TND - 072388 - 148909-Tech. Specs.

ROURKELA STEEL PLANT
ROURKELA
INSTALLATION OF A 4th SLAB CASTER AT SMS-II
TENDER SPECIFICATION
FOR
TH
INSTALLATION OF 4 SLAB CASTER AND LADLE FURNACE
WITH ASSOCIATED FACILITIES
INCLUDING ENABLING WORKS – MAIN PACKAGE
PACKAGE- II
STEEL AUTHORITY OF INDIA LIMITED

CENTRE FOR ENGINEERING & TECHNOLOGY
RANCHI - 834002
APRIL, 2019 CET/05/RN/4179/TS/ST/02/R=2

CONTENTS - CHAPTERS
Chapter Description Page No.

No.
1 Introduction 1.1 - 1.5
2 Scope of Work 2.1 - 2.97
3 Technical Specification 3.1 - 3.424
4. Commissioning and Performance Guarantee 4.1 - 4.7
Annexures
Schedules
Drawings
PACKAGE LEADER(PL) TASK FORCE HOD (PL)

LEADER(TFL)
FEROZ KHAN, FEROZ KHAN, P K THAKUR,
DGM (STEEL) DGM (STEEL) DGM I/C STEEL
RSP CONTENTS CET/05/RN/4179/TS/ST/02/R=2

4TH CASTER – MAIN PACKAGE PAGE 1 OF 6
CONTENTS - ANNEXURES
Annexure No. Description No. of Pages
2.1.4-1 List of Acceptable Makes of Equipment & 33

Supplies (May 2017)
2.1.16.2-1 Indicative project implementation schedule 1
2.6.2-1 List of extg. cables to be relocated at the 3

gable end of the caster shop for proposed
extension of “ LM, MN, NP, PQ, QR and R’S
bays” towards existing scale pit side
2.10.15-1 List of empanelled parties for 2

“Topographical Survey & Soil Investigation
work”
2.10.15-2 List of empanelled parties for “Locating & 1

Mapping of Underground Utilities”

CONTENTS - SCHEDULES
Schedule No. Description No. of Pages
1.8-1 Declaration of site visit 1
1.8-2 List of exclusions 1
1.8-3 List of deviations 1
1.8-4 List of recommended spares for two years 1

normal operation
1.8-5 List of commissioning spares 1
1.8-6 List of special tools and tackles 1
1.8-7 List of first fill of oils and lubricants 1
1.8-8 Details of authorised person of Bidder 1

during tender evaluation
1.8-9 Requirement of construction water & power 1

CONTENTS - DRAWINGS
Sl. Drawing No. Description

1. CET RN 4179 ST2 00 001 R=3 Installation of proposed 4th slab caster –
Layout of proposed facilities
2. CET RN 4179 ST2 00 002 R=1 Installation of proposed 4th slab caster –
Layout of facilities to be dismantled
3. CET RN 4179 ST2 00 003 R=1 Installation of proposed 4th slab caster – Layout
of existing and proposed facilities in KL and LM
bays
4. CET RN 4179 UT0 00 001 R=1 Scheme for open loop spray cooling water for
proposed caster-4, common flume flushing
system & scale water transportation in existing
WTP of caster
5. CET RN 4179 UT0 00 002 R=1 Closed loop water system for proposed Caster
# 4 & LF
6. CET RN 4179 UT0 00 003 R=0 Scheme for industrial & soft water pipe routing
for proposed caster no. -4 & LF-2D
7. CET RN 4179 EE1 00 001 R=4 Single line diagram of power distribution for
slab caster-4
8. CET RN 4179 EE1 00 002 R=0 Single line diagram of proposed extension at
33kV switchyard of MSDS-3
9. CET RN 4179 CE0 00 010 R=0 Location of Bore Hole, ERT, Extent of survey &
underground mapping.
10. CET RN 4179 CE0 00 011 R=0 Detail of Standard Concrete Road.
11. CET RN 4179 CE0 00 012 R=0 Location of Bore Hole, ERT, Extent of survey &
underground mapping- For new MSRS.
12. CET RN 4179 CA1 00 001 R=0 Proposed system automation configuration
(2 Sheets) diagram for 4th slab caster & LF
13. PDR-137688 Slab casting shop in SMS-2 : Plan of columns
and numbering system
14. PDR-137691 Slab casting shop in SMS-2 : Tunnels and
trenches – Layout plan
15. PDR-137692 Slab casting shop in SMS-2 : Layout of inshop
premises
16. PDR-142369 Slab casting shop in SMS-2 : Main cable tunnel
(CT1 top CT6) Lighting layout
17. PDR-145667 Slab casting shop in SMS-2 : Layout of pipeline
for the drainage of cable tunnels
18. PDR-139208 Slab casting shop in SMS-2 : Ventilation and
water tunnels connecting turret-1 and 2, near
(N-35), Shuttering details, plans and sections.

19. PDR-141866 Slab casting shop in SMS-2 : Water supply
tunnel (Part-A & B) Shuttering details
tunnel (Part - A & B) - Strengthening of tunnel
for overloading due to Slag dumping – GA Plan
& Sections
tunnel (Part - A & B) - Strengthening of tunnel
for overloading due to Slag dumping – RC detail
of slab and retaining wall
22. PDR-141441 Slab casting shop in SMS-2 : Water system –
Scale pit pump house – General Arrangement
Scale pit pump house – Equipment and piping
installation details – Section A-A & C-C
Scale tunnel and surface channel near scale pit
and pump house – Plan and Section
25. PDR-137547 Slab casting shop in SMS-2 : Analytical
laboratory & Elect. Sub-Stn – Basement Floor
Plan
26. PDR-137548 Slab Casting Shop In SMS-2 : Analytical
Laboratory & Elect. Sub-Stn – First Floor Plan
And Sections
laboratory & Elect. Sub-Stn – Elevations
laboratory & Elect. Sub-station – Section and
details
29. PDR-141835 Slab casting shop in SMS-2 : Emergency
overhead tank – Shuttering details
overheat tank – Shuttering details
overhead tank – RC Details of foundation &
Shuttering
overhead tank – Reinforcement Detail of stairs
overhead tank – Pipe/ valve support
foundations. Inside the shaft at -300. Plan and
sections

34. PDR-141512 Chilled Water Pipe Routes for various Air
Handling Unit Rooms
35. PDR-141511 Water System-Scale Channel and Surface
Channel near Scale Pit and Pump House-Plan
and Sections
36. PDR-141449 Water System- Fire-fighting Water Line to
Analytical laboratory Building Details
37. PDR-137801 Scheme of Inside Mixed Gas, Oxygen, Nitrogen,
Argon, Acetylene and Steam pipe lines
38. PDR-141416 Water System- In shop pipelines-Layout plans
39. PDR-137690 Layout Plan at ±0.00 Level
40. PDR-138525 Water System-Water Supply Tunnels and
Channels Piping Erection details-Support
Details
41. PDR-141409 Water System-Water Supply Tunnel and
Channels-Piping Erection Details for the Branch
Tunnel and Surface Channel at N-31
42. PDR-141405 Emergency water Overhead Tank - Details of
piping Inside the shaft

1 INTRODUCTION
1.1 GENERAL:
1.1.1 Rourkela Steel Plant (RSP), a unit of Steel Authority of India Limited (SAIL),
has two Steel Melting Shops (SMS). Both Steel Melting Shops (SMS) have
BOF (Basic Oxygen Furnace), secondary steel making facilities and slab
casters.
1.1.2 Major technological facilities in SMS for steel making and continuous
casting at RSP are as given below :
Facilities SMS-I SMS-II

HM De-Sulphurization unit 6 x 80t BF ladle 2 x 150 t
Primary steel making 2 x 66 t BOF 3 x 150 t BOF
facilities (nos. x heat size)
Secondary steel making 1 x 66 t VOR, 1 x 150 t ARS,
facilities (nos. x heat size) 1 x 66 t VAR, 3 x 150 t LF
1 x 66 t LF 1 x 150 t RH-OB
Continuous Casting 1 x 1- strand slab 3 x 1- strand slab
Facilities caster casters
1.1.3 Continuous Casting Machines (CCM) of SMS-II shall produce 3.1 Mtpa;
considering 1.6 Mtpa from Caster # 1 & 2 and 1.5 Mtpa from Caster # 3,
whereas rated capacity of SMS-II in terms of crude steel is 3.7 Mtpa. Hence
there is a shortfall of 0.6 Mtpa in casting capabilities at SMS-II. Enhancement
of casting capacity is required in order to achieve crude steel production of
3.7 Mtpa from SMS-II.
RSP is contemplating to install one new Slab Caster (Caster #4) and one new
Ladle Furnace, to fulfil production shortfall as well as future requirements.
The proposed caster shall also be capable of producing value added steel.
Installation of proposed Caster #4 shall improve the operational flexibility in
SMS-II in terms of availability of casters and grades of steel to be cast.
1.2 EXISTING FACILITIES:
Facilities in SMS-II units are as below:
BOF shop:
Existing facilities Nos. x Capacity
 Hot Metal Mixers 2 x1300
 Torpedo ladle receiving station
 De-Sulphurization unit 2x 150 t
RSP PAGE 1.1 CET/05/RN/4179/TS/ST/02/R=2

4TH CASTER – MAIN PACKAGE
 BOF converters 3 x 150t
Caster Shop:
 Argon Rinsing Station (ARS) 1 x 150t
 Ladle Furnaces 3 x 150t
 RH-OB 1 x 150t
 Slab Casters 3 x 1-Strand
1.3 OVERVIEW OF THE PROJECT

1.3.1 It is envisaged to install a new slab caster (Caster #4) and a new Ladle furnace
(LF-2D) with all associated facilities for both these units/ facilities. New ladle
furnace shall assist the new slab caster along with adjacent slab casters,
(Caster #1 & 2) for timely supply of liquid steel to improve overall
productivity of the shop.
1.3.2 The new caster shall be capable of producing value added steel like API
grades, boiler quality, extra deep drawing (EDD), structural steel, steels for
SWPP / ERW PP / tin plates / galvanised sheets, chequered plates, SAILMA,
HSLA, micro alloyed high tensile strength steel etc. Proposed ladle furnace
shall be utilised for secondary refining and feeding the slab casters as per
requirement. This shall help to improve the operational flexibility in SMS-II
in terms of availability of casters and grades of steel to be cast.
1.3.3 Installation of new slab caster and a new ladle furnace require dismantling
of some of the facilities, relocation/ re-routing of many existing facilities,
erection of new associated facilities, bay extensions etc.
1.4 IMPLEMENTATION STRATEGY
1.4.1 Complete job of installation of Caster #4 in SMS-II is envisaged to be
executed through following three (3) nos. of packages:
Pkg. No. Name Execution Mode
Package-I Geotechnical Investigation, Area Non-turnkey basis –
Survey & Underground Mapping already executed and
Works. report is available
Package-II Installation of 4th Slab Caster and Turnkey basis
Ladle furnace with associated
facilities including enabling works -
Main Package

1.4.2 This tender specification pertains to Package-II only which is to be executed
on turnkey basis and includes dismantling of some of the facilities,
relocation/ re-routing of facilities, erection of new combined associated
facilities, integration of new /relocated facilities with existing system etc.
1.4.3 Details of pre-shutdown and shutdown activities with duration
Execution of entire work shall be carried out in such a manner that normal
working of the existing plant is not interrupted. Shutdown shall be arranged
by the employer for interconnections/ modifications of existing facilities
with the new units. The Bidder shall intimate the schedule of shutdown
details required before execution of specific work. Shutdown of Casters 1 &
2 combined in two phases of 4 days each has been envisaged for the project.
During the shutdown period interfacing portion of work of Caster # 1, 2 for
installation of the proposed Caster #4 shall be carried out. The Bidder shall
intimate the schedule of such required shutdown in details, before execution
of specific work.
1.4.3.1 Details of pre-shutdown and shutdown activities with duration/ period shall
be mentioned by the Bidder in their offer and also to be shown in the
implementation schedule, considering the total implementation period
intact.
1.4.3.2 During the rerouting/ construction of water pipe tunnel, the movement of
cranes in MN bay shall be restricted upto column axis-33.
1.4.4 Other site related details
Details of over ground/ on ground /underground facilities at erection site
which may need diversion and details of special handling equipment
required to be deployed at site, if any, are to be clearly brought out by the
bidder in their offer.
1.5 INTENT OF SPECIFICATION
1.5.1 The intent of this tender specification is to furnish required details for
enabling the Bidder to submit their best offers (technical & commercial) as
per the scope of work mentioned at chapter 2, technical specifications at
chapter 3, and commissioning & performance guarantee at chapter 4.
1.5.2 This tender specification shall be read in conjunction with other documents
enclosed with the NIT.
1.6 SITE VISIT AND OTHER REQUIREMENTS
1.6.1 Bidder shall visit the site, study drawings/ documents and discuss with the
employer/ consultant, if required, regarding any technical clarification and
get satisfied with respect to the nature and extent of work involved. Bidder

shall also obtain first-hand information regarding location, work terrain,
climate condition, railways, roads, airports and communication etc. before
offering the bid for the job.
1.6.2 All materials/ equipment/ machinery/ fabricated items used in the subject
package shall be according to the specification given herein and any
deviation should be clearly brought-out in schedules of exclusions and
deviations attached with this TS. No mention of exclusions and deviations
shall mean that the Bidder has accepted the scope and specification given
herein.
1.7 DRAWINGS AND TECHNICAL DOCUMENTS TO BE SUBMITTED WITH
THE OFFER
1.7.1 Bidder shall submit along with the bid, drawings / documents / data as per
the following details:
1) General layout showing disposition of all major units and
interconnection with the existing facilities such as roads, railway tracks,
utility and power lines etc.
2) General layout showing dismantling/ rerouting/ protection/ diversion
of existing facilities for disposition of proposed units and
interconnection with the existing facilities such as roads, utility and
power lines etc.
3) General arrangement drawings of all units, equipment and systems
with relevant dimensions.
4) Functional description of proposed unit/ installation along with
technical and capacity assessment details description.
5) SLD of HT & LT power distribution giving full details of connected load
and maximum demand of offered system
6) Drive list covering all major HT & LT drives.
7) Power single line diagram.
8) Process flow diagram.
9) Automation configuration drawing.
10) Schedule of quantity of equipment/ scope of supply matrix.
11) Delivery/ commissioning schedule (Bar chart/PERT Network).
12) Details of major construction equipment required for carrying out the
job within the stipulated time which they possess, with location and
details of construction equipment, which they would hire to facilitate
the dismantling and construction activities.

1.7.2 Drawings & documents listed above are minimum requirement only. Bidder
shall ensure that all other necessary write-ups, curves and information,
required to fully describe the equipment and system offered are submitted
with this offer.
1.8 SCHEDULES TO BE DULY FILLED AND SUBMITTED WITH THE OFFER

1.8-1 Declaration of site visit
1.8-2 List of exclusions
1.8-3 List of deviations
1.8-4 List of recommended spares for two years
normal operation
1.8-5 List of commissioning spares
1.8-6 List of special tools and tackles
1.8-7 List of first fill of oils and lubricants
1.8-8 Details of authorised person of Bidder during
tender evaluation
1.8-9 Requirement of construction water & power

2 SCOPE OF WORK
2.1 GENERAL
2.1.1 Bidder shall be responsible for execution of the jobs envisaged for Package-
II – Main package for installation of Caster #4 and a Ladle furnace with
associated facilities for both the units/ installation on Turnkey basis.
2.1.2 The scope of work shall cover design, engineering, procurement,
manufacture, fabrication, supply, transportation, insurance, storage,
handling, dismantling & removal of debris, construction, erection, testing,
commissioning, stabilisation and demonstration of performance guarantee
of the complete plant and equipment to the satisfaction of the employer.
The plant and equipment supplied shall be new and best of its kind.
2.1.3 This scope also includes dismantling, civil work, structural work, modification
in the existing system (if required), diversion/ relocation/ protection of
existing over ground and underground facilities interfering with the
proposed units in agreement with the Employer, interconnection of utilities
system & power supply system, Erection, supervision for erection &
commissioning, commissioning, Preliminary Acceptance Tests (PAT),
commissioning, conducting Performance Guarantee Tests (PGT) and
establishment of performance guarantee parameters, Final Acceptance Test
(FAC), Technical know-how & Training of Employer's personnel and
Employer's consultant's personnel.
2.1.4 All indigenous items shall be as per the “List of Acceptable Makes of
equipment and supplies” MAY 2017 furnished at Annexure-2.1.4-1.
2.1.5 The equipment and facilities envisaged under this package shall be located
generally as per indicative general layout drawings enclosed with the TS.
Layout of plant and equipment shall have provision for easy and safe
movement of operation/ maintenance personnel for operation/ inspection
of the running plant. Adequate space for dismantling/ removal of
equipment/ parts for repair shall also be built in the layout.
2.1.6 Bidder may propose any other feasible methodology considering
technological/ serviceability/ maintenance/ operation/ safety and statutory
requirement, time schedule and all peripheral constraint and coordination
to achieve the project within the time frame, space and the area available.
2.1.7 All the manufacturing/ fabrication works shall be carried out only on the
basis of approved drawings and schemes or as directed by the employer.
Approval given by the employer shall not relieve the Bidder of any
obligations under the contract.

2.1.8 Wide Parallel Flange Beam (WPB) and Narrow Parallel Flange Beam (NPB)
sections, being produced by SAIL, shall be used. In case of non-availability
/non- suitability of WPB or NPB sections, tapered rolled SAIL sections or
built up sections using SAIL steel shall be used. This is in addition to the
relevant clauses of SBD with regards to usage of SAIL steel.
2.1.9 Any equipment/ work/ service, within the battery limit, which may not have
been specifically mentioned in this document but is necessary for
completeness of the work, shall be clearly brought out in the offer and
included in their scope of work.
2.1.10 Scope of Services

1. Receiving of equipment from Bidder’s stores/ employer’s stores and
transportation to site.
2. Unloading of equipment at site, unpacking, cleaning up, and
checking for completeness and transportation to site for erection.
3. Transferring of centre lines and levels from standard benchmark(s),
including geodetic survey.
4. Filling of lubricants/ grease as per manufacturer’s instructions.
5. Supply of all erection consumables like oil, kerosene, cotton waste,
Oxygen and acetylene gas cylinders, electrodes, asbestos sheets,
asbestos ropes, sealing compounds etc.
6. Arranging tools, tackles, construction & erection machineries, cranes
and other handling & testing equipment, scaffolding, temporary
platforms, erection fixtures, skilled/ semi-skilled/ unskilled personnel
etc.
7. Required loading/ unloading / transportation of the equipment part,
which may require repairs at employer’s repair shop(s).
8. Arranging inspection of equipment at manufacturer’s/ sub-supplier’s
works wherever required as per approved QAP.
9. Arranging and rendering equipment and personnel to employer for
checking the correctness of the work in progress.
10. Submission of test certificates and data sheet from approved third part
testing laboratory or manufacturer respectively.
11. All equipment shall conform to the relevant provisions of Statutory and
other Regulations in force such as Indian explosives Act, Indian
Factories Act, Indian Boiler Regulation, State Factories Act, Indian
Electricity Rules, Central Pollution Control Board, Indian Weights &
Measures Act as applicable. The Bidder shall provide all necessary
assistance to the employer to get all the installations within the scope
of supply approved by the concerned legal authorities as per prevailing
practice.
12. Any rectification / modification of existing facilities required during
erection of equipment.
13. Bidder shall be responsible for protection and / or diversion of
underground and all existing over-ground services, wherever required
and / or diversion of the underground services which are indicated in
the drawing made available to the Bidder. In case there are under-
ground services which need to be protected and / or diverted but are
not shown in the drawing, the Bidder shall be responsible to execute
the same at extra price, if any, to be mutually agreed between Bidder
& employer as per provision of SBD.
14. Sundry works such as making of holes, grouting, chiselling of holes/
opening through walls, ceiling, floors, steel structures, etc. including
providing inserts as per requirement, cleaning of site periodically and
at the time of final handing over.
15. Periodic transportation including Loading, unloading and spreading
the unserviceable material, debris & surplus excavated earth with all
lift and lead within plant premises unless otherwise specified.
16. All instructions in the manuals for assembly, erection, testing and
commissioning of the equipment shall be in English language.
2.1.11 Tests and Inspection
2.1.11.1 The Contractor shall furnish a Quality Assurance Plan (QAP) in respect of
manufacture of equipment, which he proposes to follow for the purpose of
ensuring the quality of equipment and workmanship at various stages. The
Contractor shall furnish the test certificates of all the materials of
construction. For bought out items, manufacturers test certificates and
performance report shall be furnished as per QAP. The QAP shall be mutually
discussed and approved by the Employer.
2.1.11.2 Testing shall be done as per relevant latest Indian Standards/ international
codes or practices as per approved QAP and test certificates for the same
shall be submitted to Employer for dispatch clearance.
2.1.11.3 Inspection of different equipment/ items shall be done by the Employer
before dispatch on the basis of approved QAP
2.1.11.4 The tests/ inspection shall be carried out for performance test of individual
equipment/ sub-system/ total system and checking the dimensions with
tolerance as per the drawings.

2.1.11.5 The FOB items/ equipment shall be tested by the FOB supplier in their works
before dispatch. The test certificates shall be sent along with delivery of the
FOB items. Details of tests at FOB supplier's works shall be finalized jointly
by Contractor and Employer.
2.1.12 Other Miscellaneous Services
2.1.13 Project co-ordination relating to customs & port clearances, transit
insurance, claim settlement, inspection of Indian and foreign supplies,
construction planning and scheduling, erection planning and field
construction engineering shall be provided.
2.1.14 Periodic progress report shall be prepared and submitted by the Contractor
as per mutually agreed format between Contractor and Employer.
2.1.15 Quality control & time schedule control of site work & for manufacturing,
fabrication, procurement at Indian & foreign works shall be in the scope of
Contractor.
2.1.16 Implementation Schedule
2.1.16.1 The project shall be implemented within a period of 27 months from the
effective date of contract up to commissioning.
2.1.16.2 An indicative implementation schedule is shown at Annexure 2.1.16.2-1.
However, the Bidder may improve upon the same and submit a schedule
with their offer, showing all major activities, with respective duration
proposed keeping the total implementation period with in 27 month.
2.1.17 Area wise scope of work has been elaborated in the subsequent clauses of
the chapter 2.

2.2 PROCESS AND TECHNOLOGY
2.2.1 The existing process flow for casting of liquid steel is given below:
i) After tapping from BOF, the liquid steel shall be treated in ladle furnace
and then shall be transported to ladle turret of slab caster with the help
of EOT crane.
ii) For smooth operation of slab caster, the liquid steel shall have desired
degree of superheat above liquidus temperature.
iii) Steel ladle shall be placed on the ladle turret of the slab caster. Shroud
shall be fixed by shroud manipulator. Tundish shall be brought to the
casting position with the help of tundish car. The tundish shall be
positioned accurately above the mould and ladle slide gate of the ladle
shall be opened to allow the flow of liquid steel in to tundish. After
reaching the desired level in tundish, nozzle of the tundish shall be
opened and metal shall be allowed to flow in to the mould through
submerged entry nozzle (SEN)/ submerged entry shroud (SES).
iv) When the metal level in the mould reaches 100-150 mm from top,
drives of oscillation mechanism as well as roller segments unit shall be
switched on. The withdrawal of dummy bar shall start immediately.
After casting, the slag remaining in the steel ladle shall be dumped and
handled as per prevailing practice.
v) Metal level in the mould (meniscus) shall be measured with the help of
Automatic Mould Level Control (AMLC) during casting operation.
Mould lubrication shall be done with the help of casting powder. The
partially solidified strand after leaving the mould shall pass through
the strand guide roller segment where it shall be further cooled by air-
mist cooling. The dummy bar shall be separated from the hot strand
just after the roller segments unit and the cast strand shall be cut into
slabs of desired length by Oxy-Propane flame. The strand shall pass
though soft reduction to provide better internal soundness.
vi) Slabs shall be lifted by EOT crane and piled in the storage area. The
slabs shall be inspected in the storage area and then shall be loaded
on the railway wagon for transport to the Rolling Mills or for despatch
to sister plant/ direct sale.
vii) Tundish movement: Capacity of tundish for Caster #4 shall be 38 ton
(overflow) and it should be such designed so that the existing 80t
cranes of NP bay can handle it. In normal operation, tundish from
Caster #4 shall be brought by existing tundish car track from NP bay
to KL bay and shall be taken by the new EOT cranes to proposed

tundish repair area in KL bay. Caster IV, tundish preparation shall be
carried out at existing tundish preparation area of Caster# 3. Ready
tundishes shall be following the same route backwards. The existing
track shall be extended to KL bay and full tundish shall be transported
with the EOT cranes in KL bay (new crane of 100/10t being provided)
to the ladle repair area.
viii) PC room which is under erection is fouling with the proposed tundish
car extension to KL bay. The room shall be relocated or raised by the
bidder suitably to allow movement of tundishes on the car.
ix) A new mould & segment repair shop (MSRS), equipped with required
equipment and facilities, shall be provided for repair & maintenance of
the mould & roller segments of the proposed caster including
associated facilities. Moulds and segments shall be transported
between casting shop of SMS-II and MSRS by road with tractor - trailer.
x) Existing tundish repairing facilities at LM bay shall be shifted to
adjacent KL bay. Ladle repairing facilities at KL bay, some of the
facilities shall be dismantled and some of the facilities shall be
relocated to create space for installation of tundish repairing facilities
for Caster# 1, 2 & 4.
2.2.2 Production Plan
New slab caster shall have the potential to produce at least 1.0 Mtpa of cast
slabs of commercial and value added steel grades. The Caster #4 shall make-
up the existing shortfall in the production and shall also cast additional
quantity as required.
The proposed Ladle furnace shall feed liquid steel to Slab Caster # 4 as well
as casters # 1 & 2.
2.2.3 Grades of Steel
Following main grades of steel shall be produced in SMS-II:-
Boiler Quality, Extra Deep Drawing (EDD), Structural steel, steels for SWPP /
ERW PP / Tin plates / Galvanised sheets, Chequered plates, commercial
quality of steel, API-grades, SAILMA, HSLA etc.
2.2.4 Layout of Shop and Location of Proposed Facilities
New caster- Caster# 4 shall be located in the proposed extended portion
next to existing Caster #2 location. New Ladle Furnace shall be located in
LM bay (existing tundish repair area). Both these facilities shall be designed
for processing heats in sequence casting mode. The proposed locations of
Caster# 4 and Ladle Furnace have been shown in the drawing no. CET RN
4179 ST0 00 001 R=3. The turret of Caster# 4 shall be near the existing

column N31. To accommodate the new caster and associated facilities, LM
& MN bays shall be extended by 32m, NP & PQ bays by 76m, QR bay by
44m and R’S bay shall be extended by 47m.
Dimensions shown in these enclosed drawings, pertaining to extension of
building and also stated above are minimum requirement. Extension of bays
over and above the minimum requirement shall be finalized as per the basis
of system design, technological, process and other requirements.
Following points are to be noted:
a) The New caster and associated auxiliary facilities shall be
accommodated within the available space as shown in the layout
drawing. Orientation of auxiliary facilities may change but shall be
restricted to the available area as shown in the drawing.
b) The Ladle furnace location in LM bay has also been shown in the Layout
drawing. However, a more suitable layout of the same may be
proposed by the bidder in the available space considering the actual
site condition to feed the treated liquid steel to the existing casters as
well the new caster without any logistic issues.
2.2.5 Main Technological features of slab caster and ladle furnace units envisaged
in this project as are follows :
Technological Features of proposed continuous slab caster:
Item / Parameter Description
No. of slab caster & 1, Single-strand
strand
Heat size (liquid steel) 150 t (nominal); 165 t (maximum)
Tundish practice Hot tundish practice, Flying Tundish practice
Tundish Capacity 36/38 t
Machine radius As per design; multi-point unbending
Pass line level Above shop floor
Mould Straight mould, plate type
Width adjustment Remote Adjustable Mould for on-line width
changing
Slab thickness M/c designed for 210-250 mm
Cast thickness : 220mm & 250mm
Mould width Automatic on-line width changing device
Slab width (cold) 1050 – 1850 mm
Slab Length 6000 – 10500 mm
Tentative casting speed a) LC grade- 2.0 m/min
b) MC grade – 1.6 m/min
c) Alloy steel – 1.4 m/min

Casting Time Approx. 35-45 minutes (depends on casting grade)
Machine preparation 50 minutes; (bottom fed)
time
Caster yield 98.5%
Stream protection Refractory shroud between ladle to tundish and SEN
between tundish to mould. Shroud lancing bucket
Dummy bar Chain link type bottom fed
Non-radioactive type Automatic mould Level control
Mould level control
Mould Oscillation Hydraulic design, adjustable stroke, oscillation
frequency linked to casting speed suitable to Quick
Change practice
Secondary cooling Multi zones, high-pressure automatically controlled
spray/ air mist cooling system, dynamic control of
cooling water flow w.r.t. casting speed
Segment removal By EOT crane
Withdrawal and Multi point straightening, hydraulic pinching,
straightening unit modular design
Single split rollers Secondary cooling zone
Slab cutting Oxy-propane torch cutting machine
Slab marking Slab marking machine; Aluminium spray type
Control PLC based system
Process control Computerised process control
Other features - AMLC system,
- Break-out prediction system,
- Electro-magnetic Brake (EMBR)
- Process Control software / models,
- Soft Reduction system,
- Slag detection system,
- Strand monitoring system
- Slab marking system
- Slab tracking system and yard management
system
- Continuous temperature measurement system
in tundish to enable dynamic soft cooling
- Any other model as per technological
requirement.
- Quick Nozzle Changing (QNC) device in tundish
for long sequence

- Facilities for flying tundish
- Shroud Manipulators
- In addition to above features, any other feature
which will enhance productivity/ production/
maintenance; technological supplier/ bidder may
incorporate.
Technological Features of proposed Ladle furnace

The ladle furnace shall receive steel ladle in MN bay and shall be
transferred to LM bay by LF transfer car. All facilities and structures of the
LF unit shall be installed in LM bay. Existing facilities for tundish repair in
LM bay shall be relocated to KL bay to create space for ladle furnace
facilities. Ladle Furnace shall broadly consist of following equipment and
systems:
Sl. Feature Description
1 Furnace Rated power minimum 30 MVA considering
transformer heating rate of 50C/min
2 Ladle Roof Water Cooled, complete with Supporting System
3 Roof Lifting Hydraulic system
4 Electrode handling Electrode Masts and Arms & Electrode Holder and
Clamp System
5 Electrode storage Electrode Nippling and Storage Stand / Station
6 Ferro Alloy Feeding Ferro Alloy Feeding Arrangement (FAFA) complete
with overhead bunkers / bins, weighing, conveyors
etc.
7 Ladle Transfer Ladle Transfer Car, Transfer car track
8 Lubrication Centralized Lubrication System
9 Al / CaSi addition Al / CaSi Wire feeding system
10 Temperature Mechanized temperature measurement and
measurement and sampling lance system
sampling
11 Bath stirring Inert Gas Stirring System through quick coupling
12 Emergency lancing In-arcing emergency top lance system
13 Maintenance Hoists for maintenance

2.3 MECHANICAL
2.3.1 The Proposed Continuous Casting Machine (CCM) shall broadly consist of
following equipment and facilities:
Sl. Description Unit Quantity

1 Ladle Equipment
1.1 Ladle turret Set 1
1.2 Ladle cover Nos. 4
1.3 Ladle cover manipulator Nos. 2
1.4 Ladle slide gate operating mechanism Nos. 2
1.5 Ladle weighing system on turret Sets 2
1.6 Ladle slide gate lance Set 1
1.7 Ladle Shroud manipulator (Hydraulically Set
1
operated)
2 Tundish & Associated Facilities
2.1 Tundish car Sets 2
2.2 Tundish at casting station Nos. 2
2.3 Tundish cover (Split type) Nos. 2
2.4 Tundish stopper rod system Nos. 2
2.5 Automatic SEN/ SES changing device Nos.
2
(Hydraulically operated)
2.6 Tundish preheating station Sets 2
2.7 SEN/ SES preheating device Sets 2
2.8 Exchange SEN/SES preheating device Set 1
2.9 Tundish stopper rod along with operating No.
1
mechanism
2.10 Pulpit - operation of mechanical No.
1
equipment
3 Mould, Bender & Segment
3.1 Mould 220mm No. 1
Mould 250mm No. 1
3.2 Mould Cover (Fixed part) No. 1

3.3 Mould Cover (Movable part) No. 1
3.4 Mould Oscillator No. 2
3.5 Bender 220mm No. 1
Bender 250mm No. 1
3.6 Bow Segment No. 6
3.7 Straightener Segment No. 2
3.8 Horizontal Segment No. 7
3.9 Strand guide support structure No. 1
4 Machine Supporting Structure
4.1 Casting platform with columns
4.2 Ladle operator platform
Set As per
4.4 Slide gate connecting platform
technological
4.4 Stairs and access platforms requirement
4.5 Guides for segment exchange
4.6 Temperature and sampling platform
5 Break-Out Prediction System Covered
under PC&A
6 Emergency Equipment
6.1 Overflow box for tundish/ ladle (below the No.
1
tundish)
6.2 Splash protection system No. 1
6.3 Tundish emergency/ slag box including Nos.
2
cover (below tundish car)
6.4 Emergency ladle with slide gate No.
1
mechanism
7 Withdrawal Units and Straightener Segment
7.1 Sets As per
Drive rollers with gear box, coupling &
technological
universal joint and supporting structures
requirement
8 Dummy Bar System
8.1 Dummy bar transition piece 220mm Set 1
Dummy bar transition piece 250mm Set 1

8.2 Dummy bar head (4 nos. each for 220mm Nos. As per
& 250mm) requirement
8.3 Dummy bar receiver Set 2
8.4 Dummy bar head storage stand Set 1
9 Cutting & Crop Handling
9.1 Automatic torch cutting machine No. 1
9.2 Runway supporting structure Set 1
9.3 Emergency torch cutter Nos. 2
9.4 Crop & sample removing system Set 1
9.5 Automatic Length measurement system Set As per
technological
requirement
10 Run Out Equipment
10.1 Torch approach roller table
10.2 Torch cutting roller table
As per
Set
10.3 Run out roller table technological
requirement
10.4 Weighing roller table with weighing grid
10.5 Discharge roller table
10.6 Slab pusher & piler in dispatch bay Set 1
10.7 Roller table auxiliaries (moveable stop & Set As required
fixed stop )
11 Slab Handling Area
11.1 Slab pusher Set 1
11.2 Piler table Set 1
12 De-burring & Marking Equipment
12.1 De-burrer No. 1
12.2 Burr discharging device Set 1
12.3 Slab marking machine No. 1
13 Slab Inspection Equipment
13.1 Moulds and segment repair and storage Set As per
stands near caster requirement
14 New Mould & Segment Repair Shop (MSRS)

14.1 Mould alignment stand & templates Set 1
14.2 Mould dismantling stand Set 1
14.3 Ready mould storage stand Sets 4
14.4 Mould water testing stand Set 1
14.5 Bender- Loose side aligning stand Set 1
14.6 Bender- Fixed side aligning stand Set 1
14.7 Bender water testing stand Set 1
14.8 Ready bender storage stand Sets 4
14.9 Segment - Loose side aligning stand Set 1
14.10 Segment - Fixed side aligning stand Set 1
14.11 Segment dismantling stand (with tilter) Set 1
14.12 Hydraulic segment adjustment stand(HSA) Set 1
14.13 Segment water testing stand Set 1
14.14 Ready segment storage stand Sets 7
14.15 Bearing washing facility Set 1
14.16 Common hydraulic system for operating Sets 1
mould, segment tilting stand and segment
HSA stand
14.17 Special tackles and chain ropes for Set
1
handling mould / bender / segments
14.18 Mould measuring instruments Set 1
14.19 Online Strand monitoring system (Digital Set
1
type) etc.
14.20 Laser alignment system for mould, bender Set
1
and all the segments
14.21 As mentioned
in
Machine Tools
subsequent
clause
15 Lubrication Systems
15.1 Set As per
Centralized air oil lubrication system
requirement

15.2 Centralized / Portable grease lubrication Set As per
system requirement
16 Oil Hydraulic Systems
16.1 Hydraulic system for casting machine
16.2 Hydraulic system for ladle slide gate
Set
16.3 Hydraulic system for ladle to tundish
shroud manipulator
As per
16.4 Hydraulic system for mould oscillator
technological
16.5 Hydraulic system for slab turnover device, requirement
pusher, piler etc.
16.6 Hydraulic power unit for machine
maintenance
16.7 Hydraulic power unit for tundish tilting
16.8 Portable Nitrogen compressor Nos. 2
16.9 Electrostatic oil cleaner ( 1 no. per each Nos.
6 (minimum)
system)
16.10 Online particle counting machine Nos. 2
16.11 Special tools & tackles for hydraulics Set 1
17 Operational Spares
17.1 Tundish Nos. 6
17.2 Tundish cover (Split type) Nos. 12
17.3 Tundish stopper rod mechanism Sets 4
17.4 SEN/SES change device Sets 2
17.5 Overflow box Nos. 4
17.6 Splash protection system No. 1
17.7 Tundish emergency/ slag box No. 1
17.8 Dummy bar chain Set 2
17.9 Dummy bar transition link Nos. 2
17.10 Dummy bar head ( for each section of slab) Nos. 6
17.11 Crop and sample box Nos. 1
17.12 Burr box (at de-burrer) Nos. 1
17.13 Mould 220mm with Ni alloy coating No. 4

Mould 250mm with Ni alloy coating No. 2
17.14 Mould Cover (Fixed part) No. 1
17.15 Mould Cover (Movable part) No. 4
17.16 Mould Oscillation System No. 1
17.17 Bender No. 4
17.18 Bow Segment No. 2
17.19 Straightener Segment No. 2
17.20 Horizontal Segment No. 2
17.21 Narrow face chamfered type assembly with Nos.
water jacket and copper plate 250 mm size 2
for converting 220mm to 250mm size
17.22 Spares for converting 220mm to 250mm Sets
2
size
The above list is minimum and not exhaustive. The number of equipment
and facilities not mentioned above shall be provided by the bidder as per
technological requirement.
2.3.2 The proposed Ladle Furnace shall broadly consist of following equipment/
system;
Sl. No. Description Unit Quantity

1 150 t new Ladle Furnace Set 1
1.1 Transfer car 250t for LF unit with rail tracks Set
1
& pits
1.2 Water Cooled Ladle Roof Complete with Sets
Supporting System [One additional unit of
water cooled roof with doors and flaps but 1+1
without accessories]
1.3 Roof Lifting Arrangement Set 1

1.4 Arc Heating System consisting of Electrode Set 1
Masts and Arms & Electrode Holder and
Clamping System
1.5 Electrode Nippling and Storage Stand / Set
Station (One additional set of electrode
1
fixing Torque Wrench for electrode
Nipping/ handling facilities)

1.6 Ferro Alloy Feeding Arrangement (FAFA) Set 1
1.7 Wire feeding system (Aluminium/ copper / Set
café / CaSi) 1
1.8 Cutter near the guide for cutting the wires No. 1
1.9 Temperature measurement and sampling Set
Lance 1
1.10 Inert Gas Stirring System Set 1

1.11 Set As per
Hydraulic System requireme
nt
1.12 Centralized grease Lubrication System for Set As per
LF proper requireme
nt
1.13 Emergency top lance (Off line) Set 1

1.14 Set As per
Ladle lancing facility requireme
nt
1.15 Handling facilities at all required locations Nos. As per
for smooth operation & Maintenance requireme
nt
2.3.3 Handling Facilities

The handling facilities to be provided in various bays are as follows;
Sl. Description Quanti Main Aux. Hoist

No. ty Hoist Capacity
(Sets) Capacity (minimum
(minimu ) (t)
m) (t)
1 Double Girder EOT Crane in LM 1 50 10

bay
2 Double Girder EOT Crane in NP 1 120 20

bay
3 Double Girder EOT Crane in KL 1 100 10

bay with magnet on 10t hook

4 Double Girder EOT Crane in new 2 50 10
Mould & segment repair shop
(MSRS)
5 Pendant operated single girder 2 5 -

EOT crane at primary scale water
pump house
6 Double girder grab bucket crane 1 10 -

at primary scale pit (Cabin and
fixed pendant/RRC operated)
7 Pendant operated double girder 1 5 -

grab bucket crane at secondary
settling tank

Underslung crane at secondary
water pump house

Underslung crane at compressor
room
10 Cantilever crane in KL bay 1 5 -
11 Repair trolley (Double rail type) 1 10 -

for maintenance of 120/20t EOT
crane in NP Bay
12 Electric Hoist capacity for 1 1 -

maintenance of Grab bucket
crane in PQ bay (Scale pit)
13 Electric hoist at primary scale 1 5 -

water pump house
14 Electric hoist at ventilation room 2 2 -
15 Electric hoist at chiller room 2 2 -
16 Electric hoist at booster pump 1 2 -

house
17 Electric hoist for maintenance 1 7.5 -

of 100t/10t EOT crane in KL Bay
18 Electric hoist for maintenance of 2 5 -

50/10t EOT crane in Mould and

segment repair shop(MSRS)
19 Repair trolley (Double rail type) 1 12.5

for maintenance of 250+80/10t
EOT crane in MN Bay
20 Repair trolley (Double rail type) 1 5

for maintenance of 15+15t tong
crane in PQ bay

for maintenance of EOT crane in
QR Bay

for maintenance of EOT crane R’S
bay

crane at spray cooling pump
house
24 Trailer for sifting of segments 1 55 -

(Gross Vehicle Weight: 55t)

for maintenance of EOT crane in
LM Bay
The capacity and quantity mentioned above are minimum requirements and
indicative only. The handling facilities not mentioned above shall be
provided by the bidder as per technological requirement.
2.3.4 Goods cum passenger Elevator
Sl. No. Description Quantity (Nos.)

1. Goods-cum-passenger Elevator- 1t 01
Goods-cum-passenger Elevator shall be provided near caster platform.

2.3.5 Transfer cars
Sl. No. Description Quantity (Nos.)

1. Tundish transfer car -100t 01
2. Ladle transfer car for LF -250t 01
2.3.6 New mould and segment repair shop(MSRS)

A new mould & segment repair shop (MSRS) of minimum size 108m
length x 30m width x 12m crane rail height shall be provided to equip all
the testing & storage stands and machine tools for repair and maintenance
of mould, segment etc. The following machine tools shall be provided in the
new MSRS;
Sl. No. Description Quantity
(Sets)
1. CNC Lathe 2
2. High speed precision lathe 1
3. CNC Milling Machine for machining of both broad 1

& narrow face of mould
4. Vertical Milling Machine 1
5. Universal Drilling machine 1
6. Power Saw 1
7. Roll cladding facility including heat treatment 1

facilities
The machine tools mentioned above are minimum requirement and any
other machine tool required for repair and maintenance of mould and
segments shall also be supplied by the bidder.
2.3.7 New bulk oil storage shed
A new bulk oil storage shed of minimum size 54m x 14 m shall be provided
to equip hydraulic test bench, oil filtration system, spares, consumables etc.
The hydraulic test bench shall be installed in a separate brick wall enclosure
alongwith air conditioners inside the new bulk oil storage shed. Rest rooms
also shall be provided in the shed. The EOT crane (7.5t capacity) along with
accessories from old compressor house shall be installed in shed for
handling of equipment.
2.3.8 Shifting/ Dismantling/ Relocation/ New addition of equipment

2.3.8.1 The equipment, which are to be relocated from LM bay to KL bay are as
follows:
Sl. Description Dismantling Re-location and New
Quantity addition
(Nos.) (Nos.)
A Tundish repair facilities in LM bay

1. Tundish tilter 2 3 nos. new to be
(Tundish tilter of Caster #4 installed at KL bay
shall be similar to the existing ( 2nos. for Caster #1 &
tilter of Caster #3) 2 and 1 no. for Caster
#4)
2. Tundish de-skuller 2 Existing to be shifted
and re-installed
adjacent to tilter at KL
bay
3. Power pack in Hydraulic room 1 Re-installed at KL bay in
new hydraulic room
4. Tundish re-lining/ setting 11 8 nos. to be shifted to
stand KL bay, 2 nos. to be
suitably relocated in LM
bay and 1 no. to be
dismantled
5. Tundish stopper fitting stand 3 Shifted to KL bay
6. Jib crane (1 t) (for tundish 1 Shifted to KL bay
stopper fitting stand)
7. Tundish cooling assembly 4 Existing to be
dismantled.
3 nos.
[2 nos. new portable
type to be provided at
KL bay for Caster #1 &
2 and 1 no. for Caster
#4 in LM bay]
8. Tundish tackle hanger 2 Shifted to KL bay
9. Tundish cooler 1 Shifted to KL bay
B Passenger-cum-goods Elevator
1. Passenger-cum-goods Elevator 1 To be suitably relocated
(1t capacity) alongwith all
accessories, electrics etc.
2.3.8.2 The major equipment/ facilities, which are to be dismantled and relocated
are as follows and indicated in attached drawings CET RN 4179 ST2 00 001
R=3 and CET RN 4179 ST2 00 002 R=1;
Sl. Description Quantity Existing Relocated to

No. (set) Location
i). Hydraulic test 1 Bulk oil New Bulk oil

bench, oil filtration storage shed storage shed
system, spares,
consumables etc.

Milling machine, 1 Marco new Macro
ii).
Shaping machine, etching etching
spares & laboratory laboratory
consumables,
electric hoist (1t
capacity) etc.
EOT crane 1 Old air New Bulk oil
iii).
(7.5t capacity) compressor storage shed
along with station
accessories
Ladle cooler 2 KL bay KL bay
iv).
(col. No. 33- (tentatively
34) near col. no.
K 48- 49)
Ladle stand 3 KL bay KL bay
v).
(col. No. 34- (tentatively
35b) between col.
no. 51-53)
Ladle relining pit 4 KL bay near 4 nos. shall
vi).
col. 33-36 be levelled
off
vii). Cantilever crane 1 KL Bay KL Bay
(5t capacity) (Crane travel
to be suitably
extended for
Tundish and
ladle
handling as
per
requirement)
viii). Box for waste 2 KL Bay KL Bay
material (To be
suitably
relocated as
per
requirement)
Crane buffers stop As per Near gable To be suitably
ix).
requirement end relocated in
the bay
where shed is
being
extended

2.3.8.3 Laying of hydraulic pipelines from New bulk oil storage shed to Caster#1, 2,
3 & 4:
Laying, testing & commissioning of seamless tube NB50 schedule80
hydraulic oil pipelines along with associated clamps, valves, etc. shall be laid
from New Bulk oil storage shed to Caster# 1, 2, 3 & 4 as per requirement.
2.3.8.4 The dismantling of major equipment/facilities are as follows;
Description Quantity
Sl. No.
(set)
i. Cantilever crane of 5t capacity in LM bay 1
(tundish repair area)
ii. Automatic Ladle tilter in KL bay 1
iii. Mortar mixer in LM bay 1
iv. Mortar mixer in KL bay 1
2.3.8.5 Modification of existing Grab bucket crane in PQ bay over scale pit shall be
as per the details mentioned in chapter-3
2.3.9 Tundish repair facilities for Caster #4
The new facilities to be installed at LM bay & KL bay for Caster #4 are as
follows;
Sl. Quantity Location
Description
(Nos.)
1. Platform for existing tundish 1 KL bay
tilting stand
2. Tundish cooling fan (Portable 2 1 no. each at LM bay
type) & KL bay
3. Tundish SEN/ SES changer 1 KL bay
support stand
4. Tundish stopper rod harness 1 KL bay
stand
5. Tundish cover 2 KL bay
6. Tundish tackle hanger 3 1 no. each at LM, KL
and caster machine
bay

The quantities mentioned above are minimum requirements and indicative
only. The equipment not mentioned above shall also be relocated by the
bidder as per requirement.
2.3.10 Oil-Hydraulic System shall be provided as per requirement
2.3.11 Centralized grease lubrication system shall be provided as per requirement
2.3.12 Centralized air oil lubrication system complete with programmable control
unit shall be provided as per requirement.

2.4 UTILITIES
2.4.1 Bidder’s scope shall cover shifting work of existing utilities to create space
for installation of 4th slab caster as well as new facilities of 4th slab caster. The
scope is mentioned in subsequent paragraphs
2.4.2 Scope of Utilities involved in Shifting/ Re-Routing of Existing Facilities
The job involves rerouting of existing pipes and facilities which are presently
located where expansion of existing SMS-II shop is proposed. All utility
pipelines are presently supported in existing gable end. Further critical water
pipes as well as ventilation air are routed through water tunnel and
ventilation tunnel respectively. All these facilities are critical for the normal
operation of Caster # 1 & 2 and Ladle Furnace. Bidder shall specifically note
that proposed work shall be executed in a working brownfield environment
and requires rerouting of critical and also hazardous utility (propane, mixed
gas, Oxygen) system. Bidder's scope shall also cover design & engineering
of all proposed system and facilities under the scope of supplies. Location
of rerouted facilities and interfacing points shown in the attached layout
drawing are indicative. Final route & interfacing points may vary slightly and
shall be finalized during engineering and execution stage.
Bidder’s scope for utilities shall cover following:
2.4.2.1 New Chilled Water Plant and dismantling of existing chilled water plant
Existing chilled water plant consisting of 3x60 TR chillers along with
condenser cooling pumps (2 nos.), chilled water pumps (2 nos.) and roof
mounted cooling tower. The chilled water is supplied to various AHUs of
existing shop. For supply and return of chilled water, 80 NB insulated chilled
water pipes are employed. Existing chilled water plant and chilled water
piping are shown in enclosed Drg. No. PDR-141512 titled as “Chilled Water
Pipe Routes for various Air Handling Unit Rooms”.
This chilled water plant is fouling with the proposed shed extension of M- N
bay. Hence, a new chilled water plant shall be installed as explained in
subsequent paragraphs. Once this new chilled water plant is in operation,
existing chilled water plant along with associated system shall be dismantled
by the bidder.
For installation of new chilled water plant, existing macro-etching lab shall
be dismantled and area of approximately 16 m x 16 m shall be created. This
space shall be utilised for installation of new multi-storied ACVS building
with chiller plant in ground floor. The chilled water pipe shall be routed by
creating temporary supports and shall be routed through existing gable
end at column L-31. Initially the new supply and return

chilled water pipes shall be joined with existing piping at column N-31. After
installation of new gable end columns, new supply and return insulated
chilled water pipe shall be laid through new gable end columns at an
elevation of approx. +9 m.
Proposed chilled water plant shall have following minimum facilities-
1. Water cooled condenser based screw type chiller units with minimum
operating capacity of 120 TR. The chiller units shall be provided with
1w+1s. The standby shall be in addition to the operating capacity.
2. 2 nos. (1w+1s) condenser cooling pumps
3. 2 nos. (1w+1s) chilled water pumps
4. 2 nos. (1w+1s) cooling towers
5. Associated insulated chilled water piping and condenser cooling
piping
6. Material handling facility by 2t electric hoist arrangement in monorail
2.4.2.2 New Ventilation System and dismantling of existing ventilation system
In existing ventilation set-up (with ventilation chamber-I & II), two separate
washed air ventilation systems consisting of pre-filter, washing chamber, fan
and associated ducting have been provided. One system, catering to Caster
# 1 & 2, is consisting of 1x75 kW air washer fan. Second system having 1x45
kW air washer fan is catering to adjacent electrical building basement.
Existing ventilation system is fouling with proposed shed extension of M-N
bay. Hence, a new ventilation system shall be installed as explained in
subsequent paragraph. Once this new ventilation system is in operation,
existing ventilation plant along with associated system shall be dismantled
by the bidder.
The new ventilation system shall be installed in the first floor of new above
mentioned multi-storied ACVS building of approx. size 16 m x 16 m. A
common washed air system catering to both Caster # 1 & 2 and electrical
building basement shall be provided. A common over ground duct shall be
laid over electrical building for a length of approx. 30 m. Then this duct shall
be branched into two. One branch shall connect to underground duct for
electrical building basement and another branch shall connect to a new
ventilation tunnel underground duct for caster #1&2. This ventilation tunnel
shall be connected with existing ventilation tunnel as shown in the enclosed
layout drawing.
The major facilities shall cover following -

1. Spray chamber based washed air ventilation system with fan having
minimum capacity of 1,20,000 Nm3/h and discharge pressure of 200
mmWC.
2. Washed air chamber with spray nozzles
3. 2 nos. (1w+1s) spray water pumps along with piping, strainers, valves
etc.
4. Material handling facility by 2t electric hoist arrangement in monorail
5. Air intake louver with dry panel High Density Polyethylene (HDPE)
intake air filters for coarser and finer airborne suspended impurities
6. Over-ground insulated duct for a length of 30m from new ventilation
room to new ventilation tunnel
2.4.2.3 New Booster Pump House and dismantling of existing booster pump
house
Existing booster pump house catering to the requirement of flume flushing
of Caster # 1 & 2 is fouling with proposed shed extension of P-Q bay. A new
booster pump house shall be made below overhead conveyor gallery near
new column P-28. The pipelines shall be supported through new columns
along P-row at an elevation of +9m. After interface matching and
commissioning of rerouted pipes, dismantling of existing booster pump
house along with associated pipes shall be done. Dismantling of pipelines
shall also include overhead pipelines from scale pit to existing gable end in
axis-32.
The major facilities shall cover following-
1. Extension of suction header of booster pumps to new location
2. 4 nos. of booster pumps (1W+1S for each caster) having capacity 200
m3/h and head 40mWC
3. Associated pipes, valve and fitting. The pipe shall be internally lined
with basalt coating
4. 1t Manual chain pulley arrangement for booster pup handling
2.4.2.4 New Gable End Piping system and dismantling of existing gable end
piping
Due to shed extension towards scale pit side, existing pipeline headers
passing through gable end in axis 32 and 31 need to be relocated. Headers
of these pipelines are catering to the requirement of gases, propane, chilled
water, compressed air, water, steam and pneumatic sample conveying of
caster-1 & 2 and LHF. The pipes are further tapped from these headers at
columns and laid along rows for further distribution inside shop.

Existing gable end consists of column "L31-M31-N31-N32-P32-Q32-R32-
R’32A-S32". With proposed extension, new gable end shall consist of
column "L31-L29-M29-N29-N28-P28-Q28-Q29-R29-S29". After erection of
new columns of gable end, new pipeline headers for all these services shall
be erected at minimum elevation of +9m. New instruments similar to
existing utility lines for mixed gas, steam etc. shall be installed in new
pipelines as well. Further tapping from each header shall be taken at new
column locations and joined with existing piping system of various utilities
at existing gable end.
After interface matching and commissioning of new pipes and headers,
dismantling of existing piping headers at existing gable end shall be done.
Following drawings with respect to existing system are attached with this
document:
Sl. PDR No. Description
1 137801 Scheme of Inside Mixed Gas, Oxygen, Nitrogen,
Argon, Acetylene and Steam pipelines
2 141416 Water System- In-shop pipelines-Layout plans
3 141512 Chilled Water Pipe Routes for various Air Handling
Unit Rooms
2.4.2.5 New Steam Piping system and dismantling of existing steam piping
Steam pipe of size DN100 meant for supply of steam in other unit of RSP is
passing through gable end columns "R32-S32". A new pipe shall be laid at
minimum elevation of +9m by taking supports of new gable end columns
"R29-S29-S32". After interface matching and commissioning of new steam
pipe at R29 and S32, dismantling of existing steam pipe shall be done.
2.4.2.6 New Pressure Reducing Stations (PRS) of Oxygen, Nitrogen & Argon and
dismantling of existing PRS
Installation of new pressure reducing stations (PRS) of Oxygen, Nitrogen &
Argon having the same capacity & parameters as that of existing respective
PRS near existing air storage tank after extended shed in Q-R bay of column
29 shall be in the scope of the bidder.
After commissioning and establishment of successful operation of PRS for
all mentioned services and connecting it with Caster # 1 & 2, exiting PRS
shall be dismantled. Scope and specifications shall be as per details
mentioned in PC&A portion of this TS.

2.4.2.7 Water Tunnel Extension
Existing water tunnel carrying soft water for Caster # 1 & 2, soft water for
LHF and spray water for Caster # 1 & 2 is fouling with new turret foundation
of proposed caster#4 near existing overhead tank. This tunnel is also fouling
with proposed new column N-30. Considering this, existing water tunnel
shall be rerouted as shown in the enclosed layout drawing. New water tunnel
shall be made towards M-row after clearing space requirement for
foundation of turret of caster#4.
After interface matching and commissioning of all new water pipes in new
tunnel with the existing pipes, dismantling of existing water pipes shall be
done.
Following drawings with respect to details of existing water tunnel system
are attached with this document:

1 137690 Layout Plan at ±0.00 Level
2 138525 Water System-Water Supply Tunnels and Channels
Piping Erection details-Support Details
3 141409 Water System-Water Supply Tunnel and Channels-
Piping Erection Details for the Branch Tunnel and
Surface Channel at N-31
2.4.2.8 New Emergency Overhead Tank and dismantling of existing overhead tank
Existing emergency overhead tank catering to the emergency water
requirement of CASTER 1 & 2, LHF and spray water is fouling with proposed
caster#4.
A new emergency water tank having same volumetric capacity as that of the
existing one, shall be installed as shown in the layout drawing. The tank
bottom shall be at minimum +33 m elevation. Emergency connection with
supply lines of mould cooling, machine cooling, spray cooling and LHF shall
be connected with piping going through water tunnel nearby to proposed
emergency overhead tank location.
After interface matching and commissioning of piping connection along-
with establishment of successful working of all interlocks with new
emergency overhead tank, dismantling of existing overhead tank as well as
existing water pipe connection shall be done.
Following drawings with respect to existing emergency overhead tank and
piping connection are attached with this document:

1 141405 Emergency water Overhead Tank - Details of
piping Inside the shaft
2 141409 Water System-Water Supply Tunnel and Channels-
Piping Erection Details for the Branch Tunnel and
Surface Channel at N-31
2.4.2.9 Relocation of Water Trench & Valve Pit

Existing water pipes going through water trench near scale pit are fouling
with proposed column P-28a. This trench is further fouling with proposed
extension of grab bucket crane bay extension towards Q-row.
A new trench along with water pipes shall be made towards new gable end
and Q-row. After interface matching and commissioning of new pipes,
dismantling of existing pipes shall be done.
Existing water piping from scale pit are shown in enclosed Drg. No. PDR-
141511 titles as “Water System-Scale Channel and Surface Channel near
Scale Pit and Pump House-Plan and Sections”.
2.4.2.10 Shifting of pipe by raising elevation between N-31 and N-33 and providing
heat shield
Existing utility pipe such as water, air & gas are routed through existing
columns at N-31 and N-33 at approx. +9m elevation. These pipes are fouling
with turret on proposed caster#4. New pipes for these utilities shall be laid
at higher elevation (approx. +25m) and a heat shield shall be provided
beneath new pipes. After installation of new pipes, existing pipes shall be
dismantled.
2.4.2.11 Temporary support/ shifting of pneumatic sampling pipes and fire fighting
pipe between N-31 and existing chilled water plant
Approx. 12 numbers of pipes of fire water and pneumatic sampling are laid
between existing column N-32 and existing chilled water plant. The pipes
shall be supported temporarily during erection of new column N-30B. After
erection of new column, support shall be provided at column N-30B.
However, if shifting of these pipes are warranted for erection of column N-
30B, same shall also be under bidder's scope.
Existing piping details are shown in enclosed Drg. No. PDR-141449 titles
as “Water System - Fire-fighting Water Line to Analytical laboratory Building
Details”.

2.4.2.12 Duct for Ventilation of Hot Fumes from Scale Pit
Exhaust of hot fumes is presently done at +2m elevation at scale pit. A
suitable duct shall be laid along P-row and fume shall be discharged to
atmosphere after new gable end.
2.4.2.13 Relocation of Water Pipe

Existing over-ground water pipes are fouling with proposed new gable end
columns at Axis 28. New pipes shall be laid adjacent to the existing pipes
after clearing the space requirement for foundation of gable end columns
as well as material movement. After interface matching and commissioning
of new pipes, dismantling of existing pipes shall be done.
2.4.3 Scope of Utilities for New Caster#4, Ladle Furnace and MSRS
2.4.3.1 Utilities required for proposed Slab caster (CASTER#4), Ladle furnace (LF-
2D) and MSRS like Oxygen, Nitrogen, Argon, mixed gas, Propane gas,
compressed air and industrial water shall be tapped from the respective
takeover points and shall be transported up to the battery limits with
installation of necessary piping system. Details system description &
specification provided in chapter 3 of this TS shall be read in conjunction
with this scope. The scope shall broadly include, but not limited to, the
following:
a) Make up water system as per process requirement shall be provided
alongwith pumping & distribution facility.
b) Soft Water recirculation system with soft water make up plant (1W
+ 1S) along with industrial cooling water including pumping, cooling
tower, surge tank, chemical treatment facilities with “Zero discharge
concept” as per requirement.
c) A common RCC Emergency Overhead tank as per capacity
requirement with suitable partition shall be provided for Slab caster
(CASTER#4) and Ladle furnace (LF-2D).
d) Industrial water recirculation system with necessary water treatment
plant (WTP) comprising of scale pit, primary settling tank, secondary
settling tank, pumping system, pressure filters, cooling tower,
chemical treatment facilities etc.
e) Dedicated flume flushing system with 2 nos. of pumps (1W+1S)
f) Oxygen supply system as per process requirement.
g) Argon supply system as per process requirement.
h) Nitrogen supply system as per process requirement.

i) Steam supply system for as per requirement.
j) Pneumatic sample transport systems at Caster #4 and LF-2D units for
transportation of steel sample to existing laboratory.
k) Mixed gas for heating & Propane supply system for process
requirements.
l) Compressed air system with one working and one standby
compressors for process requirement and other applications.
Refrigerated type air dryers (1W + 1S) for process requirement in
compressed air circuit.
m) Transformer cooling system for LF transformers.
n) Taking tapping from individual supplies at the battery limits.
o) Provision of isolation valves at tapping points.
p) All piping to and from battery limits to consumer point along with
necessary trestles/ bridges etc.
q) All valves / valve stands within battery limits.
r) All control valves as specified in chapter on Instrumentation.
s) Mixed gas booster Fan and Reducing Valve as per system
requirement.
t) Electrics, automation & instrumentation for all the utility items.
u) Re-location of existing piping & utility system at the site of the
proposed facilities which are required to be done for completion of
the project within battery limit.
v) Interconnection of all the utilities with their existing supply network.
These interconnections shall be done during plant shutdown (as and
when provided) of respective units.
w) Dismantling of existing utility pipe lines, equipment and facilities
which are no longer required for the new facilities based on mutual
agreement.
x) Bidder shall indicate the quantity and working parameter of all the
utilities required in the proposed installations of slab caster
(Caster#4) and Ladle furnace (LF-2D).
y) Pump houses as per system requirement shall be provided for all the
pumps with under-slung crane in main pump house and electric hoist
for other locations.
Process flow diagram and complete detail of major equipment along with
material specification shall be submitted with the Bid.

2.4.3.2 Bidder shall design the water system in a manner that no water is wasted
and cause harm to the environment. Blow down water from the cooling
towers and backwashed water from the pressure filters shall be collected in
a sump and shall be pumped for slag cooling of BOF slag in slag yard.
Necessary pumping system along with pipes etc. shall be provided.
Depending over the water quality of back washed water and blow down
water may be used in the open loop air mist spray recirculation circuit after
necessary treatment. Treatment process and quality of water to be obtained
out of it shall be indicated by the Bidder. Slag cooling system including
piping, nozzles, pumps and handling system shall be provided in the slag
cooling yard. Zero discharge of liquid shall ensure no water discharge to
drain and to be utilised suitably
2.4.3.3 Pollution Control System
1. Pollution control system shall be provided for the proposed project in
such a way that it should not pollute the shop floor/ atmosphere as
per latest Central Pollution Control Board (CPCB) norms. All necessary
pollution control facilities such as fume collection hoods and ducts,
fans/boosters, stack; bag filters etc. shall be provided to take care of
the emissions from the proposed Ladle furnace (LF-2D).
2. Water system shall be designed for zero discharge. Necessary
treatment facilities if required shall be provided to re-use water.
3. Solid waste generated (scale/FES dust) from the system shall be
suitably utilised in the plant. Facilities for handling the same within
battery limit shall be provided by Bidder.
4. The Ladle furnace unit generates noise during arcing and ID fan
operation. The equipment / facilities shall be designed in such a way
that it shall not create sound pollution beyond noise level as per
OHSAS norms.
5. Fume extraction system in slab caster during slab cutting.
6. Suitable Dust suppression system in tundish tilting area.
2.4.3.4 Fire Fighting System
1. The entrance of all cables through the walls and floors shall be properly
sealed with fire resistant material of 2 hour rating. The fire resistant
material shall be UL listed/FM approved with UL certification.
2. Portable fire extinguishers shall be provided in all new installations,
electrical and instrument control rooms, PLC rooms, transformer
rooms, pump houses, ventilation rooms, hydraulic rooms, control

pulpits, control rooms etc. Type and quantity of fire extinguishers shall
be as per statutory /TAC norms/ BIS norms.
3. Existing fire fighting water in the CCS, SMS-II area shall be extended
for the new installations of water system of slab caster (Caster#4).
External hydrant posts in front of all the outside installations and
internal hydrant with hose reel, landing valves shall be provided for
inside installations as per TAC/ NFPA/ BIS norms. A dedicated new
pump house along with dedicated water tank, electric & diesel engine
driven pumps shall be constructed near water system of caster for
caster#4 proper and ladle furnace area. The area to be covered shall
include LM, MN, NP bay and columns 29 to column 34. Hose reel shall
be installed in each column.
4. Automatic clean agent gas based (IG-541) fire suppression system shall
be provided in main control room and associated PLC room as per
NFPA norms.
5. Automatic CO2 gas flooding fire suppression system shall be provided
in hydraulic rooms, oil cellars etc.
2.4.3.5 Air Conditioning & Ventilation System (ACVS)
The Air Conditioning (AC) & Ventilation system shall be provided in the
control rooms, electrical rooms and all other rooms required for the
proposed facilities of Caster #4 and LF-2D. Complete AC & Ventilation
system shall be included in the scope of supplies. However, some of the
installation areas of electrical and electronic equipment are listed below
where ACVS system shall be provided, which shall not be deemed complete:
i) Air Conditioning System
a) The following premises shall be air-conditioned to maintain room
temperature at 23+20C with 55+5% RH:
Sl. Premises Envisaged System
1. Intelligent MCC, PLC & Central chilled water based air
Control Room at Main Pump conditioning system
House consisting of chillers (nW+1S)
at one place and floor
mounted Air Handling Units
(1W+1S) near each air
conditioned premise.
2. VFD, Intelligent MCC,
PLC/DCS rooms, Level1,
Level2 server rooms,

Control Rooms, Soft starter,
UPS, control pulpits of
caster-4 and LF-2D
ii) Ventilation System

a) For Caster# 4 & LF-2D ventilation system and details of the
premises to be ventilated are as follows:
Sl. Premises Description of Proposed Ventilation

No. system
1 Transformer Exhaust ventilation System using heavy duty
rooms tube axial fan. Capacity to be decided for
maintaining premise at +50C above ambient
or 20 air-changes per hour, whichever is
higher
2 Pump house Exhaust ventilation System using heavy duty
(on ground) tube axial fan. Capacity to be decided for
maintaining premise at +30C above
ambient or 15 air-changes per hour,
whichever is higher
3 Battery room Exhaust ventilation System using heavy duty
tube axial fan. Capacity to be decided for
maintaining premise at +30C above ambient
or 20 air-changes per hour, whichever is
higher
4 Cable Push-pull ventilation System using
basement & centrifugal fan on push side and heavy duty
cable vaults tube axial fan on pull side. Capacity to be
and scale pit decided for maintaining premise at
pump house +30C above ambient or 15 air-changes per
hour, whichever is higher.
5 Switchgear Washed air ventilation system by means of
rooms air washer. Capacity to be decided for
maintaining premise at 350C or 15 air-
changes per hour, whichever is higher.
6. MCC Room Dry Pressurised ventilation
7. 33 kV VCB Dry Pressurised ventilation
room

2.5 REFRACTORY
The scope of work of the Bidder shall cover the following:
 Design of refractory
 Procurement, inspection, supply & storage of all refractory and
auxiliary material
 Erection and supervision of refractories
2.5.1 Design
Design & detailed engineering of refractory arrangement for the following
process equipment:
Continuous Equipment & Quantity Guaranty

casting shop For
supply of
refractory
Lining  Tundish (38 ton overflow capacity) – 8 nos. For 500
Refractories  Tundish cover – 8 nos. heats for
 Ladle cover – 2 nos. each
equipment
Casting  Ladle shroud and gasket For 500
Refractories  Tundish internal refractories (impact pad, heats for
well blocks etc.) each
 Tundish mono block stopper rod system equipment
 Tundish submerged entry nozzle/
submerged entry shroud
Other areas  Casting floor lining One set
 Slag box lining for each
 Overflow box lining equipment
 Emergency run-out trough lining
 Splash protection spray covering
 Mould cover lining
 Emergency ladle
 Ladle furnace roof – For delta portion
 Ladle transfer car for splash protection
 Ladle transfer car pit
 Protection lining of ladle transfer car
 Working platforms and columns near LF
etc.
 Hot gas generator
 Tundish dryer

2.5.1.1 Submission of the followings for all the equipment mentioned at TS clause
2.5.1 after placement of order:
 Refractory bricks shape album with complete dimension and quality
 Equipment wise bill of materials for all refractory materials and
auxiliary materials.
 Material specification for all refractory material and all auxiliary
material
 Complete set of refractory erection drawings
 Refractory erection instruction
 Refractory heating up manual
 QAP for refractories
2.5.1.2 Refractory lining of proposed slab caster shall be designed for following
lining life-
 Tundish: 10-12 heat sequence minimum.
2.5.2 Procurement, Inspection, Testing & Supply of Refractory & Auxiliary
Materials
a) Scope of work shall cover procurement, inspection & supply of all
refractory and auxiliary materials for all the equipment mentioned at TS
clause 2.5.1 as per the bidder’s design.
b) Bidder to supply all refractory materials and all auxiliary materials shall
be considered for initial lining along with lining required for
consumption of 500 heats.
c) Bidder to carryout inspection of all refractory material at manufacturer’s
premises as per latest IS standard or ISO standard. However, employer
reserves the right to cross-check the materials on receipt at RSP site
randomly basis.
d) The procured total quantity of materials shall also include the site
breakages, handling & erection wastes.
2.5.3 Handling and Safe Storage of Refractory Materials

a) Bidder shall responsible for unloading, storage, safe custody, loading,
transportation, handling and protection of all refractory and auxiliary
materials at storage, all the transit locations and the work site till
completion of work.
b) Bidder shall develop and construct suitable storage shed and open
space for storage of refractory & auxiliary materials required for this

project. Unloading, storage and safe custody of all refractory and
auxiliary materials till completion of work.
2.5.4 Erection & Supervision of Refractory

a) Erection and supervision of refractory lining of equipment mentioned at
clause 2.5.1 as per approved erection drawings.
b) All the refractory maintenance/ repair job for equipment till 500 heats
shall be done by the bidder.
c) Heating & commissioning of equipment refractory as per mentioned TS
clause 2.5.1.
d) Bidder shall be responsible for the project management of erection work
with proper and adequate supervision for ensuring progress of
refractory erection work, quality of workmanship and completion of
work as per schedule

2.6 ELECTRICAL
2.6.1 The scope of work of the bidder shall cover all individual electrical &
automation equipment and system with all related accessories and
auxiliaries for the successful commissioning of Caster # 4, a new ladle
furnace and MSRS. The scope also includes dismantling and removal of
existing electrical equipment and cables that are not required.
2.6.2 Detailed Scope of Work for enabling job:
The Bidder's scope of work shall broadly include but not limited to the
following:
1. Electrics for relocated Chiller plant and ventilation Lot
system:
Electrics at existing Auxiliary Electrical room no. 4
(AER-4) shall be dismantled and new electrical
equipment similar to existing electrical equipment
at AER-4 shall be provided at new room at second
floor of proposed ACVS building.
Presently AER-4 is having PDB and MCCs for chiller
plant & ventilation system, illumination system etc.
Relocated AER-4 shall have new PDB and MCCs for
the new chiller plant and ventilation similar to
existing system. Power source for the same shall be
taken from existing source at substation no. ILBDS-
5.
New chiller plant, ventilation room and AER-4 shall
have illumination, welding system and earthing
system.
Required power cables, control cables and
complete cabling arrangement for the relocated
chiller plant and ventilation shall be under the
scope.
2. Electrics for relocated macro etching laboratory Lot

Complete new electrical system shall be provided
for the relocated macro etching laboratory which
shall include electrical panel, cables, cabling
arrangement, illumination, welding system and
earthing system.

Power source for the same shall be taken from
existing source at laboratory above substation no.
ILBDS-5.
Electrics at existing macro etching lab shall be
dismantled.
3. Electrics for relocated booster pump house Lot
Electrics at existing booster pump house shall be
dismantled and new electrical equipment similar to
existing electrical equipment of the pump house
shall be provided at the new electrical room for
relocated booster pump house.
Relocated booster pump house shall have new
MCC and LCS. Power source for the same shall be
taken from existing source at LCSS 301 located at
substation no. ILBDS-5.
New booster pump house and electrical room shall
have illumination, welding system and earthing
system. Required power cables, control cables and
complete cabling arrangement for the relocated
booster pump house and associated electrical
room shall be under the scope.
4. Electrics for relocated Hydraulic oil and grease Lot
barrel store facilities
Complete electrical system shall be provided for
the relocated Hydraulic oil and grease barrel store
facilities which shall include electrical panel, cables,
cabling arrangement, illumination, welding system
and earthing system.
Power source for the same shall be taken from
existing source at LCSS-301 at substation no.
ILBDS-5.
Electrics at existing Hydraulic oil and grease barrel
store shall be dismantled.
5. Electrics for relocated Ladle cooler Lot
Shifting of complete existing electrical system of 2
nos. ladle cooler from KL bay (col. No. 33-34) to KL
bay (tentatively near col. no. K 48- 49)

Existing power supply source shall be utilized
New power & control cables as required and
cabling arrangement including cable trays/GI
conduits shall be considered
6. Electrics for relocated Mortar Mixer Lot
Shifting of complete existing electrical system of
Mortar Mixer (To be suitably relocated as per
requirement) in KL bay.
Existing power supply shall be utilized
New power & control cables and cabling
arrangement including cable trays/GI conduits shall
be considered
7. Illumination system including lighting distribution Lot
board, lighting fixtures, cables, conduits, cabling
arrangement, earthing etc. shall be provided for the
following facilities:
 New Overhead water tank (caster# 1 , 2 and
Ladle furnace)
 Area development for LF, fume extraction
system(FES) facilities
 PRS station lighting
 Ladle repair bay -area development
 New car parking shed, cycle stand & toilet
Power supply for new overhead tank and PRS
station shall be taken from the existing sources.
Power supply for above mentioned LF FES facilities,
area development, ladle repair bay area
development, car parking shed, cycle stand and
toilet shall be taken from new MLDB at proposed
HT/LT substation. Till installation of new MLDB,
temporary power supply arrangement including
cables shall be provided by the bidder. Nearby
power source for the same shall be decided in
consultation with employer.
Lightning protection and aviation lighting for
overhead tank shall also be under the scope.
LF fume extraction area and ladle repair bay area
shall have 63A welding socket with ELCB/RCCB.
Power supply for these welding socket shall be
taken from the WDB at proposed HT/LT substation
8. Complete electrics shall be provided for the new Lot

shop offices including PDB, lighting distribution
boards, LED illumination, ceiling fans in each room,
exhaust fans in toilets, earthing and lightning
protection system. Power source for one of the new
buildings shall be taken from existing source
presently feeding to office which shall be
dismantled. Power source for rest of the new office
building(s) shall be taken from new substation.
9. Existing cables shall be relocated at the Gable end Lot
of the Caster Shop for proposed extension of “LM,
MN, NP, PQ. QR and R’S bays” towards existing scale
pit side. Relocation shall include dismantling of all
the old cables at the gable end and replacing these
old cables with new cables from the existing source
points up to the existing destination points through
the relocated gable end.
A list of existing cables at the present gable end is
given at Annexure-2.6.2-1. This list is tentative for
reference. Bidder’s scope shall include any other
cable which is not mentioned in this list but required
for gable end shifting. For this, bidder shall assess
the requirement during site visit. Bidder shall also
provide 20% spare cable length above actual cable
requirement 20% spare power cables and control
cables more than the tentative cable requirement
mentioned in the Annexure- 2.6.2-1. Spare
quantity shall be for each type and size of cables.
The cabling shall include cable trays, GI conduits,
terminations, cable tray supports and other cabling
accessories.
10. Electrics required for any other facilities to be Lot

relocated and other new equipment to be installed
shall also be under the scope of bidder.

2.6.3 Detailed Scope of Work related to Caster # 4 proper, Ladle furnace
and Mould and segment repair shop (MSRS)
Bidder's scope of work shall broadly include but not limited to the
following:
Sl. Description Quantity
1. 33kV Power Source tapping for the new 33/6.6kV Lot
substation for Caster # 4:
33kV power sources for the new Caster # 4shall be
taken by extension of 33kV GIS switchboard at
substation no. LBSS-1. The extension shall include two
nos. feeders for caster no.4, one spare feeder and
sectionalizer for both buses. Required Relay & control
panels shall be also be under the scope along with all
accessories.
Single run of 400 sq.mm 33kV Al XLPE cable for each
feeder (total two runs) along with FO cables from
LBSS-1 up to new HT/LT substation along with all
cabling accessories shall be under the scope
Downstream power supply arrangement of caster
proper, ladle furnace, pump house and MSRS shall be
as per Single line diagram no. CET RN 4179 EE1 00
001, R=4.
2. 33kV Power Source tapping for Ladle Furnace: Lot
 33kV Power source shall be taken from MSDS-III
by extension of 3 nos. bays at section no.-I.
Suitable reshuffling of existing 33kV feeders shall
be done as detailed in single line diagram no.
CET RN 4179 EE1 00 002, R=0.
 Each 33kV outdoor bay at MSDS-III shall have
33kV outdoor circuit breaker, 2 nos. Isolators,
current transformers, Lightning arrestors, bay
marshalling kiosk, required bus work, insulators
and all accessories. All the equipment of 33kV
switchyard extension shall be similar as existing.
 Required Relay & control panels shall be also be
under the scope along with all accessories.
 Illumination, earthing & lightning protection
system for the 33kV bay extension area
 2 runs of 400 sq.mm (minimum) 33kV Al XLPE
cables along with FO cables from MSDS-III up to

new ladle Furnace along with all cabling
accessories shall be under the scope
 For ladle furnace auxiliary system, 6.6kV supply
shall be taken from new 6.6kV switchboard at
proposed HT/LT substation and shall be stepped
down to LT supply through dedicated
6.6kV/433V transformers. HT load shall be fed
from above mentioned 6.6kV switchboard
3. Ladle furnace transformer and associated system: Lot
 Ladle Furnace transformer with
accessories including Nitrogen based fire
protection system. The furnace transformer shall
be located in the transformer room. Oil soak pit
shall be provided for the LF transformer.
 One set of 33 kV, single bus GIS switchboard shall
be provided for power distribution to furnace
transformer circuit and capacitor bank. This
switchboard shall be provided at the incoming
side of furnace switch. This shall be installed in
the HT room of Ladle furnace. 33kV switchboard
shall have 1250 A GIS Circuit breakers for
incomer, transformer feeder and power factor
improvement feeder.
 Disconnecting switch: A 33 kV, 3-pole
disconnecting switch shall be provided for
isolation of ladle furnace circuit. The
disconnecting switch shall be equipped with key
interlock to prevent it being operated unless the
circuit breaker is open.
 33kV Furnace Switch: (Circuit breaker in a type
tested cabinet for furnace shall be suitable for
furnace duty application (similar to Siemens
make 3 AH4 with 120000 operating cycles). This
circuit breaker shall be rated for 1250A.
 Necessary 33 kV, CT's and 33 kV/110V PT's of
shall be provided for metering and protection
purpose
 An indoor type power factor (PF) compensation
equipment to improve power factor to minimum
0.92 shall be provided at 33kV voltage level. The
power factor equipment shall

comprise of capacitor bank, air cored series
reactors, isolator, surge arrestors, discharge PT,
busbar system, neutral CTs etc. These equipment
shall be located in the power factor compensator
room.
 Secondary current carrying system
 Electrode control and regulation system
 ID fan electrics
 Electrics for equipment/ item under the scope of
work
 Twin Battery charger for 220 V DC system with
Lead acid Battery bank (Plante type) for control,
protection, indication & annunciation. Suitable
DCDB shall be provided. AH capacity of battery
shall be decided as per calculation, such that 30%
spare capacity is kept.
Location for 33 kV HT Board, Power factor
compensation, etc.: New building for HT & LT
facilities for Ladle Furnace.
4. HT /LT substation for Caster# 4 and new Ladle Furnace.
To cater to the load of proposed caster proper, ladle
furnace and pump house a new HT /LT substation shall
be installed near proposed slab caster. Please refer
Single line diagram no. CET RN 4179 EE1 00 001, R=4.
The rating and number of the switchgears and
components as mentioned in the SLD is minimum,
however based on the load requirement, if higher
rating and number of switchgears and other items are
required, same shall be provided by the bidder. This
substation shall broadly comprise of
following (as minimum):
i) 33kV Isolator 2 nos.

ii) 12.5 MVA 33kV/6.9kV ONAN transformer with 2 nos.
Nitrogen injected fire protection system (NIFPS) and
NGR
iii) 6.6kV bus duct 2 sets
iv) 6.6kV switchboard 1 set
v) 6.6kV Isolator 8 nos.
vi) 2 MVA 6.6kV/433V dry type transformer 8nos.
vii) LT bus duct 8 sets
viii) LT switchboard 4 sets
ix) Battery, battery charger and DCDB 1 set
x) ACDB 1 no.
xi) RTU for provision of connectivity with existing SCADA 1 set
system of RSP. RTU shall have interface with new 6.6kV
switchgear
xii) Illumination system Lot
xiii) Earthing& lightning protection system Lot
xiv) 33kV bus tubes from 33kV Isolators to 12.5 MVA Lot
transformers
xv) 6.6kV cables, LT cables and controls cables along with Lot
complete cable laying arrangement, termination,
cabling accessories
5. LT substation for pump house Lot
i) 6.6kV Isolator 6 nos.
ii) 2 MVA 6.6kV/433V dry type transformer 6 nos.
iii) LT bus duct 6 sets
iv) LT switchboard 3 sets
v) ACDB 1 no.
vi) Illumination system Lot
vii) Earthing& lightning protection system Lot
viii) 6.6kV cables, LT cables and controls cables along with Lot
cabling accessories
6. LT substation for mould and segment repair shop Lot
i. 6.6kV Isolator 2 nos.
ii. 2 MVA 6.6kV/433V dry type transformer 2 nos.
iii. LT bus duct 2 sets
iv. LT switchboard 1 set
v. ACDB 1 no.
vi. Illumination system Lot
vii. Earthing& lightning protection system Lot
viii. 6.6kV cables, LT cables and controls cables along with Lot
cabling accessories. 6.6kV supply shall be taken from
spare feeders from existing 6.6kV switchboard of
LBDS-12 substation.
7. Emergency power supply arrangement as per Single lot
line diagram no. CET RN 4179 EE1 00 001, R=4 and
as explained in brief description at chapter 3.
8. Electrical equipment and facilities for slab caster,
Ladle furnace, pump house and MSRS as
mentioned below:
i. Intelligent Motor control centres (MCC) for process Lot
areas
ii. Non intelligent MCCs for non-process areas like Lot
ACVS, fire fighting etc.
iii. Power Distribution Boards ( PDBs) Lot
iv. VFDs for the mechanisms which require speed control Lot
v. Electronic soft starting system along with DOL bypass Lot
shall be provided for all the motors rated 90kW and
upto 200 kW for LT motors
vi. Electrical panels related to Hydraulic system, Lot
Lubrication/greasing system, auxiliary relay panel (if
required)
vii. HT & LT motors and actuators Lot
viii. Control desk/panel as per technological/ operational Lot

requirement.
ix. Local control stations Lot
x. Welding Distribution Boards ( WDBs) 4 nos.
xi. 415V, 63A welding sockets with ELCBs/RCCBs as per Lot
operational and technological requirement including
one welding socket on each of the columns in the
extended portion of the bays
xii. Lighting transformers 8 nos.

xiii. Main Lightning Distribution board 4 nos.
xiv. Electrical Panels/ Starters for Sump Pumps etc. Lot
xv. Complete illumination of all the areas under the scope Lot
of work (technological areas, new rooms, peripheral
areas, approach road), new rooms/ buildings, including
LDBs, SLDBs, SDBs, light fittings with lamps, cables,
ceiling fans, exhaust fans, 240V receptacles, 24V
network for hand lamps in all areas,
junction boxes, pull boxes, wiring, GI conduits, trays,
emergency lighting, switches, lighting GI wires, all
accessories.
All luminaires shall be divided in three categories of 24
hour, 12 hour and Emergency operation and the
distribution scheme shall be made accordingly.
24V A.C supply and 230V A.C supply Receptacles with
Socket, Plug & Switch of each type shall be considered.
xvi. Earthing and lightning protection of the all the areas Lot
under the scope of work
xvii. Field switches/ proximity switches, local isolating Lot
MCCBs for cranes & hoists
xviii. Parallel redundant uninterrupted power supply (UPS) Lot
system with VRLA maintenance free battery bank and
respective distribution boards. Two sets of battery
bank for each parallel redundant UPS shall be
provided. Back up time for each battery bank shall be
30 minutes. UPS rating shall be based on the load
calculation and 40 percent spare capacity. Number of
UPS system shall be finalized during engineering stage
as per operational requirement and location
xix. Supply & installation of complete electrics for the new Lot
EOT cranes, new cantilever crane and any other
handling facilities
Power supply arrangement of cranes is mentioned at
chapter 3 electrics.
The crane shall have Squirrel cage induction motor
with VFD drive. Crane shall have hardwired cabin
control and also radio remote control. The VFD panels
shall have air conditioning system.
For all process cranes , VFD redundancy shall be
provided such that in case of failure of one VFD, the
other VFD/VFDs should be able to run the system with
required speed and torque control
xx. Wherever additional cranes will be installed in the Lot

existing bay, DSL strengthening will be under the
scope, if required, based on additional load and
voltage drop calculation.
xxi. Complete electrics required for the crane to be Lot
relocated from existing compressor house to new bulk
oil storage building shall also be under the scope.
Complete electrics required for the cantilever crane to
be relocated for tundish and ladle handling as per
requirement shall also be under the scope.
Complete electrics shall be under the scope for
modification required in power supply arrangement of
existing scale pit grab crane. The scope shall include
modification in the DSL of grab crane, cabling (if
required) and associated accessories.
The scope of the electrics for the new cranes shall
include DSL and all the electrics for the crane proper.
Radio remote control shall be provided for the new
EOT cranes in addition to cabin operation. For the new
cantilever crane, radio remote control shall be provided
in addition to pendant operation.
The detail of the power supply scheme for cranes is

mentioned at chapter 3.0
xxii. Complete electrics shall be under the scope for all the Lot
maintenance hoists/repair trolleys for the new cranes
and other electric hoists under this project.
Tap off isolator shall be provided at working floor near
the hoist.
xxiii. Complete new electrics shall be under the scope for Lot
electric hoist for maintenance of existing grab bucket
crane at PQ bay.
Complete new electrics shall be under the scope for
electric hoist for maintenance of existing EOT crane at
MN bay.
Power supply source shall be provided for the same
with new cables and cable laying arrangement from the
new substation.
xxiv. Supply & installation of all electrics pertaining to ladle Lot
transfer car including cable reeling drum, local control
post etc.
For all transfer cars , VFD redundancy shall be provided
such that in case of failure of one VFD, the other
VFD/VFDs should be able to run the system
with required speed and torque control
xxv. Complete electrics for all repair and maintenance Lot

machines in new mould and segment repair shop.
9. Supply, laying and termination of all 33kV cables, 6.6kV Lot
cables, LT power & control, FO cables for cable
differential protection , signal cables, interfacing cables
with existing system and special cables for all items
under the scope of work. All incoming cables for the
panels, outgoing cables from panels shall be under the
scope.
10. Cabling arrangement: Lot
Preparation of route, cable installation materials like
MS painted ladder type cable trays, Galvanised
perforated cable trays, Galvanised steel conduits,
supporting materials for cables trays & conduits,
installation materials, hardware & accessories for cable
terminating and jointing, cable fixing, dressing, tag
numbers and route markers.
33kV Cable route for new Ladle furnace-

 From MSDS-3 to LBSS-6 cables shall be taken
through existing tunnel
 From LBSS-6 to KP-6 (near SP-3 ADMIN bldg.)
cables shall be taken through existing cable
tunnel
 From KP-6 to LBSS-5 tunnel entry, cables shall
be taken through existing overhead cable
gallery
 From LBSS-5 tunnel entry to substation no.46
(inside SMS-2), cables shall be taken through
existing cable tunnel.
 From substation no. 46 to substation ILBSD-5,
tunnel.
 From ILBDS-5 to new ladle furnace, cables shall
be taken through new cable tunnel proposed
under this project.

33kV Cable route for 12.5 MVA transformers -
 From LBSS-1 to KP-6 (near SP-3 ADMIN bldg.)
tunnel
 From KP-6 to LBSS-5 tunnel entry, cables
shallbe taken through existing overhead cable
gallery
 From LBSS-5 tunnel entry to substation no.46,
tunnel.
 From substation no. 46 to substation ILBSD-5,
tunnel.
 From ILBDS-5 to new HT/LT substation, cables
shall be taken through new cable tunnel
proposed under this project
In order to lay bulk cables between HT/LT substation
and the electrical buildings inside Caster area and ladle
furnace, new cable tunnels have been proposed which
shall be interconnected.
For cable laying from HT/LT substation to proposed LT
substation near pump house, overhead cable bridge
shall be provided.
Cable basements shall be provided below HT & LT
switchgears, MCC rooms. Cables shall be laid in cable
trays, GI conduits etc as per requirement.
Incoming cables for MSRS substation shall be laid
partly overhead and partly buried under ground.
Wherever required concrete cable trench shall be
provided.
11. Roof Top Solar Plant of 150kW capacity shall be under Lot
the scope without battery bank. Generated solar power
during day time shall be evacuated at the LT switchgear
level.
Roof top solar panels shall have polycrystalline PV cells
with required electrical interconnections with the
inverters. Required synchronization system along with
switchgears shall be provided for downstream power

evacuation through the LT switchgears.
Cleaning water supply arrangement for roof-top solar
panels shall be provided.
12. Construction of Electrical building and rooms as Lot
detailed in civil chapter
13. Complete Electrical system for Air conditioning and Lot
ventilation system as detailed in Utilities chapter
14. Miscellaneous items: Lot
a. Sump pumps alongwith complete electrics for the
basement of substations which are below ground
level
b. Complete electrics for Drainage pumps
c. Anti-static / epoxy insulated flooring suitable for the
application in all the electrical rooms.
d. Danger Boards and Shock Treatment Charts at
appropriate locations in English, Hindi and Local
language.
e. Portable Emergency Light Set in the Control Room
and MCC room (2 x 15 sets of portable Emergency
lights)
f. Fire extinguishers suitable for general, oil and
electrical fires, as required
g. Safety equipment like, insulating rubber mat, sand
bucket, danger boards, Caution Boards, Rubber
gloves, marker etc. as per IE rules
h. Furniture comprising of almirah, cabinet, chairs &
tables, wherever required for installation of PC,
Monitor & Printer shall be provided. HT & LT Sub-
stations shall also be provided with one table, two
chairs, two almirahs and one step tools.
15. Tools & tackles: Lot
 Measuring instruments: Digital multimeter, digital
2.5 kV & 5 kV Digital insulation megger with inbuilt
printer, Digital earth megger.
 Wrench, spanner sets etc.
16. Painting of all relevant installed equipment/ Lot
frame/structure etc. with red oxide primer and two
coats of finish paint.

17. Dismantling and shifting work: Lot
Dismantling of existing electrical equipment, cables,
lighting and other items wherever required shall be
under the scope of bidder
Dismantled items shall be transported to employer’s
stores.
Shifting of electrics for tundish repair facilities from LM
bay to KL bay. Existing power supply source shall be
utilized with new cables and cabling arrangement.
18. Preparation of drawings and documents and Lot

submission for approval
19. Relay setting and co-ordination Lot
20. Getting statutory clearances from the Government Lot
authorities shall be under the scope of bidder
21. Arrangement of Construction Power supply as Lot
mentioned in the SBD

2.7 PROCESS CONTROL AND AUTOMATION
2.7.1 Process control & automation system consisting of Control & measurement
system (Level-0), PLC system (Level-1) & Level-2 automation system for
Installation of Slab Caster (Caster#4), Ladle furnace and enabling facilities
shall be provided.
Level-2 process automation of proposed Slab Caster and Ladle furnace shall
depend mainly on execution of process model software. The application
software of various models shall be running on the system in online real time
environment. These models shall be executed through process computer,
which shall receive on-line process data from PLC system (Level-1). Level-I
system shall get the field data from field instruments (Level-0). Proposed
Level-II system shall be interfaced with the existing Continuous Casting
Shops/ BOFs/ Existing LFs/ RH-OB / ERP system for exchange of data and
proper coordination. . All the tasks shall be divided on hierarchical basis to
ensure maximum flexibility, reliability & availability of the automation
system. The hierarchy consists of following levels:
Level-0: Instrumentation system consisting of primary sensing elements,
transmitters, converters, gauges, panel instruments, final control elements
etc.
Level-1: Programmable logic controllers (PLCs) complete with operator
consoles, engineering stations / programming terminals, printers etc. The
tasks to be carried out by Level-1 system are as follows:
 Sequence and Logic control of drives,
 Loop optimization and set point control,
 Data acquisition,
 Report generation and event logging,
 On-line graphical display,
Level-2: The associated software with appropriate hardware like Process
control computer, peripherals, printers shall be associated as part of Level-
2 Automation with the offered schemes. Further, the offered automation
shall be hooked up with the existing network of CCS/ BOF/ LF/ ERP etc. with
network switch, patch panel etc.
The tasks to be carried out by Level-2 system shall be as follows:
 Execution of Process model software
 Data communication with Level-1 system
 Data logging

 Generation of MIS Reports and Graphics
2.7.2 Modes of Operation
The automation system shall have following mode of operation:
 Computer Automatic Mode
 Semi-automatic Mode
 Manual Mode
 Local Mode
2.7.3 Slab caster & Ladle furnace (Broad Scope)
Ref: Drg. No. CET RN 4179 CA1 00 001 R=0 for proposed system
configuration.
SL. DESCRIPTION QTY.

A) SLAB CASTER
1. LEVEL-0 automation system (Measurement and control
system)
For smooth functioning of Slab caster, area wise List of
measurement and control (minimum) is indicated below:
a) Mould Cooling system 1 Set
- Flow measurement and control for mould
cooling water (soft water)
- Inlet and outlet temperature measurement
for mould cooling water (soft water)
- Pressure measurement of mould cooling
water (soft water) with low pressure alarm
- Tank Level measurement
- Break Out Prediction System
- Control valves
- Any other measurement as required
b) Secondary cooling system 1 Set
- Flow measurement & control of secondary
cooling water (Industrial water) in branch
line.
- Pressure measurement of secondary cooling
water (Industrial water) in main line.
- Temperature measurement of secondary
cooling water (Industrial water) in main line.
- Mist air pressure control.
- Mist air flow control.
- Differential pressure measurement across
Heat exchanger
- Optical measurement of strand temperature
and it will be linked with level-2 model
- Back pressure measurement ahead of
nozzles for all designed spray loops
c) Closed circuit machine cooling 1 Set
- Flow measurement of machine cooling
water in main supply header.
- Local pressure and temperature gauges on
up-stream and downstream of pumps &
heat exchangers
Heat exchanger
- Tank Level measurement
d) Emergency cooling system
- Flow measurement (magnetic flow meter) of
machine cooling water in main supply
header.
- Local pressure and temperature gauges on
up-stream and downstream of pumps &
heat exchangers
Heat exchanger
- Tank Level measurement through ultrasonic
type level transmitter

e) Control & measurement of subsystems/ TCS :
- Media measurement
- temperature measurement and Oxygen
ppm measurement in Tundish
- Score board
- Strand surface temperature measurement
- Process data acquisition system
- Break Out Prediction System (BOPS)
- Argon shrouding system
f) Torch cutting station
- Pressure measurement and control of
Propane.
- Flow measurement of Propane.
- Pressure measurement and control of
Oxygen.
- Flow measurement of Oxygen.
- Suitable slab length and width
measurement system
- Online vibration monitoring system after ID
fan, pumps etc.
g) Weighing System:
Load cell based hopper weighing system shall
be provided with indication in the control room
for following subsystems:
- Ladle weighing system
- Tundish weighing system
- Roller table weighing system
h) Pump House & water treatment Plant
- Flow measurement & control.
- Pressure measurement
- Temperature measurement
Heat exchanger
i) Pressure Reducing Station (PRS)
- Flow measurement & control.
- Pressure measurement
- Temperature measurement
- Control Valves
j) Others
- Slag detection system in Ladle to Tundish
- Continuous tundish temperature
measurement and display with recording
- Dip type temperature measurement in
Tundish
- Disposable (sample & temperature) tips-
500 Nos.
- Lance & accessories for temperature
measurement (5 Nos.)
- Slab marking system etc.
2. LEVEL-I automation system

a) PLC system with Parallel redundant CPU, Lot
redundant communication, redundant Power
supply, redundant HMI servers, non-redundant
I/O system with remote I/O sub system, along
with necessary system & application software,
HMI screen, programming unit, operator station
& peripherals for the following:
- Safety & E-stop control system with zone
wise emergency stop system & key transfer
system
- Casting Platform with common & safety
functions
- Strand PLC
- Instrumentation system
- Marking system
- Torch cutting machine
- De-burrer
- Tundish preheating unit
- Argon shrouding control system
- Hydraulic system
- Mould level control
- Remote adjustable mould
- Hydraulic mould oscillation
- Hydraulic segment adjustment
- Pump house & Water treatment Plant (WTP)
- Any other system as required
b) Interface with subsystems, package units, High/ Lot
Medium voltage equipment control & Intelligent
MCCs
3. LEVEL-II automation
a) Level-II automation system consisting of 1 Set
redundant servers, HMIs, engineering stations,
work stations, Laser printers with following

process models (minimum):
i) Automatic Mould Level Control System
(AMLC)
ii) Dynamic solidification calculation model
iii) Secondary Cooling Model
iv) Break out Prediction System (BOPS)
v) Cut length optimisation model
vi) Quality assurance model
vii) Simulation model (on development
system)
viii) Any other model as required
Implementation of Industry 4.0 standard with
respect to data collection of each and every
parameter and utilising these data for the above
models shall be provided. However, the database
shall not reside on external cloud. Bidder may
offer any other Industry 4.0 standard
implemented till date in the area of Caster and
Ladle Furnace system and its subsystems.
b) Interface & communication of Level-II system Lot

with new PLC system of slab caster, LF & existing
plant automation network (BOF, CASTER LF, RH-
OB) and plant ERP system.
4. Servers/ HMI/ work station (minimum)
4.1 Level-I
a) HMI server with OPC driver 2 nos.
b) HMI client station 7 nos.
c) Emergency HMI client station 2 nos.
4.2 Level-II
a) Level-2 Server 2 nos.
b) Operator work station 2 nos.

c) HMI client 4 nos.
d) Engineering station 2 nos.
5. Network switches (minimum)
a) Layer- 2 edge switch Lot
b) Layer- 3 switch 2 nos.
c) Firewall & router / Unified threat Management 2 nos.
System
6. Supply & laying of Fibre optic cable and CAT-6 Lot
UTP cable
7. Software
a) All necessary Software like System software, 1 Set
antivirus with 3 years licenses, process models ,
application software along with media and
licenses, system monitoring software and
reloadable image backup software etc.
b) Network management software 1 Set
8. Peripherals (min)
a) Network A3 laser printer 1 no.
b) Laser A4 colour printer 2 nos.
9. Large LED display screen (52”) 1 no.

10. Control desks/local control desk
a) Main control desk for caster operation 1 no.
b) Control desk for Water treatment plant at pump 1 no.
house
c) Local control desks/ stations Lot
11. Networking hardware & accessories- LIU, media Lot
convertors, passive components, connectors etc.
B) LADLE FURNACE
12. LEVEL-0 automation system (Measurement and Lot
control system) for smooth functioning of Ladle

furnace, area wise List of measurement and
control (minimum) shall be as indicated below:
a) Fume Extraction system- 1 Set
- Temperature indication and control by
regulating dilution air damper.
- Temperature measurement with high alarm
at the inlet of Bag filter for operation of
safety air damper.
- Differential pressure measurement with
alarm across bag filter.
- Suction measurement and control through
fan air damper.
- ID fan motor winding & fan bearing
temperature measurement
- Vibration monitoring for fan & motor in
both the directions.
b) Inert gas (Nitrogen / Argon) Stirring System 1 set
- Pressure measurement (local indication)
with low pressure alarm both at Nitrogen /
Argon inlet and delivery points.
- Nitrogen / Argon pressure control through
self-actuated type control valve.
- Flow measurement and control
- Redundant Argon & Nitrogen pressure
control through PLC based PID control
c) Cooling Water System (both for industrial and 1 Set
soft water plant)
- Pressure measurement (local) at delivery of
all pumps
- High and low level alarm at emergency
overhead water tank

- Level switches for all sumps.
- Temperature measurement (local) at the
common water header
- Pressure measurement with low alarm at the
common water header
- Temperature measurement with high alarm
at the outlet of each branch line.
- Flow switch with low alarm at the outlet of
each branch line.
- Differential pressure switches across
strainers/filters/Heat exchangers.
- Flow measurement as per requirement.
- PH measurement at the outlet of soft water
plant.
d) Temperature Measurement and Sampling System 2 Sets
for molten metal:
- The system shall be complete with immersion
lance, measuring cable, traffic light, large
display, temperature & sampling tips (1000
Nos.), horn and related electronics. The
measuring lance shall be suitable for two-in-
one type disposable tip for temperature
measurement and sampling in single stroke.
e) Hopper Weighing System 1 Set

- Load cell based hopper weighing system shall
be provided with indication in the control
room
13. LEVEL-I automation system

PLC system with Parallel redundant CPU, 1 set
redundant communication, redundant Power
supply, redundant HMI servers, non-redundant
I/O system with remote I/O sub system, along
with necessary system & application software,
HMI screen, programming unit, operator station
& peripherals for the following:
i) Ladle heating Furnace automation
ii) Weighing & batching system
iii) Aluminium wire feeding system
iv) Argon stirring system
v) Fume extraction system
vi) Cooling water system
vii) Ladle car drive
viii) Emergency lance
ix) Sampling equipment
x) Hydraulic system
xi) Tap changer
xii) Electrode regulation system
Interface with Electrode regulation system, 1 set
Medium voltage equipment control & Intelligent
MCCs
14. LEVEL-II automation
a) Level-II automation system consisting of 1 set

redundant servers, HMI, engineering station,
work station, Laser printers with following
process models (minimum):
i. Ferro alloy addition model
ii. Electrode regulation model
iii. Heating Model
iv. De-oxidation model
v. De-sulphurization model
vi. Set Point Generation (Adaptation model)
vii. Process tracking model
viii. Any other model as required
b) Interface & communication of Level-II system 1 set
with new PLC system of LF, Slab Caster no-4 &
existing plant automation network (BOF, CASTER,
LF & LAB) and plant ERP system.
15. Servers/ HMI/ work station (minimum)
15.1 Level-I
a) HMI server with OPC driver 2 nos.
b) HMI client 3 nos.

c) Engineering station 2 nos.
15.2 Level-II
a) Level-2 Server 2 nos.
b) Operator work station 2 nos.
c) Engineering station 2 nos.
d) HMI client 2 nos.
16. Network switches (minimum)
a) Layer- 2 edge switch Lot
b) Layer- 3 switch 2 nos.
c) Firewall & router / Unified Threat Management 2 nos.

System
17. Supply & laying of Fibre optic cable and CAT-6 Lot
UTP cable
18. Software
a) All necessary Software like System software, Lot

process models, antivirus with 3 years licenses,
application software along with media and
licenses, reloadable image backup software,
system monitoring software etc
b) Network management software lot

19. Peripherals (min)
a) Network A3 laser printer 1 no
b) Laser A4 colour printer 2 nos.
20. Large LED display screen (52”) 1 no.
21. Control desk/local control station
a) Main control desk for LF operation 1 no.
b) Local control desk/station Lot
22. Networking hardware & accessories- LIU, media Lot

convertors, passive components, connectors etc.
C) Common facilities (For Caster & Ladle Furnace)
23. Furniture as Server rack, Work station table, Lot

printer table, ergonomically designed chair, steel
almirah etc. in all new control rooms & L-2 server
room.
24. Microprocessor based Fire Detection and Alarm Lot
System shall be provided for Slab caster, LF &
associated areas:
i) Control rooms, PLC / level-II computer
rooms
ii) Building for HT & LT facilities
iii) New Laboratory rooms
iv) Cable gallery
v) Other strategic locations
25. Telecommunication System for Slab caster, LF Lot
& associated areas as described:
a) Selective Loudspeaker Inter Com (SLIC)
system: SLIC system shall be provided to cover
major areas. The locations shall mainly include
the following places of the plant:
 Control rooms
 Working platforms

 Water treatment plant control room
 electrical sub-station buildings
 Shift offices
 Laboratory
 Other strategic location
b) Plant Telephone System
Requisite nos. of plant telephone connection
including telephone sets shall be provided in
proposed Slab caster & LF area. Required
cabling from nearest DP box of plant
telephone network shall also be included.
c) Walkie-talkie communication system
26. Closed circuit Television (CCTV) System Lot
Supply, installation, testing & commissioning of
CCTV Hardware, software, cable & connectors
for the entire area of Caster #4, Ladle furnace,
new control rooms, electrical sub-station, water
treatment plant, mould and segment repair shop
& associated facilities as required.
27. Supply, routing, laying and termination of Lot
communication, control, instrumentation,
screened, compensation and special cables as
required.
28. Minor Civil work as chipping, cutting, making Lot
foundation for panels/modification in existing
rooms and making good all damage thereafter to
facilitate cable laying. The work shall be deemed
complete only after restoration of the surface/
spot to original shape & finish by plastering,
painting etc.
29. Electronic earthing of all new equipment in Lot
accordance with the code of practice for earthing
as in IS: 3043-1987.
30. Special Tool & measuring instruments 2 sets

i) Meggar- 5 nos.
ii) Multimeters- 5 nos.
ii) HART calibrator- 2 nos.
iii) Tong tester for AC & DC- 2 no.
31. Necessary erection material for electrical Lot
equipment, PLC, panels, cabling & earthing
equipment.
2.7.4 Enabling work (Broad scope)
The scope of work for process control & automation shall broadly cover the
following items:
2.7.4.1 Provision of Control & instrumentation system such as flow measurement,

pressure measurement, pressure switch, pneumatic controller, magnetic flow
meter, solenoid valves, orifice plate, control valves etc. for the following units
:
Indicative list for measurement/instruments is given below:
2.7.4.2 New PRS (3 nos.) for Caster # 1& 2
a) Flow measurement
b) Pressure measurement
c) Pressure switch
d) Pressure Relief Valve
e) Pneumatic controller etc.
Two streams for each controlled media shall be considered. This will facilitate
changeover between lines without affecting the process.
2.7.4.3 Shop Inlet Measurement station for Mixed Gas
a) Flow & Pressure measurement for Mixed gas line, Argon, Oxygen
and Nitrogen
2.7.4.4 New Chiller Plant
a) Temperature measurement

2.7.4.5 New Overhead Emergency Tank (Caster # 1,2 & LF )
a) Level measurement by Ultrasonic level transmitters
b) Flow switch
c) Pressure switch
d) Interlocking with inlet valve
2.7.4.6 New Booster Pump House (Caster # 1,2)
a) Temperature measurement
2.7.4.7 ACVS System
a) Temperature gauge
b) Pressure gauge.
2.7.4.8 Interconnection of Analog signals (4-20mA) and Digital signals of various

instruments of new PRS, shop inlet measurement station for mixed gas, any
other facilities to be relocated etc. to Caster # 1 & 2 PLC.
2.7.4.9 Supply, laying and termination of instrumentation, signal, power and control
cables, special cables, heat resistant cables as required, cable laying
accessories like trays, G.I. protection pipes, supporting structures, clamps and
other cable laying accessories, identification ferrules, etc.
2.7.4.10 Above instrumentation cable, signal, power, control cable, junction boxes,
impulse pipes considered for the instruments coming under new units shall
be installed / laid upto the existing BOFs / Casters / LF & RH units as per
requirement.
2.7.4.11 Relocation of existing cables shall be done at the Gable end of the Caster
Shop for proposed extension of “LM, MN, NP, PQ, QR and R’S bays” towards
existing scale pit side. Relocation shall include dismantling of all old cables
at the gable end and replacing these old cables with new cables from the
existing source points upto the existing destination points through the
relocated gable end.
List of automation cables listed below & given in Annexure-2.6.2-1 shall be

changed. This list is tentative for reference. Bidder’s scope shall include

any other cable which is not mentioned in this list but required for gable
end shifting.
i) DEC Net Cable (Thick-wire): From LHF2A control room to SMS2 RCL
level-2 computer room.
ii) Single Mode FO Cable:
a) From LHF2B control room to SMS2 RCL OES room.

b) From LHF2C control room to SMS2 RCL OES room.
c) From RHOB control room to SMS2 RCL OES room.
d) From Caster-2 control room to SMS2 RCL OES room.
e) From BOF computer room to SMS2 RCL level-2 computer room.
2.7.4.12 Provision of Electronic earthing system with dedicated earth pits for new
equipment as per IE rules.
2.7.4.13 Accessories as Instrument panels, transmitter cabinets, field termination

racks, auxiliary racks for housing various instrumentation equipment
completely wired as per requirement, junction boxes, mounting accessories,
electrical and mechanical accessories like terminal blocks, terminal units,
panel illumination equipment including lamps, panel exhaust fans, door
switches etc. Power supply and distribution equipment, transmitter supply
units, circuit breakers etc. as required.
2.7.4.14 Approach platforms for all remote field Instruments for maintenance.
2.7.4.15 All Panels for housing servers/HMI/PCs etc shall have locking system.
2.8 C&IT
Void

2.9 STRUCTURAL
The scope of structural steelworks described below gives general description
of structural steel works under the bidder’s scope of work. The structural
steelwork shall not be limited to these but shall be guided by technical/
technological aspects for the total scope of the work.
2.9.1 Design, engineering, supply of raw materials, fabrication, erection, painting
including supply of paint, testing of structural steel works for the following
works:
2.9.1.1 Dismantling and modification of structures
1) Dismantling and modification of existing column bracings between
columns L39 and L40 for creating passage of tundish transfer cars from
LM bay to KL bay.
2) Dismantling of existing lift well structures.
3) Dismantling of existing platforms, cross overs, stair/ ladders, handrails
etc. in the existing tundish repairing area as per technical/
4) Dismantling of existing gable end structures along with sheeting work
for LM & MN bay along axis 31, for proposed extension of the LM &
MN bays.
5) Dismantling of existing side sheeting work on row N between axis 31
& 32, gable end structures including sheeting work between N & P on
axis 32, structures for handling facility, column no. N-31, roof truss,
roof girder, crane girder, auxiliary girder, chord bracing, roof sheeting
work etc. as is necessary for dismantling of column no. N-31 for
proposed extension of NP bay.
for PQ & QR bay along axis 32, for proposed extension of the PQ &
QR bays.
for R’S bay along axis 32A, for proposed extension of the R’S bay.
8) Dismantling of existing trestle, pipe supporting bridges, structures for
PRS system and other associated structures for proposed shed
extension.
9) Dismantling of existing old compressed air station (store) structures
for proposed extension of the shed.

10) For existing scale pit area, grab bucket crane girder, column structures
shall be partly dismantled to enable erection of new P-row column, but
after erection of the same, the existing crane girders shall be re-
installed with necessary modification, if any, as per requirement,
Existing grab bucket crane supporting structures shall be extended
suitably towards Q row.
11) Dismantling of existing pipe supporting bridges presently through the
gable of the building, providing temporary supports wherever required
and then routing the pipes through the building columns in the line.
12) Dismantling of existing staircase between column no. M32 and M33
and rebuilding of the same at a suitable location.
13) Dismantling of all existing structures/ shed complete in the proposed
area for construction of new mould and segment repair shop.
14) Dismantling of existing temporary structures, parking sheds, cycle
stands and miscellaneous structures for proposed facilities with in
battery limit as per technical/ technological requirements.
2.9.1.2 New structures
1) Extension of existing SMS-II building towards scale pit area as shown
in the drawing no. CET RN 4179 ST2 00 001 R=3. While extending the
building, profile shall be kept similar to the existing one. Crane level
walkway arrangement, lighting walkway shall be similar. Chequered
plates shall be provided for steps with nosing. Grating shall be
provided for lighting walkway. For the extended part, structures for
crane maintenance handling facility along with maintenance platform
/ walkway, access staircase / ladder shall be provided at a suitable
location as per technological requirement. Envisaged extension of
various bays is as follows:
a) LM & MN bay beyond axis 31 with existing EOT cranes of capacity
50 t & 250 t respectively and these cranes shall operate in the
extended portion also Existing roof trusses from which monorail
and lighting walkway system are to be supported shall be
checked for additional loading only.
b) NP and PQ bay beyond axis 32. Top of crane rail for the extended
part of the PQ and NP bay is envisaged at the same level as
existing. One no. new EOT crane of required capacity is envisaged
in extended NP bay. This new EOT crane is envisaged for
operating in the extended part of the NP bay between proposed
axes 31A and 28 only. Necessary arrangements for

restricting the new crane of NP bay within the extended part of
the building shall be provided by the bidder.
c) QR bay beyond axis 32 and R’S bay beyond axis 32A. Existing
shop cranes shall run in the extended part also.
The major structures shall include columns, column bracings, roof
structures, gable end structures, crane girder, crane level
walkway, maintenance platform, lighting walkway, gable end
platform, roof, side & gable end sheeting (CGS) along with access
stair, ladder, handrails & structures for handling facilities etc.
d) Modification in relevant columns of K row for accommodating a
new cantilever crane.
At all bays, expansion joint shall be provided between existing &
new building. Crane run way shall be made continuous. Based on
the detail of end of existing girders, cantilever or suitable
arrangement shall be provided for new crane girders.
2) Monorail for handling facility along with supporting structures in KL
bay, as per technological requirement.
3) Necessary structural works and load due to solar panels shall be
considered on the roof of extended part of the caster shed. Loading
for installation and maintenance for the same shall also be considered.
4) New bulk oil storage shed size as per technological requirement along
with CGS sheet for roof and sides. The building shall have necessary
arrangements for handling facilities. Major structures shall include
columns, column bracings, roof structures, gable end structures, crane
girder, crane level walkway, maintenance platform, gable end platform,
access stair/ ladder, handrails & structures for handling facilities etc.
5) Pipe supporting trestles, bridges, walkway all along. Access ladder/
staircase and platforms at suitable locations. Supporting structures for
pipelines from shed structures (both old and new).
6) Heat shield shall be provided as per technological requirement.
7) Structures for handling facilities of New Booster Pump House, ACVS
building as per technological/ technical requirement.
8) Structures for Ferro Alloy & Flux addition (FAFA) system, bunkers &
weigh hopper including maintenance & working platforms, stairs,
walkways, handrails, toe-guards etc. All walkways & bunker tops shall
have gratings for safety & cleanliness.

9) Structures for new pollution control systems in LF: The major structures
to be considered are Bag filter supporting structures, ID fan shed with
handling facility, CGS sheeting for roof, side & gable, translucent sheet
in wall area for daylight working conditions and uniform illumination
in the inside part of the shed, mixing chamber supporting structures,
maintenance platforms, walkway, access stair, ladder, handrails etc. &
other structures as per technological requirement.
10) Self-supported steel chimney with structural staircase up to sampling
port level, ladder, lifting beam etc. as per CPCB norms and
11) Duct & cable tray supporting trestles, bridges, pipe trestles, pipe
bridges including access stair, ladder, platform & handrail etc. as per
12) Fume extraction duct for new LF shall preferably be routed through the
two legs of the bay columns in the extended portion of the shed or as
per technological layout..
13) Structures for handling facilities in the new pump house for fire-
fighting arrangement.
14) Structures for cable gallery (covered at top and open on all other three
sides) with walkway all along, access staircase/ ladder at suitable
locations & safety handrails etc.
15) Connecting platform/ walkway from existing operating platforms of
Caster # 1 & 2 to operating platform for Caster #4 with necessary
safety handrails, access ladder/ stair etc.
16) Crane girder structures with crane rail, crane level walkway, gable end
platform and structures for handling facilities, access stair, ladder &
handrails etc. for the following buildings:
a) Primary scale water pump house.
b) Secondary scale water pump house.
c) Chiller plant.
d) Ventilation room.
e) Spray cooling pump house.
17) Structures for the new open gantry for grab bucket crane of adequate
capacity over the secondary scale pit and primary scale pit area along
with structures for handling facilities, access stair, ladder & handrails
etc. Necessary maintenance bay shall be provided with roof covering.

18) New mould and segment repair shop of size as per requirement.
Translucent sheet in wall area shall be provided for daylight working
conditions and uniform illumination in the inside part of the shed. Rest
portion of the wall and the entire roof shall be covered with CGS
sheeting. CGS sheet shall be provided for roof. The building shall have
necessary arrangements for supporting EOT crane of adequate
capacity. Major structures shall include columns, column bracings, roof
structures, gable end structures, crane girder, crane level walkway,
maintenance platform, lighting walkway, gable end platform, access
stair/ ladder, handrails & structures for handling facilities etc.
19) Platforms, cross overs, stair/ ladders, handrails etc. in the proposed
tundish repairing area (in KL & LM bay for caster #1, 2 and Caster #4)
as per technical/ technological requirement.
20) Pipe supporting trestles, bridges, walkway all along. Access ladder/
21) New gantry structures, supporting structures for isolator, current
transformer, circuit breaker and cable support structures at the MSDS-
III switchyard area.
22) New lift well structures along with necessary sheeting works.
23) Necessary strengthening works in existing structures wherever
supports are taken from these.
24) Miscellaneous platforms, access stairs/ ladders, structures for handling
facilities, safety handrails etc.
2.9.2 Scope of supply and services
2.9.2.1 Bidder shall prepare all general arrangement drawings and design drawings
with all necessary plans, elevations, and sections giving design section
adopted, their specification and details of major connections. Quantity of
structural work involved shall be indicated in design drawings. Steel
structural design drawing shall have all necessary information required for
preparing fabrication drawings. Design drawings of structures prepared by
the bidder shall necessarily contain:
1) Dimension.
2) Level.
3) Plan and sectional views showing general arrangement of structures.
4) Member sizes.
5) Member forces.

6) Complete base plate details including welding detail.
7) Nature and type of connection details of beams, girders, bracings etc.
showing weld details (type, size, length etc.), gusset plate/ face plate
thickness etc. Connection detail shall be shown for all major members.
8) Bolt hole details (number, diameter, dimension etc.)
2.9.2.2 Bidder shall supply relevant structural design calculations (including load
data for RCC foundations, insert details, if any, foundation bolts and all other
necessary information for RCC work) along with the G.A and design
drawings. The employer reserves the right of offering, at his discretion, his
comments/ observations on them which the bidder shall incorporate in his
drawings to the satisfaction of the employer and submit the revised
drawings. Design calculation shall be submitted for reference only.
2.9.2.3 Acceptance of the general arrangement drawings (on the basis of the design
calculation) means that they are checked for the general conformity with the
engineering requirement and applicable specifications covered in
T.S. Bidder shall, however, remain fully responsible for the completeness,
adequacy, correctness of his design and successful implementation and
satisfactory running of the plant and structures under his scope of work.
2.9.2.4 Bidder shall submit fabrication drawings (based on already accepted GA/
design drawing) along with BOQ to the employer in hard copies for record
purpose only. He shall also submit softcopy of fabrication drawings.
2.9.2.5 Before starting the work bidder shall prepare structural design criteria and
get it cleared by the employer.
2.9.2.6 Structural analysis/ design shall be carried out either manually or with the
help of STAADPRO software or using MS excel sheets. Softcopy of input data
for analysis/ design to be submitted along with design calculation in
editable format.
2.9.2.7 Bidder, prior to submission of his offer, visit the site and make him
acquainted with the site condition. He shall submit along with his offer a
broad scheme of major dismantling/ erection/ re-erection work involved,
including the type and tentative location of major handling facilities (e.g.
tower crane, mobile crane, derricks, winches etc.) in alignment with the
overall project completion schedule.
2.9.2.8 Bidder shall supply all material for structural steelwork including paint
materials, materials for fabrication, transportation, delivery and storage of
all steel structures, sheeting including site bolts, fixtures, all consumables,
handling equipment, labour etc. complete in all respects.

2.9.2.9 Erection of fabricated structures (including tools, tackles, labour, cranes,
handling equipment and any staging or false work required for erection),
alignment, levelling, fixing, bolting/ welding, inspection and testing of weld.
2.9.2.10 Bidder shall possess facilities/ equipment to carry out structural works at all
heights.
2.9.2.11 Bidder shall also prepare necessary fabrication drawings/ sketches for
modification jobs as per site requirement and take necessary clearance from
employer.
2.9.2.12 All mobile equipment and cranes including Tower crane as may be required
to facilitate dismantling, handling, erection etc. shall be supplied by the
bidder along with all construction and erection materials, equipment and
consumables, but not limited to, gauges, welding, brazing, gases and rods,
electrodes and wires, Oxygen, acetylene, fuel, bolts, nuts, washers, Spring
plates, NDT materials, packing plates, non-shrink grouting materials, safety
nets shims and temporary support etc. as required for incidental work and
for the completion of erection work.
2.9.2.13 Bidder shall prepare dismantling and erection scheme/ drawing including
temporary supporting structures and submit to employer for reference.
Employer may indicate observations on said schemes/ drawings which shall
be incorporated before starting work.
2.9.2.14 Painting of all fabricated & erected structural steel work after suitable
surface preparation as per specification along with existing structures. For
all structures surface preparation and application of primer and finish paints
shall be under the scope of bidder.
2.9.2.15 All necessary site measurements and study of available existing drawings as
may be required for developing the aforesaid design and drawings shall also
be deemed to be under the scope of the bidder. The existing drawings are
to be collected from RSP.
2.9.2.16 Dismantling of existing steel structures as per technological necessity and
transportation/ disposal of dismantled structures from the area to the place
earmarked by the employer.
2.9.2.17 Site cleaning, preparation, transfer of benchmarks & geodetic lines,
checking & fixing, aligning of structures, final cleaning of site after
completion of the work shall be under the scope of the bidder.
2.9.2.18 Inspection, testing including radiographic and ultrasonic testing and
commissioning of all steel structures shall be under the scope of the bidder.

2.9.2.19 Any other work not specifically mentioned but required for completeness of
the job considering technical/ technological aspects shall also be included
in the scope of work of bidder.

2.10 CIVIL
2.10.1 Broad scope of civil works is elaborated as under:
1. Site clearance, removal of all bushes, shrubs, uprooting stubs, etc.
including cutting/ filling of earth, compacting & area development as
per requirement.
2. Area survey, underground mapping and field tests as Electrical
Resistivity Tests, Boreholes shall be done as per Drg. No.-CET RN
4179 CE0 00 010 and CET RN 4179 CE0 00 012.
3. Dismantling of the existing emergency overhead tank for caster 1 & 2
including staging and foundation through diamond wire saw/ wall saw
machine including debris removal.
4. Dismantling of the RCC foundations/pedestals of existing shop column
no. N-31 including disposal of the debris & muck.
5. Dismantling of RCC foundations/pedestals of existing scale pit grab
bucket crane supporting columns inside proposed extended part of
NP bay. This also includes disposal of the debris & muck and
construction of same on the opposite side.
However it shall be noted that the existing scale tunnel, scale pit and
scale-pit pump house alongwith MCC room shall be retained and shall
come under the shed of proposed extension of PQ bay.
6. Dismantling of existing RCC storage pit for scales and re-construction
of the same on the Q-bay side, as per requirement.
7. Dismantling of other existing RCC foundations/ pedestals/ RCC piles
caps as per requirement at the proposed site.
8. Cleaning, area development including shifting/ dismantling of
equipment foundations of the ladle repairing facilities in the KL bay
between Columns 32 to 37 which shall be shifted to area between
column no 48-57 in the same bay.
9. Dismantling of civil works for tundish repair facilities like Tundish tilter,
Tundish de-skulling machine, mortar mixture etc. as per requirement.
10. Dismantling including removal & disposal of debris of existing RCC
framed buildings like existing ventilation room, chiller plant, lubrication
store building, macro etching laboratory, booster pump house and
auxiliary electrical room, parking areas, shift Office and any other
building / facility, as per technological system and process
requirement.

11. The following existing facilities shall be relocated. Dismantling and
reconstruction of civil components of following facilities and
associated works, are included in scope of bidder.
Sl. Name of the Facility
1 PC room in L-M bay near column 39-40
2 Tundish Settling Stand
3 Tundish relining Stand
4 Tundish Cooling Assembly
5 Tundish Stopper/stand
6 Tundish Hanger
7 Hydraulic Room
8 Deskuller
9 Any other equipment as per technological requirement
12. Dismantling of civil components of existing Lift room of caster I & II

and civil works for new lift as per system & technological requirement.
13. Dismantling including removal & disposal of debris of existing
temporary shed for crane maintenance and ACVS office.
14. Tundish transfer car track between axes 39-40 shall be extended
towards the KL bay as per technological requirement.
15. Extension of slab despatch rail track in R’S bay, including all associated
civil works, as per requirement.
16. Construction of RCC framed emergency overhead water tank of
existing capacity for Caster # 1 & 2 as per technological, process and
system requirement. This work shall be done expeditiously. Height of
the tank shall be decided as per technological requirement, which has
been stated at clause no 2.4.2.8 of the TS.
After construction of new emergency overhead water tank, it shall be
connected with the existing system and shall be tested and
commissioned within shut down period. After that the existing
emergency overhead water tank shall be dismantled.
17. Construction of RCC foundations/ pile foundations as required for the
extension of existing structural building of SMS-II as per technological
drawing including flooring, cable trenches/ tunnels, water tunnels, pipe
tunnels etc.

18. For construction of foundations of shed column at axis no 31 and 32,
existing foundations may be combined with proposed foundations.
Design shall be carried out accordingly. Bidder shall also take
necessary special precautions in this case. However, bidder may
propose alternative proposal for the column shed foundations.
19. Rerouting of existing water pipe tunnel and ventilation tunnel as per
system, process and technological requirement including dismantling
of existing. The tentative layout is shown in the attached drawing.
20. There are existing water pipe tunnel and ventilation tunnel by the side
of N-row. These tunnels are required to be rerouted, as indicated in
the drawing, for construction of new column foundation including
turret. Top of rerouted tunnel inside and outside shall be finalised
considering constraints and operations of the shop and proposed LF.
Further, it may be noted that these area shall be used for slag/material
dumping during and after execution. The travel of shop crane may be
restricted upto axis-33 in MN bay during execution in these areas.
Foundations and structures shall be designed accordingly.
21. Dismantling and relocation of pent house/ entry stairwell of scale
tunnel/water pipe tunnel/ventilation tunnel etc. suitably as per
technological, system and process requirement.
22. Construction of RCC foundation and other civil works for proposed
slab caster and associated facilities like turret foundation, scale tunnel,
pump house, hydraulic room, lubrication room, run out roller table,
technological structures etc. as per technological system and process
requirements.
Civil works for construction of new RCC scale tunnel as per
technological, system and process requirement. New scale tunnel shall
cross over the existing scale tunnel near PQ row column no 30-
32. The design and construction of new scale tunnel shall be such that
the existing and new tunnels should behave as independent entities,
both structurally and process wise. No load of new system shall be
allowed to be put on existing scale tunnel. The existing scale tunnel
and scale pit, scale-pit pump house and MCC room shall be retained
as it is without affecting its normal operation.
23. Construction of RCC foundation and other civil works for proposed
Ladle Furnace and associated facilities like FAFA, stack, technological
structures, bag filters with supporting structures, transfer car track,
control room, transformer room, MCC, power compensation room,
hydraulic room etc. as per technological system and process
requirement.

Bidder shall note that existing cable tunnel is passing below the
proposed location of the Ladle Furnace. Care shall be taken so that no
load from the new system shall be supported on the existing scale
tunnel.
24. Construction of RCC foundation and other civil works for complete
water system for proposed Caster and Ladle Furnace and associated
facilities as per technological system and process requirement. The
water system for proposed Caster and Ladle Furnace and associated
facilities shall include Emergency overhead tank, for the Caster IV and
new LF, Pump house for closed loop water system, Scale water pump
house, Secondary settling tank, Spray cooling pump house, Soft water
pump house etc.
25. Construction of RCC foundation and other civil works for extension of
MSDS-3 as per technological system and process requirement.
Extension of MSDS-3 shall include foundations for gantry structures,
isolators, circuit breakers, transformers, cable supporting structures,
cable trenches with precast RCC cover, paving, laying of gravel/pebbles
etc.
26. Construction of RCC foundations and other associated civil work for
new structural steel building for Mould & Segment Repair Shop
(MSRS) including foundations for equipment, shop flooring, RCC
framed shift rooms, strong room for valuable items, store rooms, rest
rooms, utility and process rooms, electrical panel room etc. with brick
cladding, as per process, system and technological requirement.
Prior to the construction of the new MSRS, the existing structural
storage shed at the proposed location, shall be dismantled.
Dismantling of the existing foundations, floorings and other civil
components of the shed including disposal of debris shall be under the
scope of bidder.
27. Construction of RCC framed 3 storied building for macro etching lab
room on the ground floor and office rooms in the other two stories.
28. Construction of 3 storied RCC framed office building for SMS-II as per
requirement.
29. Construction of RCC framed 3 storied building for the chiller plant,
ventilation room, auxiliary electrical room for Caster # 1 & 2 as per
technological, process and system requirement.
30. Construction of RCC framed ventilation room for Caster # 1 & 2 as per
technological, process and system requirement.

31. Construction of RCC framed booster pump house as per technological
requirement. The building shall have necessary arrangements for
handling facilities.
32. Construction of RCC framed fire-fighting pump house as per
technological system and process requirement including foundations
for equipment and necessary handling facilities.
33. Construction of two storied RCC framed with brick cladding store
rooms building for mechanical and electrical along with associated
facilities and civil work as per requirement.
34. Provision of RCC foundations/ pile foundations for the structural shed
for bulk oil and grease barrels building including suitable flooring,
brick cladding, finishing etc. as per technological, process and system
requirement.
35. Modification/ strengthening of the existing RCC foundations/
structures as per technological requirement. However, additional load
on the existing foundations/ structures shall be avoided.
36. Construction of RCC retaining wall to facilitate construction of units
under this package by the side of Fertilizer nallah as per requirement.
37. Construction of retaining wall for land reclamation / site protection/
sheet piling including cutting & filling as per site requirement.
38. Barricading around the existing scale pit area with stainless steel posts
and with handrails as per requirement.
39. Construction of protective brick wall as per process and technological
requirement to protect the area where ready mould, segment and
bender are to be stored.
40. Construction of RCC framed with brick cladding electrical buildings for
HT-LT substation, pump houses, caster proper, ladle furnace etc. along
with associated facilities/ amenities as per technological system and
process requirement. These buildings shall accommodate
transformers, panels, MCCs, PLCs, switch gears, batteries, handling
facilities, cable basement/vault/trench etc. as per technological system
and process requirement.
41. Civil works for construction of control pulpits along with associated
facilities/amenities for new caster and ladle furnace as per
technological system and process requirement.
42. Civil works for construction of hydraulic room with associated facilities
for new caster as per technological system and process requirement.

43. Construction of foundation and associated facilities for tundish dryer
and auxiliaries as per technological system and process requirement.
44. Civil works for installation of associated facilities/amenities for new
caster as per technological system and process requirement like
accumulator bank, valve stand, ladle gates, slag pot, vibro mass
refractory lining system, slag dumping area etc.
45. Shop floors shall be provided with Ironite topping and concrete
hardener as per technological system and process requirement.
46. Necessary Heat Resistant Concrete work (Reinforced and / or plain), as
per technological, process and system requirement.
47. Rain water harvesting facilities shall be provided as per requirement to
buildings which are open to sky.
48. All finishing work, necessary heat resisting work, fireproofing work and
anti-corrosive treatment to building, foundations and other units as
per technological system and process requirement.
49. Civil works including earthwork in excavation & backfilling for laying
of buried pipelines as per site requirements.
50. Apron around the new buildings and area drainage around the
proposed construction area and connection of the side drains with the
main storm water drains.
51. Construction of 4/7 m wide RCC road for approach to new facilities
including interconnection with the existing roads, along with PCC
encased RCC Hume pipes / RCC culverts at the location of rail / road
crossings as per requirement. 7m wide road shall be provided to
approach major facilities like caster/LF shop, WTP area, MSRS, electrical
substations, bulk oil storage building, all multi-storied buildings and
any other areas subjected to frequent heavy vehicle movement. Roads
shall be constructed as per attached drawing no CET RN 4179 CE0 00
011.
52. RCC foundations including piling works for structural buildings,
structural steel trestles for pipeline supporting structural steel trestles
& pipeline saddles, cable-bridge, trestles etc.
53. Any other foundations and civil works required for completeness of
foundations as mentioned in the scope of other disciplines.
54. General
i. The general arrangement, layout, sizes, finishes, doors, windows,
flooring, apron, drain around the buildings, trenches/vaults/cellars,
cut-outs, false floors & roofs, handling facilities, roof treatment with
APP, foundations for equipment, inserts, grouting, amenities like
gents & ladies toilets, sanitary & drinking water facilities, sewerage &
drainage system, rainwater harvesting, approach road to various
buildings, covered and open parking etc. shall be under the scope of
bidder, as per technological system and process requirement.
ii. All Transformer rooms shall be complete with transformer mounting
arrangement, oil soak pit, bi-fold steel door with wicket gates and oil
drainage pit outside the transformer rooms. Oil soaking pits shall be
provided below each transformer and oil drainage pits shall also be
provided as per requirement. Suitable doors/windows shall be
provided.
iii. No foundation shall rest on back filled soil or slag, including those of
shift rooms, toilets, other ancillary single storey buildings, parking
sheds, pits etc. Ground improvement, wherever adopted, shall be by
confined sand filling and / or cementitious filling, as per design
requirement.
iv. Open/Pile Foundations, in general, shall be considered for bay
columns, stacks, equipment and their drives. However, wherever deep
excavation are proposed for cellars, tunnels, open / Pile foundation can
be adopted with ground improvement by confined sand filling and /
or cementitious filling, as per technological, system, process
requirement, load data, soil characteristics, soil investigation report
and site conditions etc.
v. Necessary water proofing/protection shall be done for roofs of all
rooms, cellar and underground structures as per requirement.
vi. Grouting under the base plates & bolts/inserts as per the requirement.
Necessary chipping, Grouting under the base plates and pockets for
equipment and technological structures, if any, which forms part of the
equipment is also under the scope of contractor.
vii. Bidder shall collect and refer the existing drawings for underground
and over ground services on its own from RSP before quoting.
viii. Scope of bidder shall also include protection/ diversion/ rerouting of
all existing underground, on ground and over ground facilities like
buildings, foundations, trenches, tunnels, cables, pipe lines etc. during
the course of execution of civil works for the proposed facilities. Any
shoring/ sheet piling required for construction of deep excavation shall
be under the scope of Bidder. No extra claim on account of this shall
be entertained after award of work.
ix. Excavation work, rock cutting etc. shall be done in such a way that
adjoining existing foundations/ structures/ facilities shall not be
damaged. Suitable measures shall be taken up to protect the
adjoining existing foundations/ structures/ facilities. In case, if any
existing foundations/ structures/ facilities are disturbed, the same shall
be strengthened and its stability in totality must be ensured.
2.10.2 The other works shall also include:
1) Necessary geodetic surveying work including transferring & fixing of
reference lines & bench marks for set up of layout & construction /
erection works shall also be part of the scope of work for the Bidder
2) The area survey, soil investigation and underground mapping work, as
per requirement, of the area where new facilities are proposed but not
covered in the report provided by the Employer, shall be under the
scope of the bidder. The bidder shall submit the report to
employer/consultant for acceptance/approval.
3) The scope of work also includes sampling & testing of construction
material on the specimens taken during execution of the work. The
testing shall be performed by a separate agency, approved by the
Employer.
4) Temporary approach road, site office, cement & other construction
material storage go-downs and fabrication yard for reinforcement,
inserts etc. shall be constructed by the Bidder at his own cost
5) All construction equipment required for execution of the work shall be
arranged, procured & hired by Bidders along with operations, skilled
& semi-skilled personnel. Bidders shall also furnish a list of
construction equipment to be deployed by him.
6) Bidder shall also be responsible for co-ordination with other agencies
working for the successful and timely implementation of the work.
7) Bidder shall abide by the safety rules, IE rules and all rules imposed by
State Government & Central Government as in force
8) Bidder shall render all labour, tools and appliances to the Employer for
day-to-day supervision of the work & checking of the accuracy of
works.
9) Site cleaning, dewatering of foundation pits / trench, final cleaning of
site after completion of the work shall be under the scope of the
Bidder.
10) Site cleaning on regular basis during construction & final cleaning of
site after completion including loading, transportation, unloading,
levelling / disposal of debris shall be under the scope of Bidder.
11) Hard rock breaking and removal of the same as per site requirement.
Excavation may be carried out by chiselling/blasting etc. as per site

requirement. However rock blasting if required, shall be carried out
with prior permission from the employer.
No separate price shall be paid on account of the scope mentioned all
above and the same shall be deemed to be included in the quoted price.
2.10.3 Dismantling of RCC, PCC & Brickwork (including concretes of all grades) as
required or encountered during execution of civil works including loading,
transportation, unloading and dumping as per instructions of Engineer-In-
Charge shall be under the scope of Bidder.
2.10.4 Miscellaneous works, as may be required, such as Conduits for cables at the
road crossings dismantling & reconstruction of surface drain, cleaning of
site etc. shall be under the scope of work and the cost towards this shall be
included in the quoted price.
2.10.5 Separate gents and ladies toilets, facility for drinking water with water cooler
etc. shall be provided in offices, control rooms, shops etc. as per
requirement.
2.10.6 Shift rooms including shift in-charge rooms (RCC framed type) each of
minimum 30 sq. m area with separate toilets for Gents and Ladies and
drinking water facilities shall be provided as per requirement at bay
extension area, MSRS, Casting Floor, WTP etc.
2.10.7 Rest rooms :- Adequate no of rest room (RCC framed) of size minimum 30
sq. m each shall be provided at Caster floor and ground floor, MSRS and
WTP. Space provision for entrance, large space for lockers with work
distribution space, rest area, separate toilets for ladies and gents nearby and
as per requirement with bathing facilities & drinking water facilities shall be
provided. Separate lockers (for shift & rest rooms) of reputed make shall be
provided in sufficient no. Lockers for keeping tools and tackles for workers
shall be provided in rest room.
2.10.8 Shower facility with enclosure and incoming and outgoing water lines,
sanitary system etc. shall be provided at caster floor as per safety
requirement.
2.10.9 Toilet Blocks:- Each toilet block (RCC framed type) shall have separate space
provisions for the ladies and gents as follows:
 Minimum 2 WCS, 2 Urinals, One shower and 2 wash basins for gents’
toilet
 Toilet facilities for ladies toilet
 Drinking water facilities

2.10.10 Covered Parking Facility
RCC framed covered parking shed shall be provided with associated
facilities in the following areas as per indicated capacity.
Area No of 4 wheelers No of 2 No of VIP
wheelers parking(4
wheelers)
New Crane 6 20 2
Maintenance Office
Building
MSRS Shed 3 20 -
Outside Caster bay 4 30 -
WTP area 2 20 -
New Office Building 2 10 -
cum Micro-etching
Lab
2.10.11 Following drawings with respect to existing system are attached with this
document for reference. However, the actual site condition shall also be
verified.
PDR-137688 PDR-215443 PDR-137550
PDR-137691 PDR-215444 PDR-137551
PDR-137692 PDR-141441 PDR-141835
PDR-142369 PDR-141442 PDR-141836
PDR-145667 PDR-141511 PDR-141837
PDR-139208 PDR-137547 PDR-141839
PDR-141866 PDR-137548 PDR-141843
2.10.12 The underground mapping report provided to bidder by the employer is

indicative only. Bidder is required to check, ensure and confirm the same for
planning, engineering and execution. The underground mapping work and
other such work carried out by the bidder, to check, ensure and confirm the
existing underground facilities for planning and execution shall also be
under the scope of bidder. Bidder shall submit the report to
employer/consultant for acceptance/approval.
2.10.13 Design calculations, drawings and documents
2.10.13.1 The design calculations shall be submitted by the bidder for approval, prior
to the submission of construction drawings. These shall include but not
limited to, the following

1. The design calculations shall include static design calculations for all
structures and foundations, dynamic analysis for all structures and
foundations subjected to impact/vibration induced by equipment and
other external elements.
2. Building data shall include specifications of materials, design standards
followed, load data assumed including the loading on floor, bulk
material density, crane and hoist loading, wind and seismic loading,
wind thrusts and vibration considerations, deflection, type of flooring,
roofing and sheeting and type of construction to be indicated. The
loading combinations and other assumptions made in the design are
to be furnished.
3. Measures required for protection of the existing foundations shall also
be indicated.
2.10.13.2 Drawings:
1. The bidder shall prepare general layout drawings giving salient levels
and dimensions of the whole areas showing all services and facilities,
nearby buildings/roadways etc., provided for the co-ordination with
the other areas of the plant. Detailed working drawings shall be
prepared based on the general layout drawings considering overall
foundation layout, building, services, space requirement and
clearances as necessary. The bidder shall submit a comprehensive and
complete unit wise list of drawings in reproducible form/softcopy.
2.10.13.3 The bidder shall submit for approval/reference of the employer general
arrangement and detailed working drawings for all concrete, reinforced
concrete and other civil works as indicated in consolidated list of drawings
in this document.
2.10.14 The designs prepared by the bidder shall cover the requirements indicated
in this specification considering the overall process requirements, service
conditions. The designs shall be compatible with the operating conditions
in the steel plant and the atmospheric conditions prevalent at Rourkela.
2.10.15 SAIL has got separate set of empanelled parties for conducting
Topographical Survey & Soil Investigation work and Locating & Mapping of
Underground Utilities. It is required that these works need to be got done
by the bidder from any of the empanelled parties from the empanelled list
as per Annexure 2.10.15-1 and Annexure 2.10.15-2. The reports shall be
submitted to Employer for approval.
2.10.16 Any other job, not specifically mentioned above but necessary for the
successful completion of the project considering technical/technological
aspects shall also be under the scope of work of the Bidder.

2.11 DRAWINGS AND TECHNICAL DOCUMENTS
2.11.1 Following drawings and documents are to be submitted by the Bidder
within 30 days of effective date of contract.
1. L-II network / CPM PERT Chart
2. General layout of facilities
3. List of drawing and documents with submission schedule
4. Dismantling scheme
5. Design criteria of civil and structural work
6. Process Flow Diagram for Utilities
2.11.2 Following documents are to be submitted by the Bidder within 60 days of
effective date of contract:
Copy of un-priced purchase order of following items:
1. 12.5 MVA transformer
2. 33 kV GIS
3. Crane and hoists
4. Ladle turret swivel bearing
5. Ladle turret lifting Cylinder
6. Ladle turret turning device
2.11.1 The following drawings / documents shall be submitted by the Bidder after
placement of order:-
List of drawings below mentioned are not exhaustive; however Bidder may
include additional drawings as per project requirement.
Discipline Description
Process and 1. GA & Details of all technological equipment of
Technology caster & Ladle furnace
2. L-II network (To be submitted within 30 days of
placement of order)
3. General Layout
4. Process flow diagram
5. Functional description
6. Media consumption list (air/ water/ gases)
7. QAP
8. A single unified, combined 3D model in AutoCad
compatible platform

9. General Layout
10. Dismantling scheme
Mechanical 1. GA & Details of all mechanical equipment of caster
& Ladle furnace
2. GA & Details of belt conveyors
3. GA & Detail of Vibrating feeder
4. GA & details of FAFA
5. GA, circuit diagram & detail of Hydraulic system
along with design calculations
6. GA & details of grease lubrication system
7. Power calculation of mechanical equipment, belt
conveyors, EOT Cranes, Hoists and etc.
8. GA & Details of EOT Cranes, Hoists, Jib Crane etc.
9. GA & details of Tractor trailer
10. QAP of all equipment
11. GA & detail of flap gates
12. Design calculation of individual components
including drives of mechanical equipment such as
belt conveyors, feeders, cranes, hoists, transfer cars,
passenger lift etc.
13. GA of mechanical equipment such as conveyors,
feeders, screens, cranes, Jib cranes, under slung
cranes, Electric Hoists
14. GA/ assembly/ sub assembly of individual
components of all equipment
15. Structural drawings of EOT Cranes along with
design calculation
16. GA for modification of existing Grab bucket crane
17. Hydraulic pipe routing drawing
18. Catalogue of all bought out items
Utilities 1. Schedule of drawing and documents to be
submitted for review, approval and information with
submission dates
2. Equipment & Drive List
3. Performance and characteristic curves of, pumps,
cooling towers etc.
4. Area wise Flow and P&I diagram of water system and
others showing terminal points.
5. GA drawings of the complete system including
sections showing full details along with bill of
materials and design calculations.
6. Technical specification and data sheet of all
equipment and pipe work.
7. Piping layout drawing showing complete details of
support, valves, etc. along with BOM.
8. Pipe, Valve and Insulation Schedule.
9. Calculation for equipment and piping sizing.
10. Calculation for Drive motor sizing
11. Quality assurance plan (QAP) of all equipment
Refractory 1. Refractory GA drawings of all equipment mentioned

at TS clause 2.5.1.
2. Sectional drawings of all equipment mentioned at
TS clause 2.5.1
3. Drawing of all the template forms
4. Complete bricks shape album for all equipment. Brick
shape drawings shall necessary include the following
information
 Unit wt.
 Brick shape no.
 Material quality
 Complete dimension
5. Complete technical specification all refractory items
including auxiliary items.
6. Equipment wise complete BOM of refractory and
auxiliary item.
7. Refractory erection instruction
8. Refractory heating up manual
9. QAP for refractories
Electrical 1. Single line diagrams with ratings of HT & LT power
distribution
2. Equipment layout drawings
3. Technical datasheet sheet for all items
4. Power & control schematic diagrams and wiring
diagrams of HT& LT equipment
5. Cable Schedule
6. Cable layout drawing
7. General arrangement drawing of all other major

equipment
8. Cable termination plans of all equipment with
terminal block arrangement and markings
9. Internal wiring diagrams of equipment.
10. Performance characteristic curves for motors
11. Illumination drawings
12. Earthing and lightning protection drawings
13. Bill of materials
14. Relay setting and co-ordination chart
15. QAP
16. Bidder shall submit all other necessary write-up,
characteristics curves and information required to
fully describe the equipment.
Process 1. Schematic drawing and Control description
Automation including PLC configuration
2. Configuration of PLC based automation
3. System configuration diagram for level-2
4. System Requirement specification for Level-2
automation system
5. Process & Instrumentation diagram.
6. List of instruments
7. Instrument data sheet
8. Operation & control philosophy
9. Cable list, termination schedule, I/O list, listing of
internal bits, words, registers, timers, counters etc.
with tag details and description, listing of HMI
station status and control tags for all objects.
10. Technical details/write up, scheme & system
configuration diagram for PLC based control &
monitoring system for LF
11. Technical literature / manual for individual
instrumentation equipment
12. Equipment Schedule
13. List & details of hardware of PLC
14. Interface description and procedure of interface
links
15. Application software documentation, ladder, block
diagrams

16. Soft copies of PLC & HMI programmes in CDs
17. Quality Assurance Plan of each equipment
18. Power supply scheme
19. Panel wiring diagram
20. Hook-up diagram
21. Cable & GI pipe schedule and routing
Structural 1. Drawing list for structural steel works.
2. Design criteria
3. Design calculations substantiating design
drawings
4. GA & Design drawing
5. QAP
6. Fabrication drawings for record purpose only
Civil 1. General layout and arrangement of the new
facilities / units
2. Design calculations
3. Excavation drawings
4. Foundation plans and sections
5. Loading drawings indicating superstructure
loading, equipment loading, floor loadings etc.
6. Comprehensive anchor pocket plan along with
complete details of anchor bolts and anchor pockets
for foundation including schedule for bolts and
anchor plates.
7. Reinforcement details with bar bending schedules
for all reinforced concrete works.
8. Drawings for all types of bolts, inserts, embedment,
covers, miscellaneous steel works.
9. All drawings for floors and floor finishes.
10. QAP for civil works
Manuals 1. Operation Manual
2. Maintenance Manual
3. Erection Manual
4. Safety Manual
2.11.2 The drawings/ documents submitted after placement of order shall be

submitted for approval as per SBD Cl. No. 20.3. The drawings of sub-
suppliers shall be duly vetted and stamped by the principal Bidder before
submission to employer.
2.11.3 Drawings shall be submitted in pre-decided and agreed sequence. In order
to expedite the approval of drawings, engineering meeting shall be routinely
held with the Bidder at plant/ consultant’s location every 2 to 4 weeks for
clearing of drawings across the table and sorting out issues, if any. These
meetings are to be held during the entire engineering phase of a project.
2.11.4 Drawing / document submission methodology:
Bidder shall submit 2 hard copies of the drawing to the consultant and 3
hard copies to the employer for scrutiny. After scrutiny, the comments of
consultant along with the comments from employer shall be incorporated
in the hard copy and necessary stamping shall be done by the consultant.
Scanned copy of the stamped drawing shall then be mailed to the Bidder by
the consultant. After receipt of the scanned copy of the drawing from
consultant through e-mail, the Bidder shall take out 5 prints of the same and
out of these, 4 hard copies shall be sent to the employer and 1 hard copy
shall be sent to the consultant.
In case, the drawing is not approved, the Bidder shall prepare the revised
drawing, after suitably incorporating the comments given by employer/
consultant, and submit the same for approval, in 2 hard copies of the
drawing to the consultant and 3 hard copies to the employer for scrutiny.
The above process shall be continued till the drawing is approved.
After approval and stamping, the consultant shall send the scanned copy of
the approved drawing to the Bidder by e-mail. After receipt of the scanned
copy of the drawing from consultant through e-mail, the Bidder shall take
out 10 prints of the same and out of these, 4 hard copies shall be sent to the
employer and 1 hard copy shall be sent to the consultant.
2.11.5 Format of Bidder drawing list shall have minimum following fields:-
1) Sl. No.
2) Employer drawing No
3) Bidder drawing No
4) Name of consortium member
5) Area
6) Drawing/ Document Name
7) Category (Approval/Reference)
8) Discipline

9) Stage (BE/ DE)
10) Schedule date of submission
11) Remarks
2.11.6 Drawing list shall be in MS-Excel format. Any additional field, if required,
shall be added after Column 11. In case the drawing has more than one
sheet, employer drawing shall include the sheet number as part of drawing
number.
2.11.7 Editable format soft copies (3 sets) on CD/DVD of all “As-Built” drawings
(full set of drawings as per the approved drawing list) and manufacturing
drawings of critical parts, spares and fast wearing parts shall be supplied by
the Bidder.
2.11.8 In case the proposed plant uses any process, equipment or software which
is covered under any patent and SAIL / RSP is required to have the relevant
user’s license for the same, the scope of work of this tender shall include
transferring such licenses to SAIL and indemnifying SAIL against
infringement of any intellectual property rights.
2.12 BATTERY LIMIT
Incoming
Process and 1. Liquid steel shall be transported from Converter# 1, 2 & 3
Technology through steel ladle transfer cars to MN bay.
2. Heats shall be treated in secondary unit (Ladle furnaces).
Utilities 1 Oxygen gas Existing DN 100 size pipe carrying Oxygen
(>99.5% for caster-1, 2 and other units of CCS-II at
pure) the end of CCS shed towards existing scale
pit side.
For MSRS: with in 150m
2 Nitrogen gas Existing DN 50 size pipe carrying Nitrogen
(100% pure) for caster-1, 2 and other units of CCS-II at
the end of CCS shed towards existing scale
pit side.
3 Nitrogen for Existing DN15 size pipe feeding to Caster
Inst. (100% # 1&2
pure) For MSRS: with in 150m
4 Argon gas Existing DN 40 size pipe carrying Argon for
(100% pure) caster-1, 2 and other units of CCS-II at the
end of CCS shed towards existing scale pit
side.
5 Mixed gas Existing 02 numbers of DN 400 size pipes
carrying mixed gas for caster-1, 2 and
other units of CCS-II at the end of CCS shed
towards existing scale pit side.
6 Propane gas Existing DN 200 size pipe towards TOP-II
side, feeding Propane to caster-3 and RH-
OB unit. Approximate distance is 250m
from proposed location of Caster #4.
7 Compressed Existing DN 250 size delivery pipe after the
air air receiver of new compressed air plant
towards existing scale pit side.
Approximate distance is 75m from
proposed location of caster-4.
8 Make up Existing underground DN 600 size pipe
water from expansion pump house passing by
near to proposed location of WTP of
caster-4.
Approximate distance is 40m from
proposed location WTP.
Electrical i) 33kV Power Source Tapping from LBSS-I:
Two nos. 33kV power sources for the new 4thslab caster shall
be taken by extension of 33kV indoor GIS switchboard at
substation no. LBSS-1. Downstream distribution shall be as
mentioned in scope of work. Refer single line diagram no.
CET RN 4179 EE1 00 001, R=4
ii) 33kV Power Source Tapping from MSDS-III:
33kV Power source shall be taken from MSDS-III by
extension of section no.-I. Suitable reshuffling of existing
33kV feeders shall be done as detailed in single line diagram
no. CET RN 4179 EE1 00 002, R=0. Downstream
distribution shall be as mentioned in scope of work.
For MSRS : 6.6kV supply tapping from spare feeders at 6.6kV
switchboard of existing LBDS-12 substation
2.13 EMPLOYER’S OBLIGATION

Construction water and power shall be provided to the Bidder as per SBD
Cl. No. 20.4.2 and 20.4.3.
2.14 TRAINING
Bidder shall make arrangement for training of employer’s and consultant’s
personnel in the area of design & engineering, operation & maintenance of
plant and equipment under the scope of work as below:
a) On-site training (Classroom / on-the-job): it shall be provided to 40
persons for 20 working days.
b) Manufacturer’s premises in India: It shall be provided to 30 persons for
5 working days.
c) Foreign training: Foreign training for a total of 300 man-days shall be
provided to Employer’s & Consultant’s persons in design, technology,
operation, electrical & mechanical maintenance, instrumentation &
automation and other related areas at the technology supplier’s overseas
premises. Out of this 200 man-days training shall be imparted to
Employer’s personnel and 100 man-days training shall be imparted to
consultant’s personnel. The training shall include classroom theoretical
training and plant visit. Trainees may be sent in batches separately for LF
and Caster.
2.15 Bidder shall identify any hazard / risks which may result in fatal accidents /
severe damage to human health and safety, damage to equipment and
material resulting in loss of time and having cost implication. Bidder shall
carry out the above assessment and formulate appropriate action plan to
prevent such incidents. This action plan shall be submitted to the Employer
before start of the work.

3 TECHNICAL SPECIFICATION
3.1 GENERAL
3.1.1 Rourkela Steel Plant (RSP), a unit of Steel Authority of India Limited (SAIL),
presently has two Steel Melting Shops (SMS). Both Steel Melting Shops
(SMS) have BOF converters, secondary steel making facilities and slab
casters.
3.1.1.1 Major technological facilities in SMS for steel making and casting at RSP are
as given below:
Facilities SMS-I SMS-II

HM De-Sulphurization unit 6 x 80t BF ladle 2 x 150 t.
Primary steel making facilities 2 x 66 t BOF 3 x 150 t BOF

(nos. x heat size)
Secondary steel making facilities 1 x 66 t VOR, 1 x 150 t ARS,
(nos. x heat size) 1 x 66 t VAR, 3 x 150 t LF
1 x 66 t LF 1 x 150 t RH-OB
Continuous Casting Machine / 1 x 1-strand slab 3 x 1-strand slab
Facilities (Caster) caster casters
3.1.1.2 In SMS-II, a new Slab Caster (Caster #4) and a new Ladle Furnace proposed
to be installed which shall take care of the present production shortfall. This
caster shall also be capable of producing value added steel like API higher
grades, EDDS etc. This shall also improve the operational flexibility in SMS-
II in terms of availability of casters and grades of steel to be cast.
3.1.1.3 New caster- Caster# 4 shall be located in the proposed extended portion of
casting bay next to existing Caster #2 location. New Ladle Furnace shall be
located in LM bay (existing tundish repair area) in SMS-II. Both these facilities
shall be designed for processing heats in sequence casting mode. The
proposed locations of Caster# 4 and Ladle Furnace have been shown in the
drawing no. CET RN 4179 ST0 00 001 R=3. The turret of Caster# 4 shall be
near the existing column N31. To accommodate the new caster and
associated facilities, LM & MN bays shall be extended by about 32m, NP &
PQ bays by about 76m, QR bay by about 44m and R’S bay shall be extended
by about 47m.
Dismantling scheme has been shown in the drawing no. CET RN 4179 ST2
00 002 R=1. Further, layout of existing and proposed facilities in KL and LM
bays have been shown in drawing no. CET RN 4179 ST2 00 003 R=1.
Following points are to be noted:

c) New caster and associated auxiliary facilities shall be accommodated
within the available space as shown in the layout drawing. Orientation
of auxiliary facilities may change but shall be restricted to the available
area as shown in the drawing.
d) The Ladle furnace location in LM bay has also been shown in the Layout
drawing. However, a more suitable layout of the same may be
proposed by bidder in the available space considering the actual site
condition to feed the treated liquid steel to the existing casters as well
the new caster.
3.1.1.4 The existing scale pit and scale-pit pump house shall be retained and shall
come under the shed of proposed extension of PQ bay. In order to avoid
fouling, the scale flume tunnel of proposed Caster # 4 shall be at a slope of
approximately 2% at the point of crossing over the existing flume tunnel of
casters 1&2. Slope of the said Caster # 4 flume tunnel may increase after the
cross-over point.
3.1.1.5 A new mould & segment repair shop (MSRS) shall be provided for repair &
maintenance of the mould & roller segments of the proposed caster
including associated facilities. Location of the MSRS shall be at the site of
temporary store beside the overhead tank of Slab Caster #3.
3.1.1.6 Bay extension
i) Extension of existing SMS-II building towards scale pit area shall be
done as shown in the drawing no. CET RN 4179 ST2 00 001 R=3.
While extending the building, profile shall be kept similar to the
existing one. Crane level walkway arrangement, lighting walkway shall
be similar. For the extended part, structures for crane maintenance
trolley in each bay shall be provided at a suitable location as per
technological requirement. Extension of various bays are as follows:
a) LM & MN bay by about 32 m beyond axis 31 with existing EOT
cranes of capacity 50 t & 250 t respectively and these cranes shall
operate in the extended portion also. One new crane of required
capacity is also envisaged in the LM bay. Crane runway girder in
MN bay shall be extended as per requirement and buffer stop on
it shall be placed at a suitable location, so that when one no.
existing 250 t crane is at one extreme end and under
maintenance, the other crane can serve the caster.
b) NP and PQ bay by about 76 m beyond axis 32. Top of crane rail
for the extended part of the PQ and NP bay is envisaged at the
same level as existing. One no. new EOT crane of required
capacity is envisaged in NP bay. Proposed new EOT crane is

envisaged for operating in the extended part of the NP bay
between proposed axes 31A and 28 only. Necessary
arrangements / facilities shall be provided by the bidder to
restrict movement of new EOT crane between proposed axes 31A
and 28 only.
c) QR bay by about 44 m beyond axis 32 and R’S bay by about 47
m beyond axis 32A. Existing shop cranes shall run in the extended
part also.
d) Modification in relevant columns of K row for accommodating a
new cantilever crane of suitable capacity designed for LT distance
of approx. 50m.
ii) For existing scale pit area, grab bucket crane girder, column structures
shall be dismantled to put P-row column, but after erection of the
same, the same crane girders shall be re installed with necessary
modification and to take support from new P row columns of extended
shed. Existing grab bucket crane supporting structures shall be
extended towards Q row by approximately 10m. Dismantling shall be
done for RCC foundations/ pedestals of existing scale pit grab bucket
crane supporting columns inside proposed extended part of NP bay.
This also includes disposal of the debris & muck and construction of
same on the opposite side
iii) New bulk oil storage shed size as per technological requirement along
with CGS sheet for roof and sides. The building shall have necessary
arrangements for handling facilities. Major structures shall include
columns, column bracings, roof structures, gable end structures, crane
girder, crane level walkway, maintenance platform, gable end platform,
access stair/ ladder, handrails & structures for handling facilities etc.
iv) Pipe supporting trestles, bridges, walkway all along. Access ladder/
v) Heat shield shall be provided as per technological requirement.
vi) Structures for handling facilities of New Booster Pump House, ACVS
building as per technological/ technical requirement.
vii) Miscellaneous platforms, access stairs/ ladders, gutters and down
comers, access to roof, roof handrail, structures for handling facilities,
safety handrails etc.

3.2 PROCESS AND TECHNOLOGY
3.2.1 Process Flow
3.2.1.1 After tapping from BOF, the liquid steel shall be treated in secondary refining
unit (ladle furnace) and then the steel ladle shall be transported to ladle
Turret of Slab caster with the help of EOT crane.
3.2.1.2 For smooth operation of continuous casting machine (Caster) the liquid steel
shall have correct degree of superheat above liquidus temperature.
3.2.1.3 Steel ladle shall be placed on the ladle turret of the slab caster machine.
Tundish shall be brought to the casting position with the help of tundish car.
The tundish shall be positioned accurately above the mould and ladle slide
gate of the ladle shall be opened to allow the flow of liquid steel in to tundish
through shroud. After reaching the desired level in tundish, nozzle of the
tundish shall be opened and metal shall be allowed to flow in to the mould
through submerged entry nozzle (SEN)/ submerged entry shroud (SES).
3.2.1.4 When the metal level in the mould reaches 100-150 mm from top, drives of
oscillation mechanism as well as roller segments unit shall be switched on.
The withdrawal of dummy bar shall start immediately. After casting, the slag
remaining in the steel ladle shall be dumped and handled as per prevailing
practice.
3.2.1.5 Metal level in the mould (meniscus) shall be measured with the help of
Automatic Mould Level Control (AMLC) during casting operation. Mould
lubrication shall be done with the help of casting powder. The partially
solidified strand after leaving the mould shall pass through the strand guide
roller segment where it shall be further cooled by air-mist cooling. The
dummy bar shall be separated from the hot strand just after the roller
segments unit and the cast strand shall be cut into slabs of desired length
by Oxy-Propane flame. The strand shall pass though soft reduction to
provide better internal soundness.
3.2.1.6 Slabs shall be lifted by EOT crane and piled in the storage area. The slabs
shall be inspected in the storage area and then shall be loaded on the railway
wagon for transport to the Rolling Mills or for despatch to sister plant/ direct
sale.
3.2.1.7 Tundish movement : Capacity of tundish for Caster #4 shall be
approximately 38 ton (overflow) and it should be such designed so that the
existing 80t cranes of NP bay can handle it. In normal operation, tundish
from Caster #4 shall be brought by existing tundish car track from NP bay
to KL bay and shall be taken by the new 100/10t EOT cranes to proposed
tundish repair area in KL bay. Ready tundishes shall be following

the same route backwards. The existing track shall be extended to KL bay
and full tundish shall be transported with the EOT cranes in KL bay (new
crane of 100/10t being provided) to the ladle repair area.
3.2.1.8 PC room which is under erection is falling in-line with proposed tundish car
extension to KL bay. The room shall be relocated or raised suitably to allow
movement of tundishes on the car.
3.2.1.9 A new mould & segment repair shop (MSRS) of minimum size 108m length
x 30m width x 12m crane rail height shall be provided for repair &
maintenance of the mould & roller segments of the proposed caster
including associated facilities. The MSRS shall be equipped with equipment
and facilities for repair, maintenance and testing of moulds and segments.
Moulds and segments shall be transported between casting shop of SMS- II
and MSRS by road trailer.
3.2.1.10 Liquid steel shall be received from BOF’s. The liquid shall be transfer to
secondary refining units for further processing. The processed/ treated steel
shall be send to slab caster and finally cast in to slab.
3.2.1.11 New slab caster shall have capacity to cater the required production. Both
commercial and value added steel slab shall be produced. During the capital
repair of Caster# 1 and Caster# 2, liquid steel can be diverted to Caster# 4
for maintaining the steady supply of slabs to various mills. In future, when
the liquid steel capacity shall get further enhanced from BOF, then the
additional steel can be cast in Caster#4.
3.2.2 Grades of Steel
Following main grades of steel shall be produced in SMS-II:
Boiler Quality, Extra Deep Drawing (EDD), Structural steel, steels for SWPP /
ERW PP / Tin plates / Galvanised sheets, Chequered plates, commercial
quality of steel, API-grades, SAILMA, HSLA, Peritectic grades etc.
3.2.3 Technological features of proposed caster and ladle furnace described in
various clauses in chapter#3 of this Technical specification.
3.3 MECHANICAL
3.3.1 Salient design features of the proposed Caster are as below:
Sl. Description Design feature

1. Ladle Turret  Ladle Turret with lifting / lowering,
rotating and weighing facility, equipped
with ladle cover manipulator.
 Emergency rotation facility with
Hydraulic system

Sl. Description Design feature
2. Ladle stream Ceramic shroud
protection
3. Tundish Refractory lined, suitable for hot tundish
practice
4. Tundish stream Through submerged entry nozzle / shroud
protection
5. Tundish transfer car Overhead cantilever design with lifting /
lowering and weighing facility with tundish
overflow bucket mounted in the tundish car
6. Type of mould Plate mould, straight type
7. Mould lubrication Casting granules for closed casting
8. Mould level control Eddy current type
9. Mould oscillating Hydraulic design, adjustable stroke,
mechanism oscillation frequency linked to casting speed
suitable to Quick Change practice
10. Secondary cooling Multi zones, high-pressure automatically
controlled spray/air mist cooling system,
dynamic control of cooling water flow w.r.t.
casting speed
11. Withdrawal and Multi point straightening, hydraulic
straightening unit pinching, modular design
12. Dummy bar Chain link type bottom fed
13. Strand cutting device Oxy-propane torch cutting machine
14. Marking unit Slab marking machine; Aluminium spray
type
15. Slab discharge Roller Table, pusher & pilers and by EOT
crane
16 Roll design Independent single split rolls with dual flow
rotary joints
17 De-burring machine Bidder to indicate
18 Slab weighing Weighing system in roller table
3.3.2 Proposed Caster shall broadly consist of following equipment / system:

i) Technological Equipment and Structure
ii) Cooling Chamber
iii) Ladle Turret
The steel ladle from BOF and LF is placed on the ladle turret by means
of a crane and positioned above the tundish. Ladle Turret shall consist
of following equipment:
 Ladle cover manipulator
 Ladle slide gate connecting platform
 Ladle slide gate operating mechanism
 Emergency launder for ladle
 Ladle weighing system: Weighing system shall be load cell based
and the system shall be able to monitor individual signal from each
load cell.
iv) Ladle slide gate lance
In the event that liquid steel does not flow after opening of the slide
gate, the Ladle slide gate Oxygen lance is utilized to burn open the
ladle nozzle. The lance is also used for cleaning of the ladle shroud
between ladle exchanges.
v) Shroud manipulator (Hydraulically operated)
Mechanized Ladle Shroud Manipulator shall be provided for quick &
easy positioning and connection of the shroud to the ladle. The shroud
manipulator applies an upward force sealing the ladle shroud to the
ladle nozzle during the pouring process. With the shroud manipulator
all necessary movements of the shroud can be performed. Ceramic
Shrouds will have Argon sealing system.
vi) Tundish
Tundish receives the liquid steel and distributes the steel through one
tundish bottom opening to the mould.
There shall be provision for hot tundish with dual heating system.
Stopper rod system along with system for emergency closing shall be
provided for controlling the flow of liquid metal from tundish to
mould. Flow modifier shall be provided.
The submerged entry nozzle/ shroud quick change mechanism shall
be provided under the tundish outlets so that preheated submerged
entry nozzles / shrouds can be quickly changed during casting without
interruption or delay in the process. Argon purging facility through
stopper rod to dislodge tundish nozzle chocking shall be provided.

Tundish shall be made of welded steel plates of heavy section. Each
tundish shall be supplied with refractory lined metal covers having
suitable openings.
Tundish will have continuous temperature monitoring system.
It shall also be provided with weighing facility.
Ladle to tundish slag detection system shall also be provided.
Emergency box for tundish, over flow box for tundish and over flow
trough for turret shall also be provided.
Tundish design shall be similar to that of tundish of Caster #3. New
tundish shall be Compatible to existing tundish maintenance facilities
vii) Tundish Car
Tundish car picks up the tundish in heating position and transport it to
the casting position and positions it above the mould. In combination
with a second tundish car, tundish change is possible without
interrupting the casting process.
The tundish cars shall be operating on the casting platform. It shall be
provided with electro mechanical drives for travelling and hydraulic
system for lifting and lowering. It shall also be provided with
hydraulically operated centering mechanism to facilitate centering of
SEN/ SES with respect to mould.
It shall have both normal and creep speed for proper positioning of
tundish over the mould. There shall be a cable trolley mechanism with
drag chain arrangement for supplying power to the drive motors and
controls. Local control desks with necessary controls, indication and
annunciation shall be provided. Arrangement for tundish weighing
(load cell based) shall also be provided in the car, and display of
tundish weight shall be indicated on control desk and casting platform.
Weighing system shall be strain gauge type load cell based and the
system shall be able to monitor individual signal from each load cell.
Tundish car shall have calibration arrangement with standard weight
pieces.
The tundish transfer car shall be design to suit tundishes of both
casters# 1,2 and 4.
viii) Mould & Mould assembly

Mould assembly is located below tundish on the oscillating table. It
provides initial solidification to forms slab shell in the adjusted
thickness and width.
Straight type plate mould shall be provided. Mould assembly along
with foot rollers shall be quick change cartridge type. The mould shall
be located on the oscillating tables at the start of the casting machine.
The mould assembly shall be having water cooling arrangement for
the copper plates and complete with necessary fittings for cooling
water arrangement for fixing on to the mould oscillation table and
protection cover to avoid damage due to metal splash and metal
overflow.
Mould fume extraction shall be provided in the mould assembly.
The mould inner plate shall be coated with Ni/Ni alloy for giving higher
mould life.
Mould shall be provided with Automatic Width Change Facility of latest
design to adjust section without stoppage of machine.
Off-line mould width calibration facility shall also be provided.
ix) Automatic Mould Level Control (AMLC)
An eddy current based Automatic Mould Level Control (AMLC) system
shall be provided. AMLC shall be mounted directly above the mould.
AMLC shall be used to maintain the level in the mould constant during
casting. AMLC system shall be complete with off line calibrator and
spare sensors, sensor cable, cooling air hose etc.
x) Mould Oscillation System
Hydraulic type mould oscillation system shall be provided. Oscillation
frame shall be water cooled. Frequency of oscillation shall change
automatically with change in casting speed. Quick release coupling
shall be provided for water hose connection / disconnection. Off line
calibration facilities shall be provided.
Necessary grease lubrication system shall be provided. All necessary
access and maintenance platform shall be provided.
xi) Strand Guide System
Sets of rollers and their supports, strand guides and various segments
along with drives, Segment exchange arrangements / facilities (quick
change with automatic connections) and all accessories shall be
provided. The roller in the strand shall have hard facing for giving

longer life and should be split design having intermediate bearing
blocks.
Strand Guide System shall be multi point bending and straightening
with soft reduction. Design of segments shall ensure easy access for
maintenance & inspection. Automatic roll gap adjustment facilities
shall be provided.
xii) Withdrawal & Straightener Segment
Withdrawal & straightener units with direct drive shall be provided. The
withdrawal & straightener units shall have reversible drives with
infinitely variable speed and shall be complete with motors, gear
boxes, brakes etc. Withdrawal speed shall be synchronized with the
frequency of mould oscillation. Top rolls shall be provided with
hydraulic cylinders. The design of frame and housing shall be such that
roll changing can be carried out with minimum dis-assembly within
minimum time. The housing frame, rolls and bearing housings shall be
water cooled.
An electric hoist of suitable capacity shall be provided for maintenance
of withdrawal & straightener units.
xiii) Dummy Bar System
Dummy Bar System consisting of Dummy bars, Dummy bar body,
Dummy bar heads (4 nos. for each section of slab), Dummy bar
disconnecting & storage facility(1 set), Dummy bar receiver with
platform, Storage stand and transport device for dummy bar heads,
Roll gap checker (dummy bar head type) etc. shall be provided.
Suitable handling facilities for dummy bar shall be provided.
xiv) Torch Cutting Machine (TCM)
The cast strands shall be delivered from the last segment of the strand
guide to the approach roller table of torch cutting machine. The
products shall be cut with the help of Oxy-propane flame. A cutting
torch for the strand of Caster shall be provided for cutting the products
and the operation of the unit shall be fully automatic. The unit shall
comprise of a machine frame, oxy- propane torches with pre-heating
burners, a gas distribution system including necessary hoses,
connectors, hose guides, travel and pneumatic clamping mechanism
for the torch cutting machine and the related control and electrical
equipment. The unit shall be suitable for cutting the maximum size of
products envisaged to be cast in the Caster. Facilities for sludge
granulation and disposal shall be provided. The carriage and the
holding arms shall be soft water cooled and
RSP PAGE CET/05/RN/4179/TS/ST/02/R=2
4TH CASTER – MAIN PACKAGE 3.10
provided with necessary heat shields. Emergency torch cutting facility
shall be provided by the side of the machine to cut products in case of
failure of the GCM torches. De-burring facilities shall also be provided.
The roller tables supporting the products during cutting operation
shall be of shifting type / tilting type to protect the rolls from the flame
of gas cutting torches. Each roller shall be individually driven and
water-cooled. Speed of strand movement shall be synchronized with
the speed of casting.
Sample cutting facility, Manual cutting facility, crop end handling
system shall also be provided.
xv) Run out equipment
Run out equipment shall consist of the following:
 Intermediate roller tables
 De-burrer
 Weighing roller table
 Slab marking machine
 Automatic length measuring systems
 Fixed / Disappearing stoppers
 Pusher and Piler
 Roller tables inside pusher and piler
 Fixed end stops
 Discharge roller table
 On line slab inspection system
 Inter bay roller tables
xvi) Tundish preparation / maintenance facilities
 Tundish tilting stand
It shall be provided to support the tundishes and rotate them
hydraulically for skull and refractory dumping. Tundish de-
skulling facilities shall be provided. The design shall be suitable
to accommodate tundishes of both casters#3 and 4.
 Tundish cooling device
 Tundish relining stand. The design shall be suitable to
accommodate tundishes of both casters 3 and 4.

 Tundish drying station. The design shall be suitable to
accommodate tundishes of both casters 3 and 4.
 Tundish support stand
 Tundish nozzle aligning, gunning & drying equipment
 Handling facilities as per requirement shall be provided.
xvii) Mould and segment preparation/ maintenance facilities
 Mould assembly storage stand
It shall be provided to support the moulds for storage. The stand
shall be made of welded steel sections complete with centering
pins for moulds and lifting trunnions.
 Mould tilting stand
It shall be provided to support the moulds during maintenance,
operation and allow the pressurized testing of moulds. The stand
shall be made of a frame for mould support with tilting facility.
The tilting shall be provided with motorized system. A
pressurized circuit shall be supplied to allow pressure test of the
mould.
 Mould alignment stand
It shall be provided to hold the mould in the correct position to
allow their alignment prior to the casting. The stand shall be
designed to hold the mould for each casting section.
 Mould measuring instruments
These shall be provided to measure the mould internal
dimensions for all sections and calibration.
 Bender & segment storage stand
 Bender & segment tilting stand
 Bender & Segment loose side frame alignment stand
 Bender & Segment Fixed side frame alignment stand
 Mould and segment cleaning and water test stand area
 Hydraulic compact unit for mould and segment maintenance
 Pump station for mould and segment testing stands
 Poratble grease pump unit
 Movable platform
xviii) Mould & Segment Repair shop(MSRS)
A new mould & segment repair shop (MSRS) shall be provided for
repair & maintenance of the mould & roller segments of the proposed
caster. The MSRS shall be equipped with equipment and facilities for
repair and maintenance of mould, bender and segments.
xix) Any other equipment required for completeness of the plant.
3.3.3 EOT Cranes
3.3.3.1 The Broad technical parameters of the major / critical EOT cranes shall be as
given below:
(i) Double Girder EOT Crane in LM Bay
S. N. Parameters Details
MH AH1 AH2 LT CT
1 Type Double Girder EOT Crane
2 Area Tundish Preparation bay
3 Bay LM
4 Quantity(Nos.) 01
5 Lifting Capacity on 50 10
Hook (t)
6 Bay width (m) 27
7 Crane span (m) 24
8 Top of Crane rail (+)25.00
over floor (m)
9 Runway Length (m) 32
(Approx.)
10 Lift (above floor/ 22+3= 24+5=29 - - -
below floor) (m) 25
11 Speed (m/min) 12.5 20 - 100 40
(Approx.)
12 Hook approach L axis: L axis: 2000 - - -
(mm) (Maximum) 4000 M axis:
M axis: 2200
4200
13 Motor (RPM) 750 750 - 1000 1000
14 Type of rails - - - CR- CR-80
15 No. of wheels - - - 8 4
16 Mechanism class Class-4 Class-4 - - -
17 Type of hook & Point Point Hook - _ _
attachment Hook
MH AH1 AH2 LT CT
18 Operation from Fixed AC Cabin + Radio remote control

19 VFD MH, AH, LT & CT with VFD Control
20 Indoor ambient 55
temp (⁰C)
21 Power Supply MS rail type DSL as per existing
22 Electrical panel On crane platform with e-room with AC.
location Redundant AC to be provided.
(ii) Double Girder EOT Crane in NP Bay
MH AH1 AH2 LT CT
2 Area CC Machine Bay
3 Bay NP
4 Quantity(Nos.) 01
5 Lifting Capacity on 120 20
Hook (t)
6 Bay width (m) 33
7 Crane span (m) 30
over floor (m)
(Approx.)
10 Lift (above floor/ 26+3= 27+5= - - -
below floor) (m) 29 32
11 Speed (m/min) 12 16 - 80 40
(Approx.)
12 Hook approach N axis: N axis: - - -
(mm) (Maximum) 4200 2200
P axis: P axis:
4000 2000
13 Motor (RPM) 750 750 - 1000 1000
14 Type of rails - - - CR- CR-
15 No. of wheels - - - 16 4
MH AH1 AH2 LT CT
16 Mechanism class Class-4 Class-4 - - -
17 Type of hook & Point Point - - -

attachment Hook Hook
18 Operation from Fixed AC Cabin +Radio remote control
19 VFD for LT, CT & MH, AH LT & CT with VFD Control
Hoist
temp(⁰C)
NP bay is also having EOT Crane of 80t/20t capacity. Suitable mechanical &
electrical stopping arrangement shall be provided for restricting the
movement of this crane with more than 80t load towards the 80t/20 t crane
bay portion. However, the crane can travel with a load of 80t (max.) towards
the 80t/20t crane bay portion.
Crane hook shall be designed to accommodate existing tackles.
(iii) Double Girder EOT Crane in KL Bay

S.N. Parameters Details
MH AH1 AH2 LT CT
1 Type Double Girder EOT Crane with magnet
2 Area Ladle preparation area
3 Bay KL
4 Quantity(Nos.) 01
5 Lifting 100 10 - - -
Capacity on (DC
Hook (t) Electro
magnet
on 10t
hook)
Circular
Magnet
65” for
handling
of
debris,

MH AH1 AH2 LT CT
skull etc.
of 5 ton)
6 Bay width (m) 26.5
7 Crane span (m) 24
8 Top of Crane (+)18.00
rail over floor
(m) (Approx.)
9 Runway Length Existing Bay
(m) (Approx.)
10 Lift (above 18.25 18.25 - - -
floor/ below
floor) (m)
11 Speed (m/min) 8 20 - 80 45
(Approx.)
12 Hook As per technological requirement and shall able
approach to handle all the equipment in the shop floor
13 Motor (RPM) 750 750 - 1000 1000
14 Type of rails - - - CR-100 CR-80
15 No. of wheels - - - 16 4
16 Mechanism Class-IV Class-IV - - -
class (M-8) (M-8)
17 Type of hook Point Point
& attachment Hook Hook
18 Operation Fixed AC Cabin + Radio Remote Control

from /by
20 Indoor 55
ambient
temp(⁰C)
21 Power Supply MS rail type DSL ( existing to be used)
23 Battery back- 20 minutes
up for magnet
Crane hook shall be designed to handle old and new tundish handling
tackles.

iv) Double Girder EOT Crane in MSRS

MH AH1 AH2 LT CT
2 Area New Mould & Segment repair shop
3 Bay New bay of Mould & Segment repair shop
4 Quantity(Nos.) 02
5 Lifting Capacity 50 10 - - -
on Hook (t)
6 Bay width (m) 30

(minimum)
7 Crane span (m) 27.0
(minimum)
8 Top of Crane (+)12.0
rail over floor
(m) (Approx.)
9 Bay Length (m) 108
(minimum)
10 Lift (above floor/ 12+4 12+4 - - -
below floor) (m)
11 Speed (m/min) 12 16 - 80 40
(Approx.)
12 Hook approach As per technological requirement and shall able
to handle all the equipment in the shop floor
13 Motor (RPM) 750 750 - 1000 1000
14 Type of rails - - - CR-100 CR-80
15 No. of wheels - - - 8 4
16 Mechanism Class-IV Class-IV - - -
class (M-8) (M-8)
17 Type of hook & Point Point - - -
attachment Hook Hook
18 Operation from Fixed AC Cabin + Radio Remote Control

/by
temp(⁰C)
MH AH1 AH2 LT CT
v) Cantilever Crane in KL Bay

MH AH1 AH2 LT CT
1 Type Single Girder Cantilever Crane
2 Area KL Bay
3 Bay K axis of KL bay
4 Quantity(Nos.) 01
5 Lifting Capacity on 5 -
Hook (t)
6 Bay width (m) 26.5
7 Crane overhang 7.5
span (m)
(Indicative)
over floor (m)
(Indicative)
(Indicative)
10 Lift (above floor/ 8+4 - - - -
below floor) (m)
11 Speed (m/min) 5 - - 30 10
(Approx.)
12 Motor (RPM) 750 - - 1000 1000
13 Type of - - - As per
rails(Approx.) requirement
14 No. of wheels - - - As per
requirement
15 Mechanism class Class-2 - - - -
16 Type of hook & Point - - - -

attachment Hook

MH AH1 AH2 LT CT
17 Operation from Pendant push button + Radio Remote
temp(⁰C)
19 Power Supply LT- As per requirement
Hoist – Festoon cable arrangement
20 Electrical panel On crane platform
21 Brake Hoist- DCEM Shoe brake
LT & CT- DCEM Disc brake
3.3.3.2 The list of envisaged EOT cranes is indicative only. Any other cranes required
for the project but not included in this list shall also be considered as per
3.3.3.3 Selected wheel of cranes shall be compatible with rail sizes mentioned
above.
3.3.3.4 The technical parameters of cranes mentioned above are minimum
requirements and parameters over & above shall also be supplied/
considered by the bidder as per requirement.
3.3.3.5 The technical parameter of cranes not mentioned above shall be in line with
above.
3.3.3.6 The selection of all the components of all the cranes & hoists shall be
designed on selected motor kW and all the factors shall be considered for
the worst condition.
3.3.4 Design standards for EOT cranes
i. The cranes shall be designed in accordance with IS 4137: 2015, IS 807:
2006 and any other standards referred to therein.
If certain design criteria are not specified in the IS 4137: 2015,
provisions laid in IPSS:2-02-001-18 for “Design parameters for EOT
Cranes”, IPSS: 2-02-003-18 for “General Code of Practice for Design of
EOT Cranes (Mechanical Aspects)”, IPSS: 2-02-004-18 for “General
Code of Practice for Design of EOT Cranes (Electrical Aspects)”, IPSS: 2-
02-002-18 for “Acceptance Norms for EOT Cranes” shall be followed
for design of EOT Cranes to be used in steel works of SAIL plants.
However, for design of components Provisions laid in IPSS shall be
followed.
ii. All EOT cranes shall be designed as per class-IV (M-8).

iii. Other Cantilever crane, Gantry cranes, Jib Cranes, under hung/slung
cranes, single girder EOT cranes, hoist shall be designed as per class-
II/M5 in accordance with IS 3177:1999.
iv. Wherever certain components of crane are covered by IPSS Standard,
latest revision of these standards shall be followed irrespective of
whether such standards are specifically mentioned against the
individual items or not. The list of IPSS Standards on cranes/ crane
components is as follows.
1. IPSS:1-03-003-94 A.C. Mill / Crane duty slip-ring induction
motors
2. IPSS: 1-03-004-95 Specification for A.C. Crane duty squirrel cage
induction motors
3. IPSS:1-03-005-03 Specification for dc Crane / Mill duty motors
(600 series)
4. IPSS: 1-04-001-03 Specification for Contactors for voltages not
exceeding 1000 V ac. or 1500 V dc
5. IPSS: 1-04-003-03 mechanically operated limit switches for
control circuit for voltages up to and including 1000 V ac. and
1500 V dc.
6. IPSS: 1-04-004-03 Specification for moulded case circuit breakers
for voltages not exceeding 1000 V A.C. for 1200 V D.C.
7. IPSS: 1-04-016-90 Minimum oil circuit breakers (MOCBs).
8. IPSS: 1-08-001-18 Crane wheels (third revision).
9. IPSS: 1-08-002-18 Sheaves assembly for EOT cranes
10. IPSS: 1-08-003-18 Wire ropes for cranes
11. IPSS: 1-08-004-18 Forged crane hooks
12. IPSS: 1-08-005-18 Brakes for cranes
13. IPSS: 1-08-007-18 Hook blocks.
14. IPSS: 1-08-008-18 Forged ramshorn hooks.
15. IPSS: 1-08-009-18 Laminated ladle hooks.
16. IPSS:1-08-010-18 Crane wheel assembly (live axle type)
17. IPSS: 1-10-001-11 Lifting magnets (third revision).
18. IPSS:1-10-002-02 Resistance boxes for power circuits
19. IPSS: 1-10-003-02 Electro hydraulic thrustor.

20. IPSS: 1-10-005-81 Master controller.
21. IPSS: 1-10-006-81 Drum/ Cam controllers.
22. IPSS: 1-10-008-00 Current collector assembly.
23. IPSS: 1-10-009-88 Brake coils.
24. IPSS: 1-10-010-84 General requirements for control panels for
cranes (with Amendment 1).
25. IPSS:1-04-042-03 Particular requirements for control panels
for ac Cranes (first revision )
26. IPSS:1-04-043-03 Particular requirements of Control Panels for
dc Cranes
27. IPSS: 2-02-005-18 Code of practice for selection of electric
cables for use on EOT Cranes.
28. IPSS: 2-02-006-18 Code of practice for laying of electric cables
on EOT Cranes.
29. IPSS: 2-02-007-18 Guidelines for safety in EOT Cranes.
30. IPSS: 2-02-008-18 Tests and checks for acceptance of EOT
Cranes.
v. All components for cranes of identical capacity and duty shall be
interchangeable unless otherwise required.
vi. All machinery or equipment included under this specification shall be
equipped with safety devices and provided with adequate clearance to
comply with this standard and Employer's requirements along with
safety codes and statutes prevalent at the place of installation of the
equipment.
vii. For welded construction such as that of bridge girders, end carriages,
trolley frames, rope drums, gear box casings etc., steel shall be of IS
2062:2011, E 250/E-350 Gr quality. Low hydrogen electrodes shall be
used for welding these members.
viii. No cast iron parts shall be used on the crane except for electrical
equipment. Similarly, no wood or other combustible material shall be
used in any part of the crane.
ix. Foot walks shall be of sufficient width to give at least 500 mm clear
passage at all points, except between railing and bridge drive where
this clearance may be reduced to not less than 400 mm.

x. Guards of an approved design, which shall push forward or off the
track any object placed across it, such as a person's foot or arm, shall
be attached to each end of the end carriages.
xi. All wheels, couplings, open gears etc. shall be provided with cover
openings on strong hinges. These covers shall preferably be made of
minimum 5 mm thick plates. All heavy covers shall be provided with
inspection windows.
xii. Fasteners
 All bolts shall be hot dip galvanized with minimum 8.8 grade.
 Black bolts shall not be used.
xiii. Standardization and unification shall be carried out to the maximum
extent for the various sub-assemblies constituting the mechanism of
the crane. Units shall be designed such that they can be dismantled
quickly without disturbing the installation of the neighbouring units
with which they are connected. Units as a whole like wheel assembly,
gear box, brake rope drum assembly, snatch block etc. shall be
replaceable and interchangeable with other identical units. In design,
care shall be taken so that inventory is kept low and the down time
becomes minimum
3.3.4.1 Structural Details
a) General
Crane structures shall be designed in accordance with the latest edition
of IS 807:2006 taking the following additions/ deviations as applicable,
into account:
i. Unless otherwise specified, only bolted or welded joints shall be
used. In case of welded joints, only low hydrogen electrodes as
per IS 814:2004 shall be used.
ii. Not less than two turned fitted bolts or equivalent length of
welding at each joint shall be used for connections.
iii. The calculated strength of joints made by friction grip bolts in
structural members shall not be less than the calculated net
strength of the member. The calculated strength of other bolted
joints in structural members shall be not less than the net
strength of the member plus 25%.
iv. Bolts used in shear shall be fitted into reamed holes.

v. Where bolts pass through sections having tapered flanges, taper
pads shall be welded to the tapered flange. Taper washers shall
not be used.
vi. Transverse fillet welding on load carrying members shall be
avoided.
vii. All butt welds on structural members, subject to tensile stress
shall be x-rayed.
viii. Plates, bars, angles and where practicable, other rolled sections
used in the load bearing members of the structure shall not be
less than 8 mm thick. Steel tubes, if sealed at the ends, shall not
be less than 4.9 mm (6 S.W.G.) and if unsealed, not less than 8
mm thick.
ix. For cranes working outdoors or in corrosive conditions a
corrosion allowance of 1.5 mm shall be added to the thickness of
the members required to resist all calculable stresses and the
minimum thickness of the member shall, however, be not less
than 10 mm.
x. Minimum thickness of Chequered plates for platforms shall be 6
mm over plain for indoor cranes and 8 mm over plain for outdoor
cranes. Chequered plates shall not be considered for strength
calculations of load carrying members.
xi. Splice shall be designed to resist all the forces and moments to
which it is subjected to, plus 50% thereof. However, in no case
the strength developed by the splice shall be less than 50% of the
effective strength of the material spliced. Splices shall be
proportioned and arranged, so that the gravity axis of the splice
is in line with the gravity axis of the members jointed so as to
avoid the eccentricity of the loading.
xii. Air conditioned E-room shall be provided for all class-IV cranes.
xiii. Air conditioned inline panels for VVVF drives shall be provided
for other than class-IV cranes.
b) Bridge Girders
The bridge girders shall be of box construction with (double web plate)
girders. Girders shall be sufficiently strong and rigid to withstand the
most severe combination of loads that may develop under different
working conditions.
The design of the bridge girder shall be in accordance with the latest
edition of IS 807:2006, IS 800:2007 and IPSS: 2-02-003-97 for
“General Code of Practice for Design of EOT Cranes (Mechanical
Aspects)”. Number of splices to make up the requisite lengths for web
and flange materials of the girders shall not be more than 2 for girders
up to 24 m span and 3 for girders over 24 m span.
c) End Carriage
End carriages shall be fabricated from rolled steel sections or plates, or
both, bolted or welded together to form a box, except for essential
openings which shall be reinforced. If more than two wheels are
required bogies shall be provided or articulated end carriages shall be
used. The end carriages shall be fitted with substantial safety stops to
prevent the crane from falling more than 25 mm in the event of
breakage of a track wheel, bogie or axle. These safety stops shall not
interfere with the removal of wheels.
Suitable jacking pads at a height of 300 mm from rail level shall be
provided on each end carriage for jacking up the crane when changing
track wheels. Jacking pads shall be coaxial with the rail and shall not
interfere with the replacement of track wheels.
d) Trolley Frame
Trolley frame shall be produced in one piece unless there are transport
limitations. In the case of splicing of the frame, the design shall be such
that one unit of a mechanism mounted on one part of the trolley does
not come over the other part. Connection between the two parts of
the trolley shall be done by machined bolts.
Drum bearings and supports for upper sheaves shall be located so as
to equalize the load on the trolley wheels as nearly as possible.
The trolley frame shall be built of rolled sections and plates to form a
rigid structure capable of withstanding all stresses that shall develop
during the working of the crane and shall be arranged to afford
maximum accessibility to mechanical and electrical parts placed on it.
It shall be designed such that at the highest position of hook there
shall be a clear distance of 700 mm between the lowest point of trolley
obstruction and the highest point of bottom block. Deviations shall be
made only with specific approval of Employer.
The top of the trolley frame shall be plated all over except for openings
required for the ropes and flexible cables for bottom block etc., to pass.
The openings in the trolley frame shall be such as to keep the ropes or
cables at least 125mm away from any part of the trolley frame or
equipment to prevent damages for all positions of the bottom block.
All the mechanical and electrical equipment shall
be placed above the trolley top plate as far as practicable. For any parts
placed below the trolley top plate, access for maintenance, repair and
replacement shall be provided. Hand rails shall be provided on all the
four sides of the trolley (except in case where protective guard is fitted
on the trolley conductor side when rails on the three other sides hand
only shall be provided) with openings on the platform side opposite to
the trolley conductor side.
The trolley shall be fitted with substantial safety stops to prevent the
trolley from falling more than 25 mm in the event of breakage of a
track wheel, bogie or an axle. The safety stops shall not interfere with
the removal of wheels. Suitable jacking pads shall be provided for
changing trolley wheels. Jacking pads shall be coaxial with the rail.
e) Trolley Rail
Trolley track rails made of rail steel shall be clamped to the girders with
double bolt clamping plates. Rail clamp shall be as per 1-08- 017-14.
f) Repair Cages
i. Repair cages shall be provided on the inside of the end carriage
for attending to the crane current collectors. Repair cages shall
also be provided at the corners of the crane, if required, to
facilitate removal of long travel wheels. The repair cages shall be
minimum 1000 mm wide and shall be such that two persons can
work comfortably in the space provided.
ii. The floor of the repair cages shall be about 1500 mm below the
LT wheel centres except the one on which the main current
collectors are mounted, where it shall be suitably adjusted.
iii. The cages shall be of structural steel and shall be made
substantially rigid by gusset plates and braces welded or riveted.
Repair cages shall be provided with railings on all sides except for
the repair cages on the down shop lead side, which shall be
provided with easily removable type protection guards on three
sides for safety reasons.
g) Operator's Cabin
i. The operator's cabin shall be of sufficiently rigid metal frame and
shall be connected to the bridge girder with turned and fitted
bolts in reamed holes with washer and lock nuts. It shall be built
with a clear head room of not less than 2 m.

ii. The operator’s cabin frame shall be made of rolled sections such
as ISMC, ISMB & ISA.
iii. Air conditioned cabins to be provided for the EOT cranes
operating at hot zones. Air condition shall be of LINTERN, USA /
FRIGO TECH, Germany make (SS body).
3.3.4.2 Mechanical details
i. Design of Mechanisms
The cranes shall be designed in accordance with the design standards
mentioned above.
ii. Rope drums
Rope drums of dia. ø500 and more shall be fabricated from
ultrasonically tested steel plates conforming to IS:2062:2011, E- 250/E-
350 Gr and shall be stress relieved. Rope drums of dia. less than ø500
shall be from ultrasonically tested seamless steel pipes conforming to
ASTM A 106 Gr-B
iii. Hoist ropes
Ropes shall be selected from IPSS 1-08-003-18.
iv. Rope sheaves
All sheaves shall be of cast or forged steel conforming to IPSS-1-08-
002-18. All sheaves shall be identical. However, exception may be
made for equalizer sheave.
v. Wheels
Wheels shall be double flanged with straight tread, conforming to IPSS
1-08-001-09 'Specification for Crane Wheels'.
vi. Buffers
Hydraulic buffer shall be provided for LT & CT of all class-IV cranes
Hydraulic buffers shall be fitted on all the four corners of the crane and
also at the four ends of the bridge girders (and not on the trolley
frame) for soft dashing of the crane and trolley respectively against
stops.
The maximum deceleration rate for both bridge and trolley shall not
exceed 5 m/s2 at 50 percent of the full load rated speed. Between
cranes or trolleys (if two trolleys are located on one bridge) bumpers
shall be capable of absorbing the energy from 70 percent of full load
rated speed of both cranes and trolleys travelling in opposite
directions, whichever is the greatest.

vii. Drives
The drives for various mechanisms shall be according to the following
schemes:
 Hoist Drives
The electric motor of hoist mechanism shall be connected to the
gear box through a Flexi pin bush coupling. The output of the
gear box shall be connected to the rope drum by drum barrel
coupling. The brake shall be mounted on the input shaft of the
gear box preferably on the extended portion of the shaft.
Planetary gear box shall be provided for hoist ≥100t.
Magnet Crane
The scheme of hoist mechanism of a magnet crane shall be
similar to the hoist mechanism scheme in conformity with hoist
drive. The cable reeling drum shall be driven by hoist drum by
suitably enclosed gear transmission unless otherwise specified
(not spring loaded) as required. A suitable clutch to disengage
the cable reeling drum, when not in use, shall be provided in the
latter case.
 Travel Drive
For long travel motion individual wheel drive shall be considered
50% of the long travel wheels shall be positively driven unless
agreed otherwise by the Employer.
In case of four motor individual wheel drives, if any one corner
motor fails, the other corner motor on the same side of the failed
motor shall also trip to avoid skewing of the crane and the two
other motors shall be capable of driving the crane at rated speed
and reduced acceleration.
For cranes with 16 nos. and above LT wheels, epicyclic gear train
shall be provided.
Magnet Crane
The scheme of hoist mechanism of a magnet crane shall be

similar to the hoist mechanism scheme in conformity with hoist
drive. The cable reeling drum shall be driven by hoist drum by
suitably enclosed gear transmission unless otherwise specified
(not spring loaded) as required. A suitable clutch to disengage
the cable reeling drum, when not in use, shall be provided in the
latter case.
viii. Gearing
Straight and helical spur gearing shall normally be used for all drives.
Worm and bevel gears shall not be used unless specified otherwise.
First and high speed reductions shall be through helical gears. All first
reduction pinions and also other pinions if feasible shall be integral
with the shafts. All gears shall be of hardened and tempered alloy or
carbon steel with machine cut teeth. Gear teeth shall be cut in metric
module system. Surface hardening of teeth is not allowed.
Gears and pinions of such design and size which are not suitable for
forging or gears for which suitable wrought steel blanks are not
available, shall be of cast steel. Overhung or split gears and pinions
shall not be used. In order that speeds of the various motions may be
changed in future, design shall be such as to allow 15 per cent increase
or decrease in the total gear ratio of each drive, if specified.
Surface hardness for pinion shall be 255 to 300 BHN and for gear it
shall be 217 to 255 BHN. Difference in hardness of pinion and gear
shall not be less than 20 BHN.
ix. Gear boxes
All gears shall be enclosed in oil tight housings sealed with compound.
The gear boxes shall be splash lubricated. All gear shafts shall be
supported in bearings mounted in gear box. In case of totally enclosed
gear boxes splash automatic lubrication system shall be used. The gear
boxes shall be fabricated. Fabricated gear boxes shall be made of
minimum 8 mm thick steel plate. All fabricated gear boxes shall be
stress relieved. In case of horizontal gear box covers shall be split
horizontally at each shaft centre line and fastened and arranged so that
the top half can be removed for inspection and repair without
disturbing the bottom half. The gear boxes shall be provided with
breather vents, oil level indicator, dip sticks and easily accessible drain
plugs.
For all class IV cranes, horizontal gearbox shall be provided for hoist &
LT motions. But for CT motion horizontal or vertical gearbox can be
considered. For vertical gearbox, horizontal split type boxes shall be
considered. Vertical gearbox mounting shall be near to the base (on
output stage).
x. Bearings
Anti-friction bearings of SKF/FAG makes shall be used throughout
except where specified otherwise or mutually agreed.

xi. Couplings
Motor shafts shall be connected to gear box input extension shafts
through Flexi pin bush coupling /flexible shock absorbing couplings.
For driving hoist drum barrel couplings shall be used between hoist
rope drum and hoist gear box output shaft. Solid couplings shall be
used only for connecting intermediate lengths of long travel and cross
travel shafts.
All couplings shall be made of forged or cast steel and shall be
designed to suit the maximum torque that can be developed. Toothed
couplings shall be used wherever possible in crane mechanisms.
Hardness of geared coupling casing shall be more than 220 BHN and
that of toothed bush shall be more than 280 BHN. Bolt connection of
couplings shall be easily accessible for inspection and tightening.
xii. Lifting hook
Standard shank hook shall be used unless otherwise specified. The
hook shall conform to the latest edition of IS: 15560/DIN. Forged single
point shank hook shall conform to IPSS 1-08-004-89.
For loads up to 60 tonnes, shank type plain hooks may be used. Hook
of magnet duty cranes shall be prevented from rotation and shall have
latch to prevent jumping out of the suspension chain of the electro-
magnet.
xiii. Brakes
 DC Electromagnetic Brake
Brakes shall conform to IPSS:1-08-005-86. D.C. electro-magnet
brakes only shall be used.
Double shoe brake shall be provided for each drive. 2 nos. of
brakes shall be provided in each hoist drive for capacities 20t and
above.
Service factors
Hoist brakes = 1.5 x Selected motor kW (for single brake)
= 1.25 x Selected motor kW (for 2 brakes) Travel
brakes = 1.25 x Selected motor kW (For both LT & CT)
Brake shall be mounted on the input pinion shaft of the gear
train. Brake drums shall be forged or of cast steel. Brake drums
shall be completely machined and dynamically balanced.

Long travel motions of outdoor cranes shall be provided with an
additional storm brake. Adequate means, independent of the
additional storm brake shall also be provided on outdoor cranes,
for securely anchoring the crane to the gantry when not in use.
Co-efficient of reserve of the holding force shall not be less than
2 considering maximum wind pressure
Metric system shall be considered for DC electromagnetic brakes.
Electro hydraulic thrustor brake shall not be considered
Hydraulically operated emergency disc brake shall be considered
for all cranes ≥100t capacity
xiv. Shafting
High speed shafts shall be checked for critical speed. The ratio of
critical speed to speed of shaft shall be not less than 1.2.
xv. Crane lubrication
Automatic centralized lubrication with dual line system shall be
preferred. Motorized centralized lubrication with dual line system shall
be considered for all class IV cranes.
The system shall be 1 no. working (minimum) and 1 no. standby for
main pumps with reservoirs, filters, relief valves, and change over
valves etc.
Minimum internal diameter of the grease pipes shall be 8 mm and
thickness 2mm. Material of pipe shall be DIN 2391 C. All pipe work
shall be securely fixed, protected from damage and accessible
throughout. Effective protection shall be provided to prevent access of
dust to the lubricant and such protection shall also be weather proof
on outdoor cranes. A lubrication chart shall be provided, indicating all
lubricating points, the type of lubricant required, and the
recommended frequency of lubrication.
Wire rope & wheel track lubrication (non-graphite type) shall be
provided for Class-IV duty.
3.3.4.3 Lubrication System for other areas
Minimum 2(two) units of portable motorized grease pump unit with
container along with one unit of refilling pump shall be provided for
lubrication of other equipment. 2 nos. hand grease guns shall also be
provided for manual lubrication.

3.3.5 Under-slung crane
3.3.5.1 The broad technical specification of the under-slung crane shall be as
follows;
Sl. Nomenclature Description
1 Type Single girder, suspended, trolley type
underslung crane
2 Location As mentioned above
3 Purpose Maintenance of equipment
4 Quantity As mentioned above
5 Capacity (t) As mentioned above
6 Height of lift As per requirement
7 Span As per requirement
8 Length of travel As per requirement
9 Hoisting speed 4.0 (approx.)
(m/min)
10 Travel speed (m/min) L.T - 10.0 (Approx.)
C.T – 8.0 (Approx.)
11 Hoisting and travel All motorized
12 Duty class & Design Indoor as per IS:3177, IS:807 2006 &
standard IS:3938 1983 (Class-II) (M-5)
13 Control Pendant operated push button
14 Brakes DC Electromagnetic
Hoist- Shoe brakes
LT & CT- Disc brake
15 Motors Standard frame motors
16 Control panel & The control panel and brake panel of the
Brake panel hoists shall be separately mounted on
structures and shall not be mounted on
the hoist.
17 Walkway & Platform Walkway shall be provided on both sides
of gantry along the entire length of LT
movement. Platform shall also be provided
on both sides of crane girder along the
entire length of CT movement
18 Crane maintenance Maintenance platform shall be provided at
platform the end of the building for maintenance of
the crane. Width of the platform shall
accommodate the entire over buffer
length of the crane.
The level of the platform shall be 100mm
(minimum) below the level of the hoist
Sl. Nomenclature Description
hook at highest position
19 Buffers LT - Spring buffers
CT - Rubber buffers
20 Lubrication Manual grease lubrication
21 General The design & constructional requirements
of major components like hook, gear,
trolley wheel, all structural components,
lubrication and bearings, load brakes,
safety devices and clearances etc. shall be
as per the relevant standards.
3.3.5.2 Design Standards & General
i) Under slung cranes shall be designed, manufactured, assembled and
tested in accordance with the latest revision of IS:807, IS:3177, IS:3938
and other relevant codes and practices for the cranes to be used in
steel plants, steel industry (IPSS) unless otherwise stated.
ii) The components of the hoist shall be designed, manufactured,
assembled and tested in accordance with the latest revision of IS:3938
and shall be of standard make.
iii) All working parts requiring replacement or inspection or lubrication
shall be easily accessible without the need for dismantling of other
equipment or structure.
iv) All electrical cables shall be so laid that they are not liable to be
damaged and can be easily inspected and tested.
v) No cast iron parts shall be used except for electrical equipment and no
wood or other combustible material shall be used unless specifically
mentioned otherwise.
vi) Where down shop leads are located below runway rails, guard shall be
provided on the crane to prevent the hoist ropes from coming in
contact with down shop leads.
vii) All bolts except those with nyloc nuts shall be provided with grip lock
nuts or spring washers.
viii) All trailing cables shall be clamped with PVC or non-metallic clamps.
ix) Steel frames carrying machinery shall be machined to true surface.
x) All gears and bearings shall be lubricated by splash lubrication/ grease
as required. All greasing points shall be easily accessible.

xi) The lift and travel length of the hoists shall be suitable for handling
equipment from the ground floor level.
3.3.5.3 Structural design
i) The crane structure shall be designed in accordance with the latest
revision of IS: 807.
ii) The bridge girder shall consist of main and an auxiliary structure
wherever necessary.
ii) End-carriages shall be fabricated from rolled steel sections or plates,
or both, welded together to form a box.
iv) End-carriages shall be of ample strength to resist all stresses likely to
be imposed on them under severe conditions, including collision with
other cranes or stops. The length of the end-carriage shall be such that
no other part of the crane is damaged in collision.
v) The end-carriage shall be fitted with safety stops to prevent the crane
from falling more than 25 mm in the event of breakage of a track wheel
or axle. Suitable jacking pads shall be provided on each end- carriage
for jacking up the crane while changing track wheels.
vi) Black bolts shall not be used in the load bearing structures of the crane.
Also high tensile friction grip bolts shall not be used unless approved
by the employer.
vii) Bolts used in shear shall be fitted into reamed holes.
viii) Transverse fillet welding on the load carrying members shall be
avoided.
ix) All butt welds on structural members, subject to tensile stress, shall
undergo radiography tests.
x) Plates, bars, angles and where practicable, other rolled sections used
in the load bearing members of the structure shall not be less than 8
mm thick.
xi) Steel sections and plates, used for construction shall be of the latest
revision of IS: 2062 (2011).
3.3.6 Repair trolleys & Electric Hoists
3.3.6.1 The facilities to be provided for handling purpose are as follows:
Sl. No. Location Description Capacity Qty.
(nos.)
i) NP Bay Repair trolley (Double rail 10t 1
type) for maintenance of

120t/20t EOT crane
ii) MN Bay Repair trolley (Double rail 12.5t
type) for 250t+80t/10t
maintenance of EOT crane
iii) KL Bay Electric hoist for 7.5t 1

maintenance of 100t/10t
EOT crane
iv) New Mould Electric hoist for 5t 2
& Segment maintenance of 50t/10t
Repair Shop EOT crane
v) LM Bay Repair trolley (Double rail 5 1
EOT crane
vi) PQ Bay Repair trolley (Double rail 5 1
15+15t tong crane
vii) QR Bay Repair trolley (Double rail 5 1
EOT crane
viii) R’S Bay Repair trolley (Double rail 5 1
EOT crane
ix) Primary scale 5 1
Electric hoist for
water pump
maintenance purpose
house
x) Chiller room Electric hoist for 2 2
maintenance purpose
xi) Ventilation Electric hoist for 2 2
room maintenance purpose
xii) Booster Electric hoist for 2 1
pump house maintenance purpose
3.3.6.2 The broad technical specification of the electric hoists shall be as follow;
Sl. No Nomenclature Description

1 Type Motorized, trolley suspended electric
hoist
2 Location At suitable locations as per requirement

Sl. No Nomenclature Description
3 Purpose Handling/ Maintenance purpose
4 Quantity As per requirement
5 Capacity (t) As per requirement
6 Lift (m) As per Requirement
7 Hoisting speed As per Requirement
(m/min)
8 Travel speed (m/min) As per Requirement
9 Hoisting and travel All motorized
10 Duty class II as per IS 3938:1983
11 Monorail for hoist Suitable for electric hoist
12 Control Pendant Operated
13 General The design and constructional
requirements of major components like
load chain, hook, gear, trolley wheel, all
structural components, lubrication and
bearings, load brakes, safety devices and
clearances etc. shall be as per the
relevant standards.
The lift and travel length of the hoists
shall be suitable for handling equipment
from the floor level.
i) The hoists shall have dc electro-magnetic brakes. For hoisting shoe

brakes and for travelling disc brakes shall be provided.
ii) The control panel and brake panel of the hoists shall be separately
mounted on structures and shall not be mounted on the hoist.
ii) The hoist shall have trailing cable arrangement for power supply.
iv) The hoist shall have provision of maintenance platforms.
v) The motors offered for hoist shall be standard frame motors only.
vi) All electric hoist ≥ 10t capacity shall be double rail (repair trolley)
type.
3.3.7 Belt Conveyors
1. Application

i. This covers general requirements for belt conveyor for handling
of proposed material. Specific requirement and layout shall be as
per Technical Specification and drawings mentioned in this
document.
ii. The belt conveyors shall include all types of pulleys, idlers,
belting, drive unit, drive frame, head frame, tail frame, take-up
unit, short post, stringer channel, deck plate, seal plate, discharge
chute, skirt board, external scraper, internal scraper, protection
switches, protection cage, fastener between equipment and its
support.
2. Design of Belt Conveyors
Belt Conveyors shall be designed as given below:
S.N. Item Description
i. IS 11592:2000
Belt
However, the design capacity of the conveyor
Conveyors
belts shall be 1.2 times of the rated capacity
and the design factor for kW calculation of
the motor shall also be 1.2
ii. 70% of rated capacity
Maximum
loading
iii. Gearbox kW ratings of gearbox=1.8 x Selected Motor

kW
iv. High Speed Rating of High Speed Coupling=Selected

Coupling Motor kW
v. Low Speed =(Selected motor kW*1.36*1.5*100) / (Motor

Coupling rpm / reduction ratio)
(HP/100 rpm)
vi. Braking =(Selected motor kW*1.36*1.5*4500*10) /

Torque (2*3.14*Motor rpm)
(DCEM) (Nm)
vii. Pulleys IPSS: 2-03-007-88
viii. Idlers IS 8598:1987
ix. Plummer Plummer blocks for pulleys shall be with 4

bolts and horizontally split type construction
Blocks made of cast iron.
x. Take-up Horizontal take up for C/C distance

Arrangements upto=50m and Vertical gravity take up for
C/C distance more than 50 m as per IS
11592:2000.
xi. Take up travel 2.5% * Belt C/C distance(mm) + 600 mm
xii. Factors for All the factors shall be considered for worst
design of condition
conveyor
3. Broad technical parameter of the belt conveyors shall be as below:
S.N. Item Description
i. Belt Conveyor As per requirement

Details
Rated Capacity (tph) As per requirement
1.2 x Rated Capacity

Designed
capacity(tph)
Purpose Handling of Ferro alloys & lime
Material to be Ferro Alloys

handled
Bulk density
(t/m^3)
Ferro Alloys
3.8
Calcined lime 1.0
Lump size (mm) 0-60
50
Ambient temp (°C )
Belt Width (mm) 650 (minimum)
C/C Length (m) As per requirement
Lift (m) As per requirement

Belt Speed (m/s) As per requirement
Length of skirt (m) 3
Deck plate(mm) 3.15
Take Up
 Type As per requirement
 Travel (mm) As per requirement
ii. Belting
Type N/N
Rating 400/3 (minimum)
Cover grade
Top cover (mm) 5
Bottom cover (mm) 2
Drive System
iii. Electric Motors
Type Squirrel cage induction motor
Quantity(No.) As per requirement
Rating(kW) As per requirement
Speed(rpm) As per requirement
iv. Gear Boxes
Type As per requirement
Reduction ratio As per requirement
Nominal rating (kW) 1.8 x Selected Motor kW

v. High Speed
Coupling
Rating (kW) Selected Motor kW
vi. Low Speed / Gear

Coupling
Rating (HP/ 100 As per requirement

rpm)
vii. Brakes As per requirement
Pulleys
viii. Drive Pulley
Quantity (No.) 1(minimum)
Pulley diameter 500 (minimum)

(unlagged) (mm)
Pulley shaft 100 (minimum)

diameter (mm)
Pulley face width 750 (minimum)

(mm)
Shell thickness(mm) 16
ix. Tail / Take-up and

Bend Pulley
Quantity (No.) As per requirement
Pulley diameter 400 (minimum)

(unlagged) (mm)

diameter (mm)

(mm)
x. Snub Pulley Both at tail end & Head end
Quantity (No.) 2 (minimum)
Pulley diameter 315(minimum)

(unlagged) (mm)

diameter (mm)

(mm)
Idlers
xi. Carrying idler
Troughing angle 350
Belt width (mm) 650 (minimum)
Idler diameter (mm) 152.4
Length per roll 250 (minimum)

(mm)
Type 3-roll in line
xii. Impact idler
Troughing angle 350

Cushioned ring 88.9
inside diameter (mm

(mm)
Type 3-roll in line
xiii. Return idler
Length of roll (mm) 750 (minimum)
Type Single roll inline
xiv. Self-aligning
carrying idler
Troughing angle 350

(mm)
Type 3-roll in line
xv. Self-aligning return

idler

(mm)
Type Single roll inline
xvi. Transition idler

Troughing angle 100, 200 and 300

(mm)
Type 3-roll in line
xvii. External scrapper
Type Primary scrapper shall be of

polyurethane while secondary
scrapper shall be sprung bladed type
tungsten carbide tip with modular
segments complete with all
accessories
Location At discharge pulley of the conveyors
xviii. Internal scrapper
Type V-type internal scrapper
Location On the upper side of the return belt

near the tail end
4. Steel structure
i. Steel structure specified herein shall be applied to steel structures
such as conveyor stringers, short posts, head frame, drive frame,
take up structure, tail frame. The spacing of short posts of
conveyors shall not exceed 3000 mm. The construction of stringer
and short post shall be of ISMC 125 (minimum section).
ii. Construction of steel structures shall be rigid being made by
shaped steel and steel plate.
iii. Conveyors shall be provided with continuous MS deck sheet of
3.15 mm thickness.
iv. Conveyors shall be provided with 3.15 mm steel seal plate
throughout their lengths

v. Couplings shall be covered with protection covers made of 3.15
mm thick sheet.
vi. Tail pulleys shall be covered with protection cages.
vii. All conveyor galleries shall be as per relevant IPSS. The walkway
shall be provided on both sides of conveyor galleries and shall
have clear space 1000mm (minimum). For conveyors with double
gallery the central walkway shall also have clear space of 1000mm
(minimum). The minimum clear height of conveyor galleries shall
not be less than 2500mm.
viii. All idlers shall be mounted on ISA 90x90x8mm (minimum).
ix. Seal plate / pre cast slabs shall be provided on the entire
conveyor gallery.
x. Conveyor frames shall be made of joists and/or channels suitably
stiffened and braced. The spacing of supports shall not exceed
3000 mm. Frames shall be connected to floor beams/civil
foundation of junction house by bolting.
xi. Drive Base Frame
The drive unit consisting of motor, gear-box, coupling and brakes
along with protective guards shall have a common base frame
and shall be fabricated form heavy structural sections and plates.
Suitable bracings should be provided wherever necessary on the
drive unit base frame and structure to make it rigid. Proper
arrangements shall be provided with gear-boxes and motors to
maintain correct alignment with finish pads for mounting. The
drive base frames shall be bolted to the structural floor
beams/civil foundation of junction houses.
xii. Guards on the conveyor shall comply with the relevant IS/ IPSS
Standard. Safety guards shall be provided for all couplings,
brakes etc. of the conveyor drive and screwed on the above base
frame.
5. Chutes and liners
i. All transfer points shall be provided with non-choking chutes and
shall be designed such that impact of the material on the
conveyor is minimum. It shall be designed to ensure continuous
flow of material to the centre of the belt. Minimum angle of slope
of chute plate shall be 60 deg. The slope angle shall be suitably
increased for handling wet or sticky material.

ii. Chutes shall be made of 10 mm thick MS plates with angle
stiffeners and shall be rectangular cross-section with welded
connection. Chutes shall be constructed in pieces of suitable size
and length so as to facilitate their maintenance. Chute pieces
shall be joined together by bolted flange connection with rubber
sealing in between two flanges. Inclination angle of chutes shall
be sufficient to facilitate easy flow of materials.
iii. All surfaces of chutes shall be provided with Hardox 500 liners of
10 mm thick to be fitted with countersunk screws. Snub pulley
and belt cleaner for head pulley shall be provided inside the chute
to prevent raw materials from spilling from the conveyors. Each
chute shall be provided with inspection hole with hinged cover at
suitable height and location. Adequate sized flanged openings
with inspection doors are to be provided near bends where there
is chance of clogging for inspection and poking to clear the
accumulation. Chute construction below gate shall be such that
there shall not be any clogging of materials between chute and
gate in that zone.
6. Skirt boards
Skirt boards of minimum 3000 mm length shall be provided at each
feeding point of conveyors and shall terminate above an idler. The
width of skirt shall be two third of conveyor width. The thickness of the
skirt plate shall be 10 mm with 10 mm (minimum) Hardox 500 liner
plate fitted with countersunk bolts. Skirt shall flare slightly outwards in
the direction of belt travel to prevent material from wedging. The
height of the skirt boards shall be 450 mm and shall be sufficient to
contain the material volume as it is loaded on the belt. The skirt plates
shall be fitted with rubber strips (100 mm wide x 12 mm thick) of
hardness 65-700 Shore A by means of vertically slotted holes to permit
adjustment. Cut pieces of conveyor belting shall not be used. Rubber
strips shall be so fixed as to facilitate their replacement. Edges of
rubber strips shall have an angle for providing better seal. All care shall
be taken while designing to combine sealing with minimum belt wear.
Rubber curtains shall be provided at the exit of skirt to enclose the
chute outlet. The thickness of top cover plate shall be 3.15 mm.
7. Discharge hood

Discharge hood over the head pulley of various conveyors shall be
made of 6 mm thick MS plate and shall be provided with hinged and
gasketed inspection doors with a suitable access to them. For portion
of hood below the pulley frame and upto 500 mm below the floor, the
thickness of plate shall be 10mm. 10 mm thick liner plate shall be
provided in this portion of hood in the material impact zone. The hood
shall be in segments bolted to each other for ease of maintenance. The
hood shall cover discharge opening for the chute as well as pulley. The
serrated rubber seals also are provided at the very inlet of head chute
to minimise dust nuisance.
8. Belt cleaners
i) Internal scraper
Each belt conveyor shall be provided with 1 No. V-type internal
scrapper on the upper side of the return belt near the tail end,
fitted with wear resistant non-metallic scraper blade to remove
spilled materials on the belt. The blade shall be adjustable after
the wear.
ii) External belt cleaners
External belt cleaners shall be provided at discharge pulley of each
conveyor. It shall consist of 01 no. primary and 01 no. secondary
scrapper. Primary scrapper shall be of polyurethane while secondary
scrapper shall be sprung bladed type tungsten carbide tip with
modular segments complete with all accessories.
Polyurethene deflector skirts shall be provided below the tips to
prevent materials build up on the unit. The cleaners shall be
mounted on an elastomount system to facilitate automatic blade
adjustment on wear. The inclination of the blades should be such as
to effect efficient scrapping of the belt. The spring action of the
individual metallic blades should ensure constant contact with belt
during operation and suitable sprung deflection of contact with
uneven surface of the belt. The blades shall be in segments for ease
of replacement and mounting on the head pulley frame. The
material scrapped should fall inside the discharge chute directly.
9. Belt take-up arrangement
i. Take up for proposed belt conveyor less than 50m shall be screw
take up type.
ii. Vertical type gravity take-up systems shall be provided for all other
proposed belt conveyors as detailed below, complete with all

pulleys, counter weights & all other accessories. The counter
weights shall be of cast iron and each block shall weigh 20 kg
approximately. Suitable chequered plate platform with ladder,
handrails for maintenance of the gravity take-up system shall be
provided. A protective cage of suitable size and expanded metal
construction shall be provided. Necessary safety arrangement with
sand bed shall be provided for counter weight systems. The
allowance for take-up movement shall be 2.5% of the centre to
centre distances of the belt conveyors + 600 mm.
iii. Bidder shall consider EP belts, wherever, accommodating take-up

system shall be a constraint due to space.
iv. Suitable handling facility shall be provided for handling of counter

weights. Electric hoist with monorail shall be provided for lifting
weight ≥ 3t and/or height of lift ≥ 8m. For lifting weight < 3t and/or
height of lift < 8m manual hoist shall be provided.
10. Spacing for idlers and safety switches shall be generally as follows:
i. The carrying idlers shall be placed 1000 mm apart along the
profile of the belt conveyor.
ii. 1 No. 100, 1 No. 200 and 1 No. 300 transition idler shall be
located at the head as well as tail end of the belt conveyor. The
transition distance shall be approximately equal to the belt
width. The distance between the two transition idlers shall be
also approximately equal to the belt width.
iii. 6 Nos. impact idlers each at a spacing of 400 mm shall be
located at the feed point of material of the belt conveyor, along
the profile of the belt conveyor.
iv. Self-aligning carrying idlers shall be located with a spacing of
15000 mm in-between them, along the profile of the belt
conveyor.
v. Self-aligning return idlers shall be provided with a spacing of
15000 mm in-between them, along the profile of the belt
vi. The return idlers shall be provided 3000 mm apart along the
profile of the belt conveyor.
11. Safety Switches
i) Pull cord switches

Pull cord switches shall be provided for emergency stoppage of
conveyor. Pull cord switches shall be placed on both sides of the
belt conveyor with a spacing of 20 mm in-between them, along
the profile of the belt conveyor. Minimum 2 pairs of switches shall
be provided if the centre-to-centre distance is less than 20
m. All pull cord switches shall have individual local indication
lamps to indicate when operated.
ii) Belt sway switches
Belt sway switches shall be provided on each conveyor for
protection against excessive sway of the belt. Belt Sway switches
shall be placed on both sides of the belt conveyor with a spacing
of 20 m in-between them, along the profile of the belt conveyor.
Minimum 1 pair of switch shall be provided if the centre-to-
centre distance is less than 20 m. A pair of these switches shall
also be provided before the belt weighing scales.
iii) Zero speed switch
1 no. zero speed switch shall be provided at tail pulley of all the
conveyors.
iv) Belt Slip Switches
Belt slip switches shall be provided for each conveyor to stop the
drive in case of excessive slippage of belt or over speeding.
Provision shall be made such that preceding conveyor does not
start unless the running conveyor picks up 80% of the rated
speed.
12. Drive System:
Drive systems consisting of motors, gearboxes, couplings, brakes etc
as per the system requirement. The design capacity of the conveyor
belts shall be 1.2 times of the rated capacity and the design factor for
kW calculation of the motor shall also be 1.2.
The details are furnished below:
i. Gear Boxes
a. The gearbox casing shall be of fabricated construction and free

from harmful defects.
b. The gearbox shall be selected with a service rating of minimum
1.8 times of motor kW.
c. Breathers, inspection covers, drain out plugs and dowel holes
shall be provided at conveniently accessible location. There shall
be a provision for indicating the level of oil. Dowel pins shall be
supplied along with the gearbox.
d. The bearings shall be of antifriction type. The offered bearing
life shall be minimum 100000 working hours.
e. Oil splash lubrication shall be provided.
f. Every gear box shall have a name plate bearing the following
particulars:
 Manufacturer’s name, trade-mark and year of manufacture
 Designation of gear box indicating its size, reduction ratio,
input power, input speed and output torque
 Manufacturer’s serial number
g. Every gear box shall be accompanied with the following
information
 Specification and quantity of lubricant
 Bearings and oil seals used
 List and specification of wearing parts
h. The Gearbox input couplings, output couplings and drive pulleys
shall be assembled at supplier’s works by the Successful Bidder
and shall be dispatched after dismantling the coupling bolts only
with half coupling fitted on the respective shafts. Care must be
taken while dispatching to avoid any damage to the mounted
coupling or shaft. Proper markings are to be given for easy
assembling at site
ii. High Speed Coupling (Fluid couplings )
a. Fluid couplings shall be provided for all motors above 30 kW.

b. Fluid couplings shall be manufactured conforming to the
following specifications: -
 Impeller, casing and runner shall be made of high tensile
aluminum alloy castings conforming to IS 617: 1994
 Shaft shall be made of steel conforming to class IV of IS
1875:1992 or C 40 of IS 7283:1992.
 The material of coupling shall conform to Grade 20-40 of
IS 1030:1998
 Provision of brake drum along with coupling
 The fluid coupling shall be traction type
c. Fluid couplings shall be provided with additional following items
as spares:
 5 nos. of fusible plugs
 5 Nos. of resilience plates
 5 Nos. of multi disc plates
 Repair kit for fluid coupling
13. Low Speed Coupling (Gear couplings):

i) The half casing and toothed hubs shall be made of steel
conforming to C-45 of IS 1570 (Part 6): 1996 and shall be heat-
treated to a hardness BHN 241-280.
ii) The bolts shall be made of steel C-45 of IS 1570 (Part 2, Sec
1):1979 in normalized condition and nuts shall conform to
property class 4 of IS 1367 (Part 1):2002.
iii) Provisions shall be made for easy filling and discharge of
lubricants. The Bidder shall indicate the type and quantity of
lubricant to be used with each coupling.
iv) The coupling shall be marked with the following details on the
periphery of the casing:
 Manufacturer’s name
 Type and coupling number
14. Brakes and Hold Back with panel
D.C. Electro-magnetic brake shall be provided on all conveyors after
calculating the coasting time. Brake shall have min 1.5 times the
maximum calculated torque rating. Brakes shall be mounted on brake
drum coupling at input shaft end of gear box. Rectifier panel complete
with contactors, timer, fuses, rectifier, resistors etc. shall be provided
with each brake
All inclined conveyors shall be provided with suitable roller type hold
back devices (other than brakes) to prevent belt from running back in
case of conveyor stoppage due to power failure or otherwise.
Holdback rating shall be minimum 1.5 times the maximum calculated
torque. It shall be external to gearbox.
15. Pulleys
 Pulleys shall be of welded construction as per IPSS: 2-03-007- 88/
IS 8531-1986.

 All drive pulley surfaces shall be hot lagged with vulcanised
natural rubber lagging of hardness 65 shore A, grooved in
diamond pattern. The lagging thickness shall be 20 mm
(minimum). The depth and width of the grooves in the lagging
shall be 6 mm spaced at 30mm interval. The eccentricity of pulley
shell shall not be more then + 0.5% of the diameter prior to
lagging.
 All pulleys shall be statically balanced to minimize the vibration
during running.
 All non-drive pulley (tail/take-up/bend and snub) surfaces shall
be hot lagged with vulcanized natural rubber of hardness 65
shore A, with plain lagging. The lagging thickness shall be 12 mm
(minimum).
 Pulley shafts shall be provided with double row spherical roller
bearings with proper greasing arrangement. The plummer blocks
for pulleys shall be horizontally split type construction made of
cast iron . The plummer blocks shall be dust tight with double
labyrinth seals. Conical head shape nipples conforming to IS 4009
(Part II):1981, shall be provided for greasing. Side covers of
plummer blocks shall be heavy-duty metallic sheets. No plastic
components shall be used. Minimum shaft dia. shall be 100 mm.
Plummer blocks shall have 4 holes covers & 4 holes mountings.
 The thickness of the drive, tail / take-up and bend pulley shell
shall be 16 mm and snub pulley shell shall be 12 mm.
 Welding on the pulley shell shall be tested radio graphically or by
ultrasonic method. Pulley shafts shall be ultrasonically tested.
16. Idlers
 The idlers shall conform to IS 8598:1987.
 Carrying idlers shall be provided with 2o forward tilt.
 Roller used in idlers shall be made from Carbon steel ERW steel
tube. Wall thickness shall be 5.4 mm. The roller spindles shall be
provided with seize resistant type ball bearings (SKF / FAG) of
minimum 30 mm size for carrying and return idlers. The bearings
shall be adequately sealed and lubricated for life. All bearings
shall be rated for minimum 40,000 working hours. The rolls shall
be supported from fabricated steel brackets. Fixing arrangement
of rollers with brackets shall be drop-in type. For adjusting the
alignment of the idlers, slotted holes shall be

provided in idler supporting base plates. Direction of belt travel
shall be clearly marked on the brackets of carrying idlers.
 Idler rollers shall be waterproof, dust proof and weather proof
against a high velocity water jet. All idlers shall be provided with
minimum double labyrinth dust seal.
 Impact idlers used at the loading and transfer point shall be so
designed as to avoid direct impact, belt damage and excessive
punishment to the carrier. The material used in construction of
this type of idlers shall be of resilient type.
 The self-aligning idlers shall be direct acting type, complete with
actuating rollers fitted with the grease lubricated anti-friction
bearings at pivot points and mounted inclined towards the belt.
The idler frame shall be suitably cradled about a vertical pivot,
supported in bearing over a fixed plate. Adequate sealing
arrangement shall be provided to prevent contamination of the
lubricant by dirt and moisture.
 Proper arrangement shall be provided in the brackets of all types
of idlers for presenting the rollers from coming out of the
brackets during normal / abnormal conditions.
 The idler sets shall consist of idlers along with mounting brackets.
The size of angles used in the idlers shall be ISA 90X90X8mm
(Minimum)
17. Belting
i. Conveyor belts shall be provided as per the latest Indian
Standards.
ii. In general belts shall be heavy duty NN or EP type with no

longitudinal cut/joint for any applications.
iii. Top cover & bottom cover, belt rating, cover grade shall be
decided by the Bidder based on requirement.
iv. Suitable HR belts shall be provided wherever temperature of

material is more than 700C
v. For designing the belt conveyors, maximum loading factor shall

be considered 70% of rated capacity.
vi. Bidder shall consider EP belts, wherever, accommodating take-

up system shall be a constraint due to space

18. Reversible belt Conveyors:
i. Reversible belt conveyors shall have single drive for travel motion
through electric motor and bevel helical gearbox. Stringer frame
for the conveyor shall be in segments independently supported
on wheels and connected together through hinged pins. Screw
take - up arrangements for the belt conveyors shall be positioned
at one of the hinged joints to avoid shifting of discharge pulley
location in the discharge hood.
ii. Double flanged parallel tread wheels shall run on flat bottomed
rails of minimum 60 lb/yd and shall have min hardness of 350
BHN. Cleaners shall be provided to sweep the rail from spilled
material. Anti-friction bearings shall be used throughout. The
travel drive shall be so designed that no part of equipment shall
project below rail level.
iii. The belt conveyor shall be driven through motor and bevel-
helical gear box. All other stipulation for conveyor component as
detailed above shall be applicable for the shuttle conveyor.
19. Chute Jamming Detectors

Chute jamming detectors shall be provided on each chute. The
detectors shall be so located or protected that they do not come in
contact with regular flow of material. The detector shall, also, be
protected against deposit of fine particles causing false alarm or
stoppage of the conveyors. The position of each detector shall be
decided based on the braking time of the delivery conveyor at rated
capacity and the holding capacity of the chute.
3.3.8 Vibrating Feeder
The broad parameters of vibrating feeder shall be as follows;
Description Parameter
Type Mechanical vibrating feeder
Material to be handled Fello Alloys
Quantity (no.) As per requirement

Description Parameter
Rated capacity (tph) As per system requirement
Design Capacity 1.2 x Rated capacity
Maximum feed size (mm) As per requirement
Bulk density of material (t/m3)

Ferro alloys 3.8
Calcined lime 1.0
Power supply 415 V, 50 Hz, AC
Hours of operation 24
Type of mounting Floor mounted / Mounted on

structures
Inclination As per system requirement (to be

decided by the Bidder)
Trough size As per system requirement (to be

Power (kW) rating of motor and As per system requirement (to be

rpm decided by the Bidder)
Material of tray Carbon steel plate of 6mm thickness

(minimum) as per IS 2062: 2011 / As
per system requirement (to be
Liners Hardox500 of 10mm thickness
Spring Spring Steel
Frame Structural Steel as per IS 2062: 2011
General for vibrating feeders

1) The feeder shall be complete in all respect including drive units,
cables, safety switches and all other standard accessories.
2) The vibrating feeder shall be of robust construction and shall be
designed for smooth, uniform and trouble free operation.

3) Ambient conditions prevailing at site are dusty. While designing or
selecting components, the Bidder shall pay special attention so that all
equipment chosen should work satisfactorily under these severe
conditions.
4) All the items supplied in loose condition, shall be properly marked
before despatch to ensure smooth erection.
5) Temporary protection shall be provided to prevent deformation of
items during transportation. All machined surfaces shall be coated with
anticorrosive grease/compound.
6) The noise level shall not be more than 85dB at a distance of 1m from
the equipment.
7) Provision of necessary fixtures, supporting angles and brackets
required for mounting and supporting the equipment & drive with
floor / bins shall be supplied alongwith the feeder.
8) All equipment shall be designed, manufactured, supplied, erected,
tested and commissioned in accordance with relevant Indian
Standards and International Standard where applicable in addition to
the requirement mentioned herein.
9) The Supplier shall make his own calculation in respect of motor kW to
ensure satisfactory performance of the equipment.
10) Standardisation of components and assemblies shall be carried out to
the maximum possible extent to ensure interchangeability.
11) All equipment shall be designed such that all components are easily
accessible for inspection, repair and maintenance.
12) The parts exposed to abrasion shall be lined with suitable liner plate
for the required application.
13) 5 Nos. of springs for rear side and 5 Nos. of springs for front side for
each of vibrating feeder shall be supplied as spares.
3.3.9 Belt Weigh Feeder
3.3.9.1 Belt weigh feeders shall have weighing facilities to monitor and regulate
the discharge of materials online as per requirement. The brief description
of belt weigh feeders is as below;
Sl. Description Parameters
i. Quantity (nos.) As per requirement
ii. Conveyor:
Capacity (tph) As per requirement

Centre distance As per requirement
between pulleys
Type of conveyor Flat
Belt width(mm) As per requirement
Tension arrangement Screw take up/gravity take up
iii. Weighing Idler weighing system
iv. System accuracy 0.5% of F.S
v. Power supply 415 V, 3 phase ,50 Hz
vi. Motor Squirrel Cage Induction motor with VFD
vii. Controls On the front panel/front door

 Feeder ON/OFF(Push button)
 Emergency OFF(Push button)
 Remote /Control/Local selector
switch
 Fault reset(Push button)
 Power ON/OFF(Rotary switch)
viii. Display 2 line 16 character with back lit LCD/ as
. per requirement
 Load in Kg/m
 Rate in tph
 Belt speed in m/s
 Totalizer in tonnes
 Set points
 Normal/Maintenance/Calibration
modes.
 Deviation error between set and
actual feed rate.
 Service data such as measured
value, controller output, control
signal level etc.
 Event messages/fault messages.
ix. Programmable Programmable through keypad
parameters  Calibration of load, belt speed and
totalizer
 Set value for overload
 Output percentage high limit
setting for material starvation

 Selectable operating mode –
Gravimetric/Volumetric
 Password protection for all
parameters and functions
x. Duty Continuous 24 Hrs per day
3.3.9.2 Design Basis For Belt Weigh Feeder

The consistency of the feed rate shall be guaranteed within +/- 0.5% of the
set value within the operating range of 10% to 100% of rated capacity. The
weighing control shall be totally automatic with close loop control. The feed
rates of different materials shall be calculated by the computer and set
points of Belt weigh feeder shall be set by the computer through PLC. In
case of computer failure manual setting (remote manual) and operation of
feeders shall be possible.
3.3.9.3 General
i. Weigh feeders shall be efficient compact & rugged system suitable for
feeding bulk solid material to the process in a controlled proportional.
ii. Weigh feeders shall include DC or AC Drive, Gear Box, Coupler, Load
cells, Process Controller, Speed Sensor Assembly, Automatic Belt
Tracking Aid, Scrapers for carrying & Running Side Belt, Skirt boards,
Belt Limit Switches, Test Weights for Calibration (Calibration Rod or
Calibration Chain), Impact Idlers, Pulleys & Pulley Bearings and Control
Panel. It shall be supplied with Remote Flow Rate Indicator & Remote
Totalizer.
iii. It shall have following features to convey, weigh & control the rate of
flow materials by varying the speed of the belt. Following indicators
shall be provided:
 Actual flow rate indicator.
 Set rate feed indicator.
 Totalised amount indicator.
 Belt load indicator.
 Belt speed indicator.
 Deviation indicator.
 Fault messages (separate lamps).

 Operational mode selector switch for gravimetric
/volumetric/calibration mode selection.
 Auto taring & calibration.
iv. Multiple weigh feeders shall be connected using digital/ analog signals
for cascaded proportional blending
v. Users can make minute changes in feed rates/ blend ratios without
leaving the control room, & can track raw material usage very closely
on HMI.
vi. Fully automated weigh feeder electronics
vii. Bin scale with loss in weight flow control
viii. On Stream Calibration
ix. Manual and automatic set point control
x. Isolated outputs for rate, total and alarms
xi. Custom software, control needs and ongoing support available
xii. Simple menus option
xiii. Batch Controller (controlling device for precise weighing applications
in industrial environment)
3.3.10 Transfer Cars (For Tundish & Ladle)
3.3.10.1 The broad technical specifications of the transfer car shall be as under:
Sl. No. Parameters Brief description
1. Quantity (Nos.) 01 01
2. Purpose Transfer of Transfer of Ladle
Tundish (shall for LF
be capable of
handling both
tundishes of
caster #1, 2 &
4)
3. Capacity(t) (minimum) 100 250
4. Speed of Car (m/min) 30
(approx..)
5. Permissible acceleration/ ---
retardation (m/sec2)
6. Motor kW As per requirement

7. Travel length (m) (approx.) KL to NP Bay: LM bay to MN
100m bay: 60 m
8. Track gauge(mm) As per requirement
9. Rail size (minimum) CR120
10. Drive Electro-mechanical / Electro-
hydraulic
11. Brakes DCEM brake
12. Coupling Flexible Gear Couplings
13. Dimensions of the Car As per requirement

14. Level (m) On the existing shop floor
15. Power supply As per existing Through cable
system reeling drum
16. Control From control post( 2nos) at ±0.00
level as well as from control
pulpit
3.3.10.2 Detail Technical Specification

i. General
a) The transfer car shall be designed, manufactured and tested in
accordance with the relevant clauses of IS: 3177-1999. The standards
referred there in and subject to any modifications and requirements
specified in this specification.
b) The receiving pedestals shall be welded on the car frame and shall be
suitable for the existing requirement. Suitable refractory lining shall be
provided on the platform and the sides to prevent damage due to
accidental spillage in case of hot metal/slag. Protection / heat shield
shall be provided for the car drive units to prevent damage due to
leakage, if any, of metal/slag through bottom/ sides of the Pot.
c) The transfer car components shall be standardized to keep the number
of spares minimum.
d) All parts requiring replacement or inspection or lubrication shall be
easily accessible without the need for dismantling of other equipment
or structures. All electrical cables shall be so laid that they are not liable
to be damaged and can be easily inspected and maintained.
e) Operation of the Car shall be controlled from the main control pulpit

as well as two local control posts, one situated near the one end of the
car at ground level and the other at the end of travel position.
ii. Structural Details
a) Transfer car structures shall be designed in accordance with IS: 807-
2006 taking the following additions/deviations into account.
b) The Transfer Car shall be made from fabricated steel frame and shall
be designed to take up the shock while placing the load on the transfer
car in operating condition.
c) For welded construction such as that of main frames, gear boxes and
other load bearing members, steel shall conform to IS: 2062-2011.
d) For welding these members low hydrogen electrodes shall be used as
per IS 81-1991 grade E8 –542 -C-83H.
e) Black bolts shall not be used in the main structures of the transfer car.
f) Bolts used in shear shall be fitted into reamed holes.
g) Transverse fillet welding on load carrying members shall be avoided.
h) All butt welds on structural members subject to tensile stress shall be
X-rayed.
i) Minimum thickness of chequered plates for platforms shall be 6 mm
over plain for indoor transfer cars and 8 mm over plain for outdoor
transfer cars. Chequered plates shall not be considered for strength
calculations of load carrying members. Chequered plates shall be
supported on a frame of beams adequately designed to take the rated
load anywhere on the transfer car platform.
j) The under frame shall be fitted with substantial safety stops to prevent
the transfer car from falling more than 25 mm in the event of breakage
of track wheel, bogie or axle. These safety stops shall not interfere with
the removal of the wheels.
k) Suitable jacking pads at a height of 300 mm from rail top shall be
provided on under frames for jacking up the transfer car when
changing track wheels. Jacking pads shall not interfere with the
replacement of track wheels.
l) Main frame shall be fabricated in one piece unless there are transport
limitations. Connection between the two parts of the frame shall be
done by machined bolts or rivets.
m) All the mechanical and electrical equipment shall be placed below the
top plates.

n) The maximum settlement of the platform under rated load shall not
exceed 2-3 mm limited to span/1000.
o) Chequered plate steps suitably welded at convenient location on either
side of the transfer car shall be provided for climbing up on the
platform wherever necessary.
p) Drive Suspension Frame
All the driving mechanism such as motor, brake, gear box etc. shall be
mounted on a rigid rolled section steel frame and suspended below
the under frame with one end resting on the drive axle on anti-friction
bearing, while the other end shall be elastically fastened to the under
frame through helical compression springs. Drive Mechanism shall be
protected from heat by providing heat shield on heat exposed area.
q) Clearance between ground and bottom most portion of the car shall
not be less than 100 mm.
iii. Mechanical Details
a) Wheels
 The wheels and axles shall be of sturdy design and fixed to the
frame of the Car. The Bidder shall provide wheel size matching
with the existing Transfer Cars and existing rail size, wherever
possible.
 Solid wheels of forged, rolled or cast steel conforming to 55C8 of
IS: 1570 -1978 shall be used.
 Wheels shall be heat treated to have a hardness of BHN 300 to
350 on the rolling surface and flanges to a depth of not less than
10 mm with a smooth pass to the non- hardened zone.
b) Axles
 Axle shall be made of class 4 steel to IS: 1875-1992.
 The axles of track wheels shall run in self-aligning roller bearings.
 The axles shall be suitably designed and shall be machine finish
in accordance with the steel gauges and templates to achieve
necessary alignment and other functional requirement after
assembly.
c) Axle Box Assembly
 The axle assembly consisting of axle box casting, bearings dust
shield, bearing cover plate, grease nipples etc. shall be of sound

design, maintaining various important dimensions with in close
tolerances so that the axle box assembly can fulfill the requisite
alignment and other functional requirements. The axle boxes
shall be supported as shown in the drawing.
 The material of axle box casting shall conform to steel as per IS:
1030-1998 grade-1.
 Spring seats, wherever required, shall be finished by machining
d) Axle Box Frame
 Axle box frame of cast steel or fabricated steel construction shall
be stress relieved and accurately machined and the parallelism
between the face plates and their perpendicularity with the top
surface shall be closely maintained so that the assembly can
satisfy the requisite alignment and other functional requirements.
e) Springs
 All helical compression springs shall be designed in accordance
with IS: 7906-1997 Part-1.
 Spring ends shall be finished square with respect to its axis.
 The spring shall be designed on the basis of virtually infinite life
i.e. to withstand ten million load cycles or more without failure.
f) Buffers
 Spring loaded or other better type buffers shall be fitted on the
four corners of the transfer car for ensuring soft dashing of
transfer car against stop.
 Buffers shall be rigidly bolted in place, preferably along the centre
line of transfer car track such that the bolts are not in direct shear.
 Buffers shall be designed to absorb the kinetic energy released at
50% of the full load rated travelling speed, the average rate of
deceleration not exceeding 4.8m/sec2 at 40% of the rated
travelling speed.
 Buffers shall have a contact surface of not less than 125mm in
diameter and mounted so as to provide 100mm clearance
between the fixed structures and car outreach when buffers of
transfer cars are fully compressed.
g) Drive mounted on transfer car
 The Car shall have two individual drive arrangements on both
ends of the cars. The system shall be such that any one motor

shall be driving the car with full load at any point of time.
 A scraper drive arrangement shall be provided for cleaning
between the track, which shall be attached to one side of the
frame of the Car as shown in the drawings
 The power to the car shall be provided by a cable wound on an
externally mounted motorized CRD (Cable Reeling Drum). The
Cable shall move on rollers fitted at ground level. The position of
CRD shall be decided as per site condition. The rollers shall be
supplied and fitted by the Successful Bidder. Rollers shall be
sturdy and shall move on bearings to give smooth rolling motion.
They shall be spaced so as to be capable of taking up the load of
the reeling cable without any sagging
 End position limit switches shall be provided for the movement
of the car.
 There should be facility for creep speed for the Transfer Car
movement.
 All parts of the travel drive shall be easily accessible for
inspection, maintenance and removal from topside of platforms.
 The car shall be similar to existing cars of LHF 2b & 2c to the
extent possible
h) Gearing
Straight and helical spur gearing shall be used. Worm and bevel
gears shall not be used. Surface hardness for pinion shall be 255
to 300 BHN and for gear it shall be 217 to 255 BHN. Difference
in hardness of pinion and gear shall not be less than 20 BHN.
 The car shall be similar to existing cars of LHF 2b & 2c to the
extent possible.
i) Gear Box
 All gear shafts shall be supported in anti-friction bearings.
 In gearboxes splash or automatic lubrication systems shall be
used.
 The gearbox shall be fabricated of cast steel. Fabricated gearbox
shall be made of minimum 8-mm thick steel plate and shall be
stress relieved.
 Covers shall be split horizontally at each shaft centre line and
fastened and arranged so that the top half can be removed for
inspection and repair without disturbing the bottom half.

Vertical gearbox may be provided with T-splits.
 Directly above the mesh line of teeth, there shall be hand-hole
with oil tight bolted covers.
 The gearboxes shall be provided with breather vents, oil level
indicator, dipsticks and easily accessible drain plugs.
 Radial clearance between the gear box inner surface and the
outside diameter of the gears shall be at least 1.25 times the
depth of the largest gear tooth inside the gear box or 20 mm
whichever is higher. The facial or side clearance between the
inner surface of the gearbox and the face of the gear or pinion
shall be at least 20 mm.
 Gearbox shall be mounted on machined surfaces and shall have
machined feet. Shims shall not be used.
j) Bearings
 Only anti friction bearings shall be used.
 Rated life of anti-friction bearings shall not be less than 40,000
hours.
k) Couplings
 The power shall be transmitted from the motor through full gear
coupling to gear unit. Each gear unit shall be flanged to one pair
of driven track wheels by a set of gear couplings. Full gear
coupling shall be as per RSN 51.17/ equivalent standard and half
gear coupling shall be as per RSN 51.18/ equivalent standard.
 Motor shaft shall be connected to gear box input extension shaft
through flexible gear couplings with crowned teeth. Gear
coupling shall also be provided between gearbox and axle wheels
if required.
 All couplings shall be of forged steel and shall be designed to suit
the maximum torque that can be developed.
 Hardness of gear coupling casing shall be more than 340 BHN
and that of toothed bush shall be more that 340 BHN. Bolt
connection of couplings shall be easily accessible for inspection
and tightening.
l) Brakes
 The electric motors of the travel drive shall be provided with
suitable DC electromagnetic brakes

 Double shoe brake shall be provided for the drive of the transfer
car and shall be mounted on the input pinion shaft of the
gearbox. The brake shoe shall be of hinged type.
 Brake drum shall be forged or of cast steel and shall be
completely machined and dynamically balanced. Diameter of the
brake drum shall be selected from preferred number series.
Width of the brake drum shall be 10 mm more than the width of
the brake shoes of each size. Hardness of the brake drum shall
be 300 to 350 BHN.
 Braking against travelling shall be capable of arresting the mote
within a distance in meters equal to 10% of speed in meters
/minute when travelling with rated load and speed, provided
there is no skidding.
 Adequate means shall be provided on outdoor transfer car for
securely anchoring the same to the rail when not in use. Co-
efficient of reserve of the holding force shall not be less than 2
considering maximum wind pressure.
 In case of power failure there shall be automatic braking of the
transfer car.
 Brake shoes shall be of cast or forged steel.
m) Shafting
 Shafts and axles shall also be checked for endurance and
strength. In proportioning shafts, allowance shall be made for
keyways and splines.
 Changed of section in shafts shall be made with due allowance
for stress concentration.
n) Lubrication
 Grouped grease lubrication system for bearings shall be provided
for transfer cars. Minimum internal diameter of grease pipe shall
be 6mm. The pipe shall be securely fixed and protected from
damage and assessable throughout.
 Effective protection shall be provided to prevent ingress of dust
on the lubricant and such protection shall also be weather proof
on outdoor transfer car.
3.3.10.3 Inspection & testing
a) The Bidder shall ensure that the transfer car is manufactured as per
the tolerances specified below:

. No. Parameters Value
1. Track gauge (mm)
2. Diagonal of wheels (mm)
3. Travel wheel alignment

(mm)
4. Tilt of wheels or balancer

axle (mm)
5. Wheel base (mm) 1000 (horizontal & vertical.)
6. Travel speed at full notch + 10% and – 5 % of specified

with rated load, voltage and speed
frequency
7. Permissible deviation from ≤1 mm for every 1000 mm

parallelism length
b) No load test:
The transfer car shall be run in both the directions at maximum speed
with no load. During this period, the speed and noise shall be checked.
The bearing lubrication system shall also be checked for proper
operation. At the end of this test, no part shall be excessively heated.
c) Speed test:
 Travel motion of the transfer car shall be tested in both directions
with rated load on all the notches and the speeds shall be
attained at various notches as per approved speed- torque curve
of the transfer car within the tolerance limits. The absorbed power
as well as the speed shall be recorded and compared with
guaranteed values. At the end of these tests no parts shall be
excessively heated.
 Travel motion of the car shall be tested with 25% over-load in
which case the specified speeds need not be attained but the car
shall show itself capable of dealing with the overload without
difficulty.
d) Brake Test
The travel brakes shall be capable of arresting the motion within a
distance in meters equal to 10% of speed in meters/minutes when

travelling with rated load at rated speed, provided there is no skidding.
3.3.11 Water Cooled Ladle Roof Complete with Supporting System
3.3.11.1 Water Cooled Ladle Roof Complete with Supporting System shall be
provided. The roof of the Ladle Furnace shall be water-cooled. The ladle roof
are formed by rigid steel tubes, closely packed one to another, divided into
different water circuits. It shall be built up of ASTM A-106, Gr. B seamless
tubes arranged concentrically. The test pressure of individual cooling circuit
shall be 1.5 times the working pressure. Suitable lugs shall be provided for
suspension of the Ladle Roof by means of hydraulic cylinders.
3.3.11.2 The Ladle Furnace Roof shall be designed accordingly to suit the dimensions
of the ladles, which shall be supplied by the Employer and drawing/design
of the ladle shall be provided by the Employer.
3.3.11.3 The lower edge of the roof shall be designed to match with the top of the
Ladle. This design shall provide good sealing so that a minimum volume of
gases escapes out. The lower section of the Roof shall consist of a
pneumatically operated water-cooled working door, which shall normally be
closed. Suitable water inlet and outlet flanges with flexible hose connections
in inlet and outlet of tube shall be provided. In addition, suitable openings
for the following shall be provided in the roof :
 3 Electrodes
 Ferro alloy addition chute
 Fume extraction elbow
 Opening for wire feeding
 Opening for temperature and sampling lance and inspection window
3.3.11.4 The opening for alloy addition shall also have a pneumatically operated gate
in upper portion of roof to disconnect the inside atmosphere of the Ladle
Furnace from the outside.
3.3.11.5 One additional roof shall be provided without accessories but with doors /
flaps, which shall be kept ready so that as per need, it can be replaced with
the working roof by simply fixing the pneumatic cylinders and connections.
3.3.11.6 Fumes generated during operation shall be extracted through the fume
extraction elbow, which shall be kept aligned to the fume extraction system.
This elbow shall also be of the same tubular construction as the roof and
shall be water-cooled. It shall be connected to the fume extraction duct in
such a manner that there shall be minimum or no leakage of fumes during
operation of the Ladle Furnace.

3.3.12 Roof Lifting Arrangement
3.3.12.1 The roof shall be lifted and lowered with the help of hydraulic cylinders. The
support structure shall comprise a vertical portal frame suitably designed for
holding and operating the ladle roof. The Roof shall be lifted by means of
above-mentioned hydraulic cylinders connected to a common hydraulic
power pack for roof lifting, de-clamping and electrode regulation. This
hydraulic power pack shall be installed in the hydraulic room. The hydraulic
cylinders shall be fixed to the Roof supporting structure and connected to
the lifting lugs on the Roof by means of pins to provide some flexibility. The
arrangement shall be such that the movement of the roof is proper and
smooth, and it shall always remain in horizontal position while raising or
lowering. There shall be complete and proper synchronization between all
the hydraulic actuating mechanisms. The Bidder shall furnish complete
details for proper synchronization methods giving all salient features of the
offered mechanism. Any interlock provided for actuating mechanism shall
also be indicated. The roof lift stroke shall be so that there is sufficient
clearance between the roof and metal build up on the rim of the Ladle. The
roof lifting cylinder piston sealing and all “O” rings shall withstand high
temperature in the surroundings.
3.3.13 Arc Heating System consisting Electrode Masts and Arms & Electrode
Holder and Clamp System
3.3.13.1 Arc Heating System consisting of Electrode Masts and Arms & Electrode
Holder and Clamp System shall be provided.
3.3.13.2 The Arc Heating system shall basically comprise of electrode masts with
guide rollers, electrode arms either copper cladded steel type or fitted with
electric bus tubes and insulated supports, electrode holders with clamping
devices and hydraulic electrode regulation system.
3.3.13.3 Electrode Masts and Arms
3 (three) electrode masts shall be suitably fixed on a foundation and shall
be designed to hold the electrode arm through individual adjustable guide
rollers for the movement of electrode. 3(three) electrode arms, preferably of
rectangular steel box construction shall be fitted on the electrode masts. The
support for fastening the secondary conductor system shall also be welded
to the arms. The electrode arm shall carry forced water-cooled electrode
holders, which shall clamp the electrodes positively by means of spring
holder assembly. The electrode supporting arms shall be fixed to the
electrode masts, which can be moved up and down with the help of
hydraulic cylinders, supported by guide rollers. It shall also have an
automatic speed regulation control system for the electrodes. The release

of electrodes from the holder shall be by means of hydraulic system, which
shall be mounted on the electrode arm assembly. In case bus tubes are used
for carrying current to the electrodes, conductor material shall not be used
for supporting the bus tubes. Electrode lifting / lowering stroke shall be long
enough to fully lift the Electrode from its arcing position in one station and
place it in the other station.
3.3.13.4 The electrode cylinders shall be guided by suitable number of guide rollers
inside the supporting masts and shall be used for movement of the
electrode arms and accordingly the electrodes. The Bidder shall furnish the
number and type of guide rollers with complete details of its lubrication
arrangement.
3.3.13.5 Electrode Holder and Clamp System:
Electrode holder used for holding the electrode shall be made of pure
Copper. It shall be water-cooled and designed to withstand high pressure
as well as high current. The clamp-operating unit (pull type) shall be installed
inside the electrode holder and shall be used for tightening the electrode
against the contact pad.
3.3.14 Electrode Nippling and Storage Stand / Station:
3.3.14.1 3 (three) pieces of Graphite electrodes of suitable diameter are to be joined

together to form a full length electrode assembly for each phase. The joining
shall be done in a separate electrode nippling stand located close to the
working platform. A new electrode nippling station with a storage stand for
3 electrodes shall be provided. It shall have a manual clamp for nippling
(jointing) the electrodes and three vertical steel tubular stands each of
sufficient diameter and length for holding 3 electrodes on it. A door opening
shall be provided at the bottom of each tube for inspection etc. The entire
top platform of the structure shall be made of chequered plate or grate. A
suitable staircase shall be provided for access to the top platform from
ground level.
3.3.14.2 For nippling, the electrodes shall be clamped in the nippling stand. The
stand shall be lever / screw operated. New piece of electrode shall be
brought by the shop EOT crane and shall be placed on the clamped piece
of electrode for jointing.
One set of electrode fixing Torque Wrench and other necessary tools and
tackles shall be provided for electrode nippling / handling. Suitable handling
facilities and approach facilities shall be provided wherever required, for
proper operation and maintenance of the equipment.
3.3.15 Ferro Alloy Feeding Arrangement (FAFA)

3.3.15.1 A precisely controllable Ferro alloys feeding arrangement shall be provided
for the proposed Ladle Furnace for feeding Ferro-alloys, lime & other
additives into the ladle at both the stations. The technological structure for
this system shall have platforms at different levels to support the various
equipment such as bunkers, Weigh hoppers and Conveyor Belts. The alloy
addition system shall be complete with storage bunkers, vibro-feeders,
weigh hoppers, belt conveyors, dump box and chutes. The FAFA system shall
be designed to ensure complete discharge of all additives into the Ladle at
both stations through a two way chute with flap gate. The system shall be
operated from the control room as well as local control station.
3.3.15.2 There shall be 14 bunkers each of 12m3 geometric volume (minimum) in two
rows, made of steel conforming to IS 2062:2011 with a minimum thickness
of 10 mm plates. All the bunkers shall be lined with 10 mm thick Hardox500
liner plates on all sides. Lime, Ferro-Silicon, Ferro-Manganese, lime and
Silico-Manganese has been envisaged to be added through the system. The
alloying material shall be discharged through vibro-feeders into weigh
hoppers.
3.3.15.3 Electro-magnetically operated vibro-feeder of adequate capacity shall be
fitted under each bunker to feed material from the bunker into the weigh
hopper below it. All vibro feeders shall have unbalanced motors.
3.3.15.4 Below the vibro-feeders of the bunkers, weigh hoppers each of suitable
volume, supported by load cells, shall be provided. One vibro-feeder shall
be provided below each weigh hopper. These vibro-feeders shall be similar
to those provided below bunkers. The number of weigh hoppers below the
Bunkers shall be minimum 4 (1 weigh hoppers for every 4 bunkers or part
thereof).
Brief description is as below:
Sl. Parameters Brief description
1. Geometric volume of each weigh hopper 1.5
(m3)
2. Effective volume of each weigh hopper 1.05
(m3)
3. Weighing system Load cells
4. Weighing capacity(kg) 2000
5. Minimum graduation (kg) 1
6. Weighing accuracy + 0.5 %
7. Thickness of base plate (IS 2062:2011) 10 (minimum)
mm
8. Thickness of liner plate (Hardox500) mm 10 (minimum)

3.3.15.5 Under the vibro-feeders of the weigh Hoppers, a reversible belt conveyor of
adequate capacity and suitable length, shall be fixed on the platform. The
belt width and speed of the conveyor shall be selected accordingly. Weighed
quantity of material shall be discharged onto this reversible belt conveyor
underneath the weigh hoppers through vibro-feeders. It shall be ensured
that there is negligible spillage from the conveyor during normal operation.
A conveyor bottom cover for spillage material shall be provided.
3.3.15.6 From the Ladle Furnace end of the belt conveyor, material shall fall into the
charging hopper of the Ladle furnace through an electro-mechanically
operated vibro-feeder. From the charging hopper the material shall be
discharged with the help of a chute into the Ladle Furnace through the
opening provided in the roof. The conveyors shall be electrically driven and
fitted with limit switches.
3.3.15.7 The length of the belt conveyor, vibro-feeders and other equipment shall be
designed as per the actual location of the bunkers from LF unit proper. The
full alloy addition system shall be automatically controllable with the help of
PLC. The bunkers shall have material level switches (low and high) and
support stools for bottom discharge bucket on top of the bunkers. The
installation shall be complete with supporting steel structure platforms,
walkway, stairs, hand railings, toe guards etc.
3.3.15.8 One no. weighing system (weigh scale) of adequate capacity (100 kg
approx.) shall be provided at suitable location (at treatment station) for
weighing of materials not meant to be kept in bunkers.
3.3.15.9 4(four) nos. self-discharging bucket of 2m³ shall be provided for FAFA
system.
3.3.16 Wire feeding system
3.3.16.1 Wire feeding system shall be provided. The system shall be capable of
feeding of minimum 4-wires (Aluminium / Ca-Si /Ca-Fe/ Fe-Si/Fe-Ti) with
minimum two nos. of wires at a time (Four strands system). Each wire shall
be driven by roller pairs independently with independent clamping system.
The speed and wire length for each wire shall be provided with independent
controls, for which encoders shall be given. All necessary feeding system
including drive mechanism shall be included. One set of Aluminium and Ca-
Si core wire shall be supplied.
3.3.16.2 The coils shall be located in the de-coiling unit with provision for housing
4 nos. of coils, which shall also be provided. The wire feeder shall be
equipped with its own control system based on PLC. Automatic and manual
modes of operation shall be possible. The injection length and

speed shall be controlled at the control desk, which shall be provided with
all necessary switches, indicators and lamps.
3.3.16.3 The system shall allow injection of wire into the liquid steel in the ladle after
the treatment is over in the LF unit. The wire feeding machine shall be a four
strand machine suitable for injection of Aluminium and cored Ca-Si wire of
9-16 mm diameter at a speed up to 300 m/minute. The machine shall be
located on the working platform of LF unit. The wire coil shall remain
stationary while the wire shall be drawn from inside of the coil. The diving
unit shall draw the wire through the set of rollers mounted on the unit. Each
strand of the machine shall be individually driven. The wire shall be guided
by means of guide pulleys and guide tube. Facilities for coil housing for 4
coils shall be provided. The wire feeding hole shall be separate and close to
centre of the hood. An cutter shall be provided near the guide for cutting
the wires.
3.3.16.4 The machine shall mainly consist of a head unit which houses several parts
of drives / guides rollers and pneumatic actuators for the rollers. The drive
unit shall consist of AC motors, electrical cabinet and control panel.
Parameters Brief description
No of wire feeding system 1
No. of strand / machine 4
Wire diameter 9 - 16 mm
Wire speed Up to 300 m/ minute
Coil weight 2.5 t, each (approx.),
Control Micro-processor based,
(hooked with PLC)
3.3.17 Temperature measurement and sampling Lance
3.3.17.1 For temperature and Oxygen measurement of the liquid steel, manipulator
lance shall be provided, which shall be installed on the LF platform near to
the corresponding opening in the ladle roof. This lance shall also be used
for taking samples.
3.3.17.2 The lance manipulator shall be of a 2-carriage design. The carriages shall be
mounted on a tiltable guide column by means of guide rollers. Each carriage
shall hold a lance and shall move independently by means of a chain and
sprocket system. Limit switches shall be provided for the extreme positions.
The tilting shall be done by means of a pneumatic cylinder. The signal from
the probes for temperature and sampling shall be processed by an analyzer
unit and the results displayed on the computer. Oxygen measurement range
of the probes shall be 1 to 1000 ppm.
3.3.17.3 For temperature and Oxygen measurement of the liquid steel, a manipulator
lance shall be provided, which shall be installed on the LF platform near to
the corresponding opening in the ladle roof. This lance shall also be used
for taking samples.
3.3.17.4 The temperature measurement/ sampling system shall be installed on the
working platform. It shall be designed for sampling and temperature
measurement under atmospheric condition. The lance shall be suitable for
two in-one type disposable tip for temperature measurement and sampling
in single stroke. The probes shall be fixed and detached manually by
operator. Lowering / lifting of the lance shall be done by electromechanical
device and shall be control from the local control post as well as control
room. The positioning (lowering and lifting) of lance shall be operated
automatically with the help of microprocessors. When immersing the
temperature sensor in the melt, a threshold thermo-electric voltage shall be
detected to establish the bath level of steel. Through this the effect of worn
out lining and different slag thickness shall be estimated at a constant &
reliable immersion position control shall be achieved.
3.3.17.5 The lance shall be driven by a geared motor through a chain drive. Limit
switches shall be provided for stopping at extreme ends of the travel
positions. A cable reel to guide cable during the movement of the lance shall
be provided. However, proximity switch of suitable rating shall be provided
except places which are very hot, where chances of conductive dust (iron
filling) and at places where rotation is to sensed.
3.3.17.6 The system shall consist mainly of lance transport car, drive unit including
gear motor & endless chain, cable reel, support structures, set of limit
switches, set of operation & control system, etc.
Sl. No. Parameters Brief description
1. Length of probe 1.2 m (approx.)
2. Depth of immersion in 600 mm (approx.)
molten metal
3. Lance moving range 4.1 m (approx.
4. Lance speed 30 m /minute (approx.)
3.3.18 Inert Gas Stirring System
3.3.18.1 Argon is proposed to be used as purging gas, through a porous plug at the
bottom of the ladles for stirring the liquid steel. The porous plug shall
be connected to the gas line through connecting hoses and quick fix
coupling. One valve station shall be provided for the same. Facilities for
measuring the gas consumption shall also be provided and signals shall be
transferred to control room through transmitters. Flexible hoses shall be
provided for connecting the porous plug of ladle with the fixed pipeline.
3.3.18.2 In case of porous plug chocking, for an emergency operation, refractory
lance mechanism (off line preferably) shall be provided for purging the inert
gas into the liquid steel, which shall be operated with the help of
mechanized drives. The mechanized emergency lance system shall be
located at in-arcing position through the ladle furnace roof in such a way
that Argon/ Nitrogen purging can be done in the liquid steel in the ladle.
There shall be a provision for storing three (3) nos. of top lance at the
working platform.
3.3.19 Goods-cum-passenger elevator
3.3.19.1 Design Basis
Sl. Parameters Design Basis

i. Goods-cum-passenger IS 14665 (Part 1 to 5) : 2000 or
elevator reputed codes BS, DIN, JIS or
equivalent is also accepted
ii. Design lifting capacity for 1.2 x Rated Lifting capacity
motor sizing. However
minimum motor power shall be
as follows;
(a) 1t capacity 11 kW
(b) 1t <capacity <4t 18.5 kW
(c) 4t capacity 22 kW
(d) 5t capacity 30 kW
iii. Gearbox rating (kW) =1.6 x Selected motor kW

iv. High speed coupling (kW/rpm) =(Selected motor kW *1.36*1.5)
/ (motor rpm)
v. Low speed coupling =(Selected motor kW *1.36*1.5)
(kW/100rpm) / (motor rpm / reduction ratio)
vi. = (Selected motor kW *1.36 *
Braking Torque (DCEM type)
1.5*4500*10) / (2*3.14*Motor
N.m RPM)
(Heavy duty hoist brake)
vii. Rope Safety factor (minimum) 8
3.3.19.2 Brief description of Goods-cum-passenger Elevator is as below:
Sl. Parameters Brief Description

i. Capacity (t) 01
ii. Quantity (Nos.) 01
iii. Location Near caster platform to facilitate
movement of man & material to
various floor levels and shall
operate from lower most level
to top most level
iv. Total lift (m) As per requirement
v. Height of upper stop (m) As per requirement
vi. No. of Stoppages / landings As per requirement
vii. Motor power (min.) kW 11
viii. Gearbox 1.6 x Selected motor power
ix. Speed (m/sec) (Approx.) 0.5
x. Cabin size (Inside) - mm wide 1400 x 1800 x 2200
* mm deep * mm high
xi. Door size (mm x mm) 1400 x 2200
xii. Lift well (shaft) size (inside)- 2300 x 2100
mm wide * mm deep
xiii. Lift pit required (mm) As per requirement
(Finished clear after plaster).
xiv. Overhead (mm) As per requirement

xv. Duty Continuous 24 hrs per day,
7days/week
xvi. Entrance One side / two sides as per
requirement
xvii. Operation Automatic Push Button
Operation from Outside and
Inside with direction and parking
indication on all Push Button
Stations
xviii. Cabin Frame Design The cabin frame structure shall
be manufactured to resist all
static and dynamic loading
xix. Bed platform Designed and fabricated as per
ISI specifications. Anti-vibration
frame, Isolation Pads and
Rubberized metal framing
ensures no vibrations.
xx. Cabin Floor MS heavy duty platform with
non-slip type chequered plate
xxi. Cabin enclosure SS hairline featured having
thickness 18 gauge (minimum)
xxii.
Cabin and landing doors Motorized, auto open/close,
auto centre horizontal bi-
parting door with electrical
safety interlock & mechanical
locking device
xxiii. Door Safety Landing doors shall prevent the
lift from starting unless they are
fully shut. Once the lift leaves a
particular floor, that door cannot
be opened.
Electro mechanical Limit safety
shall be installed inside the
cabin

xxiv. Cabin Control Designed with stainless steel
switches for all stations,
Emergency Alarm, Light, Fan
with auto sleep arrangement,
Emergency Stop Switch with
clock
xxv. Power Supply 415 V (+10 %, -15 %), 3 phase
,50 Hz
xxvi. Control A.C. Variable Voltage Variable
Frequency.
Microprocessor Based
Programmable Controller for
jerk free ride
xxvii. Machine room size & location As per IS & shall be at the top of
the lift shaft
xxviii. Motor Squirrel Cage TEFC, Duty S4,
60% CDF, 150 starts/hr,
Insulation Class F
xxix. Coupling & Shaft As per requirement
xxx. Brake DCEM Shoe type
xxxi. Gearbox As per requirement
xxxii. Wire ropes As per requirement
xxxiii. Guide Rail Heavy Duty Guide Rails are
anchored on the sidewalls with
the help of guide brackets as
per site requirements. 2 Nos.
Guide Rails each are provided
for the cabin
xxxiv. Electrical Panel Housed in a dust proof cabinet
is Microprocessor Based
Programmable
Controller

xxxv. Other Panel Accessories  Phase Reversal Prevention
Relay.
 Incoming MCB.
 Microprocessor Based
Programmable Controller.
 Transformer.
 Thermal over Load Relay
xxxvi. Safety Apparatus  Locking Device and electrical
interlock on all Landing Doors
and Electrical Interlock on
Cabin Door.
 Final overshoot limit switches
are provided beyond the top
and bottom landing levels.
 Terminal Limit Switch on top
landing.
Motor overload protection.
 Speed Governor for down
speed monitoring
 Mechanical clutch safety
activated by speed governor
 Single Phase Prevention for
Phase reversal thru AC VVVFF
device
 Other safety features as per IS
xxxvii. Painting As per manufacturer’s standard
3.3.19.3 Major components of elevator

i. Cabin
ii. Electrical and control equipment
iii. Drive station
iv. Steel structure
v. Guide rails
vi. Safety equipment
vii. Doors
viii. Counterweight over load protection & etc.
3.3.19.4 Safety
The elevator shall be equipped with all standard safety systems such as Bell
and cranking in case of power failure, emergency rescue battery backup,
hand wheel connected with motor shaft for manual lowering of elevator to
the nearest landing level in case of power failure, limit switches, indicators,
over speed safety governor for cabin, emergency light fittings, etc.
i. Mechanisms & Operations
a. VVVF Drive: Ensure low consumption of Electricity with jerk free
smooth
b. Over Speed Governor: Ensures the safety from free falling.
automatically
c. Door safety: All doors shall be locked mechanically and
electrically and doors shall function and open only when the
cabin shall come in front of commanded landing.
d. Overshooting protection: This safety ensures complete
protection of overshooting works as a final terminal protection
only for last top and last bottom landing floors.
e. Terminal Buffers: Maximum tension buffers (as per requirement)
shall be installed inside the pit, works when the cabin or the
counter weight exceeds from its final determined position.
f. Cabin and Landing Sill: Extruded Aluminium.
g. Pillars: Duly designed to sustain maximum jerk under all safety
factors.
h. Forgemers: Fabricated with steel section along with all fixtures.
ii. Main Safety Features
a. Cabin shall automatically stop in case all the loading wires break
away at any stage.
b. Counter weight shall stop automatically through safety rope
(safety governor) at any stage if loading wires break away. The
counter weight shall rest over minimum 2 nos. of springs at the
pit.
c. Extra rope shall be provided for safety. In case loading ropes
break away and the automatic mechanical break also fails, then

the extra wire/safety rope shall save the cabin from free fall on
ground / top.
d. Counter weight and cabin shall operate/run in their respective
lines of steel structures bulb section guide rail.
e. If all the wires break away at any stage, the counter weight shall
also stop immediately hence passengers / material are safe.
f. The double size wire ropes having double in capacity against the
required capacity shall be provided to keep maximum safety.
g. Buffer springs shocker shall be provided in order to avoid jerks
while the elevator is in operation.
h. Automatic rescue device (ARD) shall be provided so as to enable
cabin to travel to nearest station in case of power failure.
i. Cabin shall automatically stop at the predetermined highest and
the lowest level without command through limits sensors.
j. Highest and lowest points shall be governed by photo sensors/
proximity sensors / laser sensors.
k. An emergency stop switch is provided inside the cabin.
l. An emergency speaker alarm is provided inside the cabin in case
of emergency.
m. Electric key lock is provided inside the cabin.
n. Cabin shall automatically stop in case of opening of cabin door
at any stage.
o. Unless the gates of the cabin are properly closed, the elevator
shall not function or shall not start moving for its other desired
landing.
p. An extra limit sensor switch is provided in the machine unit & in
case all the safety features as enumerated herein above failed,
the said limit switch shall be adjusted at highest and lowest and
stop the machine at the predetermined highest/ lowest points.
q. The elevator shall not start travelling in case the overload system
is activated due to the overloading the material.
r. The elevator shall stop function if the cabin/ landing doors are
not closed.
3.3.20 Tractor-trailer (Road trailer)

Tractor-trailer shall be provided for transportation of mould & segments
from casting shop to new MSRS. Tractor-trailer shall consist of a standard
tractor capable of hauling a trailer with required payload. A brief technical
parameter of the Tractor-trailer shall be as below:
Sl. Description Specification
1 Quantity (set) 1(One)
2 Type Tractor with low deck full trailer
3 Prime mover Tractor capable of hauling trailer of
55t Gross vehicle weight
4 Gross Vehicle Weight of 55
trailer( t )
5 Bed area of trailer As per requirement
6 Max. Speed (kmph) 50
7 Frame All steel
8 Brake Internal expanding shoe type service
brakes, automatic emergency brake,
hand wheel operated parking brake
9 Handling material Moulds & segments of slab caster
10 Loading arrangement Overhead crane
Trailer shall be of welded steel structure platform mounted on tyre wheels.
The platform of trailer shall have a flat top surface to accommodate moulds
& segments of slab caster. The platform shall be adequately stiffened along
the entire length and corners. The trailer shall be equipped with suitable
arrangement at one end for manual coupling with the tractor.
3.3.21 Liners for Bunkers (Hoppers) & Chutes
a) All the bunkers (hoppers) and chutes shall be made of 10mm thick mild
steel plates with 10mm thick Hardox 500 liners in all the surfaces of the
bunkers & chutes. The liners shall be fitted with countersunk bolts.
b) Each chute shall be provided with inspection hole with hinged cover at
suitable height and location. Adequate sized flanged openings with
inspection doors are to be provided near bends where there is chance
of clogging for inspection and poking to clear the accumulation. Chute
construction below gate shall be such that there shall not be any
clogging of materials between chute and gate in that zone.
3.3.22 New mould and segment repair shop
A new mould & segment repair shop (MSRS) of minimum size 108m
length x 30m width x 12m crane rail height shall be provided to equip

all the testing & storage stands and machine tools for repair and
maintenance of mould, segment etc. However, as per requirement, if
larger size of mould and segment repair shop is required, same shall be
in the scope of the bidder. The broad technical parameters of the machine
tools to be installed at new MSRS are as follows.
3.3.22.1 CNC Lathe

1 Quantity 02 nos.
2 Purpose Machining of round
components including strand
guide and run out rollers
3 Type of construction Computer controlled flatbed
lathe
4 Operating sequence Automatic and manual
5 Working range (Approx.) 3000mm long x 500mm
diameter
6 Main motor power As per manufacturer standard
7 Rapid Travel power As per manufacturer standard
8 Coolant pump power As per manufacturer standard
9 Purpose Machining of round
components including strand
guide and run out rollers
The main components include base frame or lathe bed, headstock,
tailstock, carriage with quick change tool post, CNC programming and
operating facilities etc. The machine shall be provided with all required
accessories, spares, cooling system, tools & tackles etc.
3.3.22.2 High speed precision lathe

1 Quantity 01 no.
2 Purpose General machining works
3 Job dia. (max.) 450 mm
4 Distance between center’s 2000 mm
5 Swing over cross slide As per manufacturer standard
6 Maximum weight of job As per manufacturer standard
handled
7 Main motor power As per manufacturer standard

10 Material of Bed Full body cast iron SG40
Accessories to be supplied along with equipment:

3 jaw chuck, 4 jaw chuck, Universal face plate, swarf-tray, drive plate,
coolant equipment with tank fittings, splash guard, low voltage machine
lamp, tool box (including set of allen keys and spanners), thread dial
indicator, Live center, center, center sleeve, foot brake system, steady rest,
follow rest, chip guard, Inch and metric change gears, oil can, keyway
cutting attachment, quick change tool post with tool holders, taper
turning attachment, tool post grinder, etc.
3.3.22.3 CNC Milling Machine (Horizontal)

1 Quantity 01 no.
2 Purpose Machining of both broad &
narrow faces of mould copper
plate
3 Type of construction 3 axis bridge type machining
center
5 Copper plate dimensions 2800 mm x 900 mm x 150 mm
(Approx.) (L x W x T)
6 Metal removal depth 1.5 mm per machining
(approx.)
7 Main motor power As per manufacturer standard.
The main components include base frame, rotating machine head, CNC
programming and operating facilities, etc. The machine shall be provided
with all required accessories, spares, cooling system. tools & tackles etc.
3.3.22.4 Vertical Milling Machine

1 Quantity 01 no.
2 Type of construction 3 axis bridge type machining
center
4 Spindle position Swiveling type vertical

5 X/Y/Z axis As per manufacturer standard.
6 No. of table T-slots As per manufacturer standard.
7 Metal removal depth 1.5 mm per machining
(approx.)
8 Main motor power As per manufacturer standard.
The main components include electric motor with control gear, milling
arbor, machine lamp, set of requisite tools etc., etc. The machine shall be
provided with all required accessories, spares, cooling system, tools &
tackles etc.
3.3.22.5 Universal drilling Machine
The brief technical parameters of universal drilling machine are as follows:

No.
1 Quantity 01 no.
2 Drilling capacity (mm) in steel Ø 50 or more
(of 600 Mpa tensile strength)
3 Drilling capacity (mm) in cast Ø 65 or more
iron (of 250 Mpa tensile
strength)
4 Tapping in steel M 48 or more
5 Drilling length (mm) 400 (approx.)
6 Drilling depth 5 times drill size
7 Horizontal travel / vertical 1000/1500/1500
travel / column traverse along
bed (minimum)
The main components include self-centering device, machine vice
without swivel, machine lamp, set of spares, complete coolant equipment,
etc. The machine shall be provided with all required accessories, spares,
cooling system, tools & tackles etc..
3.3.22.6 Power saw
Sl. No. Description Parameters

1 Quantity (no) 01
2 Round cutting capacity Ø 300 mm
(minimum)
3 Square cutting capacity 200 mm
(minimum)
4 Cutting capacity at 45° As per manufacturer standard
5 Material to be cut Carbon steel & alloy steel
The main components include electric motor, adjustable material stop,

hacksaw blade, material stand (adjustable bar rest), machine lamp, jaws
for bundle cutting, set of spares, complete coolant equipment, etc. The
machine shall be provided with all required accessories, tools & tackles
etc.
3.3.22.7 Roll cladding including heat treatment facilities

1 Quantity (no) 01
2 Purpose For cladding of segment rolls,
roller assembly, dis assembly
(with twin wire feeding facility)
3 Heat treatment facilities Accommodate at least 10 rolls
at a time
3.3.22.8 Above specification/ technical parameters for all the equipment of mould
and segment repair shop are the basic requirement for the equipment/
machine. Manufacturer’s specification/ technical parameter may slightly
vary. However, specification/ technical parameters offered by the bidder
shall not be inferior to the specified technical parameters.
3.3.22.9 The machine tools mentioned above are minimum requirement and any
other machine tool required for repair and maintenance of mould and
segments shall also be supplied as per technological requirement.
3.3.23 Dismantling & relocation of equipment/ facilities
The following facilities are to be dismantled and re-located as per following

details
(i) Hydraulic test rig, oil filtration system, spares & consumables and etc.
in the existing Bulk oil storage shed to be relocated in New Bulk oil
storage shed
(ii) Milling machine (Model FN2V, HMT make), shaping machine, spares &
consumables, electric hoist (1t capacity) etc. in the micro etching
laboratory to be relocated in new Macro etching laboratory

(iii) 7.5t EOT crane alongwith accessories (Make: Armsel) from old air
compressor station to new Bulk oil storage (Approx. weight= 10t)
(iv) Ladle cooler from KL bay (col. No. 33-34) to KL bay (tentatively near
col. no. K 48- 49) (Approx. weight of each= 5t)
(v) Ladle stand from KL bay (col. No. 34-35b) to KL bay (tentatively
between col. no. 51-53) (Approx. weight of each set= 10t)
(vi) Ladle relining pit (2 nos. to be retained and 4 nos. shall be levelled off)
in KL bay near col. 33-36.
(vii) Cantilever crane 5t capacity (To be suitably relocated for Tundish and
ladle handling as per requirement) in KL bay (Approximate weight: 10t)
(viii) Box for waste material (To be suitably relocated as per requirement) in
KL bay
(ix) Shifting and relocation of existing crane buffers in the bay where shed
is being extended i.e. LM, MN, PQ, NP, QR & R’S bay and removal of
the buffers after completion of bay erection.
3.3.24 Dismantling of equipment/facilities
The equipment/ facilities to be dismantled are as per following details

(i) Cantilever crane of 5t capacity in LM bay (Approximate weight : 10t)
(ii) Automatic ladle tilter (Approximate weight of each: 14t)
(iii) Mortar Mixer in LM bay (Approx. weight= 6t)
(iv) Mortar Mixer in KL bay (Approx. weight= 6t)
3.3.25 Modification of 5t Grab bucket crane
The existing 5t grab bucket crane located over the scale pit (Rail top level
+7.5m) shall be suitably modified so that the existing tong crane (Rail top
level +12m) shall pass over it. The major modifications to be carried out are
as follows;
(i) Modification of the canopy over the drive system
(ii) Dismantling of electric hoist
(iii) Relocation of buffers as per requirement
(iv) Dismantling & re-erection of LT rails & DSL
(v) Any other modifications as per requirement
3.3.26 Hydraulic oil pipelines from new bulk oil storage to caster#1,2,3 & 4

Laying of new hydraulic oil pipelines along with associated valves, fixtures,
supports & etc. from new bulk oil storage upto caster# 1, 2, 3 & 4. All the
pipes shall be seamless tubes NB50, schedule80 as per DIN EN 10305-1-
2010 and DIN EN 10220-2003, material ST 52.4 (E355+N)
The pipes to be laid in the existing pipe tunnel near col. no 45 & 46 up to
casters 1, 2, 3 & 4.
3.3.27 Oil Hydraulic System
3.3.27.1 Oil hydraulic system shall be provided for equipment of proposed system as
per requirement. Hydraulic system shall be provided for the following;
 Continuous casting machine
 Ladle slide gate
 Mould oscillator
 Slab turnover device, pusher & piler
 Machine maintenance
 Tundish tilting etc.
Bidder to note that above list of envisaged hydraulic system is indicative only.
Bidders are free to offer system as per their design. However, any other
system required for the project but not included in this list shall also be
considered.
3.3.27.2 Broad details of each Oil Hydraulic System shall be as below:
i. System shall be so designed that the peak flow requirement during
simultaneous operations is fulfilled by the main pump(s) only.
Accumulator shall be designed to carry out all emergency operations
in the event of any type of power failure.
ii. Flow and pressure for the systems shall be selected by the Bidder
based on the system requirement. Numbers of such system shall be
decided by the Bidder.
iii. Main pumps shall be axial piston variable displacement type. The
number of standby pumps for each system shall be as below:
Number of operating pumps Number of standby pumps

1-2 1
3-6 2
7-8 3
iv. All filters except pressure line filters shall be duplex type with
electrical clogging indicators. rating of the filters shall be as per
system requirement. ratio shall be ≥ 200. Pressure line filters shal
be simplex type with electrical clogging indicators.
v. Flow capacity of all pressure line filters shall be 2 times the maximum
flow rate of pumps and flow capacity of all return line filters shall be 3
times the total flow rate of pumps.
vi. Fire resistant fluids shall be used in all the areas dealing with liquid
metal and hot product surfaces. Mineral oil shall be used in other areas.
vii. For the pipelines, following to be considered (unless otherwise
specified elsewhere in the TS):
 All the hydraulic, fittings, hoses in both cooling chamber and on
the segment shall be of stainless steel
 All the hydraulic pipe lines shall be routed above the working
platform of the Cooling Chamber
 All spray pipe/conduit, fittings and hoses shall be of Stainless
steel
 Tanks shall also be of stainless steel.
viii. Air breathers shall be desiccant type. rating of the breathers shal
be matching with the lowest rating of the filters for the system.
ix. The system shall be designed with oil level monitoring in the tank,
pressure monitoring in the system, temperature monitoring etc.
x. Power Pack shall be provided with tray at the bottom for taking care
of leakage of oil.
xi. Off-line filtering-cum-cooling system shall be provided. The number
of standby pumps shall be as below:
Number of operating pumps Number of standby pumps
1-4 1
5-8 2
xii. 2 Nos. Portable motorized oil filling pump with filter shall be provided
for filling of oil from the barrel into the tank. All hydraulic system shall
have topping up facility through off line filter
xiii. 2 Nos. On-line particle counting machine shall be supplied for
checking oil contamination shall be provided.
xiv. 2 no’s of LVDH machines shall be supplied for moisture separation in
Hydraulic oil.

xv. Each hydraulic system shall be equipped with ELC machine
(Electrostatic cleaner).
xvi. Hydraulic systems shall be supplied with Nitrogen charging kit with
N2 booster.
xvii. Centralized monitoring station for monitoring of levels, pressures and
other parameters shall be provided.
3.3.27.3 Major component of hydraulic system shall be as given below:

i. Reservoir including accessories like air breather, oil level and oil
temperature monitoring items
ii. Main Pump
iii. Filter
iv. Valves (Directional control, Flow control for speed control, Pressure
control for load control etc.)
v. Filtering-cum-cooling system
vi. Actuator
vii. Accumulator
viii. Pipelines
Brief description of major components:
i. Reservoir including accessories like air breather, oil level and oil
temperature monitoring items
 Reservoir shall be generally selected based on application and type of
system (open or close).
 For open circuits having mineral oil, reservoir capacity shall be at least
5 times total capacity of all pumps running at a time
 For open circuits with fire resistant fluids, reservoir capacity shall be at
least 8 times total capacity of all pumps running at a time, due to poor
air separation and contaminant separation capacity of fire resistant
fluids
ii. Main Pump

 Flow and pressure for the systems shall be selected by the Bidder
based on the system requirement.
 Number of operating pumps & standby pumps shall be as
mentioned above.
 Power Pack shall be provided with tray at the bottom for taking care
of leakage of oil.
iii. Filter
 Fluid cleanliness required for typical hydraulic components shall be
considered as below.
Component As per As per NAS Recommended

ISO 4406 1638 filter rating (µ)
Servo valve 16/14/11 5 3-5
Proportional valve 17/15/12 6 5 - 10
Vane and piston 18/16/13 7 10 - 12
pump/motor
Directional & pressure 18/16/13 7 10 - 12
control valve
Gear pump/motor 19/17/14 8 10 - 12
Flow control valve, 20/18/15 9 12 - 15
cylinder
iv. Valve
 Types of valve like directional control, flow control (meter-in or meter-
out) for speed adjustment and pressure control (relief, reducing,
sequence, un-loading, counter balance etc.) for load control shall be
selected based on the operational requirement
 Selection / sizing of a valve shall be done based on the flow
requirement and pressure drop across the valve, as per manufacturer’s
chart supplied with their product catalogues.
v. Filtering-cum-cooling circuit
 Pressure rating is usually 10 to 15 bar but shall depend on the
resistances like filter, cooler, valves etc. located in this offline route
 Pump shall be screw (for high volume and low pressure) or gear type
based on requirement of flow. Screw pump is very silent during
operation but is less efficient
 Number of operating pumps & standby pumps shall be as mentioned
above.

 ß ratio of the filter shall be selected for the required micron rating
based on the operation requirement. 3 to 5 μ rating filter is
recommended.
 Water-to-oil type gasketted Plate Heat Exchanger (PHE) with by-pass
arrangement shall be used for cooling circuit.
 Heat load for the cooler shall be 40 % of the kw rating of all the running
main pumps
vi. Accumulator
 Bladder or piston type accumulators along with safety blocks and
Nitrogen bottle of desired capacity shall be provided. All accessories
inclusive of charging device, shutoff valves, monitoring and control
devices and initial fill of Nitrogen shall be provided.
 The design capacity of the accumulator shall be such that the power
pack is able to carry out all emergency operations in the event of any
type of power failure. Bidder shall specify the emergency operations to
be performed by the accumulator in the event of power failure.
 Accumulator is used mainly for:
- Requirement of higher volume of oil for a short period
- For emergency operation during power failure
 The available volume (∆V) of oil from an accumulator shall be
calculated from the graph provided in the manufacturer’s catalogues,
based on the minimum operating pressure and maximum operating
pressure of the system
 The charging pressure shall be considered as 0.9 times the minimum
operating pressure
vii. Actuator
 Actuator may be linear, rotary or motor type.
 Actuator shall be sized based on the load/force requirement and
pressure of the system
 Speed of the actuator shall be checked for the system requirement. As
a rule, for reliable continuous operation, piston speed for a cylinder
shall not exceed 500 mm/sec.
 The ratio of the rod end area and piston end area shall be kept in mind
(for η of the system).
 Necessity of cushioned ends shall be checked.

 Hose safety rupture device shall be provided in cylinders wherever
applicable.
viii. Pipelines
 Sizing of pipelines is very critical for any hydraulic system, as it plays
an important role in fixing pressure drop in a system. Based on the
length of pipelines and various components involved, the pipeline shall
be sized correctly as mentioned above.
 Pipelines and fittings shall be as per system requirement.
 Internal diameter of pipelines shall be selected based on the following
permissible velocity:-
Service Pressure Maximum permissible

(bar) Velocity (m/sec)
Suction line All <1
Return line All 3.5
Delivery line Up to 50 4
50 to 100 4.5
100 to 150 5
150 to 200 5.5
200 to 400 6
 Thickness of the pipe shall be selected from manufacturer’s pipe
selection charts showing OD (mm) x thickness (mm) for different
pressure ranges
 Pipelines shall be properly pickled and flushed during erection and
commissioning.
3.3.27.4 On-line particle counting machine
Sl. No. Description Parameter

1 Quantity(Nos.) 2 (two)
2 Type Portable
3 Display Digital Analyser with LCD Display
4 Accessories Flexible hose for Suction & discharge
3.3.27.5 Electrostatic Oil Cleaner

1 Quantity (Nos.) 1 no. for each hydraulic system /
minimum 6 (six) nos.
2 Type Portable with wheel mounted
3 Pump Flow rate 10 lpm
4 Accessories Flexible hose for Suction & discharge
5 Type of Oil Hydraulic oil of various types
6 Cleaning level Up to NAS5
7 Oil hose 10 m each for suction & discharge
8 Power supply 3 phase, AC, 50 Hz
3.3.27.6 Portable Nitrogen Charging Compressor / Nitrogen Booster

1 Quantity (Nos.) 2 (two)
2 Type Portable Nitrogen Charging Compressor
3 No. of Stages As required
4 Flow 8 lpm
5 Working 350 bar
pressure
6 Purpose For charging of accumulators
7 Power supply 3 phase, ac, 50 Hz
3.3.27.7 Low vacuum de-hydration unit (LVDH)

1 Quantity (Nos.) 2 (two)
2 Type Portable Low vacuum de-hydration unit
5 Type of Oil Hydraulic oil of various types
6 Purpose for separation of moisture
7 Power supply 3 phase, ac, 50 Hz
3.3.28 Grease Lubrication system

3.3.28.1 Centralized motorized dual line grease lubrication system shall be
provided for greasing of equipment of proposed system. Number of such
system shall be decided by the bidder based on requirement. The broad
details for Grease Lubrication System shall be as below:
i) Centralized motorized dual line grease lubrication system shall be
provided for greasing of equipment of proposed system.
ii) The system shall be 1 No. working (minimum) and 1 No. standby for
main pumps with reservoirs, filters, relief valves, and change over
valves etc. Complete lubrication system shall be suitable for 400 bar
pressure.
iii) Refilling pump, main pumps & Change over valves shall be electric
motor operated.
iv) Pipe sizing shall be carried out based on actual pressure drop
calculations. However, minimum pipe sizes shall be as below:
Pipe Zone Pipe OD (mm) x Material of pipe
pipe thickness
(mm)
Main header 30 x 3 Stainless steel
Branch lines from main 20 x 2 Stainless steel
header up to inlet of
distributors
Feed lines from 10 x 2 Stainless steel
distributors up to inlet
of bearing points
v) The system shall be operated based on end pressure relays as well as

timers.
vi) Reservoirs for main pumps shall have minimum capacity of 100 litre.
vii) 2 Nos. pneumatic operated grease refilling pump with provision of
easy taking out or putting in of the refilling pump inside the barrel, like
provision of a hand operated winch, shall be provided.
viii) Operating period shall be considered as 24 hours per day
3.3.28.2 Each system shall consist of the following major equipment.
i. Pumping unit with dedicated reservoir
ii. Automatic change over valve
iii. End pressure relay
iv. Metering manifold / Dose feeders

v. Grease filling pump
vi. Interconnecting piping
vii. Electrics and controls
viii. Indicating and control instruments
i) Pumping Unit with Dedicated Reservoir
2(two) nos. of motor operated grease pumping unit (1W+1S), of
required grease flow capacity and pressure complete with filter, relief
valve assembly and pressure gauge of 1.5 times the working pressure.
One (1) line strainer of suitable micron rating for system working
pressure shall be located between pump and reversing valve.
Reservoir for grease lubrication systems shall be of minimum 100 liters
capacity to feed grease for reasonable hours of operation at least for
7 days of operation. It shall be made from general purpose structural
steel of adequate thickness fitted with accessories to achieve specific
purposes. It shall be of cylindrical shape and mounted on top of
pumping equipment for efficient priming. The interior shall be oiled
but not painted
The reservoir shall be complete with a heavy inertia follower plate, tell-
tail rod, fill connection with strainers & check valve, limit switches on
the container lid to indicate full and empty reservoir for audiovisual
alarms for low level & high level and for automatic starting of the filing
pump at low level of the reservoir.
ii) Automatic Change Over Valve

24 VDC electromagnetically operated change over valve shall be
mounted after the pump. The change over valve shall be of spool type
of robust construction and shall have gland packing to suit high grease
pressure. The reversing valve shall be supplied with manual over ride.
The pressure drop across valve with rated flow shall not exceed 3
kg/cm2.
The above components shall be assembled on a common base frame
and suitably piped up and supplied with necessary foundation bolts.
iii) End Pressure Relay
The system shall be operated based on end pressure relays as well as
timers. End pressure relays shall be mounted at the end of the circuit
just before the last dose feeder / metering manifold to ensure pressure
attainment at the furthest end of the system during the

cycle of operation and to alter the path of grease flow by actuating the
automatic change over valve by electrical impulses. This relay shall
dictate the automatic change over valve for supply of grease line from
one line to the other line. The relay shall be equipped with two nos. of
pressure gauges.
Two Nos. strainers of suitable micron rating for system working
pressure, shall be installed before the end pressure relay.
iv) Metering Manifold / Dose Feeder
Metering Manifolds shall have suitable inlet and outlet connections.
The manifold shall be complete with 5 mm thick mounting pads and
fasteners. Plastic caps to be provided for all openings.
The metering manifolds shall be suitable for delivering quantities (as
per requirement) of grease per stroke per outlet. The metering
manifolds shall be suitable for 1.5 times maximum working pressure.
Leakage test shall be carried out with a lubricant of viscosity 120 to 150
cst at 400C. The manifolds shall be kept at a pressure of 1.5 times
maximum working pressure for two minutes in each extreme positions
of piston. The rate of lubricant escape shall not exceed 3 drops per
outlet per minute. Required pressure for movement of pistons against
no load shall not exceed 20 bar. Dose feeder may be supplied with
options of different outlets. Dose feeders shall be of adjustable
discharge /stroke within the range from 0 to 2 cc.
v) Grease Filling Pump
1 (one) no. motor operated grease refilling pump with provision of
easy taking out or putting in of the refilling pump inside the barrel, like
provision of a hand operated winch, shall be provided.
vi) Interconnecting Piping
vii) The main header, branch lines & feed lines of grease system shall be
stainless steel (unless otherwise specified elsewhere in the TS).
Welded nipple type fittings with ‘O’ ring or welded fittings shall be
used for main headers & branch lines to metering distributors.
Flareless compression type fitting shall be used only on the feed lines.
Pipe sizing shall be carried out based on actual pressure drop
calculations. However, minimum pipe sizes shall be as below:

Pipe Zone Pipe OD Material of pipe
(mm) x pipe
thickness
(mm)
Main header 30 x 3 Stainless steel
Branch lines from main header 16 x 2/2.5 Stainless steel

up to inlet of distributors
Feed lines from distributors up 10 x 2 Stainless steel

to inlet of bearing points
viii) Electrics & Controls

Required necessary PLC based electrics & controls including pump
start/ stop panels shall be supplied for proper function of the system.
ix) Indicating And Control Instruments
All necessary indicating and control instruments shall be supplied.
3.3.28.3 General Notes
i) Provisions of IS 8593(Part 2):1988; Recommendations for Centralized
Lubrication as applied to plant and machinery shall generally be
complied with.
ii) Grease station shall generally be located on the shop floor level
iii) The piping shall include pipes, pipe fittings, valves & fastening
material.
iv) All necessary clamps, fixing brackets, screws, foundation bolts, nuts
and washers shall be supplied for installation.
v) All isolating valves shall be ball valves and shall be equipped with visual
indicator indicating fully open or fully closed conditions of valve.
vi) All butt weld joints shall be made by TIG welding only.
vii) Tubes/ pipes shall be cleaned by pickling and oiled after fabrication
but before assembly.
viii) After assembly, all the piping shall be dismantled pickled, rinsed
neutralized, air dried, oiled with system fluid and then re-assembled
for inspection and testing.
ix) Quantity of first fill of grease & flushing grease supply shall be in
Bidder’s scope as required till commissioning.

x) Commissioning spares & consumables such as flushing filters, flushing
oil etc. shall be in Bidder’s scope as required till commissioning.
xi) All equipment shall be supplied with drives, associated electrics,
instruments and control equipment, technological structures (if any),
maintenance and working platforms, railing, safety guards
xii) Tools & tackles for all systems.
xiii) Material handling facilities.
xiv) Any other equipment / part / facility not specifically mentioned in the
specification, but is necessary technically or safety point of view for the
satisfactory and smooth operation of the system shall also be included
in the scope of the supply of the supplier.
xv) The successful Bidder shall furnish a complete quality assurance plan
indicating all the tests to be conducted to ensure that the items
supplied are without any defect. The QAP shall be approved by the
Employer/ consultant.
xvi) The Bidder shall have right to visit the supplier / sub-supplier’s works
during various stages of manufacture.
xvii) The tests / inspection shall be conducted based on approved QAP &
include broadly the following: -
a) Visual inspection of offered equipment, modified equipment etc.
b) Checking the dimension with tolerance
c) Performance test of individual equipment, sub-system and total
system
d) Complete units shall be pressure tested at 1.5 times of system
working pressure.
xviii) Painting specification for Reservoir (outside only) and equipment is as
follows;
a) Two (2) coats of red oxide zinc chromate primer and one (1) coat
of finish enamel paint. Thickness of each coat should be around
30 microns and total thickness should not be less than 100
microns.
b) Color code shall be shade no. 221 to IS: 5-1994, if not specified
otherwise.
xix) Name plates with the following description shall be attached to the

grease equipment and/or component at a place easy to be read.
a) Name of equipment and/or component
b) Manufacturing serial no. and / or type
c) Specification of rating
d) Date of manufacture
e) Name of manufacturer
3.3.28.4 Grease Lubrication System for other areas
Minimum 2(two) units of portable motorized grease pump unit with
container along with one unit of refilling pump shall be provided for
lubrication of other equipment not covered under centralised grease
lubrication system.
3.3.28.5 Manual Grease Lubrication
Manual grease system shall be provided only in rare cases where it is not
possible to provide centralized auto dual grease system. Each manual dual
line grease system shall not have more than twenty five (25) consumer
points.
Lubrication points which are not covered by centralized lubrication systems
shall generally be provided with lubrication nipple conforming to IS
4009(Part-1): 1981. The connector for the hand lubrication device shall suit
the connections provided at the lubrication points.
Each manual dual line grease system shall consist of the following
 Grease Reservoir.
 Manual pump
 Change over valve
 Metering Manifold / Dose feeders.
Indicating instruments
3.3.29 Centralised air oil lubrication system
3.3.29.1 Centralized air oil lubrication system complete with programmable control
unit shall be provided as per requirement. Where ever, it is not possible to
provide air oil lubrication system, centralized dual line grease lubrication
system shall be provided and where ever, it is not possible to provide
centralized grease lubrication system, portable manual grease lubrication
system shall be provided. The system shall mainly consist of;
a) Oil main unit for supply of oil to the mixing station
b) Mixing stations to cater to all the lubrication points

c) Air pipe line with set of valves, filters with water separator, pressure
gauge, pressure switches etc.
d) Air compressor
e) Air receiver of suitable capacity with moisture trap
f) Pipeline shall be seamless stainless steel
g) Hoses, distributors etc. required for the system
h) A venting line shall be provided for venting extra lubricants from
pressure regulating valves in case of high system pressure for safety
i) Venting shall also be performed to ensure bubble free supply of
lubricant to the metering unit
j) All respective pipelines shall be flushed with air or oil at requisite
pressure before operation to inspect for leakage and cleaning of dust
particles.
k) Necessary valves for isolation and moisture separator. The moisture
separator shall have automatic moisture traps with individual strainer,
by-pass valve, drains & vents.
3.3.29.2 Major components of air-oil lubrication system

The major components of air-oil lubrication system shall be as follows:
Main Oil Unit
The oil main unit shall be responsible for supplying oil to the mixing station.
It shall consist of oil tank and a power pack. The oil main unit shall be
equipped with following minimum items:
i) The power pack shall consist of two pumps (1w+1s) of suitable
capacity as per system requirement
ii) Oil tank of carbon steel material with suitable capacity
iii) Breather
iv) Valves stand for pressure relief and regulation
v) Pressure switch for monitoring of oil pressure
vi) Pressure gauges
vii) Oil level indicator
viii) Oil level switch
ix) Cleaning/inspection cover
x) Filling port & filters
xi) Safety valves
xii) Oil Filter with clogging indicator,
xiii) Accumulators
xiv) Direction Control Valves
xv) Non-return valves
xvi) Suction Filter etc.
xvii) Pressure instrument for monitoring the delivery pressure
xviii) Oil filling station with filter
xix) The oil level indicator shall be equipped with the feedback system for
automatic filling of the pump in case of low level.
xx) Circuit diagram embossed in metallic plate shall be mounted on the
oil main unit
xxi) Lubricant grade shall be mounted on the lubricant reservoir in order
to prevent accidental mixing of lubricants.
xxii) Viscosity grade of oil shall be considered in calculating pipe diameter.
xxiii) All oil pipelines shall be of seamless type stainless steel construction.
xxiv) All the lubrication pipe lines shall be routed above the working
platform of the Cooling Chamber
xxv) All spray pipe/conduit, fittings and hoses shall be of stainless steel.
Air Compressor
Air compressor (1W+1S) alongwith drive system of suitable capacity as per
system requirement shall be supplied.
Air Line
i) A buffer of suitable capacity with moisture trap shall be installed in the
line to ensure smooth flow of air.
ii) Control valves required to set the air pressure required for the system.
The system shall be designed in such a way that fluctuations in
pressure do not cause inconsistency in the performance of the
lubrication system.
iii) The compressed air shall be fed uniformly to ensure constant transport
of oil streak to the lubrication points.
iv) Air filter with an integrated water separator shall be used.
v) Pressure switch shall be mounted to continuously monitor the
minimum air pressure required for the system to ensure transport of
lubricant reliably for proper lubrication of points.
vi) Minimum pressure fault shall be fed back to the new lubrication PLC
for manual intervention.
RSP PAGE CET/05/RN/4179/TS/ST/02/R=2

4TH CASTER – MAIN PACKAGE 3.100
vii) The air-line shall also be equipped with set of valves, pressure gauges,
pressure switches etc. for proper control of the system.
viii) The air pressure shall be set according to the delivery volume of
compressed air in each lubrication point line, taking into account
pressure losses in the lubrication point line and the bearing assembly.
Air and oil mixing station
i) The mixing of air and oil shall take place in the mixing station. The
capacity of the mixing station shall be sufficient for mixing the air and
oil in right amount and supplying the mixed air-oil to all the consumer
points as per the requirement of the system. The mixing station shall
be equipped with different types of valves, distributors, mixing block,
filters, feedback system etc. for proper control.
ii) Air and oil are separately injected into the mixing station. Progressive
distributors shall be used for metering the oil required for each
lubrication point before passing into the mixing block.
iii) Flow sensors in lubrication lines and lubricant point lines for
monitoring lubricant transport shall be provided.
iv) The mixing station shall be wall mounted or foot mounted as per
requirement.
v) It shall be ensured that the required quantity of lubricant is supplied
to the lubrication point to avoid under lubrication
Pipelines
i) All pipelines in the air-oil lubrication system shall be seamless and
stainless steel type of grade suitable to the working environment.
ii) The lubrication line shall be so designed for maximum pressure and
volume for which the air-oil system is designed. The pipeline shall be
tested for 1.5 times the maximum working pressure. Test certificate
shall be submitted for approval.
iii) Lubricant distributors shall be of robust design with suitable no. of
outlets to feed the bearing points.
iv) A venting line shall be provided for venting extra lubricants from
pressure regulating valves in case of high system pressure for safety.
Venting shall also be performed to ensure bubble free supply of
lubricant to the metering unit.
v) Sharp bends and change in cross section of pipelines in the direction
of flow, check valves etc. shall be avoided to ensure free flow of
lubricants. For unavoidable bends and cross section change, smooth
transition pieces shall be used.

vi) Lubrication lines must be laid in a way to avoid forming of air pockets
anywhere in the system.
Positioning and Erection
i) All components of the air-oil lubrication system shall be so mounted
to protect them from humidity and vibration. The components shall be
easily accessible for installation, operation and maintenance.
ii) The system shall be installed at sufficient distance from the source of
heat to avoid damage and malfunction of the system.
iii) The lubrication system shall be protected against excessively high
pressure by means of pressure relief valve.
iv) Distributors of air-oil lubrication shall be properly protected against
heat and breakouts.
v) The bearing housing, seals and oil pipelines shall be jointly tested for
oil leak.

3.4 UTILITIES
3.4.1 Shifting of existing utilities passing through gable end of Caster#1&2 as
detailed in chapter 2
3.4.2 Various utilities for each of the proposed facilities shall be provided as
under:
i) For new caster-4 utilities like Oxygen, Nitrogen, Argon, mixed gas,
Propane gas, compressed air, steam, soft water and industrial water are
required which shall be drawn from their respective battery limits up to
the consumer ends.
ii) For proposed ladle furnace, LF-2D utilities like Nitrogen, Argon,
compressed air, soft water and industrial water are required which shall
be drawn from their respective battery limits up to the consumer ends.
3.4.2.1 Oxygen
Another new Oxygen supply system shall be provided for proposed caster-
4 and for other new units as per their technological requirement. Both of the
PRSs shall be installed just outside the extended shed in the manner it is
installed at present or at any other suitable location.
i) Proposed Oxygen Supply System for New Caster-4 and LF-2D:
Oxygen for proposed caster-4 shall be tapped suitably from existing
incoming DN100 header within 50m from Battery Limit. Pressure at the
tapping point is 16 – 35 kg/cm2(g). An Oxygen PRMS (Pressure Reducing
and Mixing Station) of 2 streams (1W + 1S) consisting of suitable
pressure control valves, isolation valves at the upstream and
downstream both shall be installed as per the technological
requirement. Downstream pipe from PRS shall be suitably laid over the
columns of extended shed/ new trestles/bridge up to the consumer
ends with necessary supports etc.
3.4.2.2 Mixed Gas
For heating purpose and other process requirement mixed gas is required.
Two numbers of DN 400 size pipes are entering to CCS-II from scale pit side
of casters- 1 & 2 over the columns of CCS shed. Pressure available is 1100 –
1200 mm WC. These two lines fulfil the mixed gas requirement of CCS-II
units. From these lines mixed gas is drawn for casters- 1 & 2 inside the CCS
shed.
Necessary tapping for caster-4 shall be drawn from these headers.

3.4.2.3 Propane
Propane gas is being supplied to caster-3 and existing RH-OB unit at 1.5
kg/cm2(g) with the help of DN 200 size pipe from Propane plant laid towards
Tonnage Oxygen Plant-II (TOP-II) side. Propane for caster-4 shall be suitably
drawn from above DN 200 size pipe. Necessary valves, pipe fittings, supports
etc. shall be provided.
3.4.2.4 Nitrogen
New Nitrogen supply system shall be provided for proposed caster-4,
proposed LF-2D and for other new units as per their technological
requirement. Both of the PRSs shall be installed just outside the extended
shed in the manner it is installed at present or at any other suitable location.
i) Proposed Nitrogen Supply System for New Caster-4 and LF-2D:
Nitrogen for proposed caster-4 and LF-2D shall be tapped suitably from
existing incoming DN50 size header, pressure at the tapping point is 18
– 40 kg/cm2(g). A Nitrogen PRS of 2 streams (1W + 1S) consisting of
suitable pressure control valves, isolation valves at the upstream and
3.4.2.5 Argon
New Argon supply system shall be provided for proposed caster-4,
proposed LF-2D and for other new units as per their technological
requirement. Both of the PRSs shall be installed just outside the extended
shed in the manner it is installed at present or at any other suitable location.
i) Proposed Argon Supply System for New Caster-4 and LF-2D:
Argon for proposed caster-4 and LF-2D shall be tapped suitably from
above existing DN40 size header , pressure at the tapping point is 18
kg/cm2(g). An Argon PRS of 2 streams (1W + 1S) consisting of suitable
pressure control valves, isolation valves at the upstream and
3.4.2.6 Compressed Air

New compressed air plant is installed at the existing scale pit side of CCS,
delivery of which is connected to existing compressed air grid. Tapping of
compressed air for the caster-4 and LF-2D and other consumers as per
technical requirement shall be drawn from the existing compressed air
header of DN 250 size after the air receiver. The compressed air pipe shall
be laid up to proposed caster-4 and proposed ladle furnace LF-2D along the
columns of CCS shed. Necessary valves, pipe fittings, supports etc. shall be
provided. 2 nos. of air driers of refrigerated type shall be provided to avoid
choking of compressed air pipe lines because of condensation. Water traps
shall also be provided at suitable locations.
3.4.2.7 Make Up Water
Water Treatment Plant (WTP) for open loop cooling water system as well as
closed loop cooling water system of caster-4 and LF-2D shall be installed as
indicated in layout Drawing no. CET RN 4179 ST0 00 001 R=3. A DN 600
size pipe from expansion pump house is laid underground and passing by
near to proposed location of WTP of caster-4. Tapping for makeup water
line shall be drawn from above underground header and shall be laid up to
the make-up water chamber. Bidder shall design the system with minimum
of makeup water requirement (maximum 100 m3/h). Necessary valves, pipe
fittings, supports etc. shall be provided.
Quality of makeup water is as under:
Parameter Value
Turbidity (mg/l) : 70 (max.)
Conductivity (micro mho/cm) : 190 (max.)
pH : 7.0 to 8.6
Total suspended solids (mg/l) : 100 (max.)
Total dissolved solids (mg/l) : 240 (max.)
Total Hardness as CaCO3 (mg/l) : 100 (max.)
Calcium Hardness (mg/l) : 47 (max.)
Methyl Orange Alkalinity (mg/l) : 105
Phenolphthalein Alkalinity (mg/l) : 10
Sulphate (mg/l) : 80
Chloride (mg/l) : 6
Silica (mg/l) : 10
Fe (mg/l) : 1.6 (max.), 0.2 (min.)

Further treatment of this water is in the scope of the Bidder. If water of any
other quality is required, appropriate treatment shall be provided by the
Bidder.
3.4.3 Proposed Cooling System for caster-4
3.4.3.1 Open Loop Cooling System (Air-Mist Spray Cooling)
Air-mist spray cooling system shall meet the direct cooling requirement of
various components of slab caster-4 mainly hot stand, external cooling of
the stand guide rollers, cooling of torch cutting machine, cutting slag
granulation, cooling of the run out table rollers in cutting area. Proposed
scale pit, primary settling tank and primary scale water pump house shall
meet the requirement of the proposed Caster # 4 along with common flume
flushing. Treated industrial water shall be fed to the open loop cooling
system of caster-4 from the pumps to be installed in spray cooling pump
house.
All pipes and its fittings in the secondary cooling zone shall be made of
stainless steel (AISI 316)
a) Primary Scale Water Handling Facilities (Scale Water Pump House):
A grab bucket crane of suitable capacity for scale removal scale pit shall be
provided. The grab bucket crane shall cover the entire length and width of
both of the compartments of scale pit.
Proposed scale water pump house shall be constructed at underground
level. Scale water pumps shall be suitably installed at bottom most level.
Push-pull type ventilation system shall be provided in proposed scale water
pump house. Pendant operated EOT crane of suitable capacity for material
handling shall be provided at ground floor and at each of the floor. At the
pump installation floor crane shall be of minimum 5 ton capacity. At the
road end side of the pump house a covered hatch opening at the ground
level shall be provided in which an electrical operated EOT crane of
minimum 5 ton capacity shall be installed for handling of material from
ground level (+0.00) to each of the floor of pump house including ground
floor and vice versa. Proposed scale water pump house shall have three
groups of pumps as under:
Pumps shall transport the primary scale water to proposed WTP for caster-
4. For this, 3 nos.(1W+2S) of horizontal centrifugal pumps of suitable
capacity shall be installed. Delivery header of suitable size shall be laid to
carry the scale water to proposed WTP of caster-4 for further treatment to
recycle it in the spray cooling system. Proposed water treatment plant shall
broadly include but not limited to the following:

 Scale water from scale water pump house to Secondary Settling Tank
(SST). SST shall have 02 compartments (1W + 1S), with scrapper and
oil skimmer facility. A grab bucket crane of suitable capacity for scale
removal from SST shall be provided. The grab bucket crane shall cover
the entire length and width of both of the compartments of SST.
 From above SST, overflown clarified water shall be transported to a
hot water sump by gravity. From this hot water sump, hot water shall
be pumped to ‘N’ no. working +2 nos. stand-by of pressure sand
filters with the help of 03 nos. (1W+2S) of hot water pumps of suitable
capacity. From pressure filters, hot water shall be transferred to 2-cells
(1W+1S) RCC structure cooling tower of suitable capacity. Cold water
from cooling tower shall be collected in cold water sump through
gravity pipe; here from cold water shall be pumped to the caster-4 for
air-mist spray cooling with the help of 03 nos. (1W+2S) of cold water
pumps of suitable capacity.
 Above pumps shall be installed in proposed spray cooling pump
house at ground level.
 Necessary chemical dozing system shall be provided.
 Backwashing of pressure sand filters along with pumps, blowers etc.
shall be provided.
 Back washed water shall again be treated and reused in the system.
Drain water pit along with drainage pumps along with necessary piping,
valves etc. shall also be provided inside the pump house in both ends of
primary scale water pump house at pump installation level.
Drawing Nos.: CET RN 4179 UT0 00 001 R=0 & CET RN 4179 UT0 00
003, R=0 may be referred for above.
3.4.3.2 Closed Loop Cooling System
Mould and machine cooling of caster shall be done by soft water in closed
loop system. Soft water make-up plant of 2 streams (1W+1S), each of 10
m3/h capacity shall be installed in a new civil building (which is also in the
scope of Bidder) adjacent to proposed closed loop water pump house. A
soft water RCC basin (tank) of suitable capacity shall be provided which shall
be perfectly sealed as per technical and process requirement. From here soft
water shall be pumped in the closed loop circuit for mould and machine
cooling of caster-4. During emergency use of soft water from proposed soft
water emergency overhead tank, return hot soft water shall also be stored
in the above soft water basin; accordingly sizing of the soft

water basin shall be done. Closed loop soft water system shall broadly
consist of but not limited to as under:
a) Soft Water Closed Loop System for Machine Cooling
Main components shall be:
 03 nos. (1W+2S) of pumps of suitable capacity shall be installed
in the closed loop water pump house to supply the soft water in
machine cooling circuit. For this a pipe of suitable size shall be
laid up to the caster-4. Pipe for return hot soft water shall also be
laid from caster-4.
 After machine cooling, return hot soft water from machine shall
pass through 02 nos. (1W+1S) of plate type heat exchangers of
suitable capacity to cool the return hot soft water. Both the heat
exchangers shall be installed inside the closed loop water pump
house.
b) Soft Water Closed Loop System for Mould Cooling
Main components shall be:
 03 nos. (1W+2S) of pumps of suitable capacity shall be installed
in the closed loop water pump house to supply the soft water in
mould cooling circuit. For this a pipe of suitable size shall be laid
up to the Caster-4. Pipe for return hot soft water shall also be laid
from Caster-4.
 After mould cooling, return hot soft water from mould of Caster-
4 shall pass through 02 nos. (1W+1S) of plate type heat
exchangers of suitable capacity to cool the return soft water. Both
the heat exchangers shall be installed inside the closed loop
water pump house.
c) For indirect cooling of soft water in proposed heat exchangers, cold
water pumps ‘N’ nos. working+2 nos. standby shall also be installed
inside the closed loop water pump house. After cooling the return hot
soft water, hot industrial water from heat exchangers shall be cooled
in proposed RCC cooling tower having ‘N’ nos. working+2 nos.
standby cells. Number of industrial water supply pumps to supply
industrial water to heat exchangers and capacity of cooling tower shall
be decided based on requirement of proposed ladle furnace, LF-2D
also. Cold water from cooling tower shall be brought to the proposed
cold water sump. From this sump above pumps shall deliver cold water
to heat exchangers with required makeup water.

d) By-Pass automatic self-cleaning filter shall be provided for filtering part
of the circulating soft water in each of the circuit.
e) By-Pass automatic self-cleaning filter shall be provided for filtering part
of the industrial water in heat exchanger cooling circuit in each of the
system.
f) Necessary chemical dozing facilities shall be provided.
g) Nitrogen filled surge tanks shall be provided separately in each of the
soft water supply circuits.
h) Arrangement of closed loop water system is indicated in drawing No.
CET RN 4179 UT0 00 002 R=1.
Indicative routing of soft water supply pipes for both of the circuits from
closed loop water pump house are shown in the Drawing No. CET RN 4179
UT0 00 003 R=0.
3.4.4 Water Cooling System in Proposed Ladle Furnace, LF-2D
3.4.4.1 For ladle furnace cooling soft water supply system in closed loop shall be
provided. This mainly covers the cooling of roof & electrode, LF transformer
etc.
Cold soft water shall be supplied by soft water supply pumps, ‘N’ nos.
working+2 nos. standby which shall be installed in closed loop water pump
house described under cl.no. 3.1.3.2. Hot soft water shall be transported to
plate type heat exchangers which shall be installed in the same pump house.
Industrial water for cooling the soft water shall be pumped to heat
exchangers which (hot industrial water) again shall be cooled in the cooling
towers considered for proposed caster-4. Common soft water makeup plant
and on ground sealed RCC tank for soft water shall be considered for caster-
4 and proposed ladle furnace.
For soft water system installation and pipe routing drawing No.: CET RN
4179 UT0 00 002, R=1 and drawing No.: CET RN 4179 UT0 00 003, R=0
may be referred.
3.4.5 Fume Extraction System for Ladle Furnace
Bag filter type fume extraction system suitable to handle the fumes
generated in LF-2D shall be provided.
Necessary bag house along with ID fan and structural stack (minimum
height 50m), ducts etc. for the fume extraction system shall be installed at
the back of existing new air compressor house to meet discharge norms of
50 mg/Nm3.

Provisions shall be made to enable stack sampling in the chimney as per
recommended standard procedure. This shall be done as per the relevant
standard. Necessary caged access ladder with platforms, etc., shall be
installed on the stack as per the relevant standard. Caged access ladders
shall be provided with rest points at every 7 m. The ladder shall be 800 mm
wide 300 mm rung spacing. Lightening conductor along with earth pits shall
be provided. Protection against lightning shall be made in accordance with
IS: 2309-1989. One no. 230 V, AC power supply socket shall be kept at the
sampling platform level. Further, lifting beam with manual chain pulley
block shall also be kept at the sampling platform level
Proposed duct to carry the fumes shall be laid over new columns of
extended shed and new trestles to be routed from the back of the existing
scale pump house and old air compressor building.
3.4.6 Emergency Overhead Tank

3.4.6.1 Proposed Emergency Overhead Tank
Proposed emergency overhead water tank of RCC structure shall meet the
requirement of industrial water for air mist spray cooling and soft water
cooling of proposed Caster # 4 and LF-2D. Height of the emergency
overhead tank shall be suitable enough to meet the emergency cooling
water requirement of each of the consumers.
However, capacity of new caster-4 & LF-2D shall be decided on the basis of
duration of emergency water requirement as indicated below:
i) Industrial water for spray cooling of proposed caster-4: for 30 min.
ii) Soft water for machine cooling of proposed caster-4 : for 30 min.
iii) Soft water for mould cooling of proposed caster-4 : for 30 min.
iv) Soft water for proposed ladle furnace : for 30 min.
3.4.6.2 Necessary filling arrangement of each of the compartment along with
electrics and instrumentation shall also be provided with piping, valves,
supports etc.
3.4.7 Technical Specifications
3.4.7.1 Pumps
1) Total no. of pumps for a particular group shall be selected in the
following manner:
i. Minimum 2 nos. standby for 1 no. of working pump.
ii. Minimum 2 nos. standby for 2 or 3 nos. of working pumps.
iii. Minimum 3 nos. standby for more than 3 nos. of working pumps
but less than 6.
Technical Specification of Pumps
Sl. Description Scale Industrial Soft Drain
No. Water Cooling Water Pump
Pump Water Pump
Pump
1.0 Pump Characteristics
1.1 Mode of Direct Direct Direct Direct
connection coupled coupled coupled coupled
1.2 Capacity Bidder to decide and indicate in offer
and Head
1.3 Operation Parallel Parallel Parallel Parallel
1.4 Suction Flooded Flooded Flooded Submerged
1.5 Duty Continuous Continuous Continuous Intermittent
with 6
start/ stop
per hr.
1.6 Noise level Less than Less than Less than Less than
85dB(A) 85dB(A) 85dB(A) 85dB(A) at
at 1m at 1m at 1m 1m from
from from from source
source. source. source.
1.7 Vibration 75 (max.) 75 (max.) 75 (max.) 75 (max.)
level at Bearing at Bearing at Bearing at Bearing
& shaft & shaft & shaft & shaft
1.8 Pump IS 5120: IS 5120: IS 5120: IS 5120:
design 1977 1977 1977 1977
standard
2.0 Pump Construction
2.1 Type of Horizontal Horizontal Horizontal Vertical
Pump Centrifugal Centrifugal Centrifugal Centrifugal
2.2 Preferred <1500 1500 1500 1500
speed (RPM)
2.3 Shaft seal Clean Self- Mechanical Self-flushed
Water flushed Seal gland
Flushed gland packed end
gland packed
packed end

2.4 Coupling Direct Direct Direct Direct
Type Flexible Flexible Flexible Flexible
2.5 Base Plate/ As per IS As per IS As per IS As per IS
Frame 2062: 2062: 2062: 2062:
2006 2006 2006 2006
2.6 Bearing Heavy duty Ball/ Roller Thrust bearing
3.0 Material
3.1 Casing/ Ni-Hard/ CI as per IS 210: 2009 FG-260
Bowl 27%
Assembly Chrome
(BHN 600
minimum)
3.2 Impeller Ni-Hard/ SS CF-8M (AISI-316)
27%
Chrome
Shaft SS 316/ 410
Suction liner Ni-Hard/ - - -
27%
Chrome
(BHN 600
minimum)
Shaft Sleeve SS 316
Wearing SS 316
Ring
Stuffing Box CI/CS
4.0 Accessories & Services Required
4.1 Discharge YES
pressure
gauge
4.2 Coupling YES
guard
4.3 Vibration Online vibration monitoring shall be provided in
monitoring control room
5.0 Testing
5.1 Hydrostatic Witnessed at 1.5 times of shut off head or 2 times of
test of the required head whichever is higher for 30
casing/bowl minutes.

5.2 Performance As Per IS 5120: 1977
test
5.2 Field Test Required
5.3 Visual Required
Inspection
Test
5.4 Performance Witnessed at full scale, full speed
test at works
5.5 Static bal. Required
test
6.0 Drive Data Refer Electrical section for motors
Note:
i. Test Certificates for all tests (material test, dynamic balancing test,
performance test, noise and vibration test) to be submitted before
giving Inspection call.
ii. Full scale full speed performance test for each pump and strip test
shall be witnessed by the employer.
iii. Pumps shall have following features:
- Corrosion allowance shall not be less than 3mm.
-
Jack screws, lifting lung or equivalent for handling and
alignment
3.4.7.2 Specification of Booster Pumps for flume flushing in Caster#1&2
1.0 Pump Booster Pump
Characteristics
1.1 Quantity 3
1.2 Capacity 200 m3/h
1.3 Total Head 35 mWC (Differential)
1.4 Suction Pressure 10-20 mWC
1.5 Mode of connection Directly coupled
1.6 Operation Parallel
1.7 Duty Continuous
1.8 Noise level Not more than 90 dB (A) (at 1m. from
source)
1.9 Vibration level Not more than 75  at Bearing & Shaft

2.0 Pump Construction
2.1 Type of pump End suction back pull out horizontal
single stage pump.
2.2 Speed 1500 RPM
2.3 Shaft seal Gland Packed Seal with external
flushing.
2.4 Bearing Antifriction, Heavy Duty Ball / Roller
Guaranteed Bearing Life - 40,000 Hrs
3.0 Material
3.1 Case or bowl Ni-Hard/ 27% Chrome
3.2 Impeller Ni-Hard/ 27% Chrome
3.3 Shaft Ni-Hard/ 27% Chrome
3.4 Suction Cover Ni-Hard/ 27% Chrome
3.5 Shaft Sleeve
SS 316
3.6 Wearing Ring
3.7 Stuffing box CI/ CS
4.0 Accessories & Services Required
4.1 Discharge pressure Yes
gauge
4.2 Coupling guard Yes
5.0 Testing
5.1 Hydrostatic test of Witnessed at manufacturer’s work
casing
5.2 Performance test Witnessed at manufacturer’s work
5.3 Field test Reqd.
5.4 Visual insp. Check Reqd.
6.0 Drive Data Refer Electrical section for motors
3.4.7.3 Automatic Self Cleaning Filter

Items Specification
Type Automatic self-cleaning filter
Quantity (No.) 1 (One)
Pipe Size (both inlet / outlet) DN 100
Operating Pressure 14 bar (g)
Items Specification
Design Pressure 16 bar (g)
Operating temperature 27-38oC (normal), 55oC (Max.)
Flow Rate 70 m3/h
Suspended Solid in inlet 200 ppm
water
Pressure drop across filter 2mWC (Max) in clean condition
Adjustable pressure Between 0.2 and 2.0 bar
difference of limit switch
Filtration rating 200 micron
Power Source 415V (+10 %), 3 phase, 50 Hz (+5 %)
Drive Electric Motor
Back flushing pressure diff. 1.5 bar
Type of Element Slotted tube (Imported, reputed make).
Successful Bidder to submit relevant
import papers along with a certificate
from the manufacturer indicating the
suitability of the selected filter element
for the specified application.
Material of Construction
Housing Carbon Steel (IS: 2062 -2006)
Filter Element SS 316
Internal parts Brass MS 58/ SS316
Seats PTFE / EPDM
Companion flanges CS (IS 2062 -2006)
Gaskets (1.6 mm thick) CAF (IS: 2712-1979, Gr. W/2)
Accessories Differential pressure gauge, companion
flanges, bolts, nuts, gaskets, washers and
drain valve.
3.4.7.4 Duplex Filter

Duplex basket type water filter complete with change over valves, all
accessories like drain valves, pressure equalizing valve, pressure equalizing
pipe, pressure drop measurement instruments, vent valve, drain valve etc.
shall be provided separately in each of soft water and industrial water
system.

The various parameters for the online basket filter shall be as follows:
Type : Duplex design with removable baskets.
End connections : Flanged

Installation : In horizontal pipe
Permissible pressure drop : 3 m WC
across the filter in clean
condition (under normal
flow).
Design Temp oC : 40
Mesh Opening (micron) : Bidder to select and indicate in offer
Material of construction
Body & Cover : MS, IS 2062:2011, Gr. A
Bracket & clamp : MS, IS 2062:2011, Gr. A
Spindle : SS (AISI – 410)
Basket mesh : SS (AISI- 304)
Basket cage : MS- IS 2062: E250 (BR/B0)
Companion flanges : MS- IS 2062: E250 (A)
Valve Disc : CI (IS 210: 2009, FG 300)
Accessories : Two nos. plug type drain valves, two nos.
vent valves, pressure equalizing valve,
changeover mechanism with hand-wheel,
foundation bolts, nuts, inlet and outlet
flanges with nuts, bolts and gaskets,
provision of connection for DP
transmitter, indicating pointer showing
which basket is in use, and cleaning
handle.
3.4.7.5 Heat Exchanger
Selection and design of heat exchanger shall be carried out by the Bidder
to cool the soft water. The velocity in the heat exchanger shall be selected
to achieve the required heat transfer rate; however the velocity in secondary
side shall be at least 10% higher than primary side to avoid choking of
passage in secondary side. Pressure gauge shall be provided at the inlet and
outlet of both circuits and temperature gauge at outlet of primary circuit.
The various parameters for the Heat exchanger shall be as follows:
1. Quantity As required
2. Type Plate type
3. Type of flow Cross flow

4. End Connection Flanged
5. Fluid inlet temp.:
a) Primary side : Bidder to indicate
b) Secondary side : 35oC
6. Outlet temp.
b) Secondary side : 45oC
7. Pressure drop (m WC) 5 m WC (max.)
8. Heat load (Mcal./h) Bidder to indicate
9. Max. Operating pressure
b) Secondary side : 40 m WC
10. Test pressure
a) Primary side : 1.5 times max operating pressure
b) Secondary side : 1.5 times max operating pressure
11. Plate material AISI 316

12. Gasket material and fixing NBR duly fixed and glued
13. Plate thickness 0.5 mm
14. Frame and Pressure Plate IS-2062: 2011 (Gr. B)
Material
15. Accessories Companion flanges, bolts, nuts,
gaskets, washers and drain valves.
16. Inspection and Testing The Inspection of Heat exchangers
shall be carried out at the
manufacturer’s premises. The test shall
be carried out on the basis of the
approved QAP and relevant
national/international code. Generally
the following inspection and tests shall
be carried out:
Visual Inspection of the Heat
Exchanger for workmanship.
Visual Inspection of the dimensions of

the Heat Exchanger on the basis of
Approved drawing.
Visual inspection of the material used
and material test certificates.
Hydrostatic test.
3.4.7.6 Soft Water Plant

One number-2 streams (1W + 1S), fully automatic soft water plant each of
10 m3/h capacity shall be installed. The soft water plant shall be used as
make-up to the soft water sump of both the soft water systems i.e one for
proposed slab caster-4 and other for LF-2D. The effluent from soft water
plant shall be taken to neutralization pit. Bidder shall provide neutralization
pit of adequate capacity with waste handling facility.
Soft water plant shall be compact, easy to operate, simple to install. All soft
water line along with fittings, in and outside soft water system shall be
provided by the Bidder. The soft water line shall be of stainless steel and
shall confirm to SS304.
Technical specification of softeners

No. of units : As required
No. of streams for each unit : As required
Capacity : Bidder to Design
Function : To soften water as per reqd.
quality
Soft water quality : Hardness- commercial zero
Supply : Continuous
Regeneration cycle : Bidder to provide
Material for Exchanger vessel (2 : To suit requirement preferably
nos.) MSRL
Material for Brine preparation : FRP
tank (I no.)
Brine Transfer Pump/ Ejector : Standard Design
Soft water piping up to soft : Stainless steel (SS–304)
water sump
The softener unit shall be a sodium zeolite softening system and shall
consist of softener tanks, brining system and interconnecting valves.
The tanks shall be constructed of steel and shall be vertical shell dished end
pressure vessel. It shall have an inlet water distributor system, a
freeboard space, a regenerant distributor, a bed of ion-exchange resin,
supporting media and under drain system. The shell shall be lined with
rubber lining of 5 mm thick as per IS-4682, 1991, part-I.
The inlet water distributor should prevent the water from impinging on the
resin bed and creating channelling effects. It should also collect the
backwash water going to the resin.
The freeboard space should allow the resin to expand without loss to the
drain during backwashing. This should be at least 75% of the resin bed
volume.
The regenerant distributor should spread the brine uniformly over the
surface area of the resin and it should not allow the water in the softener of
the freeboard space to dilute the brine.
The resin bed should be made up of a strong cation resin & should operate
in the sodium cycle. The depth of bed should be at least 0.6 M.
The under drain system should support the resin bed and collect the treated
water, waste brine, rinse water and distribute the backwash water. This
should collect the water evenly from all portions of the bed during the
service, brine and rinse operation to prevent channelling through resin bed.
This should be of stainless steel construction and located within the lower
rubber lined dished ends. This shall be fitted with strainers of
stainless/HDPE/PVC with slit 0.2 mm
3.4.7.7 Expansion Vessel/ Surge Tank
The Expansion Vessel/ Surge Tank shall be installed in primary soft water
system on the downstream of the PHE separately on each of the soft water
circuit. It shall be pressurised with Nitrogen for compensating the pressure
fluctuation of the primary soft water system during heating and cooling
cycles. For emergency, interconnection with existing compressed air headers
shall also be provided in case of Nitrogen failure.
The various parameters for the Surge Tank shall be as follows: -
1. Quantity 1 No.
2. Type Vertical cylinder with dished
ends
3. Design Code IS:2825-
4. Design Pressure Bidder to indicate
5. Design Temperature 50 oC
6. Hydraulic Test pressure 1.5 times max operating

pressure
7. Corrosion allowance 1.5 mm
8. Radiography (on shell & heads) 100 % on Tee joints & rest 10 %
9. Plate material : IS-2062: 2006 (Gr. B)
10. Plate thickness : min. 8 mm
11. Frame : IS-2062: 2006(Gr. B)
12. Wetted surface of tank To be lined with SS-316 sheet of
1.5 mm thickness (minimum).
3.4.7.8 Cooling Towers

There shall be two nos. of cooling towers with 01 no. of standby cell in
each as described in the earlier clauses.
Design, Performance parameters & MOC shall be as under:
Type Induced draft Counter flow/ Cross flow
Inlet water temperature As per system requirement
Outlet water temperature As per system requirement
Design wet bulb temperature 28oC
Number of fans per cell One
Maximum drift loss 0.2%
Cooling tower body & fan RCC
cylinder
Fill Splash type PVC (virgin quality)
Drift Eliminator PVC (virgin quality)
Fan Blades FRP
Fan Hub HDG Steel
Fan Drive Shaft Mild Steel Galvanised
Distribution Pipes As per IS: 1234-2004, Part-I (Heavy Duty)
or as per IS: 3589-2001 (Gr. Fe410) as
applicable
Nozzle PVC
Screen, Gate & Handrail SS-304 wire mesh for screen
Sluice Gate – CI
Hand Rail – Galvanised iron
Bolts, Nuts & Washers 18-8 stainless steel
Noise level of fans 85 dBA at 1 m from source.
fmet Cooling Tower Institute of USA, Bulletin
ATP 105
Materials Handling Device The tower shall be equipped with suitable
handling facility for removal and
handling of the reduction gear unit,
motors, fans and other equipment.
Blow down Shall be collected in a separate pit and
shall be pumped for slag cooling of BOF
slag in slag yard.
The cooling towers shall have the following also:

i. Low lubrication oil level alarm in gearboxes.
ii. Fan tip speed shall not exceed 3600 m/min.
iii. Complete water distribution system including piping, flow control
valves, distribution nozzles etc.
iv. Each fan assembly shall be provided with vibration switches to de-
energise the motor in the event of excessive vibration.
v. Sluice gate valve shall be as per IS: 13349-1992, Class-3.
3.4.7.9 Chemical Dosing System
Bidder shall include suitable chemical dosing systems in his scope for soft
water as well as industrial water system for controlling the corrosion, scaling
and fouling as per requirement. The Bidder shall design and recommend
the most effective dosing system, and furnish the value of parameters to be
controlled. Minimum cycle of concentration for industrial water system shall
be considered as ‘3’.
The Chemicals and their doses shall be such that the blow-down water is
not toxic and meets the effluent standards stipulated in IS 2490: 1981.
3.4.7.10 Pressure sand filters
The Pressure sand filters (PSF) shall consist of horizontal/vertical cylindrical

shell with dished ends and structural steel supporting legs. Filter media shall
be graded sand and gravel of approved size and quality. PSFs shall have
minimum 600 mm free board over sand bed. Design code shall be IS 2825:
1969. The filter body shall be fabricated from Tubular section/ plate of mild
steel conforming to IS 2062: 2011, Gr. E-250 (A or B). Inside surface of filter
shall be epoxy based anticorrosive paint. Flanged nozzles shall be provided
for connecting various fittings. Instruments shall be provided as per
approved drawings. Inspection manhole of adequate size, tray for inlet

water distribution and collector system for filtered water shall be provided.
Valves in filter unit shall be pneumatic actuated with manual override.
PSFs shall be of high rate surface loading. Surface loading shall be designed
based on the consideration that minimum 2 filter units go under backwash
at a time.
Empty space below the filtered water collector shall be filled with concrete.
Minimum two nos. of standby filter in each group of filtration system shall
be installed.
PSFs shall have automatic backwashing system with necessary back wash
facilities including 2 nos.(1W+1S) of backwash pumps and 2 nos.(1W+1S) of
blowers. Noise level at 1m from pumps and blowers shall not exceed 85dBA.
3.4.7.11 Scale Scrapper, Oil Skimmer in Settling Tank (Secondary Settling Tank) and
Scale Pit
The Scale Scraper is conventionally used to scrap scale and sludge deposits
at the bottom of the settling tank, to form heap, suitable for removal by
grabbing crane. The SST shall be of on ground RCC construction with
arrangement of drainage by gravity.
i. The details of the Scraper are as under:
Type of scale scrapper Heavy duty type
Shape of pit Horizontal, rectangular
Content of oil in effluent Bidder to consider
Content of scale in effluent Bidder to consider
Equipment for scale removal a) Scraper
b) Grab bucket crane having travel
throughout the length and width
of scale pits
Equipment for oil removal Oil skimmer
MOC Standard as prevalent for steel slab
casters.
ii. All the equipment / materials supplied shall be designed to work
smoothly under average ambient temperature of 50oC (max.) and - 2oC
(min.) with relative humidity of 100 %.
iii. Equipment Description
a. Scale Scraping shall consist of a moving bridge, scraper beam

suspended from the bridge by pantograph linkages, hoist
mechanism, travel mechanism and electrical control gears.

Electric power shall be supplied to the machine by festoon trailing
cable arrangement. Remote control of the scraper shall also be
provided from a fixed location on the ground, control leads from
the panel on the scraper to the remote PB-unit shall also be
bunched in the trailing cable arrangement.
b. The machine frame shall be fabricated from rolled steel section

mounted on steel wheels suitable for rolling on standard rails.
c. Travel mechanism shall consist of centrally located drive

comprising of motor, gear boxes, brake, floating shafts with
flexible gear coupling and wheels.
d. The scrapper movement shall be automatic and same shall be

controlled from the PLC and control panel. There shall be remote
control post at a fixed location where bunch of cables shall be
terminated for further connection to MCC & PLC.
e. Scrapper blade shall be suitably fitted to the scrapper arms. The

scrapper arms shall be raised or lowered by centrally driven twin
drum hoisting mechanism, suitably located on machine frame and
consisting of motor, worm gear boxes, float shafts with flexible
geared coupling, brake, rope drums, wire rope & rope pulley.
f. Skimmer blade of flexible material shall be suitably fitted to the

skimmer arms. The skimmers arms shall be connected to the
scrapper arms with rope pulley arrangement.
iv. Tube type oil skimmers shall be provided in addition to the skimmers
attached with the scrappers.
3.4.8 Other Technical Requirement
3.4.8.1 All utilities systems required for smooth and guaranteed operation of the
proposed plant and facilities shall be provided by the Bidder. If the quality
and pressure of any utilities made available at the TOP by the employer is
not sufficient for the proposed systems offered by Bidder then necessary
facilities required for improving the quality and pressure of the utilities shall
be provided by the Bidder. The utility system shall be designed as per
Annexure No. 3.4.8.1-1 (GTS) in general unless and otherwise specified
elsewhere. However, following specific system shall be provided in
general:
 All make up tapings shall have flow meters with bye pass
arrangement and isolation facility.

 Sluice gates shall have SS gate and spindle. The Frame and wedge
shall be of CI (IS: 210, FG-220) as per IS: 3042-1965. Slab Caster
pump houses, sump shall be compartmentalized for individual
pump.
 Drainage pumps: There shall be one reserve pump for one working
pump.
 Each pump shall have independent suction. The delivery line of each
pump shall be connected to the main header with isolating delivery
valves, header gate valves and Non Return valves for isolating
delivery valves. Segment-wise isolation facilities shall be provided
for maintenance of delivery valve of each pump.
 Butterfly valves shall be employed for regulatory and auto-control
usage; motorized gate valves shall be provided in automated
pumping system for pumps’ suction & delivery.
 Each circulation system shall be provided with ring main concept
from the Pump House to each consumer with isolation facilities. The
water carrying capacity of each pipeline should be such that in case
one of the pipelines is under maintenance the other pipeline should
be in a position to carry required quantity of water to the consumers
i.e. 100 % of designed flow, so that normal production of unit is not
affected with only one delivery pipeline in operation.
 All the valves of diameter 450 mm and above and the valves
requiring remote control operation shall be electrically /
pneumatically operated. Electrically operated valves shall be
provided with limit switches as a safety measure. Electrically
operated valves shall have provision for manual operation also. All
Manual valves of sizes of 350 up to 450 and above shall be gear
operated.
 The pumps of kW rating more than 250 kW shall be of synchronous
speed 1500 rpm.
 Pump houses of shop complex shall have dry pressurised ventilation
system.
 Cooling Towers shall be of RCC construction. Energy Efficient Fans
to be considered. The fan cylinder shall be of RCC construction.
Hoisting equipment shall be electrically operated with parking shed
for Cooling towers. Side stream filters for minimum 10% of
recirculation water shall be provided in cooling towers.
 All the cooling water circuits shall be provided with chemical
conditioning system to control corrosion & scaling and prevent bio
fouling. To reduce blow down, higher cycle of concentration

shall be targeted. Chemicals used in water conditioning system shall
be supplied for 3 months after the date of commissioning. The
chemical storage capacity shall be for a minimum of 90 days
consumption of chemicals.
 Local flow, pressure and level indicating instruments shall be
provided in addition to instruments provided under PLC operation
for running the water circuit in case of PLC failure.
 Contaminated Water coming out of back washing of self-cleaning
auto backwash filters, pressure sand filters, cooling towers blow
down water, AVGFs etc. shall be treated suitably and collected in a
pit to pump it to the BOF slag yard for cooling of slag etc. If the
water quality of treated water permits its further uses in open
cooling circuit of caster, then it may be pumped to scale pit/ settling
tank. Necessary pumping and piping system shall be provided.
Location of BOF slag yard from proposed WTP is approximately
300m.
 Make-up water system shall include extension of pipelines from the
battery limit (Pressure 2.0 Kg/cm2 approx.) with isolation valve in a
valve pit, along with pumps (if required), valves, valve pits, sumps
etc., to the circulation system as well as process/service/fire fighting
needs.
3.4.9 Air Conditioning & Ventilation System
3.4.9.1 Air Conditioning System
Some of the new areas of electrical and electronic equipment installations
are listed below where air conditioning system shall be provided, which is
indicative only and shall not be deemed complete.
Air conditioning system shall be designed considering 10% additional
capacity in heat load. Following premises shall be air-conditioned to
maintain room temperature at 23+20C with 55+5% RH:
No.
1. Intelligent MCC, PLC & Control Water Cooled Package Air
Room etc. at Main Pump House Conditioners (‘n’ no. working
and other units in WTP area +1 no. standby)
2. VFD, Intelligent MCC, PLC/DCS Central chilled water based air
rooms, Level1, Level2 server conditioning system consisting
rooms, Control Rooms, Soft of chillers (‘n’ nos. Working+1
starter, UPS, control pulpits etc. no. standby) at one place and
of caster-4 and LF-2D floor mounted Air Handling
Units (1W+1S) near each air
conditioned premise/ Air
cooled package AC
3 Existing chiller Units for New units at specified location
Caster#1&2
3.4.9.2 Chiller Units
i) Screw Type Chillers
Factory fitted screw chiller inclusive of evaporator, water cooled
condenser, energy efficient single/ multiple screw compressors, motor,
lubrication system, all interconnecting unit piping and wiring shall be
provided. The unit shall use R-134A/R-407C refrigerant gas. The initial
charge of refrigerant and oil shall be supplied for each unit including
anti vibration mounts for base frame. The chiller units shall be rated in
accordance with the latest issuance of AHRI Standards 550/590 and
551/591 and tested in AHRI certified test bed. The chillers shall be
factory charged.
ii) Evaporator & Condenser
Evaporator & condenser shall be designed, fabricated and certified as
per ASME / BIS code, for unfired pressure vessels and tubes expanded
as per TEMA recommendations. The condenser shall have sufficient
capacity to pump down the entire charge of refrigerant at normal room
temperature for repair/ isolation purposes. Evaporator & condenser
shall be horizontal shell and tube type with shell of welded steel
construction. The tube sheets shall be welded to each end of the shell
and drilled and reamed to accommodate the tubes. Tubes shall be of
internally grooved and externally finned type and of copper and
tubesheets of alloy steel. Tubes shall have intermediate supports at
suitable spacing. Tube side (water) shall be designed for 10 kg/cm2
working pressure and shell side (refrigerant) for 14 kg/cm2. Both
evaporator and condenser shall have flanged nozzles of suitable
thickness welded to it. Screw Chillers shall be fitted with marine water
boxes for having flexibility of connecting of either side. End fittings of
condenser and evaporator should be provided with rubber expansion
joints. Condenser and evaporator piping insulation and valves are in
supplier scope. Welding joints in evaporator and condenser of screw
chillers to be 100% radiography tested.
Accessories:
i) Bypass flow replaceable type filter driers, of angle type and
rated for the full refrigeration duty of the system.

ii) Angle type, back seating, capped liquid charging valves with
flare charging connections fitted with flare-fitting cap nuts.
iii) Liquid line solenoid valves.
iv) Electronic type expansions valves
v) Moisture indicating sight glass. Sight glass between condenser
and evaporator
vi) Temperature sensors shall be provided with suitable thermo
well to indicate liquid refrigerant temperature.
vii) Spring loaded Relief valves, and drain valve.
viii) Water inlet and outlet connections with DP switch to ensure flow
through evaporator.
ix) Chiller shall have one set of inlet / outlet water connection on
either side of chiller.
x) Freeze up thermostat fitted with proper passage / Antifreeze trip
through microprocessor
xi) Self-metering adjustable thermal expansion valve for control of
refrigerant flow in evaporator.
xii) Flexible connection to eliminate vibration of the compressor,
reaching condenser.
xiii) Water inlet and outlet connections with thermometer and
pressure gauges with isolation valves, air release/ drain valves for
water boxes etc.
iii) Control and Measuring Instruments
The air-conditioning system as envisaged in the specification shall be
microprocessor based controller complete with all measuring and
control equipment, required for smooth and efficient working of the
system. The system shall include following control equipment and
instruments.
a) Electronic type expansion valve in refrigerant circuit.
b) High pressure and low pressure cut out together with high
pressure and low-pressure indicators in the refrigerant circuit.
c) Indication lamps, Ammeter and volt meter at the incoming feeder
of MCC and indication lamp, ammeter at all out going feeders
connected to A/C units.
d) Flow, pressure and temperature indicator for water &
refrigerants, as applicable.
3.4.9.3 Refrigeration Pipework
Refrigeration piping shall be carried out in seamless, bright, clean
refrigeration quality copper tubing and recessed solder joint fittings. Fittings
shall be wrought copper or tinned cast brass. Soft annealed tubing shall be
used on all pipe sizes up to 19.1 mm O.D. whilst hard drawn tubing shall be
utilized on all larger sizes. The thickness of copper piping shall not be less
than 20 gauges for pipes up to 19.1 mm and 18 gauges for bigger sizes.
Liquid refrigerant lines shall incorporate the following components:-
 Bypass flow replaceable type filter driers, of angle type and rated for
the full refrigeration duty of the system.
 Y - type full flow strainers.
 Isolating valves of the diaphragm type.
 Moisture indicating type liquid sight glasses.
 Angle type, backseating, capped liquid charging valves with flare
charging connections fitted with flare-fitting cap nuts.
 Liquid line solenoid valves.
Suction lines shall be vapour proof insulated with 25mm thick preformed
insulation. The insulation lengths shall be applied to the piping as and when
the joints are being soldered in order to reduce the joints in the insulation
to a minimum. Once the piping has been tested for leaks the insulation joints
shall be glued and taped.
All visible refrigeration piping and/or exposed to the weather shall be
housed within galvanized or ultra violet resistant P.V.C. trunking.
All refrigeration pipe work passing through walls and concrete floor slabs
shall have P.V.C. sleeves of minimum 3mm thickness for the full depth of the
wall and/or floor.
The sensing bulb of the thermostatic expansion valves shall be securely
fastened to the suction line using copper strip and brass screws.
Care shall be taken to ensure that pipework is neatly run in straight lines,
this applying especially to soft copper tubing.
3.4.9.4 Refrigerant Charge
Refrigerant pipework systems shall be charged with refrigerant after
evacuation and testing for leaks as outlined below:-
Complete refrigeration circuits shall be tested by means of dry Nitrogen to
a pressure of at least 50% above working pressure. With the system under

the pressure of the Nitrogen, brush all possible points of leakage with a
solution of soap and water to which a few drops of Glycerine have been
added. All soldered joints shall be tapped with a hammer to break possible
flux seals. Any leaks which may be found by bubbling of the soapy water
should be made good after the Nitrogen has first been released. When a
leaking joint is detected, the fitting shall be taken out, cleaned and re-
soldered into the pipe work again.
Systems should next be charged with Refrigerant to a minimum pressure of
200 kPa and then brought to a pressure of at least 50% above working
pressure with dry Nitrogen. A "HALIDE" or Electronic leak detector shall at
this stage be used to detect any further leaks.
Systems found to be free of leaks shall be allowed to remain under pressure
for a 24 hour period. If no pressure drop is observed after this period, taking
into account ambient air temperatures, the Nitrogen mixture shall be
discharged to atmosphere.
The system shall then be evacuated by means of a suitable vacuum pump
before charging with refrigerant via the charging valve.
3.4.9.5 Air Handling Units (AHUs)
Double skin type Floor mounted AHUs shall be provided. AHUs shall be
constructed in sections such as fan section, coil section, damper section and
filter. The AHUs shall be mounted on vibration isolation serrated rubber
pads.
The AHU shall be of metal construction using best quality galvanized sheet
steel treated for rust prevention. Double skin wall panels shall be pressure
injected with PUF having 38 kg/cubic-m density. The outer panel shall be
fabricated from pre-coated/ powder coated GI sheet of thickness not less
than 0.63 mm. The inner panel shall be fabricated from GI sheet of thickness
not less than 0.63 mm.
Floor and roof panels shall be Double skin type and shall be of same
construction as the wall panels. AHUs shall have hinged quick-opening
insulated access door on fan and filter sections. Access doors shall be double
skin type and shall be of same construction as the wall panels.
Fan Section including wheels and housing shall be fabricated from heavy
gauge steel. Fan wheels shall be of the forward curve DIDW multi blade type
HOT DIP galvanized. Fan and motor shall be internally housed and mounted
on a common steel base of channel section, epoxy coated with vibration
isolation mountings for absolute silent and vibration free operation.

The cooling coils shall be of copper tubes and external Aluminium plate fins
bonded mechanically. Coils shall be sized so that the face velocity shall not
exceed 2.7 m/s. The coil depth shall be adequate to maintain humidity in all
seasons. The coil should be suitably braced during manufacture to withstand
all handling stresses. The braces should be of galvanized iron. Cooling coil
assembly shall be on Aluminium rails and nylon rollers for easy withdrawal
from either side.
The filter section shall incorporate 50mm thick washable non-woven
synthetic pre-filters having anodized extruded Aluminium frame. The media
shall be supported with HDP mesh on one side and Aluminium mesh on the
other side. The efficiency of the filter shall be equivalent to or not less than
85% down to particle size of 10 microns. The velocity through filters shall
not exceed 100m/min. and pressure drop through the filters shall not exceed
15mmWC. The filter and filter section shall be so installed that filters can be
readily removed for cleaning.
Extended drain pans for the AHUs shall be provided on both right and left
hand sides. External drain piping shall be connected to both sides with
suitable air seal trap.
3.4.9.6 Package Air Conditioners (PACs)
The packaged air-conditioners shall be designed for continuous duty. The
equipment shall be designed, manufactured and tested as per IS: 8148- 1976
(RA 1995). Each package air-conditioner shall essentially comprise of
hermetically sealed compressor, cooling coil, refrigerant circuit, water
cooled condenser, blowers, air filter, electric drives, instruments and controls
and other standard accessories assembled in steel cabinet. The compressor
shall be mounted on anti-vibration pads & dynamically balanced. Cooling
coil shall be direct expansion type with integrally finned copper tubes and
fitted with equalising distributors to ensure equal amount of refrigerant in
each circuit. Condensate drip pan shall be provided below the cooling coil
for collecting the condensate. The refrigerant circuit shall be completely
piped at factory and charged with required amount of refrigerant. The
refrigerant shall be R134A. For control of temperature and dehumidification
of the conditioned premises, thermostat and humidistat shall be provided
in the package A.C. plant room as per job specification requirement. The
centrifugal blower shall be designed for distribution of the conditioned air
through the network of duct and supply air diffusers. The impeller shall be
of forward curved, dynamically balanced for low noise and vibration free
operation. The fan shall be mounted on the top, coupled with motor by V-
belt and anti-

vibration mounting. The cooling water system shall essentially work in
closed loop system with cooling tower, pumps (1W + 1S ), piping etc.
3.4.9.7 Ventilation System
1) Dry Pressurized Ventilation System
a. Design Basis
Inside condition: Ambient temperature + 3° C (max. rise) over
ambient temperature throughout the year. The measurement shall be
taken 1.5 m above floor level at any location inside the proposed
rooms. All rooms with dry pressurised ventilation system shall have
positive pressure of 2 mm WC above atmosphere to prevent the
ingress of dust & hot outside air. The design of the system shall be
done based on minimum 20 air changes per hour or actual heat load
condition, whichever is higher.
b. Tube Axial Fan
The tube axial fan shall be industrial, heavy duty type, suitable for
continuous operation, statically and dynamically balanced, single
stage, directly coupled with drive motor and shall be manufactured,
tested according to IS: 3588-1987.
c. Centrifugal Fan(s)
The fan (s) shall be centrifugal single/ double width with forward
curved / back ward curved blades depending upon pressure
requirement. It shall be coupled to drive motor through Vee belt. HP
of drive motor shall be at least 15% higher than shaft BHP of fan. The
fan shall be statically and dynamically balanced at different speed.
The fan shall be fitted with self-aligning, self-lubricated ball / roller
bearings. Suitable vibration isolators shall be provided at the fan
pedestal. The centrifugal fan shall conform to IS: 4894-1987/ BS: 848/
AMCA: 210. The fan shall be fitted with variable inlet vanes for
accurate control of air volume. To prevent transmission of fan
vibration to ducting network and air washing chamber, flexible canvas
connection shall be provided at the fan inlet and outlet
2) Evaporative Cooling Machine (Washed Air Ventilation)
i) Outer cage/ casing of evaporative cooling machine
Casing of minimum 16 gage galvanized steel panels secured to a
welded steel angle frame shall be provided in case of Single Skin.
For Double skin air washer, 24 gauge GI sheet inside and PP sheet
outside shall be provided. Exterior panels shall be removable to
permit access to any interior component. Coating shall be done
with epoxy on frame members, sump drains, entire casing bottom
and interior wet surfaces. Exterior steel surfaces shall be primed with
epoxy and finished with baked enamel. All exterior wiring shall be
terminated outside the casing in a weather tight junction box.
Hoisting lug shall be provided for installation.
ii) Inlet Air Filter
A 50 mm thick pleated HDPE or wire mesh metallic filters shall be
provided at the air entry side of the evaporative cooling machine. It
shall be sufficient to filter at least 80% particles upto 10-micron size.
iii) Spray Chamber
Spray chamber shall consist of required number of water
distribution header and nozzles..
iv) Pumps
The unit shall be provided with 2 nos. circulating water centrifugal
pump sets (1W+ 1S). The pumps shall be directly coupled with the
drive motor. The maximum speed of the pump shall not exceed
1500 RPM.
v) Fan
Centrifugal fan shall be as per specification mentioned above.
vi) Water distribution system
Water distribution system shall consist of related valves and piping
along with water filters/ strainers to recirculate the water. It shall
thoroughly wet and continuously flush evaporative surfaces of the
media material. It shall be designed to provide equal flow of water
directly to the pads or to each trough. Troughs, if used, shall be
adjustable hot-dip galvanized steel, stainless steel, or polymeric and
suitably designed in a manner that shall effectively regulate the flow
of water to the media pad to obtain even and complete saturation.
3) Duct
a. Material: Galvanized Steel Sheet (GSS) conforming to IS 277: 2003
(Class VIII)
b. Thickness
Max. Size (mm) Thickness of Sheet (mm)
Up to 750 0.63
751 to 1500 0.8

c. Duct Support
Max. Size (mm) Spacing
Up to 750 2.5 m
751 to 1500 2.5 m
d. Ducting shall be as per BS 8313/IS: 655-1963, the angle of
divergence should not exceed 20o. All ducts shall be rigid and shall
be adequately supported and braced where required with standing
seems, tees or angles etc. to keep the ducts true to shape and to
prevent buckling, vibration or breathing. Rubber gasket shall be
installed between duct flanges in all connections and joints. Access
eye/measuring hatch for measurement of air quantity shall be
provided in ducting at convenient location.
e. Acoustic Insulation : First 5 m of supply air duct near fan shall be
acoustically insulated from inside with 12 mm thick rigid board fiber
glass wool covered with perforated Aluminium sheet / finished RP
Tissue paper
f. Duct exposed to atm. : If the duct is exposed to the atmosphere then
together with thermal insulation can be done
g. Velocity of air in the duct : Main duct-8 to 10 m/s, Branch duct- 6 to
8m/s, Grills/diffuser outlet- 4m/s.
4) Fusible Link Fire Damper
Spring loaded, fusible link fire damper to be installed at the main supply
air duct of A/C system. Limit switch shall be connected to the fire
damper for transmission of damper closure signal to the fire panel for
subsequent switching off the air circulation device.
5) Humidifier
Pan type humidifier complete with immersion heater, humidistat and
control accessories. It shall consist of water container and electrical
heater of suitable capacity.
6) Strip Heater
Electric strip heater (used for winter heating and de-humidification)
complete with thermostat and control equipment, suitable for power
supply specified in clause 3.3.1. The strip heater shall be suitably
interlocked with AHUs.
Terminal box shall be fabricated by mild steel having detachable cover,
mounted on the body of the heater with tubular distance piece to
ensure all internal and external connections remain cool. It shall be

provided with safety thermostat to protect the heating elements against
excess temperature.
7) Fresh Air Intake Louvers with Bird Screen
The fresh air intake louvers at least 50 mm deep shall be made of powder
coated extruded Aluminium construction. Bird/ insect screen shall be
provided with intake louvers. The blades shall be inclined at 45 degrees
on a 40 mm blade pitch to minimize water ingress. The lowest blade of
the assembly shall be extended out slightly to facilitate disposal of rain
water without falling on door/ wall on which it is mounted. The intake
louvers shall be provided with volume control dampers.
8) Supply Air Diffusers
Supply air diffuser shall be connected with collar piece provided at the
duct bottom. No part of diffuser shall project into the main duct. Each
diffuser shall be provided with volume control damper. Each diffuser
shall comprise of fixed plate, damper blade, damper blade operating
knob, spindle, connecting rod etc. and shall be of removable core type
extruded Aluminium section duly powder coated. The diffuser bottom
shall flush/ match with the false ceiling.
9) Return Air Duct
The air supplied in the served premises shall return above false ceiling
through the return air slit all around the false ceiling along the walls/
through return air grills mounted on the false ceiling. From there, it shall
pass into the AC plant room through a return air duct. Insulated return
air duct of suitable size shall be provided for smooth flow of return air
duct. The return air duct shall be connected to the AHU/ AHU Room.
10) Cold Insulation
Thermal insulation of duct shall be carried out with Aluminium foil faced
fibre glass of density not less than 24 kg/m3. The thermal conductivity
shall not exceed 0.03 kcal/h-m2-0C. Thickness of insulation shall be 50
mm. 75 mm wide Aluminium tape shall be used for covering the joints
of the foil face of insulation.
3.4.9.8 Cooling Tower for AC
Cooling tower to be employed in chiller plant shall be designed to meet the
condenser cooling requirement of proposed chillers. General features and
technical details of cooling tower shall be as follows-

Parameter Description
Quantity 2 Nos. (1W+1S)

Capacity As per design requirement
Type Induced draft type package unit with motor on top
(Counter Flow)
Design WBT 27.40C
Vibration level 75 at Bearing
Noise Level 85 dB (A) at 1 m from source
Accessories Inlet makeup water line with float valve along with
by-pass line with isolation valve. Temperature
gauges shall be installed in hot & cold water
circuits.
Performance Test As per manufacturer’s standard
Material of construction for different cooling tower components shall be
Cooling tower body FRP
Fill supports and grid FRP/PVC coated steel/ Stainless Steel
Fill PVC (virgin quality)
Drift eliminator PVC (virgin quality)
Fan cylinder FRP
Fan blades Anodized Aluminium/ FRP
Fan drive shaft MS. Galvanised, dynamically balanced
Bolts, nuts and 18-8 stainless steel
washers
All other steel and HDG Steel/stainless steel
iron parts except
valves and gear boxes
All access platforms, handling facilities etc. shall be included in the cooling
tower. The Employer shall approve data sheet, Thermal Calculations and GA
drawings of Cooling Towers
3.4.9.9 Condenser Water Pump sets
 Type: Horizontal, split casing, centrifugal type
 Pressure & Capacity: As calculated by bidder with 10% additional
margin Maximum speed shall preferably be 1500 rpm
 Standard: IS: 5120-1977 and IS: 9137-1978
 Material of construction
 Body – CI as per IS 210(2009) FG-260
 Impeller & shaft–Stainless Steel
 Starting: Direct–on–line
 Medium: Industrial water
3.4.9.10 Chilled Water Pump sets
 Type: Horizontal, split casing/mono-block end suction type,
centrifugal type
 Pressure & Capacity: As calculated by bidder with 10% additional
margin. Maximum speed shall preferably be 1500 rpm
 Standard: IS: 5120-1977 and IS: 9137-1978
 Material of construction
 Body : CI as per IS 210(2009) FG-260
 Impeller & shaft : Stainless Steel
 Starting : Direct–on–line
 Medium : Chilled water
Motor for the pumps to be designed taking at least 10% design margin
Filters in suction side of all the pumps and AHU with bypass arrangement
shall be provided.
3.4.10 Fire Fighting System

3.4.10.1 Fire Pump House
Major Equipment and Facilities
Major equipment/ items for HVWS system to be supplied are broadly as

follows:
 Centrifugal pump of minimum 171 m3/h capacity with electric 1 set
motor, base frame, foundation bolts etc.
 Centrifugal pump of minimum 171 m3/h capacity with diesel 1 set
engine set, base frame, fuel tank, foundation bolts etc.
 Jocky pump of minimum 11 m3/h capacity with electric motor, 1 set
base frame, foundation bolts etc.
 Pump house along with an on ground covered RCC water tank 1 No.
of 200 m3 capacity with two compartments.
 Suction and delivery piping for each of above pump along with 3 set
isolation valve on each of suction and delivery pipe. Non return
valve as well as isolation valve on each of delivery pipe of the
above pumps.
 Delivery header inside pump house with isolation valves in Lot
between to facilitate running of selected pumps without any

obstruction.
 Pipeline from tapping point to the sump with motorized valves Lot
on both the compartment and facility for their operation with
level indicator / switch.
 All piping, valves etc. Lot
 Duplex Filter 1 set
 Material handling facility of 3t chain pulley block and a monorail 1 set

inside pump house
 Piping, valves supporting & other structures and other items etc. Lot
within design limit
 Composite control panel in pump house control room for Lot
automatic operation of the pumps as per water requirement
depending upon line pressure. Above panel shall have battery
charging facilities with indicators.
 Battery charger unit as backup power supply along with battery 1 set
 Hose reel cabinet in each column covering in L row to p-row 1 set
and Column 28 to Column 34.
 Hooters with different tones for Pump start, Pump not-start, Lot
power failure condition and automatic HVWS start with
indicators.
 Level indicators in both compartment of the tank. Lot
 Providing illumination system (surrounding area and inside the Lot
pump house)
3.4.10.2 Portable fire extinguishers

Different types of portable fire extinguishers shall be provided in various
area of the complex as a measure of first-aid fire fighting as per TAC norm
/ IS: 2190-1991.
Depending on application area type and size of fire extinguishers shall be
selected. Actuation of extinguishers shall be done by cartridge pressure and
not by stored pressure. Different Fire extinguishers shall be as under:
1. CO2 Type Extinguisher
CO2 type (minimum 4.5 kg) fire extinguishers conforming to IS: 15683-
2006, fitted with screw down type high pressure control valve as per
IS: 3224-2002, ISI marked, with 1m long wire breaded high pressure
discharge hose & nonconductive horn mfd., complete with initial
charge of CO2 gas as per IS: 15222-2002, wall mounting bracket
screws. Cylinder confirming to IS: 7285-2004 with ISI mark
and approved by Chief Controller of Explosive, Nagpur Manufacturer’s
test certificate and CCE approval certificates to be submitted. This is
suitable for operating between -300C+ 550C.
2. Clean Gas Agent Extinguisher
Clean Gas Agent type (minimum 6 kg) Fire extinguishers shall conform
to IS: 15683-2006. The cylinder duly charged with clean agent and
pressurized with Nitrogen gas suitable for operating between + 5°C to
(+) 55°C. The extinguisher shall complete with all accessories like
squeeze lever discharge valve, fitted with pressure indicating gauge,
internal discharge hose (for 3 kg and above) and nozzle, suspension
bracket .The capacity of the extinguisher is 4 kg and Fire Rating Class
– 1A & 13B (6 kg and Fire Rating Class – 2A & 21 B).
3. DCP Type Extinguisher
DCP type (minimum 6 Kg) fire extinguishers conforming to IS: 15683-
2006. ISI marked, and complete with all accessories, mounting bracket
and screw Powder shall be Potassium bi carbonate base comply with
IS: 4308-2003 and CO2 gas cartridge both bearing ISI marked. Neck
ring, discharge nozzle and cap made of leaded tin bronze with nickel
plated. Length of discharge hose shall not be less than 500 mm.
4. Mechanical Foam Type
Mechanical foam extinguishers shall be of minimum 9 Litters capacity
conforming to IS: 15683-2006 and of portable stored pressure type.
Extinguishing medium shall be a mixture of water and AFFF (Aqueous
Film Forming Foam) 6% conforming to IS: 4989-2006. Valve shall be of
brass forging and discharge nozzle shall be of either Aluminium alloy
or heavy duty reinforced fiber plastic. Percentage of discharge shall not
be less than 90%. Extinguisher shall have minimum class B rating of
21B & minimum class A rating of 2A.
5. Water Type Extinguisher
Water type fire extinguishers conforming to IS: 15683-2006. This shall
be ISI mark and complete with all accessories including gas cartridge
and cartridge holder, plunger rod and plunger mechanism, mounting
bracket and screw, neck ring, discharge nozzle and cap etc.
3.4.10.3 Water based fire fighting system

Ring main concept hydrant line shall be extended as per additional
requirement of the proposed units. The stand post type conform to

IS: 908:1975 with valve pit and isolation valve external hydrants shall be
provided at 45 m spacing. Landing valves as internal hydrants conform to IS:
2290:1993 shall be provided at 30 m spacing in the buildings. Each hydrant
points shall be provided with cabinet containing hydrant hose with
instantaneous and nozzle. Water Monitors shall be provided at strategic
location. All the pipes shall be of heavy grade. The pipes shall conform to
IS1239:2004 (Part-1) and IS 3589:2001 depending upon its sizes whereas all
the valves shall conform to the respective IS. The underground pipeline shall
be laid with wrapping coating protection conform to IS 10224:1982 with
double layer. The over ground hydrant pipes shall be supported properly
and painted with two coats of primer paints and two coats of enamel paints
as approved by employer.
3.4.10.4 Gas Flooding System
For hydraulic cellar, oil cellar etc. CO2 flooding system shall be provided
whereas for control room, PLC rooms etc. clean agent (IG-541) gas flooding
system shall be provided. However, for on-ground hydraulic stations
automatic foam spray system shall be provided.
The system shall be fully automatic in across but means shall be provided to
operate the installation manually in case the system shall be under
maintenance. This system shall be provided with 100% standby cylinder
bank with pipes, valves, master cylinder, manifolds (one working and other
standby). The system shall be designed as per TAC/ NFPA/BIS guidelines.
System shall be designed over UL listed / FM approved design software with
the UL no. and Bidder shall submit the design calculation.
All equipment of the system including manifolds up to orifice except
downstream pipes, fittings & structural support pressure vents shall be UL
listed / FM Approved. Manifolds are mandatorily to be factory made and UL
listed / FM Approved.
3.4.10.5 Passive Fire Protection

Passive fire protection is an integral part of a complete fire prevention
system and is essential for prevention of spread of fire through electrical
cables. Following passive fire protection shall be provided to check the
propagation of fire,
Fire sealing for all floor openings (including conduit openings, cable
openings), below electrical panels/ equipment and wall openings for
electrical cables and fire check doors in cable tunnel shall be provided.
Fire barrier / sealing shall be provided to wall opening, floor opening for the
electrical cables in the electrical rooms. It shall be provided to all the entry
as well as exit of electrical cables. The barrier /sealing shall be of 2 hours fire
rating. The barrier /sealing shall be UL listed / FM Approved. It

shall be completely resistant to moisture, humidity and chemicals and shall
remain, unaffected by oil/lubricant etc. The system shall be completely free
from shrinkage/cracking and shall be smoke & gas tight during fire
conditions. There shall be a provision in the system so that cables can be
added or replaced without difficulty or impairing its fire resistance
performance. All the constituents of the fire barriers shall be odourless, non-
hazardous and non-toxic.
3.4.11 Pollution Control System

3.4.11.1 Secondary Emission Control System
The collected fumes shall be taken to the inlet of bag filter units through MS
fabricated duct along the shop building. The dust laden fumes, after
cleaning in the bag filters shall be released to the atmosphere through a
chimney via 2 nos. of ID Fans (1W+1S).
Suitable fume collection hoods shall be installed to capture the fumes from
the hot metal mixture and shall be taken to the header duct going to the
inlet of bag-house along the shop building and new trestles/ bridges.
3.4.11.2 Specification of Major Equipment
A. Bag Filters
1 Type : Suction, built in single row

2. Air to cloth ratio : <85 m3/h/m2
3. Bag Dimensions : Bidder to specify
4. Pressure drop across : Less than 150 mmWC
bag
5. Hopper type/ valley : Pyramidal/ 60oC (minimum)
angle
6. Bag material : Non-oven glass fibre
7. Cleaning mode : Pulsejet On-line
8. Cleaning media/ : Dry compressed air
pressure
9. Bag fixing arrangement : Snap band, top removal type
10 Gas volume : Bidder to design
11. No. of bags : Bidder to specify
12. Bag protection Emergency air dilution damper
arrangement

13 MOC : Casing-IS 2062-1992/ 5 mm thick
Hopper-IS:2062-1992/ 8 mm
thick
Duct- IS 2062-1992/ 6 mm thick
Bag cages-GI wire
B. I.D. Fan
No. of ID Fan Two(1W+1S)
Capacity (Volume and Bidder to specify (10% margin over
static pressure) system volume)
Type of fan Simply supported, Centrifugal,
backward curved
Drive Electrical Motor & Direct driven
Motor rating Bidder to indicate
Noise level 85 dB (A) max. at 1 m from source
MOC Housing/Scroll/inlet box: IS-
2062:2011, 8 mm thick (minimum);
Blade: 10 mm with lining,
Shaft EN-8: Ultrasonically tested
Fan speed 1000 rpm
Bearing Anti-friction, self-aligned, spherical
roller bearing with plumber blocks
with grease nipples
Accessories Hinged inspection doors, drain plugs,
lifting lugs
VIV damper at inlet Motorised damper to be provided
Multi-louver Damper at Manual damper to be provided
outlet
Handling equipment Electric Hoist of suitable capacity as

per system requirement

C. Stack:
One no. self -supported stack shall be provided which shall be common
to both the system. The stack height shall be 50 m or more as per CPCB
Norm. Suitable manhole, stairs, platforms etc., are to be provided as per
norms. Suitable RCC foundation as per IS: 456–2000 is to be made by
the Bidder for the erection of the stack. Provisions shall be made to
enable stack sampling in the recommended standard procedure. The
data from the stack monitoring device shall be sent to a central server
so that the same can be sent to the Pollution Control Authority for
compliance. This shall be done as per the relevant standard. Caged
access ladders shall be provided with rest points at every 7 m. The ladder
shall be 800 mm wide 300 mm rung spacing. Lightening conductor
along with earth pits shall be provided. Protection against lightning shall
be made in accordance with IS: 2309- 1989.
D. Duct work:
Ducting shall be of welded construction with miter bends, expansion
joints, flanges, associated supporting saddles, brackets, etc. Material
used for ducting shall be MS plate sheet having thickness not less than
6 mm. Ducting shall be suitably routed without infringement with any
equipment and facilities. The elbow in the ductwork shall have at least
1.5D-centerline radius. The velocities in the ducts shall not less than 22
m/s to avoid deposition of dust in the duct. Measuring and cleaning
hatches shall be provided at suitable locations in the ducting. Clean out
doors shall be provided on horizontal runs before elbow junctions and
at lowest points of slopes.
E. Dust Disposal System
The dust collected in the dust hoppers of the bag filters shall be
continuously discharged into the dust storage silo with the help of
rotary air lock valves and screw conveyor. From the dust storage silo, the
dust shall be unloaded to dumpers/trucks, to be placed below the dust
storage silo with the help of pug mill to eliminate fugitive emission of
dust.
F. Air Drier
Air dryers (nW + 1S) of suitable capacity shall be provided for supplying
dry air for instrumentation and pneumatic transport. Dryness shall be
minimum -200C. Bidder to design the capacity and operating pressure.
Atleast one vessel for storing dry air shall be provided.

G. Screw Conveyors
1. Quantity : 2 nos. (1 no. each for each bag filter)
2. Type : Single flight with direct drive
3. Capacity : Bidder to design
4. Length : Bidder to design
5. Drive : Direct through geared motor coupling
6. Motor power : Bidder to design
7. MOC : Flight - IS:2062: 1999, 6 mm thick
(min., Stub Shaft: EN-8, Shaft: ERW pipe as-
per IS:1239 (Part-1)-1990
8. Painting : To be provided
H. Rotary Air Lock Valves

1. Quantity : Bidder to design
2. Size : Minimum 350 x 350 mm flange opening
3. Drive : Direct through geared motor
4. MOC of body : MS
5. MOC of blade : SS 304
6. MOC of rotor shaft : EN-8
7. Bearing : Anti-friction type
8. Painting : To be provided
I. Air Compressor
The major parameters of the compressor are as follows:
Type Centrifugal compressor integrally geared
Capacity Min. 5000 Nm3/h
Discharge Min. 7 bar (g)
Pressure
Quantity 2 nos. (1 W+1 S)
Drive Electric Motor
Motor RPM 1500 RPM (max)
Noise Level Not more than 85 dB (A) at a distance of 1.0 m
from source. Acoustic enclosure shall be
provided as per requirement.
Oil content Less than 5 ppm
Instrumentation Micro-processor based control system shall be
and Control provided for efficient operation of compressor

System unit.
Operating On line pressure, Off line pressure, Control mode
Parameter selection, Auto start & stop on/off
Control
Each air compressor shall be provided with check valve, pressure relief valve
& isolation valves. The above compressors shall be interconnected with a
provision of isolation valve between them. Apart from above mentioned
instrumentation, the Bidder, if required should give any extra
instrumentation required for efficient operation of the system.
J. Air Receiver
1no. air receiver of required capacity (min 20 m3) at the required working
pressure, complete with accessories like safety valve, vent valve, drain valve,
inlet & outlet opening complete with matching flanges, gaskets, bolts &
nuts, and inspection door shall be provided. The air receiver shall conform
to IS: 7938-1976. The air receiver shall be designed manufactured & tested
according to IS: 2825-1969 and shall be complete with pressure gauge,
lifting lugs & foundation bolts. The material of construction shall be as per
IS: 2002-1992. The receivers shall be of welded construction.
3.4.12 Pneumatic Sample Transport System

3.4.12.1 The sample collected in caster-4 and LF-2D shall be pneumatically conveyed
separately up to existing laboratory with the help of pressurised air through
this system.
3.4.12.2 Design Basis of the System
Material to be conveyed : Steel Samples
Conveying Capacity : Bidder to suitably select and indicate
Working Temperature : Room Temperature

3.5 REFRACTORY
3.5.1 Design Specification of Refractory
3.5.1.1 Tundish
Flying and hot tundish practice is being envisaged for this project. Each
tundish shall have capacity of 38t (overflow capacity). Tundish shall be lined
with suitable refractory materials for safety, permanent and wear out lining.
Tundish covers shall be provided and it will be lined with suitable refractory
material. Precast – prefabricated (PCPF) blocks shall be used for well blocks
and nozzle area.
Tundish back up lining shall be designed with monolithic casting. The
Former / template (1 set) for the casting shall be included in the scope of
supply.
Over flow box for tundish, splash protection system and slag box shall also
be provided and those shall be lined with suitable refractory materials.
3.5.1.2 Shroud & Submerged Nozzle / Shroud (SEN/ SES)

Steel casting process is to have ladle shroud and SEN / SES below the
tundish. The design profile and material quality shall be suitable to process
requirement and cast clean steel. Employer intends to use Alumina graphite/
Alumina carbon/ Alumina zircon materials.
Drawings of items shall be submitted by bidder for future procurement.
3.5.1.3 Ladle Furnace Roof

Ladle furnace roof will be a tubular construction and shall be designed for
existing 150 ton steel ladle. The LF roof tubes shall be made of boiler quality
steel and will no refractory coating.
3.5.1.4 Protection Refractories

Caster working platforms and working platform and columns near LF,
emergency ladle, ladle transfer car and ladle furnace run-out pit etc. shall be
lined with IS-8 bricks for metal / heat protection.
3.5.1.5 Tundish Dryer
Bidder shall design and engineering refractory lining of tundish dryer as per
technological & operating parameters.

3.5.1.6 Refractory not mentioned above at clause 3.5.1.1 to 3.5.1.6 but required for
lining & commissioning of equipment will also be supplied by the Bidder.
3.5.2 Procurement, Inspection, Testing & Supply of Refractory Material
3.5.2.1 Procurement, Inspection & Supply
1) Bidder shall be responsible for procurement, inspection, and supply of

all refractory and auxiliary materials required as per his design for initial
lining and lining materials required for up to 500 heats.
2) Each refractory brick/material shall be clearly marked with
 Manufacturer’s Name
 Mark No
 Material Quality
Marking shall be done with water insoluble ink in English or with
indelible paint
3) Packing of refractory materials shall be done as follow
 Dense bricks shall be suitably packed in wooded box
 Insulation bricks shall be supplied individually wrapped and
packed in cardboard cartons.
 Mortars shall be supplied packed in 25 kgs single polythene lined
gunny bags/HDPE bags.
 Castables shall be supplied packed 25 kgs HDPE bags.
4) Bidder shall carry out the inspection of all refractory materials at the
works of the manufacturer. Inspection of entire refractory materials
shall be done as per latest IS standard or ISO standard.
5) Quality shall be checked on the following aspects
a) Visual inspection on manufacturing defects.
b) Inspection for physical & chemical properties.
c) Inspection on damages due to packaging & transport
6) Bidder as per specified standards shall carry out the inspection of all
refractory materials at the works of manufacture. Sampling and testing
of materials shall be checked as per approved QAP and approved
materials specification. Employer may at his sole discretion depute his
authorized representative(s) to witness the inspection at manufacture’s
premises.
7) Bidder shall furnish necessary test certificates both visual and physico-
chemical for all the refractory materials under his scope of supply to

employer.
8) Employer on receipt of all materials at site reserves the right to
randomly crosscheck the materials against specified specifications. Any
material rejected during cross checking shall have to be replaced by the
bidder at no extra cost to the employer without affecting erection
schedule. In case of disagreement on the result of physical & chemical
testing done by employer, a retest of the material shall be carried out
at a mutually agreed laboratory or at National Laboratory and the cost
of retest shall be borne by the bidder. For carrying out the re-test, a
fresh joint sampling shall be carried out from each lot by bidder and
employer. All records of inspection shall be submitted to employer.
9) All auxiliary materials shall be supplied under TC/GC.
10) The responsibility of entire inspection management of refractories lies
with the bidder.
3.5.3 Storage
1) Bidder shall develop suitable covered storage for storing refractory
materials at his own cost. There shall be proper arrangement for
handling the materials. Reviving illumination shall be done by the
bidder as per requirement.
2) Bidder shall be responsible for the storage of all refractory and auxiliary
materials to be supplied as per his design. Insulation bricks, mortars,
castable, paper cardboard and all other auxiliary materials etc. likely to
be damaged in open shall be stored under cover in dry conditions.
3) Bidder shall make his own arrangement for unloading, stacking, sorting,
storage, loading, transportation, and safe custody of the materials till
completion of work.
4) Bidder shall be required to maintain records of receipt, issue and
consumption of all materials. Custody and record of all rejected
materials shall also be maintained. Balance materials shall be handed
over to the employer in proper manner with proper cataloguing
3.5.4 Erection and supervision of Refractories

3.5.4.1 The erection and supervision of refractory lining of all equipment shall be
done by bidder in accordance with the approved drawings for initial lining
and lining required for up to 500 heats.

3.5.4.2 The rectification if required for refractory shall be done by the bidder at no
extra cost.
3.5.4.3 Heating & commissioning of refractory for all equipment shall be done by
the bidder. Monitoring of refractory heating up schedule shall be done by
the bidder as per his design.
3.5.4.4 The refractory bricks shall be handled carefully and kept stacked properly to
avoid breaking of corners & edges. The surfaces of the bricks shall be
thoroughly cleaned of dirt and grease, with wire brush prior to use. The
laying of bricks shall be such that there should be no open joints. Cracked
and badly broken bricks at corners should not be used. Mortar shall be
prepared by using mortar mixture for erection of refractories.
3.5.4.5 Supply and erection of all scaffoldings, temporary arrangements for

erection, wooden platforms and planks, and other consumables necessary
for facilitating erection job.
3.5.4.6 Arranging all tools and tackles, brick cutting machines, grinding machines,
mortar mixers, rammers etc. and any other erection equipment like winch,
elevator, etc. including erection consumable for the execution of the work.
3.5.4.7 Bidder shall keep the work sites and storage areas clean and tidy at all time.
At the end of each shift the sites shall be cleaned of all debris. All the debris
generated during refractory lining has to be cleaned by the bidder and same
should be transported to the dump yard of employer. The entire debris shall
be removed without causing excess accumulation at site. Proper stacking of
refractories and housekeeping shall be done by the bidder.
3.5.4.8 Total management of refractory erection work shall be done by the bidder

3.6 ELECTRICAL
3.6.1 Basic Design & Site Conditions
The site conditions and system design parameters for entire electrical
system shall be suitably designed unless otherwise specifically mentioned in
the clauses of this document against the respective equipment.
3.6.1.1 Power Supply System Voltages
1. HT Power:
 33 kV+10%, AC 3-phase, 50 Hz +/- 5%, solidly earthed system,
short- circuit level – 40 kA for 3 sec for GIS and 31.5 kA for 3 sec for
AIS.
 6.6 kV+10%, AC 3-phase, 50 Hz +/- 5%, earthed through
resistance, short- circuit level – 40 kA for 3 sec
2. LT Power: 415 V + 10%, AC 3-phase, 4-wire, 50 Hz + /-5%, solidly
earthed system with 50kA (r.m.s) for 1 sec.
3. Control Voltage:
 For HT Board: 220 V DC
 For LT Board and MCC: 240 V AC
 For Solenoid coil: 24 V DC
4. The Bidder shall develop all other voltages (AC, DC) as required for his
system from the above power supply.
3.6.1.2 For the purpose of equipment design, the ambient conditions are to be
considered as 500C for indoor & 550C for outdoor equipment and 100%
maximum relative humidity. All indoor equipment shall be de-rated for 500C
if not designed for 500C. Similarly, all outdoor equipment shall be derated
for 550C if not designed for 550C.
3.6.1.3 550C design ambient temperature shall be considered for all electrical
equipment of process cranes.
3.6.1.4 All the equipment & components shall be located in hot, humid, tropical
and dusty atmosphere in an adverse industrial environment as prevalent in
steel plant.
3.6.1.5 All equipment and accessories shall conform to the latest revision of the
Indian Electricity Rules, as regards safety, earthing and essential provisions
specified therein, for installation and operation of electrical plants.

3.6.2 Standards
3.6.2.1 The electrical equipment/ items shall be designed, manufactured, installed
and tested in accordance with latest IS/ IPSS/ IEC, as applicable to respective
equipment.
3.6.2.2 All equipment/ items shall generally comply with the latest revision of the
following:
1) Indian Electricity Rules, 1956 (latest revision)
2) Indian Electricity Act, 1910 (latest revision)
3.6.2.3 All equipment/ items shall also comply with the statutory requirements of
the Government of India and the Government of Orissa.
3.6.2.4 The Bidder shall follow the safety rules of Rourkela Steel Plant (RSP) and
shall take clearance from RSP before starting the work to ensure compliance
to rules and extant practice.
3.6.2.5 Design and selection of equipment/ items shall be done taking into
consideration of easy inspection, testing, maintenance, cleaning etc. to be
carried out at site without disrupting process or taking prolonged
shutdowns.
3.6.3 Brief description of Electrical system
3.6.3.1 Power Source
a) Slab Caster
33kV power sources for the new 4th slab caster are proposed to be taken
by extension of 33kV GIS switchboard at substation no. LBSS-1. The
extension shall include two nos. feeders for caster no.4, one spare feeder
and sectionalizer for both buses. Downstream power supply
arrangement of caster proper, pump house, MSRS and LT supply
arrangement of Ladle furnace has been indicated in single line diagram
no. CET RN 4179 EE1 00 001, R=4.
b) Ladle Furnace
33kV Power source shall be taken from MSDS-III by extension of section
no.-I. Suitable reshuffling of existing 33kV feeders shall be done as
detailed in single line diagram no. CET RN 4179 EE1 00 002, R=0.
For ladle furnace auxiliary system, 6.6kV supply shall be taken from new
6.6kV switchboard at proposed HT/LT substation and shall be stepped
down to LT supply through dedicated 6.6kV/433V transformers. HT load
shall be fed from above mentioned 6.6kV switchboard.

3.6.3.2 Power Supply Arrangement of Caster #4
i) One no. HT/LT substation shall be provided where two nos. 12.5 MVA
33/6.9kV transformers shall be installed. One no. 6.6kV indoor
switchboard shall be installed with two incomers and one bus coupler.
Incoming 6.6kV power to this switchboard shall be taken from the
above mentioned 12.5 MVA transformers through bus duct. The
downstream 6.6kV/433V transformers shall be fed from this 6.6kV
switchboard.
The proposed substation shall also have 33kV isolators, NGRs, NIFPS
system, four nos. LT substations comprising of 4 nos. 2 MVA
6.6kV/433V transformers, 4 nos. 2.5 MVA 6.6kV/433V transformers,
6.6kV Isolators, LT bus ducts, LT switchboard etc. as required for
downstream supply to the loads of proposed slab caster and ladle
furnace auxiliaries.
ii) Emergency Power supply
Presently one no. 33kV feeder from CPP-1 is being stepped down to
6.6kV level at LBSS-1 area and feeding to one no. 6.6kV emergency
switchboard which is located at LBSS-1 substation.
For emergency power supply for Cater-4, one no. spare 6.6kV feeder
(panel no.10) in 6.6kV Emergency Board at LBSS-1 shall feed one no.
2 MVA transformer to be located at new HT/LT substation for Caster
-4. Secondary of this transformer shall feed one emergency bus
section of LT switchboard as shown in single line diagram no. CET RN
4179 EE1 00 001, R=4. The buscoupler of this LT switchboard shall
have auto changeover facility.
iii) Power supply arrangement of Pump house Area
In order to feed the pump house loads, incoming 6.6kV supply shall be
received from the above mentioned 6.6kV switch board at HT/LT
substation.
Two nos. LT Substations have been envisaged to meet the total load
requirement of proposed Pump house and water treatment facilities
and one no LT substation shall be provided for new Ladle furnace
auxiliaries.
Each LT substation for pump house shall have 6.6kV isolators, 2 nos. 2
MVA 6.6kV/433V transformers, LT bus ducts, LT switchboard etc. as
required for downstream supply for loads of the proposed pump
house and water treatment facilities.
iii) Complete electrics shall be provided for all the new cranes envisaged
under this package. The electrics required for the crane to be
relocated from existing compressor house to new bulk oil

storage building and cantilever crane relocation (if required) at KL
bay shall also be provided.
iv) For the cranes to be relocated, existing power source shall be utilized
with new cables. Laying of cables with necessary structures, cable
racks/trays , termination and testing of the system shall be under the
scope of bidder.
Power supply arrangement for cranes:
General design considerations for cranes:
Wherever bay extensions are taking place, associated DSL extensions
shall also be provided by the bidder. Power feeding arrangement to
the new extended DSL section shall be given. Also sick bay isolators
(ACBs) with associated cabling shall be provided in all extended bays.
Wherever additional cranes will be installed in the existing bay, DSL

strengthening will be under the scope, if required, based on additional
load and voltage drop calculation.
For all cranes equipment design, the ambient conditions are to be

considered as 550C instead of 500C. Accordingly, the de-rating of the
motors is to be done and E-room ACs have to be designed. All the E-
rooms of Cranes shall have dual redundant AC systems.
All the cables to be installed on cranes and repair trolleys are to be of
copper only.
Drag chain arrangement shall be provided for all the cross travels
system of the cranes.
Other details for the cranes shall be as mentioned below
 NP bay : Presently NP bay cranes are being fed from LT
substation no. 304 having 2 x 1.6 MVA transformers. To feed
existing cranes of NP bay alongwith additional one. no. new
crane in NP bay for Caster # 4, one no. new LT substation (2x
2.5 MVA) shall be under the scope. This LT substation shall
feed existing DSL and new DSL through new PDBs and new
cables. Additional looping cables shall also be connected in
the old DSL to take care of voltage drops and load
requirements of new crane. In the existing bays, DSL bus bars
shall remain same. DSL bus bars shall be provided for the
extended portion of bay only. DSL looping cables and
additional DSL feeding cables shall be provided for the

existing bay also. Radio Remote operation facility for the new
crane shall be provided. Existing PDBs for NP bay cranes shall
be replaced with new PDBs. Sick bay isolator alongwith
associated cabling shall also be provided. Suitable
arrangement shall be provided for alarm generation through
wireless sensors to avoid cross over of this crane to the track
of existing cranes. Additionally, red caution lamps shall be
provided to avoid cross over of this new crane to existing
track.
 KL bay: Presently KL bay cranes are being fed from LT

substation no. 305 having 2 x 1.6 MVA transformers. To feed
existing cranes of KL bay along with additional one. no. EOT
crane and one no. new cantilever crane for Caster # 4, one no.
new LT substation (2x2.5 MVA) shall be under the scope. This
LT substation shall feed existing DSL and new DSL through
new PDBs and new cables. Additional looping cables shall
also be connected in the old DSL to take care of voltage drops
and load requirements of new crane. In the existing bays, DSL
bus bars shall remain same. DSL bus bars shall be provided for
the extended portion of bay only. Existing PDBs for KL bay
cranes shall be replaced with new PDBs. Sick bay isolator shall
also be provided alongwith associated cabling. Power supply
to the cantilever crane shall be provided through Tap off
isolator near the crane. DSL looping cables and additional DSL
feeding cables shall be provided for the existing bay also.
Radio Remote operation facility for the new EOT crane has to
be provided. Radio Remote operation facility for the
Cantilever crane shall also be provided.
 LM bay: The existing LM bay cranes and new crane for Caster
# 4 shall be fed from existing substation no. 305 (2x1.6MVA )
which shall be freed after shifting of KL bay crane loads to new
substation. Substation 305 shall feed existing DSL and new
DSL through new PDBs and new cables. Additional looping
cables shall also be connected in the old DSL to take care of
voltage drops and load requirements of new crane. In

the existing bays, DSL bus bars shall remain same. DSL bus
bars shall be provided for the extended portion of bay only.
DSL looping cables and additional DSL feeding cables are to
be provided for the existing bay also. Existing PDBs for LM bay
cranes shall be replaced with new PDBs .Sick bay isolator
alongwith associated cabling shall also be provided.
 Complete electrics for the maintenance hoists/repair trolleys

for the cranes shall be provided. Power supply for the new
repair trolleys shall be taken from the respective isolator
located at the working floor near repair trolley.
v) MSRS
One no. LT Substation has been envisaged to meet the total load
requirement of proposed MSRS.
vii) Roof Top Solar Plant of 150kW capacity has been considered without
battery bank. Generated solar power during day time is envisaged to
be evacuated at the LT switchgear level.
viii) Complete electrics shall be provided for 2 nos. new shop offices
including PDB, lighting distribution boards, LED illumination, ceiling
fans in each room, exhaust fans in toilets, earthing and lightning
protection system. Power source for one of the new buildings shall be
taken from the existing source presently feeding to office which shall
be dismantled. Power source for the other new building shall be taken
from new substation considered under this package.
3.6.3.3 Power Supply Arrangement of Ladle Furnace

33kV power supply for the ladle furnace transformer shall be taken from
proposed extension of section-I at MSDS-III.
6.6kV supply for ladle furnace auxiliary system shall be taken from new 6.6kV
switchboard at proposed HT/LT substation and shall be stepped down to LT
supply through dedicated 6.6kV/433V transformers to be located at pump
house substation. HT load shall be fed from above mentioned 6.6kV
switchboard
An indoor type power factor (PF) compensation equipment to improve
power factor to minimum 0.9 is considered at 33kV voltage level. The power
factor equipment comprising of capacitor bank, air cored series reactors,
isolator, surge arrestors, discharge PT, busbar system, neutral CTs etc., shall
be located in the power factor compensator room provided for the purpose.

3.6.3.4 Control/ Operation
All equipment are considered to be operated in one of the three following
modes:-
i) Programmed operation through PLC
ii) Operation through monitor key board (manual intervention through
PLC)/control desk
iii) Local Operation from the Local control (start /stop push button)
station near drive motor of individual equipment. This operation shall
be only in de-interlocked mode and for testing only. However, Stop
PB shall always remain active irrespective of selected mode.
The detailed specification of the PLC system is mentioned at Automation
chapter.
3.6.3.5 Following Electrical buildings have been considered tentatively for various
areas. The buildings shall be finalized during engineering stage as per
technological requirement :
i) HT/LT substation building comprising of cable basement, transformer
rooms, switch gear rooms, capacitor rooms, battery room etc. The HT
switchgear room shall have provision for additional 6 nos. 6.6kV panels
in future.
ii) LT substation building at Pump house area shall comprise of cable
basement, transformer rooms, switchgear rooms, MCC room etc.
iii) Electrical buildings at caster proper area shall comprise of cable
basement, MCC rooms, PLC rooms, VFD rooms, Control rooms etc. as
per technological requirement.
iv) Electrical rooms at Ladle Furnace shall be provided for installation of
furnace transformer, MCCs, VFDs/PLCs and equipment as per
technological requirement. Furnace transformer removal shall be from
side and not from top.
v) LT substation building for mould repair area shall comprise of
transformer rooms, switchgear rooms etc.
vi) Other electrical rooms as per requirement
3.6.3.6 Electrical system for the enabling work:

i) New electrical system shall be provided for the following facilities to
be relocated. Power supply shall be taken from the existing sources
for all these facilities:
 Chiller plant
 Ventilation system
 Macro etching lab electrics
 Booster pump house
 Hydraulic oil and grease barrel store facilities
ii) Illumination system cables, cabling arrangement, earthing etc shall
be provided for the following facilities:
 New Overhead water tank (caster# 1 , 2 and Ladle furnace)
 LF FES facilities area development
 PRS station
 Ladle repair bay -area development
 New car parking shed, cycle stand & toilet
3.6.4 Design basis for selection of equipment & installations

3.6.4.1 Motor rated above 200 kW and below 1000kW: 6.6 kV input supply ,3ph,
50Hz
 In general, HT loads above 200kW & below 1000kW shall be fed from
6.6kV supply for the DOL starting. Loads above 200kW & below 1
MW which require speed control shall have VFD system with 690V AC
output.
3.6.4.2 Motors rated 200 kW and below: 415 V ,3 ph, 50 Hz
 AC induction motors rated 200 kW and below shall be fed at LT, 415
V, 3 phase, 4 wire, 50 Hz.
 VFD system shall be provided for 415 V motor drives having
requirement of speed control.
 Electronic Soft starters with DOL bypass shall be provided for drives
ratings ranging from 90 kW to 200 kW where full torque load starting
is not required.
 For conveyor loads from 90 kW to 200kW suitable VFD based soft
starting shall be provided. Conveyors with LT motor less than 90kW
shall be started DOL.
3.6.4.3 For the electrical system, all digital outputs of PLC shall be through
interposing relays and all digital inputs shall be through interposing relays.
3.6.4.4 Where common PLC is provided for both Electrical & Instrumentation
system, separate Input/ Output units for Electrical & Instrumentation system
shall be provided.

3.6.4.5 Epoxy based Insulated flooring shall be considered in front of all new
electrical panels, except for the rooms where false floor is provided.
3.6.4.6 As per requirement, motor shall be provided with a power JB (near the
motor) for terminating the motor with flexible Copper cable from JB to
Motor.
3.6.4.7 All electrical equipment like panels, push button stations, motors,
receptacles, light fittings, actuators, cranes & hoists etc. to be housed in
hazardous areas shall be of flame proof design suitable for application in
hazardous area (Zone-2), gas group IIA/ IIB, temperature class-T3.
3.6.4.8 All communication cables shall be laid through proper pipe conduit in
separate tray.
3.6.5 33 kV GIS Switchgear
3.6.5.1 Standards and codes
All electrical switchgear, the components of the control system, the
protection scheme shall be conforming to the relevant IEC standards and
publications of the latest issue.
The following standards are applicable in the relevant parts to the individual
components of the gas insulated switchgear.
 IEC 62271- 200: High-voltage alternating-current circuit breakers
and panels
 IEC 62271-102: Alternating current dis-connector and earthing
switches
 IEC 60694 : Common specifications for high-voltage switchgear
and control gear standards
 IEC 60044: Current and voltage transformers
 IEC 60060: High voltage test techniques
 IEC 60071: Insulation coordination
 IEC 60099: Surge arresters
 IEC 60376: Specification and acceptance of new sulfur hexa-fluoride
 IEC 60480: Guide to checking of sulphur hexafluoride (SF6)
 IEC 60529: Degrees of protection
 IEC 60815: Pollution levels
 IEC 60859: Cable connections for GIS
 IEC 61000: Electro-magnetic compatibility (EMC)
 IEC 61634: Use and handling of SF6
 CENELEC/SVDB: Pressure vessel codes
 CIGRE – 44: Earthing of GIS - an application guide
3.6.5.2 Technical Particulars of 33 kV GIS Circuit Breaker:
1) Nominal system voltage 33 kV
2) 36 kV
Highest system voltage
3) Rated frequency 50 + 5%Hz

4) Phases 3 phase
5) Design short circuit level 40 kA for 3 Seconds
6) Internal Arc fault withstand 40 kA for 1 sec
capacity (as per IEC62271-200)
7) Rated peak withstand current 100 kA peak
8) Type of switchgear Indoor SF6 insulated type
switchgear, modular type
9) Type of Interrupter Vacuum
10) Type of Isolators Isolators shall be motor
operated. In cases of
emergency, manual
operation must be possible.
These isolators operations to

be interlocked in such a way
that load transfer is possible
without
interrupting power flow.
During load changeover the
feeder breaker shall be
interlocked with Bus Coupler
CB in such a way that, when
both the isolators are in
closed position then Bus
Coupler CB tripping remains
out of service and
normalizes after the
operation. Isolator operation
of individual
module shall be interlocked
in such a way that in no case
isolators can be operated
when CB’ is “ON”. These
isolators shall have three
positions of operation
(Closed, OFF, Earthed) and
these are to be suitable
interlocked with the CB
operation
11) Earthing switches As required shall be provided
with position indicators
12) No. of trip coils
13) Bus bar system Double bus bar, SF6

insulated bus bar chamber
14) Material of busbar Copper
15) Insulation level
a) Rated one min. power 70 kV rms
frequency withstand voltage.
b) Rated impulse withstand 170 kV peak
voltage
1) Operating duty 0-0.3 sec – CO – 3 min – CO
2) No. of poles per phase Single pole per phase
3) Degree of protection :
HV-live parts IP65
Low voltage IP4X
compartment
4) Trip Free, anti-pumping design To be provided
5) safety features - Internal Arc resistant
-Integrated pressure relief
arrangement with utmost
care for human safety
6) Power cable entry From bottom
7) Cable Terminations Cable terminations shall be
supplied with the GIS for

power cable of 400sq.mm
XLPE-3 core cables for all out
going feeders &singlecore
for generator & station
transformer feeders. The
cable termination shall be
plug in type.
Facilities for easy cable
testing including cable
voltage test and fault
location and for primary
current injection, with busbar
live, shall be provided
8) Accessories -Gas leakage detection kit

-Gas filling Arrangement
without gas evacuation of
any other switchgear
-temperature-compensated
sensors for pressure
measurement and Gas
Monitoring Arrangement for
Busbar/ Breaker/
Disconnector Compartment.
Individual module shall have
pressure monitoring system
with required protection and
interlocks including the bus
pressure monitoring system
-Mechanical & Electrical
Switch Position Indication for
CB, Disconnector and
Earthing Switch
-earth bus bar
-cable testing arrangement
-Counter for circuit breaker
operation
-Pressure relief devices

-view ports as required
9) Auxiliary Contacts Total 6 NO + 6 NC,
additional contacts shall be
given if add on is possible
10) Closing mechanism Motorised spring charged
stored energy.
11) Operating voltage for Spring 220V D.C.
charging
12) Operating voltage for Closing 220 V DC
coil Tripping coil
13) Control supply voltage 220 V DC
14) Type tests for performance As per IEC & IS
verification.
15) ON/OFF indicator Mechanical as well as
electrical
16) Emergency tripping & closing Mechanical/ manual
mechanism
17) Control Power Voltage Range, 85% - 110%
Motor for spring charged
mechanism
18) Local & Remote control Shall be suitable for both
local and remote control
from the electrical control
room
19) Control wiring Minimum 1.5 mm sq.mm ,
1.1kV
20) Current transformer The current transformer shall
be suitably located outside
the HT chamber The CTs to
be selected as per the
protection & measuring
requirements of the feeders.
The CT ratio shall be finalised
during engineering stage as
per requirement
and shall be similar to

existing system.
CT class shall be as
following:
Class 0.5 for metering
5P20 for feeder protection
PS class for differential
protection
21) Voltage transformer The voltage transformers
shall be provided with
isolating mechanism with
plug in type connection
arrangement. The rating of
the voltage transformers
shall be suitably selected as
per the protection &
measuring requirements of
the system. Voltage
Transformers to be provided
for each bus sections for Bus
Voltage & in incoming
feeders (6 nos.) & generators
(4 nos.)
PT class shall be as
following:
Class 0.5 for metering
3P for protection
22) Metering Analogue ammeter,

analogue voltmeter, digital
multifunction meter
23) Maintenance/ repair provision For repair it must be possible
to exchange panels or circuit
breakers within an installed
switchboard
without removing adjacent
panels.
24) Provision for future extension Without affecting feeder
shutdown and section
shutdown
25) Special tools for installation & Shall be provided
commissioning, monitoring,
testing & maintenance
3.6.6 Relay and Control Panels for 33kV Switchgear

3.6.6.1 Relay and Control Panels(RCP) shall have following features:
i) All protective relays shall be mounted in the RCP.
ii) RCP shall have following :
 Multifunction energy meters comprising of Ammeters,
Voltmeters, trivector meter, power factor meter, frequency meter.
This shall be duplicated at the RCP & Switchgear. Analogue type
energy meter, power factor meter, frequency meter, ammeters &
voltmeter shall also be provided
 All protective relays and auxiliary relays
 Breaker Control.
 Semaphore Indicating lamps
 Switches
 Annunciator
3.6.6.2 All the protective relays shall be Numerical relays conforming to IEC-255-5
and shall be suitable for communicating with RTU for SCADA system.
3.6.6.3 Feeder protection
1 IDMTL Overcurrent and IDMTL earth fault protection alongwith high set
instantaneous trip facility
2 Differential protection for 33kV cable / transformer alongwith 33kV
cable(as applicable)
3 Intertrip facility
4 Local breaker backup
3.6.6.4 Busbar Differential Protection

- 33kV switchgear shall have busbar differential protection
3.6.6.5 Constructional Feature

1) Panels shall be arranged to form a continuous board with the mimic
and control equipment.
2) Panels shall be vertical, free standing, simplex type with rear hinged
door, side terminal blocks control signalling circuit breakers, resistors,
fuses, links, isolating switches etc.
3) Flush mounted meters, relays, switches, signal lamps etc. on front of
the panel.
4) Made of cold rolled pressed sheet steel thickness 2.5 mm.
5) Shall have bottom cable entry
6) Anodised Aluminium inscription plate both at back and front side of
appropriate size to enable a person to read from 5 meters shall be
provided.
7) Painted after proper degreasing, pickling and chemical phosphatising
as per painting procedure.
8) Earth bus securely fixed.
3.6.6.6 Wiring
1) Panels shall be wired with 1100 volt grade multi strand copper wire
PVC insulation having cross-sectional area 1.5 sq. mm. CT
connections and external connection shall be made with 2.5 sq. mm
copper wires. The CT & PT wiring shall be done with colour coded
wires with no lugs in CT secondary termination.
2) Wire shall not be joined or tied between the terminal points.
3) No bunch shall contain more than 12 wires.
4) Wire end shall be fitted with moisture and oil resistant insulating
material having glass finish with identification number clearly
engraved in black.
5) More than 2 (two) wires shall not be terminated at one terminal.
3.6.6.7 Terminal Blocks

1) Stud or open screw type vertically mounted terminal blocks shall be
used.
2) Stud type terminal blocks shall be provided with brass studs of not
less than 6 mm in diameter.
3) Insertion type shall have pressure plates.
4) In each terminal block 20% spare terminals shall be provided.
3.6.6.8 Control Supply
1) The control voltage shall be 220V DC.
2) For switching off supply disconnecting devices with auxiliary
contacts for indication of control supply.
3) One number 220 V single phase 15 A plug point in all panels for
testing purpose.
3.6.6.9 Annunciators
Static type alarm annunciators for fault and alarm conditions shall be
provided.
3.6.6.10 Technical Particulars
a) Panel Sheet steel 2 mm thick
b) Enclosure IP- 54
c) Extendable feature Yes
d) Illumination with door switch Yes
e) Provision of cable glands Yes
f) Inscription Both sides, front and rear
g) Control supply 220 V DC
h) Signalling bus isolation ON/OFF switch (stay put
type)
i) Signalling supply isolation By switch
j) Base channel provision Yes
k) Control buses As per circuit requirement
o) Instrument size 144 mm square
p) Provision of test block for CT and Yes
PT circuit.
q) PT secondary voltage 110 V / 3
r) CT secondary current 1A
3.6.7 33 kV Indoor Isolator

3.6.7.1 A motor operated off load, triple pole disconnecting switch with earthing
device shall be installed for disconnection of transformer primary for
inspection and maintenance purpose as per IS 9920 (Pt1-1985), (Pt2, 3-
1982), (Pt.4-1985).
Model type : Motor operated, air break, Indoor. Isolator
shall have also provision for manual
operation in addition to motorised

operation
Rated voltage : 33 kV, 50 Hz, 3 phase
Arrangeme : Local/ Remote

nt for
operation
Interlock : Key interlock to prevent it being operated
unless Circuit breaker is open. Provision of
solenoid operated mechanical interlock,
padlocking facility and auxiliary switch shall
be kept.
Mounting : Wall mounted type
3.6.8 12.5 MVA 33/ 6.9 kV ONAN Transformers

3.6.8.1 The transformers shall comply with latest revisions of the following Indian
standard specifications.
IS:335-1993 New insulating oil.

IS:1866-1983 Code of practice for maintenance and
supervision of insulating oil in equipment.
IS:2026 (Pt.1,2,4- Power transformer
1977)
(Pt.3-1981)
(Pt.5-1994)
IS:3639- 1966 Fitting & accessories for power transformer
IS:6600-1972 Guide for loading of oil immersed transformer.
IS:6792-1992 Method for determination of electric strength of
insulating oil.
IS:10028(Pt.1-1985) Code of practice for selection, installation &
(Pt.2,3- maintenance of power transformer
1981)
In addition to above Indian Standards transformers shall also comply with
IPSS : 1-04-012-99.
3.6.8.2 Technical parameters of transformers .
1. Voltage HV/LV 33/6.9 kV
2. Normal System 33 kV
Voltage
3. Maximum System 36 kV
Voltage
4. Rated frequency 50 Hz + 5 %
5. Duty Indoor installation in transformers pens
and suitable for heavily polluted area.
6. Type 3 phase, ONAN

7. Specification to be IS 2026: 1977 & 1981, IS: 10028:1981
complied with & 1985
8. Continuous rating 12.5 MVA
10. Winding Delta/ Star
connection
11. Vector group DYn 11
12. Winding Copper
13. Insulation level
One minute Power 70 kV rms (primary)
frequency 20 kV rms (secondary)
withstand Voltage
(kV)
Peak impulse test 170 kV :peak (primary)
withstand voltage 60 kV :peak (secondary)
(kV)
14. Neutral grounding 6.6 kV – resistance grounded.
15. Termination 33 kV – through insulated bus
bars/tubes
6.6 kV – through Bus duct
6.6 kV neutral to NGR – IPS AL tube
33kV Bushing shall be capacitor type.
16. 33 kV , 6.6kV CTs 33kV trafo differential CTs and 6.9kV
CTs for REF should be mounted inside
bushing . CTs for other functions shall
be mounted at the corresponding
switchgears.

CT for differential Class PS
protection ,
restricted earth
fault protection
CT for protection Class 5P20
Neutral side CT PS class & 5P20
17. Permissible
maximum
temperature rise
over 50 deg C
ambient temp.
Top oil (by 35oC
thermometer)
Windings (by 40oC
resistance)
Hot spot temp. As per IS 2026 - Part II- 1977
18. Tap changer on 33 On load tap changer
kV side
Range + 10% at steps of +/- 1.25 %
Total tap positions 17
Tap change OLTC shall be complete with RTCC for
controls auto and manual (Local and remote)
control
19. Impulse test
withstand
20. One minute dry
and wet power
frequency
withstand voltage
a) Induced over
voltage
withstand
voltage

b) Withstand time
without injury
for 3 phase short
circuit at
terminals shall
be for 5 sec.
21. Short circuit level 40kA for 3sec.for 33 kV side
on HV side 40kA for 3 sec. for 6.6 kV side
22. Auxiliary supply 220 V DC
voltage
23. Parallel operation Suitable for parallel operation with
transformers of similar ratings
24. Overload capacity As per IS 6600-1972
25. Radiator Detachable type
26. Painting Shade 632 of IS 5: 1994.
3.6.8.3 Transformers shall be capable of delivering rated current at an applied

voltage upto 105% rated voltage without exceeding the temperature limits
specified below.
3.6.8.4 Transformers shall be operable at its rated capacity at any voltage within +
10% of rated voltage of the particular tap.
3.6.8.5 Transformers shall be designed to withstand the thermal and dynamic
stresses due to short circuits at its terminals. The duration of short circuit
shall be 5 seconds.
3.6.8.6 The maximum temperature at the end of the specified duration shall not be
more than 250oC with the temperature prior to short circuit corresponding
to maximum permissible overload.
3.6.8.7 Transformers shall be designed for suppression of harmonics especially 3rd
and 5th.
3.6.8.8 Transformers shall be able to deliver rated power for 10 minutes even if the
forced cooling fails with the winding hot spot temperature limited to 140oC.
3.6.8.9 Magnetic Circuit
i) Low loss CRGO silicon steel shall be used.
ii) 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. CRGO sheets shall
be coated with varnish insulation compatible with the sealing liquid.
iii) Insulation shall withstand annealing temperature as high as 850oC and
shall reduce eddy current to minimum.
iv) Ducts shall be provided to ensure adequate cooling.
v) Core, framework and clamps shall be arranged and tightened to
securely hold laminations in order to prevent any settling of
displacement in case of heavy shocks during transport, handling or
short circuits.
vi) Flux density under specified over voltage or frequency shall be within
the maximum permissible for the lamination.
vii) Transformers shall be designed to withstand 110% over fluxing
corresponding to rated voltage.
3.6.8.10 Windings
i) Material shall be electrolytic grade work hardened copper of high
proof stress with more numbers of radial supports.
ii) Windings shall be pre-compressed, press board, pre-stabilization of
coil.
iii) Completed core and winding shall be vacuum dried in full vacuum
and impregnated immediately.
iv) Windings shall be braced to withstand shocks due to rough handling
and forces due to short circuit, switching or other transients.
v) Permanent current carrying joints in winding and leads shall be
brazed.
vi) Coils shall be supported using high pressure compressed wedge type
insulation spacers.
vii) Insulating materials shall be compatible with transformer liquid under
all service conditions.
viii) Leads to the terminal board and bushings shall be rigidly supported.
3.6.8.11 Insulation
i) Interturn and inter coil insulation shall be designed such that di-
electric stress is uniformly distributed throughout the windings under
all operating conditions.
ii) 33kV and 11kV windings shall be fully insulated.
3.6.8.12 Tank
i) Welded thick gauge plates stiffened and reinforced to withstand
without deformation for all stresses applied during transport and
operation or short circuit conditions. The tank shall be of Bell Type

ii) Oil tight weld and joints
iii) Fully assembled transformer with its radiators, conservator and other
fittings shall withstand for one hour a pressure corresponding to twice
the normal head of liquid or to the normal pressure plus 35 kg/ sq. m,
whichever is higher, measured at the base of the tank.
iv) Plates shall be protected internally against corrosion due to
insulating liquid.
v) Provided with inspection opening and cover/ with handling
equipment) to provide access to bushing connections.
vi) Form of cover shall be such as to prevent any stagnant water deposit
and to drain gas bubbles towards the buchholz relay.
vii) Tank shall be capable of withstanding of 760 mm of mercury
vacuum.
viii) Diaphragm cover for diverter switch shall be provided.
3.6.8.13 Conservator and Breather
i) Conservator mounted on frame, integral with tank in such a manner
that under all conditions and the lowest oil level in the bushings remain
under the head of liquid.
ii) Conservator volume shall be sufficient to maintain oil seal from
ambient to oil temperature of 90oC.
iii) Oil filling hole with cap, a drain valve to drain the oil completely shall
be provided at one end of the conservator and shall be bolted into
position so that it can be removed for cleaning purposes.
iv) Silica gel breather with window and oil seal shall be mounted at 1.4 m
from ground level and connected to conservator.
v) Prismatic type oil level gauge with max. and min. levels marked. Tap
and valves shall not be fitted to oil gauge. 150 mm diameter dial type
magnetic level gauge with alarm and trip contacts shall also be
provided.
3.6.8.14 Buchholz Relay
i) Double float relay as per IS 3637 - 1966
ii) 50 mm diameter of connecting pipe shall have minimum number of
bends.
iii) Shut off valves on either sides of the buchholz relay.
iv) Pot cocks at the top and bottom of relay drain plug, inspection
window, calibrated scale, terminal box with oil tight double
compression type brass gland.

v) Potential free self-reset independent alarm and trip contacts rated to
make, break and carry 2 amps at 220 V DC. No auxiliary relay shall be
used to multiply the contacts. Contacts are to be wired to the
marshalling box.
3.6.8.15 Cooling
i) The cooling system shall be Oil natural, air natural type.
ii) Radiators may be detachable type directly mounted or separately
mounted.
iii) Bolted, gasketted and flanged connections shall be used for
connecting the radiators to the tank.
iv) The following accessories shall be provided for each radiator/radiator
bank.
 Top and bottom shut off valves and blanking plates.
 Bottom drain plug and top filling plug, air release plug.
 Lifting lugs
 Thermometer pockets with thermometers in the inlet and outlet
pipes (for separately mounted radiator banks)
 Top and bottom filter valves for each separately mounted
radiator bank.
3.6.8.16 Valves and Connections
i) Valves of sluice type with hand wheels.
ii) Made of gun metal
iii) Clear indication of open and closed position
iv) Provided with blanking plates or screwed plugs
v) Padlocking facility to lock in closed/open position.
3.6.8.17 Terminations
i) It shall be possible to withdraw the transformer easily after
disconnecting the connections without disturbing the busduct / line /
terminations.
ii) For bus duct termination
iii) Flanged throat shall be provided to suit the bus duct. Flange ends and
inspection openings shall have weather proof gaskets.
3.6.8.18 Bushings ( 33 kV bushings shall be condenser type )
i) Conform to IS:3347 and IS:2099-1986
ii) Minimum rated current of line and bushings shall be 1.5 times rated
current of the corresponding windings.

iii) Clamps and fittings made of steel or malleable iron shall be hot dip
galvanised.
iv) Bushing rated 400 Amps and above shall have non-magnetic clamps
and fittings only.
v) Neutral bushings shall be provided as required for earthing of neutral
point.
vi) Bushing Current Transformers (Where applicable)
vii) CTs for REF protection and back up earth fault shall be provided on
the neutral end.
viii) For differential protection, CTs shall be provided on primary side and
on the secondary side.
ix) Removable leads shall be brought to a weather proof terminal box
and from there to the marshalling box.
x) Secondary leads shall be brought to a weather proof terminal box
and from there to the marshalling box.
3.6.8.19 Oil Temperature Indicator
i) 150 mm dial type thermometer with manual reset maximum reading
pointer. There shall also be two potential free contacts for alarm and
trip signals. The alarm and trip settings shall be independently
adjustable. The temperature sensing element mounted in a pocket of
oil, shall be connected to the indicator through capillary tubing.
Contact rating at DC shall be minimum 0.5 amps at 220V DC.
3.6.8.20 Winding Temperature Indicator
i) Local winding temperature indicator (WTI) shall have a 150 mm
diameter dial type indicator with a manual reset max. reading pointer.
There shall be two potential free contacts for alarm and trip signals.
For transformers with forced cooling another set of contacts shall be
provided to start/stop the forced cooling system automatically. The
settings for closing/opening of each contact shall be independently
adjustable. Contact rating at 220 V DC shall be minimum 0.5 amps. The
device shall be complete with lamp, sensing element, image coil,
calibration device aux. CTs etc. as required.
ii) Remote winding temperature indicator with resistance type
temperature detector shall be provided additionally.
ii) 4-20mA output using necessary transducers shall be provided for
hooking up to RTUs.
3.6.8.21 Marshalling Box
i) All outgoing connections from the transformer i.e. buchholz relay,
temp/ level indicators, CT secondary fault contact for annunciations,
forced cooling system and OLTC etc. through microprocessor based
scanners shall be wired to a marshalling box.
ii) Degree of protection of enclosure shall be IP 55.
3.6.8.22 Earthing
i) All metal parts of the transformer with the exception of individual core
laminations, core bolts, and clamping plates shall be maintained at
fixed potential by earthing.
ii) Two tinned copper earthing terminals.
iii) One end of bushing CTs shall be earthed.
3.6.8.23 List of Fittings and Accessories
i) Resistance type (PT 100) embedded temperature detector for
measuring winding temp. and hot spot temperature with alarm and
trip contacts connected to RTU/Numerical relays
ii) Rating and Name plate and connection diagram
iii) Pressed steel radiator with shut off valve.
iv) First fill of oil as per IS 335 - 1993 with 10% excess in drums
v) Cooling system complete with accessories as specified.
vi) Off tap changer.
vii) Conservator ( Air cell type )
viii) Dehydrating breather
ix) Buchholz relay
x) Oil filter valves at top and bottom of tank
xi) Drain off valve at the lowest location to allow complete draining.
xii) Oil sampling device at top and bottom.
xiv) Pressure relief valve
xv) Pockets with thermometers for oil temp. and winding temperature
indicators.
xvi) Bar type level gauge with alarm contacts
xvii) Lifting lugs and jacking pads
xviii) Bushing CTs
xix) Dial type oil and winding temp. indicator with alarm and trip
contacts.
xx) Lifting lugs and jacking pads
xxi) Rating and diagram plates
xxii) Earthing terminals
xxiii) Inspection cover

xxiv) Flat base and foundation bolts
xxv) Bi-directional Flange wheel suitable for broad gauge rail
transportation for transformers.
xxvi) Pulling Hooks
xxvii) Prismatic oil level indicator on main tank of transformer
3.6.9 Neutral Grounding Resistor (NGR)
The NGR panel shall have following features:
Location Transformer pen
Type Punched stainless steel grid, Metal clad, rigid
mounting, indoor, floor mounted, free
standing.
Applicable standards IEC-32 1972
Voltage rating 6.6 kV
1 minute power 20 kV
frequency withstand
voltage
Current rating Neutral current at 6.6kV side shall be limited
to 700A. NGR shall be rated for 30 seconds
Design temp rise IEEE-32
Degree of protection IP 33
Termination Suitable Earthing strip
3.6.10 33 kV Outdoor Isolator/ Disconnecting Switch
3.6.10.1 Type and Construction
1) Triple pole gang operated horizontal double break type with earth
switch, motorized suitable for outdoor installation in open yard under
the specified site conditions.
2) Common actuating mechanism for all three poles.
3) Single pole units shall be interchangeable
4) Switch blades shall be of copper and of one solid piece construction.
5) Clearance between live parts and grounded structures, shall be as per
the relevant standards/ CBIP procedures.
6) Inter-phase clearance and mounting height shall be as per relevant
standard.

7) Length of break in full open position shall be such that there is
absolutely no possibility of arc over from the live parts to the de-
energised parts.
8) Speed of operation during opening or closing shall ensure minimum
arcing.
9) Shall conform to IS : 9921 – 1981(Part I) , 1982 (Part II & III) , 1985 (Part
IV & V)
3.6.10.2 Technical Particulars of Isolator

a) Nominal system voltage 33 kV
b) Highest system voltage 36 kV
c) Rated frequency 50 Hz+ 5 %
d) Type Triple pole, air break, off load,
motorized, Double break with
earth switch
e) Continuous current rating 1250 A
f) Short time rating 3 sec. 31.5 kA
g) Making capacity and dynamic 80 kA peak
stability current ratings
h) Insulation level of:
 Impulse withstand voltage 170 kV
 One min. power freq. 70 kV
withstand voltage
i) Min. creepage distance 31mm/kV
j) Operating mechanism Motor driven with provision
for hand operation in
emergency
k) Operating place Local –Electrical & Manual
Remote-Electrical
l) Main contacts Pressure relieving type,
copper material
m) Termination provision Suitable for Aluminium tube /
ACSR conductor
n) Earthing switch mechanically interlocked
with disconnecting switch/
isolator. Rating of earthing
switch shall be same as that
of isolator.
Earthing switch shall be
operated manually.
o) Auxiliary contacts 12 NO + 12 NC for isolator 12
NO + 12 NC for earthing
switch.
p) Installation Outdoor pole structures with
pad locking facility.
q) Structure/Hardware Structure/Hardware used for
isolator mounting and
mechanical operation shall be
hot dip galvanised
r) Electrical interlock  Between isolator and
circuit breaker (for correct
sequence of operation
and safety)
 Between isolator & earth
switch.
s) Control voltage 220V DC
t) Auxiliary voltage for motor 415 V AC
u) Temperature rise As per relevant standard
v) Degree of protection IP-55
3.6.10.3 Making and Interrupting Capability

i) Disconnecting blades shall be capable of carrying rated current
continuously as well as specified short circuit current for the duration
indicated and under specified temperature rise without causing
mechanical damage to any part and the insulation.
ii) Switches shall be capable of making on to faults specified and
withstanding the dynamic stresses involved.
ii) Switches shall also be suitable for making and interrupting small
inductive charging and capacitive charging currents such as those
which occur while disconnecting lines at no-load, busbars or
transformers under energised condition.
3.6.10.4 Contacts

i) Contacts shall be high pressure self-aligning adjustable type and shall
have sufficient wiping action to make contacts self-cleaning. These
shall be well protected all round by a metal cover to provide not only
electrostatic screening but also to prevent coarse dust from entering
between the contacts.
ii) Contacts pressure shall be released before any movement of the
blades and the opening direction takes place and shall be applied after
the closing travel is completed.
iii) Contacts shall be of high grade high conductivity heat resistance
copper and shall be silver plated.
iv) Temperature rise of contacts shall not exceed 50degC over the
ambient of 55 deg. C.
3.6.10.5 Operating Mechanism
i) The operating mechanism shall be motorized as well as manual type.
Direction for both open and close shall be embossed on the top of the
mechanism box. End stoppers shall be provided for both close and
open position. The mechanism box shall house the auxiliary contacts,
solenoids, Push buttons etc.
ii) Signalling device for all pole both for closed position and open
position for remote as well as local indication.
iii) Provision for padlocking the mechanisms in either the open or closed
position.
3.6.10.6 Earthing Switches
i) Disconnecting switches shall be provided with earthing switches on
both sides or on side (as per single line diagram) forming integral part.
The operation and movement of the earthing switches on two sides of
the isolators shall be independent of each other but they shall have
mechanical as well as electrical interlock with the isolator.
ii) Rating of earthing switch shall be same as that of the isolator/
disconnecting switch with respect to rated short time current and
dynamic peak withstand current.
ii) Grounding blade shall be operated by a separate mechanism but
interlocked so that it can be closed only when the disconnecting switch
is open and vice-versa.
3.6.10.7 Interlocks
i) To be interlocked with associated isolator, circuit breakers and earthing
switches.

ii) For closing of isolators, associated earthing switches, shall have to
open and it is to ensure that isolators are not used for on load closing.
ii) Final wiring or contact multiplication relays blocking solenoid etc. shall
have to be provided as per approved logic diagram.
iv) Breakers can be closed if associated earthing switches are open and
isolator are in closed position.
v) Auxiliary relays and circuitry shall be such that interlocking cannot be
bypassed even on failure of control supply.
3.6.11 33 kV Outdoor Circuit Breaker
3.6.11.1 The 33kV circuit breaker shall be suitable for installation in open yard in
heavily polluted environment. Circuit breakers shall be capable of
interrupting induction currents caused by switching operations of unloaded
transformers and low capacitive currents without causing undue over
voltage. The 33 kV CB shall conform to IEC 62271-100.
3.6.11.2 Technical Particulars of 33 kV Circuit Breaker:
1) Nominal system voltage 33 kV
2) 36 kV
Highest system voltage
3) Rated frequency 50 + 5%Hz

4) Rated continuous current 1250 A
5) Design short circuit level 31.5 kA for 3 Seconds
6) Type Vacuum circuit breaker
7) Closing mechanism Motorised spring charged
stored energy.
8) Operating voltage for Spring 240 AC
charging
9) Operating voltage for Closing coil 220 V DC
Tripping coil
10) Number of poles 3 (three)
11) Total break time for any current Less than 2.5 cycles
upto the rated breaking current
measured from the instant of trip
coil energization.
12) First pole to clear factor 1.5

13) Temp. rise As per IEC
14) Whether the circuit breaker is Yes
intended for rapid re-closing
15) Operating duty 0-0.3 sec – CO – 3 min – CO
16) Dead time of the breaker Adjustable between 0.3 sec.
to 15 sec.
17) Latching requirement Trip free
18) Insulation level
c) Rated one min. power 70 kV rms
frequency withstand voltage.
d) Rated impulse withstand 170 kV peak
voltage
19) Min. creepage distance 31 mm/kV
20) Control supply voltage 220 V DC
21) Aux. contacts with each circuit 6 NO + 6 NC, with provision
breaker interchangeable at site to extend no. of contacts
additional contacts shall be
given if add on is possible
22) Type tests for performance As per IEC
verification.
23) ON/OFF indicator Mechanical as well as
electrical
24) Emergency tripping & closing Mechanical
mechanism
25) Termination suitability with Al Tubular bus bar
connectors
26) Anti-pumping relay operation, Shall be provided
counter, local control panel, local
/ remote selector switch.
27) Space heater with thermostat Shall be provided
panel illumination lamp, 240 V
switch socket in local control
panel, gland plate with double
compression glands.
28) Degree of Protection IP-55

29) Tentative phase to phase 750 mm
clearance (centre to centre)
30) Minimum ground clearance 4000mm
3.6.11.3 Bushings
 Equalised electrical stress internally and over the bushing surface
 Free from radio interference
 Provision for expansion over normal operating temperature range
 Bushings with combination potential and power factor test cap.
 Circuit breakers shall be suitable for remote control from the electrical
control room.
 A local control switch with locking arrangement shall be provided for
each circuit breaker for local operations i.e. tripping and closing during
maintenance, test etc.
 Local/remote selector switch shall be provided in the mechanism
cabinet.
 Provision for connecting oscillograph recorder to measure the
operation timings of the circuit breaker.
 Each circuit breaker shall have ON/OFF indication lamp along with a
mechanical òpen/closed' position indicator visible with the
mechanism cabinet closed.
 One close coil and two trip coils.
 Cabinet for operating mechanism and its accessories shall be of IP55
protection with pad locking facility. Cabinet shall be simplex type all
equipment mounted on front side and wiring on back in proper wire
ways.
 Anti-condensation heater shall be provided in the local cabinet with
load break fuse switch. It shall house relays for control and interlocking
as per scheme requirement.
 Wire-ways/cable ways shall be provided in operating mechanism
cabinet so that wiring is neat. All the connection shall be at back and
equipment in front.

 Closing circuit to operate satisfactorily from 80% to 110% of the rated
control voltage and tripping from 50% to 110% of the rated control
voltage.
3.6.11.5 Interlocks
 Opening or closing of the isolator / disconnecting switch shall be
prevented when the circuit breaker is in closed position.
3.6.11.6 Terminal Connections
 The terminal connector shall be suitable for Al. Tubular Busbar
 Suitable terminal earth connector for earthing connections shall also
be supplied.
3.6.12 Current Transformer ( 33 kV outdoor type)
3.6.12.1 Type
i) Outdoor type suitable for installation in open yard where no protection
against sun, rain and inclement atmospheric conditions exists.
ii) Oil immersed Nitrogen topped, hermetically sealed type, self-cooled,
Live Tank design
iii) Suitable for service in industrial environment.
3.6.12.2 Technical Particulars of CT
1 Standard IS-2705- 1992
2 Nominal system voltage 33 kV
3 Highest system voltage 36 kV
4 Rated frequency 50 Hz + 5%
5 Short time thermal current rating for 3 31.5 kA for 3 sec
seconds
6 Class of insulation A
7 Insulation level:
 Rated lightning impulse withstand 170 kV peak
voltage (1.2 /50 micro second
impulse)
 Rated one minute power frequency 70 kV RMS
wet and dry withstand voltage
8 Temperature rise over ambient temp.
 Oil top of housing (measured by 40oC
thermometer)
 Winding (measured by increase in 50oC
resistance method)

 Oil level gauge and pressure reliving Yes
devices, lifting lugs, drain plug, oil
filling port rating and diagram plate to
be provided for all CTs.
9 Terminals Al tubular busbar
10 Degree of protection IP-55
11 Minimum creepage distance 31mm/kV
12 Primary current rating As per design
requirement
13 Minimum VA burden 30 VA
14 Accuracy class 5P20 for protection
0.2S for metering
PS class for
differential protection
3.6.12.3 Current Transformer Secondary Circuit
 CT ratio shall be finalized during detailed engineering as per
requirement.
 Knee point voltage, CT secondary resistance and magnetising current
of class PS core of CTs shall be suitably matched with the requirement
of relevant relays offered and secondary leads used.
3.6.13 Lightning Arrestor ( 30 kV)
3.6.13.1 Type
1 Station class, heavy duty, non-linear resistance type, metal oxide
gapless lightning arrestor and shall conform to IS: 3070-1993 (Part3).
2 Suitable for pedestal mounting
3 Out-door type suitable for installation in open yard.
4 Shall be designed to provide full protection against lightning and
switching surges.
3.6.13.2 Technical Particulars of Lightning Arrestors
i) Nominal system voltage 33 kV

ii) Maximum system voltage 36 kV
iii) Rated Arrestor voltage 30 kV
iv) Frequency 50 Hz + 5 %
v) Long Duration Discharge class Class III

vi) Continuous operating voltage 25.5 kVrms
vii) Nominal discharge current 10 kA
viii) Power frequency with stand test voltage 70 kV
ix) Impulse voltage 170 kV peak
x) Standard discharge current for 8/20 micro 2.5 kA peak
second
xi) Maximum residual voltage As per IS 3070 :
1993.
xii) Thermal discharge capacity Shall be adequate
for switching
surges long
duration surge
and multiple
strokes.
xiii) Minimum creepage distance 31mm/kV
xiv) Degree of protection IP-55
3.6.13.3 Surge Monitor

i) Surge monitor connected in series between the lightning arrestors and
ground shall be provided to determine the service performance and
on-line condition of the lightning arrestors.
ii) Surge monitor shall include counter with ammeter to record the
number of operation and healthiness performed by the arrestor.
iii) To monitor health of arrestor, diagnostics and alarms.
3.6.13.4 Fittings & Accessories
i) Surge monitors shall be fitted with pressure relief device
ii) Surge monitors shall be supplied complete with supporting insulators,
terminal connectors, standard fittings and accessories
3.6.14 33 kV Outdoor Buswork & Accessories
3.6.14.1 The bus-work comprising of suitable ACSR conductors, EHIPS Aluminium
tubes shall be provided for interconnecting all outdoor equipment and
accessories covered under this specification. 33 kV main bus shall be similar
to existing main bus of WESCO. Interconnections between Isolator, CTs, PTs,
breaker and LA shall be through EHIPS Aluminium tubes. The bus work shall
be complete with supporting insulators, clamps, connectors and hardware
to make the installation complete in all respects. Post insulators
for isolators and bus supports shall be identical and shall have adequate
strength. All the accessories for the conductors and earthwire for overhead
power line shall conform to IS 2121 (PtI,II& III): 1981.
3.6.15 33 kV switchyard Insulators & Hardware
3.6.15.1 All the steel members like bolts, nuts, fittings, clamps, dampers shall be hot
dip galvanised except spring washers, which shall be electro-galvanised. All
insulators shall be porcelain insulators and shall be suitable for heavily
polluted atmosphere,, high dust environment , and shall be able to
withstand the duty requirement of the related equipment. Porcelain shall be
homogeneous, free from any laminations, cavities, flaws or imperfections
and shall be thoroughly vitreous. Individual disc insulators as well as
complete insulator string for supporting conductors shall be designed,
manufactured and tested as per IS: 731 – 1971 and IS: 3188- 1980. All fittings
and accessories shall conform to IS: 2486 –(Part 1 , Part 2 , Part 3 & Part4) –
1993 , 1989, 1974 ,1981 . Insulators shall be of ball and socket type. The
socket shall be malleable cast iron and the pin shall be of steel. After
machining is completed, the balls and sockets shall be hot dip galvanised.
Individual units of each string shall be identical and interchangeable.
Electromechanical strength of bus post insulator shall be finalized during
detail engineering based on IS/IEC specifications.
3.6.15.2 Technical Particulars of the insulators:
1. Type Post/string
2. Normal System Voltage 33 kV
3. Maximum System Voltage 36 kV
4. Frequency 50 Hz + 5 %
5. Designed short circuit level 31.5 kA for 3 sec
6. Insulation level
a) Rated one minute power frequency 70 kV RMS
wet and dry withstand voltage
b) Rated lightning impulse withstands 170 kV Peak
voltage.
7. Degree of protection IP-55
8. Minimum creepage distance 31mm/kV
3.6.16 33 kV Bay Marshalling Kiosk
3.6.16.1 Outdoor type weather-proof bay marshalling kiosks shall be provided as
required for LT cable terminations etc. The kiosk shall be made of 2 mm thick
sheet steel and shall have lockable hinged door with internal illuminating
lamp with control switch and supporting structures. No relay shall be
mounted inside the kiosk
3.6.17 33kV Indoor Switchgear (GIS) for Ladle Furnace
3.6.17.1 Single busbar 33kV GIS switchboard shall be provided for Ladle furnace. All
other specification of 33kV GIS for switchboard of Ladle furnace shall be
same as GIS specification mentioned above at clause no. 3.6.5
3.6.17.2 Protection and metering requirement for 33 kV GIS switchgear
Sl. Name of Common meters& relays Protection features
No. feeder (Numerical relays
conforming to IEC-
61850)
1. Incomer Ammeter & Voltmeter of Definite time O/C
appropriate range without protection.
selector switch, Electronic Instantaneous O/C.
Trivector meter, close/ Trip
circuit supervision relay,
with lamp, high speed
master trip relay of Areva
make VAJH type or
equivalent, aux. relay of
Areva make VAA type or
equivalent, aux. relay DC
operated aux. relay and
locking relay as required.
2. Transform Ammeter & voltmeter Integrated trafo
er feeder without selector switch of protection.
appropriate range ,  IDMT type
Electronic Tri-vector meter, overload
close/ Trip circuit protection
supervision relay, with  Definite time O/C
lamp, high speed ,master protection with U/V
trip relay of Areva make blocking
VAJH type or equivalent,
 Sensitive type
aux. relay of Areva make
directional earth
VAA type or equivalent, DC
fault protection
with a facility to
connect it to signal
or trip circuit at site.
 Instantaneous O/C.
E/F signal.
4. 33 kV PTs Four voltmeters MCB and  Fuse failure relay

Sl. Name of Common meters& relays Protection features
No. feeder (Numerical relays
conforming to IEC-
61850)
fuse in secondary side. (one U/V relay.
with s/s for reading line  Neutral
voltages & three for displacement
reading phase to neutral relay for E/F
voltages. indication
 U/V and Under
frequency relays
for tripping of
selected feeder
5. 33 kV Ammeter &Voltmeter of  Instantaneous

Outgoing appropriate range, O/C
feeders Electronic Tri-vector meter,  Definite time O/C
close/ Trip circuit protection.
supervision relay, with  Sensitive
lamp, high speed, master Directional earth
trip relay of Areva make fault relay
VAJH type or equivalent,
aux. relay of Areva make
VAA type or equivalent, DC
Note for above Table:

1) Multi pole version of auxiliary relays with flags and timers as required
shall be considered for protection of Transformer feeders
incorporating the following features.
 Audio & visual Indication on temp. rise of oil &wdg, buchholtz
signal operation, low oil level, over load signal (CT operated)
 Tripping of the CB on operation of temp. rise of oil &wdg,
buchholtz protection
2) All components in each panel as detailed & elaborated in this T.S

3) Suitable arrangements for termination of required no. of cables in the
panels shall be finalized during DE stage. If necessary, dummy
chambers shall be provided
3.6.17.3 Other Accessories

Supply of GIS switchboard shall necessarily include the following
accessories.
a) Special tools & tackles 1 Set
b) Commissioning spares To be indicated by
the Bidder.
3.6.18 Ladle Furnace Transformer with Accessories
3.6.18.1 The furnace transformer shall be of special design to meet the specific
demands of furnace operation. The system shall be robust in construction
to meet the stresses generated in the transformer by the high secondary
current and shall be provided with special winding, cores and mountings.
The furnace transformer shall be designed for indoor installation. The
furnace transformer shall conform to the following specification.
Sl. Standard IS 12977- 2004 , IS 12188-2003 ,IS 2026

– Pt-1-5;1977-1994-2009, IEC 76-1
no.
through 76-5
1. Power rating Minimum rated power is given at clause
2.2.1. Overload of 20% for one hour
should be considered over and above
the final rated power.
2. Rated primary 33kV, 3phase, 50 Hz
voltage
3. Percentage 6-8%
impedance
4. Vector group Dd0 (open delta) as required for
operation
5. Total no. of taps 8 to 9 taps as required for the
operation
6. Type of cooling OFWF with two nos. oil to water heat
exchanger (1w+1s) each having its own
oil pump
7. Heat exchanger 2 x 100% continuous

8. Termination Primary- Bushings
Secondary- Copper bus tubes (water
cooled)
9. Power frequency Primary – 95 kV (RMS)
withstand voltage
Secondary – 10 kV (RMS)
10. Impulse withstand 170 kV (Peak)
voltage
11. Induced over 2 times rated voltage

voltage
12. Short circuit design Suitable for 3 seconds. Short circuit on

the secondary after prolonged use at
rated power as required for the
operation.
13. Temperature rise Winding : 45 deg C when oil circulation
over 55 deg is natural
ambient Oil: 40 deg C for cooling water inlet
temp. at 35 deg C
Cooling water temp. shall not rise more
than 10 deg C at rated load.
14. Special Transformer shall be designed
requirements considering that it shall be operated by
VCB, additionally necessary capacitor
bank shall be installed in the 33 kV side
to obtain 0.92 power factor
compensation.
The side wall of the transformer from
where the bus tubes go through must
be anti-magnetic material and no heat
shall occur due to magnetic induction.
Trafo shall be designed and selected to
take care of RMS load current as well
temperature rise of hot metal
Current limiting choke shall be provided
at the primary end of the furnace trafo
to limit the surges
16 taps and shall be arc free and
contacts shall break only after make of

the contacts.
Witnessing of temp. run test, impulse
test along with routine tests and the
tests approved in QAP.
3.6.18.2 On-Load Tap changer: On-load tap-changers shall be with vacuum

interrupters. The motor drive unit of the on-load tap-changer must be
installed in a rigid control cabinet, protection class IP 66 and shall be
equipped with padlock facility. Fixing lugs shall be placed at the motor drive
housing, to allow the installation to the transformer tank without opening
the drive door. Fixing lugs shall not be placed in the housing. The life-time
of the diverter switch and vacuum interrupters shall not be less than 600000
operations.
3.6.18.3 The OLTC protection shall be done by a protective relay, installed between
the OLTC and the OLTC oil conservator. The protective relay shall be
equipped with test device, with an easy visualization and signals for remote
control. The protective relay shall be connected in the trip circuit of the
transformer.
3.6.18.4 The Bidder shall furnish the efficiency, heat load, weight and dimension of
the transformer. The transformer shall be complete with accessories as per
IS 2026: including in particular, but not restricted to the following:
a) One set of piping and fitting for oil cooling circuits.
b) One set of equalizer pipe connection in external cooling water
circuit.
c) One number control panel for controls for pumps for heat
exchanger
d) One set of transport rollers
e) One no. auxiliary CT for measurement of winding temp.
f) One set of jacking lugs, lifting lugs
g) One set of inspection covers.
h) Tap position indicator
i) Digital winding temperature indicator
j) Oil temperature indicator (digital type)
k) Rating plate and diagram plate
l) Terminal marking plate
m) Earthing terminals

n) Dehydrating silica gel breather
o) Thermometer pocket
p) Bulb thermometer
q) Conservator with detachable end plate, oil filling hole cap and drain
valve (OLTC oil should not come in contact with the main oil tank)
r) Air release device.
s) Pressure relief valve with a trip contact
t) Bucholtz relay with alarm trial contacts and shutoff valves on either
side of relay for main transformer
u) Oil temperature indicator with alarm and trip contacts
v) Winding temperature indicator with maximum temperature
reading pointer with alarm and trip contacts
w) Winding temperature for remote indication
x) Drain valves
y) Shutoff valves
z) Oil sampling valves
aa) Filter valves
bb) Water flow and oil flow indicators.
cc) High-tension switchgear shall be connected to the ladle furnace
transformer by sleeved copper bus bar.
3.6.18.5 Acceptable makes of furnace transformer are as follows: EMCO/CGL/
BHEL/ ALSTOM/TAMINI
3.6.19 Secondary side current carrying system
Fully triangulated arrangement of all the conductors in the secondary circuit,
the bus bars, flexible cables, bus tubes and electrodes shall be provided for
the proposed Ladle Furnace.
3.6.19.1 The transformer delta closure
The details of transformer delta closure shall be furnished by the Bidder.
3.6.19.2 Secondary Flexible Cables
The triangulated secondary design shall use multiple runs of cables per
phase. Should one cable fail during a heat, it shall be possible to finish a
heat on the remaining cables by completing the water circuit. The cables
shall be of the same length and shall be interchangeable.

Bumpers shall be provided on the water-cooled cables so as to eliminate
the possibility of rubbing of cables.
3.6.19.3 Water cooled bus tubes and clamps
New water-cooled bus tubes and electrode clamps shall be provided to carry
current to the electrodes. Not more than two bus tubes shall be used per
phase in order to simplify the connection to the electrode clamp. Necessary
pre-fabricated non-magnetic insulated suspension structures to support the
secondary bus bar system and water cooled cables are to be provided.
3.6.19.4 Electrode Control System

A new electronic electrode control system shall be provided by the Bidder
to fulfil the following requirements:
Maintain the target operating point set to suit the momentary operating
conditions by the crew of the automatic system, and to do so accurately.
The controlled variable in the electrode control system shall be true arc
impedance. An over-riding logic circuit shall be provided to ensure a fast
and sure ignition phase and rapid reduction of over-current in the event of
short circuits.
Electrode control system should be fast, accurate, and responsive.
Electrodes must rise up on switch-off or power failure.
Manual control of electrodes shall be possible.
Servicing and setting up should be simple to do.
The operating point, that is, the impedance value per phase, shall be
selected automatically for each secondary voltage step of the furnace
transformer during operation.
The electrode control system shall have adequate testing, monitoring and
diagnostic facilities to facilitate rapid maintenance.
3.6.19.5 Furnace Control System
The Furnace Control system shall consist of
PLC system and peripherals
Human Machine Interface
Main Control Desk
Local control Posts /desk
Supervisory Panel
The Supervisory Panel shall contain the supervisory equipment for
electrode movement and for the furnace high voltage equipment including
the transformer.
3.6.19.6 The Technical specifications of the control equipment shall confirm to the
requirements

3.6.19.7 Control Philosophy
A PLC based Furnace Control and Basic automation system (level 1) shall be
provided for the proposed Ladle Furnace installation. The PLC system shall
perform all the sequencing, interlocking, process control and data
management functions. The following shall be considered as main units for
control:
High Voltage equipment
Cooling water system
Hydraulic system
Electrode Regulation system and control
Ladle Transfer Car
Ferro alloy and Flux addition system
Temperature and sampling
Fume Extraction System
Ladle Furnace shall be able to perform following functions:
3.6.19.8 To fully utilize the PLC system two nos. of intelligent CRT terminal (HMI) in
combination with Main Control desk shall be provided to serve as Operator
interface. Main Control Desk shall be provided with hardware pushbuttons,
lamps and switches for critical operations. HMI, Main Control Desk, PLC and
its peripherals shall be housed in Furnace Control Room.
One emergency control desk shall be provided with display of critical
parameters that shall be configured to access data directly from PLC and
allow safety shutdown procedures during HMI server failures/other
emergencies.
3.6.19.9 The field devices like the motors, valves, pumps, magnetic vibrators, chutes,
conveyors etc. shall be controlled as per the process under different process
and safety interlocks. These shall form the level 0 system. The control of their
starting and stopping etc. shall be by the PLC (level I), which shall execute
the command on the basis of the set points given form HMI. Control loops
for speed control, charging control; flow control shall also be executed by
PLC.
3.6.19.10 The following equipment shall be considered in Level 1 automation. PLC, PC
unit for PLC programming, 2 nos. of PC based HMI and 2 nos. Laser printers.
Software shall include licensed version of software for PC, development
software and application software for PLC. The PLC & HMI shall
communicate through ethernet.

One no of emergency client station shall also be under the scope.
3.6.19.11 The operator shall directly input the commands from a HMI which shall be
provided with several coloured operating and graphic screens giving the
overview of the plant and can be progressively selected to a greater detail
as required.
3.6.19.12 The set points fed into Level I by the operator through HMI shall execute
the controls taking into account the physical control and safety interlocks to
command the field devices.
3.6.19.13 Control modes
Normal stop push button shall be with soft wired signal and lockable
emergency stop push button shall be hard wired and soft wired signal.
The plant shall operate in the following modes:
a) Local Mode
The local mode shall be provided primarily for maintenance purposes
to ensure that a drive is started with the equipment is sight. Local
Control Posts shall be provided with.
Local/Remote selector switch (whenever applicable)
Start Switch (In case of reversible drive Start FWD/REV)
Key lockable Stop Switch/Stop Push button
In addition to the local Control posts, Local Control Desks are
provided where a Group of devices are to be controlled.
A local control desk on the platform and another on the track level to
control the transfer car.
Local desks on the Ferro alloy and Flux addition system to control the
conveyor belts, flaps and the magnetic chutes.
Local panel in the Hydraulic room
Local operation of HT breaker and Isolator
b) Remote Mode
Generally the equipment except the Transfer Car shall be controlled
from the Main control Room. Main Control Desk with hardware
buttons and lamps for the critical signals and the HMI are to be used
to control the equipment.
Operating from the Furnace Control room (MCR) the operator can
use any one of the following modes:
Manual

Auto
c) Manual Mode
In manual mode the operator can give a command from the HMI. In
this mode the motor or the valve shall remain under the safety
interlocks like limit switches, number of starts per hour etc. For
example :-
For a valve command can be given directly in terms of control output
(4-20 mA)
For a vibrating feeder, it can be started and stopped directly
A pump can be started or stopped.
Roof can be lifted or lowered.
Electrodes can be lifted or lowered.
d) Auto Mode
In auto mode the system is controlled by the Level I PLC. The
equipment operate as per the set points as given by the level I. These
set points shall be derived from the Batch table/Recipe as input by the
operator through the HMI screen.
Some typical interlocks to be implemented in level I system
e) Lifting The Roof:
Electrodes must be in highest position
Furnace Breaker is switched off.
Temperature & sampling lance is retracted
f) Furnace Breaker On
Hydraulic plant OK
No fault in the cooling water circuits
Roof in the lowest position
Ladle Transfer Car in the treatment position
Furnace Transformer is Healthy
High voltage switchgear has no faults
Access door to the electrodes is closed
OLTC is not running
Electrodes Regulators are in automatic mode
No emergency push button is pressed

Fume extraction is running
g) Movement of Transfer car
Roof in top position
Furnace Breaker off
h) Alarm Representation
When any fault occurs, first an acoustic signal shall be given and
simultaneously an optical signal (blinking or colour change of symbols)
is generated on the CRT. An alarm summary shall give the details of
the alarm.
3.6.20 Nitrogen Based Fire Protection System for Transformer
Automatic NIFPS shall be provided for fire fighting of the transformer. This
system shall be capable of prevention of external and internal fire and
subsequent explosion of oil filled transformers by injection of Nitrogen. The
system shall comprise of injection of Nitrogen through ports located on the
transformer body, responding to the signals from strategically located fire
detectors and pressure relays etc. Electrically operated relays shall
automatically drain the top oil from transformer. The injected Nitrogen shall
facilitate stirring and cooling of oil and prevent fire.
Major Equipment:
i) Cabinet:
The cabinet shall be placed out outdoor. The cabinet shall be constructed
with MS plate preferably of thickness 3mm and fitted with hinged split
door in front. The locking system shall also be provided. The base frame
and foundation bolts shall be provided with the cabinet to fix it on the
civil foundation. The cabinet shall be of IP55 protection whereas the
instruments and valves on housed in it shall be of IP67 protection. The
sizing of the cabinet shall be done in consideration to house the following
equipment:
ii) Nitrogen gas cylinder / cylinder bank
iii) Oil drain pipe with mechanical quick drain valve;
iv) Electro mechanical control equipment for oil drain.
v) Pre-determined regulated Nitrogen flow reducer to release the
Nitrogen;
vi) Pressure monitoring switch for back-up protection for Nitrogen
release
vii) Limit switches for monitoring of the system;
viii) Flanges on top panel for connecting oil drain and Nitrogen
injection pipes for transformer;
ix) Panel lighting (CFL Type);
x) Oil Drain pipe extension of suitable sizes for connecting pipes of
oil pit;
xi) Anti-seismic mechanical protection.
xii) Cylinder
Nitrogen cylinders provided with the system shall be readily and
commercially available. One set (as required for one transformer) of
Nitrogen filled cylinders shall be provided as spare.
Release valve and pressure electrical contact manometer shall also be
provided
The cylinder shall be certified by the Chief Controller of Explosive (CCE)
and the certificates shall be submitted to the Employer.
xiii) Oil Drain valve:
A quick operating valve shall be provided for the depressurisation / drain
out of predetermined transformer oil. A gate valve shall also be provided
to facilitate the isolation of the aforesaid valve during maintenance.
xiv) Isolation Valve for Transformer conservator
The isolation valve is to be fitted in the conservator pipe line between
conservator tank & Buchholz relay. It shall have the proximity switch for
remote alarm, indication and with visual position indicator.
xv) Control Box
Control Box for monitoring system operation, automatic control and
remote operation, with following alarms indication, light switches, push
buttons, audio signal, suitable for tripping and signalling on DC supply:
a. System on
b. Isolation Valve for Transformer conservator open
c. Oil drain valve closed
d. Gas inlet valve closed
e. Isolation Valve for Transformer conservator closed
f. Fire Detector Trip
g. Oil drain valve open

h. Extinction Mode activated
i. Cylinder pressure low
j. PRV / RPRR trip
k. Transformer trip
l. Fault in cable connecting detector,
m. PRV, Buchholz relay, Conservator Isolation valve
n. System Out of service
o. Auto/Manual/Off
p. Lamp test
q. Visual /Audio Alarm.
r. Fire sensing device
The System shall be provided with (Water Proof/Weather Proof)
fire sensing device placed on the transformer oil tank & OLTC.
The sensing shall be suitably rated to detect the early fire
depending upon the heat rise.
Control box should be microprocessor based and compatible to
be interfaced to FDA system through existing LAN network and
SCADA system for centralized monitoring. One full set of spare
Nitrogen gas filled cylinder and one set of the installed no. of fire
sensors shall be provided in addition to other recommended
spares.
xvi) Signal Box
The signal box shall be fitted on the transformer; this shall be
connected through cables to isolation valve for transformer
conservator & fire detecting device and for further connection to
the control box.
xvii) Limit Switches
The Limit Switches shall be rotary lever operating head type and
shall be manufactured conforming to IS: 6875 –1973. Degree of
protection of the Limit Switches shall be IP-67.
xviii) Pipes
All piping shall be of MS and conform to the IS-1239 (Part 1): 2004:
heavy grade for pipe up to DN 150.
xix) Oil drain and Nitrogen injection openings with gate valves on
transformer tank at suitable locations.

xx) Brackets for heat sensing device on transformer top cover.
xxi) Cabling on transformer top cover for fire detectors to be connected
in parallel and inter cabling between signal box to control box and
control box to fire extinguishing cubicle.
xxii) Gate valves on oil drain pipe & Nitrogen injection pipe should be
able to withstand full vacuum. A non-return valve shall also be fitted
on Nitrogen injection pipe between transformers & gate valve.
xxiii) General Notes For All Valves
a. All the valves and utility piping shall be carefully selected
considering the application, working pressure and type of fluid
handled.
b. All valves shall be of reputed make and MOC duly approved by
the employer.
c. Additional manually operated gate valves shall be provided for
maintenance of each electrically/pneumatically operated valves.
d. All the valves shall be installed in a dusty, humid and tropical
atmosphere in an adverse industrial environment.
e. All valves shall be sealed with wooden plug/blanks and properly
packed before dispatch to avoid contamination on treated and
finished surfaces during transit.
f. Make of limit switch, electric actuator shall be as per approval of
Employer
g. All valves shall be provided with embossed nameplates of stainless
steel giving details of type, size, rating, tag no. etc.
h. Valve testing shall be as per DIN:3230, Pt.3. Accordingly leakage
rate shall be 60 drops per minute and duration of test shall be 2
minutes.
i. Bolting for companion flanges shall be as per IS : 1364 (Part-1) -
2002.
j. Flanges shall be raised faced type.
k. Valves shall be painted with two coats of primer and two coats of
finish paint. The dry film thickness shall not be less than 50 micron
per coat.
l. Marking shall be as per manufacturing standard.
xxiv) Erection, Testing and Commissioning of Pipelines

a. All pipelines shall be laid by the Bidder as per approved drawings
and instruction.
b. Before erection, pipes, valves, fittings etc. shall be thoroughly
cleaned and scales, rust, dirt, oil, grease etc. shall be completely
removed from inside as well as outside. The Bidder shall provide
all cleaning materials required for this purpose.
c. Contacting surfaces of flanges shall be strictly perpendicular to
pipes and shaped parts axes. Insertion of gaskets of unusual
thickness shall not be allowed.
d. In case of pipes running horizontally, all the flanges and flanged
fittings, etc. shall be installed in such a way that top bolt holes are
displaced by half pitch from the vertical axis.
e. Flanges shall be fabricated from steel plates of IS: 2062-1999 Gr.B
and shall be machined. Un machined flanges shall not be used.
f. While laying several pipelines parallel to each other, flanged joints
shall be staggered suitably.
g. Gasket materials and dimensions shall conform to the instructions
given in the relevant working / erection drawings, unless specified
otherwise.
h. The flanged joints shall be as near the supports as possible.
i. Slope of pipelines, drainage, vents, and arrangement of pipe-
connections for inlet and outlet of various services etc. shall be in
conformity with the drawings.
j. Valves with spindles, location of which is not provided in the
erection drawings shall be installed in such a way as to ensure easy
access from the ground level or nearest working platform.
k. In general pipework shall be routed overhead. All overhead pipe
work shall have a minimum clearance of 6 m over the ground
installation.
l. Inspection, testing of pipelines
a) Manufactured or details shall be presented for acceptance
in unpainted condition.
b) Testing of pipelines shall be carried out in presence of the
Employer.
c) Prior to testing, pipes shall be cleaned up by metal swab in
order to remove the grit, sand and other solids deposited

on the inner pipe surfaces followed by blowing air through
pipes.
xxv) Other Works
Other works not specified herein this document but required for
execution in the project shall be carried out as per provision of relevant
code of practices and / or prevalent practices as may be the case.
3.6.21 Power Factor Compensation
All necessary equipment/ items as per relevant standards for Power factor
improvement to attain unity power factor for Ladle furnace shall be
considered. Tenderer shall install requisite power factor improvement
equipment to attain a compensated power factor better than 0.95 and total
harmonics less than 5% on 33 kV bus when Ladle furnace is in operation.
The system shall be complete with capacitor bank, discharge device, surge
suppressor, series reactor, etc., for automatic correction of power factor.
3.6.22 6.6 kV busduct
3.6.22.1 The bus-ducts shall be metal enclosed type conforming to IS: 8084-1976,
Reaffirmed –1987. Inspection covers shall be provided at the end and at
points where different sections are joined together and also at points where
bus bars are supported on insulators. The bus-duct shall be complete with
all fittings and accessories as required including but not being limited to
straight run, bends, solid core porcelain bus-support insulators, E91-EWP
grade Aluminium channel bus bars, flexible expansion joints made up of
welded Aluminium laminations for straight run and terminations at
switchboard and transformer end, HTS (galvanized) bolts and nuts with
suitable plain and spring washers, silica-gel breathers (one in transformer
cell and one in switchgear room for each set), space heater with automatic
thermostat control and marshalling box for the same, rubber bellows, wall
frame assembly with epoxy seal off bushing, bus-duct supporting structures,
Aluminium earth busbar of E91-EWP grade, phase changeover box .
3.6.22.2 Gaskets shall be provided at the joints of bus-duct sections and at the
terminal flanges. The degree of protection for bus-duct shall be IP-55.
Flexible terminal connectors shall be provided for termination at transformer
and switchgear ends. Expansion type joints shall be provided in the bus-duct
sections to take care of variations in lengths due to variation in temperature.

3.6.22.3 Metallic barriers of non-magnetic material or insulating barrier shall be
provided between phases to eliminate chances of phase to phase short
circuits.
3.6.22.4 Continuous Aluminium earth bus of suitable rating shall be provided
throughout the length of the bus duct.
3.6.22.5 Bus-ducts shall be provided with complete supporting steel structure as
required.
3.6.22.6 Other technical features shall as given below:.
Type 3 phase, phase segregated and metal enclosed

type,
Highest system 7.2 kV
voltage
1minute Power 20 kV rms
Frequency with
-stand capacity
Impulse test 60 kV peak
Rated 1600 Amp

continuous
current for bus
duct
Fault with stand 40 kA RMS for 3 seconds
capacity
Maximum 850 C
permissible
Temp. Rise
including
ambient
3.6.23 6.6 kV Switchgear
3.6.23.1 Codes and Standards
IS:12729 General requirements for switchgear and control
gear for voltages
exceeding 1000 V.
IS:13118 General requirement for circuit breakers for voltages
above 1000
IS:3427 Metal-enclosed switchgear and control gear for
voltages above
IS:5082 Material for data for aluminium bus bars.
IS:9920 Switches and switch isolators for voltages above

IS:9921 AC disconnectors (isolators) and earthing switches
for voltage
above 1000 V.
IS:9046 AC tenderers of voltage above 1000 V upto and
including 1100 V.
IS:12661 HV motor starters.
IS:13703 Low voltage fuses.
IS:2705 Current transformers.
IS:3156 Voltage transformers.
IS:1248 Electrical indicating instruments.
IS:722 Integrating meters.
IS:3231 Electrical relays for power system protection.
IS:6875 Control switches and push buttons.
IS:694 PVC-insulated cables for working voltages voltage
upto and including 1100 V.
IS:2544 Porcelain post-insulators for systems with nominal
voltage greater than 1000 V.
IS:11353 Guide for uniform system of marking and

identification of conductors& apparatus terminals.
IS:5578 Guide for marking of insulated conductors.
IS:3618 Phosphate treatment of iron and steel for protection
against corrosion.
IS:6005 Code of practice of phosphating of iron and steel.
IS:5 Colours for ready mixed paints and enamels.
IEC Specification for high voltage alternating current
62271-100 circuit breaker
IEC Common specification for HV switchgear & control
62271-1 gear
IEC Specification for HV alternating current
62271-102 disconnectors and earthing devices
IEC Specification for AC metal enclosed switchgear and
62271-200 Control gear for rated voltage above 1kV and up to
and including 52kV.
3.6.23.2 General Requirement

 Circuit Breaker & Panels shall be supplied from the (same) unit /
factory, which will supply the Circuit breaker/ panel on which
successful type test was conducted.
 Manufacturer of the switchgear panel shall be same as the
manufacturer of Circuit Breaker.
 All circuit breakers in the switchboard shall be of same model & design,
except for the continuous current rating.

 The switchgear shall be of Indoor metal clad bolted/riveted design,
single bus bar, self-standing, dust proof construction, internal arc
tested for designed fault current, indoor cubicle type fitted with VCB
in fully truck mounted so that it directly rolls on to the floor when taken
outside without usage of any external breaker handling truck.
Switchgear should be tested as per IEC for highest system voltage for
all short circuit duties ( for 6.6kV it should be 7.2KV).
 VCB with stored energy spring mechanism with mechanical endurance
class M2 shall be considered.
 The circuit breakers shall be suitable for following duties:
 To withstand in rush magnetizing currents of transformers &
capacitor bank ‘ON’ and ‘OFF’ operation
 To withstand switching off over voltages caused due to break of
lightly loaded low capacity cage type induction motors. It shall also
withstand DOL starting of motor with large starting time, and
repeated starting like one hot start and two successive cold
starts.
 Transient surge produced by one CB due to severe chopping
during rapid interruptions of inductive current e.g. motors, shall be
within limits allowable for overhauled motors according to IEC34
part 1 otherwise suitable surge absorber shall be provided.
 All normal current rating of breaker shall be in panel rating and not
free air rating. Required normal current rating shall be achieved by
single breaker principle inside the cubicle without fan. The controls,
indicating lamps, relays and meters shall be mounted on breaker
cubicle itself.
 Operation counter, close/ open mechanical indications spring
charged/ discharged indication shall be provided.
 Closing coil shall be suitable to operate between 85% to 110% of
voltage and tripping coil between 70-110% of rated voltage. Spring
charging motor shall operate between 85-110% and motor shall be
of universal type and operate in 240V AC.
 Jumpers in the cubicle also shall be of same current rating as that
of the breaker. Connections from Bus to CB, CB to CT and CT to
cable connection shall be designed for continuous current rating
same as that of the Circuit breaker as specified in the SLD,
irrespective of the CT Ratio.
 Seal off bushing type fixed isolating contacts in power circuit of
panel shall be provided for preventing any arc transfer from
breaker compartment to bus bar and CT cum cable compartment
in the event of internal arc in breaker compartment. It shall be
preferable to have epoxy cast bar
primary or for lower ratio epoxy cast wound primary should be
used. There should not be any air gap between CT primary and
secondary to avoid failure on account of partial discharge.
 A manually operated device to enable charging of closing springs.
 Manual / Mechanical tripping arrangement for emergency tripping
of CBs.
 All circuit breaker truck shall have service, test and draw out
position. Test position shall engage only the auxiliary (control)
contacts to close the circuit breaker during testing. All the three
interrupters of individual phases shall be mounted on a common
phase segregated hydrophobic epoxy body mounted on a truck for
better insulation and avoidance of non-simultaneity of poles.
 Space heater shall be provided for each compartment of 6.6kV
board and same be operated by differential temperature controller
to maintain temperature of 5deg higher than ambient. Suitable
indication for healthiness of space heater shall be provided.
 Bus riser panel shall have removable link with necessary
interlocking arrangement adjacent to bus coupler panel
 Panel door switch shall be provided for illumination inside panel.
Panel illumination lamp with socket shall be provided in low
voltage compartment.
 Anti-pumping feature shall be provided.
 6.6kV switchboard live parts shall be insulated with heat shrinkable
sleeves including bus bars up to full potential of 7.2kV with special
sleeves (Raychem or equivalent) with integral epoxy cast shrouds
at joints to avoid any sharp edge causing corona discharge.
 The cubicle shall be provided with a position changing gear
arrangement in such a way that by engaging detachable device
from outside the front door, it shall be possible to move the breaker
truck and change position without opening the cubicle door.
Facilities for pad locking in each position shall be provided. The
cubicle shall be provided with necessary arrangement for smooth
rack in and rack out. Facility shall be provided for all operation with
door closed. Shutters shall be earthed metallic and shall have
provision for padlocking. Breaker shall also have facility for position
padlocking facility by locking mechanical push to trip and push to
close buttons to avoid any inadvertent movement of breaker from
test to service position when operator is working on cable side.

 Safety shutters complying with IEC 62271-200(2003) shall be
provided to cover up the fixed high voltage contacts on bus bar
and cable side when the truck is moved to ISOLATED position. The
shutters shall move automatically, through linkage with the
movement of the truck. Necessary tests shall be carried out inline
with IEC 62271-200(2003).
 The switchgear construction shall be such that the operating
personnel are not endangered by breaker operation and internal
explosions. Front portion of the panels shall be specially designed
to withstand the same. Party shall furnish necessary type test
certificate for internal arc withstand capability of panel.
 Pressure relief device shall be provided in each high voltage
compartment of a panel, so that in case of fault in a compartment,
the gases produced are safety vented out, thereby minimizing the
possibility of its spreading to other compartments and panels. The
pressure relief device shall not however reduce the degree of
protection of panels under normal working conditions. 6.6kV
panels shall be internal arc tested as per design fault current
defined in TS for 1 sec Duration. Procedure of arc test shall be as
per IEC.
 Each cubicle shall have painted mimic diagram
 Each cubicle shall be of compartmentalized construction as per
“Loss of Service continuity” and “Partition Metallic” criteria of latest
edition of IEC 62271-200(2003) and shall have separate
compartments for bus bars, CTs and outgoing cables, metering &
protection devices.
 All circuit breaker trucks of same rating shall be identical in all
respects (except metering and protective devices) and shall be
interchangeable with similar breaker panel.
 Continuous earth bus (minimum 50x6 mm copper cross section)
shall be provided throughout the board.
 The position of various control switches, push buttons, levers etc
requiring manual operation shall be at a height not less than
450mm and shall not exceed 1850mm from the finished floor level.
 In the design of the switchgear the following positive interlocking
shall be provided:
i) It shall not be possible to move the truck/ cassette from the
isolated to the Service Position unless low voltage plug and
socket connections have been made.

ii) It shall not be possible to disconnect the low voltage plug
and socket as long as the circuit breaker truck/cassette is in
service position.
iii) It shall not be possible to withdraw the truck/cassette
without disconnecting the low voltage plug and socket.
iv) It shall not be possible to move the truck/ cassette from the
service to the isolated position or vice versa with the circuit
breaker in the ÒN' position.
v) It shall not be possible to switch on the circuit breaker when
the truck is in between the isolated and the service
positions (except in test position).
vi) It shall be possible to switch on the earthing switch only
when the truck is in the isolated position, wherever an
integral earth switch is provided.
vii) It shall not be possible to open the circuit breaker enclosure
when the breaker is ON or to have access to any part of the
draw out assembly which is live when the circuit breaker is
in the service position.
viii) Shutters shall be lockable in closed position and earthed
metallic.
ix) It shall not be possible to rack the CB in to service position
unless the panel door is closed.
x) After circuit breaker has been inserted in service position, it
shall not be possible to open the panel door.
xi) Where local/remote selector switches are called for , it shall
be ensured that:
- The breaker can be closed locally only if the breaker
truck is in the test position and the local/remote selector
switch is in local position.
- The breaker can be operated from remote (from process
end) only when the breaker truck is in service position
and the local/remote selector switch is in remote
position.
- The breaker can be tripped locally/ from remote
regardless of the position of the breaker in local/
remote selection.

The operating mechanism parts shall be designed to give longer life,
trouble free operation and require minimum maintenance.

3.6.23.4 Insulation Levels
Nominal voltage (kV) 6.6
Highest system voltage (kV) 7.2
One minute power frequency 28

withstand voltage (kV)
1.2/50 micro sec impulse withstand 75

voltage (kVp)
Insulation levels corresponding to the rated voltage shall be as above.
3.6.23.5 Short Circuit Strength

Rated short time withstand current shall not be less than the system short
circuit level specified for the stipulated duration.
Rated peak withstand current shall not be less than 2.5 times the system
short circuit level.
3.6.23.6 Auxiliary Buses for Control & Protection

 Control supply buses for AC and DC
 Signalling supply
 PT secondary voltage
 Spare buses - 2 nos.
 The control shall be loop in/loop out type.
3.6.23.7 Provision of Surge Suppressor

In case of breakers like VCB that give rise to overvoltage surges due to
current chopping phenomenon, surge suppressors to be provided at the
load side terminals of the breakers to limit the switching surges to value
limited for as per IEC. Surge suppressor shall be metal oxide gapless type.
(ZnO, 9 KV, 10 KA, class-II).
3.6.23.8 Annunciation Schemes

 Flag or LED indications for all faults for which individual protective
relays have been specified
 Warning signalling (as applicable) on individual panels
 All transformer warning / signalling conditions (group signal from
corresponding transformer control panel / substation
 Loss of trip circuit supply
 Earth fault
 Control supply failure
 PT fuse failure / MCB tripping
 Emergency signalling for tripping of HT breakers on fault
 One common signal for warning and one signal for emergency from
each panel to be wired to a common annunciation panel of the
switchboard, where specified.
 Annunciators for warning and emergency signalling condition on
individual panels of solid state facia window type. Common audio
signalling with Accept, Reset, and Test push buttons for the
switchboard where common annunciation panel is not specified.
Audio signalling to have distinct tones for warning and emergency.
3.6.23.9 Bus Bar and Connections

 Power buses shall be of EC grade aluminium alloy equivalent to E91E
WP as per IS-5082-1981 or Copper. Combination of copper and
aluminium bus bar in one switchboard is not acceptable. Rectangular
/ Round or any type tested special shape busbar are acceptable .The
busbars shall be tinned /silver plated at joints.
 Control and Auxiliary buses of electrolytic grade copper and shall be
loop in loop out type.
 In case of 6.6 kV switchboard, the busbars shall be insulated with
insulating sleeves of full potential and supported by hydrophobic
cycloalaphatic resin insulator or wet process porcelain insulators.
Even that part of isolating contacts which projects into the bus
compartments shall be covered with an insulating sleeve. All fixed
and isolating contacts in panel shall be through seal off bushing and
termination process
 The main busbar shall be loaded up to 50% of its rating Anti-
condensation measures shall be provided in each compartment
including main busbar chamber by tubular high grade heaters.
There shall be no condensation in the bus
bar chamber irrespective of the loading of bus bar. Space heaters

shall be provided in bus bar chamber to ensure that there is no
condensation in the busbar chamber irrespective of the loading
condition.
3.6.23.10 The vertical bus rating
For incomer Not less than that of horizontal bus
Outgoing Not less than that of the outgoing breaker, irrespective

of relay setting
 Final operating temperature under continuous operation in enclosure

limited to 90 degree C by thermometer method. For 6.6kV switchboard,
End temperature over a design ambient of 50 deg. C shall be as per IEC.
Both horizontal and vertical bus bars to be designed and supported to
withstand the thermal and dynamic stress corresponding to rated short
time and peak withstand current specified.
 Cross-section of main horizontal bus to be uniform throughout the
switchboard and continuous in one transport unit
 Bus bar arrangement as per IS:375
 Phase identification by colour in each panel
 Bus bars (horizontal as well as vertical) shall be provided with heat
shrinkable, non-tracking, low absorption type sleeving conforming to
international standards to the full potential.
 Bus bar joints and tap off connections of bolted type with zinc
dichromate high tensile steel bolts, nuts and spring washers, fishplates
with accessories at the end of a transport unit for site connections.
 All support insulators shall be of porcelain or hydrophobic material
(cycloalaphetic type) having high impact and dielectric strength with an
anti tracking contour.
3.6.23.11 Internal Control Wiring

 Control wiring shall be carried out by 1100V grade PVC insulated;
single core multi stranded copper wire of minimum cross section 2.5
sq. mm. Similarly for CT circuits minimum cross section of 2.5 sq. mm
shall be used.
 Flexible wire of 2.5sq.mm shall be used from CT chamber to relay
chamber and shall have protection against heat & mechanical

damage due to flash over. Use of heatproof sleeves and rigid conduit
shall be made to run the control wires from back to front.
 Wiring and terminal arrangement for all panels shall be carried out as
per approved scheme
 Flexible wires protected against mechanical damage for wiring to door
mounted devices.
 Wires identified at each end in accordance with schematic diagrams
by interlocked type ferrules. These shall be firmly located so that these
do not move.
 Colour code for control wiring
Black Earth wire- Green
DC-Light gray Trip circuit-Red
 All spare contacts wherever available shall be wired and brought to

the terminal block.
 Interconnection between panels of adjacent shipping sections to be
brought out to a separate terminal block.
 No bunch shall contain more than 12 wires
 Wiring shall not be joined or tied between the terminal points
 Control wires shall be run in earthed metallic flexible conduits when
laid in HV bus chamber.
 Not more than two connections shall be provided on any one
terminal
 Heat proof arrangement for the passage of wiring in HT panel
 All telemetering signals shall be wired to terminal strips
3.6.23.12 External Terminations

1. Control Terminations
 1100V grade multi-way open type terminal blocks of non-tracking
moulded plastic complete with insulated barriers, stud type terminals,
washers, nuts and lock nuts and identification strips.
 All terminals going out of the switch board shall be brought to a
separate terminal board marked "External Termination". These will
be easily accessible.

 External terminal block shall be provided in the relay chamber with
proper clamping facilities for cable dressing
 Control terminals shall be suitable to receive two numbers 2.5 sq. mm
copper conductor
 20% spare terminals in each control terminal block. Terminal blocks in
separate groups shall be provided for DCS, remote control
panels, transformer marshalling boxes, local push button stations, etc.
 Gland plate for control cables shall be of adequate size to
accommodate and to facilitate glanding of all the control cables
coming from external equipment.
 Terminal blocks shall be placed separately for internal looping and
external looping
2. Power Terminations
 Suitable for accepting cable/bus trunking as specified.

 Sufficient space and support arrangement inside each panel to
accommodate HT cable termination kits and sealing kits suitable for
the size and number of XLPE cables. Minimum head room of cable
chamber of cubicle for 7.2KV shall be 600mm without usage of any
cable pan. Gland plate in cable chamber shall have built in adjustable
cable holding clamp.
 Dummy panels to be provided adjacent to the switch panel, where the
required number cable terminations cannot be accommodated in the
cabling chamber of the main panel. Provision of rear extension /
dummy panel shall be decided based on the optimization of building
layout during DE.
 Where more than one cable has to be terminated per unit, the
arrangement shall permit connection and disconnection of cables
separately without disturbing other cables
 Where specified the following cable termination accessories, suitable
for the type, size and number of cables to be terminated, to be
supplied with switchboard.
 Cable sockets with all HT terminals (sockets set at such an angle that
cable tails can be brought up for termination with minimum bending
and setting)
 HT cable termination and sealing kits

 Power cable termination facilities shall be designed to facilitate
easy approach to CTs.
 Double compression type brass cable glands and crimping type
tinned heavy duty copper lugs for HT, LT power and control cables
3.6.23.13 Protection and Measurement

1. Electrical Protection and Metering
Selection of protective scheme will be based mainly on reliability, sensitivity,
selectivity. All main protections shall be fast acting type in order to clear the
faulty system from the healthy system in earliest possible time to minimise
damage to equipment and ensure continuity of power supply. The details
of major protections and metering for 6.6kV system are elaborated below.
(Indicative only)
Sl.No. Feeder Designation Protection and Metering

6.6kV Protection 6.6kV Metering
1. Bus Coupler Over-Current and Multifunction
Earth fault meter.
(50,51,51N,50N)
Check Sync Relay Ammeter with

(25) selector switch
Auto changeover relay

2. 6.6kV Incomer Check Sync Relay Multifunction meter
from 33/6.9kV (25)
Trafo Ammeter with
Auto changeover selector Switch
relay Voltmeter with
voltmeter selector
Over-Current and switch
Earth fault
(50,51,51N,50N)
U/O voltage
protection
(27,59) with timer (2)

Fuse failure
protection of
line PT (97) (for
alarm)
Standby earth fault

relay (51G)
Transformer
Differential
protection relay (87T)
Restricted earth fault

relay (64R)
3. 6.6kV Incomer Check Sync Relay Multifunction meter
(25)
Ammeter with
Auto changeover selector
relay switch
Over-Current and Voltmeter with

Earth fault voltmeter selector
(50,51,51N,50N) switch
U/O voltage
protection (27,59)
with timer (2)
Fuse failure
protection of line PT
(97) (for alarm)
4. Trafo Feeder Over-Current and Multifunction meter
Earth fault Ammeter with
(50,51,51N,50N) selector switch
5. Motor feeder Over-Current and Multifunction
Earth fault meter.
(50,51,51N,50N)
Ammeter with
Motor protection selector switch
relay (99) with U/V

feature. Transducer with
dual (4-20mA)
All the motor feeders ouput for Remote
shall have no of start Ammeter
protection, starting
current recording One 1:1 interposing
and other standard CT shall be
motor protection provided in B-
features phase for remote
ammeter.
6. Capacitor Bank Over-Current and Multifunction
Feeder Earth meter.
fault (50,51,51N,50N)
Neutral displacement Ammeter with
protection relay selector switch
Under voltage with

timer
Over voltage
protection
7. Outgoing 6.6kV Over-Current and Multifunction meter
Feeder Earth fault
(50,51,51N,50N) Ammeter with
selector switch
8. Bus PT Relays for use in Voltmeter with
interlock of other selector switch
feeders, incomers
& buscouplers) Frequency meter
Under voltage with

timer (27+2)
Over voltage
protection (59)
Fuse failure
protection (97)
(for alarm)

Neutral displacement
protection relay (60)
Note:
i. Major primary relays shall be microprocessor based numerical
and communicable type(IEC 61850 compliant). All multifunction
transducer shall be communicable on MODBUS protocol. All auxillary
and multiplier relays are of electromechanical type
ii. Protection scheme specified above is indicative. Final protection
scheme shall be as per approved drawing during detail engineering (
after placement of order).
iii. The multifunction meter shall have the following minimum features:
 Ammeter
 Voltmeter
 Frequency meter
 Power Factor meter
 kW, kWH, kVA & kVAR meter
 30 min or 15min maximum demand meter
2. Protective scheme requirement

 All the main protective relays shall be microprocessor based
numerical/ communicable type(IEC 61850 compliant)
 Auxiliary relays, timers switches etc. required to make the scheme
complete shall be considered as part of the scope of work and shall
be of electro mechanical type.
 All CT-PT wires shall be brought to test terminal blocks before
connecting to circuits
 The circuits of various protections (coming from other panels) shall
be connected to master trip relays through aux. relays (flag
indicated).
 VAA type (or equivalent) aux. relays shall be provided for each
transformer fault. Connection of the relay shall be through links to
facilitate maintenance

 Relay ranges and scale of meters shall be finalized during drawing
approval stage.
 Contact arrangement, number of poles/ways in control/selector
switches shall be as per the requirement/approved scheme
 For control supply distribution, panel to panel separate set of
terminal blocks shall be provided at top of the panel. All
items/accessories required for above in each panel and in
incoming panels shall be provided by the supplier
 All relays shall be hand/self-reset type with flag indication. NO/NC
contacts for relays shall be as per the requirement of approved
protection, annunciation & interlock schemes. Wherever required
supplier shall provide aux. relays for contact multiplication
 Centre line of switches, lamps, meters shall be matched to give
uniform appearance. and mounting height of switches shall be
between 1.1 to 1.8 m
 Line PT’s shall be provided on all incomers with suitable 0.11 kV
secondary two winding transformer. For 6.6kV Line PT shall be part
of incomer panel.
For Bus PT separate panel shall be provided.
 Each feeder shall have master trip relay and close/trip coil
supervision relay
 Aux. Relays to be considered as per scheme requirement
 Separate trip circuit supervision relay shall be provided even if
functionality is available in main protection relay
 Relays shall be mounted on the 6.6kV switchboard itself unless
otherwise specified
 All protection trip from 415V switchboard to 6.6kV switchboard
and from 6.6kV switchboard to upstream 33kV switchboard of
various substations shall be hardware wired
 Local /Remote selector switches, Trip selector switches , close
permissive switches, TNC Switches, Synchro Switches ,
Auto/Manual selector switches , Emergency pushbuttons etc shall
be provided in the panels as required to fulfil the control logics
 Control logic shall be finalized during Detail Engineering

3. Current Transformer (Panel Mounted)
 Separate sets of current transformers shall be used for differential
protection and separate cores shall be used for, protection and
measurement purposes. CT’s on incomer side shall be mounted in
the main bus before incomer breaker and CT’s for outgoing feeder
shall be put after the breaker
 Short time ratings and insulation level of CT’s shall be similar to
rating of associated breaker. However, short time rating of lower
ratio CTs without primary current below 400A shall be rated for
equivalent short circuit current of breaker for 1 second only
 CT ratios specified are provisional. Where outputs and accuracy are
not specified, these shall be such as may be required by the circuits
in which they are used. Generally the protection CT’s and metering
CT’s shall have 5P20 and 0.5 class respectively
 All CTs depending upon primary current rating shall be
hydrophobic epoxy cast bar or wound primary. There should not
be any air gap between primary and secondary of CT to avoid
failure due to partial discharge between primary and secondary
 CT’s shall have shorting link on secondary side to facilitate
insertion of meters on secondary side without opening CT circuits
 CT Ratio shall be as finalised during engineering stage as per load
requirement.
 All CT shall be single phase design.
4. Potential Transformers
 Three no single phase PT shall be provided for each Line PT/ Bus
PT
 Bus potential transformer shall be provided in separate cubicle
 High voltage side of PTs shall have fuses and MCB’s on low
voltage side
 Insulation levels shall be similar to rating of associated board
 Accuracy class 1.0 shall be used
 VA burden shall be selected based on meters and relays
connected with the PT.
 PTs shall be dry type hydrophobic resin cast or polycrete type

5. Relays
 All protective relays shall be Microprocessor based numerical
and communicable type, confirming to IEC-61850 standards
 All relays shall be flush mounted in dust proof cases and shall be
mounted on front side of cubicle.
 Major relays are as indicated in the specification
 All numerical relays shall have sufficient no of independent DI and
DO to communicate all digital status of the panel to the SCADA.
Actual DI/DO requirement shall be finalized during Detail
Engineering as per scheme requirement
 Numerical Relays for a feeder type shall be of same model across
the switchboard and shall be interchangeable ( without disturbing
the external connection)
 Master trip relay shall be hand reset and shall have minimum 3
NO and 3 NC contacts in addition to those required by the
protection/control scheme. All timers and protection relays shall
have flag indicators
 Relay ranges, exact type , number of aux. relays , timers shall be
finalized during detail engineering
 All instantaneous current protection relays shall be of 3 pole type
 In HT switchboard two nos. bus PT’s, with U/V relays neutral
displacement relays , timer etc. to be provided
 ICT’s wherever considered necessary shall be included in the scope
 Numerical relays of the switchboard shall be connected to the
plant SCADA of the purchaser through new RTU under this project.
All the relays shall communicate with the SCADA system on IEC
61850 protocol. Supply and installation of necessary IEC 61850
compatible network switches for connecting the numerical relays
shall be included in the scope. The quantity and model no of the
switches shall be finalized during detail engineering. The switch(es)
shall be preferably mounted in the Bus-link panel.
6. Indicating Instruments

 All indicating instruments shall conform to IS :1248-
1983 and IS 2419-1979.
 Shall be capable of withstanding system fault current taking
account CT saturation.
 Shall be back connected
 Shall be located in the upper part of the panel
 Shall have 144 sq. mm square flush case, non-reflecting type,
clearly divided and indelibly marked scales, sharply out lined
pointers and zero adjusting device.
 The minimum scale reading shall not be more than 10%. Maximum
reading shall be 15% full load for transformers panels
 Each voltmeter shall be calibrated with coil hot. The scale shall be
open between 60% to 125% of normal volts and shall be
suppressed below 60% of normal volts
 Class of accuracy shall be 1.0 or better.
 The full load reading of each ammeter shall occur at the most pen
part of the scale the minimum scale reading shall not be more than
10%. Maximum reading shall be 150% full load for transformer
panels and 600% full load for motor panels.
7. Annunciation
 Shall be of static type
 Hooter and bell for trip and alarm indication respectively
 Shall be suitable to work on DC supply as specified
 Test, accept and reset facilities (with push button) shall be
provided on each panel
 Suitable audio - visual indication shall be provided on DC failure.
Audio alarm with reset facility shall be provided. Visual indication
shall be panel- wise
 Spare annunciation points shall be wired upto terminal blocks. 20%
spare facia shall be provided
 Each point shall have two bunch LEDs in parallel
 All trip points facia shall have red colour and non-trip points
white colour. The cover plate of facia shall be flush with panel
 Shall be capable to receive simultaneous signals
 Shall be capable to receive signal during testing mode
 Scope of supply includes all interconnections, bell hooter, buzzer,
alarm facility, push button etc. required to achieve complete
function of above scheme
 Sequence shall be as follows
VISUAL AUDIO
ON OCCURRING OF FLASHING ON
FAULT
ON ACCEPTING STEADY ON OFF
ON RESET (Fault OFF OFF

Cleared)
ON RESET (Fault STEADY ON OFF
Persists)
 Annunciation fascia (minimum 12 Window) shall be mounted on

each switchgear panel. A common alarm & annunciation facilities
for control AC and control DC system with necessary flashers,
hooters, bells as required shall be provided in the switchboard.
However details shall be finalized during drawing approval stage.
 Bus coupler, Incomer, tie and all outgoing feeders shall have 12
facia (for each feeder to indicate tripping + 20 % spare).
 All auxiliary relays of transformer feeders shall have 4 NO contacts
and all master trip relays shall have two NO contact for remote/
DCS indication for repeat annunciation in addition to contacts
required for scheme under scope of works
 Warning and emergency points shall be as per the list approved
during detail engineering stage. In general all tripping points and
alarm points shall be annunciated. (Transformer alarm and tripping
point shall be provided with auxiliary relays to have duplicate
annunciation at remote panel/PLC/DCS, etc.).
 One common point shall be provided to indicate operation of
annunciation system of the complete board (in case of any trouble
in the board in tie feeder, bus coupler, incomer, etc.)
 Detailed common annunciation scheme shall be decided during
DE.
8. Control Supply
 Control supply buses shall run throughout the switchgear

 Two DC feeders and two AC feeders shall be taken in each board
controlled by MCB’s with desired interloking philosophy between
two feeders
 In each panel for controlling of its DC supply MCB (DC duty) shall
be used. DC auto changeover and manual changeover facility shall
be provided. Failure of each DC supply shall be monitored in the
switchboard as well as at remote.
 240V AC supply shall be taken from a station Aux. Board
 Each section shall have separate feed with changeover scheme
 Each panel shall have one MCB for controlling its AC supply
 Sub circuits shall be protected with HRC fuses in each panel for
indication lamps, closing and tripping circuits
3.6.23.14 Earthing Devices

 Integral earthing switch shall be provided to facilitate earthing of
all outgoing feeder circuit. For 6.6kV switchgear Bus bar earthing
shall be through earthing truck. For each bus section,
one no. bus earthing truck shall be provided. Feeder
earthing shall be through integral earth switch only.
 Interlock provision shall be there so that incomer cannot be
closed if bus earthing device is connected
 Rating of earthing device shall be in line with associated board
3.6.23.15 Control & Indication

1. Indicating Lamps
 LED cluster type with OVGP (over voltage glow protection)
 LEDs used shall be of the colour of the lamp
Colour shall be as follows:
TYPE OF LAMP LED COLOUR

ON RED
OFF GREEN
AUTOTRIP AMBER
TRIP CKT. HEALTHY WHITE
SPRING CHARGED BLUE

2. Control and Selector Switches
 Control switches for circuit breaker ON/OFF control - 3 position
spring return to neutral with lost motion device and pistol grip
handle
 Other control and selector switches - stay put type with wing type
knobs. Ammeter selector switches, make before break
 Voltmeter selector switches
 Colour : Black
 Contact Rating:
Continuous 10 amps
AC 11 4 amps, 240V
DC 11 0.5A, 220V, L/R - 40

ms
3. Push Buttons
Contact Rating:
Continuous 10 amps
AC 11 4 amps, 240V
DC 11 0.5A, 220V, L/R - 40

ms
Colour:
ACCEPT BLUE
RESET BLACK
TEST YELLOW
3.6.23.16 Protective Earthing

 Continuous earth bus of minimum size 50x6 mm of copper, designed
to carry the peak short circuit and short time fault current as specified
 Provided at the bottom extending throughout the length of the
board, bolted/brazed to the frame work of each panel with an

earthing terminal at each end for terminal at each end for
terminating external earth conductor
 Vertical earth bus for earthling individual functional units
 All non-current carrying metal work (including metallic cases of
instruments and other panel mounted components effectively) shall be
effectively bonded to the earth bus
 Hinged doors earthed through flexible earthing braid
 Looping of earth connection resulting in loss of earth connection to
other devices when the loop is broken not permitted
 Withdrawable units provided with self-aligning, spring loaded, silver
plated copper scrapping earth contacts of make before/break after
type, ensuring earth continuity from service to the test position
3.6.23.17 Test and Maintenance Equipment
Each board shall be supplied with following items;
i) 1 set of test plugs to test CB in withdraw able condition
ii) Any other special purpose tools for maintenance
3.6.23.18 Constructional Features
1. Mechanical Design
 Sheet steel clad, compartmentalized, floor mounted, free standing
design. Minimum sheet steel thickness: doors & covers - 2 mm cold
rolled, other load bearing members - 2.5 mm.
 Doors shall be provided with lock and key arrangement

 Degree of protection shall be IP4X or better
 Assembled on base channel (If required as per manufacturer’s
standard)
of structural steel of minimum height 50mm. painted black
 Earthed metallic barriers between compartments and between
vertical sections
 Seal off bushings wherever bus bars pass through metallic
partition
 Zinc bi-chromated and passivated hardwares
 Transport unit not larger than 3.2 m
 Removable lifting arrangement for each transport unit

 Lockable front doors with concealed hinges with the door not
forming part of the draw-out truck
 Panels shall be extensible on both sides
 Removable sheet steel covers shall be provided at rear.- with hinged
door over bolted wire-mesh or bolted cover with transparent
window provided the design satisfies the conditions laid by IAC,
FLR-A
 Explosion vent for each chamber
 Control cables entry shall be from front side
 CTs shall be located in such a way that that they are easily accessible
 Panel door switch shall be provided for illumination inside the panel
 All live parts shall be insulated by taping or encapsulation supported
by suitably designed hydrophobic cast resin or wet porcelain
insulators. Proper insulation of bus bars, upper and lower contacts
of breakers and sealing of opening of bushings shall be provided to
eliminate accidental contacts.
 Screw wire mesh in the power cable chamber of all feeders is to be
provided
2. Labels
 Switchboard designation nameplate at the centre of the board
with letters not less than 25 mm high
 Panel designation number on each panel, both in front and rear
 “DANGER- DO NOT OPEN COVER WHEN THE PANEL IS
LIVE” inscription on rear of the panel
 Inscription plate for each feeder on the door
 Door front mounted devices to have labels directly below them
 Labels made on non-rusting metal or 3 ply lamicoid with engraved
inscription of white letters (minimum 3 mm high) on black
background. Label designation and size of lettering subject to
approval
 Bus side and cable side shutters labelled for identification

3. Surface Treatment
All metal parts of the panel to undergo surface treatment that includes
de-rusting, cleaning, chemically degreasing, pickling in acid, cold
rinsing, phosphating and passivating followed by spraying with two
coats of zinc oxide primer and baking in oven. For CRCA seats pre-
treatment with in-house nine tank process followed by single colour
RAL 7032 inside outside with epoxy based powder by electrostatic
spray painting.
Shade of paint
Panel interior Off white shade
Exterior RAL 7032
Control relay and metering instruments shall be mounted in the 6.6kV

switchboard.
3.6.23.19 Technical particulars and design parameters:
Sl. Particulars 6.6kV switchboard Details

1. Type VCB with stored spring mechanism
2. Service Indoor
3. Enclosure IP4X or better
4. Nominal System Voltage 6.6 kV
5. Highest System Voltage 7.2 kV
6. No. of phases and 3ph. 50 Hz
frequency
7. Busbar material Aluminium / Copper
8. Bus Color code RYB
9. System Earthing Non-Effectively Earthed
10. Circuit Breaker Rating
A) Continuous Current As per SLD
Rating at 50°C Design
Temperature
B) Short Circuit Rating 40 KA for 3 Sec
C) Rated making Current 100 KAp(6.6kV)
11. Internal arc withstand As per IEC 62271-200(2003) for full
capability short circuit current

Sl. Particulars 6.6kV switchboard Details
12. Circuit breaker Mechanical M2 Class
Endurance Class
13. Circuit breaker Electrical E2 Class
Class
14. Circuit breaker class for C2 Class
Capacitive breaking
current
15. Operating Duty O-0.3s-CO-3 min-CO
16. Bus bar Rating As per SLD
17. Power Frequency 28KV
Withstand voltage
18. Impulse withstand 75 kV
voltage(1.2/50 micro sec)
19. Control Voltage 220V DC
20. Spring charge motor 240 V AC
voltage
21. Aux. Contacts (Minimum) 6NO + 6NC
22. Termination
23. Incomers HT Bus duct
24. Outgoings XLPE Al Cables
25. Joints And Isolating Tinned/Silver
contacts
3.6.23.20 Interlocking Scheme

 Auto changeover from one incomer to another after tripping of first
incomer
 If there is a prolonged under voltage on any one of the bus
sections, the respective incoming, breaker shall trip and the bus
coupler breaker shall close provided voltage is available on the
other bus section. Total changeover time shall not exceed 1.5
seconds. This auto changeover shall be blocked if the incoming
breaker had tripped either on a bus fault or in
manual mode through selector switch. Changeover back to the
normal source of supply shall be affected manually.
 The automatic transfer circuit shall be controlled by an auto-
manual change-over switch. The bus section breaker shall be

allowed to close only if there is no earth fault or O/C fault on
affected section of the switchboard bus-bars.
AUTO CHANGE-OVER Scheme shall be finalized during
detail engineering.
3.6.23.21 Additional Notes

 CT ratio shall be finalised during detail engineering stage based on
load requirement and breaker ratings shall be as per SLD enclosed
with TS.
 All relays and MFM shall be microprocessor based numerical and
communicable type and shall be compatible for hooking up with
SCADA
 Dummy/ rear extension panels to be provided, where the required
number cable terminations cannot be accommodated in the cabling
chamber of the main panel
 Bus link panel shall be provided in each switch board before
sectionliser in stead of dummy panel
3.6.23.22 SCADA Connectivity:

 The existing switchboards are connected to the SCADA system of the
purchaser. Analogue Transducers are there for measurement of
parameters like Current, Voltage , power, energy, frequency etc.
Outputs of these transducers are connected to the AI input channel
of the station RTU through shielded twisted pair cables. Digital
signals ( CB ON/OFF, TEST/SERVICE position, SP CHARGE etc. ) are
directly wired up to the DI channels of the station RTU.
 The new switch board shall have IEC 61850 compliant numerical
relays . All the digital inputs of the panel shall be directly wired up to
the relay. Relay in turn shall communicate these data to the RTU
through the network switch. A suitable network switch with sufficient
no of copper ports to connect each relay in the switchboard shall be
provided. Each switch shall have minimum
2 nos. FO ports for communication to other switches in the RTU
ring through SMFO cable. The network switch and the LIU for FO
cable shall be mounted preferably in the bus link panel.
 Make and Model of the network switch shall be finalized during Detail
Engineering

 Connection of all numerical relays to the switch through CAT 5e/6
cable with RJ45 terminations at both ends shall be done. All the
inter-panel networking cabling shall be pre-wired and shall run on
separate cable troughs inside the panels. Sufficient openings
in the inter-panel barrier ( both at top and at bottom) shall be kept
for accommodating the cables.
 Supply and installation of SMFO cable link between the Switch to the
RTU installed in the same switchgear room shall be in the scope of
the bidder
 Multifunction Meters shall be connected in daisy-chain connection
for communication over MODBUS protocol. Dedicated terminals shall
be provided in each panel for the same. Inter-connection of the MFM
shall be pre-wired in the factory. Connection of the MFM ring to the
RTU shall also be done by the bidder
 Apart from the above some digital signals of the switchboard ( e.g.
DC fail/ AC fail etc. Shall be directly wired up to the DI channels of
RTU through shielded twisted pair cables.
 Existing data/ signal cables can be re-used by the bidder to the extent
possible
 The bidder shall generate and provide the purchaser necessary ICD
files of the numerical relays for establishing communication with
purchaser’s SCADA. The relay manufacturer shall extend all
information/ co-operation to the SCADA engineer of purchaser for
integration of data of the new switchboard with existing SCADA of
purchaser.
3.6.23.23 Other Accessories

Supply of each of the 6.6kV Switchgear shall necessarily include the
following accessories.
a) - Earthing truck suitable for earthing For each bus section,

the bus side one no. bus
earthing truck shall
(outgoing side earthing shall be
be provided
through integral earthing switch)
b) - Device for hand charging of 1 no.
breakers
c) Breaker rack in / rack out device 1 no.
d) High voltage tester 1 no
e) Wheel mounted trolley for attending 1 no
relays and meters
f) Special tools & tackles 1 Set
3.6.23.24 The above mentioned technical parameters shall be finalized during

engineering stage based on IS/IEC guidelines, availability and
manufacturing standard of the makes given in TS
3.6.24 Battery Bank for Substation

Type Plante Lead Acid type
Output Voltage 220 V DC for substation
Capacity Minimum 200 AH for 10 hours
discharge capacity
3.6.24.2 Batteries shall be provided with metallic stands. The battery shall be
complete with all the accessories as detailed below. The battery shall be
generally conforming to IS:1651-1991/IEC:623.
3.6.24.3 The accessories to be supplied shall include the following in addition to all
standard accessories. 10% of the no. of cells in each battery set as end cells
along with end cell bypassing diode. An appropriate circuit for end cell
discharge shall also be provided.
3.6.25 Battery Charger
Supply voltage 415+10%, 3 phase

Frequency 50+6% Hz
Charge characteristic Constant voltage/ constant current
Degree of Protection IP-52
Output supply Output supply voltage shall be suitable for
charging the 220V battery bank
3.6.25.2 The battery charger panel shall be sheet steel fabricated, minimum 2 mm
thick, dust and vermin proof, free floor mounting, having ventilating louvers,
fluorescent lamp and lockable hinged door. The charger panel shall be
placed on an insulated base. A removable gland plate shall be provided at
the bottom of the panel for cable entry. The charger panel

shall have removable side plates with openings on front and back and
enough space for facility of maintenance. The charger shall have hinged
doors for easy maintainability.
3.6.25.3 The charger panel shall consist of a float cum boost circuit capable of
charging the battery in float or boost mode. Charger should be full wave
half controlled type . It should be a dual battery charger.
3.6.25.4 The cells of the battery bank shall be suitably arranged on metal shelves
which should be painted with anticorrosive paint and shall be located in a
forced ventilated room.
3.6.25.5 Input Power Supply

 The mains supply for the chargers shall be 3 phase, 415 V. This input
shall be received necessarily prior to an isolating transformer for
each charger. The AC input to the rectifier circuit shall be through a
saturable core reactor and the output shall be filtered in a filter
circuit to minimise the ripple content (Maximum ripple content shall
be within 2% of RMS value).
3.6.25.6 Output Supply
 Output supply voltage shall be suitable, for charging the battery. A
permanent load for tripping, closing, signalling etc. adequate for the
switch boards, circuit breakers of the yard etc. shall be supplied by
the chargers in addition to the float/boost charging current.
3.6.25.7 The battery bank and battery charger shall be operated in parallel, both
being connected to a common bus.
3.6.26 DC Distribution Board
Purpose : DC power needs of all the protection, control and
annunciation of the system as well as for emergency
lighting of the Substation
Type : IP 54, floor mounted, compartmentalized type.
Incomer : MCCB( 50 kA )
Outgoing feeder : MCB suitable for DC duty.
Enclosure : shall be made of 2 mm thick sheet steel.
3.6.27 415 V ACDB

Purpose : To cater to all LT auxiliaries and control
requirement for different switchgears,

transformers at Substation.
Type : Sheet steel clad (2 mm) thick, fully
compartmentalized, floor mounted, indoor type.
Enclosure : IP 54
Busbars : Shall be 3 ph, 4 wire, electrolytic grade
Aluminium.
Incomer & Bus : Non drawout type with MCCB ( 50 kA )
coupler
Outgoing feeders : MCCB of suitable rating.
3.6.28 6.6 kV Isolator

3.6.28.1 Standards
The isolators shall comply with the following standard specifications and
publications with latest revisions ;
IS:9920(pt.1-2002), (pt.2-2001),(pt.3-1988), (pt.4- H T Isolators

1985)
3.6.28.2 All isolators shall also conform to the latest Indian Electricity Rules as regards
safety, earthing and other essential provisions specified therein for
installation and operation.
3.6.28.3 Design Criteria

The following system voltage and power supply conditions shall be
applicable:
 6.6 kV + 10% 3 phase 50 HZ + 5% AC, with 40kA for 3 sec s.c. withstand
capacity.
 One minute Power frequency withstand Voltage (kV): 20 kV (rms)
3.6.28.4 Selection Criteria
1. The isolator shall be floor mounted type within enclosure with IP 52
protection. HT isolator shall be triple pole, air break, manually operated,
quick break and make, load break type and shall be designed as per
IS:9920(pt.1-2002), (pt.2-2001),(pt.3-1988), (pt.4- 1985). All the three
poles shall operate simultaneously by a operating handle.
2. On the outgoing side of the isolator, an earthing switch shall be
provided for the earthing of the outgoing equipment. It shall have

interlock with the main switch i.e. the earthing switch cannot be closed
unless the main switch is OFF.
3. Design and selection of isolators shall be done taking into consideration
the fact that the isolators are called upon to operate continuously and
hence all facilities to simplify inspection, testing, maintenance, cleaning
can be carried out at site without disrupting process / prolonged
shutdowns.
3.6.28.5 The isolators shall be complete with approved safety devices wherever a
potential hazard to personnel exists and with provision for safe access of
personnel to and around equipment for operational and maintenance
functions. Design and selection shall include all reasonable precautions and
provisions for the safety of operating and maintenance personnel
3.6.29 Dry Type Transformer
3.6.29.1 Standards
The Transformers shall in all aspects comply with the following standard
specifications and publications with latest revisions:
IS:2026(Pt.1,2,4-1977) Power transformer
(Pt.3-1981) (Pt.5-1994)
IS:2099-1986 Bushing of transformer
IS:3639- 1966 Fitting & accessories for power transformer
IS:10028 (Pt.1-1985) Code of practice for Selection, Installation

(Pt.2, 3- 1981) & Maintenance of power transformer
IS:10561-1983 Application guide for power transformer
IS:11171-1985 Dry type power transformer

3.6.29.2 Technical Specification
Sl. Specific Aspects Technical Features
No.
1 kVA rating 2000kVA
2 Voltage Ratio HV/ LV 6.6/ 0.433 kV
3 Normal System Voltage 6.6 kV
4 Maximum System 7.2 kV
Voltage
5 Rated frequency 50 Hz + 5 %
6 Duty Indoor
7 Type 3 phase core type, Dry type, air
cooled, Cast resin type
No.
8 Vector group DYn 11
9 Winding Copper
10 Class of Insulation Minimum class F
11 Insulation level
a) One minute Power HV side: 20 kV rms
frequency withstand LV side: 2.5 kV rms
Voltage (kV)
b) Peak impulse test HV side: 60 kV peak
withstand voltage (kV)
12 Neutral grounding 415 V secondary side solidly
grounded
13 Percentage impedance To be indicated by the Bidder at
principal & end taps
14 Bushings Porcelain bushings shall be provided
in HV & LV side and shall confirm to
IS: 2099-1986
15 Termination At HT primary side – through XLPE HT
cable. HV cable box (self- supported
detachable type such that transformer
can be taken out without
disconnecting cable)
At secondary side- through busduct
16 Neutral CTs 2 nos.
17 . CT for Backup earth Class 5 P20
fault Protection
18 CT for restricted earth PS class
fault protection
0
19 Maximum Temperature 70 C
rise in winding after Over 500 C ambient temp (Indoor)
continuous operation (total temperature 120 deg C)
with rated load
20 Tap changer on 11 kV Off circuit tap changer
side Tap changer shall be hand operated
through hand wheel. Padlocking
facility to be provided.
21 Range + 5%
22 Taps above nominal 2
voltage
23 Taps below nominal 2

No.
voltage
24 Voltage per step 2.5%
variation
25 Short circuit level on HV As mentioned in design criteria
side & LV side
26 Short circuit withstand 3 seconds
duration
27 Auxiliary supply voltage 240 V AC
28 Parallel operation Suitable for parallel operation with
transformers of similar ratings
29 Overload capacity IEC 60076
30 Over fluxing withstand 120%
(without heating)
capacity for one
minute due to combined
voltage & frequency
variation
31 Degree of protection for IP:21
Transformer Enclosure
32 Accessories - Scanner with alarm and rip contacts
for Winding temperature
-- Neutral CTs
- surge arrestor alongwith earthing
bar for surge arrestor
- bushing for grounding surge
arrestor
- Off circuit tapping switch
-Ventilation louvers and ventilation
grid
- Roller ( bi directional)
- Marshalling box
-Warning plate
-Earthing pad
-Lifting lugs for complete
transformer
-Base channel with hauling hole
-Inspection cover for changing tap
with glass & door switch
-Rating and diagram plate
-LV neutral bushing
No.
-HV cable box
-LV busduct connecting chamber
-Other accessories as required
33 Marshalling box Fabricated with 1.6 mm CRCA steel
with rubber gasket and lockable door,
IP – 54 enclosure.
Suitable for housing winding temp.
indicators with 100 W lamp and 3 pin
switch socket.
3.6.29.3 Tests
All routine tests as per relevant standards shall be carried out at the
manufacturer's works:
 Measurement of winding resistance
 Measurement of voltage ratio & check voltage vector
relationship
 Measurement of impedance voltage / short circuit impedance &
load loss
 Measurement of no load loss & current
 Measurement of insulation resistance
 Dielectric test
 Type test certificate for Temperature rise tests shall be
furnished.
3.6.30 LT Bus Duct
IS: 8623(Pt.1, 2, 3) - Bus bar trunking system

1993
IS: 5350 (Part-1)-1970 Indoor Post insulators
IS: 191 -2007 Copper busbar& flexible
IS: 3965 -1981 Dimension for Aluminium alloy bar
IS: 1897 -2008 Copper strip for electrical purpose
IS: 5082 -1998 Aluminium alloy busbar
IS: 9431 -1979 Post insulators of organic material
,Insulators & Seal off Bushing
IS: 10192 -1982 Resin bonded glass fibre sheet
IS: 13947 -1993 Busbar Assembly Clearances
IS: 5578-1984 Busbar marking colour code
IS:11353-1985 Identification of conductors & apparatus
terminals.
3.6.30.1 Technical particulars of Bus Duct shall be as following:

Sl. No. Specific aspects Technical features
1 Type Totally enclosed with
Interleaved Aluminium busbars
2 Rated voltage (V) 415 V + 10%
3 Current rating Bus Duct shall be rated for full
load (100%) of the terminating
Switchgear
4 Phase (Nos.) 3 phase and neutral
5 Frequency (Hz) 50 Hz + 5%
6 Power frequency withstand 2.5 kV rms for one minute
voltage
7 Maximum temperature rise
over 50oC ambient
a) Bus Conductor oC 400C under normal operating
condition with full load
b) At joints oC 550C for silver plated joints and
400C for other joints
8 Short circuit withstand 50 kA rms for 1 sec
capacity
9 Material of Enclosure 2mm thick CRCA sheet steel
10 Material of busbar Aluminium (E91E WP grade)
black matt painted &colour
coded
11 Bus insulator FRP type
12 Degree of protection for the IP 54
enclosure
13 Earthing Two earthing pads for 50 mm x

6 mm GI flats at each end of
Sl. No. Specific aspects Technical features
duct
14 Other constructional features - Inspection covers with
handle
- Flexible expansion joints for
enclosure
- Expansion joint with
Aluminium strips for busbars
- Silver faced Busbar and tap
joints or application of
suitable m-oxide contact
grease at the ends after
thorough cleaning before
making the joints.
- Non-inflammable, non-
hygroscopic, track resistant
and high strength porcelain
or SMC Busbar supports
- Space heaters at suitable
locations
15 Painting
a) Surface Treatment for Seven tank process.
Painting
16 Paint shade
a) Outer surface Shade No.631 (light grey) of IS
5: 1994
b) Inner surface Black paint matt finish
3.6.31 LT Switchboard
IS Code & Year Title
IS: 1248 (Part1-2003) (Part Direct acting indicating analogue
2-6, 9-2003) (Part 7, 8- electrical measuring instruments & their
2003) accessories
IS: 2705-(Part 1-4)-1992 Current transformer
IS: 3156-(Part 1-4)-2002 Voltage transformers

IS Code & Year Title
IS: 3231(Part 1-3)-1987 Electrical Relays for power system
protection
IS: 5578 –1984 Guide for marking insulated conductor.
IS: 11353-1985 Guide for uniform marking &
identification of conductor and terminals
IS: 8623 (Part 1-3)-1993 Low voltage switchgear and controlgear
assemblies.
IS: 10118 (Part 1-4)-1982 Code of practice for Selection, installation
and Maintenance of Switchgear and
Control gear.
IS: 11182 (Part 1,2-1984) Guide for evaluation of insulation system
(Part 3,5,6,7-1986) of Electrical Equipment.
IS: 13947(Part 1-5)-1993 Specification for LV switchgear and
control gear
Technical particulars of LT Switchboard shall be as following:
Sl. Specific aspects Technical features

No
1. Voltage 415 V + 10%
2. Phase 3 phase
3. Frequency 50 Hz + 5%
4. Neutral system Solidly Grounded
5. System Fault level 50 kA (RMS) for 1 second
6. Rated Insulation Voltage 2.5 kV rms for 1 min
7. Duty Continuous operation
8. Construction
8.1. Type of board Single Front, Compartmentalised,
modular & Drawout.
8.2. Mounting Vertical, Floor mounted, Free
standing type and to be mounted
on base frame / base channel
8.3. Sheet Steel type & Cold Rolled sheet steel, 2 mm &

No
thickness 1.6 mm (for door).
8.4. Degree of protection of IP-42
enclosure
8.5. Front access Hinged door
8.6. Back access & clearance Back access of LT panels shall be
hinged door; Back clearance-
minimum 800 mm
8.7. Future extension provision Provision on both side by addition
of new vertical section
8.8. Cabling Space Side Cable Alley or at the back
8.9. Height of panels Maximum 2350 mm including
base channel.
Operating height: 450 mm
(minimum) and 1800mm
(maximum) from floor level.
8.10. Busbar arrangement Top horizontal
8.11. Power feed to outgoing Sleeved busbar droppers for
modules connection of cables (bottom
entry)
8.12. Power feed to incomers Through sheet steel enclosed non
segregated phase bus ducts (top
entry)
9. Busbar
9.1. Main horizontal busbar 3 Phase & neutral at top
9.2. Busbar Material (Make: Aluminium Alloy
INDALCO/ HINDALCO)
9.3. Maximum temperature 90 degC
rise including the specified
ambient temperature and
derating factor if any
9.4. Short time withstand 50 kA (RMS) for 1 sec
current of Phase &
Neutral bus

No
9.5. Short time withstand 50 kA (RMS) for 1 sec
current of earth bus
9.6. Earth busbar Galvanised steel earth Busbar of
adequate size & running
throughout the length of panels at
bottom
10. Insulation Heat Shrunk PVC Sleeve.
11. Colour coding IS 5578: 1984
IS 11353: 1985
12. Clearance between Phase 25 mm (minimum)
& Phase and Phase &
Earth / Neutral
13. Air Circuit Breakers
13.1. Type Electrically operated with closing
coil, tripping coil, motorised spring
charging mechanism for all circuit
breakers- incomer & outgoing
feeders.
13.2. Drawout type Yes
13.3. Cubicle door can be Yes
closed when ACB is in
Isolated position
13.4. Rated Interrupting 50 kA (RMS)
capacity (symmetrical)
13.5. Rated making Current 105 kA peak
13.6. Adjustable short circuit Yes
releases
13.7. Adjustable over load Yes
releases
13.8. Anti-pumping & trip free Electrical anti-pumping & trip free
features feature in addition to mechanical
anti-pumping feature.
14. Protection

No
14.1. -For incomers & and microprocessor based release shall
outgoing feeders be provided in the ACBs for short
circuit protection , overload
protection and earth fault
protection. All ACBs shall have 240
V AC shunt trip releases.
14.2. For Incomer In addition to above
microprocessor based protection
release, standby E/F protection
shall be provided in Incomer only
by using IDMTL relay with NCT.
15. Metering
15.1. Ammeter Ammeter with selector switch for
incomers & all outgoing feeders
15.2. Voltmeters Voltmeter with selector switch for
incomer & phase healthy
indication lamps for all three
phases of incomer
15.3. Energy Meter Digital Energy Meter shall be
provided in Incomer
16. Wiring
16.1. Power Circuit Insulated (1.1 kV) Flexible Copper
Wire/ strip
16.2. Control circuit Copper 2.5 mm2 multi strand PVC
wire, insulated
16.3. Inter panel Wiring To be completed in each
transportable Section. Provision
for inter shipping section wiring
shall be provided with complete
termination facility
17. Control Transformer Adequately rated (minimum 2
kVA)
18. Indication lamps LED cluster with luminous
intensity min. 100 mcd.

No
19. CT & PT As required
20. Painting
20.1. Surface Treatment for Seven tank process .
Painting
20.2. Paint shade Shade No.631 (light gray) of IS 5:
1994
3.6.32 Motor Control Centre (MCC)

3.6.32.1 Intelligent Draw-out type, Motor Control Centres (MCC) shall be provided in
process areas with communication capability on Profi-bus DP in redundant
configuration with PLCs for Plant Automation System.
Each Intelligent MCC shall have two incomers one bus coupler and required
no. of outgoing feeders. 20 % spare feeders shall also be provided. All the
incomers and bus couplers shall have air circuit breakers. For outgoing
feeders, MPCB shall be considered upto 30kW. Above 30kW MCCB shall be
considered. The Intelligent MCC modules shall be draw out type.
3.6.32.2 Non intelligent conventional, fixed type, Single front with two incomers &
one bus-coupler Motor Control Centres (MCC) shall be provided for non-
process areas like Air Conditioning & Ventilation system, Fire fighting
system.
3.6.32.3 Non intelligent MCCs shall have two incomers, one bus coupler and required
no. of outgoing feeders with 20 % spares. Air circuit breakers/MCCBs shall
be provided for all Incomers and buscoupler. . For outgoing feeders, MPCB
shall be considered up to 30kW. Above 30kW MCCB shall be considered.
3.6.32.4 Intelligent MCC modules shall have state of the art controllers complete with
I/O interface cards, communication facilities etc.
3.6.32.5 The MCCs shall be modular, sheet steel enclosed, operable from front, floor
mounted type. Heavy duty and reliable type of isolating contacts (both
power & control) should be provided for draw out MCCs panels.
3.6.32.6 The power bus bars shall be 415 V, 3-phase, 50 Hz with grounded neutral,
and short circuit level is 50 kA for 1 sec.

3.6.32.7 Control circuits of MCCs shall be 240 V, 1-phase, 50 Hz. provision shall be
made for two power supply sources (two transformers of 415/ 240 V each
at full power rating) for the MCCs.

No.
1. Reference Standards IEC 60947 : 2004- Low Voltage
Switchgear and Control gear
IS 8623 (Part 1-3): 1993- Low
voltage switchgear and control gear
assemblies
2. Supply system & variation
a) Voltage 415 V + 10%
b) Phase 3 Φ & Neutral
c) Frequency 50 Hz + 5 %
3. Neutral system Solidly grounded
4. System Fault level 50 kA (RMS) for 1 second

5. Rated Insulation Voltage 2.5 kV for 1 min
6. Construction
a) Type of board Single Front Compartmentalised,
Maximum operating height shall be
1800mm and minimum operating
height shall be 300mm from floor
level.
b) Degree of protection IP-54
c) Mounting Vertical, Floor mounted, Free
standing
d) Front access Hinged door
e) Back access & clearance Back access shall be provided.
f) Future extraction provision Provision on both side by addition
of new vertical section.
g) Sheet Steel type & thickness Cold Rolled sheet steel, 2 mm & 1.6

No.
mm (for door).
h) Paint Shade No. 631 (light gray) of IS 5 :

1994
i) Cabling Space Side Cable Alley

7. Busbar
a) Main horizontal busbar 3 Phase and neutral (RYBN)

b) Busbar Material Aluminium Alloy
c) Max. temp. rise including the 90 deg C
specified ambient temp. and
derating factor if any
d) Busbar arrangement Top horizontal
e) Power feed to outgoing Sleeved busbar dropper
module
f) Insulation Heat Shrunk PVC Sleeve.
g) Short time withstand current 50 kA (RMS) for 1 sec
of Neutral Bus
h) Short time withstand current 50 kA (RMS) for 1 sec

of earth bus
i) Colour coding IS 5578 : 1984
IS 11353 : 1985
j) Clearance between Phase & 25 mm (minimum)
Phase and Phase & Earth /
Neutral
8. Component Details
8.1 ACB/MCCB for incomer &
bus coupler
Protection feature  ACB: Microprocessor based short
circuit, overload and earth fault
release shall be provided
 MCCB: short circuit, overload
and earth fault release shall be
No.
provided
 For Incomer load current 400 A
and above ACB shall be provided
and below 400A shall be MCCB.
Rated Interrupting capacity 50 ka for 1 sec

(symmetrical)
8.2 MCCB /MPCB for outgoing
feeders
Rated Interrupting capacity 50 kA (RMS)- both Ics&Icu
(symmetrical)
Current limiting type Yes
Capacity to protect Type 2 Co-ordination IS13947 (Part
downstream equipment 4/ Sec 1) : 1993
8.3 Contactors (Power)
Utilisation Category AC3 for non-reversible feeders
AC4 for all reversible feeder
Coil voltage (VR) 240 V
Drop out voltage 50% VR
Pick up 85 – 110% VR
Auxiliary Contacts & rating 2 NO + 2 NC, 10A, 240V AC.
8.4 Overload protection  Through microprocessor based
intelligent module at each
cubicle of intelligent MCC.
 Through EMPR for non-
intelligent MCCs of process areas
 Through thermal o/L relays for
non-process area MCCs like A/c,
ventilation, fire fighting
8.4 Wiring
Power Circuit Insulated (1.1 kV) Flexible Copper

No.
Wire / strip
Control Circuit Copper 2.5 mm2 multi strand PVC

wire, Insulated
8.5 Control Transformer 2 nos. with auto changeover
scheme.
8.6 Indication lamps LED cluster
8.7 CT & PT As required
8.8 Ammeters For incomers & all motor feeders
8.9 Voltmeters For incomers
8.10 Surge suppressor Across all power contactors
3.6.32.9 Intelligence feature requirement in MCC:
i) Each incomer cubicle and each outgoing feeder cubicle shall be provided
with dedicated inbuilt intelligence module for Status, control, protection
and diagnostic features.
ii) The motor feeders shall be provided with Intelligent Motor control and
protection device, in place of overload relay, in the power circuit. All motor
protection and control functions and interlocking schemes shall be
implemented with microprocessor.
iii) The Intelligent Motor control and protection device shall be provided with
interface communication cable (The interface shall be an integral part of
the relay and not an add-on-plug)
iv) The intelligent motor control and protection device shall be provided with
current measuring module which shall be used for detecting the electric
current, which shall form the basis of overload protection, warning,
current thresholds, On/ off check back signals, calculation of operating
hours etc.
v) Intelligent motor control and protection device shall have integral
microprocessor and current detection features.
vi) All motor protection and control functions shall be processed in a
decentralized principle , so that in event of failure of PLC or disturbance
in the communication path , the motor branch shall continue to get
controlled.

vii) Control commands, operating, diagnostic and statistical data shall be
transmitted through suitable communication cable. Communication
between IMCC and PLC shall be through profibus DP/ Ethernet.
Redundant communication cable with connector shall be provided for
each module or ring based communication shall be provided such that in
case of failure of one path, the communication to PLC shall continue
through another path.
viii) The intelligent motor control and protection device shall also be equipped
with RS 232 / RS 485 interface for connecting to PC.
ix) The Intelligent motor control and protection device shall be provided with
integral test / reset push button and at least 3 LED lamps. The Test / Reset
push button, when pressed for less than 5 seconds, shall test the current
detection, thermistor and earth fault monitoring and a lamp test of LED
lamps shall be initiated. When pressed for more time continuously for
more than 5 seconds, the test of tripping shall also be activated.
x) The Bidder shall supply licensed copy of the parameterization, software,
which shall enable parameterization from a PC or PLC. The software shall
be user- friendly, with “help” menu providing the definition of parameters
to be set.
xi) Basic Protections, controls and diagnostic features required in intelligent
Motor control and protection device.
xii) All field input to IMCC controller shall be through auxiliary relays.
Protections:
a) Overload Protection
b) Current Asymmetry
c) Phase failure
d) Blocking protection
e) Current limit values
f) Earth fault detection
g) Thermistor protection, with a facility to choose among the binary
& analog detectors.
Control functions:
Intelligent motor control and protection device shall offer parameterizable
control functions for the actuators.

Signal processing
Intelligent motor control and protection device shall offer following
supplementary functions:
i) Signal matching
ii) Truth table
iii) Timer counter
Standard function blocks:
Intelligent motor control and protection device shall have standard function
control blocks for various functions ( e.g. time graded restarting of drives
after main failure)
i) Check back signal test
ii) Operating protection off
iii) Ready to start
iv) Under voltage off
v) Graded restart
vi) External fault
vii) External wiring
viii) Emergency start
ix) External check back signal
x) PLC / CPU fault
xi) DP fault
xii) Test 1 with shut down
xiii) Test 2 without shut down
xiv) Reset
Operating and diagnostic data
Intelligent motor control and protection device shall provide following
data:
i) Motor On / Off / open / close
ii) Fault : Overload/ thermistor etc.
iii) Warning : Overload / threshold for upper current exceeded etc.
iv) Operating current
v) Operating hours
vi) Number of switching cycle
vii) Number of overload trips
viii) Current of last over load trip.
3.6.32.10 Technical parameters of Intelligent motor control and protection device:
Sl.No. Specific aspects Technical features

1. Ambient Temperature 50 deg C
2. Supply voltage 415 V +/- 10 %
3. Insulation voltage 1.1kV
4. Reset With Test / Reset button
on the device or automatic
reset shall be
parameterizable
5. Auxiliary circuit continuous current 5 A
rating
6. Digital Inputs / Outputs Based on the control
requirement with 20%
spare
7. Safe Isolation All circuits shall be safely
isolated according to IEC
60947-1
Above details shall be finalized during engineering stage as per
manufacturer’s type tested design complying IS/IEC standards.
3.6.33 Power Distribution Board (PDB)
Power distribution board (PDB) shall be complete with ACBs, MCCBs,
Aluminium bus bar, ammeters & voltmeters, power & control terminal
boards, clustered LED lamps for indications, necessary protections including
power & control cables.
The PDBs shall meet the specifications given below:
Type Sheet steel clad, fully compartmentalized, non-draw

out, indoor type, floor mounted, free standing
conforming to IS 8623 (Part 1-3): 1993- Low voltage
switchgear and control gear assemblies
Enclosure IP54
Incomer 2 nos incomers and bus coupler of suitable rating
ACBs/MCCBs . For Incomer rating 630A and above,
ACB shall be provided and Incomer rating below 630A
MCCB shall be provided.
Outgoing MCCBs (no. & rating as required), 20% spare feeders
feeders shall be provided.
Bus bars 3 ph, 4 wire, electrolytic grade Aluminium
MCCBs All MCCBs shall be of 50kA breaking capacity with
short circuit, overload and earth fault protection.
Auxiliary loads The PDB shall meet the Power requirement of Air
conditioning, ventilation, EOT Crane, hoist,
illumination, repair facilities, any other load as required
at detail engineering stage.
3.6.34 Soft Starter

3.6.34.1 The soft starter shall be suitable for 415V, 3 phase, squirrel cage rotor
induction motor for application having rating 90 kW and upto 200 kW. The
drives are required to be controlled automatically through PLC. The soft
starter shall be designed for reference from PLC.
3.6.34.2 The soft starter shall be microprocessor based using solid state electronic
devices. The starter shall be complete with MCCB, semiconductor fuse,
contactors, electronic/ thermal overload protection and electronic unit. The
voltage ramp during starting shall be adjustable to suit the conveyor
requirement. The soft starter shall reduce surges during starting & stopping
of conveyor by smoothly accelerating & decelerating the motor. Indication
lamps for “On” & “Off” and ammeter & voltmeter with selector switch shall
be provided on the panel.
3.6.34.3 The panel shall also have arrangement for DOL starting by passing the soft
starter. For selecting this mode from the panel, one selector switch shall be
provided on the panel itself.
3.6.34.4 The soft starter shall be enclosed in panel made of cold rolled sheet steel of
minimum 2 mm thickness. The panel shall have IP-54 degree of protection.
The panel shall be floor mounted & suitable for cable entry from bottom.
3.6.35 HT & LT Induction motors
3.6.35.1 Standards
1) The motors covered under this specification shall comply to the
following specification and to the specific standards mentioned in the
respective clauses:
IPSS:1-03-001-95 General purpose squirrel cage induction motor
(third revision).

IPSS:1-03-018-95 General purpose HT Squirrel cage Induction
motor
IPSS:1-03-004-95 AC Crane duty Squirrel cage Induction motors
(second revision)
IPSS:1-03-007-85 AC Roller table motors (with amendment 1 & 2).
IPSS:1-03-003-94 AC mill/ crane duty slip ring Induction motors
(second revision)
IS:325-1996 Three phase Induction Motors
IS:900-1992 Code of practice for installation and maintenance
of Induction Motors
IS:1231-1974 Designation of three phase foot mounted
Induction Motors
IS:2148-1981 Flame proof enclosure for electrical apparatus
IS:2253-1974 Designation of type of construction and mounting
arrangement of Rotating electrical machine.
IS:3682-1966 Flame proof A C Motors for use in Mines
IS:6381-1972 Construction and testing of electrical apparatus
with type of protection ‘e’.
IS:9628-1980 Three phase Induction Motors with type of
protection ‘n’.
IEC 34 & IEC 72
2) All motors shall also conform to the latest Indian Electricity Rules and
Indian Electricity Act as regards safety, earthing and other essential
provisions specified therein for installation and operation.
3) All motors shall also comply with the statutory requirement of the
Government of India and the state government in which the plant is
located as given in the Employers `Tender specification'.
3.6.35.2 Selection Criteria
1) Design and selection of motors shall be done taking into consideration
the fact that the motors are called upon to operate continuously and
hence all facilities to simplify inspection, testing, maintenance, cleaning
can be carried out at site without disrupting process/ prolonged
shutdowns.
2) The motors shall be complete with approved safety devices wherever
a potential hazard to personnel exists and with provision for safe
access of personnel to and around equipment for operational and
maintenance functions. Design and selection shall include all
reasonable precautions and provisions for the safety of operating and
maintenance personnel.
3) The following types of motors shall be considered by the tenderer for
the application and duty indicated against each.
4) For continuous duty electric drives not requiring speed control like
pumps, compressors, conveyors, fans etc, General purpose squirrel
cage motors shall be employed.
5) For variable speed A.C. drives, squirrel cage induction motor with
Variable Voltage Variable Frequency (VVVF) supply shall be adopted.
6) In hazardous locations either flame-proof motors conforming to
IS:2148-1981 or increased safety of motors conforming to IS:6381-
1972 shall be employed.
3.6.35.3 Technical Particulars for HT & LT motors (general purpose)
1. Type of motor/ rotor Squirrel cage induction motor

All LT Motors shall be energy efficient IE3
as per IS 12615:2011
2. Variation in Rated + 10%
voltage (%)
3. Rated frequency 50 Hz
4. Variation in rated + 5%
frequency (%)
5. Duty As per requirement
6. Speed (RPM) To be matched with the driven equipment
7. Time to withstand 2 minutes
120% of rated speed
8. Mounting Horizontal/ Vertical mounting as per
application
9. Type of enclosure TETV/CACA: for 6.6kV motors
TEFC: for 415 V motors
10. Degree of protection IP 55
11. Class of insulation F
12. Temperature rise (over 70oC
ambient temp. of
50oC).
13. Starting current in 600 % (tentative)
percentage of rated
current (Ist / Ir)
15. Starting time at 100% Not more than 10/ 15 sec for 100%
and 85% rated voltage voltage.
with load

16. Safe stall time at 110% 5 –10 Sec more than locked Rotor
rated voltage at Hot withstand time
condition
17. Thermal time 45 min.
constant, in min.
18. Margin on Hot Minimum 10% over full load current to
thermal withstand facilitate relay setting using motor’s rated
curve capacity
19. Minimum permissible 80% of rated voltage
voltage at terminal for
starting (with full load)
20. Permissible running 5 min

time with full load at
minimum (75%)
allowable voltage.
21. Whether suitable for Yes
150% of rated voltage
during Bus transfer.
22. Transient recovery The motor shall be capable to accelerate
after temporary with load to rated operating point from
system disturbance for such condition.
0.2 Sec and sudden
restoration to 70% of
rated Voltage
23. Fault withstand 6.6 kV motors : 40 kA (rms) for 0.25
current and time for seconds
terminal box
415 V motors : 50 kA (rms) for 0.25 sec.
24. Withstanding ability of 175/2500 micro second
Switching Surge of (4U
+ 5kV) Where U is
rated line voltage.
25. Direction of rotation Bi-direction
26. Winding Material Copper
27. Winding Insulation Non-hygroscopic, oil resistant and
type resistant to flame propagation
28. Winding connection Star: For HT motors
Delta: For 415 V motors
29 Whether windings Yes
have adequate
tropical protection
against fungus,
corrosion etc.
provided.
30. Motor terminal box Phase segregated type. An insulated
type (for HT motors) barrier shall be provided between the
motor terminals thus eliminating the
possibility of direct short circuit across the
terminals. The outer case is to be
fabricated from heavy gauge steel plate. It
shall be suitable for termination of actual
no. and sizes of cables as per kW rating of
the motor considering derating
31. Motor terminal box It shall be suitable for termination of actual
type (for 415 V no. and size of cables as per kW rating of
motors) the motor considering derating due to site
ambient temp. as well as method of
installation.
32. Degree of protection IP - 55
for terminal boxes
33. RTD for Winding and 6 nos. RTD (Platinum wire having
Bearing temperature resistance of 100 ohm at 0oC) for windings
measurement for HT and 2 nos. RTD for bearing temp.
motor (Temperature inputs shall be directly taken
to RTD input cards of PLC)
34. Space heater for HT To be provided

motor
35. Supply system for 240 V, 1 phase, 50 Hz
space heaters for HT
motor

36 Whether separate Yes
terminal box for space
heater is provided for
HT motor
37. Bearing Self-lubricated anti friction roller bearing
38. Earthing of motor Each motor frame shall have two distinct
body grounding pads, one on each side,
complete with tapped hole and bolt
THE SIZE OF THE EARTH CONNECTION OF THE
MOTORS TO THE SHOP EARTH GRID SHALL BE AS PER
IS: 3043-1987.
39. The motor shall be Yes
provided with
adequate & suitable
lifting devices and with
the foundation bolts.
40. Noise level The noise level shall be as per IS

12065:1987 and shall not exceed 85 dBA at
1 m. from motor
3.6.35.4 415V Inverter Duty Motor:

Sl.No Parameters Description
1.0 Type - AC Squirrel cage induction motor.
- Inverter Duty
- Energy efficient type
2.0 Constructional Features
2.1 Frame size & rating - As per IS 325
- 10:1 constant torque speed range
motors may exceed frame standard by
one frame rating.
2.2 Protection for Motor & IP - 55
Bearing
2.3 Motor Shaft Shall be provided with an external
recessed slinger at the drive end of the
motor to provide additional (minimum
IP-54) protection from moisture and
foreign material.
2.4 Shaft ends & Extension - Cylindrical as per requirement
- Shaft shall be extended for encoder /
tacho. mounting, accordingly suitable
hole shall be drilled and tapped.
2.5 Internal Encoder Motors with speed variation of 1000:1 at

constant torque shall have internal
builtin encoder for speed feedback
2.6 Bearing - Roller type bearing upto 5 kW .
- Ball Bearing at NDE end for above 5
kW.
- All motors shall have fully re-
greasable, anti-friction bearings.
- All motors shall have inner bearing
caps.
- Bearings shall be heavy duty type
- All motors shall have a charged
lubrication system to inhibit moisture
condensation.
- Standard motors shall have extended
grease fittings on the opposite drive-
end to facilitate re-lubrication. Grease
ports shall be located on the periphery
of the motor endshield.
- Motor shall be fitted with a shaft
slinger or V ring seal on the drive end
for a minimum of IP-54 protection (to
help protection of bearing from
ingress of dust , dirt or fluids).
2.7 Hazardous Area safety NA
design
3.0 Terminal box
3.1 Location RHS viewed from DE / On top
3.2 Suitability - 4 Core Aluminium Cable
- The terminal box shall be oversize as
compared to NEMA requirements.
3.3 Earthing stud Inside Terminal Block
3.4 Miscellaneous - Shall be gasketed between the
terminal box halves.
- The conduit box shall be field
convertible to cast iron.
- External screws and bolts shall be
grade five, hex heads and be plated to
resist corrosion.
4.0 Cooling - TEFC, Effective bi-directional
- Motor with 1000:1 speed range and
constant torque shall have external
fan.
- External fan motor shall be 3 phase,
415 V AC
- Thermistors shall be provided in the
windings.
5.0 Quality of operation
5.1 Vibration intensity - Shall be limited as per IS 12075-1986.
- Shall not exceed .08 inches / second
velocity.
5.2 Noise level As per IS: 12065-1987
6.0 Electrical design
6.1 Power Supply 415 V +/-10 %, 50 Hz +/- 5%, 4-wire AC,
solidly earthed.
6.2 Starting Variable Frequency Drive
6.3 Service factor - 1.0 for VFD power.
- 1.15 for sine wave power.
6.4 Peak transient voltage 1600 V
6.5 Minimum rise time 0.1 microsecond
6.6 Starting Torque 200 % rated torque for 1 minute below
base speed
6.7 Constant horsepower 1.5 times base speed.
operation
6.8 Duty Application dependent
6.9 Max speed permissible 150 % rated for 2 minutes
6.10 Derating for VFD As per above mentioned standard
6.11 Insulation Class H limited to class F.
6.12 Load Type Constant Torque / Variable Torque
(As per application)
6.13 Space Heater - Outdoor motors above 45 kW
- Indoor Motor above 110 kW
6.14 No. of Poles 4/6/8
7.0 Operating Characteristics
7.1 Operation with variation Motors shall operate successfully under
in the voltage or the running conditions at rated load with
frequency variation in the voltage or the
frequency not exceeding the following
conditions:
 +/-10% rated voltage at rated

constant V/f ratio except for specific
torque boost situations.
Motors shall operate successfully under
running conditions at rated load and
V/f ratio when the voltage unbalance at
the motor terminals does not exceed
one percent.
7.2 Torques Motors shall meet or exceed the
minimum locked rotor (starting) and
breakdown torques specified in NEMA
Standard MG1 Part 12 for Design B for
the rating specified when on sine wave
power.
7.3 Operating speed range - Zero to base speed in case of VT.
- 1000: 1 for CT (with blower cooling)
- 10:1, 6:1, 4:1 for CT.
7.4 Locked rotor (starting) Shall not exceed NEMA Design B values
currents for the specified rating on 5:1 constant
torque or less and variable torque
motors. NEMA Design A values are
allowed for 6:1 constant torque or higher
value constant torque rated motors.
Motors shall be capable of a 20 second
stall at six times full load current without
injurious heating to motor components.
7.5 Efficiency - Shall have a nameplate minimum and

nominal full load efficiency for motors
when tested in accordance with NEMA
standard MG1 Part 12, IEEE Test
Procedure 112 Method B, using
accuracy improvement by segregated
loss determination including stray
load loss
measurements.
8.0 Motor location Outdoor / indoor installation.
9.0 Nameplate - Shall be of corrosion resistance
stainless steel.
- In addition to standard nameplate
information following information
shall be included:
Nominal efficiency.
o
Bearing identification numbers.
o
Power factor.
o
Torque values with speed range
o
and amps for that torque value.
o Full Load Slip RPM.
o Magnetizing amps
o Encoder PPR and Voltage rating (if
included).
The above mentioned technical parameters are tentative which shall be
finalized during engineering stage based on IS/IEC guidelines, availability
and manufacturing standard of the makes given in TS.
3.6.35.5 Tests
The tests to be carried out on equipment are subdivided under the
following heads:
 Factory tests (Routine tests and Type tests)
 Site tests
FACTORY TESTS
All routine tests as per relevant standards referred above shall be carried out
by the Successful Tenderer at the manufacturer's works. However, the
following Routine test shall necessarily be carried out in the presence of
Employer/ consultant unless otherwise waived off in writing by the
Employer.
Factory tests for AC motor:
 Insulation resistance test
 High voltage test
 No-load running of motor & reading of voltage, current, power
input & speed.
 Locked-rotor readings of voltage, current & power input at a
reduced voltage (Values of torque are to be indicated in type test)
 Reduced voltage running-up test
 Open-circuit voltage ratio (for slip-ring motors only)
 Calculation of efficiency

 Temperature rise test
 Momentary over load test
 Over speed test: The motors shall be suitable to withstand 120% of
rated speed for specified duration (2 minutes) without any mechanical
damage.
 Switching surge test for HT Motors: Motors shall be capable of
withstanding a 175/ 2500 micro second switch surge of (4u+5)kV,
where u is the line to line voltage.
 Temperature rise test listed under Type Test, as per IS-325-1996 shall
necessarily be carried out on at least one motor of each type, rating
and category for which certificate shall be provided.
3.6.35.6 Any other tests as per approved QAP during detail engineering stage
3.6.36 Variable Frequency Drive (VFD)

VFDs shall be provided for the Motors as mentioned in the scope of work.
All the VFD drives shall be suitably derated with respect to temperature (1.5
% / deg. C rise) and due to voltage and frequency variation as specified in
design condition. The drives shall be able to meet the load torque
requirement at all range of the speed. The VFD shall be such that the rated
current of the VFD is not less than 150% of the rated full load current of
motor.
The motors to be controlled from variable frequency drives shall have
suitable insulation system to withstand the high voltage spikes from IGBT-
type VFD. In order to provide protection against damaging bearing current
due to circulating currents, insulated bearing/ bearing housing at NDE shall
be provided for motors of frame sizes 250 S and above. 20% spare I/O shall
be provided.
Details of VFDs are mentioned below.
1. Basic design - Digital control technology with vector
particulars control (with programming (PG) unit as per
requirement).
- IGBT based with sine coded PWM control.
- VFD shall communicate to basic
automation system on system
communication bus.
- Suitable for variable torque or constant
torque applications requiring harmonic
control as defined by IEEE 519-1992.

- The drive shall have an internal EMC filter
capable of meeting the second
environment levels for the EMC directive
without the need for additional
components.
- hall conform to IEC 146 - International
Electrical Code.
2. Drive - Software configurable to Sensor less
controller Dynamic Torque Vector mode (single
technology motor).
- Full, closed loop flux vector control shall be
available for constant torque applications.
- Drive can be operated with motor
disconnected for testing purpose.
- Adjustable PWM carrier frequency within a
range of 3 – 15 KHz.
- Suitable for use on both Constant &
Variable Torque loads as per operational
requirement.
- Multiple programmable stop modes
including - Ramp, Coast, Ramp-to-Hold.
- Multiple acceleration and deceleration
rates.
3. Type Air-cooled designed as per requirement for :

 Single quadrant operation, 6/12 pulse, line
commutated
 Four quadrant operation, 6 pulse line
commutated
4. Type of - Three full wave diode rectifiers to provide a
connection fixed DC voltage.
- DC bus inductor on all ratings
- DC link capacitors
- Latest generation IGBT based Inverter
section for variable/ constant torque
applications. The power section shall use
vector dispersal pulse width modulated (PWM)
IGBT gate control algorithm and soft switching
IGBTs to reduce motor terminal dv/dt and
allow longer cable length from drive to motor
without output filters.
- Common control connection for all
ratings.
5. Efficiency More than 97% or better at full speed and full
load.
6. Input power - Suitable line chokes to mitigate the
supply harmonics. AC side reactor/
communication choke. Isolation
transformer for group drives shall be
provided
7. Voltage - Voltage variation of (+/-) 0.1 % with an
variation input variation of +10%, - 10%.
- Steady state regulation of (+/-) 0.25%
guaranteed against 100 to 200 % load
disturbance and + 5% & -5% input supply
frequency variation.
- The drive should be designed to operate on
an AC supply, which may contain line
notching, and up to 10% harmonic
distortion.
9. Reference
9.1 Input +/- 10 V DC / 0 – 10 V DC / 4 – 20 mA
reference
voltage
9.2 Reference 
signals All reference signals may have a trim signal
applied to them for finer resolution and
accuracy. Trim source and amount should be
programmable.
9.3 Loss of The drive should be capable of sensing the
reference reference loss conditions.
In the event of loss of an analog input
reference signal, the drive should be user
programmable to the following
 Fault the drive
 Alarm and maintain last reference
 Alarm and go to preset speed
 Alarm and go to minimum speed
 Alarm and go to maximum speed
 Alarm and maintain last output frequency
Signal loss detection should be available
regardless of the function of the analog input.
10. Output
10.1 Output From 0 to rated motor voltage.
voltage
10.2 Output Shall have provision for minimum 6 step set
frequency points or as per operational requirement
10.3 Output The inverter section should produce a pulse
Waveform width modulated (PWM) waveform using
latest generation IGBTs.
10.4 Output 0.01 Hz.
frequency
resolution
11. Reflected As per relevant standards
wave
12. Overload relay For multi motor drive
13. Starting 150 % / 0.3 Hz. (without programming unit)
torque 150 % / 0 RPM (with programming unit)
14. Torque + / - 5 %.
accuracy
15. Speed control + / - 0.02 %.
accuracy
16. Ramp rate - Linear acceleration and deceleration
adjustable independently from 0 to 3600
seconds.
- Provision of remotely selectable accel /
decel settings should be accessible through
digital inputs also.
17. Main power - ACB/ MCCB with 50 KA rating
components in - Matching input isolation transformer / line
incoming AC reactor for harmonic and noise suppression.
side For input isolation transformer, the K factor
shall be 4.0 or less.
- AC line surge suppression network.
- Input contactor.
18. Converter – - 4Q regenerative PWM-type controlled

Inverter rectifier bridge with IGBTs or 6-pulse diode
Equipment rectifier bridge on the input
- DC link circuit with reactor/ capacitor.
- IGBT bridge for Inverter.
- Harmonic transformer.
19. Load side - Filter network
components - Electronic over-load relay for each motor
(with display).
- Line contactors in output side (if required).
- Output reactor / terminator to take care of
extra cable length than specified for the
drive
20. Terminal - Separate for control and power wiring.
blocks - Terminal blocks with colour codes for
different voltage levels in VFDs shall be
considered.
- Power terminal blocks to withstand a
minimum of 90 deg C and marked for both
inputs and outputs.
21. By-pass By-pass arrangement shall be provided to
Arrangement operate the motor in case of failure of VFD.
22. Diode Bridge Minimum ratings of Diode cells.
- PIV rating: 2.5 times the peak value of line
voltage
- dv/dt rating: 200V/microsecond for voltage
control and 1000V/ microsec. For inverter
control.
- di/dt rating: 100A / microsecond.
23. Input / - Hard-Wired I/O
Outputs - Hardwired I/O should be provided via
separate I/O cards
- Standard I/O Card
- The “Standard I/O board should consist of
both digital and analog I/O. It should be
available in two versions; one for 115/240
VAC digital I/O and one for 24V AC/DC
digital I/O.
- Analog I/O
- Differentially isolated 10V (bi-polar) /
20mA analog inputs.
- Digital Outputs
- Relay outputs – Minimum 04 nos.
- Contact output ratings should be 240V AC
/ 24V DC, maximum 2.0 Amp
- 2 programmable analog input (0-10v, +/-
10v, 0/4-20ma)
- 2 programmable analog output (0/4 to
20mA)
- Provision for PTC Connection to protect
the motor from over temperature
- One spare I/O card shall be supplied as
loose items for each VFD
24. Protective - AC line surge suppression network and
features overvoltage protection.
- Under voltage in supply network
- Phase sequence protection and
monitoring
- Single phase failure
- Motor loss
- Under voltage in DC bus
- Over voltage in DC bus
- Over load
- Earth fault
- Instantaneous over current
- Cooling fan failure
- Stall monitor for motor alarms
- Stall protection
- shall have a selectable function to prevent
reverse operation of the drive.
- Password protection, if available.
25. Annunciations Following faults shall be annunciated in
keypad of the drive / HMI.
- AC line surge suppression network and
overvoltage protection.
- Under voltage in supply network
- Phase sequence protection and
monitoring
- Under voltage in DC bus
- Over voltage in DC bus
- Over load
- Earth fault
- Instantaneous over current
- Cooling fan failure – Stall monitor for
motor alarms
- Motor fault (winding/ bearing
temperature, vibration) as applicable
- Loss of frequency command
- Shall be able to store at least 16 previous
faults in memory on FIFO sequence.
26. Meters - Output voltmeter and ammeter with

selector switches.
- Input volt meter and ammeter with
selector switches.
- Output frequency meter (digital type).
- KW meter for drive ratings and below 200
KW.
- All digital display shall be programmable.
27. Other features
27.1 Load Programmable current limit from 0.1 amps to
dependent 150% of drive rated amps. Current limit to be
current limit active for all drive states; accelerating, constant
speed and decelerating.
27.2 Dynamic The drive shall have an internal, built in 7th
braking IGBT for use as a dynamic braking chopper.
This IGBT shall have enough capacity to handle
greater than or equal to 100% regeneration
power from the output, continuously. The
drive shall also have a “drive mounted”
dynamic braking resistor for low level braking
applications and interactive software to
protect the “internally” mounted resistor from
abuse. The braking resistor of a hoisting drive
shall be selected considering the possible
lowering height of the load being lowered at
the maximum speed. The sizing of the braking
resistor shall take into consideration the
regenerative energy due to overhauling load
and the lowering time The Hoisting drive
should preferably have the flexibility of
connecting external Dynamic braking module.
For cross traverse and long travel motions, the
braking resistor shall be capable of absorbing
the regenerative energy during deceleration of
the motion also taking into account the
possibility of a swinging load (the load and
load attachment included).The braking resistor
shall be thermally capable to absorb the
regenerative energy during
successive drive cycles of the application.
27.3 Fault Memory 16 nos. of faults to be stored on FIFO basis
for fault analysis.
27.4 Ride Through The control logic should be capable of "riding
through" a power outage of at least 0.5
seconds in duration. The inverter section
should be shut off after an 18% drop in bus
voltage to conserve power for the drive logic.
28. Selector - Local / Remote.
switches - Auto / Manual.
- Main / Bypass.
All the selector switches shall be of 10 A
rating.
29. Pushbuttons - Trip reset.
- Start.
- Emergency stop.
30. Lamps - Drive ready.
- Drive trip.
- R, Y, B phase power ON.
- Control supply ON
31. Remote - Shall have transducer to monitor the
control outputs like motor speed at remote place
facilities / HMI.
- Facility to accept speed reference from
HMI / engineering station.
32. Communicatio - RS485 (ModBus, ProfiBus-DP, DeviceNet)
n Bus bus
- Internally mounted interfaces shall be
provided to connect to different buses
33. Test points Two electronic test point parameters should
be available to examine data within the drive
memory that is not available through other
parameters.
34. Operator - Shall be mounted on the front door of the
panel unit.
- IP 66 protection class.
- All adjustments to be made with the door
closed.
- Status and Power LEDs viewable through
the cover
- Status LEDs for communications status,
35. Membrane - The keypad shall be logically designed for
keypad two operating areas with required number
of keys.
- Local operator control like
- Local start /stop ,
- jog forward / reverse .
- Programming.
- Facility to run the drive without HIM shall
be provided.
36. LCD display - Display shall be black lighted , enabling
viewing in extremes of lighting conditions
- Display shall be in alphanumeric (in
English only)
- All the faults stored in memory shall be
displayed by scrolling.
37. Construction - Floor mounted, free standing
features - Dust and vermin proof
- Sheet steel clad
- Minimum 2.0 mm thick for panels.
- Minimum 1.5 mm thick for doors and side
covers.
- Suitable to withstand vibrations to be
encountered in mine application.
- Cubicles with illumination lamps, door
switches, space heaters and adequate
sockets for soldering.
- All control blocks plug–in-type with
necessary test sockets.
- Units shall be self-contained and
serviceable.
38. Enclosure and - Enclosure conforming to IP-42 or better
ventilation with weather proof enclosures
- Units shall be provided with cooling fans
and louvers at the bottom sides.
- All louvers shall have fine mesh filter
behind them.
- For larger drives cooling fans of drives shall
be powered from different power source.
39. Painting Rigorous metal treatment, degreasing, rinsing,

pickling, passivating, oven drying followed by
two coats of red oxide primer and two coats
of finished stove enamelled painting.
Paint shade as per IS:5 1994
40. Safety Inverters shall be complete with safety

devices against hazards and shall be suitable
for provision for safe access of operation and
maintenance
41. Selection Characteristics of the VFD Inverters matching
criteria the speed torque characteristics of the a.c
motors associated with the mechanisms shall
be the prime consideration for selecting the
VFD Inverters.

finalized during engineering stage based on IEC guidelines, availability and
manufacturing standard of the makes given in TS.
3.6.37 Remote Terminal Unit (RTU)
3.6.37.1 RTU shall be provided for provision of connectivity with existing SCADA
system of Employer. Communication link between RTU and Employer’s
SCADA system shall be executed by Employer later on.
3.6.37.2 The RTU system shall encompass the following
3.6.37.3 All line parameters (V, I, f, MW, MVAR etc.)
3.6.37.4 33 kV & 6.6kV breaker status
3.6.37.5 Twenty percent spare points shall be included in the total I/O point count
to allow for future expansion.
3.6.37.6 Necessary software required for connectivity of the RTU s with the
Employer’s SCADA system shall be under the scope of the Tenderer
3.6.38 Uninterruptible Power Supply (UPS) System
The UPS system shall be complete with UPS distribution board as per the
requirement, battery bank rack, battery charger & interconnecting cables.
Two sets of battery bank for each parallel redundant UPS shall be provided.
Back up time for each battery bank shall be 30 minutes.
kVA rating of the UPS shall be selected based on load. Rating shall be
selected such that UPS is loaded upto 60%.
3.6.38.1 System Features
Under normal conditions, both the UPS in parallel redundant mode shall
supply regulated AC power continuously to share the loads. The rectifier
battery charger shall convert the normal AC incoming power to DC power
for the inverter and for float charge of the storage battery. When incoming
AC power supply to one of the UPS fails or it suffers from loss of output/half
cycle operation, the other UPS system shall take full load immediately to
ensure un-interruptible power supply to critical loads. The configuration of
the UPS system shall be such that the rectifier and inverter section of both
the UPS can function in criss-cross manner such that

rectifier of one UPS can feed inverter section of both UPS and vice-versa.
UPS shall be online type for bump-less load transfer.
If both AC incoming power supply fail or deviate from specified tolerances,
the storage battery shall supply DC power to the inverter of working UPS
ensure continuous AC Power supply to the loads.
When incoming AC power supply returns to normal, rectifier/ charger of UPS
system assumes the DC load from the battery and simultaneously supply the
DC power to inverter and recharge the storage battery. This shall be
achieved automatically without any disturbance in power supply to the
loads.
When both UPS systems develop fault, static by pass transfer switch shall
automatically transfer the loads from inverter output to bypass AC incoming
power supply. The static by pass transfer switch shall automatically re-
transfer the load back to UPS, when it starts functioning in normal condition
and stabilizes. Retransfer shall be inhibited if the two sources are not in
phase. Manual by-pass transfer switch shall also be provided for test / repair
/ maintenance of the UPS system.
The battery reserve time capability shall not be available if it is taken out of
service for maintenance. However, UPS system shall continue to function as
before and meet all performance criteria as specified.
The UPS shall have isolation transformers at the incoming side of both
parallel redundant circuit as well as in the bypass circuit. SVC shall be
provided at the bypass circuit.
3.6.38.2 Technical Parameter
1) Input power supply conditions shall be as below :
Voltage: 415 V + 10%, -10%, 3 phase 4 wire AC
Frequency: 50 Hz + 5%, -5%
Power factor: 0.8 lagging (minimum)
2) The UPS System shall be designed to function under the following
design conditions:-
Applicable standard: IEC – 60146-4 (1986-09), IEC - 60146-
5 (1988-11)
Design ambient temperature: 50 deg C
Acoustic noise: 55 dBA at 1 M
Degree of enclosure: IP 42
3) UPS output shall meet the following requirements:
Voltage 230 V AC single phase output.
Frequency 50 Hz
Voltage regulation + 1 % nominal for any of following
conditions :
1. No load to full load
2. 1.0 - 0.8 lagging power factor
3. Min to max DC input voltage
Voltage transient 10% maximum deviation (average over half-
response cycle for 100% load application or removal.)
Voltage adjustability +5%
Voltage unbalance 5 % maximum line to line or line to neutral,
with 100 % load unbalance
Phase separation 1200 + 5% with 100 % load unbalance
Voltage wave form 5% total harmonic distortion (THD)
maximum with loads containing upto at
least 25 % third and 10 % fifth harmonic
current
Frequency stability + 0.1 % free running
Frequency slew rate 1.0 Hz / second (maximum)
Frequency adjustability + 2 Hz
Overload capacity 100 % continuous
125 %for 15 minutes
150 % for 60 sec
1000 % for 10 milliseconds
Battery recharge time 8-10 hours
4) Storage battery
Voltage As required by the inverter
Protection time 30 Minutes
Type Inverter grade SMF ( VRLA)
5) Both converter (rectifier) and inverter section of the UPS system shall
be IGBT based.
6) Complete operation and control of UPS system shall be
microprocessor based with fault diagnostic and data logging features.
7) Touch membrane switches along with LCD display on the front side of
UPS panels shall be provided to facilitate UPS operation in desired
mode locally and for display of all input, output and battery
parameters.
8) LED based block mimic diagram shall be provided on the UPS panels
indicating the complete status of the system including the power

route to the UPS, output and other system elements which are in
energised state of operation.
9) Provision of contacts shall be kept in the UPS panel for annunciation
of abnormal operation/ alarm condition in any other operator panel/
annunciation panel.
10) UPS system shall also have RS-232 serial communication port interface
capacity for alarm and status monitoring at supervisory control station.
The UPS system shall have data as well as I/O communication with the
PLC system. Necessary hardware & software for the same shall be
included.
11) UPS shall have battery health monitoring feature.
12) UPS shall have selectable feature of automatic charging/ discharging
the battery for enhancing the battery life.
3.6.38.3 Protection Indication and Annunciation
The protection of the UPS system are to be provided as suitable and
required for rectifier and inverter unit and shall generally include the
following:
1) Rectifier
 Current limiting to maximum value.
 Reduced setting of current limiting value when cooling system
failure occurs
 Current limiting during boost charging & float charging
 Control power supply failure
 Any other protection as required for particular application.
2) Inverter Unit
 High or low output voltage
 High or low link voltage
 Overcurrent on rectifier output
 Overcurrent on inverter output
 Low battery voltage
 Cooling fan failure
 Auxiliary supply failure
 Control & regulation failure
 Any other protection as required for particular application
3) The following meters shall be provided:-
 Output voltage
 Output frequency
 Ammeters
 Ammeters for battery charging/discharging
4) The annunciation /alarms shall be provided as listed but need not be
limited to :
 Main power off
 Control supply off
 Earth fault
 Load on AC mains/battery
 Battery run out warning
5) The following indication are to be provided for the rectifier unit:-
 Rectifier on
 Battery on float charge
 Battery on boost charge
 Charging failure
 AC mains failure due to fuse blown
 Overcurrent
 High battery voltage
 Low battery voltage
 Battery on load timer
 Tests
Above shall be finalized during engineering stage as per manufacturer’s
type tested design complying IEC standards.
3.6.38.4 Test at manufacturer's works
1) Routine Test
 Assembly inspection/painting check
 H.V test on main circuits.

 H.V test on auxiliary circuit
 Protective device co-ordination
 Functional tests including inverter settings and inverter efficiency
 Current limiting test
 Supply variation
 Insulation resistance measurement
 Spike buster test
 Ripple voltage
 Tests on control circuits
 Over load capacity tests
 Steady state regulation at no load, 50% and 100% of load
 Harmonic distortion test
 Acoustic noise test
 Battery operation
3.6.38.5 Any other test not specifically mentioned but required as per relevant IEC
standard shall also be carried out and test certificate for the same furnished
by the bidder.
3.6.39 Control Desk
3.6.39.1 General
Control desk shall have all switches (for selection of modes & actuation),
push buttons for remote operation of the system through PLC, along with
other facilities.
3.6.39.2 Construction
1) Control desks shall be free standing, floor mounted, totally enclosed,
dust & vermin proof, bench board type construction having degree of
protection of IP-52.
2) Necessary number of fault annunciation Windows are to be provided
on the vertical facia at a convenient location. The annunciation system
shall have Accept, Reset & Test Push Button. Annunciator windows
may also be located with the LVS also. The vertical facia of the Desk
shall not obstruct vision for the Large Video Screen for all possible
Control room layout.
3) Control desk shall be of folded sheet steel construction fabricated out
of cold rolled sheet steel of thickness not less than 2 mm and free from
all surface defects.
4) The complete structure shall be rigid, self-supporting, free from twists
& dents. All cut-outs for mounting of components shall be true in
shape and devoid of sharp edges.
5) The control desks shall be provided with hinged doors of width not
exceeding 600 mm (with in-built locking arrangement and handle) on
the rear side.
6) To have access to the wiring & maintenance of components mounted
on control desk hinged covers made out of sheet steel thickness not
less than 3 mm shall be provided.
7) Cable gland plates of removable type shall be provided at the bottom
of the control desk. These shall be of sheet steel of thickness not less
than 3.0 mm.
3.6.39.3 Control And Selector Switches
1) Control and selector switches shall be of rotary type with escutcheon
plates clearly marked to show the function and positions. The switches
shall be of sturdy construction suitable for mounting on panel front.
Switches with shrouding of live parts and sealing of contacts against
dust ingress shall be preferred.
2) Control switches shall be spring return type with pistol grip handle.
Selector switches shall be stay put type with oval handle with adequate
number of contacts. Handles of control/ selector switches shall be
black in colour.
3) Contacts of the switches shall be spring assisted and shall be of
suitable material to give a long, trouble free service.
4) The contact ratings shall be at least the following:
Make and carry continuously : 10 A
Breaking current at 220 V dc : 2 A (Inductive) Breaking
current at 220 V ac : 10 A at 0.3 p.f. lagging.
5) Each position of the control and selector switches shall have minimum
two contacts (per position) for one working and the others left as spare
with properly wired up to the terminal strip of the panel.
3.6.39.4 Push Buttons

1) Push button shall be spring return push to actuate type and rated to
make, continuously carry and break 10A, 220V, AC and 2 A 220 V, DC.
The push buttons shall have 2 NO and 2 NC contacts. All contact faces
shall be of silver or silver alloy.

2) All push button shall be provided with integral escutcheon plates
marked with its function.
3) The colour of push buttons shall be follows:-
Green For motor Start, valve/damper/gate open.
Red For motor Stop, valve/damper/gate close.
Black For all annunciator functions, reset and

miscellaneous.
4) Red push-button shall always be located to the right of green push-

buttons for any drive and shall have mushroom head..
3.6.39.5 Indicating Lamps (LED)
1) Indicating lamp assembly of LED cluster shall be of the panel mounting
type and capable of clear status indication to operator under the
normal room illumination intensity 100 mcd. Indicating LED lamps shall
be rated for 24 V DC & shall be suitable for continuous operation.
2) LED lamp assembles shall have following colours:
Red FOR MOTOR ON, VALVE/ DAMPER/ GATE OPEN, SUPPLY ON

ETC.
Green FOR MOTOR OFF, VALVE/ DAMPER/ GATE CLOSED SUPPLY OFF.
Amber FOR ALL OTHER CONDITIONS.
3.6.39.6 Indicating Instruments

1) All indicating meters shall be flush mounted on panel front. The
instruments shall be of at least 96 mm2 size with 90 degree scales and
shall have an accuracy class of 2.0 or better. The covers and cases of
instruments and meters shall provide a dust and vermin proof
construction.
2) Ammeters for motors shall have a compressed scale at the upper
current region to cover the starting current. They shall be suitable to
withstand five times nominal currents suitable for 1A/5A CT secondary
current.
3.6.40 Local Control Station (LCS)
Technical details of local control station shall be as follows:
1. All Local Control stations shall be made of 2 mm CRCA sheet steel
enclosure and shall be have degree of protection IP-55.

2. The Local Control Station shall be provided with “DRIVE ON, OFF & TRIP”
or “Valve OPEN, CLOSE, TRIP indicating lamps. Indicating lamps shall be
LED block type, and suitable for panel mounting.
3. Local control stations shall have required push buttons like start –stop,
Open-close push buttons for valves etc. The stop push-button shall be of
red colour, mushroom headed with ‘press to lock” and Lockable type
feature. The start push-button shall be of green colour and shrouded
spring return type. Selector switch, if any, based on control philosophy
shall also be provided.
4. The LCS shall have industrial type heavy-duty terminal block and the
terminals shall be suitable for termination of 2.5 mm2 copper conductors.
Each terminal-block shall have 20%. terminal as spare terminals.
5. For motors rated 110kW and above ammeter shall also be provided at
LCS.
3.6.41 Electrical Motor Actuator
3.6.41.1 The actuators supplied shall be suitable for the following power supply
system:
- Power supply 415 Volts, 3 phase, 4 wire 50 Hz
- Voltage variation + 10%
- Frequency variation +5%
- System short 50kA (RMS) for 1 second
circuit level
3.6.41.2 All equipment & components shall be suitable for operation in a hot, humid,
tropical and dusty atmosphere as prevalent in a steel plant.
3.6.41.3 The electrical actuator shall be complete with drive motor, torque and end-
of-travel limit switches, hand wheel for manual operation and internal
wiring. All electrical equipment, accessories and wiring shall be provided
with tropical finish to prevent fungus growth. The actuator shall be designed
for mounting in any position without any lubricant leakage or operating
difficulty.
3.6.41.4 The actuator shall be provided with dust tight, weather-proof enclosure
suitable for outdoor use without necessity of any canopy. IP67 enclosure
protection for actuator assembly as a whole shall be provided.
3.6.41.5 Limit Switches : Each actuator shall be provided with following limit switches:

1) Torque limit switches, one for each direction of travel, self-locking,
adjustable torque type, each having 2 NO + 2 NC potential free
contacts.
2) End-of-travel limit switches, one for each direction of travel, each
having 2 NO + 2 NC potential free contacts.
3) Contact rating of each limit switch shall be 5 Amps at 240 V AC.
4) The torque switch shall have a minimum accuracy of 3% of set value.
Calibrated knobs shall be provided for the torque switches.
5) The torque and other limit switches shall be housed in a separate
enclosure with protection class same as that of actuator i.e. IP 67.
3.6.41.6 Hand Wheel
Each actuator shall be provided with a hand wheel with limit switch for
emergency manual operation. The hand wheel shall declutch automatically
when the motor is energized. The hand wheel limit switch shall disable
energization of motor during manual operation.
3.6.41.7 Actuator Terminal Box
All terminals of limit and torque switches, space heaters shall be brought to
a common terminal box. There shall be at least five (5) spare terminals for
spare cores of cable.
3.6.41.8 Electric motor for actuator
1. The drive motor shall conform to IS 325:1996. The motor shall be with
class ‘F’ insulation for stator winding with temperature rise limited to
class ‘B’. The motor shall be designed for high torque and reversing
service. Thermostats shall be placed in the stator winding for thermal
protection of motor. The motor shall be suitable for S2 duty cycle.
2. The motor shall be designed for full voltage direct on line. The motors
shall be capable of starting at 85% of rated voltage and running at 80%
of rated voltage at 33% excess rated torque for a period of 5minutes
each. Earthing terminals shall be provided on either side of motor. The
torque capability of the motor shall match the requirement of the load.
3.6.42 Illumination System

Complete Illumination of all the areas under the scope (technological areas,
new buildings, new offices, new rooms, peripheral areas, approach road,
overhead tank, are development, parking etc.):

Sl. Room/ Area Average Maint- Type of
No. Illumination enance Fittings
Level (Lux) Factor
1. High bay lighting 150 0.7 High bay LED
fittings
2. Technological areas 150 0.7 LED fittings
3. Control rooms 300 0.7 LED decorative
4. Electrical rooms 200 0.7 LED fittings
having switchgears,
PDB, MCC, VFD
panels, PLC panels
5. Staircases, cable 70 0.7 LED fittings
basement
6. Pump house 200 0.7 LED fittings
7. Lab building 300 0.7 LED fittings
8. Area lighting 70 0.7 LED based
floodlight
9. Office rooms 300 0.7 LED decorative
10 Stores 150 0.7 LED fittings
11 Platform 100 0.7 LED fittings
12 Street light 20 0.7 LED fittings
13 Car parking shed, 150 0.7 LED fittings

cycle stand, toilets
14 Aviation light (if 20 0.7 Neon aviation
required) obstruction
lights
3.6.42.1 Automatic switching ON/OFF of these circuits shall be done through timers.
Re-wireable fuse in a sheet steel box shall be provided near each fitting to
facilitate removal of lamp in off position.
3.6.42.2 Illumination for the 33kV bay extension area shall have LED lighting and
mounting arrangement shall be similar to the existing switchyard.
3.6.42.3 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.
3.6.42.4 Power distribution
The distribution of lighting power supply for the individual areas shall be
done at 415V, 3 phase, 4 wire bus system through Main Lighting

Distribution Boards (MLDB) for the area. The outgoing feeders of the MLDB
shall feed the required numbers of Sub Lighting Distribution Boards (SLDB)
for lighting. Each SLDB shall receive power at 415V AC, 3 phase, 4 wire and
distribute it into 240V, 1 phase circuits for connection to the lighting fixtures
and 240V receptacles. The SLDB shall be located in the rooms, bays etc.
covering the respective zone. The SLDB shall be located in the electrical
rooms in the respective area
3.6.42.5 There shall be three types of LDB/SLDBs for three different purposes as
indicated below:-
 Type-1 : All lights that required to glow for 24 hours .
 Type-2 : All lights that required to glow from dusk to dawn
 Type-3 : All emergency lighting fixtures located in every area
The selection and operation switching shall be carried out with Timer and
Contactors and at either LDB or SLDB level considering the reliability of
desired operation.
3.6.42.6 20% of the lamps used for emergency illumination shall have in-built
capability of glowing during power failure condition i.e without battery
based inverter system.
3.6.42.7 Maintenance lighting
For maintenance lighting, power supply shall be fed from 240/26.5V small
capacity step-down transformers to the 24V socket outlets.
3.6.42.8 Outdoor lighting
Flood lights for area lighting shall be mounted on High mast/Structures/
poles or building structures.
Street/ road lighting and boundary wall lighting shall be provided with LED
lamp fittings mounted on poles of 9m to 11m height.
Neon aviation obstruction lights shall be provided on chimneys and other
such tall installations as per regulation.
3.6.42.9 Power factor improvement
Power factor of all the light fittings shall be improved so that it is not less
than 0.90. Power factor shall be improved by providing capacitor banks with
discharge resistor in the light distribution or by providing capacitors with
individual fittings.
3.6.42.10 Illumination wiring from SLDBs upto light fittings shall be through 1.1kV PVC
insulated, PVC sheathed, 2.5 sq.mm copper unarmoured cables in GI
conduit/ armoured cables in trays for Technological areas and through 1.1kV
PVC insulated 2.5sq.mm wires in GI conduits at rooms. For offices

and control rooms, wiring shall be through concealed wiring in MS conduits.
3.6.42.11 The switches shall be provided for controlling lighting circuits. The rotary or
toggle switches provided shall be of sturdy design. The unit shall be housed
in cast iron or cast Aluminium box having gasketted, screwed front cover
plate, fixing lugs and suitable provision for terminating conduit/cable at the
top, bottom or sides as specified.
3.6.42.12 The system shall be suitable for 1phase 240 V or 3 phase 415 V ,50 Hz power
supply with MCCB/MCB as incoming & outgoing feeders.
3.6.42.13 The system shall be provided with meters to monitor voltage, current,
power, power factor ,energy consumption etc.
3.6.42.14 Inverter based emergency lighting shall also be provided at strategic
locations.
3.6.42.15 Two nos. Lighting transformer shall feed MLDB. Number of MLDBs shall be
finalized as per technological areas. Lighting transformers shall get incoming
feed from PDB of respective area. Lighting transformer shall be dry type of
adequate rating. Rating shall be selected based on load calculation.
3.6.42.16 Main Lighting Distribution Board (MLDB)
1. The MLDB shall be metal enclosed, single front, fixed type fabricated
from CRCA sheet steel of minimum 2 mm thick, free standing, floor
mounting vertical modular cubicle type compartmentalised & factory
assembled. The MLDB shall be indoor type, dust and vermin proof with
neoprene rubber gaskets having degree of protection of IP-54.
2. The MLDB shall have enclosed busbar chamber at the top, vertical bus
bars for outgoing feeders and cable compartments separately.
Maintenance access shall be provided from front only after opening
the front covers/doors.
3. MLDB shall have two nos. TPN MCCB incomers & one bus coupler and
TPN MCCBs as outgoing feeders. The MCCBs shall have Short circuit,
overload and earth fault portion features. MCCB shall be have 50 kA
breaking capacity.
4. Each outgoing feeder shall feed lighting power to the respective Sub
Distribution Board (SDB) for lighting. 30% spare outgoing feeders shall
be provided for MDB with minimum of 2 nos.
5. Cable entries shall be made from the bottom. Detachable cable gland
plates of minimum 3 mm thick sheet steel with knock-out type cable
entry holes shall be provided.

6. MLDB shall have one no 0-500V voltmeter (size:72mm x 72mm) with
selector switch and 3 nos. indication lamps for R-Y-B indication in each
incoming cubicle. MLDB shall have Ammeter at the incomers.
3.6.42.17 Sub Lighting Distribution Boards (SLDBs)
1. SLDBs shall be metal-enclosed, cabinet type, fabricated from CRCA
sheet steel minimum 2 mm thick, suitable for wall/column mounting
on brackets.
2. SLDBs shall be indoor and outdoor type as required. Indoor panels
shall be dust and vermin proof, IP-54 or better. Outdoor panels shall
be weather-proof, double door with canopy, IPW-55.
3. Each SLDB shall have an incoming triple pole MCB and a number of
20A, 240V, 1-pole MCBs as outgoing feeders. The quantity of MCBs
shall correspond to the requirement with at least 30% spare quantity
of actual use. The total outgoing feeders shall preferably be minimum
six (6) nos. up to maximum twenty four (24) nos. and with a multiple of
six (6) in between.
4. Each 20A MCB 1 phase circuit of a SLDB shall feed a group of lighting
fixtures a group of maximum 2 nos. receptacles.
5. The SDBs for outdoor area lighting shall be provided with contactor
(matched with TP & N switch rating), 20A, 1 pole MCBs as outgoing
feeders, frequency compensated timer switch, push buttons for
automatic control of area lighting with provision for manual override.
6. The incoming TPN MCBs shall be of 100A/ 63A/32A rating with suitable
nos. of outgoing feeders of 20MCB with 30% spare MCBs.
3.6.42.18 Lighting Fixtures, Ceiling fans
1. Fixtures shall be suitable for 20 mm conduit entry and 16 SWG GI earth
wire connection. Necessary conduit to pipe adapters shall be furnished
for fixtures suitable for pipe entry.
2. High bay fixtures shall have provision for vibration damper to ensure
rated lamp life.
3. Fixtures shall be fully wired up to the respective terminal blocks, suitable
for connection of PVC wires.
4. Flame proof fittings and control gearboxes shall be provided as per
relevant IS in hazardous area
5. Ceilings fans in the offices, store rooms etc. shall be provided. Ceiling fans
shall have double ball bearing.
3.6.42.19 Receptacles with Socket, Plug & Switch
1. The receptacles to be installed shall be of the following types:
- 5A, 240V AC, 2 pole, 3 pin with third pin earthed, decorative type
suitable for flush mounting in office areas and control rooms. The
switch shall also be flush mounted piano type.
- 16A, 240 V AC, 2 pole, 3 pin with third pin earthed, decorative
type suitable for flush mounting in office areas and control
rooms. The switch shall also be flush mounted piano type.
- 20A, 240 V AC, 2 pole, 3 pin with third pin earthed, industrial type
wall/column mounted metal clad gasketted construction, 20 mm
conduit entry, screwed metal cover tied to it by metallic chain,
weather proof, suitable for indoor & outdoor installation.
2. Receptacles shall be fed from the nearest SLDB.
3. The conduit box of the receptacle shall be provided with earthing
screws with washer and nuts, welded on the surface for grounding with
16 SWG G.I wires. Arrangement shall be provided inside the conduit
box for grounding of third pin.
4. 20A Receptacles shall be of cast steel/ Aluminium heavy duty type.
5. Shrouded type plug shall be provided with corresponding matching
arrangement at sockets to prevent accidental contact with finger
during plug insertion.
6. 24 V switch sockets, suitable transformer shall be provided for hand
lamps.
3.6.43 Welding Distribution Board (WDB)
 The welding distribution board shall be suitable for operation at a
power supply of 415V, 3 phase 4 wire 50 Hz system. WDB shall have,
MCCB as incomer and outgoing feeders as per requirement. Earth fault
protection shall be provided in each feeder.
 WDB shall be floor mounted type, dust and vermin proof, weather
proof with rubber/ neoprene gaskets & glass of enclosure shall be IP-
54. The board shall be made of polycarbonate and shall be front
operated, compartmentalized in design and shall be factory
assembled.
3.6.44 Welding Receptacle

Welding receptacles shall be 63A, 415V, AC, 3phase, 50Hz with socket outlet,
interlocked 63A TPN ELCBs/RCCBs & plug made of poly carbonate type
enclosure shall be considered for various location of the furnace. The
receptacle shall be dust & vermin proof, gasketted industrial type with
degree of protection IPW-55 and interlocked type. For outdoor installations
canopy shall be provided.
3.6.45 Electrics for handling facilities
3.6.45.1 Electrical Hoists
1) Motors
The motors shall be generally as per AC motor specification given
above. The motor shall be suitable for Hoist & Crane duty ie for
plugging / reversible type of operation and suitable duty class (S4) with
150 starts per hour and Cyclic Duration factor (CDF) not less than 40%.
2) Electrical Starter Panel
The panel shall be made of 2 mm thick sheet steel and shall be of box
type construction. The panel shall be wall/floor mounted.
The incoming and outgoing cables from the panel shall be terminated
at the lower part of the Panel on the terminals consisting of cadmium
coated bolts mounted on at least 15 mm thick fibre insulating sheets.
All the control cables shall be terminated in one clip-on type terminal
block and both end of cables shall be properly ferruled and identified.
The control voltage shall be 230V AC where operation is from control
panel directly and 110V AC where pendant operation is provided.
Following indication lamps shall be provided at the panel door:
 Power Supply On
 Drive On
 Drive trip
3) Pendant Push Button Station
The Electric hoist shall be provided with Pendant Switch Push Button
(P/B) control. Pendant Control switch shall be adequately protected to
prevent accidental contact with live parts. The P/B station shall be of
momentary contact type and shall turn to off position when pressure
is released (spring return type). Contacts shall be rated for
110 V AC, 10 Amp. The weight of pendant shall be supported
independent of the electric cable by means of chain / wire rope.
Pendant Push Buttons shall be operative at a height of 1m above the
floor level. The push button station shall be clearly marked with
marking UP and DOWN for Hoist and LEFT and RIGHT for travel
movement.

4) Limit switches
Limit Switches shall be provided at both ends of the monorail to stop
the Hoist before hitting the mechanical buffer.
Hoist motion shall be provided with rotary-geared type Limit Switches
to prevent over Hoisting and over lowering. These offered Limit
Switches shall be as per relevant clause of IS 3938:1983. These limit
switches shall automatically reset, when the hook is returned to normal
operating zone. Gravity type limit switch shall also be provided for
back-up protection against over Hoisting.
5) Emergency Stop Push Button
Lockable mushroom head off push-button shall be provided to cut off
/ trip main power in case of any fault or emergency. It shall be provided
on the Pendant Push Button Station. The colour of the Push Button
shall be red.
6) Cabling
3.5 core, 1.1 kV grade PVC armoured, Aluminium conductor cable from
the outgoing terminals of starter panel up to the Junction Box at one
end of the monorail shall be provided. From junction box to hoist, 1.1
kV, flexible trailing, Copper conductor cable shall be supplied and laid
with festoon arrangement.
The number of jockeys shall be selected based on the span of the Hoist,
cable size and minimum clearance as required for smooth travel. All
the jockeys shall be connected with link chain smaller than the cable
length so that load is not transferred on the cable during pulling of the
jockeys. The cable shall have ample length and shall be supported by
means of properly designed movable clamps.
7) Earthing
The Hoist structure, motor frames and metal cases of all electrical
equipment, including metal conduit or cable guards shall effectively be
connected to earth.
3.6.45.2 Electrics for EOT Crane
a) DSL System and power supply arrangements for cranes
Power to EOT crane shall be fed through Trolley line Feeder Board (TLFB) to
be installed at a suitable location in respective crane bay. Draw-out type
MCCBs with earth fault protection and magnetic overcurrent release shall be
provided in TLFB.

Signal lamps shall be provided just below the trolley lines at 60m intervals
as well as at the beginning and end to indicate whether the trolley lines are
energized or not.
b) DSL power conductors
The Power conductors or down shop lead (DSL) shall have 4 conductors, 3
phase, 4 trolley line system (3 power + 1 earth). The topmost conductor shall
be used for earthing. The vertical clearance between top of crane rails and
top-most earth conductor shall not be less than 300mm.
The DSL conductors shall be of standard MS angle. The angle size shall be
selected to suit the total current requirement of the EOT crane as well as
keeping the voltage drop within 3% along with conductors.
Expansion gaps shall be provided in power conductors at every 30m. The
gaps shall be provided with flexible joints. The power conductors shall be
supported at 3000 mm intervals by insulators mounted on brackets welded
to crane girders.
In order to provide electrical continuity across the expansion joints the
power conductors on both sides of the joints shall connected by stranded
aluminum conductor jumper, fitted with steel Aluminum strap and lugs
suitable for the steel angle sections .
The power supply feeder and trolley line conductors shall be selected so as
to limit the voltage drop within 15% of rated motor voltage from LT
switchboard to the motor terminals for the short time peak current
corresponding to the starting of the largest capacity motor and the
maximum continuous operating current of the rest on the system.
c) Insulators and trolley line holders
The insulators used for the manufacture of trolley line holders shall be
preferably steatite, tufnol or porcelain insulation material having substantial
mechanical strength specifically against blows and vibrations. They shall be
capable of withstanding the impact and shocks resulting from operation of
the machine. The creepage distance of the insulators shall not be less than
80 mm.
All sharp edges shall be ground smooth. The porcelain insulators shall be
manufactured and tested as per IS 1445:1997.
d) Supporting brackets
The DSL conductors shall be mounted on holders. The holders shall be
bolted on to brackets which in turn shall be welded on to gantry girder at
stiffeners at regular intervals. In normal run, intermediate type of brackets

shall be used, but when expansion joints are provided, sectionalizing type
of brackets shall be provided.
e) Steel to Aluminium straps
These are meant for connecting at expansion joints & power supply cables
from TLFB. They shall be complete with MS cadmium coated bolt nuts,
spring washers, Aluminium lugs etc.
f) Signal lamp assembly
Signal lamp assembly shall be industrial, heavy duty dust tight and water
proof in construction suitable for indoor or outdoor locations. The units shall
comprise three lamps for three phases with red glass lens and reflectors. The
lamp shall be provided with dropper resistance connected in series with the
lamp and the resistance shall be rated for continuous inclusion in the circuit.
Alternatively, a built-in transformer may be provided to suit the lamp
voltage.
g) Current Collectors
2 nos. current collectors shall be provided per DSL conductor, each rated for
100% of total rating. The collector shoe shall be of heavy duty design and
chamfered at both ends, each rated for 100% of total crane rating. Double
collectors on earth trolley line shall also be provided and these shall be
different from those on power trolley line. Collector shall be shall be of cast
iron multi hinged gravity type for self – aligning. Collector shall be designed
in such a way that load is transmitted not to the insulators but on the
insulator stud to avoid damage to insulators. The width of the collector
shoes shall be sufficient to cover the permissible lateral movement of the
crane.
Current carrying shunts on all the collectors shall be designed so that there
is no danger of contact with adjacent collectors. The shunts shall be easily
replaceable. All collectors shall be mounted on rigid steel shafts and suitably
insulated there from. Collectors shall be designed for ease of maintenance
and mounted so that they are readily accessible for this purpose.
h) Trolley Travel
For feeding power to crane trolley, flexible cable arrangement shall be
provided. The flexible trailing cable shall be of multi-strand copper
conductors with permanent terminations on the bridge and the trolley. The
cable shall have ample length and shall be supported by means of properly
designed movable clamps which shall be fitted with rollers mounted on
bearings and shall run freely on a guide rail allowing relative movement of
bridge and trolley without undue stress or wear on the suspended cables.

The cables supported on moving cable carriers shall be so mounted on the
crane bridge that the trolleys are easily accessible for maintenance and
convenient for replacement from the bridge platform. Power and control
cables shall be arranged in separate cable supporting brackets. Two (2)
numbers spare clamps shall be provided on cable trolley for future
requirement.
i) Power Distribution on Crane
1. Power distribution on crane shall generally comprise one
incoming isolator, one circuit breaker in combination with a
contactor suitable for protection against short circuits, earth
faults, over current and shall be provided with no-volt release,
indicating lamps, operating handle for manual operation and all
safety interlocks/standard accessories.
2. The power distribution shall be planned in such a way that in case
of tripping of main incoming circuit breaker the power shall be
still available for essential auxiliaries such as lighting, plug,
sockets, control transformer, etc as required
3. Sheet steel enclosed triple-pole incoming isolator shall be
provided on the crane bridge walkway as close as possible to the
main current collectors. This shall isolate all the circuits except the
crane lighting circuit and the circuit of transformer supplying
portable lighting socket outlets. This switch shall be off- load
isolating type.
4. The above mentioned main isolating switch shall be rated to carry
at least combined full load current of two motions of crane
having the largest kW rating and shall be provided with a means
of locking the switch operating handle in the OFF position. The
switch cover shall be interlocked with the operating handle so
that it cannot be removed or opened unless the operating handle
is returned to the OFF position. The live contacts inside the switch
shall be shielded to prevent accidental contact.
5. The circuit breaker serving as main incoming protective switch,
shall also be rated to carry at least combined full load currents of
the two motions having largest power (kW). Instantaneous
adjustable over-current releases shall be provided to trip the
circuit breaker. The setting of these over current releases shall be
such that the circuit shall be tripped instantaneously when
current rises to 250 per cent of the value specified above.

6. The circuit breaker shall have adequate rupturing capacity to
withstand and clear fault current of the order of 50 KA.
7. The trip circuit of the circuit breaker shall be designed to indicate
whether power and control sources are ON, and whether any
emergency switch has been operated. Indication lamps shall be
provided for it.
8. The main power shall be available through a main power
contactor. It shall be rated to carry the combined full load
currents of the two motions of the crane having largest power.
9. Isolating switches fitted with HRC fuses/ miniature circuit
breakers (m.c.b.) shall be provided for the following branch
circuits:
a) Lighting and hand lamp socket outlets.
b) Control circuits.
10. Voltmeter of suitable range and ammeter to indicate the total
current drawn by the protective panel.
j) Motors:
1. The rating of motors driven by Variable frequency drives shall be
selected as per IS 4137(latest version) and considering the
following requirements-
2. Duty type of the crane & CDF
3. No of switching per hour
4. Inertia of motor and mechanism
5. Ambient correction factor
6. Heating due to harmonic content of inverter waveform.
7. Reduced ventilation due to low speed operation.
8. Constant torque requirement of load.
9. Other limiting factors eg. maximum permissible motor speed,
wind pressure. etc.
10. Technical Parameters
Sl. Parameters Description
1.0 Type - AC Squirrel cage induction motor.
- Inverter Duty
2.0 Standard IS 1231-1974 (For dimension)

3.0 Constructional Features
A Frame size & rating As per IS 325-1996
B Motor body Grey iron casting as per IS:210-1978
C Motor Feet Integrally cast with the stator
D Protection for Motor & IP - 55
Bearing
E Shaft ends & as per requirement
Extension
4.0 Terminal box
A Location On top
B Suitability 4 Core screened Aluminium conductor
Cable
C Earthing stud Inside Terminal Block
5.0 Cooling - TEFC, Effective bi-directional
- Thermistors shall be provided in the
windings. Matching thermistor relay shall
be provided in motor control panel. Device
and associated circuitry shall serve as an
alarm activating an amber signal or pilot
light visible to control station when motor
temperatures become excessive. Set point
shall be set below the Class F insulation
temperature limit. Thermal- sensitive
device and associated circuits shall be self-
restoring (automatic reset).
6.0 Quality of operation
A Vibration intensity Shall be limited as per IS 12075-1986.
B Noise level As per IS: 12065-1987
7.0 Design parameters
A Starting Through Variable Frequency Drive
B Peak transient voltage 1600 V
C Minimum rise time 0.1 microsecond
D Breakaway Torque Minimum 200 % of rated torque
E Duty CDF & Starts/h as per Duty class of the crane
F Max speed 250 % of rated speed or 2000 rpm whichever
permissible is less
G Derating for VFD As per Manufacturer’s standard

H Insulation Class F, temperature rise limited to class B.
I Load Type Constant Torque
J Space Heater To be provided for motors above 110 kW
8.0 Operating Characteristics
A Operation with Motors shall operate successfully under
variation in the running conditions at rated load with
voltage or the variation in the voltage or the frequency not
frequency exceeding the following conditions:
 +/-10% rated voltage at rated constant V/f
ratio except for specific torque boost
situations.
 Motors shall operate successfully under
running conditions at rated load and V/f
ratio when the voltage unbalance at the
motor terminals does not exceed one
percent.
C Operating speed 10:1
range
9.0 Motor application EOT Crane
/location
1.0 Painting Total thickness of painting shall be 140
microns.
11.0 Nameplate - Shall be of corrosion resistance stainless
steel.
- In addition to standard nameplate
information following information shall be
included :
o Nominal efficiency.
o Bearing identification numbers.
o Power factor.
o Full Load Slip RPM.
o Magnetizing amps
o Encoder PPR and Voltage rating
12 Data/ information to - Loadability curve of motor
be submitted by - Efficiency of the motor
manufacturer - Overload capacity ( in percentage of FLC)
with duration

k) Variable Frequency Drive (VFD)
i) Technical specification of VFD is given in a separate clause of this
TS. The VFD for crane shall be suitable for crane application.
l) Control Systems
A separate controller shall be provided for each motion.
i) Control Panels
There shall be separate panels for each motion in addition to the
protective panels and resistance panels.
Hinged doors shall be provided for closed type panels. Panels shall be
front wired. Power and control terminals shall be segregated. 10%
spare terminals shall be provided in each panel.
Equipment in the panel shall be so mounted that their removal or
replacement from the front is easy.
The panels shall be mounted along the girder facing the hand railing.
Sufficient clearances shall be provided between the panels. A minimum
clearance shall be provided in front of the panels for walkway and
approach as per I.E. Rules. The panels shall be supported in the back
from the girder to avoid vibrations
i) Control
Control system shall provide ac variable frequency-regulated, control
of ac squirrel cage motors for hoist, CT & LT motions. Control shall
provide speed adjustment from minimum speed (5-10 percent at no-
hook load) to full-speed. Minimum hoist position of the control shall
not allow hook to lower with 100 percent of full-rated design load on
hook, and the minimum lower position of control shall provide a full-
rated design-load lowering speed at not more than 5-10 percent of
rated speed. Control shall provide automatic regenerative or dynamic
braking for speed reduction and slow down before brake setting.
m) Master Controller (provided in Cabin)
Master Controllers shall be suitable for giving speed reference to VFD.
Master controllers and other control devices shall be ergonomically
located in the Operator’ cabin. Cam type master switches/controller
with joysticks type levers shall be provided for control of different
motions of the crane. The contact shall be of double-break type.
Each controller shall be provided ‘OFF’ position interlock contacts. The
operating handle shall be capable of being latched firm in ‘OFF’

position. The lever shall not remain in between two consecutive notch
positions and shall locate exactly and remain positively at each notch
unless moved to the other position.
Separate master controllers for MH, AH , LT & CT shall be provided
Master controller for each motion controls shall have four/ five notches
in each direction
n) Equipment in operator’s cabin
The operator’s cabin shall contain the following:
- Master controllers for all the motions
- Emergency stop push button.
- Foot switch for alarm or bell.
- Switches for all lighting fixture on crane.
- Switches for cabin fan.
- A fire extinguisher.
- Insulating mat and operator’s chair.
- Cabin light.
o) Radio Remote Control (RRC) ) (as per requirement of technological

process requirement):
Crane shall be equipped with a complete digital radio remote-control
system to permit full control of all motions of the crane from a portable
wireless transmitter.
System shall use proven product of a manufacturer regularly engaged
in design and manufacture of crane radio remote-control systems.
System shall be of a "fail-safe" design so that the failure of any
component or loss of signal shall cause all crane motors to stop. The
system shall permit complete, independent and simultaneous
operation of all the crane functions. System frequency shall be in the
450MHz-470MHz band.
The system shall have capability to provide range of 1.5 times the long
travel distance of the crane. However, the maximum working range
shall be limited to 50 m from the transmitter
The Radio Remote Control (RRC) shall conform to IS-3177/IS 4137
.The system shall have facility of controlling speed in two steps:-

i) Slow speed on the first step of the pushbutton of the radio
remote transmitter representing the first or second notch of the
master controller.
ii) Full speed on the second step of the pushbutton of the radio
remote control representing the final notch of the master
controller.
ii) Following Features shall be provided for RRC:
A 2-position key-operated switch shall be provided to allow transfer
of control from RRC to Pendant Push Button station. Selection of one
operating station shall lock out the controls of other station.
Transmitter:-
- The transmitter shall be portable hand held Push Button type.
- Transmitter shall be provided with the following controls:
Main Hoist - Up/Down.
Aux Hoist- Up/Down
Bridge- Forward/Reverse
Trolley- Left/Right.
POWER- ON.
POWER- OFF.
- A blue signal light mounted on crane visible from floor shall be
provided to indicate the main contactor is energized. POWER-
OFF toggle-switch shall be bright red
- A key-switch with the key removable in the OFF position only or
equivalent security device shall be provided to control
transmitter operation.
- There shall be a common push button for siren and START and a
separate push button for under-bridge lights
- Constructed with microprocessor technology and surface
mounted electronics
- Transmitter shall be provided with two spare rechargeable
batteries and battery charger to permit continuous operation
- Transmission type :- FM FSK
- Built in self- test for all functions .

- Indications :-
 Operation status
 Battery status
 Indicators that display information from crane
- Internal antenna.
- Different operating frequencies.
- Emergency Stop push button .
- Operating conditions:- Areas having large temperature
variations , dusty , more vibrations , oil and humidity .
- Operating temperature range :- Min. 4 deg.C to Max. 60 deg.C
- Protection class: IP - 65.
Receiver :-
Receiver shall have following features :-
- Receiver shall include transfer relays as the crane shall also be
pendant controlled
- Relays for transmitting pre-set reference values to VFD in the
crane.
- 2 safety relays (for control of main contactor)
- Power supply suitable for 110 V AC , Isolation transformer and
surge suppressor shall be provided for the receiver supply
- Two redundant microprocessors for monitoring each other.
- Cyclically redundancy check for high security of transmitted
radio messages.
- Frequency scanning in the receiver.
- Memories last 10 users.
- Interlocking of the relays.
- Momentary or latched relay functions.
- Protection class: IP - 65.
- Operating temperature range :- Min. 4 deg. C to Max. 60 deg.C
iv) Bidder/ RRC Supplier shall obtain frequency allocation letter for the
RRC system from the Dept. of Telecommunication, Govt. of India,
New Delhi on behalf of BOM/RMD, free of cost. For this purpose
frequency allocation forms should be sent to BOM/RMD
after receipt of the purchase order for filling. These forms along with
an authority letter from the BOM/RMD shall be sent back to the
supplier for further necessary action. After the system is
dispatched, necessary operating license/permission for the RRC system
on the crane shall be arranged by the supplier from statutory bodies
as per the detail given in the frequency allocation letter. License fee, if
any, should be borne by the supplier for the first time on behalf of
BOM/RMD.
p) Limit Switches
i) For each hoist motion, a rotary cam type over hoist and over
lower, self-resetting limit switch shall be provided. This limit
switch shall have independently adjustable cams for hoisting and
lowering motion. The cams shall have adjustability such that end
limit can be set to within 100 mm of the hoisting or lowering
motion. In addition to this, a backup ultimate limit switch of shunt
gravity type shall be provided to prevent over hoist. The later
shall be of manual reset type. Provision shall be made to bridge
the gravity type limit switch contact by push button/ switch or
any other means to lower the load. An indication shall be
provided to the operator whenever this limit switch has operated.
ii) Heavy-duty, roller-lever operated resetting track limit switches
shall be provided to limit the travel and traverse motion of the
cranes. Protection class of the limit switch shall be minimum IP
65.
q) Emergency Stop Push-Buttons (Safety Switches)

Safety switches of sustained contact type shall be provided at the
entrances to the crane bridge so that under any emergency conditions,
by operating any one of the switches, the incoming circuit breaker is
tripped thus cutting off power to all the motions. A pilot lamp
incorporated in the control circuit shall glow up when any of these
switches is operated. Further, a mushroom head type “OFF”
pushbutton shall be operated in the operator’s cabin so that main
incoming breaker may be tripped under any emergency condition, by
pressing the operating head.
r) Brakes
Brakes shall be D.C. electromagnetic shunt type, confirming to AISE
standard. The brake coils shall be made of copper and of insulation

class ‘F’. Brakes shall be designed to fail safe whenever the current is
interrupted either intentionally or by failure of the main supply. Brake
circuit forcing shall be provided for D.C. brakes. D.C brake circuit shall
be switched off on D.C. circuit for quick operation of brakes.
s) Lighting on the Crane
Energy efficient lighting shall be provided for approaches and for
carrying out maintenance work without danger. The crane lighting
system shall consist of the following:
i) One 415/240 V lighting transformer which shall be designed to
have minimum 50% reserve capacity. This transformer shall be
separately mounted. The secondary of the lighting transformer
shall have centre tap for earthing.
ii) One metal-clad lighting distribution board with one double- pole
MCB and required nos. of. double-pole outgoing MCB for
controlling crane lighting.
iii) Minimum 4 nos. 250 W/400W under-slung industrial type high-
bay luminaire with dispersive anodised Aluminium reflector
complete with lamps and other accessories shall be provided so
that the working area under the crane is properly illuminated
.The luminaire shall be provided with shock absorbing and anti-
swing suspension device.
iv) Fluorescent lamps with necessary fittings shall be used for
operator’s cabin, staircases, platforms etc.
v) 4 Nos. red warning lights shall be installed on both sides of the
crane to indicate that the crane is down & undergoing repairs.
Provision with socket facility shall also be provided to make the
lamps glow from the external power supply during ‘total power
off’ condition of the crane.
vi) Adequate number of hand lamp socket outlets ( 2 Pin, 10A, 24V)
and power socket outlets ( 3 Pin, 20A, 240V) shall be provided
along with switches socket & switch shall be interlocked suitably.
An inspection hand lamp (with 9W, Multiple white LED, box
design with insulated handle and wire guard) along with
sufficient length (15m) of cable with a plug shall also be provided
for each crane.
t) Cables& Cable laying on Crane
i) All wiring for power, control, lighting etc. shall be carried out with
armoured cables except flexible cables where armouring

shall not be provided. The cables shall be selected with due
regards to the system fault level, design ambient temperature,
the starting and rated current, the distance of load from the
source and the method of laying of cables.
ii) The LT power cables for use in cranes shall be 1.1 kV grade, multi
core, heavy duty, armoured, PVC insulated, PVC sheathed with
stranded H grade Aluminium conductor conforming to table 2 of
IS 8130:1984 for fixed wiring on cranes The inner sheath shall be
PVC and outer sheath shall be extruded PVC type ST2 as per IS
5831:1984.
iii) The control cables & Lighting cables for cranes shall be 1.1 kV
grade, multi core, heavy duty, PVC insulated, steel wire armoured
with stranded 2.5 mm2 annealed high conductivity double tinned
copper conductors conforming to table 2 of IS 8130:1984. The
inner sheath shall be PVC and outer sheath shall be extruded PVC
type ST2 as per IS 5831:1984.
iv) Flexible trailing cables to be provided on the crane for festoon
arrangement shall be 1.1 kV grade, heavy duty type having
double tinned annealed high conductivity flexible copper
conductor conforming class 5 in accordance with IS:8130-1984
.The insulation shall be heat resisting elastomeric based on EPR
conforming to IS:6380-1984. The sheath shall be
Chlorosulpheneted (CSP) or Polychloroprene (PCP) sheath type
HD HOFR. The cable shall be tested as per IS: 9968 (Part-II- 1981).
Interstices of the core shall be filled with non- hygroscopic
material.
v) Cable selection and routing on the crane shall form part of the
crane design. Cable troughs shall not be routed behind the
panels as far as possible. Terminal connectors used shall be got
approved by the Employer. Conduits and conduit fittings if used
on cranes for running cables shall be of standard design and shall
be supplied with complete accessories. Each motor shall be wired
through separate conduits. Only 50% of the conduit inside space
shall be occupied by the cables. All cables remaining live in open
position of the isolator shall be installed separately. Cables
carrying AC and DC power of different voltages shall be laid in
different conduits. Power and control cables shall be laid
separately and terminated in separate terminal boxes.

vi) Use of unarmoured cables other than flexible cables on the crane
can be permitted only at Employer’s discretion and prior
approval. In case use of unarmoured cables is agreed, the cables
shall be laid in sheet metal trunking on the bridge and through
conduits on the trolley.
vii) Incomer Cables of DSL
1) The power cable to be used for power supply arrangement to DSL
shall be 1.1 kV grade multi core heavy duty PVC insulated, PVC
sheathed steel wire armoured with stranded Aluminium
conductor. The cable shall be suitable for steady conductor
temperature of 700C. The insulation of inner and outer sheaths
shall be of extruded PVC type ST1 as per IS: 5831-1984.
2) The control cable shall be 1.1 kV grade heavy duty extruded PVC
insulated, PVC sheathed, steel wire armoured with stranded
copper conductors.
3) The cables shall be laid in concrete cable trench or taken
overhead on cable trays supported on columns, girders or
structural steel members. Cable laying materials like cable trays,
conduits and their supports shall be provided by the Bidder for
both existing as well as the new routes. Making cable trenches
and backfilling with good excavated soil after laying of cables is
included in the scope of work of the Bidder.
4) The cables shall be laid on ladder type cable trays. MS brackets
made of 50x50x6 mm MS angles shall be provided at intervals of
1500mm for supporting the cable trays. Wherever protection is
required from mechanical damage and / or radiation from heat,
GI conduits/ GI pipes of suitable sizes shall be provided.
5) The cores of multi-core control cables shall be serially numbered.
ISI marking at every meter of cable length shall be provided.
u) Identification of Circuits, Cables etc.
Labels of permanent nature shall be provided on supports of all
switches, fuses, contactors, relays etc. to facilitate identification of
circuits and replacement. All panels, controllers, resistors etc. are to be
properly marked for each motion. All cables shall be provided with
permanently identifiable metallic tags at both ends as per cable
number indicated in the supplier’s drawing. The individual cores of
each cable shall be tagged with preformed printed sleeve type PVC
tags. All equipment terminals shall also to be marked likewise.

v) For Inspection and testing of Cranes,3 pin plug and socket with 1 phase
230Vsupply inside each panel for checking and testing purposes shall
be provided.
w) Earthing
Earthing of all electrical equipment shall be carried out as per IS 3043-
1987 in addition to Indian Electricity Rules as applicable
A ring earthing system shall be provided on the crane. Each and every
electrical equipment shall be connected to this earthing at least at two
points. However the electronic circuit insulated earth wire shall run in
panel and terminate at main earth connection only at one point. The
earthing shall be connected to the fourth trolley line in DSL system
through 2 nos. of current collector.
An earth core shall be provided in trolley feed cable
x) Safety
i) Insulating rubber mats shall be provided on the cabin floor and
in front of all electrical panels.
ii) A minimum clearance shall be provided in front of the panels for
walkway and approach as per I.E. Rules. The panels shall be
supported in the back from the girder to avoid vibrations.
iii) Carbon dioxide type fire extinguishers as per safety rules shall be
placed in the area where control panels are to be installed.
Ambient temperature, motor load, date performed and person
performing the alignment.
3.6.46 Roof top solar system
3.6.46.1 PV Modules
 Photo-voltaic module shall be a packaged interconnected assembly of
photo-voltaic cells, which shall convert sunlight into electrical power.
The solar PV modules capacity shall be selected within the system
voltage range.
 The solar modules shall be Mono/ multi-crystalline type. Modules shall
be made of high trans-missive front glass giving high encapsulation
gain and silicon rubber edge sealant for module protection,
mechanical support and moisture proofing. The SPV modules supplied
shall conform to IEC 61215/ IS14286 for PV module

design qualification and type and IEC 61730. In addition, the modules
must conform to IEC 61730 Part 1-requirements for construction &
Part 2 - requirements for testing, for safety qualification or Equivalent
IS (Under Dev). PV modules to be used shall also comply with safety
qualification testing as per IEC 61730. Modules shall be as per BIS or
relevant IEC certification or other international certification on
qualification and safety.
 The efficiency of the module shall not be less than 15.00% and fill
factor shall be more than 70%.
 The glass used to make the crystalline silicon modules shall be
toughened low iron glass with minimum thickness of 4.0 mm for 72
cell module and 3.2 mm for 60 cell modules. The glass used shall have
transmittance of above 90% and with bending less than 0.3% to meet
the specifications.
 The back sheet used in the crystalline silicon based modules shall be
of 3 layered structures. Outer layer of fluoro-polymer, middle layer of
Polyester (PET) based and Inner layer of fluoro-polymer or UV resistant
polymer. Back sheet with additional layer of Aluminium also shall be
considered. The thickness of back sheet should be of minimum 300
microns with water vapour transmission rate less than 3g/m2/day. The
Back sheet shall have voltage tolerance of more than 1000 V.
 The module frame shall be made up of anodized Aluminium, which has
corrosion resistant properties. Bypass diodes of suitable rating shall be
incorporated in the SPV modules to prevent voltage surges. The SPV
Modules shall be equipped with module junction boxes that shall be
IP rated.
 The junction box used in the modules shall have protective bypass
diodes to prevent hot spots in case of cell mismatch or shading. The
material used for junction box shall be made with UV resistant material
to avoid degradation during module life and the Junction sealing shall
comply IP65 degree of protection.
 The rated output of the modules shall have positive tolerance of 3-5
% and no negative tolerance is allowed.
 Modules of rating between 250Wp to 350Wp shall be preferred. These
PV modules shall meet the highest technical standards. These PV
modules shall have weather and waterproof foil back & solar safety
glass front with cells embedded in EV.
 All modules shall be certified

• IEC 61215 2nd Ed. (Design qualification and type approval for
Crystalline Si modules),
• IEC 61730 (PV module safety qualification testing @ 1000 V DC or
higher)
• IEC 61646 (for thin film modules)
• Test certificate from NABL approved or /ILAC member body
certified labs shall be provided.
 The PV modules shall suffice all visual, mechanical and electrical testing
during and post production. Automated production level shall be
ensured for consistent and high level of product quality. The PV system
provides shall also have protection against PV reverse polarity AC over
voltage and PV surge protection AC under voltage.
 The module frame shall be made of corrosion resistant material, which
shall be electrically compatible with the structural material used for
mounting the modules. In case of metal frames for modules, it is
required to have provision for earthing.
 Identification & traceability
A RF identification tag (RFID) shall be placed inside the module
laminate for the following information:
1. Name of the manufacturer of PV Module
2. Name of the Manufacturer of Solar cells
3. Month and year of the manufacture (separately for solar cells
and module)
4. Country of origin (separately for solar cells and module)
5. I-V curve for the module
6. Peak Wattage, Im, Vm and FF for the module
7. Unique Serial No and Model No of the module
8. Date and year of obtaining IEC PV module qualification
certificate
9. Name of the test lab issuing IEC certificate
10. Other relevant information on traceability of solar cells and
module as per ISO 9000 series.
3.6.46.2 Mounting Structure
 The modules support structure should be mild steel, hot dipped
galvanized (Min. 80 microns) for holding the PV modules. Each
panel frame structure shall be so fabricated as to be grouted on
ground or roof on its legs. It shall withstand severe storm with the
speed of 150 km/hr.
 Each panel frame structure shall have provision to adjust its angle of
inclination to the horizontal between 10 to 40 degrees with a step of
10 degree, so that the inclination can be adjusted at the specified tilt
angle whenever required. Each panel frame shall be complete with a
weather-proof junction box as per the relevant BIS specifications,
where the module terminals should be interconnected and output
taken.
 All fasteners shall be of Stainless steel - SS 304.
 The foundation for Module Mounting structures shall be 1:2:4 PCC
Construction. There shall be minimum necessary clearance between
ground level and bottom edge of SPV modules. The structure should
be designed to allow easy replacement of any module. The array
structure should be so designed that it shall occupy minimum space
without sacrificing the output from the SPV panels.
 The specification are as follows:
Type RCC Rooftop
Configuration Designed to suit site requirements
Material Mild Steel for RCC roof
Tilt Angle Suitable to site
3.6.46.3 Inverter with Power Conditioning Unit/ Solar Charge Controller

It shall convert the DC Power into 415 V three phase AC power and feed that
s into the grid. It shall deliver the max. power generated through solar
modules in to grid due to its inbuilt feature of Maximum Power Point
Tracking (MPPT) operations. It shall have an internal self-protection to
prevent any fault from the grid side. It shall have inbuilt contactors/ breakers
with fuses for self-protection.
Each PCU shall have a remote and local data monitoring system with which
all the parameters and current energy generation & past generation for the
given period can be monitored. It shall be able to take reference supply
parameters from the grid for its continuous running, i.e., the AC output
voltage and frequency of the inverter must synchronize automatically to the
exact AC voltage and frequency of the grid. Therefore grid voltage shall be
continuously monitored. The continuous power rating
of this individual unidirectional inverter shall be equivalent to minimum 80
% of peak power rating of each power pack array.
The specifications of inverter are as follows:
Output Voltage 415 V, 3 phase AC
Output Frequency 50 Hz
Voltage Regulation +/- 2 %
Frequency Regulation +/- 0.5 Hz
THD <3%
Ripple DC voltage ripple content shall be not
more than 3 %
Power Factor 0.99
Efficiency (Peak) 90 %
Efficiency (@ 100% Load) >90 %
Efficiency (@ 20% Load) >80 %
Over Load 60 seconds Up to 110 %
Operation Completely automatic including wake
up, synchronization (phase locking) and
shut down
Auto Bypass Feature To be provided
Protections  Over voltage; both input and
output
 Over Current ; both input and
output
 Over/ Under grid frequency
 Over Temperature
 Short circuit
 Surge voltage induced at output
due to external source
 Manual intervention must be
possible through an accessible
emergency switch-off button

The panel shall have following display parameters Inverter Current, PV
Current, Grid Voltage, PV KW Grid Current, PV KWH, Battery Voltage,
Inverter/ Grid Frequency, Battery Current, Inverter Output KVA, Inverter
Voltage, PV Voltage, Battery Charging / Discharging Status, Battery Charging
Mode. Faults shall also be displayed on the user interface panel.
3.6.46.4 Protection against faults for Inverter/ PCU

 The PCU shall include appropriate self-protective and self-diagnostic
feature to protect itself and the PV array from damage in the event of
PCU component failure or from parameters beyond the PCU’s safe
operating range due to internal or external causes.
 The self-protective features shall not allow signals from the PCU front
panel to cause the PCU to be operated in a manner which may be
unsafe or damaging.
 Faults due to malfunctioning within the PCU, including commutation
failure, shall be cleared by the PCU protective devices. In addition, it
shall have following minimum protection against various possible
faults.
 Grounding Leakage Faults: The PCU shall have the required protection
arrangements against grounding leakage faults.
 Over Voltage & Current: In addition, over voltage protection shall be
provided between positive and negative conductor and earth ground
such as Surge Protection Devices (SPD).
 PCU shall have arrangement for adjusting DC input current and should
trip against sustainable fault downstream and shall not start till the
fault is rectified.
 Galvanic Isolation: The PCU inverter shall have provision for galvanic
isolation.
 Each solid state electronic device shall have to be protected to ensure
long life of the inverter as well as smooth functioning of the inverter.
 Anti-islanding (Protection against Islanding of grid): The PCU shall
have anti islanding protection. (IEEE 1547/UL 1741/ equivalent BIS
standard)
 Unequal Phases: The system shall tend to balance unequal phase
voltage (with 3-phase systems).
 Reactive Power: The output power factor of the PCU should be of
suitable range to supply or sink reactive power. The PCU shall have
internal protection arrangement against any sustained fault in the
feeder line and against lightning in the feeder line.

 Isolation: The PCU shall have provision for input & output isolation.
Each solid- state electronic device shall have to be protected to ensure
long life as well as smooth functioning of the PCU.
 All inverters/ PCUs shall be three phase using static solid state
components. DC lines shall have suitably rated isolators to allow safe
start up and shut down of the system.
 Fuses & Circuit breakers used in the DC lines must be rated suitably.
3.6.46.5 DC and AC Distribution box

The DC and AC distribution boxes shall be mounted inside the control room/
closed space.
DC distribution box shall incorporate DC disconnect switch, lightning surge
protectors, any other protection equipment, screw terminal strips and strain
relief cable glands.
AC distribution box shall incorporate AC circuit breaker, surge voltage
protectors, any other protection equipment, plant energy meter, screw type
terminal strips and strain relief cable glands.
3.6.46.6 Junction Box
 All junction/ combiner boxes including the string junction box, array
junction box and main junction box/ combiner box should be equipped
with appropriate functionality, safety (including fuses, grounding,
contacts etc.) and protection.
 The terminals shall be connected to copper bus-bar arrangement of
proper sizes to be provided. The junction boxes shall have suitable cable
entry points fitted with cable glands of appropriate sizes for both
incoming and outgoing cables. Suitable markings shall be provided on
the bus-bars for easy identification and UV resistant cable ferrules shall
be fitted at the cable termination points for identification.
 The Junction Boxes shall have suitable arrangement for the followings:

individual fuses.

 sub-group for quick fault location and
to provide group array isolation.

 The rating of all component of JB’s shall be suitable with adequate
factor of safety to inter connect the Solar PV array.

 The junction boxes shall be dust, vermin, and waterproof and made of
thermoplastic/ metallic in compliance with IEC 62208, which should be
sunlight/ UV resistive as well as fire retardant & must have minimum
protection to IP65 (Outdoor)/ IP21 (indoor) and Protection Class II.
 The Array Junction Box shall also have suitable surge protection. In
addition, over voltage protection shall be provided between positive and
negative conductor and earth ground such as Surge Protection Device
(SPD). The maintenance free earthing shall be done as per the relevant
standards.
 Each Array Junction Box shall have suitable Reverse Blocking Diodes of
maximum DC blocking voltage of 1000V with suitable arrangement for
its connecting. The bypass & reverse blocking diodes should work for
temperature extremes and should have efficiency of 99.98%, confirmed
by appropriate IEC standards.
 Adequate capacity solar DC fuses & isolating miniature circuit breakers
should be provided if required.
3.6.47 Cables & Cabling Accessories
3.6.47.1 33 kV Cables
Type 3 core, 33 kV, earthed, XLPE insulated PVC inner sheathed,
PVC FRLS outer sheathed armoured Aluminium conductor
cables.
Size Size 400 mm2
Standard IS: 7098 (Part-II)-1985
core 33kV, XLPE cable shall be compact circular stranded (rm/V), Aluminium
conductor, provided with conductor screening of semi- conducting
compound, XLPE insulated, provided with insulation screening over
individual cores consisting of extruded semi-conducting compound,
followed by lapped semi-conducting tape and copper tape, cores laid up
together with suitable non-hygroscopic fillers in the interstices, provided
with inner sheath of extruded PVC, galvanised steel round armoured and
overall extruded PVC FRLS outer sheathed heavy duty cable conforming to
IS:7098 (P-II)-1985.
3.6.47.2 The 6.6kV cables shall have the following specification:

Sl Specific aspect of Specification
No. Cable
1. Grade 6.6 kV (UE)
2. Type XLPE ( dry cured )
3. Conductor Circular conductor made of stranded and
compacted electrical grade Aluminium wires
as per IS 8130- 1984
4. Maximum 90oC
conductor
temperature with
rated current
5. Insulation High quality crossed linked polyethylene
compound (XLPE) applied by extrusion
process.
6. Shielding The conductor and the insulation shielding
(Screening) shall be made by extruded semi-conducting
compound. Non-magnetic metallic tape shall
also be provided over insulation as additional
screening.
7. Inner Sheath Extruded PVC inner sheath with non-
hygroscopic fillers for suitably holding the
cores in circular configuration.
8. Armouring galvanised steel round armoured as per IS
7098 (PART-II-1985)
9. Outer Sheath Extruded PVC FRLS outer sheath (type ST2
as per IS 5831-1984)
Minimum size of 6.6kV(UE)cables shall be 3 core 185 sq.mm and shall have
requisite no. of runs based on the load.
3.6.47.3 LT Power Cables
LT power cables shall be 1.1 kV grade multicore heavy duty PVC/XLPE
insulated, PVC inner sheathed, FRLS PVC outer sheathed, steel round/flat
armoured with stranded Aluminium conductor as per IS: 1554 (Part-1) -
1988/ IS 7098 (Part 1)-1988.. The insulation of inner and outer sheath shall
be of extruded PVC (ST2) as per IS: 5831-1984. Minimum size of multicore
stranded Aluminium LT power cables shall be 6 sq.mm. For motor rated
2.2kW and below 2.5mm2 copper cable shall be considered.

3.6.47.4 Control Cables
LT control cables shall be 1.1 kV grade multicore heavy duty PVC/XLPE
insulated, PVC inner sheathed, FRLS PVC outer sheathed, steel round/flat
armoured with 2.5 sq. mm stranded copper conductor as per IS: 1554 (Part-
1) -1988/ IS 7098 (Part 1)-1988 . The inner & outer sheaths shall be of
extruded PVC (ST2) as per IS: 5831-1984.
3.6.47.5 Cable Laying & Installation
i) Incoming 33kV cables from LBSS-1 and MSDS-III shall be as mentioned
in the scope of work.
ii) In order to lay bulk cables between HT/LT substation and the electrical
buildings inside Caster area and ladle furnace new cable tunnels have
been proposed which shall be interconnected.
iii) For cable laying from HT/LT substation to proposed LT substation for
pump house, overhead cable bridge has been considered. Incoming
cables for MSRS substation shall laid partly overhead and partly buried
under ground.
iv) Cable basements have been considered below HT & LT switchgears,
MCC rooms. Cables shall be laid in cable trays, GI conduits etc as per
requirement.
v) Cables may also be taken in Structure/ galleries (overhead cable
routes), underground cable trenches (concrete or buried) and along
Wall, etc. on MS fabricated cable trays depending on necessity of
Cabling. The mode of Cable laying to be followed shall comply with
site condition, required precautions etc. Fire retardant paint shall be
applied at required interval for all cables
vi) In the plant buildings, substations, switch/control rooms etc. power
and control cables shall generally be taken exposed on brackets, cable
racks/hooks laid in tunnels, concrete trenches, cable cellars,
basements, cable galleries or along building and technological
structures. In the auxiliary shops and utility buildings, power and
control cables shall generally be taken on cable racks either laid in
concrete trenches or supported from building structures, walls, ceiling
etc.
vii) Power and control cables installed along buildings and technological
structures, ceiling, walls etc. which are required to be protected against
mechanical damage and/or radiation of heat shall be taken in GI
conduits. GI conduits shall also be used for flame-proof installation,
where required. In corrosive atmosphere where 1,100 V grade cables
are required to be taken in pipes, rigid heavy duty PVC

pipes shall be adopted. Where direct heat radiation exists, heat
isolating barrier shall be provided.
viii) Cables to individual drives, control devices etc. shall be taken in
embedded/ exposed rigid GI pipes/ flexible conduits. Extra length of
cables shall be provided suitably where possible for any future
contingency.
ix) All cables irrespective of type of installation shall be protected by
means of GI pipes or sheet metal protective cover up to a height of
1500 mm from the working floor level and platforms for protection
against mechanical damage.
x) For higher size cables a loop of about 4/ 5m is to be kept in the cables
for meeting future contingency of jointing/termination length.
xi) For 415 V power wiring in auxiliary buildings offices and laboratories
etc. cables shall be taken in embedded/exposed GI conduits or rigid
PVC pipes.
xii) The installation work shall be carried out in a neat workman like
manner by skilled, experienced and competent workmen, with
experience in jointing and termination of Aluminium conductor cables.
Cable runs shall be uniformly spaced, properly supported and
protected in an approved manner.
xiii) All bends in runs shall be well defined and made with due
consideration to avoid sharp bending and kinking of the cable.
xiv) The bending radius of various types of cables as per IS: 1255-1983.
xv) Cable installation shall be properly co-ordinated at site with the
routing of other services/utilities. Where necessary, suitable
adjustment shall be made in the cable routings with a view to avoid
interference with any part of the building, structures, equipment,
utilities and services. Exit of cables from underground trenches or
tunnels shall be through pipe sleeves. Pipe sleeves shall be properly
sealed.
xvi) All cables shall be provided with identification tags indicating cable
numbers in accordance with the cable/circuit schedule. Tags shall be
fixed at both ends of cable, at joints and at 20 m spacing for straight
runs. When a cable passes through a wall, tags shall be fixed at both
sides of the wall. The tags shall be of Aluminium sheet with the
numbers punched on them and securely attached to the cables with
non-corrosive wire. For single core cables wire shall be non-ferrous
materials. Individual cores of control cables shall have for

identification, plastic ferrules with engraved numbers at both ends of
the circuit.
xvii) All cables shall be tested for proper insulation prior to laying. The cable
drums shall be transported on wheels to the place of work. The cable
shall be laid out in proper direction as indicated on the drum using
cable drum stands. In case of higher size cables, the laid out finally
transferred carefully on to the trenches and racks. Care shall be taken
so that kinks and twists or any mechanical damage does not occur in
cables. only approved cable pulling grip or other devices shall be used.
xviii) Adequate length cables shall be pulled inside the switchboards, control
panels, terminal boxes etc so as to permit neat termination of each
core/ conductor. Control cables entering switchboard or control panels
shall be neatly bunched/ strapped with PVC perforated tapes and
suitably supported to keep it in position at the terminal block. All spare
cores shall be neatly dressed and suitably tapped at both ends.
xix) Power cable terminations shall be carried out in such a manner as to
avoid strain on the terminals by providing suitable clamps near the
terminals. All power cable terminations shall be by means of crimping
type cable lugs. Control cables shall be terminated directly at the
terminal blocks by screws.
xx) No joint shall normally be made at any intermediate point in through
runs of cables unless the length of the run is more than the length of
standard cable drum. In cases where jointing is unavoidable, the same
shall be made by means of standard cable jointing kits.
xxi) All opening for cable entry in the equipment shall be sealed and made
proof against entry of creeping reptiles.
xxii) Ladder type cable racks shall be selected from three sizes viz., 300, 450
and 600 mm and shall be fabricated from 50 x 50 x 6 mm MS angles
for longitudinal members and 30 x 6 mm MS flats for cross members
placed at an interval of 300 mm along the length of the rack with a
provision of double cross members at locations, where cables are to
be clamped. Supporting brackets for ladder type racks shall be
provided at an interval not exceeding 1500 mm. Both horizontal and
vertical members shall be of 50 x 50 x 6 mm MS angle and the bracket
shall be welded to the embedded inserts. Alternatively prefabricated
sheet steel/ Aluminium racks and supporting brackets of bolted
construction may be used for power and control cables.
xxiii) Cable racks shall be mounted vertically to the extent possible.

xxiv) Vertical spacing between cable racks shall be between 300 mm to
250m depending upon size and number of cables.
xxv) Power cables of different voltage grades shall be laid in separate racks/
hooks. Control cables as well as signal and communication cables shall
be laid in separate racks. The cables in racks/hooks shall be laid in the
order of their voltage grades such that the cables of lowest voltage
grade are on the topmost tier and highest voltage grade on the
bottom-most tier.
xxvi) Where there is possibility of mechanical damage cable rack shall be
adequately protected by sheet steel covers.
xxvii) For future installation of cables, provision shall be made to keep 20
percent space as spare on each rack. Alternatively, one spare rack can
be provided all along the route.
xxviii) Cable racks shall be so arranged that they do not obstruct or impair
movement in passage way. Particular attention shall be given to this
aspect at rack crossing in cable tunnels and cable cellars where a
minimum clearance of around 1800 mm shall be kept for free
movement. For dusty area cable racks shall be vertical type(for
horizontal run).
xxix) For laying cables along steel/technological structures on concrete
walls/ceiling etc. the cable shall be taken by clamping with MS saddles
screwed on to MS flats welded to the structure or to embedded inserts
provided in walls. Where inserts are not available the saddles may be
directly fixed to the walls using rawl plugs and MS flat spacers of
minimum 6 mm thick.
xxx) The MS saddles shall be placed at an interval of not less than 500 mm
both for horizontal and vertical runs. However, at bends, it shall be
placed with in 300 mm and when terminated to equipment/junction
box the cable shall be clamped immediately before such termination.
In areas prevailing with corrosive atmosphere, PVC saddles instead of
MS saddles shall be provided.
xxxi) GI Pipes
a) GI pipes shall generally be adopted for routing cables embedded
through concrete foundations/ floors/walls (including the portion
above floor level to be laid in continuation for protection against
mechanical damage) generally in plant buildings. These shall be
medium gauge, hot dip galvanised, electric resistance welded
(ERW) screwed type conforming to IS:1239-1990 (Part-I). All pipe
fittings shall conform to IS:1239 -1992 (Part-II).

b) Not more than 40% of GI pipe cross sectional area shall be
used(Blocked).
c) G.I conduits shall generally be used for exposed cabling along
building walls/structures etc. in both plant and non-plant
buildings as well as concealed cabling in offices, canteens and
other non-plant buildings. These shall be of galvanised steel,
screwed type conforming to IS:9537-1981 (part-II). Conduit
accessories and fittings shall be of standard types conforming to
IS:3837-1976 and IS:2667-1988.
d) All GI pipes/conduits shall be provided with pull wires to facilitate
cable pulling.
e) GI pipe/conduit runs shall not have more than three 900 bends
(2700 total) including bends immediately at the outlet or fitting.
Straight runs shall be limited to 30 m by providing approved type
pull/junction boxes as required.
f) Normally, no joints shall be made in through runs unless same is
more than standard cable lengths. In cases where a jointing is to
be done, the same shall be made with proper jointing material
and kits.
g) G.I conduit/PVC pipe systems shall be firmly supported in
position by means of heavy gauge saddles either screwed to
concrete/brick walls using suitable plugs or screwed to MS
brackets/cleats welded on to building structures. The spacing
between support for both horizontal and vertical runs shall not
be more than 1000 mm for straight runs. At or termination to
junction/pull boxes, the nearest support shall be 300 mm from
such fittings. Exposed GI conduits shall run parallel or
perpendicular to column/building lines to match the existing
architectural arrangement. Embedded GI pipes shall however, run
in direct lines with minimum bends.
h) Bends for GI pipes/conduit where required shall be made such
that the diameter of the pipe is not deformed. The radius of inner
edge of field bend shall not be less than 8 times diameter for GI
pipes and 6 times for conduits.
i) In damp locations exposed GI conduit and fittings shall be made
water tight. Also, the conduit shall be mounted on steel spacers
having a minimum thickness of 6 mm. Stub ups of embedded GI
pipes shall be fitted with coupling plugged suitably to avoid
damage to threads or entry of foreign matters during
construction.
j) GI pipes/conduits shall be selected on the basis of percent fill in
area as given in IS:1239-1990 (Part-I) for medium gauge GI pipe
as per IS 9537-1981 (Part-II).
k) The termination of GI pipes/conduits to rotating or other
equipment subject to vibration or connection/disconnection at
intervals shall be made by means of flexible metallic conduits. The
use of flexible metallic conduits in outdoor locations shall be
avoided as far as practicable.
l) Flexible pipes shall be liquid tight, galvanised heavy duty
interlocked type with extruded PVC jacket on top generally
conforming to IS:3480-1966. The adapter for coupling flexible
conduit to rigid pipes/equipment shall be of cast Aluminium,
screw/gland type. Alternatively, steel wire reinforced PVC hose
may be used with matched adapters.
m) All fabricated pull/junction boxes shall be made of 3 mm thick
sheet steel, painted as specified. The pull boxes shall be sized to
suit the largest recommended bending radius of the cables to be
accommodated. Larger boxes (generally exceeding 600 mm in
length) shall be fabricated with standard steel sections.
xxxii) Buried Cables
a) Power and control cables laid directly buried in ground shall be
laid as per the requirements of code of practice IS: 1255-1983.
Generally cables shall be taken at a depth of 1000 mm from
finished ground level.
b) For laying of multiple 6.6 kV grade power cables horizontal axial
spacing shall be 250 mm. For 1100 V grade power cables, the
horizontal axial spacing shall be 150 mm. Control cables shall be
laid touching each other without any horizontal spacing.
However, the distance of the control cable from the nearest
power cables shall be 200 mm. Power and control cables may be
laid in a common trench, but power cables for each voltage grade
and the control cables shall be laid separately in groups.
Generally cables shall be laid in one layer. In general,
communication cables shall not be taken in a common trench. In
case the same is required to be taken along with power cables,
the minimum axial spacing between two cables shall be 300 mm.
c) Precast concrete protective cover shall be placed centrally along
the cables. The concrete slab shall be of RCC type as per
Appendix-C of IS:1255-1983 having suitable provision for

dovetailing with the adjacent slab. The length depending on the
number of cables in the trench as well as axial spacing. The
minimum width of slab shall not be less than 200 mm.
d) After laying of cables, the trench shall be back filled with good
excavated soil and well rammed in successive layers not less than
300 mm depth. The excavation of trenches shall be done with
vertical sides and trenches shall be kept as straight as possible.
the width of trench shall be in accordance with the number of
cables to be laid out but in no case shall be less than
400 mm. The minimum clearance between trench edge and cable
shall not be less than 100 mm.
e) At turning and tee-off points of the cable trench suitable
chamfering shall be made keeping in view the minimum bending
radius of cables.
f) Where cables are required to cross roads, railways tracks and
surface drains they shall be taken through reinforced concrete
spun pipes at a minimum depth of 1000 mm.
g) For crossing water oil, gas or sewage pipes etc. cables shall be
taken above the pipes where minimum 500 mm clearance is
available from top of pipes. Where 500 mm clearance is not
available, the cables shall cross these pipes through RC pipes at
minimum depth of 750 mm from finalised ground level keeping
distance of 300 mm between the utility and cable pipes.
h) In each cable run some extra length shall be kept at a suitable
point to enable one or two straight through joints to be made in
case the cable develops fault at a latter date. Also when group of
cable are laid together the cable length shall be adjusted to
stagger the straight through joints.
i) Directly buried underground cable shall be generally laid by the
utility alley along the roads and cable routing shall follow the
road layout. However, in special cases to keep the cable lengths
minimum the cables may be laid by the shortest route and the
same shall be taken through RC pipe where required.
j) Galvanised iron cable markers and identification tags shall be
provided at each joint, entry to building/tunnels, each turn, either
side of the road crossings and at 30 m intervals for straight cable
runs. The markers shall be conspicuous and fixed in concrete
block in a durable manner.
xxxiii) Termination and Jointing

Termination and jointing of Aluminium conductor power cables shall
be by means of compression type Aluminium lugs. Alternatively, tinned
copper compression type lugs may also be used with application of
corrosion inhibiting compound. Copper conductor control cables shall
be terminated directly into screwed type terminals provided in the
equipment.
Straight-through joints and end sealing of cross linked polyethylene
cables shall be of any of the following types:
 Heat shrinkable type
 Self-amalgamating tape type
The jointing and end sealing kits shall be complete with stress relief
system and all accessories, straight through joint for direct burial
installations shall be provided with cast resin enclosure for protection
against water and corrosion.
Straight-through joints for 1100 V grade PVC insulated cables shall be
with epoxy resin compound for direct burial cables. Cable glands for
terminating PVC insulated, armoured/ unarmoured cables shall be
made of brass or Aluminium alloy.
xxxiv) Cable Racks
Cable racks made of MS angles and flats shall be provided inside the
cable trench.
1. Ladder type cable racks of width 600/450/ 300 mm to be
fabricated from 50 x 50 x 6 mm MS angles for longitudinal
members and 25 x 6 mm MS flats for cross members placed at
an interval of 300 mm along the length of the rack with a
provision of double cross members at a distance of 600 mm for
cable clamping. Length of single piece of cable rack shall be 3
metres.
2. Supporting MS brackets for the support of cable racks shall be
provided at an interval of 1500 mm. Brackets shall be made of 65
x 65 x 6 mm MS angles.
3. Two coats of primer and two coats of black colour finished paint
shall be applied on the cable trays.
Alternatively, prefabricated GI cable trays shall be provided.
3.6.48 Earthing System
3.6.48.1 Earthing network with new earth pits and underground earthing ring shall
be provided for all new electrical & automation equipment. Earthing
network shall be separate for power earthing, electronic earthing&
lightning arrestor circuit. Earthing network shall include equipment level
earthing ring. All new electrical & electronic equipment shall be connected
to respective earthing network. Earthing shall conform to IS 3043 -1987. GI
pipes and galvanised MS flats shall be used for earthing& earth grids. All
joints shall be made with pressure type fitting or welded. Earthing network
shall have earthing resistance below 1 Ohm. Earthing shall be designed
based on earthing calculation. Bidder shall carry out soil resistivity test for
earthing calculation.
3.6.48.2 Electronic earthing network shall be developed considering copper plate
and copper cable etc.
3.6.48.3 Earth electrodes shall have facilities for measurement of resistance and
watering during dry season.
3.6.48.4 Earthing conductors of following minimum sizes & materials shall be used
in the power earthing system as listed below:
Sl. Description Size Material

No.
1. Main Earthing ring/ grid below 75x10 mm Galvanized

ground Flat Steel
conductors
2. Sub grid above ground 50x6 mm Flat -do-
3. Riser/ Pigtail from earthing grid/ 50x6 mm Flat -do-

Mat
4. Earth Electrodes 100 mm dia, -do-

3metres long.
5. Conductors to be used for ground

connection of various equipment/
structures as listed below:-
a) HV Equipment 50x6 mm Flat Galvanised

Steel
b) Structures, Bus Duct, Cable Trays 50x6 mm flat -do-

etc.
c) 415V Power Control Centre/ Motor 50x6 mm flat -do-

Control Centre/ Power Distribution
Boards etc.

Sl. Description Size Material
No.
d) Control Panels 50x6 mm flat -do-
e) Local Panels 25x6 mm flat -do-
6. Motors:
a) Above 90 kW 50x6 mm flat -do-
b) Above 30 kW up to 90 kW 25x6 mm flat -do-
c) Above 5 kW up to 30 kW 25x3 mm flat -do-
d) Up to 5 kW 8 SWG Wire -do-
e) Miscellaneous items, viz. Push 8 SWG Wire -do-

Button Station, Junction Boxes etc.
3.6.48.5 The sizes of copper flat/ copper conductor/ copper strip/ copper wires for
earthing of electronic equipment shall be based on recommendation of PLC/
VFD manufacturers.
3.6.49 Lightning Protection
3.6.49.1 Lightning protection system shall be designed as per IS: 2309-1989.
3.6.49.2 Lightning mast shall be provided on structures and if required separate
earthing masts of steel structure shall be provided to protect all the
equipment / structure. The vertical Air termination rods shall be of 25mm
dia galvanized steel rods. Whereas the horizontal air termination conductor
and down conductor from air terminals (mast) to earth electrode shall be of
50x6mm2 size galvanised steel strip.
3.6.49.3 Lightning Protection system shall have separate dedicated earth pits i.e
other than equipment earthing system earth pits.
3.6.50 Inspection & Testing
3.6.50.1 The tests to be carried out on equipment are sub-divided under the
following heads:
1) Factory Tests (Routine Tests and Type Tests)
2) Site Tests
3) Acceptance Tests
3.6.50.2 Factory tests

All routine tests as per relevant standards referred in respective IS shall be
carried out by the at the manufacturer's works. However, the following
Routine test shall as applicable be carried out in the presence of Employer
/ consultant unless otherwise waived off in writing by the Employer.
Purchase shall be present at workshop as per inspection call schedule, unless
inspection is waived-off:-
1. Visual inspection
2. Insulation test
3. Temperature test (ageing test)
4. Functional test
5. Mechanical vibration test
6. Noise immunity test
7. Integrated functional test
Type/ routine test certificates for all items not specifically covered above
shall be furnished during inspection.
3.6.50.3 Site Tests
1. Verification of hardware as per System configuration
2. Insulation test with 500 V megger
3. Downloading of Application software and checking of all I/O channels,
interposing relays etc. for proper functioning.
4. Checking of field inputs, operation from local/ remote stations,
sequencing, interlocking, reference generation and all other
mathematical calculation functions etc.
3.6.51 Erection & Installation
3.6.51.1 The erection and installation of all equipment items under the scope of
present package shall be done by the Bidder .
3.6.51.2 Erection of the panels shall be carried out in accordance with the guide lines
given by the respective IS Specification.
3.6.51.3 HT Isolators/ Transformers/ PCC/ MCCs / Mimic panel/ Local Control Panels
and all other items under the scope of present package shall be mounted
on steel sections i.e. angles, channels, embedded in the floor and fixed either
by bolting or tag welding after proper aligning and levelling. The supply of
mounting structure, frame etc shall be made by the .
3.6.51.4 During installation, special care shall be taken to check and thoroughly clean
all contacts of breakers, contactors, relays etc. and panels as a whole.

Also, all operating mechanisms shall be checked for smooth operation and
linkages in the mechanism shall be properly greased/ lubricated.
3.6.51.5 The Bidder shall furnish the following information of the VCBs/
Transformers/ PCCs/ MCCs / Mimic panel/ Local Control Panels with the
technical offer:
 Dimensions of each equipment
 Weight of each equipment
 Dimension of cut-out for erection.
3.6.51.6 The floor opening cover required to be removed for erection shall be put
back in position by the after completion of erection.
3.6.51.7 Single Line Diagram (SLD) shall be painted on front & back side of HT & LT
Boards. Cable sizes and no. of runs shall be indicated on back side of the
panel.
3.6.52 Testing & Commissioning
3.6.52.1 The testing and commissioning of the equipment supplied & installed under
the present package shall be carried out by the present package.
3.6.52.2 Site Tests for Commissioning
1) After completion of installation at site, checking and testing of all
equipment shall be carried out in accordance with the specific
instructions furnished by the respective equipment manufacturer.
2) The checking required to be made on the equipment after installation
at site shall generally comprise but not be limited to the following :
 Physical inspection to verify that the transformers/ boards/
panels are in proper condition.
 Check for free movement of mechanisms viz. circuit-breakers,
rotating parts of rotating machine etc.
 Check for tightness of all cables, bus bars, earth connections etc.
 Check for clearance of exposed bus bars/ conductors from
metal enclosure, if any.
 Check for proper alignment of all draw out devices like draw out
type circuit-breakers, if any.
 Continuity check of all control circuits and correctness of wiring.
 Checking of all mechanical and electrical interlocks with manual
actuation of relays as necessary.

 Checking of alarm and annunciation circuits by manual actuation
of relays
 Checking and calibration of device requiring field
adjustment/calibration.
3.6.52.3 Tests to be carried out on the individual electrical equipment shall generally
include in addition to the manufacturer’s instructions but not be limited to
the followings:
Transformers:
 Insulation resistance test with 2500 V megger
 Insulation resistance test with 500 V megger for control circuits.
 Tests to ensure proper dielectric strength of insulating oil.
 Tests to ensure proper operation of buchholtz relay by injecting
compressed air.
 Phasing out test of the transformers which are required to be
operated in parallel.
 DC winding resistance test for various taps.
MCC/ other panels:
 Insulation resistance test with 1000 V megger for main circuits.
 Insulation resistance test with 500 V megger for control circuits.
 Sequential operation test by application of control voltage only.
 Checking of settings of all relays/releases as per drawings.
Control desk, LCS:
 Insulation resistance test with 500 V megger.
 Operation test by application of control voltage only.
3.6.53 Integrated System Commissioning
Integrated System Commissioning shall be carried out by the as per the
following procedure :
1) Cold Trial and Run
After the completion of erection of the electrical equipment as
described in the scope of work cold trial run of the drives shall be
undertaken. Steps involved for the cold trial run shall comprise but
not limited to the following:
 Completeness of supply & erection activities at site along with
accessories, field devices of the individual electrical items as per
relevant drawings and specification and manufacturers manual.
 Completeness of testing of control schematics, electrical and
operational interlocks of power supply equipment and individual
drives
 Elimination of defects found during testing
 Provision of safety features.
 Completion of earthing system as per relevant standards.
 Correctness of inter panel cabling and LT cables
 Availability of special tools and tackles and commissioning
spares.
 Satisfactory result of insulation resistance by meggering.
 Checking of the foundation and final adjustment of alignment.
 After completion of above steps, power supply system shall be
put on and each drive is driven individually in no load condition,
at least for 24 hrs unless otherwise specified. All the circuit
protections shall be kept at minimum settings.
2) Hot Run Test and Integrated Trial Run
The responsibility of hot run test and integrated trial run may lie also
with the other agency of the Employer. The bidder shall co-ordinate
with the agency concerned during hot run test and integrated trial run.
In the hot run test/ trial, the drives are coupled to the mechanisms and
the mechanism in turn are driven with the process input materials by
keeping all the operational interlocks intact and as per the defined
control philosophy. The following aspects shall be checked prior to hot
trial run:
 Interlocking between equipment of different areas
 Electrical interlocks and settings
 Sequential operation of equipment in local/ remote mode
 Rectification of defects/ abnormalities observed during
checking
 Replacement of defective items
 Setting / Resetting / Calibration of relay, protection as may be
applicable for an integrated trial run

3.7 PROCESS CONTROL AND AUTOMATION
3.7.1 Brief Description of the Proposed Control & Automation System
The proposed process automation system shall consist of control &
measurement system at Level-0, PLC based automation system at Level-I
and Process computer system at Level-II. A common PLC shall be considered
for both Electrical and Instrumentation systems. The Instrumentation field
signals shall be terminated on the PLC I/O sub systems for indication,
recording & generating alarms with respect to process parameters.
The complete system shall be able to function in two modes of operation,
namely Computer and Auto modes. In computer mode, process models shall
perform required technological calculations in Level-II process computer
and down load set points to the Level-I system. In auto mode, operator shall
enter the set points in the Level-I system and rest of the functions shall be
taken care of by PLC of Level-I.
All the hardware and system software shall be latest at the time of basic
engineering approval.
3.7.2 System Configuration
Network switch shall be used for providing connectivity among all Level- I
& II equipment, like process computer server, PC based development
station, PC based operator interface, printer etc. through UTP cable. The
Level-I system (PLC) shall be connected with the above-mentioned switch
using suitable media converter and UTP cable. The proposed Level-2
computer system shall be connected with operator interface system (PC),
developmental system (PC), Level-1 system and existing Ladle Furnace /
Caster / BOF/ RHOB / ERP system through a local area network using UTP/
Fibre optic cable so that information about the heats processed at BOF
converters and Casters can be shared / exchanged.
3.7.3 Design Basis
The system shall be designed considering the following:
 Unit distribution of plant.
 Size and importance of plant or unit.
 Number of continuous control loops and supervisory loops.
 Number of digital and analog inputs and outputs
 Man-machine interface requirement.
 Communication requirement at various levels to create an
integrated control system.

 Reliability, flexibility, expandability and maintainability of the
system.
 Cost effective.
 Necessary redundancy as deemed essential.
3.7.4 Control & Measurement
The basic functions of Control & Instrumentation system shall be for
monitoring and control of process parameters as per technological
requirement and ‘Events & Report generation’.
3.7.5 PLC System
3.7.5.1 A PLC based control and automation system (Level-I) shall be provided for
the proposed Ladle Furnace installation. The PLC system shall perform all
the sequencing, interlocking, process control and data management
functions.
3.7.5.2 PLC system shall comprise of required nos. HMIs in combination with Main
Control desk to serve as Operator interface. Main control desk shall be
provided with hardware push buttons, lamps and switches for critical
operations.
3.7.5.3 The field devices like the motors, valves, pumps, magnetic vibrators, chutes,
conveyors etc. shall be controlled as per the process under different process
and safety interlocks. The control of their starting and stopping etc. shall be
by the PLC (level I), which shall execute the command on the basis of the set
points given from Level-II system. Control loops for speed control, charging
control; flow control shall also be executed by PLC.
3.7.5.4 Control Modes
Normal stop push button shall be with soft wired signal and lockable
emergency stop push button shall be hard wired and soft wired signal.
The plant shall operate in the following modes:
i) Local Mode
The local mode shall be provided primarily for maintenance purposes to
ensure that a drive is started with the equipment in sight.
ii) Remote Mode
Generally the equipment except the Transfer Car shall be controlled from the
Main control Room. Main Control Desk with hardware buttons and lamps for
the critical signals and the HMI are to be used to control the equipment.

Operating from the Furnace Control room (MCR) the operator can use any
one of the following modes:
- Manual Mode
In manual mode the operator can give a command from the HMI. In this
mode the motor or the valve shall remain under the safety interlocks like
limit switches, number of starts per hour etc.
- Auto Mode
In auto mode the system is controlled by the Level-I PLC. The equipment
operate as per the set points as given by the level-I.
3.7.5.5 Provision in software:
- for taking backup of entire system and retrieval shall be kept for easy
commissioning.
- System monitoring software to monitor all the important system
parameters (like. CPU/memory/network utilization, memory leakages
etc.) of all the systems remotely on a single dashboard
- Reloadable image backup software
3.7.5.6 Spare Philosophy
The spare philosophy shall be as follows:
1. Control desk and control cabinet shall be provided with 20% spare
terminals.
2. Marshaling panel of PLC shall be provided with 20% spare terminals
blocks.
3. 20% spare interposing relays fully wired up to the terminal blocks
shall be provided in PLC panels.
4. 10% spare components of each type shall be provided in each
control desk /control cabinet / signaling panel.
5. Spare I/o philosophy for PLC shall be as follows:
 Minimum of 20 % of I/o modules used (with at least one module
of each type) for input and output shall be offered as spare for
each programmable controller and the same shall be mounted
and wired to the terminal block in the cubicle suitably.
 No. of spare Channel per card shall be 20 %.
 Provision shall be provided with empty slots for future
expansion for 20% I/o modules.

 Minimum 40 % spare memory capacity shall be available in the
system for Employer’s use after loading of application and
system software.
3.7.6 Process Models for Slab Caster
The relevant process parameters shall be monitored and controlled with the
help of guidance received from the execution of process model software in
online environment. The model software shall run on the process computer
server machine, which shall receive/transmit data from/to Level-I system.
The Model shall be complete with model tuning facilities. Following process
models (min) related to Slab caster shall be used:
3.7.6.1 Secondary Cooling Model
Air Mist /spray cooling system are used in the secondary cooling zone. This
shall be controlled by a dynamic cooling control model. The purpose is to
maintain the strand surface temperature at predefined levels during the
casting process. The temperature is controlled by adjusting the water flow
through the tuyere and the compressed air. The set point of air/mist control
system shall depend on the casting speed, grade and section size of the slab.
This shall facilitate the caster to produce the improved surface quality of the
slabs under flexible casting conditions.
3.7.6.2 Break out Prediction System (BOPS)
A break out prediction system with thermal mapping capable of detecting
sticking, break-out, cold tooth, narrow side crack, slag washing, incorrect
narrow side taper etc. shall be provided to predict possible breakout
conditions in the mould. It shall consist of thermocouples (minimum 3 rows)
inserted in the backside of mould for measurement of the temperature
gradients. Based on the variation in temperature profile, the model shall
predict the abnormal conditions in the mould during casting. Suitable alarm
and annunciation shall be provided. Based on the prediction of break out,
the corrective action shall be taken automatically by Level- I/Level-II system.
3.7.6.3 Soft Reduction Model
A mathematical model for Dynamic Soft Reduction shall be provided to
achieve minimum Slab centre line segregation.
The introduction of Dynamic Soft Reduction, whereby the machine
containment geometry can be changed as required. The machine geometry
is varied via hydraulically gapped segments. Each segment is gapped with
four clamping cylinders, which are equipped with position feedback sensors
that work in conjunction with the automation control

system to ensure that the roller spaces are correct for soft reduction practice.
The Model shall work closely with secondary cooling system and shall
accurately predict the final point of solidification of the strand. Model shall
be used to gather operating variables and together with secondary cooling
system properly gap the soft reduction segments. The amount of soft
reduction, and the length over which soft reduction is applied, shall be
dependent on steel grades and specific chemical composition.
3.7.6.4 Cut Length Optimization
An important function of Level-2 system shall be to ensure that slabs are
produced precisely according to the order. This involves casting the slabs at
correct width, cutting to the ordered length and ensuring that the steel is of
proper composition.
In order to achieve that, order scheduling program shall be fed to level-2
computer, which shall download the length set-point to the torch control
system.
Cut length set point is downloaded to the torch controls by the level-2
system. Slabs are cut to ordered length as long as there are no scrap sections
in the line. Scrap sections are created by stop/teem joints and are tracked
from the time they occur in the mould. As long as there is scrap in the line,
a cut length optimization algorithm is run to adjust the planned cut lengths
so as to place the scrap in an optimum location so as to maximize the yield.
Slab lengths are adjusted between ordered maximum and minimum limits.
If these limits are insufficient to produce an optimum solution, then lengths
are adjusted between absolute usable limits. An attempt is always made to
reduce the length variation in minimum number of slabs as far as possible.
3.7.6.5 Automatic Mould Level Control System
Cassette type eddy-current based AMLC system with capability to suppress
the effects of standing waves, dynamic bulging and roll eccentricity shall be
installed on the moulds. Moulds of the caster shall be designed in such a
way so as to accommodate the AMLC system and mould oscillation.
Integration of AMLC System with the overall Automation System of the
Caster shall be under the scope of the Bidder.
3.7.6.6 Expert System for Slab Caster
The slab caster shall have on line expert system for prediction of slab quality.
The expert system shall predict the quality of slab based on the various real
time operational parameter and chemistry. The expert system should have
built in data base of casting events vis-a-vis slab quality. For any outrage in
casting parameter the expert system be used to track the

surface, sub surface and internal quality of the slab. This is a prime
requirement for high quality steel slabs. The data logging shall be done
automatically and the heat history of any slab shall be known. Decision to
reject /accept the slab shall be based on the expert system. The system shall
be based on mathematical models and AI system.
3.7.7 Process Models for Ladle furnace
The relevant process parameters shall be monitored and controlled with the
help of guidance received from the execution of process model software in
online environment. The model software shall run on the process computer
server machine, which shall receive/transmit data from/to Level-I system.
The Model shall be complete with model tuning facilities. Following process
models (min) related to Ladle furnace shall be used:
3.7.7.1 Ferro Alloy Addition Model
Best possible combination of alloying materials shall be calculated on the
basis of actual steel analysis. These alloying instructions shall be used to
achieve required aim analysis. Necessary GUI screens shall be provided for
entering additive material and Grade related data in Level-2 system for
functioning the model
3.7.7.2 Heating Model
The thermal process control for the LF station shall carry out the calculation
of the aim storage energy to obtain the desired target temperature. Before
the start of LF treatment all expected energy inputs and energy losses during
treatment should be considered to achieve the aimed temperature.
3.7.7.3 Set Point Generation
Various set points for alloy additions, deoxidization, heating, Nitrogen
purging, etc. shall be generated by the computer system and down loaded
to Level-1 system. All relevant data shall be taken from the Level-1 system.
3.7.7.4 Process Tracking
This model keeps track of the heat in the LF area, viz:
Heat arrival at LF
Treatment steps at LF
Departure to the caster
3.7.7.5 De-oxidation Model

De-oxidation Model calculates the quantity of Aluminium required for killing
the excess Oxygen in the melt.
3.7.7.6 De-sulphurization Model
This model calculates the quantity of flux required for de-sulphurization of
the melt.
3.7.8 Programmable Logic Controller (PLC) and Peripherals:
The PLC shall be used for sequencing, monitoring operational parameters
and for event data recording, event monitoring, historical trending,
annunciation and mimic generation. The PLC shall generate output signals
for various drives based on the various field inputs.
3.7.8.1 Standards
The programmable logic controllers and all components shall be designed,
manufactured and tested in accordance with the latest applicable following
standards:
IS / IPSS/IEC Code & Title

Year
IPSS:2-07-015-88 Modular programmable logic controllers.
IPSS:2-07-016-88 Specification for panels.
IPSS:2-07-030-88 Guidelines for application software
documentation.
IPSS:2-07-036-93 Guide for supply of computer hardware
manuals.
IS:12021-1987 Specification for control transformers for
switchgear and control gear for voltages not
exceeding 1000 Volt ac.
IS:8623(Part1)- 1993 Specification for low voltage switchgear &
control gear assemblies.
Programmable controllers (PLC)-General
IEC 61131-Part 1-1992 Information, Definition of basic terminology and
concepts
Equipment requirements & tests, Electronic and
IEC 61131-Part 2-1992
mechanical construction and verification tests
IEC 61131-Part 3-1993 Programming languages, PLC software

structures, languages and program execution
Guidance on selection, installation,
IEC 61131-Part 4-1994
maintenance of PLCs
Guidelines for implementation of languages for
IEC 61131-Part 4-1994 programmable controllers, application &
implementation guidelines for IEC
3.7.8.2 General Features:
1.0 Power Supply System
1.1 Power supply PLC system shall have two independent Input
system supply voltage :-
- 240V AC single phase, 50 Hz from UPS for

CPU and other required control modules,
interrogation voltage and output voltage.
- Two nos. of redundant power supply

modules in each chassis with diode O Ring .
- One source of 240 V AC single phase, 50 Hz

from MCC for auxiliary power supply e.g fans
, panel lamps , power sockets etc.
- Redundant 24 V DC regulated power supply

unit shall be provided for interrogation
voltage and output voltage .
- Separate power supply bus shall be provided

for interrogation voltage supply for all inputs
and output respectively (even if the input
interrogation voltage and output voltage is
same)
- Power supply unit shall be provided with

diode multipliers for input interrogation &
output voltage for driving outputs
(interposing relays, solenoid valves ,lamps
etc.).

- DP MCBs shall be provided for each rack of
the PLC system .
- 20 % spare DP MCB shall be provided in

each panel .
1.2 Built-in power - Suitable for the power supply system as

supply units specified above.
- Following power supply unit shall be
provided for following units :
 Redundant 24 V DC power supply units
(with multiplying diodes for powering field
instruments (2-wire transmitters).
 Separate power supply modules, to be
supplied by the Tenderer for each segment
of Foundation Field bus system, shall be of
Type 132: Non-I.S. power supply intended
for feeding a non-I.S. barrier. Output
voltage shall be 32 V DC maximum. Power
supply module shall have in-built power
conditioner. DP MCBs shall be provided for
each segment of the Foundation Field bus
system.
- Redundant regulated power supply unit of
proper rating shall be provided for special
control module ( if any required).
Following features shall be provided in the

power supply unit mentioned above .
- Insulation level 2.5 KV for 1 minute.
- Protection against surge protection &
short circuit
- Electronic over current protection with
feedback feature.
- Thermostat protection against over
temperature .
- Over voltage protection .
- Fuse protection in the input and output
circuit.
2.0 Central - Hot standby Configuration with CPUs in
Processor different panels (with appropriate
Unit hardware communication module). Both
the CPUs shall update each other in
continuous basis.
- Modular and plug-in type
- 32 bit microprocessor based, fault tolerant
type
- Static RAM (inbuilt, integrated onboard)
minimum 8MB for program memory. This
shall be exclusive of data memory. NV RAM
(Flash card) shall be minimum 8MB.
- PLC shall be able to scan and execute all
close loops (approx. 40 PID loops) in less
than 100 milliseconds and scan digital
inputs in 50 milliseconds simultaneously.
- Execution time between 1 milliseconds to
3 milliseconds per 1K instruction or better.
- Provision to latch desired outputs.
- The CPU system shall have facility of
bumpless transfer in case of failure of one
.
- CPU shall have crystal clock generator .
- Peer to peer communication through I/O
channels shall be possible .
- Backup system communication (redundant
communication bus) shall be provided.
- The processor shall have proper
communication modules (for each CPU) for
communicating with redundant processor ,
remote I/O modules and for
communicating with other communication
bus protocols like Ethernet bus / Profibus

/ Modbus / Controlnet etc.
- The processor shall have in-built provision
for software timers , counters , examining
input conditions, compare, compute,
logical, conversion from/ to BCD, bit
manipulation, block memory
manipulation, diagnostic, shift,
sequencing, conditional jumping,
subroutine instructions etc.
- CPU shall be capable of handling PID
functions including mathematical functions
,weighing and batching functions.
- CPU shall be capable of handling 30 %
additional (future) I/Os over and above 20
% spares (installed) I/Os indicated in basic
configuration diagram.
- Maximum CPU loading shall be limited to
50 % for the intended applications.
- The CPU shall have the facility of initializing
a synchronizing pulse to the server
periodically (Minimum once in a day).
- The operation of PLC shall be completely
unaffected by a momentary loss of power
of the order of 20 msec.
3.0 Timers The timers shall be OFF delay, ON delay,

retentive type timer with a range from few
millisecond to few hours .Accuracy shall be
+/- 0.1 % of the set value . Timer range : 10
ms to 9990 ms or better
4.0 Counters The counters shall be of counter up and
counter down type . It shall have the range
from 0000-9999 with retentivity
5.0 Input Units - Plugin and run type.
- Online replacement of modules without

affecting system operations.
- CPUs & I/O modules shall be of same
series.
- I/O racks shall be provided with redundant
power supply units.
- Separate I/o racks for Electrical &
instrumentation items
- High density, modular, rack based (channel
based I/O not acceptable) and plug-in
type.
- Insulation level of 1.5 kV
- Input interrogation voltage 24 V DC.
- Individual fuse for each unit shall be
provided for protection against cable
fault/earth fault.
5.1 Digital Input Digital input units shall have the following
Modules features :-
 16 / 32 inputs per module.
 With insulation level of 1.5 kV (channel
to earth)
 Channel to channel isolation minimum
500V
 Time delay of about 10 millisecond to
filter out noise and contact bounce .
 Optocoupler to galvanically isolate each
input device from the decision making
logic of the controller
 LED status indication
 BCD input units suitable for four digit
input
 Pulse inputs ( Incremental encoder /
digital tacho )
 Absolute / incremental encoder inputs.
 High speed counter type inputs
 All the cards shall be compatible of
receiving digital signals from field
sensors and switches directly.
 All the control modules / cards shall be
lacquered.
 All the Digital inputs with fused
terminal
 LED status indication in the front of I/O
cards
 Input line, length 600 mtr. with
unshielded
5.2 Analog input Analog input units shall have the following
Modules features:
 Shall be 8 channels, rack based & plug–
in type.
 Suitable for 4-20 mA / 0-10V DC / RTD/
thermocouple / weighing signal inputs.
 Provided with internal temperature
compensation
 With necessary A/D converter having at
least 12 / 14 bit resolution based on
application.
 Suitable for J/K/S/E/N type
thermocouples & for PT100, 2- wire / 3
wire /4 wire
 Galvanically isolated differential inputs
with insulation level of 1.5 kV.
 For 4 – 20 mA analog inputs, fused TB
with blowing fuse shall be provided.
 Healthiness of every input shall be
monitored & diagnostic LED indication
provided.
 Analog module shall have the facility to
be configured in voltage or current
mode and differential or single ended
inputs mode.
 Pulse/ frequency input module shall

have range upto 50 kHz. For very high
frequency applications, the range shall
be upto 1 MHz.
 All the cards shall be compatible of
receiving analog signals from field
sensors and switches directly . If not
suitable converters shall be provided
5.3 Output units - High density, modular, rack based (channel
based I/O not acceptable) and plug-in
type.
- Insulation level of 1.5 KV
- Individual fuse for each unit shall be
provided for protection against cable
fault/earth fault.
5.4 Digital Output Digital output units shall have the following
modules features:
 16 / 32 digital outputs per module.
 High Density modular and plug-in type.
 Isolated outputs with two separate
terminals for each outputs.
 Rated for 24 V DC
 With insulation level of 1.5 KV (channel
to earth)
 Channel to channel isolation minimum
500V
 The output module shall be able to
drive interposing relays (24V DC coil),
solenoids, annunciation lamps, LEDs,
Instrumentation control equipment etc.
 Power devices like contactors etc. shall
be actuated through interposing relays.
The interposing relays shall be
mounted in the same panel. Proper

surge suppressor shall be mounted
across the coil of the output relays.
 Any special requirement e.g position
control to control field devices shall be
met by using separate interface
modules.
 All outputs connected to field through
inter posing relay mounted in the PLC
panel
- BCD output units shall be as follows: -
 Suitable for four-digit output.
 Rated to drive seven segment LED
displays
 With insulation level of 1.5 KV

5.5 Digital Output Digital output units shall have the following
modules features:
 16 / 32 digital outputs per module.
 High Density modular and plug-in
type.
 Isolated outputs with two separate
terminals for each outputs.
 Rated for 24 V DC
 The output module shall be able to
drive interposing relays (24V DC coil),
solenoids, annunciation lamps, LEDs,
Instrumentation control equipment etc.
 Power devices like contactors etc. shall
be actuated through interposing relays.
The interposing relays shall be
mounted in the same panel. Proper
surge suppressor shall be mounted
across the coil of the output relays.
 Any special requirement e.g position
control to control field devices shall be
met by using separate interface
modules.
 All outputs connected to field through
inter posing relay mounted in the PLC
panel
 BCD output units shall be as follows: -
 Suitable for four-digit output.

 Rated to drive seven segment LED
displays
5.6 Analog Analog outputs shall have the following

output features:
modules  Shall be of 4 / 8 analog output

channels.
 Suitable for 4-20 mA / 0-20 mA / +/- 20
mA / 0-10V DC / +/-10V DC outputs as
per requirement
 With necessary D/A converters having
12 bit resolution
 Each output shall be galvanically
isolated.
 With short circuit protection
 Combining analog I/P and analog O/P
in the same card not permitted
6.0 Additional - On-line replacement of any module shall be
Features possible in such a way that the removal and
addition of any module shall be possible
without de-energizing the system. Further
there shall not be any interruption in the
system while replacing a faulty module
except for the inputs / outputs which are
being handled by the module.
- Fully pre-programmed connection of field
devices with input units through ordinary
multi-core copper control cables of 1.5 sq.
mm size (twisted pair) , upto a length of 500
m.
- Communication with computer in
distributed hierarchical control system and
operator consoles / display units.
- Shall have adequate FO ports
- High speed communication among PLC
and operator consoles/ display units shall
be provided through dual redundant TCP/IP
Ethernet using Ethernet cards (no propriety
cards) on HMI station .
- Switch to disable all outputs of the
controller during start-up / debugging

Test sockets on input modules for input
simulation
- Serial interface, RS232C and better
- Any special requirement to control field
devices shall be met by using separate
interface modules.
- The PLC system shall be immune to the
following: -
 Radio frequency interference
 Electromagnetic interference (EMC
compatible)
 Power system spikes
The methods and standards followed for
these features shall be furnished.
7.0 Mounted - Min of 20 % of I/O modules used (with at
Spares least one module of each type) for input
and output shall be offered as spare for
each programmable controller and the
same shall be mounted and wired to the
terminal block in the cubicle suitably.
- No. of spare Channel per card shall be 20%.
- 40% spare memory capacity shall be

provided
- Provision shall be provided with empty slots

for future expansion for 20% I/O modules.
Minimum 50 % spare memory capacity shall
be built in the system after loading of
application and system software.
Spare capacity of the spares mentioned

above shall be applicable at the time of
handing over of the plant .
8.0 Self- - Parity errors, cycle errors and under voltage
Diagnostic - Failure in central processor unit, memory
Features and power supply.
- Indication of type of failure
- Automatic turning OFF of all outputs or
optionally holding of all outputs in their last
state on failure detection.
- Fault detection upto card level.
- Communication failures – all types
- Fuse failure indication for outputs
9.0 Monitoring - Monitoring of internal voltages
Functions - CPU Status monitoring
- Memory status monitoring
- I/O Status monitoring
- Address monitoring
- Bus & communication signal monitoring
- Broken sensor detection
- A milli-ammeter with selector switch shall
be provided on panel facia to monitor the
earth leakage current.
10.0 Terminations - All inputs and output wired up to easily
accessible terminal blocks rated for 660V
- Screened cables for mA signals from
Instrumentation I/O rack and other field
sensors to terminal blocks of PLC.
- Control cables for contact signals from
Instrumentation I/O rack to terminal blocks
of PLC.
- Suitable for terminating up to 2.5 sq. mm.
copper conductor industrial control cables.
- Fuse terminals for all input & output
signals (with LED indication).
- 20% spare terminal blocks
- Cross ferruling for identification of
individual strand termination
11.0 Earthing - Separate earthing bus for power / panel
earthing and electronic earthing shall be
provided. Minimum two numbers of

electronic earth pits shall be provided for
each set of PLC .
- Electronic earthing bus shall be suitably
insulated. Earthing requirements / earthing
schemes for the equipment supplied shall
be clearly indicated in appropriate
drawings.
12.0 Construction - Unitized construction .
al Features - Floor mounted, free standing and indoor
type.
- Bottom cable entry through gland plate.
- Sheet steel clad
- Dust and vermin proof
- Anti-vibration pads to be provided to
withstand vibrations as per application.
- All modules plug-in type.
- Panel illumination with door interlock limit
switch.
- Switch-socket outlet for maintenance.
- Suitable fans & inlet air filters shall be
provided at the bottom/ top of each panel
for proper air circulation.
- Empty slots of the racks shall be provided
with dummy cards for protection against
dust & damage.
- Colour shade outside and inside shall be
RAL 7035.
13.0 Enclosure  PLC rack shall be of front glass type for
easy view of modules without opening
the door, lockable door, internal cooling
fan (if required), totally enclosed, external
heat sink (if required) with dust and
moisture ingression resistant. IP-52 may
be considered for PLC enclosures.
 Conforming to IP-54 class for remote I/O
cubicles located in Plant/field.

 Programmable controllers, even if housed
in air-conditioned enclosure, shall be
suitable for normal industrial
environment and ambient temperature
up-to 50 C.
 Relative humidity
 Daily average 80 to 90% (8 hrs.) and 65
to 90% (16 hrs.)
 Maximum 98%, not occurring
simultaneously with maximum
temperature.
14.0 Data Sheet Bidder shall submit the data sheet of the PLC
to be system. The following information shall be at
Furnished by least mentioned in the data sheet:
 CPU processing speed
The Bidder
 I/O handling capacity
 CPU in built communication port
 CPU programming memory capacity
 Minimum scan time achievable
 CPU self and diagnostic features.
3.7.9 Computer Server/ HMI/work station

Computer servers shall be used as Level-I servers, level-II servers & Interface
server as per the requirement. Level-I & II servers shall be configured as
requirement.
Level-II applications of Slab caster & Ladle Furnace shall be executed using
dedicated set of servers (with redundancy and fallback arrangement).
3.7.9.1 The servers shall have following minimum specifications:
Processor 2 x Intel Xeon Processor, Minimum E-5 series

processor, Minimum 2.4 GHz processor speed
Cache memory Minimum 12 MB Cache Memory
Main Memory Minimum 8 GB RAM of Advanced ECC
Hard disk drive 6 X 300 GB SAS disks @ 15000 rpm, dual

channel, RAID-0+1 & Mirroring support. The SAS
Disks shall be Hot Swappable.
Slots 4x133-MHz PCI/PCI-X slots
Bays 2 or more Disk bays
Architecture PCI bus based architecture
Monitor Minimum 21” LED Monitor
Keyboard Multimedia USB Keyboard
Mouse Optical PS2 Mouse
DVD Writer Minimum 16X DVD Read/write drive
Ethernet Card 2 Nos. dual port 10/100/1000 Mbps network

interface card with RJ-45 ports
Power supply units Redundant set of power supply units with server
capable of running on one.
Fans Redundant set of fans with server capable of

running on one.
Security features Mechanical locks, Power-on password, Remote

control password, selectable boot, Unattended
start-up
Form factor Rack mountable (2u)
Cables & Power, Control, communication cables with

accessories connectors & accessories
Operating System As Required and Latest proven edition.
Management First fail data capture, Dynamic allocation of

features processors & Automatic system recovery
RDBMS Oracle 11g Standard Edition with minimum 5

named user license
Front end tool Visual Studio (latest version) for running the GUI
based applications on the server to cater
minimum 10 nos. of clients
Antivirus Software Perpetual Antivirus Software Server Edition

(latest version) complete with subscription,

updates, patches etc.
Graphic cards High end with latest configuration
3.7.10 PC (Personal computer)

PCs shall be used as development system, engineering station and Level- I
& II clients.
Processor Intel Core i7 Processor with minimum 3 GHz

processor speed or latest at the time of supply
Mother Board Intel Q77 Express
RAM Minimum 4 GB DDR3 RAM
Monitor Minimum 21” LED Monitor
Video graphics Integrated Intel HD Graphics
Model Rack mountable (1U)
HDD Minimum 1 TB SATA, RAID 1configuration
with mirroring
Architecture PCI bus based with PCI-2.1 support
DVD Writer Minimum 16X DVD Read/write drive
Bays 2-3.5”(front open), 2-5.25”(Front Open) & 1-
3.5”(internal)
Port 2-9 Pins fast serial port (16550 UART), 1-25 pins
parallel port (EPP/ECP Bi-directional
Centronics), 2-USB ports
Ethernet Card 32 Bit 10/100/1000 Mbps Ethernet Interface
card with RJ-45 Connectors
Mouse USB type
Keyboard 105 Keys extended Internet keyboard
General Cable, connectors, operation & reference

manual for H/Ws.
Software MS Windows-7 professional 32 Bit complete
with user license, manual, recovery CD &
antivirus software CD

RDBMS Oracle 11g or latest with user license
Front end tool Visual studio (latest version) for PC based
development station
Antivirus software Perpetual Antivirus software complete with
subscription, updates & patches
Development All compliers, front end development tools,
software for PC Utilities and tools with paper licenses, and all
based development user specific application source codes as
system indicated in the earlier clause.
3.7.11 Firewall / Unified Threat Management System
The Security Appliance shall be used to provide proper security to the

network and servers from any kind of attack. The appliance shall be Unified
Threat Management (UTM) based system. The system shall have following
minimum specification:
Sl. Item description Specification

1. Authenticated / Licensed Un limited
Users
2. Firewall Throughput 1500 Mbps
3. IPS Throughput 500 Mbps
4. VPN Throughput 100 Mbps
5. Concurrent Sessions 400,000
6. New Sessions / Sec 5,000
7. VLAN 200
8. RAM 2 GB
9. LAN Port 6 Ports, 10/100/1000 Mbps
10. WAN Port 10/100/1000 Mbps
11. DMZ/WAN2 Port 10/100/1000 Mbps
12. USB Ports 2
13. Console Port (RJ45/DB9) 1
14. Form factor Rack mountable

15.
16. Firewall & Security  Stateful Inspection Firewall
Features  Instant Messenger and P2P
Blocking/ Monitoring
 Port-based , Tag-based and
Bridge mode supported VLAN
17. Add-on Services  Bandwidth management
 Gateway Antivirus / Anti
spyware / Anti Malware
 Antivirus Supported
 Protocols : HTTP, FTP, NBT,
POP3,
 IMAP, SMTP, user-defined TCP
and UDP ports
 Anti-spam
 Web / URL Filtering
 Browser enabled Reporting
solutions
18. HA Support :  Should have HA features with
failsafe option for future
expansion
19. VPN  Remote Access Client Software
 Site-to-site VPN
 Remote Access VPN
 IPSec, L2TP VPN
20. Networking Supported Standards : Static IP,
DHCP, PPPoE, PPTP, Telstra, L2TP
Dialup Backup : USB, Serial
Dynamic Routing : OSPF, BGP, RIP
Multicast Routing : DVMRP, PIM SM
v2
21. Physical specifications Operating Environmental Range

Temp Operational: 0ºC - 40ºC
Storage/Transport: -5ºC - 80ºC
Humidity : 10% - 90% (non-
condensed)
Power : 100-240 VAC, 50Hz
22. Certifications ICSA lab certificates
3.7.12 Peripherals
3.7.12.1 Laser printer
Size A-4
Print speed Up to 17 PPM for black text printing in draft
mode
Print quality Colour printing
Resolution 1200X1200 dpi
Connectivity USB connectivity & TCP/IP based network
connectivity through RJ-45 port
Software driver For printing with Windows, Unix, Linux etc.
Memory 8 MB built in RAM
Duty Cycle Up to 3000 single sided A-3/ A-4 sheets per
month
Cable & Manual Power cable, communication cable &
manuals
3.7.13 Network Switch
Architecture Layer-III /II Gigabit managed Switch

Required Port Density 24 100/1000Base-T ports and 2
independent GBIC/Mini-GBIC/SFP uplink
slots populated with two 1000BaseLX
module
Switching Bandwidth/ Switching bandwidth should be 52 Gbps or
Backplane higher
Throughput Performance throughput should be 35
Mbps or higher for the minimum packet
size of 64 Bytes
Interface Supported GBIC/Mini-GBIC/SFP, 1000BaseSX,
1000BaseLX
Functionality Functionality at Half Duplex and Full
Duplex speed
IPv4/IPv6 Dual Protocol Yes
Stack
VLAN IEEE 802.1Q VLAN support for at least 250
VLANs
RMON Embedded RMON: 4 groups of RMON
(Statistics, Alarm, Events, History)
Standards Supported IEEE 802.1p prioritization with min. four
priority queues
IEEE 802.3x Flow control
IEEE 802.3ad Link aggregation
IEEE 802.1w
IEEE 802.1s
Management capability Management through Web View (Web
Based
Management)/Telnet/SNMPv1/v2/v3/Cons
ole/RMON
Security Security: 802.1x, MAC port Locking,
RADIUS, ACL (Access Control List)

Others Features Rack Mountable with rack mounting
hardware
Quality of Service  Four Egress queues per port
 Trafic prioritization
 802.1p support
Manageability Managed along with embedded Network
Management Software (NMS).
Note: All the switches should have its own mountable cabinet with lock
and key facility. Also, all the switches shall be provided with M12
connectors.
3.7.13.1 Light Interface Unit

Light Interconnect Unit (LIU) shall be 19” rack mounting type suitable for 6
core fiber termination on SC connectors.
3.7.14 Networking (Level-I & Level-II)
Networking & control equipment comprising of switches, routers, media
converters, communication medium (FO & UTP cables) etc. and
development of suitable protocol for interfacing of control & automation
equipment like PLC, HMI & Historian Server, HMI terminals etc. The network
shall be designed to support multi-vendor communication based on
international standards organization's open system interconnection
standard (OSI). It shall be easily expandable to keep pace with growing
application requirements. Networking shall be established through hybrid
network with industrial Ethernet and radio communication link connecting
various resources like PLC systems, servers, HMI terminals etc. Ring topology
based FO network shall be drawn. Main parameters are given below:
3.7.14.1 All FO cable shall be laid through MS pipes when laid over structures and
through HDPE pipes when laid through cable tunnels with sufficient buffer
lengths. All the conduits above shall be painted orange, and shall be covered
with insulating material in heat prone areas.
3.7.14.2 The laying of the network shall be within the reachable limit so that in case
of any cable fault, the same can be easily diagnosed and corrective action
can be taken suitably.
3.7.14.3 The LAN shall be based on 1000 Mbps (TCP/IP gigabit Ethernet) network
with single mode fiber optic cable and Cat 6 UTP (unshielded twisted pair)/
STP (shielded twisted pair) cable as the medium of communication. Cat 6

cable may be used inside the control rooms for short distances (limited to
90 meters), wherever required. Clients located outside the building premises
(greater than 90 meters) FO cable shall be used to provide the connectivity.
Redundancy in network equipment shall also be considered.
3.7.14.4 PCs shall be connected through Information Outlets. There shall be enough
provision for additional clients in future. PCs and the network equipment
shall be powered from 5/15 ampere UPS socket outlets with proper Earthing.
Indoor cabling between switch and PCs shall be of Cat 6 UTP/STP cable in
PVC pipes in a structured fashion from information outlet to patch panel
and from patch panel to switch in wall mounted racks. For shop floor
overhead laying of Cat 6 UTP/STP cable medium duty GI conduit shall be-
used.
3.7.15 Large LED Display Screen (52”)

Important information on production, plant equipment status and process
parameter information shall be displayed on LSDs provided at Central
monitoring station & Main Gate display board. It shall have high reliability
and high resolution with improve image quality in a variety of environmental
conditions. The features for LSD shall be as follows:
Sl No. Features Specification

1 Display Resolution 1024x768 (XGA)
2 Aspect Ratio (W:H) 4:3
3 Screen Dimension:
Diagonal 52”
4 Screen type Wide View Glass

5 Contrast ratio > 1200:1
6 Brightness > 80%
7 Colours 16.7 million
8 Operating Temperature 0-450 C
9 Display Technology LED
10 Data input Analog, digital, video

11 Display control Wireless, IR, Ethernet, Remote etc.
3.7.16 Main Control Desk

3.7.16.1 Multifunctional control desk with selector switches and push buttons shall
be provided to facilitate the operations through three position selector
switch having 4-positions i.e. for ‘PLC/ Off/ Local/ Remote’ with the selection
of a group of mechanisms. However, in ‘PLC’ mode the system shall ‘start’
& ‘stop’ automatically based on the sequential logic. In ‘Local’ mode a group
of mechanism shall ‘start’ & ‘stop’ from Local control stations (LCS) near the
equipment without any sequential interlock and in ‘Remote mode’ a group
of mechanism shall ‘start’ & ‘stop’ from control desks through push buttons
with all interlocks. The grouping of a number of mechanisms shall be
decided during engineering stage. There shall be a common ‘start’ push
button which shall start the system once the system is in ‘PLC’ mode and in
addition there shall be a ‘Emergency stop’ push button which shall stop the
entire system in case of any emergency situation.
3.7.16.2 The Control Desks shall be horizontal, floor mounted, totally enclosed, dust
& vermin proof, bench board type construction having degree of protection
of IP-52.
3.7.16.3 The Control Desk shall be provided with hinged doors of width not
exceeding 1000 mm (with in-built locking arrangement and handle) on the
rear side. It shall be possible to open the door through 100 degrees. All the
access doors, covers, cut-outs shall be provided with neoprene rubber
gaskets all round and latches sufficiently strong to hold them in alignment
when closed and to achieve the degree of protection as specified. To have
access to the wiring & maintenance of components mounted on slant
portion of control desk, removable, bolted covers made out of sheet steel
thickness not less than 3 mm shall be provided on the lowermost slant
portions of the control desks.
3.7.16.4 All equipment mounted on the front face of the desks shall be flush type.
All equipment shall be so located that their terminals and adjustments are
readily accessible for inspection and maintenance. and their removal and
replacement can be done without disturbing the other equipment and
within hand limits from floor, without requirement of additional elevation.
3.7.16.5 All internal components of the desks shall be arranged neatly. Sufficient
clearances shall be maintained between different components for ease of
operation & maintenance. Detailed internal arrangement drawing
indicating spacing between different components should be submitted by
the Bidder for Employer's approval.

3.7.16.6 In case of space constraint, new vertical type control posts can be also
acceptable in place of control desk. However, the other features shall be
same. The existing control desks shall be dismantled by the Bidder only
when the new control desks shall be fully commissioned.
3.7.17 Molten Steel Temperature Measurement System
The immersion temperature measurement system shall consist of a Pt/Rh,
“S”-type (Pt/Rh {10%} – Pt) thermocouple sensor, a microprocessor
controlled measurement and evaluation unit and a 4 digit 20 mm height LED
display along with necessary cables. The evaluation unit shall have a serial
data output with 20 mA current loop for interfacing with main computer
system. Storage, retrieval & display of data shall be provided.
Major technical Data for the Molten Steel Measurement system:
Measurement Measurement value processed by microprocessor

Principle using digital differentiation and mean value
formation algorithm.
Measurement 400-1800 o C
Range
Resolution 1.0 o C
Accuracy 0.5 o C
Data output Serial data output with 20 mA current loop (300
BAUD)
Large Display Unit Required with 300 mm size
Measurement Measurement sequence, signaling ‘ Ready,
Sequence measurement , complete ‘ by signaling lamps .
3.7.18 Temperature & Oxygen Measurement System

The temperature & Oxygen measurement system shall consist of Rh/Pt
sensor and Oxygen sensor, a microprocessor based measurement &
evaluation unit and digital display along with necessary cables. The
evaluation unit shall have a RS 232 serial data link with PLC. Immersion lance,
cables, display unit, horn, temperature & Oxygen probes, etc. shall also be
provided. Measurement shall be based on the measurement values
processed by microprocessor using digital differential and mean value
formation algorithm.
Measurement range for temperature : 300 – 1800 oC,

Measurement range for Oxygen content : 1 – 1000 ppm, (in liquid steel),
Display : digital
3.7.19 Argon Measurement & Control Device

Pressure measurement shall be provided (local indication) with low-
pressure alarm both at inlet and delivery points. Pressure control shall be
done through self actuated type control valve. Flow measurement and
control shall be done through PLC with totaliser. All control & ON/OFF
valves shall have isolation valve in inlet & outlet. NRVs shall be provided and
pneumatic valves shall have limit switches for indication in HMI.
3.7.20 Flow Measurement
3.7.20.1 Orifice Plate
The orifice plate shall specifically be designed as per B.S. 1042 section 1.1:
1981, 1.2 & 1.4: 1984. The orifice plate shall in general be of square edge
type with flange tapping. All orifice plates shall be supplied with matching
flanges of suitable rating. All tapping arrangements shall be complete with
a piece of nipple and a shut off valve of adequate pressure rating.
Material of orifice plate assembly shall be of SS 316. The matching flange
shall be of carbon steel. For line sizes above 50 mm the diameter ratio (d/D
ratio) shall preferably be selected between 0.548 to 0.775. Base of the orifice
plate shall be parallel within 0.5 degree. Other details as well as design
guidelines shall be as per BS 1042 section 1.1: 1981, 1.2 & 1.4: 1984.
3.7.20.2 Magnetic Flow Meters

Magnetic flow meters shall be provided for water flow measurement. The
system shall be smart remote type. Ultrasonic flow meter shall be provided
for standardization of magnetic flow meters.
For gaseous medium, Orifice, Vortex or Thermal mass flow shall be
considered.
3.7.20.3 Flow Switch
Type Calorimetric type

Display Local display in terms of percentage %
Measuring range As required
(m3/hr)

Normal flow (m3/h) As required
Maximum flow (m3/h) As required
Line Size As required
Hydraulic Test Pressure 10 Kg/cm sq
Maximum Working 5 Kg/cm sq
Pressure
Operating temperature 55 c
Liquid Water
Mounting Cast Aluminium
Enclosure class IP:66
Switching One SPDT micro switch
Switch rating 5 A, 230 V AC
Cable entry ½ ‘ NPT (F)
Repeatability +/- 2 %
Accuracy +/- 5 %
3.7.20.4 Smart type Flow transmitter/ pressure transmitter

Flow Transmitter shall be of smart type with variable capacitance / piezo
electric type sensor. Transmitters shall be with built in field indicator, two /
three way manifold and mounting accessories etc. For flow transmitters
square root extractor shall be provided in addition to the above. One set of
Hand Held Calibrator (universal HART protocol) shall be provided for
calibration. The tech data is as follows:
Range As required
Output 4-20 mA dc & superimposed digital signals on
HART protocol.
Power supply 12-48 V dc.
Power supply Maxim. Zero shift 0.005% of span/volt change in
variation effect power supply.
Load limit 600 ohms.
Zero adjustment Continuously adjustable.
Ambient temp. 0 to 60 oC limit.
Over pressure limit 200% of upper range limit.
Accuracy < 0.25% of span.
Linearity < 0.1% of span.
Repeatability < 0.05% of span.
Sensitivity < 0.05% of span.
Dead band < 0.05% of span.
Elevation/suppressi - 50% of lower range limit to + 100% of upper
on range limit.
Reverse polarity Reverse polarity protection shall be provided.
The reverse current should be limited to 1 mA.
Transient protection Up to 2500 v pulse (8 micro sec rise time and 20
micro sec decay to half value).
Lightning protection Required
Damping Damping shall be step or continuously
adjustable, so that the time constant varies from
0-3.0 sec or 0-6.0 sec.
Humidity limit 0-100% R.H.
RFI, EMI effect R.F.I. filter shall be built in. The output error due
to this shall be less than 0.1 % of span for
frequency upto 500MHz & field intensity
20v/m/60 to 120 dB.
Temperature effect Maximum zero shift + 0.5% upto 55.5 oC
Over pressure effect Maximum zero shift + 0.5% by 100% maxm.
Static pressure
Vibration effect + 0.05% of URL/g for frequency 15 to 150 Hz.
Mounting position Rotation in plane of diaphragm should have no
effect. Maximum zero shift 1.0% for 90 oC tilt.
Static pressure Zero shift less than 0.5% of span for pressure
effect change upto static pressure limit.
Response time Less than 0.1 sec.
Housing IP-65, IS-2147-1990.

Mounting As required
3.7.20.5 Rotameter
Function Continuous flow measurement of water

Range 10 m3/hr
Fluid pressure 2 Kg/cm2
Fluid temperature 100 oC max.
Body material Metal tube of SS 316
Accuracy +1%
Process connectivity Through flange at both sides.
3.7.21 Level measurement

3.7.21.1 Level switch
Function Level switching of tank / sump
Type Capacitance
Fluid Cooling water
Construction MS sheet
Ambient temperature 60 0 C
Mounting As required
Probe Material Ss 316 flexible wire rope, Teflon taped
Housing protection IP 66
Overall probe length below As required
flange
Process connection 21/2” A NSI 150 RF in CS
Cable entry ½” NPT
Probe head material Dough Moulding Compound
Material of Construction of Cast Aluminium
Switch
Input Compatible with probe unit
Relay output 3 NO for Hi, Low & Low- Low level
Adjustable over entire range Yes
Contact rating 5A 230 V AC, resistive
Switching accuracy +/- 1 % of FSD
Repeatability +/- 1% of FSD
Signal lamp LED for output status
Power supply 24 V DC,
3.7.22 Pressure Measurement

3.7.22.1 Pressure switch
The pressure switch shall be diaphragm, bellows or bourdon type. The
sensing element material shall be SS AISI 316. The case shall be of die cast
Aluminium, weather resistant, black epoxy resin painted and provided with
neoprene gasket. The scale shall have black graduation on white linear scale
with 0-100 % graduation with red pointer. The switches shall have
specifications as follows:
Range As per requirement

Over range  PS-150% of maximum pressure protection.
 DPS-Static pressure on one side with other side
open to atmosphere.
Adjustment  Set point
 Internal differential adjustment nut with dial.
 Set point adjustability over span range.
 ON-OFF differential limits +/- 0.5% FSD or better
adjustable throughout the range.
Switch Two nos. SPDT suitable for 240 V AC 5 Amp or 220 V
DC, 2 Amps.
Accuracy + 0.5% of span or better
Repeatability + 0.5% of span or better
Enclosure class Hermetically sealed.
Protection class As per standard.
Accessories 1. SS union nut and tail piece suitable for welding to

impulse pipe.
2. Snubber for pulsating fluid.
3. Siphon for steam/hot water services.
4. SS 316 with Teflon Coating diaphragm seals (with
capillary extension if required) for corrosive,
viscous, solid bearing or slurry type process fluids.
5. Valve manifold of SS.
6. Blow out disc.
7. Chemical seal as required.
3.7.22.2 Differential Pressure switch
Type Purge DP type

Enclosure Pressure Die cast Aluminium.
Finish Powder Coated
Protection class IP:66
Mounting Field
Sensor 316L SS diaphragm
On Off differential As required
Repeatability +/- 1% FSR
Adjustable range As required
Operating temp. As required
Operating pressure As required
Indication Local indication of the differential pressure value
along with LED for its status.
Range As required
Contacts Snap acting SPDT micro switch.15A ,230V AC
Process connection ¼ “ NPT(F)
Cable entry ¾ “ ET
Other wetted parts 304 SS
3.7.22.3 Pressure/ Differential pressure gauge

Direct mounted bourdon tube type pressure gauge with SS 3 way cock,
mounting accessories and suitable for bottom / back entry. For viscous fluids
/ slurries application the pressure gauge shall be with built-in SS diaphragm
separator.
Dial Size 150 mm

Case Cast Aluminium
Blowout Protection Required
Moving parts material AISI 316 SS
Element material AISI 316 SS
Element C – Bourdon
Accuracy +1%
Process Connection 1/2 “ NPT
3.7.23 Temperature measurement
3.7.23.1 Smart Temperature measurement

The smart type temperature transmitter shall be used for converting
resistance signal from a Pt-100 resistance temperature detector into output
signal of 4-20 mA dc. The converter shall have following specifications:
Input RTD input - Pt-100.

Output 4-20 mA dc (Load resistance 0-600 ohms or more)
and superimposed digital signals on HART
protocol.
Power supply 24 V dc.
Ambient 60 oC
Temperature
Process temp. As required
Humidity 0-100 %
Accuracy + 0.25 % of full span
I/O isolation The input, output and power circuit shall be
isolated.

3.7.23.2 Resistance Temperature Detectors (RTD)
The resistance elements shall be of platinum (R0=100 Ohm) conforming to
Grade-B IS-2848-1986. The element shall be duplex ungrounded with 3 wire
connection. For special applications like heat flux monitoring in Blast
furnaces, matched pair type RTDs, PT-1000 shall be used. The detail
specifications shall be as follows:
Response time Better than 40 seconds with thermo well and

15 seconds without thermo well
Accuracy As per DIN-43760.
Protective Tube  Material-SS 316 Stainless.
 OD- 8 mm or as required.
Loading Spring loaded to ensure positive contact with
well. Rotation of insert with respect to head &
resultant twisting of leads shall be prevented.
Terminal Head Material Die cast Al painted with black enamel paint.
Terminal Brass screw type - silver plated
Cable ¾" Cable gland complete with neoprene/
Teflon / grommet to suit cable
Terminal head cover Shall have gasket and SS chain
Terminal head Type NEMA-4 screwed type or equivalent
(removable from sheath). Terminal shall be
brass screw type silver plated
Insulation The insulation resistance between terminal
and the sheath shall not be less than 10 M
Ohms at 250 V dc at room temperature.
Type: MGO filled (Purity 99.49 %)
Immersion length As applicable
Tests As per IS 2848:1986.
Accessories  External nipples with thermowell
connection,
 Adjustable Compression fittings / unions
for variable insertion,

 SS 304/316 thermowell as per ASME 193
with process connection as required,
 3 Mtr long PVC insulated metallic flexible
conduit with end fittings.
 Thermowell ( as per specification to be
supplied)
Protection Index IP-67
Lead wire of element Silver/Silver plated copper
3.7.24 Control Valves

Control valves shall be designed to function continuously and satisfactorily
under most severe conditions with minimum maintenance.
It shall be made of high quality material, cast bodies and X-rays inspected.
Body, flange and term material shall comply with physical and chemical
operating conditions of process fluid. Thickness of the valve body shall be
as per API/ASTM standards.
Pneumatic actuator shall be used in regulatory control. The actuator shall
receive 4 to 20 mA input signal from the controller and shall have electro-
pneumatic converter, valve positioner, limit switches, capacitance
/inductance type valve position transmitter, companion flanges and other
accessories as required.
Leakage class of the valve shall be min. class II as per ANSI b16.21.
Control valve specification shall be generally as follows:
Valve type Single seated Globe Valve

Line size As Required
Guiding /points Top guided, V-port
Bonnet Finned
Body material ASTM –A216 NCB (Carbon steel)
Packing material Grafoil
Valve action Energy failure to stay-put
Trim material AISI-316ss
Leakage Class-IV

Actuator Pneumatic actuator
Class of insulation B
Enclosure IP-65
Duty-cycle As required
Position Indicator As required
Position Transmitter Inductance / Capacitance type with 4-20
mA DC output
Matching With nuts , bolts gaskets etc.
Limit Switch 2 nos.
Torque Switch 1 nos.
Hand Wheel Yes
3.7.25 Load Cell

Type Compression / shear beam based Strain
gauge type.
Capacity As required
Accuracy 0.05 %
Temp. Compensation Reqd. in the range of –20 to 80 deg. C.
Hysteresis 0.05 %
Repeatability error 0.02 %
Drift <0.02 in a period of 6 months
Over load capacity 200 % of rated load
Lateral load capacity Min. 30 % of rated load.
Dead load Required
compensation
Output Mfr. To specify
Power Supply To be drawn from weigh electronics (230 V
AC, 50 HZ )
Protection Weatherproof IP-67, IS 2147:1962
Connection cable Screened cable
Mounting accessories Required

3.7.26 Fire detection & alarm system
Intelligent type addressable fire alarm system shall contain intelligent type
addressable multi criteria sensors, heat detectors, manual call points,
response indicators, fire alarm panel, FRLS cables and hooters.
Automatic Fire detection & Alarm System shall be designed, manufactured,
supplied, erected and tested as per requirement laid in fire protection
manual issued by Tariff Advisory Committee of India and relevant Indian
Standard specification / IPSS.
3.7.26.1 Operating Conditions
All equipment and accessories for Fire Detection & Alarm System shall be
designed for operation at the required capacity in tropical humid climate
with an ambient temperature of 55oC maximum and 50oC average over 24
hours. The de-rating of all equipment shall be done for an ambient
temperature of 55oC unless otherwise specifically stated in the Technical
Specification.
3.7.26.2 Power Supply
Suitable normal & back up power supply system shall be provided as per
smooth functioning of the system.
3.7.26.3 Earthing System
Suitable earthing as per system requirement shall be provided for smooth
functioning of the system.
3.7.26.4 System Features
In the event of fire, detectors shall sense and transmit the signal to the Main
Control Panel. Audio visual alarms shall be initiated simultaneously on main
control panel, repeater panel and locally. Main control panel and repeater
panel shall display the address of the detector where the smoke/fire has
been sensed.
The total area under surveillance shall be divided into several zones
(detector loops). Detectors and Local Response Indicators shall be installed
depending upon the area under monitoring. Local response indicators shall
be provided for detectors installed either above false ceiling or below false
flooring, if any, and shall be installed at a place where it is easily visible.
Various detectors used with the system shall continuously report about the
general condition of the area being monitored.

Detectors shall produce analogue signal instead of on-off contacts, which
shall be varying with smoke density or heat. In the detector itself the
analogue signal shall be converted into digital data, which is sent back to
the main control panel.
The system shall permit varying alarm level for each detector. This can be
programmed from the main control panel.
In the main control panel, the analogue value of the detector shall be
compared with the limits set in advance to determine the following alarm
conditions - "Normal, Pre-warning, Alarm, Fault" etc.
During the "Pre-warning" limit, no external alarm shall be raised. Only after
confirmation that the analogue value of the detector signal has increased
up to "Alarm" level, the external alarm shall be initiated by the system and
alpha numeric display on the main panel shall display the exact address of
the location of fire.
Cross-zoning of detectors shall be provided preferably in all the areas to be
covered under fire detection system. Repeater panels shall be provided at
the strategic locations.
The complete system shall be fail-safe type. All the external cable connected
to the individual fire stations shall be fully supervised for short circuits or
open circuits. An audiovisual alarm shall be annunciated on the main control
panel displaying the location where the above-mentioned condition has
developed. The audio signal can be silenced but the visual fault indication
shall however continue to glow till the fault in particular zone is removed.
The system fault audio alarm shall be differentiated from the fire audio
alarm.
A test switch shall be provided to check the proper functioning and
healthiness of the system.
Provision shall be kept in control panel to repeat the fire signal in the plant
fire station.
There shall be provision to interlock the Fire detection and alarm system
with ventilation/air conditioning system to prevent further spreading of fire.
There shall be provision for automatic operation/actuation of firefighting
system e.g. water sprinkling system etc. after detection/ confirmation of fire
through Fire Detection & Alarm System.

In all fire prone areas, two separate and isolated detection circuits in each
fire zone shall be provided which shall have alternative ionization and
photoelectric type smoke detectors.
In transformer rooms/ battery rooms, rate of rise-cum fixed temperature
detectors shall be provided.
System Components
The Fire Detection & Alarm system shall consist of the following:
 Main Control Panel (CCU)
 Detectors (Ionization Smoke Detectors/ Thermal sensor (Heat
detectors)/ Photoelectric smoke detectors.).
 Repeater Panel
 Manual Call Stations
 Response indicators
 Electronic Hooters
 Connectivity of proposed FDA system with the existing centralized
monitoring & control system installed at central fire station of
plant.
3.7.27 Telecommunication system
3.7.27.1 Plant telephone network- Requisite nos. of plant telephone connection
including telephone sets shall be provided in proposed Slab Caster, LF &
associated area. Required cabling from nearest DP box of plant telephone
network shall also be included.
3.7.27.2 SLIC system shall be provided to cover major areas.
3.7.27.3 Walkie-talkie communication system to cover major areas.
3.7.28 CCTV
3.7.28.1 The camera shall be suitable for day and night operations. The camera shall
be IP based with digital output signals. Each of the TV cameras shall be
hooked up to the network. Remote viewing of cameras shall be provided.
The monitors along with its controls and its associated equipment shall be
installed at main control pulpit. All control functions related to CCTV systems
comprising of Cameras, Monitors, Water cooling jacket, blower unit and
wipe & wash unit of the weather proof housing shall be affected from the
control unit to be installed in strategic location & main control room.
The CCTV system shall comprise of colour TV cameras with manual and
motorized zoom lenses as required, camera mounting platforms/ structure

as required at site, Water cooling jackets, complete with wipe & wash units,
Remote controlled Pan & tilt units, Control console with control units for
complete control of cameras and associated devices, colour TV TFT
monitors, Interconnecting video & control cables, UPS system, Video
distribution amplifier/ Video cable equalizers, Camera streamers , NVR
Database & Camera Servers etc. as per requirements. All other auxiliary
equipment, connectors, erection accessories etc. shall be provided as
required.
3.7.28.2 IP Video Management System
a) The Network Video Recorder should support required nos. of IP
cameras as per project requirement.
b) The IP video management system shall support recording of H.264,
MPEG-4 and JPEG streams.
c) The IP video management system shall have a fully open architecture
with support for both IP-specific camera as well as third party
cameras with ONIVIF compliance.
d) The IP video management system shall support an unlimited number
of systems connected over a network. Each system shall contain two
1GB network ports; one for IP camera data, and one to connect to a
network for client computer access.
e) The IP video management system shall be viewed, managed, and
played back through a single user interface
f) The IP video management system shall operate on a 2nd Generation
Intel® Core™ I7 processor or better and minimum 8 GB of RAM
g) The IP video management system shall provide a client application
for viewing ,monitoring and controlling the PTZ cameras and the
client should be a separate workstation/machine connected to the
network
h) The IP video management system shall operate on a 2nd Generation
Intel® Core™ I7 processor or better and minimum 4 GB of RAM
i) A client computer with system compatible software shall be the user
interface for viewing one or more systems. Live and recorded video
and current event video shall be displayed on any client computer
using a proper login and password. The client computer shall be able
to connect to an unlimited number of recorders simultaneously to
display live and recorded video.
j) Client Software shall be for minimum 10 clients and available to be
installed on as many clients as required by the user.
3.7.29 Furniture
Suitable furniture as console for computers, tables, chairs, storage cupboard,
book shelves, workbench etc. shall be provided in MCC room, control & PLC
rooms.
3.7.30 DC Voltage Power Pack
All 24V dc bulk power supply units shall operate on redundant configuration
with reverse polarity protection. Under no condition, loading any of the
power supply unit shall not exceed more than 60% of the rated capacity of
each unit. The power pack shall be redundant & suitably designed to provide
output voltage of + & - 24 VDC & adjustable + 10% of the rated voltage
and load current limit from 115% down to 10% of the rated current. The
power pack shall be fully protected against over load and short circuit. RFI
filter shall be incorporated in the input line to prevent RF interference from
main supply. The output voltage shall be electrically floating from the
ground. Setting regulation shall be at least 20mV, load regulation + 0.2%
with transient recovery of approx. 100usec. It shall have recovery within
regulation band for a load change from 10% to 90% and the output
adjustability from 20.4V to 32.4V. The ripple and noise shall be within 1mv
rms. The unit shall be provided with voltmeter and ammeter.
3.7.31 Instrument Panels & Cabinets
3.7.31.1 The panels shall be of 2250 mm height and open type or cabinet type in
simplex or duplex construction as per the requirement of instrumentation
systems. The panels shall be manufactured from cold rolled carbon steel
sheet confirming to IS 513-1992. Panels shall be manufactured of 3 mm thick
sheet except for doors which can be of 2 mm thick sheets. For duplex panels
sheet size of 4 / 5 thickness may be used depending upon size of panels.
3.7.31.2 The panels shall be free standing type and of welded / bolted construction.
All welds shall be ground smooth, all corners be rounded and all weld
spatters shall be cleared. Surface of panels shall be free from all mars &
defects. The finished panel shall be flat within 2 mm in any 2 meter radius
and shall be smooth. Removable eye bolt lifting lugs shall be furnished and
installed in all panels.
3.7.31.3 All instrument cut outs and drilling shall be straight and through. All panels
shall be supported on suitably sized vibration isolators, designed for bolting
to panel frame and flooring. Access doors on enclosed panels shall be 750
mm wide by 1800 mm high, single sheet with suitable latch, hooks, knobs
on inside and outside and shall open forward.

3.7.31.4 The panel surface shall be thoroughly degreased, smoothed phosphated,
filled and painted with rust resistant primer to present a flat and smooth
finish.
3.7.31.5 The front panels shall be primed and given at least two under coats and
minimum two finish coats to provide a smooth mat finish. Preferred paint
schedules are:-
3.7.31.6 Exterior surface: Light grey shade no.631 of IS 5:1991 in semi-gloss finish.
3.7.31.7 Interior surfaces shall be painted with Brilliant white enamel.
All above paints shall be air-drying type.
3.7.31.8 The legend plates of non-conducting material shall be installed on panel
face for identification. The overall dimensions of name plates shall preferably
be 20 x 80 mm.
3.7.31.9 All cables from field to the control room shall be terminated in the
marshaling boxes / field termination racks mounted near main panels. The
cables shall be provided with U-lugs and shall be terminated on screwed
terminals.
3.7.31.10 Cabinet type panel having panel width of 2000mm (in between front and
back panel) with sufficient internal illumination and exhaust / ventilation
facility shall be considered.
3.7.31.11 Electrical Accessories and Wiring
1. All electrical accessories e.g. circuit breakers, control switches, push-
buttons, panel lighting fixtures, light switches, receptacles, horns etc.
required for the panel shall be provided.
2. Electrical accessories shall be suitable for the environment of specific
location. Devices mounted on control room panels shall be flush
mounted.
3. All panel wiring except power and thermocouple circuits shall be done
with 1100 V grade PVC insulated, 1.0 Sq. mm stranded copper
conductor. Wiring shall be continuous between terminal points
without splicing and shall terminate on solderless type wire
connections at the instruments and to terminal blocks.
4. All incoming and outgoing wires except the thermocouple lead wires
shall be routed through heavy duty carrier type, single depth terminal
blocks having flanged partitions between terminals.
5. All terminal blocks shall include minimum 20% spare terminals and
shall not have terminal screws smaller than 4 mm.
6. All wires shall run in suitable plastic wiring sleeves between terminal
ends. Wires shall be plainly and durably labeled at both ends with non-
conducting materials for easy identification and must conform to wire
labeling scheme shown on electrical inter connection drawings:-
7. Cabinet type panels shall be fitted with fluorescent tube of suitable size
and energized through door switch. The internal illumination shall be
350-400 lux/m2.
8. One spare socket of 240 V - 3 pin, 15/5 Amp shall be provided in each
cabinet type panel for soldering iron etc.
9. All instruments with 230 V ac power supply shall be supplied through
individual MCB. All instruments with 24 V DC power supply shall be
through two nos of regulated DC power pack, each capable of
supplying entire load, connected in parallel with four nos of diodes in
order to prevent loop current flow between the power packs. A DC bus
shall be formed with this system. Individual instruments shall be
connected to the DC bus through individual switch fuse units.
3.7.32 Impulse Pipe Laying
1. All Impulse piping shall be 20 mm SS316 with SS fittings.
2. All impulse piping in general shall be given a slope of not less than 1
in 12 except where otherwise specified. The scope of impulse pipe
work shall be done from the tapping point for liquids, steam and
condensable and up from the tapping points for gases unless specific
provisions are made for venting and drawing.
3. Vents and drains shall be ensured at the highest or lowest of piping
run respectively. Impulse pipelines shall be kept as short as possible
consistent with good practice and accessibility. Piping and tubing shall
be adequately supported and fixed at distances not exceeding as
follows:-
Copper tube 12 mm or less - Continuous support
Steel tube 10 mm to 20 mm - 1.5 m.
Steel tube 25 mm - 2.0 m.
Steel pipe 40-50 mm - 3.0 m.
4. The following colour code shall be used for impulse lines:-
Green - Water
Red - Blast (Hot)
Blue - Oxygen line/ Steam line
Yellow - BF Gas line

3.7.33 Cable & Cable Laying
3.7.33.1 Communication cable
(FO/ CAT 6 UTP/ STP ) for connecting server, PCs, printers (local as well as
remote), PLC, any other system and connecting to the plant wide network
shall be provided.
3.7.33.2 Fibre Optic cable
Sl. No. Item Specification

1. Mode Single Mode
2. Coating Step index glass coated with dual
acrylate protective coatings
3. No. of Core 6, 8, 12 (as per requirement)
4. Core Dia 8 to 10.5 µm
5. Cladding Dia 125 µm
6. Compliance TIA- 492CAAA/OS1,OS2, ISO- 11801,
and ICEA-640 Standards
7. Wave Length 1310 / 1550 nm
8. Attenuation No point discontinuity greater than
Uniformity 0.1dB at either 1310nm or 1550nm
.
9. Attenuation at Water Attenuation at 1310 ± 3nm <
Peak (dB/km) 2.1dB/km
10. Temp Range -20 to +70 o C

11. Min bend Radius 30 mm
3.7.33.3 Instrumentation & Automation Cables

i. Control cables for carrying current for control systems shall be
conforming to IS: 1554(part1), IS 8130, IS 5831, IS 3975.
ii. Control cables shall be minimum 1.5 sq. mm tinned copper
/electrolytic copper stranded conductors. The cables shall be
PTFE/FRLS insulation, individual and overall screened, with inner and

outer sheath shall be PTFE/FRLS screened type and shall be
armoured.
iii. Instrumentation screened/shielded signal cables used for signal
transmission shall be confirming to IS: 5608 (part 2).
iv. Instrumentation screened/shielded signal cables shall be minimum
1.0 sq. mm tinned copper /electrolytic copper stranded conductors.
The cables shall be PTFE/FRLS insulation, individual and overall
screened, with inner and outer sheath shall be PTFE/FRLS screened
type and shall be armoured.
v. The power wiring within the cubicles shall be done with minimum
2.5 sq.mm tinned copper /electrolytic copper stranded conductor
conductors.
vi. Power cables shall be PTFE/FRLS stranded copper, armoured and
shall be derated at 50 deg C and shall confirm to relevant IS. Bidder
shall submit calculation sheets.
vii. Instrumentation (screened ) cable shall be of 500 V grade and control
cable shall be of 1.1 KV grade.
viii. Compensating cables shall be drawn directly from the temperature
sensor to the PLC panel. It shall be provided with screen and drain
wire of copper. The compensating cables shall conform to IS 8784:
1987.
ix. Multicore cables shall have printed numbers as well colour coded as
per the standards.
3.7.33.4 Cable laying
i. Cable entry to the panels/junction boxes shall be through suitable
removable gland plates and glands.
ii. Parallel run of instrument cables and power cables shall normally be
avoided but where parallel run must be made, suitable cable
spacing shall be provided.
iii. Crossing of power and control cables shall be done at right angles.
All cables must be laid in GI conduit pipes / trays mounted on rigid
supports at suitable interval to avoid sagging.
iv. Signal and power cables shall be laid on separate G.I. pipes / trays
with minimum separation as per relevant standard.
v. Cable laying: for cable other than cable tray shall be under-
grounded with 3 feet deep trench, filling with sand and top brick
layer, included in scope of work for electrical power cables.

vi. G.I. trays shall be mounted with their breadth in Vertical plane to
protect cables from falling objects, accumulation of dust. If plates
are provided horizontally these shall be provided with removable
covers and shall be supported to avoid sagging.
vii. Clips and saddles securing cables to steelworks or tray shall
preferably be plastic covered materials and shall be spaced at 0.5 m
interval.
viii. All cables shall be suitably identified with their tag numbers duly
clamped at an interval of 5 meters.
ix. Cross ferruling at both ends in JB/Fields Inst/PDB/Mashalling racks/
PLC etc
3.7.34 Earthing System

The Electronic earthing of all new equipment shall be as per the code of
practice of earthing IS 3043-1987 and IE rules.
Equipment shall be connected to main earthing ring by means of strips. The
total earth resistance of any point of the earthing system shall not exceed
0.5 ohm.
3.8 C&IT
Void

3.9 STRUCTURAL
3.9.1 Codes and Standards
3.9.1.1 The bidder shall carry out the complete design and engineering of the
structural steelwork as per provisions of Indian codes and standards. In all
cases, the latest revision with amendments, if any, shall be followed. Where
such norms are not available in Indian standards then relevant International
codes shall be adopted. All steel structures shall be designed to meet the
technological & service requirements with due consideration to the existing
plant & facilities.
3.9.2 Design parameters
3.9.2.1 The bidder shall carry out the complete design and engineering of the
structural steelwork as per provisions of IS 800: 2007. Due allowance for
impact, vibration, temperature effect shall also be kept. Structures shall be
designed either for wind or seismic loads whichever produces worse effect.
Superimposed loads shall be considered in accordance with IS 875 (Part 1,
2 & 5): 1987 in addition to technological loads from equipment as supplied
by equipment manufacturer. The design shall take into account all dynamic
loading effects in vertical, lateral and longitudinal directions apart from dead
and superimposed loads from moving machineries. Wind load on structures
shall be considered as per IS 875 (Part III): 2015 whereas seismic loads shall
be taken as per IS 1893. Design and erection of chimney shall be as per IS
6533(Part I, Part II): 1989.
Structural steel work shall be of welded construction as far as possible.
Necessary provision in the design shall be kept for temporary loads, which
are expected during erection and maintenance of equipment. For all
structural columns, base shear shall be transferred to the foundation by
shear keys only and not through foundation bolts. Tension in column
member shall be transferred to foundation by foundation bolts.
3.9.2.2 Imposed load to be considered on structural platform (areas other than
platforms having moving machineries), Staircase tread – 400 kg/ m2
3.9.2.3 Crane level walkway and repair platforms: 400 kg/ m2.
3.9.2.4 Accessible roof – 150 kg/ m2
3.9.2.5 Inaccessible roof – 75 kg/ m2 (permissible reduction for sloped roof)
3.9.2.6 Lighting walkway: 200 kg/ m2 Monorail walkway, visitors’ gallery: 250 kg/
m2.
3.9.2.7 Ladder: 120 kg at centre of rung.

3.9.2.8 Pipe trestle walkway: 250 kg/ m2
3.9.2.9 Dust load of 50 kg/ m2 on roofs shall be considered. Dust load should be
taken over and above the uniform live load specified.
3.9.2.10 Staircase wherever provided shall preferably have a slope of 380 with
horizontal unless anything else is mentioned. Minimum width of the main
staircases shall be kept 1000 mm and for secondary staircases shall be 800
mm. All new handrails shall have vertical post, top rail and mid rail. Height
of vertical posts shall not be less than 1.0 m and spacing between
consecutive vertical posts shall not be more than 1.0 m. Toe guards shall be
provided at each landing.
3.9.2.11 Permissible vertical and horizontal deflection shall generally be as per IS 800:
2007 unless otherwise specified.
3.9.2.12 Permissible horizontal deflection of column at crane rail level shall be taken
as height of column/ 2000 with a maximum limit of 10mm. due to lateral
surge load.
3.9.2.13 Permissible horizontal deflection of crane gantry girders due to surge from
one crane shall be limited to span/ 2000 with a maximum limit of 15 mm.
3.9.2.14 Minimum member size
Steel used for construction exposed to weather or other corrosive influences
shall not be less than 8 mm in thickness and in construction not exposed to
weather, thickness shall not be less than 6 mm. Sealed tubes and sealed
hollow box sections used for external construction exposed to weather shall
not be thinner than 4 mm and for construction not exposed to weather shall
not be thinner than 3 mm. Rolled sections shall be as per IS 808: 1989.
The controlling thickness as specified above, for rolled beams and channels
shall be taken as the mean thickness of flange, regardless of web thickness.
The minimum sizes of standard rolled sections to be used in all load bearing
structures design shall be as follows:
-ISMB 100
-Channel: ISMC 125
-Angle: ISA 65x65x8 respectively
In non-load bearing members such as hand railing etc. minimum sizes of
rolled beams, channels and angles to be used in exposed to weather
condition are as follows:
-ISMB 100

-Channel: ISMC 125
-Angle: ISA 50x50x6 respectively.
Gusset plate thickness shall not be less than 8 mm.
3.9.3 General Provision
3.9.3.1 Staircase shall generally be provided instead of vertical ladders, except
where ladders are absolutely necessary.
3.9.3.2 When ladders are used, its minimum width shall be 500 mm. Maximum
spacing of rungs shall be 300 mm. Safety cage shall be provided where
ladder height is more than 2200 mm from floor/GL.
3.9.3.3 Height of handrail shall be 1000 mm.
3.9.3.4 Connection System of Structural Steel Members.
Minimum weld size is 5 mm.
All erection bolts shall be 16 mm diameter (min.).
Minimum size of permanent bolt shall be 20 mm dia.
3.9.3.5 Metal heat shields or insulation shall be provided around structural elements
in intense heat zones. For floors above hot metal/ slag track 8 mm thick plate
heat shield shall be provided below floor structural elements.
3.9.4 Materials
3.9.4.1 Structural steel
All structural steel shall be of tested quality. Structural steel conforming to
IS 2062: 2011.
Steel used for construction exposed to weather or other corrosive influences
shall not be less than 8 mm in thickness and in construction not exposed to
weather, thickness shall not be less than 6 mm. The controlling thickness as
specified above, for rolled beams and channels shall be taken as the mean
thickness of flange, regardless of web thickness.
Sealed tubes and sealed hollow box sections if used for external
construction exposed to weather shall not be thinner than 4 mm and for
construction not exposed to weather shall not be thinner than 3 mm.
The Tenderer shall submit the test certificates conforming to appropriate
standards of all steel materials used for fabrication. All structural steel shall
be free from rust, scales, lamination, cracks, fissures and other surface
defects.
3.9.4.2 Steel tubes wherever used shall be as per IS 1161: 2014.

3.9.4.3 Chequered plates wherever used shall be as per IS 3502: 2009.
3.9.4.4 Skelp plates shall conform to IS 10748: 2004.
3.9.4.5 Crane rails shall be conforming to IS: 3443:1980. Crane rail fixtures shall be
as per IS 3195: 1992.
3.9.4.6 Bolts and nuts
All bolts and nuts shall conform to IS 1363: 2002 or IS 1364 as applicable
and unless specified otherwise shall be hexagonal. All nuts shall conform to
property class compatible to the property class of the bolt used. The bidder
shall submit the test certificates when called for.
3.9.4.7 Washers
Plain washers shall be made of mild steel conforming to IS 5369: 1975 unless
otherwise specified. One washer shall be supplied with each bolt. Tapered
washers conforming to IS 5372: 1975 and IS 5374: 1975 shall be used for
ISMCs and ISMBs respectively.
3.9.4.8 Gutters & Down Pipes
Rainwater gutters and down pipes shall be made of mild steel plates or steel
metal shall conform to relevant Indian Standard. Unless otherwise specified,
MS gutters and down pipes shall be manufactured from 5mm & 6mm thick
copper bearing mild steel plates respectively conforming to IS 2062: 2011.
The following Indian Standard shall be applicable:
IS 2527: 1984 Code of Practice for fixing rainwater gutters & down pipes for
roof drainage.
3.9.4.9 Roof and side covering
1. General
This specification covers the detailing, supply and erection of CGS, GPS
sheets with all necessary laying, fixing etc.
a) CGS, GPS sheets & fixtures
Galvanized corrugated steel sheets in roofs, sides and gable shall be of
10/75mm corrugation conforming to IS 277: 2018 with grade of zinc
coating shall be 275 gm/m2 (Grade IV). 18 Gauge sheeting shall be
used on roofs and 20 Gauge sheeting shall be used for side cladding.
Ridging, flashing, capping, gable and corner trimming shall be made
galvanized plain sheets bent to shape.
All fixing accessories shall be of galvanized steel and shall conform to
IS 730: 1978. Bitumen washers shall be of approved quality.

Material used for translucent sheets shall be as per IS 12866: 1989.
Laying and fixing of sheets shall be as per IS 15224: 2002.
Sealant for weather tightness shall be as per sheet manufacturer’s
specification.
2. Laying & Fixing
Laying, fixing and laps of roof & side CGS sheeting shall be as IS 12093:
1987.
The Bidder shall submit manufacturer’s test certificates of all materials
supplied by him and used for fabrication and erection.
3.9.5 Welding of building structures

3.9.5.1 The welding and the welded work shall generally conform to IS 816: 1969
and IS 9595: 1996 unless otherwise specified. As much work as possible shall
be welded in shops and the layout and sequence of operations shall be so
arranged as to eliminate distortion and shrinkage stresses. Electrodes shall
conform to IS 814: 2004.
The welding surfaces shall be smooth, uniform and free from notches, loose
scale, slag, rust, grease, moisture or any other foreign material.
3.9.5.2 Criteria for test of weld
1. Visual examination - Hundred percent (100%) of the welded joints for
fillet welds and butt welds.
2. Ultrasonic method - Hundred per cent (100%) for all butt-welded
joints.
3. Radiographic test- At least 2% of the butt welds shall be tested by
Radiographic examination.
3.9.5.3 The bidder shall engage a reputed or any Government test agency having
Level II Ultrasonic and Radiography examination certificate holder inspector
to carry out the Ultrasonic or X- ray examination tests. The third party shall
carry out tests, interpret test results and recommend necessary rectification
measures. Bidder shall carry out the rectification work as recommended by
the test agency to ensure defect free welding. Bidder shall obtain certificates
from the testing agency certifying defect free welds and submit to the
employer.
3.9.6 Expansion Joints
Expansion and setting out joints shall be provided to take into account the
effect of temperature variation and which shall also act as anti-seismic

joints. Expansion joints shall be provided as per provisions of relevant
clauses of IS 800: 2007.
3.9.7 Painting
3.9.7.1 Paint specification for new structures
All structures shall be given two coats of single pack air drying phenolic
modified alkyd composition with zinc phosphate as a primer (DFT/ coat 40
micron) and two coats of single pack air drying high gloss phenolic alkyd
modified synthetic enamel paint as finishing coat (DFT/ coat=25 micron).
One coat of primer shall be applied before erection and one coat after
erection.
One intermediate coat of a single pack high built phenolic based paint with
micacious iron oxide (DFT=75 micron) shall be provided for all open
structures. One coat of primer shall be applied before erection and one coat
after erection.
3.9.7.2 Paint specification for existing structures
All existing structures to be re used after modification/ strengthening shall
be given single coat (DFT=150 micron) of a two pack high build surface
tolerant epoxy mastic coating and two coats of two pack epoxy high build
coating as finishing coat (DFT/ coat=100 micron).
3.9.7.3 Paint specification for Chimney
Inner surface of the chimney up to 3m height from base shall be given two
coats of (DFT/ coat=40 micron) a single pack air drying phenolic modified
alkyd composition with zinc phosphate as a primer and three coats of (DFT/
coat=40 micron) a heavy duty single pack air drying anti-corrosive black
bituminous paint as finishing coat. Rest of the height of the chimney at the
inner side shall be primered with two pack heavy duty zinc dust rich silicate
with just a single coat (DFT= 60 micron) and three coats of a single pack
heat resistant silicon resin based paint with leafing Aluminium / graphite
powders shall be used as finishing coat (DFT/ coat=20 micron). Top two
courses of the chimney at the outer side shall be given two coats (DFT/
coat=40 micron) of a two pack air drying Epoxy polyamide resin based red
oxide zinc phosphate as primer, one intermediate coat of a single pack high
built phenolic based paint with micacious iron oxide (DFT=75 micron) and
two coats (DFT/coat=40 micron) of a two pack air drying epoxy polyamide
enamel suitably pigmented as finishing coat. Rest of the outer surface of the
chimney shall be painted as per specification mentioned for general
structures. Intermediate/ finishing paint shall be applied only after
completion of erection.

3.9.7.4 Paint application
Surface preparation and application of paint shall be applied in accordance
with manufacturer's recommendations. The work shall generally follow IS
1477(Part-II): 1971. Prior approval of the Employer shall be taken in respect
of all primers and/or paints before their use in the works.
3.9.8 General provision
3.9.8.1 Type of Construction
The steel structures shall generally be of shop-welded construction. Site
connections shall generally be provided by welding with erection bolts.
Elements shall be fabricated in largest possible sizes optimal with transport
requirements to minimize site work.
Important members shall be assembled under control assembly in
manufacturing shop to prevent any mismatch at site.
3.9.8.2 Splices in structures
Shop splice: Where shop splices in plates are necessary due to non-
availability of plates in required lengths, full penetration defect free sound
butt welds shall be made. Shop splice in rolled steel angle, joists and
channels shall be developed by fillet welding and cover plates/angles etc.
Site splice: Site splice for members required due to transportation, assembly
and erection facilities shall be developed by fillet welds and cover plates and
angles or high strength friction grip bolts. In case, butt welding in plates is
employed for site splice, the same shall be sound, defect free and of full
penetration
3.9.8.3 Fabrication of steel structures shall be in accordance with IS 800: 2007.
Fabrication tolerances shall be within specified limits as per IS 7215: 1974.
Erection tolerances shall be within specified limits as per IS 12843: 1989.
3.9.9 Dismantling
The Bidder shall ensure that during dismantling of any structural assembly,
the stable equilibrium of balance structures is not disturbed.
3.9.9.1 Method of Dismantling
For dismantling of various steel structures, gas cutting is permitted with
the following guidelines.
1. For cleated connection, only cleat shall be gas cut.
2. For gusseted connection, gusset plates shall be gas cut.
3. Before cutting/removing the end supports, the items to be
dismantled shall be held/secured by appropriate means.
3.9.9.2 Sequence of Dismantling and Stacking:
The Bidder shall prepare the sequence of dismantling to be employed and
submit it to the employer for reference.

3.10 CIVIL
3.10.1 General
3.10.1.1 This specification covers the design criteria for Civil Engineering work. The
term ‘Design Criteria’ includes loading standards, permissible stresses,
functional requirements and quality standards to be adopted as a basis for
preparation of designs and drawings by the Bidder. These designs and
drawings shall cover buildings for production and non-production facilities,
auxiliary facilities, ancillary buildings and structures, foundations for
buildings and equipment, roads, railways, drains, sewers and other
miscellaneous civil engineering items of work to be provided and/or to be
modified/ rectified by the Bidder.
3.10.1.2 The designs prepared by the Bidder shall not only provide for the
requirements indicated in this specification but also consider the overall
process requirements, and service conditions. The new facilities shall be
planned in such a manner that the existing structures in the vicinity shall not
be in anyway adversely affected. The designs shall be compatible with the
existing and proposed structures.
3.10.2 Standards
3.10.2.1 The design criteria for civil engineering work shall be in accordance with this
specification. Detailed instructions on such aspects as are not indicated
herein shall be as per the latest standards, codes. In the absence of suitable
IS specification and codes of practices other recognized international
standards and codes may be followed with the prior approval from
Employer.
3.10.2.2 Complete design and engineering of shall be as per provisions of Indian
codes and standards. In all cases, the latest revision with amendments, if any,
shall be followed.
3.10.2.3 This specification covers design of major Civil Engineering items of work.
Other items of work shall be designed according to the relevant standards,
recommendations and stipulations referred above.
3.10.2.4 Bidder shall carry out NDT tests for the existing foundations to assess the
strength of existing concrete wherever new foundation needs to be
combined with existing foundation.
3.10.2.5 At the starting point of proposed bay extension of shop bays, the proposed
foundations shall be combined with the existing foundation of the shop. The
combined foundations shall be designed taking into account the load data
of both existing column and proposed column. If the load data of the
existing columns are not readily available, bidder shall assess

and calculate same on the basis of actual operation and function
requirement of the shop.
3.10.2.6 At the time of construction of combined foundations with the existing
foundations, necessary and suitable measures shall be taken up for proper
integration between the old and new RCC by using bonding chemicals,
lapping of reinforcements, anchorages etc. so as to behave as combined
foundation.
3.10.2.7 In case anything mentioned in this specification is at variance with IS or other
codes of specification mentioned herein, the provisions of this specification
shall prevail.
3.10.3 Setting Out and Levelling
The Bidder shall set out and level the work and shall be responsible for the
accuracy of the same. He has to provide all instruments and qualified staffs
with labour for getting his work checked by Engineer-in-Charge, if so
desired by the Employer. Such checking, if any, shall not, however, relieve
the Bidder in anyway, of his responsibility for correct setting out.
3.10.4 Safety
The Bidder shall take adequate precautions to ensure complete safety and
prevention of accidents at site and shall be responsible for the same. The
safety precautions shall conform to the safety regulations prescribed by the
safety code for constructions and relevant Indian Standard Codes, some of
which are listed below:
IS: 3764-1992 : Safety code for excavation work.
IS: 4014-2013 : Safety regulations for scaffolding work.
IS: 4081-2013 : Safety code for drilling and blasting
operations.
IS: 4138-1977 : Safety code for working with compressed
air.
IS: 7923-1985 : Safety code for working with construction
machinery.
3.10.5 Keeping Work Free from Water
The Bidder shall provide and maintain at his cost, pumps and other
equipment to keep the works free from water and shall continue to do so
until the handing over of the works.
3.10.6 Cleaning of site
The Bidder shall keep the site clear on a continuous basis, from muck,

rubbish etc., which may arise out of the work executed by him and dispose
them suitably in allotted areas.
3.10.7 Bench Marks, Reference Pillars etc.
The Bidder shall protect all benchmarks, and reference pillars /lines including
ground water gauges from damage or movement during working. In case
of any damage the Bidder shall have to restore the same to its original
condition at his own cost.
3.10.8 Concrete and Reinforced Concrete for Structures and Foundations
3.10.8.1 General
a) Concrete work shall secure a dense, homogeneous, smooth mass
including required finishes, possessing required strength and
resistance to weathering and abrasion for the structures and
foundations.
b) Design of all reinforced concrete structures shall be as per IS: 456-
2000. The structural safety of all foundations on soil shall, in general
be based on IS: 1904-1986.
c) All reinforced cement concrete structures shall be in minimum grade
of M-25 (with 20 mm and downgraded aggregates).
d) For floor laid on grade with slag boulder soling base, drains & trenches,
the grade of concrete shall be M-20 (with 20 mm and downgraded
aggregates).
e) Plain cement concrete shall be M-10 (with 40 mm and downgraded
aggregates). However, for mass filling plain cement concrete PCC
1:5:10 (I cement, 5 sand, and 10 aggregates) shall be used.
f) For calculation purpose ‘Limit State Design’ methods shall be adopted.
3.10.8.2 Permissible Stresses
Allowable stresses for all reinforced concrete structures shall be as per IS:
456 – 2000.
3.10.8.3 Foundations
a) Selection of type of foundation shall be based on the
recommendations of soil investigation & survey report, supported
loads, system requirements and site constraints.
b) Open/pile foundations for structures and equipment shall be
proportioned to resist the worst conditions of loading and shall be
generally designed as per the provisions of IS:1904-1986.

c) The depth of foundation shall be determined based on loading on
foundations and bearing capacity at the founding level, constructional
and technological requirements. The maximum allowable bearing
pressure for design of foundation shall correspond to values indicated
in detailed soil investigation report taking into account limits of
allowable settlement considered for design of structures. However, in
no case shall be the foundation is taken down to less than 600 mm
below natural ground level in case of soil and 200 mm in case of rocky
strata. In no case foundation shall be placed on the filled up soil and
the depth of the foundation shall be taken upto the depths where the
virgin soil strata is found and extra depth shall be filled with PCC 1:5:10
(cement: sand: aggregate).
d) The foundation of the new structure /facility shall be taken at least to
the depth of the foundation of adjoining existing structure/ facility, if
any. In no case the loads from the new foundations shall be transferred
to the existing foundation. However in exceptional circumstances, if it
is required to be done, then the existing foundation shall be checked
for the additional load transferred and shall be supported with design
calculation.
e) All faces of concrete or plastered surfaces in contact with earth shall
be provided with two coats of bituminous protective coatings of
approved make. Ground floor slab shall be cast on a layer of building
paper of approved make on slag boulder/ Blast Furnace slag soling
with moorum binding.
3.10.8.4 Piling work
The material and workmanship shall conform to the provision of following
codes and standard specifications.
IS: 456-2000 – Code of practice for plain and reinforced concrete, and
IS: 2911(Pt. I): 2010, IS: 2911(Pt. III): 1980, IS: 2911(Pt. IV): 2013– Code of
practice for design and construction of bored cast in situ pile foundations.
3.10.8.5 Soil Conditions
1) Geodetic Survey and Soil investigation of the area shall be made
available to the bidders during tendering. Recommendations
contained in the final report shall form the basis for designing of civil
foundations.
2) Less important foundations of minor structures carrying low loads can
be laid on backfilled soil with 250mm thick compacted slag boulder
soling, and the allowable bearing capacity shall be considered as 5
Ton/m2.
3) During execution, in case of any doubt regarding the reported bearing
capacity & actual site condition by Engineer-In-Charge, the scope of
bidder also include carrying out soil investigation by NABL accredited
agencies. The water table shall be assumed at existing ground level
and correction factors shall be applied accordingly. The conservative
value of the two Reports shall be considered. The water table shall be
assumed at existing ground level and correction factors shall be
applied accordingly.
3.10.9 External Cladding, Internal Partitions & Finishes
3.10.9.1 This section deals with cladding, internal partitions and finishes for
production buildings and associated ancillary and auxiliary buildings.
3.10.9.2 External cladding for steel framed production building shall be made of
galvanised corrugated sheeting (20 SWG thick) or approved equivalent.
3.10.9.3 External cladding for buildings shall be constructed of brick masonry. The
thickness of brick masonry walls shall be minimum 230mm. Design of
masonry walls shall conform to IS: 1905 – 1987.
3.10.9.4 Internal partition walls shall be 115 mm thick brick masonry.
3.10.9.5 Cement sand mortar shall be 1:6 for external walls having minimum
thickness of 230mm and also for brick work in protection walls to
waterproofing membrane in tunnels, basements etc. For walls of thickness
115mm mix shall be 1:4 with HB wire netting reinforcement at every third
layer.
3.10.9.6 All brick and rubble masonry walls shall be plastered on both sides.
Thickness of plaster shall be minimum 20mm for external surfaces and
15mm for internal surfaces of walls. Thickness of plaster for ceiling shall be
upto 6 mm.
3.10.9.7 Cement sand mortar mix shall be 1:6 for plastering of walls and 1:3 for
plaster of ceiling.
3.10.9.8 All outside plastered surfaces of masonry walls shall be applied with Anti-
algal Weather proof modified Exterior Acrylic Emulsion Paint of approved
make and quality as per environmental/aesthetics requirement and to be
applied as per manufacture’s specification.
3.10.9.9 Inside surfaces of masonry walls shall be treated with white wash/colour
wash or paint of approved quality, make and colour, or to be tiled as the
case may be, on the basis of technological and/or aesthetic requirements.
Wherever plastic emulsion paint is used, the walls shall be coated with
cement based putty on plastered surfaces.

3.10.9.10 100 mm high skirting shall be provided in all rooms except where there is
a provision for dado.
3.10.9.11 Depending on technological considerations, walls of some premises may
be made of reinforced concrete and finished appropriately.
3.10.10 Floorings:
3.10.10.1 In general, all floors on ground except in areas like public buildings, offices
and toilet blocks, shall be made of minimum M20 concrete of 150mm
minimum thickness.
3.10.10.2 For the production buildings, including pump houses, stores and electrical
buildings shall be made of minimum M25 RCC of 150mm minimum
thickness. The design of floor shall be done taking into consideration
technological requirements, imposed loading and other service conditions
etc.
3.10.10.3 Heat resistant concrete flooring with minimum M30 RCC shall be provided
as per requirement.
3.10.10.4 For areas where the loading is high (more than 5 t/sq. m), like Mill floor, SMS
floor etc., the floor shall be designed for actual loads. The computation of
edge and corner stress can be done using IRC 58:1988 or other accepted
analysis procedures including finite element modelling of the structure in
Structural analysis software. The design of RCC floor shall be done as per IS:
456-2000.
3.10.10.5 The sub-grade below the floor slab shall be minimum 250 mm thick slag
boulder soling blinded with moorum/ query dust. Building paper shall be
provided on top of sub-grade before casting the concrete slab.
3.10.10.6 All sub-grade shall be laid on compacted soil.
3.10.10.7 In specific areas of production buildings where concrete floor is not required
at ground floor level, the flooring shall consist of minimum 250mm thick
slag boulder soiling blinded with moorum/ query dust and compacted.
3.10.11 Floor Finishes
3.10.11.1 Floor finishes for production buildings and auxiliary buildings/areas shall be
provided according to technological and functional requirements, service
conditions and duty and as per manufacturer’s instruction where applicable.
However, the following types of finishes are suggested for use in the
specified areas:
1) Canteens,:
a) Lobby, Dining Hall: Vitrified floor tiles shall be provided in all

rooms, lobbies and corridors.
b) Wash area, kitchen floor, pantry floors: Minimum 25mm thick
kota stone finish.
c) Counter tops: Granite stone
d) Stores: 40mm thick granolithic cement concrete flooring with
concrete hardener.
2) Office, first aid and change rooms:
a) Staircase including treat risers:
b) Office rooms, lobby, and corridors: Vitrified floor tiles shall be
provided.
3) Toilets: Anti-skid ceramic tiles.
4) Shop Floor: Ironite flooring or as per technological requirement.
5) Control rooms, PLC Rooms, Computer Rooms, SAS Rooms, control
pulpit: Particle board false flooring/cable vault with suitable antistatic
PVC tiles.
6) Oil Cellars and Hydraulic rooms: Anti-skid floor tiles
7) Substation and Pump houses: Ironite Flooring/ Quartzite Hardner
Flooring as per technological requirement
8) Shift office in production buildings: IPS flooring.
3.10.12 Drainage
3.10.12.1 This section covers layout parameters, functional requirements and design
guidelines for storm water drainage.
3.10.12.2 All the storm water drainage shall be laid in service aisles close to the road.
Crossings with other services shall be kept to a minimum. Where the new
lines are to be connected to the existing ones, the Bidder shall carry out the
required connections.
3.10.12.3 Generally minimum earth coverage of one meter shall be provided over
underground drainage pipelines unless the same is protected by concrete
encasing for otherwise and adequately designed for the imposed loads from
soil, water, operational and construction traffic.
3.10.12.4 RC pipes of class NP2 of IS: 458 – 2003 shall be used for diameter ranging
from 300mm to 1200mm and beyond that box drains shall be provided.
However, pipes under road/rail crossings shall conform to class NP3 and
NP4 respectively of IS: 458 – 2003.

3.10.12.5 The material used for jointing of underground pipes shall be such as to make
the joints watertight for preventing ingress of sub-soil water by infiltration
and escape of inside matter to the surrounding areas. In this connection IS:
783 – 1985 for drainage shall be referred to.
3.10.12.6 Relevant provisions of IS: 1172 – 1993, IS: 13592-1992, IS: 458 – 2003, IS: 783
– 1985 and IS: 1742 – 1983 and other relevant Indian standards shall be
applicable for the design of the system.
3.10.13 Storm water Drainage
3.10.13.1 The design of storm water drainage system shall be based on maximum
hourly precipitation for a storm of duration of 20 minutes. Roof drainage
system shall be designed on the basis of an hourly precipitation for storm
duration of 5 minutes.
3.10.13.2 Gully, traps, inspection pits, junction pits, collecting pits etc. as well as other
facilities shall be located suitably and designed considering easy access,
maintenance and safety.
3.10.13.3 For the purpose of calculation of run-off from catchments area of any
drainage line, the Bidder shall estimate areas of buildings, paved area,
roadways, parking areas and open areas within the catchments area. Run-
off coefficients for design shall be as follows:
1) Open areas : 0.50
2) Roads and paved/parking areas : 0.70
3) Roof surface : 1.00
3.10.13.4 The pipes shall be so designed as to give a velocity of flow not less than one
metre per second when running half full. The maximum velocity shall not
exceed 2.5m per second.
3.10.14 Paved Areas
3.10.14.1 Paved areas shall comprise of the areas around the buildings and other
facilities which need to be paved with either concrete or paver blocks or
bituminous surface to take care of storage of material / movement of
personals and traffic / parking etc.
3.10.14.2 All service and utility lines crossing under the paved areas shall be taken
through concrete pipes/ ducts and designed for imposed loading. Number
of such crossings shall be kept to a minimum.
3.10.14.3 Sub-grade and base of all areas where paving shall be done shall be
strengthened suitably to take care of the imposed loading. Thickness of
different layers of materials shall be adequate for traffic intensity and

imposed loading. Generally the thickness of different layers to be provided
shall be as follows :
Sub-base 150mm thick consolidated moorum / query dust
filling on compacted soil
Base 250mm thick compacted slag boulder soling
blinded with moorum / query dust
3.10.14.4 Minimum thickness of the paving in each of the three options shall be as
below:
Concrete 150mm thick PCC of grade M20
Paver Block Minimum 60mm thick paver blocks of grade M30
Bituminous 80mm thick DBM in 2 layers with bitumen of grade
surface VG-30 and 25mm premix carpet on top with bitumen
of grade VG-10.
3.10.14.5 Selection of type of paving surface shall be done based on the prospective
usage of the paved surface.
3.10.14.6 RCC roads shall be designed as per relevant IRC codes and material used
shall be as per MORTH specifications. Minimum grade of concrete for RCC
road shall be M30 D.
3.10.14.7 Surface storm water from the roadways shall be drained by provision of
drain.
3.10.14.8 Sufficient areas shall be paved around plant buildings so as to facilitate
parking of vehicles. Paved areas shall have same type of construction as
roads and the top level shall be flushed with crown of the connecting
roadways with a cross slope of approximately one per cent.
3.10.14.9 Around all plant and ancillary buildings minimum 1500mm wide concrete
apron shall be provided.
3.10.15 Rock Anchors :
3.10.15.1 The design of the anchor should consider the following-
i. Loads and constraints of loading imposed by the anchors on the
overall structure
ii. The way in which the loads shall be applied to the anchor during its
designed life i.e. static or dynamic

iii. The load distribution of the anchor arrangement on the structure
during stressing and during the design life of the structure
iv. The interface between the anchor and the structure to ensure
structural stability
v. The consequence of anchor failure during stressing and thereafter.
3.10.15.2 Design of the anchor system shall be based on rock parameters and the
geometry of the anchor arrangement.
3.10.15.3 Various parameters like classification of rocks (Geometry of discontinuities,
unit weight, degree of weathering, index test), rock stratification, unconfined
compression strength of intact rock, shear strength and deformability of
rock mass, permeability, ground water conditions, corrosion potentials of
rock and ground water etc. shall be considered while finalising anchoring
system. The bidder shall be responsible for required testing to find out the
parameters which are not available.

3.11 MATERIAL AND WORKMANSHIP SPECIFICATIONS FOR CIVIL WORKS
3.11.1 Surveying
3.11.1.1 The surveying shall be done by modern three dimensional technological
equipment, Total Station or equivalent and data shall be downloaded from
the same and necessary survey maps/ drawings shall be prepared both in
digitized and Auto CAD form in 2D (i.e ‘Z’ coordinates shall be zero for each
entity).
3.11.1.2 Determination of the location & elevation of all existing features inside the
plot & outside the plot up to 25.0 m from all along the boundaries of the
plot such as big buildings, structures, roads, culverts, big trees, water supply
main ( top of pipe line elevation ), including hydrants, Tee flanges, etc.
Foundation of pylons for overhead power cables, electrical & telephone line
poles, wells, storm water ditches, nallah etc., if any shall be done and marked
in the final drawing along with the coordinates. If the outfall/sewage
disposal lines are existing in the proximity of the plot, the location & levels
of the sewer including man-hole shall be determined for the purpose of the
plot drainage.
3.11.1.3 Determination of the reduced spot levels of existing ground levels within
the boundary plus 25.0 m extra on all sides at 10.0 m grid shall be done.
Adjoining centre line & widths of existing road, with reference to the nearest
boundary line & determining reduced levels on the cross section basis at
10.0 m grid shall be located.
3.11.1.4 The level of all the conveyor trestles / trestle supports, overhead lines (pipes
and cables, if any) shall also be indicated. While measuring the exact level
of the overhead lines, if due to safety consideration the measurement is not
possible / feasible; the tentative location with approximate level of the same
shall be indicated in the Survey Drawing.
3.11.1.5 The location and level of the existing culverts/water cross-overs and the
existing cable tunnel / pipe lines in the area shall also be surveyed and
indicated in the drawing. For this available drawings shall also be referred.
Along with excavation up to a depth of about 3 m from and the top of the
tunnel shall be exposed at a minimum of 4 locations along the length of the
existing facility and the layout and levels shall be surveyed. Care shall be
taken not to damage the existing facilities.
3.11.1.6 Spot levels shall be taken at closer grid intervals as directed by the Engineer
whenever profile of land suddenly changes. Existing ridges, valleys & rock
out-crops etc., within the plot shall be located with elevation to define
general plot drainage.
3.11.1.7 Recording any other features, not specifically covered above but which are
required to be taken to prepare work like survey etc, shall be done as
directed by the Engineer-in-charge from time to time.
3.11.1.8 Reduced level of ground, if not available, shall be carried from the nearest
railway station.
3.11.1.9 Coordinate of the permanent benchmark shall be taken as origin for plant
coordinate system if not already available.
3.11.1.10 Barbed wire fencing (of height 2 m) shall be provided as protective enclosure
for the permanent benchmark while ensuring easy accessibility for future
reference, as directed by EIC.
3.11.1.11 The results of the surveying shall be presented in form of two drawings. First
drawing shall show the contours at 0.5 m interval and also showing the spot
level as collected from the site. It shall also show location of the actual field
tests. The second survey drawing shall indicate any existing facilities,
buildings, equipment, trestles, towers, junction houses, trees etc. and over
ground service line, if any, within the boundary. Further, the cross-sections
shall be shown at appropriate locations.
3.11.1.12 Three (03) permanent bench mark statue at suitable location within the plot
shall be established & constructed for the proposed site. Determination of
the bench mark elevations with reference to the existing bench mark and
determination of plot north with respect to magnetic north shall be done
and marked hereby on the permanent benchmarks. The detail drawing of
bench mark is indicated in drawing no. CET RN 4179 CE0 00 010 R=0.
3.11.1.13 In addition to permanent benchmark, local bench marks/co-ordinate pillars
at the rate of 100 m x100 m grids shall be constructed. The local bench mark
shall be plain concrete pedestal approximately 300 x 300 x 600 mm (depth)
size in 1:3:6 (1 cement, 3 sand and 6 coarse aggregates). The co-ordinates
& spot level shall be painted on the top of each of this bench mark
respectively.
3.11.2 Mapping of underground facilities
3.11.2.1 The mapping of underground facilities shall be accomplished using
instruments like Ground Penetration Radar (GPR) and Electronic buried cable
locator/ Induction locators. The Integration of Global Positioning System
(GPS) with GPR provides accurate determination of the measurement
location. The standard Guidelines for the collection and depiction of existing
subsurface utilities data as set by American Society of Civil Engineers (ASCE
38-02) shall be followed.

3.11.2.2 Ground Penetrating Radar is a geophysical technology for non- destructive
investigation of the earth, concrete & masonry structures, which uses radio
waves to detect buried objects and the internal structures of landforms. In
general GPR survey works well in sand/gravel and dry soil conditions with
low soil conductivity but cannot penetrate high conductivity materials such
as clay and salt water.
3.11.2.3 Electronic buried cable locator/induction locators are used for locating
buried cables.
3.11.2.4 The underground surveying shall be done by Ground Penetration Radar
(GPR) and the data be downloaded from the same and necessary survey
maps/ drawings shall be prepared both in digitized and Auto CAD form.
3.11.2.5 The level of all the underground lines (pipes and cables, if any) shall also be
indicated. While measuring the exact level of the underground lines, if due
to safety consideration the measurement is not possible / feasible; the
tentative location with approximate location of the same shall be indicated
in the Survey Drawing.
3.11.2.6 The location and level of the existing cable tunnel / pipe lines in the area
shall also be surveyed and indicated in the drawing. For this available
drawings shall also be referred.
3.11.2.7 Determination of the location & elevation of all existing features inside the
area as marked in the drawings and as directed by Engineer.
3.11.3 Bore Holes
3.11.3.1 Boring shall be done according to IS: 1892-1979. Shell and auger boring (dia
100-200mm) or rotary drilling (dia 65mm or more in rocks) shall be
conducted and no wash boring shall be allowed. Standard equipment to
conduct boring in soil and drilling in rocks shall be employed after approval
of the engineer. The drilling in rock shall be terminated at 3m inside rock or
20 m from the existing ground level, whichever is minimum for all the
boreholes. This is necessary to ascertain the geological type, structure,
conditions and extent of the rock mass. Drilling in rock & collection of rock
samples shall be in accordance with IS: 4464-1985.
3.11.3.2 Record of boring shall be maintained in accordance with IS: 1892-1979. The
records shall include bore hole number, time and date of start and
completion of boring, drilling, existing ground level, sub-soil water level,
description and thickness of various strata including depths below existing
ground level, N-values, nos. and types of soil samples collected and the
depths at which samples were taken and other relevant data. All boring
record shall be incorporated in the soil investigation report. The bore holes
shall be filled up with sand up to the top after the completion work.
3.11.3.3 The results shall be presented in the form of a table/graph for the details of
each bore hole sample like bore hole number, sample number, depth of
collection, consistency limits, plasticity charts, densities, specific gravity,
shear strength, cohesion, angle of internal friction, etc.
3.11.3.4 The bearing capacities may be worked out for the individual bore-hole
locations (for achieving the economical design) and presented in the form
of a table for different depths and for different settlement. The shear
parameters shall be used for calculation of bearing capacities from shear
considerations for different sizes and L/B ratios of 1, 2, 5 & 10.
3.11.3.5 Considering important nature of the structure, the bearing capacities may
be calculated for the following settlements
 25 mm
 50 mm
 75 mm
 100 mm
3.11.3.6 For cohesive soil, the effect of long-term settlement considering the
consolidation characteristics of the soil shall be taken into account while
calculating the bearing capacities. The value of Cc obtained from the
consolidation tests shall be used for calculation of the settlement of different
layers of soil strata corresponding to the bearing loads on the foundations
of different sizes calculated for shear strength considerations. If the total
settlement is more than the allowable settlement for the foundation
enumerated above then the safe bearing capacity shall be taken as allowable
bearing capacity. In case the settlement is more than the permissible limit
then back calculation shall be done to find out the loads and the
corresponding bearing capacities that satisfy the allowable settlement for
the particular type of foundation and that bearing capacity shall be reported
as allowable bearing capacity.
3.11.3.7 Ground Water
Whenever sub-soil water is encountered, the depth at which it is first met
with shall be recorded. On completion of each borehole, the static ground
water level shall be recorded after allowing sufficient time for the ground
water to come to a steady level. In addition to above, records of variations
in ground water table, isolated bodies or perched ground water table,
presence of aquifer shall be maintained.

3.11.3.8 Sampling
Disturbed soil samples shall be collected from bore holes in accordance with
IS: 1892-1979 and IS: 2131-1981 at 1.5 m intervals or change of stratum
whichever is less.
Undisturbed samples shall be collected from bore holes in accordance with
IS: 1892-1979 and IS: 2132-1986 by thin walled tube sampler or similar
suitable approved tool at 1.5 m intervals or at every change of stratum
whichever is less, taking care to ensure that the sample shall nearly as
possible be in the same state as that in which it existed before boring
commenced. The interval of collection may be changed to suit the sub-soil
condition but with the approval of Engineer.
After recovery of the sample, the tubes shall be cleaned, waxed, capped and
labelled properly according to IS: 1892-1979, IS: 2131-1981 and IS: 2132-
1986 for onward transmission to the laboratory.
For drilling through rock, cores shall be collected and stored in wooden
boxes and properly labelled for transportation to laboratory.
Block samples of different types of soil and rock shall be collected from test
pits to ascertain their physical properties.
Water samples shall be collected as per IS: 1892-1979. Care shall be taken
in collecting water samples and it shall be ensured that samples collected
represent true characteristics of water. Adequate samples shall be taken to
conduct the laboratory tests. Standard sampling bottles shall be used to
collect samples. They shall be properly sealed and labelled for onward
transmission to the laboratory. Label on each sample shall indicate the
source, location and depth from where the sample has been collected, date
and time of collection and initial of the Bidder's representative collecting the
sample.
Laboratory tests shall be conducted on undisturbed/disturbed soil samples.
These samples shall be taken out of the boreholes and 3(three) tests shall
be conducted for each of the soil sample. However, chemical testing of soil
and water shall be restricted to the soil samples collected up to 5m below
Ground level. A proper and systematic data of boring shall be maintained
and furnished in the form of logs and tables.
3.11.3.9 Classification of Soils
Classification and identification of soils shall be done as per IS: 1498-1970.
3.11.4 Testing of Rock
The procedure for testing of rock cores shall be as detailed below:

 Unit weight of Rock: These tests shall be conducted on air-dried
specimens of height to diameter ratio of about 1:1. The unit weight
shall be calculated from the weight so determined and the volume of
the specimens.
 Compressive strength of Rock: Cylindrical specimens made out of the
rock cores (diameter to height ratio of about 1:2) shall be tested.
3.11.5 Test For Electrical Soil Resistivity
By the side of bore holes the electrical soil resistivity shall be tested as per
IS: 3043-2018 and included in soil investigation report.
3.11.6 Submission of Report of Soil Investigation and Mapping of
Underground Facilities
3.11.6.1 After finishing the entire investigation, the bidder shall submit five copies of
the draft soil investigation report along with survey drawings and drawings
indicating mapping of underground facilities for approval by the employer
/consultant. After incorporation of the comments from employer/
consultant, the final report along with the relevant drawings shall be
submitted. After approval of the same by the employer the bidder shall
submit five copies of the final report of soil investigation, final survey
drawings and drawings indicating mapping of underground facilities for
final approval.
3.11.6.2 The final report shall be the complete compilation and consolidation of
available data, tests conducted Bidder’s interpretation of results of all in- situ
and laboratory investigations. It shall include general description of site,
general geology of the area, investigation procedures, description and
characteristics of soil and rock conditions, location of ground water table,
description and results of all in-situ and laboratory tests. The Bidder shall
ensure that all observations made during field investigation and all
laboratory tests are incorporated in the report. Besides, recommendation for
allowable bearing capacity, types of foundations and pile capacities shall
form part of this report.
3.11.6.3 The report shall include general assessment of the ground condition and
also precaution and special measures, if any, to be taken for protection of
concrete foundations against the action of soil and water.
3.11.6.4 The results of the surveying shall be presented in form of two drawings. First
drawing shall show the contours at 0.5 m interval and also showing the spot
level as collected from the site. It shall also show location of the actual field
tests. The second survey drawing shall indicate any existing facilities,
buildings, equipment, trestles, towers, junction houses, trees etc.

and over ground service line, if any, within the boundary. Further, the cross-
sections shall be shown at appropriate locations.
3.11.6.5 Additional information such as the layout of existing facilities such as railway
tracks, roads, bench mark locations (along with its value), drains, manhole
locations, underground tunnel, trestle support location, pipelines etc., shall
also be indicated.
3.11.6.6 In the final survey drawing, both plant north and true north shall be shown
along with their correlation.
3.11.6.7 For better readability, the geotechnical investigation report may be
presented in the following manner:
1) Main body comprising of project details, program of investigations,
discussion on the field tests, laboratory tests and results, summary of the
results, table indicating the bearing capacities, sample calculation for the
bearing capacity for different bore holes / soil strata and conclusions and
recommendations.
2) The test results (both field and the laboratory) and the relevant calculations,
bore log data, electrical resistivity test results etc., may be presented in the
Annex.
3.11.6.8 Throughout the execution of the work, the bidder shall perform cleaning on
a day-to-day basis. All external surfaces shall be cleaned of all dirt, dust,
grease, oil etc.
3.11.7 Excavation and Back Filling
3.11.7.1 Earthwork in excavation in all type of soils, soft rock, hard rock, to remove
materials of any nature or description, which may be encountered including
steel plant waste, slag fly-ash, cinders, iron fines, iron & steel scraps etc.,
back filling, stacking, loading, transportation, unloading and disposal of
surplus excavated earth/rock as per the direction of the Engineer in Charge
(Lead as per SBD). . For purpose of safety in excavation works IS: 3764-1992
shall be followed.
3.11.7.2 Stripping
The Bidder shall strip the surface of the site prior to the commencement of
excavation to remove vegetable soil and carry such soil to separate spoil
dumps in the allotted site/areas. The Bidder shall not remove any tree
without permission of the Engineer.
3.11.7.3 Excavation for foundations and Trenches
1) The Bidder shall excavate at various levels including hard rock to
remove materials of any nature or description, which may be

encountered. Side slopes, benching and/or shoring/strutting for
excavation work shall be sole responsibility of the Bidder. The bed of
the excavation shall be properly dressed and made level. All mud and
slush shall be removed before taking up concreting work. The last 150
mm of excavation shall be done just prior to laying of concrete. The
excavated materials shall not be placed within 1.5 m from the edge of
any excavation. The Bidder shall take suitable precautions to prevent
ingress of water into the excavated areas during construction.
2) The Bidder shall account for all excavated rock, if any. He shall stack
excavated rock and if the Bidder for his works requires serviceable
boulders, it may be issued based on stack measurement less 40% for
voids at the rate to be decided by the Employer.
3) The surplus excavated materials and excavated unserviceable materials
from rock excavation shall be transported and disposed off by the
Bidder in spoil dumps or fill areas as directed by the Employer.
4) If the Bidder excavates to levels lower than those shown on the
drawings, he shall fill up such extra depth at his own cost to the proper
level with lean concrete of grade M-10B.
5) Should the bottom of any excavation appear to be soft, unsound or
unstable, the Bidder shall excavate the same to required depths and
the extra depth shall be filled up by the Bidder with lean concrete PCC
1:5:10 (Cement: sand : Aggregate).
6) The Bidder shall take all precautions against slips and falls in the
excavation. No extra payment shall be made for removal of slips and
for back filling the space with materials as directed by the Employer.
7) The excavation shall be kept free from water by pumping on
continuous basis by the Bidder at his own expense. In small pits water
may be bailed out with buckets. Pumping of water shall be carried out
either directly from the excavation or from sumps made outside the
excavation as directed. Adequate care shall be taken to prevent
movement of water through freshly laid concrete or masonry work.
8) If any excavation for foundation gets filled up with water due to rain,
seepage or for any reason, the water shall be removed and bottom of
the excavation shall be completely cleared of all silt/slush by the Bidder
at his own expense.
9) All water pumped or bailed out during de-watering of pits and
trenches shall be disposed off suitably through properly laid channels
or pipes. Disposal of water shall be carried out in such a way that no

inconvenience or nuisance is caused to the work in progress in the area
or to other agencies working in the area or cause damage to property
and structures nearby.
10) Proper safety protocol shall be prepared before excavation work and
approved by the employer. Excavation scheme/drawing with required
slope shall be submitted to employer for approval where the depth is
substantial or the excavation site is close to other important existing
foundation/structure/facility.
3.11.7.4 Back Filling
1) Materials
Suitable materials obtained from excavation of foundations shall be
used as far as possible for back filling. Earth used for filling shall be free
from organic and other objectionable matter. All clods of earth shall
be broken or removed. If sufficient amount of suitable materials are
not available at site to complete filling work, then earth shall be
brought to site from outside by the Bidder as directed by the Employer
at his own cost.
2) Filling around foundations with earth
Before commencement of back filling, the Bidder shall remove from
the space around foundations all accumulated water and slush, shoring
and formwork, all debris, brickbats, bits of timber, cement bags and all
other foreign materials. Filling shall be carried out in uniform
horizontal layers, each layer not exceeding 200 mm in thickness. Each
layer shall be watered, rammed, and thoroughly compacted before the
next layer is deposited.
3) Plinth filling and special compaction with earth
Plinth filling or filling where special compaction is required shall be
carried out in uniform horizontal layers, each layer not exceeding 150
mm in thickness. Each layer shall be well watered and compacted by
mechanical means. The Bidder shall take core samples for each layer,
determine the dry density and maintain logs. The minimum dry density
to be achieved shall be 95% of maximum dry density as obtained by
Standard Proctor Test. Tests shall be conducted by the Bidder as
directed by the Employer at his own cost.
4) Removal of heaps & Mounds
Immediately upon completion of each phase of work, the Bidder shall
at his own cost clear the mounds or heaps of earth which may have
been raised or made and remove all earth and rubbish which may

have become surplus in the execution of works, as directed.
5) Filling with sand
Filling with sand shall be carried out in uniform horizontal layers, each
layer not exceeding 200 mm in thickness with approved river sand and
each layer to be watered and compacted mechanically to a well
compacted mass.
3.11.8 Plain And Reinforced Concrete Work
3.11.8.1 Materials
1) Cement
Cement: Ordinary Portland cement shall conform to IS: 269-2015 and
Portland blast furnace slag cement shall conform to IS: 455-2015.
Soundness test is to be carried out on cement samples from time to
time. Frequency of these tests shall be increased during monsoon
period.
2) Aggregates
All aggregates shall conform to IS: 383-2016. Fine aggregates shall be
approved river or pit sand. Coarse aggregates shall be approved
crushed stone. Aggregates shall be clean and free from any foreign
material. Test on aggregate shall be carried out from time to time to
ascertain the suitability of the aggregates.
3) Reinforcement
Reinforcement in general shall be of tested quality. TMT bars
conforming to IS: 1786-2008 shall be free from oil paint and rust
coatings. However, MS round bars conforming to IS: 432-1982 or IRC
mesh fabric reinforcement conforming to IS: 1566-1982 can also be
used if specifically required. The binding wire shall be 20 SWG
approved annealed iron wire.
4) Shuttering
The material for shuttering shall be steel plates as per IS: 2062-2011 or
ply boards as per the requirement.
5) Jointing materials
All rubber and PVC water stops joint fillers, sealing materials etc. used
in concrete work shall be of standard manufacture as per relevant IS
codes. Usage of these materials shall be in accordance with the
manufacturer's instructions.

6) Admixtures
Admixtures, if required, to be used shall be of approved quality and
make and shall conform to relevant IS codes.
7) Water
Water shall be clean and of potable quality as per clause 5.4 of IS
456-2000.
3.11.8.2 Workmanship
1) Concrete
a) Production and control of concrete shall be as per IS: 456-2000.
The grades of concrete shall be as indicated in the drawing. The
Bidder shall at his own cost, grade the aggregates and control the
water cement ratio, design the different mixes to required
strength and workability. The designed mix shall conform to the
requirement of IS: 456-2000 and recommended guidelines in SP:
23-1982. The minimum cement content and maximum water
cement ratio of concrete work shall conform to the requirements
of durability of concrete for moderate exposure as indicated in
Table-5 of IS: 456-2000. All concrete shall be machine mixed, and
no hand mixing shall be permitted.
b) The maximum size of aggregates used shall be as indicated in the
drawings and IS: 456-2000. Where reinforcement is too closely
spaced for the maximum size of stone in a range, the largest
suitable range shall be used. Before commencement of work, the
Bidder shall submit to the Employer for his approval complete
details of the tests for design mixes together with the grading
analysis and mix design calculations. No concrete shall be placed
on site until the Employer has approved the mix design.
c) Where nominal mixed concrete as defined by IS: 456-2000 is
permitted by the Employer for any specific reason, the proportion
of the materials shall be as indicated in IS: 456-2000. The water
cement ratio shall not exceed those specified in IS: 456-2000. If
the quantity of water is required to be increased for better
workability, the cement content also shall be increased
proportionately so that the water cement ratio as specified in IS:
456-2000 is not exceeded.
2) Mixing
Except where nominal mix concrete as defined in IS: 456-2000 is

permitted by the Engineer to be used, all components of concrete shall
be proportioned by weight using weigh batches for each grade of
concrete. Mixing shall be carried out in mechanical mixers and
preferably a batch mixing plant shall be used. Batches shall not exceed
the capacity, which can be mixed efficiently as determined by the mixer
efficiency test, and peripheral speed shall conform to the
manufacturer's recommended rate but should not vary by more than
±10%. Mixing shall continue until the mass is uniform in colour and
consistency but in no case net minimum mixing time shall be less than
1.5 minutes. Net minimum mixing time shall begin when all ingredients
including water is in the mixer. Excessive mixing shall be avoided.
Mixers shall be operated only by trained operators. Weigh batches
shall be placed level during use and the hoppers shall be loaded
evenly.
3) Consistency
Consistency of concrete shall be controlled as per IS: 456-2000 and
the Bidder shall carry out slump tests in accordance with IS: 1199-
1959.
3.11.8.3 Work tests
Over the full period of construction, the Bidder shall carry out works tests of
concrete cubes at his own cost. Sampling, making up, curing and testing of
specimen shall conform to IS: 456-2000, IS: 516-1959 and IS: 1199 - 1959.
The number of specimen to be tested and their criteria for acceptance shall
be according to IS: 456-2000. Frequency of work tests shall be as indicated
below:
3.11.8.4 Frequency of tests
Unless otherwise specified, for each grade of concrete, 2 (two) sets of test
cubes, each set consisting of three (3) twin specimens (i.e. total 6 Nos.), shall
be taken. Number of sets shall generally be calculated based on the types
and corresponding volumes of work as indicated hereunder unless
otherwise directed by the Engineer.
a). Mass concrete For every 100 Concrete placed one set, but not
m3 of foundations less than one set for each pour of
concreting
b). Equipment and building For every 50 m3 of concrete placed

column foundations one set but not less than one set
for each pour of Concreting

c). Frame and thin walled For every 30 m3 of concrete placed
structural components one set, but not less one set for
(columns, beams slabs etc.) each pour of concreting
1) The test cubes shall be taken in presence of the Engineer/Employer's

representative, who shall also sign the record of testing in a pro- forma
to be agreed between Engineer/ Employer & Bidder.
2) For testing of cube specimens Bidder shall transport the specimen to
the testing laboratory and the cost of testing of cubes shall be fully
borne by him.
3.11.8.5 Reinforcement
1) Workmanship shall conform to IS: 2502-1963. All reinforcement shall
be free from loose mill scale, rust, oil, grease and paint, etc.
Reinforcement shall not be bent or straightened in a manner that shall
injure the material, and all bars shall be bent cold.
2) Reinforcement bars shall be placed and maintained accurately in the
position as shown in the drawings. The correct cover to the
reinforcement shall be maintained by use of pre-cast concrete blocks.
3) All intersections of longitudinal and transverse bars of stirrups and all
laps shall be securely tied together with approved binding wire. The
binding wire shall be so placed that it touches all the four corners of
the intersection and the two ends shall be looped with pliers and the
end should be turned into the body of the concrete.
4) Welded joints may be used in cases of important connections. Tests
shall be carried out at the cost of the Bidder to prove that the joints
have reached the strength of the bars connected. Welding shall be
done in accordance with IS: 2751-1979 and special precautions shall
be adopted for cold worked bars. Butt-welding between the ends of a
rod in line, whereby stress is transferred across the section may be
adopted only for mild steel bars. In case of tack welding for fixing
reinforcements in their position, no special precautions need to be
taken.
3.11.8.6 Embedments
1) All embedment shall be accurately set and rigidly fastened. Anchor
bolts shall be set to template and firmly secured in vertical and
horizontal line at required positions. Water stops shall be secured
against displacement during the placing of concrete. The joints for
G.S. sheet water stops shall be soldered watertight and those of PVC
and rubber shall be joined by cementing and vulcanizing. Expansion
joint fillers shall be for the full depth of slabs or full width in walls and
shall be cemented with bituminous cement against previously placed
concrete. The ends shall be butted tight and the upper edge set flush
with finished slabs.
2) Anchor holes and anchor bolts shall be protected by covering suitably
with brickwork in lean cement mortar after thorough cleaning.
3.11.8.7 Placing of concrete
1) Transporting concrete
Concrete shall be transported from the mixing plant to the forms as
rapidly as possible by means that shall prevent segregation or flash set
in the concrete during hot weather. The containers shall be such as to
prevent large evaporation. At the time of placing concrete in very hot
weather, care shall be taken to see that the temperature in wet
concrete does not exceed 38°C. Before placing the concrete, all
formwork, embedment and reinforcement shall be checked for
completeness, location, dimension, square and plumb. All chips and
sawdust or other foul matter shall be removed from within the forms.
The base surface shall be well moistened and puddles wiped out.
Placing equipment and accessories shall be kept clean and free of
partially set grout and concrete, and maintained in proper working
order. Suitable walk cradles shall be placed over the reinforcement
when the concrete is placed by manual transportation.
2) Placing
Concrete shall be placed within a maximum period of 25 minutes of its
removal from mixer. No concrete shall be placed until the place of
deposit has been inspected and approved by the Engineer. In general,
placing shall be direct, by transporting buckets. Where it is necessary
to deposit the concrete at level differences of more than
1.5 m, short chutes shall be used. Short chutes and hoppers shall be so
designed and installed that segregation shall not take place. In cases
where chutes are impracticable due to excessive drop to placing level,
hoppers and sectional tubes (elephant trunks) shall be used.
Concreting in open shall not be allowed during rains unless all
precautions have been taken by the Bidder and permission has been
given by the Engineer.
3) Construction joints
Construction joints shall be located such that they do not impair the
strength of the structure. In walls and columns, height of each lift

shall not generally exceed 1.5 m unless otherwise specified in the
drawings. Method of forming all construction joints shall conform to
the provision of IS: 456-2000. All construction joints in the
underground structures shall be provided with rubber or PVC water
bars. The surface of previously placed concrete at the construction joint
shall be thoroughly hacked to expose the coarse aggregates of
previously placed concrete and cleaned with wire brush and water to
remove all laitance. Immediately before placing fresh concrete, such
prepared surface shall be coated with a thin layer of cement slurry.
4) Expansion joints
Expansion joints shall be provided at locations as shown in drawings or
as per IS code. Details of expansion joints shall be as shown in the
drawing and all materials like bitumen impregnated fiber board, PVC
water bar, Aluminium foil etc. shall be of approved make and quality.
Bidder shall ensure that all expansion joints are 100% watertight. If
concrete is found to leak at construction/ expansion joints or at other
places, the Bidder shall carry out necessary remedial measures at his
own cost such as pressure grouting etc., immediately to make the
structure watertight.
5) Compaction
Concrete in general shall be consolidated by vibration using high
frequency mechanically driven vibrators. Concrete shall be placed in
layers at least 300 mm deep in walls and approximately 450 mm in
mass pours. Vibrators shall not penetrate more than 50 mm into the
surface of previously placed layer but shall completely vibrate the
working layer. Care shall be taken not to over vibrate any concrete and
especially those with higher slumps. Under no circumstances vibrator
shall be attached to or allowed to touch reinforcement. Spare vibrators
in good operating condition shall be in hand during placing
operations.
3.11.8.8 Grouting bases of machine, columns, foundation bolts, etc.
1) Level pads
For preparing the level pads, the top of the foundation concrete shall
be chipped off to remove laitance formed on the concrete surface,
and all loose materials shall be thoroughly cleaned and the surface is
wetted before the grouting. In case level pads are constructed they
shall be of cement concrete with one grade higher than the mother
concrete with 6mm nominal size stone aggregates in conformity with
the grouting requirements with 6 mm size ballast. The top of the level

pads shall be finished & fine and true to level.
2) Grouting:
a) Before placing the grout, the concrete surface shall be thoroughly
cleaned, preferably with compressed air and the surface shall be
thoroughly wetted with water for several hours. Grout concrete
shall be of grade M-30D as per item of work/drawing. The
grouting shall be prepared and placed as per manufacturers’
instructions. Before placing the grout all free water shall be
removed and the flat surface shall be coated with thin cement
slurry.
b) The quantity of mixing water shall be minimum commensurate
with the workability, compaction, and filling of the grout in all
corners and crevices. The grout shall be evenly spread and
compacted by rodding or a vibrator until the whole of the space
is completely filled with concrete. The grout shall be carefully
observed for initial settlement. If any settlement is observed,
further grout is to be poured and rodded.
c) For base plate having ribs underside the base plate, proper care
is to be taken to ensure filling of the cavities between the ribs.
d) In case of wide base plates or bedplates having ribs underside, it
may be necessary to do pressure grouting.
e) Non-shrinking grout: Non-shrinking grout where required shall
be used in accordance with the method specified by the
manufacturer. Material shall be as approved by the Engineer.
3) Curing
The grout must not dry out after it is placed in position. The surface
shall be kept moist with wet sacks for at least seven days.
3.11.8.9 Curing and protecting
Curing of concrete with water shall comply with IS: 456-2000. The Bidder
shall keep the exposed surfaces of concrete in a constantly wet condition for
at least 7 days from the date of placing the concrete. Curing compound may
be used subject to approval by the Engineer. Finished floor and concrete
shall be protected carefully until completely set. Protection of concrete
against extreme weather conditions shall comply with the Code.
3.11.8.10 Repairing and patching
Pockets, honey combing and other defects, which may be formed due to
segregation, improper vibration and any other reason whatsoever shall be

completely repaired to the satisfaction of the Engineer. The voids, if any,
shall be properly keyed and reinforced, if necessary. The face shall be tightly
formed and arranged for providing a head in the concrete. The cavities shall
be filled with the same concrete as used for the structure and thoroughly
rodded or vibrated where possible. The filled hopper shall be left in place
until shrinkage has taken place and the concrete sets sufficiently to stay in
place. While still àlive', the upper part of form hopper shall be removed and
excess concrete struck off and finished with wooden flat or trowel to match
existing concrete. Any fins or unsightly grout runs or bulges shall be
removed from the surfaces exposed to view. The rod holes shall be finished
with cement or grouted to match the existing surface as closely as possible.
No cement wash shall be used unless particularly called for in the drawings.
3.11.8.11 Tolerances
Tolerance is a specified permissible variation from lines, grades or
dimensions given in drawings. No tolerances for horizontal or vertical
building lines or footings shall permit encroachment beyond the legal
boundaries. Unless otherwise specified, the tolerances shall be as per IS:456
– 2000.
3.11.9 Form Work
3.11.9.1 Shuttering For Concrete
1) The term `shuttering' shall include all centering and form work required
to support the concrete during the process of laying, compacting and
setting and all items such as planking, lagging, walling, moulds, covers,
cross bearer, struts, props, bracing, etc., shall be covered by the term
`shuttering'.
2) Shuttering shall be strong and constructed rigidly so that there shall
not be any deformation underweight and pressure of wet concrete,
constructional loads, wind and/or other forces. It shall be constructed
in such a manner that it can be easily removed afterwards.
3) The shuttering shall have smooth and even surface and so constructed
as to remain sufficiently rigid during the placing and compacting of
concrete and shall be sufficiently tight to prevent loss of liquid from
the concrete.
4) Devices shall be provided in the shuttering for forming openings,
holes, pockets, chases, recesses etc., wherever required.
5) Cutting of holes etc. in the concrete after casting shall be avoided.
Corner fillets shall be provided in the formwork to obtain chamfered
edges to beams, columns, etc. wherever required.

6) Shuttering shall conform to IS: 456-2000. Forms shall be of pre-
fabricated standard or shop-built panels or built-in-place units,
stiffened and braced. Forms shall be cleaned from all dust and loose
materials before applying oil over it. Formwork with brick lining may
be done for structures below ground level on earth face with prior
permission of the Engineer. Bricks shall be thoroughly wetted before
laying concrete and the brick lining may be left in position, if so desired
by the Bidder.
7) The shuttering shall be such that after its removal, the exposed
concrete shall be smooth and even. If any unevenness is found, The
Bidder shall chip the bulged portion of the concrete and plaster with
6 mm thick cement plaster (1:4) at his own cost, after obtaining
Engineer's approval.
8) The minimum period for removing form work from various concrete
members when normal Portland cement is used, shall be as per IS: 456-
2000. All formwork shall be removed without any shock or vibration to
the concrete.
3.11.9.2 Supports
Formwork shall be so designed that the side of beams and slabs can be
removed without disturbing soffit forms and their supports. Props and
supports shall allow accurate adjustment of the formwork to line and level
and be capable of being removed in an approved sequence without causing
any injury to the concrete. Provision shall be made for removal of formwork
without disturbing props required for supporting hardening concrete.
3.11.9.3 Setting
Panels and units shall be set to true dimensions and alignment and rigidly
tied, walled and braced to prevent distortion and displacement during
concreting. All joints shall be tight and close fitting to prevent leakage. At
all construction joints, formwork shall be tightly secured against previously
cast and hardened concrete. While fixing formwork for beams and slabs,
tight fitting collars shall be provided around the heads of columns and the
joints shall be made grout tight. Slip forms where used shall provide smooth
and even surface true to dimension and alignment and shall be free of
unsightly offsets, fins or bulges.
3.11.9.4 Ties
Standard form ties, clamps, bolts, inserts etc., shall be of adequate strength.
Spreader, either removable or embedded type, shall be used to maintain the
wall thickness. The material and position of any tie passing

through the formwork shall be as approved by the Engineer. All ties, which
shall remain embedded in the concrete, shall be fixed in a manner that shall
provide a minimum cover of 12 mm at both the ends. Any holes left after
the removal of the ties shall be filled with concrete or mortar as approved
by the Engineer. Provision shall be made for forming holes and chases for
services and for providing pipes, conduits and other fixtures as shown in the
drawing and/or as directed by the Engineer.
3.11.9.5 Cleaning and treating of forms
All rubbish shall be removed from the interior of the formwork, and inside
of the formwork shall be wetted with water before commencing the
concreting. Mould oil or other approved release agent shall be used at all
panels. Care shall be taken to prevent contact of release agent with
reinforcement.
3.11.10 Mortar for Masonry and Plaster Work
3.11.10.1 Materials
1) Cement
Ordinary Portland cement shall conform to IS: 269-2015 and Portland
blast furnace slag cement shall conform to IS: 455-2015.
2) Sand
ii. The sand used shall be of approved quality river or pit sand and it
shall conform to IS: 1542-1992 for plaster and to IS: 2116-1980 for
masonry mortar. Sand for the mortar shall be evenly graded from
coarse to fine and shall be free from loam, clay, dust and any other
organic or foreign matter.
3) Admixtures/Plasticisers
Admixtures/plasticiser of approved make and quality may be allowed
in the mortar, if permitted by the Engineer.
4) Water
Water shall be clean and of potable quality.
5) Mortar Proportion
The proportion of cement and sand for mortar shall be as specified in
the technical specification/drawing/schedule of quantities.
1) The workmanship shall conform to IS 2250: 1981 for preparation of
masonry mortars and to IS 1661: 1972 for plaster.
2) The cement and sand shall be proportioned by volume in gauge
boxes and thoroughly mixed dry. The water shall be added by sprinkler
just sufficient to make a stiff and workable paste. In case of mechanical
mixing, the mortar shall be mixed back and forth for at least 10 minutes
with addition of water.
3) Mortars shall be used within one hour of the first contact of cement
with water. All materials remaining after this period shall be discarded.
Mortars that have started to set shall not be re-tempered.
3.11.11 Brick Masonry Work
3.11.11.1 Materials
1) Cement Mortar
Cement mortar shall be as specified above in this specification
2) Brick
The brick used shall be of class 5-designation Common Burnt Clay
Building Brick conforming to IS 1077:1992 or fly ash bricks confirming
to IS 13757: 1993. Bricks shall be approved by employer before being
used. Bricks shall be whole, sound, well burnt and free from cracks,
square and well-shaped uniform in size and shall emit a clear ringing
sound when struck. The compressive strength of brick shall be
minimum 5 N/mm2.
3.11.11.2 Scaffolding
1) Scaffolding shall conform to IS 2212: 1991 and shall be designed to
withstand the loads and to ensure complete safety of workmen and
materials. Bamboos shall not be used in scaffolding.
2) The scaffolding should be double, i.e. it shall have two sets of stands
to avoid putlog holes. Where this is not possible, the inner end of the
scaffolding poles shall rest in a hole provided in a header course only.
Only one header for each pole shall be left out. Holes, if provided, shall
be filled in and made good by the Bidder to ensure that the surface
does not give any unsightly appearance.
3.11.11.3 Cleaning
The Bidder shall carry out work in as clean a manner as possible and shall
remove excess materials and mortar droppings and rubbish, daily. Where
brick walls and stone masonry are to receive plaster, the joints shall be
cleaned of excess mortar and raked to a depth of 12 mm and the surface
shall be brushed clean.
1) The whole of the brickwork shall be carried out by the Bidder in an
uniform manner according to IS 2212: 1991. All the bricks shall be kept
under water till they are completely soaked and used on the work on
their becoming skin dry.
2) The Bidder shall set out and build all brickwork to the dimensions,
thickness and heights shown in the drawings. The Bidder shall build all
brickwork in English bond and half brick walls and casing to pipes,
chases etc. in stretcher bond. Brickbats shall not be used except where
required for bond.
3) The Bidder shall lay bricks in full mortar beds with shoved joints. The
joints shall not exceed 10 mm in thickness and shall be full of mortar,
close, well finished and neatly struck. The vertical joints in any course
shall not be nearer than a quarter of a brick length from those in the
course below. All joints shall be of same width except for small
variations to maintain bond. The brickwork shall be laid plumb and true
to line and level. No portion of brickwork shall be raised more than 1.0
m above another at one time. If the mortar in any course has begun to
set, the joint shall be raked out before another course is laid.
4) The top most course of brickwork under a reinforced concrete beam
shall be wedged against reinforced concrete surface and the joint well
filled with mortar. The Bidder shall flush up all joints thoroughly with
mortar as the work proceeds.
5) The brickwork as it progresses shall be thoroughly watered on its faces
and top. New work shall be properly bonded with the old work. New
surface of unfinished work shall be cleaned and thoroughly watered
before joining new work to it.
6) Walls whose thickness is less than a full brick length shall be reinforced
with wire netting of width equal to that of the wall at every third layer.
The laying of wire netting shall be continuous.
3.11.11.5 Curing
The Bidder shall keep wet all brickwork for seven (07) days after laying.
3.11.12 Plaster Work
3.11.12.1 Materials
Mortar for plaster work shall be as specified above in this specification.
1) All plasterwork shall be carried out according to IS 1661: 1972. The
thickness and proportion of cement plaster shall be as specified in

the drawing. Where the thickness of plaster is 20 mm or more, it shall
be done in two operations (coats).
2) The surface to be plastered shall be cleaned of all extraneous matter
and rubbish. Brickwork joints shall be raked and concrete surface shall
be roughened by chipping or hacking. Any shuttering materials
adhering to the concrete shall be removed. The surface shall be
thoroughly watered and soaked, aerated and all putlog holes shall be
closed before starting plastering operation. Plaster pads of required
thickness of plaster for correctness of plumb, line and level shall be
established by the Bidder before starting plaster work.
3) For one coat plaster work, the plaster shall be laid slightly thicker than
the specified thickness and the surface then levelled with a flat wooden
rule to the required thickness. The plaster shall be well pressed into the
joints and the surface finished for getting smooth and even surface.
4) Where two coats plaster work is specified, the first coat shall be applied
as described above except that the surface shall be left rough and keys
formed for the application of second coat. The second coat shall be
applied a day or two after the first coat has set, but the first coat shall
not be allowed to dry. The second coat shall consist of mortar ground
very fine and shall be laid on with a wooden rule to specified thickness,
rubbed smooth and levelled and the surface plastered completely the
same day. The levelling shall be continued till the plaster is dry and all
moisture which exudes from the plaster shall be wiped out with fine
cloth. The surface shall be kept dry until exudation of moisture ceases,
during the process of rubbing.
3.11.12.3 Curing
After the completion of plastering works, it shall be cured by adequate
watering for a period of seven days.
3.11.13 Painting
3.11.13.1 Materials
1) Weather Proof Exterior Paint
Paint shall be of approved brand and quality. It shall be applied strictly
in accordance with the manufacturer's instructions.
2) Paint
Paints shall conform to relevant Indian Standards and shall be of
approved brands. Only ready mixed paints shall be used for the work,
unless otherwise approved by the Engineer. The materials for

succeeding coats on any one surface shall be product of the same
manufacturer supplying the first coat for that particular surface.
Aluminium paint shall conform to IS 2339: 1963.
3) Brushes
Brushes shall be of type and size suitable for the work, conforming to
IS 487: 2012. Rags or inferior quality brushes shall not be used on the
work.
1) Weather Proof Exterior Paint
a) Preparation of surface: Before painting is commenced on a
surface, all dirt, oil, grease, effloresce etc. shall be completely
removed. Traces of oil, if any from forms remaining on concrete
work, shall be removed completely by abrasive stone. Effloresce
on concrete surface shall be removed by wetting the surface and
then scrubbing with 20% solution of muriatic acid. The surface
shall be finally prepared as per instruction of manufacturer.
b) Mixing: As per manufacturer’s specifications.
c) Application: The cement paint shall be applied in two coats as per
manufacturer’s specifications.
2) Painting
a) Ready mixed paint: Only ready mixed paints of approved brands
shall be used. The product shall be such, when applied, it shall
spread evenly in a thin coat and flow on smoothly and shall dry
quickly forming a tough durable film without showing any brush
marks or cracks.
b) Preparation of surface
The surface of steelwork to be painted shall be cleaned free of
dirt, oil, rust, mill scale and be thoroughly dry before painting.
Cleaning, degreasing, de-rusting and descaling wherever
necessary shall be carried out as specified in IS 1477 (part 1):
1971.
The surface of woodwork to be painted shall be cleaned and
rendered dry, free of dirt, grit and grease and shall be rubbed
smooth with the appropriate quality of sand paper. All knots
patches and sappy spot shall be touched up with shellac varnish.

3.11.14 Pre-Cast Concrete Work
3.11.14.1 General
The formwork and/or mould for Pre-cast concrete units shall be made of
metal and true to shape and dimension of the finished product as indicated
on the drawings. The moulds shall be close jointed and perfectly smooth
with joints caulked to prevent leakage of cement slurry. The moulds shall be
of rigid construction to prevent distortion and bulging of sides and base.
The moulds shall be designed with suitable fastening to allow them to be
struck off without injury to the casting. The moulds shall generally be
vibrated on a mechanically operated vibrator.
3.11.14.2 Marking of units
All pre-cast members shall be marked in a manner approved by the Engineer
in a conspicuous place, with date of manufacture and marking number. The
upper part of the member shall be marked distinctly for proper handling.
3.11.14.3 Erection
Erection of pre-cast units shall be carried out as per the approved sequence.
3.11.15 Granolithic Bedding and Floor Hardener Finish (Ironite Flooring)
3.11.15.1 Work Included
The Bidder shall furnish materials, labour, plant, equipment and tools to
complete the work as specified and/or as shown in the drawings.
3.11.15.2 Materials
1) Cement: Cement shall conform to IS 269-1989 or IS 455-1989.
2) Coarse aggregates: It shall be of approved broken graded stone of size
10 mm and down, conforming to IS 383-1970.
3.11.15.3 Sand: The sand shall be approved river or pit sand shall conform to IS 383-
1970.
1) Floor hardener: It shall be of best quality heavy duty metallic hardener
-Ironite or approved equivalent.
2) Water: Water shall be clean and of potable quality.
3.11.15.4 Proportion of Mix:

The proportion of mix for granolithic bedding shall be 1 part of cement, 1
part of sand and 2 parts of granite chipping. The mix for the floor hardener
shall be in accordance with the manufacturer's specification.
1) The thickness of granolithic finish shall be 25 mm and shall be laid in
accordance with IS 5491-1969 -Code of Practice for laying in-situ
granolithic concrete floor toppings. The surface of the base concrete
shall be thoroughly hacked or chipped to remove laitance, well
saturated with water and cleaned. Immediately before laying
granolithic finish, any excess water shall be removed and the surface
of the base concrete shall be covered with a thin layer of cement slurry
well brushed in. Just sufficient water shall be added to the ingredient
of granolithic mix to obtain enough plasticity. The mix shall be laid over
the freshly grouted base in suitably divided panels and evenly well
tamped into place, screeded and lightly floated to required levels. No
dimensions of a panel shall exceed 2 m.
2) When the granolithic finish has partially dried, approved floor hardener
mix shall be applied on the granolithic finish in two or more coats and
finished evenly with a trowel. Each coat shall be applied before the
previous coat dries. Workmanship for floor hardener finish shall
conform to manufacturer's specification. The thickness of the floor
hardener topping shall be 15 mm minimum.
3.11.15.6 Curing
3.11.16 The finished surface after hardening shall be cured for a minimum period
of seven (7) days by impounding water on the finished surface.
3.11.17 Water-Proofing and Damp-Proofing
3.11.17.1 Water-Proofing
1) Underground structures
All underground structures and water retaining structures shall be
water-proofed with by injections of non-shrink polymeric water proof
grouting compound from inside along with an applications of water
proof plaster on external surfaces as per approved manufacturer’s
specification.
2) Roof
All roof surface exposed to atmosphere shall be made water proof by
integral water proofing compound and application of 4mm thick
Atactic Polypropylene modified plastomeric bitumen based

membrane with glass fibre reinforcement as per manufacturers’
specifications
3.11.17.2 Damp Proof Course Concrete

1) Thickness
It shall be as specified in the drawings or in the items. However,
minimum 75mm thickness shall be maintained.
2) Mix
The grade of mix shall be as specified in the drawing or schedule of
quantities. If nothing is specified, the mix shall be 1 part of cement: 1
1/2 part of coarse sand : 3 parts of stone chips. The stone chips shall
be 12 mm downgraded. Approved water proofing admixture shall be
mixed with cement as per manufacturer's specifications. The water
cement ratio shall be as low as possible to increase the impermeability
of concrete and in no case more than 0.5.
3) Preparation of base surface
The base surface shall be well roughened by chipping and brushing
with steel brush and shall be cleaned of all dirt, dust, grease, oil and all
other foreign & deleterious materials. Then the surface shall be well
moistened with water.
4) Placing and compaction
Just prior to placement of D.P.C. Concrete, a thick coat of cement slurry
shall be applied on the base surface. The placement shall be as
specified for the concrete in beams. The concrete shall be well
compacted to make it dense.
5) Finishing
When the concrete has set enough but remains still green, the top
surface shall be marked in regular pattern by steel trowel so as to have
proper bond with the future work.
6) Curing
The D.P. course shall be kept continuously moist at least 10 days.
3.11.18 Waterproofing of Roof
3.11.18.1 Work Included
The Bidder shall furnish materials, labour, plant, equipment and tools to
complete the work as specified and/or shown in drawings.

3.11.18.2 Materials
1) 4mm thick Atactic Polypropylene modified plastomeric (APP) bitumen
based membrane with glass fibre reinforcement (minimum 50gsm),
finished on both sides with a thermo fusible high molecular high
density polyethylene (HDPE) film and mineral finished on top surface.
2) Bonding material: It shall consist of blown type bitumen conforming to
IS 702-1988 or residual bitumen conforming to IS 73-2013 or a mixture
thereof.
3.11.18.3 Waterproofing of roof surface
1) Screeding of grade M20 with minimum 25mm thick on ends and sloping
towards the ridge with min slope of 1:60 shall be laid as base for laying
the APP felt.
3) Thereafter APP shall be laid as per the manufacturer’s specification.
Minimum overlaps of 100 mm shall be provided at the end and the
sides of strips of felt. All overlaps shall be firmly bonded with hot
bitumen and torching shall be done. Any entrance of air during rolling
shall be strictly avoided.`
4) In case of roofs with parapets, a chase 75mm deep shall be cut in the
parapet at about 150 mm above the roof level and the APP shall be
laid as flashings in widths with a minimum overlap of 100 mm. The
lower edge of flashing shall overlap the felt laid on flat portion of the
roof and the upper edge of the flashing shall be tucked into the chase
made in the parapet. After the flashings have been properly bonded,
the chase shall be cleaned and shall be filled up with cement mortar
(1:4) flush with the face of the wall and allowed to set by adequate
curing.
5) In case of drain mouths, waterproofing shall be done as specified for
the roof excepting that the treatment shall be carried inside the drain
pipes overlapping at least 100 mm.
6) For gutters, a bituminous priming coat shall first be applied. Over this,
specified number of layers of felt shall be laid and bonded together
with hot bitumen and finally painted with a coat of hot bitumen at not
less than 1.5 kg/m2. The felt layers laid separately in the gutters shall
be overlapped with the corresponding layers on the roof proper. The
felt treatment shall be carried down in to the outlet pipes to a
minimum depth of 100 mm.

3.11.19 The Bidder shall obtain approval from the engineer regarding the
specialized agency to be engaged by the Bidder for carrying out the
waterproofing work.
3.11.20 Metal Doors & Windows

3.11.20.1 Steel doors, windows and ventilators
Steel doors, windows, ventilators and their fittings for residential and office
buildings shall confirm to IS 1038-1983 and be of the size and type shown
on the drawings.
3.11.20.2 Steel doors / Air tight steel doors for industrial buildings shall be made as
per the drawings specified by the Employer.
3.11.20.3 Steel windows for industrial buildings shall confirm to IS:1361-1978 and shall
be of the specified type and size.
3.11.20.4 External doors shall be provided with threshold as shown in IS 1081-1960
and the internal doors with an approved size base tie bar in lieu of threshold.
3.11.20.5 Unless otherwise specified, coupling section shall be of mild steel. Handles,
peg stays and pivots shall be of leaded tin bronze (gun metal). Hinges for
side-hung shutters shall be of projecting non-friction type, unless otherwise
specified. Weather bars shall not be provided unless specifically indicated
on the drawings. The type, size, number and position of fixing lugs shall
confirm to IS 1038-1983. The steel doors, windows and ventilators shall be
painted with one coat of red oxide zinc chromate primer, confirming IS
2074-1992 before they are fixed. Final painting shall be done with two coats
of ready mixed approved flat oil paint of approved colour.
3.11.20.6 Structural steel materials shall conform to IS: 7452-1990 for door, window
and ventilator and pressed mild steel shall be as per provision of IS: 513 -
2008.
3.11.20.7 Glass pane shall conform to IS: 2835-1987.
3.11.21 False Floor (Cavity Floor)
3.11.21.1 Materials
1) Floor Jacks: The jack shall be made out of 25 mm diameter MS rods
welded to 6 mm thick MS plate of size 100 mm x 100 mm. The top
part of the jack shall be threaded and provided with double check
nuts and washers to provide for level adjustment of 50 mm

minimum. All MS members shall be galvanized as per recommended
practice for hot dip galvanizing of iron and steel specified in IS:2629-
1985. Chromating treatment conforming to IS: 1340-1977 should be
employed for providing protection to the coated surfaces. The jack
head shall be of standard pressure die cast Aluminium-zinc alloy
component of proper composition.
2) Stringers: The stringers for supporting the false floor panels shall be
made of 40 mm x 40 mm 3.15 mm thick cold formed steel plates and
be finished with electroplated coatings of cadmium conforming to
IS:1572-1986. Chromating treatment conforming to IS:1340-1977
shall be employed for providing protection to coated surfaces.
3) Floor panels shall be 35 mm thick un-veneered teak wood particle
board bonded with BWP type phenol formaldehyde synthetic resin
generally conforming to IS:3087-2005 similar to Ànchor Nova Teak
Super' or any other approved equivalent.
4) All the four edges of the floor panels shall be fitted with edge lipping
made of teak wood or rigid PVC of suitable thickness or in
combination of teak wood lipping and hard PVC Z beading to protect
from damage during installation and removal of panels, and also to
protect from moisture absorption.
5) 22 gauge galvanized iron sheets shall be fixed to the underside of
floor panels for moisture resistance as well as to further improve fire
resistance quality.
6) Top of the floor panels shall be provided with 2 mm thick
homogeneous PVC sheets conforming to IS: 3462-1986 and having
anti-static property similar to "Anstat" of Premier Vinyl Flooring
Limited or any other approved equivalent.
3.11.22 False Ceiling
Standard Aluminium false ceiling with anodized Aluminium T-bar inter-
locking ceiling system as per following specification shall be adopted.
3.11.22.1 Materials
1) Particle board ceiling tiles shall be un-veneered teak wood particle
board bonded with BWP grade phenol formaldehyde synthetic resin
of approved make and shall conform to IS:3087-2005 exterior grade.
Back side and all the edges of the boards shall be provided with a
protective coat of epoxy based paint over a coat of primer to prevent
moisture absorption.
2) Minimum thickness of ceiling tiles shall be 12 mm.

3) The frame work for the false ceiling system shall be of approved make
and quality and consist of anodized Aluminium main Tees of size 23.5
mm X 23.5 mm X 1.6 mm and wall angles of size 25 mm X 25 mm X
1.6 mm.
4) Suspension arrangement including adjustable hooks, suspenders,
etc. shall be concealed and adequate for the spans involved. Hangers
supporting the anodized Aluminium frame work shall be galvanized.
The whole of the ceiling shall be firmly and securely fixed against the
walls.
5) The suspension system shall include all necessary support for light
fittings, ventilation grills, etc.
Entire ceiling system including suspension arrangement, frame work of grid
system, levelling of false ceiling, panels, alignment of light fitting and
ventilation grills shall be carried out as per the instruction of the relevant
manufacturers.
3.11.23 Anodized Aluminium doors, windows and Internal Flexible Partitions
3.11.23.1 Materials
1) Anodized Aluminium sections of ÌNDAL' extrusions or of any other
approved equivalent. Minimum wall thickness of the Aluminium box
section frames shall be 3.18 mm.
2) Glass shall be 5.5 mm thick, clear sheet glass of approved quality and
make.
3) Decorative laminated particle board panels of approved make and
finish. Particle board shall conform to IS: 3097:2006 exterior grade.
Minimum thickness of decorative laminate shall be 1.5 mm.
4) Minimum thickness of panels shall be 12 mm.
5) All edges of the particle board panels shall be provided with a
decorative coat of epoxy based paint over a coat of primer to prevent
moisture absorption.
All works shall be fixed straight and levelled, so as to guarantee perfect
working of all components. Assembling of components and fixing of
frames shall be as per the manufacturer's specification/instructions.
3.11.24 Dismantling

3.11.24.1 The dismantling work shall be carried out with utmost care so that the
adjacent structures, which are not to be dismantled, do not get damaged.
However, if any existing structures get damaged during dismantling, the
rectification and restoring of the entire structures shall be carried by the
Bidder without any extra cost.
3.11.24.2 The Bidder shall assess the entire dismantling work independently and
decide accordingly the resource to be employed by him so that the work
can be executed in the stipulated time frame. For precision and safe
dismantling work wherever required Diamond wire/saw cutter shall be used.
Diamond core cutter shall be used for dismantling of epoxy in the anchor
pockets, if required.
3.11.24.3 The Bidder shall obtain the necessary clearance certificates from safety
department of RSP, Rourkela, if required, for the arrangement of dismantling
work at every stage.
3.11.24.4 The dismantled material shall be stacked within the Plant boundary in
consultation with engineer in charge as stipulated in SBD.
3.11.25 Road work
3.11.25.1 RCC road shall be constructed. Premix bitumen carpet of minimum thickness
25 mm shall be laid over the top of RCC road.
3.11.26 The materials, specifications, workmanship and design shall be as per latest
MOST and relevant IRCs.
3.11.27 Railway Track Work
3.11.27.1 Layout Parameters & Design Geometrics
1. The layout of the railway track system shall be such that connections
to the existing plant units are convenient, as per technological logistic
requirement, clear of present and future installations and follow the
norms laid down by Indian Railway Standard (IRS).
2. Railway track shall be laid with 60kg/m rail sections with FF-Class-II
conforming to IRS-T-18. Rly track shall be laid as per RDSO and Indian
Railways standards and specifications.
3. The minimum CL distance between two tracks shall be 5.0 m.
1. The rail track on shop floor shall be laid and fixed on RCC foundations
and necessarily be provided with check rails all along the rail inside
the shop.
2. Tie rods of minimum diameter 20 mm shall be provided at an interval
of maximum 1 m to maintain the Board Gauge distance.
3. The spacing blocks in between the main running rail and check rail
shall be provided as per IRS specifications.
4. The rail head top inside the shop shall match with the finished floor
level of the shop. The level crossings shall be provided as per
requirement for the movements of heavy vehicles.
5. Re- railing switches/blocks shall be provided inside the shop as per
requirement. However, 4 nos. of Re- railing switches/blocks may be
considered for a track of full rake length.
3.11.28 Rock Anchors
3.11.28.1 Anchor Plate of size 200mm x 200mm (min) and thickness of plate 10mm
(min) shall generally be used based on support necessities. The shape shall
allow a uniform seat over rock, if the bolt is not installed exactly
perpendicular to the surface.
3.11.28.2 Rock bolts should conform to Indian Standard code IS-1786: 2008 High
Strength Deformed Steel Bars and Wires for Concrete reinforcement-
Specification.
3.11.28.3 Test certificates as per relevant Indian Standards shall be submitted for the
anchor bolts.
3.11.28.4 Pull out test on Rock Bolts shall be performed as per IS: 11309 -1985 –
Method for conducting Pull-Out Test on Anchor Bars and Rock Bolts. -
Minimum three pull out tests shall be conducted in one rock formation as
mentioned in clause 4.8 of IS: 11309-1985 or as per the instructions of
Engineer-in-charge.
3.11.28.5 One end of the anchor shall be fitted with a suitable thread to fix anchor
plate with nut. The steel rods shall be corrosion protected.

4 COMMISSIONING AND PERFORMANCE GUARANTEE
4.1 PRELIMINARY ACCEPTANCE

On completion of erection of the facilities by the Bidder, trial runs for
individual equipment / units shall be conducted by the Bidder to prove that
the facilities have been supplied and erected as per contract and after
erection, facilities are fit for start-up and commissioning. After liquidation of
all the defects and after fulfilling all the provision of clause 24 of GCC of
Standard Bidding Document (SBD) employer shall issue Preliminary
Acceptance Certificate (PAC) for the subsequent commissioning of facilities.
4.2 COMMISSIONING
Commissioning test shall be undertaken by the Bidder as per the provisions
of Clause 25 of GCC of SBD. On successful completion of commissioning
test employer shall issue commissioning certificate.
4.2.1 For commissioning purpose, 100 numbers of heats shall be considered
within 10 dayswith normal steel grades of RSP, which shall be produced at that
time. The facilities shall be deemed to be commissioned on fulfilment of
following:
4.2.2 The production capacity shall be tested during commissioning as follows:
LadIe Furnace
• Production capacity for 72 hourscontinuously:
72 heatsx 66% = 48 heats
Slab Caster
• Production capacity for 72 hours continuously :
72 heats x 66% = 48 heats
However, during commissioning tests, performance regarding production
capacity can be simultaneously demonstrated for ladle furnace as well as slab
caster while testing for other parameters.
4.2.3 Quality parameters regarding dimensional accuracy of cast slabs may be
tested during commissioning. These parameters shall be decided mutually.
In case of any interruption during the specified period/ duration of
commissioning on account of reasons attributable to the Employer, the
acceptance of commissioning with regards to duration of commissioning

tests shall be as per the mutually agreed terms between the Employer and
the Bidder.
4.3 PERFORMANCE GUARANTEE

4.3.1 General
4.3.1.1 Bidder shall guarantee the equipment for its workmanship, materials, design
and satisfactory operation in accordance with relevant specifications and
provisions of the contract. The guarantee for performance shall include
individual items and systems for various ratings
/ out puts as well as for the integrated operation of the plant.
4.3.1.2 The details of the performance guarantee tests, test procedures, test
schedules for the demonstration of performance guarantee parameters shall
be submitted to the employer which shall be mutually agreed upon.
4.3.1.3 Bidder shall conduct the performance guarantee tests to demonstrate PG
parameters as defined hereunder in subsequent paragraphs and as per
provisions of Clause 27 of GCC and Appendix-V of SBD.
4.3.1.4 PG Test shall be conducted within a period of six months after the date of
commissioning once facilities achieve stable operation as well as production
level.
4.3.1.5 PG Test shall be conducted for 100 heats of mutually agreed steel grades
provided by Employer.
4.3.2 Preconditions for Performance Guarantee Tests
4.3.2.1 Preconditions for the employer:
1) Heats shall be produced in BOF and shall be processed in Ladle
Furnace before supplying to Slab Caster for casting.
2) Weight of steel in ladle shall be 150 t nominal and 165 t maximum.
3) Supply of required number of heats shall be made within stipulated
period.
4) All raw materials shall be provided on regular basic.
5) Super heat in tundish shall be 40oC (max.) above liquidus temperature
of the steel grade being cast.
6) Heat making as per the advice of Employer.
7) Test procedure for tundish change, SEN change and steel grade
change shall be mutually discussed and agreed before start of PG Test.

4.3.2.2 Preconditions for the Bidder:
Bidder to indicate in bid document.
4.3.3 Performance Guarantee Parameters
4.3.3.1 Ladle furnace & Caster productivity related parameters :
Bidder shall have to demonstrate following parameters as listed hereunder:
Sl. PG PARAMETERS PG VALUE
Ladle furnace
1 Liquid steel temperature rise (heating up) rate 5˚ C/min
2 Specific consumption of electric power 0.5 kWh/t/ ˚ C rise in temp
3 Production capacity (for 2 consecutive days) 24 heats/day

4 Dust content at emission stack of pollution 30 mg/N3
control facility
Slab caster
5 Casting Speed (m/min): Low carbon steel (D,DD, EDD) grades
for 220mm thick slabs 2.0 m/min
for 250mm thick slabs 1.65 m/min
6 Machine preparation time 50 minutes
7 Rate of production: 24 heats / day
No. of heats/ day (for two consecutive
working days)
8 Caster Yield (%) 98.5%
LC steel grades, 8 heat sequence
4.3.3.2 Quality Related Parameter in cold condition

Slabs cast in the machine shall be of acceptable quality for further
processing by rolling mills and shall produce end products of acceptable
standard grade. Slabs from heats cast during the PGT period (randomly
selected) shall be measured in cold condition for following quality tests.
Width ± 0.5% (max.) of width (measured at 400 mm from

both ends & one in centre)
Thickness ± 1% (max.) of thickness (220mm and 250mm)
Length ± 25 mm (max.) (length range 6m to 10.5m)
Flatness ≤ 3 mm/m over the whole length
(Warpage)
Corner Angle 900 ± 20 max.
Rhomboidity
Narrow Face ≤ 3.5 mm max. per side for a thickness of 220 mm
Bulging ≤ 4.0 mm max. per side for a thickness of 250 mm
Camber ≤ 4.0 mm/m over the whole length
Wedge ≤ 1% of slab thickness
Taper ≤ 4.0 mm/side in width at max. slab length
The above quality parameter shall be analysed at Employer's laboratory by

the Bidder in association with employer. The actual procedure/ formula for
measuring and testing the above parameters shall be mutually agreed
between Bidder and Employer before starting the test.
4.3.3.3 Evaluation of the PG parameters
1) Ladle Furnace
a) Liquid steel temperature rise (heating up) rate:
Temperature of liquid steel in ladle before arcing and after arcing shall be
noted and the temperature rise due to arcing shall be noted for each heat.
The arcing time shall also be measured with the help of clock. Rise in
temperature shall be divided by the duration of arcing and the temperature
rise rate (temperature rise per minute) shall be calculated for each heat.
Average value of all the test-heats shall be calculated and compared with
the PG parameter.
b) Specific consumption of electric power:
Total power consumed during arcing shall be noted down from the power
meter for each heat. The weight of liquid steel in ladle shall also be noted
down with the help of EOT crane which is having load cells. Similarly, the
temperature rise during arcing shall also be noted down.
The power consumed shall be divided by the weight of liquid steel and rise
in temperature to calculate the specific consumption of electric power for
each heat. Average value of the entire test -heats shall be calculated and
compared with the PG parameter.
c) Production capacity:
Number of heats processed successfully in two (2) consecutive days shall be
noted down. Processing of heat shall mean arcing for temperature rise, alloy
addition, wire feeing, etc. for successful secondary treatment of liquid

steel in ladle to make it suitable for continuous casting in the slab caster.
The average of the number of heats per day shall be compared with the PG
parameters.
2) Slab Caster
a) Casting Speed (meter/ minute) :
Casting speed (meter / minute) of the machine during casting of heat shall
be calculated on average basis. Casting speed shall be noted down from the
control desk panel / HMI. Casting speed shall be noted down at each 10
minutes interval during the casting operation. Average casting speed shall
be calculated based on the readings noted down for complete sequence of
casting operation. Average casting speed shall be calculated for each heat.
Similarly the casting speed shall be calculated for different section sizes of
the slabs for each heat. Average casting speed shall be calculated for
comparing with the PG parameter
b) Machine Preparation Time (Minutes):
Time of casting -finish of previous heat / sequence (i.e. closing of tundish
nozzle) and time of dummy bar positioned and sealed for casting-start of
next heat / sequence shall be noted down to calculate the machine
preparation (re-stranding) time. Average of re-stranding time shall be
calculated for comparing with the PG parameter.
c) Caster Yield (%):
It shall be calculated as the percentage of output quantity from the caster
divided by input quantity to the caster. The Slabs produced from the caster
shall be considered as output of the caster. Short Slabs shall also be
considered for yield calculation. Average yield shall be calculated for each
sequence of casting operation. Total average yield shall be considered for
comparing with the PG parameters. The yield shall be calculated as:
Y = (Wc / WI) x 100
Wc : Weight of slabs cast
WI : Weight of Liquid steel teemed into tundish
However, proper method of calculating yield shall be mutually agreed
between Employer and Bidder.
d) Heats / day:
Number of heats processed successfully through Slab Caster shall be
counted per day. It has to be demonstrated for two (2) consecutive days in
PGT period. Liquid steel shall be available at the proper time at Slab Caster
for casting. The average number of heats per day shall be calculated and
compared with PG parameter.
4.3.3.4 Variance of input conditions for PG parameters
In the event of any variance in the input conditions w.r.t quality, quantity, or
any other parameter as defined in cl. 4.3.2 and 4.3.3, which has a bearing on
the PG parameter, the output PG parameter shall be mutually discussed and
revised as per the agreement between the Employer and Bidder, before the
start of PG tests.
4.3.3.5 Non fulfilment of PG Parameters and Liquidated Damage
In case the Bidder is unable to attain the guaranteed value of performance
guarantee parameters but attains within the minimum acceptable level of
the performance guarantee parameters as specified either in whole or in
part then employer shall recover the amount of liquidated damage as
mentioned hereunder:
Sl. PG PARAMETERS PG Acceptable Limit Rate of LD (% of Max. LD

No VALUE With LD contract value) (% of
contract
value)
For Ladle furnace
1 Liquid steel 5˚C/min 4˚ C/min 1% for each 0.5 ˚ 2.0 %
temperature rise (< 4˚ C/min not C/min decrease or
(heating up) rate. acceptable) part thereof.
2 Specific 0.5 0.55 kWh/t/ ˚C 0.2 for each 0.01 1.0%
consumption of kWh/t/˚C rise in temp.( kWh/t/ ˚ C
electric power rise in >0.55 Kwh/t/ ˚ C increase or part
temp. not acceptable) thereof.
3 Production capacity 24 22 heats/day (<22 0.5% for each 1 1.0
(for 2 consecutive heats/da heats / day not heat decrease of
days) y acceptable) part thereof.
4 Dust content at 30 No relaxation -- --
emission stack of mg/N3 (more than 30
pollution control mg/ Nm3 not
facility acceptable)
For Slab Caster
5 Casting Speed (m/min): Low carbon steel (D,DD, EDD) grades 5.0
For 220mm thick 2.0 1.8 (<1.8 not 0.05% for each
slabs acceptable) 0.02m/min
decrease or part
thereof.
For 250mm thick 1.65 1.55 (<1.55 not 0.1% for each

Sl. PG PARAMETERS PG Acceptable Limit Rate of LD (% of Max. LD
No VALUE With LD contract value) (% of
contract
value)
slabs acceptable) 0.02m/min
decrease or part
thereof.
6 Machine preparation 50 55 min(>55 min 0.5% for each 2.5 1.0
time (minutes) minutes not acceptable) min increase or
part thereof.
7 Rate of production: 24 heats 22 heats (<22 0.5% for each 1.0
No. of heats/ day / day heats not 1heat decrease or
(for two consecutive acceptable) part thereof.
working days)
8 Caster Yield (%) 98.5% 97.5% 0.5% for each 2.0
LC steel grades, 8 (<97.5% not 0.25% decrease
heat sequence acceptable) or part thereof
Total Liquidated damage for non-fulfilment of PG parameters shall be

limited to 7.5% of contract value, excluding taxes and duties, as stipulated
in GCC of SBD.
4.1 FINAL ACCEPTANCE

Final acceptance shall be as per clause no. 28 of GCC of SBD.

SCHEDULE – 1.8-1
DECLARATION OF SITE VISIT

(To be filled up by the Bidder)
I, hereby, declare that I have visited the site to understand the site conditions, and
acquainted myself with atmosphere prevalent therein. I have also understood the
extent of total works involved for this package.
Signature of the Bidder:

Seal of company Name:
Designation:
RSP Schedule 1.8-1 CET/05/RN/4179/TS/ST/02/R=2

SCHEDULE – 1.8-2
LIST OF EXCLUSIONS
Sl. No. Reference clause of TS Details of Exclusions Reasons
Signature of the Bidder

Seal of company Name
Designation
Note: Exclusion in line with TS points/ clauses only to be mentioned. No additional/

other points shall be included in the format.
RSP SCHEDULE – 1.8-2 CET/05/RN/4179/TS/ST/02/R=2

SCHEDULE – 1.8-3
LIST OF DEVIATIONS
Sl. No. Reference clause of TS Details of Deviations Reasons

Designation
Note: Deviation in line with TS points/ clauses only to be mentioned. No additional/

other points shall be included in the format.
RSP SCHEDULE – 1.8-3 CET/05/RN/4179/TS/ST/02/R=2

SCHEDULE – 1.8-4
LIST OF RECOMMENDED SPARES FOR

TWO YEARS NORMAL OPERATION
(To be filled by the Bidder)
Bidder shall recommend and tabulate below the list of additional spare parts for two
years trouble free operation. Additional sheet of like format may be used if necessary.
Sl. Name of Sub Assembly Description of Items Quantity

No. recommended
Seal of Company Signature of the Bidder

Name:
Designation:
SCHEDULE – 1.8-5
LIST OF COMMISSIONING SPARES

(To be filled by the Bidder)
Bidder shall tabulate below item wise the list of commissioning spares necessary for
the equipment offered. Additional sheet of like format may be used if necessary.
Sl.No. Name of Sub Assembly Description of Quantity

items recommended
Seal of Company Signature of the Bidder

Name:
Designation
SCHEDULE – 1.8-6
LISTS OF SPECIAL TOOLS AND TACKLES

Designation
SCHEDULE – 1.8-7
LIST OF FIRST FILL OF OILS AND LUBRICANTS

Designation
SCHEDULE – 1.8-8
DETAILS OF AUTHORISED PERSON OF BIDDER DURING TENDER EVALUATION
1. Name of Project :
2. Tender No. :
3. Name & Address of Bidder :
4. Name of authorized person (TECHNICAL) :
5. Email address :
6. Mobile No. :
7. Name of alternate authorised person (TECH) :
8. Email address :
9. Mobile No. :
10. Name of authorized person (COMMERCIAL) :
11. Email address :
12. Mobile No. :
13. Name of alternate authorised person (COMM) :
14. Email address :
15. Mobile No. :
Authorised Signatory
SCHEDULE – 1.8-9
REQUIREMENT OF CONSTRUCTION WATER & POWER

Designation
ANNEXURE 2.1.16.2-1
PROJECT IMPLEMENTATION SCHEDULE
(INDICATIVE ONLY)
PACKAGE-II (Main Package)
Time → 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Activity ↓
Placement of order and signing of contract
Submission & approval of Basic Engg. drawings
Submission & approval of Detail Engg. drawings
Area devlopment
Civil work (all buildings, emergency tank, tunnels, shed

fdn. etc,)
Manufacture and supply of equipment
Structural work
Installation of equipment, piping

Dismantling-Civil, Utilities and Structures
Shutdown*
Testing and commissioning
Shutdown* : Total 8 days (Staggered) - 4 days before and 4 days after installations of new gable & columns for interconnection of Utility
pipelines (water, gas etc.) with the existing lines, shifting of facilities etc. Details to be decided as per site conditions.
RSP ANNEXURE 2.1.16.2-1 CET/05/RN/4179/TS/ST/02/R=2

Annexure-2.7.4.12-1
LIST OF EXTG. CABLES TO BE RELOCATED AT THE GABLE END OF THE CASTER
SHOP FOR PROPOSED EXTENSION OF “ LM, MN, NP, PQ, QR AND R’S BAYS”
TOWARDS EXISTING SCALE PIT SIDE
Sl. System Incoming Load Cable size Approx.

(from ) side(to) length of
existing
cables
1. VC-05 (outside KL MER Fan motor 3x50 sq.mm 450 m
bay) (10.5 kW) Al
2. VC-05 (outside KL MER Control 6x1.5 sq.mm 450 m
bay) cable for fan copper
motor local
panel
3. VC-05 (outside KL MER Pump motor 3x35 sq.mm 450 m
bay) (11kW) Al
bay) cable for copper
pump motor
local panel
5. VC-05 (outside KL MER Viscous filter 3x10 sq.mm 450 m
bay) motor Al
(1.1kW)
bay) cable for copper
filter local
panel
7. Shop office lighting AER-III Now 3.5x50sq.mm 450 m
(existing- outside KL connected Al
bay) with VC-05,
PC room,
Retractor
shift office
& rest room,
AER-II
lighting
8. Shop peripheral AER-III Front side 3.5x50sq.mm 800 m
lighting and back Al
side
9. Shop street light AER-III Front side 3.5x 800 m

Sl. System Incoming Load Cable size Approx.
(from ) side(to) length of
existing
cables
and back 50sq.mm Al
side
10. Repair hoist AER-II Hoist block 3.5x 300 m
Cr#2131 50sq.mm Al
11. Sample Carrier Mixer, Conv-I , Laboratory 14x 1.5 1500 m
II & III Building sq.mm (10
nos.) copper
Caster-I, II &
III
LHF-2A, 2B, 2C
RHOB
12. Welding socket AER-III R Column 3.5 x 90 200 m
sq.mm Al
13. Repair trolley (PQ MER Q column 3.5 x 35 200 m
& QR) sq.mm Al
14. Ladle tilter AER-II R column 2 nos. 3.5 x 2x 200 m
35 sq.mm Al
15. PRS cable Main PLC Middle of 5 x 1.5 200 m
room Q-R column sq.mm
copper
16. PRS cable Main PLC Middle of 12 x 1.5 200 m

room Q-R column sq.mm
copper
Note: Cable lengths mentioned above are tentative only. Bidders shall assess the actual
cable lengths at site and shall provide length of new cables as per actual site
requirement after extension of shop building. Bidder shall also provide 20%
spare cable length above actual cable requirement and 20% spare power cables
and control cables more than the above mentioned tentative cable requirement.

ANNEXURE 2.10.15-1
List of empanelled parties for Topographical Survey & Soil
Investigation work
Sl. Name of the Party Email id Phone No

1. M/s Tecpro Engineers Pvt. info@tecproindia.com 91-9793209918,
Ltd., Kanpur. 9336185051
+91-9310043298
2. M/s Superintendance Co. Of supindkolkata@vsnl.net Ph: (033) 2288-9015
India Pvt. Ltd., Kolkata
3. M/s KCT Consultancy kctconser@yahoo.com Phone : +91 (079)
Services, Ahmedabad. 65103088, +91 (079)
65103089, +91 (079)
65103090
Email: kct@kctcs.in
4. M/s Project engineering & kkrpecpl@gmail.com +91-33-2474-7806
controls Pvt Ltd. Kolkata, ceo@pecpl.co, admin@pecpl.co, +918335049800
sales@pecpl.co
5. M/s Creative Studio, creative_arch_studio@yahoo.c 91)-674-2434137
Bhubaneswar om
6. M/s San Survey Engineering, sansurvey@gmail.com; 9433281788 /
Hoogly sansurvey@rediffmail.com 9433524683 /
9433733505 /
9432856887
7. M/s C&C Consulting Firm, info@ccconsultingfirm.co.in; 033-6550-2411/2419-
Kolkata cccf@cal3.vsnl.net.in 8402.
8. M/s Suvadra Consultants, suvadraconsultants@gmail.co (0674) 6536124

Khudra, Odisha m Mob : 09437024020
Suvadra_consults@yahoo.corn
9. M/s IDAX Consulting and info@idaxconsulting.com
research group, Bhubneshwar
10. M/s SS Solutions, Durgapur info@sssolution.org 0343 2549865 ,
sssolution_88@rediffmail.com 09434388886
11. CEG Test House and Research info@cegtesthouse.com 91-141-4046596

centre Pvt. Ltd Jaipur, 91-98297-46596
91-011-25532899,
25541406
12. M/s ARKI TECHNO business@arkitechno.com 0674-2554205
Consultants (P Ltd
13. M/s Aakar Abhinav info@aakarabhinav.com 91-22-27580192 /
Consultants Pvt. Ltd. amol.khair@aakarabhinav.com 2757201
RSP ANNEXURE 2.10.15-1 CET/05/RN/4179/TS/ST/02/R=2
Sl. Name of the Party Email id Phone No
neha.khair@aakarabhinav.co +91-22-275725332
m
14. M/s Geo Tech Services, info@geotechservices.in 8308812676
Nagpur
15. M/s S M Consultants, sarmistha@smcindia.com 0674 258 0683
Bhubaneswar support@smcindia.com
16. M/s Arun Soil Laboratory Pvt arunsoillab.asl@gmail.com 094150 25566
Ltd, Lucknow
17. M/s CE Testing Company Pvt marketing@cetestindia.com; 033 2421 9810
Ltd, Kolkata cetest@gmail.com
18. M/s Sun-Tech, Ranchi sun.tech.lab@gmail.com Phone: 078082 66661
19. M/s D K Consultants, hb@dkcindia.org;
Bhubaneswar dkconsultants@ymail.com
20. M/s Pioneer Surveyors, pioneer.surveyors@gmail.com 91-33-
Kolkata 64554201/64546664
21. M/s Nirman, Kolkata nirman05@rediffmail.com; 9433310183

nirman05@yahoo.co.in 3324524945

ANNEXURE 2.10.15-2
List of empanelled parties for Locating & Mapping of Underground
Utilities
Sl No Name of The Agency Email-id

1. Results Survey Pvt Ltd, Chennai hari@resultssurvey.in
2. M/s Tech 27 Systems Pvt. Ltd., Calicut. seena@tech27.com
3. mukesh@parsan.biz;
M/s Parsan Overseas Pvt. Ltd, New Delhi
info@parsan.biz
4. M/s SS Solutions, Durgapur info@sssolution.org
5. M/s Ridings Consulting Engineers India Pvt bdinfo@ridingsindia.com;
Ltd, Noida nbshukla@ridingsindia.com
6. softacomputer@gmail.com;
M/s Softa Geotechnical Pvt Ltd, Kolkata
mondall.swa@gmail.com


TND - 072388 - 148909-Tech. Specs.

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ROURKELA STEEL PLANT

INSTALLATION OF A 4th SLAB CASTER AT SMS-II

STEEL AUTHORITY OF INDIA LIMITED

APRIL, 2019 CET/05/RN/4179/TS/ST/02/R=2

Chapter Description Page No.

1 Introduction 1.1 - 1.5

2 Scope of Work 2.1 - 2.97

3 Technical Specification 3.1 - 3.424

4. Commissioning and Performance Guarantee 4.1 - 4.7

PACKAGE LEADER(PL) TASK FORCE HOD (PL)

RSP CONTENTS CET/05/RN/4179/TS/ST/02/R=2

Annexure No. Description No. of Pages

2.1.4-1 List of Acceptable Makes of Equipment & 33

2.1.16.2-1 Indicative project implementation schedule 1

2.6.2-1 List of extg. cables to be relocated at the 3

2.10.15-1 List of empanelled parties for 2

2.10.15-2 List of empanelled parties for “Locating & 1

RSP CONTENTS CET/05/RN/4179/TS/ST/02/R=2

Schedule No. Description No. of Pages

1.8-1 Declaration of site visit 1

1.8-2 List of exclusions 1

1.8-3 List of deviations 1

1.8-4 List of recommended spares for two years 1

1.8-5 List of commissioning spares 1

1.8-6 List of special tools and tackles 1

1.8-7 List of first fill of oils and lubricants 1

1.8-8 Details of authorised person of Bidder 1

1.8-9 Requirement of construction water & power 1

RSP CONTENTS CET/05/RN/4179/TS/ST/02/R=2

Sl. Drawing No. Description

RSP CONTENTS CET/05/RN/4179/TS/ST/02/R=2

RSP CONTENTS CET/05/RN/4179/TS/ST/02/R=2

RSP CONTENTS CET/05/RN/4179/TS/ST/02/R=2

Facilities SMS-I SMS-II

RSP PAGE 1.1 CET/05/RN/4179/TS/ST/02/R=2

1.3 OVERVIEW OF THE PROJECT

RSP PAGE 1.2 CET/05/RN/4179/TS/ST/02/R=2

RSP PAGE 1.3 CET/05/RN/4179/TS/ST/02/R=2

RSP PAGE 1.4 CET/05/RN/4179/TS/ST/02/R=2

1.8 SCHEDULES TO BE DULY FILLED AND SUBMITTED WITH THE OFFER

RSP PAGE 1.5 CET/05/RN/4179/TS/ST/02/R=2

RSP PAGE 2.1 CET/05/RN/4179/TS/ST/02/R=2

2.1.10 Scope of Services

RSP PAGE 2.3 CET/05/RN/4179/TS/ST/02/R=2

RSP PAGE 2.4 CET/05/RN/4179/TS/ST/02/R=2

RSP PAGE 2.5 CET/05/RN/4179/TS/ST/02/R=2

RSP PAGE 2.6 CET/05/RN/4179/TS/ST/02/R=2

RSP PAGE 2.7 CET/05/RN/4179/TS/ST/02/R=2

RSP PAGE 2.8 CET/05/RN/4179/TS/ST/02/R=2

Technological Features of proposed Ladle furnace

RSP PAGE 2.9 CET/05/RN/4179/TS/ST/02/R=2

Sl. Description Unit Quantity

RSP PAGE 2.10 CET/05/RN/4179/TS/ST/02/R=2

RSP PAGE 2.11 CET/05/RN/4179/TS/ST/02/R=2

RSP PAGE 2.12 CET/05/RN/4179/TS/ST/02/R=2

RSP PAGE 2.13 CET/05/RN/4179/TS/ST/02/R=2

RSP PAGE 2.14 CET/05/RN/4179/TS/ST/02/R=2

Sl. No. Description Unit Quantity

1.3 Roof Lifting Arrangement Set 1

RSP PAGE 2.15 CET/05/RN/4179/TS/ST/02/R=2

1.10 Inert Gas Stirring System Set 1

1.13 Emergency top lance (Off line) Set 1

2.3.3 Handling Facilities