Dual
52X Read/Write
Redundant Hot swappable, 230 V, 50Hz, 1Phase
1 TB minimum
10 nos.
ASCII
Optical Mouse
rate min. 85 Hz
Table 6.22
Specifications for PADO Workstation
S.No. Features
Same as Table 6.16
Table 6.23
Specifications for PADO Laser jet Printer
S.No. Features
Same as Table 6.13
Document Number
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No.
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Description
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No.
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6.4.5
[Logo of Utility]
Management Information System

1. An integrated Management Information System (MIS) shall be provided for the
plant. System shall be able to provide information related to the following
aspects to management personnel:
a) Plant Operation Information (Dynamic Mimics)
b) Plant Maintenance related Information
c) Environmental Information
2. MIS shall provide following plant information:
a) Environmental and hazard management
b) Equipment maintenance history
c) Fault cause analysis
d) On job information report
e) Plant Operation history
f) Plant performance details
g) Any other plant operation data/ details
3. MIS shall be based on client server & relational data base environment. The
system shall operate on commonly used hardware platform & network operating
system.
4. System shall be suitable for simultaneously used by multiple users. It should
have at least 20 user licenses.
5. The system shall be password protected. It shall be possible to organize system
a group.
6. MIS processing shall be carried out in an independent server interfaced with
plant DCS, All BOP & offsite plant PLC control systems, Plant Performance
Analysis, diagnostics & optimization system (PADO), Computerized Maintenance
management system (CMMS) for polling of plant operational and performance
data, and maintenance details. Plant environmental data shall be obtained from
DCS. The MIS system server shall be connected with station LAN and all user
PCs shall be connected with the station LAN.
7. The system shall have facility to store bulk data with facility for retrieval of the
8. MIS shall include all hardware and software as required for proper functioning of
the system including
a) One (1) No. Redundant Server (with monitor, keyboard, Mouse, colour printer
etc.) per unit
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No.
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b) Twenty (20) Nos. (to be finalized by purchaser during detail engineering) User
Workstation (with monitor, keyboard, mouse, etc.)
c) 42 LCD Monitor for display in different areas of plant such as Conference
Room, station Entrance etc. These display boards shall include the following
minimum parameters along with engineering units:
Unit MW
Unit frequency
Unit auxiliary power consumption
Station-Total MW (common)
Station-Total auxiliary power consumption (common).
d) MIS Software with minimum 50 nos. user Licenses
e) Bulk Data Storage & Retrieval facility
f) Redundant OPC communication Link with all necessary hardware & software.
g) Servers & user PCs operating licenses
of the plant.
Table 6.24
Specifications for MIS Server
S.No. Features
Same as Table 6.21
Table 6.25
Specifications for MIS Workstation
S.No. Features
Same as Table 6.16
Table 6.26
Specifications for MIS Laser jet Printer
S.No. Features
Same as Table 6.13
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No.
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No.
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Table 6.27
Specifications for MIS LCD Monitor
S.No.
6.5
Features
Viewable Picture Area
42 inch measured diagonally
2
3
4
5
6
7
Resolution
Aspect Ratio
Display Colors
LCD Panel
Contrast Ratio
Brightness
1920 X 1080
16:9
16.9 million colors
Active matrix TFT LCD
800:1
500 cd/m2, Anti-glare
8
9
10
11
12
13
Viewing Angle
Computer Interface
Cabinet Material
Finish
Mounting
Power supply
14
Accessories
1780 Horizontal & Vertical both

VGA, DVI-D, HDMI,
ABS
Black
Fixed Wall Mounting
230 V, 50 Hz, 1-phase
Universal Tilt wall mount stand, IR Remote,
Power cord
DCS Power Supply Requirements

1. Redundant UPS power feeder shall be provided for all 230VAC equipments
and/or redundant feeders for 24 V DC for DCS requirements. The necessary
cabling & termination at both ends for receiving the power supply shall be
furnished as per the contact requirement.
2. The DCS shall work on 24 V DC Power supply & Computers and peripherals
shall work on single phase AC supply from UPS.
3. All power supply in the System cabinets shall be redundant and shall have auto
change over facility or diode auctioneering. Power supply monitoring shall be
provided in the DCS.
4. The power supply shall be provided with suitable arrangements with redundant
distribution boards for each system with proper auto change over scheme to
change the load from one feeder to other, in case of one feeder failure.
5. Redundant DC feeders (One each from DCDB) shall supply each of the
connected loads. The exact rating & number of feeders of each DCDB shall be
approved by the purchaser/consultant. However, 25% spare feeders (minimum 1
no.) of each rating shall be provided in each DCDB.
6. Redundant AC UPS feeders (One each from UPS ACDB) shall supply each of the
connected loads. The exact rating & number of feeders of each UPS ACDB shall
be subject to approval. However, 25% spare feeders (minimum 1 no.) of each
rating shall be provided in each UPS ACDB.
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No.
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No.
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6.6
[Logo of Utility]
DCS System Cabinets/Panels

1. All Control system modules, power supply components, other control devices
which are required for completeness of the system shall be housed in cabinets.
All equipment and dedicated cabinets required for termination, marshalling and
proper interface within system and also with other systems shall also be
provided.
2. The cabinet mounted equipments shall be fully assembled, installed in mounting
racks, wired and fully tested as per specification requirements and approved
drawings in the manufacturing works of a qualified manufacturer prior to
shipment to the project site. It shall be ensure that the cabinets are complete
and ready for installation before dispatch from manufacturing works. The
installation work at project site for these cabinets should only involve
connections through multi pair cables from marshalling cabinets (wherever
provided) to system cabinets and inter-cabinet.
3. The Control system cabinets shall be grouped into physically separate cabinets
as follows:
a) Control System Cabinets
b) Marshalling Cabinets
c) Relay Cabinets
However, in case the system design requires the termination cabinet
independent from system cabinet, the marshalling cabinets can be combined
with the termination cabinet. In case, the termination arrangement is part of
the system cabinet, independent marshalling cabinets shall be provided.
4. A special note shall be indicated that in case termination of field cables directly
to control system cabinet is not acceptable.
5. The Control system cabinets shall house all types of modules / hardware to
achieve all functions of Control System including signal conditioning modules,
controller modules, I/O modules, communication controller modules and all
other requisite hardware for a complete system.
6.7
DCS System Response Requirements

DCS System response requirement (Under worst loading conditions) shall be as
follows:
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Table 6.29
DCS System Response Requirements
S.No.
Parameter/Function
Requirement
Scanning rate of Analog Signals
Maximum 1 sec for measurement
Scanning rate of digital signals
Maximum. 100 ms
Scanning rate of pulse signals
Maximum 100 ms
Loop execution time for CLCS
Maximum 250 ms (For all Loops)
Loop execution time for OLCS
Maximum 100 ms (For all Loops)
Controller output update for CLCS
Every 250 ms (For all CLCS Loops)
Controller output update for OLCS
Every 100 ms (For all OLCS Loops)
Updating rate of Analog display
Maximum 2 seconds (for measurement)
Updating rate of Analog display
Maximum 1 second for OLCS/CLCS
10
Updating rate of Digital value

display
Maximum 4 seconds (for measurement)
11
Updating rate of Digital value

display
Maximum 1 second for OLCS/CLCS
12
Time for display in CRT screen
Maximum 1-2 seconds on demand
13
Keyboard command execution time
Maximum 1 sec
14
Controller Loading
Maximum 60 %
15
Data Bus Loading
Maximum 50 %
Table 6.30
DCS System Display Response Requirements
S.No.
Parameter/Function
Requirement
All control related displays
1-2 seconds
Point details display (single point)
1-2 seconds
Bar chart display (20 points, current display)
2-3 seconds
Plant mimic display of fair complexity with a

minimum of 120 nos. of dynamic data items
2-3 seconds
Group review display (20 points, current values)
2-3 seconds
X-Y Plot display ( 2 X-Y Plot & single display

requiring both history as well current data)
2-3 seconds
X-T Plot display (Trend of six analog points and

a single display requiring both history as well as
current data)
3-4 seconds
Plant summary display ( e.g. bad points

summary, limit check removed point summary.
Assume the whole database search is required &
summary display contains ten points)
3-4 seconds
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6.7.1
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Performance Requirement for Close Loop Control System

Table 6.31
Performance Requirement for CLCS
S.No.
Load/Rate
of
load
change (%
of
MCR
per min.)
Maximum Deviation of Parameters from Set Point
Throttle
pressure
deviatio
n
(Kg/cm2
)
Flue gas
oxygen
deviation
(% O2)
Furnace
pressure
deviation
(mmwcl)
S.H.
steam
temperature
deviation
(Deg.C)
R.H.
steam
temperature
deviation
(Deg.C)
*Drum
Level
deviation
(mmwcl)
2.0
0.4
8.0
5.0
5.0
15.0
2.0
0.4
8.0
5.0
5.0
15.0
Steady state condition
90%
100%
60%
Ramp test (change for max. duration of five minutes)
3%
3.0
0.6/0.4
12.0
8.0
8.0
25.0
5%
3.0
0.8/0.4
12.0
10.0
10.0
30.0
10%
4.0
0.1/0.5
15.0
15.0
15.0
50.0
Step Load changes
From 100%
to
80% at the
rate of 10%
per minute
1.5/0.5
20.0
15.0
15.0
50.0
to
5.0
Notes:
1. Sufficient time shall be allowed as setting period between conducting the tests.
Plant operating condition, i.e. main equipment status, availability of auxiliaries,
operational and equipment constraints, which can influence the test, shall also
be recorded.
2. Control system shall be running in the coordinated master control (CMC) mode
i.e. boiler master, fuel flow, air flow, feed water and turbine load control shall
be in automatic mode. Load set point, maximum and minimum load set point,
rate of raise / lower of load shall be set through the TFT,
keyboard/conventional console.
3. The the control system shall be responsive and stable and shall maintain the
deviation of controlled variables from set point within the limits specified so
that the equipment being controlled shall operate as specified over the range
required. The controls shall operate automatically, with no assistance from the
operator. The controller shall successfully demonstrate the performance of
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Closed Loop Control Systems before acceptance and taking over of this
system.
4. Applicable for Drum type boiler.
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No.
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7.
PROGRAMMABLE LOGIC CONTROL (PLC)
7.1
General Technical & Design Requirements
[Logo of Utility]
Programmable Logic Controller (PLC) shall be microprocessor-based system. The

PLC shall be versatile, expandable, user friendly and latest state of art
technology. The system shall be envisaged for the purpose of sequential
operation, protection and interlock, data acquisition system, alarm functions,
closed loop control and data archiving for fully automatic operation. Logic
controller shall be used with adequate and reliable protection safeguard for
various equipments and to assist the operator for easy safe and efficient starting
and stopping of various drives in the process. The system shall be designed by
selecting high-grade components of proven quality and proper design of system
electronics. The system shall be able to operate satisfactorily with reference to
the specified environmental conditions as indicated in the specification.
1. The system shall be modular in construction and expandable in future by adding
additional electronic modules, which shall be easily accessible for maintenance
and repair. The modules shall preferably be Rack/Rail mounted. The types of
modules shall be kept to minimum possible in order to have interchangeability
and spares inventory.
2. The system shall have extensive self-diagnostic hardware and software features
for easy and fast maintenance of the PLC. Safety barriers shall be used for
intrinsically safe input / output circuits.
3. The PLC shall have very high noise immunity in order to ensure safe and reliable
operation when subjected to electrical radio frequency interference and
electromagnetic disturbances expected in a power plant.
4. The system shall be programmed as per the logic requirements required for the
functioning of the systems and equipment.
5. Operation of the PLC shall be completely unaffected by a momentary power loss
of the order of 20 milliseconds.
6. On-line replacement of any module shall be possible in such a way that the
removal and addition of the module shall be possible without de-energizing the
system or causing any interruption in the system while replacing a faulty module
except for the inputs /outputs which are being handled by that module.
However, in case of triple modular redundant or dual PLC configurations, there
shall not be any process upset while replacement.
7. PLC shall be used with 20% hard wired installed spare I/O Channels.
8. The system shall be capable of handling the long-term storage of data for 15
days and retrieval.
9. The system shall be used with programming and diagnostic facility. Each PLC
shall be used with one no. Laptop of latest configuration with programming
software & communication cable.
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03
Description
Page
No.
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[126]
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7.2
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PLC System Configuration

PLC shall consist of following sub systems:
7.2.1
1.
2.
3.
4.
5.
6.
7.
8.
9.
Input/output Sub system

I/O subsystem shall be suitable for accepting discrete inputs, BCD inputs and
analog inputs. The I/O modules shall be mounted in the I/O racks.
Each I/O shall be electrically isolated from external control circuit by suitable
means. The minimum isolation level between I/O and logic circuit shall be 500 V
DC.
Each module shall have LED for each digital I/O channel to indicate the status of
each input / output. Redundancy in I/O level shall be maintained as per the
process requirement.
PLC inputs shall be used with potential free dry contacts. All the inputs shall be
double ended i.e., two wires per input and not common return for all inputs. The
contact interrogation voltage for input contacts shall be 24V DC minimum. Each
input channel shall be protected by separate fuse.
Output contacts from the PLC shall be potential free dry contacts. Each output
shall be short-circuit proof and protected by fuse.
Visual indication of fuse blown must be provided for each input and output
channel.
There shall be at least 20% spare capacity available on input & output modules,
over and above the system requirement.
All input/output cards shall have quick disconnect terminations allowing for card
replacement without disconnection of external wiring and without switching of
power supply.
PLC shall have the following monitoring features:
a) Power supply monitoring.
b) Contact Bounce filtering.
c) Optical isolation between input and output signals with the internal circuits.
d) In case of power supply failure or hardware fault, the critical outputs shall be
automatically switched to the fail-safe mode.
e) Further, keying-in of individual wire connectors shall be used to ensure that
only the correct card is plugged on the I/O module. It shall be possible to
remove I/O module without disconnecting wiring from field inputs or outputs.
7.2.2
Processor Sub system

1. The processor sub system shall include CPU, memory, power supply,
communication interface etc.
2. Dedicated PLCs shall be envisaged for each Auxiliary system. The processor
shall have capability to implement all the control functions required. The
processor shall have sufficient memory for storage of the program instructions as
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3.
4.
5.
6.
7.
7.2.3
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applicable to the logic requirements. CPU shall be of 32/64 bit or upgraded

version of microprocessor.
Memory shall be non-volatile, preferably EEPROM type. However, in case volatile
memory is provided, battery backup shall be used for a minimum of three
months to keep the stored program intact. A battery drain indication shall be
used at least one week before the battery gets drained. Memory shall be used
with adequate capacity with 40% spare capacity under worst loading condition.
The healthiness of processor hardware and software shall be continuously
monitored by watchdog timer.
PLCs shall be used as a minimum with dual redundant processor subsystem
including CPU, memory and power supply. Redundancy shall be used such that,
in case of failure of the main processor, the standby processor shall take over
automatically and vice - versa. The changeover shall be bumpless and shall not
result any process or system upset.
In case of failure of complete processor system i.e., both processors, outputs
shall take fail safe state automatically.
The scan time of programmable controller shall be of the order of 100
milliseconds or better. Scan time of PLC is defined as the cycle time taken by the
system to read input, process input executing logic and update control output for
all the logics configured within the system. Other activities like diagnostic
routines, output / dump of data to peripherals, or any other activity which
consume processor time shall also be accounted while computing scan time.
Communication Sub system
1. The communication subsystem shall provide reliable and high speed data transfer
between the processor subsystem, I/O subsystem, PLC console and other
devices connected to the system.
2. Redundancy in communication subsystem shall be used, such that on the failure
of the active device, communication link or bus, the redundant device
communication link or bus shall take-over automatically without interrupting the
system operation. The communication bus shall be of coaxial / Fiber optic type.
3. Information about the failed device shall be displayed locally as well as on the
PLC console. It shall be possible to manually switch-over the communication
from main bus device to redundant bus device without interrupting the PLC
functions.
4. The PLC shall have provisions of communication interface facility with Plant DCS
system in order to make the entire system operational from CCR. Bi-directional,
Redundant soft links shall be used in the PLC for the connectivity with the Plant
DCS.
5. Following are also included in the system:
a) Cables required for interfacing with DCS.
b) Implementation of Tags and establishing the Link.
c) Any other software/hardware required.
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Description
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No.
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7.2.4
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System Power Supply
7.2.5
1. For PLC system, redundant 24 V DC power supply shall be used. The required
power supply cable shall be used from the UPS DCDB & ACDB for SG integral
control system
2. For separately mounted I/O racks, separate power supplies shall be used. Power
supply module shall be of ample capacity to supply all modules. In addition 20%
spare capacity for future shall be used. All the drives shall be switched ON/OFF
through 24V DC coupling relays to be provided in HT/LT SWGR panels.
3. For the Operator Stations and Engineering Station the power supply shall be from
the 230 VAC UPS system.
PLC Console
7.2.6
1. PLC Console or operating panel/display panel shall be used as operator Interface

station for control and monitoring of the plant. This shall be done through
dynamic mimic displays and control displays.
2. PLC console shall also be used for program storage, display, fault diagnostic and
alarm monitoring. It shall be possible to modify, add or delete the application
program on-line without affecting the outputs. It should be possible to modify or
create new displays from PLC Console.
3. Isolation shall be used between programming terminal and related subsystems, if
there is any possibility of high voltage from TFT being transmitted to other
subsystems.
4. The PLC system shall have provision to shift the Operator Station/ Engineering
Station to the CCR in future with third party interactive communication facility.
Displays
The system shall be capable of reading the status of equipments, acquiring the
analog signals, displaying the status in the form of mimic diagram, video trend,
bar graph, periodic display, alarm display, alarm overview display, logs such as
hourly/shift/daily logs, alarm logs etc.
Displays include plant mimic diagrams, which shall include the complete auxiliary
plant system indicating each major components of the system and the operating
status of individual equipment and devices
7.2.7
Alarms
1. The system shall display history of alarms in chronological order of occurrence
on the Operator Station TFT. At least three (3) levels of alarm priority shall be
available which shall be displayed in different color. It should be possible to
display and print alarms. System shall have all alarm related functional keys like
acknowledge, reset etc. Other design features like set point / dead band
adjustment, alarm priority, manual and automatic inhibition based on predefined
logic etc. shall be used.
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2. The alarm display shall be built bottom up with the most recent alarm at the top
of the list. When a point returns to normal, the associated alarm line shall change
color suitably and on acknowledgement, the line shall be blanked out.
3. The alarms below the blank lines shall move upward to fill the empty lines. If the
capacity of the OWS display page is exceeded, alarm history shall be stored in
memory to accept the overflow. This alarm history shall be displayed upon
operator demand.
4. When a point goes into an alarm state and appears on the alarm screen, the time
of alarm shall flash until acknowledged by the operator. Acknowledgement by
the operator shall cause the time to stop flashing. All alarm initiations and return
to normal, shall be logged on a printer.
7.2.8
7.2.9
System Software
1. Complete licensed software for PLC based system including the communication
software system shall be supplied and implemented to meet completely the
specification requirements.
2. Application software shall be built based on approved logic diagram, graphics etc
and shall include controls, graphics, logs, trends, history, report generation etc.
3. The system software shall include all programs for the PLC and PLC console
which are required to perform all the PLC functions including communication and
self-diagnostics.
4. Diagnostic software shall have the capability to provide information about the
failed module / system either in the form of a system configuration display or
provide information in the form of a statement.
5. The softwares shall not be machine specific. All software licenses shall be valid
for the continuous service life of the plant and equipment.
6. Password security shall be used in order to ensure security level to the plant
operation.
Peripherals
Following Peripherals shall be used for PLC:
1. VDU/ TFT shall be multi-sync, 21 color monitor with intelligent terminal and key
board. TFT shall be used with graphic and mimic capabilities with minimum 64
distinct colors. The graphic resolution shall be 600x 1280 dots minimum with
0.25 mm dot pixel and refresh rate shall be 85 Hz or better
2. Suitable optical filter for minimum secondary glare shall be used.
3. One number black & white laser printer shall be used for printing A4 size paper.
Printing speed shall be minimum 24 ppm. The printer shall be heavy-duty type
with minimum 50,000 pages/month printing capability, 600 dpi resolution, 128
MB memory and 3000 sheet input capability.
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No.
LII-GETS12021-G-00129-001
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Description
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No.
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8.
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COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM (CMMS)

8.1
General
1. A completely integrated computerised maintenance management system
(CMMS) with relevant data base completely populated and system customised
for power plant application shall be used. The system includes all necessary
hardware, software, firmware and interfaces required for implementing a fully
functional CMMS system suitable for integrated maintenance management
function for a modern power generation utility.
2. CMMS system shall be common for the equipment/systems for the whole plant
including all the units and the plant common systems.
3. If CMMS is procured under TG Package then it shall be deleted from SG
package.
8.2
Functional Requirement
CMMS shall meet following functional requirements:
8.2.1
Asset Management & Asset Register Function

1. Asset management function shall facilitate the creation of an asset register
which shall hold the comprehensive details of each asset/ equipment. It shall
have following features:
a) Building the location details and its hierarchy
b) Building the equipment, its hierarchy and specification details including
drawings.
c) Creating hierarchies identifying operating locations as a part of multiple
systems.
d) Defining relationship between equipment, location and system.
e) Building spare parts and sub-assembly catalogues of the asset/equipment.
f) Tracking the equipment, movements, associated costs, histories of planned
and un-planned maintenance & failures.
g) Facility to launch condition based preventive maintenance work orders based
on preset equipment- wise upper and lower limits.
h) Links to inventory management and purchase functions.
2. The asset management facility shall be capable of performing the following:
a) Control the companys list of maintainable assets through an asset register.
b) Control the accounting of assets, purchase price, depreciation rates etc.
c) Control maintenance
purchasing).
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inventory
(stores
management,
Description
requisition
and
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8.2.2
8.2.3
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Inventory Management Function

Inventory management function shall have following features:
1. Specifying attributes and then ability to search by attribute for items, equipment
and locations
2. Tracking of stocked and non-stocked items through multiple stores.
3. Tracking of items, costs and balances by bin, lot and storeroom.
4. Stock replenishment when inventory falls below minimum levels
5. Automatic reorder of items through lights out replenishment
6. Tracking of items by last cost, average cost or user definable standard cost.
7. Usage of ABC analysis to assign inventory item prioritising.
8. Employing just in time methodologies to generate purchase orders.
9. Identifying out of stock items and making substitutions with alternate parts,
vendor and location tracking capabilities.
10. View of work order reservations for inventory items
11. Linked up with asset register.
Work Order Function
Work order function shall have following features:
1. Viewing comprehensive and detailed planning information such as following:
a) Work Plans
b) Schedules (Target and scheduled date tracking)
c) Costs
d) Labour, materials, Skill set / crafts, Special tools requirement etc.
e) Equipment
f) Failure analysis
8.2.4
2. Recording of maintenance work and closure of work orders.

3. Scheduling of work orders based on real time criticality and logistics.
4. Sequencing of work orders for multiple equipment based on location and / or
equipment.
5. Comparison of real time budgets or estimates with actual and historical data.
6. Tracking of equipment down time.
7. Tracking of equipment failure history with cause and remedy. Facility for
generation of micro-level failure/ cause stratification diagram.
Job Planning Function
Job planning function shall have following features:
1. Tracking of costs by operation or job plan
2. Linking job plans sequentially, each with its own parts, labour and tool
estimates.
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8.2.5
8.2.6
8.2.7
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3. Duplicate job plans for modification and use as templates

Resource Planning Function
Resource function shall allow to maintain detailed resource information to plan
and analyze maintenance work related to company, service contract, tools etc.
Schedule Planning Function
Scheduling function shall enable to forecast future preventive maintenance dates
for resource planning.
Preventive Maintenance Function
1. Preventive maintenance schedule shall be capable of performing the following:
a) Allows each asset / equipment to have a defined maintenance profile
b) Helps to schedule planned preventive maintenance routines
c) Control preventive maintenance procedures
d) Control the issue and documentation of planned and un-planned maintenance
work.
2. Preventive maintenance function shall have following features:
a) Generation of preventive maintenance work-orders on demand, batched or
automatically.
b) Generation of preventive maintenance work-orders for planned shut downs.
c) Sequence multiple job plans and consolidate multiple procedures on one
preventive maintenance schedule.
d) Facilitates clustering of PM work orders for various departments / divisions to
take reduced planned equipment downtime.
e) Capable of generating PM work orders on the basis of fixed frequency
intervals or run hours.
f) Reservation of inventory for scheduled PM works.
8.2.8
Purchasing Function
Purchasing function shall have following features:
1. Creation of purchase requisitions or purchase orders either from scratch or from
the inventory or work order modules
2. Create RFQs for multiple vendor bids
3. Automatic release of agreement Purchase orders
4. Creation of special orders for parts not stocked in inventory.
5. Elimination of costly Maverick Buying by establishment of approved vendors.
6. Direct issue of purchase orders and issue parts and services directly to work
orders for the expense off items.
7. Analyzing of vendor performance before ordering of parts
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8.2.9
8.2.10
8.2.11
8.2.12
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8. Use of invoice matching

9. Defining multiple tax rates to budget for interstate and international purchasing
10. Auto re-orders PR/PO generation for the spares, when stock falls below re-order
level.
11. PR to PO consolidation to group PRs by vendor into single purchase order.
12. Line item /Purchase order status generation-Initiated (Unapproved), Approved,
Partial receipt, Completion of receipt, Invoice matched, Cancelled etc.
Personnel Function
Personnel function shall have following features:
1. Creation of employee details including employment and personnel information
tracked.
2. Assignment details like department, preferred staff and available weekly work
hours tracked.
3. Craft / salary rates-employees can be expensed to work orders by an average
craft rate or actual hourly rates.
4. Training / certifications of employees tracked by the system.
5. Security levels-each employee can be assigned access security levels for each of
the functional areas in the system.
Financial Function
Financial function shall have following features:
1. Facility for supporting double entry accounting for integration with any financial
system.
2. Creation of user defined financial calendars to correlate directly with accounting
periods.
Other Functions
Other facilities required are as follows:
1. Interface to MS project/Primavera to permit planning of work carried out in
CMMS system to MS project/Primavera for scheduling. Work progress can then
be tracked in CMMS and used to update the project.
2. CAD / Image viewing capability to enable users to store, mark up and view
drawings, scanned images, word documents etc.
3. Account code or project budgeting to enable users to set up periodical project
budgets. The system shall then be able to track actual and committed costs
against budgeted costs
4. Interfacing with existing On Line Integrated Material Management System
(OLIMMS)
Reporting Functions
Reporting facilities required are as follows:
1. Standard Reports-Generation of standard reports on work orders, safety plans,
inventory values and other critical points about maintenance operations.
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2. Report types- Capabilities shall include columnar reports, forms, Bar Charts, Pie
Charts, Cross tabs etc.
3. Report generation- Crystal reports.
4. Data export capability via crystal reports to Text, Excel, Word documents, Email, HTML & ODBC etc.
8.3
Design Requirements
1. CMMS shall be based on client server & relational data base environment. The
system shall operate on commonly used hardware platform & network operating
system.
2. System shall be suitable for simultaneously used by multiple users. It should
have at least 20 user licenses.
3. The system shall be password protected. It shall be possible to organize system
a group.
4. CMMS processing shall be carried out in an independent server interfaced with
plant DCS, All BOP & offsite plant PLC control systems. Further CMMS system
shall be interfaced with MIS system server for transmission of maintenance
related details for usage with MIS. To meet the above requirements CMMS
system shall be interfaced with all control systems through redundant
communication links. The CMMS system server shall be connected with station
LAN and all user PCs shall be connected to CMMS server through station LAN.
5. The system shall have facility to store bulk data with facility for retrieval of the
6. Wherever required same user workstations shall be used for CMMS & MIS
systems. Together with MIS system total 50 nos. user workstations shall be
provided.
of the plant.
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9.
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SMART TRANSMITTER MAINTENANCE STATION (STMS)

9.1
General
A dedicated standalone PC based Smart Transmitter Maintenance Station
(STMS) for each unit shall be provided for centralized configuration,
maintenance, diagnostic and record keeping of all electronic smart transmitters,
smart positioners & Analyzers. Transmitter signals shall be wired parallel to DCS
and HART modules of STMS, which shall be connected to PC through suitable
communication modules. Complete diagnostic, record keeping, calibration and
configuration, event and log reports, historical data base records of all
transmitters shall be possible from the STMS.
9.2
Design Requirements
1. The signals from each of the transmitter shall be wired in parallel to DCS and to
HART interface modules. The DCS shall necessarily use 4-20 mA analog signals
and superimposed digital signal shall be used in HART interface modules.
2. The multiplexed signal from HART interface modules shall be hooked up to a PC
through associated communication modules, converters, etc. The communication
module shall provide data on RS-485 link at a minimum speed of 19.2 K baud. If
HART interface modules has integral communication module to provide RS-485
link, the same shall also be acceptable. In all HART interface modules, provision
for connecting at least 30% extra transmitters over and above the engineered
quantity shall be kept for future additions.
3. An RS-485 to RS-232 Converter shall be provided for interfacing HART data of
transmitters to PC station. This converter shall also provide proper isolation to
ensure data integrity.
4. Any failure / short / open-circuit and / or removal of any of the cards /devices /
cables in this centralized configuration, maintenance, diagnostics and record
keeping system, including failure / removal of HART interface modules,
communication modules, converter, etc. shall, in no way, affect the 4-20mA
analog signals being used in DCS. Further, the HART interface modules shall be
organized in such way that separate cards are used for signals going to different
DCS cabinets.
5. Suitable redundant & diode auctioneered 24V power supply packs / modules and
redundant feeders shall be provided to feed all modules / devices. These power
supply packs / modules shall be fed from redundant feeders of UPS system or
from 24V DC power supply system.
6. All modules / cards / power supplies shall be mounted in cabinets to be located
in Control Equipment Room. The PC station and printer shall be located in
Engineering Room.
9.3
Functional Requirements
The system shall have following functionalities as a minimum:
1. Constant scanning to monitor faults or changes to instrument configuration.
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2. Purchaser-defined and standard calibration and configuration procedures for all

transmitters.
3. Constant signal data collection facilities to maintain continuously updated
records.
4. Automatic tracking of configuration changes made in the field, such as may be
introduced by hand-held communicator. All configuration function associated
with hand-held communicators shall be available in the system.
5. Event and log reports on screen as well as on printer.
6. Any addition / deletion of transmitter shall be reported on printer and logged in
hard disk
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10.
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STATION WIDE LOCAL AREA NETWORK

10.1
General
1. A plant wide Local Area Network (LAN) encompassing the different plant
buildings shall be provided. The Station LAN shall interconnect the buildings
together and shall facilitate the smooth transfer of Data from one building to the
other.
2. A plant wide Fibre Optic high speed (100/1000 MBPS) back bone & work groups
is envisaged. This network is used by different users for viewing selective plant
graphics & data on real time basis, historical data & trends, MIS reports &
CMMS data.
3. The MMI of unit & common system, all BOP & offsite PLCs, PADO, CMMS,
MIS, CCTV etc. Shall be connected to station wide redundant Ethernet LAN. The
interface with these systems shall be through OPC client-server architecture. PC
stations shall also be connected to this LAN to monitor data.
4. For achieving this, the above requirement all necessary hardware & interfaces
such as the Station LAN Server, LAN Switches (main & secondary) with suitable
number of ports, electric / optic and optic / electric converters / trans-receivers
etc., software and data communication cables shall be provided. The redundant
unit LANs of the each unit shall be connected through the station LAN switch
and server. It shall be ensured that failure of this network component(s) shall in
no way affect individual unit operation & monitoring function in any way.
5. The Station LAN shall connect following buildings:
a) Station Building- Central Control Room
b) Service Building
c) Coal Handling Plant
d) Ash Handling Plant
e) ESP Control Room
f) CW Pump House
g) Water Treatment & effluent Treatment Plant
h) Air Compressor House
i)
Hydrogen Generation Plant (if applicable)
j)
Workshop
k) Stores
l)
Switchyard Control Building
m) Any other plant area/ building where Station LAN needs to be provided for
the purpose of CMMS, MIS or for Plant security/ surveillance system.
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6. The LAN network to be provided for all user points in all the rooms in the
buildings.
7. The various buildings shall be interconnected through the use of minimum 4 Core
single mode fibre and shall be connected to the main switch in the CCR in a
STAR topology.
8. Each building shall be provided with a 12.U high wall-mountable communications
cabinet complete with glass door, 6 way power distribution unit, shelves and
force ventilation. All units are to be supplied with cage nuts and bolts to house
LAN switches.
9. Inter building wiring shall be a minimum of Category 5E STP cable manufactured,
tested and verified to ISO11801 EIA/TIA standard. Internal building wiring shall
be of the structured cabling type and shall incorporate patch panels on every
floor or as required.
10. A minimum of two RJ-45 ports shall be provided for each specified location.
Category 5E shuttered modules shall be used in pre-assembled faceplates to
save installation time. Modules shall include a slide label system.
11. If Station Wide LAN is procured under TG package, then it shall be deleted from
SG package.
10.2
Design & Functional Requirements

1. The station LAN shall be achieved through the station LAN Server and High
capacity Ethernet switch (station LAN switch). The Station LAN server shall have
the hardware and shall maintain a combined plant database (complete database
from each unit MMI updated at 1 sec.) and data from other systems through
industry standard protocols and formats, on an Open standard RDBMS package
like Oracle Enterprise version or equivalent, for open access to the same from
any PC station in the plant running a suitable client software. This server shall
function as a database server for the Plant Wide LAN.
2. The LAN shall be of the Gigabit type (1000 MBPS) and shall utilize standard IEEE
806.3 protocols such as Ethernet.
3. The Station LAN Switch shall be a layer-III switch & shall have hot pluggable
redundant power supply, Gigabit back plane (switch fabric) capability, 1000
MBPS per port minimum data speed, fibre optic and UTP cable connectivity and
Gigabit ports and shall support expandability / Stackability through a dedicated
high speed expansion port. It shall support minimum Four numbers virtual LANs
as a minimum and shall be routable, remotely manageable and configurable. The
switch shall have extensive self diagnostic and logging facilities and shall use
structured cabling facilities. The Station LAN switch shall be suitably sized to
provide additional ports for connecting Servers / PC-stations etc. In future and
fibre optic ports for connectivity and DCS TCP/IP ports for interconnection to
standard third party sub-systems.
4. Network Monitoring & Management tool shall be provided so that loading etc. on
the LAN switch can be ascertained.
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5. The station wide LAN shall connected to IT LAN, through which the CMMS
server data shall be made available to existing Online Integrated Maintenance
Management System (OLIMMS). Also the PC stations for various plant personnel
shall be connected to station LAN for monitoring data of all units as well as that
of common systems & offsite systems. These Connections shall be through
Firewall.
6. Redundant Hardware Firewalls in failover mode with intrusion prevention system
(IPS) features shall be provided to ensure security of network & prevent
unauthorised access.
7. Firewall shall have minimum three zones. One inside (DCS network), one outside
(IT LAN/ OLIMMS network) & the De-militarized zone (DMZ). Station LAN
Servers shall be placed in DMZ zone. Data required for intranet (plant PC
Network) & for OLIMMS shall be made available to the redundant station LAN
Servers.
8. Station LAN switch shall be provided with a network based intrusion detection
system (IDS) of a make different from IPS provided with Firewall to achieve a
multi layered defence mechanism against intrusion as well as to guard against
possible misuse/attack from within LAN.
10.3
Security Features Requirements

1. Firewall
a) Firewall
appliance
should
facilitate
multi-vendor,
multi-application
environment and should support third-party products on open alliance. It
should support Active-Active configuration.
b) The firewall should contain following features:
Stateful inspection of packets.
NAT functionality, including dynamic and static NAT translations
Latest version of SNMP
c) The firewall must send log information to a separate log server via an
encrypted connection. Firewall logging must not impact firewall performance.
d) Remote network access to the firewall should only be possible through the
administration interface.
e) The firewall administration station must be capable of pushing firewall
security policies and configurations to individual or multiple firewalls through
a secure, encrypted connection to the firewall administration interfaces.
f) Graphical User Interface (GUI) and a Command Line Interface (CLI) for making
changes to the firewall rules set should be provided. (Access to the firewalls
via the GUI or the CLI must be through a secure encrypted channel).
g) Any changes or commands issued by an authenticated user should be logged
to a database configured on any of the machines in the LAN.
The
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Description
Page
No.
Date of Issue
[140]
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administration station must allow for a hierarchical architecture for rules set
administration and viewing of firewall configurations Management.
h) Firewall should also meet the following requirements.
The firewall must not support any unencrypted means of access to the
firewall.
It should Monitors ALL network traffic-traffic at Firewalls (Internet and
external networks) and detects known threat through deep
packet
inspection.
Detects unknown threats via anomaly scanning.
Detect unknown threats via behaviour pattern to protect from zero day
attacks.
Keeps up-to-date on new threats and vulnerabilities.
2. Intrusion detection system (IDS) & Intrusion Protection System (IPS)
In order to inspect all inbound and outbound network activity and identify
suspicious patterns that may indicate a network or system attack from someone
attempting to break into or compromise a system on the Station LAN Network,
the recommended IDS/IPS should contain the following features as a minimum:
a) Able to analyze, detect and report on security related events.
b) Able to inspect traffic and to drop malicious traffic based on the
configuration of security policy.
c) Able to inspect the
Sequences/signatures.
content
of
network
packets
for
unique
d) Able to detect and prevent known types of attacks such as worm or Trojan
infections and hacks.
e) Able to prevent denial of service (DOS) and Distributed Denial of Service
attacks.
f) Able to prevent abnormal behaviours by monitoring and learning normal
network behaviours.
g) Keeps up-to-date on new threats and vulnerabilities.
h) Should provide user friendly interface to queries and reports on threats and
event data so that security administrators can gain a better understanding of
their ability to protect their network.
i)
Should provide detailed activity logs for auditing.
j)
Able to detect known threats via deep-packet inspection.
k) Able to defect unknown threats via anomaly scanning.

l)
Able to detect unknown threats via behaviour pattern to protect from zero
day attacks.
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Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[141]
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10.4
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Network Monitoring & Management Requirements

The network monitoring & management software should contain the following
features as a minimum:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Graphical user interface (GUI) management.

Automated discovery and display of Ethernet topology and devices.
Real-Time SNMP Support
Monitor traffic flow through the device
View a device image indicating which ports are active and which modules are
installed. It a particular network device is down, it should give the tools like
ping/telnet options in the same screen to further diagnose the problem.
Real-time activity and utilization statistics and graphical trends.
Facility of providing pre-defined actions like e-mail, SMS etc. upon any event
generated in the network.
Facility of viewing logical graphs of devices like routers, web servers, according
to the needs.
The following parameters should be monitored.
a)
Device status
b)
Port Status
c)
CPU utilization
d)
Memory Utilization
e)
All port utilization including uplink ports.

Table - 10.1
Specifications for Station LAN Switch
S.No.
Features
Type
Layer-3 Ethernet Managed type
Ports
24/48 RJ45 connectors for 100 Base-T/1000

Base-TX; Two (2) 10BASE-T/100BASETX/1000BASE-T ports; 2 mini-GBIC ports;
console port; auto medium dependent
interface (MDI) and MDI crossover (MDI-X);
RPS port for connecting to redundant power
supply unit
Cabling Type
Unshielded twisted pair (UTP) Category 5 or

better for 10BASE-T/100BASE-TX; UTP
Category 5 Ethernet or better for 1000BASET
Switching Capacity
17.6 GBPS non-blocking
Management interface
One 10/100/1000 Mbps RJ-45 out-of-band

management port
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[142]
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S.No.
Features
[Logo of Utility]
One DB9 serial console
through)
port
(straight-
Management Methods
SNMP, SSH, RMON, RADIUS etc.
Optical Transceiver
SFP/ XFP- 1 GBPS/10 GBPS
Power supply
Redundant
Standards compliance
802.3 10 BASE-T Ethernet,

802.3u 100 BASE-TX Fast Ethernet
802.3ab 1000 BASE-T Gigabit Ethernet
802.3z Gigabit Ethernet,
802.3x flow control,
802.3ad; 802.1D Spanning Tree Protocol
(STP),
802.1Q/p VLAN,
802.1w Rapid STP,
802.1s Multiple STP,
802.1x port access authentication
10
Enclosure protection class
IP 67
11
Mounting
DIN Rail or Direct panel mounting
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Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[143]
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11.
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STEAM & WATER ANALYSIS SYSTEM (SWAS)

11.1
1. The steam and water analysis system shall be designed to monitor the chemistry
of the steam and water cycle to ensure the desired quality. The online chemical
analysis for pH, Conductivity, hydrazine, sodium ion, Silica, dissolved oxygen,
chloride, phosphate etc. Shall be carried out in the plant cycle at strategic points.
Information from the analyser shall be used to control the high pressure and low
pressure dosing system. Long term monitoring and trending of essential elements
shall be carried out, to provide an indication of the general condition of the
mechanical plant.
2. The sample points, their location, type of chemical analysis to be carried out for
each sample, measurement ranges etc., shall be as per plant standards. The
SWAS as a composite system includes sample probes, sample piping, safety
valves, ball valves, relief valves, grab sample collection facility, pressure,
temperature, level, flow indications, coolers, on line analysers etc. The SWAS
shall include the following:
a) Sample conditioning panel with all accessories.
b) Analyzer Panel housing cells, analyzers, monitors etc.
c) The sample conditioning and analyser panels shall be physically separated
from each other. Analyser panel shall be located in a separate air-conditioned
room. Sample conditioning panel shall be walk in corridor type/open rack
type. All SWAS panels shall be designed for ready access of components for
easy maintenance.
d) PC based station for display of information & alarms to the operator, to be
located in SWAS room (connected to station LAN)
3. The SWAS system should be unitised and located at the ground floor of TG
building.
11.2
Design Requirements
1. Design criteria for continuous on line analytical measurements of important plant
media such as water, steam shall be based on microprocessor based instruments
only.
2. Separate Steam and Water Analysis System shall be furnished for continuous
monitoring and control of water and steam purity in the plant cycle of each Unit
and at other important points as specified in this specification.
3. The sampling system shall obtain samples from steam and water system, which
shall be adequately conditioned and fed to analyzers for continuous analysis and
provide parallel facility for grab sampling as specified.
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No.
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Description
Page
No.
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4. The system shall be designed in accordance with the recommendations in ASME

PTC 19.11 Part II, Water and Steam in Power Cycle, ASTM standards - 31 water
and ASTM D1066-69 standard method of sampling steam.
5. The equipment shall be constructed to operate accurately and safely under the
operating conditions described or implied in this specification, without undue
heating, vibration, wear, corrosion or other operating troubles.
6. All parts subject to high pressure or temperature or other severe duty shall be of
materials suitable for the service.
7. All piping, tubing, fittings and other wetted parts in the sampling and analyzing
system shall be of SS 316 or other suitable material for the service. No plastics
or rubber shall be permitted except within analyzers as furnished by the
manufacturer.
8. All SWAS system components and accessories shall be from the latest proven
product range of qualified manufacturers.
9. To ensure operation under adverse conditions the equipments mounted outside
the Sampling and Analysis Room shall be designed for outdoor conditions.
10. Sample room located instruments and electronic hardware shall be required to
operate normally in an air-conditioned area.
11. However, they shall also be able to operate indefinitely with ambient room
temperature between + 50C to + 550C and relative humidity up to 95%, during
air conditioning failure.
11.3
Sample stream Requirements

SWAS shall be provided in accordance with the following guidelines:
Table 11.1
Guideline for Analytical requirements
S.No.
Stream
Make up water
Hotwell
CEP Discharge
Deaerator Outlet
Feed water at Economizer Inlet
Main Steam
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Analysis
Specific Conductivity
Cation Conductivity
Specific Conductivity (both sides)
Cation Conductivity (both sides)
pH
Cation Conductivity
Dissolved Oxygen
Sodium
Dissolved Oxygen
pH
Cation Conductivity
Silica
Hydrazine
Dissolved Oxygen
pH
Description
Page
No.
Date of Issue
[145]
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S.No.
11.4
Stream
Saturated Steam
Reheated Steam
Condenser Cooling Water
[Logo of Utility]
Analysis
Cation Conductivity
Sodium
Silica
pH
Cation Conductivity
Sodium
Cation Conductivity
pH
Sample Conditioning System

1. The sample conditioning system shall provide samples at 250C or a preset
temperature required by the analyzer with in tolerance of +/- 1 0C, at a pressure
of about 2 Kg/cm2 and at a flow rate as required by individual Analyzer/stream.
2. Sample conditioning system shall be designed and constructed to receive and
condition all samples as required by the respective analyzers connected to the
sample streams. This shall include all conditioning equipment mentioned herein
and covers the following:
a) Primary Sample Cooling in the field
b) High Pressure reduction in the field
c) Two (2) nos. racks shall be provided per unit for mounting primary coolers &
high pressure reducing elements in the field.
d) Sample filtering
e) Secondary sample cooling & temperature control
f) Pressure reduction & control as required
g) Flow rate control & measurement
h) Other treatment as required by individual analyzers or mentioned herein
11.4.1
3. Sample line to analyzers shall incorporate an anti-siphon design to prevent

possibility of running dry because of a broken or plugged sample line.
Primary Sample Cooling
1. Primary cooling of all samples having temperature in excess of 45 C shall be
accomplished by passing each sample through one or more individual sample
coolers of shell and tube heat exchanger type.
2. The primary coolers shall use plant auxiliary cooling water.
3. The overall capacity (flow rate and heat transfer capacity) for both sides of
cooler/ coolers in cascade shall be adequate to cool all samples to within 5 C
of the cooling water inlet temperature for the combined flows of each required
analyzer sample plus a manual grab sample flow rate of 500 CC/Min.
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No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[146]
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11.4.2
11.4.3
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4. Provision shall be kept for adjustment of the temperature of each sample line
individually to an optimum value.
5. Sample coolers shall be of submerged helical coil type of shell and tube design
with removable shell meeting the intent of ASTM D1192-64 (Equipment for
Sampling Industrial Water and Steam). Sample tubing and coils in the coolers
shall be continuous and shall extend through the cooling jacket. The sample
tubing shall be of seamless type with no welded or other joints inside the cooling
jacket. Unions shall be provided to facilitate removal of coils.
6. All sample tubing, fittings and other components wetted by the samples shall be
constructed of SS 316.
7. Primary cooler/s shall be removable without disturbing the sample coil
connections.
8. Primary cooler shall be protected on the cooling water side by relief valve on the
water header. The cooling water header is provided with pressure gauge and
isolating valves.
9. Provision shall be made for draining the heat exchanger shell. The drain line shall
be valved and piped to waste drain header.
High Pressure Reducing Element
1. Pressure reduction of samples above 40 kg/cm2 shall be accomplished by means
of a "variable rod-in-tube capillary" or equivalent capable of discharging low flow
at low pressure into a sample stream as per the requirements of all
samples/analyzers under all operating conditions.
2. The device shall be designed for inlet pressure of 350 kg/cm2 operating
temperatures of 65 C and flow rate of not less than 2000 milliliters per minute.
The device shall be sized for maximum required sample flow rate under all
operating conditions (i.e. from 25% of rated operating press onwards to
accommodate starting conditions).
Sample Filtering
Sample particulate removal shall be accomplished by passing samples through
cartridge type filters with 316 stainless steel body or Y-Strainer. The filter
elements shall be capable of retaining particulates of 40 microns and larger. The
filter elements shall be installed immediately after the sample shut off valve.
11.4.4
Temperature Switch & Solenoid Valve

Thermostat and Solenoid Valves shall be provided in the sample line downstream
of sample filter and upstream of the Secondary Cooler. The thermostat shall be a
bimetallic sensor to operate a micro-switch when a preset temperature is
reached. This shall close the Solenoid Valve through logic, when sample
temperature is above preset value (60 C).
11.4.5
Secondary Sample Cooling

1. Secondary Cooler shall be employed to cool the sample from approximately 45
0C to 25 0C+/-1 0C. The secondary coolers shall also be of submerged helical
coil type of shell and tube design. The secondary cooler shall use chilled water at
Document Number
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No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[147]
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11.4.6
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20 0C. Chilled water for secondary cooler shall be provided by packaged

refrigeration unit (chillers). Secondary cooler shall be protected by a relief valve
on the cooling water jacket of each cooler in addition to a relief valve at the
cooling water header. Provision shall be made for heat exchanger shell drain duly
valved and piped to waste drain header.
2. Alternatively, secondary cooling may also be proposed with field proven
isothermal bath.
Chilled Water System
1. Each chiller unit shall be designed with sufficient refrigeration capacity to ensure
each sample stream temperature to 25 0C 1 0C when all streams are
simultaneously at maximum flow rate and maximum temperature. The chiller
capacity shall have a provision of 25% spare capacity for future samples.
2. Suitable temperature monitoring and control systems shall be provided for
maintaining the chilled water temperature at chiller outlet at 20 0C or at a
designed preset value and within the desired band.
3. The compressor shall be readily accessible for service and shall include low noise
hermetically sealed motors. Compressor assembly shall also include crank case
heaters, suction and discharge valves, oil sight glasses, forced feed lubrication
system and an integrated motor protection system along with the necessary
instruments.
4. The condenser shall be water cooled, cleanable shell and tube with water
regulating valve. The cooling water shall be supplied from closed cooling water
system at a maximum temperature of 40C and a maximum flow rate of 100
litres per minute.
5. Chiller shall be of the direct expansion type with refrigerant tubes inside a shell,
completely insulated and to be constructed in accordance with the ASME code
for unfired pressure vessels.
6. Refrigerant circuit shall be complete with a thermostatic expansion valve, liquid
line solenoid valve, sight glasses, filter-dryer, refrigerant shut-off and charging
valves.
7. The chiller water pump shall be of the centrifugal type, close coupled, bronze
fitted construction, complete with motor. Pump & motor shall be designed for
continuous operation.
8. Vibration dampeners shall be mounted between the packaged chiller and the
channel base.
9. Cooling water and chilled water piping shall be provided with block valves.
10. The chiller system shall be provided with 100% redundant chilled water pumps
with suction and discharge pressure gauges and temperature gauges; Chilled
water circulation pump with 100% standby facility; Storage tank automatic
water make up with manual by-pass facility, temperature indicator, level gauge
and drain and overflow connection, in addition to any other
instruments/equipments required for smooth, convenient operation of the
system.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[148]
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11.4.7
1.
2.
3.
4.
11.4.8
11.4.9
[Logo of Utility]
Sample Pressure Conditioning

Pressure reduction of samples above 40 kg/cm2 shall be accomplished by using
high pressure reducing element.
All samples below 40 kg/cm2 pressure shall be provided with back-pressure
(upstream pressure) regulating valves (PCV).
Each sample line shall have Pressure Indicator and Temperature Indicator
upstream of pressure reducer. The gauge shall be 100 mm dial with suitable
stainless steel wetted parts. Casing shall be stainless steel construction.
Each sample line shall include a safety relief valve set at about 3 kg/cm2g,
upstream of the rate set valve, having stainless steel wetted parts.
Flow Restricting Element
Flow Restricting Element located at grab sample line tapped from common
samples to analyzers shall be provided for all samples, to maintain constant
sample flow at a preset sample inlet pressure.
Other Requirement
The Steam and Water Analysis system shall be provided with the sample
shut off valves, blow down valves, solenoid actuated valves, pressure
reducing valves, safety relief valves, back pressure regulating valves, high
pressure reducing values etc. The requirements of the important valves are
specified as under:
1. The sample shut off valves, blow down valves and pressure reducing valves shall
have stellite spindle tip and shall be suitable for an operating pressure of 400
bars and an operating temperature of 400C.
2. The back pressure regulating valve shall be globe type and shall be suitable for a
pressure range of 0 - 50 psi. The back pressure regulating valve shall consist of
a range spring and a diaphragm assembly. The back pressure of the regulating
valve is adjusted to the required set point by the range spring. In case of any
excess pressure the diaphragm shall be lifted to release the excess pressure to
maintain back pressure equal to the set value.
11.5
Sample Pumps
1. Two (2) nos. of sample pumps for each generating unit, along with necessary
pipes, valves, etc. shall be provided for condenser cooling water samples.
Sampling pump motor shall be adequately rated for continuous service duty and
shall meet the requirement for drive motors as per international codes and
standards.
2. Pump start/stop shall be done from local. All necessary accessories including
power supply, wiring and grounding for control and safe operation of the
pumping system.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[149]
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11.6
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Sample Patch Board

1. A quick disconnect patch board area shall be furnished on the SWAS panel. The
patch board shall allow sample to be routed to any analyzer through quick
disconnect valve at patch board on the sample conditioning panel. The area shall
consist of a patch board with bulk head tube fittings with double end shut-off
and hose inserts. Body protector plugs shall be provided for each bulkhead tube
fittings.
2. The plugs shall be of type 316 SS construction. Sufficient length of 6mm ID,
9.5mm OD tygon tubing shall be provided for complete spanning of the patch
board area for interconnection of the bulkhead tube fittings. Each connection
shall be provided with a Phenolic name plate engraved with a legend.
11.7
Grab Sample
Grab sample valves on the SWAS panel front shall be furnished to allow grab
sample flow to be directed to either a drain header or through grab sample
nozzles to the sample trough. Approximately 300 mm of flexible tubing shall
be furnished for each sample to allow grab sample collection and prevent
splashing. Valve body and trim shall be of SS-316.
11.8
Sample Sink
A continuous sink, located at the place of grab sample analysis, shall be
provided. The sink shall be of 316 stainlesssteel, 14 gauge minimum. The
sample sink shall be connected to waste drain header. Sample sink shall
contain an integral stainless steel ledge to accommodate sample container. DM
water connection shall be provided for cleaning of s ample containers.
11.9
Analyzers
All Analyzers shall be of microprocessor-based design. The general technical
specification of the analyzers is provided in this section.Each analyzer shall be
indicated with the sample flow requirement and the total quantity of cooling
water required for the system.
Table 11.2
Specifications for Conductivity Analyzer
S.No.
A
Features
Sensor
Continuous flow through type.
2
3
Type of Cell
Removable type cells for Hotwell
Conductivity Range
0 - 1 s/cm to 0 - 10,000 s/cm
Cell Constant
0.01/0.1/1.0 depending upon range
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[150]
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S.No.
4
Features
Temperature Compensation
Process Connection
[Logo of Utility]
Manual in steps of 0.1 0C selectable and
Automatic (Integral) up to 0 - 120 0C with
Pt-100 Sensor
Screwed
Electrodes: HASTALLOY
7
8
9
B
1
2
3
4
6
7
9
10
11
12
Wetted Parts
Insulators: KYNAR and VITON
Pressure rating
10 Kg/cm2
Accessories
Tee/Vessel (PVC or Hastalloy)
Cable
Up to transmitter in flexible conduit
Transmitter
Type
Microprocessor based
Mounting
Flush Panel
Protection Class
As per TS requirement
Output
4-20 mA DC (isolated)
Digital Display of process variable in
Engineering
Unit,
Temperature,
Alarm Status
Red / Green LED
Character Height 18 mm
Front Panel Membrane type Keyboard
Display
Zero/span Adjustment
Manual
or
Automaticselectable through keyboard
Diagnostics
Self diagnostic programme for electronics,

measuring electrode, open wiring etc
Alarm
Dual alarm set point, hysteresis and time

delay adjustable on membrane keyboard.
Enclosure
Polypropylene
Cable Termination
Internal (cable entry through conduit}
Accuracy
0.25% of measured range
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Compensation
Page
No.
Date of Issue
[151]
02.09.2015
S.No.
13
14
15
16
17
18
19
20
[Logo of Utility]
Features
Response Time
less than 1 sec.
Measuring Cycle
less than 5 sec.
Repeatability
0.95% output range
Stability
0.5% of output range / month noncumulative
Power Supply
230 V AC, 50 Hz, 1-phase
Operating Temp
0 - 60C
For Cation conductivity analyzer Dual
Ion- Exchange column, resin, etc.
(minimum 12 months requirements)
Phenolic Nameplate
Portable test Kit.
Accessories
ASME PTC 19.11 except as modified in this

specification.
Applicable Standard
Table 11.3
Specifications for pH Analyzer
S.No.
A
1
3
4
5
6
7
8
9
Features
Sensor
Type of Cell
Continuous flow through type.
Manual in steps of 0.1 0C selectable and

Automatic (Integral) up to 0 120 0C with
Pt-100 Sensor
Process Connection
Screwed
Pre Amplifier
Integral
Pressure rating
10 Kg/cm2
Range
0 14 pH
Measuring
Glass, ORP or Antimony Electrodes
Liquid Junction
Ceramic / Kynar or Equivalent
Accessories
Tee/Vessel (PVC or Hastalloy)
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[152]
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S.No.
10
11
B
1
2
3
4
9
10
11
12
13
14
15
16
Features
Cable
[Logo of Utility]
Up to transmitter in flexible conduit
Applicable Standard
IS: 6804 except as modified in this

specification.
Transmitter
Type
Mounting
Flush Panel
Protection class
As per TS requirement
Output
4-20mA DC (isolated)
Digital Display of process variable in
Engineering
Unit,
Temperature,
Alarm Status
Red / Green LED
Character Height 18 mm
Computer assisted 2 point
calibration
within pH 0 to 14 for zero with standard
buffer solutions.
Display
Calibration
Temp. Compensation
Manual or Automatic selectable through

keyboard
Diagnostic
Self
diagnostic
required/calibration
checking etc.
Alarm
Dual alarm set point, hysteresis and time

delay adjustment on membrane keyboard.
Enclosure
Polypropylene
Cable Termination
Internal (cable entry through conduit)
Accuracy
+ 0.02 pH or better
Repeatability
+ 0.1% or better
Response Time
7 seconds for FSD or better
Stability
< + 0.001 pH per week
Power Supply
230 V AC, 50 Hz
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
for
Calibration
O.K.,
electrode
Page
No.
Date of Issue
[153]
02.09.2015
S.No.
17
18
Features
Operating Temp.
[Logo of Utility]
0 - 600C
Ultrasonic Electrode Cleaner.
Phenolic nameplate giving tag number,
service, etc.
Pre-amplifier, special cable. Ultrasonic
cleaner, etc.
Buffer tablets.
Sample coolers, flow and pressure
Regulators, standard pH solutions, SS
impulse tubing & fittings, isolation and
drain valves as required, electrode
holders, RFI/EMI shielded, whether &
corrosion proof casing, alarm settings &
indications on monitor, sample rate set
valves and other accessories as required
Accessories
Table 11.4
Specifications for Silica Analyzer
S.No.
2
3
4
5
6
7
8
9
10
Features
Multi Channel Calorimetric Analyzer (With
auto reagent shut-off feature in case of
sample loss or power loss) built in
phosphate
inhibition
feature
and
Microprocessor based.
Type
Operating range
0-50/500/5000 g/litre (field adjustable)
Output
4-20 mA DC (isolated) into 600 ohm
Readout
Digital indicating meter for direct Readout
Accuracy
+ 1% of F.S.D or better
Reproducibility
+ 2% of F.S.D or better
Calibration
Manual and Automatic 2 point zero & slope

Programmable 1 240 hrs
Response time
<
16
switching)
Operating ambient
0-600C temperature
Ambient humidity
Up to 95% relative humidity
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
minutes
Description
(including
sample
Page
No.
Date of Issue
[154]
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S.No.
11
12
13
14
15
16
17
18
[Logo of Utility]
Features
Mounting
Flush panel
Life of light source
10,000 hours (min.)
Power supply
240V, 50Hz, 1 Phase
Alarm Facility
2 HI and 2 LO independently adjustable over

span.
Alarm for
Preferred features
Accessories
Applicable Standard
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Monitor mal-function
Monitor on standby
Monitor auto-zeroing
Concentration high
Loss of sample
Concentration low
Loss of reagent
Hi and Lo alarm LED visible from front.
Power supply on/failure LED visible from
front.
user friendly menu operated programming
Serial interface
Reagent cabinet
Sample strainer
Reagent Reservoir etc.
Phenolic nameplate
Reagents and consumables
Special cables up to transmitter with
flexible conduit
Chilling Plant ( if required)
Automatic temperature compensation
between 5 to 50 Deg.C
Automatic serving provision
SS tubing and vessels
All chemical reagents for 12 months
operation of analyzer
Sample rate set valves
Comprehensive diagnostic & alarm
features
Others as required
ASME PTC 19.11 except as modified in this
specification.
Description
Page
No.
Date of Issue
[155]
02.09.2015
[Logo of Utility]
Table 11.5
Specifications for Sodium Analyzer
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Features
Type of cell
Continuous Flow through Sample
Flow Chamber
Flexi Glass Body or equivalent
Operating Range
0.05-1.0ppm
Measuring Electrode
Sodium Selective Glass Electrode
Output
4-20mA DC (isolated) into 600 ohms
Temperature
Automatic up to 60 Deg. C Compensation
Read Out
Digital Indicating meter
Accuracy
+0.01 ppb/2.5% or better
Response Time
2 minutes or better
Operating Ambient
0-600 C
Ambient Humidity
Mounting
Flush panel
Calibration
Manual through Zeroing Solution
Power Supply
230 V, 50 Hz 1 Phase
Alarm Facility
2 HI and 2 LO independently adjustable over

span.
Serial Interface
To be provided as per requirement
Error Reports
Accessories
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Excessive zero drift

Lack of sample
Slope value out of the acceptable range
Temperature & flow over-range or underrange
Phenolic tag plate etc.
Sample filter.
Pressure regulator & flow meter
Automatic calibration kit
Reagents and consumable
Special cables up to transmitter with
flexible conduit
Others as required
Description
Page
No.
Date of Issue
[156]
02.09.2015
[Logo of Utility]
Table 11.6
Specifications for Hydrazine Analyzer
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Features
Type
Continuous Electrochemical
Operating Range
0-50, 0-100, 0-200 ppb
Output
4-20 mA DC linear and 1-5 volts
Readout
Digital Indicating Meter, linear read-out
Accuracy
+/- 4% of FSD or better
Reproducibility
2% of FSD or better
Drift
2ppm/month or better
Automatic up to 1200 C
Operating
Temperature
0-600 C (maximum)
Ambient
Response Time
2 minutes or better
Mounting
Flush panel
Pressure rating
0 - 5 Kg/Sq. cm
Power Supply
230 V 50 Hz, 1 Phase
Alarm Facility
2 HI and 2 LO, Independently adjustable

over span.
HI and LO alarm LED visible from front
front
All chemical reagents for 12 months
operation etc.
Phenolic nameplate etc.
High sensitivity
Self cleaning electrode
Preferred Feature
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[157]
02.09.2015
[Logo of Utility]
Table 11.7
Specifications for Dissolved Oxygen Analyzer
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Features
Continuous Flow through Sample Electrochemical, Microprocessor based
Type
Range
0-0.1,
0-1.0,
selectable range
0-10.0
ppb
manually
Enclosure
IP-55 or better
Output
4-20mA DC isolated to load of 600 ohms

(minimum)
Automatic up to 650 C
Ambient Temp.
0-600 C
Readout
Digital indicating meter
Accuracy
Better than +
Transmitter
Sensor Response Time
Automatic up to 60 0C
Mounting
Flush Panel
Readable Distance
3 meter (minimum)
Power Supply
230V AC, Single Phase, 50Hz
Sample
Flow rate approx. 500 ml/minute
5% of full scale for
2 HI & 2 LO independently adjustable over

entire span
14
15
16
Alarm facility
Contact rating, 5A, 230 V AC/0.5A, 220V
DC
HI and LO Alarm LEED visible from front.
front.
In-built calibration facility
Phenolic nameplate giving tag no.,
service etc.
reagent Cabinet (if applicable)
Reagent Reservoir (if applicable)
Other as per requirement including
piping etc.
Preferred Feature
Accessories
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[158]
02.09.2015
[Logo of Utility]
Table 11.8
Specifications for Phosphate Analyzer
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Features
Type of Cell
Colorimetric / flow through
Flow Chamber
Plexi Glass Body or equivalent
Operating Range
0.1-10 / 20 / 50 Selectable manually
Output
4-20mA DC linear
Read Out
Accuracy
+ 1% of scale range or better
Response Time
90% in 3 minutes or better
Operating
Temperature
Ambient
0-600 C
Ambient Humidity
Mounting
Automatic

Flush Panel
Power Supply
Manual through Zeroing solution / Automatic 2

point zero & slope programmable
Alarm facility

entire span
Calibration
Contact rating, 5A, 230 V AC/0.5A, 220V DC
15

Sample filter.
Pressure regulator and flow meter
Reagents and consumables.
Accessories
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[159]
02.09.2015
[Logo of Utility]
Table 11.9
Specifications for Chloride Analyzer
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Features
Type of Cell
Continuous flow through sample type
Flow Chamber
Flexi Glass Body or equivalent
Operating Range
0-10 , 0 100, 0 -1000 ppb, manually

selectable
Output
4-20mA DC linear
Read Out
Accuracy
+ 1% of scale range or better
Sensitivity
Better than 1 ppb
Response Time
90% in 3 minutes or better
Operating Ambient Temperature

Ambient Humidity
Mounting
Calibration
Power Supply
Alarm facility
Automatic
0-600 C
Flush Panel
Manual through Zeroing
solution
/
Automatic 2 point zero & slope programmable
entire span
Contact rating, 5A, 230 V AC/0.5A, 220V DC
16
Accessories
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03

Sample filter.
Pressure regulator and flow meter
Reagents and consumables.
Description
Page
No.
Date of Issue
[160]
02.09.2015
11.10
[Logo of Utility]
SWAS Panels
1. The SWAS Panels shall have two sections namely sample conditioning section
and analyzer section. The first section shall be the wet section of SWAS panels
which shall be called as the "Sample Table". The second section shall be the dry
section housing the analytical transmitters, signal conditioning devices and other
requisite accessories.
2. All monitoring instruments and controls for sampling system shall be located on
the front panel and shall be grouped accordingly to function in a logical and
orderly fashion. There shall be a general progression of flow from top-to-bottom
and left-to-right to minimize sample line length, purge times and material
exposed to sample. Similarly, the conditioning components for each stream shall
be grouped together wherever possible.
3. Indicating instruments such as pressure, temperature and flow shall be arranged
in a vertical line directly above the grab sample valve. Sufficient clearance shall
be maintained between instruments banks of adjacent sample points so that
there is no confusion in reading these instruments.
4. Sample conditioning & analyzer panels shall be designed for ready access of
components. Panel design shall ensure that:a) Parts subject to wear, corrosion or other deteriorations or requiring
adjustments, inspection or repair are readily accessible and capable of
convenient removal, when required.
b) Individual components or groups of components mounted on sub-panels can
be removed for replacement or repair without the need of prior removal of
components of other healthy streams.
c) Flow meters, pressure gauges and temperature indicators can be removed for
repair or replacement from the front of the panel without disturbing any
piping.
d) Filter elements and pressure reducing elements can be easily disassembled
for periodic cleaning.
5. SWAS panels shall be designed based on human engineering considerations fully
keeping in view the convenience of operation and maintenance personnel.
6. Each sample inlet shall be provided with bulkhead type tubing connection and an
isolation valve or block valve suitable for sample operating conditions. A blow
down connection and suitable blow down valve shall be furnished upstream of
each isolating valve. Blow down valves shall be manifolded into a suitable blow
down header. Strainers, filters, relief valves etc. shall be provided as specified
and as required to properly protect the coolers, valves, analyzer elements etc.
7. All drains shall be piped into two separate drain headers. One header shall be
called "Waste Drain Header" and shall receive all drains which contain
substances not wanted in the plant heat cycle water. The other header shall be
called "recoverable drain header" and shall receive all other drains not containing
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[161]
02.09.2015
[Logo of Utility]
unwanted substances. All drains shall be headered as indicated above. Vendor

shall pipe the waste drain header to the building drain system.
11.11
Constructional Features
1. The SWAS panel (wet panel) shall be constructed of 3 mm thick steel plates
except for the extreme top of the Sample Table and Analyzer Panel (Dry Panel)
which shall be of 2 mm sheet steel. The counter top, sample sink and front
section above the counter top shall be 2.5 mm type 304 or 316 stainless steel.
2. The sample table shall be of free standing, open rack whereas the Dry Panel shall
be of free standing, totally enclosed construction with back doors.
3. All SWAS panels shall be furnished with 100 mm base angle for bolting to 100
mm high concrete curb.
4. Following panels are to be provided:
a) Sample conditioning panel : 5000 (W) x 2300 (H) x 2400 (D) mm
(Wet Panel)
b) Analyzer Panel
: 3000 (W) x 2300 (H) x 2400 (D) mm
(Dry Panel)
The dimensions given above are tentative only.
5. Panel sections shall be reinforced to ensure true surfaces and adequate support
for instruments and equipment. All equipment and piping shall be firmly anchored
and supported from within the respective panel section to ensure vibration free
operation.
6. Doors and equipment arrangement shall be such that all items are readily
accessible for maintenance and repair. Doors shall have concealed type hinges
and three point type latches to assure tight closing. Doors shall have turned back
edges and additional bracing where required to assure rigidity.
7. All surfaces shall be free from waves, bellies, or other imperfections. All
stainless steel surfaces shall have uniform finish. All exterior steel surfaces shall
be sand blasted, ground smooth, filled, primed, sanded and finished with smooth
backed enamel.
11.12
Piping, Tubing & Accessories
11.12.1
Internal Piping & Tubing

1. All internal piping, tubing and system components required for making the
system complete shall be shop installed and tested as per applicable codes, prior
to shipment to project site.
2. All tubing and wiring shall be located behind the face of the panel with
projections allowed only for indicator faces, valve handles, manual grab sample
lines etc. The physical arrangement of the tubing and wiring shall, in all cases,
be so as to permit easy access for maintenance of all items of equipments.
3. All piping and tubing materials, fabrication, erection and application of piping
materials shall be in accordance with the latest applicable requirements of the
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[162]
02.09.2015
4.
5.
6.
7.
8.
9.
11.12.2
1.
2.
3.
4.
11.12.3
[Logo of Utility]
code for pressure piping (ANSI B 31.1,B36.19) and all other applicable
regulations.
Unless otherwise specified, fittings used with pipe 50 mm and smaller shall be
socket welding type, and fittings used with larger pipe shall be butt-welding
type. All fittings shall be constructed of materials equivalent to the pipe with
which they are used.
All piping and tubing shall be neatly installed and securely braced to ensure
adequate mechanical rigidity. Routing and support of tubing shall be such that
expansion and contraction of tubing or equipment mounted in the sample table
do not impose any excessive stress on the tubing.
Special tools shall be used for all bending and forming operations. Bends in
tubing shall be based on the requirement of the code for Pressure Piping (ANSI B
31.1), concerning tube thinning at the bends. Tubing shall be carefully handled
to avoid flat spots, kinks and short bends. Any tubing so damaged shall not be
used in this sample table.
All piping and tubing shall be blown with oil free compressed air after installation
and before attachment to equipment at either end.
All piping and tubing terminal connections shall be suitably capped after
completion of installation and tests to prevent entry of foreign materials during
transit, storage etc.
All piping and tubing shall be installed so as to ensure easy accessibility for any
maintenance or repair that may be required. High density tubing runs shall not
interfere with accessibility to any system component and shall not impair system
function.
Sample Piping
This shall include piping, fittings, valves and accessories from tapping points up
to SWAS conditioning panel located in SWAS rooms on as required basis. All
sample piping shall be 3/4" NB seamless type of material ASTM A213 TP 316 H,
conforming to ANSI B36.19. The schedule number shall be suitable for the
particular application.
All fittings shall be socket welding type and of material ASTMA182 F316H
conforming to ANSI B 16.11.
Single and multi tubes shall run with the minimum number of changes in
direction. Suitable identification tags shall be provided for easy check up and for
proper connections.
The valves to be used in sample piping shall be of globe type, forged
construction and stainless steel conforming to ASTM A182. The pressure
temperature ratings shall be as per ANSI B16.34. The valve design shall be such
that the seats can be reconditioned and stem and disc can be replaced without
removing valve body from the line
Material Specification for Piping
The material for piping to be furnished and installed for SWAS shall be as
indicated below:-
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[163]
02.09.2015
[Logo of Utility]
Table 11.10
Specifications for Piping Material
S.No.
11.13
Piping System
Material Requirement
Piping from the sample inlet bulk-head

fittings the shut-off valve for low
pressure samples
Stainless Steel, ASTM A-213 Type

304 or 316, 16 BWG tubing
Piping from the sample inlet bulk-head

fittings to the pressure reducing valves
for high pressure samples and sample
blow down piping

Blow down header

304 or 316, Sch. 160
Miscellaneous drains receiver header

Piping from the shut-off valves for low

pressure samples and from the
pressure reducing valves for high
pressure samples to the terminal points
including branch piping

Closed cooling water piping except

grab sample
Carbon Steel, ASTM A-53 Gr. A,

Sch. 40
Sample through drain piping and waste

header piping
Carbon Steel, ASTM A-53 Gr. A,

Sch. 40
Wiring
1. All control and instrumentation wiring used within the SWAS panel sections shall
conform to NEC and NEMA standards. All measurement and control circuits shall
be factory wired and tested by energizing at operating voltage.
2. All electric connections shall be made between devices within the SWAS panel
sections and shall be made to suitable terminal blocks, if devices are to be
connected to equipment outside the SWAS panel.
3. All electrical connections shall enter and leave through the top or bottom of the
panels.
4. High impedance circuits shall be connected using shielded or co-axial wire
suitable for the service. Terminals shall be furnished for termination of shield.
5. Wiring in the sampling section shall be routed in covered metallic trays located
as distant as is practicable from sampling lines and drains with due care taken to
isolate electric wiring, termination etc. from liquid areas.
11.14
Power Supply & Grounding

Power supply to all instruments and control systems shall be through UPS and
separately fused, it should be possible to disconnect any instrument without
interrupting power supply to any other equipment/device.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[164]
02.09.2015
11.15
[Logo of Utility]
Lighting & Receptacles

1. Sample table and analyzer section shall be provided with rapid start, low noise,
fluorescent strip fixtures installed in a continuous row along the top of each
section.
2. The panel shall have a ceiling mounted fluorescent illumination. Light switches
shall be provided within the panel sections at suitable locations.
3. Three receptacles shall be provided on the front of the sample table below the
work surface. These shall be equally spaced. Two more receptacles shall be
provided inside the sample table and one receptacle shall be installed inside the
panel.
4. Wiring for lighting and receptacles shall be run in flexible metallic conduits.
11.16
Control & Monitoring System

All alarm shall be available on the panel for the entire SWAS system, with repeat
facility for each alarm in DCS, in the Control Room.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[165]
02.09.2015
12.
CONTINUOUS STACK EMISSION MONITORING SYSTEM
12.1
General
[Logo of Utility]
1. A fully certified Continuous Emission Monitoring System (CEMS) shall be

provided at the stack to determine emissions of dust, SO x, NOx, CO, CO2 etc as
per state Pollution Control Board requirements.
2. A CEMS shall be provided to measure stack emissions and produce all required
data logging and reporting. The analyzer system shall include microprocessor
based in-situ and sampling type analyzers, a fully programmed controller, auto
calibration accessories and mounting hardware for installation to provide a
complete and operable system. The data logging and reporting system shall store
a data for a stipulated number of years and shall be able to produce reports of
required format.
3. All analysers at stack shall be located at an elevation as per state pollution
control board norms and shall be accessible for maintenance.
4. CEMS shall be provided with all interconnection tubing and cabling between
probe and analyser/analyser panel and cabling from analyser / analyser panel to
local junction box. All the calibration gases required for one year continuous
operation shall be provided. The calibration gas container material shall not
contaminate the calibration gas. Auto gas calibration facility shall be provided.
12.2
Design Requirements
1. A PC based Continuous Stack Emission System shall be provided for monitoring.
All output signals of all stack monitoring analysers shall be connected to plant
DCS /MIS as applicable for monitoring, archiving and report generation for
environmental monitoring authorities. DCS / MIS shall be equipped with
necessary calculations and report generation software packages for generation of
reports for submission to environmental monitoring authorities.
2. Air purge system associated with each analyser shall be adequate to keep
analyser optical windows, probe elements, source elements and gas interface
tubing free of particulate and other contaminants on the continuous basis.
3. A fully assembled environmentally controlled shelter shall be provided at the
bottom of the chimney to house the stack gas monitoring analysers as well as all
equipment required to condition the sample gas.
4. Flue gas analyzer instruments shall be provided with following common
requirements:
Table 12.1
Common Requirements of Analyzers
S.No.
1
2
3
4
5
Features
Analog Output
Binary Output
Zero & Span Adjustment
4 20 mA DC, HART compatible
2 NO + 2 NC for alarm
To be provided
Ambient Temperature
Local Indication
60 Deg C
Digital
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[166]
02.09.2015
S.No.
6
7
8
9
10
[Logo of Utility]
Features
Enclosure Type/ Material
Type of Electronics
Weather & Dust Proof IP67/ SS 316
Microprocessor Based with self diagnostic
Calibration
Error Diagnostic
Digital Signal Transmission
Auto & Manual

To be provided
Modbus protocol / Ethernet TCP / IP Protocol
5. Sampling type systems (if applicable) shall be provided with dual sample probes
along with all required accessories such as redundant heavy duty pumps with
continuous rated motors, moisture detection facility, prefabricated heated sample
lines from probes to analyzer panel, solenoid valves, filters, coolers along with
level switch in gas coolers for auto drain purpose & flow meter etc.
12.3
Technical Requirements of Analyzer Shelter
12.3.1
1.
2.
3.
4.
5.
6.
The Analyzer Shelter shall be a completely assembled unit suitable for installation
on a concrete Pad or as a stand-alone unit. All internal piping and tubing shall
terminate in bulkhead connections. Internal wiring shall terminate in external
junction boxes. All equipment including tubing, conduit fittings, junction boxes,
etc. shall be installed so as not to interfere with the removal of analyzers, sample
handling systems and related equipment. Accessibility for maintenance shall be
the prime consideration.
Construction Features
The Analyzer Shelter shall consist of a self-framing exterior skin assembled on a
rigid primed and painted steel superstructure. All materials used in the
construction shall be non- combustible.
Wall panels design to be completely weather resistant. The design shall allow for
thermal expansion / contraction of the structure over the complete range of
ambient temperatures applicable for the location without causing harmful
buckling or opening of joints, etc. Materials of construction shall be 2mm thick
SS sheet for external walls and 18 gauge galvanized steel for internal walls with
ribbed interlocking. The ribbed interlocking shall provide a strong column for the
sheets on the side valves, where the U profile created at the edges, when
interlocked with the second sheet, increases the section modulus of ribbing.
The wall panels of the shelter shall be insulated and designed for the given
ambient conditions by glass/ rock wool of appx. 100 mm insulation thickness.
Roof panels design and construction to be completely weather resistant. The
design shall allow for thermal expansion / contraction of the structure over the
complete range of ambient temperatures applicable for the location without
causing harmful buckling or opening of joints, etc
The base structure of the shelter shall be constructed using ISMC
(1501125)/ISMB (100) welded properly and adequately sized to ensure
structural rigidity to prevent deformation during dragging, lifting, loading and
unloading of the shelter.
The roof panels shall be provided with 80 mm thick rock wool insulation.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[167]
02.09.2015
[Logo of Utility]
7. The analyzer house shall have two doors; one as the main entrance and the
other as the emergency exit. The doors are to be mounted on special hinges to
ensure gas-tight construction of the shelter. Doors shall be sturdy, doublewalled, insulated with rock wool and open to the outside. Each door shall have a
window with transparent toughened safety glass. The main entrance shall carry
a plate indicating the Plant/Unit number and the tag- list of all the analyzers
inside the shelter.
8. All tubes and cable entries to the shelter shall be through Multi-cable Transit
Blocks - to ensure gas tightness of the shelter.
9. The floor is to be fabricated with anti-slip sheet and sealed continuously to
ensure no loss of pressure.
10. Analyzer Shelter shall meet the standards of the Uniform Building Code with the
following design loads:
12.3.2
12.3.3
12.3.4
a) Roof
20 lb. / sq ft live load
b) Wind
35 lb. / sq ft at 0-30 ft above grade elevation.
c) Seismic Zone
As applicable for the site
Painting
1. Preliminary cleaning involving removing of grease, oil, paint and dirt, which
prevent pickling acid from coming in contact with the scale or mist.
2. Structural painting shall include scraping, chemical cleaning, one coat of etch
primer, one coat of Epoxy Zinc Chromate Red Oxide primer and two coats of
Epoxy finish Paint. The surface coating shall take sufficient care of removing all
the contaminants thus ensuring against premature and complete coating failure.
Precautions to be taken to avoid air bubbles and uneven coat thickness.
3. The internal walls shall be powder coated.
4. Painting for the shelter shall be completed in every respect before despatch. No
painting shall be done at site except touch-up of scratches made during site
erection.
Environmental Conditioning
Analyzer shelters shall be environmentally conditioned to keep the inside
atmosphere of the shelter at a constant temperature of 24 degree 3 deg. C.
to obtain repeatability and reliability of the analyzers and also a comfortable
working environment for workman. For this purpose either a Skid Mounted type
air conditioning unit or Split Type air conditioner shall be provided.
Illumination
1. Illumination level in the shelters shall be at a minimum of 300 lux at 750mm
elevation inside the shelter. Maintenance factor shall be 0.65.
2. External Dome type lighting shall be under the overhangs to provide sufficient
illumination for maintenance work.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[168]
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12.3.5
[Logo of Utility]
3. Power switches for internal and external lighting shall be provided near to the
main entrance on the outside of the shelter.
Other Requirements
1. Fire Detection & Protection: Necessary fire detection & protection measures for
the analyzer shelter shall be provided as per NFPA requirement.
2. Power distribution board for distribution of power for all individual consumers
such as individual analyzers, auxiliary equipment inside and around the shelter,
lighting receptacles shall be provided. Each of the main systems shall have an
individual isolation circuit breaker mounted next to the individual power users
3. Telephone connection shall be provided inside the shelter.
12.4
Technical Requirements of Analyzers

Table 12.2
Specifications for carbon monoxide (CO) analyzer
S.N
1
2
3
Features
Type of Instrument
Principle of Measurement
Measurement Range
In-Situ Type
IR absorption
0-200, 0 1000 ppm programmable
4
5
6
7
Accuracy
Linearity
Repeatability
Response Time
+/- 2% of F.S
+/- 1% of F.S
</= 0.5% of Span
Less than 3 seconds to 90% of final value
Zero Drift
<1% span/week
9
10
Span Drift
Operating Temperature Range
11
Purging System
12
Diagnostic
<1% of measured value/week

0 300 0C
Purging System to be provided with heavy
duty blowers & shutter mechanism for
automatic isolation of lens during purge air
failure.
IR light transmittance
Intensity Indicator
Detector Level Indicator
Microprocessor Status Indicator
Calibration check
Table 12.3
Specifications for carbon dioxide (CO2) analyzer
S.N
1
2
3
4
5
Features
Type of Instrument
In-Situ/ Sample Extraction Type
NDIR absorption
Measurement Range
Accuracy
Linearity
0 40% programmable
+/- 1% of F.S
+/- 1% of F.S
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[169]
02.09.2015
S.N
6
7
[Logo of Utility]
Features
Repeatability
Response Time
</= 0.5% of Span
Temperature Drift
+/- 1% in 24 hrs.
Zero Drift
<1% span/week
10
11
12
Span Drift

0 300 0C
Automatic
13
Filter
14
Purging System
15
Diagnostic
Ceramic 3.5 micron (if extraction type)

failure.
Error diagnostic to be provided
Table 12.4
Specifications for SOx NOx (combined) analyzer
S.N
1
2
3
4
5
Features
Type of Instrument
Measurement Range
Accuracy
Linearity
Sampling Type
Radiation absorption
0 - 300, 0 1000 mg/Nm3 selectable
+/- 1% of F.S
+/- 1% of F.S
6
7
8
Repeatability
Response Time
Temperature Drift
</= 1% of Span
Zero Drift
<1% span/week
10
Span Drift
11
12
13
14
15

Filter
Purging System
Diagnostic
0 300 0C
Ceramic 3.5 micron
Automatic
Required with Auto scavenging facility
+/- 1% /10 C
TABLE 12.5
Specifications for Dust Density/ Opacity Analyzer
S.N
1
2
3
4
5
6
Features
Type of Instrument
In situ dry-type visible light (through LED)
Measurement Range
Accuracy
Resolution
Linearity
Transmission & Absorption

0 1000 mg/Nm3
+/- 0.2% of F.S
0.1 mg/Nm3
+/- 1% of F.S
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Description
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S.N
7
8
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Features
Repeatability
Response Time
</= 1% of Span
9
10
11
12
13
Temperature Drift
Zero Drift
Span Drift
14
Purging System
15
Diagnostic
+/- 1% /10 C
<1% span/week
0 300 0C
Automatic
failure.
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13.
VIBRATION MONITORING SYSTEM
13.1
General
The vibration monitoring system shall provide health of rotating machines on
continuous on-line basis and shall guide the plant maintenance personnel
regarding the nature of fault and the maintenance action required.
The system to be provided shall include all necessary hardware, software,
firmware and interfaces, all special and field signal cabling required for
implementing a fully functional system. System shall include but not limited to
the details specified in subsequent paragraphs/Clauses.
Vibration monitoring system shall be independent for each unit.
Design & Functional Requirements
The vibration monitoring system shall provide condition monitoring the bearings
of all critical machines, equipments with HT drives and their driven equipment.
These shall include but not limited to the following:
1.
2.
3.
13.2
1.
a) ID Fans
b) FD Fans
c) PA Fans
d) Any other device with HT motor
2. The vibration monitoring system shall be complete with vibration sensors, Key
Phasor sensors, signal conditioning cards, amplifiers, special cables, vibration
monitor (if required) etc. together with all necessary equipment and accessories.
3. Vibration sensors shall be provided for measurement in both X (horizontal) and Y
(vertical) axis at 900 angle to each other for each bearing.
4. For bearings of high speed machines (= / >1500 rpm) accelerometer type
sensor and for low speed machines (<1500 rpm) velocity type sensor shall be
provided.
5. Necessary, one or two stage integrators for obtaining vibration measurement in
terms of displacement shall be provided in the system.
6. Vibration monitoring system shall provide the vibration measurement in the form
of 4 - 20 mA DC signal to be directly connected by hardwired cable to plant DCS
for monitoring. Limit value generation (soft) for alarm and protection applications
for the auxiliaries and their drive equipment shall be carried out in DCS or
applicable control system (PLC).
7. Vibration monitoring system shall be an independent microprocessor based
system (PC based). The system shall be interfaced with Plant DCS system
through redundant communication link in addition to hardwired signal exchange.
The system shall interface with plant DCS for any process signals which may be
required to perform condition monitoring functions through soft link.
8. The Vibration Monitoring system shall have Following minimum features:
a) Bar graph and point display indicating the set points.
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b) Graphical plant and machine area representation with location of sensors and
the current value.
c) Diagnostic of the system and sensors. Alarm to be retransmitted to DCS.
d) Current and history trend with resolution of 10 msec.
e) Spectral band and waveform plotting
f) Multiple trends display including process value for data correlation.
g) Orbit and time base plotting.
h) Shaft centreline plot indicating position of a machine rotor.
i)
Bode and polar plot.
j)
Date and Time stamped alarm list.
k) Log and Report generation.

l)
Provision for beeping icon in case of appearance of alarm.
m) Export and import of DCS data. Both way redundant communication links
with the DCS shall be provided.
n) Electronic documentation.
13.3
13.3.1
9. The system shall have facility to store bulk data for 5 years duration with facility
for retrieval of the same. The system shall have facility to share all the data in
the hard disk/ back up media and provide user friendly utilities to retrieve and
analyze stored data.
10. Data collected in the system shall also be accessed by CMMS resident on the
Station LAN for condition based maintenance.
11. The system shall be time synchronised with GPS based master clock.
12. The vibration transducers shall be installed in accordance with API-670
requirements.
13. Two nos. (One for each unit) vibration monitoring cum programming stations
shall be provided in Central Control Room.
Technical Requirements
Vibration Sensors
1. Inductance/ piezoelectric type transducers shall be used. The sensors shall be
either velocity or accelerometer type. However, the sensor type shall be selected
taking into consideration equipment manufacturers recommendation. Vibration
sensors as recommended by main equipment manufacturers shall be installed both
in horizontal (X) and vertical (Y) directions at each bearing housing of pump and
motor. One number key-phasor (proximity type) shall also be provided for each
equipment i.e. Pump/ Fan.
2. The vibration sensors shall have wide frequency response to monitor the
harmonics and be housed in stainless steel enclosure conforming to protection
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degree of IP-67. Sensor shall be provided with all accessories like mounting pad/
cube, Low noise cables & conduits, Extension cables, Junction boxes, Prefab
connectors etc.
3. Vibration transducers shall be complete with all required pre-amplifier /
driver/charge amplifier as necessary for proper operation of the entire vibration
monitoring system.
Table 13.1
Specifications for Vibration Sensor
S.N
1
2
3
4
5
6
7
8
9
10
11
12
13
Features
Sensitivity
Measurement range
4 mv/mm/sec
0 to 25.4 mm/s pk
Frequency Range (+/- 10%)

Resolution
Linearity
Temperature Range
Sensing Element
Sensing Geometry
3 1000 Hz
0.1 mm/s pk
+/- 1%
0 60 0C
Ceramic
shear
Housing material
Sealing
Electrical connection
position
Excitation Voltage
Cable type/length
SS 316
Welded hermetic
type/
Molded Integral cable / Top

12 30 V DC
Polyurethane/ 10 ft.
Table 13.2
Specifications for Key Phasor Sensor
S.N
1
Features
Type
Proximity non-contact type
2
3
4
6
7
8
Sensitivity
Measurement range
Frequency Range
Linearity
Temperature Range
Probe tip material
200 mv/mil
0 to 20 mil
0 10 KHz
+/- 1%
0 60 0C
Polyphenylene sulfide
Probe body material

Electrical connection
position
Excitation Voltage
Cable type
SS 316
Molded Integral cable 1 metre length with
connector for extension / Top
24 V DC from monitoring unit
Polyurethane
10
11
12
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type/
Description
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13.3.2
13.3.3
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Vibration Monitors/ Signal Conditioning Modules

1. The vibration monitors/ modules shall be micro-processor based with extensive
self diagnostic facility. Monitoring module shall be fully software configurable.
2. One buffered 4-20 mA signal for connection to Plant DCS, and one buffered raw
signal for use in vibration monitoring system shall be made available from each
measuring point channel of monitor/ module. The signal shall be suitable for use
as an input to DCS for analog monitoring, linear in proportion to vibration
velocity as well as displacement. Monitor shall provide vibration indication
calibrated in velocity units along with provisions of changing to displacement
unit (field-programmable) for each measurement point in both horizontal &
vertical planes.
3. Monitoring modules shall allow hot insertion or removal.
4. The maximum no. of channels per monitor/ module shall be four. The allocation
of channels shall be such that loss of one monitor shall not affect more than one
side of the bearing of one machine.
5. Sensor fault, monitor fault, power supply fault monitoring shall be provided. On
sensor fault / wire break in the sensor circuit, the system shall have the feature of
identifying the same through suitable means like the output being forced to a value
less than 4 mA, to enable bad signal detection. In case, such a feature is not
available, then suitable contact shall be provided from the monitor for sensor fault/
wire break in sensor circuit.
6. Programmable high pass and low pass filtering facility shall be available to improve
the frequency response.
7. All the calibration of the monitors/ modules and transducers shall be possible from
the front panel.
8. All incoming and outgoing signals shall be connected through a terminal block or
connection mounted at the back of the monitor.
9. In addition to the above, the monitor/ module shall contain all other required signal
conditioning devices and accessories required for proper functioning.
10. Sensitivity of vibration monitoring module shall be 100 mV/mil or better
11. The Vibration monitoring system shall have an accuracy of +/- 1% of Full Scale.
12. Input frequency shall be user programmable.
Power Supplies
1. System shall have provision to receive two numbers 230 V, 50 Hz feeders from
purchaser UPS, further conversion and distribution shall be in done as per scope. If
required, redundant external Power supply shall be provided to ensure that failure
of one power supply shall not affect any monitoring function in the system. Also
any power supply failure/ earth
fault in any of the monitors shall be isolated
without affecting other monitors/ common power supply. However, if any power
supply modules internal to the monitors are envisaged, the failure of one such
module should not affect more than one monitor.
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Description
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13.3.4
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2. Power supply monitoring feature with suitable indication and external alarms shall
be provided.
Cables, Conduits & Junction box
1. Each transducer shall be furnished with low noise cable in flexible conduit, as
indicated earlier, in actual length as required. Conduit fittings shall be furnished or
connection to vibration transducer. The other end of the flexible conduit shall be
connected to a suitable junction box. The flexible conduit shall not be directly
terminated to the vibration transducer to avoid any damages due to vibration. Prewired plug-in- type connector shall be provided for connection of the low noise
cable to the vibration transducer. Terminals shall be provided for terminating the
low noise cable to the junction box.
2. Provision of suitable canopy on the JB and panels installed in open area shall be
provided.
Table 13.3
Specifications for Flexible Conduits
S.N
1
2
3
Features
Type
Material
Formation
Stainless steel flexible conduit
AISI 304
Single overlapped/Square Locked
Minimum Bending Diameter
Flexibility
6
7
Tensile strength
Diameter & length
75 mm
Should not be permanently distorted when
bent in complete turn round on a cylinder of
75 mm diameter.
400 N or better
As per requirement
13.3.5
Programming Functions
13.3.6
Suitable means shall be provided for programming the components of the system.
This shall include range change, set point change, sensor fault detection/
monitoring related functions etc.
System Cabinet/ Monitor Racks
1. The system mounting rack shall preferably be 19" EIA rack mount for monitor
based systems. The system mounting rack shall house monitor modules, indicating
units, power supplies. Rack shall be fully factory wired up to rear terminal block.
The Internal arrangement shall take into consideration aspects of access/ ease of
maintenance etc.
2. Panel shall be provided with necessary Isolation transformers, MCBs, switch etc.
Power and signal cable shall be routed in separate raceways.
3. All necessary accessory items and electrical materials shall be installed in the
monitoring panels as required for completeness of the panels. These shall include
but not be limited to the following:
a) Terminal blocks with identification tags.
b) Terminal lugs and wire markers at both ends of all wires.
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c) Panel hardware including vibration isolating devices

d) Grounding bus
13.3.7
4. Incoming cables from the field shall be terminated in suitable terminal blocks in
logical sequence.
5. Each vibration monitor and mounting rack shall have nameplate engraved to
indicate the main equipment to which the module is catering and the bearing
details.
6. In case of monitor based system, the front door shall be of glass, for the portion
where the monitors are mounted to enable viewing of the same.
Wiring
13.3.8
1. All instrument wiring used within the panels shall conform to NEC and NEMA
standards and shall be factory installed and tested at the works.
2. Signal circuit shields shall be grounded at the system cabinet end only or as
recommended by manufacturer.
3. All internal wiring (except low level instrument wiring) shall be National Electric
Code Type SIS, Polymeric / Elastomeric insulated, copper stranded conductor &
switchboard wire.
4. Panel wiring shall have a flame resistant insulation with adequately sized copper
conductor based on current carrying capacities as set forth by the National Electric
Code.
Terminal Blocks
1. For all inputs to the system emanating from the field or others systems, the
system shall be furnished with screw less cage clamp type terminals suitable for
core size of 0.5/1.5 square mm. stranded conductor.
2. At least 20 per cent spare unused terminals shall be provided, for circuit
modifications and for termination of all conductors in a multi conductor control
cable
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No.
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Description
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No.
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14.
FIELD INSTRUMENTS & FINAL CONTROL ELEMENTS
14.1
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1. All instruments shall be of proven reliability, accuracy, repeatability requiring a

minimum of maintenance. They shall comply with the acceptable international
standards.
2. Every panel mounted instrument requiring power supply shall be used with a pair
of easily replaceable glass cartridge fuses of suitable rating. Every instrument
shall be used with a grounding terminal and shall be suitably connected to the
panel grounding bus.
3. All local gauges as well as transmitters, sensors, and switches for parameters
like pressure, temperature, level, flow etc. as required for the safe and efficient
operation and maintenance as well as for operator and management information
(including all computation) of equipment shall be used.
4. The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks,
valve manifolds and all the other accessories required for mounting/erection of
these local instruments shall be furnished, even if not specifically asked for, on
as required basis. The contacts of equipment mounted instruments, sensors,
switches etc. for external connection including spare contacts shall be wired out
in flexible/rigid conduits, independently to suitably located common junction
boxes. The proposal shall include the necessary cables, flexible conduits,
junction boxes and accessories for the above purpose. Double root valves shall
be used for all pressure tapings where the pressure exceeds 40 kg/sq cm.
5. For protection purposes, transmitters can be considered in place of switches.
14.2
Pressure / Differential Pressure / Flow / Level Transmitter

Table 14.1
Specifications for Pressure / Differential Pressure / Flow / Level Transmitter
S.N
Features
Type
Sensor Type
Output Signal
Signal Processing Unit
Overpressure
Turn-down Ratio
Stability
Span and Zero drift
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Microprocessor based 2 wire type, HART
protocol compatible
Capacitive/ Piezo-electric
4-20 mA signals superimposed with HART
signal.
150% of max. operating pressure.
For vacuum service, the element shall have
under range protection to full vacuum
10:1 for vacuum / very low pressure
applications.
100:1 for other applications.
0.1% of calibrated span for six months up to
70 Kg/cm and 0.25% for range more than
70 Kg/cm(g).
0.015% per deg. C at max span & 0.11%
per deg. C at min. span.
Description

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S.N
9
Features
Weather proof as per IP 67 with corrosion
resistance coating. For hazardous area explosion
proof enclosure as described in NEC article 500
Continuous, tamper proof, remote as well as
manual from instrument with zero suppression
and
elevation facility.
To be provided
Digital LCD Integral Display (minimum 5 digit)
Engineering Unit
NPT (F)
NPT
Aluminum Alloy or better
65 Deg. C
Enclosure Class
10
Zero & span adjustability
11
Local Indicator
12
Display
13
14
15
16
Process connection
Electrical Connection
MOC of Electrical Housing
Ambient Temperature
17
18
19
20
22
Operating Voltage
Load
Accuracy
Response Time
Adjustment/
calibration/
maintenance
Diagnostic
23
Accessories
21
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16 48 Volts DC
600 Ohms (minimum) at 24 Volts DC
0.075% of span or better
100 millisecond or better
Port/provision for Centralised PC based system
maintenance.
Self Indicating feature
Diaphragm seal, pulsation damper, siphon, 3valve or 5valve manifolds.
1. All transmitters shall be equipped with all necessary accessories like valve
manifolds, mounting bracket etc. Pulsation dampeners shall be used where the
process media is unstable for measurement such as at the discharge of a pump.
For absolute pressure transmitter, 2 valve manifold; for gauge / vacuum pressure
transmitter, 3 valve manifolds and for DP / level / flow transmitter, 5-valve
manifold shall be
provided. In case if it becomes necessary to use a DP
transmitter for
pressure measurement then a 3 valve manifold shall be
used in place of 2 valve manifold.
2. Pressure transmitter shall have easily accessible span, zero and time constant
adjustments. A range suppression / elevation device shall be used wherever
required.
3. For pressure / differential pressure transmitter, proof pressure shall be 200% of
maximum static process pressure.
4. All transmitter cases shall be dust tight and rugged. Weather proof and
explosion proof cases shall be used in outdoor and hazardous areas
respectively. Protection clause shall be of IP 67 or better.
5. Transmitters for pressure / DP measurements of liquid and steam shall always be
installed below the sampling point, preferably with the connection at the top.
6. Transmitters for pressure / DP measurements for gases and air shall always be
installed above the sampling point, preferably with the connection
at
the
bottom.
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7. Transmitters with diaphragm seal system shall be considered when

a) The process temperature is outside of the normal operating ranges of the
transmitter and cannot be brought into those limits with impulse piping.
b) The process is corrosive and would require frequent transmitter replacement
or unusual materials of construction or
c) The process contains suspended solids or is viscous and may plug the
impulse piping or
d) There is a need to make density or interface measurements or
e) The process medium may freeze or solidify in transmitter or impulse piping.
8. Diaphragm seal shall be either capillary type or direct mounted type depending
upon the application. Parts below the diaphragm shall be removable for cleaning.
The entire volume above the diaphragm shall be completely filled with an inert
liquid suitable for the application.
9. Differential pressure type level transmitters shall be used for range above 1219
mm, for services requiring purge or where liquid might boil in external portions.
10. Differential pressure type level transmitters for use on corrosive service shall
generally be diaphragm wafer with extended filled capillary type. Flush or
extended diaphragm type DP transmitter shall be considered for special
application. Diaphragm material shall normally be stainless steel or any other
special alloy.
11. Differential pressure type flow transmitters shall have in-built square-root
extractors.
14.3
Temperature Transmitter
Table 14.2
Specifications for Temperature Transmitter
S.N
1
2
3
4
Features
Type
2-Wire, Smart (HART)
Output Signal
4-20 mA signals superimposed with HART

signal.
Accuracy
Local Indicator
Display
Input
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
0.075 % of span or better

To be provided
Digital LCD Integral Display (minimum 5 digit)
Engineering Unit
Ohm input from Pt-100 RTD/ mV signal
from thermocouples
Description
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S.N
Features
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0.1 % of reading or 0.10 C, whichever is
greater, for 24 months for RTDs.
Stability
0.1 % of reading or 0.1 0C, whichever is
greater, for 12 months for thermocouples
Output
4-20 mA DC, linear
Load
600 Ohms (minimum) at 24 Volts DC
Power Supply
24 VDC, 2- Wire Loop Power
12
MOC of Electrical Housing
13
Enclosure Class
Aluminum Alloy or better

resistance coating. For hazardous area
explosion proof enclosure as described in
NEC article 500
9
10
11
1. The temperature transmitter of following types (2-wire Loop Powered

temperature transmitter) compatible with thermocouples and RTDs shall be used.
Cold junction temperature compensation of the thermocouples shall be
performed in the temperature transmitter itself.
Single Input DIN-rail mounted Temperature Transmitter
These shall be suitable for mounting on DIN-rails in Panels/JBs in air conditioned
room. This temperature transmitter shall be the ones which are especially
designed for DIN-rail mounting with IP 20 protection class. These shall have
terminals for input/output provided on front side when mounted on DIN-rail.
Head mounted temperature transmitter with clamps to make it suitable for DINrail mounting shall not be acceptable under this category.
Dual-input Temperature Transmitter with Indicator
These shall be suitable for mounting on pipes/ supports. Indicator shall be used
with these transmitters. These transmitters shall have bump-less change over
facility to second sensor in case first sensor fails .This changeover is to be
alarmed. Protection class shall be IP67 minimum.
2. Transmitters shall be used with following features:
a) Sensor drifts alarm for sensor failure prediction
b) Differential & average temperature measurement if required.
c) Automatic switch-over to back-up sensor on primary sensor failure.
d) Accepts any combination of two sensor types (RTDs, T/Cs, mV or ohms)
e) Ambient temperature compensation
f) Fault detection for electronics & sensors with fail-safe alarming.
g) Provision of built-in CJC
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3. Transmitters to be used for RTD sensors shall be used with RTD EMF correction
features so that it shall detect and eliminate EMF errors which are the result of
small voltage produced by RTD sensing elements.
4. The product and make shall be selected so that with one make of transmitter all
applications with respect to measuring range, temperature sensor (resistance
thermometer / thermocouple) and connection type (2/3/4) wire connection of
resistance thermometers) shall be covered.
5. Transmitters shall be capable of communication with HART (Highway
Addressable Remote Transducer) communicator. HART communicator shall be
used with transmitters for tuning / configuring / diagnosing / maintenance of the
transmitters. It shall meet the intrinsic safety requirement if required depending
upon the application.
6. All transmitters cases shall be dust-tight and rugged. Weather-proof and
explosion-proof cases shall be used in outer and hazardous areas respectively.
14.4
Thermocouple
Table 14.3
Specifications for Thermocouple
S.N
1
Features
Wire Gauge
16 AWG (for K type

24 AWG (for R type)
O.D. 8 mm
Protective tube
Material SS 316 seamless

Filling Compacted
(Purity above 99.4)
Magnesium
Oxide
Loading
Shall be spring loaded to ensure positive

contact with the well. Prevention of rotation
of the insert with respect to head and
resultant twisting of leads shall be ensured.
Accuracy
As per ANSI MC 96.1 / IEC 751 / IS-2054 /

2055.
Characteristic
Linear with respect to temperature within

+/- per cent of top range value.
Reference
Head
Type
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
For temperature vs. mV characteristics,

following IS shall be applicable :
Type K
IS 2054
Type R
IS - 2055
IP-65 universal screwed type (Explosion

proof for NEC class-1, division-1 area)
Description
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S.N
Features
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Material
Die-cast aluminium or better

painted with black enamel paint.
Terminal Block
Brass screw type / silver plated on ceramic

head.
Cable Connection
NPT gland & grommet
Cover
Screwed cover with suitable gasket & SS

Chain
Instrument
Well
Accessories
connection
to
material
NPT
a)
Adjustable nipple-union-nipple {1/2

Sch. 80 X1/2 NPT (M)} with
thermowell connection
b)
Compression fittings/union
c)
Flanges etc. (For flanged connection

only)
d)
SS 316 forged/barstock thermowell

as per ASME PTC code. Process
connection M33X2 (M)in general or
1 Flanged for Flue gas/ Furnace air
etc. application
1. The following types of sensors shall be used for the different temperature
ranges:
a) For measurement of temperatures of up to max. 1100 C, rapid-responded
sheathed thermocouples with insulated tip, 16 AWG wire, as Chromel-Alumel
(NiCr-NiAl, ISA type K) measuring element, with admissible deviation of
thermo voltage of half the values stated in IS-2054, or DIN 43710.
b) For measurement of temperature between 1100 C and 1300 C, 24 AWG,
Platinum Rhodium (13%) Platinum (ISA type R) measuring elements, with
admissible deviation of thermo voltage of half the values stated in IS-2055,
or DIN-43710.
2. All thermocouples shall be duplex type with tip grounded. Thermoelectric
properties and accuracy shall be as per ANSI MC 96.1 / IS-2054 / 2055.
3. The design of thermocouple assemblies shall be such that replacement on line is
possible.
4. Gas-tight ceramic sheaths partially reinforced with stainless steel sheath shall be
used as protective tube for Pt Rh Pt thermocouples. For other type of
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5.
6.
7.
8.
9.
14.5
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thermocouple stainless steel tubes shall be used as protective sheaths. For

measuring temperature of high pressure process fluid, tapered protection sheath
made from solid bar stock shall be used.
The time-constant of thermocouples shall suit the process requirement.
The thermocouples shall be supplied with factory tested and calibrated
assemblies. The assemblies shall be complete with thermo well, sensing element,
connection lead, duplex terminal block, extension nipple, compression fittings /
unions /flanges etc. to meet all functional requirements. The thermocouples
equipped with thermo well shall be spring loaded for positive contact with the
well.
The duplex terminal block shall be constructed with high temperature ceramic
base with brass screw type terminals.
Thermocouple shall be suitable for steam, water or any other liquid application.
For air & flue gas service, suitable protection tubes shall be used for the
thermocouples.
All thermocouples shall be terminated to the nearest junction boxes. The cold
junction compensation shall be implemented within the measuring module level,
no local/ field cold junction compensation box is allowed.
Resistance Temperature Detector (RTD)
Table 14.4
Specifications for RTD
S.No.
Features
Type
No. of Element
4
5
6
7
8
9
3 / 4 wire , Pt-100 (100 ohm at 0 deg C) (as
per DIN 43760)
Duplex
IP-65/Diecast Aluminium.
Housing/Head
Plug in connectors are to be provided for

external signal cable connection
Sheathing of RTD
Metal sheathed , mineral insulated, ceramic

packed
Calibration and accuracy

Stability
Characteristic
Standard
Accessories
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
As per DIN-43670 Class-A for RTD

Zero & span drift within 0.1% of span for a
6 month period.
Linear with respect to temp, within
1/2percent of top range value
As per DIN-43670 for RTD & ASME PTC19.3 for Thermowell
Adjustable
Nipple-Union-Nipple
with
a) thermo well connection / plug in
connectors
Description

Page
No.
Date of Issue
[184]
02.09.2015
S.No.
Features
[Logo of Utility]
b) Compression fittings / unions
c) Flanges etc.
d)
Thermowell as per requirement
1. RTDs shall be of duplex, platinum three / four wire type with a nominal
resistance of 100 ohms at 0 C and conform to DIN 43760 / BS 1904.
2. Stability of RTD over full range shall be better than 0.05 ohms and the
repeatability figure shall be better than 0.02 ohms. Accuracy shall be of the
order of 0.15% or better and response time shall be less than 20 seconds with
thermo well.
3. The protective-sheath material shall be SS 316, seamless tubes using compacted
magnesium oxide packing for insulation. The insulation resistance at 540 C shall
not be less than 5 mega-ohms.
14.6
Metal Temperature Thermocouple

Table 14.5
Specifications for Metal Temperature Thermocouple
S.No.
1
2
3
4
5
6
Features
Measuring medium
Type
Metal Temperature
K-Type
Wire Gauge
16 AWG
No. of Element
Sheathing/Insulation/Dia.
Bending Radius
Duplex
with
separate
hot
junctions,
ungrounded type
Metal sheathed (SS 321) , mineral insulated
(Magnesium oxide), ceramic packed, 8 mm
Dia.
30 mm (minimum)
Cold End Sealing
SS pot seal with color coded PTFE headed

sleeve insulated flexible tails.
Sealing compound Epoxy Resin
8
9
10
Standard
ANSI MC 96.01
Thermocouple Length
Accessories
30 Mtrs. (minimum)
1/2" BSP SS sliding end connector, weld
pad, weld on clamps of heat resistant steel
SS310.
1. For metal temperature measurement, care shall be taken for proper contact with
metal surface. The thermocouples sheath for metal temperature measurement
shall have to be thermally insulated to avoid radiation / conduction / convection
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[185]
02.09.2015
2.
3.
4.
5.
6.
14.7
[Logo of Utility]
loss. Thermocouple assembly for metal temperature measurement shall suit the
functional requirement.
The thermocouple shall be attached to the heater tube surface by being
furnished with stainless steel welding pads or by the use of thermocouple
attachment blocks. The multiple holes in these blocks shall allow for spare
thermocouple element for quick replacement.
For boiler metal temperature measurement, the lead wires shall have to be
brought into nearest Junction Boxes which are located in accessible safe zones,
using suitable protection pipes.
For measurement of wall temperatures at boiler tubes, sheathed thermocouples,
dia 3.0 mm NiCr-Ni single thermocouples shall be used. The thermocouple line
shall be designed as Teflon-insulated stranded conductor, provided with glass
filament insulation and stainless steel wire braiding. The thermocouple shall be
welded to the compensation line outside of the boiler insulation, with the
welding point spilled hermetically in a coupling element. The area of the boiler
penetration shall be designed with an anti-kink spring of stainless steel and a
line-fixing sleeve of stainless steel, encapsulated in synthetic resin.
The differential temperature inside / centre of the wall shall be measured by
means of sheathed thermocouples NiCr-Ni, dia 3.2 mm. For this special
protective sleeve shall be used. Particular emphasis shall be put on compliance
with the stipulated depth of the bores in the tube wall material.
For detection of leakage of various drain valves, drain pipe metal temperature
thermocouples and for SH, RH metal temperature thermocouples shall be used.
Cold junction Compensation (CJC) Boxes
Table 14.6A
Cold Junction Compensation (CJC) Boxes
S.No.
Medium
MOC
600C (+/- 1.30C) for type K thermocouple
Reference Temp
Effect of
variation
Material
4 mm thick fiberglass reinforced polyester

with polyeutherene paint and glazed finish
Protection class
IP 55
Cable entry
Bottom with gland plate suitable for cable

used along with blanking facility.
Temp. Control
Automatic with remote temp. monitoring
Power supply
24VDC
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
ambient
600C (+/- 20C) for type R thermocouple

temp.
+/- 0.1% per 100C
Description
Page
No.
Date of Issue
[186]
02.09.2015
14.8
[Logo of Utility]
Thermowell for Temperature Elements

1. The design of the thermo well shall take into consideration the temperature,
pressure, medium and fluid velocity specified in the process in accordance with
ASME Standard PTC 19.3.
2. Thermo wells shall, in general, be of SS 316 and shall be drilled from bar stock
except for air and flue gas services. However, selection of thermo well material
shall be as per following guideline.
3. Welded type thermo wells with 38 mm O.D. for welding & NPT internal
threads shall be used for pressure above 100 kg / sq cm or temperature above
400 deg C. Socket weld type thermo well with 34 mm O.D. for welding &
NPT internal thread, shall be used for pressure between 40-100 kg/cm2 and
temperature up to 400 C. Screwed type thermo wells with NPT internal
threads & M33X2 (M) outer threads shall be used for pressure below 40 kg/cm2
and temperature below 400 C. For pipes having probability of prolonged
vibration, seal welding may be done all around after tightening the thermo well
within the base.
Table 14.6B
Thermowell MOC Selection
S.No.
Medium
MOC
Preheater
Black Steel, SS446
Steam lines
SS 316 and pipe material compatible for

high temperature steam
Water lines
Low carbon steel/ SS316
Boiler Tubes
SS304 / SS309 / SS310
4. Thermo well manufacturing drawing covering material specification, dimensional

details, details of special treatment, finish etc. as well as test procedure. Material
certificate shall have to be furnished for each thermo well.
5. Wherever any approval is necessary from any recognized body / authority during
manufacturing of high pressure wells.
6. The thermo well immersion depth (U) shall be sufficient to eliminate conduction
error. A general rule which may be followed is to use an immersion length
equaling a minimum of 10 times the diameter of the protective tube or well. In
general, immersion length of thermo wells for different line sizes shall be as
follows:
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[187]
02.09.2015
[Logo of Utility]
Table 14.6C
Thermowell Immersion Length
S.No.
14.9
Line Size
Immersion Length
From 4 to 6
65 mm
From 8 & onwards
140 mm
Vessels
400 mm
Pressure Gauge/ Differential Pressure Gauge/Draft Gauge

Table 14.7
Specification for Pressure Gauge/ DP Gauge/ Draft Gauge
S.No.
1
Feature
Type
Minimum Requirement
Bourdon / Bellows / Diaphragm
Sensing Element Material
AISI 316 SS
Movement Material
Case Material / Protection
Class
AISI 304 SS
Dial Size
Scale
Range Selection
Over range Protection
Adjustment
10
11
Stop at Max. Reading

Element Connection
12
Process Connection
13
Accuracy
Operating Ambient
Temperature
14
15
Safety Feature
16
Window
17
Chemical Seal Unit
18
Accessories
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
SS / IP 65
150 mm
For Special application like drum pressure,
Main Steam pressure etc. 250 mm shall be
used
Black lettering on white background in 270
C arc
Normally operate at 75% of its maximum
pressure range. Instruments measuring
varying pressures shall operate in a band of
60% of its maximum pressure range.
150% of maximum range by internal stop.
External stop below zero.
External Micrometer screw for zero
adjustment. Internal micrometer screw for
range adjustment.
Shall be used
Argon welding
NPT(M) bottom connection for local
mounting, back connection for panel
mounting
+/- 1.0 % of full scale or better
50 C (Max. continuous)
Neoprene Safety Diaphragm (Blowout disc)
at the back
Shatter-proof glass
SS 316 Flange and Diaphragm, PTFE coated
/ block, Silicon Oil filling fluid
Snubber for pulsating fluid applications / 3Description

Page
No.
Date of Issue
[188]
02.09.2015
S.No.
Feature
[Logo of Utility]
Minimum Requirement
way gauge cock / 2-valve manifold / Pigtail /
Siphon for steam service / Gauge Saver, if
maximum or Design Pressure is very high
than the Operating Pressure / Counter
Flanges / Bolts, Nuts, Gaskets / SS Tag
Plate
1. Directly connected pressure measuring instruments shall be diaphragm, bourdon

or bellow type elements depending upon the
services conditions. In general,
diaphragm elements shall be used in
the range of 0 to 1000 mm water
column pressure, bellow type element for ranges of 0 to1 Kg/cm2 and bourdon
type element for ranges greater than 1 Kg/cm2.
2. Primary element material shall be corrosion resistant to process fluid or
diaphragm seals shall be used for protection.
3. For draft measurement Teflon coated beryllium copper diaphragm shall be used.
4. Snubber shall be floating pin type, externally mounted and externally adjustable.
It shall be used for all pulsating services.
5. Diaphragm seals, filled type or mechanical type shall be furnished where plugging
of the element may occur or where suitable material is not available in highly
corrosive services. When chemical seals are required, they shall be the clean out
type with flushing connection.
6. Over-range protection shall be used to at least 150 % of range. For vacuum
service, the element shall have under-range protection to full vacuum
7. Ranges of the gauges shall be so selected that the gauge normally operates in
the middle third of the scale and conform to IS 3624 standard dials, wherever
necessary.
8. The sensing elements for all gauges shall be properly aged and factory tested to
remove all residual stresses and shall be SS 316 with forged socket and tip of
the same material. Elements above 70 Kg/sq. cm range shall be bored instead of
drawn.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[189]
02.09.2015
14.10
[Logo of Utility]
Temperature Gauge
Table 14.8
Specification for Temperature Gauge
S.No.
1
2
3
Feature
Type
Sensing Element material
Movement Materials
Case Material/Protection
class
Capillary Armouring
Capillary
7
8
Bulb/Stem Diameter
Dial Size
Window
10
Scale
11
Adjustment
12
Pointer
13
Range Selection
14
15
Stop at Max. Reading

16
Instrument Connection
17
18
Process Connection
Performance :-
a
b
Accuracy
Repeatability
Response Time
Minimum Requirement
Mercury filled
Bourdon AISI 316 SS
AISI 304 SS
SS / IP65
SS Flexible
SS 316 ( 5 mtr. Length for Local & 15 metre
for panel Mounting)
12 mm
150 mm
Shatterproof glass
Black lettering on white background in 270
C arc
Micrometer screw for zero adjustment.
Internal micrometer screw for range
adjustment.
Externally Adjustable
Normal Process Temperature
approximately two third of Temperature
range.
Shall be used
150% of FSD
Bottom connection for local mounting, back
connection for panel mounting.
NPT with Thermowell
+/-1.0% of full scale or better
Less than 0.5% of full range
30 seconds (max.) with Thermowell and 15
seconds Bare.
19
Operating Ambient
Temperature
50 C (Max. continuous)
20
Accessories
Mounting brackets, Bolts, Nuts, Gaskets /

SS Tag plate, SS Thermowell etc.
1. Temperature gauges shall be dial thermometers (liquid spring / steam pressure

spring / metal expansion thermometer), either rigid stem or capillary tube
depending upon application; if this is not possible for design reasons, industry
type liquid in glass thermometers shall be used.
2. Case shall have back or bottom connection with adjustable gland to permit
adjustment of thermometer into the thermo well.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[190]
02.09.2015
[Logo of Utility]
3. Thermometer stem adjustable gland with union connection and bushing shall be
suitable for inch NPT connection.
4. Bi-metallic type dial thermometer, if used, shall be hermetically sealed, back or
bottom connection type, with 150 mm dial.
5. The gauges shall be used with automatic ambient temperature compensation.
6. Scale ranges shall be selected so that normal process temperature in middle two
third of full scale range.
14.11
Level Gauge
Table 14.9
Specification for Level Gauge
S.No.
Feature
Sensing Element & material
Body Material
End Connection
4
5
Accuracy
Scale
Range Selection
Over Range Test
Housing
Identification
10
Packing
11
Illumination
12
Accessories
13
Others
Minimum Requirement
Tempered toughened Borosilicate gauge glass
steel Armored reflex or transparent type
Forged carbon steel / 304 SS
Process connection as per ASME PTC and
drain / vent 15 NB
+2%
Linear vertical
Cover 125 % of max. of scale
Test pressure for the assembly shall be
1.5 to the Maximum design pressure
at 38 degree C
CS / 304 SS leak - proof
Engraved with service legend or
or laminated phenolic Name plate
PTFE Teflon
220 V, 50 Hz, 25 / 40 Watts either
with deflector or diffuser (for
transparent type level gauge) / 220V ,
50 Hz, 25 /40 Watts with red and
green filter for bicolor gauge
Gasket for all KEL F shield for transparent
type vent and drain valves of CS / SS as per
requirement
Anti Frost extension for low temperature
service.
Heating / cooling arrangement
1. Level gauges shall be steel armoured reflex or transparent or bi colour type, top
and bottom connection as per pressure vessel standard of ASME PTC code and
15 mm NB (1/2 inch NPT) Drain and Vent connection.
2. Body material and cover material shall normally be forged carbon steel, 304
stainlesssteel or other superior material.
3. Reflex type gauges shall be used for clean and colorless liquids and transparent
type for other liquids. For boiler and condensate services, treated water, the
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[191]
02.09.2015
[Logo of Utility]
transparent type with KEL F shields shall be used to avoid their attack on the
glands.
4. The gauge glass must have a rating equal to or more than the vessel design
pressure and temperature.
5. The maximum length of a single gauge glass shall not exceed 1400 mm. Where
large range is required, multiple gauges of preferably equal lengths shall be used
with 50 mm over lapping in visibility.
6. The visibility shall cover the operating level range and the maximum and
minimum ranges expected considering start up conditions as well as alarm and
shut down points. Internal heating shall be used for viscous liquids. Integral
illuminators shall be used for transparent gauges, if necessary.
7. Stand pipes shall be used for multi gauge glass and level controller
installation and on horizontal drum or exchanger with top and bottom
connections to have visibility of the complete span. The stand pipe shall not be
used with block valves.
8. Primary isolation valves shall be used In addition to the gauge glass valves unless
otherwise specified. When the process fluid may create lugging or leakage
problem, gauge valves may be omitted. For low temperature liquid having high
vapor pressure at ambient temperature, isolation and gauge valves shall not be
permissible. Safety valve shall be used at the vent connection of the gauge glass
where isolation is required.
9. For high pressure service such as boiler water etc., the gauge glass shall be multi
port illuminated type (Bi colour type). Indication of water space shall be
`green and indication of steam space shall be `red.
10. Bi colour level gauges shall have following features:
a) Temperature equalizing column expansion bend and chain patterned hand
wheel
b) Certification by Inspectorate of Boiler
14.12
Pressure/ Differential Pressure Switch

Table 14.10
Specification for Pressure/DP Switch
S.No.
Feature
Minimum Requirement
Piston for high pressure application
Bellow/Diaphragm for low pressure application
AISI 316 SS
AISI 316 SS
Epoxy coated Die Cast Aluminium
Black graduation on white linear scale.
Graduation 0 100% with red pointer for set
points.
Type
2
3
4

Wetted Parts material
Case Material
Setter Scale
Over range for Pressure /

Vacuum Switch
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
150% of maximum pressure
Description
Page
No.
Date of Issue
[192]
02.09.2015
S.No.
7
Feature
Set Point
Static Pressure for Differential

Pressure Switch
Adjustments
10
11
Process Connection
Switch Configuration
12
Switch Rating
13
Switch Type
14
Cable Connection
15
Enclosure Class
16
Accuracy
17
18
a)
b)
c)
d)
Repeatability
Accessories
[Logo of Utility]
Minimum Requirement
Adjustable throughout switch operating range.
Maximum Line Pressure or Static Pressure on
either side without permanent deformation or
loss of accuracy.
Internal set point
Differential adjustable feature
NPT(M) bottom connected
2 SPDT / 1 DPDT
230 V, 5A AC / 220 V, 0.25 A DC/24 V, 2A
DC
Snap acting, shock and vibration-proof
ET conduit connections or compression
gland
resistance coating.
1% of span up to 3Kg/cm2
0.5% of span for more than 3 Kg/cm2.
0.5% of span
Snubber for pulsating fluid application.
Tag Number, service engraved in SS tag plate
Teflon back-up sheath protection, as required.
i) Remote diaphragm seal with SS 316
armored capillary for typical application.
MOC of seal material shall be as per
process fluid requirement.
ii) Silver coated diaphragm for corrosive
services like chlorinated water.
Retention ring and screws for surface
mounting.
3-way Gauge Cock (SS 316) for PS / 5-Valve
Manifold (SS 316) for DPS.
Mounting bracket / Clamp for 2 pipe, bolt &
nut.
e)
f)
g)
1. The pressure switches shall have sensing elements made of copper alloy or
stainless steel sealed diaphragm and piston actuated for high pressure service
and bellows for low pressure / vacuum service.
2. Low differential pressure switches for low static pressure ranges shall be
diaphragm type with snap action switch elements.
3. Low differential pressure switches for high static pressure shall be elbows and
torque tube type and snap action switch elements and metric scale dial
indicators.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[193]
02.09.2015
[Logo of Utility]
4. For corrosive, viscous process fluids diaphragm sealed with completely filled
inert liquid shall be used. Material of diaphragm and wetted parts shall be
selected considering the nature of process fluid.
5. The sensing elements shall be properly aged and factory tested to remove all
residual stresses. They shall be able to withstand at least 150 % the full scale
pressure without any damage or permanent deformation.
6. Actuation set point, dead band shall be internally adjustable throughout the
range with tamper proof facilities.
7. Electrical connection for the switch devices shall be suitable for plug in type
connection.
8. Process connection shall be inch NPT. Process piping connections shall
include necessary union, nut, nipple, tail pipe, isolation valve and test connection
to permit servicing, testing, calibration and removal of the instrument device.
9. Instrument for steam & hot water service, shall be connected through siphon, of
stainless steel or suitable material. Pulsation dampeners shall be used for all
pulsating fluids.
10. Pressure switches shall be tested as per BS 6134.
14.13
Conductivity Type Level Switch

Table 14.11
Specification for Conductivity Type Level Switch
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Feature
Sensing elements
Material
Minimum Requirement
Conductivity type
SS 316
Repeatability
Accuracy
Working temperature
0.5 % of full range or better

0.5 % of full scale or better
As per process requirement
Probe length
Mounting
No. of contact
Enclosure
Housing
Ambient Temperature
Cable connection
As per requirement
Flanged- on external cage
2 NO. + 2 NC, SPDT, snap action type dry
contact
5A, 240 V AC / 2A, 24 V DC / 0.25 A,220V
DC
IP 65
Cast aluminum epoxy coated weather proof
60*C (max.)
Plug-in type
NPT with cable gland
Set point
Accessories
Adjustable
All mounting accessories
Rating of contacts
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[194]
02.09.2015
14.14
[Logo of Utility]
Capacitance Type Level Switch

Table 14.12
Specification for Capacitance Type Level Switch
14.15
S.No.
1
2
Feature
Type
Probe
Minimum Requirement
Capacitance type
Rod or Suspended Electrode
SS 316
Material
Insulation
5
6
7
8
9
Repeatability
Accuracy
Working temperature
Probe length
Probe Mounting
PTFE/PP/Kynar part/full as required
10
No. of contact
11
Rating of contacts
12
Enclosure

As per requirement
1 Flanged
contact
5A, 240 V AC / 2A, 24 V DC / 0.25 A,220V
DC
IP 65
13
14
15
16
17
14
Housing
Cable connection
Ambient Temperature
Accessories
Set point
Cast aluminum epoxy coated weather proof

NPT with Cable gland
60*C (max.)
Plug-in type
Counter flange, Cable gland, Prefab cable etc.
Adjustable
15
Accessories
Float/Displacer Type Level Switch

Table 14.13
Specification for Float/Displacer Type Level Switch
S.No.
1
2
3
4
5
7
8
9
10
Feature
Type
Float/Stem/Displacer Material
Minimum Requirement
Float/Displacer type
SS 316
Repeatability
Accuracy
Working temperature
Process connection
Over-range proof
No. of contact

As per requirement
150% of max. design pressure
contact
5A, 240 V AC / 2A, 24 V DC / 0.25 A,220V
Rating of contacts
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[195]
02.09.2015
S.No.
11
Feature
Enclosure
Hydro Test
12
13
14
Accessories
[Logo of Utility]
Minimum Requirement
DC
IP 65
Chamber 100% at 1.5 times rated pressure
or as per ANSI flange rating
Float 1.1 times of operating pressure
Plug-in socket
1. Level Switch shall work on gland less magnetically coupled float or displacer
operated mechanism having separate float chamber.
2. Float, stem and displacer shall be 316 stainless steel.
3. Level switch body, cage and process connections shall be designed to withstand
the maximum pressure and temperature of the operating fluid.
4. A setting adjustment on the level set point of + / - 25 mm shall be used. The
adjustment shall be made externally to the switch.
5. The accuracy & repeatability of the switch shall be within +/- 0.5 % of full-scale
range. On Off differential shall be adjustable.
6. Process connections of the cage shall be 25 NB male plain nipples connected
through socket / welded isolation valves of adequate rating.
7. Level switch connections shall also include 15 NB test and drain connections to
permit servicing, testing, calibration of the instrument.
8. The switching elements shall be snap-acting, shock-proof and vibration-proof. All
switches shall have two electrically isolated SPDT contacts with provision of
external adjustment of set points and
dead bands. The contact ratings shall
be 5 amps at 240 V AC 50 Hz or 0.25 amps at 220 V DC.
9. Switch enclosures shall be cast aluminium, weather-proof, NEMA -4X type with
cable entry through compression type cable glands / NPT conduit
connections. Switches located in hazardous areas shall have dust-ignition-proof
enclosure as per NEC article 500 provisions.
14.16
Ultrasonic Level Transmitter

Table 14.14
Specification for Ultrasonic Transmitter
S.No.
Feature
Minimum Requirement
Application
Level measurement in silos, sump water level

etc.
Medium
Coarse, hard solid materials like ash etc.

Materials may be slowly falling through the
detection range.
Type
Non contact Microprocessor based 2 wire

type, HART protocol compatible Ultrasonic
Transmitter
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[196]
02.09.2015
S.No.
[Logo of Utility]
Feature
Minimum Requirement
Principle
Time of flight
Sensor Material
Corrosion resistant material to suit individual

application requirement.
False signal tolerance
Transmitter shall be capable of ignoring false

echoes
from
internal
tank
/
sumps
obstructions such as pipes, heating coils or
agitator blades. Also transmitters shall have
adjustable damping circuitry.
Range
Capable of covering the complete level span

of tank/vessel taking care of blocking
distance, frequency, attenuation due to
surface, obstructions, vapours etc.
Output
4 20 mA DC with 600 ohms load with

HART compatibility.
Display
minimum 4 characters display with Integral

keypad, access protected by user code.
10
Diagnostics
Loss of echo alarm etc.
11
Resolution
+/- 0.1 % of range or better
12
Accuracy
+/- 2 mm or 0.2% of span
13
Repeatability
3 mm or better
14
Operating temperature
0 to 600 C
15
Power supply
24 V DC + / - 10 %
16
Mounting
Flanged connection at top of covers / side

walls as per requirement.
17
a)
All weather canopies for protection from

direct sunlight and direct rain.
b)
For hazardous areas, explosion proof

enclosure as per NEC article 500 shall be
used.
c)
All mounting hardware and accessories

required for erection and commissioning.
Mounting fittings material shall be SS
316.
Accessories
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[197]
02.09.2015
[Logo of Utility]
1. The power and frequency of transmission for the transmitter shall be selected to
assure a sufficient signal / noise ratio.
2. The transmitter shall be designed with an electronic circuit having the features
such as temperature compensation, rejection of unnecessary echoes and noises
and adjusting zero and span. It shall consist of sensors, electronic unit and
accessories.
14.17
Guided Wave Radar Type Level Transmitter

Table 14.15
Specification for Guided Wave Radar Type Transmitter
S.No.
Feature
Minimum Requirement
Application
Level measurement of vessel under vacuum or

low pressure application
Type
Guided wave radar
Principle
TDR (Time domain reflectrometry)
Probe Material
SS 316
Accuracy
5 mm or better
Resolution
+/- 0.1 % of range or better
Signal Output
4 20 mA DC with 600 ohms load with HART

compatibility
Power Supply
24 V DC + / - 10 %
10
Display
Integral
11
Mounting
External cage type
12
Transmitter
housing
Protection Class
IP-65 with corrosion resistance coating
13
a)
All weather canopies for protection from

direct sunlight and direct rain.
b)
For hazardous areas, explosion proof

enclosure as per NEC article 500 shall be
used.
Accessories
c)
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
All mounting hardware and accessories

required for erection and commissioning.
Mounting fittings material shall be SS 316.
Description
Page
No.
Date of Issue
[198]
02.09.2015
14.18
[Logo of Utility]
Flow Switch
Table 14.16
Specification for Flow Switch
S.No.
1
2
3
4
5
7
8
9
10
11
12
13
14
14.19
Feature
Type
Vane/bellow Material
Repeatability
Accuracy
Working temperature
Process connection
Over-range proof
No. of contact
Rating of contacts
Enclosure
Cable connection
Accessories
Minimum Requirement
Vane actuated/Differential bellow type
SS 316
As per requirement
contact, shock & vibration proof
5A, 240 V AC / 2A, 24 V DC / 0.25 A,220V
DC
Cast Aluminium/IP 65
Compression type cable gland/ NPT
Conduit connection
Plug-in socket
Rotameter
Table 14.17
Specification for Rotameter
S.No.
1
2
3
4
5
6
7
8
9
Feature
Type
Fluid media
Float Material
Minimum Requirement
Variable area Linear scale
Water/Oil
SS 316
Accuracy
Working temperature
Process connection
Over-range proof
Enclosure
Accessories
2 % of full scale or better

0 to 70*C
As per requirement
Transparent toughened glass/IP 65
Flange, orifice in case of bypass Rotameter
Rotameter shall be used for low flow & low viscosity applications of liquid.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[199]
02.09.2015
14.20
[Logo of Utility]
Sight Glass Indicator (Flow Glass)

Table 14.18
Specification for Flow Glass
S.No.
1
Feature
Application
Type
Size
3
4
Body Material
Glass
Minimum Requirement
Online observation of fluid flow in Pipeline
Double window for pressurized pipe with
rotary wheel for installation in horizontal or
vertical pipeline.
Full view for non-pressurized pipeline.
Double window up to 12 and 600 lbs
rating.
Full view up to 6 and 150 lbs rating.
SS 316
Pyrex tempered glass
Rotor & wetted parts shall be bronze
All accessories shall be SS316
IP-65
Screwed up to 50 NB size
Flanged ANSI 150 RF above 50 NB size
Name plates, mating flanges with gasket,
bolts & nuts etc.
Others
14.21
Protection class
Connection
Accessories
Flow Elements
a) Orifice Plate
Table 14.19
Specification for Orifice Plate
S.No.
Feature
Minimum Requirement
Concentric as per ASME PTC 19.5 (Part III);
ISA RP 3.2, 960; BS 1042; ISO 5167
SS 316
Type
Material
Thickness
3
4
5
6
7
8
Beta ratio
Tappings
Material of Branch Pipe
Root Valve type
Root Valve material
Root Valve size
Accessories
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
3 mm for main pipe diameter up to 300 mm

and 6 mm for main pipe dia above 300 mm.
0.34 to 0.7
Flanged weld neck 3 pairs of tappings.
Same as main pipe
Globe
SS 316
1
Root valves, flanges, vent / drain hole (as
required)
Description
Page
No.
Date of Issue
[200]
02.09.2015
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1. Each orifice plate shall be used with a handle on which the orifice diameter, pipe
diameter and pressure tap distances are stamped. This information shall be so
located that it can be read without removing the orifice plate from pipe line.
2. The standard primary element shall be thin plate, square-edge concentric orifice
plate mounted between a pair of weld-neck type orifice flanges with flange taps.
The minimum pressure rating of flanges shall be 300 pounds ANSI. The material
of the orifice plates shall be SS 316 in general. Orifice plates shall be not less
than 3 mm thick for nominal pipe diameters up to and including 300 mm, and
not less than 6 mm thick above 300 mm NB pipe.
3. Quadrant edge or quarter circle orifice plates shall be used for highly viscous
liquids and for pipe Reynolds Number below 10,000. Conical entrance type of
orifice plates shall preferably be used for very highly viscous liquids up to
Reynolds Number below 250. Vent and drain holes shall be used wherever
necessary.
4. Orifice diameter shall be selected, so that d/D ratio is between 0.20 to 0.70 for
gas and steam and up to 0.75 for liquids.
5. Metering orifices shall not be installed in lines less than 1 (40 mm) the lines
shall be blown to the 1 (40 mm) size for the meter run, keeping the d/D
ratio within limits.
6. Restriction orifices and integral orifice transmitters do not require upstream or
downstream straight pipe runs.
7. The orifice plate shall be supplied and fitted in conformity with ISO. When the
pipe diameter is larger than the value specified in ISO, the restriction ratio shall
be decided by extending the specific curve externally.
8. The length of straight pipe run required for metering accuracy shall be in
conformity with ISO. When it is extremely difficult to comply with the standard,
a minimum straight length of 1OD (D = pipe inner diameter) on the upper stream
and a minimum length of 5D on the downstream shall be considered.
9. All orifice plates shall be supplied with matching flanges of material and pressure
rating not less than the rating of the associated pipe system.
10. For pipeline sizes of 500 mm and less, the orifice plates shall be an integral unit
comprising of carrier ring assembly, tapping arrangement on both upstream as
well down stream side. For line sizes more than 500 mm, the orifice plate shall
be disc type. For disc type orifice plate, suitable corner tapping arrangement on
both upstream as well as downstream side shall be used. All tapping
arrangements shall be complete with a piece of impulse pipe line and a shut off
valve suitable for specified line pressure.
11. For steam applications, orifice plate shall be supplied with a pair of steam
condensation chambers suitable for specified line pressure.
12. Data sheets, sizing calculation, fabrication & sheets for the elements shall be
submitted for approval and finalization.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[201]
02.09.2015
[Logo of Utility]
b) Flow Nozzle
Table 14.20
Specification for Flow Nozzle
S.No.
Feature
Type
2
3
3
4
Material
Thickness
Beta ratio
Tappings
Minimum Requirement
Long Radius welded type ASME PTC 19.5
(Part III) or BS 1042
Same as Pipe material
Suitable for intended application
Around 0.7
D and D/2 (3 nos. tappings)
5
6
7
8
9

Root Valve type
Root Valve material
Root Valve size
Accessories
Same as main pipe

Globe
SS 316
1
Root Valves, Vent & Drain Hole
1. The branch pipes for holding the flow nozzle shall also be furnished along with
the flow nozzle.
2. Flow nozzles in high pressure pipes shall be subject to a test according to DIN
50049, 3.1C, considering the technical guideline. The test of flow nozzles shall
contain:
a) Check of drawings
b) X-ray testing of the circular bead or colour soaking or ultra-sonic testing
c) Test of sizes.
3. Flow nozzle shall be used with a permanent mark indicating:
a) Measuring point number
b) Direction of flow
c) Plus and minus tapping
d) Material
Moreover, the actual inside pipe diameter D and the diameter of the flow nozzle
shall be stated on the identification plate.
4. The supplier shall provide the following documents:
a) Design drawings of the flow nozzle
b) Calculation documents
c) Fabrication, assembly and installation drawings
d) Test reports.
5. For measurements of steam, balancing vessels shall be used. Balancing vessels
shall be used for flow measurement in steam system based on the differential
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[202]
02.09.2015
[Logo of Utility]
pressure method to ensure a defined water column. The balance vessels shall be
arranged on the same geodetic level. If this is not possible for design reasons,
the level difference shall be taken into account during calibration
c) Venturi
Table 14.21
Specification for Venturi
S.No.
14.22
Feature
Minimum Requirement
1
2
3
4
5
6
Design standard
Material
Type
Mounting
Root Valve type
Root Valve material
BS 1042/ISO5167
SS 316
Fabricated Machine Cast
Flanged
Ball
SS 316
Root Valve size
Accessories
1/2
All
required
mounting
accessories
&
piezometric ring with 4 nos. tappings for
choke removal & screwed cap/plug on the ring
Oxygen Analyzer
Table 14.22
Specification for Oxygen Analyzer
S.N
1
2
3
4
5
Feature
Minimum Requirement
In-situ Heated type
Partial pressure using Zirconium oxide cell
Zirconium Oxide cell
0.01 to 10 % O2
+/- 0.2 % of full scale
Type
Principle
Sensor Type
Measurement Range
Accuracy
6
7
Linearity
Response time
Drift
9
10
11
12
13

Temperature compensation
Sample filter
Ambient Temperature
14
15
Indication
Enclosure Type/Material
16
Type of Electronics
17
Calibration
18
Output signals
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
+/- 1% of full scale

3 seconds or less (Up to 90% of full scale )
+/- 0.005% per 2 Deg. Centigrade temp.
change
0-1600 *C
Automatic
Ceramic 3.5 micron
Required
60*C
Digital
Weather & Dust proof IP-65/ SS 316
Microprocessor based with self diagnostic
facility
Auto & manual
Analog: 4-20 mA DC
Binary: 2 NO + 2 NC for Alarms
Description
Page
No.
Date of Issue
[203]
02.09.2015
S.N
14.23
Feature
19
Digital Signal transmission
20
Other requirement
[Logo of Utility]
Minimum Requirement
RS-232 or RS-485 OR as per requirement to
suit connection protocol of Plant DCS
HART Communication protocol compatibility &
suitable for connection to Smart Transmitter
Maintenance system.
Purging System
Carbon Monoxide Analyzer

Table 14.23
Specification for Carbon Monoxide Analyzer
S.N
Feature
Minimum Requirement
1
2
3
4
5
6
Type
Principle
Sensor Type
Measurement Range
Accuracy
Linearity
In-situ type
IR Double beam absorption
IR
0-999 ppm selectable
+/- 0.2 % of full scale
+/- 1% of full scale
Response time
Drift
3 seconds or less (Up to 90% of full scale )

+/- 0.005% per 2 Deg. Centigrade temp.
change
0-1600 *C
Automatic
Ceramic 3.5 micron
Required
60*C
Digital
9
10
11
12
13
14

Sample filter
Ambient Temperature
Indication
15
16
Type of Electronics
17
Calibration
18
Output signals
19
20
Other requirement
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Weather & Dust proof IP-65/ SS 316

facility
Auto & manual
Analog: 4-20 mA DC
Binary: 2 NO + 2 NC for Alarms
RS-232 or RS-485 OR as per requirement to
suit connection protocol of Plant DCS
HART Communication protocol compatibility &
suitable for connection to Smart Transmitter
Maintenance system.
Purging System.
Description
Page
No.
Date of Issue
[204]
02.09.2015
[Logo of Utility]
14.24
Control Valves
14.24.1
Introduction
The control valves and accessories equipment furnished by the Supplier shall be
designed, constructed and tested in accordance with the latest applicable
requirements of code for pressure piping ANSI B 31.1, the ASME Boiler &
Pressure Vessel code, Indian Boiler Regulation (IBR) & ISA or acceptable equal
standards.
14.24.2
Control Valve Design & Sizing

The design of all valve bodies shall meet the specification requirements and shall
conform to the requirements of ANSI for dimensions, material thickness and
material specification for their respective pressure classes.
The valve sizing shall be suitable for obtaining maximum flow conditions with
valve opening at approximately 80% of total valve stem travel and minimum
flow conditions with valve stem travel not less than 10% of total valve travel.
All the valves shall be capable of handling at least 120% of the required
maximum flow. Further, the valve stem travel range from minimum flow
condition to maximum flow condition shall not be less than 50% of the total
valve stem travel. The sizing shall be in accordance with the latest edition of ISA
Handbook on control valves. While deciding the size of valves, Supplier shall
ensure that valves outlet velocity does not exceed 8 m / sec. for liquid services,
150 m/sec. for steam services and 50% of sonic velocity for flashing services.
Manufacturer shall furnish the sizing calculations clearly indicating the outlet
velocity achieved with the valve size selected by him as well as noise
calculations.
Control valves for steam and water applications shall be designed to prevent
cavitations, wire drawing, flashing on the downstream side of valve and
downstream piping. Thus for cavitations / flashing service, only valve with anticavitations trim shall be used. Detailed calculations to establish whether
cavitations shall occur or not for any given application shall be furnished.
Trim shall be multistage type having sufficient number of discrete pressure drop
turns (stages) to ensure elimination of vibration, erosive action, cavitations.
Identity the number of pressure drop turns in the given equipment and shall also
provide calculation demonstrating compliance to the trim exit velocity.
To prevent flow induced vibration and to protect the valve internals from foreign
particles such as weld slag flow, direction shall be a flow to close (over the plug)
configuration for liquid applications. To maximize noise attenuating benefits and
to allow for constant fluid expansion, flow direction shall be under the plug for
steam and gas applications.
Control valves for application such as SH spray control, RH spray control, Heavy
oil pressuring & control system shall have permissible leakage rate as per leakage
class V. All other control valves such as low and high range feed control valves
etc shall have leakage rate as per leakage class IV.
1.
2.
3.
4.
5.
6.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[205]
02.09.2015
14.24.3
14.24.4
[Logo of Utility]
7. The control valve induced noise shall be limited to 85 dBA at 1 meter from the
valve surface under actual operating conditions. The noise abatement shall be
achieved by valve body and trim design and not by use of silencers.
8. The characteristic of the control valves shall be determined based on the
application / service.
9. On supply air or electrical failure for pneumatic / electrical drive, the valve shall
remain full closed, open or stay put position as per process safety requirement.
Valve Construction
1. Proper selection of valve type and material of construction to meet operating
requirement.
2. All valves shall be of globe body design and straightaway pattern with single or
double port unless otherwise recommended by the manufacturer to be of angle
body type. Rotary valve may alternatively be offered when pressure or pressure
drops permit.
3. Valves with high lift cage guided plugs & quick charge trims shall be supplied.
4. Cast iron valves are not acceptable.
5. Bonnet joints for all control valves shall be of the flanged and bolted type for
easy dis-assembly. Bonnet joints of internal threaded or union type shall not be
acceptable.
6. Plug shall be of one piece construction either cast, forged or machined from
solid bar stock. Plug shall be screwed and pinned to valve stems or shall be
integral with the valve stems.
7. All valves connected to vacuum on down stream side shall be used with packing
suitable for vacuum applications (e.g. double vee type chevron packing).
8. Valve characteristic shall match with the process characteristics.
9. Extension bonnets shall be used when the maximum temperature of flowing fluid
is greater than 280 degree celcius.
10. Flanged valves shall be rated at not less then ANSI pressure class of 300 lbs.
11. Teflon shall be used for valve gland packing to suit process requirement.
12. The valve body shall be marked to show direction of flow.
Valve Materials
1. The control valve body material shall be
a) Carbon steel as per ASTM A216 GR WCB for non corrosive, non
flashing and non cavitations services below 275 deg c temperature like
Auxiliary Steam flow to Deaerator, CRH flow to Deaerator, Condensate flow
to Deaerator etc.
b) Alloy steel as per ASTM A217 GR WC 9 for severe flashing / cavitations
services like low load and full load feed water control, HP and LP heaters
emergency drains, Deaerator overflow drain to Hotwell etc.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[206]
02.09.2015
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c) Alloy steel as per ASTM A 217 GR WC 6 for low flashing / cavitations

services like HP heaters & LP heaters normal drain control, drain cooler
normal level control, gland steam cooler minimum flow etc.
d) 316 SS for condensate service below 300 deg C like condensate normal and
emergency make up controls etc.
2. The control valve trim material shall be
a) 17 4 PH SS for severe services listed under item D.1, 2nd point & 3rd
point above
b) 316 SS for services listed at D.1, 4th point above and
c) 316 SS with stellite faced guide parts and bushings for remaining
applications.
14.24.5
14.24.6
1.
2.
3.
4.
5.
6.
End Preparation
Valve body ends shall be either butt welded / socket welded, flanged or
screwed. The welded ends wherever required shall be butt welded type as per
ANSI B 16.25 for control valves of sizes 65 mm and above. For valves sizes 50
mm and below welded ends shall be socket welded as per ANSI B 16.11.
Flanged ends wherever required shall be of ANSI pressure temperature class
equal to or greater than that of the control valve body.
Valve Actuator
The regulating control valves shall be furnished with pneumatic actuators. The
supplier shall be responsible for proper selection and sizing of valve actuators in
accordance with the pressure drop and maximum shut off pressure and leakage
class requirements. The valve actuators shall be capable of operating at 60 *C
continuously.
Valve actuators and stems shall be adequate to handle the unbalanced forces
occurring under the specified flow conditions or the maximum differential
pressure specified. An adequate allowance for stem force, at least 0.15 kg / cm2
per linear millimeter of seating surface, shall be used in the selection of the
actuator to ensure tight seating unless otherwise specified.
The travel time of the pneumatic actuators shall not exceed 10 seconds.
For quick opening / closing services (such as fuel oil shut off valve), the
actuator shall be pilot solenoid operated pneumatic drive; the rating of solenoid
shall be 24 V DC.
Selection of actuator shall be such that it meets the requirements of thrust /
torque, stroke length, angular movement, full scale travel time, repeatability &
accurate positioning for successful operation of final control element.
All the actuators shall have also provision for manual operation during emergency
/ maintenance along with graduated local position indicator.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[207]
02.09.2015
14.24.7
[Logo of Utility]
Control Valve Accessory Devices

All control valve accessories such as air locks, hand wheels / hand-jacks, limit
switches, SMART positioners, diffusers, external volume chambers, reversible
pilot for positioners, tubing and air sets, solenoid valves and junction boxes etc.
shall be used as per the requirements.
Table 14.24(i)
Specification for E-to-P converter
S.N
1
2
3
4
5
6
7
8
9
10
Feature
Air Supply
Input Signal
Output Signal
Linearity
Hysteresis
Ambient Temperature Effect (
-20 to +60 *C)
Mounting
Minimum Requirement
1.5 Kg/Sq. cm
4-20 mA DC
0.2 to 1.0 Kg/ Sq. cm
Protection class
Enclosure
Drift
IP-65
Die cast Aluminium
+/- 2% of set point per hour
<0.2 % of span per Degree centigrade

Close to Actuator
Table 14.24(ii)
Specification for Smart Positioners
S.No.
1
2
Feature
Input
Power Supply
Type of Electronics
Valve position sensing
Ambient conditions
Operating Range
Modes of operation
Flow characteristics
10
Fail safe/Freeze feature
11
Air Capacity
12
Air supply pressure
13
14
Process Connection
Characteristic Deviation
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Minimum Requirement
4-20 mA DC
24 V DC Loop powered
facility & digital communication by means of
HART Protocol
Non-Contact type with 4-20 mA DC Output
Weather & Dust proof to IP-65/ Die cast
Aluminium
Suitable for - 30 to +80 *C temperature & 095% Humidity
Suitable for Full range & Split Range operation
Suitable for Direct & reverse valve action
Suitable for Linear & Equal percentage
Characteristics
Required
Sufficient
to
handle
the
Valves
Selected/Boosters to be supplied if required.
To suite the Air Supply Pressure / Quality
available
1/4 NPT
< =0.5% of span
Description

Page
No.
Date of Issue
[208]
02.09.2015
S.No.
15
Feature
Ambient Temperature effect
16
Configuration
17
Cable Entry
18
Accessories
[Logo of Utility]
Minimum Requirement
<=0.01%/Deg C or better
Remote
Calibration,
Auto
&
Manual
Calibration shall be possible
NPT, Side or Bottom Entry to avoid
water ingress
Display
with
push
buttons
for
configuration and Display on the
a)
positioner itself (Password Protected /
Hardware Lock).
For Supply & Output Pressure, Filter
Regulator and other accessories shall be
b)
used as on required basis for making
system complete
Valves Mounting Assembly For Sliding
c) Stem / Rotary / Single Acting / Double
Acting on required basis
1. SMART positioner shall be a Double stage positioner. The first stage of the
positioner shall be typically a flapper-nozzle that serves as a high-gain preamplifier. This sensitivity shall be maintained over a wide range of dynamic
conditions. Second stage shall be a power amplifier that provides power to drive
the actuator. Preferably this shall be a pneumatic relay. Spool Driven type
SMART positioners are not preferred due to Higher Dead Band and Poor
responsiveness. The SMART positioner shall have pressure sensors to measure
the pneumatic outputs to the actuator.
2. The control algorithm for the positioner shall use feedback signal from the
motion of the pneumatic relay beam instead of pressure feedback to minimize
pneumatic related effects and for stable and smooth response of the control
valve. The SMART positioner shall have user adjustable tuning sets to identify
the optimum tuning for the total valve assembly. SMART Positioner with HART
Communication facility shall communicate all the valve diagnostics to Plant DCS.
Table 14.24(iii)
Specification for Air Filter Regulator (AFR)
S.No.
1
2
Feature
Type
Inlet Pressure
Output
4
5
6
Filter Element
Filter Element Material
Bowl Material
Drain
Material
Process connection
8
9
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Minimum Requirement
Constant Bleed type
10 Kg/Sq. cm (maximum)
Adjustable from 0-2 Kg/Sq. cm or 0-7 Kg/Sq.
cm (Continuous) as required
5 microns
Phosphor Bronze
Metallic
Automatic
class/
IP-65/ Die cast Aluminium

NPT
Description
Page
No.
Date of Issue
[209]
02.09.2015
S.No.
10
Feature
[Logo of Utility]
Minimum Requirement
All mounting accessories.
2 dial size Pressure gauge.
Accessories
Table 14.24(iv)
Specification for Position Transmitter
S.No.
1
2
3
4
5
Feature
Power Supply
Type
Output
Minimum Requirement
24 V DC Loop powered
Non-Contact/ LVDT type
4-20 mA DC/ Linear
Accuracy
Enclosure
Material
+/- 1%
Cable Entry
Accessories
Protection
class/
IP-65/ Die cast Aluminium

NPT, Side or Bottom Entry to avoid
water ingress.
Table 14.24(v)
Specification for Limit Switch (Non Contact Type)
S.No.
14.24.8
Feature
Type
2
3
Sensing distance
Hysteresis
4
5
6
7
8
Indicator
Protection class
Integral Cable
Power supply
Mounting
Other Feature
Minimum Requirement
Non-contact type inductive Proximity/Namur
type
10 mm minimum
Maximum 10% of sensing distance
LED indication
IP 67
1 mtr.
24 V DC/ 8 V DC
Flush mounting with check nut
Explosion proof enclosures shall be used
wherever required by the application.
Shock & Vibration proof.
Test & Examination

1. All valves shall be tested in accordance with the quality assurance programme
agreed which shall meet the requirement of IBR and other applicable codes.
2. The tests shall include but not but limited to the following:
a) Non-destructive test as per ANSI B 16.34.
b) Hydrostatic shell test in accordance with ANSI B16.34 prior to seal leakage
test.
c) Valve closure test and seal leakage test in accordance with ANSI B16.34 and
as per the leakage class indicated under clause no. B.6.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[210]
02.09.2015
[Logo of Utility]
d) Functional test: The fully assembled valves including actuators control

devices and accessories shall be functionally tested to demonstrate times
from open to close position.
e) All control valves shall be tested with the positioners for accuracy of
positioning and reproducibility over the full range of travel.
f) CV Test: CV test shall be carried out as type test on each size, type and
design of the valves as per AISA 75.02 standard.
g) Magnetic particle inspection shall be performed on all machined surfaces of
valves having ASA rating of 1500 lbs ASA or greater. All carbon steel valves
with 1500 lbs ASA or greater shall receive 100% radio graphic examination
in accordance with ASTM E71.
14.24.9
3. The certificate shall be in the prescribed forms III A & III C and shall be endorsed
by an Inspection Authority recognized by the Indian Boiler Regulations.
Pneumatic Power Cylinder
Table 14.25
Specification for Pneumatic Power Cylinder
S.No.
1
2
Feature
Applicable standard
Mounting Type
Cylinder
Piston rod
Tie rod
End Cover
Sealing
Material
Control Signal
5
6
7
8
Supply Air
Accuracy
Repeatability
Hysteresis
Dead Band
10
Selection
11
Accessories
12
Fail safe operation
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Minimum Requirement
ISO 6431
Fixed Position mounting/ Trunion mounting
Seamless Steel Tube
Hard Chrome Plated Steel
Stainless steel
Cast Iron
Polyurathane
4-20 mA DC signal to Smart positioner with
HART protocol for modulating purpose.
Solenoid valve operating on pneumatic line for
open & closing purpose of ON-OFF Damper.
0-7 Kg/cm2
Better than +/- 1%
Better than 0.5 % of full travel
Less than +/- 0.2% of full travel
+/- 0.1%
Based upon thrust/torque, stroke length,
angular movement, full scale travel time,
repeatability, space factor etc. Provision for airto-open or air-to-close operation
Air lock relay, hand wheel, AFR, Volume
booster, Limit switch, Positioner, Solenoid valve,
position transmitter & all required mounting
accessories etc.
Stay put for regulating duty
Description

Page
No.
Date of Issue
[211]
02.09.2015
14.25
[Logo of Utility]
Solenoid Valves
Table 14.26
Specification for Solenoid Valves
14.26
S.No.
1
Feature
Operating Principle
Coil Voltage Rating
3
4
5
6
Ways
Port size
Body
Trim
Minimum Requirement
Electromagnetic (noiseless), Pilot operated
24 V DC (in general)/220 V DC/230 V AC/
110 V AC as required
3 ways in general others as required
NPT all ports
SS Bar stock/Brass
AISI 316 SS
7
8
9
10
11
12
Manual Operation
Duty
Sealing
Coil Enclosure
Insulation class
Coil Casing
In built
Suitable for continuous Energisation
Airtight & leak proof
SS 316/Moulded type
Class H
IP-67
13
14
15
16
Mounting
Cable connection
Accessories
Other Features
Suitable for mounting On pipe or in panel

NPT Cable gland
Mounting Bracket, nuts, bolts etc.
LED Indication
Dew Point Meter

Table 14.27
Specification for Dew Point Meter
S.No.
Feature
Type
2
3
Accuracy
Repeatability
Minimum Requirement
Sensor- Hyper Thin Film high capacitance
Al2O3, Transmitter- Microprocessor based 2wire loop powered
5.5F (3C)
0.9F(0.5C
4
5
6
7
8
9
Storage temperature
Local Indication
Input Resolution
Power Supply
Output
Enclosure material
-40F to +176F (-40C to +80C)

To be provided
0.1C dew point
24 VDC
4 - 20mA
Die cast Aluminium
10
11
12
13
Enclosure protection
Electrical connections
Process connection
Accessories
Weatherproof IP 65
NPT
As per requirement
All required mounting accessories.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[212]
02.09.2015
14.27
[Logo of Utility]
Speed Probe
Table 14.28
Specification for Speed Probe
S.N
1
2
14.28
Feature
Type
Frequency Response
Minimum Requirement
Proximity type (inductive / NAMUR)
0-10 KHz
3
4
5
6
Housing
Sensing distance
Enclosure class
Power supply
SS 316/ Polyurethane tip

10 mm minimum (2mm for embedded type)
IP67
24 V DC/8 V DC (for NAMUR)
Cable
Integral Cable 6 mtr.
Mounting
Flush with check nut
Accessories
Flexible conduit, Non-conductive mounting

plates etc.
Speed Transmitter
Table 14.29
Specification for Speed Transmitter
S.No.
1
14.29
Feature
Type
Minimum Requirement
Microprocessor based Programmable
2
3
4
5
6
Accuracy
Power Supply
Range
Resolution
IP-67
+/- 1 RPM
24 V DC
Programmable
0.1 RPM
Output
4-20 mA
Input signal
Pulse Input from Proximity Probe
Display
LCD display
Flow/No Flow Detector Switch

Table 14.30
Specification for Flow/No Flow detector switch
S.No.
1
2
3
4
Feature
Operating Principle
Detection Range
Power Supply
Housing
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Minimum Requirement
Microwave
Adjustable
230 V AC, 50 Hz
SS 316
Description

Page
No.
Date of Issue
[213]
02.09.2015
S.No.
5
[Logo of Utility]
Feature
Protection Class
Minimum Requirement
IP 67
Output
Potential free contact output
Contact Rating
5A, 240 V AC; 0.5A, 220 VDC
Time
delay
Changeover
Accessories
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
for
contact
Adjustable
All required mounting accessories
Description
Page
No.
Date of Issue
[214]
02.09.2015
15.
[Logo of Utility]
PROCESS CONNECTION PIPING

Installation and testing of all required material for completeness of impulse piping
system, sample piping system and air piping system as per the requirements of
this clause on as required basis for the connection of instruments and control
equipment to the process and make the system complete.
Control and instrument piping & connections shall generally be designed in
accordance with the following criteria and these criteria shall be closely coordinated with Mechanical Piping / Erector to fulfill the Mechanical Design
Criteria also. This is a guideline for Piping design & selection.
1. Pressure connections and piping up to the root valves for all pressure indicators,
pressure switches, pressure transmitters, etc., shall be as indicated for
miscellaneous piping.
2. Temperature indicators, temperature controllers, temperature switches, temperature detectors, and test well connections shall be as follows:
a) Main steam
--
40 mm NPT.
b) Extraction steam
--
40 mm NPT.
c) Boiler feed water
--
32 mm NPT.
d) Reheat steam
--
40 mm NPT.
e) All others
--
19 mm NPT.
3. Draft pressure connections on steam generator walls and ducts shall be 50 mm

pipe couplings.
4. Flow transmitter connections and piping up to the root valves shall be 25 mm for
all piping except orifice flanges, where 15 mm piping and valves shall be used.
5. Level switch connections and piping up to root valves shall be 25mm.
6. Level controllers and level transmitters of the displacement type shall have connections and piping up to root valves of 50 mm.
7. Level controllers and level transmitters of the differential pressure type shall have
connections and piping up to root valves of 25 mm.
8. Instrument columns at tanks and pressure vessels shall generally be 65 mm
minimum.
15.1
Design Pressure and Temperature

Instrument primary piping design pressure and temperature shall be selected
consistent with the requirements discussed in Mechanical Design Criteria of this
specification, for the process pipe to which the instrument primary piping is
connected. The following general criteria shall also apply:
Instrument primary piping for steam and other systems shall be designed for 1-
times the maximum sustained process pressure and temperature (plus 20 C).
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[215]
02.09.2015
15.2
[Logo of Utility]
Sizes of Instrument Primary Piping

Instrument primary piping shall not be smaller than the connection at the process
pipe root valve and/or the following (metric sizes are nominal):1. 20 mm for pressure measurement piping with a design pressure equal to or less
than 42.0 bar and a design temperature equal to or less than 400 C.
2. 25 mm for pressure measurement piping with a design pressure greater than
42.0 bars or a design temperature greater than 400 C.
3. Flow and level measurement by differential pressure shall also use primary piping
conforming to the above requirements; however, flange tap connections may be
of 13 mm size.
4. Float actuated level switch devices shall be supported on connecting piping not
smaller than 25 mm.
5. Level controllers and transmitters of the displacement float type shall be
supported on connecting piping not smaller than 50 mm.
6. Instrument columns for float actuated level switches and displacement float
devices shall be piping of not less than 65 mm.
7. Primary piping internal diameter shall not be less than 8 mm between the
process connection and instrument blow down valve.
15.3
Materials for Instrument Primary Piping

Material for instrument primary piping connecting to the root valve shall
preferably be the same as that used in the process system to which it is
connected. Higher strength materials may be substituted in the interest of
standardization; however, welding procedures at the point of joining the
instrument primary piping to the process piping must be appropriate to the
combination of materials involved. Copper may be used only for compressed air
services that use copper process piping.
15.4
Insulation of Instrument Primary Piping

Instrument primary piping connecting to high temperature systems, which might
become hot enough to injure personnel during blow down of the instrument line,
shall be insulated where such hazard exists. Insulation materials, exterior finish,
and metal lagging shall conform to the standards adopted for the process piping.
All materials supplied shall be suitable for intended service, process operating
conditions and type of instruments used and shall fully conform to the
requirements of this specification.
15.5
Process Connection Size

Size of tapping point, stub no and size of Root valves for different type of
measurements.
These shall be as follows:
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[216]
02.09.2015
[Logo of Utility]
Table 15.1
Process Connection Stub & Root valve
S.No.
Quantity of
root valves
(Nos.)
Size of stub and root

valves
Service condition
A. Pressure and Differential pressure measurement

1
25NB
>=62 bar or 425degree C
15NB
<62 bar and 425 degree C
25 NB
>= 62 bar or 425 degree C
2
1
25NB
C. Level Transmitter (Displacement Type)
B. Level Gauge and Switch

1
40NB
40NB
D. Stand pipe for Level measuring instrument

1
80 NB
80 NB
25NB
25NB
E. Flow measurement
1
F. Level measurement
1
G. Sampling system measurement (system and water service)

1
25 NB
25 NB
Document Number
Rev
No.
Description
LII-GETS12021-G-00129-001
03

Page
No.
Date of Issue
[217]
02.09.2015
15.6
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Impulse Piping, Tubing, Fittings, Valves & Valve Manifolds

All impulse pipes shall be of seamless type conforming to ANSI B36.10 for
schedule numbers, sizes and dimensions etc. The material of the impulse pipe
shall be same as that of main process pipe. For various applications specification
of impulse pipe materials and associated fittings and valves shall be as given in
Table 15.2 (Process Connection Piping).
Table 15.2
Process Connection piping
Size
S.No.
Service
Pipe
2.
5.
6.
Impulse
tube
material
Main
steam/
Saturated
steam
Boiler Fuel
Gas/Air
System
Water
system
Instrument
air system
Service air
system
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
SCH.XX
S
21.34m
m OD
Impulse
tube
material
Impulse
line fitting
material
valves
material
ANSI
rating
ANSI
Rating
Tube
1.7 mm
ODX
1.65HK
SS 316
SS 316
(pipe
through
out)
12.7 mm
ODX
1.65mm
THK
SCH.40
21.34m
m
OD(pipe
through
out)
12.7 mm
ODX
1.65mm
THK
SCH.40
21.34m
12.7 mm
ODX
ASTM-A182-Gr-F22
9000 LBS
2500
SPL.
Class
ASTM-A105-Gr-II
ASTM-A105-Gr-II
3000LBS
150LBS
ASTM-A106-Gr-B
(carbon
steel)
ASTM-A105-Gr-II
ASTM-A105-Gr-II
3000LBS
400LBS
IS 1239
Heavy
Class
ASTM-A105-Gr-II
ASTM-A105-Gr-II
(Galvaniz
ed)
3000LBS
150LBS
ASTM-A105-Gr-II
ASTM-A105-Gr-II
(alloy
steel)
SCH.80
21.3
mm OD
SCH.80
21.34m
m OD
ASTM-A182-Gr-F22
ASTM-A335-GrP-22
SS316
SS316
SS 316
ASTM-A106-Gr-B
(carbon
steel)
IS 1239
Heavy
Description
Page
No.
Date of Issue
[218]
02.09.2015
Size
S.No.
Impulse
tube
material
Service
Pipe
m OD
Impulse
tube
material
[Logo of Utility]
Impulse
line fitting
material
valves
material
ANSI
rating
ANSI
Rating
Tube
1.65mm
THK
Class
3000LBS
150LBS
(Black)
Notes:1. Impulse pipe thickness shall be selected as per ANSI B 36.10. based on the
schedule indicated against each service.
2. Wherever impulse tubes are provided, all the fittings required for these shall be
SS316. The following guidelines shall also be considered along with the Table
15.2 for size, material and rating for impulse line/tube fittings and accessories:
a) Impulse line / tube fittings and accessories
Nipple shall be used for root valve size more then inch and the nipple
size shall be same as the root valve size. Reducer / adepter shall be used
to suit instrument connection, where nipple, root valve size is more then
inch.
Bulk head fitting socket welded type to be provided at instrument rack /
enclosure.
b) Fittings
All fittings except the last fitting connecting to the instrument shall be
socket welded. The size of the fittings shall be same as the impulse line
size.
The fitting connecting to the instrument shall have a size and thread to suit the
instrument connection.
c) Drain
Drain shall be used for all water / steam and non-inflammable / non-corrosive
fluids only.
d) Drain Valve
Two numbers of globe drain valves shall be used for process conditions of
425 degree C or 62 bar and higher.
One number globe drain valve shall be used for process conditions of less
than 425 degree C and 62 bar.
The valve size shall be same as impulse piping / tubing size.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[219]
02.09.2015
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e) Funnel with drain header

This shall be used in the racks for blowing / draining out the process fluid
in the impulse tubings.
The size of drain header shall be 1
When instruments are mounted local to the tapping point and are not
mounted in rack, or panel or enclosure. The drains shall be connected to
the nearest floor level or plant drain.
f) Instrument Valves
Type of the valve shall be needle valve with built in drain valve.
Sizing of the valve shall be .
g) Right / left threaded fittings
This shall be used for installation / removal of instruments without
disturbing the tubing / piping.
A suitable adapter shall be used to install the instruments on right-left
threaded fittings.
A vent line with a isolation valve shall be used in the instrument rack
for air and compressible fluids or other wise if the installation call for eg., for
liquid service where the transmitter is located at a higher elevation than the
tapping point.
Stainless steel tube shall be used inside enclosures and racks from tee
connection to valve manifold and then to instrument. For high
pressure/temperature applications the material shall be ASTM A 213 TP
316H and for other applications material shall be ASTM A 213 TP 316L. The
wall thickness of the tube shall be in accordance with the ANSI B31.1
standard.
All fittings shall be forged steel and shall conform to ANSI B16.11. The
material of forged tube fittings for shaped application (e.g. tee, elbow etc.)
shall be ASTM A182 Gr. 316 H for high pressure/ temperature applications
(as defined above) and ASTM A182 Gr. 316L for other applications. The
material for bar stock tube fitting (for straight application) shall be 316 SS.
Metal thickness in the fittings shall be adequate to provide actual bursting
strength equal to or greater than those of the impulse pipe or SS tube, with
which they are to be used.
The disc and seat ring materials of carbon steel and alloy steel valves shall be
ASTM A-105 and ASTM A-182, Gr. F22, hard faced with stellite (minimum
hardness - 350 BHN.) The surface finish of 16 RMS or greater is required in
the area of stem packing. The valve design shall be such that the seats can
be re-conditioned and stem and disc may be replaced without removing the
valve body from the line.
The valve manifolds shall be of 316 s Furnishing Recommended protection
interlock logics stainless steel with pressure rating suitable for intended
application. 2-valve manifold and 3 valve manifold shall be used for pressure
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[220]
02.09.2015
[Logo of Utility]
measurements using pressure transmitters/ pressure switches and differential

pressure transmitters/ switches respectively. 5-valve manifold shall be used
for remaining applications like DP, flow and level measurements.
For Pressure/D.P gauges in fluid application two-way globe valve on each
impulse line to the instrument and in air/flue gas application two way gate
valve on each impulse line to the instrument shall be used near the
instrument. These shall be in addition to the three way gauge cock provided
along with the pressure/D.P gauges.
Table 15.3
Specification for Seamless SS Pipe
S.No.
1
2
3
4
5
6
Property
Reference
Material Grade
Requirement
ASTM A-312 TP-316
TP-316
Type
Size
Schedule
Standard Length
Seamless/Plain end
NB
40/60/80
5 metre
Table 15.4
Specification for Seamless SS Pipe Fittings
S.No.
Property
Requirement
1
2
3
4
5
Reference
End Connection
Type
Size
Rating
Type of Fittings
ASTM A-182 F-316

Socket welded
Forged conforming to ANSI B16.11
NB
3000/6000/9000 lbs
Reducing coupling, Male-Female reducer,
Straight coupling, Equal Tee, Three Piece
Union, Elbow, Cap etc.
Table 15.5A
Specification for Seamless SS Tube (1/2)
S.No.
1
2
Property
Reference
Material Grade
Type
Size
Properties
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Requirement
ASTM A-213 TP-316
TP-316
Cold Drawn annealed, pickled, passivated,
descaled, hydraulically cleaned seamless
tube.
OD X 2.1 mm thick
Tube shall be free from scratches & suitable
for bending & capable of being flared by
hardened & tapered steel pin. The expanded
tube shall show no crack or rupture.
Description
Page
No.
Date of Issue
[221]
02.09.2015
S.No.
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Property
Requirement
Hardness shall be RB 80
Test Pressure
Tolerance
8
9
Test
Standard Length
400 Kg/Sq mm minimum

+/- 0.13 mm for outside dia.
+/- 15% for wall thickness
Flare, Hardness, Ball & Bubble test
5 metre
Table 15.5B
Specification for Seamless SS Tube (1/4)
S.No.
1
2
Property
Reference
Material Grade
Type
Size
Properties
Test Pressure
Tolerance
8
9
Test
Standard Length
Requirement
ASTM A-269 TP-316
TP-316
Cold Drawn annealed, pickled, passivated,
descaled, hydraulically cleaned seamless
tube.
1/4 OD X 1.2 mm thick
Tube shall be free from scratches & suitable
for bending & capable of being flared by
hardened & tapered steel pin. The expanded
tube shall show no crack or rupture.
Hardness shall be RB 80
400 Kg/Sq mm minimum
+/- 0.13 mm for outside dia.
+/- 15% for wall thickness
Flare, Hardness, Ball & Bubble test
5 metre
Table 15.6
Specification for Seamless SS Tube Fittings
S.No.
Property
Requirement
1
2
3
4
5
Reference
Material Grade
Type
Ferrule
Size
Type of fittings
ASTM A-182
SS 316 forged
Double ferrule double compression
SS 316
To suit SS tubing & NPT end connection
Male/Female connectors, elbow, Equal &
Unequal Tee, Cross, Straight connector, bulk
head unions, etc. as required to suit the
installation.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[222]
02.09.2015
[Logo of Utility]
Table 15.7
Specification for Instrument Valve Manifolds
S.No.
Property
Type
2
3
Mounting
Construction
Requirement
Two valve manifold/Three Valve Manifold
Five valve manifold
Remote 2 pipe mounting
Single Block (Bar Stock)
4
5
6
7
8
9
Material
Ports
Rating
Packing
Seat & Stem
Plug
Forged body & bonnet AISI 316 SS

NPT
420 Kg/ cm2 at ambient
PTFE Wafer
AISI 316 SS
AISI 316 SS free to turn on stem/ 17-4 PH
10
11
Handle
Connection
12
Accessories
AISI 316 SS
Straight
Plug for all ports
Mounting Bracket, nut, bolts etc.
Table 15.8
Specification for Condensate Pot
S.No.
1
2
3
4
5
15.7
Property
Requirement
Reference
Material
Construction
End Connection
Accessories
ASTM A 182 F22/ ASTM A105

Alloy Steel/Carbon Steel as per application
Drilled Bar stock
3 nos. SW
Vent Valve
Air Supply Piping

1. All pneumatic piping, fittings, valves, air filter cum regulator and other
accessories required for instrument air for the various pneumatic devices/
instruments shall be used.
2. This shall include as a minimum air supply to pneumatically operated control
valves, actuators, instruments, continuous and intermittent purging requirements
of Local Instrument Enclosures (LIE) etc.
3. For individual supply line and control signal line to control valve, 1/4 inch size
light drawn tempered copper tubing conforming to ASTM B75 shall be used. The
thickness of copper tubing shall not be less than 0.065 inch and shall be PVC
coated. The fittings to be used with copper tubes shall be of cast brass, screwed
type.
4. All other air supply lines of 1/2 inch to 2 inch shall be of carbon steel hot dipped
galvanized inside and outside as per IS-1239, heavy duty with threaded ends.
The threads shall be as per ASA B.2.1. Fittings material shall be of forged carbon
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[223]
02.09.2015
5.
6.
7.
8.
[Logo of Utility]
steel A234 Gr. WPB galvanized inside and outside, screwed as per ASA B2.1.
Dimensions of fittings shall be as per ASA B16.11 of rating 3000 lbs.
In the boiler area the 2 inch head shall be used up to top most elevation of boiler
floor and from this 2 inch header, 1 inch sub-header shall be branched off at
each floor with isolation valve. From this 1 inch sub-header, branch line of 1/2
inch, with isolation valve shall be used up to various devices. Similar air supply
piping shall be done in the turbine area also. Similar system is to be followed for
service air required for intermittent purging in the Local Instrument Enclosures
(LIEs) etc.
Instrument air filter cum regulator set with mounting accessories shall be used
for each pneumatic device requiring air supply. The filter regulators shall be
suitable for 10 kg/ sq.cm max. inlet pressure. The filter shall be of size 5 microns
and of material sintered bronze. The air set shall have 2 inch size pressure gauge
and built in filter housing blow down valve. The end connection shall be as per
the requirement.
All the isolation valves in the air supply line shall be gate valves as per ASTM
B62 inside screw rising stem, screwed female ends as per ASA B2.1. Valve
bonnet shall be union type & trim material shall be stainless steel, body rating
150 pounds ASA. The valve sizes shall be 1/2 inch to 2 inch.
Purge Air Connection for Air and Flue Gas Applications
a) The continuous purging with instrument air shall be done, for all air and flue
gas measurements excepting instrument air and service air instruments, at
the process source connection end. Necessary arrangements required for
continuous purging shall be used inside all the air and flue gas local
instrument enclosures.
b) For intermittent purging with service air, necessary arrangements inside all
the air and flue gas Local Instrument enclosures/racks shall be used. The SS
three way valve provided in the SS tubing shall be used for isolating the
transmitter and connecting the service air quick disconnect line.
c) One air filter regulator, purge Rotameter and blow down device per
instrument shall be used in the transmitter rack/enclosure.
Table 15.9
Specification for Instrument Air Header
S.No.
Requirement
Property
For Panel
For Field
Material
SS 316
SS 316
2
3
4
5
Inter Connection
Header Take-Off
Take-Off Connection
Take-Off Valve
Drain
2 NPT (M)
SS 316
NPT (M)
Ball Valve SS 316
Ball Valve SS 316 at
the lowest point
1 NPT (M)
SS 316
NPT (M)
Ball Valve SS 316
Ball Valve SS 316 at
the lowest point
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[224]
02.09.2015
[Logo of Utility]
Table 15.10
Specification for CS Pipe
S.No.
1
2
Property
Reference
Material
Type
4
5
6
Size
Schedule
Standard Length
Requirement
ASTM A-106 Gr. C
Cold Drawn Seamless CS
Seamless/ threaded ends as per ASA B2.1/
Hot dip Galvanised from Inside & outside as
per IS-1239
to 2 NB
80/160
5 metre
Table 15.11
Specification for CS Pipe Fittings
S.No.
1
Property
Reference
Type
3
4
5
Size
Rating
End Connection
Type of Fittings
Requirement
ASTM A-234/ ASA B16.11
Forged/ hot dip galvanised from inside &
outside
to 2 (as required)
3000/6000/9000 lbs.
Threaded as per ASA B2.1
Reducing Coupling, Male-Female reducer/
Straight Coupling/ Equal Tee/ Three piece
Union/ Elbow/ Cap etc.
Table 15.12
Specification for CS Globe Valve
S.No.
1
2
Property
Reference
Type
Requirement
ASTM A-105/ASTM B62
Globe
3
4
5
Construction
Rating
End Connection
Material
Forged body cadmium plated

PN 40/PN 160/ PN 320/ PN 400
Screwed Female ends as per ASA B2.1
Body- Carbon steel
Stem- Hardened Steel
Plug- AISI 316 SS
Seat- SS Stellited
to 2 as required
Teflon/Grafoil as required
CS
ASTM A105
As per ANSI B16.34
7
8
9
10
11
Size
Packing
Hand wheel
Yoke
Design Standard
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[225]
02.09.2015
16.
INSTRUMENTATION CABLES & ACCESSORIES
16.1
Specifications of Instrumentation Cables
16.1.1
Common Requirements
[Logo of Utility]
Table 16.1
Specification of Instrumentation Cables- Common Requirement
SNo.
1
3
4
Property
Voltage grade
Codes and Standard
Continuous operation
suitability
Progressive automatic on-line
sequential marking of length in
meters.
Marking to read FRLS
Allowable Tolerance on overall

diameter
Variation in diameter
Ovality at any cross-section
Others
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Requirement
1100 V (Peak Value)
All instrumentation cables shall comply with
VDE 0815, VDE 0207, Part 4, Part 5, Part 6
, VDE 0816, VDE 0472, SEN 4241475,
ANSI MC 96.1, IS-8784, IS-10810 ( latest
editions) and their amendments read along
with this specification
At 70 deg. C for all types of cables, while
205 deg C for Type-C cables
To be provided at every one meter on outer
sheath.
To be provided at every 5 meters on outer
sheath except for type-C cable.
+/- 2 mm (maximum) over the declared
value in data sheet.
Not more than 1.0 mm throughout the
length of cable.
Not more than 1.0 mm
a)
Durable marking at intervals not
exceeding 625 mm shall include
manufacturers name , insulation
material, conductors size, number of
pairs, voltage rating, type of cable, year
of manufacture to be provided.
b)
Cables shall be suitable for laying in
conduits, duct, trenches, racks and
underground-buried installation
c)
Repaired cables shall not be acceptable
Description
Page
No.
Date of Issue
[226]
02.09.2015
16.1.2
[Logo of Utility]
Table 16.2
Specification of Instrumentation Cables- Specific Requirement
SNo.
A.
i.
Specification
Requirement
Conductors
Cross section area
Type-A
Type-B
Type- F&G
0.5 Sq. mm
High
conductivity
annealed tin
coated
copper
As per VDE0815
ii.
Conductor material
ANSI type
KX
ANSI type
SX
iii.
Colour code
Yellowred
Black-Red
iv.
Conductor Grade
v.
No. & dia. of stands
7x0.3 Sq. mm (nom)
vi.
No. of Pairs
2, 6
vii.
Max. conductor
resistance per Km (in
ohm) at 20 deg. C
As per ANSI MC 96.1
73.4 (loop)
viii.
Reference Standard
As per ANSI MC 96.1
VDE 0815
B.
i.
ii.
iii.
iv.
As per ANSI MC 96.1
4, 8, 12,
16, 24, 48,
2
As
ANSI
96.1
As
ANSI
96.1
per
MC
per
MC
Insulation
Material
Thickness in mm
(Min/Nom/Max)
Volume Receptivity
(Min) in ohm-cm
Voltage rating
PVC type YI 3 with FRLS properties
Teflon (i.e.
extruded
FEP)
0.25 / 0.3 / 0.35
0.4 / 0.50
1x1014 at 20 deg. C & 1x 10 11 at

70 deg.
1100 V peak operating voltage
vi.
Core diameter above

insulation
Suitable for cage clamp connector
C.
Pairing & Twisting

Max. lay of pairs (mm)
Single layer of
numbered binder tape
on each pair provided
Unit formation of four
pairs with printing of
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
--VDE 0207
part 6 &
ASTMD
2116.
VDE 0207 Part 4
iii.
Yellow-red
As per
ANSI MC
96.1
Reference Standard
ii.
ANSI type
KX
Electrolytic
v.
i.
Type-C
50
Yes
NA
Description

Yes
NA
Page
No.
Date of Issue
[227]
02.09.2015
SNo.
iv.
D.
i.
ii.
iii.
iv.
v.
vi.
Specification
Requirement
no. of Unit provided
Conductor / pair
identification as per
VDE0815
Type of shielding
Individual pair shielding
Minimum thickness of
individual pair shielding
Overall cable assembly
shielding
Minimum thickness of
overall cable assembly
shielding
Shielding coverage
viii.
Drain wire provided for

overall shield
F.
i.
ii.
iii.
iv.
v.
Type- F&G
Type-C
To be
provided
NA
No
To be
provided for
Type-F
cable
No
No
28 micron
No
NA
Al-Mylar tape
Drain wire provided for

individual shield
i.
Type-B
Shielding
vii.
E.
Type-A
[Logo of Utility]
To be provided
55 micron
100% with at least 20% overlap
Yes ( for Ftype) 7 strand 20
AWG (0.51
NA
NA
mm2 )
annealed Tin
coated
copper
Yes ( for F-type) 7 -strand 20 AWG (0.51 mm2 )
annealed Tin coated copper
Fillers
Non-hygroscopic, flame
retardant
To be provided
Outer Sheath
Extruded PVC compound YM1 with
FRLS properties
Material
Minimum thickness at
any point
Nominal Thickness at
any point
Color
Resistant to water,
fungus, termite &
rodent attack
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Teflon
(i.e.
extruded
FRP)
0.4 mm
1.8mm
0.5mm
>1.8mm
Blue
Required
Description
Page
No.
Date of Issue
[228]
02.09.2015
SNo.
vi.
vii.
viii.
ix.
Specification
Requirement
Oxygen index as per
ASTM D-2863
Temperature index as
per ASTM D-2863
Acid gas generation by
weight as per IEC60754-1
Smoke Density rating

as per ASTM D-2843
x.
Reference Standard
xi
Armour
G.
Electrical Parameters
i.
Mutual capacitance
between Conductors.
At 0.8KHz (Max.)
Type-A
Type-B
[Logo of Utility]
Type- F&G
Type-C
Not less than 29%
NA
Not less than 250 deg. C
NA
Maximum 20 %
NA
Maximum 60%
(defined as the average area under the
curve when the results of smoke
density test plotted on a curve
indicating light absorption vs. time as
ASTM D-2843)
NA
VDE 207
Part 6 &
VDE 207 part 5
ASTM D
2116
Galvanised steel wire armoured type conforming to
IS-3975
120 nF / Km
for F type
1000 nF /
Km for Gtype
200 nF /
Km
60 dB
60 dB
NA
iv.
Characteristics
impedance ( Max) At 1
KHz
NA
320 ohm for

F type
340 ohm for
G type
v.
Attenuation Figure at 1
KHz
NA
1.2 dB / Km
H.
Complete Cable
i.
Complete Cable
assembly
ii.
Flammability
I.
Accessories
i.
Cable accessories of
flame retardant quality
ii.
iii.
Insulation resistance
(Min.)
Cross talk Figure (min.)
at 0.8 KHz
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
200 nF / Km
100 M ohm / Km
Shall pass Swedish chimney test as

per SEN-SS 4241475 class F3.
Shall pass flammability test as per
IEEE-383 read in conjunction to this
specification
NA
NA
NA
NA
Yes. (Accessories such as harnessing components,

markers, bedding, cable jointer, binding tape etc.)
Description

Page
No.
Date of Issue
[229]
02.09.2015
SNo.
J.
i.
ii.
iii.
iv.
16.1.3
Specification
Requirement
Type-A
Type-B
[Logo of Utility]
Type- F&G
Type-C
Cable Drum
Non-returnable wooden drum (wooden drum to be
constructed from seasoned wood free from defects
with wood preservative applied to the entire drum)
or steel drum.
Type
Outermost layer
covered with
waterproof paper
Painting
Length
Yes
Entire surface to be painted
1000m + 5% for up to & including 12 pairs
500m + 5% for above 12 pairs
Type Test
Table 16.3
Type Test Requirement for Cables
S.No.
1
Item
Conductor
Insulation
Inner sheath
Outer sheath
Filters
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Test Requirement
Resistance Test
Diameter test
Tin coating test (drain wire)
Loss of mass
Ageing in air ovens
Tensile strength & elongation
test before & after ageing
Heat shock
Hot deformation
Shrinkage
Bleeding & Blooming
Loss of mass
Heat shock
Hot deformation
Shrinkage
Cold bend / Cold impact test
Loss of mass
Ageing in air ovens
Tensile strength & elongation
test before & after ageing
Heat shock
Hot deformation
Shrinkage
Bleeding & Blooming
Colour fastness to water
Cold bend / Cold impact test
Oxygen Index test
Smoke Density test
Acid gas generation test
Oxygen Index test
Smoke Density test
Description
Standard
VDE 0815
IS 10801
IS - 8130
VDE 0472
VDE 0472
VDE 0472
VDE 0472
VDE 0472
VDE 0472
IS 5831
VDE 0472
VDE 0472
VDE 0472
VDE 0472
IS 5831
VDE 0472
VDE 0472
VDE 0472
VDE 0472
VDE 0472
VDE 0472
VDE 0472
IS 5831
IS 5831
IS 5831
ASTM D 2863
ASTM D 2843
IEC 754 I
ASTM D 2863
ASTM D 2843
Page
No.
Date of Issue
[230]
02.09.2015
16.1.4
16.1.5
S.No.
Item
AL-MYLAR
Shield
Overall cable
Test Requirement
Acid gas generation test
Continuity test
Shield thickness
Overlap test
Flammability
Noise interference
Dimensional checks
Cross talk
Mutual capacitance
HV test
Drain wire continuity
[Logo of Utility]
Standard
IEC 754 1
Yes
Yes
Yes
IEEE 383 & IEC 332
IEEE -TRANSACTION
IS 10810
VDE 0472
VDE 0472
VDE 0815
Routine Test
To be carried out by supplier during various stages of manufacture.
1. Insulation & jackets: All tests as per IS 5831 except insulation resistance,
voltage & spark test shall be as per BS 5308, Part II
2. Armor test as per IS 3975
3. Conductor resistance
4. Cable capacitance and L/R ratio.
Acceptance Test
These following tests shall be carried out as acceptance test:
1.
2.
3.
4.
5.
6.
7.
Continuity test
Voltage test as per BS 5308 Part II
Conductor resistance and drain wire resistance
Cable capacitance and L/R ratio test.
Tests for uniformity of galvanization of armor as per IS 2633
Oxygen and temperature index test as per ASTM D 2863
Dimensional checks for overall diameter and under armour / over armour
diameter.
8. Checking of drum length & overall length tolerances.
Immediately after completion of electrical tests, the ends of the cable shall be
sealed to prevent ingress of moisture with suitable PVC / Rubber caps
16.2
Specifications of Optical Fibre Cables (OFC)

1. OFC shall be installed on cable tray, duct bank, cable trench installation as
necessary. For outdoor applications the cable shall be armoured with Poly
Ethylene sheathing. In all cases cable shall be routed through suitable grade
HDPE permanently lubricated protection pipe as per IS-4984, IS-12235 &
TEC.G/CDS-08/01 of suitable size @ 53% fill factor.
2. The optical fibre core shall be of ultrapure fused silica glass coated with UV
cured acrylate suitable to withstand temperature of about 80 deg. Centigrade
continuously.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[231]
02.09.2015
[Logo of Utility]
3. OFC shall be 4 / 8 / 12 core, galvanized corrugated steel taped armored, fully

water blocked with dielectric central member for outdoor / indoor application so
as to prevent any physical damage. The cable shall have multiple single-mode or
multi-mode fibres on as required basis so as to avoid the usage of any repeaters.
The outer sheath shall have Flame Retardant, UV resistant properties & to be
identified with the manufacturers name, year of manufacture, progressive
automatic sequential on-line marking of length in meters at every meter on outer
sheath.
4. The cable core shall have suitable characteristics and strengthening
for
prevention of damage during pulling viz. steel central member, Loose buffer tube
design, 4 fibres per buffer tube (minimum), Interstices and buffer tubes duly
filled with Thixotropic jelly or better material etc. The cable shall be suitable for
maximum tensile force of 2000 N during installation, and once installed, a tensile
1000 N minimum. The compressive strength of cable shall be 3000N minimum
& crush resistance 4000 N minimum. The operating temperature shall be -20
DegC to 70 DegC.
5. The splicing loss of any two fibres in any case shall not exceed 0.10 db/splice.
6. The total additional attenuation above the nominal attenuation due to regular
splices, repair splices, connectors, temperature variation, ageing etc. shall be
indicated.
7. Fibre coloring shall conform to EIA/TIA-598. The color-coding shall be permanent
thus withstanding normal handling; e.g., during termination, testing, or cable
relocation. Refer to EIA 359 for color identification and coding.
8. Cables shall be designed & tested in accordance with ISO 11801, TIA-568 &
ICEA 596 and Performance specifications shall be measured in accordance with
the Fibre Optic test procedures(EIA/TIA -455 documents) test procedures of IEC60793 & IEC-60794
9. The OFC shall generally conform to the following specifications
Table 16.4A
Specifications for Single Mode Optical Fibre
S.No.
Feature
Minimum Requirement
@1310 nm
0.4 dB/km
Maximum Uncabled
Attenuation Coefficient
Mode field Diameter
Maximum Cable Cut-off Wavelength
1260 nm
Maximum Zero Dispersion Wavelength
1321.5 nm
Minimum Zero Dispersion Wavelength
1301.5 nm
Maximum Zero Dispersion Slope
0.092 ps/nm2km
Maximum Polarization Mode Dispersion
0.2 ps/km
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
@1550 nm
0.3 dB/km
@1310 nm
9.20.4 m
@1550 nm
10.40.8 m
Description
Page
No.
Date of Issue
[232]
02.09.2015
S.No.
[Logo of Utility]
Feature
Minimum Requirement
Gigabit Ethernet Length 1000BASE-LX
2-5000 mtrs.
Ten Gigabit Ethernet

Length
10GBASE-LX
2-10000 mtrs.
10GBASE-LX4
2-10000 mtrs.
10
Maximum Core/cladding Concentricity Error
0.5 m
11
Cladding Diameter
125.0 1.0 m
12
Cladding Non-circularity
1%
13
Coating Diameter
245 5 m
14
Maximum Coating Concentricity Error
12.5 m
15
Temperature Dependence (-60 to +85C)
0.05 dB/km
16
Temperature & Humidity Cycling (-10 to +

85C, 4 to 90% RH)
0.05 dB/km
17
Minimum Proof Test
100 kpsi
18
Bending Induced Attenuation (100 turns,

75mm diameter)
0.5 dB
Table 16.4B
Specifications for Multi Mode Optical Fibre
S.No.
Feature
Minimum Requirement
Maximum Uncabled
@850 nm
Overfilled Launch
Bandwidth
@850 nm
200 MHzkm
@1300 nm
500 MHzkm
Gigabit Ethernet Length
1000BASE-SX
2-300 mtrs.
1000BASE-LX
2-550 mtrs.

Length
10GBASE-SR
2-33 mtrs.
10GBASE-LX4
2-300 mtrs.
@1300 nm
3 dB/km
0.7 dB/km
Numerical Aperture
0.275 0.015
Core Diameter
62.5 3.0 m
Maximum Core Non-circularity
6%
3 m
Cladding Diameter
125.0 2.0 m
10
2%
11
Coating Diameter
245 10 m
12
12.5 m
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[233]
02.09.2015
S.No.
Feature
[Logo of Utility]
Minimum Requirement
13
0.2 dB/km
14

85C, 4 to 90% RH)
0.2 dB/km
15
Minimum Proof Test
100 kpsi
16

75mm diameter)
0.5 dB
10. The cables shall be supplied in non-returnable strong wooden (or alternatively
steel) drums provided with lagging of adequate strength, constructed to protect
the cable against any damage and displacement during transit, storage and
subsequent handling and stringing operations in the field.
11. Test on Fibre optic cable:
Table 16.4C
Type Test Requirement for Fibre Optic Cables
S.No.
A
Test Requirement
Optical Characteristics of Fibres
IEEE Std. 1138

IEEE STD. P1222
(EIA/TIA 455-61,78A)
(IEC 793-1-C1A,B,C)
IEEE STD. 1138
IEEE STD PI222
(EIA-455-80, 170)
(IEC-793-1-C7A,B)
IEEE STD. 1138
IEEE STD. P1222
(EIA/TIA-455168A,169A,175A)
(IEC-793-1-C5A,B,C)
IEC-793-1-C2B
IEEE STD. 1138
IEEE STD. P1222
(EIA/TIA-455164A,165A,167A)
(EIA-455-174)
(IEC 793-1-C9A,B,C,D)
IEEE STD. 1138
IEEE STD. P1222
(EIA/TIA-455-69A)
(IEC 793-1-D1)
Attenuation
Cut off wavelength
Fibre Dispersion
Frequency Response
Mode Field Diameter
Temperature Cycling
B
1
2
Mechanical Characteristics of Fibres

Abrasion
Core Concentricity
Macro Bending
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Standard
IEC 793-1-B4
IEC 793-1-A3
EIA/TIA-455-62A
(IEC 793-1-C11)
Description
Page
No.
Date of Issue
[234]
02.09.2015
S.No.
4
C
16.3
[Logo of Utility]
Test Requirement
Micro Bending
Proof Test
Standard
IEC-793-1-C3
IEC-793-1-B1
Strippability
Visual Examination
IEC 793-1-B6
EIA/TIA-455-13
(IEC 793-1-B5)
Instrumentation Cable Interconnection & Termination Philosophy

The cable interconnection philosophy to be adopted shall be such that expensive
grouping of signals by large scale use of field mounted Group Junction Boxes
(JBs) at strategic locations. (Where large concentrations of signals are available,
e.g. valves limit and torque switches, switchgear) is done and consequently
cable with higher number of pairs are extensively used. The details of
termination to be followed are mentioned in the following Table:
Table 16.5
Instrumentation Cable Interconnection & Termination Philosophy
S.No.
1.
2.
3.
4.
5.
6.
Application
Type of Termination
Type of Cables
From (A)
To (B)
End A
End B
Limit, Torque
switches of
valves /
dampers /
drives (integral
junction box)
Marshalling
cubicle /
Marshalling
cum
Termination
Cubicle /
Local group
JB
Plug-in
connector
Posts mount
cage clamp
type
Transmitters,
E/P converters,
process
actuated
switches
mounted in LIE
/ LIR
Integral
junction box
of LIE / LIR
Plug-in
connector
Cage clamp
(rail mount)
F, G
RTD heads
Local
junction Box
Plug-in
connector
Thermocouples
Junction Box
Plug in
connector
Other Field
Mounted
Instrument
Local JB /
Group JB
Junction Box
(For
Thermocouples
Marshalling
Cubicle /
Marshalling
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Cage clamp
(Rail mount)
type
Cage clamp
(Rail mount)
type
Plug in
connector
Screwed, Cage
clamp (Rail
mount) type
Cage
clamp (Rail
mount)
Screwed, Cage
clamp (Rail
mount) type
Description
A, B, C*
F
(For analog
signals)
G
(For Binary
Signals)
A, C*.
These
signals shall
Page
No.
Date of Issue
[235]
02.09.2015
S.No.
7.
8.
9.
Application
Type of Termination
From (A)
To (B)
End A
for interlock
and protection
cum
Termination
Cabinet
type
Local junction
box,
Instrument
Junction box
of LIE / LIR /
Group JB /
MCC / SWGR
Local junction
box,
Instrument
Junction box
of LIE / LIR /
Group JB /
MCC / SWGR
Marshalling
Cubical /
Termination
Cabinet
[Logo of Utility]
Group JB
Marshalling
Cubical /
Marshalling
cum
termination
Cabinet
Electronic
system
cabinet
End B
Type of Cables
preferably
through 6
pair cable
Cage
clamp (Rail
mount)
type
Cage clamp
(Rail mount)
type
Cage
clamp (Rail
mount)
type
Posts mount
cage clamp
type
Cage
clamp post
mounted
type
Plug-in
connector /
Other System
as per
manufacturers
Standard
F, G
F, G
Internal
Wiring
Notes:
1. Normally 10% spare cores shall be used when the numbers of pairs of cables are
more than four pairs.
2. For analog signals, individual pair shielding & overall shielding & for binary
signals only overall shielding of instrumentation cables shall be used.
3. * For high temperature applications only.
4. Instrument Cabling for instruments / equipment of specialized / proprietary
Control System shall be as per manufacturers standard.
16.4
Terminal Blocks
1. All terminal blocks shall be rail mounted/post mounted, cage clamp type with
high quality non-flammable insulating material of melamine suitable for working
temperature of 105 deg. C. The terminal blocks in field mounted junction boxes,
temperature transmitters, instrument enclosures/racks, etc. shall be suitable for
cage clamp connections. The terminal blocks in Control Equipment Room logic /
termination / marshalling cubicles shall be suitable for the post mounted cage
clamp connection at the field input end. The terminal blocks for SG integral
control system Input/ Output connections from/to SWGR/MCC, shall be used
with built in test and disconnect facilities complete with plug, slide clamp, test
socket etc.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[236]
02.09.2015
[Logo of Utility]
2. All the terminal blocks shall be used complete with all required accessories
including assembly rail, locking pin and section, end brackets, partitions, small
partitions, test plug bolts and test plug ( as specified above for SWGR
connections), transparent covers, support brackets, distance sleeves, warning
label, marking , etc.
3. The marking on terminal strips shall correspond to the terminal numbering on
wiring diagrams. At least 20% spare unused terminals shall be used everywhere
including
local
junction
boxes,
instrument
racks/enclosures,
termination/marshalling cabinets, etc. All terminal blocks shall be numbered for
identification and grouped according to the function. Engraved labels shall be
used on the terminal blocks.
4. The terminal blocks shall be arranged with at least 100 mm clearance between
two sets of terminal blocks and between terminal blocks and junction box walls.
5. Internal wiring in factory pre-wired electronic equipment cabinets may be
installed according to the applicable standards as to wire size and method of
termination or internal equipment. Terminal blocks for connection of external
circuits into factory pre-wired electronic equipment cabinets shall meet all the
requirements as specified above.
16.5
Internal Panels, Cabinets, System Cabinet Wiring Philosophy

1. Internal panel/cabinet wiring shall be of multi-stranded copper conductor with
FRLS PVC insulation without shield and outer sheath meeting the requirements
of VDE 0815.
2. Wiring to door mounted devices shall be done by 19 strand copper wire provided
with adequate loop lengths of hinge wire so that multiple door opening shall not
cause fatigue breaking of the conductor.
3. All internal wires shall be used with Tag identification of printed type (partex
labels) at both ends. All wire directly connected to trip devices shall be
distinguished by one additional red color.
4. All external connection shall be made with one wire per termination point. Wires
shall not be tapped or spliced between terminal points.
5. All floor slots of desk/Panels/cabinets used for cable entrance shall be used with
removable gasketed gland plates and sealing material. Split type grommets shall
be used for prefabricated cables.
6. All the special tools as may be required for solder less connection.
7. Tag identification for internal wires shall be printed (partex labels)
8. Wire sizes to be utilized for internal wiring shall be as per following table.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[237]
02.09.2015
[Logo of Utility]
Table 16.6
Wire Size for Internal Wiring
S.No.
1
2
3
16.6
Application
Current (4-20mA), low voltage signals
(48 V)
Ammeter/ Voltmeter circuit, control
switches etc. for electrical system.
Power supply and internal illumination.
Wire Size
0.5 Sq. mm
1.5 Sq. mm
2.5 Sq. mm minimum (shall be as
per load requirement)
Cable Installation & Routing

1. All cable assigned to a particular duct/conduit shall be grouped and pulled in
simultaneously using cable grips and suitable lubricants. Cables removed from
one duct/conduit shall not be reused.
2. Cables shall be segregated as per IEEE Std. 422. In vertically stacked trays, the
higher voltage cable shall not be in higher position and instrumentation cable
shall be in bottom tier of the tray stack. The distance between instrumentation
cables and those of other system shall be as follows:
a) From 11KV/6.6KV/3.3KV tray system
900 mm
b) From 415KV tray system
600 mm
c) From control cable tray system
300 mm
3. Cables shall terminate in the enclosures through cables glands. All cable glands
shall be properly gasketed. Fire proof sealing (to prevent ingress of dust entry
and propagation of fire) shall be used for all floor slots used for cable entrance.
Compression cable glands (double for armored and single for other cables) shall
be used.
4. All cables shall be identified by Tag. Nos. provided in approved format at both
the ends as well as at an interval of 5 meters.
5. Line voltage drop due to high resistance splices, terminal contacts, insulation
resistance at terminal block, very long transmission line etc. shall be reduced as
far as practicable.
6. The cables emanating from redundant equipment/devices shall be routed through
different paths. The above segregation of cables & wiring for redundant
equipment / devices shall be in accordance with IEEE-Std-422
16.7
Cable Laying
1. Cable shall be laid strictly in line with cable schedule. In general, the cable
routing from the local instrument to JB shall be such that the cable go away
from the hot zone.
2. Identification tags for cables.
Indelible tags to be provided at all terminations, on both sides of wall or floor
crossing, on each conduit/duct/pipe entry/exit, and every 20 m in cable trench /
tray.
3. Cable tray numbering and marking.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[238]
02.09.2015
[Logo of Utility]
To be provided at every 10m and at each end of cables way & branch
connection.
4. Joints for less than 250 Meters runs of cable shall not be permitted.
5. Buried cable protection
With concrete slabs; Route markers at every 20 meters along the route & at
every bend.
6. Road Crossings
Cables to pass through buried high density PE pipes encased in PCC. At least
300 mm clearance shall be used between.
a) HT power & LT power cables,
b) LT power & LT control cables,
c) LT control & instrumentation cables,
Spacing between cables of same voltage grade shall be in accordance with the
derating criteria adopted for cable sizing.
7. Segregation (physical isolation to prevent fire jumping)
a) All cable associated with the unit shall be segregated from cables of other
Units.
b) Interplant cables of station auxiliaries and unit critical drives shall be
segregated in such a way that not more than half of the drives are lost in
case of single incident of fire.
8. Cable clamping
All cables laid on trays shall be neatly dressed up & suitably clamped/tied to the
tray. For cables in trefoil formation, trefoil clamps shall be used.
9. Optical fibre cables inside conduits shall be laid on cable trays wherever available
and feasible. In areas where the same are required to be buried, the same shall
be buried in separate trench approx. 1.6 meter depth, to be laid in 2 GI/rodent
proof HDPE conduits covered with sand, brick and soil along the pipe line route.
10. While crossing roads-to be laid in GI/rodent proof HDPE conduits with sand filling
at bottom and sand, soil filling at top with cement concrete;
While crossing canals/river- to be laid in GI/rodent proof HDPE conduits within
Hume pipe.
16.8
Cable Accessories
1. Cables, which terminate in cabinets of draw out sections, shall have sufficient
cable coils in the bottom of the cabinet to permit full withdrawal of draw out
sections without disconnecting the cables. When prefabricated cables with
factory connectors on both ends are longer than required, the excess cable shall
be coiled in the bottom of one or both termination cabinets.
2. No splices shall be made in conductors for instrument and control circuits except
where required at connections to devices equipped with factory installed pigtails.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[239]
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[Logo of Utility]
Such splices shall be made only in approved splicing boxes of fitting with
removable cover. The splices shall be made with sufficient slack left in the wire
to permit withdrawal of the splice from the splicing boxes for ease of future
disconnection of the splices. All exposed conductor or connector surfaces shall
be covered with a minimum of three half-lapped layers of all weather vinyl plastic
electrical tape. Taping shall extend a minimum of two cable diameters over the
cable jacket and a similar distance over the other insulation or connections
requiring insulation.
3. Proper grounding of all equipments shall be done. Further, proper termination of
cable shield shall be verified and the grounding of the same shall be coordinated
so as to achieve grounding of all instrumentation cable shields at same potential.
This shall be completed prior to system tests.
4. Take full care while laying/installing cables as recommended by cable
manufacturers regarding pulling tensions and cable bends.
16.9
Cable Conduits
1. Conduits shall be generally used for interconnecting cables from field instruments
to Local JBs. All unarmoured cables shall be installed in conduit. All rigid
conduits, couplings and elbows shall be hot dipped galvanized rigid mild steel in
accordance with IS: 9537 Part-I and Part-II. The conduit interior and exterior
surfaces shall have continuous zinc coating with an overcoat of transparent
enamel lacquer or zinc chromate. Flexible metal conduit shall be heat resistant
lead coated steel, water leak, fire and rust proof. The temperature rating of
flexible conduit shall be suitable for actual applications. The flexible metal
conduit shall be constructed with interlocked corrosion resistant steel &
manufactured in accordance with UL1 & NEC Article 348.
2. All grounding bushings within all enclosures shall be wired together and
connected internally to the enclosure grounding lug or grounding bus with 8
AWG bare copper conductors. Conduit runs to individually mounted equipment
shall be grounded to the cable tray grounding conductor with 12 AWG bare
copper conductors.
3. All rigid conduit fittings shall conform to the requirements of IS: 2667.
Galvanized steel fitting shall be used with steel conduit. All flexible conduit
fittings shall be liquid tight, galvanized steel. The end fittings shall be compatible
with the flexible conduit supplied.
4. All individually mounted equipment and devices shall be connected to the supply
conduit, using not more than one meter of flexible conduit adjacent to the
equipment or device. Flexible conduit shall be installed in all conduit runs, which
are supported by both building steel and structures subject to vibration or
thermal expansion .This shall include locations where conduit supported by
building steel or foundation becomes supported by steam generator framing.
5. Special areas, such as Control Rooms in which external noise is to be minimized,
shall have flexible conduit in conduit runs where the runs cross from the main
building framing to the Control Room framing.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[240]
02.09.2015
[Logo of Utility]
6. Conduit supports shall be furnished and installed in accordance with these

specifications. Support material shall comply with the requirements.
a) Hanger rods shall be 12 mm diameter galvanized threaded steel rods.
b) Single conduit support shall be one-hole cast straps and clamp backs.
Multiple conduit bank supports shall be constructed of special galvanized
support channels with associated conduit clips.
7. Conduit sealing, explosion proof, dust proof and other types of special fittings
shall be used as required by these specifications and shall be consistent with the
area and equipment with which they are installed. Fittings installed outdoors and
in damp locations shall be sealed and gasketed. Hazardous area fittings and
conduits sealing shall conform to NEC requirements for the area classification.
8. Double locknuts on all conduit terminations shall be used. Water tight conduit
unions and rain tight conduit hubs shall be utilized for all the application which
shall be exposed to weather. Moistures pockets shall be eliminated from
conduits.
9. Conduits shall be securely fastened to all boxes and cabinets.
16.10
Cable Sub Trays & Support

1. The cable sub-trays and the supporting system, to be generally used between
Local/Group JBs and the main cable trays. It is the assembly of section and
associated fitting forming a rigid structural system used to support the cable
from the equipment or instruction enclosure up to the main cable trays (trunk
route).The material of cable tray shall be GI.
2. The covers on the cable sub-trays shall be used for protection of cables in areas
where damage may occur from falling objects, welding spark, corrosive
environment, etc. & shall be electrically continuous and solidly grounded. The
cable trays shall not have sharp edges, burrs or projections injurious to the
insulation or outer sheath of the cables.
3. The supporting arrangement of cable tray system shall be able to withstand the
weight of the cable and cable tray system. The supporting interval shall not be
more than the recommended span for the above loading for the type of cable
tray selected. The tray shall not overhang by more than one meter from the
support at the dead end. As far as practicable the cable sub-tray system shall be
supported from one side only, in order to facilitate installation and maintenance
of cables.
4. Install the estimated quantities and size of sub trays / troughs including all
required fittings and adaptors on as required basis.
Table 16.7
Specifications for Cable Tray
S.No.
Feature
Minimum Requirement
1
2
Material
Thickness
Finish
Length
Mild Steel as per IS-2062

Not Less than 2 mm
Hot Dip galvanised as per IS-2629,
2633 & Zinc Coating as per IS-4579
2.5 Mtr. +/- 10 mm
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[241]
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S.No.
[Logo of Utility]
Feature
Minimum Requirement
5
6
Width
Inward Bend
Coupler Plate
8
9
Coupler plate material

Nuts, Bolts, washer etc.
10
Cover
11
Cover Material
W +/- 3mm
25 mm
Thickness 2 mm, length 100 mm,
Width 50 mm
MS with Hot dip galvanised
As required/ Hot dip galvanised
Dome Fixed type, Thickness 1.2 mm
(Minimum)
Hot dip galvanised MS sheet
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[242]
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17.
SYSTEM CABINETS, PANELS & JUNCTION BOX
17.1
[Logo of Utility]
1. All control panels, system cabinets, local panels and local instrument enclosures,
racks shall be furnished fully wired with necessary provision for convenience
outlets, internal lighting, grounding, ventilation, space heating, anti-vibration
pads and accessories as per IS:5039 as required for completeness of the
system.
2. All panels & cabinets shall be free standing type and have bottom entry for
cables unless otherwise specified. The bottom of panels, cabinets, enclosures
shall be sealed with bottom plate, compression cable glands and fire proof
sealing material to prevent ingress of dust and propagation of fire. The Cabinets
shall be designed for front & back access to components, terminals and wiring.
3. The cabinets shall be used with bottom glanding plate which shall be removable
from inside and shall be used with sufficient no. of knockouts. All knockouts
shall be used with pluggable grommets.
4. The cabinets shall be of max. 2200mm height including base channel. The base
channel shall be of 100 ISMC. All cabinets shall be of same height. Construction
shall be modular.
5. System & non-system cabinets shall have "look alike" appearance.
6. All electronic system cabinets shall be designed for 50 deg C operating under
maximum ambient temperature without air conditioning system in service.
Further cabinets, panels shall be so designed that temperature rise due to heat
load does not exceed 10 deg. C above ambient temperature under all operating
conditions. Necessary louvers, fans, limited packing density, adequate spacing
between instruments, devices etc. shall be used to maintain temperature rise
within permissible limits.
7. Panels, cabinets enclosures wiring shall be arranged to enable the removal of
modules/instruments and devices without unduly disturbing them.
8. All panels, cabinets, enclosures interiors shall be illuminated with rapid start
fluorescent strip fixtures with door actuated switches. Door switch terminals
shall be shrouded. All illuminated lights shall be used with isolation switch in
addition to door switch for maintenance & switching off when not required.
Illumination light shall be used on both front & back sides if both sides are
provided with equipments/instruments/terminal blocks requiring maintenance.
9. Sufficient number of power receptacles with disconnect switches shall be
installed within panels, enclosure and racks.
10. The local instrument enclosures/racks shall be used locally for mounting of
electronic transmitters and switches, etc.
11. Exterior steel surface shall be sand blasted, ground smooth, filed, primed, sanded
and smooth enamel painted to give a good finish subject to minimum paint
thickness of 65-75 microns for sheet thickness of 3 mm and 50 microns for
sheet thickness of 2mm. Minimum 2 coats of primer and two sprays of final
finish colour shall be applied to all surfaces.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[243]
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[Logo of Utility]
12. The colour of the panels interior shall be brilliant white. External colour of the
panels shall be as RAL 7032 for LIE/ LIR and RAL 7035 for control room system
cabinets.
13. All panels, enclosures, system cabinets, marshalling cabinets shall be used with
a minimum of 20% spare terminations and system cabinets shall be used with
spare space for 20% additional modules fully wired with connectors etc. in
excess of the total requirement of the system design when the cabinets are
delivered. The spare space capacity shall be distributed evenly throughout the
cabinets.
17.2
System Cabinets
Table 17.1
Specifications for System Cabinets
S.No.
Features
Application
2
3
4
Location
Type
Protection class
Material & Thickness
Doors
Cable entry
Anti vibration pad
Painting
10
Cabinet Dimension
11
Grounding
12
Ventilation
13
Lighting
14
Lifting arrangement
For housing Signal conditioning

cards, input/output cards, processor
cards, power supply units etc.
Indoor
Free standing Vertical type
IP-44
CRCA steel/ min. 2mm for panel
sides & 3mm for gland plates
Double door with neoprene gasket,
Lockable,
Bottom with fire proof compound
thickness 50 mm for sealing
Required, 15mm
Interior- Brilliant White
Exterior- RAL 7035
To be decided during detail
engineering
M6 earthing stud shall be used
Fans & louvers with brass mesh
required
rapid start fluorescent strip fixtures
with door actuated switches required
Removable lifting eyebolts shall be
used
1. Beacon Lamps shall be used in each cabinet to indicate panel having fault
condition.
2. The racks in system cabinets shall have provision along with plug in
sockets/back plane to house accommodate the spare slots/modules as specified
elsewhere.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[244]
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17.3
[Logo of Utility]
3. The system cabinets, racks in system cabinets, slots in the racks & the terminals
shall have identification numbers. A stainless steel metal tag (plate) shall be fixed
to the inside of the door & the layout of the racks, slots & details of the card
type/service shall be inscribed on this metal tag.
4. Each cabinet shall be used with one each 3 pin receptacles for 230 V, 1P, 50 Hz
and receptacles for 24V DC.
5. One of the doors shall be used with folder to keep the relevant engineering
document of the cabinet.
6. All cabinets shall have common key for locks.
7. Door shall have concealed type of hinges with 120 degree swing.
8. Door latches shall be of the three-point type to ensure tight closing.
9. Separate Power & shield earthing bus shall be used at the front & rear side of
the cabinets. The earthing bus shall be isolated from panel body by suitable
insulation material.
Marshalling Cabinets
Table 17.2
Specifications for Marshalling Cabinets
S.No.
Features
Application
2
3
4
Location
Type
Protection class
Doors
Cable entry
Terminal Blocks
Anti vibration pad
10
Painting
11
Cabinet Dimension
12
Grounding
13
Ventilation
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
For termination of all cables

originating from field.
Indoor
Free standing Vertical type
IP-44
CRCA steel/ min. 2mm for panel
sides & 3mm for gland plates
Double door with neoprene gasket,
Lockable,
Bottom with fire proof compound
thickness 50 mm for sealing
Rail mounted cage-clamp suitable for
conductor size up to 2.5 mm2 &
fused type with LED indication for
power supply (24 VDC, 230 V AC,
110 V AC etc.) for instruments &
equipments.
Required, 15mm
Interior- Brilliant White
Exterior- RAL 7035
To be decided during detail
engineering
Fans & louvers with brass mesh
required
Description

Page
No.
Date of Issue
[245]
02.09.2015
S.No.
Features
14
Lighting
15
Lifting arrangement
[Logo of Utility]
rapid start fluorescent strip fixtures

with door actuated switches required
Removable lifting eyebolts shall be
used
1. Separate Marshalling cabinets for the system shall be supplied for terminating all
cables originating from the field and for distributing the signals to different
functional panels and cubicles.
2. The terminal blocks shall be cage clamp type. Fused terminal blocks hinged at
one end to facilitate easy isolation shall be used wherever necessary. All
cabinets shall be used with spare terminals for the spare inputs/outputs as
specified elsewhere in the specification. The type of terminals for terminations
from cabinets/panels shall match with the pre fabricated cables and pins
supplied.
3. The terminals for field cables shall be arranged in a logical order of
equipment/system wise.
4. The marshalling cabinets, the terminal blocks, the terminals and the electronic
hardware if any, shall have identification numbers.
5. Each cabinet shall be used with one each 3 pin receptacles for 230 V, 1P, 50 Hz
and receptacles for 24V DC.
6. One of the doors shall be used with folder to keep the relevant engineering
document of the cabinet.
7. All cabinets shall have common key for locks.
8. Door shall have concealed type of hinges with 120 degree swing.
9. Door latches shall be of the three-point type to ensure tight closing.
10. Separate Power & shield earthing bus shall be used at the front & rear side of
the cabinets. The earthing bus shall be isolated from panel body by suitable
insulation material.
17.4
Local Instrument Enclosure & Racks

1. Transmitters and switches, devices, etc. mounted in the field shall be suitably
grouped together and mounted in local instruments enclosures in case of open
areas of the plant and in local instrument racks in case of covered areas. These
local instrument enclosures and racks shall be furnished as per the project
requirements.
2. The local instrument enclosures shall be constructed of 2 mm sheet plate and
shall be of modular construction with one or more modules and two end
assemblies bolted together to form an enclosure. Vibration dampeners shall be
installed for supporting each enclosure. The internal layout shall be such that the
impulse piping/ blow down lines are accessible from back doors of the enclosure
and the transmitters etc. are accessible from front side for easy maintenance.
Gaskets shall be used between all mating sections to achieve protection class of
IP-65.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[246]
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[Logo of Utility]
3. The local instrument racks shall be free standing type constructed of suitable 3
mm thick channel frame of steel and shall be used with a canopy to protect the
equipment mounted in racks from falling objects, water etc. The canopy shall not
be less than 3 mm thick steel, and extended beyond the ends of the rack. Bulk
heads, especially designed to provide isolation from process line vibration shall
be used. Exact fabrication details shall be as finalized during detailed engineering
stage. The junction box for racks also shall conform to IP 65 protection class.
4. Provision for continuous purging arrangement is to be made for all air and flue
gas applications.
5. Each transmitter enclosure housing instruments i.e. for air and flue gas
applications, requiring purge air for continuous air purging shall be used with
common purge air header, air filter regulators of sufficient capacity, required
pressure gauges, valves, fittings, SS tubing and individual purge meters for each
purge line etc. as required.
6. The junction box of Local Instrument Enclosure & Racks shall be used with
hinged type door, latch for locking & gland plates for cable entry. All terminals in
junction box shall be of rail mounted cage clamp type suitable for conductor size
up to 2.5 Sq. mm.
17.5
Local Junction Box

Table 17.3
Specifications for Junction Box
S.No.
Features
No. of Ways
2
3
4

Protection class
Cable entry
Mounting
Terminal Blocks
7
8
Grounding
Gland plate
Door
10
Accessories
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
32 (2X16) with 20% spares

terminals
3 mm thick Stainless steel
IP-65 for outdoor/ IP 55 for Indoor
Bottom
Suitable for Wall/column/structures
mounting
Rail mounted cage-clamp type
suitable for conductor size up to 2.5
mm2
Removable type
Single Lockable door with gasket,
able to open sideways, turnable
hinge based, latch type lock without
handle with common key.
Tag plate, clamps, fixtures, bolts
(SS), nuts (SS), Gasket (Neoprene),
cable glands (SS), Lugs (Brass), Fire
proof compound for sealing.
Description
Page
No.
Date of Issue
[247]
02.09.2015
[Logo of Utility]
1. All JBs for outdoor application shall be used with individual canopies to prevent
ingress of water.
2. All JB shall have provision to add 10% additional TBs.
3. The marking on terminal strips shall correspond to the terminal numbering on
wiring diagrams.
4. Separate Terminal blocks shall be used for Analog & Digital Signals & also for
signals with different voltage levels.
5. The terminal blocks shall be arranged with at least 100 mm clearance between
two sets of terminal blocks and between terminal blocks and junction box walls.
6. Separate shield bus shall be used with screw connection for terminating cable
shields.
7. All spare cable entries shall be used with plugs.
8. All wires in JB shall be neatly dressed & ferruled.
9. Double deck type terminal block shall not be used.
Table 17.4
Specifications for Cable Glands
S.No.
Features
1
2
3
4
5
Type
Entry Thread
Material
Finish
Protection
Accessories
Double compression
NPT
Brass
Cadmium Plated
IP-54 or better
Neoprene gasket, Locknut, Reducer
etc.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[248]
02.09.2015
18.
TIME SYNCHRONIZATION SYSTEM (MASTER CLOCK SYSTEM)
18.1
1.
2.
3.
4.
18.2
[Logo of Utility]

General
A Global Positioning Satellite (GPS) based Master Clock System shall be provided
with the Plant DCS system. Necessary signal output for time synchronization
from Master Clock System shall be made available to the SG control system to
have common time reference.
The system shall be provided with a GPS based date insensitive master & slave
clock system (common for the station) for time synchronization of all plant
control systems & equipments.
The system shall be complete with receiving antennae (for receiving time from
GPS), receiver and associated electronics, Redundant Master Clocks, Slave
Clocks, interconnecting cables, cubicles, power supplies & any other
accessories.
The master clock shall have adequate number of communication ports to provide
independent time reference signals for the following applications:
a) All DCS system equipment including plant common systems.
b) SER systems.
c) All PLC based BOP & offsite plant control systems
d) Vibration monitoring system for Unit specific requirements and for plant
utilities.
e) PADO system.
f) Computerised Maintenance Management system
g) Management Information system
h) Station LAN Server
i) SG Integral control systems.
j) TG Integral control systems.
k) SG Flame monitoring & analysis system.
l) Any other equipment requiring time synchronising.
The following spare ports shall be as a minimum:
a) Spares for Hour Pulse
b) Spares for Minute Pulse
c) Spares for Second pulse
d) Spares for BCD real time output with one (1) second frequency
e) Spares for serial time code in IRIG-B format with one (10 second frequency.
f) Spares for serial time code in RS 232 C with one (1) minute frequency.
Design Requirements
1. The offered master clock system shall be a fully wired panel consisting of the
following minimum items & shall be located in Equipment Room in CCR :
Document Number
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03
Description
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No.
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[Logo of Utility]
a)
b)
c)
d)
e)
f)
2.
3.
4.
5.
6.
GPS Antenna
GPS Receiver
Local display unit
Power supply
All required cables, mounting accessories, cabinet for the processing
electronics etc.
The system shall be designed in a 100% redundant configuration and shall
include two master clock systems.
The Master Clock System shall receive the synchronizing pulses from the GPS
system and form a common time reference for recording of any event, logs and
reports, which may take place in any portion of the network distributed
throughout the Plant. Global Positioning System, to which the Master Clock gets
synchronised, shall be an absolute system to provide continuously 3 dimensional
position fixing, velocity measurement and Time reference generation
The master Clock shall be configured as Real Time Clock with display of time in
24 hrs format & it shall drive the slave display units. It shall be ensured that loss
of any slave display unit does not affect the display of any other slave unit. The
character size of slave display unit shall be minimum 100 mm LEDs (4). Since
the timing synchronization of many off-site facilities is being done through
station LAN, the slave clocks may be alternatively driven by respective systems /
sub-systems.
Accuracy of the master clock system shall be as follows:
a) PPS output
: +/- 500 nano second or better.
b) IRIG-B output
: +/- 200 micro second of UTC or better
All the cables for interconnection between Master Clock and Slave Clocks &
other systems shall be provided. This shall include all signal cables, (minimum
Type-G cable as per specification) as well as power supply cables.
Table 18.1
Specifications for Master clock system
S.No.
Features
1
2
3
4
5
6
7
8
9
10
GPS Antenna type

Noise
GPS Receiver
Tracking method
Output data format
Communication speed
Output rate
Signal Processing unit
Reference
Time accuracy
Helical
Less than 6 dB
Micro processor based
Code/carrier tracking
NEMA 0183 or equivalent
9600 BPS or better
Every Second
Micro processor based digital type
OCXO with stability of 1 PPM
1 PPM
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[250]
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19.
[Logo of Utility]
UNINTERRUPTED POWER SUPPLY (UPS)

19.1
General
assembly, testing at manufacturer's works, supply in properly packed condition
for transport to site, Erection, site testing and commissioning] of UPS system
complete with all accessories for efficient and trouble-free operation of R&M of
Unit No. [..] of [Name of the Power Plant] at [District], [State] for [Name of the
Client].
19.2
Scope of Supply
Redundant, 230 VAC Uninterrupted Power Supply (UPS) System for various C&I
packages including the plant control system (DCS) consisting of 2x 100%
capacity static inverters, 2 x 100% capacity static switches, Manual by-pass
switch, 2x 100% capacity float-cum-boost chargers, Battery with accessories,
Step-down transformer, Voltage Stabilizer, 2x 100% AC Power Distribution
Boards etc. shall be provided. UPS shall be provided with all interconnecting
cable between UPS equipment and battery, UPS system cabinets and enclosures
etc.
UPS shall be provided with all equipment and accessories required for
completeness of the system including any feeder distribution as required for
protecting UPS equipment and connected inputs and outputs shall be furnished
in line with the specification.
19.3
Technical requirements
1. The equipment furnished under this subsection of the specification shall meet the
requirements of all applicable codes and standards including ANSI, NEMA, IEEE,
NEC and IS.
2. The UPS equipment and the complete system shall have Surge Withstanding
Capability (SWC) to meet the requirements of ANSI C 37.90a - IEEE Standard
472-1974.
3. The UPS shall be provided to cater to all the loads for systems, equipment and
instruments requiring UPS supply. Spare feeders of at least 10% of the total
number of feeders shall be built in.
4. The selection and selective co ordination of all the protecting devices including
fuse free circuit breakers/ fuses shall conform to the requirements of National
Electric Code NEC 1984 and other applicable codes and standards. The
selectivity ratios of the fuses shall be such that there is a sufficient margin
between the total electric energy of the upstream fuse. The selectivity ratio shall
be not be less than 2:1 in any case.
5. The following general requirements shall be met for ensuring proper branch and
circuit protection-
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LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
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[Logo of Utility]
a) The feeder fuse ampere rating and feeder conductor ampacity must be at
least 100% of the non continuous load plus 125% of the continuous load as
calculated per Article 220 (220-10 G) of NEC Code- 1984. The feeder
conductor must be protected by a fuse not greater than the conductor
ampacity.
b) Each ungrounded service entrance conductor shall have a fuse in series with
a rating not higher than the ampacity of the conductor.
c) If secondary fuses are sized not greater than 125% of transformer secondary
current, individual transformer fuses are not required in the primary, provided,
the primary feeder fuses are not larger than 250% of the transformer rate
primary current.
6. The UPS system shall be suitable for operation at ambient conditions indicated in
the specification.
19.4
Functional requirements
1. The Uninterrupted Power Supply (UPS) system of continuous duty shall supply
regulated, filtered and uninterrupted 230V, 50 Hz, single-phase power, within
specified tolerances. Each of the UPS loads shall receive one feeder each from
the AC Distribution Board of Inverter A& B. However, each inverter shall supply
only 50% loads under normal conditions.
2. Each UPS System component shall be compatible for satisfactory and well
coordinated operation with other related components as well as with the input
and output systems.
3. The KVA rating of the UPS shall be guaranteed at 230VAC, 50 Hz, single phase
output at 50 deg C ambient temperature and load factor of 0.8 lagging. In case,
the standard UPS rating are applicable at an ambient temperature lower than 50
deg C, then derating factor of at least 1.5 % / deg C shall be considered. The
Bidder shall demonstrate the above stated capacity at 50 Deg C during shop
testing.
19.5
Normal Operation
1. During normal operation, UPS loads shall be supplied by both 100% capacity
inverters each working at 50% load. The inverters shall receive power from DC
source (Charger/Battery) and their static switches shall be in the respective
"Inverter" position. In this mode the two inverters shall act as hot standby for
each other.
2. Necessary paralleling networks shall be included to ensure equal load sharing by
both inverters. The rating of the paralleling device / circuit shall be such that it
does not act as a limiting factor on the fault clearing capability of the inverters
individually and when working in parallel. Load sharing network details shall be
provided to establish all functionalities including fuse clearance.
3. One inverter shall act as 'Master", working on its internal oscillator and the
other inverter shall follow by using the synchronising signal from master inverter
for automatic control of its output frequency.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[252]
02.09.2015
19.6
[Logo of Utility]
Emergency operation
In case of failure of any inverter, the static switch shall automatically transfer
the UPS loads of faulty inverter (say Inverter-"A") to the healthy Inverter-"B"
which shall start working at 100% capacity. Thus the feeding of UPS power is
continued automatically to all loads connected to both inverters despite the
failure of one inverter and the quality power supply to all UPS loads connected to
both inverters shall be maintained without interruption. Isolation of faulty
inverter shall be automatic and achieved in less than 4 mille seconds.
1.
2.
3.
4.
5.
6.
On inverter failure, the plant AC source is automatically brought in as the

standby source to healthy Inverter working at 100% capacity. In this mode, the
healthy Inverter shall get the synchronizing signal from the standby AC source.
Operation on internal oscillator and transfer/retransfer to standby source shall be
as follows:
The output frequency of the healthy inverter shall be automatically synchronised
with the plant stand-by AC source supplied through step down transformer and
voltage stabilizer using synchronizing signal from the standby source. If the
frequency of the standby source is beyond these limits, the inverter frequency
control shall be automatically disconnected from stand-by synchronizing signal
and the inverter shall maintain the output frequency at 50 Hz within + 0.1
percent under all conditions of load and input voltage by working on its own
internal oscillators.
During operation on its own internal oscillator, the inverters shall continuously
monitor the frequency of standby source. Upon restoration of proper frequency
conditions of stand-by source, the inverter shall automatically start using standby source frequency as the synchronizing signal for inverter output frequency
control.
During the operation of any inverter on its internal oscillator due to synchronizing
frequency being beyond the specified limits, the transfer of static switch from
"Inverter" to "Standby source" shall be inhibited.
While one of the inverters (healthy) is feeding 100% load and the AC source is
acting as standby, and in case this inverter also fails, the 100% load shall be
automatically transferred from inverter to standby AC source through static
switch, provided the standby source is synchronized to the inverter (synchronous
transfer). However, such transfers shall be inhibited during operation of inverter
on its internal oscillator due to standby AC source frequency being beyond the
synchronization limits. Asynchronous transfer of inverter loads to standby AC
source with a beak, on inverter failure shall be envisaged.
Retransfer of loads from standby AC source to inverter shall be automatic or
manual as pre selected by the operator and shall be accomplished only after
synchronism of the inverter output with the standby source has been
automatically accomplished.
The manual bypass switch shall have the provision for fully by-passing the UPS
system and connecting all UPS loads to the standby AC source.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
[253]
02.09.2015
[Logo of Utility]
19.7
Static inverters and auxiliary equipment
19.7.1
The static inverters shall be solid state type employing silicon controlled rectifiers
or power transistors and other solid state devices to convert direct current power
to essentially sinusoidal alternating current power as per this specification. Ferro
resonant type inverters shall not be acceptable. The inverter equipment shall
include all necessary circuitry and devices to conform to requirements like
voltage regulation, current limiting, wave shaping, transient recovery, surge
suppression network, automatic synchronisation etc. as specified herein.
Inverter shall be of continuous duty. Natural convection or forced cooling using
redundant fans shall be used. Equipment shall be designed for operation with
full load even with cooling fans failure / non-availability.
Inverter Capacity
Each static inverter shall have the following minimum capabilities. Continuous
full load rating: meeting specification stipulations Over load capacity: 125% of
full load rating for 10 minutes and 200% for 10 seconds minimum and 300% for
4ms minimum for all specified input voltages.
The inverter shall have sufficient I2t capability to clear a slow acting HRC fuse
having a continuous current rating equal to at least 20% of the continuous full
load current rating of the inverter, while feeding 100% rated loads of the
inverter.
19.7.2
Voltage regulation:
1% for 0-100% load at all input voltage and all power
factors.
Step load pick up: Upon transfer of full load, the inverter output voltage shall not
drop below 85% of nominal voltage during the first half cycle after transfer and
90% of nominal voltage in the next half cycle. The recovery to within 1% of
voltage shall be in less than 50 milliseconds.
The Bidder shall indicate the maximum current rating (in Amps) of slow acting
HRC fuse which can be cleared by the proposed inverters upon a branch circuit
or bus fault. This shall also be accompanied by calculations and test data.
Input / Output Voltage
The inverters shall be fed from Battery and chargers which do not feed any other
loads. Input voltage shall be nominal DC output voltage of battery and charger of
range from final voltage after discharge of battery to maximum DC bus voltage
during equalize charging of battery. The inverter shall also be capable of working
satisfactorily meeting all specification requirements with only the chargers
connected to its input without battery in circuit. Filtering on the input of the
inverters shall be furnished as required to operate with the output ripple of the
chargers. Each inverter shall include equipment necessary to protect itself from
damage resulting from excursions, loss or restoration of DC input voltage and
synchronizing voltage. The inverter output voltage shall be 230V AC, 50 hz,
single phase. Total harmonic content shall be 4% (max) and harmonic content of
any single harmonic shall not exceed 3%. The inverter efficiency at 100% load
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
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No.
Date of Issue
[254]
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[Logo of Utility]
19.7.3
and 0.8 pf shall be minimum 85% and at 50% load and 0.8 pf shall be minimum
80%.
Over loads, Short Circuits and Load loss
19.7.4
1. The inverters shall be provided with suitable fuses at the input and output which
shall permit proper co-ordination with other protective devices and at the same
time protect the inverter against damage due to internal faults. All necessary
equipment shall be provided to protect the inverters against over loads, short
circuits and 100% loss of load. The inverter shall be self protecting against
damage if energized with full load connected. All the fuses used in inverter
power & control circuits shall be fast acting type, operating in less than 5 ms.
2. The inverter shall be provided with current limiting circuitry which shall limit the
output current to a value which will not damage the inverter or blow its fuses.
3. The inverter shall have sufficient I2t capability to prevent damage to itself until
short circuit conditions on the output are cleared.
4. Each inverter shall be capable of operation with non linear loads. Bidder shall
furnish details of non linearity for the loads. Output waveform of the inverters)
shall remain within specified limits when operating with non linear loads at 100
percent rated load.
5. The inverters shall be self protecting against all AC and DC transients, voltage
surges and steady state abnormal voltages and current likely to be encountered
in utility power station.
Automatic Synchronization
1. Inverter equipment shall include stable solid state oscillator devices designed to
automatically maintain the inverter output in phase and in synchronism with the
standby AC source. The frequency regulation shall be automatic within +/0.1% for all conditions of inputs, loads and temperature occurring
simultaneously or in any combination.
2. Facility shall be provided for automatic transfer to internal oscillator operation
when the standby source frequency is not within the synchronization limits.
3. Provision shall be made for step less adjustment of synch disconnect frequency
range from 50 Hz +/- 0.5 Hz to 50 Hz +/- 2 Hz.
4. Automatic adjustment of phase relationship between inverter output and standby
AC source shall be gradual, at a controlled slew rate which shall not exceed one
Hz per second.
5. The inverter shall normally work on the internal oscillator with either of the two
inverters as master synchronizer and the other following it. Suitable selector
facility shall be provided to select the master. When any one inverter fails the
healthy inverter gets the synchronizing signal from the standby A.C. source.
The DC input current shall never exceed the full load current except for a short
circuit within the inverter. This limitation applies to transient as well as steady
state currents and includes in rush currents upon initial energisation of the UPS,
load energisation, short circuits external to the inverter etc. For any value of the
load and load power factor drawn by the equipment served, the inverter shall not
Document Number
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impose on DC source any voltage oscillations in excess of 5 volts (RMS total, all
frequencies) or any current oscillations in excess of 3 percent (RMS total, all
frequencies) of the DC current at full load.
19.7.5
Static inverter auxiliary equipment

In addition to the inverter equipment specified above, auxiliary equipment shall
be furnished with each static inverter as follows:
1. Output ammeter, Output voltmeter, Output KVA meter, Input voltmeter,
Frequency meter, Power factor meter, Inverter ON-OFF switch, Alarm Reset
Push Button etc. of one number each shall be provided on the front panel of the
inverter enclosures.
2. Indicating lights shall be furnished on front of the UPS panels. For those
abnormal conditions which could be of a momentary nature, the indicating lights
shall remain energized and the contact remain closed until cleared by a reset
push button on the panel.
3. The following indications shall be provided as a minimum i.e. DC voltage to the
Inverter Low/ High, Loss of DC input to the inverter, Inverter output voltage
High/ low, Inverter failure, Standby AC source failure, Inverter synchronized with
standby AC source in case of failure of the other inverter, Inverter feeding 100%
UPS load, Standby AC source feeding 100% UPS loads, Fan failure and
temperature high etc.
4. In addition to the above indications, the Bidder shall furnish electrically
independent, potential free contacts for each of the above conditions. These
contacts shall be rated for 0.5 Amps, 220 Volts DC and shall be wired to the
terminal blocks.
5. The 4-20 mA signals for Inverter A & B output voltages, output currents, output
frequency etc shall be furnished.
19.8
Static transfer switches and auxiliary equipment

1.
2.
3.
4.
5.
The static transfer switches shall be provided to perform the following functions
To transfer the load automatically between the Inverter to the standby inverter
as described under automatic synchronization.
To transfer UPS load under manual control from standby AC source to inverter
when placing the UPS System in service and from inverter to standby AC source
when taking the UPS out of service.
The static transfer switches shall have two modes of operation namely
automatic and manual.
The static transfer switches shall use silicon controlled rectifiers and other static
devices required for automatic transfer of load from Inverter to Standby source
and vice versa.
The static switches shall be provided with the requirements specified herein
including the following:
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Description
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No.
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a)
b)
c)
d)
e)
f)
g)
h)
i)
[Logo of Utility]
Capacity(continuous)
Continuous full load capacity of the

inverter.
Capacity (overload)
As per overload capacity of inverter
indicated in the specification
Capacity (Peak)
1000% of continuous rating for 5
cycles.
Transfer Time
1/4 cycle maximum. (The transition
shall be "make before break". Voltage
failure shall be sensed at the output of
static switch
Voltage Rating (Nominal) 230 Volts, 50 Hz, single phase.
Transient
Voltage 340 Volts peak above the normal line
Tolerance
voltage.
Ambient temperature
50 deg C max.
Cooling
Natural or forced circulation, using
redundant fans.
Duty
Continuous
6. The transfer of static switch from normal "Inverter" position to "Stand-by"

position shall be initiated by Inverter failure and UPS system trouble, Static
switch output voltage failure, over current or manual push button operation.
The UPS bus shall be monitored by two voltage detectors. One fast acting circuit
shall be used for detecting a complete and instantaneous voltage loss while the
other slower acting averaging circuit with adjustable trip level shall be employed
to detect voltage deviation beyond selected limits. Both voltage detector circuits
shall automatically initiate operation of static transfer switch.
UPS bus current shall be continuously monitored by a current monitoring
detector. This detector shall operate the static transfer switch when the load
current exceeds the overload rating of any inverter. The detector shall rest when
the load current falls below the rated current of the inverter resulting in
retransfer of static switch with inverter position.
The static switch shall automatically transfer the load from inverter to stand-by
AC source when the maximum I2t capability of the inverter is reached or when
the inverter output voltage drops below 90%.
Over current transfer limit shall be continuously adjustable from inverter
continuous rating to inverter current limit rating.
7. Transfer Inhibit of static switch shall be under the following conditions:
a) Automatic or manual synchronous transfer of load from inverter to stand-by
AC source or vice versa, shall be inhibited when the inverter frequency is not
synchronized to the alternate source. However, asynchronous transfer facility
under such condition shall be provided.
b) Transfer resulting from overload shall be inhibited when the standby AC
source is not available. In this case the load fed by the inverter shall be
automatically disconnected.
Document Number
Rev
No.
LII-GETS12021-G-00129-001
03
Description
Page
No.
Date of Issue
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[Logo of Utility]
19.8.1
8. Static transfer switches shall be provided with necessary protective devices

(circuit breakers) both in "Normal" as well as "Stand by" position.
9. The static switches shall be furnished with contacts to alarm failure of the
alternate source or opening of any fuse protecting the static switches.
10. Auxiliary equipment for static transfer switch
11. Following auxiliary equipment shall be furnished with each static transfer switch
a minimum:
a) Red indicating Light to indicate switch in Normal position, Green indicating
Light to indicate switch in Standby position, White indicating Light to
indicate Normal and Standby, power sources in synchronism, Pushbutton to simulate normal AC UPS power failure (sensed at static switch
output) to test the satisfactory working of static switch, transfer labeled
Transfer Test, Push-button for manual retransfer of static switch to
Normal position, Push-button for manual transfer from normal to alternate
source, Light to indicate standby AC source voltage deviation high, Light to
indicate voltage transfer enabled, Light to indicate voltage transfer disabled
etc shall be provided on the front of the enclosure.
b) Two (2) number each of NO contact for static switch transfer to Standby
position and standby source voltage deviation > +/- 2 % from normal shall
be provided within the static transfer switch enclosure.
Manual by-pass switch
19.8.2
1. The manual by-pass switch shall be used to isolate any static switch from its
load and stand-by power supply and to take the static switch out of service
without power interruption to the load. In doing so, the manual by-pass switch
shall connect both load buses to a single inverter. The manual bypass switch
shall provide the facility for by passing the entire UPS system during the
operation of the UPS in the option of the operator.
2. The manual bypass switch shall have make before break contacts to ensure
continuous supply to UPS loads during the operation of the same.
3. The manual bypass switch shall be rated for 600 Volts, 50 Hz, single phase
operation. It shall have continuous load carrying capacity equal to full load
inverter current and necessary short term load carrying and interrupting capacity
to meet the requirements of the UPS system.
4. Another bypass and disconnect devices shall be envisaged as required for orderly
start up, shut down and maintenance of UPS system and system components.
5. The manual by-pass switch and required disconnect devices shall be furnished
duly mounted and wired in enclosure.
Float-cum-boost chargers and auxiliary equipment
1. Two 100% capacity chargers shall be furnished for the UPS system. Each
charger shall confirm to the following requirements.
2. Each charger furnished for UPS system shall be adequately rated to ensure that
any one shall meet full DC load of UPS system operating at 100 % rating plus
recharge the fully discharged UPS batteries.
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Description
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No.
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3. The chargers shall be served from a 415 volt, 50 Hz, 3 phase system. The
chargers shall maintain the output voltage within plus and minus 0.5 % from no
load to full load, with an input power supply deviation in voltage level of +/- 10
% and input power supply deviation in frequency of +/- 5 % and with both
deviations present in any combination.
4. In addition to supplying DC power for inverters, the chargers shall be designed to
charge a fully discharged battery without over loading or causing over voltage or
without causing interrupting operation of AC or DC circuit breakers for the entire
range of intended operating regimes. Suitable solid state electronic circuits shall
be provided to ensure that the charging current is voltage regulated and current
limited. After the battery is recharged the charger shall maintain the battery at
full charge until the next emergency operation when the UPS battery is again
required to provide DC power.
5. Float and equalizing controls shall have an adjustment range of +/- 5%
continuous (without steps).
6. The chargers shall be self-regulating, solid state, silicon controlled, full-wave
rectifier type designed for single and parallel operation with the battery specified.
The chargers shall be designed for automatic load sharing during parallel
operation.
7. The charger shall be current limited at 125% of full load to reduce output
voltage for charger circuit protection and for protection of battery from
overcharge. The current limit shall be continuously adjustable from 80% to
125%.
8. All necessary equipment and devices shall be provided to protect the charger
from short circuits, transient voltages, surges, load and supply fluctuations
including sudden loss of input or load.
9. The charger shall have a slow walk-in circuit which shall prevent application of
full load DC current in less than 10 seconds after AC power is energized.
10. The minimum full load efficiency at nominal input and float output shall be 90%
or better. The output regulation, ripple content and power factor shall meet the
requirements of UPS system offered.
19.9
Battery Charger Auxiliary Equipment

Following auxiliary equipment shall be furnished for battery charger a minimum:
1. AC Voltmeter, DC Voltmeter, AC Ammeter, DC Ammeter, Charger On-Off push
buttons, Potentiometers (one "Float Voltage Adjust" and one "Equalizing Voltage
"Adjust", both with manual adjustment knobs, the settings of these knobs, shall
be independent of each other), Selector Switch for float charge / Equalizing
charge, Charging rate setter, Selector switch and lights for ground fault detector,
Indicating lights with proper actuating devices, Circuitry and legend etc shall be
furnished on the front of the panel of the charger enclosure.
2. Indications such as Failure of input AC supply, Charger failure, System on
battery operation, Battery equalize timer 'on', Low battery voltage, DC ground
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fault, Redundant fan failure and temperature high (if provided), Charger fuse
failure, Low DC output voltage, High DC output voltage etc.
3. One set of independent potential free contacts rated for 0.5 amps, 220 volt DC
shall be furnished for the alarms above and wired to terminal block for use of
alarm annunciation system.
19.10
Ground Detector System

Each charger shall be furnished with a ground detector system consisting of a
relay and a centre tapped resistor. The resistor shall be connected between the
positive bus and the negative bus. The relay coil shall be connected to resistor
and ground. The relay shall be furnished with one normally open and one
normally closed contact wired to terminal blocks for connection to external
circuits.
Two indicating lights and one three position spring return to centre selector
switch mounted on front of charger cabinet shall be provided for each ground
detector system.
19.11
UPS Battery
1. The battery shall be heavy duty Nickel-cadmium type and shall have sufficient
Amp-hour capacity to supply 100% full load current of UPS for one hour. The Nicd battery shall conform to IS: 10918 and shall be sized according to IEEE Std.
1115.
2. The battery shall be high discharge performance type to withstand
discharge/charge cycles throughout life without loss of capacity. In battery
sizing calculation, Bidder shall also take into account a minimum voltage drop of
2.5 volts from battery room to the inverter input.
3. Battery sizing calculations, supporting curves/data etc. with the proposal to
demonstrate that the proposed battery capacity meets the above specification
shall be furnished.
Various correction factors such as capacity factor,
temperature derating factor (at a minimum electrolyte temperature of 4 C),
design margin shall be take in to account as per data below:
a)
b)
c)
d)
i)
Temperature derating factor (At : (Td)

an electrolyte temperature of
40C)
Design margin
: 20% = 1.2
Capacity
factor
(KT)
(For : AH capacity of chosen cell
discharge duration of1 hr. & end
/(discharge current in amp for
cell voltage of1.1 volts)
chosen cell Corresponding to 1
hour) x Float correction factor.
The UPS battery shall be :
furnished as specified herein
and
shall
meet
following
requirements.
Nominal Voltage
: As per the requirement of
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ii)
iii)
iv)
Ambient temperature
Specific gravity, full charge
Voltage per cell
Nominal
Floating
Boost
End cell voltage
[Logo of Utility]
nominal DC voltage level at

the input of the inverters.
: 50 C max.
: 1.19 0.01
:
:
:
:
1.2 V
1.40 V to 1.42V
1.53 V to 1.67V
1.1 Volts
19.12
Battery Accessories
19.12.1
2 nos. of Hydrometer along with syringes suitable for vent holes in different
cells, Thermometers, Specific gravity correction chart, Wall mounted type holder
made of teak wood for hydrometer & thermometer, Cell testing voltmeter (3-03V), Acid/Alkali mixing jar 2 nos. Rubber apron, Rubber gloves, Set of spanners,
Goggles (industrial) Instruction Card, Variable metallic resistor & shunt, lnter cell
connectors, Suitable terminal lugs for cables, Two tier teakwood battery rack,
Jack for lifting the cells etc shall be provided as accessories and fittings of the
Batteries and auxiliaries.
Step-down transformer & voltage stabilizer
19.12.2
One 415 Volt, 3 phase to 240 Volt, single phase transformer along with
associated voltage stabilizer shall be furnished.
This transformer and stabilizer combination shall convert 415 Volt +/- 10%
plant auxiliary AC supply to 230V, +/- 2% single phase standby AC Power,
which shall serve as UPS system back up supply source.
The transformer and stabilizer shall be sized for 100 % UPS load and shall coordinate with the largest branch circuit protection device for feeder short circuit
current without sacrificing voltage regulation. The voltage stabilizer shall employ
silicon solid state circuitry and shall maintain a stabilized voltage for 0 -100%
load with input voltage variations as indicated above.
The stabilizer shall meet the following characteristics as a minimum. Fast rate of
correction - within 5 cycle; Output distortion - less than 5% under worst
conditions; Efficiency shall be better than 94%; No load losses less than 5%.
AC Distribution Boards
Panel boards for distribution of continuous AC power to essential loads shall be
dead-front type panel boards rated for 600 V, AC service. Sheet steel thickness
shall be 3 mm for load bearing member and 1.6 mm for other members. The
hinged panel board front shall cover the fuses and wiring gutter but not the
switch handles. The hinged front and switch handles shall be covered by the
enclosure-door.
Each panel board shall be constructed for 2 wire, single phase distribution with
solid neutral bar. Phase and neutral bars shall be of copper. Rating of the main
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19.12.3
[Logo of Utility]
lugs shall be equal to the rated continuous full load current of each inverter.
Type of enclosure shall be IP 42 as a minimum.
Each panel board shall have one fused disconnect switch of adequate rating for
incoming feeder for AC Bus and requisite single pole, suitably rated disconnect
switch branch circuit devices. Fused switches shall be equipped with arc
quenchers, visible blades and quick-make quick-break operating mechanisms.
The number of feeders and rating of each feeder shall be to suit the individual
load requirements.
The AC distribution board and components thereof shall be from the latest
proven product range of a qualified manufacturure. However, 25% spare feeders
with fuses of each rating shall be provided.
Wiring and interconnections
All interconnections required from input to output terminals or outgoing inverter,
transfer switches and distribution board equipment shall be provided within the
enclosures in accordance with the manufacturers proven practice, applicable
international standards and good engineering practice. Internal wiring in factory
pre-wired electronic systems cabinets may be installed according to the standard
practice as to wire size, insulation and method of termination on internal
equipment. Wiring for external circuits including all alarm contacts shall be
brought to grouped terminal blocks located for convenient connection for
external circuits entering from top or bottom.
Document Number
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No.
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No.
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OF

R&M CONTRACTORS

VOLUME-II
SECTION-II, PART-D
DETAILED TECHNICAL SPECIFICATION-CIVIL
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Power Plant]
[Logo of Utility]

Volume
Volume-I
Section
Part
Description
---
---
Commercial
Section-I
---
Part-A
Detailed Technical Specifications Mechanical
Part-B
Detailed Technical Specifications Electrical
Part-C
Detailed Technical Specifications

I&C
Part-D
Detailed Technical Specifications Civil
---
Part-A
---
Part-B
---
Part-C
---
Part-D
Not Used
Volume-II
Section-II
Volume-III
*****
Document No.
LII-GETS12021-G-00129-001
Rev
No.
02
Description
Volume-II, Section-II, Part-D
Page
No.
[i]
Date of issue
25.09.2014
Power Plant]
[Logo of Utility]
1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
*****
Document No.
LII-GETS12021-G-00129-001
Rev
No.
02
Description
Page
No.
[ii]
Date of issue
25.09.2014
Power Plant]
[Logo of Utility]

1.
2.
3.
4.
5.
6.
7.
8.
9.
Spare Parts
10.
Annexure
SECTION-II:
1.
2.
3.
4.

*****
Document No.
LII-GETS12021-G-00129-001
Rev
No.
02
Description
Page
No.
[iii]
Date of issue
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Power Plant]
[Logo of Utility]

1.
2.
3.
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
02
Description
Page
No.
Date of Issue

[iv]
25.09.2014
Power Plant]
[Logo of Utility]
TABLE OF CONTENTS
1
CIVIL, STRUCTURAL, ARCHITECTURAL WORKS-DESIGN & EXECUTION CRITERIA . 1

1.1 Introduction ............................................................................................ 1
BUILDINGS & STRUCTURES ............................................................................ 2

2.1 Brief description of Buildings, Structures and Facilities .................................. 2
DESIGN REQUIREMENTS ................................................................................ 7

3.1 Location................................................................................................. 7
3.2 Ground Condition .................................................................................... 7
3.3 Climatic Condition ................................................................................... 7
3.4 Seismic Zone .......................................................................................... 8
3.5 Wind Zone ............................................................................................. 8
3.6 Loads and Load Combinations ................................................................... 8
EARTHWORK AND ROCKWORK .................................................................... 13

4.1 General ................................................................................................ 13
4.2 Fill Materials ......................................................................................... 14
4.3 Excavation ........................................................................................... 15
4.4 Safety Precautions ................................................................................ 15
4.5 Over Excavation .................................................................................... 15
4.6 Stockpiles and Disposal .......................................................................... 15
4.7 Preparation of Foundation ....................................................................... 16
4.8 Backfilling ............................................................................................ 16
4.9 Soil Replacement................................................................................... 17
4.10 Protection of Existing Utilities and Services ............................................... 17
4.11 Dust Control ......................................................................................... 18
4.12 Dewatering during Construction .............................................................. 18
4.13 Equipments .......................................................................................... 19
4.14 Execution ............................................................................................. 19
REINFORCED CONCRETE STRUCTURES AND FOUNDATIONS ............................ 21

5.1 General ................................................................................................ 21
5.2 Design Methodology .............................................................................. 21
General ...................................................................................................... 24
Loads ......................................................................................................... 25
Foundation Sizing......................................................................................... 25
Analysis and Design ..................................................................................... 26
Temperature Control of Concrete.................................................................... 27
Document Number
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Non-Shrink Grout for Equipment Foundations ................................................... 27

5.3 Stability of Structures ............................................................................ 29
5.4 Minimum Thickness of Concrete Structural Elements .................................. 30
5.5 Minimum Heights for Pedestal of Steel Columns ........................................ 31
5.6 Minimum heights for encasement of steel columns ..................................... 31
5.7 Concrete Works .................................................................................... 31
5.8 Strength of Concrete ............................................................................. 36
5.9 Materials .............................................................................................. 38
5.10 Dismantling/Demolishing and Modification in PCC&RCC .............................. 46
5.11 Minimum Cover to Foundation Bolts ......................................................... 47
5.12 Miscellaneous Requirements ................................................................... 47
5.13 Major Equipment Foundation ................................................................... 48
5.14 Transport of Concrete ............................................................................ 49
5.15 Concreting Operations............................................................................ 49
5.16 Compaction and mechanical vibration of concrete ...................................... 50
5.17 Finish of concrete .................................................................................. 50
5.18 Construction, expansion and contraction joints .......................................... 51
5.19 Concreting at night ................................................................................ 52
5.20 Protective measures for concrete ............................................................. 52
5.21 Concrete with Special Properties ............................................................. 53
5.22 Formwork ............................................................................................ 56
5.23 Water stoppers ..................................................................................... 59
5.24 Curing ................................................................................................. 60
5.25 Waterproofing/Damp proofing ................................................................. 61
5.26 Repair of damaged and defective concrete ................................................ 61
6
PRESSURE GROUTING.................................................................................. 62
6.1 Materials .............................................................................................. 62
6.2 Pressure Grouting Equipment .................................................................. 64
6.3 Execution ............................................................................................. 64
6.4 Field Quality Control .............................................................................. 66
6.5 Submittal ............................................................................................. 66
RETROFITTING WORKS ................................................................................ 67

7.1 General ................................................................................................ 67
7.2 Chipping of Unsound/Weak Concrete Material ........................................... 68
7.3 Removing concrete all around reinforcement including from its behind ........... 70
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7.4 Cleaning reinforcement of total rust including from behind reinforcement ....... 71
7.5 Cleaning Reinforcement and exposed concrete surface................................ 71
7.6 Providing drilling and inserting nipples along crack lines ............................... 72
7.7 Sealing of cracks by injection of advance grout .......................................... 73
7.8 Providing and inserting shear key bars ...................................................... 75
7.9 Reinforcement for RCC works etc. ........................................................... 76
7.10 Alkaline Passivating bond coat over Reinforcement ..................................... 77
7.11 Bonding coat for hardened concrete with repair concrete/ cement mortar....... 78
7.12 Curing of RCC Surfaces etc .................................................................... 80
7.13 Engineered Steel Tubular double Scaffolding System .................................. 82
7.14 Temporary barricading using angle iron verticals and sheet panels ................ 83
7.15 Temporary protective fabric screens ......................................................... 84
8
CONCRETE RETROFITTING METHODS ............................................................ 85

8.1 Retrofitting of concrete members ............................................................. 85
8.2 Retrofitting as a structural body .............................................................. 86
8.3 Foundation retrofitting ........................................................................... 86
8.4 Repair of cracks and missing sections....................................................... 87
SHORING AND UNDERPINNING ..................................................................... 88

9.1 Material and Equipment .......................................................................... 88
9.2 Execution ............................................................................................. 88
9.3 Shoring and Underpinning ....................................................................... 89
9.4 Concrete Piers, Walls and Pile caps .......................................................... 89
9.5 Piles and Caissons ................................................................................. 89
9.6 Load testing of piles and acceptance criteria.............................................. 90
9.7 Fill and backfill ...................................................................................... 91
9.8 Temporary Supports .............................................................................. 91
9.9 Restoration........................................................................................... 91
10 STRUCTURAL STEEL WORK.......................................................................... 92

10.1 Design ................................................................................................. 92
10.2 Fabrication ........................................................................................... 97
10.3 Erection .............................................................................................. 107
11 ARCHITECTURAL WORKS............................................................................ 111
11.1 General ............................................................................................... 111
11.2 Finishes .............................................................................................. 111
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11.3 Design Requirements ............................................................................ 111

11.4 Guideline for Architectural Works............................................................ 113
11.4.1 Roof Insulation and Ventilation ....................................................... 113
11.4.2 Roof Waterproofing....................................................................... 113
11.4.3 Brick/stone masonry and parapet wall .............................................. 113
11.4.4 Cement based polymer modified mortar ........................................... 114
11.4.5 Partition Wall ............................................................................... 116
11.4.6 Metal cladding ............................................................................. 116
11.4.7 Plastering .................................................................................... 117
11.4.8 Removal of plaster manually from masonry or concrete surface using chisel
and hammer and disposal of debris etc .......................................................... 118
11.4.9 False ceiling and under deck insulation ............................................. 118
11.4.10
Doors ....................................................................................... 118
11.4.11
Rolling shutters ......................................................................... 119
11.4.12
Windows & Ventilators ............................................................... 119
11.4.13
Plywood Covering Panels to Cover Windows etc. During repairs ....... 119
11.4.14
Facilities in Buildings .................................................................. 120
11.4.15
Glazing & Glazed Partition ........................................................... 121
11.4.16
Sealant..................................................................................... 121
11.4.17
Damp Proof Course .................................................................... 121
11.4.18
Plinth Protection ........................................................................ 121
11.4.19
Painting .................................................................................... 121
11.4.20
Flooring .................................................................................... 122
11.4.21
Miscellaneous............................................................................ 123
11.4.22
Skirting/DADO ........................................................................... 123
11.4.23
Roof access .............................................................................. 124
11.4.24
Roof Drains ............................................................................... 124
12 GENERAL REQUIREMENTS ........................................................................... 125
12.1 Roof ................................................................................................... 125
12.2 Waterproofing of underground structures ................................................. 125
12.3 Anti-termite treatment/Anti-weed treatment ............................................. 125
13 GENERAL CIVIL WORKS AND CONSTRUCTION TOLERANCES .......................... 126
13.1 Basic requirements for all civil works ....................................................... 126
13.2 Basic requirements during construction .................................................... 127
14 STANDARDS, CODES AND REFERENCES ....................................................... 129
14.1 General ............................................................................................... 129
14.2 Codes for Loads ................................................................................... 130
14.3 Codes for RCC ..................................................................................... 130
14.4 Codes for Structural Steel...................................................................... 130
14.5 Miscellaneous Codes ............................................................................ 132
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CIVIL, STRUCTURAL,
CRITERIA
1.1
Introduction
ARCHITECTURAL
WORKS-DESIGN
&
[Logo of Utility]
EXECUTION
This specification covers the design, preparation of general arrangement,

construction as well as fabrication drawings, supply of all labour as well as
materials and construction of all civil, structural as well as architectural work on
EPC basis for Boiler and associated structures for the Renovation and
Modernisation of existing [Name of project] Thermal Power Project of
[210/215/220/250] MW capacity. Description of various items of work under
this specification and nature of work in detail are given hereinafter. The
complete work under this scope shall be as per Volume-II, Section-I, Civil Scope
of Work.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
02
Description
Page
No.
Date of Issue

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BUILDINGS & STRUCTURES

Design and construction of new buildings, structures, foundations etc. as well
as repairing / retrofitting of existing buildings, structures, foundations shall take
into account requirement for operation and maintenance of all equipments and
its users. The buildings will have good architectural features. The surrounding
areas shall be properly micro levelled and graded. The architectural design
concept of buildings structure shall be evolved considering the functional,
technological and other requirements for efficient operation ensuring
comfortable working environment for personnel, satisfying the aesthetic
requirements. Special care shall be taken to provide elegance and aesthetics,
with effective use of appropriate treatment, materials fittings and finishes.
2.1
Due consideration shall be given for adequate natural lighting and ventilation
for both plant and non-plant buildings.
Retrofitting / repair works / new constructions shall not cause damage to the
existing structures. The temporary supports shall not be allowed on the
existing structures for any of these works unless the loads are minor and
may not cause any damage to any existing structure. However in such a
case Bidder shall take approval from the Owner/Consultant prior to initiating
the work.
Internal finishes shall be provided with latest available materials approved by

Owner/Consultant with due consideration of the functional aspect of the
area.
External finishes shall be provided with latest materials approved by

Owner/Consultant for improving the aesthetics.
The orientation of the important buildings shall be in line with the existing
site condition and function as such.
Each building shall have its own identity. However, a total homogeneity shall
be maintained in the design of all buildings.
Adequate frontage shall be provided to all important buildings to create a

better visual impact.
All other civil and structural buildings shall be developed in conjunction with
the above aspects.
Brief description of Buildings, Structures and Facilities

a) Boiler Structure and Boiler Area
[The Boiler shall be suspended from a steel structure provided by the Boiler
supplier, which shall be supported on reinforced concrete foundation
considering isolated /strip foundation based on soil investigation report.
Criteria for designing the steel structure are described in section-2. Roof of
steam generator shall be of permanently colour coated galvanised M.S
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troughed metal sheet of approved profile conforming to IS 14246. Minimum

base metal thickness shall be 0.8 mm. Proper drainage of the roof shall be
provided by means of gutters and down take pipes. Down take pipes shall be
GI pipes with threaded connections. Side cladding shall be of permanently
colour coated sheet as above but minimum base metal thickness of 0.6 mm.
Provision of Air conditioned rooms for VFD panels shall also be suitably
made in the steam generator area.
The reinforced concrete ground slab in the Steam Generator Areas shall
include floor drainage for cleaning purpose. All the floor drains shall be
connected to peripheral drains.
The RCC Transient pit for each unit (of suitable capacity as per technological
requirement) for collecting & transferring the water from the Slag bath
overflow water.
The RCC Underground sump with suitable compartments of adequate
capacity for settling, cooling of the hot water upto the required temperature
as per the system requirement along with suitable barricading system above
Finished floor level.]
b) Mill and Bunker Building including Bunkers
[The framing shall be of structural steel. This shall be designed as a moment
connection framing in the transverse direction and braced in the longitudinal
direction. These structures primarily support coalbunkers, coal feeders and
tripper arrangement to feed the coal into coalbunker.
The bunker shall be circular in plan and shall have the capacity as per the
requirement
stipulated
elsewhere
under Mechanical
section.
A
comprehensive flow ability study shall be conducted by the CONTRACTOR
for the coalbunker hopper to ensure smooth flow of coal in all seasons with
different moisture contents and different percentage of fines. Geometric
parameter of hopper and lining material shall be decided considering the
findings of flow ability study. For the cylindrical portion of the bunker 50 mm
concrete lining shall be provided using gunning technique, with nominal
reinforcement unless the CONTRACTOR recommends use of other types of
liners. Conical portion shall be provided with 5 mm thick liner of stainless
steel of grade SS 409.
Mills are to be located on the ground floor. In addition to Mill foundations
provision has to be made in the Mill bay ground floor for trenches
accommodating Mill reject system conveyors.
A Mill maintenance platform shall be provided at appropriate elevation to
attend to routine maintenance. This shall be a platform with chequered plate
or gratings over steel framing with handrail all round. Above this floor a
framing shall be provided to support under slung crane used for handling mill
maintenance work. The crane runway girders shall extend to the full length
of Mill bay to enable approach to the service bay also.
Document Number
LII-GETS12021-G-00129-001
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02
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Above this framing, feeder floor is provided. The extent of the feeder floor
shall be decided by the CONTRACTOR based on his maintenance
requirements. Feeder floor will be of RCC supported on structural steel
framework. Handrails shall be provided on all the sides. A steel staircase
shall be provided for access to feeder floor from ground floor. Access shall
so be provided to feeder floor from boiler elevator.
Framework for supporting the circular bunker shall be provided above the
feeder floor based on geometry of the hopper.
Bunker shall be provided with a top steel cover with slit openings for entry of
coal. On sides of the bunker necessary openings shall have to be provided
for bunker ventilation / dust extraction.
Tripper floor shall be immediately above the bunker. This floor shall be of
RCC supported on structural steel framework.
Tripper roof shall be of RCC supported on structural steel framework. Tripper
roof supports bunker ventilation / dust supporting structure. An RCC
parapet or steel handrail shall be provided for the tripper roof. An access
stair / ladder shall be provided from tripper floor to roof in each unit.
In addition to the above, framing arrangement for structural steel platform at
various levels around the bunker shall be provided with proper access ladder,
for poking, striking and attending to air cannons.
Tripper floor shall be given access through Boiler staircase / elevators.
Bunker supporting structure is normally left uncladded up to the bottom of
tripper floor. For tripper floor up to 3000 mm above finished tripper floor
level, brick wall shall be provided. Above this level permanent colour coated
galvanised trough sheet cladding shall be provided. Fixed steel windows
with 6 mm thick-wired glass shall be provided in the tripper house as per
requirements for conveyor gallery.
As the roof is accessible and maintenance crew is likely to work on this
floor, the entire floor shall be provided with cement / clay tiles set in CM
1:3, 25 thick and the tiles pointed with cement mixed with crude oil.
Rigid polyvinyl chloride pipes (PVC) of approved manufacturer conforming to
IS: 13592 shall be provided as rainwater down comer (RWDC) pipe. These
pipes shall be fixed and jointed strictly in accordance with the
manufacturers instruction. The minimum diameter of the pipe shall be 100
mm.
All structural steel work shall be given two coats of primer and minimum 2
coats of synthetic enamel paint of approved brand and shade. All exposed
gratings and handrails shall be galvanised. Expansion joint shall be provided
to the structure as required by IS: 800.]
Document Number
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02
Description
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c) Equipment Foundations (PA Fan, FD Fan, ID Fan etc.)

[All foundations shall be designed and constructed with the input data from
equipment manufacturer matching with the layout and levels of the relevant
structures. The foundation systems for rotating equipment will be sized and
proportioned not to exceed the bearing and settlement criteria and to assure
satisfactory performance of the equipment. In addition to a static analysis, a
dynamic analysis will be performed to determine the fundamental
frequencies of the foundation system. To preclude resonance, the
fundamental frequency of the foundation will be 20 percent away from the
operational frequency of the equipment. Amplitudes shall be kept within the
allowable limits specified by the manufacturer or in absence of
manufacturer's specified value, as specified in the IS Codes/ DIN Codes. The
dynamic behaviour of the foundation will meet the requirements of IS: 2974
(Part I to IV) Code of Practice for Design and Construction of Machine
Foundations. Foundations for rotating equipments like Boiler feed pumps,
ID/FD/PA fans, Coal mills, etc. shall be designed to carry loads furnished by
the equipment manufacturer.
All rotating equipment will be provided with vibration isolation system
mounted on foundations. The vibration isolation system supplied will be of
proven make, consisting of steel helical spring units and viscous dampers
(providing damping resistance in all three planes). The vibration isolation
foundation system will be provided for Boiler feed pumps, ID/FD/PA fans and
Coal mills. Equipment foundation will be separated from adjoining part of
building and other foundations joints at floor/slab will be suitably sealed
The vibration isolation system will be capable of vibration isolation not less
than 95%.
Foundations for static equipment e.g. Boiler, ESP shall be designed to carry
the loads furnished by the equipment Manufacturer.
If minor equipments with dynamic load are required to be supported on
building structures, floors etc. suitable vibration isolation will be provided.
The boilers shall be suspended from a steel structure provided by the boiler
supplier, which shall be supported on reinforced concrete foundation resting
on isolated /strip foundation. The Coal Bunkers, FD fans, PA Fans and PF
Mills sited adjacent to the Boilers shall similarly be supported on reinforced
concrete bases.
The foundations to the I.D Fan, units shall include reinforced concrete blocks
with anti-vibration mountings.
The reinforced concrete ground slab in the Boiler Areas shall include drainage
channels with water-jets for removal of boiler ash.]
d) Electro Static Precipitator
[Electrostatic Precipitator shall be supported by steel structure designed &
supplied by ESP manufacturer. ESP columns shall be supported by RCC
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pedestal resting on RCC strip/raft foundation based on soil investigation

report. External platforms shall be provided at various levels as per operation
and maintenance requirements. Access to the external platform shall be from
the internal staircase. Platforms shall be provided with steel grating or
chequered plate for access up to the roof of each ESP. Area below the ESP
shall be paved.]
e) ESP Control Room
[This shall be two-storied RCC framed structure. The ground floor shall
accommodate cable vault, toilet, and staircase. First floor shall accommodate
switchgear room, control room etc. Side cladding shall be of brick wall.
Staircase area shall be protected from fire safety angle as per TAC
regulations. Main door to switchgear room shall be steel sliding door having
adequate area to admit switchgear. There shall be minimum two doors to the
switchgear room of flush welded steel type. Control room should have one
swing type aluminium glazed double panel door and one single panel door.
Windows shall be steel glazed for switchgear room with wired glass. For
control room if window is provided the same shall be fixed with 5.5 mm
thick sheet glass. Main entrance of the building shall be provided with
suitable door matching with the aesthetic and architectural features of the
building. False ceiling of Aluminium type shall be provided in the Control
room. Under deck insulation shall be provided above false ceiling and Air
washer room.
Roof shall be given a slope of minimum 1 in 100 towards the side opposite
to transformer yard. Adequate number of rainwater down take pipe shall be
provided using rigid PVC pipe with a minimum dia. of 100 mm. Garland
drain as well as plinth protection shall be given around the building.]
f) Cable & Pipe racks
[The cable and pipe rack shall be structural steel. All the structural steel shall
be welded/ bolted. The foundations for the supports shall be of reinforced
concrete. All the pipe/cable racks falling in the Steam Generator area shall be
suitably connected to the pipe/cable racks of other areas as per the
piping/electrical requirements.
All cable and pipe routing in and out lying area shall run over ground on
structural steel pipe/cable racks at a height as per mechanical Volume II A.
Where the pipes cross roads clear headroom shall be as per mechanical
Volume II A. The racks can be multi tiered .Cable shall normally be laid
above the pipes. Expansion provision shall be provided wherever there is a
change in direction or where length of the racks exceeds 100 m. Access
ladder shall be provided at suitable location. Pipe & cable racks shall be
provided with walkways as per mechanical Volume II A throughout with GI
gratings.]
Document Number
LII-GETS12021-G-00129-001
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02
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g) Duct Supports
[Supports for ESP inlet duct between air preheater and ESP, between ESP
outlet flue duct and structure of Chimney shall be of structural steel
supported on RCC foundation and also columns supporting ESP.]
3
DESIGN REQUIREMENTS
3.1
Location
Geographical location of the plant site is approximately between [ N] to
[. N], Latitude and [.. E] to [.. E], Longitude.
3.2
Ground Condition
Subsurface condition: The natural ground surface level approximately varies
from [60 m to 74.5 m] from MSL.
[The soil profile in the plant area can be broadly classified into 3 layers namely
laterite, cemented sand and cemented silt in general as per detail soil
investigation report. Top soil upto a depth ranging from 0.4 m to 0.75 m is
entirely non-uniform. The underlying layer is laterite whose depth varies from
4.0 m to 5.5 m followed by deep layers of cemented silt and cemented sand].
The ground water table (GWT) at finished ground level shall be considered for
foundation design purposes.
The detailed soil investigation report conducted for plant shall be made available
to Bidder for required replacement / refurbishment / retrofitting of Foundations,
if any.
Bidder is advised to carefully study the content of detailed Soil investigation
report for the existing type of foundations and design of new ones.
The type, size, depth of the foundation shall be based on the detail soil
investigation report provided by OWNER.
3.3
Climatic Condition
a) Temperature
Maximum
: [..] C
Minimum
: [..] C
For design purpose, maximum temperature to be considered: [..] C
minimum temperature to be considered: [..] C
b) Rain fall
Minimum
Maximum
: [.. mm in May]
: [.. mm in October]
Peak hourly rain fall: [183mm] (corresponding to 50 years return period)

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[Note: Maximum per day rainfall as per weather report has been considered
conservatively as peak hourly rain fall which will be used for drainage
system design etc.]
Annual average: [.. mm to .. mm & average .. mm]
3.4
Seismic Zone
The site is located in [Zone II] as per IS: 1893-2002. Zone factor shall be
[0.10]. Importance factor shall be considered as [1.75].
3.5
Wind Zone
The site is located in wind speed zone [.. m/s] as per IS: 875 (Part 3)-1987.
3.6
Loads and Load Combinations

All new structures shall be designed and old structures requiring modification
shall be checked for the most critical combinations of dead loads, imposed
loads, equipment loads, wind loads, seismic loads, temperature loads, forces
developed due to differential settlement and any other loading conditions which
can occur during the design life of the facility.
(a)
Dead Loads
Dead loads consist of the weights of the complete structure with finishes,
fixtures, partitions, wall panels and all existing / modified / replaced equipments
of semi-permanent nature including storage structures partitions, roofing, piping,
cable trays, bus ducts etc. The content of storage structures etc. shall be
measured at full capacity for this purpose.
The piping loads (for empty, operating and test conditions), cable tray loads and
the contents of the storage structures shall be listed separately so that they can
be excluded from dead load when dead loads are acting as stabilizing load for
uplift.
The following unit weight of material shall be considered for computation of
loads. Loads given in IS: 875 (part-I) shall be made use of for material not listed
below.
Table 2.1
Weights of Material
Unit weight (kN/m3)
Material
Plain cement concrete
24.0
Reinforced cement concrete
25.0
Structural steel
78.5
Brick work
19.0
Cement plaster
21.0
Floor Finish
24.0
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Unit weight (kN/m3)
Material
lignite
(b)
[Logo of Utility]
12.6
Superimposed Live Load (SILL)
Listed below is the minimum SILL for the areas involved. Floors and supporting
members subjected to heavy equipment live loads shall be designed on the basis
of the equipment loads specified by vendor or specifically defined SILL
whichever is greater.
The specific minimum floor SILL is listed below:
Table 2.2
Superimposed Live Load (SILL)
S.No
a)
Description
SILL Value
Roof
Flat accessible roof
1.5 kN/m2
Flat accessible roof with HVAC

equipments, etc.
5 kN/m2
Flat inaccessible roof
0.75 kN/m2
Sloped Roof
As per code IS: 875 (Part-2)
b)
All building floors & Stairs
5 kN/m2
c)
Walkways of Conveyor Galleries
5 kN/m2 or Concentrated Load

of 3 kN at centre which ever
is critical
d)
M.C.C. Floor
10 kN/m2
e)
Equipment Load
As applicable
f)
Tunnels under road, culverts & its allied

structures including Concrete pipes
Class A / Class 70R as

per IRC standard whichever is
higher / load due to bull
dozers
g)
Underground basement, tunnel
Surcharge of 10 KN/m2
h)
Vehicular traffic
i)
Covers for Channels
j)
Other areas:
RCC floors (Offices, laboratories,
conference rooms and general floors)
5 kN/m2
Balconies
5 kN/m2
Chequered plate / gratings
5 kN/m2
Walkways
3 kN/m2
Toilets
2 kN/m2
In addition to LL, Hung loads for electrical, ventilation & air conditioning
minimum of 0.5 kN/m2 shall be considered.
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Load of 1 kN/m2 shall be considered as hung load for piping unless

otherwise mentioned. However, the actual loads will be as furnished by the
supplier. The stringent most will be followed.
For other areas LL shall be considered as per IS: 875 (Part-2).
(c)
Seismic Load
The proposed plant is located in Seismic [Zone-I] as per IS: 1893, Seismic force
on the structures will be considered accordingly.
(d)
Wind Load
The proposed plant is located in Wind Speed Zone of [50 m/s] as per IS: 875
(Part 3). The wind force on the structures will be considered as follows:
Table 2.3
Wind Speeds
Description
Wind Speed
Basic Wind Speed Vb (at 10m above mean ground

level)
[50 m/sec]
Risk coefficient K1 (for 100 years)
[1.07]
Category of terrain
[Category 1]
Factor K2
As per IS: 875
Topography factor K3
As per IS: 875
For the design of structures, wind force on Equipment, supported on frame

including all fixtures, piping, staircase, ladder, etc, shall be considered.
Design of structures shall be checked for the condition of wind load with gust
factor.
(e)
Earth Pressure Loads
For earth pressure the worst condition with dry / submerged and active, passive
or at rest shall be considered. The pressure coefficient shall be adopted as
recommended in Soil Report or for the backfill material used.
(f)
Temperature Loads
The total temperature variation shall be considered as 2/3rd of the average

maximum annual variation in temperature. The average maximum annual
variation in temperature for this purpose shall be taken as the average between
the mean of the daily minimum ambient temperature during the coldest month
of the year and mean of daily maximum ambient temperature during the hottest
month of the year. The structure shall be designed to withstand stresses due to
50 % of the total considered temperature variation with temperature load
applied with positive and negative sense.
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For design purpose average maximum annual variation shall be taken as

[+50C] to +5C.
Coefficient of thermal expansion of steel shall be taken as per IS: 800 where the
value is given as 12x10-6/C. Coefficient for thermal expansion for concrete
shall be taken as per IS: 456.
(g)
Thermal Loads (during operating condition)
When thermal loads (such as produced by temperature changes in piping,

equipment and structures) results in friction between equipment and supports
(exchangers) or piping and supports, the friction force will be taken as the
operating load on the support multiplied by the applicable friction coefficient
given below:
Table 2.4
Thermal Loads
Description
Value
Surfaces
Friction coefficient
Rolling supports
0.05
Steel to steel
0.30 (longitudinal) and 0.10 (lateral)
Concrete to steel
0.30
(h)
Equipment Loads
Static and dynamic loads of major existing / modified / replaced equipments

shall be based on the manufacturers data of the specified equipments and shall
be considered in design in addition to the live load.
Equipments to be tested for hydraulic test, tanks and piping design loading shall
include hydraulic test loading. Weight of equipments, ducts, tanks, pipes,
conduits, etc. supported by structure shall include maximum possible loading
conditions i.e. flooded conditions and associated impacts, test loading,
anchorages and constraint effects.
Air and gas duct loads shall include weight of insulation, duct attachments, dust
accumulation loads, seismic, wind and other loads applicable.
(i)
Cranes, Hoists, Monorail and Elevator loads
All lifting beams and monorails shall have their design loads increased for impact
factor. Loads for overhead cranes, hoists, monorails and elevators shall be taken
as per IS: 875.
100 % of the lifted load including elevator live load plus the cab weight shall be
considered for the elevator support beam design. Pedestals in elevator pits shall
be designed assuming impact factor as per IS codes.
(j)
Vibration and Noise
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The design shall ensure that vibrations from any moving machinery transmitted
from its immediate foundations to adjacent buildings or areas of the same
building shall be suppressed in accordance with the recommendations of
relevant codes of practice.
(k)
Other Loads
Stresses imparted to structures due to differential settlements, variation of

water table, erection and maintenance loads, creep and shrinkage shall also
be considered in design of all structures.
Dust loads
All buildings / structures shall be designed for a dust load of 1 kN/m2 for
flat roof and 0.5 kN/m2 for sloped roof.
Construction/Erection/Maintenance Loads
The integrity of the structures shall be maintained without use of temporary framing struts or ties and cable bracing as far as possible. However,
construction or access considerations may dictate the use of temporary
structural systems. Special studies shall be made and documented to
ensure the stability and integrity of the structures during any periods
involving use of temporary bracing systems.
Future Loads
Loads from future expansion shall be considered when so directed by the
Owner/Consultant. Future loads may include any of the loads listed above.
Surge Loads
Surge loads may occur in some vessels or equipment. In such cases, the
magnitude and direction of the load shall be given by the equipment
supplier.
(l)
Basic Load Cases
Following basic loads shall be considered for analysis and design:

Dead load
DL
Superimposed dead load
:
:
SIDL
Steam piping (Static & Dynamic) & other piping

loads
PL
Cable loads
CL
Live load on floor / walkway
:
:
Superimposed live load
SILL
Live load on roof
LLR
Seismic load
SL
Self weight of permanent equipment
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(m)
Wind load
WL
Load due to soil pressure
SP
Load due to surcharge
SCL
Load due to hydrostatic pressure
HP
Load due to temperature
TL
Hoist, monorail loads
MR1
Crane loads
CRL
Special loads
SPL
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Load Combinations
The individual members of the frame shall be designed for worst combination of
forces such as bending moment, axial force, shear force and torsion. Permissible
stresses for different load combinations shall be taken as per IS: 456, IS: 800 &
IS: 875 (all parts) and other relevant IS codes.
Wind and seismic forces shall not be considered to act simultaneously.
Criticality of erection / maintenance loads shall also be checked separately in
combination with other simultaneously occurring loads for possible design
loading.
(n)
Load Combinations for underground structures
For the design of sub structure only liquid pressure from inside and no
earth pressure and ground water Pressure and surcharge pressure from
outside (applicable only to the Structures which are liable to be filled with
water or any other liquid) shall be checked.
For the design of sub structure combination of earth pressure, surcharge

pressure and ground water pressure from outside and no water pressure
from inside shall be applied.
(o)
[Coal] Bunkers
The following densities shall be considered for design of [Coal] bunkers:

For volume calculations
[8 kN/cum]
For structural design
[12.6 kN/cum]
EARTHWORK AND ROCKWORK
4.1
General
This section applies to all earth and rockwork required for the replacement /
refurbishment / retrofitting of existing foundations or construction of new
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buildings foundations (if any), any types of structure and burying service lines in
the ground.
The Bidder shall satisfy himself as to the ground conditions on the site including
the nature of the strata to be excavated, obstructions, possibilities of flooding
and such like and shall allow for all provisions necessary to carry out the work in
the most suitable manner when submitting his tender.
Generally, all buildings and structures must be founded on bearing strata which
means that all excavation work for foundations shall meet the requirements of
structural analysis based on the results obtained from the detailed soil
investigation and of the available information and instruction given in writing by
the Owner/Consultant.
Excavation shall be done to the required dimensions and shall be finished
according to the specified lines and slopes, in a way acceptable to the
Owner/Consultant. All necessary precautions shall be taken to cause the
minimum possible alteration or disturbance to the other existing foundations,
material lying under and adjacent to the excavation final lines.
4.2
Fill Materials
The fill materials used and source are to be examined and approved.
Excavation materials can be used if they fulfil the requirements.
a)
Select fill shall have the following properties:
Well graded (uniformity index not less than 5), non-cohesive and nearly silt free
(silt content not greater than 5%; up to 10% tolerated, except below footings
of structures), salt free (content less than 3%), soils free of organic matter (limit
2%). Decomposing or compressible materials shall not be used.
All materials shall be of such nature and character that it can be compacted to
the specified densities in a reasonable length of time. It shall be free of highly
plastic clays, of all materials subject to decay, decomposition or dissolution, and
of cinders or other materials, which will corrode piping or other metal.
The intention is to use select fill below plinth, floors, roads, parking areas etc.
b)
Ordinary fill shall have the following properties:
c)
Natural inorganic soils: salt content not greater than 5%, organic
matter less than 3%. For other properties see under Select fill.
The intention is to use ordinary fill for non-built areas.
Special fill:
Special fill material shall be gravel or crushed rock (for other properties
see under Select fill). The intention is to use special fill e.g. as subbase material for tanks.
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4.3
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Excavation
The works shall be excavated either by hand or by use of excavating plant and
tools acceptable to the Owner/Consultant.
Last 300 mm shall be excavated by hand tools only to ensure that natural
conditions of soil at foundation level should not be disturbed. In case if over
excavation has been done, the depth of soil over excavated shall be filled with
M10 Grade concrete and no earth filling shall be allowed to fill over excavated
earth.
Also excavation by hand may be required close to existing installations, existing
foundations and/or underground services, but subject to special instruction of
The Bidder shall carry out all kind of earth and rockwork for the following
particular works as defined hereafter (where applicable):Clearing and grubbing
i)
ii)
Excavation of topsoil
iii) Open cut excavation
iv) Backfilling
v)
Safety precaution during earthwork
vi) Mining or underground excavation (if required)
vii) Grading
viii) Replacement of material
ix) Trench excavation for service lines
x)
Embankments
xi) Archaeological findings
4.4
Safety Precautions
The Bidder shall be responsible for all necessary safety measures.
Proper strutting, sheeting and bracing, including re-arrangement of the
installations when necessary, stabilization and protection of slopes, methods of
excavation to reduce risks of slides etc shall be to the Bidders debit. The
additional moving of soil resulting from such damages will not be paid for.
4.5
Over Excavation
Bidder shall ensure that no excavation work is carried out beyond the founding
level of existing nearby building/equipment. Any damage to adjoining structure/
foundation shall be rectified by the Bidder without any extra cost to Owner.
4.6
Stockpiles and Disposal

Excavated material from the works selected by the Owner/Consultant for re-use
shall be placed immediately in its final position, if possible, or otherwise may be
stockpiled or deposited on site as directed by the Owner/Consultant.
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Distance of stockpiling of excavated material from the pit edge shall be

minimum 1.5 meters or half of the depth of the pit whichever is higher. The
Bidder shall not have the right either to additional payment or to claim because
of work involved in stockpiling materials, re-use of for carting to the waste
disposal areas. Soil unfit for re-use shall be removed to sites approved by the
Owner and shall not be permanently deposited elsewhere. The Bidder shall trim
and form the edges of spoil to profiles and levels as directed by the
Owner/Consultant.
The placing of materials within the waste disposal areas shall be made in layers
not exceeding 0.50 m in thickness in order to obtain an appreciable degree of
compaction by means of transportation equipment and/or if required by
appropriate compaction equipment.
All traffic to or from the waste disposal areas shall run over the surface of such
areas in order to achieve compaction.
4.7
Preparation of Foundation
All earth surfaces, against which concrete is to be poured, shall be clean and
free of any detrimental impurities, organic matter or unsuitable material.
Immediately after excavation, all such surfaces shall be moistened and treated
as directed by the Owner/Consultant and then protected by means of a lean
concrete layer, 7.5 cm or PCC thickness as shown in the design drawings,
whichever is greater. No concrete is to be poured until formation is inspected
and approved by the Owner/Consultant.
No structural concrete shall be poured against earth surface. Shuttering shall be
used at sides and PCC shall be provided below foundations.
4.8
Backfilling
Foundations and structures shall be backfilled with approved material compacted
in layers not exceeding 150 mm by suitable equipment upto the required
designed levels. Compacting shall be carried out with special care by means of
pneumatic or mechanical rollers or other compactors of a type previously
approved by the Owner/Consultant.
Density requirements as per standard Proctor Test shall be in accordance with
relevant parts of IS: 2720 and all tests shall be made by/on under the
supervision of Owner/Consultant at Bidders own expenses, at optimum
moisture content:
a) Backfilling of foundations and under grade slabs - 98%
b) Under roadways and parking areas
- 98%
c) Embankment
- 95%
The thickness of fill layers, number of passes and type of equipment to be used
shall be proposed to the Owner/Consultant after compaction tests have been
made.
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Surfaces receiving fill layers shall, if smooth, be previously scarified to obtain a

good key between the new fill layer and the sub-grade.
Backfilling of foundation work with approved materials shall be carried out only
after foundations have been inspected by the Owner/Consultant.
4.9
Soil Replacement
The material to be used for replacement of soil shall not contain soluble or
swelling components such as clays, or organic matters. Sand gravel mixtures of
favourable grain size distribution shall be used in exchange. The suitability of soil
for its use for filling shall be as per provisions of Indian Standards.
Prior to the commencement of work, three samples shall be taken from the
anticipated borrow area and tested in respect of IS: 2720 or Proctor density,
optimum moisture content, grain size distribution and content of soluble
matters.
These three samples shall cover the approximate variation of materials to be
expected within the borrow area.
The fill material shall be placed in horizontal layers of not more than 15 cm in
compacted thickness. The fill moisture content shall be controlled and adjusted
in order to achieve a maximum of compaction. Fresh water shall be used for
watering of soils.
The fill material shall be compacted by vibratory roller (min. weight 20T.).
However for small compaction works such as small patches etc., comparatively
low weight compactors or other compaction methods may be used after taking
approval from Owner / Consultant. The minimum required degree of compaction
should be as defined under Tests and Properties. One Proctor and three
density tests shall be made at every fourth fill layer prior to continuation of
filling work. The testing location will be indicated by the Owner/Consultant. The
Bidder shall either provide all required laboratory facilities and staff to perform
the tests or he shall co-operate with an experienced soil testing laboratory,
subject to the approval of the Owner/Consultant.
Filling work may be continued in case all tests performed show satisfactory
results.
4.10
Protection of Existing Utilities and Services

During modification/rehabilitation of existing structures or construction of new
structures, the Bidder shall provide all protection for existing utilities and
services as may be required by his modification and construction operations.
Permanent protection of certain items shall be as included under other sections
or as instructed by the Owner/Consultant.
In addition to the requirements as specified, herein the Bidder shall comply with
the following requirements:
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a) Use all necessary precautionary and protective measures required to

maintain existing structures, utilities, services and appurtenances that must
be kept in operation. In particular, the Bidder shall take adequate measures
to prevent undermining of existing structures and utilities/services
presently in service.
b) Protect existing or new utilities and services where required by the Bidders
operations and/or as directed by the Owner/Consultant. The Bidder shall be
responsible for bracing and supporting existing structures, utilities and
services to prevent settlement, displacement or damage.
4.11
Dust Control
The Bidder shall use all means necessary to control dust on roads,
dismantling/demolition and modification areas, construction areas and borrow
pits.
Surfaces shall be regularly watered to prevent dust becoming a nuisance for the
public and interfering with the proper execution of the works.
4.12
Dewatering during Construction

This division applies to the methods and techniques of ground water control.
Prior to the decision for the method and technique to be applied, a
comprehensive knowledge of the soil and ground water conditions have to be
obtained from the results of the detail soil investigation and/or information given
in writing by the Owner/Consultant.
Ground water control for keeping the construction pits dry shall be included in
the Bidders scope of work.
The method and technique shall be based on the IS: 3764.
The scope of supply includes removal of all equipment, plants, pipes, machinery,
etc for modification /rehabilitation of existing foundations and re-installation of
all equipment, plants, pipes, machinery, etc and its removal after completion
including operation & maintenance of the equipment during the construction
period.
Where necessary, cofferdams, sheet piles, pump sumps, equipment and
channels, troughs, inlet gutters, pipes and any other works required for the
water control and discharge shall be part of the scope of supply. The dewatering
system shall be designed and installed in such a way that alterations and
extensions can be made at any time throughout the operating time, if necessary.
Reserve units shall be kept ready for service when failure of any of the installed
units occurs.
The Bidder has to consider the possibility of a temporary failure of any pump,
diesel engine and/or the electric power service and shall install emergency
power units with sufficient capacity to feed the necessary power to the installed
unit at the moment of failure. The Bidder shall submit to the Owner/Consultant,
the detailed method of the envisaged pumping system for dewatering, the pump
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capacity and the standby reserve units. The Bidder shall adjust the system if
required by the Owner/Consultant.
The Bidder must ensure that any dewatering works will not cause any
interference to his own work and to those of other Bidders working elsewhere
on site. Any damage occurring during the above mentioned period should then
be made good by the Bidder at his own expense.
During the foundation works, the excavated areas, foundation levels, and pits
are to be kept free of water down to at least [0.50] m below the foundation
level.
4.13
Equipments
All equipments, instruments, machineries, tools, pipelines, etc required for
execution of the water control shall be kept in good working condition
throughout the operation period.
4.14
Execution
The Bidder shall keep records of all data of importance occurring during
operation of the water control system. The records shall be submitted to the
Owner/Consultant for information and checking every working day. For that
purpose, the lowering of the water table shall be controlled by piezometers. The
numbers and position of them shall be submitted to the Owner/Consultants
approval. The Bidder shall provide and maintain these piezometers at his own
expenses during the dewatering works or as long as the Owner/Consultant
requires it.
Pump operations shall not be stopped nor pipes, channels and equipment for
dewatering and water control removed or altered in any way, except with the
express permission of the Owner/Consultant. The Owner/Consultant will
stipulate the time of removal. Until then, the pumps and water drainage facilities
shall be kept in proper working order without extra payment being granted.
Pump sumps and channels:
Provision of pump sumps and channels of the dimensions required for each
particular case shall include all necessary excavation of any kind of soil above
and under water, backfill and consolidation, sheeting, bracing, stiffening,
sealing, scaffolding accesses, as well as the disposal of water and all auxiliary
works.
Routing of channels or pipes for discharge water shall be such as not to impede
or obstruct any of the other works and/or operations.
The same shall be applicable for pump sumps. Prior to the determination of any
arrangement of pump sumps, the Owner/Consultants approval shall be
obtained.
Routing and location of water discharge lines shall be submitted to the relevant
authorities and to the Owner/Consultants approval.
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Difficulties during dewatering:

The Bidder shall consider all difficulties and additional work due to the presence
of unexpected ground water during subsequent construction work. Where it is
possible to keep off or divert such water without special dewatering
arrangements or where work can be carried out normally under or in water, such
a method may only be applied after approval from Owner/Consultant has been
obtained.
Ready for service condition:
The Bidder shall maintain ready for service and regularly clean all dewatering
equipment and accessories and shall keep all access clear so that they can
safely be used without risk of accident. Any recommendations made by the
Owner/Consultant in this matter shall be carried out immediately.
Leakage:
Blockouts and pipe connections through structures and their closure, proper
grouting of joints, etc or repairs in the event of leakage shall be the
responsibility of the Bidder.
Piezometers:
The ground water lowering effect is to be checked by piezometers in
unfavourable positions (e.g. in the middle of the building pit) before starting the
excavation. The piezometers are to be installed at unfavourable positions or in
more permeable layers (in stratified sub-soil) below the bottom of the
excavation. They serve to check whether or not the water pressure (head) has
been sufficiently reduced in those layers below the bottom of the excavation,
which are more permeable. Security against hydrostatic uplift is to be
demonstrated by calculation.
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REINFORCED CONCRETE STRUCTURES AND FOUNDATIONS
5.1
General
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All structures, building foundations, machines / equipment foundation, water

retaining structures, trenches, pits, etc. shall be designed as per latest relevant
IS codes in general. Construction in general shall follow provisions of IS: 456
and IS: 3370 for normal and water retaining structures respectively.
5.2
Design Methodology
a) General
All designs of RCC structures shall be carried out by limit state method as per
IS: 456 unless use of working stress method is specifically mentioned. Design
strength of materials and design loads shall be calculated using appropriate
partial safety factors over characteristic strength and characteristic loads as per
IS: 456.
IS: 11384 shall be followed for design of steel concrete composite beam.
For reinforcement detailing IS: 5525 and SP: 34 shall be followed.
The walls shall be provided with reinforcement on both faces for sections 150
mm or more, even if not required from design consideration.
b) Foundation and Underground Structures
Type of foundation system, i.e. isolated, strip, raft shall be decided based on the
loading arrangement, load intensity and soil strata. Design of foundations at
various levels shall be dependent upon the soil bearing capacity at that level.
Foundation system adopted shall ensure that settlement / relative settlement is
as per provision of IS: 1904 and other Indian Standards. However, the
settlement shall be restricted to a lower value, if necessary as per the system
requirement.
All foundation including machine / equipment foundations shall be of RCC
construction. All foundations shall be designed in accordance with relevant parts
of the latest revisions of Indian standards IS: 2974 and IS: 456. Raft
foundations shall be designed as per IS: 2950.
All foundations shall be treated as per the guidelines prescribed in IS 456: 2000
against sulphate/other aggressive chemicals if found present in soil or as per the
requirements of detail Geotechnical Investigation Report.
For design of underground structures, subsoil water level shall be assumed at
Finished Ground level. All underground pits, tunnels, basements, cable and pipe
trenches, etc. shall be designed as leak proof RCC structure, where depth of
ground water table so warrants. In case of leakage in the above structures
injection grouting method shall be applied to repair the structure according to
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the requirement of IS: 6494. Effects of uplift and reduction in bearing capacity
due to underground water table shall also be considered.
For Subsoil conditions, Average ground water table, Foundation system, Earth
Pressure Coefficient, refer to detail geo-technical investigation report of the site.
The soil conditions met during the foundation works especially in the foundation
level are to be checked by the Bidders soil Engineer, recorded and compared
with previous known or investigated results. If essential differences occur,
which could be detrimental to the structures, the Bidder has to inform the
Owner/Consultant and to propose further measures. Foundation works in such
areas are to be continued only after approval of such measures by the
Owner/Consultant
If there is any doubt about the soil quality or if discrepancies appear with regard
to the previous decisions or investigations stated by the Owner/Consultant, then
additional measures are to be taken after consulting the Owner/Consultant (e.g.
additional excavation and lean concrete fill)
Allowable settlements, elastic plus consolidation, shall be limited as follows: i)
Total settlement
ii) Differential settlement
38 mm
6 mm
Foundations for equipment shall be designed to meet the total and differential
settlement established by the equipment manufacturer if they are more stringent
than the allowable settlements listed above. Foundations for buildings shall be
designed to meet the total and differential settlement as required for the building
function if they are more stringent than the allowable settlements listed above.
c) Settlement and Expansion Joints
Joints are to be arranged in such a way that stresses and strains caused by
settlements, temperature, differential settlement, etc do not adversely affect the
structures. This primarily applies to differently loaded areas and structures
having different foundations or foundations of different depths. The settlement
joints shall run through the complete structure down to foundation level, the
expansion joints however shall stop on the top level of foundations.
The joint width is to be at least 2 cm is to be planned considering all relevant
factors (settlements, tilting, movements, aspects etc.).
Settlements of all relevant structures shall be measured, recorded and shown in
diagrams according to IS: 8009 Code of Practice for calculation of settlement
of foundation.
d) Foundations at Different Depths
Foundations at different levels should be based beyond a load-spread angle of
30 (against the horizontal). Otherwise, the load influence (e.g. earth pressure)
of the higher-level structures on the lower ones must be taken into
consideration.
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e) Replacement
If unsuitable soils are encountered below the grade slabs or basement floor, they
are to be replaced by suitable layer wise compacted material down to the good
bearing soil.
Materials and compaction method as well as quality control are described in
clause Earth and Rockworks of this section. Selected fill is to be employed
below all grade paving and basement floors.
f) [Liquid Retaining Structures]
[RCC water retaining structure like storage tanks shall be leak proof and
designed as un-cracked section in accordance with IS: 3370 (Part 1 to IV) by
working stress method. However the parts of such structures not coming in
contact with liquid may be designed according to IS: 456.
Water channels and substructure of pump houses shall be designed as cracked
section with steel stresses as per IS: 3370 (Part 1 to IV) by working stress
method and limiting crack width to 0.2 mm.
All water retaining / storage structures shall be designed assuming liquid upto
the height of wall irrespective of provision of any over flow arrangement. No
pressure relieving devices shall be permitted in underground structures.
In all liquid retaining structures, PVC water bar shall be provided at each
construction / expansion joint. The sequence of construction shall also be
specified on drawings showing construction joints.
The walls shall be designed for a surcharge load of 2000 Kg/m or actual
whichever is higher.
Liquid Retaining Structure shall be checked for two loading conditions. With
water inside up to operating level and no earth fill outside or water in one
compartment and no water in the other compartment (where two compartments
are provided).
Base slab / raft of all liquid retaining structure shall be designed to withstand the
uplift pressure.]
g) Modification of the existing foundation (as required) for the new equipment
supplied
The new equipment shall be supported on an RCC deck which in turn shall be
supported over steel helical springs and viscous dampers. The steel helical
springs and viscous dampers shall be supported over structural steel beams
which in turn shall rest over columns. The columns shall be supported over
foundation. The modification of existing foundation may involve partial to full
dismantling and reconstruction of new foundation as per design & constraints of
space.
Precautions shall be taken not to disturb the basic building structure & other
foundation and it shall be ensured that no excavation work is carried out beyond
the founding level of existing nearby building/equipment. Any damage to
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adjoining structure/ foundation shall be rectified by the Bidder without any extra
cost to Owner.
The contractor shall be responsible for maintaining all safety norms including the
stability of existing structures. Any propping, shoring and under pinning required
to this effect shall be put in place before the dismantling work is undertaken.
Wherever any existing concrete member is required to be partially dismantled, a
coat of epoxy paint shall be applied to the exposed reinforcement and the cut
surface of concrete shall be built up by providing 40 mm thick concrete with
wire mesh.
h) Machine Foundations
General
Design of equipment foundation for block type machine foundation (if any) shall
be done for the actual equipment loading data. The foundation arrangement shall
be decided keeping in mind the existing structural arrangement and space
limitation.
Block foundations resting on soil shall be designed using the elastic half space
theory. The mass of the RCC block shall not be less than three times the mass
of machine. Dynamic analysis shall be carried out to calculate natural
frequencies in all modes including coupled modes and to calculate vibration
amplitudes. Frequency and amplitude criteria as laid down by the relevant codes
and/or machine manufacturer's recommendations whichever is more stringent
shall be satisfied. Minimum reinforcement for all machine foundations shall be
governed by 18:2974 and 18:456.
The following geotechnical data shall be worked out from the soil investigation:
Bearing capacity
Total permissible settlement
Bulk Density
Poisson's Ratio of founding strata
Shear Modulus (G) (average)
The design of machine / equipment foundation shall be as per IS: 456 and IS:
2974. The provisions of DIN 4024 shall also be followed for machine
foundations. All machine / equipment foundations and structures subject to
vibrations shall be suitably proportioned so that amplitude and frequency of the
foundation / structures are within permissible limits.
Dynamic analysis shall be carried out to calculate natural frequencies in all
modes including coupled modes and to calculate vibration amplitudes. Frequency
and amplitude criteria as laid down by the relevant codes or machine
manufacturers shall be satisfied. Minimum reinforcement shall be governed by
IS: 2974 and IS: 456.
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For the foundations supporting minor equipment weighing less than one ton or if
the mass of the rotating parts is less than one hundredth of the mass of the
foundation, no dynamic analysis is necessary. However, if such minor
equipment is to be supported on building structures, floors, etc. suitable
vibration isolation shall be provided by means of springs, neoprene pads, etc.
and such vibration isolation system shall be designed suitably. All such
foundation shall be separated from adjoining part of building and other
foundations. Joints at floor/ slab shall be suitably sealed. All appendages to such
foundations shall be reinforced suitable to ensure integral action.
The frequency criteria and amplitude criteria shall be satisfied for all values of
shear modulus (G) ranging from 0.5 times the average value to 1.5 times the
average value.
The extent of foundation shall be based on the general arrangement of the
equipment and the design requirement. However minimum width of any
foundation shall not be less than one meter. Water table has to be considered at
finished ground level for design of all foundations.
Suitable arrangement shall be made for prevention of transmission of vibration
from the proposed foundation to the nearby structure/ foundation/ paving slab.
All design calculations and drawings shall be submitted to Owner for approval.
In case any modification to any existing nearby structural steel bracing/support
system/ concrete work is required, the contractor shall check the adequacy of
the design of the existing structures for the new loads. Suitable modification to
the existing structure as required shall be carried out by the contractor.
Loose pockets if any found below the foundation shall be removed and filled up
with PCC of grade M10.
Loads
All static and dynamic forces / loads which equipment supplier considers
applicable shall be considered for analysis and design of machine foundations.
Foundation Sizing
The outline plan dimensions of foundations as given by the machine supplier will
be adopted. The height of foundation will be selected after taking into
consideration soil strata and operating level of the machine. The eccentricity of
common CG of machine and foundation with respect to the centroid of base
area should not exceed 5 % of the corresponding base dimensions of
foundation. Partial contact between the foundation and soil strata shall be
considered wherever applicable. The footing will be checked for minimum
contact area of 80 % and maximum bearing pressure will be calculated for the
actual contact area only.
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Analysis and Design

The minimum grade of reinforced cement concrete shall be M25, unless
specified otherwise.
The analysis and design of machine foundations will be carried out to ensure the
following:
Compliance with the manufacturers requirements and relevant
standards
No resonance phenomenon of a disturbing nature to machine operation
should exist at the normal running speed
Calculations to be performed for dynamic as well as static cases for
reinforced concrete block type pedestal
Soil bearing capacities
Deep foundation capacities
Lateral earth pressures
Allowable settlements
Structure, equipment and environmental loadings
Equipment performance criteria
Access and maintenance requirements
Temporary construction loadings
The foundation will be designed for the most critical combinations of forces and
moments, resulting from all possible combinations of the various loading from
the equipment system. The foundation sections will be sized and reinforced
adequately for bending moments and shear stresses and uplift.
The foundation shall be checked for overturning, sliding and uplift as per
relevant IS Codes. The foundation will be checked for overturning with minimum
and maximum vertical loads.
For analysis of machine foundation following data will be furnished by the
equipment manufacturer:
Loading diagram showing static and dynamic loads and points of
application of loads
Operating speed of machine
Weight of rotating parts, maximum eccentricity of rotating mass from
the geometric axis of rotation
Location of C.G. of machines in all three axis
Mass moment of inertia
Allowable amplitude / velocity of vibration at machine bearing points
Temperatures at various areas during operation
While designing following aspects shall also be taken care of:
All dynamic foundations shall be isolated from building foundations. The

isolation gap shall be of minimum 25 mm.
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Natural frequencies of structures and components shall be away from

running speed of equipment by at least 20 % generally but for
important ones it shall be away by at least 30 %.
For design of foundation of large fans etc., provision shall be kept in

the foundation for addition of mass / area for retaining of the
foundations if required at a later date
However following minimum factor of safety shall be followed:
Factor of safety against overturning due to wind, seismic or other

lateral loads shall be 1.5
Factor of safety against sliding shall be 1.5
Factor of safety against uplift due to hydrostatic forces shall be 1.2 and
due to any other loads shall be 1.5. Uplift check shall be carried out
during construction stage also.
For miscellaneous machines, most suitable type of foundation shall be provided.

Foundation for pumps, and minor rotating equipment etc., are usually in the
form of solid block foundations, resting on the ground or on a floor of the
building. At such machine supports, floor may be thickened and extra
reinforcement may be provided. Also the machines, which are almost vibration
free, light to moderately heavy, may be supported in the above manner. Rubber
or neoprene pads under some of these machines to reduce transmission of
vibrations to the supporting floor will be provided if required.
All block foundations resting on soil shall be designed using the elastic half
space theory. The mass of the RCC block shall not be less than three times
mass of the machine. Dynamic analysis shall be carried out to calculate natural
frequencies in all modes including coupled modes and to calculate vibration
amplitudes. Frequency and amplitude criteria as laid down by the relevant codes
or machine manufacturers shall be satisfied. Minimum reinforcement shall be
governed by IS: 2974 and IS: 456. Suitable vibration isolation shall be provided
by means of springs, neoprene pads, etc. and such vibration isolation system
shall be designed suitably. All such foundation shall be separated from adjoining
foundations.
Temperature Control of Concrete
The temperature of fresh concrete shall not exceed 25C when placed. For
maintaining the temperature of 25C in the top decks of machine foundations,
crushed ice shall be used in mixing water.
Non-Shrink Grout for Equipment Foundations
Special non-shrinking grout of approved make shall be provided in strict
accordance with the manufacturers instructions / specifications. Ready mix
non-shrink grout of GP2 brand or equivalent, of approved make shall be used for
base grouting of major rotating equipments.
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(a)
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Increase in Stresses
Where stresses due to wind (or seismic) and temperature are combined
with those due to other loads, the allowable stresses in concrete and
reinforcement steel shall be increased by 33.33% in case of working stress
design.
Bearing capacity of the soil shall be allowed to be increased by 25 % under
seismic/ wind load condition.
(b)
Elevated Foundations
Design of all equipment foundations shall be done for the actual equipment
loading data. The foundation arrangement shall be decided keeping in view
the existing structural arrangement and space limitation. Adequacy of the
design of the existing structures, for the new loads shall be, checked by
the contractor. Suitable modification as required shall be carried out by the
Contractor and complete design for the same shall be furnished to owner
for approval. Where ever new columns/foundation is required the same
shall be designed and constructed by the contractor as per relevant Indian
Standard Code.
For the foundations of the all equipments details static and dynamic
analysis shall be done. The static analysis shall include all operating
condition, load cases and abnormal loads like short circuit, loss of blades &
unbalance and seismic forces as per 18:1893. The dynamic analysis shall
consist of free vibration analysis and forced vibration analysis. Design of
RCC foundations/as well as structures, checking of design of existing
structure shall be carried out by working stress method. A fatigue factor of
2.0 shall be considered for dynamic forces.
The foundation general arrangement shall be such that the spring units are
placed over the structural steel beams. The isolation efficiency for steel
helical springs and viscous dampers shall be at least 90%. The vibration
amplitudes at the bearing locations shall not exceed the limits as per VDI
2060 or limits specified by the machine supplier whichever is more
stringent. The ratio of actual spring supported weight to the nominal spring
capacity shall not exceed 0.80. At least 3% to 5% of critical damping shall
be provided in the fo1rm of viscous dampers.
The grade of concrete for the top deck shall be M35.
(c)
Steel Helical Springs and Viscous Dampers

The supporting structural beam and columns shall be designed for the
loads transferred through springs and all other loads such as piping loads,
seismic loads as per IS:1893. The stiffness of the beams supporting the
springs shall be at least 10 times the stiffness of the springs supported
over it along both vertical and horizontal direction.
The scope of work shall be deemed to include all activities which may not
have been explicitly mentioned but are reasonably implied for the
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successful completion of the work for which these specifications are

intended.
Scope of work of the bidder shall include manufacturing, testing, supply,
transport to site, pre-stressing, erection, supervision of erection, release of
pre-stress, alignment, commissioning etc of Steel helical springs and
viscous dampers:
Steel helical spring units and viscous dampers along with viscous
liquid including associated auxiliaries tor installation of the spring
units and dampers like steel shims, adhesive pads, etc.
Frames for pre-stressing of spring elements.
Suitable hydraulic jack system including electric pumps, highpressure tubes etc. required for the installation, alignment etc, of the
spring units. One set of extra hydraulic jacks, and hand operated
pumps shall also be provided.
Any other items which may be required for the complete installation
and satisfactory commissioning of the spring system.
Supervision of complete erection and commissioning of the steel helical

springs and viscous dampers including pre-stressing of elements, placing of
elements in position, checking clearances on the shuttering of the RCC top
deck, releasing of pre-stress in spring elements and making final
adjustments and alignments after machine installation etc.
The steel helical springs and viscous dampers supplied should be of proven
make. The bidder or his sub-contractor should have designed spring
supported machine foundations, manufactured, supplied and installed steel
helical springs and viscous dampers (conforming to DIN 2096 & DIN2089)
and viscous dampers (providing damping resistance in all three planes) for
not less than 2 (two) machine foundations of heavy rotating machine
systems such as ID/FD/PA fans and coal mills.
The damper units or spring-cum-damper units should be of viscous type
offering velocity proportional damping. The damper units should be suitable
for temperatures ranging from 0 to 50C. The damping resistance of
individual damper units should be such that the designed damping can be
provided using reasonable number of units.
All design calculations and drawings shall be submitted to Owner for
approval.
5.3
Stability of Structures
Design shall be checked against buoyancy due to the ground water during
construction and maintenance stages for structures like underground storage
tanks, pits, trenches, basements, etc. Minimum factor of safety of 1.2 against
buoyancy shall be ensured considering empty condition inside and ignoring the
superimposed loading. For the purpose of calculating downward load due to any
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overburden, only the mass located vertically above the projected area of the
base slab shall be taken in to consideration.
All building sub-structures including pump houses shall be checked for sliding
and overturning stability during both construction and operating conditions for
various combination of loads. Factor of safety for these cases shall be taken as
mentioned in IS: 456 and other latest relevant IS codes. However following
minimum factor of safety shall be followed:
Factor of safety against overturning due to wind, seismic or other lateral

load shall be 1.5 minimum
Factor of safety against sliding shall be 1.5 minimum
Factor of safety against uplift due to hydrostatic forces shall be 1.2 and
due to any other loads shall be 1.5
Stability of the structure shall also be investigated for loading conditions during
construction, repair or other temporary measures. Lower factor of safety may be
used for such loading conditions as per relevant IS codes.
In cases where dead load provides the restoring force, only 0.90 times
characteristic dead load shall be considered. Imposed loads shall not be
considered as restoring force.
5.4
Minimum Thickness of Concrete Structural Elements

The following minimum thickness shall be followed:
Table 2.5
Minimum Thickness of Concrete
S.No
Description
Thickness, mm
a)
Suspended floor / slab / walkways /canopy slabs,

etc.
125
b)
Ground floor slab (non-suspended)
150
c)
Water Retaining slabs / walls
200
d)
Cable/pipe trenches/underground pits/Launder walls

and base slab
125
e)
All footings (including raft foundations)
300
f)
Parapets
g)
Sunshades
h)
Precast louvers / fins
50
i)
Precast trench cover slabs / floor slabs / louvers
75
j)
Paving
100
k)
Basement walls and base slab
200
l)
125
75 at edge
Underground tank:
Below ground water table
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S.No
Description
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Thickness, mm
Above ground water table
150
From fire resistance point of view minimum cover to reinforced concrete

members shall be as per Table 16A of IS: 456.
5.5
Minimum Heights for Pedestal of Steel Columns

Pedestals to Steel Columns for building structures:
Top of RCC foundations (pedestals) shall normally be kept at a minimum [250
mm] above finished floor level (FFL) unless specified otherwise. Foundation
levels for columns shall be decided to accommodate underground services, pits,
trenches, etc.
Stair and ladder pedestal shall be kept [200 mm] above the finished floor level.
Pedestals to Steel Columns for Equipment structures:
a) Equipment in open area
as required [(300 mm min)]
b) Equipment in covered area
as required [(150 mm min)]
as per vendors data subject to

minimum as specified above.
c) Structures and equipment

Supplied by vendor
5.6
Minimum heights for encasement of steel columns

In case the top of pedestal is kept at a lower level so that the column base plate
together with gussets and stiffeners remain below finished floor level (FFL) the
column bases as well as the column sections shall be encased in concrete above
FFL as per following:
a)
Open area
: [300 mm] above paved level
b)
Covered area
: [150 mm] above FFL
5.7
Concrete Works
i) General Description, Proportions and Mixing
Mix Design
At the commencement of the contract the Bidder shall make preliminary
tests to determine the proportions by weight of cement, fine aggregates,
coarse aggregates and water necessary to produce required grades of
concrete. The mix proportions shall be selected to ensure that workability of
the fresh concrete is suitable for the conditions of handling and placing and
when concrete hardens, it shall have the required strength, durability and
surface finish. The Bidder shall get approval of Owner/Consultant to such
proportions before he starts concreting. However, such approval shall not
relieve the Bidder of his responsibility to produce concrete having
compressive strengths as laid down in the foregoing Table.
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No departure from the approved proportions will be permitted during the

works unless and until the Owner/Consultant gives written authorisation for
any change in proportion. The Owner/Consultant shall have authority at any
time to check whether the mixing of concrete is being carried out according
to the approved proportions.
For the all major and important R.C. works and for all special works, the
design of mixes shall be made by the Bidder at his own cost, for each grade
of concrete as well as for various workability. The design of mixes shall be
made according to I.S. 10262 or any other approved standard methods.
The concrete made by designing the mix is termed hereinafter as "Design
Mix Concrete".
The cement content for various grades of concrete shall be based on design
mix. However, irrespective of requirement of cement found out from design
mix, cement content of concrete shall not be reduced below the quantities
specified as under.
Grade of
concrete
Minimum cement content per Cu.m

finished concrete
M-15
290 kg
M-20
320 kg
M-25
380 kg
M-30
not less than 400 kg
M-35
not less than 400 kg
ii) Water Cement Ratio
Where a particular water cement ratio is stipulated in the design or drawing
along with the characteristic grade of concrete the design of mix shall be
carried out by adjusting the other variable factors to obtain the characteristic
strength of concrete with stipulated water cement ratio.
In the structures where the impermeability and shrinkage of concrete have an
important bearing on the durability and serviceability of the structures, such
as water retaining structures, basements, underground premises, tunnels,
pump houses, pre-stressed structure, thin precast members etc. the water
cement ratio shall be kept low and preferably not exceeding 0.45.
The water cement ratio, as achieved in the Mix Design, or as specified in the
drawings shall be adhered to strictly and shall not be varied without the
permission of the Owner/Consultant.
iii) Workability
The workability of fresh concrete shall be such that the concrete is just
suitable for the conditions of handling & placing so that after compaction if
becomes completely consistent and homogeneously surrounds all the
reinforcement and completely fills the formwork.
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The workability of fresh concrete at the place of batching/mixing shall be

measured by compacting factor test and at the place of disposition by means
of slump test. During the finalisation of Trial Mixes, the relationship between
compacting factor and slump test shall be established for each grade of
concrete as well as for various levels of workability. The workability tests
shall be carried out in accordance with IS:1199.
Normally, in the condition of low water cement ratio as well as for
medium/high workability, the workability shall be achieved by increasing the
cement content, in consistent with added water.
In cases where the cement content is to be limited to reduce the heat of
hydration, and the water/cement ratio is also to be kept low to reduce the
permeability or due to other requirements the desired workability may be
achieved with use of limited doses of plasticiser or air entraining agent. In
such cases the method of mixing and dosage of the plasticiser/air entraining
agent shall be according to the manufacturer's specification and with the
approval of the Owner/Consultant.
The usual limits of consistency for various types of structures are given
below:
iv) Limits of consistency
Degree of
Workability
Slump in mm with
Standard - Cone
Minimum
Maximum
Very low
0.0
25.0
Low
25.0
50.0
Medium
25.0
75.0
High
75.0
125.0
Use for which concrete is suitable

as per IS : 1199
Large mass concrete structure with

heavy compaction equipment,
roads and the like.
Uncongested wide and shallow
R.C.C structures
Deep but wide R.C.C structures
with congestion of reinforcement
and inserts
Very narrow and deep R.C.C
structures with congestion due to
reinforcement and
Inserts
v) Durability
The durability of concrete, depending on the exposure condition, is to be
taken into account while designing the mix. For given aggregates, the
cement content should be sufficient to make sufficiently low water cement
ratio and Appendix A of IS: 456 shall be taken as guideline for durability
considerations.
Minimum fire rating of 2 hours shall be considered where fire hazard is
expected and accordingly minimum cover shall be taken as per Table 16 A of
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IS: 456. For structures below ground level which are exposed to sulphate
attack, requirement of cement shall be as per Table 5 of IS: 456. Intermixing
of different grades of concrete in the same structure shall not be allowed in
a particular element.
Mix design concrete shall be used for all areas other than plain concrete
work used for lean concrete, screeds and backfill.
The following minimum grades of concrete as per IS: 456 shall generally be
used for the type of structures noted against each grade.
Table 2.6
Grades of Concrete
Concrete
mix/Grade
1:5:10
1:4:8
Type of structure
Fill concrete
Blinding layer below foundations, trenches and underground
structures, foundation below brick wall, etc.
Minimum thickness of layer shall be 75 mm
M15
Plinth protection work around buildings
M25
Base plate encasement, encasement of structural steel work,

all RCC paving work, ground floor slabs, cable and pipe
trenches, precast concrete work etc.
M30
All RCC structures and equipment foundations, super

structure, grade beams, columns, roof slabs and all
underground RCC structures, cable and pipe rack foundation,
pedestals, etc. water retaining structures below and above
ground, boiler foundations, mill foundations, etc.
Inter mixing of different grade of concrete in the same structure shall not be
allowed normally.
vi) Trial Mixes
Before concreting commences, the Bidder shall, at his own expense,

make trial mixes to determine the mix proportions required to produce
the strengths specified for each class of concrete and for each degree
of workability required to allow placing, transporting and compacting of
the concrete with the equipment he proposes to use in any particular
situation. Only materials which the Bidder intends to use for concreting
(including all admixtures) shall be used in the trial mixes.
Test cubes from trial mixes shall be made and tested in accordance
with IS: 516.
As per IS: 456 and IS: 516, three separate batches of concrete should
be made, workability of each batch determined and three test cubes
shall be made from each batch for each age (e.g. for 7 and 28 days) at
which tests are required. The strength shall conform to target mean
strength as per IS: 456 Requirements for design mixes.
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The appropriate strength requirements may be considered to be

satisfied if none of the strengths of the cubes is below the required
characteristic strength and if the average strength of the nine cubes is
not less than recommended by IS: 456 and IS: 516, trial mixes.
vii) Quality and Testing
Not more than 5% of the test results may fall below the 28 days specified
strength. Making and curing of test specimens shall be in accordance with
relevant IS: 456, IS: 516 and IS: 1199.
All mixes can only be placed following approval by the Owner/Consultant.

The mean strength shall exceed the characteristic strength by a margin of
1.65 times the standards deviation expected from the batching plant.
However, no standard deviation less than 3.5 N/mm2 shall be used as a
basis for designing a mix.
viii) Trial Mixes and Field Tests
Sufficient laboratory trial mixes shall be prepared to show that concrete
complies fully with the specified performance criteria. The following tests are
to be included:
Air content < 1%
Slump: Piles 170 + 25 mm, regular work 80 + 20 mm as per IS: 1199
Fresh and hardened concrete densities
Field trial mixes shall be carried out under full-scale site conditions as
per IS: 4925 (for structural concrete only).
Where directed by the Owner/Consultant, concrete incorporating

reinforcement details shall be cored to assess stratification of mixes.
Cores of 150 x 200 mm (diameter and length) shall be used.
Each trial mix shall have 9 x (150 x 150 x 150 mm) cubes taken to
measure 24 hours/7 days and 28 day compressive strengths. These
trials shall be run for three consecutive days (for structural concrete
only).
At least 3 x sets of field trials shall be tested according to the

provisions laid down in laboratory testing.
The average 28 day characteristic strength for trial mixes shall be as

per IS 456. Failure to comply shall result in the mix having to be redesigned.
All test results shall have to be complied before approval can be given.
ix) Consistency of Concrete

The amount of water used in the concrete shall be adjusted as required to
ensure such a consistency that it can be readily transported, placed and
compacted without segregation of the materials or bleeding of free water at
the surface. Addition of water to compensate for stiffening of the concrete
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before placing shall not be permitted. Consistency of the concrete shall be

checked by slump tests measured in accordance with IS: 1199 and shall not
exceed the values given in clause 7.1 of IS: 456-2000.
x) Mixing of Concrete
The cement and aggregate shall be thoroughly mixed in a batch-type
pull mill mixer. The capacity of the mixer shall not be less than 1 (one)
cubic meter and the total capacity of the batching mixing plant shall be
such to accommodate the various concrete quantities to be cast in a
continuous way and shall comply with the requirements of IS: 456, IS:
1791 and IS: 12119.
The water shall not be added until all the aggregate and cement are in
the drum. Mixing shall continue until the concrete is uniform in colour
and for not less than 2 (two) minutes after all the materials and water
are in the drum.
Partly set or excessively wet concrete shall not be used. No concrete

shall be mixed by hand.
xi) Laboratory
The Bidder shall establish and maintain a field laboratory on the site and this
laboratory shall be available at all time to the owner.
The laboratory must have qualified technicians to carry out all tests and
must be adequately equipped to ensure that all necessary testing work can
be carried out in compliance with the standards.
5.8
Strength of Concrete
i)
Testing of fresh concrete by means of test cubes

a) All test cubes shall be made and tested for compressive strength in
accordance with IS: 456, IS: 516 and IS: 1199.
b) The minimum required strength for different classes of concrete shall be
as shown in clause General description and proportions and mixing
here above.
c) The grade of concrete required will depend partly on the particular use
and the characteristic strength needed to provide the structure with
adequate ultimate strength and partly on the exposure conditions and
the cover provided to any reinforcement.
d) A minimum of four test samples (of six test cubes each) shall be taken
on each concreting day (from the same mix) and for at least each 40
m3 of concrete mixed. At least one sample shall be taken for each
shift.
e) For columns, beams and cantilevers seven (7) cubes for every 15 m3 of
concrete poured shall be taken. The concrete for test samples shall be
taken directly from the concrete mixer and shall be handled (vibrated
etc) under similar conditions to those prevailing during the construction.
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The moulds for the test cubes shall be made of steel. Tests shall be
carried out in an approved laboratory.
f) The strength level of each type and each strength concrete will be
evaluated separately and the concrete strength will be considered
satisfactory if:
Compressive strength: The concrete shall be deemed to comply

with the strength requirements when both the following conditions
are met: The mean strength determined from any group of four
consecutive test results complies with the appropriate limits in
column 2 of table 11 of IS: 456.
Any individual test result complies with the appropriate limits in
column 3 of table 11 of IS: 456.
Flexural strength: When both the following conditions are met, the
concrete complies with the specified flexural strength: The mean strength determined from any group of four
consecutive test results exceeds the specified characteristic
strength by at least 0.3 N/mm2.
The strength determined from any test result is not less than the
specified characteristic strength less 0.3 N/mm2..
g) If the results are less than those specified, the Owner must suspend all
concreting work and order further tests. Any concrete found not to
comply with the specification shall be broken out and replaced to the
satisfaction of the owner.
h) The Bidder shall pay all costs incurred in making, curing, delivering and
testing of concrete cubes.
ii)
Testing of concrete in structures

a) The types of tests described hereinafter are applicable to the finished
parts of the structures. They may be used in routine inspection and for
quality control.
b) Type of tests:
Cutting cores: The procedure used shall comply with

requirements of IS: 516 or an approved equivalent standard.
Gamma radiography: The testing shall be carried out in accordance

with the requirement of IS: 13311, part 1 or equivalent.
Ultrasonic test: Such tests may be used to obtain approximate

indications of the strength of the concrete in the structures (IS:
13311, part 1).
Electromagnetic cover measuring devices: Such tests may be used

to verify the position of the reinforcement and shall be in
accordance with the requirements of design (IS: 13311, part 1).
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Rebound hammer test: Such tests may be used to obtain

approximate indications of the strength of the concrete (Ref. IS:
13311, part 2).
Load tests of structures or parts of structures: If the results of the

above mentioned check tests show that the quality of the materials
is inadequate or if other defects are revealed, the owner may require
a loading test to be made.
c) For the purpose of testing floors, roofs and similar structures and their
supports, the test load shall be equivalent to the sum of the
characteristic dead load and one-and-a quarter times (1.25 times) the
characteristic imposed load for a period of 24 hours which the works or
part thereof to be tested have been designed.
d) Wherever certain procedures for testing of parts in structures are
required by standards or codes of practice, these are to be followed. All
tests must be conducted in the presence of the Owner/Consultant.
e) If within 24 hours of removal of the imposed load, the structure does
not recover at least 75% of the deflection under superimposed load,
the test may be repeated after a lapse of 72 hours. If the recovery is
less than 80%, the structure shall be deemed to be unacceptable.
f) If the result of the test is not satisfactory, the Owner/Consultant shall
instruct that the part of the works concerned be taken down or cut and
reconstructed to comply with this specification. The Bidder shall at his
own cost take down or cut out and reconstruct the defective work.
g) The Owner/Consultant may require other tests to be made. Number of
samples, tests and types will be as per Owner requirements.
h) All the costs for the above mentioned tests shall be borne by the
Bidder.
5.9
Materials
a. Storage of materials
All materials shall be stored and handled in a manner that will prevent
contamination and/or deterioration. Storage of materials shall conform to
IS-4082 Recommendation on stacking and storage of construction
materials and components at site. Deteriorated and/or contaminated
material shall not be used for the concrete and shall be removed from the
site at the expense of the Bidder.
b. Cement
OPC / PPC Cement of reputed make conforming to relevant codes, shall be
used for all Concreting works and the certificate of manufacturer shall be
furnished with each batch. Cement used shall be ordinary Portland cement
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unless the chemical nature of the soil warrants special cement for
structures below ground level.
Sampling and Testing of Cement
All deliveries of cement to the concrete supplier shall be accompanied

by a certified mill test report and shall include all of the physical and
chemical properties as required by relevant IS: 8112 for grade 43 and
IS-12330 for sulphate resistant cement.
The manufacturers test certificate will normally be accepted as proof

of compliance with the specification, but the Owner may order further
tests of a character specified in the appropriate Indian standards. The
confirmatory tests are to be conducted by a recognized quality control
organization. The Bidder shall bear all expenses required for the
preparation, dispatch, and tests of the samples. In case the results of
such tests show any sample to be inferior to specifications, the whole
consignment from which the sample was taken shall not be used and
shall be immediately removed from the site.
Delivery and Storage of Cement
The following information shall be provided for all cement shipments

(either whole or part) which are intended for delivery to site: date of
manufacture, date of original loading, destinations en-route, date of
unloading, intended date of delivery to site.
The Bidder shall obtain and provide to the owner the manufacturers
average test certificate for each consignment of cement to the works.
The certificates shall be provided before the consignments are required

for use and shall show the chemical composition and physical
properties determined in accordance with the relevant standard.
Samples shall be taken from each consignment of cement and tested as

directed by the owner in an approved independent laboratory.
Consignments shall be used in the order in which they were delivered.
Bagged cement shall be stored in a weatherproof building having dense

impervious bituminous or concrete floors which shall be kept swept
clean at all times. The storage arrangements shall be fully completed
and approved by the owner before any cement is delivered to site.
Each consignment of cement shall be separately stored for ease of

access, identification, inspection and sampling. Sufficient stocks shall
be maintained on site to ensure the proper progress of the works and
the stock holdings shall be to the approval of the owner.
No cement from any consignment shall be used in permanent works

without the approval of the owner.
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Cement which contains air-set or hardened lumps, re-powdered air-set

material, foreign matter or which has been contaminated or is
otherwise unsatisfactory in the opinion of the Owner/Consultant will be
rejected and shall be removed from site without delay.
The Bidder shall be responsible for satisfying himself that the

performance characteristics of cement are not such as to necessitate
excessive cement content or be likely to cause or accentuate any
undesirable properties in the fresh or hardened concrete
notwithstanding apparent compliance with this specification.
c. Reinforcing steel
General
Reinforcing steel used in reinforced concrete shall comply with the
following standards:Deformed bars shall be of grade Fe500 and conform to IS: 1786.
Mild steel shall conform to IS: 432.
Mesh reinforcement shall conform to IS: 1566.
Binding wire
Binding wire for general use shall be annealed wire 16/18/20 BWG
conforming to IS 280. The number of strands shall be as per IS
specification.
Reinforcement supports
Reinforcement supports shall include all spacers, chairs, ties, slab

bolster, clips, chair bars, and other devices for properly assembling,
placing, spacing; supporting, and fastening the reinforcement.
Spacers shall be cast from concrete of the same quality as that in

which they will be embedded.
Concrete block spacers shall be cast in metal moulds with an approved

means of separating blocks and of ensuring that the blocks are of the
proper size.
Binding wire shall be incorporated into the blocks to enable them to be

securely attached to vertical or horizontal bars and the Bidder shall
demonstrate both that the blocks are of the requisite strength and that
the means of attachment to the reinforcement are adequate.
Certificates
Each consignment of steel reinforcement shall be accompanied by a test
certificate from the manufacturer showing that the steel has been tested
and analyzed and the date of such tests and analyses and that such tests
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and analyses comply in all respects with the standards. The following tests
shall be carried out on reinforcement:
Cast analysis
Carbon equivalent value
Tensile strength, yield stress, elongation
Bend test
Bond classification
Chemical analysis
Stock of reinforcing steel

In order to ensure due progress of the works, the Bidder shall at all times
maintain on the site a stock of reinforcing steel sufficient for the following
months work. No reinforcing steel shall be used upon the works until it
has been accepted as satisfactory by the Owner/Consultant.
Rejection
The owner at his discretion may order random testing of the reinforcement
steel and in the event of any failed test reject the entire lot
notwithstanding the manufacturers or coating applicators certificates.
The Bidder shall remove all rejected reinforcing steel from the site without
delay at his own expense.
Storage
All bars for reinforcement and steel fabric reinforcement shall be stored on
the site under cover on timber or concrete supports suitably spaced and of
sufficient height to keep the steel not less than 150 mm clear of the
ground.
Bar-bending Schedules
The Bidder shall prepare bar bending schedules based on the detailed
reinforcement drawings. These shall be presented to the Owner/Consultant
for review. The Bidder is fully responsible for their completeness and
correctness in every way nor shall any claim for extra cost or time be
allowed on the grounds of errors or discrepancies which may arise
between drawings and schedules.
d. Water
Water used for mixing and curing shall be clean and free from injurious
amounts of oils, acids, alkalis, salts, sugar, organic materials or other
substances that may be deleterious to concrete or steel. pH value of water
shall not be less than 6.
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Only potable water shall be used. Tests and quality of water shall be in
accordance with IS: 456 or equivalent.
e. Aggregates
General
The aggregates for concrete shall be crushed natural rock subject to Owners
approval.
The aggregate to be used in the work shall be supplied from an established pit or
quarry.
The concrete supplier shall obtain from the aggregate producer, or otherwise
provide current test, examination, and inspection reports performed and certified
by an approved laboratory for submittal to the Owner/Consultant.
As a minimum, this information shall include the following items:-
Item 1
A comprehensive description, with current photographs of the pit or

quarry, including but not limited to, identification by name and location,
type of deposit, age, potential reserves, primary products by size including
average gradation based on previous six (6) months production and the
range for each sieve size; mining methods, process equipment, quality
control organization and laboratory; the primary and alternate means of
product transportation; listing of primary and secondary users of the
product.
Item 2
Petrographic examination in accordance with IS: 2386 (Part-8) and ASTM

C-295 performed by a qualified concrete aggregate petrographer. This
report shall be based on material produced and examined within the
previous six (6) months and must be representative of the current
production.
Item 3
Coarse aggregate shall be sampled from current production in accordance

with IS: 2386 (Part 1 to 8). Three [20 mm, 10 mm & 5 mm] nominal
maximum size (NMS) aggregates shall be sampled and tested as follows:
IS 2386(Part 1):
Methods of test for aggregates for cement: Part 1

Particle size and shape (Amendments 3)
IS 2386(Part 2):
Methods of test for aggregates for concrete: Part 2

Estimation of deleterious materials and organic
impurities (Amendment 1)
IS 2386(Part 3):

Specific gravity, density, voids, absorption and
bulking
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IS 2386(Part 4):

Mechanical properties (Amendments 3)
IS 2386(Part 5):

Soundness
IS 2386(Part 6):

Measuring mortar making properties of fine
aggregates (Amendments 2)
IS 2386(Part 7):

Alkali aggregate reactivity
IS 2386(Part 8):

Petrographic examination
ASTM C-295
Standard guide for petrographic examination of

aggregates for concrete
Aggregates when subjected to the tests defined in items above, unless

otherwise approved by the Owner/Consultant shall meet the requirements
of IS: 383 and IS: 456.
Testing is to be carried out at the following intervals:
Table 2.7
Grades of Concrete
Type
Coarse Agg.
Fine Agg.
Daily
Daily
7 days
7 days
Grading
Specific Gravity
Magn Sulphate soundness
30 days
Clay, Silt and dust content
Daily
Daily
3.5 days
Initial stage only
Initial stage only
Moisture content
2 days
Daily
Drying shrinkage
Initial only
Initial only
30 days
30 days
7 days
Shape (elongation and flakiness)

Los Angeles Abrasion
Organic impurities
10% fines value for concrete
Combined grading shall also be done on a daily basis.

Storage and handling of aggregates
Aggregate stockpiles shall be arranged and used in a manner to avoid

segregation and to prevent contamination with other materials or with
other sizes of like aggregates. Aggregate delivery trucks shall be covered
to prevent wind blown contamination. Aggregate stockpiles shall be
located relative to prevailing winds to mitigate the accumulation of windborne dust.
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Adequate storage shall be provided for each aggregate. The aggregate

storage area shall be on concrete pavement sloped to drain excessive
moisture. The aggregate storage area shall provide bulkheads to separate
piles and protect against wind blown contaminants. Provision shall be
made to shade and sprinkle the aggregates with potable water.
Aggregate stockpiles shall be built in successive horizontal layers not

exceeding 1 m in thickness, with each layer being completed before the
next is started. No vehicles shall be allowed to operate on top of the
stockpiles.
Rescreening Coarse Aggregate: Rescreening and washing of coarse

aggregates is required, if necessary, to reduce total chloride and/or
sulphate contents to a level less than the maximum allowed by the
specifications. If rescreening is required, the screening and washing shall
be just prior to transferring aggregate to batch plant bins. Aggregates
shall be dewatered over a screen to remove excess water before being
stored in the batch plant bins.
Natural or manufactured sand shall be allowed to drain until it has

reached somewhat uniform moisture content before it is used.
Fine Aggregate
Fine aggregate source shall be manufactured crushed stone or river sand,
excluding fines, which are by products/rejects of coarse aggregate
production. The crushed stone sand shall be graded from fine to coarse
with the coarse sizes predominating to give maximum density.
The amount of fine particles as ascertained by the laboratory sedimentation
method shall not exceed 10% for crushed stone nor 4% for natural sand.
The amount of material passing a 75 micron sieve (IS test sieve) shall not
exceed the following limits:Crushed Stone Sand
i) Concrete subject to abrasion
1% by weight
ii) All other concrete
3% by weight
There shall be no clay or fine silt present.

The amount of hollow shells like to form voids or remain partially unfilled
and present in material retained on an IS 2.36 mm sieve, determined by
direct visual separation, shall not exceed 3% by weight of the entire
sample.
Tests are to be executed in accordance with IS: 2386. The grading of fine
aggregate for concrete work shall comply with the requirements of IS:
383.
The grading of the aggregates should be such as to produce a concrete of
the specified proportions, which will work readily into position without
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segregation and without the use of excessive water content. The grading
should be controlled throughout the work so that it conforms closely to
that used for the preliminary tests.
A check on the moisture content of sand should be made at least once a
day before concreting. The amount of water to be added to the concrete
mix should be adjusted accordingly. Any washing, screening, classifying
and other operations on the fine aggregate required to meet this
specification shall be done by the Bidder. Washing is required if the content
of silt adhering to the aggregate is found to be unacceptably high.
Coarse Aggregate
Coarse aggregate shall be crushed rock and shall be free from decomposed
stone, clay, earth or other deleterious substances. The unit weight of the
coarse aggregate shall not be less than 2.5 t/m3. Aggregate of crushed
natural stone is deemed adequate if the stone reveals a crushing strength
of 1000 kg/cm2 when tested. Friable, flaky and laminated pieces, mica and
shale shall only be present in such quantities as not to affect the strength
and durability of the concrete.
The grading of coarse aggregate for concrete shall comply with the
requirements of IS: 383.
Samples of aggregates shall be submitted to the Owner/Consultant,
together with sieve analysis showing the proportion by weight passing
sieves. When aggregates which are satisfactory to the Owner/Consultant
have been selected, the Bidder shall secure his entire supply of each
material from the same source so as to maintain the same quality and
grading throughout the work. Should it become necessary to change the
source or characteristics of the material supplied this shall only be done
after additional tests.
f. Concrete additives
Use of Concrete Additives
Concrete additives approved by the Owner/Consultant shall be used to
improve consistency, workability, quality and strength of the concrete.
Chemical admixtures manufacturer shall provide certified test reports from
qualified independent laboratories showing actual test results indicating
material that complies in all respects with the applicable specification.
Admixtures used in concrete shall conform to the appropriate specification
and requirements as indicated below:
Air entraining admixtures shall conform to IS: 9103.
Water reducing and retarding admixtures shall conform to IS: 9103.

Accelerating admixtures shall not be used.
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High range water reducers shall be naphthalene-sulfonated polymer

based material. No admixtures containing chlorides shall be used.
Chemical admixture suppliers shall provide certified test reports with

each shipment indicating compliance with the appropriate specification.
The test reports shall include the chloride content of the admixture,
specific gravity and solids content.
Fibers: Polypropylene fibers shall be collated, fibrillated polypropylene

fiber of approved manufacture.
Admixtures used in production of concrete shall be the same as used in

establishing the required concrete mix and shall be used in accordance
with the manufacturers directions.
Liquid admixtures shall be stored in such a manner to avoid

contamination, evaporation and segregation in accordance with the
manufacturers recommendations.
Accelerating and Retarding Additives

Such additives shall only be used in case of necessity and after obtaining
the written approval of the Owner/Consultant.
Plasticizers and Air entraining Additives
Plasticizers and air entrainers are intended to reduce bleeding of free water
at the surface. It shall only be used after the written approval of the
Owner/Consultant and in accordance with the manufacturers instructions.
5.10
Dismantling/Demolishing and Modification in PCC&RCC
The dismantling implies, carefully taking up or down and removing without

damage. This shall consist of dismantling one or more parts of a structure.
This includes chipping work, cutting of reinforcement, making holes/opening
etc. in concrete members, according to the required shape, size and profile
at all elevations.
The term demolition implies, taking up or down or breaking up of a

structure/member, in part or full, as specified or shown in the drawings or as
directed by Engineer.
In a structural member, both dismantling and demolishing work may be

involved. In such case, the portion of work treated as demolishing shall be as
shown on the drawing or as directed by the Engineer.
All material obtained from the demolition/dismantling work shall be property

of the Owner, unless otherwise specified.
All serviceable materials obtained, shall be separated out and stacked

properly up to a lead of [500 meter] or shall be returned to OWNERs stores
and all unserviceable materials, rubbish etc., shall be disposed off as directed
by the Engineer, up to a lead of [2kms].
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5.11
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The dismantling / demolishing operations shall be carried out in proper

sequence so that the serviceable material can be salvaged, without being
damaged during the process or work.
Necessary propping, shoring and under pinning shall be provided for safety
of adjoining work or property which is to be left intact, before
dismantling/demolishing work.
All demolition work shall be carried out in conformity with the local safety
regulations, extreme caution being exercised to avoid damage to the work
and the equipment, which are to be left intact. Necessary precautions shall
be taken to keep the dust nuisance down. Safety requirements stipulated in
IS: 4130 shall also be followed.
As and where necessary, the dismantled/demolished materials shall be

lowered to the ground and not thrown and then properly stacked as directed
by the Engineer. Wherever required, temporary enclosures shall be erected to
minimize the dust or moisture infiltration.
Wherever fresh concrete is laid over old concrete, to ensure proper bond
between old concrete and fresh concrete, the surface of old concrete shall
be thoroughly cleared by removing all loose particles and coat of epoxy paint
shall be applied.
Minimum Cover to Foundation Bolts

Minimum distance from the centre line of foundation / anchor bolt to edge of
pedestal shall be the maximum of the following:
Clear distance from the edge of base plate / base frames to the outer edge of
the pedestal shall be minimum 50 mm
Clear distance from the face of pocket to the outer edge of pedestal shall be 75
mm
Clear distance from the edge of sleeve or anchor plate to the edge of pedestal
shall be 75 mm
5.12
Miscellaneous Requirements
Fillets at the junction of roof and vertical walls shall be provided with cast in-situ
cement concrete 1:2:4 (nominal mix) followed by 12 mm thick 1:4 cement
mortar.
A screed layer not less than 100 mm thick of cast in-situ concrete of nominal
mix 1:3:6 shall be provided below all water retaining structures. A sliding layer
of craft paper or bitumen paper shall be provided over the screed layer to
destroy the bond between screed and base slab.
Plywood formwork shall be used for all water retaining / conveying structures
and for all over ground concrete works. For other areas steel/ plywood
formwork shall be used.
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Unless specified 20 mm and down graded aggregates shall be used for all
structural concrete works. However 40 mm and down graded aggregates may
also be used under special conditions for foundation.
Tolerance for formed and concrete dimension shall be as per IS: 456.
5.13
Major Equipment Foundation

Special requirements for concreting of major equipment foundations shall be as
given below:
Coarse Aggregates
Sound and durable crushed stone aggregates shall be used. All aggregates shall
be tested for alkali aggregate reaction. Materials, which contain high percentage
of reactive silica, shall not be used. In exceptional cases of high percentage of
reactive silica content, aggregate may be allowed where low alkali cement shall
be used. Lime stone aggregate shall not generally be used for foundations,
which are subjected to high temperature and repeated temperature cycles (like
in the case of all machine foundations).
Temperature Control of Concrete
The temperature of fresh concrete shall not exceed 250 C when placed. For
maintaining the temperature of 250 C in the top deck of machine foundations,
crushed ice shall be used in mixing water.
Admixture
Plasticizer cum retarder/accelerating type admixture shall generally be added to
the concrete for promoting workability in addition to retarding / accelerating
setting time for mass concreting work. The Bidder shall submit the mixing
proportion/report after conducting the design mix as per the relevant codes and
standards. The slump of concrete shall generally be in the range given below:
Fan and Mill deck
: 100mm to 150mm
Block foundation
: 100mm to 150mm
Column
: 100mm to 150mm
Formwork
Plywood formwork shall be used for the top deck of all machine foundations.
Any other type of formwork required to be used may be permitted subject to
prior approval of the OWNER/CONSULTANT after submission of the required
data.
Scheme for Concreting
Batching plants shall be mobilized for all RCC works. Concrete pump shall be
mobilized for fans and mill foundations. Arrangements for stand-by Plant and
Equipments shall also be made.
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Placing of Concrete
Base mat as well as top deck of machine Foundations shall be cast in a single
pour. However the BIDDER shall submit method statements for various
structures and shall get the prior approval from the OWNER/CONSULTANT
before placing the concrete.
Ultrasonic Testing
Ultrasonic pulse velocity test shall be carried out for the top deck of all machine
foundations to ascertain the homogeneity and integrity of concrete. In addition,
additional cubes (at the rate of one cube per 150 cum of concrete subject to a
minimum of six cubes) shall be taken to carry out Ultrasonic Pulse velocity
(UPV) testing on the cubes to serve as reference UPV values. Testing shall be
done as per IS: 13311 (Part-1). In case of any defects, the BIDDER shall rectify
the defects suitably using cement / epoxy grout etc.
5.14
Transport of Concrete
Immediately after mixing, the concrete shall be conveyed to the place of use as
rapidly as possible using methods, which will prevent the segregation, loss or
contamination of materials. The concrete shall be placed and compacted within
90 minutes of the addition of water to the mix. Any concrete left unplaced after
this time shall be rejected and removed from the site.
The Concrete shall be transported by transit mixers of adequate capacity. Before
using concrete pumps, placer pipelines, chutes or spouts it is necessary to have
the written approval of the Owner/Consultant.
The Bidder shall obtain permission well in advance of any concrete pour.
5.15
Concreting Operations
Inspection prior to Concreting
All concreting methods
Owner/Consultant.
shall
be
subject
to
the
approval
of
the
Concrete placing shall not be started until the Owner/Consultant has approved
all preparation of forms, reinforcement, joints and all mixing, conveying,
spreading, curing, finishing and protection equipment.
Placing of Concrete
Concrete shall be placed in the forms as close as possible to its final position in
a single operation to the full thickness of slabs and beams and shall be placed in
horizontal layers, not exceeding 2.5 m height in a single pour in walls, columns
and similar members.
The Bidder shall organize the pouring of concrete in such a manner that once
concreting of a section has started the operation shall be continuous and each
operation shall be completed prior to a stoppage.
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The temperature of concrete shall not exceed 40C measured at discharge into
the works.
The maximum allowable temperature of any point within any cast element is
60C. The maximum allowable differential temperature between any two points
in the same element is 15C. Additional temperature control measures during
construction (such as the use of insulated formwork) will be required. Bidder to
prepare a process control chart and method statement verifying measures to
achieve these requirements.
Temperature monitoring of concrete work is required where:
The minimum dimension of any casting is 0.8 metres or more, or otherwise
instructed by the Owner/Consultant.
Where specified on the drawings, construction, expansion or contraction joints
shall be provided and the concrete shall be poured continuously between two
adjacent joints. No other joints than shown on the drawings shall be permitted.
Stoppage (cold) joints formed between two concreting operations separated by
more than 6 hours time shall be subject to the same treatment as the
construction joints.
Concrete shall not be dropped into place from a height exceeding 1.5 metres.
Trunking and chutes to Owner/Consultants approval shall be used for any
concrete to be deposited from a height exceeding 1.5 m.
Concrete which has partially hardened shall not be exposed to injurious vibration
or shock, except for controlled re-vibration where specified. When concreting of
a certain large structural element is specified strictly as to be poured
continuously, then the concreting operations shall be organized for day and
night working, in long shifts, as necessary.
5.16
Compaction and mechanical vibration of concrete

As concrete is being placed it shall be compacted by mechanical vibrators
complying with IS: 2505, IS: 2506, IS: 2514 & IS: 4656, to obtain a dense
material free from honeycombing, free from water and air holes.
The Bidder shall ensure that the vibrators are used in such a manner that the
reinforcement is not displaced, the formwork not damaged and no
segregation/bleeding caused, but complete compaction of the concrete is
achieved.
5.17
Finish of concrete
The concrete face shall have the finishes indicated on the drawings or in the
present specification. The finished surface of the concrete shall be sound, solid
and free from honeycombing, protuberances, air holes or exposed aggregate. No
plastering, cement wash, mortar or paint shall be applied to cover defective
concrete surfaces.
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5.18
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Construction, expansion and contraction joints

Construction joints
The number of construction joints should be kept as low as possible consistent
with reasonable precautions against shrinkage. Concreting should be carried out
continuously up to construction joints.
Where it is necessary to introduce construction joints, careful consideration
should be given to their exact location, which should be indicated on the
drawings. Alternatively, the location of joints should be subject to agreement
between the Owner/Consultant and the Bidder before any work commences.
Construction joints should be at right angles to the general direction of the
member and should take due account of shear and other stresses.
Concrete should not be allowed to run to a featheredge and vertical joints
should be formed against a stop board.
The top surface of a layer of concrete should be level and reasonably flat unless
design considerations make this undesirable. Joint lines should be so arranged
that they coincide with features of the finished work.
If a kicker (i.e. a starter stub) is used it should be at least 70 mm high and
carefully constructed. The kicker must be incorporated with the previous
concrete. Where possible, the formwork should be designed to facilitate the
preparation of the joint surface, as the optimum time for treatment is usually
two to four hours after placing.
The maximum horizontal length of wall to be poured in one operation in any one
direction is 7.5 metres. A period of 7 days to be allowed between adjacent
pours except where water stops are provided when this can be reduced with
Owner/Consultants approval. Alternatively a gap of 600 mm width shall be left
between adjacent pours and filled after 7 days from the date of formation
subject to Owner/Consultants approval.
Immediately prior to recommencement of concreting on a joint, the surface of
the concrete against which new concrete will be cast should be free from
laitance and should be roughened to the extent that the largest aggregate is
exposed but not disturbed. Care should be taken that the joint surface is clean
immediately before the fresh concrete is placed against it.
Particular care should be taken in the placing of the new concrete close to the
joint. This concrete should be particularly well compacted and if possible a
vibrator should be used.
Where the Owner/Consultant considers that special preparation is necessary, i.e.
for an in-situ structural connection, preparation should be carried out preferably
when the concrete has set but not hardened, by spraying with a fine spray of
water or brushing with a stiff brush, which is sufficient to remove the outer
mortar skin and expose the larger aggregate. Where this treatment is
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impracticable, sand blasting or a needle gun should be used to remove the

surface skin and laitance. Hacking of hardened surfaces should be avoided.
A record shall be kept on site of the time and date of placing the concrete in
each section of the work.
Expansion and contraction joints
The expansion joints, contraction joints and other permanent structure joints
shall be provided in positions as shown in the drawings.
Joints shall be straight and vertical, except where otherwise specified, and
concrete surfaces on both sides of the joint shall be flush. Where necessary,
water stoppers of a type approved by the Owner/Consultant shall be embedded
in the concrete. The water stopper should be made of high quality material,
which must obtain its resilience through the service live of the structure for the
double function of movement and sealing. The surface of water stoppers should
be carefully rounded to ensure tightness of the joint even under heavy water
pressure. To ensure a good tightness with or without movement of the joints
the water stopper should be provided with anchor parts. The cross-section of
the water stoppers should be determined in accordance with the presumed
maximum water pressure and joint movements. The complete works of fixed
and welded connections must be carried out strictly in accordance with the
manufacturers instructions.
All joints between structural steel and concrete parts shall be sealed by a
suitable permanent flexible compound.
5.19
Concreting at night
When approval is given to carry out concreting operations (under control of the
Owner/Consultant) at night or in places where daylight is excluded, the Bidder
has to provide adequate lighting at all points of mixing, transportation and
placing of concrete.
5.20
Protective measures for concrete

In general, the cover of rebars shall be as per IS: 456 taking into account the
site conditions. However, the minimum concrete cover shall not be less than:
Concrete parts above ground (external surface)
: 40 mm
Concrete exposed to underground & groundwater
: 50 mm
Isolated footings
: 50 mm
Raft
: 75 mm
Slabs
: 25 mm
Beams
: 25 mm
Columns
: 40 mm
Immediately after the compaction of the concrete has been finished, the Bidder
shall ensure adequate protection from the weather. Excessive drying can lead to
crack formation as a result of plastic contraction. The concrete surface shall be
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covered with a layer of sacking, canvas, straw mats or similar absorbent

material, special protection sprays kept constant moist for at least 7 days.
Curing compounds or other methods of preventing evaporation may be used if
approved by the Owner/Consultant. Where formwork cannot be removed within
24 hours after placing the concrete, the formwork shall be kept shaded from the
direct rays of the sun and shall be sprayed with water.
Owner/Consultants approval to the use of a particular curing compound and to
the method of application will only be given after the Bidder has completed
satisfactory site trials and a sample panel has stood for at least 28 days.
Where large sections of concrete are poured, special precautions to the approval
of the Owner/Consultant shall be taken to reduce and dissipate the heat
generated by the setting and hardening of the concrete.
The minimum amount of reinforcement shall be present to prevent shrinking
cracks.
No load of any kind, however light, shall be allowed on concrete which has not
properly set and the Bidder shall prevent any load to be imposed on the concrete
structures until it has been declared by the Owner/Consultant to be ready to
carry loads.
5.21
Concrete with Special Properties

General requirements
The pre-condition for obtaining concrete with special properties is that it should
be made with the appropriate composition, that it is placed in such a way that
segregation does not occur and further that it is fully compacted and given
appropriate curing.
Waterproof concrete
This concrete must meet the provisions of IS: 3370. Waterproof concrete must
be sufficiently dense (impermeable).
Waterproofing and protection of underground concrete structures
Water aggressive to concrete should be kept away from the fresh concrete.
Concrete, which is exposed for a prolonged period to very severe chemical
attack, must be protected against direct access of the aggressive substances.
The protection, which is to be laid as protection to all concrete surfaces in
contact with the ground, shall consist of an approved waterproofing membrane.
The membrane shall adhere to all concrete surfaces, including undersides of
structures and other surfaces where concrete is cast in contact with the
membrane.
Such membranes shall be PVC sheets of minimum 0.35 mm thickness with
knobs of Maxlock.
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The waterproof membranes shall be installed in strict accordance with

The membranes shall extend 15 cm above ground level.
When setting forms and reinforcing steel caution shall be exercised to avoid
damage to the impervious membrane. The surface of the impervious membrane
extending outside the forms shall be protected during subsequent operations.
Any puncture or damaged areas shall be cleaned and patched according to
Concrete with high wearing resistance
Concrete which is exposed to severe mechanical action, e.g., due to intensive
traffic, sliding of bulk materials, frequent impact blows or movements of heavy
objects, or due to fast-flowing water carrying solids, or other causes, should
possess high wearing resistance and correspond at least to grade M30.
The aggregate upto 4 mm size should consist predominantly of quartz or
materials of at least equal hardness; the coarser particles should consist of
stone or artificial materials possessing high abrasion resistance. In the case of
particularly severe mechanical action, it will be necessary to use special hard
materials. The particles of all types of aggregate should have a moderately
rough surface and be of compact shape. The combined aggregate should be as
coarsely graded as possible.
Furthermore, the concrete should be as stiff as possible, in order that there will
be no concentration of cement slurry or water in the top layer. The concrete
should be kept moist for at least 7 days after placing.
Finishing of formed surfaces
Fins and other surface projections shall be removed from all formed surfaces
except exterior surfaces that shall be covered with earth backfill. Exterior
surfaces that shall be exposed above grade and all interior surfaces, except
those not usually exposed to view shall be cleaned and rubbed. Rubbing shall
produce a smooth, uniform surface free of marks, voids, surface glaze, and
discolorations.
Rubbing shall be done by hand with a carborundum stone using only the mortar
produced by the rubbing action and the application of water.
Projecting ends of all form ties shall be removed. The resulting recesses shall be
cleaned, wetted, and filled with patching mortar. Patches on rubbed surfaces
shall match the texture of the adjacent concrete.
Finishing of unformed surfaces
No surface treatment shall be required for buried or permanently submerged
concrete. As a minimum, unformed surfaces shall be finished by screeding and
floating. Surfaces requiring a trowelled finish shall be finished by screeding,
floating, and trowelling.
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Float finished and screeded surfaces shall be finished to provide a flat profile
within a 6 mm deviation as measured from a 3 m straightedge. Trowel finished
surfaces shall be finished to form a flat plane. The surface profile shall not
deviate more than 3 mm when measured from a 3 m straightedge.
Screeding
Screeding shall provide a concrete surface conforming to the designated
elevations and contours with all aggregates completely embedded in adjacent
mortar. Surface irregularities in screeded surfaces shall be limited to the
tolerances specified.
Floating
The surfaces shall be screeded and given an initial float finish as soon as the
concrete has stiffened sufficiently to work. Coarse aggregate disturbed by the
float or causing a surface irregularity shall be removed and replaced with mortar.
Initial floating shall produce a surface of uniform texture and appearance.
Initial floating shall be followed by a second floating at the time of initial set.
The second floating shall produce a smooth float finish of uniform texture and
colour.
Floating shall be performed with hand floats or suitable mechanical compactor
floats.
Trowelling
The exposed portions of the tops of equipment bases, tops of interior curbs, and
the surfaces of interior slabs not receiving a separate finish shall receive a steel
trowel finish. Trowelling shall be performed after the second floating when the
surface has hardened sufficiently to prevent excess cement from being drawn to
the surface. Trowelling shall produce a dense, smooth, uniform surface free
from blemishes and trowel marks.
Surfaces to be covered with neoprene-hypalon coatings shall be lightly trowelled
but not burnished.
Brooming
Brooming shall follow the float finish for exterior surfaces where a nonslip
surface is required. Brooming shall be done with an acceptable steel or fiber
broom not less than 450 mm wide. Brooming ridges shall be transverse to the
normal traffic direction and shall be between 1.5 mm and 3 mm deep. Adjacent
strokes of the broom shall overlap slightly. Broomed surfaces shall be free of
porous spots, irregularities, depressions, and small pockets or rough spots.
Aggregate Exposure
Surface mortar shall be removed and the aggregate exposed from surfaces that
shall be covered with mortar, concrete, or grout at a later time.
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Edging
Unless specified otherwise, exposed edges of floated or troweled surfaces shall
be edged with a tool having a 6 mm corner radius.
Finishing mortar
Finishing mortar shall be added if there is not sufficient mortar available from the
concrete mix. The proportions for this finishing mortar shall be 102 kilograms of
concrete sand to one sack of Portland cement, mixed with enough water for
proper application. Slump for finishing mortar shall not exceed 50 mm.
Separate finishes
Certain slabs surfaces shall be finished with a separate concrete finish or floor
covering.
Base slab surfaces shall be ground or filled until each surface is within the
specified tolerances. Low areas shall be filled. High spots shall be ground
slightly lower than required and then filled and smoothed to the proper elevation
and surface.
Surfaces that receive epoxy set quarry tile and resilient tile shall be flat with a
profile that shall not deviate more than 3 mm from a 3 m straightedge placed on
any part of the surface. These surfaces shall be either trowel finished concrete
at the elevation indicated on the drawings or a float finished surface set 3 mm
low and levelled with trowel finished fill material.
Surfaces that receive a mortar set quarry tile, ceramic tile, or vitrified finish shall
be given a smooth, tight, and uniform float finish with a profile tolerance of
6 mm as measured from a 3 m straightedge.
5.22
Formwork
Design and construction
For stability and type of formwork and support framing used, IS: 14687 is to be
observed.
The formwork and the supporting structure are to be so dimensioned as to be
able to withstand all vertical and horizontal forces safely.
Supporting structures shall be sufficiently rigid to maintain the forms in their
correct position and to be true to shape and dimensions so that the final
concrete is within the limits of the dimensional tolerances specified in section)
Dimensional Tolerances.
The Bidder shall submit in sufficient time in advance for the approval of the
Owner/Consultant the calculations, designs and details of the methods adopted
and materials proposed for the formwork.
Particular attention must be paid to the formwork supports and braces to avoid
any slip when the concrete is poured.
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Materials for formwork

Forms shall be constructed from steel or from sound timber well seasoned and
free from shakes. Plywood lining for forms shall be of timber, which is resinbonded and water repellent.
Formwork surfaces in contact with concrete shall be free from adhering grout,
projecting nails, splits or other defects.
Joints shall be sufficiently tight to prevent the leakage of cement grout.
Connections shall be constructed to permit easy removal of the shuttering and
shall be either nailed, screwed, bolted, or otherwise secured so as to be strong
enough to retain the correct shape during consolidation of the concrete. Where
a slope exceeds 1 V: 2 H, formwork shall be provided for the top of the
concrete faces and anchored to prevent flotation.
The details of fair-faced concrete facades have to be to the satisfaction of the
Owner/Consultant. The concrete surface for facades has to be absolutely
stainless and all efforts have to be taken to achieve this. All the proposed
formwork shall be properly designed before its usage.
Grading of formwork and of finished concrete surfaces
Quality of formwork, materials to be used and treatments of surface are graded
according to the finish of the concrete surface as given in IS: 14687.
The type and treatment of the formwork lining (plywood, metal, plastics, etc)
should be appropriate to the grade of concrete finish required.
Preparation and inspection of formwork
Before concrete is placed, all formwork shall be inspected to see if it is built
according to the approved plans and to see if it has been cleaned and is free
from sawdust, shavings, dust, mud, earth or other contamination and properly
oiled. Contact surfaces of panels shall be treated with a suitable release agent
(e.g. non-staining mineral oil) where applicable. Surfaces, which are not oiled,
shall be wetted thoroughly to prevent warping.
Erection and placing of formwork
All formwork shall be erected and placed in accordance with the construction
drawings approved by the Owner/Consultant. Shuttering shall be true to line and
braced and strutted to prevent deformation under weight and pressure of the
wet concrete, live loads, wind and other forces. The deflections shall not exceed
3 mm.
The formwork for beams and slabs shall be erected so that the form on the
sides of the beams and of the soffits of slabs can be removed without disturbing
the beam soffit.
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If the formwork for columns is erected to the full height of the columns, one
side shall be provided with openings for concreting in order to guarantee a
proper compaction of the poured concrete.
Formwork for walls and elsewhere shall be arranged for a maximum concreting
height of 2.5 m in a single pour. Wherever necessary, panel openings are to be
provided in the forms for cleaning, inspection, access of vibrators, etc.
Before placing of concrete, bolts, ties and fixings shall be positioned and all
devices used for forming openings, holes, pockets, chases, recesses, etc shall
be fixed to the formwork carefully.
Panels shall be put together to ensure a perfect fit at the joint and fixed in both
directions.
Where concrete surfaces will
surfaces) the formwork shall be
surface, free from perceptible
texture. Such formwork shall
Formwork.
be exposed to view (permanently exposed

such as to produce a completely true, smooth
irregularities or to show clearly the desired
be marked on the drawings as Fair-faced
Where concrete surfaces are covered (non-exposed surfaces), the formwork

shall be referred to and marked as Sawn Formwork.
Internal spacers and ties, if any, shall be so arranged that after removing of the
forms no holes shall extend through the concrete, in the case of watertight
concrete or to be closed by plastic plugs and epoxy mortar in all other cases.
All formwork will be inspected and approved by the Owner/Consultant before
concrete placing commences but this shall not relieve the Bidder of any of his
responsibilities under the contract.
Striking of formwork
Formwork shall not be removed until the concrete has sufficient strength to
carry its own weight plus any constructional or designed loads likely to be
applied with a normal factor of safety. It shall be removed in such a manner that
no shock or injury shall result to the concrete.
Before removal of the formwork, the concrete shall be examined and removal
shall proceed only on the instructions and under the supervision of a competent
person.
In accordance with IS: 456 clause 11.3.1, the striking period for cast in-situ
concrete under certain conditions may be taken as follows: Table 2.8
Formwork
Minimum period before
striking formwork
Type of Formwork
Vertical formwork to columns, walls, beams
16 to 24 hours
Soffit formwork to slabs (props to be refixed

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Minimum period before

striking formwork
Type of Formwork
immediately after removal of formwork)
Soffit formwork to beams (props to be refixed
immediately after removal of formwork)
7 days
Props to slabs:
1) Spanning upto 4.5 m
7 days
2) Spanning over 4.5 m
14 days
Props to beams and arches:

1) Spanning upto 6 m
14 days
2) Spanning over 6 m
21 days
Special care is necessary in the case of components, which have to carry nearly
the full-calculated load as soon as the formwork is struck.
Columns, piers and walls are to be struck before the beams and slabs supported
by them. Scaffolds, formwork supports and self-supporting floor formwork are
to be carefully lowered by releasing the devices.
Extreme care shall be taken to avoid chipping of corners during removal of
formwork.
To keep deflections through creep and shrinkage to a small amount, auxiliary
supports should be left in place or immediately repositioned after striking.
5.23
Water stoppers
Water stoppers shall be of PVC or equivalent and shall be eye-letted with a
minimum 25 cm width. Type and manufacturer shall be submitted to the
Owner/Consultants approval.
All intersection pieces shall be prefabricated by the manufacturer and only
welding of butt-joints in running lengths will be allowed to be carried out on the
site.
The site welding of butt-joints shall be executed by using the manufacturers
purpose-made electrically heated jig and work shall be done by competent and
trained personnel only. The manufacturers instructions shall be carefully
observed.
The wings of the water stoppers shall be formed with corrugations or bulbs to
achieve a good bond. Moreover, the water stoppers shall conform to the
following requirements:
The tensile strength not less than 10 N/sq.mm when tested.
The ultimate elongation shall not be less than 22% when tested.
The tear resistance shall not be less than 2 N/sq.mm when tested.
The material shall not crack when tested.
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Under accelerated elongation, the tensile strength shall not be less than 8
N/sq.mm and the ultimate elongation shall not be less than 200%.
The water stoppers shall be installed so that they are securely held in position
during the placing of concrete, which shall be fully and properly compacted
around the water stoppers to prevent voids or porous areas. Adequate clearance
between the reinforcement and all the water stoppers shall be kept to permit
proper compaction of concrete.
No holes or nailing shall be made through any water stopper for fixing purposes.
Jointing by lapping two pieces of water stoppers shall not be permitted.
The free edges of water stoppers shall at all times be protected from direct
sunlight.
5.24
Curing
Concrete shall be protected from loss of moisture for not less than 7 days after
the concrete is placed and if required the concrete may be protected for few
more days as per the design mix / approved methodology.
Trowelled surfaces except those that receive a separate finish or coating, shall
be cured with a membrane curing compound. Float finished surfaces, except
those that receive a separate finish, may be cured with either a membranecuring compound or with water. Only water curing shall be used if the surface
receives a separate finish.
Water curing
Water saturation of concrete surfaces shall begin as quickly as possible after
initial set of the concrete. Water curing shall begin within 12 hours in dry
weather and within 24 hours in damp weather. The rate of water application
shall be regulated to provide complete surface coverage with a minimum of
runoff. The application of water may be interrupted for surface rubbing. The
concrete surface shall not be permitted to dry.
After the rubbing has been completed, rubbed surfaces shall be covered with
burlap and kept saturated for the remainder of the curing period.
Membrane curing
Membrane curing compound shall be applied within 30 minutes after final
finishing of the surface or as soon as possible after finishing without causing
damage to the surface. Membrane curing compound shall be spray applied at
coverage of not more than 7.4 sqm/litre. Membrane curing shall not be used on
surfaces that shall be covered at a later date with mortar, concrete, damp
proofing, tile, or any coating. Membrane curing shall not be used on cast-inplace concrete bases for field-erected tanks. Membrane curing will be permitted
only after prior approval of the OWNER/CONSULTANT.
Floor sealer
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All concrete floors shall be given two coats of clear floor sealer in addition to
that applied as membrane curing compound. The first coat shall be applied at
the end of the curing period before any traffic is permitted on the floor. The
second coat shall be applied after the floor has been cleaned in preparation for
the final inspection. Floor sealer shall be applied in strict accordance with the
manufacturer's recommendations.
5.25
Waterproofing/Damp proofing
A waterproofing seal shall be provided for all below grade structures where
applicable by external tanking with PVC sheets of 1.0 mm thickness with knobs
for membrane type waterproofing. In addition, joints in deep underground
structures shall be provided with structural waterproofing.
Damp-proof course 40 mm thick, consisting of cement concrete 1:2:4, with
admixture of approved water-proofing compound shall be laid at plinth level for
walls of all buildings for protection of super-structure against moisture and
dampness.
5.26
Repair of damaged and defective concrete

Concrete after its final setting shall be inspected by the Owner/Consultant and
any cracks, honeycomb areas, segregations, etc shall be marked. No repairs
shall be carried out until directed by the Owner/Consultant.
Surface defects in formed concrete shall be repaired to the satisfaction of the
Construction Manager within 24 hours. Concrete that is porous, honeycombed,
or otherwise defective to a depth in excess of 25 mm shall be cut out and removed to sound concrete. Edges shall be square cut to avoid feathering. Cut
surfaces shall be coated with epoxy bonding compound before the concrete is
placed.
Defective concrete shall be replaced within 48 hours after the forms have been
removed.
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PRESSURE GROUTING
The work shall consist of drilling grout holes, exploratory holes and check holes,
pressure testing, pressure washing, and injecting suspension grout under
pressure, and shall include furnishing of all materials, labor, and equipment as
described and specified.
6.1
Materials
a) Cement
Portland cement shall be ASTM C150 Type II or Type V, containing less than
0.6 percent alkali.
b) Aggregate
Aggregate shall be non reactive and shall be washed before use. When
sources of aggregate are changed, test reports shall be provided for the
material from the new source prior to commencing grout work. Fine
aggregate shall be sand or crushed stone.
c) Admixtures
Admixtures shall be compatible with the grout and shall comply with the
manufacturer's recommendations. Admixtures shall be added to the grout
mix separately.
Water Reducing Retarder: Water reducing retarder shall comply with relevant
Indian standard or as approved by Owner.
Lubricant: Lubricant additive for cement pressure grouting shall be Intrusion
Prepakt Intrusion Aid, Sika Intraplast N, or as approved by Owner.
d) Water
Waste for washing aggregate, for mixing and for curing shall be potable,
shall not contain more than 1000 mg/l of chlorides as Cl, nor more than
1300 mg/l of sulfates as SO4, and shall not contain impurities which may
change the setting time by more than 25 percent or a reduction of more than
5 percent of the compressive strength of the grout at 14 days when
compared to the results for grout made with distilled water.
e) Grout
Drypack Grout
Drypack grout shall be a mixture of approximately one part cement, 1.5
parts sand, water reducing retarder and sufficient water to make a stiff
workable mix, branded Dry Pack or approved equal.
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Cement Grout
Cement grout shall be a mixture of one part cement, two parts sand
proportioned by volume admixtures for pressure grouting and sufficient
water to form a workable mix.
Nonshrink Grout:
Non-shrink expansive flowable grout shall be used for under pinning work
below base plate of columns. Non-shrink cum plasticiser admixture shall be
added in the grout. For grouting of base of machine foundation high
strength ready mixed non-shrink flowable grout shall be used.
Type and grade of grouting for structural columns and equipment bases
shall be as indicated. Crushing strength of the grout shall generally be one
grade higher than the base concrete. Minimum grade of grout shall be M
30.
Nominal thickness of grouting shall be at least 50 mm for building columns

and pedestals of major equipment. For secondary posts, stair and ladder
base, etc. grouting shall not be less than 25 mm thick.
Special grout, where specified on the drawings, shall be provided in strict
accordance with the manufacturers instructions/specifications. Pre-mixed
Grout Conbextra GP-2 of FOSROC make or equivalent of crushing
strength 650 kg/cm2 for major equipment foundations and Conbextra GP-1
or equivalent having crushing strength of 450 kg/cm2 for other
foundations where concrete grade M30 or higher is provided
Forms and shims used to obtain adequate clearance shall not be removed
and the anchor bolts shall not be tightened for at least three days after
placing the grout. After the removal of forms and shims, area occupied by
shims shall be filled and the area between the base and edge of the
foundation shall be finished smooth to allow drainage away from the base.
Attachment of interconnecting piping of machinery and complete load
transfer of machinery shall not be done before the bolts are tightened.
During this period, grouting work shall be properly cured using rags/gunny
bags.
In view of extremely small proportion (about 0.01% by weight of cement)
of the aluminium powder required, it is necessary to take all precautions to
ensure thorough mixing. It is advisable to mix the blend of aluminium
powder thoroughly with sand and cement before water is added because
aluminium powder has a tendency to float on water.
Proprietary material of approved manufacture used as an admixture to

obtain non-shrinking grout shall be mixed in the proportion of 1:1:1 (1
cement: 1 admixture: 1 sand), or as per manufacturers instructions.
Pre-mixed non-shrinking grout shall be used as per manufacturers
instructions and without any additional materials/admixtures such as cement,
sand and aggregates etc.
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Epoxy Grout for Crack Repair and Dowel Anchorage

Except for applications involving pressure grouting or crack injection, epoxy
shall be a high modulus, moisture insensitive, two components, 100 percent
solids, thermosetting modified polyamid epoxy compound. The material shall
equal which is capable of not sagging in horizontal or overhead anchoring
applications.
Epoxy for applications involving pressure grouting or crack injection, shall be
a high modulus, moisture insensitive, two components, injection grade, 100
percent solids blend of epoxy resin compounds. The material shall equal
which is capable of achieving complete penetration of hairline and larger
cracks.
Polymer Concrete for Resurfacing and Patching
Polymer concrete shall consist of a liquid binder and dry aggregate mixed
together to make a flowable mortar. The liquid binder shall be a chemical and
oil resistant, stress relieved, low modulus, moisture insensitive, two
component epoxy resin compound. The binder material shall equal with a
consistency similar to light weight oil for proper mixing with the aggregate.
The aggregate shall be oven dry, kept in sealed packages until the time of
mixing and be of size and consistency compatible with recommendations of
the manufacturer of the liquid binder for the intended application.
Adhesive Resin for Dowel Anchorage:
Pneumatically operated caulk gun and automatically mixed at nozzle. Subject
to compliance with one of the following: HIT RE500-SD Adhesive Anchoring
System, Hilti, Inc. (ICC ESR-2322), HIT-HY 150 MAX-SD Adhesive
Anchoring System, Hilti, Inc. (ICC ESR-3013), SET-XP Adhesive Anchoring
Systems, Simpson Strong-Tie Co. (ICC ESR-2508).
6.2
Pressure Grouting Equipment

Pressure grouting equipment shall include a mixer and holdover agitator tanks
designed to place grout at pressures up to 0.345N/mm2 (50 psi). Gauges
indicating grouting pressure shall be provided and the mixer shall be equipped
with a meter capable of indicating to within 0.003 m the volume of grout
placed.
6.3
Execution
Bonding compounds for use with grout is to be provided and installed per the
a) Drypack Grout
Drypack grout is to be used for built-up surfaces, setting miscellaneous metal
items and minor repairs.
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Surfaces required to be built-up with drypack grout are to be roughened by

brushing, cleaned and coated with the bonding compound before application
of grout. The grout is to be applied to the required thickness.
b) Cement Grout
Cement grout is to be used for filling nonbearing portions of equipment pads
and pressure grouting.
Except for the specialized requirements for pressure grouting, grout is to be
mixed and placed in the same manner as cast-in-place concrete. Grout is to
be mixed for at least one minute and diluted grout is to agitated until placed.
c) Non-shrink Grout
Nonshrink, nonmetallic aggregate grout is to be used under equipment,
bearing plates and column base plates. Nonshrink, metallic aggregate grout is
to be used under rotating equipment where high strength and fatigue are of
concern, to grout anchor bolts and to grout reinforcing steel. Grout is to be
placed and cured in accordance with the manufacturer's recommendations.
Holes required for grouting shall be blown clean with compressed air and are
to be free of dust or standing water. Horizontal holes for grouting are to be
drilled at a slight downward angle and with the inserted dowel or bolt bent
to match.
d) Epoxy Grout
Epoxy grout shall be used for repairing cracks by pressure grouting or
gravity, repairing structural concrete and may be used for setting dowels or
bolts in holes. Concrete is to be primed in accordance with the grout
The use of epoxy grout must comply with the following restrictions:
Limited to areas where exposure, on an intermittent or continuous basis, to
acid, chlorine gas or to machine or diesel oils, is extremely unlikely.
Limited to applications where exposure to fire or to concrete temperatures
above the product heat deflection temperature or 120 deg F (40 deg
C)(whichever is less) is extremely unlikely. Overhead applications are not
allowed.
Holes for the anchors shall be drilled (not cored), shall be blown clean with
compressed air and shall be free of dust or standing water.
The anchor type, size and embedment depth shall be as shown on the
drawings and the anchor must be installed in accordance with the
The anchor must not be loaded until after the full curing period has
elapsed.
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e) Pressure Grouting
Prior to grouting, cracks and holes to be grouted shall be washed clean.
Washing is not required for grouting soil voids. Once started, grouting shall
be continuous until completed. In case of a mechanical failure or other
stoppage of the work, the grout equipment shall be washed out sufficiently
to ensure that fresh only grout is pumped when the work is restarted.
After grouting is completed, the Contractor shall remove the grouting plant and
all related parts, equipment, and supplies from the site, including unused
materials and waste.
6.4
6.5
Field Quality Control
The Testing Laboratory will Develop and utilize an effective method of field
marking anchor and dowel test locations and results.
Testing of grout mixes for conformance to manufacturers specified strength:

The independent testing laboratory shall take four test samples of each day's
grout mix and test grout mix samples at 7 and 28 days. Test reports shall
be submitted to the Owner for review.
Test 25 % of reinforcing steel dowels installed with adhesive resin on a

given day in tension using pullout procedure. Test to 80% of specified yield
strength of the dowel with special inspection. Dowels specifically noted on
the drawings as No test required do not require tension testing.
If the failure rate of dowels exceeds 10 percent, testing will be increased to

100 percent of that days installation of similar anchors or dowels. Testing
will be reduced to 25 % of that days installation when the failure rate is
reduced to 10 percent or less. Failed dowels will be replaced at no
additional cost to the Owner. The Contractor will produce daily reports of all
testing activities; copies of daily reports will be submitted to the Owner in a
timely manner.
Submittal
Manufacturer's data shall be provided for bonding compounds, dry pack,

non-shrink, pressure grout, retardants, epoxy grout, polymer concrete.
Test reports, accompanied by a manufacturer's statement that previously

tested material is of similar type, quality, and manufacture as that which is
proposed for use on this projects, shall be submitted for Cement,
Aggregates, Retardants, Bonding compounds and Epoxy resin
The Contractor's testing laboratory shall provide evidence of correction of

deficiencies noted in the inspection report before materials specified in this
section are delivered to the job site.
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RETROFITTING WORKS
7.1
General
[Logo of Utility]
a) The Work shall, in general, conform to other works/items specified in this

Specification.
If the specifications for any item are not available in in this Specification
cited above, relevant BIS Specifications should be followed.
In case BIS Specifications are also not available, the decision of Engineer-inCharge given in writing based on acceptable sound engineering practice and
local usage shall be final and binding on the contractor.
b) The work will be carried out in accordance with the architectural and
structural drawings to be approved by Owner. The structural and
architectural drawings shall have to be properly correlated before executing
the work.
c) For items where so desired, samples shall be prepared before starting the
particular items of work for prior approval of the Owner and nothing extra
shall be payable on this account.
d) Materials brought at site of work shall not be used in the work before getting
satisfactory Mandatory test results.
Equivalents for the various materials and the materials of approved make
shall be got approved from the Owner in writing before using them on the
work.
e) The contractor shall submit the required documents regarding the

genuineness of materials used such as manufacturers certification that the
firm has manufactured the supplied materials.
f)
The contractor shall get approved from the Owner the storage space for
epoxy/polymer/patented/other manufacture of materials to ensure that the
storage temperature is maintained between 5 C and 38 C unless
recommended otherwise by the manufacturer.
g) Contractor shall comply with manufacturer recommendations so as to

comply with environmental conditions under which the repair materials may
be applied.
h) The contractor shall employ Principal Technical Representative & skilled site
workers who shall have adequate qualifications and experience for the
proper execution of such works and already performed works of this kind
with success.
i)
Contractor shall advise all workers working with epoxies to avoid contact
with eyes and skin, inhalation of vapours, and ingestion. Necessary
protective and safety equipments in the form of hand gloves, welders
goggles, shall be provided by the contractor and used on site.
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j)
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Care shall be taken to ensure that vibrations are well within acceptable limits
for structural safety and users of the building.
k) For the execution of protection and repair works, properly maintained plant
and equipment permitting adequate treatment of the concrete substrate,
proper execution of the work and determination of the required properties of
the construction materials and construction measures must be present on
the construction site.
l)
7.2
To ensure efficient and effective functioning, all plant and equipment must
be checked on-site and at field material testing laboratory prior to first use
and at appropriate intervals thereafter.
Chipping of Unsound/Weak Concrete Material

a) Purpose
To remove weak, loose or carbonated concrete over an area from its surface
with pneumatically operated or power driven tools by chiselling, chipping
etc.
b) Materials and T&P
Power or pneumatically driven chisel, chipping tools complete with
accessories, hand-tools like chisels, hammer, pH indicator (0.2%
phenolphthalein solution) with pH range at least up to 10.5 and clinical
injection syringe.
c) Safety
Safety shall be ensured in accordance with contract conditions and
specifications.
d) Procedure
Step-1: Prop and support to relieve the structural member of stress and
strains.
Step-2: Scaffolding, if necessary for the exterior members, shall be done for
working upon the area.
Step-3: Working Platforms for interior members, if necessary, shall be
erected suitably or provided as mobile.
Step-4: Provide Protective Screen, if necessary.
Step-5: Mark off the area to be repaired using straight lines between corners.
The marked area shall have 90 corners with the sides parallel or normal to
the direction of the reinforcement. The marked boundaries for the repair area
should be a minimum of 50 mm outside the perimeter of the spall. For a
single spall, the repair area should have a minimum width of 100mm in any
direction. If a number of spalls are closely located to each other, these spalls
should be included in a single area marked for repair.
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Step-6: Cut shall be made along the marked boundary, normal-to-the

surface. It should be made with a diamond cutter blade. However, when
diamond cutting is not practical, the normal cut can be made with a power
driven chisel. Minimum depth of cut shall be 10 mm. In situations where the
diamond saw could cut into the reinforcing steel due to inadequate concrete
cover, the boundary edge should be formed manually by means of chisel and
impact hammers. A cover meter could be used to estimate the depth of
cover.
Step-7: Chipping to remove all the unsound and weak concrete material shall
be done carefully from the damaged portions of structural members by
adopting mechanical or manual means up to the required depth to produce
sound concrete surface to a near uniform depth for the repair area.
e) Tolerance
The chipping tolerances shall be 5mm.
f) Chiselling
Hand Tools are typically applicable for concrete removal for smaller,
moderate and areas of limited access. Removal should begin at the interior of
the repair area and progress toward the boundaries, using suitable hammer.
Power Driven Chisels/Hammers are normally applicable for chiselling smaller
thicknesses up to about 50 mm. Pneumatic Hammers are normally applicable
for chiselling larger thicknesses in excess of 50 mm Mechanical Milling
(single drum, rotary cutter head with Tungstencarbide bits ) is applicable for
large areas where the concrete cover is to be removed. Care must be taken
to avoid contact with the reinforcing steel as both the reinforcement and the
cutter drum could be damaged. Rounded And Feathered Edges should be
hand cut to form normal-to-the-surface boundaries. All the edges and
cavities shall be square shouldered.
Step-8: Test for carbonation shall be carried out at embedded or exposed
reinforcement locations, by spraying phenolphthalein indicator on concrete in
contact and in the immediate vicinity of reinforcement soon after its
chipping. As otherwise, chipped concrete surface in contact with air is likely
to get carbonated soon after its coming in contact with atmospheric carbon
dioxide.
Step-9: A full-depth chiselling and removal of concrete all round
reinforcement shall be carried out, in case the concrete in contact and in
immediate vicinity of the reinforcement is carbonated.
Step-10: Inspection and soundness testing, after concrete removal &
cleaning, for weaknesses and delamination of exposed surfaces shall be
visually carried out. If required, additional removal will be done.
Step-11: Cleaning of debris and dust shall be carried out from within the
chiselled/ chipped area and its disposal as per direction of the Engineer-inCharge.
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7.3
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Removing concrete all around reinforcement including from its behind

a) Purpose
To create an average clear air gap equal to nominal size of coarse aggregate
plus 5 mm all around embedded reinforcement, in contact with carbonated
concrete for rust removal & passivating its surface with fresh alkaline
passivating coat and concrete/ mortar.
Power or pneumatically driven chiselling, abrading, chipping tools complete
with accessories, hand-tools like chisels, hammer, pH indicator i.e. 0.2%
solution of phenolphthalein indicator for pH range preferably up to 11.5 or at
least up to 10.5, clinical injection syringe.
c) Safety
specifications.
d) Procedure
Step-1: Prop and support, if not done already, to relieve the structural
member of stress and strains.
Step-2: Scaffolding & working platforms for the exterior members, if not
already done and if necessary, shall be erected for working upon the area.
Step-3: Working Platforms for interior members, if not already done and if
necessary, shall be erected suitably or provided as mobile.
Step-4: Provide Protective Screen, if not already done and if necessary.
Step-5: Test for carbonation shall be carried out at embedded or exposed
reinforcement locations, by spraying phenolphthalein indicator on freshly
chipped concrete in contact and in the immediate vicinity of reinforcement.
Step-6: A full-depth chiselling and removal of concrete all round
reinforcement shall be carried out, if the concrete in contact and in
immediate vicinity of the reinforcement is carbonated. The concrete around
reinforcement shall be removed so as to have a near uniform air gap of about
5 mm plus the nominal size of coarse aggregate to be used in repair
concrete/mortar. However, the air gap shall not be less than 15 mm in any
case. Power/pneumatic driven tools/chisels shall be used for such portions of
carbonated concrete around reinforcement, which could not be removed
manually, to achieve a near uniform required air gap all around including
behind the reinforcement. Power Driven Chisels/Hammers are normally
applicable for chiselling smaller depths up to about 50 mm. Pneumatic
Hammers are normally applicable for chiselling larger depth in excess of 50
mm.
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Step-7: Cleaning of debris and dust shall be carried out from within the
chiselled /chipped area and its disposal as per direction of the Engineer-inCharge.
7.4
Cleaning reinforcement of total rust including from behind reinforcement

a) Materials and T&P
Chiselling, abrading, chipping, hammering, wire brushes, paint brush,
abrading cloth, etc hand tools complete with accessories, tested and
approved chemical rust remover.
b) Safety
specifications.
c) Procedure
Step-1: Cleaning by manual methodRemove the rust manually from all round the surface along the length of
reinforcement, using hand tools like chisels, hammers, wire brushes,
abrading cloth/paper, etc. This shall be continued manually along the length
of the rusted reinforcement till such time that the steel surface is cleared of
all rust that could be removed manually.
Step-2: Cleaning by chemicals
Remove the Rust by using tested chemicals, if directed by Engineer-inCharge, due to unsatisfactory results of manual rust removal. Chemical rust
remover shall be brush applied over the reinforcement surface thoroughly all
around the circumference and along the full length of rusted reinforcement.
After 24 hours (or as prescribed by manufacturer) of its application, the
surface shall be cleaned with wire brush and all loose particles removed. It
shall be washed with water thoroughly and allowed to dry.
7.5
Cleaning Reinforcement and exposed concrete surface

a) Purpose
Clean the prepared concrete surface of all-loose, lightly sticking materials
including the foreign materials, loose concrete, aggregates etc to provide a
good bond with the applied repair material and clean the reinforcement
surface of any minor rust remaining after manual and chemical cleaning to
achieve shining bright metal.
Coarse sand conforming to Zone I or II as per IS: 383, Air compressor of a
minimum 35 Kilowatt capacity, spray gun for sand, all related accessories
for sand blasting, hand tools like wire brushes, chisels, etc
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c) Testing of Materials and T&P

The sand shall be tested to conform to the specification.
The air compressor shall be tested to perform to the required standards as
laid down in specifications of shotcreting.
d) Safety
specifications.
e) Procedure
Step-1: Specified tested coarse sand shall be collected at site in required
quantity for sand blasting.
Step-2: Make available mechanical power driven air compressor in working
condition at site with all required accessories for carrying out sand blasting
as well as air blasting operations.
Step-3: Coarse sand shall be sprayed under pressure over the exposed
surface so as remove all loose and foreign material and to cause an intense
abrading of the reinforcement and removal of rust from entire surface of
reinforcement to achieve shining bright surface. The sand blasted surface
shall be subsequently cleaned with oil free air blast.
7.6
Providing drilling and inserting nipples along crack lines

a) Purpose
To fix injection nipples and seal the remaining portion of honey combed or
cracked concrete /masonry for grout injection.
12 mm diameter approved PVC/aluminium /Galvanised Iron nipples, Chisel,
hammer, power driven tool for chase cutting & drilling, hand operated blow
out pump, sealing putty of polyester/epoxy/polymer modified mortar etc. and
all related accessories and materials.
c) Testing
The sealing putty and the nipples shall be tested to conform to the
manufacturers specifications. The power driven tools shall be test driven and
their drill/cutting bits shall be tested for effectiveness before taking up the
repair operation.
d) Procedure
Step-1: Follow the guidelines for Safety, Quality Assurance, Environmental
Protection, Personnel, Supervision, Product delivery, Storage and Handling
etc.
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Step-2: Identify the Cracks and mark the area for injection grouting.
Step-3: Prop & support the structural member, if required, to relieve it of
stress and strains.
Step-4: Open up cracked surface by making V notch or groove of size 12
mm x 12mm.
Step-5: Remove plaster, if required, to identify and mark the honey combed
area.
Step-6: Drill holes at least 25 mm diameter and 40mm deep along crack lines
at spacing of 300 mm or thickness of the structural member, whichever is
less. In honey combed area @ 9 nos per sqm. as directed by Engineer-inCharge and up to 30 mm to 40 mm depth.
Step-7: Remove coarse debris and dust in opened up cracks and drilled holes
by blowing oil free compressed air, if available with air compressor,
otherwise with hand operated blow out pump. Concrete surfaces required to
be grouted shall be free from all loose and unsound materials by means of
mechanical abrasion using stiff wire brushes, after removing all loose areas
with chisel and hammer. Area shall be made free from any deleterious
materials, such as oil dust dirt etc. by means of oil free jet of compressed
air. All prepared concrete surfaces shall be thoroughly inspected and got
approved by the contractor.
Step-8: Insert 12mm dia specified injection nipples in holes drilled along
crack lines and fix them by sealing only its sides with epoxy or polymer
modified mortar.
Step-9: Seal the crack or the honey combed surface between the nipples by
polymer modified mortar as may be approved by Engineer-in charge. The
polymer used shall be of approved grade and applied as per specifications
mentioned separately elsewhere. The polymer-modified mortar shall be moist
cured for 1-3 days and allowed to gain strength before actual grouting
commences.
7.7
Sealing of cracks by injection of advance grout

a) Purpose
To inject the specified grout into honeycombed or cracked concrete/
masonry
b) Materials and T&P:
Cement, sand. Water and admixture for cementitious grout shall be as per
clause 5 of this specification.
Polymer: It shall be as specified and shall conform to ASTM-C-1059.
Hand/power operated grouting pressure pump/gun with pressure gauge. The
grouting equipment shall be capable of supplying, mixing, stirring and
pumping grout to the satisfaction of the Owner. The equipment shall have
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the capacity to inject grout at a pressure upto 7 kg per square centimeter

measured at the grout connections. It shall be capable of mixing and
pumping of cement sand grout 1:2 with water cement ratio ranging from 0.5
to 1.
Air compressor with all related accessories for carrying compressed air to the
required location. Hand operated blow out pump may be allowed by Owner
for small crack depths/areas.
Calibrated Spring Balance (for accurately weighing different components of
materials in required proportions), Mechanical blender for mixing, Spray
equipment/brush for application of polymer modified/ bonding cement slurry
c) Execution:
Protection, Product delivery, Personnel, Supervision, Storage and Handling,
etc.
Step-2: Full quantity of manufactured material (e.g. specified resin, hardener,
polymer, cement, etc as may be required) shall be received at site in factory
sealed containers with labels legible and intact provided that the shelf life so
permits. Otherwise substantial quantity as could be consumed within the
storage period shall be received as per quantity approved by Engineer-inCharge. Full quantity shall be worked out as theoretically required for
consumption in the whole work.
Step-3: If directed by Owner, collect random samples of materials for test
and send to approved laboratories so as to ensure that they satisfy the
physical and mechanical properties. The grout pump and the pressure gauge
shall be tested before taking up the repair operation.
Step-4: Identify the Cracks and mark the area for injection grouting.
Step-5: Surface Preparation: The appropriate propping/supporting, surface
preparation and crack sealing as per site requirements shall be completed,
which may sequentially cover one or more of the following items of work:
Prop & support the structural member to relieve it of stress and strains.
Provide grouting nipples.
Step-6: Blow the compressed air followed by washing with water through
nipples located at the highest level and downwards to ensure removal of
even fine dust particles from the cracked surface, which could obstruct the
free flow of grout material and impede its bonding with cracked surface (and
drying with air blast wherever epoxy injection grout is to be used).
Step-7: Saturate the cracked surface in the vicinity of crack/honeycombed
concrete/ masonry with water (but without excess water), only if the
cementitious grout is to be injected. Otherwise, this step may be skipped.
Step-8: Prepare the injection grout as specified under clause 5 of this
specification.
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Step-9: Inject the approved & specified grout into the cracks by means of
suitable gun or pump at a pressure of 1- 2 kg./cm2 for epoxy grout and 4-7
kg./cm2 for cementitious grout. In case of vertical cracks injection shall be
started at the lowest nipple and continued until the injected grout begins to
flow out at the next higher nipple. Whereas in other cases of horizontal
locations, the injection shall be started from one nipple and continued until
the injected grout begins to flow out at the other nipple.
The first nipple shall then be closed off and injection continued at the second
until the grout flows out at the third. The process shall be repeated until the
whole of the crack has been sealed. As soon as the system is cured, the
nipples shall be cut.
In case of Honeycombed Area, each grout hole shall be grouted individually.
Grouting pressures to be used in the work will vary with the conditions
encountered and different areas and the pressure used shall be between 1 to
4 kg/cm2. The sequence of injection shall be as per the direction of Engineerin-Charge.
7.8
Providing and inserting shear key bars

a) Purpose
Shear key bars are used for providing a structural connection of the applied
repair material with the substrate/parent surface for transfer of forces
occurring at the interface.
Epoxy cartridges and specified lengths and diameter of steel reinforcement.
Standard Power driven drilling/hammering equipment, Hand operated blow
out pump, brushes, epoxy dispenser, epoxy cartridge holder, disposable PVC
mixing nozzle for epoxy, and any other incidental accessories and T&P items.
c) Procedure
Step 1: Mark the locations of shear keys and get the same approved for
structural connection from the Owner.
Step 2: Drill holes to specified depth and diameter in concrete at marked
locations for the specified dia of shear key bars.
Step 3: The drilled hole in dry state shall be cleaned with round brushes and
by blowing air through a tube inserted in the hole and connected to hand
operated blow out pump.
Step 4: Inject epoxy from the foil pack with the help of epoxy dispenser,
epoxy cartridge holder and disposable PVC mixing nozzle inserted inside the
drilled hole to fill it from bottom of the hole and upwards.
Step 5: Insert the reinforcing bar and allow the epoxy adhesive to cure.
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7.9
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Reinforcement for RCC works etc.

a) Purpose
To provide reinforcement in repair concrete for structural purposes,
controlling effects of thermal variation or holding shotcrete/gunite material in
position. The reinforcement material may comprise specified grade and
quality with or without zinc coating.
b) Material & T&P:
Specified reinforcing material, necessary hand or power driven tools for
cutting, bending, binding, transportation, handling and placement etc.
Reinforcement bars if used shall conform to I.S. 432 (Part-I) or I.S. 1786.
Welded wire fabric where used shall conform to I.S. 1566.
c) Procedure
The general requirements, placing in position, measurement etc. shall be
generally followed as in clause 4 of this specifications excepting those
specifications provided in the following clauses.
etc.
Step-2: Testing of Material: The requisite number of test specimens of
specified reinforcing material shall be collected from each batch of
manufacture or supply received (whichever is less) for these to be tested for
conformance to the specified requirements before use on the work.
Step-3: Execution:
The required reinforcement as per approved detailed drawings in the form of
round bars or welded wire fabric in such a way so as to cause the least
interference with placement of repair material.
d) Overlaps:
Lapped reinforcing bars shall not be tied together. They shall be separated by
at least 50 mm wherever possible. Wire mesh shall be lapped by 1-1/2
squares in all direction. Minimum requirement of lap length of bars shall be
as specified in I.S. 456.
e) Clearance around reinforcement:
Sufficient clearance shall be provided around the existing exposed and
additional reinforcement to permit complete encasement with sound repair
material.
f) Cover:
Minimum cover to reinforcement shall be as specified under clause 4 or as
per I.S. 456. As far as possible the bars shall be arranged so as to permit
shooting from opposite side.
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g) Fixing:
Reinforcement shall be fixed to existing shear key bars and depth gauges
driven into the concrete with wires and secured rigidly so that the vibration
resulting from the deposition of repair material shall not impair or displace
them.
h) Where Gunite /shotcrete to be done in more than one layer
In such cases, the additional reinforcement should be so fixed that it is
encased in succeeding layer. No additional reinforcement is required to be
fixed in first layer of gunite.
Mesh reinforcement shall be fixed in the manner so that it is firmly held at
least 12 mm away from the parent concrete surface as well as from the final
finished surface. It shall be ensured that it is stiffened enough and cannot
belly out during the guniting / jacketing / concrete overlays with consequent
lack of cover. It shall be done by tying with parent concrete surface through
shear key bars or depth gauges. GI-wire mesh fabric will add sacrificial
Zinc coating & shall reduce corrosion process in the reinforcement. The
wire mesh spacing shall be as specified in the drawings.
7.10
Alkaline Passivating bond coat over Reinforcement

a) Purpose
To protect steel reinforcement with a passivating alkaline layer provided all
around its circumference along the length with strong adhesive to bond with
applied repair concrete or mortar.
Specified alkaline passivating & bonding materials e.g. CPCC material,
epoxy, epoxy phenolic IPN-RB or specified polymer and cement, mixing
water, necessary T&P for mixing and applying bond coat e.g. brush,
mechanical mixer, mechanical stirrer, etc.
Epoxy Adhesives shall conform to ASTM C-882.
Polymer Latex shall conform to ASTM C-1059.
Cement shall be ordinary Portland cement conforming to IS: 269.
Patented materials e.g. CPCC or epoxy-phenolic IPN-RB as per licensees
specifications
c) Execution:
etc.
Step-2: Full quantity of manufactured repair materials shall be received at
site in factory sealed containers with labels legible and intact, if the shelf life
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so permits. Full quantity shall be worked out as theoretically required for

Step-3: Prepare the surface for treatment.
Step-4: Thoroughly inspect all the concrete surfaces prior to applications of
passivating/ bond coat and get approved from the Engineer-in-Charge.
Step-5: Test the materials by taking random samples and testing in approved
laboratories so as to check whether they satisfy the physical and mechanical
properties.
Step-6: Make available at site all necessary mechanical equipment as under:
materials in required proportions),
Mechanical blender for mixing
Brush for application of specified and approved passivating/bond coat.
Step-7: Material Mixing: Components of the passivating/ bond coat mix shall
be weigh batched and mixed in specified proportions in a clear container free
from harmful residue or foreign particles. The components shall be
thoroughly blended with a mechanical mixer to a uniform and homogeneous
mixture. Small batches (upto 1 litre) may however be allowed by manual
mixing using spatulas, palette, knives etc.
Step-8: Material Application: The alkaline passivating & bonding material
shall be applied to prepared reinforcement substrate after tying in new
reinforcement wherever specified in the form of bars or welded wire fabric. It
shall be applied to reinforcement surfaces by stiff nylon bristle brush. The
coating material shall be worked well all round the periphery and along its
exposed length using a stiff brush ensuring that no pinholes are remaining.
The second coat, if required, the same shall be applied as per manufacturers
recommendation after the first coat is touch dry.
7.11
Bonding coat for hardened concrete with repair concrete/ cement mortar
a) Purpose
To provide adequately strong adhesion of parent concrete with applied repair
concrete or mortar.
Specified bonding materials e.g. epoxy or polymer and cement, mixing
water, necessary T&P for mixing and applying bond coat e.g. brush, spray
gun, mixer, mechanical stirrer, etc.
Epoxy Adhesives shall conform to ASTM C-882
Polymer Latex shall conform to ASTM C-1059.
Cement shall be ordinary Portland cement conforming to IS: 269.
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c) Execution
etc.
Step-2: Full quantity of manufactured repair materials shall be received at
site in factory sealed containers with labels legible and intact, if the shelf life
so permits. Otherwise substantial quantity as could be consumed within the
shelf life shall be received as per quantity approved by Engineer- in-Charge
Full quantity shall be worked out as theoretically required for consumption in
the whole work
Step-3: Prepare the surface for treatment.
Step-4: Saturate the surface with water but shall be free of excess surface
water, debris and dust, where cementitious bond coat is to be applied.
Otherwise, surface to remain dry and clean of debris and dust.
Step-5: Thoroughly inspect all the concrete surfaces prior to applications of
adhesive and get approved from the Engineer-in-Charge.
Step-6: Test the materials by taking random samples and testing in
approved laboratories so as to check whether they satisfy the physical and
mechanical properties.
Step-7: Make available at site all necessary mechanical equipment as under:
materials in required proportions), Mechanical blender for mixing Spray
equipment, brush for application of epoxy, polymer modified, bonding
cement slurry.
Step-8 Bond Coat Mixing: Components of the bonding coat mix shall be
weigh batched and mixed in specified proportions in a clear container free
from harmful residue or foreign particles. The components shall be
thoroughly blended with a mechanical mixer to a uniform and homogeneous
mixture. Small batches (upto 1 litre) may however be allowed by manual
mixing using spatulas, palette, knives etc.
Step-9 Bond coat application for jacket concrete/ shotcrete/ Mortar
placement: The specified adhesive shall be applied to concrete surface at
atmospheric temperatures below 40C for epoxy adhesive and below 30C
for polymer modified cement or cement-sand slurry adhesive. Bonding coat
shall be applied by spray equipment or stiff nylon bristle brush as approved
by Engineer-in-Charge. The bonding material shall be worked well into the
surface of the parent body ensuring that no pinholes are visible.
Polymer modified bonding cement slurry shall be applied to a thickness not in
excess of 2 mm.
If necessary, a second coat shall be applied at right angles to the first to
ensure complete coverage and absence of pin holes.
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All concrete surface shall be well protected beyond limits of surface

receiving adhesive against spillage.
Step-10 Repair Material Application: Fresh plastic concrete/ shotcrete/
mortar shall be applied while adhesive is still tacky and well within the potlife/ setting period. If adhesive cures to the extent of loosing its tack or has
set before plastic concrete/shotcrete/mortar is placed, the same shall be
removed or slightly abraded and second coat of adhesive applied. Freshly
placed plastic concrete shall be thoroughly consolidated to ensure full
bonding of new concrete with the substrate.
d) Bond of repair with parent concrete:
Evaluate bonding of fresh concrete/ shotcrete/ mortar to existing concrete
after the fresh material has cured for not less than 7 days by sounding and
tapping fresh concrete with a blunt metal instrument to the satisfaction of
Engineer-in-charge. Suspect inadequate bonding, if a hollow sound is
detected in any area. In case of conflicted location contractor shall extract
one core from the repaired surface area at the end of 28 days.
Conduct one core test at random for checking the bond, for every 100
square metre or part thereof. The contractor shall core each area after 28
days of application of concreting/ shortcreting/ repair mortar application for
determination of bonding adequacy.
Core drilling shall be done through applied repair material and into the
existing concrete. Core diameter shall be not less than three times the
nominal size of the coarse aggregate used in repair material or as required by
the Engineer-in-Charge. Length of cylindrical cores shall preferably be twice
the core diameter or twice the thickness of applied repair material or as
instructed by Engineer-in-Charge but in any case not less than the dia of the
core.
Cores shall be visually inspected by Engineer-in-Charge for evidence of poor
workmanship.
Cores shall be tested in tension to evaluate the quality of bond between new
concrete/shotcrete/mortar and the parent concrete. If the failure is in the
parent concrete the bond of new repair material shall be deemed to be
satisfactory.
Failure at the bond line or in the repair material shall be concluded as lack of
proper bond or inadequate strength of repair mortar
Dismantle such areas of work failed in bond or repair material and re-prepare
the surface after chipping off new concrete/mortar work and abrading the
epoxy/ polymer/cement slurry interface. Nothing for testing concrete for
bond between old and new concrete shall be paid separately.
7.12
Curing of RCC Surfaces etc

a) Purpose
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To ensure satisfactory hydration of cement by retaining or replenishing the

mixing water lost due to natural drying and evaporation process for a
specified period through exposed cementitious surfaces of the freshly placed
cement mortar/ concrete.
b) General
Importance of wet curing to all items of work involving use of cement can
not be over emphasised. Any surface experiencing discontinuity of dampness
of surface with any patch having dried out during the specified period of
curing, it shall be prominently marked with lime or other suitable prominent
colour.
c) Materials and T&P:
Curing compound, brush or hand operated spraying gun and all other related
accessories for application on Concrete/Plastered Surface.
d) Procedure:
etc.
Step-2: Full quantity of specified manufactured material shall be received at
site in factory sealed containers with labels legible and intact provided that
the shelf life so permits. Otherwise substantial quantity as could be
consumed within the shelf life shall be received as per quantity approved by
Engineer-in-Charge. Full quantity shall be worked out theoretically for
Step-3
Moist Curing:
Cover all exposed surface of concrete, when the concrete begins to harden
i.e. two to three hours after compaction with moist gunny bags or any other
material approved by the Owner.
Keep the exposed surfaces continuously damp after its final setting (i.e. after
a maximum of 8 hours of concreting) by ponding with a sheet of water or by
covering with a layer of sacks, canvass, hessian or similar water absorbent
materials constantly kept wet by water sprinkling for at least 7 days, where
ordinary portland cement is used and 10 days, where portland pozzolana
cement is used from the date of placing of concrete. For concrete work with
other types of cement, curing period shall be as per manufacturers
recommendations or as directed by the Owner.
Using Curing compound:
Testing of Materials:
It must be ensured that curing compound should neither affect the strength
nor the surface of concrete. It shall not leave any undesirable stains on
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surface to affect the bond of plaster or other finishes to be applied later. It

should be soluble in water, so that it can be removed by splashing or
washing with water without scrubbing the surface.
Test for Efficacy:
The testing of curing compounds shall be done from each lot of curing
compound received at site by casting two sets of 15 cm cubes with each set
having 6 cubes. One set shall be moist cured by covering with damp gunny
bags and subsequently by immersing under water and the other set by
applying curing compound on top after 2 to 3 hours of casting and
subsequently on de-moulding apply on the remaining faces all around. The
cubes shall be kept in an environment similar to which the actual structure is
exposed for a period of 7 days after its casting. Three concrete cubes each
from both sets shall be tested after 7 days for their crushing strength as per
standard test procedure. The average crushing strength of cubes cured with
curing compound shall be not less than 95% of the crushing strength of
cubes cured under damp or immersion curing.
Test for Staining:
The set of three sample cubes applied with curing compound, remaining
after 7-day cube crushing strength test, shall be washed with water with
soft brush scrubbing with nylon bristles and allowed to dry for a period of
seven days in an atmosphere with relative humidity not exceeding 40% at
ambient temperature. The other set of three cubes cured for seven days
under damp or immersion conditions shall also be kept for another seven
days under identical humidity and temperature conditions. The surface of the
two sets of such cubes shall be compared by closely observing for any
visible stain and texture that may detrimentally affect its bond with
subsequently applied plain plaster or aesthetic appearance. Such
observations shall be recorded in three categories as no effect, slight effect
and moderate effect. The curing compound shall be considered as acceptable
in the no effect category and unacceptable in the moderate category. The
decision of Engineer-in-Charge, which shall be final and binding, based on
the likely use of finished surface of concrete/plaster shall determine the
acceptability of the slight effect category.
Concrete curing compounds, after testing satisfactorily for efficacy, may be
used in lieu of moist curing with the permission of the Engineer-in-Charge.
Such compounds shall be applied to all exposed surfaces of the concrete by
spraying or brushing within two to three hours of casting and well within an
hour of removal of formwork.
7.13
Engineered Steel Tubular double Scaffolding System

Purpose
To provide a scaffolding system with adjustable working platforms on the
exterior of the building for the workmen to work upon any part of the area to be
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accessed safely and with ease for surface preparation, application of repairs and
construction activity.
Materials
The standard proprietary tubular double scaffolding system of repute with all
accessories, working platforms etc.
Design
It shall be designed for all the incidental dead, live and wind loads as per IS: 875
in steel tubular sections as per general design considerations governed by
IS:800. The design of the scaffolding system shall cater to the safety features
for the workmen.
Fabrication and Erection
Fabrication and erection shall be done as per the design brief and installation
instructions of the proprietary firm. It shall be maintained in functional condition
for the work duration.
7.14
Temporary barricading using angle iron verticals and sheet panels

Purpose
To provide a barricading on ground to physically define the boundaries of the
site of construction/repair activity for restricted entry of only those involved
with the construction work.
Materials
Available Corrugated G.I. Sheet minimum 24 G thick; Framing structural material
at least MS Angle iron of size [40x40x5mm] or equivalent.
Fabrication & Erection
Size of framing panel shall be decided depending upon site conditions and these
could be approximately 2.0 metres long with height as 1.8 metre.
It shall be made up at least of two verticals, each with additional length of about
600 mm for fixing in to ground firmly and two horizontals equal to the length of
panel.
It shall be made up by cutting the structural sections to size, shear punching
holes in verticals and horizontals for nuts and bolts or making other suitable
provision for receiving CGI sheet or other specified panelling material and
connection of panel with adjoining panels.
Fabrication of frame of an individual panel shall be by welding at corners,
welding MS plate at base of verticals or any other acceptable practice approved
by Engineer-in-charge.
G. I sheet or other specified panelling material shall be suitably fixed. It shall
preferably be done by means of nuts and bolts at its ends spaced at about 300
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mm c/c transversely and at about 600 c/c longitudinally along corrugations. The
corrugations of CGI sheet shall run along the shorter span of the panel.
In case of newly fabricated panels, these shall be painted with red oxide zinc
chromate primer on steel work and approved primer on other material and at
least one coat of paint of approved shade. In case of used panels, one coat of
paint of approved shade shall be applied over the existing paint. The portion of
verticals to be embedded in ground shall be suitably protected against rusting by
painting it with bitumen or other suitable paint.
The fabricated panels shall be suitably fixed vertically and firmly in to the ground
to the satisfaction of Engineer-in charge by maintaining a uniform height of
about 1.8 metres above GL and connecting each panel with the adjoining panels
with nut and bolts or other suitable means.
Suitable provision of frame/posts in the openings provided in barricading shall be
made for receiving door shutter at locations as approved by Engineer-in-Charge.
7.15
Temporary protective fabric screens

Purpose
To protect passersby from falling debris and also to protect the workmen and
structure being repaired against direct exposure to sun.
Materials:
For screening purpose jute cloth, woven PVC cloth, geo-textile or wire-mesh as
specified and approved by Engineer-in-Charge shall be used, which shall conform
to their relevant BIS Code. Screen materials shall be fixed by suitable means
comprising of M.S.Flats/ J-bolts /nails/clamps, etc with washer or any other
suitable means on frames of existing scaffolding etc.
Procedure
Scaffolding, if required, comprising of verticals, horizontals and diagonal
bracings of steel tubes shall be fixed over ground which is payable separately.
One end of the screening material, brought to site in looms/rolls, shall be
properly fixed over top horizontal member with suitable means and suspended
so as to cover the required area.
The vertical fall of screen shall be suitably fixed/firmed up at intermediate levels
so as to keep it in position during the work duration.
Next strip of the screening material shall be fixed with its sides stitched or
suitably jointed or lapped with the previous ones as approved by Engineer-incharge.
Spacing of frame member of scaffolding shall be so selected that the sagging of
screen shall not hinder the repair process.
The contractor shall maintain the protective screens in acceptable conditions for
the entire work duration as required by the Owner.
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CONCRETE RETROFITTING METHODS

In selecting the retrofitting method, the current status of the existing concrete
structure as determined through inspection, the performance of the structure,
the performance required of the structure after retrofitting, the conditions for
retrofitting construction work, the ease of maintenance, economy and other
factors shall be considered.
At the stage of selecting the retrofitting method, the current status of the
existing structure and its performance shall be obtained, and the performance
required for the structure after retrofitting and the conditions for retrofitting
work shall be determined. Factors that should be considered in selecting the
method include the effectiveness of the various retrofitting methods with
respect to the required performance improvements, the viability of execution of
the retrofitting work, the impact of the retrofitting work on the surrounding
environment, the ease of maintenance after retrofitting, economy and other
factors.
Various retrofitting methods listed below shall be used for retrofitting objective:
8.1
Retrofitting of concrete members

Continuous fiber reinforced plate bonding construction method:
Bonding continuous fiber reinforced plates to the surface of the existing
structure to restore or improve load-carrying capacity
Continuous fiber reinforced plate jacketing construction method:
Jacketing with continuous fiber reinforced plates around the periphery of the
existing structure to restore or improve load-carrying capacity and deformation
characteristics
Prestressed concrete jacketing construction method:
Placing pre-stressing wires and pre-stressing stranded steel wires in place of
lateral ties around the periphery of existing member sections and using mortar
and concrete to bond them in order to reinforce the structure. To increase the
restraining effect of the inner concrete, the pre-stressing steel is generally
stressed during placement.
Pre-stressing introduction (internal cable) construction method:
Using internal cables for the existing concrete members to provide pre-stressing
and restore or improve the load-carrying capacity of the members.
Repaving method:
Replacing some or all of the existing concrete members with new members
through the use of precast members or concreting on site to restore or improve
load-carrying capacity.
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8.2
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Retrofitting as a structural body

Beam (girder) addition method:
Adding beams between the main girders of the existing reinforced concrete deck
to reduce the deck span and restore or improve the load-carrying capacity of the
reinforced concrete deck.
Seismic wall addition method:
Placing new reinforced concrete walls between existing reinforced concrete
rigid-frame bridge piers and bonding them to form a continuous unit in order to
restore or improve the load-carrying capacity as a structural body.
Support point addition method:
Supporting the intermediate sections of the beams and other existing concrete
members with new members to reduce the span of the members in order to
restore or improve the load-carrying capacity as a structure.
Seismic isolation method:
Using seismic isolation bearings and the like to reduce the seismic energy
applied to the structure in order to improve its various performance values
during an earthquake.
8.3
Foundation retrofitting
Underground wall (beam) addition method:
Connecting the foundations with cast-in-site diaphragm walls and underground
connecting beams to distribute stress and ensure the stability of the entire
system.
Pile/footing addition construction method:
When pile foundations are damaged or there is residual displacement, adding
piles or footings to increase the load-carrying capacity of the foundation.
Foundation improvement method:
Improving the ground around the foundation with cement improvement materials
to improve the ground bearing capacity and horizontal foundation resistance.
Also prevents excessive pore water pressure and liquefaction.
Steel sheet-pile coffering construction method:
Placing sheet-piles around the periphery of the footings and bonding them to the
footings to improve bearing capacity and horizontal resistance.
Foundation compacting method:
When insufficient foundation bearing capacity is a concern due to scouring or
the like, using concrete or the like to compact the ground around the foundation
in order to restore bearing capacity.
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8.4
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Repair of cracks and missing sections

Cracks fill method:
Forcing low viscosity resin and ultra-fine cement into the cracks in existing
concrete members to seal the cracks.
Fill method:
Filling cracks, rock pockets, cavities, peeling and other small-scale missing
sections in existing concrete members with resin and mortar to repair sections.
Section repair method:
Removing deteriorated or damaged portions of existing concrete members and
then restoring these members to their original sectional status using materials
with excellent bonding to existing concrete.
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SHORING AND UNDERPINNING
9.1
Material and Equipment
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a) The contractor shall furnish all materials, tools, equipment, facilities and
services as required for providing the necessary shoring and underpinning
work and facilities. Jack and jacking equipment shall be more than adequate
for the imposed loads and shall be provided with calibrated gauges.
b) Shoring and bracing materials
Provide heavy timber posts, beams, planks, boards, pipe struts, pin piles,
and accessories as required.
c) Lagging and sheeting material
Provide heavy timber boards, planking or sheeting as required. Lagging board
shall be secured in place by steel H-piles, with boards inserted between the
H-flanges.
d) Underpinning Pier
An excavation pit, provided generally by manual excavation, which is carried
to a pre-selected bearing surface and then filled with concrete to provide
supplementary foundation support for the underpinning structure.
e) Concrete
Refer clause 4 of this specification for concrete requirements.
f)
Grout
Refer to Clause 5 of this specification for Non-Shrink Grout requirements.
g) Structural Steel
Refer to Clause 9 of this specification for Structural steel requirements
9.2
Execution
a) Detection of Movement
For each existing structure that may be affected by the work, install
settlement markers on each
footing, building corners, wall
or
surrounding improvements to be monitored. Settlement markers shall be
capable of being read to an accuracy of 1.52mm.
Take and record readings not less than once per week during performance of
the work until the permanent structures is complete to the ground level.
Stop work; notify the Engineer, and take immediate remedial action if
movement of the existing structure occurs during performance of the work.
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9.3
9.4
9.5
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Upon completion of the work, take weekly readings of the measurement

points for a period of 4 weeks, or longer if movement persists, and report
the results to the Engineer.
The detection of movement shall be performed by a qualified licensed land

surveyor or civil engineer.
Shoring and Underpinning
Existing footings, foundations, pile caps, grade beams, retaining walls, or

pavement which may be affected by excavation operations shall be
shored
or
underpinned adequately or otherwise protected against
settlement and shall be protected against lateral movement.
Provide soldier piling,

lagging
and
sheeting, tie-backs,
slurry
diaphragm wall, and cementitious grouting, as required, to hold back
earth at excavations and as required to prevent cave-ins and earth
sloughs.
Footings, foundations, pile caps, grade beams,

retaining walls, or
pavements which have been undermined by earthwork and pile-driving
operations shall be filled
and supported with concrete extended to
undisturbed bearing earth or bedrock.
Concrete may be placed as a stiff mix of minimum slump (dry pack),

or concrete may be pneumatically placed (shotcrete), or concrete may be
placed by conventional methods with concrete formed to hold it in proper
position.
Concrete Piers, Walls and Pile caps
Install concrete underpinning piers, walls, and pile caps as indicated, with
the bottom at the indicated or bearing elevation and the top approximately
three inches below the structure to be underpinned.
Dry pack the
space within three days after concrete placement is completed.
Where earth forms are indicated, install waterproof building paper or

board between the earth and concrete to prevent water loss from the
fresh concrete.
Do not remove support of existing structure until concrete piers, walls, or

pile caps have attained design strength.
Piles and Caissons
Install pipe pile shells or drilled shafts at locations indicated, and extend
from underside of existing footings to indicated elevations, plus additional
penetration if required to develop the design working load of the pile or
caisson.
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9.6
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Distribute jacking reactions over the existing structure in a manner that will
not overstress or deflect the existing structure.
Weld splices where indicated. Provide watertight welds capable of

developing the full strength of the pile or caisson. Align splices to ensure the
straightness of the pile from top to tip. Use outside sleeves and backup rings
as necessary.
Where the pile tip is below the ground-water table, maintain the elevation of
the water inside the shell at approximately the elevation of the ground-water
table during installation of the shell.
After installation of the shell, apply the full design-working load to the empty
pile shell and maintain until there is no measurable settlement over a one
hour period.
Maintain the excavation within the pile shell approximately 12 inches above
the tip during driving, and dewater pile shells prior to filling with concrete in
a manner which will prevent loss of earth or soil at the tip. An earth plug
may be left in the pile tip or a concrete plug may be placed and cured prior
to dewatering pile shells.
After load testing to the design load, dewatering, and inspection of the shell
by the Engineer, fill accepted pile shells with concrete in the presence of the
Engineer.
Keep an accurate record of the volume of concrete deposited in
each pile. Deficiencies revealed by comparing the volume of the inside of
the pile with the volume of placed concrete will be cause for rejection of the
pile or correction of the deficiency.
Securely wedge in place with steel wedges those piles that have satisfied
the load-testing requirements. Weld and encase in concrete all wedges,
plates, wedging struts and piles, as indicated or required.
Following completion of load transfer of underpinned structures, fill the

underpinning pits with concrete as indicated. Provide reinforcement, shear
keys, dowels, and water stops as indicated or required. Place concrete to
within 3 inches of the underside of the existing foundation. After three
days, dry pack the space between the foundation and concrete.
Load testing of piles and acceptance criteria
After the concrete within the pile or shaft has set for at least 24 hours, test
each pile or pier by jacking to a load equal to 150 percent of the designworking load of the pile.
Maintain the load until there is no measurable
settlement of the pile over a one-hour period.
Load-test piles in sequences and groupings that will minimize or eliminate

eccentric loadings on the existing foundation and piles.
Piles will be rejected and shall be retested if, in the opinion of the
Engineer, there is a danger of unequal loading.
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9.7
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Should the existing structure fail to furnish sufficient reaction to installed

underpinning piles to the test loads specified, provide additional reaction to
prevent damage to, and movement of, the structure during installation of
piles, and to obtain specified underpinning test loads. The additional reaction
shall not detrimentally affect the structure.
Maximum out-of-plumb tolerance for installed piles: two percent.
Maximum offset of top of pile from the design center: 3 inches.
Fill and backfill

Provide engineered
fill and backfill in accordance
with Clause 3 of
this specification, after acceptance of the underpinning by the Owner.
9.8
Temporary Supports
Install temporary supports where necessary to support structures to be
underpinned and those that will be affected by underpinning and restoration
work.
9.9
Restoration
Restore existing structures to conditions equivalent to those existing prior to the
start of shoring and underpinning work, including repair of any settlementrelated damage.
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10
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STRUCTURAL STEEL WORK

Design of structural steel work shall include generally but not be limited to the
steel constructions listed below:
10.1
Steel building structure and open structures including beams, columns,

bracings, supporting structures for floors, roof slabs, cladding etc.
Hoist & monorail supporting beams etc.
Platforms and walkways
Ladders, staircases, handrails, etc.
Design
(a) General
Concrete floors shall be considered to provide continuous lateral support to the
top (compression) flange of the support beams. However where large cut outs
are to be provided in the floor slabs horizontal floor bracing shall be provided.
Grating / Chequered plate floor shall neither be considered to provide lateral
support to the top flange of supporting beams nor to provide a shear diaphragm.
Adequate lateral support and horizontal bracing shall be provided as required in
such cases.
Floors for vibrating machines of all kind together with supporting framework
shall be adequately braced in both horizontal and vertical planes. Floors or
structure supporting mechanical equipment shall be designed to minimize
vibration, avoid resonance and maintain alignment and level.
(b) Design of structure
The Design of steel structures shall be done by Working stress or Limit state
method, in accordance with the provisions of IS: 800 and other relevant IS
codes as applicable to specific structures. Basic consideration for structural
framing shall be stability, rigidity, building usage, ease of fabrication / erection
and overall economy. Additional bracings / moment connections shall be used to
assure stability of structures. Structure shall be designed such that the surfaces
of all parts shall be accessible for inspection, cleaning, painting and
maintenance. Most of steel superstructure shall be designed as simple space
frame structures. Simple space frame design utilizes single-span beam systems,
vertical diagonal bracing at main column lines and horizontal bracing at the roof
and major floor levels.
Large span built-up girders shall be single web plate girders of welded
construction with bearing and intermediate stiffeners. For lifting / monorails
beams ISMB sections shall be preferred and the bottom flange of all beams shall
be checked separately for distortion and reinforced suitably if required.
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Columns shall be designed to support the load combination which results in

maximum interaction ratio. Exterior columns shall be designed to resist moments
due to wind & seismic. Columns shall also be designed to resist moments
caused by discontinuous vertical bracing or non-concentric bracing work points.
Column base can be fixed or pinned. Lateral forces shall be resisted by rigid
jointed moment connections in rigid frame design. For design which requires the
use of the minimum column load (such as, uplift on anchor bolts, column axial
tension, etc.) use 90 % of the column dead load and no live load. Uplift forces
from vertical bracing and Wind uplift on the roof shall be included where
applicable.
Permissible stresses for different members shall not be allowed to exceed by
33.33 % under wind and seismic conditions. However, members who shall be
designed primarily to resist wind load such as bracing members, no increase in
permissible stresses will be permitted. However, permissible stresses in bolts
and welds shall be allowed to exceed up to 25 % only.
Base plates shall be placed on foundation pedestal with grouting. For large base
plates necessary grout holes shall be provided. All anchor bolts for fastening
steel columns on foundation shall be embedded in foundation during concreting
itself. No anchor pockets in foundation shall be allowed. Design of base plates
shall be based on design pressure on foundation which shall not exceed the
following:
7.50 N/mm2
Pedestal in concrete grade M30
The total horizontal shear force at the base of column is transferred to the
column pedestals through friction between the base plate and the grout. A
coefficient of friction of 0.30 shall be used in conjunction with the minimum
column load. If the horizontal shear force exceeds the frictional resistance force
or if the column is subjected to a net uplift load, the total force shall then be
transmitted through shear bars / shear keys welded to the base plate. Anchor
bolts are not assumed to resist any horizontal shear force. Necessary recesses
shall be kept in the foundation concrete for shear lugs.
Static analysis of overhead conveyor galleries upto a span of 24 m is allowed.
However dynamic analysis shall be carried out for overhead conveyor galleries
exceeding 24 m span.
For equipments, the bolt shall be either embedded or placed inside the pedestal
and grouted with non-shrink grout.
The following criteria shall be followed for posting loads on the design drawings.
For vertical beam reactions, the load shall be posted whenever the value
exceeds the maximum allowable uniform distributed load. For axial loads in floor
beams, the actual horizontal load which the beam end connection must resist
shall be posted for each end of the beam. Note that this value may be different
for opposite end of the same beam. For truss members, only one member force
shall be noted for each member.
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(c) Permissible deflections

The permissible deflections of various steel members under normal loading
conditions shall be as specified below. For calculation of deflections in
structures and individual members dynamic effects shall not be considered,
unless specified otherwise. Also, no increase in deflection limits shall be allowed
when wind or seismic loads are acting concurrent with normal loading
conditions.
a)
b)
c)
d)
e)
Vertical deflection
For beams supporting dynamic

equipment
For beams supporting floors / masonry
For beams supporting pipes (pipe
racks)
For roofing and cladding components
For gratings and chequered plates
Span / 500
Span / 325
Span / 400
Span / 250
Span / 200 subject to a
maximum of 6 mm
For crane gantries or any member subjected to working loads, the maximum
deflection under dead load and live load excluding impact shall not exceed the
following values:
For manually operated cranes and monorails
: Span / 500
For electric overhead cranes
i)
Up to 50 t capacity
: Span / 750
ii)
Over 50 t capacity
: Span / 1000
Horizontal deflections
The permissible horizontal deflections shall be as per following unless specified

otherwise:
a)
b)
c)
d)
e)
Single storey building (without crane load)

Multistoried building (without crane load)
Pipe rack columns
Open Structures
Crane gantry girder due to surge
f)
Building main columns at crane rail due to action of

crane surge load only
g)
Open gantry columns at crane rail level due to

action of crane surge load only
Height / 325
Height / 500
Height / 200
Height / 200
Span / 2000 limited
to maximum of 15
mm
Height / 2500 limited
to level maximum of
10 mm
Height / 4000 limited
to
maximum of 10 mm
Provisions of IS: 800 and relevant latest IS Codes shall be followed for limiting
deflections of structural elements not listed above.
Document Number
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(d)
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Minimum thickness and size of steel elements
Minimum Thickness
The minimum thickness of various components of a structure and hot rolled

sections shall be as follows. The minimum thickness of rolled shapes shall mean
flange thickness regardless of web thickness. Structural steel members exposed
to significantly corrosive environment shall be increased suitably in thickness or
suitably protected otherwise as per good practice and sound engineering
judgement in each instance.
Trusses, purlins, girts and bracing
6 mm
Columns and beams
8 mm
Gussets
8 mm
Stiffeners
8 mm
Base plate
10 mm
Chequered plates
6 mm o/p
Grating flats
5 mm
Minimum thickness of structural members other than gratings and chequered

plate directly exposed to weather and inaccessible for painting and maintenance
shall be 8 mm.
Chequered plate shall conform to IS: 3502 (latest) and minimum thickness of
chequered plate for floorings, covers etc shall be 6 mm.
Minimum Sizes
The flange width of purlins supporting light weight concrete slab shall not be
less than 65 mm and for those supporting roof sheeting and wall cladding it
shall not be less than 50 mm. Width of steel rolled section connected to other
member shall be at least 50 mm. The depth of beams for platform of all
structures shall not be less than 125 mm.
(e) Slenderness and depth ratios
The slenderness ratio of main members in tension, compression or bending shall
be in accordance with IS: 800.
The following limiting ratios of depth to span shall be considered as a general
guide.
Truss
1 / 10
Rolled beams and girders for Ordinary floors and rafters
1 / 24
Supporting floor beams for vibrating Machines / equipments
1 / 15
Roof purlins and girts
1 / 45
Gable columns
1 / 30
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(f) Design of Connections

Welding will be done in accordance with the recommendations of IS: 816 and
IS: 9595.
Shear connections will be designed for 75 % of section strength for rolled
sections and 80 % of section strength for built up section or rolled section with
cover plates. Designed shear force shall be more than actual shear. Moment
connections between beam and column will be designed for 100 % of moment
capacity of the beam section.
All butt welds will be full penetration butt welds.
Size of fillet weld for flange to web connection for built up section will be as
follows:
i)
Able to take full shear capacity or actual shear whichever is more for
box section
ii) Able to take 80 % of full shear capacity or actual shear (if indicated in
drawings) or shall be 0.5 times of the web thickness whichever is
more. For I-section Weld will be double fillet
iii) All welds will be continuous. The minimum size of the fillet weld will be
6 mm as per relevant IS code
Connection of vertical bracings with connecting members will be designed for
full tensile capacity of the bracings. The connection between top flange & web
of built-up girder will be full penetration butt weld & for bottom flange,
connection may be fillet weld.
Connection of base plate & gusset members with the columns will be done
considering that total load gets transferred through weld.
Splicing
All splicing work will be full strength. Field splicing will be done with web /
flange cover plates. For, exceptional cases the field splicing will be designed for
50 % of load carried by the cover plates and remaining 50 % load through full
penetration butt weld. Shop splicing for all sections other than rolled will be
carried out by full penetration butt welds with no cover plates. Splicing for all
rolled sections will be carried out using web and flange cover plate. For design
efficiency of site weld shall be considered as 80 %.
Insert plates
Insert plates shall be designed / checked for shear and bending moment. All lugs
shall be checked for tension. Bond strength of concrete shall also be checked.
Lugs using steel bars shall preferably be fillet welded to the plate to transfer full
strength of the lug.
Document Number
LII-GETS12021-G-00129-001
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02
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Fabrication
(a)
General
Fabrication drawings shall be prepared according to the provision of IS: 800, IS:
813, IS: 816, IS: 9595, IS: 1367 and IS: 9178.
The work to be provided by the Bidder, unless otherwise specified elsewhere in
the contract, shall include, but not be limited to the following:
i)
Preparation of complete detailed fabrication drawings and erection marking

drawings required for all the structures covered under the scope of the
contract based on design drawings submitted by the Bidder and approved by
ii) To submit revised design with calculations and detailed fabrication (drawings
in case any substitution of the designed sections are to be made.
iii) To submit design calculations for joints and connections developed by the
Bidder along with detailed fabrication drawings.
iv) Furnish all materials, labour, tools and plant and all consumables required for
fabrication and supply, all necessary bolts, nuts, washers, tie rods and
welding \ electrodes for field connections. The field connection materials
supplied by the Bidder shall be to the extent of actual requirement plus 10 %
(ten percent).
v) Furnish shop painting of all fabricated steelwork as per requirements of this
Specification.
vi) Suitably mark, bundle and pack for transport all fabricated materials.
vii) Prepare and furnish detailed Bill of Materials, Drawing Office Dispatch lists,
Bolt List and any other list of bought out items required in connection with
the fabrication and erection of the structural steelwork.
(b)
Conformity with Design
Except where the standard connection details are furnished, the Bidder shall
design all connections, supply and fabricate all steelwork and furnish all
connection materials, Shear connectors / shear lugs on the beams in accordance
with the approved drawings and / or as instructed by the Owner/Consultant
Keeping in view the maximum utilization of the available sizes and sections of
steel materials. The methods of painting, marking, packing and delivery of all
fabricated materials shall be in accordance with the provisions of the contract
and / or as approved by the Owner/Consultant. Provision of all relevant Indian
Standard Specifications and Codes of Practice shall be followed unless
otherwise specified in the contract.
(c)
Quality control
The Bidder shall establish and maintain quality control procedures for different
items of work and materials to the extent he deems necessary to ensure that all
work shall be performed in accordance with this specification. In addition to the
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Bidder's quality control procedures, materials and workmanship at all times shall
be subjected to inspection by the Owner/Consultant. As far as possible, all
inspection by the Owner/Consultant shall be made at the Bidder's fabrication
shop whether located at Site or elsewhere. The Bidder shall co-operate with the
Owner/Consultant in permitting access for inspection to all places where work
shall being done and in providing free of cost all necessary help in respect of
tools and plants, instrument, labour and materials required to carry out the
inspection. The inspection shall be so scheduled as to provide the minimum
interruption to the work of the Bidder.
Materials or workmanship not in reasonable conformance with the provisions of
this Specification may be rejected at any time during the progress of the work.
The quality control procedure shall cover but not be limited to the following
items of work
a) Steel Quality, manufacturer's test certificates, test reports of representative
samples of materials from unidentified stocks if permitted to be used.
b) Bolts, Nuts Manufacturer's certificate, dimension & Washers checks,
material testing.
c) Electrodes Manufacturer's certificate, thickness and quality of flux coating.
d) Welders .Qualifying Tests
e) Welding sets Performance Tests
f) Welds Inspection, X-ray, Ultrasonic tests
g) Paints Manufacturer's certificate, physical Inspection reports
h) Galvanizing Tests in accordance with IS: 2633 and IS: 4759.
(d)
Materials
If desired by the Owner/Consultant, Test Certificates of materials supplied by

the Bidder in respect of each consignment shall be submitted in triplicate.
Whenever the materials are required to be used from unidentified stocks, if
permitted by the Owner/Consultant, a random sample shall be tested at an
approved laboratory from each lot of 50 tonnes or less of any particular section.
Materials for main and secondary members shall be selected in line with good
engineering practice and shall be arranged within any structure with due regard
for maintenance of the structure and Plant and Equipment supported or
sheltered by the Structure and also with regard to corrosion.
All steel materials shall be free from all imperfections, mill scales, slag
intrusions, laminations, pitting, rusts, etc. that may impair their strength,
durability and appearance.
All rolled steel shall conform to the requirements of the Indian Standards.
i)
Structural Steel will conform to IS: 2062 Grade-A for rolled steel members or
plates up to 20 mm thickness.
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ii) For plates above 20 mm thickness and welded construction, steel

conforming to IS: 2062 Grade-B will be used.
(e)
Workmanship
All workmanship shall be equal to the best practice in modern structural shops,
and shall conform to the provisions of IS: 800 and other relevant Indian
Standards or equivalent.
Straightening Material
Rolled materials before being laid off or worked, must be clean, free from sharp
kinks, bends or twists and straight within the tolerances allowed as per IS:1852.
If straightening is necessary, it may be done by mechanical means or by the
application of a limited amount of localized heat. The temperature of heated
areas, as measured by approved methods, shall not exceed 600OC.
Cutting
Cutting shall be affected by shearing, cropping or sawing. Use of a mechanically
controlled gas cutting torch may be permitted for mild steel only. Gas cutting of
high tensile steel may also be permitted provided special care is taken to leave
sufficient metal to be removed by machining, so that all metal that has been
hardened by flame is removed. Gas cutting without a mechanically controlled
torch may be permitted if special care is taken and done under expert hand,
subject to the approval of the Owner/Consultant.
To determine the effective size of members cut by gas, 3 mm shall be deducted
from each cut edge. Gas cut edges, which will be subjected to substantial stress
or which are to have weld metal deposited on them, shall be reasonably free
from gouges. Occasional notches or gauges not more than 4 mm deep will be
permitted. Gouges greater than 4 mm that remain from cutting shall be removed
by grinding. All re-entrant corners shall be shaped notch-free to a radius of at
least 12 mm. Shearing, cropping and gas cutting shall be clean, reasonably
square and free from any distortion.
Planning of Edges
Planning or finishing of sheared or cropped edges of plates or shapes or of
edges gas-cut with a mechanically controlled torch shall not be required, unless
specifically required by design and called for on the drawings, included in a
stipulation for edge preparation for welding or as may be required after the
inspection of the cut surface. Surface cut with hand-flame shall generally be
ground, unless specifically instructed otherwise by the Owner/Consultant.
Clearances
The erection clearance for cleated ends of members connecting steel to steel
shall preferably be not greater than 2 mm at each end. The erection clearance at
ends of beams without web cleats shall be not more than 3 mm at each end,
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but where, for practical reasons, greater clearance is necessary, suitably

designed cleatings shall be provided.
Bolted construction
All bolts and nuts shall conform to the requirements of IS: 1367.
Field connections shall preferably be bolted connections unless specified
otherwise. Weld connections at site shall be avoided.
High strength friction grip bolts shall be of property class 8.8 and shall conform
to IS: 3757 and shall not be less than 20 mm in diameter unless designated
otherwise. High strength bolts shall be installed as bearing type joint except
where loads are reversible. Bearing Type connection (H.T. bolts Grade 8.8) shall
be used for all removable type connections. Bolts will be tightened to develop
the required pre-tension during their installation.
All erection bolts shall be of minimum 16 mm diameter of property class 4.6
conforming to IS: 1367 unless specified otherwise.
Holes for bolts shall not be more than 1.5 mm for bolt of diameter equal or
lesser than 25 mm and shall not be more than 2 mm for bolt of diameter greater
than 25 mm.
Holes through more than one thickness of material for members, such as
compound stanchions and girder flanges, shall be drilled after the members are
assembled and tightly clamped or bolted together. Punching may be permitted
before assembly, if the thickness of the material is not greater than the nominal
diameter of bolt plus 3 mm subject to a maximum thickness of 16 mm provided
that the holes are punched 3 mm less in diameter than the required size and
reamed after assembly to the full diameter.
Holes for turned and fitted bolts shall be drilled to a diameter equal to the
nominal diameter of the shank or barrel subject to a tolerance grade of H8 as
specified in IS: 919. Parts to be connected shall be firmly held together by
tacking welds or clamps and the holes drilled through all the thicknesses in one
operation and subsequently reamed to size. Holes not drilled through all
thickness in one operation shall be drilled to a smaller size and reamed out after
assembly.
Holes for bolts shall not be formed by gas cutting process.
Assembly
Drifting to enlarge un-matching holes shall not generally be permitted. In case
drifting is permitted to a slight extent during assembly, it shall not distort the
metal or enlarge the holes. Holes that must be enlarged to admit the bolts shall
be reamed. Poor matching of holes shall be cause for rejection. The component
parts shall be so assembled that they are neither twisted nor damaged and shall
be so prepared that the specified cambers, if any, are maintained.
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Bolted construction shall be permitted only in case of field connections if called

for on the Drawings and is subjected to the limitation of particular connections
as may be specified. In special cases, however, shop bolt connections may be
allowed if directed by the Owner/Consultant.
Washers shall be tapered or otherwise suitably shaped, where necessary, to give
the heads and nuts of bolts a satisfactory bearing. The threaded portion of each
bolt shall project out through the nut at least one thread. In all cases the bolt
shall be provided with a washer of sufficient thickness under the nut to avoid
any threaded portion of the bolt being within the thickness of the parts bolted
together. In addition to the normal washer, one spring washer or locknut shall
be provided for each bolt for connections subjected to vibrating forces or
otherwise as may be specified on the Drawings.
Welded Construction
Welding shall be in accordance with relevant Indian Standards. Welding shall be
done by experienced and good welders who have been qualified by tests in
accordance with IS: 817. All shop connections shall be welded type.
Preparation of Material
Surface to be welded shall be free from loose scale, slag, rust, grease, paint and
any other foreign material except that mill scale which withstands vigorous wire
brushing may remain. Joint surfaces shall be free from fins and tears,
Preparation of edges by gas-cutting shall, wherever practicable, be done by a
mechanically guided torch.
Parts to be fillet welded shall be brought in as close contact as practicable and
in no event shall be separated by more than 4 mm. If the separation is 1.5 mm
or greater, the size of the fillet welds shall be increased by the amount of the
separation. The fit of joints at contact surfaces which are not completely sealed
by welds, shall be close enough to exclude water after painting. Abutting parts
to be butt-welded shall be carefully aligned. Misalignments greater than 3 mm
shall be corrected and in making the correction the parts shall not be drawn into
a sharper slope than 20C.
The work shall be positioned for flat welding whenever practicable.
In assembling and joining parts of a structure or of built-up members, the
procedure and sequence of welding shall be such as will avoid needless
distortion and minimize shrinkage stresses. Where it is impossible to avoid high
residual stresses in the closing welds of a rigid assembly, such closing welds
shall be made in compression elements.
In the fabrication of cover-plated beams and built-up members, all shop splices
in each component part shall be made before such component part is welded to
other parts of the member. Long girders or girder sections may be made by shop
splicing not more than three sub-sections, each made in accordance with this
paragraph.
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When required by the Owner/Consultant, welded assemblies shall be stress

relieved by heat treating in accordance with the provisions of the relevant Indian
Standard or any other Standard approved by the Owner/Consultant.
All complete penetration groove welds made by manual welding, except when
produced with the aid of backing material not more than 8 mm thick with root
opening not less than one-half the thickness of the thinner part joined, shall
have the root of the initial layer gouged out on the back side before welding
shall be started from that side, and shall be so welded as to secure sound metal
and complete fusion throughout the entire cross-section. Groove welds made
with the use of the backing of the same material as the base metal shall have
the weld metal thoroughly fused with the backing material. Backing strips need
not be removed. If required, they may be removed by gouging or gas cutting
after welding is completed, provided no injury is done to the base metal and
weld metal and the weld metal surface is left flush or slightly convex with full
throat thickness.
Groove welds shall be terminated at the ends of a joint in a manner that will
ensure their soundness. Where possible, this should be done by use of extension
bars or run-off plates. Extension bars or run-off plates need not be removed
upon completion of the weld unless otherwise specified elsewhere in the
Contract.
To get the best and consistent quality of welding, automatic submerged arc
process shall be preferred. The technique of welding employed, the appearance
and quality of welds made, and the methods of correcting defective work shall
all conform to the relevant Indian Standards.
No welding shall normally be done on parent material at a temperature below (-)
50C. However, if welding is to be undertaken at low temperature, adequate
precautions as recommended in relevant Indian Standard shall be taken. When
the parent material is less than 40 mm thick and the temperature is between (-)
50C and 00C, the surface around the joint to a distance of 100 mm or 4 times
the thickness of the material, whichever is greater, shall be preheated till it is
hand warm. When the parent material is more than 40 mm thick, the
temperature of the area mentioned above shall be in no case be less than 200C.
All requirements regarding preheating of the parent material shall be in
accordance with the relevant Indian Standard.
Submerged arc welding process shall be used for welding longitudinal fillet
welds (connecting flanges with web) and longitudinal / transverse butt joints for
fabrication of columns, framing beams and all other built up members unless
manual arc welding is specifically required. All electrodes, flux, bare wire etc will
be procured from approved manufacturers. All butt welds in beams, girders &
columns will be of full penetration. All butt welds will be radio-graphically or
ultrasonically tested as per relevant IS codes and standard practice. The base
wire electrodes for submerged arc welding will conform to IS: 7280. The
combination of wire and flux will satisfy requirements of IS: 3613.
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Peening
Where required, intermediate layers of multiple-layer welds may be peened with
light blows from a power hammer, using a round-nose tool. Peening shall be
done after the weld has cooled to a temperature warm to the hand. Care shall
be exercised to prevent scaling or flaking of weld and base metal from over
peening.
Equipment
These shall be capable of producing proper current so that the operator may
produce satisfactory welds. The welding machine shall be of a type and capacity
as recommended by the manufacturers of electrodes or as may be approved by
Finish
Column splices and butt joints of compression members depending on contact
for stress transmission shall be accurately machined and close-butted over the
whole section with a clearance not exceeding 0.2 mm locally at any place. In
column caps and bases, the ends of shafts together with the attached gussets,
angles, channels etc., after welding together, should be accurately machined so
that the parts connected butt over the entire surfaces of contact. Care should
be taken that those connecting angles or channels are fixed with such accuracy
that they are not reduced in thickness by machining by more than 2 mm.
Slab bases and caps
Bases and caps fabricated out of steel slabs, except when cut from material
with true surface, shall be accurately machined over the bearing surface and
shall be in effective contact with the end of the stanchion. A bearing face which
is to be grouted direct to a foundation need not be machined if such face is true
and parallel to the upper face.
Miscellaneous
Lacing bars
The ends of lacing bars shall be neat and free from burrs.
Separators
Rolled section or built-up steel separators or diaphragms shall be required for all
double beams except where encased in concrete, in which case, pipe separators
shall be used.
Bearing Plates
Provision shall be made for all necessary steel bearing plates to take up reaction
of beams and columns and the required stiffeners and gussets whether or not
specified in Drawings.
Architectural Clearances
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Bearing plates and stiffener connections shall not be permitted to encroach on

the designed architectural clearances.
Shop Connections
i) All shop connections shall be welded as specified on the Drawings.

ii) Certain connections, specified to be shop connections, may be changed
to field connections if desired by the Owner/Consultant for convenience
of erection and the Bidder will have to make the desired changes at no
extra cost to the Owner.
Shop Erection
The steelwork shall be temporarily shop-erected complete or as directed by the

Owner/Consultant so that accuracy of fit may be checked before despatch. The
parts shall be shop-erected with a sufficient number of parallel drifts to bring
and keep the parts in place. In case of parts drilled or punched using steel jigs to
make all similar parts interchangeable, the steelwork shall be shop erected in
such a way as will facilitate the check of interchange ability.
(f)
Shop Painting
All fabricated steel material, except those galvanized or to be embedded in

concrete, shall receive paint coatings as specified below. All paints shall be of
approved brand and shade as per the Owners requirement.
Steel surface, which is to paint, shall thoroughly be cleaned of all loose mill
scale, rust, grease, dirt and other foreign matter by wire brush & if required by
sand blasting prior to actual surface preparation. The surface shall be cleaned
to grade ST-2.5 as per SIS05-5900 or as per IS: 1477 (Part -I).
All steel structures shall receive two primer coats and two finish coats of
painting. After fabrication the first coat of primer shall be immediately given
over the prepared steel surface. The second coat of primer shall be applied over
the dried first primer coat. Two finish coats shall be applied over the primer
coats before dispatch of structure at site.
Primer paint shall be red oxide zinc chromate conforming to IS: 2074. Dry film
thickness of each coat shall be 50 microns. Adequate care should be taken such
that the surface does not possess a slick finish to which paint may not adhere
properly. Top coat shall consist of two coats of HB Synthetic enamel of
approved shade and colour with glossy finish and DFT as 75 microns (total).
Thus the total DFT of painting including that of primer coats shall not be less
than 175 microns.
Following care shall be taken while painting:
i)
Joints to be site welded shall have no paint applied within 100 mm of

welding zone. Similarly where friction grip fasteners are to be used no
painting shall be provided. On completion of the joint the surfaces shall
receive the paint as specified.
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Surfaces inaccessible after assembly shall receive two coats of primer prior
to assembling.
iii) Surfaces inaccessible after erection, including top surfaces of floor beams
supporting gratings or chequered plate, shall receive one additional coat of
finish paint over and above number of coats specified above before
erection.
iv) Portion of steel member embedded / to be encased in concrete shall not be
painted.
v)
Areas / Surfaces subjected to chemical attacks shall be painted with acid

resistant paint.
vi) Machine finished surfaces shall be protected against corrosion by a rust

inhibiting coating that can be easily removed prior to erection or which has
characteristics that make removal unnecessary prior to erection.
(g)
Inspection, testing and acceptance criteria
Unless specified otherwise, inspection to all work shall be made by the

Owner/Consultant at the place of manufacture prior to delivery. The Owner /
Consultant shall have free access at all reasonable times to those parts of the
manufacturers works which are concerned with the fabrication of the steelwork
under this Contract and he shall be afforded all reasonable facilities for
satisfying himself that the fabrication is being done in accordance with the
provisions of this Specification. The Bidder shall provide free of charge, such
labour, materials, electricity, fuel, water, stores, tools and plant, apparatus and
instruments as may be required by the Owner/Consultant to carry out inspection
and / or tests in accordance with the Contract.
The Bidder shall guarantee compliance with the provisions of this Specification.
The Bidder shall carry out sampling and testing in accordance with the relevant
Indian Standards and as supplemented herein for the following items at his own
cost, unless otherwise specified in the Contract. The Bidder shall get the
specimens tested in a laboratory approved by the Owner/Consultant and submit
to the Owner/Consultant the test results in triplicate within 3 (three) days after
completion of the test.
Steel
All steel supplied by the Bidder shall conform to the relevant Indian Standards,
except otherwise mentioned in the Contract, only tested quality steel having mill
test reports shall be used. In case unidentified steel materials are permitted to
be used by the Owner/Consultant, random samples of materials will be taken
from each unidentified lot of 50 ton or less of any particular section for tests to
conform to relevant Indian Standards. Cost of all tests shall be borne by the
Bidder.
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All material shall be free from all imperfections like mill scales, slag intrusions,
laminations, pittings, rusts etc. that may impair their strength, durability and
appearance.
All raw steel plate of thickness more than 20 mm supplied by the Bidder shall be
checked against lamination before procurement & prior to commencement of
fabrication work in the following ways as directed by the Owner/Consultant:
i)
Ultrasonic testing along the edge of specified points of the plates shall
be carried out to delete lamination in the plates, if any.
ii) If the results of the tests in (i) are not satisfactory, the whole area of
the plates shall be checked by ultrasonic testing at specified nodal
points formed at equidistant grid locations. The spacing of the grids
shall be determined from tests in (i) or as directed by the
Owner/Consultant.
If the results of the above tests are not satisfactory, the plates shall not be
taken up for fabrication work. Even after fabrication at shop, if the
Owner/Consultant requires any ultrasonic testing to detect lamination of plates,
the same shall be carried out by the Bidder. If the plates in the fabricated item
are found to be laminated, the component will be rejected.
Welding
All electrodes shall be procured from reliable manufacturers with test
certificates. The correct grade and size of electrode which has not deteriorated
in storage shall be used. The inspection and testing of welding shall be
performed in accordance with the provisions of the relevant Indian Standards or
other equivalents. For every 50 tonnes of welded fabrication, the Owner may
ask for at least one test-destructive or non-destructive including X-ray,
ultrasonic test or similar, the cost of which shall be borne by the Bidder. In the
event of further tests as may be desired by the Owner. The cost of such test
shall be borne by the Bidder if the results are found to be unsatisfactory; and if
the test shows no defect, the cost shall be borne by the Owner. In cases of the
test results showing deficiency, the Owner / Consultant shall have option to
reject or instruct any remedial measures to be taken free of charge to the
Owner.
Bolts, nuts and washers
All bolts, nuts and washers shall be procured from reputed manufacturer
approved by the Owner/Consultant and shall conform to the relevant Indian
Standards. If desired by the Owner/Consultant, representative samples of these
materials may have
i)
Name of the Bidder
ii) Number and date of the Contract

iii) Name of the office placing the contract
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iv) Nomenclature of stores

v) A schedule of parts or pieces, giving the parts or piece number with
vi) Tolerance
The tolerance on the dimension of the individual rolled steel components shall be
as specified in IS: 1852. The tolerances on straightness, length etc. of various
fabricated components (such as beams, girders, columns, etc) of the steel
structures (other than steel railway and road bridges structure) subjected to
dynamic loading (like wind, seismic etc.) and thin walled constructions (like box
girders) shall be as specified in IS: 7215.
10.3
Erection
(a)
General
The work to be provided for by the Bidder, unless otherwise specified in the Bid,
i)
The Bidder shall provide all transport equipment, lifting equipment, tools,
tackle, consumables, materials, labour and supervision required for the
erection of the structural steelwork.
ii) Receiving, unloading, checking and moving to storage yard at Site including
prompt attendance to all insurance matters as necessary for all fabricated
steel materials arriving at Site. The Bidder shall pay all demurrage and / or
wharfage charges etc. on account of default on his part.
iii) Transportation of all fabricated structural steel materials from Site storage
yard, handling, rigging, assembling, bolting, welding and satisfactory
installation of all fabricated structural steel materials in proper location
according to approved erection drawings and / or as directed by the
Owner/Consultant. If necessary, suitable temporary approach roads to be
built for transportation of fabricated steel structures.
iv) Checking centre lines, levels of all foundation blocks including checking line,
level, position and plumb of all bolts and pockets. Any defect observed in the
foundation shall be brought to the notice of the Owner/Consultant. The
Bidder shall fully satisfy himself regarding the correctness of the foundations
before installing the fabricated steel structures on the foundation blocks.
v) Aligning, plumbing, levelling, bolting, welding and securely fixing the
fabricated steel structures in accordance with the Drawings or as directed by
vi) Touch up paintings, making good any damaged shop painting and completing
any unfinished portion of the shop coat shall be carried out by the Bidder
free of cost to the Owner.
vii) All minor modifications of the fabricated steel structures as directed by the
Owner/Consultant including but not limited to the following:
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(b)
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Removal of bends, kinks, twists etc. for parts damaged during transport
and handling.
Cutting, chipping, filling, grinding etc. if required for preparation and

finishing of site connections.
Reaming of holes for use of higher size bolt if required.
Welding of connections in place of bolting for which holes are either

not drilled at all or wrongly drilled during fabrication. Welding in place
of bolting will be permitted only at the discretion of the
Owner/Consultant.
Re-fabrication of parts damaged beyond repair during transport and

handling or re-fabrication of parts which are incorrectly fabricated.
Fabrication of parts omitted during fabrication by error, or subsequently

found necessary.
Drilling of holes which are either not drilled at all or are drilled in
incorrect location during fabrication.
Carry out tests in accordance with this Specification if directed.
Conformity with design
The Bidder will erect the entire fabricated steel structure, align all the members,
complete all field connections and grout the foundations all as per the provisions
of this specification and the design criteria detailed in the approved erection
drawings and / or other stated document. All work shall conform to the
provisions of the relevant Indian Standard Specifications and / or the
instructions of the Owner/Consultant. The testing and acceptance of the erected
structures shall be in accordance with the provisions of this Specification and /
or the instructions of the Owner/Consultant.
(c)
Storage of materials
All material shall be so stored as to prevent deterioration and to ensure the

preservation of their quality and fitness for use in the works. Any material which
has been deteriorated or damaged beyond repairs and has become unfit for use
shall be removed immediately from the site.
(d)
Yard
The Bidder will have to establish a suitable yard in an approved location at site
for storing the fabricated steel structures and other materials which will be
delivered to him by the Owner according to the Contract. The yard shall have
proper facilities like, drainage, lighting, suitable access, trailers I and other heavy
equipments. The yard shall be fenced alI round with security / arrangement and
shall be of sufficiently large area to permit systematic storage of the fabricated
steel structures without overcrowding and with suitable access, trailers and
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other equipment for use in erection work in proper sequence in accordance with
the approved programme of work.
The Bidder should visit the site prior to submission of his Tender to acquaint
himself with the availability of land and the development necessary by way of
filling, drainage, access roads, fences, sheds etc. All of which shall be carried
out by the Bidder at his own cost as directed by the Owner.
(e)
Covered Store
All field connection materials, paints, etc. shall be stored on well designed racks
and platforms off the ground in a properly covered store building to be built at
the cost of the Bidder.
(f)
Workmanship
Erection Plant and equipment

The suitability and adequacy of all erection tools and plant and equipment
proposed to be used shall be efficient, dependable, in good working condition
and shall have the approval of the Owner/Consultant.
Method and sequence of erection
The method and sequence of erection shall have the prior approval of
Owner/Consultant. The Erection shall arrange for most economical method
sequence available to him consistent with the Drawings and Specifications
such information as may be furnished to him prior to the execution of
Contract.
the
and
and
the
Temporary bracing
Unless adequate bracing is included as a part of the permanent framing, the
erector during erection shall install, free of cost to the Owner, temporary guys
and bracings where needed to secure the framing against loads such as wind or
seismic forces comparable in intensity to that for which the structure has been
designed, acting upon exposed framing as well as loads due to erection
equipment and erection operations.
If additional temporary guys are required to resist wind or seismic forces acting
upon components of the finished structure Installed by others during the course
of the erection of the steel framing, arrangement for their installation by the
erector shall be made free of cost to the Owner.
The responsibility of the Bidder in respect of temporary bracings and guys shall
cease when the structural steel is once located plumbed levelled, aligned and
grouted within the tolerances permitted under the specification and guyed and
braced to the satisfaction of the Owner/Consultant.
The temporary guys, braces, false work and cribbing shall be removed
immediately upon completion of the steel erection and shall return to the
Owners store in good condition if the materials are supplied by the Owner
otherwise permission shall be given to Bidder to take out the materials from the
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project site. The Owner may remove and return the materials in good condition
to the Bidder without any charge if they have been left in place under other
agreed arrangement.
Temporary floors for buildings
It shall be the responsibility of the Bidder to provide free of cost planking and to
cover such floors during the work in progress as may be required by any Act of
Parliament and / or by-laws of state, Municipal or other local authorities.
Setting out
Positioning and levelling of all steelwork, plumbing of stanchions and placing of
every part of the structure with accuracy shall be in accordance with the
approved Drawings and to the satisfaction of the Owner/Consultant. Concrete
foundations, where required, shall be made by other agencies. Anchor bolts and
other anchor steel shall be embedded by other agencies. The Bidder shall check
the positions and levels of the anchor bolts, etc. before concreting and get
them properly secured against disturbance during pouring operations.
He shall remain responsible for correct positioning. For heavy columns, etc. the
Bidder shall set proper screed bars if desired by the Owner/Consultant, to
maintain proper level. No extra payment shall be made for this.
Each tier of column shall be plumbed and maintained in a true vertical position
subject to the limits of tolerance allowable under this Specification.
No permanent field connections by bolting or welding shall be carried out until
proper alignment and plumbing has been attained.
Field bolting
All relevant portions in respect of bolted construction of the Specification for
Fabrication of Structural Steelwork applicable to the Project shall also be
applicable for field bolting in addition to the following:
Bolts shall be inserted in such a way so that they may remain in position under
gravity even before fixing the nut. Bolted parts shall fit solidly together when
assembled and shall not be separated by gaskets or any other interposed
compressible materials. When assembled, all joint surfaces, including those
adjacent to the washers shall be free of scales except tight mill scales. They
shall be free of dirt, loose scales, burns, and other defects that would prevent
solid seating of the parts. Contact surfaces within friction-type joints shall be
free of oil, paint, lacquer, or galvanizing.
Drifting
Correction of minor misfits of bolts will be considered as permissible. For this,
light drifting may be used to draw holes together and drills shall be used to
enlarge holes as necessary to make connections. Reaming, that weakens the
member or makes it impossible to fill the holes properly or to adjust accurately
after reaming shall not be allowed.
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11
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ARCHITECTURAL WORKS
The architectural design concept of buildings shall be evolved considering the
functional, technical and other requirements for efficient operation, ensuring
comfortable working environment for personnel, satisfying the aesthetic
requirements. Special care shall be taken to provide elegance and aesthetics,
with effective use of appropriate treatment, materials, fittings and finishes. To
achieve above objective Bidder shall employ a qualified architect / architectural
firm to carry out all designs and hold all other architectural responsibilities for
the project.
The Bidder shall obtain and be conversant with all laws, by-laws and regulations
of local and Statutory Bodies as applicable to the project. The architectural
concept evolved should also take care of these requirements. The Bidder shall
provide the drawings and documents for such statutory approvals.
11.1
General
The architectural services shall cover finishing work of new buildings and
modernised existing buildings/structures, included under the specification
starting from masonry work, partition walls, cladding walls, roof protection,
finishing of walls, floors and ceilings, false ceiling as required potable water
system, sanitation etc.
During execution of the contract, the Bidder shall take approval from the Owner,
for all building materials and finish items (e.g. floor tiles, doors, and windows,
paints etc.) to be used for the contract by submitting samples and/or product
literature as appropriate.
Finishing works including material used for renovation/modernisation work shall
be matched with the finishing of existing structures to make similarity in
architectural view of new and existing structures.
11.2
Finishes
All exposed surfaces shall be clean and smooth and members shall be sized to
give a pleasing appearance. The Finishes for all Structures and Buildings shall
meet the functional requirements and shall be as per the approved Finishing
Schedule. However, the finishing schedule shall be pre-approved by the
Owner/Consultant.
11.3
Design Requirements
(a) Architectural Concepts
All buildings and structures shall be architecturally treated in such a way so

as to be in complete harmony with the surrounding structures and
environment. Local architectural characters may be judiciously imbibed.
The building shall be designed initiating an architectural control common to
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all buildings. The architectural control shall be clearly spelt out in terms of
scale, man & form.
Overall colour scheme of the plant and other buildings shall be designed
judiciously and in a comprehensive manner taking into account the mass
and void of buildings, its facade, equipments, exposed structural elements,
piping, trestles, bus ducts and other service elements.
Overall emphasis shall be on developing an eco-friendly architecture,

merging with the nature with its own sustainable energy management
systems.
The scheme shall be conceptually finalized in totality including that of

equipments so that the proper co-ordination with other agencies can be
taken up at appropriate time.
(b) Architectural Design
Natural light shall be used to the maximum extent. For adequate light and
ventilation, National Building Code recommendation shall be followed.
Entrance canopies, chajjas (projections, recesses) over openable windows

and door openings on exterior facades shall be provided.
All the buildings shall be architecturally designed to meet the National

Building Code.
Architectural design and detailing aspects of all the buildings shall be

rendered through professional services of an Architect Statutory
requirement and any clearances from local authority may be required to be
met with, wherever essential. The Architect Consultant shall be of national
- International repute having experience in similar kind of works. The
consultant shall evolve the design philosophy and shall present it in the
form of presentation drawings, prospective views, 3-D Models & detail
drawings.
A comprehensive interior design scheme shall be conceived with the

intention of projecting a definite theme and aesthetic appearance to inside
working environment. It shall take into account the multidisciplinary
engineering activities involving plant technology and architectural & civil
engineering for a smooth control hierarchy and man machine interface.
The Bidder shall develop the architectural layout of all the buildings listed in this
document as per the final approved equipment disposition and other layout
considerations indicated elsewhere in this specification. These drawings shall
need the approval of the Owner/Consultant before construction. The Bidder shall
also have to submit perspective views if so desired by the Owner/Consultant at
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no expenditure to the Owner. Approval from statutory authorities, e.g. Factories

Inspector, Explosives Inspector, Loss Prevention Association of India / Tariff
Advisory Committee etc. shall be the responsibility of the Bidder without any
obligation of the Owner.
The entire complex shall have an architectural character and style of its own and
shall be visually and functionally integrated with the existing landscape. The
Bidder must visit the site and have a feel of the overall environment, so that a
harmonious as well as integrated architectural concept of the proposed phase of
development is achieved. Special care must be taken to enhance the visual and
technological quality of development by adopting updated technology, materials,
finish etc.
11.4
Guideline for Architectural Works
11.4.1 Roof Insulation and Ventilation

Wherever required the roof of buildings shall be insulated with foam concrete.
For ventilation requirements relevant section of the specification shall be
referred.
11.4.2 Roof Waterproofing
All roofs of buildings shall be provided with 3 layers, first being elastomeric
membrane water proofing treatment, secondly screed concrete shall be laid and
finally the wearing course. Elastomeric membrane shall be laid as per
manufacturers specifications which shall adhere to specifications as given in IS
2645. Run off gradient shall be given a minimum of 1 in 100. Gradient shall
comprise screed concrete 1:2:4 using 12.5 mm or below coarse aggregate.
Over the screed concrete waterproofing treatment shall be provided as below:
A wearing course shall consist of pressed clay tiles of size 230x230x18 mm laid
in water proofing compound mixed cement mortar (1:3) and sealing of joints
using sealing compound.
11.4.3 Brick/stone masonry and parapet wall
All masonry works shall be designed in accordance with IS: 1597, IS: 1905, IS:
2212, IS: 4326 and other relevant IS codes as applicable. Structural design of
load bearing and non-load bearing walls constructed with solid or perforated
burnt clay bricks or concrete blocks shall be in accordance with criteria specified
by National Building Code of India.
All walls shall be non-load bearing infill panel walls. External walls of all
buildings shall be at least one brick thick. All internal walls shall be at least one
brick thick except for internal partition walls for office area, canteen, change
rooms, first aid rooms and toilets, which may be half brick thick.
Minimum 50 kg/sq.cm compressive strength brick shall be used for non-load
bearing super structure brickwork. Cement sand mortar 1:6 for one brick thick
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wall and 1:4 for half brick thick wall shall be used. For half brick walls, RCC
transoms and mullions shall be provided to reinforce the wall where required.
All brickwork shall be plastered as per specification.
Even where metal cladding is specified, for initial [3 m] height from the ground
level, minimum one brick thick masonry wall shall be provided.
All up stands and parapet walls on roof shall be of RCC construction, minimum
height of parapet walls shall be [1050 mm] and a minimum thickness of [125
mm].
11.4.4 Cement based polymer modified mortar
a) Purpose
To carry out structural repairs to prepared patches of spalled concrete with an
alkaline impervious repair material comprised of polymer admixed cement-sand
mortar.
b)
Materials and T&P
Polymers in emulsion or powder forms as may be specified conforming to

ASTM C1059, Ordinary Portland Cement of 43 grade conforming to relevant BIS
code, Sand conforming to Zone-II or Zone-III grade of IS: 383, Mixing water
conforming to IS: 456-2000, mortar mixer with mechanical water dozer,
spatulas, trowels, etc.
c) Procedure:
Protection, Product delivery, Personnel, Supervision, Storage and Handling, etc.
Step-2: Full quantity of specified polymers shall be received at site in factory
sealed containers with labels legible and intact provided that the shelf life so
permits. Otherwise substantial quantity as could be consumed within the shelf
life shall be received as per quantity approved by Engineer-in-Charge. Full
quantity shall be worked out as theoretically required for consumption in the
whole work.
Step-3 Testing of Material: The requisite number of test specimens of mortar
shall be cast from each batch of manufactured or supplied materials received
(whichever is less). These are to be tested for conformance to the specified
requirements before use on the work. Polymer modified cement mortar with
cement: sand proportion by weight as (1:3 ) shall have the following properties
Minimum compressive strength -20N/sq.mm after 28 days at 27oC
Step-4: Identify and mark the area for Polymer modified mortar repair.
Step-5 Surface Preparation: The appropriate propping/supporting, surface
preparation and crack sealing as per site requirements shall be completed, which
may sequentially cover one or more of the following items of work:
Prop & support the structural member to relieve it of stress and strains.
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Removal of existing surface plaster/treatment shall be done.

Chipping unsound/weak concrete material shall be done.
Removing concrete all around embedded rusted reinforcement shall be done.
Removing and cleaning reinforcement of rust from its surface to give it a shining
bright metal shall be done.
Sealing the cracked or honeycombed concrete with injection grouting shall be
done.
Providing and inserting mild steel shear key bars shall be done with minimum 3
nos per square meter of surface area of substrate, which may also be used as
depth measuring gauge.
Additional fresh reinforcement, if required, shall be tied with required overlaps or
welded.
The rust, if any, persisting over the existing exposed reinforcement or the new
reinforcement shall be removed mechanically or chemically.
Cleaning of lightly sticking materials and foreign matter from the exposed
concrete surface and steel reinforcement by suitable means shall be done.
Step-6: Clean the dust and saturate the prepared surface of concrete and
reinforcement with a clean oil free air blast and water fit for construction.
Step-7: Inspection of concrete surface prior to adhesive application shall be
thoroughly inspected and got approved by the Engineer-in-Charge. Surfaces shall
be ensured to be free from any deleterious materials such as oil, dust, dirt etc.
using oil free air blast.
Step-8: Alignment & thickness Control- Ground wires shall be fixed at reference
points to measure and control the thickness of overlay. Shear keys fixed earlier
could also function as depth gauges. Adequate ground wires shall be installed to
establish thickness and surface planes of the overlay build up. Ground wires
shall be tight and true to line and placed in such a manner that they may be
further tightened.
Step-9: Apply Passivating & bonding coat over the cleaned existing and new
reinforcement.
Step-10: Apply bond coat on the cleaned concrete substrate.
Step-11: Mix and Prepare Polymer Modified Mortar to have a uniform
consistency and texture by adding cement sand and polymer as weigh batched
ingredients of the design mix, a specified proportion of water through water
dozer.
Use of prepacked ready to use components supplied by manufacturers in
containers may be allowed subject to approval of Owner. In case where
prepacked ready to use materials are to be used, the contractor shall submit the
manufacturers certificate verifying conformance to material specification as
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specified, manufacturers mixing and application procedure for approval by

Engineer-in-charge.
Plastering with cement based polymer modified mortar shall be done
immediately after applying the bonding slurry to the prepared surfaces,
preferably in coats of approximately 10mm thickness as greater thickness may
lead to delamination/collapse. However, coats shall be applied in fairly rapid
successions within 15 to 30 minutes. After applications of mortar the surface
shall be finished using a wooden float.
Step-12: Moist cure the polymer modified mortar surface for 1-3 days followed
by air curing at ambient temperature or as per manufacturers specification, if
specified otherwise. Use of flowing water or ponding of water shall not be done
for curing. Steam curing shall not be permitted.
Step-13: Test the Surface of 7-day cured concrete overlay for soundness by
tapping or sounding with hard blunt surface.
d) Inspection & Quality control
The mortar application work shall be continuously inspected by a qualified
supervisor who shall check materials, application of mortar, curing stoppage of
work during low temperatures (minimum working temperature being 8C in
most of the polymer modified mortar or as per manufacturer direction) and high
winds etc. Each completed work of mortar shall be systematically sounded with
a hammer to check for drummy areas after hardening.
In suspect areas or whenever directed by Engineer-in-Charge, the contractor
shall drill the cores from the finished work and in to the host concrete after 28
days of mortar application. The cores shall be examined for evidence of poor
workmanship by the Owner, and if he is satisfied that either the bonding work
or the subsequent layer of mortar are not of the required workmanship, the
contractor at the instruction of Engineer-in-Charge shall dismantle such areas of
work as required by the Owner and re-do the same after re-preparing the surface
by chipping off mortar work and abrading the bonding slurry interface.
11.4.5 Partition Wall
All intermediate walls shall be full brick thick wall in 1:6 cement sand mortar.
Half brick thick wall in1:4 cement: sand mortar with [2 nos. 6 mm] diameter rod
in every fourth layer shall be provided. For long walls intermediate RCC pillars
and RCC horizontal tie shall be provided. Full glazed partition in anodized
aluminium frame shall be provided for operator's cubicles for clear view of the
operating equipment and in Control room area.
11.4.6 Metal cladding
a) Permanent colour coated sandwiched insulated metal cladding system
Trough zinc-aluminium alloy coated (both sides) M.S. sheet having 0.6 mm
minimum thickness (or high tensile steel sheet of 0.5 mm minimum
thickness) shall be used on external face (outer face) of cladding system.
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Weight of coating shall not be less than 180 gm / sq.m. The outer side
(exposed face) shall be permanently colour coated with Polyfluro Vinyl
Coating (PVF2) of Dry Film Thickness (DFT) 20 microns (minimum) over
primer. Inner side of external sheet shall be provided with suitable precoating of minimum 7 microns.
Galvanised M.S. sheets of minimum 0.6 mm thickness shall be used as inner
liner (internal face) of cladding system. The exposed face shall be
permanently colour coated with silicon modified polyester paint of DFT 20
microns (minimum) over primer. Inner face of external sheet shall be
provided with suitable pre-coating of minimum 7 microns. The rate of
galvanising shall not be less than 180 gm / sq. m.
The permanent colour coated sheet shall meet the general requirements of
IS: 14246 and shall conform to class 3 for the durability.
Inner sheet shall fixed directly to side runners and Z spacers made of at least
2 mm thick galvanised steel sheet of grade 375 as per IS: 277. Inner sheet
shall be fixed at the rate not more than 0.75 m centre to centre to hold the
insulation and external sheeting.
The insulation shall be of bonded mineral wool of minimum thickness 50
mm conforming to IS: 8183, having a density of 32 kg / cu. m for glass
wool & 48 kg / cu. m for rock wool.
b) Permanent colour coated (non-insulated) metal cladding system
Trough zinc-aluminium alloy coated not less than 180 gm/sq.m M.S. sheets
having 0.6 mm minimum thickness (or High tensile steel sheet of 0.5 mm
minimum thickness) shall be used for the cladding system. The outer side
(exposed face) shall be permanently colour coated with PVF2 paint of
minimum DFT 20 microns over primer and the inner side (internal face) shall
be coated with same paint of minimum DFT 12 microns over primer. These
shall be fixed directly to runners. The sheets shall meet the general
requirement of IS: 14246 and shall conform to class 3 for the durability.
c) Flashings, Cap, Trim Closures etc.
All flashings, trim closures, caps etc. required for the metal cladding system
shall be made out of plain sheets having same material and coating
specification as mentioned above for the outer face of the sandwiched metal
cladding.
11.4.7 Plastering
On the exterior wall & rough side of interior brick wall [18 mm] thick minimum
with cement-sand mortar in two layers shall be applied. Where external finish
will require rich plastering for special finish plaster shall be of 1:4/1:3.
Interior wall: [12 mm] thick with 1:4 cement-sand mortars
Ceiling: [6 mm] thick with 1:3 cement-sand mortar shall be provided to all
exposed ceilings.
Document Number
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02
Description
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11.4.8 Removal of plaster manually from masonry or concrete surface using chisel and
hammer and disposal of debris etc
a) Purpose
For removal of all type of loose /delaminated /damaged/weak cement plaster
from surface of masonry or concrete.
b) Procedure
Step-1: Safety shall be ensured in accordance with contract conditions and
specifications.
Step-2: Provide double scaffolding, protective screens etc.
Step-3: Existing plaster to be to be identified for removal by tapping all areas
and its boundary shall be marked with a colour marking (in an optimal
rectangular shape), which shall be approved by Engineer-in-Charge.
Step-4: Make a cut normal to the surface all along the boundaries with
power driven cutters. The depth of cut shall not exceed the thickness of
plaster.
Step-5: Remove the plaster manually with the help of chisel and hammers to
completely expose the parent masonry or concrete surface, so as not to
have any traces of such plaster left behind.
11.4.9 False ceiling and under deck insulation
All air conditioned areas shall be provided with the suspended false ceiling
system. Under deck insulation system shall be provided on the under side of the
roof / floor slab of the air-conditioned areas based on the functional requirement.
Aluminium false ceiling system shall comprise of [84 mm] wide [12.5 mm] deep
closed type plain panels of approved colour, roll formed out of [0.5 mm] thick
corrosion resistant aluminium alloy AA 5050 fixed on roll formed carriers.
Additional hangers and height adjustment clips shall be provided for return air
grills, supply air diffusers, light fixtures, AC ducts etc. Suitable M.S channel
(minimum ISMC100) grid shall be provided above false ceiling for movement of
personnel to facilitate maintenance of lighting fixtures, AC ducts etc.
Bidder shall prepare a layout of the false ceiling system incorporating light
fixtures, supply air diffuser, return air grills, fire detectors, fire protection
sprinklers etc. such that the ceiling looks aesthetically pleasing. Work shall
commence only after the Owner approves the layout. Under deck insulation shall
comprise of [50 mm] thick resin bonded mineral wool insulation mat conforming
to IS:8183. This mat shall be backed with [0.05 mm] thick aluminium foil and
[24 Gx25 mm] wire mesh netting. These shall be fixed to ceiling or wall as the
case may be with [100x50x6 mm] slotted mild steel plate welded to M.S. plate
inserts embedded at the soffit of the slab at [600 mm c/c and 14 G] steel wire
drawn through slots and fixed to wire netting.
11.4.10 Doors
Document Number
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Generally hollow metal (steel) flush doors with pressed steel frame shall be
provided for plant and utility areas.
Solid core factory made wooden flush doors in hard wood frame shall be
used in interior office areas. Aluminium doors shall be provided in at
entrances and important areas.
Special areas like control rooms and other special area shall be provided with
minimum 15 micron pre-coated Le. colour anodised aluminium glazed
partitions with air lock facilities having two sets of doors.
Fire rated doors with panic bar shall be provided in cable spreader rooms and
other areas having fire hazard and also to all fire exists as per TAC
requirement.
Doors shall be provided at appropriate location to prevent dust ingress from

outside.
FRP Doors with FRP Frames shall be provided for all the toilet doors.
Weather stripping shall be provided to all outside doors as well as airconditioned areas and all other doors where dust-free environment is
required.
11.4.11 Rolling shutters

Rolling steel shutters conforming to IS: 6248 will be used for large openings
where frequent use is not envisaged. Unless noted otherwise, main entry doors
of width and height to suit the requirements. Rolling shutters with area up to 8
m2 shall be pull and push type hand operated, while above 8 m2 shall be pull
and push type with ball bearings (Electrically operated) as per IS specification.
11.4.12 Windows & Ventilators
In all buildings, full glazed windows and ventilators in minimum [15 micron]
colour anodized aluminium window frame shall be provided with [4 to 6 mm]
thick (depending on the size of panel) clear float glass and [6 mm] thick clear
wired/laminated glass where required from safety point of view. Structural
glazing may be considered as an important facade element.
The window area shall be so decided as to allow adequate natural ventilation
and light.
Note: Glass thickness and member sizes of Aluminium Glazed doors and
windows shall be designed by the manufacturer and to be submitted for
approval by the Bidder before execution.
11.4.13 Plywood Covering Panels to Cover Windows etc. During repairs
a) Purpose
Document Number
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Description
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To protect the finished items against their spoiling/damage to finishes during

the process of carrying out repairs in a building. The items could include
finished windows, doors, glass curtain wall or other such items.
b) Materials:
Wooden Battens of size 50mm X 50mm (approximately) or as approved by
Engineer-in-charge, free from warping, cracks etc. made from locally
available timber.
Plywood of suitable thickness, preferably 6 mm thick, as approved by
Engineer-in-Charge.
Nails, screws etc. as per requirement.
c) Fabrication:
Size of covering panels shall be more than the size of windows etc. to be
shielded/ protected, enough to be fixed to the walls without damaging the
windows etc.
Wooden battens shall be cut approximately to the size of panels of windows
etc. to be protected. The joints of the wooden framework shall be lap joint or
as approved by Engineer-in-Charge.
Where the panel size is more than 2 square metres or as specified by the
Engineer-in-Charge, the stiffening shall be done with batten backing to
impart stiffness enough to provide rigidity against undue deflection due to
impact of falling debris, self load, etc.
Plywood shall be fixed with nails/screws over the batten frames. The
spacing of nails/screws shall be about 300mm c/c or as may be required at
site.
d) Fixing:
The plywood covering panel shall be suitably fixed without damaging the
windows etc. being protected by such panels with nails/screws fixed in walls
strong enough to resist the forces likely to be imparted during repair work. It
shall be done in such a manner that it can be removed with ease without
damaging the covered windows etc. after completion of repairs.
e) Removal:
After completion of work, the covering panels shall be removed carefully, so
as not to cause any damage to windows etc. covered. The damages, if any,
shall be made good.
11.4.14 Facilities in Buildings
Adequate toilet and drinking water facilities shall be provided for personnel
working in each building. Each building shall have toilet facilities both for Gents
and Ladies. Number of toilet fixtures shall be adequate for the occupancy as per
National Building Code.
Document Number
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Rev
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02
Description
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However minimum 1 Water Closet, 1 washbasin, 1 urinal shall be provided in

each toilet.
Each floor shall have drinking water facility connected through water purification
system like Aquaguard or similar approved make.
11.4.15 Glazing & Glazed Partition
Glazing in Control room between AC. and non-AC. areas shall be insulating
glass consisting of [two 6 mm] thick toughened float glass sheet
hermetically sealed and separated by [12 mm] gap for thermal insulation.
Clear glass shall be provided where clear view is required. In other areas
tinted glass may be provided.
[4 mm] thick ground glass shall be provided for toilets.
Glazing between two AC. areas shall be with 6 mm thick clear float glass.
All glazing shall be in aluminium frame.
[6mm] thick Wired / laminated glass shall be used for windows / ventilators
at higher level for safety.
[24mm] thick insulated double glazing having 6mm thick tinted heatreflecting type float glass on outer side and 6mm thick clear float glass on
inner side with [12mm] air gap & hermetically sealed shall be mounted on
[15 micron] coloured anodised aluminium frame suitable for structural glazing
system.
11.4.16 Sealant
Silicon sealant or polyurethane sealant shall be used in all expansion joints
exposed to weather. All joints around exterior doors, windows, and expansion
joints, etc. shall be sealed for proper water-lightness.
11.4.17 Damp Proof Course
[40 mm thick 1:1.5:3] concrete with waterproofing admixture. Water proofing
compound shall be of Zydex, SIKA, or similar approved.
11.4.18 Plinth Protection
Minimum [1000 mm] wide and minimum [100 mm] thick M 15 grade concrete
plinth protection along building periphery shall be provided with surface drain of
required size and slope, to suit storm water quantity, shall be provided. The
plinth protection shall be laid over prepared sub-grade and base formed with
locally available broken laterite stone to thickness of [150 mm].
11.4.19 Painting
Document Number
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Exterior Masonry Surface : Buildings shall be finished with [Acrylic Emulsion

pain] as per IS specification with approved colour and scheme.
Exterior Steel Work : Anti-corrosive synthetic enamel paint over [anti

corrosive primer].
All Woodwork: [Synthetic paint over a coat of primer].
All Internal Steel Work : [Synthetic enamel over a coat of primer].
Interior Office Spaces Rooms, All AC Areas : Acrylic emulsion paint over [2
mm] control thick plaster of paris punning.
Balance areas: As indicated in finish schedule in this document.
Fire Door: Post Office red shade shall be provided.
11.4.20 Flooring
Unless and otherwise specified, the nominal total thickness of floor finish shall
be [50 mm] including under bed and topping. The flooring shall be laid on
already matured concrete base. The under bed for floors shall consist of
minimum grade of M 15 with stone chips [12.5 mm] downgraded as coarse
aggregates. The under bed shall be provided appropriate slope towards catch pit
for floor drainage.
False Flooring System

Removable type false flooring system shall be provided wherever required
(computer rooms etc.). RCC floor slab will be sunk to a depth [800 mm],
which shall be height of the false floor system. The flooring shall consist of
fire resistant phenol formaldehyde bonded particle board panels
[600x600x35 mm] size, mounted on steel pedestals of adjustable height and
supporting steel grid system to provide under floor space. [2 mm] thick
flexible anti-static PVC topping on top and PVC strip edging on sides of each
panel shall be provided.
PVC Floor Finish

Two mm thick PVC as per IS: 3462 and laid as per IS: 5318 over concrete
under bed of [48 mm] shall be provided in electronic cubicle rooms,
conference room, etc. PVC tiles shall ensure anti static surface.
Vitrified ceramic Tiles

Heavy duty vitrified ceramic tiles of appropriate thickness and of minimum
size [600 mm x 600 mm] of approved shade & colour shall be provided for
control room as per relevant code and manufacturers specification over
concrete bedding to result in an overall thickness of [50 mm].
IPS Flooring
IPS (cement concrete flooring) with metallic floor hardener topping [12 mm]
thick with a total thickness of [50 mm] shall be provided in maintenance and
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unloading area of Mill and bunker bay, operating floor of pump house,
permanent stores and other plant building areas where heavy duty flooring is
required.
IPS flooring with non-metallic floor hardener shall be provided in all MCC and
switchgear rooms, which are not air-conditioned.
IPS flooring shall also be provided in areas, which are not provided with any
special finish. Areas which are likely to be subjected to oil spillage shall be
provided with two coats of oil resistant painting over IPS floor finish. If
required, Bidder has to use floor hardeners at appropriate locations.
Heavy Duty Ceramic Tiles

Heavy duty vitrified ceramic tiles with suitable finish shall be used in toilets,
pantry, dining hall of canteen, locker rooms etc. The tiles shall be minimum
of [300 x 300 x 7 mm] of approved shade, brand and colour.
Acid / Alkali Resisting Tiles

Battery rooms and other areas coming into contact with acid / alkali vapours
or fumes shall be given acid / alkali resistant tiles [25 mm] thick, jointed with
acid / alkali resistant cement slurry. Bedding shall comprise of potassium
silicate mortar conforming to IS: 4832 (Part-I) and resin based mortar like
epoxy for jointing. Total thickness of flooring shall be [50 mm].
Integral Floor Finish

For cable vaults floor finish integral to the concrete base shall be provided as
per IS: 2571.
11.4.21 Miscellaneous
PVC nosing shall be provided for edge protection of R.C.C. stair treads.
Angles [50x50x6 mm] (minimum) with lugs shall be provided for edge protection
of cutouts / openings in floor slabs, edge of drains covering gratings, edge of
R.C.C cable / pipe trenches of any other place where breakage of edges /
corners is expected.
Floors of switchgear rooms shall have embedded steel channel suitable for easy
movement of breaker panel.
11.4.22 Skirting/DADO
[150 mm] skirting matching with floor finish shall be provided in all areas
unless specified otherwise elsewhere.
Toilets and locker rooms shall be provided with dado of [2100 mm] high
with glazed tiles of minimum 5 mm thickness generally as per IS: 777.
For battery room and other areas coming in contact with acid / alkali spillage
/ fume, dado of acid / alkali resistant tiling as per IS: 4457 shall be provided
to a height of [2100 mm] set in potassium silicate mortar and joints pointed
with resin bonded mortar
Document Number
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Rev
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02
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Staircase wall shall be given dado of vitrified tiles of approved colour and
shade to a height of [2100 mm] or as per approved drawings.
11.4.23 Roof access

All roofs shall be provided with access thorough a staircase / cage ladder.
Minimum [1000 mm] wide access path shall be provided with suitable tiles to
approach equipment on roof.
11.4.24 Roof Drains
(a)
Roof drains design criteria
Minimum diameter of the pipe shall be [150 mm]. The roof drains shall be sized
for the roof area runoff for a maximum rainfall per hour at site.
Detailed specification is mentioned elsewhere in this specification.
(b)
Roof Drainage and Water Proofing
All roofs of buildings shall be provided with 3 layers, first being elastomeric
membrane water proofing treatment, secondly screed concrete shall be laid and
finally the wearing course. Elastomeric membrane shall be laid as per
manufacturers specifications which shall adhere to specifications as given in IS
2645. Run off gradient shall be given a minimum of 1 in 100. Gradient shall
comprise screed concrete 1:2:4 using 12.5 mm or below coarse aggregate.
Over the screed concrete waterproofing treatment shall be provided as below:
A wearing course shall consist of pressed clay tiles of size [230x230x18 mm]
laid in water proofing compound mixed cement mortar (1:3) and sealing of joints
using sealing compound.
Document Number
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02
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12
GENERAL REQUIREMENTS
12.1
Roof
[Logo of Utility]
Roof of conveyor galleries and Boiler shall be of permanently colour coated

galvanised M.S troughed metal sheet of approved profile. Minimum base metal
thickness shall be 0.8 mm. The rate of zinc consumption for galvanising shall be
275 gm/sq. m. The external face shall have permanent colour coating of PVF 2
paint of minimum DFT of 20 microns and inner surface shall be coated with
silicon modified polyester paint with DFT of 20 microns.
12.2
Waterproofing of underground structures

All underground structures like basements, pump houses, water retaining
structures etc. shall have plasticiser cum waterproofing cement additives
conforming to IS: 9103. In addition, limits on permeability as given in IS: 6494
shall also be met with. The concrete surface of these structures in contact with
soil shall be provided with minimum two coats of bituminous painting of grade
85/25 conforming to IS: 702 @ 1.7 kg/sq.m (minimum) for water/ damp
proofing. Also provision shall be made on the inner surface of walls and base
slab, so that waterproofing grouting can be injected later in case of leakage.
12.3
Anti-termite treatment/Anti-weed treatment

Pre-constructional anti termite treatment shall be given to all buildings as per IS:
6313 and other relevant Indian Standards.
Reservoirs shall be given an anti-weed treatment of approved quality and
quantity as per the manufacturers specification. Anti weed treatment shall be
carried out before carrying out the lining work.
Document Number
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No.
02
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13
GENERAL CIVIL WORKS AND CONSTRUCTION TOLERANCES
13.1
Basic requirements for all civil works
[Logo of Utility]
Design requirements
The design of all structures under this contract shall be such that differential and
total settlements or other movements shall not exceed acceptable limits and full
provision shall be made for all expansion and other joints. The design shall be to
the approval of the Owner/Consultant.
Structural members subjected to flexure shall be designed to have

adequate stiffness to limit deflections or any deformations that affect
strength or serviceability of a structure adversely. The maximum allowable
deflections of structural members shall be in accordance with the relevant
design standards and/or the limits prescribed by the machinery
manufacturers (whichever is less).
The superstructures and foundations subjected to vibrations (the primary

source of these vibrations being the unbalanced forces generated by
rotating or reciprocating equipment) shall be designed such that vibrations
will be neither intolerable nor troublesome to personnel and will not cause
damage to the machine or structure.
The natural frequency of the whole of the superstructures and foundations

or parts thereof and all structures adjacent thereto shall not coincide with
the operating frequency of the vibrating plant.
The differences between frequencies and the dynamic analysis of the

superstructures and foundations shall be in accordance with the relevant
design standard.
The dimensions of all the buildings shall be such as to provide adequate

space for the safe installation and proper operation, maintenance and repair
of all plant and equipment.
Throughout the works all floor slabs above rooms containing electrical
equipment shall be watertight. No drainpipes or water pipes are permitted
to pass through these rooms.
All materials used in the works shall be of the best quality of their
respective kinds as specified herein, obtained from sources and suppliers
approved by the Owner/Consultant and shall comply strictly with the tests
prescribed hereinafter or, where tests are not laid down in this
specification, with the requirements of the latest issue of the relevant
Indian, American, British, German Standards or other Standards approved
by the Owner/Consultant.
Samples of all materials proposed to be used in the works may be called

for at any time by the Owner/Consultant.
Document Number
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13.2
[Logo of Utility]
The work shall be carried out by competent personnel skilled in their

various trades.
Before commencing the works, the Bidder shall ascertain the locations and
nature of all existing underground services and shall take every possible
precaution against any damage occurring to them or interference
therewith, during the execution of the works.
Suitable access to the roofs of the buildings by means of steel stairs shall
be provided for maintenance and repair of any installation.
All rooms with fire hazard shall be provided with suitable emergency
exists.
Proper access roads with footpaths shall be provided to bring in all the
equipment and to take it out in case of maintenance. These access roads
shall be suitable for the vehicles, which will be used (cars, forklifts,
trucks/trailers etc) to reach up to the point of unloading of the equipment.
Safe, convenient and straight forward accesses and means are to be

provided to take equipment in and out of all rooms, at all levels using
suitable stair wells and suitable electric hoists. The dimensions of rooms,
stairwells, doors, etc shall be designed to suit the a.m. transport concept.
Before starting of design works, the Bidder shall submit to the Owner/
Consultant for approval the project design manual containing the design
data and the detailed design criteria for all civil works. Design works shall
commence only after approval of the project design manual by the
Owner/Consultant.
Before starting of design works, the Bidder shall submit to the

Owner/Consultant for approval the project design manual containing the
design data and the detailed design criteria for all civil works. Design works
shall commence only after approval of the project design manual by the
Owner/Consultant.
Basic requirements during construction

Basic Cleaning
Basic cleaning includes all floors, walls, ceilings, built-in fittings and equipment,
including the furnishings. The basic cleaning operation must result in a degree of
cleanness, which permits the fully equipped buildings and rooms and associated
outdoor installations and secured surfaces to be taken over without complaint.
Advertising boards and stickers, temporary protective coatings and claddings,
remains and splashes of paint, must be removed with water or suitable solvents.
Dust and other dirt must be completely removed from all wall and floor surfaces,
as well as from all furniture.
Windows and mirrors must be cleaned so that they are completely clear and
without streaks.
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Perlator gauges, showerheads, odour traps and floor drains of the sanitary
installations must be cleaned and the fittings and bright pipe work must be
spotlessly polished.
Petrol and oil separators must be emptied, cleaned and refilled if necessary
during basic cleaning.
Lamps, including dishes, lighting units and tubes, switches and sockets as well
as bases and skirting boards, doors with frames and glazing, windows, window
seats and other furniture and fittings must be included in the basic cleaning
operation.
Initial Equipment
The specification is drawn up on the assumption that the scope of the initial
equipment and consumption materials is to be provided complete in every
respect; everything required for the use and care of the installations must be
supplied, even if this is not expressly specified in the documentation.
Bidder shall ensure that during excavation ground water level shall be lowered
by at least 0.50 m below the founding level adopting appropriate method of
dewatering. Lean concrete below foundation shall be laid soon after excavation
with minimum loss of time.
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14
STANDARDS, CODES AND REFERENCES
14.1
General
[Logo of Utility]
The Design of the Steel Structural Works shall be prepared and presented in
accordance with IS codes. In absence of guidelines of specific items in the IS
codes, International codes viz., American, BS, DIN or Australian code shall be
used. All the Indian Standards referred to shall be the latest revision (including
all amendments issued thereto) on the date of opening of the price bid. The
Standards adopted shall be clearly stated in the calculations.
The Design shall comply with the current Local Authority Building Regulations
(National Building Code) where appropriate. Subject to the agreement of the
Owner, other International / Foreign National Standards, and, International /
Foreign National Standard Codes of Practice, may be used.
To the extent that the Design shall include materials, methods or workmanship
to be incorporated into the works, they shall be selected and incorporated into
the design in accordance with the recommendations and requirements of the
following (as appropriate in order of precedence but not mutually exclusive):
Statutory requirements
The Contract provisions
Bureau of Indian Standard Codes of Practice
International / Foreign National Standards
Agreement Certification for Materials
Manufacturers recommendations for materials
Competent Trade Association recommendation
Engineering judgment
In case of any deviation / conflict between provisions of IS codes and the design
criteria, the provisions that are more stringent shall be followed unless
specifically directed otherwise.
Reference to only some of the codes in this document and various clauses of
design criteria shall not limit or restrict the scope or applicability of other
relevant codes. It shall be ensured that all other codes relevant to a specific job,
in addition to those already mentioned, are followed wherever applicable.
Where British / American / DIN or other codes and standards are referred to in
this document, equivalent Indian Standards may be substituted if available.
Materials supplied from India shall follow the Indian Standard Specifications.
Field and laboratory testing procedures for materials follow Indian Standard
Specifications.
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14.2
14.3
14.4
[Logo of Utility]
Codes for Loads

IS: 875
: Code of Practice for design loads (other than earthquake)

for Buildings and structures (All parts)
IS: 1911
Schedule of unit weights of building materials
IS: 1893 (Part

1)
Criteria for earthquake resistant design of structure

General provisions and buildings
IS: 1893 (Part

4)
Criteria for earthquake resistant design of structure

Industrial structures including stack-like structures
IS: 456
Plain and reinforced concrete - Code of Practice
IS: 2974
: Code of Practice for design and construction of machine

foundations
IS: 2911
: Code of Practice for design and construction of pile

foundation
IS: 4326
Code of Practice for earthquake resistant design and

construction of buildings
IS: 5525
Recommendation for detailing of reinforced concrete works
IS: 1786
Specification for high strength deformed steel bars and

wires for concrete reinforcement
Codes for RCC
Codes for Structural Steel

IS: 800
Code of Practice for general construction in steel
IS: 801
Code of practice for use of cold-formed light gauge steel

structural members in general building construction
IS: 806
Code of Practice for use of steel tubes in general building

construction
IS: 808
Dimensions for hot rolled steel beam, column channel and

angle section
IS: 812
Glossary of terms relating to welding & cutting of metals
IS: 813
Scheme of symbols for welding
IS: 814
Covered electrodes for manual metal arc welding of carbon

and carbon manganese steel - Specification
IS: 815
Classification coding of covered electrodes for metal arc

welding of mild steel and low alloy high tensile steel
IS: 816
Code of Practice for use of metal arc welding for general

construction in mild steel
IS: 817
Training of welders - Code of practice (Part 1 & 2)
IS: 818
Code of practice for safety and health requirements in

electric and gas welding and cutting operation.
Document Number
LII-GETS12021-G-00129-001
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Description
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IS: 819
Code of practice for resistance spot welding for light

assemblies in mild welding
IS: 822
Code of practice for inspection of welds.
IS: 1182
Recommended practice for Radiographic Examination of

Fusion Welded Butt joints in steel plates.
IS: 1200
Method of measurement of building and civil engineering

works
IS: 1161
Steel tubes for structural purpose
IS: 1363
Indian standard- Hexagonal head bolts, screws and nuts of

product grade C
IS: 1367
Technical supply condition for threaded fasteners
IS: 1477
Code of practice for painting of ferrous metal in building
IS: 1852
Specification for rolling and cutting tolerance for hot-rolled

steel products
IS: 2062
Structural steel (fusion welding quality)
IS: 2074
Ready mixed paint, air drying, red oxide zinc-chrome,

priming
IS: 2645
Specification for integral cement waterproofing compound
IS: 2932
Specification for enamel, synthetic exterior type I
IS: 3613
Acceptance tests for Wire flux combination of submerged

arc welding
IS: 3757
Specification for high strength structural bolts
IS: 4000
Code of practice for High Strength bolts in steel structures
IS: 7205
Safety code for erection of structural steel work
IS: 7215
Specification for Tolerances for fabrication of steel

structures
IS: 7280
Specification for Bare wire electrodes for submerged arc

welding of structural steel
IS: 8640
Recommendations for dimensional parameters for industrial

building
IS: 9178
Criteria for design of steel bins for storage of bulk material

(All parts)
IS: 9595
For Metal arc welding of carbon and carbon manganese

steel - Recommendation
IS: 11592
Conveyor galleries
IS: 12843
Tolerances for erection of steel structures
Document Number
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14.5
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Miscellaneous Codes
IS: 919
ISO system of limits and fits
IS: 1038
Specification for steel doors, windows and ventilators
IS: 1172
Code of basic requirements for water supply, drainage and

sanitation
IS: 1346
Code of Practice for water proofing of roofs with bitumen

felts
IS: 1742
Code of Practice for building drainage
IS: 1905
Code of Practice for structural use of unreinforced masonry
IS: 2210
Criteria for design of reinforced concrete shell structures

and folded plates
IS: 2633
Method for testing uniformity of coating on Zinc Coated

Articles
IS: 3067
Code of Practice for general design details and preparatory

works for damp proofing and water proofing of buildings
IS: 4759
: Specification for Hot-Dip Zinc coatings on Structural Steel

and other allied products
IS: 10440
Code of Practice for construction of reinforced brick and

reinforced brick concrete floors and roofs
IS: 13592
Un-plasticized polyvinyl chloride (UPVC) Injection molded

fittings for soil & waste discharge system for inside and
outside buildings including ventilation and rail water
system specification
IS: 15658
Precast concrete blocks for paving
SP: 6
Handbook for structural engineers - All parts
SP: 7
National Building Code of India
SP: 16
Design Aids for reinforced concrete to IS: 456-1978
SP: 20
Handbook on masonry design and construction
SP: 22
Explanatory handbooks on codes for earthquake

engineering (IS: 1893-1975 and IS: 4326-1976)
SP: 24
Explanatory handbooks on Indian Standard code of

Practice for plain and reinforced concrete
SP: 25
Handbook on causes and prevention of cracks in buildings
SP: 32
Handbook on functional requirements of industrial buildings
SP: 34
Handbook of concrete reinforcement and detailing (SCIP)
TAC
Traffic Advisory Committee
Indian Explosive Act
Indian Factory Act and State Factory Act
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Indian Electricity Act
Any statutory codes / standards / regulations other than listed above, as may be
applicable, shall be followed.
Unless covered otherwise by Indian codes & standards and in case nothing to
the contrary is specifically mentioned elsewhere in this document, the latest
editions of the codes and standards given below shall also apply:
a) Japanese Industrial Standards (JIS).
b) American National Standards Institute (ANSI).
c) American Society of Testing and Materials (ASTM).
d) American Society of Mechanical Engineers (ASME).
e) International Organization for Standardization (ISO).
f) American Welding Society (AWS).
g) National Electrical Manufacturers Association (NEMA).
h) National Fire Protection Association (NFPA).
i)
International Electro-Technical Commission (IEC).
j)
German national codes (DIN)
k) Expansion Joint Manufacturers Association (EJMA)
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OF

R&M CONTRACTORS

VOLUME-II
SECTION-II, PART-A
ANNEXURE-M1
SPECIFICATION OF CFBC BOILER
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R04
January 2016
Power Plant]
[Logo of Utility]
ANNEXURE - M1
TABLE OF CONTENT
1
GENERAL .......................................................................................................................... 1
SPECIFIC DESIGN CRITERIA OF BOILER & AUXILIARIES ............................................ 2
DESIGN AND CONSTRUCTION ........................................................................................ 5

3.1
Steam Drum................................................................................................................. 5
3.2
Safety Valves & Silencers ............................................................................................ 5
3.3
Superheater and Reheater........................................................................................... 6
3.4
Economizer .................................................................................................................. 6
3.5
Furnace ....................................................................................................................... 7
3.6
Combustion Chamber .................................................................................................. 8
3.7
Hot Plate Cyclone ........................................................................................................ 9
3.8
Fuel Feeding System ................................................................................................... 9
3.9
Limestone (Sorbent) Feeding System .........................................................................10
3.10
Loop Seal ...................................................................................................................10
3.11
External Fluidized Bed Heat Exchanger (EFBHE) .......................................................10
3.12
Bottom Ash Removal System .....................................................................................10
3.13
Bottom Ash Cooling System .......................................................................................11
3.14
Enclosures ..................................................................................................................11
3.15
Air Heaters ..................................................................................................................11
3.16
Air and Flue Gas System ............................................................................................12
3.17
Soot Blowing System ..................................................................................................16
3.18
Boiler Coal feeding system .........................................................................................17
3.19
Blow Down System .....................................................................................................17
3.20
Chemical Dosing System & SWAS .............................................................................19
3.21
Pressure parts design criteria .....................................................................................19
3.22
Pressure part materials ...............................................................................................20
3.23
Thermal Insulation ......................................................................................................20
3.24
Welding and Repair welding .......................................................................................21
3.25
Start Up Light Diesel Oil System .................................................................................22
Document Number
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Date of Issue
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Volume-II, Section-II, Part-A, Annexure-M1
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GENERAL
[The CFBC boiler shall be outdoor type, top supported with natural circulation,
balanced draft , two pass circulating fluidized bed combustion using crushed
limestone as the sulfur absorbent with all necessary auxiliaries, integral piping,
elevator etc. The Boiler shall produce [..] ton/hour steam to drive a steam
turbine and its associated electric generator with the capacity of approximately
[] MW Gross of each Unit. All components of the Boiler shall be designed to
burn the coal with the analysis furnished. CFBC Boiler complete with all the
accessories shall be covered under this section of specification.
The proposed boiler will be provided with all supporting structure, platforms,
galleries and stairways for access to maintenance of each unit. All boiler
platforms will be accessible by suitably located stairways. Monorails and hoists,
as required, will be provided for handling of heavy pieces of equipment. The
boiler design will focus on efficient & reliable operation, optimized capital &
operating cost and environment protection.]
Document Number
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SPECIFIC DESIGN CRITERIA OF BOILER & AUXILIARIES
2.1
Each Boiler shall be of the top supported with natural circulation, balanced draft,
two pass circulating fluidized bed combustion using crushed limestone as the
sulfur absorbent suitable for outdoor installation.
The Boiler Maximum
continuous Rating (BMCR) shall correspond to 102% of the steam flow at turbine
inlet under VWO conditions plus the steam requirement for auxiliary systems of
the unit. Preliminary steam turbine throttle conditions shall be [130 kg/cm (a)],
537C main steam and [537C] reheat temperature respectively.
2.2
Boiler shall be an outdoor boiler with canopy at top. All electrical and C&I
equipment shall be designed for outdoor operations. Where necessary, outdoor
equipment such as pumps etc shall be protected by suitable enclosures or rain
canopies to facilitate maintenance.
2.3
The Boiler will be operated continuously. The Boiler shall be capable of

maintaining stable operation at 30% BMCR while firing worst coal without oil
support. The step load change shall be minimum 10%/min and the ramp rate
shall be minimum 2% per minute for 30-50% BMCR load and minimum 3% per
minute for 50-100% BMCR load.
2.4
Design life of the Boiler equipment shall be 25 years minimum. However, the unit
shall also be capable of operation for two shifting cycles. The design duty for
[20/25] years shall be as follows:
Hot start
[4000]
Warm start
[1000]
Cold start
[150]
2.5
The Boiler unit shall be primarily designed for sliding pressure/ modified sliding
pressure mode of operation. However flexibility to operate with constant pressure
at lower loads shall also be provided.
2.6
Design pressure of the furnace walls shall be sufficient for the specified pressure
at the superheater outlet, plus drop through superheater at the specified full load,
plus not less than 6% margin. All gas side design pressures shall be in
accordance with NFPA 85 or equivalent. Boiler vendor shall be responsible for
determining the actual pressures based on its calculations. A furnace implosion
study shall be completed to verify adequate design pressure. The minimum
furnace and convection pass flue gas transient pressure shall be 660 mmwcl at
67% of yield stress. The bidder shall consider furnace explosion vents if required.
2.7
The furnace shall be of the balanced draft type.
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2.8
In line with automatic run back capability of the unit load on loss of critical
auxiliary equipments, the Boiler equipments and systems shall ensure smooth
and stable runback operation.
2.9
Minimum 100% TMCR load under H.P. Heaters out Condition.

The Boiler shall be designed for continuous operation with all the High Pressure
Feed Water Heaters out of service, when the feed water temperature at
economiser is low. The economiser shall be suitably designed to take a thermal
shock of sudden change in feed water temperature, under such conditions. The
superheater and reheater temperature control system shall be designed to
maintain the rated steam temperature with the HP heaters out of service from
60% to 100% TMCR.
2.10
Low Frequency Operation

The Unit shall operate the interconnected electrical net work for which the
frequency may go as low as 47.5 Hz. These criteria should be considered while
sizing the Boiler and its all auxiliaries.
2.11
The Boiler and auxiliaries shall perform continuously within the specified noise
limit mentioned in General Technical specification.
2.12
All major auxiliaries shall be sourced from such reputed manufacturer(s) who
would have supplied equipments of similar type, design for at least one (1) other
power station of similar size, which are as on date of NIT, in successful
commercial operation for a period of at least one year.
2.13
Limits of NOx Emission

To reduce the NOx emission from Boiler, the Bidder shall make all provisions in
the Boiler design and fuel firing system.
The Bidder shall bring out the special measures incorporated in the Boiler design
to keep the NOx emission within the specified limit value in the proposal.
2.14
Boiler shall be capable to undertake forced cooling under emergency.

The furnace and superheater, when cleaned by operation of soot blowers
supplied with the Boiler, shall have sufficient surface to provide the BMCR
Guarantee performance.
2.15
The Boiler shall be capable of 100 % BMCR load with 100% worst coal as
specified.
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2.16
The Boiler shall be capable of 100% BMCR load with worst ambient air
conditions.
2.17
1x100% boiler fill pump shall be adequately sized to fill each boiler in not more
than 2 hrs time of continuous operation, taking suction from condensate storage
tank (CST). The pump shall also supply water for filling of the deaerator.
[Provision shall be kept for interconnecting the discharge of boiler fill pumps of
the 2 units for flexibility and transferring condensate].
2.18
The quality parameters of steam shall be as per the requirement of the turbine
manufacturer. However, the same shall not be inferior to the following under all
operating conditions:
2.19
a)
[Silica as SiO2 :<20ppb]
b)
[Sodium + Potassium as Na + K :<10ppb]
c)
[Copper as Cu :<3ppb]
d)
[Iron as Fe :<20ppb]
e)
[Conductivity at 25 deg C :<0.3 S/cm]
The quality parameters of the boiler water shall not be inferior to the following
limits:
a) [Phosphate ions : 0.5 to 3 ppm]
b) [Silica_
c) [TDS_
: 0.25 ppm]
: 0.20 ppm]
d) [Conductivity at 25 deg C: 50 S/cm]

e) [pH at 25 deg C : 9.2 to 9.4]
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DESIGN AND CONSTRUCTION

The Boiler shall be designed and fabricated in accordance with ASME Boiler and
Pressure Vessel (B & PV) Code, Section I, or International equivalent. Piping not
falling within the jurisdiction of ASME B & PV Code, Section I, shall be designed
and fabricated in accordance with ANSI B31.1.
3.1
Steam Drum
The steam drum will be provided with:
3.2
Fully welded drum with hemispherical dished ends in both sides.
Manholes with hinged manhole doors on both sides.
Steam drums internals comprising cyclones, scrubbers, demisters, vortex

breakers etc (Demister is of SS construction).
All nozzle connections for steam, feed water, down comers, safety valves,
level gauges, mountings, CBD & IBD lines, chemical dozing lines, sampling
connections etc as per approved P&IDs.
Necessary supports like sling support/ U-rod for supporting the steam drum
and disc springs (total supporting assembly).
N2 gas system design, N2 nozzles and connecting piping from one point near
the boiler operating floor.
Local drum level gauges.
Remote level gauge (Electronic drum level indicator -EDLI).
Pressure gauges at drum floor & operating floor.
Level transmitters and pressure transmitters.
Temperature elements/ indicators for skin metal temperature.
Supply of necessary piping & fittings, valves etc as per approved P&IDs.
Supply of instruments as per approved P&IDs.
Rust preventive painting at shop floor.
Steam drum will be manufactured and supplied as per approved QAP.
Safety Valves & Silencers

The following safety valves and silencers shall be provided:
Steam Drum
a)
b)
Spring loaded mechanical safety valves as per ASME requirements.

Drain piping.
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Main Stream (FSH Outlet) Line

a)
b)
c)
d)
Spring loaded mechanical safety valves (as per ASME) along with
silencers and necessary piping.
Drain piping
EMRV (as per ASME) with hand operated isolation valves, silencers and
necessary piping up to silencer.
Motor operated start up vent valve (as per ASME) with manual operated
isolation valve, silencer and necessary piping.
Reheater
a)
b)
c)
d)
3.3
Spring loaded mechanical safety valves on inlet header (as per ASME)
along with silencer and necessary piping.
Spring loaded mechanical safety valves on outlet header (as per ASME)
along with silencer and necessary piping.
Motor operated start up vent valve on outlet header (as per ASME) with
manual operated isolation valve, silencer and necessary piping.
Drain piping.
Superheater and Reheater

The boiler shall be equipped with suitable superheaters and reheater of sufficient
capacity and surface to superheat the steam to the required condition.
Standard and proven design shall be offered with full details for customers
review and acceptance.
3.4
Economizer
The economizer shall be of non-steaming type. The economiser shall be
designed for counter flow design with the water flow upwards, through the
elements and the gas flow from top to bottom. Tubes shall be arranged in parallel
in-line rows. Tubes shall be welded to nipples on headers. Plain tubes or
extended heating surface are acceptable, spiral fins are not acceptable. Feed
stop and check valves shall be located in the feedwater piping upstream of the
economizer. Double drain valves shall be provided. Economiser filling line and
sampling lines shall be provided at the inlet of economiser. The sub-cooling of
the economizer shall be minimum 40 deg C. The sub-cooling is defined as
saturation temperature at 30% MCR load minus economizer outlet water
temperature at 30% MCR load.
Maximum gas velocity through economizer section should not exceed maximum
average 10 m/sec.
Boiler vendor shall furnish retractable economizer soot blowers as required to
limit the buildup of fly ash between banks, tubes, and headers.
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Handholes shall be provided with welded covers. Where required for access and
inspection, doors shall be provided with tight gasketed joints.
A pyramidal watertight hopper shall be constructed to include the entire active
area of the economizer. Hopper sides shall be inclined to provide a valley angle
of at least 65 degrees. Flanged connections shall be provided to connect to ash
removal equipment.
The economizer shall be arranged for external water washing and an access
platform shall be provided at the hopper outlet.
Space provision shall be kept for augmenting line coils/ bank in economiser
sealing if required.
3.5
Furnace
The furnace may have vertical tubing configuration. Front, rear and sides of the
furnace shall have fin-welded or fusion welded walls with fully welded tube walls.
The roof shall be fin-welded or fusion welded where possible. Location of the
wall tube field welds shall be easily accessible for testing, inspection and
maintenance. The rear wall shall be accessible from the outside from the bottom
elevation of the furnace to an elevation above the nose cone for operation and
maintenance of soot blowers, instrumentation and other accessories. The
furnace shall be designed with sufficient volume to provide complete and efficient
combustion of fuel.
All furnace casing penetrations shall be gas tight.
Openings i.e. peepholes shall be provided in the furnace walls for observation of
furnace conditions. There shall be an opening in each sidewall at the level of the
hopper restriction.
Tubing material shall be selected for the most severe conditions imposed by
operation in this application. The wall tubing material and wall thickness shall be
conservatively selected to withstand all anticipated transient and steady state
operating conditions expected including the erosion characteristics of the coal.
However, material diagram shall also be provided from the bidder as part of the
boiler specification requirement.
The tube thickness calculation shall use the maximum tube mean temperature as
the design metal temperature. However, the maximum outer wall surface
temperature shall be checked to make sure the selected tube thickness is
adequate for the maximum outer wall surface temperature.
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Sleeves shall be provided in the furnace roof to permit installation of hanging

scaffolds for maintenance and repair purposes. Sleeves shall extend through the
penthouse roof.
The minimum distance between tubes forming the throat and discharge opening
of the hopper bottom (centerline to centerline) shall be no less than 1 meter, and
shall extend the full width of the furnace.
A carbon steel skirt plate of sufficient depth to accommodate furnace expansion
plus 150 mm shall be securely attached to the furnace tubes and sealed to
prevent air leakage. The plate shall be dimensioned in accordance with the
bottom supported flooded ash hopper. The skirt plates shall be shielded from
furnace radiation. The minimum height of bottom ring header shall be 10.0
meters from the ground level.
At all loads there shall be no flame impingement on any part of the furnace walls
and no accumulation of slag on the walls or hoppers that will interfere with
continuous satisfactory operation of the plant.
The gas velocities shall be low bearing in mind the high ash content of the fuel.
The gas passages shall be designed to ensure a smooth flow without any abrupt
change in direction. Erosion problems in tubes shall be taken care of by providing
least nos. of baffles, screens etc. The erosion allowances considered in tube
design shall be clearly indicated. Allowance of 1.0 mm to furnace tube thickness
and 0.5 mm allowance to FSH and final RH tube thickness shall be considered.
The gas temperature at furnace exit shall be minimum 60 Deg.C less than ash
initial deformation temperature so as to minimize possible surface fouling
consistent with the requirements of superheat temperature.
Furnace shall be designed in such a way that it will provide sufficient tolerance
against Departure from Nucleate Boiling (DNB) for all furnace upset conditions
while operating in subcritical regime.
Provision shall be made for installation of additional soot blowers in the furnace
after the unit is commissioned, if the operational requirements warrant the same.
Furnace/evaporator/waterwalls shall comply requirements at 100% BMCR and
HP Heaters out conditions for the range of specified coals, under most stringent
combination of conditions.
3.6
Combustion Chamber
A balanced draft, water-cooled combustor, of fusion welded membrane wall type
construction complete with water wall tubes and headers and drains etc shall be
provided to make it gas and pressure tight envelope.
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This shall be as per bidders standard practice but the details will be furnished
along with the offer for customers review and acceptance.
3.7
Hot Plate Cyclone

The entire cyclone and loop seal assembly shall be designed as top supported to
expand downwards with the furnace and the back pass. The tube metal
temperatures in both furnace and cyclone / loop seal assembly would be same to
avoid any differential thermal expansion between the components.
This shall be as per bidders standard practice but the details shall be furnished
along with the offer for customers review and acceptance.
3.8
Fuel Feeding System

The fuel feeding system shall consist of fuel (coal/Lignite) bunkers, outlet gate
valves, coal feeders, outlet chutes etc. The system shall be provided with the
necessary arrangements to continue feeding within design range of fuel size and
within design range of moisture content.
Crushed fuel (coal / Lignite) matching the design size requirement will be supplied
by the owner through the belt conveyors and trippers (covered in a separate
package) to the steel bunkers included in the scope of this package. The storage
capacity of the bunkers shall be designed for 14 hrs capacity corresponding to
worst fuel quality. The bunker supporting structures shall be designed considering
the optimum bulk density of the worst fuel. The conical hopper portions of the
bunker shall be lined with stainless steel including an optimum height from the
bottom. The bunker valley angle shall be maintained not to exceed 65 degrees
and the bottom openings shall be liberally sized to ensure a smooth flow of fuel
from the bunkers by preventing any hang up or plugging.
Fuel feeders of drag chain type shall be provided to receive fuel from each bunker
The fuel feeders shall be provided with variable frequency drives (VFDs) so that
fuel feed rate can be controlled by varying the speed of the feeders. The feeders
shall be designed in such a way that even when one feeder goes out of operation,
the full steam capacity of the boiler can be met with the required fuel feeding
through other feeders. The fuel feeders shall be designed to deliver the
maximum specified output when the boiler is in operation either with the design
fuel or the worst fuel.
The fuel feeders shall be entirely enclosed with casing. The complete feeder shall
be kept at a slightly positive pressure with the provision of seal air connection to
prevent any back flow of fuel and air from the high pressure furnace bottom. The
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outlet of the feeders shall be fitted with an air bustle to supply the necessary
assistance air to augment smooth fuel feeding apart from the gravity fed
provision.
Inclined coal chutes of stainless steel shall be provided at the outlet of the air
bustle of each feeder. The inclination of the chutes shall be selected to ensure
smooth flow of fuel at all operating conditions.
3.9
Limestone (Sorbent) Feeding System

Limestone feeding system shall be provided to reduce SOx emissions. The
capacity of the system shall be designed on the basis of sulfur content in the fuel.
The system shall consist of limestone milling plant, limestone powder handling
system for conveying the pulverized limestone pneumatically up to limestone
storage bunkers in the boiler area and limestone injection system from the
storage bunkers up to the furnace inlet. Airlock feeders of gravimetric type shall
be provided for injecting the limestone powder from the storage bunkers to the
furnace inlet.
3.10
Loop Seal
A loop seal consisting of a bubbling fluidized bed shall be provided between the
cyclone separator and the furnace. The loop seal shall be complete with
distribution grid, air nozzles, fuel injection arrangement, sorbent injection
arrangement and dedicated air blowers with accessories shall be provided. The
pressure in the Loop seal shall be higher than the furnace pressure so as to
prevent combustion gases to back flow into the cyclone. The details of loop seal
shall be furnished along with the offer for customers review and acceptance.
3.11
External Fluidized Bed Heat Exchanger (EFBHE)

EFBHE consisting of a bubbling fluidized bed complete with distribution grid, air
nozzles, heat exchanger tube bundles and dedicated air blowers with
accessories shall be provided as per the bidders standard practice. The details
of EFBHE shall be furnished along with the offer for customers review and
acceptance.
3.12

Bottom ash removal system shall be designed to remove bed ash by continuous
overflow to maintain bed height and also by intermittent flow from the bottom
through ash drains to remove oversize particles, maintain bed pressure drop,
avoid accumulation and consequent de-fluidization. The system shall be
designed as the bidders standard practice. The details of Bottom ash removal
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system shall be furnished along with the offer for customers review and
acceptance.
3.13

Bottom ash cooling system shall be provided to cool the bottom ash to 120 to
150 deg C before entering the bottom ash conveying system. For this purpose,
suitable ash coolers either of air cooled or water cooled type shall be provided as
the bidders standard practice. The details of Bottom ash cooling system shall be
furnished along with the offer for customers review and acceptance.
3.14
Enclosures
The Boiler shall be constructed to form an air and gas tight chamber from air inlet
to flue gas outlet for preventing leakage.
Adequate number of access and observation openings/doors shall be provided at
various levels and positions in the furnace, superheaters, reheater and other
enclosed parts. Doors shall be hinged and air tight and shall meet all safety
requirements by law or special regulations.
Access shall be adequate for taking power operated maintenance cradle within
the furnace, either in assembled or dismantled condition. Adequate openings on
roof and fixing arrangements as required shall also be provided.
Enclosure shall include a fin-welded or fusion-welded wall or a welded steel plate
casing fastened directly to furnace tubes, necessary insulation and an outer
lagging or ribbed type clad aluminum alloy 3004 with stucco embossed finish, not
less than 1 millimeter (0.040 inch).
Furnace and rear pass enclosure walls shall be suitable for water washing.
Hinged access doors, arranged to permit convenient and safe access for
maintenance, shall be provided at floor and platform levels. Access and
observation doors shall be also provided to permit access to all compartments
and the easy removal of slag accumulation. Access doors shall be not less than
400 millimeters (16 inch) in diameter. All doors shall be provided with seals.
3.15
Air Heaters
Tubular type air heaters shall be provided for heating the primary air and
secondary air and shall be designed for 60% BMCR condition.
Gas velocity through air heater should not exceed 10 m/sec.
Access doors shall be air and gas tight when closed and be of adequate size for
inspection, cleaning and replacement of parts.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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Isolating gates/ dampers (flap type with sealing efficiency > 99.5%) shall be
provided for both APH at inlet & outlet of the APH and carrying out maintenance.
The Steam Coil Air Preheater (SCAPH) shall be adequate to maintain cold end
mean metal temperature 10 deg.C above acid dew point. SCAPH shall be
complete with necessary valves, remote operated control valve, motor operated
isolating valve, steam piping, steam traps etc.
Suitable water wash hopper(s) shall be furnished with flanged connection(s).
Hoppers shall be water tight for water washing. The air heaters shall be arranged
for external water washing. An access platform shall be provided at each hopper
outlet flange.
A complete air heater soot blowing system shall be provided with each air heater.
The Steam Coil Air Preheater (SCAPH) shall be adequate to maintain cold end
mean metal temperature 10 deg.C above acid dew point. SCAPH shall be
complete with necessary valves, remote operated control valve, motor operated
isolating valve, steam piping, steam traps etc.
Bidder may propose alternate arrangement for the SCAPH for the back end
corrosion protection (viz hot air recirculation or gas bypass etc). However, for
such alternative bidder shall clearly explain their proposed arrangement in the bid
document for Owners review.
Design of air and gas ducts to and from the air heater shall be of suitable design
for even distribution of gas and air across the air heater at all loads. Design of air
heater shall permit off-load water washing with suitable hoppers.
3.16
Air and Flue Gas System

The air and flue gas system shall be designed to meet the requirements of 100%
SG MCR conditions and with the fuels specified.
The air and flue gas system shall consist of 2x 60% capacity centrifugal
backward curved fans of each type, tubular air preheater (APH), Air heater
bypass system, cold air, hot air, and flue gas ducting, dampers and expansion
joints etc.
The air and flue gas system for each of the Boiler unit shall be balanced draft
system and shall consist of 2 x 60% capacity PA fans, 2 x 60% capacity SA
Fans, 2 x 60% capacity centrifugal type ID fans with variable speed hydraulic
coupling, 1 x 100% tubular air preheater shall be provided for preheating the
(a)Primary Air and
(b)Secondary Air
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[12]
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High pressure blowers (2 x100 % capacity) shall be provided for supplying the
fluidizing air for the ash coolers and ash classifier [if applicable] with 100 %
isolation and handling arrangement for individual streams with associated cold air,
hot air and flue gas ducting and dampers to handle the Boiler requirements.
All the dampers and shafts shall be bearing supported.
The sizing criteria for the fans shall be as follows:
Sl no Particulars
Primary
fan
a.
No of fans 2 x 60 %
per unit
b.
Test
block
margins
i)
Flow,
Rate
ii)
Variable
pressure *
iii)
air Secondary Seal

Wall HP
ID Fan
air (SA) Fan blowers for fluidising air
sealing
air Blower for
requirement ash coolers
2 x 60 %
2 x 100 %
2 x 100 %
2 x 60 %
+ 20 %
+ 20 %
+ 20 %
+ 20 %
+ 30 %
+ 30 %
+ 20 %
+30 %
Temperature + 5
, OC
+5
+14
Max
Ambient
+15
c.
Maximum
rotating
speed, rpm
<1500
<1500
<3000
<750
d)
Type
motor
Induction
Induction
Induction
Induction
Mass + 20 %
+ 30 %
< 1500
of Induction
*Variable pressure is defined as pressure loss associated with ducts, dampers

and valves.
Fans shall be sized to provide adequate air flow for the range of fuels specified at
BMCR load. Owner reserves the right to review all fan and blower calculations,
including supporting calculations.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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The rotor shall be overspeed tested to at least 10% above the maximum
operating speed and shall be dynamically balanced. The fan shaft is to be
supported in bearings on either side independent of the casings. Overhung
impellers will not be acceptable.
All fans shall be designed for under frequency operation up to 47.5 Hz without
any reduction in its performance. The first critical speed of the rotor shall be well
above the operating speeds (by at least 15%).
Forced oil lubrication system (if offered) for the fans and motors shall consist of 2
x 100% oil pumps each with motor, 2 x 100% oil coolers and filters; one (1) oil
tank associated valves, piping, one number nitrogen filled pressure vessel etc.
The flow induced pulsation should be avoided by suitable design of fan and
connecting duct work.
Suitable design of shaft sealing shall be provided to prevent ingress of
atmospheric air.
Each bearing pedestal of all the fans and blowers shall be provided with vibration
sensors to facilitate on line monitoring from the control room.
Each bearing housing of all the fans and blowers shall be provided with adequate
number of duplex RTDs and temperature indicators for remote and local
monitoring.
Each bearing is to be provided with oil level indicator and a screwed drain plug.
Adequate sealing arrangement shall be provided at each end of the bearing
housing to prevent leakage of lubricating oil.
Silencer shall be provided at the inlet of fans sucking atmospheric air with
weather hood and inlet screen. The suction shall be taken at least 10m above the
ground. The silencer shall be adequately designed with GI sheets of 2 mm
thickness.
Each bearing shall be provided with an oil bath to prevent bearing damage in
case of complete loss of plant auxiliary power when the fans must coast down
without power.
An adequate number of interconnecting, isolating and control dampers with
drives shall be provided on all cold air, hot air, seal air and flue gas ducting
before and after equipment on these systems to permit proper operations. The
control dampers shall be pneumatically operated and isolation dampers shall be
electrically operated along with manual operation provision.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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The gas and air ducts shall be designed for wind loads as loads as specified for
the steam generating unit proper and their own weight including fly ash load
which may get deposited at the duct bottom, insulation and lining. The top of the
ducts shall be crowned to ensure proper drainage. The bottom portion of the flue
gas duct between air heater outlet and ESP inlet shall have wall thickness of
minimum 10mm to counter erosion. However the thickness of the other three
sides of this duct shall be of minimum 6 mm thick.
The duct work shall be free to expand, but it shall be rigid against wind and
seismic disturbances. Adequate provision shall be made for all expected
expansion or contraction. Metallic expansion joints shall be used in air and flue
gas systems. MEJ shall be provided with internal sleeve to protect against ash,
bed material etc. If Non metallic Expansion joints are used, same shall be with
bolster arrangement.
All gas and air ducts shall be designed to ensure uniform distribution of gas and
air flow to the various portions of the unit. These ducts shall consist of turning
vanes / baffle plates, stiffening devices, metallic expansion joints, interior
bracings, access doors and brackets, support structures and hangers as
necessary. Compensator protection plates shall be provided in all the metallic
expansion joints.
The maximum air and flue gas velocity to be considered for sizing of duct system
considering 25 % excess air requirement shall be as follows:
a) Maximum air velocity
b) Maximum flue gas velocity
: 13 meter /sec for cold air

: 20 meter /sec for hot air
: 12 meter /sec for ducting up to ESP inlet
: 16 meter /sec for ducting from ESP
outlet to chimney inlet
Access Doors shall be provided in all air and flue gas ducts particularly near all
dampers for maintenance purposes. Each ID fan shall be provided with an
access door before discharge damper.
Aerofoils shall be provided in the air ducts for the measurement of air flow of PA
& SA fans at individual limbs and total air flow after air pre-heaters.
Individual continuous purging shall be provided for all Air and Flue gas
transmitters. The tap points for these services shall be Y shaped.
The purging line shall be connected near the root valve only and not at the
Transmitter end.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[15]
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Locking devices shall be provided to dampers to permit locking in both open and
shut positions. All damper bearing shafts shall be bearing supported.
Electrical operated guillotine type isolation dampers along with drives shall be
provided at locations required for carrying out internal repairs and maintenance
of the equipments /fans when the Boiler is on load. The inlet dampers for ID fans
shall be located in horizontal duct of main inlet duct to avoid fly ash build up
when in closed position. All other regulation dampers shall be pneumatically
operated and isolation dampers shall be motor operated. As a minimum guillotine
type isolation dampers shall be provided before and after each ID fan.
The flue gas duct layout shall be designed considering the following aspects:
- The change of direction of flue gas duct shall be gradual to avoid ash collection
at the bottom of the duct and also to prevent erosion by local concentration of
fly ash.
- The number of direction changes of the flue gas duct shall be minimal to
minimise the ash collection points. Adequate number of baffles to be provided
at all direction changing locations.
- However, the air preheater, economiser and duct hoppers shall have provision
for removal of fly ash during maintenance period when the steam
generation is out of operation. To facilitate such fly ash removal, a 100% gas
tight isolation gate near the hopper bottom shall be provided. The hopper
bottom shall be blanked with a blind chute suitable for unloading fly ash from
all the above mentioned hoppers.
All the fans and blowers shall be provided with electrically operated hoists both
on fan and motor side. The primary air discharge ducts of left and right shall be
interconnected with isolation dampers. The similar interconnection shall be
carried out in secondary air system.
3.17
Soot Blowing System

A complete set of automatic, programmable, selective sequential-type electric
motor operated and driven soot blowing equipment shall be furnished for the
furnace walls, superheater, reheater, economizer and air heaters. The soot
blowing system shall include all necessary blowers, electric drive motors, DCS
based sequence control, all piping including drain system piping (to grade floor
level), valves, safety valves, switches, hoses, electrical accessories, relays,
support frames and hangers complete including all components for operation.
Soot blowers shall be provided with a means of locally de-energizing both power
and control circuitry for maintenance.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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The soot blower elements shall be as automatic sequentially operated. Adequate

wall blowers have been considered for dislodging of the ash on coils and tubes.
Necessary valves for PRDS station have been considered foe steam soot
blowing system. LT Switchgear, control panel, complete power, control & inst.
Cable of soot blower system.
The soot blower piping includes the following
a)
Supply piping through pressure reducing station.
b)
Drain piping
c)
Vent piping
d)
The complete soot blower piping shall have warm up and automatic
draining features.
e)
All necessary valves, relief valves and mountings and fittings have been
considered.
Electrically operated long retractable/ rotary soot blowers complete with PRV and
other accessories & fittings should be supplied as per design requirement.
Sequential operation of the soot blowers will be realized in soot blower PLC
panel.
3.18
Boiler Coal feeding system

The coal burning system shall be designed to meet the requirement of Boiler at
100% SG MCR condition.
To transport the solid fuel (coal) from the bunker outlets to the boiler, the system
shall be complete with isolation valves /gates, chutes, feeders, with all supports /
hangers, instrumentation etc for a complete system.
3.19
Blow Down System

Systems indicated below shall be as per Bidders standard practice but details of
which shall be furnished along with the offer for customers review and
acceptance.
Other specific requirements are indicated below. These are, however, minimum
required.
A
Blow down Tanks
One (1) no. continuous & One (1) intermittent blow down tanks (as applicable)
including level gauges, redundant level transmitters for remote level control
through SG C&I system, control valves, safety valves with silencer, vents, drains.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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All other local instruments like gauge glass, level switch, high/low level alarms
and pressure/temperature instrumentation shall also be provided.
B
Valves
All necessary isolating, control, regulating, check and relief valves and/or
pneumatic valves, motorized valves including main steam stop valves, vent
valves, drain valves, root valves, safety valves with silencer, mountings etc., as
required for the boiler integral piping system. All Pneumatic operated valves
shall be complete with actuator assemblies and accessories like limit switch
assemblies, position transmitters, air locks etc. Integral bypass valves with
actuators and accessories, for all high pressure isolating valves as specified. Any
valve/mounting not specifically indicated but required for safe/efficient/reliable
operation of the boiler shall be included.
The valves and accessories shall comply with the following requirements and
shall include:
a)
Drain, vent, air release, instrument root drains and sampling lines shall be
provided with two valves in series. However, single isolating valve shall
be provided in case pressure is less than 40 Kg/ sq cm (a).
b)
Main stream stop valves with motor drives along with motorized bypass
valves and piping.
c)
One non-return valve and a motor operated isolating valve with integral
bypass valve on feed line(s) at inlet and as close as possible to the
economizer.
d)
Steam drum safety valves with silencer and drain pans.
e)
Superheater and reheater safety valves with silencer and the drain pans
for these.
f)
Electromatic relief valves, on SH outlet and RH outlet and the drain pans
for these. Each of these electromatic relief valves at SH/RH outlet(s)
shall be composite unit including solenoid valve assembly, pressure
sensing device, impulse piping, accessories etc. The control of ERV shall
be erformed in DDCMIS with CRT/KBD operation. A motorised remote
operated isolation valve shall be provided on upstream side of each relief
valve.
g)
Start-up drain and vent isolating valves with motor drives.
h)
All start-up vents, lowest set pressure spring loaded safety valve and
electromatic safety valves at superheater outlet, lowest set pressure
spring loaded safety valves on steam drum and reheater outlet and
impulse safety valve on reheater outlet shall be provided with separate
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[18]
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Power Plant]
[Logo of Utility]
and independent silencers for each. The silencers shall meet specified
noise levels and the safety/ relief valve floats.
3.20
3.21
i)
All instrument tapping points with root valves. Two root valves in series
shall be provided for lines above 40 kg/cm2 (a) pressure.
j)
Isolating and drain valves for each of gauge glasses.
k)
Necessary drain system including low noise drain valve to ensure

draining of the Boilers in one hour without any assistance.
l)
A non return valve and isolation valve on boiler fill line.
m)
Any other valves not mentioned specifically but needed to complete the
system with drives, wherever required.
n)
The start-up, load maneuvering and shut down of Boiler is proposed from
the unit control room. The Contractor shall provide all required valves with
their actuators and remote operation facilities to achieve this.
o)
Emergency drum drain valves, two (2) in series with motor drives.
p)
Power operated, regulating type valve on continuous blow down line with
motorized isolation valve on either side.
q)
An identical bypass arrangement to the valves on continuous blow down

line, as indicated above, shall also be provided.
r)
All other operational requirements specified elsewhere shall also be

complied with. The Bidder shall provide all required valves with specified
type of actuator to meet such operational requirements.
Chemical Dosing System & SWAS

a)
Skid mounted HP dosing system comprising of mixing cum storage tank

(MSRL/ SS304) with motorized agitator and variable stroke, positive
displacement type pumps. The plunger of the pump will be of SS304.
b)
Associated piping from pump outlet to steam drum inlet, valves,

mountings, fittings, safety valves within system as per approved P&IDs.
c)
Base frame, foundation bolts & nuts, coupling set, safeguard, mating
flanges etc.
d)
Necessary supports & supporting structure.
e)
Complete SWAS system.
Pressure parts design criteria

The design of all pressure parts (tubes, headers, vessels etc.) shall be as per
ASME or other international codes with the approval of the purchasers. It is
however, the responsibility of the Contractor to get various calculations and other
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[19]
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Power Plant]
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technical documentations approved by the statutory authorities in the State and

country of location of the plant.
Design pressure of the boiler pressure parts shall be atleast 1.05 times the
maximum operating pressure, or as required by ASME/ other international codes,
whichever is higher.
For boiler drum, the design pressure shall be higher of the value as per above or
highest set safety valve pressure for full discharge.
The thickness of the pressure parts (steam and water tubes/ headers, pressure
vessels etc.) shall be calculated using ASME formulae/factor of safety etc.
Additional erosion allowance on the calculated tube thickness shall be provided
at specified locations as specified by the purchasers in these specifications.
3.22
Pressure part materials

Materials used for boiler tubing, headers, piping, vessels and other pressure
parts shall comply with maximum permissible temperature limits for various
materials as specified below:
a)
Up to and including 400 deg C
: Carbon steel to ASTM 106 Gr C. or

SA 210C or approved equivalent
b)
Above 400 deg C but below : Alloy steel to ASTM A335, P-11/T11, 22/T22, P91/T91 or approved
550 deg C
equivalent.
c)
For SH/RH outlet leg (High

temperature zone)
: T-91/P-91
d)
Above 550 deg C
: P-91/T-91* Austenitic Steel Grade to

owners approval.
*Note: P91/ T91 material could be used only up to 590 deg C.

Water walls shall be of membrane type and water wall tubes shall be of seamless
design.
3.23
Thermal Insulation
The furnace, fans, air heaters, flues, ducts, hoppers, and piping, shall be
thermally insulated so that the outside surface temperature will not exceed 60
deg C. In areas where surface temperature exceeds 60 deg C, personnel
protection shall be provided within 1 meters (3 feet) of platforms, walkways and
general access areas, and up to 2meters (7 feet) from grade or
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[20]
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platforms/walkways, or where personnel may inadvertently make contact with

those surfaces.
Thermal insulation on flues, ducts, and the wind box shall be mineral fiber block
or mineral fiber blanket type insulation complete with outer lagging. Lagging of
the ribbed type clad aluminum alloy 3004 with stucco embossed finish, not less
than 1 millimeter (0.040 inch) thick shall be provided. All surfaces shall be selfdraining.
Thermal insulation on the furnace casing shall be non-corrosive, non-asbestos
material, readily removable and designed to prevent hot spots due to passage of
hot gasses past butted joints. Insulation shall be thoroughly dried prior to
installation of the casing.
Thermal insulation on pipe and equipment shall be calcium silicate or mineral
fiber block type insulation complete with aluminum outer lagging. Aluminum
lagging shall be of alloy 3003 or 3005, with a minimum thickness of 0.5
millimeters (0.016 inch) and fastened with stainless steel bands. Multi-layer
insulation shall be applied where the inner surface of the insulation is 316oC
(600F) and above. The maximum thickness of the insulation per layer shall not
exceed 75 millimeters (3 inches).
Procedure qualification and welder performance qualification shall be in
accordance with either ASME B&PV Code, Section IX or ANSI B31.1 as
applicable.
3.24
Welding and Repair welding

Post-weld Heat Treatment (PWHT) along with careful attention to welding
procedures is required for welded joints to ensure minimal stress and optimum
ductility. Boiler design shall maximize shop-welding and minimize field
connections to reduce field heat treatment as much as possible. In the weldment
of dissimilar alloys, material selection must be based on consideration of PWHT
temperature. All boiler field welds will be on similar tubes. All welds between
transition stub tubes and austenitic stainless steel tubes should be shop-welded.
All boiler field welds shall be on similar tubes. Welds between transition stub
tubes and austenitic stainless steel tubes shall be shop-welded.
All pressure parts welding and repair welding, including non-destructive
examinations, shall comply with ASME B&PV Code, Section I and ANSI B 31.1,
as applicable or Equivalent International Standards.
Procedure qualification and welder performance qualification shall be in
accordance with ASME B&PV Code, Section IX or ANSI B31.1 as applicable.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[21]
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Power Plant]
3.25
[Logo of Utility]
Start Up Light Diesel Oil System

LDO system shall comprise of pressurizing pump sets of adequate capacity to
meet startup requirement of Boiler, filters, strainers, burners, control valves,
control and instrumentation etc with equipment redundancy and flexibility of
operation, complete piping, valves, and fittings commencing from pump suction
inlet from tanks right up to the burners in combustor, and re-circulating system,
high energy arc igniters, scanners, and scanner cooling air system.
The startup firing system shall not require adjustment to increase capacity. The
burners shall be furnished complete with all piping, manual valves, strainers,
instruments, pressure regulators, solenoid valves, safety valves, and all
necessary equipment and controls in accordance with NFPA 85C as applicable.
Flexible stainless steel hoses to connect the burners to the LDO piping shall be
provided. The system shall provide stability to solid fuel firing system. The
contractor shall supply all piping and hangers for piping between each burner
valve rack and the main shutoff rack.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

[22]
15.01.2016

OF

R&M CONTRACTORS

VOLUME-III
PART-A
TECHNICAL SCHEDULES-MECHANICAL
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R04
January 2016
Power Plant]
[Logo of Utility]

Volume
Section
Part
Description
Volume-I
---
---
Commercial
Section-I
---
Part-A
Part-B
Part-C
Part-D
---
Part-A
---
Part-B
---
Part-C
---
Part-D
Not Used
Volume-II
Section-II
Volume-III
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[ii]
15.01.2016
Power Plant]
[Logo of Utility]
1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[iii]
15.01.2016
Power Plant]
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1.
2.
3.
4.
5.
6.
7.
8.
9.
Spare Parts
10.
Annexure
SECTION-II:
1. Detailed Technical Specification-Mechanical

2.
3.
4.
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[iv]
15.01.2016
Power Plant]
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1.
2.
3.
*****
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[v]
15.01.2016
Power Plant]
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{Guidelines for Using the Document}

{This document of Technical Schedules covers the data applicable both to the PF as well
as CFBC Boilers. Since the Construction Features of CFBC Boilers vary widely from
Manufacturer to Manufacturer, the Utilities are advised to ensure that the data to be
sought for the R&M of CFBC Boilers is in line with the design of existing CFBC Boilers.}
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[1]
15.01.2016
Power Plant]
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TABLE OF CONTENTS
Page
1.0
PERFORMANCE DATA
2.0
STEAM GENERATOR AND PRESSURE PARTS
14
3.0
REGENERATIVE AIR PREHEATER
30
4.0
TUBULAR AIR PRE HEATER
33
5.0
SCAPH
34
6.0
DRAFT PLANT
35
7.0
SOOT BLOWERS
39
8.0
BLOW DOWN VESSELS
41
9.0
COAL PREPARATION & FIRING EQUIPMENT
42
10.0
CYCLONE
51
11.0
LOOP SEAL
52
12.0
EXTERNAL FLUIDIZED BED HEAT EXCHANGER
52
13.0
BOTTOM ASH REMOVAL SYSTEM
52
14.0
ELECTROSTATIC PRECIPITATOR
53
15.0
FUEL OIL UNLOADING, PREPARATION & FIRING EQUIPMENT
64
16.0
INSTRUMENTATION & CONTROL
73
17.0
AC MOTORS
73
18.0
DC MOTORS
73
19.0
BOTTOM ASH REMOVAL SYSTEM
74
20.0
INSULATION
75
21.0
EQUIPMENT DIMENSIONS AND WEIGHTS
76
22.0
FURNISHING OF ADDITIONAL DATA
79
23.0
DRAWINGS AND EQUIPMENT LOADING DATA
86
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[2]
15.01.2016
Power Plant]
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S.No
Detail
Description
1.0
PERFORMANCE DATA
1.1
Load Data
1.1.1
Steam flow from Super-heater, T/hr
1.1.2
Steam flow through Re-heater T/hr
1.1.3
Super-heater De-superheating
Spray water flow, kg/hr
1.1.4
Re-heater De-super heating Spray

water flow kg/hr
1.1.5
Auxiliary steam flow for soot

blowing, oil burner atomization
100%
BMCR
100%
TMCR
60%
BMCR
HP Heater
out of
service
100%
BMCR
100%
TMCR
60%
BMCR
HP Heater
out of
service
etc., kg/hr
1.2
Calculated Flow quantity kg/hr.
1.2.1
Total air to Regenerative Air Preheater (RAPH) / Tubular Air Preheater inlet (Tubular APH) {As the
case may be}
1.2.2
Air leakage thru' RAPH/ Tubular Air

Pre-heater {As the case may be}
1.2.3
Total secondary air at Wind boxes.
1.2.4
Flue gas at RAPH inlet / Tubular

APH
1.2.5
Flue gas at RAPH outlet / Tubular

APH
1.2.7
Coal firing
a)
With Design Coal
b)
With Worst Coal
1.2.8
FD fan outlet air
1.2.9
Cold Air fan outlet air
1.2.10
ID fan inlet flue gas
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[3]
15.01.2016
Power Plant]
S.No
Detail
Description
1.2.11
Tempering air for each

pulverizer(Not Applicable for CFBC
Boiler)
1.2.12
Total air to each pulverizer (Not

Applicable for CFBC Boiler)
1.3
[Logo of Utility]
Steam/Water Pressure & Pressure

2
Drops, Kg/cm g
1.3.1
Steam at Super-heater outlet
1.3.2
Pressure drop in Super-heater(s)
1.3.3
Steam in Boiler Drum
1.3.4
Pressure drop in Economizer*
1.3.5
Water at Economizer inlet **
1.3.6
Steam at Re-heater inlet
1.3.7
Pressure drop thru' Re-heater(s)
1.3.8
Steam at Re-heater outlet
1.3.9
Steam at Aux. Steam tap-off
100%
BMCR
100%
TMCR
60% BMCR
HP Heater
out of
service
100%
BMCR
100%
TMCR
60% BMCR
HP Heater
out of
service
* Less static head

** Including static head
1.4
Steam/Water Temperature C
1.4.1
Steam at Super-heater outlet
1.4.2
Steam at Reheater outlet
1.4.3
Steam at Reheater inlet
1.4.4
Water at Economizer inlet
1.4.5
Water at Economiser outlet
1.4.6
Steam for Aux. Steam tap-off
1.5
1.5.1
1.5.2
1.5.3
1.5.4
Flue Gas Temperature, deg.C

Theoretical Combustion Zone temp.
Furnace Exit Temperature, deg.C
Primary Superheater Inlet
Primary Superheater Outlet
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[4]
15.01.2016
Power Plant]
S.No
1.5.5
Detail
Description
Secondary Superheater Inlet
1.5.6
Secondary Superheater Outlet
1.5.7
Final Super heater inlet
1.5.8
Final Super heater outlet
1.5.9
Primary Reheater Inlet
1.5.10
Primary Reheater Outlet
1.5.11
Secondary Reheater Inlet
1.5.12
Secondary Reheater Outlet
1.5.13
1.5.14
1.5.15
Economizer Inlet
Economizer Outlet
RAPH / Tubular APH Inlet
1.5.16
RAPH Outlet / Tubular APH

(uncorrected)
1.5.17
RAPH Outlet / Tubular APH

(corrected)
1.5.18
Electrostatic Precipitator Inlet
1.5.18
Electrostatic Precipitator Outlet
1.5.20
1.5.21
1.5.22
I.D. Fan Inlet

I.D. Fan Outlet
Stack Inlet
100%
BMCR
1.6
1.6.1
1.6.2
[Logo of Utility]
100%
TMCR
60% BMCR
HP Heater
out of
service
Air TemperatureC
FD fan inlet
At SCAPH
i. Air at SCAPH inlet
ii. Air at SCAPH outlet
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[5]
15.01.2016
Power Plant]
S.No
1.6.3
1.6.4
Detail
Description
Air at RAPH/ Tubular APH Inlet

Air at RAPH/ Tubular APH Outlet
1.6.5
Combustion air at
burner inlet
1.6.6
Coal air mixture at

outlet
pulverizer
1.6.7
Coal air mixture at burner inlet
1.7
[Logo of Utility]
Combustion air pressure drop in

mm of WG
1.7.1
FD fan inlet duct
1.7.2
Duct and dampers

i. From FD fan to SCAPH
ii. Thru SCAPH air side
iii. Ducts and dampers from SCAPH
to RAPH/ Tubular APH
1.7.3
1.7.4
1.7.5
Thru' RAPH-air side / Tubular APH

Ducts & Dampers from RAPH/
Tubular APH to Furnace Windbox
Burner Windbox to Furnace
1.7.6
Between inlet and throat of air flow

measuring device
1.7.7
Unrecovered loss across air flow

measuring device
1.7.8
Total loss through the system
1.8
1.9
1.9.1
1.9.2
1.9.3
1.9.4
Flue gas to each Coal mill ( Not

Applicable to CFBC Boiler)
Flue Gas Pressure & Pressure
Drops, mm WG
100%
BMCR
100%
TMCR
60%
BMCR
HP Heater
out of
service
Furnace pressure (suction)

Drop Across Superheater
Drop Across Reheater
Drop Across Economiser
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[6]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
1.9.5
Drop Across RAPH / Tubular APH

(gas side)
1.9.6
Drop Across Electrostatic

Precipitator (ESP)
Drop thru' Ducts & Dampers from
1.9.7
100%
BMCR
100%
TMCR
60%
BMCR
HP Heater
out of
service
100%
BMCR
100%
TMCR
60%
BMCR
HP Heater
out of
service
100%
BMCR
100%
TMCR
60% BMCR
HP Heater
out of
service
a)
RAPH/ Tubular APH outlet
to ESP Inlet
b)
ESP outlet to ID fan Inlet
c)
ID fan outlet to Stack Inlet
1.9.8
Total drop through the system
1.10
Excess Air (%)
1.10.1
1.10.2
1.10.3
1.10.4
1.10.5
1.11
1.11.1
1.11.2
1.12
1.12.1
1.12.2
At Burners
At Furnace Exit
At Economizer Outlet
At RAPH / Tubular APH Outlet
At ID fan Inlet
Pulverizers ( Not Applicable to
CFBC Boiler)
Total number offered
Number required for operation with a)
Design Coal
b)
Worst Coal
Steam Purity (ppm)

Total dissolved solids
Silica
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[7]
15.01.2016
Power Plant]
S.No
1.12.3
1.12.4
1.12.5
1.12.6
Detail
Description
Sodium
Chlorides
Copper
Iron
1.13
Percentage load change while

maintaining safe flame conditions
1.14
Time required for draining the

complete steam generator
1.15
Acid dew point temp. adopted, C
1.15.1
1.15.2
1.16
1.16.1
1.16.2
1.16.3
1.16.4
1.17
1.17.1
1.17.2
1.17.3
1.17.4
1.18
1.18.1
[Logo of Utility]
For Design Coal Firing

Worst Coal Firing
Flue gas velocities M/Sec.
In Superheater Section
In Reheater Section
In Economiser Section
In Ducts
Percentage of Oxygen in Flue Gas
100%
BMCR
100%
TMCR
60% BMCR
HP Heater
out of
service
At Furnace exit
At Economiser outlet
At RAPH/ Tubular APH outlet
At ESP outlet
Heat Absorbed per Unit Weight of
Coal Fired, Kcal/Kg.
In RAPH/ Tubular APH with a)
Design Coal
b)
Worst Coal
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[8]
15.01.2016
Power Plant]
S.No
Detail
1.18.2
In Economiser with -
1.18.3
1.18.4
1.18.5
1.18.6
a)
Design Coal
b)
Worst Coal
[Logo of Utility]
Description
In Superheater with a)
Design Coal
b)
Worst Coal
In Reheater with a)
Design Coal
b)
Worst Coal
In Water Walls with

a)
Design Coal
b)
Worst Coal
Total heat absorbed

by the unit with -
1.19
a)
Design Coal
b)
Worst Coal
Losses and Efficiency, %
1.19.1
Standard/Code as per which the

losses & efficiency will be measured
1.19.2
Moisture in fuel loss for
1.19.3
1.19.4
a)
Design Coal firing
b)
Worst Coal firing
100%
BMCR
100%
TMCR
60% BMCR
HP Heater
out of
service
100%
100%
60% BMCR
HP Heater
Hydrogen in fuel loss for

a)
Design Coal firing
b)
Worst Coal firing
Moisture in Air loss for
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[9]
15.01.2016
Power Plant]
S.No
1.19.5
1.19.6
1.19.7
1.19.8
1.19.9
1.19.10
1.19.11
1.19.12
Detail
[Logo of Utility]
Description
a)
Design Coal firing
b)
Worst Coal firing
BMCR
TMCR
100%
BMCR
100%
TMCR
out of
service
Unburnt Combustible Loss for

a)
Design Coal firing
b)
Worst Coal firing
Radiation loss for

a)
Design Coal firing
b)
Worst Coal firing
Total gas loss for

a)
Design Coal firing
b)
Worst Coal firing
Unaccounted loss for

a)
Design Coal firing
b)
Worst Coal firing
Other losses (if any) for

a)
Design Coal firing
b)
Worst Coal firing
Total losses for

a)
Design Coal firing
b)
Worst Coal firing
Heat Credits considered for the

following items (to be filled in by
Bidder) a)
............
b)
............
c)
............
60%
BMCR
HP Heater
out of
service
Total Heat Credit for a)
Design Coal firing
b)
Worst Coal firing
c)
Net loss
(Total loss- Heat credits)

Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[10]
15.01.2016
Power Plant]
S.No
1.19.13
1.20
1.20.1
1.20.2
1.20.3
1.20.4
Detail
[Logo of Utility]
Description
Efficiency for
a)
Design Coal firing
b)
Worst Coal firing
Energy Quantities kcal/hr.

Energy to Steam & Water
Energy to Reheated Steam
100%
BMCR
100%
TMCR
60% BMCR
HP Heater
out of
service
100%
BMCR
100%
TMCR
60% BMCR
HP Heater
out of
service
Heat output of unit

Heat input from fuel
3
1.20.5
Net heat input per m of Furnace

volume, Kcal/hr./m3
1.20.6
Maximum net heat input per m of

2
furnace plan area, Kcal/hr/m
1.20.7
Maximum Burner Zone heat release

2
rate, Kcal/hr./m
1.20.8
Maximum heat liberation rate

2
Kcal/m
1.20.9
Maximum hot input/

Kcal/hr.
1.20.10
Cooling factor Kcal/hr./m
1.21
1.21.1
1.21.2
1.21.3
burner,
2
Particulate matter concentration

Particulate concentration at ESP
inlet a)
Design Coal firing, g/Nm
b)
Worst Coal firing, g/Nm
ESP Efficiency
a)
Design Coal
b)
Worst Coal
Particulate concentration at ESP
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[11]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
Outlet
1.22
Distribution of Ash (kg/hr.)
1.22.1
Furnace bottom hoppers with
1.22.2
1.22.3
1.22.4
1.22.5
1.23
a)
Design Coal
b)
Worst Coal
Economiser hoppers with

a)
Design Coal
b)
Worst Coal
RAPH/ Tubular APH hoppers with

a)
Design Coal
b)
Worst Coal
ESP hoppers with

a)
Design Coal
b)
Worst Coal
Any other hoppers with

a)
Design Coal
b)
Worst Coal
Power Requirement of
Auxiliaries, KW
100%
BMCR
1.23.1
Coal Mills
1.23.2
PA Fans
1.23.3
FD fans
1.23.4
ID fans
1.23.5
Air Heater
1.23.6
Coal Feeders
1.23.7
Boiler Start up drain Recirculation

Pump (If applicable)
1.23.8
Seal Air Fan
Document Number
LII-GETS12021-G-00129-001
100%
TMCR
60% BMCR
HP Heater
out of
service
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[12]
15.01.2016
Power Plant]
S.No
Detail
Description
1.23.9
Lube Oil Pumps for Fans/Air

Heaters/Mill System etc
1.23.10
Scanner Air Fans
1.23.11
Electrostatic Precipitator
1.23.12
Gas Recirculation Fan (If applicable)
1.23.13
DM Cooling Water Fan for Boiler &

Auxiliaries
1.23.14
Auxiliary Cooling Water Pumps (If

applicable within Boiler & Auxiliaries
Package)
1.23.14
1.24
[Logo of Utility]
Recommended time (in Hrs.)

period to bring Boiler on load
with HP LP bypass system
1) Cold start
2) After 24 Hrs. Shut down
3) After 8 Hrs. shut down
1.25
1.26
Control range of Boiler (% MCR)

Instrument and Service Air
Requirement for the Boiler &
auxiliaries
Quantity, m /min.
1.26.2
Pressure, Kg/cm g
Noise Level
1.27.1
ID fan
1.27.2
FD fan
1.27.3
Mills
1.27.4
Safety, relief, start up valves
1.28
Service Air
1.26.1
1.27
Instrument Air
Estimated fuel oil consumption at

a) Cold start up in T/H
b) Oil support below 40% BMCR
1.29
Rate of emission
a) NOx Emission
b) CO Emission
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[13]
15.01.2016
Power Plant]
S.No
Detail
Description
2.0
STEAM GENERATOR AND PRESSURE PARTS
2.1
General Data
2.1.1
Manufacturer
2.1.2
Operation (fixed pressure/sliding

pressure) from 100% TMCR to 40%
BMCR
2.1.3
2.1.4
Design code
Type of firing
2.1.5
Type of circulation for steam

generator
2.1.6
Minimum load at which steam

generator can be operated
continuously with complete
flame stability without oil support
(%MCR)
2.1.7
Minimum load at which the steam

generator can be operated
continuously with
complete flame stability with oil
support (%MCR)
2.1.8
Total water content of the steam

generator for hydraulic test
2.1.9
Maximum load for each individual

pulveriser with no oil support (Not
applicable for CFBCBoiler)
2.1.10
Details of permanent thermocouples

giving the number and their location
2.1.11
Write up on Burner management

system furnished?
2.1.12
Submitted evidence to support

adequacy of design proposed
considering furnace slagging, Coal
ash corrosion & erosion,
Superheater and Reheater fouling?
2.2
2.2.1
2.2.2
2.2.3
[Logo of Utility]
Furnace (Applicable to PF Boilers)

Type
Wall Cooling Arrangement
Bottom (Whether dry)
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[14]
15.01.2016
Power Plant]
S.No
2.2.4
Detail
Draft
[Logo of Utility]
Description
(Whether balanced)
2.2.5
Tube Arrangement (Whether

Membrane type)
2.2.6
i)
Explosion/Implosion
withstand capacity (mmwg) at 67%
yield point
ii)
Protective measures
provided to prevent implosion/
explosion
2.2.7
Residence time for fuel particles in

the furnace (supported with
calculations), hrs.
2.2.8
Effective volume used to

3
calculate the residence time M
2.2.9
Height from top of furnace bottom

ash hopper to furnace roof, M
2.2.10
Depth (M)
2.2.11
Width (M)
2.2.12
2.2.13
2.2.14
2.2.15
Furnace projected area M

Furnace volume M
Furnace temperature probe

a)
Type
b)
Manufacturer
c)
Quantity
d)
Size
e)
Location
Furnace (Applicable to CFBC

Boiler)
2.2.17
Furnace Volume, m3
Dimensions of Furnace
(Width x Depth x Height), m
2.2.18
Height of Refractory lined lower
2.2.16
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[15]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
zone,m
2.2.19
Elevation of Fuel Injection,m
2.2.20
Elevation of Sorbent Injection,m
2.2.21
Elevation of Secondary Air

Injection,m
2.2.22
Minimum fluidization velocity,

m/s
2.2.23
Superficial velocity,m/s
2.2.24
Bed Temperature deg C
2.2.25
Coal / Lignite Feed Particle

Size[] to []mm
2.2.26
Type of Sorbent Used
2.2.27
Sorbent Feed Particle Size,

microns
2.2.28
Calcium/Sulfur Ratio
2.2.29
Sulfur Removal Efficiency,%
2.2.30
NOx emission, ppm
2.2.31
Combustion Efficiency,%
2.2.32
2.2.33
Water Walls, m2
2.2.34
Superheaters, m2
2.2.35
Reheaters, m2
2.2.36
Economiser, m2
2.2.37
Air Heater, m2
2.2.38
Steam Coil Air Heater, m2
2.2.39
Temperature Measurement of
Super-heater tubes, whether
provided.
Temperature Measurement of
Re-heater
tubes,
whether
provided.
2.2.40
2.3
Water Walls
Front
a)
Number/Type
b)
Outside diameter (mm)
Document Number
LII-GETS12021-G-00129-001
Side
Rear
Roof
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[16]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
c)
Design thickness (mm)
d)
Pitch
e)
Actual thickness used (mm)
f)
Design standard
g)
Material
h)
Total projected surface area
of tubes, M2
i)
Method of joining long tubes
j)
drum
Method of attachment to
k)
Method of joining to headers
l)
Total weight of tubes, Kg
m)
Design pressure of tubes
2
kg/cm
n)
Maximum pressure of tubes
2
Kg/cm abs
o)
Design metal temperature
deg.C
2.4
2.4.1
Water Wall Headers
Front
Height of the lowest header above

the ground level, M
2.4.3
Outside diameter, mm
2.4.4
Design thickness, mm
2.4.5
Actual thickness provided, mm
2.4.7
2.4.8
Roof
Length of each header, M

Design standards
Maximum header unbalance
2.4.9
Design pressure of headers, kg/cm

g
2.4.10
Maximum working pressure of

2
headers, Kg/cm g
2.4.11
Material specification
2.5
Rear
Number of headers
2.4.2
2.4.6
Side
Boiler Drum
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[17]
15.01.2016
Power Plant]
S.No
2.5.1
Detail
Description
Number
2.5.2
Construction
2.5.3
Material specification and

composition
2.5.4
Manufacturer of plate material
2.5.5
2.5.6
[Logo of Utility]
Composition
Ultimate tensile strength of plates,
2
Kg/cm
2
2.5.7
Design pressure, Kg/cm g
2.5.8
Design metal temperature deg.C
2.5.9
Design stress at working metal

temperature (0.2% proof stress)
2
Kg/cm
2.5.10
Maximum operating pressure kg/cm
2.5.11
Design standard
2.5.12
Design thickness for straight

portion, mm
2.5.13
Design thickness for dished ends,

mm
2.5.14
Actual thickness used for straight

portion, mm
2.5.15
Actual thickness used for dished

ends, mm
2.5.16
Overall length of drum, mm
2.5.17
Outside diameter of drum, mm
2.5.18
Internal diameter, mm
2.5.19
Corrosion allowance, mm
2.5.20
Elevation of drum centre line above

ground level, M
2.5.21
Number of distribution headers
2.5.22
2.5.23
No. of cyclonic separators

No. of secondary driers
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[18]
15.01.2016
Power Plant]
S.No
2.5.24
2.5.25
2.5.26
Detail
[Logo of Utility]
Description
No. of final driers

Shroud material
Maximum permissible temperature
differential between any two parts of
the drumC
a. During normal operation
b. During accelerated starting
c. During sliding pressure operation
from 100%
TMCR to 40%
TMCR
2.5.27
2.6
2.6.1
Water capacity at MCR conditions

(in seconds) between normal and
lowest water level permitted
Purity of saturated steam leaving the drum (ppm)
Total dissolved solids
2.6.2
Silica content
2.6.3
Sodium
2.6.4
Chlorides
2.6.5
Copper
2.6.6
Iron
2.6.7
Moisture
2.7
2.7.1
2.7.2
2.7.3
Superheaters
Type (Radiant/convection)
Platent (drainable/non-drainable)
Pendant (drainable/non-drainable)
2.7.4
Horizontal headers (drainable/

non-drainable)
2.7.5

composition
2.7.6
Effective heating surface area M2
2.7.7
Total circumferential heating surface

area,M2
2.7.8
Gas flow path area, M2
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[19]
15.01.2016
Power Plant]
S.No
Detail
2.7.9
Depth of each bank in the direction

of the gas flow, mm
2.7.10
Clear space between the two banks

in the direction of gas flow, mm
2.7.11
Maximum steam side metal

temperature C
2.7.12
Maximum gas side metal

temperature C
2.7.13
Type of flow (counter or parallel)
2.7.14
Material of tube support

(composition)
2.7.15
Description
Design standard
2.7.16
Design tube thickness, mm
2.7.17
2.7.18
Actual thickness used, mm
2.7.19
Margin on tube thickness over and

above pressure requirement, mm
2.7.20
Number of elements/section
2.7.21
2.7.22
[Logo of Utility]
Total number of tubes

Tube Pitch
a. Parallel to gas flow
b. Across gas flow
2.7.23
2.8
2.8.1
2.8.2
2.8.3
2.8.4
Number and type of thermocouples

fitted to Superheater tubes
Reheater
Platen (drainable/non-drainable)
Pendant(drainable/non-drainable)
Horizontal headers (drainable/
non-drainable)
Material composition
2.8.5
Total effective heating surface. m
2.8.6
Total circumferential heating

2
surface, m
2.8.7
Gas flow path area, m
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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[20]
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S.No
Detail
Description
2.8.8
Depth of each bank in the direction

of gas flow, mm
2.8.9
Clear space between the two banks

in the direction of gas flow, mm
2.8.10
Maximum operating pressure

Kg/cm2 g
2.8.11
Design pressure, Kg/cm2 g
2.8.12

temperature, deg.C
2.8.13

temperature, deg.C
2.8.14

temperature with IP turbine out of
operation deg.C
2.8.15
Design standard
2.8.16
2.8.17
2.8.18
2.8.19
Margin on tube thickness over and

above pressure requirement, mm
2.8.20
2.8.21
[Logo of Utility]
Total number of tubes

Tube pitch, mm
a. Parallel to gas flow
b. Across gas flow
2.9
2.9.1
2.9.2
2.9.3
2.9.4
2.9.5
Headers of Superheater & Reheater

Material specification
Location (outside/inside gas path)
Maximum operating pressure,
Kg/cm2 (g)
Design pressure, Kg/cm2 (g)
Design standard
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[21]
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S.No
2.9.6
2.9.7
Detail
Description
Thickness, mm
2.9.8
Whether any diaphragm is used in

any header and if so give details
2.9.9
Details of final outlet header

connection
2.9.10
Method of internal inspection
2.9.11
2.9.12
2.10
2.10.1
[Logo of Utility]
Total volume, m
Maximum header unbalance

Superheater & Reheater Temperature Control
Attemperator
Superheater
Reheater
a. Type
b. Number of stages of
attemperation
c. Position in steam circuit
d. Specification of material
e. Superheater steam temperature
range that can be maintained
between 60% to 100% of Boiler
MCR, deg.C
f. Spray nozzle material
g. Maximum spray water flow rate
and corresponding steam output,
T/hr
h. Minimum spray water rate and
corresponding steam output T/hr
2.10.2
Tilting burners (if applicable)

a. Maximum angle of tilt upwards
b. Maximum angle of tilt downwards
c. Type of tilt mechanism
d. Reheat steam temperature range
that can be maintained between
60% to 100% of boiler MCR,
deg.C
2.11
2.11.1.0
Piping, Valves and Specialties for Critical (external) Piping

Pipes & Fittings
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[22]
15.01.2016
Power Plant]
S.No
2.11.1.1
2.11.1.2
Detail
[Logo of Utility]
Description
Basic codes and standards for

a)
Design
erection
fabrication
and
b)
Testing and inspection
Indicate the following for each pipe

class
a. Design pressure, Kg/cm2g
b. Design temperature, deg.C
c. Design flow T/hr
d. Design velocity M/sec
e. Primary rating, lbs
f. Pipe manufacturing process and
construction
g. Material of construction for
i) Pipes
ii) Fittings
h. Pipe sizes, mm (outside dia x
thickness) and/or (Max inside dia
x min thickness)
i. Tolerance for dia x min. thickness
j. Pipe wall thickness for bends, mm
(corresponding to each pipe size)
k. Design metal temp deg.C
l. Friction factor
m. Pressure drop in Boiler MCR
condition Kg/cm2
n. Temp drop at 92.2% BMCR
(deg.C)
o. Butt weld and socket weld and
preparation standard
p. Welding process
q. Hydrostatic test pressure, at shop
& after erection (for piping
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[23]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
systems under purview of IBR

shall also be indicated) Kg/cm2g
r. Minimum duration of hydrostatic
test, (indicate for shop test as
well as after erection) minute
s. Reference standard for ultrasonic
examination of pipe bend for
thickness conformance
t. Type of rust inhibiter given before
shipment
u. Valve specification code
2.11.1.3
Procedure and acceptance standard

of non-destructive
examination on weld joints
2.11.2.0
Gate/Globe/Check/Stop Check Valves

For each type (construction,
pressure class & body/bonnet
material wise) of valve, indicate the
following
2.11.2.1
2.11.2.2
Reference valve specification code

as designated in Section2.09
Basic specification
2.11.2.3
Manufacturer
2.11.2.4
Pressure class, lbs
2.11.2.5
Nominal size
2.11.2.6
Construction
2.11.2.7
a.
Bonnet/cover
b.
Disc
c.
Ends
d.
Seat
e.
Others
Materials
a.
Body & bonnet/cover
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[24]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
b.
Stem/hinge pin
c.
Disc and seat ring
d.
Back seat stem guide
bushing
2.11.2.8
e.
Gland packing
f.
Bolts and nuts
Hardness, BHN
a.
Stem
b.
Disc
c.
Seat
d.
Backseat/stem guide
bushing
2.11.2.9
Type and details of end connections
2.11.2.10
Hydrostatic tests
a.
Shell test pressure,
Kg/cm2g
b.
Seat test pressure, Kg/cm2g
c.
Acceptable seat leakage rate in

ml of water per hour per 25 mm
of nominal valve size
d.
Duration of shell and seat tests

minutes
2.11.2.11
Valve weight, Kg
2.11.2.12
Gear operator provided?

If so for what size of valves?
2.11.2.13
Integral bypass valves provided?

If so for what size of valves?
2.11.3.0
Electric Actuator for Valves

Furnish the following for each type
of valve
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[25]
15.01.2016
Power Plant]
S.No
Detail
2.11.3.1
Manufacturer
2.11.3.2
Model No. and Type
2.11.3.3
[Logo of Utility]
Description
kW rating and power factor
2.11.3.4
Rated voltage
2.11.3.5
Enclosure type
2.11.3.6
Insulation type
2.11.3.7
Space heater provided? Indicate

rated voltage
2.11.3.8
Valve operating speed, mm of stem

travel/minute
2.11.3.9
Limit Switches
a. Manufacturer
b. Model No. & Type
c. No. of position limit switch fori) Opening
ii) Closing
d. No. of torque limit switch for
i) Opening
ii) Closing
2.11.3.10
e.
No. of normal closed and

normally open contacts for each
limit switch
f.
Contact rating (at 240V AC)
g.
Enclosure type
h.
Space heater provided
Weight of actuator, kg
2.11.4.0
Steam Traps
2.11.4.1
Manufacturer
2.11.4.2
Model No. & type
2.11.4.3
Rated differential pressure(kg/cm )

and discharge capacities (T/hr)
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[26]
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Power Plant]
S.No
2.11.4.4
Detail
Description
Material
a.
Body
b.
Internals
2.11.4.5
Whether provided with integral or

separate strainer
2.11.5.0
Strainers
2.11.5.1
Manufacturer
2.11.5.2
2.11.5.3
2.11.5.4
Type
Material
a.
Body
b.
Internals
Screen mesh size
2.11.5.5
Ratio of screen open area and pipe

internal cross sectional area
2.11.6.0
Welding of piping
2.11.6.1
Type of weld
2.11.6.2
Special electrode details

(type, quantity)
2.11.6.3
Number of welds envisaged for each

piping covered in this spec
2.12.0
Economiser
2.12.1
Type (plain, drainable,

non-steaming)
2.12.2

composition
2.12.3
Manufacturer
2.12.4
Water side effective heating surface

2
area, m
2.12.5
Gas side effective heating surface

2
area m
2.12.6
[Logo of Utility]
Gas flow path area, m
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[27]
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Power Plant]
S.No
Detail
Description
2.12.7
Heat transfer co-efficient (gas to

water) at 100% BMCR Kcal/M2/hr
2.12.8
Provisions made for economizer on

load cleaning?
2.12.9
Details of re-circulating system
2.12.10
Design pressure of tubes, kg/cm2

(g)
2.12.11
Outside diameter of tubes, mm
2.12.12
2.12.13
2.12.14
2.12.15
2.12.16
2.12.17
2.12.18
2.12.19
[Logo of Utility]
Length of tubes, mm
Pitch, mm
Pitch across gas flow, mm
Design standard
Total volume of tubes m
Tube supports
a. Type
b. Material
2.12.20

temperature deg.C
2.12.21

temperature deg.C
2.12.22
Minimum allowable inlet feed water

temperature the economizer can
handle safely deg.C
2.12.23
Headers
Inlet header
Outlet header
a. Material specification
b. Outside diameter, mm
c. Design thickness, mm
d. Actual thickness used, mm
e. Design standard
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[28]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
f. Type of construction
g. Method of internal inspection
h. Maximum header unbalance
2
i. Design pressure, kg/cm g

j. Maximum working pressure,
Kg/cm2 g
2.13
2.13.1
Boiler Mountings and Fittings

Drum safety valves
a. Manufacturer
b. Type and rating
c. Number
d.
Specification of material for -
i) Body
ii) Trim/spring
iii) Seat
e. Set pressures, kg/cm2g
f. Flow capacities, T/hr
g. Type of end connections
2.13.2
Safety Valves
Superheater
Reheater
(for each safety valve)

a. Manufacturer
b. Type and rating
c. Number
d. Specification of material for i) Body
ii) Trim/spring
iii) Seat
e. Set pressures, Kg/cm2g
f. Flow capacity, T/hr
g. Type of end connections
2.13.3
Power operated Impulse/

Electromatic safety valve at SH
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[29]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
outlet
a. Manufacturer
b. Type of actuator
c. Number
d. Capacity of valve T/hr
e. Set pressure, Kg/cm2 g
2.13.4
Drum Level Gauges

a. Manufacturer
b. Type
c. Number
d. Location
e. Size
2.13.5
Reheater isolating device

a. No provided
b. Manufacturer and Model
c. Design Pressure and temperature
d. Material of construction
2.14
Desuper
heating
Feed
Water
flow
Flow Meters
2.14.1
Service
2.14.2
Pressure drop Kg/cm2
2.14.3
Material
2.14.4
Nozzle/orifice plate
2.14.5
Maximum flow T/hr
2.14.6
Type of end connections

(Welded/flanged)
HFO Flow
Return
HFO Flow
LDO Flow
3.0
REGENERATIVE AIR PREHEATER (RAPH) (Not applicable for CFBC Boiler)
3.1
Manufacturer
3.2
Type
3.3
Number offered per boiler
3.4
Mounting (vertical/horizontal)
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[30]
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Power Plant]
S.No
Detail
3.5
Maximum handling capacity, NM3/hr
[Logo of Utility]
Description
a. Flue gas
b. Air
3.6
Handling capacity at 100% BMCR,

NM3/hr
a. Flue gas
b. Air
3.7
Flue gas temperature at air heater

outlet deg.C
3.8
Specification and composition

a. Cold and elements
b. Intermediate elements
c. Upper hot element
d. Shaft
e. Seals
3.9
Recommended average cold end

temperature at 100% BMCR to
minimise corrosion C
3.10
Total effective heating surface m
a. Gas side
b.
3.11
3.12
3.13
Air side
Casing material
Casing thickness, mm
Pressure drop at 100% BMCR, Min.
wg
a. Air side
b. Gas side
3.14
Type of radial seals

a. Hot end
b. Cold end
3.15
Type of circumferential seals
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[31]
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Power Plant]
S.No
3.16
Detail
[Logo of Utility]
Description
Type of axial seal
3.17
Gas velocity at 100% Boiler BMCR,

M/sec
3.18
Air velocity at 100% boiler BMCR,

M/sec
3.19
Net free area for air and gas flow m
3.20
Electric motor drives
a. No. of motors
b. Motor speed, RPM
c. Motor name plate rating
3.21
Speed reducer
a. Type
b. Speed ratio
c. Manufacturer
3.22
Emergency drive
a. Type
b. Speed, rpm
c. Pressure, (kg/cm2g) and flow
requirements of air M3/sec)
3.23
Bearings a. Manufacturer
b. Type
c. Type of lubrication
3.24
Bearing cooling water requirement

a. Quantity, M3/hr
b. Inlet pressure, Kg/cm2g
c. Pressure drop, kg/cm2
d. Temperature rise, deg.C
3.25
On load cleaning
a. Type of blower (single/ multiple
nozzle)
b. Type of drive (sweep
action/retractable)
c. Pressure of steam jet, Kg/cm2g
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[32]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
d. No. of blowers
3.26
Off load cleaning

a. Provision made for off load
cleaning
b. Type of drive
c. Medium used (water/air)
d. Pressure of water/air required,
Kg/cm2g
e. Quantity of water/air required
M3/hr
3.27
Accessories (provided/ not provided)

and Number provided
a. Lube oil pumps
b. Oil coolers
c. Oil filters
d. Oil tanks
e. Oil pump
f. Support legs & foundation bolts
g. Coupling guards
h. Solenoid valve (air motor)
I. Air pressure adjusting device
j. Relief valve
k. Pressure gauges
l. Temperature indicator
m. Differential pressure gauges
n. Sight flow fittings
o. Main drive motor
p. Duplicate (emergency) drive
motor
3.28
Air heater fire preventive measure

envisaged and details
4.0
Tubular Air Preheater
4.1
Number per Boiler
4.2
4.3
Type
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[33]
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Power Plant]
S.No
Detail
Description
4.4
No. of gas passes
4.5
No. of air passes
4.6
Whether of Counter Flow Type
4.7
Number of bank in the main

section
4.8
Number of bank in the cold end

section
4.9
4.10
Tube outside diameter, mm
4.11
Tube thickness, mm
4.12
Tube material
4.13
Tube arrangement
4.14
Tube length, m
4.15
4.16
4.17
Tube pitch with air flow,mm
4.18
No. of tubes
4.19
Heating surface , m2
4.20

heater, m2
4.21

per boiler , m2
5.0
SCAPH
5.1
No. offered per boiler
5.2
Manufacturer
5.3
Steam pressure KSC
5.4
Steam Temperature C
5.5
Design air flow Nm3/hr
5.6
BMCR air flow Nm3/hr
5.7
Air velocity m/s
5.8
Design air inlet temperature C
5.9
Design air outlet temperature C
5.10
Quantity of steam corresponding to
Document Number
LII-GETS12021-G-00129-001
[Logo of Utility]
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
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Power Plant]
S.No
Detail
[Logo of Utility]
Description
i) Design air flow, kg/hr

ii) Normal air flow, kg/hr
5.11
Drain
i) Drain Temperature C
ii) Drain Enthalphy , kcal/kg
2
5.12
Total Surface area m
5.13
Accessories (State whether

provided or not & numbers provided)
i) Local instrument
ii) Isolating valves
iii) Regulating valves
iv) Condensate collection tank
v) Inter connecting piping
vi) Instrument tapping points
5.31
Flue and Air duct

1. Thickness and material of flue
gas duct
2. Thickness and material of air duct
3. Velocity of flue gas max/min
4. Velocity of air max/min
6.0
DRAFT PLANT
Forced draft fans
Induced draft fans
6.1
Manufacturer
6.2
Type
63
6.4
Capacity (flow rate for each
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[35]
15.01.2016
a. At 100% Boiler BMCR

b. At design (test block) conditions
c. Max flow rate the fan handle
d. Min flow rate the fan can handle
6.5
Static Pressure, mmWC

a. At 100% Boiler BMCR
i) For fan inlet
ii) For fan outlet
b. At design (test block) condition
Document Number
LII-GETS12021-G-00129-001
Power Plant]
S.No
Detail
[Logo of Utility]
Description
i) For fan inlet

ii) For fan outlet
c. At shut off condition
d. Min safe pressure
6.6
Design margin provided

a. Flow rate %
b. Static pressure %
6.7
Density of air/gas at working

temperature, Kg/Cm3
6.8
Synchronous speed of connected

electric motor, Rpm
6.9
Normal fan speed, Rpm
6.10
Critical speeds of fan

a. First critical speed, Rpm
b. Second critical speed, Rpm
6.11
Design tip speed of blades, M/sec.
6.12
Fan efficiency at
a. Design (Test block) condition
b. 100% BMCR
c. 100% T MCR Turbine rated
output)
d. 60% Boiler MCR
6.13
Direction of rotation facing fan

coupling (clockwise or
anti-clockwise)
6.14
Impeller details
a.
Impeller diameter, mm
b.
Shaft diameter, mm
c.
6.15
6.16
Moment of inertia of shaft and

impeller, kg/m2
Overall dimensions of fan& motor

Size of motor provided, KW
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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[36]
15.01.2016
Power Plant]
S.No
6.17
Detail
b.
6.19
6.20
Description
Power Consumption, KW
a.
6.18
[Logo of Utility]
At 100% Boiler MCR

At 100% T MCR
rated output)
(Turbine
c.
At 60% Boiler MCR
d.
MCR
Shaft HP at 100% Boiler
Moment of inertia of fan and motor,

Kg/M2
Type of coupling
Lubrication System
(forced/ring-lubrication)
a. For fans
b. For motors
6.21
Features of Construction
a.
Blades provided with
renewable wearing noses? Yes/No
b. Mode of adjustment of gas/air
flow control
c.
Range of above flow

control
d. Type of casing
e. Type of diffuser
6.22
Material of construction and

thickness
a. Casing
b. Casing side plates
c. Casing liner
d. Impeller blade
e. Inlet cone
f. Outlet diffuser
g. Impeller hub/shroud
h. Impeller wear plate (if any)
i. Shaft sleeve
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[37]
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Power Plant]
S.No
Detail
[Logo of Utility]
Description
j. Coupling
k. Base plate and foundation bolts
l. Inlet guide vane/Inlet damper
6.23
Bearings
a. No. and make
b. Type of bearings
c. Bearing liner material
d. Method of lubrication
e. Grade of lub oil
f. Thermometers provided ?
g. Thermocouples provided?
h. Method of cooling the bearings (if
not forced lubrication)
6.24
Shaft sealing arrangement
6.25
Hydraulic servo drive
6.26
Lube Oil System

a. Number of pumps per fan
b. Number of pumps in standby/service
c. Type of pump
d. Number of oil cooler fan
e. Number of oil coolers in
standby/service
6.27
f. Relief valves provided?
Yes/No
Yes/No
g. Pressure switches provided?
Yes/No
Yes/No
h. Thermometers provided?
Yes/No
Yes/No
i. Electric heaters with oil tanks

provided?
Yes/No
Yes/No
a. Coupling guards provided?
Yes/No
Yes/No
b. Base plate and foundation bolts
Yes/No
Yes/No
Accessories
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[38]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
provided?
c. Forced lubrication unit with
pumps, filters, coolers,
connected piping
etc.
provided?
Yes/No
Yes/No
d. Local instruments provided?
Yes/No
Yes/No
e. Provision for vibration sensors

made?
Yes/No
Yes/No
f. RTDs for fan and motor bearings

provided?
Yes/No
Yes/No
6.28
Minimum load of fan at which it can

operate in parallel without any
knocking and bumping
7.0
SOOT BLOWERS
7.1
Manufacturer of
a.
Blowers
b.
Control Equipment
7.2
Location & Mounting
7.3
Cleaning Medium
a.
Pressure, Kg/cm2 g
b.
Temperature, deg.C
c.
Source of cleaning medium
7.4
Number of groups of soot blowers
7.5
Total operating time per group min
7.6
Number, voltage and capacity of

power supply feeder to soot blower
MCC
7.7
Blowers
Furnace
Blower
Reheater
Blower
Economiser
Blower
Superheater
a. Type and make

b. Number of soot blowers
c. Number of blowers in operation at
a time
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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S.No
Detail
[Logo of Utility]
Description
d. Duration of operation per

operating group, min.
2
e. Operating pressure, Kg/cm g

f. Steam consumption rate, T/hr
g. Rate of steam consumption per
blower, T/hr
h. Total time required for one
complete cycle of soot blowing
operation. min
i. Length of travel, mm
j. Blowing radius/angle
7.8
Materials of Construction
a. Lance/swivel tube in high
temperature area
b. Lance/swivel tube in intermediate
temperature area
c. Lance/swivel tube in low
temperature area
d. Nozzles
e. Travelling carriage
f. Gland packing
g. Bearings in high temperature
area
h. Bearings in intermediate
temperature area
i. Bearings in low temperature area
j. Feed tube
k. Blowing head
l. Chain
m. Compression hangers
n. Bolts
7.9
MOTOR particulars
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[40]
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S.No
Detail
[Logo of Utility]
Description
a. Type
b. Capacity
c. Volt-ampere
d. RPM
7.10
Accessories provided
a. Blowing head
b. Pressure reducing valve
c. Relief valve
d. Orifices
e. Travelling carriage
f. Clamps of required
sizes
g. Limit switches
h. Gear boxes
i. Speed reducer
j. Supporting frame
8.0
BLOW DOWN VESSELS
Continuous
Blowdown Tank
8.1
Whether separate vessels offered

for Continuous & Intermittent blow
down?
8.2
Numbers
8.3
8.4
Intermittent
Blowdown Tank
Design code followed

Operating conditions
a. Pressure, Kg/cm2 g
b. Temperature, deg.C
c. Approx. Flow, m3/hr
8.5
Design conditions
a. Pressure, Kg/cm2 g
b. Temperature deg.C
8.6
8.7
8.8
Weld joint efficiency

Radiography (spot or full)
Stress relieving
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[41]
15.01.2016
Power Plant]
S.No
8.9
Detail
[Logo of Utility]
Description
2
Hydraulic test pressure, Kg/cm g

2
8.10
8.11
8.12
8.13
Hammer test pressure, Kg/cm g

Shell thickness, mm
Corrosion allowance, mm
Shell diameter, M
8.14
Shell height, M
8.15
Capacity adequate to receive drains

from Deaerator, main steam and hot
reheat lines?
8.16
Drain & overflow arrangement
8.17
a. Shell and head
b. Nozzle necks
c. Nozzle flanges
d. Manhole nozzle
e. Manhole flanges & namef. Supports & structures
9.0
COAL PREPARATION & FIRING EQUIPMENT (APPLICABLE TO PF BOILERS)
9.1
Coal bunkers
a) Number per boiler
b) Storage capacity at 100% MCR
c) Specific weight of material
considered for bunker design
d) Max moisture content considered
for bunker design
e) Min valley angle
f) Construction material
g) Lining material thickness
h) Type of isolation gate provided
9.2
9.2.1
Raw Coal Feeding Equipment

Raw Coal bunker shut off gates
a. Manufacturer
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[42]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
b. Type & Number

c. Material of the gate
d. Motor rating
9.2.2
Down spout from Coal bunker to

feeder
a. Manufacturer
b. Inside diameter x thickness, mm
c. Height, m
d. Material
e. Offset between feeder outlet and
centre line of Coal bunker, mm
9.2.3
Raw Coal feeders

a. Manufacturer
b. Numbers
c. Type
d. Feeder size
e. Normal capacity each, T/hr
f. Maximum capacity each T/hr
g. Method of output control
h. Speed pulser allowable VA
burden
e. Power consumption, KW
i) At 100% Boiler MCR
ii) At 100% T MCR
100% MCR)
(ie. turbine
iii) At 60% Boiler MCR

j. Type of drive
9.2.4
Raw Coal Weighters

a. Manufacturer
b. Model number
c. Number
d. Method of measurement
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[43]
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Power Plant]
S.No
Detail
[Logo of Utility]
Description
e. Range of measurement, T/hr

9.2.5
Downspout from feeder outlet to

Pulveriser
a. Manufacturer
b. Inside diameter x thickness, mm
c. Material
d. Height, m
e. Offset between feeder outlet &
pulveriser
9.3
Coal Pulverisers
(APPLICABLE TO PF BOILERS)
9.3.1
Manufacturer
9.3.2
Type
9.3.3
Number
9.3.4
Performance of Pulverisers with

Design Coal Operation (Turbine
rated output)
100%
BMCR
100%
TMCR
60%
BMCR
40%
BMCR
100%
BMCR
100%
TMCR
60%
BMCR
40%
BMCR
a. Fuel heat input required, Kcal/hr.

b. Coal required, T/hr
c. Percentage through 0.3 mm and
0.09 mm mesh
d. Number of pulverizers in service
e. Coal throughout per Pulverizers
T/hr
f. Maximum capacity of each
Pulveriser, T/hr
g. Percentage of operating
Pulveriser capacity
h. Power consumption for all the
operating Pulverisers, KW
9.3.5
Performance of Pulverisers with

Worst Coal Operation
a. Fuel heat input required Kcal/hr.
b. Coal required, T/hr
c. Percentage through 0.3 mm and
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[44]
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Power Plant]
S.No
Detail
[Logo of Utility]
Description
0.09 mm mesh
d. Number of Pulverisers in service
e. Coal throughout per Pulveriser
T/hr
f. Maximum capacity of each
Pulveriser, T/hr
g. Percentage of operating
pulveriser capacity
h. Power consumption for all the
operating Pulveriser, KW
9.3.6
Maximum crushed Coal size the

Pulveriser can accept, mm (
9.3.7
Speed of pulveriser, Rpm
9.3.8
Maximum flue gas flow, NM3/hr
9.3.9
Minimum flue gas flow, NM3/hr
9.3.10
Flue gas inlet temperature C
i) Before tempering
ii) After tempering
iii) After Mill temperature
9.3.11
Pressure inside the pulveriser

mmwc
9.3.12
Design pressure of housing, mmWC
9.3.13
Overall dimensions
9.3.14
Construction features
a. Describe the provisions made in
preventing fire in the pulveriser
b. Method of detections of fire in the
pulveriser
9.3.15
Type of drive transmission)
9.3.16
Type of coupling
9.3.17
Classifiers
a) Whether classifiers are provided
b) Adjustment of classifier vanes
provided
9.3.18
Materials of construction
a. Beater wheels
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[45]
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S.No
Detail
[Logo of Utility]
Description
b. Liners
c. Housing
d. Classifier
e. Base plate and foundation bolts
f. Bearing housing
g. Pulveriser base
9.3.19
Estimated life of beater wheels in

hours
9.3.20
Estimated life of liners
9.3.21
Estimated labour for replacement of

the above wear parts in man-hours.
9.3.22
Whether the following accessories

are provided
a. Coupling guards
b. Air seal arrangement for
Pulveriser
c. Oil cooler
d. Coal fineness sampling devices
e. Local instruments
f. RTD's for motor bearings
9.3.23
Pulveriser lube oil system

a. No. of lub oil pumps per
pulveriser
b. No. of lub oil pumps working
c. No. of oil coolers per pulveriser
d. No. of oil coolers working
e. Power consumption of lub oil unit,
KW
i) At 100% BMCR
ii) At 100% TMCR(Turbine rated
output)
iii) At 60% BMCR
9.4
Pulverised Coal Piping

9.4.1
a. Inside diameter x thickness mm
Straight Portion
Bend Portion
b. Material (indicate liner material

Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[46]
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Power Plant]
S.No
Detail
[Logo of Utility]
Description
also)
c. BHN
9.4.2
Estimated length of pulverized Coal

piping, M
9.4.3
Provisions made for equalizing the

Coal/air mixture flow in the
Pulverised Coal piping
9.4.4
Elaborate the arrangement for

preventing fire in the pulverized Coal
piping when corresponding
pulveriser is not in operation
9.4.5
Method of detection of fire in the

Coal pipes
9.4.6
Estimated life of pulverized Coal

pipes in hours
9.5
9.5.1
9.5.2
9.5.3
Seal Air Fans

Manufacturer
Type
Number of fans
9.5.4
Mounting & Arrangement
9.5.5
Capacity (flow rate for each fan)

3
NM /hr
9.5.6
9.5.7
Source of air supply

Normal speed rpm
9.5.8
Auxiliary power consumption
9.5.9
Overall dimensions of fan and motor
9.5.10
Size of motor provided, KW
9.5.11
Method of lubrication
a. For fans
b. For motors
9.5.12
9.5.13
Mode of air flow control adjustment

and range of control
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[47]
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Power Plant]
S.No
9.5.14
Detail
[Logo of Utility]
Description
Bearings
a. Make
b. Number and type
c. Bearing liner material
d. Type of cooling
e. Type of lubrication
f. Grade of lube oil
9.6
9.6.1
9.6.2
g. Thermometers provided ?
Yes/No
h. Thermocouples provided ?
Yes/No
PULVERISED COAL BURNERS

Type
Make
9.6.3
Number of Coal burners fed by each

pulveriser
9.6.4
Number of burners per elevation
9.6.5
Number of elevations of burners
9.6.6
Total number of Coal burners
9.6.7
Number of Coal burners in operation

from 20% to 100% Boiler MCR, their
locations and tilt (if applicable)
9.6.8
Design data
a. Temperature of Coal air mixture,
deg.C
b. Maximum allowable temperature
of burners deg.C
c. Turn down ratio
d. Temperature of hot secondary
combustion air, deg.C
e. Capacity of each burner at
i) 100% Boiler MCR
ii) 92.2% Boiler MCR
iii) Maximum
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[48]
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S.No
Detail
[Logo of Utility]
Description
f. Type of combustion air entry

g. Pressure drop in the Coal burner,
mmWC
h. Velocity of Coal air mixture at
entry to burner m/s
i. Log mean density of Coal air
mixture
j. Critical Coal air fall outvelocity and
corresponding load
k. Velocity of secondary air at entry
to burner, m/se
l. If burner tilt offered in degrees
m. Number & type of burner tilt
drives (if applicable)
n. Percentage of excess air
the burner
9.6.9
at
a. Angle of fuel entry (fixed/
variable)
b. Cooling device (while in
operation/idle)
c. Provision of measurement of
burner metal tip temperature
d. Mode of adjustment of
combustion air
9.6.10
a. Coal burner nozzle
b. Guide plates
c. Drive liner
d. Connecting liner
e. Air damper
f. Support bearing inside wind box
g. Connecting bar
h. Level
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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S.No
9.6.11
9.6.12
9.7
Detail
[Logo of Utility]
Description
Whether the following accessories provided

a. Drive for tilting Coal burners?
Yes/No
b. Flexible connection between Coal

pipe and burner?
Yes/No
c. Position indicator for all dampers?
Yes/No
d. Limit switches?
Yes/No
e. Drive for air damper?
Yes/No
Codes and Standards applicable?
Yes/No
Fuel Bunkers
(Applicable for CFBC Boiler)
for bunker design
e) Min valley angle
Fuel Feeding Equipment
Raw Coal bunker shut off gates
a. Manufacturer
b. Type & Number
d. Motor rating
ii) At 100% T MCR
100% MCR)
(ie. turbine

j. Type of drive
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[50]
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Power Plant]
S.No
9.8
Detail
[Logo of Utility]
Description
Sorbent Bunkers
(Applicable for CFBC Boiler)
for bunker design
e) Min valley angle
Sorbent Feeding Equipment
Sorbent unker shut off gates
a. Manufacturer
b. Type & Number
d. Motor rating
ii) At 100% T MCR
100% MCR)
(ie. turbine

j. Type of drive
10.0
CYCLONES (Applicable to CFBC

Boiler)
i) Number of Cyclones
ii) Type of Cyclones
iii) Method of Cooling( Water
Cooled / Steam Cooled)
iv) Inlet gas velocity, m/s
v) Concentration of solids at the
inlet, kg/m3
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
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S.No
Detail
[Logo of Utility]
Description
vi) Particle Size Range

[to ] m
vii) Pressure drop, mmwc
11.0
Loop Seal
(Applicable to CFBC Boiler)
i) Type of Loop Seal
ii) Arrangement of fuel feeding
iii) Arrangement
feeding
of
sorbent
iv) Number of Blowers

v) Capacity of Blowers, m3/s
vi) Discharge
Pressure
Blowers, mmwc
12.0
of
External Fluidized Bed Heat

Exchanger (EFBHE)
i) Material of Heat Exchanger
tubes
ii) Surface
Area
of
Exchanger tubes;m2
iii)
Arrangement
feeding
Heat
of
fuel
iv)
Arrangement of sorbent
feeding
v)
Number of Blowers
vi)
Capacity of Blowers; m/s
vii)
Discharge Pressure
Blowers; mmwc
13.0
of
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[52]
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S.No
Detail
[Logo of Utility]
Description
i)
13.1
Type of Bottom Ash Removal

System
ii) Method of
removal of
oversized particles
iii) Combustor Bed height as per
design
iv) Combustor Bed Pressure
drop as per design
i) Type of Cooling System
Provided
ii) Method of Cooling (Water
Cooled/Air Cooled)
iii) Temperature of Cooled Ash
14.0
ELECTROSTATIC PRECIPITATOR WITH AUXILIARIES
14.1
ESP Equipment Data
14.1.1
14.1.2
Manufacturer
Type
14.1.3
No. of ESPs per Boiler
14.1.4
Dimensions (associated with one

ESP)
a) Width (across gas flow) (mm)
b) Flange to Flange length (In
direction of gas flow) (m)
c) Height between bottom of
hoppers to support level (m)
d) Gap between two ESP casings
14.1.5
14.1.6
14.1.7
14.1.8
Number of ESP casing per boiler

Number of gas path per ESP
Number of electrical fields in series
in each gas path
Maximum bus voltage (KV)
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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S.No
14.1.9
14.1.10
14.1.11
Detail
Description
Average bus voltage (KV)

Maximum available corons power
per 100 Sq.m. surface, watts
Installed Power, kW
14.1.12
Proposal Standard for conducting

the performance tests
14.1.13
Aspect ratio
14.2
14.2.1
[Logo of Utility]
Design
Coal fired
Worst
Inlet dust concentration (g/NCu.m)

a) at 100% BMCR
b) at 60% BMCR
14.2.3
Outlet dust concentration with one

series field out of operation
(mg/NCu. m)
a) at 100% BMCR
b) at 60% BMCR
14.2.4
Outlet dust concentration with two

series field out of operation
(mg/NCu. m)
a) at 100% BMCR
b) at 60% BMCR
14.2.5
Collection efficiency with one field

out of service (%)
14.2.6
Collection efficiency with two series

fields out of service (%)
14.2.7
Collection efficiency with three

series fields out of service (%)
14.2.8
Total Design gas flow rate,

Cu.m/Sec.
a)
at 100% BMCR
b)
at 60% BMCR
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
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S.No
Detail
Description
14.2.9
Design gas flow rate through each

ESP casing at 100% BMCR,
cu.m/sec.
14.2.10
Gas temperature drop across ESP
14.2.11
Pressure drop across the ESP,

mmwc
14.2.12
Specific collecting area, Sq.

m/NCu.m /Sec. of flue gas
14.2.13
[Logo of Utility]
Total effective collection area, Sq.m

a)
With n fields
b)
With n 1 fields
Where n is the total no. of fields

14.2.14
Gas velocity inside ESP, m/sec

a) at 100% BMCR
b) At 60% BMCR
14.2.15
14.2.16
14.2.17
Treatment time, seconds

Design flue gas temperature, Deg.C
Ash collection rate
a)
First row
b)
Second row
c)
Third row
d)
Fourth row
e)
Fifth row
f)
Sixth row
g)
..........
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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S.No
14.3
14.3.1
14.3.2
14.3.3
14.3.4
14.3.5
14.3.6
14.3.7
14.4
14.4.1
Detail
[Logo of Utility]
Description
Precipitator casing
Material
Plate thickness
Design pressure (mm WC)
Design temperature (C)
Maximum temperature withstanding
capacity and duration
Number of inspection doors per
precipitator casing
Dimensions of access opening of
inspection doors (mm x mm)
Gas Distribution System
Method of ensuring gas distribution
i) Inlet
a. Type
b. Quantity per ESP pass
c. Total for ESPs of one boiler
d. Location
e. Material used and thickness (mm)
ii)
Outlet
a. Type
b. Quantity per ESP pass
c. Total for ESPs of one boiler
d. Location
e. Material used and thickness (mm)
14.4.2
14.4.3
Free area per gas screen m
Details of rapping gear for

distribution plates
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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[56]
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S.No
14.4.4
Detail
[Logo of Utility]
Description
Motor for rapping gas distribution

system
a) Nos. provided per ESP pass
b)Type
c) Rating, kW
d) Location
14.5
14.5.1
14.5.2
14.5.3
14.5.4
14.5.5
14.5.6
14.5.7
14.5.8
14.5.9
14.5.10
14.5.11
14.5.12
Discharge (Emitting) Electrodes

Type
Material of the electrode
Material of the frame
Configuration
Diameter
Spacing of electrodes in the
direction of gas flow
No. of electrodes in each field
No. of electrodes per ESP pass
No. of electrodes in ESPs of one
boiler
Height in contact with the gas
Total assembled electrode frame
height
Maximum available corona power
per Linear meter of electrodes, watts
a) First field
b) Second Field
c) Third field
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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S.No
Detail
[Logo of Utility]
Description
d) Fourth field
e) Fifth field
f) Sixth field
g)
h) .
14.6
14.6.1
14.6.2
Collecting Electrodes
Material & Type
Size of electrodes
a) Width
b) Height
c) Thickness
14.6.3
Type of construction
14.6.4
Distance between collecting

electrodes across gas path, mm
14.6.5
Number of collecting electrodes per

ESP casing
14.6.6
14.6.7
14.6.8
14.6.9
14.6.10
No. of electrodes in each field

No. of electrodes per ESP pass
No. of electrodes in ESPs of one
boiler
Effective collection surface area per
electrode (Sq.m)
Method of interconnection of plates
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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S.No
14.6.11
14.6.12
Detail
[Logo of Utility]
Description
Method of suspension
Maximum available corona power
per Sq.m. of effective collecting
surface, watts
a) First field
b) Second Field
c) Third field
d) Fourth field
e) Fifth field
f) Sixth field
g)
h)
14.7
14.7.1
14.7.2
14.7.3
14.7.4
14.7.5
14.7.6
Rapping Mechanism
Discharge Electrode
Collecting Electrode
Type of rappers, whether PLC

Operated?
Rapper size
Frequency of rapping
Drive
Location
Number of rappers
14.7.7
Location of drive (top/side)
14.7.8
Number of hammers per shaft
14.7.9
Location of rapping points
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

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[59]
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S.No
Detail
14.7.10
a) Maximum effective electrode

length and its percentage rapped
at any time (m,%)
[Logo of Utility]
Description
b) Number of plates rapped per

rapper
14.7.11
Rapper controller
a) Type
b) Method of frequency control
c) Method of intensity control
14.7.12
14.7.13
14.7.14
14.7.15
Nominal time interval between raps

(minutes)
Time of single rapping cycle
Accessibility/Location
Motors for rappers
a) Nos. provided per ESP pass
b) Type
c) Rating, kW
d) Location
14.7.16
Nominal time intervals between

raps, minutes
a) First field
b) Second Field
c) Third field
d) Fourth field
e) Fifth field
f) Sixth field
g)
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[60]
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S.No
Detail
[Logo of Utility]
Description
h) .
14.8
14.8.1
14.8.2
14.8.3
14.8.4
Insulators
Type
Material
Creepage distance
Number of insulators per T/R set
14.8.5
Minimum flashover voltage (Kv)
14.8.6
Heating arrangement for Insulators

provided?
14.8.7
14.9
14.9.1
Reference drawing number

Transformer Rectifier Sets
General
a) Type
b) Manufacturer
c) Rating (KVA)
d) Number per field per gas stream
e) Number per ESP
f) Number of bus sections per field
per gas stream
g) Total number provided per boiler
h) T/R control panel dimension (mm)
i) Method of cooling and type of
cooling
j) Overall size (maximum)
k) Average amperes per set (mA)
l) Peak voltage available (KV)
m) Output current (mA)
n) Expected power required per
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[61]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
stream (KW)
o) Efficiency of T/R set
14.9.2
Transformers
a)
Type
b)
Rating of each set
i) Output voltage (KV)

ii) Output current (mA)
iii) Number of primary taps supplied
iv) Tap voltage (volts)
c) Transformation ratio
d) Class of insulation
e) Volume of oil (litres)
f) Temperature rise over ambient
14.9.3
Rectifiers
a)
Type & Rating, kW
b)
Number per T/R set
c)
Number per boiler
d) Half wave/full wave rectification

e) Rated current output of each
rectifier set, mA
f) Rated voltage output of each
rectifier set, kV
14.9.4
Type of voltage control device

a)
Type of current limiting
device
b)
Type of voltage limiting
device
c)
Power supply
d) No. of control cabinets per boiler

e)
Rating of each unit
14.10
ESP Dust Hoppers
1410.1
No. of hoppers per ESP
14.10.2
No. of hoppers per boiler
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[62]
15.01.2016
Power Plant]
S.No
Detail
Description
14.10.3
Type and Material
14.10.4
Plate thickness (mm)
14.10.5
Valley angle (degrees)
14.10.6
Storage capacity of each hopper

(hrs)
14.10.7
Volumetric storage capacity of each

hopper (Cu.M)
14.10.8
No. of access doors per hopper,

dimension
14.10.9
Height of the hopper bottom flange

above the ground level (metres)
14.10.10
14.10.11
[Logo of Utility]
Size of hopper outlet flanges

Hopper heating
a) Type
b)
Control temperature, (C)
c)
Rating (kW / hopper)
d) No. of heating element per

boiler
e)
Location
f)
Thermostat setting for
tripping
g)
14.10.12
14.11
14.11.1
14.11.2
14.11.3
14.11.4
Name of manufacturer
Hopper vibrating arrangement

provided?
ESP INSULATION AND CLADDING
List of areas to be insulated per
casings of precipitators, (Sq.m)
Insulating Material
Insulating material standard
Thickness (mm)
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[63]
15.01.2016
Power Plant]
S.No
14.11.5
14.11.6
14.11.7
Detail
[Logo of Utility]
Description
Density (Kg/Cu.m)
Cladding material
Cladding thickness, mm
15.0
FUEL OIL UNLOADING, PREPARATION & FIRING EQUIPMENT
15.1
Storage tank
HFO System
LDO System
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[64]
15.01.2016
a) Type of tank
b) Capacity of each tank
c) Quantity
d) Applicable code for design
e) MOC
f) Dimension, dia and height
g) Shell plate thickness,
h) Roof plate thickness
i) Details of accessories Pipes and
fittings
a) Size
b) Standard Valves
Valve
a) Types of valves
b) Make
c) Type of end connection
d) MOC
e) Material for gasket
f) Motor operated valves
Flexible hoses
a) Type of hose
b) Make of hose
c) Std/Code
d) Size
- nominal bore
- length
Document Number
LII-GETS12021-G-00129-001
Power Plant]
S.No
Detail
[Logo of Utility]
Description
e) material
f) Type of end fittings
g) Pressure rating
h) material specification
Oil filter
a) Type and make
b) Mesh size
c) End connections
d) Flow rate max
e) Pressure drop
f) Hydraulic test pressure
g) Design code
h) Area of filteration gross/net i)
m2
i) Material specification
- filter housing
- filter media
- sealing material
Unloading and delivery of oil pumps
a) Type and make
b) Capacity
c) Head
d) KW rating of motor
e) Suction and discharge
connection
f) Bearing external/internal
g) Material of major parts
Weight of various equipments
a) Bulk oil storage tank
b) Unloading and discharge pump
c) Piping /valves etc.
d) Ladders/Platforms etc.
15.2
15.2.1
Oil Firing pumps

Manufacturer
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[65]
15.01.2016
Power Plant]
S.No
15.2.2
15.2.3
Detail
[Logo of Utility]
Description
Type
Number of pumps
15.2.4
Number of pumps in standby/

service
15.2.5
Liquid data
a. Liquid handled
b. Minimum temperature of
the pumps can handle, C
oil
c. Specific gravity at above

temperature
d. Maximum viscosity of the oil
pump can handle, centistokes
e) Oil temperature and viscosity
considered for selection of pump
capacity, C and centistokes
f) Oil temperature and viscosity
considered for selection of motor
rating C & centistokes
15.2.6
Rated capacity per pump, M3/hr
15.2.7
Discharge pressure at rated

capacity, Kg/cm2g
15.2.8
Rated speed of the pump, rpm
15.2.9
Efficiency at rated capacity, %
15.2.10
Rated temperature and viscosity

considered for selection of motor
rating, deg.C & centistokes
15.2.11
Relief valve set pressure, Kg/cm2g
15.2.12
Maximum pressure pumps can

develop, Kg/cm2g
15.2.13
Pump BHP/KW at rated capacity

and total head
15.2.14
Pump BHP/KW at relief valve setting
15.2.15
Drive motor rating and speed, KW &

RPM
15.2.16
Type of coupling
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[66]
15.01.2016
Power Plant]
S.No
15.2.17
15.2.18
15.2.19
15.3
Detail
[Logo of Utility]
Description
a.
Electric tracing jackets
b.
Stuffing box
c.
Mechanical seal
d.
Built in relief valve
Yes/No
Yes/No
e.
Relief valve set pressure

adjustable?
Yes/No
Yes/No
f.
Common base plate for pump &

motor
Yes/No
Yes/No
g.
Drain rim
Yes/No
Yes/No
h.
Foundation bolts
Yes/No
Yes/No
i.
Coupling guard
Yes/No
Yes/No
a.
Casing
b.
Rotor
c.
Shaft
d.
Shaft sleeves
e.
Base plate
f.
Wearing rings (if reqd.)
g.
Bearing
h.
Type of gland seal provided
Codes and Standards applicable

Heavy Fuel Oil Heaters
15.3.1
Manufacturer
15.3.2
Type
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[67]
15.01.2016
Power Plant]
S.No
Detail
15.3.3
Total number
15.3.4
Numbers standby
15.3.5
Fluid on
15.3.6
a.
Tube side
b.
Shell side
[Logo of Utility]
Description
Design data
a.
T/hr
Capacity of each heater,
b.
Normal steam consumption per

heater, T/hr
c.
Inlet temperature deg.C
d.
Outlet temperature, deg.C
e.
Operating pressure,
2
Kg/cm g
2
Design pressure, Kg/cm g
f.
g.
Hydraulic test pressure,

2
Kg/cm g
h.
Fluid velocity, M/sec
i.
Maximum allowable pressure

2
drop, Kg/cm
j.
Heat transfer surface area (M2)
k.
15.3.7
Fouling resistance
Construction Features
a.
Number of tubes
b.
Number of passes per
heater
c.
Tube outside diameter, mm
d.
Tube thickness, mm
e.
Tube length, mm
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[68]
15.01.2016
Power Plant]
S.No
15.3.8
Detail
[Logo of Utility]
Description
f.
Tube pitch, mm
g.
Inner diameter of shell, mm
h.
Outer diameter of shell, mm
a.
Shell/shell cover
b.
Flanges for shell & shell cover;

channel & channel cover
c.
Nozzles on shell & channel
d.
Flanges for above nozzles
e.
Tubes
f.
Tube sheets-stationary/ floating
g.
Floating head (cover/

cover flange/backing ring/
gland & packing)
h.
Baffles
i.
Support plates
j.
Pass partition plates
k.
Impingement plate
l.
Tie rods
m.
Spacers
n.
Bolting for fixed and floating

tube sheet joints
o. Bolting for all other shell and

tube side joints
p.
Gaskets for shell & channel

covers
q.
Gaskets in between tube sheet

and shell/channel
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[69]
15.01.2016
Power Plant]
S.No
Detail
r.
15.3.9
15.4
15.4.1
15.4.2
15.4.3
15.4.4
15.4.5
[Logo of Utility]
Description
Saddle supports/brackets
Codes and standards applicable

HFO/
Pumps
suction
Oil Strainers
HFO/
Pumps
discharge
LDO
Pump
suction
Others (if
any)
Manufacturer
Type
Number provided
Number in standby service
Mesh size
15.4.6
Ratio of straining area to inlet area
15.4.7
Maximum pressure drop at rated

flow in Kg/Cm2 with
a. 100% cleanliness
b. 75% cleanliness
15.4.8
15.4.9
Whether Steam/ Electric tracing of

jackets provided or not?
a. Body
b. Basket
15.4.10
End connection (flanged/ welded

/screwed)
15.4.11
Codes and standards applicable
15.5
Oil-Burners
15.5.1
Manufacturer
15.5.2
15.5.3
HFO/ Burners
LDO Burners
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[70]
15.01.2016
Type
Design data
a. Number of oil burners per boiler
b. Elevation of boiler burners (if
applicable)
Document Number
LII-GETS12021-G-00129-001
Power Plant]
S.No
Detail
[Logo of Utility]
Description
c. Number of burners per elevation

(if applicable)
d. Atomising medium
e. Scavenging medium
f. Duration of scavenging
g. Parameters of scavenging
medium
h. Temperature of oil at burner inlet,
deg.C
i. Atomising steam parameters
- Maximum flow rate, Kg/hr
- Maximum / minimum steam
pressure range required for
atomising, Kg/cm2g
j. Atomising air parameters
- Maximum flow rate, NM3/hr
- Maximum / minimum pressure
range required for atomization,
Kg/cm2g
k. Maximum / minimum oil pressure
range required at burners,
Kg/cm2g
l. Turndown ratio
m. Oil viscosity before the burners,
centistokes
n. Combustion air temperature
deg.C
o. Capacity of each burner Kg/hr
p. Percent Boiler MCR capacity
that can be carried by
i. All the burners
ii. One single burner
15.5.4
a. Angle of fuel oil entry
(fixed/variable)
b. Mode of adjustment of
combustion air
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[71]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
c. Type of diffuser
d. Type of cooling/sealing device
e.
15.5.5
a.
15.5.6
Type of drive for each oil burner

for inser
Oil burner mixing plate/ spray

plate
b.
Guard pipe
c.
Diffuser
d.
Concentric tubes
e.
Clamp
f.
Gaskets
g.
Flexible tubing
h.
Burner body
i.
Burner tip
Whether the following accessories

provided
a.
Limit switches
Yes/No
Yes/No
b.
Clamps
Yes/No
Yes/No
c.
Gaskets
Yes/No
Yes/No
d.
Flexible hose
Yes/No
Yes/No
e.
Insertion, retract facility
Yes/No
Yes/No
f.
Position indicators
Yes/No
Yes/No
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[72]
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Power Plant]
S.No
15.5.7
15.6
15.6.1
15.6.2
15.6.3
15.6.4
15.6.5
15.6.6
15.6.7
Detail
[Logo of Utility]
Description
Codes and Standards applicable

Oil Ignition System
Manufacturer
Type (high energy arc igniters)
Number of igniters
Number of spare igniters
Heat input per igniter, Kcal/hr
Retractable or stationary?
If high energy arc igniters are
offered then following data shall be
furnished
a) Whether suitable for firing both
HFO/ and LDO?
Yes/No
b) Electrode material
c) Expected life of electrodes
d) Experience list of bidder for
similar igniters furnished?
Yes/No
16.0
INSTRUMENTATION & CONTROL
16.1
Whether following systems

provided?
a)
Burner Management System
Yes/No
b) Furnace Protection System

including Master Fuel Trip
Yes/No
c)
Yes/No
Safety Shut down System
17.0
AC MOTORS
17.1
Provide the following Details

a)
Number of HT Motors and

their locations
b) Number of LT Motors and their

locations
18.0
DC MOTORS
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[73]
15.01.2016
Power Plant]
S.No
Detail
Description
18.1
Provide the details of DC Motors

and their locations
19.0
19.1
Bottom ash hopper

a)
[Logo of Utility]
No. provided per boiler
b) Storage capacity up to operating

level, tonne of dry ash
c)
Type and make of refractory
d)
Thickness of refractory
e) Material & thickness of hopper

plate
f)
No. of outlets per hopper
g) Quenching nozzles, seal trough

make up, overflow, etc.
provided?
h)
19.2
Type of hopper gate
i)
Material of construction of
hopper gate
j)
Method of actuation of gate

(manual / hydraulic / motor
operated)?
k)
Necessary access doors,

platforms, walkways, ladders/
stairs provided or not?
Scraper Chain Conveyor

a)
No. provided per boiler
b)
Make & Model Number
c)
Guaranteed capacity, t/hr of dry

bottom ash
d)
Capacity of slag Bath, Cu.m
e)
Rating of drive motor
f)
Material of construction
- Slag Bath
- Slag bath liner
- Scraper Bars
- Scraper chains
- Scraper sprockets
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[74]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
g) Quantity of cooling water per

boiler
h) Rails, rails for clamp fixing, etc.
provided for each conveyor?
20.0
Insulation
20.1
Insulating materials
20.1.1
Type of insulating material(s)
20.1.2
Manufacturer's name
20.1.3
Maximum temp(deg.C) the

insulating materials can withstand
20.1.4
Insulating materials standard
20.1.5
Density of insulating materials

(Kg/M3)
20.1.6
Thermal conductivity (Kcal/M/hr C)

at mean temperature of
a.
50C
b.
100C
c. 150C
d.
200C
e.
250C
f.
300C
g.
350C
h.
400C
20.1.7
Resistance to micro-organism
Yes/No
20.1.8
Incombustibility
Yes/No
20.2
Provide the following Details

- Block mineral fiber mattresses,
mm/Qty
- Pourable insulation, mm/Qty
- Segmented Blocked calcium
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[75]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
silicate, mm/Qty
- Cement, mm/Qty
- GI sheet jacket, mm/Qty
- Others(specify details), mm/Qty
20.2.1
Furnace extended side backpass

walls
20.2.2
Enclosure
a.
Roof
i) Horizontal
ii) Vertical
b.
Extended side
i) Horizontal
ii) Vertical
c.
Bottom
i) Horizontal
ii) Vertical
20.2.3
21.0
Any other (give details) area

including auxiliaries and ducting etc.
EQUIPMENT DIMENSIONS AND WEIGHTS
Dimensions
21.1
21.2
21.3
21.4
Supporting structure
Galleries and stairways
Interconnecting platforms
Steam drum
21.5
Manholes/Peepholes, inspection
windows etc.
21.6
Water walls
21.7
Superheater
21.8
21.9
Weight (Tonnes)
Reheater
Desuperheaters
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[76]
15.01.2016
Power Plant]
S.No
Detail
21.10
Economiser, Downcomers, supplies

and raisers etc.
21.11
Valves & fittings
21.12
Air Preheater
21.12.1
21.12.2
Description
Air heater with drive

SCAPH
21.13
Fabricated components for Main

steam generator under sheet casing
21.14
Firing & insulation material for steam

generator & other equipment
21.15
Steam generator casing
21.16
Fabricated components for

insulation of Steam Generator
equipment
21.17
Skin casing
21.18
Integral HFO & LDO lines
21.19
Fuel oil preheating unit
21.20
HFO & LDO pumps with drives with

decanting pumps
21.21
HFO & LDO burners
21.22
Ignitor/scanner air system
21.23
Coal burners
21.24
Coal piping
21.25
Cold air ducts
21.26
Hot air ducts
21.27
Flue ducts
21.28
Other ducting
21.29
21.30
21.31
21.32
[Logo of Utility]
Soot blowers with drives

Soot blowing equipment
Pulverisers with drives
Pulveriser group piping
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[77]
15.01.2016
Power Plant]
S.No
21.33
21.34
21.35
21.36
21.37
Detail
Description

insulation of milling system
Insulation of milling system
FD Fans with drives
ID fans with drives
Other fans with drives
21.39
Coal feeders with drives
21.40
Fan duct
21.41
[Logo of Utility]
Platforms and rails
21.42
Supporting structure for fuel gas

system
21.43
Dampers/vanes with actuators
21.44

insulation of flue gas system
21.45
High pressure piping, valves &

fittings, auxiliaries & accessories
e.g. main steam, CRH, HRH lines,
etc.)
21.46
Insulation and cladding for high

pressure piping
21.47
ESPs with electrics
21.48
Support structures for ESPs

including platforms, interconnecting
galleries,
walkways, etc.
21.49
Insulation and cladding for ESPs
21.50
Auxiliary boiler with accessories and

auxiliaries
21.51
Compressors with drives
21.52
Air receivers, Air drying units for

compressed air
21.53
Compressed air piping, headers,

supports, etc.
21.54
AC and ventilation system
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[78]
15.01.2016
Power Plant]
S.No
Detail
Description
21.55
HP Dosing System
21.56
Bottom ash handling system

including ABG, scraper chain
conveyor
21.57
[Logo of Utility]
Other (list down items)
21.58
Total weight of the package
22.0
Furnishing of Additional Data
22.1
Performance Data
(No. of Reference Drg./
Leaflet/Write-up)
22.1.1
Boiler efficiency Vs load
22.1.2
Characteristic curves showing the

variation of superheated and
reheated steam temperature with
load clearly indicating the regime of
attemperation.
22.1.3
Characteristic curves of Steam

Generating unit showing variations
in efficiency, steam temperature and
pressure with loads, for Coal firing
22.1.4
Correction curves for Steam

Generator efficiency for variation in
parameters such as
a) Load
b) Superheater outlet pressure
c) Superheater outlet temperature
d) Feed water inlet temperature
e) Excess air
f) Humidity
g) With variation in Coal quality
parameters from those stated in
Annexure-I
h) Flue gas temperature at air
heater outlet
i) Ambient air temperature
22.1.5
FD fan blade angle lines; stall lines;

equal efficiency lines; and system
resistance lines with all fans in
service & with one FD fan out, both
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[79]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
at 50 Hz. and 47.5 hz respectively

showing BMCR and test block
points for both one fan and two fan
operation
22.1.6
ID fan blade angle lines; stall lines

equal efficiency lines; and system
resistance lines for all ID fans and
Electrostatic Precipitator sections in
service and also with one ID fan and
one Electrostatic Precipitator section
out of service both at 50 Hz and
47.5 respectively showing the
BMCR and test block points, for
both one fan and two fan operation.
22.1.7
Characteristic Curves for the

plant
mill
a.
Variation of Pulveriser capacity

with moisture content in raw
Coal
b.
Variation in fineness of
Pulverised Coal with moisture
content in raw Coal
c.
Variation in quantity and

temperature of Flue required
with moisture content in raw
Coal
d. Relation between Pulveriser

output and hard grove
grindability index of Coal
e. Energy consumption per tonne of
through put of Pulveriser for
varying Pulveriser output
22.1.8
Characteristic curves of the HFO &

LDO pressuring pumps
22.1.9
HFO &LDO burners output

characteristics
22.1.10
For ESPs
a)
Gas flow rate vs. efficiency
b)
Gas temperature vs.
efficiency
c)
Inlet dust concentration vs.
efficiency
d) Gas flow rate Vs pressure drop
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[80]
15.01.2016
Power Plant]
S.No
Detail
22.1.11
Characteristic curves showing the

acid & dew point temperature Vs.
sulphur content, moisture content in
the Coal and percentage of excess
air
22.1.12
Characteristic curves of the SH

Spray attemperator
22.2
22.2.1
[Logo of Utility]
Description
Supplementary Data
Complete list of all the equipment
requiring the following shall be
furnished indicating parameters,
continuous requirement and the
maximum requirement
a) Auxiliary steam
b) Cooling water
c) Service air
d) Instrument air
e) Number and electrical rating of
AC and DC power supply feeders at
available voltage for control
instrumentation system
22.2.2
Detailed list of Main Steam

Generator auxiliaries with the
respective continuous power
consumption (in KW) of each
auxiliary
22.2.3
Complete schedule of motors giving

voltage, phase, KW rating
(calculated and installed capacity)
service factor etc.
22.2.4
Complete valve schedule giving

design conditions, normal working
conditions, pressure drop across
valves, type, body/trim material
pressure and temperature rating,
make, size etc
22.2.5
Pressure Parts
a.
Details of Furnace construction
b.
Details of Steam Drum
c.
Details of Economiser,
superheater and reheater
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[81]
15.01.2016
Power Plant]
S.No
22.2.6
Detail
[Logo of Utility]
Description
d.
Details of Pressure vessels
e.
Details of Safety valves
f.
Items, a,b,c shall also include

tube sizes, materials, quantities
and spacing
Recommended mode of erection,

erection sequence and other
relevant particulars in respect of
installation of
a.
Structural steel
b.
Pressure parts
c.
Rotating and static
equipment
d.
Ducting
e.
Steam drum
f.
Others, as applicable
22.2.7
Detailed recommended procedures

for welding and erection
22.2.8
Complete Fuel firing equipment

description
22.2.9
Complete description and functional

writeup of the Burner
Management system / FSSS
including Pulveriser automation and
combustion air control and general
arrangement and cutout details of
console inserts with bill of materials.
22.2.10
General Arrangement and writeup

on Rotary Air heaters giving details
of lubrication system and
instrumentation
22.2.11
Soot blowing system description

complete
with Control system
write-up, console Mimic diagram
,logic panel general arrangement
and cut out drawings
22.2.12
Write-up on general description of

Flue ducts and dampers
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[82]
15.01.2016
Power Plant]
S.No
Detail
22.2.13
Recommended Functional block

diagrams with write-ups for each
Control loop required for safe and
efficient Steam Generator operation
22.2.14
A complete list of local instruments,

sensing devices and control
equipment covered in the proposal
with type, make, accuracy, range,
connection sizes, contact details,
dial size etc. in the Bidder's scope.
22.2.15
Write-up on interlocks and

protection other than BMS/FSSS
with logic diagrams
22.2.16
22.2.17
[Logo of Utility]
Description
Startup and shut down procedures

Startup diagrams showing the
following plotted vs. time from
ignition of first ignitor to BMCR
a. Ignitor fuel input
b. Main fuel input
c. Drum pressure
d. Feed water flow
e. Steam flow through Super-heater
f. Primary Superheater outlet
temperature
g. Superheater attemperator spray
water flow
h. Final Superheater outlet
temperature
i. Steam flow through Reheater
j. Reheater outlet temperature
k. If burner tilt offered
22.2.18
Limiting conditions if any for Quick

starting and loading
a) Write up on the boiler variable
and constant pressure operations
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[83]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
b) Detailed write-up with supporting

technical literature on the method
proposed to limit NOx emission
c) Complete list of mill wear parts
with materials and anticipated life
of each part
d) For ESP
i) Schedule of power consumption
for all gas streams connected to
one boiler
ii) List of annunciations giving
suggested set values of
parameters
iii) Write up on ESP internals
iv) Description of T/R sets
v) Write up on interlocks and
protections
vi) Detailed hopper sizing
calculations
vii) Write up on rapping mechanism
e) Write up on control philosophy of
F.O.system along with a list of
annunciation
f) Write up on tracing
g) Write up on control philosophy of
compressed air system
h) Write up on control philosophy of
auxiliary boiler
22.2.19
a. Schedule of valves with full

particulars of valves with actuators
(for powered valves) such as type,
make motor rating, pneumatic
consumption, limit & torque switch
details, time for full
opening/closing etc.
b. Schedule of control valves
giving type and make of valves
and actuators, size body & trim
material etc. stroking time and full
technical particulars of valves and
their actuators and associated
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[84]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
accessories
c. Schedule of Dampers and
vanes with full particulars of
dampers and their actuators (for
powered dampers) such as type
of Damper & actuator, make,
torque rating, stroke and stroking
time, electrical rating/pneumatic
consumption, limit and torque
switch, position
transmitter details etc. including
details of associated accessories.
22.2.20
List of insert panels, control cabinets

and local control panels included in
the proposal with GA drawings,
mounting and cutout details
22.2.21
List of flow elements covered in the

proposal with full particulars such as
design details, data sheets, make
and dimensions
22.2.22
List of Field mounted junction boxes

included in the proposal
22.2.23
List & details of Instruments and

Control items mounted on control
panels, including details like type,
make, cutout and dimensional
drawings etc.
22.2.24
Instrument and control equipment to

be made available for Light up &
Steam blowing
22.2.25
List of Measuring signals to be fed

to DAS
22.2.26
List of Annunciations giving

suggested set values of parameters
22.2.27
Boiler GA drawings for making

instrument taping points
22.2.28
Particulars of prefabricated & other

special cables included in the steam
generator scope
22.2.29
Electromatic impulse safety valve

functional write-up, type, make & cut
out details of the remote control
station
22.2.30
Boiler tube metal thermocouples
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[85]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
details, number, type, make etc.

23.0
DRAWINGS AND EQUIPMENT LOADING DATA
23.1
Steam Generator
a.
Plan of Steam Generator and its

auxiliaries at ground floor level;
at lowest burner level; drum
level; and at an intermediate
level (preferably at the long
retractable soot blower level),
indicating the galleries,
platforms and stairways.
b.
Front elevation; side elevation

and cross section of the Steam
Generating unit showing
location of headers and drums,
manholes etc.
c.
Layout of Steam Generator

structural steel columns upto
Stack. These shall indicate the
size of members and main
dimensions, with design
loadings and all lifting facilities
for purposes of maintenance
d.
Layout of interconnecting
platforms
e.
Preliminary layout of air and gas

ducts showing damper location,
manholes, expansion joints,
supports etc.
f.
Drawing for fully gas tight

dampers clearly indicating how
sealing is effected and the gas
tightness efficiency (on flow)
g.
General arrangement drawings

of the pulverised Coal
preparation and firing equipment
including locations of various
dampers
h.
Schematic drawings of the

fuel/oil preparation and firing
equipment
i.
General arrangement drawings

showing arrangement of FD,ID
fans, air heaters, Coal
pulverisers, ducting
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[86]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
arrangement between the Boiler

and the Electrostatic Precipitator
inlet cone and Precipitator outlet
cone to stack with dimensions
and weight
j.
Schematic diagram indicating

terminal points and
Instrumentation and Controls
included in Bidder's scope and
suggested for following circuits
clearly indicating pipe duct size
(OD's and ID's) operating
parameters; maximum fluid
velocities; insulation thickness;
and material specifications of
MS,CRH, HRH, Steam
Generator feed and fuel oil
piping, type of actuators
i) Steam flow
ii) Feed water flow
iii) Blow down
iv) Vents and drains
v) Air, fuel and flue gas
vi) Pulveriser system
vii) HFO/ & LDO system in the boiler
area and burner system.
viii) HFO heating and HFO/ &LDO
pressurising system
ix) lubrication systems of fans/ fan
motors and any other equipment
x) Rotary air heaters
xi) Soot blower piping arrangement
xii) Auxiliary steam system
xiii) Cooling water
xiv) Service Air
xv) Instrument air
k.
Drawings of Drum with

preliminary dimensions and
indicating stubs, locations and
details for local and remote
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[87]
15.01.2016
Power Plant]
S.No
Detail
[Logo of Utility]
Description
instruments and controls.

l. Scheme drawing of Chemical
Dosing
m. Necessary erection drawings for
all equipment, piping, systems,
sub systems etc.
23.2
23.3
Boiler Duct Supporting Columns

a.
Location plan Details of location

and arrangement scheme of
columns, embedments and
fixing details, sizes of pedestals,
levels, blockouts and anchor
bolts and channels indicating
scope of supply by equipment
supplier.
b.
Loading on foundations Axial

load, bending moments and
shear forces transmitted to
foundations
c.
Complete bracing arrangement

for Boiler supporting structure
and combinations of (+ve) and
(-ve) forces for the seismic or
wind (whichever is governing).
*Foundation and loading details of

ID, & FD Fans and their drives
Including Lube Oil system
a.
Location plan, dimensions and

levels of foundation, pedestal,
giving details of blockouts,
inserts & embedments etc.
b.
Fixing details of motor & fan
c.
Details of fan giving weight of

fan, weight of rotating parts,
GD2 max. unbalanced force,
speed of fan etc.
d.
Complete loading data at

various points of fan foundation
e.
Loading details of the Motors

giving total weight of motor;
weight of stator ; weight of rotor;
GD2 of rotating parts; short
circuit Torque; motor speed and
its rating etc.
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[88]
15.01.2016
Power Plant]
S.No
Detail
23.4
*Foundation and Loading Details of

Pulveriser including lube oil system
a.
[Logo of Utility]
Description
Location plan dimensions and

levels of foundation pedestal
giving details of blockouts,
inserts & embedments etc.
b. Fixing details of Pulveriser &

motor
c. Details of Pulveriser giving total
weight and its speed
d.
Details of Pulveriser motor

giving total weight of motor,
weight
of stator, weight of
rotor, GD2, short circuit torque,
speed and rating.
e. Pulveriser handling arrangement

drawings
f. Details and loading of monorail in
Pulveriser bay, if any
g. Loading, level & arrangement
details for Pulveriser
maintenance platform.
23.5
Coal Feeder
Location, size, loading
(static+dynamic) and fixing
arrangement with floor and floor
cutouts.
23.6
Fuel Piping
Layout and location of supports,
loading at support points.
23.7
Miscellaneous
a). Arrangement of interconnecting
platforms between Steam
Generator with Power house
and Mill bunker indicating
location in plan, levels, loads
transmitted from these platforms
to Power house structure in the
vertical & horizontal direction
due to dead load & seismic
effects
Document Number
LII-GETS12021-G-00129-001
Rev
No.
Description
Page
No.
Date of Issue
04

Volume-III, Part-A
[89]
15.01.2016

OF

R&M CONTRACTORS

VOLUME-III
PART-B
TECHNICAL SCHEDULES-ELECTRICAL
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Technical Specification For R&M of Unit No. [..] Capacity [..] of [Name
of the Power Plant]
[Logo of Utility]

Volume
Section
Part
Description
Volume-I
---
---
Commercial
Section-I
---
Part-A
Part-B
Part-C
Part-D
---
Part-A
---
Part-B
---
Part-C
---
Part-D
Not Used
Volume-II
Section-II
Volume-III
*****
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02
TECHNICAL DATASHEET FOR R&M WORKS OF

VOLUME-III, PART-B
[i]
25.09.2014
of the Power Plant]
[Logo of Utility]
1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
*****
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[ii]
25.09.2014
of the Power Plant]
[Logo of Utility]

SECTION-I:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Spare Parts
10.
Annexure
SECTION-II: DETAILED TECHNICAL SPECIFICATION

1.
2.
3.
4.
*****
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[iii]
25.09.2014
of the Power Plant]
[Logo of Utility]

1.
2.
3.
*****
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[iv]
25.09.2014
of the Power Plant]
[Logo of Utility]

R&M CONTRACTORS

VOLUME-III, PART-B
TECHNICAL SCHEDULES-ELECTRICAL

OF
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[v]
25.09.2014
of the Power Plant]
[Logo of Utility]
Contents
1
MOTOR ........................................................................................................... 1
MOTOR ACTUATORS ...................................................................................... 10
LT TRANSFORMER (OIL TYPE/DRY TYPE) .......................................................... 11
LT PCC/MCC/DISTRIBUTION BOARD ................................................................. 14
415V NON SEGREGATED PHASE BUS DUCT ...................................................... 20
HV CABLES ................................................................................................... 22
LT POWER & CONTROL CABLES ...................................................................... 26
ILLUMINATION SYSTEM .................................................................................. 30
CABLE CARRIER SYSTEM ................................................................................ 34
10 EARTHING & LIGHTNING PROTECTION SYSTEM ................................................ 35

11 VARIABLE FREQUENCY DRIVE ......................................................................... 36
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[vi]
25.09.2014
of the Power Plant]
MOTOR
SL.
NO.
DESCRIPTION
UNIT
1.
Manufacturer
2.
Type and frame size
3.
Nos. required
4.
Application
5.
Specification & Codes
6.
Capacity for specified climatic conditions [500C]
7.
Location for installation
8.
Type of enclosure & ventilation
9.
10.
Type of duty
11.
No. of phases, frequency & voltage
12.
Permissible variations in
a)
Voltage
b)
Frequency
c)
Combined
13.
[Logo of Utility]
DATA
At rated voltage & frequency
a)
Full load current
b)
Full load speed
c)
No load current
14.
Minimum permissible voltage during starting :
15.
Maximum permissible time at minimum permissible

voltage during running at full load.
16.
Maximum permissible time at 75% of rated voltage

during running at full load.
17.
Whether motor stalls at 70% of rated voltage Efficiency

& power factor.
18.
Stator winding
Type & nos. of terminals Brought out
Resistance between terminals at 20C
Resistance per phase at 20C
Inductance per phase
Capacitance per phase
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[1]
25.09.2014
of the Power Plant]
SL.
NO.
DESCRIPTION
[Logo of Utility]
UNIT
DATA
Starting current as % of full load current

19.
Torque at full load in Kgm.
a)
Break away torque in % of full load torque
b)
Pull up torque in % of full load torque
c)
Pull out torque in % of full load torque
20.
Starting time in sec.
a)
Without mechanism coupled
b)
Mechanism coupled through hydraulic coupling when it

may be presumed that load is transferred to motor shaft
only after attaining almost full speed.
i. with rated voltage
ii. with 80% of rated voltage
iii. with 110% of rated voltage
21.
Starting time in sec. With mechanism coupled through

flexible coupling
a)
with rated voltage
b)
with 80% of rated voltage
c)
with 110% of rated voltage
22.
Safe stall time (hot motor)

i. At rated voltage
ii. At 80% of rated voltage
iii. At 110% of rated voltage
23.
Safe stall time (Cold motor)

i. At rated voltage
24.
Limiting motor temperature to determine safe stall time
25.
Permissible maximum accelerating time (hot motor)

i. At rated voltage
26.
Permissible maximum accelerating time (cold motor)

i. At rated voltage
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[2]
25.09.2014
of the Power Plant]
SL.
NO.
DESCRIPTION
[Logo of Utility]
UNIT
DATA

27.
Class of Insulation And Material
28.
Whether insulation is suitable for 415 V, 6.6kV system
29.
Temperature rise under normal conditions over 500C

ambient temperature
30.
By resistance method --- C over cooling water temp.

for CACW motors.
31.
Degree centigrade over cooling air temp. for CACA

motor.
32.
By Thermometer method
---Degree centigrade
over cooling water temp. for CACW motor.
33.
Degree centigrade over cooling air temp. for CACA

motor.
34.
Method of starting
35.
Permissible starting duty cycles
36.
Stator thermal time constant
37.
Method of cooling (If applicable)
Details of water cooling system

a)
No. of cooler
b)
Water requirement per cooler
c)
Losses removed by cooler
d)
Max. permissible temperature of cooling water at inlet
e)
Max. permissible temperature of cooling water at outlet
f)
Maximum permissible pressure at water outlet
g)
Water pressure drop through the cooler
h)
Temp. of cold air coming out & entering the machine

For permissible cooling water temperature of [31oC]
i)
Temp. rise of air passing through machine at full load.
j)
Air pressure drop through The cooler
k)
Temp. rise of water through cooler
l)
Protection against leakage of water :
m)
Arrangement to ensure the water flow
38.
Bearings
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[3]
25.09.2014
of the Power Plant]
SL.
NO.
DESCRIPTION
[Logo of Utility]
UNIT
a)
Number
b)
Type
c)
Lubrication system
d)
Quantity of lubricant reqd. For both the bearings. Life in

hours at rated speed
:
e)
Recommended lubricant
f)
Bearing end play
g)
Inlet oil pressure
h)
Temp. rise of oil
i)
Max. permissible temp. of bearing :
j)
Max. Permissible temp. of Oil
k)
Permissible running time without forced oil at full load &

full speed
:
39.
Whether bearings are provided with 4 wire, platinum RTD

having100-ohm resistance at 0C for remote temp.
Indication.
DATA
:
:
:
:
a)
Whether bearings are provided with local temperature

indicator having two adjustable contacts rated for 5A at
240V AC or 0.5A at 220V DC.
:
Yes/No
b)
If forced lube oil system provided
c)
Qty of lubricant required for initial filling.
d)
Recommended period after which lubricant should be

replaced
e)
Bearing cooling water requirement
f)
Max. Permissible bearing cooling water inlet temp.

(permissible)
g)
Max. Permissible bearing cooling water outlet temp.
h)
Terminal designation corresponds

rotation (Facing driving end).
i)
Terminal boxes with accessories separate terminal

boxes provided.
40.
Winding temp. detectors
41.
Bearing temp. detectors
42.
Moisture detectors
43.
Neutral terminals
44.
:Yes / No
to
direction
of
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[4]
25.09.2014
of the Power Plant]
SL.
NO.
DESCRIPTION
[Logo of Utility]
UNIT
DATA
a) Type & Nos.

b) Fault level permissible for 0.25 sec.
c) Location
d) Cable gland size & no.
e) Direction of cable entry.
45.
Space Heater
a) Number
b) Location
c) Capacity of each
d) Total power requirement
e) Voltage.
46.
Details of 4 wire platinum RTD having 100 ohm

resistance at 0oC for winding temp. detector.
a) Nos. provided
b) Location
47.
Whether CTs for differential protection are provided

Yes / No
a) If Yes, no. of CTs supplied along with motors C.T. details

i. C.T. ratio
ii. Knee point voltage
b) S.C. withstand capacity
c) Type of mounting
48.
Shaft orientation
49.
Shaft extension
50.
Grounding pads size nos. & location
51.
Method of coupling to driven mechanism
52.
Motor GD2
:
53.
Lifting device
54.
Weight
a) Weight of stator (wound)

b) Weight of rotor (wound)
c) Weight of base plate
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[5]
25.09.2014
of the Power Plant]
SL.
NO.
DESCRIPTION
[Logo of Utility]
UNIT
DATA
d) Weight of cooler
e) Net weight of motor
f)
55.
Shipping dimensions & weight

Thermometer provided
a) In cold air path

b) In hot air path
c) For measurement of oil temp.
56.
Characteristic curves furnished
a) Speed vs. current at rated voltage
Yes / No
b) Speed vs. torque at 110%, 100%, 90% and 80% of

rated voltage:
Yes / No
c) Thermal withstand curve for hot & cold conditions.
Yes / No
d) Efficiency vs. load:
Yes / No
e) P.F. Vs. load:
Yes / No
f)
Yes / No
Current vs. time:
g) Negative phase sequence curve:

57.
Yes / No
Drawings furnished
a) General arrangement of motor
Yes / No
b) Main terminal box showing the method of terminating the

incoming cables Yes/No
Yes / No
c)
Yes / No
Instruction manuals
MOTOR (DC)
1.
GENERAL
a)
Manufacturer :
b)
Equipment driven by Motor
c)
Motor type
d)
Country of origin
2.
:
:
DESIGN & PERFORMANCE
a)
Frame Size
b)
Type of duty
c)
Type of enclosure & type of cooling
d)
Applicable standard to which motor generally confirms:
e)
Type of mounting
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[6]
25.09.2014
of the Power Plant]
SL.
NO.
DESCRIPTION
f)
Direction of rotation
g)
KW rating at amb. Temp. 50 C
h)
Rated power supply voltage
UNIT
i. Armature circuit (V)
ii. Field circuit (V)
Permissible voltage variation
j)
Minimum permissible starting voltage :
k)
Rated speed at rated voltage (RPM)
l)
At rated voltage
n)
RPM
i. Full load current (A)
ii. NO load current (A)
Starting current (A)
i. 100% voltage
ii. 85% voltage
Starting time (with pump coupled)

i. 100% voltage (Sec)
o)
DATA
i)
m)
[Logo of Utility]
ii. 85 % voltage
iii. 80 % voltage
Efficiency at rated voltage at :

i. 100% load
ii. 75% load :

iii. 50% load :
p)
q)
r)
3.
a)
Safe stall time (sec) at 110% :

i. Hot condition
ii. Cold condition
Torque (Kg-m) :
i.
Starting at min. permissible voltage:
ii.
Rated:
Fly wheel moment (GD2) motor (Kg-m)

CONSTRUCTIONAL FEATURES
Winding insulation
i. Class & type
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[7]
25.09.2014
of the Power Plant]
SL.
NO.
DESCRIPTION
ii. Tropicalised (Yes/No)
UNIT
DATA
iii. Temp. rise over specified ambient of 50 C.

iv. Method of temp. measurement
b)
[Logo of Utility]
Degree of protection of terminal box for :

i. Main terminal box
ii. Space heaters (AUX. TB) :

c)
For main terminal box :

i. No. and type of cable gland
ii. Recommended cable size (Armature/field)

d)
Fault level (KA, sec)
e)
Bearings
i. Type (at DE/NDE) :

ii. Make
iii. Recommended lubricant :

iv. Life
f)
Weight of motor (Kg.) :
g)
Field current at rated speed (A)
h)
Field resistance (Ohm) at rated speed at 30 C
i)
Field trimmer rating (Ohm) for getting basic speed at 30

C.
j)
Resistance (Ohm) between terminals at 30C.

i.
Armature
ii. Series winding
:
:
iii. Inter pole winding
iv. Shunt winding resistance :

k)
1st and 2nd critical speed
l)
Overload that can be carried by motor without changing

overall performance and period for which it is applicable
m)
Grounding device
n)
Space heater
i. No. & location
ii. Volt & KW rating :

4.
RESISTORS
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[8]
25.09.2014
of the Power Plant]
SL.
NO.
DESCRIPTION
a)
Starting (external) resistance
[Logo of Utility]
UNIT
DATA
i. Type of resistor :
ii. Ohmic, current & power rating of resistor elements
iii. Max. permissible temp. of resistor elements
iv. Connection diag. Of resistor elements

v. No. of startup stages/steps
vi. Resistance values of stages
-at 30 deg. C (Ohm)
-at running condition (Ohm)
vii.
Expected temp of resistor at running condition
viii.
Expected temp of box at running condition
ix.
b)
5.
Mounting/stacking of resistor elements and G.A.

of resistor box
Schematic connection diag. Of motor with starting

resistor and field trimmer resistor.
CHARACTERISTIC CURVES
a)
Staring current/times :
b)
Thermal withstand curve for hot and cold condition
c)
Torque/speed
d)
Load/Efficiency
e)
Speed/Time
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[9]
25.09.2014
of the Power Plant]
[Logo of Utility]
MOTOR ACTUATORS
S. NO.
DESCRIPTION
1.
Type
2.
Application
3.
Motor type
UNIT
Supply voltage
4.
Phase, frequency
Hz
5.
Motor rated voltage
6.
Control Voltage
7.
Voltage and its variation
8.
Frequency and its variation
9.
Combined V & f variation
10.
11.
Winding Insulation
12.
Temperature Rise
(over ambient temperature)
13.
Painting
14.
Motor Starting
DATA
Hz
%
a) Method
b Staring Current
)
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[10]
25.09.2014
of the Power Plant]
[Logo of Utility]
LT TRANSFORMER (OIL TYPE/DRY TYPE)
6.6/0.433 kV LV AUXILIARY TRANSFORMER

Dry Type
1.
Make
2.
Application
3.
Location
4.
Type
5.
Reference standard
6.
Rated power (indicative)
7.
Rated winding voltage ratio (line to line)
8.
Number of phases
9.
Winding
10.
Rated frequency
11.
Type of cooling
12.
Insulation Class
13.
Temperature rise Over ambient

temperature of 50oC
Oil Type
a For Winding by resistance method

b For Oil by Thermometer method
14.
Insulation level
( LI/AC)
a HV-
(LI/AC)
b LV-
(LI/AC)
-KVp/3KVrms
Vp/3KVrms
15.
Vector group
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[11]
25.09.2014
of the Power Plant]
16.
Short-circuit impedance on principal

tap
17.
Parallel operation of transformer
18.
Type of taps provided
19.
Taps provided on
20.
Range of taps
21.
Method of Tap charge control-
[Logo of Utility]
a Manual local
b Electrical local
c Electrical remote
d Automatic
22.
System earthing
a H.V.
b L.V.
23.
a H.V.
b L.V.
24.
Neutral for earthing
25.
Transformer bushing
26.
Voltage class KV(r.m.s.)
27.
Creepage distance
28.
Min. Ph-Ph/ Ph-E clearance
29.
System fault Level
HV
LV
LV - N
mm
mm
a HV Side
b LV Side
30.
Max. Noise level
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[12]
25.09.2014
of the Power Plant]
31.
Auxiliary supply
32.
LV neutral side current transformer

for standby earth fault protection
33.
Guaranteed no load loss (kW)
34.
Guaranteed load loss (kW)
35.
Efficiency
[Logo of Utility]
a At full load
b
At 75% load
c At 50% load
Accessories
36.
Each transformer furnished With

fittings and accessories as per
specification.
Approximate overall dimensions
37.
a
Length
Breadth
Height
Crane lift for un taking core and coil
assembly Approximate Weights
38.
a
Core and coil
Enclosure and fittings
Oil
Total weight
Shipping Details:
39.
40.
Weight of the heaviest package
Dimension of the largest package

:(LxBxH)
Tests
Routine test as per IS and other
tests as per specification
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[13]
25.09.2014
of the Power Plant]
[Logo of Utility]
LT PCC/MCC/DISTRIBUTION BOARD
S. No.
DESCRIPTION
UNIT
1.0
General
1.1
1.2
1.3
2.0
Switchgear Details
2.1
2.2
2.3
Voltage & frequency variation
2.4
Rated frequency
Hz
DATA

2.4
Voltage
a) For power Circuits
b) For Control Circuits
2.5
Continuous current rating of busbars under site reference

ambient temp.
2.6
Reference ambient temperature
2.7
Maximum
temperature
of
bus
bars
droppers/connectors under site conditions specified
2.8
Short circuit current withstand for busbars and droppers
and
Short time
kA (rms)
Dynamic Rating
kA (peak)
2.9
Whether busbars have been insulated
Yes
2.10
Type of insulation
2.11
Material of bus bar supports
2.12
Switchgear designation
2.13
Bus bar material
2.14
Fully draw out (FD)/ Fixed (F)
2.15
Entry Top (T)/Bottom (B)
2.16
2.17
Colour finish shade
Cu/Al
Interior
exterior
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[14]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
2.18
Earthing bus
Material
2.19
Minimum clearances in air of live parts
mm
3.0
Starters
3.1
Type
3.2
Contactor rated duty
3.3
Single phasing preventer required.
Yes / no
3.4
Thermal overload relay reset
Manual /
Auto
4.0
Circuit breakers
4.1
Makers name
4.2
Voltage, frequency & no.of phases , poles
4.3
4.4
Circuit breakers type
DATA
DOL Rev /
Star-Delta
4.5
Short circuit withstand current for 1 sec. Duration
kA
4.6
kAp
4.7
Rated current at site reference ambient temp
A
0
4.8
[Logo of Utility]
Type of operating mechanism
4.9
Minimum no. of auxiliary

Contacts for purchasers use
4.10
Control voltage
a
For Spring charging motor
V AC/DC
For closing/tripping
V AC/DC
4.11
Limits of voltage for satisfactory operation of the

following devices as a % of normal voltage
a
Operating mechanism
Closing at normal voltage
Trip coil
4.12
Power required for closing at normal voltage
4.13
Power required for tripping at normal voltage
4.14
Spring charging motor details:
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[15]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
Rating
kW
Rated voltage
V, AC/DC
Spring charging
Sec.
Electrical and mechanical anti-pumping features been

provided
Yes/No
5.0
MCCBs/MPCBs
5.1
Voltage, frequency & no. of phases
5.2
5.3
kA (rms)
5.4
kA (Peak)
[Logo of Utility]
DATA
On/Off operation
5.5
5.6
Manual
Yes/No
5.7
Over-load inverse time, short circuit and earth fault
Yes/No
5.8
Auxiliary contacts required
Yes/No
6.0
Contactors
6.1
Make
6.2
Rated duty
6.3
No of poles
6.4
Utilization category
6.5
Rated voltage of auxiliary contacts
6.6
Rated voltage of coil
6.7
Factor of
rated
current
6.8
Rated making capacity
Factor of
rated
current
6.9
Limits of operation
AC3/AC4
Supply voltage variation
Supply frequency variation for closing
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[16]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
c
6.10
UNIT
[Logo of Utility]
DATA
Drop out voltage

No of auxiliary contacts:
Normally open
Normally closed
7.0
Instrumentation transformers
7.1
Voltage Ratio
7.2
CT Ratio
7.3
Measuring CTs
7.4
Protection CTs
7.5
Measuring VTs
7.6
Protection VTs
8.0
Control transformers
8.1
Make
8.2
Type
8.3
8.4
Ratio
8.5
Class of insulation
8.6
Rated output
9.0
Fuse (if applicable)

a
Type
Voltage rating
VA
10.0
Instantaneous over current relay
10.1
Application (phase fault or earth fault)
10.2
Make
10.3
Type designation
10.4
Setting range
11.0
Inverse time and thermal overcurrent relay
11.1
Application
11.2
Make
11.3
Type
11.4
Current setting range
11.5
Time setting range at 10 times the current setting
12.0
Under voltage relay
Sec
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[17]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
12.1
Make
12.2
Type
12.3
Voltage rating
12.4
Setting range
13.0
Auxiliary relays and timers
13.1
Make
13.2
Type
13.3
Coil voltage
14.0
Control/selector switch
14.1
Make
14.2
Type designation
15.0
Meters
15.1
15.3
Accuracy Class
15.4
Make
15.5
Type
16.0
Voltmeter
16.1
Make
16.2
Type
16.3
16.4
Accuracy class
17.0
Ammeter
17.1
Make
17.2
Type
17.3
17.4
Accuracy class
18.0
Indicating lamps
18.1
Make
18.2
Type
[Logo of Utility]
DATA
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[18]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
18.3
Voltage
18.4
Wattage of lamp
19.0
Push buttons
19.1
Make
19.2
Type designation
19.3
Contact rating
20.0
Space heater
20.1
Make
20.2
Type
20.3
Rated voltage
21.0
Wiring and terminal blocks
21.1
Voltage grade
21.2
Insulation
21.3
Minimum size of conductor for:
21.4
[Logo of Utility]
DATA
Power wiring
Sq.mm
Control wiring
Sq.mm
Type of terminal blocks:

I) For Withdrawable Type
II) For Fixed Type
21.5
Minimum current rating of terminal blocks
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[19]
25.09.2014
of the Power Plant]
5
S. No.
415V NON SEGREGATED PHASE BUS DUCT

DESCRIPTION
UNIT
1.
Make/ Name of Manufacturer
2.
Type of Busduct
Segregated
/non
segregated
3.
Type of cooling
Natural/Forc
ed
4.
Reference Standard
5.
Rated Voltage
6.
No of phase and Frequency
Hz
7.
Insulation level
a)
Min Power frequency Voltage
kVrms
b)
Impulse withstand voltage
kVp
8.
Rated Continuous current
9.
Short time withstand capability
10.
a)
Symmetrical for 1 sec
kA
b)
Momentary
kAp
Maximum temperature rise over 50 degree design

ambient temperature
a)
Bus bar
b)
Enclosure
Degree of protection of enclosure
12.
Bus bar
14.
a)
Material & Grade
b)
Conductivity
c)
Size
DATA
Amp
11.
13.
[Logo of Utility]
Degree
Enclosure
a)
Material & Grade
b)
Thickness
c)
Ph- ph spacing
d)
Over all dimension
Dc resistance in micro ohm/metre/phase

a)
At 20 degree
b)
At 85 degree
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[20]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
15.
Reactance in ohm/meter/phase
16.
Capacitance to ground
17.
Losses in watt/meter/phase
18.
Insulators
a)
Make
b)
Material
c)
No per support
d)
Voltage Glass
e)
Compression strength
f)
Cantilever strength
19.
Size and material of ground bus
20.
Support steel structure
21.
Whether the following has been provided
22.
a)
Thermostat controlled space heater
b)
Silica gel breather
c)
Drain plug
d)
Neoprene rubber gaskets at joints
e)
Disconnecting links
[Logo of Utility]
DATA
Painting shade
a)
Interior
b)
Exterior
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[21]
25.09.2014
of the Power Plant]
6
S. No.
1.1.
HV CABLES
DESCRIPTION
UNIT
DATA
1.2
1.3
1.4
1.5
System Particulars (Fill separate columns for the following

particulars for each type and size of cables)
1.6
ISI registration and validity date
1.7
Cable type
1.8
Whether cable shall carry ISI mark
1.9
Voltage grade
1.10
No. of cores and size
1.11
Suitable for earthed/unearthed system
1.12
Permissible voltage and frequency variation for

satisfactory operation
Voltage
Frequency
Voltage and Frequency combined

carrying capacity
1.13
For standard conditions as per IS
In air
In ground
In duct
In trench
1.14
For site conditions :
in sq.mm
Continuous current
a)
In air
b)
In ground
c)
In duct
d)
In trench
1.15
De-rating factors for various conditions of laying are not

worse than the ones specified in applicable IS Yes/No
1.16
Conductor
a)
[Logo of Utility]
Material reference standard for conductor
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[22]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
b)
Grad and Shape of conductor
c)
Nominal cross section area
d)
Number of wires
e)
Diameter of wire
mm
f)
Diameter/size of conductor
mm
1.17
[Logo of Utility]
DATA
mm2
Screening/Shielding / heat barrier tape (as applicable)
a)
Material
b)
Type/applicable std.
c)
Thickness
1.18
Insulation
a)
Material composition and confirming standard and type
b)
Thickness of insulation
i.
Between cores
mm
ii.
Between cores and inner sheath
mm
c)
Tolerance on thickness of insulation
d)
Diameter of core over insulation
mm
e)
Specific insulation resistance at 90 degrees centigrade
ohm-cm
1.19
Screening/Shielding / barrier tape(as applicable)
a)
Material
b)
c)
Thickness
1.20
Inner sheath
a)
Material, confirming standard / type
b)
Extruded
c)
Calculated diameter over laid up cores
d)
Thickness (min)
mm
e)
Diameter of cable over inner sheath
mm
f)
Whether inner sheath shall be of FRLS material and meet

special Tests as per specification for FRLS cables
g)
Filler Material
1.21
Yes/No
Yes/No
details
Armouring
a)
Material
b)
Type of armouring
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[23]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
c)
No. and size of strip/wire
d)
Whether galvanized
Yes/No
e)
Diameter of cable over armouring
mm
1.22
[Logo of Utility]
DATA
Outer sheath
a) Material confirming standard/ type
b) Extruded
Yes/No
c) Minimum Thickness of sheath
mm
d) Tolerance on thickness of sheath
mm
e) Min. tensile strength
N/sq mm
f) Min. elongation percentage at rupture

g) Colour of Outer sheath
h) Whether outer sheath shall be of FRLS material and shall
meet the special tests as per specification and standards
1.23
Overall diameter of cable and

Diameter
1.24
Scheme for identification of cores
1.25
Short circuit withstand capacity
and tolerance for Outer
a Short circuit current

)
b)
Yes/No
KA
Duration of short circuit
sec
1.26
Allowable/attainable maximum conductor temperature

when carrying rated continuous current
1.27
Allowable/attainable maximum conductor temperature at

the termination of short circuit current
1.28
Cable constants
a)
Max. DC resistance of conductor at twenty (20) C
ohm/km
b)
AC resistance per core at twenty (20) C
ohm/km
c)
Reactance per core at 50 HZ
ohm/km
d)
Capacitance per core at 50Hz
microfarad/k
m
e)
Insulation
Insulation resistance constant at 27C and at max. rated
temperature
ohm-km
Volume resistivity ohm cm at 27C and at max. rated

temperature
Min. tensile strength
N/sq.mm
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[24]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
[Logo of Utility]
DATA
Min. elongation percentage at rupture

Loss tangent
Dielectric constant
1.29
Maximum cable charging current at normal operating

voltage
1.30
Factory tests (Enumerate in detail for each type of cable)
A/km
a)Type tests
b) Acceptance tests
c) Routine tests
d) Special tests to prove FRLS/FS properties.
1.31
Is the offered cable guaranteed to safely withstand

continuous conductor temperature of 90C for XLPE
Yes/No
1.32
Cable weight
kg/km
1.33
Recommended minimum bending radius
mm
1.34
Safe pulling force
Kg
1.35
Maximum allowable spacing for angle iron supports
mm
1.36
Length of cable per drum
1.37
Cable drum
a)
Material
b)
Dimensions of drum
c)
IS reference
d)
Standard drum length for each size of

length)
e)
Cable weight
Kg
f)
Shipping weight
Kg
g)
Drum weight
Kg
cable (single
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[25]
25.09.2014
of the Power Plant]
7
S. No.
[Logo of Utility]
LT POWER & CONTROL CABLES

DESCRIPTION
UNIT
1.2.
1.2
1.3
1.4
1.5
System Particulars (Fill separate columns for the following

particulars for each type and size of cables)
1.6
ISI registration and validity date
1.7
Cable type
1.8
Whether cable shall carry ISI mark
1.9
Voltage grade
DATA
1.10
No. of cores and size
in sq.mm
1.11
Suitable for earthed/unearthed system
1.12
Permissible voltage and frequency variation for

satisfactory operation
a Voltage
b Frequency
c
1.13
1.14
Voltage and Frequency combined

carrying capacity
Continuous current
For standard conditions as per IS

a
In air
In ground
c In duct
d In trench
For site conditions :
e)
In air
f)
In ground
g)
In duct
h)
In trench
1.15
De-rating factors for various conditions of laying are not

worse than the ones specified in applicable IS Yes/No
1.16
Conductor
g)
Material reference standard for conductor
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[26]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
h)
Grad and Shape of conductor
i)
Nominal cross section area
j)
Number of wires
k)
Diameter of wire
mm
l)
Diameter/size of conductor
mm
1.17
Material
e)
f)
Thickness
a)
mm2
Insulation
Material composition and confirming standard and type
b)
Thickness of insulation
iii.
Between cores
mm
iv.
Between cores and inner sheath
mm
c)
Tolerance on thickness of insulation
d)
Diameter of core over insulation
mm
e)
1.19
Specific insulation resistance at 90 degrees centigrade
ohm-cm
Screening/Shielding / barrier tape(as applicable)
d)
Material
e)
f)
Thickness
1.20
Inner sheath
h)
Material, confirming standard / type
i)
Extruded
j)
Calculated diameter over laid up cores
k)
Thickness (min)
mm
l)
Diameter of cable over inner sheath
mm
m)
Whether inner sheath shall be of FRLS material and meet

special Tests as per specification for FRLS cables
n)
Filler Material
1.21
DATA
Screening/Shielding / heat barrier tape (as applicable)
d)
1.18
[Logo of Utility]
Yes/No
Yes/No
details
Armouring
f)
Material
g)
Type of armouring
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[27]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
h)
No. and size of strip/wire
i)
Whether galvanized
j)
DATA
Yes/No
Diameter of cable over armouring
1.22
[Logo of Utility]
mm
Outer sheath
i) Material confirming standard/ type
j)
Extruded
Yes/No
k) Minimum Thickness of sheath
mm
l) Tolerance on thickness of sheath
mm
m) Min. tensile strength
N/sq mm
n) Min. elongation percentage at rupture

o) Colour of Outer sheath
p)
Whether outer sheath shall be of FRLS material and shall

meet the special tests as per specification
1.23
Overall diameter of cable and

Diameter
1.24
Scheme for identification of cores
1.25
Short circuit withstand capacity
and tolerance for Outer
a Short circuit current

)
b)
KA
Duration of short circuit
sec
1.26
Allowable/attainable maximum conductor temperature

when carrying rated continuous currents
1.27
Allowable/attainable maximum conductor temperature at

the termination of short circuit current
1.28
Yes/No
Cable constants
a)
Max. DC resistance of conductor at twenty (20) C
ohm/km
b)
AC resistance per core at twenty (20) C
ohm/km
c)
Reactance per core at 50 HZ
ohm/km
d)
Capacitance per core at 50Hz
microfarad/k
m
e)
Insulation
Insulation resistance constant at 27C and at max. rated
temperature
ohm-km
Volume resistivity ohm cm at 27C and at max. rated

temperature
Min. tensile strength
N/sq.mm
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[28]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
[Logo of Utility]
DATA
Min. elongation percentage at rupture

Loss tangent
Dielectric constant
1.29
Maximum cable charging current at normal operating

voltage
1.30
Factory tests (Enumerate in detail for each type of cable)
A/km
a)Type tests
b) Acceptance tests
c) Routine tests
d) Special tests to prove FRLS/FS properties.
1.31
Is the offered cable guaranteed to safely withstand

continuous conductor temperature of 90C for XLPE
Yes/No
1.32
Cable weight
kg/km
1.33
Recommended minimum bending radius
mm
1.34
Safe pulling force
Kg
1.35
Maximum allowable spacing for angle iron supports
mm
1.36
Length of cable per drum
1.37
Cable drum
a)
Material
b)
Dimensions of drum
c)
IS reference
d)
Standard drum length for each size of cable (single length)
e)
Cable weight
Kg
f)
Shipping weight
Kg
g)
Drum weight
Kg
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[29]
25.09.2014
of the Power Plant]
ILLUMINATION SYSTEM
S. No.
DESCRIPTION
1.0
GENERAL
1.1
Normal Supply Voltage, Phase and Frequency
1.2
Variation in Supply
a) Voltage
b) Frequency
c) Combined voltage & frequency
Design Ambient Air Temperature
a) At 415V AC
b) At 220V DC (For DC LP)
Luminaries Earthing Terminal Suitable for
Conductor material
Conductor size
1.3
1.4
1.4
a
b
2.0
2.1
2.2
2.3
2.4
UNIT
DATA
AC
%
%
%
C
kA(rms)
kA(DC)
SWG
3.0
Lighting Distribution Board and Lighting panel

Manufacturer Name
Rated Voltage, phase and Frequency
Mounting Type
a) LDBs
b) Single Phase LP
Type and no of circuits & feeder rating
Colour shade
Lighting Transformer
a) Type
b) Voltage Ratio
c) Taps
d) Vector Group
e) Impedance
f) Rating
Fixture details:
3.1
Name of Manufacturer and Country
3.2
Luminaries
3.3
a) Fluorescent
b) HPMV
c) HPSV
d) Metal Halide
e) Compact Fluorescent Lamp
f) Flame proof
Applicable Standards for
2.5
2.6
2.7
[Logo of Utility]
AC
V
V
%
%
KVA
a) Luminaires
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[30]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
[Logo of Utility]
DATA
b) Accessories
3.4
Manufacturers type and Catalogue No.
4.0
5.0
5.1
a) Luminaires
b) Accessories
Schedule of fitting and Accessories
Technical details of luminaries
Lamps
a
Maximum permissible supply voltage variation
Luminous output
i)
ii)
Lumens
Lumens
Average burning hour life
Hours
Ballasts & Starters

Maximum permissible supply voltage variation
Power loss at nominal working voltage
Maximum hot spot temperature of ballast
Conductor material of ballast
Insulation class of ballast winding
Average life of
5.2
i) Ballast
ii) Starters
Hrs.
Hrs.
Capacitors
Power factor
Luminaires
Weight of luminaries
Kgs
Earthing terminal
i) Material
ii) Suitable upto conductor size
Internal wiring size
SWG
Sq.mm
Terminal block suitable for conductor size
Sq.mm
Sheet steel thickness of
i) Housing
ii) Reflector
Wire guard thickness
SWG
SWG
mm
Descriptive catalogues enclosed
Yes/No
5.3
a
5.4
6.0

Miniature circuit breaker
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[31]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
6.1
6.2
6.3
Make
Type
Literature enclosed
Yes/No
7.0
7.1
7.2
7.3
7.4
Earth leakage circuit breaker

Make
Type
Leakage Current I N
Literature enclosed
mA
Yes/No
8.0
Instrument transformers
8.1
8.2
8.3
8.4
8.5
Make
Type
Output
Accuracy Class
Literature enclosed
9.0
9.1
9.2
9.3
9.4
Meters
Make
Type
Accuracy Class
Literature enclosed
10.0
10.1
10.2
10.3
10.4
10.5
Relays (if any provided)

Make
Type
Voltage Rating
Setting Range
No. of Contacts
a)Normally open
b)Normally closed
Literature enclosed
10.6
11.0
11.1
11.2
11.3
11.4
12.0
12.1
12.2
[Logo of Utility]
DATA
VA
Yes/No
Yes/No
V
%
Yes/No

Make
Suitable for use in hazardous area
a)Area classification
b)Gases/Vapor group
Dimensional Drawings and Literature of each required
equipment flameproof enclosure including fixing details
enclosed
Approval certificates of relevant statutory authorities
enclosed
Yes/No
Yes/No
Lighting Control Switches

Make
Decorative
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[32]
25.09.2014
of the Power Plant]
S. No.
DESCRIPTION
UNIT
12.3
12.4
12.5
Industrial
Flame proof
Literature Enclosed
Yes/No
13.0
13.1
13.2
13.3
13.4
13.5
Receptacle units
Make
Decorative
Industrial
Flame proof
Literature Enclosed
Yes/No
14.0
14.1
14.2
14.3
14.4
14.5
14.6
14.7
Lighting wires
Make
Applicable Standard
Voltage Grade
Conductor Material
Size
No. of Strands
Colour Coding
15.0
CONDUITS
15.1
15.2
15.3
15.4
15.5
15.6
Make
Rigid Steel
Rigid Non-metallic
Sizes offered and wall thicknesses
Supply of necessary couplings, bends, tees, necessary
for conduit routing included
Literature Enclosed
16.0
16.1
16.2
16.3
16.4
16.5
16.6
Junction boxes
Make
Material and Gauge
Galvanised
Dimensioned Drawings Enclosed
Weather Proof Construction Required
Flame Proof / Non-flame proof
17.0
17.1
17.2
17.3
17.4
Lighting poles/towers
Make
Type of Poles/Towers
Dimensioned Drawing/Particulars of Flood Light Tower
enclosed
Junction Box with Pole
18.0
18.1
18.2
18.3
Ceiling fans
Make
Blade Sweep
Suspension Rod Length
[Logo of Utility]
DATA
V
Cu/Al
Sq.mm
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
mm
mm
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[33]
25.09.2014
of the Power Plant]
9
SL NO.
1.

DESCRIPTION
UNIT
DATA
Make/Manufacturer
2.
Size of Tray
3.
Material
4.
Application
5.
Type of Tray
6.
Thickness of Tray
mm
7.
mm
8.
Tray Cover Size
mm
9.
9.1
Tee
mm
9.2
Cross
mm
9.3
Bends
Deg
9.4
Reducer
mm
9.5
Steel Supports
a) ISMC
mm
9.6
[Logo of Utility]
mm
b) ISA
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[34]
25.09.2014
of the Power Plant]
[Logo of Utility]
10 EARTHING & LIGHTNING PROTECTION SYSTEM

SL NO.
1.0
1.1
1.2
DESCRIPTION
EARTHING SYSTEM
Manufacturer Name
Main ground grid conductor material & size
UNIT
1.3
Ground electrode material & size
1.4
Riser material & size
1.5
Grounding installation work carried out as per

pecification
2.0
LIGHTNING PROTECTION SYSTEM
2.1
Manufacturer Name
2.2
Vertical air termination conductor material & size
2.3
Horizontal air termination conductor material & size
2.4
Down Conductor material & size
2.5
Electrode material & size
2.6
Riser conductor material & size
2.7
Lightning Protection work carried out as per

specification.
DATA
Y/N
Y/N
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[35]
25.09.2014
of the Power Plant]
[Logo of Utility]
11 VARIABLE FREQUENCY DRIVE

S.No
1
2
3
4
5
6
Manufacturer Name
Model No.
Application
Quantity
Enclosure Protection Rating
Output Current Rating at ambient
temperature
% derating considered for specific ambient
Rated Voltage (volts) Input
Output Frequency Range (Hz)
Number of Phases and Frequency (Hz)
Short time current rating
Dynamic rating
Rectifier type & Design
Inverter type & Design
Min/Recommended / Max switching
frequencies (kHz)
Filters
Line Side
Load Side
Drive Input
Output Modulation Method
Speed Accuracy (+/- %)
Response time (speed)
Response time (Torque)
Type of cooling
Whether VVFD is suitable for outdoor
installation
Drive Control Capabilities
Start/Stop Push button
Modbus control
Permissible % variation
Voltage
Frequency
Load parameters at rated voltage &
frequency
Output Frequency (Hz)
Full Load current (Amp)
VVF Heat dissipation (w)
VVF Efficiency
At Full rated Torque
7
8
9
10
a.
b.
11
12
13
14
a.
b.
15
16
17
18
19
20
21
22
a.
b.
23
a.
b.
24
a.
b.
c.
25
a.
b.
c.
26
6.6 kV (HV)
415 V (LV)
Drive Power factor range

At rated speed, Torque
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[36]
25.09.2014
of the Power Plant]
S.No
27
28
29
DC Voltage
Fundamental power factor
Switching Frequency
Drive Dimensions
Length
Height
Depth
Weight
Metering
Accuracy Class
Make
Type
a.
b.
c.
d.
e.
30
a.
b.
c.
d.
6.6 kV (HV)
[Logo of Utility]
415 V (LV)
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

VOLUME-III, PART-B
[37]
25.09.2014

OF

R&M CONTRACTORS

VOLUME-III
PART-C
TECHNICAL SCHEDULES-I&C
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-001 R02
September 2014
Technical Specification For R&M of Unit No. [..] Capacity [..] of [Name of
the Power Plant]
[Logo of Utility]

Volume
Section
Part
Description
Volume-I
---
---
Commercial
Section-I
---
Part-A
Part-B
Part-C
Part-D
---
Part-A
---
Part-B
---
Part-C
---
Part-D
Not Used
Volume-II
Section-II
Volume-III
*****
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02
Technical Specification for R&M Works of

Volume-III, Part-C
[i]
25.09.2014
the Power Plant]
[Logo of Utility]
1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
*****
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[ii]
25.09.2014
the Power Plant]
[Logo of Utility]

1. Intent of Specification
2.
3.
4.
5.
6.
7.
8.
9.
Spare Parts
10.
Annexure

1.
2.
3.
4.
*****
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[iii]
25.09.2014
the Power Plant]
[Logo of Utility]

1.
2.
3.
*****
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[iv]
25.09.2014
the Power Plant]
[Logo of Utility]

R&M CONTRACTORS

VOLUME-III, PART-C
TECHNICAL SCHEDULES-I&C

OF
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[v]
25.09.2014
the Power Plant]
[Logo of Utility]
{Only the Applicable portion of the Data Sheet based on the scope of work as
firmed up in Section-I, Volume-II should be retained and the remaining portion
should be deleted. The scope of work in Section-I, Volume-II is based on Residual
Life Assessment (RLA) / Condition Assessment (CA) and Energy Audit (EA)
Report. The bidder is to provide datasheet for each type and make of the
instrument/equipment offered by them.}
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[vi]
25.09.2014
the Power Plant]
1
[Logo of Utility]
PROGRAMMABLE LOGIC CONTROLLER (PLC)

Table 1.1
Data Sheet for PLC
S.N
Feature
To be Filled by Bidder
Type of the system offered and Model No.
Make -
Year of launching of the system
Is the system offered, the latest system

available/ being marketed in the international
market by the vendor
Place of Manufacturing
Is the offered system confirms to the

Specification provided in the tender document
with regard to Spare Capacity, Expandability,
Redundancy,
Is the System offered is with open system

architecture to enable integration of third
party hardware/ software applications
Support direct connectivity to Ethernet based

LAN
Deterministic and secure architecture
10
On-line removal/replacement of I/O modules/

drive control modules possible without
switching
off
power
supply
to
the
corresponding rack & without affecting
controller operation
11
Total I/O handling capacity of Controller
12
No. of Tags handling capacity of Controller
13
Total Power requirement for the offered system
14
Total Heat Load of all cabinets
15
Scanning rate for
Analog Signal
T/C Signal
RTD Signal
Binary Signal
16
Loop Execution Time for
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[1]
25.09.2014
the Power Plant]
S.N
Feature
Interlocks
Close loops
17
[Logo of Utility]
Auto switchover to backup redundancy Level
Controller Level
Power supply Level
Communication Level
18
Output Status on Controller Failure
19
Battery back-up duration for control processor
20
Non-volatile memory capacity to store programs,

standard software to perform control, DAS &
Diagnostic functions
21
Maximum no. of Channels for
Analog Input module
T/C Input module
RTD Input module
Analog Output module
Binary Input Module
Binary Output module
22
Optical Isolation
provided.
for
Binary
Input/Output
23
Galvanic
provided
for
Analog
Input/Output
24
Can the analog and binary controls be

implemented at different execution speeds, in
the multi-function controllers.
25
Simulation
possible.
26
Data Transmission speed for
isolation
of
Ethernet LAN
Data Highway
I/O Bus
Analog/Digital
Input/Output
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[2]
25.09.2014
the Power Plant]
[Logo of Utility]
Table 1.2
Data Sheet for High Level Analog Input Module
S.N
Feature
No. of Inputs/Module
Types of Input (Linear)
Accuracy
A/D Converter
Temperature Effect
CMRR
NMRR
MTBF
Stability
10
Diagnostic
11
Isolation
Table 1.3
Data Sheet for Low Level Analog Input Module
S.N
Feature
Model No.
Types of Input (Grounded/ Ungrounded
Cold junction compensation
Accuracy
A/D Converter
Temperature Effect
CMRR
NMRR
10
MTBF
11
Stability
13
Diagnostic
14
Isolation
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[3]
25.09.2014
the Power Plant]
[Logo of Utility]
Table 1.4
Data Sheet for Binary Input Module
S.N
Feature
Model No.
Types of Input
MTBF & MTTR
Isolation
Interrogation Voltage
Input Current
Surge Withstand
Maximum Switching Frequency
10
Diagnostic
11
Isolation
13
Contact Bounce Filtering Provided
Table 1.5
Data Sheet for SOE Input Module
S.N
Feature
Model No.
Types of Input
MTBF & MTTR
Isolation
Input Current
Surge Withstand
10
Diagnostic
11
Isolation
13
Time stamping provided
14
Time Resolution
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[4]
25.09.2014
the Power Plant]
S.N
15
Feature
[Logo of Utility]
Filter Delay Time
Table 1.6
Data Sheet for Smart Transmitter Interface Module
S.N
Feature
Model No.
Types of Input
MTBF & MTTR
Protocol
Accuracy
Function
Diagnostic
Isolation
Table 1.7
Data Sheet for Pulse Input Module
S.N
Feature
Model No.
Types of Input
MTBF & MTTR
Isolation
Input Current
Surge Withstand
10
Diagnostic
11
Isolation
13
Minimum Pulse Width
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[5]
25.09.2014
the Power Plant]
[Logo of Utility]
Table 1.8
Data Sheet for Analog Output Module
S.N
Feature
Model No.
No. of Outputs/Module
Types of Output
MTBF & MTTR
Isolation
Accuracy
Load
Diagnostic
Isolation
10
Power supply
11
Short circuit Protection
Table 1.9
Data Sheet for Binary Output Module
S.N
Feature
Model No.
No. of Outputs/Module
Types of Output
MTBF & MTTR
Contact rating
Contact Voltage
Switching Frequency
Contact Life
Power supply
10
Isolation
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[6]
25.09.2014
the Power Plant]
[Logo of Utility]
Table 1.10
Data Sheet for Controller
S.N
Feature
Model No.
Processor make
Type of Processor/minimum word length
Memory Size
No. of Loops
No. of I/O
Configuration
Battery Backup Available
Duration of Battery backup
10
Redundancy
11
Change Over Time
12
Failure of any one of the processor not to

affect system operation
13
What could be the maximum loading of the

Controller CPU with the configuration offered
14
15
16
17
Cycle Time
Expansion facility available
Data Transfer mode
MTBF & MTTR
Table 1.11
Data Sheet for Engineering Station
S.N
Feature
Make & Model no.
Processor
Cache Memory
RAM
Hard disk Drive
CD Drive
Video card
Operating System
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[7]
25.09.2014
the Power Plant]
S.N
9
10
Feature
Monitor
Type
Size
Resolution
Colors
Sync
Dot per inch
Glare Filter
Make & Model no.

Keyboard
Type
Make & Model No.
Key lock control
12
Interfacing Ports
11
[Logo of Utility]
Mouse
Type
Make & Model no.
13
Is on line program modification (Control

algorithms, logic, sequence programs etc.)
and loading possible from Engineering
console through data highway without taking
the controller in standby mode? Specify
limitation, if any
14
Is it possible to access the control

configurations (both regulatory and discrete)
along with dynamic updating of process
variables (analog values and binary status)
from the Engineering station.
15
Can the system configuration modified and

loaded into controller from engineering
station
16
Programming language used for implementing

logics / control schemes
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[8]
25.09.2014
the Power Plant]
[Logo of Utility]
FIELD INSTRUMENTS
Table 2.1
Data Sheet for Transmitter
S.N
Features
Make & Model No.
Working Principle
Type
Turn Down ratio
Accuracy
Repeatability
Enclosure Class
Sensor Type
MOC of Housing
10
Process Connection
11
Calibration
12
Operating Voltage
13
Output Signal
Table 2.2
Data Sheet for Thermocouple
S.N
Features
Make & Model No.
Type
Wire Gauge
Protection tube OD/ Material/ Filling
Response time
Accuracy
Characteristics
MOC Head/ Protection Class
Cable connection
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[9]
25.09.2014
the Power Plant]
[Logo of Utility]
Table 2.3
Data Sheet for RTD
S.N
Features
Make & Model No.
Type
No. of Elements
Wire Gauge
Protection tube OD/ Material/ Filling
Response time
Accuracy
Characteristics
MOC Head/ protection class
10
Cable connection
Table 2.4
Data Sheet for Thermowell
S.N
Features
Make
MOC
Process Connection
Immersion Length
Table 2.5
Data Sheet for Pressure Gauge/DP Gauge/ Draught Gauge
S.N
Feature
Make & Model No.
Type
Sensing Element Material
Movement Material
Case Material / Protection Class
Dial Size
Scale
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[10]
25.09.2014
the Power Plant]
S.N
Feature
Adjustment
Element Connection
10
Process Connection
11
Accuracy
12
Repeatability
13
Response time
14
Chemical Seal Unit
[Logo of Utility]
Table 2.6
Data Sheet for Temperature Gauge
S.N
Feature
Make/Model No.
Type
Stem
Movement Materials
Case Material/Protection class
Dial Size
Scale
Adjustment
Range Selection
10
11
Instrument Connection
12
Process Connection
13
Accuracy
14
Repeatability
15
Response Time
Table 2.7
Data Sheet for Level Gauge
S.N
Feature
Make & Model no.
Type
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[11]
25.09.2014
the Power Plant]
S.N
Feature
Sensing Element & material
Body Material
End Connection
Accuracy
Housing
Zero / Span adjustment
Packing material
[Logo of Utility]
Table 2.8
Data Sheet for Pressure/DP Switch
S.N
Feature
Make & Model no.
Type
Wetted Parts material
Case Material
Over range for Pressure / Vacuum Switch
Process Connection
Switch Configuration
Switch Rating
10
Cable Connection
11
Enclosure Class
12
Accuracy
13
Repeatability
Table 2.9
Data Sheet for Conductivity Type Level Switch
S.N
Feature
Make & Model no.
Sensing elements
Probe Material
Repeatability
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[12]
25.09.2014
the Power Plant]
S.N
Feature
Accuracy
Probe length
End connection
Rating of contacts
Enclosure class
10
Housing material
11
[Logo of Utility]
Table 2.10
Data Sheet for Capacitance Type Level Switch
S.N
Feature
Make & Model no.
Sensing elements
Probe Material
Repeatability
Accuracy
Probe length
End connection
Rating of contacts
Enclosure class
10
Housing material
11
Table 2.11
Data Sheet for Displacer Type Level Switch
S.N
1
2
3
4
5
6
7
8
Features
Make & Model No.
Working Principle
Type
MOC of Float/Stem
Accuracy
Repeatability
Enclosure Class
Sensor Type
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[13]
25.09.2014
the Power Plant]
S.N
9
10
11
12
13
Features
MOC of Housing
Process Connection
Calibration
Output Signal
[Logo of Utility]
Table 2.12
Data Sheet for Displacer Type Level Transmitter
S.N
1
2
3
4
5
6
7
8
9
10
11
12
13
Features
Make & Model No.
Working Principle
Type
MOC of Float/Stem
Accuracy
Repeatability
Enclosure Class
Sensor Type
MOC of Housing
Process Connection
Calibration
Output Signal
Table 2.13
Specification for Ultrasonic Transmitter
S.N
1
2
3
4
5
6
7
8
9
10
11
Feature
Make & Model No.
Type
Principle
Sensor Material
Output
Resolution
Accuracy
Repeatability
Power supply
Mounting
Transmitter housing material/enclosure
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[14]
25.09.2014
the Power Plant]
[Logo of Utility]
Table 2.14
Data Sheet for Radar Type Level Transmitter
S.N
1
Feature
Make & Model No.
Type
Principle
Sensor Material
Output
Resolution
Accuracy
Repeatability
Power supply
10
Mounting
11
Transmitter
class
housing
material/enclosure
Table 2.15
Data Sheet for RF Type Level Switch
S.N
Feature
Make & Model No.
Particle size
Insertion length
Mounting
Process connection
Protection Class
Cable connection
Table 2.16
Data Sheet for Flow Switch
S.N
Feature
Make & Model No.
Insertion length
Mounting
Process connection
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[15]
25.09.2014
the Power Plant]
S.N
Feature
Protection Class
Cable connection
[Logo of Utility]
Table 2.17
Data Sheet for Rotameters
S.N
Feature
Make & Model No.
Type
Fluid media
Float Material
Accuracy
Process connection
Enclosure material & protection class
Table 2.18
Data Sheet for Flow Glass
S.N
Feature
Make & Model no.
Type
Size
Body Material
Glass material
Pressure Rating
Temperature Rating
Protection class
Connection
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[16]
25.09.2014
the Power Plant]
[Logo of Utility]
Table 2.19
Data Sheet for Hydrogen Analyzer
S.N
Feature
Make & Model No.
Type
Principle
Sensor Type
Measurement Range
Accuracy
Linearity
Response time
10
Sample filter
11
12
Indication
13
14
Type of Electronics
15
Calibration
16
Output signals
Table 2.20
Data Sheet for Pneumatic Actuator
S.N
Feature
Make & Model No.
Type
Diaphragm Material
Spring Material
Body Material
Stem material
Coupling type & material
Pneumatic Connection
Action on Air Failure
10
Angle of operation
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[17]
25.09.2014
the Power Plant]
S.N
Feature
11
Signal Range
12
Manual Operation
[Logo of Utility]
Table 2.21
Data Sheet for Electrical Actuator
S.N
Feature
Make & Model No.
Type
Motor rating
Power supply
Control Supply
Body Material & Protection Class
Gear Train Material
Input Signal
10
Output Signal
11
Manual Operation
Table 2.22
Data Sheet for I-to-P Converter
S.N
Feature
Make & Model no.
Air Supply
Input Signal
Output Signal
Linearity
Hysteresis
Mounting
Protection class
Enclosure
10
Drift
11
Direct/Reverse action Facility
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[18]
25.09.2014
the Power Plant]
[Logo of Utility]
Table 2.23
Data Sheet for Smart Positioner
S.N
1
2
3
4
5
6
7
8
9
10
11
12
Feature
Make & Model No.

Input
Power Supply
Type of Electronics
Valve position sensing
Operating Range
Modes of operation
Flow characteristics
Fail safe/Freeze feature
Air supply pressure
Process Connection
Table 2.24
Data Sheet for Air Filter Regulator
S.N
Feature
Make & Model No.
Type
Inlet Pressure
Output
Filter Element size
Filter Element Material
Drain
Bowl Material
Enclosure Protection class/ Material
10
Process connection
Table 2.25
Data Sheet for Position Transmitter
S.N
Feature
Make & Model No.
Power Supply
Type
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[19]
25.09.2014
the Power Plant]
S.N
Feature
[Logo of Utility]
Output
Accuracy
Enclosure Protection class/ Material
Cable Entry
Table 2.26
Data Sheet for Limit Switch
S.N
Feature
Make & Model No.
Sensing Element
Material
Repeatability
No. of Contacts
Contact Ratings
Enclosure type/material
Set point
10
Mounting
Table 2.27
Data Sheet for Solenoid Valve
S.N
Feature
Make & Model No.
Operating Principle
Coil Voltage Rating
Body
Trim
Manual Operation
Duty
Sealing
Coil enclosure
10
Coil Insulation Class
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[20]
25.09.2014
the Power Plant]
S.N
Feature
11
[Logo of Utility]
Cable Connection
Table 2.28
Specification for Aerofoil
S.N
Feature
Type
Material
Tappings
Root Valve type
Root Valve material
Root Valve size
Accessories
Minimum Requirement
Table 2.29
Specification for Venturi
S.N
Feature
Design standard
Material
Type
Mounting
Root Valve type
Root Valve material
Root Valve size
Accessories
Minimum Requirement
Table 2.30
Specification for Flow Nozzle
S.N
Feature
Type
Material
Thickness
Beta ratio
Minimum Requirement
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[21]
25.09.2014
the Power Plant]
S.N
Feature
[Logo of Utility]
Minimum Requirement
Tappings
Root Valve type
Root Valve material
Root Valve size
Accessories
Table 2.31
Specification for Oxygen Analyzer
S.N
Feature
Type
Principle
Sensor Type
Measurement Range
Accuracy
Linearity
Response time
Drift
Operating
Range
Minimum Requirement
Temperature
10
11
Sample filter
12
13
Ambient Temperature
14
Indication
15
16
Type of Electronics
17
Calibration
18
Output signals
19
20
Other requirement
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[22]
25.09.2014
the Power Plant]
[Logo of Utility]
Table 2.32
Specification for Coriolis Flow meter
S.N
Feature
Service
Primary Element
Heating arrangement
Temperature control
Allowable pressure drop
End Connection type/size
Cable entry
Accuracy
Power supply
10
Drain
11
Enclosure
12
Display
13
Output
14
Load
15
Turn down Ratio
16
Housing
17
Hazardous duty Version
18
Accessories
Minimum Requirement
Table 2.33
Specification for Carbon Monoxide Analyzer
S.N
Feature
Type
Principle
Sensor Type
Measurement Range
Accuracy
Linearity
Response time
Drift
Minimum Requirement
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[23]
25.09.2014
the Power Plant]
S.N
9
Feature
[Logo of Utility]
Minimum Requirement
Operating Temperature
Range
10
11
Sample filter
12
13
Ambient Temperature
14
Indication
15
16
Type of Electronics
17
Calibration
18
Output signals
19
20
Other requirement
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[24]
25.09.2014
the Power Plant]
[Logo of Utility]
INSTRUMENTATION CABLES & ACCESSORIES

Table 3.1
Data Sheet for Thermocouple Cable
S.N
Feature
Make
Type
No. of pairs
Conductor material/Size
No. of Strands/Area of cross section
Conductor Insulation
Lay
Shielding
Drain Wire
10
No. of twist per metre
11
Pair Identification
12
Inner Sheath
13
Armour
14
Outer Sheath
15
Color Coding
16
Voltage Grade
17
Code/Standard
Table 3.2
Data Sheet for RTD Cable
S.N
Feature
Make
Type
No. of Triads
Conductor Material/Size
Conductor Type
Resistance
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[25]
25.09.2014
the Power Plant]
S.N
Feature
Core Insulation
Lay
10
Shielding
11
Drain Wire
12
Triad Identification
13
Inner Sheath
14
Inner screen
15
Armour
16
Outer Sheath
17
No. of Twist per metre
18
Color Coding
19
Voltage Grade
20
Code/Standard
[Logo of Utility]
Table 3.3
Data Sheet for Instrumentation Signal Cable
S.N
Feature
Make
Type
No. of Pairs
Conductor Material/Size
Conductor Type
Resistance
Core Insulation
Lay
10
Shielding
11
Drain Wire
12
Pair Identification
13
Inner Sheath
14
Inner screen
15
Armour
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[26]
25.09.2014
the Power Plant]
S.N
Feature
16
Outer Sheath
17
No. of Twist per metre
18
Color Coding
19
Voltage Grade
20
Code/Standard
[Logo of Utility]
Table 3.4
Data Sheet for Fibre Optic Cable (Single Mode)
S.N
Feature
@1310 nm
Maximum
Uncabled
Mode field Diameter
Maximum Cable Cut-off Wavelength
Maximum Zero Dispersion Wavelength
Minimum Zero Dispersion Wavelength
Maximum Zero Dispersion Slope
Maximum Polarization Mode Dispersion
Gigabit Ethernet Length 1000BASE-LX

Length
@1550 nm
@1310 nm
@1550 nm
10GBASE-LX
10GBASE-LX4
10
11
Cladding Diameter
12
13
Coating Diameter
14
15
16

85C, 4 to 90% RH)
17
Minimum Proof Test
18

75mm diameter)
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[27]
25.09.2014
the Power Plant]
[Logo of Utility]
Table 3.5
Data Sheet for Fibre Optic Cable (Multi Mode)
S.N
Feature
Maximum
Uncabled
Overfilled Launch
Bandwidth
Gigabit Ethernet Length

Length
@850 nm
@1300 nm
@850 nm
@1300 nm
1000BASE-SX
1000BASE-LX
10GBASE-SR
10GBASE-LX4
Numerical Aperture
Core Diameter
Maximum Core Non-circularity
Cladding Diameter
10
11
Coating Diameter
12
13
14

85C, 4 to 90% RH)
15
Minimum Proof Test
16

75mm diameter)
Table 3.6
Data Sheet for Cable Tray
S.N
Feature
Make
Material
Size (Width/Height)
Perforation
Length
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[28]
25.09.2014
the Power Plant]
S.N
Feature
[Logo of Utility]
Thickness
Coating of Hot dip Galvanizing
Accessories
Code/Standard
Table 3.7
Data Sheet for Cable Glands
S.N
Feature
Make
Type of Protection
Compression
Threading Type
Material
Check Nut
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[29]
25.09.2014
the Power Plant]
[Logo of Utility]
PROCESS CONNECTION PIPING & ACCESSORIES

Table 4.1
Data Sheet for Impulse Piping
S.N
Feature
Make
Material
Size
Schedule/Thickness
Test Pressure
Table 4.2
Data Sheet for Copper Tubing
S.N
Feature
Make
Material
Size
Schedule/Thickness
Test Pressure
PVC Coating thickness
Table 4.3
Data Sheet for Fittings for Impulse Piping
S.N
Feature
Make
Type of Fitting
Material
Size
Pressure Rating
Temperature Rating
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[30]
25.09.2014
the Power Plant]
[Logo of Utility]
Table 4.4
Data Sheet for Compression Fittings for Impulse Tubing
S.N
Feature
Make
Type of Fitting
Material
Size
Ferrule
Pressure Rating
Temperature Rating
Table 4.5
Data Sheet for CS Piping
S.N
Feature
Make
Material
Size
Schedule/Thickness
Test Pressure
Type of threading
Thickness of galvanization
Table 4.6
Data Sheet for Ball Valves
S.N
Feature
Make
Size
Rating
Design Pressure
Design Temperature
Bore
End Connections
Body Material
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[31]
25.09.2014
the Power Plant]
S.N
Feature
Ball Material
10
Seat Material
11
Stem material
[Logo of Utility]
Table 4.7
Data Sheet for Globe Valves
S.N
Feature
Make
Size
Rating
Design Pressure
Design Temperature
Bore
End Connections
Body Material
Ball Material
10
Seat Material
11
Stem material
Table 4.8
Data Sheet for Air Header
S.N
Feature
Make
Material
Size
Thickness
Test Pressure
Inlet Connection
Outlet Connection
Drain Connection
Inlet Valve type/size
10
Drain Valve type/size
11
Distribution Valve type/size
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[32]
25.09.2014
the Power Plant]
[Logo of Utility]
Table 4.9
Data Sheet for Instrument Manifolds
S.N
Feature
Make
Material
Size
Type
Ports
Rating
Connection
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[33]
25.09.2014
the Power Plant]
[Logo of Utility]
SYSTEM CABINETS & JUNCTION BOX

Table 5.1
Data Sheet for Cabinets
S.N
Feature
Make
Cabinet Dimension
Protection class
Doors
Cable entry
Anti vibration pad
Painting
Gland Plate thickness
10
Grounding
11
Ventilation
12
Lighting
13
Lifting arrangement
14
Tag Plates
Table 5.2
Data Sheet for Junction Box
S.N
Feature
Make & Model No.
Dimension
Mounting
Protection class
Doors
Cable entry
Gasket
Painting
10
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[34]
25.09.2014
the Power Plant]
S.N
Feature
11
Grounding
12
Tag Plates
[Logo of Utility]
16
Table 5.3
Data Sheet for LIE/LIR
S.N
Feature
Make & Model No.
Mounting
Protection class
Doors
Cable entry
Air Connection
Sample line Entry
10
Drain Pipe
11
Painting
12
Anti Vibration Pad
13
Grounding
14
Tag Plates
15
Dimension
Document Number
Rev
No.
Description
Page
No.
Date of Issue
LII-GETS12021-G-00129-001
02

Volume-III, Part-C
[35]
25.09.2014

OF

R&M CONTRACTORS

VOLUME-I
COMMERCIAL
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-002 R02
September 2015
[Logo of Utility]
Power Plant]

Sec
tio
n
Volume
Volume-I
Part
Description
---
---
Commercial
Section-I
---
Part-A
Part-B
Part-C
Part-D
---
Part-A
---
Part-B
---
Part-C
---
Part-D
Not Used
Volume-II
Section-II
Volume-III
*****
Document Number
Rev No
LII-GETS12021-G-00129-002
02
Description
Tender Document for Selection of R&M Contractors
Turbo Generator & Auxiliaries
Volume-I
Page No.
Date of Issue
[i]
30.09.2015
[Logo of Utility]
Power Plant]
1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
*****
Document Number
Rev No
LII-GETS12021-G-00129-002
02
Description
Volume-I
Page No.
Date of Issue
[ii]
30.09.2015
[Logo of Utility]
Power Plant]

SECTION-I:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Spare Parts
10.
Annexure
SECTION-II:
1.
2.
3.
4.

*****
Document Number
Rev No
LII-GETS12021-G-00129-002
02
Description
Volume-I
Page No.
Date of Issue
[iii]
30.09.2015
[Logo of Utility]
Power Plant]

1.
2.
3.
*****
Document Number
Rev No
LII-GETS12021-G-00129-002
02
Description
Volume-I
Page No.
[iv]
Date of Issue
30.09.2015
[Logo of Utility]
Power Plant]
TABLE OF CONTENTS
1.0 INVITATION FOR BID ................................................................................................... 1
1.1
1.2
1.3
1.4
1.5
1.6
2
Introduction............................................................................................................. 1
Invitation ................................................................................................................. 1
Brief Scope of Work ................................................................................................ 1
Tender Details ........................................................................................................ 1
Time Schedule........................................................................................................ 2
Bid Submission ....................................................................................................... 2
INSTRUCTIONS TO BIDDERS...................................................................................... 3
2.1
Introduction............................................................................................................. 3
2.2
Address and Contact Details of Owner ................................................................... 3
2.3
General Project Information .................................................................................... 3
2.4
Owners Consultant ................................................................................................ 3
2.5
Sources of Fund ..................................................................................................... 3
2.6
Cost of Bidding ....................................................................................................... 3
2.7
Non-Transferability of Bid document ....................................................................... 3
2.8
Scope of Work & Single Bidder Responsibility ........................................................ 3
2.9
Time Schedule........................................................................................................ 4
2.10 Tender Documents ................................................................................................. 4
2.11 Preparation of Bids ................................................................................................. 6
2.11.1
Language of Bid ............................................................................................ 6
2.11.2
Bidding Procedure ......................................................................................... 6
2.11.3
Bid Submission ............................................................................................. 6
2.11.4
Bid Guarantee ............................................................................................... 7
2.11.5
Bid Opening .................................................................................................. 8
2.12 Composition of Techno Commercial Bid (Part-1 Bid) .............................................. 9
2.13 Composition of Price Bid (Part-II Bid) ..................................................................... 9
2.14 Bid Prices ............................................................................................................. 10
2.15 Signature of Bids .................................................................................................. 11
2.16 Clarifications/Corrigendum/ Amendment of Tender Specifications ........................ 11
2.17 Modification of Bids .............................................................................................. 11
2.18 Information to be Furnished with the Bid ............................................................... 11
2.19 Policy of Bids under Consideration ....................................................................... 12
2.20 Validity of Bid ........................................................................................................ 12
2.21 Understanding & Clarification on Documents & Specifications .............................. 12
2.22 Latest Hour for Receipt of Bids ............................................................................. 13
2.23 Single Bidder Responsibility ................................................................................. 13
2.24 No Claim for Compensation for Submission of Bid ............................................... 13
2.25 Deputation of Representatives for Discussion....................................................... 13
2.26 Evaluation of Bid................................................................................................... 13
2.27 Local Conditions ................................................................................................... 15
2.28 Deviations............................................................................................................. 16
2.29 Blacklisting/Debarring ........................................................................................... 16
2.30 Award of Contract ................................................................................................. 16
2.31 Agency Commission ............................................................................................. 18
Document Number
Rev No
LII-GETS12021-G-00129-002
02
Description
Volume-I
Page No.
Date of Issue
[v]
30.09.2015
[Logo of Utility]
Power Plant]
2.32
2.33
2.34
2.35
3
GENERAL PROJECT INFORMATION ........................................................................ 20

3.1
Contract Performance Bank Guarantee (CPBG)................................................... 18

Contract Quality Assurance .................................................................................. 19
Codes & Standards ............................................................................................... 19
Vital Clauses......................................................................................................... 19
Project & Site Information ..................................................................................... 20
GENERAL CONDITIONS OF CONTRACT (GCC)....................................................... 21

4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.27
4.28
4.29
4.30
4.31
4.32
4.33
4.34
4.35
4.36
4.37
4.38
Definitions............................................................................................................. 21
Contract Documents ............................................................................................. 25
Order of Precedence of Contract Documents ....................................................... 25
Interpretation ........................................................................................................ 25
Construction of the Contract ................................................................................. 25
Independent Contractor ........................................................................................ 26
Joint Venture or Consortium ................................................................................. 27
Non-Waiver .......................................................................................................... 27
Severability ........................................................................................................... 27
Origin.................................................................................................................... 27
Notices ................................................................................................................. 27
Governing Laws.................................................................................................... 27
Settlement of Disputes.......................................................................................... 28
Scope of Facilities ................................................................................................ 29
Spare Parts .......................................................................................................... 29
Contractors Responsibilities................................................................................. 31
Owners Responsibilities ....................................................................................... 32
Taxes & Duties ..................................................................................................... 32
Intellectual Property .............................................................................................. 33
Confidential Information ........................................................................................ 33
Representatives.................................................................................................... 34
Work Program ...................................................................................................... 35
Subcontractors and Subvendors ........................................................................... 36
Design and Engineering ....................................................................................... 36
Procurement ......................................................................................................... 37
Installation ............................................................................................................ 38
Testing & Inspections ........................................................................................... 40
Completion of the Facilities ................................................................................... 41
Commissioning & Operation Acceptance .............................................................. 42
Completion Time and Liquidated Damage ............................................................ 43
Defects Liability .................................................................................................... 43
Functional Guarantees ......................................................................................... 44
Patents Indemnity ................................................................................................. 44
Limitation of liability .............................................................................................. 44
Transfer of Ownership .......................................................................................... 45
Care of Facilities ................................................................................................... 45
Loss of or Damage to Property; Accident or Injury; Indemnification ...................... 45
Document Number
Rev No
LII-GETS12021-G-00129-002
02
Description
Volume-I
Page No.
[vi]
Date of Issue
30.09.2015
[Logo of Utility]
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4.39
4.40
4.41
4.42
4.43
4.44
4.45
4.46
5
SPECIAL CONDITIONS OF CONTRACT (SCC) ......................................................... 57

5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
Insurance.............................................................................................................. 45
Change in Laws & Regulation............................................................................... 47
Force Majeure ...................................................................................................... 48
Change in the Facilities ........................................................................................ 48
Extension of Time for Completion ......................................................................... 50
Suspension........................................................................................................... 50
Termination .......................................................................................................... 51
Assignment........................................................................................................... 56
Contract Details .................................................................................................... 57
Effective Date ....................................................................................................... 57
Liquidated Damage for Delay ............................................................................... 58
Rate of Liquidated Damage for Delay ................................................................... 58
Liquidated Damage for Non-fulfillment of Functional Guarantees ......................... 58
Maximum Leviable Liquidated Damages .............................................................. 59
Contract Price ....................................................................................................... 59
Terms of Payment ................................................................................................ 60
Bank Guarantees.................................................................................................. 60
FORMS AND SCHEDULES ......................................................................................... 62
Document Number
Rev No
LII-GETS12021-G-00129-002
02
Description
Volume-I
Page No.
Date of Issue
[vii]
30.09.2015
[Logo of Utility]
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List of Acronym
CIF
Cost Insurance Freight
CPBG
Contract Performance Bank Guarantee
CST
Central Sales Tax
EDI
Electronic Data Interchange
EUR
Euro
FOB
Free on Board
GCC
General Conditions of Contract
GOI
Government of India
GST
Goods & Service tax
ICB
INR
Indian Rupees
I&C
Instrumentation & Control
ITB
JV
Joint Venture
LOA
Letter of Award
LOI
Letter of Intent
MoEF
Ministry of Environment and Forests
MSL
Mean Sea Level
PERT
Program evaluation and review technique
RBI
Reserve Bank of India
R&M
Renovation and Modernization
SCC
Special Conditions of Contract
TMCR
UNCITRAL
United Nations Commission on International Trade Law
USD
US Dollar
VAT
Value added Tax
Document Number
Rev No
LII-GETS12021-G-00129-002
02
Description
Volume-I
Page No.
Date of Issue
[viii]
30.09.2015
[Logo of Utility]
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1.0
INVITATION FOR BID

Tender No
1.1
[ ---------------------------------------------------------------------------]
Introduction
[Give brief introduction about the name, ownership, business & Power Projects of the
utility inviting tender for R & M work]
[XXX is undertaking renovation & modernization of XXX MW Unit no.-XX --------- of the
Power Plant]
1.2
Invitation
[Name of The Utility], hereinafter referred to as Employer / Owner / Purchaser, invites
sealed Tenders in English language from Prequalified Bidders for the Renovation &
Modernization of Turbo Generator & Auxiliaries package of Unit No.[XXX] of the [XXX]
Power Plant on International Competitive Bidding (ICB) basis as per the scope of work
given Technical Specification Volume-II.
1.3
Brief Scope of Work

The scope of work under this R&M package involves disassembly of existing
equipment / systems, replacement of specified equipments / systems by supplying new
equipments/ systems including supply of assembly materials, inspection & testing at
suppliers works, supply of mandatory spares, packing and forwarding, transportation &
insurance, receipt at site, unloading, handling & storage at site, pre-assembly,
fabrication, repair, servicing/ overhauling, erection, all associated civil works including
supply of cement, steel etc., testing & commissioning, successful completion of trial
operation and guarantee tests for [Turbo Generator & Auxiliaries] package of Unit no.
[XXX] of [XXX] Power Plant. The detailed scope of work is given in technical
specification Vol. II.
The brief scope of work is given below: [-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------]
For detailed Scope of Work & Services, refer Section-I of Volume-II of this
Specification.
1.4
Tender Details
(a)
Cost of Tender
Documents
: INR [---]/ USD [---]/ EUR [---]
(b)
: INR [--------]/ USD [--------]/ Euro [--------]
(c)
Date of issuance of
Tender Document
: [----------------------------]
(d)

Conference
: [----------------------------]
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Contractors Turbo Generator & Auxiliaries
Volume-I
Page No.
- 1-
Date of Issue
30.09.2015.
[Logo of Utility]
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1.5
(e)
Last Date & Time of

Part I & Part II)
: [----------------------------]
(f)
Date & Time of

Opening of Unpriced
Techno-Commercial
Bid (Part-I)
: [----------------------------]
Time Schedule
The time schedule for completion of facilities and performance guarantee test shall be
as per SCC.
1.6
Bid Submission
(b) The Bid proposals are to be submitted in two parts in separate sealed covers as
follows:
Part I
Bid Guarantee and Technical & Commercial Proposal without

prices
Part II
Price Schedule and Schedule

parameters with values.
of
Functional
Guarantee
(c) All other terms and conditions along with the Technical Specifications, General
Guarantee details, Validity of Bid and Instructions to Bidders, etc. are contained
in the Tender Documents.
(d) Bidder shall submit the bid on or before the scheduled date and time as specified.
Any offer received after the expiry of the time specified for receiving the
completed bids are liable for rejection. The bid shall be submitted to:
------------------------------------------------------------- ]
(e) Issuance of Tender Documents to a Bidder shall not be construed to mean that
such Bidder would be automatically considered.
(f) The Bid may be made in Indian Rupees as well as in Foreign Currencies
made in Indian Rupees as well as in the respective quoted Foreign Currencies.
(h) The Tender Documents are meant for the exclusive purpose of bidding against
the subject package and shall not be transferred, reproduced or otherwise used
for purposes other than for which these are specifically issued.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 2-
Date of Issue
30.09.2015.
[Logo of Utility]
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2.1
Introduction
[Name of Utility], the Owner, intends to carry out the Renovation & Modernization of
[Unit no.-XX --------- of the XXXX Power Plant].
Under the subject Tender, [Utility] invites bid for Renovation & Modernization of Turbo
Generator & Auxiliaries package of the said Renovation & Modernization work to be
carried out as per the accompanying Technical Specifications. The Bidder shall submit
the offer for complete scope of work indicated in the Technical Specification.
2.2
Address and Contact Details of Owner

---------------------------------------------------------------------------------------------------------------------------]
2.3

2.4
Owners Consultant
[------------------------------------------], hereinafter referred to as Consultant is the
Consulting Engineer for the project, appointed by the Owner, [---------------------], to
provide project consultancy services.
2.5
Sources of Fund
[Utility] intends to finance the subject Package of the said renovation & modernization
work, through Internal and other sources & External/ Domestic Commercial/ Borrowing
from international development funding agencies. [Utility] has tied up the required fund
for this package.
2.6
Cost of Bidding
The Bidder shall bear all costs associated with the preparation and submission of its
bid, and the Owner will in no case be responsible or liable for these costs, regardless
of the conduct or outcome of the bidding process.
2.7

Transfer of Bid documents issued to one intending bidder to another is not permissible.
2.8

The scope of the work shall be on the basis of single Bidder responsibility, covering the
complete scope of work specified under these specifications and documents. It shall
include the following:
(a) Disassembly of existing equipment/ systems as required.
(b) Detailed design of the systems/equipment covering all Mechanical, Electrical,
Control & Instrumentation, Civil and Structural works.
(c) Complete manufacture, including shop inspection and testing.
(d) Providing engineering drawings, data, operational & maintenance manuals, etc.,
for the Owners review/ approval.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 3-
Date of Issue
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[Logo of Utility]
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(e) Packing, forwarding and transportation including insurance from the

manufacturers works to plant site and transportation from storage yard to
erection site.
(f) Receipt, storage, preservation and conservation of system/equipment at site
including construction of storage facility viz. covered, semi-covered, airconditioned, open yard at the space allocated at site by Owner including storagecum-erection and all other specified & statutorily required insurance.
(g) Pre-assembly, if any, erection, testing, commissioning, completion of plant and
equipment/ system, conducting trial operation, performance guarantee test and
handing over of all the plant and equipment/ system covered under this
specification.
(h) Carrying out all related civil and structural works at site including construction of
foundations, buildings, structures etc. Including supply of cement and steel and
all other required materials.
(i) Supply of mandatory spares and tools & tackles.
(j) Training of Owners personnel.
Detailed scope is provided in Volume-II of the Technical Specifications.
Bids not covering the entire scope mentioned hereinabove may be treated as
incomplete and hence are liable for rejection.
2.9
Time Schedule
The completion Time Schedule for Completion of R&M work and Performance
Guarantee Tests shall be as given in the SCC.
2.10
Tender Documents
The scope of contract, technical specification, bidding procedures and contract terms
are prescribed in the Tender Documents. The Tender Documents comprise, inter alia,
the following volumes:
Volume I
Commercial
Volume I
Chapter-1
Invitation for Bid
Volume I
Chapter-2
Volume I
Chapter-3
Volume I
Chapter-4
Volume I
Chapter-5
Volume I
Cahpter-6
Forms & Schedules
Volume II
Technical Specifications
Volume II
Section-I
Volume II
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
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[Logo of Utility]
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Section-II, PartA
:
Volume II
Section-II, PartB
:
Volume II
Section-II,
Part-C
Volume II
Section-II,
Part-D
Volume III
Technical Schedules
Volume III,
Part-A
Technical Schedule-Mechanical
Volume III,
Part-B
Technical Schedule-Electrical
Volume III,
Part-C
Technical Schedule-I&C
The Bidder is expected to examine all instructions, forms, terms and specifications in
the Tender Documents including clarifications/corrigendum/amendments for
completeness and obtain clarifications, if any, from the Owner.
The Bidder is expected to examine all instructions, forms, terms, conditions,
specifications and other information in the bidding documents. Failure to furnish all
information required as per the bidding documents or submission of a bid not
substantially responsive to the bidding documents in every respect will be at the
Bidder's risk and may result in rejection of its bid.
A prospective Bidder requiring any clarification to the Tender Documents may notify the
Owner in writing by post or by e-mail followed by postal confirmation at the Owner's
address indicated in ITB. The Owner will respond in writing by post or by e-mail
followed by post confirmation to any request for clarification or modification of the
bidding documents that it receives not later than twenty-one (21) days prior to the
deadline for submission of bids prescribed by the Owner. Owner's response will be
sent to all prospective Bidders that have been issued the Bidding Documents.
information that may be necessary for preparing the bid. The Owner will facilitate the
bidder to collect such information about the plant in the manner that does not interface
with plant operation and does not in any way adversely impact the interest of the
Owner. The costs of visiting the site including engaging any third party consultant by
Bidder, if required as per the assessment of Bidder, shall be borne by the bidder fully.
personnel and agents from and against all liability during such information collection
and will be responsible for death or personal injury, loss of or damage to property and
any other loss, damage, costs and expenses incurred as a result of the inspection.
At any time prior to the deadline for submission of bids, the Owner may, for any reason,
whether at its own initiative, or in response to a clarification requested by a prospective
Bidder, amend the bidding documents.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 5-
Date of Issue
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[Logo of Utility]
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confirmation to all prospective Bidders that have received the bidding documents and
will be binding on them.
At any time prior to the deadline for submission of bids, the Owner, at its discretion may
extend the deadline for submission of the bids.
2.11
Preparation of Bids
2.11.1
Language of Bid
The bid prepared by the Bidder and all correspondence and documents related to the
bid shall be in English language, provided that any printed literature furnished by the
Bidder may be written in another language, as long as such literature is accompanied
by a translation of its pertinent passages in English language in which case, for
purposes of interpretation of the bid, the translation shall govern.
2.11.2
Bidding Procedure
The bidders are required to submit, the bids for the Renovation and Modernization
work in two parts. Both the parts are to be submitted together before the indicated Bid
components of the Techno-Commercial Bid are Bid Guarantee, Scope of Work &
Terminal Points, Technical descriptions/details, Technical Data Sheets, List of Tools &
Tackles, Deviations to Technical and Commercial Specifications/Conditions, Overall
Completion Time Period & L-1 Network Schedule, Resource Deployment Schedule,
Detail of Sub-Contractors/Sub-Suppliers/Sub-Vendors, Spares list, Quality Assurance
Programme, Details of the present commitments & details of contracts in hand, Indices
and Coefficients for Price Variation etc. Part-II Bid will comprise Quoted Price and
Quoted Performance Guarantee Parameters. Initially, only the Part-I Bid will be opened
and Part-II Bid is kept in safe custody.
After evaluation of the Techno-Commercial (Part-I) Bids, each Bidder who has
submitted a broadly responsive Part-I Bid, will be invited for Techno-Commercial
Discussion, during which, all the required amendments, additions, deletions and other
adjustments are noted and recorded in a memorandum. Part-II Bid (Price Bid) of only
those Bidders will be opened, whose Part-I Bid is found to be responsive to Tender
Specifications and Conditions. The date & time for opening of Price Bid will be
intimated separately.
Techno-Commercial Bid should not contain any price data.
Price Bid should not contain any matter in respect of Technical and / or Commercial
aspects other than the details specifically sought by the Owner.
2.11.3
Bid Submission
(1). Bid proposals shall be accepted from only those eligible bidders who are found
qualified during the pre-qualification process & are issued Tender Documents.
Unsolicited bids shall not be taken into cognizance.
separate sealed covers, with all pages serially numbered. All bids shall be
prepared in the English language only, by typing or printing.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 6-
Date of Issue
30.09.2015.
[Logo of Utility]
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(3). [One original and 9 (nine) identical] copies of the original with all enclosures shall
be submitted by each Bidder for Part-I and Part-II, clearly indicating the original
and the number of the copy (i.e., Original, Copy No. 1, Copy No. 2 etc.).
(4). All these covers shall be individually sealed and put in an outer cover which also
shall be sealed and super scribed as in other covers.
(5). The covers should be pasted properly before applying the wax seal. Failure to do
so may result in rejection of such bids.
(7). In the event of discrepancy between Original and any copy of the bids, the hard
copy of Original shall prevail.
(8). The Bid shall be submitted to [---------------------------]. Bid submitted to any other
office of Owner is liable for rejection. Bids submitted by Telefax or e-mail will be
rejected
(9). Owner will receive Bids in respect of all the equipment/systems and scope of
work as set forth in the accompanying Technical Specifications. All bids shall be
prepared and submitted in accordance with the Tender Documents.
(10). Failure to furnish all information required in the Tender Documents or submission
of a Bid not substantially responsive to the Tender Conditions and Technical
Specifications in every respect or bids received in incomplete shape shall be
liable for rejection. A bid shall be determined as substantially responsive in every
respect, if it conforms to all the terms, conditions and specifications specified in
Tender Documents without material deviations, objections, conditionality or
reservations.
(i). That affects in any substantial way the scope, quality or performance of the
contract;
(ii). That limits in any substantial way, inconsistent with the Tender Documents,
the Owners rights or the successful Bidders obligations under the contract.
Tender Documents, the Bidder has to make independent inquiries and generally
obtain his own information on all matters that may in any way affect prices, risks
and obligations of the Contractor under the Contract.
(14). Either the Indian agent or the foreign Principal directly could bid in a tender, but
not both. The same applies to an Indian agent/dealer representing and Indian
manufacturer. In case both submit the tenders, the tender of the manufacture will
alone be considered.
(15). An agent representing one manufacturer in a tender will not be allowed to quote
on behalf of another manufacturer along with previous manufacturer in a
subsequent / parallel tender for the same item.
2.11.4
Bid Guarantee
(Part-I) or Demand Draft of equivalent amount drawn in favour of [--------------]
payable at [--------].
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 7-
Date of Issue
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[Logo of Utility]
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authorized by Reserve Bank of India,, to issue such Bank Guarantee on a nonjudicial stamp paper of value not less than Rs. [---]/-.The stamp paper shall be
purchased in the name of the Bank. Foreign Bidders may submit the Bank
Guarantee from any bank in India as above or from any foreign bank which is in
the approved list of RBI.
a) The Bid Guarantee shall be executed only on behalf of the Bidder in whose
b) The Bid and other documents shall be submitted only by the Bidder in whose
Owner at ([--------------]). In the event of any deviation in this regard, the
decision of Owner as to whether the same could be accepted or not, will be
final and binding on the Bidder.
Euro/ Indian Rupee.
Guarantee or with short Bid Guarantee or Bid Guarantee in the form other than
that specified herein above or from banks not specified hereinabove will be liable
for rejection.
(6). Any Bid not accompanied by the Bid Guarantee shall be rejected and the Bidder
shall not be permitted to participate in the tender.
(7). The Bid Guarantee shall be forfeited if the Bidder withdraws / modifies / changes
/ impairs / derogates the bid proposal on its own after the Bids are opened or
submits forged/bogus certificates or fails to accept the Letter of Award issued by
Owner or fails to submit Contract Performance Guarantee.
(8). The Bid Guarantee of all unsuccessful Bidders shall be returned after price cover
opening and price evaluation. The Bid Guarantee of the successful Bidder shall
be returned after furnishing of the Contract Performance Bank Guarantee to the
Owner and acceptance thereof.
2.11.5
Bid Opening
1.
2.
This is a single stage two part tender. On the specified date and time of opening,
Part I Bid containing Bid Guarantee and Technical and Commercial Proposal
without Prices will be opened. At the time of opening of PartI of the bids, the
names of the bidders who submitted their bids shall be read out and other such
details as Owner, at its discretion, may consider appropriate, shall be read out.
The Part II (Price Bid) will be lodged and opening date of the same will be
intimated separately to those Bidders whose Part-I Bid will be determined to be
substantially responsive to Tender Conditions and Technical specifications in all
respects.
If the Bidder desires to be present at the time of opening of Part-I of bids, it shall
depute its representatives (not more than two persons) in time with due
Document Number
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Rev No.
02
Description
Volume-I
Page No.
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Date of Issue
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[Logo of Utility]
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3.
2.12
Owner takes no responsibility for delays, loss or non-receipt of Bid documents or

any letters sent by post/courier either way and also reserve the right to reject any
Bid in part or full without assigning any reasons thereof.
Composition of Techno Commercial Bid (Part-1 Bid)
This part shall, inter alia, include the following in the same order as listed below.
One original and 9 (nine) identical copies shall be submitted.
(i).
Duly filled in "Form of Bid" (As per Annexure-B & Annexure-C of this Volume).
(ii).
Power of Attorney/Authorization with the seal of the company in favour of the
person signing the Bid.
(iii).
Letter of consent: To be furnished by the Bidder and Consortium
Partners/Individual Companies of the Group (as the case may be)- as per
AnnexureD of this Volume
(iv).
Letter of Unequivocal Consent to be furnished by the Bidder and Assignee as
per Annexure-E of this Volume
(v).
(vi).
Schedule of Prices as per Schedule F1 (Table 1 to Table-7) with the word
Quoted in lieu of Price data and all other details except price data.
(vii). Mandatory spares as per Technical Specifications (with the word Quoted in
lieu of Price data)
(viii). Recommended spares (with the word Quoted in lieu of Price data)
(ix).
Tools & Tackles as per Technical Specifications (with the word Quoted in
lieu of Price data)
(x).
Schedule of Performance Guarantees- as per Schedule F1 (Table-8) with
the word Quoted in lieu of Performance Guarantee parameters
(xi).
Signed copy of all the corrigendums/amendments/clarifications, if any issued
for the tender
(xii). Overall Time Schedule as per Schedule F2 and Bar chart/PERT Network
(xiii). Deviations to the Commercial specification, if any, as per Schedule F3.
(xiv). Deviations to Technical Specifications, if any, as per Schedule F4.
(xv). Requirements of the Contractor at site, as per Schedule F5.
(xvi). Resource deployment schedule as per Schedule F6
(xvii). Details of the present commitments of the Bidder, details of contracts in hand
(xviii). Details of Sub-Contractors/Sub-Suppliers/Sub-Vendors, if any
(xix). Quality Assurance Programme
(xx). Technical Details to be furnished with the Bid as called for in the Technical
Specification Vol-II and Technical Bid Data Sheet Vol-III.
(xxi). Schedule of weights and dimensions
(xxii). Coefficients and indices for price variation formula
2.13

The Bidders are requested to quote the Prices and the Performance Guarantee
parameters only in the specified format. Price given in Part-II should cover the entire
Document Number
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Rev No.
02
Description
Volume-I
Page No.
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[Logo of Utility]
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scope of work as given in Part-I of the offer including list of mandatory spares and
Tools & tackles with itemized price and should be as per Schedule of Price enclosed.
[One original and 9 (Nine) identical] copies shall be submitted.
1.
The Price Bid shall contain the following :
(i). Duly filled in Form of bid as per Annexure-B & Annexure-C
(ii). Completely filled in Schedule of Prices Schedule F1 (Table 1 to Table-7)
(iii). Completely filled in Schedule of Performance Guarantees Schedule F1
(Table-8).
2. The Bidder shall quote his price against each item of the schedules as indicated in
the enclosed formats. The Bidder shall quote the prices only once after
considering all the pros and cons, risks and contingencies. Rebate percentage
etc., if any, should be spelt out by the Bidder in the first Bid itself.
overwriting is allowed. All scoring and cancellations should be countersigned by
the Bidder. In case of illegibility, the interpretation of the Owner shall be final. All
entries shall be in English language only.
4. The Bid may be made in Indian Rupees as well as in Foreign Currencies
made in Indian Rupees as well as in the quoted Foreign Currencies.
5. Prices in Indian supply shall be quoted on Ex-works supply of plant & equipment
basis including Packing & forwarding. Inland transportation, Insurance charges,
etc. shall be indicated separately.
6. Prices of imported supply of plant & equipment directly consigned to site shall be
quoted on CIF Indian port on entry basis. The bidder shall also quote separately
for FOB port of shipment price for ocean freight for Marine insurance, all port
charges including customs clearance and inland transport charges from port of
destination to Owners site.
7. Custom Duty, Excise Duty, Central sales tax (CST), service tax, Value Added Tax
considered for bid evaluation.
2.14
Bid Prices
total bid price covers all the Contractor's obligations mentioned in tender document
specification or to be reasonably inferred from the tender documents/ specification in
respect of the disassembly/ dismantling of existing equipment facility as specified,
design, manufacture, including procurement and subcontracting (if any), delivery,
construction, installation, commissioning, completion of the facilities and conductance
of Performance Guarantee tests for the facilities including supply of mandatory spares,
recommended spare & tools/ tackles (if any). This includes all requirements under the
Contractor's responsibilities for testing, pre-commissioning and commissioning of the
facilities, conducting Guarantee tests and, where so required by the tender documents,
the acquisition of all permits, approvals and licenses, etc.; the operation, maintenance
and training services and such other items and services as may be specified in the
tender documents, all in accordance with the requirements of the Conditions of
Contract and Technical Specifications.
Bidders are required to quote the price for the commercial, contractual and technical
obligations outlined in the tender documents.
Document Number
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Rev No.
02
Description
Volume-I
Page No.
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Prices quoted by the Bidder shall be subject to adjustment during performance of the
Contract to reflect changes in the cost of labour, material, etc. A bid submitted with a
fixed price quotation will not be rejected, but the price adjustment will be treated as
zero. The price adjustment provision will not be taken into consideration in bid
evaluation.
2.15
Signature of Bids
signature. The names of all persons signing should also be typed or printed below the
signature. Satisfactory evidences of authority of a person signing on behalf of the
Bidder shall be furnished with the Bid. Erasures or corrections in the Bid documents if
any shall be signed by the person signing the Bid. Printed literature, it enclosed need
not be signed. Bids not conforming to the above requirements are liable to be treated
as non-responsive.
2.16

1. At any time prior to the deadline for submission of Bids, the Owner may, for any
reason, whether at his own initiative or in response to clarification(s) requested by
a prospective Bidder, modify the Tender Specifications by amendment.
2. Clarifications/Corrigendum/Amendment shall be construed to be an integral part of
the Tender Specifications, which will be notified. Amendments will be hosted in
Owners website. Bidders are requested to visit Owners website and note
amendments, if any, before submission of bid. Owner shall not be responsible if
any bidder fails to notice any amendment.
2.17
The Bidder is not permitted to modify his Bid suo-moto after the Bid submission.
2.18
Information to be Furnished with the Bid

1.
2.
3.
4.
The Bid (Part-I) must clearly indicate the name of the manufacturer, the type or
model of each principal item of equipment proposed to be supplied and erected.
The Bid should also contain drawings and descriptive materials indicating general
dimensions, material from which the parts are manufactured, principles of
operation and the extent of pre-assembly involved, major erection equipment
required to be deployed, method of erection and the proposed erection
Organization structure.
The above information shall be provided by the Bidder in the form of separate
sheets, drawings, catalogues, etc.
Any Bid not containing sufficient descriptive material to describe accurately the
system / equipment proposed may be treated as incomplete and hence rejected.
Such descriptive materials and drawings submitted by the Bidder will be retained
by the Owner. Any major departure from these drawings and descriptive material
submitted will not be permitted during the execution of the Contract without
specific written permission of the Owner.
Oral statements made by the Bidder at any time regarding quality, quantity or
arrangement of the equipment or any other matter will not be considered.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 11-
Date of Issue
30.09.2015.
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5.
6.
2.19
Standard catalogue pages and other documents of the Bidder may be used in the
Bid to provide additional information and data as deemed necessary by the
Bidder.
In addition to the hard copy of Part-I Bid, the Bidder shall submit soft copy of all
data sheets, Schedule, List of Mandatory spares, tools & tackles and Bar
Chart/PERT as well as deviation tables in a compact disk (CD). However, hard
copy alone will be considered as authentic for evaluation. Bidder shall submit all
the filled in datasheet also in soft copy. Bidder shall also furnish soft copies and
hard copies of Data Sheet with filled in details wherever details are required to be
indicated by the Bidder.

Bids shall be deemed to be under consideration immediately after they are opened.
While the Bids are under consideration, Bidders and/or their representatives or other
interested parties are advised to refrain from contacting by any means, the Owner
and/or his employees/ representatives on matters related to the Bids under
consideration. The Owner, if necessary will obtain clarifications on the Bids by
requesting for such information from any or all the Bidders, in writing as may be
necessary.
2.20
Validity of Bid
1.
2.
3.
2.21
The Bid shall be kept valid for acceptance for [180 days] from the schedule date
of opening of the Part-I Bid.
The Bidder will not be permitted to change the substance of the Bid suo-moto,
after Bid has been opened.
Unilateral revision or withdrawal of offer by the Bidder within the subsistence of
the validity period of offer shall not be permitted. Violation of this condition shall
result in rejection of the Bid without notice, besides forfeiture of Bid Guarantee.
The Bidder shall also be debarred either permanently or for a fixed period, at the
discretion of Owner from participating in any of the Owners tenders.

1.
2.
The Bidder is required to carefully examine the specifications and documents and
fully informs himself as to all the conditions and matters which may in any way
affect the Renovation and Modernization work to be carried out or the cost
thereof. Bidders are required to visit the plant to get familiarized with local
conditions. However, the Bidders visit to site shall be at their cost and risk,
without any liability on part of the Owner.
Bidders may seek clarifications to the prescribed clauses and / or different part of
the Tender Specifications. Such a request for clarifications, if any, should reach
the Owner at least [7 (seven) days] before the date stipulated for pre-bid meeting.
The Owner then will issue interpretations and clarifications as it may think fit in
during the pre-bid meeting. After pre-Bid meeting, Bidder may seek further
clarification till [21 days] prior to schedule opening date of Part-I Bid. After receipt
of such clarifications, the Bidder may submit its Bid but within the time and date
as specified in the Invitation for Bid or as amended by the Owner. All such
clarifications and the relevant exchange of correspondence between the parties
shall be construed to form part of the tender specifications.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 12-
Date of Issue
30.09.2015.
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3.
4.
5.
2.22
Pre-Bid Conference will be organized and outcome of the pre-bid conference is

binding on all the Bidders. Outcome of the Pre-Bid Conference will be intimated
by the Owner to all the Bidders.
A copy of such clarifications duly signed and stamped shall be enclosed with the
Bid (Part-I). In case any queries remain un-replied, it shall be construed that in
respect of those queries, the respective stipulations of the Tender
Specifications/Conditions shall continue to apply and/or no new stipulations are
made with respect to those queries.
No extension of time for submission of Bid will be granted on account of Bidders
request for interpretation/clarifications.

Invitation for Bid. Bids delivered / received after the time and date fixed for the receipt
of the bids shall be liable for rejection.
2.23
Single Bidder Responsibility

1.
2.
2.24

1.
2.
2.25
The scope of supply and services shall be under single Bidder responsibility.
The successful Bidder should not sub contract the entire work on back to back
basis or otherwise.
The submission of any Bid connected with these documents and specifications
shall constitute an agreement that the Bidder shall have no cause of action or
claim against the Owner for rejection of his Bid.
Regardless of the conduct or outcome of the bidding process, Bidder shall not be
entitled to claim any costs, charges and expenses incidental to or incurred by him
through or in connection with his submission of Bid or its consideration by the
Owner, even though the Owner may elect to modify/withdraw the Invitation for
Bid or does not accept the Bid(s).
Deputation of Representatives for Discussion
After opening of the Bid, if the Owner desires to have techno-commercial

discussion on the Bid, the Bidder shall be in a position to depute his competent
representatives of various disciplines at short notice with full authority for finalising
technical parameters as well as Commercial Terms and Conditions of the Tender.
2.26
Evaluation of Bid
1.
2.
For evaluation and comparison of price bid, the prices indicated at [------]
summary of Prices as per Schedule [------] will be considered. The Bids received
will be evaluated by the Owner to ascertain the lowest evaluated substantially
responsive Bid vis--vis the Tender Specifications. The Bidder has to satisfy
himself that full information is furnished as required in the specifications. Lack of
particulars or incomplete information furnished will run the risk of rejection of the
bid. The following major procedures would be followed for evaluation of bids.
All the Bidders would be brought on par with reference to Technical Specification,
Commercial Condition, Instructions to Bidders and subsequent technocommercial discussions/ clarifications.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 13-
Date of Issue
30.09.2015.
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3.
4.
5.
6.
7.
8.
9.
After the evaluation of Part-I bids (techno-commercial bids) and before opening of
Part-II bids (Price Bids), in case the bidders are asked to make changes to their
techno commercial offer that may have price implications, Owner may give the
bidders opportunity to submit addendum to price bid covering the price
implication only against such changes before the opening of PartII bids (Price
Bids). All the bidders will be notified, at least 15 days before the Price Bid
opening date, about such changes against which they can submit addendum to
Price Bid.
Commercial loading would be done for non-compliance of commercial terms and
conditions of the Tender Specifications other than the vital clauses, as the case
may be.
To facilitate evaluation and comparison, the Owner will convert all bid prices
expressed in foreign currencies into Indian Rupee at State Bank of India Bills
Selling exchange rates prevailing on the date of opening of the price bid.
The Bidder is eligible for a price variation as per Tender Condition. However
Price variation shall not be considered for Bid evaluation.
Technical loading will be done for omission of price data in respect of
equipment/facilities, spares, tools & tackles, etc. The highest quoted
corresponding price will be loaded against such omission. If no quoted price is
available, the loading will be done as per the corresponding price as estimated by
the Owner.
The Bidder has to meet the minimum functional performance levels indicated in
Volume-II Technical Specification for all categories of Guarantees. If one or more
of Functional Performance Parameters offered by the Bidder is inferior to the
minimum functional performance level (i.e. higher or lower than maximum or
minimum value specified in Technical Specification), then such bid will be
considered non-responsive and rejected.
The quoted values for Performance Guaranteed Parameters given in Table below
would be evaluated using evaluation factors specified. The evaluation factors
shall be applicable to the differential values calculated from among the Bidders of
corresponding item with appropriate highest or lowest value (i.e., the best quoted
value) as the base. The evaluation will be based on the guarantee parameters
inclusive of all tolerance furnished at the Guaranteed Condition. Bidders to note
that the values indicated in the Schedule of Performance Guarantees shall be
inclusive of all tolerances including measurement uncertainty.
Table-Bid Evaluation Factors
Sl. No.
Functional Performance Parameter
Evaluation Factor Rate

[------]INR per kCal/kWhr
1.
Turbine Cycle Heat Rate
2.
Auxiliary Power
[------] INR per kW
3.
[TG output]
[------] INR per kW
{NOTE: The utilities may decide whether credit has to be given for higher TG
output during Bid Evaluation and structure the Tender Document accordingly.
If the bidders are asked quote the value of TG output, then credit will be given
for higher quoted TG Output during Bid Evaluation. However, if Owner
specifies the TG Output, it may decide not to give any credit to Bidders
offering TG Output higher than specified value and structure the Tender
Documents accordingly.}
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 14-
Date of Issue
30.09.2015.
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The evaluation factors rate shall be prorated for any fractions of the specified
value.
(1). Arithmetical errors will be rectified on the following basis:
If there is any discrepancy between the unit price and the total
price that is obtained by multiplying the unit price and the quantity,
the unit price shall prevail and the total price will be corrected.
the rates expressed in words shall only prevail and shall be
adopted.
no prices are envisaged for any of the entries, Nil shall be mentioned. In
this context Nil mentioned against any item shall construe that the Bidder
shall not charge any amount separately for that item from the Owner. If the
2.27
Local Conditions
1.
2.
The Bidder shall inspect the site and shall satisfy himself of the site conditions
and shall apprise himself of the procedure for engagement of agencies/labour
and shall collect any other information, which may be required before submitting
the Bid.
Wages not less than Minimum wages for Contract labour shall be paid as
applicable in this region from time to time. Claims and objections due to
ignorance of site conditions will not be considered after submission of Bid.
(i). The Bidder is required to carefully examine the Technical & General
Specification, commercial Terms and Conditions, drawings and other details
relating to work given in the Tender Specification and get fully acquainted
as to all conditions and matters which may in any way affect the work or the
cost thereof.
(ii). The Bidder shall be deemed to have exhaustively examined the Tender
Specifications including the Form of Contract, to have obtained all
information and clarifications on all matters whatsoever that might affect the
carrying out of the work and to have satisfied himself as to the adequacy of
his Bid. He is deemed to have known the scope, nature and magnitude of
the work and the requirements of materials and labour involved etc. and as
to all work he has to complete in accordance with the Contract for the
adequacy of his Bid.
(iii). The Bidder shall be deemed to have visited and carefully examined the
plant/ site and surroundings, to have satisfied himself about the nature and
details of all existing structures, if any, and also as to the nature and
conditions of the railways, roads, bridges and culverts, means of transport
and communications, whether by land, water or air and as to possible
interruptions thereto and the access to and from the site, to have made
independent enquiries, examined and satisfied himself as to the sources for
obtaining earth, gravel, sand, stones, bricks and all other construction
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 15-
Date of Issue
30.09.2015.
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materials, the site for disposal of surplus earth and debris, the available
accommodation, underground existing services, sub-soil water conditions,
storms, prevailing winds, climatic conditions and all other similar matters
which may affect the work.
(iv). The Bidder shall be deemed to have acquainted himself with the Indian
Income tax Act, 1961, Indian Companies Act, 1956, Indian Customs Act,
1962, Indian Central Excise Act, Value Added Tax, Indian Sales Tax Act,
Indian Electricity Act, Central Electricity Authority Regulations, Indian Boiler
Regulations, Factories Act, Pollution Control Regulations and other related
Acts & Laws prevalent in the State of [-------------] and in India and as
amended from time to time. The Owner shall not entertain any request for
clarifications from the Bidders regarding such local conditions.
(v). Any neglect or omission or failure on the part of the bidder in obtaining
necessary and reliable information as stated above or on any other matter
affecting the Bidder shall not relieve him from any risk or liabilities or the
entire responsibility for completion of the work in accordance with the
Tender Specifications.
2.28
Deviations
1.
2.
3.
2.29
technical specification. Nevertheless, if the Bidder takes any deviation, it shall be
clearly indicated in the deviation schedule (Schedule [------] and Schedule- [------]
with a soft copy in MS-Word format in compact disc, with Original of Part-I of the
Bid). Deviation listed elsewhere in the Bid shall be summarily rejected and
ignored. Separate printed standard terms and conditions of the Bidder shall not be
taken into cognizance and shall be totally rejected.
No alterations or disfigurement, other than filling in particulars wherever called for
in the formats of the Tender Specifications shall be made in the Bid. Any
changes/modifications made by the Bidder in Bid documents itself shall not be
taken into consideration.
If at any later date, it is found that documents, information, averments and data
submitted by the bidder in the Bid, based on which the Bidder has been
considered eligible or successful or has been awarded the Contract is incorrect or
false to the extent that had the correct or true information been made available to
the Owner at time of tender evaluation, the Bid would have been declared
ineligible or unsuccessful, the Bidder shall be forthwith disqualified or, as the case
may be, the Contract awarded based on such incorrect or false information shall
be cancelled and the Bid Guarantee / contract performance Guarantees deposited
shall be appropriated by the Owner towards Owners cost, loss and damage to
Owner.
debarred by the Owner. Owner would also be at liberty to inform the matter to other
PSUs of the Government of India / Statutory Bodies.
2.30
Award of Contract
1.
Award Criteria
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 16-
Date of Issue
30.09.2015.
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2.
3.
4.
5.
The Owner will award the contract to the successful Bidder whose Technocommercial bid has been determined to be substantially responsive and
Price Bid to be the lowest evaluated bid, further provided that the Bidder is
determined to be qualified to perform the contract satisfactorily.
The Owner reserves the right to vary the quantity of any of the Items /
Spares and / or delete any Item / Spares altogether at the time of Award of
Contract.
The Owner reserves the right to accept or reject any bid, for any reasons including
National defense and security consideration and to annul the bidding process and
to reject all bids at any time prior to award of contract, without thereby incurring
any liability to the affected Bidder or bidders or any obligation to inform the
affected Bidder or bidders of the grounds for the Owner's action.
successful Bidder in writing by registered letter (Letter of Award or LOA) or by
email to be confirmed in writing by registered letter, that its bid has been accepted.
The notification of award will constitute the formation of the contract.
Upon the successful Bidder's furnishing of the performance securities the Owner
will promptly notify each unsuccessful Bidder and will discharge its bid security.
At the same time as the Owner notifies the successful Bidder that its bid has been
accepted, the Owner will send to the Bidder the Contract Agreement provided in
the bidding documents, incorporating all agreements between the parties.
successful Bidder / assignee of foreign bidder (if applicable) shall sign and date
the Contract Agreement and return it to the Owner.
The Owner requires that Bidders, Contractors and Suppliers observe the highest
standard of ethics during the procurement and execution of the contracts. In
pursuance of this policy, the Owner:
The Owner requires that Bidders, Contractors and Suppliers observe the
highest standard of ethics during the procurement and execution of the
contracts. In pursuance of this policy, the Owner :
procurement process or in contract execution; and
the detriment of the Owner, and includes collusive practice among
of the benefits of free and open competition;
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 17-
Date of Issue
30.09.2015.
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6.
2.31
will reject a proposal for award if it determines that the Bidder

recommended for award has engaged in corrupt or fraudulent practices in
competing for the contract in question;
Will declare a firm ineligible, either indefinitely or for a stated period of
time, to be awarded a contract if it at any time determines that the firm has
engaged in corrupt or fraudulent practices in competing for or in executing
a contract of the Owner.
Fraud Prevention Policy
The Bidder along with its associate/collaborator/sub-contractors/sub-vendors/
consultants/service providers shall strictly adhere to the Fraud Prevention Policy
of Owner displayed on its tender website and shall immediately apprise the Owner
about any fraud or suspected fraud as soon as it comes to their notice. A
certificate to this effect shall be furnished by the bidder along with his bid.
Agency Commission
No Agency commission shall be payable under the Contract.

2.32

As a Contract security, the successful Bidder, to whom the work is awarded, shall be
required to furnish a Contract Performance Bank Guarantee (CPBG) in the Format
attached as Annexure- G, in favour of the Owner within 30 days from the date of issue
of Letter of Award (LOA). The guarantee amount shall be equal to ten percent (10%) of
the Contract Price and it shall guarantee the faithful performance of the Contract in
accordance with the terms and conditions specified in these documents and
specifications. The CPBG shall be valid till the end of Warranty Period plus Ninety
(90) days grace period. If the contract price is in more than one currency, CPBG shall
be 10% of respective currency.
case, the value of Contract Performance Bank Guarantee furnished by the Bidder and
Additional Contract Performance Bank Guarantee furnished by the JV partners taken
Guarantee (CPBG) of 10% furnished by the Consortium Leader, the other consortium
member will furnish Additional Contract Performance Bank Guarantee equal to 2% of
Contract Price. To clarify further, in such a case, the value of Contract Performance
Bank Guarantee furnished by the Bidder (Consortium Leader) and Additional Contract
Performance Bank Guarantee furnished by the other consortium member taken
In case of a successful foreign bidder, if the Owner accepts to enter into the Second
Contract and / or Third Contract with the assignee, then, within Thirty (30) days after
receipt of Letter of Award, the assignee shall furnish an additional Contract
Performance Bank Guarantee for five percent (5%) of the value of the Contract entered
into with the assignee (i.e. for five percent of aggregate value of component
Contract(s) entered into with the assignee).
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 18-
Date of Issue
30.09.2015.
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2.33
Contract Quality Assurance

1. The Bidder shall include in his Bid a detailed Quality Assurance Programme
containing the overall quality, management and procedures which he proposes to
follow in the performance of the Works during various phases.
2. After Letter of Award (LOA) the detailed Quality Assurance Programme to be
followed for the execution of the Contract will be mutually discussed and agreed to
and such agreed Programme shall form a part of the Contract.
2.34
Codes & Standards
Specifications give reference to Indian or internationally accepted Standards.

However, equipment or materials meeting other recognized National or
International Standards, which ensure an equal or superior quality than Standards
specified, will also be accepted. For details of codes and standards refer Technical
specification, Volume-II.
2.35
Vital Clauses
The following clauses in the Tender Specification & Draft Contract are vital. Bidder
is advised not to take deviations to these clauses. If deviations are taken from the
stipulations of these clauses, such Bids would be liable for rejection:
Scope of Work
Time Schedule
Price Basis
Warranty
Liquidated Damages
Force Majeure
Arbitration
Taxes & Duties
Bid Guarantee
Patents, Indemnity
Validity of Bids
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 19-
Date of Issue
30.09.2015.
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3.1
Owner / Purchaser
[-------------------------------------------------]
Consultant
[-------------------------------------------------]
Project Title
[-------------------------------------------------]
Location
[-------------------------------------------------]
Latitude
[-------------------------------------------------]
Longitude
Elevation above MSL
:
:
[-------------------------------------------------]
[-------------------------------------------------]
[-------------------------------------------------]
Nearest Sea Port
[-------------------------------------------------]
Nearest Airport
:
Site
[-------------------------------------------------]
[-------------------------------------------------]
For Project & Site related detailed information, refer Clause No. 2 of Section-I of
Volume-II.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 20-
Date of Issue
30.09.2015.
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4.1
Definitions
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
"Applicable Laws" means the laws of any national, state, local or municipal
legislature in India, or of any other Competent Authority, including all laws,
acts, judgments, statutes, rules, regulations, ordinances, orders, decrees,
injunctions, governmental authorizations, requirements of Applicable Permits
and any agreements, decisions, acts, instructions, requirements, directions
and notifications of any competent or other Competent Authority or court or
tribunal or arbitrator having jurisdiction over the matter in question, including
those related to taxes, assessments, expropriation and duties, or authoritative
interpretation, as amended, modified, enacted, reinterpreted or revised from
time to time hereafter.
Applicable Permits" means all permits, licenses, authorizations, consents,
decrees, waivers, privileges, acknowledgements, concessions, approvals,
rulings, decisions and visas from, filings with or applications submitted to, any
Competent Authority or court or tribunal of competent jurisdiction necessary
from time to time for or in relation to the performance of the Works, including
as detailed in this GCC.
"Agreement" means the Contract Agreement (entitled "Contract Agreement")
executed by the parties to which these Conditions are annexed and also
includes supplements & amendments to the Contract Agreement.
Contractor as per the 'Contract Agreement' signed by the parties, including
contract documents, contract schedules, all attachments and appendices
thereto and all documents incorporated by reference therein.
Contract Documents means the complete documents, which are the basis
of finalization of the contract, including correspondence exchanged from issue
of tender till date of signing the contract. All such documents shall be listed in
the Contract Agreement.
Contractors Equipment means all plant, facilities, equipment, machinery,
tools, apparatus, appliances or things of every kind required in or for
installation, completion and maintenance of Facilities that are to be provided
by the Contractor, but does not include Plant and Equipment, or other things
intended to form or forming part of the Facilities.
Contractor means the person(s), Firm or a Company whose bid to perform
the Contract has been accepted by the Owner and shall be named as such in
the Contract Agreement, and includes the legal successors or permitted
assigns of the Contractor.
Contract Price means any sum or sums finally accepted by the Owner for
the execution of this contract, subject to such additions and adjustments
thereto or deductions there from, as may be made pursuant to the Contract.
Contractors Representative means any person nominated by the
Contractor & approved by the Owner hereof to perform the duties delegated
by the Contractor.
Consulting Engineer means Owners Engineer appointed by the Owner.
Also refers to any other firm(s) or person(s) as may be appointed by the
Owner from time to time.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 21-
Date of Issue
30.09.2015.
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xi.
xii.
xiii.
xiv.
xv.
xvi.
xvii.
xviii.
xix.
xx.
xxi.
xxii.
Commissioning means the construction of plant and equipment for

operation of the Facility at rated capacity are complete and the plant and
equipment achieves the designated full load/full capacity, at designated
fuel/input.
Completion means that the Facilities (or a specific part thereof where
specific parts are agreed) have been completed operationally and structurally
and put in a tight and clean condition, and that all work in respect of precommissioning of the Facilities or such specific part thereof has been
completed and commissioning has been attained as per Technical
Specifications.
"Competent Authority means any agency, authority, department,
inspectorate, ministry or statutory person (whether autonomous or not) of
GOI, [Name of the State], Ministry of Environment and Forests (MoEF) any
other State of the Republic of India or any local authority.
Defect Liability Period means the period of validity of the warranties given
by the Contractor, commencing at completion of the Facilities or a part
thereof, during which the Contractor is responsible for defects with respect to
the Facilities.
Effective Date means the date from which the Time for Completion of the
facilities and other milestones for execution of the Renovation &
Modernization work as per the scope of work under this tender by the
Contractor shall be determined.
Erection Services means those entire services ancillary to the supply of
the plant and equipment for the Facilities, to be provided by the Contractor
under the Contract. e.g. transportation and provision of marine or other similar
insurance, inspection, expediting, site preparation works (including the
provision and use of Contractors Equipment and the supply of all
construction materials required), installation, testing, Pre-commissioning,
commissioning, operations, maintenance, the provision of operations and
maintenance manuals, training of Owners Personnel etc.
Facilities means the plant and equipment to be supplied and installed, as
well as all the Erection Services to be carried out by the Contractor under the
Contract.
Force Majeure means mean any event beyond the reasonable control of
the Owner or of the Contractor, as the case may be, and which is unavoidable
diligence and prudence which would reasonably and ordinarily be expected
from a skilled and experienced Contractor, equipment manufacturer or
operator applying the standards generally adopted by global Contractors,
global equipment manufacturers and operators in the construction or
operation of power generation facilities or the manufacture of equipment
therefore, except in so far as inconsistent with any applicable Indian law or
directive.
Guarantee Test(s) means the test(s) specified in the Technical
Specifications to be carried out to ascertain whether the Facilities or a
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 22-
Date of Issue
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xxiii.
xxiv.
xxv.
xxvi.
xxvii.
xxviii.
xxix.
xxx.
xxxi.
xxxii.
xxxiii.
xxxiv.
xxxv.
xxxvi.
xxxvii.
specified part thereof is able to attain the Functional/Performance Guarantees

specified in the Technical Specification.
Incoterms means International rules for interpreting trade terms published
by the International Chamber of Commerce (latest edition), Paris (France).
Unless inconsistent with any provisions of the contract, the meaning of any
trade term and the rights and obligations of the parties there under shall be as
prescribed by Incoterms.
"Inspector/Inspecting Engineer" means the Owner or any person
nominated by the Owner from time to time, to inspect the equipment of works
under the contract and/or the duly authorized representative of the Owner.
"Latent Defect" means the defects inherent in the material or arising out of
design deficiency which does not manifest itself during the Warranty
Period/Defect Liability Period, as described in this GCC.
issued by the Owner notifying the Contractor that its Bid Proposal has been
accepted.
Manufacturer's Works or "Contractor's Works" means the place used
by the Contractor, its manufacturer, supplier, collaborators or subcontractors/vendors/sub-vendors for the performance of the works.
Operational Acceptance means the acceptance by the Owner of the
Facilities (or any part of the Facilities where the Contract provides for
acceptance of the Facilities in parts), which certifies the Contractors
fulfillment of the Contract in respect of performance guarantees of the
Facilities.
Owner or Purchaser shall means the [Name of the Utility], and includes
its legal successors or permitted assignees.
"Person" means any natural person, firm, corporation, company, voluntary
association, partnership, joint venture, trust, and incorporated organization,
unincorporated organization, Competent Authority or other entity.
Pre-commissioning means the testing, checking and other requirements
specified in the Technical specifications that are to be carried out by the
Contractor in preparation for commissioning.
Project means the Owners [----------------------------] in respect of which the
Contract has been signed.
Project Consultant or Owners Consultant means the engineering firm
or person(s) appointed by the Owner to render engineering project
consultancy services for the project.
Plant and Equipment means permanent plant, equipment, systems,
machinery, apparatus, articles and things of all kinds to be provided and
incorporated in the Facilities by the Contractor under the Contract (including
the spare parts to be supplied by the Contractor under the Contract
Agreement), but does not include Contractors Equipment.
SCC means the Special Conditions of Contract hereof.
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xxxviii.
xxxix.
xl.
xli.
xlii.
xliii.
xliv.
xlv.
Site means the land and other places upon which the Facilities are to be
installed, and such other lands or places as may be specified in the Contract
as forming part of the Site.
Sub Contractor, including Vendors/Sub-Vendors, means any firm or
person to whom execution of any part of the Facilities, including preparation
of any design or supply of any plant and equipment is subcontracted directly
or indirectly by the Contractor, and includes its legal successors or permitted
assignees.
Technical Specification / Tender Documents means the document,
setting out a description and specification of the Works and statement of the
technical and other standards to which the Works are to be performed
including any modifications thereto made in accordance with the Conditions.
This includes the technical & commercial specifications and other Tender
Documents forming a part of the Contract and such other Schedules and
drawings as may be mutually agreed upon.
Tenderer"/"Bidder" means the Person(s), Firm/Company who has
submitted its Bid Proposal in response to the bid invitation by the Owner, for
the Project.
Time for Completion means the time within which completion of the
Facilities as a whole (or of a part of the Facilities where a separate time for
completion of such part has been specified) is to be attained in accordance
with the stipulations and provisions of the Contract.
"Warranty Period" or Defect Liability Period means the period during
which the Contractor shall remain liable for repair or replacement of any
defective part of the works performed under the contract, free of cost.
"Work(s)" means and includes the tasks of furnishing of equipment, labour &
services, transport, handling, unloading and storage at site, civil construction
and complete erection, testing, commissioning putting into satisfactory
operation and completion of successful performance tests, reliability tests and
any other guaranteed parameters as defined in the Contract, replacement,
modification, repair of defective parts or equipment during warranty period
and rectification of latent defects during latent defect period.
"Writing" or "Written" shall include any manuscript, type-written or printed
statement, under or over signature and/or seal as the case may be.
When the words "Approved", "Subject to Approval", "Satisfactory", "Equal to", "Proper",
"Requested", "As Directed", "Where Directed", "When Directed", "Determined by",
"Accepted", "Permitted", or words and phrases of similar importance are used, the
approval, judgment, direction, etc., is understood to be a function of the Owner. Words
implying persons or the gender neutral pronoun it, shall include firms, companies,
corporation, associations or body of individuals whether incorporated or not. Words
implying masculine gender or singular number shall also include the feminine gender
and plural number and vice-versa where the context so requires or permits.
Terms and expressions not herein defined shall have the same meaning as are
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4.2
Contract Documents
a) All documents forming part of the Contract (and all parts thereof) are intended to be
correlative, complementary and mutually explanatory. The Contract shall be read
as a whole.
with one signed original and the rest will be retained by the Owner.
4.3

precedence)
4.4
Interpretation
All Contract Documents, all correspondence and communications to be given, and
all other documentation to be prepared and supplied under the Contract shall be
written in English, and the Contract shall be construed and interpreted in accordance
with English language.
Unless inconsistent with any provision of the Contract, the meaning of any trade
term and the rights and obligations of parties there under shall be as prescribed by
Incoterms. Incoterms means latest edition of International Rules for Interpreting Trade
Terms published by the International Chamber of Commerce Paris, France.
4.5
Construction of the Contract

The Contracts to be entered between the Owner and the Contractor shall be as under:
'First Contract' for CIF Supply of all Offshore Plant and Equipments and
Materials including Mandatory Spares to be supplied from abroad.
'Second Contract" for Ex-Works Supply of all Plant and Equipments and
Materials including Mandatory Spares of Indian origin.
Third Contract for providing all services i.e. Port Handling, Port Clearance and
Port Charges for the imported goods, further Loading and Inland Transportation
for Delivery at Site, Unloading, Storage, Handling at Site, Installation,
Insurance, Testing and Commissioning including carrying out Guarantee Tests
for all the Equipments supplied under the First Contract and the Second
Contract and all other services specified in the Tender Documents.
All the above Contracts will contain a cross-fall breach clause specifying that breach of
one Contract will constitute breach of the other Contracts which will confer a right on
the Owner to terminate the other Contracts also at the risk and the cost of the
Contractor.
The foreign bidder, however, has the option, to be exercised as a part of its bid
proposal, to propose an Assignee in its bid to execute the Second Contract and/or the
Third Contract. Such foreign bidder shall furnish a written unequivocal consent (with
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Part-I Bid) of the proposed Assignee to work as independent Contractor on the terms
and conditions offered by the bidder For the scope of work envisaged by the foreign
bidder, in its bid, to be executed by Assignee, the Assignee should have
relevant/required capacity and experience of executing similar job. The bidder shall
substantiate with relevant/required documents in the bid to establish capacity and
experience of the Assignee.
If the foreign bidder has proposed an Assignee in its bid to execute the Second
of the proposed Assignee to work as an independent Contractor on the terms and
conditions offered by the bidder and if the Owner is satisfied with the capacity and
experience of the Assignee proposed in the bid, the Owner will enter into the Second
Contract and/or the Third Contract with the Assignee. However, if the Owner in its
judgment does not find acceptable the Assignee proposed in the bid as its Contractor,
then on the request of the Owner, the Bidder shall have option to propose an alternate
Assignee on the same terms and conditions and cost as offered in its bid. In case the
Assignee option is not exercised by the Bidder or if the Assignee fails to enter into
Contract(s) with the Owner or if the Owner in its judgment does not find acceptance of
the Assignee as its Contractor, then the foreign bidder shall be obliged to enter into
and execute all the contracts envisaged to be entered upon this Tender with the Owner
covering the entire scope of work envisaged in the Tender Documents on the same
terms and conditions and cost as offered in its Bid.
If any foreign bidder has proposed an Assignee in his bid to execute the Second
of the proposed Assignee to work as independent Contractor on the terms and
conditions offered by the bidder and if the Owner is satisfied with capacity and
experience of the Assignee, the Owner will enter into the Second Contract and/or
Third Contract with the said Assignee. In case no Assignee has been proposed by the
foreign bidder in his bid or if the Assignee fails to enter into the Second Contract and/or
Third Contract with the Owner or if the Owner in its judgment does not find acceptance
of the proposed Assignee as its Contractor, then the foreign bidder shall be obliged to
enter into and execute all the three Contracts with the Owner.
If the Owner accepts to enter into Second Contract and/or Third Contract with the
Assignee of foreign bidder, the said Assignee, in addition to the Contract Performance
Securities to be provided by the foreign Contractor shall provide within [twenty eight
(28)] days of Notification of Award, separate Contract Performance Bank Guarantee
equivalent to five percent (5%) of the value of the Contract(s) entered into with the
Assignee for the due performance of the Contract, with an initial validity up to [ninety
(90) days] beyond the scheduled Defects Liability Period.
The award of the separate Contracts shall not in any way dilute the responsibility of the
Contractor for the successful completion of the Facilities as per Contract Documents
and a breach in one Contract shall automatically be construed as a breach of the other
Contract(s) which will confer a right on the Owner to terminate the other Contract(s)
also at the risk and the cost of the Contractor.
4.6
Independent Contractor
The Contractor shall be an independent contractor performing the Contract. The
Subject to the provisions of the Contract, the Contractor shall be solely responsible for
the manner in which the Contract is performed. All employees, representatives or
Subcontractors engaged by the Contractor in connection with the performance of the
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Contract shall be under the complete control of the Contractor and shall not be
deemed to be employees of the Owner, and nothing contained in the Contract or in any
subcontract awarded by the Contractor shall be construed to create any contractual
relationship between any such employees, representatives or Subcontractors and the
Owner.
4.7

If the Bidder/Contractor is a joint venture or consortium of two or more firms, all such
firms shall be jointly and severally bound to the Owner for the fulfillment of the
provisions of the Contract and the Bidder shall submit a letter of consent to this effect
(with Part-I Bid) signed by all joint venture partners / consortium members. The joint
venture/consortium partners shall designate one of such firms to act as a leader with
authority to bind the joint venture or consortium. The composition or the constitution of
the joint venture or consortium shall not be altered without the prior consent of the
Owner.
4.8
Non-Waiver
No relaxation, forbearance, delay or indulgence by either party in enforcing any of the
terms and conditions of the Contract or the granting of time by either party to the other
shall prejudice, affect or restrict the rights of that party under the Contract, nor shall
any waiver by either party of any breach of Contract operate as waiver of any
subsequent or continuing breach of Contract. Any waiver of a partys rights, powers or
remedies under the Contract must be in writing, must be dated and signed by an
authorized representative of the party granting such waiver, and must specify the right
and the extent to which it is being waived.
4.9
Severability
unenforceable, such prohibition, invalidity or unenforceability shall not affect the validity
or enforceability of any other provisions and conditions of the Contract.
4.10
Origin
Origin means the place where the materials, equipments and other supplies for the
Facilities are mined, grown, produced or manufactured, and from which the services
are provided.
4.11
Notices
personal delivery, or post, or special courier, or telefax, or E-mail to the address of the
relevant party indicated in the Contract.
Either party may change its postal address, telefax number, or E-mail ID or addressee
Notices shall be deemed to include any approvals, consents, instructions, orders and
certificates to be given under the Contract.
4.12
Governing Laws
The Contract shall be governed by and interpreted in accordance with laws in force in
India. The Courts of [........] shall have exclusive jurisdiction in all matters arising under
the Contract.
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4.13
If any differences/ dispute arises between the Owner and the Contractor in
abandonment or breach of the Contractthe Owner & Contractor shall seek to
resolve any such dispute or difference by mutual consultation. If the parties fail to
resolve such a dispute or difference by mutual consultation, then the dispute shall
be referred in writing by either party to the Arbitrator, with a copy to the other party.
b) Arbitration
Either Owner or the Contractor may, of its intention to commence arbitration, as to
the matter in dispute, and no arbitration may be commenced unless such notice is
given.
Any dispute, in respect of which a notice of intention to commence arbitration has
been given, as above shall be finally settled by arbitration. Arbitration may be
commenced prior to or after completion of the Facilities
panel composed of three arbitrators, in accordance with the provisions set forth
below.
The Owner and the Contractor shall each appoint one arbitrator, and these two
panel. If the two arbitrators do not succeed in appointing a third arbitrator within
[twenty eight (28)] days after the latter of the two arbitrators has been appointed,
the third arbitrator shall, at the request of either party, be appointed by the
Appointing Authority for arbitrator is given below.
Appointing Authority for Arbitrator:
President, Institution of Engineers in case of an Indian Contractor.
President, International Chambers of Commerce, Paris in case of a Foreign
Contractor.
If one party fails to appoint its arbitrator within [forty-two (42)] days after the other
party has named its arbitrator, the party which has named an arbitrator may
request the Appointing Authority to appoint the second arbitrator.
If for any reason an arbitrator is unable to perform its function, the mandate of the
Arbitrator shall terminate in accordance with the provisions of applicable laws and a
substitute shall be appointed in the same manner as the original arbitrator.
Arbitration proceedings as follows: In case of a foreign contractor the arbitration proceeding shall be conducted
in accordance with the United Nations Commission on International Trade
Law (UNCITRAL) Arbitration Rules of 1976.
In case of an Indian Contractor Adjudication/Arbitration proceedings shall
be conducted in accordance with Indian Arbitration and Conciliation Act
1996.
In case of a foreign associate of the contractor, the arbitration proceedings
shall be conducted in accordance with the United Nation Commission on
International Trade Law (UNCITRAL) Arbitration Rules of 1976.
The Place for Arbitration shall be: [New Delhi], India.
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The decision of a majority of the arbitrators (or of the third arbitrator chairing the
arbitration, if there is no such majority) shall be final and binding and shall be
enforceable in any court of competent jurisdiction as decree of the court. The
parties thereby waive any objections to or claims of immunity from such
enforcement.
The Owner shall pay the Contractor consideration due to the Contractor.
4.14
Scope of Facilities
a) Unless otherwise expressly limited in the Technical Specifications, Facilities the
Contractors obligations cover the provision of all Plant and Equipments including
spares and the performance of all Services required for design, manufacture
(including procurement, quality assurance, construction, installation, associated
civil works, Structural and others construction works, precomissioning and delivery)
of the Plant and Equipment and the installation, commissioning, completion of
facilities and performance testing of the Facilities in accordance with the plans,
procedures, specifications, drawings, codes and any other documents as specified
in the Technical Specifications. Such specifications include, but are not limited to,
the provision of supervision and engineering services; the supply of labour,
materials, equipment, spare parts and accessories; Contractors Equipments;
construction utilities and supplies; temporary materials, structures and facilities;
transportation loading & unloading.
b) The Contractor shall, unless specifically excluded in the Contract, perform all such
work and/or supply all such items and materials not specifically mentioned in the
Contract but that can be reasonably inferred from the Contract as being required
for attaining Completion of the Facilities.
4.15

a) The Contractor shall commence work on the scope of work under this Tender from
the date of Letter of Award. Contractor shall thereafter proceed with the Facilities in
accordance with the time schedule specified in SCC & detailed network schedule
agreed & appended to the contract.
b) The Contractor shall attain Completion of the Facilities (or of a part where a
separate time for Completion of such part is specified in the Contract) within the
time stated in the SCC subject to time extensions, the contractor is entitled under
the contract conditions or time extension expressly grouted by the Owner.
4.16
Spare Parts
In addition to the supply of Mandatory Spare Parts included in the Contract, the
Contractor agrees to supply other spare parts (recommended spares) required for the
operation and maintenance of the Facilities for 3 years. However, the identity,
specifications and quantities of such spare parts and the terms and conditions relating
to the supply thereof are to be agreed between the Owner and the Contractor, and the
price of such spare parts shall be that given in Price Schedule for recommended
spares. The price of such spare parts shall include the purchase price thereof and
other costs and expenses (including the Contractors fees) relating to the supply of
spare parts. The prices of recommended spares covered in price schedule shall be
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valid for a period of six months after the date of Notification of Award of Main
Equipment and Mandatory Spares.
The Contractor shall supply the recommended spares at the same terms and
conditions as are otherwise applicable to this Contract.
All the spares for the equipment under the Contract will strictly conform to the
Specification and other relevant documents and will be identical to the
corresponding main equipment/components supplied under the Contract and
shall be fully interchangeable.
All the Mandatory Spares covered under the Contract shall be manufactured
along with the main equipments as a continuous operation and the delivery of
the spares will be affected along with the main equipments in a phased
manner and the delivery would be completed by the respective dates for the
various categories of equipment as per the agreed schedule. If order for the
Recommended Spares has been placed with the Contractor prior to
commencement of manufacture of the main equipment this shall be
applicable for manufacturer of recommended spares as well.
The Contractor will provide the Owner with the manufacturing drawings,
catalogues, assembly drawings and any other document required by the for
the recommended spares. Such details will be furnished to the Owner as
soon as they are prepared but in any case not later than six months prior to
commencement of manufacture of the corresponding main equipment.
In addition to the spares recommended by the Contractor, if the Owner
further identifies certain particular items of spares, the Contractor will submit
the prices and delivery quotation for such spares within [30] days of receipt of
such request with a validity period of 6 months for consideration by the Owner
and placement of order for additional spares, if the Owner so desires.
The quality plan and the inspection requirement finalised for the main
equipment will also be applicable to the corresponding spares.
The Contractor will provide the Owner with all the addresses and particulars
of his sub-suppliers while placing the order on vendors for items/components/
equipment covered under the Contract and will further ensure with his
vendors that the Owner, if so desires, will have the right to place order for
spares directly on them on mutually agreed terms based on offers of such
vendors.
The Contractor shall guarantee the long term availability of spares to the
Owner for the full life of the equipment covered under the Contract. The same
provision will also be applicable to spares supplied by Sub-contractors.
For the first 6 years from the schedule date of completion of facilities the
prices will be derived from the corresponding Ex-Works Price at which the
order for such spares have been placed by Owner as a part of Mandatory
Spares or Recommended Spares, or from the rates of Mandatory Spares or
Recommended Spares as quoted by/negotiated with the Contractor. ExWorks order price of future spares shall be computed in accordance with the
price adjustment provisions covered under the main Contract excepting that
the base indices will be counted from the scheduled date of Commissioning of
the last equipment under the main project. The Contractor will indicate in
advance the delivery period of the items of spares, which the Owner may
procure in accordance with this clause. In case of emergent requirements of
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spares, the Contractor would make every effort to expedite the manufacture
and delivery of such spares on the basis of mutually agreed time schedule.
In case the Contractor fails to supply the mandatory or recommended spares
in the terms stipulated above, the Owner shall be entitled to purchase the
same from the alternate sources at the risk and the cost of the Contractor and
recover from the Contractor, the excess amount paid by the Owner over the
rates worked on the above basis. In the event of such risk purchase by the
Owner, the purchases will be as per the Works and Procurement Policy of the
Owner prevalent at the time of such purchases and the Owner at his option
may include a representative from the Contractor in finalising the purchases.
It is expressly understood that the final settlement between the parties in
terms of relevant clauses of the Contract Documents shall not relieve the
Contractor of any of his obligations under the provision of long term
availability of spares and such provisions shall continue to be enforced till the
expiry of 6 years period reckoned from the scheduled date of Commissioning
of the Plant and Equipment unless otherwise discharged expressly in writing
by the Owner.
The Contractor shall warrant that all spares supplied will be new and in
accordance with the Contract Documents and will be free from defects in
design, material and workmanship. The defects liability period for spares shall
be 12 months from the date it is put to use. In case of failure of any spare part
due to fault in design material or workmanship the same part will be replaced
by the contractor without any extra cost of the Owner.
In case of any failure in the original component/equipments due to faulty designs,
materials and workmanship, the corresponding spare parts, if any, supplied will be
replaced without any extra cost to the Owner unless a joint examination and analysis
by the Owner and the Contractor of such spare parts prove that the defect found in the
original part that failed, can safely be assumed not to be present in spare parts. Any
replaced spare parts will have the Defects Liability period of 12 months from the date it
is put in use. The discarded spare parts will become the property of the Contractor as
soon as they have been replaced by the Contractor. In any case the defect liability of
spares will expire at the end of 48 months from the date of their receipt at site
The Defects Liability of spares that are not used within 18 months from the respective
date of the delivery at Site will, be subject to condition that all such spares are stored in
accordance with Contractor's standard recommended practice, if any, and the same
has been furnished to the Owner.
4.17
Contractors Responsibilities
a) The Contractor shall design, manufacture (including associated purchases and/or
subcontracting), disassemble/dismantle wherever required, install, commission and
complete the Facilities and carryout the Guarantee tests with due care and
diligence in accordance with the Contract.
b) Before entering into this contract the Contractor is responsible to have examined
the data relating to the Facilities provided by the Owner, and on the basis of
information that the Contractor could have obtained from a visual inspection of the
Site and of other data readily available to it relating to the Facilities as at one month
days prior to bid submission. Any failure to acquaint itself with all such data and
information shall not relieve contractor of its responsibility for properly estimating
the difficulty or cost of successfully performing its scope of work under this contract.
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c) The Contractor shall acquire all permits, approvals and/or licenses from all local,
state or national government authorities or public service undertakings in the
country where the Site is located that are necessary for the performance of the
Contract, including, without limitation, visas for the Contractors and
Subcontractors personnel and entry permits for all imported Contractors
Equipment.
d) The Contractor shall comply with all laws in force in India and the place where the
facility is located out. The laws will include all national, provincial, municipal or
other laws that affect the performance of the Contract and bind upon the
Contractor. The Contractor shall indemnify and hold harmless the Owner from and
against any and all liabilities, damages, claims, fines, penalties and expenses of
whatever nature arising or resulting from the violation of such laws by the
Contractor.
4.18
a) The Owner shall be responsible for acquiring and providing legal and physical
possession of the Site and access thereto, and for providing possession of and
access to all other areas reasonably required for the proper execution of the
Contract, including all requisite rights of way.
b) The Owner shall acquire and pay for all permits, approvals and/or licenses from
all local, state or national government authorities or public service undertakings,
which such authorities or undertakings require the Owner to obtain them in the
Owners name, are necessary for the execution of the Contract.
c) If requested by the Contractor, the Owner shall use its best endeavours to assist
the Contractor in obtaining in a timely and expeditious manner all permits,
approvals and/or licenses necessary for the execution of the Contract from all local,
state or national government authorities or public service undertakings that such
authorities or undertakings require the Contractor or Subcontractors or the
personnel of the Contractor or Subcontractors, as the case may be, to obtain.
d) The Owner shall be responsible for the continued operation of the Facilities after
Completion.
4.19
Taxes & Duties

a) Custom Duty, Excise Duty, Central sales tax (CST), service tax, Value Added Tax
considered for bid evaluation. The reimbursement of these taxes shall be on actual
subject to the quoted value of these taxes as ceiling corresponding to the base
price. Additional liability of taxes and duties arising out of price variation shall be
reimbursed against documentary evidence over and above the ceiling (quoted
value). Statutory variation in Indian taxes and duties will be dealt with as per the
relevant stipulations of the specification.
b) Except as otherwise specifically provided in the Contract, the Contractor shall bear
and pay all Taxes, Duties, Levies and Charges including Entry Tax, Service Tax, if
applicable in connection with the Facilities in India and outside India. All taxes,
duties & levies on works contract, if any, shall be to the Contractor's account and
no separate claim in this regard will be entertained by the Owner.
c) All taxes, duties and levies including entry tax/octroi (if any) in respect of all
components, equipments and material to be dispatched directly from the subvendor's works to site shall be to the Contractor's account and no separate claim in
this regard will be entertained by the Owner.
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d) In case there is introduction of GST or any other tax in lieu of existing Excise
Duty/Service Tax and VAT/ Sales Tax, the contract price will be adjusted for the
impact of any differential tax liability subject to documentary evidence. This will be
restricted to direct transaction between the owner and contractor, and bought out
items directly dispatched from sub-vendor's works to project site.
e) Further all taxes, duties and levies including sales tax on works contract, Entry Tax,
if any, in respect of civil construction works, erection & commissioning if any and
custom duty/sales tax as applicable on the materials used for such construction
works shall be to the contractor's account and no separate claim in this regard will
be entertained by the Owner. Incidence of Service Tax & cess on any component
of the Bid Price shall be to the Contractor's account and bidders shall include
Service Tax as applicable at the date seven (7) days prior to the date of bid submission in the bid price. The Contract Price will be adjusted for impact of any
change in the rate of service tax or cess on service tax subsequent to this date for
direct transactions between the Owner and the Contractor.
f) If any tax exemptions, reductions, allowances or privileges may be available to the
Contractor, the Owner shall use its best endeavours to enable the Contractor to
benefit from any such tax savings to the maximum allowable extent.
4.20
information furnished to the Owner by the Contractor herein shall remain vested in the
Contractor or, if they are furnished to the Owner directly or through the Contractor by
any third party, including suppliers of materials, the copyright in such materials shall
remain vested in such third party. The Owner shall however be free to reproduce all
drawings, documents and other material furnished to the Owner for the purpose of the
contract including, if required, for operation and maintenance.
4.21
a) The Owner and the Contractor shall keep confidential and shall not, without the
written consent of the other party hereto, divulge to any third party any documents,
data or other information furnished directly or indirectly by the other party hereto in
connection with the Contract, whether such information has been furnished prior
to, during or following termination of the Contract. Notwithstanding the above, the
Contractor may furnish to its Subcontractor(s) such documents, data and other
information it receives from the Owner to the extent required for the
Subcontractor(s) to perform its work under the Contract, in which event the
Contractor shall obtain from such Subcontractor(s) an undertaking of confidentiality
similar to that imposed on the Contractor.
b) The Owner shall not use such documents, data and other information received
from the Contractor for any purpose other than the operation and maintenance of
the Facilities. Similarly, the Contractor shall not use such documents, data and
other information received from the Owner for any purpose other than the design,
procurement of Plant and Equipments, construction or such other work and
services as are required for the performance of the Contract.
c) The obligation of a party, shall not apply to that information which
disclosure and which was not previously obtained, directly or indirectly, from
the other party hereto
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
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Page No.
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Date of Issue
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4.22
Otherwise lawfully becomes available to that party from a third party that
has no obligation of confidentiality.
Representatives
a) Project Manager
If the Project Manager is not named in the Contract, then within fourteen (14) days of
the Effective Date, the Owner shall appoint and notify the Contractor in writing of the
name of the Project Manager. The Owner may from time to time appoint some other
person as the Project Manager in place of the person previously so appointed, and
shall give a notice of the name of such other person to the Contractor without delay.
The Owner shall take reasonable care to see that no such appointment is made at
such a time or in such a manner as to impede the progress of work on the Facilities.
The Project Manager shall represent and act for the Owner at all times during the
currency of the Contract. All notices, instructions, orders, certificates, approvals and
all other communications under the Contract shall be given by the Project Manager,
Contractor to the Owner under the Contract shall be given to the Project Manager,
b) Contractors Representative & Construction Manager
If the Contractors Representative is not named in the Contract, then within
[fourteen (14) days] of the Effective Date, the Contractor shall appoint the
Contractors Representative and shall request the Owner in writing to approve
the person so appointed. If the Owner makes no objection to the appointment
within [fourteen (14)] days, the Contractors Representative shall be deemed
to have been approved. If the Owner objects to the appointment within
[fourteen (14)] days giving the reason there for, then the Contractor shall
appoint a replacement within [fourteen (14) days] of such objection.
The Contractors Representative shall represent and act for the Contractor at
all times during the currency of the Contract and shall give to the Project
Manager all the Contractors notices, instructions, information and all other
communications under the Contract. All notices, instructions, information and
all other communications given by the Owner or the Project Manager to the
Contractor under the Contract shall be given to the Contractors
Representative or, in its absence, its deputy, except as herein otherwise
provided. The Contractor shall not revoke the appointment of the Contractors
Representative without the Owners prior written consent, which shall not be
unreasonably withheld. If the Owner consents thereto, the Contractor shall
appoint some other person as the Contractors Representative.
The Contractors Representative may, subject to the approval of the Owner
(which shall not be unreasonably withheld), at any time delegate to any
person any of the powers, functions and authorities vested in him or her. Any
such delegation may be revoked at any time. Any such delegation or
revocation shall be subject to a prior notice signed by the Contractors
Representative, and shall specify the powers, functions and authorities
thereby delegated or revoked. No such delegation or revocation shall take
effect unless and until a copy thereof has been delivered to the Owner and
the Project Manager.
From the commencement of installation of the Facilities at the Site until
Operational Acceptance, the Contractors Representative shall appoint a
Document Number
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Rev No.
02
Description
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4.23
suitable person as the construction manager (hereinafter referred to as the

Construction Manager). The Construction Manager shall supervise all work
done at the Site by the Contractor and shall be present at the Site throughout
normal working hours except when on leave, sick or absent for reasons
connected with the proper performance of the Contract. Whenever the
Construction Manager is absent from the Site, a suitable person shall be
appointed to act as his or her deputy.
The Owner may by notice to the Contractor object to any representative or
person employed by the Contractor in the execution of the Contract who, in
the reasonable opinion of the Owner, may behave inappropriately, may be
incompetent or negligent, or may commit a serious breach of the Site
regulations.
If any representative or person employed by the Contractor is removed.
Work Program
a) Contractors Organization
The Contractor shall supply to the Owner and the Project Manager a chart showing
the proposed organization to be established by the Contractor for carrying out work
on the Facilities. The chart shall include the identities of the key personnel together
with the curricula vitae of such key personnel to be employed within [twenty one (21)]
days of the Effective Date. The Contractor shall promptly inform the Owner and the
Project Manager in writing of any revision or alteration of such an organization chart.
Within [twenty-eight (28)] days after the date of Notification of Award of Contract,
the Contractor shall prepare and submit to the Project Manager a detailed Program
of Performance of the Contract, made in the form specified in the SCC and showing
the sequence in which it proposes to design, supply, transport, assemble, install and
precomissioning the Facilities, as well as the date by which the Contractor
reasonably requires that the Owner shall have fulfilled its obligations under the
Contract so as to enable the Contractor to execute the Contract in accordance with
the program and to achieve Completion and Acceptance of the Facilities in
accordance with the Contract. The program so submitted by the Contractor shall
accord with the Time Schedule included in Contract Schedule-3 (Time Schedule) to
the Form of Contract Agreement and any other dates and periods specified in the
Contract. The Contractor shall update and revise the program as and when
appropriate or when required by the Project Manager, but without modification in the
Times for Completion.
c) Progress Report
The Progress Report shall be in a form acceptable to the Project Manager and shall
indicate: (a) percentage completion achieved compared with the planned percentage
completion for each activity; and (b) where any activity is behind the program, giving
comments and likely consequences and stating the corrective action being taken.
If at any time the Contractors actual progress falls behind the program, or it becomes
apparent that it will so fall behind, the Contractor shall, at the request of the Owner or
the Project Manager, prepare and submit to the Project Manager a revised program,
taking into account the prevailing circumstances, and shall notify the Project Manager
of the steps being taken to expedite progress so as to attain Completion of the
Facilities within the Time for Completion.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 35-
Date of Issue
30.09.2015.
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e) Work Procedures
The Contract shall be executed in accordance with the Contract Documents and the
procedures given in the section on Forms and Procedures of the Contract
Documents.
If agreed between the Owner and the Contractor, the Contractor may execute the
Contract in accordance with its own standard project execution plans and procedures
to the extent that they do not conflict with the provisions contained in the Contract.
4.24
Subcontractors and Subvendors

a) The Contract Agreement specifies major items of supply or services and a list of
approved Subcontractors against each item, including vendors. Insofar as no
Subcontractors are listed against any such item, the Contractor shall prepare a list of
Subcontractors for such item for inclusion in such list. The Contractor may from time
to time propose any addition to or deletion from any such list. The Contractor shall
submit any such list or any modification thereto to the Owner for its approval in
sufficient time so as not to impede the progress of work on the Facilities. Such
approval by the Owner for any of the Subcontractors shall not relieve the Contractor
from any of its obligations, duties or responsibilities under the Contract.
b) The Contractor shall select and employ its Subcontractors/Subvendors for such
major items from those listed.
4.25
Design and Engineering

a) Specifications and Drawings
The Contractor shall execute the basic and detailed design and the engineering work
in compliance with the provisions of the Contract, or where not so specified, in
accordance with good engineering practice. The Contractor shall be responsible for
any discrepancies, errors or omissions in the specifications, drawings and other
technical documents that it has prepared, whether such specifications, drawings and
other documents have been approved by the Project Manager or not, provided that
such discrepancies, errors or omissions are not because of inaccurate information
furnished in writing to the Contractor by or on behalf of the Owner.
b) Codes and Standards
Wherever references are made in the Contract to codes and standards in
accordance with which the Contract shall be executed, the edition or the revised
version of such codes and standards current at the date [twenty eight (28)] days prior
to date of bid submission shall apply unless otherwise specified. During Contract
execution, any changes in such codes and standards shall be applied after approval
by the Owner.
c) Approval/Review of Technical Documents by Project Manager
The Contractor shall prepare (or cause its Subcontractors to prepare) and furnish to
the Project Manager the documents for its approval Any part of the Facilities covered
by or related to the documents to be approved by the Project Manager shall be
executed only after the Project Managers approval thereof.
Project Manager shall either return one copy thereof to the Contractor with its
approval endorsed thereon or shall notify the Contractor in writing of its disapproval
thereof and the reasons there for and the modifications that the Project Manager
proposes. The Project Manager shall not disapprove any document, except on the
grounds that the document does not comply with some specified provision of the
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
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Date of Issue
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Contract or that it is contrary to good engineering practice. The procedure for

submission of the documents by the Contractor and their approval by the Project
Manager shall be discussed and finalised with the Contractor.
If any dispute or difference occurs between the Owner and the Contractor in
connection with or arising out of the disapproval by the Project Manager of any
document and/or any modification(s) thereto that cannot be settled between the
parties within a reasonable period, then such dispute or difference may be referred to
an Adjudicator. If such dispute or difference is referred to an Adjudicator, the Project
Manager shall give instructions as to whether and if so, how, performance of the
Contract is to proceed. The Contractor shall proceed with the Contract in
accordance with the Project Managers instructions, provided that if the Adjudicator
upholds the Contractors view on the dispute, then the Contractor shall be
reimbursed by the Owner for any additional costs incurred by reason of such
instructions and shall be relieved of such responsibility or liability in connection with
the dispute and the execution of the instructions as the Adjudicator shall decide, and
the Time for Completion shall be extended accordingly.
The Project Managers approval, with or without modification of the document
furnished by the Contractor, shall not relieve the Contractor of any responsibility or
liability imposed upon it by any provisions of the Contract except to the extent that
any subsequent failure results from modifications required by the Project Manager.
4.26
Procurement
a) Plant and Equipment
The Contractor shall manufacture or procure and transport all the Plant and
Equipments in an expeditious and orderly manner to the Site.
b) Transportation
The Contractor shall at its own risk and expense transport all the Plant and
Equipments and the Contractors Equipments to the Site by the mode of transport
that the Contractor judges most suitable under all the circumstances. Unless
otherwise provided in the Contract, the Contractor shall be entitled to select any safe
mode of transport operated by any person to carry the Plant and Equipments and the
Contractors Equipment. Upon dispatch of each shipment of the Plant and
Equipments and the Contractors Equipments, the Contractor shall notify the Owner
by telex, cable, telefax, facsimile or Electronic Data Interchange (EDI) of the
description of the Plant and Equipments and of the Contractors Equipments, the
point and means of dispatch, and the estimated time and point of arrival in the
country where the Site is located, if applicable, and at the Site. The Contractor shall
furnish the Owner with relevant shipping documents to be agreed upon between the
parties.
The Contractor shall be responsible for obtaining, if necessary, approvals from the
authorities for transportation of the Plant and Equipments and the Contractors
Equipments to the Site. The Owner shall use its best endeavours in a timely and
expeditious manner to assist the Contractor in obtaining such approvals, if requested
by the Contractor. The Contractor shall indemnify and hold harmless the Owner from
and against any claim for damage to roads, bridges or any other traffic facilities that
may be caused by the transport of the Plant and Equipments and the Contractors
Equipments to the Site.
c) The Contractor shall, at its own expense, handle all imported Plant and Equipments
and spares and Contractors Equipments at the point(s) of import and shall handle
any formalities for customs clearance.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
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Page No.
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Date of Issue
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4.27
Installation
a) Setting Out/Supervision/Labour
Bench Mark: The Contractor shall be responsible for the true and proper setting-out
of the Facilities in relation to bench marks, reference marks and lines provided to it in
writing by or on behalf of the Owner.
If, at any time during the progress of installation of the Facilities, any error shall
appear in the position, level or alignment of the Facilities, the Contractor shall
forthwith notify the Project Manager of such error and, at its own expense,
immediately rectify such error to the reasonable satisfaction of the Project Manager.
If such error is based on incorrect data provided in writing by or on behalf of the
Owner, the expense of rectifying the same shall be borne by the Owner.
Contractors Supervision: The Contractor shall give or provide all necessary
superintendence during the installation of the Facilities, and the Construction
Manager or its deputy shall be constantly on the Site to provide full time
superintendence of the installation. The Contractor shall provide and employ only
technical personnel who are skilled and experienced in their respective callings and
supervisory staff who are competent to adequately supervise the work at hand.
The Contractor shall provide and employ on the Site in the installation of the Facilities
such skilled, semi-skilled and unskilled labour as is necessary for the proper and
timely execution of the Contract. The Contractor is encouraged to use local labour
that has the necessary skills. Unless otherwise provided in the Contract, the
Contractor shall be responsible for the recruitment, transportation, accommodation
and catering of all labour, local or expatriate, required for the execution of the
Contract and for all payments in connection therewith.
The Contractor shall at its own expense provide the means of repatriation to all of its
and its Subcontractors personnel employed on the Contract at the Site to their
various home countries. It shall also provide suitable temporary maintenance of all
such persons from the cessation of their employment on the Contract to the date
programmed for their departure. In the event that the Contractor defaults in providing
such means of transportation and temporary maintenance, the Owner may provide
the same to such personnel and recover the cost of doing so from the Contractor.
The Contractor shall, in all dealings with its labour and the
labour of its
Subcontractors currently employed on or connected with the Contract, pay due
regard to all recognized festivals, official holidays, religious or other customs and all
local laws and regulations pertaining to the employment of labour.
b) Contractors Equipments
All Contractors Equipments brought by the Contractor onto the Site shall be deemed
to be intended to be used exclusively for the execution of the Contract. The
Contractor shall not remove the same from the Site without the Project Managers
consent that such Contractors Equipments are no longer required for the execution
of the Contract. Unless otherwise specified in the Contract, upon completion of the
Facilities, the Contractor shall remove from the Site all Equipments brought by the
Contractor onto the Site and any surplus materials remaining thereon.
The Owner will, if requested, use its best endeavours to assist the Contractor in
obtaining any local, state or national government permission required by the
Contractor for the export of the Contractors Equipments imported by the Contractor
for use in the execution of the Contract that is no longer required for the execution of
the Contract.
c) Site Regulations and Safety
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
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Date of Issue
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The Owner and the Contractor shall establish Site regulations setting out the rules to
be observed in the execution of the Contract at the Site and shall comply therewith.
The Contractor shall prepare and submit to the Owner, with a copy to the Project
Manager, proposed Site regulations for the Owners approval, which approval shall
not be unreasonably withheld.
Such Site regulations shall include, but shall not be limited to, rules in respect of
security, safety of the Facilities, gate control, sanitation, medical care, and fire
prevention.
d) Opportunities for Other Contractors
The Contractor shall, upon written request from the Owner or the Project Manager,
give all reasonable opportunities for carrying out the work to any other contractors
employed by the Owner on or near the Site. If the Contractor, upon written request
from the Owner or the Project Manager, makes available to other contractors any
roads or ways the maintenance for which the Contractor is responsible, permits the
use by such other contractors of the Contractors Equipments, or provides any other
service of whatsoever nature for such other contractors, the Owner shall fully
compensate the Contractor for any loss or damage caused or occasioned by such
other contractors in respect of any such use or service, and shall pay to the
Contractor reasonable remuneration for the use of such equipments or the provision
of such services.
The Contractor shall also so arrange to perform its work as to minimize, to the extent
possible, interference with the work of other contractors. The Project Manager shall
determine the resolution of any difference or conflict that may arise between the
Contractor and other contractors and the workers of the Owner in regard to their
work.
The Contractor shall notify the Project Manager promptly of any defects in the other
Contractors work that come to its notice, and that could affect the Contractors work.
The Project Manager shall determine the corrective measures, if any, required to
rectify the situation after inspection of the Facilities. Decisions made by the Project
Manager shall be binding on the Contractor.
e) Emergency Work
If, by reason of an emergency arising in connection with and during the execution of
the Contract, any protective or remedial work is necessary as a matter of urgency to
prevent damage to the Facilities, the Contractor shall immediately carry out such
work.
If the Contractor is unable or unwilling to do such work immediately, the Owner may
do or cause such work to be done as the Owner may determine is necessary in order
to prevent damage to the Facilities. In such event the Owner shall, as soon as
practicable after the occurrence of any such emergency, notify the Contractor in
writing of such emergency, the work done and the reasons there for. If the work done
or caused to be done by the Owner is work that the Contractor was liable to do at its
own expense under the Contract, the reasonable costs incurred by the Owner in
connection therewith shall be paid by the Contractor to the Owner. Otherwise, the
cost of such remedial work shall be borne by the Owner.
f) Site Clearance
Site Clearance in Course of Performance: In the course of carrying out the Contract,
the Contractor shall keep the Site reasonably free from all unnecessary obstruction,
store or remove any surplus materials, clear away any wreckage, rubbish or
temporary works from the Site, and remove any Contractors Equipments no longer
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02
Description
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required for execution of the Contract. Clearance of Site after Completion: After
Completion of all parts of the Facilities, the Contractor shall clear away and remove
all wreckage, rubbish and debris of any kind from the Site, and shall leave the Site
and Facilities clean and safe.
g) Watching and Lighting
The Contractor shall provide and maintain at its own expense all lighting, fencing,
and watching when and where necessary for the proper execution and the protection
of the Facilities, or for the safety of the owners and occupiers of adjacent property
and for the safety of the public as per specification.
4.28
Testing & Inspections

a) The Contractor shall at its own expense carry out at the place of manufacture and/or
on the Site all such tests and/or inspections of the Plant and Equipments and any
part of the Facilities as are specified in the Contract.
b) The Owner and the Project Manager or their designated representatives shall be
entitled to attend the aforesaid test and/ or inspection, provided that the Owner shall
bear all costs and expenses incurred in connection with such attendance including,
but not limited to, all travelling and board and lodging expenses.
c) Whenever the Contractor is ready to carry out any such test and/or inspection, the
Contractor shall give a reasonable advance notice of such test and/or inspection and
of the place and time thereof to the Project Manager. The Contractor shall obtain
from any relevant third party or manufacturer any necessary permission or consent to
enable the Owner and the Project Manager (or their designated representatives) to
attend the test and/or inspection.
d) The Contractor shall provide the Project Manager with a certified report of the results
of any such test and/or inspection. If the Owner or Project Manager (or their
designated representatives) fails to attend the test and/or inspection, or if it is agreed
between the parties that such persons shall not do so, then the Contractor may
proceed with the test and/or inspection in the absence of such persons, and may
provide the Project Manager with a certified report of the results thereof.
e) The Project Manager may require the Contractor to carry out any test and/or
inspection not required by the Contract, provided that the Contractors reasonable
costs and expenses incurred in the carrying out of such test and/or inspection shall
be added to the Contract Price. Further, if such test and/or inspection impede the
progress of work on the Facilities and/or the Contractors performance of its other
obligations under the Contract, due allowance will be made in respect of the Time for
Completion and the other obligations so affected.
f) If any Plant and Equipment or any part of the Facilities fails to pass any test and/or
inspection, the Contractor shall either rectify or replace such Plant and Equipment or
part of the Facilities and shall repeat the test and/or inspection upon giving a notice.
g) If any dispute or difference of opinion shall arise between the parties in connection
with or arising out of the test and/or inspection of the Plant and Equipments or part of
the Facilities that cannot be settled between the parties within a reasonable period of
time, it may be referred to the Adjudicator.
h) The Contractor shall afford the Owner and the Project Manager, at the Owners
expense, access at any reasonable time to any place where the Plant and
Equipments are being manufactured or the Facilities are being installed, in order to
inspect the progress and the manner of manufacture or installation, provided that the
Project Manager shall give the Contractor a reasonable prior notice.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
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i)
The Contractor agrees that neither the execution of a test and/ or inspection of Plant
and Equipments or any part of the Facilities, nor the witnessing of any test by the
Owner, nor the issuance of any test certificate shall relieve the Contractor of any
obligation under this Contract.
j) No part of the Facilities or foundations shall be covered up on the Site without the
Contractor carrying out any test and/or inspection required under the Contract. The
Contractor shall give a reasonable notice to the Project Manager whenever any such
part of the Facilities or foundations is ready or about to be ready for test and/or
inspection; such test and/or inspection and notice thereof shall be subject to the
requirements of the Contract.
k) The Contractor shall uncover any part of the Facilities or foundations, or shall make
openings in or through the same as the Project Manager may from time to time
require at the Site, and shall reinstate and make good such part or parts.
4.29
Completion of the Facilities

a) As soon as the Facilities or any part thereof has, in the opinion of the Contractor,
been completed operationally and structurally and put in a tight and clean condition
as specified in the Technical Specifications, excluding minor items not materially
affecting the operation or safety of the Facilities, the Contractor shall so notify the
Owner in writing.
b) The Owner shall supply the operating and maintenance personnel as specified in the
Contract for Precomissioning of the Facilities or any part thereof.
c) As soon as all works in respect of Precomissioning are completed and, in the opinion
of the Contractor, the Facilities or any part thereof is ready for Commissioning, the
Contractor shall commence Commissioning as per procedures stipulated in
Technical Specifications, and as soon as Commissioning is satisfactorily completed,
the Contractor shall so notify the Project Manager in writing.
d) If the Project Manager notifies the Contractor of any defects and/ or deficiencies, the
Contractor shall then correct such defects and/or deficiencies.
If the Project Manager is satisfied that the Facilities or that part thereof have reached
Completion, the Project Manager shall, within [seven (7)] days after receipt of the
Contractors notice, issue a Completion Certificate stating that the Facilities or that
part thereof have reached Completion as at the date of the Contractors notice.
If the Project Manager is not so satisfied, then it shall notify the Contractor in writing
of any defects and/or deficiencies within [seven (7)] days after receipt of the
Contractors notice, and the above procedure shall be repeated.
e) If the Project Manager fails to issue the Completion Certificate and fails to inform
the Contractor of any defects and/or deficiencies within [seven (7)] days after receipt
of the Contractors notice, or if the Owner makes use of the Facilities or part thereof,
then the Facilities or that part thereof shall be deemed to have reached Completion
as of the date of the Contractors notice, or as of the Owners use of the Facilities, as
the case may be.
f) As soon as possible after Completion, the Contractor shall complete all outstanding
minor items so that the Facilities are fully in accordance with the requirements of the
Contract, failing which the Owner will undertake such completion and deduct the
costs thereof from any monies owing to the Contractor.
g) Upon Completion, the Owner shall be responsible for the care and custody of the
Facilities or the relevant part thereof, together with the risk of loss or damage thereto,
and shall thereafter take over the Facilities or the relevant part thereof.
Document Number
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02
Description
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Date of Issue
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4.30
Commissioning & Operation Acceptance

a)
b)
c)
d)
Commissioning
Commissioning of the Facilities or any part thereof Acceptance shall be
completed by the Contractor as per procedures detailed in the Technical
Specifications. The Contractor shall, unless otherwise specified in Contract/
Tender Specifications, supply the utilities, lubricants, chemicals, catalysts,
facilities, services and other matters required for Commissioning.
Guarantee Test
The Guarantee Tests (and repeats thereof) shall be conducted by the Contractor
after Commissioning of the Facilities or the relevant part thereof to ascertain
whether the Facilities or the relevant part can attain the Functional Guarantees
specified in the Contract Documents. The Contractors and Project Managers
advisory personnel shall attend the Guarantee Test. The Owner shall promptly
provide the Contractor with such information as the Contractor may reasonably
require in relation to the conduct and results of the Guarantee Tests (and any
repeats thereof). If for reasons not attributable to the Contractor, the Guarantee
Tests of the Facilities or the relevant part thereof cannot be successfully
completed within the period from the date of Completion, specified in the SCC or
any other period agreed upon by the Owner and the Contractor, the Contractor
shall be deemed to have fulfilled its obligations with respect to the Functional
Guarantees.
Operational Acceptance
Operational Acceptance shall occur in respect of the Facilities or any part thereof
when
the Guarantee Tests have been successfully completed and the Functional
Guarantees are met; or
The Guarantee Tests have not been successfully completed or has not
been carried out for reasons not attributable to the Contractor within the
period from the date of Completion specified in the SCC or any other
agreed upon period as specified in GCC.
The Contractor may give a notice to the Project Manager requesting the
issue of an Operational Acceptance Certificate in respect of the Facilities or
the part thereof specified in such notice as at the date of such notice.
The Project Manager shall, after consultation with the Owner, and within
forty five (45) days after receipt of the Contractors notice, issue an
Operational Acceptance Certificate. If within [forty five (45)] days after
receipt of the Contractors notice, the Project Manager fails to issue the
Operational Acceptance Certificate or fails to inform the Contractor in
writing of the justifiable reasons why the Project Manager has not issued
the Operational Acceptance Certificate, the Facilities or the relevant part
thereof shall be deemed to have been accepted as at the date of the
Contractors said notice.
Partial Acceptance
If the Contract specifies that Completion, Commissioning and Guarantee Tests
shall be carried out in respect of parts of the Facilities, the provisions relating to
Completion and Commissioning including the Guarantee Tests shall apply to
each such part of the Facilities individually, and the Operational Acceptance
Certificate shall be issued accordingly for each such part of the Facilities. If a part
of the Facilities comprises facilities such as buildings, for which no
Document Number
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02
Description
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Commissioning or Guarantee Tests are required, then the Project Manager shall
issue the Operational Acceptance Certificate for such facility when it attains
Completion, provided that the Contractor shall thereafter complete any
outstanding minor items that are listed in the Operational Acceptance Certificate.
4.31
Completion Time and Liquidated Damage

a)
b)
c)
4.32
Completion Time Period

The Contractor guarantees that it shall attain Completion of the Facilities (or a
part for which a separate time for completion is specified in the SCC) within the
Time for Completion specified in the SCC.
If the Contractor fails to attain Completion of the Facilities or any part thereof
within the Time for Completion, the Contractor shall pay to the Owner liquidated
damages in the amount computed at the rates specified in the SCC. The
aggregate amount of such liquidated damages shall in no event exceed the
amount specified as Maximum in the SCC.
However, the payment of liquidated damages shall not in any way relieve the
Contractor from any of its obligations to complete the Facilities or from any other
obligations and liabilities of the Contractor under the Contract.
No bonus will be given for earlier completion of the facilities or part thereof.
Defects Liability
a) The Contractor warrants that the Facilities or any part thereof shall be free from
defects in the design, engineering, materials and workmanship of the Plant and
Equipments supplied and of the work executed.
b) The Defects Liability Period shall be [eighteen (18)] months from the date of
Completion of the Facilities (or any part thereof) or [twelve (12)] months from the
date of Operational Acceptance of the Facilities (or any part thereof).
If during the Defects Liability Period any defect should be found in the design,
engineering, materials and workmanship of the Plant and Equipments supplied or
of the work executed by the Contractor, the Contractor shall promptly, in
consultation and agreement with the Owner regarding appropriate remedying of the
defects, and at its cost, repair, replace or otherwise make good (as the Contractor
shall, at its discretion, determine) such defect as well as any damage to the
Facilities caused by such defect. The Contractor shall not be responsible for the
repair, replacement or making good of any defect or of any damage to the Facilities
arising out of or resulting from any of the following causes:
improper operation or maintenance of the Facilities by the Owner
operation of the Facilities outside specifications provided in the Contract
Normal wear and tear.
c) The Owner shall give the Contractor a notice stating the nature of any such defect
together with all available evidence thereof, promptly following the discovery
thereof. The Owner shall afford all reasonable opportunity for the Contractor to
inspect any such defect.
d) The Owner shall afford the Contractor all necessary access to the Facilities and the
Site to enable the Contractor to perform its obligations.
e) If the repair, replacement or making good is of such a character that it may affect
the efficiency of the Facilities or any part thereof, the Owner may give to the
Contractor a notice requiring that tests of the defective part of the Facilities shall be
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made by the Contractor immediately upon completion of such remedial work,

whereupon the Contractor shall carry out such tests.
f) If the Contractor fails to commence the work necessary to remedy such defect or
any damage to the Facilities caused by such defect within a reasonable time (which
shall in no event be considered to be less than fifteen (15) days), the Owner may,
following notice to the Contractor, proceed to do such work, and the reasonable
costs incurred by the Owner in connection therewith shall be paid to the Owner by
the Contractor or may be deducted by the Owner from any monies due to the
Contractor or claimed under the Performance Security.
g) If the Facilities or any part thereof cannot be used by reason of such defect and/or
making good of such defect, the Defects Liability Period of the Facilities or such
part, as the case may be, shall be extended by a period equal to the period during
which the Facilities or such part cannot be used by the Owner because of any of
the aforesaid reasons. Upon correction of the defects in the Facilities or any part
thereof by repair/replacement, such repair/replacement shall have the Defects
Liability Period extended by a period of [twelve (12) month] from the time such
replacement/repair of the Facilities or any part thereof.
4.33
The Contractor guarantees that during the Guarantee Tests, the Facilities and all parts
thereof shall attain the Functional Guarantees as per the Contract. If, for reasons
attributable to the Contractor, Functional Guarantees are not met either in whole or in
part, the Contractor shall, within a mutually agreed time, at its cost and expense make
such changes, modifications and/or additions to the Plant or any part thereof as may
be necessary to meet such Guarantees. The Contractor shall notify the Owner upon
completion of the necessary changes, modifications and/or additions, and shall seek
the Owner's consent to repeat the Guarantee Test. If the specified Functional
Guarantees are not established even during the repeat of the Guarantee Tests, the
Owner may at its option, either reject the plant and equipment and recover from the
Contractor payments already made or Accept the equipment/system/plant after levying
Liquidated Damages as specified.
4.34
Patents Indemnity
The Contractor shall indemnify and hold harmless the Owner and its employees and
officers from and against any and all suits, actions or administrative proceedings,
including attorneys fees and expenses, which the Owner may suffer as a result of any
infringement or alleged infringement of any patent, utility model, registered design,
trademark, copyright or other intellectual property right registered or otherwise existing
at the date of the Contract by reason of: (a) the installation of the Facilities by the
Contractor or the use of the such Facilities.
4.35
Limitation of liability
Except in cases of criminal negligence or wilful misconduct by the Contractor, the
aggregate liability of the Contractor to the Owner, whether under the Contract, in tort or
otherwise, shall not exceed the total Contract Price, provided that this limitation shall
not apply to any obligation of the Contractor to indemnify the Owner with respect to
patent infringement.
Except in cases of criminal negligence or wilful misconduct by the Contractor,
the Contractor shall not be liable to the Owner, whether in contract, tort, or otherwise,
for any indirect or consequential loss or damage, loss of use, loss of production, or
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loss of profits or interest costs, provided that this exclusion shall not apply to any
obligation of the Contractor to pay liquidated damages to the Owner.
4.36
Transfer of Ownership
Ownership of the Plant and Equipments (including spare parts) to be imported into
India shall be transferred to the Owner upon loading on to the mode of transport to be
used to convey the Plant and Equipments from the country of origin to that country.
Ownership of the Plant and Equipments (including spare parts) procured from within
India shall be transferred to the Owner when the Plant and Equipments including
spares are loaded on to the mode of transport to be used to convey the Plant and
Equipments including spares from the works to the site and upon endorsement of the
despatch documents in favour of the Owner. Ownership of the Contractors
Equipments used by the Contractor and its Subcontractors in connection with the
Contract shall remain with the Contractor or its Subcontractors. Ownership of any Plant
and Equipments in excess of the requirements for the Facilities shall revert to the
Contractor upon Completion of the Facilities or at such earlier time when the Owner
and the Contractor agree that the Plant and Equipments in question are no longer
required for the Facilities, provided quantity of any Plant and Equipments specifically
stipulated in the Contract shall be the property of the Owner whether or not
incorporated in the Facilities. Notwithstanding the transfer of ownership of the Plant
and Equipments, the responsibility for care and custody thereof together with the risk
of loss or damage shall remain with the Contractor until Completion of the Facilities.
4.37
Care of Facilities
The Contractor shall be responsible for the care and custody of the Facilities or any
part thereof until the date of Completion of the Facilities, where the Contract provides
for Completion of the Facilities in parts, until the date of Completion of the relevant
part, and shall make good at its own cost any loss or damage that may occur to the
Facilities or the relevant part thereof from any cause whatsoever during such period.
The Contractor shall also be responsible for any loss or damage to the Facilities
caused by the Contractor or its Subcontractors in the course of any work carried out.
4.38

The Contractor shall indemnify and hold harmless the Owner and its employees
and officers from and against any and all suits, actions or administrative proceedings,
including attorneys fees and expenses, in respect of the death or injury of any
person or loss of or damage to any property (other than the Facilities whether
accepted or not), arising in connection with the supply and installation of the Facilities
and by reason of the negligence of the Contractor or its Subcontractors, or their
employees, officers or agents, except any injury, death or property damage caused by
the negligence of the Owner, its contractors, employees, officers or agents.
4.39
Insurance
a)
The Contractor shall at its expense take out and maintain in effect, or cause to be
taken out and maintained in effect, during the performance of the Contract, the
insurances set forth below in the sums and with the deductibles and other
conditions as specified. The identity of the insurers and the form of the policies
shall be subject to the approval of the Owner, who should not unreasonably
withhold such approval.
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b)
c)
d)
e)
f)
Cargo Insurance during Transport:-Covering loss or damage occurring while in

transit from the Contractors or Subcontractors works or stores until arrival at
the Site, to the Plant and Equipments (including spare parts thereof) and to the
Contractors Equipments.
Installation All Risks Insurance:-Covering physical loss or damage to the
Facilities at the Site, occurring prior to Completion of the Facilities, with an
extended maintenance coverage for the Contractors liability in respect of any
loss or damage occurring during the Defects Liability Period while the
Contractor is on the Site for the purpose of performing its obligations during the
Defects Liability Period.
Third Party Liability Insurance: - Covering bodily injury or death suffered by third
parties (including the Owners personnel) and loss of or damage to property
occurring in connection with the supply and installation of the Facilities.
Automobile Liability Insurance:-Covering use of all vehicles used by the
Contractor or its Subcontractors (whether or not owned by them) in connection
with the execution of the Contract.
Workers Compensation:-In accordance with the statutory requirements
applicable in any country where the Contract or any part thereof is executed.
Owners Liability: - In accordance with the statutory requirements applicable in
any country where the Contract or any part thereof is executed.
Other Insurances Such other insurances as may be specifically agreed upon by
the parties.
The Owner shall be named as co-insured under all insurance policies taken out by
the Contractor pursuant except for the Third Party Liability, Workers
Compensation and Owners Liability Insurances, and the Contractors
Subcontractors shall be named as co-insureds under all insurance policies taken
out by the Contractor except for the Cargo Insurance During Transport, Workers
Compensation and Owners Liability Insurances. All insurers rights of subrogation
against such co-insureds for losses or claims arising out of the performance of the
Contract shall be waived under such policies.
The Form of Contract Agreement, deliver to the Owner certificates of insurance (or
copies of the insurance policies) as evidence that the required policies are in full
force and effect. The certificates shall provide that no less than twenty one (21)
days notice shall be given to the Owner by insurers prior to cancellation or
material modification of a policy.
The Contractor shall ensure that, where applicable, its Subcontractor(s) shall take
out and maintain in effect adequate insurance policies for their personnel and
vehicles and for work executed by them under the Contract, unless such
Subcontractors are covered by the policies taken out by the Contractor.
The Owner shall at its expense take out and maintain in effect during the
performance of the Contract those insurances specified.
the Owner may take out and maintain in effect any such insurances and may from
time to time deduct from any amount due the Contractor under the Contract any
premium that the Owner shall have paid to the insurer, or may otherwise recover
such amount as a debt due from the Contractor. If the Owner fails to take out
and/or maintain in effect the insurances the Contractor may take out and maintain
in effect any such insurances and may from time to time deduct from any amount
due the Owner under the Contract any premium that the Contractor shall have
paid to the insurer, or may otherwise recover such amount as a debt due from the
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g)
h)
i)
4.40
Owner. If the Contractor fails to or is unable to take out and maintain in effect any
such insurances, the Contractor shall nevertheless have no liability or
responsibility towards the Owner, and the Contractor shall have full recourse
against the Owner for any and all liabilities of the Owner herein.
The Owner shall give to the Contractor all such reasonable assistance as may be
required by the Contractor. With respect to insurance claims in which the Owners
interest is involved, the Contractor shall not give any release or make any
compromise with the insurer without the prior written consent of the Owner. With
respect to insurance claims in which the Contractors interest is involved, the
Owner shall not give any release or make any compromise with the insurer without
the prior written consent of the Contractor.
Wherever total damages/loss of equipments/materials, would occur, the
Contractor will be entitled to payment of all payments received from the
underwriters except the following amounts:
The amount paid to the Contractor under the Contract in respect of
equipments/materials damaged/lost (excluding the pro-rata initial advance)
but including the entire amount of escalation, if any, already paid to the
Contractor.
Custom Duties and taxes which have already been paid by the Owner.
In case of damage to any equipments/materials during any stage, the
Contractor upon rectification of the damaged equipment to the satisfaction of
the Owner shall be paid to the extent of full claims settled by the underwriters.
All the Plants & Equipment being supplied by the Owner free of cost for installation
of the equipment, cabling, earthing and lightning protection etc. by the Contractor,
covered by this specification shall be kept insured by the Contractor against loss,
damage, theft, pilferage, fire etc. from the point of unloading at Site up to the time
of taking over by the Owner including handling, in plant transportation, storage,
installation, testing and commissioning, etc. and the Contractor shall be fully
responsible for making good of any loss or damage at his own cost within a
reasonable time as mutually agreed upon by the Owner and the Contractor. Any
loss/damage shall be brought to the Owner's notice immediately. The premium
paid by the Contractor to the Insurance Company for such insurance shall be
reimbursed by the Owner to the Contractor at actual against documentary proof to
be furnished by the Contractor. The Contractor shall obtain competitive quotation
for such insurance and shall take prior approval from the Owner before taking the
insurance. The insurable value of the equipment being procured by the Owner will
be intimated to the Contractor for the purpose of insurance.
It will be the responsibility of the Contractor to lodge, pursue and settle all
claims with the Insurance Company in case of any damage, loss, theft,
pilferage, fire, etc. and the Owner shall be kept informed about it. The losses,
if any, will have to be borne by the Contractor, if the claims are not lodged
and pursued properly or in the time or if the same are not settled by the
Insurance Company.

a)
any law, regulation, ordinance, order or by-law having the force of law is enacted,
promulgated, abrogated or changed (which shall be deemed to include any
change in interpretation or application by the competent authorities) that
subsequently affects the costs and expenses of the Contractor and/or the Time
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extent that the Contractor has thereby been affected in the performance of any of
its obligations under the Contract. However, these adjustments would be
restricted to direct transactions between the Owner and the Contractor and not
on procurement of raw materials, intermediary components etc. by the
Contractor. Notwithstanding the foregoing, such additional or reduced costs shall
not be separately paid or credited if the same has already been accounted for in
the price adjustment provisions wherever applicable.
4.41
Force Majeure
(a)
Owner or of the Contractor, as the case may be, and which is unavoidable
notwithstanding the reasonable care of the party affected. Force Majeure events
include Acts of God, Acts of Government, war, sabotage, riots, civil commotion,
revolution, flood, earthquake, cyclone, fire, epidemic etc.
(b) If either party is prevented, hindered or delayed from or in performing any of its
obligations under the Contract by an event of Force Majeure, then it shall notify
the other in writing of the occurrence of such event and the circumstances thereof
within [fourteen (14)] days after the occurrence of such event.
(c) The party who has given such notice shall be excused from the performance or
punctual performance of its obligations under the Contract for so long as the
relevant event of Force Majeure continues and to the extent that such partys
performance is prevented, hindered or delayed.
(d) The party or parties affected by the event of Force Majeure shall use reasonable
efforts to mitigate the effect thereof upon its or their performance of the Contract
and to fulfil its or their obligations under the Contract, but without prejudice to
either partys right.
(e) No delay or non-performance by either party hereto caused by the occurrence of
any event of Force Majeure shall
- to any claim for damages or additional cost or expense occasioned thereby
if and to the extent that such delay or non-performance is caused by the occurrence of
an event of Force Majeure.
(f) If the performance of the Contract is substantially prevented, hindered or delayed
for a single period of more than [sixty (60)] days or an aggregate period of more
than one hundred and [twenty (120)] days on account of one or more events of
Force Majeure during the currency of the Contract, the parties will attempt to
develop a mutually satisfactory solution.
(g) Force Majeure shall not apply to any obligation of the Owner to make payments
to the Contractor herein.
4.42
Change in the Facilities

(a)
Introducing a Change
-
Contractor during the performance of the Contract to make any change,
modification, addition or deletion to, in or from the Facilities (hereinafter called
Change), provided that such Change falls within the general scope of the
Facilities and does not constitute unrelated work and that it is technically
practicable, taking into account both the state of advancement of the Facilities
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(b)
and the technical compatibility of the Change envisaged with the nature of
the Facilities as specified in the Contract.
The Contractor may from time to time during its performance of the Contract
propose to the Owner (with a copy to the Project Manager) any Change that
the Contractor considers necessary or desirable to improve the quality,
efficiency or safety of the Facilities. This includes any additional scope of
work that the contractor thinks is essential for achieving the minimum
performance level specified in the SCC or the Contract. The Owner may at its
discretion approve or reject any Change proposed by the Contractor.
No change made necessary because of any default of the Contractor in the
performance of its obligations under the Contract shall be deemed to be a
Change, and such change shall not result in any adjustment of the Contract
Price or the Time for Completion.
Changes Originating from Owner

-
If the Owner proposes a Change, it shall send to the Contractor a Request

for Change Proposal, requiring the Contractor to prepare and furnish to the
Project Manager as soon as reasonably practicable a Change Proposal,
which shall include the following:
brief description of the Change
effect on the Time for Completion
estimated Cost of the Change
effect on Functional Guarantees (if any)
effect on any other provisions of the Contract.
The pricing of any Change shall, as far as practicable, be calculated in
accordance with the rates and prices included in the Contract. If the rates
and prices of any change are not available in the Contract, the parties thereto
shall agree on specific rates for the valuation of the Change.
If before or during the preparation of the Change Proposal it becomes
apparent that the aggregate effect of compliance therewith and with all other
Change Orders that have already become binding upon the Contractor to
increase or decrease the Contract Price as originally set forth in the Contract
Agreement by more than fifteen (15) percent, the Contractor may give a
written notice of objection thereto prior to furnishing the Change Proposal as
aforesaid. If the Owner accepts the Contractors objection, the Owner and
the Contractor shall agree on specific rates for valuation of the change.
Upon receipt of the Change Proposal, the Owner and the Contractor shall
mutually agree upon all matters therein contained including agreement on
rates if such rates are not available in the Contract or if the limit of 15% set
forth has been exceeded. Within [fourteen (14)] days after such agreement,
the Owner shall, if it intends to proceed with the Change, issue the Contractor
with a Change Order.
If the Owner is unable to reach a decision within [fourteen (14)] days, it shall
notify the Contractor with details of when the Contractor can expect a
decision.
If the Owner decides not to proceed with the Change for whatever reason, it
shall, within the said period of [fourteen (14)] days, notify the Contractor
accordingly.
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If the Owner and the Contractor cannot reach agreement on the price for the
Change, an equitable adjustment to the Time for Completion, or any other
matters identified in the Change Proposal, the Owner may nevertheless
instruct the Contractor to proceed with the Change by issue of a Pending
Agreement Change Order.
Upon receipt of a Pending Agreement Change Order, the Contractor shall
immediately proceed with effecting the Changes covered by such Order. The
parties shall thereafter attempt to reach agreement on the outstanding issues
under the Change Proposal.
(c)
Changes Originating from Contractor

-
4.43

(a)
(b)
(c)
4.44
The Contractor shall submit to the Project Manager a written Application for
Change Proposal, giving reasons for the proposed Change and including the
information. Upon receipt of the Application for Change Proposal, the parties
shall follow the procedures indicated above for Request for Change
Proposal.
Contractor is delayed or impeded in the performance of any of its obligations
- any suspension order given by the Owner or reduction in the rate of progress
or
- any default or breach of the Contract by the Owner, or any activity, act or
omission of any other contractors employed by the Owner or
By such period as shall be fair and reasonable in all the circumstances and as
shall fairly reflect the delay or impediment sustained by the Contractor.
Except where otherwise specifically provided in the Contract, the Contractor shall
submit to the Project Manager a notice of a claim for an extension of the Time for
Completion, together with particulars of the event or circumstance justifying such
extension as soon as reasonably practicable after the commencement of such
event or circumstance. As soon as reasonably practicable after receipt of such
notice and supporting particulars of the claim, the Owner and the Contractor shall
agree upon the period of such extension.
The Contractor shall at all times use its reasonable efforts to minimize any delay
in the performance of its obligations under the Contract.
Suspension
(a)
The Owner/ Project Manager may, by notice to the Contractor, order the
Contractor to suspend performance of any or all of its obligations under the
Contract. Such notice shall specify the obligation of which performance is to be
suspended, the effective date of the suspension and the reasons thereof. The
Contractor shall thereupon suspend performance of such obligation (except those
obligations necessary for the care or preservation of the Facilities) until ordered in
writing to resume such performance by the Project Manager/ Owner.
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(b)
(c)
4.45
If, by virtue of a suspension order given by the Project Manager/ Owner, other
than by reason of the Contractors default or breach of the Contract, the
Contractors performance of any of its obligations is suspended for an aggregate
period of more than [ninety (90)] days, then at any time thereafter and provided
that at that time such performance is still suspended, the Contractor may give a
notice to the Project Manager requiring that the Owner shall, within [twenty eight
(28)] days of receipt of the notice, order the resumption of such performance or
request and subsequently order a change, excluding the performance of the
suspended obligations from the Contract.
If the Contractor is unable to carry out any of its obligations under the Contract for
any reason attributable to the Owner, including but not limited to the Owners
failure to provide possession of or access to the Site or other areas;
Then the Contractor may by [fourteen (14)] days notice to the Owner suspend
performance of all or any of its obligations under the Contract, or reduce the rate
of progress. If the Contractors performance of its obligations is suspended or the
rate of progress is reduced, then the Time for Completion shall be extended, and
any and all additional costs or expenses incurred by the Contractor as a result
of such suspension or reduction shall be paid by the Owner to the Contractor in
addition to the Contract Price, except in the case of suspension order or
reduction in the rate of progress by reason of the Contractors default or breach
of the Contract.
During the period of suspension, the Contractor shall not remove from the Site
any Plant and Equipment, any part of the Facilities or any Contractors
Equipment, without the prior written consent of the Owner.
Termination
(a)

The Owner may at any time terminate the Contract for any reason by giving the
Contractor a notice of termination. Upon receipt of the notice of termination, the
Contractor shall either immediately or upon the date specified in the notice of
termination
(i)
cease all further work, except for such work as the Owner may specify in
the notice of termination for the sole purpose of protecting that part of the
Facilities already executed, or any work required to leave the Site in a clean
and safe condition.
(ii)
(iii)
remove all Contractors Equipments from the Site, repatriate the

Contractors and its Subcontractors personnel from the Site, remove from
the Site any wreckage, rubbish and debris of any kind, and leave the whole
of the Site in a clean and safe condition
(iv)
The Contractor, subject to the payment, shall

deliver to the Owner the parts of the Facilities executed by the Contractor
up to the date of termination
benefit of the Contractor to the Facilities and to the Plant and Equipments
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Subcontractors
documents prepared by the Contractor or its Subcontractors as at the
date of termination in connection with the Facilities.
In the event of termination of the Contract for Owners convenience, the
Owner shall pay to the Contractor the following amounts
the Contract Price, attributable to the parts of the Facilities executed
by the Contractor as on the date of termination
the costs reasonably incurred by the Contractor in the removal of the
Contractors Equipment from the Site and in the repatriation of the
Contractors and its Subcontractors personnel
any amounts to be paid by the Contractor to its Subcontractors in
costs incurred by the Contractor in protecting the Facilities and leaving
the Site in a clean and safe condition
the additional cost of satisfying other obligations, commitments and
claims that the Contractor may in good faith have undertaken with
third parties in connection with the Contract.
(b)
Termination for Contractors Default

(i)

circumstances by giving a notice of termination and its reasons thereof to
the Contractor:
- If the Contractor becomes bankrupt or insolvent, has a receiving
order issued against it, compounds with its creditors, or, if the
Contractor is a corporation, a resolution is passed or order is
made for its winding up (other than a voluntary liquidation for the
purposes of amalgamation or reconstruction), a receiver is
appointed over any part of its undertaking or assets, or if the
Contractor takes or suffers any other analogous action in
consequence of debt
- If the Contractor assigns or transfers the Contract or any right or
- If the Contractor, in the judgement of the Owner has engaged in
Contract.
"corrupt practice" means the offering, giving, receiving or soliciting of
anything of value to influence the action of a public official in the
detriment of the Owner and includes collusive practice among Bidders
(prior to or after bid submission) designed to establish bid prices at
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artificial non-competitive levels and to deprive the Owner of the benefits

of free and open competition.
(ii)
If the Contractor
-

has without valid reason failed to commence work on the Facilities
promptly the progress of Contract performance for more than [twenty
eight (28)] days after receiving a written instruction from the Owner to
proceed
Contract or persistently neglects to carry out its obligations under the
Contract without just cause
refuses or is unable to provide sufficient materials, services or labor to
execute and complete the Facilities in the manner specified in the
Owner that the Contractor can attain Completion of the Facilities by the
Time for Completion as extended
then the Owner may, without prejudice to any other rights it may possess
under the Contract, give a notice to the Contractor stating the nature of the
default and requiring the Contractor to remedy the same. If the Contractor
fails to remedy or to take steps to remedy the same within [fourteen (14)]
days of its receipt of such notice, then the Owner may terminate the Contract
forthwith by giving a notice of termination to the Contractor.
(iii)
The Contractor shall, either immediately or upon such date as is specified

in the notice of termination,
-
(iv)
cease all further work, except for such work as the Owner may specify
in the notice of termination for the sole purpose of protecting that
part of the Facilities already executed, or any work required to leave the
Site in a clean and safe condition
pursuant to paragraph (d) below
benefit of the Contractor to the Works and to the Plant and Equipment
Subcontractors
Deliver to the Owner all drawings, specifications and other documents
prepared by the Contractor or its Subcontractors as at the date of
The Owner may enter upon the Site, expel the Contractor, and complete
the Facilities itself or by employing any third party. The Owner may, to the
exclusion of any right of the Contractor over the same, take over and use
with the payment of a fair rental rate to the Contractor, with all the
maintenance costs to the account of the Owner and with an indemnification
by the Owner for all liability including damage or injury to persons arising
out of the Owners use of such equipment, any Contractors Equipments
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 53-
Date of Issue
30.09.2015.
[Logo of Utility]
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owned by the Contractor and on the Site in connection with the Facilities
for such reasonable period as the Owner considers expedient for the
supply and installation of the Facilities.
Upon completion of the Facilities or at such earlier date as the Owner
thinks appropriate, the Owner shall give notice to the Contractor that such
Contractors Equipment will be returned to the Contractor at or near the
Site and shall return such Contractors Equipments to the Contractor in
accordance with such notice. The Contractor shall thereafter without delay
and at its cost remove or arrange removal of the same from the Site.
(v)
The Contractor shall be entitled to be paid the Contract Price attributable

to the Facilities executed as at the date of termination, the value of any
unused or partially used Plant and Equipments on the Site, and the costs,
if any, incurred in protecting the Facilities and in leaving the Site in a clean
and safe condition. Any sums due to the Owner from the Contractor
accruing prior to the date of termination shall be deducted from the amount
to be paid to the Contractor under this Contract.
(vi)
If the Owner completes the Facilities, the cost of completing the Facilities
by the Owner shall be determined.
If the sum that the Contractor is entitled to be paid, plus the reasonable
costs incurred by the Owner in completing the Facilities, exceeds the
Contract Price, the Contractor shall be liable for such excess.
The Owner and the Contractor shall agree, in writing, on the computation
described above and the manner in which any sums shall be paid.
(c)
Termination by Contractor
i.
If
-
the Owner has failed to pay the Contractor any sum due under the
Contract within the specified period, has failed to approve any invoice
or supporting documents without just cause pursuant to [-----------]
(Terms and Procedures of Payment) of the Form of Contract
Contractor may give a notice to the Owner that requires payment of
such sum, requires approval of such invoice or supporting documents,
or specifies the breach and requires the Owner to remedy the same, as
the case may be. If the Owner fails to pay such sum, fails to approve
such invoice or supporting documents or give its reasons for withholding
such approval, fails to remedy the breach or take steps to remedy the
breach within [fourteen (14) days] after receipt of the Contractors
notice, or
the Contractor is unable to carry out any of its obligations under the
Contract for any reason attributable to the Owner, including but not
limited to the Owners failure to provide possession of or access to the
Site or other areas or failure to obtain any governmental permit
necessary for the execution and/or completion of the Facilities which the
Owner is required to obtain as per provision of the Contract or as per
relevant applicable laws of the country,
then the Contractor may give a notice to the Owner thereof, and if the
Owner has failed to pay the outstanding sum, to approve the invoice or
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 54-
Date of Issue
30.09.2015.
[Logo of Utility]
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supporting documents, to give its reasons for withholding such approval,

or to remedy the breach within [twenty eight (28) days] of such notice, or
if the Contractor is still unable to carry out any of its obligations under
the Contract for any reason attributable to the Owner within twenty eight
(28) days of the said notice.
of termination to the Owner.
ii.
If the Owner becomes bankrupt or insolvent, has a receiving order issued

against it, compounds with its creditors, or, being a corporation, if a
resolution is passed or order is made for its winding up (other than a
voluntary liquidation for the purposes of amalgamation or reconstruction), a
receiver is appointed over any part of its undertaking or assets, or if the
Owner takes or suffers any other analogous action in consequence of debt,
of termination to the Owner,.
iii.
If the Contract is terminated, then the Contractor shall immediately

-
iv.
cease all further work, except for such work as may be necessary for
the purpose of protecting that part of the Facilities already executed, or
any work required to leave the Site in a clean and safe condition
pursuant to paragraph (d)(ii)
remove all Contractors Equipment from the Site and repatriate the
Contractors and its Subcontractors personnel from the Site
In addition, the Contractor, subject to the payment, shall
benefit of the Contractor to the Facilities and to the Plant and
Equipments as of the date of termination, and, as may be required
by the Owner, in any subcontracts concluded between the
Contractor and its Subcontractors
documents prepared by the Contractor or its Subcontractors as of
the date of termination in connection with the Facilities.
If the Contract is terminated, the Owner shall pay to the Contractor all
payments, and reasonable compensation for all loss or damage sustained
by the Contractor arising out of, in connection with or in consequence of
such termination.
(d)
The expression Facilities executed shall include all work executed, Erection
Services provided, any all Plant and Equipments acquired (or subject to a legally
binding obligation to purchase) by the Contractor and used or intended to be
used for the purpose of the Facilities, up to and including the date of termination.
(e)
In calculating any payment due from the Owner to the Contractor, account shall
be taken of any sum previously paid by the Owner to the Contractor under the
Contract, including any advance payment paid.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 55-
Date of Issue
30.09.2015.
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4.46
Assignment
The Contractor shall not, without the express prior written consent of the Owner,
obligation or interest therein or there under, except that the Contractor shall be entitled
to assign either absolutely or by way of charge any monies due and payable to it or
that may become due and payable to it under the Contract
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 56-
Date of Issue
30.09.2015.
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5.1
Contract Details
Name of Contract: Renovation & Modernization of Turbo Generator &

Auxiliaries Package for [---------------------------------------]
Bid Document No. :[-------------------------]
The Owner is:

Name of Owner: [-------------------------]
Address of Owner: [-------------------------]
Telephone No. : [-------------------------]
Fax No: [-------------------------]
E-Mail: [-------------------------]

Telephone No. : [-------------------------]
Fax No: [-------------------------]
E-Mail: [-------------------------]
5.2
Effective Date
formal Letter of Acceptance. This Letter of Acceptance will be the Effective Date for
determining the Time for Completion of the facilities and other milestones for execution
of the Renovation & Modernization work as per the scope of work under this tender by
the Contractor.
The following three activities will be completed within [two (2)] months from the date of
Letter of Acceptance:
(a) The contract agreement will be executed by the Owner and the Contractor. (b) The
Contractor will submit to the Owner the Contract Performance Bank Guarantee, any
Additional Contract Performance Bank Guarantee by assignee, JV Partner,
Consortium Member etc if applicable, and the Advance Payment Bank Guatrantee.
(c) The Owner will pay the Contractor the Advance Payment as per the Terms of
Payment.
The Owner will make the advance payment promptly once Contractor has fulfilled the
necessary conditions specified in Terms of Payment. If payment of Advance is delayed
beyond two months from the date of Letter of acceptance for reasons attributable to
the Owner, the date of payment of advance shall be the effective date for determining
the time for completion of facilities. However, failure of the contractor to provide all the
required Bonds/Guarantees within the prescribed period will cause the Bid Security to
be forfeited.
5.3

tender and commencement of unit shut down by Owner shall be as follows:
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
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Date of Issue
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1.
2.
3.
4.
Time for completion (by Contractor) of

Engineering and Supply activities and other
L-2 network
Time for Commencement (by Owner) of
Unit Shut Down.
activities as at serial no.1, Owner may, at
its discretion, reschedule commencement
of unit shut down
Time for Completion of all R&M activities
that are to be carried out under unit shut
Performance
Guarantee
Test
(By
Contractor)
5.4
Liquidated Damage for Delay
5.5
Rate of Liquidated Damage for Delay
By []
Effective Date
months from
By []
Effective Date
months from
By [..] days from start

of unit shut down
By [] months from
the
completion
of
trial
R&M activities
If the Contractor fails to successfully achieve completion of R&M activities and

commissioning of the retrofitted facilities as per the scope of work within the time
period specified in SCC, the Contractor shall pay to the Owner amount calculated as
per the rates given in the following table as Liquidated Damage and not as penalty.
1.
Delay in completion (by Contractor) of Liquidated Damage payable at

Engineering and Supply activities and other the rate Rs.[] for each
resources mobilization that are required to week of delay
L-2 network
2.
Delay in Completion of all R&M activities Liquidated Damage payable at
that are to be carried out under unit shut the rate Rs [..] for
down and subsequent commissioning each day of delay
The Liquidated Damage for Delay in completion (by Contractor) of Engineering and
Supply activities and other resources mobilization that are required to be completed
before unit shut down as per L-2 network and Liquidated Damage for Delay in
Completion of all R&M activities that are to be carried out under unit shut down and
subsequent commissioning activities including trial operation as per the scope of work
under this tender are independent and shall be applied separately.
5.6
Liquidated Damage for Non-fulfillment of Functional Guarantees

If the Contractor fails to successfully achieve the Functional Guarantees during
Performance Guarantee Test as per the Tender Specification, the Contractor shall pay
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
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Page No.
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Date of Issue
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to the Owner amount calculated as per the rates given in the following table as
Liquidated Damage and not as penalty.
Sl. No.
Rate of Liquidated
Damage
Gross Output of each unit
[..] INR per kW

shortfall
[..] INR per

kCal/kWhr increase
Condenser Pressure (mm of Hg)
[..]INR per mm
HG increase in
Condenser Pressure
Auxiliary Power in kW
[..] INR per kW

increase
The reference condition for Performance Guarantee Parameters shall be as per

Volume-II Technical Specification.
The Liquidated Damage for non-fulfillment of the different Functional Guarantee
Parameters are independent of one another and shall be applied separately.
{Note: The rate of LD for any Functional Guarantee Parameter shall be at least 1.5
times the corresponding Bid Evaluation Factor}
5.7
Maximum Leviable Liquidated Damages

The amount of Liquidated Damage for delay shall be limited to a maximum of 10 % of
the total contracts price (i.e. sum of Ist, IInd and IIIrd )contracts, as applicable) price
including price variation as per the provisions of the contract and excluding price of
Mandatory Spares. This limit is applicable for the Liquidated Damage for Delay in
completion (by Contractor) of Engineering and Supply activities and other resources
mobilization that are required to be completed before unit shut down as per L-2
network and Liquidated Damage for Delay in Completion of all R&M activities that are
to be carried out under unit shut down and subsequent commissioning activities
including trial operation as per the scope of work under this tender taken together.
The aggregate amount of Liquidated Damage for non-fulfilment of functional
guarantee shall be limited to a maximum of 10 % of the total contracts price (i.e. sum
of Ist, IInd and IIIrd )contracts, as applicable) price including price variation as per the
provisions of the contract and excluding price of Mandatory Spares.
The limit on maximum leviable Liquidated Damage for Delay and maximum leviable
Liquidated Damage for non-fulfillment of functional guarantee are independent of each
other and shall apply separately.
5.8
Contract Price
a) The Contract Price shall be as (Contract Price and Terms of Payment) of the Form
of Contract Agreement.
b) The Contractor shall be deemed to have satisfied itself as to the correctness and
sufficiency of the Contract Price, which shall, except as otherwise provided for in
the Contract, cover all its obligations under the Contract.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 59-
Date of Issue
30.09.2015.
[Logo of Utility]
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5.9
Terms of Payment
a) The Contract Price shall be paid as Terms and Procedures of Payment to the Form
of Contract Agreement. The procedures to be followed in making application.
b) No payment made by the Owner herein shall be deemed to constitute acceptance
by the Owner of the Facilities or any part(s) thereof.
c) The currency or currencies in which payments are made to the Contractor under
this Contract to the Form of Contract Agreement, subject to the general principle
that payments will be made in the currency or currencies in which the Contract
Price has been stated in the Contractors bid.
5.10
Bank Guarantees
a) The Contractor shall provide the Bank Guarantees specified below in favour of the
b) Advance Payment Bank Guarantee
The Contractor shall, within [thirty (30)] days of the Notification of Contract Award,
provide a security for an amount equal to the advance payment, and in the same
currency or currencies, with a initial validity of up to [ninety (90)] days beyond the
date of Completion of Facilities.
Advance payment Bank Guarantee shall be reduced prorata every three (3)
months after First Running Account Bill/Stage Payment under the Contract based
on the value of equipment/facilities received. The cumulative amount of reduction
at any point of time shall not exceed ninety percent (90%) of the advance
corresponding to cumulative value of the Facilities supplied and received as per a
certificate issued by the Project Manager and the balance of 10% shall be released
on Completion of those Facilities. It should be clearly understood that reduction in
the value of security for advance shall not in any way dilute the Contractor's
responsibility and liabilities under the Contract including in respect of the Facilities
for which the reduction in the value of security is allowed.
c) Performance Bank Guarantee
The Contractor shall, within [twenty-eight (28)] days of the notification of award,
provide a Bank Guarantee for the due performance of the Contract for ten percent
(10%) of the Contract Price with an initial validity upto [ninety (90)] days beyond the
Defects Liability Period. If the Owner enters into the Contract with the Assignee of a
foreign Contractor, the said Assignee, in addition to the Contract Performance
Bank Guarantee to be provided by the Contractor for ten percent (10%) of the
value of all the Contracts shall provide within [thirty (30)] days of the Notification of
Award, a separate Contract Performance Bank Guarantee equivalent to five
percent (5%) of the value of Contract entered into with the assignee (i.e. five
percent of the aggregate value of the component Contracts entered to with the
Assignee) , for the due performance of Contract with an initial validity up to [Ninety
(90)] days beyond the Defects Liability Period.
case, the value of Contract Performance Bank Guarantee furnished by the Bidder
and Additional Contract Performance Bank Guarantee furnished by the JV partners
taken together shall be 12% of the Contract Price.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 60-
Date of Issue
30.09.2015.
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Guarantee (CPBG) of 10% furnished by the Consortium Leader, the other
consortium member will furnish Additional Contract Performance Bank Guarantee
equal to 2% of Contract Price. To clarify further, in such a case, the value of
Contract Performance Bank Guarantee furnished by the Bidder (Consortium
Leader) and Additional Contract Performance Bank Guarantee furnished by the
other consortium member taken together shall be 12% of the Contract Price.
d) The performance Bank Guarantees shall be denominated in the currency or
currencies of the Contract, or in a freely convertible currency acceptable to the
Owner.
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 61-
Date of Issue
30.09.2015.
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FORMS AND SCHEDULES

I
Bid Forms and Schedules/Annexure to be submitted with

Bid
Annexure-A
Annexure-B
Form of Part-I Bid
Annexure-C
Form of Part-II Bid
Annexure-D
Sample Format for Letter of Consent to be furnished by The

Bidder And Consortium Partners / Individual Companies of the
Group
Annexure-E
Sample Format
Letter Of Unequivocal Consent To Be Furnished By The Bidder
and The Assignee
Schedule F1
Table-1
Summary Of Price Schedule
Schedule F1
Table-2
Price Schedule For Supply Of Plant And Equipment Including

Packing And Forwarding Charges
Schedule F1
Table-3A
Price Schedule For Mandatory Spares
Schedule F1
Table-3B
Price Schedule For Recommended Spares
Schedule F1
Table-4
Price Schedule For Tools & Tackles

.
Schedule F1
Table-5
Price Schedule For Unloading, Handling, Storage, Preservation

At Site, Erection, Testing, Commissioning And Performance
Guarantee Tests Of Plant And Equipment
Schedule F1
Table-6
Price Schedule For Civil works
Schedule F1
Table-7
Price Schedule For Training Charges
Schedule F1
Table-8
Schedule Of Performance Guarantee Parameters
Schedule F2
Over All Time Schedule
Schedule F3
Deviation Schedule To Tender Document Vol-I Commercial
Schedule F4
Deviation Schedule To Technical Specification
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 62-
Date of Issue
30.09.2015.
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Schedule F5
Requirements Of The Contractor At Site
Schedule F6
Contractors Resource Deployment Schedule
Schedule F9
Coefficients And Indices for Price Variation Formula
II
Forms and Appendices to form part of Contract
Annexure-F
Contract
Schedule-1
Terms of Payment
Contract
Schedule-2
Price Adjustment
Contract
Schedule-3
Time Schedule
Contract
Schedule-4
Contract
Schedule-5
Scope of Works and Supply by the Owner
Contract
Schedule-6
III
Annexure-G
Format for Contract Performance Bank Guarantee
Document Number
LII-GETS12021-G-00129-002
Rev No.
02
Description
Volume-I
Page No.
- 63-
Date of Issue
30.09.2015.
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[Logo of Utility]
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[1]
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[Logo of Utility]
ANNEXURE - A
1. This Guarantee should be furnished by a scheduled commercial Bank in India authorized
by RBI to issue a Bank Guarantee in the same format as given below. [Name of Utility],
reserves its right to reject the Bank Guarantee if the same is not in the specified format.
[Rs..]
3. The stamp paper should have been purchased in the Name of the Bank executing the
guarantee.
Ref.:
Bank Guarantee No:

Date
To:
[-Name of Utility]
Dear Sirs,
] dated [.................] M/s [Name of Bidder]
hereinafter
called
the
Bidder,
having
its
registered/head
office
at
1.
2.
3.
5.
4.
6.
7.
8.
9.
10.
wish to participate in the said Bid for [Name of package and R&M project], India, as an
irrevocable Bank Guarantee against Bid Guarantee for a sum of [..]
(in words and figures) valid for 300 days from [..] (the date of Bid Opening) is
required to be submitted by the Bidder as a condition precedent for participation in the said
bid, which amount is liable to be forfeited on the happening of any contingencies mentioned
in the Bid Documents, we, the [] Bank at (local address)
[] having our Head Office at [] guarantee and
undertake to pay immediately on first demand by [Name of Utility]the amount of
[.] (in figures and words) to the said
[Name of Utility] without any reservation, protest, demur and recourse. Any such demand
made by [Name of Utility] shall be conclusive and binding on the Bank irrespective of any
dispute or difference raised by the Bidder.
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[2]
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[Logo of Utility]
further extension of this Guarantee is required, the same shall be extended to such required
period on receiving instructions from M/s [Name of Bidder] on whose behalf this Guarantee
is issued.
Signature
Name
Designation
Staff Code No.
Bankers Seal
Date
Witness:
1.
2.
Signature
Designation
Address
Signature
Designation
Address
:
:
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[3]
30.09.2015
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[Logo of Utility]
ANNEXURE - B
FORMAT OF BID
From:
[Bidder Details]
[]
[]
To:
Sub

Tender
[]_____________________________________
No.
1. We agree to complete the works in conformity with all the terms and conditions stated in
Tender Specifications and its Amendments/Corrigendum/Clarifications issued till the date
of tender opening and as per time schedule given in Tender Specification. The plant,
equipment and systems offered are of the best and latest technology and of international
standards.
Letter of Award and to complete and deliver the whole of the work and responsibilities
comprised in the Contract within as per Time schedule given in SCC of Tender
Specification.
Rupees___[..]_only)/US$__
(US
Dollars________
[-------]
_
_________________only)/Euro___________
(Euro__________
[-------]
_
____________________only) in the form ________________ as instructed by you. This
Bid Guarantee shall be governed as per the stipulations provided in the "Instructions to
Bidders".
4. We agree to abide by and keep our Bid valid initially for a period of 180 (One Hundred
and Eighty) days from the date of opening of bids by Purchaser and it shall remain
binding on us and may be accepted at any time before the expiry of that period.
conditions of Tender Specification as accepted by us and in default thereof, to forfeit
and pay to [Name of Utility], assignees or authorized nominees such sums of money as
are stipulated in conditions contained in Tender Specification and agree to furnish Bank
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


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Guarantee for Contract Performance as per the proforma prescribed by Purchaser and
for the sum equal to 10% of the "Contract Price", for the entire scope of work within 30
days from the date of Letter of Award.
6. We understand that Purchaser is not bound to accept the lowest or any Bids received
and Purchaser has the right to reject any Bid, without assigning any reason whatsoever.
7. This Bid together with written acceptance thereof shall constitute a binding Contract
between Purchaser and ourselves till a formal Contract is executed.
Signed this __________________ day
of _______________
Signature
Name
Designation
Company
Date
Company Seal
Witness:
1.
2.
Signature
Occupation
Address
:
:
Signature
Occupation
Address
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


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[Logo of Utility]
ANNEXURE - C
FORMAT OF BID
Part-II [Price Bid]
Tender No.
[-----------]
Bid No
[------------]
From:
[]
[]
Dated:
[]
To :
[]
[]
[]
Dear Sirs
1.
2.
We hereby agreed to carry out the entire works as described in the specifications in
conformity with the specifications and Tender Specifications, as per prices quoted by
us in the Schedule of Prices and Schedule of Performance Guarantees [Schedule .]
enclosed herewith
In the event of our proposal being accepted, we agree to furnish a Bank Guarantee for
Contract Performance as per the proforma prescribed by Employer [Name of Utility ]
and for the sum equal to 10% of the "Contract Price". The Bid Guarantee shall be
released only after the Contract Performance Guarantee issued in favour of Employer
is received and accepted by the Employer
Signature
Name
Designation
Company
Date
Company Seal
Witness:
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


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1.
2.
Signature
Occupation
Address
Signature
Occupation
Address
[Logo of Utility]
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


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[Logo of Utility]
ANNEXURE D
(SAMPLE FORMAT)
LETTER OF CONSENT
TO BE FURNISHED BY THE BIDDER and CONSORTIUM PARTNERS / INDIVIDUAL
COMPANIES OF THE GROUP (as the case may be)
Consortium Partners / Individual Companies of the Group) hereby agrees to associate with [------------] (Name and Complete address of the Bidder) for the successful completion of part scope of
work as enclosed in the attachment (authenticated by the Bidder and Consortium Partner /
Individual Companies of the Group) [-------------] Package for the [-------------] Project at [------------] in the state of [-------------], India. We also hereby undertake to ensure the quality of
manufacture, timely delivery and the successful performance of the equipment/system covered in
our scope of [-------------] package, fully meeting the guarantee and also depute our technical
experts from time to time for advice on procedures and guidance during design, engineering,
manufacture, erection, testing and commissioning, as applicable to the place of work / Owners
Project site.
On award of LOA, we the Associate(s) / Consortium Partners / Individual Companies of the
Group (as the case may be) agree to furnish an on demand back up bank guarantee for 5 % for
our portion of work.
1.
Witness
For Consortium Partner / Individual Companies

of the Group (as the case may be)
Signature:
Name:
Name:
Designation:
Designation:
Office Address
Seal of the Company
2.
Witness
For Bidder
Signature:
Name:
Name:
Designation:
Designation:
Office Address:
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


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Scope of Work of the Each Consortium Partner / Individual Company of the Group (as
the case may be):
For Each Consortium Partner /

Individual Company of the Group (as
the case may be)
For Bidder
Name:
Name:
Designation:
Designation:
Seal of the Company
Seal of the Company

*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[9]
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[Logo of Utility]
ANNEXURE E
SAMPLE FORMAT
LETTER OF UNEQUIVOCAL CONSENT TO BE FURNISHED BY THE BIDDER AND THE
ASSIGNEE
Assignee) hereby agree to act as a Assignee to the Firm [-------------] (Name and Complete
address of the Bidder) for the successful completion of part scope of work as enclosed in the
attachment (authenticated by the Bidder and the Nominee) of [-------------] Package for the [------------] Project at [-------------] in the state of [-------------], India. We also hereby undertake to ensure
the quality of manufacture, timely delivery and the successful performance of the
equipment/system covered in our scope of [-------------] package, fully meeting the guarantee and
also depute our technical experts from time to time for advice on procedures and guidance
during design, engineering, manufacture, erection, testing and commissioning, as applicable to
the place of work / Owners Project site.
We, the Assignee, agree to work as an independent contractor, with respect to the 2nd/3rd
Contract or both, on such additional terms and conditions, as may be agreed to, between the
Owner and the Foreign Bidder.
On award of LOA, we the ASSIGNEE agree to furnish an additional Contract Performance Bank
Guarantee for 5%, of the aggregate value of the component contracts entered in to with us.
1.
Witness
For Assignnee
Signature:
Name:
Name:
Designation:
Designation:
Office Address
Seal of the Company
2.
Witness
For Bidder
Signature:
Name:
Name:
Designation:
Designation:
Office Address:
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[10]
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Power Plant]
[Logo of Utility]
ATTACHMENT TO THE LETTER OF UNEQUIVOCAL CONSENT

1
Scope of Work of the Assignee:
For Bidder
For Assignee
Name:
Name:
Designation:
Designation:
Seal of the Company
Seal of the Company
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


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SUMMARY OF PRICE SCHEDULE
S.No.
Foreign
Currency
Description
1.1
Supply of imported Plant & equipment including

technological and misc. structures with all accessories
(FOB) including design, engineering, manufacturing, shop
testing, packing and forwarding charges on lumpsum and
firm price basis.
1.2
Ocean freight on lumpsum and firm price basis for 1.1

above.
1.3
Marine insurance on lumpsum and firm price basis for 1.1

above.
1.4
CIF Cost (1.1+1.2+1.3)
2.
All port charges including port handling, port rent, and port
clearance on lumpsum and firm price basis.
3.
Supply of indigenous Plant & Equipment including

Technological and misc. structures with all accessories
(Ex-Works) including design, engineering, manufacturing,
shop testing, packing and forwarding charges on lumpsum
price basis.
4.
Sales Tax Payable on Indigenous equipment - on Ceiling

basis.
(a) VAT
(b) Central Sales Tax (CST)
5.
(a) Inland transport of imported plant & equipment on

lumpsum and firm price basis.
INR
(b) Inland transport of Indigenous plant & equipment on

lumpsum and firm price basis
6.
Lumpsum price for Civil Works including, supplies such

as cement, reinforcement steel, all foundation bolts etc.at
site cost, including Design & Engineering and Construction
of entire Civil works.
7.
Erection services including dismantling/disassembly.

unloading, handling, storage and preservation at site,
Erection, testing, commissioning and PG tests of plant &
equipment on lumpsum price basis
8.
Marine cum erection insurance on lumpsum and firm price

basis (excluding marine insurance indicated in Sl. No. 1.3
above)
9.
Foreign supervision charges in India during erection,

commissioning & PG test on firm price basis with ceiling.
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


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S.No.
Foreign
Currency
Description
10.
Training charges on firm price basis with ceiling.
11.
VAT on Works Contract on ceiling basis
12.
Service Tax including Education Cess on Ceiling basis
13.
Others, if any (Please specify),
14.
Total price of package (excluding mandatory spares and

Tools & Tackles.
(Total of Sl.Nos.1.4 + 2 to 13).
15.
Mandatory Spares on lumpsum and firm price basis.

16.
Tools & Tackles on lumpsum and firm price basis.

17.
Grand total price of package including Mandatory Spares

and Tools & Tackles.
(Total of Sl Nos 14+15+16).
Signature
Name
:
:
Designation
Company
Date
INR
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[13]
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[Logo of Utility]

PRICE SCHEDULE FOR SUPPLY OF PLANT AND EQUIPMENT INCLUDING
PACKING AND FORWARDING CHARGES
S.No.
Description
Foreign Supply
Indigenous Supply
FOB Price in
Foreign Currency
Supply
Ex-works
price
including
packing
and
forwarding in INR
1.1
1.2
Sub Total (1)
2.
2.1
2.2
Sub Total (2)

3
3.1
3.2
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[14]
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[Logo of Utility]
S.No.
Description
Foreign Supply
Indigenous Supply
FOB Price in
Foreign Currency
Supply
Ex-works
price
including
packing
and
forwarding in INR
---Sub Total (3)

4
Total (1 + 2 + 3)
Signature
Name
:
:
Designation
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[15]
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SCHEDULE F1: TABLE 3A

PRICE SCHEDULE FOR MANDATORY SPARES
Foreign Price
In
Foreign
Currency
S. No.
Description
1.1
1.2
Supply (FOB) of Mandatory Spares including Packing

and Forwarding on lumpsum and firm Price
1.3
1.4
CIF Cost (1.1 +1.2+1.3)

Supply (Ex-works) of Mandatory Spares including

firm price basis.
4.
Indigenous
Price in INR

5
6

price basis)
a) VAT
b) CST
Total price of Mandatory Spares (landed cost at site).
Signature
Name
Designation
Company
:
:
:
:
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[16]
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SCHEDULE F1: TABLE 3B

PRICE SCHEDULE FOR RECOMMENDED SPARES
Foreign Price
In
Foreign
Currency
S. No.
Description
1.1
1.2
Supply (FOB) of Recommended Spares including

Packing and Forwarding on lumpsum and firm Price
1.3
1.4
CIF Cost (1.1 +1.2+1.3)

Supply (Ex-works) of Recommended Spares including

firm price basis.
4.
Indigenous
Price in INR

5
6

price basis)
a) VAT
b) CST
Total price of Recommended Spares (landed cost at
site).
Signature
Name
Designation
Company
:
:
:
:
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[17]
30.09.2015
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[Logo of Utility]

PRICE SCHEDULE FOR TOOLS & TACKLES
Foreign Price
in
Foreign
Currency
S. No
Description
1.1
1.2
Supply (FOB) of Tools and Tackles including Packing and

Forwarding on Lumpsum and Firm Price
1.3
1.4
C.I.F Cost (1.1 +1.2+1.3)
2.
All port charges including port rent, port handling charges,

port clearance on Lumpsum and firm price
3.
Supply (Ex-works) of Tools and Tackles including Packing

and Forwarding on Lumpsum and firm Price
4.
a) Inland transport for imported items on lumpsum and firm

price basis.
b) Inland transport for indigenous items on lumpsum and
firm price basis.
Insurance excluding 1.3 above (lumpsum and firm price
basis)
a) VAT
b) CST
5.
6.
7.
Indigenous
Price in INR
Total price of Tools and Tackles (landed cost at site).

Signature
Name
Designation
:
:
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[18]
30.09.2015
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[Logo of Utility]

PRICE SCHEDULE FOR ERECTION SERVICES INCLUDING
DISMANTLING/DIASSEMBLY, UNLOADING, HANDLING, STORAGE,
PRESERVATION AT SITE, ERECTION, TESTING, COMMISSIONING AND
PERFORMANCE GUARANTEE TESTS OF PLANT AND EQUIPMENT
Total Price for complete work at Site in
Indian Rupees
S.No.
Description
1.1
1.2
Sub Total (1)
2.
2.1
2.2
Sub Total (2)

3
3.1
3.2
Sub Total (3)

4
Total (1 + 2 + 3)
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[19]
30.09.2015
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[Logo of Utility]
Sign
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[20]
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[Logo of Utility]

PRICE SCHEDULE FOR CIVIL WORKS
S.No.
Foreign Currency
Description
INR
1.
2
3
4
5
..
Total
Signature
Name
Designation
:
:
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[21]
30.09.2015
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[Logo of Utility]

PRICE SCHEDULE FOR TRAINING CHARGES
S.No.
Man-Months
Description
Foreign
Currency
INR
1.
2
3
4
5
..
Total
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[22]
30.09.2015
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[Logo of Utility]

SCHEDULE OF PERFORMANCE GUARANTEE PARAMETERS
The Bidder shall furnish performance guarantee of the Package in respect of all items listed
below.
Category I: Performance Guarantees under Liquidated Damages [L.D]
S. No
Particulars
Unit
Value inclusive of design,

manufacture and all other
Tolerances including
..
Category II: Mandatory Performance Guarantees

S. No
Particulars
Unit

Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[23]
30.09.2015
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S. No
Particulars
[Logo of Utility]

Unit
..
Category -III: Requirement under Demonstration Category
S. No
Particulars
Unit
Value
Inclusive
of
design,
manufacture
and
all
other
tolerances
including
1
2
3
.
Signature
Name
Designation
Company
Date
Company Seal
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[24]
30.09.2015
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[Logo of Utility]
SCHEDULE F2
S.No
Days from Effective Date
Work Description
Start
1
Design & Engineering
Manufacture of Plant/Equipment
Finish
(a)
(b)
(c)
....
......
3
Delivery of Plant/Equipment & Systems

(a)
(b)
(c)
....
......
Dismantling/Disassembly of Plant/Equipment & Systems

(a)
(b)
(c)
....
......
Civil work at Site
Erection of of Plant/Equipment & Systems

(a)
(b)
(c)
....
......
Trial Operation & Provisional Take Over
Performance Guarantee tests Completion and Final Take Over
Document Number
LII-GETS12021-G-001129-002
Signature
Name
Rev No
Description
02


[25]
30.09.2015
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Designation
Company
:
:
Date
[Logo of Utility]
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[26]
30.09.2015
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[Logo of Utility]
SCHEDULE F3
All deviations to commercial condition (Tender Document Vol-I) shall be filled in by the Bidder
clause by clause in this schedule.
S.No
Clause
Deviation
commercial condition (Tender Document Vol-I) . The Bidder further confirms that in the event
any other data or information presented in the Bidders proposal and accompanying documents
are at variance with the specific requirements laid out in the commercial condition (Tender
Document Vol-I) , then the latter shall govern and shall be binding on the Bidder for the quoted
price.
Signature
Name
Designation
:
:
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[27]
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[Logo of Utility]
SCHEDULE F4
DEVIATION SCHEDULE TO TECHNICAL SPECIFICATION
All deviations from the Technical Specification shall be filled in by the Bidder, clause by clause,
in this Schedule:
S.No
Volume /
Section
Clause
No
Description
Deviation
Purchasers Technical Specifications for this enquiry. The Bidder further confirms that in the
event any other data and information presented in the Bidders proposal and accompanying
documents including drawings, catalogues, etc are at variance with the specific requirements
laid out in the Purchasers Technical Specifications then the latter shall govern and shall be
binding on the Bidder for the quoted price.
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


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SCHEDULE F5
REQUIREMENTS OF THE CONTRACTOR AT SITE
The Bidder shall state his requirements against each of the following including the basis of
requirements:
A.
Requirements Description
Quantity
Signature
Name
Designation
:
:
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


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SCHEDULE - F6
CONTRACTORS RESOURCE DEPLOYMENT SCHEDULE
A) Construction Equipment
The Bidder shall indicate the schedule of construction equipment, proposed to be deployed
at the site for executing the works as per the pro-forma below:
S. No.
Type of Resource
Months
1
2
3
B) Resource Deployment Schedule

The Bidder shall indicate the schedule of manpower resources proposed to be deployed at
the site for executing the works as per the pro-forma below:
S. No.
Type of Resource
Months
2.
Human Resources
2.1
Engineering Category
2.1.1
Project Engineers
2.1.2
Mechanical Engineers
2.1.3
Electrical Engineers
2.1.4
Civil Engineers
2.1.5
C&I Engineers
2.1.6
Commissioning Engineers
2.1.7
Structural Engineers
2.1.8
Others (bidder shall indicate) as applicable for the work
2.2
Supervisory Category
2.2.1
Const. Manager
2.2.2
Electrical Supervisors
2.2.3
Mechanical Supervisors
2.2.4
C&I Supervisors
2.2.5
Civil Supervisors
2.2.6
Purchase Officer (s)
2.2.7
Finance/Site Office
2.2.8
Inspection/Quality Control
2.2.9
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


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S. No.
Type of Resource
[Logo of Utility]
Months
2.3
Labour Category
2.3.1
Welder
2.3.2
Fitter
2.3.3
Rigger
2.3.4
Un-skilled labour
2.3.5
Signature
Name
Designation
Company
Date
Company Seal
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[31]
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SCHEDULE F9
COEFFICIENTS AND INDICES FOR PRICE VARIATION FORMULA
Sl No
Component of Contract Price
a=
Ex-Works/FOB price
component of Plant and
b=
Equipment excluding mandatory
c
spares
A=
Lb
L=
2
3
Coefficients
Indices
B=
C=
Erection Services Component
EF=
Civil Works Component
a=
MI=
b=
LI=
c=
FI=
d=
SI=
e=
CI=
Signature
Name
Designation
Company
Date
Company Seal
*****
Document Number
LII-GETS12021-G-001129-002
Rev No
Description
02


[32]
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Document Number
LII-GETS12021-G-00129-002
Rev No
Description
02


[1]
30.09.2015
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[country of Employer] and having its principal place of business at [address of Employer]
(hereinafter called the Employer), and (2) [name of Contractor], a corporation
incorporated under the laws of [country of Contractor] and having its principal place of
business at [address of Contractor] (hereinafter called the Contractor)
WHEREAS the Employer desires to engage the Contractor to dismantle/disassemble,
design, manufacture, test, deliver, install, complete and commission certain Facilities,
viz.
[
..]
(the Facilities) and the Contractor have agreed to such engagement upon and subject
to the terms and conditions hereinafter appearing.
1.1
Contract Documents
annexure/appendices, and the complete documents, which are the basis of
finalization of the contract, including correspondence exchanged from issue of
tender till date of signing the contract. The following will constitute the Contract
Documents:
i. The signed Contract Agreement & the annexure/ appendices thereto (highest
precedence)
vi. The bid & its schedules/ attachment.
a) All documents forming part of the Contract (and all parts thereof) are intended to
be correlative, complementary and mutually explanatory. The Contract shall be
read as a whole.
with one signed original and the rest will be retained by the Employer.
1.2

precedence)
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
02


[2]
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1.3
Definitions
The Definitions of terms and expressions shall be as per GCC clause 4.1. Terms and
expressions not defined in GCC shall have the same meaning as are assigned to them
in the Indian Sale of Goods Act (1930), failing that in the Indian Contract Act (1872) and
failing that in the General Clauses Act (1897) including amendments thereof, if any.
1.4
Contract Price
The Contract Price shall be the aggregate of: [amount of foreign currency in words],
[amount in figures], and [amount of local currency in words], [amount in figures], or such
other sums as may be determined in accordance with the terms and conditions of the
Contract.
1.5
Term of Payment
The terms and procedures of payment according to which the Employer will reimburse
the Contractor are given in Contract Schedule 1 (Terms and Procedures of Payment)
hereto.
1.6

tender and commencement of unit shut down by Employer shall be as follows:
1.
Time for completion (by Contractor) of By [] months from
Engineering and Supply activities and other Effective Date
L-2 network
2.
Time for Commencement (by Employer) of By [] months from
Unit Shut Down.
Effective Date
activities as at serial no.1, Employer may,
at
its
discretion,
reschedule
commencement of unit shut down
3.
Time for Completion of all R&M activities By [..] days from start
that are to be carried out under unit shut of unit shut down
4.
Performance
Guarantee
Test
(By By [] months from
Contractor)
the
completion
of
trial
R&M activities
Contract Schedules
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
02


[3]
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Reference in the Contract to any Contract Schedule shall mean the Contract Schedules
attached hereto, and the Contract shall be read and construed accordingly.
IN WITNESS WHEREOF the Employer and the Contractor have caused this Agreement
to be duly executed by their duly authorized representatives the day and year first above
written.
_-----------------------------------------------------------------------------[Signature]
_------------------------------------------------------------------------------- [Title]
_----------------------------------------------------------------------------- [Signature]
_------------------------------------------------------------------------------- [Title]
CONTRACT AGREEMENT
dated the_-----------day of---------------, 20_---------_____
BETWEEN
[The Employer]------------------------------------------------------------------------------------------and
[The Contractor]------------------------------------------------------------------------------------Contract Schedules:
Contract Schedule 1
Contract Schedule 2
Contract Schedule 3
Contract Schedule 4
Contract Schedule 5
Contract Schedule 6
Document Number
LII-GETS12021-G-00129-002
:
:
:
:
:
:
Terms of Payment
Price Adjustment
Time Schedule
Scope of Works and Supply by the Employer
Rev No
Description
02


[4]
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Contract Schedule-1
Terms of Payment
times, on the basis of the Price Break down given in the Section on Price Schedules.
Payments will be made in the currencies quoted by the Bidder unless otherwise agreed
between the parties. Application for payment in respect of part deliveries may be made
by the Contractor as work proceeds.
I.

Spares and Recommended Spares) supplied from Abroad:
1
60% of FOB price for each

identified
equipment
as
progressive payment and 100%
of Ocean Freight and Marine
Insurance Charges pro-rata to
the value of the equipment
15% of FOB price for each On receipt of equipment at site and
the Employer
Guarantee Test
4
5
II.
Initial Advance on Acceptance of Letter of

Upon dispatch of the identified equipment

Spares and Recommended Spares) supplied from within India:
1
10% of the total Ex-Works Initial Advance on Acceptance of Letter of

price
60% of Ex-Works price for each Upon dispatch of the identified equipment
identified
equipment
as after dispatch clearance by employer on
progressive payment
15% of Ex-Works price for each On receipt of equipment at site and
the Employer
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
02


[5]
30.09.2015
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4
5
III.

Guarantee Test
Terms of Payment for Supply of Mandatory Spares and Recommended Spares

1

IV.
Upon dispatch of the identified Spare

raising of invoice by the Contractor and
On receipt of Spare at site and physical
verification and certification by the
Employer
Terms of Payment for Local Transportation, Inland Transit Insurance and port
clearance charges & port charges
V.
For Plant & Equipment except Spares

Port Charges pro-rata to value of the
equipment
For Spares
Port Charges pro-rata to value of Spare
On receipt of Equipment at site and

upon raising of Invoice by the
Contractor
On receipt of Spare at site and upon

raising of Invoice by the Contractor
Terms of Payment for Erection of Plant & Equipment

1
3
4
10% of Total Price for Erection of Plant Initial Advance on Acceptance of Letter
& Equipment
Contract
Performance
Bank
Guarantee,
Additional
Contract
Contractor
75% of Price for Erection of Plant & On certification by Employer of
Equipment as progressive payment pro- successful erection of plant &
rata to value of plant & equipment equipment and successfully passing of
erected
quality checks
10% of Total Price for Erection of Plant On Completion of Facilities
& Equipment
5% of Total Price for Erection of Plant & Successful completion of Performance
Equipment
Guarantee Test
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
02


[6]
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VI.
Terms of Payment for Civil Works

1
3
4
VII.
Initial Advance on Acceptance of Letter

Contract
Performance
Bank
Guarantee,
Additional
Contract
Contractor
75% of
Price for Civil Works as On certification by Employer regarding
progressive payment
value of work completed & successfully
passing of quality checks
Guarantee Test
Terms of Payment for Price Adjustment Amount
Any increase in the Price of any component Contract shall be paid as per the Terms
of Payment for base price. The initial 10% advance payment pertaining to increase
in price shall be paid along with progressive payment of that equipment. Reduction
to the Contract Price, if any, due to price adjustment provisions, shall be effected by
recovering 100% of the reduction amount (including advance) from any of the
Contractor's bills falling immediately due for payment.
VIII.
IX.

Any Tax or Duty payable by Employer as per the Terms & Conditions of Contract
and is directly payable to Statutory Authorities/Government as per law shall be
directly paid to the concerned authority or Government by the Employer. Any other
Tax or Duty payable by Employer as per the Terms & Conditions of Contract shall
be reimbursed to the Contractor/Assignee upon receipt of corresponding Plant &
Equipment or Spare at site and submission of evidence by the Contractor/Assignee
to the Employer as to the Contractor/Assignee having paid such Taxes & Duties.
Any amount towards statutory variation in Taxes & Duties payable by Employer as
per the Terms & Conditions of Contract shall be reimbursed to the
Contractor/Assignee upon submission of evidence by the Contractor/Assignee to the
Employer as to the Contractor/Assignee having paid such variation.
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
02


[7]
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Contract Schedule-2
PRICE ADJUSTMENT
(i)
The Contract Price shall be subject to price adjustment during performance of the
Contract to reflect changes in the cost of labour and material in accordance with the
provisions described below.
(ii)
Only following components of the Contract Price will be subject to Price adjustment :
(a)
Ex-Works (India) price of plant and equipment excluding Mandatory Spares

manufactured within India and FOB price component for plant and equipment
excluding Mandatory spares supplied from abroad. The price adjustment amounts
towards these price components shall be without any ceiling.
(b)
Erection Services component of the Contract Price. The price adjustment amounts
(c)
Civil Works component of the Contract Price. The price adjustment amounts
(iii)
Price adjustment amounts towards aforesaid components of Contract Price shall be paid
in the respective currencies of Contract.
(iv)
The indices for price adjustment shall necessarily be of the country of origin of
goods/labour and shall be well established and nationally recognized in that country.
Preferably Government indices shall be used.
(v)
The price adjustment formula for the components of the Contract Price above shall be as
stipulated hereinafter.
(vi)
Ex-Works/FOB price component of Plant and Equipment excluding mandatory

spares
The price component of the equipment for any shipment/ dispatch comprises of a fixed
portion (designated as 'F' and the value of which is specified hereunder) and a variable
portion linked with the indices for various materials and labour.
The amount of price adjustment towards variable portion payable/recoverable on each
shipment/dispatch shall be computed as under:
ES = ES1 - ES0
ES1 will be computed as follows:
ES1 = ES0 {F + a x
Where
ES
A1
A0
x f1 + b x
B1
B0
x f2 + c x
C1
CO
x f3 + Lb x
L1
L0
x flb }
Adjustment to Ex-Works/FOB price component expressed in the currency

of the Contract payable to the contractor for each shipment/dispatch
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
02


[8]
30.09.2015
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ES1
ES0
Adjusted amount of Ex-works/FOB price component expressed in the

currency of the Contract payable to the Contractor for each
shipment/dispatch
Ex-works/FOB price for the plant and equipment in the currency of the
Contract, shipment/dispatch wise.
The fixed portion of the ex-works/FOB component of the Contract Price

(F) shall be 0.15.
a, b,c etc. shall be co-efficient of major materials/items involved in the exworks/FOB component of the Contract Price. The sum of these coefficient shall be between 0.50 to 0.60.
f1, f2, f3,

flb etc
A, B, C etc. shall be published price indices of corresponding major

materials/items. Such indices shall necessarily be of the country of origin
of goods.
'Lb" shall be co-efficient for labour component in the ex-works/ FOB
component of the Contract Price which shall be between 0.25 to 0.35.
'L' shall be labour index.
Sum of all the material co-efficient and the labour co-efficient shall be
0.85.
f1, f2, f3 etc. are Exchange rate correction factors for the respective
materials and flb is the exchange rate correction factor for labour with
reference to the currency of the country of origin of index and the
f=
Z0
Z1
where Z is the no. of units of the currency of the country of the origin of index, which is
equivalent to one unit of the respective contract currency. The exchange rates to be used
for calculation of factor 'f' shall be as per State Bank of India Bills Selling Exchange Rates.
For the indices(A, B, C etc.), subscript 'o' refers to indices as on 30 days prior to original
scheduled date for opening of Part-I Bid.. For 'Z0, subscript o refers to value as on the
Subscript '1' refers to indices/exchange rates as of:
(a) three months prior to the date of shipment/dispatch for labour, and
(b) six months prior to the date of shipment/dispatch for material.
In case of shipments/dispatches which are delayed beyond the schedule date of
shipment/dispatch for reasons attributable to the Contractor, the price adjustment
provision shall not be applicable for the period of time between the schedule date of
shipment/dispatch and the actual date of shipment/dispatch.
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
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The above formula for price adjustment will be applicable if the currency in which the
contract price is expressed is different from the currency of the country of origin of labour
and material indices. In other case, formula shall be applied without the exchange rate
correction factor 'f'.
(vii) Erection Services Component
The price component for erection services comprises of a fixed portion and a variable
portion linked with the index of labour.
The monthly price adjustment amount for the erection services component of the Contract
Price will be computed separately for Indian currency and for foreign currency part, if any,
related to expatriate supervision/labour as per the formula given below:
(a) Indian Rupee part of the Erection Services
ER = ER1 - ERo
ER1 will be computed as follows:
ER1 = ER0 (0.15 + 0.85
Where:
FL1
FL0
ER
Adjustment to erection services component of contract price expressed in

Indian Rupees payable to the contractor for each billing.
ER1

expressed in Indian Rupees payable to the Contractor.
ER0
Value of the Erection work done in the billing period (month)
FL
.
=
Indian field labour index namely, All India Consumer Price Index for
Industrial Workers (All India Monthly Average) as published by Labour
Bureau, Simla, Government of India.
(b) Foreign Currency portion of the Erection Services

EE = EE1 - EE0
EE1 will be computed as follows:
EE1 = EE0 (0.15 + 0.85
Where:
EF1
EF0
x f)
EE
Adjustment to erection services component of Contract Price expressed in

foreign currency payable to the contractor for each billing.
EE1

expressed in foreign currency payable to the contractor for each billing.
EE0
Value of foreign currency portion of Erection work done in the billing

period (month)
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
02


[10]
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EF
Index for Expatriate field labour component of the Erection Price of

Installation work. Such index shall necessarily be of the country of
nationality of the labour.
Exchange rate correction factor for expatriate labour with reference to

currency of country of origin of index for expatriate labour and the
Z0
Z1
where Z is the no. of units of the currency of the country of origin of index,
which is equivalent to one unit of the respective contract currency. The
ex-change rates to be used for calculation of factor 'f' shall be as per State
Bank of India Bills Selling Exchange.
f=
For the indices, subscript 'o' refers to indices as on 30 days prior to date
set for opening of bids. For 'Z0 ', subscript 'o' refers to value as on the
For the indices, subscript '1' refers to the indices as applicable for the
month of execution of the erection work. For the exchange rates,
subscript '1' refers to the exchange rates as applicable on the last day of
the month of execution of the erection work.
In case of erection activities which are delayed beyond the schedule date
for reasons attributable to the contractor, the price adjustment provision
shall not be applicable for the period of time between the schedule date of
completion and actual date of completion of the respective erection
activity.
(viii) The following components of the contract price shall not be subject to price adjustment
and shall remain firm during the execution of the contract :
(1) Ocean Freight and Marine Insurance for Plant and Equipment, mandatory spares and
recommended spares.
(2) Ex-works/FOB price component for Mandatory spares & Recommended Spares.
(3) Inland Transportation charges (including Inland Transit Insurance, port clearance, port
handling & port charges) for plant & equipment and Spare Parts.
(ix) Civil Works Component
The Price of Civil Works for any month comprises a fixed part designated as F and
variable parts linked to indices for labour, steel, cement, other commodities and Fuel &
Power. The monthly price adjustment amount for the civil works component of the
Contract Price will be computed as per the formula given below:
EC = EC1 - EC0
Document Number
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Rev No
Description
02


[11]
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EC1 will be computed as follows:

EC1 = EC0 {F + a x
Where
MI1
MI0
+bx
LI1
LI0
+cx
FI1
FIO
+dx
SI1
SIO
+ex
CI1
CIO
EC
Adjustment to Civil Works price component expressed in the currency of

the Contract payable to the contractor for each month
EC1
Adjusted amount of Civil Works price component expressed in the

currency of the Contract payable to the Contractor for each month
Value of Civil Works done expressed in the currency of the Contract for
the billing period (month).
The fixed portion (F) of the Civil Works component of the Contract Price
shall be 0.15.
a is the coefficient for material cost other than cement and steel involved
in the Civil Works component of the Contract Price and it shall be 0.15.
b is the coefficient for labour cost involved in the Civil Works component
c is the coefficient for Fuel & Power cost involved in the Civil Works
component of the Contract Price and it shall be 0.05.
d is the coefficient for steel cost involved in the Civil Works component of
the Contract Price and it shall be 0.25.
e is the coefficient for cement cost involved in the Civil Works component
EC0
MI shall be All India Whole Sale Price Index for all commodities as
Commerce & Industry.
LI shall be All India Consumer Price Index for industrial labour as
published by Labour Bureau, Government of India
FI shall Index Number of Wholesale Price for group Fuel & Power as
Commerce & Industry
SI shall Index Number of Wholesale Price for Steel as published by the
Economic Adviser to Government of India, Ministry of Commerce &
Industry
CI shall Index Number of Wholesale Price for Cement as published by
the Economic Adviser to Government of India, Ministry of Commerce &
Industry
For the indices(MI, LI,FI, SI and CI), subscript 'o' refers to indices as on 30 days prior to
original scheduled date for opening of Part-I Bid. Subscript '1' refers to indices as of one
prior to the month for which Civil Works is being billed.
Document Number
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Rev No
Description
02


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Contract Schedule-3
TIME SCHEDULE
Sl No.
Work Description
Start
Finish
(Months from
Effective Date)
(Months from
Effective Date)
1
2
Note: Detailed PERT network agreed between Owner and Contractor to be placed below above
table.
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
02


[13]
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Contract Schedule-4
LIST OF SUB-CONTRACTORS
Sl No.
Equipment / Work Description
Approved Sub-Vendor / Sub-Contractor
1.
2.
3
4
5
1.
2.
3
4
5
1.
2.
3
4
5
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
02


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Contract Schedule-5
SCOPE OF WORKS AND SUPPLY BY THE EMPLOYER
[Scope of Works and Supply by the Employer shall be placed]
Sl No.
Description of Works/Supply by Employer
1
2
3
Document Number
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Rev No
Description
02


[15]
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Contract Schedule-6
FUNCTIONAL GUARANTEES
[Functional Guarantees shall be placed]
Sl No.
Unit
Guaranteed Value
Category-I Performance Guarantee

1
2
3
4
.
Category-II Performance Guarantee
1
2
3
4
.
Category-III Performance Guarantee
1
2
3
4
.
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
02


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ANNEXURE - G
[To be furnished by Contractor]
Place:
Bank Guarantee No:
Date:
To:
..
]
Dear Sirs,
1
In consideration of the [........................................] hereinafter referred to as the OWNER,

which expression shall, unless repugnant to the context or meaning, thereof include its
successors, representative and assignees, having awarded in favour of
M/s.[Contractors Name] having its
registered office at..hereinafter referred
to as the CONTRACTOR, which expression shall, unless repugnant to the context or
meaning thereof include its successors, administrators, representatives and assignees, a
Contract,
hereinafter
referred
to
as
the
"CONTRACT"
for
OWNER's
Contract/Letter
of
Award
No..datedas
well
as
CONTRACT documents, valued at [amount of foreign currency in words], [amount in
figures], and [amount of local currency in words], [amount in figures] and the same having
been unequivocally accepted by the CONTRACTOR and the CONTRACTOR having
agreed to provide a Contract Performance BANK Guarantee for the faithful performance
of the entire CONTRACT including the Warranty Obligations /Liabilities under the
CONTRACT equivalent to 10% (ten percent) of the said value of the CONTRACT to
OWNER
amounting
to

and having its Head Office at., hereinafter referred to as
the Bank which expression shall, unless repugnant to the context or meaning thereof,
include its successors, administrators, representatives and assignees do hereby irrevocably
guarantee and undertake to pay the OWNER merely on demand without any previous
notice and without any demur and without referring to any other source, any and all monies
payable by the CONTRACTOR by reason of any breach of the said CONTRACTOR of any
of the terms and conditions of the said CONTRACT including non-execution of the
CONTRACT AGREEMENT, to the extent of ..(%). of the Contract price to
OWNER
amounting
to
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
01


[1]
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Rs(Rupees.only).
Any
such demand made by the OWNER on the Bank shall be conclusive and binding, absolute
and unequivocal notwithstanding any difference between the OWNER and CONTRACTOR
or any dispute or disputes raised/ pending before any Court, Tribunal, Arbitrator or any other
authority. The Bank agrees that the guarantee herein contained shall continue to be
enforceable till this sum due to the OWNER is fully paid and claims satisfied or till the
OWNER discharges this Guarantee.
The Bank further irrevocably guarantees and undertakes to pay any amount due and
payable by the CONTRACTOR by reasons of non-fulfilment of any of the following
obligations of the Contractor:
(a) Successful and satisfactory operation of the plant & equipment supplied and erected
under the said Contract as per the Technical Specifications and other Tender/Contract
documents.
(b) That the equipment installed under the said Contract shall be new and in accordance
with Contract Documents and be free from all defects in design, engineering, material
workmanship and performance for a period of 12 calendar months after final takeover
of the equipment by the OWNER and that upon written notice from the OWNER, the
CONTRACTOR shall remedy free of any expense to the OWNER, such defects as
noticed and developed under the normal use of the said plant & equipment, within the
said guarantee period.
The OWNER shall have the fullest liberty without affecting in any way the liability of the
Bank under this guarantee, from time to time, to extend the time of Performance by the
CONTRACTOR. The Bank shall not be released from its liabilities under these presents by
any exercise of the OWNER of the liberty with reference to the matter aforesaid.
The OWNER shall have the fullest liberty, without affecting this guarantee to postpone from
time to time the exercise of any powers vested in them or of any right which they might have
against the CONTRACTOR and to exercise the same at any time in any manner, and either
to enforce or to forbear to enforce any covenants, contained or implied in the CONTRACT
between OWNER and the CONTRACTOR or any other course or remedy or security
available to the OWNER and the Bank shall not be released of its obligations/liabilities
under these presents by any exercise by the OWNER of his liberty with reference to the
matters aforesaid or any of them or by reasons of any other act or forbearance or other acts
of omission or commission on the part of the OWNER or any other indulgence shown by the
OWNER or by any other matter or thing whatsoever which under law would, but for this
provision, have the effect of relieving the Bank Guarantee. The Bank further undertakes not
to revoke this guarantee during its currency without the previous consent of the OWNER.
The Bank further agrees that the decision of the OWNER as to the failure on the part of the
CONTRACTOR to fulfill their obligations as aforesaid and/or as to the amount payable by
the Bank to the OWNER hereunder shall be final, conclusive and binding on the Bank.
guaranteed sum either in full or part, in the manner suitable to them. However, payment
made for a sum lesser than the guaranteed amount shall not relieve or discharge the bank
from their obligations guaranteed under the bank guarantee, till the contractual obligations
are fully performed by the Contractor or the Bank Guarantee is discharged by the OWNER,
as the case may be and the Bank Guarantee shall continue to be in force till such time.
guarantee against the Bank as a Principal Debtor, in the first instance notwithstanding any
other security or guarantee that it may have in relation to the CONTRACTOR's liabilities.
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
01


[2]
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This guarantee will not be discharged due to the change in the constitution of the Bank or
the CONTRACTOR(S).
10 Notwithstanding anything contained hereinabove, our liability under this guarantee is
it will remain in force upto and including and shall be extended from
time to time for such period as may be desired by [Name of Contractor]
on whose behalf this guarantee has been given.
11
Signature
Name
Designation
Staff Code No
Date
Bank Seal
Witness:
1.
2.
Signature
Occupation
Address
Signature
Occupation
Address
:
*****
Document Number
LII-GETS12021-G-00129-002
Rev No
Description
01


[3]
25.09.2014

OF

R&M CONTRACTORS

VOLUME-II
SECTION-I
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-002 R03
January 2015
Power Plant]
[Logo of Utility]

Volume
Section
Part
Description
Volume-I
---
---
Commercial
Section-I
---
Part-A
Part-B
Part-C
Part-D
---
Part-A
---
Part-B
---
Part-C
---
Part-D
Not Used
Volume-II
Section-II
Volume-III
*****
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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[Logo of Utility]
1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
*****
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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[Logo of Utility]

1.
2.
3.
4.
5.
6.
7.
8.
9.
Spare Parts
10.
Annexure
SECTION-II:
1.
2.
3.
4.
*****
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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1.
2.
3.
*****
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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[Logo of Utility]
TABLE OF CONTENTS
1
INTENT OF SPECIFICATION............................................................................................. 1
SITE & PROJECT SPECIFIC INFORMTION ...................................................................... 6
2.1
Project Name ............................................................................................................... 6
2.2
Project Location ........................................................................................................... 6
2.3
Climatological Data ...................................................................................................... 6
2.4
Fuel ............................................................................................................................. 7
2.5
Water Analysis ............................................................................................................. 8
EXISTING PLANT DETAILS .............................................................................................11

3.1
Operational Background .............................................................................................11
Units Average Performance Parameters during the last five years ....................................12
3.1.1
Auxiliary Power Consumption of Turbine Generator & Auxiliaries ........................12
3.1.2
Stack Emissions, Ambient Air Quality and Process Effluents ...............................13
3.1.3
Feedback from the Plant Operators .....................................................................15
3.1.4
Tripping and Maintenance Record .......................................................................16
3.1.5
Maximum Achievable Load due to performance constraint ..................................16
3.1.6
Record of Reportable Accidents...........................................................................17
3.1.7
Operation & Maintenance Difficulties due to Plant Limitations ..............................17
3.1.8
Start up History of the Plant over the life ..............................................................18
3.2
Salient Technical Feature of Power Plant ...................................................................18
3.2.1
Turbine & Auxiliaries ............................................................................................18
3.2.2
Electrical System .................................................................................................46
3.2.3
Control & Instrumentation ....................................................................................83
3.2.4
Civil Works ...........................................................................................................83
SCOPE OF SUPPLY & SERVICES ...................................................................................85
TERMINAL POINTS & EXCLUSSIONS ..........................................................................117
5.1
Terminal Points .........................................................................................................117
5.2
Exclusions ................................................................................................................119
GENERAL TECHNICAL REQUIREMENTS ....................................................................120
Document Number
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Rev
No.
Description
Page
No.
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6.1
Codes & Standards ...................................................................................................120
6.2
Name Plates .............................................................................................................121
6.3
Guards and Fences ..................................................................................................122
6.4
Operation, Maintenance & Availability .......................................................................122
6.5
Materials ...................................................................................................................122
6.6
Lubricants, Control Fluids and Chemical ...................................................................123
6.7
Plant Life and Modes of Operation ............................................................................123
6.8
Packaging & Marking ................................................................................................124
6.9
Protection .................................................................................................................124
6.10
Painting.....................................................................................................................124
6.11
Environment Protection .............................................................................................126
6.12
Inspection and Testing ..............................................................................................127
LAYOUT CONSIDERATION ...........................................................................................130
PERFORMANCE GUARANTEES ...................................................................................132

8.1
8.2
Performance Guarantees under Category-I ..............................................................134
8.3
Guarantees under Category-II ..................................................................................138
8.4
Guarantees under Category-III..................................................................................138
SPARE PARTS ...............................................................................................................142

9.1
Mandatory Spares.....................................................................................................142
9.2
Recommended Spares .............................................................................................142
9.3
Start-up & Commissioning Spares ............................................................................143
9.4
10
ANNEXURES ...............................................................................................................145
10.1
Annexure-I (List of Existing Drawing) ........................................................................145
10.2
Annexure-II (Mandatory Spares) ...............................................................................145
10.3
Annexure-III (List of Sub-Vendor)..............................................................................145
10.4
RLA/CA Study Report ...............................................................................................145
10.5
EA Study Report .......................................................................................................145
10.6
Baseline Study Report ..............................................................................................145
Document Number
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Rev
No.
Description
Page
No.
Date of Issue
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ABBREVIATIONS
ACB
Air Circuit Breaker
ACG
ASME
ATRS
ATT
AVR
BOD
BFP
BMCR
BOP
Balance of Plant
CAVT
CBD
CCTV
CCW
Circulating Cooling Water
CEA
CEMS
CERC
CFBC
CMMS
COD
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
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COLTCS
Condenser Online Tube Cleaning System
CRH
Cold Re-Heat
CT
Current Transformer
CLCS
CV
Control Valve
CW
Cooling Water
DCA
Drain Cooler Approach
DCDB
DDCMIS
DG
Diesel Generator
DGA
DM
Demineralization
DMCW
DP
DVR
Digital Voltage Regulator
ECO
Economizer
EHC
ELCID
EOT
ESV
EWS
PF
Pulverized Fuel
GC
Gland Condenser
Document Number
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Rev
No.
Description
Page
No.
Date of Issue
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GCV
GT
HMI
HP
High Pressure
HPTBV
HP Turbine Bypass Valve
HRH
Hot Re-Heat
HT
High Tension
HVAC
HVWS
IBD
ICB
IGV
Inlet Guide Vane
I/O
Input / Output
IPT
IPR
Inter Posing Relay
ISMB
IV
Interceptive Valve
LAVT
Lightning Arrestor & Voltage Transformer
LE
Life Extension
LP
Low Pressure
LPT
LPTBV
LP Turbine Bypass Valve
LT
Low Tension
Document Number
LII-GETS12021-G-00129-002
[Logo of Utility]
Rev
No.
Description
Page
No.
Date of Issue
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[Logo of Utility]
LTSH
LVS
Large Video Screen
MCC
MCCB
MOCB
MoEF&CC
Ministry of Environment & Forest and Climate Change
MS
Main Steam
MSSV
OPC
OWS
P.I.V
Peak Inverse Voltage
PLF
Plant Load Factor
PRDS
PLC
R&M
RfP
RfQ
RH
Reheater
RLA
RSO
RTD
SADC
SH
Super Heater
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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SPM
SSE
Shunt Static Exciter
STMS
Smart Transmitter Maintenance Management System
SWAS
TFT
TMCR
TPS
TC
Thermocouple
TSE
TSI
TTD
Temperature Terminal Difference
UCR
Unit Control Room
UPS
VWO
Valve Wide Open
VT
Voltage Transformer
VVVFD
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
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INTENT OF SPECIFICATION
1.1
This Project Specification is for the Renovation & Modernization of Unit No [.

]
of [Name of the Power Plant] located at [.], [District], [State]. The intent of this
Specification is to Renovate and Modernize various equipment & systems of
Turbo Generator and its auxiliaries including but not limited to [HP & LP bypass
valve, HP & LP Heaters, Deaerator, Condenser, Boiler Feed Pump (BFP),
Condensate Extraction Pump (CEP), Turbine Cycle Piping (Excluding Main
Steam, Cold Reheat, Hot Reheat, Upstream & downstream piping of HP & LP
Turbine bypass valve and Auxiliary Steam Piping), Valves and all associated
Electrical system, Control & Instrumentation systems and associated Civil &
Structural work] as envisaged at Clause No. 4.6. The renovated Turbo Generator
shall be capable of producing the output of [210/215/220/250] MW with the given
steam/water parameters at the terminal point of Turbine as per Table:1.1 below:
Table: 1.1
Description
Steam Flow at Final ESV inlet
Steam Pressure at ESV inlet
Steam Temperature at ESV inlet
Re-heater Flow
Steam Pressure at IV inlet
Steam Temperature at IV inlet
Feed Water Flow
CW flow to Condenser
CW Temperature at Condenser Inlet
Allowable Temperature Rise across
Condenser
Available CW pressure at condenser
inlet
Allowable Pressure drop across
condenser
1.2
Units
Design Parameters
T / hr
[.]
kg/cm2
[.]
deg C
[.]
T / hr
[.]
kg/cm2
[.]
deg C
[.]
T / hr
[.]
m3/h
[.]
deg C
[.]
deg C
[.]
[.]
mwc
[.]
mwc
The Bidder shall carry out the required replacement / refurbishment / retrofitting
of the Turbo Generator & its Auxiliaries as per the requirements of his design so
as to make the same capable of operating for an extended life of [20/25] years
Document Number
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and producing the output as mentioned in Clause No. 1.1 above with defined
number of start-ups/shut down and stipulated steam parameters as delineated in
Table-1.1. The scope of replacement / refurbishment / retrofitting shall include
but shall not be limited to the scope of work mentioned at clause 4.6 which is
based on the recommendation of RLA/CA and EA studies conducted during
[..]. However, any other items/systems which have not been specifically
mentioned but are considered necessary by the Bidder for giving the intended
performance of the Turbo Generator & its Auxiliaries, shall also be included in the
scope of Bidder and shall be separately highlighted by the Bidder in his proposal.
1.3
Bidders are required to quote the performance guarantee values for Turbo
Generator output, Turbine Cycle Heat Rate and the Auxiliary power consumption
in response to the minimum performance parameters specified in the Table 1.2
below.
Table: 1.2
S.No.
Parameter
Performance Guarantee Values
Turbo Generator Output (MW)
Turbine
Cycle
(kCal/kWh)
Auxiliary Power Consumption (kW)
Heat
[.]
Rate
[.]
[.]
Bidders to note that in case performance guarantee values quoted for Turbo
Generator output is inferior to the minimum specified value, the bids will be
considered as non responsive. In case of Turbine Cycle Heat Rate and Auxiliary
power consumption, the best quoted value shall be considered as base
parameter and other bids shall be cost loaded as per difference between base
parameter and respective quoted guaranteed parameter multiplied by
evaluation factors specified in the Commercial Volume (Volume-I).
1.4
The modified/replaced/retrofitted equipment will conform to the requirement of

the Specification prescribed in Section-II of Volume-II. The relevant technical
details like OEMs Specifications and Drawings for the existing equipment
required to be modified / replaced / retrofitted have also been provided in
Volume-II, Section-II for the reference of the Bidders.
1.5
Bidders are required to carry out necessary modifications / replacement in the

existing mechanical / electrical /C&I equipment or systems including related
civil/structural works as per Specification requirement and also based on their
own assessment.
1.6
The scope of work for R&M shall include designing / re-designing, basic and
detailed engineering, re-engineering, refurbishing / retrofitting, supply, inspection
and testing at supplier's works, packing, forwarding to site, forwarding from site to
Bidder's facilities, unloading and storage at site, pre-assembly, machining if
required, site fabrication, erection, replacing of various equipment and systems,
Document Number
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application of thermal insulation, carrying out all pre-commissioning checks/ tests

and any other work required to complete the system, commissioning and trial
operation, performance tests of various equipment and systems covered under
this Specification. Bidders scope shall also include dismantling of the existing
equipment/ facilities, including unloading & transportation to designated storage /
disposal yard, wherever required as a result of augmentation of existing
mechanical, electrical, I&C and civil/structural/ architectural works. The Bidder
shall restore the equipment/ facilities, whenever applicable, after carrying out
necessary renovations/modifications under the scope of R&M works.
All the tools & tackles, labour and other facilities required for dismantling and
restoration shall also be in the scope of the Bidder.
Bidder shall also put back into service all the systems/equipment of the units
after completion of R&M works, whether any modification is carried out on the
same or not. All necessary tools, tackles, labour, instruments, spares,
consumables etc. required for putting back into operation shall also be provided
by the Bidder.
1.7
It is not the intent to specify completely herein all aspects of services and
equipment to be provided by the Bidder who in any case shall be responsible for
fulfillment of the intent of Specification. Irrespective of whether specifically
mentioned or not, the services, equipment and systems to be provided in
accordance with this Specification shall also form a part of the scope of work and
shall conform in all respects to the highest standard of engineering, design,
quality and workmanship so that after completion of R&M work by the Bidder, the
plant shall be capable of performing completely in a safe, reliable and sustained
manner under various modes of operations as acceptable to the Owner.
1.8
Unless otherwise specifically clarified by the Owner, interpretation by the owner

in respect of scope of supplies & services and the meaning of the Specifications,
drawings, requirements of operation, maintenance, redundancy etc., shall be
final and binding on the Bidder. Owner shall have the right to reject or accept any
work or material which in his assessment is not technically complete and proven
to meet the requirements of this Specifications and/or applicable National and
International Codes & Standards mentioned elsewhere in this Specification.
1.9
The requirements, conditions, appendices etc, given in various parts/ sections of

technical Specifications shall form integral part of this Specification. Bidder is
required to carefully examine and understand the Specifications and seek
clarifications, if required, to ensure that he has understood the Specifications as
intended by the Owner. In the absence of any specific clarifications made to the
Owner during bidding stage, the interpretation of Owner shall be final. The
Bidder's offer should not carry any sections like clarifications, interpretations
and/or assumptions. All such points are required to be clarified & resolved during
bidding stage.
Document Number
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1.10
Any deviation or variation from the scope of supply and services or the intent of
the Specification shall be clearly brought out under the schedule of Technical /
Commercial deviations, irrespective of the fact that such deviation / variation may
be standard practice or possible interpretation of the Specifications by the Bidder.
In case, no clear and specific deviation is taken by the Bidder in the relevant
schedule of Bid Proposal Sheet while making his Bid proposal, it will be
construed that the Bidder shall comply with the stipulations of the Specification
fully with regard to scope of services and supplies to be provided by him to
achieve the objective of R&M. Further, unless otherwise specifically clarified by
the Owner, the interpretation by the Owner in respect of scope of supplies and
services to be performed by the Bidder shall be final and binding.
1.11
If the Bidder feels that, in his opinion certain features brought out in his offer are
superior to what has been specified, these may be highlighted separately in the
Bid. The Bidder at his own discretion may also make alternate offers, which in his
opinion are of superior technology, material etc. to the specified requirements
leading to better performance like efficiency / output etc. of the units after
renovation. In such case, the Bidder shall carry out a comprehensive study and
clearly identify the scope of offer in his alternate proposal. The Bidder shall
furnish that detailed study to Owner along with the Bid where the Bidder shall
bring out in detail the scope of modifications required to be carried out by him in
the various systems and equipment including but not limited to [Turbo Generator
and its Auxiliaries, HP & LP Bypass Valve, HP & LP Heaters, Deaerator,
Condenser, Boiler Feed Pump (BFP), Condensate Extraction Pump (CEP),
Turbine Cycle Piping (Excluding Main Steam, Cold Reheat, Hot Reheat,
Upstream and downstream piping of turbine bypass valve and Auxiliary Steam
Piping), Valves and all associated Electrical system, Control & Instrumentation
systems and associated Civil & Structural work etc.]
Such Alternate proposals shall be supplemented with sufficient amount of
information like specified design standards and performance requirements,
Bidder's experience, operating feedback, provenness, etc. for justifying such
proposals. Implications of such Alternate offers on the performance, output,
efficiency, auxiliary power consumption, etc. shall be clearly brought out in the
Bid to enable the Owner to determine the advantages, superiority and
acceptability of the proposals.
However the Bidder's Base offer shall necessarily be in line with the Specification
requirements. Under no circumstances the equipment and services as specified
shall be brought out as an Alternate offer.
The Base offers will be evaluated as per procedure outlined in the Bid documents
and the Alternate Offers of the lowest evaluated Bidder will only be considered
for acceptance or otherwise. Owner may reject alternative proposals submitted
by the Bidder at his sole discretion, without assigning any reason what so ever.
1.12
In the event of conflict between requirements of any two clauses of the

Specification documents or requirements of different Codes/ Standards specified,
Document Number
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the more stringent requirement as per the interpretation of the Owner shall apply,
unless confirmed otherwise by the Owner in writing.
1.13
The General technical conditions pursuant to the Contract, placed separately in

this Specification, shall form an integral part of the Specification. These
conditions shall supplement all the detailed technical Specification and
requirement identified in this Specification.
1.14
Out of complete unit comprising of mechanical, electrical, C&I systems and

equipment, some components/systems are envisaged to be replaced with new
ones having better design features while some of the other components are to be
refurbished / upgraded by the Bidder under present R&M Work. It shall be the
responsibility of the Bidder to ensure that components/ equipment/ systems
being supplied new OR components/ equipment/ systems being refurbished /
upgraded by him are fully compatible and integrated with the existing equipment /
systems so as to give safe, reliable and sustained operation of the complete unit.
Modifications needed on the assembled equipment to ensure complete
integration are to be brought out by the Bidder in the Bid and such modifications,
if any, after Owner's approval shall be carried out by the Bidder to the satisfaction
of the Owner.
1.15
The unit shall be designed to operate continuously in base load, cyclic load
operation. The systems shall operate without any restriction over the entire range
of operating conditions. The Bidder shall ensure that after R&M there are no
restrictions/ alterations in modes of operations of this unit, as per the
original/existing plant operation philosophy, including achieving base load, peak
load and cyclic load operation.
1.16
As the various equipment/ systems/ components are to be fitted in the unit,

Bidder is advised to visit the plant site to get fully conversant with the job, site
conditions, and constraints, and collect all the information as required and as
available before quoting against this Specification.
1.17
A brief extract of the existing unit, the original design details/ performance
parameters along with plant details, operating history and known problem areas;
wherever possible are brought out in the successive section of this Specification.
Relevant plant layout drawings and certain key schematic drawings, as available,
have also been furnished in Annexure-I of this section of the Specification for the
purpose of familiarization & guidance only. The successful Bidder shall prepare
and provide the additional drawings and documents describing the design and
engineering details and the manuals for carrying out erection, commissioning and
operation of the renovated unit.
Document Number
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No.
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SITE & PROJECT SPECIFIC INFORMTION
2.1
Project Name
[Logo of Utility]
Project Title: []
Existing Capacity: [. x ..MW]
2.2
Project Location
The proposed project site is located at [.], in District [.] in the state of [.].
The location details of the project site are as indicated below:
Table-2.1
2.3
Latitude
[. Deg. ....] N
Longitude
[.Deg . ....] E
Height above mean sea level
[.] m
Seismic Zone
Zone - [.]
Distance from [. ] town
[.] km
Distance from national highway No. [.]
[.] km
Distance from state highway No. [.]
[.] km
Distance of nearest airport [.]
[.] km
Distance of nearest seaport [.]
[.] km
Climatological Data
Table-2.2
Highest monthly
temperature
mean
of
daily
maximum
[.] deg C
Lowest monthly
temperature
mean
of
daily
maximum
[.] deg C
Highest monthly
temperature
mean
of
daily
minimum
[.] deg C
Lowest
mean
of
daily
minimum
[.] deg C
monthly
Document Number
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temperature
Annual mean of daily maximum temperature
[.] deg C
Annual mean of daily minimum temperature
[.] deg C
Extreme highest temperature
[.] deg C
Extreme lowest temperature
[.] deg C
Design ambient temperature (unless specified

otherwise)
{50 } deg C
Relative Humidity: Maximum
[.] %
Minimum
[.] %
Design Relative Humidity
[.] %
Average annual rainfall
[.] cm
Heaviest rainfall in 24 hours so far
[.] cm
Number of rainy days in a year
[. ]
Highest monthly mean of wind speed
[.] km/h
Lowest monthly mean of wind speed
[.] km/h
Maximum wind speed
[.] km/h
Table-2.3
Season
2.4
Dry bulb temperature
Wet bulb temperature
Summer
[.] deg C
[.] deg C
Monsoon
[.] deg C
[.] deg C
Winter
[.] deg C
[.] deg C
Fuel
At present the power station is sourcing coal from [..] coal mines/
[..] port {incase of imported coal}. The coal is being transported to the
project site by [Indian Railways/ MGR system/ cross country conveyor]. Proximity
of Railway line to site from . Railway Station is about [.] km. The
Document Number
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railway link shall also be used for transportation of heavy equipment to site
during execution phase and to bring main and secondary fuel to the power plant
during operation of plant.
2.5
Water Analysis
[Source (sea or river or Bore Well etc.) and quality of cooling water (sea water or
clarified water etc.) for condenser and other heat exchangers and type of cooling
system (once through or closed cycle), type is in use to be described herein.]
Chemical analysis of water which is used for this project is indicated as below:
Table-2.4
Sl.
No.
Units
Concentration
(Range/Value)
Raw Water Analysis
Calcium
mg/l
[.]
Magnesium
mg/l
[.]
Sodium
mg/l
[.]
Potassium
mg/l
[.]
Total Cations
meq/l
[.]
Bicarbonates
mg/l
[.]
Carbonates
mg/l
[.]
Nitrate
mg/l
[.]
Chloride
mg/l
[.]
10
Sulphate
mg/l
[.]
11
Total Anions
meq/l
[.]
12
Silica
mg/l
[.]
13
Iron Fe
mg/l
[.]
14
pH value
..
[.]
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Sl.
No.
Units
Concentration
(Range/Value)
15
Turbidity
NTU
[.]
16
mg/l
[.]
17

absorbed from Acid
mg/l
[.]
18
BOD
mg/l
[.]
19
COD
mg/l
[.]
Clarified Water Analysis
Calcium
mg/l
[.]
Magnesium
mg/l
[.]
Sodium
mg/l
[.]
Potassium
mg/l
[.]
Total Cations
meq/l
[.]
Bicarbonates
mg/l
[.]
Carbonates
mg/l
[.]
Nitrate
mg/l
[.]
Chloride
mg/l
[.]
10
Sulphate
mg/l
[.]
11
Total Anions
meq/l
[.]
12
Silica
mg/l
[.]
13
Iron Fe
mg/l
[.]
Document Number
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Sl.
No.
Units
Concentration
(Range/Value)
14
pH value
..
[.]
15
Turbidity
NTU
[.]
16
mg/l
[.]
17

absorbed from Acid
mg/l
[.]
Demineralised Water for Power Cycle Make up
The quality parameters of demineralised water is in use for make up to the

condenser hotwell and make up to the closed cycle equipment cooling water (ECW)
system is as below:
1
pH
..
{6.8 7.2}
Silica, as SiO2
ppm
{0.01}
Conductivity
micro mho/cm
{0.1}
Document Number
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No.
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No.
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EXISTING PLANT DETAILS

The Power Plant, is of the configuration of [xMW]. The Unit no. [.] of the
power plant, which is proposed to be taken up for Renovation and Modernization
was first commissioned in the year [.]. For the above unit, M/s [..] and M/s
[.] are the Original Equipment Manufacturers (OEMs) for the Boiler and TurboGenerator, respectively. The boiler for the unit is of [PF/CFBC] design. The boiler
is provided with [front & rear/ corner/down shot] firing system. LP stage of
Turbine is designed with [Bauman] exhaust. Condenser cooling system of the
unit is designed on [once through / re-circulation system]. Power generated from
the unit is being supplied to [...State/Central grid]. Power is being evacuated
through [.numbers of 220/400kV Double/Single Circuit lines] to [. substation.]
The primary fuel is [domestic/imported/blended] [coal/lignite] fuel being sourced
from [..&] coal mines. The consumptive water for the power plant is being
sourced from [.river /sea].
3.1
Capacity of [210 MW] was commissioned in the year [..]. The boiler is of
[] design and the turbine is of [LMZ] design. Though the boiler was
originally designed for coal with Gross Calorific Value (GCV) of [.kCal/kg], it
presently operates on coal supplied with GCV of about [..kCal/kg]. The
deterioration experienced over the years in Plants Average Performance
Parameters is shown in Table 3.1.
{Furnish in the Table 3.1 below, the Average Values over the life (say 25 years)}
Table-3.1
Units Average Performance Parameters over the life
Years after
Installatio
n
PLF
(%)
Availabilit
y (%)
Output
(MW)*
Units
Gross Heat
Rate
(kCal/kWh)
Units
Gross
Efficiency
(%)
Aux. Power
Consumptio
n (%)
Specific Oil
Consumptio
n (ml/kWh)
[]
[]
[]
[]
[]
[]
[]
10
[]
[]
[]
[]
[]
[]
[]
15
[]
[]
[]
[]
[]
[]
[]
20
[]
[]
[]
[]
[]
[]
[]
25
[]
[]
[]
[]
[]
[]
[]
Document Number
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Rev
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[Logo of Utility]
{Furnish in the Table 3.2 below, the Average Values for the last five years.
However, for the Parameters in respect of One Year back and Current Year,
furnish the Maximum, the Minimum and the Average Values.}
Table-3.2
Units Average Performance Parameters during the last five years
Period
PLF
(%)
Availabilit
y (%)
Output
(MW)
Aux. Power
Consumptio
n (%)
Specific Oil
Consumptio
n (ml/kWh)
Units
Gross
Efficiency
(%)
Units
Gross
Heat Rate
(kCal/kWh)
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Two Years
back
[]
[]
[]
[]
[]
[]
[]
One Year
back
[]
[]
[]
[]
[]
[]
[]
Current
year
[]
[]
[]
[]
[]
[]
[]
Four Years
back
Three
Years back
3.1.1
Auxiliary Power Consumption of Turbine Generator & Auxiliaries

Table-3.3
Sl. No.
1
Equipment/System
Units
Boiler Feed Water Pumps (BFPs)

including booster pumps and lube oil
pump sets of BFPs
kW
Condenser Vacuum Pumps
4
5
6
Excitation Power of Turbo Generator

Set
DM CCW
Pumps for Turbo
Generator Auxiliaries
LP Drain Condensate Pumps (if
Applicable)
Document Number
LII-GETS12021-G-00129-002
Power Consumption
[.]
kW
[.]
kW
[.]
kW
[.]
kW
[.]
kW
[.]
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Sl. No.
3.1.2
Equipment/System
Turbine Oil Pumps
Control Oil Pumps
Seal Oil Pumps
10
Oil Vapor Extractor Fans
11
Gland Steam
Extractor Fans
12
13
Total Auxiliary Power Consumption of

Turbine Generator and Auxiliaries
Condenser
[Logo of Utility]
Units
Power Consumption
kW
[.]
kW
[.]
kW
[.]
kW
[.]
kW
[.]
kW
[.]
kW
[.]
Vapor

The Project has been regularly monitoring the environmental parameters such
as stack monitoring, ambient air quality (AAQ), noise pollution and liquid waste
pollution in accordance with applicable norms by employing [M/s., which is
an agency approved by State Pollution Control Board].
The existing environmental data at rated load and the limits specified for different
pollutants, the locations of their measurements and the frequency of monitoring
are given in the table below.
Table 3.4
Environmental
Aspects
State Pollution and
Stack
Emissions
SPM
3
(mg/Nm )
Ambient Air
Quality
SPM
Document Number
LII-GETS12021-G-00129-002
Parameters
Achieved
Not to exceed
[]
On
24
Hrs
Basis
On
Annual
Basis
[]
[]
No. of
locations for
measurement
[]
[]
On
24
Hrs
Basis
On
Annual
Basis
[]
[]
Frequency
of
Sampling.
[]
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Environmental
Aspects
State Pollution and
Parameters
Achieved
[Logo of Utility]
No. of
locations for
measurement
Frequency
of
Sampling.
(g/m )
RPM
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
(g/m )
SO2
3
(g/m )
NOX
3
(g/m )
Process
Effluent
Leaving the
Plant Boundary
Document Number
LII-GETS12021-G-00129-002

pH
[]
[]
Colour
[]
[]
Odour
[]
[]
Temperat
ure
[]
[]
TSS
(mg/l)
[]
[]
Oil &
grease
(mg/l)
[]
[]
COD
(mg/l)
(mg/l)
[]
[]
BOD
(mg/l)
[]
[]
Chloride
(mg/l)
[]
[]
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Environmental
Aspects
3.1.3
State Pollution and
Parameters
Achieved
Sulphate
(mg/l)
[]
[]
TDS
(mg/l)
[]
[]
Zinc
(mg/l)
[]
[]
Fluoride
(mg/l)
[]
[]
Mercury
(mg/l)
[]
[]
[Logo of Utility]
No. of
locations for
measurement
Frequency
of
Sampling.

Detailed discussions with the Plant operators provided the feedback about the
design and operation related problems about the various systems which are
listed in the Table 3.5 below.
Table 3.5
S.
No.
Name of the
System/Equipment
Type of Problem
Probable Solution as
per the Operators
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
Document Number
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S.
No.
3.1.4
[Logo of Utility]
Name of the
System/Equipment
Type of Problem
Probable Solution as
per the Operators
[]
[]
[]
[]
[]
[]
[]
[]
[]

{Indicate in the table below the tripping and maintenance record for the past
three years.}
Table: 3.6
Year
3.1.5
Total
Trippings
No. of
Trippings due
to Turbo
Generator &
Auxiliaries
Other Major
Causes of
Trippings
Maintenance
carried out
Two
Years
Back
[]
[]
[]
[]
One
Year
Back
[]
[]
[]
[]
Current
Year
[]
[]
[]
[]
Maximum Achievable Load due to performance constraint

[Due to performance constraints of various equipment of Turbine Generator &
Auxiliaries, the maximum generation from the unit is restricted to [...] MW. The
operational data at the above maximum load is indicated in the table below.]
Table: 3.7
Nature of
constraint
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units Gross
Efficiency
(%)
[]
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00129-002
Units Gross
Heat Rate
(kCal/kWh)
[]
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3.1.6
[Logo of Utility]
Nature of
constraint
Output
(MW)
Aux. Power
Consumption
(%)
Specific Oil
Consumption
(ml/kWh)
Units Gross
Efficiency
(%)
Units Gross
Heat Rate
(kCal/kWh)
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]

[The record of reportable accidents for the past three years, is mentioned in the
Table below]
Table-3.8
Year
3.1.7
Man hours
lost due to
accidents
No. of Fatal
Accidents
No. of Accidents
leading to
Permanent
Disablement
Actions taken
to reduce the
number of
accidents
Two
Years
Back
[]
[]
[]
[]
One
Year
Back
[]
[]
[]
[]
Current
Year
[]
[]
[]
[]

design deficiency, layout of the plant, obsolescence of equipment and non
availability of spare parts etc. These are mentioned in the Table below]
Table: 3.9
S.No.
Specific Reason
(Design deficiency/ layout of the plant /
obsolescence of equipment / non availability of
spare parts etc)
Document Number
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3.1.8
[]
[]
[]
[]
[]
[]
[]
[]
[]
[]
[Logo of Utility]
Start up History of the Plant over the life

[The record of Plant Start-up history under various conditions over the plant life is
mentioned in the Table below:]
3.2
S.No.
Type of Start
No. of
Starts
Shut down time

(Duration in
hours)
Average Start-up
Time in hours
Hot Start
[]
[]
[]
Worm Start
[]
[]
[]
Cold Start
[]
[]
[]
Salient Technical Feature of Power Plant

{Describe in this chapter, the Design Parameters and Salient Features of all the
important Equipment and Systems of the Turbine Generator & Auxiliaries as
mentioned below}
3.2.1

A)
Steam Turbine
[The steam turbine is of three cylinder, 3000rpm, tandem compound, condensing
type designed to operate on a re-heat and re-generative feed water cycle. The
LP stage of turbine is designed with Bauman exhaust. The turbine is provided
with HP/LP bypass system of 30% / 60% capacity of Steam Generator MCR. The
turbine is provided with an electro - hydraulic control system, automatic turbine
run up system and turbo supervisory instrumentation. The condensing system
consists of a surface condenser of single shell and two pass, divided water box
construction. Cooling water being supplied to the condenser is of raw water/
clarified water quality. The design parameters of the steam turbine are furnished
below]
Table-3.8
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
(i) TURBINE
Manufacturer
..
[.]
Rated Output at TMCR
MW
[.]
Rated Output at VWO
MW
[.]
Rated Speed
rpm
[.]
Critical Speed of rotor
rpm
1st - [.]
2nd - [.]
3rd - [.]
4th - [.]
5th - [.]
Type of Governing
..
[Nozzle/Throttle]
Steam Flow at TMCR condition
T/hr
[.]
Steam Flow at VWO condition
T/hr
[.]
HP Turbine Efficiency
[.]
No. of Stages in HP Turbine
..
[.]
[.]
No. of Stages in IP Turbine
..
[.]
LP Turbine Efficiency
[.]
Turbine Heat Rate
kCal/kWh
[.]
Pressure of Steam at inlet of ESV

of HPT
kg/cm2
[.]

ESV of HPT
deg C
[.]
kg/cm2
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[19]
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Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
Temperature of Cold Reheat

(CRH) Steam at HPT Exhaust
deg C
[.]
Pressure of Hot Reheat (HRH)

Steam at IPT Interceptor Valve
inlet
kg/cm2
[.]
Temperature of Hot Reheat

(HRH) Steam at IPT Interceptor
Valve inlet
deg C
[.]
Steam at HPT exhaust
Pressure at the inlet of LP Turbine kg/cm2
[.]

Turbine
deg C
[.]
Rated pressure at the exhaust of

L.P. turbine
mm of Hg
[.]
Height of working blade of 1st

stage in H.P. Turbine
mm
[.]
Mean diameter of 1st stage

moving blade in H.P. Turbine
mm
[.]
Height of last stage moving blade
mm
[.]
Mean diameter of last stage

moving blade
mm
[.]
Number of ESV
No.
[.]
Nominal diameter of ESV
mm
[.]
Number of Interceptor Valve
No.
[.]
Nominal Diameter of Interceptor

Valve
mm
[.]
Number of HPT control Valve
No.
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[20]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Nominal diameter of HPT control

Valve
mm
[.]
Number of IPT control Valve
No.
[.]
Nominal diameter of IPT control

Valve
mm
[.]
LPT Exhaust Area
m2
[.]
LPT Exhaust Loss
kg/cm2
[.]
LPT Last Blade Length
mm
Material of Construction of HP
casing
..
Applicable Correction Curve
Material of Construction of IP
casing
..
[.]
Material of Construction of LP
casing
..
[.]
Material of Construction of Rotor
..
[.]
Total weight of Turbine
Tones
[.]
Weight of the heaviest part of Tones

turbine for erection (weight of the
lower half of LPC)
[.]
Weight of the heaviest part for Tones

operation (weight of upper half of
LPC in assembled stages)
[.]
Weight of H.P. Rotor
Tones
[.]
Weight of I.P. Rotor
Tones
[.]
Document Number
LII-GETS12021-G-00129-002
[.]
[.]
[Drawing No. ..
(Applicable Correction
curve to be attached)]
Rev
No.
Description
Page
No.
Date of Issue
03

[21]
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Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
Weight of L.P. Rotor
Tones
[.]
Overall length of turbine
mm
[.]
Overall length of H.P. rotor
mm
[.]
Overall length of I.P rotor
mm
[.]
Overall length of L.P rotor
mm
[.]
Length of H.P rotor between axes mm

of bearings
[.]
Length of I.P rotor between axes mm

of bearings
[.]
Length of L.P rotor between axes mm

of bearings
[.]
(ii) TURNING GEAR

Number
No.
[.]
Turbine rotor turning speed
rpm
[.]
Motor Type
..
[.]
Rated Volts
kV
[.]
Rated Output
kW
[.]
Motor speed
rpm
[.]
Gear Ratio
..
[.]
(iii) TURBINE LUBE OIL SYSTEM

[The lube oil system consists of Main Oil Tank, Turbine driven main oil pump,
2x100% AC driven starting oil pumps,1x100% DC driven emergency oil
pump, 1x100%each AC&DC driven jacking oil pumps and oil coolers of
3x50% capacity and Lube Oil Filters. Lube oil is being purified by means of a
centrifuge. Oil storage tanks consisting of Clean Oil Tank and Dirty Oil Tank
have been provided.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[22]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Also provision of Central Lube Oil purification system, if applicable, should

also be described in this chapter.]
Turbine Oil Specification
Trade Name
..
[.]
Specific gravity at 50 deg C
..
[.]
Flash point
deg C
[.]
Kinematic Viscosity at 50 deg C
Centistokes
[.]
Neutralization Number
..
[.]
Pour point
deg C
[.]
Mechanical Impurities
..
[.]
Ash content
[.] by weight
Turbine Lub Oil Equipment

a) Turbine Driven Main Oil
Pump
Type
..
[.]
Location
..
[.]
Drive
..
[.]
Speed
rpm
[.]
Discharge Pressure
kg/cm2 (a)
[.]
Type
..
[.]
Drive
..
[.]
b) AC Driven Starting Oil

Pumps
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[23]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Speed (Starting)
rpm
[.]
Speed (Testing)
rpm
[.]
Pressure developed (Starting)
mwc
[.]
Pressure developed (Testing)
mwc
[.]
Capacity (Starting)
m3/hr
[.]
Capacity (Testing)
m3/hr
[.]
Motor rating (Starting)
kW
[.]
Motor rating (Testing)
kW
[.]
Rated Volts (Starting)
kV
[.]
Rated Volts (Testing)
kV
[.]
Supply
..
[.]
Type
..
[.]
Capacity
m3/hr
[.]
Drive
..
[.]
Discharge Pressure
kg/cm2 (a)
[.]
Speed
rpm
[.]
Motor Rating
kW
[.]
Type
..
[.]
Capacity
m3/hr
[.]
c) AC&DC driven jacking Oil

Pumps
d) DC Driven Emergency Oil

Pump
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[24]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Drive
..
[.]
Discharge Pressure
kg/cm2 (a)
[.]
Speed
rpm
[.]
Motor Rating
kW
[.]
Capacity
Liter
[.]
Circulation Capacity
Changes/hr
[.]
Location
..
[.]
Type of coolers
..
[.]
Number of coolers
No.
[.]
Cooling Surface area
m2
[.]
Quantity of Oil cooled
Liter/m
[.]
Cooling Water Flow
m3/h
[.]
e) Turbine Oil Tank
f)
Oil Coolers
Working pressure of oil to be kg/cm2

cooled (design)
[.]
water kg/cm2
[.]
Working
(design)
pressure
of
No. of water paths
No.
[.]
Diameter of tubes
mm
[.]
Length of tubes
mm
[.]
Hydraulic resistance of water
mwc
[.]
g) Oil Filters
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[25]
15.01.2016
Power Plant]
Description
B)
Units
[Logo of Utility]
Design Parameters
Quantity
No.
[.]
Size
[.]
Condenser
[The condenser is a [single/double] pass, horizontal, surface type with integral air
cooling section designed to maintain a pressure of 76 mm of Hg at turbine
exhaust with a cooling water temperature of [] deg C and an outlet temp of []
deg C. The condenser is capable of operation with [] tubes plugged and has hot
well storage capacity of [] minutes.]
Table-3.9
Description
Units
Design Parameters
Make and Model
[.]
Type of Condenser
[.]
Condenser Heat Load
kCal/h
[.]
m2
[.]
..
[.]
Length of Tubes
mm
[.]
Material of Tubes
..
[.]
mxmm
[.]
Design Cleanliness Factor
..
[.]
Nature of connection to exhaust neck

of turbine
..
[.]
Type of condenser support
..
[.]
Water Side Pressure drop across

condenser
mwc
[.]
m3/h
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[26]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters

inlet to Condenser
deg C
[.]
Cooling Water Temperature at

Condenser Outlet
deg C
[.]
Condenser Vacuum
mm Hg
[.]
[On Load Tube Cleaning System]
..
[Yes/No]
[Cleanliness of Tube]
..
[.]
[Details of Debris Filter]
..
[Details of Screens in case of Once

Through System ]
..
Condenser
[.]
[.]
C) Ejectors
[The Condenser is provided with two quick starting ejectors which operate in
parallel to remove large volumes of air for raising the initial vacuum during the
starting of the Unit. Two main ejectors of 100% capacity each have been provided
remove air and non condensable gases from the condenser to maintain the
required vacuum in the condenser during the normal operation of the unit.]
Table-3.10
Description
Units
Design Parameters
(i) Starting Ejector

Number
No.
[.]
Type
..
[.]
Working steam pressure
kg/cm2(a)
[.]
Steam temp.
deg C
[.]
Steam Consumption
kg/h
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[27]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
(ii) Main Air Ejector

Type
..
[.]
Working steam pressure
kg/cm2(a)
[.]
Steam temp.
deg C
[.]
Steam Consumption
kg/h
[.]
D) Vacuum Pump (If Applicable)

[The Condenser is provided with [2x100%] vacuum pumps with all accessories
for condenser air evacuation. Capacity of each pump in free dry air at standard
condition with condenser operating at design pressure of 25.4 mm of Hg (abs)
and sub-cooled to 4.17 deg C below temperature corresponding to absolute
suction pressure is . scfm (. m3 per hour) under standard condition. The
capacity of each pump during hogging is [..] scfm. Details of existing vacuum
pump is given below:]
Table: 3.11
S.No.
E)
Description
Units
Value
Source of vacuum pump heat

exchanger cooling water
..
[.]
Source of sealing water
..
[.]
Source of make-up water
..
[.]
2
Design pressure (cooling water

side) for vacuum pump heat
exchanger
kg/cm (a)
[.]
Pressure of make-up water
kg/cm2(a)
[.]
Maximum temperature of
condenser cooling water
deg C
[.]
Duty code
[.]
Design back pressure
mm
[.]

[Condensate extraction pumps are of vertical, multistage, centrifugal pumps of
cannister type.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[28]
15.01.2016
Power Plant]
[Logo of Utility]
Table-3.12
Description
Units
Design Parameters
Make and Model
..
[.]
Type
[.]
Number of Pumps
[.]
Number of Impeller Stages
[.]
Capacity
m3/h
[.]
mwc
[.]
Efficiency of Pump
[.]
Condensate temp
deg C
[.]
Speed
rpm
[.]
Suction pressure
kg/cm2
Minimum flow
m3/h
[.]
mwc
[.]
Motor make
..
[.]
Rated Voltage
kV
[.]
Motor Speed
rpm
[.]
Frequency
Hz
[.]
Phase
[.]
Motor Rating
kW
[.]
kW
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[29]
15.01.2016
Power Plant]
F)
[Logo of Utility]
Gland Steam Cooler

[A Gland Steam Cooler has been provided to condensate the leak-off steam from
intermediate chambers of end sealings of HP and IP turbine, thereby heating the
main condensate water. The Gland Steam Cooler consists of shell, tube bundle
and removable water box.]
G) LP Heaters and Drain Coolers

[Each steam turbine is provided with four numbers of low pressure heaters to
increase the temperature of the condensate in stages. LP Heater -1 consists of
two halves and is installed in neck of the condenser. The remaining LP Heaters
are of shell and tube design and have been placed vertically. An integral drain
cooling section is provided in each LP Heater. The design details of LP Heaters
and Drain coolers are furnished in the table below.]
Table-3.13
LP Heaters
Heater No.
[1]
[2]
[3]
[4]
Type
[...]
[...]
[...]
[...]
Tube Size
(Dia./Thick.)
[...]
[...]
[...]
[...]
Tube Material
[...]
[...]
[...]
[...]
Shell Size
(Dia./Thick.)
[...]
[...]
[...]
[...]
Shell Material
[...]
[...]
[...]
[...]
Extraction
Nozzle
Location
[...] stage
LP turbine
of [...] stage of [...] stage of [...] stage of

LP turbine
LP turbine
LP turbine
Bled Steam
Flow (kg/h)
[...]
[...]
[...]
[...]
Bled Steam
Pressure
(kg/cm2)
[...]
[...]
[...]
[...]
Bled Steam
[...]
[...]
[...]
[...]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[30]
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[Logo of Utility]
Temperature
(C)
Saturation
Pressure
[...]
[...]
[...]
[...]
Condensate
Flow (kg/h)
[...]
[...]
[...]
[...]
Condensate
Inlet
Temperature
(C)
[...]
[...]
[...]
[...]
Condensate
Outlet
Temperature
(C)
[...]
[...]
[...]
[...]
Drain
Temperature
(C)
[...]
[...]
[...]
[...]
Drain Coolers
Description
Units
Design Parameters
Type
------
[...]
Number per Unit
No.
[...]
Orientation
..
[...]
Shell
[...]
Tubes
[...]
Tube Plate
[...]
Tube side Design Pressure
mwc
[...]
Shell side Design Pressure
mwc
[...]
H) Deaerator
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[31]
15.01.2016
Power Plant]
[Logo of Utility]
[The deaerator is of [horizontal spray cum tray type]. It is designed to remove

dissolved oxygen from the condensate in excess of 0.005 cc per liter. The feed
water storage tank has a capacity of [] minutes feed water requirement of the
boiler corresponding to TMCR Heat Balance]
Table-3.14
Description
Units
Design Parameters
Make
..
[...]
Type and Arrangement
..
[...]
Diameter
mm
[...]
Overall length
mm
[...]
Overall thickness
mm
[...]
Design pressure
kg/cm2(g)
[...]
Design Temperature
deg C
[...]
Relief valve set pressure
kg/cm2(g)
[...]
Total No. of trays
No.
[...]
Total surface area of trays
m2
[...]
Dimension of each tray
mxm
[...]
No. of spray nozzles
No.
[...]
Type of spray nozzles
..
[...]
Size of each nozzle
mm
[...]
Shell
Trays
Spray System
Feed Water Storage Tank
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[32]
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Power Plant]
[Logo of Utility]
Description
Units
Design Parameters
Make
..
[...]
Outside Dia
[...]
Overall length
[...]
Wall thickness
mm
[...]
Water Level
Normal Operating Water level (from
tank bottom)
mm
[...]
Highest water level (from tank bottom)
mm
[...]
Lowest water level (from tank bottom)
mm
[...]
Storage capacity with normal

operating water level
m3
[...]
Source
..
[...]
Quantity
T/h
[...]
Operating Pressure
kg/cm2(a)
[...]
Operating Temperature
deg C
[...]
Start-Up Steam
I)
Boiler Feed Pumps

[The boiler feed pumps are horizontal, multi stage centrifugal pumps of barrel
type, motor driven pumps coupled with hydraulic coupling, taking the suction
from the deaerator. The boiler feed pumps discharge feed water through HP
heaters to the economizer of the boiler.]
Table-3.15
Description
Document Number
LII-GETS12021-G-00129-002
Units
Design Parameters
Rev
No.
Description
Page
No.
Date of Issue
03

[33]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Booster Pump
Make and Model
..
[.]
Type
[.]
Number of Pumps
Nos.
[.]
No of stages
Nos.
[.]
Capacity
m3/h
[.]
mwc
[.]
Efficiency of Pump
[.]
Feed water temp
deg C
[.]
Speed
rpm
[.]
Suction pressure
kg/cm2
[.]
Power Consumption
kW
[.]
Make and Model
..
[.]
Type
...
[.]
No of Pumps
Nos.
[.]
No of stages
Nos.
[.]
Capacity
m3/h
[.]
mwc
[.]
Efficiency
[.]
Main Pump
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[34]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
Feed water temp
deg C
[.]
Speed
rpm
[.]
Suction pressure
kg/cm2
[.]
Minimum flow
m3/h
[.]
mwc
[.]
Motor make
..
[.]
Rated Voltage
kV
[.]
Motor Speed
rpm
[.]
Frequency
Hz
[.]
Phase
[.]
Motor Rating
kW
[.]
Power Consumption
kW
[.]
Details of worm-up water
[.]
Make and Model
..
[.]
Type
...
[.]
Duty
...
[.]
Efficiency
[.]
Range of Operation
...
[.]
Fluid Coupling
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[35]
15.01.2016
Power Plant]
Description
J)
Units
[Logo of Utility]
Design Parameters
...
[.]
Cooling Water Parameters
...
[.]
HP Heaters
[Each steam turbine is provided with three numbers of high pressure heaters to
increase the temperature of the feed water in stages. The Heaters are of shell
and tube design and have been placed vertically. The design details of HP
Heaters are furnished in the table below.]
Table-3.16
Heater No.
[6]
[7]
[8]
Type
[...]
[...]
[...]
Tube Size
(Dia./Thick.)
[...]
[...]
[...]
Tube Material
[...]
[...]
[...]
Shell Size
(Dia./Thick.)
[...]
[...]
[...]
Total Heat
Transfer Area
(m2)
[...]
[...]
[...]
Shell Material
[...]
[...]
[...]
Extraction
Nozzle Location
[...] stage
turbine
Bled Steam Flow

(kg/h)
[]
of
IP [...] stage of IP [...]

stage
turbine
IP/HP turbine
[]
[]
Bled Steam
Pressure
(kg/cm2)
[]
[...]
[...]
Extraction Line
Pressure drop
[...]
[...]
[...]
Document Number
LII-GETS12021-G-00129-002
of
Rev
No.
Description
Page
No.
Date of Issue
03

[36]
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Power Plant]
K)
[Logo of Utility]
Bled Steam
Temperature
(C)
[...]
[...]
[...]
Saturation
Pressure
[...]
[...]
[...]
Feed Water Flow

(kg/h)
[...]
[...]
[...]
Feed Water Inlet

Temp (C)
[...]
[...]
[...]
Feed Water
Outlet Temp
(C)
[...]
[...]
[...]
Drain
Temperature(deg
C)
[...]
[...]
[...]
HP/ LP Bypass
[HP/LP bypass system has a capacity of 30% / 60% of BMCR (Boiler Maximum
between the Hot Reheat Line and the Condenser. HP bypass water spray has
been taken from the discharge of Boiler Feed Pumps. LP bypass water spray has
been provided from the discharge of Condensate Extraction Pumps.
Table-3.17
Description
Units
Design Parameters
HPTBV
LPTBV
Make
..
[]
[]
Model
..
[]
[]
mm
[]
[]
Capacity
Opening through full travel
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[37]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
HPTBV
LPTBV
Closing through full travel
mm
[]
[]
Opening Time
Sec.
[]
[]
Closing time
Sec.
[]
[]
Pressure Reducing & Desuperheating Station

{In case of pressure reducing & desuperheating station is not integral, the parameters
as mentioned below shall be provided separately for pressure reducing valve &
desuperheater}
Type
..
[...]
[...]
Number of Valves
No.
[...]
[...]
Size
mm
[...]
[...]
Actuation type
..
[...]
[...]
Spray quantity at different load

(% TMCR)
m3/h
60% [...]
[...]
70% [...]
[...]
80% [...]
[...]
90% [...]
[...]
Spray water pressure
kg/cm2(a)
[...]
[...]
Spray water Temperature
deg C
[...]
[...]
Type of pressure control
..
[...]
[...]
Type of temperature control
..
[...]
[...]
MOC of valve body
..
[...]
[...]
MOC of Valve seat
..
[...]
[...]
MOC of Valve internals
..
[...]
[...]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[38]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
HPTBV
LPTBV
Oil Supply Unit

No of pumps
..
[...]
[...]
Capacity of the tank
m3
[...]
[...]
Method of purification of oil
..
[...]
[...]
No. and capacity of accumulators
..
[...]
[...]
L)
Turbine Governing System

[The turbine is equipped with an electro-hydraulic system of automatic governing
for the smooth and stable operation of turbo-set under all conditions of operation.
The system is designed to sustain full load dump from the generator. The system
is provided with a quick closing Emergency Stop Valve (ESV), to interrupt the
supply of steam from the boiler and stop the turbine under emergency conditions.
The turbine governing system includes, speed governor]
M) Generator Seal Oil System

Table-3.18
Description
Units
Design Parameters
A.C. Seal Oil Pump

Manufacturer
..
[.]
Type
..
[.]
Number
No.
[.]
Discharge Head
kg/cm2
[.]
Capacity
m3/hr
[.]
Speed
rpm
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[39]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Efficiency
[.]
Motor Manufacturer
..
[.]
Motor Rating
kW
[.]
Power Consumption
kW
[.]
Manufacturer
..
[.]
Type
..
[.]
Number
No.
[.]
Discharge Head
kg/cm2
[.]
Capacity
m3/hr
[.]
Speed
rpm
[.]
Efficiency
[.]
Motor Manufacturer
..
[.]
Motor Rating
kW
[.]
Power Consumption
kW
[.]
D.C. Seal Oil Pump
N)
Condensate Storage Tank

Number
..
Design code
..
Capacity of each tank
m3
Overall Dimension of the Tank
..
Document Number
LII-GETS12021-G-00129-002
[.]
[.]
[.]
[.]
Rev
No.
Description
Page
No.
Date of Issue
03

[40]
15.01.2016
Power Plant]
Free Board
mm
Type and pressure class
..
Material of construction and Thickness
..
O)
P)
[Logo of Utility]
[.]
[.]
[.]
DM Make-UP Pumps
No. of Pumps
..
No. of Pumps Working
..
No. of Pumps Stand-by
..
Suction Lift/Head Available
mlc
Flow
m3/h
Total Dynamic Head
mlc
Rated Speed
rpm
Range of Operation
Suction specific speed
US unit
Pump Efficiency
Motor Rating
kW
..
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
[.]
Miscellaneous Operational Parameters of Turbo Generator

Table-3.19
Description
Units
Design Parameters
Turbine oil cooler oil outlet temp.
deg C
[.]
Cold gas temp.
deg C
[.]
Stator cooling water flow
m3/hr
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[41]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
Stator cooling water pp discharge pr.
kg/cm2
[.]
Seal oil cooler oil outlet temp.
deg C
[.]
Stator cooling water expansion tank

volume
m3
[.]
Hydrogen cooler water inlet pr.
kg/cm2
[.]
Stator cooling water temp. at inlet to

stator winding and distillate temp. at
outlet of stator winding
deg C
[.]
M.O.T. Level
cm
[.]
Stator cooling water resistivity
k-cm
[.]
Under steady state condition, normal

turbine differential expansion
mm
HPT= [.]
IPT= [.]
LPT= [.]
Q) Piping
Table-3.20
Description
Units
Design Parameters
[Line Designation. & Tag No...]

Flow
T/hr
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Document Number
LII-GETS12021-G-00129-002
[.]
Rev
No.
Description
Page
No.
Date of Issue
03

[42]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
[Line Designation. & Tag

No...]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]

No...]

No...]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[43]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s

No...]

No...]

No...]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[44]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]
Flow
T/hr
[.]
Velocity
m/s
Schedule/Thickness
[.]
Size
mm
[.]
Material
[.]
Class
[.]

No...]

No...]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[45]
15.01.2016
Power Plant]
3.2.2
[Logo of Utility]
Electrical System
A brief extract of the existing Equipments and Systems of Turbo Generator &
Auxiliaries package describing the original design details are given below.
Relevant plant layout drawings and certain key schematic drawings have also
been furnished in Annexure-I of this section of the specification for the purpose of
familiarization and modification if required.
A)
Generator & its Auxiliary system

[Turbo Generator is having rated output of 210/215/220/250 MW with the Voltage
rating of [as per existing generator voltage] kV provided with Static/Brushless
excitation system. The design parameters of Generator and Its auxiliary system
are furnished below:].
Description
Units
Design Parameters
Name of the manufacturer
[.]
Model No.
[.]
Rated MW Capacity
MW
[.]
Rated MVA Capacity
MVA
[.]
kV
[.]
Rated Power Factor
..
[.]
kA
[.]
Rated Speed
rpm
[.]
Rated Frequency
Hz
[.]

Rated Power Factor
[.]
Excitation Current
kA
[.]

kV
[.]
Short Circuit Ratio
..
[.]
Generator
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[46]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
kg/cm2
[.]
Amp
[.]
Phase Connection
[.]
Type of Excitation
[.]
[.]
Line charging capability
[.]
Efficiency
[.]
[.]
Direct Axis Sub-Transient Reactance,

Xd
P.U.
[.]
Direct Axis Transient Reactance, Xd
P.U.
[.]
Direct Axis Synchronous Reactance,

Xd
P.U.
[.]
Negative Phase Sequence

Reactance, X2
P.U.
[.]
Zero Sequence reactance, X0
P.U.
[.]
Sub transient current on 3 phase short P.U.

circuit
[.]
Transient current on 3 phase short

circuit
P.U.
[.]
Steady State current on 3 phase short

circuit
P.U.
[.]
Reactances
Short Circuit Currents
Time Constants
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[47]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
Field Time Constant with open

circuited Stator Winding, Tdo
Sec.
[.]
Field Time Constant with 3 Phase

Short Circuit of Stator Winding, Td3
Sec.
[.]

Sec.
[.]

Sec.
[.]
Time Constant of the aperiodic

component for 3 Phase, 2 Phase
short circuit, Ta1
Sec.
[.]
Time Constant of the periodic

component of the sub-transient
current for 3 Phase, 2 Phase and
single phase short circuit, Td
Sec.
[.]
Permissible pressure of H2
kg/cm2(g)
[.]
Permissible variation on above
kg/cm2(g)
[.]
Nominal Temperature of Cold Gas
deg C
[.]
Purity of H2
[.]
Oxygen content
[.]
Nominal pressure at inlet to winding
kg/cm2(g)
[.]
kg/cm2(g)
[.]
Nominal temperature cold distillate at

inlet to stator winding
deg C
[.]
deg C
[.]
Hydrogen in Stator Casing
Distillate to Stator Winding
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[48]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
Rated flow of distillate
m3/hr
[.]
m3/hr
[.]
Nominal specific resistivity of distillate
-cm
[.]
Minimum permissible specific

resistivity
-cm
[.]
Nominal temp. of Cooling Water at deg C

Inlet
[.]
Minimum allowable temp. of water
deg C
[.]
Nominal Flow of Water
m3/hr
[.]
Water to Gas Cooler
Maximum permissible pressure of kg/cm2(g)

cooling water in the gas cooler
[.]
Water to Stator Winding Water Cooler:

Nominal consumption of cooling water m3/hr
at a temp of [35C]
[.]

at a temp of [37C]
[.]

at a temp of [40C]
[.]
Permissible Temperature Rating

Class of
Windings
Insulation
of
generator ..
Maximum temp of Stator

(measured by embedded RTD)
[.]
Core deg C
[.]
Maximum temp of Stator Winding deg C

(measured by embedded RTD)
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[49]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Maximum temp of Rotor Winding deg C

(measured by resistance method)
[.]
Permissible temp rise of

Winding over Cold gas temp
Rotor deg C
[.]
Maximum temp of distillate at the deg C

outlet of Stator Winding as measured
by RTD
[.]
Maximum temp of Hot gas measured deg C

by RTD and Mercury Thermometer
[.]
Maximum temp of Stator Winding as deg C

measured by RTD placed under the
wedges
[.]
Difference between the readings of deg C

RTDs
showing
maximum
and
minimum tem
[.]
Consumption of oil per generator

bearing (excluding shaft seal)
lit/min
[.]
Oil pressure at the inlet of bearing
kg/cm2(g)
[.]
Consumption of oil in both the shaft

seals
lit/min
[.]
Total gas volume of the generator
m3
[.]
Number of passes in the gas cooler

water
..
[.]
Critical speed of the rotor
rpm
[.]
Flywheel moment of the rotor
T-m2
[.]
Ratio of Short circuit torque to Full

Load Torque
..
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[50]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
Line charging capacity
MVAR
[.]
Basic impulse insulation level w.r.t

body
kVpeak
[.]
level kVpeak
[.]
Basic
impulse
between turns
insulation
Resistance of Stator Winding per

phase at 20C
Ohm
[.]
Resistance of Rotor Winding at 20C
Ohm
[.]
Capacitance of Stator Winding

(calculated value) in hot condition
[.]
Overall diameter of Stator
mm
[.]
Length of the Stator
mm
[.]
Length of the rotor
mm
[.]
Diameter of Rotor Barrel
mm
[.]
Weight of the heaviest lift (Stator with

Gas Coolers and Lifting trunions)
Tones
[.]
Weight of Rotor
Tones
[.]
Weight of Gas Cooler
Tones
[.]
Weight of Bearing with Brush Gear

along with foundation plates
Tones
[.]
Weight of end terminal
kg
[.]
Weight of end shield
Tones
[.]
Total weight of the generator
Tones
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[51]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Static Excitation System

Excitation Transformer:
Make
..
[.]
Type
..
[.]
Cooling
..
[.]
Rating
kVA
[.]
Voltage ratio
..
[.]
Phase
..
[.]
Frequency
Hz
[.]
Vector Group
..
[.]
% Impedance
..
[.]
Make
..
[.]
Type
..
[.]
Cooling
..
[.]
Rated Rectifier current
[.]
Rated Rectifier voltage
[.]
Ceiling Current
[.]
Ceiling Voltage
[.]
Ceiling duty duration
Sec
[.]
Rated P.I.V.
[.]
Static Converter
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[52]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Voltage drop across thyristor
[.]
Total No. of Parallel Thyristor Bridges
..
[.]
No. of redundant Thyristor Bridges
..
[.]
Cooling Power Requirement
kW
[.]
Amount of heat dissipated
kW
[.]
Make
..
[.]
Type
..
[.]
Accuracy of voltage regulator
[.]
Range of Voltage control in auto
[.]
Range of Voltage control in manual
[.]
Response time
sec
[.]
Response ratio
..
[.]
Field forcing
sec
[.]
Operating frequency
Hz
[.]
Dead band
..
[.]
Range of reactive drop adjustment
[.]
Rated current & Voltage of SSE
[.]
Excitation System with DVR
Brushless Excitation System

Pilot exciter
a) Manufacturer
[.]
b) Type
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[53]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
c) Type of drive
[.]
d) Normal Speed
rpm
[.]
e) Rated Voltage
Volts
[.]
f) Rate frequency
Amp
[.]
g) Rated current
Amp
[.]
h) Type of insulation
[.]
Rectifier for pilot exciter

a) Manufacturer
[.]
b) Type
[.]
c) Rated rectifier voltage
Volts
[.]
d) Rated rectifier current
Amp
[.]
e) Total number of rectifier cells per

parallel path of a bridge
[.]
f) Number of parallel paths per bridge

arm
[.]
g) No. of bridge arms
[.]
a) Manufacturer
[.]
b) Type
[.]
c) Type of drive
[.]
d) Normal Speed
rpm
[.]
e) Rated rectifier voltage
Volts
[.]
f) Rated rectified current
Amp
[.]
g) Ceiling rectified voltage
Volts
[.]
h) Ceiling rectified current
Amp
[.]
i) Exciter field voltage with manual

control (rectified)
Volts
[.]
i) Maximum
Volts
[.]
ii) Minimum
Volts
[.]
Main Exciter
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[54]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
k) Nominal exciter response ratio
[.]
l) Class of insulation
[.]
a) Manufacturer
[.]
b) Type of rectifier
[.]
c) Total number of rectifier cells per

ring
[.]
d) Number of parallel paths per bridge

arm
[.]
e) Number of bridge arms
[.]
[.]
Exciter rectifier assembly
Air/Water Coolers (For Exciter)

a) Number of Coolers
b) Material of
B)
[.]
i) Tubes
[.]
ii) Fins
[.]
c) Material of tube plates
[.]
d) Material of water boxes
[.]
e) Quantity of circulating water

required per cooler
m /hr
[.]
f) Maximum allowable water

temperature
deg C
[.]
Generator Protection & Metering Panel

[Generator protection panel is covering Protection requirements of Turbo
Generator, Generator Transformer (GT) and Unit Transformer (UT). It has been
envisaged that there are two groups of protection each are physically,
mechanically and electrically separated into two separate systems. And Metering
systems will comprise of Metering requirements of Generator, GT and UT
transformers. The design parameters of Generator Protection panel and Metering
Panel are furnished below:]
Description
Make/Manufacturer of Panel
Document Number
LII-GETS12021-G-00129-002
Unit
Design Parameters
[.]
Rev
No.
Description
Page
No.
Date of Issue
03

[55]
15.01.2016
Power Plant]
Description
Unit
Design Parameters
[.]
{For Protection/Metering panel}
[.]
Model No
Panel Designation
[Logo of Utility]
{Relay/Metering panel of
GT/UT/Generator}
Type of Panel
[.]
{Simplex/Duplex}
(a) Load bearing members
mm
[.]
(b) Non-loading members
mm
[.]
Colour Shade of Panel
[.]
Cable Entry of Panel
[.]
{Top/Bottom}
[.]
(a) AC
[.]
(b) DC
Sheet Steel Thickness
Auxiliary Voltage Requirement of

Panel
Minimum rating of contacts for

auxiliary relays :
(a)
Voltage
V, DC
[.]
(b)
Continuous current
A, DC
[.]
(c)
Make & carry for 1 sec.
A, DC
[.]
(d)
Breaking capacity
(i) Resistive
(ii) Inductive
[.]
Watts
[.]
Weight of Each Panel

Dimension of each panel
Document Number
LII-GETS12021-G-00129-002
kg
[.]
mm
[.]
Rev
No.
Description
Page
No.
Date of Issue
03

[56]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Unit
Design Parameters
Relay type and protection

[For Generator]
[.]

[For Generator Transformer]

[For Unit Transformer]
Tripping Relays
(a)
Make / designation
[.]
(b)
Static / Electromagnetic
[.]
(c)
Rated voltage
V, DC
[.]
{List out protections envisaged

for Generator in Group I and
Group II separately}
[.]
for Generator Transformer in
Group I and Group II
separately}
[.]
for Unit Transformer in Group
I and Group II separately}
Trip circuit Super Vision Relays

(a)
Make / designation
[.]
(b)
Static / Electromagnetic
[.]
(c)
Rated voltage
V, DC
[.]
Indicating Lamps
Type
Ratings
(a)
Voltage
(b)
Wattage
[.]
[.]
W
[.]
Energy Meters
Make
Document Number
LII-GETS12021-G-00129-002
.
Rev
No.
Description
Page
No.
Date of Issue
03

[57]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Unit
Design Parameters
Type of measurement
[.]
Measuring range in primary watts.
[.]
CT ratio
A/A
[.]
VT ratio
V/V
[.]
Accuracy class
[.]
Burden
[.]
(a)
Current coil
VA
[.]
(b)
Voltage coil
VA
[.]
a) Output
[.]
b) Accuracy
[.]
c) Burden
VA
[.]
Transducers
C)
ISOLATED PHASE BUS DUCT

[Isolated Phase Bus duct is envisaged for main connection between Generator to
Generator transformer and Tap off connection is envisaged to Unit Transformer.
Connection to Station Transformer is tapped from Switchyard. Isolated bus duct
are natural cooled and having voltage rating of [to suit generator terminal
voltage.] kV. The design parameters of Isolated Phase Bus Duct are furnished
below:].
Description
Unit
Design Parameters
[.]
[.]
{IPBD}
Type of Cooling
[.]
System Voltage
kV
[.]
Rated Voltage of Bus duct
kV
[.]
Rated frequency
Hz
[.]
Make/Manufacturer
Type of Bus Duct
Current Rating- Continuous

i) Main Connection
Document Number
LII-GETS12021-G-00129-002
Amp
[.]
Rev
No.
Description
Page
No.
Date of Issue
03

[58]
15.01.2016
Power Plant]
Description
Unit
Design Parameters
[.]
ii) Tap off connection to UT/any other

system (Exct. Transf / LAVT
Cubicle)
Current Rating- Short Time
i) Main Connection
ii)
Tap off Connection to UT/any

other system (Exct. Transf /
LAVT Cubicle)
Dynamic withstand Rating

i) Main connection
ii) Tap off connection
Basic impulse withstand level
[Logo of Utility]
kAmp
[.]
[.]
kApeak
[.]
[.]
[.]
kVpeak

withstand voltage
kV
Phase to phase spacing
mm
[.]
[.]
{ List out for Main/Tap off}
{List out for Main/Tap off}
Bus Conductor
.
[.]
Shape and dimension
[.]
Cross sectional area
Sq.mm
[.]
Material and Grade
Method of joining adjacent sections

Resistance per phase at 20 deg.C
[.]
Ohms
[.]
{List out for main and tap off}
Bus Enclosure
.
[.]
Shape and dimension
[.]
Diameter and thickness
mm
[.]
Material and Grade
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[59]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Unit
Design Parameters
Sq.mm
[.]
[.]
Resistance/metre/Phase at 20C for

bus duct
Ohm/ph/m
[.]
Inductive reactance/metre/phase at
20C for bus duct
Ohm/ph/m
[.]
Capacitive reactance/metre/phase at
20C for bus duct
Ohm/ph/m
[.]
[.]
[.]
.
.
[.]
[.]
[.]
Maximum temperature rise of

conductor over 50oC ambient
deg C
[.]

enclosure over 50oC ambient
deg C
[.]
Cross Sectional area
Length of Bus duct

i)
Generator to Generator
Transformer
ii) Tap off to UT
iii) Tap off to other system (if
applicable)
Power Loss
Power loss in bus conductor @ rated
current
kW/
ph/meter.
[.]
Power loss in bus enclosure @ rated

current
kW/
ph/meter.
[.]
Total power loss as per length of bus

duct
kW
[.]
Manufacturer
[.]
Material and grade
[.]
Bellows
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[60]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Unit
Design Parameters
Maximum permissible expansion
[.]
Gasket for Inspection cover

i) Material
[.]
[.]
Manufacturer
[.]
Type of Insulator
[.]
Rated Voltage Class
kV
[.]
One Minute Power frequency

withstand Voltage
kV
[.]
kVpeak
[.]
Pressure of supply air
kg/cm2
[.]
Pressure to be maintained inside bus

ducts
kg/cm2
[.]
Scavenging rate
l/hr
[.]
Guaranteed leakage rate
l/hr
[.]
Quantity of air required
[.]
Location of opening for hot air

blowing
[.]
{List out no of opening at
generator, GT and UT}
Yes/No
[.]
Paint Shade of Bus duct
[.]
Disconnecting Link
[.]
[.]
[.]
ii) Grade
Insulator and seal of bushing
Impulse withstand Voltage

Pressurization equipment
Sun shade Provided
i) Rated Current
ii) Location
Whether CT are provided in Bus duct

(if yes)
i)
Application
Document Number
LII-GETS12021-G-00129-002
[.]
{List out CT details wherever
Rev
No.
Description
Page
No.
Date of Issue
03

[61]
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Description
Unit
[Logo of Utility]
Design Parameters
CT parameters CT Ratio & .
applicable}
ii) Core
iii) Accuracy class
iv) Rated burden
v) Knee point voltage
vi) Magnetization Current
D)
6.6 kV SEGREGATED PHASE BUS DUCT

[6.6 kV segregated phase bus duct is envisaged for connection between Unit
Transformer to6.6 kV unit switchgear, Station Transformer to 6.6 kV Station
switchgear and Tie between 6.6 kV Unit and Station switchgear. The design
parameters of 6.6 kV segregated phase bus duct are furnished below:].
Description
Unit
Design Parameters
[.]
[.]
{SPBD}
[.]
System Voltage
kV
[6.6.]
Rated Voltage of Bus duct
kV
[7.2.]
Rated frequency
Hz
[.]
Make/Manufacturer
Type of Bus Duct
Type of Cooling
Current Rating- Continuous

i) UT to 6.6 kV unit switchgear
ii) ST to 6.6 kV station
switchgear
[.]
[.]
Amp
[.]
iii) Tie between 6.6 kV Unit and

Station Switchgear
Current Rating- Short Time
switchgear
Document Number
LII-GETS12021-G-00129-002
[.]
[.]
kAmp
Rev
No.
Description
Page
No.
Date of Issue
03

[62]
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Description
Unit
[Logo of Utility]
Design Parameters

Station Switchgear
Dynamic withstand Rating
switchgear
[.]
[.]
kApeak

Station Switchgear
Basic impulse withstand level
[.]
kVpeak

withstand voltage
kV
[.]
Phase to phase spacing
mm
[.]
Phase to Earth spacing
mm
[.]
[.]
Shape and dimension
[.]
Cross sectional area
Sqmm
[.]
Bus Conductor
Material and Grade

Resistance per phase at 20 deg.C
[.]
Ohms
[.]
{List out for main and tap off}
Bus Enclosure
.
[.]
Shape and dimension
[.]
Diameter and thickness
mm
[.]
Sqmm
[.]
[.]
Material and Grade
Cross Sectional area

Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[63]
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Power Plant]
Description
[Logo of Utility]
Unit
Design Parameters
[.]
Resistance/metre/Phase at 20C for

bus duct
Ohm/m/ph
[.]
Inductive reactance/metre/phase at
20C for bus duct
Ohm/m/ph
[.]
Capacitive reactance/metre/phase at
20C for bus duct
Ohm/m/ph
[.]
Length of Bus duct

meter
[.]
[.]
Material of Phase Barrier

switchgear
[.]
[.]
[.]

Station switchgear
deg C
[.]

deg C
[.]
Power Loss
Power loss in bus conductor @ rated
current
kW/
ph/meter.
[.]
Power loss in bus enclosure @ rated

current
kW/
ph/meter.
[.]
Total power loss as per length of bus

duct
kW
[.]
Manufacturer
[.]
Type of Insulator
[.]
Rated Voltage Class
kV
[.]
One Minute Power frequency
kV
[.]
Insulator and seal of bushing
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[64]
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Description
[Logo of Utility]
Unit
Design Parameters
kV (Peak)
[.]
No of heaters
[.]
Voltage and Wattage required
[.]
Yes/No
[.]
Paint Shade of Bus duct
[.]
Disconnecting Link
iii) Rated Current
iv) Location
[.]
[.]
withstand Voltage
Impulse withstand Voltage
Bus Duct Space heating
Sun shade Provided
E)
415 V NON SEGREGATED BUS DUCT(NSPBD)

[The 415 V Non Segregated Bus Duct (NSPBD) which connects LV Transformer
to 415 V switchgears of TG and its Auxiliaries packages. The design parameters
of the 415V NSPBD are furnished below:
Description
Units
Make/Manufacturer
Design Parameters
.
[.........]
Type of bus duct
[.........]
Rated voltage and No. of phase
[.........]
Material of Bus bar and Enclosure
[.........]
Rated Current
[.........]
Designation (From and To)
[.........]
Type of cooling (NSPBD)
[.........]
of deg C
[.........]
Maximum temperature rise

Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[65]
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Power Plant]
Maximum temperature rise

F)
of deg C
[Logo of Utility]
[.........]
One minute power frequency voltage kV (RMS)

withstand
[.........]
Continuous current rating at 50oC A

design ambient air temperature
[.........]
One second short circuit withstand

rating
kA (RMS)
[.........]
Momentary short circuit withstand

current
kA (Peak)
[.........]
6.6 kV Switchgear
6.6 kV Switchgear is envisaged for feeding unit auxiliaries as well as station
auxiliaries at {6.6} kV level. These 6.6 kV Unit and Station switchgear are
connected to Unit Transformer and Station Transformer respectively through 6.6
kV segregated phase bus duct. Motors of rating greater than [160] kW is
envisaged at these boards. And also provided power to Mechanical system of
AHS, CHS, Intake Water system etc at this level. The design parameters of 6.6
kV switchgear are furnished below:].
Description
Units
Design Parameters
Make/Manufacturer
[.........]
V, Hz
[...]
[.........]
Maximum system voltage
[.........]
kV (rms)
[.........]
Impulse withstand voltage
kV (Peak)
[.........]
Continuous current rating of bus
[.........]
Voltage
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[66]
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Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
bars
Short Circuit rating of Bus bar with
duration
kA & sec
Dynamic Withstand rating
kAp & sec
[.........]
Bus bar Material
Al/Cu
[.........]
Type- Fully Draw out/Fixed
[.........]
Maximum temperature of Bus .

Bars, dropper, connectors &
contacts at continuous current
rating under site reference ambient
temperature
[.........]
Cable Entry
[.........]
[.........]
i)
Bus bar
[.........]
[.........]
ii) Others
Thickness of steel
i)
[.........]
Load bearing members
ii) Non load bearing members
Paint Shade
[.........]
[.........]
G) 415 V SWITCHGEAR/MCC
[415 V Switchgear/MCC is envisaged for feeding unit auxiliaries as well as
station auxiliaries at {0.415} kV level. These 415V unit and station auxiliary
switchgear are connected to its respective LV transformer through 415V Non
Segregated Phase Bus Duct. Motors of rating less than and equal to [160] kW is
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[67]
15.01.2016
Power Plant]
[Logo of Utility]
envisaged at these 415 V switchgear. The design parameters of 415 switchgear

are furnished below:].
Description
Units
Design Parameters
Make/Manufacturer
[.........]
V, Hz
[...]
[.........]
Maximum system voltage
[.........]
[.........]
[.........]
Voltage
Continuous current rating of bus
bars
Short Circuit rating of Bus bar with
duration
kA & sec
[.........]
Dynamic Withstand rating
kAp & sec
[.........]
Bus bar Material
Al/Cu
[.........]
Type- Fully Draw out/Fixed
[.........]
Maximum temperature of Bus

Bars, dropper, connectors &
contacts at continuous current
rating under site reference ambient
temperature
[.........]
Cable Entry
[.........]
-Bus bar
[.........]
- Others
[.........]
[.........]
Thickness of steel
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[68]
15.01.2016
Power Plant]
Description
Units
-Load bearing members
[Logo of Utility]
Design Parameters
[.........]
-Non load bearing members
[.........]
Paint Shade
[.........]
H) LV TRANSFORMER (DRY/OIL) TYPE

[The LV Transformer is designed to cater 100% of Power plant auxiliary load of
respective system like Boiler, Turbine, HVAC etc, with 2 x100% configuration is
followed. The design parameters of the LV Transformer {Oil/Dry} type are
furnished below:]
Description
Units
Design Parameters
Make/Manufacturer
[..............]
Type
[Oil/Dry.......]
Duty
[..Continuous.........]
Transformer application
[..Service ..........]
Installation
[Indoor/Outdoor.]
Insulation Class
[..............]
Rating of transformer
MVA
[...........]
No load voltage ratio at principal tap

HV/LV
kV
[..............]
Impedance value at principal tap on

rated MVA base.
Tolerance on impedance at nominal

tap
Rated frequency
Hz
[..............]
[..............]
[..............]
Winding connection and vector group
Document Number
LII-GETS12021-G-00129-002
[..............]
Rev
No.
Description
Page
No.
Date of Issue
03

[69]
15.01.2016
Power Plant]
Description
Units
System fault level
kA
Impulse withstand voltage / Power

frequency withstand voltage of
windings
kV(rms)/
kV(Peak)
[Logo of Utility]
Design Parameters
[HV.........]; [LV.........]
[..............]
.
System earthing
[..............]
(a) HV
(b) LV
[..............]
Type of tap changer
Termination Details
[..............]
a) HV side
[..............]
b) LV side
[..............]
Maximum operating temperature for

i)
Oil(if applicable)
[..............]
ii) Winding
[..............]
Guaranteed no load loss
kW
[..............]
kW
[..............]
Guaranteed efficiency at
[..............]
a) Full load
b) 75% load
[..............]
Noise Level
I)
MOTORS
[The design parameters of motors of TG and its Auxiliary package are furnished
below:].
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[70]
15.01.2016
Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Make/Manufacturer
[.........]
Application
Rating
kW
[.........]
Rated Voltage, Phase, Frequency
kV, Hz
[.........]
Frame Size
[.........]
Type of Cooling
[.........]
Installation
[.........]
Duty Type
[.........]
Load Factor
[.........]
Full load current
[.........]
Starting current & Starting PF
Times
Normal
current
[.........]
Winding connection
Star/Delta
[.........]
Full load speed
[.........]
Power factor and Efficiency
[.........]
Class of insulation
temperature rise
[......]
Starting Duty
[.........]
Method of starting
[.........]
[.........]
[......]
CT details if provided with differential
[......]
Document Number
LII-GETS12021-G-00129-002
and
Rev
No.
Description
Page
No.
Date of Issue
03

[71]
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Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
protection
RTD/BTD Details
J)
[......]
MOTORIZED ACTUATORS
[The design parameters of Motorized Actuators used for TG and its Auxiliary
package are furnished below]:
Description
K)
Units
Design Parameters
Make/Manufacturer
[.........]
Application
Rating
kW
[.........]
Rated Voltage, Phase, Frequency
kV, Hz
[.........]
Installation
[.........]
Duty Type
[.........]
Load Factor
[.........]
Type
[ Integral/Non Integral.........]
Class of Insulation
[.........]
VARIABLE FREQUENCY DRIVES (VFD) {If applicable}

[The design parameters of VFD used for TG and its Auxiliary package are
furnished below]:
Description
Units
Design Parameters
Mains connection
[.]
Voltage and power range
[.]
Frequency
[.]
Power factor
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[72]
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Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Motor connection
[.]
Voltage
[.]
Frequency
[.]
Continuous loading capability

(constant torque at design ambient
temperature )
[.]
Overload capacity (at design ambient

temperature )
[.]
Switching frequency Selectable
kHz
[.]
Acceleration time
Sec
[.]
Deceleration time
Sec
[.]
Speed control
[.]
Open loop
[.]
Closed loop
[.]
Torque control
[.]
Open loop
[.]
Closed loop
[.]
Programmable control connections
[.]
Two analog inputs
[.]
Voltage signal
[.]
Current signal
[.]
Potentiometer
[.]
Reference value
[.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[73]
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Power Plant]
Description
L)
Units
[Logo of Utility]
Design Parameters
Maximum delay
ms
[.]
Resolution
[.]
Accuracy
[.]
Serial communication EIA-485
[.]
220 V DC SYSTEM
[The 220 V DC system covered in TG package will be provided with 2 x100%
battery with Battery Charger. This 220 V DC system will comprise of DC load
requirement of Boiler, TG package and other mechanical system packages
except CHS, Intake Water System. The design parameters of the 220 V DC
system comprising of Battery and Battery Charger are furnished below:
Description
Units
Design Parameters
Make/Manufacturer
[.........]
DC System Voltage
[220V.]
Battery Type
AH Rating/Rated Capacity
AH
Number of cells
End Cell Voltage
Expected fault level at bus due to

battery
kVA
AH Efficiency at Rated load
BATTERY
BATTERY CHARGER
Make/Manufacturer
Document Number
LII-GETS12021-G-00129-002
[.........]
Rev
No.
Description
Page
No.
Date of Issue
03

[74]
15.01.2016
Power Plant]
Description
Units
Design Parameters
Type of Battery Charger
[Float & boost/Float cum

Boost.........]
Battery Charger Rating
Amp
AC Input Voltage , Phase ,

Frequency
V,Hz
Short Circuit Level
kA/Sec
Efficiency of Charger
Guaranteed Efficiency
a) At 50% load
b)At rated load
Power Factor
a) At 50% load
b)At rated load
Description
M)
[Logo of Utility]
Units
Design Parameters
HV CABLES
[The HV cables of 6.6kV UE Voltage grade is used for feeding HV motors as well
as LV Transformers and feeding other mechanical packages like CHS , AHS,
HVAC , Water system etc. The design parameters of the HV Cables are
furnished below:]
Description
Units
Design Parameters
Make/Manufacturer
[.........]
Voltage Grade
[.........]
Nominal Power System Voltage
kV
[.........]
Maximum System Voltage
kV
[.........]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[75]
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Power Plant]
Description
G)
Units
[Logo of Utility]
Design Parameters
[.........]
No. of Cores
[.........]
Conductor Material
[.........]
Conductor (stranded/solid)
[.........]
Conductor Screen
[.........]
Insulation
[.........]
Insulation Screen
[.........]
Inner Sheath
[.........]
Outer Sheath
[.........]
Armoured/Unarmoured
[.........]
[.........]
Type of End Sealing
[.........]
LV CABLES
[The LV cables of 1.1kV Voltage grade are used for feeding LV motors as well as
for sub distribution system boards. The design parameters of the LV Cables are
furnished below:]
Description
Units
Design Parameters
Make/Manufacturer
[.........]
Voltage Grade
[.........]
kV
[.........]
kV
[.........]
[.........]
No. of Cores
[.........]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[76]
15.01.2016
Power Plant]
Description
N)
Units
[Logo of Utility]
Design Parameters
Conductor Material
[.........]
[.........]
Conductor Screen
[.........]
Insulation
[.........]
Insulation Screen
[.........]
Inner Sheath
[.........]
Outer Sheath
[.........]
Armoured/Unarmoured
[.........]
[.........]
Type of End Sealing
[.........]
CONTROL (CORE) CABLES

[The Control cables of 1.1kV Voltage grade are used for Protection, CT, VT
connection and feedback/interlock signals. The design parameters of the LV
Cables are furnished below:]
Description
Units
Design Parameters
Make/Manufacturer
[.........]
Voltage Grade
[.........]
kV
[.........]
kV
[.........]
[.........]
No. of Cores
[.........]
Conductor Material
[.........]
[.........]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[77]
15.01.2016
Power Plant]
Description
O)
Units
[Logo of Utility]
Design Parameters
Conductor Screen
[.........]
Insulation
[.........]
Insulation Screen
[.........]
Inner Sheath
[.........]
Outer Sheath
[.........]
Armoured/Unarmoured
[.........]
[.........]
Type of End Sealing
[.........]
ILLUMINATION SYSTEM
[The illumination system is categorized mainly as Normal, Emergency and DC
lighting. The illumination system requirement of TG area and its boundary,
perimeter and road lighting within TG area battery limit is covered in this
specification. Other areas like Boiler area, Balance of plant, Ash Handling Plant
and Coal Handling Plant are covered in respective package itself. Lighting
Distribution Board (LDB) is normally getting supply from 415V PMCC. Each LDB
is provided with lighting transformer for isolation of lighting circuit from power
circuit and also for limiting short time current rating. Outgoing circuits of LDB will
feed Lighting panels which is placed local to fixtures. It is envisaged that
separate LDB for indoor as well as for outdoor area will be provided. Emergency
Lighting system is same as normal system however it will get supply from
Emergency 415V PMCC backed up with DG set. The Design parameters of
Illumination System and its major components comprising of LDB with
transformer, Lighting Panel, Lighting Fixtures, Lighting wires and Lighting Poles
are furnished below]:
Description
Units
Design Parameters
Lighting System:
Voltage
a) AC system
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[78]
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Power Plant]
Description
Units
[Logo of Utility]
Design Parameters
Rated Voltage
[.........]
Maximum Voltage
[.........]
Rated Voltage
[.........]
Maximum Voltage
[.........]
[.........]
b) 220 V DC system

a) 415V AC
kA(rms)
[.........]
b) 220V DC
kA(DC)
[.........]
[.........]
a)LDB
[Floor.........]
b) LP
[.Wall........]
Installation
[.........](For each application

ie for Indoor/Outdoor and area )
Type, No of Circuits/Feeder rating
[.........]
Make of Transformer
[.........]
Type of Transformer
[Dry]
Rating
kVA
[.........]
Voltage Ratio
[.........]
LDB/LP:
Manufacturer Name
Mounting
Lighting Transformer:
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[79]
15.01.2016
Power Plant]
Description
Units
Impedance
[Logo of Utility]
Design Parameters
[.........]
Make
[.........]
Voltage Grade
[.........]
Conductor Material
Cu/Al
[.........]
Size
Sq.mm
[.........]
Make
[.........]
Type of Luminaries
[.........]
Ballast Type
[.........]
Make
[.........]
Type of Poles
[.........]
Lighting Wires:
Lighting Fixtures:
Lighting Poles:
P)

[The Cable Carrier system is described as below: Indoor Buildings are provided
with Cable cellar/Trench and outdoor areas are provided with Pipe cum cable
rack/Duct bank/Trench. Separate Tray is envisaged for HV cables. LV cables,
Control cables and Instrumentation cables in the order that HV cables Tray at the
top followed by LV, Control and Instrumentation Tray. Ladder type tray is used
for HV, LV and Control cables, however Perforated Tray to be used for
Instrumentation cables. The Cable carrier system other than TG area battery limit
is covered in respective packages. The Design parameters of Cable Carrier
System are furnished below]:
Description
Units
Design Parameters
Make/Manufacturer
[.........]
Size of Tray
mm
[.........]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[80]
15.01.2016
Power Plant]
Description
Units
Material
[Logo of Utility]
Design Parameters
[.........]
[.........] (I.e.
HV/LV/Control/Inst.)
[.........]
(i.e.Ladder/Perforated)
Thickness of Tray
mm
[.........]
mm
[.........]
Tray Cover Size
mm
[.........]
Tee
mm
[.........] {List out all size}
Cross
mm
Bends
Deg
mm
[.........] to [.........]{List out

all size}
a) ISMC
mm
b) ISA
mm
Application
Type of Tray
Reducer
Steel Supports
Q)
EARTHING AND LIGHTNING PROTECTION SYSTEM

[The Earthing & Lightning System of TG package is described as below: In this
specification above ground earthing and lightning protection system is covered in
bidders scope of work. Connection to main earth grid riser and electrode is
covered in other packages. The Design parameters of Earthing and Lightning
Protection System are furnished below]:
Description
Document Number
LII-GETS12021-G-00129-002
Units
Design Parameters
Rev
No.
Description
Page
No.
Date of Issue
03

[81]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
[.........]
a) Material
[.........]
b) Dia
[.........]
Earthing System:
Make/Manufacturer
Main Earthing Conductor
Treated Earth Pit/Earth Rod(Dia and

Length)
mm & m
[.........]
Size of Earth Conductor
[.........]{List out size of Flat

Earth conductor used for
different equipments of Power
plant and no of points }
a) 6.6kV Switchgear
b) 415 V Switchgear
c) HV Motors
d) LV Motors {List out
rating wise}
KW
mm x mm
e) Control panel, LPBS Etc.

f)
Transformer Body
g) Transformer Neutral List out

Transformer wise}
h) Any other panel/Equipments
Lightning System:
Air Termination Rod
a) Dia & Length
[.........]
b) Material
[.........]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[82]
15.01.2016
Power Plant]
Description
[Logo of Utility]
Units
Design Parameters
a) Material
[.........]
b) Size
[.........]
a) Material
[.........]
b) Dimension(Length and Dia)
[.........]
Down comer
Lightning Electrode with test link
3.2.3

[The existing control and instrumentation system generally is an old analogue
based system and requires large scale replacement owing to obsolescence of
the existing equipment. Integrated microprocessor based closed loop control,
open loop control, sequential control and bulk data acquisition system for TG &
auxiliaries, station C&I including auxiliaries in hierarchical levels and integrated
unit monitoring and station monitoring systems in the upper level are therefore to
be envisaged for the plant. DCS & other common system/items, if applicable and
procured by Owner separately shall not be considered under TG package.]
3.2.4
Civil Works
Bidder shall go through the details of the existing Buildings / Structures /
Foundations / Facilities mentioned hereunder (but not limited to) for the thorough
understanding of conditions of the same. In order to assess the quantum of Civil /
Structural / Architectural R&M work within the package, Bidder shall also carry
out a brief or detailed survey (as required) of the site to acknowledge and obtain
any other information/data about present conditions at site and identification of
modification requirements in any other structure or foundation not included here.
Conditional details of important buildings / structures / foundations / facilities
which require major modifications have been described below:
{Details of the existing buildings / structures and their foundations in the Turbine
Generator area like TG Building, deaerator bay, bunker bay, condenser pit,
Document Number
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Rev
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Date of Issue
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Power Plant]
[Logo of Utility]
central control building, DG building, A/C plant building, TG foundations, BFP

foundation etc. shall be indicated in this section. Also the available
GA/Construction Drawing including Load Data shall also be provided.}
Turbine Generator Area
[..x200 MW units have been placed side by side. Centre to centre placing of units
is [. m.] The railway entry has been provided from the rear side of Power
House Building. Turbine Generator (TG) Sets have been placed between AB
rows of columns are laid out longitudinally. The TG bay, also houses, the Boiler
Feed Pumps, Regenerative Heaters, Lube Oil System and other TG accessories.
The total length of TG bay for x210 MW units is [. m] and width [. m]. The
spacing of the column is at [.. m]. TG bay is provided with Nos. of overhead
EOT Cranes. In order to make the handling facilities of the cranes available to
the heat exchangers, boiler feed pumps and other equipment, removable
chequered plates have been provided at appropriate locations.
suitably connected and provided with a common sump for drainage purposes.
Three stairs for approaching the operating floor level at [+.. m] have been
provided in this bay adjacent to B row columns. In addition, there are stairs for
providing access to various equipment at intermediate platforms and sub zero
pits.
Switchgear and Control Room bay has been provided in the BC bay which is [.
m] wide. The length of the bay is [.. m]. A common Control Room for all the
three units is provided at [.. m] floor. In BC bay at [ m] elevation, equipment
for chemical dosing, air handling and MCC for soot blowers etc have been
located. The deaerator is placed at an elevation of [. m]. Air washer units and
cooling water tanks are also located at [.. m] floor.
Mill Bunker Bay, designated as CD bay, has a span of [. m] which
vertical mills at Zero m and has space for collection of disposal of mill rejects at
sub zero levels adjacent to D row. A stair to connect operating floor at [.. & .
m] of BC & CD bay has been provided.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
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Power Plant]
[Logo of Utility]
SCOPE OF SUPPLY & SERVICES
4.1
The scope of supply and services to be provided by the Bidder shall include all
such activities as required to meet the target and intent of this Specification. The
scope for each unit shall generally cover, but will not be limited to the following:
(i)
Replacement of some of the existing components with new components of

improved and better design.
(ii)
Incorporation of new systems / components wherever required in line with the

Specification.
(iii)
Refurbishing / Retrofitting of some of the components in the existing

equipment/system.
(iv)
Modification of layouts, wherever requires for Replacement/ Refurbishing /

Retrofitting of new Equipment/Components.
All types of civil/structural works like modification and strengthening of foundation
of existing and upgraded equipment, making new structures or foundations (if
applicable), dismantling, restoration, supply and erection of any temporary
supports or any other construction work required for implementation of
renovation work.
All structural modifications/strengthening of existing structure of building , Turbo
Generator, Condenser, Deaerator, Boiler Feed Pump, Condensate Extraction
Pump, Heaters, modification of pipe supports etc. including supply, fabrication
and erection of any new structure and provision of any additional platform if
required for access to new equipment or existing equipment as specified.
Supply of all materials, equipments, machinery and manpower required for
civil/structural R&M works.
Site enabling works as per the requirements to support civil/structural R&M
works.
(v)
Design, engineering, submission of design calculations for review and approval,

manufacturing, inspection and testing at suppliers works, packing, forwarding to
site, unloading, erection, supervision, pre-commissioning, testing and
commissioning and performance testing of the equipment / system and works
indicated in clause No. 4.6 of this technical Specification.
(vi)
Mandatory spares, start-up and commissioning spares. The general

requirements in respect of various types of spares are given in Clause 9 of this
section of Technical Specification.
(vii)
Packing, transportation and transit insurance of all materials required for

renovation / replacement work as per this Specification from the supplier's/sub
supplier's works to [Name of the Plant], unloading, preservation and storage at
site. Packing, transportation, transit insurance, clearance from all concerned
agencies etc. of all components/materials required to be forwarded from [Name
of the Plant] to Bidder's facilities and back to [Name of the Plant].
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
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Power Plant]
[Logo of Utility]
(viii)
Dismantling of the systems, handling and storage of dismantled equipment,

reassembly and re-erection / reinstallation along with associated inspection,
testing, commissioning and trial run of equipment individually as well integrated
with the overall plant trial operation.
(ix)
Materials which are removed from the existing machines but are not re-used
during the re-assembly of the machines as well as those components which are
found to be beyond refurbishment shall be the property of Owner and shall be
deposited at Owner's designated stores. Bidder shall prepare a record of all such
dismantled material and hand it over to the Owner.
(x)
Loading, transportation, unloading and disposal of scrap to the designated

storage/disposal yard.
(xi)
It shall be responsibility of the Bidder to obtain on behalf of the Owner the

necessary approvals of Inspection Authority / Chief Inspector as may be required
for design and design calculations, manufacturing, erection procedure repairing /
servicing and renovation. Bidder shall also be responsible for obtaining approval
from the other statutory authorities in India, as may be required, for other plants
and systems supplied by him. All such documentation submitted to statutory
authorities shall also be submitted to the Owner for his review.
Handling of materials at site including handling / transportation as required to
take equipment components to the workshop for carrying out the modification
work and to bring it back for installation. All arrangement for such activities is to
be done by the Bidder.
(xii)
Erection of all material supplied new for renovation (including erection of

components, replacing old components). Re-erection of any component /
equipment removed for modification so as to make complete unit consisting of
Turbo Generator and related auxiliaries including electrical & control and
instrumentation equipment /system ready for commissioning.
(xiii)
All gas cutting / dismantling, edge preparation, welding, bolting etc. and
conductance of all NDTs like radiography, ultrasonic testing, MPI, die penetration
testing etc. Any new matching pieces, piping, hangers & supports etc. required
for assembly of equipment/ systems, as per system requirements shall also be
included in the scope of the Bidder.
(xiv)
All Pre-commissioning activities as may be required such as hydraulic testing, air

& gas tightness test, steam blowing, floating of safety valves, oil flushing etc.
including erection and dismantling of all temporary systems like piping / tanks
etc. and Conductance of all demonstration tests including performance test.
(xv)
Assisting and coordinating with Owner in tuning various control loops finalizing
protection and control requirements of all Turbo Generator & auxiliaries.
(xvi)
Insurance for all items / activities in line with the provisions of General Condition
of Contract as specified in Volume-I of this Technical Specification.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
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Power Plant]
[Logo of Utility]
(xvii)
Civil / Mechanical work (such as grouting, cutting, welding etc.) related to

mounting of New Cabinets, CRT / Keyboards, laying & termination of associated
Cables.
(xviii)
Supply of all necessary tools, tackles, commissioning spares, test instruments

and deputing of experienced personnel for completion of the above erection,
testing and commissioning work.
(xix)
Dismantling of existing C&I cabinets along with associated cabling, for Turbo
Generator & Auxiliaries related to the unit for retrofitting the new C&I systems,
based on requirement as described in clause No. 4.6.
(xx)
Providing all site execution and supervision by qualified and experienced

engineering personnel during execution of all works under the scope of Bidder.
Also providing all facilities and qualified personnel for implementing the approved
quality assurance programme.
(xxi)
Dismantling of the existing Instrumentation Cables and relaying of new cables as

may be required.
(xxii)
The Bidder shall conduct all shop and site tests as per the requirements of this
specification and Owner approved "Quality Assurance Program" to be finalised
before the award of this Contract. Facilitating inspection, witness of shop and site
tests by the representatives of Owner shall be in the scope of the Bidder.
(xxiii)
Performance Guarantee tests after successful completion of initial operation.
(xxiv)
Construction Water
[Construction water shall be made available to Bidder at a single point in a
suitable location. The Bidder shall arrange at his own cost the required pumps,
distribution pipe line network for further distribution as required to carry out
construction work.]
(xxv)
Construction Power
[Construction power shall be made available to bidder at single point at [.] kV
level. Further distribution as required to carry out the construction work shall be
carried out by Bidder at his own cost.]
(xxvi)
4.2
Providing all other services necessary for meeting the intent and requirement of
this Specification. This shall include but not limited to system engineering,
furnishing drawings, data, information for owner's review, participation in meeting
& reviews, System warranty, revision of O&M Manuals etc.
Tools & Tackles
One (1) set of special tools and tackles required for the maintenance of
equipment/systems have to be supplied by the Bidder. These tools and tackles
shall be separately packed and brought to site. These shall not be used for
erection/commissioning purposes and shall be in an unused and new condition,
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
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Date of Issue
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Power Plant]
[Logo of Utility]
when they are handed over to the Owner. A list of all such special tools and
tackles shall be submitted along with the offer.
For C&I system, Bidder shall supply one set for each unit of special non standard
tools, module testing kit, cables, and any other equipment required for erection
commissioning, testing, trouble shooting, calibration, maintenance and inspection
of all systems / equipment provided. Any tools required to make changes (DIP
shunt cutter, soldering irons, tips, wire wrap guns and bit unwrapping tools,
strippers, terminal guard, connector repair tool, dies etc.) shall also be supplied.
Bidder's scope shall also include supply of all Cranes, welding sets and NDT
testing equipment, scaffolding, special tools and tackles, jigs and fixtures as may
be required during modification / erection and commissioning. Those items
specifically brought to site solely for erection / modification purpose and if no
more needed for regular maintenance of the equipment, can however, be taken
back by the Bidder after completion of the work at site, subject to the approval of
Owner.
4.3
Safety
4.3.1
The design of the equipment shall incorporate every reasonable precaution and
provision for the safety of all personnel and for the safety and security of all
persons and property. The design shall comply with all appropriate statutory
regulations relating to safety.
Newly constructed structures and equipment shall be designed and constructed
to withstand every foreseeable static and dynamic loading condition, including
loading under earthquake conditions, with an adequate margin of safety.
Ready and safe access with clear head room shall be provided to all the newly
supplied parts of the plant for operation, inspection, cleaning and maintenance.
4.3.2
While carrying out the R&M work as per this Specification, the Bidder may have
to modify the existing equipment foundations, or do the excavation work and
make new foundations. The Bidder may also have to make new supporting
arrangements with / without modified loads for the items/ equipment supplied by
him. Under all such conditions Bidder shall be solely responsible for ensuring the
safety of the adjacent equipment / foundations and of the existing supporting
structures. The R&M work by the Bidder shall be carried out in such a manner
that no damage is caused to existing equipment / foundations / structure and all
precautions, including strengthening of existing structures, as may be necessary,
shall be taken by the Bidder to ensure safety of existing plant / equipment /
foundation / structures.
4.4
Training Requirements
Bidder shall include in his offer the training programme for Owner's Operation &
Maintenance staff in view of introduction of new systems/ equipment. This
training shall be organized before handing over the unit.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
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Power Plant]
[Logo of Utility]
4.5
In case there is any difference in scope of work and services as described in this
section of the Specifications and individual Specification volumes, then more
stringent of the Scope of work and services shall prevail.
4.6
Detail Scope of Work:
4.6.1
Steam Turbine & Its Auxiliary System

{Describe in this chapter, all the equipment/components which need to be
replaced/refurbished/retrofitted as finalized in the DPR on the basis of RLA/CA
and EA report. Scope with regard to Civil, structural and architectural work as
required for the Power Plant due to incorporation of new equipment/components
shall also be incorporated in this chapter.}
The Bidder shall include in his scope the following works for the R&M of the Unit,
which are based on RLA/CA and EA studies. The overall scope of work shall
include but shall not be limited to the scope of work mentioned below in Table
4.1. Any other items not specifically mentioned but considered necessary by the
Bidder for carrying out the R&M work, shall also be included in his scope so as to
meet the intended performance of Turbo Generator & Auxiliaries as specified in
Clause No. 1.1
TABLE: 4.1
Equipment
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Steam Turbine]
[LP Turbine Retrofit]
[HP Turbine Retrofit]
[IP Turbine Retrofit]
[Turbine Governing
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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Power Plant]
Equipment
System]
[Emergency Stop Valve

Assemblies]
[IP Stop Valve

Assemblies]
[Main Steam Control

Valve Assemblies]
[Reheat Steam Control

Valve Assemblies]
[Bearing & Pedestals]
[Lube Oil System]
[Control Oil System]
Document Number
LII-GETS12021-G-00129-002
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page
No.
Date of Issue
03

[90]
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Power Plant]
Equipment
[Seal Oil System]
[Turbine Gland Steam

Sealing System]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Condenser]
[Condenser Tubes]
[Any Other Component

of Condenser]
[Condenser On load
Tube Cleaning System]
[Condenser Air Evacuation System]

[Starting Ejector]
[Main Ejector]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[91]
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Power Plant]
Equipment
[Vacuum Pump, If
Applicable]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Other Cycle Equipment]

[Condensate Extraction
Pumps]
[Deaerator]
[Boiler Feed Pumps]
[LP Heaters]
[HP Heaters]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[92]
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Power Plant]
Equipment
[HP Turbine Bypass

Valve]
[LP Turbine Bypass

Valve]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[DMCW System, As
Applicable]
[Plate Type Heat

Exchanger (PHE)]
[HP & LP Piping]

Tag
No.
Description
Fluid
Size
Schedule /
Thickness
Class
Material
Qty
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[Motorized Valves]
Tag
Service
Document Number
LII-GETS12021-G-00129-002
Size/
Class
End
Travel
Drg. No.
Qty
Rev
No.
Description
Page
No.
Date of Issue
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[93]
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Power Plant]
Equipment
No.
Scope of Work
Description
Type
Conn.
[Logo of Utility]
Quantity
time
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Material
Drg. No.
[Manually Operated Valves]

Tag
No.
Service
Description
Size/
Type
Class
End
Conn.
Qty
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Material
Drg. No.
[Non Return Valves]

Tag
No.
Service
Description
Size/
Type
Class
End
Conn.
Qty
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
Material
Drg. No.
Qty
[Relief Valve]
Tag
No.
Service
Description
Size/
Type
Class
End
Conn.
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[Electric Actuator for Valve]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[94]
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Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
Tag
No.
Description & Service
Torque (Nm)
Wattage (W)
Qty
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[...]
[Control Valve]
[Insulation &
Cladding]
[Replacement and
Retrofitting of Pipe
Hangers]
[Equipment Cooling
Water System]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Electrical System
[Generator and accessories]
[Generator Stator]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[95]
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Power Plant]
Equipment
[Generator Rotor]
[Generator Cooling
Water System]
[Hydrogen Coolers]
[Excitation system]
[Neutral Grounding
cubicle]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Generator Protection and Metering Panel]

[Relays]
Document Number
LII-GETS12021-G-00129-002
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page
No.
Date of Issue
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Power Plant]
Equipment
[Meters]
[Any other
components]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Isolated phase bus duct]

[Conductor &
Enclosure]
[Bellow]
[Insulator]
[Seal off Bushing]
[Any other
components]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[97]
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Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[6.6 kV Segregated Phase Bus Duct ]

[Conductor &
Enclosure]
[Insulator]
[Insulator]
[Seal off bushing]
[Any other
components]
[415 V NSPBD]
[..]
[6.6kV Switchgear ]
[Breaker]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[98]
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Power Plant]
Equipment
[Relays]
[Meters]
[CT and VT]
[Any other
components]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[415 V Switchgear (PMCC/MCC)]

[Breaker]
[MCCB]
[Relays]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[99]
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Power Plant]
Equipment
[Meters]
[CT & VT]
[Any other Equipment]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[HV motors]
[..]
[LV motors]
[..]
[Motorized Actuators]
[..]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[100]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Variable Frequency drive]

[..]
[LV Transformers(oil/dry type]

[..]
[220 V DC System]
[Battery Charger]
[Battery]
[220V DCDB]
[HV Cables]
[..]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[101]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Lighting Panel]
[..]
[..]
[Lighting Poles]
[..]
[..]
[..]
[..]
[Lighting Fixtures]
[..]
[..]
[Wires, Conduits,
[..]
[..]
[LV Cables]
[..]
[Control Cables]
[..]
[Illumination system]
[LDB with Lighting
Transformer]
[Lighting Panel]
[LDB with Lighting
Transformer]
[Lighting Fixtures]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[102]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
Junction box]
[..]
[..]
[Lighting Poles]
[..]
[..]
[MCCB/MCB/ELCB]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[MCCB/MCB/ELCB]
[..]
[..]
[Cable Carrier System]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Wires, Conduits,
Junction box]
[Any other equipment]
[Cable Tray]
[Accessories like Tee, Cross, Couplers, Bends etc.]

[Cable Tray]
[..]
[..]
[Structural members
like ISMC/ISA etc.]
[..]
[..]
[..]
[..]
[Accessories like Tee,

Cross, Couplers,
Bends etc.]
[..]
[..]
[..]
[..]
[Any other
Equipment]
[..]
[..]
[Structural members
[..]
[..]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[103]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
like ISMC/ISA etc.]
[..]
[..]
[Earthing & Lightning

Protection System]
[..]
[..]
[Earthing Conductor]
[..]
[..]
[..]
[..]
[..]
[..]
[Earthing Conductor]
[..]
[..]
[Air Termination Rod]
[..]
[..]
[..]
[..]
[Earth
Electrode(Rod/Treated
]
[..]
[..]
[..]
[..]
[Down Conductor]
[..]
[..]
[Air Termination Rod]
[..]
[..]
[Any other
Equipment]
[..]
[..]
[..]
[..]
[Down Conductor]
[..]
[..]
[Generator and
accessories]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[Earth Electrode(Rod/Treated]
[Generator Stator]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[104]
15.01.2016
Power Plant]
Equipment
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Control and Instrumentation System

[Turbine Protection]
[Turbine Controls
EHC]
[Turbine ATRS]
[Turbine Supervisory
System]
[Automatic Turbine
Testing]
[Turbine Stress
Evaluator ( TSE)]
[Gland Steam
Pressure Control]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[105]
15.01.2016
Power Plant]
Equipment
[BFP Scoop Control]
[Deaerator level
Control]
[Deaerator Pressure
Control]
[Hot well level Control]
[HP Heaters Level

Control]
[LP heaters Level

Control]
[BFP Recirculation
valve]
[Feed Water Control

Document Number
LII-GETS12021-G-00129-002
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page
No.
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[106]
15.01.2016
Power Plant]
Equipment
Valve]
[Hydrogen Purity
Measurement]
[Hydrogen Leak
Detector]
[Generator
Instrumentation]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Station C&I (if applicable)

[DCS]
[Station LAN]
[Master Clock]
[Panel Earthing /
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[107]
15.01.2016
Power Plant]
Equipment
Grounding]
[PLC System]
[Dosing System
Instrumentation]
[COLTCS]
[CMMS]
[STMS]
[SWAS]
[Machine Condition
Monitoring System]
Document Number
LII-GETS12021-G-00129-002
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page
No.
Date of Issue
03

[108]
15.01.2016
Power Plant]
Equipment
[Pressure / DP
Gauges]
[Temperature Gauges]
[Pressure / DP
Switches]
[Temperature
Switches]
[RTD / TC s]
[Level
Transmitters(DP Type,
Displacer, Radar]
[Flow Elements
(Nozzle/Orifice)]
Document Number
LII-GETS12021-G-00129-002
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page
No.
Date of Issue
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[109]
15.01.2016
Power Plant]
Equipment
[Pressure &
Transmitters]
[Control Valves]
[ Impulse Pipeline &

Instrument fittings]
[Instrumentation &
Control Cabling]
[Junction boxes/LIRs]
[Time Synchronization
System]
[Any other systems]
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Civil & Structural Work

Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
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[110]
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Power Plant]
Equipment
[Turbo Generator
Foundation]
[CEP Foundation]
[BFP foundation]
[Heater Foundation]
[TG Building including

Deaerator and bunker
bay]
[Central Control
Building]
[DG Building]
[Any Other Civil &

Document Number
LII-GETS12021-G-00129-002
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
[..]
Rev
No.
Description
Page
No.
Date of Issue
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[111]
15.01.2016
Power Plant]
Equipment
Structural Work]
4.6.2
[Logo of Utility]
Scope of Work
Quantity
[..]
[..]
[..]
[..]
Miscellaneous
a.
In addition to the above listed works, scope of civil / structural / architectural

works and supplies shall be as detailed below.
Bidder shall be provided with the existing drawings and documents as listed in
Annexure-I by the Owner to facilitate the civil / structural / architectural ,
refurbishment and replacement works.
Bidder shall carry out a brief or detailed survey (as required) of the site to
acknowledge and obtain any other information/data about present conditions of
the buildings, structures, foundations & facilities mentioned in this specification
and identification of modification requirements in any other structure or
foundation not included here.
Subsequently Bidder shall prepare and submit for approval by Owner, a detailed
scheme including methods techniques, requirements etc. for carrying out
civil/structural/architectural R&M works to executed in the plant.
b.
The scope of Civil / Structural / Architectural works to be carried out by the

Bidder under this package shall generally cover the following:
Inspection, checking the design adequacy and foundation analysis of the

existing structure foundations like [turbine generator, boiler feed pump,
heaters, TG building, control building, DG building etc.] for all the applicable
loads and construction of new foundations / modification of existing, wherever
required.
Inspection and checking the design adequacy of existing structures [such as

TG building, control building, DG building, pipe & cable racks etc.] for any
corrosion/damage and rectification / strengthening of the same.
Carrying out all interior / exterior architectural modification and replacement

works [such as flooring, painting, plastering, door/windows, roof finishing,
water proofing, sheet cladding, roof sheeting, new false ceiling, glass
partitions, lighting works replacement or modification of AC duct where ever
applicable] is also included in contractors scope. etc.
Any other civil related work required in buildings / structures of the package
from aesthetics ambience & ease of operation point of view.
In addition to this any other modification/alteration to existing nearby

foundation/structural steel/concrete/underground pipes work if required for
satisfactory execution of intended work covered under this specification shall be
Document Number
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Rev
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[112]
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Power Plant]
[Logo of Utility]
carried out by the Bidder. Supply of all material required for the above work is
included in Bidders scope.
c.
Supplies for Civil/Structural Work

The Bidder shall supply all material needed for completion of all civil, structural
and architectural works as per this specification. The Bidder's scope of supply
generally includes but is not limited to the following:
d.
Supply of cement, steel (for reinforcement as well as for any other use),
grout, admixture for RCC work, sand and all other construction/architectural /
building materials as may be required for any repair/modification of existing
civil works / foundation or for construction of new foundation / civil works.
Supply of structural steel for all structural erection / modification /

strengthening.
Supply of all foundation bolts, and nuts base plates, embedments with lugs,
miscellaneous steel where ever needed
Supply of steel helical springs and viscous dampers for new equipment (if
any).
Construction Enabling Works

[The owner shall provide the following facilities to the by Bidder to carry out the
construction work.
e.
Temporary Stores to store construction material.
Fabrication Yard]
Quality Control Laboratory

[To conduct acceptance test on all construction material, weldments, concrete
cubes etc laboratory facilities if available in the existing unit shall be used. In
case the laboratory facility is not available within the unit, Bidder shall get the
testing at his own cost from a reputed test laboratory approved by the Owner.]
f.
Construction Tools & Materials Supplied By the Bidder. The Bidder shall arrange
adequate number and type of machinery and equipment for proper setting out
and timely completion of the various works covered under the scope of the work.
All arrangements for transporting the equipment to and from the site shall be
done by the Bidder at his own expense.
The Bidder shall provide all fuels and lubricants required for the operation and
maintenance of construction machinery and equipment as well as his transport
vehicles at his own cost.
g.
The Bidder shall furnish manufacturer's test certificate for all the manufactured
items supplied by him. Representative specimens of the material shall also be
submitted to the Owner and shall be tested at a recognised testing laboratory at
the Bidder's cost in case Owner so desire.
Document Number
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[113]
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Power Plant]
h.
[Logo of Utility]
Work Execution and Supervision:

The Bidder shall have at the site accredited and qualified engineers and foremen
/ supervisors with adequate number of years of experience in execution of similar
works and also operators of machinery and equipment, for satisfactory progress
and timely completion of the works.
i.
The Bidder shall be fully responsible for the correctness and accuracy of the
tests performed, results obtained / tabulated, interpretation of test results and
recommendations made. The work shall be executed in a professional manner
with full understanding of the importance of work for a R&M project of this
magnitude.
j.
In the event of occurrence of any accidents at / near the site of the work or in
connection with execution of the work, a report shall be made immediately to the
Owner, giving full details of the accident. He shall also report such accidents to
all the competent authorities wherever such reports are required by those
authorities.
k.
Owner reserves the right to order in writing, from time to time, during the
progress of the work, removal and re-execution of any work which in the opinion
of the Owner is not in accordance with the specification / bid document.
l.
During inclement weather, rain etc., the Bidder shall suspend all works for such
time as the Owner may direct and shall protect from damage all works already in
progress or completed just then. All such temporary protective measures shall be
at the Bidder's cost and any damage to works shall be made good by the Bidder
at his own expense.
m.
Safety of Adjacent Plant/Equipment and Civil Structure

While carrying out the R&M work as per this specification, the Bidder may have
to modify the existing equipment foundations, or do the excavation work and
make new foundations. The Bidder may also have to make new supporting
arrangements with / without modified loads for the items / equipments supplied
by him. Under all such conditions Bidder shall be solely responsible for ensuring
the safety of the adjacent equipments / foundations and of the existing supporting
structures. The R&M work by the Bidder shall be carried out in such a manner
that no damage is caused to existing equipments / foundations / structures and
all precautions, including strengthening of existing structures, as may be
necessary, shall be taken by the Bidder to ensure safety of existing plant /
equipment / foundation / structures.
4.6.3
Spares
All spares as specified in Annexure-II of this Specification in accordance with
Clause No. 9.
4.6.4
Consumable, Oil & Lubricants
Document Number
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Power Plant]
[Logo of Utility]
All the first fill and consumables such as greases, oil, lubricants, servo
fluids/control fluids, gases and essential chemicals etc. as required up to the
complete commissioning of the Turbo Generator & Auxiliaries, are covered in the
scope of Bidder. Suitable standard lubricants as available in India are preferable.
Efforts should be made to limit the variety of lubricants to minimum.
4.6.5
Embedded Parts & Fixture

All fixtures, embedded parts, steel embedment including fixing lugs and welding
between them, foundation plates, grouting, nuts, bolts etc. for fixing all the
equipment, piping on civil works shall be included in scope work of this package.
All structures which would be required by the Bidder for supporting the piping
shall also be included in scope of work of this package.
4.6.6
Other Services
The scope of Erection, Commissioning and Testing shall include the following:
a) Complete pre-commissioning work including tests of facilities such as line
flushing, hydraulic testing of various pressure parts, chemical cleaning, steam
blowing, etc. and all other tests as mutually agreed in the Bidders quality
assurance programme as well as those identified in the Specification.
b) Supply of all consumables (except coal and fuel oil for firing) like chemicals for
chemical cleaning, passivation, inhibition etc., oil for line flushing, nitrogen for
blanketing, consumables for air/gas tightness tests and any other consumable as
required for above pre-commissioning/ commissioning activities.
c) Necessary arrangement as requires for the start up of Turbo Generator &
Auxiliaries. However, Owner will arrange start up power, instrument & service air
and DM water as required for the star up purpose of the Turbo Generator &
Auxiliaries system.
d) Supply of all temporary equipment such as tanks, piping, including supports,
valves, nitrogen blanketing equipment including nitrogen cylinders, pumps and all
necessary instrumentation for successful conductance of pre-commissioning and
commissioning activities. All temporary equipment and instruments shall be
clearly listed out in the Bid.
e) Providing safety barricades and signage during dismantling, erection and testing
etc.
f)
Supply of all labour, skilled/semi skilled supervisors, engineers and any other
manpower.
g) All the erection materials and consumables like shims, welding rods, soldering
and brazing alloys, industrial gases insulating tapes, compounds, chemicals etc.
required for the erection and commissioning works.
Note: The temporary equipment specifically brought by the Bidder solely for the
pre-commissioning and commissioning work shall, on completion of these
activities, remain the property of the Bidder. Nitrogen blanketing equipment
Document Number
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[115]
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Power Plant]
[Logo of Utility]
including nitrogen cylinders shall get included in the Bidders permanent scope of
supply and become property of the Owner.
The selection of material of all the temporary equipment/instruments shall be
compatible with the service conditions expected during pre-commissioning/
commissioning activities.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
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No.
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[116]
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Power Plant]
TERMINAL POINTS & EXCLUSSIONS
5.1
Terminal Points
[Logo of Utility]
[For all terminal points, scope of this contract shall include supply of matching
flanges, gaskets, bolts, nuts etc and including any isolation valve. Terminal
Points mean Engineering, Procurement and Erection in entirety. The terminal
points of the complete package to be supplied shall be as follows.
(i)
Mechanical
(a)
(b)
(c)
(d)
(e)
Main Steam: Inlet of Main Steam Stop Valve at Turbine hall

Cold Reheat: Outlet of HP turbine
Hot Reheat: Inlet of Reheat Steam Stop Valve.
Feed Water: At Economiser Inlet
Turbine Bypass Piping: HP Turbine Bypass valve inlet & Outlet and LP turbine
bypass valve inlet & outlet.
Condenser Cooling Water System (CW system):
[CW Inlet Header near A row of TG Building at
: . Deg N, .. Deg E
CW Outlet Header near A row of TG Building at
: . Deg N, .. Deg E]
(f)
(g)
(h)
(i)
(j)
(k)
(ii)
Exact elevation of the pipe shall be furnished during detail engineering.

ACW System:
[ACW Inlet Header near A row of TG Building at
: . Deg N, .. Deg E
ACW Outlet Header near A row of TG Building at : . Deg N, .. Deg E]
DM water make up to Condensate Storage Tank:
[Bidder shall terminate the DM water lines at the inlet to the flow meter(s) to the
Condensate Storage Tanks (CSTs). at . Deg N, .. Deg E]
Service Water:
[One no. stub connection with isolation valve shall be provided on service water
supply header Near C row at 4m elevation for TG Building at .Deg N, .Deg E].
[Drinking Water
One no. Stub connection with isolation valve shall be provided on potable water
supply header near C row at 4m elevation for TG Building at . Deg N,.. Deg E].
[Compressed (Service & Instrument air System) Air System
Service Air Header near A row of TG Building at
: . Deg N, .. Deg
E
Instrument Air Header near A row of TG Building at : . Deg N, .. Deg E]
Electrical
The terminal points for the electrical equipment under TG package shall be as
below:
(a)
Isolated Phase Bus Duct: LV terminals of generator transformers and HV

terminals of Unit transformers. Termination of Bus duct on Unit Transformer is in
the scope of bidder.
Document Number
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Power Plant]
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
[Logo of Utility]
6.6 kV Segregated Phase Bus Duct: LV terminals of Unit transformers and

Station Transformers. Termination of Bus duct on Unit/Station Transformer is in
the scope of bidder.
6.6 kV Power Supply to SG Package: At the terminal of 6.6kV Unit Switchgears
for power supply to transformers and HV Motors of SG Package. All Power and
control cables up to terminals of 6.6 kV Unit Switchgears and termination is
included in the scope of SG package-1.
6.6 kV Power Supply to CW Pump Motors: At the terminal of 6.6 kV Unit
switchgears. All Power and control cables up to terminals and Termination at 6.6
kV Unit Switchgear are included in the scope of BOP package
6.6 kV Power Supply to BOP Package: At the terminal of 6.6 kV Station / Unit
switchgear for power supply to numerous load centers of BOP package and BOP
motor loads. All Power and control cables up to terminals of 6.6 kV Station / Unit
Switchgear and termination are included in the scope of BOP package
220 V DC Power Supply to SG Package: At the outgoing terminals of Unit DCDB.
Power Cables interconnection between Unit DCDB to the DCDB of SG package
and termination is included in scope of SG Package.
Power Supply to Boiler MCC, Boiler Valve MCC, Soot Blower MCC: Power
supply at 415V level at the outgoing terminals of 415 V Unit Switchgear / 415 V
Emergency PMCC. All cables from the above terminal points and termination are
included in the scope of SG package.
Power Supply to BOP MCCs: Power supply at 415V level at the outgoing
terminals of 415 V Unit Service Switchgear / 415 V Station Switchgear/ MCC/
415 V Emergency PMCC. All cables from the above terminal points and
Termination are included in the scope of BOP package.
Power Supply to Illumination System of SG area: Power supply at 415V level at
the outgoing terminals of 415 V Lighting Service Switchgear. All cables from the
above terminal points and Termination are included in the scope of SG package.
Power Supply to Welding System of SG area: Power supply at 415V level at the
outgoing terminals of 415 V Welding Service Switchgear. All cables from the
above terminal points are included in the scope of SG package.
Earthing and Lightning Protection System: All above Ground earthing is in the
scope of bidder. Terminal point is Riser at 300mm above FGL provided by
others. Connection to Equipments of TG package and to riser is in the scope of
bidder. Building with more than one floor, all the floor other than ground floor will
be provided with periphery earth conductor for connecting to equipment, and
intermediate floor will be connected by earth conductor at four corner of the
building is included in the scope of bidder. Terminal point for Lightning system is
bring the down conductor at 0.3m above FGL. Risers will be provided by others
at 300m above FGL Terminal point for connection to below ground is 0.3m above
FGL. Bidder Grounding for Steam Turbine Generator (TG) Island and including
Main Under Ground Grounding Grid for TG Island & transformer yard and
grounding connection to all equipment included in scope of TG package. Under
Ground Grounding Grid shall be connected to Grounding Grid of SG package at
least at four (4) points and nearby BOP Package at least at 2 points at each side.
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(l)
For the inputs required by TG package contractor from other packages, the
required auxiliary relays, control cables including their laying & termination shall
be in the scope of other package contractor. Similarly, necessary contacts
required by other package contractors shall be provided by this package bidder.
.
(iii)
(a)
Inst. & Control Cabling: Up to ATRS/ATT/ Turbine protection/ TSI panel for TG
integral control systems and for rest upto DDCMIS Panels Terminal Block.
Field Instruments: Up to Economiser Inlet and Boiler steam lines (MS, CRH &
HRH)
(b)
5.2
Exclusions
(a)
Boiler & Its Auxiliary Equipment including Coal Mills, Coal Feeders, Primary Air
fans, Forced Draft fans, Induced Draft fans, Electro Static Precipitator, Main stem
piping, Cold reheat piping, Hot reheat piping, Auxiliary Steam System
(b)
HP/LP turbine Bypass piping: Entire upstream and downstream steam piping of
HPTB Valve. Entire upstream and downstream steam piping of LPTB Valve.
(c)
Plant Water System including DM plant. However; CW, ACW, DM water, potable
water & service water piping, valves, fittings etc. within terminal point is under the
scope of Bidder.
(d)
(e)
Compressed Air System, However; service and instrument air piping, valves,
fittings etc. within terminal point is under the scope of Bidder.
(f)
400kV and 220kV switchyard.
(g)
Generator Transformer (GT).
(h)
Unit Transformer (UT).
(i)
Station Transformer (ST).
(j)
Boiler and BOP switchgear, cables, interconnection and other system.
(k)
Interplant earthing, cabling and lighting system work.
(l)
Plant communication system.
(m)
Any other equipment/system which not in battery limit of TG package.
(n)
Boiler Integral Controls]
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GENERAL TECHNICAL REQUIREMENTS
6.1
Codes & Standards
6.1.1
Apart from some specific application, the proposed R&M equipment shall comply
with the appropriate Indian Standard / DIN or equivalent international Standard.
Specification as listed below in this section and mentioned in detailed
Specifications, each incorporating the latest revisions at the time of tendering.
6.1.2
Wherever specified or required the Plant & Equipment shall conform to various
statutory regulations such as Indian Boiler Regulations, Indian Electricity Act /
Rules / Regulations, Factories Act, etc.
6.1.3
In the event of any conflict between the codes and standards referred above, and
the requirements of this Specification, the requirements, which are more
stringent, shall govern.
6.1.4
In case of any change of code, standards and regulations between the date of
purchase order and the date, the Bidder proceeds with manufacturing, the Owner
shall have the option to incorporate the changed requirements.
6.1.5
List of Reference Codes/Standard

a)
American Society of Mechanical Engineers (ASME).
b)
American National Standards Institute (ANSI).
c)
American Society for Testing and Materials (ASTM).
d)
American Institute of Steel Construction (AISC).
e)
American Welding Society (AWS).
f)
Architecture Institute of Japan (AIJ).
g)
Bureau of Indian Standards Institution (BIS).
h)
British Standards (BS)
i)
Central Board of Irrigation and Power (CBIP) Publications.
j)
Deutsches Institut fr Normung (DIN).
k)
Electricity Act 2003.
l)
Electric Power Research Institute (EPRI).
m)
Emission regulation of Central Pollution Control Board (CPCB)
n)
Federal Occupational Safety and Health Regulations (OSHA)
o)
Heat Exchanger Institute (HEI).
p)
Hydraulic Institute (HIS).
q)
Indian Electricity Rules.
r)
Indian Boiler Regulations (IBR).
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s)
Indian Explosives Act.
t)
Indian Factories Act.
u)
Institute of Electrical and Electronics Engineers (IEEE).
v)
International Electro-Technical Commission Publications.
w)
Instrument Society of America (ISA).
x)
International Organization for Standardization (ISO).
y)
International Electro-technical Commission (IEC).
z)
Japanese Standards (JIS).
aa)
Japanese Electro-technical Committee (JEC).
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bb) National Fire Protection Association (NFPA).

cc)
National Electrical Manufacturer's Association (NEMA).
dd) National Electric Code (NEC).

ee)
Power Test Code for Steam Turbines (PTC).
ff)
Pollution Control regulations of Dept. of Environment, Govt. of India
gg) Regulations of CEA

hh) Standards of Manufacturer's Standardization Society (MSS).
ii)
Stipulations made by Ministry of Environment & Forests and Climate Change

while issuing clearance to the Project
jj)
Stipulations made by State Pollution Control Board while issuing consent to the
Project
kk)
Tariff Advisory Committee (TAC) rules.
ll)
Tubular Exchanger Manufacturer's Association (TEMA).
mm) VDI Standards

6.2
Name Plates
6.2.1
Instruction plates, nameplates or labels shall be permanently attached to each

main and auxiliary item of plant in a conspicuous position. These plates shall be
engraved with the identifying name, type and manufacturers serial number,
together with the loading conditions under which the item of plant has been
designed to operate.
6.2.2
Items such as valves, which are subject to hand operation, shall be provided with
nameplates so constructed as to remain clearly legible throughout the life of the
plant giving due consideration to the difficult climatic conditions to be
encountered. Nameplates shall be securely mounted where they will not be
obscured in service by insulation, cladding, actuators or other equipment.
Direction of flow is also to be engraved.
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6.2.3
All trade nameplates and labels shall be in Bilingual language. All measurements
shall be in M.K.S. Units.
6.2.4
The size and location of nameplates shall be subject to Approval of the Owner.
6.3
Guards and Fences
6.3.1
Effective guards and fences must be provided to prevent injury to operators.
6.3.2
Mesh guards which allow visual inspection of equipment with the guard in place
are generally preferable. The guards shall be constructed of mesh attached to a
rigid framework of mild steel rod, tube, or angle and the whole galvanized to
prevent loss of strength by rusting or corrosion. The guards shall be designed to
facilitate removal and replacement during maintenance.
6.3.3
Guards for couplings and rotating shafts shall be in accordance with BS

5304-1975 or similar approved standard. All rotating shafts and parts of shafts
must be covered.
6.4
Operation, Maintenance & Availability
6.4.1
Equipment/works offered shall be designed for high availability, high reliability,

low maintenance and ease of operation & maintenance. The Bidder shall
specifically state the design features incorporated to achieve high degree of
reliability, availability, operability and ease of maintenance. He shall also furnish
details of availability records in plants stated in his experience list.
6.4.2
Wherever required platforms and walkways with access ladders having hand
rails shall be provided to facilitate operation and maintenance.
6.5
Materials
6.5.1
In selecting materials of construction of equipment, the Bidder shall pay particular

attention to the atmospheric conditions existing at the Site and the nature of
material/fluid handled. Wherever deviations are taken in respect of materials
specified, the reasons shall be spelt out clearly in the proposal.
All materials shall be new, and shall be of the quality most suited to the proposed
application.
6.5.2
As far as possible; materials shall be in accordance with Indian or international

standard Specifications. Where such standards are not available, sufficient
information shall be provided to allow the Owner to assess the suitability of the
material for the particular application.
All materials used shall have performed lengthy satisfactory service in similar or
more arduous conditions to those proposed by the Bidder.
6.5.3
All parts which could deteriorate or corrode under the influence of the
atmospheric, meteorological or soil conditions at the Site, or under the influence
of the working conditions shall be suitably and effectively protected so that such
deterioration or corrosion is a minimum over the life of the plant.
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6.6
Lubricants, Control Fluids and Chemical
6.6.1
Provision shall be made for suitable efficient lubrication where necessary to

ensure smooth operation free from undue wear.
6.6.2
Non ferrous capillary tubing shall be used throughout.
6.6.3
Oil baths shall be provided with filling and drain plugs, both of adequate size. An
approved means of oil indication including level switches and temperature
indication shall be provided.
6.6.4
Lubrication points shall be conveniently situated for maintenance purposes. It

must be possible to carry out lubrication from a gangway or landing and without
the removal of guarding or having to insert the hand into it. Where accessibility to
a bearing for oiling purposes would be difficult a method of remote lubrication
shall be fitted.
6.6.5
The Bidder shall provide a detailed and comprehensive Specification for all
lubricating oils, greases and control fluids required for the for Turbo Generator
and its Auxiliaries. A sufficient supply of these shall be provided by the Bidder for
initial commissioning, first fill and till handing over of the unit.
6.6.6
The Bidder shall supply a detailed schedule giving the lubricant testing, cleaning
and replacement procedures. All equipment and facilities necessary for the
testing, cleaning and changing of lubricants and control fluids shall be provided.
The Bidder shall endeavour to reduce the varieties and grades of required
lubricants, chemicals and control fluids to a minimum, matching them where
possible to those already in use in the generating station in order to simplify
procurement and minimise storage requirements. All lubricants, chemicals and
control fluids shall be of internationally recognised standards and shall be easily
obtainable from a large number of Indian suppliers. Bidder shall also indicate the
equivalent Indian Standard for the above for easy procurement in future.
6.6.7
No lubricant or control fluid shall have toxic or other harmful effects on personnel
or on the environment.
6.7
Plant Life and Modes of Operation
6.7.1
On completion of the R&M project, the plant/equipment and systems individually

and collectively shall be possible to operate continuously with routine
maintenance and overhauls for an economic service life of not less than [20/25
years] under the prevailing site conditions and for the type of duty intended.
6.7.2
After R&M of Turbo Generator and associated auxiliaries, the unit shall be able to
operate to its rated capacity continuously and there shall be no restriction of the
operation of the unit during Base Load, Peak Load & Cyclic Load operation.
6.7.3
The capability of the unit operations including Cold, Hot & Warm Startups shall
be in no way inferior to its original design capabilities. Accordingly, Bidder shall
indicate the operation capabilities in various regime of operation in his Bid.
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6.8
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Packaging & Marking

All the equipment shall be suitably protected, coated, covered or boxed and
crated to prevent damage or deterioration during transit, handling and storage at
site till the time of erection. While packing all the materials, the limitations from
the point of view of availability of railway wagon sizes in India should be taken
account of. The details of various wagons normally available with Indian
Railways for transportation of heavy equipment shall be considered by the
Bidder. The Bidder shall be responsible for all loss or damage during
transportation, handling and storage due to improper packing.
The identification marking indicating the name and address of the consignee
shall be clearly marked in indelible ink on two opposite sides and top of each of
the packages. In addition the Bidder shall include in the marking gross and net
weight, outer dimension and cubic measurement. Each package shall be
accompanied by a packing note (in weather proof paper) quoting specifically the
name of the Bidder, the number and date of Contract and names of the office
placing the Contract, nomenclature of contents and Bill of Material.
6.9
Protection
Equipment having antifriction or sleeve bearings shall be protected by weathertight enclosures. Coated surfaces shall be protected against impact, abrasion,
discoloration and other damages. Surfaces Paints which are damaged shall be
repainted.
Electrical and C&I equipment shall be protected against moisture and water
damages. All external gasket surfaces and flange faces, couplings, rotating
equipment shafts, bearings and like items shall be thoroughly cleaned and
coated with rust preventive compound as specified above and protected with
suitable wood, metal or other substantial type covering to ensure their full
protection. All exposed threaded parts shall be greased and protected with
metallic or other substantial type protectors.
All piping, tubing and conduit connections on equipment and other equipment
openings shall be closed with rough usage covers or plugs. Male threaded
openings shall be closed with rough usage covers or plugs. Female threaded
openings shall be closed with forged steel plugs. The closures shall be taped to
seal the interior of the equipment. Open ends of piping, tubing and conduit shall
be sealed and taped.
Returnable containers and special shipping devices shall be returned by the
manufacturer's field representative at the Bidder's expense.
6.10
Painting
6.10.1
General
All exposed metallic surfaces subject to corrosion shall be protected by shop
application of suitable coatings. Surfaces not easily accessible after shop
assembly shall be treated before-hand and protected for life of the equipment.
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Surfaces to be finish painted after installation shall be shop painted with at least
two (2) coats of primer. Steel surfaces, which are not to be painted, shall be
coated with suitable rust preventive compound subject to the approval of the
Owner.
All paints shall be used in accordance with the manufacturer's instructions. No
thinners or other substance shall be added to the coating material without the
approval of the Owner. The quality and vendor of the paints shall require
approval of the Owner.
All paints, when applied in a normal full coat, shall be free from runs, sags,
wrinkles, patchiness, brush marks or other defects.
All primers shall be well marked into the surface, particularly in areas where
pitting is evident, and the first priming coat shall be applied as soon as possible
after cleaning, within four hours maximum. If the drying interval between
successive coats, which should not exceed one week, has been so long as to
endanger the adhesion of the following coat, the paint already applied shall be
lightly rubbed down with fine abrasive paper before putting on the next coat.
Paint spraying on large surfaces shall not normally be done indoors, except with
the approval of the Owner. Spray guns shall not be used outdoors in windy
weather or near unprotected surfaces of a contrasting colour and under no
circumstances shall spray guns be used where spray may be carried into or onto
exposed electrical equipment.
Paint containers shall not be opened until required and the paint shall be
mechanically mixed thoroughly before use, and agitated occasionally during use.
Electrical equipment shall be shop finished with one or more coats of primer and
two coats of high-grade oil resistant enamel. The interior of all panels cabinets
and enclosures shall be finished with gloss white enamel.
The Bidder shall furnish sufficient touch up paint for one complete finish coat on
all exterior factory surfaces of each item of equipment. The touch up paint shall
be of the same type and colour as the factory applied paint and shall be carefully
packed to avoid damage during shipment. Complete painting instructions shall be
furnished.
Shop primer for steel and iron surfaces which will have a continuous operating
temperature below 35 C shall be selected by the Bidder, in accordance to the
relevant standard. Special high temperature primer shall be used on surface
exposed to operating temperature above 35 C.
The colour scheme shall be submitted during execution of Contract for approval
by the Owner.
6.10.2
Preparation
Oil and grease shall be removed from the surface by washing with a suitable
detergent, rinsing with clean water, and drying.
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Surfaces to be shot blasted shall be cleaned to Swedish Standard SA 2.5 or

equivalent, and all dust remaining after cleaning shall be removed.
The priming coat shall be applied without delay.
6.10.3
Damaged Paintwork
Any damaged paintwork shall be corrected / modified as follows:
6.10.4
a)
The damaged area, together with an area extending 25mm around its
boundary, shall be cleaned down to bare metal.
b)
A priming coat shall be immediately applied, followed by a full paint finish

equal to that originally applied and extending 50mm around the perimeter
of the original damage.
c)
The repainted surface shall present a smooth surface. This shall be

obtained by carefully chamfering the paint edges before and after priming.
Painting Systems
The requirements for the dry film thickness (DFT) of paint and the materials to be
used shall be as stated below, unless otherwise specified elsewhere in this
Specification.
a) Surfaces Subject to Weathering
Primer coat
35 micron DFT
Tie coat
35 micron DFT

b) Surfaces Inside Buildings
All surfaces shall have a minimum of Four coats of paint made up as follows:
Primer coat
35 micron DFT
Tie coat
35 micron DFT

The type and colour of primer & finish coat shall be selected by the Bidder after
approval by the Owner.
6.11
6.11.1
The plant & equipment under this R&M project shall be designed for installation
and operation in harmony with the surrounding environment and all measures of
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pollution control shall be ensured by the Bidder to restrict pollution from the liquid
effluent and stack emission within the limits as given below with due
consideration of Environment (Protection) Rules.
6.11.2
For Liquid Effluent

During construction activities, Bidder shall maintain the statuary compliance of
State Pollution Control Board and MoE&F in respect of pollution control and
environmental protection within and around plant boundary. Any specific
requirement of State Pollution Authorities over and above shall be maintained.
6.11.3
Noise Level Requirement

The plant & equipment under this R&M project will be designed, constructed and
provided with suitable acoustic measures to ensure the noise level criteria as per
the following stipulations of MoEF & State Pollution Control Board.
a) Maximum noise level shall not exceed 85 dB (A) when measured at 1.0 m away
from the noise emission source.
b)
Maximum noise level from its source within the premises shall not exceed 70 dB
(A) as per Environment (Protection) Rules 1986, Schedule-III, Àmbient Air
Quality Standards in respect of noise.
c)
Any statutory changes in stipulations regarding noise limitation that may occur in
future according to State Pollution Control Board or Central pollution Control
Board or Ministry of Environment & Forest regulation during tenure of the
contract, the Bidder shall comply with the updated/amended requirement.
An exception will be made for the plant at startup operations of other big
pressure reducing devices operating during emergency periods and for the safety
valves.
6.12
6.12.1
Inspection and Tests during Manufacture
6.12.1.1
The method and techniques to be used by the Bidder for the control of quality
during manufacture of all plant and equipment shall be agreed with the Owner
prior to the Award of Contract.
6.12.1.2
The Owners general requirements on quality control and shop tests is mentioned
in Section II of Volume-II.
6.12.1.3
Owner shall be informed for witnessing the shop tests of any item of the plant or
equipment for checking the compliance with the Specification requirement and or
related standards prior to leave place of manufacturing.
6.12.1.4
Advance notice shall be given to the Owner as agreed in the Contract, prior to
the stage of manufacture being reached, and the piece of plant must be held at
this stage until the Owner has inspected the piece, or has advised in writing that
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inspection is waived. If having consulted the Owner and given reasonable notice
in writing of the date on which the piece of plant will be available for inspection,
the Owner does not attend, the Bidder may proceed with manufacture having
forwarded to the Owner duly certified copies of his own inspection and test
results.
6.12.1.5
The Bidder shall forthwith forward to the Owner the Test Certificates in []
copies for approval.
6.12.1.6
Under no circumstances any repair or welding of castings be carried out without

the consent of the Owner. Proof of the effectiveness of each repair by
radiographic and/or other non destructive testing technique, shall be provided to
the Owner.
6.12.1.7
All the individual and assembled rotating parts shall be statically and dynamically
balanced in the works.
6.12.1.8
Where accurate alignment is necessary for component parts of machinery

normally assembled on site, the Bidder shall allow for trial assembly prior to
dispatch from place of manufacture.
6.12.1.9
All materials used for the manufacture of equipment covered under this
Specification shall be of tested quality. Relevant test certificates shall be made
available to the Owner. The certificates shall include tests for mechanical
properties and chemical analysis of representative material.
6.12.1.10
All pressure parts connected to pumping main shall be subjected to hydraulic

testing at a pressure of 150% of design pressure. The duration of the pressure
tests shall be sufficient, as approved by the Owner, to show any leakage paths
and to permit a thorough examination of the component whilst under pressure.
6.12.1.11
All necessary non destructive examinations shall be performed to meet the

applicable code requirements.
6.12.1.12
All welding procedures adopted for performing welding work shall be qualified in
accordance with the requirements of Section-IX of ASME code or IBR as
applicable. All welded joints for pressure parts shall be tested by liquid penetrant
examination according to the method outlined in ASME Boiler and Pressure
Vessel code. Radiography, magnetic particle examination magnuflux and
ultrasonic testing shall be employed wherever necessary/ recommended by the
applicable code. At least 10% of all major butt welding joints shall be radio
graphed. Payments in respect of IBR approvals including inspection shall be
made by Owner. Bidder scope shall be limited to preparation of all necessary
documents, coordination and follow up for above approvals.
6.12.1.13
The Bidder shall furnish the quality procedures to be adopted for assuring quality
from the receipt of material at site, during storage, erection, pre-commissioning to
tests on completion and commissioning of the complete system/equipment.
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6.12.2
Performance Tests at Site
6.12.2.1
The full requirements for testing the system shall be agreed between the Owner
and the Bidder prior to Award of Contract. The completely erected System shall
be tested by the Bidder on site under normal operating conditions. The Bidder
shall also ensure the correct performance of the System under abnormal
conditions, i.e. the correct working of the various emergency and safety devices,
interlocks, etc.
6.12.2.2
The Bidder shall provide complete details of his normal procedures for testing, for
the quality of erection and for the performance of the erected plant. These tests
shall include site pressure test on all erected pipe work to demonstrate the
quality of the piping and the adequacy of joints made at site.
6.12.2.3
For details of specific tests required on individual equipment refers to respective

section of this specification.
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LAYOUT CONSIDERATION
{Effort shall be made to keep the Layout of the newly equipped system /
packages under the R&M project unchanged to the extent possible with respect
to existing layout to avoid disturbance to the existing equipment & facilities for
which any modification/changes are not envisaged based on RLA/LA and EA
assessment. However a general guidelines, which needs to be followed, as
required, are given below :}
The broad salient features of the existing and expected layout arrangements of
various equipment in the main plant building housing the turbine generator and
its auxiliaries and Boiler area are given as hereunder:
7.1
The arrangement of the turbine- generator in the main plant building is of

[longitudinal type]. The boiler centre line is in the [same as that of TG condenser].
Unit pitching distance between centre lines of two boilers is [approximately
120m]. The column spacing of main plant building is [about 10 m].
7.2
[The conventional arrangement of AB, BC and CD longitudinal bays with D row

as first row of boiler columns is adopted with their respective widths of about
30m, 10m and 11m. The mill bunker building is about 12m wide].
7.3
[Two transverse bays at 0.0 m elevation equivalent to minimum area of .m2

has been provided for unloading and maintenance at one end of main plant
building].
7.4
[The location of control room (common for two units) is in BC bay at the operating
floor level. Adjoining the control room, there is a control tower which
accommodates control equipment room, AC plant room, battery room and UPS
for C&I system, cable vault etc. at its different floor levels].
7.5
The local pits/trenches in main plant building/ mill bunker bay building/ boiler/
ESP area is to be avoided as far as possible.
7.6
Clear walk ways of minimum 1.5 m width at all the levels shall be provided in the
main plant building. Adequate fire escape staircases shall be provided with fire
doors at each landing.
7.7
[Interconnecting walkways (minimum 2.0 m clear) shall be provided between

main plant building and boiler on either side of boiler at three elevations viz.
mezzanine, operating and deaerator floor levels].
7.8
[The layout arrangement of critical piping connecting the steam generator and
steam turbine shall be developed in such a way as to optimize the use of
materials and resulting in minimum pressure losses in the steam flow].
7.9
[In the TG building area, facility of crane/ chain pulley block/ monorail hoist etc.
will be provided, as required, along with provision of space for maintenance/
overhauling of equipment/components such as Turbo Generator, Boiler Feed
Pump, Condensate Extraction Pump, Motors, Heaters and Valves etc.]
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7.10
Trestles to be provided for routing of cables, pipes etc. shall have a clear height
of 8.0m at road crossings so as to clear the road spaces, approach to
maintenance bays of different equipment. A walkway with hand rails and toe
guards of 750mm (minimum) width shall be provided all along length of the
trestle for maintenance of cables and pipes. Ladders for approach to these
platforms shall be provided near roads, passage ways.
7.11
Floor drains shall be provided at all floors and drain discharge pipes shall be
properly sized taking into account the fire water sprinkler system wherever
provided.
7.12
Valves shall be located in accessible positions. All piping shall be routed at a

clear height of minimum 2.5 m from the nearest access level for clear man
movement. Best engineering practices shall be adopted for keeping the minimum
clear working space around equipment and clear headroom within main
structures and cable trays etc.
7.13
Fire water pipes in main plant area may be routed in trenches filled with sand and
covered with pre-cast RCC covers.
7.14
The safety requirements as per the Factories Act, Indian Electricity Rules and
other applicable codes/standards etc. shall be observed while developing the
layout.
7.15
The Existing layout details of the plant are indicated in the enclosed drawings as
per Annexure-I. However, the Bidder to suggest his own modified layout
arrangement which shall be subject to approval of the purchaser.
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PERFORMANCE GUARANTEES
The term "Performance Guarantees" wherever appears in this Section shall have
the same meaning and shall be synonymous to "Functional Guarantees".
Similarly the term "Performance Tests" wherever appears in this Section shall
have the same meaning and shall be synonymous to "Guarantee Test(s)".
The term BMCR (Boiler Maximum Continuous Rating) appearing in the
Technical Specification shall mean the maximum continuous steam output at
super heater outlet of Boiler at rated parameters.
The term "TMCR" (Turbine maximum continuous rating) appearing in the
Technical Specification shall mean [210/215/220/250] MW electrical power
output at generator terminals under [3%] cycle make-up and [76] mm Hg (abs)
condenser pressure, unless used in conjunction with a different cycle make-up.
8.1
8.1.1
The Bidder shall guarantee that the equipment offered shall meet the ratings and
performance requirements stipulated for various equipment covered in this
technical Specifications.
8.1.2
The guaranteed performance parameters furnished by the Bidder in the Bid

proposal, shall be without any tolerance values and all margins required for
instrument inaccuracies and other uncertainties shall be deemed to have been
included in the guaranteed figures.
8.1.3
The Bidder shall demonstrate all the guarantees covered herein under Category
I, II & III during functional guarantee / acceptance test. The various tests which
are to be carried out during performance guarantee/acceptance test are listed
elsewhere in this-Section. The guarantee tests shall be conducted by the Bidder
at site in presence of Owner on the unit.
8.1.4
All costs associated with the tests including the cost associated with the supply,
calibration, installation and removal of test instrumentation shall be included in
the price offered by Bidder.
8.1.5
At all times during the Performance Tests, the emissions and effluents from the
Plant shall not exceed the Guaranteed Emission and Effluent Limits.
8.1.6
It shall be the responsibility of the Bidder to make the plant ready for the
performance guarantee tests.
8.1.7
All instruments required for performance testing shall be of the type and accuracy
required by the code and prior to the test, the Bidder shall get these instruments
calibrated in an independent test institute approved by the Owner. All test
instrumentation required for performance tests shall be supplied by the Bidder
and shall be retained by him upon satisfactory completion of all such tests at site.
All calibration procedures and standards shall be subjected to the approval of the
Owner. The protecting tubes, pressure connections and other test connections
required for conducting guarantee test shall conform to the relevant codes.
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8.1.8
Tools and tackles, thermowells (both screwed and welded) instruments/devices

including flow devices, matching flanges, impulse piping & valves etc. and any
special equipment, required for the successful completion of the tests, shall be
provided by the Bidder free of cost.
8.1.9
The Performance/ Acceptance test shall be carried out as per the agreed
procedure. The PG test procedure including demonstration tests shall be
submitted within [90 days] of the date of Notification of Award and finalization of
the PG test procedure shall be done within [180 days] from the date of
Notification of Award. After the conductance of Performance test, the Bidder shall
submit the test evaluation report of Performance test results to Owner promptly
but not later than one month from the date of conductance of Performance test.
However, preliminary test reports shall be submitted to the Owner after
completing each test run.
8.1.10
The P&G test procedures shall be submitted for equipment/ system & subsystem
under Bidder's scope for all Guarantees under category I, II & Ill as mentioned
below, as per ASME PTC 6 or latest International codes & standard including
correction curves, meeting the Specification requirements along with sample
calculations & detailed activity plan of preparation (including test
instrumentation), conductance and evaluation of Guarantees.
8.1.11
The Bidder shall submit for Owner's approval the detailed Performance Test
procedure containing the following:
8.1.12
Objective of the test.
Various guaranteed parameters & tests as per Contract.
Method of conductance of test and test code.
Duration of test, frequency of readings & number of test runs.
Method of calculation.
Correction curves.
Instrument list consisting of range, accuracy, least count, and location of

instruments.
Scheme showing measurement points.
Sample calculation.
Acceptance criteria.
Any other information required for conducting the test.
In case, during performance guarantee tests, it is found that the

equipment/systems has failed to meet the guarantees, the Bidder shall carry out
all necessary modifications and/or replacements to make the equipment/system
comply with the guaranteed requirements at no extra cost to the Owner.
However, if the Contractor is not able to demonstrate the guarantees, even after
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the above modifications/replacements within [ninety (90)] days or a reasonable

period allowed by the Owner after the initial performance guarantee tests have
been completed, the Owner will have the right to impose the stipulated clauses
under Guarantee Category I, II & III as specified in this specification:
For Category-I Guarantees
8.1.13
Reject the equipment/system/plant and recover from the Contractor payments already
made
(OR)
Accept the equipment/system/plant after levying Liquidated Damages (LD) as
specified in Clause No. 5.6 of Volume I of this specification. The LDs shall be prorated
for the fractional parts of the deficiencies.
For Category-II Guarantees
8.1.14
Reject the equipment/plant/system and recover, from the Contractor, the payments
already made. Conformance to the performance requirements under Category-II is
mandatory.
For Category-III Guarantees
8.1.15
Reject the equipment/system/plant & recover, from the Contractor, the payments
already made.
(OR)
Accept the equipment/system after assessing the deficiency in respect of the
various ratings, performance parameters and capabilities and recover from the
contract price an amount equivalent to the damages as determined by the
Owner. Such damages shall however be limited to the cost of replacement of the
equipment/systems replacement of which shall remove the deficiency so as to
achieve the guaranteed performance.
8.2
Performance Guarantees under Category-I

The performance guarantees which will attract liquidated damages shall be as follows:
(i)
Maximum continuous electrical output, in MW, at Generator terminals of each unit at

rated parameters under VWO Condition.
(ii)
Turbine Cycle Gross Heat rate in kCal/kWh at rated steam conditions at 76 mm Hg

(abs) design condenser pressure with 3% make up at 100% TMCR load. Heat rate
shall be calculated as per the formula shown in clause 8.2.2
(iii)
Condenser Pressure with Unit Operating at VWO Condition.
(iv)
Unit Auxiliary Power Consumption at 100% TMCR unit load at condenser pressure of
[76] mm Hg (abs)] with 3% make-up and with design ambient air condition.
Note: Power consumption of each of the pump/fan/compressors etc. wherever
mentioned shall be measured with its own drive.
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8.2.1
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Limit of Technical Parameters under Liquidated Damages Applicable For

Category-I Guarantees:
Table: 8.1
Performance Limit for Rejection (LD
is
Applicable
within
below
mentioned Limit. Beyond the Limit
S.No.
Parameter
as
below,
the
equipment/system/plant will call for
Rejection.)
1
Gross Output of each unit
Shortfall beyond [1%] of guaranteed

value
(i.e. [1.0 %])

value
(i.e. + [1%])

value
Condenser Pressure
(i.e. + [1%])
4
8.2.2

value/.
(i.e. + [5.0 %])
Auxiliary Power
Calculation of Turbine Heat Rate

a) Turbine Cycle Heat Rate
Turbine Cycle Heat Rate shall be calculated as follows & indicated in all
computed heat balance diagrams:
Heat Rate =
M1 (H1-h1) + M2 (H3-H2) + Mis (h1 - his)+Mir (H2 - hir)

------------------------------------------------------------------------------------Pg
Where,
M1 Quantity of live steam entering the turbine stop valve including any live
steam supplied to valve stems, or glands etc. in kg/hr.
M2 Quantity of Reheat steam from reheater to turbine in kg/hr.
Mis Quantity of desuperheating water flowing into Superheater system for
regulation of steam temperature in kg/hr.
Mir Quantity of desuperheating water flowing into reheater system for
regulation of steam temperature in kg/hr.
H1- Enthalpy in kCal/kg of live steam.
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H2
H3
h1
i)
ii)
iii)
iv)
v)
vi)
vii)
i)
Enthalpy in kCal/kg of steam HPT Exhaust to reheat.

Enthalpy in kCal/kg of reheated steam from reheater to IP turbine.
Enthalpy of feed water in kCal/kg at the downstream of the junction of feed
flow and bypass flow of HP heaters.
hir Enthalpy of desuperheating water flowing into reheat system in kCal/Kg.
his Enthalpy of desuperheating water flowing into Superheater System in
kCal/Kg.
Pg Unit output after deducting the power consumption by auxiliaries as listed
below and the same shall be [210/215/220/250] MW at 100% TMCR unit
load:
Power taken by Excitation system (kW) including transformer losses, as
applicable for various guarantee points in case of static excitation system. (The
transformer losses at various points shall be based on factory test to be
conducted).
Power required for ventilation of oil and control fluid tanks, if ventilating fans are
separately driven (kW).
Power required for lubrication, if lubricating pumps are separately driven (kW).
Power required for control fluid pumps, if control fluid pumps are separately
driven (kW).
Power required for hydrogen, seal oil auxiliaries, if separately driven (kW).
Power required for stator water cooling system, if cooling pumps are driven
separately (kW).
Power required for Gland Steam Exhauster (GSC) if GSC Exhausters are
separately driven.
Notes:
Corrections Applicable for Turbine Cycle Heat rate & Turbine Generator Output
tests
Based on cycle condition & covering entire range of operation for Turbine
following correction curves for variation in Turbine Cycle Heat rate & Turbine
Generator output to be furnished:
Variation in main steam pressure and temperature.
Variation in reheater steam temperature.
Correction Curves, if applicable, due to change in superheater spray
quantities with respect to coal properties.
Correction Curves, if applicable, due to change in reheater spray quantities
with respect to coal properties.
Variation in condenser pressure for main condenser.
Variation in power factor, frequency, generator hydrogen pressure and
voltage.
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ii)
It may be noted that the heat balance diagrams and guarantees shall be
furnished considering the quantities of water for super heater and reheater
sprays with any mill combination in service to the Owner's choice.
iii)
The above list of correction curves is conclusive & curves in addition to above
shall not be applied.
8.2.3
Condenser Pressure/Vacuum
Condenser Pressure Test, with Unit operating at VWO Condition, shall be carried
out as per ASME PTC 12.2. .
8.2.4

a)

The auxiliary power consumption shall be calculated using the following
relationship.
Pau
Pu
Pau
Guaranteed Auxiliary Power Consumption.
Pu
Power consumed by each of the auxiliaries of the unit under test.
While guaranteeing the auxiliary power consumption the bidder shall necessarily
include all continuously operating unit auxiliaries.
[The auxiliaries to be considered shall include but not be limited to the following:
i)
Boiler Feed Water Pumps (BFPs) including booster pumps and lube oil
pump sets of BFPs
ii)
iii) Condenser Vacuum Pumps
iv) Excitation Power of Turbo Generator Set
v)
DM CCW Pumps for Turbo Generator Auxiliaries
vi) LP Drain Condensate Pumps
vii) Turbine Oil Pumps
viii) Control Oil Pumps
ix) Seal Oil Pumps
x)
Oil Vapor Extractor Fans
xi) Gland Steam Condenser Vapor Extractor Fans
Power consumption of any other continuously operating auxiliary for unit
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operation at 100% TMCR]

Note:
1.
2.
8.3
The Bidder shall furnish a list of equipment to be covered under auxiliary

power consumption, which shall be subject to Owner's approval.
The Bidder shall ensure that power supply to all such equipment to be
covered under unit auxiliary power consumption is fed from unit board of
the respective unit.
Guarantees under Category-II

Liquid Effluent:
[Liquid Effluent discharge to an outside body, from the battery limit, shall meet
statutory requirements State Pollution Control Board.]
8.4
Guarantees under Category-III

The parameters/capabilities to be demonstrated for various systems/ equipment
8.4.1
Noise
All the plant, equipment and systems covered under this Specification shall
perform continuously without exceeding the noise level over the entire range of
output and operating frequency specified.
Noise level measurement shall be carried out using applicable and internationally
acceptable standards. The measurement shall be carried out with a calibrated
integrating sound level meter meeting the requirement of IEC 651 or BS 5969 or
IS 9779.
Equivalent A weighted Sound pressure shall be measured all around the
equipment at a distance of 1.0 m from the Noise emitting source.
A minimum of 6 points around each equipment shall be covered for
measurement. Additional measurement points shall be considered based on the
applicable standards and the size of the equipment. The measurement shall be
done with slow response on the A - weighting scale. The average of A-weighted
sound pressure level measurements expressed in decibels to a reference of
0.0002 micro bar shall not exceed the guaranteed value. Corrections for
background noise shall be considered in line with the applicable standards. All
the necessary data for determining these corrections, in line with the applicable
standards, shall be collected during the tests.
If the noise level recorded is beyond the limits specified above, the Bidder should
provide suitable acoustic cladding to mitigate the noise level to within allowable
limits.
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8.4.2
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Start-up, loading, Unloading and Shutdown Capabilities

a)
Unit Start-up
Start-up time (up to full load), and loading capabilities for the complete unit
turbine generator together with associated Auxiliaries for cold start conditions
[(greater than 36 hours shutdown)], warm start conditions [(between 8 and
36 hours shutdown)] and hot start conditions [(less than 8 hours shutdown)]
as indicated by the Bidder in the offer and accepted by the Owner shall be
demonstrated, ensuring that the various turbine operational parameters like
vibration, absolute and differential expansion, eccentricity and steam-metal
temperature mismatch etc.
b)
Sudden Total Loss of External Load

When the steam turbine generator unit experiences sudden total loss of all
external load, the steam turbine generator unit shall not trip on over speed but
shall continue to be in operation (house-load conditions) under the control of its
speed governor to supply power for the plant auxiliary load while staying within
the agreed limits of steam metal temperature mismatch, exhaust hood
temperature, absolute and differential expansion, vibration and eccentricity. The
same shall be demonstrated.
c)
Steam Metal Temperature

The maximum permissible steam-metal temperature differential for cold, warm
and hot start conditions and loading/unloading and shutdown conditions shall be
as indicated by the Bidder and accepted by the Owner.
8.4.3
Other Parameters for Steam Turbine and Auxiliaries

(a)
HP & LP Bypass system should satisfy the following functional requirements under
automatic interlock action. It should come into operation automatically under the
following conditions:
Generator circuit breaker opening
HP-IP stop valves closing due to turbine tripping
Sudden reduction in demand to house load
(b)
Under all these conditions, while passing the required steam flows as per the relevant
heat balances, the condenser should be able to swallow the entire steam without
increasing the exhaust hood temperature and condenser pressure beyond the
maximum permissible value indicated by the Bidder in its offer and accepted by the
Owner. The same shall be demonstrated.
Run back Capability
Run back, rate of change of load and sudden load change withstand capabilities
as guaranteed in the respective technical specifications volume.
(c)
Following Parameters shall be demonstrated for steam condensing Plant:
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i.
Temperature of condensate, at outlet of condenser, shall be less than Saturation

temperature corresponding to the condenser pressure at all Loads.
ii.
Oxygen content in condensate, at hot well outlet, shall not exceed [0.015 cc per liter]
over the entire load range and shall be determined according to calorimetric indigo
Carmine method.
iii.
Air leakage in the condenser under full load condition shall not exceed more than 50%
of design value taken for sizing the condenser air evacuation system.
iv.
When one half of the condenser is isolated, condenser shall be capable of taking at
least 60% TG load under TMCR conditions.
v.
The air and vapour mixture from air cooling zone of condenser shall be 4.17 C below
the saturation temperature corresponding to 25.4 mm hg (abs) suction pressure.
Correction curves for establishing the same at site conditions shall also be furnished.
vi.
Life of sponge rubber balls and number of balls lost during 1000 hours of plant
operation (for the Condenser on-load tube cleaning system) shall be as indicated by
Bidder in the offer and accepted by the Owner.
(d)
Following parameters shall be demonstrated for Feed Water Heaters and Deaerator:
i.
ii.
iii.
iv.
(e)
TTD's and DCA's of feed water heaters in line with 100 % TMCR heat rate
guarantee heat balance.
Dissolved O2 content at Deaerator outlet without chemical dosing at all loads, not to
exceed [0.005 cc/liter] determined as per ASTM-D-888 - Reference method A or
Indigo Carmine method.
Difference between saturation temperature of steam entering the Deaerator and
temperature of feed water leaving Deaerator.
Continuous & efficient operation and performance of feed heating plant without
undue noise and vibrations at all loads and duty conditions.
Boiler Feed Pumps

The pumps with its drives will operate satisfactorily at site for the whole range
of rated operating condition as specified. The controls such as auto starting
of pumps, speed, recirculation, etc. will also be tested for satisfactory
performance. Parallel operation of pumps with different combinations will also
be tested. During entire range of operation the vibration level will conform to
VDI 2056.
(f)
Condensate Extraction Pump

The pumps with its drives will operate satisfactorily at site for the whole range
of rated operating condition as specified. The controls such as auto starting of
pumps, speed, recirculation, etc. will also be tested for satisfactory
performance. Parallel operation of pumps with different combinations will also
be tested. During entire range of operation the vibration level will conform to
VDI 2056.
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(g)
[Drip Pump (if Applicable)]

i.
ii.
8.4.4
[Logo of Utility]
Each drip pump shall be capable of delivering flow & total dynamic head
corresponding to design point as specified.
The vibration and noise level shall be demonstrated.
Auxiliary Water System Pumps

Capacity and head and power consumption of all the pumps dedicated to Turbo
Generator & its Auxiliaries at the rated duty point (to be demonstrated and
proved at shop with the respective job motors).
Vibration, noise level and parallel operation of all the pumps at the rated duty
point shall be demonstrated at site.
8.4.5
Equipment Cooling Water System

a) Parallel operation of pumps shall be demonstrated at site.
b) Pressure drop across the heat exchanger on the primary & secondary water
circuit shall be demonstrated at site.
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SPARE PARTS
The Bidder shall include in his scope of supply all the necessary mandatory
spares, start up and commissioning spares and recommended spares and
indicate these in the relevant schedules. The general requirements pertaining to
the supply of these spares is given below:
9.1
Mandatory Spares
The list of mandatory spares considered essential by the purchaser is enclosed
in Annexure-II of this Specification. The Bidder shall indicate the prices for each
and every item (except for items not applicable to the Bidders design) in the
Schedule of mandatory spares whether or not he considers it necessary for the
Owner to have such spares. If the Bidder fails to comply with the above, the cost
of such spares shall be deemed to be included in the Contract price. The Bidder
shall furnish the population per unit of each item in the relevant Schedules.
Whenever the quantity is mentioned in sets the Bidder has to give the item
details and prices of each item.
Whenever the quantity is indicated as a percentage, it shall mean percentage of
total population of that item in the R&M Contract unless specified otherwise, and
the fraction will be rounded off to the next higher whole number. Wherever the
requirement has been specified a set, it will mean as applicable for one
complete Unit or each type & size of the Equipment being taken up for
refurbishment or replacement. .
All mandatory spares shall be delivered at site at least two months before
scheduled date of initial operation of the first unit. However, spares shall not be
dispatched before dispatch of corresponding main equipment.
Wherever quantity is specified both as a percentage and a value, the Bidder has
to supply the higher quantity until and unless specified otherwise. Price of
mandatory spare parts will also be evaluated.
9.2
Recommended Spares
In addition to the mandatory spare parts mentioned above, the Bidder shall also
provide a list of recommended spares for [five (5)] years of normal operation of
the plant and indicate the list and total prices in relevant schedule. The list shall
take into consideration the mandatory spares specified and should be
independent of the list of the mandatory spares. The purchaser reserves the right
to buy any or all of the recommended spares. The recommended spares shall be
delivered at project site at least two months before the scheduled date of initial
operation of first unit. However, the spares shall not be dispatched before the
dispatch of the main equipment.
Prices of recommended spares will not be used for evaluation of the Bids. The
price of these spares will remain valid up to execution of the Contract. However,
the Bidder shall be liable to provide necessary justification for the quoted prices
for these spares as desired by the Owner.
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9.3
[Logo of Utility]
Start-up & Commissioning Spares

Start up and commissioning spares are those spares which may be required
during the start-up and commissioning of the equipment/system. The Bidder shall
provide all such start up and commissioning spares and keep an adequate stock
of the same to be brought by him to the site for the plant erection and
commissioning. These must be available at site before the equipment are
energized. The unused spares, if any, should be removed from there, only after
handing over of the plant. All start up spares which remain unused at the time
shall remain the property of the Bidder.
9.4
The Bidder shall indicate the service expectancy period for the spares parts (both
mandatory and recommended) under normal operating conditions before
replacement is necessary.
All spares supplied under this Contract shall be strictly inter-changeable with the
parts for which they are intended for replacements. The spares shall be treated
and packed for long storage under the climatic conditions prevailing at the site
e.g. small items shall be packed in sealed transparent plastic with desiccators
packs as necessary.
All the spares (both mandatory and recommended) shall be manufactured along
with the main equipment components as a continuous operation as per same
Specification and quality plan.
The Bidder will provide Owner with cross-sectional drawings, catalogues,
assembly drawings and other relevant documents so as to enable the Owner to
identify and finalize order for recommended spares.
Each spare part shall be clearly marked or labeled on the outside of the packing
with its description. When more than one spare part is packed in a single case, a
general description of the content shall be shown on the outside of such case
and a detailed list enclosed. All cases, containers and other packages must be
suitably marked and numbered for the purposes of identification.
All cases, containers or other packages are to be opened for such examination
as may be considered necessary by the purchaser.
The Bidder will provide the Owner with all the addresses and particulars of his
sub-suppliers while placing the order on Vendors for items/ components/
equipment covered under Contract and will further ensure with his Vendors that
the Owner, if so desires, will have the right to place order for spares directly on
them on mutually agreed terms based on offers of such Vendors.
The Bidder shall warrant that all spares supplied will be new and in accordance
with the Contract documents and will be free from defects in design, material and
workmanship.
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In addition to the recommended spares listed by the Bidder, if the Owner further
identifies certain particular items of spares, the Bidder shall submit the prices and
delivery quotation for such spares within 30 days of receipt of such request for
consideration by the Owner and placement of order for additional spares if the
Owner so desires.
The Bidder shall guarantee the long term availability of spares to the Owner for
the full life of the equipment covered in the Contract. The Bidder shall guarantee
that before going out of production of spare parts of the equipment covered
under the Contract, he shall give the purchaser at least 2 years advance notice
so that the latter may order his bulk requirement of spares, if he so desires. The
same provision will also be applicable to Sub-Bidders. Further, in case of
discontinuance of manufacture of any spares by the Bidder and/or his subBidders, Bidder will provide the purchaser, two years in advance, with full
manufacturing drawings, material Specifications and technical information
including information on alternative equipment makes required by the Owner for
the purpose of manufacture/procurement of such items.
The prices of all future requirements of spares beyond [five (5)] years shall be
derived from the corresponding FOB/Ex-works price at which the order for such
spares have been placed by the Owner as a part of the mandatory spares or
recommended spares. FOB/Ex-works order price of future spares shall be
computed in accordance with the price escalation formula to be furnished by
Bidder indicating base price reference variation indices for material, labour etc.
Based on the formula and considering escalation indices prevailing at the time of
order of spares, order price shall be worked out. The base indices will be counted
from the scheduled date of successful completion of trial operation of the last
plant/equipment under the project. The above option for procuring future
recommended spares by the purchaser shall remain valid for the period of fifteen
[fifteen (15)] years from the date of successful completion of trial operation of the
last plant/equipment. In case the spare parts from the same sub-Vendor are not
available due to obsolescence or any other reason, the Bidder shall supply the
spares for a period of [fifteen (15)] years from an alternative source.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[144]
15.01.2016
Power Plant]
10
ANNEXURES
10.1
Annexure-I (List of Existing Drawing)
[Logo of Utility]

Bidder as per the list mentioned in Annexure-I for their information &
familiarization of the existing Unit}
10.2
Annexure-II (Mandatory Spares)

{Applicable Mandatory Spares for the equipment system to be replaced /
refurbished / retrofitted under the scope of this R&M Tender shall be provided as
detailed in Annexure-II}
10.3
Annexure-III (List of Sub-Vendor)

{List of Sub-vendor for the equipment system to be replaced / refurbished /
retrofitted under the scope of this R&M Tender shall be provided as per the
format in Annexure-III}
10.4
RLA/CA Study Report

10.5
EA Study Report
10.6
Baseline Study Report

Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[145]
15.01.2016

OF

R&M CONTRACTORS

VOLUME-II
SECTION-I, ANNEXURE-I
LIST OF EXISTING DRAWING
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-002 R01
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-I
List of Existing Drawing

Bidder as per the list mentioned below for their information & familiarization of the
existing Unit}
i)
MECHANICAL
S.No.
Title
[]
[General Layout (Plot Plan)]
[]
[Main plant Layout at + 0.00 M]
[]
[Main Plant Equipment Layout Plan at Different

Elevations]
[]
[Main plant Layout Cross Section]
[]
[General layout battery limit]
[]
[Symbol /Legends]
[]
[P&ID for Main Steam, CRH & HRH Steam System]
[]
[P&ID for Feed Water System]
[]
[P&ID for HP-LP Bypass System]
10
[]
[P&ID for Condensate System]
11
[]
[P&ID for Heater Drains and Vents System]
12
[]
[P&ID for Extraction Steam System]
13
[]
[P&ID for DM water make up System]
14
[]
[P&ID for LP Dosing system]
15
[]
[P&ID for Oil purification system]
16
[]
[Flow Diagram DM Cooling Water System]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[2]
25.09.2014
Power Plant]
S.No.
[Logo of Utility]
Title
17
[]
[Flow Diagram Central oil Storage & Transfer System]
18
[]
[Flow Diagram for Service water & Portable water]
19
[]
[Flow Scheme for Flash Tank, drain tank & Connection

to Hotwell]
20
[]
[GA of Pipe and Cable Rack]
21
[]
[Any other Drawing]
ii)
ELECTRICAL
S.No.
[]
[Protection diagram for Generator and its Auxiliaries]
[]
[Existing Key Single Line diagram and Main One Line

Diagram for Power Plant]
iii)
Title

S.No.
[]
[Plant DCS Configuration Drawing]
[]
[TG Integral Control System Configuration Drawing]
[]
[Instrument
Transmitter)]
[]
[Instrument Installation Diagram (Flow Measurement)]
[]
[Instrument Installation Diagram (Pressure Gauge)]
[]
[Instrument Installation Diagram (DP Measurement)]
[]

using gauge & switch)]
[]

using DP Transmitter & Displacer type Transmitter]
Document Number
LII-GETS12021-G-00129-002
Title
Installation
Diagram
(Pressure
Rev
No.
Description
Page
No.
Date of Issue
01

[3]
25.09.2014
Power Plant]
[Logo of Utility]
S.No.
Title
[]

for Open/Close Vessels)]
10
[]

11
[]

12
[]
[Instrument Source
Measurement]
Connection
Details
Flow
14
[]
[Instrument Source
Measurement]
Connection
Details
Level
16
[]
[Grounding Scheme for Cabinets/Panels]
17
[]
[C&I Power Supply distribution cabling Philosophy]
22
[]
[C&I Instrumentation cabling Philosophy]
23
[]
[PLC based Control System Configuration Diagram]
24
[]
[Turbine Protection System Configuration Diagram]
25
[]
[Drive Control Philosophy-Bidirectional drive (ON-OFF

Type MOV)]
26
[]
[Drive Control Philosophy-Bidirectional drive (Inching

Type MOV)]
27
[]
[Drive Control Philosophy- LT drive]
28
[]
[Drive Control Philosophy- HT drive]
29
[]
[Drive Control Philosophy-Solenoid Valve]
30
[]
[Drive Control Philosophy-VFD]
31
[]
[Any Other Drawing]
iv)
CIVIL
S.No.
Drawing No.
Document Number
LII-GETS12021-G-00129-002
Description
Rev
No.
Description
Page
No.
Date of Issue
01

[4]
25.09.2014
Power Plant]
[Logo of Utility]
S.No.
Drawing No.
[]
[Geotechnical Investigation Report]
[]
[Road, drains, trench layouts etc., as available]
[]
[Design documents of the existing structures]
[]
[Drawings of existing structures & foundations]
[]
[Loading data
foundations]
Document Number
LII-GETS12021-G-00129-002
Description
for
of
the
existing
structures
Rev
No.
Description
Page
No.
Date of Issue
01

[5]
25.09.2014
&

OF

R&M CONTRACTORS

VOLUME-II
SECTION-I, ANNEXURE-II
MANDATORY SPARES
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-002 R01
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-II
Mandatory Spares
{Applicable Mandatory Spares for the equipment system to be replaced / refurbished /
retrofitted under the scope of this R&M Tender shall be provided as detailed in
Annexure-II. Available Mandatory spares of the existing Unit, which can be used after
completion of R&M work, shall also be verified before finalization of the below
mentioned Spare List. Mandatory Spares shall be defined as for each Unit. The unit,
set, indicated in the table below will mean as applicable for one complete Unit or each
type & size of the Equipment being taken up for refurbishment or replacement.}
A.
MECHANICAL
1.
TG & Auxiliaries
Sl. No
Description
1.0
TURBINE & AUXILIARIES
1.1
HP Turbine
1.1.1
All studs, bolts, washers and nuts in HP inner Set

and outer casings other than in the inlet and
outlet connections
1.1.2
All studs, bolts, washers and nuts for steam Set

inlet and outlet connections to and from the
HP casing.
1.1.3
Gland sealing rings with springs assembly
Set
1.1.4
All keys, pins, bushes and screws
Set
1.1.5
Inter-stage seal strip and caulking wire (both Set

rotating and stationary)
1.1.6
Sealing rings for M.S inlet and CRH outlet Set

insert connection
1.1.7
Balance weight along with fixing screws for Set
Document Number
LII-GETS12021-G-00129-002
Unit
Quantity
Remarks
Set consists
of total length
of seal strip
and caulking
wire in all
stages both in
the
casing
and the rotor
for 1 turbine.
Rev
No.
Description
Page
No.
Date of Issue
01

[2]
25.09.2014
Power Plant]
Sl. No
Description
Unit
[Logo of Utility]
Quantity
Remarks
HP Turbine
1.2
IP Turbine
1.2.1
All studs, bolts, washers and nuts in IP inner Set

and outer casings other than in the inlet
outlet and extraction connections
1.2.2

inlet and outlet connections to and from the
IP casing.
1.2.3
Thread Rings & Angle Rings
Set
1.2.4
Set
1.2.5
Set
1.2.6
Interstage seal strip and caulking wire (both Set

1.2.7
Sealing rings for HRH inlet insert connection
Set
1.2.8

IP Turbine
1.3
LP Turbine
1.3.1
Bolts, washers and nuts in LP inner and outer Set

casings other than in the inlet outlet and
extraction connections
1.3.2

inlet, outlet and extraction connections to and
from the LP casing.
1.3.3
All types of gaskets, if applicable
Set
1.3.4
Set
1.3.5
Set
Document Number
LII-GETS12021-G-00129-002
set consists
of total length
of seal strip
and caulking
wire in all
stages both
in the casing
and the rotor
for 1 turbine.
Rev
No.
Description
Page
No.
Date of Issue
01

[3]
25.09.2014
Power Plant]
Sl. No
Description
1.3.6
Interstage seal strip and caulking wire (both Set

1.3.7

LP Turbine
1.3.8
Moving blades for last 2 LP stages (both Set

sides for double flow)
1.3.9
Lacing wire for last stage moving blades (if Set

applicable)
1.3.10
Last stage fixed blades
1.3.11
Pressure relief self closing type disc for Sets

Turbine exhaust hood
1.4
Turbine Bearings and Bearing Pedestal
1.4.1
Journal Bearings, complete
Document Number
LII-GETS12021-G-00129-002
Unit
[Logo of Utility]
Set
Set
Quantity
Remarks
set consists
of total length
of seal strip
and caulking
wire in all
stages both
in the casing
and the rotor
for 1 turbine.
set consists
of total length
of lacing wire
required for
the last stage
blades
set consists
of all the
journal
bearings
along
with
temperature
elements, if
temperature
elements are
integral with
the bearings
for HP, IP
and
LP
Rev
No.
Description
Page
No.
Date of Issue
01

[4]
25.09.2014
Power Plant]
Sl. No
Description
Unit
[Logo of Utility]
Quantity
Remarks
Turbine
as
applicable
1.4.2
Combined thrust and

complete, if applicable
1.4.3
bearing Set
Thrust bearing pads
Set
1.4.4
Auxiliary bearing, if applicable
No.
1.4.5
Oil Guard Ring Sealing rings
Set
1.4.6
Sealing strips
(if applicable) for all the Sets
bearing pedestals
1.4.7
All bolts, studs washers and nuts in all the %

bearing pedestals of Turbine
25
25% of each
bearing
pedestal
population in
one unit
1.4.8
All applicable pins, bushes, sleeves, keys, Set

screws, springs, adjusting plates and locking
plates
1 set for each

bearing
pedestal
1.5
Coupling bolts, nuts, sleeves, washers

lock plates as applicable for
1.5.1
HP-IP Coupling
Set
1.5.2
IP-LP Coupling
Set
1.5.3
LP-Generator Coupling
Set
1.6
Governing system
1.6.1
Over speed governor
No.
1.6.2
Over speed governor internals
Set
1.6.3
Spares for Electro-hydraulic governor, if Set
Document Number
LII-GETS12021-G-00129-002
journal
set consists
of all the
thrust pads in
1
bearing
including the
pads
with
thermocouple
.
Rev
No.
Description
Page
No.
Date of Issue
01

[5]
25.09.2014
Power Plant]
Sl. No
Description
[Logo of Utility]
Unit
Quantity
Set
if Set
Remarks
applicable
1.6.4
Electro-hydraulic convertor, if applicable
1.6.5
Electro-hydraulic
applicable
1.6.6
Emergency trip device
No.
1.6.7
Emergency trip device internals
Set
1.6.8
Over speed trip testing device
No.
1.6.9
Load limit device
No.
1.6.10
Load limit device internals
Set
1.6.11
Load Changer
No.
1.6.12
Load Changer internals
Set
1.6.13
Low vacuum tripping device
No.
1.6.14
Low vacuum tripping device internals
Set
1.6.15
Thrust bearing protection device
No.
1.6.16
Thrust bearing protection device internals
Set
1.6.17
Emergency over speed trip device
Set
1.6.18
Vacuum breaker valve
Nos
1.7
Turbine Valves
1.7.1.
Emergency stop valve
1.7.1.1
All internals of main steam stop valve
Set
1.7.1.2
Sealing Rings
Set
1.7.1.3
Studs, bolts, nuts and washers
Set
1.7.1.4
Main steam stop valve Servomotor
1.7.1.5
All internals of servomotor
Set
1.7.1.6
All gaskets, O rings and oil seals of Sets

servomotor
1.7.1.7
All studs, bolts, nuts and washers
Set
1.7.1.8
Test valve for main steam stop valve
Set
1.7.1.9
Servomotor for main steam stop valve
No.
Document Number
LII-GETS12021-G-00129-002
convertor
internals,
Rev
No.
Description
Page
No.
Date of Issue
01

[6]
25.09.2014
Power Plant]
Sl. No
Description
1.7.2
Main steam control valve
1.7.2.1
[Logo of Utility]
Unit
Quantity
All internals of main steam control valve
Set
1.7.2.2
Sealing Rings
Set
1.7.2.3
Set
1.7.2.4
Main steam control valve servomotor
1.7.2.5
Set
1.7.2.6
All gaskets, O rings and oil seals of Sets

servomotor
1.7.2.7
Set
1.7.2.8
Test valve for MS control valve servomotor
No.
1.7.2.9
Servomotor for main steam control valve
No.
1.7.3
Reheat stop valves
1.7.3.1
All internals of reheat stop valve
Set
1.7.3.2
Sealing rings
Sets
1.7.3.3
Set
1.7.3.4
Reheat stop valve servomotor
1.7.3.5
Sets
1.7.3.6
All gaskets, O rings and oil seals of Set

servomotor
1.7.3.7
Set
1.7.3.8
Test valve for reheat stop valve servomotor
Set
1.7.3.9
Servomotor for reheat stop valve
No.
1.7.4
Reheat control valve
1.7.4.1
All internals of reheat control valve
Set
1.7.4.2
Sealing rings
Sets
1.7.4.3
Set
Document Number
LII-GETS12021-G-00129-002
Remarks
1no. in each
type
Rev
No.
Description
Page
No.
Date of Issue
01

[7]
25.09.2014
Power Plant]
Sl. No
Description
1.7.4.4
Reheat control valve servomotor
1.7.4.5
[Logo of Utility]
Unit
Quantity
Set
1.7.4.6
All gaskets, O rings and oil seals of Set

servomotor
1.7.4.7
Set
1.7.4.8
Test valve
servomotor
valve Set
1.7.4.9
Servomotor for reheat control valve
No.
1.7.5
Extraction
FCNRVs
1.7.5.1
Disc
Set
1 Set means
1 no. in each
size,
type
and rating
1.7.5.2
Spindle
Set
1 Set means
1 no. in each
size,
type
and rating
1.7.5.3
Spindle bushing
Set
1 Set means
1 no. in each
size,
type
and rating
1.7.5.4
Body/Cover gasket
Set
1 Set means
1 no. in each
size,
type
and rating
1.7.6
Actuators of Extraction and CRH NRVs
1.7.6.1
Piston rings
Sets
1.7.6.2
Piston
Set
1.7.6.3
Oil seals, O-rings and Gaskets
Set
1.7.6.4
Complete Actuator
Set
1.7.7
Main Steam & HRH Strainers
1.7.7.1
All gaskets
Sets
Document Number
LII-GETS12021-G-00129-002
for
and
reheat
CRH
control
NRVs
Remarks
including
4 in
type
each
Rev
No.
Description
Page
No.
Date of Issue
01

[8]
25.09.2014
Power Plant]
[Logo of Utility]
Sl. No
Description
Unit
Quantity
1.7.7.2
All studs / bolts, nuts & washers
Set
1 in
type
each
1.7.7.3
Strainer mesh
No.
1 in
type
each
1.8
HP-LP by pass system
1.8.1
HP By pass System
1.8.1.1
HP by pass steam control valve
All internals
Set
All bolts, studs, washers & nuts
Set
All gaskets, sealing and packing rings
Sets
1.8.1.2
HP by pass steam control valve actuator
All internals
Set
Set
Set
1.8.1.3
HP water spray valve
All internals
Set
Set
Sets
1.8.1.4
HP water spray valve actuator
All internals
Set
Set
Set
1.8.1.5
HP water stop valve
All internals
Set
Set
Sets
1.8.1.6
HP water stop valve actuator
All internals
Set
Set
Document Number
LII-GETS12021-G-00129-002
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[9]
25.09.2014
Power Plant]
[Logo of Utility]
Sl. No
Description
Unit
Quantity
Set
1.8.1.7
Oil System / HP By Pass
Filter housing
Nos.
Filter element if any, in the oil supply unit
Sets
High Pressure hoses
Sets
Oil Supply Unit Pressure reducing valve
Sets
Bladders
Nos.
Accumulator Connecting block
Set
Oil supply pump with motor
Set
Nitrogen gas filling device
Set
1.8.2
LP By pass Syatem
1.8.2.1
LP by pass valve
All internals
Set
Set
Set
1.8.2.2
LP by pass valve actuator
All internals
Set
Set
Set
1.8.2.3
LP by pass spray water valve
All internals
Set
Set
Set
1.8.2.4
LP by pass spray water valve actuator
All internals
Set
Set
Set
1.8.3.4
Oil System / LP By Pass
Document Number
LII-GETS12021-G-00129-002
Remarks
1 no in each
type only and
total 4 nos.
Rev
No.
Description
Page
No.
Date of Issue
01

[10]
25.09.2014
Power Plant]
[Logo of Utility]
Sl. No
Description
Unit
Quantity
Filter housing
Nos.
Filter element if any, in the oil supply unit
Sets
High Pressure hoses
Sets
Oil Supply Unit Pressure reducing valve
Sets
Bladders
Nos.
Accumulator Connecting block
Set
Oil supply pump with motor
Set
1.9
Lube oil system
1.9.1
Main Oil Pump
1.9.1.1
Impeller
No.
1.9.1.2
Bearings
Set
1.9.1.3
Shaft with sleeves and lock nut
No.
1.9.1.4
Mechanical seal complete
Sets
1.9.1.5.
Set of bolts/studs, nuts, screws, keys, pins, Set

circlips and washers including spring
washers
1.9.1.6
Set of gaskets/ Orings U rings/ V rings
Sets
1.9.1.7
Coupling bolts, nuts, washers and bushes
Set
1.9.2.
Auxiliary Oil Pump
1.9.2.1
Shaft with keys
Set
1.9.2.2
Impeller with locknut, lock washer and lock Set

screw
1.9.2.3
Bearings
Sets
1.9.2.4
Shaft seal
Sets
1.9.2.5
Set of gaskets, O rings U rings, V rings as Sets

applicable
1.9.2.6
All washers other than in sl.no.1.9.2.2, Sets

screws, bolts, studs nuts, pins, circlips
1.9.2.7
Coupling (connecting Pump & Motor) Set

complete along with coupling bolts, nuts,
washers and bushes
1.9.2.8
Auxiliary oil pump motor
Document Number
LII-GETS12021-G-00129-002
No.
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[11]
25.09.2014
Power Plant]
[Logo of Utility]
Sl. No
Description
Unit
Quantity
1.9.2.9
Bearings for Auxiliary oil pump motor
Set
1.9.3
Emergency Oil Pump
1.9.3.1
Shaft with keys
Set
1.9.3.2
Impeller with locknut, lock washer and lock Set

screw
1.9.3.3
Bearings
Set
1.9.3.4
Shaft seals
Set
1.9.3.5
Set of gaskets, O rings U rings, V rings as Set

applicable
1.9.3.6
Set of washers other than in sl.no 1.9.3.2, Set

screws, bolts, studs nuts, pins, circlips
1.9.3.7

washers and bushes
1.9.3.8
Emergency oil pump DC motor
No.
1.9.3.9
Bearings for Emergency oil pump DC motor
Set
1.9.4
Jacking oil pump
1.9.4.1
Bearings
Sets
1.9.4.2
Rotating/Runner assembly
Set
1.9.4.3
Set of gaskets, O rings, U rings, V rings Set

as applicable
1.9.4.4
Set of washers including lock washers and Set

spring washers, screws, bolts, studs nuts,
pins, circlips as applicable
1.9.4.5

washers and bushes
1.9.4.6
Complete set of pressure regulating valves Set

for jacking oil system (all regulating valves for
1 unit)
1.9.4.7
Jacking oil pump without motor
No.
1.9.4.8
Jacking oil pump motor
No.
1.9.4.9
Bearings for Jacking oil pump motor
Set
Document Number
LII-GETS12021-G-00129-002
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[12]
25.09.2014
Power Plant]
Sl. No
Description
1.9.5
Control oil pump
1.9.5.1
[Logo of Utility]
Unit
Quantity
Set of bearings
Set
1.9.5.2
Rotating / Runner assembly
Set
1.9.5.3
Set of gaskets O rings, V rings, U rings as Set

applicable
1.9.5.4
Set of washers, circlips, screws, studs, bolts, Set

nuts, pins as applicable
1.9.5.5

washers and bushes
1.9.5.6
Control oil pump without motor
No.
1.9.5.7
Control oil pump motor
No.
1.9.5.8
Bearings for Control oil pump motor
Set
1.9.6
Duplex Oil Filter for Lub Oil
1.9.6.1
Filter element
Set
1.9.6.2
O rings/sealing rings
Sets
1.9.6.3
Change over valve
Set
1.9.7
Duplex Oil Filter for Control Oil, if

applicable
1.9.7.1
Filter element
Set
1.9.7.2
O rings/sealing rings
Sets
1.9.7.3
Change over valve
Set
1.10
Shaft Turning Gear Spares
1.10.1
Shaft turning gear hydraulic motor
No
1.10.2
Bearings in the shaft turning gear
Set
1.11
Oil Coolers
1.11.1
Set of gaskets, O rings as applicable for oil Sets

coolers
1.12
Oil vapour extractor
Document Number
LII-GETS12021-G-00129-002
Remarks
Nozzle box
for
turbine
type turning
gear
Rev
No.
Description
Page
No.
Date of Issue
01

[13]
25.09.2014
Power Plant]
[Logo of Utility]
Sl. No
Description
Unit
Quantity
1.12.1
Set of bearings
Set
1.12.2
Shaft with sleeves, keys lock washer, lock Set

nut if applicable
1.12.3
Impeller
No.
1.12.4
Set of gaskets/ O rings
Set
1.12.5
Set of bolts, studs, washers, screws, nuts, Set

circlips, pins
1.12.6
Coupling (connecting fan & Motor) complete Set

(if applicable) along with coupling bolts, nuts,
washers and bushes, if applicable
1.12.7
Oil vapour extractor, with motor
No.
1.12.8
Bearings for Oil vapour extractor motor
Set
1.13
Lube oil purification unit
1.13.1
Centrifuge oil inlet valve
No
1.13.2
Brake for centrifuge
Set
1.13.3
All internals of centrifuge clutch assembly
Sets
1.13.4
Clutch assembly
Set
1.13.5
All types of bearings in the centrifuge
Set
1.13.6
Springs, rubber rings, O rings, observation Set

glasses, seal rings, disc, gaskets, sleeves
pins and bolts & nuts
1.13.7
All filters
Set
1.13.8
Heater elements
Set
1.13.9
Centrifuge motor
No.
1.13.10
Bearings for Centrifuge motor
Set
1.13.2
Dirty oil pump in Oil Purification System,

if applicable
1.13.2.1
Rotating assembly
Set
1.13.2.2
Bearings
Set
1.13.2.3
wearing rings
applicable
if Set
1.13.2.4
Dirty oil pump motor
No.
Document Number
LII-GETS12021-G-00129-002
(for
centrifugal
pump)
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[14]
25.09.2014
Power Plant]
Sl. No
Description
Unit
Quantity
1.13.2.5
Bearings for Dirty oil pump motor
Set
1.13.3
Clean oil pump in Oil Purification System, if

applicable
1.13.3.1
Rotating assembly
Set
1.13.3.2
Bearings
Set
1.13.3.3
wearing rings
applicable
if Set
1.13.3.4
Clean oil pump motor
No.
1.13.3.5
Bearings for Clean oil pump motor
Set
1.14
2.
[Logo of Utility]
(for
centrifugal
pump)
Remarks
Gland sealing system
1.14.1
Gland seal regulator
No
1.14.2
Set of gaskets and O rings
Set
1.14.3
Filters and traps
Set
1.14.4
Gland steam exhauster with motor
No.
Unit
Quantity
TG Cycle Auxiliary Equipment

Sl. No
Description
2.0
CONDENSER SYSTEM
2.1.
Condenser
2.1.1
All Gaskets, O-rings
2.1.2
Set
10
2.1.3
Tubes
2.1.4
Plugs for tube plugging
2.2
Condenser on load tube cleaning system
2.2.1
Sponge balls
Charges
24
2.2.2
Abrasive balls
Charges
2.2.3
Worm gear assembly for Ball separator screen
Set
2.2.4
Ball separator screen
Set
2.3
Remarks
DP Measuring System
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[15]
25.09.2014
Power Plant]
Sl. No
Description
Unit
[Logo of Utility]
Quantity
Connecting board
No
O Ring
Set
Micro switch assembly
set
Glass window
No
Gasket
Set
Pointer
No
Remarks
DPG
2.4
Ball recirculating pump for tube cleaning

system
2.4.1
Rotating assembly
Set
2.4.2
Shaft with sleeves
Set
2.4.3
Wearing rings (if applicable)
Set
2.4.4
Bearings
Set
2.4.5
Impeller
No.
2.4.6
Ball recirculating pump motor
No.
2.4.7
Bearings for recirculating pump motor
Set
3.0
CONDENSATE EXTRACTION PUMP
3.1
All gaskets, O-rings, U-rings/V-rings
Sets
3.2
Impellers (complete set)
Set
3.3
Shaft sleeves
Sets
3.4
Wearing rings
Set
3.5
Guide bearings
Sets
3.6
Thrust bearing including radial and axial shoes

and thrust collars
Sets
3.7
Pump shaft
Set
3.8
Sets
Document Number
LII-GETS12021-G-00129-002
Rotating
assembly
consists of all
the
rotating
parts
except
bearings
Rev
No.
Description
Page
No.
Date of Issue
01

[16]
25.09.2014
Power Plant]
Sl. No
Description
Unit
[Logo of Utility]
Quantity
3.9
All bolts, nuts, washers, keys, pins, screws

and circlips
Set
3.10
Connecting coupling with motor complete with

coupling bolts, nuts washers & bushes
Set
3.11
Motor bearings of each type & size
Set
3.12
Terminal bushings of each type
Nos.
3.13
Cooling fan assembly
No.
3.14
Condensate Extraction Pump Motor complete
No.
4.0
FEED HEATERS AND DEAERATOR
4.1
H.P Heaters (Spares for each HP heater)

Set
10
Nos.
Set
10
Nos.
4.1.1
Gaskets of all sizes
4.1.2
Bolts, washers and nuts for Manhole cover

assembly
4.1.3
Heater vent orifice for each heater
4.2
L.P Heaters (Spares for each LP heater)
4.2.1
Gaskets of all sizes
4.2.2
Bolts, washers and nuts for Manhole cover

assembly
4.2.3
Heater vent orifice for each heater
4.3
Deaerator
4.3.1
Spray valves/nozzles assembly
Set
4.3.2
Bolts, nuts and washers for fixing spray nozzle

assembly
Set
4.3.3
Gaskets of all types
Set
4.3.4
Bolts, washers and nuts for manhole cover

assembly
10
5.0
Remarks
BOILER FEED PUMPS
5.0.1
Complete BFP cartridge assembly
Set
5.0.2
All wearing rings with fixing screws, if any
Set
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[17]
25.09.2014
Power Plant]
Sl. No
Description
Unit
[Logo of Utility]
Quantity
5.0.3
Balancing device (stationary & rotory)
Sets
5.0.4
Shaft with shaft sleeves, keys and locknuts.
Set
5.0.5
All bolts, nuts, washers, screws and bushes
Set
5.0.6
All O-rings, U-rings/V-rings, oil seals and

gaskets
Sets
5.0.7
Mechanical seal assembly complete
Sets
5.0.8
All bearings
Sets
5.0.9
Thrust pads
Sets
5.0.10
Thrust collar if not integral with shaft
No.
5.0.11
Recirculation valve with actuator
Sets
5.0.12
Set
5.0.13
Nos.
5.0.14
No.
5.0.15
Boiler Feed Pump Motor complete
No
5.1
Remarks
1 set consists of
total
no.
of
mechanical seal
assemblies
in
one pump
Lubrication oil pump for Boiler Feed pump

set
5.1.1
Rotating Assembly complete
Set
5.1.2
Bearings
Set
5.1.3
Wearings rings
applicable)
Set
5.1.4
Lubricating oil pump motor
No.
5.1.5
Bearings for Lubricating oil pump motor
Set
5.1.6
Duplex filter assembly
Set
5.1.7
Duplex Filter elements
Sets
Document Number
LII-GETS12021-G-00129-002
for
centrifugal
pump
(if
Rotating
assembly
consists of all
the
rotating
parts
except
bearings.
Rev
No.
Description
Page
No.
Date of Issue
01

[18]
25.09.2014
Power Plant]
Sl. No
6.0
Description
Unit
[Logo of Utility]
Quantity
BOOSTER PUMP FOR BOILER FEED PUMP
6.0.1
All Bearings
Set
6.0.2
Shaft with shaft sleeves, keys and locknuts
Set
6.0.3
Wearing rings
Sets
6.0.4
Shaft coupling between Motor and booster

pump along with coupling bolts, bushes, nuts
and washers
Set
6.0.5
All O-rings, U-rings/V-rings, oil seals and

gaskets
Sets
6.0.7
Mechanical seal assembly complete
Sets
6.0.8
Rotating assembly complete
Set
6.0.9
Impeller
No.
6.1
Rotating
assembly
consists of all
the
rotating
parts except the
bearings.
Booster pump suction strainers
6.1.1
Fine mesh screens
Sets
6.1.2
Coarse mesh screens
Sets
6.1.3
Gaskets
Sets
6.1.4
Bolts, nuts & washers
Set
7.0
Remarks
HYDRAULIC
FEED PUMP
COUPLING
FOR
BOILER
7.0.1
All bearings
Sets
7.0.2
Primary and secondary wheels along with

shafts
Set
7.0.3
Scoop tube & actuator
Set
7.0.4
Oil filter elements
Sets
7.0.5
All Gaskets, oil seals, O-rings, U-rings/ V-rings

and sealing rings
Sets
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[19]
25.09.2014
Power Plant]
Sl. No
Description
Unit
[Logo of Utility]
Quantity
7.0.6
All thrust collars
Sets
7.0.7
Gears for filling pump drive
Set
7.0.8
Fusible plug
Set
7.0.9
Guide bush for scoop tube
Nos.
7.0.10
Starting lub oil pump
No.
7.0.11
Duplex oil filter complete
Set
7.0.12
Motor for Starting lub oil pump
No.
7.0.13
Bearings for motor of Starting lub oil pump
Set
7.0.14
Shaft coupling between Hydraulic coupling and

Boiler Feed pump along with coupling bolts,
bushes, nuts and washers
Set
7.0.15
Shaft coupling between Hydraulic coupling and

Motor along with coupling bolts, bushes, nuts
and washers
Set
8.0
NOT USED
9.0
NOT USED
10.0
DM COOLING WATER SYSTEM
10.0.1
DM Cooling Water Pumps
10.0.2
Complete rotating assembly
Set
10.0.3
Shaft sleeves
Set
10.0.4
All wearing rings
Set
10.0.5
Pump shaft
Set
10.0.6
Impeller
No
10.0.7
Bearings
Set
Document Number
LII-GETS12021-G-00129-002
Remarks
Rotating
assembly
consists of all
the
rotating
parts except the
bearings.
Rev
No.
Description
Page
No.
Date of Issue
01

[20]
25.09.2014
Power Plant]
Sl. No
Description
Unit
[Logo of Utility]
Quantity
10.0.8
Set
10.0.9
All bolts, nuts, washers, pins, keys and

gaskets
Set
10.0.10
Coupling (connecting Pump & Motor) complete

along with coupling bolts, nuts, washers and
bushes
Set
10.0.11
Set
10.0.12
Nos
10.0.13
No
10.0.14
Motor for Auxiliary Cooling Water Pump
No
11.0
11.1.1
LP CHEMICAL DOSING SYSTEM

Hydrazine Dosing Pumps
11.1.1.1
Plunger / Diaphragm
Set
11.1.1.2
Bearings
Set
11.1.1.3
All gaskets, O-rings and Gland packing
Set
11.1.1.4
All Ball valves
Set
11.1.1.5
Relief Valves
No.
11.1.1.6
Oil and Grease seals
Set
11.1.1.7
Hydrazine dosing pump motor
No.
11.1.1.8
Bearings for hydrazine dosing pump motor
Set
Set
11.1.2
11.1.2.1
11.2.1
Remarks
Agitator for Hydrazine Dosing Tank

Impeller/Propeller with Shaft
Ammonia Dosing Pumps
11.2.1.1
Plunger / Diaphragm
Set
11.2.1.2
Bearings
Set
11.2.1.3
All gaskets, O-rings and Gland packing
Set
11.2.1.4
All Ball valves
Set
11.2.1.5
Relief Valves
No.
11.2.1.6
Oil and Grease seals
Set
11.2.1.7
Ammonia dosing pump motor
No.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[21]
25.09.2014
Power Plant]
Sl. No
11.2.1.8
11.2.2
11.2.2.1
Description
Unit
Bearings for Ammonia dosing pump motor
[Logo of Utility]
Quantity
Set
Set
Remarks
Agitator for Ammonia Dosing Tank

Impeller/Propeller with Shaft
12.0
Condensate transfer pumps
12.1
Set
12.2
Shaft sleeves
Set
12.3
All wearing rings
Set
12.4
Pump shaft
Set
12.5
Impeller
No
12.6
Bearings
Set
12.7
Set
12.8
All bolts, nuts, washers, pins, keys and

gaskets
Set
12.9
Coupling (connecting Pump & Motor) complete

along with coupling bolts, nuts, washers and
bushes
Set
12.10
Set
12.11
Nos
12.12
No
12.13
Motor for Auxiliary Cooling Water Pump
No
13.0
Vacuum Pumps
13.1
Set
Document Number
LII-GETS12021-G-00129-002
Rotating
assembly
consists of all
the
rotating
parts except the
bearings.
Rotating
assembly
consists of all
the
rotating
parts except the
bearings.
Rev
No.
Description
Page
No.
Date of Issue
01

[22]
25.09.2014
Power Plant]
Sl. No
13.2
Description
Unit
Bearings
Document Number
LII-GETS12021-G-00129-002
Set
[Logo of Utility]
Quantity
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[23]
25.09.2014
Power Plant]
B.
[Logo of Utility]
ELECTRICAL
Sl.No
Description
Unit
Qty.
1.0
GENERATOR
1.1
Generator Bearing
Set
1.2
Generator terminal bushings complete with

hardware
Nos.
1.3
Brushes
Sets
1.4
Brush holders
Set
1.5
Labyrinth seal for seal oil H2 side, air side
Set
1.6
Labyrinth seal for Bearings
Set
1.7
Seal ring for shaft seal
Sets
1.8
O rings, gaskets, rubber chords, sealing paste
Set
1.9
Slot wedges (rotor)
Set
Slot wedges (stator)
Set
1.10
Current carrying bolts (inner and outer)
Set
1.11
Slip rings complete with insulated bush
Set
1.12
Fan blades & pins
10
1.13
Gas cooler complete
No.
1.14
Retaining ring complete
Set
1.15
Bolts of each type used in endshields,

bearings, manholes, seal body & inspection
holes
Nos.
10
1.16
Stator winding bar(lower)
Nos.
1.17
Stator winding bar(upper)
Nos.
1.18
Stator Water Cooling System
1.18.1
Teflon Water hose with terminal connectors at

turbine end and exciter end.
No.
1.18.2
Cartridge for Stator water pump
No.
1.18.3
Pump bearings
Set
1.18.4
Motor bearings
Set
1.18.5
Water seals for stator water pump
Set
1.18.6
Filter element
No.
Document Number
LII-GETS12021-G-00129-002
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[24]
25.09.2014
Power Plant]
[Logo of Utility]
Sl.No
Description
Unit
Qty.
1.18.7
Gaskets
Set
1.19
Sight glass
No.
1.19.2
Liquid detectors
No.
1.19.3
H2&CO2 System
1.19.3.1
Valves in H2 cooling system of each type &

size
Set
1.19..3.2
H2 pr. reducing valve each type in gas post
No.
1.19.3.3
CO2 pressure reducing valve each type in gas

post
No.
1.19.3.4
CO2 vapouriser heater
No.
1.19.3.5
Thermostat for CO2 vapouriser heater
No.
1.19.3.6
H2 gas dryer heater
No.
1.19.3.7
Thermostat for H2 gas dryer heater
No.
SEAL OIL SYSTEM
1.20.1
AC&DC Seal oil pump bearings
Set
1.20.2
AC&DC Seal oil pump motor bearings
Set
1.20.3
AC&DC Seal oil pump motors each
No.
1.20.4
Vacuum pump with motor
No.
1.20.5
Crank shaft seal for AC&DC seal oil pumps
Set
1.20.6
Differential pressure regulator of each type
No.
1.20.7
Seal oil system valve of each type
No.
1.20.8
AC&DC Seal oil pumps each
No.
1.20.9
Seal oil filter element
No.
1.20.10
Seal oil vapour extractor
No.
1.20.11
Float valve each type
No.
1.20.12
Gaskets
Set
1.21
Set comprises
the complete
requirement
Miscellaneous Items for Generator
1.19.1
1.20
Remarks
Set comprises
the complete
requirement
Local Cubicle (Seal oil system & Gas system)
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[25]
25.09.2014
Power Plant]
[Logo of Utility]
Sl.No
Description
Unit
Qty.
1.21.1
Electronic cards/modules of each type
No.
1.21.2
Relays of each type
No.
1.21.3
Contactor of each rating
No.
1.22
DC Starter Panels
1.22.1
Relays of each type
No.
1.22.2
Contactor of each rating
No.
1.22.3
Fuses of each type & rating
Nos.
1.23
Static Excitation System
1.23.1
Thyristor cooling fan
No.
1.23.2
PLC cards of each type
Nos.
1.23.3
Relays of each type
Nos.
1.23.4
Fuses of each type and rating
Nos.
10
1.23.5
MCBs of each rating
No.
1.23.6
Semi-conductor fuses of each type
Nos.
1.23.7
Switches of each type
No.
1.23.8
Push Buttons of each type
Nos.
1.23.9
Power pack of each type/function
No.
1.23.10
Transducers of each type
No.
1.23.11
Diodes of each type
No.
1.23.12
Contactors of each type
No.
1.23.13
Timers of each type
No.
1.23.14
Transformers of each type
No.
1.23.15
Field flashing diode bridge
No.
1.23.16
Field flashing contactor
No.
1.23.17
DC over voltage (crow bar) protection with

diode and PCB
Set
1.23.18
Thyristor with fuses and micro switches for

100% load
Set
1.23.19
Thyristor bridge isolating switch(AC&DC) of

each type
No.
1.23.20
Static excitation Transformer complete
No.
Document Number
LII-GETS12021-G-00129-002
Remarks
(2 bridges)
Rev
No.
Description
Page
No.
Date of Issue
01

[26]
25.09.2014
Power Plant]
Sl.No
[Logo of Utility]
Description
Unit
Qty.
1.23.21
Resistors and capacitors of each type
No.
1.23.22
RC network for exciter circuit for AC overvoltage protection
Set
1.23.23
Electronic cards/Modules of each type
No.
1.23.24
Field circuit breaker
No.
1.24.1
Two (2) sets of each type of cards, including

One (1) set of each type of fixed connectors for
cards
Lot
1.24.2
Control transformer of each type and rating
sets
1.24.3
Fuses of each type and rating including

thyristor fuses
sets
12
1.24.4
Terminal connectors for external connection
set
1.24.5
Field breaker (Static crowbar type)
No
1.24.6
Thyristors
sets
1.24.7
Switches of each type and rating
sets
1.24.8
Indicating lamps
sets
1.24.9
Discharge registor
no
1.24.10
Power supply module
no
1.24.11
Contractors and Auxiliary switches of each type

and auxiliary relays
no
1.24.12
Motorized fan for forced air cooling (if required)
nos
1.24.13
Pulse transformer
sets
1.24.14
Key board with LCD screen
no
1.24
Remarks
AVR and Brushless Excitation System (If

Brush less Excitation system is offered instead
of Static Excitation System)
2.0
NEUTRAL GROUNDING TRANSFORMER

(FOR GENERATOR)
2.1
NGT mounted CT of each ratio, type and rating
No.
2.2
Seal off bushing
No.
2.3
Supporting insulator
No.
2.4
Resistor unit
Set
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[27]
25.09.2014
Power Plant]
Sl.No
3.0
Description
[Logo of Utility]
Unit
Qty.
Remarks
PROTECTION , CONTROL & RELAY

PANELS
(FOR Generator ,GT,& UT ) (to be repeated
for each panel)
3.1
Protective relays of each type
No.
3.2
Trip relays of each type
No.
3.3
Auxiliary relays of each type
Nos.
3.4
Timers of each type
No.
3.5
Power supply module of each type
No.
3.6
Meters of each type
No.
3.7
Energy meter of each type
No.
3.8
No.
3.9
Push Buttons of each type
Nos.
3.10
Fuses of each type & rating
Nos.
20
3.11
Disconnecting type Terminal Blocks for CT

wiring
Nos.
3.12
Non-disconnecting type Terminal Blocks
Nos.
3.13
Auxiliary CTs of each ratio
No.
3.14
Auxiliary VTs of each ratio
No.
3.15
Transducers of each type
No.
4.0
ISOLATED PHASE BUSDUCT
4.1
Bus support insulators of each size and type
Nos.
10
4.2
Seal off bushing of each type
Nos.
4.3
Flexible connectors of each type &

rating(complete set for all the phases)
Set
4.4
Disconnecting links
Nos.
4.5
Expansion joints(for conductor for all the

phases)
Sets.
4.6
Belleville washer
Nos.
20
4.7
Silica gel breather
No.
4.8
Current Transformers of each ratio, type and

rating
No.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[28]
25.09.2014
Power Plant]
Sl.No
Description
[Logo of Utility]
Unit
Qty.
5.0
6.6 kV SEGREGATED PHASE BUS DUCTS
5.1
Set of seal-off bushing of each type and rating
Nos.
5.2
Set of flexible of each type and rating
Nos.
5.3
Drain plug with cap
Nos.
5.4
Silica gel breathers
Nos.
5.5
Gaskets of each type and rating
Sets.
5.6
Belleville washers
Nos
5.7
Densal or equivalent compound
Kg.
5.8
Space heater set
Sets
6.0
415 V NON-SEGREGATED PHASE

DUCTS
6.1
Set of flexible of each type and rating
Nos.
6.2
Gaskets of each type and rating
Sets.
6.3
Space heater set
Set
6.4
Set of seal-off bushing of each type and

rating(Applicable for oil type transformer)
Nos.
7.0
6.6 KV SWITCHGEAR (TO BE REPEATED

FOR EACH MAKE OF 6.6 kV SWITCHGEAR)
Remarks
BUS
SPARES FOR VACUUM CIRCUIT BREAKER

(Spares for each rating of Breaker)
7.1
Closing & tripping coils each
Nos.
10
7.2
Spring charging motors
Nos.
7.3
Aux. switch assembly, limit position switches
Nos. each
7.4
Operating mechanism rods
Nos.
7.5
Surge suppressor units
Nos.
7.6
Vacuum bottles
Nos.
7.7
Multi pin plug and socket for control
Sets
7.8
Selector Switches of each type and rating
Nos.
7.9
Busbar support insulators of each type
Nos.
20
7.10
Nos.
7.11
Moving and Fixed contact Assembly of each
set
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[29]
25.09.2014
Power Plant]
Sl.No
Description
[Logo of Utility]
Unit
Qty.
Remarks
rating and type

7.12
Numerical Relays of each type
No.
7.13
No.
7.14
Interposing relay for DCS each type
No.
7.15
Clustered type LED of each type/color
Nos.
7.16
CTs of each ratio , type and rating
Nos.
7.17
VTs of each ratio , type and rating
Nos.
7.18
Timer each type
No.
7.19
No.
7.20
Meters of each type
No.
7.21
Contactors of each rating and type.
Nos.
7.22
Disconnecting type Terminal block for CT

wiring
Nos.
7.23
Non-disconnecting type Terminal Block
Nos.
7.24
Shrouds each type
Nos.
7.25
MCB of each type and rating
Nos.
7.26
Shutter mechanism complete of each type
Nos.
7.27
Indicating lamps of each type and rating
Nos.
7.28
Complete assembled Auxiliary Contactor of

each rating
Nos.
7.29
Bi-metal thermal overload relays with single

phase preventers of each rating
Nos.
7.30
Single phase control transformer 415V/110V of

each rating
Nos.
7.31
Fuses of each type and rating:
7.31.1
Power
Nos.
10
7.31.2
Control
Nos.
10
7.32
Fuse puller for each type of fuse
Nos.
7.33
MCCB of each rating & type
Nos.
8.0
FAST BUS TRANSFER PANEL
8.1
Relay of each type
No.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[30]
25.09.2014
Power Plant]
Sl.No
[Logo of Utility]
Description
Unit
Qty.
8.2
MCB of each rating
No.
8.3
Terminal block of each type
No.
8.4
Fast bus transfer unit
No.
9.0
415V SWITCHGEAR (Spares to be repeated

for each make of board)
Remarks
Spares for Breaker (Spares for each rating

of Breaker)
9.1
Breaker complete with operating mechanism

and truck mounted
Nos.
9.2
Closing & tripping coils each
Nos.
9.3
Fixed and moving contact assemblies of each

breaker
Nos.each
9.4
Spring charging motors
Nos.
9.5
Gaskets
Sets
9.6
Aux.switch assembly, limit position switches
nos. each
9.7.1
Busbar support insulators of each type
Nos.
10
9.7.2
No.
9.7.3
Numerical Relays of each type
No.
9.7.4
No.
9.7.5
Interposing relay of each type for DDCMIS
No.
9.7.6
Clustered type LED of each type/colour
Nos.
9.7.7
CTs of each ratio , type and rating
Nos.
9.7.8
VTs of each ratio , type and rating
Nos.
9.7.9
Meters of each type
No.
9.7.10
Fuse and fuse base assembly of each type &

rating
Nos.
10
9.7.11
Timer each type
No.
9.7.12
No.
9.7.13
Disconnecting type Terminal block for CT

wiring
Nos.
9.7.14
Non-disconnecting type Terminal Block
Nos.
9.7.15
Selector switch of each type and rating
Nos.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[31]
25.09.2014
Power Plant]
Sl.No
11.0
Description
[Logo of Utility]
Unit
Qty.
Nos.
10
Remarks
415 V Distribution Board

(ACDB/PDB/MLDB)
(Spares to be repeated for each make of
BOARD)
11.1
Busbar support insulator
11.2
Fuses of each type and rating:
11.2.1
Power
Nos.
10
11.2.2
Control
Nos.
20
11.3
MCB of each type & rating
Nos.
11.4
Switch Fuse Units of each rating & type
Nos.
11.5
MCCB of each rating & type
Nos.
11.6
Meters of each type
Nos.
11.7
Switches of each type and rating
Nos.
11.8
Terminal Blocks
Nos.
10
12.0
415 V Sub-Distribution Board/FUSE

DBS/LDBS/ALDBS
(Spares to be repeated for each make of
Board/panel)
12.1
Nos.
10
12.2
Push button
Nos.
10
12.3
Terminal Blocks
Nos.
10
12.4
MCB of each type & rating
Nos.
12.5
SFU of each rating & type
Nos.
13.0
LT TRANSFORMER (Oil/Dry type)

(for each type and rating of transformers)
13.1
Complete Winding Temperature indicating

equipment
Set
13.2
CTs of each type and rating
No.
13.3
Support Insulators
Set
13.4.1
HV bushing
Nos
13.4.2
LV bushing
Nos
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[32]
25.09.2014
Power Plant]
Sl.No
Description
13.4.3
[Logo of Utility]
Unit
Qty.
LV neutral Bushing
Nos
13.4.4
Bushing CT(LV) of each rating
Nos
13.4.5
Complete set of gaskets
Sets
13.4.6
One valve of each type
Sets
13.4.7
Magnetic oil level gauge with contacts

(for oil type)
Nos
13.4.8
Winding temperature indicator(WTI) with all

accessories
Nos
13.4.9
Dial type Oil temperature indicator(OTI)

(for oil type)
Nos
13.4.10
Silica gel breather
Nos
13.4.11
Buchholz relay
Nos
13.4.12
Radiator unit
No.
13.4.13
Pressure relief device
Nos
13.4.14
Tap Changer Contact
Set
14.0
220 V DC SYSTEM
14.1
Battery
14.1.1
Stand Insulators
Nos.
50
14.1.2
Connectors with Nuts and Bolts
Nos.
50
14.2
Remarks
Battery Chargers
14.2.1
Contactors of each type
Nos.
10
14.2.2
Coils for each type of Contactor
Nos.
10
14.2.3
Main & Aux Contact sets
Nos.
10
14.2.4
DC Ammeter of each type
Nos.
14.2.5
DC Voltmeter of each type
Nos.
14.2.6
AC Ammeter of each type
Nos.
14.2.7
AC Voltmeter of each type
Nos.
14.2.8
Control Switch of each type
Set
14.2.9
Current regulators of each type
Set
14.2.10
Fuses/MCBs of each type & rating
Nos.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[33]
25.09.2014
Power Plant]
Sl.No
[Logo of Utility]
Description
Unit
Qty.
14.2.11
Over load relays of each type
No.
14.2.12
Filter condenser & Filter Fuses
Set
14.2.13
MCCBs of each rating
Nos.
14.2.14
LED Lamps
Sets
14.2.15
PCBs of each type
No.
14.2.16
Control Unit Relay
Nos.
10
14.2.17
SCR module of each type
Nos.
14.2.18
Blocking diode for Battery Charger per board
Nos.
14.2.19
Push Buttons
Nos.
14.2.20
Cooling Fan
No.
15.0
NOT USED
16.0
NOT USED
17.0
NOT USED
Document Number
LII-GETS12021-G-00129-002
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[34]
25.09.2014
Power Plant]
C.
[Logo of Utility]

Sl.No
Description
Unit
1.0
TURBINE SPARES
1.1
Gland seal system
1.1.1
Limit switches for positioning actuator for

seal steam supply and pump valves (gland
seal system)
1.2
Reheater stop valves
1.2.1
Qty.
Nos
Proximity sensor / limit switch for Reheater

stop valves position of each type and range
as applicable
Nos
1.2.2
Limit
switches/inductive
displacement
transducer for Reheater interceptor valve
Nos
1.3
Reheater control valve
1.3.1
Limit switches/Proximity sensor of each type
Nos
1.4
Governing system
1.4.1
Electrical speed measuring device
Nos
1.4.2
Electronic cards for governing system
1.4.2.1
Power supply module (24V DC)
10
1.4.2.2
CPU module (MPU)
10
1.4.2.3
Main power supply unit
10
1.4.2.4
Analog module (I/O)
1.4.2.5
Controller module
10
1.4.2.6
RS 232 / RS 422 Communication cable of %

each type.
10
1.4.2.7
Specialized pre fabricated cable
1.4.2.8
Digital module
10
1.4.2.9
Special types of fuses of each type and %

rating
1.4.2.10
Terminal strips of each type and rating
1.4.2.11
Isolator / MCB of each type and range
Document Number
LII-GETS12021-G-00129-002
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[35]
25.09.2014
Power Plant]
[Logo of Utility]
Sl.No
Description
Unit
Qty.
1.4.2.12
Termination module
1.4.2.13
Contactor (of each type and range)
1.4.2.14
Power supply for unit for governing control %

system
Remarks
10
NOTE: Cards applicable as mentioned above and any other card used in the system other than
mentioned above also shall be included as 10% of each type of modules used in the system for each unit
or minimum one no. Whichever is higher
1.4.3
All types of limit switches / proximity sensors

for position indication used in governing
system of each type
Nos
1.4.4
All type of solenoids valve in the governing

system of each type
Nos
1.4.5
Trip solenoids of each type
Nos
1.5
Oil system
1.5.1
Oil tank level indicator
Nos
1.5.2
Oil tank level transmitter
Nos
1.5.3
Pressure limiting valve
Nos
1.6
ESV
Nos
Nos
Main steam stop valve

1.6.1
Limit switches / Proximity sensor
1.7
MSCV (main steam control valve)
1.7.1
Limit switches / Proximity sensor of each

type
1.8
Valves & Specialties
1.8.1
Position transmitter for all valves of each

type and make
Nos
1.8.2
Solenoid operated valve used in Turbine

area (of each type)
Nos
1.8.3
Solenoid valves (of various types) each type

and make
Nos
1.9
Turbine instruments (for

Turbine & Main Turbine)
1.9.1
Bearing oil drain temp. Indicator of each type
Nos
Document Number
LII-GETS12021-G-00129-002
both
BFP
Rev
No.
Description
Page
No.
Date of Issue
01

[36]
25.09.2014
Power Plant]
Sl.No
Description
Unit
[Logo of Utility]
Qty.
Remarks
and range
1.9.2
Bearing vibration pick up each type
Nos
1.9.3
Eccentricity pick up each type
Nos
1.9.4
Axial shift pick up each type
Nos
1.9.5
Differential expansion pick up for HPT each

type
Nos
1.9.6
Differential expansion pick up for LPT if No.

applicable each type
1.9.7
Casing expansion pick up each type
No.
1.9.8
Speed pick up each type
No.
1.9.9
Zero speed pick up each type
No.
1.9.10
Key phasor each type
No.
1.9.11
Turbine Bearing RTDs supplied separately
10
1.10
HP & LP Bypass
1.10.1
Controller for HP & LP bypass system each No.

type
1.10.2
Safety control unit for HP & LP bypass No.

system (each type) ON OFF hydraulic
valves each type
1.10.3
Electronic modules
1.10.3.1
CPU/PLC module
10
1.10.3.2
Analog signal module
10
1.10.3.3
Digital signal module
10
1.10.3.4
Electronic position module
10
1.10.3.5
Relay module
1.10.3.6
Relay contact and optical isolator
1.10.3.7
Pre fabricated cable along with plug
1.10.3.8
Power supply unit
10
1.10.4
Position transmitter of each type and model
Nos
1.10.5
Limit switches / Proximity sensors of each

type and model
Nos
1.10.6
Proportional control valve
Nos
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[37]
25.09.2014
Power Plant]
Sl.No
Description
1.10.7
Pressure switches for HP/LP bypass system

Each type and range
1.10.8
Level gauge / indicators of each type and No.

range
1.10.9
Flow switch of each type and range
Nos
1.10.10
Solenoid valve of each type and module
Nos
1.11
CEP
1.11.1
Local Temperature indicator for CEP motor No.

bearings and pump bearings each type and
range
1.11.2
Local Bearing oil temp. Indicator each type Nos

and range
1.11.3
RTD for Bearing each type and range
Nos
1.11.4
Winding temp. Sensor for CEP motor
Nos
1.12
Lube oil purification system
1.12.1
Temp. Indicator (0-120 deg.C)
Nos
1.12.2
Level switch
Nos
1.12.3
Pressure gauge range 0-6 bar
Nos
1.12.4
Vacuum gauge of each type and range
No.
1.12.5
Temperature switch
No.
1.12.6
Pressure switch
No.
1.12.7
Resistance thermostats (RTD)
Nos
1.12.8
Temperature controller
Nos
1.12.9
Flow meter
No.
1.12.10
Flow switch
No.
1.12.11
Gauge glass assembly
Sets
1.12.12
Temperature indicator
1.13
MDBFP
1.13.1
Electronic cards of each type and model %

used in BFP scoop tube/speed control. (If
applicable)
10
1.13.2
Scoop tube position pick up sensor
Document Number
LII-GETS12021-G-00129-002
Unit
Nos
Nos
Nos
[Logo of Utility]
Qty.
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[38]
25.09.2014
Power Plant]
Sl.No
Description
1.13.3
Thermometer of each type and range
Nos
1.13.4
Pr. Switches of each type and range
Nos
1.13.5
Diff. Pr. Gauge of each and range
Nos
1.13.6
Pr. Gauges of each range
Nos
1.13.7
Thermocouple / Thermo resistances
Nos
1.13.8
BFP motor winding RTDs
Nos
1.13.9
BFP motor Bearing Temp. Sensor
Nos
1.13.10
Temp. Switches of each range
Nos
1.13.11
Level switches of each range
Nos
1.13.12
Solenoids of each type
Nos
1.13.13
Speed sensor
Nos
1.13.14
Vibration sensors (if applicable)
Nos
1.13.15
Vibration monitor (if applicable)
No.
1.13.16
4 channel vibration / seismic monitor cards
Nos
1.13.17
110 V AC PS unit for vibration analysis
No.
1.13.18
Contactor of each type and ratings
Nos
1.13.19
Rack interface module
No.
1.13.20
Reverse rotation switch for BFP
Nos
1.14
Turbo supervisory instruments
1.14.1
TSI power input module
10
1.14.2
TSI dual vibration monitor
10
1.14.3
TSI dual thrust position monitor
10
1.14.4
TSI dual differential expansion monitor
10
1.14.5
TSI casing expansion monitor
10
1.14.6
Any other electronic module / monitor used in %

TSI and vibration monitor system if any
10
1.14.7
Contactor (of each type)
1.14.8
Rack interface module
1.14.9
Power supply unit
10
1.14.10
Special type connectors, if any
10
Document Number
LII-GETS12021-G-00129-002
Unit
[Logo of Utility]
Qty.
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[39]
25.09.2014
Power Plant]
Sl.No
Description
1.15
Surface condenser HP & LP Feed water heaters

Deaerator, hot well and any other system to
complete the scope
1.15.1
Level switches consisting of each type and

model
No
1.15.2
Complete level switches of each type and

size
No
1.15.3
Switch level mechanism of each type and

model
Nos
1.15.4
Mercury / Micro switch of each type and size
Nos
1.15.5
Float assembly of each type and size
Nos
1.15.6
Gasket of each type and model
Nos
1.15.7
Magnets of each type and size
Nos
1.15.8
Gauge glasses as follows:
1.15.9
Glasses of each type and model of each

type, model and size
Nos
1.15.10
Complete gauge glass assembly including No.

illumination arrangement & isolation valves
1.16
Ball cleaning system
1.16.1
Diff. Pr. Transmitter of each type
Nos
1.16.2
Diff. Pr. Indicators of each type
Nos
1.16.3
Pressure Gauges of each type
Nos
1.16.4
Ball counter of each type
Nos
1.16.5
Valves, of each type
1.16.6
Diff. Switches of each type
1.16.7
Motor operated valves and actuators
Set
1.16.8
PLC and its cards
1.17
I&C Equipments for Turbine area (Feed water

system, Steam extraction system, Heaters, Drain
system, DM Water system, A.C.W system Service
Water system, Condensate system, Drains system
Main steam system and any other system to
complete the scope
Document Number
LII-GETS12021-G-00129-002
Unit
No.
Nos
[Logo of Utility]
Qty.
Remarks
2
2
Rev
No.
Description
Page
No.
Date of Issue
01

[40]
25.09.2014
Power Plant]
Sl.No
Description
Unit
1.17.1
Thermocouple of each type
1.17.2
Temperature switches of each type and

range
Nos
1.17.3
Local temp. Gauge / Thermometer of each

type and range
Nos
1.17.4
Thermo wells of each type
1.17.5
Resistance
(RTD)
type
Nos
1.17.6
Level indicators / gauge of each type and

range
Nos
1.17.7
Pressure switches of each type and range
Nos
1.17.8
Pressure gauge of each type and range
Nos
1.17.9
Level switches of each type and range
Nos
1.17.11
Limit switches of each type and range
Nos
1.17.12
Position limit switch of each type and make

(for all type of actuators)
Nos
1.17.13
Torque switches of each type and model (for

all type of actuators)
Nos
1.17.14
Proximity sensors of each type and make
Nos
1.17.15
Pressure transmitters of each type and range

and make
10
1.17.16
Temperature transmitters of each type, range

and make
10
1.17.17
Differential pressure transmitter of each type

and range and make
10
1.17.18
Level transmitters including Radar type Level

Transmitter of each type and range and
make
10
1.17.19
Transmitters mounting accessories such as manifolds

and its necessary fitting
1.17.19.1
Three way manifolds
1.17.19.2
Five way manifolds
thermometers
each
Qty.
Remarks
%
of
[Logo of Utility]
1.17.10
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[41]
25.09.2014
Power Plant]
Sl.No
Description
Unit
1.17.19.3
Two way manifolds
1.17.19.4
Snubbers
1.17.19.5
Isolation valves
1.17.19.6
Drain valves
1.18
Control valves for Turbine area (Feed water

system, Steam extraction system, Heaters, Drain
system, Demiwater system, A.C.W. system,
Service water system, Condensate system, Drains
system Main steam system and any other system
to complete the scope
1.18.1
Complete set of control valve each size and

type with actuator and its control
1.18.2
Control valves internals
1.18.2.1
Valve stem with plug & seat ring each size Nos
and type
1.18.2.2
Gasket of each type and Size
Nos
1.18.2.3
Body seal gaskets of each size and type
Nos
1.18.2.4
Cage of each size and type
Nos
1.18.2.5
Gland packing each size and type
Sets
1.18.2.6
Valve Trim of each size and type
Nos.
1.19
Actuator internals
1.19.1
Complete set of control valve each size and %

type with actuator and its control
1.19.2
Diaphragm of each type and size
1.19.3
Seal box O ring of each type and size
1.19.4
Color O ring of each type and size
1.19.5
Limit switch (complete instrument) of each %

model and type
1.19.6
Solenoid valve (complete instrument) of each %

model and type
1.19.7
Valve 42ositioned (complete instrument) of %

each model and type
1.19.8
Position transmitters (complete instrument) %
Document Number
LII-GETS12021-G-00129-002
[Logo of Utility]
Qty.
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[42]
25.09.2014
Power Plant]
Sl.No
Description
Unit
[Logo of Utility]
Qty.
Remarks
of each model and type

1.19.9
Air set / regulator with gauge
1.19.10
Air lock relay
1.19.11
Air booster / accumulator
1.20
NOT USED
2.0
GENERATOR
2.1
Resistance thermometer (RTD) of each type

and model
Nos
2.2
Temperature control valve
no
2.3
Duplex RTD for Gen. Winding each type
Nos
2.4
Duplex RTD of Gen. Bearing
Nos
2.5
Level transmitter
Nos
2.6
Portable gas analyzer
No
2.7
H2 pressure gauge of each type and range
Nos
2.8
H2 purity analyzer (complete unit)
No
2.9
Pressure gauge of each type and range used

in generator area
Nos
2.10
Diff. Pressure instrument of each type and

range in generator area
Nos
2.11
Thermometers
Nos
2.12
Pressure switch
Nos
2.13
Temp. Switch
Nos
2.14
Pr. Transmitter each type
Nos
2.15
Diff. Pr. Transmitter
Nos
2.16
Resistance Thermometer used in seal oil

system & H2 circuit, Generator area each
type
Nos
2.17
Level indicator of each type and model
Nos
2.18
Flow indicator
Nos
2.19
Moisture Analyser
Nos
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[43]
25.09.2014
Power Plant]
Sl.No
Description
Unit
3.0
TG INTEGRATED CONTROL SYSTEM
3.1
Work station
3.1.1
Work station including LAN card
Nos
3.1.2
TFT colour monitors
Nos
3.1.3
Color Inkjet Printer A4 B/W
Nos
3.1.4
Color Laser Printer A4
Nos
3.1.5
Printer network connector
Nos
3.1.6
21 TFT Color monitor for OS & ES
Nos
3.1.7
Compact disk boxes
Nos
3.2
Control cabinets
3.2.1
Analog input module
3.2.2
Analog output module
3.2.3
Digital input module
3.2.4
Digital output module
3.2.5
Input temperature module
3.2.6
Any other module used in DDCMIS
3.3
Power supply distribution & SOV
3.3.1
Breakers 220V each current rating
3.3.2
Solenoid breaker (2A)
3.4
Relay
3.4.1
Relay for SOV
Nos
25
3.4.2
Trip relay (master fuel trip)
Nos
3.4.3
Relays
3.4.4
Voltage monitor relay
Nos
10
3.4.5
Supply unit 24 volt
Nos
[Logo of Utility]
Qty.
Remarks
10
NOTE: Cards applicable as mentioned above and any other card used in TG integral control system other
than mentioned above also shall be included as 10% of each type of modules used in the system for each
unit or minimum one no. Whichever is higher
3.5
Push buttons
3.5.1
Trip push button each type
Document Number
LII-GETS12021-G-00129-002
Nos
Rev
No.
Description
Page
No.
Date of Issue
01

[44]
25.09.2014
Power Plant]
Sl.No
Description
3.5.2
Round PB each type
Nos
3.5.3
Lamp test white each type
Nos
3.5.4
Release black each type
Nos
3.5.5
Alarm RED each type
Nos
3.5.6
Reset RED each type
No
3.6
Miscellaneous Items
3.6.1
Preformed cable of each length (50 m)

different cores with male/female connectors
of pre fabricated cables each type & each
unit
Nos
3.6.2
Connectors used for pre fab. Cables each

type
Nos
3.6.3
Coaxial 10 Base 2 (as applicable)
3.6.4
Coaxial 75 ohm Base 2 (as applicable)
3.6.5
Duplex optical fiber
2.5
3.6.6
Wire cable connectors
Nos
100
3.6.7
Nos
50
3.6.8
MCB of each type and rating
Nos.
10
3.6.9
Terminals of each type
Nos.
100
3.6.10
Indicators of each type & model (ammeter,

voltmeter) (if applicable)
3.6.11
Digital indicators of each type & model
Nos.
3.6.12
Digital bargraph indicator
Nos.
3.6.13
Digital indicator MVAR
No.
3.6.14
Digital indicator MW
No.
4.0
PLC
4.1
Electronics modules for each type
10
4.2
Power supply unit for each type
10
4.3
Graphical Interface units for each type
No.
4.4
Cooling fan in PLC system / cabinet
Nos.
4.5
TFT Monitor for each type & size
No.
Document Number
LII-GETS12021-G-00129-002
Unit
[Logo of Utility]
Qty.
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[45]
25.09.2014
Power Plant]
Sl.No
Description
Unit
4.6
Printer for each type
No.
5.0
CABLE
5.1
FRLS cables of each size and type (1 std std

drum
drum = 500 mts.)
5.2
Thermocouple compensating cable of each std

drum
size and type (1 std drum = 500 mts.)
5.3
Turbovisory cable (special shielded cables of std

drum
each size and type) (1 std drum = 500 mts.)
5.5
Fibre optic cable. (1 set = maximum length Sets

used in the installed quantity along with its
connectors)
5.6
Serial link cable. (1 set = maximum length Sets

used in the installed quantity along with its
connectors)
5.7
DDCMIS cables of each type
200
5.8
Communication cable. (1 set = maximum Sets

length used in the installed quantity along
with its connectors)
Document Number
LII-GETS12021-G-00129-002
[Logo of Utility]
Qty.
Remarks
Rev
No.
Description
Page
No.
Date of Issue
01

[46]
25.09.2014

OF

R&M CONTRACTORS

VOLUME-II
SECTION-I, ANNEXURE-III
LIST OF SUB-VENDOR
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-002 R01
September 2014
Power Plant]
[Logo of Utility]
ANNEXURES-III
List of Sub-vendor
{List of approved vendor for the equipment system to be replaced / refurbished /
retrofitted under the scope of this R&M Tender shall be provided as in the given
format.}
A.
MECHANICAL
Sl. No
B.
Sub Vendors
1.
[]
[]
2.
[]
[]
3.
[]
[]
4.
[]
[]
5.
[]
[]
[]
[]
ELECTRICAL
Sl. No
Sub Vendors
1.
[]
[]
2.
[]
[]
3.
[]
[]
4.
[]
[]
5.
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[2]
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Power Plant]
C.

Sl. No
D.
[Logo of Utility]
Sub Vendors
1.
[]
[]
2.
[]
[]
3.
[]
[]
4.
[]
[]
5.
[]
[]
[]
[]
CIVIL
Sl. No
Sub Vendors
1.
[]
[]
2.
[]
[]
3.
[]
[]
4.
[]
[]
5.
[]
[]
[]
[]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
01

[3]
25.09.2014

OF

R&M CONTRACTORS

VOLUME-II
SECTION-II, PART-A
DETAILED TECHNICAL SPECIFICATIONMECHANICAL
PREPARED BY
THE CONSULTANT
LII-GETS12021-G-00129-002 R03
January 2016
Power Plant]
[Logo of Utility]

Volume
Section
Part
Description
Volume-I
---
---
Commercial
Section-I
---
Part-A
Part-B
Part-C
Part-D
---
Part-A
---
Part-B
---
Part-C
---
Part-D
Not Used
Volume-II
Section-II
Volume-III
*****
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[i]
15.01.2016
Power Plant]
[Logo of Utility]
1.
Invitation For Bid
2.
3.
4.
5.
6.
Forms and Schedules
*****
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[ii]
15.01.2016
Power Plant]
[Logo of Utility]

1.
2.
3.
4.
5.
6.
7.
8.
9.
Spare Parts
10.
Annexure
SECTION-II:
1.
2.
3.
4.
*****
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[iii]
15.01.2016
Power Plant]
[Logo of Utility]

1.
2.
3.
*****
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[iv]
15.01.2016
Power Plant]
[Logo of Utility]
TABLE OF CONTENT
1
TURBINE GENERATOR & AUXILIARIES ......................................................................... 1

1.1
General Information ..................................................................................................... 1
1.2
Material Requirements ................................................................................................. 1
1.3
Maintenance Requirements ......................................................................................... 3
1.4
Accessories to be Furnished ........................................................................................ 3
1.5
Steam Turbine Rating .................................................................................................. 5
1.6
Salient Design Features of Turbine and its Accessories .............................................10
1.7
Steam Turbine Performance Requirements ................................................................28
CONDENSER AND CONDENSER AIR EVACUATION SYSTEM .....................................31

2.1
General .......................................................................................................................31
2.2
Codes and Standards .................................................................................................31
2.3
Design Parameters .....................................................................................................32
2.4
Design and Construction Requirements ......................................................................36
2.5
2.6
Drawings, Data and Information Required ..................................................................42
FEED WATER HEATER AND DEAERATOR ....................................................................43

3.1
General .......................................................................................................................43
3.2
Low Pressure Heaters and Drain Cooler .....................................................................44
3.3
Deaerator....................................................................................................................45
3.4
High Pressure Heaters ................................................................................................46
3.5
General Performance Requirement ............................................................................46
3.6
Design & Construction Requirement ...........................................................................47
POWER CYCLE PUMPS...................................................................................................53

4.1
General Information ....................................................................................................53
4.2
Equipment and Accessories to be Furnished ..............................................................53
4.3
General Performance Requirement ............................................................................55
4.4
Boiler Feed Pump Design and Construction ...............................................................58
4.5
Condensate Extraction Pump Design and Construction ..............................................64
4.6
Drawings, Data and Information Required ..................................................................65
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[v]
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Power Plant]
4.7
5
[Logo of Utility]
Specific Design Criteria for Power Cycle Pumps .........................................................65
LP CHEMICAL DOSING SYSTEM ....................................................................................68

5.1
General .......................................................................................................................68
5.2
Equipment and Accessories to be Furnished ..............................................................68
5.3
Strainer .......................................................................................................................70
5.4
Piping..........................................................................................................................70
5.5
Valves .........................................................................................................................70
5.6
Control Skid ................................................................................................................70
5.7
PIPING, VALVES & FITTINGS ..........................................................................................71

6.1
General .......................................................................................................................71
6.2
Codes & Standards .....................................................................................................72
6.3
Design Basis ...............................................................................................................77
6.4
Piping Design..............................................................................................................80
6.5
Stress Analysis ...........................................................................................................81
6.6
Statutory Approvals.....................................................................................................83
6.7
Installation ..................................................................................................................83
6.8
6.9
Low Pressure Piping, Valves and Fittings ...................................................................85
6.10
Thermal Insulation ......................................................................................................87
6.11
Fittings ........................................................................................................................88
6.12
Design and Construction .............................................................................................88
6.13
Piping Layout ..............................................................................................................89
6.14
Valves .........................................................................................................................91
6.15
Cleaning .....................................................................................................................94
6.16
Inspection and Tests ...................................................................................................94
6.17
6.18
Specific Requirement For Valves ................................................................................95
6.19
Gates ..........................................................................................................................97
6.20
Strainers .....................................................................................................................97
6.21
Steam Traps ...............................................................................................................98
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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Power Plant]
[Logo of Utility]
6.22
Instrument Connections ..............................................................................................99
6.23
Drain and Vent Connections .......................................................................................99
6.24
Welding and Heat Treatment ......................................................................................99
6.25
Underground Protection ..............................................................................................99
6.26
Non-Destructive Examination ....................................................................................100
6.27
Hydrostatic Test Pressure .........................................................................................100
QUALITY ASSURANCE ..................................................................................................101

7.1
Quality Assurance, Inspection & Testing ...................................................................101
7.2
General Requirements - Quality Assurance ..............................................................101
7.3
QA Documentation Package .....................................................................................105
7.4
Inspection, Testing and Inspection Certificates .........................................................106
7.5
Shop and Site Tests:.................................................................................................107
7.6
Turbine .....................................................................................................................108
7.7
Tests on Auxiliaries ...................................................................................................109
7.8
Condenser ................................................................................................................109
7.9
L.P. & H.P. Heaters...................................................................................................110
7.10
Deaerator..................................................................................................................111
7.11
Condensate extraction Pump (CEP) .........................................................................111
7.12
Boiler Feed Pump & Booster pump of BFP ...............................................................112
7.13
Other Major Pumps (More than 75 kW).....................................................................113
7.14
Minor Pumps & Fans (Less than 75 kW): ..................................................................114
7.15
Turbine Oil Purification System .................................................................................114
7.16
Acceptance Tests for STG ........................................................................................115
7.17
Piping & Fittings: .......................................................................................................115
7.18
Valves .......................................................................................................................116
7.19
Heat Exchangers ......................................................................................................117
7.20
Lube Oil Systems / Hydraulic Power Pack ................................................................117
7.21
Motors.......................................................................................................................117
7.22
Control & Instrumentation: ........................................................................................117
7.23
Site Tests..................................................................................................................117
7.24
System Checking / Reliability Trials: .........................................................................117
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[vii]
15.01.2016
Power Plant]
TURBINE GENERATOR & AUXILIARIES
1.1
General Information
[Logo of Utility]
[The steam turbine-generator shall be located within a weather proof enclosure

with a roof above the operating floor. The turbine-generator shall consist of a
3000 RPM tandem compound, single reheat, uncontrolled extraction, condensing
type turbine, directly coupled to the generator. The HP, IP and LP casing shall be
either independent of each other or a combination of these. The turbine low
pressure ends shall be arranged for bottom exhaust to water cooled condenser.
The unit shall have nominal 210/215/220/250 MW output. The steam turbine
generator shall be horizontal, fully enclosed, hydrogen cooled type or direct
water-cooled stator and hydrogen cooled rotor conductors. All the auxiliaries for
turbine generator shall be provided.
Each 210/215/220/250 MW Steam Turbine shall be connected to a Steam
generator. The steam turbine shall be supplied with steam for generation of
power and for regenerative feed heating through uncontrolled extraction points.
Determination of number of turbine casing extraction points, turbine stages for
extraction and final feed water temperature extraction parameters shall be based
on the cycle optimization study by the Bidder considering turbine manufacturer's
proven standard design.
The turbine shall provide extraction steam for feed water heating, gland sealing,
as required.
This section of the specification shall be read in conjunction with the other
Sections & Volumes of the specification as appropriate and the equipment
offered shall meet the requirement as spelt out there-in and to complete the
system requirement.]
{The double flow Baumann exhaust of LP stage of LMZ design Steam Turbine
shall be retrofitted to improve the efficiency of LP Turbine. In addition retrofitting
of LP Stage/ HP stage / IP stage / both HP & IP stages shall be carried out both
for LMZ and KWU Turbines as per the findings of Steam Path Audit conducted
during the RLA studies. The Utilities may appropriately incorporate the
specifications of retrofitting the Turbines in Section-II of the specifications after
the scope of work under Section-I is finalized.}.
1.2
Material Requirements
The Bidder shall submit the schedule of materials used in turbine construction.
The materials to be used shall not be inferior to those mentioned below.
Table: 1.1
S.No
Description
i)
[Turbine casing]
Material
HP outer casing
Document Number
LII-GETS12021-G-00129-002
GS-17 Cr. Mo V 511
Rev
No.
Description
Page
No.
Date of Issue
03

[1]
15.01.2016
Power Plant]
S.No
ii)
iii)
iv)
Description
Material
HP blade casing
GS-17 Cr. Mo V 511
IP casing
GS-22 Mo 4
LP casing
R St 37-2N
[Turbine shaft and shaft coupling]

HP shaft
28 Cr. Mo Ni V 59
IP shaft
30 Cr. Mo Ni V 511
LP shaft
26 Ni Cr. Mo V 145
[Moving blade]
HP turbine first stage
X 22 Cr Mo V 121
HP turbine other stage
X 20 Cr Mo 13
IP turbine stages
X 22 Cr Mo V 121
LP turbine stages
X 20 Cr 13
[Fixed blades]
HP turbine first Stage
X 22 Cr Mo V 121
HP other stages
X 20 Cr Mo 13
IP turbine first Stage
X 22 Cr Mo V 121
IP other stages
X 20 Cr Mo 13
LP turbine first Stage
X 20 Cr 13
LP other stages
v)
[Logo of Utility]
X 20 Cr Mo 13
[Casing joint bolts]

HP Cylinder
X 21 Cr Mo V 57
IP Cylinder
X 21 Cr Mo V 57
LP Cylinder
X 24 Cr Mo V 5
vi)
IP/LP crossover/ Cross around piping
R St 37-2 N
vii)
[Turbine steam admission valves]

Valve Body
GS-17 Cr Mo V 511
Valve Spindle
X 22 Cr Mo V 121
Valve seat
Stellited 21 Cr Mo V Ni 47
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[2]
15.01.2016
Power Plant]
1.3
[Logo of Utility]
Maintenance Requirements
i)
Wet Steam a) Each turbine shall be provided with Wet Steam

washing
washing facility as per standard proven practice of the
OEM. For this necessary stub connections on turbine
and required piping shall be provided, if required.
b) Recommended Washing procedures as per standard
proven practice of the OEM shall be furnished.
ii)
iii)
Forced
Cooling
Turbine
of
Turbine
preservation
Necessary equipment shall be provided for forced

cooling of turbine as per standard proven practice of
the OEM to have quick access during emergency
condition.
a) This shall be provided to protect turbine against
corrosion during non working Period.
b) Write up for the recommended preservation system
shall be submitted.
1.4
Accessories to be Furnished
Each steam turbine-generator shall include the following equipment:
i.
[Turbine rotor shall be of solid forged type. The Bidder shall provide material
certificate including material chemical composition, high temperature mechanical
properties, allowable temperature range, non-destructive testing method and
manufacturers name. Minimal contact between the rotor and the cylinder should
not cause rotor damage or bending of the rotor shaft.]
ii.
[Steam pipe from inlet of emergency stop valve up to exhaust flange including all
extraction valves and interceptor valves complete with all integral accessories.
For hot reheat line, scope of Turbine proper shall be limited up to and including
the interceptor valve near the turbine. For cold reheat line, scope of turbine
proper shall be limited up to and including non return valve at the turbine
exhaust.]
iii.
[Complete turbine integral piping and other piping including all valves (isolating,
regulating, non-return, hand-operated and/or pneumatic, motorized), actuators,
air vents, safety valves, relief valves, drains, hangers, supports, anchors and
other fittings.]
iv.
[Power operated (hydraulic/pneumatic) quick closing non-return flow valves for

each extraction line and cold reheat line at HP exhaust.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[3]
15.01.2016
Power Plant]
[Logo of Utility]
v.
[60% BMCR capacity High Pressure (H.P) and Low Pressure (L.P) steam
by-pass station and complete spray system, control valves, desuperheating
devices, valves, controls and instrumentation etc.]
vi.
[Turbine Digital electro hydraulic governing system with triple redundancy

including governors, low vacuum tripping device, bearing protective devices,
solenoid trip etc. as specified hereinafter and all equipment mounted/local
instruments, pressure, temperature, level switch, primary sensing devices etc. as
required.]
vii.
[Suitable turning gear device, either High-speed hydraulic type or motorised

turning gear as per standard proven practice of the Bidder with the provision for
manual barring.]
viii.
[Complete high pressure control oil/fluid and lubricating oil systems with tanks,
shaft driven oil pumps and other necessary pumps and drives, lube oil coolers,
Jacking oil pumps, all connected piping, valves, filters, strainers, vapour
extractors, instruments etc.]
ix.
[Turbine control and protective valve high pressure hydraulic actuation system.]
x.
[Gland steam sealing system with steam pressure regulators, desuperheater (if
required), all piping, valves, steam traps, specialties and associated instruments
and also gland steam condenser, vapour extractors etc Gland sealing system.]
xi.
[All piping, valves and accessories for turbine flanges, casing and stud heating
system as recommended by Bidder for unitized and common system.]
xii.
[Steam turbine exhaust hood spray system including nozzles, power operated
valves and specialties, hangers, supports and insulation, instruments etc.]
xiii.
[Turbine drain system complete with integral piping, valves, fittings, Motor
Operated (M.O) valves, hangers, supports and insulations. Wet steam washing
system for Turbines, if recommended by the OEM.]
xiv.
[Blanking discs for emergency stop and reheat interceptor and control valves
and special bonnets, as required for steam blow out. Provision for steam
blow-out pipe connection with cold Reheat line non-return valve.]
xv.
[Turbine exhaust casing pressure ruptures diaphragms.]
xvi.
[3x50% hot well makeup pumps taking suction from CST. Hotwell makeup pumps
shall serve the makeup requirement of DM water in condenser normal/
emergency makeup, ECW system, AC system chilled water expansion tank and
stator water expansion tank through an alkalizer.]
xvii.
[DC solenoid operated pneumatic vacuum breaker valve with provision for
remote operation.]
xviii.
[Thermal insulation and lagging for turbine equipment and piping covered under
this turbine generator package.]
xix.
[All inserts / embedment / anchor bolts with necessary templates.]
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[4]
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Power Plant]
[Logo of Utility]
xx.
[Coupling between turbine and generator including coupling guard as

necessary.]
xxi.
[Excitation system including AVR, field suppression/flushing equipment,

inter-connecting cables/ bus ducts.]
xxii.
[Generator hydrogen system equipment and controls including associated

piping, valves, coolers, motor starters and control panels as required and
necessary CO2 system, defrostery, manifold, piping and monitoring instruments.]
xxiii.
[Generator terminal bushings and current transformers.]
xxiv.
[Stator water cooling system (if required).]
xxv.
[All pumps and fans.]
xxvi.
[Generator protection equipment such as rotor grounding device and alarms and
runback for abnormal conditions, frame grounding pads, and neutral enclosure.]
xxvii.
[Acoustic cladding for complete steam turbine generator units along with turbine
generator load.]
xxviii.
[Preservation System: Turbine preservation system consisting of adequate

numbers of air drives including fans, motors, filters, heater drying wheel,
connecting piping, valves, fittings etc. for preservation of corrosion of turbine
during idle periods shall be provided.]
Miscellaneous Items
i.
[All sole plates, sub-sole plates, shims, jack-screws and wedges, as required, to
set and align the turbine generator unit.]
ii.
[All foundation frames/base plates, anchor bolts, sleeves, nuts etc. for all
equipment under this section.]
iii.
[Special lifting slings, lifting beams etc. for erection and maintenance of the
turbine cylinders and rotors, generator stator and rotor, bolt heating device,
tongue wrenches etc.]
iv.
[Suitable lifting attachments i.e., lifting lugs, eye bolts slings, etc. for all
equipment to facilitate erection/maintenance.]
v.
[Closed Cycle DM Cooling Water System along with 3 x 50% DM cooling water
pumps, 3 x 50% Plate type heat exchangers, DMCW make-up tank (10 cubic m
capacity), chemical dosing system to maintain pH of closed system, with all
valves, distribution piping etc. for steam Turbine and auxiliaries shall be
provided.]
1.5
Steam Turbine Rating
1.5.1
Indicative Steam Turbine Parameters

[Bidder is free to optimize all terminal parameters viz main pressure, temperature
final feed water temperature and condenser back pressure together with turbine
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

[5]
15.01.2016
Power Plant]
[Logo of Utility]
cycle configuration to offer high availability and most economical plant operation.
Turbines, thus offered shall be highly reliable, proven and well established and
shall be in operation for not less than two (2) years, continuously. Performance
requirements shall be as follows]:
Table: 1.2
(i)
Output under maximum [210/215/220/250] MW

continuous
rating
(TMCR)
(guaranteed
output
load)
at
generator terminals.
(ii)
Over-pressure operation
As per IEC 45
Turbine heat rate at Not more than [1955] kCal/kWh

100% TMCR at rated
condenser vacuum and
0% make-up
(ii)
Turbine throttle steam Not less than [130] kg/cm2 (abs) at the inlet of HP
turbine inlet nozzle
pressure
(iii)
Turbine throttle
steam temp.
(iv)
Reheat steam temp. at [537] C

turbine inlet
(v)
Variations
in
rated As per IEC 45
steam temp. & pressure
(vi)
Pressure drop in reheat [10%] of H.P.T exhaust pressure (max.)

circuit i.e. between H.P.
turbine exhaust & IP
turbine inlet.
(vii)
Condenser
pressure
(viii)
Turbine speed
(ix)
Frequency
variation + 3% to 5% (47.5 Hz to 51.5 Hz)
range around rated
frequency of 50 Hz
(x)
Max DM water make up 3% of throttle steam flow

to thermal cycle under
Document Number
LII-GETS12021-G-00129-002
main [537] C
design [76] mm Hg or as applicable for heat rate

optimization
3000 rpm
Rev
No.
Description
Page
No.
Date of Issue
03

[6]
15.01.2016
Power Plant]
[Logo of Utility]
TMCR condition
(xi)
Final feed water temp. As optimized by the Bidder but not less than [247] o
for Heat Rate guarantee C
point & TMCR condition
(xii)
Turbine
protection As per ASME-TDP-I-Latest Edition
against water induction
(xiii)
Design
Circulating [33] 0 C
Water(CW)
Temperature
(xiv)
Quick start capability
1.5.2
Turbine shall have quick start capability under all

modes of start up. Start up time shall not be more
than 360 minutes during absolute cold start.
Operational Capabilities
Table: 1.3
(i)
Turbine Generator set shall be capable of

continuous operation under HP heaters out of
service with maximum output Commensurate with
boiler max heat duty at BMCR condition but not
less than rated output.
H.P. heaters out of

service:
(Heat Duty at BMCR shall be calculated based on

the respective HBD)
(ii)
Variation in parameters
(a) Bidder shall indicate the turbine over

pressurization (under V.W.O) possible and ensure
corresponding continuous output of TG set (if
applicable).
(b) Turbine shall be capable of accepting variation
in steam temperature & pressure as per IEC-45 in
case continuous over pressure operation is
possible.
(iii)
Two shift & cyclic load
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Turbine shall be suitable for two-shift operation &

cyclic load variations.
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(iv)
Part load & start up
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Turbine shall be capable of operation on constant

pressure mode as well as on variable pressure.
Mode during part load & start up operation
TG set shall be capable of being started from cold
condition to full load operating conditions in as
short time as possible even without availability of
HP/LP Bypass system.
(v)
House load operation:
TG set shall be capable of operating on house

load during sudden total export load throw off
using HP-LP bypass system. Unit shall not trip on
over speed in the event of total export load throwoff. Same shall be physically demonstrated prior to
handing over of the unit.
(vii)
Operation in High
Condenser back
pressure in emergency
condition
Turbine Generator set shall be capable of

continuous operation under high condenser
pressure at
89 mm
Hg
to generate
[210/215/220/250]
MW
output. (Condenser
pressure corresponding to Max [36] C water
temperature).
Bidder shall also indicate the maximum allowable
condenser back pressure at the rated MCR load.
The turbine generator unit shall comply with general requirements and standards
of relevant latest versions of IEC & IEEE or their approved equivalents or as per
the suppliers standard practices to be mutually agreed between the Bidder and
Owner and the additional requirements as specified hereinafter. All materials,
equipment and fabrication procedures, wherever applicable for the equipment
covered in this specification, shall also be in accordance with the latest
applicable code requirements of the Indian Boiler Regulations.
The generator and accessories shall withstand, without damage, any rate of
acceleration/deceleration, which the steam turbine may impart and any transient
electrical conditions caused by sudden load reduction or electrical trip. The
steam turbine and accessories shall be able to withstand, without damage, any
transient thermal stresses, acceleration and deceleration to which they may be
subjected within limitations set by proper function of the supervisory and
protective devices, and within the limitations set forth in the Bidder's operation
and maintenance manuals.
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The turbine generator unit shall be capable of synchronizing and running in

parallel with utility Power Grid. The turbine generator and all its auxiliaries
including integral piping shall be designed for continuous and cyclic load
operation.
The rotating components of the turbine-generator shall be statically and
dynamically balanced. The Bidder shall indicate the maximum vibration level
that can be tolerated on the bearing housings and shaft (and on bearing housing
only for Exciter) during operation of the machines. The turbine-generator shall
also be capable of operation at any speed above the rated speed up to 110
percent of the rated speed without exceeding the maximum vibration specified
below, and without showing any sign of stress or instability. The unit shall be
sufficiently strong to withstand without damage any stresses or deflections that
might result from transient speed up to 120 percent of the rated speed.
1.5.3
Other General Requirements

In case the Bidder anticipates the use of spray and make up water during the
performance guarantee test, the corresponding heat rate shall be guaranteed
and the related heat balances shall be furnished with the bid.
The Bidder shall furnish correction curves applicable for heat rate calculations
under varying parameters of steam (pressure and temperature), reheat circuit
pressure drop, inlet temperature of condenser cooling water and condenser
vacuum.
Bidder shall state the maximum continuous capability of the Turbine with valves
wide open (VWO) and indicate the maximum flow passing ability of the machine
corresponding to rated steam parameter and at rated condenser vacuum at [76]
mm Hg absolute and with condenser cooling water temperature [33] C.
The units shall be capable of operating with all the H.P. heaters out and no
extraction steam supply to them. The Bidder shall indicate the maximum output
the unit is capable of delivering continuously under such condition.
The turbine generator units shall be designed to operate satisfactorily under
prevailing climate. They shall be suitable for indoor installation on reinforced
concrete foundation.
The turbine generator units shall comply with general requirements and
standards of relevant latest versions of IEC & IEEE or their approved equivalent
or as per the Suppliers standard practices to be mutually agreed between the
Bidder and Owner and the additional requirements as specified hereinafter. All
materials, equipment and fabrication procedures, wherever applicable for the
equipment covered in this specification, shall also be in accordance with the
latest applicable code requirements of the Indian Boiler Regulations.
For quick restarting and flexibility during start-up of the Turbine-Generator, a
suitable HP-LP bypass system shall be provided. Bidder should specifically
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indicate the feature considered for bypass system and the minimum flow
requirement to enable warm and hot start-up of the machine.
The rotating components of the Turbine-Generator shall be statically and
dynamically balanced. Bidder shall indicate the maximum vibration level that can
be tolerated on the bearing housings and shaft (and on bearing housing only for
Exciter) during operation of the machines. Maximum vibration shall be within
GOOD range of VDI- 2056.
1.6
Salient Design Features of Turbine and its Accessories
1.6.1
Steam Turbine
i)
Casing
The casing shall have provision for temperature sensing elements (RTD's or
thermocouples) to indicate metal temperatures in casing, nozzle block, and
steam chest. Dual element temperature sensing elements shall be provided.
The main horizontal and vertical joints in the turbine shell shall be metal-tometal. The turbine low-pressure ends shall be arranged for bottom exhaust
condenser.
Each turbine casing shall be provided with efficient draining facility. The parts of
the turbine casing which may come in contact with wet steam in normal
operation or during start-up, shall be provided with an inter-stage drainage
system whereby extracted water shall be prevented from re-entry to the blading
and shall be transferred to either a convenient heater extraction branch or to the
condenser. The casing drains shall be provided with temperature sensing
devices to ensure proper evacuation of drains.
The steam extraction branches shall be located on the lower half casings and
shall be machined with weld end preparation except in the case of LP casing
where bolted flanges will be acceptable.
Pressure relief bursting diaphragm for LP casing(s) to limit the exhaust hood
pressure within a safe margin from design pressure shall be provided. A
completely self contained exhaust hood spray system for L.P casing(s) to protect
the turbine against excessive temperature due to windage at no load / low load
and HP/LP Bypass operations shall also be provided.
Dismantling of casing should be possible with minimum removal of insulation.
Guide rods to prevent damage to blades during erection and maintenance shall
be provided.
Bearing inspection should be possible without necessity of dismantling the
turbine casing.
The supports of the turbine on the foundation shall be designed considering the
expansion and contraction of the machine during thermal cycling. Axial
movements shall be allowed by anchoring at one point and central position shall
be maintained by fitted keys.
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ii)
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Rotor
After the assembly of the blades, each complete rotor shall be balanced for both
static and dynamic conditions so that the assembled rotor will perform
satisfactorily under all conditions of operation.
Ensure heat stabilization of the rotor as per SEP 1950, ASTM-A-472, Maximum
permissible shaft vibration measured at bearing housing will be as per zone A of
ISO 7919 (or approved equivalent standards) and maximum permissible bearing
vibration measured at bearing housing will be as per zone A of ISO 10816-2 The
turbine generator unit shall be designed to withstand the stresses due to an over
speed of 20% above the normal synchronous speed, without reducing the life of
the machine.
iii)
Nozzles & Blading

All nozzles and blading shall be of hard; corrosion and erosion resisting alloy
steel suitable for the temperatures encountered. In the low pressure stages
where the moisture percentage and the blade peripheral speeds are high,
additional protection against erosion by way of hardened surface of blades or
strips of erosion and corrosion resistant material such as stellite, secured to the
leading edge, shall be provided. LP stage blade hardening upto 1/3rd (min) of
blade length & width 25mm (min) or stelliting as per the proven standard practice
shall be provided.
Ensure stress induced in LPT blading due to back end steam loading under
V.W.O. conditions not to exceed 90% of design stress value.
Suitable arrangement for the removal of moisture from at least the last LP stage
shall be provided.
The method of fixing of the blades to the rotor needs to have been satisfactorily
proven by long use in operation. Care shall be taken to ensure that the natural
frequency of the rotor blades is far away from the rotational frequency of the
machine, which may vary from 47.5 Hz to 51.5 Hz.
L.P. Turbine shall have stand-alone type blades capable of sustaining + 3% to 5% grid frequency variations.
1.6.2
Bearings and Seals

All Turbine Generator main shaft bearings shall be provided with seals to control
oil and vapor leakage along the shaft. Bearings shall be of the self-aligning type
and split to permit removal of the upper half for inspection. Bearings shall be
accessible for inspection without removal of the turbine shells. Each main shaft
bearing shall be equipped with a minimum of one dual element type
temperature-sensing element imbedded in each main bearing. In addition,
thermocouples shall be located in all main bearing drains.
Each thrust bearing shall be equipped with dual element type temperature
sensing elements located in each front and back thrust bearing plate or shoe to
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provide for indication of excessive thrust bearing temperature. Pressure

switches sensing thrust-bearing position shall be provided and shall initiate
automatic tripping of the turbine in case of excessive thrust bearing wear.
1.6.3
Couplings
The couplings connecting the turbine and generator and the various turbine
shafts shall be of a type that can be readily disconnected for purposes of
inspection and repair.
1.6.4
Main Steam Emergency Stop Valves

Hydraulically operated stop valves shall be provided in the main steam line and
shall be capable of being tripped automatically during over speed or at other
predetermined limit points. The stop valves shall be designed with provisions for
sequential remote testing while the unit is in operation. Triple-coil servo valves
for valve positioning using hydraulic fluid shall be provided.
Start-up bypass operation shall be controlled from TGCS and valve position shall
be indicated on the DCS via redundant communications links.
1.6.5
Reheat Stop and Intercept Valves

Combination reheat stop and intercept valves, or individual reheat stop valves
and intercept valves shall be furnished with provisions for sequential remote
testing while the unit is in operation. All valves shall be furnished with triple
redundant position transducers that input to the TGCS for control and indication.
Triple-coil servo valves for valve positioning using hydraulic fluid shall be
provided.
1.6.6
Steam Strainers
Each main steam stop valve and each reheat intercept valve or combination
reheat stop and intercept valve shall be equipped with permanent, integral
strainers made of mesh, perforated steel plate, or equivalent elements for normal
operation. Each valve shall also be equipped with removable fine-mesh
strainers for initial operation. Strainer screens shall be removable without
disturbing steam piping.
1.6.7
Control Valves
Governor-controlled, hydraulically operated turbine control valves shall be
provided. Provisions for sequential remote testing while turbine is in operation
shall be provided. All valves shall be furnished with triple redundant position
transducers that input to TGCS for control and indication. Triple-coil servo
valves for valve positioning using hydraulic fluid shall be provided.
The Bidder shall also submit valve opening/ closing characteristic curves for both
high pressure control valves (HPCV) and intermediate pressure control valves
(IPCV) respectively.
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1.6.8
[Logo of Utility]
Turbine Oil System

Complete lubrication and oil pumping system, including, but not necessarily
limited to, the following shall be provided:
i.
Oil reservoir with top mounted relief valves and access doors (manholes), and all
associated instrumentation and controls.
The turbine set shall be provided with an oil reservoir of adequate capacity. The
capacity of the tank shall be so chosen that the full quantity of oil circulating
through the system is retained for a controlled time ensuring thereby proper
sedimentation and air removal. The retention time should be indicated. The
capacity of the oil tank shall also be adequate to contain the total volume of oil
that can be drained from the circuit into the tank. It shall be provided with
removable stainless steel basket strainers and at least two oil level indicators out
of which one should be visible from turbine operating floor. High and low level
alarm switches to be connected to the supervisory control panel annunciation
system and overflow device shall be provided. A suitably located temperature
switch (with duplicate contacts), for remote high temperature annunciation,
indicating the possibility of fire inside the tank, shall be provided. Two
independent connections shall be provided for the tank - one for draining and
sampling and the other to facilitate connection to oil purification system.
Necessary manholes with self closing covers, pipe connections with flanges etc.,
as required shall be provided. The proposal shall include necessary access
ladders, platforms and railings. 2x100% capacity A.C. vapour extractors, driven
by explosion proof motors shall be furnished. The extracted vapour shall be led
outside the turbine house building and provided with mist eliminator/oil separator
at the terminating end of the vapour extractor line. The necessary supports,
piping, accessories etc., shall also be furnished. The outer surfaces of all piping
in the reservoir and the inner surface of the tank shall be coated with corrosion
resistant paint
ii.
Pumping System
(a) A self contained oil system for each TG Unit consists of:
Centrifugal / gear type, Main oil pump (MOP) directly driven by Turbine as
per Bidder's standard practice with capacity to cater control oil, lube oil for
bearings & emergency seal oil requirement.
2x100% AC Auxiliary oil pumps for start-up shut down of TG unit and as
standby to M.O.P. for automatic operation, each pump having capacity to
cater to lube oil and turning gear oil requirement.
One (1x100%) DC motor driven emergency oil pump with sufficient capacity
for meeting lube oil requirement of bearings during emergency with
automatic starting on low lube oil pressure preset value.
1x100% each AC & DC jacking oil pumps having reset solenoid with an
interlocking not to start till lube oil pressure is established.
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iii.
Each Unit Lube Oil tank to have capacity to allow 5 to 8 oil changes per
hour (at normal operating level), fitted with non-corrodable strainers, level
indicator visible from turbine operating floor, and necessary manholes,
platforms, railings, necessary piping, supports and accessories etc.
2x100% DM water cooled lube oil coolers with 10 % excess tube surface
area, designed as per TEMA having oil pressure greater than water
pressure fitted with Dial type Thermometer and Manual 3-way valve on oil
side for change over of coolers. Oil temperature at outlet of coolers to be
maintained within permissible limits at the inlet to the bearings.
All the pumps shall be provided with necessary strainers, valves and other
fittings. Pressure switches shall be provided for the automatic sequential
starting of the motor driven oil pumps. A panel incorporating pressure
switches, transmitters and testing push buttons shall be furnished for
on-load testing of all interlocks. Such on-load testing shall be so arranged
that safety of the system is not jeopardized at any time.
Purification System
Provide permanently Connected, Continuous Oil Purification having following
major equipment.
(a) Oil centrifuge having capacity to purify 20% of total oil charge in system per hour
and constructed from high grade stainless steel. Purified oil with no free moisture &
maximum particle size conforming to code 15/12 as per ISO 4406. This shall be
demonstrated with inlet oil quality conforming to code: 21/18 as per ISO: 4406.
(b) Carbon steel anti flood tank for each purifier.
Positive displacement feed & discharge pumps (if required), each having
capacity 10% higher than purifying unit. Necessary interlocks for preventing
centrifuge operation in case these feed and discharge pumps are not
operating shall be provided.
Indirect Electric oil heater to heat oil to temperature not more than 65C
with possibility to cut heater elements in steps.
Entire purification equipment to be mounted upon a substantial metal base
having a raised lip around the outside with a drain connection.
(c) Filters & Strainers
Duplex type filters/strainers with stainless steel element, with differential pressure
switches with alarm at suction of each pump and common oil supply line shall be
provided. The filter element size shall be of five (5) microns or a size suited to
TG manufacturer's requirements. In addition to above, the Bidder may provide
filter/strainers at oil supply line to /oil return lines from bearing and generator
seals as per his standard
(d) Fire hazard safety precautions shall determine the design of oil piping in the high
temperature zones of the turbine lubrication oil system. Oil piping shall be
stainless steel. Flanged joints shall be used where necessary for assembly and
dismantling of oil piping.
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1.6.9
[Logo of Utility]
Turning Gear
The turbine generator shall be equipped with an electric motor-driven or oil
driven rotor turning gear capable of continuously rotating the turbine shaft to
affect fast uniform cooling and warming during the coasting down and start up
respectively.
An AC motor driven turning gear shall be furnished, complete with oil piping and
all associated hangers and valves, and all necessary interlocks to prevent the
turning gear from operating until proper oil pressure has been established in the
turbine-generator bearings. The turning gear motor shall have provisions for
rotating the motor shaft manually to engage the turning gear with the main
turbine shaft. The turning gear shall automatically disengage when the turbinegenerator speed rises above the turning gear speed and re-engage on turbine
shutdown, when the turbine speed slows down to preset speed. Local turning
gear instrumentation, including control switches and indicating lights, shall be
provided.
1.6.10
Turbine Governing System, Protective Devices and Unloading Gears
1.6.10.1
Governing System
The steam turbine generator unit shall be equipped with an electro-hydraulic
governing system with mechanical-hydraulic back up or electro-hydraulic system
with 100% hot back-up. The turbine governing system shall meet the following
requirements:
i.
ii.
iii.
iv.
1.6.10.2
The governing system shall be capable of controlling with stability the turbine
speed between zero to maximum power output when the unit is operating in
isolation [or in parallel with other units].
Over speed during full load loss shall be limited to 8% of the rated speed.
Adjustable steady state speed regulation shall be provided between +3% to +6%
of rated speed.
Dead band at rated speed and at any power output within rated output shall not
exceed 0.06% of rated speed.
Speed Load Changer
The governing system shall be equipped with speed and load changers to
control the speed or power output of the steam turbine within the limits. The
speed/load changer provided shall be capable of adjusting the speed of the turbo
set to any value in the range of 94% to 106% of rated speed for manual/auto
synchronization of the generator with the bus. It shall be capable of varying the
load on the machine from no load to full load.
For remote control, suitable motor drive shall be provided. Indication of the
speed/load changer position shall be provided on the operators work station and
console panel insert.
1.6.10.3
Load Limiting Device
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The governing system shall be equipped with a load limiting device capable of
being operated both locally as well as remotely from unit control room for the
purpose of limiting the amount of opening of the governor controlled valves to set
the load at a pre-determined limit, while the turbine is in operation. A remote
position indicator shall be provided on the console panel insert for indication of
the setting of the load limit. Contacts shall also be provided on the load limiter for
signaling load limited operation in unit control room.
1.6.10.4
Turbine Protection Devices

Emergency governor
i.
ii.
iii.
Bidder shall provide a separately actuated overspeed device called quick acting
emergency governor to trip the unit at 110% of rated speed in case speed
governor fails to limit the turbine overspeed.
The emergency governor resetting shall be as per manufacturer's standard
practice. However, it shall meet the IEC-45 requirements for overspeed trip.
Bidder shall provide means for testing the operation of emergency governor
when the machine is on load without exceeding the rated speed of the unit.
Emergency hand trip
Bidder shall provide emergency hand trip device on front pedestal/panel near
turbine to facilitate manual tripping of the unit along with facility to trip turbine
from UCB.
1.6.10.5
Other protection devices

The following other turbine protection devices shall also be included. Essentially
the protection system shall include:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
Manual trip from control room and from local.

Mechanical over speed trip.
Electrical over speed trip with sensors independent of speed governing sensors
(with triple sensors).
Thrust bearing excess wear trip (with triple sensors).
Condenser very low vacuum trip (with triple sensors).
Lube oil pressure very low trip (with triple sensors).
Control oil pressure very low trip (with triple sensors).
Main steam temperature low trip (with triple sensors).
Generator trip
Reverse power relay operated trip
Under frequency relay operated trip
Boiler trip operated trip (with triple signals)
Power failure for turbine control and protection system (triple signals)
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xiv.
xv.
1.6.10.6
[Logo of Utility]
DDCMIS trip, closure of valve and reduction in the load and also Alarm for
operator guidance in case of defects in the Turbine Control System (TCS).
Any other trips recommended by Bidder (which shall be with triple sensors)
All normal annunciations shall be configured in DDCMIS and displayed on HMI.
Certain critical annunciation shall be hardwired to the panel envisaged.
Steam Turbine Supervisory Equipment
The steam turbine supervisory equipment shall indicate and record the
behaviour of the steam turbine under varying conditions and provide adequate
warning of the development of potentially dangerous steam turbine conditions.
The steam turbine supervisory equipment shall include detection and recording
of, but not limited to the following:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
xvii.
xviii.
xix.
xx.
1.6.10.7
For Bearing, shaft vibration indication in the Vibration Monitoring system (VMS)
and recording in the DDCMIS (Digital distributed control management information
system) shall be provided.
Shaft eccentricity
Differential expansion.
Axial shift of rotor bearing vibration indication in the Vibration Monitoring system
(VMS) and recording in the (DDCMIS).
Overall expansion
Vibrations in the bearing pedestals
Steam turbine speed
Load
Main steam, emergency stop and governing valve positions
Interceptor stop and control valve positions
Load limiter position
Speed Changer position
Inlet steam temperatures and pressures
Metal temperature
Cylinder/flange metal temperatures, top and bottom casing temperatures
including differentials
Bearing metal temperatures
Body metal temperatures of main steam and reheat steam stop and control
valves
Oil drain temperatures
Turbine Stress Control System (TSCS) capable of maintaining the thermal
stresses within allowable limits and suitably integrated into plant DDCMIS.
Turbine acceleration in the DDCMIS.
Unloading Gear
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Initial Pressure Regulator

i)
ii)
iii)
Initial pressure regulator shall ensure turbine unloading to a preset point to run
on house load in case main steam pressure falls below a predetermined value.
It shall be possible to adjust or bypass the initial pressure regulator from UCB at
start up condition to facilitate starting with low steam pressure and during sliding
pressure operation.
Contact shall be provided for signaling the device in Operation and Reset.
Low vacuum unloading gear (if applicable)
i)
ii)
1.6.10.8
Based on the standard proven practice of the Bidder, the Bidder shall provide a
low vacuum unloading gear which shall ensure progressive decrease of steam
flow to turbine below a preset value of condenser vacuum, thus restoring the
condenser vacuum.
Contact shall be provided for signaling the device in Operation and reset.
Vacuum Breaker
Bidder shall provide suitable device for rapid reduction of vacuum in condenser
for turbine rotor to be brought to rest as quickly as possible. Provision shall be
made to operate it both manually and through DC actuator.
1.6.11
Gland Sealing System

The turbine shall be provided with Labyrinth type gland seals to prevent steam
leakage to the atmosphere or air leakage into the turbine. The Labyrinth will be
of multiple section spring backed type, which would allow for any temporary
deformations of the rotor shaft without overheating the rotor due to friction. A
gland seal regulator shall automatically control steam pressure to the gland seals
over the entire load range. The gland exhausting system shall include a surface
type seal steam condenser suitable for the inlet condensate temperature and
pressure provided with drip level indicators/ gauges and two 2x100% capacity
AC motor driven exhausters. The system shall operate automatically. Means
shall also be provided for manual operation of the gland seal system when the
regulator is out of order.
Suitable arrangement shall be provided to bypass gland steam condenser
(designed to operate under vacuum condition also) along with desuperheating
arrangement, if required, for the bypass. The exhaust shall be discharged above
the TG hall roof level. The gland steam condenser shall be provided with bypass
on water side also.
The turbine shall be self sealing during normal operation of the unit. During
startup and low load operation, sealing steam shall be supplied from high
temperature or low temperature auxiliary steam header or CRH depending upon
the sealing requirement. Facility shall be provided for automatic switchover from
alternative source to the main source and vice versa.
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During changeover of steam supply source from turbine or CRH or auxiliary

steam header, there shall be no rubbing at glands and no undue increase in
vibration and the system shall be capable of withstanding thermal shock
Effective drain system shall be provided along with instrumentation to monitor
and maintain the required temperature to avoid thermal shock to the rotor during
changeover from self sealing to alternate source of sealing steam.
Two nos. modulating type control valves shall be provided, one discharging
surplus steam to condenser and other for supplying extra steam to gland sealing
header from steam source to maintain sealing steam header pressure at a
preset value. These control valves shall be provided with electrically operated
bypass valves. Control valves shall be stay put during power failure and sealing
steam header pressure shall be maintained by manual control of these valves.
Gland sealing arrangement provided by the Bidder shall permit easy examination
and replacement of glands without lifting the upper half of the turbine casing.
1.6.12
High Pressure Hydraulic System

Each unit will be provided with a high pressure hydraulic system which shall
supply the required active power for operation of the electro-hydraulic control
system and shall utilize a phosphate ester or equivalent fire resistant fluid. All the
elements of the system shall be furnished with compatible hydraulic fluid, and
shall include, but not necessarily is limited to, the following:
i)
ii)
iii)
iv)
v)
vi)
Fluid reservoir of sufficient capacity to contain all the hydraulic fluid when the
turbine is shutdown. The reservoir shall be provided with access cover plates for
cleaning, fluid level indicator, high and low level alarms and independent critical
high alarm, high and low temperature alarms, and provisions for filling and
draining by means of fluid transfer and filtering unit which shall be included.
Two (2) independent pumping systems, each consisting of motor driven variable
displacement pump with automatic stroke adjustment, wire-mesh suction strainer
on the intake side of the pump and a disposable cartridge filter in the pump
discharge line, and a pressure compensator on each pump to maintain the preset
pressure by stroke adjustment.
The filters at the pump discharge shall be designed for maximum particle size of
not more than 5 microns. Excess pressure drop shall be annunciated in the
unit's DCS and automatic start-up of the standby pump shall be initiated if the
filter pressure drop continues to increase and no remedial action is taken.
Two (2) full capacity fluid-to-DM coolers. The coolers shall be arranged for either
single or parallel operation and shall be located on the return side of the
hydraulic fluid to the reservoir.
Two (2) nos. thermostatically oil tank heaters indirect type to regulate the oil
temperature.
One (1) air dryer for the air breather by the fluid reservoir, of the desiccant type
filled with layers of activated alumina, charcoal, and silica gel.
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viii)
ix)
x)
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FRF recirculation pumps two (2) nos. to recirculate the oil in earth filters/
mechanical filter and to facilitate oil top up & using oil from drain tank.
Hydraulic accumulators, charged with nitrogen, in sufficient number to provide
immediate source of hydraulic fluid when required for sudden transient
conditions.
Transfer and filtering unit for filling the system and filtering the fluid before it
enters the reservoir. The unit shall be complete with motor-driven pump, filter,
relief valve, discharge and suction hoses, and all operating valves. The unit shall
form an integral part of the high pressure hydraulic system.
Fuller's Earth filtering equipment, installed in the reservoir to maintain low
neutralization of the hydraulic fluid.
All the above equipment shall be installed on a common skid for mounting below
the turbine. High pressure stainless steel piping and tubing to all points of usage
of the high pressure hydraulic fluid system with all necessary hangers and
supports shall be included. Also, the initial charge of the hydraulic fluid shall be
included.
1.6.13
Steam Turbine Extraction

The uncontrolled extraction steam system shall supply steam for the
regenerative feedwater heaters and direct contact heater (Deaerating Heater).
Extraction steam system piping shall be routed and supported in such manner as
to provide for thermal expansion and to maintain end reaction forces and
moments within allowable limits. All low-pressure extraction piping inside the
steam turbine exhaust hood shall have sleeved inconel bellows expansion joints.
A forced closed check valve (pneumatically or hydraulically operated), SCNRV
and a motor operated stop valve shall be provided in each extraction line.
However, 2 nos. forced closed check valve shall be provided in the direct contact
heater (deaerator). The check valves shall protect the steam turbine from over
speeding due to reverse flow of steam from the extraction piping when the steam
turbine is tripped and is under a vacuum condition. The motor operated shutoff
valves, operating in conjunction with the automatic drain valves, which are
located, both upstream and downstream of the valve station containing the
reverse flow check valve and the motor operated isolation valve, shall protect the
steam turbine against water induction. During a steam turbine trip, controls shall
automatically initiate the closing of all forced closed check valves and the
opening of all the drain valves. High water level in a heater shall initiate a high
water level alarm in the affected heater and opening of its alternate drains. All
piping drains shall be routed to the main condenser.
The steam shall be bled as un-controlled extractions from the high, intermediate
and low pressure stages for regenerative feed heating. Suitable arrangements
shall be provided to prevent induction of water into turbine in accordance with
manufacturer's standard practice and the stipulations of ASME Standard No.
ASME-TDP Part-I (Latest edition).
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1.6.14
[Logo of Utility]
HP/LP Bypass System

The HP bypass system shall have capacity not less than 60% of BMCR steam
flow with [2x50%] valves considering rated main steam parameters at upstream
of valves and CRH steam parameters corresponding to 60% TMCR condition on
the down stream with constant pressure operation and no steam extraction for
regenerative feed heating except deaerator pegging at 3.5 ata with only MDBFP
in service. The system should be capable of opening in a fast mode (within 2
seconds) under emergency conditions like sudden load throw-off, turbine tripping
etc. Suitable arrangement shall be made to achieve such fast opening of the
bypass valves
The high pressure (HP) portion of the steam turbine bypass system shall include
a pressure-reducing valve and attemperator that shall accept steam flow diverted
around the HP steam turbine. The valve and attemperator shall reduce the main
steam pressure and temperature to a level where it can be safely admitted to the
cold reheat piping and reheater.
The LP bypass system shall consist of [2x50%] valves and shall be designed to
condition the incoming steam from reheater to parameters matching with those
of LP turbine exhaust steam and the capacity shall be commensurate with that of
the HP bypass system plus the spray water used in HP bypass. The low
pressure (LP) portion of the steam turbine bypass system shall include a
pressure-reducing valve and attemperator and a diffuser in a circuit receiving
steam flow diverted around the IP and LP steam turbines to the main condenser.
The diffuser shall be designed to protect the condenser. Materials and design
parameters for equipment downstream of the LP bypass pressure reducing valve
and attemperator are set by both the condenser and bypass system suppliers.
The control system for the Steam Turbine Bypass will be configured in the
Turbine Control System (TCS).
HP bypass shall be designed to accept continuous spray water at temperature
corresponding to all HP heaters out of service and deaerator pegged at 1.5 ata.
Spray water shall be sprayed at the most turbulent zone inside the valve having
steam velocity in the order of 350 to 400 m/s. The entire atomization and
evaporation of spray water shall be complete within shortest possible distance
but not exceeding 1.0 m from the spray point. The HP bypass spray controller
shall have state controller with observer to achieve accurate control over outlet
steam temperature under different operating conditions including the transients.
For LP bypass system, desuperheating may be done outside the valve body with
spray water tapped from condensate pump discharge
The steam turbine bypass system shall be used mainly to reduce startup times
for the steam generator under hot and cold startup situations. Feed water is the
source of the high-pressure bypass spray water. Condensate is the source of
low-pressure bypass spray water.
Each turbine bypass system shall consist of the following:
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ii)
iii)
iv)
v)
vi)
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[Two (2)] high pressure hydraulically actuated steam pressure reducing valves
with integral (or separate) desuperheaters.
[Two (2)] high pressure hydraulically actuated spray water isolation valves.
[Two (2)] low pressure hydraulically actuated steam pressure reducing valves.
[Two (2)] low pressure desuperheaters for mounting on the condenser L.P. bypass
inlet nozzles.
[Two (2)] low pressure hydraulically actuated spray water admission valves with
split range type (i.e. low load & High Load).
[Two (2)] hydraulic supply units, each with redundant hydraulic oil pumps.
The HP/LP Bypass System is intended for use at following situations:
i)
ii)
iii)
iv)
v)
On hot starts to facilitate matching boiler steam to turbine metal temperatures prior
to steam admission to the turbine thus achieving a faster start-up and reduced
thermal stresses in the turbine.
The turbine bypass system shall be utilized to warm up the boiler and main steam
lines after an appropriate vacuum is established.
During cold starts, for Boiler temperature control and condensate conservation.
On load rejection or turbine trips, the bypass system will handle sufficient steam
flow to avoid a boiler trip out, thus allowing rapid reloading when fault condition
clears.
The HP Bypass valve shall serve as pressure relief valve in case of transient main
steam pressure excursion. The HPBP valve shall modulate to maintain HP turbine
inlet pressure, if it goes at about 6 kg/sq.cm above normal operating pressure.
The turbine bypass system controls shall perform the following functions:
i)
The control system shall generate the steam generator pressure/flow and reheat
pressure/flow characteristics.
ii)
High pressure bypass valves and low pressure bypass valves shall open to control
pressure in the main steam lines and reheat steam lines.
iii) Water shall be added to the bypasses to control high pressure bypass
temperature and limit low pressure bypass enthalpy.
iv) All valves shall be designed to fail closed.
v)
The turbine shall be protected from bypass system malfunction by temperature
trips.
vi) Water valve control shall be consistent with ASME Standard TDP-1 Fossil Fueled
Plants Recommended Practices for the Prevention of Water Damage to Steam
Turbines used for Electric Power Generation or International equivalent.
vii) Bypass system control shall be integrated into the Turbine Control System (TCS)
and fully coordinated with normal turbine operation.
viii) The bypass system shall be operationally tested to assure acceptable functional
performance of the bypass control system.
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1.6.15
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The HP/LP bypass system shall come in operation automatically in case of (a)
generator breaker opening (b) turbine trip i.e. ESV/CV close (c) sudden reduction
in load.
Vacuum Trip and Pressure Relief Diaphragms
Triple redundant condenser vacuum sensors shall be provided as inputs to
TGCS to initiate a closure of the turbine stop valves and control valves when the
turbine exhaust pressure rises above a set limit. The vacuum trip shall be part of
the turbine trip system and have the capability of testing via the DCS. Pressure
relief diaphragms shall be provided and located in the turbine exhaust casing for
condenser overpressure protection.
1.6.16
Turbine Exhaust Hood Spray Control System

Steam turbine exhaust hood spray cooling system shall be provided to permit
low load operation of the turbine- generator set without excessive rise in the
exhaust-hood temperature. Steam turbine exhaust hood spray cooling system
shall be self-contained and complete with spray arrangements, associated
piping, instrumentation and control devices, valves and fittings, motor/solenoid
operated valves and specialties, hangers, supports and insulation etc. The spray
arrangement shall be activated automatically under the condition of low load or
exhaust hood temperature exceeding the permissible value.
1.6.17
Supplemental Protective Devices

In addition to the protective devices specified herein this technical specification,
the following shall be provided:
i)
ii)
iii)
iv)
v)
vi)
High exhaust hood temperature switches for alarm and trip.

Low bearing oil pressure switches for alarm and trip.
Thrust bearing wear and failure switches for alarm and trip.
TG shaft vibration high alarm/ trip as per the OEMs design requirements.
Turbine over speed mechanical protection, mounted on turbine rotor shaft at 10%
to 11% above the rated speed.
Vacuum breaker valves for an automatically initiated vacuum
relief system
complete with actuation initiation devices.
1.6.18
Warming Up, Drain, Vent System And Flash Tanks
1.6.18.1
The Bidder shall provide warming-up and drainage system for the turbine system
to drain away the condensate which may be formed due to steam coming into
contact with cooler metal during start-up and stagnant steam sections. The
system shall comply with the requirements of ASME TDP-1, Recommended
practices for the prevention of water damage to steam turbines used for electric
power generation. The drainage system shall be provided but not limited to the
following:
i)
Main steam, CRH and HRH line drains
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iii)
iv)
v)
vi)
vii)
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Main steam stop and control valves

Reheat stop valves and interceptor valves
Steam lead and turbine drains
Steam seal system
HP & LP bypass valves and warming up line
Turbine extraction steam piping system
The drains shall be provided for every low point with automatic disposal of
collected condensate. The drains shall be connected to the flash tanks via
headers. The connections on the header shall be graded according to the
pressure, the farthest from the tank being the drain connection with highest
pressure. The drains from main steam piping, HRH, CRH, and auxiliary steam
headers etc. shall also be connected to the flash tanks described herein.
1.6.18.2
The following flash tanks shall be provided as a minimum to receive the drains
and safety valve connections from various equipments and systems.
i)
ii)
iii)
iv)
v)
vi)
Unit flash tank

Turbine drain flash tank (left)
Turbine drain flash tank (right)
HP drain flash tank
LP drain flash tank
FWSV discharge flash tank
The arrangement for connection of various drains to the flash tanks shall be as
under:
i)
ii)
iii)
iv)
The drains from MS piping and HP bypass piping including warm up line shall be
connected to unit flash tank.
The turbine integral and power cycle drains shall be connected to turbine flash
tanks. The left side drains shall be connected to left side flash tank and right side
drains to the right side flash tank.
The drains from CRH, HRH, LP bypass piping including warm-up line, extractions
to HP heaters, CRH and auxiliary steam line and deaerator (high pressure side)
and drain, vent and safety valve connections on HP heaters shall be led to the HP
flash tank. The drains of extractions to LP heaters, IP extractions, CRH to
deaerator (low pressure side), auxiliary steam header, drain, vent and safety valve
connections of LP heaters and drain coolers, deaerator overflow and CEP
discharge vent shall be led to the LP flash tank.
The drains led to HP drain flash tank, LP drain flash tank and turbine drain flash
tanks shall be recovered by connecting drains and vents of these vessels to the
condenser. The vents of unit flash tank shall be open to atmosphere and drains of
these tanks shall be led as waste to the plant drain/ channel.
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The above drain connections are indicative only. The Bidder may provide
alternative scheme/ arrangement for connection of drains to different flash tanks
as per his standard practice which shall be subject to approval of the purchaser.
Drains shall be tapped off from main line through a drip pot with provision for
removal of entrapped dirt. Each drain shall be provided with one locked open
manual valve followed by one motor/ pneumatic operated leak proof angle valve
on downstream side to be used for draining and warming-up the pipes as
applicable. For sections having drain formation during normal plant operation
such as auxiliary steam header lines and alternate steam lines to deaerator,
steam trap assembly shall be provided in parallel to the motorized/ pneumatic
drain valve.
The drain valves shall be located in accessible positions to facilitate their
maintenance.
Facility shall be provided for remote manual operation of the drain valves from
the control room. Motor operated drain valves shall be interlocked to open/ close
as per the process requirements. Detailed operation philosophy/interlocks shall
be furnished by the Bidder along with the bid.
1.6.18.3
On the CRH line downstream of NRV, a drain pot shall be provided at the lowest
point in the CRH line. The following features shall be provided for drain pot valve
control system:
i)
ii)
iii)
On high level in the drain pot, the motorized drain valve shall open automatically
and an alarm shall be initiated in the control room. Closing of motorized valve shall
be by remote manual.
On high-high level in the drain pot, an alarm shall be raised in the control room,
and an automatic repeat command shall be given for opening of the motorized
drain valve.
Position indication of drain valve shall be provided in the control room.
Flash Tanks
i)
ii)
iii)
iv)
The flash tanks shall be adequately sized to take care of the total drains in the
complete power cycle piping system. There shall be sufficient margin to
accommodate the possible variation in drain quantities as well as flash steam.
Flash tanks shall be designed as per the requirement of ASME boiler and
pressure vessels (B&PV) codes, and ANSI standard.
The design pressure and temperature for the pressure vessels (except bellows) to
be designed shall be 3.5 kg/cm2 and 215 C respectively. Flash tanks shall also
be designed for full vacuum condition.
Corrosion allowance of 3 mm shall be added to the design thickness of the shell
and head of the vessels. The minimum thickness of the vessels including
corrosion allowance shall not be less than 8 mm.
The flash tanks and manifolds shall be designed to take care of the impact forces
due to incoming drains.
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1.16.18.4
i)
ii)
iii)
iv)
v)
vi)
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The temperature in the flash tanks shall be maintained by using condensate spray
or service water spray (for flash tanks open to atmosphere). The spray shall be
automatically controlled. However, for flash tanks open to atmosphere continuous
spray through an orifice shall also be acceptable.
In case the spray is in the manifold, the material for the flash tank manifolds shall
conform to ASTM A335 Gr. P22 or better and its thickness shall not be less than
Schedule 100 of ANSI B36.10 irrespective of temperature of the fluid handled.
Constructional features
Flash tanks shall be vertical, cylindrical design and of welded construction with
torispherical or hemispherical heads.
Drain/hot water inlet nozzles shall be tangential/ radial to the vessel periphery.
Suitable vortex breaker arrangement shall be made at the liquid outlet to the
vessel. In case the Bidder finds better alternate arrangement, the same can be
submitted for the purchasers acceptance and approval.
A manhole shall be provided on the flash tanks for inspection purpose. It shall be
of minimum 500 mm diameter. The manhole shall be of devit type and shall be
provided with grip.
The flash tanks shall be located on the ground/ mezzanine floor of the power
house. Necessary structural supports including anchor bolts shall be provided.
Three support legs at 120 degree spacing shall be provided on each flash tank.
Necessary lifting lugs for handling by the main plant building EOT crane shall be
provided.
The flash tanks shall be provided with a full length level indicating gauge glass
complete with protective rods, isolation valves and drains. Temperature indicators
and temperature switches shall be provided on the flash tanks.
The flash tanks shall be provided with access ladders.
Schedule of materials
Shell and head
: ASTM 285 Gr. C
Wear plate/ baffle
: ASTM 285 Gr. C
Nozzle neck
: ASTM A 106 Gr. B
Manhole nozzle flange and cover
: ASTM 285 Gr. C
Couplings
: ASTM A 105
Bolts and studs
: ASTM A 193 Gr. B7
Nuts
: ASTM A 194 Gr. 2H
Gaskets
: Spiral wound SS 316 with graphite
In place of ASTM 285 Gr. C material, the Bidder may also offer ASTMA 516 Gr
60 or IS 2062 Gr B materials provided the relevant code/standard permits use of
these materials for the intended design parameters.
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1.6.19
[Logo of Utility]
Drains and Drain Valves

Drains shall be provided at all low points of the turbine shells, steam chest,
valves and interconnecting pipes. The individual drains shall be brought into a
common manifold header which shall discharge into the condenser. Automatic
valves remotely controlled from the control room shall enable draining and
warming of the turbine, piping and valves with steam during startup. A second
manual locked-open shutoff valve shall be provided upstream of each drain
valve.
1.6.20
Valves
All miscellaneous gate, globe, and check valves shall be designed in accordance
with ASME B16.34 or International equivalent.
Electric valve operators shall be designed to withstand, in both directions, the
stalled torque that may be developed at 110 percent of the rated voltage.
1.6.21
Insulation
The turbine casing, valves, piping and equipment shall be thermally insulated by
non-combustible materials where the hot surface temperature is above 60 C.
The insulation above the turbine operating floor shall be covered with metal
lagging formed into panel jackets arranged for convenient removal. All insulation
which is normally removed during routine turbine inspection shall be of the
reusable "blanket" type. All blankets shall be tagged and identified on an
insulation arrangement drawing supplied with the turbine. Aluminium jacketing
on all pipe insulation shall be included. The insulated portion of the steam
turbines shall be provided with suitable anti-drumming and sound pressure
attenuating material inside. The insulation and steel covering should be so
designed and erected as to provide easy accessibility to parts requiring frequent
inspection.
Thermal insulation of the crossover pipe shall be covered with aluminium
sheeting. Split metal covers, packed with insulation shall be used to cover the
exhaust flanges and permit bolt access. The feed heating system, drain coolers,
ejectors, deaerator and its storage tank including all accessories, flash vessels,
H.P. and L.P. bypass systems and all associated piping and valves shall be
efficiently insulated.
1.6.22
Vibration Limits
The turbine-generator unit at the rated speed of 3000 rpm shall not exceed the
vibration and shaft movements specified as follows:
With the rotor on turning gear, the rotor eccentricity measured at any bearing oil
ring shall not be more than 1 mil (0.0254 mm) double amplitude. When
measured directly on the turbine shaft, the eccentricity at each bearing point
shall not exceed 3 mil (0.0762 mm) double amplitude during the startup period.
Maximum permissible vibration measured at bearing housing will be as per zone
A of ISO 10816-2 and ISO 7919-2:2001.
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1.7
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Steam Turbine Performance Requirements

i.
ii.
The steam TG set apart from being capable of operation on base load shall also
be suitable for two shift operation and cyclic load variations as the unit is
expected to operate in automatic load-frequency control system. For catering to
two shift and cyclic operation, turbine shall have following design features:
Low thickness and weight of components
Uniformity and symmetry of section
Small rotor diameters
Small size horizontal flanges for casings
Thinner casing outer shells
Operation with HP/LP Bypass System
The unit will be provided with a HP/LP bypass system. The HP/LP bypass
system will be provided primarily to enable suitable steam/metal temperature
matching at the turbine for a quick restart following a steam turbine generator
(STG) trip out as well as to prevent a steam generator trip in case of steam
turbine generator trip. The bypass system will also be used during cold start-up
of the STG unit. The capacity of the HP bypass system shall be 60% of BMCR
flow.
iii.
Operating Frequency Range

The STG unit shall be capable of safely operating and continuously delivering
100% unit output (with maximum condenser cooling water inlet temperature to
the condenser) under following operating conditions:
iv.
v.
vi.
With a frequency variation of +3% and -5% over the rated system frequency
of 50 Hz.
Within +5% and -5% of voltage variation of the rated generator voltage at
maximum and minimum of rated frequency range.
Auxiliary Equipment Performance with Fluctuation in Power Supply conditions
Although the rated system frequency is 50 Hz, it is expected that reduced
frequencies will prevail over sustained periods of time. All motor driven auxiliary
equipment and accessories shall be capable of continuously delivering
satisfactorily their rated outputs for a voltage variation of +/-10% and a frequency
variation of + 3 % and 5% and a combined variation of +10%.
Rate of Loading
The unit shall be loaded as fast as practicable subsequent to synchronisation
after cold/warm/hot start-up with the bypass system in service. The Bidder shall
indicate the criteria that will govern the rate of loading.
Start-up, Loading, Unloading and Shutdown Requirements
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Each unit shall be capable of being started-up and loaded in the shortest
possible time. The unit shall be able to start up and synchronise within the start
up time indicated below:
Cold start [Greater than 36 hours shutdown- To achieve Synchronization

within 6.0 hours and to achieve full load within 3.5 hours from
Synchronization]
Warm start [Between 8 and 36 hours shutdown- To achieve
Synchronization within 3.5 hours and to achieve full load within 2.0 hours
from Synchronization]
Hot start - [Less than 8 hours shutdown-- To achieve Synchronization within
1.0 hour and to achieve full load within 1.0 hour from the Synchronization]
Following cyclic loading criteria shall be considered in design:
vii.
Cold starts
: [150 nos. for 20 years]
Warm starts
Hot starts
[The units shall be designed for operation in the modified sliding pressure mode
between 40 % and 90% load. The unit has to fulfill the following Indian grid code
requirement:
The unit shall be capable of (and shall not in any way be prevented from)
instantaneously picking up five percent (5%) extra load when frequency falls due
to a system contingency. After an increase in generation as above, the unit may
ramp back to the original level at a rate of about one percent (1%) per minute in
case continued operation at the increased level is not sustainable.
Bidder shall highlight in his bid how the above condition could be fulfilled. In any
case Bidder shall consider adequate throttle reserve in the design so that Turbine
VWO (valve wide open) flow capable of generating 105% TMCR loads.]
viii.
Operation without Top Feed Water Heater

The steam turbine generator shall be designed for operating continuously
corresponding to the condition when any one the top high pressure feed water
heaters is out of service.
ix.
Sudden Loss of External Load

On occasions, the unit may experience sudden total loss of all external load.
Under these conditions, the HP-LP bypass system shall operate and the Boiler
and the steam turbine generator together shall continue operation without
tripping to supply power for the power plant auxiliaries (about 5-6% of 100%
TGMCR). The complete instrumentation and control system shall be adequately
designed to take care of the above operation of the power plant.
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x.
Sound Pressure Levels inside Power Plant Area

The individual machines / components / system shall be acoustically designed for
a surface sound pressure level of < 85 dB (A), measured in accordance with ISO
2746 respectively at a distance of 1 m from equipment surface and at a height of
1.5 m above floor level. The surface sound pressure level (Lp) shall be averaged
over the measurement surface and corrected for effect of background noise and
the influence of reflected sound at measurement surface (environmental
correction).
xi.
Bidder shall provide adequate temperature measurement and other

instrumentation etc. for adequately guiding the operator to regulate loading of
unit to keep the thermal stresses and fatigue levels within safe limit.
TG set shall be capable of operating on constant as well as variable pressure
mode. Necessary facilities shall be provided for switching over to variable
pressure mode of operation from constant pressure operation and vice versa
from unit control board.
Adjustable throttling reserve from 0 to 20% shall be provided.
TG set shall be capable of operating continuously with HP heaters out of service,
with [89] mm Hg condenser pressure, 3% make-up and auxiliary steam
requirement tapped from CRH, generating maximum output without
overstressing turbine components.
The peak to peak value of vibration measured on bearing housing shall be
minimized and shall be within limits as per ISO 10816 and ISO 7919.
During HP and LP bypass operation, the deaerating feed water heater and
accessories shall be able to heat feed water from [45 deg C to 140 deg C].
All cycle drains shall be led to condenser through flash tanks. In addition, the
provision shall be kept for main steam line drains and HP bypass line drains to
be led to a separate atmospheric flash tank.
Condenser shall be designed to accept additional flows from boiler during startup
(as applicable).
xii.
xiii.
xiv.
xv.
xvi.
xvii.
xviii.
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CONDENSER AND CONDENSER AIR EVACUATION SYSTEM
2.1
General
The condenser shall be designed to receive and condense the whole of the
exhaust steam from the turbine, including HP-LP steam bypass system and
drains & vents under all modes of operation. The condenser shall be designed
for a temperature raise of [10 deg C]. Each Turbine Generator unit shall be
provided with steam condensing plant consisting of condensers to suit the
requirement of the turbo generator sets proposed by the Bidder, and a set of air
extraction equipment and accessories as described in this specification. The
steam inside condensers shall be cooled by cooling water pumped by circulating
water pumps and recirculated through cooling towers. During start up and other
operating conditions, steam will be dumped into the condensers fully or partly
bypassing the steam turbine. The Condensers shall be suitably designed to
receive such bypass steam.
The Air extraction equipment to be used for creating the necessary vacuum in
the condensers during starting up of the unit and during normal operation by
removing non-condensable vapours and gases and shall be designed suitably to
work satisfactorily in conjunction with the condensing unit.
2.2
Codes and Standards

Nomenclature, definitions, design, materials and construction of the condenser
and air removal equipment furnished under this specification shall comply in all
respects with requirements of the latest edition of Heat Exchange Institute (HEI)
standards for steam surface condenser. HEI standards or equivalent shall be
followed for thermal design and IS-2825 for strength design of condenser.
Table: 2.1
S.No.
Code
PTC 12.2
ASTM
American
National
Standards (ANSI) on
OSHA
Document Number
LII-GETS12021-G-00129-002
Description
ASME Performance test codes for Steam
Surface Condensers.
Standards of the Hydraulic Institute of USA
American Society for Testing & Materials
Steel Pipe Flanges and Flanged Fittings (B
16.5)
Steel Fittings S.W. and Threaded (B 16.11)
Butt welding ends-Pipe, valves, & fittings
(B16.25)
Valves Flanged, Threaded and Welding
End (B 16.34)
American Society for Non destructive Testing
(SNT-TC-1A)
American Society for Non destructive Testing
(SNT-TC-1A)
Occupational Safety and Health Act
Rev
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Other standards such as, DIN, BS, IS etc. shall also be accepted subject to the
Purchaser's approval. In case bidder intends to use alternate standards (if same
is acceptable to Owner), Bidder shall furnish a copy of the same in English
version during detail engineering.
2.3
Design Parameters
2.3.1
Condenser
i)
ii)
The steam condensing plant shall be designed, manufactured and tested as per
HEI (latest edition). The condenser(s) shall be designed for heat load
corresponding to unit operation for valves wide open (VWO) conditions, 3%
make-up, design condenser vacuum and other conditions specified in the given
below table. The value of design condenser pressure to be measured at 300 mm
above the top row of condenser tubes shall be guaranteed under VWO condition,
3% make-up, design CW inlet temperature and CW flow. The condenser vacuum
shall be measured with a vacuum grid utilizing ASME basket tips. The grid is
fitted with at 300 mm above top row of tubes of condenser.
The condenser hotwell shall be sized for three (3) minute storage capacity
(between normal and low-low level) of total design flow with the turbine operating
at VWO condition, 3% make-up, design condenser pressure. The low low level of
hotwell shall be at least 200 mm above the bottom of hotwell.
Table: 2.2
S.No.
Particulars
Value
Condenser design parameters
Number of passes
[Divided water box type, Double pass]
Design cold water temp/Type of

water
[33 C]/ Clarified water
Minimum thickness of the tube
22 BWG
Tube velocity
1.6 to 2.2 m/sec
Design condenser pressure
[76] mm Hg (abs)
Temperature
water
[10] C
Tube material
rise
of
circulating
Stainless steel
ASTM A249 TP304
Cleanliness factor
0.9
Fouling factor
As per HEI
Tube plug margin
5% under design condenser condition
Maximum CW side pressure drop in

condenser and associated systems
under CW design flow and CW inlet
6 mwc
Document Number
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S.No.
Particulars
[Logo of Utility]
Value
temperature with tube cleaning

system CW intake and discharge
ducts in bidders scope within the
terminal point..
2
Maximum temperature of circulating

water
[36 deg C]
Minimum temperature of circulating

water
[29 deg C]
Flow
Able to handle exhaust steam

corresponding to VWO condition
with rated steam pressure and
temperature at turbine inlet, 3 %
make up and all feed heaters in
service along with all other heat
rejections
and
maintaining
a
guaranteed condenser pressure of
[76] mm Hg considering tube
cleanliness factor as 0.9
Water box design pressure
Vacuum and 5 kg/cm
Water box test pressure
1.3 times the design pressure
Water box design temperature
60 deg C
Shell side design pressure
Full vacuum and 5 kg/cm (g)
Shell side design temperature
120 deg C
10
Design parameters for expansion

joints
11
Design pressure
Vacuum (0.108 bar (abs)) and 5 kg/ cm

(g)
Design temperature
60 deg C
Test pressure
1.3 times
(minimum)
Design parameters of
butterfly valves with
Design pressure
Design temperature
Document Number
LII-GETS12021-G-00129-002
the
design
pressure
isolating
actuator
Vacuum (0.108 bar (abs)) and 5 kg/ cm
(g)
60 deg C
Rev
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S.No.
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
Particulars
Value
Test pressure
1.3 times
(minimum)
the
[Logo of Utility]
design
pressure
Condenser shall be designed to receive exhaust steam from steam turbine, HPLP bypass system, heater drains and vents, drains during startup, low-load and
abnormal conditions.
Steam dumping device shall be provided for dumping of desuperheated steam
from LP bypass. Sizing of steam dumping device shall be adequate to accept the
steam from HP-LP bypass with necessary spray water including abnormal
condition like HP heaters out of service etc.
Air removal section shall be designed to cool the air and vapour mixture to at
least 4.17C below saturation temperature corresponding to 25.4 mm Hg (abs).
Connections to air evacuation pumps shall be made at this section.
Condenser shall be designed to carry flooded weight (upto tip of last stage of LP
turbine blades) for hydraulic and hydrostatic testing of condenser without
installation of temporary supports or bracing.
CW butterfly valves with actuators shall be designed as per AWWA-C-504-80 or
purchaser approved equivalent standards. Valve material shall be suitable for the
duty intended.
CW expansion joints shall be made from high quality natural/synthetic rubber
with stainless steel reinforcement rings and with flanges of 125 lb as per ANSI
B16.25. The materials used shall be suitable for service intended. The expansion
joints shall be designed to the deflection fluid pressures throughout plant life and
shall be suitable to withstand full vacuum without collapse and the proposed
arrangement for this shall be indicated in the offer. Further the design shall limit
the reaction forces/ moments on condenser CW nozzles and on CW piping.
There shall not be any damaging effect due to vibrations during normal,
abnormal and transient conditions and during turbine trip from full load to HP-LP
bypass operation. Satisfactory operation under all operating conditions shall be
ensured including HP-LP bypass operation, feed heaters out of operation, VWO
condition, 100% load and start-up conditions etc.
Condenser design shall provide for maximum deaeration and removal of non
condensable gases from steam and make-up water. Air removal section shall be
suitably baffled to prevent water carryover.
Condenser shall be provided with arrangement for complete drainage of water
from the hot well.
Catch trough shall be provided below tube sheet in hotwell for detection of water
leakage into steam side.
Document Number
LII-GETS12021-G-00129-002
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2.3.2
[Logo of Utility]
Condenser Air Evacuation System

Each unit shall be provided with 2x100% vacuum pumps with all accessories for
condenser air evacuation. Pumps shall be sized as per latest HEI requirements.
Capacity of each pump in free dry air at standard condition with condenser
operating at design pressure of 1inch (25.4 mm) of Hg (abs) and sub-cooled to
4.17C below temperature corresponding to absolute suction pressure shall not
be less than 30 scfm (51 m3 per hour) under standard condition (i.e 76 mm of Hg
(abs) and 21.1C). The capacity of each pump during hogging shall be as per
criteria given in latest version of HEI plus 20% margin.
Table: 2.3
S.No.
i)
ii)
iii)
iv)
Particulars
Value
Source of vacuum pump heat

exchanger cooling water
Auxiliary cooling water (ACW)
Source of sealing water
Condensate
Source of make-up water
Condensate
Design pressure (cooling water

side) for vacuum pump heat
exchanger
Vacuum (0.108 bar(abs)) and 5 kg/ cm2 (g)
Pressure of make-up water
CEP discharge pressure
Maximum temperature of
condenser cooling water
36 deg C
Duty code
HEI
Design back pressure
25.4 mm (1 inch) of Hg (abs)
Note: Design pressure for CW piping, valves, fittings, COLTCS equipment etc
shall be for Vacuum (0.108 bar(abs)) and 5 kg/cm2 (g) minimum.
Air evacuation pumps shall be single/two stage liquid ring type with both stages
(if two stage pump required) mounted on a common shaft. The pumps shall be
suitable for indoor installation and for continuous duty.
Each pump and its accessories shall be mounted on common steel base plate.
Pump shall be connected to its motor by flexible couplings.
Heat exchangers shall be shell and tube type with tubes of SS 316, and shell and
tube plates of ASTM-A285 Gr. C15. For U-tube type heat exchangers, the tube
bundle shall be of removable type. Alternatively, plate type heat exchangers with
SS 316 plates and 20% area margin on plates shall also be acceptable.
Selection of materials for vacuum pumps and seal water recirculation pump shall
be as below:
Casing
: Nickel cast iron
Shaft
: Carbon steel (EN8)
Impeller
: Nodular iron/stainless steel
Document Number
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v)
vi)
vii)
viii)
ix)
[Logo of Utility]
Shaft sleeves
: Nodular iron/stainless steel
Air evacuation pumps shall be designed for vibration levels as per VDI 2056.
Flexibility shall be provided for operating both pumps during hogging and must
be able to evacuate the condenser in specified time as per HEI.
Standby pump shall cut-in automatically in case running pump fails or when
condenser pressure falls back to a preset value.
Each pump shall be suitable for evacuating 100% designed air steam mixture
and non-condensable gas as per HEI.
Pumps shall be designed for no cavitation under all operating conditions.
2.4
Design and Construction Requirements
2.4.1
Condenser Type and Duty

The condensers shall be of single/dual pressure type two pass, horizontal,
surface type with integral air cooling section with water as the cooling medium.
The condensers shall be so designed that it can operate satisfactorily under the
different off-normal operating conditions of the turbine such as fully or partly
by-passing of the turbine, closing of one or more extraction openings etc. The
condenser shall be designed for efficiently deaerating the heat cycle make-up,
which will be introduced into the condenser. Sub-cooling of the condensate shall
be avoided.
The condenser Hotwell should have a minimum available volume sufficient to
contain between its "normal" and "low" levels the condensate that may be
produced in the condenser in a period of three (3) minutes under condition of
maximum steam load. Hotwell shall preferably be divided longitudinally with
pump suction from both sides.
The condensers shall be arranged for installation with the tubes at right angle to
the axis of turbine rotor and shall be designed for a minimum width and for
installation below a reinforced cement concrete turbine generator foundation.
Condenser shall be furnished in two sections. Each water box shall be divided
into two halves and the two sections shall be completely isolated from each other
with separate inlet and outlet connections so that one half of the condenser can
be isolated on the cooling water side for inspection and maintenance while the
other half is in operation. The cooling water inlet connections shall be at the
bottom and outlet connection at the top.
The condenser overall dimensions, together with the space required for
withdrawal of condenser tubes and dismantling/opening of each water box cover
shall be suitable for the T.G. building dimensions and local pipe layout so that no
dismantling of any equipment or CW or other piping or breaking of wall/floor is
required for condenser tube/water box maintenance or replacement.
Corrosion allowance of minimum 0.8 mm on each welded side for the shell side
and 3.2 mm for water boxes and tube plates shall be applied to the design
thickness of each component.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
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2.4.2
[Logo of Utility]
Condenser Shell and Fittings
i)
The condenser shell shall be carefully shaped in conjunction with the tube
arrangement and provided with baffles as necessary to ensure proper distribution
of steam over the whole of the tube nest with minimum shock load and to
eliminate all areas of excessive steam velocity. Extraction pipes passing through
condenser neck shall be provided with stainless steel shroud around each pipe to
prevent erosion due to steam. Condenser shell shall conform to ASTM
Specification A285 Gr.C or equivalent. The design shall be as per ASME
pressure vessel code. The condenser shell (steam side) shall be designed for full
vacuum to a minimum internal pressure corresponding to the bursting / relieving
pressure of the turbine exhaust hood safety diaphragm and the same is expected
to be 10% more than the saturation pressure corresponding to the condenser
design temperatures whichever is greater. The shell side design temperature
shall be 120 deg C. The minimum wall thickness for the shell shall be 16 mm and
the tube shall be 0.7mm.
Shell shall be designed for a minimum number of site welds. Expansion joints
shall be provided in the condenser shell to take care of differential expansion
between the shell and tubes.
The condensers shall be adequately supported so that no upward thrust is
imposed on the turbine under all conditions of operation. If the design
incorporates an expansion piece, it shall preferably be in fully stabilized
Austenitic stainless steel all welded type, designed to reduce flow interferences
to a minimum. Design of expansion joints shall take care of the set pressure of
bursting disc on turbine exhaust and corresponding temperature along with the
turbine movements. Means shall be provided to prevent any load being imposed
on the turbine casing when the condenser steam space is filled with water during
hydrostatic testing of the condenser.
Suitable manhole with hinged covers on the upper part of the shell and hotwell
portion shall be provided to facilitate maintenance. Manhole sizes shall be
minimum 600 mm.
Necessary connections on the condenser shell and hotwell for air removal,
introduction of make-up, recirculation from main condensate line (to maintain
minimum flow through condensate extraction pump), drains, vents &
instrumentation shall be provided.
At all points where steam and water enter the condenser shell, baffles shall be
provided to prevent direct impingement on the tubes. All bolts, nuts, stays etc.
inside the steam space shall be of approved material and where such parts
project through the tube plates they shall be fitted with approved cap nuts and
protective sleeves. Spray piping shall be provided to distribute cold make-up
water in such a manner as to provide suitable heating and deaeration. The other
fittings shall include but not be limited to the following:
Drain valves with cap and one set of water level gauge for each section of the
condenser hot well as also a complete arrangement for sample collection and
conductivity measurement from each section.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
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ii) Nozzles with strainers and vortex breaker for connection to extraction pumps from
each section of the hot well. The suction pipe of Condensate Extraction pumps
should be laid above ground floor and valves should be easily accessible.
iii) Air outlet connections.
iv) Steam throw-off device to effect pressure reduction and condensate spraying on
the steam from L. P. bypass station when the turbine is bypassed.
v) All necessary connections for instrument and controls.
vi) One isolating valve on the top of the steam space of each condenser shell or top of
each turbine exhaust piece for vacuum gauges.
vii) Suitable thermometer pockets on each of the cooling water inlet and outlet
branches, at top of the steam space of the condenser shell, in the air suction
branch of the shell, in each section of the hotwell and also thermowells on each
end of the condenser shell.
viii) Flash boxes with manifolds to receive all feed heater drains, and various other
system drains; vent and drain piping from each flash box for connection to the
condenser steam space and hot well.
2.4.3
Condenser Tube Plates

The condenser tube plates shall be conforming to international standards. The
tube plate shall preferably be welded to the shell. The tubes shall be solid drawn
type, manufactured and tested in accordance with the approved standard. All
tubes shall be of tested quality and the Bidder shall submit the test certificate of
the tubes. Each tube shall be eddy current tested for soundness.
Condenser tube material shall be conforming to international standards of
adequate thickness and size as per unit size. The tubes shall be cleaned and
annealed followed by quenching, pickling and passivation.
The tube water velocity shall be within a range suitable for the material selected
as recommended by Heat Exchanger Institute (USA).
Tube nest as a whole shall be slightly inclined to provide self-draining of tubes
when the condenser is shut down.
A catch trough shall be provided at the bottom of each tube-plate towards the
steam side so that any leakage of cooling water through a tube-tube sheet joint
will first get collected in the catch trough. A drain pipe from each catch trough
shall be provided penetrating out through the condenser/hot-well shell and
having an isolating cock at the outlet end for sampling connection/conductivity
measurement.
2.4.4
Tube Support Plates

The tube support plates shall be of appropriate material construction and
arranged suitably so that no periodic vibration of tubes may be induced by the
running of the Turbo Generator and the maximum span shall be limited such that
vibration induced by steam flow may not occur. Tube holes shall be accurately
drilled to provide suitable clearances on the diameter of the tube. Edges of the
Document Number
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tube holes in the support plates shall be chamfered to facilitate tube insertion and
shall be deburred to prevent tube damage.
2.4.5
Water Boxes and Covers

The water boxes shall be designed for a pressure of 5 kg/cm2 (g) minimum. (The
same shall be checked against the Condenser Cooling Water Pumps shut-off
heads.)
Water boxes shall be supported from condenser shell by flange connection.
Condenser design and construction shall assure complete support of the fully
flooded water boxes from the condenser shell without requiring auxiliary
supports.
Material of construction for the water boxes and its covers shall be conforming to
international standards.
Water boxes shall be tested with a hydrostatic test pressure as recommended by
Heat Exchange Institute (USA).
The water boxes, covers and water side of tube sheets shall be sand blasted,
applied with coal tar epoxy primer and then coated with coal tar epoxy paint of
minimum 0.25 mm thickness. The outer surface shall be painted with suitable
paint after the surface is cleaned and degreased. Cathodic protection of water
boxes and tube sheets shall be provided.
Suitable drain and vent connection with necessary valves shall be provided for
each compartment of the water box.
Design shall provide the optimum entrance condition to the tubes. Strengthening
ribs shall be suitably provided on outside face only.
Access doors and inspection windows shall be provided in each compartment at
minimum two levels to permit easy internal access and inspection.
Adequate arrangement shall be made for removal of water box cover for tube
replacement without disturbing C.W. piping. Necessary monorail, hoist block etc.
shall be included.
2.4.6
Air Evacuation System - Vacuum Pumps

i)
The condenser air evacuation system shall be suitable for operation in conjunction
with the turbine and condenser offered. It should comprise 2 x 100% vacuum
pumps with all accessories for condenser air evacuation. These mechanical
vacuum pumps shall be sized as per latest HEI requirements. Capacity of each
pump shall be sufficient to maintain continuously the condenser vacuum
corresponding to the saturation pressure of the condensate in hotwell at design
cooling water temperature, when the condenser is working at its design capacity of
steam, condensate and heat input (VWO steam flow, 3% make-up heater drains
diverted to condenser etc.), and also during operation of the unit at lowest TG load
for all C.W. Temperature.
ii) Besides, the pump capacity shall also be such that at starting, with both pumps
working in parallel, it is possible to create within 30 minutes sufficient vacuum in
the condenser suitable for raising the steam turbine to its full speed.
Document Number
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iii) The design capacity of each pump shall be selected to meet both the above
requirements with a margin of 10%. The pump TDH shall take into account the
pressure drop, in suction pipeline between pumps and condenser and in the pump
discharge side including air vent pipe stack outside Turbine building, as estimated
for the design capacity. The sizing calculation of the system shall be furnished with
the offer.
iv) The pumps should not trip under low system frequency (47.5 Hz) operation.
v) The pumps shall be single stage/double stage, as necessary to meet the design
conditions. The pumps shall not cavitate under all operating conditions.
vi) Suitable compression ratio shall be selected so that the pumps operate effectively
at all conditions of operation with cooling water temperatures mentioned above.
vii) The pumps shall be designed for indoor installation and for continuous duty, to
handle mixture of air, steam and non-condensable gases. Bidder shall ensure and
guarantee that pumps shall not cavitate at any load, including part loads and
design point.
viii) The pumps shall be of liquid ring design with both the stages (in case of two stage
pump) mounted on a common shaft. The unit shall require no internal lubrication
and shall be free from damage by water vapour, entrained droplets or slugs of
water.
ix) The unit shall be complete with liquid ring vacuum pump, drive motor, flexible
coupling and coupling guards, water separator in the discharge air line, (The line
should be self draining to pump) with gauge glass and automatic make-up and
overflow valves, suction and discharge piping, expansion joints, inlet system valve
with differential pressure switches, system vacuum switch to start automatically the
standby unit, heat exchanger for seal water cooling, seal water recirculation
pumps, air ejector, rotameters for discharge air measurement, vacuum gauge for
system inlet pressure, pressure gauge for seal water pressure, temperature gauge
for seal water, outlet check valve, relief valves (if required) and other necessary
instrumentation, control and wiring. The entire unit shall be mounted on a common
steel base frame. Water separator in the vacuum pump discharge air line.
x) Necessary device shall be incorporated in the design of the equipment so as to
prevent loss of vacuum by flow of atmospheric air back into the condenser upon
shut down of the pump.
xi) The heat exchangers shall be arranged to permit access to tubes without
disturbing the piping connections. The heat exchanger tubes shall be seamless/
welded. If U-tube heat exchangers are offered, the tube bundle shall be of
removable type.
xii) The material of the pumps shall be so chosen as to accept condensate as the
source of sealing water.
Document Number
LII-GETS12021-G-00129-002
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No.
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Page
No.
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2.4.7
[Logo of Utility]
Air Evacuation System- Steam Jet Air Ejectors

i)
1x100% single stage non-condensing type Starting Ejector and 2x100% two
stage condensing type Main Ejectors shall be provided. The ejectors shall be
suitable for operation in conjunction with the turbine and condenser offered.
ii) Two stage main ejectors shall be provided with inter-condenser and aftercondenser.
iii) Both types of ejectors shall be complete with accessories like steam nozzle,
strainer, interconnecting piping, valves, air vent, instruments and controls.
iv) The ejectors shall be sized as per latest HEI requirements.
v) Capacity of the starting ejector shall be such that at starting, it is possible to
create within 30 minutes sufficient vacuum in the condenser suitable for raising
the steam turbine to its full speed.
vi) Capacity of main ejectors shall be sufficient to maintain continuously the
condenser vacuum corresponding to the saturation pressure of the condensate
in hot well at design cooling water temperature, when the condenser is working
at its design capacity of steam, condensate and heat input (VWO steam flow,
3% make-up heater drains diverted to condenser etc.), and also during
operation of the unit at lowest TG load for all C.W. Temperature.
vii) The air ejectors shall be designed for indoor installation and for continuous
duty, to handle mixture of air, steam and non-condensable gases.
viii) Necessary device shall be incorporated in the design of the equipment so as to
prevent loss of vacuum by flow of atmospheric air back into the condenser
upon shut down of the air ejectors.
2.4.8
Nozzle Connections
All necessary nozzle connections for the system as required by the
Turbine-Generator manufacturer and the heat cycle system shall be provided.
All water (make-up water, exhaust hood spray, condensate recirculation etc.) to
the condenser shall be fed through perforated pipes suitably located. The supply
shall include necessary internal piping with spray holes. In regions where
impingement is likely to occur, the tubes shall be protected by stainless steel
baffles & extraction pipes shall be protected by stainless steel shields.
2.4.9
Condensate Storage Tank and DM Make Up Pumps

For normal make up to the power cycle, DM water shall be added in the
condenser hot well. The DM water shall be supplied from DM water storage
tanks of DM plant, and shall be added in the hot well through a control valve. The
indication for status of operating DM water supply pumps shall be provided in the
UCB.
Emergency make up to the condenser hot well shall be supplied by 2x100 %
centrifugal pumps of adequate capacity taking suction from the condensate
storage tank which shall also receive excess flow from discharge of condensate
Document Number
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extraction pumps. The condensate storage tank shall be of epoxy coated mild
steel to IS 2062 Gr- B and its capacity shall be to meet 12 hour normal make up
requirement of the unit subject to a minimum effective storage of [300 m3]
2.5

i)
ii)
iii)
iv)
v)
vi)
2.6
The water box and shell shall be hydrostatically tested as per Heat Exchange
Institute Standards. During hydro test the gasket tightness shall be to measured
extent. Gaskets shall be replaced by new ones after shop test.
All condenser tubes shall be hydraulically tested to 7.5 kg/cm2 g internal and
outside pressure and also inspected ultrasonically or by eddy current testing as per
ASTM E213-68 and ASTM E243-67T respectively prior to shipment.
The completely assembled and tubed condenser shall be hydrostatically tested
after erection, according to the standards of Heat Exchange Institute.
Condenser shell shall be tested for any leakage by filling the steam space with
water.
A field performance test shall be conducted in conjunction with approved
Acceptance Tests Procedure.
Performance of the air removing equipment shall be tested at the manufacturer's
shop according to the applicable ASME Performance Test Code, PTC 24 "Ejectors and ASME Performance Test Code, PTC 9- Vacuum Pump.
Drawings, Data and Information Required
i)
ii)
Characteristic curves for condenser performance showing condenser pressure for

heat load range of 30 percent to 120 percent of the design heat load with varying
circulating water temperatures (26.9 deg C to 36 deg C) for tube cleanliness factor
of 100% and 90%.
Rubber expansion joint GA drawing with material of construction.
Document Number
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FEED WATER HEATER AND DEAERATOR
3.1
General
[Logo of Utility]
i)
The design shall be capable for meeting all operating conditions including
sudden load throw-off, HP-LP bypass operation, one or two heaters out of
operation etc.
ii)
The system shall be designed for handling drains from preceding heaters for all
operating conditions and emergency drains to condenser bypassing the drain
cooling zone.
Easy for floor mounting and shell dismantling except for LP heater in Condenser
neck (if provided).
Provision for complete drainage from both shell and tube (water box) side.
Provision of start-up and operating vents with orifices and provision for removing
non condensable gases to be collected on the shell side to condenser shall be
made. Vent orifices shall be sized to pass one half percent of rated steam flow to
respective heater.
Material
Table: 3.1
iii)
iv)
v)
vi)
Tube
(For
seamless)
circumferential joints
vii)
viii)
ix)
x)
xi)
xii)
with
ASTM A 213 Gr. TP 304
Tube (For welded)
ASTM A 688 Gr. TP 304
Tube sheet
Carbon steel as ASTM A 216 Class II or SA

350-LF-2
The tube sheet shall be welded to shell and water box. Tube support plates of
common quality steel of 16 mm (min.) thickness shall be provided.
Water box channels shall have access opening (manhole openings) of minimum
450 mm dia. This shall be of self sealing type. Bolted design shall not be
acceptable.
The design shall provide prevention of super heated steam contact with tube to
tube plate joints at entry to heaters.
Preservation by nitrogen blanketing during shut down.
Minimum tube thickness shall be 20 BWG (0.89mm) after bending. Stress
relieving of U tube bends shall be carried out up to a distance of 150 mm from
bend area.
Minimum fouling resistance at tube side shall be 0.00004098 hr-m2-deg C /kCal
and an additional 0.000061475 hr-m2-deg C /kCal on outer tubes as per HEI.
Document Number
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xiii)
A corrosion allowance of 3.2 mm shall be considered for each heater shell and
water box.
xiv) Heaters shall be provided with stand pipes with necessary connections for
instruments, water level gauges, isolation valves etc.
xv)
Each bled steam line shall have one number power assisted NRV and one
number ordinary NRVs, motorized isolation valves except for the L.P. heater
No.1, if mounted in condenser neck. However the bled steam (extraction steam)
from IP turbine to deaerator shall be provided with two numbers of power
assisted NRVs with motorized isolation valves.
xvi) Baffle plates shall be provided to prevent vibration, ensure uniform steam
distribution and enable free drainage of condensate.
xvii) Shall have provision of pass partition plates to facilitate easy removal and access
to tubes.
xviii) Provide sentinel relief valve on tube side. Relief valve on shell side shall be sized
to pass flow from two ruptured tubes (four open ends) or 10% of design water
flow at 10% accumulation whichever is higher and set to open at heater design
pressure.
xix) Adequate handling facilities shall be provided for removing the heaters for
maintenance in case of horizontal heaters.
3.2
Low Pressure Heaters and Drain Cooler

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Vertical / Horizontal type having U-tubes with integral drain cooler except for LP
heater no. 1 if mounted in the condenser neck.
Shell shall be made of ASTM A-516 Gr. 70 with SS-304 bands at cut points on
shell to prevent damage against flame impingement during torch cutting.
Water box shall be made of carbon steel as per ASTM 516 Gr. 70 and shall be
welded to tube sheets.
Expansion of tubes to tube sheets shall be rolled. Tubes shall be cold bent for
fabrication.
Roller support shall be provided for shell removal of heaters (in case of horizontal
heaters). For LPH-1 roller support shall be provided for heater channel during
tube bundle removal if LPH 1 is located in the condenser neck.
Provision of shell attachments for supports of LPH in condenser neck and Antiflash baffles to protect the turbine from water ingress shall be made.
Provision of integral desuperheating, condensing and drain cooling zones except
for LPH-1, if mounted in condenser neck shall be made.
There shall be provision of differential expansion between shell and tube.
Details of tube sheets, tube to tube sheet joint, tube supports plates, material of
construction for drain cooler shall be identical to other LP heaters.
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3.3
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Deaerator
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Horizontal, spray-cum tray with integral vent condenser mounted on horizontal

storage tank.
Design and construction shall be as per Indian Boiler regulations, ASME code for
unfired pressure vessels, Section- VIII or any other equivalent code.
The storage tank shall have reinforced wire mesh strainer and anti-vortex baffles
at discharge connections from deaerator.
Fixed and Saddles support shall be provided for the storage tank.
All pressure parts such as shell, heads and nozzles shall be made of carbon
steel as per ASTM A 515 Gr. 70. Shell plate shall have thickness of 15.8 mm
minimum with welded construction.
Hardened 400 series stainless steel impingement plates for flashed drain inlet
from HP heaters, BFP recirculation, boiler start-up drains etc shall be provided.
All water spray valves, splash plates, trays, vent condenser and other elements
coming in contact with undeaerated water or non-condensable gases shall be
made of stainless steel SS 304.
Deaerator safety valves shall have adequate relieving capacity and shall be
made of Stainless steel disc and spindle.
Vents with orifice plate and vent with motor operated valve shall be provided.
The Deaerator shall be designed for efficient steam distribution and deaeration of
condensate under all operating conditions including VWO, 3% make-up, HP-LP
bypass, one/both the strings of HP heaters out of operation.
The Deaerator shall be of variable pressure type (Floating pressure Type) Pegging pressure shall be 3.5 ata during warm and hot startup, HP- LP bypass
operation, major load rejection, turbine trip and low load when extraction steam
pressure is less than 3.5 ata. During cold startup the deaerator pressure shall be
maintained at 1.5 ata with steam from auxiliary steam header. Deaerator
pressure shall vary according to load due to variation in steam parameters of
turbine extraction. Design pressure & temperature shall not be less than the
extraction or CRH pressure at the downstream of PCV or the worst operating
conditions with sufficient design margins.
Source for heating:
a. [Extraction steam from turbine IP-LP crossover pipe (normal operation)].
b. [Steam from CRH (up to 60% load)]
c. [Steam from auxiliary steam header (for Initial heating & low loads)].
Sizing of feed storage tank shall be adequate to take requirements of any steady
load from 0% to 110% of rated capacity including boiler start up drains as
applicable. Minimum feed storage tank capacity between normal and low-low
level shall be 7 (Seven) minutes of BMCR flow.
Design shall be adequate to withstand full vacuum and pressure decay during
start-up condition.
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xv)
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3.4
Shell thickness shall have corrosion allowance 3.2 mm.

Provision of sparger pipe and nozzle for feed water heating shall be made.
Size of vent orifice shall be for one half percent of rated flow to deaerator.
Provision of access platform and ladders with hand rails on deaerator and
storage tank shall be made.
2 nos. of manholes of 450 mm dia. (min.) each on deaerator and storage tank for
maintenance including trays shall be provided.
High Pressure Heaters
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Vertical/Horizontal type HP heaters having U-tubes with integral desuperheating,

condensing and drain cooling sections shall be provided.
Shell shall be made of carbon steel as per ASTM A-516 Gr. 70 and water box as
per ASTM A-226 class II and shall be welded to tube sheet.
Roller supports for shell removal shall be provided in case of horizontal type.
Tubes shall be welded to tube sheets and then roller expanded.
Level of condensate in the heaters is to be maintained in the preset range. In
case of level rise beyond permissible limits in any of the HP heaters,
group/individual (based on the configuration) hydraulic bypass arrangement shall
operate and drains shall be led to the condenser.
Provision for differential expansion between shell and tube shall be made.
All other features indicated for LP heater shall be applicable to HP heaters also.
General Performance Requirement
The feed heating system shall be capable of raising the temperature of feed
water from that in the condenser to the final optimized value specified at the
outlet of the top high pressure heater with turbine generator (T.G) set operating
at rated parameters.
The extraction steam pressures and flows shall be determined by the Bidder by
working out the turbine cycle heat balance.
The maximum oxygen content of the feed water discharge from the deaerator
without chemical dosing shall not exceed 0.005 cc/liter at all loads upto and
including the rated capacity. The carbon dioxide content of the feed water
discharge shall be nil.
Heaters shall be capable of operation under the condition of preceding lower
pressure heater taken out of service. The heaters shall be designed to
accommodate increased steam and drain flows (for the next higher pressure
heaters and the deaerator) in such an event. Contractor shall submit
performance data on affected heaters in the train when one heater at a time is
removed from service. Data shall be calculated for conditions when each of the
heaters is removed from service individually and/or in group, and the remaining
heaters are on line. Besides submission of off-performance data, the Contractor
shall also indicate limitation of service, if any, during such condition. The
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deaerator shall be designed for the maximum incoming steam flow when none of
the L.P. heaters is working under HP & LP Bypass condition.
During HP & LP By-pass operation, feed water shall be heated in deaerator to a
minimum permissible temperature as per boiler requirement. Minimum
acceptable H.P. heater outlet temperature during turbine low load operation shall
be finalized as per boiler requirement.
The operation of the deaerator shall be stable and free from vibration etc. when
subject to transient condition which may occur at full load trip out conditions of
the T.G. and during introduction of alternative steam service.
All equipment warrant high reliability, low down time and ease of maintenance.
Equipment offered shall have an operating noise level as per ISO - 85.
3.6
Design & Construction Requirement
3.6.1
3.6.1.1
Closed Feed Water Heaters

Design requirement
The heaters shall be of surface type. Water shall flow inside the tubes and the
heating steam outside the tubes. High & Low pressure heaters shall be horizontal
U tube as per Manufacturer's standard proven practice. Heaters shall have
integral desuperheating sections, as required.
The lowest pressure heater may be located in the condenser neck in case that is
the standard arrangement of the manufacturer. In such a case, drain cooler may
be provided either internal or external to the heater. L.P Heater mounted inside
the condenser neck shall be provided with required shell attachments for
supports and for closure plates for sealing the penetrations through the
condenser shell. The heater shall also be provided with antiflash baffles to
protect the turbine from water ingress. Arrangement for heater tube withdrawal
shall be provided; piping connected to the heater shall be so routed as to
facilitate the tube withdrawal without dismantling the pipes.
Start-up vent from the heater mounted in condenser neck shall be provided with
orifice plate.
Contractor shall select the terminal temperature difference and the drain cooler
approach of the feed heaters keeping in mind the overall economy. However,
following shall be the minimum criteria.
H.P. heaters shall be provided with desuperheating and drain cooling zones in
addition to the condensing zone. The maximum terminal temperature difference
and maximum drain cooler approach shall be as per the HEI guidelines.
L.P. heaters shall be provided with drain cooling zone in addition to the
condensing zone. Terminal temperature difference shall be as per the HEI
guidelines.
Heat transfer area shall be calculated considering 10% of the tubes plugged.
Fouling factor shall be taken as per the recommendation of the Heat Exchanger
Institute, USA.
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The L.P. heaters shall be designed for the shut-off pressure developed by the
condensate pumps on the tube side. The H.P. heaters shall be designed for the
shut-off pressure of the boiler feed pumps (at maximum speed of operation) on
the tube side. The design pressure for the feed piping shall be the shut-off
pressure of the boiler feed pumps. Each heater shall be designed for removal
from service individually without shutdown of unit, using hydraulically operated or
motorized bypass and isolating valves. In addition, spring loaded relief valves
shall be provided in the bypass arrangement of HP Heaters so as not to exceed
the feed water pressure in heaters above design pressure.
The shell side shall be designed for the maximum extraction steam pressure with
5% margin or 3.5 Kg/Sq.cm (g) whichever is higher. The shell side design flow
shall be calculated for the normal operating as well as abnormal conditions as
specified and for a tube sheet leakage of 20% of the condensate/boiler feed
water flow. Nozzles shall be sized liberally considering various modes of
operation and shall be subject to approval by Purchaser. The tube side velocity
shall be limited to 2.5 m/sec under all operating conditions.
Corrosion allowance of 3.2 mm shall be applied to the design thickness of each
heater shell and water box. Tube thickness shall be increased to compensate for
tube wall thinning.
About 0.5% of the steam entering a heater shall be vented (from its condensing
zone) to the condenser and orifice plates shall be fitted in the vent pipe work to
control the flow. Care should be taken to prevent accumulation of pockets of gas
by positioning the vents in such a manner that every part of the tube nest is
swept by steam. Each heater shall be separately and continuously vented to the
condenser. Cascading of vents from heater to heater will not be permitted. The
vent valves shall always remain open, whenever a heater is in service.
Each heater shall be designed for removal from service individually without
shutdown of unit, using hydraulically operated or motorized bypass and isolating
valves.
Self sealing type hand holes shall be provided on the H.P. heater water box for
access to all the tubes. A skirt shall be provided around the tube bundle to shield
during a gas cutting of the shell if required for removal of the tube bundle.
The arrangement of the feed water heater internals shall be such as to minimize
rapid fluctuations of heater level during operation and the heaters shall be
designed to operate without excessive noise and vibration.
Shell side relief valves shall be sized for 10% of the feed water flow, or maximum
feed water inflow to shell due to the rupture of two (2) nos. tubes, whichever is
greater, at 10% accumulation. Tube side relief valves shall be provided to guard
against overpressure from water expansion when inlet and outlet valves are
closed. The shell side relief valve set pressure shall be above the maximum
working pressure of the extraction steam line, connected to the feed heater, in all
possible operating conditions.
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3.6.1.2
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Necessary vent and drain connections with valves shall be provided. Vents and
drains on the feed water side of H.P. heaters shall be provided with double
valves.
The heaters shall be designed for the minimum tube side pressure drop, and the
same shall be indicated (for rated operating condition) in the Bid.
Materials and Construction
The water box for the high pressure heaters shall be of forged construction and
welded to the shell. The low pressure heaters may be of bolted head or with
welded water box. For bolted head type, copper jacketed gaskets or other
metallic packing of approved quality shall be used.
The heater shells shall be of carbon steel welded construction. The tubes shall
be of U-type. The L.P. heater tubes shall be roller expanded into the tube plates
provided with at least two grooves.
The H.P. heater tubes shall be joined to the tube plates by welding to the
stainless steel overlay by a proven technique. The Contractor shall, in his
proposal, give complete description of the process adopted.
The tube nest shall be supported by baffles which shall prevent vibration and
also ensure an even distribution of steam. Stainless steel impingement plates
shall also be provided at all steam and water inlet branches to prevent direct
impingement and wear of the tubes. The water box baffle plates shall be
positioned to give good flow distribution through the heater tubes. The heaters
shall be designed for most economical length and shall have suitable lifting
arrangement such that a heater or shell can be removed for maintenance
purposes.
The tube sheet shall be of forged carbon steel for L.P. heaters. For H.P. heaters,
the tube sheet of forged carbon steel shall be overlaid first with one layer of SS309, and then another layer of SS-308, to a total thickness of overlay not less
than 7 mm. The feed water heater tubes shall conform to the applicable
requirements of ASME specification. Seamless or welded type stainless steel
(SS-304) tubes shall be provided. Details of experience of the Contractor with the
type of tubes provided (seamless or welded) shall be furnished in the bid.
Minimum tube diameter shall be 5/8" (0.625 inch/ 15.88mm) and thickness shall
not be less than 20 BWG (0.035 inch / 0.89 mm). Stress relieving of U-bends
shall be carried out up to a distance of 150 mm from bend area. Drawing and
bending lubricants shall be non-chlorinated.
Bolting material, not in contact with steam or water, shall be ASTM A-193 Grade
B7. For other bolting, manufacturer's standard corrosion resistant material shall
be used.
H.P. water box nozzle connections shall be butt-weld type for sizes above 50 mm
and socket weld for sizes below 50 mm. Other connections may be flanged type.
All flanged connections shall be of the bolted type and the use of studs shall not
be permitted unless with special approval.
All tube holes in the tube sheets, baffles and supports shall be deburred.
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3.6.2
3.6.2.1
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Insulation cleats shall be provided on shell and water box.

The interior surfaces of all the heaters shall be cleaned of all mill scale. The
exterior surfaces shall be painted as required.
Material of construction for different parts of the drain cooler shall be identical to
those specified for LP heaters.
The design pressure of the feedwater line and feedwater heater will be in line
with the recommendations of Indian Boiler Regulation (IBR), ASME Section-1
and ASME B31.1 as applicable.
DEAERATOR
Design Requirement
Deaerator shall be capable of operating satisfactorily with two of the adjacent
L.P. heaters out of service. Adequacy shall also be checked for the condition of
HP & LP bypass when no feed heating is taking place in LP heaters and also for
initial heating, steam blowing, initial commissioning etc.
Storage tank shall be fabricated at shop in minimum number of sections (to be
determined on the basis of the size of tank and the transportation limitations) so
as to minimize fabrication work done at site.
A horizontal, direct contact, spray-cum-tray type single deaerating vessel
mounted on a horizontal storage tank shall be provided. Spring loaded nozzles
for spray control shall be provided for guaranteed operation of the deaerator for a
flow range from 100% to 30% without water hammering. The trays shall be
provided for final stages of deaeration and shall be of rigid clamped type. The
terminal temperature difference shall be zero at all load conditions. The
deaerator will be operated for variable pressure. During load swing, cold
condensate at hot well temperature and 110% of normal flow may enter the
deaerator. The extraction steam during such operation may be zero such that
flash steam from the storage tank will flow to the dearator. For this purpose
adequately sized vent pipe from the storage tank to the deaerator and internal
water and steam distribution shall be provided.
Alternatively, a spray type (stork or equivalent) deaerator, which otherwise fulfills
all design and performance requirements stipulated here in, may be offered.
If the Deaerator is provided with an external shell and tube type vent condenser,
the same shall condense all vapour and vent out non-condensible gases to
atmosphere. The vent condenser shall minimise loss of steam through the vent
connection under all conditions of operation by providing at least 1 deg C subcooling of vented vapours over entire load range. The vented gases shall be free
of any visible vapour.
The deaerator shall be capable of deaerating all the incoming condensate, HP
heater drips and emergency make up water at a rate adequate to provide boiler
feed to match the boiler MCR requirements continuously.
The dissolved oxygen content at the discharge from the deaerator without
chemical dosing shall not be more than 0.005 cc/liter in the boiler feed water at
all loads, up to and including the rated capacity. The deaerator shall also
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effectively remove even traces of any other dissolved gases such as CO2 likely to
be present in the condensate/feed water.
The deaerator is proposed to be located to meet all the operating criteria Bidder,
however, shall check and confirm the adequacy of this level considering the
system offered, types and requirement of Boiler Feed Pumps considered etc.
such that system can operate safely and smoothly under all operating conditions,
abnormal and transient conditions and also for full load throw off condition.
The operation of the deaerator shall be stable and free from vibration and water
hammer when subjected to pressure decay which may occur at full load trip out
conditions of the T.G. and during introduction of the alternative steam service.
For supporting of the storage tank, one support leg shall be fixed and the other
shall be sliding type to accommodate expansion of the equipment. The supply
shall also include suitable ladder, platform & handrailing for access to various
parts of the deaerating heater.
The deaerator proper may be supported from the storage tank, or independently
from floor level and all support structures in either case shall be included in the
Bid.
The following connections shall be provided over & above condensate/feed water
inlet and outlet connections:
A perforated pipe connection of suitable size for steam supply for initial heating
and deaerating of water stored in feed storage tank at the time of starting of the
unit.
Connections on the tank for boiler feed recirculation, chemical dosing (if required)
etc.
Drain connections with valve and drain pipe to the flash box at ground floor level.
Suitable over-flow connection on the feed storage tank including control valve
and motorized by-pass valve.
HP Heater drip inlet.
Extraction/pegging steam inlet.
Safety valve connections.
Vent connections.
Sufficient number of inspection openings/man-holes (of minimum 600 mm
diameter) with suitable covers for easy cleaning, inspection and maintenance.
Covers for these openings/man-holes shall be hinged type.
All local/remote instrument connections including root valves.
Stand pipe connections.
Other connections as necessary.
Number, size, location and orientation of the connections, as necessary, shall be
decided by the supplier considering the performance of the deaerator. If found
necessary, it shall be possible to reorient the nozzle connections of deaerator so
as to match the layout of associated piping.
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3.6.2.2
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Anti-vortex baffle together with a coarse strainer shall be provided for feed water
outlet. Safety relief valve/s with adequate compensating pad for full relieving
capacity at the worst operating conditions shall be included.
Following materials of construction shall be used for deaerator:
Shell and heads
:
ASTM: A-285 Grade C or equivalent
Spray Nozzles
:
304 stainless steel
Trays
:
304 stainless steel
Tray supports
:
Stainless steel
Internal bolting
:
Stainless steel
All metal parts in contact with non-condensible vapour shall be of type 316
stainless steel.
Hardened 400 series stainless steel impingement plate shall be provided for the
flashed drain inlet from the high pressure heaters and boiler feed pump
recirculation.
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POWER CYCLE PUMPS
4.1
General Information
4.1.1
Boiler Feed Pumps (BFP) and Drives

[Three (3x50% capacity)] motor driven BFP (with suction booster pumps, drives,
hydraulic fluid coupling and accessories), shall be installed for supplying feed
water to each Boiler unit. Out of these [three (3)] pumps, [two (2)] feed pump will
be operating normally while the [third pump] shall remain as a standby unit and
will come into operation automatically in case any of the working pumps fail.
Each pump is having separate suction feed line to the booster pump.
The pumps shall receive the water from Deaerator and then pump it through high
pressure feed water heaters to the Economizer inlet of the Boiler. The location of
the pumps and design shall take care of all the transient operating conditions.
The deaerator shall be supplied with extraction steam from the turbine and shall
normally operate at a variable pressure depending on the extraction pressure at
different loads. A steam connection from the auxiliary steam header/cold reheat
pipe shall be provided for initial heating and deaeration at start-up as well as
pegging at low extraction steam pressure. However, the boiler feed pumps shall
be capable of withstanding transient instabilities in the suction pressure caused
due to load swing of the turbine generator from full load to no load and
interruption of steam supply to the deaerator. Boiler feed pumps shall also be
adequately designed for turbine by-pass operation.
The pumps shall be designed for efficient and reliable operation and shall be of
proven design with at least five years of satisfactory operating experience.
Condensate Extraction Pumps and Drives
Each Unit shall be provided with [3x50%] Condensate extraction pumps. Pumps
shall be capable of handling the full condensate from the Condenser to the
Deaerator through LP heaters, gland steam condenser etc. Each Pump capacity
shall be calculated considering the maximum condensate flow.
The pumps shall be required to handle hot condensate at or near saturation
temperature and shall be designed for very low NPSH service. The suction
specific speed selected shall be suitable to permit part load operation as per
system requirement without any trouble.
The pumps shall be designed to withstand transient due to load swing of the unit
from full load to no load. Adequate design margins shall be provided in the
pumps for turbine bypass operation.
4.1.2
4.2
Equipment and Accessories to be Furnished
4.2.1
Boiler Feed Pumps and Accessories

[The equipment and accessories for each boiler feed pump and drive shall
include, but not be limited to the following:
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Horizontal shaft, single suction, multistage, centrifugal type pump with radially
split inner assembly encased in a heavy outer barrel type casing, having both
suction and delivery openings at the top.
Horizontal, single stage, split casing, double suction booster pump (if required)
directly driven by the boiler feed pump drive motor.
Sole plates, pin and key blocks or other supporting structures, fabricated steel
base plate/plates for the pump, hydraulic coupling, motor and accessories
complete with foundation anchor bolts/inserts etc. as required. Preferably the
entire pump and drive assembly shall be mounted on a common base frame,
with provision for separately collecting any leakage water and leakage oil and
draining through isolating valves and also arrangement to facilitate grouting on
the foundation.
Flexible couplings with safety guards between BFP motor, gear box, hydraulic
coupling and pump as required.
Hydraulic coupling suitable for variable speed operation of the pumps.
Motor for the boiler feed pump as required.
Forced lubricating oil and working oil systems complete with oil reservoir, shaft
driven main oil pump and A.C. motor driven 100% standby pump, 2 x 100% lube
oil coolers, 2 x 100% working oil (Hydraulic Oil) coolers, duplex cleanable filters
with all interconnecting valves, fittings, specialties, pipe work and control panels,
provision for connecting purifier with oil tank.
Low load recirculation system complete with piping up to Deaerator end, all
valves, pressure breakdown orifices and control valves, supports, hangers etc.
as required.
The boiler feed pumps shall be capable of withstanding thermal shocks from cold
to hot for emergency start and hot to cold during Deaerator transient conditions.
No separate warm-up system is preferred.
Balancing drum for axial thrust balance, with balancing chamber leak-off system
complete with all piping, valves, fittings, instruments, supports, hangers etc. as
required.
Non-return valves on the pump discharge lines.
100% duty temporary strainers with spool pieces complete with counter flanges
and fasteners etc. for mounting on Boiler Feed suction piping to each pump.
Interconnecting piping with fittings etc. in between Booster pump discharge and
Main Pump Suction, if applicable.
Set of locally mounted instruments as specified and/or as required.
Set of interconnecting water and oil piping, valves, fittings and specialties
required to render installation complete including seal water cooling system as
applicable.]
Condensate Extraction Pump and Accessories
[Condensate Extraction pumps ( 3 x 50%) together with all accessories required
to make complete and well integrated units to satisfy requirements of the
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specification, including but not limited to the following (for each pump, unless
otherwise noted).
Drive motor
Pump and motor coupling
Temporary strainer before pump suction.
All instrumentation and control as specified and/or as required. The scope shall
also include initiating contacts for the alarms and interlocks. A gauge board shall
be supplied with each pump housing instruments.
Foundation ring/frame with bolts, nuts, sleeves etc.]
4.3
General Performance Requirement
4.3.1
Boiler Feed Pump

Capacity and discharge pressure of the pumps shall be selected to meet the
requirements of the steam generator. The Bidder shall furnish the pump sizing
calculation with the Bid.
The boiler feed pump shall be driven by squirrel-cage induction motor through a
variable speed hydraulic coupling. Appropriate step-up gears as required shall be
provided.
Each pump shall exhibit the same type continuously rising characteristic from
rated duty point to shut-off. The pumps should be capable of parallel operation
without instability at all speeds and share equal load. Shut-off head shall not,
however, be less than 120% and shall not be more than 130% of the head
developed at pump design point.
The pumps shall have their best efficiency at the normal duty point, i.e.,
corresponding to [210/215/220/250] MW load, 3% (of throttle flow) make up and
design CW temperature of [33] deg C.
The pump shall be designed for working at its operating temperature without
setting up destructive temperature strain causing warping, buckling,
misalignment, rubbing or other objectionable effects.
The pumps shall be capable of accepting, without damage, any transient
reduction in suction pressure causing cavitations condition and shall accept,
without distress, the re-establishment of normal suction conditions following the
transient, with no necessity for a pump shut down.
The Deaerator storage tank shall be located to meet the normal and transient
operating condition. Bidder shall check the requirement of NPSH against
available NPSH considering the worst transient situation of load dump. Bidder to
ensure that adequate margin over the required NPSH shall be available under
worst condition for safe and trouble free operation. The booster pump should
either be directly driven by the boiler feed pump motor shaft or driven by an
independent drive motor. The head developed by the booster pump shall be
sufficient to give adequate NPSH at the main pump suction.
Bidder shall furnish necessary calculations to establish the availability of excess
NPSH over the actual NPSH requirement of the pump.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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Suction specific speed for BFP and Booster Pumps must not exceed 9000 US
Units.
Pumps shall be capable of withstanding reverse rotation for a limited time
required to close discharge shut off valve following an emergency failure of the
main discharge Non-Return Valve of a standby pump. All bearings & mechanical
seals shall be capable of withstanding this operation.
The capacity, head and efficiency of the pumps shall be guaranteed within the
tolerances stipulated by Hydraulic Institute Standards, USA or any other
equivalent International Standard.
The pump and drive assembly shall be so constructed that dismantling and
repairing may be accomplished without difficulty. Complete interchangeability of
parts between the pumps shall be ensured.
Pump and drive assembly shall run smooth, free from undesirable vibration,
noise and leaks. Acceptable peak to peak vibration limits of the Hydraulic
Institute Standards of USA will be applicable.
The Units shall be so arranged that start-up, running and shut down operation
may be carried out from the central control room. Necessary interlock and
provisions shall be made so that the standby pump will come into operation
automatically and immediately without any thermal shock whenever any
operating pump trips.
Speed control range of the BFP drive unit (with hydraulic coupling) shall cover
the entire range of boiler feed pump operation, from minimum flow (i.e. pumps on
recirculation) to the design head-capacity point with at least 5% margin on pump
speed both on the high and low sides.
Pump drive shall be rated for cold water operation. Pumps shall be capable of restarting following a hot or warm shut-down without recourse to barring or
warming up. Bidder shall indicate the maximum allowable conditions for
restarting such as maximum casing differential temperature and maximum
difference between casing temperature and incoming water temperature.
Boiler Feed Pump first stage impeller and if applicable, the booster pump shall be
so designed that wear due to cavitation will not restrict its service life to less than
40,000 - 45,000 running hours when operating under steady state design suction
condition.
Boiler Feed Pumps and auxiliaries shall be adequately designed to meet the
Turbine HP and LP by pass condition without any problem.
The drive motor shall be so selected that a margin of at least 15% is provided
over the total power required by the Boiler Feed Pump, Booster Pump, Oil Pump
and losses in the gear box and hydraulic coupling, at the rated condition of the
pump. It should also be checked that when the pump operates with control valve
stuck open, the power requirement is lower than the drive power, irrespective of
whether the pump is working singly or in parallel with the other pumps. Detailed
calculation for sizing of motors shall be submitted to the Owner for approval.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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4.3.2
[Logo of Utility]
Pumps shall have short, stiff shafts, with least number of stages for the specified
duty. The critical speed of the rotor assembly, in dry as well as water filled
conditions shall be beyond the maximum possible running speed by at least
30%, even after considering power supply to pump drive motor at 51.5 Hz.
Plain cylindrical pressure fed journal type bearings and tilting pad, double acting
100% thrust bearing shall be provided. The sleeve bearings shall be horizontally
split type.
Duplex type basket strainers shall be provided on the booster pump suction to
protect the fine clearances of the pump. The screening area of the strainer shall
be 4-5 times the cross-sectional area of the inlet pipe.
All the design parameters are to be met during under frequency conditions of
47.5 Hz at grid.
The flow impulse for the purpose of recirculation control shall be initiated from
flow measuring device installed at the pump suction. Balancing chamber leak-off
shall be piped back to the suction of the respective pump.
The Boiler Feed Pump set shall be capable of continuous safe, and trouble free
operation under other than normal condition, like under and over frequency (47.5
to 51.5 Hz), abnormal pressure decay in Deaerator, VWO with 3% make-up,
overpressure of TG (if envisaged), H.P. heaters out of service, sudden load
throw-off, start-up of unit, HP-LP bypass operation, rapid starting and load
changes during cyclic load operation.
The successful bidder shall furnish necessary details and calculations
establishing the suitability of the proposed pumps for meeting the above
requirements.
The motors shall be able to accelerate the pumps from normal standby condition
to rated pumping condition in less than 15 seconds after receipt of starting signal.
It shall be possible to run the pumps singly as well as in parallel with other
pumps.
Condensate Extraction Pump
Vertical "can" type condensate extraction pumps shall be provided.
The contractor shall submit pump sizing calculations for approval of the Owner.
The pump impellers shall be so designed that wear due to cavitations will not
restrict its service life to less than 40,000 running hours when operating under
steady state design suction conditions.
The pumps shall be designed for highest practicable degree of reliability under all
conditions of operation.
The pumps shall have continuously rising head capacity characteristics from
design point to shut-off.
The condensate extraction pumps shall be suitable (without cavitation) for
handling saturated water, at the maximum possible flow rate from the condenser
hot-well, with the NPSH available at hot-well "Low- Low" level.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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[Logo of Utility]
Suction specific speed for condensate extraction pumps must not exceed 9000
U.S. units.
Pumps shall be capable of operating either single or in parallel. Suitable
Automatic Starting devices shall be provided to bring the standby pump into
operation in case of failure of any operating pump.
Rating of the motor shall be selected with at least 15% margin over the maximum
power required within the range of operation.
The shut-off head of the pump shall not be less than 115% of design head.
The pump rotor assembly (with guides) shall be so designed as to keep its
vibration, in both wet and dry running conditions, within the safe limits as
specified in relevant International Standards/Codes.
4.4
Boiler Feed Pump Design and Construction
4.4.1
General
The pump shall be of the horizontal centrifugal type supported in such a manner
as to permit free expansion both axially and radially whilst maintaining alignment.
The boiler feed pump and suction booster pump will be expected to accept from
the main pipe work reasonable forces and moments, the least values being those
stipulated in API-610. Therefore, the Bidder shall ensure that all materials and
terminal connections are suitable for such terminal forces and moments.
Inter-stage bleed shall be provided in the pump for reheat desuperheating.
Requirement of flow shall be decided by Bidder based on the steam generator
demand.
Pump Casing
The casings shall be of suitable design to withstand any possible thermal shock
and/or high pressure and shall be constructed of materials specifically selected to
prevent erosion and corrosion.
The barrel type outer casing of the BFP as well as the booster pump casing shall
be supported at horizontal centre line of the pump. The inner casing shall be of
axially/radially split type in accordance with the standard proven practice of
Manufacturer. The joints shall be constructed in such a way that the feed water
discharge pressure acting between outer barrel and inner casing acts to seal the
joints. The casing assembly complete with the rotating elements should be
located accurately in the outer barrel and it should be possible to remove this
assembly without disturbing the suction and discharge piping connections.
The Bidder shall supply a cradle with rollers and necessary attachments for the
removal of the inner assembly.
Pump casings shall be provided with adequate number of vent and priming
connections with valves. Casing drain, as required, shall be provided complete
with drain valves. Necessary insulation cleats shall also be provided on the
casing.
Rotor
Shaft
4.4.2
4.4.3
i)
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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ii)
iii)
iv)
[Logo of Utility]
The shaft shall be of tested forgings accurately machined and ground. The
material specification and its heat treatment as well as particulars of thermal
treatment, proposed to minimize distortion during manufacture, shall be stated in
the Bid. Shafts should withstand the stresses set up when the pump will be
started quickly. Shaft size should be so selected that full driver output can be
easily transmitted without excessive deflection, vibration, distortion or whip.
Impellers
The impellers should be accurately machined, finished to close tolerance and
installed individually on the shaft giving special consideration to prevent
recirculation between shaft and impeller.
The first stage of inlet impeller should be specially designed to provide most
favourable conditions free from cavitation even during stringent suction condition.
Each impeller shall be balanced individually and the entire rotor assembly should
be statically and dynamically balanced. The rotor shall be so designed that its
first critical speed in air or water is above the operating speed. The first critical
speed in water shall be at least 130% of maximum speed of the pumps.
Shaft sleeves of hardened wear resisting material shall be provided at all points
of wear. Ferritic wear surfaces shall be preferred. They shall be firmly secured
and keyed to the shaft. The material and design shall be such that no internal
leakage occurs between shaft and sleeve. The axial thrust of the rotor shall be
carried by an approved type of hydraulic balancing device and an external oil
lubricated thrust bearing fitted at the outboard end of the pump integral with the
journal bearing housing. No axial thrust should be transferred to the electric
motor at any condition of operation. The thrust bearing shall be designed for
additional load when pump gets vapour bound.
Shaft Seals
Shaft seals shall be of mechanical seal type. The seals shall be designed to have
a minimum life of 20,000 running hours between overhauls. Feed Water for
sealing shall be supplied from pump discharge header. All pressure reducing and
control valves, instruments, fittings and special integral piping etc. shall be
included under Bidder's scope of supply. A filter or a fine mesh screen should be
installed in the condensate feed line to the seals to ensure clear condensate.
Stuffing box should be so designed that easy replacement of the mechanical seal
is possible. All necessary protection to prevent damage to seal due to over
temperature operation shall be provided by the bidder. Seal water cooler shall be
provided if necessary.
Bearings
Each pump shall be equipped with forced oil lubricated babbit lined sleeve
bearings and tilting pad, double acting 100% thrust bearing. The sleeve bearings
shall be horizontally split type. The thrust bearing shall be of sufficient size to
carry the maximum unbalanced load in either direction due to any emergency
operating conditions like the non-operation of the balancing device etc.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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v)
vi)
vii)
[Logo of Utility]
Thrust bearing shall be suitable for reverse rotation of pump. Temperature

sensing elements shall be provided for bearing metal temperature indication and
thermometers with alarm contacts shall be provided for bearing oil drain.
Lubrication
Each pump, drive motor and hydraulic coupling for motor driven pump set of
each unit shall be provided with a complete pressure lubrication system of
sufficient capacity for both pump and drive motor, consisting of oil pump, sump
tank, water cooled oil coolers (2 x 100%), duplex oil filter, level indicator, sight
flow indicator, thermometers, relief valves, pressure regulators and necessary
valves, all interconnected piping and accessories. Bidder may offer for common
oil pressure lubrication system for each unit. The oil cooler tubes shall be of
stainless steel SS-304. The coolers shall be designed for service with
demineralised water. The oil pump shall be driven by the feed pump shaft and all
parts of the system shall be mounted as an integral part of the feed pump
assembly. Provision must be made to ensure continuity of oil supply even during
reverse rotation of feed pump, and during low frequency operation of oil pumps.
In addition, a standby electric motor driven lubricating oil pump shall be furnished
including the motor drive and pressure switch. This pump will come into
operation automatically whenever the normal lubricating system pressure drops
below a predetermined setting.
The oil system shall cover the entire lubrication of the pump, motor, step up
gears, the booster pump as also the supply of oil to the hydraulic coupling.
Arrangement for proper distribution shall be made using needle valves and orifice
plates.
Required electrical interlock shall be provided for continuous, safe and troublefree operation of the lubricating oil system, including supply pressure switches for
automatic standby pump start, trip and alarm interlocks.
Provisions of pressure lubrication, if necessary, at the time of coasting down of
the feed pump and drive in case of A.C. power failure, shall be arranged by the
Bidder.
Base Plate
The base plate for each pump shall be of rugged fabricated steel construction
reinforced with heavy ribbing. The common base plate shall also accommodate
the drive motor, the booster pump, the fluid coupling and the step up gear box as
necessary. Adequate arrangement to collect leakage oil and leakage water
separately and draining up to area drains of plant with piping, isolating valves,
funnels etc. shall be provided.
Suction and Discharge Nozzle
Heavy reinforced suction and discharge nozzles shall be located vertically
upward on the centre line of the BFP casing. The suction shall be flanged raised
face type and drilled in accordance with ANSI/ASME code requirement for the
rated pressure and temperature. The discharge nozzle shall have approved
welding ends. The construction of suction and discharge nozzle must assure
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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viii)
ix)
x)
[Logo of Utility]
maximum strength and reliability and eliminate possibility of leakage at the joints
at any operating condition
Coupling
Adequately sized spacer type, extension type or other approved type flexible
couplings shall be used between the pumps, the fluid drive, the step up gear, and
the motor drive. Couplings shall have adequate permanent lubrication
arrangement and shall be provided with safety guards.
Axial Thrust Balancing Device (Hydraulic)
A suitable device for hydraulic thrust balancing shall be supplied. The balancing
drum shall be designed to balance pump axial thrust. Drum designs shall be
relatively long so as to reduce the pressure per linear unit and thus the rate of
wear. This should be optimized with the pump shaft span.
Combination of disc and drum or any other suitable modifications may be used if
proven by satisfactorily long experience, and in every case the Bidder shall
furnish in his bid the complete details of the system provided.
It is proposed to lead the balancing chamber leak off back to the respective boiler
feed suction line. A flow measuring arrangement shall be provided in the
balancing leak off line to monitor the condition of wear in balancing device. All
necessary local instruments including leak off flow indicator with alarm contact,
valves and fittings required for safe operation of this system shall be supplied by
the Bidder.
Each pump shall be constructed preferably with the following listed materials.
The Bidder shall offer equivalent or better materials with suitable heat treatment
as per the standard of the manufacturer for similar duty.
Part
:
Material
Base Plate
:
Structural Steel
Casing
:
Forged Steel
Shaft
:
ASTM-A-276, Type 410
Impeller
:
ASTM-A-296, Grade CA-6NM
Diffusers
:
ASTM-A-296, Grade CA-6NM
Wearing ring
:
Balancing drum
:
Balancing head
:
Shaft Sleeves
:
Bearings:
Radial
:
Sleeve type (Babbit metal)
Thrust
:
Tilting pad, double acting, 100% thrust
bearing (suitable material)
Pressure bolting
:
Chrome-molybdenum steel
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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xi)
xii)
xiii)
xiv)
[Logo of Utility]
Between rubbing faces a minimum difference in hardness of 50 BHN may be

maintained.
Non-return Valve
A non-return valve of approved design and manufacture shall be fitted on the
discharge pipe line from each feed pump. The following requirements shall be
satisfied.
The closing time of the valve, from the fully opened position, shall not be greater
than the time taken for the pump to stop feeding after being tripped. This shall be
of the order of one second.
The valve shall be of adequate pressure rating, alloy cast (or forged) steel body,
12-14% chrome stainless steel stellited trim, welding end joint, non-slam type.
Where internal components, other than valve seats, are of welded construction,
full penetration butt welds shall be used.
Low Load Protection: Recirculation System
A minimum flow recirculation arrangement shall be provided along with each
pump.
Capacity of the recirculation devices shall be so selected (not less than 25% of
normal rated flow) that under closed condition of the BFP discharge valve, the
temperature rise within the pump remain within allowable limits and the internal
recirculation at the pump suction impeller does not give rise to cavitation.
Bidder may offer ON-OFF type recirculation control valve. The impulse for the
control valve shall be from the flow measuring device installed at the boiler feed
pump suction.
The valve shall be of reputed make and of design proven in similar application for
three (3) years.
For reducing the bypass pressure to a value suitable for returning to the
deaerator, each pump shall be provided with suitable multiple stellited orifice
plates of 11-13% chrome steel with companion flanges for installation in the
recirculation piping and adequately designed for prolonged continuous service.
Each recirculation line shall be routed independently to deaerator storage tank.
An orifice, with a small pressure drop, shall be fitted in each line near the
deaerator to prevent any flashing in the pipeline.
The recirculation control valves and all necessary equipment required for making
the system complete shall be furnished by the Bidder for each recirculation
control system. All equipment shall be welded end type.
The recirculation control valves shall be designed to open in the event of air or
power failure. Signal lights shall be mounted in the local panel/remote control
room to indicate open/closed position of the valve.
Pump Warming Up Device
The boiler feed pump should be designed to start working without warming up
arrangement and shall accept hot fluid from deaerator immediately on starting.
High Speed Gear Unit
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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xv)
[Logo of Utility]
The gear unit shall be specifically designed for continuous service at the speeds
required by this application. Precision and accuracy of manufacture is essential
in order to minimize problems of vibration, impact stress, noise (to attenuate
noise level of 85 dB at one meter distance), distortion and lubrication.
Dynamically balanced double helical / epicyclic gears shall be used. The high
speed pinion integral to BFP shaft and the low speed gear securely keyed to the
input shaft should be of approved type of properly heat treated steel according to
standard code of practice. The Bidder shall submit detailed specification of the
materials used including factor of safety etc. and the detailed description of heat
treatment process followed.
Bearings shall be of the split sleeve type, bronze backed with a high grade
centrifugally cast tin base babbit lining. Bearings shall be adequately sized and
accurately machined to assure perfect alignment. Gear journal bearings shall
have babbitted thrust faces next to the gear to act as locating surfaces for the
gear train.
The gearing shall be enclosed in an oil and dust proof gear case made of close
grained cast iron or fabricated steel. The gear case shall be horizontally split and
stress relieved before machining. Two oil level gauges, drain, fill; vent
temperature switch, thermometer, dipstick, vibration limit switch and other
required connections equipped with approved mountings, valves and fittings shall
be furnished for the gear casing. The housing shall be of rigid construction to
maintain alignment of rotating parts and keep vibration to a minimum. The
arrangement shall be such that it will be possible to lift gear case cover without
disturbing the alignment of shaft, gear and pinion.
Forced oil lubrication system shall be adopted to lubricate the gearing and
bearings.
Fluid Drive (Hydraulic Coupling)
The fluid drive shall be a full duty, generously sized, infinitely variable, remotely
controlled, totally enclosed, hydraulic coupling adequately rated to meet the
requirement of pump characteristics while operating in the range of capacities
specified and required. The speed of the feed pump shall be varied smoothly and
stably (automatic control) over the entire range.
It shall be complete with stainless steel impellers, heavy duty roller bearings,
pillow blocks and Kingsbury or Mitchell type thrust bearing for input and output
shafts. An enclosed steel housing with removable cover, oil tank, duplex oil filters
to remove all particles up to 5 microns, oil temperature and pressure gauges,
pumps for oil circulation, stainless steel scoop tube and two full duty integral oil
coolers suitable for D.M. Water cooling shall be furnished. The oil cooler shall be
adequately rated and shall have arrangement for changing over the cooler
without discontinuing the oil flow. Necessary water inlet, outlet, drain and vent
piping and valves including sight flow glasses in the water outlet shall be
furnished.
Full description of the coupling with cross-section and tentative control circuits,
shall be included in the Bid.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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xvi)
4.5
[Logo of Utility]
The Bidder shall specify the quantity and grade of oil required and mention its
Indian equivalent and furnish speed, torque and efficiency curve for the coupling.
The power consumption data for various loads with and without couplings shall
be furnished in the Bid for economic evaluation.
Booster Pumps
The booster pump shall be driven directly by the boiler feed pump motor shaft or
by a separate motor and shall protect the boiler feed pump from cavitation under
all operating conditions. It shall be of single casing, double suction, single stage,
horizontally split, self-supported type with adequate number of bearings,
designed to carry its load and axial thrust. Shaft sleeve and wearing rings shall
be provided at all points of wear.
The material of construction for the booster pumps shall be identical to those
specified for the main pump or better.
Each pump shall be furnished with a flanged suction strainer (the duplex strainer
as already specified for the Boiler Feed Pump) complete with other accessories
as per requirement.
Necessary pipe connection from booster pump discharge to the suction of the
main boiler feed pump, complete with pipe hangers, flow meters and other
necessary instruments, valves etc., shall be included in the supply.
Proper shaft sealing and lubrication system are to be provided to ensure safe
and smooth operation of the pump.
Condensate Extraction Pump Design and Construction
The pump unit will be of vertical can type design. The unit shall consist of a
vertical centrifugal pump submerged in an airtight outer barrel with a pump base
plate flange, above which shall be suction and discharge nozzles, a motor
mounting stand and a motor coupled to the pump.
The first stage impeller shall be specifically designed for low NPSH requirement
and minimum risk of cavitation. The shaft coupling shall be of flexible type in
case the thrust bearing is provided on the pump and it shall be of rigid type if the
thrust bearing is provided on the motor.
The condensate extraction pumps shall be of heavy duty type suitable for long
periods of uninterrupted service. These shall be fitted throughout with renewable
wearing parts such as wearing rings, shaft sleeves, stage sealing rings etc.
The design and workmanship shall be such that the pumps are readily
assembled or dismantled and that they will operate satisfactorily under all
operating conditions without cavitations, pitting, excessive vibration, noise or
undue wear.
The glands of the pumps and their associated suction valves shall be suitably
sealed to avoid ingress of air into the condensate under all conditions. The
casing vent shall also be complete with all valves, piping, etc., for each pump.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
03

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[Logo of Utility]
In selecting material of construction of the pumps only proven material for such
services shall be used. The following material of constructions is suggested for
guidance only:
Bowl
: Cast Iron
Impeller for 1st stage
: Stainless steel (12% Cr.)
Stage impeller
: Bronze or chromium steel
Shaft
: Stainless steel
Can
: Fabricated steel
The impeller shall be cast in one piece finished all over and carefully balanced
both statically and dynamically. Finally the assembled rotor shall be dynamically
balanced and checked for eccentricity.
4.6
Drawings, Data and Information Required

The Bidder shall submit the following with his formal Bid besides the different
information required/asked in Volume III of this specification.
Characteristic curves of pumps showing effective head, pump input power,
efficiency, submergence and NPSH, against capacity ranging from shut-off
condition to at least 120% of rated capacity (at several running speeds from
minimum to maximum in the case of B.F. Pumps).
Speed Vs. torque curve of the pump corresponding to recommended mode of
pump starting, super-imposed on Speed Vs. torque curve of the motor,
corresponding to 80%, 90%, 100% rated voltage and also extending from
Quadrant-I to Quadrant-II covering reverse flow conditions, if applicable.
Detailed calculations for deriving capacity and head of pumps and sizing of
motors.
4.7
Specific Design Criteria for Power Cycle Pumps

Table: 4.1
S.No.
ITEM
CRITERIA
Boiler Feed Pump
1.1
Type
Horizontal barrel type

multistage with suction
booster pump
1.2
Number
[3x50%]
1.3
Rating
Document Number
LII-GETS12021-G-00129-002
REMARKS
Rev
No.
Description
Page
No.
Date of Issue
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S.No.
1.3.1
ITEM
Design Point:
[Logo of Utility]
CRITERIA
REMARKS
Combined Flow of 2x50%

pumps to be based on 10%
margin on feed water flow
corresponding to VWO
condition with 3% make-up,
design Condenser pressure
and corresponding head.
1. Pump shall be capable of

handle BMCR flow (without
taking account of 10%
margin)
Best efficiency
point
TMCR with design vacuum

and 3 % make-up
Run out point
One pump to meet 65%

unit load.
Emergency Point
VWO flow and head

corresponding to highest
safety valve set pressure
and 2% margin on head.
Condensate
Extraction Pump
2.1
Type
Vertical can type centrifugal

design.
2.2
Number
[3x50%]
2.3
Rating
a) Capacity - Maximum
steam flow at exhaust
during VWO condition
with
3%
make-up)
operation of turbine
with maximum steam
inlet pressure plus all
heater drains & vents
diverted to Condenser.
2.The pumps shall also be

capable
of
sustaining
emergency
transient
consisting like H.P.heater(s)
out, Turbine HP & LP
bypass in operation etc.
The pumps shall also be

capable
of
sustaining
emergency
transient
consisting like HP heater(s)
out, Turbine HP & LP bypass
in operation etc.
b) Head
Maximum
deaerator
pressure
operation etc. plus
static and dynamic
head under maximum
capacity condition
Document Number
LII-GETS12021-G-00129-002
Rev
No.
Description
Page
No.
Date of Issue
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S.No.
2.4
ITEM
Margin on
Capacity
Document Number
LII-GETS12021-G-00129-002
CRITERIA
[Logo of Utility]
REMARKS
10% over highest

condensate flow envisaged
during Unit operation
(Excluding HP/LP bypass
operation).
Rev
No.
Description
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No.
Date of Issue
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LP CHEMICAL DOSING SYSTEM
5.1
General
[Logo of Utility]
This section of specification complete is for the Low Pressure chemical dosing
system. It is not the intent of this specification to completely specify all details of
design construction and installation here. Nevertheless, the equipment
accessories and installation shall confirm to a high standard of engineering
design and workmanship and capable of performing continuously and
satisfactorily.
5.2
Equipment and Accessories to be Furnished
i)
ii)
iii)
iv)
v)
vi)
vii)
Low pressure chemical dosing system shall remove residual dissolved oxygen in
feed / condensate water and shall maintain the pH of condensate and feed water.
Each unit shall be provided with independent and skid mounted LP dosing
system. The arrangement shall consist of the total system for dosing hydrazine
and ammonia at boiler feed pump suction and on condensate discharge line. The
system shall include the following:
Hand pumps complete with flexible hose and couplings for transferring hydrazine
from storage drum to mixing / storage tank shall be provided.
One number hydrazine solution preparation & storage tank for preparation of the
hydrazine solution of about 0.6% concentration or as recommended for dosing by
the Bidder whichever is higher shall be provided. The tank shall have storage
capacity for 48 hours consumption of hydrazine and shall be complete with
motorized stirrer, breather to arrest the hydrazine vapours coming out of the tank,
graduated level indicator, over flow line with sealing arrangement etc.
One number hydrazine measuring tank to receive hydrazine from storage
tank/container. The flow of hydrazine from measuring Tank to solution
preparation/storage tank shall be by means of gravity flow.
Two numbers hydrazine dosing pumps of 100% capacity complete with drive
motors, pressure relief valves and pressure gauges in the discharge line shall be
provided. These pumps shall be of positive displacement type. The suction of
these pumps shall be from the hydrazine solution metering tank. Each pump
shall be provided with duplex filter in the suction line of each pump with
differential pressure switch.
The pump shall have the facility of adjusting the stroke to vary pumps discharge
from 0 - 100% while the pump is in operation.
One (1) number bulk aqueous Ammonia storage tank common for [both units] for
storing aqueous Ammonia of [33% Concentration] for 6 weeks requirements of
both the units shall be provided. This shall be kept outside the main power house
building. This ammonia storage tank shall be provided with a receiver tank on the
vent to capture fumes during tank filling, vacuum breaker, relief valve and
overflow line with sealing arrangement.
One number Ammonia mixing / storage tank of adequate capacity for 48 hours
storage of 1.5% concentrated solution (or the recommended concentration for
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dosing by the Bidder whichever is higher) complete with motorized stirrer,

breather, graduate level indicator, over flow line with sealing arrangement shall
be provided.
viii) 2x100% Ammonia transfer pumps complete with drive motors shall be provided
for transferring ammonia from bulk aqueous ammonia storage tank to ammonia
mixing storage tank.
ix)
One number Ammonia measuring tank to receive Ammonia from storage tank.
The flow of Ammonia from measuring Tank to solution preparation/storage tank
shall be by means of gravity flow.
x)
Ammonia feed (dosing) pumps two (2) nos. each of 100% capacity complete with
drive motors, pressure relief valves and pressure gauges discharge line shall be
provided.
xi)
All the inter-connecting piping, valves and fittings, locally mounted instrument
and switches shall be included.
xii)
The Bidder shall supply all necessary C&I for satisfactory operation of the
chemical dosing system.
xiii) The normal mode of operation of the chemical dosing system shall be through
DDCMIS including on/off command of the individual pumps. However Bidder
shall provide local free wired control panel complete with (a) start / stop push
button, (b) indicating lamps, (c) local/remote indication, (d) stroke position
indicator, (e) Raise/ lower push button for stroke position, (f) local annunciation,
etc.
xiv) Local/remote selection shall be done from control room. The stroke position and
adjustment shall be done by 4-20 mA DC signal from DDCMIS and the pump
stroke actuation shall be suitable for accepting 4-20 mA DC signal. The pumps
shall be provided with 24 V DC, two wire LVDT type position feedback transmitter
which shall generate 4-20mA signal indicating stroke position.
xv)
The LP dosing unit shall be skid mounted. It shall be provided with necessary
lifting eyes, special tools & tackles etc. for maintenance.
xvi) The drain of all tanks & pipes etc. shall be led to the Owners chemical pit for
neutralization.
xvii) All the foundation plates, foundation nuts and bolts, clamps and auxiliary
structure required for supporting the equipment, shall be included in the scope of
the Bidder.
xviii) The material of construction of all the equipment & components including tanks,
pumps & valves shall be of stainless steel SS 304.
xix) Arrangement shall be made for flushing the various pipe lines and pumps by the
condensate. The condensate shall be tapped from the main condensate line for
preparation of solution and for flushing.
xx)
The bidder shall furnish the sizing calculations of the tanks and pumps of LP
dosing system for Purchasers approval.
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5.3
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Strainer
All strainers shall be Y-type with cast steel body and 50 mesh stainless steel
screen. The screen opening area shall be at least 4 times the pipe cross
sectional area. Necessary screwed blow off connection fitted with plug shall be
provided.
5.4
Piping
All piping shall be supplied under the specification shall be of stainless steel SS
304 for LP dosing system. The size of the piping shall be selected in conformity
with the maximum design temperature and pressure of the system
5.5
Valves
All manual operated valves shall be stainless steel SS 304 body and trim for LP
dosing system, and shall be related to withstand the design pressure of the
system. The valve shall be welded/socket welded ends as applicable.
All flanged terminal shall be provided with necessary counter flanges, bolts, nuts
gaskets.
5.6
Control Skid
i)
ii)
5.7
A group alarm for dosing system shall be provided in the control room for the
following conditions:
Pump and stirrer trip due to low level in the tank.
Manual starting and stopping of stirrer motors and dosing pumps from control
room.
Performance test (head, capacity, efficiency & BHP) of the pump shall be done
according to the requirement of the hydraulic institute of USA or approved
equivalent.
The pump accessories will be subjected to the tests as per OEM standard
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PIPING, VALVES & FITTINGS
6.1
General
[Logo of Utility]
The Bidder shall design, manufacture, supply, erection, testing and

commissioning of complete power cycle piping/fittings/ accessories, associated
tanks, vessels, valves and controls within the battery limit along with specialties,
strainers, expansion joints, restraints, hangers/ supports with all components,
thermal insulation and auxiliary structures as per the scope specified in Section-I
of Volume-II. Bidder shall carry-out complete design and engineering including
but not limited to pipe sizing, flexibility analysis, hanger support engineering,
tanks, vessels and engineering of thermal insulation etc.
Bidder shall carry-out chemical cleaning of piping systems after complete
erection, which also includes complete supply, erection and dismantling of
temporary piping, valves and fittings etc.
The Bidder shall supply all standard and non-standard matching pieces as may
be needed within the piping system and for connection of piping systems with
equipment. Pipe stubs for mounting thermo wells and other instrumentation,
including for the instruments supplied by others, along with necessary root
valves, reducers/matching pieces and instrument tubing shall be provided.
Thermal insulation and cladding along with all necessary accessories for all
piping systems, tanks and vessels, etc. shall be provided by the Bidder.
The Bidder shall design and provide for additional guides/ stops/restraints etc.
along with auxiliary steel for control of pipe line vibration within allowable/
acceptable limits. Bidder shall provide all valves, actuators and specialties
including expansion joints, orifice plate assemblies, steam traps, strainers,
instrument root valves, etc.
The Bidder shall also supply special accessories like floor stands, chain operator,
extended spindle etc. as required. Valve, especially for which approach from
existing floors are not possible for operation and maintenance, Bidder shall
provide appropriate platforms with the access ladders for the same. All pipe
supporting elements such as constant load spring hangers, variable spring
hangers, supports, guides, restraints, stops, etc. and all associated auxiliary steel
and hardware such as beams, channels, insert plates section attachments to
pipe supports, pipe and beam clamps, straps, slings, stools, shoes, saddles,
devices, rods, turn buckles, graphite/steel plate/ Teflon sheet etc. shall be
Bidder shall provide all erection material such as bolts, nuts, washers, gaskets,
electrodes, filler materials, welding gas, consumable inserts and backing rings,
accessories and miscellaneous specialties required for the proper installation of
piping systems. All temporary piping, supports, valves, tanks, vessels, blanking
plates, target plates, spool pieces for valves, flow nozzles & specialties and other
accessories required to complete the chemical cleaning operation, Hydro testing
and steam blowing & arrangement, temporary connections, supports, blowup
valve, target plates and associated piping systems as required shall be provided.
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6.2
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Codes & Standards

The Design, manufacture, shop testing, erection, testing and commissioning of
piping and valves shall conform to the latest revisions of the following codes and
Indian Standards or equivalent international codes, in addition to other standards
mentioned in the tender documents subject to any modification and requirement
as specified hereinafter.
IS: 778
Gunmetal gate, globe and check valves for general purpose.
IS: 780
Sluice valves for water purpose (50 to 300 mm).
IS: 1239
Mild steel tubes and fittings - Part I & II, ERW pipe
diameter..
IS: 1536
Centrifugally cast (spun) iron pipes for water, gas and sewage.
IS: 8329
Centrifugally cast (Spun) Ductile Iron Pressure Pipe for water, gas
and sewage
IS: 1537
Vertically cast iron pressure pipe for water, gas and sewage.
IS: 1538
Cast iron fittings for pressure pipes for water, gas and sewage.
IS: 1703
Ball valves (horizontal) plunger type including floats for water

supply purposes.
IS: 2379
Colour for the identification of pipe line.
IS: 2685
Code of practice for erection, installation, and maintenance of

sluice valves.
IS: 2906
Sluice valve for water works purposes (350 to 1200 mm).
IS: 3042
Single faced sluice gates (200 to 1200 mm).
IS: 3589
Electrically welded steel pipes for Water gas & sewage (200 to
2000 mm).
IS: 4038
Foot valve for water works purposes.
IS: 4984
High Density polyethylene pipes.
IS: 4985
Unplasticized PVC Pipes.
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IS: 5312
Swing check type reflux (non-return) valve Part-I.
IS: 458
Concrete pipes (with and without reinforcement).
IS: 3952
Cast Iron butterfly valves for general purposes.
IS: 554
Pipe thread for pressure tight joints.
IS : 1363
Black hexagon bolts, nuts and lock nuts.
IS: 1364
Precision and semi-precision hexagon bolts, screws, nuts and lock

nuts.
IS: 2062
Structural steel fusion welding quality.
IS: 4736
Hot dip zinc coating on steel tubes.
IS: 2825
Code of unfired pressure vessels.
IS: 2712
Gaskets.
IS: 4192
Part-I Rubber lining.
IS: 9523
Specification for Ductile Iron fittings for pressure pipes for water,
gas and sewage
IS: 3006
Acid resistant SWG Pipe.
IS: 783
Code of practice for laying RCC pipes.
IS: 3114
Code of practice for CI Pipes.
IS:4984 - Class-5
High density polyethylene pipes
IS:4985 - Class-4
PVC Pipes.
ANSI:B 16.5
Steel pipe flanges and flanged fittings.
ANSI:B 31.1
Power Piping code.
ANSI B 16.34
Valves-Flanged, threaded and welding ends
ASME Sec VIII

Div 1
Boiler and pressure vessels code
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ASME B 16.21
Non metallic gaskets for flange
ASME B 16.20
Metallic gaskets for flange
ASME B 16.11
Screwed joints
ASME B 16.25
Welded joints
ASTM-A 106
Gr.C Seamless carbon steel pipe.
ASTM 53
Seamless carbon steel.
ASTM A 106, Gr.

C
Schedule 80 - Seamless carbon steel pipe
ASTM A 312
Grade TP-316
Schedule 40s - Stainless Steel pipes
ASTM D 3517 /
4024
GRP pipes
ASTM A 105
Standard specification for carbon steel forgings for piping

application.
ASTM A 182
Standard specification for forged or rolled alloy and stainless steel,

pipe flanges, forged fittings and valves and parts for high
ASTM A 216
Standard specification steel casting suitable for fusion welding for

high temperature service.
ASTM A 217
Standard specification for steel castings maretensitic stainless and

alloy for pressure containing parts suitable for high temperature
service.
ASTM A 234
Standard specification for pipe fittings of wrought carbon steel and

alloy steel for moderate and high temperature service.
ASTM A 312
Standard specification for seamless welded and heavily cold

worked austenitic stainless steel pipe.
ASTM A 335
Standard specification for seamless ferritic alloy steel pipe for high
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ASTM A 403
Standard specification for wrought austenitic stainless steel pipe

fittings.
ASTM A-193-194
Specification of alloy steel and stainless steel bolting material;/

nuts for high temperature services
AWWA-C-504
Standard for butterfly valve.
MSS SP-58
Pipe hangers and supports- Materials, designs and manufacture
MSS SP-69
Pipe hangers and support Selection and application
API-6D
Specification for pipe line valves
API-607
Fire teat for soft seated ball valves
API-598
Valve inspection test
API-594
Standard for dual check valve
BS: 5156
Standard for Diaphragm valve.
BS: 5142
Cl globe valve.
Pipe lines carrying water, chemicals, air etc. shall be sized generally on the
following velocities. However wherever minimum pipe sizes are defined in the
tender drawing /data sheets the selected size shall not be less than the specified
size.
Table-6.1
Service
Below 50 mm
50-150 mm
200 mm & above
1.2 - 1.5
1.2 - 1.5
1.2 - 1.8
1.8 - 2.4
2.1 - 2.5
1.5 - 2.4
2.1 - 2.4
Pump suction
Pump discharge and
recirculation
Header
Compressed air
Note All above velocities are in m/sec

Pipe line under gravity flow shall be restricted to a flow velocity of 1 m/sec generally.
Channels under gravity flow shall be sized for a maximum flow velocity of 0.6 m/sec.
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The following "C" Value shall be used in WILLIAM & HAZEN formula for calculating the
friction loss in piping systems.
Carbon Steel pipe
100
C.I Pipe / Ductile Iron
100
Rubber lined steel pipe
120
PVC / HDPE / GRP pipes
140
For calculating the pump head, at least 10% margin shall be taken over the pipe
friction losses.
Material of construction for pipes carrying various fluids shall be as below:Table: 6.2
S.No
Service
Recommended Material
1.
Clarified water/Filtered Water
Carbon Steel
2.
Acidic Water
FRP/CPVC/SS
3.
Demineralised Water
SS 316
Passivated Demineralised Water
Carbon Steel
5.
Acid (hydrochloric)
FRP/CPVC/SS
6.
Alkali (Sodium Hydroxide)
FRP/CPVC/SS
a)
Strong (5% & above)
Stainless Steel
b)
Dilute
FRP/CPVC/ SS
7.
Chlorinated Water
Rubber lined Carbon Steel
8.
Sludge
Cast Iron/ Ductile Iron
9.
Instrument Air
Galvanized Steel
10.
Waste effluent
HDPE/ MS Rubber lined
However the portion downstream of the isolation valves of pipe lines conveying
flushing water shall be of the material & type as that of the chemical pipelines
which is being flushed.
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6.3
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Design Basis
i)
ii)
iii)
iv)
v)
vi)
vii)
Design, fabrication, testing & erection of Power Cycle Piping, valves & specialties
for critical piping system under purview of IBR, shall satisfy IBR, and ANSI/ASME
B31.1 latest code. The design pressure of the feedwater line and feedwater
heater will be in line with the recommendations of Indian Boiler Regulation (IBR),
ASME Section-1 and ASME B31.1 as applicable.
Design, fabrication, testing & erection of Power Cycle Piping, valves & specialties
for non-critical piping system which are not purview of IBR, shall satisfy ANSI/
ASME B31.1 latest code.
Sizing, design and installation of safety valves shall conform to IBR and the nonmandatory rules for the design of safety valve installation of ANSI/ ASME B31.1.
Piping Flexibility analysis shall be carried-out for all piping having sizes equal to
or above 50 mm NB & design temperature 100 deg C and more, according to
ANSI/ASME B-31.1 latest & also satisfying IBR latest.
Design pressure and temperature shall be as per IBR. Wherever not clearly
stipulated in IBR, criteria stipulated in ASME/ ANSI B31.1 for selecting design
pressure & temperature shall be followed.
Material of construction of piping, valves & specialties shall conform to relevant
ASME / ASTM / BS / IS or equivalent codes/standards. In case materials not
approved by IBR are used, it is the Bidders responsibility to obtain IBR approval,
without affecting the Construction schedule.
Type of Hangers, supports etc. shall be selected as per the following criteria:
a.
Variable spring hangers
Where the variation in supporting effort between hot and cold condition
does not exceed 20% of the higher of the operating load and cold
setting load.
The resulting effect of load take-up/ release by a group of hangers in a

span does not overstress the piping span or cause overloading at
equipment terminals.
Thermal deflection between hot & cold conditions does not exceed 40
mm.
b.
Constant load hangers
When thermal deflection between hot and cold conditions exceeding
40mm, these are used.
c.
Spring hangers
These should not be loaded more than 80% of the spring travel range.
d.
Rigid hangers & restraints

To be judiciously selected, without exceeding the stipulated limits of
terminal forces & moments and stress level. Struts shall be considered
where compressive load is expected.
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viii)
ix)
x)
xi)
xii)
[Logo of Utility]
Design Requirement of Hangers & Supports:In order to minimize any horizontal force components of the dead weight or any
binding of the pin or rocker joints used on the hangers, the hanger rods should
be as long as possible. In critical piping systems, the length of the hanger
assembly capable of swinging shall not be less than 20 times the maximum
expected pipe movement in the horizontal plane at the hanger location.
Constant support type of hangers shall be adopted at all locations on critical
piping excepting where the smaller of vertical movements of pipe justifies the use
of variable spring hangers.
As far as practicable, connections of hangers to supporting structure shall be
achieved without welding to structural members. If welding is inevitable,
adequate factor of safety shall be considered in the design and specification of
the weld.
The attachment of support brackets to brick walls shall be avoided as far as
possible and where this is not possible, details of the attachment shall be
furnished to the Owner for his approval. Under unavoidable circumstances, when
medium or heavy brackets are bolted to walls, back plates of adequate size and
thickness shall be furnished to distribute the load against the wall. Where the
use of a back plate is not practical, the brackets shall, be fastened to the wall in
an approved manner.
Diameter of hanger rods for piping NB 50 mm and smaller shall not be less than
10 mm and for piping with size NB 65 mm and larger shall not be less than 13
mm.
All components for hangers such as turn buckles, clamps, etc. shall be of forged
steel.
Snubbers, dampers etc.
To take seismic / dynamic loads, thrust due to safety valve discharge. Effort shall
be made to limit its use by judicious placement of rigid hangers. Bottom support
spring hangers are to be avoided as far as possible.
Design, materials, fabrication, testing and erection of hangers, supports, anchors,
guides etc. shall be as per ANSI/ASME B31.1 latest code. Material of support
packing used for alloy steel piping shall be same or better than the parent pipe
material.
Hanger suspension rods, tie-rods/ struts should have proper arrangement &
adequate length, so that thermal movements in direction which are free are not
constrained and should not make an angle more than 4 degree with vertical due
to horizontal pipe movement.
Pipe Thickness calculations shall be made on the basis of procedure and formula
given in ANSI B31.1. Stress values of piping material for calculation shall be
selected from tables given in ANSI B31.1. Thickness, thus calculated shall be
checked as per the formula of IBR and the more stringent of the two shall then be
selected. If it is seen that sizes arrived at for main steam, hot reheat and boiler
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xiii)
xiv)
a.
b.
c.
d.
e.
f.
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feed pumps discharge pipes are not in the standard range of the manufacturers,
ID controlled piping, shall then be selected for these piping systems.
Pipe sizing and piping system design shall conform to the requirements of power
piping code ANSI B31.1. Statutory requirements as laid down in Indian Boiler
Regulations (latest edition) will also be taken care in pipe system designs. Pipe
wall thickness as calculated by ANSI Code formula will also be checked for IBR
requirements for piping systems falling under IBR purview.
Inside diameters of piping shall first be calculated for the flow requirement of
various systems. The velocity limits for calculating the inside diameters are listed
below used to determine line size if dictated by considerations of pressure drop,
NPSH, surges, water hammer, etc.
Steam
Main Steam hot and cold reheat pipes
75 m/sec.
Saturation steam
40 m/sec
Auxiliary steam
30 m/sec.
Feed Water :
Suction
2.0 m/sec.
Discharge
5.0m/sec.
HP bypass :
Upstream
75 m/sec.
Downstream
100 m/sec.
Upstream
75 m/sec.
Downstream
100 m/sec.
LP bypass
Extraction steam :
Superheated steam
60 m/sec.
Saturated steam
30 m/sec.
HFO & LDO suction
< 1 m/sec
HFO & LDO discharge
2 m/sec
3.4 m/sec.
Condensate :
Discharge
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Suction
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1.5 m/sec.
g.
Heater vents
25m/sec
h.
Heater drains
1.5m/sec
xv)
xvi)
6.4
Other piping - As per good engineering practice.

Drains shall be provided, at all low points and vents at all high points as per
actual layout regardless of whether the same have been shown in the flow
diagrams or not. Pipelines shall be sloped towards the drain points. For operating
temperatures of greater than 400 C, drip leg with drains, operated by a motor
operated valve shall be provided. At all other drain locations (operating
temperatures less than 400 C) traps shall be provided. All traps shall be
provided with strainers, isolating, bypass and free blow valves. Traps shall be
thermodynamic type.
Piping Design
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
Complete design, engineering, etc. for the power cycle piping systems and other
piping systems shall be the responsibility of the Bidder. Owner's responsibility/
function in this connection shall be limited to review and approval of Bidder's
design/ calculation, engineering, drawings, documents. Bidder's scope of
services for complete engineering of the piping systems shall include but not be
limited to the following:
Preparation of engineering piping diagram indicating flow schematic, flow
parameter, pipe sizes, line designations and tag nos. of various components etc.
Design parameter selection, pipe sizing calculation, pipe schedule, valve
schedule, insulation schedule, specialties schedule and hanger schedule for the
systems.
Preparation of preliminary as well as final composite piping layout drawings of
pipe size 65mm NB & above.
Design in detail all piping supports including restraints, guides, stops etc., after
deciding the final location of hangers and supports and based on final stress
analysis and hanger/ support load data.
Prepare separate sketches for each hanger/ support, restraint, anchor, etc.
These sketches shall include the location with reference to column co-ordinates,
identification number, bills of material, design loads, operating load, spring
stiffness, amount of spring pre-compression etc., the method of attachment to the
pipe and steel structure. Additionally the sketches shall show a key plan
referenced to plant north and centre line elevation of the pipe at the point of
attachment for cold and hot conditions.
Preparation of fabrication and erection isometric (with material take off) drawings
for shop fabricated piping which are of size 65 mm NB and above.
Sizes of Boiler feed pump suction piping shall be selected to meet the NPSH
requirements of the pumps under transient conditions prevailing on loss of steam
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supply to feed water tank. Similarly for all pumps, NPSH requirements shall be
satisfied in line sizing.
6.5
Stress Analysis
i)
ii)
iii)
iv)
v)
The Bidder shall carryout stress analysis of piping system using proven and
validated software and shall submit for Owners approval.
Following loading conditions shall be considered for stress analysis:
Internal pressure
Thermal loads due to (a) Piping thermal expansion and (b)

displacement due to thermal movements of piping anchors.
Piping weight consisting of weight of piping, valves, bends, fittings, insulation

etc. as well as weight of support components like clamps, shoes, suspension
rods, trapeze etc. & weight of contained fluid.
Test or cleaning fluid load
Equivalent static loads due to discharge of safety valve (SV), Electromatic

relief valve (ERV), simultaneous discharge of SV & ERV where applicable.
Dynamic load due to steam hammer (if applicable)
Seismic loads due to (i) Equivalent static load due to seismic inertia effect
and (ii) Equivalent static load due to seismic anchor displacement
Wind load where applicable
Anchor
Loading combination Design load for supports, restraints, anchors & supporting
structures shall be obtained by proper selection of one or combination of two or
more of the loads as above based on the possibility of independent or
simultaneous occurrence. Loads imposed due to hydrostatic tests shall also be
taken into consideration for the design of supports.
Bidder shall clearly indicate the basis of his judicious selection or loading
combination for support, restraints and anchor design. Component of thermal
expansion reaction range expected to appear at cold condition, as per equation 9
& 10 of ANSI/ASME B31.1 shall be considered in loading combinations. As
overload factor of 1.30 shall be considered over the computed loads except
occasional loads before combining them. Bidder shall justify with reasoning in
case any one of the specified loads is not considered in analysis.
Combination of Stresses the computed stress under different loading conditions
shall be combined as per equation 11, 12 & 13 of ANSI/ASME B31.1 & the stress
shall be within allowable limits.
Allowable stress values for piping materials other than ASME/ASTM materials,
values shall be derived as per the criteria defined in Appendix-P of ASME Boiler
& Pressure Vessel Code, Section-VIII, and Division 1 while computing pipe wall
thickness and flexibility analysis shall be conducted as per ANSI/ASME B31.1.
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vi)
vii)
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However, higher of pipe wall thicknesses derived between IBR regulation &
ANSI/ ASME B31.1 code shall be considered.
Factor to be considered in flexibility analysis.
Cyclic load operation of the Unit. Bidder shall consider value of stress range
reduction factor `f for cyclic conditions due to temperature reversals equal to
1.
Stress intensification factor at all transitions, fittings & all branches as per
ANSI/ASME B31.1.
Variation in supporting effort by variable spring due to pipe movements
Piping Flexibility analysis is to be conducted as per the piping layout in case any
modification of piping layout is felt essential to maintain stresses & terminal
reactions within allowable ranges, same are to be carried out by the Bidder after
discussion with Owner.
The following piping systems shall be analyzed:
Pipelines with a maximum operating temperature equal to or greater than

100C having size 50NB or above.
Regardless of their operating temperatures, all pipelines connected to

sensitive rotating equipment such as turbines, feed pumps etc. for which
limiting values of pipe reaction have been specified by the equipment
manufacturer
Any other pipeline which in the opinion of the Owner requires a formal
analysis.
A write up on the stress analysis including codes used and design conditions
considered.
A copy of the computer print out for input data for the various design
conditions considered for stress analysis along with the stress diagram
(piping isometric marked with node points marked.)
A copy of flexibility analysis software soft copy shall also be submitted for
Owners approval.
Analysis results in tabular form giving calculated and allowable reactions /

forces / moments on equipment nozzles/terminals for the various design
conditions considered for analysis.
Allowable and calculated code stresses at various node points in the piping
for the design conditions considered based on code requirements for
analysis.
Analysis results giving calculated forces and moments and movements at

various hanger / support / restraint / anchor points from the static analysis
corresponding to various thermal / operating conditions, sustained load case,
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hydro load case (other than water lines) and occasional loads, as applicable,
for each piping system analyzed.
6.6
Statutory Approvals
i)
ii)
iii)
iv)
6.7
It is the sole responsibility of the Bidder to identify and obtain all necessary
approvals from various Government agencies / statutory authorities including
IBR, CCoE, etc., as applicable for the design, manufacture and testing of pipes,
valves, fittings, specialties etc.
The Bidder shall also identify and obtain all necessary approvals from the IBR
authority in the state where the plant is being installed, for the erection / testing /
commissioning and any other requirement as required by IBR.
It is also the responsibility of the Bidder to get approval(s) from any other
statutory authority in other countries from where the supplies are made, as
applicable and acceptable to IBR for the design/manufacture/testing etc. for the
piping / fittings / valves / specialties etc.
In order to obtain the above approvals, all necessary documentation etc. required
shall be arranged and furnished by the Bidder to the statutory authorities.
Installation
i)
ii)
Cleaning including chemical cleaning of all systems as specified herein and

installation of temporary pipe work for the same. All hot bent, forged formed,
fabricated and straight pipes shall be chemically cleaned, pickled or wire brushed
and purged with air blast or shot/grit blast to remove all sand and scale from the
inner surface as applicable.
Making temporary closures/ stubs on piping system as required for hydrostatic
testing and performing hydrostatic test on all piping. All pipes shall be hydro
tested at shops for pressures as per standards and all erected piping shall be
tested 1.5 times the design pressure.
The Bidder shall carryout the following cleaning after hydro test.
iii)
iv)
a.
All piping shall be mass flushed, in addition to the specific cleaning

operations as described below, as required.
b.
Extraction steam, condensate, boiler feed suction and discharge, heater

drains and vents shall be alkaline flushed.
c.
Compressed air piping shall be blown by air.
d.
Turbine lubricating oil piping shall be pickled
Making interface piping connections at TP with equipment/piping etc. as

applicable.
Apart from carrying out chemical cleaning, the work shall include neutralization
disposal of water, clean up, reinstatement of the cleaned piping system,
dismantling and removal all temporary piping, equipment and materials from site.
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v)
vi)
vii)
6.8
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Painting of piping system shall be in accordance with the stipulations laid down in
Vol 2, Annexure II of this specification.
Weather hood for pipes crossing ceilings and walls.
Checks after Installation
In order to ensure that all supporting elements, anchor and restraints have been
installed and adjusted in accordance with design documentation, the Bidder shall
inspect and log the hanger readings for the hangers associated with the power
cycle piping system as follows:
a.
After hydrostatic test with the piping in the cold position, with all travel
stops removed, with the pipe completely insulated and in all respect ready
for start-up.
b.
Piping in hot position (rated parameter condition) after six (6) months of
operation.
c.
Piping in cold position during the first complete shutdown after at least six
(6) months of operation.
d.
After steam blowing, in case steam blowing is applicable for the line.
e.
At the time of each inspection, the Bidder will determine the necessity for
revision, adjustment or replacement of pipe supporting elements,
restraints and anchors. Any changes proposed shall be subject to the
concurrence of the Owner. The changes shall be incorporated by the
Bidder after Owner's concurrence.
i)
ii)
iii)
iv)
v)
All shop tests as required by the applicable codes, ANSI Standards, IBR and
other standards specified.
Obtaining approval from Chief Inspector of Boiler as per latest Indian Boiler
Regulations (IBR) is the responsibility of the Bidder. This shall include furnishing
all necessary certificates for design, manufacture and testing for pipe, valves,
fittings, specialties, certificate of manufacture and test for each erected piping in
the relevant formats to the Chief Inspector of Boilers, obtaining his approval and
furnishing the same to the Employer.
The Bidder shall also identify and satisfy all other statutory code requirements as
may be required for the piping systems covered in this specification.
Certified copies of test reports for all tests and examinations specified in the
specification and for the mandatory test and analysis required by ASME/ ASTM
material specification, for the materials used for piping, shall be furnished to
Employer.
Provide complete interface engineering with the suppliers of other equipment and
piping with which the piping systems in the Bidder's scope are connected.
Performing all tests and implementing all quality control procedures as specified
herein including provision of testing equipment, stress relieving equipment,
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radiography equipment and any other equipment necessary to meet the

requirements of the specification.
6.9
Low Pressure Piping, Valves and Fittings
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
Low Pressure (LP) piping shall, basically, cover piping systems for the following
services:
Circulating water system (Part).
DM water normal make-up system
Condenser normal/emergency make up system / condensate (storage and
transfer) system.
Deaerator fill system.
Equipment Cooling Water (ECW) system including its chemical dosing system
Service water system
Instrument Air System.
Service Air System
Lube oil System
Chemical feed lines
Auxiliary cooling water system
Drain &Vents for the piping\equipment etc.
Re-circulation pipes along with valves, break-down orifices etc., wherever
required.
Any other piping system required to make the Low Pressure (LP) piping systems
complete.
All the piping systems be designed to operate without replacement and with
normal maintenance for a plant service life of [20] years, and shall withstand the
operating parameter fluctuations and cycling which can be normally expected
during this period.
Piping Materials and Sizes
All piping system shall be capable of withstanding the maximum pressure and
temperature in the corresponding line. The pressure rating of individual piping
system component such as valves, flanges etc shall however be not less than
that specified. Nominal pipes sizes and pipe outside diameters shall generally be
as per ANSI B36.10. In case of deviation BIDDER shall bring it to the specific
attention of ENGINEER for prior approval stating reasons for the deviation.
The Steel pipes (Welded type) for the services of water/clarified water/Filtered
water shall conform to the following standards or codes.
i)
Pipes upto 150 NB
a)
IS:1239 Part-I
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b)
ASTM-A-53
(Welded)
Grade
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B Sch 80 upto 2 inch nominal size(Minimum)

Sch 40 above
(Minimum).
ii)
Pipes 200 NB and above
a)
IS:3589 Grade 410
b)
ASTM A53 Grade B Sch. 40 (Minimum)

(Welded)
inch
nominal
size
i)
Wall Thickness
The calculation of wall thickness required for pipelines subject to internal and/or
external pressure shall be based on the formulae and recommendations as given
in the applicable codes. Adequate allowances shall be made towards thinning
due to bending, weakening at branch connections, threading, commercial
tolerances on pipe wall thickness, corrosion and erosion, etc. and the same shall
be subject to approval by Owner. In any case a minimum corrosion allowance of
1.0 mm shall be considered while selecting the thickness.
In case of carbon steel materials, the nominal wall thickness of pipeline shall be
not less than the minimum acceptable values given below:
-------------------------------------------------------------------------------------------------------------------NB mm 15
20 25
32
40
50
65
80 100 125
(inch) (1/2) (3/4) (1) (1 1/4) (1.5)
(2)
(2.5)
(3) (4)
(5)
-------------------------------------------------------------------------------------------------------------------Min.
3.2
3.2 3.6 3.6
3.6
3.6
3.6
4.0
4.5
5.4
thickness,
mm
--------------------------------------------------------------------------------------------------------------------NB mm 150 200
250
300
350
400
450
500
600
(inch)
(6)
(8)
(10)
(12)
(14)
(16)
(18) (20) (24)
--------------------------------------------------------------------------------------------------------------------Min.
5.4 6.35
6.35
6.35
7.1
7.1
7.1
8.0
8.0
thickness,
mm
--------------------------------------------------------------------------------------------------------------------NB 700 mm to NB 800 mm - 10.00 mm
NB 900 mm to NB 1500 mm - 12.00 mm
NB 1600 mm to NB 2000 mm - 14.00 mm
NB 2100 mm to NB 2500 mm - 16.00 mm
NB 2600 mm to NB 3200 mm - 18.00 mm
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6.10
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Thermal Insulation
i)
ii)
iii)
iv)
v)
The thermal insulation for the turbine casing shall consist of sprayed insulation
produced by projecting specially prepared mineral wool along with a fine liquid
spray. This should be covered with prefabricated 'blanket' type insulation. These
blankets shall consist of high temperature felted mineral insulation fully enclosed
in wire inserted asbestos cloth for temperature exposure to 445 deg C to 595 deg
C. A single layer of blanket shall not be more than 75 mm thick. Voids around the
blankets should be avoided. However, unavoidable voids shall be filled with loose
mineral wool.
Nuts and other exposed portions of the casing and valve flanges shall be suitably
insulated for minimum heat loss.
The density of the mineral fiber felt shall be carefully controlled at about 200
kg/m3 and the thermal conductivity of mineral wool shall be 0.052kCal/mh deg C
at mean temperature.
Suitable stainless steel lugs shall be tack welded on turbine casing to support the
insulation. In places where welding is not permitted, suitable alternative
arrangement shall be provided by the Bidder. The design of the support shall be
so as to involve minimum number of lugs.
The mineral wool shall be capable of passing standard combustibility test, both
immediately after application and also after being subjected to its maximum
operating temperature for not less than 100 hours. The mineral wool shall be free
from objectionable odour at the ambient conditions in which it is used. The
mineral wool shall not contain substances which shall support pests or
encourage growth of fungi. The mineral wool shall not suffer permanent
deterioration as a result of contact with moisture due to condensation. The
mineral wool shall not suffer quality deterioration under the specified conditions
of use. In this connection, both hot and cold face temperatures are relevant. The
mineral wool shall be capable of being applied to the surface concerned without
causing corrosion of the surface being insulated or the cladding on it under
normal site conditions.
The thermal insulation designed, furnished and installed by the Bidder shall be
such that the following items of performance shall be guaranteed, and the
specific design and application features adopted shall be so as not to exceed the
stipulated limits in temperature differentials. The Owner shall have the option to
have any random check of specimen as per his choice, to establish conformity to
following guaranteed particulars:
a. The temperature difference between the cold face of finished insulation and
ambient shall not be more than 15 deg C. The ambient temperature shall
be considered as 50 deg C.
b.
The difference in temperature between upper and lower metallic parts of

H.P. and I.P. casings in the zone of governing stage/ steam admission shall
not be more the 40 deg C during cooling of the casing.
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The difference in metallic temperatures of upper and lower halves of both H.P.
and I.P. casings, during normal operating conditions shall not be more than 15
C.
6.11
Fittings
Fittings to be used with carbon steel pipes shall conform to IS: 1239 Part-II
(Heavy grade) or ASTM A 234 Gr. WPB. for sizes up to 150 NB.
For sizes 200 NB & above steel fittings shall conform to ASTM A 234 Gr. WPB.
However for sizes above 300 NB fabricated fittings (mitre bends etc) may be
used.
Wherever regular pipe bends are employed for change of direction the same
shall be to a radius of 5 times the pipe diameter. Mitre bends shall be 1.5D
radius.
Inside surface of all the fittings used for the rubber lined application shall be de
beaded and made suitable for rubber lining.
Galvanized pipe application all the fittings shall be galvanized as per IS: 4736.
Fittings to be used in other type of piping shall conform to relevant IS/BS ANSI
Standards and in conformity with the parent pipe standard.
Branch connections in piping shall be made by the use of wrought or forged
seamless fittings such as tees, laterals and crosses. Small stubs as may be
required for instrument, drain and vent connection may be provided in the form of
weld outlet fittings or forged couplings. Intersection welds are acceptable only in
the event of non-availability of fittings.
6.12
Design and Construction

i)
Pipes, valves and Fittings

Following items shall be included for piping:
Pipes, bends, elbows, tees, branches laterals, crosses, reducing unions,

couplings, cap, expansion joints, flanges, blank flanges, saddles, shoes,
sampling connections etc. necessary for making a reliable piping system.
Valve, gates, dampers, etc.
Strainers and filters.
Instrument tapping connection, stubs and thermo-wells, root valves.
Matching flanges, pipe spools and matching pipes to connect to equipment,

instruments, etc. as necessary.
Gaskets, ring joint, bracing rings, jointing material etc. as required.
Bolts, nuts, fasteners as required for interconnecting piping, valves and fitting
as well as for terminal points.
Pipe supports like pedestals, Anchor blocks (for buried / over ground piping),
brackets, hangers, clamps, trestles, etc.
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ii)
6.13
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Secondary steel for pipe supports and embedded steel. Also pipe supports
and necessary embedment required to be embedded in concrete for
underground/above ground pipes.
Painting, anti-corrosive coatings, wrapping and coating, thermal insulation,

etc. inside and outside of pipes as necessary.
End connections
Unless otherwise specified, following types of end connections shall be used:
Pipes 50 NB and smaller shall have socket welded joints for chlorine line. For
water, air and other services where steel pipes are used, joints of this size range
shall be Socket welded/screwed/flanged type (For rubber lined pipes).
All unlined steel pipes 65 NB and above (other than CI pipes and air service
pipes) shall be connected by butt welding. All rubber lined pipes shall have
flanged joints.
Butt welding edge preparation shall be done as per ANSI B 16.25.The Bidder
shall furnish details/specifications for all welding electrodes and welding rods
including special ones, if any for approval.
Steel pipe flanges shall be generally slipped on flat face type. Weld neck flanges
shall be used when flange follows immediately after a butt welding or where it is
required with respect to service conditions. Slip-on type of flanges may be only
up to a maximum pressure rating of ANSI 300 lbs. In case of higher pressure
ratings, weld-neck type of flanges shall be employed. When weld neck or socket
weld flanges are used, their bore must be made the same as that of the pipe
being welded to. Socket welded or threaded flanges may be used, with the
appropriate piping system for connection of pipe to the flanged equipment.
All the piping flanges and counter flanges shall conform to ANSI B 16.5 Cl. 150
(minimum). However wherever the interferences is involved with the Owners
pipe, the flange/interconnection details shall be designed to match the piping and
the details of which will be intimated later.
For easy handling & removal of equipments, valves etc. and for maintenance
purpose, break up flanges for 65 NB and above sizes and suitable type of
compression flexible coupling for flanged joints of 50 NB and below size shall be
provided. The over ground piping wherever routed inside building, shall have a
clear head room of minimum 2.2 m from floor in passages/walkways.
Piping Layout
i)
ii)
Pipes shall be generally routed above ground but where specifically

indicated/specified the pipe may be laid in trenches or buried. Buried piping shall
be generally installed so that the top of pipe is 1.5 meter below the ground level
unless otherwise specifically mentioned. Full length of buried piping shall be
provided with 100 mm thick sand bed.
Complete supporting system for the pipe line shall be designed, fabricated and
supplied by the Bidder. Inside the building, the overhead portion of the pipe line
may be supported from the building structures. No support shall be taken from
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iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
[Logo of Utility]
the brick wall. Outdoor, pipes other than buried pipes shall run on steel trestles.
Crossing of the road shall be on a pipe bridge with a clear height of at least 8.0
meters (minimum) over the road surface. All the steel structure for the pipe
bridge and the supporting posts/trestles along with all necessary hangers
clamps, connecting steel, fixing bolts, nuts etc. shall be supplied and erected by
the Bidder. All pipe racks shall be provided with 750 mm (Minimum) clear width
walkways.
Hangers and supports shall be capable of carrying the sum of all concurrently
acting loads. They shall be designed to provide the required supporting effects
and allow pipe line movements as necessary. All guides, anchors, braces,
dampener, expansion joint and structural steel to be attached to the
building/structure, trenches etc. shall be provided.
Mitre bends will not be accepted for steel pipes of 250 NB and below. For sizes
300 and above, the mitre bends shall conform to BS: 534.
For rubber lined pipe of acid service, lining should be applied in two (2) layers,
giving a total thickness not less than 3 mm.
Pipe coming under purview of IBR should meet its requirements and getting the
IBR approval shall be under Bidders scope.
Thickness calculation of CW duct/large diameter buried pipes as per AWWA-M11
Anti corrosive protection shall be provided for all buried piping including
galvanized steel piping. In case of buried pipes of size 1000 mm NB and above,
the Bidder shall stiffen them and/or increase the thickness of pipe adequately
against ovality formation in use.
Flexibility analysis for piping systems wherever required. Whenever, straight run
of the above ground yard pipes are more than 50 meters, flexibility analysis shall
be conducted by the Bidder to identify the requirement of loops, type of supports
etc.
The Bidder shall prepare the flow diagrams, detailed dimensional piping layout/
Isometric/ fabrication/ as built drawings of all the systems along with Cross
sectional drawings, showing all supports and equipment as required.
All pipelines with size greater than NB 50 mm are considered as shop fabricated
piping and detailed piping layout drawings shall be prepared for all such
pipelines. The drawings shall be to scale and shall be prepared as plan &
sections and shall carry the following minimum details:
a) Fully dimensioned layout with locating dimensions referred to plant axes
and coordinates
b) Details of all stub connections and other welded attachments as required
for anchors, restraints, hangers supports, etc.
c) Slope, drains and vents
d) Edge preparation details of weld ends
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e) Mounting and orientation of valves and specialties and maintenance

space requirements
f)
Location and tag numbers of hangers, supports, restraints, anchors, etc.
g) Location and magnitude of cold cuts, if any

h) Pipe sizes, materials,
requirements
i)
Insulation details
j)
Tolerances, if any
design
parameters,
shop
and
field
test
k) Any specific requirements on shop fabrication and/or field erection

l)
xii)
xiii)
6.14
Any other detail considered necessary by the Owner.
The piping shall be arranged to provide clearance for the removal of equipment
requiring maintenance and for easy access to valves and other piping
accessories required for operation and maintenance. Layout drawings shall
indicate valve orientations and availability of access to valves and specialties.
Layout of all piping shall ensure that all valves including motor operated valves
are located as to be accessible conveniently for operation. Valves for operation
and maintenance shall have 1.0 m clear approach space. If any of the valves are
not accessible, suitable access platform shall be provided by the Bidder.
Provision shall be made while preparing piping layout to accept control valves,
flow measurement element and any other on-line specialty or equipment.
Sufficient upstream and downstream lengths shall be provided for flow
measuring devices, control valves, desuperheaters and other specialties as
required by the respective equipment manufacturer.
Valves
i)
ii)
iii)
iv)
v)
All valves shall be suitable for service conditions i.e. flow, temperature and
pressure under which they are required. The valves shall be of standard pressure
rating as per the relevant code/ standard.
Either Butterfly type or sluice/gate valves shall be used for isolation purposes in
raw water, Clarified & Filtered water application. Butterfly valves shall be of
double flanged or lugged wafer type of low leakage rate conforming to AWWA-C504 class 150 or EN-593 Class 150.
Manually operated valves shall be provided with reduction gear unit for valves of
size 200 NB and above. Valve provided with motorized or pneumatic actuator
shall be provided with a hand wheel for manual operation.
All the valves shall be equipped with adjustable mechanical stop-limiting devices
to prevent over travel of the valve disc in the open and closed positions. The
valve operators (Hand wheel or Gear reduction unit or Motor actuator etc.) shall
be designed as per relevant International Standard.
Ball valves or Globe Valves may also be provided for the application of Raw/
Clarified / Filtered water services for sizes 50 NB and below.
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vi)
Butterfly valves or proven patented diaphragm valves shall be used for the
services of demineralised water application for isolation purposes.
vii)
Sluice valve/knife edge type slide valves shall be used in the sludge and drain
pipe line.
viii) For Air services, globe valves or Ball valves may be used for sizes 50 NB and
below. For sizes higher than 50 NB, either Butterfly valve or Ball valves shall be
used.
ix)
Check valves for Raw / Clarified / Filtered water may be offered in Gun metal
construction and with threaded ends for sizes 50 NB and below conforming to
IS:778 or Equivalent.
x)
For Chlorine gas and Chlorinated water application check valve of Lift Ball type
may be used in PVC construction (in case of PVC pipes). In case of rubber-lined
pipes, the check valves of swing check type shall be lined construction.
xi)
The safety valves / relief valves at the down stream of positive displacement type
metering pumps shall be of the standard type manufactured by the pump
manufacturer and the material of construction shall suit to the fluid handled.
xii)
Safety valve
xiii) The butterfly valves for DM water application shall conform to the following
requirements:
xiv) Body shall be lined (minimum 3 mm) with natural rubber, ebonite, polypropylene
or PVDF.
xv)
Disc shall be lined with PVDF, polypropylene, or natural rubber.
xvi) Seat rings shall be of Nitrile rubber or Hypalon
xvii) Valves for Acid & Alkali Services shall be proven patented diaphragm type.
Diaphragm shall be of reinforced teflon, EPDM/Black Butile/appd. eqv. For acid
services and reinforced Neoprene/Hypalon/app eqv for alkali services.
xviii) For air application, Body material of Ball valves shall be leaded Tin Bronze (IS:
318 Gr.2) or stainless steel (AISI: 304/316). Body & Disc of Butterfly valves shall
be either cast iron lined with elastomer such as PVDF or PTFE or stainless steel
construction (AISI 304/316).
xix) For the application of alum, lime, coagulant aid solution, DM water and air, the
body, cover & Disc of Non return valves shall be lined with natural Rubber, PTFE
or Viton.
6.14.1
Design and Construction Features
The following design and construction features of valves shall be complied with.
i)
All gate and globe valves shall be of rising stem, outside screw and yoke type.
The design of valves shall ensure a streamlined passage and gate valves shall
have low pressure drop. The seats and discs shall be easily renewable and/or
shall be suitable for easy refacing and grinding. Valve discs shall be of such
design as to keep the seats tight when the valve body is subjected to pressure,
temperature variations and piping stresses. Gate valves shall close in both flow
directions.
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ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
[Logo of Utility]
All globe valves shall be capable of being closed against pressure.

In the case of all end-welded valves, the stub ends of the valves shall project
from the valve body a sufficient amount to ensure that the welding process will
not distort the valve body and internal parts.
Valves for regulating duties shall be of the globe type with tapered plug type disc.
Hardness of seating surfaces shall be a minimum of 350 BHN and a minimum
differential hardness of 50 BHN shall be provided between seats to prevent
galling. This is not applicable for stellited seats.
Check valves of sizes 400 mm NB and larger shall have dash pot arrangement.
All gate and globe valves shall have back-seating arrangement to facilitate easy
replacement of packing with the valve in service.
All valves shall be so designed that the hand-wheel moves in a clockwise
direction to close the valve. The face of the hand-wheel shall be clearly marked
with the words 'OPEN' and 'CLOSE' and an arrow to indicate the direction for
opening. All hand-wheels shall be fitted with name plate. All globe valves shall be
provided with position indicator.
Piston lift check valves shall have accurately guided pistons so that the pistons
are cushioned in their cylinders as they move up.
All gate, globe, Y-type and angle valves intended for manual operation and
falling under the following categories shall be equipped with a gear operator
for ease of operation and to ensure fast and tight closure:
ANSI Pressure Rating Valve Sizes for which Gear Operator is required
--------------------------------------------------------------------------------------------------Class 300 and below
350 mm and larger
Class 600 and above
200 mm and larger
--------------------------------------------------------------------------------------------------All gate valves falling in the following categories shall be provided with integral
bypass valve. Bypass size shall conform to MSS-SP-45 as a minimum standard.
The bypass valve shall be hand operated unless specified otherwise. Pipe for
bypass shall be of at least schedule 80 seamless and of a material of the same
nominal chemical composition and physical properties as that used for the main
line. Orientation of bypass arrangement shall be subject to the approval of
Owner.
ANSI Pressure Rating Valve Sizes for which Bypass is required
----------------------------------------------------------------------------------------Class 600 and over
200 mm and larger
Class 300 & 150
350 mm and larger
------------------------------------------------------------------------------------------All gate valves of ANSI pressure rating class 150 and 300 shall have solid or
flexible wedge and ANSI pressure rating class 600 and above shall have
flexible or parallel slide type of wedge.
Document Number
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Rev
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xiii)
Valves with flexible wedge shall have provision for relieving the pressure in the
neck of the valve when the valve is in the closed position.
xiv) All valves of ANSI pressure rating up to class 600 shall have bolted bonnet
construction and class 900 and above shall have bonnet construction of the
pressure seal type. Pressure seal valves shall have stainless steel inlay in the
gasket area and silver-plated gaskets or other acceptable proven features.
All carbon steel valves of ANSI pressure rating up to class 150 and 300 shall
have stainless steel trim (13% Cr) and ANSI pressure rating class 600 and above
shall have stellited trim.
xv)
All alloy steel valves shall have stellited seats.
xvi) All valves of ANSI pressure rating up to class 900 and higher shall have yoke
with anti-friction bearing arrangement.
xvii) Valves that are to be kept in full 'OPEN'/'CLOSE' position shall be provided with a
non-detachable locking arrangement. The locking arrangement provided shall be
subject to approval by the Owner.
xviii) All gate, and globe valves of size 50 mm and below in vacuum service shall have
extra deep gland packing without requiring water gland sealing. All gate and
globe valves of size 65 mm NB and above in vacuum services shall have
adequately deep gland packing and shall be equipped with lantern rings to admit
pressurized water for gland sealing. The inlet and outlet connections shall be NB
15mm. The BIDDER shall indicate the maximum and minimum sealing water
pressure and the required flow rate.
xix) Motor actuators for motor operated valves shall meet requirements mentioned in
the specification.
6.15
Cleaning
Prior to factory inspection, all manufacturing waste, such as metal chips and
filings, welding rods and stubs, rags, debris and all other foreign matter shall
be removed from the interior of each valve. All mill scale, rust, oil, grease, chalk,
crayon, paint marks and other deleterious material shall be removed from the
interior and exterior surfaces. At the time of shipment, valves shall be clean
inside and outside.
6.16
Inspection and Tests

Inspection and tests shall be as per the Data Sheet given below.
Defects in excess of acceptance standards shall be removed by suitable means.
If removal of surface defects does not result in reduction in wall thickness below
5% of intended thickness of metal at that location, the area shall be blended
smoothly into the surrounding surface. Where defect removal results in a wall
thickness less than the above resultant cavity may be repaired by welding. The
procedure and operator shall be qualified as per applicable standards. Major
weld repairs shall be stress relieved or heat treated in accordance with ASME
Section VIII Division I-UCS 56.
Document Number
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Rev
No.
Description
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The required area shall be re-examined and the acceptance standards shall be
as in the original examination.
Weld repairs made as a result of radiographic examination shall be radiographed
after welding. Repairing a particular area more than 2 times is not permitted and
the component shall be rejected. The acceptance standards for welds shall be as
per ASME Boiler and Pressure Vessel Code, Section VIII, Division I, UW - 51.
Prior approval shall be obtained from the Owner before taking up major weld
repairs (major weld repair - when depth of repair exceeds 20% of thickness or 1
inch whichever is smaller). Mapping of major weld repairs is also required.
All valves shall be tested hydrostatically for strength, tightness of seats and
tightness of back seating at the pressures, in accordance with MSS-SP 61,
"Hydrostatic Testing of Steel Valves". Water used for hydrostatic testing of valves
with stainless steel components shall not have chloride content exceeding 20
ppm. Clean potable water may be used for testing of all other valves.
All valves except check valves shall be tested for seat tightness by air at a
pressure of 6 bar (g) on both sides of seat.
All check valves shall also be hydro tested at 125% of the seat hydro test
pressure.
All valves shall be checked for correctness in respect of specified end details as
per applicable standards.
6.17

Two coats of primer of thickness 35 microns for each coat shall be applied to
all steel and cast iron exposed surfaces as required to prevent corrosion, after
release has been given for painting and before dispatch. The use of grease or oil,
other than light grade mineral oil, for corrosion protection is prohibited. Bores of
all valves shall be covered immediately after testing, draining and drying with
suitable plastic end covers to avoid ingress of foreign materials.
All pipe lines, piping components shall be adequately protected against corrosion
during manufacture, fabrication, shipment and storage by appropriate protective
paint. For details, refer Section on Painting.
6.18
Specific Requirement For Valves
SERVICE
SIZE
Steam lines
(temp > 400
C) except
for
main
steam and
hot-reheat
> 65NB
< 50 NB
Document Number
LII-GETS12021-G-00129-002
BODY/
BONNET
ASTM
A217
WC6/WC-9
ASTM
A182
Gr.F-
DISC
STEM
HAND
WHEEL
VALVE
ENDS
ASTM
A217
WC6/WC-9
ASTM
A182 Gr.
F6a
ASTM A47
Gr. 32510
Butt
welded.
ASTM
A182
ASTM
A182
ASTM A97
Socket
Weld
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SERVICE
SIZE
BODY/
BONNET
11/Gr.F22
[Logo of Utility]
HAND
WHEEL
Gr.32510
VALVE
ENDS
ASTM
A182 Gr
F6a
ASTM A47
Gr 32510
Butt
welded
DISC
STEM
Gr.F11/Gr.F22
ASTM
A216 Gr
WCB
Gr.F6a
Steam lines
(temp < 400
C),
feed
water,
Condensate
blow down,
steam
tracing
>65NB
ASTM
A216 Gr
WCB
< 50 NB
ASTMA1
05
ASTM
A182
Gr F6a
ASTM
A182
Gr F6a
ASTM A47
Gr 32510
Socket
welded
Boiler feed
system
65NB
ASTM
A216 Gr.
WCB/W
CC
ASTM A
216 Gr.
WCB/WC
C
ASTM A
182 Gr.
F6a
ASTM 417
Gr. 32510
BW
<50NB
A105
ASTM A ASTM A ASTM 417

182
182
Gr. 32510
Gr.F6a
Gr.F6a
AWWA C-504; flanged or long body wafer type;
Body A 216 WCB;SHAFT A 182 304; seal & O
ring: EPT/ BUNA N / Neoprene
SW
>65NB
ASTM
A216 Gr
WCB
ASTM
A216 Gr
WCB
ASTM
A182 Gr
F6a
ASTM A47
Gr 32510
Flanged
< 50 NB
ASTMB6
2 / IS318
Gr.2
ASTM
B62 /
IS:318
Gr.2
ASTM A47
Gr 32510
Screw
type
>65NB
ASTM
A216 Gr
WCB
ASTM
A216 Gr
WCB
ASTM
B312
Gr A /
IS320
HT2
ASTM
A182 Gr
F6a
ASTM A47
Gr 32510
Butt
welded
< 50 NB
ASTM
A105
ASTM
A182
Gr F6a
ASTM
A182
Gr F6a
ASTM A47
Gr 32510
Socket
welded
BFV
Cooling
water
system
Instrument
air system,
potable water
system
(ball valves)
Service
air
system, (ball
valves)
FL
Note:
Document Number
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Rev
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Description
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No.
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i. Testing of body, seat and back seat shall be as per ANSI B16.34
ii. For water system with sizes greater than NB200 butterfly valves shall
be used and shall conform to AWWA C-504.
iii. All valves of size 400 NB and above shall be provided with electrical
actuators.
6.19
Gates
Design standard for gates shall be IS: 3042 or equivalent. The gates shall be
rectangular or square sluice, rising spindle type conforming to class-1 of IS:
3042. The Material of Construction shall be as follows:
i)
Frame and Door
: Cast Iron IS:210 Gr. 260
ii)
Spindles, bolts & nuts
: ASTM A 182 Gr. F6A
iii) Face & seat rings
: Gun metal (as per IS:3042).
All the parts of gates shall be applied with the coats of heavy duty bitumastic
paint.
Each of the gates shall be provided with hand wheel, and a position indicator.
The gates for DM plant drains shall be rubber lined to a minimum thickness of 4.5
mm.
6.20
Strainers
i)
Basket Type Strainers

Basket strainers of simplex design shall have the following materials of
construction for raw/clarified/filtered water application.
a)
Body
: Fabricated mild steel : IS:2062 (Tested quality)
b)
Strainers
: Wire shall be stainless steel (AISI: 316, 30 mesh

suitably reinforced. Reinforcement material shall
also be of stainless steel construction)
c)
Drain Plug/Nuts
: Gun metal
Screen (strainer) flow area shall be at least four times pipe sectional area. Flow
area in any portion of Basket strainer assembly shall not be less than the pipe
cross sectional area. Pressure drop in clean condition shall not be more than 1.0
MWC.
Basket Strainer shall be provided with lifting lugs and suitable mounting
arrangement. Suitable Vent and drain valves shall be provided for the strainers.
Document Number
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ii)
[Logo of Utility]
For DM water service, body shall be rubber lined to minimum 4.5 mm thickness
(soft rubber of shore Hardness 65 5A).
Y-Type Strainers
Y-Type strainer for water application shall be constructed of following materials
a)
Body
: Cast Iron IS: 210 Gr. FG 260
b)
Strainers
: Wires of stainless steel AISI-316, 30 mesh suitably

reinforced. Reinforcement material shall also be of
stainless steel construction.
c)
Drain Plugs
: Gun metal (threaded construction)
Body of the Y-type strainers of alkali, and demineralised water shall be of Cast
Iron (IS: 210, Gr.FG 260) and lined with soft or hard rubber to a thickness of 4.5
mm.
For acid services, apart from the rubber lined body material, the screen material
shall be Polypropylene or HDPE wire cloth of suitable mesh and thickness.
6.21
Steam Traps
i)
ii)
iii)
iv)
The steam traps shall be inverted bucket or thermodynamic type complete with
integral or separate strainers.
The internal components of traps shall be of AISI-316 stainless steel
construction. Material of construction of the body shall be selected by the Bidder
based on the service conditions stipulated.
All Y-type strainers, wherever provided with steam traps or otherwise, shall have
AISI-316 stainless steel screen of not more than 20 mesh size. Screen open area
shall be at least three (4) times the pipe internal cross-sectional area. The
strainer shall have a screwed blow-off connection with a removable plug. Material
of construction of the body shall be selected by the Bidder based on the duty
conditions specified.
All traps and strainers shall have socket weld ends as per ANSI B16.11 for size
NB 50 mm and smaller and butt weld ends as per B 16.25 for size NB 65 mm
and above.
Steam drain traps shall be provided with strainers, inlet and discharge valves and
by-passes and test cocks as schematically indicated in the enclosed drawing.
Materials and other details of these valves shall meet the specified requirement.
General:
Note: The specification furnished above shall be considered as broad
requirement. The Bidder shall consider compatible material and specification for
all piping components as well as specialties for the corresponding service
applications.
Document Number
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Rev
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6.22
[Logo of Utility]
Instrument Connections
Unless otherwise called for by Owner all thermo well stubs shall have an internal
threading to M33 x 2.
All stubs for pressure or flow measurement for pipelines with a maximum working
pressure equal to or above 42 bar(g) or with a maximum working temperature
equal to or above 350C shall be NPS 25 mm and double root valves shall be
used.
Stubs, which are used for pressure or flow measurement on pipelines, with a
maximum working pressure less than 42 bar (g) and a maximum working
temperature less than 350C shall be of NPS 15 mm size and single root valves
can be used.
Measurement stubs on fuel oil lines shall be of NPS 25 mm size and provided
with two root valves.
6.23
Drain and Vent Connections

Drain and vent connections on pipelines shall be at least of NPS 25 mm size. All
systems having pressure greater than 6.2 MPA shall have double isolating valves
on drain, vent lines and instrument connections. For pressure conditions other
than as mentioned above single isolating valves are considered adequate.
Where with single root valve, instrument and root valve are not accessible,
double root valve shall be provided with one root valve near the tap off and the
second root valve with instrument at accessible point. For fuel oil drain and vent
lines double isolation valves shall be provided irrespective of the pressure and
temperature.
6.24
Welding and Heat Treatment

All heat treatment, welding, post and pre weld temperatures shall be as per the
code ASME B31.1.
6.25
Underground Protection
i)
ii)
iii)
iv)
v)
vi)
Where pipelines are buried, underground protection shall be provided for the
piping system as indicated any one of the methods given below:
Coal tar primer, coal tar enamel, inner wrap of fiber glass, final outer wrap of
enamel impregnated fiber glass. Total thickness of coating shall not be less than
4.0 mm.
With anti-corrosive tape of 4 mm thick conforming to IS-10221 and AWWA C
203-93.
Pipe surfaces shall be cleaned by shot or sand blasting before application. Slag
blasting may also be considered.
Tests to be carried out after application
Bond/Adhesion test
Holiday test
Document Number
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Description
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6.26
[Logo of Utility]
Non-Destructive Examination
i)
ii)
iii)
iv)
v)
6.27
Mandatory as per ASME B31.1 & Regulation 360(d) of IBR.

Special requirements:
100% UT/RT & MPI and 3% hardness testing on butt welds of P12, and P11
materials.
100% UT/RT & MPI and 100% hardness testing on butt welds of P91, P92 and
X20 materials .
100% MPI on butt welds of carbon steel materials.
100% UT/RT for fittings of 200NB & above for X20 & P91, P92 material.
100% UT/RT for fittings of all other piping of size OD 508mm & above.
Hydrostatic Test Pressure
i)
ii)
Piping system under IBR purview:

a)
At Shop: All piping including fabricated piping shall be hydro tested at 1.5
times the design pressure subject to regulation 374 of IBR. However,
non-destructive testing in lieu of hydro test is also acceptable subject to
regulation 343 (3) of IBR
b)
After Erection all piping systems shall be hydro tested at 1.5 times the
design pressure subject to regulation of 374 IBR. However, for such
systems where it is practically not possible to do hydro tests, the tests as
called for in ANSI B31.1& IBR in lieu of hydro test shall also be
acceptable.
Non-IBR Piping Systems:a)
At Shop All piping including fabricated piping shall be hydro tested at 1.5
times the design pressure.
b)
After Erection All piping systems shall be hydro tested at 1.5 times the
design pressure. However, for such systems where it is practically not
possible to do hydro tests, the tests as called for in ANSI B31.1 in lieu of
hydro test shall also be acceptable.
Document Number
LII-GETS12021-G-00129-002
Rev
No.
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No.
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QUALITY ASSURANCE
7.1
Quality Assurance, Inspection & Testing
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
7.2
[Logo of Utility]
The Bidder shall adopt Quality Assurance Programmes as per relevant standards
subject to Owners approval, to ensure that the equipment and services under
the scope of contract, whether manufactured or performed within the Bidders
works or at his sub-vendors premises or at the Owners site or at any other place
of work, are in accordance with the specifications. Such programmes shall be
outlined by the Bidder and shall be finally accepted by the Owner/Owners
authorized representative after discussions before the award of the contract. The
QA programme shall be generally in line with IS/ISO-9001. The Quality
Assurance Programme of the Bidder shall generally cover the following:
Organization structure for the management and implementation of the proposed
Quality Assurance Programme.
Quality System Manual.
Design Control System.
Documentation and Data Control System.
Qualification data for Bidders key personnel.
The procedure for purchase of materials, parts, components and selection of
sub-contractors services including vendor analysis, source inspection, incoming
raw-material inspection, verification of materials purchased etc.
System for shop manufacturing and site erection controls including process,
fabrication and assembly.
Control of non-conforming items and system for corrective actions and resolution
of deviations.
Inspection and test procedure both for manufacture and field activities.
Control of calibration and testing of measuring testing equipment.
System for Quality Audits.
System for identification and appraisal of inspection status.
System for authorizing release of manufactured product to the Owner.
System for handling, storage and delivery.
System for maintenance of records, and
Quality plans for manufacturing and field activities detailing out the specific
quality control procedure adopted for controlling the quality characteristics
relevant to each item of equipment/component.
General Requirements - Quality Assurance
i)
All materials, components and equipment covered under this specification shall
be procured, manufactured, erected, commissioned and tested at all the stages,
as per a comprehensive Quality Assurance Programme. This is, however, not
intended to form a comprehensive programme as it is the Bidders responsibility
to draw up and implement such programme duly approved by the Owner. The
Document Number
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ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
[Logo of Utility]
detailed Quality Plans for manufacturing and field activities shall be drawn up by
the Bidder and will be submitted to Owner for approval.
Manufacturing Quality Plan (MQP) will detail out for all the components and
equipment, various tests/inspection, to be carried out as per the requirements of
this specification and standards mentioned therein and quality practices and
procedures followed by Bidders/ Sub-vendors Quality Control Organization, the
relevant reference documents and standards, acceptance norms, inspection
documents raised etc., during all stages of materials procurement, manufacture,
assembly and final testing/performance testing. The Quality Plan shall be
submitted to the Owner for review and approval.
Field Quality Plans (FQP) will detail out for all the equipment, the quality
practices and procedures etc. to be followed by the Bidders "Site Quality Control
Organization", during various stages of site activities starting from receipt of
materials/equipment at site.
The Bidder indicate in the QP the reference documents/plant
standards/acceptance norms/tests and inspection procedure etc., These Quality
Plans and reference documents/standards etc. will be subject to Owners
approval without which manufacturer shall not proceed. These approved
documents shall form a part of the contract. In these approved Quality Plans,
Owner shall identify customer hold points (CHP), i.e. test/checks which shall be
carried out in presence of the Owner or his authorized representative and
beyond which the work will not proceed without consent of Owner in writing. All
deviations to this specification, approved quality plans and applicable standards
must be documented and referred to the Owner along with technical justification
for approval and dispositioning.
The material shall be dispatched from the manufacturers works before the same
is accepted by the Purchaser/Consultant.
All material used for equipment manufacture including casting and forging etc.
shall be of tested quality as per relevant codes/standards. Details of results of
the tests conducted to determine the mechanical properties; chemical analysis
and details of heat treatment procedure recommended and actually followed
shall be recorded on certificates and time temperature chart. Tests shall be
carried out as per applicable material standards and/or agreed details.
The Bidder shall submit to the Owner Field Welding Schedule for field welding
activities in the format enclosed at acceptable to owner. The field welding
schedule shall be submitted to the Owner along with all supporting documents,
like welding procedures, heat treatment procedures, NDT procedures etc. at
least [ninety days] before schedule start of erection work at site.
All welding and brazing shall be carried out as per procedure drawn and qualified
in accordance with requirements of ASME Section IX/BS-4870 or other
International equivalent standard acceptable to the Owner.
The welding/brazing procedures shall be submitted to the Owner for approval
prior to carrying out the welding/brazing.
Document Number
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No.
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x)
All brazers, welders and welding operators employed on any part of the contract
either in Bidders/sub-vendor works or at site or elsewhere shall be qualified as
per ASME Section-IX or BS-4871 or other equivalent International Standards
acceptable to the Owner.
xi)
Welding procedure qualification & Welder qualification test results shall be
furnished to the Owner for approval. However, where required by the Owner,
tests shall be conducted in presence of Owner/Owners authorized
representative.
xii)
For all pressure parts and high pressure piping welding, the latest applicable
requirements of the IBR (Indian Boiler Regulations) shall also be essentially
complied with. Similarly, any other statutory requirements for the
equipment/systems shall also be complied with.
xiii) On all back-gauged welds MPI/LPI shall be carried before seal welding.
xiv) Unless otherwise proven and specifically agreed with the Owner, welding of
dissimilar materials and high alloy materials shall be carried out at shop only.
xv)
No welding shall be carried out on cast iron components for fabrication or repair.
xvi) All the heat treatment results shall be recorded on time temperature charts and
verified with recommended regimes.
xvii) All non-destructive examination shall be performed in accordance with written
procedures as per International Standards but qualified operator. NDT shall be
recorded in a report, which includes details of methods and equipment used,
result/evaluation, job data and identification of personnel employed and details of
co-relation of the test report with the job.
xviii) All plates of thickness above 40mm and all bars stock/Forging above 40mm dia
shall be ultrasonically tested. For pressure parts, plate of thickness equal to or
above 25mm shall be ultrasonically tested.
xix) The Bidder shall list out all major items/ equipment/ components to be
manufactured in house as well as procured from sub-Bidders (BOI).
xx)
For components/equipment procured by the Bidders for the purpose of the
contract, after obtaining the written approval of the Owner, the Bidders purchase
specifications and inquiries shall call for quality plans to be submitted by the
suppliers. The quality plans called for from the sub-vendor shall set out, during
the various stages of manufacture and installation, the quality practices and
procedures followed by the vendors quality control organization, the relevant
reference documents/ standards used, acceptance level, inspection of
documentation raised, etc. Such quality plans of the successful vendors shall be
finalized with the Owner.
xxi) Owner reserves the right to carry out quality audit and quality surveillance of the
systems and procedures of the Bidders or their sub-vendors quality
management and control activities. The Bidder shall provide all necessary
assistance to enable the Owner carry out such audit and surveillance. The Bidder
shall also take requisite corrective measures for restoring/ improving the system
in line with the outcome of such quality surveillance and audits.
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xxii)
xxiii)
xxiv)
xxv)
xxvi)
xxvii)
xxviii)
[Logo of Utility]
The Bidder shall carry out an inspection and testing programme during
manufacture in his work and that of his sub-vendors and at site to ensure the
mechanical accuracy of components, compliance with drawings, conformance to
functional and performance requirements, identity and acceptability of all
materials, parts and equipment. Bidder shall carry out all tests/inspection
required to establish that the items/equipment conform to requirements of the
specification and the relevant codes/standards specified in the specification, in
addition to carrying out tests as per the approved quality plan.
Quality audit/surveillance/approval of the results of the tests and inspection will
not, however, prejudice the right of the Purchaser to reject the equipment if it
does not comply with the specification when erected or does not give complete
satisfaction in service and the above shall in no way limit the liabilities and
responsibilities of the Bidder in ensuring complete conformance of the
materials/equipment supplied to relevant specification, standard, data sheets,
drawings, etc.
For all spares and replacement items, the quality requirements as agreed for the
main equipment supply shall be applicable.
Repair/rectification procedures to be adopted to make the job acceptable shall be
subject to the approval of the Owner.
In case any deviation is observed with respect to relevant document or good
engineering practices, and the same is considered by the Bidder to be
acceptable, as it is or with certain rectifications/ modifications, based on his
detailed technical analysis, then the Bidder shall refer the same to Owner along
with reason for deviation, proposed corrective action, technical justification for
suitability of the proposal and preventive measures for avoiding recurrence of
similar deviations. Based on his evaluation, the Owner may accept the proposal
as it is or with modifications or may reject the same. Such proposals shall be
raised in suitable No-conformity report format (NCR). The NCR can be raised
irrespective of the CHP stages in the QP.
Burn in and Elevated Temperature Test Requirement for Electronics Solid State
Equipment:
All solid state electronic systems/equipment shall be tested as a complete
system/equipment with all devices connected for a minimum of 168 hours (7
Days) continuously under energized conditions prior to shipment from
manufacturing works, as per the following cycle.
Elevated Temperature Test Cycle
During the elevated temperature test which shall be for 48 hours of the total 168
hours of testing, the ambient temperature shall be maintained at [50 C]. The
equipment shall be interconnected with devices which will cause it to repeatedly
perform all operations it is expected to perform in actual service with load on
various components being equal to those which will be experienced in actual
service.
Document Number
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[Logo of Utility]
During the elevated temperature test the cubicle doors shall be closed (or shall
be in the position same as they are supposed to be in the field) and inside
temperature in the zone of highest heat dissipating components/modules shall be
monitored. The temperature rise inside the cubicle should not exceed [10 C]
above the ambient temp at [50 C].
Burn in Test Cycle
The 48 hours elevated temperature test shall be followed by 120 hours of burn in
test as above except that the temperature shall be reduced to the ambient
temperature prevalent at that time.
During the above tests, the process I/O and other load on the system shall be
simulated by simulated inputs and in the case of control systems; the process
which is to be controlled shall also be simulated. Testing of individual
components or modules alone shall not be acceptable.
In case the Bidder/ sub-vendor is having any alternate established procedure of
eliminating infant mortality of components, the detail procedures followed by the
Bidder/ sub- vendor along with the statistical figures to validate the alternate
procedure may be submitted to the Owner for his consideration.
The Bidder/Sub-vendor shall carry out routine test on 100% item at Bidder/subvendor's works. The quantum of check/test for routine and acceptance test by
Owner shall be generally as per criteria/sampling plan defined in referred
standards. Wherever standards have not been mentioned quantum of check/test
for routine / acceptance test shall be as agreed during detailed engineering
stage.
7.3
QA Documentation Package
7.3.1
The Bidder shall submit the QA Documentation in [two hard copies] and [two CD
ROMs], as identified in respective quality plan with tick () mark.
Each QA Documentation shall have a project specific Cover Sheet bearing name
& identification number of equipment and including an index of its contents with
page control on each document.
The QA Documentation file shall be progressively completed by the Bidder/ subvendor and the same shall be submitted to the Owner in [2 hard copies] and [2
CD-ROMs], within [two weeks] of dispatch of the equipment.
Typical contents of QA Documentation is as below:Approved Quality Plan.
Material mill test reports on components as specified by the specification and
approved Quality Plans.
Manufacturer / works test reports/results for testing required as per applicable
codes and standard referred in the specification and approved Quality Plans.
Non-destructive examination results /reports including radiography interpretation
reports. Sketches/drawings used for indicating the method of traceability of the
radiographs to the location on the equipment.
i)
ii)
iii)
iv)
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v)
vi)
vii)
viii)
7.4
[Logo of Utility]
Heat Treatment Certificate/Record (Time-temperature Chart).

All the accepted Non-conformance Reports (Major/Minor) / deviation, including
complete technical details / repair procedure).
Inspection reports duly signed by the Inspector of the Owner and Bidder for the
agreed Customer Hold Points.
Certificate of Conformance (COC) wherever applicable.
Similarly, the Bidder shall be required to submit [two sets (two hard copies and
two CD ROMs)], containing QA Documentation pertaining to field activities as per
Approved Field Quality Plans and other agreed manuals/ procedures, prior to
commissioning of individual system.
Inspection, Testing and Inspection Certificates
i)
ii)
iii)
iv)
The word Inspector shall mean the Owners Inspection engineer and/or Owners
authorized representative acting on behalf of the Owner to inspect and examine
the materials and workmanship of the works during its manufacture or erection.
The Owners Inspection Engineer and/or Owners authorized representative
acting on behalf of the Owner shall have access at all reasonable times to
inspect and examine the materials and workmanship of the works during its
manufacture or erection and if part of the works is being manufactured or
assembled on other premises or works, the Bidder shall obtain for the Owners
Inspection Engineer and/or an outside inspection agency acting on behalf of the
Owner, permission to inspect as if the works were manufactured or assembled
on the Bidders own premises or works.
The Bidder shall give the Owner fifteen [(15) days] written notice of any material
being ready for inspection/testing. Such tests shall be to the Bidders account
except for the expenses of the Inspectors. The Owners Inspection Engineer
and/or an outside inspection agency acting on behalf of the Owner, unless the
witnessing of the tests is virtually waived and confirmed in writing, will attend
such tests within [fifteen (15)] days of the date on which the equipment is noticed
as being ready for test/inspection failing which the Bidder may proceed with test
which shall be deemed to have been made in the inspectors presence and he
shall forthwith forward to the Purchaser duly certified copies of test reports in [two
(2) copies] for his review and approval.
The Owners Inspection Engineer and/or Owners authorized representative
acting on behalf of the Purchaser shall within [fifteen (15) days] from the date of
inspection as defined herein give notice in writing to the Bidder, on any objection
to any drawings and all or any equipment and workmanship which is in his
opinion is not in accordance with the contract. The Bidder shall give due
consideration to such objections and shall either make modifications that may be
necessary to meet the said objections or shall inform in writing to the Owners
Inspection Engineer and/or Consultants inspection agency acting on behalf of
the Owner, giving reasons therein, that no modifications are necessary to comply
with the contract. After due consideration, Owner may accept or reject the same.
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v)
vi)
vii)
viii)
ix)
7.5
[Logo of Utility]
When the factory tests have been completed satisfactorily at the Bidders or subvendors works, the Owner shall issue a certificate to this effect within [fifteen
(15)] days of completion of tests. The completion of these tests or the issue of
the certificates shall not bind the Owner to accept the equipment should it, on
further tests after erection be found not to comply with the contract.
In all cases where the contract provides for tests whether at the premises or
works of the Bidder or any sub-vendor, the Bidder, except where otherwise
specified, shall provide free of charge such items as labour, material, electricity,
fuel, water, stores, apparatus and instruments as may be reasonably demanded
by the Owners Inspection Engineer and/or Owners authorized representative
acting on behalf of the Owner, to carry out effectively such tests on the
equipment in accordance with the Contract and shall provide the facilities to
accomplish testing.
The inspection by the Owners Inspection Engineer and/or Owners authorized
representative acting on behalf of the Purchaser and issue of Inspection
Certificate thereon shall in no way limit the liabilities and responsibilities of the
Bidder in respect of the contract.
To facilitate advance planning of inspection in addition to giving inspection notice,
the Bidder shall furnish quarterly inspection programme indicating schedule
dates of inspection at Customer Hold Point and final inspection stages. Updated
quarterly inspection plans will be made for each three consecutive months and
shall be furnished before beginning of each calendar month.
All inspection, measuring and test equipment used by Bidder shall be calibrated
periodically depending on its use and criticality of the test/measurement to be
done. The Bidder shall maintain all the relevant records of periodic calibration
and instrument identification, and shall produce the same for inspection by
Owner. Wherever asked specifically, the Bidder shall re-calibrate the
measuring/test equipment in the presence of Owners Inspection Engineer and/or
Owners authorized representative acting on behalf of the Purchaser.
Shop and Site Tests:
i)
ii)
iii)
Shop tests will include all tests to be carried out at Bidders works, at works of
his sub-vendor and at works where raw material supplied for manufacture of
equipment is manufactured.
All materials will be of tested quality supported with correlated test certificates.
Whenever tested quality material is specified and wherever called upon by Indian
Boilers Regulations or by design code, the test pieces are to be prepared and
tested to Owner's satisfaction. The results of the tests will be certified.
Shop and Site tests will include electrical, mechanical, performance and
hydraulic tests in accordance with relevant IS, IBR or any other approved
standard or any other tests called for by the Owner under these specifications to
ensure that the plant being supplied fulfills the requirements of the specifications.
For equipment not covered by any IS or other approved standards, the tests to
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a.
b.
c.
d.
7.6
[Logo of Utility]
be carried out will be in accordance with the quality plan to be agreed to between
the Bidder and the Owner.
General Notes
For IBR items, stamping on the components, inspection and certification will be
carried out by the IBR as per the IBR procedures. However; the Bidder will also
be identified the same to which project they are meant by stamping/ stenciling.
For non IBR items inspection will be as per mutually agreed QAP. The QAP will
be submitted for major items and will be finalized during detail engineering. Joint
protocol and dispatch clearance will be based on the agreed QAP.
Major items for which the QAP are to be furnished will be mutually discussed and
agreed during detail engineering.
For items/ components not covered in the QAP, Bidder will furnish the certificate
of compliance.
Turbine
i)
ii)
iii)
The following shop tests will be conducted as applicable on the various

components such as rotor, casings, blades, diaphragms, valves, pipes, flanges,
etc. All such tests will be documented and forwarded to the Owner for his review.
a)
Material analysis.
b)
Boro-scope test.
c)
Ultrasonic test.
d)
Magnetic particle test for crack detection.
e)
Radiographic test at welds.
f)
Heat stability test.
g)
Hydrostatic pressure test.
h)
Resonant vibration tests.
i)
Examination of threading tolerances etc.
j)
Overall mechanical inspection.
k)
Molybdenum content test on blades (moving).
After the shop assembly of the various components of the turbine, the following
tests will be conducted at shop:a)
Verification of fits and operating clearances and dimensions.
b)
Test at 120% over speed for 2 minutes.
c)
Tests for checking the proper operation of Governors, control valves and
auxiliaries.
d)
All motor driven oil pumps will be operated at normal speed and checked
for proper alignment, smoothness in operation, head and capacity. Oil
tanks will be tested at operating temperatures for leaks.
After completion of erection the following test will be conducted at site:
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a)
b)
c)
d)
e)
f)
7.7
[Logo of Utility]
Running test with steam. Running test with steam will include but not be
limited to:
Barring gear operation
Steam turbine performance to be proved by running at operating

speed and maintaining this speed for at least one hour.
Governor speeder range to be checked and recorded.
Trip and reset speed of emergency governor.
Operation of HP turbine stop valves and control valves and IP

turbine stop valves and control valves to be checked for tripping.
All testing devices (Protective devices) to be checked for

satisfactory operation.
Tests for checking the proper operation of governors, control valves and
auxiliaries.
All motor driven oil pumps will be operated at normal speed and checked
for proper alignment, smoothness in operation, head and capacity. Oil
tanks will be tested at operating temperatures for leaks.
Bearing and shaft vibration, shaft eccentricity, bearing oil pressure and
return oil temperature will be recorded at increment of speed up to over
speed.
Certified copies of casing level records, rotor alignment checks including
sling & concentric checks and alignments in cylinder, rotor clearance
giving all axial, radial clearance between moving and fixed blades, glands
etc. will be furnished.
Tightening strains on high temperature bolts will be recorded.
Tests on Auxiliaries
i)
ii)
iii)
iv)
v)
7.8
The following shop tests will be conducted as applicable on the various

auxiliaries:
All the pressure vessels/heat exchangers will be tested at a hydrostatic test
pressure of 1.5 times the maximum working pressure or 1.3 times the design
pressure whichever is higher or as required by IBR.
Radiography tests at welds as per requirements of IBR as applicable.
Functional tests of equipment wherever applicable.
Overall mechanical inspection.
Complete performance tests of all pumps to establish flow vs head, power input,
efficiency and NPSH. Performance curves corrected for site condition will be
provided.
Condenser
i)
All materials used for the manufacture of the equipment covered under this
Specification will be of tested quality. Relevant test certificates will be made
available to the Owner.
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ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
7.9
[Logo of Utility]
All welded joints will be tested by liquid penetrant examinations according to the
method outlined in ASME Boiler and Pressure Vessel code. Radiography and
ultrasonic testing will be employed wherever necessary. At least 10% of all butt
welding joints will be radiographed.
The water box and shell will be hydrostatically tested as per Heat Exchange
Institute Standards. Gaskets will be replaced with new ones after shop test.
All condenser tubes will be hydraulically tested at [70.0] kg/cm2 (g) internal
pressure and carefully inspected (ultrasonically or by eddy current testing) as per
ASTM E213-68 and ASTM E243-67T respectively prior to shipment. All other
parts subjected to pressure will be hydrostatically tested as per relevant ASME
Standard.
The completely assembled condenser will be hydrostatically tested at site after
erection, according to the standards of Heat Exchange Institute.
Condenser shell will be tested for tube leakage by filling the steam space with
water in which a fluorescent will be added.
A field performance test will be conducted in conjunction with approved
Acceptance Tests Procedure. It will be based on ASME Power Test Code
PTC-12.2, or equivalent and include all tests necessary to demonstrate the
performance guarantees.
Performance of the air removing equipment will be tested at the manufacturer's
shop in accordance to the applicable ASME Power Test Code.
Condenser on load tube cleaning system will be tested for increase in pressure
drop in cooling water system due to the installation of the same. The various
controls provided will also be checked for satisfactory performance. Also, the
recovery rate of the balls will be demonstrated at site.
L.P. & H.P. Heaters
i)
At Manufacturer's Works:
a)
All heaters will be subjected to manufacturer's standard shop inspection
and all inspection and tests called for elsewhere in this specification. Mill
certificates for the material for heater shell, tube support plates, tube
sheets, water boxes, flash tanks etc. will be submitted to the Owner for
review.
b)
Heat exchanger tubes and water boxes will be tested by one of the
following methods for cracks, imperfections etc.
Black light
Magnetic particles
Dye penetrant
c)
Each tube will be "Eddy Current" tested to detect any imperfection. The
following tests will be performed on each lot of Heat Exchanger tubes.
Microscopic
Chemical Analysis
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d)
ii)
7.10
[Logo of Utility]
Yield strength
Flattening
Flanging
Hydrostatic testing of the heat exchangers will be done in accordance
with ASME TEST CODE for unfired Pressure Vessels Section VIII and
I.B.R. as applicable. The LPH-1 will be hydraulically tested at 1.3 times
the design pressure.
At site:
The feed water heat exchangers will be field tested along with the TG set as per
applicable code to determine the following. :a)
Temperature rise of the feed water/condensate at guaranteed capacity
points.
b)
Pressure drop in the water circuit.
The Bidder will furnish all instruments necessary to perform the above tests.
Deaerator
i)
ii)
7.11
At Manufacturer's Works
Each deaerating heater and storage tank will be shop inspected during
fabrication in accordance with applicable provisions of ASME Code for unfired
pressure vessel Section VIII Div 1. Hydrostatic testing will be carried out as per
the above code. Mill certificates for all the materials used will be submitted to the
Owners for review. However hydro test for FST will be conducted at site.
At site
The Bidder will conduct field tests on the deaerating feed water heater. Tests will
cover the determination of dissolved oxygen and free carbon dioxide in
Deaerator outlet water along with thermal and hydraulic performance of the
Deaerator.
All performance tests will be done and evaluated as per applicable code..
Condensate extraction Pump (CEP)
i)
ii)
All tests will be conducted by the Bidder to demonstrate the capability,

guarantees, performance and compliance with the specification. The Bidder will
provide all instruments and temporary equipment including their installation for all
test requirements. Prior to testing, the detailed test procedure will be submitted
for the Owner's approval. After the test, the copies of final report including the
performance calculations shall be submitted for Owners approval. Following
Tests shall be conducted.
Tests at Shop
a)
Material analysis and testing.
b)
Radiographic and Magnetic Particle Examination of material and welds.
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c)
iii)
7.12
All pressure parts will be subjected to hydraulic testing at a pressure of

150% of shut-off head or 200% of rated head (effective head), whichever
is higher, for a period not less than half an hour.
d)
Static and dynamic balancing tests of rotating parts at specified over
speeds to determine the mass centre and vibration level.
e)
Performance tests are to be conducted to cover the entire range of
operation of the pumps. These will be carried out in the range from 125%
of rated capacity to pump shut-off condition. The tests will be conducted
as per hydraulic institute standards of USA. Overall performance of the
Pump will be tested for the following:
Total head developed by the pump at rated capacity.
Horsepower required of the pump under rated condition.
Efficiency at rated condition.
NPSH requirement at rated condition In any of the pump
To establish the pump characteristic curves for capacity Vs Head,

power NSPH and efficiency.
Tests at Site :
The pumps with its drives will operate satisfactorily at site for the whole range of
rated operating condition as specified. The controls such as auto starting of
pumps, speed, recirculation, etc. will also be tested for satisfactory performance.
Parallel operation of pumps with different combinations will also be tested. During
entire range of operation the vibration level will conform to VDI 2056.
Boiler Feed Pump & Booster pump of BFP
i)
ii)
All tests will be conducted by the Bidder to demonstrate the capability,

guarantees, performance and compliance with the specification. The Bidder will
provide all special instruments and

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RENOVATION & MODERNISATION

MODEL FEASIBILITY REPORT

Feasibility Report For R&M of Unit No.[..]Capacity [..]of [Name of the

21st Aug 2012

22nd Aug 2012

First edition Issued (Draft Report).

Minor Revision (Draft Report).

04th Dec 2012

Revised edition submitted based on

16th July 2013

Revised edition submitted based on

25th Sep 2014

15th Jan 2016

Clause 6.4.12 revised to include

FEASIBILITY REPORT FOR R&M WORKS

Feasibility Report For R&M of Unit No.[..]Capacity [..]of [Name of the

To overcome technological obsolescence and non-availability of spares.

To improve the performance parameters in terms of Plant Load Factor, Efficiency,

FEASIBILITY REPORT FOR R&M WORKS

Feasibility Report For R&M of Unit No.[..]Capacity [..]of [Name of the

To reduce maintenance requirements and enhance the ease in maintenance.

Compliance of stringent environmental norms, safety and other statutory requirements.

Objectives of R&M/LE Programme:

Extension of useful economic life of generating units by another 20 years.

To restore rated capacity and design parameters such as heat rate,

Improvement in Auxiliary Power Consumption Secondary Oil Consumption etc

Up-rating of Generating Unit.

Improvement beyond design parameters.

Criteria for the Consideration of R&M and R&M/LE Programmes

Plant Life should be extended by about 20 years.

The Pay Back Period should be from 5 to 7 years.

Need of Preparation of Model R&M Documents

FEASIBILITY REPORT FOR R&M WORKS

Feasibility Report For R&M of Unit No.[..]Capacity [..]of [Name of the

85-86 to 89-90 &

11th Plan R&M Programme & Achievements (2007-12)

FEASIBILITY REPORT FOR R&M WORKS

Feasibility Report For R&M of Unit No.[..]Capacity [..]of [Name of the

efficiency in thermal power stations, constituted as per decision of meeting of IGEF in

Standard Bidding Procedure for engagement of Consultants and R&M Works

II) Residual Life Assessment (RLA) / Condition Assessment (CA) Report.

Due Diligence done by LII of the R&M Documents of other Projects

FEASIBILITY REPORT FOR R&M WORKS

Feasibility Report For R&M of Unit No.[..]Capacity [..]of [Name of the

Documents Provided by CEA

Remaining Life Assessment I Condition Assessment Report- Nasik Unit-3 of

Documents Provided by WBPDCL

Energy Audit Report of Bandel Unit -5 (210 MW) of WBPDCL.

Model Contract Document issued by KfW.

World Bank Documents

FEASIBILITY REPORT FOR R&M WORKS

Feasibility Report For R&M of Unit No.[..]Capacity [..]of [Name of the

GUIDELINES FOR USING THE MODEL FEASIBILITY REPORT

FEASIBILITY REPORT FOR R&M WORKS

Feasibility Report For R&M of Unit No.[..]Capacity [..]of [Name of the

MODEL FEASIBILITY REPORT

FEASIBILITY REPORT FOR R&M WORKS

Feasibility Report For R&M of Unit No.[..]Capacity [..]of [Name of the

Objective of the Feasibility Study

R&M Model Feasibility Report

R&M Model Feasibility Report

R&M Model Feasibility Report