Section 7 Ancillary Equipment: 7.1 General 1 7.2 Overhead Travelling Crane 1

LOT 3 – ELECTROMECHANICAL WORKS
SANJEN JALAVIDHYUT COMPANY LTD. Bidding Documents: Volume 3.2

SANJEN (UPPER) HYDROELECTRIC PROJECT Particular Technical Specifications
SECTION 7
ANCILLARY EQUIPMENT
Table of Contents
7.1 General 1
7.2 Overhead Travelling Crane 1
7.2.1 Scope 1
7.2.2 General 2
7.2.3 Capacity 2
7.2.4 Dimensions and Clearances 2
7.2.5 Speed 3
7.2.6 Crane Bridge 3
7.2.7 Longitudinal Travel Rails 4
7.2.8 Axles and Wheels 4
7.2.9 Bridge and Trolley Driving Machinery 4
7.2.10 Hoist 4
7.2.11 Sheaves 5
7.2.12 Hook Blocks 5
7.2.13 Hoisting Rope 5
7.2.14 Lubrication 5
7.2.15 Hand Operation 6
7.2.16 Hoist Brakes 6
7.2.17 Cab 7
7.2.18 Control Equipment 7
7.2.19 Electric Motors 7
7.2.20 Controllers 7
7.2.21 Switchboard 8
7.2.22 Safety Limit Switches 8
7.2.23 Lighting and Convenience Outlets 8
7.2.24 Wiring 8
7.2.25 Accessories 8
7.2.26 Spare parts 9
7.2.27 Assembly and Tests in the Workshop 9
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3.2.7–i
7.2.28 Field Installation and Tests at Site 10
7.3 Diesel Engine Generating Set 11
7.3.1 General 11
7.3.2 Diesel Engine 11
7.3.3 Generator 12
7.3.4 Spare parts 13
7.3.5 Tests 14
7.4 Oil Purifying and Handling Equipment 14
7.4.1 General 14
7.4.2 Scope of Works 14
7.4.3 Performances 15
7.4.4 Oil Transfer Pump and Strainer 15
7.4.5 Vacuum Oil Purifier 16
7.4.6 Oil Tester 16
7.4.7 Transfer Cart 17
7.4.8 Miscellaneous 17
7.4.9 Spare Parts 17
7.4.10 Tests 17
7.5 Tools and Meters 17
7.5.1 Machine and Tools 18

7.5.2 Meters 24
7.6 Fire Fighting System 27
7.6.1 General 27
7.6.2 Scope of Work 27
7.6.3 Fire Detection and Alarm System 28
7.6.3.1 Detectors 28
7.6.3.2 Alarm call boxes 29
7.6.3.3 Central Alarm Control Panel 29
7.6.3.4 Fault Monitoring System 30
7.6.3.5 Cables and Conduits 30
7.6.4 Water Fire Fighting System 30
7.6.4.1 Main Fire Hydrant Pump 31
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3.2.7–ii
7.6.4.2 Stand-by Fire Hydrant Pump 31

7.6.4.3 Control panel 31
7.6.4.4 Hydrant box 32
7.6.4.5 Piping System and Accessories 32
7.6.4.6 Fire Hose System 32
7.6.5 Transformer Deluge System 32
7.6.5.1 Fire Detectors 32
7.6.5.2 Deluge System 33
7.6.5.3 Deluge Valves 33
7.6.5.4 Detection and Activation 33
7.6.5.5 Manual Operation 33
7.6.5.6 Piping 34
7.6.6 Switchyard Fire Protection 34
7.6.7 Mobile Dry-type Fire Extinguishers 34
7.6.8 Spare Parts 35
7.6.9 Tests 35
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3.2.7–iii
SECTION 7 ANCILLARY EQUIPMENT
7.1 General
This section covers the design, manufacture, testing before shipment, transportation to site,
erection and commissioning and performance tests of the followings:

One (1) Lot of overhead travelling crane.

One (1) Lot of diesel engine generating set.

Two (2) Lot of oil handling and purifying equipment

One (1) Lot of tools and meters.

One (1) Lot of fire fighting system.

One (1) Lot of elevator system
7.2 Overhead Travelling Crane

7.2.1 Scope
The Contractor shall be responsible for the design, manufacture, shop tests, delivery,
erection and site tests of the cranes, and shall provide the technical instructions for their
operation and maintenance. The standards, materials, material tests, working stresses
workmanship, welding operation, non-destructive examination and other general technical
requirements shall meet the requirements specified in these documents.
One set of overhead travelling crane shall be installed in the powerhouse. The crane shall be
provided with a main hoist and an auxiliary hoist. The crane capacity shall be determined by
the generator manufacturer considering the required flywheel effect of the generator rotor
and thus the definite rotor weight. Also, the crane capacity shall be determined by the
heaviest load of the turbine-generator to be lifted during installation and operation and
maintenance of the unit. The scope of works shall include the followings:

One set of overhead travelling crane including hoisting appliances with a main hook
of appropriate capacity and a 5 ton auxiliary hook,

One crane runway with rail dampers, all fasteners and embedded parts,

One main contact conductor system along the crane runway,

Control equipment for the crane operation, including mechanical and electrical
operating elements, protection elements and corresponding panels, as well as
main contact conductor, power cables, etc.

Lighting,

One lifting beam,

One test block,

Tools and devices for the assembly, disassembly and maintenance of the equipment,

Spare parts,

Oil and grease,

Submission of Documents.
Accessories not specifically outlined in this Section, but necessary for the effective operation
of the crane, shall be included in the Scope of Works.
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3.2.7–1
The overhead travelling crane shall be of electrically-operated, cab-controlled, suitable for

400-volt, 3-phase, 50 Hz supply and shall be equipped with a single trolley having both main
and auxiliary hoists.
The crane shall be complete with bridge girder, cab, main and auxiliary hoist, shafting,
gearing and complete electrical equipment including motors, control gear, current collecting
gear, trolley hoisting ropes, blocks and hooks, ladders, platforms, guards and hand rails,
spares, tools and spanners with rack, and other gear and necessary accessories for its
proper and efficient operation.
The tenderer shall furnish the ISO 9002 or equivalent certificate of the Crane Manufacturer
along with its details of certifying agency (accreditation, validity date etc.). The technical
specification submitted with tender shall be in English language.
7.2.2 General
The powerhouse cranes shall be used during erection and maintenance of the turbines,
main inlet valves, generators and other equipment. Normally, the crane shall pick up
equipment from the erection bay and transport it to the generating units. The design shall be
such that all movements take place smoothly and positively. No slipping or creeping of the
loads shall occur at any time.
The design shall take into account the lateral stresses due to starting and stopping the crane
suddenly when carrying rated load.
The crane shall be designed for continuously repeated cycles up to a half-hour total duration,
starting with cold motors and brakes.Safety factors used in the design except hoisting ropes
shall in no case be less than four. Special care shall be taken to guard against oil or grease
dripping from the crane, and where necessary, easily removable catch pans shall be
provided.
The Contractor shall indicate the quality of the materials with reference to international
standards and their mechanical and chemical properties. Rhe Contractor shall consider the
most adverse conditions which will have to be withstood by the equipment in operation or
during manufacture, transport and erection. The design calculations and loading conditions
shall conform to international codes.
Materials and workmanship shall be governed by Clauses mentioned in General
Specification.
7.2.3 Capacity
The crane shall be capable of easily handling, both during erection and afterwards, the
heaviest piece of plant covered by this Specification.
The lifting capacity of the main hoist shall be the heaviest assembled parts or components of
turbine or generator to be erected as one piece plus 25% extra or 30 tons, whichever is
greater, and that of the auxiliary hoist shall be 5 tons. The crane shall be capable of
travelling with its full load suspended in any position.
7.2.4 Dimensions and Clearances

The indicative crane clearance shall be as shown on tender drawing. The span of the crane
will be 12 m centre to centre of crane rails. Lifting height of the main hoist and auxiliary hoist
will be 12 meters and 14 meters or that necessary to reach the lowest component of the
equipment, whichever is greater. The suitable provisions shall be provided so that all parts of
the turbine and generator can be lifted and assembled under the above-mentioned
conditions.
The trolley shall be so designed that in the extreme position of its traverse the hook can
plumb vertically as close as possible to the crane rail at either end. The actual minimum
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3.2.7–2
possible distance of each crane hook from centre-line of rail at each end shall be as stated in
the Bid.
7.2.5 Speed
The various motions of the crane shall have not less than the following speeds under full
load conditions:-

Bridge longitudinal travel 20 meters per minute

Trolley cross travel 10 meters per minute

Main hoist 1.25 meter per minute

Auxiliary hoist 8 meters per minute

Creeping speed 10% of the above speed.
7.2.6 Crane Bridge

The main bridge girders of the crane shall be constructed as box type girder or plate girders
and shall include the rails and end stops for the crane trolley. The rails for the translation
motion of the trolley shall be bolted to the girders. The temporary deflection of the bridge
structure under full load in any position shall not exceed 1/1000 of the span. The footbridges
shall be made of slip-proof sheet metal, and shall include handrails and foot protection strips.
Two end carriages, the cross girders of fabricated box design, shall connect the main
girders. End bumpers shall be attached to each end and be aligned with the rail track
buffers.
After the welding, all welds of the bridge girders and cross girders shall be subjected to
100% X-ray examination as applicable, complemented by a 100 % ultrasonic test.
The bridge drive gears shall be rigidly mounted to the crane carriages. Each end carriage
shall be supported by at least eight wheels. At least one bridge wheel on each rail shall be
driven by synchronised induction motors. High speed and low speed operations shall be
achieved using separate motors. The motors shall be connected to reduction gears using
semi-elastic couplings. The drive units shall operate without excessive noise and no harmful
vibrations. The motors shall start progressively to avoid uneven starting and reduce swinging
of the loads to a minimum. For the same reason, the brakes shall also act progressively.
Provisions shall include four proximity switch contacts; two of the contacts shall slow down
the crane before it reaches the end buffers. The other two contacts shall induce low speed
operation in the vicinity of the end buffers.
Bridge girders shall be mounted on equalizing type end trucks with buffer and shall be rigidly
attached to the trucks by machine fitted bolts. Heavy gusset plates shall be attached to the
bottom of the trucks to keep them square with the main girders. The end trucks shall be
designed so that the end reaction from the bridge girders is divided equally between the
wheels.
The end of the trucks shall be tied together to prevent spreading in the event that the crane
runs into the end stops. Trucks shall be bored to receive wheel axles. Suitable stoppers
shall be provided at the both ends on the rails.
The trolley frame shall be a rigidly fabricated steel structure to ensure uniform distribution of
the loads to all wheels without undue deflection. The trolley frame shall be stress-relieved
after fabrication.
Spring bumpers shall be designed to absorb impacts from forces that would arise when the
trolley approaches the end stops of the bridge at maximum speed, with nominal load
suspended. Separate drives on either side of the trolley with synchronised induction motors
for two speeds, closed oil bath lubricated reduction gear, brake and steel pinions shall be
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3.2.7–3
provided. The design of the drive elements and brakes of the trolley shall be similar to those
of the bridge drive.
Safety lugs shall be placed on the trolleys and end trucks to limit the drop in the event of a
broken axle or wheel, unless this emergency is provided for in the general design. Rail
sweeps and buffers shall be provided on both bridge and trolley travel.
Rails, with buffer of adequate height, shall be provided on the main bridge girders for the
trolley travel. Rails shall be secured to the bridge girders in an approved manner and shall
have provision to prevent creeping.
7.2.7 Longitudinal Travel Rails

Suitable longitudinal travel rails shall be provided by the Contractor. The runway rails and
anchoring material shall be installed within the allowable tolerances given in applicable
standards. Foundation plates, anchor bolts, fasteners and end buffers shall be included in
the supply. The impact of concrete contraction joints shall be adequately considered in the
rail track design.
7.2.8 Axles and Wheels

Axles shall be of stationary-type, kept from turning in the truck or trolley frame by means of a
key plate fitted in a milled slot in the axle. They shall be made from alloy-steel, heat-treated
when necessary, and accurately machined and ground to size to receive the bearing inner
races.
Wheels shall be made of cast, forged or rolled steel double-flanged of approved contour to
suit the longitudinal travel and bridge rails. They are to be accurately ground to exact
diameter and are to be provided with grease-lubricated antifriction bearings. The motorised
and the non-driven wheels shall be interchangeable.
7.2.9 Bridge and Trolley Driving Machinery

One pair of wheels in each end of the bridge shall be driven by an electric motor driving a
cross shaft through a helical, spur, or herring bone gear speed reducer unit mounted near
the centre of the bridge. The motor shall be coupled to the reducer by a flexible coupling.
The cross shaft shall be supported on self-aligning bearings along the bridge. Final drive
pinions shall be mounted on shaft sections of shaft coupled to the main cross shaft for
convenience in assembly and replacement of parts.
The motor, speed reducer unit and brake shall be mounted on a common structural steel
base, supported from the bridge drive-side girder.
The trolley drives shall be generally as described for the bridge drive except that gear head
motors may be provided with direct drive to the wheel shafts.
All gearing, other than final drive gears at the wheels shall be enclosed in oiltight gear cases
designed for splash lubrication of the gears and bearings, enclosed within the case.
Adequate inspection openings shall be provided in each case, together with an oil filler plug
drain cock and oil level indicator or dipstick.
7.2.10 Hoist
The lifting equipment on the trolley shall include two hoists, the main hoist for main hook and
the second hoist for the auxiliary hook. Hoists shall include rope drums, journal bearings and
geared motors. The hoist drums shall be of the two-way, opposite-groove type to yield
vertical lifting of the load. The grooves shall be machined. The drums shall be dimensioned
to leave at least three complete windings of lifting ropes in the grooves with the hook in the
lowest position. It shall also not be necessary to wind double layers when the hook is in its
highest position.
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3.2.7–4
All movements shall be protected by limit type proximity switches which shall, if activated,
interrupt the power supply to the motor and activate the brake. In addition to the holding
brake for normal operation, a control brake shall be actuated, for instance by a centrifugal
switch. An overload-protection device and slack rope contact shall also be provided.
Hoist drums shall be mounted on the trolley and located so that the hoisted load will at all
times be transmitted equally to the crane girders. Each drum shall be dimensioned so as to
receive the required amount of hoisting rope in one layer with at least 1-1/2 turns to spare on
each half of the drum with the hook in the maximum raised position, and when the hook is in
the lowest position at least three full wraps of rope shall remain unwound on each half of the
drum.
Hoist drums shall be fabricated or cast with adequate stiffening ribs to prevent deformation
and to minimize deflection under all operating conditions. Drum diameters and rope grooves
shall be in accordance with the recommendations of the rope manufacturer. All surfaces to
come in contact with the rope shall be machined true to approved tolerances and surface
finished to minimize wear and prevent permanent deformation of the rope.
7.2.11 Sheaves
The sheaves shall be of cast steel or fabricated steel properly dimensioned to suit the
recommendations of the rope manufacturer. The grooves as well as all surfaces to come in
contact with the rope shall be machined true to approved tolerances and surface finish to
minimise wear on the ropes. Sheaves shall be mounted on bronze-bushed bearings. The
sheave pins shall be made of alloy steel. The load block shall be designed with a rope-guard
for close encasement of the lifting ropes.
All sheaves shall be provided with guard plates to retain slackened rope within the grooves.
Ample means for lubricating the bearing shall be provided in easily accessible locations.
7.2.12 Hook Blocks

The main hook shall be of double-type and the auxiliary hook shall be of single standard
type. Hooks shall be made of forged steel properly annealed after forging and finish-ground.
Maximum stress at load test shall not exceed two third of the ultimate strength. The hooks
shall be load tested to 150% of rated load and x-rayed or magnafluxed after testing to
ensure that no hidden damage occurred to the hook. The hook shall rotate freely on sealed
anti-friction bearings and be provided with safety latch. The design of the lifting beam for
transportation of the generator rotor, and of the lifting attachment for the test block has to
match the main hook dimensions. The lifting beam design must be coordinated with the
generator manufacturer.
7.2.13 Hoisting Rope

The wire ropes for the hoists shall be of twist-free design, preferably with a fibre core. The
wires shall be made of preformed, regular-lay extra-flexible hardened and tempered steel.
Rope stresses shall be calculated for maximum load including the weight of the hook and the
rope sheaves.
Hoisting ropes shall be designed so that the maximum working load includimg hook block
does not exceed one-fifth of the breaking strength of the rope. Hoisting ropes shall be
grease-impregnated during manufacture.
7.2.14 Lubrication
All bearings requiring grease shall be fitted with grease fittings easily accessible from the
crane walkways. A hand-operated grease gun of ample capacity shall be supplied with all
necessary extensions and fittings for greasing the bearings.
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3.2.7–5
The Contractor shall advise the Engineer, in writing, as to the recommend type and make of
grease and other lubricating oils to be used. In addition, the Contractor shall recommend a
lubricating cycle to guide the Employer's operating staff in their maintenance work. The
Contractor shall provide the initial lubrication for all the equipment, including the hoisting
ropes.
7.2.15 Hand Operation

All electrically operated hoisting mechanisms shall be arranged such that hand operation
can be used if required in case of any emergency or during maintenance. Provision shall be
made for emergency hand operation of the lowering motions of the main and auxiliary hoists.
Engagement of hand gearing shall embody a safety device, which will open power circuits to
the motors. Hand gearing shall be so arranged that the operating cranks cannot run away
under load.
7.2.16 Hoist Brakes

Each motor of any motions shall be provided with a separate spring-actuated solenoid-
released electro-magnetic brake capable of rapidly decelerating and holding the full load.
The brake control shall be so arranged to operate after a time delay to ensure that the load
is held by the drive motor before the brake is released. There shall be no slipping of loads
when the drive motor is stopped or the electricity supply fails.
Main and auxiliary hoists shall be equipped with two independent brakes, an electro–
magnetic holding brake and a control brake. The control brake shall preferably be an electric
brake controlled by frequency transformer.
The rubbing surface of brake drums shall be machined and free from defects. Under
operating conditions, the temperature of the rubbing surface of the brake shall not exceed
100°C with fabric lining or 200°C with metal linings. Asbestos will not be accepted. The
brakes shall be designed for simple accessibility for adjustment due to wear of the lining.
All brakes of any type shall exert a braking torque of at least 2 times the nominal driving
torque. The brakes shall be capable of operating 600 times per hour.
The hoist brakes shall be able to stop the nominal load at rated speed with a maximum slip
of 4 mm, and also maintain the load at rest without any slipping. A failure of the motor
coupling or gear box shall not cause the load to drop.
The trolley drive shall also have a spring-actuated solenoid-released brake capable of
rapidly decelerating the trolley to rest from full speed with full load. Each brake shall be so
arranged as to become automatically applied when power is cut off and shall also be
arranged to release automatically upon application of power to the drive motor.
Each brake shall consist of a pair of shoes normally pressed against steel or cast iron drums
of ample diameter and width by adjustable helical springs in compression. Each brake shoe
shall have an ample thickness of renewable friction lining. Brake drums shall preferably be
on the input shaft of the gearbox but where brake drums are on the motor shaft, they shall
be so placed that they can be readily removed to change a rotor and so as not to interfere
with proper access to the brushed and bearings.
In addition, the main and auxiliary hoists shall be provided with either:-
(a) An electro-hydraulic thruster brake for lowering speed control in slow
operation. An overspeed safety device shall be incorporated in the hoist
controls to interrupt the power supply and operate the spring-actuated
solenoid-released brake to stop the hoist if over-speeding occurs, or
(b) A multiple-disk, self-adjusting mechanical load brake, capable of sustaining
the load in the event of power failure and failure of the hoist electro-
mechanical brake.
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3.2.7–6
The bridge shall be provided with a friction brake of sufficient capacity to bring the crane
quickly to rest from full speed with rated load.
7.2.17 Cab
The cab for accommodating the control gear and operator shall be constructed of mild steel
section fixed under the end of and to one side of main girders. It shall have ample
dimensions to be well ventilated with neat half-walls and roof and have liberal open areas to
give the operator a clear view of the hoist hooks. It shall have a comfortable chair. A warning
gong shall be fitted to indicate movement of the crane.
The cab shall be of the open-type and accommodate the control desk, the operator’s seat,
illumination, fire extinguisher, electric fan, socket outlets, etc. A ladder shall be provided from
the cabin to the bridge walkway.
Handrails shall be provided for inspection and maintenance walkways or operation platforms
on the girders, trolleys, cabin, etc. There shall be middle rails provided and breast boards at
the bottom of the handrails.
7.2.18 Control Equipment

All crane operations shall be controlled from the control desk firmly installed in the cab. The
crane control system shall include all master switches, controls, resistors, time or current
relays, reversing contactors, overload relays, phase failure relays, auxiliary relays,
accelerating contactors, limit switches and accessories as necessary for reliable operation.
The crane shall be equipped with control circuit transformers, motor starters, thermal
overload protections for each motor and trip for thermal sensors of the motors.
All hoists shall also be equipped with switch-off switches at loads exceeding the rated
capacity. The main hoists shall be equipped with additional contact initiating automatic speed
reduction for heavy loads.
7.2.19 Electric Motors

The crane shall be supplied from power station low-tension switchgear cubicle with 400-volt,
3-phase, 50 Hz current. Power supply shall be routed to the lockable main circuit breaker
located on the machine hall floor. The crane internal power supply system shall include a
main switch, the main contact conductor along the crane runway, the suspended, flexible
power cables to main hoist, trolley and all internal cabling and wiring.
The main contact conductor shall be composed of 4-wire (3-phase plus grounding) copper
conductors protected against accidental touching using corrosion resistant material.
Fastening material and the current collectors shall also be included. The current collectors
shall be of the trolley-shoe or spring-mounted double-roller type to ensure continuous
contact and avoid arcing.
The longitudinal travel drive, the cross traverse drive, main and auxiliary hoist drives shall be
operated by suitable number of electric motors each of totally enclosed, wound-rotor,
reversing, fan-cooled or self-cooled type with Class "B" insulation and suitably impregnated
to be non-hygroscopic and unaffected by conducting dirt or dust. Motor lead insulation shall
be Class H. Motor shall be a half-hour rated. Motor bearings shall be ball or roller type
mounted on the end covers.
7.2.20 Controllers
A separate reversing tramcar-type drum controller shall be provided for each motor. Each
controller shall be fitted with renewable contact fingers and tips on the drum. Each controller
shall be provided with arc shields of incombustible non-hygroscopic material. When in the
"OFF" position, the controller shall isolate the motor on all three phase. Each controller shall
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3.2.7–7
be provided with a dead man's button or spring return to "OFF" position. Emergency stop
buttons convenient to controllers shall be provided. No less than five steps of speed control
shall be provided to allow a gradual speed increase from standstill to the maximum.
7.2.21 Switchboard
A steel-enclosed switchboard with doors, suitable for working with controllers shall be
provided. The switchboard shall be equipped with circuit breakers, contactors, protective
relays, indicating instruments, transformers, fuses and other necessary apparatus.
A main circuit breaker shall be provided to cut off all power to the crane and to lock in the
open position. Independent overcurrent, under-voltage and thermal protection for each
motor shall be provided.
All controls, switches and components shall be adequately labelled and numbered for easy
maintenance. A lighting and convenience outlet panelboard shall be included on the
switchboard.
7.2.22 Safety Limit Switches

The crane shall be designed to prevent overwinding of hoists, unreeling of wire ropes from
drums and overrunning of travel and traverse drives by means of limit switches arranged for
quick make and break of the motor circuits. The upper main hoist limit switches shall be
arranged to open by the rising hook blocks without coming in contact with the rotating
sheaves on the hoisting wire ropes.
Adjustable limit switches of the inductive type to limit the lifting and lowering range, for
automatic slowdown of travelling movements, and as additional safety precaution for the
highest hook positions of all hoists shall be provided.
7.2.23 Lighting and Convenience Outlets

Adequate lighting shall be provided and wired in the cab so located as to prevent any direct
or reflected glare from the driver's seat. A hand lamp with approximately 30 m cable shall be
included.
Adequate number of lighting fixtures with ample wattage, reflector-type mercury lamps or
halogen lamps arranged in a regular pattern underneath the crane bridge, ballasts, fittings
and wiring shall be suitably mounted under the crane to illuminate the work area.
The contractor shall supply in the crane cab a 230 V convenience outlet. A 400 V, 3- Phase,
30 A, AC no-fuse breaker shall also be supplied and mounted on the crane in a convenient
location for connecting temporary load during maintenance.
7.2.24 Wiring
The Contractor shall supply and install all wiring, cabling and conduit on the crane taking the
supply from the low-tension switchgear in the cubicle room. The main runway contact wires
and trolley conductors shall be of approved design and shall be as per relevant standards
and located on the outside of the bridge girders to prevent interference with hoisted loads.
The minimum size of conductor used shall be 3.5 square millimetres.
All current collectors shall be of substantial construction with ample capacity and designed to
eliminate all sparking and flashing and to ensure continuous contact. The wearing parts shall
be easily replaceable. Suitable guards or screens shall be provided to comply with the safety
requirements.
7.2.25 Accessories
One complete set of all special tools and devices necessary for the assembly, disassembly
and maintenance of the crane including rope slings shall be provided.
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3.2.7–8
The following accessories shall also be provided:


Trolley wire, insulators and brackets 1 lot

Lubricating oil, grease, machine oil 1 lot with 50% spare

Hand-operated grease gun 1 set

Wrenches and tools for maintenance 1 lot

Other necessary accessories 1 set

600 V cross-linked polyethylene insulated
PVC sheathed power cable with suitable
cable ends 1 lot
7.2.26 Spare parts

The Contractor shall supply two sets of wear and tear items and one set of customary spare
parts. Additionally, following spare parts shall also be provided:

One set of hoist ropes, per each type of hoist

One set of brake parts subject to wear, per brake

Two current collectors complete

Two sets of sliding contacts for current collectors

Two sets of limit switches of each type

One set of centrifugal switch of each type

Two sets of time relays of each type

Two sets of lamps of each type

One set of trip apparatus with time retardation for thermal sensors for each type of
motor

One set of cold conductive thermistor of each type of motor

Two sets of fuses of each type

One set of brush holders with two sets of carbon brushes for each slip-ring motor

One set of insulators for travelling trolley wires

One set of bearings of each type

Two sets of grease nipples of each type

One complete assembly set of switches, contactors, relays, etc.

One set of fingertip and segment for controller

Five sets of carbon brushes for motors, fuses and lamps

One set of brake shoes of each type

One set of brake sleeve of each type

One set of other necessary spare parts including coils, thermal relays, resistors,
capacitors, etc.
Spare parts additionally recommended by the Tenderer for a five years operation periodshall
be listed in the Data Sheets and Price Lists.
7.2.27 Assembly and Tests in the Workshop

The crane shall be completely assembled at Contractor's plant for the inspection of
functional tests. All parts shall be correctly doweled and match-marked to facilitate assembly
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3.2.7–9
at the site. The Contractor shall give the Engineer notice in writing of the date and place of
inspection and testing not less than two weeks before the parts are ready, and give the
Engineer full facilities for witnessing the tests. Three copies of the test reports shall be
provided to the Engineer.
In particular, the following tests shall be carried out under the supervision of the Engineer
and the results certified before shipment:

Checking of the main dimensions.

Operation tests of all drives, including measuring of operating.

Function tests of the complete control system, measurement of stator winding
insulation resistance on all driving motors, voltage test and insulation test on
electrical installations.

Structure deflection test.

Full load test (including brake system tests).

Overloading test (125 per cent of the rated load).
Tests certificates for materials and equipment shall be provided in triplicate to the Engineer,
which shall include the following:

Material tests and chemical analysis of steel and other principal used metals.

Welds shall be physically and radiographically or ultrasonically tested as specified.

Routine tests on purchased equipment.

Insulation tests, operating tests, heating tests, load tests, etc. on electric motors,
starters, transformers, and other electrical and mechanical components.

Load rope breaking tests.
All welding on the crane structure exposed to stresses shall be subject to non-destructive
tests. The test equipment and instrumentation shall be provided by the Contractor.
7.2.28 Field Installation and Tests at Site

After complete assembly at site, The Contractor shall conduct the following commissioning
tests to ensure that the equipment has been correctly installed, all necessary adjustments
and settings been made, and that it is in sound and safe condition to operate. The tests shall
also demonstrate that all guarantees have been met and that the equipment meets the
contractual requirements.
The contractor shall furnish 'Crane clearance diagram' giving all the dimensions, clearance
required, dead weight of crane, wheel loads (including and excluding impact), instruction and
operation and maintenance manuals, general assembly drawings,crane rail fixing details,
power supply conductor fixing details, calculations for motor ratings, wheel load details, etc .
The Contractor shall conduct the commissioning tests to ensure that the equipment has
been correctly installed, all necessary adjustments and settings been made, and that it is in
sound condition to operate. Rail-track position shall be checked before and after its definite
setting and clamping. During no-load test the following items shall be checked:

Correct operation and efficiency of brakes and limit switches,

Vertical and horizontal traveling distances and approach measurement,

Synchronization of pulley operation,

Operating speeds,

Operation and characteristics of manual and emergency control,

Examination of paintwork.
As far as possible, the Contractor shall carry out the load tests under the worst operating
conditions under which the hoisting equipment will be operated. All measuring equipment,
June 2012 Page

3.2.7–10
including test loads, test load carrying structures, ropes etc. shall be provided by the
Contractor.
With the handling mechanism in a fixed position, the hoisting equipment shall be tested
under an overload 25% greater than its rated load. This load shall be maintained for one
hour. The load shall then be relieved gradually. No defect or permanent deformation shall
remain after complete removal of the load.
After satisfactory completion of the static test, the testing load shall be decreased to a value
20% greater than that of the rated load of the hoisting equipment. Under these conditions, all
the lifting and lowering operations shall be carried out successively for a period of fifteen
minutes of effective operation, without vibration, deformation or detrimental temperature rise.
Transversal movements of the handling mechanism shall be tested under the same
conditions as above.
The crane shall be loaded to its rated load and the following shall be checked:

The deflection;

The horizontal and vertical travel distances;

Correct general operation of the safety mechanisms and accessories;

The operating speeds;

The lifting and lowering movements, which shall be made in a continuous smooth
manner so that all manoeuvres shall be possible with adequate accuracy;
The hoist brakes shall be capable of stopping the rated load operating at a normal slow
speed with a maximum slip of 4 mm and maintaining this load in a stationary position without
slipping. The bearings and other mechanical parts shall also be checked for temperature
rise.
After successful completion of all commissioning tests, the bridge crane and the associated
equipment shall be subject to a Trial Operation Period. The Trial Operation shall be carried
out under supervision and responsibility of the Contractor.
7.3 Diesel Engine Generating Set

7.3.1 General
One 250 kVA diesel engine generating set complete with the necessary switchgear and
accessories shall be provided to supply emergency electric power for operation of cooling
water system, governor oil system, battery charger, communication facilities, powerhouse
lighting and ventilation system, black starting of the units and for any other system as
deemed necessary. One set of geared trolley-type, hand-operated chain-hoist, mono-rail
crane shall be provided in the diesel engine room for maintenance of the diesel engine.
The tenderer shall furnish the ISO 9002 or equivalent certificate of the Diesel Engine
Generating Set Manufacturer along with its details of certifying agency (accreditation, validity
date etc.). The technical specification submitted with tender shall be in English language.
The location of diesel engine generating set shall be in the vicinity of the powerhouse and
will be finalised during contract negotiation.
7.3.2 Diesel Engine

The diesel engine shall be of the full compression ignition with V-configuration, single-acting,
4-cycle, solid injection, radiator-cooling type. Engine cylinder liners shall be of the full length
replaceable type. The diesel engine and generator shall be placed on a common bedplate.
The engine shall be provided with jacketed water heater suitable for cold-weather starting.
June 2012 Page

3.2.7–11
Continuous output of diesel engine generating set shall be guaranteed to be 250 KVA at
generator's terminal, under the climatic conditions stated in General Specification. The diesel
engine shall be designed to use high speed diesel oil, which should be easily available in
Nepal.
The diesel engine shall be capable of manual and/or automatic starting on main’s failure.
The starting shall be selected by key-operated test/manual/auto switch. While in auto, the
generator shall automatically start on detection of the main’s failure. The generator shall
also be capable of starting from the centralized control room by the operator. The generator
shall be self-supervised and change-over circuit breakers shall be provided to change all the
auxiliary power supplies and essential loads to the generator automatically.
The diesel engine generator shall be stopped automatically when the normal main supply
resumes. However, it may continue running for set period of time at no load, so that it can
take the auxiliary supply load immediately if the main fails within that time period. The
revolution per minute of engine shall be minimum of 1500.
In addition, the following items shall be supplied for the engine.

A fuel oil tank with float level gauge for minimum eight running hours.

Pumps for lubricating oil and fuel oil injection. The forced lubrication system shall
cover main bearings, crank pin bearings, piston pins, timing gears, camshaft
bearings, valve rocker mechanism and governor;

Filters for fuel oil and lubricating oil, cleanable-type to avoid frequent replacements,
with bypass valves;

Thermometers for cooling water and lubricating oil;

Flywheel guard;

A tachometer;

A lubricating oil cooler;

Common bedplate, foundation bolts and nuts;

Reamer bolts with nuts, for coupling up with generator;

Alarm and automatic shut-down devices in the event of lubricating oil pressure drop,
cooling water high temperature and over-speed;

Panel for safety device with alarm, associated with the generator control panel;

Pressure gauge for lubricating oil:

All piping materials with valves and cocks;

Air suction strainer, cleanable-type to avoid frequent replacements;

Expansion or fexible joint for exhaust pipe;

Maintenance tools;

Silencer and exhaust pipe to atmosphere;

Any additional accessories as recommended by the manufacturer.
7.3.3 Generator
The generator shall be 3-phase, 4-wire, revolving field type with damper winding, self-
excited, self-ventilated open-type single-bearing synchronous alternator. The rating of the
generator shall be 400 V, 50 Hz, 0.8 lagging power factor, 250 KVA maximum continuous
output and shall be directly connected and flange mounted to engine. Insulation shall be
Class "B" or higher class.
The excitation current shall be controlled by both voltage and current of the generator
through rectifiers to have compound characteristics. The automatic voltage regulator shall be
provided for the excitation system capable of controlling voltage within ± 2% from no load to
June 2012 Page

3.2.7–12
full load. The neutral point of armature winding will be connected to neutral bus of the low
tension switchgear and solidly grounded.
The maximum temperature rise of the generator shall not exceed the following:-

Stator winding (by thermometer) 700C

Rotor field winding (by resistance) 800C

Iron core and other parts (by thermometer) 800C
Generator control cubicle shall be of sheet metal dead front, indoor type, floor mounted and
self-standing or wall mounted. The panel-mounted equipment and devices shall include, but
not be limited to, the following:

One 600 V, 600 A air or moulded-case circuit breaker

One A.C. ammeter with selective switch

One A.C. voltmeter with selective switch

One frequency meter

One wattmeter with three elements

One watthour meter with three elements

One power factor meter

One frequency meter

One regulating switch for governor motor

One group annunciator

One group of annunciator alarm, collectively annuoncing the diesel generator set
faults to be available in control room.

Three potential transformers, single phase 400/110 V, dry type

Three current transformers of 500/5A, dry type

One rheostat for AVR voltage setting

One set of cable terminals, back wiring and terminal boards and nameplates

One set of test terminals

One over-voltage relay

Three over-current relays

One alarm bell

One set of connections for fault indication of excessive temperature rise of cooling
water, pressure drop of lubricating oil and overspeed
The following accessories shall be supplied:

Indicating lamps

Local starting stand with starting switch

One set of cabinet type static exciter with automatic voltage regulator and necessary
accessories

Battery and charger for a starter motor

Special tools for erection and repair

150% of the quantity of lubricating oil

Foundation bolts and nuts

Contact for one group of alarm of diesel generator set, one position indicator of ACB
of diesel generator shall be available at auxiliary control panel of control room

Other necessary accessories as recommended by the manufacturer
June 2012 Page

3.2.7–13
7.3.4 Spare parts

Following spare parts shall be supplied for diesel engine and generator:

Fuses and lamps 300%

AVR card 100%

Rotating diode 100%

Fuse and protection for rotating diode 100%

Contactors, relays 2 sets of each type

Main’s charger 1 set

Filter elements for fuel, lubrication and air 5 sets of each type

Electrical spares like contacts, coils, resistors, rectifiers,
rheostats, transistors, capacitors, etc. 1 set
7.3.5 Tests
The following tests shall be carried out on the combined engine and generator before
shipment at contractor's plant:

Starting test

Load test including temperature rise and fuel and lubrication oil consumption
measurement

governor test

Overspeed test (120% for one minute)
The following tests of generator only shall be carried out at Contractor's plant:

Wave form test

Insulation tests for stator and rotor coils

Test of the panel and cubicle
The diesel engine generator set with excitation system and necessary accessories shall be
tested in accordance with the requirements of the Commissioning Test specified in General
Specification.
7.4 Oil Purifying and Handling Equipment

7.4.1 General
The oil purifying and handling equipment shall be two (2) sets of mobile oil treatment system
for the powerhouse. One system shall be used for the treatment of the bearing lubricating oil
of turbine/generators and governor pressure oil. The second one shall be used for the
treatment of the transformer oil.
The Tenderer shall furnish the ISO 9002 or equivalent certificate of the oil purifying and
handling equipment manufacturer along with its details of certifying agency (accreditation,
validity date etc.). The technical specification submitted with tender shall be in English
language.
7.4.2 Scope of Works

This specification covers the supply, delivery and tests of the oil treatment system.
The Scope shall include the following supply and services:

Two (2) sets of oil treatment system with all necessary accessories, each set
consisting of:
June 2012 Page

3.2.7–14
 One (1) mobile transfer pump.

 One (1) mobile oil purifier
 One (1) set of piping, valves, flexible hoses, controls and instrumentation

Two (2) sets of transfer cart.

One (1) set of any special tool required for the maintenance and operation of the
system.

one (1) set of instruments including:
 Instruments to measure
 dielectric capacity of oil,
 acidity index,
 water content of oil,
 particle-size of solid
 Calorimeter.
 Viscosity meter.
 Mechanical foreign substance identifying instrument

One (1) set of spare parts
7.4.3 Performances
The oil purifier shall be able to remove all particles above 10 microns.
Under the assumption of an initial water content of 50 ppm, the final water content of oil after
only one passage in the treatment system shall not be above 10 ppm.
The oil purifier for bearing oil shall be able to process 1000 l/h. That for transformer oil shall
be able to process 3000 l/h.
System capacity shall be such that any oil sump can be treated without having to stop the
cleaning process to remove the collected sludge or to replace a clogged filter.
Transfer pump for bearing oil shall have capacity of 1000 l/h. That for transformer oil shall
have capacity of 3000 l/h.
7.4.4 Oil Transfer Pump and Strainer

The oil transfer pump shall be of self-priming positive displacement type and be able to
handle the most viscous oil at the lowest average daily ambient temperature. The pump shall
have a capacity of about 3 m3/h. The pump shall be provided with safety relief valves and
high temperature shutdown. A pressure gauge shall be attached to the pump discharge line
and shall be fitted with filter-pulsation damper.
The pump pressure rating shall include an allowance for the hoses, connecting pipes and
filter. The pump shall be provided with a relief valve connected to discharge to the pump
suction and set to protect the pump from overpressure.
A pressure gauge shall be attached to the pump discharge and shall be fitted with a filter-
pulsation dampener. The pump shall be driven by an electric motor. The available power
supply outlets are for 400 V, 3-phase, 50 Hz.
The transfer pump and strainer shall be mounted on a mobile cart.The cart shall be provided
with oil resistant tired casters, lifting lugs and pull bar. Racks shall be provided on the cart for
storing hoses and the electrical power cable.
A suction and a discharge oil-resistant hose shall be provided, each about 10 meters in
length for connections. These hoses shall also be used for connecting the oil purifier to the
sump or transformer. All hose connections shall be of the swivel coupling type and
June 2012 Page

3.2.7–15
corresponding adaptors and coupling halves shall be provided on each sump fill and drain
connection.
An electrical oil-resistant insulated cable shall be provided of 25 meter length with a metal
plug suitable for the outlets.
The strainer shall be mounted on the mobile cart and shall be rated for the transfer pump
discharge at corresponding viscosities.The strainer shall be fitted with a differential pressure
gauge and the body shall be rated for the pressure setting of the pump relief valve. The
filtering medium shall be of non-corroding metal or synthetic fibre and shall be cleanable.
The filter shall effectively remove up to 98% of particle of 0.25 mm size and shall, when 2/3
blocked, pass the rated flow at a differential of 1 kg/cm2. The filter element shall not blow out
or fail at this differential and shall not form channels, which will conduct the flow. The strainer
body shall have a suitable drain, supports and easy means of access to the filter element. A
suitable flexible connection shall be provided between the pump and strainer.
7.4.5 Vacuum Oil Purifier
A vacuum oil purifier shall be provided to dehydrate, de-aerate, purify and filter the bearing
lubricating oil and governor pressure oil.
The oil purifier shall be provided with:

Centrifugal separator

Filter press

vacuum dewatering,

direct heating,

vacuum and circulating pumps, controls and instrumentation.
The purifier shall have all components, controls, valves, thermostats, pumpdrives, motors,
starters, relays, filters etc., required to ensure the performance stated in 5.4.3..
The oil purifier shall be of the closed circuit operation type and shall not need oil transfer into
a tank. The oil treatment system shall be able to extract oil by suction from the equipment for
treatment and return it by gravity after treatment or vice versa.
Oil treatment shall include:

Filtration or centrifugal separation.

Dewatering.
If the purifier uses disposal filtering or oil dispersion material, the Contractor shall supply with
the unit not less than 5 years supply of such material. The quantity of filtering material shall
be sufficient to allow changing the filtering media after an annual treatment of the oil in each
of the bearing sumps and governors. The filtering media shall be changed after the
treatment of the quantity of oil in each sump or system.
The purifier shall be movable and provided with all attachments appropriate to obtaining
easy manoeuvrability and to locating the purifier adjacent to the oil container on the
generating unit. The purifier shall be rated for the 400/230 volt A.C. power and shall take
power from the nearest motor control centre or distribution panel.
The purifier shall have two flexible hoses: one of them to be connected to the oil sump drain
line or to be inserted through the filling opening of the oil sump, and able to reach the bottom
of the sump. The return flexible pipe shall be connected to a refill line or be inserted in the
filling opening.
The purifier shall be provided with its own electrically driven transfer oil pump and electric
supply cable. The purifier system shall be mounted on an easily manoeuvrable trolley,
provided with lifting lugs and a sling.
June 2012 Page

3.2.7–16
7.4.6 Oil Tester

A portable dielectric oil tester shall be provided. The rating shall be 1 kVA, with maximum
capacity of a test voltage of 70 kV. The test voltage shall be adjustable by the voltage
regulator and indicated on a kilovolt-meter. The unit shall be complete with switches,
instruments and accessories.
7.4.7 Transfer Cart

The contractor shall supply a transfer cart of steel construction with oil resistance tired
casters, lifting lugs and pull bar. The transfer cart shall be designed to carry 200 litres
shipment container.
The clean oil will be received and stored in 200 litre metal drums. The clean oil will be taken
to the vicinity of the turbine/generator bearing or governor sump in the shipment container
and transferred to the receiving sump through a hose by gravity or a transfer pump. All oil
used to fill a sump will pass through a strainer to ensure the cleanliness of the oil. The
shipment container will be moved about the power plant on a transfer cart. The transfer cart
will be mobilized manually. Dirty oil will be carried from the generating equipment in a
shipment container on the transfer cart.
7.4.8 Miscellaneous
The Contractor shall furnish all necessary piping, valves, hoses, connectors, pipe supports
and other accessories.
7.4.9 Spare Parts

The following spare parts shall be supplied:

Two (2) sets of vacuum pump,

Two (2) sets of oil filters.

Two (2) sets of seals and gaskets for pumps and valves of the oil purifier and transfer
pump of two different capacities.

One (1) set of bearing or bushings, including one of each size and type used in the
pumps, motors, wheels or other rotating component of the equipment supplied
under this item.

One (1) set of components for the control equipment associated with the equipment
supplied under this item, such as, contactors, relays, thermostat, pressure switch,
etc.
7.4.10 Tests
The equipment to be supplied shall be tested as per recent international standards and
codes at Contractor's plant before shipment. At the Client's discretion a site test shall be
carried out on at least one oil sump to check the system ability to suck oil from the sump
under the most unfavourable conditions.
The complete oil treatment system shall be shop assembled and tested prior to shipment to
the site. The test shall include the treatment of a minimum of 200 l of oil.
The Contractor shall provide the descriptive documents, the operating and maintenance
instructions of the oil treatment systems and associated instruments as well as the operating
and maintenance manuals of all machines and instruments.
7.5 Tools and Meters
June 2012 Page

3.2.7–17
The machines, tools and meters, as listed, with necessary accessories and spares shall be
supplied for the repair shop under the contract. These may be used by the Contractor
during construction with the approval of the Engineer and shall be returned in good repair
after completion of the works. The electric source for following apparatus is 400 V, 3-phase,
400 V or 230 V, single phase, 50 Hz.
The contractor shall furnish thedetails of tools and meters with catalogues or leaflets during
contract negotiation. The contractor shall furnish set of viewgraphs with overlays to explain
machine operation, wall chart, machine manual in English language, overall dimensioned
diagram, foundation details and list of standard spare parts for the tools and meters to be
supplied under this contract.
The Tenderer shall furnish the ISO 9002 or equivalent certificate of the tools and meters
manufacturer along with its details of certifying agency (accreditation, validity date etc.). The
technical specification submitted with tender shall be in English language.
The location of powerhouse workshop, where all the tools and meters will be placed, shall be
in the vicinity of the powerhouse and will be finalised during contract negotiation.
7.5.1 Machine and Tools

Sufficient machine and tools with accessories to fully equip a maintenance machine shop
and sufficient meters for inspection and maintenance of the major and ancillary equipment
installed in the powerplant shall be supplied.
The machines and tools shall include, but not be limited to, the following:
1. Horizontal Lathe
Horizontal lathe shall be designed and sturdily constructed for metal turning, facing, thread
cutting etc. It should be floor-mounted and driven by suitable electric motor. The bed shall be
of rigid box-type construction of adequate stiffness capable of withstanding forces resulting
from heavy stock removal. All gears in the main drive and feed drive shall be of alloy steel,
case hardened and ground. The lathe shall have a geared head stock with hollow spindle,
compound slide, hand and automatic feed for saddle and cross slide, tail stock and thread
dial indicator. A work light shall be fitted. A coolant pump and associated equipment, index
table for speeds, feeds and thread cutting and electric control switches shall also be
provided.
Approximate Specification
S. No. Items Specification

1. Centre 230 mm
2. Max. turning dia. over bed 720 mm
3. Max. turning dia. in gap 850 mm
4. Distance between centres 1600 mm
5. Spindle bore 82 mm
6. Bed width 465 mm
Lathe accessories to be supplied with machine shall include:


All change gears set to permit the cutting of metric, British and unified threads

Universal 3 jaw self-centring chuck

4 jaw independent chuck with reversible jaws

Face plate

Set of dogs
June 2012 Page

3.2.7–18

Steady rest, adjustable

Follower rest, adjustable

Set, turning tool bit holders (straight right hand and left hand)

Taper turning and boring attachment

Dead centre

Live centre

Set, taper reducing sleeves for tailstock

Foot brake

Rear splash guard

Chip guard

Tool post grinder
Safety features shall include head stock safety switches and longitudinal safety stops.
2. Bench Drilling Machine
The machine shall be bench-type, drilling head to be raised and lowered on column, spindle
with adjustable speed, spring-balanced drilling spindle, adjustable depth stop with millimeter
scale, built-in machine light, etc.
S.No. Items Specification

1. Drilling capacity in steel 15 mm
2. Drilling depth 90 mm
3. Distance between column & spindle 286 mm
4. Diameter of column 85 mm
5. Size of table 310x360 mm
3. Shaping Machine
Machine shall be of metric-type, lubrication of the slide surface ensured by a built-in
adjustable high pressure pump, 45 deg. swivelling of the tool head, running against lowest
extreme of the tool head prevented by a safety attachment, feed motion either operated
manually or automatically.
The machine shall be complete with standard equipment such as automatic vertical feed
motion device, clamping vice for the job.

1. Maximum ram stroke 550 mm
2. Planing width (Horizontal table movement) 550 mm
3. Maximum distance between table and ram 425 mm
4. Vertical adjustment of tool slide 160 mm
5. Surface of table (length x width) 330x550 mm
4. Power Hacksaw
June 2012 Page

3.2.7–19
The machine shall be of heavy duty type with hydraulic saw frame control, automatic blade
lift on return stroke, adjustable cutting pressure, adjustable length of stroke, automatic stop
at end of cut, swivelling vice and complete with coolant pump.

1. Length of blade 450 mm
2. Cuts round 150 mm
3. Cuts square 100 x 100 mm
4. Max. length of stroke 150 mm
5. Number of strokes 90-150 str./min
Accessories required shall be material stand adjustable with solid roller tommy bar and saw
blade, length 450 mm (fine, medium, coarse teeth blades 3 packets of each)
5. Bench Grinding Machine
The machine shall be double-ended bench type, totally enclosed, complete with electric
motor with ball bearings, adjustable toolrests for grinding of tools, detachable wheel guards
and eyeshields, complete with two grinding wheels, one fine and one coarse.

1. Wheel size 300x50x25 mm
2. Distance between wheels 600 mm
3. Electric motor 2 kW, 2800 rpm
Accessories required shall be:


Grinding wheel, straight, 40 grit, 300x50x25 mm


6. Welding Transformers
The machines shall be of built-in transformer and rectifier type with preferably stepless
current control, portable on wheels.

1. Primary current (Adjustable) 39 Amps, 380 V
2. Secondary current rectified 310 Amps, 50 V
3. Insulated electrode holders 2 nos.
4. Ground lead 30 m
5. Electrode lead 30 m
6. Welding helmet 2 nos.
7. Leather apron 2 nos.
June 2012 Page

3.2.7–20
8. Leather gloves 4 pairs

9. Wire scratch brush 4 nos.
10. Chipping hammer 2 nos.
11. Earthing clamps 2 nos.
Welding transformer shall be specially designed for continuous-duty welding purposes. Its
cores shall be constructed of high quality. The steel shall be of thin lamination. Both sides of
each steel plate should be insulated with durable insulating material. It should have minimum
vibration.
The complete assembly of core and coil shall be dried in a vacuum sufficient to ensure
elimination of air and moisture within the insulating structure. Coil should be made of copper.
The transformer shall be designed and constructed to withstand without injury the thermal
stresses produced while working on the max. current of 310 Amps. Its primary nominal
voltage shall be 220/400 V, AC. The secondary voltage shall be rectified and welding
Transformer shall be used as direct current source of 50 V.

Rutile electrode for unalloyed steel or mild steel [3-Packets]

Nickel-copper alloyed electrode for low alloy steel [3-Packets].

Rutile electrode with extra low carbon
content for stainless steel [3-Packets].

Nickel core electrode for cast iron welding [3-Packets].
7. Oxyacetylene Set
The set shall be suitable for welding and cutting for equipment repair and maintenance
workshop facilities. The trolley shall be designed for easy movement of cylinders and tools.
The tool box provided on the trolley shall be large enough to carry welding/cutting blow pipes
etc.
1. Wheel cart for cylinder transport 1 no.
2. Single stage oxygen regulator with gauges 1 no.
3. Single stage acetylene regulator with gauges 1 no.
4. Twin hose 15 m
5. Welding torch complete with assorted
welding heads, 0.5 to 30 mm (8 in total) 1 set
6. Assorted cutting heads,3 to 100 mm (3 in total) 1 set
7. Welding table 900x600x800 mm
8. Goggles 2 nos.
9. Oxygen cylinder 2 nos.
10. Acetylene cylinder 2 nos.


Nozzle cleaning kit

Copper coated mild steel rod for mild carbon steel and wrought iron [3 Packets].
June 2012 Page

3.2.7–21

Silicon bronze rod for bronze welding and brazing of copper and brass [3 Packets].

Pure aluminium or 5% silicon aluminium for aluminium welding [3 Packets].

Stainless steel rod for stainless steel [3 Packets].

Super silicon cast iron for grey cast iron [3 Packets].

Fluxes

All suitable fluxes for above rods such as Aluminium welding flux, stainless steel and
cast iron.
8. Air Compressor
Air compressor shall be reciprocating, air-cooled, single/double acting and multi stage-type
complete with drive motor, drive arrangement, suction air filter/silencer, unloader, high outlet
air temp. switch, coolers and an integral air receiver of 400 liters capacity. Air receiver shall
be designed in accordance with international standards and shall be tested hydrostatically to
a pressure of 1.5 times the design pressure.
The compressor shall have over-load protection and shall require minimum maintenance
work. Its interval of maintenance should be greater than or equal to 1000 working hours. Air
receiver shall be complete with supporting stand, fixing bolts and nuts, handhole for
inspection, safety valve, pressure gauge and other necessary accessories.
The compressor shall have auto recloser pressure switch closing at 8 bar and opening at 10
bar and a running hour meter. A suitable high pressure hose of 50 m. long shall be included.

1. Delivery pressure 10 bar
2. Suction capacity 500 ltrs/min
3. Discharge capacity 400 ltrs/min
9. Hand Drill
The item shall be having variable speed and reversible rotation control. It should be supplied
complete with drill chuck, key and cable with plug.

1. Drilling capacity in steel 13 mm
2. Rated voltage 220 V
3. Supply details AC, 50 Hz, single phase
4. Power consumption at full load 500 W
5. No load speed 2600 rpm


A set of drills from 0-4,5,6,7,8,9,10,11,12,13 mm

Collet chuck set for sanding.

Sanding disc (fine) [3-packets]

Sanding disc fixing set.
June 2012 Page

3.2.7–22

Catalogue and operation and instruction manual.
10. Hand Grinder

The grinder shall be used for weld dressing work, general grinding work and for cutting off
purposes. It shall be useful for fast cutting work too.
Approximate specification

1. Grinding wheel diameter 178 mm
2. Grinding wheel thickness 5 to 10 mm
3. Spindle speed (no load) 8000 rpm
4. Spindle speed (full load) 6000 rpm (with two speeds)
5. Power supply details 220 V,AC, single phase, 50Hz.


Grinding wheels with different shapes suitable to be used in them. (Each single
quantity)

Catalogue with internal drawing and instruction manual
11. Tools
Item Description Specifications Quantity
1 Hot Blower 114mm (4 1/2"), motor driven 1
2 Surface plate 500mm x 500mm (20" x 20") 1

750mm x 750mm (30" x 30") 1
3 Anvil 100 kg 1
4 Swage block 55 kg 1
5 Leg vise 150 mm (6") 1
6 Parallel vise 150 mm (6") 1

100 mm (4") 1
7 Pipe vise 10 mm - 77 mm 1
8 Blower type drier 20 kW with accessories 1
9 Portable submersible 200 lr/min 1

centrifugal pump and AC 230 V, 1 ø, 15 m head
motor with cab type
cable, 20 m, and drainage
hose, 20 m
June 2012 Page

3.2.7–23
10 Winch Motor driven, double drum, 20 1

HP
Hand operated, 5 ton 1
11 Chain block 5 ton 1

3 ton 1
1 ton 1
12 Rack and pinion jack 5 ton 2
13 Hydraulic type jack 25 ton 2
14 Portable electric blower 1/4 HP motor driven 1
15 Chain tong 38 mm - 200 mm (1 1/2" - 8") 2
16 Bolt clipper 13 mm (1/2") 1
17 Die stock with ratchet 13 mm - 50 mm (1/2" - 2") 1
18 Pipe cutter 13 mm - 57 mm (1/2" - 2-1/4") 1
19 Screw plate metric size, 6mm - 24mm 1
20 Micrometercaliper 0.1 - 25 mm 1
21 Extensible inside micrometer 50 - 1,000mm 1
22 Iron bench level 450 mm (18") 1
23 Precision square level 0.02mm/1m, 250mm square 1
24 Dial indicator 0.01mm-20mm 3
25 Straight edge 1 beam type 1,000mm 1
26 Vernier Calliper 0-250 mm 1
27 Wire rope 12mm (1/2") diameter 200m

18mm (3/4") diameter 100m
24mm (1") ,, 100 m
32mm (1-1/4"),, 50m
28 Hemp rope 12mm (1/2") ,, 100 m

18mm (3/4") ,, 100 m
24mm (1") ,, 100 m
29 Hand tools including files, 1 Lot

emery-cloth, punches,
hammers, screw drivers, pipe
threaders,taps, drills, reamers,
clamps, wrenches etc. sufficient
for five years operation.
June 2012 Page

3.2.7–24
7.5.2 Meters
The following meters shall be supplied:
S. No. Item Description Quantity
1 Voltmeter Portable precision, A.C. 4

0-30/100/300/1,000V
Vacuum Tube type, A.C. - 1
D.C.
1.5 - 1,500 V with accessories
2 Ammeter Tongs tester, A.C. 1

0-10/100/1,000 A
Portable precision, A.C. 2
0-0.2/1.0 A
0-2/10 A 2
0-10/50 A 2
Portable precision, D.C. 1
0-1/3/10/30/60 A
with external shunt
3 Watt meter Portable precision, 120/240 V 3

1/5 A single phase
4 Tan-delta meter Portable, 50% scale, 110V, 1

0-1, 500 mA
5 Vibrometer Electromagnetic type or 1

dynamic electricity type,
1-1,000 micro-meter
Mechanical type 1
6 Lux meter Portable photovoltaic cell type 1
0-300/1,000/3,000 lux
7 Cycle counter 20-80 Hz, 220/110 V 1
8 Earth resistance tester 0-10/100/1,000 ohm 2
9 Insulation tester 2,000V, 5,000 meg.ohm 1

1,000V, 2,000 meg.ohm 1
500V, 1,000 meg. ohm 1
10 Phase rotation indicator 50-450 V 1
11 Frequency meter Portable type, 1

45-65 Hz, 0.2 Hz step, 120-
240V
12 Universal circuit tester 1

D.C. voltage 10/50/250/500/1,000 V
D.C. current 0.5/25/500mA
A.C. voltage 10/50/250/500/1,000V
A.C. current 10A
June 2012 Page

3.2.7–25
Resistance 1-1,000 kilo-ohm
13 Magnet bell 2
14 Hand tachometer Hasler type, 10,000 rpm 2
15 Stop watch Integration type (1/5 sec) 5
16 Current transformer Portable, through type, 2

Insulation - 11 kV class
10-15-30-50-100-250-300-
500-
750-1,500/5A 10 taps, 15VA
17 Potential transformer Portable, single phase, 3

230/110V,
15VA, dry type
Portable, single phase, 3
11,000/110V
15VA
18 Sliding rheostat Insulation, 600V

approx. 15A, 10 ohms 2
5A, 30 ohms 3
19 Sliding voltage regulator Single phase, 230 V, 10 A 3

20 Grounding tools With all necessary 2
accessories,
66 kV use
21 Digital Multimeter Portable 4

0-1000V AC
0-750V DC
0-2/10A AC
0-100mA/DC
0-200A/1K/20K/1M
22 Calibrator Portable Precision 3

Inject 0-200mA DC
0-200mV/20V DC
Measure 0-20/200mA DC
0-200mV/20V DC
23 High voltage Detector for Portable 1

132 kV with accessories
24 DC variable voltage Portable 1

regulator 0-110V DC
0-5A
Each equipment shall be tested in accordance with applicable code and standards at
the manufacture’s shop.
June 2012 Page

3.2.7–26
The Employer shall be given the opportunity to witness all the tests according to approved
test plan.All test report shall be certified by the Contractor whether witnessed or not.
7.6 Fire Fighting System

7.6.1 General
The Contractor shall be responsible for design, manufacture, transport to site, erection, site
testing and commissioning of the permanent fire fighting system at the powerhouse.
The supply shall include the fire fighting equipment comprising fire hydrant pumps, fire hoses
and piping system, fire detection and alarm system, deluge system for the transformers,
portable CO2 and dry chemical extinguishers. The transformer deluge system shall, in
addition to piping, valves and nozzles, include fire detectors and local control units for deluge
water release and for giving audible and visible alarms. All internal alarm/control cables are
part of the supply.
The powerhouse will be equipped with an independent fire alarm system based on smoke
detectors, heat detectors and manual call points. The fire alarm system as well as control
cables between local control units will also be supplied.
The permanent fire fighting system for the powerhouse shall be based on the following type
of equipment:

A deluge type arrangement for the transformers.

Fire hydrants with guard valves installed at the switchyard area.

Fire hoses with fog-nozzles at each of the powerhouse floors in the vicinity of stairs
and entrances.

Dry chemical extinguishers (DCE) and carbon dioxide (CO2) extinguishers located
throughout the powerhouse area.
In addition the generator pits will be provided with an automatic CO2 fire extinguishing
system.
The equipment shall be supplied from a reputable manufacturer according to approved
standards. The quality and type of equipment shall be illustrated and documented in the
Tender by brochures. The system layout and the equipment utilized shall, whenever
applicable, conform to the relevant standards.
The Contractor shall submit detail drawings and all pertinent technical documents as well as
the design and an explanation in detail of the equipment operations of the fire fighting
system to the Engineer for approval.
7.6.2 Scope of Work

The scope of work shall include, but not necessarily be limited to, the followings:

One (1) set of main fire hydrant pump with motor and other accessories.

One (1) set of stand-by fire hydrant pump with diesel engine and other accessories.

One (1) complete galvanized steel piping system for water supply to fire hoses and
deluge equipment from the header pipe of fire hydrant pumps, complete with all
the required valves, flanges, blind flanges, drains, air vents, fittings, gaskets,
brackets, anchors, bolts, screws, and electrical controls.

Three (3) complete deluge systems for the power transformers.

One (1) complete set of fire detection and alarm system.

Twenty-four (24) portable dry chemical extinguishers, 4.5 kg each.

Twenty-four (24) portable CO2 extinguishers, 4.5 kg each.
June 2012 Page

3.2.7–27

Ten (10) cabinet-mounted fire hoses with auxiliary equipment.

One (1) set of all tools, special keys, spanners, etc. for the repair, servicing and
maintenance of the supply, all kept in a metallic cabinet with lock.

All components, accessories, items and equipment not specifically mentioned above,
but necessary for the safe and proper transportation, erection, successful
operation, and maintenance of the supply.
7.6.3 Fire Detection and Alarm System

The fire detection and alarm system shall be used for early detection of fire, warning and
sending of signal for fire fighting automatic system activation. It shall consist of various types
of detectors installed in rooms or areas to be protected and control panel, to which are
connected the detection loops, manual alarm tripping loops in closed circuits, cables and
accessories.
The system shall be designed base on Local Area Network (LAN). The system shall consist
of network control annunciator, network control system, graphic mimic panel, central alarm
control panel and power supply. All status information of equipment in the network shall be
displayed and recorded on the central alarm control panel in the control room of the
powerhouse.
7.6.3.1 Detectors
Automatic fire detection system shall cover the fire detectors, which shall be installed in all
required areas to provide early detection of any fire which might occur. The Contractor shall
be responsible for determining the most appropriate type of detector on the basis of a fire
risk analysis and appraisal of environmental conditions. The detectors shall be of the
draw-out type on the standard base, so that the type may be changed at any time.
Smoke detectors shall be ionic detectors, reacting to visible and invisible combustion
products. They will shall be equipped with a self-compensating system against temperature,
humidity and atmospheric pressure variations.
Heat detectors shall be UV or thermostatic detectors, responding to a rapid rise in
temperature and to an abnormally high temperature.
The detectors will shall be provided with a built-in alarm indicator.
Smoke detector:

Principle : Optical

Operating voltage : 8.8 VDC to 33 VDC

Operating current : 60 mmA

Setting time :1s

Protection area at 4 m height : 100 m2

Threshold : smoke concentration  15% volume

Working temperature : 0 °C to 70 °C
Thermal detector:

Principle : temperature rise and fix temperature

Threshold :  70 °C or temperature rise 15 °C/min

Protection area at 4 m height : 40 m2

Beam smoke detector:
June 2012 Page

3.2.7–28

Type : Infrared transmiter and reciver

Operating span : minimum 50 m

Operating voltage : 24 VDC

7.6.3.2 Alarm call boxes

In case personnel are present, it shall be possible to activate the alarm manually by means
of special alarm call boxes installed throughout the different buildings and accesses to be
covered. They shall be wall-mounted and of the type, in which a frangible glass cover plate
is smashed releasing a switch, which initiates an alarm without further action by the user.
They shall be coloured red, with the words "FIRE ALARM" in white either on or immediately
adjacent to the body of the Call Point.
The Call Points shall have a "Test" facility, whereby fire alarm may be triggered without
breaking the glass or dismantling the unit. The Call Points shall be surface mounted on the
walls. The center of the frangible plate shall be 1400 mm above the finished floor levels.
Alarm call boxes

Waterproof type (IP65) for outdoor and IP54 for indoor


Maximun operating voltage and current : 125 VAC/10A

Alarm bell:

Cover by aluminium alloy


Audibility : 90 dB/1m

7.6.3.3 Central Alarm Control Panel

Enclosure of the control panel shall be made of steel plate 1.2 mm or thicker with such a
construction as the internal equipment can be easily inspected. When the fire alarm signal is
received from a detector or manual alarm station, the control panel shall clearly indicate the
place where a fire has broken out by illuminating the zone indicator and sounding the main
alarm bell in the panel.
When an alarm is initiated, the alarm condition shall remain until reset switch of the panel is
operated.
When any trouble has occurred in the equipment of the system, the LED and Piezosouder
alarm shall be operated; the all trouble shall be displayed in the LCD display and can be
print-out the trouble list by printer.
The control panel shall have the reporting function. The following devices shall be provided,
but not limited to, on the control panel:

Main alarm and Local alarm bell silence switch,

Fire reset and test switch,

Signal transfer stop switch,

Battery test switch,

Line selector and continuity test switch,

Fire alarm and local alarm lighting,

AC/DC power source lighting.
June 2012 Page

3.2.7–29
7.6.3.4 Fault Monitoring System

The power supply and release and initiating devices shall be continually monitored for wiring
shorts or ground faults and battery low voltage value.
An alarm from any initiating device shall cause the audible signals to sound for a full period,
whether or not a previous alarm has partially or fully timed out by means of an automatic
time limit cut off, or has been silenced manually. Silencing by any means shall cause a red
"Signal Silenced" indicator on the panel to illuminate and the "System Failure" signal to
sound.
In case any one of the above fault conditions occurs, the relevant alarm panel shall:

Indicate "System Failure" visually by a common, amber indicator.

Indicate visually the loop number of the affected alarm initiating circuit.

Indicate visually the nature of the failure: wiring fault, ground fault, low battery
voltage, etc.

Start the internal system failure sounder of the alarm panel.
The audible portion of the system failure signal shall be silenced with a "System Failure
Silence" push-button. Optical indicators shall remain lit. The signal and indication shall
automatically reset to normal when a fault condition is corrected. To eliminate any confusion,
all visual and audible fault signals shall automatically turn off and remain off during
development of a fire alarm. Release, alarm and fault signals shall be forwarded to the fire
alarm control panel in the control room.
Power supply for valve operation, signals, lamps, audible alarm, etc., shall be from the
powerhouse 110 VDC supply. All signals for alarm, stop, control and operation shall be wired
to identified terminal blocks.
7.6.3.5 Cables and Conduits

The fire detection system cable installation shall be of copper wire type, PVC insulated,
aluminium shield. Identification markers shall be fitted to the ends of all cables in accordance
with relevant standardsraceways.
Conduit shall be made by zinc plated steel. All conduits shall be grounded.
7.6.4 Water Fire Fighting System

The system shall be used to protect all structures at powerhouse and switchyard including
from fire.It shall consist of two pumping plants with distribution supply system and stop,
control and fire fighting fittings.
The water used for the fire fighting system shall be drawn from the sump connected to tail
race and used for drawing water for cooling water system. So the pumps for fire fighting shall
be installed in the same room as used for cooling water system. The system includes the
water deluge system and the water to the fire hoses.
The system shall be designed for pump’s capacity equal to simultaneous fire fighting of a
transformer and external fire fighting and is equal but not less than 10 l/s.
Two water pumps shall be installed in the system - one pump of electrical-driven type for
normal operation and the second of diesel engine-driven type for stand-by purpose.
The main pump is automatically put into operation by receiving signal from pressure switch
or from remote control switch such as detector signals. It also can be started by START push
button on the control panel.
Water supply for the system is taken from the fire pumping plant. The distributing water
supply network shall be of circular type with diameter of 150mm for main pipe.
Fire fighting is realized by fire hydrants ensuring to supply the water minimum of 600 l/min
with pressure of 4.5 bar at the fire nozzle. Fire hydrant box shall be installed at each floor in
June 2012 Page

3.2.7–30
the powerhouse. Remote control buttons of fire fighting pumps shall be provided near the fire
hydrant box.
Putting into operation of the pumps at fire fighting of the main structures is provided by
means of remote control buttons installed near the fire hydrants and from the control panel.
7.6.4.1 Main Fire Hydrant Pump

The system shall consist of a main fire hydrant pump of centrifugal-type directly coupled with
motor with all necessary accessories such as valves, operation panel, meters, piping, pipe
joints, pressure gauges and other necessary devices in the steel frame. The pump shall be
of such a construction as to operate with low noise and vibration.
Main part of the pump shall be as following:

Casing : cast iron or stainless steel

Impeller : Bronze or stainless steel.

Shaft : Stainless steel.

Shaft sealing : Soft packed

Electrical motor : Open drip – proof

Rated speed : 3000 rpm

Starting mode : Star/Delta

Power supply : 380 VAC/3phase/50Hz
7.6.4.2 Stand-by Fire Hydrant Pump

The system shall also consist of a stand-by fire hydrant pump of centrifugal-type directly
coupled with diesel engine with all necessary accessories such as valves, operation panel,
meters, piping, pipe joints, pressure gauges and other necessary devices in the steel frame.
The pump shall be of such a construction as to operate with low noise and vibration.
Main part of the pump shall be as following:

Casing : cast iron or stainless steel

Impeller : Bronze or stainless steel.

Shaft : Stainless steel.

Shaft sealing : Soft packed
Diesel engine shall be of type specially used for fire fighting purpose and shall be as
following:

Rated speed : 3000 rpm

Engine : 4-stroke, turbocharged type, water-cooling of Heat
Exchanger type.

Startng voltage : 12V DC battery

The engine shall be coupled directly to the AC generator, with both machines being
anchored to the same rigid metal block via shock-mounts.

Accessories : speed meter, operating time counter, temperature
meter, volt meter, ampermeter, starting battery, oil
tank with oil level gauge, etc.
7.6.4.3 Control panel

Control panel of each pump unit shall have the minimum following function and devices:

Switches : Push button switch ON-OFF with buzzer ON-OFF.
June 2012 Page

3.2.7–31

Signal lamp : Power-Operation-Over-current of motor.

Meters : Voltage, Current

Buzzer : Over-current of motor

Automatic start by receiving signal from pressure switch or remote starting signal
such as push button and/or detector.
7.6.4.4 Hydrant box

The hydrant box shall consist of hydrant valve, alarm switches, horse rack, horse and
nozzles. The box shall be constructed of steel plate 1.6 mm thick, shop-coated with oil paint.
The door shall be a steel flush door.
The alarm switches in hydrant boxes shall directly activate the fire hydrant pump and be
connected with the fire alarm system. The box shall be surface mounted or flush mounted
type depending on the places.
The hydrant valve shall be 65 mm diameter, 90° angle globe valve having hose connection
rated at 10kg/cm2 working pressure.
The hose rack shall be of cast bronze construction, chromium-plated, swing-out type.
The hose shall be of cotton or linen rubber lined hose treated to prevent mildew, rated for
4.5kg/cm2 water pressure. The hose shall have 65 mm diameter and 20 m length and shall
be provided with suitable couplings for connection to the hydrant valve and nozzle.
The nozzle shall be of bronze construction, stream water discharge-type.
7.6.4.5 Piping System and Accessories

The material of pipe shall be black steel for diameter greater than 80 mm and zinc-plated
steel for diameter up to 80 mm. The whole assembly of pipes and supports shall include all
necessary flanges and bolting to allow rapid dismantling in case to be removed for
maintenance. The tank, collectors, water spray distribution pipes, valves, supports shall be
galvanized.
7.6.4.6 Fire Hose System

The fire hose system shall consist of fire hose cabinets and piping. Required numbers of fire
hose cabinets shall be installed in the powerhouse. The cabinets shall be of stainless steel
construction. They shall be of the wall recessed type, wire-glass door style with door hinges
and provided with door handles with lock. The cabinets shall be suitable for outdoor
installation and shall include a valve.
A hose rack with at least 30 m of approximately 40 mm diameter polyester double jacket fire
hose shall be supplied.
The nozzle shall be of the fog type, suitable for all types of fire, shall have diameter not less
than 35 mm and shall be provided with adjustable features from shut-off to 30 degrees fog
without producing a straight stream of water.
Pipe headers and risers shall be provided for the fire hoses. From the risers, a branch shall
be provided at each floor to each hose cabinet. The pipes shall be made from black steel
pipe with welded and screw fittings. The supply shall include all valves and necessary
equipment.
7.6.5 Transformer Deluge System
7.6.5.1 Fire Detectors

Each transformer fire fighting system shall have a fire detection system. At each transformer,
there shall be installed a double detector loop for deluge release. Each loop shall be
June 2012 Page

3.2.7–32
provided with combined heat/flame detectors covering infrared and ultraviolet range of light
spectrum. In addition at least one pressure detector shall be included in each loop. All
detectors shall be of the analogous addressable type.
7.6.5.2 Deluge System

Each of the three transformers shall be protected by an automatic stationary water spray
system. The water deluge system shall provide complete spray coverage of the surfaces of
the transformer and the surrounding area. Number of nozzles at each transformer shall be
fixed as per requirement.
The water shall be applied at a rate not less than 0.20 l/s per square meter of projected area
of rectangular prism envelop for the transformer and its appurtenances and not less than
0.15 l/s per square meter on the expected non-absorbing ground surface area of exposure.
7.6.5.3 Deluge Valves

Outside each transformer bay the lines shall be equipped with a manually operated
maintenance valve of the gate type and an automatic deluge valve electrically activated by
the heat sensors. The automatic valves shall be equipped with means for manual operation
and shall always be manually closed after deluging has been finalized.
The deluge valve may be of the butterfly- or gate valve type being electrically operated. The
valve actuator shall be energized from the powerhouse 110 DC supply.
7.6.5.4 Detection and Activation

Activation of the system will be supervised by transformer fault detector relays. If a loop is
activated and the fault detector relay is energized then, the system shall be released after
having initiated the following signals:
First sequence:

An alarm to the fire alarm control panel in the control room.

A signal to the starting mechanisms for audible and visible alarm within the affected
area.

A signal to de-energize the generating unit.
Second sequence:

A signal to the release deluge extinguishing system.

A signal to the fire alarm control panel in the control room.
There shall be an adjustable time delay of 0-30 s to give interval between first and second
sequence. Loss of electrical power shall not result in release of the deluge system. Loss of
water pressure shall cause the local control units to initiate a system failure signal to the
control room.
7.6.5.5 Manual Operation

Each system shall be fitted with the following means of release:

A manual electrical release by an electrical push button at the control panel.

A manual mechanical emergency release for each transformer; the release shall
be installed near the spare transformer.
It shall be possible to isolate the automatic release signals to the system by a key-operated
lock-off switch located within the control unit. The manual release buttons assembly shall
include an indicating lamp that is lit when power is available to the release station from the
control unit.
June 2012 Page

3.2.7–33
Each manual electrical release button assembly shall have three system status lamps
receiving signal from the control unit. One lamp shall be ON when the system is in its normal
automatic operation mode ("System Normal"). The second lamp shall be ON when the
system is on manual release only ("System Manual"). The third lamp shall be ON when
water has been discharged ("Water Discharged").
7.6.5.6 Piping
The pipes shall be made from seamless or lapwelded black steel pipes with standard weight
butt welding steel fittings. Spray headers shall be made of galvanized steel pipe with
galvanized malleable iron screw fittings. The supply shall contain all valves and necessary
equipment.
There shall be a minimum of two ring lines around each transformer located approximately 1
m from the transformer. Spray headers and piping shall be designed for dismantling and
reassembling so that piping will not interfere with the replacement of the transformers.
7.6.6 Switchyard Fire Protection

The Works include the furnishing and installing at the switchyard two fire hydrants and
associated pipe and valves, and two fire hose storage cabinets.
The fire hydrants shall be of the compression type, the hydrant opens against the water
pressure and closes with the pressure. The hydrants shall be complete including a positive
drain valve, weather cap, test plug, lubrication points, bronze top stem, nozzle caps with
chains, compression type main valve and bronze seat ring, and bronze cap nut.
The drain valves shall operate automatically without springs or plungers, and shall
automatically be flushed when the hydrant is open.
The hose storage cabinets shall be of 2 mm thick aluminium, complete with doors, sides,
roof and shelves, built on an angle iron frame, and with ventilating louvers. The cabinets
shall be suitable for outdoor installation, and shall include 600 mm high legs, continuous
piano type hinges, shelf, equipment brackets, door catch, and all the basic equipment
required.
The shutoff valve upstream of the fire hydrant shall be a gate valve suitable for direct buried
installation. The valve body shall be cast iron body, with flanges fully faced and drilled.
7.6.7 Mobile Dry-type Fire Extinguishers

The mobile dry-type fire extinguishers shall be applied for initial fire fighting at specified
zones in the powerhouse.
The fire extinguishers shall consist of a bottle and carrying assembly, pressure reducing
valve, rubber medium pressure hose line, demand valve and face piece. The bottle shall
supply sufficient extinguishing agent for one man to operate at a medium to heavy rate for
one hour. The carrying assembly shall be lightweight, made of fire resistant material and
shall be of robust construction and incorporate a pressure gauge graduated in MPa and
kg/cm². The face piece shall fully enclose the wearer's face, form an effective seal against
the ingress of smoke and have a scratch resistant visor providing an unobstructed field of
vision.
The fire extinguisher medium shall be of dry chemical, heavy duty, ABC and CO 2 contained
in the steel bottle as following:
Dry Chemical Extinguishers
The dry chemical extinguishers shall be designed for fighting of fires in solids, oil and
electrical equipment (ABC type). Each of the portable units shall be complete with short
flexible tube, pistol nozzle, and wall bracket.
June 2012 Page

3.2.7–34

Extinguishing agent : ABC powder

ABC quantity in container : 4 kg and 8 kg

Container pressure : 12 kg/cm2

Equipment: : lever plunger, diffuser with grip
CO2 Fire Extinguishers
The CO2 units shall be designed for fighting of fires in oil and electrical installations (BC
type). Each of the portable units shall be complete with short flexible tube with diffusor made
of dielectric material, operating lever protected against unintended utilization, carrying
handle and wall bracket.
The extinguishers for the diesel generator unit shall be housed in a weather-proof metal
cabinet on the outside wall of the unit housing.

Extinguishing agent: : carbon dioxide

CO2 quantity in container : 5 kg

Discharge duration :9s

Discharge distance :2m

Equipment: : trigger valve
7.6.8 Spare Parts


One (1) fire detector of each type.

One (1) module of each type in central alarm control panel.

One (1) set of sundry spare parts (fuses, warning lights, etc.).

10% of each size of valves used, but minimum one of each type.

10% of each size and type of nozzle used, but minimum one of each type.

10% of each type of switch, solenoid and relay used, but minimum one of each type.

Ten (10) sets of all lamps, fuses, indicators of each type used.

Two (2) sets of all gaskets.

10% of steel piping of all dimensions (relative to length installed).

10% of steel piping parts: elbows, tees, reducers, etc., but not less than one of each.

Spare parts as recommended by the Tenderer for 5 years of operation of the fire
fighting equipment and components including spare parts for control system. The
list accompanying the supply of recommended spare parts shall include the price
of each part.These spare parts shall be in addition to those furnished for use
during the warranty period.
7.6.9 Tests
The equipment shall be subject to relevant tests as specified under the General Technical
Specifications with regards to material, manufacture and functions both in the workshop and
at the site.
After installation, the fire detection system shall be tested to the satisfaction Client. The test
shall include testing of all items of equipment and audibility tests. Each detector shall be
tested with specific equipment recommended by the Manufacturer.
After completion of erection random tests of one dry chemical extinguisher unit and one CO 2
unit shall be carried out by the Engineer to prove correct operability. The tested units shall be
recharged by the Contractor.
The deluge system tests shall include the followings:
June 2012 Page

3.2.7–35

Operation of the water deluge systems with actuation by the automatic detection
system, alarm system and manual release.

Pipe shall be flushed clean and hydrostatic pressure tested as specified in General
Specifications.
All pipes embedded in the ground shall be at the pipe top a minimum 30 cm below the grade
where no heavy traffic is expected and minimum 90 cm below the grade at road crossing
and where heavy traffic is expected.
The embedded pipes in the ground shall be painted with 2 layers of anti-erosion and 2 layer
of bitium with thickness not less than 2 mm.
The exposed pipes shall be painted with 2 layers of anti-erosion and 2 layer of coating (red
colour for water fire fighting pipe and blue for CO2 pipe). The painting thickness of each layer
shall not be less than 50 microns. The treatment method before painting shall be submitted
to Engineer for approval.
The pipe lines shall be pressure tested by clean water at pressure of 1.5 time of rated
system pressure and ensure that the pressure drop shall not exceed 5% of testing pressure
after 12 hour without any addition of water to the system.
June 2012 Page

3.2.7–36

Section 7 Ancillary Equipment: 7.1 General 1 7.2 Overhead Travelling Crane 1

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LOT 3 – ELECTROMECHANICAL WORKS

SANJEN JALAVIDHYUT COMPANY LTD. Bidding Documents: Volume 3.2

7.2 Overhead Travelling Crane 1

June 2012 Page

7.2.28 Field Installation and Tests at Site 10

7.3 Diesel Engine Generating Set 11

7.4 Oil Purifying and Handling Equipment 14

7.5 Tools and Meters 17

7.5.1 Machine and Tools 18

7.6 Fire Fighting System 27

June 2012 Page

7.6.4.2 Stand-by Fire Hydrant Pump 31

June 2012 Page