BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number

PANKI TPS (UPRVUNL) IS-1-17-2001/007

Technical Enquiry Specification for
CHP/GHP/LHP Package

TECHNICAL ENQUIRY SPECIFICATION

for
CHP/LHP/GHP Package
of

1x660MW PANKI THERMAL POWER STATION

UTTAR PRADESH RAJYA VIDYUT UTPADAN NIGAM LIMITED

Prepared By Checked by Approved by

Mechanical
LOVEKUSH VERMA GANESH YADAV TIRUPATHI RAO R

Electrical
MALLAPURAM VENKATESHWAR RAO
VEERANJANEYUL VANGALA SANGEETHA MA

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 1 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

CONTENTS
Sl. No. DESCRIPTION SHEET No.
1. PROJECT INFORMATION 03 of 46
2. BROAD SCOPE OF CONVEYOR PACKAGE BIDDER 03 of 46
3. SYSTEM DESCRIPTION AND SCOPE OF WORK & SERVICES 08 of 46
4. ADDITIONAL NOTES FOR CHP PACKAGE (MECHANICAL SCOPE OF WORK) 23 of 46
5. ERECTION, COMMISSIONING AND SUPERVISION 28 of 46
6. WORK INSTRUCTIONS FOR STORAGE & HANDING OVER OF MANDATORY 31 of 46
SPARES
7. OPERATION AND MAINTENANCE TILL HANDING OVER 31 of 46
8. TOOLS AND TACKLES 35 of 46
9. SPARE PARTS 37 of 46
10. EXCLUSIONS 39 of 46
11. PERFORMANCE GUARANTEE 39 of 46
12. LIQUIDATED DAMAGES FOR POWER CONSUMPTION 41 of 46
13. QUALITY ASSURANCE. 41 of 46
14. DRAWINGS AND DOCUMENTS SUBMISSION 44 of 46

LIST OF ENCLOSURES:
Following enclosures is an integral part of this technical enquiry and must be signed and stamped and
submitted along with the offer:
001- ANNEXURE-1- Project Information
002- ANNEXURE-2–Electrical and C&I Scope of Work
003- ANNEXURE-3-NIT Specification
004- ANNEXURE-4-Amendment and Clarification
005- ANNEXURE-5- Drawing & Documents
006- ANNEXURE-6- Auxiliary Power Format
007- ANNEXURE-7- Billing Break-Up format
008- ANNEXURE-8- Scope Matrix between Mechanical & Civil-Structural Vendors
009- ANNEXURE-9- BHEL’s HSE Manual & PPE Manual
010- ANNEXURE-10- Drive List to Be Filled By Bidder
011- ANNEXURE-11- Drawing Doc Submission list
012- ANNEXURE-12- List of Drg for prorata payment

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 2 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

01.00.00 PROJECT INFORMATION:

Coal Handling Plant for 1 X 660 MW Panki Thermal Power Station of Uttar Pradesh Rajya Vidhyut
Utpadan Nigam Ltd. For the Salient Features of the Project site refer Annexure-1 enclosed.
02.00.00 BROAD SCOPE OF CONVEYOR PACKAGE BIDDER:
The scope for CHP package (Which consists of coal handling system, limestone handling system &
Gypsum handling system), vendor shall include detail engineering, submission of engineering & civil
assignment drawing/ doc. / datasheets/ QAPs/ FQPs/PG test procedures, getting approval from
customer, manufacturing/ fabrication, inspection/ shop floor testing, shop floor painting, packing,
supply, transportation to site in proper packing, receipt & unloading at storage, Construction of Open
storage yard and closed storage shed, preservation & security at site, shifting to erection work place,
erection, drive alignment, Filling of the Consumables, Trial Run, Commissioning, final painting at site
after erection, Functional Testing, handing over, Training, O&M till handling over and upto 6 (six)
months after that, Performance Guarantee Testing of total conveyor system ( except machines which
are not in bidder’s scope) , handing over to customer (UPRVUNL), training to UPRVUNL persons upto
6 (six) months from handling over conveyor system .
The following Main Equipment with Associated Accessories are under Bidder’s Scope of Supply and
Work.

SLNO DESCRIPTION QTY UNIT

Coal Handling Plant (CHP)
1. Complete side discharge Wagon tippler with integral weigh bridge, all accessories,
complete drives system and associated electrical and control & instrumentation, air
2 Set
conditioning equipment along with startup and commissioning spares as applicable as
per latest RDSO norms and NIT specification
2. Complete Rail Mounted, Rack & Pinion Type Side arm charger complete with drives, all
accessories and associated electrical and control & instrumentation equipment along
2 Set
with startup and commissioning spares as applicable as per latest RDSO norms and NIT
specification
3. Complete Wagon Shifter & Pusher with all accessories, complete drives system and
associated electrical and control & instrumentation equipment along with startup and 2 Set
commissioning spares as applicable as per latest RDSO norms and NIT specification
4. Apron feeder with dribble conveyor complete with drives and associated electrical and
control & instrumentation equipment along with startup and commissioning spares per 2 Set
NIT specification.
5. Double girder EOT Crane complete with rail/ box, drives and associated electrical and
control & instrumentation equipment along with startup and commissioning spares per 1 Lot
NIT specification.
6. Unidirectional Bucket wheel Stacker cum Reclaimer machine complete with drives and
associated electrical and control & instrumentation equipment along with startup and
02 Set
commissioning spares, belt weighers, air conditioning system for operator's cabin & E-
House and machine mounted dust suppression system.
7. Common rails, rail accessories, clamps, fixtures, storm anchor, splice plate, end stops
2 Lot
etc. for above machines.
8. Conveyor System as per layout and technical specification complete with
1 Lot
necessary supporting structure, platforms, idlers, pulleys, fixed trippers, take-

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 3 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

SLNO DESCRIPTION QTY UNIT

ups, gear-boxes , couplings with guards, LT Motor, hold-back device, brakes,
skirt boards, belt cleaning devices, electrics,pull chord switches, belt sway
switches, zero speed switches, chute block switches and LPBS, etc. as applicable
and other necessary units/accessories for completing the system of coal
handling system
9. Diverter Gate (Travelling type through rack & pinion arrangement) with 30 set
actuator including electrical and C&I, fixing supports, maintenance access as per
technical specifications
10. Flap Gates (Motorized) with actuator including electrical and C&I , fixing 2 set
supports, maintenance access as per technical specifications
11. Rack & Pinion Gate including electrical and C&I, fixing supports, maintenance 8 Set
access as per technical specifications
12. Rod Gate Rod gates, fixing supports, maintenance access. 8 Set
13. VGF screens with drive unit with supporting structure including electrical and 4 Set
C&I as per technical specifications
14. Vibrating feeder with drive unit with supporting structure below Reclaim 4 Set
hoppers including electrical and C&I as per technical specifications
15. Ring Granulator Crushers with bypass arrangement (including gates) for coal 4 Set
complete with scoop couplings (air cooled type), hydraulic door opening
mechanism, vibration isolation system, drive base frames and associated
electrical (except HT motor) and C & I as per technical specifications.
16. Inline Magnetic Separators with belt, drives, fixing lugs, slings, fixing 4 Nos.
accessories, tramp iron chute up to ground level, reject trolley and with all
electrical and C&I etc. as per technical spec.
17. Metal Detectors along with all electrical and C&I as per technical spec. 6 Nos.
18. Coal Scooper to operate in conjunction with metal detector including electrical 6 Nos
and C&I as per technical spec.
19. Suspended Magnet along with fixing lugs, slings, fixing accessories, tramp iron 6 Nos.
chute, reject trolley with all electrical and C&I as per technical specifications
20. Belt Weigher complete with indicators, recorders etc, including electrical and 6 Nos.
C&I as per technical specifications
21. Complete Reversible Belt Feeder including supply of belt with all electrical and 2 Set
C&I as per technical specifications.
22. All transfer chutes, floor cleaning chute with all necessary supporting structure, 1 Lot
liners, hood for all transfer points, Crusher House, W. T. Complex, Reclaim
Hopper Complex, Boiler Bunker top. All Inter-connecting chute (along with
liners). Stone picker for pre & Post crushing conveyor on both side with
associated structures.
23. Deck plates as per technical specifications 1 Lot
24. Coal Sampling Units (In ST building) including electrical and C&I as per technical 2 Set
specifications
25. Fixed Tripper with accessories as per technical specifications 4 Set

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 4 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

SLNO DESCRIPTION QTY UNIT

26. Travelling tripper along with festoon cable arrangement, flap Gates (Motorized) 4 Set
with actuator, structures, mechanical equipments, rails, rail fixtures, clamps,
wheel & axle, bearings, tripper drive equipments etc, including electrical and
C&I as per technical specifications
27. Bunker sealing arrangement complete with belt, idler tensioning arrangement 1 Lot
and supporting structures as per Technical specification
28. Belting of all CHP conveyors 1 Lot
29. Electric, Manual Hoist and chain pulley block along with Mono rail including 1 Lot
electricals for entire CHP as per technical specifications
30. Passenger cum goods elevator, rope & sieve Type, 2000 Kg in Crusher house, 3 Set
JT-6 and JT-7 with structures, guides, all electrics, C&I drives, panels as per
Technical specification
31. Dust Extraction System at Crusher house & Bunker including Compressors, 1 Lot
electrical and C&I as per Technical specification
32. Ventilation System for WT, Tunnel, ERH, MCC rooms ,Battery rooms, bulldozer 1 Lot
shed, Pump House, toilets etc, including electrical and C&I as per Technical
specification
33. Bunker grating as per Technical specification 4 Set
34. Air conditioning system Control room, DCS/RIO room, Cabins, Office room, 1 Lot
dozer room etc. including electricals and C&I as per Technical specification
35. Belt Vulcaniser (Hydro-mechanical press type) with complete with splicing 1 Nos
tools/kit/ consumables and all accessories –upto1600 mm BW
36. Portable motorized winch of 5T including 430 mtr length of rope as per 1 Nos
Technical specification
37. Complete water package for CHP/LHP/GHP i.e DS/PW/SW/SA system including 1 Lot
electricals and C&I as per specification
38. Submersible Sump Pumps with piping, valves, instruments, supporting structure 1 Lot
including electrical and C&I as per Technical specification
39. CSSP Sump Pumps with valves, instruments, supporting structure, piping upto 1 Lot
rain water harvesting pond including electrical and C&I as per Technical
specification
40. Maintenance Tools and Tackles as per list enclosed 1 Lot
41. Commissioning Spares as required 1 Lot
42. Electrical Items including Motors, Field electrics, , Field Instruments, Cables, 1 Lot
cable trays, earthing protection material, JBs, LPBS, VFD Panels, Local panels,
Stator Panels, Power distribution board ,UPS etc as per detail scope, please
refer Annexure-2
43. Air Curtain with auto door facility at entrance door of Control room in MCC 1 Lot
and office Bldg. g
44. Mechanical Mandatory spares for entire CHP system 1 Lot

45. Electrical and C& I Mandatory spares for entire CHP system 1 Lot

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 5 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

SLNO DESCRIPTION QTY UNIT

46. Construction of open & closed storage yard 1 Lot
47. Operation & Maintenance (O&M) of equipment before handing over the 300 Shift
CHP/LHP/GHP
48. Operation & Maintenance (O&M) of equipment till six (6) months after 1 Lot
handing over the CHP/LHP/HGP system
49. Training to O&M person of UPRVUNL upto six(6) months after handing over 1 Lot
the CHP/LHP/GHP system

50. Receipt, storage, erection, alignment & commissioning of BHEL supplied free 1 Lot
issue items like HT motors etc.
Limestone Handling Plant (LHP) and Gypsum Handling Plant (GHP)
1. Conveyor System as per layout and technical specification complete with 1 Lot
necessary supporting structure, platforms, idlers, pulleys, fixed trippers, take-
ups, motors, gear-boxes , couplings with guards, LT Motor, hold-back device,
brakes, skirt boards, belt cleaning devices, electrics,pull chord switches, belt
sway switches, zero speed switches, chute block switches and LPBS, etc. as
applicable and other necessary units/accessories for completing the system of
LHP/GHP
2. Flap Gates (Motorized) with actuator including electrical and C&I, fixing 10 Set
supports, maintenance access as per technical specifications
3. Rack & Pinion Gate including electrical and C&I, fixing supports, maintenance 6 Set
access as per technical specifications
4. Rod Gate Rod gates, fixing supports, maintenance access. 6 Set
5. Vibrating screens with drive unit with supporting structure including electrical 4 Set
and C&I as per technical specifications
6. Vibrating feeder with drive unit with supporting structure below Reclaim 4 Set
hoppers including electrical and C&I as per technical specifications
7. Hammer Mill crusher for limestone with gear box, air cooled scoop coupling, LT 2 Set
Motor, vibration isolation system, hydraulic door opening mechanism drive
base frames and associated electrical and C & I as per technical specifications
8. Inline Magnetic Separators with belt, drives, fixing lugs, slings, fixing 2 Nos
accessories, tramp iron chute up to ground level, reject trolley and with all
electrical and C&I etc. as per technical spec.
9. Metal Detectors along with all electrical and C&I as per technical spec. 2 Nos
10. Belt Weigher complete with indicators, recorders etc, including electrical and 2 Nos
C&I as per technical specifications
11. Bucket Elevator complete with electrical and C&I as per technical specifications 2 Set
12. Complete Belt Feeder(Reversible and uni-directional) including supply of belt 3 Set
with all electrical and C&I as per technical specifications.
13. All transfer chutes, floor cleaning chute with all necessary supporting structure, 1 Lot
liners, hood for all transfer points, Crusher House, Reclaim Hopper Complex,

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 6 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

SLNO DESCRIPTION QTY UNIT

Bucket elevator inlet& outlet, silo top. All Inter-connecting chute (along with
liners). Stone picker with associated structures.
14. Deck plates as per technical specifications 1 Lot
15. Limestone Sampling Units (In crusher house) including electricals and C&I as per
technical specifications
16. Electric, Manual Hoist and chain pulley block along with Mono rail including 1 Lot
electricals and C&I entire LHP & GHP as per technical specifications
17. Belting of LHP/GHP Conveyors 1 Lot
18. Dust Extraction System at Crusher house, Gypsum shed including electricals and 1 Lot
C&I as per Technical specification
19. Ventilation System for ERH, tunnel ,limestone shed including electricals and C&I 1 Lot
as per Technical specification
20. Submersible Sump Pumps with piping, valves, instruments, support complete 1 Lot
system including electricals and C&I as per Technical specification
21. Mandatory spares (Mechanical, Electrical and C&I) for Conveyor Package 1 Lot
as per spec
22. Electrical Items including all Motor, Field electrics, Field Instruments, 1 Lot
Cables, cable trays, earthing protection material, JBs, LPBS, VFD Panels,
Local panels, Stator Panels, Power distribution board, UPS etc . For
detail scope, please refer Annexure-2.
23. Received, storage, erection & commissioning of BHEL supplied free issue items 1 Lot
like HT motors if any etc.

Note:
a. The UPRVUNL NIT specification, Amendments, Pre-bid & post bid clarification, Electrical and C&I
Scope of Work and BHEL HSE given with this specification, which shall be read with this technical
specification and shall form part of the enquiry. Bidder shall submit a signed copy of BHEL’s this
Tender Enquiry Specification along with all enclosures as Technical Offer with the Bid without any
Deviation.
b. Complete Detailed Engineering Drawings, Calculations, Selection of Components etc. shall be
reviewed by BHEL Engineers and Plant Owner/ consultant during Detail Engineering.
c. BHEL shall prepare GA drawing of building and conveyor gallery. Bidder to prepare final GA drawing
after superimposing all fabricated equipment, its fixing, foundation or footing details on BHEL’s GA
drawings.
d. Bidder to prepare and furnish all drawing of CHP/LHP/GHP in editable 2D AutoCAD and 3D PDMS
format. Also Bidder to furnish 3D modelling of total CHP/LHP/GHP including all civil/structural
building. Relevant civil/ structural input shall be provided by BHEL.
e. Bidder to follow drawing submission schedule as per Drawing Doc Submission list attached in
Annexure-11 .

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 7 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

f. Successful Bidder shall take Prior Approval from BHEL while placing the E&C Contract Order for this
Package to their Sub-Contractor. BHEL reserves the Right to Disapprove/Reject any such E&C
Contractor which BHEL deems not fit for executing E&C of this Contract.
g. Bidder to quote for this offer considering the Enclosed Plot Plan, Coal Flow diagram, Conveyor
Profile and conveyor cross-section provided in Annexure-5.
h. Bidder shall furnish the Guaranteed Power Consumption in KW for the conveyor system path wise
as per specification along with the offer and Complete Drive Schedule. Bidder to note that BHEL has
considered/declared the auxiliary power consumption of 1603 KW along the longest path as
described in Cl. No. 5.25.3 of NIT Vol-II, which is including Wagon tippler, Side Arm Charger, Apron
Feeder and dribble conveyor & Stacker Reclaimer. BHEL shall load the price per kW of guaranteed
power consumption for any increase on BHEL declared value (i.e. 1603 kW) during price evaluation
of excess power consumption.
i. For PRE QUALIFICATION REQUIREMENT bidder is requested to refer contract terms and conditions.
Only qualified bidders will be considered for further bid evaluation.
j. For Sub QR items like CSU, bidder shall follow NIT specification of provenness criteria.
k. For Water package, sub-vendor should have experience of design, supply and executed the dust
suppression system in material handling plant.
l. Bidder shall be responsible for obtaining RDSO approval for Wagon tippler including fees. All other
equipments like elevator, the statutory approvals shall be obtained by bidder.

03.00.00 SYSTEM DESCRIPTION AND SCOPE OF WORK & SERVICES

03.01.00 INTENT OF SPECIFICATION
The package shall be on the basis of single point responsibility, completely covering the following
activities and services in respect of all the equipment & works specified and covered under the
specifications:
a. Review and acceptance of engineering & civil assignment drawings/ Building GA and load data
drawings, design calculations prepared by BHEL, detail engineering based on the GA and load data
drawings prepared by BHEL, preparation of equipment drawings/datasheets/ quality assurance
documents/ field quality plans, part drawings consisting of sequence of installation required for
erection, control philosophy for the system under this package, commissioning procedures, operation
& maintenance manuals, Performance Guarantee test procedures and obtaining approval from
UPRVUNL/DCPL/BHEL. Incorporating all equipment/ structural/ fabrication drawing, minor
modification etc in BHEL GA drawing, preparation of as built drawings and getting it approved from
end UPRVUNL is included in bidder’s scope.
b. Complete Detailed Engineering Drawings, Calculations, Selection of Components etc. of all
equipments shall be reviewed by BHEL Engineers and UPRVUNL of his consultant (NTPC & DCPL) during
Detail Engineering.
c. Successful bidder shall prepare and submit 3D PDMS design review model of all GA of Transfer Points,
wagon tippler with SAC & shfter -pusher, Wt complex, crusher house, Stacker Reclaimer, GA of
conveyors & tunnel, Reclaim hopper complex, Bunker floors, coal stockpile area, Limestone storage
shed, gypsum storage shed, bull dozer shed, equipments associated with the scope of work of this

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 8 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

package as indicated in the flow diagram of CHP, LHP, GHP and also for CHP Pump houses, MCC
buildings with electrical equipment & Cable Rack. For Pump houses, pumps & pipings, HT motors, CHP
MCC buildings & Cable Tray & Earthing layouts BHEL shall furnish the 2D PDF/ autocad models which
shall be converted in 3D model. The 3D models shall include visual interference check, walk-through
animation, video simulation for major equipment placement and removal, visual effect, photo realism
etc.). After the completion of engineering of the corresponding complete 3D model shall be handed
over to the UPRVUNL, It’s consultant & BHEL for its reference. Successful bidder shall ensure that the
3D model preparation is started within 1 month of LOA and are available to make a presentation of
the same every 2 months to BHEL & UPRVUNL for review the progress of engineering or as & when
required by BHEL & UPRVUNL, if bidder fails to provide 3D Model drgs on time then BHEL reserved
the right to place the order for 3D modeling at successful bidder’s risk and cost. Also, the 3D models
shall be integrated with BHEL’s intelligent 3D software and bidder shall depute their engineers in
assisting such integration in BHEL PEM Noida premises as and when required.
The price of 2D AutoCAD drgs and 3D PDMS shall be deemed to have been included in the total bid
price.
d. Providing detail engineering drawings, civil assignment drawing/ doc. / datasheets/ QAPs/ FQPs,
equipment sizing & performance data, instruction manuals, as built GA drawings of building &
conveyors and other information.
e. Responsibility of getting drawing approval from customer is in bidder’s scope.
f. Compliance with statutory requirements and obtaining clearances from statutory authorities,
wherever required for all the equipments and systems covered under the scope of bidder.
g. Complete manufacturing including shop testing/ type testing. Bidder to offer all the items/ materials
for inspection, by BHEL/ UPRVUNL/third party as the case may be, prior to dispatch from shop.
Necessary approval for drawing/ documents for all item/ equipments from UPRVUNL/ BHEL shall be
obtained by the bidder prior to procurement/ manufacturing. Make approval shall be taken by the
bidder from UPRVUNL for all the items prior to procurement/ manufacturing
h. Packing and transportation from the manufacturer’s works to the site including logistic studies,
customs clearance & port clearance, port charges, if any.
i. Receipt, storage (Open & Closed), preservation, handling and conservation of equipment at the site.
j. Fabrication, pre-assembly, if any, transportation within site, erection, testing, commissioning and
completion of facilities including putting into satisfactory operation of all the equipment including
successful completion of initial operation.
k. Performance and guarantee tests after successful completion of initial operation
l. Supply of spares on FOR site basis
m. Reconciliation with customs authorities, as required
n. Conclusion of the contract.
The Bidder shall be responsible for providing all material, equipment and service, which are required
to fulfill the intent of ensuring operability, maintainability, reliability and complete safety of the
complete work covered under scope of work in this specification, irrespective of whether it has been
specifically listed herein or not. It is not the intent to specify herein all aspects of design and
construction; nevertheless, the equipments shall conform in all aspects to high standard of
engineering, design and workmanship and shall be capable of performing in continuous commercial
operation in a manner acceptable to UPRVUNL, who will interpret the meaning of the specification

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 9 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

and drawings and shall have a right to reject or accept any work or material which in his assessment
is not complete to meet the requirements of this specification and/or applicable to Indian/
International standards mentioned elsewhere in this specification.
Bidders shall submit the offer strictly in line with the technical specifications and instructions provided
in this document. In case the requirements mentioned in these documents are not complied with, the
offers may be considered as incomplete and would become liable for rejection.
All standards, specifications and codes of practice referred to herein shall be the latest editions
including all applicable official amendments and revisions as on date of opening of bid. In case of
conflict between this specification and those (IS : codes, standards, etc.) referred to herein, the former
shall prevail. Equipment shall conform to the requirements of the standards and codes as applicable.
03.02.00 Wagon Tippler, Side Arm Charger, Wagon Shifter & Pusher and Apron feeder
3.02.01 Bidder shall refer UPRVUNL NIT specification VOL-III, Chapter-19, Clause-1.10, sub clause M-13 to M-17 ,
page no. 60 to 73 of 116 for WT, SAC EOT crane, & AF and other relevant clauses/ technical specifications,
amendment & clarification for WT,SAC , wagon shifter & pusher, AF and EOT crane machines.
Data Sheet:
WAGON TIPPLER MACHINE

Type Rotaside, Side Discharge Type to suit tipping capacity of Tippler as per
latest RDSO technical pamphlet G-33 Rev-01.
Material of Construction of IS:2062
main Parts / Units
Type of Wagons that can be BOX, BOXN, BOXNHA, BOXNLW, BOXNHL, BOXN25,DFC & other type of
Handled at a time open wagons for coal as per RDSO standard and design used by Indian
Railways to move coal.
Gross Weight of Wagon that Min. 140 T
can be handled at a time
Rail Gauge 1676 mm

No. of Tips per Hr (Guaranteed) Rated 25tip/hr

Duty 24 hours
Type of clamping Hydraulic
Hydraulic motor for tippler drive Low speed high torque type
Angle of rotation 160 Degree. (maximum) as per G-33 Rev-01
Type of clamping Hydraulic clamping arrangement, articulated
Type of motor, brake etc Hydraulic motor operated by Power pack
Diesel loco passage Yes, allowed
Clearance profile As per RDSO G-33 rev-1
Mode of Control Semi automatic/manual, PLC control for remote operation & control shall
be provided.
Safety Features All the necessary safety features shall be provided for each machine

Lubrication Arrangement Motorized group Lubrication system of proven design shall be provided.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 10 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

Special Feature, Heavy Duty Tippler as per Proven Design, suitable for Round the Clock
Duty
EOT crane for tippler Required
maintenance
G.A drawing of W.T Complex Bidder to furnish along with offer
including tunnel

Side Arm Charger

Type Rail Mounted, Rack & Pinion Type
Type of wagon to be Hauled All types as per RDSO Standard
Hauling Capacity 60 Nos. wagon, each having gross wt. of 140 t
Duty Continuous; 24 hr/day
Operating Speed (Forward & Forward: ~ 0.6 m/s (To Suit) ; Reverse: ~1.2 m/s (To Suit)
Reverse) However travelling Speed of SAC shall be to suit tippler design capacity of
25tip/hr
Mode of Control Semi Automatic from Remote Control & Local
Mode of Power Supply Festooning Cable Arrangement
Drive Arrangement Hydraulic motors (operated by Power Pack) driving a set of pinions onto
ground drive rack.
Safety Features Over Travel Protection / other safety features as necessary shall be
provided for safe operation
Arm Raise / Lower Arrgt. Hydraulic cylinder operated by Power Pack
Type of Lubrication Manual centralized
arrangement
No. of Carriage Wheels 4Nos
Track Gauge (approx.) 1500mm to 1800 mm
Length of Track (approx.) 62 m
Location of Control Desk Duly covered control desk provided on Side Arm Charger
Detail of Color Signal lights Red & Green Light
provided for Loco Operator’s
guidance
Apron Feeder
Pan Width (Minimum) 2000 mm
Pan Speed, 0 to 0.2 m/ sec
Pan Type Over lapping
Angle of Installation Horizontal
Chain Link Forged alloy Steel
Apron pan Fabricated from 12thk SAILMA HI + 10thk MS IS:2062
Head sprocket As per standards of crawler chain manufacturer
Traction wheel : As per standards of crawler chain manufacturer
Rollers : Carrying/ return Forged Alloy Steel/IS: 2707 – Gr-1 flame hardened
Head and Jack shafts CK-45/equal
Skirt board 20mm thk SAILHARD or superior wear resistant plate
Hood above head sprocket 6mm thk. M.S[IS:2062]
Assembly
Drive AC Motor with VFD control device for speed variation

Reducer Bevel Helical

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 11 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

Couplings Provided to suit drive complete with guard

Dribble Conveyor Integral matching Dribble belt conveyor with built-in drive to handle
spillage shall be provided (Please ref. Vol-III, chapter-19, Coal Handling
System for belt, pulley, idler, structural requirement etc. specification.)
Wagon shifter and pusher
No. of wagons to be handled by 1 (Wagons as per RDSO G33 Rev.1)
shifter
Capacity of Shifter Diesel locomotive and/or loaded wagon weighing upto 140 T
Capacity of Pusher To push wagon as per RDSO G-33 rev-1 on empty line
DESIGN & CONSTRUCTION
REQUIREMENTS
Shifter/pusher carriage Robust construction of heavy duty fabricated
steel.
Shifter/pusher Drive Direct hydraulic drive without gear box or electric motor and reducer unit
controlled through VVVF drive
Travel brake Integral/ independent hydraulic disc brake
Rails on shifter /pusher 52 Kg/m
Working pressure for the 250 bar Maxi.
hydraulic system in Hydraulic
Power Pack
EOT Crane
Type of Crane required Double girder EOT Crane for WT complex shed
Duty Class : M5,Indoor [ IS 3177 / IS:807]
Mode of operation Pendant Station [consists of push buttons housed in dust proof
housing and suspended from hoist, movable on independent
monorail]. To prevent pull on pendant, cable steel wire rope
provided
Capacity of Main Hoist 20tonne/ 6.3tonne
(SWL)/
Aux. Hoist (SWL)
Rated Speed Main hoist - 3m/min
[For any load from zero to Aux. hoist - 6m/min
SWL] Trolley travel - 10m/min
Bridge travel - 15m/min
Design Temperature for 50 degree C
Motors
No. of Starts Per Hour 150
Type of Main Hook C-shank Type swiveling hook with locking device, Trapezoidal
section
Type of Auxiliary hook Standard single swiveling type with locking device
Wire rope/ Drum IS:2266,6x36,steel core/ seamless pipe drum ASTM A106
Crane Structure Bridge Girders of box steel type steel fabricated construction.
Full-length access platforms shall be provided on both sides of
crane with walkways [IS:807/IS:3177/ IS:800]
End carriage Fabricated from rolled sections/plate box
LT wheels EN-8/EN-9 forged steel, double flanged
LT wheel bearings Heavy duty sealed ball bearings
Pinion/axles En-9/16MnCr5, heat treated carbon alloy steel
Crane runway rails Minimum CR-60
Hoists Generally conforming to IS:3938
Brakes Hoist motion: Electro hydraulic thrustor operated
Cab travel : DC disc type
Bridge travel :DC disc type

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 12 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

Control panel Sheet metal clad in totally enclosed construction,IP-55

protection
Runway conductors (DSL) MS angle ISA – 75x75x6 section
Control supply 240 V, single phase 50 HZ AC supply (necessary step – down
transformer for control/ lighting/ space heater power supply
required for crane shall be provided by contractor)
Safety Electrical interlocking is provided to avoid accidental
simultaneous motions of crane due to activation of multiple
push buttons at the same time.
Limit switches Limit switches shall be provided against over hoisting/over
lowering/over travel in cross and longitudinal direction.

1. All Hydraulic power pack system shall be air cooled. Bidder to note that hoist, fan, input for monorail
etc for power pack shall be in the scope of this package.
2. Bidder’s scope shall also include supply of mandatory spares, start-up & commissioning spares.
Applicable spares for equipment in this package to be considered by the bidder. Mandatory spares
list shall be as per NIT Vol-II.
3. Bidder shall also furnish the list of recommended spares list along with price for three years’ normal
operation along with the offer.
4. Rail & its fixing over wagon tippler table top are included in bidder’s scope of supply and E&C.
5. Rack, Rail & its fixing for side arm charger are included in bidder’s scope of supply and E&C.
6. Rack, Rail & its fixing for wagon pusher & shifter are included in bidder’s scope of supply and E&C.
7. Rail & its fixing accessories for EOT crane are included in bidder’s scope of supply and E&C.
8. Retractable wheel chocks, wheel grippers etc. are included in bidder’s scope of supply and E&C.
9. Dribble conveyor including belting, drive etc are in bidder’s scope of supply and E&C.
10. Bidder’s scope shall also include supply and filling of consumables, lubricants upto six(6) months from
final handing over to the end customer.
11. Operation & Maintenance with all resources (man & machine) for each equipment and system under
the scope of this package shall be in bidder’s scope as specified elsewhere in this specification.
12. Bidder shall submit complete drive schedule including motor ratings for all the equipment in this
package without which the bidder’s offer shall not be considered for evaluation. Tentative list is given
below:

Motor rating in kW/per

Sl. No Description
machine
Complete Wagon Tippler drives (for tippling, clamping, track
1.
stopper, coolers, etc.)
Complete Side Arm Charger drives (arm luffing, coupler release,
2.
travel, coolers, etc.)
3. Wagon shifter drive
4. Wagon Pusher drive

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 13 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

Motor rating in kW/per

Sl. No Description
machine
5. Apron Feeder drive
6. Dribble Feeder drive

03.03.00 Stacker Reclaimer Machine

03.03.01. Two (2) numbers Stacker cum Reclaimer machines shall be provided one each on yard conveyors. The

Stacker Reclaimer machines shall operate on rails for stacking/reclaiming the coal in the stock yard area.
During reclaiming operation the reclaimed coal shall be conveyed to the yard conveyor by the boom
conveyor of the respective Stacker Reclaimer machines for Conveying to Boiler Bunker. Electronic Belt
weighers mounted one each on stacker reclaimer, boom conveyor complete with all mechanical,
supporting arrangement, electrical, and accessories. Stacker reclaimer shall be provided with hydraulic
drive for bucket wheel to reclaim at the required rate while working in conjunction with other Stacker
reclaimer for blending.
03.03.02. Stacking and reclaim capacity ( rated) shall be 1500 TPH and design capacity shall be 1650 TPH. Bucket

wheel capacity shall be 125% of rated capacity.

03.03.03. Anti-collision device shall be provided on each M/C considering all possible operating condition
including M/C travelling on adjacent track.
03.03.04. The Stacker cum Reclaimer shall conform to the latest edition of the following standards and codes.

Other internationally acceptable standards/codes, which ensure equal or higher performance than those
specified, shall also be accepted.
a. ISO 5049/1 (Latest) : Mobile Continuous Bulk Handling Equipment.
b. FEM (latest): Federation Europeanne De La Manutention Section-I-Rules for Design of Hoisting
Appliances
03.03.05. As per the layout the stacker cum reclaimer machine shall be suitable to operate and shall be able to

form 3 nos. stockpile of total capacity = 158200MT and the base of stockpile shall be 35m (minimum)
CCS-1&2 and 54m CCS-2 and height shall be 12m of each.
03.03.06. The design average capacities shall be not less than 110% of rated (guaranteed) capacities as specified

elsewhere for both stacking and reclaiming. The continuous motor rating at 50 deg C of the drive motor
to be provided on one side of the yard conveyor shall be 110% of the actual power requirement at motor
output shaft. Stacker/Reclaimer shall be capable of performing all operations for wind pressures
corresponding to 20 m/sec wind velocity. The equipment structure shall be stable, free on wheels
during wind pressures corresponding to basic wind velocity of up to 50 m/sec. A suitable

anemometer shall be provided which shall indicate the wind velocity in the control cabin.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 14 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

03.03.07. Automatic rail clamp, which will be operated through anemometer and manual rail clamp shall be
provided for holding the stacker cum reclaimer. Suitable anchoring device and suitable storm clamp
shall be provided for keeping the stacker reclaimer in fixed stable position when the weather is stormy.
The wheel load of stacker-reclaimer shall not exceed 275 KN. The rail track gauge shall be 9.2 mtere for
45m boom length.
03.03.08. The Portal/ Gantry/ Super Structure shall be adequately designed to withstand the load of boom
conveyor with drive/ its gallery, bucket wheel assembly, slewing drive unit, hoisting unit, conveyor head
section, counter weight etc. The structure (machine) shall be designed as statically determinate three
(3) point’s supports system with four (4) corners. The structure shall be designed to ensure its static
and dynamic stability and shall be fabricated from tested quality structural steel (IS: 2062). It shall be
of box type or lattice construction comprising of platform at different elevations, stairways, ladders,
walkways etc and complete with carriage and truck frames etc.
03.03.09. Long travel Drives (VVFD control) shall be electric motor driven mechanical type with gear
reducers shaft mounted on the driven wheels. Torque reaction shall be via flexible mounting on
bogie. Brakes shall be separate assemblies mounted on motor or reducer high-speed shaft. At
least half the wheels shall be driven. The truck assembly shall be fully equalized to ensure all
wheels share the load equally.
03.03.010. Provisions shall be made at each corner of the under carriage for jacking to permit the removal
of travelling wheels/ bogies. The jacks required for replacement shall be the part of supply.
03.03.011. Travel wheels shall be double flanged having minimum tread width 40 mm more than the rail
head. Wheel spacing shall not be less than 800 mm. The top of rail level shall be maintained at
0.7 m above ground level i.e., coal pile base level unless otherwise stated. Suitable number of
rail scrappers shall be provided. Wheels shall be of forged/cast steel. The tread shall be hardened
to in excess of 300 BHN and tested ultrasonically. All wheels shall be mounted on shaft with
self-aligning bearings.
03.03.012. Rail Track Tolerances: Following tolerance/better for the long travel track shall be provided.
a. Max. Permissible variation in rail level, vertical [one rail to another] = ±15mm
b. Max. Permissible track variation (Rail Centers) = ±10mm
c. Rail gradient = 1:500

03.03.013. The boom supporting the conveyor may be designed as a built up girder or as an open truss
and shall include walkways on both sides of the boom conveyor. Boom conveyor return belt and
idlers shall be located so that these are accessible for inspection/ maintenance & replacement
from the walkway.
03.03.014. Deck plate at loading point only shall be provided for boom belt of Stacker Reclaimer machine.
03.03.015. The Luffing controls include all sensors which shall automatically reverse the luffing motion for
a pre-determined time upon sensing contact of the bucket wheel, boom or counterweight with
the stockpile or any other obstruction. The luffing control shall be capable of following both the

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 15 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

longitudinal and transverse slope of the stockpile base during automatic and semi-automatic
operation.
03.03.016. Luffing of boom conveyor shall be effected by hydraulic arrangement. Hydraulic boom hoist shall
be located between slew platform and bucket wheel boom on bucket wheel side. An access with
automatically levelling steps from slew platform to the boom shall be provided.
03.03.017. In Hydraulic arrangement, minimum two double action hydraulic jacks shall be provided one on
right and one on left hand side of the pylon. In the event of failure of one of the cylinders, the
other cylinder shall be able to hold the boom in position. The luffing movements shall be
controlled by solenoid valves. The hydraulic system shall be complete with pump & its drive &
tank, oil filter, all necessary valves, oil cooler, pressure switches & fittings. A level switch shall
be installed on the oil tank; this will indicate oil level & switches off the equipment when oil
reaches to a minimum predetermined level. Brake valves shall be provided for retaining the
speed once set and speed should not increase as a result of external forces on the cylinders.
03.03.018. Hydraulic cylinders shall be equipped with non-return valves. Pressure switches shall be
provided on all important points of hydraulic system, in case pressure increase a predetermined
value, the machine shall be switched off. Distance between the pivot point & lifting cylinder shall
be largest to avoid vibration. The hydraulic boom hoist shall be equipped with load measuring
and monitoring devices.
03.03.019. During the stacking operation, the boom belt operates in conjunction with tripper.
Belt width- 1400 mm
Belt troughing 35 Deg.
Belt speed – 3.2m/sec approx..
Capacity- 1500 tph(rated)/ 1650 tph(design)
Drive 1000 RPM Electric motor with Bevel Helical gearbox complete with couplings etc
Boom Belt Conveyors shall generally conform to Conveyors Specification as per Vol-III, Mechanical
Works, Chapter-19, Coal handling System.
03.03.020. Bucket wheel shall be of cell-less design and its buckets shall be designed with good emptying
characteristics and with proper cutting clearance. Bucket Wheel Assembly shall be provided with
hydraulic motor complete with speed monitor. Drive shall be reversible type so as to facilitate
withdrawal of wheel in the event of excessive undercutting and burial of wheel in the stockpile.
Wheel RPM shall be adjustable to suit. Hydraulic motor shall be radial piston cam ring design.
03.03.021. Bucket wheel drive unit shall be selected to meet the required duty. The drive shall be shaft
mounted onto the bucket wheel shaft and also supported by a single self-aligning torque reaction
mounting designed to cater for all tensile and compressive loads. The drive arrangement shall
be designed to provide proper alignment under all operating conditions. Drive shall be provided
with a quick response, reliable ultimate torque limiting protection device. Buckets shall be sized
for 125% of rated capacity. Rate of bucket discharges shall not exceed 55 per minute.
03.03.022. Bucket wheel body shall be of welded steel construction (IS: 2062) properly stiffened for the
required duty and configured to form a rigid support for the buckets. Bucket shall be fabricated
from SAILMA 350-Hi or equal and Teeth & tips shall be made out of Manganese steel. (IS: 276,
GR-I).

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 16 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

03.03.023. Bucket wheel shall be connected to the drive shaft by alloy-steel shrink disc connection to
withstand high torque during reclaiming operation. The drive shaft shall be a forging and shall
be ultrasonically tested before machining to certify that it is free from flaws.
03.03.024. Bucket shall be attached to the bucket wheel body by means of pins, or similar connections, to
permit convenient removal and replacement. An automatic lubrication system shall be provided
for all principal points on bucket wheel assembly. Access for inspection, maintenance and
replacement of all components of the bucket wheel drive shall be provided.
03.03.025. Adequate safety devices shall be provided to prevent overloading of the bucket wheel drive,

particularly when wheel will get stuck-up in the stockpile. In such an event the power supply of the
drive shall get automatically cut-off. Suitable brake (if applicable) shall be provided to avoid backward
movement of the bucket wheel after the power supply is cut-off and during maintenance work.
03.03.026. The turn table shall be adequately designed to support the boom conveyor and its drive
machinery, boom hoisting machinery, operator’s cabin and counterweight etc. Minimum life of
slew bearing shall be 50000 hrs. Safety devices shall be provided to prevent excessively large
lateral forces such as might arise when slewing against stockpile slopes or any fixed structure
or surface.
03.03.027. Slewing drive shall comprise two independent, separate drive units, driving pinions meshing
with a ring gear, slewing motion shall be infinitely variable in both directions between 0-100%
nominal speed. This shall be accomplished with hydraulic motors. Acceleration/ deceleration of
slewing drive operation shall be field adjustable. Radial piston-eccentric shaft type motor with
planetary gearbox shall be provided.
03.03.028. Hydraulic drives shall include automatic compensation for loads arising out of worst possible pile
cutting loads by the reclaiming bucket wheel.
03.03.029. Torque limiting devices shall be incorporated in all drives. These shall be achieved by hydraulic
overload circuits. Remote indication of drive overload shall be included.
03.03.030. The ring gear shall be an integrated part of the slewing bearing on the portal (or lower ring
beam). The gear ring and pinions shall be fully enclosed to prevent the ingress of dust, moisture
and other contaminants.
03.03.031. The tripper shall be complete with supporting structure, walkways, platforms, railing, belt scrapper,

head pulleys, bend pulleys, hold-down pulley, guide roller, chute and support with adequate number
of wheels in bogie construction travelling on the same rails as those of the stacker-cum-reclaimer.
03.03.032. Electrical items such as MCC, transformer with Electrical Protection system etc. shall be housed
in an Electric House located on Tripper structure and it shall be provided with vent fan suitable
for 18 air changes per hour. Cable reeling drum shall be located beside above Electric house
suitably.
03.03.033. Further, limit switches shall be provided to prevent traverse movement, slew and hoisting
etc. beyond the respective safe extremities. Interlocking shall also be provided for S/R rail
clamps and travel motors.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 17 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

03.03.034. Yard conveyor can be stopped from control panel of stacker / reclaimer. Provision also be
given to trip the stacker/ reclaimer from CHP control room.
03.03.035. Travel drive equipment and slew drive equipment shall be suitable for 150 starts/hr with
continuous reversals.
03.03.036. Speed control of long travel and slew drive motor (in case of electric drive) shall be through
Variable Voltage Variable Frequency System (VVVF) with minimum 6 (six) pulse design.
Necessary input & output devices to be provided to reduce harmonics, as per IEE 519. All
necessary protections e.g. Input Phase Loss, Earth Fault, Over Voltage, Output Short Circuit,
Load Loss, Input Transient Protection, Overload etc to be provided. VVVF system shall be
capable of generating suitable starting torque with/without encoder. Squirrel cage Induction
motor with VPI insulation shall be provided with VVVF system.
03.03.037. Hydraulic control shall be provided for Hoisting/luffing, Operator cabin level adjustment and Equalizing

arrangement for travel carriage (in case of hydraulic equalizing).

03.03.038. Axial piston pumps shall be provided for pressurising hydraulic control fluid.
03.03.039. Further for selection and specification of various individual equipment, relevant clauses of
specification shall be referred to UPRVUNL NIT Vol-III, Chapter-19 Coal Handling System.
03.03.040. The supplier shall furnish the detailed basis of design (BOD) used for design of the structural
components of the stacker reclaimer. The BOD shall be comprehensive & shall account for the
various technical requirements of the specification & should include all parameters,
assumptions, structural codes adopted, loading conditions and design software used. The
supplier shall also furnish the basis and computer printout of input and output data of
calculations of foundation loads. Manufacture of the stacker reclaimer shall be taken up by the
supplier, only after approval of the basis of design (BOD) by UPRVUNL/uprvunl’s consultant (NTPC &

DCPL)/BHEL.
03.03.041. Should the stacker reclaimer under go any structural distress/ failure during operation or in the

anchored condition during the plant life of 30 years, apart from meeting the other contractual
requirements specified elsewhere, the supplier shall have to furnish, to UPRVUNL/BHEL, the complete
structural design document / calculations, pertaining to the equipment.
03.03.042. Boom or entire machine shall be anchored with ground preferably at parking zone. Provision shall be

kept to lock the slewing part of the machine with fixed part while the machine is not operating so that
there is absolutely no movement of boom in any direction. Suitable RCC platform to be provided at one
end of travel of the stacker cum reclaimer to rest the head end of the boom while either under
maintenance or out of operation. Walkways with hand railings shall be provided on both sides of boom
conveyor. The upper structure shall consist of rigid box type steel plate construction on which the
super-structure supporting mast, boom with bucket wheel and counterweight boom with ballast are

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 18 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

erected. The upper works shall be mounted on under-carriage by means of large diameter ring bearing
of double roll roller type.
03.03.043. Control cabin shall be of modern & ergonomically designed unit with ample glassed area for
optimum visibility of the working area and shall be located near the bucket wheel. Cabin shall
be of closed type and shall be dust & water proof having adequate number of shatter proof &
tinted glass doors and windows ensuring good all round visibility to the operator and shall remain
horizontal always regardless of boom inclination. It shall have heat insulated walls and roof.
Clear height within the cabin shall not be less than 2200 mm and the area enough to install
Control Console, annunciation panel etc. & provided with ergonomically designed 360 deg.
swivelling operator’s seat. Cabin floor shall skid proof surface. Alarm units, indicators etc. shall
be contained in an annunciator fitted at about eye level to enable the operator to simultaneously
watch operation of the machine and the control indicators and alarm. In addition, the
instruments which are particularly important for proper operation of the machine and have
therefore to be continuously watched shall be located laterally in the cabin on an instrument
pillar. Cabin shall be provided with adequate illumination for working in night, sun visors and
window wipers with wash unit and a swivelling fan of adequate sweep, hydraulic door closer &
an approved type of security lock.
03.03.044. Noise and vibration level within the cabin shall be limited to such level as to ensure operator’s
comfort and safe and unhampered functioning of all sensitive instruments located within the
cabin.
03.03.045. Two (2) Co2 type 4.5 kg fire extinguisher (IS: 2878) one located inside cabin and the other
mounted on outside of cabin shall be provided.
03.03.046. Equipment installed inside the operator’s cabin shall include, but not be limited to the following:
Light fitting with dimmers, Minimum 2 No. General Purpose Outlet (GPO) suitable for 240V x 5A
x 1ph A.C. Supply, Minimum 2 No. General Purpose Outlet (GPO) suitable for 240V x 15A x 1ph
A.C. Supply, Telephone – 1 No., Fold down jump seat on the back wall to allow for an instructor,
Battery operated mains charged Emergency Lighting., Handset station for Public Address – 1
no.
Equipment installed outside the cabin shall include: Electrically amplified weatherproof
loudhailer, Emergency lighting head(s), powered by inside (cabin) located power unit.

03.03.047. Stacker-Reclaimer machine shall be designed to operate in equal load sharing mode between slew gear

boxes provided in order to avoid unequal load sharing mode. Suitable electrical interlock to be provided
for the drive units of slew gear boxes, such that in case of any unequal load sharing, the drive units shall
trip immediately.
03.03.048. Belt Scale shall be electronic and micro-processor based suitable for outdoor installation and
designed for continuous duty under all operating conditions. The guaranteed accuracy shall be
±1% over full weighing range (20% and 130%). It shall cater for all including peak handling
rates.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 19 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

03.03.049. The Belt Scale shall have a local control panel/cabinet complete with flow rate indicator,
totaliser, and automatic calibration system. The rate indicator shall be outdoor type or shall be
provided with proper enclosure with transparent cover for viewing. The test load shall be
supplied with the Belt Scale for calibration. Control panel shall have interfacing with operator’s
control room PLC for sequence interlocking, indication of status, fault indications and flow rate
& totaliser values etc.
03.03.050. Air conditioning system shall be furnished for S/R, operator’s cabin & E-house in Stacker Reclaimer,

Inter locking of yard conveyor with stacker-cum-reclaimer boom conveyor shall be provided.
03.03.051. For Electric House cum Machinery Room, an all steel construction and weather proof
enclosed space shall be provided on the equipment to house the HT Load break switch panel,
motor control centre, programmable logic controller, thrustor panels, lighting distribution board,
etc. The structure shall be lined with anti-condensation and fireproof material. It shall be
provided with propeller type Vent fan. Dust tight seals shall be provided for all doors, windows
and electric cable entry points. The room shall be of adequate size to ensure good access to all
equipment for maintenance or disassembly. Rubber insulating carpet in front of Electrical Panels
shall be provided. All cable entries to electrical room shall be sealed with fire resistant
compound. Smoke and fire detection system shall be provided including alarm in operator's
cabin. A maintenance electric hoist with monorail (Minimum 5t capacity) for lifting
components from ground level shall be provided. The hoist shall have sufficient capacity to lift
the heaviest single piece of equipment in the machinery house. All equipment shall be accessible
by the hoist. Hoisting speed in fully loaded condition shall not be less than 4 m/min.
03.03.052. Door at room shall be provided with heavy-duty latches, hinges, door stop and pad lock. The
following accessories shall be provided in the room at convenient locations:
a. Fire extinguishers CO2, 4.5kg (IS: 2878): 2 Nos.
b. Telephone - 1 No.
c. Handset station for PA system - 1 no.
d. Battery operated emergency light - 1 Nos.
e. One (1) Socket Outlet, 240V x 15A x 1 Ph A.C. supply.
f. One (1) Socket Outlet, 415V x 100A x 3 Ph A.C. supply.
03.03.053. For Safety Requirements Against Drifting bidder has to provide minimum Two (2) Manual
Rail clamps & minimum four (4) automatic rail clamps of adequate clamping force shall be fitted
to prevent the machine from drifting in non-operating/ stormy condition. The automatic rail
clamps shall be interlocked with long travel drive. For safety of the equipment, indicating lamps
shall be provided to know whether the equipment is locked or not and the machine should not
start unless the clamps are released. Operation of automatic rail clamp shall be controlled by
anemometer provided on the machine.
03.03.054. Over-Travelling Switches and End Buffers: Set of over travelling limit switches and end
buffers at both ends of travel zone shall be provided to prevent possibility of overrunning of the

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 20 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

machine. End buffers on long travel bogies and buffers at rail stop shall be provided for arresting
the motion in case of failure of the safety system.
03.03.055. Limit Switch for Hoisting/ Luffing shall be provided to restrict the luffing range from
maximum inclination to maximum declination.
03.03.056. Probe Switch: Probe sensors shall be provided at the boom part of the boom head end to
prevent the boom touching and consequential burial of head end into stockpile material, by
providing signal to luff - up the boom as the pile height increases with more discharge of material
into the pile.
03.03.057. Safety Switches: Belt sway switches, pull cord switches and zero speed switch on boom belt
conveyor & yard belt shall be provided.
03.03.058. Anemometer shall be installed on top most part of the machine to give the signal/ indication
of non-operating condition of the machine and stop all operations of the machine in case of high
wind velocity.
03.03.059. 3-D stockpile volume/ Qty measurement system shall be provided for stockpile
suitably.
03.03.060. Wheel Dia. shall be min (min.) 630 mm (Tread dia.) and stability Factor (min.) shall be 1.3, for
operating condition with max. operating wind velocity & 1.2, for non-operating condition with
max. non-operating wind velocity.
03.03.061. Supply of tools and tackles, which may be required during erection other than specified in
Vol III, chapter-19 of Coal Handing System shall be in the scope of bidder’s.
03.03.062. Guide rollers to be provided at before start of S/R tripper inclined flight in yard conveyor
as per the sketch shown below.

03.03.063. Return Idlers shall be single roll.

03.03.064. Fire resistant fibre grating/ steel grating for walk ways on stacker reclaimer and trippers to
be provided to reduce weight.
03.03.065. A common piping system for water for dust suppression and wash down facility with water
hose (at suitable location) shall be provided on machine. Suitable motorized hose reel drum
mounted on machine shall be provided. Water supply will come from a supply pipeline along
machine long travel path. This pipeline will be equipped with several quick connect tap points
and will be fed with water from nearby pump house. Locations of Dust Suppression Nozzles
(Dry Fog Type) shall be provided but not be limited to the following:
• Tripper’s discharge point
• Boom conveyor receipt point
• Boom conveyor’s discharge point to stockpile
• Boom conveyor receipt point (Bucket wheel side)

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 21 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

• Boom conveyor discharge point & yard conveyor receipt point

03.03.066. The bidder shall clearly indicate in his proposal the maximum quantity of water and pressure required

by him. Machine mounted compressor shall be installed over the machine in bidder’s scope.
03.03.067. Loading point: Impact idlers shall be provided in uncrushed coal zone only. In crushed coal
zone normal carrying idlers with 400mm spacing (min. 6 nos.) shall be provided.
03.03.068. In the inspection doors & chute plate jointing area joints area to be provided with MS round
or strip to give a labyrinth effect. Inspection doors to be provided with hinge.

03.04.00 Scope of work

03.04.01 For system description and scope of work and service bidder to consider Customer NIT specification
including all amendments and post bid resolutions attached in annexure-3 & 4. All the annexure are
the part of this enquiry specification.
03.04.02 Bidder also to follow Plot Plan, Design Memorandum, Conveyor gallery cross section, flow diagram,
and conveyor profile prepared by BHEL and attached in annexure-5 of this enquiry specification.
03.04.03 Bidder’s scope for CHP starts from wagon tippler, conveyor system with all necessary supporting
structures, SCR, skirt board, all frame work etc to bunker feeding.
03.04.04 Bidder’s scope for LHP starts from reclaiming of limestone and feeding into silo after crushing of
limestone including necessary sealing arrangement at silo. For GHP, it starts from outlet of vacuum
belt filter to discharge of gypsum at Gypsum shed. Chute below vacuum belt feeder floor shall be in
the bidder’s scope of supply. Complete Dust extraction system, Ventilation of CHP, LHP and GHP are
in bidder’s scope.
03.04.05 Civil & Structural works of all WT Houses, Trestles, Galleries, TPs, Crusher Houses, S/R foundation,
Drive House, MCC Buildings, Pump/compressor house, tunnels, are excluded from bidder scope.
However, all mechanical work with necessary support structures are in bidder's scope. Also bidder
shall prepare and furnish their mechanical GA drgs., civil assignment drgs./ load data drgs. indicating
sizes, equipment load details etc. and other input and do the grouting of equipments, minor chipping
as mentioned above scope.
03.04.06 Power requirement and belt tensions for belt conveying system shall be designed based on CEMA -
5th edition and Minimum value of Ky to be considered shall not be less than 0.025.
03.04.07 Electrical and C&I scope of work will be as per Annexure-2. Electrical load details shall be furnished
within one month from date of LOI.
03.04.08 Min. 5T electrical hoist to be provided in dozer shed.
03.04.09 Suitable hold back devices for preventing running back of the conveyor belt for all inclined conveyor
in case of conveyor being stopped in loaded conditions due to power failure or during normal
operational delays shall be provided to give positive protection. It shall be released instantly when
‘power’ resumes or the ‘delay’ is removed. The hold-back devices shall be integral gear drive.
03.04.10 Inspection & maintenance platform/ladder/stool piece required for CHP, LHP & GHP equipments like
CSU equipments, skirt boards, pulley frames etc shall be provided by bidder.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 22 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

03.01.10 Supply of rails, fixture including bolt and rail fixing accessories for entire stacker cum reclaimer travel
region shall be in bidder’s scope. bidder to select the travel length considering the space required for
parking of the machine. Supply and erection of counter weight shall be in bidder’s scope. Laying of
rail shall be in bidder’s scope, only foundation bolt fixing shall be done by BHEL civil contractor and
same shall be supervised jointly by BHEL engineer & bidder.

03.04.11 Dust & debris chute shall be designed by bidder for all junction towers and crusher house. Opening
shall be provided in all working floors. The chute shall be shall be terminated outside the building
about 1 meter above the ground.
03.04.12 All the structural work for HGTU shall be bidders’ scope for CHP, LHP & GHP.
03.04.13 Bidder shall provide VGTU consisting of cage ladder, platform, guards, guide post, maintenance
platform (if any) for entire CHP, LHP & GHP shall be in bidder's scope.
03.04.14 Supply & Erection of monorail will be in BHEL scope in all Buildings excluding bunker. Supply & Erection
of monorail in bunker shall be done by bidder. All necessary chain pulley block hook supply and fixing
are in bidder’s scope. Test weight for load testing at site for hoists shall be arranged by bidder.
03.04.15 Complete dust extraction system is included in bidder’s scope as per customer/specification and flow
diagram. Compressor with 100% standby and air receivers as required for DE system/ ventilation
system shall be in bidder’s scope.
03.04.16 Ventilation system shall be provided for underground portion of Transfer points, Wagon Tippler,
Reclaim Hopper, Conveyor Tunnels, bulldozer shed and also for CHP Control Rooms, various MCC and
Switchgear Rooms, Battery room, Cable spreader room, Pump House, Toilets, etc. Bidder has to
follow respective customer technical specification for ventilation system for technical details. Axial
flow fans are to be provided in CHP area toilets, Pantry including coal control rooms, MCC rooms and
other buildings.
03.04.17 Air conditioning system for CHP, LHP & GHP areas are included in bidder’s scope. Necessary sizing
calculation shall be provided by bidder. Wagon Tipplers MCC and other areas as specified in
specification, Vol-III Chapter-19 and FGD specification of UPRVUNL tender spec, shall be provided with
air conditioner.

03.04.01 Air conditioning also to be provided in part of Control Cabin, WT control room, SCR MCC room &
operator cabin, MCC room / Cubicles housing Programmable Logic Controllers, (PLC) Panels and other
Input / Output (I/O) modules. It should be provided in LS Sampling Unit/CSU control room also.
03.04.02 Any other area required for Air conditioning and if as per manufacturer’s requirement any Switchgear
room requires Air conditioning, the same shall be provided by the bidder.
03.04.03 Tramp iron collecting bin shall be provided in ground floor for each tramp iron chutes of suitable size.
03.04.04 The construction of store (open and close) shall be in bidder’s scope. Bidder also has to consider
proper storing of BHEL supplied HT motors and other items in their scope of unloading, storing, in-
plant transportation, E&C as per scope of work.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 23 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

03.05.00 Bidder should indicate training charges of “Operation and Maintenance” to UPRVUNL person for
six(6) months, after handing over the CHP/LHP/GHP package.
03.06.00 Bidder should indicate “Operation & Maintenance charges” per shift in their offer for total 300 shift.
O&M will become effective/ operative only after the successful commissioning of conveyor Package,
if felt necessary by BHEL. The O&M Charges are payable only with certification by BHEL’s Resident
manager. The payment will be done on actual usage on monthly basis as per contract. The quoted rate
shall be valid for a period of 2 Years after commissioning / Handing Over. (Please refer O&M scope &
manpower details described in this specification, Clause No-7.00.00)

04.00.00 ADDITIONAL NOTES FOR CHP PACKAGE (MECHANICAL SCOPE OF WORK)

General Notes:
04.01.00 The length of conveyors shall be generally as per the latest Plot plan furnished to bidder with the
enquiry specification. These are indicative and for the guidance of the bidders. The same shall be
improved upon by Bidder during detailed engineering. There shall not be any price implication for any
variation in the upto ±1% of total length and any lift of the conveyors during detailed engineering.
04.02.00 In case of any ambiguity, conflict in the standard & specification and/or interpretation of clauses in
this enquiry spec. and its enclosures the decision of BHEL shall be final and binding and any change
due to this shall have no price implication on BHEL and shall have to be absorbed by successful bidder.
04.03.00 Bidder shall strictly follow and adhere to the guidelines laid down in the enclosed BHEL’s health, safety
and Environment manual.
04.04.00 Bidder shall visit the Site to familiarize with the CHP, LHP & GHP and site constraints before submitting
the complete offer to BHEL in all respects. No issues arising out of site condition or layout constraints
shall be entertained later on during detail engineering and any modification required due to site
condition or layout constraints shall be done by successful bidder without any cost implication to
BHEL.
04.05.00 Preparation of GA drawings for the complete coal handling system, Limestone handling system and
Gypsum Handling system are included in BHEL’s scope as per UPRVUNL mechanical/electrical/civil
NIT specification. Bidder shall review the BHEL drawing, the civil assignments drawings indicating all
the load data insert details, openings etc. Bidder shall ensure the correctness of civil assignment drgs
which shall be an input for BHEL’s civil design agency & structural design package bidder. Any issues
like cutting/chipping of floors, beams shall not be permitted. Any additional civil works arising if
missed out things in civil assignment drg reviewed by the bidder like pedestal, foundation etc. shall
have to be taken care by package bidders without any cost implication to BHEL and engaging its own
resources.
04.06.00 Construction work approval and necessary certificate for building and other construction workers shall
be obtained from factory inspector/the Govt. Agencies by bidder. UPRVUNL/BHEL will assist for
obtaining such certificate.
04.07.00 Bidder shall engage a qualified civil engineer with min 3 year site experience to supervise the correct
implementation of their civil assignment drgs. prepared for their machines and correctness of civil and
structural works at site in order to suit the civil & structural works for equipment erection as civil works

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 24 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

to be done by BHEL’s civil and structural contactor at site during construction (i.e. pedestal casting,
footings, cutouts, pockets, gallery alignment, survey etc.) so that no issues like misalignment, run out
of pockets foundations arises, also a joint protocol to be prepared for record. Later on, no claims from
bidder shall be entertained that civil pedestal casting, footings, cutouts, pockets etc are not in order
or not as per their drg. and if it exist then these shall be rectified by the bidder at their own cost and
any delay on account of this shall be attributable to respective package bidders.
04.08.00 Supply of grouting cement (GP-2) and grouting of all mechanical equipment/items and its drives base
shall be in the respective bidder’s scope. BHEL’s civil contractors shall provide only the foundation
pockets for pedestals (wherever necessary) as per mech. GA drgs reviewed & submitted by the bidder.
Pocket filling concrete shall be in bidder’s scope.
04.09.00 Bidder shall depute continuously and maintain & depute following minimum nos. of engineers and
supervisors, not limited to nos., at site for supervision of E&C, coordination and commercial activity
for the package.
(a) Resident Manager- 1no.
(b) Mech. Engineer (min 2 yrs. site exp.) or mech. Supervisor (min 5 yrs. exp.)- 2 nos
(c) Civil & structural Engineer (min 3 yrs. site exp.)- 1 no. for their roll mentioned above
(d) Elect. Engineer (min 2 yrs. site exp.) or Elect. Supervisor (min 5 yrs. exp.)-1 no.
(e) Non-engineer- 1no. for Storekeeper and 1 no commercial activity.
(f) Qualified Safety officer – 1 No
(g) Office boy -01 No
In case Bidder fails to maintain the above minimum manpower /site staff at site till project
completion, suitable pro-rata deductions shall be made from RAB payables, for the duration of such
absences, at the prevailing rate of BHEL manpower cost as penalty at the sole discretion of BHEL whose
decision shall be final and binding.
04.10.00 Minor chipping i.e. up to 50mm thk, micro leveling, and providing shim plates for erection of machines
equipment / items shall be in the scope of bidder.
04.10.01 Stools supply and fixing by conveyor vendor.
04.10.02 Maintenance platforms supply & erection.
04.10.03 All consumables are in vendor scope.
04.10.04 Final painting of equipment’s after erection is in vendor scope.

04.10.05 Minor civil chipping i.e. exposing the inserts, fixing of Anchor fasters, wherever required shall be in
Vendor scope.
04.10.06 Statutory clearance for electrical items is in vendor scope.
04.10.07 Vendor to ensure all statutory requirement at site like labor license, minimum wages, PF, ESI etc as
Per local rules.
04.11.00 Bidder shall be responsible for commissioning of complete coal conveyor system, Limestone conveyor
system & Gypsum conveyor system, demonstration of performance guarantee parameters of
individual equipments as laid down elsewhere in the specification and support to BHEL’s other vendor
for integration with Main CHP machines and commissioning of the complete CHP, LHP & GHP after
integration with the machines and other CHP, LHP & GHP system. Equipments / systems offered by
the bidder shall not be accepted for final handover till the demonstration of performance guarantee

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 25 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

parameters of the equipments / systems and in case any changes required in conveyor package to
match the overall CHP, LHP & GHP system PG test parameters without affecting other associated
system shall have to be done by the bidder without any cost implication to BHEL. All necessary tools
and tackles for PG test shall be in bidder scope.
04.12.00 Bidder shall submit the weekly engineering progress reports in BHEL’s format and depute full project
team for attending all project review meetings called by BHEL and UPRVUNL ( or their consultant)
without fail.
04.13.00 Vendors proposed or considered by bidder shall be subject to approval of UPRVUNL/BHEL.
04.14.00 Bidder to note that time is the essence of this contract, thus they shall submit the submission schedule
for the list of drgs indicated in this document in no. of days from zero date i.e. LOI date. No delay shall
be entertained later on.
04.15.00 Bidder shall furnish the L-2 project schedule for complete project indicating various milestones and
constraints along with the bid. Each successful bidder shall furnish the L-3 project schedule in line with
the L-2 schedule after award of the contract. Dates of submission of GA drawings and corresponding
civil assignment drawings shall be indicated. Requirement of fronts from BHEL for starting the erection
activities shall be indicated for achieving the commissioning date.
04.16.00 Bidder shall make their own arrangements well in advance for heavy erection equipments like bigger
cranes, hydra, winch etc that are required for erection of equipments which are at higher height. List
of minimum handling facilities, tools and tackles required at site during erection shall be as mentioned
below. For any reason, such facilities are not available, BHEL has the right to arrange the same from
other agencies/Customer on hire basis as per the agencies norms and the same shall be recovered /
adjusted contractor’s subsequent running bill.
(1) 75/100 Tons crawling crane (02 nos), Hydraulic type mobile crane-01 nos,
(2) Trailer-02 nos,
(3) 03/05/10 Ton capacity winches in good working condition 1 no each.
(4) 10 nos. Other handling equipment like chain pulley blocks etc.

04.17.00 Bidder shall consider mandatory spares (Mechanical, Electrical and C&I) for three (03) years
operation and maintenance of all the machines in their scope as mentioned in specification till handing
over to customer.
04.18.00 Receipt & unloading at site, local transportation, storage, preservation & security by authorized
security agency, shifting to erection work place, E&C of all free issue items to vendor shall be in
bidder’s scope.
04.19.00 All Material of construction for all equipment shall be subject to UPRVUNL (Its consultant) /BHEL
approval during detail engineering.
04.20.00 Consumables like lubricants; oils etc for initial fill, flushing, cleaning, refill and topping up to for a
period of six (6) months from the date of handing over of CHP, LHP & FGD. Special tools and tackles,
as required, commissioning spare parts, Supply & application of rust preventive & paints at shop floor
and at site after erection as applicable for the equipment /system shall be in the scope of respective
package bidders.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 26 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

04.21.00 Provision of any temporary supports/platforms required for E& C of mech. Equipment /items including
structural material shall be in the scope of bidder.
04.22.00 All the foundation bolts, hardware, fasteners, gaskets, flushing and first filling of oils, lubricants, cables
etc required quantity to be supplied by the bidder.
04.23.00 Necessary provisions shall be considered in the equipment/ items/ systems which are in other bidder’s
scope for integrating with other equipments/ systems/ items which are part of other contractor’s
scope.
04.24.00 The coal flow diagram, Limestone Flow diagram, Gypsum flow diagram and Plot plan attached with
enclosed in this specification are indicative only and doesn’t show comprehensive scope of work and
actual things may vary during detail engineering.
04.25.00 Bidder shall strictly adhere and follow the erection & commissioning terms and conditions as
mentioned in the UPRVUNL tender specification.
04.26.00 All Coupling guards shall be in the scope of bidder’s scope.
04.27.00 During detail engineering of this package bidder shall strictly adhere to BHEL/UPRVUNNL drawing
Formats, document numbering, QP &FQP formats.
04.28.00 Painting of all the Equipment shall be as per customer Specification mentioned in general technical
requirement vol-II (Book 1 of 2), Chapter-7.0 & Vol-III, chapter 19.
04.29.00 Rust preventive after inspection at shop floor before dispatch shall be in bidder’s scope. Touch up
Painting at site after erection shall be in the scope of bidder and price of same shall be deemed to be
included with the installation services.
04.30.00 The design, manufacture, inspection and testing of the equipments shall comply with all the currently
applicable statutes, regulations and safety codes in the locality where the equipment is to be installed
and shall also confirm to the latest edition of Indian and other international standards and codes.
Nothing in this specification shall be construed to relive the contractor of the required statutory
responsibility. In case of any conflict & ambiguity in the standard to be followed the decision of the
customer shall be final and binding.

04.31.00 Construction Power: Facilities shall be provided at one location on chargeable basis based on
prevailing commercial rates of DISCOM. Bidder to make his own arrangements to take it to
his working location.
04.32.00 The Customer shall not be responsible for any inconvenience or delay caused due to interruption in
power supply and no compensation for such failure or delay in works on this account can be claimed
by the bidder.
04.33.00 The Bidder shall make its own arrangement for alternative source of power supply through
deployment of adequate number of DG Sets. (Bidder shall arrange for back-up DG set (without any
extra cost to owner) for meeting any eventuality during construction).
04.34.00 ELCB‘s (Earth Leak Circuit Breakers) at all electrical distribution points to be provided and all the
electrical appliances shall be connected to them.
04.35.00 Note:

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 27 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

04.35.01 Bidder to note that list above is not exhaustive and any work required completing the system and
ensuring its satisfactory running shall also be in the scope of this package bidder.
04.35.02 Bidder to note that no deviation shall be acceptable to BHEL (pre-bid, bid and post bid) from UPRVUNL
NIT specification, BHEL enquiry specification and corrigendum until and unless written approval from
BHEL. All the technical parameters & data shall be as per the technical enquiry specification. Wherever
specification of particular item/equipment/system, material of construction etc. is not explicitly
mentioned in the enquiry, it shall be subject to approval of BHEL/Customer/Customer Consultant
during detail engineering and if same is found to be different from what bidder considered in his offer,
it has to be absorbed & offered by bidder, without any cost implication to BHEL.
04.35.03 All the data/ ratings/ design information / scope of supply, services & works is furnished by BIDDER in
their offer shall be indicative only and the same shall be subjected to approval by
Customer/Customer's Consultant/ BHEL during detail engineering with respect to technical enquiry
specifications, Customer Specifications, corrigendum's issued & latest applicable international
standards and the bidder shall supply the items accordingly without any price implications to BHEL.
04.35.04 Bidder shall submit the signed and stamped copy of all the pages which constitutes this technical
enquiry specification signed by authorized signatory and clearly mentioning each clause under
following two categories to avoid any ambiguity in scope understanding & the scope division as a
technical offer during bidding.

a. “accepted without deviation and considered in scope of work”

b. “Not considered in scope of work”.

05.00.00 ERECTION, COMMISSIONING AND SUPERVISION

05.01.00 Vendor shall engage qualified Engineers/ supervisors with relevant site experience to supervise &
cross-check the correctness/ compatibility of civil & structural works w.r.t E&C of Mechanical systems/
Equipment’s, correct implementation of their civil assignment drgs. prepared by the BHEL/ BHEL’s
other vendor for the civil works, for their equipment erection at site during construction (i.e. pedestal
casting, footings, cutouts, pockets, gallery alignment, survey etc.), so that no issues like misalignment,
run out of pockets foundations arises, also a joint protocol to be prepared for record.
(1) For supervision of Erection & Commissioning, trial run & PG test, handover, Bidder shall depute
and maintain minimum two graduate engineers (consists of Mechanical & Electrical) in addition
to Site-in-charge and one diploma engineers having requisite relevant experience till handing over
of the systems to the customer, as per project requirement & progress.
(2) Bidder shall depute required manpower for Stores management including one Stores supervisor
& security round the clock.
(3) At least one number qualified graduates for site commercial coordination shall be made available
at site for utilizing their services by BHEL, if not complied BHEL will engage directly and recover
monthly charges as per commercial part of the enquiry specification.
The same shall be increased as per requirement at site during full-fledged erection. In case of any
additional manpower required, bidder shall arrange the same for smooth E&C activities.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 28 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

Vendor to ensure sufficient manpower throughout the project for parallel engineering, erection and
commissioning activities on all equipment’s, systems etc. Bidder shall depute continuously and
maintain minimum no of engineers and supervisors at site for supervision of E&C, coordination and
commercial activity for the package.
Bidder has to give their organization chart for the site activities along with the offer.
NOTE:
In case Vendor fails to maintain the minimum manpower /site staff at site till project completion,
suitable pro-rata deductions as per BHEL prevailing rates, shall be recovered from the vendor.
05.02.00 Open & Closed Storage Yard and Preservation for main supply material & mandatory spares
(Bidder’s scope):
05.02.01 Prepare and submit the “Dispatch & Receipt Reconciliation Report
05.02.02 Make periodic condition checks for the safety of boxes/items during storage of main material,
mandatory spares etc.
05.02.03 Maintain requisite inventory records.
05.02.04 Bidder has to keep the material properly as per storage WI. In case bidder fails to adhere the WI and
any consequential damage/missing items due to non-adherence of storage WI, No insurance claim
can be entertained by BHEL and items shall be replaced by vendor without cost implication to BHEL.
05.02.05 Monthly inspection report to be submitted by successful bidder to BHEL site-in charge / Resident
Manager for storage and preservation of materials kept under closed / open stores as part of RAB. In
case bidder fails to report the status in anyone of the month, further any damages reported in the
subsequent month will not be entertained by BHEL and entire item has to be supplied by bidder at
their own cost. No insurance claim shall be entertained.
05.02.06 Bidder has to report the damage/theft/fire, etc to Resident Manager immediately, BHEL-ISG
immediately along with detailed incident report, Joint inspection report by bidder/BHEL, photograph,
copy of invoice with received seal, etc to report to insurance agency within a week time of incident
followed by FIR. If, bidder fails to produce the document in the stipulated time as mentioned above,
BHEL will not entertain for any insurance claim and entire items are to be supplied by bidder without
additional cost to BHEL.
05.02.07 Bidder to include in their package design & construction of 1 no. semi- permanent store shed for
storing his items/ equipments as per his scope of work. The closed store should have brick wall side
covering, GI sheet roof covering & rolling shutters & windows as per BHEL’s approval. Bidder shall
ensure that the size of the closed storage shed is capable of storing heavy equipments required for
this package and shall be suitable for movement of hydra.
05.02.08 Bidder to include in their package open storage yard suitable for storing package items and BHEL free
issue items if any. Bidder has to do open yard preparation and consolidation of subgrade with power
road roller of 8 to 12 MT capacity after excavating earth to an average of 15 cm depth, dressing to
camber and consolidating with road roller including making good the undulations etc. and re-rolling
the sub grade and disposal of surplus earth and leveled with required fencing and provide security
from authorized security agency at stores (round the clock). Required concrete sleepers for keeping
the equipment & tarpaulin cover to be arranged for outdoor storage of outdoor equipments shall be
arranged by bidder.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 29 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

05.03.00 GENERAL REQUIREMENTS OF E&C

05.03.01 Bidder to note that fronts during erection may be given progressively in a staggered manner. So,
Bidder has to consider and envisage mobilization of all resources required, including manpower, in a
shortest possible time during execution time. For this bidder has to consider advance resource
planning so that erection by the successful bidder is not delayed.
05.03.02 Painting of all equipments/ items which are in bidder’s scope at site after erection & commissioning
as per painting schedule provided by customer in general technical requirement vol-II, Chapter 7.0.
05.03.03 Bidder should strictly adhere to the BHEL’s HSE manual and comply with these norms during site
erection and commissioning.
05.03.04 Bidder shall furnish details of Foundation and grouting for machines/ equipments included in this
package including BHEL/BHEL’s other vendor free issued items.
05.03.05 Supply of all insert plates & other embedment in concrete shall be in BHEL’s scope.
Bidder to mention the requirement of the same clearly in their respective GA drgs. before civil drawing
preparation and it will be erected by BHEL/ BHEL’s civil & structural Vendor. If not mentioned in the
respective drg. and if any required later stage same will be in the scope of bidder.
Later on, no claims from bidder shall be entertained that civil pedestal casting, footings, cutouts,
pockets etc are not in order or not as per the mechanical drg. and if it exists then these shall be
rectified by the bidder at their own cost and any delay on account of this shall be attributable to
respective package bidders.
05.03.06 Runner below Conveyor short post will be provided by BHEL.
Interconnections like fixing of stringer post in gallery runner by drilling hole, gas cutting & notches,
nut & bolt or by welding shall be in bidder’s scope of work.
05.03.07 Supply of support arrangement structure for gates, actuators & chutes in all junction towers, &
Crusher houses shall be in the scope of bidder.
05.03.08 Supply and Fixing Foundation/ anchor bolts for base plates of all conveyors & other equipments (for
steel to steel and for steel to concrete) including other necessary items shall be in bidder’s scope.
05.03.09 Supply of base frame and fixing foundation bolts for all mech. Equipment / items, other related
electrical equipments and motors (including BHEL supplied HT motor) shall be in bidder’s scope.
05.03.10 Breaking of wall/ brick cladding and re-doing it for laying conveyor belt for underground tunnel portion
shall be in bidder’s scope.
05.03.11 Design, Supply, E&C of Ladders, maintenance platforms for inspection of skirt, poke holes etc. and
required supports for the same shall be in bidder scope.
05.03.12 Design, supply, E&C of counter weight for all conveyors shall be in bidder’s scope.
05.03.13 Base frame and fixing/ foundation bolts for all Mechanical Equipments/ items and related electrical
equipments and motors shall be in Bidder’s scope.
05.03.14 Drilling of holes (if any) in the structure of, crusher houses, JT’s, Tunnels etc for erection of drives,
equipments shall be the bidder’s scope.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 30 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

05.03.15 Cleaning of any debris produced by the bidder during E&C shall be done immediately at each front.
The bidder should remove all the technical waste in CHP area after each maintenance and operational
activities to keep the place clean and according to the satisfaction of BHEL Engineer in charge within
3(three) days after completion of work, failing which BHEL will get the cleaning done at the risk and
cost of the bidder.
NOTE:
(1) All steel structures shall be fabricated in factory, transported and erected at site. All structures
shall have bolted field connections.
(2) Please refer attached File for complete Special Conditions for Erection Condition of Contract Vol-
II Chapter-06 from UPRVUNL. Bidder shall strictly adhere to the same and follow the erection &
commissioning terms and conditions as mentioned in the enclosed file.
05.04.00 FACILITIES TO BE PROVIDED BY THE OWNER
05.04.01 Construction Water: Contractor shall make all arrangement himself for the supply of construction
water as well as portable water for labour and other site personal at the work site.
05.04.02 Construction Power: Facilities shall be provided at one location on chargeable basis based on
prevailing commercial rates of DISCOM. Bidder to make his own arrangements to take it to his working
location.
For details erection conditions of contract bidder shall refer UPRVUNL tender Specification for Work
Execution, General Technical & Bid Schedules Vol-II for Erection Condition of Contract and other relevant
section specified elsewhere.

06.00.00 WORK INSTRUCTIONS FOR STORAGE & HANDING OVER OF MANDATORY SPARES
Following work instructions for storage & handing over of mandatory spares shall be complied and
ensured by the bidder:
06.01.00 Spares shall be sent in pre-decided lots in containers/secure boxes. This shall be applicable to both
shop items as well as BOIs.
06.02.00 All boxes/containers are to be distinctly marked in red color with boldly written "S" mark on each face
of the containers
06.03.00 Unless technically not feasible, BBU number should be put on the item(s) in a durable manner
(punching/painting, etc.), so that items can be easily linked with approved BBU for ease of handing over
to customer.
06.04.00 Expiry date for short shelf life items (oils, chemicals, insulation material etc.) should be put on the item
as well as on the packing box.
06.05.00 Storage, safety of boxes/items and maintaining requisite inventory records will be the responsibility of
bidder’s representative at site.
06.06.00 Bidders shall make periodic checks for safety of boxes/items, as the case may be.
For handing over of mandatory spares, getting MRC from customer and physical reconciliation with customer
shall be the joint responsibility of the bidder’s site representative and BHEL’s site representative.

07.00.00 OPERATION AND MAINTENANCE

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 31 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

07.01.00 Scope of Operation & Maintenance (O&M) of the Coal Handling Plant:
07.01.01 The Bidder shall be responsible to carry out the “round the clock trouble free operation” of each
equipment and system under the scope of this package for a period of 300 shifts. Each shift shall be of
8 hrs. The time calculation shall be based on the coal feeding to the bunkers while plant is in operation
and the shift will not be counted when power plant is not in operation.
07.01.02 The O&M shall be done under the overall supervision & responsibility of bidder’s resident manager and
qualified engineers as mentioned elsewhere.
07.01.03 Prior intimation for start of coal firing shall be given to bidder one or two days before. The above stated
300 shifts shall not be continuous and shall be unequally distributed over a span of 18 months from
first coal firing date of the unit. If the equipment is handed over to customer before completion of 300
shifts the bidder will be paid only for the completed shifts on pro-rata basis. The price quoted shall be
valid till the completion of the project.
07.01.04 In addition to O&M of the items supplied by the Bidder, he is also responsible to carry out the operation
and maintenance of free issue supplied items by BHEL (Excluding O&M of Stacker cum Reclaimer
machines, Wagon shifter, Wagon tippler, SAC & apron feeder, however coordination with machine
package vendor for his O&M, is in the scope of the bidder). Maintenance/repair/ replacement of
vendor supplied items and BHEL free issue items supplied to vendor shall be in the scope of the bidder.
However, spare for BHEL free issue items shall be supplied by BHEL.
07.01.05 Bidders to note that all consumables/ tools tackles/ manpower required during the period of O &M,
shall be included in the scope of Bidder and no additional payment will be made by BHEL in this regard.
07.01.06 All other consumables (gasket, rope, diesel, rustoline, waste cloth, lapping paste, jute, emery papers,
welding electrodes, grinding wheel, hacksaw-blade, cutting gas, Electric items like Insulation Tape,
Lugs, Fuses, Push Buttons, Electrical contact cleaner etc.) required shall be in the scope of the bidder.
07.01.07 All tools, tackles, via chain pulley block, pulling & lifting equipment, Trolley, Crane, Hydra, Truck, Trailer,
winch, wire rope, grinding machine, sling, D-shackle, Coupler etc. including precision measuring
instruments, welding machine & single phase portable welding machine that may be essential to
execute the job shall be arranged by the bidder at no extra cost to BHEL. Portable diesel generator
machine will have to be arranged by the bidder for carrying out maintenance job outside the plant.
07.01.08 For electrical job, HT & LT Megger (1 no.), Multimeter (02 nos.), Clamp meter (1 no.), Temperature and
Vibration measuring Instruments, Tester and screw driver set (02 nos.), Spanners/Plyers/Small tools kit
(1 set)/Crimping tools for power and control cables/ cutter (2 nos.)/ wire stripper (2 nos.)/Blower to be
arranged by the bidder at no extra cost to BHEL.
07.01.09 Necessary shifting of materials, spares, equipments etc. from store to work site and unserviceable
materials from work site to store/yard, is to be done by the bidder at their own cost.
07.01.10 The bidder must have adequate resources to undertake routine, preventive maintenance jobs of CHP.
They should have adequate resources to mobilize the site for carrying out three to four jobs
simultaneously without any delay.
07.01.11 Bidder has to compulsorily maintain log book for the O & M staff engaged for O&M jobs and submit to
Engineer in charge for certification for realization of the bills. After certification of the bill by Engineer
in charge of BHEL, bidder shall claim the amount after completion of minimum 100 shifts.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 32 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

07.01.12 Top up of oil/grease/lubricant as required during operation of plant shall be done by the bidder.
07.01.13 Housekeeping: Cleaning of all equipment and housekeeping to be carried out dedicatedly in total Coal
Handling Plant, Limestone handling plant & Gypsum handling plant area and its office premises.
07.01.14 All routine, preventive, predictive and breakdown maintenance of equipments of Coal Handling Plant,
Limestone Handling plant & gypsum handling plant inclusive of BHEL supplied equipments.
07.01.15 Fabrication and erection of platform/extra support for CHP, LHP & GHP area if felt necessary during
operation and maintenance of the plant has to be done by the bidder. Materials like channels, beam,
angle etc as required shall be supplied by bidder.
07.01.16 To maintain the daily Maintenance log book in which details of overhauling / breakdown/maintenance
of any equipment including replacement of spares/components to be recorded. Recording of any
abnormality of equipments, malfunctioning of system of the CHP, LHP & GHP also to be noted in the
Log book and informed to the Engineer-in-charge of BHEL ISG for initiating immediate corrective action
by the vendor.
07.01.17 In case the bidder does not engage required O&M staff with tools/tackles/qualification as specified
in the specification, alternate O& M staff shall be engaged by BHEL at their risk and cost on monthly
basis for a minimum period of 12 months and amount incurred shall be debited from the bidder’s
bills.

07.02.00 One shift for O&M shall be defined as deployment of following labour manpower for 8 working hours:
Sl. No. Manpower Nos. Remarks
1 Engineer (Mech. /Elect.) 1 General shift
2 Mechanical/Electrical Supervisor 1 In each shift
3 Console Operator 1 In each shift
4 Field Operator 1 In each shift
5 Electrician 1 In each shift
7 Technician /Fitter (Mech.) 1 In each shift
8 Rigger Skilled 1 In each shift
9 Helper 1 In each shift

07.03.00 Deployment for O&M shifts at any particular area will be at the sole discretion of BHEL’ resident
manager. Provision for part or pro-rata payment for some portion of O&M shift is allowed at mutual
agreement with the BHEL’s resident manager.
07.04.00 Price quoted for O&M shift shall be applicable uniformly for day as well as night shifts, no separate
price will be given for night shifts. All payment will be made on certification of BHEL’s resident manager.
In case bidder fails to provide O&M services at site till contract completion, suitable pro-rata deductions
shall be made from RAB payables, for the duration of such absence, at the prevailing rate of BHEL
manpower cost as penalty at the sole discretion of BHEL’s resident manager whose decision shall be
final and binding
07.05.00 This O&M provision is over and above the requirement of normal scope of work under installation

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 33 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

services like erection, Pre-Commissioning & commissioning activities, integrated load trial, system
stabilization, Performance Guarantee Tests and Reliability Test Run.
07.06.00 In case the number of O & M shifts gets extended beyond the quantity indicated in the price format, it
will be paid extra on the basis of unit rate agreed in the contract.
Note:
1 The above list is minimum manpower required for O&M. In case additional manpower required for
carrying out O&M, same shall be supplied by the bidder without any extra cost implication to BHEL.
2 The vendor shall take approval from Engineer-in charge of BHEL by submitting organization Chart of O&M
staff for this site clearly indicating man power deployment with their educational background& experience
with supporting documents.
3 EPF provisions for the workers shall be made by the bidder as per rule. Relevant documents regarding EPF
for the workers of the bidder shall be submitted to the concerned authority before commencement of
work.
4 The vendor shall be solely and wholly responsible for safety and security of workers engaged in the job
and the BHEL property. In case of any accident the vendor shall pay proper compensation to the workers
as per workmen’s compensation act and repair/replace BHEL property at their own cost & arrangement.
The bidder shall also make adequate provision of insurance for their workers at their own cost to cover
them against the risk of accident.
5 The vendor and their workers engaged in the job shall follow all safety rules at the time of execution of
work. It shall be responsibility of the bidder to supply all safety equipment as necessary to its O&M staff.
6 The vendor shall comply with all laws, rules & regulations of the land including but not limited to, i) Labour
rules & Acts, ii) Factories Act, iii) Minimum wages Act, IV) Payment of Wages Act, v) Bonus Act, vi) EPF
rules, vii) Contract Labour (Regulation & Abolition)Act as in vogue or comes into vogue from time to time.
BHEL will be kept indemnified against any claim arising out of non-compliance of such Acts/rules.
7 The vendor shall not pay less than minimum wages to the workers under the Minimum Wages Act and the
Govt. rules made there under subject to revision from time to time. The payment will be made to the
workers in presence of the authorized representative of BHEL. The monthly payment is to be made on the
7th day of successive month. The bidder may change the place and time of payment to his workers under
intimation to Engineer in charge of BHEL.
8 BHEL shall not be responsible in matters of employment of workers engaged in the job at any point of
time. The bidder shall be fully responsible for his workers with regard to terms of employment of services.
BHEL shall not be held responsible in any manner, whatsoever, in respect of workers engaged by the
vendor for carrying out the works at site. Regarding engagement of workers’ preference should be given
towards experienced and competent workers with bonafide testimonials.
9 Beyond general shift if any trouble/breakdown occurs in the plant, Maintenance team must reach the
plant without any delay along with Engineer/Site In charge.
10 No Person from the list of manpower shall leave the plant site without prior permission from the Engineer
in charge of BHEL.
11 However, in operation part, if any person is absent, substitute must be given immediately otherwise
proportionate deduction will be made.
12 The replacement / substitute personnel for maintenance, manpower shall have the same educational
qualification and experience.
13 If any additional manpower is required during O&M whatsoever under the scope of contract the same

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 34 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

shall be made available by bidder in time within the cost. To cater the need of time bound maintenance
jobs, the bidder shall depute additional manpower without any cost implication to BHEL.
14 During execution of work if any personnel is found not suitable for the job or his presence inside
powerhouse premises is felt undesirable, the personnel has to be replaced within 15 days.
15 BHEL will not be responsible for payment towards idle labour charges.

07.07.00 Minimum qualification & experience of personnel & manpower required

Sl. Category. Educational Work experience.
No. qualification.
01. Engineer Degree / Diploma in Min. Two (2) years of work experience for
(Mech /Elect.) Mech. & Elect Engg. Degree holders and Min. Five (5) years of work
from a recognized experience for Diploma holders in Coal Handling
University/ college. system (wet & dry) and also having a working
experience in DCS/PLC based Coal handling
system of thermal power plant having unit
capacity not less than 210 MW.
02. Supervisor Diploma in Mech./Elect Min. two (2) years of working experience in Coal
(Mech. Engg. from a recognized Handling system of large thermal power plant of
/Elect.) University. unit capacity not less than 210 MW.

03. Console Degree / Diploma in Min. One (1) year of work experience for Degree
Operator. Mech. & Elect Engg. holders and Min. Three (3) years of work
from a recognized experience in DCS/PLC based Coal handling
University/ college. system of thermal power plant having unit
capacity not less than 210 MW.
04. Field ITI (Mech.)/Elect trade Min. two (2) years of working experience in Coal
Operators. institute certificate from Handling system of large thermal power plant of
recognized institute. unit capacity not less than 210 MW.

05. Technician/ ITI (Mech.) trade Min. two (2) years of working experience in
Fitter(Mech.) institute certificate from industry /Coal Handling system
recognized institute.
06. Rigger ------- Min. two (2) years of working experience in
industry.
07. Welder ------ Min. two (2) years of working experience in
industry.
08. Gas cutter ------ Min. two (2) years of working experience in
industry.
09. Electrician ------ Min. two(2) years of working experience in
Electrical and C&I.
10. Helper ------

NOTE:

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 35 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

1-In case Vendor fails to maintain the manpower/site staff with above said quantity, qualification and experience
at site till the O&M completion, suitable pro-rata deductions as per BHEL prevailing rates, shall be recovered from
the vendor.
2-Same operation and maintenance specification shall be applicable for O&M of six (6) months after handing over
to customer also which is mandatory.

08.00.00 TOOLS AND TACKLES

08.01.00 The bidder shall furnish a complete and new set of all tools and tackle which are necessary for erection,
commissioning, maintenance and overhauling of any of the equipment/ system provided under this
specification.
08.02.00 Tools shall be shipped in separate containers clearly marked with the name of equipment for which
they are intended.
08.03.00 The bidder shall furnish an unpriced list of such tools and tackle included under the scope of supply
with the technical part of proposal along with price break up for review of Plant Owner/Consultant.
08.04.00 Supply of all tools and tackle are included under bidder's scope of work.
08.05.00 List showing minimum requirement is furnished below:

Sr Description Qty
No
1 6 inch & 4 inch dia. wheel AC motor driven portable grinding machine 1 no of each
2 Hydraulic platform trolley for transportation of spare parts, Capacity: 2 T 1 no.
3 Hydraulic Jack,50 tonne & 10tonne 1no of each
4 Extendable aluminum ladders. 2 no
5 10-inch size-flat, round, half round, bastard, fine files. 2 no of each
6 Outside micrometer, range 0 to 150 mm 2 no
7 Inside micrometer, range 0 to 150 mm 2 no
8 Vernier Calipers 4 no
9 Dial gauges (0 to 10 mm with least count 0.01). 8 no
10 Steel tapes (3m& 6m) 6 no of each
11 Steel Scales (1m, 0.5m & 0.3m) 6 no of each
12 External Caliper (0.15m, 0.3m, 0.5 m & 1m) 4 no of each
13 Internal Caliper (0.15m, 0.3m, 0.5 m & 1m) 4 no of each
14 Hacksaw frames with one dozen hacksaw blades. 2 set
15 Tri-squares (200mm size) 6 no
16 Screw operated couplings 4 no
17 Bearing pullers (300mm) 4 no
18 Rope Pull Lift, Capacity: 2 T & 5T 4 no of each
19 Oil Seal Extractor 4 no
20 Screw Driver (size:150mm & 300mm) 6 no of each
21 Pair of Slings with eye bolts & D-shackles : length (2m, 4m& 6m),) 6 set of each

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 36 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

22 20mm Φ. Steel wire rope,6x19 construction with hemp core,Gr.1570 [IS:2266] 30m
23 Belt pullers. 4 no
24 Pliers With Insulation Covered Arm [size 180mm] 6 no
25 Adjustable Pliers. 6 no
26 External Circlip Pliers 6 no
27 Internal Circlip Pliers 6 no
28 Allen Key Set 6 no
29 Ball Peen hammers(in different sizes) 6 no
30 Nylon faced hammers 2 no.
31 Sledge hammers of 5 kg. & 10 kg. 4 no. each
32 Feeler Gauge 4 no
33 Universal Spirit Level 2 no
34 Torque wrenches to suit CHP equipment 2 no
Standard Ring Spanners Set (Full Range) complete with box (10-11 to 40-42) (Make:
35 Taparia or Mekastar ) 8 set
Standard DE Spanners Set (Full Range) complete with box (10-11 to 40-42) (Make:
36 Taparia or Mekastar ) 8 set
37 Adjustable spanner Set (Full Range) complete with box 4 set
38 Tubular Box Spanner Set (Full Range) complete with box 4 set
39 Socket head spanner set complete with box 4 set
Gas cutting torch with standard regulators for oxygen cylinder and acetylene cylinder
40 and 30m flexible hose 1 set
41 Portable Welding Machine, single phase 1 no.
42 Vice Grips (suitable for up to 50mm/up to 150mm/up to 300mm). 2 no of each
43 Three legged tripod stand, 4m height 2 no
44 Cable Jointing Kits 2 set
45 Marking Punches 4 no
46 Scribers 6 no
47 Grease guns with flexible hose & grease nipple 4 no
48 Bucket Grease Gun With Flexible Hose & Grease Nipple 4 no
49 ½ inch dia portable wolf drilling machine 4 no
50 Avometers 4 no
51 Digital Multimeter with 4 ½ digits display. 4 no
52 Insulated Tester -Hand operated [500 V (2nos.), 10000V (2nos.) & 6.6kV(1nos.) ] 5 no
53 Plumb bob 8 no.
54 Vibration Monitor Equipment. 4 no
55 Tong Testers 4 no
56 Portable Emergency Light 8 no
57 Hand lamp set with flexible wire 50 m long 12 no
58 Chain pulley blocks, Capacity :3T & 5T 1no of each
59 HT cable fault locating kit for 6.6KV with Accessories. 1 set
60 Crimping tool Hydraulic type upto 640 Sq.mm. 1 no

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 37 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

61 Bearing mounting kit 1 no

09.00.00 SPARE PARTS
09.01.00 General
09.01.01 The scope of supply of bidder includes supply of mandatory spares, start-up and commissioning spares,
consumable spares and other spares as required for plant erection, testing, commissioning, startup,
initial operation etc.
09.01.02 The Bidder shall include in his scope of supply all the necessary Mandatory spares, startup &
commissioning spares and indicate these in the relevant schedules of the Bid Form and Price Schedules.
09.01.03 The bidder shall indicate the service expectancy period for the mandatory spares parts under normal
operating conditions before replacement is necessary
09.01.04 All spares supplied under this contract shall be strictly inter changeable with the parts for which they
are intended for replacements. The spares shall be treated and packed for long storage under the
climatic conditions prevailing at the site e.g. small items shall be packed in sealed transparent plastic
with desecrator packs as necessary.
09.01.05 All mandatory spares shall be manufactured along with the main equipment components as a
continuous operation as per same specification and quality plan.
09.01.06 Each spares part shall be clearly marked or labeled on the outside of the packing with its description.
When more than one spares part is packed in a single case, a general description of the content shall
be shown on the outside of such case and a detailed list enclosed. All cases, containers and other
packages must be suitably marked and numbered for the purposes of identification.
09.01.07 All cases, containers or other packages are to be opened for such examination as may be considered
necessary by the Employer.
09.01.08 The bidder will provide the Employer with all the addresses and particulars of his sub suppliers while
placing the order on vendors for items/components/equipments covered under the contract and will
further ensure with his vendors that the Employer, if so desires, will have the right to place order for
spares directly on them on mutually agreed terms based on offers of such vendors.
09.01.09 The bidder shall warrant that all spares supplied will be new and in accordance with the contract
Documents and will be free from defects in design, material and workmanship.
09.01.10 The bidder shall guarantee the long term availability of spares to the Employer for the full life of the
equipment covered under the contract. The bidder shall guarantee that before going out of production
of spares parts of the equipment covered under the Contract, He shall give the Employer at least 2
years advance notice so that the latter may order his bulk requirement of spares, if he so desires. The
same provision will also be applicable to subcontractors. Further, in case of discontinuance of
manufacture of any spares by the bidder and/or his sub vendor, bidder will provide the Employers, two
years in advance, with full manufacturing drawings, material specifications and technical information
including information on alternative equivalent makes required by the Employer for the purpose of
manufacture / procurement of such items.
General Note: -
a. Wherever quantity has been specified as percentage (%), it shall mean percentage (%) of the total

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 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

population of the item in the station (project), unless specified otherwise and the fraction will be rounded
off to the next higher whole number.
b. Wherever the quantities have been indicated for each type, size, thickness, material, radius, range etc.
these shall cover all the items supplied and installed and the break up for these shall be furnished in the
bid.
c. In case spares indicated in the list are not applicable to the particular design offered by the bidder, the
bidder should offer spares applicable to offered design with quantities generally in line with the approach
followed as per the list from Volume - II.
d. Identification: Each spare shall be clearly marked and labeled on the outside of the packing with its
description. When more than one spare part is packed in single case, a general description of the contents
shall be shown on the outside of such case and a detailed list enclosed. All cases, containers and other
packages must be suitably marked and numbered for the purpose of identification.

09.02.00 Mandatory Spare Parts

09.02.01 The list of mandatory spares considered essential by the Employer is indicated in Volume - II. The bidder
shall indicate the prices for each and every item (except for items not applicable to the bidder’s design)
in the 'Schedule of mandatory Spares' whether or not he considers it necessary for the Employer to
have such spares. If the bidder fails to comply with the above or fails to quote the price of any spare
item, the cost of such spares shall be deemed to be included in the contract price. The bidder shall
furnish the population per unit of each item in the Bid Forms and Price Schedules.
09.02.02 Whenever the quantity is mentioned in "sets" the bidder has to give the item details and prices of each
item.
09.02.03 The Employer reserves the right to buy any or all the mandatory spares parts.
09.02.04 The prices of mandatory spares indicated by the Bidder in the Bid Proposal sheets shall be used for bid
evaluation purposes.
09.02.05 Wherever quantity is specified both as a percentage and a value, the Bidder has to supply the higher
quantity until and unless specified otherwise.
09.03.00 Start-up Commissioning, Operation and Maintenance Spares
09.03.01 It will be the responsibility of the bidder to provide all commissioning spares including consumable
spares required for initial operation till the completion of facilities. The bidder shall furnish a list of all
commissioning spares within 60 days from the date of Notification of Award and such list shall be
reviewed by the Owner and mutually agreed to. However, such review and agreement will not absolve
the bidder of his responsibilities to supply all commissioning spares so that initial operation do not
suffer for want of commissioning spares. All commissioning spares shall be deemed to be included in
the scope of the Contract at no extra cost to the Owner.
09.03.02 These spare will be received and stored by the bidder at least three (3) months prior to the schedule
date of commencement of initial operation of the respective equipment and utilized as and when
required. The unutilized spares and replaced parts, if any, at the end of successful completion of
guarantee tests shall be the property of the Contractor and he will be allowed to take these parts back
at his own cost with the permission of Owner.

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 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

10.00.00 EXCLUSIONS:
10.01.00 Following equipment/items and systems are excluded from bidder’s scope.
SL NO DESCRIPTION
1. Vibration monitoring System for HT Motors and Crushers
2. Bull dozer with standard accessories.
3. Pay loader with standard accessories.
4. Bunker level indicators
5. HT Motors for Crushers and Conveyors
10.02.00 Civil & Structural works as specified elsewhere in the specification.

11.00.00 PERFORMANCE GUARANTEE

11.01.00 The successful bidder shall be responsible for proper design, smooth and trouble-free operation of all
the systems, equipment and components offered by him.
11.02.00 The successful bidder shall guarantee that the material of construction and workmanship of all the
equipment and components supplied by him are as specified under this specification and wherever
there is nothing specifically mentioned shall correspond to the best available grade and quality.
11.03.00 The successful bidder shall also guarantee that the system, equipment and components covered by
this specification shall be as per relevant standard/ code and shall be suitable for continuous
operation (i.e., 24 hours per day).
11.04.00 However, the sequence of P.G. Test shall be (1) Testing & Commissioning, (2) Trial Operation, (3) P.
G. Test. After completion of the above procedure, finally take over by Plant Owner.
Bidder shall guarantee the performance requirement of all coal handling paths for the guaranteed
capacity of 1500 MTPH per stream considering loaded start of conveyors and equipment, as
applicable. Equipment like wagon tippler, wagon shifter, apron feeder, vibrating feeder, belt
conveyors, belt feeders, crushers, magnetic separators, belt weighers, Vibrating Grizzly Feeders,
travelling trippers, Stacker Cum Reclaimer all are included in this test. Each stream shall be tested
separately for continuous running of 8 hours.
11.05.00 Major equipment shall also be tested separately as detailed below:
11.06.00 Description Guarantee Parameter of major equipment
10.06.01 Coal Handling Plant: -
a) Wagon Tippler 25 Tips / hr guaranteed rate in conjunction with side arm charger, wagon shifter
and pusher is in bidder scope.
b) Apron Feeder 1500 MTPH guaranteed capacity is in bidder scope.
c) Vibrating Grizzly Feeder 900 MTPH guaranteed capacity with 85% (-) 20 mm size underflow for
input of (-) 300mm lump is in bidder scope.
d) Crushers (Ring Granulator) 850 MTPH guaranteed capacity with (-) 250mm feed & output of 98%
(-) 20mm size is in bidder scope.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 40 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

e) Stacker-Cum-Reclaimer 1500 MTPH guaranteed capacity Stacking & 1200 MTPH guarantee
average reclaiming is in bidder scope.
f) Vibrating Feeder 750 MTPH guaranteed capacity is in bidder scope.
g) Travelling Tripper 1500TPH guaranteed capacity is in bidder scope.
h) Belt feeder and conveyor 1500TPH guaranteed capacity is in bidder scope.
10.06.02 Limestone and Gypsum Handling Plant: -
a) Crushers 75 MTPH guaranteed capacity with (-) 250mm feed & output of 90% (-) 20mm size is in
bidder scope
b) Vibrating screen 75 MTPH guaranteed capacity with (-) 20 mm size underflow for input of (-)
250mm lump is in bidder scope.
c) Bucket Elevator 82.5 MTPH guaranteed capacity is in bidder scope.
d) Vibrating Feeder 40 MTPH guaranteed capacity is in bidder scope.
e) Belt feeder 75TPH guaranteed capacity is in bidder scope

11.07.00 Bidder shall guarantee the total power consumption path-wise at capacity indicated elsewhere,
required at the input terminals of drive motors of the equipment at the above mentioned guaranteed
capacity performance requirements for CHP as well as LHP/GHP.
11.08.00 The contractor shall submit P.G. Test procedures to the Owner, for approval, prior to conduct of P.G.
Test.
11.09.00 Equipment common to different path shall be tested for performance once as per above requirement
during testing of particular path and test results of such tests shall be used for other paths, as
applicable, for common portions.
11.10.00 Bidder shall submit declaration along with bid documents in specified proforma to furnish all his
guaranteed parameters, short fall in which shall attract levy of liquidated damages as applicable.

12.00.00 LIQUIDATED DAMAGES FOR POWER CONSUMPTION

12.01.00 If the total power consumption at the input terminals of various drive motors exceed the Guaranteed
figure of power consumption, the Liquidated damages shall be payable by the bidder of excess power
consumption over the Guaranteed figure.
12.02.00 For the purpose of above, the power consumption (total) of all conveyors drives (one stream) and
other equipment as specified shall be at the guaranteed capacity of 1500 MTPH and shall be same as
obtained during the P&G test of different flow paths, specified below.
Flow Path 1 From Wagon Tippler to the farthest Boiler Bunker through all intermediate
conveyor
Flow Path 2 From Wagon Tippler to Stockyard through Stacker reclaimer positioned at the
farthest distance from tail end & boom conveyor at highest angle.
Flow Path 3 From stockyard conveyor, Reclaiming coal through Stacker Reclaimer
positioned at the farthest distance from head end, to the farthest Boiler Bunker
through all intermediate conveyor.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 41 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

Flow Path 4 From reclaim hopper through conveyor to the farthest Boiler Bunker through
all intermediate conveyor.
Flow Path 5 Reclaimed coal from machine SCR-1A & fed to conveyor-7A/7B, Reclaimed coal
(Blending) from machine SCR-1B & fed to conveyor-7A/7B and discharge to the farthest
Boiler Bunker through all intermediate conveyor.
Flow Path 6 Reclaimed coal from reclaim hopper & fed to conveyor-7A/7B, Reclaimed coal
(Blending) from machine SCR-1A/1B & fed to conveyor-7A/7B and discharge to the
farthest Boiler Bunker through all intermediate conveyor.

Contractor shall bring and calibrate any instruments that are required for measuring the power
consumption of the machine during performance and guarantee tests.
12.03.00 The liquidated damages for short fall in performance and for power consumption as per the aforesaid
provision shall be applicable independent of each other and shall be without any limit with regard to
their total amount. Such liquidated damages may be recovered by BHEL by deduction from the
contract price, by enforcing the contract performance guarantee or in any other manner.
13.00.00 QUALITY ASSURANCE.
13.01.00 Quality Assurance Documents
13.01.01 Bidder shall be required to submit in two (2) copies the following quality assurance documents within
two weeks after dispatch of the equipment:
13.01.02 All non-destructive examination procedures, stress relief and weld repair procedure actually used
during fabrication.
13.01.03 Welding procedures, welders, welding operator’s qualification certificates.
13.01.04 Welder identification list, listing welders and welding operator’s qualification procedures and welding
identification symbols.
13.01.05 Material mill test reports on components.
13.01.06 The inspection plan with verification, inspection plan check points, verification sketches, if used and
method used to verify that the inspection and testing points, in the inspection plan were performed
satisfactorily.
13.01.07 Sketches & drawings used for indicating the method of tractability of the radio graphics to the location
on the equipment.
13.01.08 Non-Destructive Examinations result reports including Radiography Interpretation Reports.
13.01.09 Stress Relief Time Temperature Charts.
13.01.10 Factory Tests results for testing required as per applicable Codes and Standards.
13.01.11 Inspection Records duly signed by Quality Assurance Personnel of the Employer and Contractor for
agreed Inspection Hold Points. The same shall be recorded during course of inspection. Also the copy
of repair/upgrading process & procedures, requiring employer’s approval shall be provided in
documentation package.
13.01.12 Record of disposition of deviations duly authorized by the Employer.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 42 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

13.01.13 Notification of Conformity certifying that the equipment is in compliance with finalized specification
requirement.
13.02.00 General Requirements - Quality Assurance:
13.02.01 The detailed quality plans for manufacturing and field activities to be drawn up by bidder, separately
as per BHEL format and should be submitted for customer approval.
13.02.02 Manufacturing Quality Plan will detail out all the components of equipment, various tests/inspection,
to be carried out as per the requirement of the specification and standards mentioned and quality
practices & procedures followed by bidder quality control organization, the Relevant Reference
Documents and Standards, Acceptance Norms, Inspection Documents raised etc. during a!) Stages of
Materials Procurement, manufacture, assembly and final testing/performance testing.
13.02.03 Field Quality Plan will detail out for all the equipment, the quality practices and procedures etc. to be
followed by the contractor during various stages of site activities from receipt of materials equipment
at site.
13.02.04 Bidder shall also furnish copies of reference documents/plant standards/acceptance norms test and
inspection, procedure, etc. as referred in quality plans. These quality plans and reference
documents/standards etc., will be subject to customer approval without which manufacture shall not
proceed.
13.02.05 No material shall be dispatched from the manufacturers work before the same is accepted
subsequent to pre dispatch final inspection including verification of records of all previous
tests/inspection by the Employer’s Engineer/Authorized Representative and duly authorized for
dispatch, issuance of MDCC.
13.02.06 All materials used for equipment manufacture including castings and forgings etc. shall be tested
quality as per Relevant Codes/Standards. Details of Results of the tests conducted to determine the
Mechanical Properties, Chemical Analysis and Details of Heat Treatment Procedure shall be recorded
on Certificates and Time Temperature Charts. Tests shall be carried out as per applicable Material
Standards and/or Agreed Details.
13.02.07 All Welding/Brazing shall be carried out as per procedure drawn and qualified in accordance with,
requirements of ASME Section IX/BS-4870 or other International Equivalent Standard acceptable to
the Customer.
13.02.08 All Brazers/Welders and Welding Operators employed on any part of the contract either in
contractors/his subcontractors works or at site or elsewhere shall be qualified as per ASME section IX
or BS 4871 or other equivalent international standards acceptable to the customer.
13.02.09 Test results of Qualification Tests and Specimen Testing shall be furnished for approval.
13.02.10 All the Heat Treatment Results shall be recorded on Time Temperature Charts and verified with
Recommended Regimes.
13.02.11 No welding shall be carried out on Cast Iron components for repair.
13.02.12 Unless otherwise proven and specifically agreed, welding of dissimilar materials and high alloy
materials shall be carried out at shop only.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 43 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

13.02.13 All non-destructive examination shall be performed in accordance with Written Procedures as per
International Standard. NDT shall be recorded in a report which includes details of methods and
equipment used, result evaluation, job data and identification of personnel employed and details of
correlation of the test report with the Job.
13.02.14 Quality Plan submitted by bidder shall detail out, various stages of Manufacture and Installation, the
Quality Practices and Procedures, the relevant reference Documents/Standards used, Acceptance
Level, Inspection of Documentation raised etc.
13.02.15 Quality Audit/Surveillance/Approval of the results of tests and inspection will not however, prejudice
the right of the customer to reject the equipment if it does not comply with the specification when
erected or does not give complete satisfaction in service and the above shall in no way limit the
liabilities and responsibilities of the contractor in ensuring complete conformance of the
materials/equipment supplied to relevant specification, standard, data sheets, drawings, etc.
13.02.16 For all spares and replacement items, the quality requirement as agreed for the main equipment
supply shall be applicable.
13.02.17 Repair/Rectification Procedures to be adopted to make the Job Acceptable shall be subject to the
Customer Approval.
13.03.00 Inspection & Testing
13.03.01 Bidder shall give 15 Days advance Written Notice of the equipment being ready for Testing. Such tests
shall be to bidder’s account except for the expenses of the inspector's. The Customer/Inspector,
unless the witnessing of the tests is virtually waived, will attend such tests within 15 days of the date
on which the equipment is notified as being ready for Test/Inspection failing which, the contractor
may proceed with the test which shall be deemed to have been made in the Inspector’s presence and
he shall forth with forward to the Inspector duly certified copies of tests in Triplicate.
13.03.02 Type & Routine Test Report/Certificates shall include details of the Standard to which the tests are
performed, Test Parameters, Acceptance Criteria, Test Set up etc. used during the Testing along with
the Test Piece Details/Rating and the Detailed Test Record and the Final Test Result.
13.03.03 All Inspection, Measuring and Test Equipment used by the contractor shall be calibrated periodically.
Bidder shall maintain all relevant records of Periodic Calibration, Instrument Identification, and shall
provide for inspection by the Bidder wherever asked specifically, bidder shall calibrate
Measuring/Testing Equipment in the presence of the Employer.
13.03.04 The details of the checks to be carried out for Various Components (MQP) are to be submitted within
one month from the date of Purchase Order by the bidder for Customer Approval. However, some
Indicative Checks on Different Items are given below which should necessarily form part of the Quality
Assurance Plan to be agreed with the Customer.
13.03.05 All plates above 20 mm Thickness to be Ultrasonically Tested for Laminations.
13.03.06 Shaft Forgings Suspension Bars to be checked for Hardness, Microstructure and Ultrasonic Testing in
addition to check for the Chemical and Mechanical Properties.
13.03.07 Following minimum NDT requirement to be ensured for Welds:
(a) Butt Welds - 10% UT/RT and 100% MPI.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 44 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

(b) Fillet welds - 10% DPT.

14.00.00 DRAWINGS AND DOCUMENTS SUBMISSION

14.01.00 Bidder shall furnish the contain Full Details and Drawings of the Equipment, Furnished Data Sheet,
Technical Particulars, Testing Procedures and O & M manuals of the Equipment. Successful bidder
has to submit drawing/documents as per tentative list of drawing with schedule of submission is
provided in Annexure-11. Other drgs. /documents to be submitted by the successful bidder shall be
finalized with UPRVUNL (or their consultant) / BHEL after award of the contract and the bidder shall
furnish the drgs. / docs accordingly. Engineering drg/doc must essentially contain the following
(individual to system, equipment and items of but not limited to these and any drg/ doc required
desired by BHEL/UPRVUNL shall be furnished by the vendor during detail engineering:
(a) General arrangements drgs. of all the junction towers, all the conveyors, crusher houses included in
the scope as specified, the individual equipments, associated accessories.
(b) Civil assignment drgs with Load data for all above
(c) Various schedules
(d) Design calculations
(e) Data sheets
(f) Fabrication drgs of chutes & technological structures of machines
(g) O&M manuals and E&C manuals
(h) PG test procedures, QAP, FQP
(i) Other drawing/documents specified in UPRVUNL NIT specification
14.02.00 The drawings sent for approval shall be in 06 sets, along with one reproducible original drawing.
One print of the said drawing will be returned marked approved / approved subjected to
incorporation of comments / to be resubmitted for approval after incorporation of comments / for
information and records only. CAD Drg. soft copy of all Drags. are also to be forwarded to BHEL to
save time in approval process.
14.03.00 The supplier shall there upon furnish eight (08) prints along with reproducible original of the
approved drawings / Data documents. The drawing shall be given in suitable form and software
which can be integrated with the customer computer aided design system.

14.04.00 ERECTION DRAWINGS

14.04.01 The Supplier shall furnish Erection Drawings for the Equipment to be erected. These shall generally
comprise of Fabrication / Assembly Drawings, Various Component/Part Detail Drawings, Assembly,
Clearance, Data Requirements etc. The Drawings shall contain details of Components/Equipment
with Identification Numbers, Match Marks, Bill of Materials, Assembly Procedures etc. For all major
Equipment apart from above details, Assembly Sequence and Instructions with Check Lists shall be
furnished in the form of Erection Manuals.

Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 45 of 46

 BHEL- ISG, BANGALORE Coal Handling Plant for 1X660 MW Specification Number
PANKI TPS (UPRVUNL) IS-1-17-2001/007
Technical Enquiry Specification for
CHP/GHP/LHP Package

14.04.02 Supplier shall submit all GA drawings of equipment, Design Calculations for Selection of equipment,
Size of Dozer Shed, Data Sheets. Any Other Drawing requested by the Customer shall also be
submitted.
14.04.03 Vendor should start submitting all the GA Drawings within two weeks of the Receipt of LOI and
complete all GA drawing submission within two Months.
14.04.04 Every Resubmission on any Drawing should be submitted within 07 Days from the Date of
Comments.
14.04.05 All Quality Plans shall be submitted within One Month after LOI.
14.05.00 Schedule & number of copies required for submission should be as per the details given below:
Sl. Description Type of copies Number of Schedule of submission
No required copies required
1 Drawings / Documents for Prints & Soft 10 Copies Starting Two Weeks from
Approval Copies LOI
2 Revised Drawings / Prints & Soft 10 Copies One Week after receipt of
Documents Incorporating Copies comments from
Customer Comments if GSECL/DCPL forwarded by
any. BHEL
3 Final Approved Drawings / Prints & Soft 12 Copies One Week after Receipt of
Data / Documents Copies Approved Drawing from
BHEL / Consultant.
4 Erection Drawings & Prints 12 Copies Eight (8) Weeks before the
Manuals Dispatch of the
Equipment.
5 Pre-Commissioning / Prints 12 copies ----------- do --------------
Commissioning Check List /
Procedures.
6 Quality Assurance Plan Prints 10 Copies One Month from The Date
of placing L.O.I
7 Final Operation & Prints & Soft One (1) Original One Month before the
Maintenance Instruction Copies & 12 Copies Dispatch of the
Manuals Equipment.

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Issued by: MECH. ENGG. Date: 10-04-2019 Rev no.00 Sheet 46 of 46