2023.03.14 Final Contract 4086 Main

CONTRACT AGREEMENT
BETWEEN
STEEL AUTHORITY OF INDIA LIMITED

DURGAPUR STEEL PLANT, DURGAPUR
(EMPLOYER)
AND
ISGEC HEAVY ENGINEERING LIMITED

NOIDA, UP
FOR
INSTALLATION OF NEW GAS FIRED BOILER
MAIN PACKAGE
PACKAGE NO. III
VOLUME -II
(CONTRACT TECHNICAL SPECIFICATION)
STEEL AUTHORITY OF INDIA LIMITED

CENTRE FOR ENGINEERING & TECHNOLOGY
RANCHI - 834002
CONTRACT NO. DATED

CONTENTS - CHAPTERS
Chapter No. Description Page No.
1 Introduction 1.1 - 1.2
2 Scope of Work 2.1 - 2.38
3 Technical Specification 3.1 - 3.224
4. Commissioning and Performance Guarantee 4.1 - 4.4
Annexures
Schedules
Drawings
DSP CONTENTS CONTRACT NO..

INSTALLATION OF NEW GAS FIRED BOILER PAGE 1 OF 4
CONTENTS - ANNEXURES
Annexure No. Description No. of Pages
2.1.3-1 List of Acceptable Makes of equipment and 34

supplies –July 2020
2.1.9.2-1 Implementation Schedule 1
3.7.10-1 Soil Investigation & Survey Works Report 134

CONTENTS - SCHEDULES
Schedule No. Description No. of Pages

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

CONTENTS - DRAWINGS
Sl. No. Drawing No. Description

Proposed schematic for new gas
1 CET RN 4086 UT2 00 001, R=5
fired boiler
Proposed SLD of HT & LT power
2 CET RN 4086 EE1 00 001, R=2
supply network for new boiler
Proposed layout of new gas fired
3 CET RN 4086 CE0 00 001, R=4
boiler

1 INTRODUCTION
1.1 GENERAL
Durgapur Steel Plant (DSP) is having a captive power plant known as
Old Power Plant (OPP) which was installed in 1959 at 1 Mt stage.
1.2 EXISTING FACILITIES
OPP was installed with 4 nos. boilers (boiler no. 1, 2, 3 & 4) of 68 tph
capacity each. Subsequently, in the expansion stage 2 nos. more boilers
(boiler no. 5 & 6) of 68 tph capacity were added in 1965.
In 1988, 1 no. more coal-fired boiler (boiler no. 7) of capacity 68 tph was
installed which was later converted to gas fired boiler in 1997.
Steam parameters for all above boilers are:
Steam pressure 35 kgf/cm2 (g)
Steam temperature 413oC
1.3 OVERVIEW OF THE PROJECT

It has been decided to install a new gas fired boiler at a new place which
shall be interconnected with the existing system of OPP.
1.4 IMPLEMENTATION STRATEGY
1.4.1 The complete job of installation of a new boiler is envisaged to be
executed through two packages.
1) Soil Investigation & Survey Works (Package-I) – Already executed.
2) Enabling Works Package (Package-II)
3) Installation of new gas fired boiler (Package -III)
1.4.2 This contract specification pertains to “Installation of new gas fired
boiler” – Package No. III to be executed on turnkey basis which includes
complete design, engineering, supply, fabrication, manufacturing,
transportation, handling, dismantling, erection, painting, testing and
commissioning for installation of new boiler at OPP of DSP. It also
includes all related works of mechanical, civil, structural, electrical,
instrumentation & automation and other accessories, as required in
accordance with the technical specification and as detailed in this
contract specification.
1.4.3 Details of pre-shutdown and shutdown activities with duration:
Details of pre-shutdown activities as well as activities during shutdown
and their duration has been shown by the contractor in the
implementation schedule.
DSP PAGE 1.1 CONTRACT NO..
INSTALLATION OF NEW GAS FIRED
BOILER
1.4.4 Other site related details
Details of any other over ground facilities at erection site which may
need diversion and special handling equipment to be deployed at site, if
any, has been studied by the Contractor.
1.5 INTENT OF SPECIFICATION
1.5.1 Void
1.5.2 This contract specification shall be read in conjunction with other
documents enclosed with the contract .
1.6 SITE VISIT AND OTHER REQUIREMENTS
1.6.1
The Contractor has visited the site, studied drawings/ documents and
discussed with the employer/ consultant, regarding any technical
clarification and is satisfied with respect to the nature and extent of
work involved. The Contractor has also obtained first-hand information
regarding location, work terrain, climate condition, railways, roads,
airports and communication etc. for the job.
1.6.2 All materials/ equipment/ machinery/ fabricated items used in the
subject package shall be according to the specification given herein and
any deviation should be clearly brought-out in schedules of exclusions
and deviations attached with this contract. The contractor has accepted
the scope and specification given herein.
1.7 Void
1.8 SCHEDULES FILLED AND SUBMITTED WITH THE OFFER
1.8-1 Declaration of site visit
1.8-2 List of exclusions
1.8-3 List of deviations
1.8-4 List of recommended spares for two years
normal operation
1.8-5 List of commissioning spares
1.8-6 List of special tools and tackles
1.8-7 List of first fill of oils and lubricants
1.8-8 Details of authorised person of contractor
during bid evaluation
1.8-9 Requirement of construction water & power

2 SCOPE OF WORK
2.1 GENERAL
2.1.1 The contractor shall be responsible for execution of the jobs envisaged
for Installation of new gas fired boiler on turnkey basis.
2.1.2 The scope of work shall cover design, engineering, preparation of
design and drawings, getting approval of the employer on the same,
procurement, manufacture, fabrication, supply, transportation,
insurance, storage, handling, dismantling & removal of debris,
construction, erection, testing, commissioning, stabilisation and
demonstration of performance guarantee of the complete plant and
equipment to the satisfaction of the employer. The plant and equipment
supplied shall be new and best of its kind.
2.1.3 All indigenous items shall be as per the List of Acceptable Makes of
equipment and supplies furnished in Annexure-2.1.3-1 and as given in
the DSP’s acceptable make list attached along with NIT, if any.
Also please note that:
a) Where more than one Vendor is listed, the Contractor is free to
choose any of them, but it must notify the Employer of its choice
well in advance prior to appointing any selected Vendor.
b) The contractor shall not be permitted to propose a new vendor for
items where at least three approved vendors are available for
providing supplies. However, where at least three vendors are not
available to provide supplies, the contractor may propose
additional vendors for approval of the employer.
c) No approval of the Employer is required to be obtained by the
contractor for procurement of items that are not listed Annexure
2.1.3-1 and the DSP’s acceptable make list attached along with
NIT, if any.
d) However, it may be noted that if contractor is the
OEM/manufacturer of boiler, Sl. No. (G-14.1) of Annexure-
2.1.3-1 shall not be applicable
2.1.4 The equipment and facilities envisaged under this package shall be
located generally as per general layout drawings enclosed with the TS.
Layout of plant and equipment shall have provision for easy and safe
movement of operation/ maintenance personnel for operation/
inspection of the running plant. Adequate space for dismantling/
removal of equipment/ parts for repair shall also be built in the layout.
2.1.5 All the manufacturing/ fabrication works shall be carried out only on the
basis of approved drawings and schemes or as directed by the

BOILER
employer. Approval given by the employer shall not relieve the
contractor of any obligations under the contract.
2.1.6 Wide Parallel Flange Beam (WPB) and Narrow Parallel Flange Beam
(NPB) sections, being produced by SAIL, shall be used. In case of non-
availability /non- suitability of WPB or NPB sections, tapered rolled SAIL
sections or built up sections using SAIL steel shall be used. This is in
addition to the relevant clauses of SBD with regards to usage of SAIL
steel.
2.1.7 Any equipment/ work/ service, which may not have been specifically
mentioned in this document but is necessary for completeness of the
work, shall be included in their scope of work.
2.1.8 Scope of Services
1) Receiving of equipment/ construction materials from contractor’s
stores/ employer’s stores and transportation to site.
2) Unloading of equipment/ construction materials at site, unpacking,
cleaning up, and checking for completeness and transportation to
site for erection/ construction.
3) Supply of all labour, materials, mobilization of resources to site,
site handling and execution complete as per Scope and
specification contained in this document.
4) Transferring of centre lines and levels from standard benchmark(s)
and fixing the reference lines & level at work site(s) including
geodetic survey for the project.
5) Filling of lubricants/ grease as per manufacturer’s instructions.
6) Supply of all erection consumables like oil, kerosene, cotton waste,
oxygen and acetylene gas cylinders, electrodes, GI sheets, ropes,
sealing compounds etc.
7) Arranging tools, tackles, construction & erection machineries,
cranes and other handling & testing equipment, scaffolding,
temporary platforms, erection fixtures, skilled/ semi-skilled/
unskilled personnel etc.
8) Arranging inspection of equipment at manufacturer’s/ sub-
supplier’s works wherever required as per approved QAP. No 3rd
party Inspection is required. Inspection shall be done as per
Contract.
9) Arranging and rendering equipment and personnel to employer
for checking the correctness of the work in progress.

BOILER
10) Submission of test certificates and data sheet from approved third
party testing laboratory or manufacturer respectively.
11) All equipment shall conform to the relevant provisions of Statutory
and other Regulations in force such as Indian explosives Act,
Indian Factories Act, Indian Boiler Regulation, State Factories Act,
Indian Electricity Rules, Central Pollution Control Board, Indian
Weights & Measures Act as applicable. The contractor shall
provide all necessary assistance to the employer to get all the
installations within the scope of supply approved by the concerned
legal authorities.
12) The contractor shall get clearance / assist DSP in getting various
statutory clearances like IBR clearance, Aviation Clearance, CEA
Clearance for electrical installations, Safety Clearance for plant
building / cranes etc from Factory inspector. The successful
contractor shall also assist in preparing application forms,
providing necessary drawings, documents, test certificates etc.,
including necessary co-ordination with statutory and other
concerned authorities.
13) Any rectification/ modification of existing facilities required during
erection of equipment.
14) The contractor shall be responsible for protection and / or
diversion of underground and all existing over-ground services,
wherever required and/ or diversion of the underground services
which are indicated in the drawing made available to the
contractor. In case there are under-ground services which need to
be protected and/ or diverted but are not shown in the drawing,
the contractor shall be responsible to execute the same at extra
price, if any, to be mutually agreed between contractor &
employer.
15) Sundry works such as making of holes, grouting, chiselling of
holes/ opening through walls, ceiling, floors, steel structures, etc.
including providing inserts as per requirement, cleaning of site
periodically and at the time time of final handing over.
16) Periodic transportation including Loading, unloading and
spreading unserviceable material, debris, surplus excavated earth
with all lift and lead within plant premises unless otherwise
specified.
17) All instructions in the manuals for assembly, erection, testing and
commissioning of the equipment shall be in English.

BOILER
18) The Contractor shall also supply complete analysis and design
calculation with the loads for proposed system. Design calculation
shall be submitted for reference only.
19) All necessary site measurements for developing the design and
drawings shall also be deemed to be under the scope.
20) All necessary safety features / facilities / equipment to be provided
in line with prevalent statutory norms for proposed systems.
21) Fabrication, erection of fabricated structures (including supply of
tools, tackles, levelling pads, labour, handling equipment and any
staging or false work required for erection), alignment, levelling,
fixing, bolting/ welding, inspection and testing of welds.
2.1.9 Implementation Schedule
2.1.9.1 The project shall be implemented within a period of 19 months from
the effective date of contract up to commissioning.
2.1.9.2 Implementation schedule is shown at Annexure 2.1.9.2-1.
2.1.10 Discipline wise scope of work has been elaborated in the subsequent
clauses of this chapter.
2.1.11 List of critical operational & maintenance spares to be submitted by the
Contractor as per Schedule No. 1.8-4 shall be finalised during offer
evaluation / tender discussion stage. Supply of all spares as per this
finalised list is included in scope of Contractor.
2.1.12 Painting shall be provided as per Scope and specs of Contract. If not
specified in Contract, OEM/ industry standards shall be followed.
2.2 PROCESS AND TECHNOLOGY
The scope of work and supply covered under this turnkey specification
is full and complete and includes all the equipment and material
whether specifically mentioned or not but considered essential for
satisfactory completion/ performance of new boiler shall also be
included in the scope of work of the contractor within battery limits.
The broad specification of the system/ components is indicated in
Chapter 3.0 of the TS. The scope of work shall broadly include but not
limited to the following:
2.2.1 Boiler & Auxiliaries
2.2.1.1 1 no. Blast Furnace (BF) gas and Coke Oven (CO) gas fired 100tph boiler
(MSV outlet pressure and temperature shall be 36 kg/cm2(g) at 413oC
±5oC respectively). Boiler shall be designed to run on BF gas for 100% of

BOILER
rated capacity. Coke Oven gas shall be used as startup fuel as well as
provision for firing COG upto 10000 Nm3/h shall be provided.
Net steam generation capacity at main steam stop valve (MSSV) outlet
shall be 100 TPH as per Contract. Contractor to consider all additional
steam requirement for internal consumption etc in addition to the net
steam gen capacity.
2.2.1.2 Boiler shall be complete with following minimum facilities:
 Set of steam super heater, set of economizer, set of steam
attemperator, steam & water drums, tubing, complete pressure
parts, etc.
 Gas firing arrangement.
 Air-preheater.
 Set of boiler furnace with casing.
 Burner management system.
 Set of refractory and insulating materials.
 Silencers and sound hood for start-up vent and safety valves.
 As boiler is gas fired, soot blower system is not required.
 Set of draught plants comprising of 2 x 60 % capacity Forced
Draught (FD) fans, 2 x 60 % capacity Induced Draught (ID) fan with
all speed control drives & auxiliaries, ducting, dampers etc.
 Set of integral steam and water piping.
 Set of all necessary isolation, control and safety valves and their
mountings.
 Set of sample coolers for feed water; drum water, saturated steam
and superheated steam.
 1 no. flash tank common for continuous & intermittent blow down
and RO reject water. Provision of cooling of blowdown water with
makeup water shall be provided. Transfer of cooled blowdown &
reject water to existing GCP thickeners by 2 nos. (1w+1s) pumps
(minimum 50 m3/h capacity of each blowdown pump. Final capacity
will depend on the amount of blow down and RO reject water
generated from the system which contractor needs to calculate) and
new piping on existing / new trestles. Contractor to study the route
during site visit. Head requirement will be based on calculations as
per actual route during detailed engineering to be decided by
contractor.

BOILER
Settled water will be provided by DSP as mentioned in Contract
battery limits. Further water treatment requirement or technology
requirement for quenching is in contractors scope
 1 no. separate surge tank of 60 m3 (minimum) capacity alongwith
(1w+1s) pumps shall be provided at deaerator inlet.
 2 nos. (1w+1s) de-aerator make-up pumps with drives &
accessories and necessary piping and isolation valves.
 One no. De-aerator (contact, spray & tray type) with storage tank
having storage capacity for minimum 15 minutes.
 One HP dosing unit with 2 nos. (1w+1s) dosing pumps, including
one tank with motorized stirrer and associated valves and piping.
 One LP dozing unit with 2 nos. (1w+1s) dosing pumps including one
tank, motorized stirrer and associated valves and piping.
 The boiler with its auxiliaries shall be located outdoor. Boiler top
shall be covered with shed. Canopy shall be provided over drum
platform to cover boiler top. There shall be suitable connectivity of
various boiler platform with staircases. Cover will be of 18-gauge
(min thickness) CGI sheet sheeting.
 3 nos. (2w+1s) boiler feed pumps with drives & accessories, self-
contained lube oil facilities, auto re-circulation valves and necessary
isolation valves.
 There shall be 1 no. main steam line which shall bifurcate into 2 nos.
lines (each of full capacity) at existing boiler house in order to be
connected to 2 nos. existing steam headers. Motorized isolation
valves for isolation of boiler from the headers shall be provided.
 Auxiliary steam line from the boiler shall be provided with 2 nos.
PRDU (1w+1s), isolation valves, by-pass valves, piping, drives, drain
etc. The outlet of PRDUs shall be interconnected with isolation
valves and shall be taken to de-aerator for complete de-aerator
heating.
 Auxiliary steam line from the boiler shall be provided with 2 nos.
PRDU (1w+1s) of 5 tph capacity, isolation valves, by-pass valves,
piping, drives, drain etc. The outlet of PRDUs shall be
interconnected with isolation valves and shall be connected to LP
steam line at 12-13 kgf/cm2 (g) going to VAD near proposed area.
Estimated temperature will be about 280-300 deg C at pressure of
12-13 kg/cm2g

BOILER
 Set of base plates, shims, pads, and foundations bolts with all
fasteners for all equipment.
 1 no. structural chimney having height (min - 60m) as per CPCB
norms. Stack top dia shall be 3m (min). However necessary
supporting calculations will be submitted by contractor for
considering height & Diameter.
 1 no. online stack monitoring device based on opacity meter at
chimney.
 Facilities for alkali boil out of boiler and steam blowing. Necessary
arrangement & target plate shall also be provided.
 Purging circuit for boiler lighting purpose and for other requirement
shall be provided.
2.2.2 Makeup Water System
 Make up water line shall be tapped from existing ‘L’ Chamber on
DN 600 settled water main at OPP coal yard. The line of DN 300
(minimum) shall be brought underground below Power Street to
boiler area and shall be provided with all necessary valves, fittings,
etc. Line shall be sized considering additional requirement for 1 no.
future similar capacity boiler.
 Existing RCC overhead tank will be refurbished. 2 nos. (1w+1s)
pumps, each of 150 m3/h (min) capacity shall be installed to lift the
settled water to upper portion of existing overhead tank.
Height of the Overhead tank: 30m (min). Normal Water level in tank:
8m. Head of pumps to be decided accordingly.
 Outlet from the overhead tank will be taken to 2 nos. (1w+1s)
automatic valve less gravity (AVG) filters of minimum capacity 150
m3/h, for filtration of settled water. Filtered water will have a TSS
level of 5 ppm (max).
 Filtered water will be stored in new RCC with epoxy painted filtered
water tank of 300 m3 (min) capacity, 2 nos. (1w+1s) filtered water
pumps, each of 150 m3/h (min) capacity will transfer the U water to
RO water plant inlet.
 2 nos. (1w+1s) service water pumps, shall be installed to transfer
water from the filtered water storage tank to cater to service water
and various cooling water requirement for proposed boiler and its
auxiliaries. Service water connections shall be provided at every
working platform on the boiler building.

BOILER
 An alternate water line of DN 300 (minimum) will be laid from
filtered make up water line of OPP to filtered water tank of
proposed area.
2.2.3 RO Water Plant
 RO water plant will serve the proposed boiler. Inlet water shall be
tapped from the proposed filtered water storage tank through
pumps.
 3 nos. streams (2 nos. working and 1 no. under
regeneration/standby) of RO water, each stream capacity (min) 60
m3/h (RO permeate flow capacity) shall be installed.
 The system shall comprise of RO generation unit, epoxy painted RO
water RCC storage tank of 300 m3 (min) capacity, RO water transfer
pumps (1w+1s), each of 120 m3/h (min) capacity and 1 no. pump for
boiler initial filling, etc.
2.2.4 Blast Furnace Gas / Coke Oven Gas firing System & Other Utility
Lines
 Blast furnace gas/ coke oven gas shall be tapped from the existing
headers at OPP.
 Necessary isolation goggle valves and U seals shall be provided
after the tapping for BF gas line. Encased type, slide plate goggle
valves shall be provided 1 no. at main header and 1 no. at branch
for proposed boiler in BF gas line.
 Necessary motorised isolation valves and U seals shall be provided
after the tapping for CO gas line.
 Necessary nitrogen purging lines shall also be laid after tapping
from existing nitrogen header near OPP.
 LP steam lines shall be provided for startup and purging purpose.
2.2.5 Compressed Air System
 Dry compressed air shall be used for instrument operation.
 2 nos. (1w+1s) oil-lubricated / non-lubricated screw type
compressors, each capable of catering to the instrument air (of
required air quality) as well as service air requirement of new gas
fired boiler and other proposed systems shall be installed.
 The system shall be complete with 2 nos. air dryers (1w+1s), pipe
network, valves and fittings, instruments and control etc.

BOILER
 1 no. instrument air receiver and one suitable capacity service air
receiver each of minimum 2 m3 capacity shall also be provided.
2.2.6 Piping Networks
 The piping networks shall comprise of all pipelines including the
fittings, valves, insulations, compensators/ expansion joints, hose
connections, steam traps, etc.
 All piping shall be tapped from or connected to the terminal points
with necessary isolation valves.
 All header piping shall be designed considering capacity for 1 no.
future boiler of same capacity.
 Steam Piping
 Main steam piping as required for connection to two existing
headers of OPP with provision of motorized isolation gate
valve.
 Auxiliary steam piping for PRDUs, deaerator heating, purging
circuit, etc.
 Feed water piping
 All integrated boiler piping
 Piping for BF gas, CO gas, purging nitrogen lines
 Settled water and Filtered water piping
 RO water piping
 Fire water piping
 Drinking water piping – DI pipe
 Oxygen piping for welding and service purpose in boiler proper
area working levels and platforms.
2.2.7 Material Handling System
 Electric hoists for the following:
 ID fans (1 no electric hoist common for 2 no. ID fans)
 FD fans (1 no electric hoist common for 2 no. FD fans)
 Boiler feed pumps (1 no electric hoist common for 3 no. BFW
pumps)
 Other equipment at boiler house.
 Compressors, pumps, RO water plant equipment and other
items as per requirement.

BOILER
Contractor to provide electric hoist for any equipment handling as
per contractors design weighing over 500 kgs. Contractor will
provide monorails for any outside equipment alongwith portable
manual hoist.
2.2.8 1 no. new 1t capacity goods cum passenger elevator shall be provided
in the boiler building. As per requirement, elevator landing platforms
shall be connected with boiler working platforms with covered
walkways.
2.2.9 Clearing of site before and after completion of work.
2.2.10 Dismantling/ diversion/ re-routing of underground, overground
pipelines, cables, etc. as required including supply of those by new
pipelines, cables, etc. as per technological requirement.
2.2.11 Any equipment/ work/ service, which may not have been specifically
mentioned in this document but is necessary for completeness of the
work, shall be deemed included in the scope of work within given
battery limits.
2.2.12 An outline of proposed facilities has been shown in Drg. No. CET RN
4086 UT2 00 001 and proposed layout is shown in Drg. No. CET RN
4086 CE0 00 001. Adequate maintenance space and approach shall be
considered while preparing layout of proposed systems. Drawings given
in the Contract are tentative and building sizing will be finalized during
detailed engineering stage.
2.3 UTILITIES
2.3.1 Air Conditioning & Ventilation System
1. Air Conditioning system shall be provided in:
 Control rooms
 Office room in electrical substation
 Office room for proposed boiler
2. Dry pressurized ventilation system shall be provided in:
 Non Intelligent MCC rooms at LT substation
3. Exhaust ventilation system shall be provided in:
 RO water plant
 Pump house
 Compressor room
 Transformer rooms

BOILER
2.3.2 Fire Fighting System
Scope of supply contains the following major equipment:
i) Portable fire extinguishers to the fire risk area as per TAC lot
norms
ii) Ring main type Water based firefighting system comprising lot
of piping, valves, hydrants, stand posts, etc.
iii) Sand buckets as per norms lot
2.4 ELECTRICAL
2.4.1 Major equipment / facilities for electrical works are mentioned below:
Sl. Description Quantity
No.
1. New 11 kV, 1250A VCB feeder (With breaker 2 sets
each, CTs, numerical relays, auxiliary relays,
metering, indication and associated accessories)
11kV power supply of the new Boiler shall be
tapped from two adjacent bus-sections of OPP
11kV board at 33/11kV substation under NPP
Power Evacuation Scheme.
The middle bus-section has a spare panel for
11kV OPP board at Evacuation Package S/Stn.
Extension of bus for bus-sections No. 1 & 3, shall
be done under this project.
Bus-section No. 1 & 3 is fed from same NPP
feeder while the middle bus-section (No. 2) is
fed from the second NPP feeder, different bus
section.
Thus one 11kV feeder for the new Boiler shall be
tapped from the middle (No. 2) bus-section,
while the other 11kV feeder for the new Boiler
shall be tapped from No. 3 bus-section, i.e., the
two feeders would be tapped from adjacent bus-
section. Hence, 11kV supply for the New Boiler
will be tapped from adjacent bus-sections of
11kV board of S/Stn under NPP Power
Evacuation Scheme. For this, bus will be
extended in section 3 to provide feeder for the
same.
Control Panels (as per existing) for 11kV breakers
BOILER
No.
to be considered
The cable will be laid partly through employer’s
overhead gallery and the rest through buried
cable trench. The new LT substation will have 2
no’s 2 MVA transformers and a Power Control
Centre (PCC) which will cater the entire LT loads
of proposed boiler. Proposed power network of
new LT S/S may be referred in enclosed Drg no.
CET RN 4086 EE1 00 001.
System shall be designed so as to prevent
unnecessary tripping of critical electrical drives
on under-voltage/ similar conditions caused by
external system disturbances.
2. 1250A Vacuum Circuit Breakers (VCBs) as 2 sets
isolators
VCB make / Panel make for 11kV Board (feeding
to Transformers) shall preferably be of same
make/model as to be supplied for 11KV
breakers/ board at NPH (as mentioned in the
above point) from where the 11kV power will be
sourced.
Since the VCBs mentioned under this clause are
to be used only for isolation, therefore there will
be no Protection releases or numerical
protection relay in these 2 breaker panels.
3. Min 2 MVA, 11/ 0.433kV AN distribution 2 sets
transformers at new LT substation which will be
fed from new 11 kV feeders of upcoming 11 kV
HT Switchboard.
Location: new LT substation
4. 4000 A LT busduct 2 sets
Aluminium bus duct shall be considered from
secondary of the transformers to new LT
Switchboard/ PCC.
Suitable cable supporting arrangement, cable
box for connecting cables at primary side of

BOILER
No.
transformer connectors, clamps, termination kit
and all accessories as required. Cable supporting
structures with busbar arrangement for
connecting cables.
5. Power Control Centre (PCC) with two incomers 1 set
and one bus coupler and required number of
outgoing feeders for feeding supply to MCC and
various other auxiliaries. In addition to spare
feeders in sections, one tie line feeder of suitable
rating shall be provided in PCC for purchaser’s
use. UPS sourced control supply shall be
provided for ACBs of PCC.
6. Motor Control Centre (MCC) with two incomers 2 sets
and one bus coupler and required number of
outgoing feeders for feeding supply to new
boiler equipment and various other auxiliaries.
7. Power Distribution Board (PDB) 1 set
8. Provision of AC motors Lot
 General purpose squirrel cage induction
motor
 Inverter duty squirrel cage induction
motor for VFD driven motors
9. Motor health monitoring equipment for critical Lot
motors like ID Fans, FD Fans, Boiler Feed Pumps,
De-aerator Feed Pumps, De-aerator Extraction
Pumps and Air Compressors.
Motor healthiness data shall be provided in the
HMI for alarm and data logging.
10. Variable frequency drive for boiler feed pumps, Lot
ID fan, FD fans and as per technological
requirements. VFDs to be standalone type. VFD
shall be kept in air conditioned environment.
Location: Control Room
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No.
11. Control Desk 1 No.
Location: Control room of new boiler area above
compressor room
12. Local Control Stations (LCS) near each motor. Lot
13. Uninterrupted Power Supply (UPS) of min 2X20 1 Set
kVA for catering all needs of equipment/ items
within the battery limit including for
instrumentation & automation equipment/ items
with parallel redundancy. Final size of UPS shall
be decided during DE stage. For UPS sizing, 40 %
spare capacity of actual shall be considered.
14. UPS for Electrical Switchgear & PLC 1 set
Final size of UPS shall be decided during DE
stage. For UPS sizing, 25 % spare capacity of
actual shall be considered.
15. UPS for Emergency Lighting. 1 set
Final size of UPS shall be decided during DE
stage. For UPS sizing, 25 % spare capacity of
actual shall be considered.
16. Ni CD type type battery bank, battery charger 1 set
and DCDB
17. Electrics for Elevator Lot
18. Illumination system for indoor, outdoor lighting, Lot
illumination for entire new boiler complex, new
LT substation, control room, RO water plant
including the following:
 MLDB, required nos. of SLDBs, energy
efficient LED Lighting fixtures inside the
control rooms, pole mounted LED lamp
fittings for outside area lighting, weather
proof luminaires in different levels of boiler
complex; junction boxes, pull boxes,
conduits, switch boards cables, etc., shall be
considered.
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No.
 Adequate nos. of 5/15A switch, sockets inside
the control room and 240V/24V receptacles.
 Power supply for ACVS in the control room
shall be drawn from the 100A triple pole
MCCB installed in the MCC.
 Panels/ boards as per requirement
 Emergency light for MCC room and control
room and critical areas of new Boiler complex
with wiring and LED lamp fittings fed from
UPS power supply
 Aviation lights for boiler chimney
19. WDB and repair and welding network for Lot
complete new boiler area
20. Earthing and lightning protection for boiler area Lot
Earthing ring and lightning protection system
complete with earthing pits, GI strips, air
termination rod, etc., shall be considered
separately for the substation room, control room,
boiler area and nearby premises. These separate
earth rings shall be interconnected and shall be
connected to the earth ring main of the plant
area. Earthing shall be as per IS 3043: 2018 and
lightning protections as per IEC 62305: 2010.
Separate earthing shall be provided for
electronic equipment.
21. Cables and Cabling Lot
Supply, laying and termination of all power &
control cables (interfacing, interlocking,
signalling, annunciation, metering, lighting etc.)
required for the package. Cable laying and cable
rack/ trays, structure etc, supply of cabling
accessories like cable glands, cable lugs, number
ferrules, junction boxes, pull boxes, cable jointing
kits and termination kits as per requirement shall
be considered.

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No.
22. Cabling accessories Lot
Laying, dressing, termination of all LT and HT
power, control and other special cables including
preparation of route, cable racks, cable trays, GI
pipes, conduits etc. as required. Crossing of
road/rail shall be done through PCC encased
Hume pipes.
All Cable trays shall be GI type.
23. 11 kV (UE) grade HT cables Lot
Supply, laying, jointing, termination of all 11kV
(UE) grade, XLPE insulated, round armoured,
FRLS outer sheathed aluminium cables.
24. LT Power, 1.1 kV grade armoured PVC insulated, Lot
FRLS and PVC outer sheathed with Aluminium
conductor & control cables shall be 1.1 kV grade
armoured, PVC insulated and FRLS outer
sheathed with multi core 2.5 mm sq. copper
conductor.
Output cable from VFD drive to motor shall be
copper cable.
25. Necessary erection material for electrical Lot
equipment, panels, cabling, lighting and earthing
like cable trays, GI conduits, M.S angles,
channels, flats, clamps, hangers, supporting
brackets, cable lugs, ferrules, glands, GI wire,
chequered plates, nuts, bolts, washers and all
related items
26. High mast towers and illumination 2 sets
i. 30 m height high mast lighting towers for
illumination of area including its civil foundation,
along with light fitting carriage, carriage raising
& lowering mechanism, luminaries carriage
suitable to install 16 no’s LED flood light
luminaries in symmetrical arrangement, lighting
cables from SDB to various light fittings,
lightning protection system & aviation light

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No.
fitting, switch socket outlet etc. Power supply to
high mast to be provide through new SDBs.
ii. Supply of approx. 240W-350W (35000 lumen
min.) LED floodlight luminaries with electronic
driver and all other associated hardware for
mounting on lantern carriage.
iii. LED type twin unit aviation light fitting including
accessories complete in all respect including
mounting brackets, cabling etc.
iv. Lightning arrestor to be installed at the top of
the 30 metre height high mast lighting towers
with down comer GI strip up to dedicated
earthing station complete in all respect including
mounting brackets etc. Each lightning arrestor
shall have dedicated earth pit.
v. Supply of outdoor type free standing SDB with IP
65 protection and canopy arrangement. It shall
have 4P MCCB incomer, SP MCB as outgoing,
single dial digital time switch, 4P contactor for
automatic switching of luminaries, power tool
control with 2 no. contactors and raise lower
push button, forward reverse indicator LED type
for winch operation, auto-manual-off three
position selection, including interlock of motor
with luminaries so that during maintenance or
motor operation luminaries power should be off,
incoming 25 sq. mm.
Location: Near each of the proposed high mast
lighting towers.
27. Miscellaneous items for safety: Lot
a. Insulated PVC rubber mats for lying in front of
new electrical panels.
b. Danger boards and shock treatment charts at
appropriate locations in English, Hindi and
local language.
c. Fire extinguishers suitable for general and
electrical fires as required.
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No.
d. Portable emergency light set in the control
room and LT room.
e. Status of transformers, PCC incomers and VFD
drives to be interface at existing ECR (OPP)
through HMI based mimic.
28. Testing instruments like Meggar, digital 1 set
multimeter
29. Furniture comprising of cabinet, chairs & table Lot
required for installation of PC, Monitor & Printer
2.4.1 The scope of work mentioned in this chapter is a broad one but details
mentioned elsewhere in this document shall also form a part of total
scope of work.
2.4.2 The quantities of equipment, cables, cable terminations, straight
through joints, cable supporting structures, earthing and erection
materials, shall be as per actual requirement in accordance with the
approved detail engineering drawings.
2.4.3 The contractor shall arrange for all statutory clearance from Govt.
Authorities/CEA etc. for obtaining necessary charging clearance of the
Electrical installation including Substation.
2.4.4 There are underground HT power cables which are running within the
space of 12 meters area from the edge of the power street towards
construction side. Contractor shall finalize the layout keeping this aside
from the construction area so that the same is not damaged.
2.4.5 Proposed SLD of HT & LT power supply network for new boiler is shown
in Drawing No. CET RN 4086 EE1 00 001.
2.4.6 Tentative list of Recommended spares for two years normal
operation for Electrical items
Sl. Equipment
No. Description Item Qty.
1. Transformer HV Bushing 1 No.
2. LV Bushing 1 No.
3. 11 kV breaker Spring charging
motor 1 No.
4. Closing coil 2 No.
5. Tripping coil 2 No.
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6. Service cum
Limit switch 2 No.
7. 2 set of each
Indicating lamp type
8. 5 % of each
type/with
minimum one
no. of each
type(whichever
MPCB/MCCB is more)
9. 5 % of each
type/with
minimum one
no. of each
type(whichever
Contactor is more)
LT MCC/PDB
10. 2 nos. of each
PB status type
11. Control selector 1 set of each
switches type
12. Indicating 2 set of each
lamps type
13. Ammeter 1 No.
14. Voltmeter 1 No.
15. 1 no. of each
Auxiliary relay type
16. 2 set of each
LED bulb type
2.5 PROCESS CONTROL AND AUTOMATION
2.5.1 The scope of work for Instrumentation & Process Automation System
shall be complete with:
1) Programmable Logic Control (PLC) system with Input / Output
cards, dual redundant CPU, dual redundant power supply units,
redundant communication Bus along with Operator stations – 5
nos., Engineering station - 1 no, Historian PC- 1no and Laptop
based programming tool, peripherals, communication interface

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(hardware cum software) for PLCs of auxiliary packages. I/O racks
shall have hot redundant power supply.
2) The main PLC system shall have OPC features and shall able to
broadcast certain tags to the ERP for data exchange. Boiler data
shall also be transmitted to MIS and ERP server. Requisite firewall
and network cables up to the respective switches of DSP shall be
considered.
3) Boiler shall be provided with flame sensors / scanners and burner
management system for safe operation. The burner management
function and other safety interlocks shall be configured in the
separate redundant PLC system having Non SIL-III functionality
IOs. Dynamic mimics shall be provided on LED display panel for
boiler and auxiliaries.
4) Field instruments shall comprise of latest generation smart
transmitters, pneumatically actuated control valves with
positioners and position transmitters, Steam & Water analysis
system, Continuous Emission Monitoring System (CEMS) etc.
5) All PLCs, control room equipment, instruments etc. shall fed from
UPS power (under the electrical scope).
6) Standalone PID controllers as backup for critical closed loop
parameters and paperless recorders to monitor and record main
boiler process parameters shall be provided for critical loops for
any unforeseen situation in PLC. Dedicated redundant Non SIL- III
type of PLC shall be acceptable for BMS.
7) Annunciator with hooter shall be considered for all critical
process parameters.
8) 10 numbers of signals from existing control room shall be
hooked up with PLC. Supply, erection and commissioning of all
necessary cabling and signal isolators shall be in the scope of
contractor.
9) All new cables laid will be through new cable trays on existing
structures of client.
10) Existing energy signals like steam flow & pressure, gas flow &
pressure, etc. (total 15 nos.) shall be connected to the new
system from the existing system at Gas control station. Supply,
erection and commissioning of all necessary cabling and signal
isolators shall be in the scope of contractor.

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11) OPC server software along with connection up to the area switch
of DSP LAN switches shall be considered. Contractor along with
DSP will ensure that data shall be received at MIS server/P
system.
12) Continuous Emission Monitoring Systems (CEMS) for Particulate
Matter (PM), SOx, NOx, CO, flow, pressure and temperature shall
be provided at the chimney and online data of the same shall be
transmitted to CPCB and SPCB servers with display at ECD.
Necessary communication cables, hardware and interfacing
software shall also be provided to fetch data in existing server of
ECD and further this server shall be used for data transmission to
CPCB server. Contractor along with DSP shall ensure that data
shall be received at CPCB and SPCB servers.
13) Instrument panels, electrical equipment panels, transmitter
cabinets, field termination racks, auxiliary racks for housing
various instrumentation equipment completely wired as per
requirement, junction boxes, mounting accessories, electrical and
mechanical accessories like terminal blocks, terminal units, panel
illumination equipment including lamps, panel exhaust fans, door
switches etc.
14) Supply laying and termination of all cables. The Contractor shall
include in his scope, any excavation work required for laying of
cables etc. All cables shall be of heat resistant, FRLS grade.
15) FO Cable shall be single mode type only and FO cables
/communication cable shall be laid inside GI Conduits.
16) Power and control cables, compensating cables for
thermocouples, special cables as required, cable laying
accessories like trays, G.I. protection pipes, supporting structures,
clamps and other cable laying accessories, identification ferrules
etc. For all high temperature area, heat resistant cables shall be
provided.
17) Independent earthing system complete with earth pits, earth bus
etc. suitable for electronic earthing. The electrical and electronic
earthing shall be separate.
18) Intelligent type fire detection and alarm system for all fire
sensitive areas including rooms with electrical / instrumentation
equipment, cable gallery, control room and other fire sensitive
areas.

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19) PA System comprising of desktop stations and wall hanging units
with cabling and battery back-up (1 station in control room + 6
stations in field)
20) Ambient CO Detection System comprising of minimum 8 nos. of
fixed detectors with display electronics and alarm interface to
PLC and C& IT server through plant network and 8 nos. of
portable detectors.
21) Extension of plant’s existing EPBAX system to telephone points in
control room and electrical rooms (with requisite cabling) and
telephone sets (6 nos.) for Control Room, Boiler area, Electrical
Rooms, Compressor House etc. along with interconnection cable
etc. for connectivity with plant exchange a 50 pair jelly filled
armoured telephone cable (approx. 700 m) shall be laid to SMS
substation from BF office and 20 pair jelly filled armoured
telephone cable (approx. 150 m) shall be laid from SMS
substation to the new gas fired boiler respectively. This scope
shall also include required JBs for termination at ends, cable
trays, tags, cable laying accessories etc.
22) DSP LAN facility shall be extended from BF/ CDI points through
optical fiber backbone and UTP / STP cables. Network
components like FO cable, UTP cables, LIU, patch cords, media
converters, network enclosures as required shall be in the scope
of work.
23) Furniture for control rooms like operator’s chairs (18 nos) and
office tables (6 nos.), HMI/ servers and peripheral’s consoles and
chairs, storage almirah (6 nos.).
24) In the central control room, a separate lockable glass enclosure
shall be considered for PLC and engineering station.
25) The central control room shall be so designed that 40% spare
space is available for future expansion / projects.
26) Special tools, tackles, testing instruments / test kits, calibration
equipment etc. Supply of one set of testing & calibration
equipment (measurement & simulation) for Pressure / dP / flow /
level transmitters (4-20 mA DC, 1-5 V dc), RTDs &
thermocouples, I/P converter, positioner etc.
27) System engineering, configuration complete with detailed
engineering, configuration complete with detailed engineering
drawing preparation and documentation.

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28) Control philosophy shall be provided by OEM of boiler with
respect to operation of the boiler in various modes including
emergency/ safe shutdown.
29) All primary sensors including flow elements, temperature sensors
etc. as per range / size / application complete with accessories
like matching flanges, carrier rings, thermo well, connection
assembly etc.
30) All transmitters including pressure, flow, temperature, level
transmitters, analysers and other field instruments complete with
all accessories like mounting accessories, three valve manifold,
isolating valves, terminal units etc.
31) Temperature transmitters shall be provided for all process
temperature measurements.
32) All converters, isolators, accessories etc.
33) Complete set of local gauges / field mounted indicators,
switches, signalizers as per process requirements.
34) Provision of access platforms with suitable approach for all field
instruments / sensors / tapping points etc. Cat ladder/ monkey
ladder is not acceptable.
35) Supply installation and mounting of all sensors, transmitters,
converters, secondary instruments, local gauges and other
equipment with proper fittings.
36) All the impulse lines shall be provided with root valves/ isolation
valves.
37) Supply and installation of impulse lines, fixing trays, Impulse
pipes, conduits, tag marks, root valves, isolating valves, unions,
erection hardware and nonstandard erection materials as
required.
38) Supply, erection and commissioning of all the sensors including
orifice plates and allied jobs like bolting, fixing, welding, gas
cutting and fixation of temporary platforms etc.
39) Control valves complete with process and companion flanges,
isolation valves, pneumatic actuators/ power cylinders,
conventional & traditional valve positioners, solenoid valves air
filter regulators, etc.
40) Compressed air and water line pipe shall be drawn to all
measurement points of steam, deaerator, feed water and PRDU
stations for purging requirements.
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41) The transmitters shall be separately mounted and not head
mounted.
42) All the transmitters shall be dual compartment type, one for field
inputs and the other for local digital indication with IP 65
protection.
43) For gas flow & pressure measurement, nitrogen with purge
rotameters shall be considered.
44) Impulse pipe entry to 3-valve manifold shall be horizontal in
nature. Vertical & bottom entry is not acceptable.
2.5.2 Electronic measurement and control system with pneumatically
actuated control valves shall be considered unless essentially desired by
the process / system / otherwise indicated specifically. For pneumatic
supply, compressed air at a pressure of 3-5 Kg/cm2 shall be made
available to the contractor within battery limit. Any further processing of
compressed air including pressure regulation, moisture trap, filtering as
well as distribution to individual instruments / control valves / actuators
/ positioner etc. shall be included in Contractor’s scope. For feedback
control loops, all valve position signals shall be transmitted to control
room with the help of encoder / capacitive type valve position
transmitters having current output (4-20 mA) and shall be connected to
PLC as analog input. Air receiver/ Buffer tank of suitable size shall be
considered under the scope of work.
2.5.3 List of important control and measurement parameters shall be as
follows:
The control & measurement parameter as per following is the minimum
requirement for boiler and auxiliaries. In case the Contractor feels that
some more instruments are required to fulfil various safety / control
requirements of the process as per their scheme, the same shall be
included in the scope of Contractor.
a) Control parameters:
1) Boiler control
2) De-aerator pressure and level control
3) Pressure & Temperature Controls in PRDS
4) Drum level control
5) Steam pressure and temperature control
6) Furnace draft control
7) Fuel / air ratio control
8) Primary / secondary air flow control

BOILER
9) Burner Management System with flame sensors / scanners
b) Measurement parameters:
1) Feed water header pressure
2) BFP suction & discharge pressure
3) Feed water flow
4) Drum Level measurement by electronic level indicator (2
nos)
5) Drum pressure
6) De-aerator level measurement by electronic level indicator
7) Feed water temperature before and after economizer
8) SWAS system for pH, conductivity and dissolved oxygen
9) SH steam temperature, pressure & flow
10) Saturated steam pressure & temperature measurement
11) Surge tank level measurement
12) Fuel gas pressure, flow & temperature
13) Air flow, pressure & temperature
14) Flue gas pressure & temperature at different locations
15) Percentage oxygen and CO measurement in flue gas
16) Compressed air flow, pressure and temperature
measurement shall be considered.
17) CEMS system for SOx, NOx, CO and dust concentration in
stack connectivity to SPCB, CPCB servers and plant server
as required.
c) RO Water System
1) RO water flow to storage tanks
2) RO water pH, conductivity & TDS at mixed bed outlet
3) Tank level measurements
4) Flow & pressure of RO water in header to boiler
5) Other instruments as per process requirement
2.6 STRUCTURAL
2.6.1 Scope of work
The scope of structural steel works shall consist of design, engineering,
preparation of GA, design & fabrication drawings, supply, fabrication,

BOILER
erection, painting, testing and commissioning of the following
structures:
1 New boiler house support structure including sheeting work,
handling and access facility as per technological requirement
2 New support structure for economizer including sheeting work,
platforms, handling and access facility as per technological
requirement
3 New air pre-heater support structure as per technological
requirement
4 New waste gas chimney with access ladder and platforms as per
technological requirement
5 New support structure for all gas, steam and other utility pipeline
along with maintenance platform and access facility as per
technological requirement.
6 Handling facility for FD and ID fans
7 Electrical cable gallery from new LT substation to boiler premises as
per requirement
8 Cable trench cover with chequered plate inside LT substation and
boiler area
9 Dismantling, Modification/ strengthening of existing / associated
pipe support structures as per requirement.
10 Any other work not specifically mentioned but required for
completeness of the job considering Technical/ Technological
aspects shall be included in the scope of work for the Contractor.
11 Painting of all technological and new as well as modified/
strengthened building structures will be as per the specifications
including supply of paint material.
2.6.2 Scope of Supply & Services
2.6.2.1 Before starting of design work, contractor shall prepare structural
design criteria and get it approved by the Employer. The design work
for structures shall be guided by the approved design criteria. This
should include the broad scheme/methodology/consideration to be
adopted for carrying out the total scope of work.
2.6.2.2 The contractor shall prepare all GA / Structural Design Drawings and
shall obtain Employer’s approval on them (after incorporating
Employer’s comments / observations if any). Design drawings shall be
submitted for approval while design calculation shall be under reference
BOILER
category. Quantity of structural work involved shall be indicated in
design drawings.
2.6.2.3 Structural analysis/design shall be carried out using STAADPRO
software. Softcopy of analysis of structures /design of structures to be
submitted along with load calculation. All loads applied on structural
frame work in STAADPRO input shall be clearly shown in load
calculation. Diagrams with dimension shall be used while preparing load
calculation.
2.6.2.4 Approval of the design drawings (on the basis of the design calculation)
means that they are checked for the general conformity with the
engineering requirement and applicable specifications covered in TS.
Contractor shall, however, remain fully responsible for the
completeness, adequacy, correctness of his design and successful
implementation and satisfactory running of the plant and structures
under his scope of work.
2.6.2.5 Contractor shall prepare fabrication drawings based on approved
structural GA/design drawings prior to start of actual fabrication.
Fabrication drawings along with BOQ shall be prepared in strict
adherence to the approved design drawings and shall be submitted as
“As built” drawings on completion of the erection work. These drawings
will be submitted for further reference only.
2.6.2.6 All necessary site measurements and study of available existing
drawings, if any, as may be required for developing the aforesaid design
and drawings shall also be deemed to be under the Scope of the
Contractor. The drawings of existing structures are to be collected from
DSP.
2.6.2.7 Contractor shall also prepare necessary fabrication drawings/sketches
for modification jobs, as may be necessary, as per site requirement and
take necessary clearance from Employer.
2.6.2.8 Site cleaning, preparation, transfer of benchmarks & geodetic lines,
checking & fixing, aligning of structures, final cleaning of site after
completion of the work shall be under the scope of the Contractor.
2.6.2.9 The Contractor shall use such items of steel as are made by Steel
Authority of India Limited (SAIL) and which are required for execution of
all civil and building structural work including sheeting, technological
structures, pipelines, etc. WPB and NPB sections, those are being
produced by SAIL, shall be used. In case of non-availability /non-
suitability of WPB or NPB sections, tapered rolled SAIL sections or built
up sections using SAIL steel shall be used. Such items of steel as are

BOILER
made by SAIL and required for the work shall be procured from SAIL-
Stockyards. To ensure availability of steel items required for
the Facilities, the Contractor has to give at least four (4) weeks
advance intimation of such requirement. In case SAIL steel is not
available within the said period, NOC shall be given by the Employer for
procurement of steel from other integrated steel producers.
2.6.2.10 Erection of fabricated structures (including tools, tackles, labour, cranes
handling equipment and any staging or false work required for
erection), alignment, levelling, fixing, bolting / welding, inspection and
testing of weld shall be under the scope of the Contractor.
2.6.2.11 Contractor shall paint all fabricated & erected structural steel work after
suitable surface preparation.
2.6.2.12 Dismantling, of existing steel structures as per technological necessity
and transportation / disposal of dismantled structures from the area to
the place earmarked by the Employer.
2.6.2.13 Before starting the structural work on the live / defunct gas lines,
necessary safety clearance shall be taken from plant energy
management, safety department and concerned shop of DSP.
2.6.2.14 Inspection, testing and commissioning of all steel structures.
2.6.2.15 The entire structural steel work covered under this package shall be
carried out on Turnkey Basis.
2.7 CIVIL
2.7.1 The major scope under civil engineering works are as follows:
1) Construction of RCC foundations for technological equipment
such as boiler, ID fans, FD fans, pipe supports, chimney, AVG filters,
pumps & dosing system equipment including inserts, bolts,
grouting etc. as per technological & system requirements
2) RCC foundation for structural steel shed of boiler house including
construction of RCC framed building with brick cladding wall for
compressor room, control room, office, toilets & its
interconnection with existing sewerage system & plumbing
system, RCC peripheral drain & its interconnection with existing
drain, all finishes, doors, windows & RCC floor with floor finish
over compacted boulder soling in shed, roof treatment, inserts,
bolts, grouting etc. as per technological & system requirement.

BOILER
3) Construction of RCC foundations & RCC floor for support structure
for economizer, air preheater including inserts, bolts, grouting etc.
as per technological requirements
4) Construction of electrical substation building in RCC framed
construction with brick cladding walls including equipment
foundation, roof treatment, cable trenches with cover, PCC apron,
RCC peripheral drain and its interconnection with existing drain, all
finishes, doors, windows, rolling shutters, RCC floor with floor
finish, inserts, bolts, grouting etc. as per technological & system
requirement.
5) Construction of RO water plant building in RCC framed
construction with brick cladding walls including foundation for
facilities, acid resistant ceramic tiles on RCC floors & dado, pipe
trenches, roof treatment, PCC apron, RCC peripheral drain and its
interconnection with existing drain, all finishes, doors, windows,
rolling shutters, inserts, bolts, grouting etc. as per technological &
system requirement.
6) Construction of pumphouse building in RCC framed construction
with brick cladding walls including equipment foundation, roof
treatment, PCC apron, RCC peripheral drain and its interconnection
with existing drain, all finishes, doors, windows, rolling shutters,
RCC floor with floor finish, inserts, bolts, grouting etc. as per
technological & system requirement.
7) Renovation of top tank of two tier overhead water tank & the
staging structures which broadly involves pressure grouting with
non-shrink polymeric waterproofing grouting compound after
fixing GI nozzles, dismantling / chipping & cleaning of damaged
RCC elements, correction of damaged reinforcement bars,
application of rust inhibitor, cleaning & application of epoxy based
bonding agent, repair of RCC elements with high strength
readymade mortar / epoxy compound as per the requirements
including painting, scaffolding, disposal of debris, cleaning, etc.
8) Construction of RCC foundations for structural steel shed for ID &
FD fan including RCC floors with floor finish over compacted
boulder soling, inserts, bolts, grouting etc. as per technological &
system requirement..
9) Construction of neutralization pit in RCC construction with acid
resistant ceramic tiles lining & hand rail as per technological
requirement.

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10) Construction of filtered water storage tank & RO water storage
tank including RCC foundations inserts, grouting etc. as per
technological & system requirement.
11) Rerouting of storm water line as per system requirement.
12) Construction of RCC foundations for 2-legged & 4-legged
structural steel trestles, saddle supports, outside cable trenches,
pipe trenches and other miscellaneous facilities including inserts,
bolts, grouting etc. as per technological & system requirement.
13) Construction of RCC foundations for industrial lift structures.
14) Dismantling of RCC, PCC, brickwork, etc. of existing redundant
structures and its disposal within all lead inside plant boundary..
15) Concrete road for approach to all the facilities as per serviceability
/ system / technological requirements and its interconnection with
existing plant road.
16) Hydrological study of area and developing scheme & design of
rain water harvesting system as per requirement and execution of
same at site.
17) Excavation, backfilling and associated civil works for laying of
process lines & industrial sewerage.
18) Enabling works such as bailing out of accumulated water,
temporary arrangement for stopping water including permanent
arrangement for underground cable tunnel connecting to existing
electrical substation, staging for repairing of tank, transportation
of debris & unusable material within lead of 13 km within plant
boundary.
2.7.2 Site preparation level, shall be under the scope of the contractor. Cost
towards the above, if any, shall be deemed to be included in the total
quoted price and no separate payment shall be made towards this.
2.7.3 The contractor shall visit the site and collect the first hand information
along with referring the available existing drawings for underground
and over ground services on its own from DSP before quoting. No
payment towards this on any account will be made by the Employer
after the award of work.
2.7.4 The scope of contractor also includes the use of MS irrecoverable
shuttering, wherever required due to technical/constructional
requirement and time schedule.
2.7.5 Hydrological survey shall be carried out through a third party, approved
by employer, for designing a suitable scheme for rain water harvesting.
The report of hydrological survey shall consist of field data, calculations
BOILER
along with recommendation & scheme and shall be submitted to
employer for reference.
2.7.6 The contractor shall also be responsible for co-ordination with other
agencies working for the successful and timely implementation of the
work.
2.7.7 The contractor shall abide by the safety rules, IE rules and all rules
imposed by State Government & Central Government as in force.
2.8 DRAWINGS AND TECHNICAL DOCUMENTS

2.8.1 Following drawings and documents are to be submitted by the
contractor within 30 days of effective date of contract.
1) List of drawings & documents
2) L-II network showing sequence of activities including shutdown
3) Layout of the complete system.
2.8.2 Following documents are to be submitted by the contractor within 60
days of effective date of contract.
1) Process & Instrumentation diagram.
2) Single line diagrams of HT & LT power supply, PCC, MCCs, PDB etc.
3) Sizing calculation for selection of drive motors, cable selection (HT
& LT), etc.
2.8.3 The following drawings / documents shall be submitted by the
contractor after placement of order:-
Discipline Description
Process and 1. General Layout, PFD and G.A. drawings of the
Technology complete system & equipment, Duct / pipe
route drawing including sections showing full
details along with bill of materials
2. Data sheet of boiler, pumps, fans, compressors
and other equipment
3. Design calculations for system, sizing, etc.
4. QAPs for equipment & system
6. Any other information required by the
Employer / Consultant
Utilities 1. Layout, GA, Design calculation & datasheets of
Air conditioning and ventilation system

BOILER
2. Layout, GA & Datasheet of fire-fighting
equipment
Electrical 1. Design calculations for the selection of all
electrical equipment and system.
2. Single line diagrams with ratings & three line
diagram with load details of HT & LT
distribution.
3. Guaranteed technical particulars/ Power &
control schematic diagrams/ datasheets/ GA/
of all equipment and components to be
supplied shall be furnished by the contractor
4. Foundation/ mounting detail, load data &
interfacing information of all equipment with
details of loading
5. Illumination & Earthing drawings
6. Cable Schedule & cable layout drawing
7. Bill of materials, location & technical
specification of items
8. Quality Assurance Plan (for all equipment and
discipline).
Process Control 1. Process & Instrumentation diagram.
and 2. Cable schedule
Automation 3. Power & Control Schematic Diagrams along
with interface drawings
4. Data sheet for individual instrumentation
equipment.
5. Loop schematic & wiring diagram
6. Power Supply distribution drawing
7. Cable schedule
8. Pipe schedule (For impulse pipes and
conduits).
9. Hook-up / external connection diagram.
10. Technical literature / manual for individual
instrumentation equipment
11. Design criteria and calculations for control
valves & flow elements
12. Detailed drawings of supplied equipment

BOILER
13. QAP for individual equipment
Structural 1. Design criteria and calculations
2. GA and design drgs
Civil 1. Design calculations
2. Loading drawings
3. General Layout & arrangement of the new
facilities / units
4. Excavation drawings
5. Architectural plan & sections.
6. Drawings for masonry work, flooring, floor
finishes, partitions
7. Shuttering drawings.
8. Reinforcement drawings
9. Comprehensive anchor bolt & insert plan and
details with bill of materials.
10. Bar bending schedule.
11. Underground / over ground storm water
drainage drawings for areas and buildings
within the battery limit.
12. Drawings for paved areas / roads
Manuals 1. Erection Manual
2. Operation Manual
3. Maintenance Manual
2.8.4 The drawings/ documents submitted after placement of order shall be

submitted for approval as per SBD Cl. No. 20.3. The drawings of sub-
suppliers shall be duly vetted and stamped by the principal contractor
before submission to employer.
2.8.5 Drawings shall be submitted in pre-decided and agreed sequence. In

order to expedite the approval of drawings, engineering meeting shall
be routinely held with the contractor at plant/ consultant’s location
every 2 to 4 weeks for clearing of drawings across the table and sorting
out issues, if any. These meetings are to be held during the entire
engineering phase of a project.

BOILER
2.8.6 Drawing / document submission methodology:
The contractor shall submit 2 hard copies of the drawing to the
consultant and 3 hard copies to the employer for approval in
accordance with SBD sub-clause 20.3.1 to 20.3.3. Within fourteen (14)
days after receipt by the Project Manager/Consultant of any drawing/
document, the comment of Consultant along with the comments from
the employer shall be incorporated in the hard copy and necessary
stamping shall be done by the consultant. Scanned copy of the
stamped drawing shall then be mailed to the contractor by the
consultant. Within seven (7) days after receipt of the scanned copy of
the drawing from consultant through e-mail, the contractor shall take
out 5 prints of the same and out of these, 4 hard copies shall be sent to
the employer and one hard copy shall be sent to the consultant.
In case, the drawing is not approved, the contractor shall prepare the
revised drawing, after suitably incorporating the comments given by
employer/ consultant, and submit the same for approval, in 2 hard
copies of the drawing to the consultant and 3 hard copies to the
employer for scrutiny within 10 days from the receipt of scanned copies
from the consultant. The above process shall be continued till the
drawing is approved.
After approval and stamping, the consultant shall send the scanned
copy of the approved drawing to the contractor by e-mail. Within seven
(7) days after receipt of the scanned copy of the drawing from
consultant through e-mail, the contractor shall take out 5 prints of the
same and out of these, 4 hard copies shall be sent to the employer and
1 hard copy shall be sent to the consultant.
In addition to the above, contractor shall also submit all the drawings in
soft format in suitable media for approval/ reference etc.
2.8.7 Format of contractor drawing list shall have minimum following fields:-
1) Sl. No.
2) Employer drawing No
3) Contractor drawing No
4) Name of consortium member
5) Area
6) Drawing/Document Name
7) Category (Approval/Reference)
8) Discipline
9) Stage (BE/DE)
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10) Schedule date of submission
11) Remarks
2.8.8 Drawing list shall be in excel format. Any additional field, if required,
shall be added after Column 11. In case the drawing has more than one
sheet, employer drawing shall include the sheet number as part of
drawing number.
2.8.9 Editable format soft copies (3 sets) on suitable media of all “As-Built”
drawings (full set of drawings as per the approved drawing list) and
manufacturing drawings of critical parts, spares and fast wearing parts
shall be supplied by the contractor.
2.8.10 In case the proposed plant uses any process, equipment or software
which is covered under any patent and SAIL / plant is required to have
the relevant user’s license for the same, the scope of work of this bid
shall include transferring such licenses to SAIL and indemnifying SAIL
against infringement of any intellectual property rights.
2.9 BATTERY LIMIT
Incoming
Utilities --
Make-up Piping shall be laid considering requirement for future 1
water no. similar capacity boiler.
system This shall be taken from existing DN 600 settled water
main of Water Management Department (WMD) at ‘L’
chamber of OPP coal yard. Distance 150 m (approx.).
Pressure 0.75 kgf/cm2 (g).
Alternate water line shall be laid from filtered make up
water line of OPP to proposed area. Distance 150 m
(approx.). Pressure – 2.0 kgf/cm2 (g).
Fire water From existing DN 200 fire water header at furnace street.
Pressure 9.0 kgf/cm2 (g). Approx distance -300m
BF Gas From the existing DN 2100 header with motorised
isolation valve. Pressure 250 to 450 mmWC, temperature
50oC. Approx distance - 150m.
Minimum gas pressures will be available near burner side
however contractor will design the burner considering
given range
CO Gas From the existing DN 700 header with motorised isolation

BOILER
valve. Pressure 200 to 300 mmWC, temperature 50oC.
Approx distance - 150m
Minimum gas pressures will be available near burner side
however contractor will design the burner considering
given range
Nitrogen Purging Nitrogen line shall be laid from the existing DN
100 nitrogen line going parallel to Furnace Street
Distance 200 m (approx.).
Purging Purging steam line shall be laid from the existing LP steam
Steam line from OPP to SMS VAD (to be rerouted under enabling
package)
Distance 200 m (approx.).
Pressure 12-13 kgf/cm2 (g).
Oxygen for DN50 Line shall be laid from the existing DN80 oxygen line
welding & to SMS (to be rerouted under enabling package)
service Distance 50 m (approx.). from site
purpose Pressure 16 kgf/cm2 (g).
Civil: From existing DN 150 drinking water header adjacent to
Drinking SMS.
water Distance 50 m (approx.). from site
Electrical Power source for the new facilities shall be taken from two
new VCB feeders of 1250 A ratings (that shall feed 11 kV
power to this new gas fired boiler).
11kV power supply of the new Boiler shall be tapped from
two adjacent bus-sections of OPP 11kV board at 33/11kV
substation under NPP Power Evacuation Scheme.
The middle bus-section has a spare panel for 11kV OPP
board at Evacuation Package S/Stn. Extension of bus for
bus-sections No. 1 & 3, shall be done under this project.
Bus-section No. 1 & 3 is fed from same NPP feeder while
the middle bus-section (No. 2) is fed from the second NPP
feeder, different bus section.
Thus one 11kV feeder for the new Boiler would be tapped
from the middle (No. 2) bus-section, while the other 11kV
feeder for the new Boiler shall be tapped from No. 3 bus-
section, i.e., the two feeders would be tapped from
adjacent bus-section. Hence, 11kV supply for the New
BOILER
Boiler will be tapped from adjacent bus-sections of 11kV
board of S/Stn under NPP Power Evacuation Scheme. For
this, bus will be extended in section 3 to provide feeder for
the same.
Any further voltage required shall be developed by the
contractor.
Outgoing
Utilities --
Main steam Steam pressure 35 kgf/cm2 (g)., temperature

413oC ± 5oC.
Existing header size – 2 nos. x DN 250.
The main steam line will be connected to
two main headers with motorised isolation
valves.
LP Steam from PRDU Steam pressure: 12-13 kgf/cm2 (g).

Existing header size – 1 no. x DN 200.
The LP steam line will be connected to the
header with isolation valve.
Blow down water & From proposed boiler area to existing GCP
Reject water thickener area.
Piping terminal points - New piperack to be installed from/till TOP as

per shown route in Contract with new trestles / supports in scope.
2.10 EMPLOYER’S OBLIGATION
Construction water and power shall be provided to the contractor as per
SBD Cl. No. 20.4.2 and 20.4.3.
Necessary shut down shall be provided for interconnection of utilities &
power.
2.11 TRAINING
The contractor shall make arrangement for training of employer’s and
consultant’s personnel in the area of design & engineering, operation &
maintenance of plant and equipment under the scope of work as below:
1. Training for PLC at manufacturer’s work (in India) for 18 mandays
(3person x 6 days).

BOILER
2) Onsite training for PLC & automation for 30 mandays and on special
instruments for 15 mandays.
3) Onsite training for 60 mandays on boiler operation and maintenance
(include training on Electrical Equipment like Transformer, VFD Drives
and Switchgears, PLC, etc)
2.12 HAZARD / RISK IDENTIFICATION

The contractor will identify any hazard / risks which may result in fatal
accidents / severe damage to human health and safety, damage to
equipment and material resulting in loss of time and having cost
implication. The contractor will carry out the above assessment and
formulate appropriate action plan to prevent such incidents. This action
plan shall be submitted to the Employer before start of the work.
2.13 SAFETY ASPECTS

Safety aspects as per following codes and standards shall be ensured
during commissioning and testing of the project:
 IPSS: 1-06-044-08 Code for practice of protocol for Shut down
work on fuel gas pipelines.
 IPSS: 1-11-001-98 Definitions of terms related to Safety.
 IPSS: 1-11-002-12 Safety procedures for oxygen, nitrogen,
acetylene and fuel gases (First Revision).
 IPSS: 1-11-005-14 Safety Procedure for working at heights by
contractor's workers (First Revision).
 IPSS: 1-11-020-15 Safety Procedure for Welding and Cutting.
 IPSS: 1-11-030-17 Safety Standard for Working on Gas Lines in
Steel Industry.
 IPSS: 1-11-31-17 Safety Guidelines for Demolition of Building and
Structure in Steel Industry.
 IPSS: 1-06-014-17 Code of practice for selection and laying of
moist fuel gas lines (third revision).
 Vent/Purge must be provided as per design.
 Necessary devices along with alarm facilities shall be provided to
detect CO gas leakage in enclosed areas (As applicable).

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3 TECHNICAL SPECIFICATION
3.1 GENERAL
3.1.1 Site Conditions
Durgapur Steel Plant (DSP) is located in West Bengal about 170 km from
Kolkata. It is well connected by both Railway and Road transport. It is
located adjacent to the G.T. Road (NH-2) and the nearest main Railway
station is Durgapur in Eastern Railway on the main track between
Howrah and Asansol. The Steel Plant is 12 km from Durgapur Railway
station.
3.1.2 Climatic Condition

1) Ambient temperature
i) Maximum : 50oC
ii) Minimum : 4oC
2) Relative Humidity
i) Maximum : 100 %
ii) Minimum : 25 %
Maximum temperature and maximum humidity do not occur
simultaneously
3.1.3 Basic System Design
3.1.3.1 For system design 65% RH at 50 oC shall be considered.
3.1.3.2 The fuel analysis for power plant design shall be as follows:
1) BF gas : Main fuel for the proposed boiler to be used for upto
100% load.
Typical BF Gas Composition
CO 24-26%
O2 0.2-0.3%
CO2 18-20%
H2 3-4%
N2 Rest
Avg. dust content 20 mg/Nm3
Avg. density 1.34 kg/Nm3

C.V. Range & Design 750 - 850
LCV- (kCal/Nm3) (For design purpose lower calorific value
of 750 kCal/Nm3 to be considered. Boiler
should be capable of handling the CV
fluctuations from 750-850 kCal/Nm3
2) Coke Oven Gas (COG) : Shall be used during start up as well as

provision for firing COG upto 10000 Nm3/h for normal operation
shall be provided.
Typical CO Gas Composition is as follows:
Chemical Analysis CO gas Composition by volume(%)
CO2 3.0
CO 8.6
H2 58.6
CH4 22.0
N2 4.8
O2 0.6
Content of impurities
(mg/Nm3)
NH3 200-600
Naphthalene 200-300
H2S 2000-2800
Tar Fog 3.0-5.0
Moisture (RH) Saturated
3
Density (kg/Nm ) 0.45-0.46
o
Avg. Gas Temp. ( C) 25 – 45
C.V. Range & Design 4000-4200
LCV- (kCal/Nm3) (For design purpose lower calorific
value of 4000 kCal/Nm3 to be
considered. Boiler should be capable of
handling the CV fluctuations from
4000-4200 kCal/Nm3)

3.1.3.3 The settled inlet water analysis for RO water plant design shall be as
follows:
Parameters Values
1. pH - 7.5
2. Conductivity - 359 micro S/cm
3. TDS - 215 mg/l
4. TSS - 15
5. Turbidity - 8.1 NTU
6. Total hardness - (as CaCO3) - 128 mg/l
7. Calcium Hardness - (as CaCO3) - 78 mg/l
8. Magnesium Hardness - (as CaCO3) - 50 mg/l
9. M-Alkalinity - (as CaCO3) - 132 mg/l
10. Fe - 0.07 mg/l
11. Dissolved Oxygen - 7.2 mg/l
12. COD< 80 ppm & BOD < 30 ppm in feed water
Water parameters is for direct settled water/river water. No clarifier is in
this circuit
3.1.3.4 Hazardous area classification for COG & BFG lines. - Gas lines Safety
Zone may be considered as per applicable TAC norms & Indian
Industrial practices. Contractor to decide the hazardous area
requirement based on fuel.
3.2 PROCESS AND TECHNOLOGY
3.2.1 Boiler & Auxiliaries
3.2.2.1 Operating Parameters
Maximum 100 tph.

continuous output at
the MSV outlet
Rated steam 36 kgf/cm2 (g) at the MSV outlet
pressure
Superheated steam 413oC ± 5oC at the MSV outlet
temperature
Range of overload Boiler shall be designed to operate 30
over which the SH minutes continuously at 110% MCR per
temperature would shift.
remain constant
Boiler Efficiency Minimum guaranteed value > 85%.
Performance test Boiler performance test code shall be ASME
and performance PTC 4, Energy balance method, 2013
calculation edition. PTC 4. 1 - Indirect abbreviated heat
loss method has been replaced by PTC 4
Energy balance method.
Efficiency calculation shall be as per ASME
PTC 4, Indirect abbreviated heat loss
method.
Main steam pressure (36 kg/cm2g) &
temperature (413 degC) shall be maintained
at main steam stop valve outlet in boiler
area.
Performance test To be done at ambient condition of 30oC
condition and 65% RH
3.2.2.2 Boiler shall be field mounted, natural circulation, balanced draft design
as per IBR. Boilers shall be designed for full load with BF gas firing. Coke
oven gas will be used as start-up fuel as well as back-up fuel. Design
provision shall be kept for consumption of around 7000-10000 Nm3/h
of COG during normal boiler operation.
3.2.2.3 Furnace
The boiler furnace shall be membrane wall construction. Peepholes,
access doors etc. shall be provided in the furnace side wall. The roof
tubes shall be suitably staggered to allow super heater coils to pass
through, however the superheater tube arrangement will be as per
contractor’s design. The headers shall be manufactured from seamless
pipes. The headers shall be provided with drain connections, air vent
connection and hand holes for inspection as required.
There shall be required nos. of burner (concentric for both BF gas & CO
gas).
Shall not have any direct flame impingement. Shall be provided with 2
nos. inspection door.
3.2.2.4 Drum
Shall be fusion-welded construction with semi-ellipsoidal dished ends.
The drum dished ends shall be provided with properly sized manholes
and manhole covers. Shall be equipped with suitable internals like

baffles, separators, driers, scrubbers etc. Water entrained in the
outgoing steam at any load shall be negligible. Provision shall be made
for installation of necessary instruments for drum.
3.2.2.5 Super-heater
Super-heater headers shall be designed and located outside the active
flue gas paths. The headers shall be provided with necessary drain
valves. Super-heater outlet headers shall have connections suitable for
welding to the main steam piping without imposing large moments on
the piping. Access facilities shall be provided to all parts of the
superheater and fitting for routine inspection, cleaning and
maintenance. Suitable inspection door shall be provided.
Adequate margin in thickness of superheater tubes shall be provided on
account of corrosion/ erosion not less than 1 mm. Material of both
primary and secondary super-heaters shall be SA 213 T11 (seamless).
Super heater tubes shall be as per design of Contractor.
3.2.2.6 Attemperator
Spray type attemperator located between primary & secondary super-
heaters shall be provided for regulating the temperature of super-
heated steam. Water for cooling shall be taken from Boiler feed system.
The attemperators shall be capable of maintaining any selected value of
steam temperature in the range  5oC between 50% and 110% of Boiler
MCR.
3.2.2.7 Economiser
Shall be complete with distribution header, feed piping from
distributing header to the inlet headers, inter-connections of
economizer with the drum and all required mountings and fittings such
as drains, vents, washing connections and instrument connections.
Shall be made of steel tubes preferably with continuous loops. The
tubes shall be welded by means of stubs to the inlet and outlet headers.
They shall be made in suitable blocks, each block complete with all
spacers and support for facility of erection at site.
Shall be provided with arrangement for internal inspection, cleaning and
means of draining.
Shall be made of seamless steel tubes with continuous loops. Suitable
design in tubes thickness shall be kept for corrosion / erosion allowance
not less than 1 mm. Tube material shall be ASTM 211 or SA 210 Gr A-1.

3.2.2.8 Air Preheater
Shall be of tubular type. The construction shall be such that no leakage
occurs between the gas and airsides. The outer casing shall not be less
than 5 mm thick steel. It shall be adequately reinforced and stiffened to
resist buckling under all explosions and implosions. The access doors
shall be air tight and of hinged type.
3.2.2.9 Soot Blower
As the boiler will be gas fired, soot blowing system is not required.
3.2.2.10 Boiler Casing
The boiler outer wall shall be as per OEM design (membrane type
construction). Over this there will be insulation alongwith Aluminum
cladding of 20 SWG.
Shall be designed for ensuring permanent and efficient air seal,
adequately reinforced and stiffened to resist buckling under all
conditions of operation including internal explosions.
The access doors provided shall be airtight and shall be hinged type.
Observation doors shall be provided in the furnaces to facilitate study of
the burner performance.
All doors in hot locations shall be lined with firebrick mixture. Provision
shall be made in the casing for insertion of draft gauges, if necessary for
tests.
3.2.2.11 Integral Piping and Fittings
1) Complete feed water piping, steam piping, blow down piping, all
vent and drain piping etc.
2) Various isolating, control, by-pass, non-return, safety, drain & vent
valves required for proper and efficient operation of the boiler and
for compliance with applicable boiler regulation.
3) 2 nos. PRDU (1w+1s) with suitable capacity and pressure for
meeting internal steam requirement of boiler.
4) 2 nos. PRDU (1w+1s) of 5 tph capacity at 12-13 kgf/cm2(g) for
meeting steam requirement of VAD.
5) All blow down and drain outlets on the boiler pressure parts shall
be equipped with at least two isolation valves in series.
3.2.2.12 Supporting Structures, Platforms & Walkways
1) All necessary structural steel work required to support the boiler,
its accessories and auxiliaries. This steel shall include column and
base plates, anchor bolts, girders, beams, hangers etc. Structural
steel of the boiler shall be so arranged that the temperature of the
steel does not exceed 60oC.
2) The boiler shall be provided with platforms and stairways needed
for access to all parts of the boiler during operation, inspection
and maintenance. Their arrangement shall provide free and quick
access to all-important parts of the boiler. Walkways and platforms
shall not be less than 1000 mm wide and staircase not less than
800 mm wide.
3.2.2.13 Safety Valves
The boiler shall be provided with adequate no. and size of drum and
super heater safety valves to ensure that when the valves are fully
opened the maximum evaporation of the Boiler can be fully discharged
without a pressure rise of more than 10% of the highest test pressure of
the Boiler.
3.2.2.14 BF gas and CO gas Firing System
The Boiler shall be equipped with BF gas and CO gas burning
equipment designed to facilitate running of Boiler. The igniter provided
shall be suitable to start up Boiler with CO gas. Burner provided will be
of dual fuel type capable of firing maximum of 100% on BF gas and on
CO gas. The burners provided will be complete with air register and
wind box. Burners will be designed for reliability, safety, ease of
operation, minimum maintenance with high efficiency. Burner shall be
provided with 2 nos. UV scanners for burners as per approved burner
vendor strategically located in the burner for enhanced flame safety.
Flame detector for burner shall also be provided.
Burner turndown ratio shall be 5:1.
Boiler will be capable of operating between 50% and 110% of Boiler
MCR with steam temperature range  5oC.
Specification of Encased Goggle valve
 Service : BF Gas
 Type : Slide plate type encased Goggle Valve
 Clamping & de- : Hydraulic Power Pack
clamping
 Plate travel : Motorised
 Design pressure & : 1.0 bar (g) and 150 0C
Temp.

 Leakage Rate : Zero leakage
 Pneumatic Test : 1.0 bar (g) [Body] and 0.4 bar (g) [seat]
Pressure
 Lubrication : Lubricating point to be provided
 Ends : Flanged as per ASME B 16.5, Class-150 or DIN
2501 PN6
MOC
 Body : MS (IS:2062-2011 E250B)
 Disc : MS (IS:2062-2011 E250B)
 Bellow Compensator : SS-304 ( minimum two plies, Ply thickness shall
not be less than 0.5mm each)
 Drive shaft : SS-410
 Seat Rings : MS (IS:2062-2011 E250B) + Hard Facing
 Gasket & Packing : Graphite/Silicone
 Gear Box : Manufacturer’s standard
 Hand Wheel : Carbon steel
 Companion Flanges : Carbon steel (IS:2062-2011 E250B)
 Other features : Valve shall be complete with limit switches
(2NO + 2NC) for Open & Close position
indication, hand wheel, SS-304 Bellow
compensator, companion flanges, nuts, bolts,
gaskets and supporting arrangement etc.
3.2.2.15 Draught Plant

1) 2 x 60% forced draught fan, 2 x 60% induced draught fan for
boiler. Fans shall be made of durable materials to minimize wear
and distortion during operation. ID fan impeller material shall be
of SAILMA. Fans shall have self-contained lubrication system.
2) The output capacity and the static head of the fans shall be so
selected as to be adequate for meeting the maximum
requirements during operation of the Boiler at MCR, and shall in
addition provide margins confirming to the test block using worst
fuel combination.
3) Test block factors are 20% on capacity and 25% on head for both
FD fans and for ID fans. All the fans shall have non-overloading
power BKW characteristics. For smooth control of fans output
Variable Frequency Drive (VFD) shall be provided.

4) In calculating the capacity of the ID fans margin of +12oC shall be
taken on the calculated gas temperature at MCR of Boiler with the
worst fuel combustion as specified. In case of FD fans the design
capacity shall be on the basis of ambient air temperature expected
to prevail in Boiler surroundings (min 50oC).
5) For ID fans tip velocity should be limited to 112 m/s.
6) Arrangement for handling of ID fan, FD fan etc. shall be provided
with required structural arrangement.
7) Broad technical specifications for FD/ ID Fans:
1. Quantity As indicated above.
2. Capacity Contractor to design
3. Static pressure at inlet Contractor to design
4. Type Double inlet, double width
/single inlet single width
construction, centrifugal type
with backward curved blades.
5. MOC of blades Suitable for the application
with wear resistant lining
(only for ID fan)
6. MOC of shaft EN-8, statically & dynamically
balanced, ultrasonically tested
7. Drive Direct with flexible coupling
with VFD drive arrangment
8. RPM (max.) 1000
For better efficiency, VFD
enabled FD fans with speed <
1500 rpm is acceptable
9. Inlet damper Motorised damper to be
provided
10. Fan & motor bearing temp. To be provided
scanners
11. Fan & motor vibration To be provided
monitors
12. Drain plug To be provided
13. Noise level Less than 85 dB (A) at 1 m

distance from source
14. Handling facility Manually operated monorail
beam with chain pulley block
of required capacity for fan &
motor to be provided.
3.2.2.16 Flue gas, air ducting system and dampers

1) All interconnecting ducting, isolating and regulating dampers,
expansion joints, by pass ducts, hangers, explosion dampers,
supports, flanges, gaskets, thermal insulation, access platforms,
required inspection holes with covers, ladders and staging for
maintenance inside the ducts etc.
2) Velocity of airflow and flue gases in ducts shall be limited to 16
m/s and 12-13 m/s respectively. Average Velocity of flue gases
through convection heating surface zones shall be 20 m/s.
3) The ducts shall be of welded plates. Thickness of air ducts and flue
gas ducts shall not be less than 5 mm and 6 mm respectively and
shall be adequately stiffened by means of rolled sections.
3.2.2.17 Blow down & Drainage system
Single atmospheric blow-down tank shall be provided with common
continuous blow down and intermittent blow down vessel adequately
sized. The flash steam from the blow down vessel shall be led to
atmosphere and the condensate shall be mixed with reject from RO
plant and cooled with makeup water and transferred to existing GCP
thickeners by 2 nos. (1w+1s) pumps and new piping on existing / new
trestles.
3.2.2.18 Sample Coolers
Sample coolers for main steam, saturated steam, drum water and feed
water lines shall be provided with valves and fittings.
3.2.2.19 HP dosing system
1) 2 nos. (1W+1S) high pressure, reciprocating type, adjustable
stroke, phosphate dosing pumps capable of handling tri-sodium
phosphate, hexameta phosphate or any other suitable chemical
solution into the boiler drum.
2) One storage tank of SS Construction and with motorized SS stirrer
shall be provided for holding the day’s requirement of chemical
solution assuming 2% concentration. Tank shall be fitted with level

glass gauge, vent and drain connection, level alarm for low level,
over-flow device, inlet water connection etc.
3) Material of all interconnecting tank, piping, measuring devices,
valves and fittings shall be SS304.
3.2.2.20 LP dosing system
1) 2 nos. (1W+1S) hydrazine dosing pumps, reciprocating type,
adjustable stroke.
2) One storage tank of SS construction and with motorized SS stirrer
shall be provided for meeting day’s requirement of chemical tank
shall be fitted with level glass gauge, vent and drain connection,
level alarm for low level, over-flow device, inlet water connection
etc.
3) Material of all interconnecting tank, piping, measuring devices,
valves and fittings shall be SS304
3.2.2.21 Deaerator with Storage Tank and surge Tank
1) 2 nos. (1w+1s) RO water make-up pumps with drives &
accessories and necessary piping and isolation valves for de-
aerator feeding shall be provided.
2) The de-aerator shall be mounted on de-aerator storage tank and
shall be capable of heating and de-aerating of condensate and
make-up water to a temperature decided by the contractor. The
oxygen content after de-aeration shall not exceed 0.007 ppm after
LP dosing.
3) Tray type design complete drain, vents, relief, isolating and by pass
valves and other fittings as required. The de-aerator shall operate
under constant pressure in spite of load variation on the Boiler.
4) The storage tank shall be of 15 minutes effective capacity
(Deaerator holdup time shall be 15min from normal water level to
low level trip) and completes with all fittings and mountings. The
water level in the de-aerator tank shall be controlled and
maintained at a height to suit the NPSH requirement of the Boiler
Feed Pumps.
Feed water temperature shall be 105 oC at deaerator outlet.
5) The contractor shall provide access ladder and platform from
bottom level of de-aerator. De-aerator and feed water storage
tank shall be insulated.

6) 1 no. surge tank shall be provided with MOC and all accessories
similar to de-aerator, if required technically.
3.2.2.22 Boiler Feed Pumps
1) 3 nos. boiler feed pumps (2w+1s) with drives & accessories, self-
contained lube-oil facilities, Auto re-circulation valves and
necessary isolation valves for boiler.
2) Pumps shall be of high efficiency, horizontal multi stage,
centrifugal type. The pump shall have slowly drooping head
characteristics from shut-off to operating point.
3) The design head of the pumps shall be fixed to deliver feed water
into the Boiler drum when the Boiler safety valves are just
simmering.
4) The casing, impellers, wearing rings etc. of the pumps is to be
consistent with good quality for the operating temperature and
pressure conditions. Casing material shall be SA-216 WCB and
impeller shall be CA6NM.
5) Automatic by pass arrangements to maintain minimum water
circulation shall be provided for each pump.
3.2.2.23 Chimney
1) Structural Chimney for the boiler shall be provided. Steel Chimney
shall be designed as per the provisions of IS: 6533 (Part 1&2) –
1989. Continuous CO, SOx, NOx and SPM monitoring instrument to
be provided and data to be displayed in the control room.
Chimney shall also have provision with proper approach for taking
sample of flue gas.
2) The height shall be as per pollution control norm. SOx, NOx
limitations shall be taken into account.
3) Chimney shall have sampling platform with spiral ladder access to
the same. 4 nos. holes of 4” dia. each at 90o apart are to be
provided at suitable height as per CPCB guidelines for manual
sampling.
4) All statutory requirements shall be taken care.

3.2.2.24 Statutory Norms and Standards
All necessary facilities shall be installed to limit the boiler outlet stack
emission to <30 mg/Nm3. Suitable online monitoring facility as per
CPCB norm shall be provided. <30mg/Nm3 value for emission stands for
SPM guarantee.
3.2.2 Makeup Water System
Make up water system shall be designed considering the requirement of
1 no. future boiler of same capacity.
3.2.2.1 Specification for major equipment of Makeup Water System
A) Electric motor operated pumps:
The selection of Pumps shall be carried out by the contractor
to suit the requirement of the system supplied by him.
Technical Specification shall be as per following table.
Parameters Industrial Water Sump Pumps
pumps
Type Horizontal Submersible
Centrifugal/ Centrifugal
Vertical Centrifugal
Quantity As per system As per system
requirement + one requirement +
stand-by in each one stand-by in
group each group
Casing CI (IS:210-2009, FG CI (IS:210-2009,
260) FG 260)
Impeller SS (ASTM A351, CF -Do-
8M)
Shaft SS (AISI-410) SS (AISI-410)
Bearing Heavy duty, Heavy duty,
antifriction deep antifriction deep
grooved, self- grooved, self-
aligning type ball aligning type
bearings. ball bearings.
Duty Continuous Intermittent
Temp. of As per design of As per design of
fluid (max.) the system the system

Parameters Industrial Water Sump Pumps
pumps
Code for IS-1520:1980/ API -
Pump
Pump Hydraulic Institute Hydraulic
Testing Institute
Standard
Testing As per Code As per Code
Pressure and
duration
Noise Level 85 dB at 1m 85 dB at 1m
distance distance
Vibration 75  (max.) 75  (max.)
Level
Seal Self-flushed gland Double, leak
pack seal proof,
mechanical seal
in oil chamber
Bearing life 50000 h (min.) 20000 h (min.)
Preferred 1450 rpm 1450 rpm
speed
Static & Rotating parts of all the pumps shall
Dynamic be statically & dynamically balanced.
balancing
Note : 1. The pump shall be complete with a plug for priming and air
cock for releasing entrapped air in the casing (wherever applicable).
B) Automatic Valve less Gravity Filters:
The selection and sizing of filters shall be carried out by the contractor
to suit the requirement of the system designed/ supplied by him.
Technical Specification shall be as per following table:-
1 Filter Type Automatic backwash valve less gravity

(AVG / VAG) type
2 Filter Capacity 150 m3/h (min) for total system
3 Minimum Quantity 1W + 1S

required
4 Surface filtration 10.0 m3/ m2/h (maximum)

velocity
6 Input Water Quality As provided in Clause No. 3.1.3.2
7 Outlet water TSS 5.0 ppm (maximum)

level
8 MOC & thickness Base plate – IS 2062:2011, 10 mm thk

(minimum) Shell – IS 2062:2011, 08 mm thk
Dish – IS 2062:2011, 08 mm thk
Strainer – Polypropylene
9 Others Standard accessories, instrumentations,
maintenance approach & safety
components including facility for manual
backwash
10 Design Codes & Designed generally as per IS 803:1976.

Standards Backwash interval – 24 hrs (minimum)
Filter media shall be graded sand and gravel of approved size and
quality. The filter body will be fabricated from Tubular section/ plate
conforming to IS 2062: 2011. Inside surface of filter shall be Tar-Epoxy
based anticorrosive paint. Contractor shall provide flanged nozzles for
connecting various fittings. Instruments shall be provided as per
approved drawings. Inspection manhole of adequate size, tray for inlet
water distribution and collector system for filtered water shall be
provided. Empty space below the filtered water collector shall be filled
with concrete.
3.2.3 RO Water Plant
The proposed RO water plant shall consist of pre-treatment section,
storage & pumping facilities for RO water and neutralisation system. A
three-stream RO water plant with each stream having minimum capacity
of 60 m3/h to meet the makeup water requirement of proposed boiler
shall be provided. The plant shall be fully automatic and shall be
capable to be operated without human intervention. Considering the
makeup water quality necessity of filters, no. of treatment stages etc.
shall be decided. Necessary monitoring and control instruments for
automatic operation shall be provided.
3.2.3.1 Technical specification of RO water plant:
1 No. of stream : 03 nos.
2 Function : To generate RO water as per
reqd. quality
3 RO water quality : Contractor to specify (as per
boiler feed requirement)
4 Supply : Continuous
5 Regeneration cycle : Contractor to specify
6 RO water piping : Stainless steel - SS–316
The plant shall be equipped with all facilities (including electrical,
instrumentation and handling) for producing required quality of RO
water.
3.2.3.2 Design Basis
Input water quality for RO water plant design is given in Clause No.
3.1.3.3. The treated water quality shall be as per requirement of Boiler
manufacturer.
3.2.3.3 Operating Philosophy of Automatic RO Water Plant
The proposed RO water plant shall be required to meet the makeup and
first fill RO water requirement for the proposed boiler. RO water plant
shall be automatically operated through PLC.
Regeneration/Backwash/cleaning shall be done by the respective end
product of the unit for the pre-planned duration. Human intervention
shall be limited to ensure timely refill of various chemical dosing tanks.
All filters, RO water storage tank and chemical tanks shall be
construction of suitable materials and fitted with corrosion resistant
internals.
All chemical dosing tanks shall be of high-density polyethylene
(MSRL/HDPE) construction.
The capacity/ size of RO unit, all filters, all pumps, agitators, air blower,
measuring tanks, piping and valves shall be as per the calculation/
engineering of Contractor and approved by Employer/ Consultant.
3.2.3.4 Specification for major equipment of RO Water System
A) Electric motor operated Pumps
The selection of Pumps shall be carried out by the contractor
to suit the requirement of the system supplied by him.
Technical Specification shall be as per following table.

Parameters RO water Pumps Industrial Water Sump Pumps
pumps
Type Horizontal Horizontal Submersible
Centrifugal axially Centrifugal/ Centrifugal
Split volute casing Vertical Centrifugal
Quantity As per system As per system As per system
requirement + requirement + one requirement +
one stand-by in stand-by in each one stand-by in
each group group each group
Casing SS 316 CI (IS:210-2009, FG CI (IS:210-2009,
260) FG 260)
Impeller SS (ASTM A351, CF SS(ASTM A351, CF -Do-
8M) 8M)
Shaft SS (AISI-410) SS (AISI-410) SS (AISI-410)
Bearing Heavy duty, Heavy duty, Heavy duty,
antifriction deep antifriction deep antifriction deep
grooved, self- grooved, self- grooved, self-
aligning type ball aligning type ball aligning type
bearings. bearings. ball bearings.
Duty Continuous Continuous Intermittent
Temp. of As per design of As per design of As per design of
fluid (max.) the system the system the system
Code for IS-1520: 1980/ IS-1520:1980/ API -

Pump API
Pump Hydraulic Institute Hydraulic Institute Hydraulic
Testing Institute
Standard
Testing As per code As per Code As per Code
Pressure and
duration
Noise Level 85 dB at 1m 85 dB at 1m 85 dB at 1m
distance distance distance
Vibration 75  (max.) 75  (max.) 75  (max.)
Level
Seal Mechanical Self-flushed gland Double, leak
proof,
Parameters RO water Pumps Industrial Water Sump Pumps
pumps
pack seal mechanical seal
in oil chamber
Bearing life 50000 h (min.) 50000 h (min.) 20000 h (min.)
Preferred 1450 rpm 1450 rpm 1450 rpm
speed
Static & Rotating parts of all the pumps shall be statically &
Dynamic dynamically balanced.
balancing
Note: 1. The pump shall be complete with a plug for priming and air
cock for releasing entrapped air in the casing (wherever applicable)
3.2.4 Compressed Air System
3.2.4.1 General
2 nos. air compressors shall be provided each capable of delivering total
air requirement for the boiler for instrument air as well as service air.
The minimum discharge capacity of each compressor will be 2.5
Nm3/min at operating pressure of 6-7 kg/cm2 (g)
Instrument quality air shall be dry, oil free, with dust content <5 micron
and dew point – 40oC. Heatless regenerative 2 nos. (1W+1S) driers shall
be installed for supplying instrument grade air.
3.2.4.2 Compressor
1) Air compressor shall be screw type. Design code shall be IS
12258:1987.
2) Compressor shall be provided with suction air filter with silencer,
inter cooler (if required), after cooler, moisture separator, air dryer
etc.
3) Tests shall be carried out as per manufacturers standard /
applicable codes such as IS 11780:1986.
3.2.4.3 Air Drier
1. Type Heatless
2. Inlet Air Temperature 45oC (max.) *
3. Working Pressure 7 kg/cm2(g) *
4. Quantity 1W+1S
5. Atmospheric Dew Point -40 oC
6. Pressure Dew point -22 oC
7. Allowable pressure drop Contractor to design
8. Purge Loss Contractor to design
9. Standard Accessories Pre Filter for oil removal & After
Filter for desiccant dust removal
with auto drain system
3.2.4.4 Air Receiver
1) 2 nos. air receiver of minimum capacity 2 m3 each for service air
and instrument quality air complete with accessories like safety
valve, vent valve, drain valve, inlet & outlet opening complete with
matching flanges, gaskets, bolts & nuts, and inspection door. The
capacity & other design features of air receiver shall confirm to IS
7938:1976.
2) Major parameters of air receiver shall be as follows:
Parameters Description
Type Vertical, self-supporting, cylindrical in
welded construction
Capacity Minimum capacity 2 m3 each
Operating Pressure To be decided based on discharge
pressure of Compressor
Nozzles and accessories Inlet & outlet connections with
of Air Receiver companion flanges, drain, vent, manhole,
safety plug, pressure gauge, lifting lug
etc. as per provisions of IS – 7938, 1976
Material of Construction IS2002 Gr–2A / SA 516 Gr70
Design, Manufacturing IS 2825: 1969/IS 7938 : 1976
Testing Code
3) Air receiver shall be provided with necessary pressure system
monitoring and control to achieve capacity regulation of the air
compressors. Provision of bypass valve and auto condensate trap is
optional as per requirement of the project
3.2.5 Piping, Valves & Fittings
3.2.5.1 General
1) The piping supplied shall include all piping required for the boiler
viz. main steam, auxiliary steam, feed water, condensate, drains,
vents etc. of the main principle thermal scheme and process steam
line and other ancillary systems of chemical injection, make-up
water, Compressed air and Instrument air, etc. Sizing shall be done
as per good engineering practice.

2) The making of pipe bends, the preparation of edges of welding etc.
shall be prefabricated in the shop before transporting to the site.
3) Welded joints shall be of the butt type for the major runs of piping
and socket type for the smaller one.
4) Hydrostatic testing in fabrication shop shall be carried for all pipe
and fabricated assemblies as per QAP and test reports shall be
furnished.
5) Full radiographic examinations and testing shall be done on welds
in all the steam pipes and boiler feed piping in accordance with
approved standards / regulations. Test certificates shall be
furnished as evidence of such testing and Employer’s
representatives shall be allowed to witness such test, if desired.
6) All hangers, supports, restraints, guides, stops and anchors and all
supplementary supporting steel required for the proper support of
all piping systems shall be supplied. The contractor shall analyse
the piping for flexibility and location of suitable anchors and stops,
calculate all loads and deflections and design all supports guides,
restraints and anchors provided constant or variable supports type
hangers as required.
7) Flexibility and stress analysis calculations shall be done to
determine forces and moments at all terminal points, maximum
stress and deflection calculations in the high pressure and
temperature systems and all such calculations, studies and results
shall be submitted to the Employer’s for reference / comments.
Main steam pipeline will be designed according to the acceptable
forces and the moments. This however shall not relive the
contractors of the responsibility and obligation in this regard.
8) All the valves, expansion joints, all other fittings required for
complete plant system shall be provided. The design of the valves
with respect to the type, size, pressure class, material of
construction, actuation, testing etc. shall be most appropriate for
the specified duty and shall be selected as per good engineering
practice.
9) All fittings in the steam line shall be forged construction.
10) Valves of class 600 lbs. and above and of size of DN 200 and above
shall have by-pass valves. Valves in other services shall have by-
pass valves as per size and code requirement.

11) All control valves shall be provided with up and down stream
isolators and by-pass valves. The control valves shall be designed
for minimum pressure drop across the valve.
12) All valves in high-pressure line (more than 20 kg/cm2g) shall have
welded ends.
13) In case of screwed end valves for low pressure and smaller size, the
same shall have taper connections for leak proofness.
14) Motorized valves: Valves in main steam, process steam & auxiliary
steam lines, all high pressure (more than 10 kg/cm2 g) isolation,
critical operation, valves located in vulnerable position shall be
provided with motorized valves. All the motorized valves shall be
provided with manual operation facility also.
15) Valves packing material will be Grafoil/ metallic as per service
temperature.
3.2.5.2 Material Specifications:
1) Pipes
Main steam ASTM A 335 Gr. P11

Auxiliary steam ASTM A 106 Gr. B
Make-up water IS 3589:2001 - heavy
Feed water ASTM A 106 Gr. B
Chemical dosing ASTM A 312, Gr. 304 / 304 L
Instrument air IS 1239 (Part-I), 2004 ERW, heavy
Service air IS 1239 (Part-I), 2004 ERW, heavy
Nitrogen ASTM A 106 Gr. B
BF Gas IS 3589:2001
CO Gas IS 3589:2001
2) Valves
Main steam Forging

Body – ASTM A 182, Gr. F11 with trim - ASTM A 182
Gr. F6a, Cl.2
Casting
Body - SA 217 WC6 with forged trim - ASTM A 182 Gr.
F6a, Cl.2

Auxiliary steam Forging
Body - ASTM A 105 / ASTM A 181 Gr. 60 with trim -
ASTM A 182 Gr. F6
Casting
Body - ASTM A 216, WCB with trim - ASTM A 182 Gr.
F6
Make-up water Forging
Body - ASTM A 105 (C-Si)
Casting
Body – ASTM A 216, WCB (C-Si) / CI, IS-210, Gr. 200 -
260.
Feed water Forging
Body - ASTM A 105 / ASTM A 181 Gr. 60 with trim -
ASTM A 182 Gr. F6
Casting
Body - ASTM A 216, WCB with trim - ASTM A 182 Gr.
F6
Chemical Forging
dosing Body & trim - ASTM A 182, Gr. 304 / 304 L
Casting
Body & trim - ASTM A 351, Gr. CF8M
Instrument air, Forging
Service air Body - ASTM A 105 (C-Si)
& Casting
Nitrogen Body – ASTM A 216, WCA (C-Si), WCB (C-Si). OR
Body - CI, IS-210, 2009
OR
Copper Alloys:
Body – Brass, DCB 2, IS-1264 / LTB 2, IS-318 as
applicable.

3) The Specification for Steam system shall be as follows:
S. No Description Size Standard/Specification

1 Pipe All sizes Seamless smooth bends as per article
Bends 361 of IBR
2 Tees All sizes BW seamless as per ANSI B.16.9

carbon steel to A-234 Gr WPB wall
thickness equal to pipe wall.
3 Reducers All sizes BW seamless reducers as per ANSI
B.16.9 carbon steel to A-234 Gr WPB.
4 Bolting All sizes Studs ASTM A 193 Gr B7 nuts ASTM
A 194 Gr 2H
5 Flanges All sizes Flanges made from carbon steel
plates to IS 2002: 2009. Gr. 2A and
drilled to Table H of Appendix E of
IBR
7 Isolation 40 & below Class 800 forged carbon steel gate
Valves (in valve body to ASTM A 182 Gr F6
feed water bolted bonnet outside screw and
line) yoke, rising stem, socket weld ends
to ANSI B16.11.
8 Isolation 50 & above Class 900 cast carbon steel gate valve
Valves (in body to ASTM A 216 Gr WCB,trim
feed water material to ASTM A 182 F6 bolted
line) bonnet outside screw and yoke,
rising stem, raised face flanged ends
to ANSI B16.5.
9 Throttling 40 & below Class 800 forged carbon steel globe
Valve valve body to ASTM A 105,trim
material to ASTM A 182 Gr F6 bolted
bonnet outside screwed yoke, rising
stem, socket welded ends to ANSI
B16.11.
10 Throttling 50 & above Class 300 cast steel globe valve body
Valve to ASTM A 216 Gr WCB,trim material
to ASTM A 182 F6 bolted bonnet
outside screw and yoke, rising stem,
raised face flanged ends to ANSI

S. No Description Size Standard/Specification
1 Pipe All sizes Seamless smooth bends as per article
Bends 361 of IBR
B16.5.
11 Non-return (in 40 & below Class 800 forged carbon steel lift
feed water check valve body and cap material
line) to ASTM A 105, trim material to
ASTM A 182 Gr F6 bolted cap,
socket welded ends to ANSI B16.11.
12 Non-return (in 50 & above Class 900 cast carbon steel swing
feed water check valve, body and cap material
line) to ASTM A 234 Gr WPA,trim material
to ASTM A 182 F6 bolted cap,
flanged ends with raised face
flanged ends to ANSI B16.5.
13 Strainer Upto 50 'Y' type strainer with cast
steel/stainless steel body with
brass/stainless steel filter.
14 Steam Trap For sizes for pipeline condensate drain-
NB15, 20 and Thermodynamics traps with inbuilt
25 strainers. Body of stainless steel. For
large oil or liquid storage tank
heating coils and heat exchangers
inverter open bucket trap body of
cast iron/cast steel internals.
4) Thermal insulation
Weather proof insulation shall be applied to piping, valves, vessels, heat
exchanges etc. to keep the surface temperature to 55oC maximum after
completion of satisfactory hydraulic / pneumatic test. All insulating
material, fixing cladding and protection shall be new and best of their
quality. Insulation materials shall be non-corrosive to the surface
insulated, fire proof, free from asbestos, starch etc. The insulation
materials shall be machine made resin bonded mattresses confirming to
IS: 8183 1993.
The insulation materials shall be rockwool of density 120 kg/m3 with GI
binding wire as per IS: 9842, 1994 machine made resin bonded
mattresses confirming to IS: 8183, 1993. The amount of resin in the rock
wool shall be 1 to 3 by weight as may be required for ideal and
adequate bindings.
Dry insulation shall be applied on metal surface free from dirt, oil, loose
scale etc. The insulation joint shall be stitched with 22 SWG soft
galvanized iron wire. The mattresses shall be further secured with 20
SWG GI wires tied, circumferentially at interval of 250 mm.
The insulation shall be applied in multi layers with joints staggered
when thickness is more than 75 mm. 0.8 mm. Aluminum jacketing shall
be as per IS 737:2008 overlapped by minimum 50 mm. Longitudinal
joints shall be staggered & avoided on top of pipe.
12 mm wide stainless steel bands shall be placed circumferentially at
250 mm centres to prevent slipping.
Insulation applied on flanges, valves shall be done in two halves for
quick removal and fixing without damage to the insulation.
In case of multiplayer insulation, all longitudinal and circumferential
joints shall be staggered to avoid direct heat transfer paths.
Valves, fittings shall be insulated with removable lined covers. Covers
shall comprise of two sections from plain aluminium alloy sheeting 1.2
mm thick and lined with the same insulation materials and thickness as
adjacent pipes.
3.2.5.3 Technical Condition for Erection of Valves
Before erection of valves, contractor shall ensure that:
All grit and foreign materials are removed from the inside of the valves.
All machined faces are thoroughly cleaned and coated with a thin layer
of mineral grease before erection.
Installation of valve shall be carried out as per drawing. Clearance
between the top of stuffing box and underside of gland shall be uniform
on all the sides.
Gland shall not be tightened hard. Hemp packing shall be adequately
soaked in grease and shall not be allowed to remain dry (except valves
for oxygen service).
The valves shall be tightly closed when being installed, as this keeps the
valve rigid and prevents any foreign material from getting in between
the working parts of the valves.
While installing flanged valves, diametrically opposite nuts shall be
tightened slowly and proper care shall be taken to tighten them
alternately. The practice of fully tightening the nuts one after another is
not permitted.
After installation of the valves, the pipeline shall be flushed with water/
compressed air/ nitrogen, as the case may be, to remove any foreign
material that may be present in them. If any leak is detected at the
valve-seat, the same shall be examined and rectified by scrapping or
replacing wherever necessary.
All valves shall be operated a few times to check free movement and
operation of various limit switches/ inter locks.
3.2.5.4 Erection, Testing and Commissioning of Pipelines
All pipelines shall be laid by the Contractor as per detailed drawings and
instruction to be given by the Employer. The interfacing and joining of
the proposed pipeline with the existing pipeline/equipment /facility are
in the scope of work. Following technical condition apply for erection,
testing and commissioning of all pipe work:
1. Mitre fittings and shaped parts shall be fabricated from the pipes of
same specifications as that of pipes. All bends will be provided with
bend radius of 1.5d unless specified otherwise in detailed
engineering drawing.
2. Before erection, pipes, valves, fittings etc. shall be thoroughly cleaned
and scales, rust, dirt, oil, grease etc. shall be completely removed
from inside as well as outside. The Contractor shall provide all
cleaning materials required for this purpose.
3. Contacting surfaces of flanges shall be strictly perpendicular to pipes
and shaped parts axes. Insertion of gaskets of unusual thickness shall
not be allowed.
4. In case of pipes running horizontally, all the flanges and flanged
fittings, etc. shall be installed in such a way that top bolt holes are
displaced by half pitch from the vertical axis.
5. Flanges shall be fabricated from steel plates and shall be machined.
Un machined flanges shall not be used.
Rotary flanges shall freely rotate without any jamming and closely fit
with flange rings.
6. While laying several pipelines parallel to each other, flanged joints
shall be staggered suitably.
7. Gasket materials and dimensions shall conform to the instructions
given in the relevant working / erection drawings, unless specified
otherwise.
8. Slope of pipelines, drainage, vents, and arrangement of pipe-
connections for inlet and outlet of various services etc. shall be in
conformity with the drawings.

9. Valves with spindles, location of that is not provided in the erection
drawings shall be installed in such a way as to ensure easy access
from the ground level or nearest working platform.
3.2.5.5 Joining
All pipes shall be butt-welded, socket welded, flanged or other type of
joints as specified in detailed engineering drawings.
Construction materials of flanges for pipelines shall conform to the
standards indicated in the drawings.
For mitre bends on the pipelines, welded butts shall be located at a
distance equal to the pipelines' diameters but not less than 100 mm
from the beginning of the curve.
Tapping and re-tapping of pipeline threads shall be carried out wherever
necessary.
3.2.5.6 Welding
General welding shall confirm to IS 816:1969, IS 9595:1996. However,
the followings are to be followed.
Assembly of elements shall be carried out with devices that ensure
correct mutual location of such elements. Assembled elements are kept
fixed during welding by the use of suitable clamps.
Clamps shall not be considered as secondary butt elements. They shall
be made, if possible, by the same welders who weld butt joints or by
welders of the same skill. Electrodes and welding wires shall also be of
the same quality as used for butt-welding.
Pipeline welding shall be carried out by using horizontal, vertical or
overhead welding positions.
As a rule, butt-welding shall be carried out without interruptions. No
interruption shall be allowed until at least 50% of welding thickness is
completed.
If there is an unscheduled interruption in such work, it is necessary to
ensure slow and uniform cooling of material by covering it with asbestos
or other similar material for eliminating the possibility of sharp zone
cooling of metal. Before starting the welding work again, it is necessary
to heat the butt weld up to required temperature and maintain this
temperature until the end of welding.
Welding of flanges, tees and other shaped parts to pipes shall be carried
out under the same conditions as specified for welding of pipes.
Following material shall be used for welding of steel pipelines.
a) For gas welding – welding wire as per IS 1278:1972.
b) For arc welding – Electrode as per IS 814:2004.
Welding Quality
All field welding of carbon steel shall be executed by qualified welders
using standard welding procedure.
a) Besides systematic operational control in the process of pipeline
erection, the quality of welded joints shall also be checked by visual
inspection and non-destructive testing.
b) All the welded joints shall be subjected to visual inspection with the
aim of detecting the following possible defects.
Cracks that come out on the joint surface of base metal located in
the zone of thermal influence of welding.
Weld fuses or cuts in spots where joint passes over the parent
metal.
Sponginess and porosity of the other surface of the joint.
Irregular width and height of a joint and its possible deviation from
axis.
Deviation from joint-dimensions shown in the drawing or in the
specification.
c) Defective spots found by such visual inspection shall be chipped off
and re-welded.
d) Non-destructive test shall be carried out by radiographic method
as specified elsewhere in the TS.
3.2.5.7 Erection of Underground Pipelines
i) Pipes shall be laid 2m (top of pipe) below ground level (+0.00).
ii) Unless otherwise specified in the layout drawings, laying of
pipelines shall be as per IS: 5822: 1994.
ii) Buried steel pipes shall be wrapped with protective wrappings as
per IS 10221:2008. The anticorrosive protection of pipelines shall
consists of the application of one coat of tar primer (cold),
application of one flood coat of coal tar enamel, one wrap of fibre
glass resin polyester tissue, impregnated with coal tar enamel
confirming to IS : 7193 -1994, application of final coat of a water
resistant white wash. The total thickness of the complete coating
shall not be less than 4.5 mm.
iii) All wrapped pipe shall be carefully handled at all times with
equipment such as wide belt slings and wide padded skids,
designed to prevent damage to the wrapping. The underside of the
pipe should be inspected while lowering and any damage shall be
repaired before the wrapped pipe is laid in position. All wrapped

pipes shall be tested by flaw detector for any insulation damage
prior to erection.
iv) 100 mm thick sand cushion shall be provided under pipes upto DN
300 and 150 mm thick under pipes above DN 300.
v) Back filling of trenches shall be carried out with the excavated earth
in layers of 150 mm thoroughly watered and compacted. Earth used
for backfilling shall not have any hard pieces of debris like stone,
brick or metal.
vi) Hume pipe class NP3 of suitable size or as shown in detailed
engineering drawing should be provided as casing pipe for each
pipeline crossing the road and hume pipe class NP4 should be used
for pipeline under railway tracks.
3.2.5.8 Inspection, Testing and Acceptance of Pipelines
i) General
a) Manufactured / Fabricated pipelines/ducts or details shall be
presented for acceptance in unpainted and non-insulated state.
b) Testing of pipelines and ducts shall be carried out in presence of
the Employer.
c) Prior to testing, pipes shall be cleaned up by metal swab in order
to remove the grit, sand and other solids deposited on the inner
pipe surfaces followed by blowing air through pipes.
ii) Acceptance:
Acceptance shall be carried out as follows
a) Documentary checking of the materials according to the drawings
/ specifications / contract.
b) Checking of documents attesting the satisfactory results of
mechanical tests.
c) Visual examination of the welding quality and checking of the
result of radiographic tests (wherever carried out).
d) Checking of the dimensions and other technical details as per the
project drawings & specifications.
iii) Ultrasound Weld Test
a) Ultrasound test for 10% of butt welds of CO gas pipeline shall be
carried out.
iv) Unless otherwise specified in the working drawings, the hydrostatic
test pressure for water and slurry pipelines shall be as follows:
a) For working pressure up to 6 kg/cm2 test pressure shall be equal
to 1.5 times the working pressure, but not less than 2 kg/cm2.

b) For working pressure above 6 kg/cm2, test pressure shall be equal
to 1.25 times the working pressure.
c) Hydrostatic test pressure shall be maintained for 30 minutes. At
this pressure, the pipelines shall be inspected for leakage etc.
Welded joints shall be tapped by 1.5-kg hand hammer. Hydrostatic
test results are considered satisfactory, if during tests, manometric
pressure does not decrease and leakage or mist is not observed on
the welded joints, fittings, body etc.
d) The hydrostatic test shall be repeated after elimination of defects.
e) Hydrostatic tests of Steam Lines shall be carried out strictly in
accordance with IBR.
v) Pneumatic Test
All gas pipelines shall be tested with dry compressed air at a test
pressure of 1.5 times the designed pressure for duration of 2 hrs, if
not specified otherwise in the detailed drawings
vi) Retest
a) Should the result of random weld and leakage tests above,
indicate any doubt about the quality of weld, then additional tests
shall be conducted as per the instructions of Employer.
b) Defective spots on welded joints shall be chipped off and re-
welded. Caulking is not allowed for repairing leaky spot in welded
joints. Any other defects including leakage in connections shall be
eliminated. After rectification the joint will be retested.
vii) Special Requirements of Testing
a) The Contractor shall furnish the result of all ultrasound test for all
the pipelines to the Employer along with the certificates of
acceptance / approval of the experts who conducted the tests. All
the testing materials and equipment shall be provided by
Contractor and a set of drawings/ schemes duly identifying the
joint locations shall be maintained. All costs to this account shall
be borne by the Contractor.
b) Equipment shall be disconnected before the test. Combined test of
the pipelines with equipment is not allowed.
c) Details in which same defects are found during repeated tests
(after rectification) shall be rejected and replaced by new ones. The
hydrostatic test shall be conducted again in such cases.
d) Representatives of the Employer and the erecting Contractor shall
make a statement regarding the pipeline acceptance mentioning
defects found during tests, nature of the defects and method of

their elimination. Pipelines shall be identified in the statement as
per the project drawings.
3.2.5.9 Painting
i) After testing and acceptance all the outside surfaces of M.S.
pipes, fittings and ducts including supports shall be cleared of
loose substance and foreign material i.e. dirt, rust, oil, grease, slag
etc. so that primer coat adheres to the original metal surface.
Thereafter Red Oxide Zinc Chromate as per IS 2074:1992 shall be
applied in two coats and dry final paint with synthetic enamel of
approved quality shall be applied in two coats with dry film
thickness of each coat of 50 micron.
ii) The scheme for painting shall be submitted by the Contractor for
the approval of the Employer.
iii) The painting shall be done in accordance with manufacturer’s
recommendations in respect of application of primer and/ or
paints with the approval of the Employer.
iv) Paint may be applied by brush. Spray painting is however
preferred.
v) For paints, which dry by chemical reaction, the temperature
requirements specified by the manufacturer shall be met with.
vi) Paint shall not be applied in rain, wind, and fog and when the
surface temperature is below 10oC resulting in condensation of
moisture.
vii) Each coat of paint shall be continuous, free of pores and of even
film thickness.
After satisfactory erection and commissioning, all spots on the pipelines,
ducts, supply structural or equipment where the painting is damaged
during commissioning shall be touched up with same type of primer /
finish paint as that already used.
3.2.6 Electric Hoist
Broad technical specification of the electric hoists shall be as follows:
Sl. Nomenclature Description
No.
1) Location At suitable locations as per clause
2.2.7
2) Purpose Maintenance job
3) Type Motorised, trolley suspended type

Sl. Nomenclature Description
No.
4) Capacity As per Requirement (20% margin
over the heaviest weight of the
equipment/ component handled).
However minimum capacity of the
electrical hoist will be 2t
5) Lift (m) As per Requirement
6) Hoisting speed (m/min) As per Requirement
7) Travel speed (m/min) As per Requirement
8) Hoisting and travel All motorised
9) Duty class II as per IS 3938:1983
10) Monorail for hoist Suitable for electric hoist along with
festoon cable arrangement, pendant
push button station
11) General The design and constructional
requirements of major components
like load chain, hook, gear, trolley
wheel, all structural components,
lubrication and bearings, load
brakes, safety devices and
clearances etc. shall be as per the
relevant standards.
The lift and travel length of the
hoists shall be suitable for handling
equipment from the floor level.
i) The hoists shall have dc electro-magnetic brakes.
ii) The control panel and brake panel of the hoists shall be separately
mounted on structures and shall not be mounted on the hoist.
iii) The hoist shall have trailing cable arrangement for power supply.
iv) The hoist shall have provision of maintenance platforms and
necessary structural arrangement.
v) The motors offered for hoist shall be standard frame motors only.

3.2.7 Goods cum Passenger Lift
3.2.7.1 Design Basis of Elevator
Sl. Parameters Design Basis
No
i. Goods-cum-passenger IS 14665 (Part 1 to 5) : 2000 or reputed
elevator codes BS, DIN, JIS or equivalent is also
accepted
Rugged design and shall incorporate all
necessary provision for the safety of
operating and maintenance personnel.
ii. Design lifting capacity 1.2 x Rated Lifting capacity
for motor sizing.
However minimum
motor power shall be as
follows;
(a) 1t capacity 11 kW
iii. Gearbox rating (kW) =1.6 x Selected motor kW
iv. High speed coupling =(Selected motor kW *1.36*1.5) / (motor
(kW/rpm) rpm)
v. Low speed coupling =(Selected motor kW *1.36*1.5) / (motor

(kW/100rpm) rpm / reduction ratio)
vi. Braking Torque (DCEM = (Selected motor kW *1.36 * 1.5*4500*10)
type) N.m / (2*3.14*Motor RPM)
(Heavy duty hoist brake)
vii. Rope IS 2365:1917
Hoisting rope diameter(min): 13 mm
Governor rope diameter(min):8 mm
Safety factor (min): 8
3.2.7.2 Brief description of Goods cum passenger elevator is as below:
Sl. No. Parameters Brief Description
i. Capacity (t) 1.0
ii. Quantity (Nos.) 01

iii. Location At boiler house to facilitate movement of man
& material to various floor levels and shall
operate from lower most level to top most
level
iv. Total lift (m) As per requirement. Till boiler top platform.
v. Height of upper stop As per requirement
(m)
vi. No. of Stoppages / As per requirement at all working platform
landings
vii. Motor power (min.) 11
kW
viii. Gearbox 1.6 x Selected motor power
ix. Speed (m/sec) 0.5
(Approx.)
x. Cabin size (min) As per IS 14665 (Part-1 to 5)
(Inside) - mm wide *
mm deep * mm high
xi. Door size (min) (mm x As per IS 14665 (Part-1 to 5)
mm)
xii. Lift well (shaft) size As per IS 14665 (Part-1 to 5)

(inside)- mm wide *
mm deep
xiii. Lift pit required (mm) As per IS 14665 (Part-1 to 5)
(Finished clear after
plaster).
xiv. Overhead (mm) As per IS 14665 (Part-1 to 5)
xv. Duty Continuous 24 hrs per day, 7days/week

xvi. Entrance One side
xvii. Operation Automatic Push Button Operation from
Outside and Inside with direction and parking
indication on all Push Button Stations
xviii. Cabin Frame Design The cabin frame structure shall be
manufactured to resist all static and dynamic
loading
xix. Bed platform Designed and fabricated as per ISI
specifications. Anti-vibration frame, Isolation
Pads and Rubberized metal framing ensures no
vibrations.
xx. Cabin Floor MS heavy duty platform with non-slip type
chequered plate
xxi. Cabin enclosure SS hairline featured having thickness 18 gauge
(minimum)
xxii. Cabin and landing Motorised, auto open/close, auto centre
doors horizontal bi-parting door with electrical safety
interlock & mechanical locking device
xxiii. Door Safety Landing doors shall prevent the lift from
starting unless they are fully shut. Once the
lift leaves a particular floor, that door cannot
be opened.
Electro mechanical Limit safety shall be
installed inside the cabin
xxiv. Cabin Control Designed with stainless steel switches for all
stations, Emergency Alarm, Light, Fan with auto
sleep arrangement, Emergency Stop Switch
with clock
xxv. Machine room size & As per IS & shall be at the top of the lift shaft
location
xxvi. Motor Squirrel Cage TEFC, VVVF Drive, Duty S4, 60%
CDF, 150 starts/hr, Insulation Class F
xxvii. Coupling & Shaft As per requirement
xxviii. Brake DCEM Shoe type
xxix. Gearbox As per requirement
xxx. Wire ropes As per requirement
xxxi. Guide Rail Heavy Duty Guide Rails are anchored on the
sidewalls with the help of guide brackets as per
site requirements. 2 Nos. Guide Rails each are
provided for the cabin

xxxii. Electrical Panel Housed in a dust proof cabinet is
Microprocessor Based Programmable
Controller
xxxiii. Other Panel  Phase Reversal Prevention Relay.
Accessories  Incoming MCB.
 Microprocessor based Programmable
Controller.
 Transformer.
 Thermal over Load Relay
xxxiv. Safety Apparatus  Locking Device and electrical interlock on all
Landing Doors and Electrical Interlock on
Cabin Door.
 Final overshoot limit switches are provided
beyond the top and bottom landing levels.
 Terminal Limit Switch on top landing.
Motor overload protection.
 Speed Governor for down speed monitoring
 Mechanical clutch safety activated by speed
governor
 Single Phase Prevention for Phase reversal
thru AC VVVF device
 Other safety features as per IS
xxxv. Painting As per manufacturer’s standard
3.2.7.3 Major Components of Elevator
i. Mechanical components such as rope, gearbox, brakes, sheaves
etc.
ii. Cabin
iii. Electrical and control equipment
iv. Drive station
v. Steel structure
vi. Guide rails
vii. Safety equipment
viii. Doors

ix. Counterweight over load protection
3.2.7.4 Rope
1) The cabin and the counter-weight shall be suspended by steel wire
ropes. The steel wire rope shall conform to IS 2365:1917.
2) The wire rope shall be steel core, right-hand-lay, best plow steel
with factor of safety not less than 8.
3) Governor ropes shall be 8 mm (minimum) and hoisting ropes shall
be 13mm diameter (minimum). Their ends shall be securely
attached to the car and to the safety gear. The governor ropes
shall be tensioned by a weight loaded device in the pit.
3.2.7.5 Drive System
1) Drive unit located in the machine room shall be complete with AC
squirrel cage induction motor, brakes, reduction gear, couplings,
rope sheaves, over-speed governor, VFD system, limit switches,
etc.
2) The drive system shall be designed to operate smoothly without
any tendency to rock or judder with no vertical, horizontal forces
as well as the moments through the track.
3) Motor: Elevator/ Hoist duty single speed squirrel cage induction
motor, having both end shaft extension of 11 KW (minimum)
rating shall be provided.
4) Gearbox: Elevator duty gear box and of base mounting type shall
be selected. However, gearless drive unit with complete system
can also be provided.
5) The rating for all other components shall be selected accordingly.
6) Limit switch - Ultimate top & ultimate bottom limit switches shall
be heavy duty type.
7) For manual operation of elevators, up & down direction of the
movement of the car shall be clearly marked on the motor or
traction machine. A warning plate in bold signal red colour to
switch off the mains supply before releasing the brake and
operating the wheel shall be prominently displayed.
3.2.7.6 Brake
1) Drive unit shall incorporate a DCEM brake and an external manual
brake release system. The brake on the electric motor shall be self-
adjusting type. In case of the power failure, the brake shall be
engaged automatically & shall stop the cab gradually.
2) The brake lever shall be of forged steel/ fabricated steel/ cast steel
construction. Hardness of brake drum shall be 300 to 350 BHN.
3) The brake shall be suitably curved and provided with fire proof
friction lining. The operation of brake shall be smooth, gradual and
with minimum noise.
4) The brake shall be designed to be of adequate size and strength to
stop and hold the car at rest with rated load. The brake shall be
capable of operation automatically by various safety devices,
current failure and by the normal stopping of the car.
5) The brake shall be released electrically. It shall also be possible to
release the brake manually so as to move the elevator car in short
stops.
6) Suitable brake release tools (total 3 nos.) shall be supplied and
stored in the machine rooms.
3.2.7.7 Sheaves
1) The sheaves shall be of cast steel or forged steel construction. All
rotating parts shall be statically and dynamically balanced.
2) The sheaves shall be easily accessible and removable from the
floor of the machine room. Proper maintenance facilities shall also
be provided.
3) The sheave shaft shall also be fitted with roller bearings to ensure
proper alignment. All shafts shall be provided with well-designed
keys. Adequate dust-proof lubrication shall be provided for all
bearings.
4) The drive sheave shall be designed with machined V-grooves to
ensure adequate traction with minimum wear on rope. All sheaves
including deflector sheaves shall conform to IS 14665 (Part 4)
Section-3.
3.2.7.8 Cabin
1) The car body shall be enclosed with walls on three sides and
motorised, auto open/ close, auto centre, horizontal bi-parting
door with electrical safety interlock & mechanical locking device
2) The cabin should be of SS sheet having thickness 18 gauge
minimum.
3) To prevent the doors from being opened while the cab is in
motion, the cab door and landing level enclosure doors shall be
electrically and mechanically interlocked so that they remain

closed and locked except when the cab is at that landing position
and also prevent the cab from being operated unless the cab door
and landing level enclosure doors are fully closed.
4) Cabin roof shall be provided with an escape hatch. Necessary
provision shall be made for adequate ventilation inside the car.
Tubular steel handrail shall enclose the cab roof for maintenance
operations.
5) Cabin roof shall have stainless steel panels with recessed
fluorescent lamps along with the fittings, noiseless cabin fans, and
battery operated emergency light, complete with battery & battery
charger. The cabin roof shall be designed to prevent entry of any
falling material/ dipping of lubricant inside the cabin.
6) The cabin floor/ platform shall be constructed of structural steel
and shall be designed on the basis of rated loads evenly
distributed on the floor/ platform.
7) Direction & position indicators shall be provided inside the cabin
and at all landings. Call registering type push buttons shall be
provided for all operation inside/ outside the cabin.
8) Cabin shall be equipped with emergency stop and alarm push
buttons. The emergency alarm bell system shall be battery
operated.
9) A stop switch in the machine room/ top of car shall be provided
for use by maintenance crew to cancel all car and landing calls for
a particular elevator.
10) Cabin shall also have facilities for intercom inside the car so as to
allow the passenger to communicate with the operator on the
ground level and machine room.
3.2.7.9 Over-Speed Governor
1) The overs-peed governor shall be located in an overhead
machine room and shall be provided for impeding elevator car
movement when a predetermined speed is exceeded
particularly during the cab downward motion.
2) Over-speed governors shall include a switch which opens when
the elevator reaches a predetermined over-speed such as 110%
of rated speed. When the switch opens, power supply shall be
stopped to the machine motor and brake. A mechanical braking
mechanism, actuated in response to movement of the elevator

car, shall impede the elevator car and stops the motion of the
cab gradually.
3) The switch shall remain open, the brake shall remain locked and
the elevator shall remain inoperable, until the switch is manually
re-set.
4) The over-speed governor shall be designed/ selected based on
the tripping speed, maximum brake force requirement, rope
tension, rope diameter etc.
3.2.7.10 Spring Buffers
1) Spring buffers shall be provided to stop the descending elevator
car or counterweight beyond its normal limit of travel. The
buffer shall be capable of stopping the fully loaded cab without
any permanent damage or deformation to themselves or any
other part of the equipment.
2) The number of buffers shall be fixed so as to ensure proper
sharing of impact loads by all of them. Minimum no. of buffers
shall be 2.
3) Buffers shall be mounted on RCC pedestal pit in the pit.
3.2.7.11 Counter weight & Guide rail
1) The elevator shall be suitably counter-balanced for smooth and
economical operation. Cast iron counter-weights shall be used.
2) Counter-weights shall be contained in a structural steel frame
properly guided with suitable guide shoes (minimum 4 Nos.). It
shall be equal to the total weight of elevator plus approx. 50%
of the contract load.
3) The guide rail shall be of heavy duty structural steel
construction.
4) Substantial expanded metal counter-weight screen guard shall
be furnished and installed at the bottom of hoist way, as
required by Elevator Inspector.
3.2.7.12 Lubrication
1) All moving part of the elevator shall be provided with proper
lubrication facilities.
2) All fittings and equipment necessary for lubrication shall be
provided.

3.2.7.13 Guides and Fastenings
1) Guide-rails for car and counterweight rails shall consist of
machined mild steel Tee sections, erected plumb, and securely
fastened to the elevator well framing by heavy steel brackets,
suitably spaced, to limit deflection of guide rails to 3 mm under
normal working conditions.
2) Guides shall be designed to withstand the action of safety gear
when stopping a counter weight or fully loaded car.
3) The guide-rails shall be with ends tongued and grooved, forming
matched joint and shall be connected with steel fish plates.
4) Guide-rails shall cover the full height of the hoist way and pit, such
that it shall be not be possible for any of the car or counter
weights shoes to run off the guides.
5) The max deviation from true plumb and alignment of guide rails
shall be 2 mm.
6) All support framing shall be rigid and shall be designed to
restrict displacement of the point of support of brackets to 2 mm
under normal working conditions.
7) The whole guide rail installation, including expansion joints, shall
be designed for a smooth ride.
8) Elevator shall be equipped with roller guides for up and down
travel. There shall not be any metal-to-metal contact between car
and rail. Roller shall be mounted on ball bearings to provide quiet
operation and excellent ride quality. (It is not required in case the
design varies however the ride quality shall not be compromised
for any other design).
9) The guide-rails shall be protected during storage and installation
with a rust inhibiting coating which shall be cleaned off on
completion of installation.
10) Guide-shoes shall be adjustable type & mounted so as to
provide continuous contact with guide rails under all conditions.
11) Guide shoes shall be provided at top and bottom of each side of
car and counterweight and shall be designed for quiet operation.
3.2.7.14 Safety
The elevator shall be equipped with all standard safety systems such as
Bell and cranking in case of power failure, emergency rescue battery
back-up, hand wheel connected with motor shaft for manual lowering

of elevator to the nearest landing level in case of power failure, limit
switches, indicators, over speed safety governor for cabin, emergency
light fittings, etc.
3.2.7.15 Mechanisms & Operations
a. VVVF Drive: Ensure low consumption of Electricity with jerk free
smooth
b. Over Speed Governor: Ensures the safety from free falling.
automatically
c. Door safety: All doors shall be locked mechanically and electrically
and doors shall function and open only when the cabin shall come
in front of commanded landing.
d. Overshooting protection: This safety ensures complete protection
of overshooting works as a final terminal protection only for last
top and last bottom landing floors.
e. Terminal Buffers: Maximum tension buffers (as per requirement)
shall be installed inside the pit, works when the cabin or the
counter weight exceeds from its final determined position.
f. Cabin and Landing Sill: Extruded Aluminium.
g. Pillars: Duly designed to sustain maximum jerk under all safety
factors.
3.2.7.16 Main Safety Features
1) Cabin shall automatically stop in case all the loading wires break
away at any stage.
2) Counter weight shall stop automatically through safety rope
(safety governor) at any stage if loading wires break away. The
counter weight shall rest over minimum 2 nos. of springs at the pit.
3) Extra rope shall be provided for safety. In case loading ropes break
away and the automatic mechanical break also fails, then the extra
wire/safety rope shall save the cabin from free fall on ground / top.
4) Counter weight and cabin shall operate/run in their respective
lines of steel structures bulb section guide rail.
5) If all the wires break away at any stage, the counter weight shall
also stop immediately hence passengers / material are safe.
6) The double size wire ropes having double in capacity against the
required capacity shall be provided to keep maximum safety.

7) Buffer springs shocker shall be provided in order to avoid jerks
while the elevator is in operation.
8) Automatic rescue device (ARD) shall be provided so as to enable
cabin to travel to nearest station in case of power failure.
9) Cabin shall automatically stop at the predetermined highest and
the lowest level without command through limits sensors.
10) Highest and lowest points shall be governed by photo sensors/
proximity sensors / laser sensors.
11) An emergency stop switch is provided inside the cabin.
12) An emergency speaker alarm is provided inside the cabin in case
of emergency.
13) Electric key lock is provided inside the cabin.
14) Cabin shall automatically stop in case of opening of cabin door at
any stage.
15) Unless the gates of the cabin are properly closed, the elevator shall
not function or shall not start moving for its other desired landing.
16) An extra limit sensor switch is provided in the machine unit & in
case all the safety features as enumerated herein above failed, the
said limit switch shall be adjusted at highest and lowest and stop
the machine at the predetermined highest/ lowest points.
17) The elevator shall not start travelling in case the overload system is
activated due to the overloading the material.
18) The elevator shall stop function if the cabin/ landing doors are not
closed.
3.2.7.17 Handling facility for elevator maintenance
i. Travelling type chain pulley block of capacity 2 ton (minimum)
for maintenance requirement of elevator. The equipment shall
be complete with all its accessories and attachments,
monorails, supporting structure, safety devices etc.

3.2.8 Oxygen Pipe Work
In general Oxygen pipeline shall be designed as per IPSS: 1-06-034-17
standards. Some provisions of the same are given below:
1. Design
1) Design velocity - 8 m/sec for carbon steel pipe.
2) Piping structure
A) The bending radius (R) of the bend shall be equal to or more
than five times the pipe diameter (D).
a) Pipes shall be bent by electric induction heating. Roundness of
pipe bends shall be as follows:
Roundness = (Max. inside diameter - Min. inside diameter)
< 0.01 x refer inside diameter
b) Welding of different types of metals in the field shall be
avoided.
B) Angle of flare of the reducer-l > 5 (D - d)
C) Branching angle at the branch point -Branch angle a < 600
D) The following measures shall be taken for the prevention of
combustion of piping and others.
a) 100% radiography of the weld shall be done.
b) Fire blocks shall be installed down stream of regulating valve.
c) The deoxidized copper pipe shall be joined at the shop to the
steel pipe by TIG welding using copper wire welding rod. The
copper pipe shall be preheated upto approx. 6000C before
welding.
E) In principle, pipe joints shall be made by welding.
F) Piping shall be constructed so as to minimize such portions
where gas stagnates.
G) To absorb expansion and contraction of piping due to
temperature changes, suitable measures shall be taken using
expansion joint or bend.
H) Piping shall be effectively earthed to prevent static electricity.
(Ground resistance : Lower than 100 ohms).and Flanges shall be
interconnected electrically.
I) The design pressure of piping shall be the maximum service
pressure of the system. In unavoidable cases, however, the
lower partial service pressure of the system may be used as the
design pressure. In such cases, however, provisions shall be
made so that any pressure exceeding the service pressure can
be immediately reduced to the service pressure or lower. For
this purpose, more than one of devices given below shall be
installed to prevent the pressure from rising above the service
pressure.
Safety valve
Relief valve
Automatic controller
J) In principle, strainers shall be installed in front of regulating
valves, etc. and the like where high-speed flow is produced
during the cold commissioning. The strainers shall be removed
before starting normal operation.
K) If abnormal temperature rise is expected, preventive measures
shall be taken.
L) Taps for instruments shall be of the boss type.
M) The piping system shall be designed so as not to produce
vibration. Piping supports shall be of rigid construction. Pipes
slope of 1:500 shall be maintained in the direction of flow.
N) Piping routes, etc.
a) As far as possible, piping shall not be laid where there is heavy
traffic, where there is electric wiring nearby, or where they have
to be buried.
b) No parts of piping shall be exposed to high temperatures.
O) Oxygen piping near electrical cables
In principle oxygen piping shall not be laid together with any
electrical cables. Oxygen piping near electrical cables shall be
avoided as far as possible. If necessary, observe the following:
a) For piping running over and in parallel with electrical cable, the
piping shall not be less than 1 meter away from the electrical
cables so that they do not make contact with each other.
b) For piping running under and in parallel with electrical cables
(for across the cable), a protective device shall be provided to
prevent the piping from making contact with the cable even if
the cable breaks.
3) Oil free
All components (piping, valves, instruments, packaging, etc.)
shall be completely free of oil or grease. All pipes for oxygen
service shall be pickled.
4) Strainers shall be of the Y-type in which the flow velocity is not
increased and the filter elements shall be selected not to be
broken due to clogging. The strainer body shall be of bronze
body and bronze/brass filtering elements.
5) Pressure gauges shall be of the oil-free bourbon type with a
scale which shows 1.5 to 2 times the service pressure.
6) The nominal pressure of the valves shall be 1.2 times higher
than the service pressure of the system.
5) Underground oxygen piping shall not be permitted in principle.
2. Materials
1) Piping
Only seamless pipes shall be used for oxygen service. Piping
materials for oxygen shall be in accordance with the following
ASTM specifications:
` Upto DN10 : Seamless tubes, deoxidised non arsenic
copper of suitable thickness (sch40 minm).
DN 15 and above :A106 Gr B/API 5L Gr.B. seamless;
schedule 40 or higher as per requirement.
2) Flanges
Size <40mm.- Class 600 socket weld raised face flanges to ANSI
B 16.5. Forged steel confirming to ASTM A 105.
Size > 50 - Class 600 weld neck raised face flanges to ANSI B
16.5. Forged steel to ASTM 105 with bore to suit pipe OD/C.S
raised face slip -on flanges to IS : 6392 made from plates to
IS:2002 Gr-A with bore to suit pipe OD.
3) Bends and fittings shall confirm to relevant ASTM/ANSI standard.
4) Fire blocks
The fire block shall be seamless deoxidized copper pipe to be
located inside steel pipe downstream of obstruction.(Length
shall be 550 mm or 5 X DN as per working drawing).
5) Valves
a) Valve materials shall conform to the table shown below.
Type Size Description
Isolation DN 50 and Class 800 HT brass/ Monel ball valve with
below Teflon packing with socket weld ends.
DN 65 and Class 300 or higher Monel ball valve with
above Teflon packing with flanged ends.
Throttling DN 50 and Class 800 Monel ball valve with Teflon

below packing socket weld ends.
DN 65 and Class 300 or higher Monel Ball valve,
above Teflon packing, flanged ends to ANSI B
16.5.
Non DN 40 and Class 600 or higher Monel, lift check valve.
Return below Teflon packing, socket weld ends to ANSI
Valve B 16.11
DN 50 and Class 300 swing check valve Monel, Teflon
above packing, flanged ends to ANSI B 16.5.
b) The seat surface of principal parts shall be subjected to stelliting.
c) Bolts and nuts
Stainless steel or materials of higher quality shall be used.
d) Gaskets
Packing to be used with flanges and the like shall be Vortex type
metallic packing (Teflon-impregnated packing with inner and outer
rings made of stainless steel). Inflammable materials shall not be
used.
3. Fabrication
Bends, branch pipe, welded pipe of a different material shall be
fabricated at shop. Bends shall be fabricated by electrical induction
heating and their inner curved surfaces shall be free from
corrugation.
 Welding
 Welders shall be qualified for the work to be done, in accordance
with relevant standards and Regulations.
 Welding procedure shall be shown in the documents and
drawings.
 Edge preparation of pipes shall be made, in general, by lathe in
the shop.
 Pipes to be connected shall, in principle, have the same inside
diameter.
 Pipe insides shall be thoroughly cleaned of foreign matter before
welding.
 In principle, pipes shall be butt welded, the first run should be by
argon gas seal welding and the second and succeeding runs by
electric arc welding.
 Sleeve welding joints may be applied to field welding.
 Preheating and stress-relief annealing shall be performed in
accordance with applicable standards, depending on the quality
and thickness of material.
 Fillet welding shall be limited to slip-on welding steel flanges. The
shape of groove and root gap of butt welding shall be designed
properly. Also, they shall be clearly stated on the piping work
drawings.
 Welding of joints having different thickness
 When members of different thickness are to be butt-welded, the
end of the thicker member shall be planned to the thickness of
the thinner member. When the offset due to the difference in
thickness exceeds 4 mm at the outside or 3 mm at the inside, the
gradient shall be 1/3 or less.
 Fillet welds shall have necessary throat thickness or leg length, as
well as proper shape.

4. Erection
1) Pipe to be connected at site shall be cleaned from scale, bead
dropping, iron powder, etc. by hammering, and then shall be
installed.
2) Valves shall be installed with proper direction of flow.
3) When connecting new pipe to existing pipe, the connection shall be
performed after removing scale, dust, etc., accumulated in the
existing pipe.
4) In principle, sizing by cutting or the like at site shall not be
performed. Piping shall be prefabricated beforehand.
5) When fabricated and installed pipes are to be s stored for a long
time before they are used, they shall, as a rule, be filled with dry, oil-
free nitrogen at a pressure of 0.1 kgf/cm2 G or more to prevent rust.
5. Cleaning
1) Cleaning before installation
 Before installation, the pipe inside shall be chemically cleaned
form oil and grease, paint, rust-preventive oil, mill scale, etc.
2) Pickling
a) The foreign matter shall be removed by pickling, consisting of
processes such as pickling, rinsing, neutralization, rinsing and drying.
b) For pickling, dilute hydrochloric acid (20 % v/v) shall generally be
used. Pickling shall be conducted at high temperatures or room
temperature.
c) Neutralization shall be done using a caustic soda solution after
pickling and rinsing. Then, rinsing and drying by steam flushing or
the like shall be performed to prevent rusting.
3) Degreasing
a) Carbon tetrachloride (Ccl4) or equivalent shall be used as a
degreasing agent. Since carbon tetrachloride is toxic, it shall be
handled with great cane.
b) Drying shall be performed to remove all trace of degreasing agent.
c) The degreasing agent to be used shall be pure and clean.
d) Piping shall be subjected to dip cleaning and shall be checked for
complete degreasing.
e) Valves shall be subjected to dip cleaning for degreasing before
shipment and installation.
4) The cleaned pipes and valves shall be capped to prevent entry of
foreign matter. If they are to be left for along time after cleaning, they shall
be filled with nitrogen gas to prevent re-oxidation.
5) Cleaning after installation

a) In principle, chemical cleaning shall not be performed after
installation.
b) Flushing shall be conducted as final cleaning for the safety of oxygen
piping. Its purpose is to remove oxidation film, iron powder, welding
bead droops and other foreign matter.
6) Source of flushing gas
a) For flushing, oil-free, dry inert gas shall be used.
b) The flushing gas shall be available in a sufficient quality.
7) Flushing system
a) Flushing of main piping and branch piping shall be conducted
separately. The gas shall be blown out to a safe outdoor place.
b) Flushing shall be performed after replacing the valves, strainers and
instruments of the systems with short pipes.
8) The Velocity of flushing gas shall be 30 m/sec or higher.
9) Flushing method
a) Flushing shall be performed by intermittent blowing in combination
with hammering. Hammering shall be applied mainly at welds and
bends.
b) Prior to the flushing by oil-free and dry inert gas, cleaning using a
scraper pig propelled by oil-free and dry inert gas shall be
performed.
c) If cleaning by pig is selected, the cleaning procedure and
characteristics of the pig shall be submitted. After cleaning by pig,
the flushing using a oil-free inert gas shall be performed. Hammering
shall be applied mainly at welds and necessary parts during cleaning
by pig and flashing.
6. Inspection and test:
The oxygen pipeline shall be tested as per IPSS-I-06-034-17.
1) Materials certificates shall be submitted and shall be inspected as per
local regulations.
2) Necessary mechanical test by the local regulations shall be performed.
3) Degreasing test
All piping systems for oxygen service except supports, brackets and
hangers shall meet the requirement of less than 100 mg/m2 of oil and
grease.
4) Welding test
Welds shall be examined by radiographic test in accordance with the
following standards.
IS : 4853:1982 Recommended practice for radiographic inspection of
fusion welded butt-joints in steel pipes.
The extent of radiography shall be as per respective standard.

5) Oxygen piping components such as valves, strainers, etc., shall be
examined by nondestructive test.
6) The pneumatic test instead of hydraulic test and air tightness test may be
performed using oil-free, dry inert gas
3.3 UTILITIES
3.3.1 Split Type Air Conditioning System

3.3.1.1 The general specification of air-cooled split type ACs is as follows:
Sl. Premises Type of AC system Inside Condition to be

No. Guaranteed by the
Contractor
1. Boiler cum RO water Hi wall mounted type, Temp: 23oC +2oC
plant Control Room split air-conditioner of throughout the year
(1 no.) minimum capacity 2
TR,
AC system to have
NW+1S configuration
2. Office room at Boiler -do- -do-
area (1 no.)
3. Office room at -do- -do-
Substation (1 no.)
3.3.1.2 Technical Specifications
Split type air-conditioning unit shall comprise of hermetically sealed
reciprocating type compressor, air cooled fin-tube condenser, low noise,
low speed, statically & dynamically balanced forward curve centrifugal fan,
dry type steel wire reinforced HDPE air filter, volume control damper, fin-
tube evaporator coil made of copper tube with suitable corrugated fin,
drive motor, heavy gauge sheet metal cabinet, vibration isolator pad,
condensate pan, control and instrumentation system, etc.
The split air-conditioners shall conform to IS:1391 (Part II)-1992. All
refrigerant piping shall be of seamless heavy duty, high quality copper.
All Split AC units shall have minimum “3Star” BEE certification.
3.3.1.3 Control and Measuring Instruments
The air-conditioning system shall be complete with all measuring and
control equipment required for smooth and efficient working of the
system. The control system shall include thermostatic expansion valves in
refrigerant circuit, HP / LP cut out of the compressor, thermometers,

digital temperature display, remote control, etc. A.C shall have both
remote and manual control facilities.
3.3.1.4 Design Considerations for Air conditioning System
The contractor shall calculate the capacity of air conditioning system by
considering solar & internal heat load of control room. Heat load
calculation of cooling air quantity calculation shall be furnished based
on ASHRAE norms for selection of equipment and system.
Contractor shall submit the heat load calculation during detail
engineering for approval. However, minimum capacity of each AC unit
shall be 2 TR.
3.3.2 Dry Pressurised Ventilation System
Cool, dust free environment for electrical equipment in MCC/Panel room
shall be provided by installation of dry pressurised ventilation system.
1) Design Conditions
The design consideration for dry pressurized ventilation system is as
follows:
i. Heat load – Contractor to decide

ii. The contractor shall size ventilation systems based on actual
solar & internal heat load of room, or at least 20 air changes per
hour, whichever is higher. Contractor to consider factor of safety
of 10%.
iii. Allowable temperature rise is +3 oC from ambient temperature.
iv. To prevent ingress of dust, all dry pressurised ventilated
premises shall be maintained at a pressure (+) 2 mmWC above
atmospheric pressure.
v. The area details are as follows:

Sl. Description Room Equipment Occupancy System details.
No. Size (m) Heat Load (No. of
LxWxH (kW) Persons)
1. MCC/Panel Contractor Contractor to 04 Dry Pressurised Ventilation
Room at LT to Decide Decide System using Centrifugal Fan,
Substation Floor Mounted.
Supply air: Through ducting.
Along with dry air filter,
electrical systems, gravity
louvers and other auxiliaries.
Quantity: 2 nos. (min)
(NW+1S)
Fan speed: <1500rpm
Head: >25 mmWC
2) Brief Specification
The dry pressurised system shall comprise of the following:
i) Centrifugal fan, floor mounted with motor
ii) Bird protection screen
iii) Air filter
iv) Over pressure gravity louvers
v) DOL starter
vi) Mounting structures
vii) Vibration isolator pads
viii) Power & control cables, conduit, etc.
a) Centrifugal Fan
The fan (s) shall be centrifugal single width with
radial/forward/back ward curved blades depending upon pressure
requirement. It shall be coupled to drive motor through Vee belt.
HP of drive motor shall be at least 15% higher than shaft BHP of
fan. The fan shall be statically and dynamically balanced at
different speed. The fan shall be fitted with self-aligning, self-
lubricated ball / roller bearings. Suitable vibration isolators shall be
provided at the fan pedestal. The centrifugal fan shall conform to
IS: 4894-1987/ BS: 848/ AMCA: 210. The fan shall be fitted with
variable inlet vanes for accurate control of air volume. To prevent
transmission of fan vibration, flexible canvas connection shall be
provided at the fan inlet and outlet.
b) Overpressure Gravity Louvers
The gravity type louvers shall be fabricated from 0.6 mm thick M.S.
sheet finished with two coats of primer and two coats of finished
paints matching to the interior decor. The number and location of
exhaust air grills shall be carefully decided considering room size,
air velocity and 2mm WG positive inside pressure, etc.
c) Grills and Diffusers
The grills and diffusers shall be fabricated from M.S. sheet of
thickness not less than 18G / 20G. All supply air grills shall be square
/ circular type with adjustable louvers, whereas return air grill shall
be fixed type
d) Duct for Ventilation System
Galvanized steel sheet (GSS) conforming to IS-277: 2003 (Class VIII)
with thickness: 0.63mm for sizes upto 750 mm and 0.8 mm for sizes
beyond that shall be considered. Velocity of air within the header
duct shall be restricted to 10 m/s. First 5m of supply air duct near
fan shall be acoustically insulated from inside with 12 mm thick
rigid board fiber glass wool covered with perforated aluminium
sheet / finished RP Tissue paper. If the duct is exposed to the
atmosphere then together with 50mm thick PUF thermal insulation
shall be provided
3.3.3 Exhaust Ventilation System
1) Design Conditions
The design consideration for exhaust ventilation system is as follows:
i. Heat load – Contractor to decide

ii. The contractor shall size ventilation systems based on actual
solar & internal heat load of room, or at least 20 air changes per
hour, whichever is higher. Contractor to consider factor of safety
of 10%.
iii. Allowable temperature rise is +3oC from ambient temperature.
(+5oC for transformer rooms).
iv. The area details are as follows:
Sl. Description Room Size Equipmen Occupanc System details.
No. (m) t Heat y (No. of
LxWxH Load (kW) Persons)
1. RO water Contractor Contractor 02 Exhaust Ventilation System
plant & to Decide to Decide using heavy duty tube axial,
pump house wall mounted.
Quantity: (NW+1S)
Fan speed: <1000rpm
Head: >15 mmWC

2. Boiler pump Contractor Contractor 01 Exhaust Ventilation System
house to Decide to Decide using heavy duty tube axial,
wall mounted.
Quantity: (NW+1S)
Fan speed: <1000rpm
Head: >15 mmWC
3. Compressor Contractor Contractor 01 Exhaust Ventilation System
room to Decide to Decide using heavy duty tube axial,
wall mounted.
Quantity: (NW+1S)
Fan speed: <1000rpm
Head: >15 mmWC
4. Transformer Contractor Contractor - Exhaust Ventilation System
Rooms to Decide to Decide using heavy duty tube axial,
wall mounted.
Quantity: (NW+1S)
Fan speed: <1000rpm
Head: >15 mmWC
2) Brief Specification
The dry pressurised system shall comprise of the following:
i) Heavy duty industrial tube axial type wall mounted fan with motor
ii) Bird protection screen
iii) Panel type washable air filter
iv) DOL starter
v) Mounting structures
vi) Vibration isolator pads
vii) Power & control cables, conduit, etc.
a) Tube Axial Fan
The fan shall be heavy duty wall mounted type, suitable for
continuous operation, statically and dynamically balanced, single
stage, directly coupled with drive motor and shall be
manufactured, tested according to IS: 3588-1987. The drive motor
shall be suitable for operation in 415 V, 3 phase, 50 Hz, AC power
supply system. Head of the fans to be 15 mmWC (min). Fan
impeller shall be as per Cast Al Alloy, IS 617:1994 and shaft shall be
as per C-45 as per IS 1570 (Part-II)-1979 or equivalent. The fans shall
have rain protection cowls.

3.3.3 Fire Fighting System
The following types of fire-fighting system shall be installed.
1) Portable fire extinguishers
2) Water based firefighting system
3.3.3.1 Portable Fire Extinguishers
Portable fire extinguishers are first aid fire-fighting appliances. These are
useful for extinguishing the small and early stage of fire. So, the fire
extinguishers should be placed in conspicuous positions and shall be
readily accessible for immediate use in all parts of the occupancy to
extinguish fire at the early stage. Fire extinguishers should be placed
not more than 15 m from the site of anticipated fire and as far as
possible at exit without hindering the escape routes.
Wall mounted fire extinguishers the bottom of the extinguishers shall be
kept 1000 mm from the ground level (floor). Higher capacity fire
extinguishers shall be located in a place so the mobility of extinguishers
within the area should not be restricted at which it is used. The fire
extinguishers should not be placed in a position where it is likely to gain
heat from the surrounding equipment or process.
Periodic inspection/ checking and maintenance of provided
extinguishers shall be in Contractor's scope during erection &
commissioning period as per scope.
a) Type of Portable Fire Extinguishers Envisaged
Sl.no. Unit / Area with size Type of fire extinguishers with
Qty (min)
CO2 (4.5 kg) DCP (6 kg)
1. Boiler Control Room 4 nos. 2 nos.
2. Office Room 2 nos. 2 nos.

3. Each MCC/Panel Room 2 nos. 4 nos.
4. RO Water Plant 2 nos. 4 nos.
5. Compressor Room 2 nos. 2 nos.
b) The portable fire extinguishers shall conform to the following IS:

i) CO2 type (4.5 Kg) fire extinguishers conform to IS: 15683-2006,
fitted with screw down type high pressure control valve as per
IS 3224:2002, ISI marked, with 1m long wire breaded high
pressure discharge hose & non-conductive horn mfd.,
complete with initial charge of CO2 gas as per IS : 15222-2002,
wall mounting bracket screws. Cylinder confirming to IS: 7285-
2004 with ISI mark and approved by Chief Controller of
Explosive, Nagpur Manufacturer’s test certificate and CCE
approval certificates to be submitted. This is suitable for
operating between -30oC+ 55oC.
ii) DCP type (DCP Type 6 Kg) fire extinguishers conform to IS:
15683-2006. ISI marked, and complete with all accessories,
mounting bracket and screw. Powder shall be Potassium
bicarbonate base comply with to IS: 4308-2003 and CO2 gas
cartridge both bearing ISI marked. Neck ring, discharge nozzle
and cap made of leaded tin bronze with nickel plated. The
discharge hose shall not be less than 500 mm
3.3.3.2 Water based Fire Hydrant System
Major work comprises of following:
1) Taking water connection from the battery limit: Suitable taping
along with an isolating shall be taken by the contractor and suitable
network shall be provided covering the entire area of proposed
boiler complex.
2) Fire Hydrant system consisting of internal as well as external
hydrants for the entire area, including chamber top/lid level.
3) Piping, valves, valve chambers for all isolation valves, etc.
4) All civil & structural works
5) Shop and site painting for all equipments, pipes etc.
6) All the requirements of TAC for complete FPS shall be
incorporated by the Contractor in their scope irrespective of
whether the details are described in specification and/or
shown in the drawings or not.
All civil works as may be required for the envisaged fire system. Civil
works pertaining to underground buried pipelines such as excavation,
laying, backfilling, compacting, construction of valve chambers,
manholes, laying of encasing pipes below roads shall also be in the
scope of the Contractor as a part of pipe laying. In case group of pipes
are crossing road, RCC culverts to be provided below the roads and the
same are included in the scope of the Contractor. Any other civil works
required for completeness of fire protection systems, which may not
have been described but may be required technically.
Ring main based pipe header to be provided to entire boiler area to
cater the fire water requirement. External hydrant shall be provided for
ever 45m spacing whereas internal hydrants shall be provided at every
30 m spacing. Every landing platform shall be provided with landing
valves and hose reel assembly. Each external hydrant shall be provided
with hose box complete with two numbers of fifteen meter hose,
instantaneous coupling, nozzles etc. The underground pipeline shall be
provided with wrapping and coating as per IS to protect it from
corrosion. The pipes shall be as per IS. It should be medium grade of IS:
1239 (part 1)-2004 for below DN 150. Whereas the thickness of the
pipes DN 150 & above shall be - 4.5mm for DN 150, 6.35mm for DN200
,DN 250 & DN300.
3.4 ELECTRICAL
3.4.1 Basic Design Criteria And Site Conditions
The following are the site conditions and system design parameters for
the electrical system.
3.4.1.1 Power Supply System Voltages:
a) HT 11kV(+10%),3 phase, 50 Hz (+/-5%),40 kA for
3 seconds, resistance earthing
b) LT 415V (+ 10%), 3 phase, 50 Hz (+5% ), solidly
grounded, 50kA for 1 second
c) AC control and 230 V
signal voltage
d) DC control and 110V DC
signal voltage
All equipment shall be dust, vermin and weather proof design and
suitable for steel plant area.
All equipment shall be suitable for continuous operation delivering
rated output without exceeding permissible temperature rise.
All the electrical equipment shall be derated for 50oC ambient
temperature for indoor equipment and 55oC ambient temperature for
outdoor equipment.
3.4.2 Standards
3.4.2.1 The electrical equipment/ items shall be designed, manufactured,
installed and tested in accordance with latest IS/ IPSS/ IEC, as applicable
to respective equipment.
All electrical equipment and installations shall conform to the latest IS
codes of practice for installation and maintenance wherever applicable.
For item / equipment where IS standard is not available, applicable IEC
standard shall be followed.
3.4.2.2 All the equipment & components shall be located in hot, humid, tropical
and dusty atmosphere in an adverse industrial environment as prevalent
in boiler area of DSP. Electrical Equipment can be designed for
maximum temperatures condition of 50 Deg C and RH of 95% (non-
condensing) both appearing at the same time. All equipment shall be
de-rated for 50oC/ 55oC if not designed for 50oC/ 55oC.
3.4.2.3 All electrical equipment and installations shall also conform to the latest
Indian Electricity Rules as regards safety, earthing and other essential
provisions specified therein.
3.4.2.4 All equipment/ items shall also comply with the statutory requirements
of the Government of India and the Government of West Bengal.
3.4.3 Brief Description of the Electrical System
 Tapping of power for new boiler complex from two 1250 A VCB
feeders (that shall feed 11 kV power to this new gas fired boiler in
OPP).
 The cable will be laid partly through employer’s overhead gallery and
the rest through buried cable trench. The new LT substation will have
2 no’s 2 MVA transformers and a Power Control Centre (PCC) which
will cater the entire LT loads of proposed boiler. Proposed power
network of new LT S/S may be referred in enclosed Drg no. CET RN
4086 EE1 00 001.
 2 MVA, 11/ 0.433 kV AN distribution transformers at new LT
substation which will be fed from new 11 kV feeders of upcoming 11
kV HT switchboard. Aluminium bus duct shall be considered
secondary of the transformers to new LT switchboard. Suitable cable
supporting arrangement, cable box for connecting cables at primary
side of transformer connectors, clamps and all accessories as
required. Cable supporting structures with busbar arrangement for
connecting cables.
 Power Control Centre (PCC) with two incomers and one bus coupler
and required number of outgoing feeders for feeding supply to MCC
and various other auxiliaries. Motor Control Centre (MCC) with two
incomers and one bus coupler and required number of outgoing
feeders for feeding supply to new boiler equipment and various other
auxiliaries.
 Other equipment as per the scope of work.

3.4.4 Control Modes
The equipment/ mechanisms shall be controlled by PLC mentioned in
separate clause of this TS.
The mode of control shall be as follows:
1) Local Mode: This mode of operation will permit operation of
mechanism on initiation from Local Control Station (LCS) without
any interlock. This mode of operation is for testing/ maintenance.
2) Manual Mode: This mode of operation will permit only one
motion of mechanism on initiation from operator’s control desk.
The safety interlocks of the drive will be in position to work.
3) Auto Mode: This mode of operation will permit the automatic
operation on initiation from operator’s control desk/ PLC with all
the safety and process interlocks in position.
4) The control switch for selection of mode of operation shall be
mounted suitably in the operator’s control desk.
3.4.5 11 kV HT Switchboard
3.4.5.1 The 11 kV switchboard shall be totally enclosed dust and vermin proof,
sheet metal clad, floor mounted, free standing, indoor type and shall
house vacuum circuit breaker, bus bars, control equipment, heat
shrinkable cable termination, current transformers, potential
transformers, instruments, numerical relays, auxiliary relays,
annunciation system and other accessories. This shall be with fully draw
out type breaker carriage, compartmentalized design with pressed sheet
steel (thickness not less than 2.0 mm) and with IP-4X class of enclosure.
For each of the incoming, outgoing and sectionalizer cubicles, the cable
connection, HT bus bars and all low voltage control devices shall be
housed in separate chambers. These chambers shall be necessarily
isolated from that for main circuit breaker chamber and shall be suitably
earthed to bid better safety and protection of working personnel. All
doors other than cable chamber shall be of hinged and lockable type
with neoprene gaskets at all joints and the cable chamber shall be fixed
with nuts and bolts. Additional wire mesh guards and gaskets shall be
provided for cable chamber. Two separate earthing terminals shall be
provided for HT panels. The HT panel shall be provided with metallic
automatic safety shutters or those made of fiberglass of suitable
insulation, which cover automatically the isolating contacts when circuit
breaker is withdrawn from service position.
3.4.5.2 The switchboard design shall have following features:

1) Bus bar of extended panels shall match with the existing bus bar
size of the HT board- 800 mm2/ per phase, copper bus bar.
2) The width of each panel shall be minimum 800mm.
3) Permit extension on both sides.
4) Provide for segregation of all low voltage auxiliary control devices
by earthed metallic barriers.
5) Provide requisite electrical safe clearances among live parts and
between live parts to earth.
6) Provide interchangeability of corresponding parts.
7) All the HT rear covers shall have lift off hinge arrangement.
8) All cable panels shall have a wire mesh cover.
9) Ventilation openings shall be provided where essential and shall
have suitable screen protection.
3.4.5.3 Technical Parameters of the 11kV Switchboard
1. Normal system voltage 11 kV
2. Maximum system voltage 12 kV
3. System Frequency 50 Hz (variation as mentioned
above)
4. Rated current of:
- Incomer As mentioned in SLD
- Bus-coupler -do-
- Outlets -do-
5. Degree of enclosure protection IP 4X
6. Standard to be followed IEC:62271-100,200
7. Rated short circuit withstand 40 kA (rms) for 3 seconds
capacity
8. Asymmetrical breaking capacity >35 %,
(D.C. component)
9. Making capacity (peak) 100 kA
10. Rated insulated level:
- Power frequency withstand 28 kV
voltage for 1 minute (RMS)

- Impulse withstand voltage 75 kV peak
(Peak) 1.2/50 µS
11. Type VCB

12. Location Indoor, truck mounted
13. No. of poles 3
14. No. of breaks/pole 1
15. Nominal current rating of bus As mentioned in SLD/ 1250A
bars
16. Permissible temp. rise over As per IEC
ambient for switch board
17. Operating voltages for
- Spring charging Universal motor on 110 V DC/
230 V AC
- Closing & Tripping 110 V DC
- Indications/ annunciation 110 V DC
18. Permissible opt. Voltage for
Closing 85% to 110% nominal
Tripping 50% to 110% nominal
Spring charging 80% to 110% nominal
19. Earth bus bar Supporting sizing calculation to
be furnished.
20. Special protection features for All VCB circuit breakers shall be
VCB provided with surge suppressor
(10kA)
22 Bus Link Panel To be provided
24 Device for hand charging of 1 set
breakers, Breaker rack in/out
device, special tools & tackles
for breaker maintenance
3.4.5.4 Protection Relays and Metering Requirement for 11 kV HT Switchboard

Sl. Name of feeder Common meters& Protection features
No. relays (Numerical relays
conforming to IEC-
61850)
1. 11 kV Outgoing Ammeter &  Instantaneous O/C,E/F
feeders Voltmeter of  Definite time O/C, E/F
appropriate range, protection.
Electronic Tri-vector
meter, close/ Trip  Sensitive Directional
circuit supervision earth fault relay
relay, with lamp,  IDMTL overcurrent
high speed, master relay with
trip relay of Areva instantaneous high
make VAJH type or set unit, CBCT
equivalent, aux. operated sensitive
relay of Areva make earth fault protection
VAA type or
 Local breaker backup
equivalent, DC
protection.
operated aux. relay
and locking relay as
required.
3. All protection
relays& meters
shall be suitable for
communicating
with SCADA
Note:
a) All protection relays & meters shall be suitable for
communicating with PLC/ Plant SCADA.
b) For extension at 11kV indoor switchgear, breakers shall be of
same make to existing switchgear for interchangeability
otherwise additional spare breaker shall be provided by
contractor.
3.4.5.5 General Features of 11 kV Switchgears
1) HT circuit breakers envisaged in the specification shall be designed
to control and protect the power distribution system. The circuit
breaker shall conform to IEC 62271.

2) The circuit breaker shall be maintenance free and shall have
adequate capacity, insulation and mechanical strength to
withstand.
a) Starting currents of drives
b) Transient surges developed during various abnormal
operating conditions
c) All electrodynamic stresses developed during abnormalities
like faults in the system.
d) Frequent start/stop duty of the industrial load. Normally, 2
(two) quick succession cold starts and one restart from hot
condition or 3 starts per hour shall be considered for design
duty.
3) All circuit breakers shall be of draw-out type construction, with
separate lockable doors over their compartment. All secondary
connections between the fixed and moving portions of the
equipment shall be provided with positive pressure contacts
without any possibility of loose connections. The circuit breakers
shall be fitted with necessary safety mechanical interlocks against:
a) Disconnection/loose connection of breaker trolley from
"service" position due to electro dynamic stress under short
circuit conditions.
b) Insertion or withdrawal of mobile trolley when circuit breaker
is closed.
c) Probability of closing operation with the trolley in an
intermediate position other than service / test.
d) Insertion of breaker carriage with control and protection
plugs disengaged.
e) Withdrawal of "truck-past-the-isolated-position" with control
plug sockets ON - However, additional flexible jumper with
plug and socket shall be provided to facilitate testing of the
breaker outside the panel.
f) Suitable sizes of channels are to be grouted in front of each
HT cubicle for smooth racking in and racking out of breakers.
4) The moving carriage of circuit breaker, which shall also carry jaw
contacts, shall be provided with earthing contacts continuously so
that the breaker remains positively earthed in "service" position

and during withdrawal operation "Test" position. The breaker shall
have anti-pumping features.
5) All circuit breakers shall have three operational positions, such as
"Service" "Test" and "Draw-out" position. It shall be possible to
achieve all the above three positions with cubicles front door
closed. Mechanical indicators for all three positions shall be
provided. The circuit breakers shall carry a single break per pole,
which shall be identical with the other 2 pole chambers of the
breaker. Simultaneous closing of the three poles of a breaker on a
single closing command shall be ensured. All circuit breakers shall
preferably be interchangeable.
6) The HT breaker shall be provided with electrical and mechanical
trip free features and an emergency mechanical push to trip the
breaker. All the features of the equipment shall ensure complete
safety of the operation and shall be complete with approved safety
devices to protect against potential hazards to operating
personnel or to the equipment around. The design shall include all
reasonable precautions and provisions for the safety.
7) All HT breakers shall be provided with at least 8 potential free Aux.
contacts to be used by employer for their interlocking/signaling
purposes. Contact arrangement may be 6 NO + 6 NC and these
shall be rated for 10 amp current duty on the control and auxiliary
voltages (both AC & DC). Further, the following features shall be
ensured in each HT switch board:
a) Control plugs provided shall be mounted in horizontal
fashion.
b) Mini bus earthing with proper interlocks.
c) All supporting insulators shall have increased creepage
distance as per IS and shall suit highly polluted atmosphere
of steel industry.
8) Bus bars
a) The Power bus bars of HT switch board shall be made of high
conductivity, electrolytic copper of purity 99.9% as per IS
613:1984 in rectangular sections.
b) The continuous current rating of main power bus bar and the
short time current rating of bus bars shall be matched with
existing system.

c) Horizontal and vertical bus bar shall be designed
manufactured and supported to withstand thermal and
dynamic stress corresponding to rated short time and peak
withstand current as specified above.
d) Bus bar arrangement shall be as per IS 5578:1985 & IS
11353:1985. Bus bar shall be sleeved with proper grade of
insulating sleeves and of proper colour code for each phase.
Care shall be taken to obviate corona formation at the joints
and connections. All joints and connecting terminals shall be
tinned.
e) Bus bar shall be housed in a separate bus bar chamber with
adequate air clearance and bushing. The insulators/ bushing
shall be cast resin type to bid higher mechanical strength,
during short circuit fault.
The clearance between bus bars shall be maintained as per
standard. The bus bar chamber shall be provided with detachable
side covers for regular maintenance and inspection and have
provision of extension on both sides.
f) HT bus bars shall be either sleeved or taped by HT tape.
9) Current Transformers (CT)
a) 2 core CTs shall be employed for measuring instruments and
automatic tripping of circuit breakers on over load and short
circuit protection. The CT shall be cast resin insulated type of
high mechanical strength. The CT shall have bar primary and
wound secondary. These CTs shall have minimum burden of
15 VA and a shorting link on secondary side to facilitate
isolation of metering devices without opening circuit. CTs
shall be mounted on outgoing side of breakers with easy
accessibility for maintenance i.e. load side of feeder breakers.
CT secondary terminals shall be accessible from the back of
the panel. Class of accuracy for protection shall be 5P20 while
class 1.0 shall be used for metering. Earthing of CT circuit
shall be provided with proper colour coding inside the relay
chamber. CT wires shall be properly glass sleeved. CT shall
conform to IS 2705:1992 with its latest amendments. Ratio of
current transformers shall be finalized during DE stage.
b) Interposing CTs, as required, shall also be provided for
interfacing with local control station.
10) Potential Transformers (PT)
a) Three (3) Nos. single phase units of 11 kV / √3 - 110 V/√3 -
110 V/3) : 11kV system PTs shall be mounted on a carriage
for bus PT and Line PT. HRC Fuse protection of adequate
rating shall be provided on HT side and LT side MCB along
with HRC fuse of appropriate rating shall be used. Accuracy
class of PT shall be 1.0 and voltage factor shall be 1.9. The
primaries and secondaries of these potential transformers
shall be star connected and shall be used for all protection
purposes (like under voltage protection of drives etc.), for
measuring bus voltages and for other meters viz. energy
meters etc. PTs shall conform to IS 3156 (part 1 to 4):1992
with its latest amendments.
b) Incoming PTs shall be provided in separate carriage and
panel.
c) All PT panels shall be provided with one voltmeter along with
selector switch.
d) For RTU interfacing (if required) 4 pole, 5A MCB for voltage
measurement with connection of 3 phases and neutral shall
be provided in PT cubicle.
11) Protective Relays
a) All protective relays shall be state-of-the art numerical relays.
The numerical relays shall have built in self supervision
system with auto diagnosis feature. Relays shall be provided
such that each relay shall have multiple protection features in
a single relay (composite type) to the extent possible. Relays
shall have IEC 61850 protocol. Relays shall be mounted on
top front chamber of CB. Relays in dust and vermin proof
enclosure. The relays should have following minimum
features:
 Provision of recording and display of setting values,
measured values, recorded fault parameters etc.
 Key pad for browsing and setting the relay menu
 High immunity to electrical interference
 Improved system reliability through built in self
diagnostic / monitoring and system supervision.
 DMT & IDMT curves as per IEC.
 Communication capacity for exchange of Data.

 LED indication and programmable LED indication.
 Programmable inputs and outputs
 Dual current rating ( 1 A or 5A nominal ) will be
provided
 Memorisation of fault parameters for each protection
operations including external trip and inhibit circuit
breaker failure protection
 The relay shall have firm latching / fixing provision in
the relay housing
b) The protection requirement in each panel of 11 kV
switchgear proposed substation shall be as indicated earlier.
c) Each panel shall have an independent high speed hand reset
master trip relay similar to the VAJH23 type (Alstom make) or
equivalent, trip circuit supervision relay, fault annunciation
relay, DC voltage operated auxiliary relay for remote
applications of and other auxiliary relays and timers as
required by the control, protection, alarm, indication and
interlocking schemes. These schemes with effective and fault
free simulation of the said functions shall be submitted to the
employer for their approval prior to manufacturing clearance
of the panel.
d) Auxiliary relays with flags and timers as required shall be
considered for following protection of motor feeders
 Temperature rise of winding and bearing.
 Temperature rise of winding and bearing.
e) Insulation of relays should withstand 2.5 kV A.C. (RMS) at 50
Hz for one second for all circuits.
12) Indicating instruments
a) Each panel shall be provided with multifunction digital
energy meter for all electrical parameters like, current,
voltage, kW, kVA, kVAR, power factor, frequency. In addition
to multifunction meters, analogue type ammeters shall also
be provided in each panel.
b) All indicating instruments shall have connection at backside,
and shall be totally enclosed dust and vermin proof
construction. The ammeters for motor feeders shall be
graduated for full load current of the motor with a

compressed end scale for reading of starting current [6 x I
nom approx.]. The scale shall be uniform at about full load
current whose value shall be marked in red. These meters
shall be provided with necessary test terminal blocks.
13) Earthing of HT switchgear
The following norms shall be adopted for earthing of HT
switchgear:
a) The HT outgoing cable shall be accessible to provide external
earthing on opening the backside lower cover of the panel.
b) Continuous copper earth bus bar shall be provided. However,
the cross section shall be checked to carry the peak short
circuit and short time fault current of the system.
c) Earthing bus bar shall be positively connected/ welded with
different sections of HT switchgear, individual functional units
and non-current carrying metallic units.
d) Hinged door shall be earthed through stranded copper
galvanized earthing braid.
e) For positive earthing of with draw able units, silver plated
copper strapping earthing contacts of "make before" / "break
after" type shall be used ensuring earth continuity from
"service" to "test" position of draw-out type breakers on both
the sides.
f) Earthing of the main bus (when only dead) shall be feasible
from PT panel only and shall be properly interlocked with the
incomer panel of the particular section of the bus.
14) Annunciation and control scheme
a) The signalling and annunciation scheme shall include the
following:
 ON-OFF-TRIP and spring charged indications shall be
provided through RED-GREEN-AMBER and WHITE
signal lamps for every panel. The green lamp shall be
energised through an auxiliary relay, which shall also
confirm to the readiness of CB for getting on. Close/trip
supervision lamps shall also be provided. Cluster type
LEDs shall be provided for indication.
 Mechanical indication for spring charged / discharged
shall also be provided.

 For all abnormal conditions hooter/bell of central audio
& visual annunciator shall be provided. Hooter / Bell
shall be discriminated for trip and non-trip
abnormalities.
 Push buttons shall be provided for the following
operations:
Fault Accept/Reset/Hooter Test/Visual lamp test.
b) Audio & visual annunciator shall operate on emergency
under the following circumstances:
 Tripping of each circuit Breaker
 Failure of warning power supply.
c) The same panel shall operate on warning under the following
conditions.
 Operation of overload signal of drives.
 Temperature rise winding and bearing
 Flag operation of trip supervision relay.
 All other faults not mentioned above, but considered
necessary may also be included in the annunciation
scheme.
d) The signalling and annunciation scheme shall operate on 110
V DC.
e) Solid state audio-visual annunciator of minimum 12 windows
shall be provided however exact number of windows shall be
finalised during detailing. The annunciator shall be provided
with flasher units, audible alarm, test, reset, Accept features
as elaborated above.
15) Selection & control switches and other miscellaneous items
a) All selection switches for voltage & current measurements
shall be suitable for 3 phases and phase to neutral
measurements. The remote/ local selector switches provided
on the switchboard shall be lockable in each position. The
control switches shall be pistol grip, spring loaded and trip-
neutral-close type with sequence device. The switchgear and
control panels shall have inscription plates for all panels with
anodised lettering.

b) Control bus shall be continuous copper conductors insulated
throughout for full voltage. Push-in type insulation box shall
be provided at tapping points.
c) The control wiring in the switchgear shall be carried out with
single core stranded copper conductor PVC cable of 1.5 sq.
mm size (min.) with 6 sq. mm open type terminals. Protection
circuit wiring shall be carried out with 2.5 sq. mm size (min.)
copper conductor adopting 10 sq. mm open type terminals.
Separate terminal blocks shall be provided for each voltage
class and carry the specific terminal number and voltage
indicated thereon. Separate terminal blocks shall be provided
for external connections in the relay chamber. At least 20%
spare terminals shall be provided for future purposes. Control
cable terminations shall be provided in the front portion of
the cubicle only in the relay chamber. All devices, wires and
the terminal blocks within the panel shall be clearly identified
by durable and legible tags (stickers shall not be acceptable)
corresponding to those used in the applicable schematic
drawings or wiring diagrams. All panels shall be provided
with space heaters with ON/OFF switch along with a
thermostat and a 10 amp. plug socket for hand lamp
connection. Space heater wattage shall be mentioned for
each panel. Inter-partition separators on control terminal
block shall be provided for control terminals of each circuit
breaker. Drive panels shall however be controlled from Drive
end or its control panel.
16) Cable Chambers
a) The cable end termination chamber for each panel shall have
adequate space for the termination of required number, type
and size of cables and shall be provided with suitable
bracings to support the weight of the cables without undue
stress on the terminals. These chambers shall be complete
with all accessories and shall form integral part of the cubicle
and shall be freely accessible for cable connection.
17) Following general features shall also be provided:
a) Panel colour shall be admiralty grey shade -631 of IS-5.
b) All 11KV epoxy insulators, equipment like CT /PT etc. shall be
of non-hygroscopic and hydrophobic type. Mimic diagram
shall be shown on the cubicle both sides.

c) Nomenclature of the relays and meters shall be written on
panel by paint (stickers shall not be used)
d) Type of Numerical relay shall be as below: Siprotec (Siemens
make)/ MICOM (Schneider/GE make)/ Relion series(ABB
make)
18) Other Accessories
Supply of each of the HT switchgear shall necessarily include the
following accessories.
a) Earthing equipment suitable for 1 no. for line side &
earthing the bus/cable for each 1no.for bus side
breaker
b) Device for hand charging of 1 Lot
breakers.
c) Breaker rack in / rack out device. 1 set
d) High voltage tester 1 no.
f) Wheel mounted trolley for attending 2 nos.
relays & meters-
g) Special device for ensuring 1 Set
mechanical interlocks (if any)
h) Special tools & tackles 1 Set
3.4.6 Battery, Battery Charger and DCDB
3.4.6.1 Battery Bank
1) The battery bank shall be Ni CD battery, 110V DC output voltage.
Capacity of battery shall be selected based on the load calculation.
Battery shall have 30% spare capacity over and above the
calculated load value. Minimum battery capacity shall be 60 AH
with 10 hour discharge.
2) The battery shall be complete with all the accessories and special
tools for battery maintenance. The battery shall be generally
conforming to IS: 1651 - 1991/ IEC 60623. Suitable tapping shall
be provided for boost charging.
3) The cells of the battery bank for 110 V set shall be suitably
arranged on a GI stand with shelves, which shall be painted with
anticorrosive paint.
3.4.6.2 Battery Charger

1) Technical Particulars
Type Twin battery charger (Two chargers in separate
panels) Automatic float cum boost chargers.
Charge Constant voltage/ constant current
characteristic
Output supply Output supply voltage will be suitable for
charging the 110 V battery bank.
Battery charger Sheet steel clad minimum 2 mm thick, indoor
panel type, floor mounted, free standing, IP-52,
having ventilating louvers, removable gland
plate at the bottom of the panel for cable
entry. The charger panel shall be placed on an
insulated base.
2) The chargers shall be suitable for the charging patterns
recommended by the manufacturers of the batteries which will be
supplied in the package.
3) Card schematics, operation manual, write up on charger
functioning and charger protection features and their set points
shall be submitted.
4) Each charger panel shall consist of float cum boost circuit capable
of charging the 110V battery in float or boost mode. A permanent
load for tripping, closing, signalling etc. adequate for the various
equipment shall be supplied by the chargers in addition to the
float/boost charging current. Float output shall be capable of
supply of the full load continuously without battery connection
including loads like Numerical relays.
5) Input Power Supply: The mains supply for the chargers shall be 3
phase, 415V from ACDB. Provision for two AC input one working
and other as standby. This input shall be received necessarily prior
to an isolating transformer for each charger. The AC input to the
rectifier circuit shall be through a saturable core reactor and the
output shall be filtered in a filter circuit to minimise the ripple
content (Max. ripple content shall be within 2% of RMS value).
6) Ammeter for reading charger output current should be capable of/
have facility for reading both trickle and boost charging currents
3.4.6.3 DC Distribution Board (DCDB)
Purpose DC power needs of all the protection,
control and annunciation of the system as
well as for emergency lighting
Type Sheet steel enclosed (IP-54)
Incomer MCCB (50 kA)
Outgoing feeders through MCBs
3.4.7 11kV / 433V, 2000 kVA Dry Type Transformer
3.4.7.1 Standards
The transformers shall in all aspects comply with the following standard
specifications and publications with latest revisions:
IS:2026(Pt.1,2,4-1977) Power transformer
(Pt.3-1981) (Pt.5-1994)
IS:2099-1986 Bushing of transformer
IS:3639- 1966 Fitting & accessories for power transformer
IS:10028 (Pt.1-1985) Code of practice for selection, installation
(Pt.2, 3- 1981) & maintenance of power transformer
IS:10561-1983 Application guide for power transformer
IS:11171-1985 Dry type power transformer

3.4.7.2 The particular requirements of the transformer are specified below:
S.No. Description Technical requirements/ features
1. Duty Indoor type
2. Capacity 2000 kVA
3. Type Cast Resin Dry type
4. Winding Copper wound with with minimum
Class-H insulation
5. Primary 11kV, 3-phase, 50Hz base voltage
6. Secondary 415V, 3-phase, 50Hz base voltage
with full capacity neutral brought out
7. Insulation level 11kV /28 kV RMS/ 75kV peak
8. Winding connections Primary – Delta / Secondary - Star
9. Vector group Dyn11
10. Cooling AN
11. Tap changing Tappings on HV side with + 2.5 % &
+ 5% taps with off load removable
link type tap changer.
12. Impedance Voltage 6.25%
13. Short circuit level at 40 kA for 3 seconds
11kV
14. System earthing Secondary neutral side to be solidly
earthed.
15. HV side terminal Cable end termination box suitable
for termination of min 1 x 3c x 185
mm2 11kV un-earthed, armoured
XLPE, FRLS cable shall be considered.
16. LV side terminal  Separate box suitable for bus
duct connection.
 Full capacity neutral terminal
shall also be provided with a
CT for standby earth-fault
protection.
17. Bushings As per IS 2099-1986

S.No. Description Technical requirements/ features
18. Degree of protection IP-21
for Transformer
Enclosure
19.. Accessories -Scanner with alarm and rip contacts
for Winding temperature
-Neutral CTs
-surge arrestor alongwith earthing
bar for surge arrestor
-bushing for grounding surge
arrestor
-Off circuit tapping switch
-Ventilation louvers and ventilation
grid
-Roller ( bi directional)
- Marshalling box
-Warning plate
-Earthing pad
-Lifting lugs for complete transformer
-Base channel with hauling hole
-Inspection cover for changing tap
with glass & door switch
-Rating and diagram plate
-LV neutral bushing
-HV cable box
-LV busduct connecting chamber
-Other accessories as required
- In Neutral, in addition to Standby
E/F CT, REF CT core shall be
provided for LV REF protection of
the Transformer.
3.4.7.3 The transformers shall conform to the following general features:
1) The impedance value on principal tap shall not vary more than 10%
from the declared value.
2) The transformer shall be designed to suppress harmonic voltages,
especially the third and fifth so as to eliminate distortion in wave
form and the possibility of circulating currents between the neutrals
at different transformer stations.
3) The transformer shall be provided with two thermistors in each
phase for winding temperature indication and protection, one for
warning and one for automatic tripping of feeder breaker when
permitted temperature is exceeded. The accuracy of WTI shall be
better than + 2 degree.
4) The marshalling box shall be totally enclosed dust proof as per IP-
52 and the dials shall not be mounted above 1600 mm level. In the
marshalling box, analog type winding temperature meter with 2
potential free contacts for alarm and trip should be provided. The
meter shall have facility of 4-20mA output signal for remote
monitoring of transformer temperature.
5) All the transformers of same size shall be suitable for parallel
operation.
6) Resistance type embedded temperature detector at hot spot zone
of each phase winding shall be provided with two sets of contacts,
for alarm and trip. Calculations shall be submitted for deciding the
hot spot zone of the winding.
7) Minimum 1250 mm clear space shall be provided on all sides of
transformers. The clearance between the highest point of the
transformer to the ceiling shall be minimum 500 mm.
8) The transformer shall be housed inside a sheet steel transformer
cubicle to prevent both direct and indirect contact with the
transformer. The degree of protection of transformer cubicle shall
be IP-23.
3.4.7.4 Marshalling Box
1) The marshalling box shall be metal enclosed vermin and dust proof
and shall house the various indicators, terminal blocks etc. The
degree of protection shall be at least IP-54 as per IS:13947 (Pt 1)-
1993.
2) The gland plate shall be 2 mm thick and removable type. All cable
cores shall terminate only on terminal block. At least 20% terminal
shall be kept spare.
3.4.7.5 Tests

All routine tests as per relevant standards shall be carried out at the
manufacturer's works:
 Measurement of winding resistance
 Measurement of voltage ratio & check voltage vector
relationship
 Measurement of impedance voltage / short circuit impedance
& load loss
 Measurement of no load loss & current
 Measurement of insulation resistance
 Dielectric test
Type test certificate for Temperature rise tests shall be furnished.
3.4.8 LT Bus duct
3.4.8.1 Standards
IS: 8623(Pt.1, 2, 3) - Busbar trunking system
1993
IS: 5350 (Part-1)-1970 Indoor post insulators
IS: 191 -2007 Copper busbar & flexible
IS: 3965 -1981 Dimension for aluminium alloy bar
IS: 1897 -1983 Copper strip for electrical purpose
IS: 5082 -1998 Aluminium alloy busbar
IS: 9431 -1979 Post insulators of organic material
,insulators & seal off bushing
IS: 10192 -1982 Resin bonded glass fibre sheet
IS: 13947 -1993 Busbar assembly clearances
IS: 5578-1984 Busbar marking colour code
IS:11353-1985 Identification of conductors & apparatus
terminals.
3.4.8.2 Technical Particulars
1. Supply system and variation:
1.1 Voltage 415V, +/-10%, 3-phase & neutral,
solidly grounded
1.2 Frequency 50Hz, +5%, -5%

1.3 Nominal current rating 4000A
1.4 Short circuit withstand 50kA (RMS) for 1 second/ as
capacity indicated in TS
2. Design ambient 50 deg C (max) for indoor installation
and 55 deg C (max) for outdoor
installation
3. Construction of Bus Duct:
3.1 Material of Bus bars Aluminum.
End connections shall be flexible.
3.2 Bus duct  Non segregated, interleaved, air
insulated with aluminum
enclosure
 Rectangular cross section, dust
and vermin proof, divided into
factory made sections suitable for
easy assembly at site.
 Minimum thickness 2.0 mm for
MS & 3.0 mm for Aluminum
3.3 Silica gel breather To be provided
3.4 Bus bar support To be provided @ 1500mm (max)
structure
3.5 Flexible Link Copper link of suitable size
3.6 Rubber bellow To be provided
assembly at
transformer flange
3.7 Mechanical Strength Capable of withstanding mechanical
stress during phase to phase short
circuit
3.8 Degree of Protection:  IP52 (for indoor)
 IP55 (for outdoor)
4. Rated continuous  Main bus: 110% of current rating
current at specified of transformer secondary.
ambient conditions (in  Neutral bus with rating not less
enclosure) than half the rating of phase bus

5. Rated insulation 1100V
voltage
6. One minute power 2.5 kV
frequency withstand
voltage (RMS)
7. Clearance in air
(minimum)
7.1 Phase to phase (mm) 25 mm
7.2 Phase to earth (mm) 25 mm
8. Rated peak withstand Not less than 2.1 times the system
current short circuit level (105kA)
9. Maximum temperature
rise over maximum
ambient temperature
under continuous
operation at rated load
9.1 Bus bars 40 degree C
9.2 Busbar joints 55 degree C for silver plated joints &
40 degree C for other joints
9.3 Enclosure 25 degree C
10. Busbar support Shall be made of non-inflammable,
insulators non-hygroscopic, track resistant and
high strength porcelain/ SMC/ FRP.
Distance between two supports shall
be 600mm (max).
11. Matching with the Bus Shall be made with flanges, flexible
duct and the connector and flexible synthetic
switchgear neoprene gasket
12. Space heaters 240V AC space heater at suitable
intervals and wired to external
terminal box with heat resistant
cables
13. Earthing of the bus  Aluminium earth bus of min size
duct enclosure 50 mm x 10 mm running
throughout the length of the
busduct, positively connected to

the body of the busduct.
 Provision at each end of busduct
for terminating external earth
conductor.
14. Standards IS 8623: Part 1, 2 & 3 – 1993 - Low
voltage switchgear and control gear
assemblies
15. Paint Color of Panel shall be Bottle Green
of Shade 221 of IS-5
3.4.9 Power Control Centre (PCC)

3.4.9.1 Standards
IS Code & Year Title
IS: 1248 (Part1-2003) (Part Direct acting indicating analogue electrical
2-6, 9-2003) (Part 7, 8- measuring instruments & their accessories
2003)
IS: 2705-(Part 1-4)-1992 Current transformer
IS: 3156-(Part 1-4)-2002 Voltage transformers
IS: 3231(Part 1-3)-1987 Electrical relays for power system
protection
IS: 5578 –1984 Guide for marking insulated conductor.
IS: 11353-1985 Guide for uniform marking & identification
of conductor and terminals
IS: 8623 (Part 1-3)-1993 Low voltage switchgear and controlgear
assemblies.
IS: 10118 (Part 1-4)-1982 Code of practice for Selection, installation
and Maintenance of Switchgear and
Control gear.
IS: 11182 (Part 1,2-1984) Guide for evaluation of insulation system
(Part 3,5,6,7-1986) of Electrical Equipment.
IS: 13947(Part 1-5)-1993 Specification for LV switchgear and control
gear
IEC 61439(Part 1—6) - 2012 Low voltage switchgear and control gear

3.4.9.2 In order to feed power to the LT motors/ equipment PCCs have been
considered. PCC shall be designed with two sections and one bus
coupler, the incoming, outgoing and bus coupler feeders be with All
incomer and outgoing feeder cubicles of PCC shall be of draw out type
ACB. 20% spare outgoing feeders shall be provided for each
switchboard. For PCC, cable shall be terminated at backside of the
panel.
3.4.9.3 Minimum nominal rating of 415V Incomer ACB shall be as follows:
a. For 2000 kVA transformer- 4000A rating
1. Reference Standards IS 60947 (Part 1): 2004- Low Voltage
Switchgear and Control gear
IS 8623 (Part 1-3): 1993- Low voltage
switchgear and control gear
assemblies
2. Supply system & variation
Voltage 415 V+10% -15%
Phase 3  & neutral
Frequency 50 Hz + 6%
3. Neutral system Solidly grounded
4. System fault level 50 kA (RMS) for 1 second
5. Rated insulation voltage 2.5 kV for 1 min
6. Construction
a) Type of board Single front compartmentalised &
draw out.
b) Degree of protection IP-54
c) Mounting Vertical, floor mounted, free standing
d) Front access Hinged door
e) Back access & Yes (as per IE rules)
clearance
f) Future extension Provision on both side by addition of
provision new vertical section.
g) Sheet steel type & Cold rolled sheet steel, 2mm & 1.6 mm
thickness (for door).
h) Paint Colour of Panel shall be Bottle Green
of Shade 221 of IS-5
i) Cabling space Side /rear cable alley
7. Bus bar
a) Main horizontal bus 3 Phase and neutral (RYBN)
bar
b) Bus bar material Aluminium alloy
c) Max. temp. rise over 400C (without deration in current
the specified 500C rating)
ambient temp.
d) Bus bar arrangement Top horizontal
e) Power feed to Sleeved bus bar dropper
outgoing module
f) Insulation Heat shrunk PVC sleeve.
g) Short time withstand 50 kA (RMS) for 1 sec
current of neutral bus
h) Short time withstand 50 kA (RMS) for 1 sec
current of earth bus
i) Colour coding IS 5578: 1984
IS 11353: 1985
j) Clearance between 25 mm (minimum)-Ph-Ph
phase & phase and 19 mm Ph-N/E
phase & earth /
neutral
8. Component details
8.1 Incomer, outgoing feeders and bus-coupler ACB:
a) Draw out type Yes
b) Cubicle door can Yes
be closed when
ACB is in Isolated
position

c) Deration of rating No deration
for cubicle
mounting and
ambient temp.
d) Rated Interrupting 50 kA (RMS)
capacity
(symmetrical)
e) Rated making 105 kA peak
Current
f) Total tripping time 100 milli second (adjustable)
g) Under voltage trip No
h) Short circuit trip Yes
i) Over load trip Yes
PCC microprocessor based communicable
type release for I/c, B/C ACB of PCC. O/G
feeders shall have non communicable
type microprocessor based release with
MFM with RS 485.
ACBs shall have self-powered
microprocessor based release with
following protections:
 Short circuit protection
 Over load protection
 Earth fault protection

8.1 The main feature of the release shall be as
Cont follows:
d…  The release shall be settable at site
 Each protection shall have separate
indications. Fault indication shall have
retention feature till it gets
acknowledged
 The long time overload protection
shall have IDMTL characteristics and
tripping time of ```six fold set value
can be set to a maximum time of
around 24 sec.
 The short circuit protection shall have
instantaneous and short time
provision to ensure discrimination
with a down stream and up stream
circuit breakers
 Earth fault protection shall be definite
time type and minimum time setting
of 100 m sec shall be on a table in the
release
 All protections shall have separate
setting dials for pickup and time
settings
 Each ACB shall have shunt trip release
of rating 240 V AC
 IDMT E/F relay type CDG 11 of M/s
Areva (setting range 20% to 80% IN,
IN=5A) or equivalent shall be
provided in addition to E/F unit of the
state release. This will be treated as
stand by earth fault protection and
will be provided in incomers only
which will be operated through
separate NCTs (CTR=1500/ 5A)’
 LV REF protection shall be included
for Incomers with CT & Relay.

8.2 Wiring
a) Power Circuit Insulated (1.1 kV) Flexible Copper Wire
/ strip
b) Control circuit Copper 2.5 mm2 multi strand PVC wire,
insulated. Panel internal wiring shall be
as per SWBD manufacturer standard
8.3 Control Transformer 2 nos. with auto changeover switch
8.4 Indication lamps LED cluster with luminous intensity
min. 100 mcd.
8.5 CT, PT & Protection Relays As required, Relays shall be from
specified make and electronic type
8.7 Voltmeters, Voltmeter selector switch-
For all incomers
Ammeters, Ammeter selector switch-
For all incomers & Outgoing feeders
MFM- For all incomers
3.4.10 Motor Control Centre (MCC)

3.4.10.1 Applicable Standards
IS 8623: 1993 Specification for low voltage switchgear and
control gear assemblies
Part 1 Requirements for type tested and partially type
tested assemblies
Part 3 Particular requirement for equipment where
unskilled persons have access for their use
IS 12063: 1987 Classification of degrees of protection provided
by enclosures of electrical equipment.
IS 12083: 1986 Electrical relays
Part 1 Contact performance
Part 2 Insulation tests
IS 13947: 1993 Low voltage switchgear and control gear
Part 1 General Rules
Part 2 Circuit breakers

Switches, disconnector, switch disconnector and
Part 3
fuse combination units
Part 4 Contactors and motor-starters
Part 5 Control circuit devices and switching elements
Degrees of protection provided by enclosures for
IS 2147: 1962
low voltage switchgear and control gear
IS 2705: 1992 Current transformers
Part 1 General requirements
Part 2 Measuring current transformers
Part 3 Protective current transformers
Part 4 Protective current transformers special purpose
applications
IS 3156: 1992 Voltage transformers
Part 1 General requirements
Part 2 Measuring voltage transformers
Part 3 Protective voltage transformers
IS 722: 1977 AC electricity meters
IS 1248: Pt1- Direct acting indicating analogue electrical
2003 measuring instruments and their accessories.
IS 6875 Specification for control switches
Part I:1973 General requirements and tests
Part II: 1973 Push buttons and related control switches
Part III: 1980 Rotary control switches
IEC 61641 Measurability of Switchgear to contain the effects
of an Internal arcing fault.
IS 10118 (Pt 1- Code of practice for selection, installation and
4)-1982- maintenance of Switch gear and control gear.
(Reaff:2006)
3.4.10.2 Technical Specification
1) Equipment Specification
MCC panel shall comprise of equipment for power supply, control
and protection of equipment. Feeder requirement and type of
switching equipment shall be as per the requirement and as
indicated in the TS. MCC shall have two incomers, one bus coupler
and required no. of outgoing feeders with 20 % spares or one of
each type.
2) Constructional Features
a) The MCC panel shall be indoor, self-supported, floor
mounting, single front, drawout fully compartmentalised to
conform to Form 3B requirement of IS 8623-1993, multi-
tiered, air insulated, natural air cooled, metal clad, factory
assembled, fully wired, type tested assemblies. The
switchgear shall allow extension at either end. The MCC panel
when erected shall form a continuous single line-up of
panels. Each shipping section shall comprise not more than
three verticals and shall be provided with lifting arrangement.
b) Air circuit breakers (ACB) shall be provided for all Incomers
and bus coupler, ACB shall be provided for all outgoing
feeders as per requirement.
c) All doors and covers shall be provided with synthetic rubber
gaskets. All hinges shall be concealed type. Feeder module
doors and cable alley doors shall open in opposite directions.
The vertical panels shall be provided with rear hinged doors
in two sections. Each lift off section shall be provided with
handles. MCC panel shall be suitable for bottom cable entry
for incomer & outgoing.
d) The MCC shall be provided with an integral base channel.
Each vertical shall be provided with anti-condensation heater
and lamp. Where ACBs are provided, breaker-handling trucks
shall be included in supply.
e) MCC feeder shall be also start/stop from PLC.
f) There shall be local/ maintenance mode and auto mode for
equipment control. In the auto mode, remote operation from
control desk/ PLC will be there. In local/ maintenance mode,
start/stop/forward/reverse/job mode shall be there with set
points for reference.
3) Drawout features
Withdrawable modules shall be provided with 3 distinct positions:
a) Service - Both power and control circuit connections to be
made.

b) Test – Power circuit shall be off while control circuit shall
remain connected and can be tested by means of "Test Push
Buttons"
c) Isolated – Both power and control circuit shall be
disconnected.
4) Technical Particulars
Sl. No Specific aspects Technical features
1) Supply system & variation
a. Voltage 415 V +/- 10%
b. Phase 3 Φ & Neutral
c. Frequency 50 Hz +/- 5 %
2) Neutral system Solidly grounded
3) System Fault level 50 kA (RMS) for 1 second
4) Rated Insulation 2.5 kV for 1 min
Voltage
5) Construction
a. Type of board: Single Front Compartmentalised,
drawout. Maximum operating height
shall be 1800mm and minimum
operating height shall be 300mm
from floor level.
b. Safety: All safety features as per relevant
standards shall be provided
c. Degree of IP-54
protection
d. Mounting Vertical, Floor mounted, Free
standing
e. Front access Hinged door
f. Back access & - Back access shall be provided with
clearance hinged two part door each not
exceeding 600 mm
- Clearance shall be as per IE Rules
g. Future expansion Provision on both side by addition
of new vertical section
h. Sheet Steel type Cold Rolled sheet steel, 2 mm & 1.6
mm (for door).
& thickness
i. Cabling Space Side Cable Alley
6) Incomer & Buscoupler
a. Circuit Breaker
i Pole 4
ii ACBs as incomers & bus-coupler
iii ACB or MCCBs as outgoing feeders
as per feeder requirement.
iv Rated Interrupting capacity: 50kA
with Ics=100%Icu
v S/C, O/L, E/F Trip
vi Contacts Silver plated
vii Releases (Settable Microprocessor based direct acting
at site) protection releases for LSIG
protections. Release shall have step
less time settable feature against
O/C faults
viii The overload function shall be
inverse-time type whereas for short
circuit and earth fault it shall be
possible to choose between inverse
time & definite time characteristics
ix Features Service, Test, Isolated positions
(These positions shall be possible
with door closed)
b. Metering
i Microprocessor based
ii a) Meters Ammeters, ASS (Ammeter Selector
Switch), Voltmeter, VSS (Voltmeter
Selector Switch)
iii Accuracy Class-0.5, size- 96 x 96
iv RS 485 Communication port
v CT accuracy class:0.5
c. Indication
Lamps (LED)

i Phase-R,Y,B
ii Status-ON/OFF/TRIP/ TRIP CKT
HEALTHY
d. Aux. Contacts
i 6 NO + 6 NC (including 2 NO+2 NC
spare)
ii Multiplication of Contacts (if
required) shall be done using
electrically reset latched type relays.
e. Relays
i ) Type Drawout Flush Mounted
f. Current
Transformers
(Both Meas. &
Protection)
i Construction Cast Resin, Bar Type
ii b ISF 5
iii ) Burden As required by measuring Circuit
g. Protection CTs
(Only)
i ) Accuracy 5P
ii Burden As req. By Protection ckt.
iii Saturation Factor 10
iv REF Protection Class PS
v IS 2705:1992, Reaff.-2002
7) Busbar
a. Main horizontal RYBN
busbar
b. Busbar Material Aluminium Alloy
c. Max. temp. rise 90 deg C
including the
specified ambient
temp. and
derating factor if
any
d. Busbar Top horizontal in totally enclosed
arrangement compartments with removable
bolted covers
e. Power feed to Sleeved busbar dropper
outgoing module
f. Insulation Heat Shrunk PVC Sleeve
g. Short time 50 kA (RMS) for 1 sec
withstand current
h. Clearance Phase-Phase-25 mm (minimum)
between Phase- Phase-Erth:19 mm (minimum)
Phase & Phase-
Neutral
i. Joints Copper Tinned.
j. Neutral busbar Rated for 50% of the continuous
current rating of the main busbar.
k. Earth bus continuous at the bottom of the
switchgear with a bolted link to the
neutral busbar
l. Support - Non-hygroscopic, anti-tracking,
flame retardant insulated.
- Busbar chamber of each panel shall
be segregated from the busbar
chamber of adjacent panels.
8) Motor feeders
a. Breakers:
i MPCB/ current limiting MCCB (with
direct acting S/C release and shunt
trip coil) with set of 1NO + 1NC
auxiliary contacts and fault signaling
contacts rated for 6A at AC 11 duty
ii Application - MPCB shall be provided for motors
rated below 15 KW
- MCCB shall be provided for motor
feeders rated 15 KW & higher.
b. Main Contactor
i Utilisation AC3 for non-reversible feeders and
Category AC4 for reversible drives
ii Coil voltage 240V AC

iii Drop out voltage 50 %VR
iv Pick up 85-110 % VR
v Auxiliary Contacts 2 NO + 2 NC, 10A, 240 V AC, rated
& rating for 6A at AC 11 duty
c. Relays:
i OLR for motors rated less than 15
kW
ii Electronic Motor Protection Relay -
15 kW & above and up to including
55 kW
iii Comprehensive, microprocessor
based, communicable motor
protection relay(with thermistor/
RTD input) shall be provided for
motor feeders above 55 KW
iv Note-If thermistor inputs are not
available in the motor protection
relay, separate thermistor relays
shall be incorporated in the feeders
v ELR with CBCT shall be provided for
Drives rated up to 55 kW.
d. Metering
i Drives rated 5.5 kW-9.3 KW: Direct
reading ammeters on Y phase
ii Drives rated above 11 KW: 3
numbers of measuring CTs,
ammeter selector switch and CT
operated ammeters
iii Ammeters Accuracy Class:1, size: 96 mm X 96
mm, suppressed scale type
Aux Contactors As per approved Control Scheme.
e. Indication - Phase-R,Y,B
Lamps(LED) - Status-ON/ OFF/ TRIP/ TRIP CKT
HEALTHY
9) MCCB feeders (Power Supply Feeders):
a. MCCB

i Pole 4
ii Releases - Below 250 A: Thermo-magnetic
releases for O/L, S/C, ELR with
CBCT
- Above 250 A: Microprocessor
based adjustable, self-powered
release for O/L, S/C and E/F
b. Aux Contacts 1NO+1 NC
c. Fault signalling
contacts:
i Rating 6A
ii Duty AC-11
10) Control Transformers:
a. No. Separate Control Transformers for
both the bus sections.
b. Control supply for I/C & B/C
breakers shall be drawn from ahead
of the I/C breaker
c. Type Dry Type, Double Wound
d. Insulation Class B
e. Taps +/- 5%,+/-10%
f. Selection Manual selector scheme for
providing “Individual / Transformer
1/ Transformer 2” /Auto selection
shall be provided.
g. Protection - Primary side-MCCB
- Secondary side-DP MCB with
neutral link
11) Control & Selector Switches:
a. Rotary Type
b. Control Switch: Spring Return Type
c. Selector Switch: Stay Put Type
12) Push Buttons:
a. Contacts 2NO+2NC
Type- Flush Type with spring aided self-
reset contacts.
Note-For ‘Emergency Stop’-
mushroom headed type (Red
Colour) with stay-put contacts
13) Internal wiring and ferrules
a. Grade 1100/650 V
b. Insulation PVC
c. material Copper
d. Size - Power Ckt:4 sq. mm, Control
Ckt:2.5 sq. mm
e. Identification By Ferrules at both ends.
14) Terminal Blocks:
a. Grade 650 V
b. Type Non Hygroscopic, Moulded Plastic
Type
c. Spare 20%
15) Cable Termination accessories:
a. Undrilled G.I gland plates with
gaskets
b. double compression type brass
glands
c. tinned, crimping type copper lugs
16) Earthing:
a. Two earth terminals shall be
provided on each cubicle, at back
b. All relay and meter bodies shall be
earthed by one separate green earth
conductor.
17) Painting:
a. Two coats of finished paint.
b. Paint Shade Shade No. 631 (light gray)
c. IS 5:2007
5) Test Requirements

The switchboards shall be tested as per approved Quality
Assurance Plan in CET’s format, which shall be handed over to the
contractor
6) Routine Tests
The low voltage switchboards shall be subjected to routine tests as
per IS 8623 (1993) at the manufacturer's works. These tests shall
include the following as a minimum:
a) Checking for correctness of wiring
b) Checking for electrical operation
c) One minute power frequency withstand test for power and
auxiliary circuits
d) Measurement of IR value for power and auxiliary circuits.
e) Test for interchangeability of identical feeders
f) Test to prove the operating range of control components viz
contactors, spring charging motor, trip and close coils etc.
g) Test to measure the millivolt – drop between the incoming
and outgoing jumpers at air circuit breakers with the breakers
in closed condition.
7) Type Tests
Type test certificates shall be submitted as per relevant standard
for similar type & rating of Switchgear. If certificates are not
available, the tests shall be carried out free of charge to prove the
design of the equipment.
8) Other Requirements
Physical inspection and check for components as per approved bill
of material. The contractor shall furnish test and calibration
certificates for all major bought out items viz relays, meters,
instrument transformers etc.
3.4.11 Control Desk
3.4.11.1 General
Control desk shall have all switches (for selection of modes &
actuation), push buttons for remote operation of the system along with
other facilities indication lamps for motor ON/OFF and TRIP, Ammeters
etc. Control desk shall be housed in Control Room.
3.4.11.2 Construction

1) Control desks shall be free standing, floor mounted, totally
enclosed, dust & vermin proof, bench board type construction
having degree of protection of IP-54.
2) Control desk shall be of folded sheet steel construction fabricated
out of cold rolled sheet steel of thickness not less than 2 mm and
free from all surface defects.
3) The complete structure shall be rigid, self supporting, free from
twists & dents. All cut-outs for mounting of components shall be
true in shape and devoid of sharp edges.
4) The control desks shall be provided with hinged doors of width not
exceeding 600 mm (with in-built locking arrangement and handle)
on the rear side.
5) To have access to the wiring & maintenance of components
mounted on control desk hinged covers made out of sheet steel
thickness not less than 2 mm shall be provided.
6) Cable gland plates of removable type shall be provided at the
bottom of the control desk. These shall be of sheet steel of thickness
not less than 2.0 mm.
3.4.11.3 Control and Selector Switches
1) Control and selector switches shall be of rotary type with
escutcheon plates clearly marked to show the function and
positions. The switches shall be of sturdy construction suitable
for mounting on panel front. Switches with shrouding of live
parts and sealing of contacts against dust ingress shall be
preferred.
2) Contacts of the switches shall be spring assisted and shall be of
suitable material to give a long, trouble free service.
3) Each position of the control and selector switches shall have
minimum two contacts per position indicated with one working
and the others left as spare properly wired up to the terminal
strip of the panel.
3.4.11.4 Push Buttons
1) Push button shall be spring return push to actuate type and rated
to make, continuously carry and break 10A, 220V, AC. 10A, 220V
DC push Button shall be provided for ON/OFF operation of HT ID
Fan Motor. The push buttons shall have 2 NO and 2 NC contacts.
All contact faces of contacts shall be of silver or silver alloy.

2) All push button shall be provided with integral escutcheon plates
marked with its function.
3) The colour of push buttons shall be follows:
Green For motor Start,
Red For motor Stop,
Black For all annunciator functions, reset and
miscellaneous.
4) Red push-button shall always be located to the right of green
push-buttons for any drive.
3.4.11.5 Name Plates and Labels
1) Each panel shall be provided with prominent, engraved
identification name plates subject to Employers approval.
3.4.11.6 Terminal Blocks
1) Terminal blocks shall be of 1100 volts grade, rated for 10 Amps
and in one piece moulding. They shall be complete with
insulating barriers, clip-on-type terminals, and identification
strips. Marking or labels on terminal blocks shall correspond to
their identification or wiring diagrams.
2) All terminal blocks shall be suitable for terminating on each side;
two nos. 2.5 mm2 size stranded copper conductors. Not more
than two (2) wires shall be connected to any terminal.
3) All terminals shall be numbered for identification and grouped
according to the function.
4) Twenty (20) percent spare terminals shall be provided, distributed
over all terminal blocks.
3.4.11.7 Wiring
1) All internal wiring shall be carried out with 1100 V grade, single
core, 2.5.mm2, stranded copper wires with colour coded PVC
insulation. Space heater circuits shall have wires having adequate
current carrying capacity, but the size shall be not less than 2.5
mm2 copper wire. Colour shall be identified for AC/DC.
2) Internal termination of stranded conductors shall be made with
solderless crimping type tinned copper lugs which shall firmly
grip the conductor. Insulating sleeves shall be provided over the
exposed part of lugs.
3.4.11.8 Space heater and lighting
1) Space heaters shall be provided in the panels wherever the
manufacturer considers them necessary and recommends their
provision for preventing harmful moisture condensation.
2) The space heaters shall be suitable for continuous operation on
230V, AC, 50 Hz, single phase supply and shall be automatically
controlled by thermostat.
3) Each free standing control panel/desk section shall have a 230 V,
AC, plug point and incandescent lamp operated by door switch.
4) Necessary isolating switches and fuses/ MCBs shall be provided
for space heater, illumination & plug point circuit.
3.4.12 Power Distribution Board
3.4.12.1 Power distribution boards shall be provided with MCCBs for incomers,
bus-coupler & outgoing feeders. Power Distribution Boards (PDB) shall
be provided with double incomer, bus coupler and required number of
outgoing feeders to meet the miscellaneous loads like hoist, air-
conditioning, ventilation, repair / maintenance network and illumination
loads.
Insulation level of shall be 2.5 kV for 1 min.
1. Reference Standards IS 60947 (Part 1-5): 1993- Low
Voltage Switchgear and Controlgear
IS 8623 (Part 1-3): 1993- Low voltage
switchgear and controlgear
assemblies
2. Supply system & variation
Voltage 415 V+10%
Phase 3 phase 4 wire
Frequency 50 Hz + 5%
3. Neutral system Solidly grounded
4. System Fault level 50 kA (RMS) for 1 second
5. Rated Insulation 3 kV for 1 min
Voltage
6. Construction

a) Type of board Single Front Compartmentalised &
fixed type with components on
removable plates.
b) Degree of IP-52
protection
c) Mounting Vertical, Floor mounted, Free
standing
d) Front access Hinged compartment door
e) Back access & Hinged two part door, each not
clearance exceeding 600 mm.
f) Future extension Provision on both sides by addition of
provision new vertical section.
g) Sheet Steel type & Cold Rolled sheet steel, 2mm & 1.6
thickness mm (for door)
h) Paint Shade No.631 (light grey) of IS 5:
1994
i) Cabling Space Side Cable Alley
7. Busbar
a) Main horizontal 3 Phase and neutral (RYB)
busbar
b) Busbar Material Aluminium Alloy
c) Max. temp. rise 900C
including the
specified ambient
temp. and derating
factor if any
d) Busbar Top horizontal
arrangement
e) Power feed to Sleeved busbar dropper
outgoing module
f) Insulation Heat Shrunk PVC Sleeve.
h) Short time 50 kA (RMS) for 1 sec
withstand current
of earth bus

i) Colour coding IS 5578 : 1984
IS 11353 : 1985
j) Clearance between 25 mm (minimum)
Phase & Phase and
Phase & Earth /
Neutral
8. Component Details
8.1 MCCB for Incoming/ Outgoing feeders
a) Rated Interrupting 50 kA (RMS)
capacity
(symmetrical)
8.2 Wiring
a) Power Circuit Insulated (1.1 kV) Flexible Copper
Wire / strip
8.3 Indication lamps LED cluster with luminous intensity

min. 100 mcd.
8.4 CT & PT As required
8.5 Ammeter For incomers & all outgoing feeders
8.6 Voltmeters For incomers
9.0 Earthing As per relevant standards
3.4.12.3 Microprocessor based non communicable type release for PDB incomer
and bus coupler feeder and thermal magnetic release for outgoing
feeders shall be considered.
3.4.13 Technical Specifications of LT Motors
Sl. Specific aspects Technical features
No.
1. Type of motor Squirrel Cage Induction Motor (SCIM)

No.
2. Duty Unidirectional drives shall be of
continuous duty;
Duty cycle of the motors shall be
selected as per the process
requirement and the contractor shall
specifically bring out in the bid the
selected duty cycle of each motor.
Operating ambient temperature of
500C
3. Name plate To be provided with power rating
4. Degree of protection IP 55
for enclosure
5. Rated voltage 415V, + 10%
Ra Rated voltage variation
(%)
6. (a) Rated frequency 50 Hz + 5%
(b) Rated frequency
variation (%)
7. Class of insulation Squirrel cage induction motor : Class F
with temperature rise limited to class
B
8. Temperature rise 70oC over the ambient
9. Method of starting DOL
10. Starting current in Starting current shall be as applicable
percentage of Rated for IE2 efficiency category L T motors,
current (Ist / Ir) for duly governed by the guidelines in the
DOL start latest revision of IS 12615 standard.
11. Power factor at rated 0.85 (minimum)
voltage and load
12. Safe stall time at 100% 5–10 sec more than locked rotor
rated voltage withstand time
a) Hot condition
b) Cold condition

No.
13. Motor characteristics The motor characteristics shall match
with the characteristics of driven
equipment for the desired starting
and acceleration
14. Thermal time constant 45 minutes
15. No. of starts/ hour for 150
reversible motors
16. Minimum permissible 85% of rated voltage
voltage at starting
(with full load) for DOL
start
17. Permissible running 5 minutes
time with full load at
min. (75%) allowable
voltage
18. Transient recovery The motor shall be capable to
accelerate with load to rated
operating point after temporary
system disturbance for 0.2 sec and
sudden restoration to 70% of rated
voltage
19. Method of cooling IC 411, TEFC;
Motors for VFD application shall have
the method of cooling recommended
by VFD manufacturer
20. Direction of rotation Bi-direction
21. Winding Material Copper
22. Winding connection Delta
23. Overload 160% for 15 seconds in line with IS
325 standard
24. Adequate tropical Yes
protection against
fungus, corrosion etc.

No.
25. Degree of protection IP 55
for terminal box
26. Fault withstand current 50 kA for 0.25 Sec
and time for terminal
box
27. Grounding pads Each motor frame shall have two
distinct grounding pads, one on each
side and complete with tapped hole &
bolt
Testing of Motors
The following tests shall be carried out by the contractor in the
presence of employer/ consultant unless otherwise waived in writing
by employer.
i) The type tests and routine tests shall be carried out as per IS 325:
1996.
ii) No-load test, reduced voltage running up test, locked rotor test,
insulation resistance test and high voltage test shall also be
carried out.
Type tests certificates shall be provided for similar ratings.
3.4.14 LT Inverter Duty Motor

Sl.No Parameters Description
1.0 Type - Inverter Duty
2.0 Standard - IPSS 1-03-001/ IS 325
- NEMA Standard MG1-1993 Part 31, or
the latest revision in so far as it is
applicable.
3.0 Constructional Features
A Frame size & rating - As per IS 325
B Motor body Grey iron casting as per IS:210-1978
C Motor Feet Integrally cast with the stator
D Body Design - Prevent breakage or other failures due

to vibrations normally encountered in
heavy industries .
- Motors shall be of weather proof
construction.
- Designed to operate in the humid air
stream .
E Protection for Motor IP – 55
& Bearing (with canopy for motor)
F Motor Shaft Shall be provided with an external
recessed slinger at the drive end of the
motor to provide additional (minimum IP-
54) protection from moisture and foreign
material.
G Shaft ends & - Cylindrical as per requirement
Extension - Shaft shall be extended for encoder /
tacho. Mounting , accordingly suitable
hole shall be drilled and tapped .

H Bearing - Roller/ball type type bearing upto 5 kW
- Ball Bearing at NDE end for above 5 kW
- All motors shall have fully re-greasable,
anti-friction bearings.
- All motors shall have cast iron inner
bearing caps.
- Bearings shall be oversized.
- All motors shall have a charged
lubrication system to inhibit moisture
condensation.
- Standard motors shall have extended
grease fittings on the opposite drive-
end to facilitate re-lubrication. Grease
ports shall be located on the periphery
of the motor end-shield.
- Motor shall be fitted with a shaft slinger
or V ring seal on the drive end for a
minimum of IP-54 protection (to help
protection of bearing from ingress of
dust, dirt or fluids).
-
4.0 Terminal box
A Location RHS viewed from DE / On top
B Suitability - 4 Core Aluminium Cable
C Rotation 4 X 90 deg.
D Earthing stud Inside Terminal Block
E Miscellaneous - Shall be gasketed between the T.B.
halves.
- The conduit box shall be field
convertible to cast iron.
- External screws and bolts shall be
plated to resist corrosion.
5.0 Cooling - TEFC, Effective bi-directional (forced
cooling fan mounted on the non-drive
end (NDE) of the rotor shaft)
- Thermistors shall be provided in the
windings.
6.0 Quality of operation
A Vibration intensity - Shall be limited as per IS 12075-1986.
B Noise level As per IS: 12065-1987
7.0 Electrical design
A Power Supply 415 V +10 & - 15%, 50 Hz +/- 6%, 4-wire
AC, 50 kA for 1 second, solidly earthed.
B Starting Variable Frequency Drive
C Service factor - 1.0 for VFD power .
- 1.15 for sine wave power .
D Peak transient 1600 V
voltage
E Minimum rise time 0.1 microsecond
F Starting Torque 200 % rated torque for 1 minute below
base speed
G Constant hp 1.5 times base speed.
operation
H Duty Application dependent
I Max speed 150 % rated for 2 minutes
permissible
J Derating for VFD As per above mentioned standard
K Insulation Class H limited to class F.
L Load Type Constant torque / variable torque
(As per application)
M Space Heater - Outdoor motors above 45 kW
- Indoor motor above 110 kW
N No. of Poles 4/6/8
8.0 Operating Characteristics
A Operation with Motors shall operate successfully under
variation in the running conditions at rated load with

voltage or the variation in the voltage or the frequency
frequency not exceeding the following conditions:
 +/-10% rated voltage at rated
constant V/f ratio except for specific
torque boost situations.
Motors shall operate successfully under
running conditions at rated load and V/f
ratio when the voltage unbalance at the
motor terminals does not exceed one
percent.
B Operating speed - Zero to base speed in case of VT.
range - 10:1, 6:1, 4:1 for CT.
C Locked rotor (starting) Motors shall be capable of a 20 second
currents stall at six times full load current without
injurious heating to motor components.
9.0 Motor location Outdoor / indoor installation.
10.0 Painting For indoor motors :
Total thickness of painting shall be 140
microns.
For outdoor motors:
Total thickness of painting shall be 240
microns.
11.0 Nameplate - Shall be of corrosion resistance stainless
steel
- In addition to standard nameplate
information following information shall
be included :
o Nominal efficiency.
o Bearing identification numbers.
o Power factor.
o Torque values with speed range and
amps for that torque value.
o Full Load Slip RPM.
o Magnetizing amps
o Encoder PPR and Voltage rating (if
included).

3.4.15 Local Control Stations
1) Material Sheet steel (CRCA)
1.6 mm thick
2) Mounting Wall / structure mounted
3) Enclosure class IP-55
4) Door opening Hinged type front door opening
5) Cable gland Removable undrilled.
To be provided on both top and bottom.
6) Internal wiring 2.5 mm, single core, stranded, black PVC
insulated copper conductor
7) No. of As per scheme requirement
components
like ON/OFF
push buttons,
selector
switches etc.
8) Contact All the components like ON/OFF PBs;
Details of selector switches etc. shall have 2 NO+2 NC
components contacts of 10 A rating
9) Stop push Stop push button shall be :-
button details RED in colour.
Mushroom headed.
Press to lock and turn to release type.
E-stop provision shall be provided.
10) Start push Start push button shall be GREEN in colour,
button details Shrouded type.
11) Indication High Density LED
lamp Details
12) Location of Local/remote selector switches shall be
selector installed in the LCS
switches
13) Terminal -shall be able to terminate wires of 2.5 sq.
Blocks mm. size
-Not more than two wires shall be
terminated in a single terminal block.
-Shall be mounted on D channels
-30% spare terminals shall be provided.
14) Miscellaneous LCS shall act as field junction box also for
wiring termination of Lt. switches, etc.
15) Provision of For motors of more than 45kW ammeters
Ammeter along with 4 position selector switches shall
be provided.
16) Earthing Earthing studs shall be provided on two
opposite sides.
Internally the earthing studs shall be
connected with the body through green
colour PVC insulated copper flexible wire.
17) Paint Shade no. 631 of IS: 5 - 2007
3.4.16 Variable Frequency Drive (VFD)
3.4.16.1 Application
This technical specification is applicable to requirements of Variable
Frequency Drive (VFD) system used for ac drives up to 690 V. VFD
system is used for controlling the speed / torque of an AC motor by
controlling the voltage and frequency of the power supply to the
motor. VFD are also termed as VFD drive, AFD, VSD, VVVF drives, ASD,
ac drives, inverter drives.
3.4.16.2 Standard
All materials and equipment shall conform in all respect to the relevant
indian/international standards, with latest amendments thereof unless
otherwise specified herein. Some of them are listed below:
Sl.no. Item Standard
1. VFD i. IEC/146-1-1 (1991-04)
ii. IEEE Standard 444(Part-I):1973
iii. EN 61800- 3(2nd environment)
iv. IEC 1800-3 industrial environment
v. IEEE 519
vi. IPSS 1-10-035-15

3.4.16.3 Selection Criteria
Matching the drive to the load characteristics of the specified
application described in below, will be a primary consideration in
selecting the VFD. The following criterion will be considered to select VFD
rating in the constant torque, constant power and variable torque
categories:
1) Constant Torque Load
The VFD power rating will be selected on the basis of starting
torque requirement not on the running load requirement.
2) Variable Torque
VFD for variable torque loads will be selected to provide
adequate torque and kW at the maximum speed that will be
required. Also, for high inertia fans VFD will have sufficient
capacity to accelerate the motor in a reasonable time to avoid
overheating the motor and VFD.
3) Constant power
Constant power loads will be handled by matching the VFDs
output torque with the machine’s requirement at low speed.
3.4.16.4 Technical Specification
VFDs will be provided for the motors as mentioned in the scope of
work. The drives will be able to meet the load torque requirement at all
range of the speed. No overload factors are applicable over this.
3.4.16.5 Details of VFDs are mentioned below.
1. Ambient temperature 50oC
Derating factors for the temperature is to
be specified by the supplier.
2. Continuous rating 150% of the name plate current rating of
the motor
3. Overload capacity - 110 % of the rated current for 1
minute and 150 % of the rated current
for 30 seconds for variable torque
applications
- 150 % of the rated current for 1
minute overload for constant torque
applications

4. Type Two quadrant
5. Braking dynamic
6. Construction features - Floor mounted, free standing
- Dust and vermin proof
- Sheet steel clad
- Minimum 2.0 mm thick for panels &
minimum 1.5 mm thick for doors and
side covers.
- Suitable to withstand vibrations to be
encountered in mine application.
- Cubicles with illumination lamps, door
switches, space heaters and adequate
sockets for soldering.
- All control blocks plug–in-type with
necessary test sockets.
7. Enclosure and - Enclosure conforming to IP-42 or
ventilation better with weather proof enclosures
- Units will be provided with cooling
fans and louvers
- All louvers will have fine mesh filter
behind them.
- For larger drives cooling fans of drives
will be powered from different power
source.
8. Basic design - Digital control technology with vector
particulars control (with programming (PG) unit
as per requirement- numbers to be
specified).
- Sine coded
- VFD will communicate to basic
automation system on system
communication bus.
- Harmonic control as defined by IEEE
519-1992.
- The drive will have an internal EMC

filter capable of meeting the second
environment levels for the EMC
directive without the need for
additional components.
9. THD External AC input choke of suitable rating
shall be provided to limit THD as per IEEE
519 & also THD should be limited to 5%
at the point of common coupling
10. Duty - Rated for continuous duty with
frequent intermittent overloads
without exceeding temperature limits.
11. Drive controller - Software configurable to sensor less
technology dynamic torque vector mode (single
motor).
- Full, closed loop flux vector control for
constant torque applications.
- Drive can be operated with motor
disconnected for testing purpose.
- Adjustable switching frequency
- Multiple programmable stop modes
including - ramp, coast, ramp-to-hold.
- Multiple acceleration and deceleration
rates.
12. Efficiency More than 95% or better at full speed and
full load.
13. Input power supply - Suitable line chokes to mitigate the
harmonics. AC side reactor/
communication choke.
14. Load side - Filter network
components - Electronic over-load relay for each
motor (with display) in case of
bypass arrangement/ multi motor
drive
- AC output contactor/ output isolator
(depending upon the requirement) to
provide a means for positive
disconnection of the drive output
from the motor terminals.
- Output reactor / terminator to take
care of extra cable length than
specified for the drive
- Harmonic suppression equipment
9. Reference
9.1 Reference signals All reference signals may have a trim
signal applied to them for finer resolution
and accuracy. Trim source and amount
should be programmable.
9.2 Loss of reference The drive should be capable of sensing
the reference loss conditions.
In the event of loss of an analog input
reference signal, the drive should be user
programmable.
Signal loss detection should be available
regardless of the function of the analog
input.
VFD shall receive the input reference via
profibus communication
10. Output
10.1 Output
d voltage From 0 to rated motor voltage/ input
voltage.
10.2 Output frequency Minimum 6 step set points or as per
operational requirement
10.3 Output waveform Sine coded waveform using latest
generation IGBTs.
11. Reflected wave As per relevant standards
12. Starting torque As per process or operational
requirement
13. Main power - ACB/ MCCB with 50 KA rating
components in - Line side choke to mitigate the
incoming AC side
harmonics, AC side reactor/
communication choke shall be
provided as per manufacturer’s

recommendation
- Matching input isolation transformer /
line reactor for harmonic and noise
suppression. For input isolation
transformer, the K factor will be 4.0 or
less.
- AC line surge suppression network.
- Input contactor.
14. Converter –inverter - Diode/ thyristor rectifiers to provide a
equipment fixed DC voltage for single/ two
quadrant
- DC link circuit with reactor/ capacitor.
- IGBT Bridge for Inverter.
15. By-pass Arrangement As per requirement/ specified
16. Input / Outputs - Hard-wired I/O
- Inbuilt I/O. One spare I/O card shall
be supplied as loose item for each
VFD
- Standard I/O card
- Analog I/O CARD
- Encoder signal will be connected to
PLC
- Digital Outputs
- Differentially isolated + 10 V (bi
polar)/ 20 mA analog inputs
- I/Os are inbuilt. External relay boards
to be used for relay output, if
required.
- Programmable analog input and
output.
- PTC provision: PTC connection to
protect the motor from over
temperature.
- Drive Operation in local and auto
mode (PLC mode) should be
provided.
17. Protective features - AC line surge suppression network
and overvoltage protection.
- Under voltage in supply network
- Phase sequence protection and
monitoring
- Single phase failure
- Motor loss
- Under voltage in DC bus
- Over voltage in DC bus
- Over load
- Earth fault
- Instantaneous over current
- Cooling fan failure
- Stall monitor for motor alarms
- Stall protection
- Password protection, if available.
- All Electronic Cards of VVVF Drive
system shall have suitable
Varnish/Conformal Coating as per
relevant standards to prevent damage
from conductive dust inherent in steel
plants.
18. Annunciations Following faults will be annunciated in
keypad of the drive.
- AC line surge suppression network
and overvoltage protection.
- Under voltage in supply network
- Phase sequence protection and
monitoring
- Under voltage in DC bus
- Over voltage in DC bus
- Over load

- Earth fault
- Instantaneous over current
- Cooling fan failure – stall monitor for
motor alarms
- Motor fault (winding/ bearing
temperature, vibration) as applicable
- Loss of frequency command
19. Meters - To display output voltage, current and
frequency of drive
- kW meter for drive ratings and below
200 KW.
- All digital display will be
programmable.
20. Other features
20.1 Load
s dependent Programmable current limit up to 150%
current
d limit of drive rated amps. Current limit to be
f active for all drive states; accelerating,
constant speed and decelerating.
20.2 Fault memory Manufacturer’s standard
20.3 Ride through The control logic should be capable of
"riding through" a power outage of at
least 0.5 seconds in duration.
21. Selector switches - Local / Remote.
- Auto / Manual.
- Main / Bypass.
All the selector switches will be of 10 A
rating. Selector switch to be provided
when bypass arrangement/ remote
operation is considered
22. Pushbuttons - Trip reset.
- Start.
- Emergency stop.
23. Lamps - Drive ready.
- Drive trip.

- R, Y, B phase power ON.
- Control supply ON
24. Remote control - Will have transducer to monitor the
facilities outputs like motor speed at remote
place / HMI.
- Facility to accept speed reference
from HMI / engineering station.
25. Communication bus - RS485 (Modbus/ Profibus-DP/ Device
net) bus
- RJ45-Ethernet port shall also be
included in the drive module for
communication bus with PLC and
other Drives.
- Internally mounted interfaces will be
provided to connect to different
buses
26. Communication Communication Compatibility with
Compatibility Ethernet standards and Protocol (UTP
and FOs)
27. Test points As per manufacturer’s standard
28. Operator panel - IP 54/55 protection class.
- Status and power LEDs viewable
through the cover
- Status LEDs for communications
status,
29. Membrane keypad - The keypad will be logically designed
for two operating areas with required
number of keys.
- Local operator control like
- Local start /stop ,
- Jog forward / reverse.
- Programming.
30. LCD display Manufacturer’s standard
31. Earthing - Positive earthing shall be provided

32. GUI - Graphic User Interface (GUI) shall
have upload and download and
parameter backup facilities in the
Operator screen of GUI.
- GUI shall have alphanumeric
parameter/ mnemonic parameter
with description should be provided.
Operator screen of GUI should have
minimum three lines of alphanumeric
character.
33. Peripherals - One Laptop with all Drive
commissioning software and
necessary hardware (Media adopter)
shall be provided.
- All programs and loaded parameters
shall be in English.
- Operating System of all PCs (windows
10 or latest based).
- Laptops shall be windows 10 or latest
based.
- Licence of all the software must be
handed over to the use department
before the start of commissioning.
Above mentioned technical details shall be finalised during detail
engineering as per manufacturing standards complying IS/IEC norms.
3.4.16.6 Tests
The tests to be carried out on equipment are subdivided under the
following heads:
1) Factory tests
2) Site tests
All type tests and routine tests as per relevant standards referred above
shall be carried out on VFD at the manufacturer's works
Type Test certificate shall be provided for:
- Short circuit test
- Temperature rise test

For all other associated equipment and accessories the relevant tests as
per relevant standards shall be applicable.
3.4.17 High Mast Lighting Towers
3.4.17.1 Applicable Standard
The following shall be the reference standards for manufacture and
design compliance of High mast towers:
Code No. Title

1) IS : 875 – 1987 Code of Practice for wind
loads
2) BS : 5649, Part 7 Structure Design
3) BS: 4360-1990 Mast Sections
4) IS : 2062 - 2011 Base Plate, Top plate and
Accessories
5) BS : 5135 or IS 9595 – 1996 Welding
6) BS : 729 / IS : 2629 – 1985 Galvanising
7) IS : 1367 (Part 3) – 2002 Foundation bolts
3.4.17.2 Structure
The high mast structure shall be of continuously tapered polygonal
cross section (at least 20 sided for 30 metre height high mast towers).
The Mast structure should be pleasant in appearance & designed for
suitable wind loads as per IS: 875-1987. Mast will be designed to have a
structural life of minimum 25 years. A type test certificate from tower
manufacturer for passing wind tunnel test from a reputed testing
authority shall be submitted for reference.
3.4.17.3 Construction
1) The mast sections shall be manufactured from MS sheets
conforming to BS EN 10025/ 10027 or equivalent cut and folded
to form a continuously tapered polygonal section having a single
longitudinal weld by MIG welding process. The welding shall
comply BS : 5135 or IS 9595 - 1986. Masts shall be delivered in
multiple sections, which shall be assembled at site by slip-stress-
fit method. The minimum overlap distance shall be 1.5 times the
diameter at penetration. There will be no circumferential welding
in any section. No site welding or bolted joints in the mast
sections will be allowed. The dimensions of the masts sections
will be decided based on sound and established design norms as
per BS 5649 - 1983.

2) The base and top plates without any laminations shall be welded
to the bottom and top sections respectively. The welded joints
will be fully penetrated and developed to the strengths of the
respective sections. The base and top plates shall be provided
with supplementary guests between the bolt holes to ensure
elimination of helical stress development.
3) Mast base section shall have a door size 1400 mm x 300 mm for
easy access to winch and power tools operations. Bottom door
shall be 600 mm above the top of the base plates. The door
design shall be done in accordance with relevant standard and
practices and adequately reinforced for prevention against
bucking.
4) Provisions for fixing safety wires shall be made in the bottom
section.
5) All sections shall be hot dip galvanised as per BS 729 / IS 2629 -
1985. The galvanisation shall be done by single dip method for
uniform thickness and better aesthetic appearance.
3.4.17.4 Dynamic Loading
1) The mast sections should be designed based on the basic wind
speed as data as mentioned at 10m level as per IS 875 (Part-III) -
1987. The structural design of the mast shall comply with BS 5649
part VII and ILE TR 7 guidelines. The design file shall be of
minimum of 25 years.
2) The foundation design shall be made by taking into
consideration the following:
a) Soil conditions
b) Dynamic loading on the mast as per ILE TR7 and IS : 875 –
1987 and
c) Static load of the total mast structure.
3.4.17.5 Raising And Lowering Mechanism
1) The high mast shall have an optimally balanced system for raising
and lowering of the Luminaries and control gear boxes for regular
maintenance work. The same shall be provided by means of a double
drum winch fixed at the base. 3 wire suspension wire ropes along
with compensating disc and safety wires, a specially designed 6pulley
head frame assembly.
2) The winch shall have provision to operate manually by a handle or
electrically through power tool. The capacity, operating speed, safe

working load, recommended lubrication and serial number of the
winch shall be marked on each winch.
3.4.17.6 Proposed Location For High Mast Tower
1) The illumination scheme with high mast towers shall be designed by
the contractor. The location of proposed illumination system using
high mast tower shall be shown by the contractor in layout drawing.
The contractor shall submit the design calculation for lux level before
the execution of the job.
2) Luminaries of high mast towers shall be provided with required no. of
approx. 240W-300W LED Flood light to achieve minimum lux level of
20, suitable for 240V, 1ph, 50 Hz supply Industrial type luminaries.
3.4.18 Accessories
3.4.18.1 Head Frame
M.S. fabricated hot dip galvanised housing using IS : 2062 - 2011 grade
steel accommodating 6 pulleys with stainless steel pins for the
suspension wire ropes and upto 3 such smaller pulleys for the electrical
cables. Pulleys are grooved suitably to ensure that the wire ropes /
cables do not get dislodged from their positions while raising /
lowering. Self lubricating bearing and stainless steel shaft shall be
provided for smooth and maintenance free operation throughout the
mast life.
The head frame shall be made in three compartments placed 120
degree part for most optimum balancing of lantern carriage. Head
frame shall have top canopy in tripod shape to protect the mast from
entry of water / solid particles etc. from the top.
Top canopy shall have provision for fixing lighting arrestor of suitable
design.
3.4.18.2 Lantern Carriage
A fabricated M S hot dip galvanized lantern carriage shall be provided
for mounting of Luminaire arm assemblies. The lantern carriage shall be
made of specifically designed square steel tube having a three piece
construction. The flanges shall be jointed at site by stainless steel bolts
and nuts. Inner side of the lantern carriage shall be provided with a
separate guise ring with PVC / rubber padding to protect the mast
surface while raising and lowering of the lantern carriage. The diameter
of the lantern carriage shall not be les than 1200 mm.
3.4.18.3 Luminaire Arm assembly

Luminaire assembly shall be made of fabricated MS hot dip galvanised
to be fixed on the lantern carriage for mounting of luminaries and
control gear boxes. Each arm shall be suitable for accommodating up to
2 nos. suitable flood lighting luminaries and their control gear boxes.
The length of the luminaire arm assembly shall be 900 mm in case of
non integral luminaries and 2300 mm in case of integral luminaries.
3.4.18.4 Suspension Wires
Three side suspension assembly from compensating disc to the lantern
carriage shall be made of 6 mm dia stainless steel wire rope as per AISI
316 Grade. This shall be of 7x19 construction having tensile strength not
less than 180 kg/ mm. Sq. No. joints shall be allowed in any length of
the wires.
The wires from compensating disc to the double drum winch shall be
made of 6/8 mm diameter stainless steel wire rope of the same grade as
above.
Breaking load capacity of each wire rope shall not be less than 2100 kg
with a factory of safety not less than 5.0.
3.4.18.5 Compensating disc
A separator of MS Construction ho t dip galvanised having provision for
fixing 3 nos. suspension wires on upper deck at 120 degree apart and
provision of fixing two nos. wires from double drum which. It will also
have the provision to connect two nos. safety wires from both side of
the base of the mast.
Shape/ size of the compensating disc shall be designed for its free
movement up to top of the mast. When the lantern carriage is at mast
top, the compensating disc position will be at door level.
Compensation Disc is mandatory as per I.L.E., TR-7. Compensating disc
enables dismantling of D/D winch which is essential during the design
life of the mast, by way of safety wires.
3.4.18.6 Double drum winch
The double drum which shall be completely self sustaining type without
the need for brake shoe, springs and clutches. The winch shall have self
lubrication mechanism by means of an oil bath. The gear assembly shall
be essentially made of phosphor bronze for optimum design life.
The gear ratio shall be 53:1 and safe working load capacity shall not be
less than 750 kg for masts of height 16m and above.
The winch drums shall be grooved to ensure perfect seat for stable and
tidy rope lay with no chances of slipping of ropes. The rope termination
in the winch shall be such that distortion or twisting is eliminated and at
least 5 to 6 tums of rope remain on the drum even when the lantern
carriage is at fully lowered position. It should be possible to operate the
winch manually by a suitably handle or by an integral / external power
tool. It shall be possible to remove the winch after dismantling it from
its mounted deposition and refix it through the door opening.
The winch shall be type tested and due certifications shall be furnished
whenever required.
3.4.18.7 Electrical Winch Cables
The electric cable shall be two (2) runs of 8 core x 2.5 sq. mm flat type
made of super fine strands of plain copper wires, core insulation of PVC
based compound, special cold resistant PVC outer sheath, black and
flame retardant, core identification in accordance with VDE 0293 or
equivalent.
The cable shall be highly flexible for optimum design life and the
bending radius shall be not more than 60 mm and VDE (or equivalent)
approved for hoist applications.
Base end of the cable shall be connected with a 10-pin male plug which
can move easily with the cables during raising / lowering. A10 socket
shall be provided at the bottom of the mast for cable termination.
One or more cables can be used depending on the electric load of each
mast.
3.4.18.8 Junction Box
One more suitable device(s) shall be provided on the lantern carriage
for connecting the luminaries and the flat cable. The number of ways is
decided by the no. of luminaries to be connected.
3.4.18.9 Power Tool
A suitable high powered, electrically driven and electrically controlled,
portable, externally mounted power tool with manual over ride shall be
provided for the raising and lowering of the lantern carriage.
The power tool mounting shall be so designed that it will only self
supporting type but also it shall align itself perfectly with respect to the
winch spindle during the operations. A handle for manual operations
shall be provided as per standard practices.
Power tool shall consist of 3-phase 415 volts, 50 c/s motor and a gear
box to match winch gear ratio duly coupled with each other. It shall be
as per standard practices and reversible speed type.

A controlling unit for rotation changes of motor with provision of
torque limiter by way of using electric circuits for electrical protection
shall be provided. A minimum length of 5m control cable shall be
provided for using push button control from a safe distance of Mast.
3.4.18.10 Test Leads
A suitable 8C x 2.5 sq mm of approx. 6m length with one end having 10
pin plug can be used for testing of Luminaries when the lantern carriage
is fully lowered position by connecting to the junction box.
3.4.19 Switch Board
3.4.19.1 Switch boards shall be made of 2 mm. thick sheet steel box having
external and internal surface finished with paints. This box shall be
covered on the front with 3mm thick hylam sheet matching with the
wall colour. Front cover shall be fixed with brass screw. All boxes shall
have adequate number of knockout holes of required diameter and an
earthing terminal screw. Outlet boxes/ switch boards exposed to the
weather shall have gasketted covers. All the switch boards shall have
one LED power availability indicator.
3.4.19.2 The arrangement of switches etc. shall be neat and systematic. Each
switchboard shall contain at least one no. of 5 A receptacles and its
switch. The size of the switchboard shall depend upon the number of
mounting on it. of switch boards and their quality shall be subject to
approval of Employer/consultant. An indication lamp (red color) shall
also be provided on the board.
3.4.20 LED Flood Light Fittings
The flood light luminaries shall be extruded aluminum, Di cast housing
suitable for long range high intensity, LED flood light of approx. 240W-
300 W so as to achieve a minimum lux level of 20 and confirming to IS
10322 (latest) and IES-LM-80-08 (IS 16105-2011) & IES-LM-79-08 (IS
16106-2011) with driver having protection against high voltage surges,
open & short circuit current, operating voltage range 198 – 242 V with
>90% efficiency and power factor better driver compartment should be
dust moisture and vermin proof and shall have minimum IP 65
protection or more as per IS 10322 and IS 13383 (latest). The luminary
shall be incorporated with vibration isolators, toughened front glass of
minimum 5 mm thickness focusing arrangement with suitable gasket as
per IP 65 protection. Heavy duty LED flood light fitting shall be supplied
from any of makes specified in the list of Acceptable makes.

3.4.21 Twin Unit Aviation Light
A suitable LED based aviation obstruction light shall be provided on the
lantern carriage of each high mast lighting tower top with its control
along with light fittings.
3.4.22 Lightning Arresters
One number lightning arrester shall be provided on the top of the each
high mast lighting towers. The lightning conductor shall be a round
galvanised iron wire of 8mm diameter confirming to IS: 2309-1989. The
conductor shall be protected against corrosion by a zinc coating as
specified in Appendix ‘D’ of IS : 2309-1989. The conductor shall be
bounded to the centre point of the platform as specified in the above IS
and the bounding shall be suitably protected against corrosion.
Lightning arrester on high mast tower structure shall be connected with
the separate earth pit with GI strip of size 40 x 6mm for making two
clear alternatepaths and reducing the impedance to earth for the
passage of lightning current. Height of the lightning arresters shall be
given in such a way that the full protection umbrella against lightning
can be achieved. Earth pit/ station and GI strips shall be laid separately
for lightning protection.
3.4.23 Uninterruptible Power Supply (UPS) System
3.4.23.1 The UPS system shall be complete with battery bank, battery charger,
ACDB & interconnecting cables as per the requirement.
3.4.23.2 System Features
 Under normal conditions, both the units of UPS in parallel
redundant mode shall supply regulated AC power continuously
to share the loads. The rectifier battery charger shall convert the
normal AC incoming power to DC power for the inverter and for
float charge of the storage battery. When incoming AC power
supply to one of the UPS fails or it suffers from loss of output/
half cycle operation, the other UPS system shall take full load
immediately to ensure un-interruptible power supply to critical
loads. The configuration of the UPS system shall be such that
the rectifier and inverter section of both the UPS can function in
criss-cross manner such that rectifier of one UPS can feed
inverter section of both UPS and vice-versa.
 If either AC incoming power supply fail or deviate from specified
tolerances, the storage battery shall supply DC power to the
inverter of working UPS system upto specified time of 30
minutes and ensure continuous AC Power supply to the loads.
 When incoming AC power supply returns to normal, rectifier/
charger of UPS system assumes the DC load from the battery
and simultaneously supply the DC power to inverter and
recharge the storage battery. This shall be achieved
automatically without any disturbance in power supply to the
loads.
 When both UPS systems develop fault, static by pass transfer
switch shall automatically transfer the loads from inverter
output to bypass AC incoming power supply. The static by pass
transfer switch shall automatically re-transfer the load back to
UPS, when it starts functioning in normal condition and
stabilizes. Retransfer shall be inhibited if the two sources are not
in phase. Manual by-pass transfer switch shall also be provided
for test / repair / maintenance of the UPS system.
 Overall bypass AC line to the UPS must be incorporated through
changeover switch.
3.4.23.3 The battery reserve time capability shall not be available if it is taken out
of service for maintenance. However, UPS system shall continue to
function as before and meet all performance criteria as specified.
3.4.23.4 Technical Parameter
i) Input power supply conditions shall be as below :
Voltage: 415 V + 10%, -10%, 3 phase 4 wire AC
Frequency: 50 Hz + 5%, -5%
Power factor: 0.8 lagging (minimum)
ii) The UPS System shall be designed to function under the following
design conditions:-
Applicable standard: IEC – 62040-3
Design ambient temperature: 50 deg C at 95% humidity
Acoustic noise: 60 dBA at 1 M
Degree of enclosure: IP 42
iii) UPS output shall meet the following requirements:
Voltage input: through input isolation transformer
output: suitable for required nos. of 230 V
single phase and 415V three phase
Frequency 50 Hz

Power rating As required; sizing calculations to be
submitted for approval;
Voltage regulation +1%, -1% in steady power conditions;
+5%, -5% from 0% to 100% step load.
Voltage transient 10% maximum deviation (average over
response half-cycle for 100% load application or
removal)
Voltage adjustability + 5 %, -5%
THD To be less than 3 %
Frequency stability + 0.1% free running
Frequency slew rate 1.0 Hz / second (maximum)
Frequency adjustability + 2 Hz
Overload capacity As per IEC: 100 % continuous, 110% for 1
hour, 125% for 10 minutes, 150% for 1
minute, 1000% for 1 sec
Battery recharge time 8-10 hours upto 95% Charging
iv) Storage battery
Voltage As required by the inverter
Protection time 30 Minutes
Type Inverter grade SMF 2V VRLA (lead acid);
The Contractor to submit the sizing
calculation of UPS batteries considering
all derating factors.
End Cell Voltage 1.75V
Guarantee period Minimum 36 months for battery to be
considered.
v) The rectifier and inverter section of UPS system shall be IGBT based.
vi) The static bypass circuit shall be with isolation transformer and solid
stage voltage stabilizer.
vii) Parallel redundant UPS system shall have common battery bank.
viii) Complete operation and control of UPS system shall be
microprocessor based with fault diagnostic and data logging
features.

ix) Touch membrane switches along with LCD display on the front side
of UPS panels shall be provided to facilitate UPS operation in
desired mode locally and for display of all input, output and
battery parameters.
x) Bypass mode facility (service/ static) shall be considered. Change
over time shall be less than 10 msec. Make before break switch
shall be provided with the bypass system.
xi) LED based block mimic diagram shall be provided on the UPS
panels indicating the complete status of the system including the
power route to the UPS, output and other system elements
which are in energised state of operation.
xii) Provision of contacts shall be kept in the UPS panel for
annunciation of abnormal operation/ alarm condition in any
other operator panel/ annunciation panel.
xiii) UPS system shall also have RS-232 serial communication port
interface capacity for alarm and status monitoring at supervisory
control station. The UPS system shall have data as well as I/O
communication with the PLC system. Necessary hardware &
software for the same shall be included.
xiv) UPS shall have battery health management & monitoring feature.
xv) UPS shall have selectable feature of automatic charging/
discharging the battery for enhancing the battery life.
3.4.23.5 Protection Indication and Annunciation
The protection of the UPS system is to be provided as suitable and
required for rectifier and inverter unit and shall generally include the
following:
i) Rectifier
 Current limiting to maximum value.
 Reduced setting of current limiting value when cooling
system failure occurs
 Current limiting during boost charging & float charging
 Control power supply failure
 Any other protection as required for particular application.
ii) Inverter Unit
 High or low output voltage
 High or low link voltage
 Overcurrent on rectifier output
 Overcurrent on inverter output
 Low battery voltage
 Cooling fan failure
 Auxiliary supply failure
 Control & regulation failure
 Any other protection as required for particular application
iii) The following high quality meters shall be provided:-
 Output voltage
 Output frequency
 Ammeters
 Ammeters for battery charging/discharging
iv) The annunciation /alarms shall be provided as listed but need
not be limited to:
 Main power off
 Control supply off
 Earth fault
 Load on AC mains/battery
 Battery run out warning
v) The following indication are to be provided for the rectifier
unit:-
 Rectifier on
 Battery on float charge
 Battery on boost charge
 Charging failure
 AC mains failure due to fuse blown
 Overcurrent
 High battery voltage
 Low battery voltage
 Battery on load timer
 Tests
3.4.23.6 Test at manufacturer's works
i) Routine Test
 Assembly inspection/painting check
 H.V test on main circuits.
 H.V test on auxiliary circuit
 Protective device co-ordination
 Functional tests including inverter settings and inverter
efficiency
 Current limiting test
 Supply variation
 Insulation resistance measurement
 Spike buster test
 Ripple voltage
 Tests on control circuits
 Over load capacity tests
 Steady state regulation at no load, 50% and 100% of load
 Harmonic distortion test
 Acoustic noise test
 Battery operation
ii) Any other test not specifically mentioned but required as per
relevant IEC standard shall also be carried out and test
certificate for the same furnished by the contractor.
3.4.24 HT & LT Power & Control Cable and Cable Laying
3.4.24.1 The Cables shall comply with the latest revision of the following Indian
Standard Specifications and to the specific standards mentioned, if any,
in the respective clauses:
IS: 7098 (Part-1)- 1988 Cross linked polyethylene insulated PVC
sheathed cables: Part 1 For working voltage
up to and including 1100 V
IS: 7098 (Part-2)- 2011 Crosslinked polyethylene insulated PVC
sheathed cables: Part 2 for working
voltages from 3.3 kV upto and including 33
kV
IS: 8130 - 1984 Conductors for insulated electric cables
and flexible cords
IS: 5831 - 1984 PVC insulation and sheath of electric cables

IS.10810 (Part.1 to 3- Methods of testing of cables
1985, 1981, 1981)
3.4.24.2 The 11 kV HT power cables shall have the following specification:
Sl. No. Specific aspect Specification
of Cable
1. Grade 11 kV (UE)
2. Type 3 core, XLPE insulated PVC sheathed round
armoured Aluminium conductor, FRLS
cable conforming to IS 7098-Part-II
3. Conductor Circular conductor made of stranded and
compacted electrical grade Aluminium
wires as per IS 8130- 1984
4. Maximum 90oC
conductor
temperature
with rated
current
5. Insulation PVC, applied by extrusion process.
6. Shielding Conductor screening of semi-conducting
(Screening) compound, insulation screening over
individual cores consisting of extruded
semi-conducting compound, followed by
lapped semi-conducting tape and copper
tape.
7. Inner Sheath Extruded PVC inner sheath (ST2) with non-
hygroscopic fillers for suitably holding the
cores in circular configuration.
8. Armouring Round
9. Outer Sheath FRLS PVC (ST2)
3.4.24.3 Specification of LT Power and Control Cables
The cables shall comply with the latest revision of the following Indian
Standard Specifications and to the specific standards mentioned, if any,
in the respective clauses:
IS 1554 (Pt 1) : 1988 PVC insulated (Heavy duty) electric cables
IS 8130 : 1984 Conductors for insulated electric cables

and flexible cords
IS 5831 : 1984 PVC insulation and sheath of electric cables
IS10810 (Part.1 to 3) : Methods of testing of cables
1985, 1981, 1981
Sl.No Technical Specification

1. Grade 1.1 kV grade
2. Core 3 Core for motor feeder, 3.5 for power
feeder
3. Type Heavy duty, PVC insulated, armoured,
FRLS PVC sheathed.
4. Conductor  Power cable: aluminium
conductor
 Control & lighting cable:
annealed tinned high
conductivity copper conductor
of 2.5 sq. mm
 Copper cable from VFD to
motors
o
5. Maximum 90 C
conductor
temperature with
rated current
6. Inner Sheath Extruded PVC
7. Armouring GS flat steel armoured
For control cable- round wired steel
armoured shall be used.
8. Outer Sheath FRLS PVC
9. Maximum 250 deg
conductor
temperature
withstanding ability
during short circuit
3.4.24.4 Cable Selection
Power Cables shall be selected considering system fault level, starting
and running current, the distance of load from the source and the type
of laying of cables, group rating factor for cable. De-rating for
temperature is also to be considered. The voltage drop at the delivery
end of cable shall not be more than 12.5% during starting of the
equipment for power application and shall not be more than 5% during
running of the equipment.
Minimum size of power cable shall be 4 sq. mm (copper cable)/ 6 sq.
mm (aluminium cable). Control cable size shall be at least 2.5 sq. mm.
3.4.24.5 General Technical Aspects
1) Cable termination and jointing: Termination and jointing of cables
shall be made with double compression type brass cable glands
and crimping type cable lugs. Aluminium conductor cables shall
be terminated with aluminium lugs and copper conductor cables
shall be terminated with tinned copper lugs. Straight through
joints shall be heat shrink resin type with complete kits.
2) Termination of cables shall be made with heat shrink type
termination kits of appropriate voltage grade.
3.4.24.6 Cable Racks (GI for non-fabricated type)
1) Cable racks made of GI type shall be provided in the cabling space
below the proposed switchgear & remote control panels, cable
trench/ tunnel as required.
2) Ladder type cable racks of width 600 mm/ 450mm/ 300mm.
3) Supporting MS brackets for the support of cable racks shall be
provided at an interval of 1500 mm. Brackets shall be made of 65
x 65 x 6 mm MS angles.
4) MS channel of size (100x50 mm) as inserts shall be given at an
interval of 1500 mm from the base of the cabling space/ cable
trench to the top of the cabling space/ trench. MS channel inserts
shall be given at the two sides of the cabling space/ trench.
5) MS insert plates of size 100mm x 100mm x 10mm at an interval of
1500 mm at centre of the roof of the cabling space/ trench shall
be given throughout the length.
3.4.24.7 Installation of Cables
Cable racks shall be ladder type made of GI type.
1) Its preferred size will be of 600/450/300 mm width.
2) Generally cables shall be laid on the cable trays exposed.
However, where protection is required from mechanical damage
and/or radiation of heat, this protection shall be given by GI
conduits/ GI pipes of suitable sizes. GI pipes shall be medium
gauge, hot dip galvanised electric resistance welded (ERW)
screwed type conforming to IS: 1239 (Part-I)-1990. GI conduits
shall conform to IS: 9537 -1980.
3) All cables shall be protected by means of GI pipes or sheet metal
protective cover up to a height of 1500 mm from the working
floor level and platforms for protection against mechanical
damage. About 40% of the pipe/conduit space shall be kept
vacant for easy pulling of cables.
4) Cables coming out of the underground cable trench or building
or concrete cable duct shall be protected by GI pipes at the point
of exit of these places and all these exit points shall sealed against
water seepage and entry of creeping reptiles with fire proof
materials. In case of road/ railway crossing, suitable hume pipes
shall be considered.
5) Power cables and control cables shall preferably be placed in a
separate rack. Where this is not possible, power cables and
control cables shall be spaced with a distance.
6) All cables shall be provided with identification tags indicating
cable numbers in accordance with the cable/circuit schedule at 20
metre spacing for straight runs, at bends in the run. The tags shall
be of aluminium sheet with numbers punched on them and
securely attached to the cables with non-corrosive wire.
7) Individual cores of control cables shall have plastic identification
number ferrules at both ends of the circuit.
8) All cables shall be tested for proper insulation before laying.
Cables shall be laid in a proper manner so that there shall not be
any damage to the cable, no kinks or twists in the cable during
cable laying. All spare cores of the control cables shall be neatly
bunched and taped at both ends.
9) Cables shall be clamped in the racks at an interval of 1500mm in
both vertical and horizontal run with aluminium alloy clamps.
10) Where a number of GI pipes or conduits are run in a bunch,
adequate number of spare pipes (30% or minimum two nos.) of
comparable diameters shall be kept for future use.
11) Flexible GI pipes/conduits shall be used at the termination points
of cables where cables are to be terminated to vibrating and or

rotating equipment or where chances of vibrations shall be there
at the time of operations.
12) The cables shall be laid through existing cable trench and/or shall
be laid through existing/new overhead cable route with new trays
and supports. At specific locations, cables shall also be taken
through GI conduits/ GI pipe for additional protection against
damage as per site condition. GI pipes shall be medium gauge,
hot dip galvanised electric resistance welded (ERW) screwed type
conforming to IS: 1239 (Part-I)-2004. GI conduits shall conform to
IS: 9537 (Part-2)-1981.
13) Where ever required new cable trays, cable trench etc. are to be
considered.
14) Cables in boiler area shall be laid along structures/ galleries, cable
trench etc., on GI fabricated and painted cable trays as applicable
15) Cables shall be taken inside the cabling space below the panels &
other equipment or in existing cable trench etc. in ladder type
cable trays.
16) Generally cables shall be laid on the cable trays exposed.
However, where protection is required from mechanical damage
and/or radiation of heat, this protection shall be given by GI
conduits/ GI pipes of suitable sizes.
17) All cables shall be protected by means of GI pipes or sheet metal
protective cover up to a height of 1500 mm from the working
floor level and platforms for protection against mechanical
damage. About 40% of the pipe/conduit space shall be kept
vacant for easy pulling of cables.
18) Cables coming out of the underground cable trench or building
or concrete cable duct shall be protected by GI pipes at the point
of exit of these places and all these exit points shall sealed against
water seepage and entry of creeping reptiles with fire proof
materials.
19) Power cables and control cables shall preferably be placed in a
separate rack. Where this is not possible, power cables and
control cables shall be spaced with a distance.
20) All cables shall be provided with identification tags indicating
cable numbers in accordance with the cable/circuit schedule at 20
m spacing for straight runs, at bends in the run. The tags shall be
of aluminium sheet with numbers punched on them and securely
attached to the cables with non-corrosive wire.
21) Individual cores of control cables shall have plastic identification
number ferrules at both ends of the circuit.
22) All cables shall be tested for proper insulation before laying.
Cables shall be laid in a proper manner so that there shall not be
any damage to the cable, no kinks or twists in the cable during
cable laying. All spare cores of the control cables shall be neatly
bunched and taped at both ends.
23) No cable joints are envisaged in the intermediate point in the
through run of cable unless the length of the run is more than the
length of the standard cable drum.
24) Cables shall be clamped in the racks at an interval of 1500 mm in
both vertical and horizontal run with aluminium alloy clamps.
25) Flexible GI pipes/conduits shall be used at the termination points
of cables where cables are to be terminated to vibrating and or
rotating equipment or where chances of vibrations shall be there
at the time of operations.
26) The cable ends shall be suitably sealed to prevent any ingress of
moisture and shall be fully protected against mechanical damage.
3.4.25 Illumination System
3.4.25.1 Lighting Power supply
1) Power supply in control Rooms from MCCB in PDB to MLDB shall
be 415 Volts, 3 phase, 4-wire 50 Hz earthed system and fault level
is 50 kA RMS at 415 volts for distribution of electric power at low
voltage. MLDB shall feed SLDBs at respective areas.
2) Power supply for lighting fixtures, ceiling fans, exhaust fans for
ventilation, receptacles shall be 240V, 1 phase, 50 Hz to be
derived from SLDB from phase and neutral of 415V, 3 phase, 4
wire, 50 Hz supply stated above.
3.4.25.2 Main Lighting distribution board (MLDB)
1) MLDB shall have two incomers, one bus coupler and required
outgoing feeders with 20 % spares. All incomers, bus coupler and
outgoing feeders shall be MCCB (50 kA). MLDB shall be of CRCA
sheet steel enclosure (IP-54).
3.4.25.3 Sub Lighting Distribution Board (SLDB)
1) Each SLDB shall receive power at 415V, three phase, 4 wire, 50 Hz
and distribute it into 240V, single phase circuits for connection to
the lighting fixtures and other single phase load of designated

premises as per detail engineering drawings,. The boards/panels
shall be designed for 50 kA short-circuit current level.
2) The SLDB shall be made of MS sheet steel of thickness 2 mm. The
board shall be dust and vermin proof with rubber / neoprene
gasket. The board shall be wall mounted type & front operated
only. All the equipment inside the boards shall be covered in front
with a 3 mm thick bakelite sheet. Only the operating knobs of the
equipment shall be protruding outside the bakelite sheet.
3) The SLDBs shall have one no. 63A TPN- MCB – incomer and
required nos. of 10A/20A (10 kA) single pole MCB for Illumination
loads. Bus-bar shall be of electrolytic grade aluminium of grade
E91E, as per IS: 5082 -1998 and shall be colour coded. Bus-bar
clearance shall be maintained as per IS. However, ample clearance
shall be kept considering the future maintenance.
4) The lighting circuit shall be segregated in such a way that in case
of any problem in any SLDB few lamps glow in every area of
illumination
a) The SLDBs shall be provided with two no. earthing studs.
b) Inscription plate shall be given for each board with white
letters in black background and shall be fixed with brass
screws.
5) The recommended Level of illumination, type of fittings and
mounting heights of various units shall be considered as:-
Sl. Area Lux Type of energy efficient
No. lighting Fixture
Level
1 MCC, LT 250 LED
substation
and control
room
2 New Boiler 150 LED
Area
3 Platforms/ 70 LED
Staircase
and Shed
area
4 RO Water 100 LED
Plant

Sl. Area Lux Type of energy efficient
No. lighting Fixture
Level
5 Peripheral 20 LED
Lighting
a) Maintenance factor for design of the illumination system in the
electrical rooms/ buildings the maintenance factor shall be
considered as 0.6.
b) All the SLDB distribution boards shall be of steel clad, dust &
vermin proof design.
c) Cabling from MLDB to SLDB shall be through armoured LT
power cables. From SLDB to respective lighting fixtures, wiring
shall be through 1.1kV grade PVC insulated 2.5 sq.mm copper
wires in GI conduits or through PVC insulated PVC sheathed 2.5
sq.mm coppers armoured cables in trays. The Control rooms
and offices shall have concealed wiring through MS conduits.
d) Small Power Receptacles (Socket Outlets)
e) 20A, 240 V, 3 pin (2 pole and earth) receptacles (socket outlets)
of suitable rating with interlocked switches in sheet steel
enclosure shall be provided in all areas of boiler and control
rooms for operation of hand tools, fans etc. MCC rooms and
control rooms shall also have 5/15A, 240 V sockets.
f) Industrial type fittings with LED lamps shall be used in the
Control Rooms.
g) Lighting shall be designed for outdoor lighting with timer
circuit (auto –manual).
h) 24 V sockets with transformers shall be provided as per the
technological requirement.
i) UPS supply based emergency lighting shall be provided at the
strategic locations of Boiler complex.
3.4.26 Repair network/ Welding Distribution Board (WDB)
3.4.26.1 The welding distribution board shall be suitable for operation at a
power supply of 415V, 3 phase 4 wire 50 Hz system. WDB shall have
MCCB as incomer and outgoing feeders as per requirement. Earth fault
protection shall be provided in each feeder.
3.4.26.2 WDB shall be dust and vermin proof, weather proof with rubber/
neoprene gaskets & class of enclosure shall be IP-54. The board shall be

made of standard steel of thickness 2 mm and shall be front operated,
compartmentalized in design and shall be factory assembled.
3.4.26.3 Welding Receptacle: Welding receptacles shall be 63A, 415V, AC,
3phase, 50Hz with socket outlet, interlocked 63A TPN switch fuse &
plug. The receptacle shall be dust & vermin proof, gasket industrial type
with degree of protection
IP-67 and interlocked type and to be provided at strategic locations for
welding & repair work.
3.4.27 Earthing & Lightning Protection System
3.4.27.1 A complete earthing system with double path to the ground for boiler
structure shall be furnished. Each casing shall be provided with two
earthing pads located on diagonally opposite corners of each casing.
The pad surface shall be tinned, drilled and to be connected to earthing
mat by 50mm x 6mm galvanized steel flat.
3.4.27.2 Manual safety earthing switches shall be furnished so that individual
equipment can be grounded during maintenance.
3.4.27.3 Double earthing shall be provided for all electrical equipment to
conform to Indian Electricity Rules. Earthing work with earthing pits shall
be provided by the contractor in accordance with IS 3043: 1987 and IE
rules. Supply of all earthing material for the installation of earthing pits
& main earthing ring, new earthing etc. as required for the earthing
network for the power, illumination and utilities system shall be in the
scope of the contractor. The new earthing rings in turn shall be
interconnected to the existing main earthing network of the area of the
plant. The main underground earthing ring shall be made of 75x 10 mm
GI flat. All 415V panels shall be earthed using 50 x 6 mm GI flats.
3.4.27.4 The main underground earthing network shall comprise of 75x10 mm GI
Strips and adequate nos. of earth pits. All the earth pits shall be
interconnected through GI Strips. GI Strips shall be laid 600mm below
the ground level. Suitable nos. of risers shall be taken out from the
ground ring for the formation of earth ring inside the control room
plant along the wall at a level+2000mm from the FFL. It will be
embedded in floor and taken up along the column. All the equipment
inside the room/plant shall be interconnected to the earthed bus inside
the room/plant.
3.4.27.5 Earth resistance of complete power earthing network shall not exceed
1ohm.
3.4.27.6 Earth resistance of electronic earthing network shall not exceed 0.5
ohm.
1) Size of the earth Electrodes shall be 100mm internal dia, 3
metres long made of galvanized steel.
2) New earthing of all equipment under the scope of work shall be
ensured.
3) Conductor Sizes for Earthing: Earthing conductors of following
minimum sizes & materials shall be used in the power earthing
system as listed below:
Sl. Description Size Material

No.
a) Main earthing ring/grid below 75x10 mm Flat Galvanised
ground Steel
conductor
b) Sub grid above ground 50x6 mm Flat -do-
c) Riser/Pigtail from earthing grid/Mat 50x6 mm Flat -do-
d) HV Equipment 50x6 mm Flat Galvanised
Steel
e) Structures, 50x6 mm flat -do-

f) 415V Motor Control Centre, etc. 50x6 mm flat -do-
g) Control desk 50x6 mm flat -do-
h) Local Control Stations/ SLDB 25x6 mm flat -do-
Motors:
i) Above 5 kW upto 30 kW 25x3 mm flat -do-
j) Upto 5 kW 8 SWG Wire -do-
k) Miscellaneous items, viz. Push 8 SWG Wire -do-
Button Station, Junction Boxes etc.
4) Electronic earthing network shall be separate from electrical
earthing network.
5) Lightning protection shall be made as per IS:2309-1989. All the
down comer for earthing conductor for lightning protection shall
follow the shortest path to the ground mat/pit and intermediate
joints shall be avoided as far as possible.

6) Contractor shall test the existing earth resistance of the
proposed area. Required earth pits, underground earth
conductors and over ground earth conductors shall be provided
to arrive at total earth resistance value less than 0.5 ohm.
7) The contractor shall submit all the calculations for earthing to
the Employer/Consultant for approval. The number of earth pits
shall be finalised based on the earthing calculation to be
furnished by the contractor for Employer / consultant’s approval
3.4.28 Erection and Installation
Design and selection of Erection & Installation material/works shall be
done taking into consideration the fact that the plant is called upon to
operate continuously and hence all facilities to be erected and installed
so as to simplify inspection, testing, maintenance, cleaning can be
carried out at site without disrupting process / prolonged shutdowns.
3.4.29 Power & Control Panel
1) The power & control panels shall include Power cum Motor Control
Centres (PMCC),
2) Erection of the boards/ panels shall be carried out in accordance with
the guidelines given by the respective IS Specification.
3) Wall/ Column mounted type local control stations, starter panels etc.
shall be mounted on wall or rigid supporting brackets made of steel
sections.
4) PMCCs and Control Desks shall be mounted on steel sections i.e.
angles, channels, embedded in the floor and fixed either by bolting or
tack welding after proper aligning and levelling. Incoming and outgoing
cables shall be laid in cable racks underneath the panels.
5) During installation, special care shall be taken to check and thoroughly
clean all contacts of breakers, contactors, relays etc. and panels as a
whole. Also, all operating mechanisms shall be checked for smooth
operation and linkages in the mechanism shall be properly greased/
lubricated.
3.4.30 Testing & Commissioning
1) Site tests for commissioning
Checking required to be made on the equipment after installation at
site shall generally comprise but not be limited to the following:
 Physical inspection to verify the boards/ panels are in proper condition.
 Check for free movement of mechanisms viz. circuit breakers, rotating
parts of rotating machine
 Check for tightness of all cables, bus-bar, earth connections etc.
 Check for clearance of exposed bus-bar/ conductors from metal
enclosure, if any. Check for proper alignment of all draw out devices like
draw out type circuit breakers, if any.
 Continuity checks of all control circuits
 Checking of all mechanical and electrical interlocks with manual
actuation of relays as necessary.
 Checking and calibration of device requiring field adjustment/
calibration.
2) Tests to be carried out on the individual electrical equipment shall
generally include, in addition to the manufacturer’s instructions, the
following:
3) For PMCC, Control Panel etc.:
 Insulation resistance test with 1000 V megger for main circuits.
 Insulation resistance test with 500 V megger for control circuits.
Checking of settings of all relays/releases as per drawings.
3.5 PROCESS CONTROL AND AUTOMATION
3.5.1 Design Condition for Instrumentation System
3.5.1.1 Applicable design Standards
IS / BS No. Title
IS 1554:1988 PVC insulated electric cables for working voltages up to
and including 1100 V
IS 2848:1986 Industrial platinum resistance thermometer sensors
IS 2054:1962 Reference table for nickel/chromium- nickel-aluminium
thermocouples
IS 2055:1962 Reference table for platinum/rhodium-platinum
thermocouples.
IS 6720:1972 Reference table for platinum / 30% rhodium-platinum /
6% rhodium thermocouples.
IS 7358:1984 Specification for thermocouples.
IS 8784:1987 Specification for thermocouple compensating cables.
IS 9858:1981 Safety requirements for electronic measuring
apparatus.

IS 13947:1993 Degrees of protection of enclosed equipment.
BS-1042 sec 1.1 Flow element design calculation & sec 1.4 (1992)
3.5.1.2 Design Conditions
1) All instrumentation & automation equipment shall be designed
for continuous duty operation in steel plant environment.
2) System shall be designed with inbuilt safety system for operating
and maintenance personnel. Facilities for inspection, testing,
maintenance and adjustment at site shall be provided without
disrupting process.
3) System shall be of modular design for future expandability /
modification. Necessary redundancy shall be considered, as
spelled out in this T.S, for reducing extent of abnormality and
enhancing Mean Time To Repair (MTTR).
4) Instruments and field equipment shall be explosion proof or
intrinsically safe in hazardous locations.
5) Signal isolators/ zenner barriers shall be used for hazardous area
field signals.
6) Selection of actuators shall be based on fail safe principle.
7) Instrumentation for steam line shall follow Indian Boiler
regulations.
8) All electrical equipment shall be designed as per IEC safety
regulation.
9) Instrumentation equipment shall be standardised to enable
maximum interchangeability of parts and reduce inventory
requirement.
10) Equipment noise shall be generally not exceeding 85 dB.
11) All process parameters, in general, shall be hooked up with PLC
for control, data acquisition and safety interlock purposes.
12) All pressure tapping points on furnace body as well as Flue / gas
lines shall be provided with steam purging facility.
13) All actuators for control application shall be provided with
capacitance/ encoder type valve position transmitters having 4-20
mA output. The position signal shall be transmitted to the control
room and shall be used as analog input to the PLC.

14) All transmitters / pressure gauges for viscous fluid, fuel gas and
slurry application shall be provided with built-in diaphragm
separator.
15) All orifice plates / nozzle / venturi tubes shall be provided with
two sets of tapping assembly.
16) For steam application all tapping point shall be provided with a
steam condensation chamber.
17) Transmitter power supply (24 V DC Regulated) for individual units
shall be with the help of two sets of regulated 24 V power supply
units connected in parallel (hot redundant) with four nos (O-ring
configuration) of diodes in order to prevent loop current between
the two units. Each of the regulated power supply unit shall have
capacity to supply entire set of transmitters. Also, there shall be
one set of hot redundant 24 Vdc SMPS for analog input & output
and another set of hot redundant 24 Vdc SMPS for digital input &
output signals.
18) Power supply to individual instrument with AC power supply shall
be through individual MCB of adequate rating.
19) The various elements of entire instrumentation & process
automation system shall be generally as per the specification laid
down in this technical specification.
20) The input power supply for Instrumentation system including PLC
and power packs shall be 220 V ac. The interrogation voltage for
PLC system shall be 24 V dc.
3.5.2 Control System Configuration
3.5.2.1 The PLC shall be of modular design consisting of hot redundant CPU
with hot redundant power supply and communication facilities. All
process parameters shall be monitored through PLC. Loop displays,
drive status, process graphics, alarm status, real time and historical
trends etc. shall be available in all operator stations.
3.5.2.2 The I/O modules shall be of plug-in and run type. Online replacement of
modules shall be possible without effecting the system operation. The
I/O modules and the CPU shall be of same series.
3.5.2.3 The PLC shall have very high noise immunity for safe and reliable
operation under electrical radio frequency interferences and
electromagnetic disturbances expected in a steel plant. The operation of
PLC shall be completely unaffected by a momentary loss of power of
the order of 20 msec.

3.5.2.4 The communication bus shall be dual redundant type with ring
topology.
3.5.2.5 Standalone type HMI system shall be provided. The HMIs shall be on
ethernet bus having bus speed of not less than 1 GBPS. The I/O bus
shall have bus speed of not less than 4 MBPS. The various drives/
IMCCs/ weighing systems/ panel views / other devices etc. shall be
hooked up to the PLC on communication bus also. Communication
Compatibility with Ethernet standards and Protocol (UTP and FOs) shall
also be ensured.
3.5.2.6 All the communication hardware including FO and UTP cables shall be
in redundant mode. Alternate routes for FO cables shall also be
considered or maintain certain gap between them.
3.5.2.7 The PLC cabinet shall be provided with an earthing lug and the same
shall be properly secured to the AC mains earthing bus. All circuit
grounds, shield and drain wires of control cables shall be connected to
the systems ground bus, which is electrically isolated from AC mains
earthing bus. All circuits including shield shall be isolated from the
cabinet.
3.5.2.8 The interrogation voltage shall be 24 V DC. The analog inputs shall be of
24 V DC, 2-wire type on 4-20 mA.
3.5.2.9 Separate power supply units with dual redundancy shall be considered
for powering of analog and digital inputs. The power supply units shall
be provided with diode protection to prevent any loop current between
two parallel units. Electronic hooters shall be provided for the audio
alarms.
3.5.2.10 Licence of all the softwares must be handed over to the user
department through projects department before the start of
commissioning.
3.5.3 Technical Specifications
3.5.3.1 Programmable logic controller (PLC)
Function Process parameters monitoring, control
(regulatory, sequential), data logging, alarms, trend
recording, plant graphics and overall supervision.
CPU Dual redundant hot standby 32 bit processor with
redundant communication cards/ bus, redundant
power supply, etc.
Operator console 24” colour LED monitor, Intel i7 processor or

better, SSD of 1 TB or higher, 16 GB DDR4 SDRAM,
optical mouse, standard WINDOWS based OS from
OEM along with run time license etc. and shall
have VGA ports – 2nos & HDMI -1 no. Latest
configuration available at the time of detail
engineering shall be supplied.
In case of failure of any operator station, it shall be

possible to monitor & control the plant through
other operator station in control room.
Programming unit/ Console mounted engineering station with each

engineering station PLC having specifications similar to operator
station along with runtime & development license
without any limitation on tags. OPC server software
shall be provided.
Additionally, One number of lap top based

engineering tool shall be supplied.
PLC memory module Static RAM shall be minimum 16 MB. CPU memory
loading shall not exceed 60% of rated capacity. No
extended memory shall be used for USER program
other than CPU inbuilt Memory.
NVRAM (flash card) shall be minimum 64 MB. Flash

Memory shall be compulsory for USER program
back up (auto download facility from flash memory
in the CPU Start process).
Communication CPU communication through dedicated PLC bus
MMIs shall be communicating over ethernet bus.
Dual ring topology shall be considered.
Media: Coax/ UTP/ optical fibre with suitable
interfaces.
USB port for printers, etc.
Control function Analog signal conditioning, PID controls including
ramps, alarm generation, lead/ lag, timer, counter,

comparator, shift register, program & data
transfer, sequence & logic controls, process &
safety interlocks, etc.
I/O capacity 4K digital input, 4K digital output, 2K analog I/O
min.
Program scan time 0.3 ms per K of instruction
CPU changeover Less than 10 ms with bumpless data transfer
time
I/O scan time 10 ms or better
PID loop execution 250 ms for closed loop & 100 ms for open loop
time
Programming, Function block programming for PID controls
configuration including signal conditioning, scaling,
compensation, biasing, feedback & feed forward
controls, cascade controls, lead lag, self-tuning,
ramp control etc.
Relay ladder, structural text or seq. functional chart

programming software for sequential control.
All programs and loaded parameters should be in

English.
HMI software Windows based software, Data base S/W, text &
graphics displays with touch screen, plant dynamic
graphics, real time & historical trending, controller
facia displays, loop displays, alarm displays,
communication & diagnostics software. Event
monitoring, report generation software, interface
S/W with OPC features without any restriction on
number of tags. A partition shall be created for
transmitting and receiving data to plant wide
network for ERP and plant server.
Communication Ethernet/ proprietary interface with employer’s PLC
interface module based integrated control system of other facilities
for seamless data communication.
Communication with electrical and automation

drives and equipment including IMCC shall be
under scope. This shall also be established on dual
link.
Input/ output I/O cards shall be rack mounted type with card
modules level diagnostic features
Interrogation voltage 24 V DC
Output voltage 24 V DC
A/I cards 8/16 channel isolated type / 2 wire differential, 4-
20 mA
A/O cards 4/8 channel isolated type
D/I & D/O cards 16/32 channel type
LED/ fuse for input/ Required

output channels
Optical/ galvanic Required
isolation
Quantity As required
Spare I/Os 20% prewired spare plus five spare card for each
type of I/O cards.
Power supply card Every rack shall have hot redundant power supply
card.
Software Operating system software, application software,
web server software and antivirus software (for 3
years validity). Detail of SCADA pages shall be
decided during detail engineering. However, there
shall be no limitation on tags.
Documentation 6 sets
Accessories
A4 size laser printer Required as per configuration drawing.
MCBs Required for power distribution
Interfacing relays Required with potential free contacts for all the
DOs and for DIs coming from electrical panels/
MCC inputs/ circuits. Relays shall be 20% spare.
Panels, consoles, As required. Connectivity to plant network switch

chassis, shall also be provided. Any network connection
interconnection going out of control room shall be on optical fibre.
cables, LAN cables, OFC cable and LIU along with patch cords etc. on
taps etc. both ends shall be under the scope of contractor.
Network switches Managed type in hot redundant configuration with
(industrial grade) copper and fibre ports.
Hardware firewall Required for connectivity with plant network
Electronic hooter Required for each system
Mounting enclosures Cabinets and desks with lock and key arrangement
Design conditions
Power supply 170 V AC to 270 V AC, 50 Hz
Frequency variation 50 Hz +/- 2.5 Hz
Enclosure class IP 42
3.5.3.2 Network Switch

The switches shall be managed type and shall have following
specifications / features:
Architecture Layer-III Gigabit managed Switch
Required Port 24 100/1000Base-T ports and 4 independent

Density GBIC/Mini-GBIC/SFP
Switching Bandwidth Switching bandwidth should be 52 Gbps or
/ Backplane higher
Throughput Performance throughput should be 35 Mbps or

higher for the minimum packet size of 64 Bytes
Interface Supported GBIC/Mini-GBIC/SFP, 1000BaseSX, 1000BaseLX
Functionality Functionality at Half Duplex and Full Duplex
speed
VLAN IEEE 802.1Q VLAN support for at least 250
VLANs
RMON Embedded RMON: 4 groups of RMON
(Statistics, Alarm, Events, History)
Standards IEEE 802.1p prioritization with min. four priority
Supported queues
IEEE 802.3x Flow control

IEEE 802.3ad Link aggregation
IEEE 802.1w
IEEE 802.1s
Management Management through Web View (Web Based
capability Management)/ Telnet/ SNMP v1/v2/v3/
Console/ RMON
Others Features Rack Mountable with rack mounting hardware
Quality of Service Four Egress queues per port
Traffic prioritization
802.1p support
Manageability Network Management Software (NMS)
Security Security: 802.1x, MAC port Locking, RADIUS,
ACL (Access Control List)
Note: Managed switches of PLC OEM’s shall also acceptable.
3.5.3.3 Smart Pressure/ Flow/Level Transmitters
Type Variable Capacitance (Smart) type

Range As required
Output 4-20 mA dc
Power Supply 12-48 V dc
Wetted parts material SS 316
Load limit 600 Ohms
Accuracy +/- 0.25% of span
Ambient temp. limit 0-75 deg C
Sensitivity +/- 0.05% of span
Elevation/Suppression -50% of LRL to 100% of URL
Zero adjustment Required
Dead band +/- 0.05% of span
Temperature effect Maxm. Zero shift +/- 0.5%
Response time Less than 0.1 sec
Housing IP-65 as per IS 13947 : 1993
Lighting protection Required up to 2.5 kV in-built
Mounting 2” NB pipe mounting
Hand held Universal HART Calibrator for Smart
Configurator transmitters with battery charger unit.
The Hand held configurator must have the
following minimum features:
1. Selectable communication mode for either
4-20 mA DC or digital communication mode.
2. Shall display all configuration parameters,
PRM/ serial no., tag no., scratch pad memory
on at least two line LCD display for displaying
actual engineering unit.
3. Shall be able to verify / configure loop
operation, loop calibration and trouble
shooting.
4. Shall have easy upgrade facility for future
DD files from internet.
5. Shall be provided with weather proof cover
carrying Ni-Cd rechargeable battery pack
with charger.
6. Shall have data back-up for Rosemount,
ABB, Fuji, Yokogawa, Honeywell, Siemens
smart transmitters.
3.5.3.4 Temperature Transmitter
Type Smart configurable

Input T/C (K, N, S, B) mV to Current converter /
RTD 3 wire- Pt. 100, Pt 1000.
Output 4-20 mA dc
Power supply 12-48 V dc
Ambient 0-75 deg C, Cold junction compensation for
temperature T/C input
Accuracy +/- 0.25%
I/O Isolation Isolated Input, Output & Power circuit
Range adjustment Field adjustable within the range
Mounting Required
accessories

3.5.3.5 Resistance Temperature Detector
Element Platinum, Duplex, Ungrounded, 3 wire connection

Standard IS-2848:1986
Response time Better than 40 sec with well & 15 sec without well
Protective tube MgO filled SS 316 tube of min. 8 mm OD
Terminal Head/block Die Cast Aluminum with black enamel paint
Brass screw type/silver plated on ceramic head
Cable connection ¾” with cable gland
Insulation resistance Min 100 M Ohms at 100 V dc
Accessories - SS316 bar stock Thermowell
- Process connection - ¾” BSP(F) Bosh
- Extension nipple with Thermowell connection -
¾” BSPT(M) connection on the outside and ½”
BSP(F) on the inside for RTD connection
-5 mtr long flexible conduit of SS up to
temperature transmitter
3.5.3.6 Thermocouples
Element Chromel Alumel (K type),

IS-2054 / 2055:1962
Wire gauge 3.2 mm dia for K-type (1.6 mm for duplex)
Thermowell OD 21 mm
Sheath material 316 SS / Inconel 600 / Si carbide as required
Thermowell material AISI 446 SS (bar stock)
Thermowell junction Spot welded & ungrounded
Response time Better than 8 sec
Filling material MgO filled (Purity above 99.4%)
Terminal Head/block Die Cast Aluminum with black enamel paint
Brass screw type/silver plated on ceramic head
Cable connection 1/2” with cable gland
Process connection 1 1/2” RF Flanged
Accessories -SS316 Bar stock thermowell
-Extension nipple, companion flange, gaskets,

nuts, bolts, etc.
-5 mtr long flexible conduit of SS up to
temperature transmitter
3.5.3.7 Steam and Water Analysis System (SWAS)

SWAS system shall consist of pH, silica, conductivity, dissolved oxygen
and TDS measurements. Other parameters shall be measured as per the
process requirement. The system shall be complete with sampling
system, sample cooling system including chillers, isolation valves, blow
down system, sample filters, cooling water isolation, sample pressure
conditioning, SWAS panels, piping and tubing accessories etc.
a) Conductivity Analyser:
Description Specifications
Conductivity Sensor
Principle Resistive conductivity measurement
Measuring Ranges/ 0.0 - 200.0 µS/cm (k=0.01)

Cell Constants 0- 2000 µS/cm (k=0.1)
0.00 - 20.00 mS/cm (k=1)
Relative accuracy ± 1% of full scale reading (±2 % >500 mS/cm)
Temperature Sensor
Temperature -10.0 to + 125.0 °C (14.0 to 257.0 °F)
Resolution 0.1 °C / °F
Relative Accuracy ± 0.5 °C (± 1.0 °F)
Sensor PT100
Temperature Auto / manual (reference at 25 °C)

Compensation
Set Point Controller

Functions
Function (switchable) limit control
P/PI control (pulse length/pulse frequency)
Integral time 0 to 999.9 minutes

Adjustable period with 0.5 to 20 sec.
pulse length controller
Adjustable period with 60 to 120 pulses/min

pulse frequency
controller
Pickup / Dropout delay 0 to 2000 seconds
Wash cycle (If 0.1 to 199.9 hours

required-optional)
Wash duration (If 1 to 1999 seconds

required-optional)
Switching conductivity 0 to 10 % of full scale

hysteresis
Contact outputs, 1 SPDT, 3 SPST relays

controller
Switching voltage Max. 250 VAC
Switching current Max. 3A
Switching power Max. 600 VA
Alarm Functions
Function (switchable) Latching / pulse
Pickup delay 0 to 2000 seconds
Switching voltage Max. 250 VAC
Switching current Max. 3A
Switching power Max. 600 VA
Display
LCD UV coat, backlit 14 segments display with symbols

for status information
Backlight On/Off selectable with four level of brightness

control
Electromagnetic
Compliance (EMC)
Specifications
Emitted Interference EN 61 326
Immunity to EN 61 326
Interference
Environmental
Conditions
Ambient temperature 0 to 40 °C
operating range
Maximum Relative 80% up to 31°C decreasing linearly to 50% at 40°C

humidity
Power Supply
Input 80 to 250 VAC/DC 50/60 Hz Approx. 10VA
Main Fuse 250 mA anti-surge, S504 BUSSMANN
Pollution Degree 2
Transient Overvoltage II
category
Electrical Data and

Connections
Signal Output Two 0/4 to 20 mA outputs for conductivity and

temperature, galvanically isolated.
Digital communication Profibus DP
Load Max. 600 Ω
Conductivity input Screw terminal
Connection terminal 5-pin, 9-pin, and 19-pin terminal blocks
Enclosure
Dimensions Panel mount
Insulation IP 54 (front) / IP 40 (housing)
b) Dissolved Oxygen Analyzer

Range 0-.9999 ppb freely programmable

Accuracy +/- 0.5 ppb / +/- 5% whichever is greater
Measuring principle Amperometric
Repeatability +/- 1 ppb or +/- 5 %
Response time For step change of 1 to 40 ppb < 30 sec
Calibration 2 point calibration
Display Backlit digital display.
Type & number of 2 relay contacts inbuilt, 240 v ac , 3a
contacts
Monitor enclosure IP 65, (NEMA 4)
Ambient -20 deg to 60 deg c
temperature
Temperature Automatic throughout the operating range provided
compensation by pt-100
Output signal 2 x 4~20 ma isolated.
Digital Profibus DP
communication
Sensitivity <=0.5 ppb

Type Microprocessor based
Calibration Computer assisted for 2 point
Local indication 4 digit LCD (12mm x 8mm)
Data input Sealed touch key pad
Self-diagnostics required
Sample flow rate 3 ~ 6 lph
Dimensions Bezel : 144 x 144 x 150 (d), cut-out : 138 x 138 mm
Mounting Panel
Power supply Self-adapting 90...265 vac, 50/60 Hz
Weight 2 kgs
Sensor details
Electrodes Gold cathode / silver anode
Membrane PFA
Sensor body NORYL
Flow through cell Stainless steel-316L

c) pH Cell And Transmitters
pH Sensor
pH Range 2.00 to 12.00 pH
Resolution & Accuracy 0.01 pH & ± 0.01 pH
mV Range 0 to 100% or -1000 to 1000 mV
Resolution & Accuracy 0.1% or 1 mV / ± 1 mV
Temperature -9.9 to 125 oC (15.0 to 257.0 oF)
Resolution & Accuracy 0.1 & ± 0.5 oC (± 1.0 oF)
Sensor Pt 100
Temperature Automatic (± 10 oC / ± 18 oF offset adjustment) /
Compensation Manual
Set-point And
Controller Functions
Function Limit / Proportional Control / Proportional Integral
(Pulse Length or Pulse Frequency)
Integral time 999.9 minutes
Pickup / Dropout 0 to 1999 seconds
Delay
Wash Cycle (If 0.1 to 199.9 hours
required-optional)
Wash Duration (If 1 to 1999 seconds
required-optional)
Switching pH 0.1 to 1 pH
Hysteresis
Switching ORP 1 to 10.0 % / 10 to 100 mV
Hysteresis
Contact Outputs, 1 SPDT; 3 SPST relays
Controller
Switching Max 250 VAC / Max 3A / Max 600 VA
Voltage/Current/Power
Alarm Functions
Function (switchable) Latching / pulse
Pickup delay 0 to 1999 seconds
Switching Max 250 VAC / Max 3A / Max 600 VA
Voltage/Current/Power

Display
LCD UV coat, backlit 14 segments display with symbols
for status information
Backlight On/Off selection with four level of brightness
control
Emissions According to EN 50081-1
Susceptibility According to EN 50082-1
Environmental
Conditions
Ambient Temp. -10 to 50 oC (14 to 122 oF)
Operating Range
Rel. Humidity 10 to 95% (non-condensing)
Electrical Data And
Connections
Power requirements 80 to 250 V AC/DC
Frequency 48 to 62 Hz
Signal output Two /4 to 20 mA outputs for pH/mv and
temperature , galvanically isolated
Digital communication Profibus DP
Load Max.600 Ω
pH / ORP Input BNC (1012 Impedance)
Connection terminal (1 x 3-pin; 1 x 9-pin & 1 x 19-pin terminal blocks)
Main fuse 250 mA, anti-surge
Enclosure
Dimensions Panel Mount
Insulation IP 54 (front) , IP 40 (housing)
3.5.3.8 Pressure Switch / DP Switch
Type Bourdon/Bellow type

Sensing material SS 316
Casing Die cast aluminum alloy
Over range 150%
protection
Adjustment 1 Set point
- On-Off differential limit +/- 0.5%
Switch Two nos SPDT suitable for 240 V ac, 5A or 220

V dc 0.5 A
Accuracy + 0.5% of span
Repeatability + 0.5% of span
Enclosure class IP-65 as per IS 13947 : 1993
Accessories 1 Remote Chemical seal with 5 mtrs.
Capillary tube
2 Valve manifold
3 Blow out disc
3.5.3.9 Orifice Plate
The orifice plate shall specifically be designed as per B.S. 1042 section
1.1: 1981, 1.2 & 1.4: 1992. The orifice plate shall in general be of square
edge type with flange tapping. For line sizes of 500 mm and less, the
orifice plate shall be an integral unit comprising of carrier ring assembly,
tapping arrangement on both upstream as well down stream side. For
line sizes more than 500 mm, the orifice plate shall of disk type.
All orifice plates shall supplied with matching flanges of suitable rating
not less than three times the maximum time pressure. For disk type
orifice plate (line size more than 500 mm) suitable flange tapping
arrangement on both upstream as well as downstream side shall be
including in the scope. All tapping arrangements shall be complete with
a piece of impulse pipe line and a ball type shut off valve of suitable
pressure rating.
For steam applications orifice plate shall with a pair of steam
condensation chambers of suitable pressure rating.
Material of orifice plate assembly shall be of SS 316, unless otherwise
specified. The matching flange shall be of carbon steel. For line sizes
above 50 mm the diameter ratio (d/D ratio) shall preferably be selected
between 0.548 to 0.775 (area ratio between 0.3 to 0.6). Base of the
orifice plate shall be parallel within 0.5 degree. Other details as well as
design guidelines shall be as per BS 1042 section 1.1: 1981, 1.2 & 1.4:
1992
Design Standard BS-1042:1992

Type Square edged concentric
Tapping Flange tapping
Orifice plate material SS316 (Min. 3mm thickness)
Flange material/ type ASTM-A-105/ WNRF
Accessories CS nipple & shutoff valve for tapping with
CS companion flanges
3.5.3.10 Venturi Tube

Venturi flow meters shall be provided for B.F. Gas and CO gas flow
meters. The Venturi shall be designed as per BS-1042:1992 standard. The
contractor shall design, manufacture and supply venture flow meters
suiting to the process requirement. The material of the venture shall be
Carbon Steel with welded process connection. Differential pressure
tappings shall be provided for accurate flow measurement. 2 nos
additional tappings shall also be provided for maintenance spares.
3.5.3.11 Continuous Emission Monitoring System (CEMS)
Type Infrared absorption

Analyzer Dust proof (IP65), field mounted
body
Insitu SS316L(Insertion length 1mtr & above depending on
Probe stack wall thickness/width)
Calibration Automatic zero calibration using plant instrument air &
manual span calibration/verification by using known
concentration gas cylinders – interval user selectable
Accuracy +/- 2% of F.S
Zero drift Less than 2% per month.
Calibration Less than 2% of span.
drift
Response Less than 200 seconds
time (T90)
Range CO : 0 – 3000 ppm fully site selectable
(Program SO2 : 0 - 3000 ppm fully site selectable
mable) NOx : 0-3000 ppm fully site selectable
H2O : 0 – 25%
CO2 : 0 – 20%
Normalizat Online normalization for Temperature, pressure, H2O &
ion CO2 measurement to convert reading in mg/Nm3. All
required sensors shall be supplied for online
normalization.
Ambient Bided analyser should be field mounted type & should be
temperatu capable for withstanding ambient temperature up to 55

re deg.c
Flue gas Flue gas dew point to 300 deg.C, hot & dusty flue gas
temperatu
re
Accessorie Online Calibration system, gas cylinders, regulator, other
s accessories and special cables as required
Output Isolated 4-20 mA output configured in mg/Nm3
Concentration for CO, SO2 / NOx for DDCMIS
Connectivity RS485 modbus interface
Alarm relay output for Hi/Low alarm for each measured
parameter & for the system fault
Power 170- 270 VAC, 50 Hz
supply
Purging Required. Plant instrument air of 4-5kg/cm2 shall be
facility provided
3.5.3.12 Pressure Gauge

The specification of the pressure gauge shall be as follow:-
Type Direct
Mounting On line (Local)
Dial size 150 mm
Case Cast Aluminium
Blowout protection Required
Moving parts matl. SS 316
Accuracy + 2%
PROCESS CONNECTION 1/2 " BSPT(M)
3.5.3.13 Temperature Gauge

The specification of the temperature gauge shall be as follow:-
Type With thermo-well
Range 0-150oC
Mounting On line (Local)

Dial size 150 mm
Case Cast Aluminium
Accuracy + 2%
Process Connection 1/2 " BSPT(M)
3.5.3.14 Control Valves

Control valves shall be designed to function continuously and
satisfactorily under most severe conditions with minimum maintenance.
The contractor shall submit control valve sizing and noise calculations.
The pressure drop across the valve shall be as per system requirements.
Globe Control valve shall be made of high quality material, cast bodies
and X-Ray inspected. Body, flange and trim material shall comply with
physical and chemical operating conditions of process fluid. Thickness
of the valve body shall be as per API / ASTM standards. The valves shall
be generally flanged types. Bonnet shall be forged and of same material
as the valve body. Self-lubricating type packing material shall be
selected. Plug and seat shall be normally of same material. Seat may be
lapped to ensure minimum leakage. Pneumatic actuator shall be used in
regulatory control. The actuator shall receive 4 to 20 mA input signal
from the controller and shall have electro-pneumatic converter, valve
positioner, limit switches, capacitance type valve position transmitter,
companion flanges and other accessories as required.
In BF & CO gas lines, butterfly valve with linear power cylinder shall be
used as final control element for control loops.
The control valve specification shall be generally as follows:
Valve type Globe type

Application All Boiler & auxiliary area control valves
Guiding/points Cage / Top guided, V-port,
Bonnet Finned
Body material ASTM-A216 WCB (Carbon steel)
Packing material Grafoil
Valve action Energy failure to stay-put (air to open)
Seat & Trim AISI-316 stellited
material
Leakage Class IV as per ANSI-B16.104 (1976).
Actuator Pneumatic actuator (suitable for control

air pressure 3 kg/cm2)
I / P Converter Required (suitable for 4-20 mA input
signal from controller & 0.2 to 1.0
kg/cm2 air output)
Air Set With air filter regulator & 2 nos. of
gauges with 8 mm SS tubing.
Positioner Required (conventional & traditional
type)
Air lock relay Required
Enclosure IP-65, IS 13947 : 1993
Position Indicator Required (Local )
Position Capacitance / encoder type with 4 - 20
Transmitter mA dc output
Matching Flanges With nuts, bolts, gaskets etc.
Limit Switches  Non-contact inductive type with two
wire connection working on 24 VDC.
 2 sets each comprising of two nos. of
independently adjustable position
switches.
Hand wheel Required
IBR certificate Required for steam service
Butterfly type
Application All Boiler & auxiliary area control valves
Body material -Carbon Steel IS-2062
-ASTM A216 WCB
Disc material SS 304
Shaft material SS 316
Bonnet Finned
Angle of opening 0-60 deg
Actuator Pneumatic actuator (suitable for control
air pressure 4-5 kg/cm2)
I / P Converter Required (suitable for 4-20 mA input
signal from controller & 0.2 to 1.0
kg/cm2 air output)
Air Set With air filter regulator & 2 nos. of
gauges with 8 mm SS tubing.

Positioner Required (direct mode)
Air lock relay Required
Enclosure IP-65, IS 13947 : 1993
Position Indicator Required (Local )
Position Capacitance / encoder type with 4 - 20
Transmitter mA dc output
Matching Flanges With nuts, bolts, gaskets etc.
Limit Switches 2 sets each comprising of two nos. of
independently adjustable position
switches.
Hand wheel Required
3.5.3.15 DC Voltage Power Pack
The power pack shall be redundant & suitably designed to provide
output voltage of + & - 24 VDC & adjustable + 10% of the rated
voltage and load current limit from 115% down to 10% of the rated
current. The power pack shall be fully protected against over load and
short circuit. RFI filter shall be incorporated in the input line to prevent
RF interference from main supply. The output voltage shall be
electrically floating from the ground. Setting regulation shall be at least
20mV, load regulation + 0.2% with transient recovery of approx.
100usec. It shall have recovery within regulation band for a load change
from 10% to 90% and the output adjustability from 20.4V to 32.4V. The
ripple and noise shall be within 1mv rms. The unit shall be provided with
voltmeter and ammeter.
3.5.3.16 Compensating Cables
Type K-type twisted pair cables

Conductor Copper & Constantan for K type
Conductor size 3/22 SWG (1.29 mm sq.)
No of strand/strand 3/0.74 (mm)
size
Conductor shape Stranded and circular
Insulation Extruded PVC type C as per IS 5831:1984, thk: 0.6
mm
Core identification Color coded as per IS 8784: 1987
Individual and Overall Al. Mylar tape 100% coverage& 25% overlap.
shielding / Screening Screen thk : 0.05 mm for individual pair and

0.05 mm for overall screen
Drain wire Annealed tinned copper, 0.5 mm sq.
Inner sheath Extruded PVC type ST-1 as per IS 5831 : 1984, thk
: 0.3 mm minimum
Outer sheath Extruded PVC type ST-2 as per IS 5831 : 1984;
FRLS, thk : 1.4 mm minimum
Colour code (overall) As per IS 8784 : 1987
Armouring Galvanized steel wire of minimum 0.9/1.2 mm
(Nom)
Electrical parameters
Capacitance between Max. 250 pF/m
core to core
core and screen
L/R ratio 40 micro H /ohm
Minimum Insulation 100 M Ohm/km
resistance at 20oC
HV Test 1.5 KV for 1 min. between core to core
1 KV for 1 min. between core to screen
Conductor resistance Max. 284 ohm/km of loop at 20oC
Standard IS 8784 : 1987
3.5.3.17 Signal & Control Cable
Type Screened & armoured

No. of Cores - 3 x 1.5 mm sq. from sensor to junction boxes
- Multi pair cables of 1.0 mm sq. conductor from
junction box to PLC.
Voltage grade 1100 Volt
Conductor Electrolytic grade stranded annealed bare
copper as per IS-8130:1984
Cross section area: 1.5/1.0 mm2
<20 Ohm/km/core
Insulation Extruded PVC type C as per IS 5831:1984, thk :
0.6 mm
Core identification Color coded and numbered

Individual and Overall Al. Mylar tape 100% coverage& 25% overlap.
shielding / Screening Screen thk : 0.018 mm for individual pair and
0.05 mm for overall screen
Drain wire Annealed tinned copper, 0.5 mm2
Inner sheath Extruded PVC type ST-2 as per IS 5831 : 1984,
thk : 0.3 mm minimum
Outer sheath Extruded PVC type ST-2 (temp=85oC) as per IS
5831 : 1984; FRLS, thk : 1.4 mm minimum
Colour code (overall Grey
sheath)
Armouring Galvanised steel wire of minimum 0.9/1.2 mm
(Nom)
Electrical parameters
core to core
core and screen
L/R ratio 25 micro H /ohm
Minimum Insulation 100 M Ohm/km
resistance at 20oC
HV Test 1.5 KV for 1 min. between core to core
1 KV for 1 min. between core to screen
3.5.3.18 Power Cable
Type Armoured power cable

No. of Cores 3 x 2.5mmsq
Voltage grade 1100 Volt
Conductor Bare copper as per IS-8130:1984;
multistrand
Cross section area: 2.5 mmsq
7.6 Ohm/km/core as per IS-8130
Insulation Extruded PVC type C as per IS-5831
0.9 mm nominal thickness
Core identification Color coded ( Red , Black & Green)

Inner sheath Extruded PVC ST-2
Outer sheath Extruded PVC ST-2 FRLS type
Colour code (overall Black
sheath)
Test -1.5KV for 1 min. core to core
3.5.3.19 Instrument Panels & Cabinets

1. The panels shall be of 2250 mm height and open type or cabinet
type in simplex or duplex construction as per the requirement of
instrumentation systems. The panels shall be manufactured from
cold rolled carbon steel sheet confirming to IS 513-1992. Panels
shall be manufactured of 3 mm thick sheet except for doors which
can be of 2 mm thick sheets. For duplex panels sheet size of 4 / 5
thickness may be used depending upon size of panels.
2. The panels shall be free standing type and of welded / bolted
construction. All welds shall be ground smooth, all corners shall be
rounded and all weld spatters shall be cleared. Surface of panels
shall be free from all mars & defects. The finished panel shall be
flat within 2 mm in any 2 meter radius and shall be smooth.
Removable eye bolt lifting lugs shall be furnished and installed in
all panels.
3. All instrument cut outs and drilling shall be straight and through.
All panels shall be supported on suitably sized vibration isolators,
designed for bolting to panel frame and flooring. Access doors on
enclosed panels shall be 750 mm wide by 1800 mm high, single
sheet with suitable latch, hooks, knobs on inside and outside and
shall open forward.
4. The panel surface shall be thoroughly degreased, smoothed
phosphated, filled and painted with rust resistant primer to
present a flat and smooth finish.
5. The front panels shall be primed and given at least two under
coats and minimum two finish coats to provide a smooth mat
finish. Preferred paint schedules are:-
i) Exterior surface: Light grey shade no.631 of IS 5:1991 in semi-
gloss finish.
ii) Interior surfaces shall be painted with Brilliant white enamel.
All above paints shall be air-drying type.

6. The legend plates of non-conducting material shall be installed on
panel face for identification. The overall dimensions of name plates
shall preferably be 20 x 80 mm.
7. All cables from field to the control room shall be terminated in the
marshaling boxes / field termination racks mounted near main
panels. The cables shall be provided with U-lugs and shall be
terminated on screwed terminals.
8. PLC panel doors shall have Perspex sheets in front for viewing
without opening the panel door.
3.5.3.20 Electrical Accessories and Wiring
1. All electrical accessories e.g. circuit breakers, control switches,
push-buttons, panel lighting fixtures, light switches, receptacles,
horns etc. required for the panel shall be provided.
2. Electrical accessories shall be suitable for the environment of
specific location. Devices mounted on control room panels shall be
flush mounted.
3. All panel wiring except power and thermocouple circuits shall be
done with 1100 V grade PVC insulated, 1.5 Sq. mm stranded
copper conductor. Wiring shall be continuous between terminal
points without splicing and shall terminate on solder less type wire
connections at the instruments and to terminal blocks.
4. All incoming and outgoing wires except the thermocouple lead
wires shall be routed through heavy duty carrier type, single depth
terminal blocks having flanged partitions between terminals.
5. All terminal blocks shall include minimum 20% spare terminals and
shall not have terminal screws smaller than 4 mm.
6. All cable connections shall follow the principle of straight and
cross ferrule.
7. All wires shall run in suitable plastic wiring sleeves between
terminal ends. Wires shall be plainly and durably labeled at both
ends with non-conducting materials for easy identification and
must conform to wire labeling scheme shown on electrical inter
connection drawings.
8. Cabinet type panels shall be considered LED lamp both at front
and back of panels and energized through door switch. The
internal illumination shall be 350-400 lux/m2. The panel shall also
be provided with filters and cooling fans.

9. One spare socket with MCB of 220 V - 3 pin, 15/5 Amp shall be
provided in each cabinet type panel for soldering iron, blower etc.
10. All instruments with 220 V ac power supply shall be supplied
through individual MCB. All instruments with 24 V DC power
supply shall be through two nos of regulated DC power pack, each
capable of supplying entire load, connected in parallel with four
nos of diodes in order to prevent loop current flow between the
power packs. A DC bus shall be formed with this system. Individual
instruments shall be connected to the DC bus through individual
switch fuse units.
3.5.3.21 Impulse Pipe Laying
1. SS pipe of 1/2” NB, schedule 80 shall be used for steam application
and feed water.
2. For other applications, the impulse lines shall be ½ inch NB,
schedule 80 and seamless pipe.
3. All pipe fittings shall be ½ inch BSP of CS type. All fittings shall be
tested at a pressure rating of 1000 lbs and stamped on each
fitting.
4. All root valves and isolation valves used on impulse lines shall be
of SS316, ½ inch BSP (F) threaded.
5. All impulse piping in general shall be given a slope of not less than
1 in 12 except where otherwise specified. The scope of impulse
pipe work shall be done from the tapping point for liquids, steam
and condensable and up from the tapping points for gases unless
specific provisions are made for venting and drawing.
6. Vents and drains shall be ensured at the highest or lowest of
piping run respectively. Impulse pipelines shall be kept as short as
possible consistent with good practice and accessibility. Piping and
tubing shall be adequately supported and fixed at distances not
exceeding as follows:-
Copper tube 12 mm or less - Continuous support
Steel tube 10 mm to 20 mm - 1.5 m.
Steel tube 25 mm - 2.0 m.
Steel pipe 40-50 mm - 3.0 m.
7. The following colour code shall be used for impulse lines:-
Green - Water

Red - Blast (Hot)
Blue - Oxygen line/ Steam line
Yellow - BF Gas line
3.5.3.22 R.F.Earthing
1. The R.F. earthing system shall conform to I.E. rules and latest
revision of relevant Indian Standards.
2. Minimum two separate grounding stations each comprising of two
earth pits at minimum distance of 3 meters shall be provided.
Earthing resistance of the pit should not be more than 0.5 ohms.
3. A continuous copper bus (size 25 mm x 3 mm) shall be provided as
logical earth grid. Whenever needed the earth bus should be
converted to a net of buses as per requirement. The safety ground
and the signal bus should never be connected together inside the
control room.
4. The metal frames or enclosures of each electrical equipment shall
be connected firmly to the safety ground at the nearest point, The
connection should be protected such that it does not loose the
bond by vibration or personnel movement.
5. The logic ground bus shall run near each panel / equipment and
shall be connected to logic ground of each equipment with
smallest length of wire as possible.
3.5.3.23 General
1. The equipment shall conform to the safety requirements of IS
8495-1987 – specification for electrical instruments for hazardous
atmospheres, IS-9858-1992 – Safety requirements for electronic
measuring apparatus etc. Wherever Indian Standards do not exist,
ISA, IEEE or NEEMA Standards or the ones laid down hereafter be
followed. Devices should be intrinsically safe.
2. All instrumentation power supply system shall be through isolation
transformers and system voltage shall be 220 V +/- 5%, 50 Hz.
Instrumentation system working on unified current signal of 4 – 20
mA DC only shall be used.
3. The control electronics chassis shall be of 19 inch frame
construction and shall be provided for housing various electronic
plug-in modules used for signal detection, conditioning,
processing etc. The construction shall be modular and shall

provide clear separation between field & control room signals as
well as between intrinsically safe and non-intrinsically safe signals.
4. Any signal duplicated shall be through signal isolator only.
3.5.4 Schedule of Instrumentation Equipment

3.5.4.1 Notes
1 All erection hardware like impulse pipe, control cables, cable laying
accessories like trays, conduits, GI pipes, erection accessories etc.
shall be quoted on as required in actual site condition. Quotation on
unit rate basis shall not be acceptable. For gas, steam and high
pressure water lines, SS impulse pipes and SS ball type isolation
valves shall be provided.
2 All flow sensors shall be quoted with two sets of tapping assembly
including impulse lines, root valves and accessories.
3 Steam and gas flow signals shall be provided with pressure &
temperature compensation.
4 All control / shut off valves to be provided with hand wheel, chains,
gear boxes etc. for manual operation as and when necessary.
5 For oil/viscous fluid applications all transmitters/ pressure gauges
shall be with built-in diaphragm separator.
6 All temperature sensors shall be of mineral insulated type with total
moisture free construction and with duplex elements.
7 The Contractor shall quote for control room furniture including 6 nos
of revolving chairs, PLC peripherals tables and chairs, one no. each of
operator's table and storage cabinet / almirah.
3.5.4.2 Instrument Schedule
S.No. Description Qty.

1. PLC complete with peripherals and accessories 1 Lot
 Hot redundant processor, redundant power
supply and redundant communication modules,
data bus, communication bus
 I/O cards with 20% spare pre-wired I/Os and 1
no. spare card for each type of I/O card used
 Panels & chassis etc.
 HMIs (3 nos.) with 24” LED monitor, keyboard
and mouse

 Engineering Station with 24” LED monitor,
keyboard and mouse – 1 no.
 Historian cum HMI with 24” LED monitor – 1 no.
 Laptop based programing tool including PLC
commissioning software and necessary hardware
(Media adopter)– 1 no.
 Required hardware to extend one operator’s
station (HMI) up to existing boiler control room
and application software & System software
 Large Screen display for Dynamic Mimic (55”
LED) along with dedicated HMI.
 Black & white A3/A4 laser jet printer-2nos
 Colour A4 printer-1
 B/W A4 printer-1
 SCADA software
 Programming tool
 Communication cables
 Application software
2. Field Instruments comprising of pressure, flow, DP, 1 Lot
temperature & level transmitters, Electronic level
indicators for Boiler Drum and Deaerator,
Thermocouples & RTDs, Flow elements, Local gauges,
switches etc. for Boiler & DM water system,
Compressed Air System etc.
3. Pneumatically operated control valves for all control 1 Lot
applications. Compressed air to be tapped and
conditioned from envisaged compressors.
4. Special instruments including Steam and water analysis 1 Lot
system (SWAS), Zirconia cell type Oxygen analyser (in-
situ), Continuous Emission Monitoring System (CEMS)
for NOx, SOx, CO and Dust Concentration etc.
5. Control room furniture including operator’s chair & 1 Lot
tables, PC & peripherals chair & tables, storage cabinet/
almirah.
6. Signal cables, power cables as well as compensating
1 Lot
cables for thermocouple and cable laying accessories
like cable trays, conduits.
7. Impulse pipes, root valves, isolation valves etc. 1 Lot
8. Erection hardware and non-standard equipment 1 Lot

9. FDA System for Control Room, Electrical Room, 1 Lot
transformer room, battery room, cable galleries, cable
vaults, false floors and false ceilings & other fire
hazardous area.
10. Extension of plant’s existing EPBAX system to telephone 1 Lot
points in control room and electrical rooms ( 6 sets with
requisite cabling)
11. PA System comprising of desk stations and wall hanging 1 Lot
units with cabling and battery back-up (1 station in
control room + 6 stations in field)
13. Ambient CO Detection System comprising of minimum 1 Lot
8 nos. of fixed detectors with display electronics and
alarm and 8 nos. of portable detectors. Ambient Co
detectors shall be hooked up to PLC for alarm display.
14. Tools and testing equipment e.g.,
 Universal HART calibrator for transmitters – 1no
 Portable digital multi meters 4 ½ digit – 4 nos
 Universal portable calibrator for pressure &
temperature and electrical signals with
measurement and simulation – 1 no
 Measurement & simulation of pressure, DP, Flow
& Level transmitters – 1 number
 Measurement & simulation of 4-20 mA dc, 1-5
Vdc, RTD, mV – 1 no
 Clamp type multi-meter for measuring 4-20 mA
dc – 2 numbers
 Portable universal temperature calibrator for RTD
& T/C – 1no.
 Mili volt & mA feed and measure – 2 nos
 Vacuum cleaner – 2 nos.
 Meggar (Digital) of 0 – 500 V dc – 1no
 Soldering and desoldering station – 1no
 Line tester – 10 nos
 Screw driver set – 4 nos
 Spanner set – 4 nos.
 Slide wrench – 4 nos.
3.5.5 Fire Detection and Alarm System

3.5.5.1 The fire detection & alarm system shall be microprocessor based
intelligent addressable type and shall be capable of giving early warning
in case of smoke & fire. The system shall be designed keeping in view
continuous and reliable performance in environment generally
prevailing in steel plant. The system shall be complete with multi criteria
detectors, heat detectors, main control panel, repeater panel, hooters,
response indicators, manual call points, FRLS cables, sealed
maintenance free battery back-up for minimum 4 hours along with
battery charger etc. Specification shall conform to NPFA norms. Fire
Detection and Alarm System (FDA) shall be provided for generally the
following areas:-
1. All control rooms
2. All transformer/ MCC/ Electrical rooms
3. Cable basement/ cable gallery
4. False floor/ false ceiling if any
5. Any other fire sensitive area of the plant
3.5.5.2 The control panel shall be installed in manned location to be mutually
decided with the Employer during detail engineering stage. Various
areas of the plant shall be monitored in different zones. Zone isolators
shall be considered. The sensor types shall be decided as per
requirement.
3.5.5.3 It shall provide early warning in case of smoke or fire in the Boiler
complex, so that the same can be extinguished in time and the whole
premises, equipment and lives of personnel can be saved. The system
shall operate on 230 V AC. Main control panel shall have a display of
minimum 600 characters. The system shall have sufficient no. of loop
cards (with 20 % spare) and programmable control modules to interface
with fire extinguishing systems. The detectors shall have features like
device wrapping, environment compensation etc.
3.5.5.4 The scope of fire detection system under Boiler & Auxiliary package
shall cover Boiler and auxiliary units. The main control panels and the
field devices (except response indicators) shall be UL listed and FM
approved. All the items as above shall be supplied from one single
manufacturer. Overall design shall be as per NFPA–72b guidelines.
3.5.5.5 The detectors shall produce intelligent signal which shall be varying with
smoke density or heat. The detectors shall continuously report about
the general condition of the area being monitored. The complete
systems shall be fail safe type. Audio visual alarm shall be generated in
case of any abnormality, short circuit or open circuit. The system shall
have provision to transmit fire alarm signal to central fire control
stations.
3.5.6 Telecommunication
3.5.6.1 Plant intercom telephone facility shall be provided in the following
locations within Compressor Station area:
S. No. Area No. of subscriber

1. Control Room 2 sets
2. MCC Room 1 set
3. DM water plant 1 set
4. Compressor House 1 set
5. Any other area 1 set
3.5.6.2 50 pair jelly filled armoured telephone cable (approx. 700 m) shall be
laid to SMS substation from BF office and 20 pair jelly filled armoured
telephone cable (approx. 150 m) shall be laid from SMS substation to
the new gas fired boiler respectively.
3.5.6.3 All the telephone cable between JBs inside the boiler area shall be 5/10
pair armoured cable.
3.5.6.4 Short length cables shall be unarmoured PVC type and should be laid
through GI (outside) / PVC (inside) conduit.
3.5.6.5 CLI Push Button telephones with 2-pin rossete box shall be provided as
per requirement.
3.5.6.6 All the telephone JBs in the boiler area shall be of 10/20/50/100 pairs.
3.5.6.7 Standard push button telephone sets shall be supplied and installed at
subscriber end.
3.5.6.8 Push button telephone
Type CLI (Name and telephone
number shall be displayed)
FSK/DTMF Compatibility Both Required
Name/ Phone Book 10 Numbers With
Names(Minimum)
Incoming Calls Memory 10(Minimum)
Outgoing Calls memory 10 (Minimum
Display 16 Digit LCD Display With
Backlight

Two Way Speaker Phone Required, With Programmable
Volume Settings/ Digital Volume
Control
Ringer Volume Selection Required
Tone / Pulse Dialing Mode Compatible
Other features  Call back for incoming/
outgoing calls
 Display of real-time and date
in idle mode
 Speaker-in-use indication
 Display of incoming numbers,
new call, total calls and repeat
calls
 Redial
 Flash
3.5.6.9 Jelly Filled Armoured Telephone cable

Type Jelly Filled Armoured
Size 5X2X0.63mm/ 10X2X0.5mm/
20X2X0.5mm/ 50X2X0.63mm
Copper Annealed high conductivity copper
Insulation PVC
Specification conforming to TEC-CR / CUG-01/03, AUG 2003,
TEC-G/CUG-01/02, FEB 1996 &
G/CUG-02/ 01, JUNE 1998
Armourer Steel Tape and Polythene Jacket
Copper Conductor Annealed high conductivity
untinned as per ITD specification
no: G/C UG-01/02 FEB 1996
3.5.6.10 Unarmoured Telephone cable

Size 3X2X0.5 mm/ 5X2X0.5mm
Duty Heavy duty

Copper Conductor Annealed high conductivity un-
tinned as per ITD specification no:
G/C UG-01/02 FEB 1996
Insulation PVC
Twisting 2 cores twisted into a pair to
minimize cross talk and tapped
with 2 layers of polythene or PVC
tape and overall PVC sheathed
Specification conforming to S/WS- ITD 114C OR 114D
3.5.6.11 KRONE JB box

Size 10pair/ 20pair/ 50pair/ 100pair
Duty  For 10 pair /20 pair 1 mm thick MS sheet box
with back mount frame having fixing
arrangement for box and back mount frame
 For 50 pair/ 100pair box should be made of 2
mm thick MS sheet properly coated with 1 coat
of primer and 3 coat of steel grey paint
Paint and fixtures Box shall be coated with paint having locking as
well as latching facility and fitted with required nos
of 10 pair LSA - plus disconnection modules
3.5.7 PA System
3.5.7.1 Analogue type Loudspeaker talk back system shall be provided for
facilitating reliable two-way intercommunication between various
strategic points of the plant complex. The subscriber stations shall be
provided at locations having very high ambient noise level. The PA
system shall be of digital type comprising of the following:-
1) Programmable type digital master control station – 1no
2) Wall mounted outdoor handset station (weather proof) with
numeric key pad in die cast aluminium alloy body – 6 nos
3) Desk top / wall mounted hand set station in die cast aluminium
alloy body along with speaker and numeric key pad for control
room – 1 no
4) Industrial horn type speaker – 6 nos
5) UPS and battery backup for 4 hours

6) Interconnection cables, GI conduits, junction boxes and other
erection hardware - Lot
3.5.7.2 The location for installation of talk back system shall be as follows:-
1) Control Rooms
2) Burner floor
3) Feed Pump area
4) Near Gas valves
5) MCC room
6) Auxiliary areas
3.5.7.3 Indoor loud speaker shall be of cone type with 4 watts RMS output
speaker.
3.5.7.4 Wall mounting handset station
Electrical
Power Supply voltage 220VAC + 10% 50/60Hz or 24VDC
Current consumption 180 mA at 220VAC,850 mA at 24VDC
MICROPHONE
Type Dynamic noise cancelling
Internal
230Ω±15%
impedance
Sensitivity 0.7mV/Pa
Receiver
Type Dynamic
Internal
230Ω±15%
impedance
Sound Pressure
116 dB +3/-1 dB (Typically at 1kHz)
Level (SPL)
Line amplifier section
Input sensitivity 3mV (adjustable by preset internally)
Input impedance 4kΩ Resistive
Load impedance 240Ω Resistive
Output 2V
Distortion 1% at 1kHz
Residual noise
50dB (w.r.t. rated output)
level
Frequency
200Hz to 12kHz (+1/-3dB)
response
Gong tone
600 Hz ±100 Hz
frequency
Gong tone
800mS +500/-200 mS
duration

Power amplifier section
Input sensitivity 2V +/- 0.2V
Input impedance >25kΩ
Distortion 1%at1kHz
Frequency
+1/-3dB at 200Hz to10kHz
response
Residual noise
-50dB (w.r.t. rated output)
level
Tone control Bass cut filter (minimum cut 10dB at 200Hz)
Output power 15W r.m.s. across 8Ω or 16Ω load on relevant tap
Protection Short circuit protection on output
Environmental
Operating
-20°Cto+55°C
temperature
Storage
-40°Cto+70°C
temperature
Relative humidity 95%
Environmental
IP 52, with weather proof cover IP 55
protection

3.5.7.5 Pilfer proof wall mounting station
Electrical
Microphone
Type Dynamic noise canceling
Internal impedance 230Ω±15%
Line receiver amplifier
Input sensitivity 2V
Output 1Watt across 25Ω
Residual noise level -50dB (w.r.t. rated output)
Frequency response 200Hz to 10kHz (+1/-3dB)
Input sensitivity 0.7mV(adjustable by preset internally)
Output 2V
Gong tone frequency 600 Hz ±100 Hz
Gong tone duration 800mS +500/-200 mS
Power amplifier section
Input sensitivity 2V +/- 0.2V
Input impedance 20kΩ
Distortion 1%at1kHz
Frequency response 200Hz to 10kHz(-3dB)
Tone control ±10dB at 200Hz
15W r.m.s. across 8Ω or 16Ω load on
Output power
relevant tap
Environmental
Operating temperature -20°Cto+55°C
Storage temperature -40°Cto+70°C
Environmental protection IP 52, with weather proof cover IP 55
3.5.7.6 Desktop handset station

Electrical
Current consumption 150 mA at 24VDC
Microphone
Type Dynamic noise canceling
Internal impedance 230Ω±15%
Line receiver
Input sensitivity 5mV adjustable by preset R1
Rated o/p 2 Volts
Input Impedance 2kohms
O/p Impedance 2kohms
Gong tone O/p 6V(+/-1 V Peak to Peak starting amplitude)
Gong tone frequency 600 Hz (± 100 Hz)
Distortion at rated output <1%
Gong tone frequency 600 Hz(±100 Hz)
Hum and Noise Better than 45 dB
Side tone cancellation Upto 15 dB below rated O/p
Environmental
Environmental protection IP 52
3.5.7.7 Wall mounting extension amplifier station

Electrical
Line receiver amplifier
Input sensitivity 2V
Output 1Watt across 25Ω
Input sensitivity 0.7mV(adjustable by preset internally)
Output 2V

3.5.7.8 Horn Frequency response 200Hz to 12kHz (+1/-3dB)
Louds Gong tone frequency 600 Hz ±100 Hz
peaker Gong tone duration 800mS +500/-200 mS
With Power amplifier section
Drive Input sensitivity 2V +/- 0.2V
Unit Input impedance 20kΩ
Distortion 1%at1kHz
Frequency response 200Hz to 10kHz(-3dB)
Tone control ±10dB at 200Hz
15W r.m.s. across 8Ω or 16Ω load on
Output power
relevant tap
Environmental
Environmental protection IP 52, with weather proof cover IP 55
Electrical
Maximum Power 15W
Rated Power 10W
Sound Pressure level
at 10 W / 1 W ( 1 KHz 118.6 dB / 106.6 dB (SPL)
3.5.7.9 S at 1m)
t Effective frequency
400 Hz - 4 kHz
a range (-10 dB)
t Opening Angle at 1
150° / 32°
i KHz / 4 KHz (-6 dB)
oRated Voltage 100 V
n Rated impedance 1000 ohm
Environmental
J Operating
u temperature -25 ºC to +55 ºC
n Storage temperature -40 ºC to +70 ºC
c
tion Box
Material of Body Pressure Die Cast Aluminium Alloy
Material of Glands Galvanized Iron (G.I.)
Terminals 6X Elmax Connector for up to 5mm Mains Cable

12X TB 05 Rapid Make Barrier Type Terminals
No. of Glands 6
IP Protection IP 55
3.5.7.10 Speaker JB
Material of Body Pressure Die Cast Aluminum Alloy
Material of Glands Galvanized Iron (G.I.)
Terminals 4 X TB10 Rapid make barrier type terminals
No. of Glands 3
Insulation resistance
between Terminal & 500 m OHMS
body
HV Test 1.5KV for 1 min
IP Protection IP 55
3.5.7.11 Protective cover for wall/ column mount station

Material Glass Fibre
IP Protection IP 65
Fit for LBD 8921/02, LBD 8922/02 and LBD 8924/02
3.5.7.12 6 core armoured copper signal cable

Type armoured cable
Voltage rating 1100v
Number of core 6
Cross section core: 14/0.2mm
Conductor material tinned copper
Insulation material PVC
Inner sheath material PVC
Inner sheath material PVC
Armouring galvanised steel( round wire/strip)
Core identification Multiple colour as per is-1554/1976,

colours of 6-cores shall be red, black,
blue, orange, green and slate.
Overall PVC sheath blue colour
3.5.7.13 Soldering station

Heater Ceramic type, 200 Watt
Voltage 230VAC
Power Consumption 80 Watts
Temperature Range 200-450 Deg C
3.5.7.14 DE soldering pump

Voltage: 230vac 50 hz
Power consumption 120 watts
Pump Diaphragm tip
Motor output 12w
Vacuum attained 650mm hg
Time required to reach 0.1 secs
maximum vacuum
Air flow rate 15 liter/minute (open)
Heater 100w ceramic
Control system Feedback zero cross over type
Temperature range 350 deg c – 500 deg c
Insulation resistance More than 100m ohm
Maximum temperature of hot 400 deg c
blow
3.5.8 Ambient CO Detection System

3.5.8.1 General:
1. Each CO detection system shall have standalone type with local
display, Flasher & Hooter.
2. All items at field shall be explosion proof and intrinsically safe.
3. 4-20 mA signal from each standalone CO detection unit shall be
hooked up with PLC through zenner barriers.
4. All glands used at field shall be explosion proof.
3.5.8.2 Sensor:
Description of Ambient co gas detector with provision of local
Instrument and remote display & alarm
Gas to be monitored Carbon Monoxide (CO)
Calibration range 0-500 ppm
Measuring Principle Electro-Chemical Measuring Cell
Expected operating 3 Years (min.)
life
Calibration Calibration at local
Outputs A) 4-20mADC linear for Carbon Monoxide
B) Local Digital Luminous Display 7 segment
high contrast LCD (BACKIT) / LED
C) Local power on, alarm condition and
sensor status display through LED
Response time 50% of FSD in 10sec or better
Accuracy +/- 1% FSD or better
Repeatability +/-2% of FSD
Zero Drift +/-2% of FSD
Temperature 55deg C
Ambient max
Humidity 0-90 % RH non-condensing
Protection Class IP 66 or better
Housing Flame proof & weather proof
Enclosure of detector Metallic; Explosion proof
& Hooter
Detector Body 316 SS
Approvals EEX D II C T 6 (+55 deg. cent.) or equivalent
Gas Group IIA / IIB
Accessories A) Calibration adaptor/aspirator
B) Tools and tackles (if any) and operation and
maintenance manuals with each unit
Quantity Minimum 8 nos. or as per site requirement
3.5.8.3 Wall mounted gas monitor for remote display

Description 12 or higher channels digital
indicating wall mounted panel
Power Supply 230 volts AC +/- 10%, 50 Hz
Display Digital LED/LCD luminous
indicating display

Display range 0-500 ppm of CO
Alarm 2 nos freely programmable contact
output through-out the range
with visual indication for individual
channel
Resolution 1 digit or better
Inputs 4-20 mA DC
Outputs A) 24V DC power to each sensor
unit
B) Relay: 2NO+2NC rated 5A,
230VAC
C) Analog Output: 4-20 mA DC
max. 950ohm load (inductive)
D) Reset and test function button
in front panel
Status display at local for: power
on alarm, sensor fault/cable fault
through LEDS
Enclosure E) IP65, rugged metallic
Display of Sensor life F) Required
Hooters G) Required
External local reset & test push H) Required
buttons for hooter alarm
Calibration Kit I) Required, e.g. gas cylinders for
calibration & other accessories
Indicator / Alarm J) CO Monitoring shall have
individual indicator, Audio-
visual Alarm & Hooter
3.6 STRUCTURAL
3.6.1 Design parameters
The steel structures envisaged here shall be designed as per IS: 800-
1984, IS: 11592-2011 and for chimney IS: 6533-1989 Superimposed
loads shall be considered in accordance with IS: 875-1987 in addition to
technological loads from equipment as supplied by equipment
manufacturer. The design shall take into account all dynamic loading
effects in vertical, lateral and longitudinal directions apart from dead
and superimposed loads from dynamic equipment. Structures shall be
designed either for wind or seismic loads whichever produces worse
effect. Wind load on structures shall be considered as per IS: 875-1987
whereas seismic loads shall be taken as per IS: 1893-2002. Structural
steel work shall be of welded construction as far as possible. Necessary
provision in the design shall be kept for temporary loads, which are
expected during erection and maintenance of equipment.
Design drawings of structures prepared by the contractor shall contain:-
 Dimension
 Level
 Plan and sectional views showing general arrangement of
structures
 Member sizes
 Member forces
 Complete base plate details including welding detail
 Nature and type of connection details of beams, girders, bracings
etc. showing weld details (type, size, length etc.), gusset plate /
face plate thickness etc. Connection detail shall be shown for all
major members
 Bolt hole details (number, diameter, dimension etc.)
 Quantity of structural steel involved etc.
For all major structural columns, base shear shall be transferred to the
foundation by shear keys only and not through foundation bolts.
Tension in column member shall be transferred to foundation by
foundation bolts.
Steel structural design drawing shall have all necessary information
required for preparing fabrication drawings. Necessary attention shall
be given while preparing fabrication detail such that it facilitates both
fabrication and erection work.
Design calculation shall contain manual load calculation aided by
diagrams if necessary, and diagram showing applied loads on
structures.
Analysis and design of structures may be carried out using STAAD PRO
software.
Minimum member size

Sizes of ISA, ISMC and ISMB shall not be less than the following:-
ISA 65x65x6
ISMC 125
ISMB 150
Gusset plate shall not be less than 8 mm.
Permissible Deflection
Permissible vertical and horizontal deflection shall generally be as per IS:
800-1984 unless specified.
3.6.2 Materials
3.6.2.1 Structural steel
All structural steel shall be of tested quality. Mild steel for rolled
sections and plates shall generally conform to IS: 2062-2011. Roof and
walls of structural shed shall be in galvanized corrugated steel sheets
conforming to Grade A with zinc coating of 275gm/m2 of IS: 277-2003
and the fasteners in accordance with IS: 730-1978. Chequered plates
shall conform to IS: 3502-1994.
Steel used for construction exposed to weather or other corrosive
influences shall not be less than 8 mm in thickness and in construction
not exposed to weather, thickness shall not be less than 6 mm. The
controlling thickness as specified above, for rolled beams and channels
shall be taken as the mean thickness of flange, regardless of web
thickness.
The Contractor shall submit manufacturer’s test certificates conforming
to appropriate standards of all steel materials used for fabrication. All
structural steel shall be free from rust, scales, lamination, cracks, fissures
and other surface defects
3.6.2.2 Bolts and nuts

All bolts and nuts shall conform to IS: 1363-2002 or IS: 1364-2002 as
applicable and unless specified otherwise shall be hexagonal. High
strength structural bolts shall conform to IS: 3757-1985. All nuts shall
conform to property class compatible to the property class of the bolt
used. The Contractor shall submit manufacturer’s test certificates as and
when called for.
3.6.2.3 Washers
Plain washers shall be made of mild steel conforming to IS: 5369-1975
unless otherwise specified. . One washer shall be supplied with each bolt
and in case of special types of bolts more than one washer as needed for
the purpose shall be supplied. An additional double coil helical spring
washer conforming to IS: 6755-1980 shall be provided for bolts carrying
dynamic or fluctuating loads and those in direct tension. Tapered
washers conforming to IS: 5372-1975 and IS: 5374-1975 shall be used
for channels and beams respectively. The Contractor shall submit
manufacturer’s test certificates as and when called for.
3.6.2.4 Welding
The welding and the welded work shall generally conform to IS: 816-
1969 and 9595-1996 unless otherwise specified. As much work as
possible shall be welded in shops and the layout and sequence of
operations shall be so arranged as to eliminate distortion and shrinkage
stresses. Electrodes shall conform to IS: 814-2004. The Contractor shall
submit manufacturer’s test certificates as and when called for.
All electrodes shall be kept under dry conditions. Any electrodes
damaged by moisture shall not be used. Any electrode which has part of
its flux coating broken away or is otherwise damaged, shall be rejected.
Any electrode older than six (6) months from the date of manufacture
shall not be used. Contractor shall submit batch certificate for electrode.
The edges shall be prepared with an automatically controlled flame-
cutting torch correctly to the shape, size and dimensions shown in the
design and fabrication drawings.
The welding surfaces shall be smooth, uniform and free from notches,
loose scale, slag, rust, grease, moisture or any other foreign material.
The welding procedure shall be arranged by the Contractor to suit the
details of the joints as indicated on the drawings and the position at
which welding has to be carried out. Welding procedure shall cover the
following: type and size of electrodes, current and (for automatic
welding) arc voltage, length of run per electrode or (for automatic
welding) speed of travel, number and arrangement of runs in multi run
welds, position of welding, preparation and set up of parts welding
sequence, pre or post heating, any other relevant information. The
welding procedure shall be so arranged that the distortion and
shrinkage stresses are reduced to a minimum and that the welds meet
the specified requirement of quality. The Contractor shall employ a
competent welding supervisor to ensure that the standard of
workmanship and the quality of the materials comply with the
requirements laid down in this specification.
Any weld found defective shall be cut by using either chipping hammer
or gouging torch in such a manner that adjacent material is not injured
in any way.
Fusion faces and the surrounding surfaces within 50mm of welds shall
be free from all mill scale and free from oil, paint or any substance,
which might affect the quality of the welds or impede the
quality/progress of welding. They shall be free from irregularities, which
would interfere with the deposition of the specified size of weld or be
the cause of defects. All mill scale within 50mm of welds shall be
removed prior to welding by thorough power wire brushing or by other
approved methods.
Parts to be welded shall be properly assembled and held firmly in
position by means of jigs and clamps or suitable arrangements prior to
and during welding.
After making each run of welding all slag shall be thoroughly removed
and the surface cleaned.
Welded joints should satisfy the following requirements
1. Strength-quality with parent metal.
2. Absence of defects.
3. Corrosion resistance of the weld shall not be less than that of
parent material in aggressive environment.
Criteria for test of weld:
Visual examination: 100% of the welded joints for fillet welds and butt
welds.
Ultrasonic method: 100% for all butt-welded joints.
The Contractor shall engage a reputed or any Government test agency
having Level II Ultrasonic examination certificate holder inspector to
carry out the Ultrasonic. The third party shall carry out tests, interpret
test results and recommend necessary rectification measures.
Contractor shall carry out the rectification work as recommended by the
test agency to ensure defect free welding. Contractor shall obtain
certificates from the testing agency certifying defect free welds and
submit to the employer.
Tests:
Visual Examination
The Contractor shall conduct visual examination and measurement of
the external dimensions of the weld for all joints. Before examining the
welded joints, areas close to it on both sides of the weld for a width not
less than 20 mm shall be cleaned of slag and other impurities.
Examination shall be done by a magnifying glass which has a
magnification power of ten (10) and measuring instrument, which has
an accuracy of ± 0.1 mm or by weld gauges. Welded joints shall be
examined from both sides.
The Contractor shall examine the following during the visual checks:
Correctness and shape of the welded joints, incomplete penetration of
weld metal, influx, burns, unwelded craters, under cuts, cracks in welded
spots and heat affected zones, porosity in welds and spot welds,
compression in welded joints as a result of electrode impact while
carrying out contact welding, displacement of welded element. All
defects observed shall be made good.
The Contractor shall document all data as per standard practices.
3.6.3 Painting
3.6.3.1 Building structure
All structures shall be given two coats of single pack air drying phenolic
modified alkyd composition with zinc phosphate as a primer having

minimum dry film thickness of 80 microns (40 microns/Coat). One coat
of primer shall be applied before erection and one coat after erection.
Intermediate paint shall be one coat of single pack high build phenolic
based paint with micaceous iron oxide (MIO) having minimum dry film
thickness of 75 micron.
Final paint shall be two coats of single pack air drying high gloss
phenolic alkyd modified synthetic enamel paint as finishing coat having
minimum dry film thickness of 50 microns (25 microns/Coat).
3.6.3.2 Waste gas chimney
The inner side of “waste gas chimney” shall be given one coat of two
pack heavy duty zinc dust rich silicate (DFT/coat = 60 micron) as primer
paint and three coats of a single pack heat resistant silicon resin based
paint with leafing aluminium / graphite powders as finishing coat (DFT/
coat=20 micron). Top two courses of the chimney at the outer side
shall be given two coats (DFT/coat=40 microns) of a two pack air drying
epoxy polyamide resin based red oxide zinc phosphate as primer, one
intermediate coat of a single pack high build phenolic based paint with
micacious iron oxide (DFT/coat=75 micron) and two coats (DFT/coat=40
microns) of a two pack air drying epoxy polyamide enamel suitably
pigmented as finishing coat. Rest of the outer surface of the chimney
shall be painted as per specification mentioned for general building
structures. Intermediate/ finishing paint shall be applied only after
completion of erection.
3.6.3.3 Surface preparation:
All surfaces shall be cleaned of loose substance and foreign materials
e.g. dirt, rust, scale, oil, and grease, welding flux etc. so that the prime
coat adheres to the original metal surface. Any oil, grease, dust or
foreign matter deposited on the surface after preparation shall be
removed and care shall be taken so that the surface is not contaminated
with acids, alkalis or other corrosive chemicals. The primer coat shall be
applied immediately after the surface preparation is completed. Surface
preparation shall be either by hand tool cleaning or by power tool
cleaning or by solvent cleaning. The grade of surface preparation shall
be St-2 quality as per IS: 1477 (Part I) (2000) or as recommended by
paint manufacture.
3.6.3.4 Brush Application
Proper brushes shall be selected for a specific work piece. Round or oval
brushes conform to IS: 487-2012 are better suited for irregular surfaces
whereas flat brushes conforming to IS: 384-2002 are convenient for
large flat areas. The width of flat brushes shall not generally exceed 125
mm.

Paint shall be applied in short strokes depositing uniform amount of
paint in each stroke followed by brushing the paint into all surface
irregularities, crevices and corners and finally smoothing or leveling the
paint film with long and light strokes at about right angles to the first
short strokes. All runs and sags shall be brushed out. The brush marks
left in the applied paint shall be as low as practicable.
3.6.3.5 Paint application
Paint shall be applied strictly in accordance with manufacturer's
recommendations. The work shall generally follow IS: 1477-1971 (Part-
II). Prior approval of the Employer shall be taken in respect of all primers
and/or paints before their use in the works.
Paint shall generally be applied by brushing. Paint shall generally not be
applied when the ambient temperature is 10 degree C and below for
paints which dry by chemical reaction. The temperature requirements
specified by the manufacturer shall be met with. Also paint shall not be
applied in rain, wind and fog or at relative humidity of 80% and above
or when the surface temperature is below dew point resulting
condensation of moisture. Any wet paint exposed to damaging weather
conditions shall be inspected after drying and the damaged area
repainted after removal of the paint.
Each coat of paint shall be continuous, free of pores and of even film
thickness without thin spots. The film thickness shall not be so great as
to affect detrimentally either the appearance or the service life of the
paint. Each coat of paint shall be allowed to dry sufficiently before
application of the next coat to avoid damages such as lifting or loss of
adhesion. Undercoats having glossy surface shall be roughened by mild
sand papering to improve adhesion of subsequent coat. Successive
coats of same colour shall be tinted, whenever practical, to produce
contrast and help in identifying the progress of work.
3.6.4 General provision
3.6.4.1 Type of Construction
The steel structures shall generally be of shop-welded construction. Site
connections shall generally be provided by
1. Welding with erection bolts.
2. Bolting with turned and fitted or high strength friction grip (HSFG)
bolts.
3. Bolting with black bolts.
Elements shall be fabricated in largest possible sizes optimal with
transport requirements to minimize site work.
Important members shall be assembled under control assembly in
manufacturing shop to prevent mismatch at site.
3.6.4.2 Splices in structures
Shop splice: Where shop splices in plates are necessary due to non-
availability of plates in required lengths, full penetration defect free
sound butt welds shall be made. Shop splice in rolled steel angle, joists
and channels shall be developed by fillet welding and cover
plates/angles etc.
Site splice: Site splice for members required due to transportation,
assembly and erection facilities shall be developed by fillet welds and
cover plates and angles or high strength friction grip bolts. In case, butt
welding in plates is employed for site splice, the same shall be sound,
defect free and of full penetration
3.6.4.3 Storing materials
All materials shall be stored properly on skids, above the ground. It shall
be kept clean and properly drained. Structural steel shall be so stored
and handled that members are not subjected to excessive stresses and
damage. Girders and beams shall be placed upright and stored. Long
members such as columns and chords shall be supported on closely
spaced skids to prevent damage from deflection
3.6.4.4 Workmanship
All workmanship shall be equal to the best practice in modern structural
shops. Greatest accuracy shall be observed in the manufacture of every
part of the work and all similar parts shall be strictly interchangeable.
All materials shall be straight and if necessary before being worked shall
be straightened and or flattened by pressure unless required to be of
curvilinear form and shall be free from twists.
The erection clearance for cleated ends of members connecting steel to
steel should not be greater than 2mm at each end. The erection
clearance at ends of beams without web cleats should not be more than
3mm at each end, but where for practical reasons the greater clearance
is necessary, suitably designed seatings or connections shall be
provided. Holes for bolts shall be drilled to conform to appropriate
clause of IS:7215 (1974). No holes shall be made by gas cutting process.
Shearing or flame cutting may be used provided that a mechanically
controlled cutting torch shall be used for the flame cutting and that the
resulting edge shall be reasonably clean and straight. Sheared members
shall be free from distortion at sheared edges. Special care shall be
taken to remove the burnt edges of high tensile steel when flame
cutting method is employed. When gas cutting is adopted, the flame
cut edges shall be machined.
The Contractor shall furnish a plan of quality assurance in respect of
fabrication and erection which he proposes to follow for the purpose of
assuring the quality of material and workmanship at various stages. The

Quality Assurance Plan (QAP) shall be mutually discussed and approved
by the Employer and shall be followed for all structural works.
3.6.4.5 Expansion joints
Expansion and setting out joints shall be provided to take into account
the effect of temperature variation and which shall also act as anti
seismic joints. Expansion joints shall be provided as per provisions of
relevant clause of IS: 800(1984).
3.6.5 Testing Erection & Commissioning
Fabrication, erection, testing and commissioning of steel structures shall
be in accordance with IS: 800-1984, IS: 7215-1974. Erection tolerances
shall be in accordance IS: 12843-1989
3.7 CIVIL WORKS

3.7.1 Design Specifications
3.7.1.1 This specification covers the design criteria for civil engineering work.
The term ‘Design Criteria’ includes loading standards, permissible
stresses, functional requirements and quality standards to be adopted
as a basis for preparation of designs and drawings by the contractor.
These designs and drawings will cover buildings for production and
non-production facilities, auxiliary facilities, ancillary buildings and
structures, foundations for buildings and equipment, roads, drains,
sewers and other miscellaneous civil engineering items of work to be
provided and/or to be modified/ rectified by the contractor.
3.7.1.2 The designs prepared by the contractor shall not only provide for the
requirements indicated in this specification but also consider the overall
process requirements and service conditions. The designs shall be
compatible with the operating conditions in the plant and the
atmospheric conditions prevalent at Durgapur.
3.7.1.3 Standards and unification shall be carried out to the maximum extent
possible and in the interest of standardisation. SAIL reserves the right of
selecting a particular make of materials and components. The contractor
shall supply materials/components of the particular make, if so required.
3.7.1.4 The work is to be carried out in an operating plant and hence design &
execution of work shall be carried out in such a manner to cause
minimum or no disturbance to the normal day-to-day operations of the
plant.
3.7.2 Standards
3.7.2.1 The design criteria for civil engineering work shall be in accordance with
this specification. Detailed instructions on such aspects as are not
indicated herein shall be as per the latest standards, codes. In the
absence of suitable IS specification and codes of practices other

international standards and codes may be followed with the prior
approval from employer.
3.7.2.2 In respect of pollution control, safety, sanitary and hygienic
requirements the stipulations of the Department of Environment of the
Government of India, stipulations of the Indian Factories Act, W.B.
Government Factories Rules, DSP’s Safety Rules, notification of W.B.
Government Department of Science, Technology and Environment on
Water and Air Pollution and other statutory authorities shall be satisfied.
3.7.2.3 This specification covers design of major Civil Engineering items of
work. Other items of work shall be designed according to the relevant
standards, recommendations and stipulations referred above. This
design specification shall also be read in conjunction with the General
specifications for Civil Engineering Work.
3.7.2.4 In case anything mentioned in this specification is at variance with IS or
other codes of specification mentioned herein, the provisions of this
specification shall prevail.
3.7.3 Concrete and Reinforced Concrete for Structures and Foundations
3.7.3.1 Concrete work shall be a dense, homogenous, smooth mass including
required finishes, possessing required strength and resistance to
weathering and abrasion for the structures and foundations.
3.7.3.2 The minimum grade of RCC shall be not less than M25. The
minimum grade of PCC shall be M10 M10 for mud mat and M5 for
mass filling.
3.7.3.3 The minimum grade of steel shall be Fe500.
3.7.3.4 Design of all reinforced concrete structures shall be as per the latest IS:
456 – 2000. The structural safety of all foundations on soil shall, in
general be based on IS: 1904-1986. The allowable settlement of
foundations shall be as per technological / system requirement. For
building structures allowable settlement shall not exceed 50mm.
3.7.3.5 For calculation purpose ‘Limit State Design’ methods shall be adopted
for design of RCC elements strictly in accordance with IS:456-2000 .
3.7.4 Grouting
3.7.4.1 Grouting under the base plate shall be done with free flow non-shrink
grout Shrinkomp 30 /ShaliGrout 73 /Sikagrout®-214 or equivalent as
per manufacturer’s specifications.
3.7.4.2 For grouting the stub bars in the existing concrete, non-shrink free
flowing solvent free pourable grout based on a combination of high
strength epoxy grout LOKFIX /ShaliGrout Anchor/Sikadur®42 or
equivalent to fix stub bars in position (vertical and /or horizontal
positions).
3.7.4.3 For waterproofing, non-shrink polymeric water proofing compound
shall be injected through GI nozzles (fixed along the line of crack /
honeycomb in spacing not exceeding 500 c/c by drilling hole in existing
concrete and fixing the nozzle by quick setting mortar). The GI nozzles
shall be cut and sealed after the grouting. All work shall be carried out
as per manufacturer’s specifications.
3.7.5 Fixing of anchor bolts & reinforcement bars
Fixing of anchor bolts & reinforcement bars in existing concrete
elements shall be done by drilling hole & providing
chemical/mechanical anchorage system as per manufacturer’s design.
All workmanship shall be as per manufacturer specification.
3.7.6 Rust Inhibitor
At the location of damaged / spalled concrete, the loose concrete shall
be totally removed. The exposed reinforcement bars shall be cleaned by
wire brushing and the damaged bars shall be restored by 2 pin welding
on each side for each bar. Rust inhibitor, SIKATOP Armatec 108 /
TankMastic® or equivalent shall be applied as per manufacturer’s
specifications.
3.7.7 Repairs Mortars
Repair Mortar for restoration of damaged portion of RCC shall be
carried out by SIKATOP 122 HS or ShaliFix MC or equivalent ready-mix
high strength repair mortar as per manufacturer’s specifications. Before
placement of this mortar, bonding layer between old & new concrete
shall be applied as per manufacturer’s specifications.
3.7.8 Load Condition
3.7.8.1 All foundations and concrete structures shall be designed to resist full
operating dead and live loads, with appropriate combinations and due
allowance for impact, inertia loading, vibration etc. as secondary effects
of live loads, temperature variation etc. While designing structures and
foundations either the effect of seismic forces or wind loads, whichever
produces the worst effect, shall be considered along with usual load
conditions. Requirement of seismic load analysis shall be based on type
& importance of structure, mass concentration etc. and shall be decided
at the time of detail engineering.
3.7.8.2 Concentrated and uniformly distributed live load on floors and
platforms shall be considered depending upon the usage and in
accordance with a maximum expected process requirements, to be
indicated by the equipment manufacturers. When the loads are
movable, they shall be so placed as to get worst effect in moment,
shear; axial loads etc. for which the elements shall be designed. The
effect of concentrated load shall not be reduced. Due allowance shall be
made, wherever necessary, for installation and operation of any
equipment as per equipment manufacturer’s data and
recommendations. The design shall be based on the maximum loading
due to uniform live load and /or equipment loading including impact,
vibrations etc.
3.7.8.3 Apart from the operating loads indicated by the equipment
manufacturers, the design shall be based on dead and imposed loads
calculated according to IS: 875 Part 1 to Part 5 – 1987.
3.7.8.4 Seismic forces shall be considered according to the provisions of IS:
1893 – (Part – 4) – 2015.
3.7.8.5 Supporting structures and foundations for equipment, which may cause
vibration shall be designed for the dynamic effect of equipment
together with the direct loads. The dynamic loads and other relevant
data required for analysing the dynamic effect shall be taken as per
manufacturer’s recommendations.
3.7.8.6 Structures and foundations supporting vibrating, rotating and
reciprocating equipment shall be proportioned to avoid resonant,
frequencies. The dynamic analysis shall be done as per the stipulations
and recommended by respective IS codes as well as the stipulations
recommended by equipment manufacturer.
3.7.8.7 Design of structures shall provide for temporary maintenance of plant
and equipment. Consideration shall be given in the design of structures
to the contributing loads form piping and cabling including provisions
for piping anchors and dead ends of electrical conductors.
3.7.8.8 In case of moving loads, full load under worst operating condition
together with minimum 25 percent vertical impact factor shall be
considered for vehicles and machinery travelling / mounted on tracks
(rails). Horizontal forces along and transverse to the rails as per
equipment manufacturer’s data and recommendations shall be
considered in design of the track supporting structures and foundations.
3.7.8.9 The design of structures shall take into account the loadings due to
future extension of units and installation of additional equipment, where
necessary, in future in the units.
3.7.9 Permissible Stresses

Allowable stresses for all reinforced concrete structures shall be as per
IS: 456 – 2000.
3.7.10 Soil Conditions
The net allowable bearing capacity shall be considered as 15 Ton/m2
upto 4.00m width which is likely to be at 2.5 m below ground level . Pile
Capacity shall be considered as 40 T for 400 dia piles in compression
5.11 T for lateral load and 19 T for uplift. However, other details,
including soil investigation, geodetic survey & underground survey
executed by DSP, are in soil & survey reports attached as Annexure-
3.7.10-1.
3.7.11 Foundations
3.7.11.1 The foundations for structures and equipment shall be proportioned to
resist the worst conditions of loadings and shall be generally designed
as per the provisions as frozen below.
3.7.11.2 Equipment requiring special foundations as a result of dynamic,
unbalanced forces, shall be designed as per IS: 2974 (Part-1) – 1982,
(Part-3) – 1992 & (Part-4) – 1979. The Contractor is required to design
and construct such foundation free of objectionable resonance,
vibration or rocking. In the event that such equipment is installed above
ground level, the supporting structure and foundation shall be
investigated also for natural frequency and designed properly to avoid
resonance and amplitude shall be within allowable limits.
3.7.11.3 Selection of type of foundation shall be based on the recommendations
of soil investigation & survey report, supported loads, system
requirements and site constraints.
3.7.11.4 The design, construction & testing of RCC pile foundations shall be in
accordance to the provisions of latest relevant IS:2911.
3.7.11.5 The depth of foundation shall be determined based on loading on
foundations and bearing capacity at the founding level, constructional
and technological requirements. The maximum allowable bearing
pressure for design of foundation shall correspond to values indicated
in detailed soil investigation report taking into account limits of
allowable settlement considered for design of structures. However, in no
case shall be the foundation is taken down to less than 600 mm below
natural ground level in case of soil and 200 mm in case of rocky strata.
In no case foundation shall be placed on the filled up soil and the depth
of the foundation shall be taken upto the depths where the virgin soil
strata is found .Extra depth shall be filled with PCC M5.
3.7.11.6 The foundation of the new structure /facility shall be taken at least to
the depth of the foundation of adjoining existing structure/ facility, if
any. In no case the loads from the new foundations shall be transferred
to the existing foundation. However in exceptional circumstances, if it is
required to be done, then the existing foundation shall be checked for
the additional load transferred and shall be supported with design
calculation.
3.7.11.7 All faces of concrete or plastered surfaces in contact with earth shall be
provided with two coats of bituminous protective coatings of approved
make.
3.7.12 Requirements of Durability
3.7.12.1 This shall be as per the provisions of IS: 456-2000.
3.7.12.2 The exposure condition shall be Moderate for normal type of structures
(open foundations and auxiliary buildings) and shall be severe for
underground cellars, water-retaining structures etc.
3.7.12.3 The minimum cement content, maximum water cement ratio and
minimum grade of concrete shall be as per Table 5 of IS: 456-2000 for
different exposure conditions.
3.7.12.4 The requirement of fire resistance shall be as per IS: 1641 2013 and as
per Clause 21 of IS: 456 – 2000. The members shall be designed for fire
resistance for a period of 2 hrs. (Refer Fig. 1 of IS: 456 – 2000).
3.7.13 External Cladding, Internal Partitions & Finishes
3.7.13.1 This section deals with cladding, internal partitions and finishes for
production buildings and associated ancillary and auxiliary buildings.
3.7.13.2 External cladding shall be constructed of brick masonry. The thickness
of brick masonry walls shall be minimum 230mm. Design of masonry
walls shall conform to IS: 1905 – 1987.
3.7.13.3 Cement sand mortar shall be 1:6 for external walls having minimum
thickness of 230mm and also for brick work in protection walls to
waterproofing membrane in tunnels, basements etc.; for walls of
thickness 110mm mix shall be 1:4 with HB wire netting reinforcement at
every third layer.
3.7.13.4 All brick and rubble masonry walls shall be plastered on both sides.
Thickness of plaster shall be minimum 20mm for external surfaces and
15mm for internal surfaces of walls. Thickness of plaster for ceiling shall
be upto 10 mm.
3.7.13.5 Cement sand mortar mix for all plasters, shall be 1:4.
3.7.13.6 All outside plastered surfaces of masonry walls shall be applied with
weather-proof paint of approved make and quality and to be applied as
per manufacture’s specification.
3.7.13.7 Inside surfaces of masonry walls shall be treated with white wash/colour
wash or acrylic emulsion paints of approved quality, make and colour, or
to be tiled as the case may be, on the basis of technological and/or
aesthetic requirements. Necessary surface preparation shall be done
prior to application of paints.
3.7.13.8 Depending on technological considerations, walls of some premises
may be made of reinforced concrete and finished appropriately.
3.7.14 Floor and Floor Finishes
3.7.14.1 In general, all floors on ground except in areas like offices and toilets,
shall be made of minimum M20 reinforced concrete of 150mm
minimum thickness. However, for the production buildings, the design
of floor shall be done taking into consideration technological
requirements, imposed loading and other service conditions.
3.7.14.2 The sub-grade below the floor slab shall be minimum 250 mm thick
stone boulder soling blinded with moorum. Building paper shall be
provided on top of sub-grade before casting the concrete slab.
3.7.14.3 All sub-grades shall be laid on compacted earth.
3.7.14.4 In specific areas of production buildings where concrete floor is not
required at ground floor level, the flooring shall consist of minimum
250mm thick compacted stone boulder soiling with moorum blinding.
3.7.14.5 Floor finishes for the production buildings shall be provided according
to technological and functional, service and duty requirements and as
per manufacturer’s instruction where applicable.
3.7.14.6 Anti-skid / glazed tiles in the floor of offices & toilets shall be provided
as per approved make, shade & manufacturer’s specifications.
3.7.14.7 Acid resistant ceramic tiles shall be provided in dado, which shall be at
least 2.1m high, in RO water plant building.
3.7.14.8 Finished Floor Level shall be as per system requirement.
3.7.15 Finishes, Fittings, Doors, Windows & Ventilators and Roof
Treatment
3.7.15.1 Rolling Shutter, doors, windows, ventilators & grills shall be provided as
per the technological & system requirement and shall confirm to the
latest BIS standards and standard practices prevailing at Durgapur Steel
Plant.
3.7.15.2 4mm thick APP with mineral finish & thermo-fusible layer shall be laid
on roofs which are open to sky. The workmanship shall be as per
manufacturer’s specification. This also includes two primer coats of
rubberized cold applied bitumen emulsion @ 0.3Kg/Sqm and slope
correction & micro levelling of roof surface and screed concrete of
grade M-20 with minimum 25mm thickness in proper slope over APP
membrane.
3.7.15.3 All windows and Ventilators shall be provided with MS grill. The design
of Grill shall be as per instruction of Engineer-In-Charge.
3.7.16 Water-Proofing and Damp-Proofing
All other water proofing & Damp-Proofing works shall be strictly in
accordance with IS:3067-1988 unless otherwise stated elsewhere in this
document.
3.7.17 Drainage
3.7.17.1 Storm water drain, around RO water plant building, boiler house &
electrical substation building, in RCC construction shall be provided with
RCC cover slab for movement of man & material.
3.7.17.2 All the storm water drainage shall be laid in service aisles close to the
road. Crossings with other services shall be kept to a minimum. Where
the new lines are to be connected to the existing ones, the contractors
shall carry out the required interconnections.
3.7.17.3 Generally minimum earth coverage of one meter shall be provided over
underground drainage pipelines unless the same is protected by
concrete encasing for otherwise and adequately designed for the
imposed loads from soil, water, operational and construction traffic.
3.7.17.4 RC pipes of class NP3, with concrete encasing, of IS: 458 – 2003 shall be
used for diameter ranging from 300mm to 1200mm and beyond that
box drains shall be provided.
3.7.17.5 Relevant provisions of IS: 1172 – 1993, IS: 1230 – 1979, IS: 458 – 2003, IS:
783 – 1985 and IS: 1742 – 1983 and other relevant Indian standards
shall be applicable for the design of the system.
3.7.18 Storm Water Drainage
3.7.18.1 The design of storm water drainage system shall be based on maximum
hourly precipitation for a storm of duration of 20 minutes. Roof
drainage system shall be designed on the basis of an hourly
precipitation for storm duration of 5 minutes.
3.7.18.2 Gully, traps, inspection pits, junction pits, collecting pits as well as other
facilities shall be located suitably and designed considering easy access,
maintenance and safety.
3.7.18.3 For the purpose of calculation of run-off from catchments area of any
drainage line, the contractor shall estimate areas of buildings, paved
area, roadways, parking areas and open areas within tree catchments
area. Run-off coefficients for design shall be as follows:
a) Open areas : 0.50
b) Roads and paved/parking areas : 0.70
c) Roof surface : 1.00
3.7.18.4 The pipes shall be so designed as to give a velocity of flow not less than
one metre per second when running half full. The maximum velocity
shall not exceed 2.5m per second.
3.7.19 Paved Areas
3.7.19.1 All service and utility lines crossing under the paved areas shall be taken
through concrete pipes/ ducts and designed for imposed loading.
Number of such crossings shall be kept to a minimum.
3.7.19.2 All paved areas shall be with concrete type of construction. Thickness of
different layers of materials shall be adequate for traffic intensity and
imposed loading. Design of concrete pavement shall be as per latest IRC
code.
3.7.19.3 Construction of concrete pavement shall be as per latest MOSRTH
specifications.
3.7.19.4 Surface storm water from the roadways shall be drained by provision of
drain network.
3.7.19.5 Sufficient areas shall be paved around plant buildings so as to facilitate
parking of vehicles. Paved areas shall have same type of construction as
roads and the top level shall be flushed with crown of the connecting
roadways with a cross slope of approximately two per cent.
3.7.19.6 Around all plant and ancillary buildings minimum 1500mm wide
concrete apron shall be provided.
3.7.20 Technical specification for civil works
3.7.20.1 General
1) Setting out and levelling
The contractor shall set out and level the work and will be
responsible for the accuracy of the same. He is to provide all
instruments and proper qualified staff with labour for getting his
work checked by engineer, if so desired by the engineer. Such
checking, if any, shall not, however, relieve the contractor in any
way, of his responsibility for correct setting out.
2) Safety
The contractor shall take adequate precautions to ensure
complete safety and preventions of accidents at site and shall be
responsible for the same. The safety precautions shall conform to
the safety regulations prescribed by the Safety Code for
constructions and relevant Indian Standard Codes, some of which
are stated below:
IS 3764-1992 : Safety Code for excavation
work
IS 4014-1967 : Safety Regulations for
scaffolding work
IS 4081-2013 : Safety Code for drilling and
blasting operations
IS 4138-1977 : Safety Code for working
with compressed air
IS 7923-1985 : Safety Code for working
with Constructions
machinery
3) Keeping work free from water
The contractor shall provide and maintained at his own cost,
pumps and other equipment to keep the works free from water
and continued to do so until the handing over of the works.
4) Rubbish
The contractor shall keep the site clear on a continuous basis of all
rubbish etc. which may arise out of the work executed by him and
dispose them suitably in allotted areas.
5) Bench Marks, Reference Pillars etc.
The contractor shall protect all bench mark, and reference pillars
/lines including ground water gauges from damage or movement
during working. In case of any damage the contractor shall have
to restore the same to its original condition at his own cost.
3.7.20.2 Dismantling Work
1) No dismantling work shall commence without prior approval of
employer on the dismantling plan prepared by the contractor.
2) The contractor will have to arrange all types of equipment for
carrying out the dismantling work satisfactory including hire
charges & running charges with all labour, tools, tackles etc.
complete as per direction of Engineer & I/c.
3) The structures shall be dismantled with due care so that no
structure & equipment are damaged. If the same gets damaged
then contractor has to change/modify/strengthen the items
without any extra cost. Care shall be taken during dismantling so
that maximum quantity of dismantled material can be reused.
4) Care shall be taken to maintain the stability of retained structures
for which necessary structural supports are to be provided without
any extra cost.
5) The contractor shall assess the entire dismantling work
independently and decide accordingly the resource to be
deployed by him so that the work can be executed in the
stipulated time frame.
6) The contractor shall obtain the necessary clearance certificates
from Safety department of the Plant for the arrangement of
dismantling work at every stage.
7) All debris collected due to dismantling shall be transported and
disposed off as per direction of Engineer-In-Charge.
8) All serviceable material shall be stacked and transported to
designated place within a lead of 13 Km including unloading &
stacking.
9) The stacking shall be done for various categories of dismantled
items. Such categorisation shall be worked out in consultation with
engineer in charge.
10) Dismantling of structures including sheeting shall be done
preferably in such a way that the items are easily identified and
can be modified and or re-erected at the new location. The
dismantled items which are not to be re-used shall be cut in such
pieces, sizes & lengths which will facilitate easy transportation and
disposal of those items to dumping yard /storage yard.
3.7.20.3 Piling
1) The materials and workmanship shall conform to the provisions of
the following codes and standard specifications in particular
mentioned hereinafter.
IS: 456-2000: Code of Practice for plain & reinforced concrete.
IS: 2911(part –I/section 2)-1979: Code of practice for design &
Construction of bored cast-in-situ pile foundations.
2) Materials & Workmanship
 Concrete
Minimum grade of concrete of grade M 25C shall be used for
all piles.
 Sequence of piling
Individual piles land pile group shall be driven in such a
sequence that the adjacent piles already installed are not
disturbed, nor their carrying capacity reduced: by subsequent
driving operation.
 Driving / Boring
For bored piles, boring shall proceed by alternately driving
the casing and extracting the bored material with the boring
tools. While boring in soft material is liable to cavitation,
boring tools shall not be operated at level below the toe of
the casing. Care shall be taken to ensure that the volume of
water added to the bore shall not be more than the minimum
requirement for the operation of the boring tools.
The casing shall be driven down through the soft material to
penetrate a hard stratum not subjected to cavitation and
shall be sealed in this material as far as possible. Thereafter
the boring shall be continued by means of the boring tools
until the approved bearing layer is reached The bearing layer
shall consist of sound materials capable of safely sustaining
the load imposed by the pile and shall be consistent in
quality for a depth of minimum 300 mm. in the pile bore.
Immediately before concreting the borehole shall be cleaned
of all the loose materials, debris and all the water shall be
removed by pumping and bailing. Concrete shall be so
placed as to fill the entire volume of the borehole without the
formation of voids caused by the faulty compaction or
entrapped air. Great care shall be taken to ensure that the
fluid alluvial soil does not penetrate between batches of the
concrete.
Concrete shall not normally be placed through water and in
unavoidable cases such concreting shall be done with
necessary precautions. The ground water shall be balanced
by adding fresh water to the bore and the concreting shall be
placed by means of an enclosed placer or by tremie pipe. In
case of bored piles after the uncased portion of the bottom
of the bore has been concreted, further concrete is to be
added. The sequence of placing concrete and withdrawing
the casing shall be so arranged that the head of concrete
above the bottom of casing is never less than 3 metres. Once
the concreting of the pile is commenced the work shall
proceed without interruption until the pile is completed.
Concreting of the pile shall continue until the pile is fully
formed up to a level not less than 600 mm. above the soffit
of the pile cap. Extraction of casing shall be done in such a
way that no necking or shearing of the concrete in the shaft
takes place.
 Trimming of pile heads
Completed pile shall be trimmed to the cut-off levels as
shown on the drawings when sound concrete has been
formed. In the event of trimming being carried below the
cut-off level, the pile shall be made up to the correct cut-off
level with concrete of the same quality as used in the piles.
Reinforcement shall be exposed for the full bond length
appropriate to the diameter of the bar and projected in the
pile-cap. The minimum distance of keying of the pile into pile
cap shall be 50 mm. All concrete and cement shall be
removed from the bars, which shall also be wire- brushed to
remove any loose rust, "dirt and scale.
 Lengthening of Piles
Where it is necessary to increase the length of any pile after it
has been driven, the head of the pile shall be cut-off to
expose the reinforcement for a full bond length of the bars to
lap with the new bars. The exposed surface of the concrete
shall be hacked to form a key, brushed to remove loose
material and covered with 25 mm. thick cement mortar (1: 2
mix,) immediately before the new concrete is placed.
3) Load Test
The longest practicable time shall be allowed to escape between
driving and testing to allow the recovery of soil conditions around
the pile and it shall not be less than two weeks.
The gross settlement under test load of any pile shall not exceed
12 mm. in case of 150% working load tests, and 20 mm. in case of
200% working load tests.
Standard of Acceptance
 The piles shall be accepted as satisfactory only when the work has
been executed in accordance with, this specification and the
Standards stated hereinafter:
 The head of the pile shall be within 65 mm. of the specified
position on the drawings.
 The pile shall not be out of plum by more than 1 in 100.
 The toe of the pile shall be as per the drawings.
 The total volume of concrete shall not be less than 10% and not
more than 40% greater than the calculated volume. The calculated
volume for this purpose shall be the cross-sectional area inside the
casting multiplied by the length of the shaft. The concrete shall
show the specified strength as indicated by the cube-test results.
 The results of the load tests carried out in accordance with the
contract and with specifications for load testing shall be
satisfactory.
Defective piles
If an individual pile fails to meet the requirements specified in
clause above such pile may be deemed to be defective. When any
pile is found defective; one or more of the following remedial
measures shall be carried out:
 Replacement of defective piles.
 Driving additional piles.
 Alteration in design of pile caps.
Recording of Data
For each pile, a record of the following data shall be kept
 The date and time of commencement and finishing of the driving
operation.
 The particulars of the equipment and method of driving.
 The location and type of the pile, with a reference to approved
drawings.
 The diameter of the pile.
 The length and cut-off level of the pile.
 The quantities of concrete, reinforcement, cement and w/c ratio
used.
 The sequence of the driving in pile groups.
 The test load and settlement for test piles as required under clause
of load testing
3.7.20.4 Excavation and Back Filling
1) Stripping
The Contractor shall strip the surface of the site prior to the
commencement of excavation to remove vegetable soil and carry
such soil to separate spoil dumps in the allotted site/areas. The
Contractor shall not remove any tree without permission of the
Engineer-in- Charge.
2) Excavation
 The Contractor shall excavate at various levels including hard rock
to remove materials of any nature or description, which may be
encountered. Side slopes, benching and/or shoring/strutting for
excavation work shall be sole responsibility of the Contractor. The
bed of the excavation shall be properly dressed and made level. All
mud and slush shall be removed before taking up concreting work.
The last 150 mm of excavation shall be done just prior to laying of
concrete. The excavated materials shall not be placed within 1.5 m
from the edge of any excavation. The Contractor shall take suitable
precautions to prevent ingress of water into the excavated areas
during construction. The contractor shall be fully responsible for
taking the precaution of slip & failure of excavated slope.
Necessary strutting & shoring for earth protection, if required,
shall be carried out by Contractor at no extra cost.
 The surplus excavated materials and excavated unserviceable
materials from rock excavation shall be transported and disposed
off by the Contractor in spoil dumps or fill areas as directed by the
Employer.
 If the Contractor excavates to levels lower than those shown on
the drawings, he shall fill up such extra depth at his own cost to
the proper level with lean concrete of grade M-5B.
 Should the bottom of any excavation appear to be soft, unsound
or unstable, the Contractor shall excavate the same to required
depths and the extra depth shall be filled up by the Contractor
with lean concrete of grade M-5B.
 If any excavation for foundation gets filled up with water due to
rain, seepage, and leakage or drainage water or for any reason, the
water shall be removed and bottom of the excavation shall be
completely cleared of all silt/slush by the Contractor at his own
expense.
 All water pumped or bailed out during de-watering of pits and
trenches shall be disposed off suitably through properly laid
channels or pipes. Disposal of water shall be carried out in such a
way that no inconvenience or nuisance is caused to the work in
progress in the area or to other agencies working in the area or
cause damage to property and structures nearby.
3) Back Filling
 Materials
Suitable materials obtained from excavation of foundations
shall be used as far as possible for back filling. Earth used for
filling shall be free from organic and other objectionable
matter. All clods of earth shall be broken or removed. If
sufficient amount of suitable materials are not available at
site to complete filling work, then earth shall be brought to
site from outside by the Contractor as directed by the
Employer at his own cost.
 Filling with earth
Before commencement of back filling, the Contractor shall
remove from the space around foundations all accumulated
water and slush, shoring and formwork, all debris, brickbats,
bits of timber, cement bags and all other foreign materials.
Filling shall be carried out in uniform horizontal layers, each
layer not exceeding 150 mm in thickness. Each layer shall be
watered, rammed, and thoroughly compacted before the
next layer is deposited. Before back filling, the contact
surfaces of RCC and earth shall be painted with two coats of
bituminous paints. Before back filling, the contact surfaces of
RCC and earth shall be painted with two coats of bituminous
paints.
 Filling with sand
Filling with sand shall be carried out in uniform horizontal
layers, each layer not exceeding 200 mm in thickness with
approved river sand and each layer to be watered and
compacted mechanically to a well compacted mass.
3.7.20.5 Plain and Reinforced Concrete Work
1) Materials
i. Cement
Ordinary Portland cement shall conform to IS 269-2015 / IS
8112-2013 and Portland blast furnace slag cement shall
conform to IS:455-2015. Soundness test is to be carried out
on cement samples from time to time. Frequency of these
tests shall be increased during monsoon period.
ii. Aggregates
All aggregates shall conform to IS 383-2016. Fine aggregates
shall be approved river or pit sand. Coarse aggregates shall be
approved crushed stone. Aggregates shall be clean and free
from any foreign material. Test on aggregate shall be carried
out from time to time to ascertain the suitability of the
aggregates.
iii. Reinforcement
Minimum grade of Reinforcement bars shall be Fe500.
Reinforcement in general shall be of tested quality. Cold
twisted steel bars or TMT bars conforming to IS 1786-2008
and shall be free from oil paint and rust coatings. However,
MS round bars conforming to IS 432-1982 or IRC mesh fabric
reinforcement conforming to IS 1566-1982 can also be used if
specifically required. The binding wire shall be 20 SWG
approved annealed iron wire.
iv. Shuttering
The material for shuttering shall be steel plates as per IS 2062-
2011 or wooden planks as per the requirement.
v. Jointing materials
All rubber and PVC water stops joint fillers, sealing materials
etc. used in concrete work shall be of standard manufacture as
per relevant IS codes. Usage of these materials shall be in
accordance with the manufacturer's instructions.
vi. Admixtures
Admixtures to be used shall be of approved quality and make
and shall conform to relevant IS codes. The admixtures may
be used for controlling the workability & other properties of
concrete. However, design mix & cube test results shall also
be provided for concrete with admixture.
vii. Water
Water shall be clean and of potable quality as per clause 5.4
of IS 456-2000.
2) Workmanship
i. Concrete
 Production and control of concrete shall be as per IS
456-2000. The designed mix shall conform to the
requirement of IS 456-2000 and recommended
guidelines in SP: 23-1982. The minimum cement
content and maximum water cement ratio of concrete
work shall conform to the requirements of durability of
concrete for moderate exposure as indicated in Table-5
of IS 456-2000.
 The maximum size of aggregates used shall be as
indicated in the drawings and IS 456-2000. No concrete
shall be placed on site until the employer has approved
the mix design.
 Where nominal mixed concrete as defined by IS 456-
2000 is permitted by the employer for any specific
reason, the proportion of the materials shall be as
indicated in IS 456-2000.
ii. Mixing
Except where nominal mix concrete as defined in IS 456-2000
is permitted by the engineer to be used, all components of
concrete shall be proportioned by weight using weigh
batches for each grade of concrete. Mixing shall be carried
out in mechanical mixers and preferably a batch mixing plant
shall be used.
iii. Consistency
Consistency of concrete shall be controlled as per IS - 456-
2000 and the contractor shall carry out slump tests in
accordance with IS 1199-1959.
iv. Work tests
Over the full period of construction, the contractor shall carry
out works tests of concrete cubes at his own cost. Sampling,
making up, curing and testing of specimen shall conform to
IS - 456-2000, IS - 516-1959 and IS - 1199 -1959. The number
of specimen to be tested and their criteria for acceptance
shall be according to IS - 456-2000. Frequency of work tests
shall be as relevant IS.
v. Reinforcement
 Workmanship shall conform to IS - 2502-1963.
 Welded joints may be used in cases of important
connections tests shall be made at the cost of the
contractor to prove that the joints have reached the
strength of the bars connected. Welding shall be done
in accordance with IS 2751-1979 and special
precautions shall be adopted for cold worked bars.
Butt-welding between the ends of a rod in line, whereby
stress is transferred across the section may be adopted
only for mild steel bars. In case of tack welding for fixing
reinforcements in their position, no special precautions
need to be taken.
vi. Embedment/ Inserts
 All embedment/ inserts shall be accurately set and
rigidly fastened. Anchor bolts shall be set to template
and firmly secured in vertical and horizontal line at
required positions. Water stops shall be secured against
displacement during the placing of concrete. The joints
for G.S. sheet water stops shall be soldered watertight
and those of PVC and rubber shall be joined by
cementing and vulcanizing. Expansion joint fillers shall
be for the full depth of slabs or full width in walls and
shall be cemented with bituminous cement against
previously placed concrete. The ends shall be butted
tight and the upper edge set flush with finished slabs.
 Anchor holes and anchor bolts shall be protected by
covering suitably with brickwork in lean cement mortar
after thorough cleaning.
3) Placing of concrete
i. Transporting concrete
Concrete shall be transported from the mixing plant to the
forms as rapidly as possible by means that will prevent
segregation or flash set in the concrete during hot weather.
The containers shall be such as to prevent large evaporation.
At the time of placing concrete in very hot weather, care shall
be taken to see that the temperature in wet concrete does not
exceed 38°C. Before placing the concrete, all formwork,
embedment and reinforcement shall be checked for
completeness, location, dimension, square and plumb. All
chips and sawdust or other foul matter shall be removed from
within the forms. The base surface shall be well moistened and
puddles wiped out. Placing equipment and accessories shall
be kept clean and free of partially set grout and concrete, and
maintained in proper working order. Suitable walk cradles
shall be placed over the reinforcement when the concrete is
placed by manual transportation.
ii. Placing
Concrete shall be placed within a maximum period of 25
minutes of its removal from mixer. No concrete shall be
placed until the place of deposit has been inspected and
approved by the engineer. In general, placing shall be direct,
by transporting buckets. Where it is necessary to deposit the
concrete at level differences of more than 1.5 m, short chutes
shall be used. Short chutes and hoppers shall be so designed
and installed that segregation will not take place. In cases
where chutes are impracticable due to excessive drop to
placing level, hoppers and sectional tubes (elephant trunks)
shall be used. Concreting in open shall not be allowed during
rains unless all precautions have been taken by the contractor
and permission has been given by the engineer.
iii. Construction joints
Construction joints shall be located such that they do not
impair the strength of the structure. In walls and columns,
height of each lift shall not generally exceed 1.5 m unless
otherwise specified in the drawings. Method of forming all
construction joints shall conform to the provision of IS 456-
2000. All construction joints in the underground structures
shall be provided with rubber or PVC water bars. The surface
of previously placed concrete at the construction joint shall be
thoroughly hacked to expose the coarse aggregates of
previously placed concrete and cleaned with wire brush and
water to remove all laitance. Immediately before placing fresh
concrete, such prepared surface shall be coated with a thin
layer of cement slurry.
iv. Expansion joints
Expansion joints shall be provided at locations as shown in
drawings or as per IS code. Details of expansion joints shall be
as shown in the drawing and all materials like bitumen
impregnated fiber board, PVC water bar, aluminum foil etc.
shall be of approved make and quality. Contractor shall ensure
that all expansion joints are 100% watertight. If concrete is
found to leak at construction/ expansion joints or at other
places, the contractor shall carry out necessary remedial
measures at his own cost such as pressure grouting etc.,
immediately to make the structure watertight.
v. Compaction
Concrete in general shall be consolidated by vibration using
high frequency mechanically driven vibrators. Concrete shall
be placed in layers at least 300 mm deep in walls and
approximately 450 mm in mass pours. Vibrators shall not
penetrate more than 50 mm into the surface of previously
placed layer but shall completely vibrate the working layer.
Care shall be taken not to over vibrate any concrete and
especially those with higher slumps. Under no circumstances
vibrator shall be attached to or allowed to touch
reinforcement. Spare vibrators in good operating condition
shall be in hand during placing operations.
4) Grouting bases of machine, columns, foundation bolts, etc.
i. Grouting
 Before placing the grout, the concrete surface shall be
thoroughly cleaned, preferably with compressed air and
the surface shall be thoroughly wetted with water for
several hours. Grout concrete shall be of non-shrink
standard ready mixed cement-based grout of approved
make as per item of work/drawing. The grouting shall
be prepared and placed as per manufacturers’
instructions. Before placing the grout all free water shall
be removed and the flat surface shall be coated with
thin cement slurry.
 Non-shrinking free flow grout:
Ready-mix non-shrinking free flow grout of 7 days
strength not less than 30N/mm2 shall be used in
accordance with the method specified by the
manufacturer. Material shall be as approved by the
engineer.
ii. Curing
 The grout must not dry out after it is placed in position.
The surface shall be kept moist with wet sacks for at
least seven days.
 Curing of concrete with water shall comply with IS: 456-
2000. The contractor shall keep the exposed surfaces of
concrete in a constantly wet condition for at least 7
days from the date of placing the concrete. Curing
compound may be used subject to approval by the
engineer. Finished floor and concrete shall be protected
carefully until completely set. Protection of concrete
against extreme weather conditions shall comply with
the code.
5) Repairing and patching
Pockets honey combing and other defects, which may be formed
due to segregation, improper vibration and any other reason
whatsoever shall be completely repaired to the satisfaction of the
engineer. The voids, if any, shall be properly keyed and reinforced,
if necessary. The face shall be tightly formed and arranged for
providing a head in the concrete. The cavities shall be filled with
the same concrete as used for the structure and thoroughly rodded
or vibrated where possible. The filled hopper shall be left in place
until shrinkage has taken place and the concrete sets sufficiently to
stay in place. While still `alive', the upper part of form hopper shall
be removed and excess concrete struck off and finished with
wooden flat or trowel to match existing concrete. Any fins or
unsightly grout runs or bulges shall be removed from the surfaces
exposed to view. The rod holes shall be finished with cement or
grouted to match the existing surface as closely as possible. No
cement wash shall be used unless particularly called for in the
drawings.
6) Tolerances
Tolerance shall be as per system requirement & relevant BIS codes.
3.7.20.6 Form Work
Shuttering & form works for Concrete shall conform to IS: 456 – 2000.
3.7.20.7 Pre-Cast Concrete Work
1) General
The formwork and/or mould for Pre-cast concrete units shall be
made of metal and true to shape and dimension of the finished
product as indicated on the drawings. The moulds shall be close
jointed and perfectly smooth with joints caulked to prevent leakage
of cement slurry. The moulds shall be of rigid construction to
prevent distortion and bulging of sides and base. The moulds shall
be designed with suitable fastening to allow them to be struck off
without injury to the casting. The moulds shall generally be vibrated
on a mechanically operated vibrator.
2) Marking of units
All pre-cast members shall be marked in a manner approved by the
Engineer in a conspicuous place, with date of manufacture and
marking number. The upper part of the member shall be marked
distinctly for proper handling.
3) Erection
Erection of pre-cast units shall be carried out as per the approved
sequence.
3.7.20.8 Brick Masonry Work
1) Materials
 Cement Mortar
Cement mortar shall be as specified in this specification
 Brick
Fly ash bricks confirming to IS: per IS:13757 or IS:12894 shall
be used. In case of unavailability of fly-ash brick within 50 Km
radius of work site, bricks as per IS:1077 can be used after
prior approval of employer. The minimum compressive
strength of brick shall be 5 N/mm2.
2) Scaffolding
Scaffolding shall conform to IS - 2212-1991 and shall be designed
to withstand the loads and to ensure complete safety of workmen
and materials.
The scaffolding should be double, i.e. it shall have two sets of
stands to avoid putlog holes. Where this is not possible, the inner
end of the scaffolding poles shall rest in a hole provided in a
header course only. Only one header for each pole shall be left
out. Holes, if provided, shall be filled in and made good by the
Contractor to ensure that the surface does not give any unsightly
appearance.
3) Cleaning
The Contractor shall carry out work in as clean a manner as
possible and shall remove excess materials and mortar droppings
and rubbish, daily. Where brick walls and stone masonry are to
receive plaster, the joints shall be cleaned of excess mortar and
raked to a depth of 12 mm and the surface shall be brushed clean.
4) Workmanship
 The Contractor shall carry out the whole of the brickwork in a
uniform manner according to IS 2212-1991. All the brick shall be
kept under water till they are completely soaked and used on the
work on their becoming skin dry.
 The Contractor shall set out and build all brickwork to the
dimensions, thickness and heights shown in the drawings. The
Contractor shall build all brickwork in English bond and half brick
walls and casing to pipes, chases etc. in stretcher bond. Brickbats
shall not be used except where required for bond.
 The Contractor shall lay bricks in full mortar beds with shoved
joints. The joints shall not exceed 10 mm in thickness and shall be
full of mortar, close, well finished and neatly struck. The vertical
joints in any course shall not be nearer than a quarter of a brick
length from those in the course below. All joints shall be of same
width except for small variations to maintain bond. The brickwork
shall be laid plumb and true to line and level. No portion of
brickwork shall be raised more than 1.0 m above another at one
time. If the mortar in any course has begun to set, the joint shall
be raked out before another course is laid. The top most course of
brickwork under a reinforced concrete beam shall be wedged
against reinforced concrete surface and the joint well filled with
mortar. The Contractor shall flush up all joints thoroughly with
mortar as the work proceeds.
 The brickwork as it progresses shall be thoroughly watered on its
faces and top. New work shall be properly bonded with the old
work. New surface of unfinished work shall be cleaned and
thoroughly watered before joining new work to it.
 Walls whose thickness is less than a full brick length shall be
reinforced with wire netting of width equal to that of the wall at
every third layer. The laying of wire netting shall be continuous.
Wire netting shall be as per IS 3150-1982.
5) Curing
The Contractor shall keep wet all brickwork for seven (7) days after
laying.
3.7.20.9 Plaster Work
1) Materials
Mortar for plasterwork shall be as specified in this specification.
2) Workmanship
 All plasterwork shall be carried out according to IS – 1661-
1972. The thickness and proportion of cement plaster shall
be as specified in the drawing. Where the thickness of plaster
is 20 mm or more, it shall be done in two operations (coats).
 The surface to be plastered shall be cleaned of all extraneous
matter and rubbish. Brickwork joints shall be raked and
concrete surface shall be roughened by chipping or hacking.
Any shuttering materials adhering to the concrete shall be
removed. The surface shall be thoroughly watered and
soaked, aerated and all putlog holes shall be closed before
starting plastering operation. Plaster pads of required
thickness of plaster for the Contractor shall establish
correctness of plumb, line and level before starting
plasterwork.
 For one coat plaster work, the plaster shall be laid slightly
thicker than the specified thickness and the surface then
leveled with a flat wooden rule to the required thickness. The
plaster shall be well pressed into the joints and the surface
finished for getting smooth and even surface.
 Where two coats plaster work is specified, the first coat shall
be applied as described above except that the surface shall
be left rough and keys formed for the application of second
coat. The second coat shall be applied a day or two after the
first coat has set, but the first coat shall not be allowed to
dry. The second coat shall consist of mortar ground very fine
and shall be laid on with a wooden rule to specified
thickness, rubbed smooth and leveled and the surface
plastered completely the same day. The levelling shall be
continued till the plaster is dry and all moisture which exudes
from the plaster shall be wiped out with fine cloth. The
surface shall be kept dry until exudation of moisture ceases,
during the process of rubbing.
3) Curing
After the completion of plasterwork, it shall be cured by adequate
watering for a period of seven (7) days.
3.7.20.10 White Washing and Cement Painting
1) Materials
 Lime
White wash shall be prepared from shell (fat) lime conforming
to IS 712-1984.
 Gum and blue pigment
Gum and blue pigment for white wash shall be of best quality
and of approved one.
 Water
Water shall be clean and of potable quality.
 Paint
Paints shall conform to relevant Indian Standards and shall be
of approved brands. Only ready mixed paints shall be used for
the work, unless otherwise approved by the Engineer. The
materials for succeeding coats on any one surface shall be
product of the same manufacturer supplying the first coat for
that particular surface. Aluminum paint shall conform to IS
2339-2013.
 Brushes
Brushes shall be of type and size suitable for the work,
conforming to IS 487-2012. Rags or inferior quality brushes
shall not be used on the work.
2) White Washing and Colour Washing
 Slaking
Slaking of lime shall conform to IS 1635-1992. The lime shall
be placed about 300 mm deep in a drum with about 1200
mm deep water standing in the drum. Lime shall be added to
the water and not water to the lime. The lime in water shall
then be vigorously stirred. Lime shall be considered to be
completely slaked when the temperature of the lime and
water shall cease to rise and any further addition of water
shall not produce any further chemical action or heat. Water
shall then be allowed to stand on for 12 hours or more until
the normal temperature is restored.
 Mixing
The slaked lime shall be dissolved in a tub with sufficient
quantity of water and shall be well mixed to give a thin
creamy consistency. It shall then be strained through a clean
coarse cloth and gum dissolved in hot water shall be added to
it at the rate of 2 kg for each cubic metre of lime and
ultramarine blue added to the mixture in small proportion just
sufficient to give a very light bluish tint.
Colour wash shall be prepared in the same way as for the
white washing except that necessary amount of colouring
matter shall be added to lime mixture in this case. No blue
shall be added to lime mixture in case of colour wash.
 Preparation of surface
Before the wash is laid, the surface shall be well cleaned and
brushed. After cleaning the surface, all holes, cracks and
patches shall be made good with approved materials.
3) Application
a) Whitewashing
White wash shall be applied with brush, each coat consisting of
vertical stroke from top downwards followed by opposite
stroke upwards over the first stroke and horizontal stroke from
left to right followed by stroke from right to left. Each coat
must be allowed to dry, before the next coat is applied. On
completion, the surface when it becomes dry, shall present a
uniform white appearance. When dry, no coat of white wash
shall show any patches, hair cracks or strokes nor shall it come
off when rubbed with hand. White wash shall be done in three
coats. Doors and windows, floors etc., must be protected from
whitewash splashes. Any splashes and droppings shall be
removed and cleaned immediately.
b) Colour washing
Colour wash shall be applied in the same manner as specified
for white wash. During application, the solution shall be stirred
continuously and wash shall be applied with care to avoid any
cut shade or brush marks on the walls when the work is
completed. For all new work, the surface to be colour washed
shall first be treated with a priming coat of lime wash. Unless
otherwise specified, two coats of white wash shall be first
applied before colour wash is applied. The colours wash,
whether applied inside or outside of a building shall be of
uniform tint and shade. Any splashes and droppings shall be
removed and cleaned immediately.
4) Painting
 Ready mixed paint
Only ready mixed paints of approved brands shall be used. The
product shall be such, when applied, it shall spread evenly in a
thin coat and flow on smoothly and shall dry quickly forming a
tough durable film without showing any brush marks or cracks.
 Preparation of surface
The surface of steelwork to be painted shall be cleaned free of
dirt, oil, rust, mill scale and be thoroughly dry before painting.
Cleaning, degreasing, de-rusting and de-scaling wherever
necessary shall be carried out as specified in IS 1477(part 1)-
1971.
The surface of woodwork to be painted shall be cleaned and
rendered dry, free of dirt, grit and grease and shall be rubbed
smooth with the appropriate quality of sand paper. All knots
patches and sappy spot shall be touched up with shellac
varnish.
 Painting steel work
Painting of steel work shall be carried out as per manufacturer’s
specification and as approved by the Engineer.
 Painting woodwork
After the primer coat has dried, nails, holes, cracks and the like
shall be filled up with approved wood putty and the surface
finished smooth. The type of intermediate and finish coat shall
be as specified in the technical specification or on drawing. The
surface shall be rubbed smooth before application of each coat.
Each coat shall be allowed to dry before the succeeding coat is
applied. Finished surface shall have no brush marks and shall be
uniform in colour.
3.7.20.11 Waterproofing of underground structures
1) Material
Non-shrink polymeric water proof grouting compound of
SIKA/CICO/FUSROC or equivalent shall be used
2) Workmanship
 The concrete for vertical wall shall be at least M-25C grade as
per IS 456-2000 having a maximum water cement ratio of
0.45. Approved super plasticiser-cum-cement water proofing
agent shall be added to the concrete as per the
manufacturer's specification. Adequate precaution shall be
taken to keep the nozzles horizontal during concreting.
 The exterior surface of the concrete shall be plastered with 12
mm thick cement sand plaster 1:3 & mixed with approved
cement waterproofing compound conforming to
manufacturer's specification. The plastered surface shall then
be finished smooth with a neat coat of cement slurry and
painted with two (2) coats of approved solvent less resin to
form a thick resilient and flexible resinous membrane over the
plastered surface. Approved non-shrink polymeric waterproof
grouting compound mixed with cement slurry shall be
injected through the nozzles under pressure by pump as per
the manufacturer's instruction. When the injection operation
is over the nozzles shall be sealed with a sealing compound as
per manufacturer's specification and instruction
 Waterproofing shall be carried out as per the manufacturer's
specification and as stated below:
 Raft
The sub-base of the underground structure shall be cleaned
of all dirts and kept dry by continuous pumping of water. 20
mm thick plaster with cement sand mortar 1:3 mixed with
cement waterproofing compound as per manufacturer's
specification shall be laid on top of the sub-base.
The plastered surface shall then be painted with two (2) coats
of approved solvent less resin to form a thick resilient and
flexible resinous membrane over the plastered surface.
Threaded nozzles of 12 mm diameter and of suitable length
shall be placed and fixed in a grid pattern of maximum 1.5 m
centre to centre over the whole raft, prior to casting of RCC
raft. Similar nozzles will also be placed along the construction
joint, if any, at regular intervals not exceeding 1.5 m c/c.
Adequate precaution shall be taken to keep the nozzles
plugged at both ends to prevent them from getting clogged
by concrete. Similar nozzles shall also be post fixed at critical
points, if required. Approved super plasticiser-cum-cement
waterproof shall be added to the concrete for the raft as per
manufacturer's specifications. The concrete shall be at least
M-25C grade as defined by IS 456-2000 and the water cement
ratio of the concrete shall not exceed 0.45. Adequate
precaution shall be taken to keep the nozzle vertical while
concreting.
Approved non-shrink polymeric waterproof grouting
compound mixed with cement slurry shall be injected through
the nozzles under pressure by pump as per instruction of the
manufacturer. When the injection operation is over, the
nozzle shall be sealed with a sealing compound as per
manufacturer's specification and instruction.
 Vertical wall
12 mm diameter threaded nozzle of suitable lengths shall be
placed and fixed in a grid pattern of maximum 1.5 m centre to
centre over the entire surface prior to concreting of the
vertical wall. Similar nozzles are to be also fixed at
construction joints, if any, at regular intervals not exceeding
1.5 m c/c. Adequate precaution shall be taken to keep the
nozzles plugged at both the ends to avoid clogging of the
nozzles by concrete. Similar nozzles shall also be post fixed at
critical points, if required.
3.7.20.12 Waterproofing
1) Work Included
The Contractor shall furnish materials, labour, plant, equipment and
tools to complete the work as specified.
2) Waterproofing of roof surface
On roof top 4mm thick Atactic Polypropylene modified
plastomeric bitumen based membrane with glass fiber
reinforcement (minimum 50gsm), finished on both sides with a
thermo fusible high molecular high density polyethylene (HDPE) film
and mineral finished on top surface (MOPLY FP MINERAL 4mm of
TEXSA INDIA Ltd. Or equivalent) Laying of the membranes shall be
done by manufacturer’s authorized applicators only. The cost
includes cleaning of the roof surfaces and filling of the joints, micro-
leveling, cutting & filling of chases in brick wall / RCC for termination
of membrane on vertical faces and necessary overlaps of the
membranes at the joint as per manufacturer specifications. Care shall
be taken for waterproofing in drain mouth and in gutter
3.7.20.13 Damp proof course

1) Work included
The contractor shall furnish materials, labour, plant, equipment and
tools to complete the work as specified and/or as shown in
drawings.
2) Materials
 Cement: Cement shall conform to IS 269-2015 or IS 455-2015.
 Aggregates: All aggregates shall conform to IS 383-2016. Fine
aggregates shall be approved river sand or pit sand. Coarse
aggregates shall be approved stone chips of size not exceeding 6
mm. Aggregate shall be clean and free from any foreign material.
 Waterproofing compound: It shall be of approved quality and
make.
 Water: Water shall be clean and of potable quality.
 Bitumen: Bitumen shall conform to IS 3384-1986.
3) Thickness and proportion

Unless otherwise specified in the technical specification, the damp
proof course shall be 40 mm thick with 1:1.5:3 concrete with 6 mm
and downgraded stone coarse aggregate with approved water
proofing compound, mixed in the proportion as specified by the
manufacturer.
4) Workmanship
The masonry surface shall be levelled and joints shall be raked to
receive the damp proof course. Damp proof course shall be
provided at positions shown on the drawings. It shall be laid for
the full width of the wall. The top surface shall be kept rough or
ribbed for proper adhesion with the mortar for masonry coming
over it. All other surfaces of the damp proof course shall be
finished fair and smooth. After the surface has partially set hot
bitumen shall be applied in two coats at the rate of 1.7 kg/m2 per
coat and dry sand spread over it.
3.7.20.14 Rolling Shutter (Hand Operated and Mechanical Gear Operated)
All rolling shutters shall be of approved make and shall conform to IS
6248-1979.
3.7.20.15 Glazing
a) Materials
 Sheet glass: Unless otherwise specified, all glass used in the work
shall be of quality approved, distortion free, transparent sheet
glass conforming to IS: 2835-1987 and shall be free from specks,
bubbles, smokes, wanes, air holes and other defects. Unless
otherwise specified, for sizes of glass above 900 mm X 900 mm
plate glass shall be used. Glazing to doors shall be done with 6.3
mm thick sheet glass weighing about 15 kg/m2. Glazing to
windows and ventilators shall be done with 4 mm thick sheet glass
weighing about 10 kg/m2.
 Plate glass: Where plate glass is specified for the work, it shall be
of thickness as specified with a permissible tolerance of 0.5 to 0.8
mm for polished plate glass. The transparent type glass shall have
polished surface giving clear and undistorted vision.
 Rough cast wired glass: The rough cast wired glass shall be about
6 mm thick weighing about 16 kg/m2 and of approved quality,
with 12.5 mm square wire mesh 0.5 mm in diameter.
b) Workmanship
Glazing of metal doors, windows and ventilators shall conform to IS:
1081-1960.
3.7.20.16 Road Works
All material, workmanship & testing for road works shall be as per
MORTH specification. All tests of material shall be carried out by
Contractor at his own cost.
3.7.20.17 Vibration Isolation System (VIS)
1) VIS system shall comprise of spring & viscous damper unit biding
velocity proportional dampening. The dampers shall be suitable
for temperature ranging from 0-500C. The size of spring cum
damper unit shall be adjusted so that the total system can be
accommodated on the existing column head after dismantling.
2) The selection of VIS system shall be done keeping in view the
configuration & strength of existing columns / foundations, load
from equipment, and the allowable amplitude of foundation
system. The VIS system shall be designed so as to transmit not
more than 5-10% of dynamic loads to the supporting
columns/structure. This shall be substantiated by appropriate
design calculation. The actual amplitude of vibration shall be
established at site during commissioning and the value shall not
exceed the allowable amplitude specified by the equipment
manufacturer. Any rectification / modification for achieving the
desired amplitude, if required, shall be carried out by Contractor
without any extra cost.
3) The analysis, design and checking of structure shall be done in
strict accordance to latest IS:2974 (relevant part) & IS:456-2000.
Static analysis.
The static analysis, design & checking shall be carried out
considering all the loads & worst load combinations specified by
the equipment manufacturer. The structure shall be designed /
checked for both strength as well as serviceability.
Dynamic Analysis
The fundamental natural frequency shall be sufficiently above or
below the frequency corresponding to operating speed and critical
speed. Vibration amplitude shall be calculated at all bearing
locations and shall satisfy the permissible limits as per IS/ ISO
10816-Part2, 2001or as specified by the equipment manufacturer.
Transient analysis shall be carried out at each fundamental
frequencies of the top deck and the amplitude of vibration shall be
within the permissible limit. The columns/foundation shall also be
checked for accidental loads/ failure load as provided by
equipment manufacturer.
4) Manufacturing and Testing
Complete manufacturing and testing of the VIS shall be done at
the manufacturing shop of the approved sub contractor/ supplier.
For this purpose the contractor/ sub contractor shall submit the
detail program for approval and take up the manufacturing/
testing after approval of schedule. The schedule shall include:
 Manufacturing schedule and quality check exercised during
manufacturing.
 Detail of test to be carried out at the manufacturing shop with
their schedule.
 Special requirements, if any, regarding concreting of top deck.
 Complete step by step procedure covering the installation and
commissioning of the VIS system.
 Manuals for erection, commissioning, testing and maintenance of
the VIS.
 A checklist for confirming the readiness of the civil fronts for
erection of VIS.
 Checklist for equipment required at each stage of erection.
 Bill of materials (data sheet) of various elements such as spring
units with their rating, stiffness etc. included in the supply.
 Bill of materials (data sheet) for frames for pre stressing, hydraulic
jack including electric pump, high pressure tubes, hand operated
pump etc., required for erection with their rating and numbers.
 Any other information required to facilitate design and
construction of the foundations/ structures.
3.7.21 Codes and Standards
Some of the relevant Indian/International standards codes etc.
applicable to this section of the specification are listed below:
IS 456 Code of practice for plain and reinforced concrete
IS 2974 Code of practice for design and construction of
machine foundations
IS 1893 Criteria for earthquake resistant design of structures
DIN 4024 Machine foundations; Flexible supporting structures for
machine with rotating masses.
DIN 2089 Helical compression springs out of round wire and rod;
calculation and design
DIN 2096 Helical compression springs out of round wire and rod;
quality requirements for hot formed compression
springs
VDI 2060 Criteria for assessing the state of balance of rotating
rigid bodies
IS 9595 Metal arc welding of carbon and carbon manganese
steels-recommendations.

4 COMMISSIONING AND PERFORMANCE GUARANTEE
4.1 PRELIMINARY ACCEPTANCE
On completion of erection of the facilities by the contractor, trial runs
for individual equipment / units shall be conducted by the contractor to
prove that the facilities have been supplied and erected as per contract
and after erection, facilities are fit for start-up and commissioning. After
liquidation of all the defects and after fulfilling all the provision of
clause 24 of GCC of Standard Bidding Document (SBD) employer
shall issue Preliminary Acceptance Certificate (PAC) for the subsequent
commissioning of facilities.
4.2 COMMISSIONING
Commissioning test shall be undertaken by the contractor as per the
provisions of Clause 25 of GCC of SBD. On successful completion of
commissioning test employer shall issue commissioning certificate.
The facilities shall be deemed to be commissioned on fulfilment of
following:
1) Commissioning:
Commissioning of the complete system shall be deemed to be
successfully completed when all the equipment shall operate in an
integrated manner uninterruptedly at a minimum steam flow rate
of 75 % of the rated capacity of the system at rated pressure.
2) Duration/period of commissioning tests
Uninterrupted operation of complete system for a period of 168
hours.
In case of any interruption during the specified period/duration of
commissioning on account of reasons attributable to the Employer, the
acceptance of commissioning with regards to duration of
commissioning tests shall be as per the mutually agreed terms between
the Employer and the Contractor.
4.3 PERFORMANCE GUARANTEE
4.3.1 General
4.3.1.1 The contractor shall guarantee the equipment for its workmanship,
materials, design and satisfactory operation in accordance with relevant
specifications and provisions of the contract. The guarantee for
performance shall include individual items and systems for various
ratings / out puts as well as for the integrated operation of the plant.

4.3.1.2 The details of the performance guarantee tests, test procedures, test
schedules for the demonstration of performance guarantee parameters
shall be submitted to the employer which shall be mutually agreed
upon.
4.3.1.3 The contractor shall conduct the performance guarantee tests to
demonstrate PG parameters as defined hereunder in subsequent para
and as per provisions of Clause 27 of GCC and Appendix-5 of SBD.
4.3.1.4 PG Test shall be conducted within a period of six months after the date
of commissioning once facilities achieve stable operation as well as
production level.
4.3.1.5 Period of PG Test shall be for 72 hours during which contractor shall
demonstrate the PG parameters.
4.3.2 Preconditions for Performance Guarantee Tests
4.3.2.1 Preconditions for the employer:
1) The Employer shall make available necessary utility, power, etc. for
conduction of P.G Test.
4.3.2.2 Preconditions for the contractor:
1) The contractor will arrange necessary instruments, tools, tackles,
consumables, personnel and other facilities required for
conducting PG tests and supervise operations from the start until
end of PG tests and shall take full responsibility of the operations.
2) PG test shall be carried out for a duration of 72 hours.
4.3.3 Performance Guarantee Parameters
Contractor shall have to demonstrate following parameters as listed
hereunder:
Sl. No. PG Parameter Guaranteed Value
1. Continuous output at 100 tph
the MSV outlet
2. Superheated steam 36 kgf/cm2 (g)
pressure at the MSV
outlet
3. Superheated steam 413oC (± 5oC)
temperature at the MSV
outlet
4. Stack outlet emission of <30 mg/Nm3
Boiler

During performance test period. LP steam export will be NIL. However,
LP steam required for internal processes will be taken care of in design.
Net capacity is 100 tph. However, performance of PRDU needs to be
tested.
4.3.3.1 Variance of input conditions for PG parameters
In the event of any variance in the input conditions w.r.t quality,
quantity, or any other parameter as defined in cl. 4.3.2 and 4.3.3, which
has a bearing on the PG parameter, the output PG parameter shall be
mutually discussed and revised as per the agreement between the
Employer and Contractor, before the start of PG tests.
4.3.3.2 Non fulfilment of Performance Guarantee Parameters and Liquidated
Damage
In case the contractor is unable to attain the guaranteed value of
performance guarantee parameters but attains within the minimum
acceptable level of the performance guarantee parameters as specified
either in whole or in part then employer shall recover the amount of
liquidated damage as mentioned hereunder:
Sl. PG Parameter Guaranteed Acceptable LD in %
No. Value Limit with
LD
1. Maximum 100 tph 95 tph 1.5% for
continuous output every
at the MSV outlet at decrease of
rated pressure and 1 tph in
temperature guaranteed
value
2. Superheated steam 36 kgf/cm2 Not N/a
pressure at the MSV (g) negotiable
outlet
3. Superheated steam 413oC (± Not N/a
temperature at the 5oC) negotiable
MSV outlet
4. Stack outlet emission Less than 30 No deviation Not
of Boiler mg/Nm3 applicable.
Plant will be
rejected
beyond PG
parameters

Total Liquidated damage for non-fulfilment of PG parameters shall be
limited to 7.5% of contract value, excluding taxes and duties, as
stipulated in GCC of SBD.
4.4 FINAL ACCEPTANCE

Final acceptance shall be as per clause no. 28 of GCC of SBD.

Annexure 2.1.9.2-1
Implementation Schedule
(Duration in months)
S.No. Activities 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
1 Effective date of Contract
2 Preparation, Submission & approval of Basic
Engg. drawings
3 Preparation, Submission & approval of
Detail Engg. drawings
4 Manufacture & Supply of Equipment
5 Civil & Structural works
6 Erection/installation of equipment
7 Shutdown *
8 Testing & commissioning
* Required for interconnection jobs, to match with planned OPP shutdown
DSP ANNEXURE– 2.1.9.2-1 CONTRACT NO..

SCHEDULE – 1.8-1
DECLARATION OF SITE VISIT
DSP SCHEDULE – 1.8-1 CONTRACT NO..

INSTALLATION OF NEW GAS FIRED PAGE 1 OF 1
BOILER
SCHEDULE – 1.8-2
LIST OF EXCLUSIONS
All Exclusions withdrawn by Contractor

vide MOM of tender discussion.
NIL Exclusions

BOILER
SCHEDULE – 1.8-3
LIST OF DEVIATIONS
All Deviations withdrawn by Contractor

vide MOM of tender discussion.
NIL Deviations

BOILER
SCHEDULE – 1.8-4
LIST OF RECOMMENDED SPARES FOR

TWO YEARS NORMAL OPERATION
(To be filled by the Contractor)
Contractor shall recommend and tabulate below the list of additional spare parts
for two years trouble free operation. Additional sheet of like format may be used if
necessary.
This list of critical operational & maintenance spares shall be finalised during
offer evaluation stage. Supply of all finalised list of spares is included in
scope of Contractor.
For electrical items, contractor shall refer the relevant clause in chapter 2.

BOILER
SCHEDULE – 1.8-4

BOILER
SCHEDULE – 1.8-5
LIST OF COMMISSIONING SPARES

(To be filled by the Contractor)
Contractor shall tabulate below item wise the list of commissioning spares
necessary for the equipment bided. Additional sheet of like format may be used if
necessary.

BOILER
SCHEDULE – 1.8-6
LISTS OF SPECIAL TOOLS AND TACKLES

BOILER
SCHEDULE – 1.8-7
LIST OF FIRST FILL OF OILS AND LUBRICANTS

BOILER
SCHEDULE – 1.8-8
DETAILS OF AUTHORISED PERSON OF CONTRACTOR DURING BID

EVALUATION

BOILER
SCHEDULE – 1.8-9
REQUIREMENT OF CONSTRUCTION WATER & POWER

BOILER

2023.03.14 Final Contract 4086 Main

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2023.03.14 Final Contract 4086 Main

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CONTRACT AGREEMENT

STEEL AUTHORITY OF INDIA LIMITED

ISGEC HEAVY ENGINEERING LIMITED

STEEL AUTHORITY OF INDIA LIMITED

CONTRACT NO. DATED

Chapter No. Description Page No.

1 Introduction 1.1 - 1.2

2 Scope of Work 2.1 - 2.38

3 Technical Specification 3.1 - 3.224

4. Commissioning and Performance Guarantee 4.1 - 4.4

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Annexure No. Description No. of Pages

2.1.3-1 List of Acceptable Makes of equipment and 34

2.1.9.2-1 Implementation Schedule 1

3.7.10-1 Soil Investigation & Survey Works Report 134

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Schedule No. Description No. of Pages

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Sl. No. Drawing No. Description

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1.3 OVERVIEW OF THE PROJECT

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2.8 DRAWINGS AND TECHNICAL DOCUMENTS

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2.8.4 The drawings/ documents submitted after placement of order shall be

2.8.5 Drawings shall be submitted in pre-decided and agreed sequence. In

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Main steam Steam pressure 35 kgf/cm2 (g)., temperature

LP Steam from PRDU Steam pressure: 12-13 kgf/cm2 (g).

Piping terminal points - New piperack to be installed from/till TOP as

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2.12 HAZARD / RISK IDENTIFICATION

2.13 SAFETY ASPECTS

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3.1.2 Climatic Condition

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2) Coke Oven Gas (COG) : Shall be used during start up as well as

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Maximum 100 tph.

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v. Low speed coupling =(Selected motor kW 1.361.5) / (motor