Scope of Work & Technical Requirement-Mechanical

PRAYAGRAJ POWER GENERATION COMPANY LIMITED
(PPGCL)
PRAYAGRAJ SUPER THERMAL POWER PROJECT

PHASE-1 : 3X660 MW
PACKAGE-B SPECIFICATION
FOR
STACKER RECLAIMER WORKS OF COAL HANDLING

SYSTEM
VOL-IIA
(SCOPE OF WORKS, TERMINAL POINTS, EXCLUSIONS &

SPARES)
TATA CONSULTING ENGINEERS LIMITED

73/1, ST.MARK'S ROAD
BANGALORE 560 001
INDIA
PRAYAGRAJ POWER GENERATION COMPANY SECTION: INDEX
TCE 5871-H-563-001B LIMITED SHEET 1 OF 1
3 X 660 MW PRAYAGRAJ SUPER THERMAL POWER PROJECT
AT BARA,UP
INDEX SHEET
INDEX SHEET FOR SPECIFICATION VOLUMES OF PACKAGE-B
Volume I : Conditions of contract.
Volume IIA : SECTION – C - Scope of works, Terminal Points,

Exclusions, Spares and Schedules
Volume IIB : SECTION - D1 - Technical requirements – Mechanical
Volume III : SECTION – D2 - Technical Requirements - Civil Works
Volume IV A : SECTION – D3 - Technical Requirements

Electrical Systems
Volume IV B : SECTION – D4 - Technical Requirements
Instrumentation and Control Systems.
Volume V : DRAWINGS
: MECHANICAL DRAWINGS
1) Plot Plan
2) Flow Diagram – Stacking and Reclaiming system
3) Gallery Cross Section – Single Conveyor
4) Gallery Cross Section – Double Conveyor
: ELECTRICAL DRAWINGS
1) Plot Plan
2) Coal Handling System - SLD Substation-1
3) Coal Handling Plant Switchgear Room – GA

Indicative Diagram
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PRAYAGRAJ POWER GENERATION COMPANY
TCE.5871A-H- VOLUME – IIA
LIMITED
563-001B SECTION: CONTENTS
AT BARA,UP SHEET 1 of 3
TITLE
STACKER RECLAIMER WORKS
VOLUME IIA - CONTENTS
VOLUME – IIA
TABLE OF CONTENTS
SUB REV
SECTION TITLE PAGES
SECTION NO.
A R0 SCOPE OF ENQUIRY 1
B R0 GENERAL PROJECT INFORMATION 2
C C1 R1 GENERAL SCOPE OF ENQUIRY 4
C2 R1 SYSTEM DESCRIPTION 5
C3 R1 SCOPE OF WORKS 17
C4 R0 PROJECT SCHEDULE, PLANNING & 8

MONITORING
C5 R0 QUALITY ASSURANCE AND MINIMUM

INSPECTION REQUIREMENTS FOR
COAL HANDLING SYSTEM
EQUIPMENTS AND MISCELLANEOUS
EQUIPMENTS
C6 R0 CODES AND STANDARDS 4
C7 R0 PAINTING 8
C8 R0 LAYOUT AND MAINTENANCE 8

REQUIREMENTS
C9 R0 PERFORMANCE GUARANTEES, PRE- 18

OPERATIONAL TESTING/START UP,
PERFORMANCE TESTING &
ACCEPTANCE PROCEDURES
C10 R0 DATA TO BE FURNISHED WITH THE 2

BID
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CONSULTANTS: TATA CONSULTING ENGINEERS LIMITED TCE FORM 329 R3
LIMITED
TITLE
SUB REV
SECTION TITLE PAGES
SECTION NO.
C11 R0 DATA TO BE FURNISHED AFTER 15
AWARD OF CONTRACT
C12 R0 POLLUTION CONTROL MEASURES 2
C13 R0 SITE SERVICES 17
C14 R0 SUPPLIERS HEALTH AND SAFETY 25

PROGRAM
C15 R0 SPARES AND MAINTENANCE TOOLS 8
C16 R0 SUB VENDORS LIST 3
F F1 R0 SCHEDULE OF PRICES 2
F2 R0 SCHEDULE OF ESSENTIAL SPARES 1
F3 R0 SCHEDULE OF DEVIATIONS FROM 1

TECHNICAL SPECIFICATION
F4 R0 SCHEDULE OF RECOMMENDED 1
SPARE PARTS
F5 R0 SCHEDULE OF WEIGHTS AND 1

DIMENSIONS
F6 R0 SCHEDULE OF EQUIPMENT 1
MANUFACTURE DESPATCH TO SITE
F7 R0 SCHEDULE OF PERFORMANCE 1
GUARANTEES
F8 R0 SCHEDULE OF ELECTRIC LOAD 1

REQUIREMENTS
F9 R0 SCHEDULE OF GUARANTEED 1
POWER CONSUMPTION
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TITLE
SUB REV
SECTION TITLE PAGES
SECTION NO.
F10 R0 SCHEDULE OF BIDDER’S 1

EXPERIENCE
F11 R0 SCHEDULE OF EXCLUSIONS 1
F12 R0 SCHEDULE OF QUALITY ASSURANCE 1

PLAN (QAP)
F13 VOID
F14 R0 REQUIREMENTS OF THE 1

CONTRACTOR AT SITE
F15 R0 SCHEDULE OF PLACES OF TEST & 1

INSPECTION
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SECTION A
SCOPE OF ENQUIRY
SPEC. NO. TCE. VOL IIA
5871-H-563-001B PRAYAGRAJ POWER GENERATION COMPANY LIMITED (PPGCL)
SECTION: A
3 X 660 MW (PHASE–I ) STPP AT BARA ( U.P )
TITLE
SHEET 1 OF1
SCOPE OF ENQUIRY
1.0 SCOPE OF ENQUIRY
The scope includes the Reversible stacker reclaimer works including yard conveyors of
coal handling system (CHS) for 3X660 MW units which involves stacking of crushed
coal and reclaiming of stacked coal and further conveying by yard conveyors which
consistsof Stacker reclaimers, Reversible yard conveyors, Drive houses. All the
necessary conveyor accessories, stockyard dust suppression system (SYDS), Coal pile
run off systemetc. shall be included. Stacker reclaimer works shall be complete in all
respects with all mechanical, electrical and instrumentation, civil and structural works to
the extent specified..
The extent of supply under the contract includes all items shown in the drawings, not
withstanding the fact that such items may have been omitted from the specifications or
schedules. Similarly the extent of supply also includes all items mentioned in the
specification and / or schedule not with standing the fact that such items may have been
omitted in the drawings.
The total price quoted for this contract shall be on lump sum basis all inclusive and shall
cover all items and services necessary for the successful completion of the contract.
Even though all the components required for this system are not explicitly identified
and/or listed herein, these shall be supplied under this contract to ensure completeness
of the system and facilitate proper operation & maintenance of the system. Changes in
quoted lump sum price shall be permissible only in case of addition/deletion of scope.
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TATA CONSULTING ENGINEERS LIMITED TCE FORM NO. 329 R4

SECTION B
GENERAL PROJECT INFORMATION
TCE. 5871A-H-563- PRAYAGRAJ POWER GENERATION COMPANY LIMITED VOL IIA
001B (PPGCL) SECTION B
3 X 660 MW (PHASE–I ) PSTPP AT BARA ( U.P )
SHEET 1 OF 2
1. OWNER/PURCHASER : Prayagraj Power Generation Company Limited
2. Consultant : TATA Consulting Engineers Limited

Sheriff Centre
73/1 St Mark's Road
Bangalore - 560001
Prayagraj Super Thermal Power Project
3. Project Title :
Phase-I : 3x660MW at Bara,
Allahabad District (U.P).
4. Location : Bara Thehsil of Allahabad District,UP (34 km
From Allahabad )
5. Nearest Railway station : Lohgara Railway station (Allahabad – Manikpur

Section) is about 2-3 km from project site.
6. Access Road : NH-76 is 0.5Km from North West Boundary of

site
7. Nearest Airport : Bamrauli, Allahabad (About 28 km from site)
8. Nearest Sea port : N. A
9. Latitude of site : 250 11” 50.95”
10. Longitude of site : 810 39’ 39.33 “
11. Site elevation : Ground level varies from 130m to 120 m from
MSL.
12 Metrological data :
a) Avg Annual Temperature : 32.50 C
b) Max Relative humidity : 80%
c) Normal Annual Rainfall : 975mm
d) Basic Wind Speed : 47 m/sec
13) Seismic zone(As per IS: 1893 ) : Zone III
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TCE. 5871A-H-563- PRAYAGRAJ POWER GENERATION COMPANY LIMITED VOL IIA
001B (PPGCL) SECTION B
3 X 660 MW (PHASE–I ) PSTPP AT BARA ( U.P )
SHEET 2 OF 2
14) Languages Spoken in the Region English, Hindi

:
15) Official language for the bidder to deal English

with:
Auxiliary Power Supply

Auxiliary electrical equipment pertaining to this project shall be suitable for
operation at the following supply system
a) For AC motors above 200 kW : 3300V (+10%), 3 phase, 50 Hz,

(+ 5%) resistance earthed neutral.
b) For AC motor rated 200 kW and : 415V (+10%), 3 phase, 3 wire, 50
below Hz, (+ 5%) Solidly earthed
c) AC Control and protective device : 110 V (+10%), 1 phase, 2 wire,
50Hz AC supply with one point
earthed.
d) For DC motors, control and : 220V (+10%, -15%), 2 wire,
protective devices unearthed DC supply from battery
/ battery charger.
e) For lighting fixtures, space : 240V, 1 phase, 2 wire AC 50 Hz
heaters, for motors rated above with neutral lead effectively
30 kW and indicators / recorders earthed.
f) For solid state controls and : (+)24V( +10%),, 2 wire, negative
annunciation earthed DC supply
g) Uninterruptible power supply : 230V, 1 phase, 50 Hz, AC supply

with one lead earthed
h) Construction power supply : 415 V, 3 phase, 4 wire, 50 Hz, AC
supply with solidly earthed neutral
will be provided at one point by
PPGCL.
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SECTION C 1
GENERAL SCOPE OF ENQUIRY
TCE-5871A- H- PRAYAGRAJ POWER GENERATION COMPANY
563-001B
LIMITED SECTION: C1
SHEET 1 of 4
AT BARA,UP
The scope of this enquiry is for supply and installation of Stacker reclaimers along with
1.0
reversible yard conveyors for 3X660 MW coal fired thermal power station at BARA situated in
the state of UTTAR PRADESH (U.P), India, as per the scope of work mentioned here in after.
1.1 BRIEF SCOPE OF WORK
Detailed scope shall be as per Sec C3 of Vol IIB. The package shall include Plant &
Equipment and all the auxiliary facilities as indicated below:
1. Reversible stacker reclaimer machines with rails and rail fixtures including yard
conveyors.
Drive houses
2.
3. Belt protection switches
4. Belt weighing systems (LOAD CELL TYPE)
5. Flap gates as per flow diagram
6. coal pile run-off system for stockyard area
7. Plain water type dust suppression system including pumps for coal stockyard.
8. Painting of all equipment.
9. Supply of lubricants, grease, oil etc. required for the equipment during testing,
commissioning and upto successful completion of trial run of Stacking and reclaiming
system.
10 Essential and start up spares. Special tools and tackles
11 Any other items, which are not listed but are required to make the package complete in
all respects as per this specification.
Electrical System
12 3.3kV flexible cable between purchaser HT board and bidder stacker cum reclaimer
through HT fuse box
13
1.1kV cable between purchasers PMCC and 415V bidders PMCCs
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TCE FORM 329 R3
563-001B
LIMITED SECTION: C1
SHEET 2 of 4
AT BARA,UP
14 415MCCs and ACDBs
15 HT and LT Motors for all rotating mechanical equipment and drive with coupling for all
equipment wherever required
Flame proof /outdoor weather proof/indoor local push button stations with de-interlock
16
switches
17 Conveyer illumination
18 Control cables, Instrumentation cables and any Special cables.
Complete installation accessories for cables, lighting, earthing, lightning protection

19
system including all structures, supports, cable trenches, cable trays, conduits, MBs,
JBs, TBs, hardware, consumables, etc.
20 Earthing & Lightning protection system

All mounting and foundation accessories and hardware for all electrical equipment.
21
Also all civil works associated with electrical installation like cable trench, embedments,
chipping, punching, making holes, openings, pipe sleeves, sealing and water proofing,
etc.
22 Fire proof sealing system material such as fire stops and fire breaks
3 Phase, 4 wire interlocked type 63 Amps, 415V, Power receptacles for maintenance
23
equipment such as portable grinders and welding sets.
Any other electrical equipment which are not specifically listed above but are required
24
to make the coal handling system complete in all respects as per this specification.
For all the inputs required by the CHP Bidder from other packages, the required
25
auxiliary relays and control cables, laying and termination shall be in the scope of this
Bidder.
Purchaser will provide two number of feeders of 415V , 3 phase , 4 wire, 50 Hz supply
26
for construction at one point. Further distribution shall be by Bidder.
Control & instrumentation including PLC panel system.
27
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TCE FORM 329 R3
563-001B
LIMITED SECTION: C1
SHEET 3 of 4
AT BARA,UP

1.2 It is not the intent to specify completely herein all details of design of the equipment
and civil design / structures works covered under this specification. However, all
equipment and works shall conform in all respects to high standards of design
engineering, materials of construction, workmanship and be capable of performing in
continuous commercial operation up to the Bidder’s guarantees in a manner
acceptable to the PURCHASER.
1.3 The extent of supply and works under this specification includes all items indicated in
the specification document, notwithstanding the fact that such items may have been
omitted from the drawings or schedules. Similarly, the extent of supply also includes all
items mentioned in the drawings notwithstanding the fact that such items may have
been omitted in the specification documents and / or schedules.
1.4 All services including specialised services necessary for proper erection,
commissioning and performance testing of all items of the plant covered under this
Specification shall be arranged by the Bidder.
1.5 All necessary co-ordination with regard to sub-contracted equipment shall be carried
out by the Bidder. The PURCHASER will communicate only with the Bidder for all
matters pertaining to this Specification.
1.6 All equipment shall be new and of reputed make. The makes of all bought out
equipment shall be subject to approval by the PURCHASER after the award of
Contract. In addition to the main equipment i.e., such as stacker reclaimers, belt
conveyors, feeders, etc. other important auxiliaries systems such as dust suppression
systems,stockpile run-off water disposal system, all I & C systems, electrical systems
and equipment such as, batteries, battery chargers, static inverters, design of civil and
structural works, etc. shall be carried out and shall be of field proven quality.
1.7 All plant, equipment, systems and works covered under these specification documents
shall comply with the latest editions including amendments there of to applicable
codes, standards, statutes, regulations and safety rules. Particular care shall be
exercised in observing compliance to the rules and regulations governing the locality
where the plant is to be installed. Bidder’s obligations in this regard shall not be limited
to only those codes and standards mentioned in these specification documents.
Nothing in these specification documents shall be construed to relieve the Bidder of his
responsibility.
1.8 In the event of any conflict between the applicable codes and standards and the
requirements of these specification documents, the more stringent of the two as per the
PURCHASER’s interpretation shall govern.
1.9 The Bidder shall make available one copy each to the CONSULTANT and the
PURCHASER of all international codes, standards, rules and regulations that are
published outside India and used by him in the design, engineering and execution of
the Stacker reclaimer works. The copies furnished shall be certified English version in
case the original of the standard or codes is in other language.
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TCE FORM 329 R3
563-001B
LIMITED SECTION: C1
SHEET 4 of 4
AT BARA,UP

1.10 In the event, the Bidder wants to deviate from any material standard specified herein or
offered by him at the bid stage and accepted by the CONSULTANT or PURCHASER,
he shall demonstrate the equivalent or superiority of the new material proposed to the
one specified or offered and accepted, to the satisfaction and approval of the
PURCHASER and CONSULTANT before proceeding further.
1.11 The Bidder shall maintain copies of all international, national, state and local codes,
standards, rules and regulations used by him in the execution of the project in his
design offices and manufacturing shops. Copies of those codes and standards that are
relevant to the performance of civil works, equipment erection, commissioning and
testing shall also be available at the Bidder’s site office.
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TCE FORM 329 R3
SECTION C 2
SYSTEM DESCRIPTION
TCE-5871A- H-563- PRAYAGRAJ POWER GENERATION COMPANY
001B
LIMITED SECTION: C2
SHEET 1 of 5
AT BARA,UP
SYSTEM DESCRIPTION
SYSTEM DESCRIPTION (REFER DRAWINGS No. TCE. 5871A-563-GA-1001 and

TCE.5871A-563-FD-001
A brief description of the complete Coal Handling System is furnished below. This
description has to be read, in conjunction with the coal handling system flow
diagram drawing No. TCE. 5871A-563-FD-002 and coal handling system plan
drawing No. TCE.5871A-563-GA-1001 and sectional drawings enclosed with this
specification document.
The coal handling system for the 3 X 660 MW comprises the unloading, conveying,
crushing, stacking, reclaiming and bunker feeding systems.
1.0 SUPPLY OF COAL
(-) 250mm size Coal will be received through rakes containing BOXN and / or
BOBR wagons and imported coal through trucks. The BOBR rakes will be unloaded
into the track hopper by engine-on-load scheme. The BOXN rakes will be shunted
upto the wagon tipplers through station locos. The BOXN wagons will then be
hauled and positioned on the wagon tippler table(s) one after another for tippling
onto the down stream conveyors. Imported coal trucks will be unloaded into truck
unloading hoppers with the help of truck tippler
2.0 NUMBER OF PATHS AND STREAMS
2.1 PATHS OF COAL HANDLING SYSTEM
BOBR wagons containing (-) 250 mm size coal will be unloaded into the track
hopper for further conveying by series of conveyors. BOXN wagons containing (-)
250mm size coal will be unloaded through the proposed wagon tippler(s) onto the
forward belt conveyors. Coal from the track hopper and / or wagon tippler(s) will
either be conveyed to the bunkers directly after crushing or will be stacked first after
crushing and then reclaimed for feeding to the bunkers of the three (3) Units. In
emergencies, coal will be stacked in a coal stockyard and will be reclaimed from
there when ever required. Based on these, the coal handling system is divided into
paths described under points No. 2.1.1 to 2.1.3. In all the cases, the coal will be
screened and crushed (except when feeding the bunkers from the crushed coal
stockpiles) before feeding to the bunkers.
Following paths will be provided in the proposed coal handling system. these are:
2.1.1 From wagon unloading to the bunkers of the three Units directly.
2.1.2 From wagon unloading to crushed coal stock yard.

2.1.3 From crushed coal stockyard to the bunkers of the three Units.
2.1.4 During emergency, both the streams of conveyors will operate either from wagon
unloading area to bunkers or from stock yard to the bunkers.
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TCE FORM 329 R3

001B
LIMITED SECTION: C2
SHEET 2 of 5
AT BARA,UP
SYSTEM DESCRIPTION
Based on the above, the system description is as furnished in para 3.0 below..
2.2 NUMBER OF STREAMS OF EQUIPMENT
There will be two (2) streams (1W+1S) of conveyors after Track hopper and wagon
tipplers upto the coal bunkers. Below each wagon tippler, for coal stockyard and
above each bunker bay, single stream of conveyors is provided. Whereas below
track hopper, two(2) streams (1W+1S) of conveyors are provided.
3.0 PATH WISE SYSTEM DESCRIPTION
3.1 TRACKHOPPER / WAGON TIPPLERS –> CRUSHER HOUSE -> COAL BUNKERS
(-) 250mm coal received by BOBR wagons would be unloaded into the track hopper
using line side equipment. Plough feeders provided below track hopper will extract
the coal and feed to the respective belt conveyors CON -3A/3B. In case coal is
received by BOXN wagons, same would be unloaded into the wagon tippler
hoppers using wagon tipplers WT-1 & WT-2. Apron feeders provided below wagon
tippler hoppers of WT-1 & WT-2 would convey coal to the Belt conveyors BCN-1 &
BCN-2 respectively. Coal received either by trackhopper or by wagon tipplers
would be conveyed to common belt conveyor CON-4A/4B. Further coal will be
conveyed to crusher house for crushing and screening. Coal from the crusher
house would be conveyed to coal bunkers by a series of belt conveyors, and
travelling trippers.
3.2 TRACKHOPPER / WAGON TIPPLER --–> CRUSHER HOUSE ---> COAL

STOCKYARD
Coal received by BOBR / BOXN wagons would be conveyed to crusher house as

explained above. When coal is not required to be fed to the boiler bunkers, coal
from the crusher house will be fed to the either of two (2) stock yard conveyors.
Coal would be stacked on either side of the yard conveyor through the boom
conveyor of the Reversible stacker-cum-reclaimer
3.3 COAL STOCKYARD --> COAL BUNKERS
When the coal rakes are not available and coal is required to be fed to the
boiler bunkers, coal would be reclaimed from either of the two the stockyards using
the bucket wheel reclaimer and fed to the bunkers through series of conveyors and
traveling trippers.
3.4 INTERCONNECTION BETWEEN CHP OF PHASE-1 AND CHP OF PHASE-2

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TCE FORM 329 R3

001B
LIMITED SECTION: C2
SHEET 3 of 5
AT BARA,UP
SYSTEM DESCRIPTION
Two(2) Nos. stacker reclaimer shall be provided for phase –1 Units. Space
provided for additional RSTR for Phase-2 would be sufficient to install only one(1)
No. RSTR. Hence Phase-2 has to operate with one(1) No. RSTR and no standby
would be available. In view of this, with the addition of one more RSTR for Phase-
2, out of total three(3) Nos RSTR, One(1) No RSTR would be working for each
phase with one(1) No. RSTR as common standby for both the Phases 1&2.
Incase RSTR of Phase-2 is out of order, Common RSTR for both phases1&2
would feed coal to Phase-2 units. System capacity of Phase-2 units would be
maintained same as that of Phase-1 units. Provision would be given in the
Junction tower of common RSTR to feed coal to Phase-2 units as shown in the
flow diagram.
4.0 DUST SUPPRESSION SYSTEM (DS SYSTEM)
Following type of dust suppression systems will be provided in different areas as

described below. For detailed description, please refer Sec.D1.6.
4.1 Plain water spray system for waiting wagons.
4.2 Chemical spray type dust suppression system for wagon tipplers and track hopper.
4.3 Only dust extraction system shall be provided in crusher house and Junction tower
JNT-1, JNT-1A, 1B, 1C, 1D, 1E & 1F. Whereas for all other junction towers and
transfer houses, Dry fog type dust suppression system shall be provided.
4.4 Plain water sprinkler type dust suppression system at coal stock yards.
4.5 Plant Cleaning System using service water
4.6 Compressed air supply system for DS and service air applications.
5.0 VENTILATION SYSTEM
Ventilation system shall be provided to keep the underground portions of wagon

tipplers, trackhopper and tunnel portion of conveyors ventilated.. Details of the
system shall be as per Vol.IIB, Sec.D1.5.2
6.0 BUNKER VENTILATION SYSTEM.
Bunker ventilation system for ventilating the coal bunkers to evacuate the generated
volatile gases will be provided. The bunkers shall be ventilated using suction fans.
The dust laden air let out to atmosphere will be passed through bag filters to meet
the emission standards. Details of the system shall be as per Vol.IIB, Sec.D1.5
7.0 TRAMP IRON SEPARATION

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TCE FORM 329 R3

001B
LIMITED SECTION: C2
SHEET 4 of 5
AT BARA,UP
SYSTEM DESCRIPTION
Tramp iron will be separated by inline magnetic separators at locations shown in the
flow diagram. The tramp iron picked up by the inline magnetic separators will be
discharged outside the structure / building such as junction tower / transfer house /
crusher house where the inline magnetic separators are located through tramp iron
chutes.
8.0 INLINE CONVEYOR SCALES
Inline conveyor scales will be provided on conveyors shown in the flow diagram to
continuously measure the rate of conveying on these conveyors.
9.0 STOCK PILE RUN OFF WATER DISPOSAL SYSTEM
Stockpile run-off water disposal system shall be provided to receive the coal pile run
off water and lead the same to a common header drain leading to a common
collecting pond.
10.0 FIRE PROTECTION SYSTEM
The following types of Fire protection system are envisaged to be provided for the
Coal handling system package,
a) Hydrant system for the entire coal handling system area

b) Medium Velocity Water Spray (MVWS) system for inclined conveyors.
The fire protection system shall be provided by others. However necessary

provisions in the coal handling system structures shall be provided/made which
shall be finalised after the award of contract.
11.0 CAPACITY OF COAL HANDLING SYSTEM
The capacity of the coal handling system will be as follows:
11.1 The rated system capacity will be 2600 TPH.
11.2 The stacking and peak reclaiming rated capacity of each RSTR will be 2600 TPH.
The average reclaiming capacity of each RSTR shall be 2000 TPH.
12.0 DUTY OF COAL HANDLING SYSTEM AND STACKER RECLAIMER MACHINES
12.1 Normally only one stream of equipment shall operate effectively for about 14 hours
in two(2) shifts in a day to fill up the coal bunkers to meet the coal requirements of
the 3 X660 MW Units. However during direct feeding and also at other times if it
becomes necessary, it shall be possible to operate both the streams for any length
of time. Also, it shall be possible to operate the entire coal handling system for 24
hours in a day continuously for any period. All structures for the coal handling shall
be designed for two(2) streams running operation.
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TCE FORM 329 R3

SECTION C 3
SCOPE OF WORKS
001B
LIMITED SECTION: C3
SHEET 1 of 17
AT BARA,UP
SCOPE OF WORKS
1.0 BROAD SCOPE
a) The scope of the Bidder shall comprise design, engineering, material selection,
manufacturing, testing at works, supply to site, construction, installation,
commissioning, performance testing at site, and other related items of work for
Stacker reclaimer machines along with reversible yard conveyors of the Coal
handling plant ( CHP). Bidder shall supply all required mechanical, electrical, I&C
equipment / system required for operation of stacking and reclaiming system
necessary for putting into commercial operation a highly reliable, safe, efficient and
environmentally compliant stacking and reclaiming system for 3 X 660 MW Thermal
power plant. The systems and equipment shall conform to the technical
requirements specified in separate sections of the specification. Mandatory spares
for the equipment supplied shall also be included in bidder’s scope.
b) Supply of rails, rail clamps, foundation bolts, fixing and aligning of the same shall be
in the scope of Bidder
c) Design of civil & foundation works for Stacker reclaimer machines, stockpile paving
shall be by the bidder. These designs and drawings shall be reviewed and approved
by TCE. Execution of these civil and foundation works shall be by PPGCL.
d) Design, supply, erection & commissioning of reversible Yard Conveyors working in

conjunction with Stacker Reclaimer machines, performance test, complete with all
conveyor accessories, short supports, stringers for trouble free operation of the
system shall be in bidder’s scope.
e) Design of Civil, structural and foundation works for yard conveyors, galleries,
trestles, drive houses, takeup towers shall be in the scope of bidder. Detailed
fabrication drawings shall be furnished by the bidder. Review of Civil, structural and
foundation design drawings shall be by TCE and review of fabrication drawings
shall carried out by PPGCL scope. Execution of cited Civil, structural and
foundation works shall be by PPGCL.
f) Design, supply, erection, testing and commissioning of Plain water type dust
suppression system for stockpiles consisting of pumps, piping, valves, sprinklers
and other necessary accessories with all related mechanical, electrical, I&C
equipment / system shall be in the scope of bidder. Required civil and foundation
designs and drawings shall be in the scope of bidder and review of these designs
and drawing is in TCE scope. Execution of civil and foundation works shall be in the
scope of PPGCL
g) Design of Coal pile run-off system consisting of peripheral drains around all the
stockpiles and leading of same to the coal-pile runoff pit including design of coal pile
runoff pit and coal pile bed preparation shall be in the scope of bidder. Review of
these designs and drawings shall be by TCE and execution of the works will be by
PPGCL. However supply and installation of sluice gates required for coal pile run-
off system shall be included in the scope of bidder. ISSUE
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TCE FORM 329 R3

001B
LIMITED SECTION: C3
SHEET 2 of 17
AT BARA,UP
SCOPE OF WORKS
h) Complete Foundation bolts and insert plates along with lugs wherever required shall
be supplied by the bidder during execution of civil works by PPGCL.
i) Height of conveyor trestle RCC pedestals shall be maintained as 2M from the
graded level.
j) Supervision of execution of complete civil and structural works including
foundations, fabrication and erection of structural works pertaining to this package
shall be in the scope of bidder.
k) Civil works such as grouting requirement and chipping works shall be in the scope
of respective package bidders.
The Bidder shall perform all the works specified or necessary to complete the works
in accordance with this specification. Further, the Bidder’s performance of the works
under the specification shall be in accordance with good engineering and
construction practices, not withstanding the fact that every item involved may not be
specifically mentioned or the item mentioned may be inadequate for its intended
purpose. Details and items, which are not specifically mentioned herein shall also
be adequately and properly performed by the Bidder at no extra cost if such details
and / or items are reasonably necessary to complete the intent of this specification
document.
1.1 MECHANICAL WORKS (Details as Per Section–D1, VOL-IIB)
The Stacker reclaimer works to be supplied under this package shall include but not
be limited to the following equipment/items, works and facilities to make the system
complete in all respects:
Equipment to be supplied as listed hereunder shall conform to specification

requirements listed in Volume IIA, Volume IIB (with all the sub sections), the
relevant data sheets in Volume IIB and the flow diagrams / general arrangement
drawings. All equipment shall be supplied with necessary auxiliaries and
accessories as per the system requirement envisaged in this specification and shall
be complete with necessary drive equipment.
Sl. No. Equipment Quantity / Requirement
1.1.1 Stacking, reclaiming,
Stacking and reclaiming system Two(2) Nos (1W+1S) Stacker cum

(a) equipment reclaimer with reversible trunk conveyor
Nos. BCN-7A & BCN-7B with Electric
drives and technological supports, in-line
conveyor scales, etc. as per flow diagram
No. TCE.5871A-563-FD-001. Each yard
conveyor shall be provided with 2X100 % ISSUE
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drives i.e. one(1) No. at tail end and one(1)
No. at head end.
(b) Storm anchors Two(2) Nos per stacker reclaimer located
at extreme travel points of machine
between drive house and junction tower.
(c) Coal pile run-off system Two(2) Nos. Sluice gates required for coal
pile run off system
1.1.2 Auxiliary Systems & Equipment.
(a) At stockpiles. Plain water spray system with one (1) lot
automatic plain water system with
sprinklers around each of the four (4)
crushed coal stockpiles comprising, piping,
valves, sprinkler nozzles, etc. as per
Volume IIB Sec.D1.3
(b) Service water at drive houses Service water required at drive houses
DH-1 & DH-2 consisting of piping, valves,
fittings…etc shall be in the scope of the
bidder. Same shall be as per Sec.D1.3 of
this specification.
1.2 General
1.2.1 Instruction manuals for One (1) lot

erection, testing,
commissioning, start up and
maintenance
1.2.2 First fill of lubricants for start One (1) lot

up, trial runs and
commissioning of the
equipment up to successful
completion of trial run of
stacking and reclaiming system
1.2.3 Grease filling for all idlers and One (1) lot
rollers
1.2.4 Base plates, shear lugs, One (1) lot

anchor bolts, nuts, washers,
stiffeners, anchors, channels,
pipe sleeves, embedments in
foundations for structural and
electrical works and machinery
1.2.5 Preparation of all design As per section C4

calculations, general
arrangement drawings, ISSUE
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equipment drawings and
submission of same for
Purchaser / Engineer’s
approval / records as per
distribution schedule.
1.2.6 Attending meetings at As required.

purchaser’s office and in
Consultant’s office.
1.2.7 Any spares required during By Bidder at no extra cost to Purchaser

commissioning and start up of
all mechanical, electrical and I
and C equipment up to and
including PG test.
1.2.8 Mandatory Spares and special As per Section C15

tools and tackles for all
mechanical, electrical and I
and C equipment
1.2.9 Painting As per section C7
2.2 ELECTRICAL WORKS (Details as per Sec-D3 Volume-IVA - Electrical)
2.3 CONTROL & INSTRUMENTATION SYSTEM

Details as per Section–D4 of Volume–IVB)
2.4 CIVIL / STRUCTURAL AND ARCHITECTURAL WORKS

(Details as Per Section–D2 of Volume-III)
2.5 PROJECT MANAGEMENT / SERVICES
2.5.1 The Bidder shall identify a separate and independent project management team
headed by a Project Manager for the execution of this project.
The Bidder shall provide effective management of the Contract, which will be
compatible with the PURCHASER’s requirements as set out in this specification
document. The Bidder will allow access to his works and those of his sub-
Contractors at all reasonable times to permit the PURCHASER / CONSULTANT’s
participation, if the PURCHASER / CONSULTANT considers it necessary in
monitoring the Contract. The Project Manager will also work with other Bidders
who interface with this Specification in order to ensure the smooth completion of
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the project. Such participation up to its completion will not, in any way affect the
Bidder’s obligations to complete the works in accordance with the Specification.
2.5.2 Management Organisation
2.5.2.1 The Bidder shall describe how his management organisation will meet the
requirements detailed herein. He shall include an organisation chart illustrating
how the management structure / lines of authority will function during the
Contract.
2.5.2.2 The Bidder shall submit the names, qualifications and experience of the proposed
managerial and senior supervisory staff to be employed on the Contract. The
Bidder shall indicate the number of staff, rating and seniority to be employed to
manage and supervise the Contract and list separately for ‘head office’ and ‘site
office’ based locations. In particular how staff are planned to be deployed with
respect to the Contract period time scale will be stated.
2.5.2.3 The Bidder shall inform the PURCHASER any proposed changes in the Senior
Staff category.
2.5.2.4 The PURCHASER reserves the right to evaluate and audit the Bidder’s
management systems and controls in the areas set forth in this section.
2.5.2.5 The Bidder shall utilise the services of specialists as needed in consultation with
PURCHASER/CONSULTANT before taking up of testing, pre-commissioning
checks, commissioning and tying/cascading /connecting with other system etc.
Bidder will have a separate planning and progress monitoring experts.
2.5.3 Engineering Services
2.5.3.1 The Bidder shall render complete engineering services for the project including
complete detailed engineering, design submission and documentation as
specified and as required for a good design and installation ensuring efficiency,
operability, availability, maintainability and reliability of the plant. Prior to
commencement of the engineering work all aspects of design, viz., criteria for
selection and sizing of all equipment and systems, design margins, analysis and
design calculations, etc. shall be stated by the Bidder in design basis reports. As
part of design submissions, the design basis reports shall be submitted by the
Bidder for approval by the PURCHASER / CONSULTANT. The approved design
basis reports shall form the basis for the detailed engineering work.
2.5.3.2 At any stage during the performance of the Contract, if the system warrants
improvements in the Contracted plant and consequent modification in the
equipment / system designs the Bidder shall make the necessary design
modifications and carry out the / improvements in the plant at no extra cost to
the PURCHASER.
2.5.3.3 During the course of review of detailed engineering, it may be essential in

PURCHASER’s opinion to obtain data and information on similar equipment and
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plants engineered by the Bidder. In case, PURCHASER so desires the Bidder
shall submit such analogous data and information to the PURCHASER.
2.5.3.4 The Bidder shall cooperate with the PURCHASER’s other Bidders and the
CONSULTANT and freely exchange with them such technical information as are
necessary to obtain the most efficient and economical design and to avoid
unnecessary duplication of efforts. The PURCHASER will be provided with
copies of all correspondences addressed by the Bidder to other Bidders and the
CONSULTANT in respect of such exchange of technical information.
2.5.3.5 The Bidder shall furnish a comprehensive and detailed schedule of drawings
and design documents, which shall be submitted by him after award of Contract
indicating submission dates against each document. The list will be subject to
the approval of the PURCHASER / CONSULTANT.
The documents will be divided into two categories:
(a) For approval

(b) For information / reference only
2.5.3.6 Documents submitted during bid stage will be revalidated or revised as required
and submitted as certified document for approval / information of the
PURCHASER, after award of contract. These will be
(a) System schematic drawings, General arrangement drawing, pipeline

and instrumentation diagrams
(b) Design basis reports
(c) Contract document for major bought-out items
(d) Equipment data sheets and general arrangement drawings
(e) Materials for construction
(f) Layout drawings
(g) Operation logic diagrams
(h) Typical control circuits
(i) Protection schemes
(j) Civil & Structural drawings
2.5.4 Operating Manuals and Maintenance Instructions
2.5.4.1 The Bidder shall submit to the PURCHASER / CONSULTANT, instruction

manuals for all equipment covered under the contract at least thirty (30) days
before the first shipment of the respective equipment.
2.5.4.2 The operating manuals and maintenance instructions shall be in sufficient detail
to enable the PURCHASER to operate, maintain, dismantle, re-assemble, adjust
or replace all equipment and components during the lifetime of the Coal
handling system. The manuals will be specifically prepared for the contracted
plant. Mere collection of manufacturer’s standard leaflets will not be acceptable
as manuals. However these can be enclosed along with O & M manual. ISSUE
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2.5.4.3 In addition, the Bidder shall provide at least six (6) months before provisional
taking over of the first stream of the Coal handling system, a consolidated
manual for the complete Coal handling system detailing out instructions for
operation and maintenance.
2.5.4.4 The operating manuals and maintenance instructions manual shall be submitted
in the form of one (1) original and twenty (20) copies as well as four (4) copies in
compact disks (CDs). One (1) hard copy and one (1) copy in CD will be
furnished to CONSULTANT. The instruction manuals shall be subject to
approval of the PURCHASER and CONSULTANT.
2.5.4.5 If after the commissioning and the initial operation of the Coal handling system,
the instruction manuals require modifications / additions, the same shall be
incorporated by the Bidder and the updated final version of the manuals shall be
submitted to the PURCHASER.
2.5.4.6 The Bidder shall submit fifteen (15) sets of spare parts catalogues.
2.5.5 Stacker reclaimer works As-Built Documentation
(a) “As-built” Documentation
The Bidder shall provide and keep up to date “As built drawings of all structures
constructed and all equipment and accessories and miscellaneous metal works
erected or installed. These drawings shall show all changes and revisions from
the original drawings and contract documents, including the exact “As-built”
locations, sizes and kind of equipment and accessories, miscellaneous metal
works, embedded piping and electrical systems and other concealed items of
work. These drawings shall be kept in Bidder’s field office but shall be made
available at all times for review of the CONSULTANT. At the end of every work,
all entries, changes or revisions made in the drawings by the Bidder shall be
checked and reviewed by the CONSULTANT. One original with fifteen (15)
copies of all “As-Built” drawings shall be progressively handed over to the
PURCHASER before final takeover of the first stream. In addition, all the as-built
drawings / documents shall be submitted to the PURCHASER in the form of
CDs.
2.5.6 Sub-Contractors
2.5.6.1 The Bidder shall submit to the PURCHASER a list of all major items/works
along with sub vender list for approval that he deems necessary to be sub-
contracted.
The Bidder’s orders to the Sub-Contractors will quote the PURCHASER’s

contract reference and station name, and instruct the sub-Contractors to quote
that number and name and also the order number in all correspondences. ISSUE
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The Bidder shall be responsible for maintaining an up-to-date list of all sub-
orders and interwork orders and will make this available to the PURCHASER as
required.
The PURCHASER’s contract reference and station name shall be added to all
interworks and sub-orders.
2.5.7 Progress Reports
2.5.7.1 During the design, engineering and manufacturing, supply, erection, testing and
commissioning stages the Bidder shall submit to the CONSULTANT reports and
information on the progress of works by him and by the Sub-Contractors of all
plant and materials required for the execution of the works. The progress of
work shall be linked to the Project Schedule.
2.5.7.2 The detailed procedure and requirements for progress reporting shall be agreed
with the PURCHASER during the early phase of the works, as part of regular
contract / project status reporting.
2.5.7.3 The Bidder shall also submit to the PURCHASER monthly progress reports and
any other reports as required by PURCHASER / Lenders / Statutory authorities.
2.5.8 Access for Progress Monitoring
The PURCHASER or his nominated representatives shall be entitled at all

reasonable times to visit all premises where design and manufacturing of the
plant is being carried out in order to monitor and verify progress with intimation
to the BIDDER.
2.6 MISCELLANEOUS
i. Design and engineering
ii. Consents, licenses and approvals from relevant statutory authorities other than
those obtained by the PURCHASER.
iii. Packing & forwarding, transportation (ocean and inland), marine insurance or local
transit insurance custom/port clearance, reconciliation with custom authorities,
receiving and unloading at site.
iv. Unloading of materials inside project area / air port / seaport, transportation to site
store, assessment of lost / damaged items in transit and arranging insurance claims
and replacement of lost / damaged items in transit.
v. Proper storage and preservation of mandatory spares, tools and tackles in BIDDER
storage area and handing over the same to the PURCHASER at PURCHASER’s
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stores. The spares and tools shall be handed over to the PURCHASER at the time
of commissioning of the first stream.
vi. Transportation of materials to their respective places of erection and erection of the
complete plant & equipment as supplied under this specification document
vii. Trial run and commissioning of individual equipment / sub-systems and the Coal
handling system as a whole to the satisfaction of the PURCHASER.
viii. Provision for preservation of individual equipment after trial run and commissioning
(e.g. Nitrogen blanketing) as necessary
ix. Supply and application of the paints on all the equipment to be erected under this
Specification.
x. Deployment of all skilled and unskilled manpower required for erection, supervision
of erection, watch and ward, commissioning and other services to be rendered
under this specification document
xi. Deployment of all erection tools & tackles, construction machinery, transportation
vehicles and all other implements in adequate number, capacity and size
xii. Supply of all consumables, e.g., welding electrodes, filler wires, gas cylinders
(hydrogen, carbon-di-oxide, nitrogen, oxygen, acetylene), cleaning agents,
lubricants as well as materials required for temporary supports, scaffolding, etc. as
necessary
xiii. Supply of all necessary calibrated instruments for carrying out performance tests of
Coal handling system and equipment.
xiv. Taking approval of all statutory authorities by paying the requisite fee as applicable
e.g., Factory Inspector, Electrical Inspectorate, etc. for respective portions of work
under the jurisdiction of such statutes or laws
xv. Quality assurance of all work executed at site
xvi. Co-ordination and project management.
xvii. Complete construction (including supply of material and labour, construction of site
office, canteen, construction stores, residential accommodation of Bidder’s staff
labour, etc.), fabrication, erection, trial run, commissioning and performance testing
of entire Syacking and reclaiming system.
xviii. Supply of lubricants/consumables and all temporary provisions till Provisional Take
over.
xix. Mandatory Spare parts, as specified, for the Coal handling system package.
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xx. Tools and tackles including all special tools and tackle, as required, for the Coal
handling system package.
xxi. Furnishing all documents, engineering & construction drawings, design basis
reports, optimisation study reports if any, design calculations, equipment data
sheets from manufacturers, quality assurance plans, testing procedures, operation
and maintenance manuals, commissioning procedures, ‘As built” drawings, etc.
xxii. Conducting shop and site tests as required
xxiii. Conducting performance tests for the entire package and for the individual
equipments as required.
xxiv. Conducting of various site acceptance tests on electrical, instrumentation and
control systems field instruments etc.
xxv. Supply of all consumables like Cable termination / joining kits, insulating materials,
cable glands, Lugs, Junction boxes, suitable sizes of cable boxes and insulating
paints.
xxvi. Furnishing of Civil, Mechanical, electrical and instrumentation coordination drawings
indicating the details like providing of cut outs, Insert plates, Embedment of
foundation bolts and providing of sleeves etc.
xxvii. Supply of all consumables like printer paper, Tonner, Ink cartridges (colour, mono),
floppies, CD R/W.
xxviii. Training of the PURCHASER’s personnel on Coal Handling System operation and
maintenance. This will include all hydraulic drives and hydraulic motors. The training
will be provided at the Bidder’s / sub-Contractor’s works for the number of man
months indicated in the schedule of training.
xxix. Diversion of roads as required

xxx. All other facilities/services as described in the section on 'Site Services'
NOTE:
The above list of work is not exhaustive. Any additional works, whether or not specifically
described in this document and incidental to complete the stacker reclaimer works in all
respects will be deemed to be in the scope of work of the stacker reclaimer works package
Bidder.
2.7 TERMINAL POINTS
1.1 Site Development : Site development works like micro grading within
the stacking and reclaiming system boundary
limits shall be in the scope of Bidder.
1.2 Roads All roads connecting the Stacker reclaimer works ISSUE
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facilities with the main roads shall be in the scope
of bidder.
1.3 Dust Suppression : Water will be supplied upto the top of the water
System water and tank located along side of the Coal handling
service water for plant system switchgear cum control cum compressor
cleaning room cum pump house. Water requirement for
SYDS shall be furnished by the bidder. Design
and construction of tank is excluded from bidder’s
scope. From this point onwards, the entire system
comprising the entire piping network, valves,
fittings, DS water supply pumps, etc. shall be in
bidder scope.
1.4 Terminal points in In Junction towers JNT-4 & JNT-5, For

JNT-4 & JNT-5 Reversible yard conveyors of stacker reclaimers,
Head pulleys along with supporting frame for
drive components such as gear box, motor,
couplings, foundation bolts and hood shall be
supplied and erected by the bidder. During
stacking mode, skirt board feeding to yard
conveyor shall be in the scope of bidder and
chute feeding to this skirt board shall be in
other’s scope.. Similarly during reclaiming mode,
Chute taking feed from the yard conveyor shall
be in the scope of bidder and Skirt board below
this chute shall be in the scope of others.
1.5 ELECTRICAL
1.5.1 PMMC Purchaser will provide two number of 3.3kv

feeders for stacker cum reclaimer. Termination of
the same at purchaser’s panel and further
distribution of Power supply is Bidder’s scope
.Purchaser will provide two (2) numbers of
feeders in PMCC. Termination of the same at
Bidder’s panel and further distribution of Power
supply at all other voltages is included in Bidder’s
scope.
1.5.2 Earthing Purchaser’s main earth grid will be available near

CHP area. Bidder shall interconnect the earthing
and lighting protection system of coal handling ISSUE
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plant with the plant grid at minimum two places
1.5.3 Construction Power : At one (1) single point two numbers of feeders at
415V level. Further distribution is by the Bidder.
2.0 I&C
2.1 Instrumentation and Control Cables
a) All I&C cables between any two points where both ends equipments
are in bidder’s scope of supply, shall be in the scope of the bidder.
b) For equipments which are to controlled and monitored from

Purchaser’s CHP PLC in CHP control room, bidder shall terminate
required I&C cables at bidder’s Junction box ( JB shall be located
inside JNT-4 / JNT-5).
c) Supply HT switchgear is in the scope of purchaser. Hence any I&C

cables required between switchgear and CHP PLC and between
switchgear and bidder’s supplied system shall be in the scope of
Purchaser.
1) At all terminal points, whether at equipment or on pipelines, it is the Package-B

Bidder’s responsibility to supply all the necessary jointing materials and make the
final connection at the terminal point.
2) BIDDER shall note that if there are minor changes in the coordinates of the
terminal points and elevations of the piping indicated above during detailed
engineering same shall be accepted without any commercial implication by him.
2.8 SCOPE MATRIX

2.8.1 SCOPE MATRIX – CHP – CIVIL
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Contractor TCE PPGCL

Execution of
Review of Civil &
Civil, structural,
Civil, foundation
Sl. foundation &
Scope / Description structural & works and
No. Fabrication
foundation Fabrication
designs &
designs & and erection of
drawings
drawings structural
works
1 9 9 9
Galleries and above ground
portals for yard conveyors with
supporting trestles.
2 Conveyor Gallery supporting 9 9 9
trestle foundations
3 Drive houses DH-1 & DH-2 super 9 9 9
structures
4 Drive houses DH-1 & DH-2 9 9 9
Foundations
5 Coal stock yard pavement, 9 9 9
Stacker cum reclaimer including
drainage
6 Stacker cum reclaimer foundations 9 9 9
7 Coal pile runoff pit 9 9 9
8 Plant roads connected stacker 9 9 9
reclaimer works
2.8.2 SCOPE MATRIX – PACKAGE-B – I&C
Vendor Purchaser
Sl. No. Scope / Description Design Erection, Design Erection,

drawings, testing & drawings, testing &
Supply Supply
specificatio commissio specificatio commissio
n ning n ning
1. Field Instruments √ √ √ X X X
2. PLC system for each √ √ √ X X X

stacker cum
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Reclaimer
Instrumentation &
3. Control cables (within √ √ √ X X X
Bidder’s battery limits)
Instrumentation &
Control cables (from
bidder’s equipment to
bidder’s JB in JNT-
4. 4/JNT-5) for √ √ √ X X X
equipment to be
control and monitored
from Stacker cum
reclaimer
Any special cables,

prefabricated cables,
any other cables not
5. √ √ √ X X X
covered in this scope
matrix (within Bidder’s
battery limits)
Instrumentation &
Control cables
6. (between HT √ X X X √ √
switchgear and
bidder’s equipment)
2.8.3 SCOPE MATRIX – CHP – ELECTRICAL
Sl Scope / CHP Bidder Purchaser

No Description
Design,
Design,
Drawing
Erection, Drawings
s &
testing & & Review /
Specific Supply Supply
commissi Specificati Approval
ation
oning on
docume
document
nt
1. Switchgears (3.3 kV X X X √ √ √
& 415 V) for CHP
2. 415V MCC’s, √ √ √ X X √
,ACDB’s,
3. 1.1kV Cable
Power schedule √
Cable √ √ X √
Cable √ X
tray ISSUE
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No Description
Design,
Design,
Drawing
Erection, Drawings
s &
ation
oning on
docume
document
nt
layout
4. LT Cable
Power , schedule √
cables
and
Control Cable
cables tray
and any layout √ √ X X √
other
special √
cables
required
for CHP
system
5. Control Cable
cables schedul √
betwee e
n
Cable
Purcha
tray
ser √
layout √ √ X √
station X
within
switchh
battery
ear and
limit of
bidders
CHP
euipmq
nt
6. Earthing and
Lightning protection √ √ √ X X √
system
7. Conveyor lighting √ √ √ X X
√
system
8. Motors √ √ √ X X √
9. Local control panels √ √ √ X X √
(LCP) and Local ISSUE
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No Description
Design,
Design,
Drawing
Erection, Drawings
s &
ation
oning on
docume
document
nt
push button stations
(LPBS)
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2.9 EXCLUSIONS
• Pumps for pumping the coal slurry from coal pile run-off pit to clarifier, pumps
required for pumping of sludge from clarifier to stockpile and clear water pumps
from clarifier to guard pond including piping, valves is excluded from bidder’s scope.
• Fire protection, Fire Detection and Alarm System.
• Potable water system.
• Plant intercommunication and area illumination except conveyor illumination.
• Dozers, station locos.
• Green belt
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SECTION C 4
PROJECT SCHEDULE, PLANNING & MONITORING
TCE-5871A- H-563-
001B PRAYAGRAJ POWER GENERATION COMPANY
LIMITED SECTION: C4
3 X 660 MW PRAYAGRAJ SUPER THERMAL POWER PROJECT SHEET 1 of 8
AT BARA,UP
PROJECT SCHEDULE, PLANNING & MONITORING:
1.0 PROJECT SCHEDULES
1.1 Following Project Schedule dates are contemplated. The Bidder to review and
modify as required keeping the Trial operation end fixed:
SL. EVENT MONTH

NO.
A PURCHASER’S SCOPE Letter of Award (LOA)

1. Site access 0 ( Zero )
2 Construction Water availability 0 ( Zero )
3 Construction Power availability 0 ( Zero )

4 Power supply to equipment 18
B BIDDER’s SCOPE
1 Clearance of 100% of drawings /
12
documents
2 Completion of supply of all major
13.2
mechanical & electrical equipment.
3 Start of erection of equipment.
11
4 Initial run of stacking and reclaiming
system 18
5 Trial operation 19
6.0 Performance Guarantee (P.G) Tests
6.1 PG Test of stacking and reclaiming 20
system
Note:
1. All months indicated herein are end of month

2. Indicative L2 PERT showing all the major activities has been enclosed along with
this section. Bidder shall furnish L2 network schedule after award of contract for
approval of Purchaser / Consultant.
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1.2 PLANNING AND MONITORING
1.2.1 Planning
The Bidder shall prepare a L1 PERT Schedule in the form of PERT network
consisting of at least 50 activities. The network shall be prepared on a Work
Breakdown Structure. The Bidder shall use Microsoft Projects (MS Projects)
software for preparation of his Project Network Schedule.
The L1 PERT shall identify milestones of key events of each system in the areas
of engineering, order for raw materials, order on sub contractors, procurement,
manufacture and dispatch, erection and commissioning. The L1 PERT shall
represent the Level I plan and will form the basis for development of detailed
second and third tier execution plans.
The L1 PERT shall be submitted along with the bid and shall be mutually
discussed and finalized before the award of Contract. The L1 PERT will identify a
complete list of inputs to be furnished by the Purchaser/Engineer which may be
required for proper interfacing and tie up. Scheduled dates for providing such
inputs shall also be indicated and the same shall be mutually discussed and
finalized.
The Bidder shall not change the L1 PERT without the prior approval of the
Purchaser/Engineer in accordance with the Conditions of Contract. In the event
that the Purchaser/Engineer approves a revision to the L1 PERT in accordance
with the Conditions of Contract, the Bidder shall submit a revised L1 PERT within
two weeks thereafter. This programme will fully comply with the requirements of
the Specification document and where necessary, reflect changes to the
sequence or progress of the Works as indicated by the Purchaser/Engineer or as
proposed by the Bidder and accepted by the Purchaser/Engineer. Such an agreed
revised programme will become the Overall Bidder Programme for the
outstanding works.
1.3 Alteration of the Programme
No material alteration to the Programme shall be made without the approval of the
Purchaser/Engineer. However, Bidder may make alterations to the Programme
without the approval of the Purchaser/Engineer being required where such
alterations are consistent with the key milestone dates set out in the Project
Schedule and do not affect the payment schedule.
The Bidder shall submit the coding procedure being adopted for computerisation
along with the logic and the Work Breakdown Schedule with their respective
weightages used for generating the life cycle curves and shall submit the Work
Intensity Chart based on weightages conforming to their overall schedule.
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1.4 REVISION OF PROGRAMME
1.4.1 If the progress of the Scope of Supply or any other part of the Works does not
conform to the Programme, the Purchaser/Engineer may instruct the Bidder to
revise the programme.
1.4.2 If for any reason which does not entitle the Bidder to an extension of time the rate
of progress of the Scope of Supply or part thereof or any part of the work is at any
time in the reasonable opinion of the Purchaser/Engineer too slow to secure
completion of the works within the Time for Completion or any extended date the
Purchaser/Engineer may so notify the Bidder in writing and the Bidder shall
thereupon take such steps as are necessary and the Purchaser/Engineer may
approve an order to accelerate (whether by re-programming the order or
sequence of work or by increasing the personnel or other resources of the Bidder
or its sub-Bidders employed on the Scope of Supply) the progress of the Scope of
Supply or part thereof or any part of work so as to achieve completion of each
section within the time for Completion as may be extended. The Bidder shall not
be entitled to any additional payment or extension of time for taking such steps.
1.5 REPORTING AND CO-ORDINATION
1.5.1 During the performance of the Work, Bidder shall submit monthly updates
comparing the Work completed against the milestone schedule in tracking GANTT
or if Bidder’s performance is not in compliance therewith, more frequently as
requested by Purchaser/Engineer. If Bidder’s performance of the work is not in
compliance with the Milestone Schedule, without restricting any other rights or
remedies of Purchaser/Engineer hereunder, Bidder shall (i) submit its plan for
schedule recovery and (ii) specify in writing the steps to be taken to achieve
ongoing compliance with such revised schedule. Bidder shall submit the overall
life cycle curve for progress curve. The Bidder shall adopt a milestone approach
and shall identify several milestones to be achieved so that they could be verified
physically. Computation of progress of the Bidder shall use weighted value
concept and submit detailed computerised linked bar chart. Bidder shall submit
work breakdown structure in detail along with the weightage and the milestone to
be achieved every week preferably in a graphical / tabular format.
1.5.2 Bidder shall comply with the Milestone Schedule and to attend/participate in
progress, site co-ordination or special purpose meetings. Progress, site and co-
ordination meeting shall be held at the place as deemed fit and notified by the
Purchaser/Engineer then and there or the Site on a weekly basis, unless
otherwise requested by Purchaser/Engineer. Bidder shall have in attendance at
any such meeting the Project Manager and other management representatives
authorised to commit additional requirement of manpower / materials etc. to the
Work and shall for any progress meeting bring a forecast showing the last period’s
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progress versus the last period’s scheduled work plan and the work plan for the
next three weekly time periods. Unless otherwise stated in writing by
Purchaser/Engineer, the forecast shall describe the Work by task, by site location,
by area or building and by bay for a one month period. The commencement and
completion of each task to be performed shall be clearly designated. If requested
by Purchaser/Engineer, representatives of Bidders of major materials shall also
attend each such meeting. Purchaser/Engineer may on reasonable notice to
Bidder call a special purpose meeting whether at Bidder’s engineering office or
the site to review any portion of the Work, the performance of which is of
substantial concern to Purchaser/Engineer.
1.5.3 The Bidder shall use the latest version of project management software of
Microsoft Projects (MS PROJECTS) to generate and submit the schedules.
1.6 SCHEDULES
1.6.1 Project milestone schedule
The Project Milestone Schedule shall be a PERT Network Schedule containing

the Project milestones for activities pertaining to conceptual design, detailed
design, procurement packages, construction packages including erection, testing
and commissioning and Take-over.
The Project Milestone Schedule indicating current status shall be submitted with
the Bidder’s monthly progress reports.
1.6.2 Project summary schedule
The Project Summary Schedule shall be a Bar Chart Schedule containing

activities pertaining to conceptual design, detailed design, procurement packages
and construction packages including erection, commissioning, testing and take-
over at a summary level.
1.6.3 Overall contract schedule
1.6.3.1 The Overall Contract Schedule shall be a computerized, critical path method
(CPM) schedule containing sufficient detail to effectively control the Project. The
schedule shall be in Precedence Diagram Method (PDM) format.
1.6.3.2 The Overall Contract Schedule shall be a composite of all other specific
schedules. The Overall Contract Schedule shall be used for Project Activity
Coordinating, Project Monitoring, Project Reporting and Progress Payments.
1.6.3.3 The Overall Contract Schedule shall have distinct areas for engineering and
design, procurement and manufacture, installation and construction of facilities by
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area, erection of equipment, construction of process systems (mechanical, civil,

instrumentation and control, and electrical) and activities for testing, checkout,
start-up, performance testing, start-up training, operation and maintenance,
Civil/structural/Construction activities shall be carried out by PURCHASER.
1.6.3.4 The Overall Contract Schedule shall show expected and required start and
completion dates for each activity listed and it shall also include,
(a) Commencement and completion of submission of preliminary final

design data, contract documents, calculations including review time of
same
(b) Design and drawing submission of different categories of drawings -

commencement and completion including Purchaser / Engineer review
time as per Specification document. If the drawings/documents
furnished by the BIDDER contain substantial omissions and major
errors in the opinion of the Purchaser / Engineer same shall be treated
as non submission of the drawings and documents.
(c) Preliminary works
(d) Procurement of raw materials and bought out items
(e) Manufacturing process (indicating all major stages)
(f) Shop inspection / testing
(g) Shipment
(h) Detailed stages of construction and erection for each equipment /

structure / system
(i) Resources such as labour, equipment, etc. planned to be mobilised
(j) Commissioning, indicating all major systems
(k) Trial operation and performance testing, performance guarantee tests

and Take-over.
(l) Dates of Purchaser/Engineer various inputs as shown in the Schedule.
(m) Other key activities considered to be critical to the progress of the

Contract.
1.6.3.5 The planning, scheduling and monitoring including resource scheduling and
monitoring shall be carried out using MS Projects latest version project
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management software and Bidder shall submit the detailed network schedule in
electronic floppy diskettes and by e-mail every month to enable
Purchaser/Engineer to review the same.
1.6.3.7 The Purchaser/Engineer shall review and comment on the Overall Contract
Schedule and, upon agreement with Bidder on any necessary changes, Bidder
shall furnish to the Purchaser/Engineer prints of the accepted schedule.
1.6.3.8 The schedule shall be updated and submitted to the Purchaser/Engineer at least
once each month. The schedule shall include all incomplete work and all work to
be completed in the next three months as per the original schedule. The updates
shall show actual progress and any proposed changes in the schedule of the
remaining work.
1.6.3.9 Diagrams of activities and relationships forming the CPM, organised by

Specification document and system shall be submitted with the output reports and
float path descriptions. Construction activities shall be included in sufficient detail
to define the work supported by engineering design deliverables, such as
drawings, lists and Specification documents, and by equipment and material
deliveries to the site.
1.6.3.10 Engineering design shall be shown in sufficient detail to clearly define all area
and system design activities and the inter-relationship between design disciplines.
Procurement of equipment and materials shall be shown in sufficient detail to
identify each equipment / system / package, preparation of Specification
document and issue, tender preparation / receipt, bid review & negotiation award,
information submittals (by discipline and type), and delivery to the site including
shipping durations.
1.6.3.11 Detailed network schedule shall show the sequence, timing and duration of the
work and the planned commencement and completion dates of all separable
portions of the work including each milestone in form, content and level of details
satisfactory to Purchaser/Engineer. It shall also show Bidder’s manpower
forecast, procurement, delivery and installation plans for major materials and
other schedule information, reasonably requested by Purchaser/Engineer.
1.6.3.12 Appropriate time shall be allocated for the approval of the documents by
Purchaser/Engineer and the same shall be indicated in the network schedule. If
any resubmission becomes warranted due to any omission or gross errors, only
the resubmission date shall be considered as the valid submission date.
1.6.3.13 The schedule for Purchaser/Engineer input shall be mutually agreed upon after
the award of Contract.
1.6.3.14 Other project activities necessary to control the work under this Specification shall
be included as mutually agreed to by the Bidder and the Purchaser/Engineer.
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1.6.4 Procurement Schedule
1.6.4.1 The Procurement Schedule shall cover all equipment and materials to be supplied
by the Bidder, and critical items to be supplied by his sub-vendors, manufacturers
and Bidders as proposed by the Bidder and accepted by the Purchaser /
Engineer. This schedule will indicate times for bid invitation, economic evaluation,
ordering of materials, approval of manufacturer’s drawings including
Purchaser/Engineer review, fabrication, shipping, delivery, testing, and other
significant Project milestones.
1.6.4.2 Procurement Schedule shall be in agreement with and supporting the Overall
Contract Schedule.
1.6.4.3 The Procurement Schedule shall be updated indicating the actual progress at
least once in each month and submitted with the Project Report to show the
status of orders placed, Engineering Submittals, and delivery. Copies or listings of
material orders or sub-contracts issued with their issue dates shall be included.
1.6.5 Detailed Start-Up Schedule
The Detailed Start-up Schedule shall include a schedule of all required tests and
shall be based on a Start-up Requirements Network which shall be prepared by
the Bidder’s start-up organisation when the design is sufficiently complete to
commence start-up planning. The Detailed Start-up Schedule shall show all sub-
system package construction completion activities, consistent with the Overall
Contract Schedule, followed by pre-operational start-up, testing, initial operation,
trial operation, characteristic tests and performance guarantee tests. Definite
“Hold” points shall be included to allow for inspections and certification.
1.6.6 Engineering Submittal Schedule
The Engineering Submittal Schedule shall be prepared in accordance with the

requirements of Section – C11: “Data to be furnished after award of Contract”.
1.6.7 Miscellaneous Schedules
1.6.7.1 The Bidder shall prepare and submit to the Purchaser/Engineer miscellaneous
schedules covering plant operation, plant maintenance and training up to
substantial completion. Each schedule shall be in sufficient detail to effectively
control and monitor the associated activities. Each schedule shall be at the
appropriate level of detail.
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1.6.7.2 Apart from the overall Contract Schedule, the Bidder shall provide detailed
network schedules for manufacturing and site activities separately from major
sub-Contractors for information and monitoring by. Purchaser/Engineer.
1.6.7.3 The following requirements apply to all schedules prepared by the Bidder. The
schedules shall be prepared and administered based on schedule plans and
procedures submitted as part of the Project Procedures.
(a) Purchaser/Engineer shall review and comment on each schedule, and

upon agreement with Bidder of any necessary changes, shall approve
the schedule.
(b) Bidder shall not change the planned portions of schedules without prior
notification to Purchaser/Engineer along with justification and reasons
thereof.
(c) The schedule would be periodically updated to reflect the activities

completed and any rescheduling of balance activities. In case any
particular activity is likely to be delayed or already delayed the Bidder
shall furnish to the Purchaser/Engineer the proposed recovery
schedule and indicating the additional resources being employed for
such recovery.
(d) Each schedule shall show the activities in a colour graphic format
suitable for displaying scheduled and actual progress. Schedules shall
be submitted on reproducible media and in electronic format (number
of copies shall be as per the contract co-ordination procedure).
(e) Each schedule shall be coordinated with the other Project schedules to
assure the timely availability of information for procurement, design
and construction purposes to avoid any delay in Work progress.
(f) The accepted schedules shall be updated to show progress at least

once in each month and submitted to the Purchaser/Engineer to show
the status of the Work.
(g) Corrective action for the slippage in the schedule also shall be
highlighted in the progress report.
Purchaser/Engineer review of any schedule does not relieve the Bidder

of any obligation to complete the work in a timely manner.
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SECTION C 5
QUALITY ASSURANCE AND MINIMUM INSPECTION
REQUIREMENTS FOR COAL HANDLING SYSTEM
EQUIPMENTS AND MISCELLANEOUS EQUIPMENTS
PRAYAGRAJ POWER GENERATION COMPANY VOLUME – IIA
TCE.5871A-H- LIMITED
563-001B SECTION: C5
3 X 660 MW PRAYAGRAJ SUPER THERMAL POWER PROJECT CONTENTS
TITLE
VOL. IIA - SECTION C5 CONTENTS
SECTION C5 TABLE OF CONTENTS

SUB REV PAGE
SECTION TITLE
SECTION NO. NUMBER
C5 C5.1 R0 QUALITY ASSURANCE 20

REQUIREMENTS
C5.2 R0 LIST OF QUALITY PLANS FOR 1

STACKING AND RECLAIMING
SYSTEM EQUIPMENTS
C5.2 R0 LEGEND 1
C5.2 R0 MINIMUM INSPECTION 4

REQUIREMENTS FOR BELT
CONVEYORS AND FEEDERS

REQUIREMENTS FOR GEAR BOXES

REQUIREMENTS FOR COLUMNS,
GIRDERS, BUILTUP BEAMS
C5.2 R0 MINIMUM INSPECTION

REQUIREMENTS FOR STACKER CUM
RECLAIMERS
C5.2 R0 NOTES APPLICABLE TO ALL QUALITY 1

PLANS OF COAL HANDLING SYSTEM
EQUIPMENTS
C5.3 R0 LIST OF QUALITY PLANS FOR 1

MISCELLANEOUS EQUIPMENTS
C5.3 R0 LEGEND 1
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TITLE
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SECTION TITLE
SECTION NO. NUMBER
REQUIREMENTS
FOR CENTRIFUGAL, PORTABLE
SUBMERSIBLE PUMPS & SUMP
PUMPS

REQUIREMENTS FOR STRAINERS &
FILTERS

REQUIREMENTS FOR BUTTERFLY
VALVES

REQUIREMENTS FOR VALVES AND
SPECIALITIES
(RATING ANSI 300 & BELOW)

REQUIREMENTS FOR FOG JET DS
SPRAY NOZZLES AND PLAIN WATER
SPRINKLERS

REQUIREMENTS FOR CARBON
STEEL AND STAINLESS STEEL
PIPING (LOW PRESSURE SYSTEM)
C5.4 R0 INSPECTION AND TESTING 9

PROCEDURES
C5.5 R0 SHOP PERFORMANCE TEST 4

PROCEDURE FOR DUST
SUPPRESSION & OTHER PUMPS
C5.6 R0 SHOP PERFORMANCE TEST 4

PROCEDURE FOR PORTABLE AND
SUBMERSIBLE PUMPS
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TITLE
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SECTION TITLE
SECTION NO. NUMBER
C5.7 R0 PROCEDURE FOR PERFORMANCE 21

TESTING OF STACKING AND
RECLAIMING SYSTEM
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SECTION C 5.1
QUALITY ASSURANCE REQUIREMENTS
TCE-5871A- H-563-
001B PRAYAGRAJ POWER GENERATION COMPANY VOLUME – IIA
LIMITED SECTION: C5.1
1.0 INTRODUCTION
1.1 The minimum Quality Assurance / Quality Control (QA/QC) requirements

and the services the Supplier is expected to provide to assure ‘Quality
Assurance’ are described in this section. `Quality Assurance’ is defined
as the entire programme adopted by the Supplier during engineering,
manufacture, procurement and construction to assure conformity with the
contract specifications and relevant codes and standards indicated in the
specifications. Quality Assurance/Quality Control procedures followed by
the BIDDER shall address the QA/QC requirements during the following
phases of the project:
(a) Engineering
(b) Procurement
(c) Manufacture
(d) Construction including erection, testing and commissioning.
Relevent codes and standards: Following points shall be noted for

IS or any other code:
(1) Tolerance given in the codes and standard shall always be taken in
positive side.
(2) If more than one option given the codes and standards, only higher
or best option shall be selected to carry out the work.
(3) Raw material (Steel) shall be supplied at site without mill scale.
1.2 Bidder shall submit documents to demonstrate that the Bidder and his
sub-vendors possess, QA/QC procedures meeting the requirements set
forth in this section. The minimum inspection requirements for all major
equipment are as indicated in the attached documents [Refer Quality
Plans (QP) enclosed]. However it is the Supplier’s responsibility to
prepare a list of all relevant major additional requirements if any to
ensure the required quality, prepare quality plans with such additional
requirements taking into account the minimum inspection requirement of
this specification and obtain these quality plans reviewed / approved by
the Purchaser / Engineer.
1.3 The BIDDER shall submit an organization chart defining the permanent
positions responsible for QA/QC accompanied by a brief description of
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each position’s function and responsibility. A second organization chart

along with a descriptive write up shall also be provided outlining the
proposed QA/QC program for this particular project. This chart and write
up shall identify the personnel responsible for the Engineering Quality
Assurance procedure for the complete duration of the project.
2.0 Engineering
2.1 Prior to finalisation of contract
Prior to finalisation of the Contract, the Supplier shall prepare and submit
a project Quality Assurance Procedure that covers the engineering
phase of the Works. The procedure shall be designed for this project and
shall address the specifics of how the Supplier shall control, monitor and
verify the requirements contained in this section. The Supplier shall
utilize all his QA/QC resources, manuals and procedures when preparing
the plan. Purchaser /Engineer Shall review the plan prior to utilization
and upon issue the plan shall become the basis by which Purchaser /
Engineer Shall evaluates the Supplier’s engineering QA/QC activities as
they relate to this project.
2.2 Purchaser / Engineer Participation
The Purchaser/Engineer reserves the right to audit and verify procedures

set forth in the Engineering Quality Plan. This audit right in no way
relieves the Supplier from performing the control verification procedures
outlined in the plan.
3.0 Engineering Quality Assurance and Quality Control Requirements
Following are the minimum Quality Assurance and Quality Control

requirements for the project. The Supplier’s Engineering Quality Plan
shall set forth in detail the procedures to satisfy these QA/QC
requirements:
3.1 Design control
The Supplier shall define, document and advise the appropriate handling
of the following design controls:
(a) Establish internal as well as external discipline relationships
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(b) Qualifications of personnel assigned for each task
(c) Establish audit procedures to ensure that the design conforms to

the requirements
(d) Define and outline the number of multidiscipline design reviews
(e) Establish procedures for handling design changes
(f) Establish guidelines to handle all issues in pre-award, award and

pre-fabrication with Manufacturer’s and Sub-Suppliers.
3.2 Document control
The Supplier shall include in his QA/QC – procedures the document

control methodology defining:
(a) Authorised use of documents
(b) Receipt, logging and distribution of documents
(c) Methodology for updating and implementation of additions

and revisions
(d) Methodology for document transmittal to Purchaser / Engineer.

Some of the requirements for document transmittal maybe
covered in other parts of this specification.
3.3 Audits
All documents shall be audited by the Supplier for conformance with the
QA/QC procedures.
The Purchaser/Engineer reserves the right to review design details,

either directly or through their Consultants. The Purchaser/Engineer may
audit detailed design including for Crushers, Conveyors, Screens and
auxiliaries related design, structural / foundation designs/piping design
and other areas.
3.4 Engineering Sub-Supplier
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The subcontracting of detailed engineering to third parties does not

relieve the Supplier of his responsibility for Engineering Quality
Assurance.
4.0 Procurement
4.1 Source quality control
It is the Purchaser/Engineer’s intent that the Supplier deal only with Sub-
Suppliers and Manufacturers (Vendors) who have established and
demonstrated effective quality assurance and quality control procedures.
Purchaser/Engineer does require, however, that the Supplier perform
such normal inspection of equipment manufactured in his own
manufacturing unit or at the works of his Sub-Suppliers/ Vendors, as is
necessary to obtain equipment and materials conforming to the project
specifications and their supporting documents (applicable codes and
industry consensus standards) and good engineering, fabrication
practices as described herein. Source Quality Control is also a valuable
input for confirmation of delivery performance.
The minimum inspection requirements in respect of major mechanical

items have been included in this section. Minimum inspection
requirements in respect of electrical and instrumentation /control
equipment and civil works are covered in their respective specifications.
4.2 After Award of Subcontract
Once Sub-Suppliers and manufacturers are established,

Purchaser/Engineer and the Supplier shall review item by item all major
engineered equipment and systems and to reach an agreement on the
need for pre-fabrication/pre-inspection and any additional quality plans
needed to ensure the required quality.
4.3 Purchaser / Engineer Participation
The Purchaser /Engineer reserves the right to audit the performance of

the Sub-Suppliers/Manufacturers and the Suppliers inspection effort.
This is normally accomplished by visiting the Sub-
Suppliers/Manufacturers with the Suppliers’ Inspector at pre-selected
points during manufacture. Supplier shall identify notification points so
that the Purchaser’s / Consultant’s representative(s) can be present at
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particularly important stages of fabrication should the Purchaser /

Engineer wish to attend. The notification points are not hold points unless
specifically identified as such. Should Purchaser / Engineer elect not to
or fail to attend, the Work shall proceed without interruption. However,
wherever customer hold points as H are indicated and mutually agreed
upon, the Supplier shall not proceed further unless the hold is
cleared/waived. The Purchaser /Engineer reserves the right, however, to
make announced spot-checks to facilitate evaluation of the Sub-Supplier
and/or the Supplier’s inspection effort. Purchaser / Engineer may wish to
hold technical meeting with the Sub-Supplier during the design and
fabrication of the machinery. Should Purchaser / Engineer desire to hold
technical meetings, the Supplier Shall be advised at a reasonable notice.
4.3.1 During audit visits to fabricator shops, Purchaser /Engineer may elect to
spot-check base materials and welds to verify proper metallurgy using
whatever methods Purchaser /Engineer may wish to utilize, but only in
the presence of Supplier’s Inspector unless otherwise agreed. Some of
these requirements have been identified in the minimum inspection
requirements listed in this section.
5.0 Communication
5.1 Direct, timely communication between the Supplier’s Inspectors and

Purchaser /Engineer auditing Inspectors is mandatory, especially in
notification points and in the event of problems, Purchaser /Engineer
shall be advised in a timely manner of all situations where changes or
compromises in specifications are considered or where non-
conformances are being encountered. Suggested format for inspection
request is enclosed with this section. The Supplier shall give advance
notice of forty-five (45) days for all overseas travel and twenty-one (21)
days for travel inside India.
5.2 Inspection reports shall be faxed from the Supplier’s Inspector to

Purchaser /Engineer’s Representative at the same time as faxed to the
Supplier’s home office. Reports shall be faxed to Supplier’s home office
for typing, editing and transmitting to Purchaser /Engineer.
6.0 QA/QC Requirements
6.1 Inspection plan
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Inspection plans with detailed instructions for the Inspector’s guidance

shall be provided for each item. The Supplier shall prepare a list of all
relevant major equipment / systems, prepare quality plans for these
equipment / systems, covering all the minimum inspection requirements
stipulated in this specification and any additional technical requirements
the Supplier’s Procurement Inspection function Shall begin with the
Letter of Award (LOA) of the purchase order and conclude when the
Inspector (including inspection by Purchaser’s inspector wherever
applicable) has duly released the equipment in the Sub-Supplier’s shop.
6.2 Inspection office
6.2.1 The Supplier shall identify the key inspection office located at its
engineering and construction office. All inspection assignments,
inspection instructions, after placement of the purchase order shall be
covered from this designated office.
6.2.2 One individual in the Supplier’s key inspection office shall be designated
to fill the function outlined in 3.5.3 and must report to the Supplier’s
Manager for Inspection. Additional staff may be added as necessary,
provided they are under the supervision of the individual designated. This
individual Shall hereafter be referred to as the “Quality Control Project
Inspector (QCPI)’.
6.2.3 For technical problems arising during manufacturing, after purchase

orders are placed, the QCPI is responsible for clearing such technical
problems with Supplier’s Engineering Department and/or Purchaser
/Engineer. All purchase orders shall have a clause requiring the Sub-
Supplier to submit all questions of a technical nature concurrently to the
QCPI and Purchaser /Engineer representative in writing via fax or letter
for resolution. The QCPI shall be responsible for obtaining replies from
Supplier’s Engineering Department, documenting the response to the
Sub-Supplier and making distribution. The assigned QCPI shall be on
distribution list for all other correspondence. When technical requests
arise from rejection made by the Supplier’s source Inspector, the source
Inspector’s rejection report must be attached to the Sub-Supplier’s
request for engineering evaluation.
6.3 Inspection Co-ordination and Responsibility
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The QCPI shall have the overall coordination responsibility for inspection
activities. The QCPI’s responsibilities shall include, but not be limited to
the following:
(a) Issue assignments for source inspection
(b) Issue specific inspection instructions when required to the

assigned source inspector
(c) Indicate the required type of report forms

(d) Coordinate and respond to questions of a technical nature
(e) Monitor inspection reports to determine if inspections are being

performed as per written instructions
(f) Forward all related order correspondence to the assigned source

Inspector
(g) Receive inspection reports from the source Inspector and make
distribution as required
(h) Ensure that comprehensive files are maintained for each job.
6.4 Inspectors’ qualifications
The Supplier shall submit with their QA/QC Manual resumes of

Supplier’s inspectors detailing their experience, education and
qualifications for Purchaser /Engineers review / approval. The Inspectors
shall have sufficient prior experience and qualifications for the equipment
assigned.
6.5 Inspector’s responsibilities
After receiving the assignment from the QCPI, the source Inspector shall
review the order, conduct a pre-inspection meeting (when instructed),
perform the inspections outlined, maintain field file in an organised
manner and report the results to the key office and Purchaser/Engineer.
The following is a more detailed, but not inclusive, list of what
Purchaser/Engineer typically expects from the Supplier’s QCPI:
(a) Pre-fabrication meeting - The Supplier’s Inspector shall conduct

a pre-fabrication meeting with the Sub-Supplier prior to start of
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fabrication. The discussion shall include, but not be limited to a

review of the following items:
(i) Purchase order requirements with emphasis on any

special requirements (technical and quality)
(ii) Specification and Code requirements
(iii) Inspection Agency for ASME Code Requirements/IBR

requirements
(iv) Sub-Suppliers Quality Control Programs
(v) Fabrication Schedule
(vi) Critical Component or Sub-Supplier Fabrication
(vii) Major Sub-Suppliers
(viii) Welding Procedure Specification (WPS), Procedure

Qualification Record (PQR) and Welder Performance
Records (WPR).
(ix) Special Welding Procedure Requirements
(x) Qualification of Non-Destructive Testing Personnel
(xi) Non-Destructive Examination Requirements
(xii) Heat Treatment Requirements
(xiii) Testing - Hydrostatic and Pneumatic
(xiv) Manufacturer’s Data Reports
(xv) Preservation, Packing and Shipping
(xvi) Extent of Purchaser/Engineer / Supplier Inspection
(xvii) Witness Points and Hold Points and Notice

requirements.
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(b) Initial inspection visit: The Inspector shall perform as a minimum,

the following inspection activities prior to start of fabrication:
(i) Review fabrication schedule to ensure required Quality

Control examinations and other intermediate tests have
been included
(ii) Establish approval of major Sub-Suppliers
(iii) Verify that Welding Procedures and Procedure

Qualifications have been approved
(iv) Verify that all welders assigned to job are qualified

(v) Review Mill Test Reports to verify materials meet
specifications
(vi) Review Sub-Supplier’s Examination and Inspection Plan
(vii) Review Sub-Supplier’s procedure for identifying and

transferring material markings
(viii) Make a visual examination of major materials, verify

Sub-Supplier’s examination of all materials, and verify
proper storage facilities (environment and security).
(c) Progressive inspection visits: The following minimum activities,

where applicable, shall be executed and reported upon by the
Inspector:
(i) Monitor on a random basis the transfer of material

marking throughout the fabrication
(ii) Initial and random inspection of edge preparation, root

gap and fit up for all vessel and fabricated machinery
components
(iii) Initial and random witnessing of production welding to

verify approved procedures, qualified welders and proper
techniques are being used
(iv) Ensure that preheat requirements are followed
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(v) Ensure that welding materials are being properly

controlled
(vi) Inspect major weld seams, nozzle and attachment welds,

overlay welding and any weld repairs
(vii) Perform random check of back gouging of pressure

retaining welds
(viii) Inspect critical/major materials from sub Sub-Suppliers
(ix) Check nozzles / manways for size, rating and extension
(x) Check dimensions and workmanship of internal tubing,

coils and components
(xi) Examine gaskets and bolting against specifications
(xii) Check location and attachment welds for support clips,

lugs, brackets and saddles
(xiii) Make final visual inspection for quality of work and for
damage
(xiv) Make complete dimensional inspection
(xv) Verify post weld heat treatment meets specifications
(xvi) Witness all hydrostatic and pneumatic testing
(xvii) Witness routine and special testing as may be outlined in

project specifications or data sheets for Electrical and
Instrumentation
(xviii) Assure electrical and instrument function and operational

checks have been performed as per project
specifications.
(d) Non-destructive Examination (NDE) - The Inspector shall

perform as a minimum the following NDE activities during
progressive inspections:
(i) Radiographic Test (RT)

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• Review Sub-Supplier’s radiography procedures

for approval
• Review all radiographs progressively through out
fabrication
• Evaluate for acceptable film quality and weld
quality.
(ii) Ultrasonic Test (UT)
• Review Sub-Supplier’s procedures and Inspector

qualifications
• Witness at least 25% Ultrasonic examinations
• Review certified results.
(iii) Magnetic Particle Inspection (MPI)
• Review Sub-Supplier’s procedures and Inspector

qualifications
• Witness the initial MPE examinations and 10%

minimum of all MPE examinations, as well as all
examinations after repair.
(iv) Liquid penetrant (LPI)
• Same as for MPI
(v) Hardness testing - production welds
• Review procedure and witness initial tests
• Verify 10% of hardness values during

progressive inspections
• Review all hardness readings for acceptance as

per specifications and require certified results
(e) Shipping
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(i) Verify that all shipping requirements related to cleaning,

dry out, surface preparation are met.
(ii) Verify that pressure equipment is appropriately code

stamped and all “Manufacturer’s Certified Data Reports”
are complete and properly signed
(iii) Verify required documentation for acceptance and record

is complete.
6.6 Inspection reports
6.6.1 Inspection reports for interim inspection visits shall be consecutively

numbered and identify non-conformance and exceptions found/
corrected at that time. Final checklists should indicate all items inspected
during interim inspections.
6.6.2 Inspection rejection reports shall be by telefax to the key office and
Purchaser/Engineer when the Sub-Supplier’s proposed resolution
deviates from order specifications, or would require repairing.
6.6.3 Final inspection reports shall be by check-off for all major equipment and
bulk piping components. The check-off indicates the inspections were
performed and would be covered on an interim inspection report.
6.6.4 Inspection release certificate shall be issued by the assigned Inspector

only after all the requirements of the purchase order is met and the
rectifications mentioned in the inspection report/s are satisfactorily
completed. The inspection release certificate issued by the inspector is
an authorisation to the sub-Supplier to present final billing to the
Supplier. A copy of the release note shall be attached to the packing list
to serve as notification to the job site about the inspection approval.
7.0 Construction
7.1 Purchaser/Engineer’s Participation
7.1.1 Purchaser/Engineer Shall have a Quality Assurance/Quality Control

organization to audit the Supplier’s QC effort. The assigned
Purchaser/Engineer’s personnel shall provide assurance to
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Purchaser/Engineer’s management that the Work meets specifications,

however, the basic inspection and quality control responsibility is vested
with Supplier. The purchaser/Consultant shall have access to the
Supplier’s/Sub-Supplier’s/site premises/site office/site stores to check the
quality of materials at any point of time during
construction/commissioning stage.
7.1.2 Purchaser / Engineer’s auditing may include spot checks of materials

including their testing in the field to ensure that inadvertent substitutions
have not been made in the fabrication shops or mixing point or in field
ordered materials. Purchaser / Engineer's auditing shall also include
testing of concrete, cement mortar, etc.
7.2 Communication
7.2.1 Direct, informal communication between the Supplier’s field Inspectors

and Purchaser /Engineer’s auditing Inspectors is mandatory. Further
Purchaser /Engineer shall be advised when major problems related to
design or fabrication are uncovered.
7.2.2 Supplier’s in-progress inspection reports, follow up/punch out sheets,

records of radiograph inspections, etc. shall be available to Purchaser /
Engineer’s auditing Inspectors during the course of the Work.
7.2.3 At the end of the Work, Supplier’s standard inspection reports, check off
sheets, radiographs, master copy of loop diagrams, electrical test data
sheets, etc. shall be handed over to Purchaser / Engineer in an
organised, agreed upon format. Supplier shall verify that all of the
required documentation of the equipment has been received and placed
in the equipment files. The Supplier is responsible for obtaining any
outstanding documentation from the suppliers.
7.3 Construction QA/QC requirements
7.3.1 It is the Purchaser /Engineer’s intent that the Supplier (and any Sub-
Suppliers employed) provide sufficient qualified Inspectors to assure that
facilities are installed in accordance with the plans and Purchaser /
Engineer’s specifications and intents and that the level of quality called
for therein is obtained. Prior to finalisation of Contract award, the
Supplier shall submit a detailed Field Quality Assurance Program for
Purchaser /Engineer’s review. The program must be tailored to show
compatibility with engineering design, compliance with applicable codes,
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specifications, standards, drawings, support documents, governmental

regulations and this document.
For the construction period, the Supplier shall provide a full time,
dedicated Quality Assurance Organization. As a minimum the Supplier’s
Construction Quality Assurance Program shall include the following:
(a) Quality control program
Details of the program to be implemented, its use, control and

identification of hold and inspection points shall be submitted to
Purchaser /Engineer Representative for approval.
(b) Organization, authority and responsibility
Delineate the Supplier’s Quality Control organization, responsibility

and authority for performance of QC functions by discipline.
(c) Inspector qualifications
The Supplier’s Construction Assurance organization shall consist of

people with qualifications similar to the requirements outlined in the
Procurement clause 13.5.4. The field QA organization shall be a full
time organization, with no other construction related duties. As with
engineering and procurement, Purchaser / Engineer shall review
Construction QA staffing plans.
(d) Document control
This system shall ensure that the latest issues of drawings,

specifications, standards, and supporting documents are being
used for fabrication and installation and that field changes are
incorporated into final “As Built” drawings.
(e) Receiving control
Procedure for receipt of purchased items delivered at the job site

initial identification, qualification and review of supporting
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documents shall be described. In addition the procedure shall

ensure that spare parts supplied by Supplier are properly labeled by
the Sub-Supplier with description and purchase order number.
(f) Receiving inspection
This shall establish the method of notification and inspection to be

performed on received items to verify the condition and
conformance to the appropriate acceptance standards reference or
contained in the purchased documents.
(g) Supplier/Sub-Supplier non-conformance
This shall provide for documentation and disposition of non-

conformances resulting from Supplier/Sub-Supplier errors and
shipping damage to material, fabrications and equipment received
at the job site. It also provides for interface with the design engineer
when the non-conformance does not comply with the engineering
design.
(h) Storage and Maintenance of Materials and Equipment
This system shall describe the controls and inspection performed to

show that the handling, storage and preservation of materials and
equipment are performed to prevent damage or harmful
deterioration to the materials and equipment received at the job
site.
7.4 Inspection, examination and testing of on-site fabrication and

installation
This section shall establish the responsibility for performance and

recording of examinations, tests and inspections as required by the
engineering design.
Inspection of work in progress to determine conformance with drawings,

specification, any field definition agreed to shall be included. Some of
the inspections are listed below:
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(a) Soil testing
(b) Earthwork, backfilling
(c) Structural concrete
(d) Performing random dimensional check and visual material

verification of field fabricated pressure equipment and of any
piping, vessel, electrical and instrument installation.
(e) Internal checking of all vessels for:

(i) Cleanliness
(ii) Proper internals. This involves opening the vessel man
ways and removal of internals.
(f) Witness testing and installation of items such as:

(i) Welder testing and qualifications and maintenance of
records thereof
(ii) Weld examination and maintenance of records thereof in
accordance with applicable codes and specifications
(iii) Monitor selected field post weld heat treating
(iv) Hydro tests, hydro-pneumatic tests, pneumatic tests,
lead and service tests
(v) Electrical inspection and testing which includes
witnessing of Hipot testing, megger testing, AC power
factor testing etc.
(vi) Instrument model/name plate data verification
(vii) Instrument installation checkout
(viii) Instrument loop checks
(ix) Mechanical and electrical equipment bearing flushing
and filling
(x) Mechanical equipment cold alignment checks and
rotation verification
(xi) Witness verification that piping loads on machinery
equipment meet specifications
(xii) Pump installation check out
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(xiii) Coating and lining tests

(xiv) Surface preparation, paint application and thickness
verification.
(g) Final checking of installed facilities, completing check out forms,

and signing on behalf of the SUPPLIER documents attesting
completion of the Work, as called for in the Contract documents.
(h) Monitoring or inspecting the work of Sub-Suppliers This requires

pre-award and pre-field start meetings for major subcontracts
with Supplier’s / Sub-Supplier/ Purchaser /Engineer participation
to establish quality (QA/QC) requirements and how they Shall be
met. Typical areas/ disciplines may include, but not be limited to
the following:
(i) Foundations
(ii) Field fabricated vessel
(iii) Tanks
(iv) Piping
(v) Electrical
(vi) Instrumentation
(vii) Insulation
(viii) Painting
(ix) Buildings
(i) Execute Supplier’s standard quality tracking program
(j) Perform final check of installed facilities with Purchaser /

Engineer’s representatives to verify completeness and accuracy
in accordance with P and ID’s / Engineering Flow Diagrams and
other scope documents as may be required.
(k) See that proper protective procedures are employed and

maintained for early installed equipment and equipment stored in
offsite staging areas.
7.5 Non-conformances of on-site fabrication and installation
This section shall control on-site fabrication and installation items, which
do not conform to the engineering design or for which the engineering
design is incorrect.
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7.6 Calibration of test equipment

Calibration of tools, gauges, instruments and other measuring and
testing devices shall be included.
7.7 QA personnel qualification and certification
The qualification required of QA/QC personnel shall be outlined.
7.8 Quality assurance/Quality control records
The system which shall ensure that all quality assurance records are
maintained for ready reference and shall also provide for the
accumulation, evaluation, retention and distribution of QA/QC records.
7.9 Interface with statutory authorities
Participation of statutory authorities, which require testing, witnessing

and inspection shall be provided.
7.10 Audits
Requirements for audits to verify implementation of the QA/QC program

on a regular basis shall be included.
7.11 Mechanical completion acceptance
SUPPLIER shall perform final inspection of the Work in accordance with

the Contract document.
7.12 Periodic reporting of QA/QC activities (once a month or earlier) as
required shall be submitted.
7.13 Quality Assurance for Electrical, Instrumentation and Control

system
Bidder shall furnish a detailed Quality Assurance/Quality Control Plan

(QA/QC) for each Electrical, Instrument/ system covered under this
specification for Purchaser / Engineer review and approval. The QAP
shall be subject to Purchaser / Engineer approval.
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INSPECTION REQUEST FORM
From :
To :
Attn: Mr
Dear Sirs,
Items detailed below are ready for inspection. Please arrange inspection and
confirm the date of inspection:
1. Purchaser / ENGINEER :
2. Project :
3. Purchaser’s order reference :
4. Consultant’s reference :
5. Sub-order reference :
6. Sub-Supplier’s name and

full address :
7. Place of Inspection
(full address) :
8. Contact person, telephone

no. and fax no. :
9. Description of item and

quantity :
10. Nature of inspection required :
11. Proposed date(s) :
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12. Weekly holiday :
We confirm that the items have been fully inspected/tested by us at all stages, of
inspection as per quality plan, and all material test certificates, QC records., test
Reports, calibration records of measuring/testing instruments with traceability to
National Level* are available with us.
Thanking you and awaiting your confirmation,
Yours faithfully,
cc : Sub-Supplier
NOTE : 1. Following clear notice periods (date of receipt to date of inspection) are
required :
(a) Local Inspection (within India) - 21 days
2. This same form is to be used for inspection notification points and

Customer Hold Points.
* The master instruments used for calibration of instruments/gauges used for

measurement/testing by the firm or by any calibrating agency should have valid
calibration certificate with reference to the master instrument at National Physical
Laboratory, New Delhi (India) or any other similar International
Laboratory/Organization.
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TCE-5871A- H-563-
001B LIMITED
VOLUME – IIA
SECTION: C5.2
AT BARA,UP
SHEET 1 of 1

QUALITY PLANS
CONTENTS
LIST OF QUALITY PLANS
Sl. QP No. Description Number of

No. sheets
1
1 A01-P0 Belt conveyors and feeders 4
2 A02-P0 Gear boxes 1
3 A03P0 Columns, Girders, Built up Beams 2
4 A04-P0 Stacker Cum Reclaimer 5
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SECTION C 5.2
LEGEND
PRAYAGRAJ POWER GENERATION COMPANY LIMITED VOLUME-IIA
TCE 5871A-H-563-001B
3 X 660 MW PRAYAGRAJ SUPER THERMAL POWER PROJECT SECTION : C5.2
AT BARA,UP
QUALITY ASSURANCE REQUREMENTS
LEGEND
QP. NO. : QP - R0 SHEET 1 OF 1
SL. NO. LEGEND EXPANSION / DESCRIPTION

1. TC TEST CERTIFICATE
2. HT HEAT TREATMENT
3. MPI/MI MAGNETIC PARTICLE INSPECTION
4. WPS WELDING PROCEDURE SPECIFICATION
5. PQR PROCEDURE QUALIFICATION RECORDS
6. WPQ WELDERS PERFORMANCE QUALIFICATION
7. UT ULTRASONIC TESTING
8. LPI LIQUID PENETRANT INSPECTION
9. RT RADIOGRAPHIC TESTING
10. PT PENETRANT TEST
11. NDT NON-DESTRUCTIVE TESTING

SECTION C 5.2
MINIMUM INSPECTION REQUIREMENTS
FOR BELT CONVEYORS AND FEEDERS
TCE-5871A- H-563-001B PRAYAGRAJ POWER GENERATION COMPANY LIMITED VOLUME - IIA
AT BARA,UP
TITLE QUALITY ASSURANCE REQUIREMENTS

MINIMUM INSPECTION
REQUIREMENTS FOR BELT CONVEYORS AND FEEDERS
QP. NO. : QP – A01, R0 SHEET 1OF 4
SR. COMPONENT / OPERATION CHARACTERISTICS TYPE / METHOD EXTENT REF. DOCUMENT / FORMAT OF AGENCY REMARKS
NO. CHECKED OF CHECK ACCEPTANCE NORM RECORD S M P
1 2 3 4 5 6 7 8 9
1.0 BELT:
1.1 Raw Material Material Properties TC Verification 100% Applicable standards, Data TC V
Sheets
1.2 Dimensional Inspection Dimensions Measurement 100% Drawings/Data Sheets Inspection Report W
1.3 Testing for mechanical Tensile strength, elongation, Lab testing, visual 100% Applicable standards, Data TC W
properties ply adhesion, abration convers inspection Sheets
1.4 Troughability tests t
Flexibility 100% Applicable standards, Data TC W
Sheets
1.5 Testing of cover properties 100% Applicable standards, Data TC W
Sheets
1.6 Testing for fire resistance Resistance to fire 100% Applicable standards, Data TC W
properties Sheets
2.0 IDLER ASSEMBLY:
2.1 MS tubes, shafts, brackets Mechanical and chemical TC Verification 100% Applicable standards, Data TC V
properties Sheets
2.2 Review of welding documents WPS, PQR, WPQ Review of records 100% ASME Sec.IX Welding V
Document
2.3 Brackets Visual, dimensional Visual, 10% Drawings/Data Sheets Inspection Report V
measurement
A. STATUTORY REQUIREMENTS SHALL BE COMPLIED WITH BY THE VENDOR.
B. MATERIAL TESTS OF SAMPLES DRAWN BY GIPCL/ TCE SHALL BE WITNESSED BY GIPCL/TCE.

N C. FOR STAGES WITNESSED / DOCUMENTS REVIEWED BY TCE, COPIES OF RELEVANT DOCUMENTS SHALL BE FURNISHED TO TCE.
O D. TCE’S IDENTIFICATION STAMP ON MATERIALS SHALL BE PRESERVED / GOT TRANSFERRED BY TCE AT APPROPRIATE STAGES.
T E. THE EXTENT INDICATED IN COLUMN 5 IS IN VENDOR’S SCOPE. TCE MAY INSPECT AS PER THIS COLUMN OR RANDOM SAMPLES.
E F. COLUMN 6 SHALL BE AS PER TCE APPROVED DRAWINGS / DATA SHEETS / SPECIFICATIONS WHEREVER APPLICABLE.
G. INSTRUMENTS FOR LEAK TESTS AND PERFORMANCE TESTS SHALL HAVE VALID CALIBRATION CERTIFICATE WITH TRACEABILITY TO NATIONAL LEVEL.

AT BARA,UP

MINIMUM INSPECTION
H. LEGENDS : S - SUB - VENDOR, M - MAIN VENDOR, P- GIPCL/ TCE, W - WITNESS, V - DOCUMENTS REVIEW, H - HOLD POINT.
1 2 3 4 5 6 7 8 9
2.4.0 Final Inspection:
2.4.1 Idler with Bracket:

Dimensions & troughing angle Measurement 100% Drawing/data sheet Inspection Report V
Free movement of rollers Movement 10% Drawing/data sheet Inspection Report V

Gap between roller edges Measurement 100% Drawing/data sheet Inspection Report V
Level of rollers Instrument 10% Drawing/data sheet Inspection Report V
Verification of thrust bearing, swivelling of self aligning idlers Verification, 10% Drawing/data sheet Inspection Report V
about the pivot movement
2.4.2 Idler Rollers:
Dimensions, Run out checks Measurement 10% Drawing/data sheet Inspection Report V
Dust ingress test Shop test 10% Drawing/data sheet Inspection Report V
Water ingress test Shop test 10% Drawing/data sheet Inspection Report V
Friction coefficient test Lab test 10% Drawing/data sheet Inspection Report V
Hardness of rubber discs (for impact rollers) Hardness check 10% Drawing/data sheet Inspection Report V
Open inspection of bearings and rollers Visual 10% Drawing/data sheet Inspection Report V
2.4.3 Pulleys:
Material TC review for pulley shell, shaft, hub, end discs, Review 100% Drawing/data sheet Inspection Report V
plummer

AT BARA,UP

MINIMUM INSPECTION
Review of welding documents (WPS, PQR, WPQ) Review 100% Drawing/data sheet Inspection Report V
Visual, dimensional Visual, dimensional 10% Drawing/data sheet Inspection Report V
1 2 3 4 5 6 7 8 9
Lagging rubber examination and hardness check Visual, hardness 10% Drawing/data sheet Inspection report V
check
Lagging rubber peel-off test on random samples Peel-off test Random Drawing/data sheet Inspection report V
samples
Verification of bearings Verification 10% Drawing/data sheet Inspection report V
examination of hub and shaft fixing arrangement (locking Visaul 10% Drawing/data sheet Inspection report V
assembly)
3.0 SHAFTS:
Physical & Chemical properties Review of TCs 100% Drawing/data sheet Inspection report V
Soundness check for shaft dia = or > 50dia UT examination 100% AM 203.2 of ASME Sec. UT Report V
VIII Div.2
4.0 BELT SCRAPERS/CLEANERS:
4.1 Raw material for blades Review of 100% Drawing/data sheet Test cetificates V
certificates
4.2 Final inspection of assembly:
Visual, dimensional checks Visaul, measurement 10% Drawing/data sheet Inspection report V
Movement of blades and elastomount on spindle Movement 10% Drawing/data sheet Inspection report V
5.0 CHUTES & LINERS:
5.1 Material Review of 100% Drawing/data sheet Test cetificates V

certificates

AT BARA,UP

MINIMUM INSPECTION
5.2 Review of welding documents (WPS,PQR,WPQ) Review 100% ASME Sec. IX Welding V
Documents
5.3 Final inspection:
Visual, dimensional Visual, measurement 10% Drawing/data sheet Inspection report V
Examination of welds NDT(PT) 10% ASME Sec. V & Sec VIII PT Report V
Div.I
6.0 SPEED REDUCERS:
6.1 For speed reducers of capacity > 30KW :
i. Checks for gear box with motor as per QP No…A04….
ii. For oil pumps, coolers, and filters Review of 100% Drawing/data sheet Test certificates V
manufacturer’s cert.
6.2 For speed reducers of capacity equal or < 30KW : Refer
QP A04
7.0 FLEXIBLE COUPLINGS:
Material test certificate, Ultrasonic test report, Dynamic Review of 100% Drawing/data sheet Test certificates V
balancing report, dimensional test report, and Torque test manufacturer’s cert.
report
8.0 FLUID COUPLINGS:
8.1 Material Review of 100% Drawing/data sheet Test certificates V

8.2 Oil Test Certificate Manufacturer’s standard Test certificates V
8.3 Dynamic Balancing Test Certificate 100% Drawing/data sheet Test certificates V
8.4 Performance test Shop Test 100% Drawing/data sheet Test certificates V
9.0 INLINE MAGNETIC SEPARATOR Performance Test 100% Drawing/data sheet/applicable Test certificates W
standards
10.0 INLINE CONVEYOR SCALE Review of 100% Drawing/data sheet Test certificates W

SECTION C 5.2
FOR GEAR BOXES
TCE-5871A- H-563-001B PRAYAGRAJ POWER GENERATION COMPANY LIMITED VOLUME-IIA
AT BARA,UP
MINIMUM INSPECTION
QP. NO. : QP – A02, R0 SHEET 1 OF 2
1 2 3 4 5 6 7 8 9
1.0 MATERIAL
1.1 Gear blanks, Shafts, Bearing, Chem. & Mech. properties Review of docs 100% Material Specification TC V
Pinions & Housing
1.2 Forgings Soundness (for dia. >50mm) UT 100% AM 203.2 of Sec. VIII Div. 2 TC V
1.3 Housing Surface defects MPI 100% ASME Sec. VIII Div. 1 TC V
1.4 Gear HT chart review Review of docs. 100% Material spec. / data sheets TC V
2.0 IN-PROCESS INSPECTION
2.1 Gears Hardness & Case depth (for Measurement 100% Material spec. Hardness report V
Hardened and Ground gears)
2.2 Gear tooth Surface defects LPI 100% ASME Sec. VIII Div. 1 LPI report V
3.0 FINAL
3.1 Mechanical run test Vibration check, Noise level, Performance check 100% Drawing / Data sheets Inspection report W
Temp. rise, Speed ratio
3.2 Visual, Dimensional Appearance and dimension Visual, dimensional 100% Drawing / Data sheets Inspection report W
A STATUTORY REQUIREMENTS SHALL BE COMPLIED WITH BY THE VENDOR

AT BARA,UP
MINIMUM INSPECTION
QP. NO. : QP – A02, R0 SHEET 2 OF 2
B. MATERIAL TESTS OF SAMPLES DRAWN BY GIPCL/TCE SHALL BE WITNESSED BY GIPCL/TCE.

H. LEGENDS : S - SUB - VENDOR, M - MAIN VENDOR, P-GIPCL/ TCE, W - WITNESS, V - DOCUMENTS REVIEW, H - HOLD POINT.

SECTION C 5.2
FOR COLUMNS, GIRDERS, BUILTUP BEAMS
AT BARA,UP
MINIMUM INSPECTION
REQUIREMENTS FOR COLUMNS, GIRDERS, BUILTUP BEAMS
QP. NO. : QP – A03 – R0 SHEET 1 OF 2
1 2 3 4 5 6 7 8 9
1.0 MATERIALS :
1.1 Plates Chem., Mech. properties, Dimns. Review of docs. 100% Material specification TC V
Soundness UT 100% SA 435 TC V For thickness > 50mm
2.0 IN-PROCESS INSPECTION :
2.1 Gas cut edges ≥ 20mm Surface defects MPI 100% AWS D 1.1/Manufacturer's procedure V
2.2 Welding Procedure, Personnel qualification Review of docs. 100% AWS D 1.1/ ASME SEC. IX WPS, PQR, WPQ V
2.3 Weld inspection Surface defects Visual 100% AWS D 1.1 Inspection report V
2.4 NDE on butt joints :
a) thickness > 32mm Soundness RT 100% AWS D 1.1/Manufacturer's procedure RT report V RT film review during
final inspection
b) thickness > 25mm & ≤32 mm Surface defects MPI 100% AWS D 1.1/Manufacturer's procedure MPI report W Random MPI during
final inspection
c) thickness ≤ 25 mm Surface defects MPI 10% AWS D 1.1/Manufacturer's procedure MPI report W Random MPI during
final inspection
B. MATERIAL TESTS OF SAMPLES DRAWN BY PURCHASER SHALL BE WITNESSED BY PURCHASER.
N C. FOR STAGES WITNESSED / DOCUMENTS REVIEWED BY PURCHASER, COPIES OF RELEVANT DOCUMENTS SHALL BE FURNISHED TO PURCHASER.
O D. PURCHASER’S IDENTIFICATION STAMP ON MATERIALS SHALL BE PRESERVED / GOT TRANSFERRED BY PURCHASER AT APPROPRIATE STAGES.
T E. THE EXTENT INDICATED IN COLUMN 5 IS IN VENDOR’S SCOPE. PURCHASER MAY INSPECT AS PER THIS COLUMN OR RANDOM SAMPLES.
E F. COLUMN 6 SHALL BE AS PER PURCHASER APPROVED DRAWINGS / DATA SHEETS / SPECIFICATIONS WHEREVER APPLICABLE.

AT BARA,UP
MINIMUM INSPECTION
REQUIREMENTS FOR COLUMNS, GIRDERS, BUILTUP BEAMS
QP. NO. : QP – A03 – R0 SHEET 2 OF 2
H. LEGEND : S - SUB - VENDOR, M - MAIN VENDOR, P- GIPCL/ TCE W - WITNESS, V - DOCUMENTS REVIEW, H - HOLD POINT.
SR. COMPONENT / OPERATION CHARACTERISTICS TYPE / METHOD EXTEN REF. DOCUMENT / FORMAT OF AGENCY REMARKS
1 2 3 4 5 6 7 8 9
2.5 NDE on fillet joints :
a) when both plates are ≥ 25mm Surface defects MPI 100% AWS D 1.1/Manufacturer's MPI report W Random MPI
procedure during final insp.

b) for other fillet welds Surface defects MPI 10% AWS D 1.1/Manufacturer's MPI report W Random MPI
procedure during final insp.
c) throat size measurement when Fillet size Measurement Random Drawings Inspection V
both the plate thickness more than report
25mm
2.6 PWHT Temp. and time control HT chart review 100% Refer Note-1 HT chart V
3.0 FINAL :
3.1 Visual, dimensional inspection and Overall dimns., Alignment, etc. Visual, 100 % Drawing Inspection V Refer enclosure
Measurement report to this QP
trial assembly of main columns and
ceiling girders
3.2 Visual and dimensional inspection of Overall dimns., Alignment, etc. Visual, 100 % Drawing Inspection V
Measurement report
other structures
3.3 Completeness Paint thk., Identification, etc. Visual, 100 % Drawing Inspection V
Measurement report
Note 1 -Heat treatment requirements :
a) All butt welds must be heat treated when thickness is > 50mm.
b) All welds to a tension member (for all thickness) must be heat treated. Web to flange fillet welds and web stiffener welds are exempt from this requirement.
Tension member must be indicated in the drawing.

SECTION C 5.2
FOR STACKER CUM RECLAIMERS
TCE 5871A-H-563-001B VOLUME-IIA
AT BARA,UP
MINIMUM INSPECTION
REQUIREMENTS FOR STACKER CUM RECLAIMERS
BELT CONVEYORS QP. NO. : QP – A04 – R0 SHEET 1 OF 5
1 2 3 4 5 6 7 8 9
1.0 BELT:
Sheets
1.2 Dimensional Inspection Dimensions Measurement 100% Drawings/Data Sheets Inspection Report V
1.3 Testing for mechanical Tensile strength, elongation, Lab testing, visual 100% Applicable standards, Data TC V
etc.
1.4 Troughability tests Flexibility 100% Applicable standards, Data TC V
Sheets
1.5 Testing of cover properties 100% Applicable standards, Data TC V
Sheets
1.6 Testing for fire resistance Resistance to fire 100% Applicable standards, Data TC V
properties Sheets
2.0 IDLER ASSEMBLY:

2.1 MS tubes, shafts, brackets Mechanical and chemical TC Verification 100% Applicable standards, Data TC V
properties Sheets
2.2 Review of welding documents WPS, PQR, WPQ Review of records 100% ASME Sec.IX Welding Document V
2.3 Brackets Visual, dimensional Visual, 10% Drawings/Data Sheets Inspection Report V
measurement
A. STATUTORY REQUIREMENTS WILL BE COMPLIED WITH BY THE VENDOR.
B. MATERIAL TESTS OF SAMPLES DRAWN BY TCE WILL BE WITNESSED BY TCE.
N C. FOR STAGES WITNESSED / DOCUMENTS REVIEWED BY TCE, COPIES OF RELEVANT DOCUMENTS WILL BE FURNISHED TO TCE.
O D. TCE’S IDENTIFICATION STAMP ON MATERIALS WILL BE PRESERVED / GOT TRANSFERRED BY TCE AT APPROPRIATE STAGES.
E F. COLUMN 6 WILL BE AS PER TCE APPROVED DRAWINGS / DATA SHEETS / SPECIFICATIONS WHEREVER APPLICABLE.
G. INSTRUMENTS FOR LEAK TESTS AND PERFORMANCE TESTS WILL HAVE VALID CALIBRATION CERTIFICATE WITH TRACEABILITY TO NATIONAL LEVEL.
H. LEGENDS : S - SUB - VENDOR, M - MAIN VENDOR, T- TCE, W - WITNESS, V - DOCUMENTS REVIEW, H - HOLD POINT.

AT BARA,UP
MINIMUM INSPECTION
1 2 3 4 5 6 7 8 9
2.4. Final Inspection:
0
2.4. Idler with Bracket:
1
Dimensions & troughing angle Measurement 100% Drawing/data sheet Inspection Report V
Free movement of rollers Movement 10% Drawing/data sheet Inspection Report V

Gap between roller edges Measurement 100% Drawing/data sheet Inspection Report V
Level of rollers Instrument 10% Drawing/data sheet Inspection Report V
Verification of thrust bearing, swivelling of self aligning idlers Verification, 10% Drawing/data sheet Inspection Report V
about the pivot movement
2.4. Idler Rollers:
2
Dimensions, Run out checks Measurement 10% Drawing/data sheet Inspection Report V
Dust ingress test Shop test 10% Drawing/data sheet Inspection Report V
Water ingress test Shop test 10% Drawing/data sheet Inspection Report V
Friction coefficient test Lab test 10% Drawing/data sheet Inspection Report V
Hardness of rubber discs (for impact rollers) Hardness check 10% Drawing/data sheet Inspection Report V
Open inspection of bearings and rollers Visual 10% Drawing/data sheet Inspection Report V
2.4. Pulleys:
3
Material TC review for pulley shell, shaft, hub, end discs, Review 100% Drawing/data sheet Inspection Report V
plummer blocks, bearings etc.
Review of welding documents (WPS, PQR, WPQ) Review 100% Drawing/data sheet Inspection Report V
Visual, dimensional Visual, 10% Drawing/data sheet Inspection Report V
dimensional

AT BARA,UP
MINIMUM INSPECTION
1 2 3 4 5 6 7 8 9
Lagging rubber examination and hardness check Visual, hardness 10% Drawing/data sheet Inspection report V
check
Lagging rubber peel-off test on random samples Peel-off test Random Drawing/data sheet Inspection report V
samples
Verification of bearings Verification 10% Drawing/data sheet Inspection report V
examination of hub and shaft fixing arrangement(locking Visaul 10% Drawing/data sheet Inspection report V
assembly)
3.0 SHAFTS:
Physical & Chemical properties, Surface defects Review of TCs 100% Drawing/data sheet Inspection report W
Soundness check for shaft dia = or > 50dia UT examination 100% AM 203.2 of ASME Sec. UT Report W
VIII Div.2
4.0 BELT SCRAPERS/CLEANERS:
4.1 Raw material for blades Review of 100% Drawing/data sheet Test cetificates V
certificates
4.2 Final inspection of assembly:
Visual, dimensional checks Visaul, 10% Drawing/data sheet Inspection report V

measurement
Movement of blades and elastomount on spindle Movement 10% Drawing/data sheet Inspection report V
5.0 CHUTES & LINERS:
5.1 Material Review of 100% Drawing/data sheet Test cetificates V

certificates
5.2 Review of welding documents (WPS, PQR,WPQ) Review 100% ASME Sec. IX Welding Documents V
5.3 Final inspection:
Visual, dimensional Visaul, 10% Drawing/data sheet Inspection report V

measurement
Examination of welds NDT(PT) 10% ASME Sec. V & Sec VIII PT Report V
Div.I

AT BARA,UP
MINIMUM INSPECTION
6.0 SPEED REDUCERS:
6.1 For speed reducers of capacity >30KW :
i. Checks for gear box and motors as per QP No A04
ii. For oil pumps, coolers, and filters Review of 100% Drawing/data sheet Test certificates V
manufacturer’s
6.2 For speed reducers of capacity equal or <30KW : Refer QP t
A04
7.0 FLEXIBLE COUPLINGS:
Material test certificate, Ultrasonic test report, Dynamic Review of 100% Drawing/data sheet Test certificates V
balancing report, dimensional test report, and Torque test report manufacturer’s
cert
8.0 FLUID COUPLINGS:
8.1 Material Review of 100% Drawing/data sheet Test certificates V

manufacturer’s
8.2 Oil Test Certificate Manufacturer’s standard Test certificates V
8.3 Dynamic Balancing Test Certificate 100% Drawing/data sheet Test certificates V
8.4 Performance test Shop Test 100% Drawing/data sheet Test certificates V
9.0 BUCKET WHEEL
Sheets
9.2 Dimensional Inspection Dimensions Measurement 100% Drawings/Data Sheets Inspection Report V
9.3 Testing for mechanical Tensile strength, elongation, Lab testing, visual 100% Applicable standards, Data TC V
9.4 Bucket wheel drive t TC Verification 100 % Applicable standards, Data TC V
Sheets

AT BARA,UP
MINIMUM INSPECTION
10.0 SLEWING SYSTEM TC Verification 100 % Applicable standards, Data TC V
Sheets
10.1 Hydraulic Drives as per QP A06 (Sl.No. 13)
10.2 Sluw bearings dimensional measurement, material inspection, TC Verification, 100 % Applicable standards, Data TC W
type and routine test (if available) etc. load test Sheets
11.0 LUFFING MECHANISM TC Verification 100 % Applicable standards, Data TC W
Sheets
12.0 STRUCTURES TC Verification 100% Applicable standards, Data TC V

Sheets
13.0 HYDRAULICS (HYDRAULIC MOTOR AND POWER PACKS) TC Verification & 100% Applicable standards, Data TC W
Type test for each Sheets
type
14.0 ELECTRICAL
14.1 Transformers Type & Routine 100% Applicable standards, Data TC * * As per Volume IIIA
test Sheets
14.2 Switchgears Type & Routine 100% Applicable standards, Data TC *
test Sheets
14.3 Cables Type & Routine 100% Applicable standards, Data TC *
test Sheets
14.4 Motors Type & Routine 100% Applicable standards, Data TC *
test Sheets
14.5 Insulation test for cables Type & Routine 100% Applicable standards, Data TC *
test Sheets

SECTION C 5.2
NOTES APPLICABLE TO ALL QUALITY PLANS
OF STACKING AND RECLAIMING SYSTEM EQUIPMENTS
VOLUME-IIA
TCE 5871A-H-563-001B PRAYAGRAJ POWER GENERATION COMPANY LIMITED
AT BARA,UP

A. NOTES APPLICABLE TO ALL QUALITY PLANS:
1. The successful bidder to indicate under column 6 ‘Ref. document/Acceptance Norm’ appropriate wordings like Approved drawing/Data
Sheet/Specification/Approved Procedure against the respective characteristic checked, in the respective Quality Plans.
2. The successful bidder to indicate under column 6 ‘Ref. document/Acceptance Norm’ ‘Approved Inspection and Test Procedure’ against the
respective characteristic checked, in the respective Quality Plans.
3. The successful bidder is required to furnish detailed Field Quality Plans, covering all the quality control activities as applicable to various
site activities commencing from receipt of material, storage till all the equipment are erected and commissioned.
4. The successful bidder is required to furnish specified No. of test certificates/inspection reports/test reports which are offered for
verification/scrutiny during inspection/testing to Client/their representatives for activities marked as V/W/H in the respective Quality Plans.
5. Refer Note ‘G’ of respective Quality Plans – With regard to calibration of instruments used during inspection/testing, it is clarified that the
instruments used during inspection/testing are calibrated with reference to a master testing instrument which in turn should have a
calibration certificate traceable to the master instrument maintained at National Physical Laboratory, New Delhi(India) or such other
accredited International Standard Laboratory.

SECTION C 5.3
LIST OF QUALITY PLANS FOR
MISCELLANEOUS EQUIPMENTS
TCE-5871A- H-563-
001B

QUALITY PLANS
CONTENTS
LIST OF QUALITY PLANS
MISCELLANEOUS EQPT.:
Sl. Number of
QP No. Description
No. sheets
1 D01-R0 CENTRIFUGAL, PORTABLE SUBMERSIBLE 2
PUMPS & SUMP PUMPS
2 D02-R0 STRAINERS AND FILTERS 1
3 D03-R0 BUTTERFLY VALVES 2
4 D04-R0 VALVES AND SPECIALITIES (ANSI RATING 2

300 AND BELOW)
5 D05-R0 CARBON STEEL AND STAINLESS STEEL 2

PIPING (LOW PRESSURE SYSTEM)
6 D06-R0 MINIMUM INSPECTION REQUIREMENTS 1

FOR FANS (AXIAL AND CENTRIFUGAL)
7 D07-R0 MINIMUM INSPECTION REQUIREMENTS 1

FOR FOG JET DS SPRAY NOZZLE AND
PLAIN WATER SPRINKLERS
ISSUE
R0
TCE FORM 329 R3

SECTION C 5.3
MINIMUM INSPECTION REQUIREMENTS FOR
CENTRIFUGAL, PORTABLE SUBMERSIBLE
PUMPS & SUMP PUMPS
PRAYAGRAJ POWER GENERATION COMPANY LIMITED VOLUME - IIA
TCE 5871A-H-563-001B
AT BARA,UP
FOR CENTRIFUGAL, PORTABLE SUBMERSIBLE PUMPS & SUMP PUMPS
QP. NO. : QP - D01 –R0 SHEET 1 OF 2

SR. COMPONENT / OPERATION CHARACTERISTICS TYPE / EXTENT REF. DOCUMENT / FORMAT OF AGENCY REMARKS
1 2 3 4 5 6 7 8 9
1.0 RAW MATERIAL
1.1 Castings Mech. & Chem. properties Review of docs. 100% Material Specification TC V
1.2 Forgings Chem., Mech. properties Review of docs. 100% Material Specification TC V
Soundness UT* 100% AM 203.2 of Sec. VIII Div. 2 UT report V *For dia >50mm
2.0 IN-PROCESS INSPECTION
2.1 NDE on Castings Surface defects for mahined PT 100% ASME Sec. I PT report V
surfaces
2.2 Hydrostatic test of Castings Strength and Leak tightness Visual 100% Approved Drawing Hydroterst report V
2.3 NDE on Impellers Surface defects for mahined PT 100% ASME Sec. I PT report V
surfaces
2.4 Hardness test on Impeller ring Surface defects LPI 100% Manufacturer’s NDT LPI report W
2.5 PT of Shafts Suface defects LPI 100% d
Manufacturer’s NDT LPI report W
procedure
2.6 Runout check of Rotor Runout test Visual 100% Approved drawing Inspection report V
assembly
2.7 Balancing of Impellers Static and Dynamic balancing Balancing 100% ISO 1940/VDI 2060 Gr. 6.3 Balancing reports W Noise level max. 85 dB
at 1m distance
2.8 Type test of motors Review of docs. 100% Approved drawing Type test report V For Motors>30 KW
2.9 Routine test of motors Review of docs. 100% Approved drawing Routine test report V

H. LEGENDS : S - SUB - VENDOR, M - MAIN VENDOR, P- PURCHASER/CONSULTANT W - WITNESS, V – DOCUMENTS REVIEW, H - HOLD POINT.

TCE 5871A-H-563-001B
AT BARA,UP
FOR CENTRIFUGAL, PORTABLE SUBMERSIBLE PUMPS & SUMP PUMPS
QP. NO. : QP - D01 –R0 SHEET 2 OF 2

1 2 3 4 5 6 7 8 9
3.0 FINAL
3.1 Performance test Performance test Visual 100% As per IS 5120 Inspection report W
3.2 NPSH test NPSH test Visual 100% Approved drawing Inspection report W If specified in data
sheets
3.3 Vibration Vibration, noise Vibration, Noise level 100% Approved drawing Inspection report W
3.4 Dimensional Check Visual 100% Approved drawing Dimensional report W
3.5 Strip down test Visual 100% Approved drawing Inspection report W

SECTION C 5.3
FOR STRAINERS & FILTERS
TCE 5871A-H-563-001B
AT BARA,UP
MINIMUM INSPECTION
REQUIREMENTS FOR STRAINERS & FILTERS
QP. NO. : QP - D02 – R0 SHEET 1 OF 1
SR. COMPONENT / OPERATION CHARACTERISTICS TYPE / METHOD EXTEN REF. DOCUMENT / FORMAT OF AGENCY REMARKS
1 2 3 4 5 6 7 8 9
1.0 MATERIALS :
1.1 Raw Materials Chem., Mech. properties, Dimns., Review of docs. 100% Material specification TC V
etc
2.1 Welding Procedure, Personnel qualification Review of docs. 100% AWS D 1.1/ASME Sec. IX WPS, PQR, V
WPQ
2.2 Weld inspection Surface defects Visual 100% AWS D 1.1 Inspection V
report
2.3 NDE of weld joints Surface defects LPI 100% AWS D 1.1/Manufacturer's LPI report V
procedure
3.0 FINAL :
3.1 Body and cover Strength Hydrotest 100 % Drawing Inspection V
report
3.2 Pressure drop test across Pressure drop Measurement 100 % Drawing Inspection V
filter in clean and clogged report
3.3 Mesh Size Measurement 100 % Drawing Inspection V
report
3.4 Performance test at shop Performance parameters Performance check 100 % Drawing, Data sheets Inspection V
report
3.5 Visual & dimensional Overall dimensions Measurement 100 % Drawing Inspection V
inspection report
3.6 Completeness Paint thk., Identification, etc. Visual, 100 % Drawing Inspection V
Measurement report
B. MATERIAL TESTS OF SAMPLES DRAWN BY TCE SHALL BE WITNESSED BY TCE.
H. LEGENDS : S - SUB - VENDOR, M - MAIN VENDOR, P- PURCHASER/CONSULTANT W - WITNESS, V - DOCUMENTS REVIEW, H - HOLD POINT.

SECTION C 5.3
FOR BUTTERFLY VALVES
VOLUME - IIA
AT BARA,UP
MINIMUM INSPECTION
REQUIREMENTS FOR BUTTERFLY VALVES
QP. NO. : QP – D03-R0 SHEET 1 OF 2
1 2 3 4 5 6 7 8 9
1.0 MATERIALS :
1.1 Body & Disc castings Chem., Mech. properties, Review of docs. 100% Material specification TC V
Dimns
Surface defects MPI 100% ASME B 16.34 TC V
1.2 Body, Disc and Flanges Chem., Mech. properties, Review of docs. 100% Material specification TC V
fabricated Dimns.
from plate Soundness UT 100% ASME SA 435 TC V
1.3 Shaft Chem., Mech. properties, Review of docs. 100% Material specification TC V
Dimns.
Soundness (for diameter > 50 UT 100% AM 203.2 of Sec. VIII Div. 2 TC V
mm)
1.4 Hard faced seat surface Visual, dimnl.,review of Visual,dimenl., 100% Drawings,ASME Sec.V, TC W
WPS/PQR doc. review,LPI Sec.IX
2.1 Welding Procedure, Personnel Review of docs. 100% ASME Sec. IX WPS, PQR, V
qualification WPQ
2.2 Weld inspection Surface defects Visual 100% ASME B 16.34 Inspection report V
2.3 PWHT Temp. and time control HT chart review 100% Drawing, Section VIII Div. 1 HT chart V
H. LEGENDS : S - SUB - VENDOR, M - MAIN VENDOR, P- PURCHASER/CONSULTANT, W - WITNESS, V - DOCUMENTS REVIEW, H - HOLD POINT.

VOLUME - IIA
AT BARA,UP
MINIMUM INSPECTION
REQUIREMENTS FOR BUTTERFLY VALVES
1 2 3 4 5 6 7 8 9
2.4 Non-destructive examination :
Butt joints > 32mm thk. Soundness RT 100% ASME B 16.34 RT report V RT Film Review
Fillet joints Surface defects MPI 100% ASME B 16.34 MPI report V
Machined areas of body, disc, Surface defects LPI 100% ASME B 16.34 LPI report V
shaft, etc.
3.0 FINAL :
3.1 Visual and dimensional inspection Overall dimns., Surface cond., etc. Visual, Measurement 100 % Drawing Inspection report H
3.2 Testing Shell test Hydro test 100 % BS 5155 & Drawing Inspection report H
Seat leakage test Hydro test 100 % BS 5155 & Drawing Inspection report H
Seat leakage test Air test 100 % BS 5155 & Drawing Inspection report H
Disc strength test for Hydro test 100 % BS 5155 & Drawing Inspection report H
valves ≥ 14 " (nominal)

Operational check (3 times) Open-Close operation 100 % Drawing Inspection report H
3.3 Actuators Review of certs., operational, Shop tests 100% Drawing Inspection report H
current drawn
3.4 Completeness Paint thk., Identification, etc. Visual, Measurement 100 % Drawing Inspection report V

SECTION C 5.3
VALVES AND SPECIALITIES (RATING ANSI 300 & BELOW)
TCE 5871A-H-563-001B
AT BARA,UP
MINIMUM INSPECTION
REQUIREMENTS FOR VALVES AND SPECIALITIES
1 2 3 4 5 6 7 8 9
1.0 MATERIALS:
1.1 Body, bonnet, ball, plug, stem Chem., Mech. properties, Review of docs. 100% Material specification TC V
Dimns
disc, cover casting/forging
Body, bonnet, disc, cover for Soundness RT 100% ASME B 16.34 RT Report V RT film review
alloy steel valves
Surface examination Surface defects LPI/MPI 100% ASME B 16.34 LPI/MPI Report V
Stem Soundness (for diameter > 50 UT 100% AM 203.2 of Sec. VIII Div. 2 TC V
mm)
1.2 Diapragm/seats Hardness Measurement 10% Drawing Hardness report V
Diapragm Endurance Type test One/type Drawing TC V

2.0 IN-PROCESS INSPECTION:
Welding Procedure, Personnel Review of docs. 100% ASME Sec. IX WPS, PQR, WPQ V
qualification
Body, bonnet, ball, plug, stem Surface defects in machined PT/MPI 100% ASME B 16.34 PT/MPI Report V
disc, cover, seat,trim area
Hardness test on trim Hardness Measurement 10% Drawing Hardness report V


TCE 5871A-H-563-001B
AT BARA,UP
MINIMUM INSPECTION
REQUIREMENTS FOR VALVES AND SPECIALITIES
1 2 3 4 5 6 7 8 9
3.0 FINAL INSPECTION:
3.1 Testing
For all valves Body, seat Hydro test 100 % IS 6157 Inspection report W
For gate and globe valves Seat Air test 100 % IS 6157 Inspection report W
Back Seat Hydro test 100 % IS 6157 Inspection report W
For check valves Low pressure seat leakage test at Hydro test 100 % IS 6157 Inspection report W
25% of seat leakage test pressure

For ball, plug, diaphragm valves Seat Air test 100 % IS 6157 Inspection report W
For steam traps, strainers, filters Body Hydro test 100 % Drawings/data sheets Inspection report W
3.2 For valves & specialities Operational checks Operational checks 100 % Drawings/data sheets Inspection report W
Dimensional, visual Dimensional, visual 100 % Drawings/data sheets Inspection report W
Completeness Visual 100 % Drawings/data sheets Inspection report V

SECTION C 5.3
MINIMUM INSPECTION REQUIREMENTS FOR FOG JET
DS SPRAY NOZZLES AND
PLAIN WATER SPRINKLERS
TCE 58712A-H-563-001B PRAYAGRAJ POWER GENERATION COMPANY LIMITED VOLUME - IIA
AT BARA,UP
MINIMUM INSPECTION
REQUIREMENTS FOR FOG JET DS SPRAY NOZZLE AND PLAIN WATER
SPRINKLERS
QP. NO. : QP – D07– R0 SHEET 1 OF 1
1 2 3 4 5 6 7 8 9
1.0 RAW MATERIAL
1.1 Review of material certificates Physical and chemical Doc. Review 100% Material Specification. TC V
properties
2.0 IN-PROCESS INSPECTION:
2.1 Dimensional inspection Visual, dimensional Visual, 100% Drawing Inspn. Report V
measurement
3.0 FINAL INSPECTION
3.1 Performance check Performance Shop test 100% Drawing/data sheet Inspn. Report V

H. LEGENDS : S - SUB - VENDOR, M - MAIN VENDOR, P- PURCHASER/CONSULTANT, W - WITNESS, V - DOCUMENTS REVIEW, H - HOLD POINT.

SECTION C 5.3
CARBON STEEL AND STAINLESS STEEL PIPING
(LOW PRESSURE SYSTEM)
TCE 5871A-H-563-001B
AT BARA,UP
MINIMUM INSPECTION
REQUIREMENTS FOR CARBON STEEL AND STAINLESS STEEL PIPING
SR. COMPONENT / OPERATION CHARACTERISTICS TYPE / EXTENT REF. DOCUMENT / FORMAT OF AGENCY REMARKS
1 2 3 4 5 6 7 8 9
1.0 MATERIALS :
1.1 Seamless steel pipes and tubes Chem., Mech. properties, Dimns. Review of docs. 100% Material specification TC V
Hydrostatic test Review of docs. 100% SA 530/SA 450 TC V
1.2 Forgings Chem., Mech. properties, Dimns. Review of docs. 100% Material specification TC V
1.3 Fittings Chem., Mech. properties, Dimns. Review of docs. 100% Material specification TC V
1.4 Ferritic alloy steel forgings and fittings Surface defects MPI 100% ASME B 31.1 MPI report V
2.1 Welding Procedure, Personnel qualification Review of docs. 100% ASME Sec. IX WPS, PQR, V
WPQ
2.2 Weld inspection Surface defects Visual 100% ASME B 31.1 Inspection report V
2.3 NDE before PWHT (Not applicable for
Cooling water line, Instrument air,
Service air and Miscellaneous water
a) Butt joint (Dia > 100NB) Soundness RT 100% ASME B 31.1 RT report V RT Film Review
b) Butt joint (Dia ≤ 100NB) Soundness RT 10% ASME B 31.1 RT report V RT Film Review

B. MATERIAL TESTS OF SAMPLES DRAWN BY TCE SHALL BE WITNESSED BY TCE.

TCE 5871A-H-563-001B
AT BARA,UP
MINIMUM INSPECTION
REQUIREMENTS FOR CARBON STEEL AND STAINLESS STEEL PIPING
1 2 3 4 5 6 7 8 9
2.4 PWHT Temp. and time control HT chart review 100% ASME B 31.1 HT chart V
2.5 NDE after PWHT (butt joints, Surface defects MPI/LPI CS - 10% ASME B 31.1 MPI/LPI report W CS - Carbon
steel
nozzles, stubs and attachment AS - 100% AS - Alloy steel
welds) SS - 100% SS - Stainless
steel
2.6 NDE (Applicable for Cooling water line,
Instrument air, Service air and
Miscellaneous water lines)
a) Butt joints in pipes, mitre bends and Soundness RT 10% ASME B 31.1 RT report V RT Film Review
in
plate formed pipes > 100 NB
b) All other weld joints Surface defects LPI 10% ASME B 31.1 LPI report V
3.0 FINAL :
3.1 Visual and dimensional inspection Weld defects, Length, Location Visual, 100 % Drawing Inspection report V
Measurement
of stubs, Cleanliness, etc.
3.2 Completeness Paint thk., Identification, etc. Visual, 100 % Drawing Inspection report V
Measurement

VOLUME-IIA
AT BARA,UP
A. NOTES APPLICABLE TO ALL QUALITY PLANS:
1. The successful bidder to indicate under column 6 ‘Ref. document/Acceptance Norm’ appropriate wordings like Approved drawing/Data
Sheet/Specification/Approved Procedure against the respective characteristic checked, in the respective Quality Plans.
2. The successful bidder to indicate under column 6 ‘Ref. document/Acceptance Norm’ ‘Approved Inspection and Test Procedure’ against the
respective characteristic checked, in the respective Quality Plans.
3. The successful bidder is required to furnish detailed Field Quality Plans, covering all the quality control activities as applicable to various
site activities commencing from receipt of material, storage till all the equipment are erected and commissioned.
4. The successful bidder is required to furnish specified No. of test certificates/inspection reports/test reports which are offered for
verification/scrutiny during inspection/testing to Client/their representatives for activities marked as V/W/H in the respective Quality Plans.
5. Refer Note ‘G’ of respective Quality Plans – With regard to calibration of instruments used during inspection/testing, it is clarified that the
instruments used during inspection/testing are calibrated with reference to a master testing instrument which in turn should have a
calibration certificate traceable to the master instrument maintained at National Physical Laboratory, New Delhi (India) or such other
accredited International Standard Laboratory.

SECTION C 5.4
INSPECTION AND TESTING PROCEDURES
PRAYAGRAJ POWER GENERATION COMPANY SECTION: C5.4
TCE 5871A-H-563- LIMITED
001B SHEET 1 OF 9
AT BARA,UP
TITLE
5.0 INSPECTION AND TESTING
5.1 GENERAL
5.1.1 All equipment covered under this specification shall be subject to

inspection and test by the purchaser’s authorized representative/
consultant during manufacture, erection and commissioning. The
approval of the purchaser or passing of such inspection or test will not,
however, prejudice the right of purchaser to reject the equipment if it
does not comply with the specifications when erected or does not give
complete satisfaction in service. The cost of all such tests shall be
borne by the supplier.
5.1.2 During manufacture, the Purchaser/Engineer shall have the right to

expedite and/or inspect the design, materials, workmanship and the
progress of manufacture of the Supplier and his sub-supplier’s and
may reject any defective materials considered unsuitable for the
intended purpose or which does not comply with the intent of this
specification. The Supplier, upon any such rejection by the
Purchaser/Engineer, shall rectify or replace the defective unsuitable
material. The Supplier shall provide every reasonable inspection facility
to the Purchaser/Engineer at his own and his sub-supplier’s works.
5.1.3 The supplier shall conduct all tests required to ensure that the
equipment furnished shall confirm to the requirements of this
specification and in compliance with the requirements of the applicable
codes. The particulars of the proposed tests and the procedures for the
tests shall be submitted to Purchaser/Engineer for approval before
conducting the tests.
5.1.4 The Supplier shall give twenty one (21) days notice for indigenous
equipment and notice for imported equipment of readiness for
inspection of component parts and/or before final assembly and tests,
so that the Purchaser/Engineer may inspect the materials and witness
such tests before shipment. The Purchaser/Engineer may, at any time,
inspect and request copies of any or all test data, which shall be
immediately furnished.
5.1.5 Material being furnished against this order shall only be shipped when
factory inspection satisfactory to the Purchaser/Engineer has been
conducted. Such inspection and acceptance for shipment shall not,
however relieve the seller from entire responsibility for furnishing
equipment conforming to the requirement of this specification nor shall
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it prejudice any claim, right or privilege which the Purchaser/Engineer

may have, because of the use of supply of defective or unsatisfactory
materials or equipment. Should the inspection be waived by the
Purchaser, such waiver shall not also relieve the seller, in any way,
from his entire obligations under this order.
5.1.6 In all cases where the contract provides for tests whether at the
premises or works of the supplier or any sub-supplier, the Supplier,
except where otherwise specified shall provide free of charge such
items as labour, materials, electricity, fuel, water, stores, apparatus and
instruments as may be reasonably demanded by the
Purchaser/Engineer or his authorised representatives to carry out
effectively such tests on the equipment and shall give facilities to the
Purchaser/Inspector or to his authorised representative to accomplish
testing.
5.1.7 The inspection by Purchaser/Engineer and issue of Inspection

Certificate thereon shall in no way limit the liabilities and responsibilities
of the Supplier in respect of the agreed quality assurance programme
forming a part of the contract.
5.1.8 To facilitate advance planning of inspection in addition to giving

inspection notice as per Clause 5.1.5, the Supplier shall furnish
quarterly inspection programme for shop testing indicating schedule
dates of inspection at hold point and final inspection stages. Updated
quarterly inspection plans will be made for each three consecutive
months and shall be furnished before beginning of each calendar
month.
5.2 SHOP TESTS
5.2.1 During the manufacture of all equipment including compressors, and

other equipment, manufacturer’s standard tests shall be performed and
requisite number of copies of test certificates shall be furnished.
5.2.2 All materials and castings used for equipment shall be of tested quality.
The test certificates shall be made available to the Purchaser/Engineer.
Hardness tests, Magnetic Particle tests shall be carried out for all
component materials.
5.2.3 Tests at shop will include but not limited to the following:
a) Material tests of principal items
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b) Hydrostatic testing of casings, pipes, valves, etc.

c) Mechanical balance tests of pumps, blowers and determination
of vibration levels
d) Calibration tests of all instruments and control equipment

e) Routine tests on all electric motors and other electrical
equipment and accessories.
f) Pumps/blowers/compressors shall be given full speed cold water

running test or other tests as applicable and indicated over full
operating range at Manufacturer’s works,
•  Noise and vibration free operation

• Head, capacity characteristics
• Efficiency of pump and HP characteristics
• Temperature rise of various parts
g) The test performance curves showing head, efficiency and

power requirement at various capacities shall be supplied by
Supplier for approval of Purchaser/Engineer.
5.2.4 Shop tests for other equipment like valves, specialties, instruments etc.
shall be conducted and shop test results/certificates shall be furnished
to the Purchaser/Engineer for approval prior to their dispatch. The
Purchaser/Engineer, if he so desired, shall have the right for inspection
of these equipment during test or otherwise.
5.3 TEST REPORTS
5.3.1 Test reports of standard factory tests carried out on each equipment
shall furnish the following information:
i) Complete identification data including serial number

ii) Method of application and duration of test
iii) Results of tests conducted.
5.4 SITE TEST
5.4.1 The requirements for the site test as required for all the
equipment/component specified elsewhere in the specification shall be
performed by the supplier to make his system complete in all respect.
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5.4.2 The supplier shall carry out site test as stipulated. This shall also
include assembly, alignment, positioning of equipment, foundation
preparation, welding, bolting, heat treatment, non-destructive
examination painting, hydraulic test, air tightness test etc. The
conveyor pulleys, rollers etc are to be erected on theodelite marked
line. This will be subject to Purchaser/Engineer inspection. All such
inspection, site erection / Installation reports shall be furnished to
Purchaser/Engineer when called for
5.4.3 The various components of the system shall be tested as detailed

herein or specified elsewhere in the specification according to the
applicable codes and standards for meeting the performance
requirements. All tests shall be carried out in presence of the
Purchaser/Engineer.
i) Determination of capacity, efficiency, power and characteristic

curves of all pumps, blowers, compressors and drives.
ii) Hydraulic test shall be carried on air receivers, pipes, valves,

fittings, bends, elbows, etc. at twice the normal operating pressure
or 1.5 times the design pressure of compressed air/ pipeline which
ever is higher. The procedure and duration of test shall be as per
applicable standards
iii) Tests on all electrical equipment including motors shall be as per

details given in the electrical part of this technical specification.
iv) All instruments shall be tested as per the relevant sections of

applicable codes, which they confirm to. The test certificates,
along with the details of tests performed and results obtained,
shall be submitted to the Purchaser/Engineer for his approval.
v) Tests as per relevant standards and applicable codes including

calibration tests of standard orifices, nozzles, pressure and
temperature switches and other instruments, as applicable.
vi) Load test on electric under slung and hoists.
5.4.4 The following minimum site performance tests and checks and other
parameters specified elsewhere in the specification, shall be done at
site to verify the guarantees given by the Bidder:
(i) Proper operations of each item of equipment

(ii) Guaranteed energy consumption
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(iii)
Noise generation of each equipment
(iv)Any other guarantee/ demonstration test specified
elsewhere in the specification
5.4.5 The duration of each test, under specified operating conditions shall be
such as to make it possible to obtain not less than three (3) periods of
simultaneous check readings for which the results shall be computed
separately. Test results shall not differ from the individual test results
for any one of the three (3) periods by more than one (1) percent.
5.4.6 Any deficiency noticed during such tests shall be rectified by the
supplier at his own cost, within two (2) months from the date of
notification or within a reasonable period agreed by the
Purchaser/Engineer. Even after attending such equipments, if he does
not achieve the rated capacity, then such equipment shall be replaced
by the bidder of correct sizing with the consent of Purchaser/Engineer.
However, Purchaser reserves the right to use the deficiently performing
equipment to avoid shutting down of units until the replacement is
made by the Supplier.
5.5 SYSTEM CHECKING / RELIABILITY TRIALS
5.5.1 Supplier shall carry out tests at site to prove to the Purchaser/Engineer
that each equipment of the plant complies with requirements stipulated
and is erected in accordance with requirements. Before the plant is put
into trial operation, the Contractor shall be required to conduct tests to
demonstrate to the Purchaser/Engineer that each item of the plant is
capable of correctly performing the functions for which it was specified.
These tests may be conducted concurrently with those required under
commissioning sequence.
5.5.2 All equipment shall, after installation, be demonstrated capable of

performing satisfactorily up to the Supplier’s guaranteed performance.
All tests required by this specification including re-tests and inspection,
that may be necessary owing to the failure to meet any tests specified,
shall be made at the Supplier expense. In case any of the above
ultimately fail to pass the specified tests, the Purchaser/Engineer will
have the option to reject those equipment/components. The supplier
shall then replace the defective equipment in such a way that the
requirement of the Purchaser/Engineer is not adversely affected. Tests
of systems guaranteed capacities shall be conducted as per the
Performance Guarantee Schedule.
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5.5.3 All equipment shall be visually inspected and checked for dimensional
tolerance to match with the Purchaser/Engineer approved drawings/
data.
5.5.4 The tests required shall specifically include the following;
Hydrostatic tests shall be carried out on all pipelines at a pressure of

1.5 times the corresponding pumps design pressure.
Checks on the operation of all controls of isolating and regulation

valves.
Checks on operation of all heaters.
Calibration tests of instruments and control equipments to the extent,

included in this specification.
5.6 PIPE LINE TESTING
5.6.1 The pipeline or section thereof under testing shall be slowly filled and
test pressure measured at the lowest point of elevation, shall be
applied by means of pump. The duration of each test shall not be less
than two hours and shall be as per relevant standards. During the test
period maximum of 1% pressure drop is allowed in case of pneumatic
test for airlines and gas lines after temperature corrections.
5.6.2 While line is under pressure all visible leaks shall be prevented by
tightening wherever possible. Other type of defective joints shall be cut
and replaced. Any cracked or defective pipe, fitting valve etc. shall be
removed and replaced by the Supplier with sound material. The tests
shall be repeated until the results are satisfactory.
5.6.3 The supplier shall arrange pumps, blanks, connections, test gauges
and all other equipments necessary for pressure testing. The Supplier
of portable compressors shall arrange compressed air. The Supplier
shall arrange and dismantle all temporary lines to the system under
test.
5.7 WELDING
5.7.1 Welding shall be carried out as per relevant international code in view of
withdrawal of Indian standard IS: 823 up till in vogue.
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5.7.2 The Supplier shall ensure the following requirement in welding joints.
a) Strength- equality with parent metal.

b) Absence of defects
c) Corrosion resistance of the weld shall not be less than that of the
parent metal in aggressive environment.
d) Method of quality control in welded joints
5.7.3 Welding procedures shall be prepared in line with IS 7307 (Part-I) -

1974, reaffirmed in 2002 and tests shall be carried out to quality
procedures will depend on variables like position of welding, thickness
range etc. Once welding procedures is finalised, strict adherence to it
shall be made during actual welding.
5.7.4 Welders employed shall be qualified as per IS 7310 (Part-I) –1974,

reaffirmed in 2000 after passing necessary tests.
5.7.5 Welding consumables shall be of approved type. Such consumables

are, however, subject to qualifying.
5.7.6 Initial check tests as per IS 814-1991 reaffirmed in 2002. The Supplier
shall strictly follow approved welding procedures during actual welding.
5.7.7 Weld edge preparation before welding, proper fit up, position of
welding, cleaning of slag between the passes, proper weld profile etc.,
shall be checked visually, amongst others.
5.7.8 Non-destructive tests of weld of welded joints shall be carried out as

per approved procedures/ drawings.
5.7.9 Radiographic test shall be carried out for l welded joints as per relevant
Quality Plan standards IS/ASTM codes or equivalent. Defective welds
shall be repaired by removing the defective piece of pipe. No weld
leaks shall be repaired by mechanical caulking.
5.8 TESTS ON WELDED JOINTS
5.8.1 Visual examination.
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The supplier shall conduct visual examination and measurement of

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 of
not less than 20 mm shall be cleared of slag and other impurities.
Examination shall be done by a magnifying lass, which has a
magnification power of ten (10), and measuring instruments hat have
accuracy of +0.1mm or by weld gauges. Welded joints shall be
examined from both sides. The Supplier shall examine the following
during visual examinations: -
i) Check the correctness of shape and size of the welded joints.

ii) Incomplete penetration of weld metal.
iii) Influx
iv) Burns
v) Under cuts
vi) Unwelded crates
vii) Cracks in welded spots and heat affected zones
viii) Porosity in welds and spot welds
ix) Compression in welded joints as a result of electrode impact
while carrying out contact welding
x) Displacement of welded element.
The supplier shall carry out any or all test as specified hereinafter to
satisfy the Purchaser/Engineer about the acceptability of the welded
joints, as directed by the Purchaser/Engineer.
5.8.2 Liquid Dye-penetrant Test.
Liquid dye-penetrant tests shall be carried out in accordance with IS:

3658-1981, reaffirmed in 2000 for surface/sub-surface defects where
ever required.
5.8.3 Test by Blowing
The surface of the weld shall be covered with soap solution consisting
of one (1) litre of water and hundred (100) grams of soap. Compressed
air shall be blown from the opposite side at pressure of 4 to 5 kg/cm.
Sq. The distance between the tip of base and the weld shall not be
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more than 50 mm. Any formation of soap bubble will indicate welding
defects.
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SECTION C 5.5
SHOP PERFORMANCE TEST PROCEDURE
FOR DUST SUPPRESSION & OTHER PUMPS
TCE 5871A-H-563- LIMITED SHEET 1 OF 4
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SHOP PERFORMANCE TEST PROCEDURE FOR

DUST SUPPRESSION & OTHER PUMPS
1.0 INTRODUCTION
The pump will be tested at motor speed and will be driven with the
job/lab motor and the readings will be converted to rated speed.
The procedure described is to be employed for testing the pump

individually without reference to final installation conditions.
2.0 PURPOSE OF THE TEST
2.1 The performance test will be conducted for deciding head, discharge,
pump input, efficiency of the pump and for noise level and vibrations
level of pump and motor.
2.2 Range of performance test :
2.2.1 Readings of head, power, discharge will be taken at seven points, ie.
One point as near as possible to rated capacity and head, two points
above and three points below rated and one point at shut off ensuring
that drive motor does not get over loaded.
2.2.2 Job/Lab motor will be employed to drive the pump
2.2.3 The liquid used for testing will be water at ambient temperature.
3.0 TESTING APPARATUS
Calibration certificates for measuring instruments and equipments like

watt meters, ammeters, voltmeter, tachometer, pressure gauge and
flow measuring devices shall be furnished at the time of test, along
with the test report and performance curve.
3.1 Speed of test
The actual speed of rotation shall be as obtained at the prevailing

voltage, frequency and load. Actual speed obtained shall be
measured at each test condition.
3.2 The test condition shall be obtained by throttling a valve fitted in the
delivery pipe.
3.3 Testing arrangement shall be done as per standard IS 5130 or other

International standards. Schematic sketch of testing arrangement
shall be furnished by MPC during detailed engineering phase for
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review and approval of Purchaser/Engineer.
4.0 PROCEDURE FOR MEASUREMENT OF DISCHARGE, HEAD,

POWER INPUT AND SPEED OF ROTATION
4.1 Discharge measurement
The discharge shall be measured by means of V-notch/rectangular

weir/flow meter.
4.2 Head Measurement
Delivery head shall be measured by Bourdon type calibrated pressure

gauge. The pressure gauge shall be fitted on delivery pipe. Suction
lift shall be measured by mercury manometer which shall be fitted on
suction pipe.
4.3 Measurement of power input
The power input will be determined from measurement of the

electrical power input to the drive motor of known efficiency coupled
with pump. The electrical power input to the motor shall be measured
by two wattmeter method. Motor output shall be computed by using
motor efficiency figures given by the motor manufacturer.
4.4 Measurement of Speed
The speed shall be measured by an electronic digital tachometer

having an accuracy of (±) 1 rpm.
4.5 Measurement of Noise Level and Vibration Level
During shop testing noise level and vibrations level shall be recorded
for reference purpose. During shop testing, values of noise and
vibrations level may be higher as testing of pump motor set is carried
on flimsy foundation and suction/delivery piping are unsupported.
However, Lignite handling system supplier shall guarantee values of
noise level and vibrations level at site as per HIS (Hydraulic Institute
Standard) or other International standards.
5.0 ANALYSIS OF TESTS
Test data obtained at the speed of rotation shall be translated to the

rated speed of rotation by using the following formulae
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Nsp
Discharge Qsp = Q x
N
a
(Nsp ) 2
Head Hsp = H x
(N ) 2
a
(Nsp ) 3
Power Nsp = H x
(N ) 3
a
Efficiency fsp = fa
Where, suffix sp implies specified
Q = Discharge in lit/sec
H = Total head in meters
N = Pump input in kW
Nsp = Specified speed
Na = Actual speed
fa = Efficiency obtained at actual speed
fsp = Efficiency for specified speed
6.0 ACCEPTANCE STANDARD FOR DUTY POINT PERFORMANCE
6.1 IS : 9137 : Method of guarantee verification
Discharge - + 7.0%
Head - + 4.0%
Efficiency - without negative tolerance
Power - Depends upon above tolerances
6.2 Only duty point shall be guaranteed as per above specified testing
standard. Other points will be recorded for plotting performance curve.
6.3 Approximate duration of testing is one hour.
7.0 INSTRUMENTS EMPLOYED AND ACCURACY OF

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MEASUREMENT
QUANTIT INSTRUMENT/ EQUIPMENT OVERALL

Y ACCURACY
(WITHIN)
Discharge Rectangular weir/ V-notch/ flow + 1.5 %
meter
Head Bourdon type pressure gauge + 0.5 %
Power Watt meters + 0.5 % of full scale
value
Speed Tachometer + 5 rpm
8.0 TOTAL HEAD CALCULATIONS
Total head (H) = Delivery gauge reading (Hd) + suction gauge reading
+ gauge correction (α) + Velocity head
(V − Vs )
2 2
Correction = d
(2xg)
8.1 Pump Efficiency calculations
8.1.1 Motor input in kW = (summation of wattmeter reading) x (wattmeter

constant)
8.1.2 Motor output kW = (motor input) x (motor efficiency)
8.1.3 Pump input kW = motor output in kW
8.1.4 Pump output in kW =
Total head (H) in meters x discharge in l/s (Q)

------------------------------------------------------
102
Pump output x 100

8.1.5 Pump efficiency (%) = -------------------------
Pump input
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PORTABLE SUBMERSIBLE SUMP PUMPS
1.0 INTRODUCTION
This procedure is applicable to witness performance testing of vertical

sump pumps.
The procedure described shall be employed for testing of the pump

individually without reference to final installation conditions.
2.0 PURPOSE OF THE TEST
The performance test shall be conducted for verifying rated head,

discharge, power absorbed and efficiency of the pump at specified
speed of the pump and to ensure its smooth running.
3.0 TEST PROCEDURE
3.1 The pump shall be tested on water at ambient temperature
3.2 The pump shall be coupled with job / job motor during performance test
3.3 The performance test shall be carried out as per IS : 5120
3.4 Prior to initiation of the test the pump shall run for atleast one hour to
attain steady state condition
3.5 The total number of readings shall be minimum five in addition to shut
off, covering the operating range of the pump as follows.
3.6 The test condition shall be obtained by throttling a gate valve in the
delivery pipe
3.7 Measurements Of Various Parameters :
3.7.1 Discharge Measurement
The discharge shall be measured 90 degree V notch. Design and

fabrication of the V notch shall be in accordance to IS 5120. Recent
calibration curve for notch shall be made available during the test and
shall be made part of document.
3.7.2 Head Measurement
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(a) Discharge pressure shall be measured by Bourdon type

pressure gauge with a least count of 0.02 Kg/cm² (0.2 meter)
shall be readable directly from the dial range.
(b) The gauge shall be calibrated prior to or after the test.
3.7.3 Measurement of Power Input
The power input to electric motor shall be measured by two wattmeter

method. Motor output shall be computed by using graph of motor
efficiency based on performance figures given by the motor
manufacturer. The electrical power measurements shall be done with
the help of following instruments:
Wattmeter accuracy ± 0.5% of full scale value
Voltage by voltmeter ± 0.5% of full scale value
Ammeter ± 0.5% of full scale value
Measuring tolerance for the total power input shall not exceed ± 1% of
the rated value.
3.7.4 Speed Measurement
The speed shall be measured by an electronic digital tachometer

having accuracy ±1 rpm.
3.8 Computation of Test Results
3.8.1 Total head = For calculating total head following formulae shall
be used
⎛ ⎞ 2
Total head (H) = (Hd +a + Hf ) + ⎜⎜ V⎟
⎟
d
2
⎝ g ⎠
Where,
Hd = Pressure gauge reading (in meters of water column)

on discharge side
a = Static level difference between water level in the

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sump and centerline of the pressure gauge (in

meters)
Hf = Frictional loss in the pipe in between pump casing and

the location where pressure gauge is connected (in
meters)
( Vd ) 2 = Discharge velocity head correction (in meters)

2g
3.8.2 Motor input in kW = (summation of wattmeter reading) x

(wattmeter constant)
3.8.3 Motor output in kW = Motor efficiency x Motor input in kW.

Motor output is pump input as motor is
directly connected to pump
3.8.4 Pump output in kW = Total head (in meters) x Discharge (litres

per second) x Sp. Gravity
102
3.8.5 Pump efficiency = ⎛ Pump output ⎞

⎜⎜ ⎟⎟ x 100
⎝ Pump input ⎠
3.8.6 Test data obtained at the actual speed of rotation shall be converted to
the rated speed of rotation by using following formulae :
QSP = Q x (NSP / N)
HSP = H x (NSP / N)2
PSP = P x (NSP / N)3
nsp = n
Where,
Suffix “sp” indicates rated condition
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Q = Discharge in liters per second
H = Total head in meters
P = Pump input in kW
N = Speed in rpm
h = Pump efficiency
NOTE : Total head and efficiency is with respect to pump casing
Tolerance on guaranteed performance data condition shall be as

follows :
a) Discharge : A tolerance of ± 2.5% shall be permissible on the

discharge
b) Efficiency – Without negative tolerance
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SECTION C 5.7
PROCEDURE FOR PERFORMANCE
TESTING OF STACKING AND RECLAIMING SYSTEM
TCE 5871A-H-563- VOLUME – IIA
001B LIMITED
SECTION: C5.7
PROCEDURE FOR PERFORMANCE TESTING

OF STACKER RECLAIMER SYSTEM
1.0 PROCEDURE FOR PERFORMANCE TESTING
1.1 Reference Documents
1.1.1 Specification for the Stacker reclaimer works with final approved
documents and guarantee requirements specified in each
equipment data sheet and write ups.
1.1.2 Purchaser’s Purchase order.
1.1.3 Proformas for P.G test of equipment given in this document.
1.2 General Instruction
1.2.1 After the Stacker reclaimer system is erected, successfully

commissioned trial run and completed in all respects, the system
shall be tested at the earliest possible, to prove the performance of
the system equipment in regard to the specified guarantee
requirements.
1.2.2 The parameters to be guaranteed for different equipment / system

are furnished in Section-C9 of this specification.
1.2.3 The guarantee requirements shall be met without undue vibrations

in the stacker reclaimer machines, conveyor supports and drive
houses.etc.
1.2.4 In the event of non-fulfilment of any of the guarantee requirements,

the Vendor shall at his own cost replace/rectify the concerned
equipment / system to improve the performance to the level of the
guaranteed performance.
1.2.5 Non ferrite metal pieces and large size boulders in the Coal cannot
be controlled by the Purchaser/Engineer.
1.2.6 The SUPPLIER may check the Stacker reclaimer system

equipment during the normal operation of the system before PG
test for mock trial purpose.
1.2.7 No Purchaser/Engineer personnel shall be employed by the

SUPPLIER for cleaning the floors / galleries during PG test period.
1.2.8 Trial Operation as specified shall be conducted by the SUPPLIER

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for the specified period. The Trial Operation shall be conducted at
specified load. Refer clause 2.0 of section C9.
1.3 Responsibilities / Facilities by the Purchaser
1.3.1 Coal supply to the yard conveyors during stacking mode.
1.3.2 Power supply with voltage and frequency as stipulated in the

contract.
1.3.3 Normal operating and maintenance staff.
1.3.4 Supply of water as stipulated in the contract.
1.4 Responsibilities / Facilities by the Supplier
1.4.1 All necessary instruments / equipment / gadgets including walkie-

talkies for carrying out performance testing of Stacker reclaimer
system equipment at site shall be provided by the SUPPLIER on
loan basis. All measuring instruments shall be recently calibrated
with calibration certificates.
1.4.2 Belt weigher shall be calibrated before commencement of PG test.
1.4.3 Adequate number of personnel for starting the system and for
taking readings.
1.5 Responsibilities / Facilities Jointly by Supplier and the

Purchaser
1.5.1 Prior to the date fixed for conducting PG test, the SUPPLIER shall
check the operation of all the equipment.
1.5.2 Controls / Sequential interlocks shall be tested on no load prior to

commencement of load tests.
1.5.3 All protection relays / fuses for protection of the electrical equipment
should be properly set and malfunction, if any should be set right
one week before the date fixed for conducting PG test.
1.6 Procedures to be Followed
1.6.1 For conducting PG tests the following procedure shall be followed:

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The Purchaser/Engineer and the SUPPLIER shall ensure and verify
that all the pre-requisites for starting the performance guarantee
tests are taken care of as per details given in this section.
1.6.2 Each Stacker reclaimer stream in the Coal handling system shall be
tested separately and recorded as per clause 1.6.3. During stacking
/ reclaiming Stockyard dust suppression system shall also be
working.
1.6.3 For the performance test, each stacker reclaimer stream shall be
running for a period of 12 hours. The testing in any particular
stream on load for 12 hours may be spread over a maximum of four
(4) days period. During this period the parameters of the plant may
be tabulated, checked and recorded on applicable proformas
attached herewith. The proposed period for guarantee performance
of the equipment at the rated capacity is for an aggregate period of
12 hours. Discontinuity of the running of the system will be allowed
for the following reasons only.
a) Power failure from control and switchgear panel.
b) Application of pull cord switch for removal of material or for

any other specific purpose.
c) Daily maintenance period required as per operation manual.
d) Filling capacity limitations in the bunker.

e) Inadequate supply of coal from the mines.
f) Breakdown in any of the conveyors other than yard conveyors.
All other failures shall be considered as breakdowns due to system
/ equipment fault.
1.6.4 The 12 hours run on load shall be provided within the maximum of
4 days in case there are no trips due to equipment fault. However, if
the trip of any equipment in the selected stream is due to stacker
reclamer system equipment fault, the complete 12 hour load test
shall be repeated. All efforts are to be put by the SUPPLIER to
complete PG tests within 15 days, provided there are no equipment
faults, except for unforeseen reasons in which case the above
period shall be extended to 30 days.
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1.6.5 Final test results shall be recorded in proformas as applicable and
jointly signed by representatives of Purchaser/Engineer,
SUPPLIER. The final results shall be supported by the detailed
observation sheets recording the details of interruptions,
adjustments made, time of starting and finishing of test, readings of
belt weigher, vibration, energy meter, etc. as applicable.
1.6.6 For determining the quantity of coal being stacked or reclaimed,

readings of belt weighers on the boom conveyors will be
considered.
1.6.7 Regular readings of Coal flow by belt weigher shall be taken during
PG Test after stable conditions. The best patches that rated to
2600TPH will be considered for PG Test evaluation subject to
approval of Purchaser/Engineer. Stable conditions will be
considered as near rated operation conditions within (±) 10% range.
1.6.8 Even if Dust suppression fails during the test period, the system
shall be considered as tripped and the test shall be conducted only
after restarting the Dust suppression.
1.6.9 If abnormal noise and vibrations are observed during the test, the
equipment will be allowed to run only on advice from
Purchaser/Engineer.
1.6.10 Performance of the stacker reclaimer system at all the specified

paths shall be checked.
1.6.11 The dust suppression system shall be set for achieving the
guaranteed dust concentration level.
1.6.12 Sequential interlocks and protection shall be checked on no load as

well as on load.
1.6.13 Illumination levels of various areas shall be checked.
ISSUE
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001B LIMITED
SECTION: C5.7

PROFORMA NO.1
PLANT STOPPAGE RECORD
: Remarks
1.0 Date & time of starting of the test :
2.0 Path being tested :
3.0 Date & time of trip
4.0 Designation of equipment responsible :

for plant stoppage
5.0 Reason for equipment trip / stop prior :

to completion of test
6.0 Date & time of restarting the plant :
7.0 Plant stoppage shall be considered as : Yes / No

equipment / system fault
8.0 Breakdown time for this plant stoppage : Hrs.

(item 6.0 – item 3.0)
9.0 Date and time of stopping the test. :
10.0 Time period of operation of the system :

(item 9.0 – item 1.0)
11.0 Cumulative time period of operation : Hrs.

during the test considering earlier time
period operated
Signature :
For Purchaser For SUPPLIER For Engineer
ISSUE
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001B LIMITED
SECTION: C5.7

PROFORMA NO.2
CONTROL & SEQUENTIAL INTERLOCKS
2.0 Date and time of completion of test :
3.0 Observations :
Control / sequential interlocks are : Working Not working

checked on no load and found satisfactorily satisfactorily
If found not working satisfactorily list :

the defects observed
Signature :
For PURCHASER For SUPPLIER For ENGINEER
ISSUE
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001B LIMITED
SECTION: C5.7

PROFORMA NO.3
CONDITION OF CHUTE & CHUTE CONNECTIONS
1.0 Location
4.0 Observations on Chutes :
Sl. Transfer Point Whether liner fixing is Remarks Dust Leakage

No. satisfactory?
(Indicate the transfer Coal Coal Coal Medium Heavy

point detail in each not sticking sticking
case) sticking negligible choking
chute
i. Transfer chute from to
ii. Transfer chute from to
iii. Transfer chute from to
Signature :
ISSUE
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001B LIMITED
SECTION: C5.7

PROFORMA NO.4
ELECTRICAL PARAMETERS TO BE RECORDED DURING
PERFORMANCE TEST
3.0 Equipment :
4.0 Location
5.0 kW rating of motor :
6.0 Torque :
7.0 Oil consumption :
8.0 Guaranteed power consumption kW :
9.0 Measurements :
Sl. Voltage in Volts Current Power Power Output Oil torque

No. in Amps Factor consumptio torque consumption in
P.F n in kW Kg.m. liters / min.
Note : The above readings shall be recorded for no load and full load run.
10.0 Any other remarks :
Signature :
ISSUE
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001B LIMITED
SECTION: C5.7

PROFORMA NO.5
COAL FLOW MEASUREMENT DURING PERFORMANCE TEST
1.0 Path :
2.0 Plant started date & time :
3.0 Plant stopped date & time :
4.0 Material started flowing over belt :

weigher, time
5.0 Observations :
Sl. Reading of counter Percentage

No.
Note : Readings shall be taken at interval of every five minutes.
6.0 Average flow rate recorded (computed :

from above observation)
7.0 Total time of plant run :
8.0 Any other remarks :
Signature :
ISSUE
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001B LIMITED
SECTION: C5.7

PROFORMA NO.6
VIBRATION & NOISE MEASUREMENT AT DRIVE HOUSES AND JTS
1.0 Designation :
2.0 Date and time of measurement :
3.0 Measurement :
Sl. Designation Floor Vibration & Noise Vibration at Remarks

No. level level at two each column
random locations
JNT No.
Crusher Houses
Note 1. The vibration shall be measured at two random locations on floor and one
: random location on each column at all the floors.
2. Vibration shall be measured when the conveyors / equipment are operating

in full load.
Signature :
ISSUE
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001B LIMITED
SECTION: C5.7

PROFORMA NO.7
SIEVE ANALYSIS OF COAL
1.0 Sample of Coal taken from : At following locations :
Inlet and outlet of :
Primary crusher
2.0 Date and time of test :
3.0 Results of sieve analysis of each of the :

Coal sample collected
Sl. Particle Size Percentage Percentage as Remarks

No. per contract
4.0 Any other remarks
Signature :
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001B LIMITED
SECTION: C5.7

PROFORMA NO.8
RECORD OF ILLUMINATION LEVEL
Sl. Location Specified Lux Measurement Remarks

No. level
Date Time Lux Meter

Reading
1.0 Junction Tower No. &

Transfer tower No.
2.0 Galleries for Conveyor

No.
3.0 Crusher house
4.0 VOID
5.0 Coal handling system

switch gear/control
room cum pump
house
Signature :
ISSUE
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001B LIMITED
SECTION: C5.7

PROFORMA NO.9
DUST SUPPRESSION SYSTEM
AT stockpiles
Sl. Location Dust suppression satisfactory / Date of Remarks

No. Not satisfactory test
1.0 Stockpiles
Signature : :
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SECTION: C5.7

PROFORMA NO.10
YARD CONVEYORS
1.0 Belt conveyor designation :
3.0 Date & time of completion of the test :
4.0 Performance on Load Remarks
4.1 Starting on load : Satisfactory / Not satisfactory
4.2 Alignment of conveyor belt on load : Satisfactory & acceptable / Not

(belt run out to be checked satisfactory & requires
improvement
4.3 Alignment of conveyor belt (belt run out : Satisfactory & acceptable / Not
on no load to be checked satisfactory & requires
improvement
4.4 Coal feed on to the belt : Central / Not exactly central but
satisfactory and requires
improvement.
4.5 Spillage of Coal when belt conveyor is : Negligible / Heavy, requires

running at rated load adjustment
4.6 Tripping of belt conveyor with field : Satisfactory / Not satisfactory

switches (on no load running):
4.7 Starting of preceding conveyor at the : Satisfactory / Not satisfactory

proper speed of zero speed switch
4.8 Cleaning of belt with belt cleaners(Belt : Satisfactory / Not satisfactory

conveyors)
4.9 Operation of hold backs / brakes during : Not applicable / Satisfactory / Not
stopping / tripping satisfactory
4.10 Vibration in conveyor galleries at 3 :

random location, microns
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4.12 Vibration in conveyor drive pulley/drive :

sprocket bearings in microns
4.13 Vibration at gear box bearings microns :

/
4.14 Vibration at motor bearing level, :

microns
4.15 Noise of conveyor drives at a distance :

of 1.80 m from the drives
4.16 General observation (temp. of bearings

……. etc)
4.17 Stoppages During Testing :
4.17. Reason for stoppage during testing :

1
4.17. Time duration of the stoppage :

2
4.18 Condition of pans after handling large Satisfactory/ Not Satisfactory

size boulders
Signature :
ISSUE
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001B LIMITED
SECTION: C5.7

PROFORMA NO.11
BELT WEIGHER / INLINE WEIGH SCALE
1.0 Location :
3.0 Date & time of completion of the test :
4.0 Performance on Full Load Remarks
4.1 Counter (Panel) :
4.2 Counter (Remote) :
4.3 TPH indicator (Remote) :
4.4 Percentage meter (Panel) :
4.5 Chart recorder (Remote) :
4.6 Readings with test weights 90 kgs/110 :

kgs
4.7 Accuracy (±) 0.5 % :
4.8 General observations :
Signature :
ISSUE
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SECTION: C5.7

PROFORMA NO. 12
FLAP GATE OPERATION
1.0 Designation :
2.0 Location :
3.0 Date & time of starting of test :
4.0 Date & time of completion of test :
5.0 Performance Remarks
5.1 Start/stop :
5.2 Observation on operation,

for no coal flow :
5.3 Observation on operation

for full coal flow :
5.4 Coal leakage/slippage in the

blocked path, if any :
5.5 Provision for operation of

gate manually made ? : Yes/No
5.6 General observations
a) Whether operation of gate

is smooth : Yes/No
b) Any other :
Signature :
for PURCHASER for CONTRACTOR

ISSUE
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SECTION: C5.7

PROFORMA NO. 13
STACKER / RECLAIMER
1.0 Designation & Location :
2.0 Date of Test :
3.0 Performance on Load Remarks
Stacking Recalaiming
Operation Operation
3.1 Whether start/stop of

the machine is smooth
without any jerks? :
3.2 Time of starting test :
3.3 Reading of totalizer

of belt weigher on boom
conveyor at the start of test :
3.4 Coal spillage/rolling back

at the tripper while stacking :
3.5 Whether belt touches the

idlers of the tripper or not? :
3.6 Long Travel
a) Speed m/min
b) Operation of cable reeling drum
c) Movement of machine on rail
d) Vibration in the m/c
e) Noise in the m/c
f) Belt sway on conveyor
g) Belt sway on boom conveyor
h) Slippage of coal from boom conveyor
j) Coal feed to trunk conveyor centrally
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while reclaiming
k) Any other observations
3.7 Bucket wheel speed RPM : N.A.
3.8 Boom conveyor speed - m/min :
3.9 Spillage of coal from boom

conveyor/intermediate
conveyor in stationary
operation position :
3.10 Vibration on Load in Stationery Position :
Horizontal/ Horizontal/
Vertical Vertical
a) In the boom conveyor at
i) drive pulley bearing
ii) bucket wheel suspension shaft

bearing
b) Vibration of boom structure at the

end of boom.
i) drive pulley bearing
ii) drive motor bearing
iii) Gear box bearing
3.11 Noise on Load in Stationary Position
a) At feed chute of boom conveyor
b) At discharge chute of boom conveyor
c) On the machine platform
3.12 Max. height of coal stack that can be

achieved. :
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3.13 Luffing Motion :
a) Observation on operation Satisfactory / Not satisfactory

of luffing action.
b) Max. angle of luffing

achieved
i. Above the horizontal

ii. Below the horizontal
iii. Total angle of luffing
c) Any other observations
3.14 Slewing Motion
a) Observation on operation of slewing :
b) Max. angle of slewing achieved :
i. Right from C/L of trunk conveyor

ii. Left from C/L of trunk conveyor
c) Slewing speed
d) Any other observation (like coal

spillage, bell sway, etc.) :
3.15 Whether coal feed centrally

on the trunk conveyor while reclaiming :
3.16 Observation on belt sway of :

trunk conveyor
3.17 Whether stacker-cum-reclaimer

is able to reclaim from farthest end of
the stack satisfactorily? : Yes/no
3.18 Time of completion of test :
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3.19 Reading of totalizer of belt

weigher on boom conveyor at
the end of test :
3.20 Average stacking/reclaiming

rate TPH (Computed from
items 3.2, 3.3, 3.18 and 3.19 above) :
3.21 Whether controls are

functioning satisfactorily : Yes/No
3.22 General observation during test period

(temp. of bearings, operation of
machine, completeness of
the machine, workmanship, etc.) :
3.23 Whether machine stopped

during the test period,
if so, reason for stoppage :
Signature :
for PURCHASER for CONTRACTOR
ISSUE
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SECTION C 6
CODES AND STANDARDS
TCE 5871A-H-563- SECTION: C6
001B LIMITED
AT BARA,UP
CODES AND STANDARDS
1.0 CODES AND STANDARDS
1.1 All equipment, system and services covered under this specification shall comply
with all currently applicable statutes, regulations and safety codes in the locality
where the equipment shall be installed. The equipment and systems shall also
conform to the latest version of applicable codes and standards on the date of bid
opening. Nothing in this specification shall be construed to relieve the SUPPLIER
of this responsibility.
1.2 The standards not indicated in the specification are also acceptable subject to the
approval of PURCHASER / CONSULTANT, if they are established to be equal or
superior to the standards indicated in the specification.
1.3 The metric units/SI units shall be used in all data / drawings submitted against this
package.
1.4 If the Supplier installs equipment and systems conforming to other International
Standards than those specified in the specification, the English translation of such
standards shall be furnished by the Supplier. In such a case, if such standards are
acceptable to the PURCHASER/CONSULTANT the stipulations of the English
version of the Standards shall alone be binding and not the stipulations in the
original language.
1.5 In the event of any conflict between the codes and the standards referred to
elsewhere in the specification and the requirements of this specification, more
stringent of the two shall govern.
1.6 The indicative list of Codes and standards is furnished below for the reference of
the Coal handling system package Supplier.
1.7 Following are some of the important codes and standards relevant to this
specification:
A. MECHANICAL WORKS
Bulk Handling Equipment - Single Boom Bucket Wheel Reclaimer - Rail Mounted -
Design, Manufacture and Erection : IS 14416.
Bulk Handling Equipment - Single Boom Bucket Wheel Reclaimer - Rail Mounted -
Design, Manufacture and Erection : IS 14417
Code of construction for structural steel

design : IS 5049 / IS 800 / BS-2573 -Part-1 / IS-
4573 whichever is applicable
Selection and design of belt conveyors : IS 11592
Conveyor and elevator textile belting : IS 1891
ISSUER
R0
TCE FORM 329 R3

001B LIMITED
AT BARA,UP
CODES AND STANDARDS
Troughed belt conveyors : IS 4776

Pulleys for belt conveyors : IS 8531
Idlers and idler sets for belt conveyors : IS 8598
Steel tubes for idlers for belt conveyors : IS 9295
Fire resistant cover grade belt : CSA-M422-M87

(Canadian Standard)
Construction of structural steel for : IS 5049
stacker reclaimer
Specification for chain pulley block : IS 3832

Drums and sheaves : IS 3938
Forged alloy Hook : IS 2758
Horizontal centrifugal pump : IS 1520
Specification for centrifugal fans : IS 4894
Specification for axial flow fans : IS 3588
Method of performance test for : IS 848
Panel type air filters : ASHRE 52.1
Methods of testing panel type air filters : IS 7613
Clean rooms and associated environments : ISO 14644-1&2

centrifugal fans : IS 4894
Basic rack and modules of straight

bevel gears : IS 5037
Selection of worm or helical gear : IS 7403

Accuracy requirements for medium
Quality medium speed gears : IS 4059
Shafts : IS 1570
Structural steel : IS 2062
Cast steel : IS 1030
Cast Iron : IS 210
Bolts and nuts : IS 1363
Specification for metal air duct : IS 655
Manganese steel liners : IS 276
ISSUER
R0
TCE FORM 329 R3

001B LIMITED
AT BARA,UP
CODES AND STANDARDS
Magnetic core material : IS 4491
ERW pipes for general application : IS 1239
Corrugated galvanised steel sheet : IS 277
Colours for ready mixed paints and enamels : IS 5
Methods for sampling of coal : IS436 (part-

1)-1976
Coal sampling system : BS–1017/

ISO-1988
Standard methods of collecting gross sample of coal : ASTM -D-

-2234
Standard methods of preparing coal samples for analysis: ASTM -D-

-2013
Compressors : IS 6206
Testing of compressors : IS 5456
Inter cooler & After coolers : IS 2825 OR

TEMA
Air receivers : IS 2825

Class II
IS 277 : Galvanised Steel sheets
IS 702 : Industrial Bitumen
IS 655 : Metal air ducts
IS 807 : Code of practice for design, manufacture, erection, testing (structural portion)
of cranes and hoists
IS 903 : Specification for fire hose delivery couplings ,branch pipes, nozzles and
nozzle spanner
IS 940 : Portable fire extinguishers, water type ( gas cartridge)
IS 1239: Mild steel tubes, Tubulars and other wrought steel Fittings, specification –
Part 1
IS 1303 : Glossary of terms relating to paints
IS 2062 : Steel for general structural purposes
IS 2266 : Steel wire ropes for general engineering purposes
IS 2871 : Specification for branch pipe, universal for fire fighting purposes
IS 3034 : Fire safety of industrial buildings: Electrical generating and distribution
stations – Code of practice
IS 3177 : Code of practice for Electric overhead travelling cranes and gantry cranes
other than steel work cranes
ISSUER
R0
TCE FORM 329 R3

001B LIMITED
AT BARA,UP
CODES AND STANDARDS
IS 3588 : Electric axial fans

IS 3589 : Seamless or electrically welded steel pipes for water gas and sewage ( 168.3
mm to 2032 mm outside diameter)
IS 3938 : Electric wire rope hoists
IS 4894 : Centrifugal fans
IS 5290 : Specification for landing valves
IS 7938 : Code for Air receivers
IS 8423 : Specification for controlled percolating hose for fire fighting
IS 9137 : Code of acceptance test for centrifugal, mixed flow and axial pumps – Class
C
IS 14846 : Sluice valve for water works purposes (50 mm to 1200 mm size) –
Specification
Underwriter Laboratories (UL) 555 – Fire dampers
Oil Industry Safety Directorate (OISD)
American Petroleum Institute
Chief Inspector of Factories in the State of Madhya Pradesh
American Water Works Association (AWWA).

PART-B ELECTRICAL
List of codes and standards shall be as per electrical section D3.10 of Vol
IVA.
ISSUER
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TCE FORM 329 R3

SECTION C 7
PAINTING
001B LIMITED
AT BARA,UP
PAINTING
1.0 PAINTING
Painting shall be as described below.
Painting of equipment shall be carried out as per the specifications indicated

below and shall conform to the relevant IS specification for the material and
workmanship.
The following Indian Standards may be referred to for carrying out the
painting job:
IS:5 : Colours for ready mixed paints and enamels
IS:1303 : Glossary of terms relating to paints
IS:2379 : Colour code for identification of pipelines
IS:1477 : Code of practice for painting of ferrous metals in
buildings (Parts I & II)
IS:2524 : Code of practice for painting of non-ferrous metals

in buildings (Parts I & II)
IS:2395 : Code of practice for painting of concrete, masonry

and plaster surfaces (Parts I & II)
IS:2338 : Code of practice for finishing of wood and wood

based materials (Parts I & II)
IS:6278 : Code of practice for white washing and colour washing
IS:3140 : Code of practice for painting asbestos cement building

products
IS:158 : Ready mixed paint, brushing, bituminous, black, lead free,

acid, alkali, water and heat resisting
IS : 2074 : Ready mixed paint, air drying, red Oxide Zinc Chrome,
priming.
IS : 104 : Ready mixed paint, brushing, Zinc Chrome, priming

IS : 2932 : Enamel, synthetic, exterior (a) undercoating (b) finishing
specification.
ISSUE
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PAINTING
1.2 PREPARATION OF SURFACES
All surfaces to be painted shall be thoroughly cleaned of all grease, oil, loose
mill scale, dust, rust and any other foreign matter. Mechanical cleaning by
power tool and scrapping with steel wire brushes shall be adopted to clear
the surfaces. However, in certain locations where power tool cleaning cannot
be carried out, sand scrapping may be permitted with steel wire brushes
and/or abrasive paper. Cleaning with solvents shall be resorted to only in
such areas where other methods specified above have not achieved the
desired results. Cleaning with solvents shall be adopted only after written
approval of the Purchaser/Engineer. Mill scale shall be cleaned by sand
blasting by the Supplier. Surface finish shall be SA 2 1/2.
1.3 PRIMER PAINTS (P)
Primer paints shall be applied only on dry and clean surfaces:
1.3.1 Primer paint P1: (Epoxy based)
A two pack air drying epoxy polyamide resin based red oxide – zinc
phosphate (primer):
Epoxy content ( % wt) 15 to 18
Air drying time About 30 minutes ( touch dry)
Over night (hard dry)
Dry film thickness ( DFT/coat) 30 microns (min)
Temperature resistance Upto 120 deg. C dry heat
1.3.2 Primer paint P2 ( Epoxy based)
A two pack air drying epoxy polyamide with zinc dust of at least 92% zinc
dust on the dry film.
Epoxy content ( % wt) 8 to 10
Air drying time About 10 minutes ( touch dry)

2 hours ( hard dry)
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PAINTING
Dry film thickness ( DFT/coat) 40 microns ( min)
1.3.3 Primer paint P3 (Ethyl zinc silicate, EZS based)
A two pack heavy duty zinc dust rich silicate primer:
Total solids (% wt) 84 + or - 2
Air drying time 16 hours
Density 3.07 +/- 0.005
Dry film thickness ( DFT/coat) 60 microns (min)
1.3.4 Intermediate paints (I)
These paints shall be applied over primer coats as an intermediate layer to

provide weather proof seal of primer coats.
1.3.5 Intermediate paint II
A two pack air drying high build epoxy resin based paint with MIO.
Air drying time 6 to 8 hours (touch dry)

7 days (full cure)
Dry film thickness ( DFT/coat) 100 microns
Compatible with Primer P1 and P2
1.4 FINISH PAINT

Finish paint coats shall be applied over primer coats and intermediate coats
after proper cleaning and touch up of primed coats.
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PAINTING
1.4.1 Finish paint F1
A two pack air drying epoxy polyamide enamel suitably pigmented.
Air drying time 2 to 3 hours (touch dry)
7 days (full cure)
Compatible with Primers P1 and P2
Intermediate II
Colour Generally all shades
1.4.2 Finish paint F2
A single pack synthetic rubber based enamel paint.
Air drying time 2 hours (touch dry)
24 hours (hand dry)
Compatible with No primers
Colour Generally all shades
1.4.3 The colure / shade shall be as approved by the Purchaser/Engineer. After

cleaning the dust on the dried up primer, first coat of synthetic enamel shall
be applied. After this first coat dries up hard, the surface is wet scrubbed
cutting down to a smooth finish and ensuring that at no place the first coat is
completely removed. After allowing the water to get evaporated completely,
the second finish coat of synthetic enamel paint shall be applied.
1.4.4 Equipment No. and the name of the equipment shall be painted on the
surface of the equipments on visible locations. Service of the Pipe/Line
designation with arrow identification for the direction of flow shall be painted
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001B LIMITED
AT BARA,UP
PAINTING
on all pipes at visible locations at an interval of 20 m. Wherever pipe lines

are insulated, the service of the piping and arrow mark shall be painted over
the clad surface.
1.5 SUGGESTED COLOUR CODES FOR PAINTING
SL. ITEM/SERVICE COLOUR IS-5 COLOUR IS-5

NO. (BAND)
1.0 Structures, Dark 632 - -
platforms, galleries, Admiralty
ladders and Grey
handrails
2.0 Fans, pumps, Light Grey 631 - -
motors,
compressors.
3.0 Tanks
3.1 Outdoor, Stand Aluminum - - -
pipes, vent pipes
3.2 Indoor Aluminum - - -
4.0 Vessels and all Light grey 631 - -

other proprietary
equipment (without
insulation &
cladding)
5.0 Switchgear Light grey 631 - -
6.0 Control & relay Light grey 631/7078 - -
panels of IS 1650
7.0 Transformers Dark 632 - -
Admiralty
Grey
8.0 Machinery guards Signal red 537 - -

9.0 Piping
9.1 Water System
a) Dust suppression Sea green 217 - -
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001B LIMITED
AT BARA,UP
PAINTING
SL. ITEM/SERVICE COLOUR IS-5 COLOUR IS-5

NO. (BAND)
system and plant
cleaning water
system
b) Potable & filtered Sea green 217 French 166
water blue
c) Cooling water Sea green 217 French 166

blue
9.2 Compressed Air
System
a) Service air Sky Blue 101 - -
b) Instrument air blue 101 White -
9.3 Fire services Fire red 536 - -
9.4 Drainage Black - - -
9.5 Stand pipes and all Aluminum - - -
Vent pipes
Notes :
1. This colour code basically refers to IS:2379 for piping with necessary
modifications.
2. Where band colour is specified, same shall be provided at 10 meter
intervals on long uninterrupted lines and also adjacent to valves and
junctions.
1.6 PAINT APPLICATION
1.6.1 Paint shall be applied in accordance with manufacturer’s recommendations.

The work shall generally follow IS 1477 (Part II) for jobs carried out in India
and SSPC-PA-I or DIN 55928 or equivalent for jobs carried out outside India.
1.6.2 Paint shall not be applied when the ambient temperature is 5 deg. C and
below. Also paint shall not be applied in rain, wind, fog or at relative humidity
of 80% and above.
1.6.3 Each coat of paint shall be continuous, free of pores and of even film
thickness without thin spots.
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PAINTING
1.6.4 Each coat of paint shall be dry sufficiently before application of next coat.
1.6.5 The Supplier shall furnish paint manufacturer’s test report or technical data
sheet pertaining to the paint selected. The data sheet shall indicate among
other things the relevant standards, if any, composition in weight percent of
pigments, vehicles, additives, drying time, viscosity, spreading rate, flash
points, methods of application quality of surface preparation required,
corrosion resistance properties and colour.
1.7 Painting scheme
1.7.1 Type of paint products like P1, P2, P3, I1, F1, F2 and F3 has been specified
elsewhere in the specification.
1.7.2 For a complete painting scheme of any item being painted, all types of paints
are to be procured from the same manufacturer as approved by the
purchaser.
1.8 Legend
Sa - 2 .5 – The quality of surface cleaning, i.e 95 % of the surface area is

free from all rust, mill scales and visible residues, foreign materials etc.
SP - surface preparation quality

2P1 - Two (2) coats of primer paint type P1
1I1 - One (1) coat of intermediate paint type I1
2F1 - Two (2) coats of finish paint type F1
DFT - Dry film thickness
CRT - Clean and retouch.
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PAINTING
The painting scheme to be followed for various equipment / structures is

briefly given below for guidance to the Supplier.
Sl. Description Painting scheme Total DFT

No. in
Microns
At shop At site
1. Steel structure As per Vol.III, civil spec
2. Mechanical equip- SP-Sa 2 ½ 2F1 240
ment (temperature 2P1 + 1 I1
not over 80 deg.C)
Both static and
rotary equipment for
indoor or outdoor
duty
3. Equipment with hot SP-Sa 2 ½ 2F2 130

surfaces
(temperature upto 2P2
400 Deg,C)
4. Equipment with hot SP – Sa 2 ½ 2F2 170

surfaces
(temperature above 2P3
400 Deg.C)
5. Pipe/duct works SP-Sa 2 ½ 2F1 240
2P1 + 1 I1
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SECTION C 8
LAYOUT AND MAINTENANCE REQUIREMENTS
001A LIMITED
AT BARA,UP
1.0 GENERAL LAYOUT
A preliminary layout of the proposed Stacker reclaimer system is shown

in the drawing no. TCE.5871A-563-GA-1001
The above drawing identifies the relative locations of various facilities

within the plot.
The tentative minimum dimensions of drive houses and junction towers

have been shown. Bidder shall consider the same while finalizing the
layout of these structures.
1.1 Availability Requirements
1.1.1 The Stacking and reclaiming system equipment and accessories shall
be designed for maximum reliability and availability particularly in respect
of the following:
1.1.2 The equipment shall be of proven design from reputed manufacturers

using material established as appropriate to the service intended if
procured from sub-vendors. Fabrication / manufacturing process shall be
subject to quality surveillance and tests as specified.
1.1.3 The Supplier shall indicate the salient features of equipment, the specific
design features, if any, which contribute towards better availability and
shall support this data by actual figures on similar capacity coal handling
systems in operation.
1.1.4 The Stacking and reclaiming system equipment shall be manufactured

with suitable materials and laid out properly for protection against erosion
and abrasion due to coal being handled.
1.1.5 All the equipment of Stacking and reclaiming systems shall be suitable
for the operation on continuous duty (i.e.) 24 hours per day and 365
days in a year.
1.2 Layout Requirements
1.2.1 Center lines of drive houses, junction towers are fixed. The lengths of
conveyors between center line of head and tail pulleys indicated in the
enclosed drawings are tentative and may be finalized by the SUPPLIER
to suit the design of equipment installed by him. The grade elevation and
finished ground floor level in drive houses , JNTs and trunk conveyor
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area are fixed. The distance between various floor elevations in drive
houses and JNTs is minimum as shown in the enclosed drawings and
the Supplier shall consider the same as per the requirement subject to
minimum height as shown in specification drawings. The Supplier shall
provide the building height based on requirement subject to minimum
elevation of top floor as per the drawings. The space and handling
facilities at head and tail-end of conveyors in the junction towers, transfer
house and crusher House shall be adequate for belt replacement and
maintenance. The size of drive houses and , JNTs in the drawings are
minimum sizes to be adopted by the Supplier. There shall be 1000 mm
(minimum) clear walkway space around the equipment in each floor of
the drive houses and JNTs . However, in case higher clearances are
required considering the operation and maintenance of equipment, the
same shall be provided. The floors of drive houses and JNTs shall be
designed based on keeping the heaviest part of equipment any where on
the floor for maintenance purpose.
1.2.2 The take-up travel allowable for all conveyors should be adequate to
avoid frequent belt vulcanising leading to conveyor outages (minimum
three belt joints to be considered). For yard conveyors horizontal gravity
take ups shall be provided to avoid take-up pits. The gravity take up
units shall be positioned so that the lower end of the take up weight is
not more than 1.5 metres from the ground. Sand pit shall be covered by
take up guards on all sides which shall have a minimum height of 2.5 M
from ground level.
1.2.3 Access walkways / steps in drive houses shall be minimum 1000 mm

wide. Suitable hand rails shall be provided for personnel safety.
Suitable access platforms with stairs shall be provided with safety hand
railing for all the equipment located in drive houses.
1.2.4 Main control and switchgear rooms for coal handling system shall be
located as indicated in the drawing No. TCE.5871A-563-GA-1001. Main
control panel for complete coal handling system and 3.3 kV switchgear
for some of HT motors of coal handling system shall be located at coal
handling system switchgear room / control room cum pump house.
1.2.5 Transfer chutes shall have a minimum side plate angle of 65 deg. All the
hoppers shall have minimum side plate angle of 65 deg. Considering
this, the layouts of conveyors, different junction towers, and crusher
House shall be made.
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1.2.6 The minimum transition distance required for fixing tail pulley location
and the specified maintenance space shall be considered while fixing the
sizes of junction towers, transfer house and crusher House.
1.2.7 Conveyor gallery shall have permanently colour coated metal sheet on
roof and both sides. Roof framing shall be given a slope of 1 vertical: 3
horizontal. Along the length of the conveyor, on either side of the
conveyor gallery, a full height opening of 900mm wide shall be provided
at 9m intervals. These openings shall be covered with translucent sheets
for one opening followed by a wire mesh grill for the other opening
alternatively. The translucent sheets and the wire mesh grill shall be
staggered for other side of the conveyor gallery. Crossover shall be
provided at approximately 100 metres interval along the conveyor
preferably at 4 legged trestle locations. Galleries of the conveyors shall
be designed as per the cross sectional drawings attached with this
specification..
1.2.8 The bottom portion of all conveyor galleries whichever are crossing
buildings, roads, main plant areas, rail tracks, bunker area, etc., shall be
provided with seal plates along the entire length of gallery as applicable,
specified elsewhere in this specification to avoid material spillage on to
the ground considering the safety aspects.
1.2.9 1.2.12 Adequate maintenance and runaround space shall be provided

for the power packs of hydraulic drives to provide unhindered movement.
1.2.10 The coal handling system switchgear room / control room cum pump
house shall house the following. Accordingly the layout of this building
shall take into, account the following.
1.2.11 11kV Incomer breakers, 3.3kV Switchgear, PMCCS, MCCs, LDB, other
DBs and other electrical equipment.
1.2.12 The control system equipment such as MMI, control stations, I/O racks,
all other equipment associated with the control system.
1.2.13 Two (2) Nos. (one operating + one standby) stock pile DS water supply
pumps for stockpile.
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1.2.14 Fan with suctions filter for pressurized and heat ventilation of switchgear
room.
1.2.15 Air and water piping network and valves
1.2.16 All local panels, distribution boards, lighting panels JBs. TBs,
Marshalling boxes, PB station, etc., shall be located in accessible
locations permitting easy maintenance. Minimum rear space for local
panels and distribution boards shall be 1000 mm from the nearest
obstruction. Cabling shall be done clearing any interference between
collars, greasing points and dust collection. There shall be minimum 2
metres head room below runs of cable trays wherever horizontally
required. Cable shall be routed along conveyor structures where
possible. Suitable structural members shall be provided on the
structures for supporting cable tray work where conveyor structures are
not available, ground supported prefabricated supports shall be provided
by Supplier. All embedments required for supporting cable supports and
other electrical services should be supplied and laid by Supplier during
civil construction. The structural design of conveyor structures shall take
into account the cable tray loading. The Supplier shall prepare civil
assignment drawings showing location and size of pipe sleeves, insert
plates, openings, etc. Pipe sleeves shall be sealed against water entry
by approved means. Any over head crossing over the above areas shall
not obstruct vehicle movement. Local control panels requiring operator’s
attention shall not be located in dust prone areas. The Supplier shall
prepare within 3 months, after receipt of LOI, complete list of electrical
drives, motors and GA drawings of control desks and panels and all local
panels and finalise the control room and switchgear room layouts. Local
panels in each area shall be housed in a dust proof cabin to minimum
dust nuisance and theft of components.
1.2.17 The layout of water pumps shall be such that it shall be possible to
maintain any pump set without disturbing the operating pump set. It shall
be possible to remove the water pump and / or motor for maintenance by
disconnecting the pump coupling from the discharge piping. It should not
be necessary to dismantle the discharge piping for removing any pump.
The pumps shall be of back pull out type.
1.2.18 The overall dimensions of the switchgear room / control room cum pump
house are minimum. Suppliers shall consider minimum maintenance
space and other layout requirements specified. The layout shall enable
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availability of proper and free working spaces to enable effective and

proper maintenance of the equipment. If higher size building is required
to be included, same shall be included. The height of the building shall
be suitable for lifting the motor of the compressor under maintenance
over the other compressor.
1.2.19 The overhead piping shall have a minimum working clearance of 2.5m
head room over walkways and working areas in buildings.
1.2.20 All piping shall be arranged to provide clearance for the removal of
equipment requiring maintenance and for easy access for valves & other
piping accessories required for operation & maintenance. Layout
drawings shall also indicate orientation of valves and availability of
access to valves and specialities.
1.2.21 All pipe joints to be provided inside the switchgear room / control room
cum pump house shall be flanged type with suitable gaskets.
1.2.22 Wherever water or air pipes are routed at more than 300 mm (top of pipe)
above the floor, crossover platforms be provided.
1.2.23 For pipe and cable rack the minimum head room to be maintained at road
and rail crossing shall be as given below:-
Road crossing – 6m
Rail crossing – 8m from top of rails
1.3 Maintenance Requirements
1.3.1 The SUPPLIER shall provide facilities for carrying out On-line and Off-
line maintenance of the Stacking and reclaiming system equipment and
accessories. In general, this should include adequate handling
equipment, working space, maintenance platforms, crossovers and
safety devices.
1.3.2 In order to carry out on-line maintenance, it is necessary that the

equipment supplied can be readily disassembled, repaired and
reassembled in the shortest period. It should be possible to attend the
equipment by a minimum disassembly of parts. Arrangement for quick
access shall also be ensured.
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1.3.3 The handling equipment as specified shall be included by the Supplier.

In addition, if maintenance of any specific equipment needs material
handling devices, the same shall also be provided by the SUPPLIER.
1.3.4 Tail pulleys of conveyors shall be located such that they are easily
accessible to carry out maintenance and changing of belt. Necessary
lifting tackles, monorails, etc. shall be provided at tail end also. There
shall be minimum clear gap of 500/300 mm between the tail / snub
pulley and floor respectively and clear space of 2000 mm behind the tail
pulley structure while fixing the sizes of junction towers and crusher
House.
1.3.5 VOID
1.3.6 Inspection and maintenance doors / poking holes at suitable location

shall be provided for all chutes. Platforms with ladders shall be provided
to facilitate poking to carryout choke cleaning works.
1.3.7 Adequate space provision shall be provided for easy maintenance of
hydraulic drives.
1.4 I & C LAYOUT REQUIREMENTS
1.4.1 For Layout requirements applicable for I &C System, please refer to,
Clause 1.2.16
1.5 ELECTRICAL LAYOUT REQUIREMENTS
1.5.1 Electrical Switchgear Panel and I&C system cabinets shall be located in
the control room-1. Cabling for these panels shall be through the cable
vault of adequate height. Cable trays shall be provided in the cable vault
for the panels located in control room.
1.5.2 VOID
1.5.3 VOID
1.5.4 Access to the rooms and doors provided shall consider movement of
panels during erection and also later during maintenance/ replacement.
1.5.5 The layout shall meet all the statutory requirements, Tariff Advisory
Committee regulations and electrical inspectorate requirements.
.5.6 General requirements for all Layouts
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1.5.6.1 The layout of the switchboard shall consider the following aspects.
(a) Adequate space for movement of personnel with breaker/modules

withdrawal.
(b) Adequate movement & operation space around
(c) Separate maintenance space
(d) Space for cable trenches
(e) Minimum statutory clearance requirements
(f) Space for additional panels that may arise during engineering
1.5.6.2 Following shall be considered as minimum spacing for various switchboards

(electrical panels)
(a) 11kV/3.3 kV switchgear facing 415V 2000 (min)

switchboard
(b) Two 415V switchboard or panels facing 2000 mm (main

each other switchboard),
1500mm (battery
chargers, LDB,
static inverter, etc.)
(c) LV switchboard or panel front facing the wall 1500 mm (2000m

shall be provided
near doors)
(d) LV switchboard / panels back side to the 1000 mm or door

obstructions like column, raceways, walls if opening space
single front plus personnel
movement
whichever is higher
(e) Space between the sides of two switchboard 1000 mm

panels or switchboard panels and the wall.
(f) From top of switchboard / panels to nearest 800 mm (min).

obstruction
1.6 GENERAL REQUIREMENTS
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1.6.1 Ramps having a slope of 1:8 shall be provided in front of all doors
provided with rolling shutters.
1.6.2 The general requirements like toilets, pantry, staircase, etc. shall be
provided in all the buildings, as applicable.
1.6.3 Based on the above, Supplier shall furnish the layout of the buildings for
review and approval by PURCHASER / PURCHASER’s
Representatives.
1.6.4 Separate toilets for men and women at all buildings and in crusher house
ground floor.
1.7 MAINTENANCE REQUIREMENTS
1.7.1 The SUPPLIER shall provide necessary equipment including hoists, tools
and tackles, lifting equipment, cranes for wagon tipplers, trackhopper etc.
as required for the maintenance of the equipment provided under this
specification under special tools and tackles.
1.7.2 Necessary mobile maintenance and access ladders shall be provided for
access to roof of buildings not provided with staircase or for maintenance
of inaccessible equipment (for e.g. light fittings) along with the main plant
equipment.
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SECTION C 9
PERFORMANCE GUARANTEES, PRE-OPERATIONAL
TESTING/START UP, PERFORMANCE TESTING & ACCEPTANCE
PROCEDURES
TCE 5871A-H-563- LIMITED SECTION: C9
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TESTING/STARTUP, PERFORMANCE TESTING AND
1.0 PERFORMANCE GUARANTEES
Performance guarantee parameters shall be as per ‘Schedule of Performance

Guarantees’ as per schedule F3 in Volume - I
The performance guarantees are classified as below
a) Performance guarantees under Liquidated Damages (LD) (Refer schedule F3

in Volume - I)
b) Performance guarantees under correction.
PERFORMANCE GUARANTEES UNDER LD FOR STACKING AND

RECLAIMING SYSTEM
1.1 The power consumption is the power consumed in individual paths of the stacking
and reclaiming system by all the equipment for conveying coal from the source to
the destination in the particular path. It will be calculated in terms of kW for the
stacking and reclaiming system. For every 1 kW increase in the power
consumption of the continuously running HT and LT drives combined together for
the stacking and reclaiming system for individual paths, Liquidated damages (LD)
will be levied at the rate of Rs. 1 lakh only for loading during bid evaluation and Rs.
1.6 lakhs only for shortfall in performance at the time of PG testing.
During PG test on any stream, power consumption shall be measured as follows:

1. For HT motors – reading of KW on 3.3kV switch gear feeding these motors
2. For LT motors - power reading at the incomer feeder on stacking and reclaiming
system plant MCC. (as individual feeder will not have KW meter)
After the stacking and reclaiming system equipments are erected, commissioned.
The system shall be tested within six (6) months to prove the guaranteed
parameters as indicated in schedule F3 in Volume - I. The capacity figures specified
in relevant data sheets for the equipment shall be achieved. The guarantee
requirements shall be met without undue vibrations in the stacker reclaimer
machines, conveyor supports, drive houses and junction towers. The procedure for
performance testing of the entire stacking and reclaiming system is furnished in
section C5.7,Vol IIA and SUPPLIER shall follow the procedure.
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2.0. The following features /aspects of various equipment shall be guaranteed under
stacking and reclaiming system.
Sl. No. Description LD in Rs. For every 1 KW Remarks

or part thereof of excess
power consumption over
and above guaranteed
figures
2.1 SYSTEM CAPACITY
2.1.1 System capacity of Each Rs. 1 lakh for loading during Stacker cum
Stacker reclaimer including bid evaluation and Rs. 1.6 reclaimers shall be
yard conveyor lakhs for shortfall in stable under
performance specified design
conditions and shall
meet all
requirements
indicated in Data
sheet-A. Stacking
capacity of 2600
TPH without any
negative tolerance
for a minimum
period of 12 hours
for each machine.
The bucket wheel
reclaimer shall
reclaim coal at the
peak reclaiming
capacity of 2600
TPH without any
negative tolerance
for a minimum
period of 12 hours
for each machine
even while handling
well compacted,
damp and sticky
coal during rainy
seasons. The rated
reclaiming capacity
shall be arrived at
on working for 4
hours over complete
cross
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figures
section of the
stockpile. The yard
conveyor shall
operate at rated
capacity specified
above both in
stacking and
reclaiming modes
for the specified
period above. The
drives of the yard
conveyers and other
equipment in the
respective path
individually should
be capable of
handling this load.
The capacity shall
be achieved without
un due vibrations.
Stacker reclaimer
machines,yard
conveyors and other
equipment shall be
stable under these
conditions.
2.2 POWER CONSUMPTION
PATH WISE
2.2.1 Path-1 : BCN-7A & RSTR- Rated stacking

1 under stacking mode capacity shall be
2600 TPH.
PURCHASER shall
Rs. 1 lakh for loading during
ensure that coal at
bid evaluation and Rs. 1.6
rated capacity of
lakhs for shortfall in
2600 TPH rated
performance during PG test
capacity being
loaded onto the yard
conveyor BCN-7A
during this test.
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figures
2.2.2 Path-2 : BCN-7B & RSTR- Peak reclaiming
2 under Reclaiming mode capacity of 2600
TPH shall be arrived
during this test.
Stockyard dust suppression Stockyard dust

system suppression system
Pumps for dust suppression shall be operating
system at stockyard for all the four (4)
stockpiles during
this test.
2.2.3 Path-3 : BCN-7B & RSTR- Rated stacking

2 under stacking mode capacity shall be
2600 TPH.
PURCHASER shall
ensure that coal at
rated capacity of
2600 TPH rated
capacity being
loaded onto the yard
conveyor BCN-7A
Rs. 1 lakh for loading during
during this test.
bid evaluation and Rs. 1.6
2.2.2 Path-4 : BCN-7A & RSTR- Peak reclaiming
lakhs for shortfall in
1 under Reclaiming mode capacity of 2600
performance during PG test
TPH shall be arrived
during this test.
Stockyard dust suppression Stockyard dust

system suppression system
Pumps for dust suppression shall be operating
system at stockyard for all the four (4)
stockpiles during
this test.
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Note : PG tests for Path-1 & Path-2 shall be conducted simultaneously for 12 hours.
Similarly PG tests for Path-3 & Path-4 shall be conducted simultaneously for 12 hours.
2.3 PERFORMANCE GUARANTEES UNDER CORRECTION
After the equipment are erected successfully completed in all respects and after
successful completion of trial operation as defined, the stacking and reclaiming
system shall be tested for performance guarantee within two (2) months to prove
the performance of the system and equipment in regard to the following which have
to be specifically guaranteed. The capacity figures specified in relevant data
sheets for the equipment shall have to be achieved with any tolerance on the
positive side. The guarantee requirements shall be met without undue vibrations in
the equipment / building / structure foundation, structures, etc. The procedure for
performance testing of the entire stacking and reclaiming system is furnished in
section C5.7, Vol IIA and SUPPLIER shall follow the procedure strictly and no
deviations will be permitted at a later date after award of contract.
The following features / aspects of the various equipment shall be guaranteed under
corrections:
SL. No. Description Performance guarantees Remarks

under corrections
2.3.1 Yard conveyor BCN-7A & Rated capacity shall be
7B 2600 TPH
2.3.2 Belt sway Belt sway under full load

and no load conditions shall
not exceed 50mm from the
true centre on either side.
2.3.3 Transfer chutes and skirt Totally dust tight.
boards
2.3.4 Dust nuisance Stockpile dust suppression

system shall be operating
satisfactorily.
2.3.5 Hopper outlets and feeders There shall be smooth flow

without hold ups, and
spillage or overloading on
the equipment. The transfer
chutes shall be designed to
ensure smooth flow of wet,
sticky coal mixed with fines
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specifically during rainy
season. There shall not be
any vibrations in the
columns etc.
2.3.6 Noise level 1) Noise level produced

by rotating equipment
individually and
collectively shall not
exceed 80 dBA
measured at a
distance of 1.8m from
it in any direction and
under any load
condition. However, for
fans of Bunker
ventilation, maximum
noise level shall be
considered as 90 dBA.
2) Control rooms,
Computer rooms shall
be less than : 65
dBA
2.3.7 Maximum permissible (a) All rotating equipment Vibration will be

Vibration levels /conveyors and feeders – measured at drive
75 microns. pulley, motor and
gearbox (as
(c) Compressors – As per applicable). The
zones A &B of ISO 1086-1 vibration levels shall
be acceptable as per
VDI 2056/BS 4675
where not
specifically specified
or as per the values
as specified here.
Note: In the event of non-fulfilment of any of the above guarantees in clause 2.0, the
Vendor shall at his own cost replace / rectify the concerned equipment / system
to improve the performance to the level of the guaranteed performance.
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LIQUIDATED DAMAGES FOR DELAY AND PERFORMANCE
2.4
A sum of maximum of 10% of the contract value will be levied for the delay in the
supplies from the Supplier side. For details refer Cl …of Volume –I.
For the Performance Guarantee with respect to capacity, a sum of maximum of

15% of the contract value will be levied in case of variation in the performance
guarantees as specified in the contract.
However the maximum ceiling in the LD is limited to 20% of the contract value.
3.0 GUARANTEES FOR I&C EQUIPMENT
Supplier shall comply with Section D4 of Volume IVB of this specification for I&C
equipment.
4.0 GUARANTEES UNDER CORRECTION

In respect of all the items 'under correction', the Supplier shall guarantee the
same as per section F10. The Supplier shall make every effort practicable to
correct the deficiencies. In case the Supplier fails to meet the guarantees, the
equipment / system is liable to be rejected and in case of such an option, the
Supplier shall replace the equipment with equipment which shall meet the
guarantee requirements without any extra cost to the Purchaser.
5.0 MECHANICAL COMPLETION
5.1 Mechanical Completion is defined as the state of readiness of Works under the
scope of Contract to undergo the pre-commissioning checks, followed
immediately thereafter by commissioning including Preliminary Operation, Initial
Operation, Trial Operation, Performance Tests including equipment
characteristics tests for functional or operational occupation of the Works.
5.2 Mechanical Completion shall be deemed to occur when the Contract

erection/installation/construction Works are completed as per Specifications with
all equipment / system including standby-
(a) All installation/erection checks duly carried out,
(b) All defects/deficiencies notified by Purchaser/Engineer during

installation/erection rectified to the satisfaction of Purchaser/Engineer
save those which, in the opinion of Purchaser/Engineer, will not affect
the safe operability and maintainability of the Works, and
(c) The Contract Works, in the opinion of Purchaser/Engineer, subject to

sub-clause (b) above, being fit, sound, safe and operable for
undertaking the pre-commissioning checks, Preliminary Operation,
Initial Operation, Trial Operation and Performance Tests including
equipment Characteristics Tests.
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6.0 SPECIFIC REQUIREMENTS OF MECHANICAL COMPLETION
6.1 Mechanical completion in different disciplines shall be determined based on

the following characteristics, signifying the readiness of the Works/Plants and
Systems for undertaking the pre-commissioning/commissioning checks and
subsequent Preliminary Operation, Initial Operation, Trial Operation and
Performance Tests including Unit Characteristics Tests as applicable to the
Contract Works.
(a) All plant construction/installation in various disciplines, as detailed

under (c) below and as applicable to the Contract are completed
including aesthetic and workmanship aspects, with all
installation/construction checks as per Specification, relevant Codes,
Standards and practices ensuring conformity to Contract and
meeting all applicable statutory requirements.
(b) All contractual obligations up to the stage of completion of

construction/ installation are fulfilled to the satisfaction of
Purchaser/Engineer.
(c) All Contract Works are otherwise ready to be taken into service, or
for functional or operational occupation save pre-
commissioning/commissioning checks, Preliminary Operation, Initial
Operation, Reliability Operation, Performance Tests, equipment
Characteristics Tests including but not limited to the following:
i) Areas inclusive of all roads, accesses, structures, housings,

platforms, walkways, stairs, ladders, safety/protective guards,
covers, hand rails and such items of work are constructed as
per Specification and approved for use
ii) Drains, sewers, waste disposal channels, vents, chutes, ducts
and such works are constructed and connected to treatment
and other disposal systems
iii) Equipment and piping in different systems/disciplines with all
appurtenances, auxiliaries and accessories along with
supporting structures, hangers, mounts, etc. are
erected/installed, supported, anchored, aligned, grouted and
adjusted for operating conditions
iv) Electrical power supply, control, communication and lighting
equipment along with control panels, control desks, switchgear,
local starters and such accessories along with protective
systems, interlocks and integral and auxiliary systems are
permanently installed, aligned and adjusted, with megger,
continuity and specified installation checks duly carried out
v) Cables are laid, routed, supported, dressed, clamped, tagged,
ferruled and terminated with clamp terminals designated and all
continuity and megger checks duly carried out
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vi) Specified pressure/vacuum/leak/NDT checks for acceptance
and any heat treatment are carried out on plant equipment and
piping
vii) All painting and lining works are completed with specified
checks to the satisfaction of PURCHASER/CONSULTANT.
7.0 OTHER PREREQUISITES FOR MECHANICAL COMPLETION
7.1 SUPPLIER shall also meet the following prerequisites for Mechanical
Completion:
(a) Submit a compilation of all reports of shop tests, material tests and
various stage inspection establishing total compliance to Contract
Specification of manufacturing items of the Contract
(b) Submission of a certificate by SUPPLIER in a format agreed with the

Purchaser/Engineer that the Contract Works have been designed,
selected, manufactured, furnished and installed under the full
responsibility of SUPPLIER
(c) All erected plants, structures, equipment and systems are maintained
and preserved in sound condition and are fit and sound to undertake
pre-commissioning checks and ‘Tests before Commercial Operation’ for
operational and functional occupation immediately thereafter
(d) All areas and constructed works are cleared of all construction
materials, temporary works, debris, rubbish water and all such
impediments to render the Contract Works safe, sound and operable
(e) All safety features and safety equipment are functional
(f) Any specific statutory approvals pre-requisite to commissioning of the

plant are duly obtained.
8.0 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES
8.1 On successful completion of erection, equipment will be subjected to pre-

commissioning tests. In this connection the Supplier shall carry out the
following:
(a) Pre-commissioning checks, individuals loop checks, power

initialisation, verification of system functioning, trouble shooting final
solutions to application and / or instrument problems, etc. is Supplier’s
responsibility. All the required software and hardware changes shall
be incorporated as required for successful commissioning to
Purchaser/Engineer satisfaction.
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(b) Any other tests as may be directed by the Purchaser/Engineer.
8.2 Necessary equipment such as materials such as gaskets, miscellaneous

fasteners, test gauges, etc. tools and tackles including test pressure gauges
etc. are to be provided by the Supplier. Any temporary and miscellaneous
piping, etc., required for completing the tests shall also be provided by the
Supplier. Traceable standard instruments shall be used for calibration.
8.3 Supplier shall carry out the following pre-commissioning and commissioning
activities:
(a) Checking the readiness of all systems and auxiliary equipment before
commissioning.
(b) Checking operation of hand and motor operated valves in the system.
8.4 Instrumentation and Control, Erection, Field Testing and Commissioning

Requirements
8.4.1 Erection requirements
(a) The actual location of transmitter racks, junction boxes and other
instruments shall be decided by the Supplier depending on the site
conditions considering the layout and maintenance aspects.
(b) The Supplier shall get prior approval as per approved quality
assurance plan of the Purchaser/Engineer before any installation work
starts. If any work is carried out by the Supplier before prior approval
from Purchaser/Engineer and modification is sought by
Purchaser/Engineer later, then the work will be redone by Supplier
without any cost / material implications to the Purchaser/Engineer.
(c) Impulse / sample piping, air supply and pneumatic tubing, cable trays
and equipment shall be supported rigid enough to prevent vibration
and anchored sufficiently to prevent strains on equipment installed.
Supporting clamps shall be provided atleast at every one metre
distance for better rigidity. Impulse / sampling piping shall be provided
with adequate slope, (preferably 1:10). Hangers and supports shall be
so installed as not to interfere with free expansion and contraction of
the piping and tubing between anchors. Suitable vibration dampeners,
etc. shall be provided wherever necessary. In addition, care should be
taken that the arrangement of impulse / sampling piping, air supply and
pneumatic tubing from detrimental sagging, mechanical injury, abuse
due to unusual service conditions from sources other than those due to
pressure, temperature and vibrations. All impulse lines of joints shall
be welded type unless otherwise specified. Argon arc welding shall be
employed.
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(d) All the panels, desk, cabinets supplied by the Supplier shall be welded
or bolted to the floor channel.
8.4.2 Testing requirements
(a) The calibration equipment shall cover complete range and shall have
the desired accuracy of not less than 0.1%. All the calibration
equipment shall have the certification from National Physical
Laboratory (NPL) or ‘IDEMI’ for the duration of Contract Period.
(b) The Supplier shall follow the standard procedures for calibration of
various instruments and as set by the manufacturer of instruments and
as instructed by the Purchaser/Engineer including any requirements of
field calibration. First, the calibrations shall be carried out
independently by the Supplier and later in the presence of
Purchaser/Engineer who shall certify the same. Proper documentation
in this regard shall be maintained and handed over to the
Purchaser/Engineer.
(c) All the instruments shall be calibrated for the entire range of the
instrument for which it is designed. Calibration shall include test for
repeatability. After first commissioning, the instruments shall be tested
for calibration again to check whether the instrument maintains its zero
and maximum of the range.
(d) All instruments and control equipment shall be calibrated to read

correctly to the satisfaction of equipment supplier /
Purchaser/Engineer.
(e) All switches shall be tested for the actuation of both normally open and
normally closed contacts at the desired set points and also for the fixed
/ differential settings.
(f) All the float operated level switches shall be tested for the movement
of the float and linkages to make to break the switch contacts by filling
up with water before installation. For such tests, necessary testing set
up required shall be arranged by the Supplier. All the conductivity type
probes and switches shall be tested for performance before
installation.
(g) Hydro test shall be performed for all other impulse lines / sampling
lines. Necessary equipment such as hydro test pumps and temporary
piping to the required point, fill pump etc., materials such as temporary
gaskets, miscellaneous fasteners, etc. tools and tackles including test
pressure gauges, etc. are to be provided by the Supplier.
(h) For all electrical actuators of the valves, functioning, setting and
performance of limit switches / torque switches of various positions
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shall be checked before and after installation of the actuators. The
position transmitters for inching applications shall also be calibrated.
(i) Pneumatic actuators shall be calibrated at site.
8.4.3 Commissioning requirements
(a) Prior to taking the instruments in service, all impulse lines, sampling
lines and air supply lines shall be blown as required with the
establishment of adequate line pressure and temperature conditions
to keep the lines thoroughly clean.
(b) After delivery of the equipment, the Supplier shall locate all the
equipment including electronic cards in its final position, check all the
power wiring, grounding and interconnection cables, all in
accordance with manufacturer’s recommendations. The Supplier
shall perform initialisation of system power, field loading of system
configuration / software and data base, demonstration of system
functionality to verify conformance with manufacturer’s instructions
and specifications, tuning of control loops, implementation of any
configuration changes including hardware, software and additional
tappings / instruments, cabinets as required and providing general
trouble shooting and final solutions to application and / or instrument
problems.
8.5 Electrical Erection, Field Testing and Commissioning Requirements
All equipment shall be checked for any physical damage and cleaned before
taking up erection. The guidelines for installation, testing and commissioning of
various electrical equipment as listed below shall be complied with.
8.5.1 The Installation of cable shall be as per code of practice detailed in Indian
Electricity Rules.
8.5.2 The Supplier shall furnish all tools, welding equipment, rigging materials, testing
equipment, test connections and kits, etc., required for complete installation,
testing and commissioning of the electrical equipment included in the contract
work.
8.5.3 Any thefts of equipment / component parts, till the installation is handed over to
the PURCHASER, shall be made good by the Supplier.
8.5.4 In order to avoid hazards to personnel moving around the equipment such as
switchgear, transformers, etc., which are kept charged after installation, before
commissioning, such equipment shall be suitably cordoned off.
8.5.5 Irrespective of whether it is explicitly stipulated in the specification / drawings or

not, any or all precautions, refinement, improvements, modifications that may
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be required to be carried out by the Supplier, in the installation shall be
executed in a workman-like, technically sound and aesthetically pleasing
manner.
8.5.6 Installation and commissioning shall be carried out after obtaining approval of
concerned statutory authorities as required by Indian Electricity Rules. The
Supplier shall be responsible for obtaining these approvals.
8.5.7 All electrical equipment shall be installed in neat, workman-like manner so that
it is level, plumb, squat and properly aligned and oriented. Tolerances shall be
as established in the manufacturer’s drawings.
(a) Switchgear, Control / Relay Panel
(i) Switchgears and control / relay panels / desks shall be installed in

accordance with specified code of practice and manufacturer’s
instructions.
(ii) In joining shipping sections of the switchgear / panels / motor control

centres together, adjacent housing or panel sections shall be bolted
together after completing the alignment.
(b) Motors
The installation, commissioning of the motors shall be as per the

applicable code of practice and the manufacturer’s instructions.
8.5.8 Site Tests:
Site tests shall be conducted on all equipments as per applicable standards

and as per Section Site test of Electrical Volume IVA:
9.0 PRELIMINARY OPERATION
Preliminary operation shall mean all activities undertaken as part of

commissioning after mechanical completion up to commencement of Initial
operation and shall include mechanical and electrical checkouts, calibration of
instruments and protection devices, commissioning of sub supporting systems.
10.0 INITIAL OPERATION
10.1 Initial Operation shall include all operations undertaken as part of

Commissioning after completion of Preliminary Operation upto commencement
of Trial Operation. It shall be the first integral operation of the complete
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Stacking and reclaiming system covered under Contract and shall include no
load on load trial runs calibration, setting and commissioning of controls
systems; and shutdown inspection and adjustment after running trials of the
Plant under the Contract.
10.2 The initial operations shall include operation of Stacking and reclaiming system
system as a whole under no load conditions.
11.0 TRIAL OPERATION
11.1 After the initial operations, the plant shall be on trial operation. Before the trial
operation, the Supplier will be allowed to make minor adjustments as may be
necessary, provided that such adjustments do not interfere with or prevent the
commercial use of the plant.
The trial operation will be considered as successfully completed only when the
stacking and reclaiming system is able to run the system without trip even once
during two(2) hours continuous operation. The individual equipment will not be
tested. If the system trips during these tests even once due to faults in the
stacking and reclaiming system which are not attributable to the purchaser, the
Supplier shall repeat the test. Each path of stacking and reclaiming system in
clause 2.0 herein above shall be tested during these tests.
11.2 Should any failure (other than of an entirely minor nature) due to or arising out
of faulty design, materials, or workmanship (but not otherwise) occur in any
item of the plant, sufficient to prevent commercial use of the plant, the trial filling
shall recommence after the defect has been remedied by the SUPPLIER. The
onus of proving that any failure is not due to faulty design, materials and
workmanship will lie with the SUPPLIER
11.3 A ‘ trial operation’ report comprising observations and recordings of various

parameters measured in respect of the ‘trial operation’ shall be prepared and
submitted to the Purchaser/Engineer in the specified formats enclosed with the
PG test procedure. This report, besides recording the details of various
observations during ‘trial operation’ shall also include the dates of start and
finish of the trial operation and shall be signed by the representatives of both
the parties. The report shall have recordings of all details of interruptions that
occurred, adjustments made and any repairs done during the ‘trial operation’.
11.4 The ‘trial operation’ shall be considered successful, provided that each item of
plant can meet the above requirements.
11.5 Provisional Takeover
On successful completion of trial operation, the stacking and reclaiming system

will be provisionally “Taken over” with a list of major and minor defects and non
conformities prepared jointly by the Purchaser/Engineer and the SUPPLIER.
Purchaser/Engineer reserves the right to differentiate the defects as major and
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minor. Upon the completion of ‘ trial operation’, as soon as practicable, or at
such time as may be otherwise agreed to by the parties concerned, the
Supplier shall notify in writing to the Purchaser/Engineer that the plant is ready
for performance tests only after liquidating all the major defects.
12.0 PERFORMANCE TESTS
12.1 The performance tests shall be conducted at site for stacking and reclaiming
system by the Supplier. The Supplier’s commissioning Engineers shall make
the plant ready for such tests. The test will be commenced after the ‘Plant /
Equipment’ has attained stable operation. The date of commencement of the
performance tests shall be after completing trial operation and after attending
all the pending works if any and major/minor defects or as may be mutually
agreed upon between the Supplier and Purchaser/Engineer.
12.2 The tests shall be binding on both the parties of the ‘Contract’ to determine
compliance of the ‘Plant’ / ‘Equipment’ with the performance guarantees.
12.3 The performance tests shall be carried out to prove the guarantees as indicated
in clauses 2.0, 3.0 and 4.0 of this section.
12.4 The performance test procedure, as given in the specification including the
definition of the calculation method to be used, the instrumentation to be
installed and indicated in the schemes, the instrument accuracy classes, the
areas of responsibility and the items which specifically require preparation and
agreement shall be submitted by the Supplier for review and approval by the
Purchaser/Engineer during detail engineering phase.
12.5 The performance test instruments shall be of precision type with instrument
accuracy limits as required and defined in the applicable performance test
codes such that measurement uncertainty does not exceed the values agreed
to by the Supplier in the Schedule of Performance Guarantees.
12.6 All test instrumentation for the performance tests as required shall be supplied
by the Supplier on loan basis. Data loggers on loan basis shall be used for
stacking and reclaiming system tests. All costs associated with the supply,
calibration, installation and return of the test instrumentation / data loggers /
computers etc. are deemed to have been included in the contract price. The
test shall be in accordance with those specified or as per agreed performance
test codes as applicable. Batch calibration will not be accepted.
12.7 Any special equipment, tools and tackles required for successful completion of
the performance tests shall be provided by the Supplier.
12.8 It is the Supplier’s responsibility to co-ordinate for suitably carrying out the
performance tests. The duration of the test shall be in accordance with the
agreed test procedure at the loads after necessary stabilising period to obtain
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steady state conditions. All other tests to prove the guarantees as indicated in
the Supplier’s offer shall also be conducted.
12.9 The stacking and reclaiming system parameters during the performance test
shall be adjusted to the guaranteed performance test conditions. The tests shall
be conducted to prove guaranteed parameters as defined in the contract.
12.10 The performance test results shall be reported as computed from the
performance test observations. The measurement tolerance limit on the
performance test guarantee values, as reported on the basis of above tests
shall not exceed the tolerance limits specified.
12.11 Reporting Of Test Results
Within two weeks after the conclusion of the performance test the Supplier shall
submit a test report to the Purchaser/Engineer stating:
(a) In the case of a performance test, whether the stacking and reclaiming
system passed or failed such test, accompanied by sufficient test data
and calculations to demonstrate the level of performance attained with
respect to each of the tested parameters.
The report(s) shall include as a minimum, the following:
(i) Description of the test procedures
(ii) Standards that were used
(iii) Instrumentation details and calibration
(iv) Full schematic diagrams with indication of instrument test

location and identification tag of same.
(v) Test logs and summary of test readings used for performance
calculations
(vi) Computation of test results.
(vii) Conclusions of performance tests : test passed or not
12.12 Within thirty (30) days of receipt such test report(s), the Purchaser/Engineer
shall submit a notice to the Supplier, stating either:
(a) That Purchaser/Engineer concurs with the information provided in the

Supplier’s test report(s), or
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(b) That Purchaser/Engineer disputes some or all of the information
provided in the Supplier’s test report(s), the areas being disputed, and
the levels of performance being disputed.
12.13 If Purchaser/Engineer disputes any or all of the results contained in the

Supplier’s test report(s), representatives of the Supplier, Purchaser/Engineer
shall meet after the receipt of the Purchaser notice at a mutually acceptable
date & location to review and discuss the dispute.
13.0 NOTICE OF TESTS
The Supplier shall give to the Purchaser/Engineer 21 days’ notice of the date
after which he will be ready to make the tests and the Supplier shall commence
the tests promptly thereafter. Any data obtained in respect of energy
consumption prior to the commencement of the Tests in relation to the
Performance Guarantees shall not be used to assess whether the Performance
Guarantees have been attained.
14.0 DELAYED TESTS
14.1 If the tests could be carried out but are being unduly delayed by the Supplier,
the Purchaser/Engineer may by notice request the Supplier to make the tests
within 14 days after the receipt of such notice. The Supplier shall make the
tests on such days within that period as the Supplier may fix and of which he
shall give notice to the Purchaser/Engineer.
14.2 If the Supplier fails to make the tests within 21 days of such notice the
Purchaser/Engineer may himself proceed with the tests. All tests so made by
the Purchaser/Engineer shall be at the risk and cost of the Supplier and the
cost thereof shall be deducted from the contract price or charged to the
Supplier. The tests shall then be deemed to have been made by the Supplier.
14.3 Retesting
If the stacking and reclaiming system fails to pass the test (which in the case of
performance tests means, not achieving the acceptable limits), the
Purchaser/Engineer may require such tests to be repeated on the same terms
and conditions save that only reasonable notice of the date and time of such
tests shall be required to be given by the Supplier to the Purchaser/Engineer.
14.4 Disagreement as a Result of Tests
If the Purchaser/Engineer and the Supplier disagree on the interpretation of the

test results, each shall give a statement of his views to other within 14 days
after such disagreement arises. The statement shall be accompanied by all
relevant evidence. If Purchaser/Engineer disputes any or all of the results
contained in the Supplier’s test report(s), representatives of the Supplier,
Purchaser/Engineer shall meet after the receipt of the Purchaser/Engineer
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notice at a mutually acceptable date & location to review and discuss the
dispute. The decision of the Purchaser/Engineer in regard to the interpretation
of the test results shall be final.
15.0 FINAL TAKEOVER
15.1 After successful completion of the Performance Tests, the stacking and
reclaiming system will be taken over and the guarantee period starts from this
date of Final takeover.
15.2 Till the final takeover the SUPPLIER shall provide qualified personnel to guide
the Purchaser’s O & M personnel.
15.3 Any non conformity arising out of the stacking and reclaiming system till Final
Takeover shall be rectified by the SUPPLIER at his own cost.
Purchaser/Engineer shall not be held responsible for any such non conformities
arising during this period.
15.4 Purchaser/Engineer reserves the right to declare the commencement of

commercial operation of stacking and reclaiming system at his discretion any
day after the synchronisation of the first Unit. The SUPPLIER shall not be
absolved of all his responsibilities for the reason that the commercial operation
has started.
15.5 In case any stoppages are required for repairing/replacing the parts of the
stacking and reclaiming system equipment by the SUPPLIER, the
Purchaser/Engineer shall release the stacking and reclaiming system
equipment for such repairs/replacement at the convenience of the
Purchaser/Engineer which will be decided considering the availability of fuel
grid conditions etc.
15.6 Certificate of ‘Final Takeover’ shall be issued by the Purchaser/Engineer when
a) All supplies and services have been completed as per the Contract
b) The SUPPLIER has rectified in a definite manner all objection/observations

mentioned in the commissioning certificate.
c) Final balance documentation, if any, incorporating latest modifications in as

built drawings has been submitted by the SUPPLIER in requisite copies
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DATA TO BE FURNISHED WITH THE BID
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1.0 The information sought out in Data Sheets-B of Section-D and in various Section
- F under Schedules shall be furnished by SUPPLIER in the format specified,
failing which his quotation may not be considered.
The SUPPLIER shall enclose with his proposal particulars of all drive motors
offered by him, in proforma as specified in section - F13 under Schedules with
ratings.
The SUPPLIER shall also enclose with his proposal the following drawings,
literature, write-up and information related to the mechanical, electrical, I&C, civil
and structural works to be executed under this contract.
The Supplier shall confirm that the system proposed by Purchaser /Engineer is in
order. All equipments proposed are also in order, available in the market and will
perform the guaranteed parameters for the fuel specified by the Purchaser
/Engineer.
The system proposed by Purchaser /Engineer is tentative only. Supplier shall re

check the suitability of the equipment and lay out of the system and confirm the
same at the time of bid submission.
SL.NO. DOCUMENTS SHALL BE FURNISHED ALONG WITH THE BID REMARKS
1.1 MECHANICAL
1.1.1 Manufacturer’s catalogues
1.1.2 General plan, showing layout of the proposed coal handling
system under his scope of supply.
1.1.3 General arrangement drawings for all major equipment and
miscellaneous items of coal handling system
1.1.4 Detailed component drawings for major equipment
1.1.5 Write-up for major equipment operation and working principle.
1.1.6 Spares drawings
1.1.7 Sectional elevation drawings for all conveyors, junction towers,
transfer house, crusher houses, tunnels etc.
1.1.8 Detailed general arrangement drawings showing carrying, return,
impact, self-aligning carrying, self-aligning return idlers and all
other types of idlers specified.
1.1.9 Block logic diagrams and write –up on controls of coal handling
system
1.1.10 A complete literature, schematic and layout, drawing for the, dust
suppression, bunker ventilation, plant cleaning facilities etc.
Outline drawings of all the associated equipment mentioned
above and flow diagrams wherever relevant.
1.1.11 Write-up on commands for controlling the system operation
through keyboard.
1.2 ELECTRICAL
1.2.1 Load List

1.2.2 Overall Single line diagram
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1.2.3 Filled up Datasheets of all equipments/system as per

specification
1.2.4 Description literature/catalogues and write-ups for the offered

equipment/systems
1.3 INSTRUMENTATION AND CONTROL SYSTEM
Bidder shall furnish the data / documents / drawings as per
clause 19.0 of Volume IVB, Section D4
CIVIL
1.4
1.4.1 Deviations , if any , from the specification shall be indicated in
the schedule of deviations.
1.4.2
List of software proposed to be used in various areas for
analysis, design, drafting as well as project monitoring along with
their sources and validation report for software
1.5 GENERAL
1.5.1 Actual user’s performance certificates in respect of coal handling

system.
1.5.2 Bar Chart/PERT Network schedule incorporating the following

major activities :
Design and Engineering.
i)
ii) Supply of equipment and accessories.
iii) Erection schedule.
iv) Testing and commissioning schedule.
1.5.3 Name of manufacturers of all major mechanical and electrical

equipment.
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DATA TO BE FURNISHED AFTER AWARD OF CONTRACT
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DATA TO BE FURNISHED AFTER AWARD OF

CONTRACT
1.0 GENERAL
Supplier shall submit as part of its Work Scope detailed documentation as

outlined in this section and / or required by the Technical Requirements. The
content and format of the documentation to be submitted are subject to
Purchaser/CONSULTANT approval.
Supplier shall utilize a computer based system for control of and management of
project documentation. The system must be capable of producing customized
reports and information on demand. This control system should have been
successfully applied to similar projects and be familiar to the project control
personnel selected. Supplier’s detailed project documentation plan shall identify
all documentation requirements for the project, the party responsible for
production of the document, the basic content of the document and the required
timing for issue. This plan shall include, but not be limited to, the details of all
Drawings to be produced, plant specification / definition documentation,
equipment orders and manuals. The documentation identified shall be entered
into the computer based control system The database thus created shall be
shared with the Purchaser/CONSULTANT and it also be capable of being sorted
and ordered on a variety of selected parameters such as document type, subject
description, responsible party, start date and finish date, to enable review and
update to be conducted only on those documents which are relevant. Monthly
update to the data base shall also be furnished to the Purchaser/CONSULTANT
in soft copies.
Regular documentation control progress reports shall be prepared by the

Supplier to record the status of documentation. In the event either
Purchaser/CONSULTANT expresses concern with the content of such progress
reports, the accuracy of progress reports, status of documentation production
and other such matters, the concern shall be identified to the Project Manager of
the SUPPLIER. Within five days of notification of this concern, the Project
Manager shall attend a meeting with relevant Purchaser/CONSULTANT and
provide details of specific actions to be initiated to satisfactorily overcome the
difficulties identified. It shall be the Project Manager responsibility to initiate
whatever action is necessary to ensure that the production of documentation is
completely in accordance with project documentation plan and overall project
requirements. The contents and format of the documents to be submitted are
subject to Purchaser/CONSULTANT approval.
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1.1 Drawings
1.1.1 All drawings submitted by the Supplier shall be in sufficient detail to indicate the
type, size, part no., arrangement, weight of each component, breakdown for
packing and shipment, the external connections, fixing arrangements required,
the dimensions required for installation and interconnections with other
equipment and materials, clearances and spaces required between various
portions of equipment and any other information specifically requested.
1.1.2 The Purchaser/CONSULTANT shall have the right at all reasonable times to
inspect at the factory of the Supplier all drawings, with prior intimation.
1.1.3 The Supplier shall not be relieved of his obligations under the Contract including
but not limited to his Guarantee obligations stated herein, by incorporating the
Purchaser/CONSULTANT comments.
1.1.4. The Supplier shall furnish the list of all drawings he proposes to submit for
approval/information identifying each by a serial number and descriptive title and
giving the expected date of submission. This list shall be revised as necessary,
during the progress of work, at least once in three months.
1.1.5 After the award of the Contract, the Supplier shall submit, copies of design basis
reports/concept notes, design calculations, material specifications and detailed
drawings as called for in the Contract for the Purchaser/CONSULTANT review.
The Supplier must satisfy the Purchaser/CONSULTANT as to the validity of his
design with reference to the requirements of Statutory Codes / Authorities, local
regulations and the contract specifications.
1.1.6 Drawings submitted for approval shall be signed by responsible representatives

of the Supplier and shall be to any one of the following sizes in accordance with
Indian or other International Standards:
A0, A1, A2, A3 or A4.
It is the responsibility of the SUPPLIER to take care of his sub Suppliers / sub
Suppliers drawings / documents and the Purchaser/CONSULTANT shall approve
either the drawing of the SUPPLIER or those submitted by the sub-Supplier and
furnished by the SUPPLIER to the Purchaser/CONSULTANT and not both.
1.1.7 All drawings shall show the following particulars in the lower right hand corner in
addition to the Manufacturer’s / Supplier’s name:
(a) Name of the Purchaser/CONSULTANT

(b) Project Title
(c) Purchaser’s Order No./Contract No.
(d) Title of Drawing
(e) Scale, if applicable and also Sheet No.
(f) Date of issue of Drawing
(g) Manufacturer’s / Supplier’s Drawing No.
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(h) Space for the Purchaser/CONSULTANT drawing number.

(i) Details of submission, revisions, reasons for revisions and approval.
(j) Signature of the authorized signatory
1.1.8 In addition to the above information provided on drawings, each drawing shall
carry a revision number, date of revision and brief details of revisions carried out.
Wherever any revision is carried out, correspondingly revision number must be
updated. All revisions carried out shall be highlighted on the drawing and a
separate sheet furnished stating the reasons for such revision. A note stating
“drawing is generally revised” is not acceptable. If any document/drawing
stamped as ‘Approved with comments as noted’, SUPPLIER may proceed with
the manufacturing activities provided the SUPPLIER shall ensure that all the
comments are suitably taken care of.
1.1.9 All dimensions on drawings shall be in Metric Units, unless otherwise specified.
The details in the drawings shall be in English language only.
1.1.10 Drawings submitted by the Supplier shall be checked/reviewed by the

Purchaser/CONSULTANT and comments, if any, on the same shall be conveyed
to the Supplier. It is the responsibility of the Supplier to incorporate correctly all
the comments conveyed by the Purchaser/CONSULTANT on the Supplier’s
drawings. The drawings, which are approved with comments, are to be
resubmitted to the Purchaser/CONSULTANT for purpose of records. Such
drawings shall not be checked/reviewed by the Purchaser/CONSULTANT to
verify whether all the comments have been incorporated by the Supplier. If the
Supplier is unable to incorporate certain comments in his drawings he shall
clearly state in his forwarding letter such non-compliance along with valid
reasons and justification.
1.1.12 Any work performed or material ordered by the Supplier prior to receipt of
drawings of approval category stamped ‘Approved’ by the
Purchaser/CONSULTANT shall be at the risk of the SUPPLIER.
1.1.13 Soft copies of drawings and documents as called for in the distribution schedule
shall be submitted after the approval of drawings. These should be of good
quality and capable of producing clear and legible prints.
1.1.14 Upon completion of the installation, the Supplier shall furnish a complete set of
drawings on Compact Discs (CD) on which the SUPPLIER/ Supplier shall make
in a neat and accurate manner, a complete record of all changes and revisions to
the original design, as installed in the completed work. These drawings shall be
submitted to the Purchaser/CONSULTANT.
1.1.15 Drawings prepared by the Supplier and approved by the

Purchaser/CONSULTANT shall be considered as a part of the Contract
Specification. However, examination and approval of the drawings by the
Purchaser/CONSULTANT shall not relieve the Supplier of his responsibility for
engineering, design, workmanship, materials and construction under the
Contract.
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1.1.16 If, at any time before the completion of the work, changes are made
necessitating revision of approved drawings, the Supplier shall make such
revisions and proceed in the same routine as for the original approval.
1.1.17 Drawings shall include all installation and detailed piping drawings. All piping,
NB65 mm and larger shall be routed in detail and smaller pipe shall be shown
schematically or by isometric drawings.
1.1.18 PURCHASER /CONSULTANT shall give comments/approval to the

drawings/documents within 7 days of receipt. SUPPLIER shall resubmit the
revised drawings/documents within 7 days of receipt of the comments.
1.2 For Information
The drawing and documents, which are not subject to approval, shall be stamped
“FOR INFORMATION”. However the Purchaser/CONSULTANT shall reserve the
right to comment on these drawings and documents and inform Supplier to treat
these drawings and documents as ‘FOR APPROVAL” category.
Any additional information/drawings/documents required by the
Purchaser/CONSULTANT shall be furnished by the Supplier except the
proprietary in nature.
1.3 As-Built Drawings
1.3.1 The Supplier shall prepare, and keep up-to-date, a complete set of "as-built"
records of the execution of the Works, showing the exact "as-built" locations,
sizes and details of the work as executed, with cross references to relevant
specifications and data sheets. These records shall be kept on the Site and shall
be used exclusively for the purposes of this Sub-clause. Two copies shall be
submitted to the Purchaser/CONSULTANT before final take-over.
1.3.2 In addition, the Supplier shall prepare and submit to the

Purchaser/CONSULTANT "as-built drawings" of the Works, showing all Works as
executed. The drawings shall be prepared as the Works proceed, and shall be
submitted to the Purchaser/CONSULTANT for his inspection. The Supplier shall
obtain the consent of the Purchaser/CONSULTANT as to the drawing size, the
referencing system and other pertinent details.
1.4 Conceptual Design
Before undertaking the project detailed design, Supplier shall submit for approval
the following:
(a) Preliminary Stacking and reclaiming system layout.

(b) Plant layouts and arrangements including plans, sections, and elevations.
(c) Arrangements and layouts of all auxiliary systems
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(d) Control room layout.

(e) Layouts of major control panels.
(f) Process and instrumentation diagrams (PID) of major systems.
(g) Civil, structural, mechanical, electrical, and instrumentation engineering
design criteria and conceptual design studies, evaluations, and optimization
for major structures, facilities systems and equipment.
(h) Construction plans and concepts.
1.5 Erection and Commissioning Manuals
1.5.1 Erection and commissioning manuals shall be written in English language only.
1.5.2 The Supplier shall submit to the Purchaser/CONSULTANT erection and

commissioning manuals (Both soft and hard copies) for all the equipment
covered under the Contract before sixty (60) days of the first shipment of the
equipment. These manuals shall contain full details and drawings of all the
equipment furnished, the erection procedures, testing procedures and
preliminary operation and maintenance procedures of the Equipment. These
instruction manuals shall be submitted as per distribution schedule in the
Contract.
1.5.3 If after the commissioning, trial operation and commercial operation of the plant,
the instruction manuals (Both soft and hard copies) require any
modifications/additions/ changes, the same shall be incorporated and the
updated final instruction manuals shall be submitted by the Supplier to the
Purchaser/CONSULTANT as per distribution schedule in the Contract.
1.6 Operation and Maintenance Manuals
1.6.1 The Supplier shall prepare and submit to the Purchaser/CONSULTANT,

operation and maintenance manuals (Both soft and hard copies) in accordance
with the Purchaser/CONSULTANT requirements and in sufficient detail prior to
commencement of Preliminary operation, for the Purchaser/CONSULTANT to get
familiarized with the Plant and to enable them to operate, maintain, dismantle,
reassemble, adjust and repair the Plant in a safe and efficient manner. The Plant
shall not be considered to be completed for the purposes of taking over, until the
final operation and maintenance manuals have been submitted to the
Purchaser/CONSULTANT.
1.6.2 A separate section of the manuals (Both soft and hard copies) shall be devoted
to each size/ type of equipment and shall contain a detailed description of
construction and operation, including preparation before starting, starting up of
equipment/system, checks after starting, achieving rated parameters, protection
and interlocks, stopping/shutting down procedure and equipment that are to be
run after stopping together with all relevant pamphlets, catalogues, drawings
and a list of parts for every critical equipments with reference to drawing
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numbers along with procedure for ordering spares. Maintenance instructions

shall include charts showing lubrication, checking, testing and replacement
procedures to be carried out daily, weekly, monthly and at longer intervals. To
ensure trouble-free operation a lubrication schedule/Chart equipment wise
indicating the lubricants, their equivalence of reputed firms, periodicity of
changing, their properties and quantity per equipment shall be provided. Where
applicable, fault location charts shall be included to facilitate finding the cause of
mal-operation or breakdown. A collection of the MANUFACTURER’s standard
leaflets shall not be accepted, to meet compliance of this clause. The manual
shall be specifically compiled for the concerned project.
1.6.3 The O & M manual (Both soft and hard copies) shall be clearly indexed and
separated into equipment wise sections and shall also contain the following:
a) Cross sectional drawing

b) Exploded views to enable assembly and disassembly
c) Part numbers
d) Spare parts ordering information
e) Operating principles
f) Startup sequence
g) Trouble shooting guidelines
h) Startup and commissioning checks and procedure
i) Revalidation tests after any overhaul
j) Consumables required
k) Wear parts list and replacement frequencies
l) Requirements of special tools.
m) Maintenance instruction and information
n) Condition monitoring parameters.
o) Characteristic curves for various equipment
p) Disassembling and assembling procedures of critical parts in the various
equipment.
q) Lube oil Charts for various equipment.
1.7 Document on Electronic Media Write-Protected
1.7.1 All documents including drawings, data sheets, manuals shall be provided on
electronic media viz. CD, cartridges, optical discs for installing on computer
network system. Each electronic media shall be high quality and suitable for
long-term storage. The reproduction from media shall be of good quality.
1.7.2 The Supplier shall submit the following data/information documents / drawings to
the Purchaser/CONSULTANT for their approval / information.
1.7.3 SUPPLIER soft copies followed by 6 hard copies of drawings/documents, which

are listed in Table –1 below.
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TABLE –1
DATA TO BE FURNISHED AFTER AWARD OF CONTRACT
Description Approval (A)/

Sl.No. Information (G)
1.0 The SUPPLIER shall furnish the schedule of motors for interface
electrical engineering for each stacker reclaimer, conveyor etc., and
all the other auxiliary equipment / systems within 12 weeks from the
date of Letter Of Award.
1.1 Design basis report shall be submitted for following system
a) Stockyard dust suppression system A
b) Coal pile run-off system A
Within in four (4) weeks from the date of Letter Of Award, the I
Supplier shall start furnishing progressively to the
Purchaser/CONSULTANT., all general arrangement and detailed
drawings showing all design particulars level, elevation, base
plate details anchorage details such as anchor, bolts, pipe
sleeves anchor channels, etc., details of pockets and all inserts
to be embedded.
1.2 Design Calculations
1.2.1 Mechanical
(a) The Supplier shall furnish the design calculations / computer output
for power consumption of conveyors within 10 weeks from the date
of letter of intent. The other calculations required to be submitted are
also listed below. These calculations shall also include details of belt
tensions at different locations, belt curvature, starting time, coasting
time etc.
The calculations for power consumption of belt conveyors shall also A

include the following :
1.2.2 Belt tensions at different locations for various conditions such as no A

load, full load, normal working and full load starting conditions.
1.2.3 Discharge trajectory of material A
1.2.4 Transition distance of tail pulley A
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1.2.5 Radius of curvature A
1.2.6 Starting time, coasting and braking time. A
1.2.7 GD2 and equivalent weight calculations of conveyors and drive A

equipment.
1.2.8 Counter weights A
1.2.9 Diameter of various pulleys, diameter of pulley shaft, etc. A
1.2.10 Selection of idlers, idler shaft size calculations A
1.2.11 Selection of scrapers A
1.2.12 Calculations for number of buckets, bucket sizing, reclaim capacity

for stacker / reclaimer.
1.3 Characteristic curves for fluid couplings, motors and super imposed A
on each other for checking selection of fluid couplings. Also data
sheets pertaining to selection of fluid couplings shall be submitted.
1.4 Sizing of equipment of Stockyard dust suppression system A

components / pumps shall be submitted. The calculations for
pressure drop and line sizing.
1.5 Input-output list for stacking and reclaiming system. A
1.6 Calculations related to stacker reclaimers. A
2.0 LIST OF DRAWINGS TO BE SUBMITTED FOR REVIEW /

APPROVAL OF THE PURCHASER / CONSULTING ENGINEERS
2.1 MECHANICAL
2.1.1 Flow diagram of stacking and reclaiming system and showing A

SUPPLIER’s scope clearly.
2.1.2 Plan of stacking and reclaiming system showing the coordinates of A

different equipment and structures.
2.1.3 General arrangement drawing of all the Stacker reclaimers, A

conveyors, Flap gates, flow divider if applicable, etc., Sectional
elevations of conveyors with center lines of supports, locations of
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idlers, pulleys, etc., elevations of tail pulley, head pulley, gravity take
up pulley, etc., loading details and general specifications of
conveyors.
2.1.4 General arrangement drawing of the following structures giving A

equipment layout in different floors both in plan and sections and
location of openings, fixing details, loading data, location of
monorails, location of stair cases, location of elevator, handrails,
details of side sheeting / cladding and roofing, doors and windows
etc.
2.1.5 Drive houses A
2.1.6 Storm anchoring A
2.1.7 General arrangement drawing showing the layout Stockyard dust A

suppression (SYDS) system
2.1.9 General arrangement drawing showing the layout coal-pile run off
system
2.1.11 Flow diagram, showing the SYDS with valves, timers, pumps, tanks A
etc.
2.1.12 GA of pulleys G
2.1.13 Pulley schedule A
2.1.14 GA of idlers and idler schedule G
2.1.15 GA of skirt boards and chutes G
2.1.17 Schedules for conveyor drive components, belting, pumps, etc.,
2.1.18 GA of pumps s and its accessories. G

GA drawing of each conveyor A
2.1.21
GA drawing of stacker cum reclaimer A
2.1.22
3.0 INSTRUMENTATION AND CONTROL SYSTEM (I AND C)
The list of drawings and documents to be submitted after award of

contract shall be as per Volume IVB, section D4, Clause 20.0
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4.0 ELECTRICAL
4.1 General arrangement drawings of all electrical equipment. A

4.2 Protection and metering single line diagram indicating parameters of A
all electrical equipment, CTs, PTs, location of meters, relays, etc.
4.3 Design basis report indicating main features & parameters, design & A
operating philosophies, sizing criteria, selection criteria, schemes
proposed, indication & alarm philosophy, etc.
4.4 Cable routing drawings for entire scope covered in the Specification G
giving details of cable trays
4.5 Cable schedules and interconnection schedules G
4.6 Design calculations and Overall Relay Co ordination chart A
4.7 Earthing & lightning protection system layout drawings, conveyer A
lighting layout drawings, cable carrier system layout drawings, etc.
4.8 Technical data sheet for all electrical equipment in the scope of Bidder A
4.9 All type and routine test reports A
4.10 QAP of all the electrical equipment A
4.11 Operating and maintenance instructions manuals of all equipment G
4.12 415V PMCC/MCCs
a) General outline drawing showing front and side elevation and plan of A
the equipment with detailed final dimensions and weight
b) Protection and metering single line diagram indicating parameters of all A
electrical equipment, CTs, PTs, location of meters, relays, etc.
c) Bus bar sizing calculations, CT and PT sizing calculations
d) Switchgear layout plan including floor openings and fixing A

arrangement
e) Schematic Control circuit drawings A
f) Relay Setting calculations along with curves A
g) Detailed wiring diagrams including terminal block numbers, ferrule G
numbers and cable connections
h) Inter panel interconnection wiring diagrams G
4.14 Cables
a) Technical particulars of all cables A
b) Cable sizing calculations A
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Cross section of all cables G

4.16 Control Cabinets (For all services),Local push button stations
a) Schematic diagram indicating terminal numbers for external A
connections and with a Bill of Material for all the equipment.
b) Control cabinet drawing showing outline dimensions, cable A
entry openings, floor / wall / pedestal fixing arrangement,
padlocking arrangement, weights
4.18 Motors (AC and DC)
(a) Dimensioned outline and general arrangement drawing of motor A
(b) Internal view of terminal boxes showing connection of motor i.e., star / A
delta terminal markings, clearance between phases, disconnecting
facilities and direction of cable entry and cable glands.
(c) Motor characteristics curves A
4.19 Motor Operated Valve Actuators
(a) Drawing indicating overall dimensions and mounting details of valve G
actuator on the valve
(b) Detailed internal wiring diagram of the actuator G
4.20 Control Cabinets (For all services)
(a) Schematic diagram indicating terminal numbers for external G
connections and with a Bill of Material for all the equipment.
(b) Control cabinet drawing showing outline dimensions, cable entry G
openings, floor / wall / pedestal fixing arrangement, padlocking
arrangement, weights
4.22 Stacker cum Reclaimer(E-House)
(a) General arrangement drawings of 3.3kV / 415V transformer, 415V A
switchgear etc. showing overall dimensions, foundation fixing details,
location of various devices, mimic diagram, list of protections,
annunciation and meters, cable openings, etc.
(b) Cable schedules and interconnection schedules of 3.3 kV trailing A
cable, LT power & control cables
(c) Lighting and earthing layout drawings with sizing calculations A
4.23 Conveyer Lighting System

Distribution boards and panels general arrangement dimensioned
a) A
drawings showing front, side and plan views, outline dimensions, floor
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openings, floor / wall / structure fixing arrangements, earthing

terminals and weights.
Schematic wiring diagram of the distribution boards / panels, showing

b) G
the terminal numbers.
Inside view of distribution boards / panels showing mounting and

c) G
wiring arrangement of various component equipments.
Conveyer Lighting layout drawings

d) A
5.0 STRUCTURAL
5.1 The Vendor shall furnish structural design calculations and drawings A
for all stacking and reclaiming system structures such as conveyor
gallery, trestle, drive houses etc.
6.0 CIVIL
6.1 Design calculations and drawings for all facilities and services A
pertaining to scope of contract.
6.2 Drawings of all architectural works including finishing schedule, colour A
schemes (both internal and external), side cladding, doors and
windows, flooring and false ceiling, etc
6.3 Design calculations and drawings for plumbing and building drainage A
6.4 Total quantity of concrete (grade wise), reinforcement steel (diameter A
wise) and structural steel (section wise) shall be indicated in all
construction drawings
6.5 Shop drawings / fabrication drawings of all structural steel works and I
design calculations for important joint connections
6.6 Write up on various statutory requirements and their compliance for A
various buildings and facilities
6.7 Copies of all reports on investigation and studies carried out by the A
Contractor as per the scope
6.8 Load data at the terminal point for further engineering by others
I
7.0 QUALITY, INSPECTION, SHOP AND SITE TESTING
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7.1 Quality assurance plan for all the systems/equipment/ components A

including materials used for civil construction
7.2 Quality assurance plan for all site activities including civil works, A
erection, pre-commissioning, testing and commissioning for the entire
plant
7.3 Preliminary and final shop test schedule for all the G
systems/equipment/ components
7.4 Detailed shop tests procedures including sample calculations for all G
the systems/equipment/ components
7.5 Detailed site tests procedures including sample calculations for all the G
systems/equipment/ components
7.6 Material test certificates and performance test certificates for all G
equipment tested at works.
7.7 Procedure for tests before taking-over which shall include A

performance guarantee tests, unit characteristic test, reliability test
etc.
7.8 Inspection test reports including test certificates as called for in G
quality assurance plan for all the systems/equipment/ components.
8.0 ERECTION AND COMMISSIONING MANUALS

8.1 Storage instructions for all equipment G
8.2 Erection and commissioning manuals for all the G
systems/equipment/components covered in the scope including
installation drawings
9.0 OPERATION AND MAINTENANCE MANUALS G
9.1 Operation and Maintenance manuals for all the systems / equipment/
components covered in the scope of the plant.
10.0 AS BUILT DRAWINGS / DOCUMENTATION
10.1 As-built drawings and documentation for the entire plant and all G
equipment / system supplied under this contract, for all building /
structures / works under this contract incorporating all changes /
modifications up-to the time of commissioning / handing over to the
PURCHASER.
10.2 Project design manual consisting of concept studies of all the G
systems, design criteria, sizing calculations for all major equipment /
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systems bill of material, equipment list etc.
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SECTION C 12
POLLUTION CONTROL MEASURES
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1.0 GENERAL
The Supplier shall offer a plant so as to meet the pollution control

requirements of statutory authorities. Emissions and discharges of Stacking
and reclaiming system effluents from the Thermal Power Plant shall fully
comply with all requirements and limits specified in Environmental
(Protection) Act, 1986, Minimum National Standards (MINAS), along with all
latest amendments to all of the above requirements, stipulations of the
Central Pollution Control Board (CPCB), Ministry of Environment and Forests
(MOEF) and Uttar Pradesh Pollution Control Board for the project, and any
other central or local statutory requirements regarding environmental
pollution and its abatement.
The Supplier shall be responsible for obtaining all necessary approvals,

licenses and permissions that are related to design, construction, installation
and operation of the plant. These shall be obtained at appropriate time to
ensure that the construction and commissioning programme can be realised.
1.1 DUST CONTROL
Dust emission to the air from the site, shall be controlled by providing
suitable dust suppression systems. The system shall be designed to control
dust emissions in the working area measured at a distance of 2m from the
dust generation source over and above the atmosphere background dust
level as follows.
a. Total dust concentration not more than 2 mg / Nm3 in areas.
1.2 NOISE CONTROL
1.2.1 An integrated approach shall be taken by the Supplier to control noise

emission, which shall include but not be limited to:
(a) Design and layout of building and structures to minimise transmission of

noise, segregation of particular items of plant and to avoid reverberant
areas.
(b) Specification of permissible noise levels for bought-out items.
(c) Choice of materials for civil construction
(d) Acoustic design of building
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(e) Use of lagging with attenuation properties on plant components /
installation of sound attenuation panels around the equipment.
1.2.2 Where the requirements stated above are not met within the basic design
of the system they shall be achieved by the supply under the Contract of
suitable means of noise control, which shall conform to the following
requirements:
(a) The noise control system shall, as far as possible, be designed to form
an integral part of the plant.
(b) The abatement system shall, wherever practicable, be applied to the

source of excessive noise rather than to the entire item or component.
(c) If above means are not adequate and enclosures are used for noise
abatement, close fitting and easily removable enclosures shall be
provided.
1.3 Noise in Control Areas
(a) Other Control Areas
The noise levels in various control areas must be such that intelligible
conversation (telephone and person-to-person) is possible and operator
fatigue is minimised.
(b) Noise Criterion in drive houses, junction towers etc.
The criterion for environmental noise is that the design of the station
and its components shall not exceed, in any continuous mode of
operation, the level stipulated by MOEF and/or Pollution Control Board
at any point on the site boundary. Presently the norm is such that the
noise level shall not exceed 80 dBA at 1.8 m from the equipment
surface.
(c) The maximum noise levels for rooms and offices must permit a good
understanding of speech. Limiting exposure values of sound pressure
levels for different areas are given below:
(i) Control rooms, Computer rooms : 65 dBA
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SECTION C 13
SITE SERVICES
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SITE SERVICES
1.0 SITE SERVICES
These services shall be rendered by the Supplier as part of the overall

project management service. The services shall broadly include but not be
limited to the following:
a) Construction water and construction power supply and their respective

distributions.
b) Providing support services for the Supplier’s erection staff e.g.

construction of site offices, temporary stores, residential
accommodation and transport to work site for erection personnel,
insurance cover, watch & ward for security and safety of the materials
under the Supplier’s custody etc. as required.
c) Maintaining proper documentation of all the site activities undertaken by

the Supplier as per the proforma mutually agreed with the
Purchaser/Engineer.
d) Securing necessary permits / clearances from authorities for

construction.
1.1 SITE ORGANISATION
The Supplier shall maintain a site organisation of adequate strength in

respect of manpower, construction machinery and other implements at all
times for smooth execution of the contract. This organisation shall be
reinforced from time to time, as required, to make up for slippages from the
schedule without any commercial implication to the Purchaser. The site
organisation shall be headed by a competent construction manager having
sufficient experience in supervision of construction of material handling
systems and adequate authority to take decisions at site.
1.2 SITE FACILITIES
1.2.1 The Supplier’s Central Administration Area
Supplier shall construct temporary buildings associated with site

administration, cycle stands and access ways shall also be constructed.
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1.2.2 The Supplier’s Site Office Accommodation
Before the erection of any temporary site accommodation, the Supplier

must obtain approval from the Purchaser/Engineer of the size, type,
condition, location, access and services proposed. The
Purchaser/Engineer approval shall be obtained before any accommodation
is dismantled or removed from the site. The site office accommodations
shall be reasonably maintained and suitably identified with the Supplier’s
name and that of his site CONSULTANT.
1.2.3 Telecommunication Facilities
The Supplier shall obtain and maintain his own on-site / off-site telephone
facilities.
The Supplier shall obtain permission from the appropriate authorities

before any radio wave emanating system is used at the site. This includes
radio, telephones, mobile phones and pagers, transceivers, cordless and
such any other systems. The Supplier shall ensure that the radio
communication systems do not cause interference to control and
instrumentation and communication systems installed in the power plant.
1.2.4 Employee Food Service
Food facility shall be provided on the site by the Supplier for the reasonable
use of both his and his sub-Supplier’s employees.
1.2.5 Site Records Office
The Supplier shall maintain a suitable records office to maintain updated

records of all relevant documentation and test certificates and to ensure
that these are available to meet obligations to all statutory bodies and to
any commissioning committee, working parties or test teams, which are
established to meet the needs of the contract. These records shall be
maintained and retained until hand over on completion of all works at site
and shall be subject to Audit by the Purchaser/Engineer.
The relevant documents envisaged shall include:
(a) Site Register for lifting appliances, cranes, slings, hooks, lifting beams
and tackle for construction of the works either mobile or fixed
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(b) Site Register for lifting appliances, cranes, slings, hooks, beams and
tackle supplied as part of the permanent works
(c) Scaffold Register
(d) Commissioning documents
(e) Test Certificates from works and site
(f) Operation and Maintenance Manuals
(g) Quality Assurance Documents
(h) Site Register for all portable electrically powered apparatus and tools,
both temporary and permanent
(i) Site Registers of all modifications carried out during execution by

deviating from the approved drawing giving modification number
against each. Such modifications shall have to be authorised /
approved by the Purchaser/Engineer
(j) Measurement, inspection & alignment protocols
(k) Mechanical completion protocol
(l) Performance test protocols
(m) Handing over / taking over protocols
(n) Final Acceptance Protocol
(o) Contract drawings and specifications
(p) Applicable codes and standards
(q) Erection procedure for various equipments, project schedule for

various levels
(r) Daily manpower deployment details
(s) Monthly progress report copies
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t) Site register showing details and number of machineries like Welding

m/c, Gas cutting and its accessories, Drilling and grinding machines
(Electrical and pneumatic), Air compressors, De-watering pumps, and
other special tools and tackles.
u) Site register for details of civil construction equipments like Mixers,

Batching plants, concrete chutes and pumps, vibrators, and lab
testing instruments etc.
v) Site register for details of electrical testing kits, measuring meters like
Multi-metres, Clip-on meter, Insulation tester and other erection tools
w) Approved quality control formats, erection check list, method

statements, testing pre-commissioning and commissioning check list
and methods.
x) Site register for latest revised drawing status.
y) Construction coordination protocol
z) Testing, pre-commissioning and commissioning protocols.
aa) Open and close loop checks protocol.
bb) Site acceptance test protocol.
cc) Weekly welding reports along with labelled weld maps.
1.2.6 Construction Camp of the Supplier
The Supplier shall provide himself and his sub-Suppliers work force
adequate lodging facilities. This facility shall have adequate sanitation and
recreation facilities for clean safe and healthy accommodation of his
workforce. This facility must be removed at project completion.
1.2.7 Site Security
The SUPPLIER shall comply with the guidelines to be issued by the

Purchaser security personnel for ensuring site security.
1.2.8 The Supplier’s Storage Areas
The Supplier shall be responsible for provision of suitable temporary

storage facilities and providing security for the same.
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1.2.9 Sign Boards
The erection of sign boards or posters shall not be allowed without the
Purchaser/Engineer approval of the size, type, location, wording, etc.
1.2.10 Use of Motor Vehicles, Parking and Cycle Sheds
Parking facilities and cycle sheds if necessary shall be provided by the

Supplier in a compound within the site boundary but outside the security
fence of the construction area and as near to the site access as possible.
Only authorised vehicles shall enter the construction area and these must
display the vehicle pass issued by the Supplier.
1.2.11 Civil Works
The Supplier shall have a dedicated QA / QC team for all civil works
consisting of a qualified and experienced engineer (having experience in
similar type of work with high quality standards) and assisted by qualified
technicians.
The Supplier shall establish a full fledged Civil Engineering Laboratory at

site. The Supplier shall list out all the laboratory equipment he proposes to
deploy. The Supplier shall submit a list of national level approved
laboratories where he proposes to conduct confirmatory or any other
special tests that may become necessary. The Purchaser/Engineer can
demand a test in any of the laboratories selected by them for re-
confirmatory tests.
Minimum Qualification Criteria:
• Establishing a state of the art fabrication yard for the steel, fully
equipped with appropriate tools & tackles, machinery.
• Establishing standard fabrication yard with shearing machine, drilling

machine, etc.
Establishing steel fabrication yard with bar cutting machine, bar bending
machine.
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1.3 SITE RESTRICTIONS
The Supplier and his employees shall not trespass beyond the boundary
limits of the site on to any adjoining land or other Supplier’s areas and the
Supplier shall take necessary action to prevent trespassing.
1.4 SITE ACCESS
The Supplier shall be responsible for any road improvement required for
construction traffic access and for the provision of traffic control where the
site access road joins the public road. Public traffic shall not be impeded
during the construction period and access must be maintained for
emergency vehicles.
1.5 GENERAL GUIDELINES FOR FIELD ACTIVITIES
1.5.1 The Supplier shall execute the works in a professional manner so as to

achieve the target schedule without any sacrifice on quality and
maintaining highest standards and cleanliness.
1.5.2 The Supplier shall co-operate with the Purchaser/Engineer and any other
Suppliers / Agencies working at site and arrange to perform his work in a
manner so as to minimise interference with other Suppliers’ / Agencies
works. The Purchaser/Engineer shall be notified promptly of any deficiency
in other Supplier’s / Agencies works that could affect the Supplier’s work. If
rescheduling of Supplier’s work is requested by the Purchaser/Engineer in
the interest of overall site activities, the same shall be complied with by the
Supplier. In all cases of controversy, the decision of the Purchaser shall be
final and binding on the Supplier without any commercial implication.
1.5.3 The Purchaser/Engineer may hold meetings with any/all the Suppliers /
Agencies at site at a time and a place to be designated by the
Purchaser/Engineer. The Supplier shall attend such meetings if called upon
to do so, take note of the decisions of the Purchaser/Engineer and shall
strictly adhere to those decisions in performing his work.
1.5.4 The works under execution shall be open to inspection and supervision by
the Purchaser/Engineer at all times. The Supplier shall give reasonable
notice to the Purchaser/Engineer before covering up any work or otherwise
placing it beyond reach of inspection.
1.5.5 The Supplier shall comply with all the rules and regulations of the local
authorities, all statutory laws including Minimum Wages, Workmen
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Compensation, etc. All registration and statutory inspection fees, if any, in

respect of the work executed by the Supplier shall be to Supplier’s account.
1.5.6 All the works such as cleaning, levelling, aligning, assembling, temporary
erection, opening, dismantling, surface and edge preparation, fabrication,
machining, chipping, scraping, fitting up, bolting / welding, etc. as may be
applicable in such erection and are necessary to complete the work
satisfactorily, are to be treated as incidental and the same shall be carried
out by the Supplier as part of the work.
1.5.7 Equipment and material which are wrongly installed shall be removed and
reinstalled to comply with the design requirement at the Supplier’s expense
to the satisfaction of the Purchaser/Engineer.
1.5.8 It shall be the responsibility of the Supplier to provide ladders on columns

for initial works till such time stairways are completed. For this, the ladder
should not be welded on the column and should be of prefabricated
clamping type. All temporary supports, cleats, etc. provided for erection
purpose shall be removed and the surfaces shall be ground to have a
smooth finish. After grinding all such places shall be painted as per the
specification for painting.
1.6 SITE HEALTH AND SAFETY MANAGEMENT
1.6.1 The Supplier shall be responsible for:
• The management organisation for implementation of health and safety

on site
• The identification of site hazards and assessment of risks
• The system of notifying all employees of the site safety plan, method
statements and site safety rules
• A schedule of safety meetings. The arrangements for site induction

course, training and security. The arrangements for emergency plans,
safety inspections and auditing
1.6.2 The Supplier shall ensure the safety of all workmen, materials and equipment
either belonging to him or to others working at site. He shall observe safety
rules & codes applied by the Purchaser/Engineer at site without exception.
1.6.3 The Supplier shall notify the Purchaser/Engineer of his intention to bring to
site any equipment or material which may create hazard. The
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Purchaser/Engineer shall have the right to prescribe the conditions under

which such equipment or material may be handled or prohibit the use of the
same for safety reasons. Supplier shall abide by Purchaser/Engineer
decision in such cases. No claim for compensation due to such prohibition
shall be entertained by the Purchaser/Engineer.
1.6.4 Storage of petroleum products & explosives for construction work shall be
as per rules and regulations laid down in Petroleum Act, Explosive Act and
Petroleum and Carbide of Calcium Manual. Approvals as necessary from
Chief Inspector of Explosives or other statutory authorities shall be the
responsibility of the Supplier.
1.6.5 The Supplier shall be responsible for safe storage of his and his sub-
Supplier’s radioactive sources.
1.6.5 All requisite tests and inspection of handling equipment, lifting tools &
tackle shall be periodically done by the Supplier. Defective equipment shall
be removed from service. Any equipment shall not be loaded in excess of
its recommended safe working load.
1.6.5 All combustible waste and rubbish shall be collected and removed from the
work site at least once each day. Use of undercoated canvas, paper,
corrugated paper, fabricated carton, plastic or other flammable materials
shall be restricted to the minimum and promptly removed.
1.6.6 All electrical appliances used in the work shall be in good working condition
and shall be properly earthed. No maintenance work shall be carried out on
live equipment. The Supplier shall maintain adequate number of qualified
electricians to maintain his temporary electrical installation.
1.6.7 All workmen of the Supplier working in construction site shall wear safety
helmets, safety boots and safety belts. The Supplier shall take appropriate
insurance cover against accidents for his workmen as well as third party.
1.7 TRANSPORTATION, RECEIVING, HANDLING AND STORAGE
The Supplier shall provide all necessary requirements to properly handle,

store, utilise and dispose of any Project materials considered hazardous
under any governmental or local law, regulation, statute or ordinance in
effect at the job site.
1.7.1 Transportation
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Supplier shall arrange for transportation of all equipment and materials from
the point of manufacture to the job site determination of required permits,
payment of required custom duties, and notification of Purchaser/Engineer.
The Supplier shall be responsible for all equipment and materials to be
transported to the power station site. In case of shipment, shipment shall
be made under deck except for such equipment and materials which, for
dimensional reasons, cannot be stored in the vessel’s hold. Supplier shall
be responsible for proper export packing for protection of such equipment
and material loaded on deck of the vessel. All goods, equipment and
materials shall be robustly prepared and packaged for moist tropical climate
in such a manner as to protect them in transit, and also from damage
without other means of protection, during storage at site and while enroute
to site.
Supplier shall also be responsible for any loss or damage or expense

arising from insufficiency or unsuitability of packing or preparation and
unfitness of vessel or craft conveyance container or lift van or truck or rail
carriage or air crafts for the safe carriage of the equipment. The cost of all
damages to the equipment incurred due to improper packing shall be at the
Supplier’s own expense.
1.7.2 Receiving
Supplier shall receive all materials and equipment delivered to Project site
for the work, pay all demurrage, and maintain a current, accurate inventory
and record of location for all equipment and materials in his custody.
1.7.3 Handling
Supplier shall handle all equipment and materials carefully to prevent

damage or loss and store them in an orderly manner. The use of bare wire
rope slings for unloading and handling materials and equipment is
prohibited.
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1.7.4 Storage
(a) Stored equipment and materials shall be located in defined areas to

maintain a neat and orderly site. Stored equipment and materials shall
be adequately supported and protected to prevent damage.
Equipment shall be moved into the permanent enclosure or onto its
permanent foundation as soon as practicable.
(b) Materials and equipment shall be stored above ground. In warehouses

without dry concrete or suspended floors, materials and equipment
shall be stored on platforms or shoring.
(c) In addition to storage instructions provided by equipment

manufacturers, motor bearings, collector rings, commutators, control
components, and other exposed parts shall be protected against
corrosion and periodically inspected.
(d) Electric motors, generators, and couplings in storage shall have the
insulation resistance of the windings checked monthly and records
kept to determine if the winding requires drying out.
(e) Mechanical dehydrators provided in control panels shall be maintained

in operation from the date of receipt until directed otherwise by
Purchaser/Engineer.
(f) Openings in equipment and piping not stored under weatherproof

covers shall be closed to prevent entrance of dirt or moisture during
storage.
(g) Platforms, enclosures, shoring and weatherproof of coverings for

storage shall be removed from the Project Site upon completion of the
Work.
1.7.5 Indoor Storage Facilities
(a) Indoor storage shall consist of fireproof buildings, which are weather-
tight, well ventilated, secure against theft and vandalism and situated
and constructed to prevent flooding. Drainage shall be provided to
intercept and divert storm or surface water. Stored equipment and
materials shall be placed on pallets or shoring to permit air circulation
under the stored item. Access doors shall be adequate to
accommodate the movement and handling of materials and
equipment and equipped with secure locks.
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(b) Plant chemicals and other hazardous materials as applicable shall be

stored separately from other materials and equipment. Chemicals
shall be protected against moisture and extreme temperatures.
Adequate ventilation shall be maintained. Non-compatible chemicals
shall not be stored adjacent to each other.
(c) Indoor storage facilities shall be acceptable to Purchaser/Engineer.
(d) Construction trailers or portable enclosures acceptable to the

Purchaser/Engineer may be substituted for the indoor storage facilities
described above.
Instrumentation, controls and computer equipment shall be stored in

separate facilities that are totally air-conditioned to control relative
humidity and temperature.
1.7.8 Open Platforms
(a) Open platforms shall be constructed from sound lumber not less than
50 mm nominal thickness sufficient to support the loads imposed by
the stored materials and equipment. Platforms shall be not less than
450 mm above grade level and supported on concrete block piers.
(b) Shoring shall utilise sound timbers not less than 150 mm by 200 mm
nominal size, arranged to provide atleast 200 mm of clearance above
grade.
1.7.9 Coverings
Weather-proof coverings shall utilise waterproof flame resistant type

sheeting of maximum practicable widths and, if necessary, may be built-up
by using water-proof taped splices. Sheeting shall be carefully placed to
prevent moisture from entering the laps and secured to prevent wind
damage.
1.7.10 Storage Methods
Except as otherwise specified, the storage method to be used for various

materials and equipment shall be determined as follows:
(a) Equipment and materials which incorporate electrical equipment or

have finish painted surfaces, and other items subject to damage by
outdoor exposure, shall be stored indoors. If indoor storage requires
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unreasonable building space or volume, the equipment or materials

may, when acceptable to Purchaser/Engineer, be stored under
weather-proof coverings on shoring or platforms. Such coverings shall
enclose the top and sides of the equipment.
(b) Small loose items easily lost, stolen, broken, or misused shall be
stored indoors.
(c) Other equipment and materials shall be stored on open platforms or

shoring.
(d) All the electronic items shall be stored in an air conditioned room.
1.7.11 Maintenance of Construction Facilities
The Supplier shall be responsible for the maintenance of construction

facilities from time of their erection and during the construction and until
completion of the Work. This shall include relocation as necessary to
facilitate the Supplier’s work, and as required to permit access for work.
Maintenance shall afford personnel safety and prevent damage to property.
1.7.12 Maintenance and Use of Roadways:
(a) The Supplier shall make adequate provisions to prevent unnecessary

interference with the use of public and private roads, walkways,
drives, and parking lots. The Supplier shall provide and maintain
suitable detours or other temporary expedients, if necessary.
(b) The Supplier shall repair roads, walkways, and other traffic areas
damaged by his operations. Traffic areas shall be kept as free as
possible of excavated materials and maintain them in a manner to
minimise dust. The Supplier shall provide adequate watering service
and equipment to wet down roads, construction areas, and unpaved
surfaces to control dusting.
(c) The Supplier shall provide traffic barricades, construction signs, speed
limit signs, warning lights, guards, and all other devices and services
necessary to adequately protect the public and site personnel.
(d) Bridging over open trenches shall be provided where necessary to

maintain traffic.
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(e) The Supplier’s employees and delivery vehicles shall use the
designated entrance road and gate to the station. Likewise the parking
lots constructed by the Supplier shall be used for parking of the
Supplier’s employees’ vehicles. Speed limits on the site shall be
observed for all vehicles under the control of the Supplier, his
employees, and those making deliveries of materials and equipment.
(f) The Supplier shall stabilise and maintain the ground in his immediate
work areas by spreading of crushed rock as required to allow the
orderly progress of work with wet grounds.
(g) The Supplier shall maintain unpaved areas including grading and
additional crushed rock as required.
1.8 CLEANLINESS AND WASTE DISPOSAL
1.8.1 Throughout the period of construction of the works the Supplier shall
maintain the whole area of his operations in a clean, tidy and safe condition
and shall arrange his materials in an orderly manner, all to the satisfaction
of the Purchaser/Engineer.
1.8.2 Scrap and waste materials are Purchaser’s property. The Supplier shall
collect all the scrap/waste materials and store them in the area earn
marked by the Purchaser/Engineer. Where practicable, screening shall be
provided to prevent the ingress of dust and dirt to any part of the works.
The Supplier shall clearly state, in the appropriate schedule, what provision
is being made for disposal of waste materials both on and off-site.
1.8.3 The Supplier shall not cause pollution of the site land drainage system or
any water course by waste products from any source whatsoever.
Whenever any pollution is attributable to any act or omission on the part of
the Supplier, the Supplier shall clear the pollution as soon as possible and
make early arrangements to remedy the cause.
1.8.4 All hoses, cables, extension cords, and similar materials shall be located,
arranged, and grouped so that they shall not block access way and shall
permit easy cleaning and maintenance. At the close of each work week
and at the close of each day preceding a holiday, all such items shall be
removed from the construction area and stored in the Supplier’s
warehouses or other storage areas.
1.8.5 Promptly upon the completion of the construction work, all scrap, waste
materials, and debris resulting from work under the Contract shall be
removed from the site. All Supplier-owned facilities, materials and
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construction plant shall be removed from the site. The Supplier shall
thoroughly clean the work, removing all the accumulations of dust, scraps,
waste, oil, grease, weld spatter, insulation, paint, and other foreign
substances. Surfaces damaged by deposits of insulation, concrete, paint,
weld metal or other adhering materials shall be restored by the Supplier.
1.8.6 The Supplier shall make himself familiar with all statutory requirements
relating to the discharge of effluent from the plant and shall take all steps to
ensure that these are not contravened by the disposal of effluent from site.
No dangerous or noxious waste products, chemicals or materials shall be
disposed of, on or off the site without proper treatment to make the quality
comply with environmental regulation.
1.8.7 The Supplier shall take all necessary measures to ensure the safe
collection and disposal of waste oils pertaining to those works or plant for
which he has responsibility and to ensure the prohibition of:
(a) Any discharge of waste oils into surface waters, ground waters or
drainage systems of any kind.
(b) Any deposit and / or discharge of waste oils on to the ground or floors
of buildings and any uncontrolled discharge of residues resulting from
the processing of waste oils or the cleaning of oil contaminated
surfaces with solvents.
In order to ensure compliance with this requirement the Supplier shall

provide suitable vessels for the collection of all waste oils. Where
large quantities of waste oils need to be stored prior to being disposed
off in bulk, suitable storage tanks shall be provided by the Supplier for
this purpose.
(c) Any processing of waste oils causing air pollution which exceeds the
level prescribed by existing statutory provisions
In the event that the Supplier fails to comply with the above, the
Purchaser/Engineer reserves the right to carry out such work on his
behalf and to recover such expenses from the Supplier.
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1.9 SANITATION AND DRAINAGE
The provision and maintenance of all temporary and permanent foul

drainage and sewage disposal at site shall, during the construction period,
be the responsibility of the Supplier,
1.10 ENVIRONMENTAL REQUIREMENTS
The Supplier shall fully comply with requirements of all acts, regulations,
and bylaws of Central and State Government of India concerning air, water,
noise and land pollution.
The Indian Environment (Protection) Act, 1986, prohibits the carrying on of
any industry, operation, or process which discharges or emits any
environmental pollutant in excess of standards prescribed under the Act.
Emission standards are prescribed in Schedules to the Indian Environment
(Protection) Rules, 1986.
The Supplier shall make every effort to minimise the negative impact to the
environment through cautious planning of the work and strict adherence to
local laws and regulations. No trees, shrubs, hedgerows, or other elements
of the terrain shall be removed or disturbed unless essential for the work
associated with the Contract without the written consent on the
Purchaser/Engineer.
Plant effluent and storm water shall be handled separately and shall not be
combined.
1.11 FIRE PROTECTION
1.11.1 The Supplier shall provide complete fire protection facilities for all his work.
1.11.2 Only work procedures which minimise fire hazards to the extent practicable
shall be used. Combustible debris and waste materials shall be collected
and removed from the site each day. Fuels, solvents, and other volatile or
flammable materials shall be stored away from the construction and storage
areas in well marked, safe containers. Good housekeeping is essential to
fire prevention and shall be practiced by the Supplier throughout the
construction period.
1.11.3 Unless specified herein for a particular application, untreated canvas,

paper, plastic, and other flammable flexible materials shall not be used on
the site for any purpose. If such materials are on equipment or materials
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which arrive at the site, they shall be removed and replaced with an
acceptable covering before storing or moving into the construction area.
1.11.4 Likewise, corrugated paper and fibreboard cartons shall not be permitted in
the construction area for the storage or handling of materials. If such
cartons do arrive in the construction area, they shall be immediately
unpacked and removed from the site. Acceptable flexible materials for
covering shall be waterproof and flame resistant.
1.11.5 Formwork, scaffolding and similar materials which are combustible but
which are essential to execution of the work shall be treated for fire
resistance or otherwise protected against combustion resulting from
welding sparks, cutting flames, and similar fire sources. Temporary heating
facilities shall not be left unattended.
1.11.6 The Supplier’s supervisory personnel and a sufficient number of workmen

shall be instructed in proper methods for extinguishing fires and shall be
assigned specific fire protection duties. When trained personnel leave the
job, new personnel shall be trained in their duties. All workmen shall be
instructed in the selection and the operation of each type of fire extinguisher
for each type of fire which might be encountered.
1.11.7 The Supplier shall provide adequate fire protection and detection equipment
in each warehouse, office, and other temporary structures, and in each
work area he is occupying as specified herein. Access to sources of fire
water shall be identified and kept open at all times. Suitable fire
extinguishers shall be provided in enclosed areas, in areas which are not
accessible to fire water, or in areas which may be exposed to fire that
cannot be safely extinguished with water. Each fire extinguisher shall be of
a type suitable for extinguishing fires which might occur in the area in which
it is located. In areas where more than one type of fire might occur, the type
of fire extinguisher required in each case shall be provided. Each
extinguisher shall be placed in a convenient, clearly identified location
which shall most likely be accessible in the event of fire.
1.11.8 The Supplier alone shall be responsible for providing adequate fire
protection. Failure of the Supplier to comply with, or the Construction
Manager to enforce, the above requirements shall not relieve the Supplier
from responsibility or obligation under the Contract.
1.12 INDUSTRIAL RELATIONS
1.12.1 The Supplier shall develop a comprehensive labour relations plan. The
objectives of the plan shall be to provide positive motivation and job
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satisfaction from the project and work, to recognise that work improvements
and Project improvements can come from the employees, and to recognise
the individual’s contributions to a job well done.
1.12.2 The Supplier shall publish a copy of the Project work rules and regulations
at the site in English & Hindi. All employees on the Project shall be required
to follow these rules and regulations upon employment at the site.
1.12.3 The Supplier shall establish a site steering committee to meet monthly. The
steering committee shall include the Supplier’s and Sub-Supplier’s onsite
field management personnel and onsite labour Representatives. The
Purchaser/Engineer reserves the right to attend these meetings. Topics at
the monthly meeting shall include Project status and schedule, safety
improvement suggestions, and site condition improvement suggestions.
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SECTION C 14
SUPPLIERS HEALTH AND SAFETY PROGRAM
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1.0. SAFETY ORGANISATION
1.1 Safety Policy
The Contract Organisation shall have a written health and safety policy
issued by the Chief Executive of the Organisation, appropriate to the scale
and nature of the risks involved in the contract works. A copy of the Policy
shall be made available to the PURCHASER before signing the contract
agreement as evidence of Supplier’s commitment to management of
employee's health and safety and compliance to Statutory and regulatory
requirements. The Policy along with its Component operation procedures
shall be evidenced as working document publicised among Supplier's and
his Sub-Suppliers' employees through appropriate language/s. All Suppliers’
employees shall be familiar with the Safety Policy and their role and
obligations in its implementation. The Policy shall meet the relevant
statutory and regulatory requirements and the requirements of the
PURCHASER. The Policy shall periodically be reviewed for updating with
respect to new and emerging legal, statutory and other requirements.
1.2 Safety Representative
a) Supplier shall appoint a Safety Representative (SR) meeting

statutory competence requirements, with a minimum experience of
five years of safety management in comparable contracts, approved
by the PURCHASER on the basis of his qualification and experience.
The SR shall give his whole time to the superintendence of the
Health and Safety Programme of the Supplier.
b) The Supplier shall also nominate in writing competent Safety

Appointees from different disciplines to assist SR in implementation
of health and safety measures in their routine contract works. The SR
shall have sufficient authority to direct Supplier’s or his Sub-
Supplier’s personnel to meet health and safety requirements and to
stop performance of work until such requirements are met.
1.3 Employee Consultations, Safety Committee and Communication
a) Supplier shall ensure full involvement of all his employees

recognizing their right to consultation on health and safety matters.
The safety appointees of the various areas, in conjunction with the
SR shall be responsible for ensuring employees' involvement through
routine safety inspections, hazard and risk assessment in new and
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changed works and their control. Supplier shall maintain appropriate

operating procedures to guide these requirements.
b) The Supplier shall also appoint a Safety Committee (SC) comprising

of Safety Appointees from the various areas under the chairmanship
of the SR. The committee shall meet at periodic intervals of atleast
once in a month to discuss the status and adequacy of the safety
management, and any safety concerns of the employees. The
committee shall also formulate and validate the safety procedures
incorporating controls to prevent or mitigate hazards and risks before
submission for approval by PURCHASER/CONSULTANT. The
minutes of SC meeting shall be submitted to the PURCHASER /
CONSULTANT. SR shall maintain the records of the meetings
c) Supplier shall communicate to the employees regularly on job

hazards applicable to their tasks in hand. Safety Appointees (SA's or
any of SR's nominees.) shall hold 'Toolbox talks' for this purpose on
a routine basis before undertaking any safety critical and /or non-
routine activities. Weekly meetings of the Supplier and his Sub
Supplier attended by the SR and SA's shall include safety as a key
item in the agenda to discuss hazards and risk assessments, Job
safety analysis, and control procedures and to review accidents and
incidents (Near-miss) for remedial measures to prevent such
occurrence. The minutes of the meeting shall be submitted to the
PURCHASER / Supplier. SR shall maintain the records.
1.4. Supplier's safety reports
The Supplier shall submit a monthly written report to the PURCHASER/

CONSULTANT, which shall be due on the fifth working day of every month.
The health and safety of all full time, part-time, permanent temporary,
contract employees and any outsourced employee undertaking any part of
the contract-works shall be included in the safety report. The report shall
include the total number of working hours for the month, the number of
recordable accidents and the number of lost-time accidents. A cumulative
trend plot of the monthly severity and frequency rate of the reportable
accidents shall be included in the monthly safety report and calculated as:
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LOST MANDAYS DUE TO LOSS-TIME INJURIES x 1000000

SEVERITY =
MANHOURS WORKED
NUMBER OF LOST TIME INJURY x 1000000

FREQUENCY=
MANHOURS WORKED
Supplier shall arrange to display the safety statistics and the cumulative
plot of severity and frequency of accidents mentioned above painted in a
safety board which shall be prominently displayed, as a means of
encouragement and assurance to all interested parties and for publicising
the safety achievements.
1.5 Supplier's accident/incident reports
"Accident" for the purpose of this clause is defined as "Undesired event

giving rise to death, ill-health, injury, damage or other loss" and "Incident" is
defined as “Event that gave rise to an accident or had the potential to lead
to an accident”. An accident where no ill health, injury, damage or other loss
occurs also referred to as "near-miss". Incident includes near miss.
The Supplier shall report orally, to PURCHASER and Engineer regardless of

their extent, duration and severity, immediately on occurrence of all
accidents resulting in:
a) Personal injury,
b) Property damages,
c) Fires,
d) Spills and
e) Near-misses
Supplier shall submit the accident/ incident report in writing to PURCHASER

/ CONSULTANT within 24 hours of its happening in the form as prescribed
by the governing statute or in the absence of which, in the form prescribed
by the PURCHASER/CONSULTANT. Supplier shall detail in the
Accident/Incident report, the particulars of the dangerous occurrence
leading to the accident, lost time of absence due to accident, root cause
analysis and the corrective and preventive actions to prevent such
recurrence. In addition, Supplier shall include his estimate of the impact of
accident on project schedule. Incidents shall also be reported in the same
manner identifying root cause/s to eliminate such potential occurrence or
risks.
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1.6. First - Aid Personnel and Facilities
a) The Supplier shall make available first-aiders, first-aid boxes and or

first aid stations as per statutory requirements. The persons holding
current certificates of competency of recognised institutions in
prescribed numbers as per any governing statute and in the absence
of such regulatory requirement a minimum of one first-aider for each
area of work for every hundred workmen. First-aiders' names shall be
prominently displayed.
b) The first-aid boxes shall display contents of medical and medicinal

articles with quantity maintained, which shall be in accordance with
governing statute. Nominated first-aider shall replenish stock
promptly.
The first-aid refresher training shall be provided at least once in a year and
all employees shall be encouraged to undergo first-aid training. A record
shall be kept of all first aid treatments with particulars of treatment and
personnel providing the treatment.
1.7. Occupational Health Centre
a) Where required by the Contract, Supplier shall establish and maintain

an occupational Health centre where hazardous Processes are
involved such as Roof work, Steel work, working above or below
water Demolition and Confined space. Where PURCHASER
maintains the Occupational Health centre facilitating the Supplier,
such a facility shall meet the requirements laid by the governing
statute and this shall be stated in the Contract. Where the Supplier
outsources such facility, it shall meet the statutory requirements and
shall be approved by the PURCHASER and the statutory body.
b) The occupational Health facility shall be served by a full time medical

officer holding a medical degree in allopathic medicine with a
minimum of five years experience in Occupational health/ medicine.
A Nurse, One dresser / Compounder and one sweeper cum Ward
boy who shall all be available during entire construction operations
during the day shall assist the medical officer.
c) The Occupational Health Centre shall be capable of undertaking

Emergency care services or Emergency treatment facilities which
shall include emergency life saving aids and appliances to handle
Head and spinal injuries, severe fractures, snake bites, burns of all
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nature, Electric shocks, cases of asphyxiation and such other severe

injuries as could be reasonably anticipated and the facilities shall
meet provisions of any governing statute.
1.8 Ambulance Room and Ambulance Vans
PURCHASER shall arrange for an ambulance room and an ambulance van

directly or outsource the facilities meeting the governing statutory needs for
prompt transportation of serious cases accident and or sickness to the
Hospital. Such facilities shall be maintained in good condition and equipped
with facilities such as dry powder type extinguishers, flashlights Portable
Oxygen Unit, self-contained breathing apparatus etc as prescribed by the
governing statute.
1.9 Induction and job-safety training
a) Supplier shall maintain a procedure for identification of the training

needs and training his employees to create a health and safety
conscious work-force that shall comply with the law and safety
requirements of the Organisation. He shall also maintain a
procedure for safety induction and initial training as well as follow-up
training on the job safety for new entrants. All employees shall
receive effective training and periodic refresher training on the
operation control procedures specific to their tasks designed to
control the job-safety risks. A booklet of such operation control
procedures and safety rules with need based pictorial illustrations
shall be made available to all employees who are to learn and be
familiar with such procedures. All training shall be monitored for
effectiveness as per established procedures. Supplier shall maintain
records of all training.
b) Safety Representative and Safety Appointees shall conduct regular

fortnightly or weekly mock-safety drills for different imaginary
accident scenarios, in premeditated work areas to provide on-job
training such as:
i Use of safety appliances such as water monitors, hydrants,

hydrant pumps, fire-hoses, extinguishers, breathing apparatus
and safety harness for working at height.
ii Response to health & safety emergencies,
iii Fighting fires using different equipment and
iv First aid
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Participants shall receive training during mock-drills through role-play

of their normal expected tasks during emergencies and fire fighting.
The degree of demonstrated ability in the chosen tasks during such
safety drills shall be recorded as participants' competence level for
planning his further training. The experience gained in mockdrills
shall be used to update of operational control procedures and the
training needs. The roster of participants and contents for routine
mock-drills shall be appropriately planned to cover all employees in
the training at least once in four months.
c) The Safety Representative and Safety Appointees shall be trained on

a standardised comprehensive advanced training programme
covering safety management, legal aspects, techniques of hazard
identification and risk assessment and specific job-safety in various
disciplines such as Civil, Electrical, Instrumentation and Mechanical
plant and equipment of the Supplier. The training records shall be
maintained subject to audit by PURCHASER/CONSULTANT.
Training effectiveness shall be assessed and recorded and used as
input for further training plans of the employee.
1.10 Health and Safety Promotion
Safety posters, banners and slogans displayed for safety promotion shall be
rotated at frequent intervals. The Supplier is encouraged to have safety
promotion as an item in the safety committee agenda. Supplier is
encouraged to include safety promotion programmes such as: safety
bulletins, magazines, competitions in slogan and poetry writing on safety,
screening of safety films, celebration of national safety and environmental
day, safety suggestion schemes and safety library etc.
1.11 Purchase and Procurement Control
a) The Supplier shall maintain a procedure for control of his purchases

to ensure that all safety requirements are appropriately vetted by the
safety personnel during all stages of procurement including planning
of specifications, inspection for acceptance and commissioning in
order that threats to safety are not overlooked and appropriate
attention is paid to the training of personnel in the operation of
Supplier's new or changed machinery and their operation control
procedures, to prevent / control risks.
b) Supplier shall exercise due diligence in appointing his sub-Suppliers

and outsourcing contract services, that no new health and safety
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threats are created. Supplier shall ensure personnel of sub-Suppliers

and outsourced contract services are competent in health and safety
management to meet the Policy requirements. They shall be made
aware of the safety rules, emergency procedures and any information
that shall have a bearing on the safety, health and related contractual
obligations
1.12 Hazard Identification and Risk Assessment
a) Supplier shall ensure that his key personnel and safety personnel are
trained to be competent in hazard identification, risk assessment and
risk control processes. Supplier shall on a routine basis identify,
evaluate and control all health and safety risks especially in the
hazardous work activities and also to validate the previous risk
assessments. Elements such as hazard identification, evaluation of
risks with existing control measures in place and estimate of
tolerability of the residual risks shall be an ongoing process. Any
additional/New control measures shall be designed based on this
process on need basis.
b) Supplier shall maintain a Hazard Identification, Risk Analysis and

Risk Control Manual (HIRARC) pertaining to all his activities duly
updated as detailed above. The HIRARC manual shall be made
available to the CONSULTANT during regular inspections and audits.
1.13 Work Permits
The Supplier shall maintain a work permit procedure to limit the hazardous
processes and high risks tasks to authorized personnel, who shall be
informed of the job safety analysis and the job specific safety precautions,
on issue of a work-permit. The work permit issued under the procedure shall
be valid for a specified period and shall be issued only after all safety
precautions are fulfilled and duly verified by SR/SA or specialists who are
authorized for safety certification as a prerequisite for issue of a work
permit. The work permit shall be appropriate for the purpose for which it is
issued. The different work-permits are:
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a) A Safety Work Permit (SWP)
SWP is mandatory for working in heights, on fragile roofs such as

Asbestos or such roofing works, Steel structural Erection, Work over
water, a live substation or switch-yard even if section of work is not
electrically charged, Demolition, Blasting and such potentially
hazardous Contract works in the opinion of the CONSULTANT /
PURCHASER
b) Hot-Work Permits (HWP)
HWP shall be used where hot working (like electric or gas welding,
gas cutting, or burning or any other operation involving heating, open
flames or electric arcs, grinding and electrical works etc) is potentially
dangerous in areas such as inflammable materials storage, plant and
pipe lines handling inflammable and or explosive materials either
presently or in the past, or where new works are undertaken
adjoining such works which in the opinion of the
PURCHASER/CONSULTANT are potential risks. A HWP shall be
deemed mandatory in all such potentially dangerous areas. Supplier
shall get areas such as Welding shops or maintenance areas
approved by PURCHASER / CONSULTANT for ‘Permit-Free
‘Operation.
c) Confined Space Entry Permit (CSP)
CSP is issued for entering and carrying out tasks in confined space.
Confined Space for the purpose of this clause is defined as an
enclosed or partially enclosed space which is not intended or
designed primarily as a work place and
i. Is at atmospheric pressure during occupancy
ii. Has restricted entry and exit
iii. Has potentially harmful levels of toxic or inflammable
contaminant or unsafe levels of oxygen.
iv. Is of a nature that could contribute to overwhelming a person
by an unsafe atmosphere
v. has a potential that safety on entry could be affected by
unsafe conditions stated above by accident or due to human
errors
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vi. Confined spaces shall include but not limited to: storage tanks,
Process vessels, Bins, Boilers, ventilation or exhaust ducts,
Sewers, Underground Utility vaults, Tunnels, Pipelines and
open top spaces more than 4 feet in depth such as pits, tubs,
vaults and vessels.
d) Electrical Safety permits/Lock-out and tag out (ESP: LOTO)
Supplier shall institute an electrical safety permit system to ensure
safe electrical isolation. Safety permits shall not be issued until safe
release tag is placed on the equipment isolated on all isolating points.
The safety permit shall be returned on satisfactory completion of the
job by the executing agencies duly signing off indicating that all
shorts and grounds and men and materials are removed from the job
and that the job safe for energizing. This is a prerequisite to energize
the isolated equipment. The safety tags shall be collected in the order
first the isolated equipment and lastly the tag on the main control of
the equipment. The tags and permit system shall be auditable.
1.14 Job Safety Inspection
The Supplier shall maintain a procedure for Safety Inspection at routine

intervals to provide assurance that the instituted safety procedures are in
place to prevent deviations from established standards that could lead to a
safety hazard and consequential risk. The Supplier shall establish
appropriate standardized checklists for systematic job safety verification to
ensure:
a) set standards are followed without deviation,

b) employees are competent to perform as per prescribed operation
control procedures,
c) monitoring of safety of the various work areas/tasks and
d) adequacy of existing operation control procedures and practices to
mitigate and eliminate risks.
Should the existing operation control procedures prove inadequate and the
residual risks are higher than tolerable levels, SR shall initiate hazard and
risk assessment/analysis and consultations with Safety Committee to deploy
appropriate remedial measures and improved operation control procedures.
Periodic inspection reports and proposed remedial measures shall be
submitted to PURCHASER. Records of changes in control procedures
consultations with Safety Committee and revision of Operational controls
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shall all constitute objective evidence of the existence of established

procedures.
1.15 Safety Audits
a) Supplier shall undertake periodic safety audits to confirm through

investigative methods the effectiveness of the measures set out in the
Safety Policy. In order to be effective such safety audit shall be
comprehensively covering all aspects detailed in this specification to
ensure effective Loss-control / accident prevention programme. Safety
audits shall take into account the safety inspection records, remedial
measures and effectiveness of the safety programme. Effectiveness
of safety Programme shall be based on Supplier’s effective Hazard
identification and risk assessment processes for design of Operation
control procedures and on the safety statistics. Audit reports and
preventive actions and Safety Improvement programmes shall be
submitted to PURCHASER.
b) PURCHASER shall retain his right to audit Supplier’s Safety

management System either directly by his Employees or his
nominated representatives for its effectiveness
1.16 EQUIPMENT AND SUBSTANCES AND PERSONAL SAFEGUARDING
1.16.1 Mechanical Safety:
a) Supplier shall ensure that all his equipment and machinery are safe
to use while in motion or working. Operators shall have received
training or instruction on operation of the machinery and the
regulatory requirements. Supplier shall have adequate procedure to
ensure the stability and securing of his working machinery during
operation. He shall restrict repair and maintenance of the machinery
to trained personnel and maintain records of repairs and
maintenance. The equipment shall have appropriately designed
means of isolating from sources of energy and shall have emergency
stop control, which is easily accessible. All controls shall be clearly
and uniformly marked. All operation controls, interlocks, sensing
devices and guards on tools and equipment shall be functional and
their status shall be regularly checked and recorded. Supplier shall
provide evidence of compliance to these requirements in any
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contractual write-ups submitted to PURCHASER /CONSULTANT for

approval in respect of critical construction/ contract works.
b) Supplier shall provide only good quality hand tools and ensure
control of condition, storage, routine inspection and use of such
hand-tools. Unsafe tools such as with cracked or broken handles,
mushroomed chisels and punches, worn screwdrivers, hardened
hammerheads; power tools with unsafe resistance to earth or without
safety guards shall be prohibited.
c) All safety ladders and scaffolding and such access equipment shall
meet requirements of IS 3696: and IS 4014:1967 and such standards
CONSULTANT/ PURCHASER may stipulate. The safety work
permits shall be issued only after ensuring that all safety
requirements of access equipment are complied with. Access
equipment shall be inspected on a routine basis to prevent injuries
caused by falls.
d) Supplier shall ensure safety of all those concerned with lifting and
those who may be affected by material hoisting, lifting and handling
using various mechanical aids. All lifting equipment such as cranes,
hoists, lifting shackles, hooks chains and links shall be designed as
per appropriate International codes of construction. Operators shall
have been trained in operation and maintenance of such equipment
besides training on standard hand signals to be employed during the
hoisting and lifting operations. Safe working loads shall be marked on
equipment prominently. SWL shall be evidenced to have been
established by test procedures in accordance with acceptable codes
of practices.
e) Riding on construction equipment, forklifts and cranes shall be

prohibited unless such vehicles are provided with passenger seats.
f) Pressurised gas and air systems shall be maintained safe in good
working order and shall meet the requirements of the Factories Act
1948,The Static and Mobile Pressure Vessels Rules 1984 and the
Gas Cylinder Rules 1934 as applicable. The safety relief valves,
safety appurtenances and isolation systems shall be compliant with
safety code of practices. Any statutory register of pressure vessel
records and the code of practices shall be subject to periodic auditing
by PURCHASER and CONSULTANT.
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g) The areas of highly dangerous activities like hoisting, lifting and rock
blasting, and radiation, shall be appropriately barricaded to protect
personnel and machinery and guided by work permit discipline.
Emergency plans shall cater to emergencies arising out of such
activities.
h) Signs, barricades, barrier tapes and warning or entry restriction

devices or accessories shall be provided to minimize work related
risks of accidents and injuries. Signage shall meet all regulatory
requirements such as under The Building and other construction
workers Act 1996, Factory Act 1948,Manufacture, Storage, Import of
Hazardous Chemicals Rules under Environmental Protection Act
1986,Indian Explosives Act 1984 and Gas Cylinder Rules1981 and
Indian Electricity Act 1910 and Rules there of and any other safety
requirements of PURCHASER and CONSULTANT.
1.16.2 Electrical Equipment-Safety
a) Supplier shall provide only such equipment for work that is electrically
safe to work. Supplier shall have a procedure to identify and record
all his electrical equipment in a register, with provisions to record his
periodic inspections of such equipment. Inspection shall cover
cables, extension leads, all electrical equipment drawing power from
socket outlet. He shall identify and maintain in good working order all
electrical installations such as distribution panels and major
switchgear ensuring safe accessibility. A clear area shall be
maintained around Panels and switchgears. The installed equipment
shall be periodically inspected by qualified personnel to ensure their
continued safe operating condition. Inspection shall include earth
polarity checks, continuity checks and earth resistance checks.
Supplier shall ensure use of flameproof and explosion proof
switchgears and lighting fittings where required as per governing
codes.
b) Approved earth leakage relays or alternative safety devices to

relevant IS/International codes shall be used on all portable electrical
hand tools. Where possible low-voltage electric power supply shall be
used for hand tools, earth leakage units shall protect electrical
installations in workshops, kitchens, cafeterias, first-aid rooms,
laboratories and Offices. Record of regular checks shall be
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maintained. Supplier shall comply with "Code of practice for earthing"

as per IS 3043:1987
c) Safety rubber matting of appropriate voltage rating conforming to IS

5424:1969 titled "Rubber mats for electrical purposes" shall be
provided in front of all switchgears and power distribution panels for
the safety of personnel operating such equipment
d) Supplier shall arrange displaying signages under Indian Electricity

Act 1910, such as :
i Danger notices as per IS 2551 in conspicuous places on all

low, medium and High voltages as per Rule 35,
ii Instruction of restoration of persons suffering from electric
shock in English and local languages as per Rule 44 in switch
gear rooms, substations and places where electricity is used
and
iii Notice prohibiting unauthorized entry in areas where electrical
apparatus are used.
e) All power cables providing construction power to various construction

machinery and the connectors shall be in safe and sound condition.
Cables shall be routed through cable trays supported on
appropriately designed structures, duly clamped, secured and
identified. Road crossing cables shall be laid in conduits buried at
least 600 mm. below the surface to prevent damage due to vehicular
traffic. All cables shall be off the floor to avoid damage or tripping
hazard. Cables shall be terminated at the switchgears and sockets in
a workman like manner to prevent loose contacts and flashover. Only
safety receptacles shall be used for providing power connection to
hand-tools. All switches and distribution boards shall be clearly
marked. All electrical distribution and panel wiring diagrams shall be
available with the electrical maintenance personnel. Supplier shall
maintain a safe electrical isolation/lockout procedure.
f) Supplier shall ensure lighting circuits are not used for hand-tools. No
electrical equipment shall be overloaded. Tools and test equipment
used on electrical systems shall be insulated.
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1.17 RADIATION EQUIPMENT SAFETY
• Supplier shall ensure no radiation related hazards.

• Supplier shall observe statutory rules in regard to radiation source.
• Supplier shall “guard-on” the area and install required sign boards.
1.18. Substances Abuse Plan
The Supplier is encouraged to have a "substance abuse programme", and

pre-employment drug testing. Drinking during working hours shall be strictly
prohibited. Supplier shall promote through poster and other publicity,
awareness on abuse of substances such as alcohol and such depressant
drugs that slows the activity of brain and spinal cord on abusive usage
endangering the safety and health of users and others affected by their
work.
1.19 Hazardous Substances Control
a) Supplier shall prevent all injuries, illnesses and damage to property or

the environment caused by any article or substance, which proves to
be hazardous. The code of practices of construction and operation
and maintenance and control procedures shall meet required statutory
and regulatory requirements. Personnel shall be trained on use,
handling, storage and disposal of and emergency spillage procedures.
b) Supplier shall detail and deploy Operational controls to reduce

hazardous wastes and their disposal as required by the statute
“Hazardous Waste (Management and handling) Rules 2000”. Oil
wastes, used oils, soil and cotton soaked in oil consequent to handling
operations, grease and many class of paints and asbestos sheets and
gaskets are typical hazardous wastes.
c) Supplier shall identify, contain and control all sources of radiation.

Appropriate regulatory approvals shall be obtained before
commencement of work involving radiation sources. Radiation
protection advisors suitably qualified and experienced shall be
appointed whose names shall be submitted to PURCHASER/
CONSULTANT. Dosimeter and surveillance of personnel engaged in
such work shall be maintained in accordance with regulatory
requirements.
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1.20 PERSONAL SAFEGUARDING
1.20.1 Personal Protection Equipment (PPE): General
Supplier shall provide his employees required PPE meeting the requirements
of the stated IS Specifications and Guidelines or equivalent International
Standards as may be prescribed by the CONSULTANT from time to time.
Supplier shall have instituted good working procedures and practices in
providing PPE, maintenance, issue and training on their use. All PPE shall
be periodically checked to ensure worn, damaged equipment are replaced
expeditiously.
a) Control of use of issue, use and maintenance of PPE

Employees shall be responsible for PPE issued to them. Supplier
shall meet requirements of IS8519: 1977 titled “Guide for selection of
Industrial safety equipment for body protection” or any equivalent
international Specification that the CONSULTANT/PURCHASER may
prescribe.
b) Head Protection:
Supplier shall comply with requirements as per IS 2925. Hardhats
shall be used and worn where a hazard of falling or flying objects
exist. Hard hats intended for use by visitors shall have replaceable
paper lining.
c) Eye and face protection:

Eye protection shall be worn during all operations by operators and
people in the vicinity, where there is a danger of flying particles of
metal such as generated during use of hand tools such as chisels,
grinding, welding and cutting lathe work on brass and cast iron acid
and alkali splash, and high pressure jet cleaning or insulation
removal from heights using high pressure jets. Supplier shall meet
the requirements of IS 8540:1978 titled ”Guide for selection of
Industrial safety equipment for eye and face protection”.
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d) Footwear:
Safety shoes, boots and gumboots fitted with steel toe-caps of
approved quality conforming to prescribed Indian or international
standards. Wearing of unsafe safety shoes such as jogging shoes,
tennis shoes, slippers and sandal etc. shall are prohibited. Supplier
shall meet the requirements of IS 10667:1983 titled ”Guide for
selection of Industrial safety equipment for protection of foot and leg”.
e) Protective clothing:
Supplier shall prevent hazards of loose clothes worn by workmen
getting caught in moving machine parts. Loose and thin garments
such as Dhoti and pyjamas shall be prohibited. While Suppliers shall
ensure that all workmen wear long sleeved shirts, jackets or the like
with the sleeves rolled down and secured at the cuff, long pants/
trousers extending upto the top of the safety shoes so as to prevent
injuries caused by contact with heat, cold abrasive and sharp
surfaces shall be strictly enforced. Such protective clothing shall be
mandatory in hazardous areas especially during start-up operations
involving hot, inflammable, and other chemical hazards, furnaces and
Boilers and such fired equipment and asphalting plants. Personnel
exposed to acids and alkalies hot fluids and steam during such
operations shall be provided with appropriate heat or corrosion
resistant clothing. Supplier shall meet the requirements of IS
8990:1978 titled “maintenance and care of industrial safety clothing.”
f) Hand Protection:
Supplier shall provide appropriate hand gloves as per IS 8807:1978
titled: ”Safety equipment for protection of arms and hands” to prevent
injuries to hands during work. Contactor shall maintain appropriate
inventory of gloves for different applications like Acid/ alkali handling,
general-purpose work gloves and asbestos or heat resistant Hand
gloves etc.
g) Safety harness : Fall arrest :

Supplier shall provide safety harness or means of restraint such as
safety Belts, harness and lifelines etc to workmen engaged to work in
heights such as Open –sided Floors, Open-sided scaffoldings, floor
and roof openings, overhead construction works of various nature etc
where there is a falling hazard of six feet or above. To prevent any
fall from a height of 2 Meters or above, storage, issue, wearing and
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maintenance of safety harness shall be under strict supervision and

records shall be maintained. All fall arrests shall consist of full-body
harnesses, lanyards with shock absorbers, lifelines, rope grabs and
associated hardware. Two alternate lanyards shall be used to
facilitate tying off at a new location before disconnecting from the
previous location of Practices for safety harnesses and fall arrests
shall conform to IS 4912:1978, IS 11972:1987, IS 8519:1977 or
equivalent international codes.
h) Falling object protection:

Where work is in progress in elevated areas, barricades, barrier
tapes signs and such entry restriction devices shall be used to keep
area below clear of personnel to prevent injury due to falling objects.
If work is required in the area below elevated work area, it shall be
scheduled at a time different from elevated works. The workmen
below shall be protected from falling objects by the debris net or a
catch platform with an adequate toe board to prevent material from
falling off. Use of safety net for elevated works shall be considered in
the work-permits where appropriate. Where a lift is made above a
working area, the area below the path of the lift shall be cleared of
personnel during the lift and barricaded and guarded to prevent entry
of persons generally in conformity with IS 4912, IS 11972 and IS
13416 for protective barriers in and around building and preventive
measures against safety hazards in work places and safety
requirements for floor and, wall opening, railings and toe-boards.”
i) Respiratory Equipment:
Supplier shall maintain where appropriate, procedures for training

and use of self-contained breathing apparatus. (SCBA) SCBA shall
be provided together with lifelines and rescue teams to safeguard
personnel working in areas where gases such as Carbon monoxide,
methane chlorine and such life endangering atmospheres. Supplier
shall meet requirements of IS 9623:1980 for “selection, use and
maintenance of respiratory protective devices”. Supplier shall have
trained adequate number of personnel including the identified fire
fighting teams, hose teams and Safety Appointees in the use of
SCBA. Supplier shall use the periodic Safety Drills to demonstrate,
train and establish competence of personnel in the use of SCBA.
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j) Hearing conservation:
Supplier shall ensure reasonable precautions are taken to avoid

injury to the hearing of the employee. All noise levels shall be
controlled within 85 dBA. Supplier shall identify noise areas where
noise levels exceed prescribed safe level for arranging for
appropriate Engineering revision. Where this is not feasible,
appropriate Earmuffs or protectors shall be provided to workmen
ensuring they are worn by those exposed to noise levels beyond safe
levels. Periodic hearing acuity tests shall be conducted on such
persons exposed to high noise levels to ensure that they do not
suffer any hearing impairment` as per requirements of IS8520: 1977
3.2 Manual handling & ergonomics
a) Supplier shall have procedures to identify risks involved in manual

handling operation and tasks. He shall ensure appropriate training to
prevent any possible injury. Full use of mechanical aids shall be
made to avoid risks arising out of such manual handling. Employees
shall be adequately trained on such manual tasks and related safety
precautions to reduce the risk of injury to personnel engaged in such
work.
b) Supplier shall undertake ergonomic study of manual operations to

prevent musculoskeletal injury during manual handling, besides
visual fatigue and mental stress giving considerations to matters such
as seating. Lighting and ventilation etc.
1.21 FIRE PROTECTION AND PREVENTION:
1.21.1 General Requirements:
a) Where PURCHASER maintains the Fire Protection Equipment,

Supplier shall comply with PURCHASER's fire regulations, warning
signals and procedures. He shall arrange to train his personnel
meeting the prescribed qualifying competence needs, in requisite
numbers in the operation of such fire protection equipment and
systems.
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b) Risk assessments shall be carried out to identify potentially

vulnerable areas to provide sufficient quantities of correct type of
extinguishers and ancillary equipment to deal with various types of
fire hazards.
c) Where required by the contract Supplier shall provide appropriate

type of extinguishers close to areas of fire hazard but not too close
they are cut off from use during a fire. Water based extinguishers
shall not be positioned close to or used on electrical equipment.
d) Extinguishers shall be marked / labelled and recorded with location

particulars in a register. They shall be inspected at monthly intervals
to ensure they are in operable sound condition. There shall be a
systematic plan for servicing, repairing and recharging fire
extinguishers and for recording such dates on the register and
equipment.
e) The location of fire fighting equipment shall quickly and easily be

identifiable especially in emergencies in a conspicuous manner
painted as high as possible to identify the location of the extinguisher
to prevent it from being obscured by machinery and goods stacked in
front and to return the equipment to its location after emergency use
in other locations. In order to ensure this, "Keep Clear" area shall be
demarcated and maintained. Location plans of extinguishers and fire-
fighting equipment shall be prominently displayed when desired by
the PURCHASER.
f) SR and SA shall be trained on firefighting techniques who shall co-

ordinate and control fire protection and prevention programs.
g) Where required by contract, Supplier shall maintain alarm systems

powered by mains and by battery for back up. Where required by the
Contract, Emergency lighting shall be provided to aid evacuation in
poor lighting conditions following the alarm. The alarm system shall
be made known to all employees. When PURCHASER extends these
facilities for use by Supplier, He shall provide appropriate training to
his personnel in the use of such emergency facilities and duties
h) A clear written procedure for action in the event of fire should be

produced. Fire teams and Hose teams shall be identified and their
responsibilities during emergencies shall be detailed in writing.
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Personnel shall be trained on their fire duties and use of fire-fighting

equipment. Regular drills shall be conducted to test procedures and
to validate them. Fire instructions and emergency procedures shall
be displayed throughout the premises. Emergency response
Procedures are detailed in Sl.No 5.0 hereunder.
i) A means of escape shall be provided in all work areas and storages

and maintained and kept free from obstruction. All exits shall be
clearly marked and kept unlocked whilst the premises are in use.
Escape routes shall be protected from fire.
j) When a Hot work Permit is issued, Supplier / SR shall ensure:
i. Identification of combustible such as paper, cardboard and

wood and moving them away from area where Hot work is
undertaken using open flame or electric arc.
ii. Determination that flammable vapors and liquids are not
present ,
iii. Protection of floor and wall openings to keep out sparks,
iv. Determination that Sprinkler and Hydrant and other installed
fire systems are functional,
v. Establishing a Fire-watch with fully loaded extinguishers or
charged water-hoses throughout the operation and 30 minutes
after completion of operation,
vi. Adequate ventilation for welders, by means of natural air
movement. Local exhaust ventilators, or air-line respirators as
required,
vii. Workmen performing the task are adequately briefed on job
safety analysis, hazards and risks and the safeguards against
risks.
1.21.2 Security:
a) Where required by the contract, Security shall do all that is

reasonably practicable to ensure the safety of employees and
property of the company in the face of accidents by fighting fires, and
containing losses due to pilferage, theft, vandalism and industrial
espionage both by employees and external elements. Security
personnel shall be appropriately competent, receive adequate safety
training. Security shall routinely report on a standardized basis on
aspects such as violation of fire-protection Rules, use of alcohol and
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narcotic drugs, condition of security fencing, floodlighting and

storages etc.
b) Where the project is located where a number of other companies are
in operation, Supplier shall plan for mutual assistance Programs in
cases of emergencies, as are practiced in the area in conjunction
with PURCHASER.
c) Where common boundaries exist between companies, Supplier in
conjunction with PURCHASER shall co-ordinate security control over
factors common: such as Floodlights, Fencing, pipelines containing
gas, fuel and electricity.
d) Security shall be represented in Safety committee through a safety
appointee nominated from the area.
1.22 EMERGENCY PLANNING/ EMERGENCY RESPONSE (ER)
Supplier shall plan to deal with emergencies. Emergency Response shall be

specific to the job. site. ER shall be written and communicated to all
employees. ER shall identify for the potential for and responses to incidents
and emergency situations and for preventing and mitigating the likely illness
and injury that may be associated with them.
a) The Supplier shall review his emergency preparedness and response

plans and procedures in particular after occurrence of incidents or
emergency operations.
b) Supplier shall designate his emergency team with their duties during
emergencies defined, including those of the hose Teams, medical
personnel, first-aiders and security. Supplier shall maintain a
procedure as to how his emergency organization shall liaise with
PURCHASER's representatives in ER.
c) The Supplier shall also periodically test such emergency procedures

by conducting Mock-drills and use the experience for updating the
emergency Plan and for training the Employees on the perceived
competence needs.
d) The emergency Response Plan of the Supplier shall be under the

control of the SR who shall be able to co-ordinate with the
PURCHASER for liasing with Government agencies neighboring
industries and the community
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e) The plans shall be designed to allow people to work under disaster

conditions when normal services such as telephone water, light
power, transport and sanitation are not available and first aid and fire
fighting facilities are not able to cope up with sudden demand on
services.
f) The telephone numbers, of ambulance, Police and Managers,
PURCHASER’s key Executives shall be prominently displayed in the
identified Emergency Response Center.
1.23 PREMISES AND HOUSE -KEEPING
1.23.1 Orderly Work-Place
Supplier shall maintain a well-managed safe working place in sound clean

condition. Supplier shall ensure that there is a place for everything and
everything in its place so that optimum use is made of valuable floor space
with commensurate cleanliness and reduced handling time. He shall ensure
that his entire infrastructure including temporary and semi temporary
buildings are kept clean and well maintained.
1.23.2 Good Lighting Natural and Artificial:
Suppliers shall provide lighting natural or artificial to enable work Processes

are carried out safely. Artificial lighting shall be adequate especially in the
nights and emergencies. The lumen levels shall meet the statutory
requirements.
1.23.2 Ventilation Natural and Artificial
Supplier shall ensure that workplaces are ventilated with at least prescribed
amount of clean or cleaned fresh air of a suitable temperature, especially
where toxic or irritating substances are present such as welding, vehicle
exhaust fumes, irritating dusts, organic solvents or any other inimical
atmosphere creating health or safety hazards.
1.23.3 Welfare and Hygiene Facilities
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Supplier shall provide welfare facilities to ensure a high standard of

cleanliness for all activities and rest. Supplier shall provide facilities for his
employees such as ablutions and toilets and change rooms kitchens and
cafeterias adequate and in a clean and hygienic state.
1.23.4 Pollution to Ground, Air and Water
Supplier shall strive to exceed established minimum performance norms in

waste and pollution control. All drains shall be identified as clean water and
foul water to aid non-harmful disposal.
1.23.5 Traffic Routes and Aisles
Supplier shall arrange to separate pedestrian and vehicular including

material handling equipment traffic wherever possible and maintain the
routes clear of obstruction. To ensure safety of users, clear painted
demarcation is encouraged as a discipline to be enforced.
1.23.6 Stacking and Storage Practice
a) Supplier shall ensure stacked material is bonded on a stable and level

footing capable of carrying the mass of the stack. Adequate
clearances shall be provided between the sides of the stack and top to
facilitate unimpeded access to service equipment like overhead
wiring, cranes, forklifts and firefighting equipment, and hoses. Free-
standing stacks of gunny bags and sacks such as Cement bags shall
be stacked to prescribed safe-stack heights with layers formed for
stable bonding, preventing slippage causing accidents. Stacking
against walls shall not be permissible.
b) Supplier shall maintain the premises and surrounding areas in clean

and clear manner with safe access and egress. There shall be
sufficient and adequate storage racks, shelving, bins and pallets and
material handling equipment to stack his construction materials such
as Pipes, structurals and his construction enabling materials.
Unwanted materials shall be promptly moved away for efficient
material movement.
1.23.7 Storage of Hazardous Materials
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a) Hazardous materials shall be stored on solid bases. Solid bases shall

include compacted earth, pallets, concrete or asphalt platforms or
paving. Hazardous materials shall be stored, stacked and secured to
prevent toppling, spillage or other unintended dislodgement. Aisles
and clearances shall be as detailed under 6.6 above. Hazardous
materials shall be stacked in such a manner that an observer standing
in the aisle can read their labels and legends
b) Each hazardous material contained hall be identified by a legible or

legend as per governing statute, code or regulation. The label shall
identify the item, quantity and appropriate warnings.
c) Hazardous materials which if brought in contact with each other could

react or pose equal or greater hazard than either material stored
alone shall be stored at a distance not lesser than twenty feet apart.
d) Warnings shall be posted and maintained in a legible condition at all

access points clearly defining the specific hazardous nature of the
stored materials such as "Corrosive", Flammable", "Explosive",
“Oxidizing", "Compressed gas" or other hazardous nature
e) Where hazardous materials are unloaded in Supplier's storages

maintained at site in a semi-permanent installation, such installations
shall be approved by relevant statutory bodies. Copies of licenses for
storage shall be lodged with PURCHASER. The Containers and
storages shall display quantities stored with name of the hazardous
material and the UN Hazard classification label in prescribed colour
code prominently painted in a conspicuous manner.
f) Supplier shall inspect the hazardous storages and installations on a

daily basis and shall undertake any requisite preventive action
necessary to avoid safety risks
1.23.8 Storage of Flammable / Explosive Materials:
a) Supplier shall secure flammable and or explosive materials against

accidental ignition.
b) Storage facilities for flammable liquids such as Petrol, Diesel and
Kerosene and Lubricants as well as the quantities stored shall meet
the legal and statutory requirements. They shall be stored in approved
fire-resistant rooms with a sump of sufficient volume to contain any
spillage.
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c) The electrical fittings shall be flame -proof and shall be on a strict

maintenance schedule.
Containers shall be appropriately bonded in receptacles into which low flash
point fuel is decanted.
1.23.9 Compressed Gas Cylinders
Compressed gas cylinders shall be stored and secured in the upright position
at safe distances shielded from welding and cutting operations. Compressed
gas cylinders in storage shall be shut off and torches, hose and manifolds
removed and capped. Cylinders shall be periodically checked for leakages.
Storage shall meet requirements of Gas Cylinder Rules 1981. Compressed
gas storages shall be provided with safety relief valves, Safety valves and
rupture disc to protect them from overpressures and shall be appropriately
designed to ensure their continued availability in the face of process changes
1.23.10Scrap and Refuse Bins-Removal System
Supplier shall ensure that he has sufficient waste bins that are identified for
different wastes and maintained in clearly demarcated areas. Wastes with
oily or other ignitable materials such as Oily cotton wastes and Hand gloves
shall be stored separately with covers to prevent fires and shall be made of
metal. Different Wastes shall be segregated and stored separately and
disposed off. They shall be emptied at routine intervals to prevent that they
do not overflow with wastes.
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SECTION C 15
SPARES AND MAINTENANCE TOOLS
TCE 5871-H-563-001B LIMITED SECTION: C15
SHEET 1 of 8
AT BARA,UP
1. SCOPE
This section covers the general requirements regarding the spares and
maintenance tools and tackles for all the equipment and systems in the
Stacking and reclaiming system
2. SPARES
The Supplier shall include in his scope: (a) Start-up / commissioning spares as
necessary and (b) Essential spares, as specified in this section. A detailed list
of recommended spares shall also be furnished by the Supplier.
The spares (both start up and essential spares) shall be delivered at the site
well in time before the start up and commissioning of the plant.
3. START UP SPARES
Start up spares (also termed as ‘commissioning spares’) are those spares

which shall be required during the start up and commissioning of the equipment
/ systems and until the plant is handed over. It is the responsibility of the
SUPPLIER to supply all necessary spares as required until the equipment /
systems are handed over to the PURCHASER. The prices of the start up
spares should be included in the price of the respective equipment / systems.
An adequate stock of start up spares shall be made available at the site such
that the start up and commissioning of the equipment / systems, performance
testing and handing over the equipment / systems to the Purchaser can be
carried out without hindrance and delay.
4. ESSENTIAL SPARES
Essential spares are those spares considered necessary by the Purchaser for
the first three (3) years of normal plant operation. The spares as listed in this
section shall be included in SUPPLIER’s scope. When a particular item of
spares is indicated as ‘percentage’, it shall be considered as percentage of total
number of that item in the station, unless specified otherwise. The fraction shall
be rounded off to the next higher whole number. Whenever the item of spares
has been indicated as ‘set’, the same shall mean the supply for single
equipment / system. One set of spares for a particular equipment shall mean
the total quantities of that particular spares for the single equipment e.g., ‘set’ of
bearings for a pump shall include the total number of bearings in a pump. The
‘set‘ shall however, include all components required to replace the item of
spares. Where ever spares are not listed for the systems / equipment, the
Supplier has to offer the same as per the recommendations of the manufacturer
/ supplier. In any case, the Supplier shall furnish a list with all details of offered
spares in his Bid.
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5. RECOMMENDED SPARES
In addition to the spares mentioned above, the SUPPLIER shall also furnish in
the Schedule of Recommended Spares a list of recommended spare parts for
three (3) years normal operation with unit prices. These recommended spares
shall be those considered necessary by the SUPPLIER on a standalone basis
without considering the essential spares as indicated in the list. The Purchaser
reserves the right to buy any of the recommended spare parts as considered
necessary by him. The prices of recommended spares shall be consistent with
those of the essential spares.
Price quoted for recommended spares will not be considered for bid evaluation.
6. MAINTENANCE TOOLS AND TACKLES
The SUPPLIER shall include all necessary maintenance tools required for
maintenance of the plant supplied by him. A comprehensive list of maintenance
tools is to be furnished in the bid in the Schedule of Maintenance Tools and
Tackles by the Supplier. The price quoted by the bidder for Maintenance Tools
and Tackles shall be excluded from the Total cost quoted by the bidder. ( i.e the
bidder to quote for the special tools and tackles separately.)
The SUPPLIER shall note that if any other tools are found to be necessary
during the engineering and erection stage of the contract, the same shall be
supplied by the SUPPLIER and no price implication due to same would be
accepted.
7. GENERAL
In the event of any equipment being changed during engineering, the

SUPPLIER shall supply start up spares, essential spares and maintenance
tools pertaining to this equipment.
The SUPPLIER shall also note that the Purchaser, if required, shall approach
directly the individual equipment manufacturers / suppliers for procuring
recommended spare parts. The Purchaser shall not necessarily procure these
spare parts through the Supplier.
Any change or variation in equipment or systems during detailed engineering

stage which would cause changes / variations in the essential spares quantity
shall be supplied by the SUPPLIER without any commercial implications.
LIST OF ESSENTIAL SPARES
SL DESCRIPTION QUANTITY
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NO.
A MECHANICAL
1.0 CONVEYORS
Idlers
Carrying idler rollers 10% of total Nos

Return idler rollers 10% of total Nos
Impact idler rollers 10% of total Nos
Non-magnetic idler rollers 10% of total Nos
Carrying idler frames 20 Nos
Return idler frames 10 Nos
Impact idler frames 10 Nos
Transition idler frames (20o) 3 Nos
Transition idler frames (10o) 3 Nos
S.A. carrying idler frame including guide rollers 10Nos
1.1 PULLEYS
Drive pulleys complete with bearings & Plummer One (1) number each for
blocks and extension keys & keyways for coupling each size and type of
halves. drive pulleys.
Non Drive Pulleys complete with bearings & Two (2) numbers each for
Plummer blocks. each size and type of
pulleys.
Bearings without Plummer blocks Two (2) numbers each for
each size and type of
bearings.
1.2 DRIVE UNIT
Gear box with hold back, Fluid coupling, Flexible One each for each size
coupling, Brake Thrustor and type of gear box with
hold back, fluid coupling,
flexible coupling and
brake.
The size, gearbox ratio,
handing, direction of
rotation, etc. shall be
indicated while quoting for
above spares.
1.3 Brake liners for thrustor operated Brake 50 M (Min 10 meters in

each size)
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1.4 Rubber strip for skirt board 100 M

1.5 Rubber strip for scrapers 100M
2.0 Belt weigher (conveyor scale)
2.1 Preamplifier unit 2 Nos
2.2 Belt weigher console 2 Nos
2.3 Transformer module 2 Nos
2.4 Regulated power supply module 2 Nos
2.5 Conveyor Modules 2 Nos each
3.0 Metal Detector complete with panel etc. 1 set
4.0 Dust Suppression System
4.1 Solenoid valves Min 2 Nos in each size
4.2 Sprinkler (complete) for stockpile 5Nos
5.0 Conveyor Belt. 10% of the total length for

each belt width and rating
6.0 ALL SWITCHES IN STACKING AND RECLAIMING SYSTEM
Pull chord switches 5% of total numbers

Belt sway switches 5% of total numbers
Zero speed switches 5% of total numbers
Inter lock and de - interlock switches 5% of total numbers
Conveyor positioning switches (limit switches) 5% of total numbers
Holdbacks for conveyors where ever applicable 1 set of each type
Polyurethane strip for primary scrapers for all belt 2 sets for each conveyor
conveyors and feeders
13.0 STACKER CUM RECLAIMER
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13.1 Drive Bogie
(a) Bogie wheel complete with bearings 2 Nos.

(b) Spur wheel One (1) set
(c) Labyrinth seal 2 Nos.
(d) Drive motor, coupling and gear box (complete 4 Nos.
assembly)
(e) Pinion 2 sets
13.2 Non-drive bogie
(a) Bogie wheel complete with bearings 2 Nos.
(b) Labyrinth seal 4 Nos.
13.3 Reduction gear for intermediate conveyor of

Stacker cum reclaimer
(a) Pinion and wheel (1st pair) 2 sets
(b) Bearings complete for GB 2 sets
(c) Oil seals 4 sets
13.4 Slewing gear mechanism
(a) Pinion & shaft (1st pair) 1 set

(b) Oil seals 2 sets
13.5 Luffing Mechanism
(a) Hydraulic piston & cylinder with bellows 2 sets
(b) Hydraulic pump complete 1 No.
13.6 Bucket wheel drive
(i) Hydraulic motor and pump 1 set
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(ii) Solenoid valves One set complete

required for bucket wheel
13.7 Bucket wheel
(a) complete buckets with teeth 2 Nos.
(b) Bucket wheel bearings One set complete

required for bucket wheel
Feed table impact idlers 5 Nos.
14.0 FLAP GATE

Actuator 1 no. for each type/ stroke
length & Torque rating
Position limit/Torque Switch 15 no.s
Seal Kit for Actuator 1 no. for each type/ stroke
length & Torque rating
ELECTRICAL
1.0 HT Motors
i. Bearing temperature indicators 1 No. of each type
ii. Bearing temperature detectors 2 Nos. of each type
iii. Bearings 1 set of each type & rating
iv. Terminal bushing assembly 1 No. of each type
v. Cooling fan 1 No. of each type
vi. RTD 1 set for each rating of

motor
2.0 415V Switchgear/DB
i. Breaker complete with operating mechanism and 1 No. of each rating

truck mounted
ii. Closing & tripping coils 2 sets of each rating
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iii. Fixed and moving contact assemblies of each 2 sets

breaker
iv. Spring charging motors 4 Nos.
v. Set of gasket 5 sets
vi. Bus bar support insulators 10 nos
vii. Aux. switch assembly, limit position switches, 5 Nos. each

Local/ Remote selector switch, breaker control
switches & other switches
viii. Relays of each type used 1 No.
ix. Clustered type LED 10 nos of each colour
x. CTs. of each ratio & type 2 Nos
xi. VTs. of each ratio & type 2 Nos
xii. Meters. of each type & rating. 1 No.
xiii. MCBs of each rating 5 Nos.
xiv. Transducers of each type & rating 2 Nos.
xv. Power / aux contactors 5 No.s of each rating
xvi. Overload relays 2 No.s of each rating
3.0 415V Motors
i. Bearings 2 sets of each type
ii. Cooling fan 2 Nos. of each type
4.0 Control Panels (Miscellaneous systems)
Air break switch 1 No. of each rating
Aux. relays, contactors Five of each type
Clustered type LEDs of different colours 20 Nos.
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Push Buttons 6 nos.
MCBs for power and control circuit 4 sets of each rating
AC & DC switches 1 set
Push buttons 1 set
C. INSTRUMENTATION
The Essential Spares shall be supplied as detailed below.
a) For all field Instruments, a min of one (1) or 20% of the quantity of
each type or range, which ever is higher is to be provided.
b) For control / pneumatic valves, a min of one (1) or 20% of the quantity
of each type or range of packing and gaskets, actuator diaphragm, pilot
relay and O-rings.
c) For solenoid valves, a min of two (2) or 20% of the quantity of each
type or range of coil (each rating and insulation), gaskets and O-rings.
d) For PLC system, minimum 1 no. of each type of module or 20 %

whichever is maximum.
Refer to Volume IVB, Section D4 for more details
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SECTION C 16
SUB VENDORS LIST
001B LIMITED
AT BARA,UP
SUB VENDOR LIST
1. Bidders through ICB shall submit their proposed list of sub vendors (in case of
deviation from the list furnished) for various equipments along with the
credentials and experience list for Purchaser’s review and approval.
2. Bidder to note that the list of preferred Sub Vendors is furnished below. In case
the bidder desires to deviate from the list furnished he shall furnish along with
his offer alternative names of Sub Vendors along with the following supporting
documentation.
3. Documentation to show that the equipment/system has been supplied for a

plant of similar or higher capacity.
4. Documentation in the form of certificate that the equipment / system has been
operating satisfactorily for two years as on the scheduled date of bid opening.
5. Note: For items not indicated below, the SUPPLIER shall obtain approval from
the PURCHASER.
LIST OF ACCEPTABLE SUB-VENDORS
PART – A – MECHANICAL
1. Idlers TRF/ELECON/KRUPP/L&T/
MCNALLY BHARAT
2. Pulleys TRF/ELECON/KRUPP/L&T/
MCNALLY BHARAT
3. Belting DUNLOP/NIRLON/HILTON/ ANDREW YULE
4. Sprung blade type belt cleaner HOSCH/ACE CONV. EQPT., U.K.
5. V Plough & Torsion Arm type Belt TRF/ELECON/KRUPP/L&T/

cleaner MCNALLY BHARAT
6. Switches JAYSHREE/AG ENTERPRISES/

BCH/SIEMENS
7. Fluid couplings
7.1 LT Drives PEMBRILL / FLUIDOMAT / VOITH

7.2 HT Drives PEMBRILL / VOITH / FLUIDOMAT
8 Resilient flexible couplings GBM / WELLMAN / INCANDESCENT
9 Gear Boxes DAVID BROWN / FMG / ELECON / NAW

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SUB VENDOR LIST
10 Brakes ELECTROMAG / STROMKRAFT / SPEED-

O-CONTROL / BCH
11 Belt Weigher POWER BUILD / J&N / RAMSEY
12 Centrifugal pumps (for dust KIRLOSKAR / BEACON / WORTHINGTON

suppression) / JOHNSON. MAXFLOW / MATHER & PLATT
13 Gates TCHNOMECH / PRECISION / TRF /

- Flap type ELECON / KRUPP / L&T
14 Sprinklers/Spray nozzles (for dust EAGLE AGRO / F.HARLEY / PREMIER

suppression)
15 Bearings SKF / FAG / NTN / TATA / NORMA
16 Paints BERGER / ASIAN / SHALIMAR /J&N
17 Hold back ELECON / DAVID BROWN / FMG /

ALLENBURY
18 Impact pads TEGA / KAVERI
19 Hydraulic motors & HAGGLUNDS / REXROTH / L&T

Power pack
20 PIPES - ERW AND SEAMLESS • TISCO

• JINDAL SURYA ROSHANI
• MAHARASHTRA SEAMLESS
• SAW
SAIL
•
21 D.S. SYSTEM • F. HARLEY

• DUVENT
• FLAKT INDIA
• C DOCTOR
• WRC, ANAND
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SUB VENDOR LIST
• TPS
21 Flow divider cum divertor TRF / ELECON / KRUPP / L&T
PART-B ELECTRICAL
List of acceptable sub-vendors shall be as per electrical section D3.8 of Vol IVA.
PART-C INSTRUMENTATION & CONTROL

List of sub-vendors for instrumentation and control system
Refer to Volume IVB, Section D 4, Clause 21.0 for vendor list of I&C items.
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SECTION F1
SCHEDULE OF PRICES
563-001B SECTION: F1
AT BARA,UP
TITLE
STACKING AND RECLAIMING SYSTEM
SHEET 1 of 2
SCHEDULE OF PRICES
SCHEDULE OF PRICES
The contract for Stacking and Reclaiming system shall be in accordance with the
specification - for supply and for erection, testing and commissioning.
The Bidder shall indicate the quoted price against each contract separately.
Sl. No. Details Rs.

1.0 Lump sum price for design and
engineering, manufacture, inspection at
works, packing and forwarding, supply and
delivery FOR site, storage at site, transport
at site, design of all civil & structural
works, erection, painting, testing and
commissioning of Stacking and Reclaiming
system including Mechanical, Electrical
and I&C as per the specification. The
quoted price shall be inclusive of start up
spares, essential spares and maintenance
tools and exclusive of transit / storage /
erection insurance charges, excise duty,
sales tax and other taxes.
2.0 Price break-up for amount indicated

against item 1.0 above
2.1 Lump sum price for design and

engineering
2.2 Lump sum price for supply of mechanical

items ex-works including packing,
forwarding
2.3 Lump sum price for supply of electrical

items ex-works including packing,
forwarding
2.4 Lump sum price for supply of I&C ex-

works including packing, forwarding
2.5 Lump sum price for supply ex-works

including packing, forwarding of start-up /
commissioning spares
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TITLE
SHEET 2 of 2
SCHEDULE OF PRICES
including packing, forwarding of

maintenance tools.

including packing, forwarding of essential
spares
2.8 Lump sum price for transportation to site

and unloading at site
2.9 Lump sum price of civil design works
2.10 Lump sum price of structural design works
2.11 Lump sum price for PLC and complete

instrumentation and control systems
2.12 Lump sum price for storage at site, intra-

site transport and handling at site
2.13 Lump sum price for erection, testing and

commissioning
SIGNATURE
NAME
COMPANY SEAL DESIGNATION
DATE
COMPANY---------------
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SECTION F 2
SCHEDULE OF ESSENTIAL SPARES
AT BARA,UP
TITLE
SHEET 1 of 1
The Bidder shall indicate the price for the Essential spares specified in Section-C.
Unit Price
Manufac- Delivery Qty. Total
Item Qty. FOB
turer and Period Description Material per Price Remarks
No. Included Port /Ex-
Part No. (weeks) Unit (7x8)
works
1 2 3 4 5 6 7 8 9 10
SIGNATURE
NAME
DATE
COMPANY---------------
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SECTION F 3
SCHEDULE OF DEVIATIONS FROM
AT BARA,UP
TITLE STACKING AND RECLAIMING SYSTEM
SCHEDULE OF DEVIATIONS FROM SHEET 1 of 1
SCHEDULE OF DEVIATIONS FROM
All deviations from the Technical Specifications shall be filled in by the BIDDER clause by
clause in this schedule.
SECTION SPECIFICATION NO. CLAUSE NO. DEVIATION
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SECTION F 4
SCHEDULE OF RECOMMENDED SPARE PARTS
AT BARA,UP
TITLE
SHEET 1 of 1
The BIDDER shall indicate below recommended spares for three (3) years of trouble
free operation of the equipment, plant or system offered by him.
EQUIPMENT TAG
MANUFACTURER
DESCRIPTION OF
PERIOD (WEEKS)
RECOMMENDED
CONSTRUCTION
FROM DATE OF
QUANTITY/SET
MATERIAL OF
TOTAL PRICE
EQUIPMENT
UNIT PRICE
DELIVERY
AND PART
REMARKS
PER UNIT
NUMBER
NUMBER
SL. NO.
SPARE
LOI
Rs.
Rs.
RECOMMENDED SPARES AS INDICATED BY THE BIDDER
1.
2.
3.
4.
5.
SIGNATURE : ________________________________
NAME : ________________________________
DESIGNATION : ________________________________
COMPANY : ________________________________
COMPANY SEAL DATE : ________________________________
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SECTION F 5
SCHEDULE OF WEIGHTS AND DIMENSIONS
AT BARA,UP
TITLE
SHEET 1 of 1
The bidder shall state below the weights and dimensions of various
packages for shipment covering the complete scope.
Description of package(s) Dimensions in ( meter ) Weight in ( tonnes )
SIGNATURE : ______________________________
NAME : ______________________________
DESIGNATION : ______________________________
COMPANY : ______________________________
COMPANY SEAL DATE :
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SECTION F 6
SCHEDULE OF EQUIPMENT MANUFACTURE
DESPATCH TO SITE
AT BARA,UP
TITLE
SCHEDULE OF EQUIPMENT MANUFACTURE SHEET 1 of 1
DESPATCH TO SITE
SCHEDULE OF EQUIPMENT MANUFACTURE DESPATCH TO SITE
Sl. Equipment / Time for Time for test, Time required Total time
No. Major manufacture / dismantling, for shipment to from date of
Bought out procurement packing & site ( weeks ) issue of
items from date of ready for letter of
issue of letter of despatch ( intent to
intent ( weeks) weeks ) shipment to
site ( weeks )
SIGNATURE : ______________________________
NAME : ______________________________
DESIGNATION : ______________________________
COMPANY : ______________________________
COMPANY SEAL DATE :
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SECTION F 7
SCHEDULE OF PERFORMANCE GUARANTEES
AT BARA,UP
TITLE
SHEET 1 of 1
Sl. No. Item Unit of Measurement Guaranteed Value
We the undersigned hereby undertake to meet the performance guarantees

as listed in the table above on the conditions as elsewhere specified. Any
variation of the specified conditions during official test will be taken in to
account by the customer.
SIGNATURE : ______________________________
NAME : ______________________________
DESIGNATION : ______________________________
COMPANY : ______________________________
COMPANY SEAL DATE :
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SECTION F 8
SCHEDULE OF ELECTRIC LOAD REQUIREMENTS
AT BARA,UP
TITLE
SHEET 1 of 1
BIDDER shall furnish the information called for in this Schedule which shall
accompany the Bid:
Sl. Equipment Qty. Voltage RPM kW

No.
SIGNATURE : ___________________________
NAME :
DESIGNATION :
COMPANY :
COMPANY SEAL DATE :
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SECTION F 9
SCHEDULE OF GUARANTEED
POWER CONSUMPTION
AT BARA,UP
TITLE
STACKING AND RECLAIMING SYSTEM SHEET 1 of 1
SCHEDULE OF GUARANTEED POWER CONSUMPTION
SCHEDULE OF GUARANTEED POWER CONSUMPTION
Bidder shall furnish the details of Auxiliary Power Consumption , in the format given
below.
The power consumption shall be considered for loading (in bid evaluation) as well
as for levying of penalty (for demonstration purpose).
The duty factors indicated are based on the number of hours of operation in a day.
Sl. Description Nos. Power required Total

No at motor input Power,
terminals, kW kW
1.0
SIGNATURE : ______________________________
NAME : ______________________________
DESIGNATION : ______________________________
COMPANY : ______________________________
COMPANY SEAL DATE : ______________________________
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SECTION F 10
SCHEDULE OF BIDDER’S EXPERIENCE
AT BARA,UP
TITLE
SHEET 1 of 1
The BIDDER shall furnish hereunder a list of similar jobs executed by him to whom a
reference may be made by the PURCHASER in case the PURCHASER considers such a
reference necessary.
Sl. Name & Scheduled Actual Value of Year of start Client. Persons to
No.. description completion completi work. and whom ref.
of work period. on completion. may be
period. made with
contact
numbers
1 2 3 4 5 6 7 8
SIGNATURE : ______________________________
NAME : ______________________________
DESIGNATION : ______________________________
COMPANY : ______________________________
COMPANY SEAL DATE :
LEGEND
S: Supply SUP: Supervision of Erection
E: Erection T&C: Testing & Commissioning
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SECTION F 11
SCHEDULE OF EXCLUSIONS
AT BARA,UP
TITLE
SHEET 1 of 1
All exclusions considered in the offer shall be filled in by the BIDDER clause by clause in
this schedule.
SECTION SPECIFICATION NO. EXCLUSION
COMPANY SEAL SIGNATURE

NAME
DESIGNATION
COMPANY
DATE
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SECTION F 12
SCHEDULE OF QUALITY ASSURANCE PLAN (QAP)
AT BARA,UP
TITLE
SHEET 1 of 1
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SECTION F 13
VOID
SECTION F 14
REQUIREMENTS OF THE CONTRACTOR AT SITE
AT BARA,UP
TITLE
SHEET 1 of 1
(Bidder to fill and return with his Bid)
The Contractor shall state his requirements against each of the following including the
basis of requirements:
A. Requirements
1.0 Land for, Stores, Site office, etc.
Area Requirement
1.1 At construction site m2
2.0 Construction Power (in kVA) – Indicate Months
same for the period.
Power Requirement
3.0 Construction Water (in cu.m/day) – Months
Indicate same for the period.
Water Requirement
B. Basis of Requirements
1. Land
2. Construction Power
3. Construction Water
SIGNATURE
NAME
NAME AND ADDRESS

OF THE COMPANY
DATE
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SECTION F 15
SCHEDULE OF PLACES OF TEST & INSPECTION
AT BARA,UP
TITLE
SHEET 1 of 1
The Contractor will indicate the item of Equipment supplied, name of the
MANUFACTURER or SUB CONTRACTOR and place of test and inspection
as shown below:
ITEM OF MANUFACTURER / PLACE OF TESTING &

EQUIPMENT SUBCONTRACTOR INSPECTION
SIGNATURE
NAME
DATE
COMPANY-------------
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(PPGCL)
PRAYAGRAJ SUPER THERMAL POWER PROJECT

PHASE-1 : 3X660 MW
PACKAGE-B SPECIFICATION
FOR
STACKER RECLAIMER WORKS OF COAL HANDLING

SYSTEM
VOL-IIB
(TECHNICAL REQUIREMENTS - MECHANICAL)

73/1, ST.MARK'S ROAD
BANGALORE 560 001
INDIA
PRAYAGRAJ POWER GENERATION COMPANY SECTION: INDEX
TCE 5871-H-563-001B LIMITED SHEET 1 OF 1
AT BARA,UP
INDEX SHEET
INDEX SHEET FOR SPECIFICATION VOLUMES OF PACKAGE-B
Volume I : Conditions of contract.
Volume IIA : SECTION – C - Scope of works, Terminal Points,

Exclusions, Spares and Schedules
Volume IIB : SECTION - D1 - Technical requirements – Mechanical
Volume III : SECTION – D2 - Technical Requirements - Civil Works
Volume IV A : SECTION – D3 - Technical Requirements

Electrical Systems
Volume IV B : SECTION – D4 - Technical Requirements
Instrumentation and Control Systems.
Volume V : DRAWINGS
: MECHANICAL DRAWINGS
1) Plot Plan
2) Flow Diagram – Stacking and Reclaiming system
3) Gallery Cross Section – Single Conveyor
4) Gallery Cross Section – Double Conveyor
: ELECTRICAL DRAWINGS
1) Plot Plan
2) Coal Handling System - SLD Substation-1
3) Coal Handling Plant Switchgear Room – GA

Indicative Diagram
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LIMITED
TITLE
VOLUME II B - CONTENTS
TABLE OF CONTENTS
SUB REV
SECTION TITLE PAGES
SECTION NO.
D D1.0 R0 PROPERTIES OF COAL 3
D1.1 STACKER CUM RECLAIMER – WRITE 20

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UP
D1.1 STACKER CUM RECLAIMER – DATA 4
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SHEET A
D1.1 STACKER CUM RECLAIMER – DATA 6
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SHEET B
D1.2 REVERSIBLE YARD (TRUNK) 13

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CONVEYORS – WRITE UP
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CONVEYORS – DATA SHEET A
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CONVEYORS – DATA SHEET B
D1.2 R0 ANNEXURE-1 TO DATA SHEET-A 3
D1.3 STOCKYARD DUST SUPPRESSION 5

R0 AND SERVICE WATER FOR
CLEANING SYSTEM– WRITE UP
CLEANING SYSTEM – DATA SHEET A
CLEANING SYSTEM – DATA SHEET B
D1.3 FOR PUMPS (BIDDER TO FILL FOR 2
R0 EACH PUMP SEPARATELY) – DATA
SHEET B
D1.3.1 HORIZONTAL CENTRIFUGAL PUMPS 4

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- WRITEUP

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– DATA SHEET A
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TCE.5871A-H- VOLUME – IIB
LIMITED
TITLE
VOLUME II B - CONTENTS
SUB REV
SECTION TITLE PAGES
SECTION NO.
R0
– DATA SHEET B
D1.4 STOCK PILE RUN OFF WATER 2

R0
DISPOSAL SYSTEM – WRITE UP
R0 DISPOSAL SYSTEM – COMMON
COLLECTING POND – DATA SHEET A
R0 DISPOSAL SYSTEM – COMMON
COLLECTING POND – DATA SHEET B
D1.5 LOW PRESSURE (LP) PIPING AND 14

R0 VALVES – WRITE UP & DATA SHEET-
A
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SECTION D1.0
PROPERTIES OF COAL
VOLUME-IIB
TCE 5871A-H-563- PRAYAGRAJ POWER GENERATION COMPANY LIMITED
001B (PPGCL) SECTION: D1.0
3 X 660 MW (PHASE–I ) PSTPP AT BARA ( U.P ) SHEET 1 of 3
PROPERTIES OF COAL
1.0 PROPERTIES OF COAL AND SYSTEM DESIGN CONSIDERATION
Sl No Aspect Value/ Feature Remarks

1.1 Material to be handled Worst Coal with a GCV
of 3400Kcal/kg
1.2 Bulk Density
1.2.1 For capacity calculation 800 Kgs/cum
1.2.2 For structural design 1200 Kgs/cum
1.3 Angle of repose 35 degrees
1.4 Angle of surcharge 20 degrees
1.5 Moisture content including 15%
surface moisture
1.6 Top lump size of as received (-) 250mm
Coal up to the crusher house
1.7 Top lump size of as received (-) 20mm
Coal up to the stock pile from
crusher house
1.8 Top lump size of crushed coal (-) 20mm
from crusher house to the
bunkers
1.9 Hard Grove Grindability Index 60
1.10 Other properties of Coal Sticky and non flow able
freely during monsoon
1.11 Basis for crusher design 95% of input material as
(-) 250mm.
1.12 Speed of crusher Shall not exceed 750
rpm in order to limit dust
generation.
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VOLUME-IIB
PROPERTIES OF COAL
APPENDIX – A – COAL ANALYSIS
SL NO Description Symbol Design coal Worst Best coal

Unit coal
A Proimate analysis
1 Fixed carbon % 39 30.5 40
2 Volatite matter % 20 23.8 27.5
3 Moisture % 10 11.4 7
4 Ash % 31 34.3 25.5
5 Total % 100 100 100
6 HHV Kcal/kg 4200 3400 4500
B Ultimate analysis
1 Carbon C% 44.11 36.31 52.52
2 Hydrogen H% 3 2.56 3.38
3 Sulphur S% 0.36 0.36 0.36
4 Nitrogen N% 0.89 0.81 0.78
5 Oxygen (differene) O% 10.64 14.26 10.46
6 Moisture % 10 11.4 7
7 Ash % 31 34.3 25.5
8 HGI 50 60 60
C ASH Characterstics
1 Initial deformation Deg C 1150 1150 1150
Temperature (IDT)
2 Softening Deg C 1200 1200 1200
temperature
3 Hemispherical Deg C 1300 1300 1300
temperature (HT)
4 Fusion temperature Deg C 1400 1400 1400

(FT)
C ASH Constituents
1 Silica SIO2 % 56.7 59.79 62.11
2 Alumins AI2O3 % 23.5 25.36 24.07
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PROPERTIES OF COAL
SL NO Description Symbol Design coal Worst Best coal

Unit coal
3 Iron oxide FE2 O3 % 8 7.2 7.99

4 Lime CAO % 1.5 0.88 1.07
5 Magnesia MGO% 1.0 0.55 0.79
6 a) sodium oxide NA2O% 1.4 1.22 1.08
max.
7 Titanium oxide TIO2% 2.2 1.2 1.79
8 Phosphoric P2O3 % 3.7 2.6 0.18
anhydride
9 Sulphuric anhydride SO3 % 2 1.2 0.42
Note
The Properties indicated under item 1.0 are to be considered for equipment design covered
under sections D1.1, D1.2 and any other section as applicable
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SECTION D 1.1
STACKER CUM RECLAIMER
PRAYAGRAJ POWER GENERATION COMPANY SECTION: D1.1
TCE5871A-H-563-001B
LIMITED SHEET 1 OF 20
3 X 660 MW PRAYAGRAJ SUPER THERMAL POWER
PROJECTAT BARA,UP
TITLE
DESIGN AND CONSTRUCTION REQUIREMENTS
1.0 MECHANICAL EQUIPMENT AND SYSTEMS
1.1 Stability factors for operating conditions with maximum operating wind
velocity and non-operating conditions with maximum non-operating wind
velocity shall be 1.5 and 1.25 respectively.
1.2 Additional protection shall be made on travelling structure to prevent the

stability being endangered in the event of derailment or breakdown of
one or more axles. Wheel mountings shall be so designed as to facilitate
easy removal of wheels, bearings and journals. Wheel mountings shall
be complete with safety lugs to prevent a drop of more than 2.5 cm in
case of broken axle. Jacking facilities are to be provided on the machine
and beside the track to facilitate removal of wheel / bogies for repairs
and re-assembly.
1.3 The cabin shall be located at higher elevation and near the bucket wheel
and shall be mounted on shock absorbers and on hydraulic cylinders to
keep the cabin always in horizontal position. An air conditioner shall be
provided for operator’s cabin. It shall be possible to see the stacking and
reclaiming operations from the operator’s cabin. The hydraulic system
shall consist of hydraulic cylinders, oil piping, valves, power pack, etc.
1.4 Adequate number of spring type / good quality rubber buffers shall be
provided at either end of the carriages to absorb the force resulting from
momentum of the machine at 40% of rated speed while conveying the
material at rated capacity.
1.5 An inline belt conveyor scale conforming to the specification given in data
sheet – A of section D1.3 shall be mounted on the boom conveyor.
Remote rate indicator and totalizer shall be mounted in operator’s cabin.
Two integrators shall be (for integrating rate of flow over a period of time)
provided which will be actuated by the direction of motion of the boom
conveyor. These measurements will facilitate finding the quantity of coal
stacked and coal reclaimed. Apart from remote and local totaliser, an
isolated 4-20mA output shall be wired to stacker cum reclaimer PLC
which shall be transferred to LHS control room PLC.
1.6 At least six sets of impact idlers shall be mounted on the impact table to
take the impact of reclaimed material. The main conveyor belt shall pass
over these impact idlers.
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1.7 The slewing mechanism shall consist of necessary horizontal ring bearing
with an internal gear rim / external gear teeth. The slewing drive shall
consist of minimum two hydraulic motors and gear pinions. Suitable brake
mechanism shall be provided for the slewing drive. The hydraulic motors
shall be fed by pumps with necessary oil piping, oil filters, control valves,
check valves, relief valves, needle valves, stop valves, suction valves,
pressure switches, etc. The hydraulic system shall be complete with oil
cooler, flexible oil hoses fittings, etc. The drive shall be equipped with
necessary over travel limit switches. Back up limit switches also shall be
provided for preventing over travel in the event of failure of normal travel
limit switches. Slewing gear and ball race shall be integral unit. Ball race
shall be fixed in machined surface (both turntable and undercarriage).
Sealing for the ball race both for lubrication and avoiding dust entering
has to be provided. The open gears for the slewing gear should have
proper protection against accumulation of dust on the rim.
1.8 When the system is to be set for stacking, chute and skirt boards
associated with bucket wheel shall be lifted automatically by suitable
device. This actuating arrangement shall be interlocked with boom
conveyor drive. Similarly when the system is to be set for reclaiming,
chute and skirt boards shall be located in correct position by the same
device automatically to adjust the coal feed for centre of the conveyor.
The actuators shall be complete with necessary hydraulic cylinders,
piping, valves and fittings. An interlock shall be provided so that unless
the brakes of bucket wheel are released, the boom conveyor shall not be
started for reclaiming operation. Since the trunk conveyor is reversible
there shall be no sway of the belt while running in both forward and
reverse direction.
1.9 The chute and skirt boards at the pivoted end of the boom conveyor shall
move along with the boom conveyor in luffing operation while the
conveyor is stacking. This shall be achieved either through electro-
hydraulic or electro-mechanical device interlocked with luffing drive.
1.10 LUFFING MECHANISM
1.10.1 Luffing (hoisting) mechanism consists of hydraulic push up cylinders

connected to the mast to which boom conveyor is connected.
1.10.2 The hydraulic system for the luffing mechanism shall be complete with
hydraulic cylinders, solenoid valves, hydraulic power pack, hydraulic
pump with AC motor, etc. Hydraulic cylinders shall be provided with
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suitable bellows to prevent ingress of dust on to the pistons, which may

enter and contaminate the oil in the cylinders.
1.11 BUCKET WHEEL ASSEMBLY
1.11.1 The bucket wheel shall be designed to give a guaranteed capacity as

specified in the data sheet – A while reclaiming specified material from
the stock pile and discharge on to the boom conveyor through discharge
chute and skirt boards. Fill factor of 0.9 and 50% of ring volume shall be
considered for reclaim capacity calculation.
1.11.2 The bucket wheel shall be cell-less type and fabricated from steel. The
welded construction shall be preferably in three parts for easy assembly
and dismantling. Renewable wear plates of 15 mm thick and liners shall
be provided as necessary. Bucket fixing holes shall be provided with
wear resistant renewable steel bushes. Cavities liable for coal
accumulation inside the buckets shall be avoided. Mounting of ring chute
shall be of solid structure devoid of complicated frame works. Effective
and suitable scraping arrangements have to be provided for the bucket
wheel to avoid sticking / accumulation of coal. Buckets shall be made of
wear resistant steel and fitted with replaceable and high abrasion
resistant Manganese steel bucket teeth or tips. Bucket wheel shall be
driven by one or more hydraulic motors. The drive for the bucket wheel
shall be independent of the boom conveyor drive. The hydraulic drive
shall be complete with power pack, pump & motor, filters, all necessary
valves, oil cooler, pressure switches, piping, fittings, etc.
1.11.3 A speed monitor built on to the bucket wheel drive shall be provided
which shall act as slip monitor for hydraulic motor and shall cut out the
bucket wheel motor when speed drops due to overload together with
subsequent drives such as travel, slewing and luffing drives.
1.11.4 The main bucket wheel hydraulic drive shall be suitable for providing the
required slow speed for maintenance.
1.11.5 The number of discharges per minute of bucket wheel while reclaiming
shall be limited to 55 per minute.
1.11.6 The power and control cable reeling drums shall be mounted on the
lower frame each of which shall have independent stall torque or
equivalent drive motors. An interlock shall be provided to start both cable
reeling drums before travel motors are started.
1.12 WHEELS FOR LONG TRAVEL:

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1.12.1 Wheels for long travel of stacker cum reclaimer shall be forged or cast
carbon steel and shall be double flanged with cylindrical “Straight” or
“Taper” tread.
1.12.2 The wheel diameter and rail sizes shall be such that the maximum wheel
load in kilograms does not exceed 0.703 times the product of the wheel
tread diameter and the gross width of the rail head, both dimensions in
mm.
1.12.3 Atleast 50% of wheels shall be driven by electric motors mounted on the
corresponding bogie through gear reduction and transmission devices.
Chain and sprocket drives are not acceptable. Each drive shall be
complete with electro-hydraulic thruster brakes, couplings, coupling
guards, etc. Axle outfits shall consist of double flanged cast steel wheels
mounted on shafts running in self-aligning roller bearings. The limit
switches shall be provided at either ends of the travel of the machine for
stopping the motors. Emergency (back up) end limit switches shall also
be provided as a safety measure.
1.12.4 Atleast two anemometers shall be mounted on top of the tower so that in
case wind pressure exceeds the operating wind pressure specified in
data sheet – A, an alarm shall be sounded to enable the operator to take
the stacker cum reclaimer machine to the parking area for manual
anchoring. Stacker cum reclaimer shall be clamped to the rails
automatically by electrically / hydraulically operated rail clamps. After
parking the machine at specified place, the entire stacker cum reclaimer
shall be put out of operation. The anemometer shall also give the signal
for restarting of machine and release the rail clamps when wind pressure
reduces below the permissible operating wind pressure. The stacker
cum reclaimer machine shall be provided with adequate number of
electrically / hydraulically operated rail clamps and anchoring devices
which would be used in case of high wind pressure. The leading bogies
on both sides and at either end of the machine shall be provided with
adjustable ploughs or rails weeps to clear the rails of any obstruction.
1.13 All brakes shall be of electro-hydraulic thruster type.
1.14 VOID
1.15 LUBRICATION
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1.15.1 Centralised high pressure group lubrication system with motor operated
grease pump shall be provided for travelling gear, hoisting arrangement,
bucket wheel hinge and slewing ring. In addition to the centralized high-
pressure lubrication system for travel, hoist & lowering, bucket wheel and
slewing, “a separate upper structure grease lubrication system for bucket
wheel fork end bearing” shall be provided as it is a vital one. Protection
for bucket wheel will be linked with these two lubrication systems.
1.15.2 All other antifriction bearings are to be lubricated manually by hand

operated grease pump through respective grease nipples. Accessibility
shall be such that parts may be safely lubricated from the walkway
platform or stairs.
1.16 ENCLOSURE WITH TOOL BOX
A separate enclosure with a steel tool box having a hinged cover shall be
conveniently located and permanently secured near the electrical house
for storing of tools, oil can, grease and cotton waste. It shall contain all
tools necessary for minor repairs and maintenance of stacker cum
reclaimer.
1.17 FIRE EXTINGUISHER
One 2.5 kg B.C.F fire extinguisher bearing the fire under-writers label
shall be provided in the operator’s cabin, electrical room and under
carriage platform. Sand buckets with sand shall also be provided for
minor fires.
1.18 SUPER STRUCTURE
1.18.1 It shall be of solid steel plate construction or of heavy build up sectional

steel section and connections of main superstructure shall also be of
solid steel plate construction.
1.18.2 Counterweight boom shall be fixed boom type. Counterweight boom shall
be of lattice girder construction. The counter weight boom shall be clear
from the rear side stockpile.
1.18.3 The pivot on the superstructure for carrying the bucket wheel boom shall
be of solid steel plate construction and construction should be such that it
is sufficiently strong to withstand even shock loads.
1.18.4 Under carriage shall be of solid plate construction. Mounting of the

superstructure turn table on the undercarriage shall be by ball race
arrangement.
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1.18.5 Turn table shall be of solid steel structure and be strong enough to carry
the entire superstructure. The top of the ball race for slewing is to be
provided at the bottom of the turn table. Fixing of the ball race, inspection
during working, checking of lubrication, etc. with care shall be provided
for.
1.18.6 The turn table has to be properly anchored to the undercarriage and
provision shall be made in the structure itself to lift the turn table along
with the super structure. Limit switches at the extreme positions of
slewing shall be provided.
1.19 BOOM CONVEYOR STRUCTURE
The boom conveyor structure can be of fabricated lattice construction

with heavy steel section having a robust design.
1.20 STAIRS, GANGWAYS AND LIFTING FACILITIES
Pulley hook shall be provided at strategic points. Gangways, stairs or

ladders (with guards) shall be provided to give safe and sufficient access
to all machinery and equipment, width shall be normally 800mm. These
shall be of the open grate type.
1.21 SAFETY DEVICES
Safety guards shall be provided over rotating equipment wherever

necessary. The guards shall be so constructed that no rotating part can
be reached without first opening an access door or removing an internal
part of the safety guards. All units of the proposed equipment shall be
provided with emergency stopping devices for the drive motors and
necessary interlocking arrangements.
1.22 TRIPPER CAR
The length of the tripper car shall be adequate for the belt to maintain
contact all the idlers. The radius of curvature shall be calculated on the
same basis as given in section D1.2 for fixed conveyors. However, the
load on the belt shall be calculated considering the percentage of
conveyed coal as stipulated in ISO standards for mobile machinery.
1.23 INTERMEDIATE CONVEYOR
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An intermediate cross conveyor shall be provided which shall be run

while stacking. During reclaiming, the bucket wheel shall discharge coal
onto the boom conveyor which shall feed the trunk conveyor running in
reverse direction. Since reclaiming will be done while the trunk conveyor
runs in reverse direction there shall be no belt sway while the trunk
conveyor belt runs in reverse direction and also during stacking when the
trunk conveyor is running in forward direction.
1.25 The specification applicable for the hydraulic drives of stacker cum
reclaimer and the requirement of hydraulic drives shall be as follows.
(I) GENERAL ARRANGEMENT
a) The hydraulic drive system shall consist of a low speed, high torque,
hydraulic motor of hollow shaft design to be mounted directly onto
the driven shaft of the equipment using a shrink disc (ring feeder)
coupling. The reaction torque shall be taken by a torque arm bolted
to the hydraulic motor and grouted to the foundation. The hydraulic
motor shall be driven by a power pack placed conveniently near the
hydraulic motor so as to minimize pressure drop in pipelines.
b) The hydraulic motor output in terms of speed and torque shall be

monitored using a suitable electronic controller installed in the
power pack, which receives speed signal from the coal handling
systems PLC. In turn, the controller supplies signals to the coal
handling system PLC regarding actual speed, hydraulic pressure,
etc. It should also be possible to monitor the prevailing belt tension
on the tight and slack side of the belt to adjust the tension in the
take up for conveyors which do not have gravity take ups.
c) The drive arrangement shall be able to smoothly go from zero to set
speed providing the specified starting torque and from running to
zero speed as per pre-programmed start and stop ramps without
the usage of fluid couplings, gearboxes, etc.
(II) HYDRAULIC MOTOR

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The hydraulic motor shall be of fixed displacement, radial piston, cam

curve design suitable for continuous industrial duty operation even at low
speeds. The hydraulic motor shall be directly mounted on the drum shaft
without any mechanical speed reducing unit such as a gear box. The
hydraulic motor should be selected such that it can deliver the full range
of torque and speed combination under various operating conditions like
start-up on full load, continuous duty at full rated capacity and to handle
specified overload. The hydraulic system pressure shall have sufficiently
wide range under continuous duty conditions and higher pressure
capability to handle peak load condition and start up condition.
(III) PARKING BRAKE
For an inclined conveyor application, to prevent its uncontrolled rolling

under load, a (parking) disc brake shall be supplied. Depending on the
required braking torque, this could either be an integral part of the
hydraulic motor mounted on its rear or be separately mounted on its own
hub. The brake should be of fail safe type being normally closed and
opening only when given the signal to release. The hydraulic system shall
respond to electric signals from coal handling system PLC to release the
brake. The brake shall be of industrial design capable of withstanding
frequent opening and closing cycles.
(IV) POWER PACK
Independent power packs shall be provided for the following:
a) Slewing
b) Bucket wheel including inching drive
c) Luffing operation
d) Boom conveyor drives
e) For movement of operator’s cabin
f) Skirt board of boom conveyor
Bidder shall provide combined power pack only for bucket wheel and
slew mechanisms.
The power pack shall include the following:
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(a) An axial piston, variable displacement and pressure compensated

pump. It shall be suitable for continuous close loop operation in all
the pressure ranges discussed in para 1.2.4 (ii). The pressure range
electro hydraulic control of the output flow from the pump shall be
possible based on electric signals supplied to the drive system
electronic controller from the coal handling system PLC. Necessary
auxiliary pump shall be provided to charge flow to the filters and oil
cooler as also for release of brake.
(b) Main pump coupled to a HT / LT squirrel cage induction motor. The
motor shall start in unloaded condition even when the drive itself
has to start fully loaded.
(c) Stainless steel oil tank of suitable capacity.
(d) Cartridge type duplex oil filter with pop up indicator of 10 micron.
(e) Suitable breather filter and bladder in oil tank.
(f) Air blast type oil cooler for stacker cum reclaimer and conveyors.
(g) Quick connecting type coupling for oil filling and oil sampling.
(h) Oil level indicator, oil temperature switch and indicator.
(i) Push to read pressure gauges for charge and system pressures.
(j) All the above assembled in a sound insulated cabinet and mounted
on anti vibration pads.
(k) Suitable electronic controller for drive operation control,

annunciation and interface with coal handling system PLC.
(l) The hydraulic motor and power pack unit shall be of same make.
(V) ELECTRONIC DRIVE CONTROLLER
(a) This shall be microprocessor based pre-programmed controller

having the facility to alter control parameter at site. It shall provide
health monitoring of the hydraulic drive system (and having all
necessary interlocks). The parameters shall include:
Drive status -alarm / warning
Setup drive
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Setup monitoring
Analog /digital inputs
Analog / digital outputs
Signal monitor and basic functions
(b) It shall be possible to control the drive either directly from the
microprocessor front (local) or from the coal handling system control
room (remote).
(c) The micro processor controller shall provide the following:
POWER PACK MONITORING

This shall be for health monitoring of various switches in the power
pack and a common warning or alarm shall be displayed and an
output signal sent to the coal handling system control desk.
ALARM CONDITIONS
Shall stop the drive and after a short time (say 1.5 sec) shall de-
energise the electric motor through an electric motor interlock.
Indication of what has happened shall be displayed on PLC and the
Common Alarm output shall be activated. An alarm condition shall
either a) prevent start of the power pack if the suction valve is
closed or b) cause a shutdown when running if low charge pressure
is sensed.
Warning Condition
Shall display what has happened and the Common Warning output
shall be activated. The drive shall continue to operate.
Specific Fault Conditions - monitored by the micro – processor

Max oil temp
When the oil reaches a temp of 700C, an alarm shall be activated.
High oil temp

When the oil reaches a temp of 650C, a warning shall be activated.
Min oil level

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When the oil level in the tank goes below minimum, an alarm shall
be activated.
Low oil level

When the oil level in the falls below the low oil level, warning shall
be activated
Return filter blocked

When the return filter is blocked, a warning shall be activated.
Drain filter blocked

When drain filter is blocked, a warning shall be activated.
Suction line closed

If the suction line is closed, an alarm shall be activated and prevent
start of electric motor.
Low charge pressure

If low charge pressure occurs than 0.5 sec during running, an alarm
shall be activated. Low charge pressure shall be interlocked to the
signal electric motor started and shall have time delay to enable
startup.
High pressure
If pressure rises to set level, a warning shall be activated.
(d) Drive control and sequencing
• The starting and stopping sequence is important to ensure the

pump and hydraulic motor are always charged with pressure
from the boost system when running. Controller shall perform
this sequencing using electric motor interlocks.
• Pump stroke signals shall also be generated from

microprocessor. The maximum level of stroke and therefore
drive speed shall be set in microprocessor. This shall also be
limited at the pump by maximum flow adjustment screws.
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• Starting sequence energise electric motor time delay for charge

pressure to establish. Electric motor started signal (dry NC
contact) shall be sent to the microprocessor control. The contact
shall be closed when the electric motor is stopped and opened
on electric motor start. (Failsafe monitoring shall continue)
• Drive ready to start signal output from microprocessor shall be

sent to coal handling system PLC.
• Start drive by closing drive start contact. Drive shall ramp up to

set point at the rate set in microprocessor for ramp up.
• Adjust set point give desired speed between zero and maximum.
• The controller shall be programmed to enable reverting of belt

and shall be as per that shown in the coal handling system flow
diagram.
• Stopping sequence stop drive by opening the drive start contact,

drive will stop at the rate set in microprocessor for ramp down.
The set point may be left at a nominal level.
• The drive may be left stopped with electric motor running

indefinitely where required.
• De-Energise electric motor
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a)
EMERGENCY STOP INPUT
A NC emergency stop circuit with a direct function shall be

connected to the microprocessor, which shall control the emergency
stopping using the electric motor interlock. This shall stop the drive
in the fastest and controlled manner. Stopping the electric motor
with pump still on stroke shall be avoided to prevent system
damage.
b) THE FOLLOWING SHALL APPEAR ON THE PLC AND THE

OPERATOR CONSOLE (MMI)
Common alarm
Output shall be activated when an alarm is present in the hydraulic

system
Common warning
Output shall be activated when a warning is present in the hydraulic

system
Drive ready to use
Output shall be activated when the electric motor is started and

charge pressure established. Drive start is interlocked internally in
microprocessor with this signal. This means that when this output is
activated the drive can be started.
Drive started
Output shall be when the drive is started and during ramp down
time.
c)
SPEED INDICATION
A speed indication signal (4-20 mA) shall be sent to the Coal
handling system PLC.
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d) CLOSED LOOP CONTROL
The actual speed from the hydraulic motor shall be fed back to the
controller and a PID regulator shall control the speed for an exact
and steady speed. The PID parameter shall be pre-set but shall be
suitable for altering site.
e)
WORKING PRESSURE
The working pressure shall be displayed on the micro processor

display (input 20 mA)
HYDRAULIC PIPING
(VI)
Hydraulic piping shall conform to the following specifications - for
pressure and return lines, cold drawn carbon steel seamless pipes
schedule 80 (DINA519), which can withstand a working pressure upto
350 bar and for the case and drain lines, cold drawn carbon steel
seamless pipes schedule 40 (DINA519), which can stand a working
pressure upto 270 bar. Hoses for high pressure and return lines (upto
350 bars) should conform to SAE 100 R13 and those for case and drain
lines should conform to SAE 100 R1.
(VII) Hydraulic oil
Standard mineral oil conforming to ISO VG 100 shall be used.

Contamination level shall be as recommended NAS 8. To prevent risk of
contamination from other hydraulic system e.g. cylinder systems for
luffing, tensioning, etc. the drive hydraulic system should be independent
of other hydraulic systems having its own dedicated oil tank hydraulic oil
filters, etc.
2.0 ELECTRICAL EQUIPMENT
2.1 All electrical equipment including drive motors, transformers, LT/HT

panels, electrically operated brakes, controllers, resistors, conductors,
insulators, current collectors, control desk, PLC, hard wired
communication cables, telemetry, protective devices, limit switches,
lighting fixtures, cables, cable reeling drums, etc. necessary for the safe
and satisfactory operation of stacker cum reclaimer shall be included in
the scope.
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2.2 Electrical equipment shall be adequately rated to permit simultaneous

operation of any combination of motions of stacking – reclaiming.
2.3 All electrical equipments viz., motors, transformers, limit switches,

operator’s cabin, control cabinet, brakes, breaker cubicles, lighting
fixtures, power receptacles, etc. shall be dust and weather proof suitable
for outdoor use.
2.4 MAIN TRANSFORMER
2.4.1 A step-down transformer 3300 / 433 volt, 3 Phase, 50 Hz shall be provided

by the Bidder. This transformer shall be suitably rated to meet the
maximum load requirement of the stacker cum reclaimer and also should
have spare capacity of 10% minimum. The transformer shall be suitably
covered with suitable enclosures. Contractor shall submit the sizing
calculation for Purchaser’s approval. The transformer shall be
conveniently mounted on the stacker cum reclaimer. Neutral of the
transformer shall be earthed through a 1A resistor and this resistor shall
be supplied and installed with suitable earthing by Contractor in the
house. The transformer shall be enclosed with a suitable enclosure.
2.4.2 The transformer shall conform to the requirements specified in the

electrical specification section D3 and Volume – IV
2.5 MOTORS
2.5.1 All motors shall be slipring or squirrel cage induction motors based on the
application & duty. When slipring motor are included the same shall be
complete with resistance in rotor circuits. All motors shall be suitable for
operation on 415 Volts, 3 Phase and 50 Hz AC system. Starting torque of
all the motors shall be minimum 160% of the full load torque.
2.5.2 The long travel motor and slewing hydraulic motor shall be suitable for
reversing, plugging control, frequent starting and mechanical braking
duties and shall meet all the requirements of IS: 3177. Whenever electric
braking is provided, motors shall withstand electric braking duty also.
2.5.3 The long travel motors shall have two speeds. Bucket wheel and boom
conveyor drives shall be of reversible hydraulic type.
2.5.4 Thrustor brakes shall be operated by totally enclosed squirrel cage
induction motors suitable for operation on 415 Volt, 3 phase, 50Hz AC
system.
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2.5.5 All motors shall conform to the requirements specified in the Electrical
Volume – IV A.
2.6 CONTROL
Motors of stacker cum reclaimer shall be operated from operator’s cabin,

controller type with soft start.
2.7 CONTROLLERS
Separate controllers shall be provided for long travel, turn table drive and
boom. In addition, control shall be effected through telemetry.
2.8 PROTECTION
2.8.1 All protections like heap collision, travel limit exceeded, wind velocity
high, etc. required for the safety of the equipment and operating
personnel shall be provided for stacker cum reclaimer. The details of such
protections provided shall be submitted for Purchaser’s approval.
2.8.2 An emergency pull wire rope with switches and local LED indication shall
be provided for stopping the conveyor (s) in the event of emergency.
Pulling of this rope shall actuate limit switches, which in turn shall trip the
conveyor(s). In addition, when pulled this pull wire rope shall give alarm to
control room and flickering indication shall also be displayed in the MMI.
2.9 SEQUENTIAL INTERLOCK
Sequential interlock shall be provided for starting as well as stopping of

the equipment. For starting of bucket wheel of reclaimer, operation of
trunk conveyor and boom conveyor in reclaiming mode shall be
permissive conditions. Similarly, for starting of trunk conveyor, boom
conveyor in stacking mode shall be operating. Tripping of any equipment
upstream shall trip all the preceding equipment sequentially in down
stream side.
The following interlocks shall be provided:

2.9.1 Long travel motors start only when cable reeling drums are ready for
operation.
2.9.2 Long travel motors start only when the rail clamps are released.
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2.9.3 Long travel motors will start only when the stacker cum reclaimer is
released from the storm anchors.
2.10 LIMIT SWITCHES
2.10.1 Automatic reset type of limit switches shall be provided to prevent over-
travel for each of the following motions :
(a) For extreme ends of long travel

(b) For luffing operation of the boom
(c) For slewing movement
2.10.2 For the motions listed at 2.10.1(b) and (c) above, there shall be back up
limit switches. In case normal limit switches fail, a visual & audible alarm
shall be initiated. For long travel extreme ends, a back up emergency limit
switch shall be provided on operation of which all drive motors of all
motions shall stop till the emergency limit switch is reset manually.
Minimum 1 “NO” and 1 “NC” spare contacts shall be provided for future
use.
2.11 STACKER CUM RECLAIMER LIGHTING / RECEPTACLE
Stacker cum reclaimer shall be provided with the following lighting

fixtures, ceiling fan and receptacles.
2.11.1 1 (one): 2 x 40 W, fluorescent type fixture in the operator’s cabin
2.11.2 3 (three): Swivel type flood light fittings of 400W mercury vapour lamps
complete with all accessories mounted conveniently. One (1) No.
mounted on the cabin so that the lamp can be focussed by the operator
on the boom and bucket wheel and two (2) Nos. mounted on the left and
right side of the stacker cum reclaimer for the long travel of stacker cum
reclaimer along the track.
2.11.3 Adequate quantity of 2 x 40 W fluorescent type lighting fixtures in electrical

house (E – house) for an illumination level of 250 lux.
2.11.4 Adequate number of 2 x 40 W fluorescent lighting fixture for illumination of

boom conveyor to achieve an illumination level of 50 lux.
2.11.5 Lighting fixtures shall be located conveniently on the stairways, super

structure, lower structure, electric house, walkways, platform, etc. to meet
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an illumination level of 50 lux. Adequate lighting shall be provided near

drives to obtain an illumination level of 100 lux.
2.11.6 1 (one): 30 cm sweep, non-swivelling but adjustable cabin type, 240V

single phase AC ceiling fan complete with guard mesh, toggle switch and
regulator at operator’s cabin and window type A.C for operator ’s cabin for
stacker cum reclaimer shall be provided.
2.11.7 4 (four): 3 pin, 240V, 15A single phase, polarised interlocked type power
receptacles, located one each in the operator’s cabin, E – house, middle
of boom conveyor gantry and on the super structure respectively.
2.11.8 Aviation warning light shall be provided on top of mast.
2.11.9 All lighting fixtures except the one mounted in cabin and power
receptacles shall be dust and water proof suitable for outdoor use.
2.12 GI conduit for power and control circuits shall not be less than the size
recommended by Indian Electricity Rules for the size of conductors
proposed to be installed therein. The entire conduit system shall be so
installed that any moisture will be drained away from the terminal boxes
and electric devices. No conduit of size smaller than 19 mm diameter
shall be used. Power wiring and control wiring shall be kept in separate
conduits wherever necessary.
2.13 The trailing H.T power cable shall be 3300V grade, stranded, annealed
tinned copper conductor, conductor screened, EPR insulated, insulation
screened, EPR inner-sheathed, with CSP outer sheath. The cable shall
generally conform to IS 9968 - Part II.
2.14 Cables running adjacent to resistor boxes where the temperature is high
shall have outer-sheath, which can carry higher temperature.
2.15 Power, control and trailing cables shall conform to the requirements
specified in the Electrical Volume – IV A.
2.16 SAFETY EARTHING
2.16.1 Stacker cum reclaimer structure, motor frames and metal cases of all
electrical equipment including metal conduit and cable guards shall be
effectively earthed. Insulated rubber mats shall be provided in front of the
panels.
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2.16.2 The arrangement to connect the earth bus of the stacker cum reclaimer to
the earth grid on the ground shall be furnished and this shall be subject to
Purchaser’s approval.
2.17 WARNING HORN
An electric warning horn shall be provided and mounted on the underside

of the cab. Control shall be arranged such that the horn operates
automatically when boom / turn table travel motor is energised. In
addition, manual control of the horn shall be provided in operator’s cabin
at a location convenient to the operator. Manual control shall not over
ride automatic control and shall be used only when stacker cum reclaimer
is stationary. Horn shall be of heavy duty with a sound level of 95 dB at
3.5 metres distance and same shall be suitable for 240V AC operation.
2.18 PUBLIC ADDRESS SYSTEM AND COMMUNICATION
2.18.1 A public address system shall be provided for stacker cum reclaimer. This
system shall have two loud speakers, one located on the superstructure
and the other in the operator’s cabin. Two hand sets shall be provided
one of the handsets shall be located in operator’s cabin and the other at
convenient place for the use of men working at lower elevation of stacker
cum reclaimer.
2.18.2 Public address system shall consist of built-in amplifier, hand sets, loud
speakers, etc. suitable for location in a dusty atmosphere.
2.19 AUXILIARY SUPPLY
Auxiliary supply required for 3.3KV breaker & 415 V breaker shall be
tapped through suitable V.Ts with protective features on both HT and LT
side from the incoming side of breaker.
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2.20 The following minimum features shall be taken care of:
2.20.1 Provision for emergency push button for HT and LT shall be included.
2.20.2 Festooning cables shall have dust tight ceiling arrangement with
provision for opening for periodical cleaning.
2.20.3 Panel wiring in electrical house and operator’s cabin shall conform to the
Volume IVA of the specification for control panel, 6.6kV and 415V
switchgear.
2.20.4 Provision for HT VCB with isolator in series shall be provided.
2.20.5 1:1 lighting transformer shall be provided.
2.20.6 Provision of LT vacuum contactor in series with LT ACB. Normal

operations through VC and protection tripping through ACB.
2.20.7 Necessary protection shall be provided in HT panel and LT panel as

specified in 3.3kV switchgear and 415V switchgear specifications in
Volume IVA
2.20.8 Provision for Electric hoist arrangement and chain pulley blocks etc.
shall be provided.
2.20.9 Provision of welding sockets of suitable rating at minimum 2 (two)

locations shall be provided.
2.20.10 Dedicated siren system with LED type warning lamps shall be provided.
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SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION D-1.1 DS-A
DATA SHEET - A
TCE 5871A-H-563-001B
STACKER CUM RECLAIMER SHEET 1 OF 4
SL.NO.
1.0 TYPE SLEWING AND LUFFING BOOM

TYPE STACKER CUM
RECLAIMER WITH REVERSIBLE
TRUNK CONVEYOR.
2.0 NUMBERS REQUIRED Two(2)
CAPACITY WHILE STACKING

3.0
3.1 RATED t/hr. 2600
3.2 AVERAGE t/hr. 2000
4.0 CAPACITY WHILE RECLAIMING
4.1 PEAK t/hr 2600
4.2 AVERAGE t/hr. 2000
5.0 MATERIAL HANDLED AS PER D1.0
6.0 DUTY CONTINUOUS DUTY
7.0 WIND PRESSURE
7.1 OPERATING N/m2 200
7.2 NON-OPERATING MAX. WIND PRESSURE AS PER

IS:875 (LATEST EDITION)
8.0 SEISMIC COEFFICIENT REFER SECTION – Vol- III
9.0 MAXIMUM WHEEL LOAD Tonnes BY BIDDER

PERMISSIBLE WITH IMPACT
10.0 TRACK GAUGE Metres 8.0
11.0 TRACK LENGTH REFER BID DRAWINGS
12.0 STOCK PILE
12.1 EFFECTIVE STOCK PILE HEIGHT M (AS PER THE BID DRAWING)
ABOVE GRADED LEVEL
REV. NO. R0 PPD BY: RC JOB NO. CLIENT: PPGCL

DATE CKD BY: BVS TCE. 5871A PROJECT: 3X660 MW PHASE-1,
REV. BY DATE: OCT’10 BARA TPS
TCE FORM 330 R1
DATA SHEET - A
TCE 5871A-H-563-001B
SL.NO.
12.2 WIDTH OF STOCK PILE AT THE M (AS PER BID DRAWING)
BASE
12.3 CROSS SECTION AND LENGTH OF (AS PER BID DRAWING)

STOCK PILE
13.0 TRACK VARIATIONS
13.1 VERTICAL: ONE RAIL TO ANOTHER mm +10
13.2 HORIZONTAL BIDDER TO INDICATE
13.3 MAXIMUM GRADIENT 1 IN 3000
14.0 RANGE OF LUFFING Degrees PLUS & MINUS: TO SUIT

STACKING HEIGHT AS
SPECIFIED
15.0 MINIMUM SLEWING ANGLE OF Degrees MINIMUM 210 DEG ± 105 DEG
BOOM OF STACKER CUM ON EITHER SIDE
RECLAIMER
16.0 Boom conveyor details
16.1 BOOM LENGTH m 35
16.2 BELT WIDTH mm 1800
16.3 DISTANCE BETWEEN CENTRE AS ENVISAGED IN THE

LINES OF TWO TRACKS. SYSTEM. REFER BID
DRAWINGS
17.0 IS INTERMEDIATE CROSS YES. BELT WIDTH, SPEED
CONVEYOR REQUIRED &TROUGHING ANGLE SHALL
BE SAME AS BOOM
CONVEYOR.
17.0 SPEEDS
17.1 TRAVEL M/min. 6 TO 10 & 15 TO 20 (TWO

SPEEDS REQUIRED)
17.2 HOISTING OR LUFFING M/min 5 (AT THE TOP OF THE BOOM)
17.3 SLEWING M/min 30+10% (AT BUCKET WHEEL

TIP)
17.4 BUCKET WHEEL Rpm TO BE DECIDED BY BIDDER
17.5 BOOM CONVEYOR M/min. BY BIDDER

TCE FORM 330 R1
DATA SHEET - A
TCE 5871A-H-563-001B
SL.NO.
18.0 TYPE OF DRIVE FOR:
18.1 BUCKET WHEEL HYDRAULIC & SHALL BE

SUITABLE FOR INCHING
OPERATION.
18.2 BOOM CONVEYOR HYDRAULIC & SHALL BE

SUITABLE FOR INCHING
OPERATION.
18.3 SLEWING HYDRAULIC
18.4 LT DRIVE SLIP RING / SQUIRREL CAGE

MOTORS.
18.5 INTERMEDIATE CONVEYOR ELECTRO-MECHANICAL
19.0 TYPE OF BRAKES ELECTRO HYDRAULIC

THRUSTOR.
20.0 IN LINE BELT SCALE ON BOOM MICROPROCESSOR BASED /

CONVEYOR FOR STACKER / ELECTRONIC BELT SCALE.
RECLAIMER / STACKER CUM WITH ACCURACY + 2 %.
RECLAIMER
21.0 TYPE OF CONTROL OF STACKER / AUTOMATIC OPERATION WITH

RECLAIMER PLC SHALL BE PROVIDED IN
ADDITION TO MANUAL
CONTROL THROUGH PLC.
SHALL ALSO BE CAPABLE OF
OPERATING THROUGH
REMOTE TELEMETRY.
22.0 NOTES
22.1 Reclaiming capacity is the capacity that is arrived based on averaging over a period of
4 hours operation.
22.2 Rail fixtures and rail interconnecting structural members at suitable intervals shall be
included in the Bidder’s scope. These shall be suitable for continuous beam type
supports.

TCE FORM 330 R1
DATA SHEET - A
TCE 5871A-H-563-001B
SL.NO.
22.3 Though independent power packs for bucket wheel & slew mechanisms have been
specified, alternatively Bidder can offer common power pack for bucket wheel & slew
mechanisms.
22.3 Performance test for stacker shall be conducted for a period of minimum twelve (12)
hours (spread over 4 days) over the entire height of cross section of stockpile for a
particular length of stockpile. During the test, boom should not experience any undue
vibrations.
22.4 Performance test for reclaimer shall be conducted for a period of minimum twelve (12)
hours (spread over 4 days) the entire height of cross section of stockpile for a particular
length of stock pile. During the test boom should not experience any undue vibrations.
22.5 In the reclaiming mode, it should be possible to cleanly reclaim from the pile nearest to
the rails also.
22.6 The integrator conveyor scale for boom conveyor shall be provided such that at any
point of time it indicates material stacked or reclaimed.
22.7 Automatic operation of stacker cum reclaimer with programmer logic controller shall be
provided in addition to manual control through PLC. There shall be auto manual
selector key for the operation of stacker cum reclaimer.
22.8 The drive of bucket wheel shall be suitable for inching operation. There shall be
separate inching push button to control the motion of bucket wheel during maintenance.
22.9 Electric house (switchgear room) should be completely closed and provided with
window type air conditioner of 2 TR capacity.
22.10 Window type air conditioner of 1.0 TR capacity shall be provided in the operator’s cabin.
22.11 Separate enclosure shall be provided near the electrical house for storing the tools,
welding sets and other consumables like grease, oil, etc. with lock and key.

TCE FORM 330 R1
SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION D-1.1
TCE 5871A-H-563-001B DATA SHEET - B

SL.NO. ITEM CONTRACTOR---->
1.0 TECHNICAL PARTICULARS
1.1 Type and make
1.2 Design and Rated capacity -
a) While stacking Rated (Design) t/hr

b) While reclaiming Rated (Design) t/hr
1.3 Wind velocity:
a) Operating Km/hr
b) Non-operating Km/hr
1.4 Maximum Wheel load Tonnes
1.5 Stock pile height, base width and length metres
2.0 RAILS FOR TRAVEL OF STACKER CUM

RECLAIMER
2.1 Rail size
2.2 Length of runway metres
2.3 Effective length of travel metres
2.4 Effective length of Stockpile metres
2.5 Track Gauge metres
2.6 Maximum permissible track variations – mm

Vertical – One rail to another
2.7 Maximum permissible variation in rail – mm
Level vertical
3.0 CONVEYORS
3.1 BOOM CONVEYOR
NOTE TO BIDDER SIGNATURE

1. ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE MARKED
WITHIN ASTERISK(*) (DETAILS TO BE GIVEN IN SCHEDULE OF DEVIATIONS) OF BIDDER:
2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL DATE:
BE ENCLOSED WITH EACH COPY OF THE BID.

3.1.1 Length (Between drive pulley to tail pulley

centres)
3.1.2 Belt Width and troughing angle
3.1.3 Belt speed m/sec
3.1.4 Drive type and motor rating kW
3.1.5 Slewing angle of boom Degrees
3.1.6 Maximum slewing speed M/min
3.1.7 Number of steps of slewing speeds
3.1.8 Range of luffing Degrees
3.1.9 Luffing speed M/min
3.2 HOPPER AND CHUTES
3.2.1 Material and thickness of plates & liners
3.2.2 Gates at hopper / chute outlets -
a) Type
b) Mode of operation
4.0 DETAILS OF WHEELS:
4.1 Number / truck
4.2 Number of trucks
4.3 Material
4.4 Wheel base
4.5 Drive motor rating kW
4.6 Total number of driven wheels
4.7 Travelling speed -
a) Maximum (Fast) m/min

b) Minimum (Slow) m/min
5.0 BUCKET WHEEL ASSEMBLY
5.1 Type Cell less
5.2 Diameter of Bucket Wheel Ring M


5.3 Width of bucket m
5.4 No. of buckets in the assembly Nos.

3
5.5 Water fill volume of each bucket M
3
5.6 Ring volume M
5.7 MATERIAL OF CONSTRUCTION
5.7.1 Bucket wheel
5.7.2 Bucket
5.7.3 Teeth and tips
5.8 DRIVE
5.8.1 Type
5.8.2 Rating kW
5.9 Is speed monitor built on the bucket wheel

drive included?
5.10 Bucket Wheel Speed RPM
6.0 OPERATOR’S CABIN
6.1 Type Air Conditioned
6.2 Location Near Bucket Wheel
7.0 LUFFING MACHINERY
7.1 Type
7.2 Location
7.3 Drive motor rating kW
8.0 SLEWING
8.1 TYPE OF DRIVE
8.2 kW rating of drive motor Kw
9.0 VOID


10.0 BRAKES
10.1 Type & make of brakes of different motions A disc brake (parking) and Elecro
hydraulic Thruster brake
10.2 Number provided for each motion
11.0 GEAR REDUCER UNITS
11.1 Type & make
11.1.1 Lubrication type
11.2 MATERIAL OF CONSTRUCTION
11.2.1 Gears
11.2.2 Pinion
11.2.3 Shafts
11.2.4 Casing (Gear box)
12.0 LIMIT SWITCHES (BOOM HOISTING,

BOOM LOWERING, LONG TRAVEL,
SLEWING LEFT & SLEWING RIGHT)
12.1 Number provided
12.2 Type
12.3 Make
12.4 Method of actuation


13.0 CABLE AND CONDUIT EARTHING
13.1 MINIMUM SIZE OF POWER CABLE
a) 6600V
b) 415V
13.2 Minimum size of control cables
14.0 CABLE REELING DRUM
14.1 Drum winding diameter of cable reels 6.6 KV CONTROL
14.2 Number furnished
14.3 Type
14.4 Size
15.0 TRANSFORMER (main) *
16.0 LIGHTING TRANSFORMER *
17.0 HT BREAKER
During Detailed Engineering
18.0 LT BREAKER
19.0 MOTORS
20.0 CABLES : 1) POWER – HT and LT

2) CONTROL
3) TRAILING
21.0 STACKER CUM RECLAIMER WEIGHTS:
21.1 Mechanical equipment including boom

conveyor
21.2 Electrical equipments
21.3 Total delivery weights
21.4 Oil fill
21.5 Ballast in counter weight boom
21.6 Live load, dirt accumulation and

incrustation
21.7 Service weights


ELECTRIC HOISTS
21.8 PROVIDED
MISCELLANEOUS
21.9
Tool room provided
21.9.1
Portable fire extinguishers (Location and
21.9.2 Capacity)
Type of control of Stacker cum Reclaimer

22.0

SECTION D 1.2
REVERSIBLE YARD (TRUNK) CONVEYORS
VOLUME – IIB
TCE 5871-H-563-001B LIMITED
SECTION: D1.2
PROJECTAT BARA,UP SHEET 1 of 13
1.0 DESIGN REQUIREMENTS
1.1 General Requirements
1.1.1 Yard conveyors shall normally handle the material continuously at the rated
capacity as indicated in the respective data sheets. However for calculating
Brake kilowatt, a margin of 10% over the rated capacity shall be considered.
1.1.2 All the belt conveyors, feeders and all other equipment, etc. shall be provided
with electromechanical drives. .
1.1.3 The ratings of motors, sizes of gear boxes (for equipment with Electro
mechanical drives), couplings and pulleys for conveyors shall be standardized.
The different types of motors, gearboxes, couplings and pulleys of different
conveyors and of different types shall be limited to minimum possible.
1.1.4 The motor rating for all the equipment (of yard conveyors) shall have a minimum
margin of 10% over the BKW. The service factor for selection of gearboxes,
resilient couplings, flexible couplings (equipment with Electro mechanical
drives), brakes, etc. shall be 1.5 times minimum on the motor rating.
1.1.5 Speed reduction units for all equipment (with Electro mechanical drives) with
drive motor rating of above 10 kW shall be helical/bevel helical type. The gears
shall be hardened and ground type. Bevel helical or helical gearbox shall be
provided for screens to suit the layout. The gearboxes shall be provided with fan
cooling arrangement wherever required and water-cooling arrangement shall not
be provided.
1.1.6 The type of high speed coupling between motor and gearbox (for Electro
mechanical drives) shall be as follows:
(a) For motor rating upto 30 kW - Resilient type
(b) For LT motors of above 30 kW rating - Traction type fluid
(c) For HT motors - Actuator operated scoop type fluid coupling
1.1.7 For the scoop type fluid coupling, cooling arrangement with water shall not be
provided. Whenever, a equipment provided with HT motor, trips due to fault in
itself or due to tripping of succeeding conveyor/equipment, the fluid in the fluid
coupling shall be emptied by the scoop for disengaging the motor from the load
and the HT motor shall continue to run. The actuation time of the scoop tube
actuator shall be less than the coasting time of the succeeding
conveyor/equipment.
1.1.8 The couplings between gear box and driven equipment shall be of resilient type.
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TCE FORM 329 R3
VOLUME – IIB
SECTION: D1.2
1.1.9 All equipment drives including conveyors drives shall be capable of starting fully
loaded equipment.
1.1.10 All the bearing pedestals shall be of horizontal split type for easy inspection,
preferably with four bolt fixing.
1.1.11 Design of chute and hopper outlets should be such that wet and sticky coal shall
flow freely without arching / plugging of chutes. The sizes of chutes and hopper
outlets shall be large enough to achieve this. The chutes shall have preferably
semi-circular cross section nearer to feed points to conveyors so that the
material while feeding on conveyor can be centralized. The chutes shall be as
far as possible straight and where bends have to be provided a minimum side
plate angle of 65 deg and hopper side plate angle shall be minimum 65 deg.
1.2 Belt Conveyors
1.2.1 The belt conveyors shall be designed based on IS-11592. The artificial
coefficient of friction shall be considered as 0.03 for calculating the power
requirement for conveyors.
1.2.2 Considerations of secondary resistance to additional impending

forces :
(a) Minimum 0.15Kw for 1m length of skirt board and a belt speed of
1M/Sec.
1.2.3 Friction coefficient "μ" (between drive pulley and the belt) shall be considered as
0.35 for arriving at tight side /slack side tension.
1.2.4 All conveyor drives shall be single snub pulley drive with minimum angle of wrap
of 210 deg.
1.2.5 The radius of curvature for all conveyors shall be calculated as per IS: 11592.
However, while calculating radius of curvature for stacker cum reclaimers the
maximum tension (Tc max) at curve may be calculated based on 20% of the full
load. The head end of conveyor shall preferably be horizontal and horizontal
length of conveyor at head end shall be minimum 3 meters. The conveyor
preferably horizontal at tail end. However in the event, it is not possible to
maintain horizontal profile at tail end, bidder can considered inclined portion with
slope not exceed 6°. The maximum spacing of carrying idlers in the convex
curve portion of conveyor shall be limited to half the normal spacing of carrying
idlers.
1.2.6 Conveyors carrying (-) 20 mm size coal shall have a maximum inclination of
14°.
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TCE FORM 329 R3
VOLUME – IIB
SECTION: D1.2
1.2.7 For all conveyors, transition idlers of 5°, 15° and 20° shall be provided at either
end at spacing similar to other carrying idlers.
1.2.8 All inclined conveyors shall be provided with hold back in addition to brakes.
These brakes shall be used for adjusting the coasting time also where required.
1.2.9 The skirt boards shall be terminated over an idler.
1.2.10 VOID
1.2.11 Snub pulleys of all conveyors at head end shall be covered in the main
discharge chute.
1.2.12 The clearance between the bottom of the tail pulley and floor in junction tower
shall be adequate to avoid fouling of the return belt with spilled material and it
shall be minimum 500 mm. Also, a minimum clearance of 300 mm shall be
provided below tail snub pulley, wherever applicable.
1.2.13 For over ground conveyors, take-up shall not be provided in the pits. The takeup
shall be positioned so that the lower end of the takeup weight is not more than
1.5 m from the ground. Mesh guard around the take up weight for a height of 2.5
m shall be provided. Sand pit shall be provided at the GL. The counter weights
shall be cast iron of suitable size for easy handling.
1.2.14 The walkways shall be covered with chequered plate to avoid falling of material
below the walkway. Seal plate shall be provided at all road / railways and plant /
building crossings.
1.2.15 The coasting time of conveyors and feeders shall be adjusted such that the
material discharge and equipment shall have highest coasting time and the
preceding equipment shall have equal or lower in descending order.
2.0 CONSTRUCTION REQUIREMENTS
2.1 Belt Conveyors
2.1.1 Each belt conveyor shall be complete unit with the belt, carrying, return, self
aligning, transition, inverted troughing and impact idlers, pulleys, drive units, belt
cleaning devices, deck plate, head frame, tail frame, flight frames, take up, hold
back etc. for all inclined conveyors.
2.1.2 Conveyor Belt
a) The fire retardant belt used for conveyor shall be carefully selected
considering the service requirements, loading cycle, loading and unloading
points. It shall be adequately designed to convey the required tonnage of
the material of specified lump size. The number of plies and tensile ISSUE
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TCE FORM 329 R3
VOLUME – IIB
SECTION: D1.2
strength shall be suitable for the performance required. The plies shall be
skim-coated and the belt shall be mill dew resistant.
b) The carcass shall have adequate strength and adequate number of plies
as specified in data sheet-A. Maximum allowable belt tension shall be
considered as 10% of the belt strength for EP belts. Maximum tension
during normal operating condition with load shall be considered for
checking against 90% of maximum allowable tension of conveyor belt and
Maximum tension during starting condition with load shall not exceed
150% of maximum allowable tension of conveyor belt. The cover shall be
of fire retardant type as per data sheet-A The cover thickness shall be as
specified in data sheet "A", The belt shall be constructed to facilitate
mounting and running on troughed idlers. The SUPPLIER shall include in
his supply sufficient length of belt to take care of field splicing. The belt
shall have enough edge rubber anchorage to resist end wear. The belts
shall be of molded edge construction and not cut edge type.
c) The percentage of elongation shall be limited to 3% of belt length for EP

belts. However, take up travel shall be based on minimum 2.5% take up
travel + 600mm. The percentage of belt sag shall be based on IS: 11592.
2.1.3 Idler units
a) All idler rolls shall be manufactured from ERW tubes conforming to latest
edition of IS: 9295 or from seamless tubes conforming to IS: 3601 /BS-
1775. The bearing housings shall be of cast steel/HRDD for impact idlers
and HRDD for other idlers. Both the bearing housings shall be welded to
the rolls simultaneously. The maximum friction of each idler unit shall not
exceed 0.015.
b) The idler units shall be heavy duty, suitable for continuous operation at
high capacities. In the case of troughing idlers having rolls of equal length,
the rolls as well as the roll components shall be interchangeable. The
minimum roll size of idlers shall be as specified in data sheet "A" idlers
shall be as specified in data sheet "A".
c) The frames for all fixed type troughing units shall be steel or malleable
form with provision for securely bolting to the stringers of the conveyor
frames. All fixing bolts shall have spring washers. Slotted holes of 1.5D on
both sides of the frames shall be provided.
d) For the impact type units, the rolls shall be made of steel tube and
securely held in place. The rolls for all other troughing units shall be of
tubular steel construction. Idler spacing at loading points shall be reduced
to prevent excessive sag. The first impact idler shall be placed approx. 150
mm behind the loading point. The number of impact idlers at each feed
point shall be minimum 6. Each set shall contain 3 rollers. For other belt
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TCE FORM 329 R3
VOLUME – IIB
SECTION: D1.2
and feeders, the impact idlers shall also be fixed type.
e) The thickness of the shell shall be as specified in data sheet A. Each roll
for all idlers shall be equipped with an approved type of anti-friction
bearings of ample capacity and shall have minimum double labyrinth type
seals for keeping the lubricant in and dirt out. The bearings and the sealing
devices shall be mounted in an internal structure that shall ensure
alignment, proper spacing and good support and minimise the size of the
lubricant chamber. Pivoted support for each self-aligning unit shall be
provided with an adequate means for pressure gun lubrication in case life
lubricated bearings as specified in data sheet-A. The idler bearings shall
be deep groove ball bearings double side sealed. Minimum life of all life
lubricate idler bearings shall be 50,000 working hours. The bearing
housing thickness at impact zone shall be 10mm thickness for all belts and
for other carrying and return rollers the bearing housing thickness shall be
5.5 mm. The external and internal labyrinth seals for all types of rollers
shall be Zamak and rain cap nylon-6, dust cover-CRCA/IS513.
Alternatively, Bidder can offer nylon-6 as the material of labyrinth and dust
cover for all idlers
f) Fixed type impact and carrying idlers shall be provided for all conveyors. In
these portions, where fixed type idlers are provided on the carrying side,
self aligning type return idlers shall also be provided. For return belt also,
same shall be applicable. For conveyors having belt width 1800mm, the
return and return training idlers shall be 2 roll 100 V-type. For horizontal
portion of conveyors, festoon type 100, 2 roll V-type return idlers shall be
provided. The return idlers shall be connected to the steel rod brackets of
minimum 16 mm diameter. Two sets of brackets shall be provided for each
idler for aligning and training of conveyor or belt. Wherever festoon type
return idlers are used, self aligning return idlers need not be provided.
However, on the carrying side of the belt, self aligning idlers shall be
provided even in portions where fixed type idlers are provided. The
spacing of V-type return idlers shall also be limited to 3m. However, the
spacing near the head pulley and tail pulley shall be less than 3.0m. All
self aligning idler units shall be offset castor cambers type with a pivoted
frame mounted on anti-friction bearings. Self-aligning idlers where
provided, on the carrying and return runs shall be placed about 15m from
each terminal or bend pulley and approximately 24.0m apart thereafter.
The supports for the self-aligning idlers shall be made of steel or malleable
iron with provision for securely bolting to the underside of the stringers.
The rolls for the other return idlers shall be mounted on sturdy steel or
malleable iron brackets bolted to the underside of the stringers. Bearings,
sealing devices, bearing mountings and lubrication arrangements for
return idlers of conveyor and all the belt feeder idlers shall be similar to
those outlined above.
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TCE FORM 329 R3
VOLUME – IIB
SECTION: D1.2
g) All idler rollers shall be painted with 2 coats of red oxide primer and two
coats enamel finish paint.
h) For a particular size of belt, each type of idler and their component shall be
identical to ensure inter changeability. All rollers of the same size shall also
be fully interchangeable.
2.1.4 Pulley Units
a) All conveyor pulleys with HT drives (more than 200kW) shall be provided
with cast steel turbo diaphragm end disc. All other pulleys shall be
provided with MS hub welded with end disc and shell conforming to IS:
1891, the end discs shall be located to give minimum rim overhang. The
face of each pulley shall be smooth, wider than the contacting belt by 200
mm with a tolerance of + 3.0 mm on the nominal width. One
circumferential and two longitudinal rim welds per pulley shall be
permitted. The welds for pulley construction shall be ground smooth and
each shall develop the full strength of the plate. The load rating for the
pulleys shall be in accordance with the latest edition of BS-2890. All drive
pulleys snub pulleys and all other pulleys shall be in accordance with the
latest edition of BS-2890. All drive pulleys shall be lagged with an
approved herringbone groove rubber lagging. All other non-drive pulleys
shall be lagged with plain rubber of 10 mm thickness. The minimum
thickness of rubber lagging for drive pulley shall be 12 mm. Grooving shall
be designed to prevent material build up and provide maximum self
cleaning.
The width and depth of grooves shall be 6 mm spaced at 30mm interval.
The shore hardness of rubber shall be minimum 60 for drive pulleys and
55 for other pulleys. The shore hardness of drive pulleys shall be mounted
such that apex of the herringbone groove points in the direction that the
pulleys rotates. All lagging shall be accurately fitted and vulcanized to the
pulleys. For the drive pulleys the lagging shall be located to provide a belt
wrap on the drive pulley of not less than 2100. The drive pulleys of
reversible conveyors / feeders shall be provided with diamond lagging.
b) All drive and take-up pulleys shall be connected to the shafts through
keyless friction grip connection of approved make. The deflection of all
pulley shafts shall be limited to 1/2000 at the centre of the shaft. The
combined shear stress in the drive pulley shaft based on the normal torque
of driving motor shall not exceed 500 kg/sq.cm. The shaft diameter of drive
pulley shall be calculated considering both the above aspects and the
maximum diameter of the two aspects shall be adopted.
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TCE FORM 329 R3
VOLUME – IIB
SECTION: D1.2
Pulley shaft of 150 mm diameter and less shall be made of machined hot
rolled or turned and ground cold finished carbon steel. Pulley shafts larger
than 150 mm in diameter shall be made of carbon steel forging. All pulleys
shafts shall have a carbon content of not less than 0.35%. Each shaft shall
be amply proportioned for both strength and stiffness. Reduction of
diameter of the shafts at the bearings shall be permitted if the bearings for
the reduced sizes have the required life and load ratings.
Reduction of the diameter at the bearings for shafts of 150 mm and

smaller shall not exceed 12 mm. All shafts shall be straight and true with
fits and surface conditions suitable for mating parts and when practicable
with fillet radii of not less than 6.0 mm where changes of section occur.
c) All shafts shall be supported by heavy duty, horizontal split type pillow
blocks equipped with self aligning spherical roller bearings and adequate
sealing devices for keeping the lubricant in and dirt out. All pulley bearings
shall have a minimum life of 50,000 hours. All pulley bearings shall have
both ends fully covered except the drive side bearings of drive pulleys. The
bearings shall be an approved make. One bearing for each shaft shall be
fixed to prevent any movement of the shaft assembly and the other
bearing shall be floating to have free axial movement. All plummer blocks
for shafts less than 75mm diameter except drive pulley shafts may be
mounted on the supporting structure by just two bolts. All pillow blocks for
shafts above 75 mm shall have four mounting bolts. Pillow blocks for drive
pulley shaft less than 75 mm shall have four mounting bolts. Adjustable
screws with locking nuts shall be provided on each side of all plummer
blocks for aligning and holding pulley units. All plummer blocks shall be
mounted on machined surfaces supporting the full face of plummer block.
Each plummer block shall be equipped with a button head or equivalent

type grease fittings for pressure gun lubrication, an approved type relief
fitting for preventing building up too much grease pressure and a suitable
drain for removing old lubricant. Where required grease fittings shall be
located in an accessible position and provide piping to the plummer block.
Either plummer blocks or bearings units of pulleys shall be provided with
multi -labyrinth type dust seals to prevent ingress of dust into the bearings.
d) All pulleys shall be statically balanced to minimize the vibrations during

running. All pulley diameters adopted shall be selected based on the
percentage of belt tension as per IS: 1891 and IS 4776 Part -I for N-N
belts.
e) All bend, snub and tail pulleys shall be shell mounted with pulley rotating
and shaft being fixed. The shaft shall be mounted in the bearings inside
the pulley hubs. The shaft shall be fixed at ends completely. The shell shall
rotate over this fixed shaft.
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TCE FORM 329 R3
VOLUME – IIB
SECTION: D1.2
2.1.5 Belt Cleaning Units
The sloping back of each transfer chute shall be spaced from the return belt to
permit use of a belt cleaning unit and arranged such that the dribbles shall be
returned to the same chute that is handling the main flow of material. On tail
pulleys, scraper shall be included on pulley contact surface of belt with
discharge chutes at approved locations. Dribble removal chutes shall be
provided according to the layout wherever required / feasible in order to return
dribble to the system or to displace it to points where it may be conveniently
shovelled back into the system to remove the coal dust scraped by internal
scrapers. The external belt cleaners shall be multi blade torsion arm type and
sprung blade type units as called for in data sheet-A.
a) Multi blade torsion arm type belt cleaners
The belt cleaner shall consist of a row of blades made of polyurethane

backed by steel plates. These blades shall be capable of being set
perpendicular to the belt surfaces but diagonal to the belt travel. Each
blade shall be pivoted upon an individual torsioned spring, which presses
the wiping edge gently, but firmly against the belt. Blades shall overlap to
cover the entire carrying width of the belt. The polyurethane strips shall
be adjustable after wear.
b) Sprung Blade type Belt Cleaner
The blade of the belt cleaner shall be made of spring steel so that the
cleaning is effective. The material of blade and construction of cleaner
shall be such that the blade shall lift in the event of any foreign material. .
2.1.6 Take Ups
a) Automatic vertical / horizontal gravity type assemblies complete with

counter weights and structural steel supports shall be provided for each
belt conveyor more than 20 m in length. Take ups shall be mounted on
steel frames with safety stops to prevent the fall of the take up pulley in
the event of belt breakage. The stops shall be permanently and positively
set at a point low enough to allow for normal belt stretch. The Gravity
take up (GTU) shall be positioned along the conveyor so that lower end
of GTU weights is not more than 1500 mm from ground level. The
gravity take up weights for bunker conveyors shall be brought down
near to ground using steel wire ropes. The take up shall be provided with
maintenance platforms at different levels. These maintenance platforms
shall be provided with access ladder.
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TCE FORM 329 R3
VOLUME – IIB
SECTION: D1.2
b) Each take up unit shall consist of a structural steel frame sliding up and
down on two vertical steel pipe guides, a take up pulley unit mounted on
anti-friction bearing pillow blocks bolted to the structural frame and
threaded counter weight rods secured to the lower edge of the structural
frame, each provided with two nuts and washer at their lower edge for
attaching counter weights. Suitable guards and a counter weight / box
shall also be provided by the SUPPLIER.
The sand pit shall have all around wire mesh of 2.5 m height above the
ground level. Each take up shall be provided with a marked up scale
beside the structural frame to monitor belt stretch. Each take up shall be
provided with a minimum travel of 2.5% of length of conveyor plus 600
mm for conveyors with E.P belts.
Provision for one (1) No. Electric hoist with monorail for each stream
shall be provided for handling take up pulleys and its counter weights for
all conveyors with vertical gravity take ups.
c) Each take up pulley, its shaft and bearings shall be as outlined in Clause
2.1.4 above.
2.1.7 Hold Back
All inclined conveyors shall be provided with integral cam roller type Holdbacks
to prevent reverse rotation of conveyor in the event of power failure. Holdbacks
shall be provided in the intermediate shaft of the gear box. Holdbacks of ratchet
and pawl type are not acceptable. Holdbacks shall be designed to prevent
reverse rotation of fully loaded belt under all weather conditions. Holdbacks
rating shall be 1.5 times the full load torque of the drive.
2.1.8 Brakes
Electro hydraulic thruster brakes shall be provided on all inclined conveyors to

serve as a back up to hold back. These shall also be used for adjusting the
coasting times of different conveyors. On horizontal conveyors, if brakes are
required to adjust the coasting time, the same shall be provided and shall be of
electro hydraulic thruster brakes. The brake actuation time without delay relay
shall be limited to 3 seconds.
2.1.9 Chutes, Skirtings, Switches, Frames, Deck Plates And Belt Housings
a) The SUPPLIER shall furnish all chutes, skirtings, rubber seals, felt
gaskets, housings, hanger rods, hanger rod end brackets and chute
supports as needed to provide the complete coal handling system outlined
in this specification.
ISSUE
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TCE FORM 329 R3
VOLUME – IIB
SECTION: D1.2
b) The chutes, skirtings and housing shall be welded and bolted units made
of structural steel plates, unless otherwise specified. All units shall be
made as dust tight as practicable. Bolted joints shall be provided with felt
gaskets. Provision for ready access to the interiors of skirtings, housing
and other possible trouble points shall be made by means of readily
removable, bolted on plates or by hinged and latched doors.
c) All discharge chutes shall be constructed as specified in Data Sheet – A.

Minimum site plate angle of all chutes shall be as indicated in Data Sheet –
A. All chutes shall be fitted with hinged inspection doors. The outlet
openings size of chutes along the length of conveyor shall be based on
minimum two times the lump size or three times the flow rates through the
chute depending upon whichever gives maximum dimension. The
minimum dimension of outlet of chute across the conveyor shall be 2/3 rd
belt width. The chute hood shall be provided with baffle plates to guide the
coal in to the discharge chute. The location of the baffle plate shall be
adjustable. The chutes shall also be provided with dust curtains. The hood
plate of chutes shall be of 5mm thick MS.
d) All skirt plates shall be made of steel plates having a minimum thickness of
10.0 mm. All cover plates for skirt boards shall be of 4.0 mm (minimum)
thick steel. Conveyor skirtings at loading points shall be equipped with
rubber dust flaps and polyurethane sealing strip, where needed to provide
a substantially dust tight job. The polyurethane blocks used for skirt board
sealing shall be made of 15 and 20 mm thick blocks for conveyors &
feeders respectively. These shall allow adjustment for wear in small
increments in any point along with conveyor belt, using only a hammer.
The backing plate shall be permanently fixed to skirt plate of the conveyor
belt. The clamp for polyurethane blade shall allow only downward
movements of blade and not upwards. The sealing block shall be
replaceable module. The skirtings below the crushers shall be equipped
with hinged adjustable deflector plates. Skirtings at discharge ends of all
conveyors shall be equipped with rubber dust flaps only. The length of skirt
boards at each feeding point shall be not less than 5.0 m from leading
edge of chute. Continuous skirt boards shall be provided wherever feeds
from multiple points on the one conveyor are involved.
e) Rope Operated Emergency Stop Switch
ISSUE
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TCE FORM 329 R3
VOLUME – IIB
SECTION: D1.2
Rope operated emergency stop switches shall be provided on all

conveyors for emergency stoppage of conveyors at belt levels and at
intervals of not more than 30.0 m. On conveyors having walkway on both
sides, rope operated switches shall be provided on both sides. However,
there shall be minimum one pair of switch for each conveyor. There shall
be provision in the control system to identify the particular pull chord
switch, which has acted and is to be reset.
f) Belt Sway Switches
Belt sway switches shall be provided on conveyor at intervals of not more

than 50.0 m. However, the minimum number of belt sway switches for
each conveyor shall be two pairs, one near the drive pulley and another
near the tail pulley. At each location, there shall be one pair of belt sway
switches. For pair of conveyors running parallel in the same tunnel / gallery
shall be provided with belt sway switches in staggered locations.
g) Zero Speed Switches
One (1) zero speed switch shall be provided for each conveyor at tail
pulley. The same shall be inductive-proximity contactless electronic type.
h) Chute Blockage Switch
One no. chute block switch of proven type shall be provided at a suitable
height of each leg of the conveyors discharge chute.
i) Rope operated emergency stop switches, belt sway switches, zero speed
switches and all auxiliary switches shall be rated at break 10 Amps at
240V AC.
j) Lockable type de-interlock switch having three positions ‘interlocked’ ‘off’ &
‘de-interlocked’ shall be provided for each belt conveyor. The de-interlock
switch shall be located in the remote control panel. However, there shall
be local ‘start’, ‘stop’ push buttons for enabling starting / stopping of
conveyor in the ‘de-interlock’ mode. The local stop switch shall be lockable
type.
k) All switches indicated in clause (f), (g), (h) (I) & (j) above shall be of non
flame proof type with IP-65 protection.
ISSUE
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TCE FORM 329 R3
VOLUME – IIB
SECTION: D1.2
l) All stringers of conveyors and reversible belt feeders, head and tail pulley
frames shall be standard quality, welded, bolted, steel structures. Each
stringer selection, head frame and tail pulley frame shall be a welded self-
contained unit ready to be set in place and connected to the structures and
to adjacent conveyor parts. Attachment of the conveyor frames to the steel
supporting structures shall be by field bolting and to the concrete
structures by bolt anchors.
m) All conveyors shall have deck plates of thickness as specified in Data

Sheet–A for full length of conveyor to prevent spillage of material on return
run of the belt. Crowned / gabled deck plates shall be used to effect
drainage of water while washing. The deck plates of all conveyors shall be
provided with ribs at frequent intervals to have adequate stiffness. The ribs
shall be provided in the transverse direction to the direction of travel
conveyor.
n) Dedicated siren system with LED type warning lamps shall be provided for
each conveyor.
2.1.10 Safety guards
Safety guards shall be provided for drive pulleys and tail pulleys of all conveyors
and feeders, couplings guards and brake drums of all conveyors.
2.2 Structural details
All structural and civil design and drawing details shall be provided by bidder.
Civil & Structural works would be done by Purchaser.
3.0 IN-LINE BELT CONVEYOR SCALE
3.1 LOAD CELL TYPE
3.1.1 Electronic in-line belt conveyor scale shall be complete with sensing element,
suspension system, speed sensor and integrating totaliser with rate indicator.
3.1.2 For the electronic scale, the load cell shall be fully temperature compensated,
hermetically sealed and protected against shock and vibration. The proximity
type speed sensor for speed signal shall be located suitably for reliable
operation.
3.1.3 The totalising shall be done by a eight digit digital totaliser. The totaliser and the
rate indicator shall be in a separate dust-tight unit. The rate indicator shall show
the readings in tonnes per hour.
ISSUE
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TCE FORM 329 R3
VOLUME – IIB
SECTION: D1.2
3.1.4 The accuracy shall be guaranteed as specified in data sheet ‘A’ from 20% of
average capacity of the conveyor to 120% of the average capacity of the
conveyor. Test weight for calibration shall be provided.
4.0 MAINTENANCE REQUIREMENTS
4.1 Necessary Provision for mounting monorails, chain pulley blocks / electric hoists
shall be provided for maintenance of all tail and head pulleys and drive
equipment of all conveyors and other equipment covered in the subject system.
4.2 VOID
4.3 Plant cleaning service water system piping shall be provided one (1) for each
conveyor all along the length of the gallery in the conveyor walkway adjacent to
extreme edge of the gallery. The service water headers shall be provided with
tap off points at 30 m intervals with isolating valves. One flexible hose of 25 m
length shall be provided in the gallery for each belt conveyor. The flexible hose
shall be of minimum 50 mm size and the pressure of water available at the
isolating gate shall be minimum 2 kg / sq.cm (g).
4.4 Provision shall be kept with platforms and ladders for crossing over the
conveyors at approximately 100m interval.
ISSUE
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TCE FORM 329 R3
SPECIFICATION NO. TATA CONSULTING ENGINEERS LTD SECTION D1.2
DATA SHEET - A
REVERSIBLE YARD (TRUNK) CONVEYORS SHEET 1 OF 7
TCE 5871A-H-563-001B
1.0 Reversible Yard (Trunk)

Conveyors General Data
1.1 Designation REFER ANNEXURE-1
1.2 Capacity TPH REFER ANNEXURE-1
1.3 Belt Width MM REFER ANNEXURE-1
1.4 Conveyor Lengths M AS PER THE PLAN AND SECTION

DRAWINGS
1.5 Belt Speed M/SEC. REFER ANNEXURE-1
1.6 Material Handled COAL
1.7 Material Properties REFER SECTION D1.0
1.8 Lump Size REFER SECTION D1.0
1.9 Troughing Angle DEGREE 35

S
2.0 Conveyor Belt
2.1 Construction EP
2.2 Type FR PROPERTY SHALL CONFORM

TO CANADIAN BUREAU OF
MINES
2.3 Minimum thickness of cover MM Top – 5, Bottom – 3
2.4 Minimum number of plies 5
2.5 Ratio of working tension to allowable % 90 (Maximum)

tension
3.0 Carrying, Impact & Return Idlers CARRYING IMPACT RETURN
3.1 Style (I) CARRYING &CARRYING

TRAINING IDLERS - FIXED TYPE.
(II) RETURN AND RETURN
TRAINING - V - TYPE 10 DEG 2
ROLL TYPE. (III) IMPACT IDLERS
- FIXED TYPE
REV. NO. R0 PPD. BY : RC JOB NO. CLIENT :PPGCL
DATE CHD. BY : BVS TCE.
REV. BY DATE : OCT’10 5871A PROJECT :3X660 MW,PHASE – I, BARA
TPS
FILE NAME : DA11606R0.DOC
DATA SHEET - A
TCE 5871A-H-563-001B
3.2 Pipe Diameter MM REFER ANNEXURE -1
3.3 Shell thickness MM REFER ANNEXURE -1
3.4 Bearing type, size & life AS PER WRITE UP LIFE - 50,000
Hrs
3.5 Lubrication Life lubricated
3.6 Spacing M CARRYING - 1.0 RETURN - 3.0.

HOWEVER THE SPACING OF
THE FIRST RETURN IDLER
FROM THE HEAD AND TAIL
PULLEYS WILL BE 2500 MM.
IMPACT – MINIMUM 6 SETS PER
LOADING POINT @400MM
SPACING
3.7 The maximum friction of each idler SHALL NOT EXCEED 0.015
unit
4.0 Carrying Training & Return

Training Idlers Data
4.1 Style SIMILAR TO CARRYING AND

RETURN IDLERS. WILL BE
PROVIDED ON THRUST
BEARING FOR SWIVELLING
4.2 Pipe Diameter MM REFER ANNEXURE –1
4.3 Shell thickness MM REFER ANNEXURE –1
4.4 Bearing type & size REFER ANNEXURE –1
4.5 Lubrication LIFE LUBRICATED
4.6 Spacing M AS PER WRITE UP
5.0 Pulleys
5.1 Type AS PER WRITE UP. HEAVY

DUTY TYPE. MINIMUM SHELL
THICKNESS WILL BE 12 MM

TPS
DATA SHEET - A
TCE 5871A-H-563-001B
5.2 Details of lagging 12 MM THICK HERRING BONE

GROOVED TYPE FOR DRIVE
PULLEYS AND 10 MM PLAIN
TYPE FOR NON DRIVE
PULLEYS
5.3 Bearing life Hours 50,000
5.4 Pulley width MM Belt width + 200
5.5 Pulley shafts will be designed considering the combined shear stress as 500 kg/cm²or
deflection at hub limited to 8 min or shaft deflection ratio of 1 in 2000 in the middle of
the shaft with respect to bearing centre to centre whichever is higher.
5.6 Shafts will be supported on heavy duty, horizontal split type plummer blocks of 4 bolts
construction. The bearings will be self-aligning spherical roller type having a bearing life
of 50,000 working hours.
6.0 Accessories
6.1 Type and number of belt cleaners THREE (3) Nos. ON EACH
CONVEYOR. OUT OF THREE
TWO (2) WILL BE AT HEAD END
(EXTERNAL) AND ONE (1) AT
TAIL END (INTERNAL)
(a) HEAD END - ONE SPRUNG
BLADE TYPE MAIN SCRAPER
AND ONE TORSION ARM TYPE
PRE SCRAPER
(b) TAIL END - ' V ' PLOUGH
TYPE
6.2 Stringers and short supports MIN STRINGER SIZE – ISMC 150
MM
MIN SHORT SUPPORT –
ISMC100MM
6.3 Deck plate MIN. 3.15 MM FOR FULL

LENGTH OF CONVEYORS
6.4 Skirt boards SKIRT BOARDS SHALL BE

PROVIDED FOR A MINIMUM OF
5 M MEASURED FROM LEADING
EDGE OF CHUTE AT EACH
FEED POINT. IF THE FEED
POINTS ARE CLOSE BY,
TPS
DATA SHEET - A
TCE 5871A-H-563-001B
CONTINUOUS SKIRT BOARD

SHALL BE PROVIDED. SIDE
PLATE WILL BE 10 MM AND TOP
PLATE WILL BE 4 MM MS. 10MM
AND 20MM THICK UHMWPE
LINERS WILL BE PROVIDED.
10MM THICK LINER WILL BE
PROVIDED FOR BELT
CONVEYORS AND 20MM THICK
LINER WILL BE PROVIDED FOR
FEEDERS.
6.5 Discharge chutes 10MM THICK MS MOTHER

PLATE WITH 5 MM THICK SS
LINERS CONFORMING TO AISI
409M.
6.6 Belt protection switches NON-FLAME PROOF TYPE FOR

OVER GROUND CONVEYORS
with IP 65 PROTECTION.
6.7 Pull-chord type emergency switches PAIRS OF ADDRESSABLE

SWITCHES AT 30M INTERVAL
ALONG EITHER SIDE OF THE
CONVEYOR WITH 2 “NC” AND 2
“NO” CONTACTS.
6.8 Belt sway switch PAIRS OF ADDRESSABLE

SWITCHES AT 50M INTERVAL
(MIN. 2 PAIRS PER CONVEYOR)
6.9 Zero speed switch ELECTRONIC NON-CONTACT

TYPE.
6.10 Emergency push buttons ONE (1) FOR EACH CONVEYOR

AND FEEDER. HOWEVER FOR
LONGER CONVEYORS OF
MORE THAN 100m LENGTH,
ONE (1) EACH AT HEAD END
AND TAIL END.
6.11 Tensioning arrangement HORIZONTAL GRAVITY TYPE

TAKE-UP
6.12 Chute Block Switch ONE NO. CHUTE BLOCKAGE

SWITCH SHALL BE PROVIDED
TPS
DATA SHEET - A
TCE 5871A-H-563-001B
AT A SUITABLE HEIGHT ON
EACH LEG OF THE CONVEYOR
DISCHARGE CHUTE ,
VIBRATING GRIZZLY FEEDER
BY PASS CHUTES , CRUSHER
FEEDING CHUTES AND MOBILE
TRIPPER CHUTES ALSO
6.13 Seal Plate 3.15 MM THICK PLATE SHALL

BE PROVIDED WHERE
CONVEYOR GALLERY
CROSSES ROAD , BUILDING
AND RAILWAY TRACKS
EXTENDING AN ADDITIONAL
THREE (3) METRES ON BOTH
SIDES OF CROSSING AND FOR
COMPLETE GALLERY OF
CONVEYOR FOR BCN-12A/12B
AND 13A/B/C/D/E/F
6.14 Flap gate Motor operated type. Gate shall be

lined with AISI 409M liners of 5mm
thickness.
7.0 Galleries
7.1 Type of gallery ENCLOSED GALLERIES FOR

ALL OUTDOOR CONVEYORS
7.2 Walkway width MM 1200 MM ON ONE SIDE AND

800 MM ON THE OTHER SIDE
7.3 Whether dust suppression system YES

provided at feed points?
8.0 INLINE BELT CONVEYOR SCALE
8.1 Type MICRO PROCESSOR BASED

LOAD CELL TYPE
8.2 Numbers Required As per Flow Diagram
8.3 Designation As per Flow Diagram
8.4 Location LOAD CELL TYPE – BOOM

CONVEYOR OF BCN-10 AND
TPS
DATA SHEET - A
TCE 5871A-H-563-001B
ON CONVEYORS BCN-1,2&
8A/8B
9.0 Details of Belt Conveyor on which

Belt Scale will be mounted
9.1 Belt width MM REFER ANNEXURE -1
9.2 Belt speed M/Sec. REFER ANNEXURE -1
9.3 Troughing angle DEGREE 35

S
9.4 Rated Capacity TPH REFER ANNEXURE -1
9.5 Numbers Required AS PER FLOW DIAGRAM

9.6 Material handled COAL
9.7 Material Properties REFER WRITE UP OF SECTION

D1.0
9.8 Accuracy for individual weighment ± 1%.
9.9 Range 20% TO 120% OF RATED

CAPACITY REQUIREMENT
WITH 100% OVERLOAD
PROTECTION
9.10 Type of load cell TEMPERATURE

COMPENSATED
HERMATICALLY SEALED AND
PROTECTED AGAINST SHOCK
AND VIBRATION
9.11 Measurement provisions FLOW RATE INDICATOR &

TOTALISER
9.12 Type of totaliser DIGITAL, EIGHT DIGITS
9.13 Local rate indicator REQUIRED
9.14 Remote rate indicator REQUIRED
9.15 Location of totalizer and remote rate CHS CONTROL ROOM

indicator

TPS
DATA SHEET - A
TCE 5871A-H-563-001B
9.16 Test weight for calibration REQUIRED

TPS
SL.NO. ITEM
1.0 YARD CONVEYORS GENERAL

DATA
1.1 Designation
1.2 Capacity TPH
1.3 Belt width MM
1.4 Troughing angle DEGREE

S
1.5 Belt speed M / Sec
1.6 Length between centers M
1.7 Angle of inclination DEGREE
1.8 Total lift M
2.0 Belt Specifications
2.1 Belt construction
2.2 Belt Rating & No of plies
2.3 Cover grade and thk
3.0 Idlers
3.1 Make
3.2 Type
3.3 Friction factor
3.4 Pipe dia & thk
3.5 Pipe rollers specification

(ERW/seamless)
3.6 Max Roll eccentricity (mm)
3.7 Bearing type, size & life

SL.NO. ITEM
4.0 Pulleys Hea Tail Take Bend Snub

d - up
4.1 Diameter of pulleys
4.2 Type and size of bearings
4.3 Lagging thickness and type
4.4 Diameter of Shaft at hub
4.5 Type of fixture of pulley to shaft
4.6 Angle of wrap Deg
4.7 Shell Thickness MM
5.0 Take-up
5.1 Type
5.2 Travel length
6.0 Drive Unit
6.1 Selected Motor Rating/Speed KW/RPM
6.2 Type of gearbox
6.3 Reduction ratio
6.4 Type of primary couplings (High speed

side)
6.5 Type of secondary couplings (Low

speed side)
6.6 Type of hold back
6.7 Type & size of brakes
6.8 Details of hydraulic drives conveyor

wise such as torque rating, motor
rating etc.,
6.9 Details of motor

SL.NO. ITEM
i) Type and make
ii) Frame size
iii) KiloWatt rating
iv) Speed
v) Voltage
6.10 Torque rating for brake
6.11 Operating voltage for brake
7.0 Belt Cleaner
7.1 Type of external belt cleaners
7.2 Type of internal belt cleaners
8.0 Chutes
8.1 Material and thickness of main plate
8.2 Material and thickness of liner plate
9.0 Technological structure
9.1 Size of stringers and short supports
9.2 Clear walkway width (side/central)
10.0 Belt protection safety Switches
a) Pull cord switch Nos.

b) Belt sway switch Nos.
c) Zero speed switch Nos.
d) Emergency push button Nos.
10.1 Type
10.2 Rating (Volts, Amps break)
10.3 Spacing M

SL.NO. ITEM
11.0 BELT SCALE
11.1 Type
11.2 Type of Load cell / Radiation source
11.3 Rate Indicator Type
11.4 Recorder Type
11.5 Accuracy
11.6 Belt Speed measurement method

VOLUME – II
001B SECTION: D1.2
ANNEXURE-1 TO DATA SHEET-A
BELT CONVEYORS
Conveyor No. BCN -7A BCN -7B
Rated Capacity 2600 2600

(TPH)
Design Capacity 2860 2860
(TPH)
Belt Width (mm) 1800 1800
Belt speed 3.5 3.5
(Max)
(m/s)
Approx Refer Section Refer Section
Lift (M) Drawing Drawing
Approx Refer Section Refer Section
Length (M) Drawing Drawing
Sl No. Description Convs No.

1.0 Designition BCN-7A/7B
1.0 Carrying & carrying Training
1.1 Pipe Dia x Thk (mm) 139.7 X 5.4mm thk
1.2 Bearing Number Suitable for idler shaft diameter of

25mm
1.3 Bearing Type Deep groove ball bearings life
lubricated
1.4 Type of seal for bearing Double labyrinth with synthetic
sealing
1.5 Life in working Hrs. 50,000( minimum)
2.0 Impact
ISSUE
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TCE FORM 329 R3

VOLUME – II
001B SECTION: D1.2
Sl No. Description Convs No.

2.1 Pipe Outer Dia x Thk (mm) 139.7 X 6.3 mm thk
2.2 Pipe Dia with rubber disc (mm) 190mm
2.3 No.of. roller 3

25mm
lubricated
sealing
2.8 Lubrication arrangement Life lubricated
3.0 Return & Return Training
3.1 Pipe Dia x Thk (mm) 139.7 X 5.4 thk

25mm
lubricated
sealing
3.6 Lubrication arrangement Life lubricated
Belting
Minimum belt rating for all belts will be as per the table indicated below.
Conveyor No. BCN -7A/7B INTERMCONV OF RSTR-
1&2
Belt Rating(Min)
KN/M & No. of plies 2000/5 500/4
ISSUE
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TCE FORM 329 R3

VOLUME – II
001B SECTION: D1.2
Top cover thickness of all the belts shall be 5mm and bottom cover thickness shall
be 3mm. The cover grade shall be fire resistant as per Canadian standards. The
minimum factor of safety of belts during normal running operation shall be 10
whereas same shall be 6 during start-up. The rating indicated above is minimum.
However if higher rated belts have to be included considering the above factor of
safety, working and allowable tensions, same shall be included.
ISSUE
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TCE FORM 329 R3

SECTION D 1.3
STOCKYARD DUST SUPPRESSION AND SERVICE WATER FOR
CLEANING SYSTEM
VOLUME – IIB
001B SECTION: D1.3
STOCKYARD DUST SUPPRESSION AND SERVICE WATER
FOR CLEANING SYSTEM
1.0 INTRODUCTION
1.1 In this section the details of Stockyard dust suppression system (SYDS) and
cleaning water requirements as indicated in Data Sheet - A are furnished.
1.2 Details of SYDS shall be as per the below table
Sl.N Water source Application No. of

o. pumps &
Desgnition
1. Plant cleaning system (PCS) : 2 Nos

Dust suppression Service water system for floor (1W+1S)
system (DSS) tank : washing of drive houses
Aboveground masonry &
water storage tank of
the DSS located SYDS
adjacent to the coal SYDS System : Stockyard dust Pumps
handling system suppression system (SYDS) with
compressor / switchgear swivelling type sprinklers
/ control room cum
pump house.
Water supply for DSS tank shall be provided by others at the inlet to the tank. It
should be possible to operate all the pumps both automatically and manually from
the coal handling system PLC located in the coal handling system compressor/
switch gear / control room cum pump (CHSCSCP) house. Whenever SYDS system
is put in operation, service water system for drive houses cleaning shall be
automatically put off using the solenoid operated valve.
2.0 DETAILED SYSTEM DESCRIPTION
2.1 STOCK YARD DUST SUPPRESSION (SYDS) SYSTEM
The SYDS supply pumps located in the CHSCSCP house shall supply water for
SYDS system only when stacking and or reclaiming is taking place. Hence when
either stacking or reclaiming or both are taking place in a pre selected section of a
particular stock pile and or a different stock pile these pumps shall automatically
start supplying water to set of sprinklers located on either side of the particular stock
pile and or a pre selected section of a particular pile where the stacking/ reclaiming
is going on. When stacking and or reclaiming shifts to another section or to another
stockpile water supply shall also get shifted automatically to those particular set of
sprinklers located in the new areas where stacking and or reclaiming is taking place
In the section(s) of a particular stock pile.
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VOLUME – IIB
001B SECTION: D1.3
FOR CLEANING SYSTEM
The SYDS pumps shall start automatically only when stacking and or reclaiming is
taking in a particular section of a stockpile or any other stockpile. When stacking
and or reclaiming is not taking place in any pre selected section of a particular stock
pile and or at any other stock pile the SYDS pumps shall not start automatically,
even if the water level in the DSS tank is at normal or high level. However if pre
spraying is to be carried out on pre selected section of a particular stock pile and or
a different stock pile then it should be possible to start one of the SYDS pumps
manually from the Coal handling system PLC. It shall be possible to start the pumps
locally using the selector switch position in “Local” and Start/Stop buttons available
at local panel for maintenance purposes. Sprinkler shall be mounted on the headers
to be buried. Sprinkler spacing shall be at 30metre interval.
2.1.2 CLEANING SYSTEM
The cleaning water system required for drive houses cleaning shall consist of tap
points (quantity and intervals specified elsewhere) located in each floor of drive
house and same piping network used for SYDS. The water required for the purpose
of cleaning shall be supplied from the SYDS supply pumps to these tap points.

3.1 The bidder shall furnish the quantity of water required for both SYDS and cleaning
requirement.
3.2 The Bidder shall select the capacity and head of the various DS pumps based on
the following:
3.2.1 For SYDS, the quantity of water to be sprayed shall be calculated based on
minimum 6.25 litres of water per hour for each tonne of coal stocked in a particular
section of 90 metres length of the stockyard wherein a set / series of spray nozzles
at an interval of 30 metres operate simultaneously.
3.2.2 The capacity of pumps for stockpile DSS shall be based on two (2) sections of the
stockyard of 90 metres length required to be sprayed with water at any given time,
not exceeding 25% of the total sprinklers provided.
3.2.5 For cleaning water requirement, one tap point with a flexible hose length of 25M on
each floor at drive houses shall be provided. Water consumption at each tap point
for plant cleaning purpose shall be considered minimum 6.25 litres per hour. 3.6
3.3 The all SYDS systems shall be started or stopped automatically from the coal
handling system PLC as described under system description. The SYDS pumps
shall be tripped automatically when a particular Stacker reclaimer is not operating.
local push buttons for maintenance purpose and pressure regulating units with start,
stop PBs, indication lamps, control wiring, interlocks, contactors, instrumentation,
etc., shall be provided.
4.0 LAYOUT AND SCHEME
ISSUE
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VOLUME – IIB
001B SECTION: D1.3
FOR CLEANING SYSTEM
4.1 Two (2) Nos SYDS pumps (one working + one standby) along with other pumps (by
other) shall be located in CHSCSCP house. These pumps shall draw water from the
main above ground masonry water storage tank which will be located adjacent to
the CHSCSCP house.
4.2.5 SYDS equipment like pumps, valves, nozzles, pressure gauges, etc., shall be
located in such a manner that they are easily accessible for inspection and
maintenance.
4.2.6 The SYDS supply water pumps shall be provided with a bypass arrangement having
safety relief valve on the delivery line and shall be connected back to the tank.
4.2.7 At every spray application point, globe valve shall be provided before the spray
nozzle’s headers to control the water spray quantity. At every air application point
also globe valve shall be provided before the nozzle to regulate the pressure
manually if required.
4.2.8 A duplex strainer shall be provided at the delivery line of SYDS pumps.
4.2.9 SYDS provided for the coal stockyard shall have the following arrangements/facilities:
(a) Water distribution all along the stockpile shall be sectionalised to enable spraying
water over a selected length of 90 metres. All the water header pipelines shall be
buried underground so as to avoid obstruction for the movement of tractor dozers or
any other coal moving machinery in the stockyard and only stand post for spray
nozzles shall be provided above ground level. Such buried pipes shall be provided
with adequate protection to prevent corrosion.
(b) Sectionalising valves shall be provided at every 90 metres intervals between main
line header and section header for isolating depending on requirement. The
sectionalising valves shall be capable of automatic operation so that spraying of
water shifts from section to section.
(c) Sprinkler Spray nozzles shall be spaced at every 30 metres along both sides of the
stockpile. However, the nozzles on opposite side of the particular stockpile shall be
staggered. The headers on which the sprinklers shall be mounted shall be buried.
(d) Each sprinkler spray nozzle shall cover the area of 30 metres of stockpile length
with a water throw of 40 metres.
(e) The control for this D.S. system shall be provided in the coal handling system
switchgear / control room cum pump house itself.
(f) The tap off points shall be provided on the main header between two sprinklers with
suitable isolation valves. The size of the tap off points shall be equal to the size of
the branch lines to be provided for each sprinkler. The minimum height of the tap off
points above the ground level will be 1.0 M. These tap off points shall be used with
ISSUE
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VOLUME – IIB
001B SECTION: D1.3
FOR CLEANING SYSTEM
necessary hoses for quenching of fire due to spontaneous combustion in the

stockyard.
4.3 Cleaning water system for drive houses shall have the following arrangements /
facilities:
4.3.1 Cleaning service water piping which is the same as the piping used for SYDS shall
be routed at suitable elevation all round on each floor of drive house with isolating
tap off point at each corner of the drive houses.
4.3.3 Each tap off point also contain isolating ball valve with quick connecting coupling to
enable fixing hoses for both water and air cleaning.
4.3.4 Each flexible hose for water and air cleaning will be of 25 metres length.
4.3.5 Each drive house shall be provided with a box for storage of the hoses. The storage
shall be provided with safety latches and locks.
4.4 The following shall be included in the scope of the Bidder unless otherwise
mentioned elsewhere in the Specification for the dust suppression system:
4.4.1 Pumps indicated under Sl.No.1.2 above complete with drive motors, base frame
foundation bolts and nuts, suction pipe line with isolating valve etc.
4.4.2 Duplex strainer at the discharge of the SYDS pumps.
4.4.4 All required interconnection piping works with fittings from the SYDS pumps
onwards, upto the application points.
4.4.5 All required valves and pressure gauges for proper operation of all SYDS system.
4.4.8 SYDS water piping which will also be used for cleaning service complete with tap
points, quick fix coupling & flexible hoses for plant cleaning purpose.
4.4.9 Supports & supporting structure for the pipelines, tanks, etc.
4.4.10 Initial fill of all consumables like oil, grease, etc., required for operation of the
equipment.
4.4.11 Final grouting of all equipments.
4.4.12 Any other equipment and / or material which are not specifically mentioned above,
but are required for completeness and trouble-free operation of the equipment /
system specified and also to ensure safe and satisfactory erection, testing,
commissioning and operation of the plant shall be included in the Bidder’s scope of
work.
5.0 CONSTRUCTION REQUIREMENTS
ISSUE
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VOLUME – IIB
001B SECTION: D1.3
FOR CLEANING SYSTEM
Horizontal Centrifugal Pump:

5.1 SYDS pumps shall comply with the companion specifications furnished in section
D1.8 and piping and valves shall comply with the companion specifications
furnished in section D 1.5.
5.2 Piping:
5.2.1 MOC of all water and air piping shall be as per Sec.D.1.5
5.2.2 Air piping (impulse lines to instruments from main headers) for gauges, switches,
solenoid valves, etc. shall be of SS only
5.2.3 Hangers & supports for the piping shall be made of structural steel sections and shall
conform to good engineering practice. Hangers and supporting arrangements shall
be got approved from the PURCHASER / ENGINEER.
ISSUE
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DATA SHEET - A
TCE 5871A-H-563-001B STOCKYARD DUST SUPPRESSION SHEET 1 OF 3
SYSTEM AND CLEANING WATER
SYSTEM
SL.NO. DESIGNATION LOCATION
1.1 Type Of Systems REFER CLAUSE 1.2 OF

WRITEUP, SEC D1.3
1.2 Terminal Points of Service Water REF SECTION C 3
1.3 Spray nozzle housing SS OR ALUMINIUM ALLOY
1.4 Spray nozzle tips CONFORMING TO AISI 304
1.4 Type of Nozzles CIRCULAR SWIVELLING

SPRINKLER
1.6 No and capacity. of Stock yard DS REFER CLAUSE 1.2 OF

Water supply pumps WRITEUP, SEC D1.3 CAPACITY
BY BIDDER
2.0 CLEANING WATER SYSTEM:
2.1 Is Plant Cleaning System as per YES

Write-up included in the SUPPLIER’s
Scope?
REV. NO. R0 PPD. BY : RC JOB NO. CLIENT: PPGCL

DATE CKD. BY : BVS TCE .5871A PROJECT:3X660 MW– PHASE – I, BARA
REV. BY DATE : Oct’10 TPS
SPECIFICATION NO. TATA CONSULTING ENGINEERS SECTION D-1.3
LIMITED
DATA SHEET - B
TCE 5871A-H-563-001B DUST SUPPRESSION SYSTEM AND SHEET 1 OF 2
SERVICE WATER FOR PLANT CLEANING
SYSTEM
ENQUIRY /SPECIFICATION NO.
SR.NO. ITEM CONTRACTOR →
SYDS SYSTEM
1.0 TYPE OF DSS
1.1 No of flow activating stations
1.2 Dust concentration in surrounding
areas
1.3 No. of pressure reducing stations
1.3.1 Whether independently operable?
1.3.2 No. of regulators provided
1.3.3 Type of regulators
1.3.4 FLOW ACTIVATION STATIONS
(FAS)
1.3.5 TYPE OF OPERATION PROVIDED
FOR FAS
2.0 METHOD OF WORKING AND
DETAILED DESCRIPTION
FURNISHED?
2.1 WHETHER CLEANING WATER
REQUIREMENT OF DRIVE HOUSES
IS CONSIDERED FOR SIZING THE
PUMPS AND PIPING?
3.0 SPRINKLERS
3.1 Area covered by each sprinkler MxM
3.2 Spacing MM
3.3 Material of Nozzles
4.0 Details of Pumps
4.1 Make
4.2 Liquid handled
4.3 Capacity and number of SYDS pumps M3/HR

5.0 Motor Details
OF CONTRACTOR
WITHIN ASTERISK (*) (DETAILS TO BE GIVEN IN SCHEDULE OF DEVIATIONS)
2. THIS DATA SHEET WILL BE FILLED UP COMPLETELY AND A COPY WILL DATE
BE ENCLOSED WITH EACH COPY OF THE CONTRACT SPECIFICATION.
SPECIFICATION NO. TATA CONSULTING ENGINEERS SECTION D-1.3
LIMITED
DATA SHEET - B
TCE 5871A-H-563-001B DUST SUPPRESSION SYSTEM AND SHEET 2 OF 2
SERVICE WATER FOR PLANT CLEANING
SYSTEM
5.1 Make and type

5.2 Rating KW
5.3 Speed RPM
5.4 Frame size
5.5 Voltage V

OF CONTRACTOR
SECTION D 1.3.1
HORIZONTAL CENTRIFUGAL PUMPS
TCE.5871A-H- LIMITED VOLUME – IIA
563-001B
3 X 660 MW PRAYAGRAJ SUPER THERMAL POWER PROJECT SECTION: D 1.3.1
AT BARA,UP
TITLE
HORIZONTAL CENTRIFUGAL PUMPS SHEET 1 of 3
1.0 SCOPE
This specification covers the general design, materials, construction features,

manufacture, shop inspection and testing at manufacturer’s works and delivery at
site of Horizontal Centrifugal Pumps required for various dust suppression systems.
The design, materials, construction, manufacture, inspection, testing and

performance of horizontal centrifugal pumps shall comply with all currently
applicable statutes, regulations and safety codes in the locality where the
equipment is to be installed. The equipment shall also conform to latest applicable
Indian or equivalent standards. Other international standards are also acceptable, if
these are established to be equal or superior to the listed standards. Nothing in this
specification shall be constructed to relieve the VENDOR of this responsibility.
3.1 Pumps of a particular category shall be identical and shall be suitable for parallel
operation with equal load division. Components of identical pupms shall be inter-
changeable.
3.2 Flow rate versus head curve shall have a stable and continuously rising
characteristics towards the shut-off head. In case of unstable ( drooping)
characteristics the duty point shall be well away from the unstable region. Besides
the actual flow rate versus head curve, curves for minimum and maximum impeller
diameters shall also be shown.
3.3 The shut-off head shall be at least 110% of the differential head.
3.4 The required NPSH at duty point shall be at least one (1) metre less than the
Available NPSH.
3.5 The rating of the pump driver shall be the larger of the following:
a) The maximum power required by the pump from zero discharge to run-out
discharge at site climatic conditions.
b) 110% of the power required at the duty point at site climatic conditions.
3.6 The corrosion allowance for pressure parts shall be 3 mm.
ISSUE
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563-001B
AT BARA,UP
TITLE
3.7 Pumps shall run smooth without undue noise and vibration. Noise level produced
individually or collectively shall not exceed 85 dB (A) measured at a distance of 66
metres from the source In any direction. The overall vibration level shall be as per
zones A and B of ISO 10816-1.
3.8 In case of fire water pumps, pumps and drivers with all the accessories shall meet
the requirements of Tariff Advisory Committee (TAC) or any other standard as
called for in data sheet A. pump type shall be approve by TAC.
4.0 CONSTRUCTION FEATURES
4.1 In addition to static balancing, impeller and balancing drum shall be balance
dynamically at or near the operating speed.
4.2 Pump shall be provided with renewable type casing ring. Pump having capacity
1,000 M3 Hr and above shall be provided with impeller ring in addition to casing ring.
The hardness of impeller ring shall be 50 BHN higher than that of casing ring.
4.3 Pump casing shall be provided with drain and vent connection with plugged or valve
connection.
4.4 Bearing shall be oil-lubricated or grease-lubricated and shall have a life of 40,000
hours of working. In case of oil-lubricated bearing, constant oil leveller with
magnetic drain plug shall be provided.
4.5 Replaceable shaft sleeves shall be provided to protect the shaft where it passes
through stuffing box.
4.6 Stuffing box shall be of such design that it can be repacked without removing part
other than the gland and lantern ring.
4.7 Mechanical seals shall be provided if called for in data sheet –A. If required a
flushing line shall be furnished, complete with strainer and orifice, from the pump
discharge to the sealing face. When pumping liquid is not suitable for this purpose,
a flushing connection shall be provided so that it can be connected to an external
source. Auxiliary piping and plan shall be in accordance with appendix D of API
610.
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563-001B
AT BARA,UP
TITLE
The allowable loads on the pump nozzles shall be at least twice the values listed in
the relevant tables of API 610 without reference to any criterion. The base plate
shall be designed to cater to the above increased loads.
4.8 All pumps, except for back-pull out type, shall be provided with flexible coupling
Back-pull out type pumps shall be provided with spacer type coupling.
4.9 Coupling guard made of expanded metal and bolted to the base plate shall be
furnished for all coupled pumps.
4.11 In addition to accessories listed in data sheet A, any other accessories required for
safe and efficient operation of pump shall be provided.
4.12 All incidental piping and valves required for sealing, lubrication and cooling for
stuffing box packing and/or bearing of pump shall b furnished by the VENDOR.
4.13 Leakage from the pump shall be led to the nearest surface drain by OTHERS.
Pump VENDOR shall provide necessary arrangement like drip tray, base plate drain
connection etc.
5.0 TESTS AND INSPECTION
5.1 Hydrotest pressure on casing shall be 1.5 times maximum discharge head or twice
differential head whichever is higher. ( Maximum discharge head = shut-off head +
maximum suction head). Unless otherwise stated in data sheet A, the hydrostatic
tests on the casing shall be conducted for a minimum duration of 30 minutes.
5.2 The pumps shall be tested as per IS 5120, at rated speed at MANUFACTURER’s
works to measure capacity, total head, efficiency and power. The negative tolerance
on efficiency shall be limited to 2.5% and not 5% as indicated in IS 5120. these
tests shall form the basis for acceptance of pumps except for vibration and noise.
The pumps shall tested be tested over the range covering from shut-off head of the
maximum flow. The duration of the test shall be minimum one (1) hour. Minimum
five (5) readings approximately equidistant shall be taken for plotting the
performance curves.
5.3 After installation, the pumps shall be subjected to testing at site also. If the site
performance is found not to meet the requirement regarding vibration and noise as
specified, the equipment shall be rectified or replaced by the VENDOR, at no extra
cost to the PURCHASER.
5.4 PERFORMANCE GUARANTEE
Performance parameters to be guaranteed by the VENDOR and tolerances

permitted shall be as indicated in section C and/or data sheet A. BIDDER shall
confirm acceptance of these by indicating values in data sheet B. Pump or any
ISSUE
R0
563-001B
AT BARA,UP
TITLE
portion thereof is liable for rejection, if it fails to give any of the guaranteed
performance parameters.
ISSUE
R0
SPECIFICATIO
N NO. PRAYAGRAJ POWER GENERATION COMPANY
TCE.5871A-H- LIMITED SECTION:
563-001B D1.3.1
PROJECT AT BARA,UP
DATA SHEET A
SHEET 1 OF 4
1.0 DESIGN PARAMETERS
1.1 Pump Designation As per clause 1.2 of Sec.D1.3
1.2 No. of Pumps As per clause 1.2 of Sec.D1.3
1.3 Design Capacity m3/hr * *
1.4 Suction head mWc FLOODED
1.5 Discharge Head mWc By Bidder
1.6 Total Head mWc *
1.7 Max. Suction Head mWc ----
1.8 Max. Discharge Head mWc *
1.9 NPSH Available mWc ----
1.10 Location INDOOR
1.11 Max. Rated Speed (At 50Hz) Rpm 1500
1.12 Max. Tolerance on power Input to Motor % (+) 0.00
1.13 Pump Efficiency (+)% MIN. 75%
1.14 Normal Supply frequency Hz 50
2.0 FEATURES OF CONSTRUCTION
2.1 Type of Pump SPLIT CASING/BACK PULLOUT
2.2 Impeller ENCLOSED
2.3 Volute SINGLE/DOUBLE/DIFFUSER (MFR.

STD)
REV.No. R0 PPD.BY JOB NO. CLIENT : PPGCL

: RC
TCE. 5871A
PPD. BY CKD. PROJECT:3X660 MW– PHASE – I,
BY : BARA TPS
BVS
CHD. BY DATE:
OCT’10
SPECIFICATIO
563-001B D1.3.1
PROJECT AT BARA,UP
DATA SHEET A
SHEET 2 OF 4
2.4 Shaft COUPLED
2.5 Drive Transmission DIRECT
2.6 Seal GLAND
2.7 Coupling FLEXIBLE
2.8 Nozzle Oreintation * SIDE SUCTION-SIDE

DISCHARGE/END SUCTION TOP
DISCHARGE
2.9 Flange Drilling AS PER ASA STD
2.10 Prime Mover AS PER ELECTRIC MOTOR
* - BIDDER TO INDICATE
3.0 LIQUID DATA
3.1 Liquid Handled PLAIN WATER
3.2 Specific Gravity

0
3.3 Temperature C AMBIENT--+
3.4 Viscosity CP }
}
3.5 Chemical Composition }
}
3.6 pH }
}
3.7 Total Dissolved Solids mg/1 }
3.9 Size of Largest Solids mm }
}
3.10 Turbidity ( REF. Note. 7.5) ppm }
}
3.11 Chlorides }
: RC
TCE. 5871A
BY : BARA TPS
BVS
CHD. BY DATE:
OCT’10
SPECIFICATIO
563-001B D1.3.1
PROJECT AT BARA,UP
DATA SHEET A
SHEET 3 OF 4
}
3.12 Calcium Hardness as CaCO3 mg/1 }
}
3.13 Total Hardness as CaCo3 mg/1 }
4.0 MATERIALS OF CONSTRUCTION
PARTS MATERIAL
4.1 Impeller Stainless Steel – Gr. 316
4.2 Casing 2.5 % Ni CI as per IS 210 FG 260
4.3 Diffuser MFG.STD.
4.4 Shaft Stainless Steel – Gr. 410
4.5 Shaft Sleeve SS-316
4.6 Impeller Ring SAME AS ITEM 4.1 & 4.2
4.7 Casing Ring MFG - STD
4.8 ST. Box Packing MFG - STD
4.9 Base Plate STEEL
5.0 ACCESSORIES AND SERVICES
5.1 Discharge Pressure Gauge YES
5.2 Suction Pre/Vacuum Gauge NO
5.3 Companion Flanges YES
5.4 Foundation Bolts YES
5.5 Common Base Plate YES

: RC
TCE. 5871A
BY : BARA TPS
BVS
CHD. BY DATE:
OCT’10
SPECIFICATIO
563-001B D1.3.1
PROJECT AT BARA,UP
DATA SHEET A
SHEET 4 OF 4
5.6 Prime Mover YES
5.7 Motor Starter YES
5.8 Priming Tank NO
5.9 Bearing Temp. Gauges NO
5.10 Recom.Sp.Maint. Tools YES
5.11 Recom. Spare Parts YES
5.12 Level Switch YES
5.13 Level Alarm
5.14 Pump Erection YES
5.15 Erection Supervision YES
5.16 NOTES
6.0 The rating of the pumps motor shall be the larger of the following :
- Maximum power input required over the complete H-Q characteristic
- a) 125% of the power input required at the pump duty point upto 200 kW rating
b) 110% of the power input required at the pump duty point beyond 200 kW rating.
6.1 The discharge head of pumps shall be fixed up considering the following
- 110% of water pressure requirement

: RC
TCE. 5871A
BY : BARA TPS
BVS
CHD. BY DATE:
OCT’10
TATA CONSULTING ENGINEERS LIMITED SECTION: D1.3.1
TCE 5871A-H-563-
001B
TITLE DATA SHEET-B SHEET 1 OF 2

1. DESIGNATION
2. NUMBER OFFERED
3. DESIGN CAPACITY M3/HR.
4. DIFFERENTIAL HEAD MLC
5. SHUT-OFF HEAD MLC
6. HYDROSTATIC TEST PRESSURE KG/CM2

(g)
7. NUMBER OF STAGES
8. PUMP EFFICIENCYA T DUTY POINT %
9. PUMP SPEED RPM
10. PUMP BKW KW
11. POWER INPUT TO DRIVER AT KW

DUTY POINT
12. NPSH REQUIRED MLC
13. DRIVER EFFICIENCY %
14. SUCTION NOZZLE
15. SIZE mm
16. DISCHARGE NOZZLE
17. SIZE mm
18. TYPE OF COUPLING
19. MINIMUM CAPACITY FOR M3/HR.

CONTINUOUS OPERATION
20. EXTERNAL WATER REQUIREMENT
NOTE TO CONTRACTOR SIGNATURE
OF CONTRACTOR
CONSULTANTS: TATA CONSULTING ENGINEERS LIMITED
TATA CONSULTING ENGINEERS LIMITED SECTION: D1.3.1
TCE 5871A-H-563-
001B
TITLE DATA SHEET-B SHEET 2 OF 2

FOR SEALING & COOLING

21. WEIGHT OF BARE PUMP KG
22. WEIGHT OF DRIVER KG
23. WEIGHT OF COMMON BASE PLATE KG
24. MOMENT OF INERTIA OF PUMP KG-M2
ROTOR
25 MOTOR RATING
26 MATERIALS OF CONSTRUCTION-
AS PER DATA SHEET -A
NOTE TO CONTRACTOR SIGNATURE

OF CONTRACTOR
CONSULTANTS: TATA CONSULTING ENGINEERS LIMITED
SECTION D 1.4
STOCK PILE RUN OFF WATER DISPOSAL SYSTEM
PRAYAGRAJ POWER GENERATION COMPANY VOLUME – II
TCE 5871A-H-563- LIMITED SECTION: D1.4
001B
3 X 660 MW PRAYAGRAJ SUPER THERMAL POWER SHEET 1 OF 2
TITLE
PROJECT AT BARA,UP
1.0 INTRODUCTION
1.1 In this section the details of stockpile runoff water from the catchment
area surrounding the stockyard have been furnished. Bidder’s scope
shall be as envisaged in Sec.C3 of Vol.IIA
1.2 DETAILED SYSTEM DESCRIPTION
All around each of the four stock piles longitudinal drains and cross
drains will be provided to receive the coal pile run off water and lead
the same to a common header drain leading to a common collecting
pond. This water mixed with coal (coal slurry) from all the drains shall
be led to a common collecting pond with two individual sections
separated by a partition. The header drain will be provided with a
bifurcation at the discharge end i.e. at the inlet to the common
collecting pond so that it gets divided in to two individual branch drains.
Each individual branch drain will be provided with a gate suitable for
operation in coal slurry at the inlet to individual section of the common
collecting pond. Each of the two sections of the common collecting
pond will be provided with provision for mounting a set of two (one
working +one standby) sump pumps by others. The water from the
main outlet header mixed with coal will be led to one of the two
sections of the common collecting pond through one of the branch
drains. The coal slurry containing coal and water shall enter the
particular section of the common collecting pond. In this section of the
common collecting pond, the clear water will float up allowing the coal
to settle down. This clear water mixed with Coal will be pumped off by
one of the two sump pumps located above the particular section of
common collecting pond to a clarifier (by others) located near the guard
pond. The location of the guard pond is furnished in the drawing No.
TCE.5871A-563-GA-1001,The coal that settles at the bottom of the
pond shall be removed manually. During the period of clearance of the
coal from this particular section of the common collecting pond, the
inlet gate on the other branch drain shall be opened and the coal slurry
shall be led to the other section of the common collecting pond which
would have been cleared of all the coal from the previous cycle of
stock pile run off water disposal to receive fresh slurry. The scheme of
water and coal disposal from this section of the common collecting
pond will be same as described earlier.
ISSUE
R0

PRAYAGRAJ POWER GENERATION COMPANY VOLUME – II
TCE 5871A-H-563- LIMITED SECTION: D1.4
001B
3 X 660 MW PRAYAGRAJ SUPER THERMAL POWER SHEET 2 OF 2
TITLE
PROJECT AT BARA,UP
2.1 The capacity and the dimensions of the common collecting pond shall
be as given in data sheet – A. The depth of the collecting pond shall be
such that the distance between the maximum and minimum levels of
the slurry shall be considered for the capacity of the total coal slurry to
be stored inside the sump. Thus the capacity of the sump shall be
equal to length x width x distance between the maximum and the
minimum slurry levels in the collecting pond + the margin for free board
+ volume due to 100mm height above the lowest invert level of the
drains.
2.2 The top level of the pond shalll be about 100mm above the lowest invert
level of the feeding drain.
2.3 The gates to be provided in the branch drains shalll be suitable for
operation in slurry with out getting choked and shall be operated
manually.
2.4 The drains shall have a slope of minimum 1:100 to enable free and
easy flow of coal slurry with out choking and causing coal build up
inside the drains. The slope of the drains shall be such that the flow of
the coal slurry through out the network of drains, shall not cause any
build up or choking.
ISSUE
R0

SPEC. NO.
TATA CONSULTING ENGINEERS LIMITED SECTION : D 1.4
TCE.5871A-H-563-
001B
STOCK PILE RUN OFF WATER DISPOSAL SYSTEM –
COMMON COLLECTING POND SHEET 1 OF 2
DATA SHEET-A
SL. NO. ITEM UNIT
1 TYPE OF CONSTRUCTION FOR CONSTRUCTION DETAILS REFER

VOLUME – III (CIVIL),
TWO (2) SECTIONS SHALL BE FORMED
WITH A CENTRAL PARTITION.
2 DETAILED DESIGN AND BY THE SUPPLIER
CONSTRUCTION, FABRICATION OF ALL
CIVIL AND STRUCTURAL WORKS
3 CAPACITY OF COLLECTING POND BASED ON 15 MINUTES OF MAXIMUM
REQUIRED INTENSITY OF RAIN FALL. EACH
SECTION OF THE COLECTING POND
SHALL BE SIZED TO HOLD THIS
VOLUME i.e. 2X100% SECTIONS SHALL
BE PROVIDED.
4 OVERFLOW CONNECTION SLEEVE
(OVERFLOW PIPE SLEEVE WILL BE
YES
DESIGNED FOR FULL CLEAR WATER
FLOW)
5.0 GATES IN THE DRAINS YES
5.1 DESIGNITION : SPINDLE OPERATED GATES FOR COAL
PILE RUN-OFF
5.2 DESIGN STANDARD : IS-3042 LATEST
5.3 QUANTITY : 2 NOS
5.4 SPINDLE TYPE : RISING
5.5 TYPE OF MOUNTING : WALL MOUNTING
5.6 SHAPE OF WATER WAY : RECTANGULAR / SQUARE
5.7 WATER WAY SIZE : BY BIDDER
5.8 FLUID FLOWING : RAW WATER
5.9 MAXIMUM UNBALANCED HEAD : BY BIDDER
5.10 WORKING PRESSURE : BY BIDDER
5.11 METHOD OF OPERATION : MANUAL
5.12 DISTANCE BETWEEN CENTRELINE OF : BY BIDDER
WATERWAY TO BASE OF OPERATING
PLATFORM :
5.13 CLASSIFICATION : CLASS1 OR CLASS2 : BY BIDDER
5.14 CENTRE LINE OF SPINDLE TO FACE OF BY BIDDER
WALL :
REV. NO. R0 JOB NO. CLIENT: PPGCL
PPD. BY RC TCE.5871A
CHD. BY BVS PROJECT: 3X660 MW, PHASE-1 ISSUE
BARA TPS R0
DATE OCT’10
FILE NAME: F330R2.DOC TCE FORM NO. 330 R2
SPEC. NO.
TATA CONSULTING ENGINEERS LIMITED SECTION : D 1.4
TCE.5871A-H-563-
001B
STOCK PILE RUN OFF WATER DISPOSAL SYSTEM –
COMMON COLLECTING POND SHEET 2 OF 2
DATA SHEET-A
SL. NO. ITEM UNIT
5.15 FREQUENCY OPERATION : DURING MAINTENANCE OF SECTIONS
5.16 TESTING : SHALL BE CONDUCTED AT BOTH SHOP

AND SITE FOR SMOOTH WORKING OF
THE COMPONENET PARTS INCLUDING
THE OPERATING GEAR AS PER IS-3042
5.17 MATERIAL OF CONSTRUCTION OF : SHALL BE AS PER IS:3042 LATEST

VARIOUS COMPONENTS
5.17.1 FRAME AND DOOR : CAST IRON OF MIN.GRADE-20 AS PER

IS:210 LATEST EDITION
5.17.2 SPINDLES, BOLTS AND NUTS : MILD STEEL AS PER IS:2062 LATEST
EDITION
5.17.3 FACE AND SEAT RINGS / TRIM AND : LEADED GUN METAL
SPINDLE NUTS
NOTE :
A) GUN METAL SHALL HAVE A TENSILE STRENGTH OF 22 KG/SQ.MM AND ELONGATION
OF NOT LESS THAN 12% ON A GAUGE LENGTH OF 5CM WHEN TESTED IN
ACCORDANCE WITH IS:2654 LATEST. THE MINIMUM HARDNESS SHALL BE 65 HB
WHEN TESTED WITH A 10MM DIAMETER BALL AND A LOAD OF 1000 KG WHEN
APPLIED FOR 15 SECONDS.
REV. NO. R0 JOB NO. CLIENT: PPGCL

PPD. BY RC TCE.5871A
CHD. BY BVS PROJECT: 3X660 MW, PHASE-1 ISSUE
BARA TPS R0
DATE OCT’10
FILE NAME: F330R2.DOC TCE FORM NO. 330 R2
SPECIFICATION NO. TATA CONSULTING ENGINEERS SECTION D1.4
LIMITED
DATA SHEET - B
TCE 5871A-H-563-001B STOCK PILE RUN OFF WATER DISPOSAL SHEET 1 OF 1
SYSTEM- COMMON COLLECTING POND
SR.NO. ITEM SUPPLIER →
1.0 CAPACITY Cu.m
2.0 DIMENSIONS
2.1 Length M
2.2 Breadth M
2.3 Depth M
3.0 ARE ALL THE ACCESSORIES INCLUDED

AS SPECIFIED?
4.0 GATES AS PER DATA SHEET –A ARE

INCLUDED?
NOTE TO CONTRACTOR
2. THIS DATA SHEET WILL BE FILLED UP COMPLETELY AND A COPY WILL
SECTION D 1.5
LOW PRESSURE (LP) PIPING AND VALVES
PRAYAGRAJ POWER GENERATION COMPANY VOLUME IIB
TCE 5871A-H-563-
001B LIMITED SECTION: D1.5
3 X 660 MW PRAYAGRAJ SUPER THERMAL POWER SHEET 1 0F 11
PROJECT AT BARA,UP
TITLE
1.0 LOW PRESSURE (LP) PIPING AND VALVES
This Section covers the basic requirements for all the piping systems,
valves and specialties to be provided for the coal handling system
package.
2.0 SCOPE OF WORK:
The scope of work shall include all the piping work including various
types of valves, pipe fittings, and pipe supports for trouble free
operation. Broad scope is outlined below.
a) Service air piping from compressed air station to various
equipment and upto termination point for the other systems as
outlined in Section C3 of Volume – IIA of the specification.
b) Service water pipelines with associated valves and fittings from

the terminal point to the required locations within the battery
limits.
c) Piperacks including civil work wherever necessary.
d) All the fire hydrant, MVWS system pipelines with valves and
specialities within the battery limits of Coal handling system
package.
Any other piping & valves, which are not specifically mentioned
but essentially required for the system to be complete in all
respects.
3.0 LINE SIZING
3.1 Sizes of pipelines shall be selected such that the velocity of fluid in
pipes does not exceed the following limits under conditions of
maximum possible volumetric flow:
Line description m/sec

Compressed air 7to 10
All water system lines 0.6 to 2

TCE 5871A-H-563-
PROJECT AT BARA,UP
TITLE
3.2 Lower values of velocities than those stated above shall be used to
determine line size if dictated by considerations of pressure drop,
NPSH, surges, water hammer, etc.
3.3 The design flows considered in line sizing shall not be less than the
rated capacities of equipment to which the piping is connected such
as pumps, compressors, valves, flow limiting orifices, etc., or, the
system mass balance diagrams.
4.0 MATERIALS
The material specifications of pipelines of various systems shall be as

specified in Data sheet – A1 attached to this specification.
5.0 WALL THICKNESS
5.1 The calculation of wall thickness required for pipelines subject to

internal and/or external pressure shall be based on the formulae and
recommendations as given in the codes shall be adopted. Adequate
allowances shall be made towards thinning due to bending,
weakening at branch connections, threading, commercial tolerances
on pipe wall thickness, corrosion and erosion, etc. and the same shall
be subject to approval by PURCHASER/CONSULTANT. In any case
a minimum corrosion allowance of 1.0 mm shall be considered while
selecting the thickness. Wherever stub connections are involved
adequate ligament efficiencies shall be ensured. Details of
calculations shall be furnished.
5.2 In case of carbon steel materials, the nominal wall thickness of

pipeline shall be not less than the minimum acceptable values given
below:
---------------------------------------------------------------------------------------------------------
NB mm 5 20 25 32 40 50 65 80 100 125
(inch) (1/2) (3/4) (1) (1 1/4) (1.5) (2) (2.5) (3) (4) (5)
---------------------------------------------------------------------------------------------------------
Min. 3.2 3.2 3.6 3.6 3.6 3.6 3.6 4.0 4.5 5.4
thickness,
mm
----------------------------------------------------------------------------------------------------------
NBmm 150 200 250 300
(inch) (6) (8) (10) (12)
----------------------------------------------------------------------------------------------------------

TCE 5871A-H-563-
PROJECT AT BARA,UP
TITLE
6.0 LAYOUT AND DETAILING
6.1 All pipelines with size greater than NB 50 mm are considered as shop
fabricated piping and detailed piping layout (isometric) drawings shall
be prepared and submitted for all such pipelines. The drawings shall
be to scale and shall be prepared as plan & sections and shall carry
the following minimum details:
6.1.1 Fully dimensioned layout with locating dimensions referred to plant

axes and coordinates
6.1.2 Details of all stub connections and other welded attachments as

required for anchors, restraints, supports, etc.
6.1.3 Slope, drains and vents
6.1.4 Edge preparation details of weld ends, detailed and approved welding
procedure specification (WPS) as per ASME section IX.
6.1.5 Mounting and orientation of valves and specialties and maintenance

space requirements
6.1.6 Location and tag numbers of supports, restraints, anchors, etc.
6.1.7 Pipe sizes, materials, design parameters, and shop and field test
requirements.
6.1.8 Tolerances, if any.
6.1.9 Any specific requirements on shop fabrication and/or field erection.
6.1.10 Any other detail considered necessary by the PURCHASER/

CONSULTANT.
6.2 Pipelines with a size of NB 50 mm or smaller are regarded as field

routed. SUPPLIER shall however indicate any specific requirements
he may have in regard to the routing of these pipelines.
6.3 Detailed bill of material shall be prepared for all piping systems. In
case of shop fabricated piping, the bill of material shall correspond to

TCE 5871A-H-563-
PROJECT AT BARA,UP
TITLE
the layout drawing prepared. The layout shall indicate the part
numbers as per the bill of materials.
6.4 While routing piping, the following requirements shall be taken into
account:
6.4.1 All piping shall be routed so as to avoid interference with other pipes
and their supports, electrical cable trays, structural members,
equipment, etc.
6.4.2 All piping shall be grouped where practicable and shall be routed to
present a neat and aesthetic appearance.
6.4.3 The piping shall be arranged to provide clearance for the removal of
equipment requiring maintenance and for easy access to valves and
other piping accessories required for operation and maintenance.
Layout drawings shall indicate valve orientations and availability of
access to valves and specialities. Layout of all piping shall ensure that
all valves including motor operated valves are located as to be
accessible conveniently for operation. Valves for operation and
maintenance shall have 1.0 m clear approach space. If any of the
valves are not accessible, suitable access platform shall be provided
by the SUPPLIER.
6.4.4 Piping shall generally be routed above ground but, where specifically
indicated/approved by the PURCHASER/CONSULTANT the pipes
may be arranged in trenches or buried. Pipes at working temperatures
above the ambient shall however not be buried.
6.4.5 Where steel piping is required to be buried, the pipe work shall be
protected from soil corrosion by suitable anti-corrosive treatment as
specified on the outer surface.
6.4.6 Overhead piping shall have a minimum vertical clearance of 2.3

metres above walkways (excluding the insulation thickness wherever
insulation is applicable) and working areas and 7.5 metres above
roadways unless otherwise approved by the
PURCHASER/CONSULTANT.
6.4.7 Drains shall be provided, at all low points and vents at all high points
as per actual layout regardless of whether the same have been shown

TCE 5871A-H-563-
PROJECT AT BARA,UP
TITLE
in the flow diagrams or not. Pipelines shall be sloped towards the

drain points to facilitate self-draining.
6.4.8 Besides at low points, tell tale drains shall be provided at other points
as necessary to remove on-line valves and specialities from piping for
repair and replacement.
6.4.9 At all the screwed valves and screwed connections on equipment,

unions shall be provided to facilitate disassembly. Likewise, unions
shall also be provided at suitable points on straight length of screwed
pipelines.
6.4.10 At all points where pipes pass through concrete floors or brick or other
walls, floor or suitable wall boxes with sufficient clearance shall be
provided. The SUPPLIER shall design and furnish the details of the
floor collars to the CONSULTANT/PURCHASER.
6.4.11 In the case of flanged pipe work, floor collars/wall boxes shall be large
enough to permit the passage of the flange.
6.5 Piping Supports
6.5.1 All piping supports, guides, anchors, and with incidental structural
subframing shall be designed by the SUPPLIER.
6.5.2 The supports shall be spaced in accordance with standard

engineering practice as outlined in applicable codes and standards.
6.5.3 The attachment of support brackets to brick walls shall be avoided as

far as possible and where this is not possible, details of the
attachment shall be furnished to the PURCHASER/CONSULTANT for
his approval. Under unavoidable circumstances, when medium or
heavy brackets are bolted to walls, back plates of adequate size and
thickness shall be furnished to distribute the load against the wall.
Where the use of a back plate is not practical, the brackets shall be
fastened to the wall in an approved manner.
6.5.4 Diameter of hangers for piping NB 50 mm and smaller shall not be

less than 10 mm and for piping with size NB 65 mm and larger shall
not be less than 13 mm.
6.6 Fittings and Flanges

TCE 5871A-H-563-
PROJECT AT BARA,UP
TITLE
6.6.1 Branch connections in piping shall be made by the use of wrought or

forged seamless fittings such as tees, laterals and crosses. Small
stubs as may be required for instrument, drain and vent connection
may be provided in the form of weld outlet fittings or forged couplings.
Intersection welds are acceptable only in the case of non-standard
sizes.
6.6.2 Wherever pipe bends are employed for change of direction the same
shall be to a radius of 5 times the pipe diameter.
6.6.3 Mitred bends shall be adopted for piping systems upto a design
pressure 10 bar (g) only. Mitre angle shall not exceed 22.5 degrees.
6.6.4 Slip-on type of flanges shall be used only upto a maximum pressure
rating of ANSI 150 lbs.
7.0 Dimensional Standards
7.1 Uniform dimensional standards for all piping components shall be

employed to ensure compatibility with each other.
7.2 Nominal pipes sizes and pipe outside diameters shall generally be as
per ANSI B36.10. In case of deviation SUPPLIER shall bring it to the
specific attention of PURCHASER/CONSULTANT for prior approval
stating reasons for the deviation.
8.0 Instrument Connections
8.1 Unless otherwise called for by PURCHASER all thermowell stubs

shall have an internal threading to M33 x 2.
8.2 Stubs for pressure or flow measurement on pipelines with a maximum

working pressure less than 62 bar (g) and a maximum working
temperature less than 300 °C shall be of NB 15 mm size and single
root valves can be used.
9.0 Drain and Vent Connections
9.1 Drain and vent connections on pipelines shall be atleast of NB 25 mm

size.

TCE 5871A-H-563-
PROJECT AT BARA,UP
TITLE
9.2 For pressure and temperature conditions as defined in Clause 8.2,

double isolating valves shall be used on drain and vent lines. For
pressure and temperature conditions as defined in Clause 8.3, single
isolating valves are considered adequate. Where with single root
valve, instrument and root valve are not accessible, double root valve
shall be provided with one root valve near the tap off and the second
root valve with instrument at accessible point.
10.0 WELDING
All welding, post and pre weld temperatures shall be as per the code
ANSI B31.1, ASME sections V VIII, IX, and I. Isometric drawings
indicating all the weld joints and the respective approved WPS shall
have to be furnished.
11.0 INSPECTION & CLEANING
11.1 All pipes shall be hydrotested at shops for pressures as per standards
and all erected piping shall be tested 1.5 times the design pressure.
All other inspection requirements shall be as per the enclosed Data
sheet – A1.
11.2 All hot bent, forged, formed, fabricated and straight pipes shall be
cleaned, pickled or wire brushed and purged with air blast or shot/grit
blast to remove all sand and scale from the inner surface as indicated.
11.3 The Supplier shall carry out the following cleaning after hydrotest.
(a) All piping shall be mass flushed, in addition to the specific

cleaning operations as described below, as required.
(b) Compressed air piping shall be blown by air.
12.0 PAINTING AND CORROSION ON PROTECTION
12.1 All uninsulated piping systems, supports shall be painted as per

Section C7 of Volume-IIA of the specification
12.2 Before application of paint, Supplier shall clean the pipes of all mill
scale, dirt, dust, soot, grease, rust etc.

TCE 5871A-H-563-
PROJECT AT BARA,UP
TITLE
12.3 All pipe lines, piping components shall be adequately protected against
corrosion during manufacture, fabrication, shipment and storage by
appropriate protective paint.
13.0 CLEANING OF PIPES
13.1 Since Sand blasting is prohibited, as per Factories Act, pipe surfaces
shall be cleaned by any other cleaning method permitted by law. The
cleaning method to be adopted shall be informed to the purchaser.
(a) Tests to be carried out after application
(b) Bond/Adhesion test
(c) Holiday test.
14.0 SPECIFIC REQUIREMENTS OF PIPING SYSTEMS
These shall be as detailed out in Data sheet-A1.
15.0 VALVES
15.1 Design and Construction Features
The following design and construction features of valves shall be

complied with.
15.1.1 All gate and globe valves shall be of rising stem, outside screw and
yoke type. The design of valves shall ensure a streamlined passage
and gate valves shall have low pressure drop. The seats and discs
shall be easily renewable and/or shall be suitable for easy refacing
and grinding. Valve discs shall be of such design as to keep the seats
tight when the valve body is subjected to pressure, temperature
variations and piping stresses. Gate valves shall close in both flow
directions.
15.1.2 All globe valves shall be capable of being closed against pressure.
15.1.3 All valves end details shall be as specified in Data sheet-A2. In the
case of all end-welded valves, the stub ends of the valves shall project

TCE 5871A-H-563-
PROJECT AT BARA,UP
TITLE
from the valve body a sufficient amount to ensure that the welding
process shall not distort the valve body and internal parts.
15.1.4 For regulating valves of size less than 65 mm, globe type with tapered
plug type disc shall be used. For regulating valves of size greater than
65 mm, globe type with needle type disc shall be used
15.1.5 Hardness of disc seating surface shall be minimum of 350 BHN and a
minimum differential hardness of 50 BHN shall be provided between
disc and seat to prevent galling. This is not applicable for stellited
seats.
15.1.6 Check valves of sizes 400 mm NB and larger shall have dash pot
arrangement.
15.1.7 All gate and globe valves shall have back-seating arrangement to
facilitate easy replacement of packing with the valve in service.
15.1.8 All valves shall be so designed that the hand-wheel moves in a

clockwise direction to close the valve. The face of the hand-wheel
shall be clearly marked with the words 'OPEN' and 'CLOSE' and an
arrow to indicate the direction for opening. All hand-wheels shall be
fitted with nameplate.
15.1.9 Piston lift check valves shall have accurately guided pistons so that
the pistons are cushioned in their cylinders as they move up.
15.1.10 All gate, globe, Y-type and angle valves intended for manual operation
and falling under the following categories shall be equipped with a
gear operator for ease of operation and to ensure fast and tight
closure:
ANSI PRESSURE RATING VALVE SIZES FOR WHICH GEAR

OPERATOR IS REQUIRED
----------------------------------- ----------------------------------------------
Class 300 and below 350 mm and larger
Class 600 and above 200 mm and larger
--------------------------------------- -----------------------------------------------

TCE 5871A-H-563-
PROJECT AT BARA,UP
TITLE
15.1.11 All gate valves of ANSI pressure rating class 150 and 300 shall have
solid or flexible wedge and ANSI pressure rating class 600 and
above shall have flexible or parallel slide type of wedge.
15.1.12 Valves with flexible wedge shall have provision for relieving the
pressure in the neck of the valve when the valve is in the closed
position.
15.1.13 All valves of ANSI pressure rating upto class 300 shall have bolted
bonnet construction. Pressure seal valves shall have stainless steel
inlay in the gasket area and silver-plated Soft Iron (SI) gaskets or
other acceptable proven features.
15.1.14 All carbon steel valves of ANSI pressure rating upto class 150 and
300 shall have stainless steel trim (13% Cr).
15.1.15 All valves of ANSI pressure rating of class 300 and higher shall have
yoke with anti-friction bearing arrangement.
15.1.16 Valves that are to be kept in full 'OPEN'/'CLOSE' position shall be

provided with a non-detachable locking arrangement. The locking
arrangement provided shall be subject to approval by the
PURCHASER/CONSULTANT.
15.1.17 Valves operating under vacuum conditions shall have glands with
water sealing. The inlet and outlet connections shall be NB 15mm.
The SUPPLIER shall indicate the maximum and minimum sealing
water pressure and the required flow rate.
15.1.18 Motor actuators for motor operated valves shall meet requirements
indicated elsewhere in the specification
16.0 CLEANING
Prior to factory inspection, all manufacturing waste, such as metal

chips and filings, welding rods and stubs, rags, debris and all other
foreign matter shall be removed from the interior of each valve. All
mill scale, rust, oil, grease, chalk, crayon, paint marks and other
deleterious material shall be removed from the interior and exterior
surfaces. At the time of shipment, valves shall be clean inside and
outside.

TCE 5871A-H-563-
PROJECT AT BARA,UP
TITLE
17.0 Inspection and Tests
17.1 Inspection and tests shall be as per the Quality Plans enclosed with
Section –C5 of Volume-IIA.
17.2 Defects in excess of acceptance standards shall be removed by

suitable means. If removal of surface defects does not result in
reduction in wall thickness below 5% of intended thickness of metal
at that location, the area shall be blended smoothly into the
surrounding surface. Where defect removal results in a wall
thickness below the above, resultant cavity may be repaired by
welding. The procedure and operator shall be qualified as per
ASME section IX. Major weld repairs shall be stress relieved or heat
treated in accordance with ASME Section VIII Division I - UCS 56.
Weld repair procedures for all critical piping system shall be provided
17.3 The required area shall be re-examined and the acceptance

standards shall be as in the original examination.
17.4 Weld repairs made as a result of radiographic examination shall be

radiographed after welding. Repairing a particular area more than 2
times is not permitted and the component shall be rejected.
17.5 Prior approval shall be obtained from the PURCHASER/

CONSULTANT before taking up major weld repairs (major weld
repair - when depth of repair exceeds 20% of thickness. Mapping of
major weld repairs is also required.
17.6 All valves shall be tested hydrostatically for strength, tightness of

seats and tightness of backseating at the pressures indicated in Data
sheet-A2, in accordance with MSS-SP 61, and “Hydrostatic Testing of
Steel Valves". Water used for hydrostatic testing of valves with
stainless steel components shall not have chloride content exceeding
20 ppm. Clean potable water may be used for testing of all other
valves.
17.7 All valves except check valves shall be tested for seat tightness by air
at a pressure of 6 bar (g) on both sides of seat.
17.8 All check valves shall also be hydrotested at 25% of the seat hydro
test pressure.

TCE 5871A-H-563-
PROJECT AT BARA,UP
TITLE
17.9 All valves shall be checked for correctness in respect of specified end
details as per applicable standards.

TCE 5871A-H-563-001
LIMITED SECTION:
3 X 660 MW PRAYAGRAJ SUPER THERMAL POWER D1.9
PROJECT AT BARA UP SHEET 1 0F 1
TITLE
SPECIFIC REQUIREMENTS FOR PIPING
SL. SERVICE SIZE PIPES FITTING FLANGES GASKETS LINE

NO. S JOINT
1.0 SERVICE NB A53 GR.B ASTM ASTM TEFLON SCREWED

WATER/ 50 MM (WELD) A105 A105
SERVICE & OR
AIR BELOW IS 1239,
SYSTEM Heavy
class
NB 65 A53 GR.B ASTM ASTM TEFLON WELDED/
MM TO (WELD) A234 A105 FLANGED
600 Gr.WPB
NB
2.0 POTABLE 50 MM A53 GR.B ASTM ASTM TEFLON SCREWED
WATER & (WELD) A105 A105
SYSTEM BELOW
(Refer NB 65 A53 GR.B ASTM ASTM TEFLON WELDED/

Note-5) MM TO (WELD) A234 A105 FLANGED
600 Gr.WPB
Notes
1. Each length of pipe shall be hydro-tested at shop as per the

Codes/Standards.
2. All branch connections shall be wrought (seamless) or forged steel based

on the size and availability based on ASTM Standards.
3. Each length of pipe shall be hydro-tested at shop as per the

Codes/Standards.
4. All gaskets shall be asbestos free type.
REV. NO. R0 PPD. BY RC JOB NO. CLIENT : PPGCL

DATE CKD.BY BVS 5871A PROJECT : 3X660 MW, PHASE-1,
BARA TPS
REV. BY DATE OCT’10
PRAYAGRAJ POWER GENERATION COMPANY VOLUME II
TCE 5871A-H-563-001
LIMITED SECTION:
3 X 660 MW PRAYAGRAJ SUPER THERMAL POWER D1.9
PROJECT AT BARA,UP SHEET 1 0F 1
TITLE
SPECIFIC REQUIREMENT FOR VALVES

SL. SERVICE SIZE BODY/ DISC STEM HAND VALVE
NO. BONNE WHEEL ENDS
T
1.0 POTABLE >65 A126 A126 B124 ASTM A126 FLANGED

WATER CLASS CLASS B C37700 CLASS B FLAT
B FACE
<50 ASTM ASTM ASTM B ASTM A47 SCREW-

B62/ B62/ IS318 312 GR.A/ GR. 32510 ED END
IS318 GR LTB 2 IS320 HT2
GR LTB
2
2.0 SERVICE >65NB ASTM A ASTM A ASTM A479 ASTM A47 FLANGED
AIR AND 216 216 GR. Type 410-2 Gr. 32510 RAISED
SERVICE GR.WC WCB FACE
WATER B
>25 & ASTM A ASTM A ASTM A ASTM A47 FLANGED

< 50 105 479,Type 479,Type Gr. 32510 FLAT
410-2 410-2 FACE
< 25 ASTM A ASTM A ASTM A ASTM A47 SCREW-

NB 105 479,Type 479,Type Gr. 32510 ED TYPE
410-2 410-2
Notes: 1 Testing of body, seat and back seat shall be as per ANSI B16.34.
2. For water system covered under sl.no.1.0 and 2.0 and for sizes 150NB
and above, only gate valves shall be used. For all sizes less than
150mm, only ball valve shall be used.
REV. NO. R0 PPD. BY RC JOB NO. CLIENT : PPGCL

DATE CKD.BY BVS 5871A PROJECT : 3X660 MW, PHASE-1,
BARA TPS
REV. BY DATE OCT’10

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PRAYAGRAJ POWER GENERATION COMPANY LIMITED

PRAYAGRAJ SUPER THERMAL POWER PROJECT

STACKER RECLAIMER WORKS OF COAL HANDLING

(SCOPE OF WORKS, TERMINAL POINTS, EXCLUSIONS &

TATA CONSULTING ENGINEERS LIMITED

INDEX SHEET FOR SPECIFICATION VOLUMES OF PACKAGE-B

Volume I : Conditions of contract.

Volume IIA : SECTION – C - Scope of works, Terminal Points,

Volume IIB : SECTION - D1 - Technical requirements – Mechanical

Volume III : SECTION – D2 - Technical Requirements - Civil Works

Volume IV A : SECTION – D3 - Technical Requirements

2) Flow Diagram – Stacking and Reclaiming system

3) Gallery Cross Section – Single Conveyor

4) Gallery Cross Section – Double Conveyor

2) Coal Handling System - SLD Substation-1

3) Coal Handling Plant Switchgear Room – GA

TATA CONSULTING ENGINEERS LIMITED

B R0 GENERAL PROJECT INFORMATION 2

C C1 R1 GENERAL SCOPE OF ENQUIRY 4

C4 R0 PROJECT SCHEDULE, PLANNING & 8

C5 R0 QUALITY ASSURANCE AND MINIMUM

C6 R0 CODES AND STANDARDS 4

C8 R0 LAYOUT AND MAINTENANCE 8

C9 R0 PERFORMANCE GUARANTEES, PRE- 18

C10 R0 DATA TO BE FURNISHED WITH THE 2

C12 R0 POLLUTION CONTROL MEASURES 2

C13 R0 SITE SERVICES 17

C14 R0 SUPPLIERS HEALTH AND SAFETY 25

C15 R0 SPARES AND MAINTENANCE TOOLS 8

C16 R0 SUB VENDORS LIST 3

F2 R0 SCHEDULE OF ESSENTIAL SPARES 1

F3 R0 SCHEDULE OF DEVIATIONS FROM 1

F5 R0 SCHEDULE OF WEIGHTS AND 1

F8 R0 SCHEDULE OF ELECTRIC LOAD 1

F10 R0 SCHEDULE OF BIDDER’S 1

F11 R0 SCHEDULE OF EXCLUSIONS 1

F12 R0 SCHEDULE OF QUALITY ASSURANCE 1

F14 R0 REQUIREMENTS OF THE 1

F15 R0 SCHEDULE OF PLACES OF TEST & 1

1.0 SCOPE OF ENQUIRY

TATA CONSULTING ENGINEERS LIMITED TCE FORM NO. 329 R4

GENERAL PROJECT INFORMATION

GENERAL PROJECT INFORMATION

1. OWNER/PURCHASER : Prayagraj Power Generation Company Limited

2. Consultant : TATA Consulting Engineers Limited

5. Nearest Railway station : Lohgara Railway station (Allahabad – Manikpur

6. Access Road : NH-76 is 0.5Km from North West Boundary of

7. Nearest Airport : Bamrauli, Allahabad (About 28 km from site)

8. Nearest Sea port : N. A

9. Latitude of site : 250 11” 50.95”

10. Longitude of site : 810 39’ 39.33 “

a) Avg Annual Temperature : 32.50 C

b) Max Relative humidity : 80%

c) Normal Annual Rainfall : 975mm

d) Basic Wind Speed : 47 m/sec

13) Seismic zone(As per IS: 1893 ) : Zone III

TATA CONSULTING ENGINEERS LIMITED

GENERAL PROJECT INFORMATION

14) Languages Spoken in the Region English, Hindi

15) Official language for the bidder to deal English

Auxiliary Power Supply

a) For AC motors above 200 kW : 3300V (+10%), 3 phase, 50 Hz,

g) Uninterruptible power supply : 230V, 1 phase, 50 Hz, AC supply

TATA CONSULTING ENGINEERS LIMITED

Scope of Work & Technical Requirement-Mechanical

Scope of Work & Technical Requirement-Mechanical