Technical Specification

SECTION-II: MATERIALS
2.0.0 Materials

All members and components listed under these specifications and specification drawings shall be
fabricated out of unused high grade materials free from any kind of defects and imperfections. The
Contractor, on the basis of the design supplied by the Employer, shall prepare and submit detail
requirement of the steel plate materials required to fabricate penstock pipe and steel liner. Such
details shall be in line with the sizes and specifications available in the Indian and/or Chinese
market. If in case the steel plate sizes proposed by the Contractor is not available in the market,
the Employer may ask the Contractor to adjust the plate sizes. However any such adjustment shall
not alter the design. Any such adjustment shall not change the price. All the materials shall
conform to the standards specified in these specifications and on the specification drawings,
however, if for any reasons the contractor desires to deviate from these standards, he shall submit
a statement stating the exact nature of deviations or substitutions along with complete and detailed
specifications and test reports of the materials which are proposed to be used as substitution or
deviation, for the approval of the Employer, prior to the fabrication work is taken up in hands. All
such materials or articles or supplies, which are not manufactured by the contractor, shall be the
product of recognized and reputed manufacturer.

The contractor shall furnish a list of names of the manufacturer(s) of the bought out complete
equipment, which are contemplated for incorporation in the work, together with their performance
characteristics and other pertinent reports along with the samples of the materials, shall be
submitted for approval of the purchaser. How the approval of purchaser shall not relieve the
manufacturer from the responsibility of supply of suitable materials. Any material or equipment
used or installed with no prior approval of the purchaser shall be at risk and cost of the contractor.
Recommended materials for some of the components of different type of gates, hoists & cranes
involved are given below :

2.1.0 Fixed Wheel Gate/Wheeled Stoplog

S. No. Component Recommended Materials Reference

1. Skin plates, Stiffeners Structural Steel IS-2062 Grade E250,

Quality B

2. Main horizontal girders, Structural Steel –––– do ––––

Vertical girders etc.

3. Seal bases, Track bases, Seal Structural Steel –––– do ––––

seat bases Seal clamps guide
shoes

4. Anchor plates, Anchorages Structural Steel –––– do ––––

etc.

5. Side guide tracks Structural Steel –––– do ––––

Bagmati Small Hydroelectric Project Page 1

 Technical Specification

6. Seal seats Stainless steel, IS-1570 (Part-V)

X04Cr18Ni10

7. Wheel tracks Corrosion resistant steel IS-1570 (Part-V)

plates X30Cr13 (BHN of
wheel track should be more
by minimum 50 points than
that of wheel)
8. Wheel Cast steel/Forged Steel IS-1030/IS-2004/1875
9. Wheel pin Stainless Steel IS-1570 (Part-V)
10. Bearings in Wheels Spherical Roller SKF or
equivalent Bearing
11. Side and top Rubber Seals PTFE cladded solid bulb IS-11855, IS-15466
music note.
12. Bottom seal Wedge type rubber seal IS-11855,IS-15466

13. Steel liner Structural steel IS-2062 Grade E250,Quality

B

2.2.0 Stoplogs for Undersluice

S. No. Component Recommended Materials Reference

1. Structural members of the Structural Steel IS : 2062 (for thickness

stoplogs, such as skin plate, more than 20mm, use only
stiffeners, horizontal girders steel conforming to IS :
& vertical girders etc. 2062)

2. Lifting brackets, guide shoes Structural Steel ––– do –––

etc.

3. Track brackets, guide shoes Structural Steel ––– do –––

etc.

4. Anchor plates & anchorages Structural Steel ––– do –––

etc.

5. Track plates and seal seats Stainless steel IS : 1570 (Part-V)

6. Slide block Structural steel with bronze IS : 2062

padding
IS : 305

7. Seals Natural or synthetic rubber IS : 11855

8. Screws/Bolts for seals Stainless steel IS : 1570 (Part V)

9. CSK screws for bronze Stainless steel IS : 1570 (part V)

padding

Bagmati Small Hydroelectric Project Page 2

 Technical Specification

2.3.0 Electrically Operated Rope Drum Hoist and Hoist Bridge

S. No. Component Recommended Materials Reference

1. All structural members for Structural Steel IS-2062 Grade E250,Quality
steel trestles and hoist bridge B
etc.
2. Rope drum Structural Steel, IS-2062 Grade E250,
Quality B
Cast steel IS : 1030
3. Wire rope Improvised plough steel IS : 2266
(galvanized)
4. Hook and wire rope socket Forged steel IS : 2004
IS: 1875
5. Gears Cast steel IS : 1030
Forged steel IS : 1875
6. Pinions Forged steel IS : 2004
7. Shafts Structural Steel IS-2062 Grade E250,
Quality B
Forged steel IS : 2004
8. Sheaves/Pulleys Structural steel IS-2062 Grade E250,
Quality B
Cast steel IS : 1030
9. Bronze bushing Lead Tin Bronze IS : 318

Aluminium bronze IS : 305

10. keys and Cotters Forged steel IS : 2048/2291/2292

11. Motor Standard manufacturer IS : 325

12. Cable and conductors IS : 9968/IS : 8130

13. Conduits IS : 9537

14. Switch gear Standard manufacturer IS : 2147

IS : 4237

IS : 2516

15. Ball & roller bearings Standard manufacturer IS : 5669

IS:5692 & other applicable

standards

Bagmati Small Hydroelectric Project Page 3

 Technical Specification

2.4.0 Lifting Beam

S. No. Component Recommended Materials Reference

1. Structural components of Structural Steel IS-2062 Grade E250,
lifting beam, guide bars, Quality B
diaphragms etc.
2. Axles, pins and their Corrosion resistant steel IS : 1570
retaining devises such as
nuts, bolts, washer.
3. Hooks Forged steel IS : 1875
IS-2062 Grade E250,
Structural Steel Quality B
4. Bush for hooks Self lubricating bronze IS : 305
bushes
5. Bearing for Pulleys Roller bearings Standard make
6. Sheaves & Rollers Cast steel IS : 1030

2.5.0 Monorail Crane

S. No. Component Recommended Materials Reference

1. Wire ropes 6  37 construction IS : 2266
ungalvanized improved
plough steel, with fibre core
or steel core, extra flexible
2. Wire rope sockets Forged steel IS : 2485
3. Lifting hooks Forged steel IS : 2004
4. Rope drum Cast steel IS : 1030
Structural steel IS : 2062
5. Gears Cast steel IS : 1030
IS : 3681,
IS : 4058,
IS : 4460 & others.
6. Pinion Cast steel IS : 1030
forged steel IS : 1875
C-45 Carbon Steel IS : 1570
7. Sheaves, pulleys and Cast steel IS : 1030
couplings Wrought steel IS : 1570
8. Shafts Structural Steel IS : 2062
Carbon steel IS : 1570
9. Threaded fasteners Bolt Steel IS : 1363
IS : 1364
IS : 1365

Bagmati Small Hydroelectric Project Page 4

 Technical Specification

IS : 1367
IS : 2389
10. Bush Bearings Aluminium Bronze IS : 305
Phosphor Bronze IS : 28
Leaded Tin bronze IS : 318
11. Turn buckles Structural steel IS : 2062
Forged steel IS : 2004
12. Hoist supporting structure Structural plates IS : 2062
Rolled steel sections IS : 808
13. Wheels Forged steel IS : 2004
Cast steel IS : 1030
14. Keys and Cotters Forged Steel IS : 2048
IS : 2291
IS : 2292
15. Ball and Roller bearings Standard IS : 5669,
Manufacturer IS : 5692 & other applicable
standards
16. Electric Motors Standard manufacturer IS : 325
IS : 900
17. Cables and conductors Standard manufacturer IS : 9968
IS : 8130
18. Switch gear Standard manufacturer IS : 1822,
IS : 13947
IS : 5124
19. Electrical bought out items. Standard approved make

2.6.0 Penstock and It’s Accessories

S.No. Component Recommended Materials Reference

i) Penstock shells, bends, Boiler quality Steel Boiler quality steel

reducers Manholes, plates/coils conforming to
bifurcation, reducers, ASTM-537 Cl-1
stiffener rings etc.

ii) Forgings for General Forged steel IS:2004

engineering purpose
iii) Piezometer plugs Stainless steel IS:1570(Part V)

Bagmati Small Hydroelectric Project Page 5

 Technical Specification

iv) Gaskets or jointing material BS:1737 or equivalent IS

specifications
v) Zinc rich primer AWWA Specifications or
equivalent IS specifications.

vi) Cold applied coal tar epoxy British Epilux -5 or

paint equivalent
vii) Red lead primer paint IS:102
viii) Aluminum Paint IS:2839
ix) Red oxide zinc chrome IS:2074

2.7.0 NOTES
The details covered in Para 3.1.0 to 3.6.0 shall be read in conjunction with the following notes.

i) In all the reference cited above the latest revised edition of Indian standards or equivalent
shall only be followed. In case the contractor proposes to use materials different from those
mentioned above, he should mention the same in his tender and indicate the exact extent to
which he proposes to use, furnishing necessary details for approval of the purchaser.
Materials conforming to international standards like ASTM, DIN, which are equivalent to
those mentioned above, can be used with the approval of the purchaser.

ii) The sizes, ratings, capacities, and dimensions of the various standard equipment items listed
in the contract Documents are based on currently available standard products. Reasonable
deviations will be allowed to permit supply of standard equipment. In no case the capacity
furnished shall be less than that specified, unless approved.

iii) Threaded fasteners, pipes, anti-friction bearings and gears : –

All bolts, nuts, screws, rivets, threads, pipe, ball and roller bearings, gauges and gears shall
confirm to US/BIS/DIN Standards. Screw threads for screws, bolts, nuts and other threaded
hardware shall conform to ANSI B 1.1.

iv) Asbestos: Equipment and materials such as, gaskets, packing, brake pads etc. shall contain
no asbestos products.

v) Only self lubricating bronze bushes of reputed manufacturers shall be used wherever
bronze bushes have been indicated.

2.8.0 LIST OF SOME REPUTED MANUFACTURERS OF MECHANICAL AND

ELECTRICAL EQUIPMENT TO BE USED IN HYDROMECHANICAL

Bagmati Small Hydroelectric Project Page 6

 Technical Specification

INSTALLATION FOR REFERENCE

S. No. Item Make

1. Reduction Unit New Allenberry, Allen-max, Allmax, Shanti, Allroyd,

Radicon, David Brown, Elecon etc.
2. Bearings KOYA, NBC , NACHI, SKF, FAG, NSK, NTN etc.
3. Flexible coupling New Allenberry.
4. Motors Siemens, Kirloskar, NGEF, GEC, Crompton Greaves
Cotton etc.
5. Brakes Bhartia Cutler Hammer, Electromag, Strom Kraft, Elmar
AEC Sterling etc.
6. Self lubricating Lubrite, Lubron, Devaglide,Oiless,Ferroglide
bronze bearings
7. Welding electrodes Modi, Adore, D&H, L&T , Esab etc.
8. Steel wire ropes Usha Martin, Fort William, Bombay wires, Winkel GMBH
etc.
9. Hydraulic Cylinder Rexroth Hydrodyne, Hunger, Montan
10. Hydraulic Power Packs Rexroth, Vickers, Montan
11. ARMAC/Remote Allen Bradley, Rockwell, Siemens, ABB, Schneider
Control System Type : PLC Electric
12. Gasoline Engine for Portable Kohler, Honda, Yamaha
Power Pack
13. D.G. Set Caterpillar, Kirloskar, Cummins, Greaves Cotton
14. Hydraulic Oil Cleaning Unit KLAROL Oil Cleaning Systems
for Hydraulic Hoists

Bagmati Small Hydroelectric Project Page 7