Name of work: - Construction of

Terminal Building & Associated works

at Leh Airport, J&K

[Tender ID No. 2018_AAI_11239_1]

TENDER DOCUMENT
(Volume - 2 Containing 1437 Pages)

Bid Manager : SATYENDRA SINGH

Tel. No. : 011-24632950
Extn. No. : 2517
Mobile No. : 9810762595
E-mail ID : [email protected]
Fax No. : 011-24693495

AIRPORTS AUTHORITY OF INDIA

ENGINEERING WING
RAJIV GANDHI BHAWAN
SAFDARJUNG AIRPORT
NEW DELHI - 110003
 INDEX
NAME OF WORK: CONSTRUCTION OF TERMINAL BUILDING &
ASSOCIATED WORKS AT LEH AIRPORT, J&K
THE DETAILS OF TENDER DOCUMENT ARE GIVEN BELOW:

Sl. No. Description Page

No.
Volume - I

1. Press Notice PN 01
2. General Instruction for Online Bid Submission IOBS 01-03
3. Notice Inviting e-Tender WNIT 01-05
4. Pre-Qualification Proforma PQ 01-06
5. General Guidelines for the Bidders NIT 01-07
6. General Conditions of Contract GCC 01-139
01-37
7. Special Conditions of Contract (Civil) SCC (Civil)
Special Conditions of Contract (GRIHA) 01-27
8. SCC (GRIHA)
Special Conditions of Contract (E&M Works) SCC (ELECT) 01-20
9.
01-14
10. List of Approved Makes (Civil) LOAM (C)
01-17
11. List of Approved Makes (Electrical) LOAM (E)
01-22
12. Proforma PR
Volume - II
01-221
13. Technical Specification (Civil) TSC
01-1216
14. Technical Specification (Electrical) TS(E)
Volume - III
01-155
15. Schedule of Quantities (Civil & Electrical) SOQ
Volume - IV
01-05
16. List of Tender Drawings LOTD
01-148
17. Tender Drawings DWG
2043
TOTAL

THIS TENDER DOCUMENT CONTAINS FOUR VOLUMES. VOLUME-I CONTAINS 298 PAGES,
VOLUME-II CONTAINS 1437 PAGES, VOLUME-III CONTAINS 155 PAGES & VOLUME-IV
CONTAINS 153 PAGES.

(TOTAL PAGES OF VOLUME-I TO VOLUME-IV ARE 2043)

 SCOPE OF WORK
(CIVIL/ STRUCTURAL)

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 1 OF 221

 I. BRIEF SCOPE OF WORK

The scope of work under this contract shall in general include (but not limited to),construction
of all relevant Civil-structural (foundation and superstructure), Plumbing (Water supply &
Sanitation works) & Fire protection works of all buildings and other required facilities for
“CONSTRUCTION OF NEW TERMINAL BUILDING AND ASSOCIATED WORKS AT LEH
AIRPORT, J&K, including supply of all materials (as defined in scope of supply), tools &
tackles, labour, etc., as per the Schedule of rates, Specifications, Standards, drawings and
addendums included in the Bid Document / As per directions of Engineer-in-charge / As per
approved for construction drawings made available to the successful bidder
The Scope of work shall generally comprise of but not be limited to the following,

 CIVIL/ STRUCTURAL &U/G WORKS

 Foundation and superstructure of New Domestic Terminal building & Utility building.
 Pre-engineered steel superstructure for New Terminal building by approved PEB vendor.
 RCC retaining wall structure in New Terminal building & Utility building.
 All other associated structures.
 Development of parking area, roads, landscaping etc.
 Structural support system for baggage belts, escalators etc. as per requirements.
 Site grading works (clearing and stripping, earthwork in excavation and back filling with
available earth) and disposal of surplus earth to approved dumping areas
 U/G Pipe Laying Works
 Manholes, Inspection chambers &Valve Pits
 PQC Pavement works
 Dismantling & Demolishing of old terminal building inclusive other allied structures.

 PLUMBING, (WATER SUPPLY& SANITARY WORKS), SEWERAGE, DRAINAGE&RAIN

WATER HARVESTING WORKS

 Water Supply works

 Sanitary Fixtures and Fittings works
 Internal and External Sewerage and Drainage works
 Storm Water Drainage works
 Rain Water Harvesting works

 FIRE FIGHTING WORKS

 Internal & External Fire Hydrant System, Fire Sprinkler System including Fire water pumps
and associated facilities.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 2 OF 221

 Hand Held Fire extinguishing
 Clean Agent System

II. DETAILED SCOPE OF WORK

i. The works shall be executed as indicated in the description of each item and technical
specifications as given here under as made applicable to this contract. The specifications
of works/ items to be executed under this contract are enclosed. Balance works / items,
which are not covered under the specifications, shall be executed as per latest DSOR
specifications or with specifications under the direction of Engineer-in-Charge.
In the absence of any definite provision in the technical specifications contained herein,
reference may be made to the latest CPWD, MORTH, IRC, ICAO Specifications and IS codes,
in that order. Wherever these are silent, the construction and completion of the works shall
conform to sound engineering practice and in case of any dispute arising out of the
interpretation of the above, the decision of the Engineer-in-Charge shall be final and binding on
the Contractor.
All the codes of practice, standards and specifications applicable shall be the latest editions
with up to date correction slips etc. or as directed by the Engineer-in-Charge.

Major Civil/ Structural activities shall include the following but not limited to the following:
ii. Earthwork in excavation in all types of soil including dewatering below ground level.
iii. Shoring & strutting wherever required.
iv. Backfilling at all depths with available good soil and transportation of surplus earth, debris
etc. to the area designated by the Engineer-in-Charge.
v. PCC works including lean concrete at all depths below foundations of all types, base slab,
plinth beams, non-suspended slabs, walls, trenches, pit, drain and in screed at all depths
below plinth level.
vi. RCC work in Sub-Structures for buildings /structures, non-suspended slabs, RCC floor
decking ,pits, drain etc. including centring, shuttering at different stages of concreting,
providing insert plates and anchor bolts, sleeves etc.
vii. RCC works in super-structure at all elevations, columns, beams, walls, floor & roof slabs,
etc. at all heights.
viii. RCC works in liquid retaining structures and casting of RCC in single pour asper concrete
casting plan and as instructed by Engineer in charge.
ix. RCC works for cable/ pipe trenches including covers etc. and any other miscellaneous
work required as per AFC drawings / instructions of Engineer-in-charge.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 3 OF 221

 x. Structural steel works with rolled steel, parallel flange and built-up sections or
tubular/hollow sections, including design, fabrication, erection and preparation of detailed
fabrication drawings for all types of structures at all locations and heights in super-
structure.
xi. Painting for Structural steel shall be as per attached job specification.
xii. Preparation of bar bending Schedule of RCC works as per the AFC drawing.
xiii. Centering & shuttering (including curved shuttering) in sub-structure at all depths and in
super-structure at all heights/ elevations.
xiv. Brick masonry in substructure and superstructure for all depths and heights as per
specifications.
xv. Fabrication & placing/ erection of miscellaneous steel items like Anchor Bolts, Metal Insert
Plates, Pipe Sleeves, Hand railing, etc. as per job specification/CPWD Specifications as
directed by Engineer-in-charge at any location wherever required.
xvi. Miscellaneous works for Anti termites, Sand filling, DPC, etc., at all locations as specified.
xvii. Providing and laying of construction joints, expansion joints, sealing joints etc. in the
buildings (expansion joints).
xviii. Clearing and Stripping of the areas earmarked for grading the site, removing shrubs,
grass, bushes, vegetables growth and other objectionable materials. Carrying out
earthwork in excavation and filling for general site grading for all heights and depths in all
kinds of soil including soft/weathered rock as per specifications& drawings.
xix. Removal of surplus earth excavated earlier including re-excavating the deposited soil
excavated earlier & clearing the site and disposal of surplus earth/ unserviceable materials
outside aerodrome boundary limit. Disposal area shall be arranged by the Contractor.
xx. Construction of PQC Pavement including supply of all materials as per drawings,
specifications & directions of Engineer–in-charge.
xxi. Supply, laying, jointing, testing and commissioning of CPVC pipes and specials domestic
& flushing water system conforming to IS 15778 including all valves & fittings complete as
per drawings &specifications.
xxii. Supply, laying, jointing, testing and commissioning of GI pipes and specials for hot water
system conforming to IS 1239 including all valves & fittings complete as per drawings,
specifications & directions of Engineer-in-Charge.
xxiii. Supply, laying, jointing, testing and commissioning of uPVC soil/ waste and vent piping
conforming to IS: 13592 inside building.
xxiv. The Contractor shall prepare plumbing and water supply shop drawing coordinating with
Electrical and other services layouts to avoid any conflict at the time of execution of work.
No extra payment shall be made to the contractor for the same.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 4 OF 221

 xxv. Supplying, laying and jointing of RCC NP2 class pipes in storm water drainage with socket
and spigot ends conforming to IS: 458as per drawings, specifications & directions of
Engineer-in-Charge.
xxvi. Construction of Brick masonry drains, pipe culverts & rain water harvesting pits including
supply of all materials as per drawings and specifications.
xxvii. Supply, installation, testing & commissioning of MS pipes and specials for U/G & A/G
fire water system conforming to IS 1239/3589 including all valves & fittings etc. complete
as per drawings, specifications & directions of Engineer-in-Charge.
xxviii. Supply & Installation, testing and commissioning of following fire fighting accessories
as per drawings & specifications:
 Fire Hydrant assembly
 Landing Valves
 Fire Hose Cabinets
 First aid Hose Reels
 Hand held & Portable Fire extinguishers
xxix. Supply, laying, fabrication, erection, testing and commissioning at all elevations, fire water
sprinkler system pipes including all specials & fittings including supply & installation of
break-up flanges, flanges for installation of Restriction Orifice, sprinkler nozzles including
providing necessary supports to sprinkler piping etc. all complete as per drawings &
specifications.
xxx. Drawings issued with the tenders are schematic and indicate the concept. Contractor shall
make his shop drawings on basis of Architectural and Interior design drawings issued by
the Engineer-in-Charge. Work will be executed only as per approved shop drawings. No
extra payment shall be made to the contractor for the same.
xxxi. Clearing and removal of all debris/unserviceable material from the site after completion of
work and disposal of the same as directed by Engineer-in-charge.
xxxii. Obtaining statutory approvals from local bodies including coordination with officials
and other designated authorities, if required.
xxxiii. Any other Civil-structural work, not specifically mentioned herein, but required for the
satisfactory completion of works as per directions of the Engineer-in-Charge shall also be
in the scope of the contractor.
xxxiv. It shall be clearly understood that all the works mentioned above together with all the
incidental works whether specifically mentioned or not shall be deemed to have been
included in the scope of work.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 5 OF 221

III. SPECIFIC REQUIREMENTS TO BE FULFILLED BY THE CONTRACTOR

Note: In case of any contradiction between Job Specific Requirements and Requirements/
Specification specified elsewhere in the tender document, the Specific Requirements given
below shall have precedence.
 Mandatory use of Mechanical Excavators.
 Mandatory installation of weigh batching plant of adequate capacity for concrete along with
transit mixers and concrete pumps as per the direction of Engineer-in-Charge.
 Mandatory use of Design mix concrete as per the directions of engineer-in–charge.
 For cutting & bending of re-bars mechanized equipment/ cutting- bending machine shall be
used.
 Use of following cement shall be considered
- 43 Grade Ordinary Portland cement conforming to IS:8112
- Portland Slag cement conforming to IS:455
- Portland Pozzolana cement conforming to IS: 1489.
 The minimum grade of reinforced cement concrete to be used for super-structures and
sub-structures shall be M30 (design mix) as per IS: 456.
 Reinforcing steel shall be high strength deformed steel bars of grade Fe500D conforming
to IS: 1786.
 Fabrication of Anchor bolts to be taken on priority to ensure placement of the same at the
time of concreting.
 All lugs shall be of high strength deformed bars of minimum grade Fe500D conforming to
IS: 1786.
 Anchor bolts shall be of mild steel confirming to IS: 2062 Grade-A/B.
 All inserts/ sleeves shall be properly secured in position before pouring of concrete.
 Structural steel shall be of grade E250C/E350C confirming to IS: 2062. RHS/SHS/CHS
shall be of grade Yst 310. All connections at site shall be Bolted Connection. Connecting
Bolts shall be High tensile bolt confirming to IS4000 & IS3757 with minimum grade 8.8.
Quoted rate for Structural Steel shall include the cost of bolts.
 Construction of structural steel part of new terminal building should be done by approved
PEB vendor only.
 Dewatering wherever required shall be carried out by the contractor at his cost.
 Various tolerances required as marked on the drawings conforming to codal requirements/
specifications or as directed by the Engineer-in-Charge shall be maintained by the
Contractor. Verticality shall be maintained at every stage and the same shall be verified
with Theodolite/ Total Station.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 6 OF 221

  All works shall be done to the entire satisfaction of the Engineer-in-Charge. Any work not
carried out as per the instructions of Engineer-in-Charge shall be dismantled and fresh
construction shall be carried out without any extra cost and time implication to the owner.
 The contractor has to take necessary precautions / safety measures for existing
underground facilities and structures above the ground level. Further, the contractor shall
take necessary work permits as per contract.

IV. LIST OF ATTACHMENTS:

The following Standards/Specifications are to be followed for executing the works:-

V. JOB SPECIFIC STANDARD DRAWING:

Refer attached job specific standard drawing.

VI. JOB SPECIFICSPECIFICATION:

Refer attached job specification.

VII. CPWD SPECIFICATIONS:

i. CPWD Specifications-Volume-1
ii. CPWD Specifications-Volume-2

VIII. PREAMBLE TO SCHEDULE OF QUANTITIES

 SOR indicates only estimated quantities. Unit rate quoted against each SOR item shall be
applicable for any addition and deletion during execution of the project.
 The maximum approximate height of structures shall be 20m. This data is for general
guidance of the Contractors; however deviation from the noted height shall not form a
basis for any extra claim).
 The expected water table depth may fluctuate from ground level during monsoon. The
quoted rate of excavation shall include requirement of dewatering etc. No extra amount is
payable on this account.
 During the performance of the work the contractor at his own cost, shall keep structures,
materials and equipment adequately braced by guys, struts or otherwise approved means
which shall be supplied and installed by the contractor as required till such time the
installation work is satisfactorily completed. Such guys, shoring, bracing, strutting, planking
supports etc. shall not interfere with the work of other agencies and shall not damage or
cause distortion to other works executed by him or other agencies.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 7 OF 221

  Item description provided in Schedule of Rates (Short Description) is in brief, while quoting
and filling the rate in this Schedule of Rates (Short Description), Bidder shall take into
consideration complete scope of work/item description as mentioned in Schedule of Rates
(Detailed Description) for the relevant item. The rate quoted in Schedule of Rates (Short
Description) shall be deemed to include all activities of work mentioned in item description
of Schedule of Rates (Detailed), scope of work, specifications, standards etc. & stringent
of all shall govern.

IX. SCHEDULE OF RATES:

For schedule of rates of Structural works refer attached SOR.

Items not included in this document (In case such items observed during execution of job) shall
be paid as per rate of DELHI SCHEDULE OF RATES (DSR) (Published by CENTRAL
PUBLICS WORK DEPARTMENT, Govt of India) in conjunction with cost index and local index.
In case the item/items is/are not found in DSR, the rate specific analysis to be done for that
item/ items.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 8 OF 221

 TECHNICAL SPECIFICATION
(CIVIL/ STRUCTURAL)

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 9 OF 221

SPECIFICATION CIVIL & STRUCTURAL WORK:

All specification pertain to civil structural work (refer item no S001 to S039 of
schedule of rate) in is listed below in specification-1 to specification -9.
Specificationspertain to balance items including specification of dismantling
and demolition should be as per latest specification of CPWD.
SPECIFICATION-1 GENERAL SCOPE FORCIVIL AND STRUCTURAL WORKS.
Relevant SOR item no:S001 to S039

Methods of measurements are indicated in these specifications; where not so specified, latest revision of
IS: 1200 shall be applicable.

Providing and operating all necessary measuring and testing devices/ equipments including all materials
and consumables are included in the scope of work. No separate measurement or payment for testing the
quality of work and materials shall be made; rates quoted for various items shall be deemed to include the
cost of such tests which are required to ensure achievement of specified quality.

All materials shall be of standard quality, manufactured by renowned concerns conforming to Indian
Standards or equivalent, and shall have IS mark as far as possible unless otherwise approved by the
Engineer-in-Charge. Vendor List attached in the Tender document shall be followed. The Contractor
shall get all materials approved by the Engineer-in-Charge prior to procurement and use. The Contractor
shall furnish manufacturer's certificates for the materials supplied by him when asked for. Further to that
he shall get the materials tested from an approved test house if asked for by the Engineer-in- Charge. The
cost for all the tests and test certificates for the material procured by the Contractor shall be borne by the
Contractor. No separate payment shall be made for the testing. The Engineer-in-Charge shall have the
right to determine whether all or any of the materials are suitable. Any materials procured or brought to
site and not conforming to specifications and satisfaction of the Engineer-in-Charge shall be rejected and
the Contractor shall have to remove the same immediately from site at his own expense and without any
claim for compensation due to such rejection.

Wherever referred to in the tender document, only the latest revision of Specifications, Codes of Practice
and other publications of Bureau of Indian Standards shall be applicable.

Wherever the Contractor executes civil and structural works involving buildings, equipment foundations,
supporting structures, etc., the following works are deemed to have been included in the quoted
rates for various works.

- Marking of centre lines of foundations etc.

- Establishing layout and levels of foundations and superstructure etc., including

establishment of reference lines, bench marks on various floors, platforms etc.

- General upkeep of the plant site.

- Preparation ofFabrication drawings and getting approval from Engineer-in-Charge after

incorporating all the comments.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 10 OF 221

 - Preparation of "As-Built" scheme of structural drawings indicating constructed details
including levels, centre lines, layouts, member sizes etc. complete.

The provisions of Schedule of Rates, specifications and drawings shall be read in conjunction with each
other and in case of conflict amongst them, clarification shall be obtained from the
Engineer-in-Charge whose decision shall be final and binding. However, the following procedure
may generally be followed:

- Description of items in schedule of rates shall be followed when provisions therein are
different from those in specifications.

- Where the description of item does not call for some specific requirement but the same is
given in specifications, the specifications shall be followed in addition to the requirement
given in description of item.

- Where drawings call for requirements different from or additional to those given in item
description and specifications, the decision of the Engineer-in-Charge shall be obtained
as to what shall be followed.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 11 OF 221

SPECIFICATION-2: CIVIL & STRUCTURAL WORKS - MATERIALS.
Relevant SOR item no:S001 to S039

1.1 This specification establishes and defines the requirements of various materials to be used in
Civil and Structural works.

1.2 Whenever any reference to BIS Codes is made, the same shall be taken as the latest revision (with
all amendments issued thereto) as on the date of submission of the bid.

1.3 Apart from the BIS Codes mentioned in particular in the various clauses of this specification, all
other relevant codes related to specific job under consideration regarding quality, tests, testing
and/or inspection procedures shall be applicable. Reference to some of the Codes in the various
clauses of this specification does not limit or restrict the scope of applicability of other referred or
relevant codes.

1.4 In case of any variation/contradiction between the provision of BIS Codes and this specification,
the provision given in this specification shall be followed.

1.5 All materials shall be of standard quality and shall be procured from renowned sources/
manufacturers approved by the Engineer-in-Charge. It shall be the responsibility of the
Contractor, to get all materials/ manufacturers approved by the Engineer-in-Charge prior to
procurement and placement of order.

1.6 Whenever called for by the Engineer-in-Charge all tests of the materials as specified by the
relevant BIS Codes shall be carried out by the Contractor in an approved laboratory and test
reports duly authenticated by the laboratory, shall be submitted to the Engineer-in-Charge for his
approval. If so desired by the Engineer-in-Charge, tests shall be conducted in the presence of the
Engineer-in-Charge or his authorized nominee.

1.7 Quality and acceptability of materials not covered under this specification shall be governed by
the relevant BIS Codes. In case BIS code is not available for the particular material, other codes
e.g. BS or DIN or API/ASTM shall be considered. The decision of Engineer-in-Charge, in this
regard, shall be final and binding on the Contractor.

1.8 Whenever asked for, the Contractor shall submit representative samples of materials to the
Engineer-in-Charge for his inspection and approval. Approval of any sample does not necessarily
exempt the Contractor from submitting necessary test reports for the approved material, as per the
specification/relevant BIS Codes.

1.9 The Contractor shall submit manufacturer's test reports on quality and suitability of any material
procured from them and their recommendation on storage, application, workmanship etc. for the
intended use. Submission of manufacturer's test reports does not restrict the Engineer-in-Charge
from asking fresh test results from an approved laboratory of the actual material supplied from an
approved manufacturer/source at any stage of execution of work.

1.10 All costs relating to or arising out of carrying out the tests and submission of test reports and or
samples to the Engineer-in-Charge for his approval during the entire tenure of the work shall be
borne by the contractor and included in the quoted rates.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 12 OF 221

1.11 Materials for approval shall be separately stored and marked, as directed by the Engineer-in-
Charge and shall not be used in the works till these are approved.

1.12 All rejected materials shall be immediately removed from the site by the Contractor at his own
cost.

2.0 REFERENCES

As mentioned in the respective clauses.

3.0 WATER

3.1 Water used in construction for all civil & structural works shall be clean and free from injurious
amount of oil, acids, alkalies, organic matters or other harmful substances which may be
deleterious to concrete, masonry or steel. The pH value of water sample shall be not less than 6.
Potable water shall be considered satisfactory. Underground water can also be used with the prior
approval of Engineer-in-Charge, if it meets all the requirements of IS:456.

3.2 Tests on water samples shall be carried out in accordance with IS:3025 and they shall fulfill all
the guidelines and requirements given in IS:456.

3.3 The Engineer-in-Charge may require the Contractor to prove, that the concrete prepared with
water, proposed to be used, shall have average 28 days compressive strength not lower than 90%
of the strength of concrete prepared with distilled water.

3.4 The Engineer-in-Charge may require the Contractor to get the water tested from an approved
laboratory before starting the construction work and in case the water contains any oil/organic
matter or an excess of acid, alkalies or any injurious amount of salts etc., beyond the permissible
maximum limits given in IS:456, the Engineer-in-Charge may refuse to permit its use. In case the
water is supplied by the owner, contractor shall get himself satisfied regarding its quality before
using the same in his works at his own expense. In case there is any change in source of water,
water samples shall be tested again to meet the specified requirements.

3.5 Water shall be stored in tin barrels, steel tanks or water-tight reservoirs made with bricks / stone
or reinforced concrete. Brick/stone masonry reservoirs shall have RCC base slab and shall be
plastered inside, with 1 part of cement and 4 parts of sand and finished with neat cement punning.
These reservoirs shall be of sufficient capacity to meet the water requirement, at any stage of
construction.

3.6 Water for curing shall be of the same quality as used for concreting and masonry works. Sea
water shall not be used for preparation of cement mortar, concrete as well as for curing of
plain/reinforced concrete and masonry works. Sea water shall not be used for hydrotesting and
checking the leakage of liquid retaining structures also.

4.0 AGGREGATE

4.1 General

4.1.1 Coarse and fine aggregates for Civil and Structural Works shall conform in all respects to IS:383
(Specification for coarse and fine aggregates from natural sources for concrete). Aggregates shall
be obtained from an approved source known to produce the same satisfactorily. Aggregates shall

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 13 OF 221

 consist of naturally occurring (crushed or uncrushed) stones, gravel and sand or a combination
thereof. These shall be chemically inert, hard, strong, dense durable, clean and free from veins,
adherent coatings, injurious amount of alkalies, vegetable matter and other deleterious substances
such as iron pyrites, coal, lignite, mica, shale, sea shells etc.

4.1.2 Source and type of aggregates shall be got approved by the Engineer-in-Charge prior to
procurement. Change in source and type of aggregates, at later stage, shall not be generally
permitted; but under specific circumstances, Engineer-in-Charge can allow a change in source
and type of aggregate. Contractor shall produce necessary test certificates from approved
laboratories regarding the quality and suitability of the proposed aggregates and submit fresh mix
design for approval of the Engineer-in-Charge. Any such change, if permitted by the
Engineer-in-Charge, shall be without any time and cost implication to the owner.

4.1.3 Aggregates which may chemically react with alkalies of cement or might cause corrosion of the
reinforcement, shall not be used. If so desired by the Engineer-in-Charge, the Contractor shall
carry out alkali reactivity tests and submit the results to him for approval.

4.1.4 The maximum quantities of deleterious materials in the aggregates as determined in accordance
with IS:2386 - Part II (Methods of Test for aggregates for concrete), shall not exceed the limits
defined in IS:383. No special test is required to prove the absence of such deleterious matters if
the aggregates are from a known source with satisfactory prior data on the properties of concrete
made with them. In case of newly developed quarry sites, the contractor shall submit necessary
test results as per IS:383 and IS:2386 to the Engineer-in-Charge prior to his acceptance and
approval. The method of Sampling shall be in accordance with the requirements given in IS:2430.

4.1.5 Coarse and fine aggregates shall be batched separately. All-in-aggregate shall be used only where
specifically permitted by the Engineer-in-Charge.

Separate sieve analysis and grading curves shall be prepared by the Contractor for any/all batches
of coarse and fine aggregates, and submitted to the Engineer-in- Charge, whenever asked for, to
ensure conformity with those submitted along with the mix design.

4.1.6 Whenever required by Engineer-in-Charge, the aggregates (coarse/fine) shall be washed and/or
sieved by the contractor before use in the works to obtain clean and graded aggregate at no extra
cost to the owner.

4.1.7 Aggregates not in conformity with the specifications shall be rejected and the Contractor shall
immediately remove them from the site of work.

4.2 Coarse Aggregates

4.2.1 Coarse aggregates are the aggregates, which are retained on 4.75mm BIS Sieve. It shall have a
specific gravity not less than 2.6 (saturated surface dry basis).

4.2.2 These may be obtained from crushed or uncrushed gravel or stone as per clause 3.1 and may be
supplied as single sized or graded. The grading of the aggregates shall be as per IS:383 or as
required by the mix design, to obtain densest possible concrete. For this purpose, the contractor
shall submit to the Engineer-in-Charge at least three sets of mix design and test results, each with
different gradings of coarse aggregates, proposed to be used. The Engineer-in-Charge may allow
"All-in-aggregates" to be used provided they satisfy the requirements of IS:383.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 14 OF 221

4.3 Fine Aggregates

4.3.1 Fine aggregates are the aggregates which pass through 4.75mm BIS sieve but not more than ten
percent (10%) pass through 150 micron BIS sieve. These shall comply with the requirements of
grading zones I,II and III of IS:383. Fine aggregates conforming to grade zone IV shall not be
used for reinforced concrete works.

4.3.2 Fine aggregates shall consist of material resulting from natural disintegration of rock and which
has been deposited by streams or glacial agencies, or crushed stone sand or gravel sand. Sand
from sea shores, creeks or river banks affected by tides, shall not be used for filling or concrete
works.

4.4 Sampling and Testing

The Contractor shall carry out all tests including mix designs of concrete, at his own expense, at
the start of work as well as during any stage of construction as required by the
Engineer-in-Charge. Test shall be carried out in accordance with IS:516- Methods of test for
strength of concrete and IS:2386-Methods of test for aggregates for concrete. Testing shall be
carried out from laboratories approved by the Engineer- in-Charge. The method of sampling shall
be in accordance with the requirements given in IS:2430.

4.5 Storage of Aggregates

4.5.1 Storage of all types of aggregates at site of work shall be at contractor's expense and risk and
shall be stored as specified in IS:4082. Aggregates shall in no case be stored near to the excavated
earth or directly over ground surface.

4.5.2 The Contractor shall maintain sufficient quantities of aggregates, near to the place of work,
required for the continuity of the work. Each type and grade of aggregate shall be stored
separately on hard, firm surface having adequate slope for drainage of water.

4.5.3 Aggregates delivered at site in wet condition or becoming wet due to rain or any other means,
shall not be used for atleast 24 hours. The Contractor shall obtain prior approval of the Engineer-
in-charge for the use of such aggregates and shall adjust the water content in accordance with
IS:2386 to achieve the desired mix. In the absence of test results, and to allow variation in mass
of aggregates and water content on account of moisture content, the Contractor can make suitable
adjustment in the masses as per IS:456, for preparation of nominal mix concrete only.

5.0 SAND

5.1 Sand for Masonry Mortars

5.1.1 The sand shall consist of natural sand, crushed stone sand or crushed gravel sand or a
combination of any of these. The sand shall be hard, durable, clean and free from adherent
coatings and organic matter and shall not contain the amount of clay, silt and fine dust more than
specified in IS:2116.

5.1.2 The sand shall not contain any harmful impurities such as iron pyrites, alkalis, salts, coal or other
organic impurities, mica, shale or similar laminated materials, soft fragments, sea shells in such

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 form or in such quantities as to affect adversely the hardening, strength or durability of the
mortar.

5.1.3 Unless found satisfactory as a result of further tests as may be specified by the Engineer-in-
Charge, or unless evidence of such performance is offered which is satisfactory to him, the
maximum quantities of clay, fine silt, fine dust and organic impurities in the sand, when tested in
accordance with IS:2386, shall not be more than 5% by mass in natural sand, or crushed gravel
sand or crushed stone sand. For organic impurities, when determined in accordance with IS:2386,
colour of the liquid shall be lighter than that indicated by the standard solution specified in
IS:2386.

5.1.4 Grading of Sand

The particle size grading of sand for use in mortars shall be within the limits as specified below:

GRADING OF SAND FOR USE IN MASONRY MORTARS

IS SIEVE DESIGNATION PERCENTAGE REF. TO

IS:460 (PART I) PASSING BY MASS METHOD OF

4.75 mm 100 IS:2386(Part I)

2.36 mm 90 to 100
1.18 mm 70 to 100
600 micron 40 to 100
300 micron 5 to 70
150 micron 0 to 15

In case of a sand whose grading falls outside the specified limits due to excess or deficiency of
coarse or fine particles, this shall be processed to comply with the standard by screening through
a suitably sized sieve and/or blending with required quantities of suitable sizes of natural sand
particles or crushed stone screenings which are by themselves unsuitable. Based on test results
and in the light of practical experience with the use of local materials, deviation in grading of
sand may be considered by the Engineer-in-Charge. The various sizes of particles of which the
sand is composed shall be uniformly distributed throughout the mass.

5.1.5 Sampling and Testing

The method of sampling shall be in accordance with IS:2430. The amount of material required for
each test shall be as specified in relevant parts of IS:2386. Any test which the engineer-in-charge
may require in connection with this, shall be carried out in accordance with the relevant parts of
IS:2386.

If further confirmation as to the satisfactory nature of the material is required, compressive test on
cement mortar cubes (1:6) may be made in accordance with IS:2250 using the supplied material
in place of standard sand and the strength value so obtained shall be compared with that of
another mortar made with a sand of acceptable and comparable quality.

5.2 Sand for Filling

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 Sand for filling shall meet the requirements of IS:383 and shall be natural sand, hard, strong, free
from any organic and deleterious materials. Any sand proposed for filling, shall be used only
after it is approved by the Engineer-in-Charge. Sand obtained from sea shores, creeks or river
banks affected by tides, shall not be used for filling. Fine aggregates suitable for concreting works
shall be suitable for filling also. No sand below grading zone-III as per IS:383 shall be allowed
for filling.

6.0 CEMENT

Cement to be used for civil and structural works shall be one of the following. Specific
requirement for the type of cement to be used shall be as shown in the drawings or as specified in
the contract or as directed by the Engineer-in-Charge.

• Specification for 43 grade ordinary portland cement IS:8112

• Specification for 53 grade ordinary portland cement IS:12269
• Specification for portland slag cement IS:455
• Specification for Portland pozzolana cement (fly ash based) IS:1489 Pt.1
• Specification for Portland pozzolana cement(calcined clay based) IS:1489 Pt.2
• Specification for Sulphate Resisting Portland cement IS:12330

6.1 Storage at Site

6.1.1 The storage of cement (lifted from the Owner's godown or procured by the Contractor himself) at
the site of work shall be at contractor's expense and risk and shall meet the requirements of
IS:4082. The cement shall be stored above ground in a suitable weather tight building or godown
and in such a manner as to permit easy access for proper inspection and also to prevent
deterioration due to moisture. In the event of any damage occurring to the quality of cement due
to faulty storage or on account of negligence on the part of the contractor, such damages shall be
borne by the contractor himself.

6.1.2 All approved cement shall be arranged in batches with type, brand and date of receipt flagged on
them. A maximum of eight bags shall be stacked one over the other. Cement bags shall be used in
the same order as received from the manufacturer/ owner. The contractor shall maintain a
register, on day to day basis, giving the details of the receipt/consumption, source of supply and
type of cement etc. The register shall always be accessible to the Engineer-in-Charge for
verification.

6.2 Tests after Delivery

Each consignment of cement supplied by Owner or contractor, shall, after delivery at site and at
the discretion of the Engineer-in-Charge, be subjected to any or all of the tests and analyses,
required by the relevant Indian Standard Codes. In case the cement is supplied by the owner, the
contractor shall get himself satisfied regarding its quality before using the same in his works at
his own expense. The contractor shall carry out and bear the cost of all tests and analyses required
to ensure quality of cement before using in actual works, irrespective of the fact whether the
cement is supplied by the Owner or procured by him.

6.3 Rejection

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 The Engineer-in-Charge may reject at his discretion any cement, notwithstanding the
manufacturer's certificate or failing to meet the requirements of relevant BIS Codes for testing of
cement. He may similarly reject any cement which has deteriorated owing to inadequate
protection from moisture or due to intrusion of foreign matter or any other cause. Any cement
which is considered defective, shall not be used and shall be promptly removed from the site by
the contractor.

7.0 STEEL

7.1 General

All steel bars, sections, plates, and other miscellaneous steel materials, etc shall be free from
loose mill scales, rust as well as oil, mud, paint or other coatings. The materials, construction
specifications such as dimensions, shape, weight, tolerances, testing etc, for all materials covered
under this section, shall conform to respective BIS Codes. Steel sections shall be conforming to
IS:808 or IS:12778.

7.2 Reinforcement Bars

Reinforcement bars, to be used for civil and structural works shall be one of the following or in
combination thereof.

• Mild Steel and Medium Tensile Steel Bars and Hard-Drawn

Steel Wire for Concrete Reinforcement IS: 432
• Specification for hard drawn steel wire fabric for concrete reinforcement IS:1566
• Specification for High strength deformed steel bars and wires for
concrete reinforcement. IS:1786

7.3 Structural Steel

Structural steel to be used for general structural purposes shall be one of the following or in
combination thereof.

Structural steel sections shall conform to following BIS Codes:

• Steel tubes for structural purposes. IS:1161

• Mild Steel Tubes,tubulars and other wrought steel fittings. IS:1239
• Steel for general structural purposes (Grade A/BR/B0/C). IS:2062
• Hollow steel sections for structural use. IS:4923

7.4 Miscellaneous Steel Materials

Miscellaneous steel materials shall be conforming to the following BIS Codes.

• Expanded Metal Steel Sheets for General purposes. IS:412

• Mild steel bars of anchor bolts, rungs, metal inserts, grating etc. IS:2062
• Hexagonal headbolts, screws & nuts of product grade C. IS:1363
• Cold formed light gauge structural steel sections. IS:811
• Technical supply conditions for threaded steel fasteners. IS:1367
• Plain washers IS:2016

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 • Steel wire ropes for general engineering purposes IS:2266
• Thimbles for wire ropes. IS:2315
• Bulldog grips. IS:2361
• Mild Steel Tubes, tubulars and other wrought steel fillings.
(For Hand rail tubular sections). IS:1239
• Drop forged sockets for wire ropes for general engineering purposes. IS:2485
• Steel chequered plates. IS:3502
• Hexagonal bolts and nuts (M42 to M150). IS:3138
• High Strength Structural Bolts IS:3757
• High Strength Bolts IS:4000

Anchor Bolts

Material for Anchor Bolts such as MS bars, washers, nuts, pipe sleeves and plates etc. shall be as
per relevant BIS Codes mentioned above.

7.5 Storage

The storage of all materials at site of work shall be at the contractor's expense and risk and shall
be done as per the requirements given in IS:4082. The contractor shall maintain the proper
records of receipt/consumption. The records shall always be accessible to the Engineer-in-Charge
for verification.

The reinforcement bars, structural steel sections and other miscellaneous steel materials etc, shall
be stored in such a way as to avoid and prevent deterioration, corrosion, bending, twisting and
wrapping. In case of any damage occurring to the material on account of faulty storage or
negligence by the contractor, same shall be borne by the contractor himself.

7.6 Tests after Delivery

Materials supplied by the Owner or Contractor, shall, after delivery at site and at the discretion of
Engineer-in-Charge, be subjected to any or all of the tests, required by the relevant BIS Codes.
The Contractor shall carry out and bear the cost of such tests irrespective of the fact whether the
material is procured by the Owner or the contractor. In case steel is supplied by the Owner, the
Contractor shall get himself satisfied regarding its quality before using the same in his works at
his own expense.

7.7 Rejection

The Engineer-in-charge may reject at his discretion any material, notwithstanding the
manufacturer's certificate or failing to meet the requirements of relevant BIS Codes for testing of
materials. He may similarly reject any material, which has deteriorated or corroded etc., due to
improper storage, handling or transport. Defective materials shall not be used and removed from
the site by the contractor at his own expense.

10.0 ADMIXTURES
10.1 General Requirements for Admixtures

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10.1.1 All concrete admixtures shall in general comply with the following BIS Codes unless otherwise
stipulated in this specification.

• Specification for integral cement water proofing compounds. IS:2645

• Specification for other admixtures for concrete. IS:9103

10.1.2 Generally, admixtures shall have ISI certification marks. However, even in case of BIS certified
admixtures, Engineer-in-Charge may require the Contractor to carry out and submit any or all the
tests (as specified in relevant BIS Codes), from BIS approved laboratories, over and above the
manufacturer's test certificate, before giving his final approval.
In case, admixtures certified by BIS are not available, the contractor shall submit to the
Engineer-in-Charge the type and/or proprietary brand of the admixture from only reputed
manufacturers along with necessary test certificates from BIS recognized/ BIS approved
laboratories or any other document directed by Engineer-in-Charge for the latter's final approval.
In such cases, names of at least two manufacturers shall be submitted to the Engineer-in-Charge
for his selection. In case, both the names are rejected, the contractor shall submit a fresh list of
two manufacturers for approval by the Engineer-in-Charge.

The Engineer-in-Charge may direct the contractor to submit test results as required by IS:2645 or
IS:9103 for any admixture proposed to be used in the concrete in any approved laboratory at his
discretion at any stage of the work. The cost of any/all tests required to satisfy compliance with
this specification shall be borne by the Contractor.

In case of non-availability of any BIS code for testing and acceptability criteria, relevant
American, British or German Code shall be applicable.

10.1.3 Prior approval of the Engineer-in-Charge shall be obtained while using water reducing
admixtures in the concrete (PCC/RCC) or mortar. Other type of admixtures such as accelerating
admixtures, retarding admixtures or air entraining admixtures, shall not be used unless specified
on the design drawings or prior approval taken from the design approving authority. Once
approved, utmost care shall be exercised at site by the Contractor to maintain the consistency in
the quality of admixture and the concrete/ mortar so produced.

10.1.4 The suitability and effectiveness of any admixture shall be verified by trial with the designed
concrete mixes using cement, aggregates together with any other materials to be actually used in
the works as per the direction of Engineer-in-Charge. If two or more admixtures are to be used
simultaneously in the same concrete mix, the Contractor must submit necessary test results from
an approved laboratory to show their interaction and compatibility. Any/all tests specified in BIS
Codes shall be carried out only with the type of material and mix design, to be actually used in
the work site.

10.1.5 No admixture shall impair the durability of the concrete nor combine with the ingredients to form
harmful compounds nor increase the risk of corrosion of reinforcement. Use of admixtures shall
not reduce the dry density of concrete. Once the proportion of admixture has been established,
strict check shall be maintained not to alter the proportions of ingredients and water-cement ratio
of the Design Mix during execution.

10.1.6 The chloride contents in admixtures shall not exceed 2% by mass of the admixture or 0.03% by
mass of the cement.

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10.1.7 Admixtures which do not meet the requirements stipulated in this specification shall be rejected
and shall not be used.

10.2 Water Proofing Compounds

10.2.1 Water proofing compounds shall be mixed with cement only.

10.2.2 The permeability of the specimen with the admixture shall be less than half of the permeability
with similar specimen without the use of these compounds. These compounds shall be used in
such proportion as recommended by manufacturer but in no case it shall exceed 3% by weight of
cement.

10.2.3 The initial setting time of the cement with the use of these compounds shall not be less than 30
minutes and final setting time shall not be more than 10 hours. Test shall be carried out in
accordance with IS:4031.

10.2.4 Compressive strength of specimen at 3 days shall not be less than 160kg/sq.cm nor 80% of the 3
days compressive strength of mortar cubes prepared with same cement and sand only, whichever
is higher. Similarly compressive strength at 7 days shall not be less than 220 kg/sq.cm nor less
than 80% of the 7 days compressive strength prepared with the same cement and sand only,
whichever is higher. The test to determine the compressive strength shall conform to IS:4031.

10.3 Anti Freezing compound:

Antifreeze is ready for use in cold conditions such as:

a. Slight daytime frost.
b. Expected overnight frost.
c. Expected cold periods.
Antireeze liquid to be added to the mixing water prior to its addition to the concrete mix as the last component.

Dosage: As per manufacturer specification.Exact quantity is determined experimentally for the particular
cases.

11.0 WATER BARS (WATER STOPS)

PVC water bars shall be used in reinforced concrete construction of liquid retaining structures or
any other structure to safeguard them from hydrostatic pressure and water leakage and any
relative movement between two parts of the structure due to thermal loading shrinkage or
differential movement of foundations. Wherever desired or shown in the drawings, they shall be
used at expansion/contraction/construction joints. These shall be pre-formed and shall provide a
permanent water tight seal along the entire joint in the poured concrete structures. These shall
also be flexible enough to withstand deflection/displacements at joints arising due to variation of
temperatures or settlement of foundations. The minimum thickness of water bar shall be as shown
on drawings or described in the schedule of rates and unless otherwise mentioned, these shall be
able to withstand a water head of at least 12 meters.

Performance requirements of PVC water bars shall meet the requirements of IS:12200. These
shall be of approved make and of ribbed/serrated/plane type with a bulb at the centre. The
thickness and width of water bars shall be as per schedule of rates/ drawings but in no case the
thickness shall be less than 5mm and width less than 150mm. The joining of the water bars shall
be carried out by vulcanising strictly as per the manufacturer's specifications. Lapped joints shall
not be allowed under any circumstances.

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12.0 BITUMEN/BITUMINOUS MATERIALS

Bitumen to be used for various types of work shall meet all the requirements of relevant BIS
Codes as given below:

• Specification of Paving Bitumen. IS:73

• Specification for bitumen mastic for flooring. IS:1195
• Specification for Bitumen felts for water proofing anddamp proofing. IS:1322
• Specification for Bituminous compounds for water proofing
and caulking purposes. IS:1834
• Specification for preformed fillers for expansion joint
in concrete pavements and structures. IS:1838
• Specification for bitumen mastic for use in water proofing of roofs. IS:3037
• Specification for bitumen primer for use in water proofing anddamp proofing. IS:3384
• Specification for Bitumen Mastic for Tanking and Damp proofing. IS:5871
• Specification for Glass fibre base coal tar pitch & bitumen felts. IS:7193
• Code of practise for damp proofing using bitumen mastic. IS:7198
• Specification for bitumen Mastic, Anti Static
and electrically conducting grade. IS:8374

The type and grade shall be as shown on the drawings or as indicated in schedule of quantities or
as directed by Engineer-in-Charge. Tests and acceptable criteria shall be as per relevant BIS
Codes.

13.0 PVC PIPES

PVC Pipes shall conform to the requirements of IS:4985.

14.0 WOOD/TIMBER

14.1 Timber required to be used for formwork shall be fairly dry before use. It should maintain its
shape during the use and even when it comes into contact with moisture from the concrete.
Storage of Wood/Timber shall be as per the requirements of IS:4082.

For proper identification and selection of suitable timber for formwork, following codes shall be
referred.

• Classification of commercial timbers and their zonal distribution IS:399

• Specification for ballies for general purposes. IS:3337
• Specification for Ply wood for concrete shuttering work. IS:4990

16.0 PAINT

16.1 Refer paintingjob Specification.

17.0 ANTITERMITE COMPOUNDS

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17.1 Chloropyrifos emulsifiable concentrates (1%) conforming to IS:8944 shall be used for treatment
of soil for protection of buildings against attack by subterranean termites.

18.0 POLYSULPHIDE SEALANTS

Polysulphide Sealants shall conform to IS:12118 and be of approved make. Test conditions and
requirements shall be as given in the above referred BIS code.

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 SPECIFICATION-3: CIVIL & STRUCTURAL WORKS - PLAIN & REINFORCED CEMENT
CONCRETE

Relevant SOR item no: S001 to S015

1.0 SCOPE
This specification is applicable for Concrete Grade up to M60 and establishes the requirements
of materials, mix proportioning, placing, curing, etc. of all types of cast-in-situ and precast
concrete (ref. section 1.6) used in foundations, underground and above ground structures,
floors, pavements etc. Any special requirements as shown or noted on the drawings shall
supersede the provisions of this specification.

1.1 Reference Codes and Specifications

Apart from this specification, construction of plain and reinforced concrete works shall be in
accordance with the Indian Standard Code of Practice for "Plain and Reinforced Concrete" IS
456: 2000 along with all amendments till date and other relevant codes mentioned therein.
1.2 For Liquid Retaining Structures, refer Specification: CIVIL & STRUCTURAL WORKS -
REINFORCED CEMENT CONCRETE FOR LIQUID RETAINING STRUCTURES.

1.3 For Structural Steel worksrefer Specification: CIVIL & STRUCTURAL WORKS -
STRUCTURAL STEEL WORKS.

In case of conflict between the clauses mentioned in this specification and those in the Bureau
of Indian Standards (BIS), specification of DSORP,this specification shall govern.

2.0 MATERIALS
Materials for concrete viz cement, Pozzolanas, Fly Ash, Ground Granulated Blast Furnace Slag,
Sand, Coarse aggregate, Water, etc. shall conformto relevant clauses under specification: CIVIL
& STRUCTURAL WORKS - MATERIALS.
Materials for all reinforcements, embedment, inserts, water bars etc. shall conform torelevant
clauses under Specification: CIVIL & STRUCTURAL WORKS - MATERIALS.
Materials to be used as additive to concrete shall conform to relevant clause of
Specification: CIVIL & STRUCTURAL WORKS - MATERIALS.

3.0 GRADES OF CONCRETE

Characteristic Compressive strength for different grades of concrete shall be as per Table-1.
TABLE – 1
GRADES OF CONCRETE

Group Grade Designation Specified Characteristic

Compressive Strength
of 150 mm cube at 28 days
(N/mm2)

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 Ordinary M10 10
Concrete M 15 15
M 20 20
Group Grade Designation Specified Characteristic
Compressive Strength
of 150 mm cube at 28 days
(N/mm2)
Standard M 25 25
Concrete M 30 30

Note: The characteristic strength is defined as the strength of material below which not more
than five (5) percent of the test results are expected to fall.

4.0 TYPE OF CONCRETE MIX

Unless otherwise noted on drawings, all lean/plain concrete shall be of Nominal Mix type and
reinforced concrete shall be of Design Mix type.

Nominal Mix Concrete

This concrete shall be made (without preliminary tests) by adopting nominal concrete mix with
proportions of materials as specified in Table 9 of IS: 456.

Design Mix Concrete

The mix shall be designed as per IS: 10262 in an approved laboratory to produce the grade of
concrete having the required workability and characteristic strength not less than appropriate
values given in Table-1. The target mean strength of concrete mix shall be equal to the
characteristic strength plus 1.65 times the standard deviation.
As long as the quality of materials does not change, a mix design done earlier but not prior to
one year may be considered adequate for later work. However, in case the source & quality of
materials changes or there is a break in the continuity of construction, the Engineer-In-Charge
shall ask for a new design mix.
Irrespective of the grade of concrete required to be produced as per characteristic strength
criteria, the minimum cement content and maximum water cement ratio in the design concrete
shall be strictly maintained as stipulated in Table 5 of IS: 456.

5.0 CONCRETE MIX PROPORTIONING

Proportioning, as used in this specification, shall mean the process of determining the
proportions of the various ingredients to be used to produce concrete of the required
workability when fresh/green and strength, durability & surface finish, when hardened. The
following information shall be collected prior to design of the concrete mix:
a) Grade designation.
b) Type of cement.
c) Maximum nominal size of aggregate.
d) Minimum cement content.
e) Maximum water cement ratio
f) Workability requirements.
g) Exposure condition as per Table 3 & Table 4 of IS:456

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 h) Maximum temperature of concrete at the time of placing.
i) Method of Placing.

The Engineer-in-Charge shall verify the strength of the concrete mix, before giving his sanction
of its use. However, this does not absolve the Contractor of his responsibility as regards
achieving the prescribed strength of the mix. If during the execution of the work, cube tests
show lower strengths than required, the Engineer-in-Charge shall order fresh trial mixes to be
made by the Contractor. No claim to alter the rates of concrete work shall be entertained due to
such changes in mix variations. Any variation in cement consumption shall be taken into
consideration for material reconciliation. Preliminary mix designs shall be established well
ahead of start of work.

5.1 Maximum Density

Suitable proportions of sand and the different sizes of coarse aggregates for each grade of
concrete shall be selected to give as nearly as practicable the maximum density as per clause
10.2.3 of IS 456. This shall be determined by mathematical means, laboratory tests, field trials
and suitable changes in aggregate gradation. The contractor shall ensure the same to the
satisfaction of Engineer-in-Charge.

5.2 Consistency

The concrete shall have a consistency such that it shall be workable in the required position and
when properly vibrated it flows around reinforcing steel, all embedded fixtures, etc.

5.3 Workability

“Workability of Concrete” shall be as per clause 7 of IS: 456.

5.4 Durability

For achieving sufficiently durable concrete, strong, dense aggregates, low water-cement ratio
and adequate cement content shall always be used. Workability of concrete shall be such that
concrete can be completely compacted with the means available. Leak-proof formwork shall be
used so as to ensure no loss of cement-slurry during pouring and compaction. Cover to
reinforcement shall be uniform. Concrete mix design shall always take into account the type of
cement, minimum cement content irrespective of the type of cement and maximum water
cement ratio and minimum grade of concrete conforming to environmental exposure conditions
(refer Table 3 of IS 456) as given in Table5 of IS: 456.

Generally, following types of cement shall be used for Plain and Reinforced concrete works:
a) 43 Grade Ordinary Portland Cement conforming to IS: 8112.
b) 53 Grade Ordinary Portland Cement conforming to IS: 12269.
c) Rapid hardening Portland Cement conforming to IS: 8041.
d) Portland Slag Cement conforming to IS: 455.
e) Portland Pozzolana Cement(fly ash based) conforming to IS:1489(Part 1)
f) Portland Pozzolana Cement (calcined clay based) conforming to IS: 1489(Part-2).
g) Sulphate Resisting Portland Cement conforming to IS: 12330

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 Sulphate Resisting Portland Cement shall be used only for specific requirements depending on
environmental and process exposure conditions to which the structures may be subjected to like
high Sulphate concentrations, processes involving Sulphur handling etc.
Water Cement Ratio
Once a mix, including its water cement ratio, has been determined and approved for use by the
Engineer-in-Charge, that water cement ratio shall be maintained. The Contractor shall
determine the water content of the aggregates frequently as the work progresses, and the
amount of mixing water shall be adjusted so as to maintain the approved water cement ratio.
Maximum free water-cement ratio shall be as per Table5 of IS: 456 for different exposure
condition.
The minimum cement content as mentioned in Table 5 of IS: 456 shall be adjusted for
aggregates other than 20mm nominal maximum size as defined in Table 6 of IS 456.

For maximum cement content refer Cl.8.2.4.2 of IS: 456.

5.5 Limits to Deleterious Constituents

Careful selection of the mix and the constituent materials shall be made to limit the presence of
deleterious constituents in concrete. The total acid soluble chloride content calculated from the
mix proportion and the measured chloride content of each of the constituents shall not exceed
0.6 kg/m3 at the time of placing of concrete. The total water soluble Sulphate content of the
concrete mix shall not exceed 4 percent by mass of the cement in the mix.

6.0 BATCHING
Refer clause 10.2 of IS: 456.

7.0 CONCRETE MIXING

7.1 Ready Mixed Concrete supplied by Ready Mixed Concrete Plants or from on/off-site batching
plants (IS: 4926) shall be used for structural concrete.
All records and charts for the batching and mixing operations shall be prepared and maintained
by the contractor in accordance with IS: 4926 or as per the instructions of Engineer-in-Charge.
In case Ready Mixed Concrete is not available, the mixing of concrete shall be strictly carried
out in an approved type of mechanical concrete mixer. The mixer shall be fitted with water
measuring devices. The mixing shall be continued until there is a uniform distribution of the
material and the mass is uniform in colour and consistency. If there is segregation after
unloading from the mixer, the concrete shall be remixed.

7.2 Mixer
Mechanical Mixers shall comply with IS: 1791 and 12119 and shall be maintained in
satisfactory operating condition. These shall be used only for producing lean/ plain concrete
and/ or nominal mix concrete wherever permitted.
Mixing Time

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 Mixing time shall be as indicated in the following Table-2. Excessive mixing requiring
additions of water shall not be permitted. Time shall start when all solid materials are poured in
the revolving mixer drum, provided that all of the mixing water shall be introduced before
one-fourth of the mixing time has elapsed. The Engineer-in-Charge may, however, direct a
change in the mixing time, if he considers such a change necessary.
`
TABLE-2
MINIMUM MIXING TIME FOR MIXERS

Capacity of mixer Minimum mixing time

2 minutes
2 m3 or less
3 minutes or as recommended
Above 2 m3
by the mixer manufacturer.

7.3 Hand Mixing

Hand mixing of concrete shall not be permitted. However, for non-critical applications namely
foundations for crossovers, isolated operating platforms etc., using concrete upto grade M20
and located at far away isolated places, this may be permitted by the Engineer-in-charge as a
special case. Mixing shall be carried out on a water tight platform and care shall be taken to
ensure that mixing is continued until the mass is uniform in colour and consistency. No extra
payment shall be made to the Contractor for mixing by hand or for using extra cement due to
hand mixing.

7.4 Additives
Additive in concrete shall be used only with the prior approval of the Engineer-in-Charge and
shall comply with Cl. 5.5 of IS: 456. Any additive used for obtaining proper workability or leak
proofness of concrete or repair/rendering works of concrete due to non-conformance to the
specifications, shall not be measured and paid for. All costs relating to such usage shall be
borne by the Contractor.

8.0 TRANSPORTATION, PLACING ANDCOMPACTION

8.1 General
The entire concrete placing programme including transportation arrangements, deployment of
equipment, layout, proposed procedures and methods, shall be submitted to the
Engineer-in-Charge 24 hours prior to concreting for approval. No concreting shall be placed
until his approval has been received. Approval of the Engineer-in-Charge for pouring concrete
shall be taken as 'conveyed', when the concrete pour card is signed by him.
8.1.1 Chuting
The use of long troughs, chutes and pipes for conveying concrete from the mixer to the forms
shall be permitted only on written authorization from the Engineer-in-Charge. In case an
inferior quality of concrete is produced by the use of such conveyors, the Engineer-in-Charge
may order discontinuance of their use and the substitution of a satisfactory method of placing
the concrete. Open troughs and chutes shall be equipped with baffles and be in short lengths to
avoid segregation. Chutes shall be designed so that the concrete is, to some extent, remixed at

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 the lower end by passing down through a funnel shaped pipe or drop chute. Alternatively, they
shall discharge into a storage hopper from which the concrete shall be transported to the point
of placing by wheel barrows or other means. Where drop chutes are used, a sufficient number
of these must be provided, so that the concrete discharged from the chute is not required to flow
laterally more than 1.0 metre. Where a drop chute is swung from the vertical, the bottom two
sections must be maintained in a vertical position to avoid segregation. The addition of water at
any point in the system of transportation, to facilitate the movement of concrete shall not be
permitted. All chutes, troughs and pipes, shall be kept clean and free from coatings of hardened
concrete by thoroughly flushing them with water after each run; water used for flushing shall be
discharged clear of the structure.

8.1.2 Vibrators
8.1.2.1 Concrete shall be compacted with mechanical vibrating equipment supplemented, if necessary
to obtain consolidation, by hand spreading, rodding and tamping. The vibrators shall be of
immersion type with operational frequency ranging between 8,000 to 12,000 vibrations per
minute. All vibrators shall comply with IS: 2505. Screed board concrete vibrators or
concreting vibrating tables or form vibrators conforming to IS: 2506, 2514 and 4656
respectively shall be used where specifically required and directed by Engineer-in-Charge.
8.1.2.2 Immersion type vibrators shall be inserted in a vertical position at intervals of about 600mm,
depending upon the mix, the equipment used, and experience on work. The vibrators shall be
withdrawn slowly. The spacing shall provide some overlapping of the area vibrated at each
insertion. In no case shall vibrators be used to transport concrete inside the forms. Over
vibration or under vibration shall not be permitted as both are harmful. Hand tamping in some
cases may be allowed subject to the approval of the Engineer-in-Charge.
8.1.2.3 In placing concrete in layers which are advancing horizontally as the work progresses, great
care shall be exercised to ensure adequate vibration, bonding and moulding of the concrete
between the succeeding batches.
8.1.2.4 The vibrator shall penetrate the layer being placed and also penetrate the layer below while the
under layer is still plastic to ensure good bond and homogeneity between the two layers and
prevent the formation of cold joints.
8.1.2.5 Care shall be taken to prevent contact of vibrators against all embedded reinforcing steel or
inserts. Vibrators shall not be allowed to come in contact with forms.
8.1.2.6 The use of form vibrators shall not be permitted for compaction of in-situ concrete without
specific authorization of the Engineer-in-Charge.
8.1.2.7 The use of surface vibrators of screed board type shall not be permitted for consolidation of
concrete under ordinary conditions. However, for thin slabs (of thickness less than 200mm)
surface vibration by such vibrators may be permitted, upon approval of the Engineer-in-Charge.
8.1.2.8 Whenever vibration has to be applied externally, the design of formwork and the disposition of
vibrators shall be carefully planned to ensure efficient compaction and to avoid surface
blemishes.

8.2 Transportation
8.2.1 All concrete shall be conveyed from the mixer to the place of final deposit such as formwork as
rapidly as possible using suitable buckets, dumpers, pumps, transit mixers containers or

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 conveyors which shall be mortar leak tight. Care shall be taken to prevent the segregation or
loss of the ingredients and maintaining the required workability. For structural concrete
produced from Ready Mixed Concrete/ Batching Plants, concrete shall be transported from the
plants to the sites only by transit mixers and Delivery Ticket for each delivery of concrete shall
be maintained by the contractor.
8.2.2 During hot or cold weather, concrete shall be transported in deep containers. Other suitable
methods to reduce the loss of water by evaporation in hot weather and heat loss in cold weather
may also be adopted. All equipment used for transporting and placing of concrete shall be
maintained in clean condition. All buckets, hoppers, chutes, dumpers and other equipment shall
be thoroughly cleaned after each use.

8.3 Placing and Compaction

8.3.1 Before placing concrete, all soil surfaces upon which or against which concrete is to be placed
shall be well compacted and free from standing water, mud or debris. Soft or yielding soil shall
be removed and replaced, with lean concrete or with selected soils/sand and compacted to the
density as directed by Engineer-in-Charge. The surface of absorptive soil (against which
concrete is to be placed) shall be moistened thoroughly so that moisture is not drawn from the
freshly placed concrete. Similarly, for concrete to be placed on formworks, all chippings,
shavings and sawdust etc. shall be removed from the interior of the forms before the concrete is
placed.
8.3.2 Concrete shall not be placed until the formwork, the placement of reinforcing steel, embedded
parts; pockets etc. have been inspected and approved by the Engineer- in-Charge. Any
accumulated water on the surface of the bedding layer shall be removed by suitable means
before start of placement. No concrete shall be placed on a water covered surface.
8.3.3 Concrete shall be discharged by vertical drop only and the drop height shall not normally
exceed 1.5 metre throughout all stages of delivery until the concrete comes to rest in forms.
However, drop height can be relaxed by the Engineer-in-Charge as per the provisions given
under Cl. 8.1.1. For continuous concreting operation windows of suitable size shall be kept in
the formwork or chutes shall be used to avoid segregation of concrete.

8.3.4 Concrete shall be deposited as near as practicable in its final position to avoid rehandling.
Concrete shall be placed in successive horizontal layers. The bucket loads, or other units of
deposit, shall be placed progressively along the face of the layer with such over-lap as will
facilitate spreading the layer of uniform depth and texture with a minimum of hand shovelling.
Any tendency to segregation shall be corrected by shovelling coarse aggregates into mortar
rather than mortar on the coarse aggregates. Such a tendency for segregation shall be corrected
by redesign of mix, change in process or other means, as directed by the Engineer-in-Charge.
8.3.5 All struts, stays and braces (serving temporarily to hold the forms in correct shape and
alignment pending the placing of concrete at their locations) shall be removed when the
concrete placing has reached an elevation rendering their service unnecessary. These shall not
be buried in the concrete. Concrete shall be thoroughly compacted with vibrators and fully
worked around the reinforcement, embedded fixtures and into corners of formwork before
setting commences and shall not be subsequently disturbed. Methods of placing shall be such as
to preclude segregation and avoid displacement of reinforcement or formwork. The formation
of stone-pockets or mortar bondage in corners and against face forms shall not be permitted.
Should these occur, they shall be dug out, reformed and refilled to sufficient depth and shape

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 for thorough bonding as directed by the Engineer-in-Charge. Care shall be taken to avoid
displacement of reinforcement and embedded inserts or movement of formwork.
8.3.6 Unless otherwise approved, concrete shall be placed in single operation to the full thickness of
foundation rafts, slabs, beams and similar members. Concrete shall be placed continuously until
completion of the part of the work between approved construction joints or as directed by the
Engineer-in-Charge.
8.3.7 The method of placing and compaction employed in any particular section of the work shall be
to the entire satisfaction of the Engineer-in-Charge.
8.3.8 During hot weather (atmospheric temperature above 40 degree Celsius) or cold weather
(atmospheric temperature below 5 degree Celsius, the concreting shall be done as per the
procedure set out in IS: 7861). CONCRETING SHOULD NOT BE TAKEN UP WHEN
ATMOSPHERIC TEMPERATURE IS BELOW 5 DEGREE CELSIUS.
8.3.9 Concrete that has set standing and becomes stiffened shall not be used in the work.

8.3.10 Continuous Concreting

Where called out on the drawings, continuous concreting shall be done in a single operation as
per the requirements of IS: 456 and IS: 2974. Sufficient "Windows" shall be left in the
formwork for pouring & compaction of concrete and inspection. These windows shall be fixed
tight once the level of concrete reaches their levels.
8.3.11 concreting under special conditions
a) Work in extreme weather conditions during hot or cold weather, the concreting shall
be done as per procedure set out in IS: 7861(Part 1) or IS: 7861 (Part2).
b) Under water concreting shall be as per clause 14.2 of IS: 456.
8.4 Items Embedded in Concrete
Concreting shall not be started unless the electrical conduits, pipes, fixtures etc., wherever
required, are laid by the concerned agency. The Contractor shall afford all the facilities and
maintain co-ordination of work with other agencies engaged in electrical and such other works
as directed by the Engineer-in-Charge.
Before concreting, the Contractor shall provide, fabricate and lay in proper position all metal
inserts, anchor bolts, pipes etc. (which are required to be embedded in concrete members) as
per relevant drawings and directions of Engineer-In-Charge.

All embedment, inserts etc. shall be fully held and secured in their respective positions by the
concerned agencies to the entire satisfaction of Engineer-in-Charge so as to avoid any
dislocation or displacement during the concreting operations. The Contractor shall take all
possible care during concreting to maintain these embedment/inserts in their exact locations.

9.0 CONSTRUCTION JOINTS

Construction joints shall be provided in position as shown or described on the drawings or as

directed by the Engineer-in-Charge. Such joints shall be kept to the minimum. These shall be
straight and at right angles to the direction of main reinforcement and shall be placed at
accessible locations to permit cleaning out of laitance, cement slurry and unsound concrete.

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 In a column, the joint shall be formed about 100mm to 150mm below the lowest soffit of the
beams framing into it. Concrete in a beam and slab shall be placed throughout without a joint
but if the provision of a joint is unavoidable, the joint shall be vertical and located within 1/3 to
1/4 of the span, unless otherwise shown on the drawings.

When stopping the concrete on a vertical plane in slabs and beams, an approved stop board
shall be placed with necessary slots for reinforcement bars. The construction joints shall be
keyed by providing a triangular or trapezoidal fillet nailed on the stop board. Inclined joints
shall not be permitted. Any concrete flowing through the joints of stop board shall be removed
soon after the initial set. When concrete is stopped on a horizontal plane, the surface shall be
roughened and cleaned after the initial set and a triangular or trapezoidal groove shall be
provided for keying with the new concrete later.

When the work has to be resumed on a surface which has hardened, such surface shall be
cleared of any foreign materials and roughened to expose the tips of the coarse aggregate. This
may be done by manual chipping of concrete, with a high pressure water jet or by any other
appropriate means as per Engineer-in-Charge’s directions. It shall then be swept clean and
thoroughly washed and wetted before any new concrete is poured. Any set mortar or concrete
sticking to the exposed reinforcing rods in and around such joints shall be thoroughly removed.
The reinforcements shall be wire brushed and washed just before pouring any cement slurry or
mortar. For vertical joints neat cement slurry shall be applied on the surface before it is dry. For
horizontal joints the surface shall be covered with a layer of mortar about 10 to 15mm thick
composed of cement and sand in the same ratio as the cement and sand in concrete mix. This
layer of cement slurry or mortar shall be freshly mixed and applied immediately before placing
new concrete.

Where the concrete has not fully hardened, all laitance shall be removed by scrubbing the wet
surface with wire or bristle brushes, care being taken to avoid dislodgement of particles of
aggregate. The surface shall be thoroughly wetted and all free water removed. The surface shall
then be coated with neat cement slurry. On this surface layer of concrete not exceeding 150mm
in thickness shall first be placed and shall be well rammed against old work, particular attention
being paid to corners and close spots; work thereafter shall proceed in normal way.

10.0 SEPARATION JOINT

Separation joint shall be obtained by using an approved Alkathene sheet stuck on the surface
against which concrete shall be placed. Adequate care shall be taken to cause no damage to the
sheet.

11.0 EXPANSION JOINTS/ISOLATION JOINT

Expansion/ Isolation joints in structures shall be formed in the positions and to the shapes
shown in the relevant drawings. Joints shall be filled with joint filling material as stipulated in
the drawings/schedule of rates. Isolation joints shall be provided around all equipment
foundations, columns, pedestals, trenches etc. on grade.

12.0 WATER STOPS

PVC water stops as per SPECIFICATION: CIVIL & STRUCTURAL WORKS - MATERIALS. shall be
accurately cut, fitted and integrally joined as per manufacturer's specifications to provide a
continuous, watertight diaphragm at all points.

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 The water stops shall be located and embedded at expansion/contraction/ construction joints as
indicated in the drawings or directed by the Engineer-in-Charge.
Adequate provision shall be made for the support and protection of water stops during the
progress of the work. Damaged water stops shall be replaced and/or repaired as directed.

13.0 PROTECTION OF FRESHLY LAID CONCRETE

Newly placed concrete shall be protected, by approved means, from rain, sun and wind.
Concrete placed below the ground level shall be protected from falling earth during and after
placing. Surface shall be kept free from contact with such ground or with water draining from
such ground during placing of concrete for a period of at least 3 days, unless otherwise directed
by the Engineer-in-Charge. The ground water around newly poured concrete shall be kept to an
approved level by pumping or other approved means of drainage and adequate steps shall be
taken to prevent floatation and flooding. Steps shall be taken to protect immature concrete from
damage by debris, loading, vibration, abrasion, mixing with deleterious materials that may, in
the opinion of the Engineer-in-Charge, impair the strength and/or durability of the concrete.
14.0 CURING
Concrete shall be cured by keeping it continuously moist wet for the specified period of time to
ensure complete hydration of cement and its hardening. Curing shall be started after 8 hours of
placement of concrete in normal weather, and in hot weather after 4 hours. The water used for
curing shall be of the same quality as that used for making of concrete.
Curing shall be assured by use of an ample water supply under pressure in pipes, with all
necessary appliances such as hose, sprinklers etc. A layer of sacking, canvas, hessian, or other
approved material, which will hold moisture for long periods and prevent loss of moisture from
the concrete, shall be used as covering. Type of covering which would stain, disfigure or
damage the concrete, during and after the curing period, shall not be used. Only approved
covering shall be used for curing.
Exposed surfaces of concrete shall be maintained continuously in a damp or wet condition for
at least the first 7 days after placing of concrete.
The Contractor shall have all equipment and materials required for curing on hand and ready to
use before concrete is placed.
For curing the concrete in pavements, floors, flat roofs or other level surfaces, the ponding
method of curing shall be used. For the first 24 hours after concreting, the concrete shall be
cured by use of wet sacking, canvas, hessian etc. The minimum water depth of 25mm for
ponding shall be maintained. The method of containing the ponded water shall be approved by
the Engineer-in-Charge. The ponded areas shall be kept continuously filled with water, and
leaks, if any, shall be promptly repaired. Areas cured by ponding method shall be cleared of all
debris and foreign materials after curing period is over.
Alternatively, membrane curing may be used in lieu of moist curing with the permission of the
Engineer-in-Charge. Such compounds shall be applied to all exposed surfaces of the concrete
by spraying or brushing as soon as possible after the concrete has set. Minimum film thickness
of such curing compounds shall be as per the recommendation of the manufacturer so as to
obtain an efficiency of 90% as specified by BS-8110. This film of curing compound shall be
fully removed from the concrete surface after the curing period specified earlier. Engineer-in-
Charge may not allow curing by curing compounds for those surfaces where use of curing
compound may be detrimental to application of future finishes over the concrete. Impermeable

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 membranes such as polyethylene sheeting closely covering the concrete surface may also be
used.

For concretes containing Portland pozzolana cement or Portland slag cement, the curing period
as given in Cl. 14.1 shall be doubled. Curing by ponding shall, however, commence after the
first 24 hours of concreting.

15.0 FIELD TESTS

15.1 Grading Test
Grading test on fine and coarse aggregates shall be carried out as per IS: 2386 at intervals
specified by the Engineer-in-Charge.
The mandatory tests and their frequencies shall be done as given in Table-3A & 3B below:

TABLE – 3A
(For Concrete prepared at site by using Mechanical mixers)
MANDATORY TESTS ON SAND & STONE AGGREGATES
MIN. QTY OF
MATERIAL/
S. FREQUENCY OF
MATERIAL TEST FIELD / LAB TEST WORK FOR
No TESTING*
CARRYING
OUT TEST
1. Sand (a) Bulking of sand Field Test 20 m3 Every 20 m3 or part
thereof or more frequently
(b) Silt content Field Test 20 m3 as decided by the
Engineer-in-Charge
(c) Particle size Field or Lab as 40 m3 1) Every 40 m3 of fine
distribution decided by the aggregate/sand required
Engineer-in-Charge in RCC works only
2) Every 80 m3 of fine
aggregate/ sand
required for other items
2. Stone a) Percentage of General visual As required For all quantities
aggregate soft or deleterious inspection, by Engineer-
materials laboratory test where in-Charge
required by Engineer
-in-Charge or as
specified
b) Particle size Field or lab. as 45 m3 For every 45 m3 or part
distribution required by thereof as decided by
Engineer-in-Charge Engineer-in-Charge
c)Ten percent Fine Laboratory 45 m3 Initial test and subsequent
value test as & when required by
Engineer-in-Charge

* Fresh testing is mandatory whenever there is change in Source of materials.

TABLE – 3B
(Refer Cl. 4.4 & 4.6.1 of IS:4926)

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 (For Ready Mixed Concrete supplied by Ready Mixed Concrete Plants
or from on/off-site Batching Plants)
MATERIALS TESTING REQUIREMENTS
ASSESSMENT
NORMAL
AGGREGATE OF TYPICAL REQUIREMENT FOR
S. TYPE OF MONITORING
PROPERTY/ PROPERTIES NORMAL MONITORING
No AGGREGATE AND LOW
PARAMETER AND HIGH AND LOW TEST RATE
TEST RATE*
TEST RATE*
Sand/Fine Weekly Monthly Last 8 results conform to IS
1. Grading
Coarse-Single 383 or representative
Weekly Monthly values
sized/ Graded
Particle density
-Oven Dry Weekly 3 Monthly Last 4 results
2.
-Saturated Surface Dry
All Types
±0.04 percent
-Apparent
Last 4 results
3. Absorption All Types Weekly 3 Monthly
±0.04 percent
ASSESSMENT
NORMAL
AGGREGATE OF TYPICAL REQUIREMENT FOR
S. TYPE OF MONITORING
PROPERTY/ PROPERTIES NORMAL MONITORING
No AGGREGATE AND LOW
PARAMETER AND HIGH AND LOW TEST RATE
TEST RATE*
TEST RATE*
Bulk Density
Last 4 results
4. - Loose All Types Monthly 6 Monthly
- Compacted ± 75kg/m³

Sand Weekly Monthly Last 10 results

Fines(Silt)
5. <75 percent maximum
Content Coarse Monthly 3 Monthly allowed
Aggregate Impact
6. Coarse As specified As specified -
Value
7. 10 % Fines Coarse Yearly Yearly -
Last 3 results conform to
8. Flakiness Coarse 2 Weekly 6 Monthly
standard
Last 3 results
9. Chloride Content All Types Weekly 6 Monthly
< 0.01 percent
Aggregate Abrasion
Yearly/
10. Value Coarse - -
(Los Angeles Method) Source Change
Fine and Yearly/ -
11. Soundness -
Coarse Source Change
Potential Alkali
Aggregate Reactivity Fine and 5 Yearly/
12. - -
Including Coarse Source Change
Petrography
Petrographic
13.
Description (General)
All Types - 5 Yearly -

*Note : The high or low test rates apply in accordance with the following conditions:
a) High test rate
i) To establish the typical characteristics of an aggregate, and

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 ii) When significant changes in properties occur outside the tolerances for low test rates
given.
b) Low test rate
i) When the typical characteristics of the aggregate have been established, and
ii) When subsequent tests lie within the tolerances for low test rates given

15.2 Compaction Factor Test /Slump Test of Concrete

For structural quality concrete (excluding pavements, flooring etc.) at least one Slump Test
shall be made for every compressive strength test carried out. More frequent tests shall be made
if there is a distinct change in working conditions or if required by the Engineer-in-Charge.

In case of Ready Mixed Concrete, provisions of IS: 4926 shall be followed.

For structural quality concrete for pavements & floorings, measurement of workability shall be
by determination of compacting factor. Value of compacting factor of 0.75 to 0.8 shall
generally be acceptable.

15.3 Strength Test of Concrete

15.3.1 Samples from fresh concrete shall be taken as per IS: 1199 and cubes shall be made, cured and
tested at 28 days in accordance with IS: 516.
15.3.2 In order to get a relatively quicker idea of the quality of concrete, optional tests on beams for
modulus of rupture at 72+2 hours or at 7 days, or compressive strength tests at 7 days may be
carried out in addition to 28 days compressive strength tests. For this purpose, the values shall
be arrived at based on actual testing. In all cases, the 28 days compressive strength specified in
Table-1 shall alone be the criterion for acceptance or rejection of the concrete in accordance
with clause 15.3.9.

15.3.3 Sampling Procedure

A random sampling procedure shall be adopted to ensure that each concrete batch shall have a
reasonable chance of being tested that is, the sampling should be spread over the entire period
of concreting and cover all mixing units.

15.3.4 Frequency of Sampling

The minimum frequency of sampling of concrete for each grade shall be in accordance with
Table-4.

TABLE – 4
(Refer Cl. 15.2.2 of IS:456)

FREQUENCY OF CONCRETE SAMPLING

Quantity of concrete in the work (m3) Number of samples

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 1-5 1
6-15 2
16-30 3
31-50 4
51 & above 4 plus one additional sample for each
additional 50m3 or part thereof.

At least one sample shall be taken from each shift.

When concrete is produced at continuous production units such as ready mixed concrete/
batching plants, atleast one sample shall be taken for every 50m3 of concrete or after every 50
batches, whichever occurs at a greater frequency or as decided by the Engineer-in-Charge.
Samples shall be avoided from the first and the last cubic metre of concrete mix in a lot.

15.3.5 Test Specimen

Three test specimens shall be made for each sample for testing at 28 days. Additional cubes
may be required for various purposes such as to determine the strength of concrete at 7 days or
at the time of striking the formwork or to check the testing error. Additional samples may also
be required for testing samples cured by accelerated methods as described in IS: 9013. The
specimen shall be tested as described in IS: 516.
15.3.6 Identification mark on concrete test cubes:
The following numbering system shall be adopted on each 150mm cube:

First line: ZZ (Alpha code assigned by the Engineer -in-Charge to the Contractor
for a particular contract starting with AA and progressing to AB,
AC and so on).
Second line: XXXX (Unique integer in ascending order starting from 1).
Third line: DD-MM-YY (Date of casting of cube)
15.3.7 Test Results of Sample
The test results of the sample shall be the average of the strength of three specimens. The
individual variation should not be more than + 15 percent of the average. If more, the test
results of the sample shall be considered invalid.
15.3.8 Standard Deviation
Standard deviation for each grade of concrete shall be calculated separately.
Standard deviation based on test results of samples:
a) The total number of test samples required to constitute an acceptable record for calculation
of standard deviation shall be not less than 30. Attempts shall be made to obtain the 30
samples, as early as possible, when a mix is used for the first time.
b) For design of mix in the first instance, the value of standard deviation given in Table 8 of
IS: 456, Amendment No. 4 may be assumed.
c) As soon as sufficient results of samples are available, actual calculated standard deviation
shall be used and the mix design shall be revised/ updated. However, when adequate past
records for a similar grade exist and justify to the designer a value of standard deviation

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 different from that shown in Table 8 of IS: 456, Amendment No. 4, it shall be permissible
to use that value.

d) For additional requirement on standard deviation refer clause 9.2.4 of IS : 456.

15.3.9 Acceptance Criteria

15.3.9.1 Compressive Strength
The concrete shall be deemed to comply with the strength requirement when both the
conditions as given in col. 2 & col.3 of Table-5 for that particular grade of concrete are
simultaneously met. For working out standard deviation compressive test result of date wise
serially logged 30 sample test result shall be used.
15.3.9.2 Flexural Strength
The concrete shall be deemed to comply with flexural strength requirements when both the
following conditions are simultaneously met:
a) The mean strength determined from any group of four non-overlapping consecutive test
results exceeds the specified characteristic strength by at least 0.3 N/mm2.
(For non overlapping consecutive compressive test result any one alternate set of four
samples shall be used for verification of compliance to clause no. 16.1.a of IS 456)
b) The strength determined from any test result is not less than the specified characteristic
strength less 0.3 N/mm2
Table-5
(Refer Cl. 16.1 & 16.3 of IS:456)

Characteristic Compressive Strength Compliance Requirement

Specified Mean of the Group of 4 Non- Individual Test

Grade Overlapping Consecutive Test Results Results in N/mm2
in N/mm2
M15 or > fck + 0.825 x established standard > fck – 3 N/mm2
above deviation (rounded off to nearest
0.5N/mm2)
or
> fck + 3 N/mm2 ,
Whichever is greater
NOTE : 1) In the absence of established value of standard deviation, the values given in Table8 of
IS:456, Amendment No. 4,may be assumed, and attempt should be made to obtain results
of 30 samples as early as possible to establish the value of standard deviation.

3
2) For concrete of quantity 30 m (where the number of samples to be taken is less than four
as per the frequency of sampling given in cl. 15.3.4, Table 4), the mean of test results of all

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 38 OF 221

 2
such samples shall be fck + 4 N/mm , minimum and the requirement of individual test
2
results shall be fck – 2 N/mm , minimum. However, when the number of sample is only one
2
as per Table 4, the requirement shall be fck + 4 N/mm .

15.3.9.3 Quantity of Concrete Represented by Strength Test Results

The quantity of concrete represented by group of four consecutive test results shall include the
batches from which first and last samples were taken together with all intervening batches.
Acceptance of concrete shall be applicable for serially logged 30 samples. In case serially
logged samples are less than 30 then standard deviation of adjoining previous sample sets will
be used for establishing acceptance criteria as per clause 16.1.a of IS: 456.
For the individual test result requirements given in col. 3 of Table-5 or in item (b) of 15.3.9.2,
only the particular batch from which the sample was taken shall be at risk.
Where the mean rate of sampling is not specified, the maximum quantity of concrete that four
consecutive test results represent shall be limited to 60m3.
15.3.9.4 If the concrete is deemed not to comply pursuant to Cl. 15.3.9.1 or 15.3.9.2, the structural
adequacy of the parts affected shall be investigated and any consequential action as needed
shall be taken (Refer Cl. 16.0).
15.3.9.5 Concrete of each grade shall be assessed separately.
15.3.9.6 Concrete is liable to be rejected if it is porous or honey-combed, its placing has been
interrupted without providing a proper construction joint, the reinforcement has been displaced
beyond the tolerances specified, or construction tolerances have not been met. However, the
hardened concrete may be accepted after carrying out suitable remedial measures and tests to
the fullest satisfaction of the Engineer-in-Charge.
15.3.9.7 Tolerance in leveling of concrete surface at foundation/ pedestal top level where grouting is to
be done:
Maximum Plan Dimension < 2m >2m but <4m > 4m
+ 10mm + 10mm + 10mm
Tolerance in leveling
- 10mm - 20 mm - 25mm

15.3.9.8 Tolerance in dimensions of pocket:

20mm overall maximum tolerance on the size of pocket.
For pockets, chemically dissolvable moulds shall be preferred. Smooth removal of moulds
without affecting the pocket size shall be ensured.

16.0 INSPECTION AND TESTING OF STRUCTURES

16.1 Inspection
To ensure that the construction complies with the design, an inspection procedure shall be set
up by the contractor and duly approved by the Engineer-in Charge covering materials used,
receipt of materials, their test results, records, workmanship and construction etc.
Contractor shall ensure that the surface which is to receive the grout is at proper level and so
are the openings for pockets as per Cl. 15.3.9.7 & 15.3.9.8.

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16.2 Immediately after stripping the formwork, all concrete shall be carefully inspected and any
defective work or small defects either removed or made good before concrete has thoroughly
hardened.

16.3 Testing
In case of doubt regarding the grade or soundness of concrete used, either due to poor
workmanship or based on results of cube strength, compressive strength tests of concrete on the
basis of clause 17.4 of IS: 456 and/or load test as per clause 17.6 of IS: 456 shall be carried out.
The Engineer-in-Charge shall be the final authority for interpreting the results of all tests and
shall decide upon the acceptance or otherwise. The decision of the Engineer-in-Charge shall be
final and binding on the contractor. In case the results of the tests are unsatisfactory, the
Engineer-in-Charge may instruct the contractor to demolish and reconstruct the structure or part
thereof without any extra cost to the Owner.

16.4 Members other than Flexural Members

Members other than flexural members like columns etc. shall be referred to the designer to
investigate the structural adequacy. The decision of the designer shall be final and binding on
the contractor.

16.5 Non-destructive Tests

Non-destructive tests using Ultrasonic Pulse Velocity and Rebound Hammer methods shall be
resorted to for checking the soundness of concrete placed and shall be as per the directions of
Engineer-in-Charge. The testing shall be based on IS: 13311, Part-1. However, the Rebound
Hammer test (IS: 13311, Part-2) shall only be used in combination with other tests (Destructive
or Non-Destructive) for checking the concrete quality.

17.0 FINISHING OF CONCRETE

17.1 On striking the formwork, all surface defects such as bulges, ridges and honey-combing etc.
observed shall be brought to the notice of the Engineer-in-Charge. The Engineer-in-Charge
may, at his discretion allow rectification by necessary chipping and packing or grouting with
concrete or cement mortar. However, if honey-combing or sagging is of such extent as being
undesirable, the Engineer-in-Charge may reject the work totally and his decision shall be
binding. No extra payment shall be made for rectifying these defects, demolishing and
reconstructing the structure. However, quantity of cement actually used for this purpose may be
considered for reconciliation of materials. All burrs and uneven faces shall be rubbed smooth
with the help of carborundum stone.
The surface of non-shuttered faces shall be smoothened with a wooden float to give a finish
similar to that of the rubbed down shuttered faces. Concealed concrete faces shall be left as
from the formwork except that honey-combed surface shall be made good as specified above.
The top faces of slabs not intended to be covered shall be levelled and floated to a smooth
finish to the rises or falls shown on the drawings or as directed. The floating shall not be
executed to the extent of bringing excess fine materials to the surface. The top faces of slabs
intended to be covered with screed, granolithic or similar finishes, shall be left with a rough
finish.

17.2 Repair and Replacement of Unsatisfactory Concrete

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17.2.1 Repair shall be made as soon as possible after the forms are removed and before the concrete
becomes too hard with prior permission from the Engineer-in-Charge, in writing. Stone
pockets, segregation patches and damaged areas shall be chipped out and the edges undercut
slightly to form a key. All loose material shall be washed out before patching. No excess water
shall be left in the cavity, but the concrete shall be damp. A good bond between the patch and
parent concrete shall be obtained by sprinkling dry cement on the wet surface or by throwing
mortar with force on to the wetted concrete, or by brush in a coat of thick cement grout of about
1:1 (1 cement:1 sand) just before applying the patching material. Before this has dried, the
remainder of the patch shall be filled with mortar or concrete, depending on the extent of the
repair.
17.2.2 Cement concrete/mortar used in repair of exposed surfaces shall be made with cement from the
same source as that used in concrete and blended with sufficient amount of white Portland
cement to produce the same colour as in the adjoining concrete. The proportions of ingredients
shall be same as those used in parent concrete. The mortar shall be as dry as possible and well
compacted into the cavity. All filling shall be tightly bonded to the concrete and shall be sound,
free from shrinkage cracks after the filling has been cured and dried.
17.2.3 For larger repairs to hardened concrete, necessary formwork bearing tightly at the edges of the
cavity shall be provided. Concrete shall be chipped out to a depth of at least 100mm and
preferably 150mm. Mortar shall be scrubbed into all surfaces with a wire brush before placing
the concrete. Damaged reinforcement shall be adequately spliced with new steel so as to
maintain the original strength. Additional reinforcement, if required in the patch, shall be
provided as per the instructions of Engineer-in-Charge.
17.2.4 In case, in the opinion of the Engineer-in-Charge, defects in the concrete is excessive or beyond
repair, the contractor shall either redo the structure or take other remedial measures as
instructed by the Engineer-in-Charge. The decision of the Engineer-in-Charge shall be final and
binding to all in this respect.
17.2.5 Approved epoxy formulation for bonding fresh concrete used for repairs with already hardened
concrete shall be used by the Contractor if asked by the Engineer-in-Charge. Epoxy shall be
applied in strict accordance with job specification and the instructions of the manufacturer.
17.2.6 All repair works due to non-conformance or non-adherence to specification, if allowed by the
Engineer-in-Charge, shall be carried out free of cost to the owner.

17.3 Curing of Patched Work

Immediately after patching is completed, the patched area shall be covered with an approved
non-staining water saturated material which shall be kept wet and protected against sun and
wind for a period of 12 hours. Thereafter, the patched area shall be kept continuously wet by a
fine spray or sprinkling for not less than 10 days.

18.0 WATERPROOF CEMENT PAINT

Wherever specified, concrete elements (whether cast-in-situ or precast) exposed to atmosphere
shall be provided with three coats of cement based waterproof paint as per IS:5410 provided
these surfaces shall not contain any protective coating. Prior to application of the paint, the
surface shall be prepared to remove all foreign particles, loose materials, extra deposited
concrete lumps, etc. using appropriate mechanical/ manual means.

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19.0 FORM WORK

19.1 General

19.1.1 Forms for concrete shall be of plywood conforming to IS: 6461 (Part-5) or steel or as directed
by the Engineer-in-Charge and shall give smooth and even surface after removal thereof.

19.1.2 If it is desired by Engineer-In-Charge, the Contractor shall prepare, before commencement of

actual work, design and drawings for formwork and get them approved by the
Engineer-in-Charge. For details regarding design, detailing etc., reference may be made to IS:
14687.

19.1.3 Form work and its supports shall maintain their correct position and be to correct shape and
profile so that the final concrete structure is within the limits of dimensional tolerances
specified below, unless required otherwise, for functional/aesthetic reasons. The decision of the
Engineer-in-Charge shall be final and binding in this regard.

(a) Deviation from specified dimensions - 5mm to +10mm

of cross section of columns and beams.
(b) Deviation from dimensions of footings (see Note below)

i) Dimensions in plan -10mm to +50mm

ii) Eccentricity 0.02 times the width of the footing in the
direction of deviation but not more than 50
mm.
iii) Thickness -10mm to +50mm or +0.05 times the
specified thickness, whichever is less
Note: These tolerances apply to Cast-in-situ concrete dimensions only, not to positioning of
vertical reinforcing steel or dowels.

(c) Deviation in length (major dimension of single unit)

upto 3m +6mm
3m to 4.5m +9mm
4.5m to 6m +12mm
Additional deviation for every subsequent 6m. +6mm

(d) Deviation in straightness or bow (deviation from specified line) for a single or continuous
member) e.g. beam, column or slab edge.
upto 3m 6mm
3m to 6m 9mm
6m to 12m 12mm
additional for every subsequent 6m. 6mm

(e) Deviation in squareness shall be measured taking the longer of two adjacent sides as the
base line.

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 The shorter side shall not vary in its distance from a perpendicular so that the difference
between the greatest and shortest dimensions exceeds 6mm. For this purpose, any error due
to lack of straightness shall be ignored. Squareness shall be checked with respect to the
straight lines that are most nearly parallel with the features being checked. When the
nominal angle is other than 90 degree, the included angle between check lines shall be
varied accordingly.

(f) Deviation in twist shall be within a limit such that any corner shall not be more than the
limit given below from the plane containing other three corners:
upto 600mm wide and upto 6m in length : 6mm
over 600mm wide and for any length : 12mm

(g) Maximum deviation in flatness from a 1.5m straight edge placed in any position on a
nominally plain surface shall not exceed 6mm.

(h) Tolerance in leveling of concrete surface at foundation/ : As per Cl. 15.3.9.7

pedestal top level where grouting is to be done

19.2 Form Requirement

19.2.1 The formwork shall be true, rigid and adequately braced both horizontally as well as
diagonally. The forms shall have smooth and even surface and be sufficiently strong to carry,
without deformation, the dead weight of the green concrete, working load, wind load and also
the side pressure exerted by the green concrete. As far as practical, clamps shall be used to hold
the forms together. Where use of nails is unavoidable minimum number of nails shall be used.
Projected part of nail shall not be bent or twisted for easy withdrawal.

19.2.2 Where through tie rods are required to be put to hold the formwork and maintain accurate
dimension, they shall always be inserted through a precast concrete block (of same mix
proportion as is to be used for concreting) with a through hole of bigger diameter. The Precast
block shall tightly fit against in inner faces of formwork. The holes left after the withdrawal of
tie rods shall be fully grouted with cement-sand mortar of same proportion as that used for
concrete. However, use of such precast block shall in no case impair the desired appearance or
durability of the structure. No such tie rods shall be used in any liquid retaining or basement
structure.

19.2.3 Tie wires shall be permitted only upon approval of the Engineer-in-Charge and shall be cut off
flush with the face of the concrete or counter sunk, filled and finished in the manner specified
in clause 17.

19.2.4 Form joints shall not permit any leakage. The formwork shall be strong enough to withstand the
effect of vibrations practically without any deflection, bulging, distortion or loosening of its
components.

19.2.5 Forms for beams and slabs (span more than 6.0m) shall have camber of 1 in 500 so as to offset
the deflection and assume correct shape and line after deposition of concrete. For cantilevers,
the camber at free end shall be 1/100th of the projected length. Where architectural
considerations and adjunctive work are critical, smaller form cambers shall be adopted as
decided by the Engineer-in-Charge.

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19.2.6 All vertical wall forms may be designed and constructed for the following minimum pressure.
The pressures listed in Table-6 are intended as guide only and the Contractor shall ensure that
the formwork is adequately strong and sturdy.

TABLE - 6
MINIMUM DESIGN PRESSURE FOR WALL FORMWORK

Pressure in KN/m2
Rate of pour in meter/hour
at 100 (in Celsius) at 240 (in Celsius)
0.6 36.0 29.0
0.9 40.0 32.0
1.2 44.0 35.0
1.5 46.0 37.0

All horizontal forms shall be designed and constructed to withstand the dead load of the green
concrete, reinforcement, equipment, material, embedment and a minimum live load of 2.0
kN/m2.

19.3 Inspection of Forms

Temporary openings shall be provided at the base of column and wall forms and other places
necessary to facilitate cleaning and inspection. Before concrete is placed, all forms shall be
carefully inspected to ensure that they are properly placed, sufficiently rigid and tight,
thoroughly cleaned, properly treated and free from foreign material. The complete form work
shall be inspected and approved by the Engineer-in-Charge before the reinforcement bars are
placed in position. When forms appear to be unsatisfactory in any way, either before or during
the placing of concrete, the work shall be stopped until the defects have been rectified as per the
instructions of the Engineer-in-Charge.

19.4 Cleaning and Treatment of Formwork

The surfaces of forms that would come in contact with concrete shall be well treated with
approved non-staining form release agents such as soft soap, oil, emulsions etc. Release agents
shall be applied so as to provide a thin uniform coating to the forms without coating the
reinforcement.

19.5 Chamfers and Fillets

All corners and angles shall be formed with 45 degree mouldings to form chamfers or fillets on
the finished concrete. The standard dimensions of chamfers and fillets, unless otherwise
detailed or specified shall be 25x25mm. For heavier work chamfers or fillets shall be
50x50mm. Care shall be exercised to ensure accurate mouldings. The diagonal face of the
moulding shall be planed or surfaced to the same texture as the forms to which it is attached.

19.6 Reuse of forms

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 Before reuse, all forms shall be thoroughly scrapped, cleaned, examined and when necessary,
repaired and retreated, before resetting. Formwork shall not be reused, if declared unfit or
un-serviceable by the Engineer-in-Charge.

19.7 Removal of Forms/Stripping Time

In the determination of time for removal of forms, consideration shall be given to the location
and character of the structures, the weather and other conditions including the setting and
curing of the concrete and material used in the mix.

Forms and their supports shall not be removed without the approval of the Engineer-in-Charge.
Forms shall not be released until the concrete has achieved a strength of at least twice the stress
to which the concrete may be subjected at the time of removal. The formwork shall be removed
without shock and methods of form removal likely to cause over stressing or damage to the
concrete shall not be adopted. Supports shall be removed in such a manner as to permit the
concrete to uniformly and gradually take the stresses due to its own weight.
In normal circumstances when average air temperature exceeds 15 degree Celsius during the
period under consideration after pouring of concrete and where ordinary Portland cement is
used, forms may generally be removed after expiry of following periods.
(a) Walls, columns and vertical faces of all 16 to 24 hours as may be decided
structural members by the Engineer-in-Charge.

(b) Slabs (props left under) 3 days.

(c) Beam Soffits (props left under) 7 days.

(d) Removal of props under slabs:

Spanning upto 4.5m. 7 days.
Spanning over 4.5m. 14 days.

(e) Removal of props under beams and arches:

Spanning upto 6m 14 days.
Spanning over 6m 21 days

(f) Cantilever Construction Formwork shall remain till structures for counter acting or bearing
down have been erected and have attained sufficient strength (minimum 14 days).

Notes:

i) For other cements, the stripping time recommended for ordinary Portland cement shall be
suitably modified as per the instructions of the Engineer- in-Charge.
ii) The number of props left under, their sizes, supporting arrangement, and disposition shall
be such as to be able to safely carry the full dead load of the slab, beam or arch as the case
may be together with any live load likely to occur during curing or further construction.
iii) Where the shape of the element is such that the formwork has re-entrant angles, the form
work shall be removed as soon as possible after the concrete has set, to avoid shrinkage
cracking occurring due to the restraint imposed.

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 iv) For rapid hardening cement, 3/7 of the above mentioned periods shall be considered subject
to a minimum of 16 hours.
v) For Portland pozzolana or low heat cement, 10/7 of the above mentioned periods shall be
considered.

19.8 Staging/Scaffolding
19.8.1 Staging/Scaffolding shall be properly planned and designed by the Contractor. Use of only steel
tubes is permitted for staging/scaffolding. The Contractor shall get it reviewed by
Engineer-in-Charge before commencement of work. While designing and during erection of
scaffolding/staging, the following measures shall be considered:
(a) Sufficient sills or underpinnings in addition to base plates shall be provided particularly
where scaffolding is erected on soft grounds.

(b) Adjustable bases to compensate for uneven ground shall be used.

(c) Proper anchoring of the scaffolding/staging at reasonable intervals shall be provided in
each direction with the main structure wherever available.

(d) Horizontal braces shall be provided to prevent the scaffolding/staging from rocking.

(e) Diagonal braces shall be provided continuously from bottom to top between two adjacent
rows of uprights.

(f) The scaffolding/staging shall be checked at every stage for plumb line.

(g) Wherever the scaffolding/staging is found to be out of plumb line it shall be dismantled and
re-erected afresh and effort shall not be made to bring it in line with a physical force.

(h) All nuts and bolts shall be properly tightened and care shall be taken that all
clamps/couplings are firmly tightened to avoid slippage

(i) Erection work of a scaffolding/staging under no circumstances shall be left totally to

semi-skilled or skilled workmen and shall be carried out under the supervision of a
technically qualified civil engineer of the Contractor.

19.8.2 For smaller works or works in remote areas, wooden ballies may be permitted for
scaffolding/staging by the Engineer-in-Charge at his sole discretion. The contractor must ensure
the safety and suitability of such works as described under clause 19.8.1 above.

20.0 EXPOSED/ARCHITECTURAL CONCRETE WORK

20.1 Form Work

Other things remaining same as per clause 19.0, formwork shall be of high quality. Care shall
be taken to arrange the forms so that the joints between forms correspond with the pattern
indicated in the drawings. The forms shall be butting with each other in straight lines, the
corners of the boards being truly at right angles. The joints between the forms shall cross in the
two directions at right angles. The size of forms shall be so selected as to exactly match with

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 the pattern of forms impression on the concrete face indicated in the drawings. Maximum care
shall be taken to make the form work watertight. Burnt oil shall not be used for treatment of
forms. The Contractor shall be permitted reuse of forms brought new on the work place only if
forms are properly cared for, stored and treated after each use.

The Engineer-In-Charge may, at his absolute discretion, order removal of any forms considered
unsuitable for use in the work.

20.2 Finishing

Repairing to exposed concrete work shall be avoided. Rendering and plastering shall not be
done. Minor repairing, if unavoidable shall be done as specified in clause 17.0 with the written
permission of the Engineer-in-Charge.

21.0 REINFORCEMENT

21.1 The Contractor shall develop the bar bending schedule for all RCC structures/ structural parts at
no extra cost to the Owner and shall get it reviewed by the Engineer-in-charge. Reinforcement
shall be cut and bent to shape as per dimensions shown in the bar bending schedule/ drawings.

If protective fusion bonded epoxy coating is required to be applied on reinforcement bars, the
same shall be done as per IS: 13620. All repairs to applied protective coating required due to
mishandling and/ or bending of reinforcement bars shall also be done as per relevant clauses of
IS:13620.
21.2 Straightening, Cutting and Bending

Procedure for cutting and bending shall be as given in IS: 2502. Bars shall be bent in a slow and
regular movement to avoid fractures by mechanical means only. In case bars are supplied in
coils, they shall be smoothly straightened without any kinks.

Cold twisted deformed bars shall be bent cold. Bars larger than 25mm in size (except cold
twisted deformed bars) may be bent hot at cherry red heat to a temperature not exceeding 8500
Celsius as per the instructions of the Engineer-in-Charge. The bars shall be allowed to cool
gradually without quenching.

Bars shall be cut & bend in a Bar Bending Machine. Bars which develops cracks or splits after
bending shall be rejected. A second bending of reinforcement bars shall be avoided but when
reinforcement bars are bent aside at construction joints and afterwards bent back into their
original position, care should be taken to ensure that at no time is radius of the bend less than 6
times bar diameter for high strength deformed bars. Care shall also be taken when bending back
the dowel bars to ensure that concrete around the bars is not damaged. All bars shall be
properly tagged for easy identification.

21.3 Placing and Fixing

All reinforcement shall be cleaned to ensure freedom from loose mill scale, loose rust, oil, form
releasing agents, grease or any other harmful material before placing them in position.
Reinforcement shall not be surrounded by concrete unless it is free from all such materials.
Rough handling and dropping of reinforcement from a height shall be avoided.

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 All reinforcement shall be fixed in the correct position and shall be properly supported to
ensure that displacement will not occur when the concrete is placed and compacted.
The uncoated reinforcement bars shall be tied at every intersection by two strands of 16 SWG
black soft annealed binding wire. The Epoxy coated reinforcement bars shall be tied with 2
strands of PVC coated GI 18 SWG wire at every intersection. Crossing bars shall not be tack
welded for assembly of reinforcement. The reinforcement bars shall be kept in position by
using the following methods:

a) In case of beam and slab construction, precast cover blocks (having the same sand contents
as the concrete which shall be placed) of size 40 x 40 mm and thickness equal to the
specified covers shall be placed firmly in between the bars and forms so as to secure and
maintain the specified covers over the reinforcement.

When reinforcement bars are placed in two or more layers in beams, the vertical distance
between the horizontal bars shall be maintained by introducing spacer bars at 1 to 1.2m
centre to centre.

b) In case of thick rafts & pile caps having two or multi layers of reinforcement, the vertical
distance between the horizontal bars shall be maintained by introducing suitable chairs,
spacers, etc.

c) In case of columns and walls, the vertical bars shall be kept in position by means of timber
templates with slots accurately cut in them. The templates shall be removed after the
concreting has been done below it.

d) Exposed portions of reinforcement bars shall not be subjected to impact or rough handling
and workmen will not be permitted to climb on extending bars until the concrete has
attained sufficient strength so that no movement of the bars in the concrete is possible.

21.5 Splicing/Overlapping
Only bars of full length shall be used as shown in the drawings. But where this cannot be done,
overlapping of bars shall be done as directed by the Engineer-in-Charge. The overlapping bars
shall be tied with two strands of 16 SWG black soft annealed binding wire. The overlaps shall
be staggered for different bars and located at points along the span where neither shear nor
bending moment is maximum.

21.6 Welded Joints

Welding of reinforcing bars shall not be permitted without the written permission of the
Engineer-in- Charge. Where welding of reinforcing bars is permitted, it shall be in accordance
with the recommendations of IS: 2751 and IS: 9417. Welded joints shall be located at suitable
staggered positions. Tests shall be made as directed by the Engineer-in-Charge to prove that the
joints are of the full strength of the bars. Maximum one welded joint shall be allowed per bar.

21.7 Mechanical Connections (upto Seismic Zone-III as per IS:1893 Part-I)

The mechanical splices in reinforcement by means of couplers, clamps etc. shall be used (as per
manufacturer's specifications) with the written approval of the Engineer-in-Charge.
Following tests, at the minimum, shall be conducted in advance to prove efficiency of the
coupled joint before putting them in actual use:

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 Name of the Test Testing Requirement Code of conformance

Each connection shall develop atleast ASTM A370/

Static Tension &
125% of the specified yield strength of ACI 318/
Compression Test
the reinforcing bar ISO 15835

Permanent elongation across the coupled

Permanent joint shall be less than 0.1mm after BS 8110/
Elongation (Slip) loading at 60% of the yield strength of ISO 15835
the reinforcing bar

Name of the Test Testing Requirement Code of conformance

Deformation across the coupled joint

Moderate Oligocyclic shall be less than 0.3mm after subjecting
(Seismic) Test the joint to a series of 20 cycles with
ISO 15835
(Cyclic Tension & 90% tension as well as 50% compression
Compression Test) of the yield strength of the reinforcing
bar

All operations relating to reinforcement coupling shall be done by using manufacturer’s

patented machine/ equipment in the presence of Engineer-in-Charge. Mechanical connections
shall be placed away from points of high stress and shall be staggered.

21.8 Tolerances on Placing of Reinforcement

Unless otherwise directed by the Engineer-in-Charge, reinforcement shall be placed within the
following tolerances:
a) For effective depth 200mm or less + 10mm
b) For effective depth more than 200mm + 15mm

21.9 Substitution
When indicated diameter of reinforcement bar is not available, the Contractor shall use other
diameter of reinforcement bars on written approval of the Engineer-In-Charge.

21.10 Tolerance to Cover

The actual concrete cover shall not deviate from the required nominal cover by + 10mm
measured over the steel reinforcement including links.

22.0 PAYMENT

22.1 Plain and Reinforced Concrete

22.1.1 Payment for plain and reinforced cement concrete (cast- in-situ) shall be made on cubic metre
basis of the volume of the actual finished work done or as per approved construction drawings,

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 whichever is less and shall be inclusive of providing pockets, openings, recesses of all sizes,
chamfers, fillets, grooves, separation/ expansion/ isolation/ construction/ movement joints,
curing by normal moist curing or using curing compound etc. as directed by
Engineer-in-Charge etc. The rates shall be deemed to include complete cost of getting the
respective mix designs approved, making and testing concrete cubes and carrying out other
tests including tests of various ingredients, as per specifications and as directed by
Engineer-in-Charge. Payment shall, however, be separately made for tests on concrete cubes
done by accelerated methods of curing as defined in IS: 9013.
22.1.2 No separate payment shall be made for any additive/ admixture/ Plasticizer/ Fibres used by the
contractor for accelerating or retarding the strength of concrete or for achieving specified
workability. The rate quoted shall be deemed to be inclusive of all costs related to any such
additive/admixture/ Plasticizer/ Fibres.
22.1.3 The rate shall however be exclusive of reinforcement, metal inserts, pipe sleeves, formwork,
water stops and any filler material in expansion/isolation joints.
22.1.4 Where the strength of concrete mix as indicated by tests, lies in between the strengths of any
two grades given in Table-1 and it is accepted by the Owner/Engineer-in-Charge, such concrete
shall be classified as a grade belonging to the lower of the two grades between which it lies. In
case the cube strength shows higher results than those specified for the particular grade of the
concrete, it shall not be placed in the higher grade nor shall the Contractor be entitled for any
extra payment on such account. The concrete giving lower strength than specified may be
accepted at reduced rates after satisfying the safety of the structure by checking it with tests as
specified or rejected entirely at the discretion of the Engineer-in- Charge. The rejected concrete
shall be dismantled at no extra cost to the owner and no payment or extension of time shall be
granted for the concrete so rejected and the formwork and reinforcement used for the same.
Cost of any material supplied by the Owner free of cost shall be recovered from the Contractor
at double the prevailing market rate. In case the concrete of lower strength can be improved by
carrying out some strengthening measures entirely at the discretion of the Engineer-in-Charge,
then the said measures including all related tests shall be carried out by Contractor at his own
cost. If the Contractor is able to make up the strength to the required grade by such
improvement measures to the entire satisfaction of Engineer-in-Charge, payment shall be made
for the grade achieved. However, if the strength of concrete is not made up to the strength of
required grade, payment shall be made only for the lower strength if such concrete is accepted
by the Engineer-in-Charge.
22.1.5 Deductions for openings, pockets etc. shall be as specified in relevant parts of IS 1200.
22.1.6 Payment under continuous concreting item in the schedule of rates shall be made only where
the total quantity of concrete between two consecutive construction joints specifically called-
out on the drawings exceeds 250 cubic metres. For any foundation/structure involving concrete
quantity upto 250 cubic metres between two consecutive construction joints shown on
drawings, the concrete shall not be measured or paid for under this category (i.e. continuous
concreting), even though the same is required to be constructed in single pour. The rate quoted
against this item shall be inclusive of all extra cost related to labour, shuttering, staging and
making all other arrangements for such continuous casting e.g. provisions for adequate
movement and storage spaces, special gangways, scaffolding, additional construction
equipments, adequate lighting and supervision while the work continues round the clock etc.
The rate shall also be inclusive of all costs related to concreting in any thickness, shape and
position and at any height or depth so as to avoid any cold joint between specified construction
joints.

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22.1.7 Form Work

Unless otherwise specified, payment for form work shall be on square metre basis of the actual
area in contact with the concrete cast. The rates shall be inclusive of keeping the formwork for
the full period as specified in the above clauses and removing the same after the period is over.
No extra payment shall be made for providing scaffolding/ staging/ access/ stairways/ ladders
etc.
The rates shall be inclusive of any provision to be made or kept in the formwork for providing
dowels, inserts etc.
Superior quality formwork for exposed/architectural concrete work shall be measured and paid
separately under the relevant item in the schedule of rates.

22.2 Reinforcement
22.2.1 Payment for plain round mild steel reinforcement bars, high strength deformed steel bars and
epoxy coated reinforcing steel bar shall be on the basis of weight of bare steel irrespective of
any coating applied in metric tons. The weight of the bar shall be derived from the sizes and
corresponding nominal unit weight given in Table-1 of IS:1786. In case actual unit weight of the
bars is less than nominal unit weight, but within permissible tolerances, the weight of
reinforcement shall be calculated on the basis of actual unit weight. In case actual unit weight of
the bars is more than nominal unit weight, the payment shall be made on the basis of nominal
unit weight. Standard hook lengths, chairs, spacer bars and authorized laps only shall be
included in the weight calculated. Binding wire shall not be weighed nor otherwise measured.
Measurements for weight shall not include cutting allowance etc.
22.2.2 Rate quoted for reinforcement shall include cost of supplying, decoiling, straightening,
cleaning, cutting, bending, placing, binding, welding (if required) and providing necessary
cover blocks of concrete.
22.2.3 Payment for a mechanical threaded coupler/ clamp shall be made by measuring the Lap length
of the respective rebar on which coupler/ clamp is used. The rate shall include supply of
complete assembly, fixing, testing etc. all complete.

22.3 Water Stops/Water Bars & Expansion/Isolation Joints

22.3.1 Payment for PVC water bars shall be made on running metre (RM) basis of the water stops
provided in position. Rate shall include supplying cutting, fixing, jointing by vulcanising or
any other approved method, wastage, etc. complete.
22.3.2 Payment for filler materials in Expansion/Isolation joints shall be made on running metre basis
of the joint provided. For boards provided at expansion/isolation joints, the measurement shall
be made on square metre basis. Rate shall be inclusive of supply, cutting, fixing, jointing,
wastage etc. complete.

22.4 Waterproof Cement Paint

22.4.1 Payment for waterproof cement paint as per Cl. 18.0 shall be made separately on Sqm basis.

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 SPECIFICATION-4: CIVIL & STRUCTURAL WORKS - REINFORCED CEMENT
CONCRETE FOR LIQUID RETAINING STRUCTURES
Relevant SOR item no: S016 to S018

SCOPE:
Concrete structures meant for liquid retaining shall cover under/over ground reservoirs/tanks,
sumps, etc. which are required to retain any liquid internally..

2.0 REFERENCES

2.1 BIS Codes

IS:3370, 6494, 12118, 1838, 2645

2.2 Job specifications

SPECIFICATION: CIVIL & STRUCTURAL WORKS - MATERIALS.

SPECIFICATION:CIVIL & STRUCTURAL WORKS - PLAIN & REINFORCED CEMENT
CONCRETE

3.0 MATERIALS

Materials for concrete viz. cement, sand, aggregate, water etc., admixtures and water stops shall
be as described in job specification for material.

4.0 GENERAL REQUIREMENTS

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4.1 The concrete structure by itself shall be leak proof to the extent as acceptable (refer to cl. 11.0).
Damp patches, if any at the initial stage, shall not be acceptable if the same do not disappear
after three months of putting the structure in service. The basic requirement is to make the
concrete sound, dense and impervious. The Contractor shall take all necessary precautions in
selecting the materials, mix design and method of construction so as to achieve this objective. If
any additional liquid-proof material is specified and/or shown on drawings, the same shall be
considered as a second-line of defense and shall not entail the contractor to any relaxation from
the conditions for the structure being leak-proof by itself.

4.2 This specification defines the materials, constructional and performance requirements for liquid
retaining concrete structures. Any special requirements as shown or noted in the drawings shall
govern over the provisions of this specification.

4.3 The work shall be done in accordance with this specification together with IS:3370 & IS:6494.
In case of conflict between the clauses mentioned in this specification and those in the Indian
Standards, this specification shall govern.

4.4 After construction, the structure shall be tested for water tightness/ leakproofness as detailed
hereunder.

5.0 CONCRETE

5.1 SPECIFICATION: CIVIL & STRUCTURAL WORKS - PLAIN & REINFORCED CEMENT
CONCRETEshall be applicable together with the following clauses:

5.1.1 Special care shall be taken to get the most suitable grading of aggregates so as to produce the
densest possible concrete. The maximum size of coarse aggregate shall be limited to 20 mm,
unless shown on the drawing. Water-cement ratio shall be strictly controlled (by making due
allowance for the surface water carried by the aggregates), consistent with the requirement of
workability to produce an impervious concrete.

5.1.2 Minimum Grade of Concrete shall be as per IS:3370.

5.1.3 Concrete shall have minimum cement content and maximum water cement ratio as per IS:3370.
In order to achieve required workability and slump, cement and water content may be suitably
adjusted, keeping the water cement ratio constant.

5.1.4 Water proofing compound of approved make, conforming to IS:2645, in proportion as specified
by manufacturer shall be mixed with concrete as per manufacturer’s specification.

5.1.5 The joints of shuttering board shall be made tight to produce a face free from pores.

5.1.6 The concrete shall be so placed and vibrated that a well compacted dense concrete free from
honeycombing is produced.

5.1.7 Admixtures

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 Admixtures in concrete shall be used only with the prior approval of the Engineer-in-Charge.
Any admixture used for obtaining proper workability or leak-proofness of concrete or
repair/rendering works of concrete due to non-conformance to the job specifications, shall not
be measured and paid for. All costs relating to such usage shall be borne by the Contractor.

5.2 Construction, Contraction & Expansion Joints

5.2.1 All vertical and horizontal joints in liquid retaining structures shall be located and executed as
shown in the drawings. For construction joints not shown in the drawing, specific approval of
the Engineer-in-Charge shall be obtained. Every endeavor shall be made to avoid vertical
construction joints. The number of construction joints shall be kept to the minimum. Where
horizontal or vertical joints are required to be left after the day's work, the same shall be done
as per directions of the Engineer-in-Charge. The face of the old concrete shall be well hacked to
expose the aggregate, care being taken to avoid damaging the aggregate.

While the remainder of the concrete should be kept continuously wet, curing of the joint surface
may be suspended a few hours before concreting is to be resumed so as to permit no more than
superficial drying of the joint surface. Just before concreting is resumed, the roughened joint
surface shall be thoroughly cleaned and freed from loose pieces of gravel, stone chips, wooden
chips, nails, laitance or any other foreign material, preferably, without re-wetting, and then
treated with a thin layer of cement grout, worked well into the surface, or treated with cement-
sand mortar in which water-cement and sand-cement ratios do not exceed those in the new
concrete.

5.2.2 Horizontal joints in vertical walls of the structure shall preferably form a closed loop.

5.2.3 Water stops installation shall be done by embedding one half of the water stop along the
proposed joints on each side of the joint by suitable jigs/supporting arrangement between the
adjacent sections of the concrete as per the manufacturer's specifications and directions of the
Engineer-in-Charge. Water stops shall be positioned accurately and supported against any
displacement during concreting. All precautions shall be taken to avoid folding or twisting of
water stops during pouring and compacting concrete. To achieve the continuity of the water
stop all along the joint, at crossings and at change of alignments, the water stops shall be
joined/ vulcanised as per manufacturer's specifications and directions of the Engineer-in-
Charge. Jigs manufactured out of reinforcing bars may be used for fixing the water stop. The
jigs shall be measured and paid under reinforcement item.

5.2.4 Expansion joints shall be filled up with non-absorbent compressible sheet/bitumen impregnated
fiber board (as per IS:1838) except the top 12mm depth on the water faces(or as shown on the
drawings) which shall be filled with two part liquid polysulphide sealant (as per IS:12118).In
case of contraction and/or construction joints, such polysulphide sealant shall be used for 12mm
depth on the water faces (or as shown on the drawings) after forming suitable grooves in
concrete.

5.3 Items Embedded in Concrete

5.3.1 All sleeves, inserts, anchors and embedded items required for the work shall be available at site
prior to start of concreting. These shall be accurately placed and embedded as described in

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 specification for : CIVIL & STRUCTURAL WORKS - PLAIN & REINFORCED CEMENT CONCRETE. In case
any protective coating for such elements is shown, Contractor shall coat the same prior to
embedment, which shall be paid separately.

5.3.2 Every precaution shall be taken to keep all embedments and water stops in position as shown
on drawings during pouring and compacting concrete. Work in such areas shall be carried out
under strict supervision.

6.0 RENDERING

6.1 Rendering by cement-sand mortar of same proportion as in original concrete shall be used with
the object of covering weak patches in the construction, as per the direction of the Engineer-in-
Charge. The rendering shall be applied to the concrete only after the inspection by the
Engineer-in-Charge and if approved by him. The concrete surface shall be well wetted and if
necessary, hacked prior to the application of mortar. The mortar shall be steel trowelled and
finished with a wooden float.

7.0 SEPARATION LAYER

Separation layer shall be provided between the lean concrete and the bottom raft/slab of the
underground liquid retaining structure. This layer shall consist of polyethylene sheet of mass
1kg/m2 or any other suitable material as directed by the Engineer-in-Charge. The top surface of
lean concrete shall be finished smooth with a wooden trowel to receive the separation layer.
Joints in the separation layers shall be lapped by 200mm. All care shall be taken to keep the
separation layer in position while progressing with further work above.

8.0 FORM WORK

8.1 SPECIFICATION : CIVIL & STRUCTURAL WORKS - PLAIN & REINFORCED CEMENT CONCRETE for Plain
& Reinforced Cement Concrete shall be applicable together with the following:

Detailed dimensioned drawing showing the arrangement of form work including its design if so
required by the Engineer-in-Charge shall be furnished to the Engineer-in-Charge before the
form work is erected. The work shall be as per the directions and approval of the Engineer-in-
Charge. No concrete element of the liquid retaining structure shall be loaded with any support
for further form work unless it has aged for minimum 21 days. After that if any form work rests
on such element, adequate external support shall be provided so that any unequal loading on the
element does not cause any local deformation.

9.0 CURING

Concrete shall be cured in accordance SPECIFICATION : CIVIL & STRUCTURAL WORKS

- PLAIN & REINFORCED cement concrete

10.0 FINISHES

All the form work shall be so done that no plastering or other external finish is required. All
burrs shall be rubbed smooth with carborandum stone and the finished work shall present a

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 uniform shade and finish. All the exposed surfaces shall be provided with a coat of cement
wash free of cost if the rendered surfaces are not of acceptable standard as per the sole
discretion of the Engineer-in-charge.

11.0 HYDRAULIC TESTING

11.1 Liquid retaining structures shall be tested strictly in accordance with IS:3370 for water
tightness in addition to the structural tests as mentioned in specification for CIVIL & STRUCTURAL
WORKS - PLAIN & REINFORCED CEMENT CONCRETE. The total maximum drop in water surface
level shall not exceed 6mm in 24 hours in case of covered reservoirs and 12mm in 24 hours in
case of open reservoirs.

11.2 If the test proves that the structure is defective, the Contractor shall rectify/repair the same at
his own cost as per the approved scheme as agreed to by the Engineer-in-Charge. The required
structure shall again be tested as per 11.1 above. If the structure is still not found to satisfy the
acceptance criteria, the same shall be dismantled and rebuilt.

11.3 All testing after construction and remedial treatments shall conform to the provision of IS:6494.

11.4 Backfilling around underground structures shall be allowed only after the test results are found
satisfactory by the Engineer-in-Charge.

12.0 PAYMENT

This clause shall apply to Item Rate tender only.

12.1 Payment shall be made on cubic metre (m3) basis of the volume of the actual finished concrete
work done or as per approved construction drawings, whichever is less. The rate shall be
inclusive of all labour, material, curing, cost of leaving pockets, blockouts for pipes/electric
conduits, recesses of all sizes, embedding fixtures, vibrating, rendering, hacking and washing
old concrete faces, applying mortar/grout on them, etc. but exclusive of reinforcement,
formwork, embedded fixtures, water stops and sealing compound which shall be paid under
separate items. In case the Contractor proposes to use any admixture in concrete for making it
water tight/leak-proof, no separate payment for such admixtures shall be made and the rate
quoted for concrete under liquid retaining structures shall be inclusive of such admixtures.
However, when such admixtures are used under job specific requirements mentioned in the
standard drawings/specifications, these shall be separately measured and paid for, under
respective item, provided in the Schedule of Rates.

12.2 No separate payment shall be made for testing and report making which is deemed to be
included in the quoted concrete rate, including cost of hydraulic tests and structural tests, all
appliances and rectifications, if any.

If the test proves that the structure is defective, the Contractor shall develop and execute with
the approval of the Engineer-in-Charge, suitable methods for making the structure, water
tight/leak-proof at his own cost. Even after this if the test fails, the Contractor shall have to
dismantle and rebuild the structure within the specified time schedule, at his own cost.

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 Cost of initial and subsequent testing, inclusive of cost of water, shall be borne by the
Contractor. The Contractor shall make his own arrangement for filling as well as emptying the
reservoir after the completion of the test and no payment shall be made on this account.

12.3 Payment for separation layer shall be based on the actual surface area in square metres (m2).
The Contractor shall include in his rate all allied works viz. cleaning, preparing of surfaces,
laying etc. all materials complete.

SPECIFICATION-5: CIVIL & STRUCTURAL WORKS - STRUCTURAL STEEL WORKS.

Relevant SOR item no: S019 to S023

1.0 SCOPE

This specification describes the information to be included in a Project Specification and also
covers the requirements for material, storage, preparation of fabrication drawings, fabrication,
assembly, tests/examinations, transportation, erection and painting of all types of bolted and/or
welded structural steel works for general construction work. Fabrication of structures shall also
include fabricating:

Built up sections/plate girders made out of rolled section and/or plates.

Compound sections made out of rolled sections.

2.0 REFERENCES

BIS Codes

IS: 800, 808, 816, 819, 822, 919, 1024, 1261, 1323, 1477, 1852, 2074, 7205, 7215,
7307, 7310, 7318, 9595, 12778 and other relevant BIS Codes.

SP: 6(1)

Job Specifications

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 57 OF 221

 -Materials SPECIFICATION: CIVIL & STRUCTURAL WORKS - GENERAL SCOPE.
Shop & Field Painting-Job specification for painting.

In case of conflict between the clauses mentioned in this specification and those in the Indian
Standards, clauses included in this specification shall govern. Any special provision as shown or
noted on the design drawings or any project specific specification specified elsewhere shall govern
over the provisions of this specification.

3.0 MATERIALS

3.1 General

All materials shall conform to their respective specifications given in specification: CIVIL &
STRUCTURAL WORKS - MATERIALS. The use of equivalent or alternative materials shall be
permitted only in very special cases and for all such cases prior written approval of the
Engineer-in-Charge shall be obtained.

3.2 Receipt & Storing of Materials

Each section shall be marked for identification and each lot shall be accompanied by
manufacturer's quality certificate, chemical analysis and mechanical characteristics.

All sections shall be checked, sorted out and arranged by grade and quality in the store. Any
instruction given by the Engineer-in-Charge in this respect shall be strictly followed.

All material shall be free from surface defects such as pitting, cracks, laminations, twists etc.
Defective material shall not be used and all such rejected material shall be immediately removed
from the store/site. The decision of the Engineer-in- Charge in this regard shall be final and
binding.
Welding wires and electrodes (packed in their original cartons) shall be stored separately by quality
and lots inside a dry and enclosed room in compliance with IS:9595 and as per the instructions
given by the Engineer-in-Charge. Electrodes shall be kept perfectly dry to ensure satisfactory
operation and weld metal soundness.
Each lot of electrodes, bolts, nuts etc. shall be accompanied by manufacturer's quality/test
certificates.

All bolts (including nuts & washers) shall be checked, sorted out and arranged diameter-wise by
grade and quality in the store.

3.3 Material Tests

The Contractor shall submit manufacturers' quality certificates for all the materials supplied by
him. In case, quality certificates are not available or are incomplete or when material quality differs

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 from standard specifications, such materials shall not be used in the construction. However, the
Contractor shall get all appropriate tests conducted in approved test houses for such materials as
directed by the Engineer-in-Charge, at no extra cost, and submit the same to Engineer-in-Charge
forhis approval. The Engineer-in-Charge may approve the use of such materials entirely at his
discretion.

The Contractor shall ensure that all materials brought to site are duly approved by the
Engineer-in-Charge. Rejected materials shall not be used and shall be removed from site forthwith.
Any material of doubtful quality for which specific tests are to be carried out as per the instruction
of the Engineer-in-Charge shall be separately stacked and properly identified and shall not be used.
These shall be removed from site forthwith.

4.0 FABRICATION DRAWINGS

Fabrication and erection drawings shall be prepared by the Contractor on the basis of "Approved
for Construction (AFC)" design drawings, jobStandards issued to the Contractor. These drawings
shall be prepared by the Contractor or by an agency appointed by the Contractor and approved by
the Engineer-in-Charge.

Fabrication and erection drawings shall be thoroughly checked, stamped "Approved for
Construction" and signed by the Contractor's own responsible Engineer irrespective of the fact that
such drawings are prepared by the Contractor or his approved agency, to ensure accuracy and
correctness of the drawings. Unchecked and unsigned drawings shall not be used for the purpose of
proceeding with the work. The Contractor shall proceed with the fabrication and erection work
only after thoroughly satisfying himself in this regard.

All fabrication and erection drawings shall be issued for construction by the Contractor directly to
his work- site. Six copies of such drawings shall simultaneously be submitted to the
Engineer-in-Charge who may check/ review some or all such drawings at his sole discretion and
offer his comments for incorporation in these drawings by the Contractor.

However, the Contractor shall not proceed with the fabrication of such structures whose fabrication
drawings are required to be reviewed before taking up the fabrication work as noted on "Approved
for Construction (AFC)" design drawings issued to the Contractor or as conveyed by the
Engineer-in-Charge. The fabrication of such structures shall be done only as per the reviewed
fabrication drawings.

The review of such drawings by consultant shall be restricted to the checking of the following
only:
i) Structural layout, orientation and elevation of structures/members.

ii) Sizes of members.

iii) Critical joint details.

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4.4 Fabrication drawings shall be drawn to scale and shall convey the information clearly and
adequately. Following information shall be furnished on such drawings:

i) Reference to design drawing number (along with revision number) based on which fabrication
drawing has been prepared.

ii) Structural layout, elevations & sections (with distinct erection marking of all
members).

iii) Framing plans, member sizes, orientation and elevations.

iv) Layout and detailing of rain water pipes and gutters showing all necessary levels, connections and
provisions wherever required.

v) Detailing of shop/field joints, connections, splices, for required strength and erection.

vi) Location, type, size and dimensions of welds and bolts.

vii) Shapes and sizes of edge preparation for welding.

viii) Details of shop and field joints/welds.

ix) Bill of materials/D.O.D. Lists.

x) Quality of structural steel, plates etc., welding electrodes, bolts, nuts and washers to be used.

xi) Erection assemblies identifying all transportable parts and sub-assemblies with
special erection instructions, if required.

xii) Method of erection and special precautions to be taken during erection as required.

xiii) Details of holes and fittings in components necessary for safe lifting and erection purpose.

4.5 The Contractor shall additionally ensure accuracy of the following and shall be solely
responsible for the same:

i) Provision for erection and erection clearances.

ii) Marking of members

iii) Cut length of members

iv) Matching of joints and holes.

v) Provision kept in the members for other interconnected members.

vi) Bill of materials/D.O.D. Lists.

4.6 Connections, splices and other details where not shown on the design drawings shall be suitably
designed and shown on the fabrication drawings based on good engineering practice developing full

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member strength. Design calculations for such connections/splices shall be submitted to the
Engineer-in-Charge alongwith the fabrication drawings.

4.7 Any substitution or change in section shall be allowed only when prior written approval of the
Engineer-in-Charge has been obtained. Fabrication drawings shall be updated incorporating all such
substitutions/changes by the Contractor at no extra cost to the Owner.

4.8 In case during execution of the work, the Engineer-in-Charge on review of drawings considers any
modifications/substitutions necessary to meet the design parameters/good engineering practice, these shall
be brought to the notice of the Contractor who shall incorporate the same in the drawings and works
without any extra cost to the owner. The Contactor will be totally responsible for the correctness of the
detailed fabrication drawings and execution of the work.

4.9 Contractor shall incorporate all the revisions made in the design drawings during the course of
execution of work in his fabrication drawings, and resubmit the drawings at no extra cost to the Owner.
All fabrication shall be carried out only as per the latest AFC design drawings and corresponding
fabrication drawings.

4.10 The Contractor shall supply two prints each of the final/as built drawings alongwith their native
soft file to Engineer-in-Charge for reference and record. The rates quoted shall include for the same.
5.0 FABRICATION

5.1 General

5.1.1 Fabrication of structures shall be done strictly as per "Approved for Construction" fabrication
drawings (prepared by the Contractor based on the latest design drawings) and in accordance with IS:800,
9595 & other relevant BIS Codes and BIS Hand Book SP:6(1).

5.1.2 Prior to commencement of structural fabrication, undulations in the fabrication yard, if any,
shall be removed and area levelled and paved by the Contractor.

5.1.3 Any defective material used in the work shall be replaced by the Contractor at his own expense.
Necessary care and precautions shall be taken so as not to cause any damage to the structure during any
such removal and replacement.

5.1.4 Any faulty fabrication pointed out at any stage of work by the Engineer-in- Charge, shall be
made good or replaced by the Contractor at his own cost.

5.1.5 Tolerances for fabrication of steel structures shall be as per IS:7215.

5.2 Fabrication Procedure

5.2.1 Straightening & Bending

5.2.1.1 All materials shall be straight and, if necessary, before being worked shall be straightened
and/or flattened (unless required to be of curvilinear form) and shall be free from twists.

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5.2.1.2 Bending of rolled sections and plates shall be done by cold unitto shape/s as shown on
drawings.
5.2.1.3 After completion of bending or straightening, welds within the area of bending or straightening
shall be thoroughly visually inspected. Nondestructive tests required to be carried out for such locations
shall be done only after straightening or bending activity.

5.2.2 Clearances

The erection clearance for cleated ends of members shall be not greater than 2mm at each end.
The erection clearance at ends of beams without web cleats and end plates shall be not more than 3mm at
each end but where for practical reasons, greater clearance is necessary, suitably designed seatings
approved by the Engineer-in-Charge shall be provided.

5.2.3 Cutting

5.2.3.1 Prior to cutting, all members shall be properly marked showing the requisite cut length/width,
connection provisions e.g. location and dimensions of holes, welds, cleats etc. Marking for cutting shall
be done judiciously so as to avoid wastages or unnecessary joints as far as practicable. Marking shall be
done by placing the members on horizontal supports/pads in order to ensure accuracy. Marking accuracy
shall be limited to + 1mm.

5.2.3.2 Cutting may be affected by shearing, cropping or sawing. Gas cutting by mechanically
controlled torch shall be permitted for mild steel. Hand flame cutting may be permitted subject to the
approval of the Engineer-in-Charge.

5.2.3.3 Except where the material is subsequently joined by welding, no loads shall be transmitted into
metal through a gas cut surface.

5.2.3.4 Shearing, cropping and gas cutting shall be clean, square, free from any distortion & burrs, and
should the Engineer-in-Charge find it necessary, the edges shall be ground afterwards, to make the same
straight and uniform at no extra cost to the Owner.

5.2.4 Holing

5.2.4.1 Holes for bolts shall not be formed by gas cutting process.

5.2.4.2 Holes through more than one thickness of material of members such as compound stanchions
and girder flanges shall, where possible, be drilled after the members are assembled and tightly
clamped/bolted together. Punching may be permitted before assembly, provided the thickness of metal is
less than 16mm and the holes are punched 3mm less in diameter than the required size and reamed, after
assembly, to the full diameter. Punching shall not be adopted for dynamically loaded structures.

5.2.4.3 Holes may be drilled in one operation through two or more separable parts and burrs removed
from each part after drilling.

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5.2.4.4 Holes in connecting angles and plates, other than splices, also in roof members and light
framing, may be punched full size through material not over 12mm thick, except where required for close
tolerance bolts or barrel bolts.

5.2.4.5 All matching holes for black bolts shall register with each other so that a gauge of 2mm less in
diameter than the diameter of hole shall pass freely through the assembled members in the direction at
right angle to such members. Finished holes shall be not more than 2mm in diameter larger than the
diameter of the black bolt passing through them, unless otherwise specified by the Engineer- in-Charge.

5.2.4.6 Holes for turned and fitted bolts shall be drilled to a diameter equal to the nominal diameter of
the shank or barrel subject to H8 tolerance specified in IS:919. Parts to be connected with close tolerance
or barrel bolts shall be firmly held together by tacking bolts or clamps and the holes drilled through all the
thicknesses in one operation and subsequently reamed to size. Holes not drilled through all the
thicknesses in one operation shall be drilled to a smaller size and reamed out after assembly. Where this is
not possible, the parts shall be drilled and reamed separately.

5.2.4.7 To facilitate grouting, holes shall be provided in column bases or seating plates exceeding
300mm in width for the escape of air.

5.2.4.8 To avoid accumulation of water in gussetted column bases of laced, battened or box type
stanchions, suitable reverse U-type holes shall be provided at the junction of base plate and column
section in the vertical gussets for draining out of any water.

5.2.4.9 Slotted holes shall be punched or formed by drilling two holes and completed by cutting.

5.2.5 Assembly

The component parts shall be assembled and aligned in such a manner that they are neither
twisted nor otherwise damaged, and shall be so prepared that the required camber, if any, is
provided. Proper clamps, clips, jigs and other fasteners (bolts and welds) shall be placed in a
balanced pattern to avoid any distortion in the members and to ensure their correct positioning
(i.e. angles, axes, nodes etc.). Any force fitting, pulling/stretching of members to join them shall
be avoided. Proper care shall be taken for welding shrinkage & distortion so as to attain the
finished dimensions of the structure shown on the drawings.

5.2.6 Welding

5.2.6.1 General

a) All joints shall be welded unless noted otherwise on the design drawings.

b) Welding shall be in accordance with IS:816, IS:819, IS:1024, IS:1261, IS:1323 and IS:9595 as
appropriate.

c) The Contractor shall make necessary arrangement for providing sufficient number of welding sets
of the required capacity, all consumables, cutting and grinding equipment with requisite

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 accessories/ auxiliaries, equipment & materials required for carrying out various tests such as dye
penetration, magnetic particle, ultrasonic etc.

d) Adequate protection against rain, dust, snow & strong winds shall be provided to the welding
personnel and the structural members during welding operation. In the absence of such a
protection no welding shall be carried out.

e) It shall be the responsibility of the Contractor to ensure that all welding is carried out in
accordance with the terms of this specification and relevant BIS codes. The Contractor shall
provide all the supervision to fulfil this requirement.

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5.2.6.2 Preparation of Member for Welding

a) Edge Preparation
Edge preparation/bevelling of fusion faces for welding shall be done strictly as per the
dimensions shown in the drawings. In case, the same are not indicated, edges shall be prepared
(depending on the type of weld indicated in the drawing) as per the details given in IS:9595.
Bevelling of fusion faces shall be got checked and approved by the Engineer- in-Charge. The
tolerances on limits of gap, root face & included angle shall be as stipulated in IS:9595.

b) Cleaning

Welding edges and the adjacent areas of the members (extending upto 20mm) shall be
thoroughly cleaned of all oil, grease, scale and rust and made completely dry. Gaps between the
members to be welded shall be kept free from all foreign matter.

c) Preheating

Preheating of members, shall be carried out as per IS:9595 when the base metal
temperature is below the requisite temperature for the welding process being used. Preheating
shall be done in such a manner that the parts, on which the weld metal is being deposited, are
above the specified minimum temperature for a distance of not less than 75mm on each side of
the weld line. The temperature shall be measured on the face opposite to that being heated.
However, when there is access to only one face, the heat source shall be removed to allow for
temperature equalization (1 minute for each 25mm of plate thickness) before measuring the
temperature.

d) Grinding

i) Column splices & butt joints of struts and compression members (depending on contact for
load transmission) shall be accurately ground and close-butted over the whole section with a
tolerance not exceeding 0.2mm locally at any place. In column caps & bases, the ends of shafts
together with the attached gussets, angles, channels etc., shall be accurately ground so that the
parts connected butt over minimum 90% surface of contact. In case of connecting angles or
channels, care shall be taken so that these are fixed with such accuracy that they are not reduced
in thickness by grinding by more than 2mm.

ii) Ends of all bearing stiffeners shall be ground to fit tightly at both top and bottom. Similarly
bottom of the knife edge supports along with the top surface of column brackets shall be
accurately ground to provide effective bearing with a tolerance not exceeding 0.2mm locally at
any place.

iii) Slab bases and caps shall be accurately ground over the bearing surfaces and shall have
effective contact with the ends of stanchions. Bearing faces which are to be grouted direct to
foundations need not be ground if such faces are true & parallel to the upper faces.

iv) Tack welding shall be thoroughly removed by grinding or gouging such that subsequent
welding shall be done properly.

5.2.6.3 Welding Processes

Welding of various materials under this specification shall be carried out using one or more of

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the following processes.

- Manual Metal Arc Welding Process (MMAW)

- Submerge Arc Welding Process (SAW)

- Gas Metal Arc Welding Process (GMAW)

- Flux Cored Arc Welding Process (FCAW)

The welding procedure adopted and consumables used shall be specifically approved by the
Engineer-in-Charge. A combination of different welding processes or a combination of electrodes of
different classes/makes may be employed for a particular joint only after qualifying the welding
procedures to be adopted and obtaining the written approval of the Engineer-in-Charge.

5.2.6.4 Approval & Testing of Welders

The Contractor shall satisfy the Engineer-in-Charge that the welders are suitable for the work upon
which they will be employed. For this purpose the welders shall have satisfied the relevant
requirements of IS:7318. If the welders will be working to approved welding procedures, they shall
have satisfied the relevant requirements of IS:7310.

Adequate means of identification shall be provided to enable each weld to be traced to the welder by
whom it was made. The Contractor shall intimate the Engineer-in-Charge sufficiently in advance, the
commencement of tests, to enable him to be present to witness the same.

5.2.6.5 Approval & Testing of Welding Procedures

The Contractor shall carry out procedure tests in accordance with IS:7307 to demonstrate by means
of a specimen weld of adequate length on steel representative of that to be used, that he can make
welds with the welding procedure to be used for the work to the complete satisfaction of the
Engineer- in-Charge. The test weld shall include weld details from the actual construction and it
shall be welded in a manner simulating the most unfavourable instances of fit-up, electrode
condition etc., which are anticipated to occur on the particular fabrication. Where material analysis
are available, the welding procedure shall be carried out on material with the highest carbon
equivalent value.

After welding, but before the relevant tests given in IS:7307 are carried out, the test weld shall be
held as long as possible at room temperature, but in any case not less than 72 hours, and shall then
be examined for cracking. The examination procedure shall be sufficiently rigorous to be capable
of revealing significant defects in both parent metal and weld metal.

After establishing the welding method, the Contractor shall finally submit to the
Engineer-in-Charge for his approval the welding procedure specification in standard format given
in IS:9595 before starting the fabrication.

5.2.6.6 Sequence of Welding

a) As far as practicable, all welds shall be made in a sequence that will balance the applied heat of
welding while the welding progresses.

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b) The direction of the general progression in welding on a member shall be from points where the
parts are relatively fixed in position with respect to each other towards points where they have a
greater relative freedom of movement.

c) All splices in each component part of a cover-plated beam or built up member shall be made
before the component part is welded to other component parts of the member.

d) Joints expected to have significant shrinkage shall be welded before joints expected to have lesser
shrinkage.

e) Welding shall be carried continuously to completion with correct number of runs.

f) The Contractor shall choose the welding sequence after carefully studying each case such as to
minimize distortion and shrinkage & submit the same to the Engineer-in-Charge for comments
and approval.

5.2.6.7 Welding Technique

a) After the fusion faces are carefully aligned and set with proper gaps, the root pass of butt joints
shall be executed properly so as to achieve full penetration with complete fusion of the root
edges.

b) On completion of each run, all slag and spatters shall be removed and the weld and the adjacent
base metal shall be cleaned by wire brushing and light chipping. Visible defects such are cracks,
cavities and other deposition faults, if any, shall be removed to sound metal before depositing
subsequent run of weld.

c) All full penetration butt welds shall be completed by chipping/gouging to sound metal and then
depositing a sealing run of weld metal on the back of the joints. Where butt welding is practicable
from one side only, suitable backing steel strip shall be used and joint shall be arranged in such a
way as to ensure that complete fusion of all the parts is readily obtained.

d) While welding is in progress care shall be taken to avoid any kind of movement of the
components, shocks, vibrations to prevent occurrences of weld cracks.

e) Any deviation desired from the recommended welding technique and electrodes shall be adopted
only after obtaining written approval of the Engineer-in-Charge.

5.2.6.8 Inspection & Testing of Welds

The method of inspection shall be according to IS:822 and extent of inspection and testing shall
be in accordance with the relevant applicable standard or, in the absence of such a standard, as
specified by the Engineer-in-Charge. Welds shall not be painted or otherwise obscured until they
have been inspected, approved and accepted.

The Engineer-in-Charge or his representative shall have access to the Contractor's work at all
reasonable times and the Contractor shall provide him with all facilities necessary for inspection
during all stages of fabrication and erection with, but not limited to, the following objectives.

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i) To check the conformity with the relevant standards and suitability of various welding
equipments and their performance.

ii) To witness/approve the welding procedure qualification.

iii) To witness/approve the welders performance qualification.

iv) To check whether shop/field welding being executed is in conformity with the relevant
specifications and codes of practice.

Inspection and testing of all fabricated structures shall be carried out by the Contractor by
any, or, a combination of all the following methods as directed by the Engineer-in-Charge and no separate
payment shall be made, unless otherwise mentioned, for inspection and testing of welds/fabricated
structures:

A. Visual Inspection

All finished welds (i.e. 100 percent) shall be visually inspected for identification of the
following types of weld defects & faults.

a) Weld defects occurring at the surface such as blow holes, exposed porosity, unfused welds
etc.

b) Surface cracks in the weld metal or in the parent metal adjacent to it.

c) Damages to the parent metal such as undercuts, burning, overheating etc.

d) Profile defects such as excessive convexity or concavity, overlapping, unequal leg lengths,
excessive reinforcement, incompletely filled grooves, excessive penetration beads, root grooves
etc.

e) Distortion due to welding i.e., local shrinkage, camber, bowing, twisting, rotation, wariness
etc.

f) Linear eccentric, angular and rotational misalignment of parts.

g) Dimensional errors.

B. Mechanical Tests

The mechanical testing (such as tensile load tests, bend tests, impact tests etc.) shall be
done in accordance with the relevant standards and as per the instructions of the Engineer-in-Charge.

C. Magnetic Particle/Dye Penetration/Ultrasonic Examination

The examination shall be done at random as directed by the Engineer-in-Charge. Whenever

such tests are directed, the tests shall be carried out on joints chosen by him. The tests shall be carried out
by employing approved testing procedure in accordance with IS:822.

D. Radiographic Examination

Radiographic examination shall be carried out only in special cases for random joints as directed by

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 the Engineer-in-Charge. The Contractor shall be paid extra for such examination except for penalty
radiographic tests for which the cost shall be borne by him. The Contractor shall make necessary
arrangement at his own expense for providing the radiographic equipment, films and all other
necessary materials required for carrying out the examination. The tests shall be carried in the
presence of the Engineer-in-Charge by employing approved testing procedure in accordance with
IS:822. The Contractor shall fulfill all the statutory safety requirements while handling X-ray and
Gamma-ray equipment and provide the Engineer- in-Charge all the necessary facilities at site such
as dark room, film viewer etc., to enable him to examine the radiographs.

5.2.6.9 Repair of Faulty Welds

No repair of defective welds shall be carried out without proper permission of the
Engineer-in-Charge and his approval for the corrective procedure.

Welds not complying with the acceptance requirements (as specified by BIS Codes & the
Engineer-in-Charge), as revealed during inspection & testing of welds or erection or in-situ
condition, shall be corrected either by removing & replacing or as follows:

a) Excessive convexity - Reduced to size by removal of excess weld metal.

b) Shrinkage cracks, cracks in - Defective portions removed down to sound metal

in parent plates and craters and re-welded.

c) Under cutting. - Additional weld metal deposited.

d) Improperly fitted/ - Welding cut & edges suitably prepared and parts.
misaligned parts.

e) Members distorted - Member straightened by mechanical means or

by the heat of welding careful application of limited amount of heat,
temperature of such area not to exceed 650 degree
Centigrade (dull red heat).

In removing defective parts of a weld, gouging, chipping, oxygen cutting or grinding shall not
extend into the parent metal to any substantial amount beyond the depth of weld penetration,
unless cracks or other defects exist in the parent metal. The weld or parent metal shall not be
undercut in chipping, grinding, gouging or oxygen cutting.

Any fabricated structure or its component which, in the opinion of Engineer- in-Charge, is
defective and/or beyond any corrective action shall be removed forthwith from the site as
instructed by the Engineer-in-Charge without any extra claim. The owner reserves the right to
recover any compensation due to any loss arising out of such rejections.

5.2.7 Bolting

5.2.7.1 All bolts shall be provided such that no part of the threaded portion of the bolts is within the
thickness of the parts bolted together. Washers of suitable thickness shall be used under the nuts to avoid
any threaded portion of the bolt being within the thickness of parts bolted together.

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5.2.7.2 The threaded portion of each bolt shall project through the nut at least one thread.

5.2.7.3 Flat washers shall be circular and of suitable thickness. However, where bolt heads/nuts bear
upon the bevelled surfaces, they shall be provided with square tapered washers of suitable thickness to
afford a seating square with the axis of the bolt.
5.2.7.4 Different bolt grades of the same diameter shall not be used in the same structure, except if
agreed otherwise by the Engineer-in-Charge.
5.2.8 Splicing

5.2.8.1 Splicing of built up/compound/latticed sections shall be done in such a fashion that each
component of the section is joined in a staggered manner.

5.2.8.2 Where no butt weld is used for splicing, the meeting ends of two pieces of joist/channel/built up
section shall be ground flush for bearing on each other and suitable flange and web splice plates shall be
designed and provided for the full strength of the flange/ web of the section and welds designed
accordingly.

5.2.8.3 Where full strength butt weld is used for splicing (after proper edge preparation of the web and
flange plates) of members fabricated out of joist/ channel/ angles/ built up section, additional flange and
web plates shall be provided, over and above the full strength butt welds, to have 40% strength of the
flange and web.

5.2.8.4 Where a cover plate is used over a joist/channel section the splicing of the cover plate and
channel/joist sections shall be staggered by minimum 500mm. Extra splice plate shall be used for the
cover plate and joist/channel section as per clause 5.2.8.2 or 5.2.8.3.

5.2.8.5 Prior approval shall be obtained by the Contractor for locations of splices where not shown on
design drawings. For members upto a length of 7m, generally no splice shall be allowed but in
exceptional cases one splice shall be allowed at approved location. Maximum two numbers of splices
shall be allowed for members exceeding this length.

5.2.9 Machining & Grinding

5.2.9.1 All slab bases and slab caps shall be accurately machined over the bearing surfaces and shall be
in effective contact with the ends of column sections (shafts).

5.2.9.2 For slab bases and slab caps, ends of column shafts shall be accurately machined. However, for
gussetted bases and caps, the column shafts shall be ground flush for effective contact with parts
connected together.

5.2.9.3 Gussetted bases and caps shall be ground flush for effective contact with ends of column
sections.

5.2.9.4 End of all bearing stiffeners shall be machined or ground to fit tightly at top and bottom without
any air gap.

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5.2.9.5 While machining or grinding care shall be taken so that the length or thickness of any part does
not get reduced by more than 2.0mm.

5.2.9.6 For all machining or grinding works for gassetted base and cap plates, the clearance between
the parts joined shall not exceed 0.2mm at any location.

6.0 MARKING FOR IDENTIFICATION

6.1 Each component shall be distinctly marked (with paint) before delivery in accordance with the
marking diagrams and shall bear such other marks as will facilitate erection. Components which are
identical in all respects may have the same erection mark.

6.2 For small members which are delivered in bundles or crates, the required marking shall be done
on small metal tags securely tied to the bundle.

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7.0 SHOP ERECTION

The steel work shall be temporarily shop erected complete or as directed by the
Engineer-in-Charge, so that the accuracy of fit may be checked before despatch.

8.0 INSPECTION & TESTING OF STRUCTURES

8.1 The Engineer-in-Charge (or his authorised representative) shall have free access at all times to

those parts of the Contractor's works which are concerned with the fabrication of the steel work and

shall be provided with all reasonable facilities for satisfying himself that the fabrication is being

undertaken in accordance with the provisions of these specifications & other relevant BIS Codes.

8.2 Should any structure or part of a structure be found not to comply with any of the provisions of this
specification (or relevant BIS Codes as referred to), it shall be liable to rejection. No structure or
part of the structure, once rejected shall be resubmitted for inspection, exception cases where the
Engineer-in-Charge or his authorised representative considers the defect as rectifiable.

8.3 Defects which may appear during/after fabrication/ erection shall be made good only with the
consent of the Engineer-in-Charge and procedure laid down by him.

8.4 All necessary gauges and templates shall be supplied free to the Engineer-in-Charge by the

Contractor whenever asked for during inspection. The Engineer-in- Charge, may at his discretion,

check the test results obtained at the Contractor's works by independent tests at a test house, and the

cost of such tests shall be borne by the Contractor.

9.0 SHOP PAINTING

9.1 All components and members of steel work shall be given one shop coat of primer, as specified in
the tender, immediately after the surfaces have been properly prepared (i.e. degreased, derusted,
descaled & cleaned) in accordance with the job specification, as applicable.

The primer coat shall be applied over completely dry surfaces (using brushes of good quality) in a
manner so as to ensure a continuous and uniform film without "holidaying". Special care shall be
taken to cover all the crevices, corners, edges etc. However, in areas which are difficult to reach by
brushing, daubers/mops shall be used by dipping the same in paint and then pulling/ pushing them
through the narrow spaces. The primer coat shall be air dried and shall have the thickness as per job
specification.

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9.2 Surfaces which are inaccessible after shop assembly, shall receive the full specified protective
treatment before assembly (this shall not apply to the interior of sealed hollow sections).

9.3 Steel surfaces shall not be painted within a suitable distance of any edges to be welded if the paint
specified would be harmful to welders or impair the quality of the welds.

9.4 Welds and adjacent parent metal shall not be painted prior to deslagging, inspection and approval

by the Engineer-in-Charge.

9.5 Parts to be encased in concrete shall have only one coat of primer and shall not be painted after
erection.

10.0 PACKING

All items shall be suitably packed in case these are to be despatched from the fabrication shop to
the actual site of erection so as to protect them from any damage/distortion or falling during transit.
Where necessary, slender projecting parts shall be temporarily braced to avoid warping during
transportation.

Small parts such as gussets, cleats etc., shall be securely wired on to their respective main
members.

10.3 Bolts, nuts washers etc. shall be packed in crates.

11.0 TRANSPORTATION

Loading and transportation shall be done in compliance with transportation rules. In case,
certain parts can not be transported in the lengths stipulated on the drawings, the position details of such
additional splice joints shall be got approved by the Engineer-in- Charge.

12.0 SITE (FIELD) ERECTION

12.1 Plant & Equipment

The suitability and capacity of all plant and equipment used shall be to the complete satisfaction of
the Engineer-in-Charge.

12.2 Storing & Handling

All steel work shall be so stored and handled at site so that the members are not subjected to
surface abrasion, excessive stresses and any damage.

12.3 Setting Out

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 Prior to setting out of the steel work, the Contractor shall get himself satisfied about the correctness of
levels, alignment, location of existing concrete pedestals/columns/brackets and holding down
bolts/pockets provided therein. Any minor modification in the same including chipping, cutting and
making good, adjusting the anchor bolts etc., if necessary, shall be carried out by the Contractor at his
own expense. The positioning and levelling of all steel work including plumbing of columns and placing
of every part of the structure with accuracy shall be in accordance with the drawings and to the complete
satisfaction of the Engineer-in-Charge.

12.4 Tolerances

Tolerances for erection of steel structures shall be as per Annexure 'A' in

13.0 SAFETY & SECURITY DURING ERECTION

13.1 The contractor shall comply with IS:7205 for necessary safety and adhere to safe erection
practices and guard against hazardous as well as unsafe working conditions during all stages of erection.

13.2 During erection, the steel work shall be securely bolted or otherwise fastened and when
necessary, temporarily braced/guyed to provide for all loads to be carried by the structure during erection
till the completion, including those due to the wind, erection equipment & its operation etc. at no extra
cost to the owner. For the purpose of guying, the Contractor shall not use other structure in the vicinity
without prior written permission of the Engineer-in-Charge.

13.3 No permanent bolting or welding shall be done until proper alignment has been achieved.

13.4 Proper access, platform and safety arrangement shall be provided for working and inspection,
(at no extra cost to the owner) whenever required.

14.0 FIELD CONNECTIONS

14.1 Field Bolting

Field bolting shall be carried out with the same care as required for shop bolting.

14.2 Field Welding

All field assembly and welding shall be executed in accordance with the requirements for shop assembly
and welding. Holes for all erection bolts - where removed after final erection shall be plugged by welding.
Alternatively erection bolts may be left and secured.

15.0 GROUTING

15.1 Prior to positioning of structural columns/girders/ trusses over the concrete

pedestals/columns/brackets, all laitance & loose material shall be removed by wire brushing & chipping.
The bearing concrete surfaces shall be sufficiently levelled, hacked with flat chisels to make them rough,

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cleaned (using compressed air) and made thoroughly wet. All pockets for anchor bolts shall also be
similarly cleaned and any excess water removed. Thereafter, the structural member shall be erected,
aligned & plumbed maintaining the base plates/shoe plates at the levels shown in the drawings, with
necessary shims/pack plates/wedges.

15.2 After final alignment and plumbing of the structure, the forms shall be constructed allround and
joints made tight to prevent leakage. Grouting (under the base plates/shoe plates including grouting of
sleeves & pockets) shall be done with non-shrink grout having compressive strength (28 days) not less
than 40N/sq.mm Non shrink grout shall be of free flow premix type and of approved quality and make. It
shall be mixed with water in proportion as specified by the manufacturer. Ordinary 1:2 cement/sand
mortar grout shall be used only for small, isolated structures e.g. operating platforms not supporting any
equipment, pipe supports, crossovers, stairs & ladders. The thickness of grout shall be as shown on the
drawings but not less than 25 mm nor more than 40mm in any case.

15.3 The grout mixture shall be poured continuously (without any interruption till completion) by
grouting pumps from one side of the base plate and spread uniformly with flexible steel strips and
rammed with rods, till the space is filled solidly and the grout mixture carried to the other side of the base
plate.

15.4 The grout mixture shall be allowed to harden for a period as decided by the
Engineer-in-Charge. At the end of this period, the shims/wedges/pack plates may be removed and anchor
bolts tightened uniformly. The alignment of the structure shall now be rechecked and if found correct, the
voids left by the removal of shims/wedges/pack plates (if removed) must be filled up with a similar
mixture of grout. In case after checking, serious misalignment is indicated, the grout shall be removed
completely and fresh grouting done after making appropriate correction of alignment.

16.0 SCHEME AND SEQUENCE OF ERECTION

The Contractor shall furnish the detailed scheme and sequence of erection to match with the project
schedule and get the same approved by the Engineer-in- Charge. All necessary co-ordination and
synchronization shall be done with the Civil contractor where Civil works are not included in the scope of
structural contractor at no extra cost so as to match with the project schedule.

17.0 PAYMENT

This clause shall apply to Item Rate tender only.

17.1 Payment for structural steel works shall be made on the basis of admissible weight in metric
tons (determined as described in clause 17.2 and 17.3) of the structure accepted by the
Engineer-in-Charge. The rate shall include supplying (as per supply conditions given in the Tender)
fabricating, erecting in position (at all levels & locations), testing/examining (excluding radiography
only) of bolted and/or welded structural steel works of all types (including all built up/compound sections
made out of rolled sections and/or plates) including all handling, transporting, storing, straightening if
required, cutting, edge preparation, preheating, bolting and welding of joints (including sealing the joints
of box sections with continuous welding), finishing edges by grinding/machining as shown, fixing in line
& level with temporary staging & bracing and removal of the same after erection, grouting with non-
shrink/ordinary grout as specified, preparation of fabrication & erection drawings, & erection schedule

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and getting them reviewed, preparation and submission of as built drawings, preparing the surfaces for
painting, and applying the primer as specified after fabrication, return of surplus materials to owner's
stores and material reconciliation in the case of materials supplied by the owner as per relevant contract
conditions etc. all complete for all the operations mentioned in the foregoing clauses.

17.2 The weight for payment shall be determined from the fabrication drawings and respective bill
of materials prepared by the Contractor. The bill of materials shall be checked and approved by the
Engineer-in-Charge before making the payment. The Contractor shall prepare full scale template in order
to supplement/verify the actual cutting dimensions where so directed by the Engineer-in-Charge. The
weight shall be calculated on the basis of BIS Hand Book wherever applicable. In case sections used are
different from BIS sections, then Manufacturers' Hand Book shall be adopted. No allowance in weight
shall be made for rolling tolerances.

17.3 Welds, bolts, nuts, washers, shims, pack plates, wedges, grout and shop painting shall not be
separately measured. The quoted rate shall be deemed to include the same.

17.4 The rate shall include all expenses related to safety & security arrangements during erection
and all plants & tools required for fabrication, transportation & erection.

18.0 PAINTING AFTER ERECTION

18.1 General

18.1.1 The scope of painting after erection shall be at the sole discretion of the Engineer-in-Charge
and the Contractor shall obtain written instruction in this regard sufficiently prior to taking up any
procurement of paint and execution of painting work after erection of steel structures.

18.1.2 The Contractor shall carry out the painting work in all respects with the best quality of
approved materials (conforming to relevant clauses of the job specification, as applicable) and
workmanship in accordance with the best engineering practice. The Contractor shall furnish
characteristics of paints (to be used) indicating the suitability for the required service conditions. The
paint manufacturer’s instructions supplemented by Engineer-in-Charge's direction, if any, shall be
followed at all times. Particular attention shall be paid to the following:

- Proper storage to avoid exposure & extremes of temperature.

- surface preparation prior to painting.
- Mixing & thinning.
-Application of paint and the recommended limit on time intervals between consecutive
coats.
18.1.3 Painting shall not be done in frost or foggy weather, or when humidity is such as to cause

condensation on the surfaces to be painted.

18.1.4 Surface which shall be inaccessible after site assembly shall receive the full specified protective
treatment before assembly.

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18.1.5 Primers & finish coat paints shall be from the same manufacturer in order to ensure compatibility.
Painting colour code shall be as per Annexure-'B' or the job specification.

18.2 Rub Down & Primer Application

The shop coated surfaces shall be rubbed down thoroughly with emery/abrasive paper to remove
dust, rust, other foreign matters and degreased, if required, in accordance with painting job
specification, as applicable, cleaned with warm fresh water and air dried. The portions, from where
the shop coat has peeled off, shall be touched up and allowed to dry.

Primer coat as per job specification, as applicable, shall be applied by brushing/ spraying over the
shop coat in a manner so as to ensure a continuous and uniform film throughout. Special care shall
be taken to cover all the crevices, corners, edges etc. The final primer coat shall be air dried and
shall have a minimum film thickness as per job specification after drying, as applicable.

In case a different cleaning procedure & primer specifications are specified in the drawing/Tender,
the same shall be adopted.

18.3 Final Paint Application

After the primer is hard dry, the surfaces shall be dusted off and the paint as per job specific for
painting, as specified, shall be applied by brushing/spraying so that a film free from "holidaying" is
obtained. The colour & shade of first coat of paint shall be slightly lighter than the second coat in
order to identify the application of each coat. The second coat of paint shall be applied after the
first coat is hard dry. The minimum thickness of each film shall be 20 microns (+ 10% tolerance)
after drying.

In case a different type of paint & painting procedure are specified in the drawing/tender, the same
shall be adopted.

18.4 Inspection & Testing of Painting Works

All painting materials including primers & thinners brought to site by the Contractor for application
shall be procured directly from reputed and approved manufacturers and shall be accompanied by
manufacturer's test certificates. Paint formulations without certificates shall not be accepted.

The Engineer-in-Charge at his discretion may call for additional tests for paint formulations. The
Contractor shall arrange to have such tests performance including batch wise test of wet paints for
physical & chemical analysis. All costs shall be borne by the Contractor.
The painting work shall be subject to inspection by the Engineer-in-Charge at all times. In
particular, the stage inspection will be performed and Contractor shall offer the work for inspection
and approval at every stage before proceeding with the next stage. The record of inspection shall be
maintained. Stages of inspection are as follows:

(a) Surface preparation

(b) Primer application
(c) Each coat of paint

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 Any defect noticed during the various stages of inspection shall be rectified by the Contractor to the
entire satisfaction of the Engineer-in-Charge before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work the Contractor shall be responsible
for making good any defects found during final inspection/guarantee period/defect liability period,
as defined in General Conditions of Contract. Dry film thickness (DFT) shall be checked and
recorded after application of each coat. The thickness shall be measured at as many locations as
decided by the Engineer-in-Charge. The Contractor shall provide standard thickness measuring
instrument such as elkometer (with appropriate range for measuring dry film thickness of each
coat) free of cost to the Engineer-in-Charge whenever asked for.

18.5 Payment

Payment for painting of structural steel works shall be made on the basis of admissible weight in
metric tons of the painted structures accepted by the Engineer-in-Charge.

The rate shall include supplying & applying the paint, specified in the tender, of approved quality
and shade over the primer, specified in the tender, over the shop primer already applied to
structural steel works of all types/shapes at all levels, locations & positions including storage,
surface preparation, degreasing, cleaning, drying, touching up of shop primer coat, providing
temporary staging, testing etc. all complete to the entire satisfaction of the Engineer-in-Charge.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 78 OF 221

 ANNEXURE-'A'
(Clause 12.4)

Maximum Permissible Erection Tolerances

A. Columns

1. Deviation of column axes at foundation top level with

respect to true axes.

i) In longitudinal direction ± 5 mm

ii) In lateral direction ± 5 mm

2. Deviation in the level of bearing surface of columns at

foundation top with respect to true level ± 5 mm

3. Out of plumb (Verticality) of column axis from true vertical

axis, as measured at top:

i) Upto and including 30m height ± H/1000 or ± 25 mm

whichever is less.

ii) Over 30m height ± H/1200 or ± 35 mm

whichever is less.

4. Deviation in straightness in longitudinal & transverse planes

of column at any point along the height. ± H/1000 or ± 10 mm
whichever is less.
5. Difference in the erected positions of adjacent pairs of columns
along length or across width of building prior to connecting
trusses/beams with respect to true distance. ± 5 mm

6. Deviation in any bearing or seating level with respect to true ± 5 mm

level.

7. Deviation in difference in bearing levels of a member on

adjacent pair of columns both across & along the building. ± 5 mm

Note: 1. Tolerance specified under 3 should be read in conjunction with 4 & 5.

Note: 2. 'H' is the column height in mm.

B. Trusses

1. Shift at the centre of span of top chord member ± 1/250 of height of

with respect to the vertical plane passing through truss in mm at centre
the centre of bottom chord. of span or ± 15mm
whichever is less.

2. Lateral shift of top chord of truss at the centre of span ± 1/1500 of span of
from the vertical plane passing through the centre of truss in mm or ± 10mm

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 79 OF 221

supports of the truss. Whichever is less.

3. Lateral shift in location of truss from its true position. ± 10mm

4. Lateral shift in location of purlin from true position. ± 5mm

5. Deviation in difference of bearing levels of truss from ± 1/1200 of span of

the true level. truss in mm or 20mm whichever is less.

C. Gantry Girders & Rails

1. Shift in the centre line of crane rail with respect ± [{web thickness (mm)}+2
mm]
to centre line of web of gantry girder. 2

2. Shift of alignment of crane rail (in plan) with respect

to true axis of crane rail at any point. ± 5 mm

3. Deviation in crane track gauge with respect to true

gauge.

i) For track gauge upto and including 15 m. ± 5 mm.

ii) For track gauge more than 15m. ± [ 5 + 0.25 (S-15)]

Subject to maximum + 10mm, where S in metres is true gauge.

4. Deviation in the crane rail level at any point from

true level. ± 10 mm.

5. Difference in level between crane track rails

(across the bay) at

i) Supports of gantry girders 15 mm.

ii) Mid span of gantry girders 20 mm.

6. Relative shift of crane rail surfaces (at a joining) in

plan and elevation. 2 mm.

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 ANNEXURE-'B'
(Clause 18.1)

PAINTING COLOUR CODE FOR STRUCTURAL STEEL*

1. GANTRY GIRDER & MONORAIL DARK GREEN

2. GANTRY GIRDER & MONORAIL STOPPER SIGNAL RED

3. BUILDING STRUCTURAL STEEL COLUMNS, DARK ADMIRALITY

BRACKETS, BEAMS, BRACINGS, ROOF TRUSS, GREY
PURLINS, SIDEGIRTS, LOUVERS, STRINGERS

4. PIPE RACK STRUCTURE & TRESTLE DARK ADMIRALITY

GREY

5. CHEQUERED PLATE (BOTH FACES) BLACK

6. GRATING BLACK

7. LADDER RUNGS BLACK

VERTICALS & CAGE RED
8. HAND RAILING

- HANDRAIL, MIDDLE SIGNAL RED

RAIL, TOE PLATE

- VERTICAL POST BLACK

• ABOVE IS INDICATIVE ONLY. SHALL BE CONFIRMED DURING EXECUTION

IN CONSULTATION WITH CLIENT /ENGINERING IN CHARGE.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 81 OF 221

SPECIFICATION-6: CIVIL & STRUCTURAL WORKS - STRUCTURAL STEEL WORKS
(TUBULAR/ HOLLOW SECTIONS)
Relevant SOR item no: S024 to S025

1.0 SCOPE

This specification covers the requirements for design (Refer Annexure 'A'), material,
fabrication, assembly, tests/examinations, transportation, erection and painting preparation of
fabrication drawings of bolted and/or welded structural steel works using tubular/hollow
sections for general construction work.

2.0 REFERENCES

2.1 BIS Codes

IS:800, IS:806, IS:816, Is:1161, IS:4923, IS:7205, IS:7215, IS:9595 & other relevant Codes.

2.2 Job Specifications

SPECIFICATION : CIVIL & STRUCTURAL WORKS - MATERIALS

SPECIFICATION : CIVIL & STRUCTURAL WORKS - STRUCTURAL STEEL WORKS.
SPECIFICATION FOR SURFACE PREPARATION AND PROTECTIVE COATING

2.3 In case of conflict between the clauses mentioned in this specification and those in the Indian
Standards, this specification shall govern. Any special provision as shown or noted on the
design drawings shall govern over the provisions of this specification.

3.0 MATERIAL

As per specification: CIVIL & STRUCTURAL WORKS-STRUCTURAL STEEL WORKS.

4.0 FABRICATION DRAWINGS

As per specification: CIVIL & STRUCTURAL WORKS-STRUCTURAL STEEL WORKS.

5.0 FABRICATION

As per specification: CIVIL & STRUCTURAL WORKS-STRUCTURAL STEEL WORKS.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 82 OF 221

6.0 MARKING FOR IDENTIFICATION

As per specification: CIVIL & STRUCTURAL WORKS-STRUCTURAL STEEL WORKS.

Each component shall be distinctly marked before delivery, in accordance with the marking
diagram and shall bear such other marks as will facilitate erection.

7.0 SHOP ERECTION

As per specification: CIVIL & STRUCTURAL WORKS-STRUCTURAL STEEL WORKS.

The steel work shall be temporarily shop erected complete or as directed so that accuracy of fit
may be checked before dispatch.

8.0 INSPECTION AND TESTING

As per specification: CIVIL & STRUCTURAL WORKS-STRUCTURAL STEEL WORKS.

9.0 SHOP PAINTING, PACKING AND TRANSPORTATION

As per specification: CIVIL & STRUCTURAL WORKS-STRUCTURAL STEEL WORKS.

10.0 SITE (FIELD) ERECTION

Similar to same clauses in specification: CIVIL & STRUCTURAL WORKS-STRUCTURAL

STEEL WORKS.

11.0 SAFETY AND SECURITY DURING ERECTION

Similar to same clauses in specification: CIVIL & STRUCTURAL WORKS-STRUCTURAL

STEEL WORKS.

12.0 FIELD CONNECTIONS

Similar to same clauses in specification: CIVIL & STRUCTURAL WORKS-STRUCTURAL

STEEL WORKS.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 83 OF 221

13.0 GROUTING

Similar to same clauses in specification: CIVIL & STRUCTURAL WORKS-STRUCTURAL

STEEL WORKS.

14.0 SCHEME AND SEQUENCE OF ERECTION

The Contractor shall furnish the detailed scheme and sequence of erection to match with the
project schedule and get the same approved by the Engineer-in-Charge. All necessary
co-ordination and synchronization shall be done with the civil contractor where civil works are
not included in the scope of structural contractor at no extra cost so as to match with the project
schedule.

15.0 PAINTING AFTER ERECTION

Painting of Structural Steel Works using (tubular/hollow sections) shall be done in accordance
with relevant clauses of PAINTING SPECIFICATION.

16.0 PAYMENT

(Where design and design drawings are excluded from the scope of the Contractor)

16.1 Payment for structural steel works fabricated and made out of tubular/ hollow sections shall be
made on the basis of admissible weight in metric tons (determined as described in clause 16.2
to 16.3) of the structure accepted by the Engineer-in-Charge.

The rate shall include supplying (as per supply conditions given in the tender), fabricating,
erecting in position (at all levels and locations), transporting, storing, testing/examining of
bolted and/or welded structural steel works using (tubular/hollow sections) of all types of
trusses, girders, purlins, side rails, columns, runners, beams, ties, portals, framework, bracings,
brackets, sagrods etc., including all handling, straightening/bending, if required, cutting, edge
preparation, welding and/or bolting of joints, providing temporary bracing, providing and fixing
end caps, fixing in line and level with necessary temporary staging, grouting with premix, free
flow, non-shrink grout as shown on drawings including preparation of detailed fabrication
drawings and getting them reviewed, preparing the exposed surface for painting, surface
cleaning, wire brushing, removal of mill scale, rust, oil or grease and applying the primer as
specified after fabrication, return the surplus materials to the owner’s stores and material
reconciliation in the case of materials supplied by Owner as per relevant contract conditions
etc. all complete for all the operations mentioned in the foregoing clauses.

16.2 The weight for payment shall be determined from the fabrication drawings and respective bill
of materials prepared by the Contractor. The bill of materials shall be checked and approved by
the Engineer-in-Charge before making the payment. The weight shall be calculated on the basis
of BIS Handbook wherever applicable. In case sections used are different from BIS sections,
then Manufacturer's Handbook shall be adopted. No allowance in weight shall be made for
rolling tolerances.

16.3 Welds, bolts, nuts, washers, shims, packplates and grout shall not be measured. The quoted rate
shall be deemed to include the same.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 84 OF 221

17.0 PAYMENT

(Where design and design drawings are also included in the scope of the Contractor).

17.1 All design and design drawings shall be prepared strictly in accordance with DESIGN
SPECIFICATIONS attached with this specification as Annexure -‘A’.

17.2 Payment for structural steel works fabricated and made out of tubular/hollow sections shall be
made on the basis of admissible weight in metric tons (determined as described in clause 17.3
to 17.4) of the structure accepted by the Engineer-in-Charge.

The rate shall include supplying, fabricating, erecting in position (at all levels and locations),
transporting, storing, testing/examining of bolted and/or welded structural steel works using
(tubular/hollow sections) of all types of trusses, girders, purlins, side rails, columns, runners,
beams, ties, portals, framework, bracings, brackets, sagrods etc., including all handling
straightening/bending if required, cutting, edge preparation, welding and/or bolting of joints,
providing temporary bracing, providing and fixing end caps, fixing in line and level with
necessary temporary staging, grouting with premix, free flow, non-shrink grout as shown on
drawings including preparation of detailed fabrication drawings and getting them reviewed,
preparing the exposed surface for painting, surface cleaning, wire brushing, removal of mill
scale, rust, oil or grease and applying the primer as specified after fabrication, return the surplus
materials to the owner’s stores and material reconciliation in the case of materials supplied by
Owner as per relevant contract conditions etc. all complete for all the operations mentioned in
the foregoing clauses.

17.3 The weight for payment shall be determined from the fabrication drawings and respective bill
of materials prepared by the Contractor. The bill of materials shall be checked and approved by
the Engineer-in-Charge before making the payment. The weight shall be calculated on the basis
of BIS Handbook wherever applicable. In case sections used are different from BIS sections,
then Manufacturer's Handbook shall be adopted. No allowance in weight shall be made for
rolling tolerances.

17.4 Welds, bolts, nuts, washers, shims, pack plates and grout shall not be measured. The quoted
rate shall be deemed to include the same.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 85 OF 221

SPECIFICATION-7: CIVIL & STRUCTURAL WORKS - MISCELLANEOUS STEEL WORKS
Relevant SOR item no: S026 to S033

1.0 GENERAL

All materials supplied by the Contractor shall conform to specifications given in specification:
CIVIL & STRUCTURAL WORKS - MATERIALS.
The Contractor shall furnish test certificates for all materials prior to their use in the works.
Structural steel materials not supported by mill test certificates may be used after confirming
their quality by carrying out appropriate tests in accordance with the method specified in
IS:1608.

Other requirements not covered under this specification shall be in accordance with
specification: CIVIL & STRUCTURAL WORKS-STRUCTURAL STEEL WORKS.
.

2.0 REFERENCES
As mentioned in the respective clauses.

3.0 MATERIAL
As mentioned in the respective clauses.

4.0 ANCHOR BOLTS

4.1 Material

Materials for anchor bolts, nuts, locknuts, washers, pipe sleeves and anchor plates shall
conform to their respective clauses given in Job Specification for material.

4.2 Fabrication

Fabrication of anchor bolts and their complete assemblies shall be strictly in compliance with
the specifications and drawings/standards.

4.3 Placement

Anchor bolt assemblies shall be placed in position strictly as per drawings and securely held
during pouring and vibrating of concrete with necessary templates and other dummy structures
to prevent their dislocation.

4.4 Tolerances

Tolerances allowed for anchor bolts positioning shall be as below:

- For sleeved bolts, one tenth of the bolt nominal diameter.
- For bolts without sleeves, one twentieth of the bolt nominal diameter.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 86 OF 221

4.5 Protection

The exposed surfaces of bolts shall be properly covered (after greasing of bolts and packing of
sleeves) with jute cloth so as to protect them from damage till final erection of
structure/equipment is over.

4.6 Payment
4.6.1 Payment shall be made on the basis of actual weight in metric tons of the anchor bolt/anchor
bolt assembly. The rate shall include supply (as per scope of supply conditions given in the
tender) of all materials, handling, transporting, fabrication, turning from available size to
required diameter, threading, welding, fixing in position at all levels and locations, providing
necessary templates, greasing, packing of sleeves, covering with jute cloth and other protective
measures etc. all complete.
4.6.2 The rate shall cover bolt of any diameter and nomenclature.
4.6.3 Payment for fixing anchor bolt assembly (already fabricated and supplied by the Owner as free
issue) in position shall be made on the basis of actual weight of anchor bolts/bolt assemblies in
metric tons. The rate shall include handling, transporting, fixing in position at all levels and
locations, welding if required, providing necessary templates, greasing, packing of sleeves,
covering with jute cloth and other protective measures etc. all complete.
4.6.4 No separate payment shall be made for templates, dummy structures, supports etc. and the rate
quoted shall be inclusive of all cost related to such provision required for correct and accurate
installation of anchor bolts/anchor bolt assembly.

5.0 METAL INSERTS

5.1 Material

Materials required for fabricating metal inserts shall conform to their respective specification
given in SPECIFICATION: CIVIL & STRUCTURAL WORKS - MATERIALS.

5.2 Fabrication
Fabrication of inserts shall be done strictly as per drawings/standards and in compliance with
the requirements given in SPECIFICATION: CIVIL & STRUCTURAL WORKS - STRUCTURAL STEEL
WORKS. .

5.3 Placement
Metal inserts shall be correctly embedded (in plain concrete/reinforced concrete) as per their
location shown on the drawings. Care shall be taken that these are securely held in position and
do not get disturbed during concreting. Where necessary, these may be welded to the
reinforcement bars. Suitable templates, spacers, dummy structures and temporary staging shall
be provided. Necessary cutting in the formwork and adjustment of reinforcement bars shall be
done for the placement of metal inserts where required.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 87 OF 221

5.4 Painting
The exposed surfaces of metal inserts shall be cleaned and given one coat of primer as per job
specification for painting, after fabrication.

5.5 Payment
Payment shall be made on the basis of actual weight in metric tons of the metal inserts. The rate
shall include supply (as per supply conditions given in the tender) of all materials, handling,
transporting, fabrication, welding, fixing in position at all levels and locations, providing
necessary templates, spacers, dummy structures, adjusting the formwork and reinforcement,
staging, preparation of surface for painting, applying one coat of primer as per job specification
for painting, etc. all complete.

6.0 CHEQUERED PLATES

6.1 Material
Material required for chequered plates shall conform to the specifications given in
SPECIFICATION: CIVIL & STRUCTURAL WORKS - MATERIALSChequering shall be
closed or open-ended or of any other pattern as shown on drawings.
6.2 Fabrication Drawings
As per the requirements given in SPECIFICATION: CIVIL & STRUCTURAL WORKS -
STRUCTURAL STEEL WORKS.

6.3 Fabrication
Chequered plates shall be fabricated as per the "Approved for Construction" fabrication
drawings (prepared by the Contractor based on design drawings). These shall be perfectly flat
and without any dents/deformations and shall be cut to the required size and shape.
Holes/notches/openings of the required size, if any, shown on drawings shall be made. Nosing
for staircase treads shall be made by cold bending of chequered plates. All edges shall be made
smooth and even. All chequered plate units shall be given distinct erection marks in accordance
with the marking drawings. Stiffeners of any description shall be welded with the chequered
plates where shown on drawings.

6.4 Erection/Fixing
Chequered plates shall be fixed to the bearing members by welding/ bolting/ screwing as shown
on drawings. All bolts/screws shall be of counter-sunk type so that the heads remain flush with
the top of plate. Where welding is used for fixing, stitch welds of minimum 50mm length with
a pitch of 150mm shall be used. Continuous sealing run of weld shall be provided along the
junction of two consecutive chequered plates parallel to the span. For removeable flooring,
details as shown on drawings shall be followed.

6.5 Painting
Chequered plates shall be cleaned (both the surfaces) and given one coat of primer/
galvanization as painting jobspecification, as specified, on both surfaces.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 88 OF 221

6.6 Payment
6.6.1 Payment shall be made on the basis of actual weight in metric tons of the chequered plate. If
any stiffening sections are provided below the chequered plates for strengthening, the same
shall be separately measured & paid under Structural Steel item.

6.6.2 The rate shall include supplying (as per supply conditions given in the tender), fabricating,
erecting M.S. chequered plates including transporting, handling, straightening if required,
cutting to required size and shape, making holes/notches/opening of required size and nosing,
smoothening the edges, fixing by welding/bolting/screwing, at all levels and locations,
preparing detailed fabrication drawings, surface cleaning, removal of rust, scale, grease and
applying one coat of primer/ galvanization as per painting job specification , etc. all complete.
6.6.3 Welds, bolts, nuts, screws, washers, clips shall not be measured. The quoted rate shall be
deemed to include the same.

7.0 GRATINGS
7.1 Categories
The electroforged galvanized gratings shall be either Type-I or Type-II as per JOB specific
Standard and shall be procured from approved manufacturers as per Vendor List.

7.2 Material
Materials for fabrication and fixing of Gratings shall conform to relevant clauses of this job
specifications.
7.3 Fabrication Drawings

As per the requirements given in specification: CIVIL & STRUCTURAL WORKS -

STRUCTURAL STEEL WORKS. .

7.4 Fabrication

The gratings shall be manufactured by electro forging process strictly as per the "Approved for
Construction" fabrication drawings prepared by the Contractor based on standard drawing
supplied to the contractor. All units shall be given distinct erection marks in accordance with
the marking drawing. The Contractor shall submit sample gratings for inspection and approval
by the Engineer-in-Charge whenever asked for.

7.5 Erection/Fixing

Gratings shall be fixed to the bearing members by welding/clamping and bolting as indicated in
the Standard.

7.6 Galvanisation

Gratings and the fixing clamps, bolts, nuts shall be cleaned as per job specification, as specified
and galvanisation shall be done as specified in accordance with IS:2629 and tested as per
IS:2633 & IS:6745.

7.7 Payment

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 89 OF 221

7.7.1 Payment shall be made on the basis of actual weight in metric tons of the gratings manufactured
in accordance with Standard drawing and accepted by the Engineer- in-Charge.

The weight for payment shall also include the weight of galvanization and welding.

7.7.2 The rate shall include supplying, fabricating, erecting electroforged galvanized gratings (of the
specified category) including transporting, handling, cutting to required size and shape, making
holes/notches/openings, smoothening the edges, fabricating clamps, fixing by
welding/clamping/ bolting, at all levels and locations, preparing detailed fabrication drawings,
surface cleaning, removal of rust, scale, grease and carrying out galvanization, all complete.

7.7.3 Bolts, clamps, nuts and washers shall not be measured. The quoted rate shall be deemed to
include the same.

8.0 TUBULAR HAND RAILING

8.1 Material

Materials for fabrication and fixing of Tubular Hand Railing shall confirm to clauses relevant to
SPECIFICATION : CIVIL & STRUCTURAL WORKS – MATERIALS.

8.2 Fabrication Drawings

As per the requirements given in SPECIFICATION : CIVIL & STRUCTURAL WORKS -

STRUCTURAL STEEL WORKS..

8.3 Fabrication

8.3.1 Hand railing shall be fabricated strictly as per the "Approved for Construction" fabrication
drawings prepared by the Contractor based on design drawings and standards. All tubes shall be
straight and without any dents/deformations. Tubes shall be cut and ends shall be prepared to a
neat and workman-like finish. All elements shall be directly welded. All welded joints shall be
cleaned and filed or ground smooth, if required, to have a smooth surface and aesthetically
pleasant appearance. Splicing of top rail shall not be allowed. Tubes shall be cold bent to shape
and curvature in case of discontinuous ends of handrails. Ripples, kinks and/or dents at bends
shall not be accepted.
8.3.2 Lower ends of vertical posts shall be cut and splayed (for grouting in pockets in the concrete
members). For removable type of handrailing, suitable base plates (with provision for bolting)
shall be welded to the lower end of vertical posts. All units shall be given distinct erection
marks in accordance with the marking drawing.

8.4 Erection/Fixing
Hand railing, shall be fixed to the bearing members by welding/ bolting/ grouting as indicated
on the drawings. Local notching shall be made in the floor plate/ grating to accommodate
vertical posts/their base plates which shall always be welded to the main supporting member.
When the posts are to be fixed in concrete members, suitable pockets shall be made in concrete
for grouting as shown on drawings/standards.

8.5 Painting

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 90 OF 221

 All hand railing components shall be cleaned and given one coat of primer/ galvanization as per
job specification for painting.

8.6 Payment

8.6.1 Payment shall be made on the basis of measured length in meters (m) of top rail only
(Horizontal and/or inclined lengths). The rate shall include preparation of fabrication drawings,
supply of all materials, handling, transporting, straightening if required, cutting to required size,
bending, welding, bolting, fixing in position at all levels and locations, grouting with 1:2
(cement: sand) mortar, surface cleaning, removal of rust, scale, grease and applying one coat of
primer/ galvanization as per painting job specification, as specified, after fabrication etc. all
complete.
8.6.2 The rate shall include making suitable notches in floor plates/gratings and pockets in concrete
structures for fixing the vertical posts.

9.0 MILD STEEL RUNGS

9.1 Material
All materials shall conform to specifications given in relevant jobspecification.

9.2 Fabrication
Rungs shall be fabricated as per standardsdrawings. Mild steel bars shall be straightened if
required, cut, bent to shape and given one coat of primer and two coat of finish paints per job
specification as specified, on exposed portions after fabrication.

9.3 Fixing
Rungs shall be fixed in position as per detailed drawing and firmly tied/welded with
reinforcement to prevent their displacement during vibration of concrete.

9.4 Payment
Payment shall be made on the basis of actual weight in kilogram (Kg) of the M.S. rungs. The
rate shall include supply of all materials, handling, transporting, straightening if required,
cutting to required size, bending to shape, tying/welding with reinforcement bars, fixing at all
levels and locations, adjustment of formwork, applying one coat of primer and two coats of
finish paint as per painting job specification, on the exposed portion of rungs etc. all complete.

10.0 LIGHT GAUGE STEEL STRUCTURAL SECTIONS

10.1 Material

All materials required for fabrication and fixing in position of Light Gauge Steel Structural
Sections shall conform to specification: CIVIL & STRUCTURAL WORKS - MATERIALS. Parent
material which used to rolled light gauge section to be prepared must be hot dip galvanized or
Protected by coating system as per protection scheme-1/protection scheme- 2 of IS: 4180.

10.2 Fabrication Drawings

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 91 OF 221

 As per the requirements given in specification: CIVIL & STRUCTURAL WORKS -
STRUCTURAL STEEL WORKS.

10.3 Fabrication

10.3.1 Fabrication of members shall be done strictly as per the "Approved for Construction"
fabrication drawings prepared by the Contractor based on the latest design drawings and in
accordance with IS:800, IS:801 and other relevant BIS Codes.

10.3.2 All members shall be straight and free from any dents/deformations/ twists. Members shall be
cut to the required sizes and ends prepared to a neat and workman like finish. Holes (for sag
rods and cleat bolts) of appropriate size shall be drilled and all members/ components shall be
given distinct erection marks in accordance with the marking drawings. Holes shall not be
formed by gas cutting process.

10.4 Erection

Structural members shall be erected in proper sequence and aligned properly without causing
any twist. Permanent bolting/welding shall be done only after proper alignment has been
achieved. Proper access, working platforms and safety arrangements shall be provided by the
Contractor for working and inspection.
10.5 Painting

All structural components shall be cleaned and given one coat of primer as per painting job
specification, after fabrication.

10.6 Payment

Payment shall be made on the basis of admissible weight in metric tons of the structure accepted by
the Engineer-in-Charge. The weight for payment shall include all structural members, cleats,
splices, gussets and sag rods and shall be determined from the fabrication drawings along with
respective bill of materials prepared by the Contractor. The bill of materials shall be checked
and approved by the Engineer-in-Charge before making the payment. The weight shall be
calculated as per IS:808/IS:1161. BIS Handbook/ Manufacturer's catalogues/ charts shall be
adopted in case relevant weights of sections used are not covered in IS:808/IS:1161. No
allowance in weight shall be made for rolling tolerances.In case of any doubt, actual weight of
the section shall be measured at site.

The rate shall include supplying, fabricating, erecting, at all levels and locations, testing of
bolted and/or welded Light Gauge structural steel works including cleats, crook bolts,
splices/sleeves, all other fixtures and accessories, straightening if required, cutting, edge
preparation, welding and bolting of joints, fixing in line and level with temporary staging and
removal of the same after final alignment, handling, transporting, storage, preparation of
detailed fabrication drawings and getting them reviewed by the Engineer-in-Charge, surface
cleaning, removal of scale, rust, oil or grease and applying one coat of primer as per painting
Specification etc., all complete.

All welds, bolts, nuts, washers, fixtures and accessories shall not be measured. The quoted rate shall
be deemed to include the same.

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11.0 EXPANSION FASTENERS

Material

Expansion fasteners (medium and heavy duty) shall be of mild steel/high tensile steel with rust
proof coating.

Classification

The expansion fasteners shall be designated as medium and heavy duty depending on their
usage. The broad classification is given below for general guidance.

Medium Duty (Mild steel/ High tensile steel)

- Ladders and stairs supports.

- Cables and cable trays supports.

- Electrical panels and fixtures.

- Hangers for pipes and cable trays.

- Pipe supports.

Heavy Duty (Mild steel/High tensile steel).

- Platform supports (beam and columns)

- Knee brackets for pipes/multi tiers cable trays/walkways etc.

Note:- Expansion fasteners shall not be used for

1. Members supporting equipment and pipes subjected to vibrations.

• Cantilever connections designed to cater for effective cantilever spans greater than
1000mm and 1000Kg of concentrated load at the free end.

11.3 Selection

The Contractor shall procure the expansion fasteners from the approved manufacturers as per
Vendor List.

11.4 Testing

If so desired by the Engineer-in-Charge, the Contractor shall carry out all the requisite tests
(pullout test, torque test etc.) of specimen expansion fasteners (representative of those to be
used) from approved laboratory/ test house and submit the report to him for approval. The
decision of the Engineer-in-Charge regarding the adequacy of strength and load carrying
capacity of the expansion fastener shall be final and binding to all. The cost of all such tests
shall be borne by the Contractor.

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11.5 Installation

The Contractor shall install the expansion fasteners at their correct location (to suit the
requirement of fixtures as shown in drawings) as per the procedure laid down by the
manufacturer. Location of all holes shall be pre-marked on the concrete surfaces and then holes
drilled carefully with an electric drill to the correct recommended size and depth. Holes shall be
exactly round and true perpendicular to the concrete surface. Edge distance and pitch of
fasteners shall be as recommended by the manufacturer. The contractor shall suitably shift the
hole with the approval of the Engineer-in-Charge in case any reinforcement bar is met with
while drilling the hole in RCC structure. Necessary staging shall be provided for working and
the Contractor shall take requisite safety precautions so as not to cause any damage to the
existing structure/ equipment. Any damage done while executing the job shall be made good by
the Contractor at his cost.

11.6 Protection
The exposed surfaces of expansion fasteners shall be properly greased & covered with jute
cloth so as to protect them from damage.

11.7 Payment
Payment for installing rust proof expansion fasteners shall be made on number basis (each).
The rate shall include supply of complete assembly, handling, transporting, providing necessary
temporary staging, installing (as per manufacturer's specifications) in PCC/RCC structures, at
all levels and locations, testing, drilling, cleaning, covering with jute cloth, relocating and re-
drilling in case of any obstruction, making good any damage done to the structure, grouting the
abandoned holes and any gap left between the contact surfaces of PCC/RCC and fixtures to be
added, etc. all complete.

12.0 CHEMICAL ANCHORS AND DOWELS

Material
Chemical Anchors shall be of high tensile steel rods of minimum grade 5.8 galvanised to atleast
5 microns.

Grade of Rebars for chemical anchoring shall be as per the General Notes of the project.

Selection

The Contractor shall select the chemical anchors based on the parameters such as Loads and
rebars for dowels as specified in the AFC drawings/ documents. The chemical anchors shall be
procured from the approved manufacturers as per Vendor List.

Testing

The Contractor shall carry out, at the work place, the requisite tests like pull out test, shear test,
etc. for chemical anchors and pull out test for dowels. The chemical anchors shall withstand the
load specified in the drawing/ documents and the Dowels shall be tested for full tensile capacity
of the rebars. The decision of the Engineer-in-Charge regarding the adequacy of strength and
load carrying capacity of the anchors/ dowels shall be final and binding to all. The cost of all
such tests shall be borne by the Contractor.

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 Installation

The Contractor shall install the chemical anchors/ dowels at their correct location (to suit the
requirement of fixtures as shown in drawings) as per the procedure laid down by the
manufacturer. Location of all holes shall be pre-marked on the concrete surfaces and then holes
drilled carefully with an electric drill to the correct recommended size and depth. Holes shall be
exactly round and true perpendicular to the concrete surface. Edge distance and pitch of
fasteners shall be as recommended by the manufacturer. The contractor shall suitably shift the
hole with the approval of the Engineer-in-Charge in case any reinforcement bar is met with
while drilling the hole in RCC structure. Necessary staging shall be provided for working and
the Contractor shall take requisite safety precautions so as not to cause any damage to the
existing structure/ equipment. Any damage done while executing the job shall be made good by
the Contractor at his cost.

Payment

Payment for installing chemical anchors shall be made on number basis (each). The rate shall
include supply of complete assembly i.e. chemical anchors along with chemical foils as per
manufacturer specifications.

Payment for installing chemical dowels shall be made on number basis (each). The rate shall
include fixing of dowels by drilling/cleaning hole and injecting odourless chemical as per
manufacturer specifications. Rebars used as dowels shall be paid separately under relevant SOR
item.

For chemical anchors/ dowels, the rate shall be inclusive of handling, transporting, providing
necessary temporary staging, installing (as per manufacturer's specifications) in PCC/RCC
structures to a required depth with a specified hole diameter, at all levels and locations, testing,
drilling holes, cleaning, covering with jute cloth, relocating and re-drilling in case of any
obstruction, making good any damage done to the structure, grouting the abandoned holes and
any gap left between the contact surfaces of PCC/RCC and fixtures to be added, etc. all
complete.

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 SPECIFICATION-8 : CIVIL & STRUCTURAL WORKS - MISCELLANEOUS ITEMS.

RELEVANT SOR ITEM NO : S034 & S035

1.0 SCOPE

The scope shall be as specified separately for different items below.

2.0 REFERENCES

2.1 BIS Codes

S.No. IS No. Title

1. IS:73 Paving bitumen - specification
2. IS:383 Specification for coarse and fine aggregates from natural sources
for Concrete
3. IS:6313 Code of practice for Anti-termite measures in buildings

2.2 Job specifications

Specification: CIVIL & STRUCTURAL WORKS - MATERIALS.

SPECIFICATION: CIVIL & STRUCTURAL WORKS - PLAIN & REINFORCED CEMENT
CONCRETE

3.0 MATERIALS

The materials shall be as specified separately for different items below.

4.0 GENERAL REQUIREMENTS

The Contractor shall test the materials, wherever applicable, in approved laboratory as required
by the Engineer-in-Charge and furnish test certificates for materials and obtain the approval of
the Engineer-in-Charge prior to the use of such materials in the works. All tests shall be in
accordance with relevant Indian Standards.

5.0 PRE-CONSTRUCTIONAL ANTI-TERMITE TREATMENT

Scope

This specification establishes the materials and method of accomplishing pre-constructional

anti-termite treatment of soil for protection of buildings against attack by subterranean termites
with the usage of chemical emulsions in accordance with the procedure laid down.

Materials

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 96 OF 221

 Refer relevant clauses of jobspecification CIVIL& STRUCTURAL WORKS - MATERIALS.

Procedure for Treatment

The treatment shall be carried out by an approved agency specialized in the field. Apart from
this specification, the work shall be carried out in compliance with IS:6313. In case of any
contradiction, this specification shall govern.

Site Preparation

Prior to start of Anti Termite treatment, area(s) shall be made free from logs, stumps, timber
offcuts, leveling pegs, roots of plants/ trees etc. Soil treatment shall start when foundation
trenches/ pits are ready to take concrete/ masonry in foundations and plinth area ready for
laying the subgrade. Treatment shall not be carried out when it is raining or the subsoil water
level is at the same or higher than the level of treatment. In the event of water-logging of
foundations, the water shall be pumped out and the chemical emulsion applied when the soil is
absorbent.

Treatment of the excavated pits/ trenches and backfill for Foundations

a) The bottom surface and the lower 300 mm side surfaces of the excavated pits/ trenches for
foundations of masonry works and RCC plinth beams supporting such masonry works,
shall be treated with specified chemical emulsion @ 5 litres/m2 of the surface area.
However, no such treatment shall be required in case of pits/ trenches made for RCC
foundations supporting RCC walls and/ or columns.

b) On completion of construction of masonry foundations, the backfill in immediate contact

with the substructure shall be treated in layers, of 300 mm, with emulsion @ 7.5 litres/m2 of
the vertical surface of the substructure (i.e. 7.5 x 0.3 = 2.25 litres/meter of perimeter) for
each side. The treatment shall be given after ramming of each layer of soil, by rodding the
earth at 150 mm centres close to the wall surface and working the rod backward and
forward (parallel to the wall surface) and then spraying the specified dosage of emulsion.
The emulsion shall be directed towards the masonry surfaces so that the soil in contact with
these surfaces is well treated with the chemical. After the treatment, the soil shall be
tamped back into place. This shall be done for full depth of the fill.

c) For RCC walls and columns, the treatment as specified in (b) shall start from a depth 500
mm below the finished ground level, and shall be done upto the FGL.

Treatment of Plinth/ Basement and Apron

a) The top surface of the consolidated earth below the non-suspended floor slabs and the
peripheral aprons of widths upto 750 mm, the bottom surface and side surfaces of the
excavated pits for the basements shall be treated with chemical emulsion @ 5 litres/m2 of
the surface area. Holes 50 mm to 75 mm deep at 150 mm centre, both ways, shall be made
on the surface with 12 mm diameter mild steel rod and then emulsion shall be sprayed
uniformly over the area. At expansion joint locations, anti-termite treatment shall be
supplemented by treating through the expansion joint @ 2.0 litres per linear metre of joint
after the sub-grade has been laid.

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 b) Treatment of Junctions of plinth filling and wall/column faces shall be done after making a
small channel 30 mm x 30 mm, by making rod holes 150 mm apart (upto the ground level)
in the channel and then by moving the rod backward and forward to break up the earth. The
chemical emulsion shall be poured along the channel @ 7.5 litres/m2 of the vertical
wall/column surface so as to soak the soil right to the bottom. The soil shall be tamped back
into place after the treatment.

5.3.5 Treatment of Soil along External Perimeter of Building

After the building is complete, the earth along the external perimeter shall be rodded at
intervals of 150 mm and to depth of 300 mm. The rod shall be moved backward and forward
parallel to the wall to break up the earth and chemical emulsion poured along the wall @ 7.5
litres/m2 of vertical surface (i.e. 7.5 x 0.3 = 2.25 litres/metre of perimeter). After the treatment,
the earth shall be tamped back into place.

5.4 Payment

This clause shall apply to Item Rate tender only.

Payment for pre-constructional anti-termite treatment shall be made on square metre (sq.m.)
basis of plinth area of the building at ground floor only.

The rate shall include supplying all materials, spray pumps, tools, tackles & other accessories,
labour, site preparation, rodding, tamping, mixing, spraying the specified chemical emulsion at
prescribed dosage, storage facilities, handling, transporting etc. all complete as directed &
specified.

7.0 DRESSING & TRIMMING

7.1 Scope

This specification covers the procedure for dressing, trimming and paving with earth the
peripheral area around the completed building/ structure.

7.2 Procedure

The ground all around the completed building/structure for 3 metres width or as specified by
the Engineer-in-Charge, shall be cleaned and dressed to suitable slope. Over the prepared
ground a layer of approved earth shall be spread, watered and well consolidated so as to
achieve an average thickness of 75 mm.

7.3 Payment

This clause shall apply to Item Rate tender only.

Payment shall be made on square metre (sq.m.) basis of the actual area dressed and paved with
earth.

The rate shall include supplying all materials, labour including cleaning, dressing the ground to
required slope, spreading of earth, watering, ramming, consolidating etc. all complete as
directed.

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 8.0 DAMP PROOF COURSE - (DPC)

All materials used for Damp Proof Course shall comply with job specification : CIVIL &
STRUCTURAL WORKS - MATERIALS.
.
The 40 mm thick Damp Proof Course shall consist of plain cement concrete of the same grade
as used for RCC work.

The Damp Proof Course shall be laid at plinth level of masonry walls, flush with the floor
surface and shall not be carried across doorways.

Before laying, the top surface of wall shall be thoroughly cleaned and watered. The DPC shall
be laid in layers of 20 mm thickness retaining the edges by necessary formwork and shall be
well tamped and troweled to smooth finish. The layer shall be cured by keeping the surface wet
for 40 hours and after it has dried, two coats of hot bitumen of grade VG10 conforming to IS:73
shall be applied over it at the rate of 1.7 kg/m2. Over this, the second layer of 20 mm thick
concrete shall be laid and cured as described in case of the first layer and two coats of hot
bitumen at the rate of 1.7 kg/m2 shall be applied again in a similar manner. Over this, dry sharp
sand shall be sprinkled evenly before hardening of second coat of bitumen paint.

Payment

This clause shall apply to Item Rate tender only.

Payment shall be made on square metre (sq.m.) basis of the area laid. The rate shall be inclusive
of formwork, curing, providing and laying bitumen, supplying and spreading sand over bitumen
etc. complete.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 99 OF 221

 SPECIFICATION-9: CIVIL & STRUCTURAL WORKS - WATER-PROOFING OF
UNDERGROUND CONCRETE STRUCTURES

RELEVANT SOR ITEM NO : S035

1.0 SCOPE

1.1 This specification covers the requirement of Waterproofing by using Tarfelt, Glass Fibre
Tissue, PVC Film, Chemical Treatment for underground concrete structures such as
basements, tunnels, ducts, pits etc., designed as per IS:456 . This specification shall also be
applicable for underground structures designed as per IS:3370, in case shown on drawings.

2.0 GENERAL REQUIREMENTS

2.1 The materials, constructional and performance requirements for water proofing treatment on
concrete structures and any special requirements as shown or noted on the drawing(s) shall
govern over the provisions of this specification.

2.2 The work shall be done in accordance with this specification. In case of conflict between the
clauses mentioned in this specification and those in the Indian Standards, this specification shall
govern.

2.3 Materials

2.3.1 Refer material specification part of :CIVIL & STRUCTURAL WORKS - MATERIALS. .

3.0 REFERENCES

3.1 BIS Codes

IS: 702, 1322,1609,3384,9918

3.2 Job Specifications

CIVIL & STRUCTURAL WORKS - MATERIALS.

4.0 UNDERGROUND WATER PROOFING

4.
Water Proofing using P.V.C. Membrane/Sheet

The material used shall be approved polyvinylchloride sheet of notified thickness with locking
mechanism consisting of studs/knobs of minimum 10mm height and spaced at 65mm x 65mm

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 100 OF 221

 in a regular grid pattern. The sheet shall be of practicable length and width so as to keep the
number of joints minimum.

Before laying the sheet on horizontal surfaces, the base concrete/mud-mat shall be rendered
smooth by a 20mm thick cement-sand plaster (1:6). Any sharp corner over which sheet is to be
laid shall be eased out by means of cement mortar fillets. After laying of the sheet, 40mm thick
protective cement-sand plaster (1:3), in three layers of equal thickness, shall be laid evenly over
the sheet.

On vertical surfaces, the sheet shall be supported and fixed on the form work before erecting
the same in position as per manufacturer's recommendation. All the holes, cuts etc. detected
after removal of the form work, shall be patched up with additional pieces of sheets as per
manufacturer's specifications. All testing shall be carried out by an electronic pin hole detector.
Proper care shall be taken to ensure a perfect jointing between the sheet on vertical and
horizontal surfaces.

For protection of sheet on vertical concrete surface, a protective brick wall of specified
thickness shall be built in cement mortar (1 : 3) over the projecting base concrete/mudmat. The
top edge of the film shall be tucked into a groove and the chase filled with cement mortar (1 :
3).

Waterproofing to the roof of an underground structure such as tunnel, tank etc. shall be done in
a similar way. The structural concrete shall be rendered smooth where necessary with cement
plaster (1:6). The sheet shall be laid on the smooth surface and then a protective layer of flat
bricks in cement mortar (1:3) over a bedding of 40 mm thick cement sand plaster (1: 3) shall be
laid.

The Contractor shall guarantee the water tightness of the structure for a period of 10 (ten) years
after the certified completion and handing over of the same. The waterproofing work shall be
done by a firm of specialists in the trade approved by the Engineer-in-Charge.

Payment

Payment for waterproofing treatment shall be based on actual surface area in square meters
(m2) to be waterproofed. The Contractor shall include in his rate all allied work viz. cleaning,
preparing of surfaces, cutting grooves and filling with cement mortar, scaffolding, drying,
patching etc. all labour and materials complete. Brick work and cement plaster shall be paid
separately under relevant items.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 101 OF 221

SPECIFICATION: JOB SPECIFICATION FOR SURFACE PREPARATION AND
PROTECTIVE COATING

RELEVANT SOR ITEM NO : S032,S033

Abbreviations:

AS : Alloy Steel
ASTM : American Society for Testing and Materials
AWWA: American Water Works Association
CS : Carbon Steel
DFT : Dry Film Thickness
GI : Galvanized Iron
ID : Internal Diameter
ISO : International Organization for Standardization
LTCS : Low temperature Carbon Steel
MS : Mild Steel
NB : Nominal Bore
OD : Outside Diameter
OSHA : Occupational Safety and Health Act
RCC : Reinforced Cement Concrete
RH : Relative humidity
SS : Stainless Steel
SOR : Schedule of Rate
MR : material requisition
SSPC : Steel Structure Painting Council
WFT : Wet Film Thickness
NA : Not applicable

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 102 OF 221

 Sl. CONTENTS PAGE
No. NO.
1.0 General 4
2.0 Scope 4
3.0 Reference codes & standards 6
4.0 Equipment 7
5.0 Surface preparation, shop primer, coating application, repair and 7
documentation
6.0 Paint materials 16
7.0 Coating systems 23
8.0 Storage 38
9.0 Colour code 39
10.0 Identification of vessels, piping 41
11.0 Painting for civil defense requirements 41
12.0 Quality control, inspection and testing 42
13.0 Guarantee 45
14.0 Qualification criteria of painting CONTRACTOR/sub 45
CONTRACTOR
15.0 Qualification/acceptance criteria of paint coating system 45
16.0 Method of sampling & dispatch for laboratory testing 48

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 103 OF 221

1.0 GENERAL

1.1 This technical specification shall be applicable for the work covered by the contract and without
prejudice to the provisions of various international codes of practice, standard specifications etc.
It is understood that the CONTRACTOR shall carry out the work in all respects with the best
quality of materials and workmanship and in accordance with the best engineering practice and
instructions of Engineer-In-Charge.

1.2 Wherever it is stated in the specification that a specific material is to be supplied or a specific
work is to be done, it shall be deemed that the same shall be supplied or carried out by the
CONTRACTOR.

Any deviation from this standard without written deviation permit from appropriate authority
will result in rejection of the job.

1.3 This specification covers the requirement for protective coating for new construction. The
intention of this specification is to prescribe corrosion protection coating systems to CS, LTCS,
SS and alloy steels.

1.4 This specification is not applicable for aesthetic or any other painting purposes

2.0 SCOPE

2.1 Scope of work covered in the specification shall include, without being limited to, the
following:

This specification defines the requirements for surface preparation, selection and application of
primers and paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel
structures, external & internal protection of storage tanks for all services and chimneys, if any.
The items listed in the heading of tables of paint systems are indicative only. However, the
CONTRACTOR is fully responsible for carrying out all the necessary painting, coating and
lining job on external and internal surfaces as per the tender requirement.

2.2 Extent of work

2.2.1 The following surfaces and materials shall require shop, pre-erection and field painting:

- All un-insulated carbon steel & alloy steel equipment like vessels, columns, storage tanks,
exchangers, parts of boilers etc.

- All un-insulated carbon steel and low alloy plant and related piping, fittings and valves
(including painting of identification marks), furnace ducts and stacks.

- All insulated parts of vessels, boilers, chimneys, stacks, piping and steam piping and other
insulated items present, if any.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 104 OF 221

 - All items contained in a package unit.

- All structural steel work, pipes, structural steel supports, walkways, handrails, ladders,
platforms etc.
- Flare lines, external surfaces of MS chimney with or without refractory lining and internal
surfaces of MS chimney without refractory lining.

- Identification of colour bands on all piping, as required, including insulated aluminium clad,
galvanized, SS and nonferrous piping.

- Identification lettering/ numbering on all painted surfaces of equipment/piping insulated

aluminium clad, galvanized, SS and non-ferrous piping.

- Marking / identification signs on painted surfaces of equipment and piping including

hazardous service.

- Supply of all primers, paints and all other materials required for painting (other than
OWNER supplied materials)

- Application of pre-erection/fabrication and shop primer.

- Repair work of damaged pre-erection/ fabrication and shop primer and weld joints in the
field/site before and after erection.

- All CS piping, equipment, storage tanks and internal surfaces of RCC tanks in ETP plant.

- Quality control, testing and inspection during all stages of work (surface preparation,
application of coating and testing of furnished coating).

2.2.2 The following surfaces and materials shall not require painting in general. However, if there is
any specific requirement by the OWNER, the same shall be painted as per the relevant
specifications:

a. Un-insulated austenitic stainless steel.

b. Plastic and/or plastic coated materials.
c. Non-ferrous materials like aluminum, Cu-Ni alloys, galvanized steel.

In general Galvanized steel doesn’t require painting. However if painting is required due to
OWNERs instructions, contractual or for colour coding requirement then coating system in
Table 4.0 shall be followed.

2.3 Documents

2.3.1 The CONTRACTOR shall perform the work in accordance with the following documents
issued to him for execution of the work.

a. Bill of quantities for piping, equipment, machinery and structures etc.

b. Piping line list.

c. Painting specifications including special civil defense requirements.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 105 OF 221

2.4 Unless otherwise instructed, final paint coating (i.e. application of field primer, intermediate and
top coats) on pre-erection/ shop primed equipment shall be applied at site, only after all
welding, testing on systems are completed as well as after completion of steam purging.

2.5 Changes and deviations required for any specific job due to OWNERs requirement or otherwise
shall be referred to EIL for deviation permit.

3.0 REFERENCE CODES & STANDARDS

3.1 Without prejudice to the provision of clause 1.1 above and the detailed specifications of the
contract, latest editions of the following codes and standards are applicable for the work covered
by this contract:

ISO-12944 : Corrosion protection of steel structures by protective

paint system.
ASTM-Vol. 6.01&6.03 : American standard test methods for paints and
coatings.
IS-101 : Methods of sampling and test for paints, varnishes and related
products.
IS-5 : Colours for ready mixed paints and enamels.
RAL DUTCH : International standard for colour shade (Dutch standard).
IS-2379 : Indian standard for pipe line identification-colour code

3.2 Surface preparation standards

The latest editions of any of the following standards shall be followed for surface preparation:

3.2.1 ISO 8501-1 / SIS-05 59 00: ISO standard for preparation of steel substrates before application of paints and
This standard contains photographs of the various standards on four different
related products.
degrees of rusted steel and as such is preferable for inspection purpose by the Engineer-In-
Charge.

3.2.2 Steel Structures Painting Council, U.S.A. (surface preparation specifications SSPC-SP).

3.2.3 National Association of Corrosion Engineers (NACE), U.S.A.

3.2.4 Various international standards equivalent to Swedish standard for surface preparations are
given in Table-1.

3.3 The CONTRACTOR shall arrange, at his own cost, to keep a set of latest edition of above
mentioned standards and codes at site.

3.4 The paint manufacturers’ instructions shall be followed as far as practicable at all times for the
best results. Particular attention shall be paid to the following:

a. Instructions for storage to avoid exposure as well as extremes of temperature.

b. Surface preparation prior to painting shall be followed as per Table-4 to 13 of this standard.
c. Mixing and thinning.
d. Application, recommended limit on time intervals in between coats & DFT.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 106 OF 221

4.0 EQUIPMENT

4.1 All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning, all
equipment, scaffolding materials, shot & grit blasting equipment , air compressors etc. required
shall be suitable for the work and shall be arranged by the CONTRACTOR in sufficient
quantity at the site. The manufacturers test certificates / data sheets for all the above mentioned
items shall be reviewed by Engineer-In-Charge at site before start of the work.

4.2 Mechanical mixer shall be used for paint mixing operations in case of two pack systems except
in case of specific requirement; the Engineer-In-Charge may allow the hand mixing of small
quantities at his discretion for touch up work only.

5.0 SURFACE PREPARATION, SHOP PRIMER / COATING APPLICATION, REPAIR

AND DOCUMENTATION

5.1 General

5.1.1 Adhesion of the paint film to the surface depends largely on the degree of cleanliness of the
metal surface. Proper surface preparation contributes more to the success of the paint protective
system. In order to achieve the maximum durability, one or more of the following methods of
surface preparation shall be followed, depending on condition of surface to be painted and as
instructed by the Engineer-In-Charge.

a. Abrasive blast cleaning

b. Mechanical or power tool cleaning

5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and
dry surface is obtained. Unless otherwise specified, surface preparation shall be done as per
provisions of relevant tables given elsewhere in this specification. The minimum acceptable
standard, in case of thermally sprayed metal coatings, in case of mechanical or power tool
cleaning shall be St. 3 or equivalent. In case of blast cleaning, it shall be Sa 2-1/2 as per
Swedish standard SIS-055900 (latest edition) or SSPC-SP or ISO 8501-01.Blast cleaning shall
be Sa 3 as per Swedish standard in case of thermally sprayed metal coatings.

Before surface preparation by blast cleaning, the surface shall be degreased by aromatic solvent
to remove all grease, oil etc as per SSPC-SP-1.

5.1.3 Irrespective of whether external or internal surface to be coated, blast cleaning shall not be
performed where dust can contaminate surfaces undergoing such cleaning or during humid
weather conditions having humidity >85%. In case of internal coating of storage tanks,
dehumidifier shall be used to control humidity level below 60%. Dehumidifier should depress
the dew point of air in the enclosed space, sufficient enough so as to maintain it 3⁰C below the
metal substrate temperature during entire period of blasting and coating application. During the
interval time between application of primer coat and subsequent intermediate and top coats or
between blast cleaning completion and start of application of primer coat, dehumidifier unit
should be in continuous operation to ensure that no condensation occurs on the substrate.

Dehumidifier should be able to maintain grain drop (moisture removal) at the rate of 25 grains
per pound of air per hour. Dehumidifier should have capacity of at least 2 air changes per hour

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 107 OF 221

 of the enclosed space. All necessary psychometric data should be collected by the
CONTRACTOR for the given site conditions, before starting operation of dehumidifier, to
ensure that desired values of dew point and moisture content in enclosed space is achieved.

Dehumidification to be maintained round the clock for surface preparation and painting till the
total coating application is over.

Dehumidifier shall not be stopped under any condition till the entire blasted surface is primed to
the satisfaction of the technical representative of the paint manufacturer. In case the
dehumidifier breaks down in middle of the job, the same shall be replaced at the risk and cost of
the CONTRACTOR.

5.1.4 The Engineer in-Charge shall have the right to disallow usage of dehumidifier if the
performance is not meeting the specified requirements. Under such circumstances, the
CONTRACTOR shall remove the equipment and replace the same with another equipment to
provide satisfactory results without any additional cost to the OWNER.

5.1.5 Irrespective of the method of surface preparation, the first coat of primer must be applied by
airless spray/ air assisted conventional spray, if recommended by the paint manufacturer, on dry
surface. This should be done immediately and in any case within 4 hours of cleaning of the
surface. However, at times of unfavorable weather conditions, the Engineer-In-Charge shall
have the liberty to control the time period, at his sole discretion and/or to insist on re-cleaning
before primer application is taken up. In general, during unfavorable weather conditions,
blasting and painting shall be avoided as far as practicable.

5.1.6 The external surface of R.C.C. chimney to be painted shall be dry and clean. Any loose particle
of sand, cement, aggregate etc. shall be removed by scrubbing with soft wire brush. Acid
etching with 10-15% HCl solution for about 15 minutes shall be carried out. The surface must
be thoroughly washed with water to remove acid and loose particles and then dried completely
before application of paint.

5.2 Procedure for surface preparation

5.2.1 Air blast cleaning with abrasives

The surfaces shall be blast cleaned using one of the abrasives such as Al2O3 particles, chilled
cast iron or steel grit, copper slag or nickel slag at a pressure of 7.0 kg/cm2 and at an appropriate
distance & angle depending on nozzle size maintaining constant velocity and pressure. Chilled
cast iron or steel shall be in the form of shot or grit of size in the range of G16 – G42
conforming to SSPC AB1 and S250 grade size of steel shots (maximum) to obtain a desired
surface profile of 35-50 microns trough to peak. For all other abrasives, size shall be in the
range of G16 – G24. The combination of steel grits and shots shall be normally in the ratio of
3:1. The quality of abrasives shall be free from contaminants and impurities and shall meet the
requirements of SSPC AB1. The compressed air shall be free from moisture and oil. The
blasting nozzles should be venturi style with tungsten carbide or boron carbide as the material
for liners. Nozzle orifice may vary from 3/16” to 3/4”. On completion of blasting operation,
the blasted surface shall be clean and free from any scale or rust and must show a grey-white
metallic luster. Primer or first coat of paint shall be applied within 4 hours of surface
preparation. Blast cleaning shall not be done outdoors in bad weather without adequate
protection. If there is dew on the metal surface, it shall be cleaned. The surface profile shall be

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 108 OF 221

 uniform to provide good adhesion (i.e. 35 to 50 microns) to the paint. If possible, a vacuum
collector shall be installed to collect and recycle the abrasives.

5.2.2 Mechanical or power tool cleaning

Power tool cleaning shall be done by mechanical striking tools, chipping hammers, grinding
wheels or rotating steel wire- brushes. Excessive burnish of the surface shall be avoided as it
can reduce paint adhesion. On completion of cleaning, the detached rust, mill scale etc. shall be
removed by clean rags and /or washed by water/steam and thoroughly dried with compressed air
jet before application of paint.

5.3 Non-compatible shop coat primer

For equipment on which application of total protective coating (primer + intermediate + top
coat) is carried out at shop, compatibility of finish coat with primer should be checked with the
paint manufacturer. If the shop coat is in satisfactory condition showing no major defect upon
arrival at site, the shop coat shall not be removed.

5.4 Shop coated equipment (coated with primer & finishing coat) should not be repainted unless
paint is damaged. Repair shall be carried out as per Table-3 of paint systems depending upon
the compatibility of paint.

5.5 Shop primed equipment and surfaces will only be 'spot cleaned' in damaged areas by means of
power tool brush cleaning or hand tool cleaning and then spot primed before applying one coat
of field primer, unless otherwise specified. If shop primer is not compatible with field primer,
then shop coated primer shouldbe completely removed before application of selected paint
system for a particular environment.
5.6 For package units/equipment, shop primer should be as per the paint system given in this
specification. However, manufacturers’ standard can be followed after review.
As mentioned in section 2.4, all coating application at field (field primer, intermediate and top
coat) on equipment, structures, piping, etc, shall be carried out only after its erection and all
welding, testing, steam purging (wherever carried out) have been completed.

5.7 Coating procedure and application

All coatings shall be applied by airless spray except for the following special cases, where
application can be carried out by brush subject to suitability of the application of the paint
product by brush.

- Spot repair
- Stripe coating on edges
- Small bore parts not suitable for spray application

Irregular surfaces such as sharp edges, welds, small brackets, and interstices may stripe coated
to ensure specified DFT is achieved. Paint manufacturer recommendation should be followed
before deciding for brush application.

5.7.1 Surface shall not be coated in rain, wind or in an environment where injurious airborne elements
exist, when the steel surface temperature is less than 5 0F above dew point, when the relative
humidity is greater than 85%, when the temperature is below 40oF and when the
ambient/substrate temperature is below the paint manufacturers recommended temperature of

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 109 OF 221

 application and curing. De-humidifier equipment shall be used to control RH and Dew point.
The paint application shall not be done when the wind speed exceeds 20 km per hour.

5.7.2 Blast cleaned surface shall be coated with complete application of primer as soon as practicable
but in no case later than 4 hours the same day.

5.7.3 To the maximum extent practicable, each coat of paint shall be applied as a continuous film
with uniform thickness and free of probes. Any spots or areas missed in application shall be re-
coated and permitted to dry before the next coat is applied. Applied paint should have the
desired wet film thickness.

5.7.4 Each coat shall be in proper state of cure or dryness before the application of succeeding coat.
Material shall be considered dry for re-coating when an additional coat can be applied without
the development of any detrimental film irregularities such as lifting or loss of adhesion of the
under coat. Manufacturer’s instructions shall be followed for inter coat interval.

5.7.5 When the successive coat of the same colour have been specified, alternate coat shall be tinted,
when practical, sufficiently to produce enough contrast to indicate the complete coverage of the
surface. The tinting material shall be compatible with the material underneath and shall not be
detrimental to its service life and shall be recommended by the original paint manufacturer.

5.7.6 Airless spray application shall be in accordance with the following procedure:
As per steel structure paint manual Vol.1 & Vol.2 by SSPC, USA. Airless spray relies on
hydraulic pressure rather than air atomization to produce the desired spray. An air compressor
or electric motor, issued to operate a pump to produce pressures of 1000 to 6000 psi paint, is
delivered to the spray gun at this pressure through a single hose within the gun. A single paint
stream is divided into separate streams, which are forced through a small orifice resulting in
atomization of paint without the use of air. This results in more rapid coverage with less over
spray. Airless spray usually is faster, cleaner, more economical and easier to use than
conventional air spray.

Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks paint
from any container, including drums. The unit shall have in-built agitator that keeps the paint
uniformly mixed during the spraying. The unit shall consist of in-built strainer. Usually, a very
small quantity of thinning is required before spray. In case of high build epoxy coating (two
packs), 45:1 pump ratio and 0.020-0.023” tip size will provide a good spray pattern. Ideally,
fluid hoses should not have ID less than 3/8” and not longer than 50 ft. to obtain optimum
results.

In case of gun choking, de-choking steps shall be followed immediately.

5.7.7 Brush application of paint shall be in accordance with the following:

a. Brushes shall be of a style and quality that will enable proper application of paint.

b. Round or oval brushes are most suitable for rivets, bolts, irregular surfaces, and rough/
pitted steel. Wide flat brushes are suitable for large flat areas but they shall not have width
over 5 inches.

c. Paint shall be applied into all corners.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 110 OF 221

 d. Any runs or sags shall be brushed out.

e. There shall be a minimum of brush marks left in the applied paint.

f. Surfaces not accessible to brushes shall be painted by spray, daubers, or sheepskin.

5.7.8 For each coat, the painter should know the WFT corresponding to the specified DFT and
standardize the paint application technique to achieve the desired WFT. This has to be ensured
in the qualification trial.

5.8 Drying of coated surfaces

5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be considered dry
for re-coating when another coat can be applied without the development of any film
irregularities such as lifting or loss of adhesion of undercoats. Drying time of the applied coat
should not exceed maximum specified for it as a first coat. If this exceeds, the paint material has
possibly deteriorated or mixing is faulty.
5.8.2 No paint shall be force dried under conditions which will cause chalking, wrinkling, blistering
formation of pores, or detrimentally affect the conditions of the paint.
5.8.3 No drier shall be added to paint on the job unless specifically called for in the manufacturers’
specification for the paint.

5.8.4 Paint shall be protected from rain, condensation, contamination, snow and freezing until dried to
the fullest extent practicable.

5.9 Spot repair of damaged primer

5.9.1 Where pre-erection/shop primer has been damaged at isolated localized spots during handling
and transportation or after erection / welding, its repair shall be done as given below and as per
the Table-3 of this specification.

5.9.2 Repair of damaged inorganic zinc silicate pre-erection/pre-fabrication/shop primer (F9) after
erection / welding in the design temperature of -90oC to 400oC and damaged silicone aluminium
(F-12) pre-erection/pre-fabrication/shop primer after erection/welding for design temperature
range of 401 – 550 °C.

Surface preparation: Quickly remove the primer from damaged area by mechanical scraping and
emery paper conforming to SSPC-SP-3 to expose the white metal. Blast clean the surface, if
possible. Feather the primed surface, over the intact adjacent surface surrounding the damaged
area, by emery paper.

Primer coating: One coat of F-9 shall be applied wherever damage was observed on pre-erection
/ pre fabrication or shop primer of inorganic zinc silicate coating (F-9). Similarly one coat of F-
12 shall be applied wherever damage observed on pre-erection / pre-fabrication/shop primer of
silicone aluminium (F-12).

5.9.3 If damaged areas are found to be extensive and spread over large areas, then entire pre-
erection/pre-fabrication/shop primer shall be removed by blasting to achieve SSPC-SP-10 and
entire blasted surface shall be primed again with F-9 or F-12, as applicable, for the intended
design temperature. (See note of Table-3).

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 111 OF 221

5.10 Paint application

5.10.1 Shop priming/pre-erection priming with F9 or F12 shall be done only on blasted surface (SSPC-
SP-10).

5.10.2 Shop priming / pre-erection priming with F9 or F12 shall be done only with airless spray or Air
assisted pressure pot.

5.10.3 Assessment of painting requirement

The paint system to be applied for a specific job shall be arrived at sequentially as given below:

- Identify the environment from area classification details and choose the appropriate table.

- Identify the design temperature from the technical documents.

- Identify the specific field paint system and surface preparation requirement from the above
identified table and temperature range.
- Identify the shop priming requirement from based on compatibility of the above paint system.
- Identify the need of repair of shop primer and execute as per Table-3.

5.11 Documentation / records

5.11.1 A written quality plan with procedure for qualification trials and for the actual work including
test and inspection plan & procedure for approval before start of work.

5.11.2 Daily progress report with details of weather conditions, particular of applications, no. of coats
and type of materials applied, anomalies, progress of work versus program.

5.11.3 Results of measurement of temperatures, relative humidity, surface profile, film thickness,
holiday detection, adhesion tests with signature of appropriate authority.

5.11.4 Particulars of surface preparation and paint application during trials and during the work.

5.11.5 Details of non-compliance, rejects and repairs.

5.11.6 Type of testing equipment and calibration.

5.11.7 Code and batch numbers of paint materials used.

The coating applicator must maintain a job record consisting of all the information as per 5.11.2
-5.11.7 above as well as the approved procedure of work (5.11.1 above). The job record
consisting of information in accordance to 5.11.2 – 5.11.7 shall be entered on daily basis and
should be daily signed by Engineer-in-charge.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 112 OF 221

 TABLE-1: SURFACE PREPARATION STANDARDS

VARIOUS INTERNATIONAL
Sl. STANDARDS (EQUIVALENT)
DESCRIPTION REMARKS
No. ISO 8501-1/ SSPC-SP, NACE,
SIS-05 59 00 USA USA
Manual or hand tool
cleaning

Removal of loose rust, St 2 SSPC-SP-2 -

loose mill scale and loose
1
paint, chipping, scrapping,
This method is
standing and wire
applied when the
brushing. Surface should
surface is exposed
have a faint metallic
to normal
sheen.
atmospheric
Mechanical or power tool
conditions when
cleaning
other methods
cannot be adopted
Removal of loose rust St 3 SSPC-SP-3 -
and also for spot
loose mill scale and loose
cleaning during
paint to degree specified
maintenance
2 by power tool chipping,
painting.
de-scaling, sanding, wire
brushing and grinding,
after removal of dust,
surface should have a
pronounced metallic
sheen.
Dry abrasive Blast cleaning
3
There are four common grades of blast cleaning:
White metal

Blast cleaning to white Extremely clean

metal cleanliness. surface can be
NACE
3.1 Removal of all visible Sa 3 SSPC-SP-5 expected to have
No.1
rust. Mill scale, paint & prolonged life of
foreign matter 100% paint system.
cleanliness with desired
surface profile.
Near white metal The minimum
requirement for
Blast cleaning to near chemically resistant
white metal cleanliness, paint systems such
NACE
3.2 until at least 95% of each Sa 2½ SSPC-SP-10 as epoxy, vinyl,
No.2
element of surface area is polyurethane based
free of all visible residues and inorganic zinc
with desired surface silicate paints. Also
profile. for conventional

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 113 OF 221

 VARIOUS INTERNATIONAL
Sl. STANDARDS (EQUIVALENT)
DESCRIPTION REMARKS
No. ISO 8501-1/ SSPC-SP, NACE,
SIS-05 59 00 USA USA
paint systems used
under fairly
corrosive
conditions to obtain
desired life of paint
system.
Commercial Blast For steel required
to be painted with
Blast cleaning until at conventional paints,
least two-third of each NACE for exposure to
3.3 Sa 2 SSPC-SP-6
element of surface area is No.3 mildly corrosive
free of all visible residues atmosphere and for
with desired surface longer life of the
profile. paint systems.
Brush-off Blast

Blast cleaning to white

metal cleanliness, removal NACE
3.4 Sa 1 SSPC-SP-7 -
of all visible rust, mill No.4
scale, paint & foreign
matter. Surface profile is
not so important.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 114 OF 221

6.0 PAINT MATERIALS
Typical characteristics and codes of various paint materials used in this specification are as
follows.TABLE-2: PAINT MATERIALS
(Refer to general notes at the end of this table)
DESCRIPTION P-6 P-7 P-4
EpoxyZinc Cold Galvanizing Etch Primer/Wash Primer
Phosphate Primer product
Technicalname

Two component One pack synthetic resin Two pack polyvinyl

polyamine cured epoxy based zinc galvanizing butyralresin medium cured
resin medium, containing min 92%of with phosphoric acid
pigmented with zinc electrolytic zinc dustof solution pigmented with
phosphate. 99.95%purity. zinc tetroxy chromate.
Type and
composition
Volumesolids % 49 37 9
Minimum
DFTpercoat, μ
40-50 40-50 8-10

Theoretical
coveringcapacity 8-10 4m²/kg 8-10
in m2/coat/litre
Weightperlitre in
1.4±0.05 2.67kg at 15oC 1.2±0.05
Kg/litre
Touchdryat
10 min. 2 hrs.
30oC(max.) 30 min.

Hard dryat30oC
(max.), 8 24 24
hrs
Over-coating
interval, hrs Min.8 Min.4 Min.4-6

Pot life at
30⁰C fortwo 6 -8 NA NA
component
paints, hrs
Adhesion
(ASTMD 4541) >7 NA NA

Temperature
resistance (min)
⁰C 80 50
NA
(ASTM D 2485) (Method A) (Method A)
*Note 8

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 115 OF 221

 TABLE-2: PAINTMATERIALS(Contd.)

DESCRIPTION F-2 F-3 F-6A/B F-6C

Acrylic Chlorinated rubber Epoxy-High Solvent less
Polyurethane based finishpaint Build coating epoxycoating
Technicalname
finishpaint

Type and Two-pack Single pack F-6ATwo- Two pack,

composition aliphatic plasticized Pack Aromatic cured with Amine
isocynate cured chlorinated polyamine Adduct; catalyzed
acrylic rubberbased cured epoxyresin suitably
finishpaint mediumwith epoxyresin pigmented
(free of chemicaland medium
alkyd/polyester weather resistant suitably
resins). pigments. pigmented.
F-6B:
polyamide
cured epoxy
resin medium
suitably
pigmented
VolumeSolids % 40 36 57 98
Minimum.
DFTpercoat,μ
30-40 30-40 100-125 250-500
Theoretical
covering
10-15 11-15 5-6 2-3
capacity in
m2/coat/litre
Weightperliter in
1.15±0.03 1.15±0.03 1.42±0.03 1.40±0.03
Kg/litre
Touchdryat 30⁰C
30 min. 30 min. 3 hrs 3 hrs
(max)

Hard dryat30⁰C 8 8 16 16
(max.), hrs

Fullcureat30⁰C
NA NA 5 days 5 days
(forimmersion/
hightemperature
Over-coating
Min. Overnight
Interval, hrs Min.12. Min. Overnight Min.8.
Max.5 days
Max.48

Potlife(approx.) at
30⁰Cfortwo 5-8
NA 3-6 0.5
component paints, hrs

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 116 OF 221

 Adhesion
(ASTMD 4541) >5 >4 >7 >8

<300 mg /1000
Abrasion Resistance cycles/CS17
(ASTM D4060) or NA NA NA
For 1000 g load <100 mg /1000
cycles/CS10

Temperature resistance
(min.) 80 60 80 120
⁰C (Method A) (Method A) (Method A) (Method A)
(ASTM D 2485)
*Note 8

TABLE-2: PAINTMATERIALS(Contd.)

DESCRIPTION F-7 F-8 F-9 (primer) F-11 F-12

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 117 OF 221

Technicalname High build coal tar Self priming type Inorganic zinc Heat resistant Heat resistant
epoxy coating. surface silicate synthetic silicone
tolerant high Coating medium Aluminium
build epoxy based two Paint suitable
coating pack up to 540°C
(complete rust Aluminium dry temp.
control Paint suitable
Coating) up to 250°C
dry temp.

Type & Two pack Two pack epoxy A two pack air Heat resistant Single pack
composition polyamide cured resin based drying self synthetic silicone resin
epoxy resin suitable curing solvent medium based based
blended with pigmented and based two medium with
coal tar medium, capable of inorganic zinc pack Aluminium
suitably adhering to silicate Aluminium flakes.
pigmented manually coating with paint suitable
prepared surface minimum 80% up to 250°C.
and old coating. zinc content on
dry film. The
final cure of the
dry film
shall pass the
MEK rub test as
per ASTM
D4752.
VolumeSolids % 62 75 57 35 18
Minimum.
DFTpercoatin
100-125 100-125 65-75 15-20 15-20
μ
Theoretical
coveringcapacity in 5.2-6.5 6.0-7.2 8-9 10-12 8-10
M2/coat/litre
Weightperliterin
1.40±0.03 1.41±0.03 2.3±0.03 0.95±0.03 1.00±0.03
Kg/litre
Touchdryat30oC
(maximum), hrs 4 3 0.5 3 0.5

Hard dryat30oC
(maximum), hrs 48 24 12 12 24

Fullcure30oC (for
immersion /high
5 days 5 days NA NA NA
temperature
service)
Min.24 hrs Min.12 hrs at
Over-coating interval,
max.5days Min.10 20oC Min.24 Min.24
hrs
& 50%RH

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 118 OF 221

Pot life at30oCfor two
component 4-6 1.5 4-6 NA NA
Paints, hrs
Adhesion MPa
>5 >5 >5 NA NA
(ASTMD 4541)

Temperature resistance⁰
80 80 400 250 540
C (min)
Dry service Dry service Dry service Dry service Dry service
(ASTM D 2485 method
B)

Temperature resistance
(min.) 80 80 400 250 540
⁰C (Method A) (Method A) (Method B) (Method A) (Method B)
(ASTM D 2485)
*Note 8

TABLE-2: PAINTMATERIALS(Contd.)

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 119 OF 221

 DESCRIPTION F-14 F-15 F-16 F-17 F-20
Technicalname Polyamine Two- Ambient Novolac epoxy Glass flake
cured coal tar component temperature curing phenolic coating reinforced vinyl
epoxy Epoxy phenolic Poly Siloxane / cured with ester coating.
coating cured Inert polymeric Polyamine adduct
with Polyamine matrix hardener
adduct coating suitable
hardener for under
insulation for CS
and SS.

Type & Specially Two pack Suitable for high Novolac Two component
composition formulated ambient temperature epoxy phenolic glass flake filled
polyamine temperature service and under coating cured with vinyl ester lining
cured coal tar curing epoxy insulation coating Polyamine adduct for under
epoxy suitable phenolic for CS, alloy steel hardener immersion
for application coating system and SS services up to 90
under suitable for deg. C.
insulation application
under
insulation
oCS/SS piping
VolumeSolids%
Minimum. 67 67 58 98 98
DFTpercoatin
100-125 75-100 75-100 300-450 500-600
microns
Theoretical
coveringcapacity 5-8 4-5 7.0-9.0 6.5–8
in M2/coat/litre 1.6 minimum

Weightperliterin
Kg/litre 1.45±0.03 1.65±0.03 1.3 1.7 >1.2
(mix paint)
Touchdryat 30oC 4 3 1 2
(max) , hrs 2

Hard dryat30oC
24 24 16 24
(max), hrs 4

Fullcure 30oC
(forimmersion 168 hrs 168 hrs 168 hrs
NA 96 hrs
/ high temp (7 days) (7 days) (7 days)
service) (4 days )

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 120 OF 221

Over-coating Min.6 hrs Min.36 hrs Min.16 hrs Min.16 hrs Min.4 hrs
interval Max.5 days Max.21 days Max.Not Max.21 days Max.3 days
applicable

Pot life at 30⁰C, hrs

(for two component
4 4-6 1 1
paints) 50 min-1 hr

>7,
Adhesion, MPa >8 : siloxane
(ASTMD 4541) >6 >7 NA: for inert >8 Tensile strength
polymeric matrix >20N/mm2
(ASTM D 638)

Temperature
resistance (min.)
125 150 550 150 90
⁰C
(Method A) (Method A) (Method B) (Method A) (Method A)
(ASTM D 2485)
*Note 8

General notes for TABLE-2:

1. Covering capacity and DFT achieved per coat depends on method of application. Covering capacity
specified above is theoretical. For estimation of actual quantity of paints required, include the losses
during application. Minimum specified DFT should be maintained in any case.
2. All primers and finish coats should be ambient temperature curing and air drying unless otherwise
specified.
3. All paints shall be applied in accordance with manufacturer's instructions for surface preparation,
intervals, curing and application. The surface preparation, quality and workmanship should be
ensured. Wherever a deviation is noticed from the specification in manufacturer data sheet, more
stringent one between the data sheet and the specification shall prevail e.g. if this
specification recommends Sa 2 ½ and the manufacturer data sheet requires Sa3, the surface
preparation shall be done as per Sa 3. However in another case if this specification requires the
surface preparation of Sa 2 ½ and the manufacturer data sheet recommends only Sa 2 as minimum,
the surface preparation shall be done as per Sa 2 ½.
4. Technical data sheets for all paints shall be supplied at the time of submission of quotations.
5. Higher specific gravity of F-9 is also acceptable.
6. Internationally recognized & acceptable testing method shall be used for lab testing (for clause –
15.1) wherever testing standards are not mentioned.
7. Theoretical covering capacity, hard dry, pot life, full cure period, & over coating interval shall be as
per manufacturer’s data sheets and no testing is required. Slight variation in the values of these
parameters along with weight per liter may be permissible with the discretion of engineer-in-charge
only.
8. Temperature resistance tests (ASTM D2485) shall be carried out for minimum required temperature
resistance indicated.
9. Wherever ASTM D 2485method B is applicable, test results of the panels subjected to salt spray
(ASTM B 117) after muffle furnace exposure shall be submitted for pre-qualification purpose.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 121 OF 221

10. F-6A shall be suitable for immersion services in line with recommendations in tables-7 to 9.
11. F-6C shall be suitable for immersion services of hydrocarbons and DM water ( in line with
recommendations in table-9)
12. F-7 shall be suitable for immersion service of underground service up to 80 Deg C minimum.
13. F-14 shall be suitable for under insulation service up to 125 deg C.
14. F-15 shall be suitable for high temperature immersion & under insulation services in line with
recommendations from table-8 to 13.
15. F-17 shall be suitable for high temperature immersion service and underground services as
recommended in table-9 to 10.

7.0 COATING SYSTEMS

The coating system should be selected based on the plant location as given below:

Classification based on plant location:

Plant located in inland area (more than 50 km from coast).

- Table-5 to be followed.

General notes for clause 7.0:

1. Coating systems (primers, finish paints etc.) based on area

classification/environments/applications are tabulated in Table-4 to Table-10.

2. Repair of pre-erection/pre-fabrication & shop priming after erection/ welding shall be done
as per Table-3.

TABLE-3: REPAIR OF PRE-ERECTION/PRE-FABRICATION OR SHOP PRIMER AFTER

ERECTION/WELDING
(For all un-insulated CS, LTCS & low allow steel items in all environments)

Total DFT
Sl. Design Temp. in Surface
o Coating System in Microns Remarks
No. C Preparation
(min.)
3.1 -90 to 400 SSPC-SP-3 1 coat of F-9 65-75 See Note-1
below and
3.2 401 to 550 SSPC-SP-3 1 coat of F-12 20 clause 5.9.3

Notes for Table-3:

Note-1: The application and repair of pre-erection/pre-fabrication or shop primer given in above tables
shall be done for all the items to be painted. In case the damages of primer are severe and spread
over large area, entire primer shall be removed by blasting to achieve SSPC-SP-10 and surfaces
to be primed again with F-9 or F-12 as applicable.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 122 OF 221

TABLE-4: COATING SYSTEM FOR GI HAND RAILS & GI ITEMS
(Refer clause 2.2.2)

Design
Sl. Total DFT
Temp. Coating System Remarks
No. in Microns (min.)
in oC
Hot Dip Galvanizing to 80-85
microns (600-610 gm/m2)as per IS 80 of finish coat (excluding
Up to
4.1 4759, 2629, 4736, 2633 + the thickness of galvanizing -
60
1 coat of P-6 @ 40µ DFT/coat + 1 )
coat of F-2 @ 40 microns DFT/coat

General notes for Table-4:

1. No galvanized specimen shall have thickness less than 80 microns.

2. Repair of the damaged areas of galvanized coatings due to welding during erection shall be carried
out as per recommended practice IS: 11759, using cold galvanizing spray process. Organic paint
systems are not acceptable for the repair.
3. After repair of damaged galvanized coating by cold galvanization (P-7), the repaired area shall be
top coated with paint system as given in table-4 above (i.e. 1 coat of P-6 @ 40µ DFT/coat + 1 coat
of F-2 @ 40µ DFT/coat).
4. Suggested cold galvanizing manufacturers are ZINGA, LOCTITE or Z.R.C.
5. Galvanized gratings don’t require painting in general until otherwise specified elsewhere or as per
the requirement of the OWNER. Ladders, stairways & hand rails require painting to meet the colour
coding requirement of the OWNER. Contractor has to ensure the applicable colour coding prior to
application of coating as per this clause.

TABLE-5: EXTERNAL COATINGSYSTEM

(For all un-insulated above ground CS, LTCS & low allow steel structures, piping, equipment, valves,
vessels & columns etc.)

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 123 OF 221

 Surface Coating System Total Final
Design Preparation &
Sl. DFT
Temp. in Pre-
No. o Primer Finish Coat in Microns
C erection/Shop
(min.)
Primer
1coat of F-6B
SSPC-SP-10; 1 coatof @ 100 µ
5.1 -45 to 80 1coat of F-9 @ P-6 @ 40 DFT/coat+ 1 245-255
65-75µ DFT/coat µ DFT/coat coat of F-2 @
Remarks
40µ DFT/coat
2 coats of F-11
SSPC-SP-10;
@ 20µ
5.2 81 to 250 1coat of F-9 @ - 105
DFT/coat
65-75µ DFT/coat
(2x20=40)
2 coats of F-12
SSPC-SP-10;
@ 20µ
5.3 251 to 400 1coat of F-9 @ - 105-115
DFT/coat
65-75µ DFT/coat
(2x20=40)
2 coats of F-12
SSPC-SP-10; This system
@20µ
5.4 >400 1coat of F-12 @ - 60 is suitable up
DFT/coat
20µ DFT/coat to
(2x20=40)
5400 C

General notes for Table-5:

1. The list of items given in the heading of the above table is not exhaustive. There may be more items
for a particular contract where these specifications are used. The CONTRACTOR is fully
responsible for completing painting including prefabrication primer for all the items supplied and
fabricated through his scope of work as per tender document.
2. If the application of pre-erection/pre-fabrication/shop primer has already been completed, the same
shall not be repeated in the field. In case the damages to the primer coat are severe and are spread
over large areas, the Engineer-In-Charge may decide & advise re-blasting and re-application of the
primer coat. Repair of pre-fabrication/pre-erection primer, if required, shall be done as per Table-3.
3. In case of paint systems as per sl. nos. 5.3 and 5.4, the colour bands shall be applied over the
aluminum paint as per the colour coding requirement for specific service of the piping.
4. All coating system including surface preparation, primer, intermediate and finish coat for piping is
recommended to be done at field only until otherwise specified.
5. For equipment, vessels, columns & valves etc scope of surface preparation, application of primers
to finish coat including repair shall be as per applicable contractual documents like SOR, MR and
PR etc.

TABLE-6: COATING SYSTEMS FOR SEWAGE TREATMENT PLANT (STP)

Sl. Design Surface Preparation Coating system Total Remarks

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 124 OF 221

 No. Temp. in oC DFT in
Primer Finish Coat Microns
(min.)
For external surfaces of C.S./M.S. items: screens, walk way bridges, baffles, dual media filters,
6.1 vertical pumps, piping in treated effluent sump, bio sludge pump, screw pump and pump house,
CS tanks, sumps and vessels.
2 coats of
F-6A
@100µ
1 coat of F- DFT/coat +
-14 to 80 SSPS-SP-10 9 @ 65-75µ 1 coat of F- 305-315 -
DFT/coat 2 @ 40µ
DFT/coat
(2x100+40=
240)
For internal surfaces of CS/MS Items: bio-sludge sump, filter feed sump, process sump, sanitary
6.2
sump, transfer sump, sludge, slop oil tank, scrapping mechanism in clarifier.
3 coats of
1 coat of
F-6A
F-6A @ 65-
-14 to 80 SSPS-SP-10 @100µ 300 Note-1
100µ
DFT/coat
DFT/coat.
(3x100=300)
All R.C.C./concrete surfaces exposed to effluent water / liquid such as tanks, structures, drains etc.
6.3
in process sump, TPI separator (process and oil), aeration tank and transfer sump etc.
Epoxy screed
Blast cleaning to SSPC-
lining shall be
SP guide lines and acid
applied as per
etching with 10-15%
-14 to 80 Epoxy screed lining 3000 manufacturer
HCl acid followed by
and Engineer-In-
thorough water
Charge
washing.
instructions
C.S/M.S dual media filters (internal), chemical dosing tanks(internal) such as di-ammonium
6.4
phosphate (DAP) and urea
1 coat of clear two
component solvent free
Up to 60 SSPC-SP-10 vinyl ester primer @ 100µ 1100 -
DFT/ Coat + 2 coats of F-
20 @ 500µ DFT/ Coat

TABLE-7: EXTERNAL COATING SYSTEMS FOR UN-INSULATED CARBON STEEL AND

LOW ALLOY STEEL STORAGE TANKS

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 125 OF 221

 Total
Surface Coating system DFT
Sl. Design Preparation (Note-1) in Remarks
No. Temp. in oC
Microns
Primer Finish Coat
(min.)
All external surfaces of shell, wind girders, appurtenances, roof tops of all above ground tank
7.1
including top side of external and internal floating roof and associated external structural works.
F-6 should
1coat of F-9 @ 65- 2 coats of F-6B @
be suitable
75µ DFT/coat + 100µ DFT/coat + 1
for
7.1.1 -14 to 80 SSPC-SP-10 1coat of P-6 @ coat of F-2 @ 40µ 345-355
occasional
40µ DFT/ coat DFT/ coat
water
immersion
1 coat of F-15
1 coat of F-15
primer @ 80µ
finish coat @80µ
DFT/ coat + 1 coat
7.1.2 81 to 150 SSPC-SP-10 DFT/ coat + 1coat 280 -
of F-15
of F-2 @ 40µ DFT/
intermediate coat
coat
@ 80µ DFT/coat
For higher
2 coats of F-12 @20 105-115 design
µ DFT/ coat temperature
1coat of F-9 @ 65-
7.1.3 151 to 400 SSPC-SP-10 or or s, system as
75µ DFT/coat
1 coat of F-16 @ per 7.2.3 of
125 µ DFT / coat 190-200 this table is
applicable
7.2 External surfaces of bottom plate (soil side) for all storage tanks.

F-7 should
3 coats of F-7@
1 coat of F-9 @ be suitable
7.2.1 -14 to 80 SSPC-SP-10 100µ DFT/coat 365-375
65-75µ DFT/ coat for
(3x100=300)
immersion
service
1 coat of F-15
primer @ 80µ
DFT/ coat + 1 coat 1 coat of F-15
7.2.2 81 to 150 SSPC-SP-10 of F-15 finish coat @ 80µ 240 -
intermediate coat DFT/ coat
@ 80µ DFT/coat
(80+80=160)
This system
is suitable
for design
1 coat of F-16 @ 1 coat of F-16 @
7.2.3 151 to 450 SSPC-SP-10 250 temperature
125 µ DFT/coat 125 µ DFT/coat
s up to
5500C

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 126 OF 221

 7.3 For underside of the bottom plate (in case tank is not lifted during PWHT) (Note- 2)

For CS
SSPC SP-10

-180 to 650 1 coat of inert 1 coat of inert

7.3.1 (Note-3) For SS polymeric matrix polymeric matrix 250-300 -
SSPC-SP-7 coating @ 125 µ coating @ 125 µ
(15-25µ
surface
profile)

Notes for TABLE-8:

1. All paint coating application including primer for tanks shall be carried out at field after erection
and completion of entire welding.

2. For underside of bottom plate :

a) Painting shall be carried out before laying the bottom plate for tanks with non-Post Weld Heat
Treatment (PWHT).
b) For tanks with PWHT, painting shall be carried out after PWHT.
c) In case tank is not lifted during PWHT then painting shall be applied before laying the bottom
plate, clause no.7.3.1 shall be followed.
3. The temperature range indicated (-180 to 650 deg C) corresponds to the temperature resistance of
coating material i.e. Inert polymeric matrix coating.

Caution: PWHT temperature shall not exceed 650oC

TABLE-8: INTERNAL COATING SYSTEMS FOR CARBON STEEL AND LOW ALLOY
STORAGE TANKS

Coating system Total

Design Surface DFT
Sl.
Temp. in Preparation in Remarks
No. o
C Primer Finish Coat Microns
(min.)

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 127 OF 221

 Raw water, Drinking water and Fire water etc.
8.1
All internal surfaces, accessories and roof structures of cone and dome roof tanks
1 Coat of F-6A 2 Coats of F-6A @
8.1.1 -14 to 65 SSPC-SP-10 @ 100µ DFT/ Coat 300 Note-1
100 µ DFT/coat (2x100=200)
Diesel, ATF and other Hydrocarbons service:
8.2
All internal surfaces, accessories and roof structures of cone and dome roof tanks.
1 coat of F-15
intermediate coat
1 coat of F-15 @ 80µ DFT/coat +
8.2.1 Upto 90 SSPC-SP-10 primer @ 80µ 1 coat of F-15 240 -
DFT/ coat finish coat @ 80µ
DFT/ coat
(80+80=160)

Notes for TABLE-8:

1. F-6A should have competent authority certification for drinking water service.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 128 OF 221

TABLE-9: COATING SYSTEMS FOR EXTERNAL SIDE OF UNDERGROUND CARBON
STEEL PLANT PIPING AND VESSLES

Surface Coating system Total

Design Preparation DFT
Sl. Surface
Temp. in & in Remarks
No. o Preparation & Finish Coat
C Shop Primer Microns
Primer (min.)
9.1 Underground carbon steel plant piping
1 layer of coal tar
tape coating @ 2mm
+1 coat of synthetic
SSPC-SP-10;
fast drying primer 25
@µ DFT/ coat + 1
1 coat of
layer of coal tar tape
9.1.1 25 to 65 - synthetic fast -- --
coating @ 2mm
drying primer
/layer as per
25 @µ DFT/
EIL Standard
coat
Specification .No
6-79-0011
(latest edition)

SSPC-SP-10;
1 coat of F-17 @
9.1.2 66 to 150 - 1 coat of F-17 800 -
400 DFT/coat
primer @400 µ
DFT/ coat
This
SSPC-SP-10;
1 coat of F-16 system is
9.1.3 151 to 450 - 1 coat of F-16 250
@125µ DFT/ coat suitable up
primer @ 125µ
to 5500C
DFT/ coat
9.2 External side of un-insulated underground storage vessels
SSPC-SP
-10;
1 coat of 3 coats of F-7 @
9.2.1 -40 to 80 - 365-375 -
F-9 @ 100µ DFT/coat
65-75µ DFT/
coat

1 coat of F-17
SSPC-SP 1 coat of F-17
9.2.2 81 to 150 primer @400 µ 800 -
-10 @400µ DFT/ coat
DFT/ coat

SSPC-SP
This
-10; 1 coat of F-16 finish
system is
9.2.3 151 to 450 1 coat of - coat @125µ DFT/ 250
suitable up
F-16 @ 125µ coat
to 5500C
DFT/ coat

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 129 OF 221

 Notes for TABLE-9:

1 For underground vessels, scope of surface preparation, application of primers to finish coat including
repair shall be as per applicable contractual documents like SOR, MR, PR etc.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 130 OF 221

 TABLE-10: COATING SYSTEMS FOR UNDER INSULATION
(For insulated piping, equipment, storage vessels, tanks, columns etc. of CS, LTCS, alloy steel & stainless
steels in all environments.)

Surface Preparation Coating system Total DFT

Sl. Design & Remarks
Microns
No. Temp. o C Pre-erection/Shop Primer Finish paint
(min.)
Primer
10.1 Carbon steel, LTCS and Low alloy steel Piping, Storage tanks, Vessels, Equipment etc

2 coats of
SSPC-SP-10;
F-15 @75µ
10.1.1 -45 to 125 1coat of F-15 @ None 225
DFT/coat
75µ DFT/coat

This system
2 coats of
SSPC-SP-10; is suitable up
126 to 450 F-12 @20µ
10.1.2 1 coat of F-12 @20µ None 60 to
(CS) DFT/coat
DFT/coat 540 0 C for
low alloy
steels
10.2 Stainless Steel, Alloy Steel, Alloy-20 Piping, Vessels & Equipment
SSPC-SP-7;
(15-25µ surface 2 coats of
10.2.1 -45 to 125 profile) None F-15 @75µ 225
1 coat of F-15 @75 µ DFT/coat
DFT/coat
SSPC-SP-7;
(15-25µ surface
1 coat of
profile)
10.2.2 126 to 550 None F-16 @125μ 250
1 coat of
DFT/coat
F-16 @125μ
DFT/coat
10.3 Cyclic service of CS, LTCS, SS, & Alloy Steel
SSPC-SP-10 For CS,
LTCS & low Alloy
steel. 2 coats of
-45 to 150 SSPC-SP-7 for SS; F-15 @75µ Note-5
10.3.1 None 225
(Note-1) (15-25µ surface DFT/coat
profile)
1 coat of F-15 @75 µ
DFT/coat

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 131 OF 221

 SSPC-SP-10 for CS,
LTCS & Alloy steel.
SSPC-SP-7 for SS 1 coat of Inert
(15-25µ surface polymer matrix
-180 to 650 profile) coating @ 125µ 250 (Note-3 & 4)
10.3.2 None
(Note-2) 1 coat of Inert DFT/coat
polymeric matrix
coating @ 125µ
DFT/coat

Notes

1. In case of overlapping of cyclic temperature ranges as mentioned in 10.3.1 and 10.3.2 then clause
10.3.1 shall be followed.
2. The temperature range indicated (-180 to 650 deg C) corresponds to the applicability of the coating
material i.e. inert polymeric matrix coating.
3. Alternatively thermally sprayed aluminium (TSA) coating @ 500μ as per Annexure-1 of 6-79-
0020 Rev.0 is acceptable.
4. This coating system is applicable for any other temperature range (-180 to 650 o C) of CS, SS
etc. which are not covered in clauses 10.1 or 10.2.
5. Alternatively, for this temperature range, 1 coat of F-17 @ 300 μ is also acceptable.

General notes for TABLE-10:

1. “Cyclic Service” is characterized by rapid or periodical temperature fluctuation or temperature

cycles.
2. The blasting abrasives for SS and alloy steels shall be aluminum oxide or garnet only.
3. For insulated vessels & equipment scope of surface preparation, application of primers to finish
coat including repair shall be as per applicable contractual documents like SOR, MR, PR etc.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 132 OF 221

8.0 STORAGE

8.1 All paints and painting materials shall be stored in rooms only which are to be arranged by
CONTRACTOR and approved by Engineer-In-Charge for the purpose. All necessary
precautions shall be taken to prevent fire. The storage building shall preferably be separate from
adjacent building. A signboard bearing the word “PAINT STORAGE- NO NAKED LIGHT-
HIGHLY INFLAMMABLE” shall be clearly displayed outside. Manufacturers’
recommendation shall be followed for storage of paint materials.

9.0 COLOUR CODE

The colour coding of OWNER is applicable. It is in the applicators/contractors scope to obtain

confirmation for applicable colour coding from the OWNER/ EIL.

9.1 Identification

The system of colour coding consists of a ground colour and secondary colour bands
superimposed over the ground colour. The ground colour identifies the basic nature of the service
and secondary colour band over the ground colour distinguishes the particular service. The
ground colour shall be applied over the entire length of the un-insulated pipes. For insulated lines,
ground colour shall be provided as per specified length and interval to identify the basic nature of
service and secondary colour bands to be painted on these specified length to identify the
particular service. Above colour code is applicable for both unit and offsite pipelines.

9.2 Ground colour

On un-insulated pipes, the entire pipe has to be painted in ground colour. On metal cladded
insulated lines, minimum 2 m long portion should be painted.

9.3 Colour bands

9.3.1 Location of colour bands:

a. At battery limits.
b. Intersection points & change of direction points in piping.
c. Midway of piping section, near valves, across culverts.
d. At 50 m interval on long stretch pipes.
e. At starting and termination points.

9.3.2 Minimum width:

NB Width
3” and below 75 mm
Above 3” to 6” NB X 25 mm
Above 6” to 12” NB X 18 mm
Above 12” NB X 15 mm

For insulated pipes, NB indicates OD of the insulation.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 133 OF 221

 Sequence: Colour bands shall be arranged in sequence as shown above and the sequence
follows the direction of flow. The width of the 1st Band to 2nd band is 4:1.
Wherever deemed required by process department or safety, pipes handling hazardous
substances will be given hazard marking of 30 mm wide diagonal stripes of black and
golden yellow as per IS : 2379.

9.4 Identification markings on equipment/piping

Equipment tag numbers shall be stenciled/neatly painted using normal ‘Arial’ lettering style on
all equipment and piping (both insulated & un-insulated) after completion of all paint works.
Lettering colour shall be either black or white, depending upon the background, so as to obtain
good contrast.

Operations group shall specify the location of the marking.

Size of the making shall be as follows:

Columns, vessels, heaters : 150 mm

Pumps and other machinery : 50 mm
Piping : OD / 2 with maximum 100 mm
Storage tanks : (as per drawings)

9.5 Colour coding for control valve

a) Carbon steel body : Light grey

Alloy steel body : Canary yellow
Stainless steel body : Natural

b) The actuator of the control valve shall be painted as:

Direct action (open on air failure) valves : Green
Reverse acting (close on air failure) valves : Red

The painting status shall be comprehensively updated every 6 months for compliance.

10.0 IDENTIFICATION OF VESSELS, PIPING ETC.

10.1 Equipment number shall be stenciled in black or white on each vessel, column, equipment &
machinery (insulated or un-insulated) after painting. Line number in black or white shall be
stenciled on all the piping of more than one location as directed by Engineer-In-Charge. Size of
letter printed shall be as below:

Column & vessels : 150 mm (high)

Pump, compressor & other machinery : 50 mm (high)
Piping : 40-150 mm

10.2 Identification of storage tanks

The storage tanks shall be marked as detailed in the drawing.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 134 OF 221

11.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS

11.1 The following items shall be painted for camouflaging, if required by the client:
a. All columns
b. All tanks in offsite
c. Large vessels
d. Spheres

11.2 Two coats of selected finishing paint as per defence requirement shall be applied in a particular
pattern as per clause 11.3 and as per the instructions of Engineer-In-Charge.

11.3 Method of camouflaging

11.3.1 Disruptive painting for camouflaging shall be done in three colours in the ratio of 5:3:2 (all
matte finish).

Dark Green Light Green Dark Medium Brown

5 : 3 : 2

11.3.2 The patches should be asymmetrical and irregular.

11.3.3 The patches should be inclined at 30º to 60º to the horizontal.

11.3.4 The patches should be continuous where two surfaces meet at an angle.

11.3.5 The patches should not coincide with the corners.

11.3.6 Slits and holes shall be painted in dark shades.

11.3.7 Width of patches should be 1 to 2 m.

12.0 QUALITY CONTROL, INSPECTION AND TESTING

12.1 All painting materials including primers and thinners brought to site by CONTRACTOR for
application shall be procured directly from manufactures as per specifications and shall be
accompanied by manufacturers’ test certificates. Paint formulations without certificates are not
acceptable (see section 14.0 & 15.0).

12.2 The CONTRACTOR must produce test certificate from pre qualified paint manufacturer for
various tests as detailed out in section 15.0 of this document. The Engineer-In-Charge shall have
the right to test wet samples of paint at random for verifying quality of paint supplied.
CONTRACTOR shall arrange to have such tests, when required by Engineer-in-Charge, performed
at his cost at any one of the NABL accredited laboratories.

Samples for the test will be drawn at random in presence Engineer-In-Charge or his
representations. Following tests to be carried out if called for by Engineer-in-Charge:

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 135 OF 221

 - Specific Gravity
- % solids by weight (% zinc content in case of inorganic or organic zinc primer)
- Drying time (touch dry & full curing)
- Adhesion
- Storage stability (pot life)

Test methods for above tests shall be as per relevant ASTM or ISO Standard.

12.3 The painting work shall be subject to inspection by Engineer-In-Charge at all times. In particular,
following stage-wise inspection will be performed and CONTRACTOR shall offer the work for
inspection and approval of every stage before proceeding with the next stage. The record of
inspection shall be maintained in the registers. Stages of inspection are as follows:

a) Surface preparation
b) Primer application
c) Each coat of paint

Following tests are to be carried out during surface preparation:

- Test for presence of oil/grease and contamination

The steel substrate after degreasing as per SSPC-SP-1 shall be tested as per following
procedure to validate absence of oil and grease contamination:

a) Visual inspection - continue degreasing until all visible signs of contamination are removed.
b) Conduct a solvent evaporation test by applying several drops or a small splash of residue-free
tri-chloromethane on the suspect area especially pitting, crevice corrosion areas or depressed
areas. An evaporation ring formation is indicative of oil and grease contamination. Continue
degreasing and inspection till test is passed.

- Tests for surface finish of blasted surface shall be done by visual inspection using SSPC-
VIS1. Clear cellophane tape test as per ISO 8502-3 shall be used to confirm absence of dust
on blasted surface. Checks shall be done on each component at least once per 200 m2 of
blasted surface and a minimum of 3 checks per shift.

- Test for presence of soluble salt as per method ISO 8502-9. Maximum allowable salt content
shall be considered 20 mg/m2.Checks shall be done on each component at least once per 200
m2 of blasted surface and minimum of 3 checks per shift. In case salt exceeds specified limit,
the contaminated surface shall be cleaned by method as per Annexure-C of IS 12944-4
(water cleaning). After cleaning, surface shall be retested for salt after drying.

- Blast profile measurement – This shall be done as described in sec 6.2 of Annexure-I of 6-
79-0020 Rev 0 (Specification for thermally sprayed Aluminium).

- Test for blasting Media and Blasting air- this shall be done as described in sec 6.6 of
Annexure-I of 6-79-0020 Rev 0 (Specification for thermally sprayed Aluminium).
In addition to above, record should include type of shop primer already applied on equipment e.g.
zinc silicate or zinc rich epoxy or zinc phosphate. Any defect noticed during the various stages of
inspection shall be rectified by the CONTRACTOR to the entire satisfaction of Engineer-In-Charge

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 136 OF 221

 before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages
of work, CONTRACTOR shall be responsible for rectifying any defects found during final
inspection/guarantee period/defect liability period as defined in general conditions of the contract.
Dry film thickness (DFT) shall be checked and recorded after application of each coat and extra
coat of paint should be applied to make-up the DFT specified without any extra cost to OWNER,
the extra coat should have prior approval of Engineer-in-charge.

12.4 Primer Application

After surface preparation, the primer should be applied to cover the crevices, corners, sharp edges
etc. in the presence of inspector nominated by Engineer-In-Charge. The shades of successive coats
should be slightly different in colour in order to ensure application of individual coats, the
thickness of each coat and complete coverage should be checked as per provision of this
specification. This should be approved by Engineer-In-Charge before application of successive
coats.

The CONTRACTOR shall provide standard thickness measurement instrument with appropriate
range(s) for measuring dry film thickness of each coat, surface profile gauge for checking of
surface profile in case of sand blasting, holiday detectors and pinhole detector and protector
whenever required for checking in case of immersion conditions.

Prior to application of paints on surfaces of chimneys, the thickness of the individual coat shall be
checked by application of each coat of same paint on MS test panel. The thickness of paint on test
panels shall be determined by using gauge such as 'Elko meter'. The thickness of each coat shall be
checked as per provision of this specification. This shall be approved by Engineer-In-Charge before
application of paints on surface of chimney.
At the discretion of Engineer-In-Charge, the paint manufacturer must provide the expert technical
service at site as and when required. This service should be free of cost and without any obligation
to the OWNER, as it would be in the interest of the manufacturer to ensure that both surface
preparation and application are carried out as per their recommendations. The CONTRACTOR is
responsible to arrange the same.

12.9 Final inspection of finished coating shall consist of the following:

1) Coating dry film thickness check: DFT measurement shall be as per ISO 2808. Type II
electromagnetic gauges should be used for ferrous substrates. DFT gauge calibration, number of
measurement shall be as per SSPC-DA-2. Measured DFT shall be within + 10% of the dry film
thickness, specified in the specifications.

2) Adhesion testing: Adhesion of the primer to the steel substrate and inter-coat adhesion of the
subsequent coat(s) after curing for at least a week after application of the topcoat shall be
examined by a knife test in accordance with ASTM D6677. For the knife test, if the rating is
better than 8, the adhesion is considered acceptable. The adhesion is destructive and tested areas
shall be repaired afterward using the spot repair procedure. Alternatively, the applicator may
perform the adhesion test on a steel panel coated using the same surface preparation and coating
application procedure as the work piece. Adhesion testing shall be carried out for each
component at least once per 200 m2 of coated surface.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 137 OF 221

 3) Holiday detection check: Holiday testing shall be conducted in accordance with NACE
SP0188. For immersion services, 100% of coated area shall be inspected for holidays. For
atmospheric exposure, 10% of coated area which must include weld seams, corners and edges to
be holiday tested. Voltage at which test is to be carried out will depend upon DFT of coating
being tested and shall be as per NACE SP0188. Any holiday is unacceptable and should be
marked and repaired immediately.

The CONTRACTOR shall arrange for spot checking of paint materials for specific gravity, glow
time (ford cup) and spreading rate.

12.11 Final Inspection of coating system

A final inspection shall be conducted prior to the acceptance of the work. The coating
CONTRACTOR and the facility OWNER shall both be present and they shall sign an agreed
inspection report. Such reports shall include:
General
- Names of the coating CONTRACTOR and the responsible personnel
- Dates when work was performed

Coating Materials
- Information on coating materials being applied
- Condition of coating materials received
Environmental conditions
- Weather and ambient conditions
- Coating periods
Surface preparation
- Condition of surface before preparation
- Tools and methods used to prepare surface
- Condition of surface after preparation
Coating application
- Equipment used
- Mixing procedure prior to application
- Coating application techniques used
Testing
- Type and calibration of inspection instruments used
- Type of quality control tests performed, and results

13.0 GUARANTEE

The CONTRACTOR shall guarantee that the chemical and physical properties of paint materials
used are in accordance with the specifications contained herein/to be provided during execution
of work.

14.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR/SUB-CONTRACTOR

Painting CONTRACTOR who is awarded any job for EIL, Projects under this standard must have
necessary equipment, machinery, tools and tackles for surface preparation, paint application and
inspection. The CONTRACTOR must have qualified, trained and experienced surface preparator,
paint applicator, inspector and supervisors. The CONTRACTOR supervisor, inspector, surface

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 138 OF 221

 preparator and paint applicator must be conversant with the standards referred in this
specification.

15.0 QUALIFICATION/ACCEPTANCE CRITERIA FOR PAINT COATING SYSTEM

15.1 Pre-qualification of paint coating manufacturer and his products

Paint manufacturer meeting the following requirements shall be considered by the
CONTRACTOR for supply of the paint products.

- Manufacturer should have been in continuous business of paint coating formulation and
manufacturer for at least past 5 years.
- Manufacturer should posses past experience of supplying his products to hydrocarbon,
petrochemical, fertilizer. Chemical processing industry or offshore platforms in the past 5 years.
- Coating manufacturer should have supplied at least 10000 litre of an individual product to
hydrocarbon, petrochemical, fertilizer. Chemical processing industry or offshore platforms.
- The manufacturer’s manufacturing procedure & QA/QC system shall meet ISO 9001
requirements and preferably should posses ISO 14000 certificate.
- The Quality control set up should be manned by qualified paint technologists whose bio data
should be sent along with quality control organization chart.

CONTRACTOR shall procure the paint materials from the qualified manufacturer meeting above
requirements and after obtaining prequalification testing approval as per requirements mentioned
in clause 15.2 below.

Pre-Qualification Testing procedure:

The paint manufacturer engaged by the mechanical contractor shall carry out the tests in NABL
accredited Govt. laboratories like national test house (NTH) as a part of qualification. Paint
manufacturer shall provide the paint samples to laboratory for testing of the parameters
mentioned in Table-2 (typical characteristics) and Table-15 (tests on coating systems) of this
specification. The testing laboratory will confirm the compliance of the paint material with
respect to the acceptance criteria mentioned in the respective tables. Contractor shall furnish these
test certificates along with all necessary supporting documents/information to EIL site for
approval/ acceptance. The paint manufacturer will be qualified and approved by EIL site for
supply of paints after review/assessment of the submissions made by the contractor. Test
certificates which are more than 3 years old will not be considered. Paint manufacturers are
advised to carryout pre-qualification testing accordingly for paints supply to EIL projects.

TABLE-15: PRE-QUALIFICATION TESTING

SYSTEM REFERENCE CLAUSE TOTAL DFT μ

COATING SYSTEM
No. (from table-3 to 10) (min)
1. F-9+P6+F6B+F2 5.1 245
2. F12+F12+F12 5.4 60
3. F15+F15+F15 7.2.2 240
4. F16+F16 7.2.3 250
5. F17 8.10.1 375
6. F8+F8 8.8.1 200

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 139 OF 221

 7. F9+F7+F7+F7 7.2.1 365
8. F-20 8.5.1 1100
9. F6A+F6C+F6C 8.4.1 500
10. Inert Polymeric Matrix 7.3.1 250
11. F6A+F6A+F6A 8.3.1 300

FOR
DURATIO ACCEPTANCE
S. No. TEST SYSTEM
N CRITERIA
NUMBER
Cyclic Test
Shall pass.
Salt Spray : 72 hrs.
No chalking,
Drying in air : 16 hrs.
cracking, flaking,
1. UV-A340 nm weather meter: 80 hrs. 1 4200 hrs
blistering or
One cycle: 168 hrs.
peeling shall be
(25 cycles at 168 hrs. each cycle) (ASTM
observed.
D5894)
2. Chemical Resistance Test (ASTM D543)

2a. 10% & 40% NaOH 1000 hrs

2b. 5% H2SO4 168 hrs

3,5,8 & 11* Shall pass.
2c. Xylene 4 weeks No cracking,
2d. *H2SO4 4 weeks discoloration,
Acetone solution pH blistering, peeling
= 5.0 to 5.5 4 weeks or softening of
2e. Ethanol for system film shall be
11 4 weeks observed.
2f. Kerosene
2g. Sea water 2000 hrs

Immersion in DM/DI water @900 3,5 & 8 30 days No softening,

3.
(ASTM C868) blistering or film
damage.
Shall pass.
No chalking,
Resistance to DM water using water
4. 9 2000 hrs cracking, flaking,
immersion. (ASTM D870)
blistering or
peeling.

1 to 11
100% Humidity Test
5. (except 1440 hrs Shall pass
(ASTM D2247)
system-2 )

Shall pass the test.

Dry Heat Resistance Test
2&4 No peeling,
6. (ASTM D2485 method B at 540⁰ C for -
cracking,
system 2 and 550⁰ C for system 4)
blistering,

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 140 OF 221

 abnormal
discoloration or
loss of adhesion.

2,3,4 & 10

Thermal Shock Resistance Test; (For

5 cycles @ 30 minutes in furnace at 120 system-2,
Shall pass
7. ⁰ C and 15 minutes in water after testing to be -
quenching in water for each cycle. done after
(ASTM D2485 method A) heating the
panels at
175°C for 2
hrs.)
Cathodic Disbondment Test
8. 3&5 - Shall pass
(ASTM G8 @60°C)

Each coating product to be qualified shall be identified by the following

1) Specific gravity of Base and curing agent (Ref. ISO 2811)

2) Ash content (ASTM D1650), volatile and non-volatile matters (ISO 3251) of each
component

The identification shall be carried out on the batch, which is used for the Pre-qualification testing.

15.3 Information to be furnished during delivery of paint materials:

CONTRACTOR along with delivery of paint material has to furnish following information from
paint manufacturer to EIL for acceptance/approval of products:

a) Batch test certificates:

Along with paint products delivery to site from the pre-qualified coating manufacturer,
CONTRACTOR has to produce test certificate (from paint manufacturer)for each category
of product for the following test items. All test results must mention clearly the batch no.
and category of product tested. Tests to be conducted for following properties:

- Specific Gravity
- % solids by weight (% zinc content in case of inorganic or organic zinc primer)

b) Product information sheet/ technical data sheet for each category of product.

The contractor shall be fully responsible for the quality of the paints products as per
prequalification testing. After the paint materials are supplied to site, the supplier shall
organize random sampling and testing in a NABL laboratoryas per discretion of the
Engineer-in-charge. Failing to meet the specified quality requirements may cause rejection of
the paint products.

16.0 METHOD OF SAMPLING & DISPATCH FOR LABORATORY TESTING

(Pre-Qualification tests (sec. 15.2), Batch testing (sec. 15.3) and Inspection testing (sec. 12.0))

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 141 OF 221

16.1 Samples of coating materials should be submitted to the laboratory in sealed containers with
batch no. and test certificate on regular format of manufacturer’s testing laboratory.
16.2 All test panels should be prepared by testing laboratory. Surface preparation for a system shall
be done in accordance with this specification. For individual products testing, minimum shall be
Sa 2.5. Colour photographs of test panels should be taken before and after the test and should be
enclosed along with test report.
Sample batch no. and manufacturer’s test certificate should be enclosed along with the report.
Test report must contain details of observation and rusting if any, as per the testing code.
16.3 Manufacturers should intimate EIL, details of sample submitted for testing, name of testing
agency, date, and contact personnel of the testing agency.

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

TECHNICAL SPECIFICATION
CENTRIFUGAL PUMPS
(WATER SERVICE)

PROJECT : AIRPORT TERMINAL BUILDING

JOB NO. : B047

LOCATION : LEH

CLIENT : M/S AIRPORT AUTHORITY OF INDIA

PMC : ENGINEERS INDIA LIMITED

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

1.0 SCOPE

1.1 This specification outlines the minimum requirements for design, engineering,
manufacture, inspection, testing, painting, supply, erection, commissioning and
performance testing of Centrifugal Pumps (Water Service) complete with all accessories.

1.2 Specific requirements and guidelines pertaining to individual equipment and system are
listed in subsequent sections. However, the following general considerations have to be
kept in view for all items while formulating their specifications and procurement engineering
activities:

- Reliability in service (assessed from the Contractors' relevant track record and improved
by incorporating certain minimum design features or requirements inthe specifications).

- Compliance with applicable national or overseas codes and standards as well as any
statutory regulation in existence for a specific item.

- Ease of operation and maintenance including any necessary measures for ensuring
safety of personnel and equipment as well as a conducive working environment.

- Standardization of components wherever feasible.

- Adherence to any limitations of space available for the equipment and its
operation/maintenance.

- Facility for any known future expansion of plant capacity with a minimum of modifications
or shutdown.

- Equipment shall be designed for the given site condition.

- Piping, Electrical, Instrumentation and controls wherever applicable for the equipment
and packages shall be engineered as per the respective sections, described in the tender
document.

1.3 The CONTRACTOR shall develop technical specification of equipment taking into
consideration the requirements defined in specifications, data sheets and the requirements
given elsewhere in the tender document.

1.4 The Equipment shall be complete in all respects and any item or feature not covered in the
specification but essential for proper operation shall be included by the Contractor. Also the
plant shall conform in all respects to high standards of engineering design, state of art,
reliability and continuous operation.

1.5 Design, engineering, fabrication etc. should meet the specifications enclosed in the tender
document.

1.6 Compliance with this specification shall not relieve the vendor of the responsibility of
furnishing equipment and accessories/auxiliaries of proper design, materials and
workmanship to meet the specified start up and operating conditions.

1.7 The requirements of Noise Limits and Equipment Vibration as defined in this specification
shall be met. In general OSHA requirements shall be complied with.

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

2.0 DEFINITION OF TERMS

2.1 The Normal operating point is the point at which usual operation is expected.

2.2 The Rated operating point is the point at which the vendor certifies that performance is
within the tolerances stated in this specification.

2.3 Maximum allowable working pressure (MAWP) is the maximum continuous pressure for
which the manufacturer has designed the equipment (or any part to which the term is
referred) when the equipment is operating at the maximum allowable temperature.

2.4 Maximum allowable temperature is the maximum continuous temperature for which the
manufacturer has designed the equipment (or any part to which the term is referred) when
handling the specified liquid at the specified pressure.

2.5 Minimum continuous stable flow is the lowest flow at which the pump can operate
continuously without exceeding the noise and vibration limits imposed by this specification.

2.6 The Pressure casing is the composite of all stationary pressure containing parts of the unit,
including all nozzles, glands and other attached parts.

2.7 The Vendor means the manufacturer of the pump.

2.8 Net positive suction head (NPSH) is the total absolute suction head, in meters of liquid,
determined at the suction nozzle and referred to the datum elevation minus the vapour
pressure of the liquid in meters absolute. The datum elevation is the shaft centerline for
horizontal pumps, the suction nozzle centerline for vertical in-line pumps and the top of
foundation for other vertical pumps.

2.9 Net positive suction head available (NPSHA) is the NPSH in meters of liquid, determined
by purchaser for pumping system with the liquid at the rated flow and normal pumping
temperature.

2.10 Net positive suction head required (NPSHR) is the NPSH in meters, determined by vendor
testing with water. NPSHR is measured at the suction flange and corrected to the datum
elevation. NPSHR at rated and other capacities is equal to the NPSH that produces a 3
percent head drop (first stage head in multistage pumps) due to cavitation within the pump.

2.11 Minimum Submergence required is the liquid level with respect to pump suction flange face,
in millimeters, determined by the vendor when testing with water for vertical pumps. This is
the level required to prevent vortex formation/ingress of air/vapour into the pump suction
resulting in loss of flow/head.

3.0 SCOPE OF SUPPLY/ WORKS

3.1 Contractor’s Scope of supply shall pertain to the following equipment as per parameters
mentioned in Process Data Sheets:

3.1.1 Electrical Driven Fire Water Main Pump (Item No. 000-PA-101A/B)

3.1.2 Electrical Driven Fire Water Jockey Pump (Item No. 000-PA-CD-109 A/B, 110A/B)

3.1.3 Hydro-Pneumatic Pumping System for Hot Water Circulation Pump Raw Sewage Water Pump
(Item No. 000-PA-CD-106A/B)

3.1.4 Hydro-Pneumatic Pumping System for Domestic Water/ Flushing Water (Item No. 000-PA-CD-
104A/B/C & 000-PA-CA-105A/B/C)
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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

3.1.5 Non-Clog fully Submersible Sewage Water Pump (Item No. 000-PA-CD-109 A/B, 110A/B)

3.1.6 Non-Clog fully Submersible Waste Water Pump (Item No. 000-PA-CD-113A/B)

3.1.7 Diesel Engine Driven Fire Water Horizontal Centrifugal Pump (Item No. 000-PA-CD-103)

3.1.8 Each equipment shall be complete with:

a) Driver

b) Foundation/ Anchor bolts

c) Companion flanges for all piping interface with nuts, bolts, gaskets

d) Commissioning & start up spares

e) Special Tools & Tackles for operation & maintenance.

f) Any other item not mentioned but required for the satisfactory operation of the pump.

3.2 Contractor’s scope shall include complete supply, transportation of equipment package from
vendor’s shop to site, receipt of material at site, handling at site and arrangement for storage
at site as per the requirements indicated in the Tender document.

3.3 Contractor shall include all the commissioning spares as required in the equipment vendor’s
scope. Contractor shall procure the same from the equipment vendors and make it available
well before commissioning of plant/equipment.

3.4 Contractor shall include all special tools & tackles, as recommended by equipment vendor, in
the equipment vendor’s scope and the same shall form part of supply by Contractor.

3.5 Contractor shall note that consumables, lubricants etc. required during erection,
commissioning and performance guarantee run of Equipment such as first fill of lubricants etc.
shall be Contractor’s scope. A consolidated list for all equipment shall be provided indicating
type of lubricant, grease, oil etc. giving specifications, quantities, brand name and their Indian
equivalent.

3.6 Equipment, which is transported by sea, shall have sea-worthy packing. The Contractor shall
strictly follow the recommended preservation procedures during the period of storage for all
equipment.

3.7 Contractor shall carry out the erection of all equipment at the specified location on the properly
designed & cast foundation as per Bid document.

3.8 Contractor shall carry out the pre-commissioning and commissioning activity at site for all
Equipment.

3.9 Contractor shall ensure the presence of equipment manufacturer (Vendor) at site for
supervision of commissioning of all Equipment. Vendor shall also check that the equipment is
erected as per his recommendation prior to pre-commissioning.

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

4.0 BASIC DESIGN - PUMP

4.1 General

4.1.1 All pumps shall be sourced from approved vendors having adequate design, engineering,
packaging, manufacturing and testing facilities. Offered pump model shall be well proven
and within the manufacturing range of the vendor and shall not involve the use or application
of any prototype in design or components.

4.1.2 Pumps with constant speed drivers shall be capable of atleast 5 percent head increase at
rated condition and pump rated speed by replacing with a new impeller or impellers. Offered
impeller shall in no case be less than the minimum diameter impeller.

4.1.3 Horizontal pumps of the close-coupled, the two stage overhung, or the single stage double
suction overhung, type shall not be furnished.
4.1.4 Pumps where difference between NPSHA and NPSHR from quoted minimum flow to rated
flow is less than 1 meter (for pumps with driver rating <55KW) & 0.6 meter (for pumps with
driver rating >55KW) are not acceptable. The said NPSHR value shall correspond to the
maximum value of NPSHR from rated flow down to the recommended minimum stable flow
specified by the vendor.

4.1.5 Pumps that have stable head/capacity curves (continuous head rise to shut-off) are
preferred for all applications and are required when parallel operation is specified.

4.1.6 The pumps for parallel operation shall have characteristics suitable for capacity sharing.
The shut off head in such cases shall not be less than 110 percent of the rated head and
no more than 120 percent of the rated head in horizontal pumps and 140 percent in the
case of vertical turbine pumps.

4.1.7 The best efficiency point for the furnished impeller is preferred between the rated point and
the normal point. However in no case the rated point shall be beyond 110 percent of the
best efficiency point of the rated impeller.

4.1.8 The maximum permissible sound pressure level of the pump driver train shall not exceed
88 dBA measured at 1 meter from pump surface for the recommended range of operation.

4.1.9 For vertical pumps, not provided with non-reverse ratchet, vendor shall describe the
precaution taken, to prevent damage due to reverse rotation.

4.1.10 Pump-Driver train shall be designed to be suitable for outdoor installation without a roof.

4.1.11 Lifting lugs/eye hooks shall be provided for ease of lifting of complete pump as well as the
heavy maintenance components of the pump (e.g. Top half casing cover of axially split
pump).

4.1.12 The guaranteed parameters shall be demonstrated during shop test without any coating on
impellers or casings.

4.1.13 Pumps with variable speed drivers shall be capable of operating continuously upto 105
percent of rated speed as well as operating briefly upto driver trip speed.

4.1.14 Casing vents alongwith vent valves, as per manufacturer standards, for all pumps shall be
provided. For all horizontal pumps, casing drain with isolation valve and flanged piping
terminated at the skid edge shall be provided. Baseplate shall also be provided with flanged
drain connection.

4.2 Pressure Casing Design

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

4.2.1 Maximum allowable working pressure (MAWP) for all pressure containing parts e.g. casing,
bowl, discharge head, discharge pipe, column pipe, stuffing box etc. shall in no case be less
than the maximum discharge pressure produced by the pump at shut-off (including
tolerances), at the maximum suction pressure, for the maximum impeller diameter and the
maximum continuous speed.

4.2.2 MAWP shall also not be less than the specified downstream design pressure.

4.2.3 These pressure containing parts shall be suitable for hydrostatic test pressure of 11/2 times
the MAWP.

4.2.4 Note: MAWP shall not be less than 10 kg/cm2G for pumps with 125# flanges (i.e. with Cast
Iron casing) & 16 kg/cm2G for pumps with 150# flanges (i.e. with Carbon Steel or Alloy Steel
casing).
4.2.5 Pumps shall have suction and discharge flanges designed for same rating. Unless otherwise
stated, flanges shall be machined and drilled conforming to ANSI B16.5 standard.

4.2.6 Pumps shall be provided with Flanged nozzles.

4.2.7 Unless otherwise specified, all pumps shall be supplied with companion flanges with rating
conforming to applicable specification of ANSI, drilled and faced in accordance with pump
suction and discharge flanges along with gaskets and fasteners.

4.2.8 For pumps with casing material as cast iron (CI), the companion flanges shall be of slip-on
(SO) type [for flange sizes 50 mm (2 inches) & above] or socket welded (SW) type [for
flanges of size 15 mm (0.5 inches) to 40 mm (1.5 inches)] with flat face (FF) & of carbon
steel material. The gasket shall be of full face type.

4.2.9 For pumps with casing material other than cast iron, the companion flanges shall be of weld
neck (WN) type with raised face (RF) & of the material compatible with piping material.

4.3 Impeller, Shafts and Shaft Sleeves

4.3.1 Impellers shall be cast as one piece.

4.3.2 Shaft shall be provided with sleeves under the packing/seal and shall be locked to the shaft.

4.3.3 The material of sleeve shall be 12 percent chrome steel (hardened).Where the size of pump
makes the use of shaft sleeve impracticable, the shaft shall be constructed of 12 percent
chrome steel (hardened). For vertical pumps, shaft material shall be 12 percent chrome
steel.

4.4 Dynamics

The following vibration limits shall be applied at rated speed and at flow of ±10 percent of
rated flow.

4.4.1 Horizontal pumps

Unfiltered vibration velocity for horizontal pumps upto 3000 rpm with antifriction bearing or
sleeve bearings when measured at the bearing housing in horizontal or vertical direction
shall not exceed 4.0 mm/sec (0.16 inch/sec).

Bearing housings shall be suitable to permit measurement of vibration.

4.4.2 Vertical Pumps

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

Unfiltered vibration velocity for vertical pumps with antifriction and or sleeve bearings when
measured at the top bearing housing of pump or top bearing housing of motor or mounting
flange for measuring points upto 3 meters above the mounting base shall not exceed the
following limit:

Pumps greater than 1500 rpm = 7.0 mm/sec (0.28 inch/sec)

Pumps upto & including 1500 rpm = 5.1 mm/sec (0.20 inch/sec)

4.4.3 The vibration limits specified vide clause. 3.4.1 and 3.4.2 above shall be applied for pumps
only. The vibration limits for the drivers shall be as per their respective applicable standards.
Where respective applicable standards do not specify such limits for the associated drivers,
the driver manufacturer's recommendation shall be applied for acceptance of the driver.

4.5 Mechanical Seal/ Packing

4.5.1 Unless otherwise specified, the pump shall be supplied with packings. Stuffing box shall
have minimum five packing rings plus lantern ring. Packing ring size shall be 3/8" or larger.

4.5.2 The mechanical seal shall be of a make, duly approved by the purchaser.

4.5.3 All auxiliaries for flushing of mechanical seal shall be in vendor's scope of supply.

4.6 Bearings

4.6.1 Antifriction bearings shall be of standard type and shall meet minimum L-10 rating life of
either 25000 hours with continuous operation at rated conditions or 16000 hours at
maximum axial and radial loads and rated speed.

4.6.2 The rise in bearing grease/oil temperature with continuous running of the pump shall be
within the allowable limits which shall not exceed 30°C for grease and 39°C for oil lubricated
bearings above ambient. Cooling arrangements shall be provided if required. Bearings shall
be equipped with constant level oilers, vent breather & drain point for oil lubricated
arrangements.

4.6.3 Unless otherwise specified, for vertical pumps with open shaft, the intermediate bearings /
bushings shall be suitable for operation without any lubrication during start / shut-down or
during normal operation (i.e. bearing bush material shall be of self-lubricating type). Details
of line shaft bearings shall be furnished with the proposal.

4.6.4 Unless otherwise specified, for vertical pumps, thrust from the pump shall not be transferred
to the electric motor.

4.7 Materials

4.7.1 The material of construction of parts shall be as specified in Process Data Sheets. Vendor
shall furnish the equivalent material as per ASTM.

4.7.2 For impellers in cast iron or bronze construction, the tip speed shall be limited to 40
meters/sec. Unless otherwise specified, for tip speeds exceeding 40 meters/sec, the
material of impellers shall be stainless steel.

4.7.3 As an alternate, vendor may suggest suitable material proven for higher impeller tip speeds.

4.7.4 Unless otherwise specified in the data sheet, material test certificates (chemical and
mechanical properties) shall be supplied for impeller, shaft, shaft sleeve, wearing rings and
casings.
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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

4.7.5 The repair of pressure castings by peening, plugging, impregnating or by the use of plastic
or cement compound is prohibited. The Inspector's prior approval shall be obtained for the
repair of castings. When authorised, repair shall be carried out in accordance with applicable
ASTM Specification. Weld repair of pressure containing parts of Cast Iron construction is
not permitted.

4.8 Specific Requirements for Hydro-Pneumatic Systems

4.8.1 Hydro-Pneumatic pumping system shall be compact packaged type skid mounted, self-
contained variable frequency drive suitable for the specified service. The skid mounted,
factory assembled hydro-pneumatic system shall be provided
with pressure transmitters, frequency convertor for noiseless operation of the pump at
varying duty point. The convertor shall be provided with short circuit safety, earthing, over
current, under voltage protection. The pump shall be complete with suction and delivery
pipe. The system shall comprise of multiple pumps working and one stand-by to meet the
system discharge requirements.

4.8.2 It shall conform to the following specifications:

(i) Pumps shall be multistage centrifugal and fulfills all specifications as specified in the Clear
water pump section.

(ii) Pressure vessel shall be of non-corrosive FRP composite construction lined with NSF and
/or FDA listed material, like high density polyethylene with fully replaceable polyurethane.
Air cell burst pressure of minimum of five times the vessel operating pressure and cycle
tested for 80,000 cycles with charging connections to discharge pipe line with necessary
flanges, gaskets, isolating valve, nuts/ bolts etc. with suitable foundation bolts & other
accessories, complete. Capacity provided shall be as per manufacture specifications.

(iii) Panel mounted microprocessor multi pump controller with large graphical display and
variable frequency drive (VFD) mounted inside a panel complete with pressure sensor
transmitter. The graphical display is capable to show number of pumps running & also
communicate with other controllers following with open protocol. System should be capable
to compensate for frictional losses at lower flows. All alarms should be displayed in the
controller. The panel should also have provision for manual / automatic alternate (cyclic)
operation of pumps, ON/OFF switch, dry run protection, inter connecting power and control
cabling etc. complete.

4.8.3 Control Panel (For Hydro Pneumatic Systems)

(i) The control panel shall have terminals for:

 Remote monitoring.
 Pump fault.
 Analog output signal for frequency convertor
(In case of VFD operated Hydro-pneumatic systems).
 Pressure sensor / Pressure switches as per system requirement.

4.8.4 The hydro pneumatic system shall be capable of maintaining a constant pressure at varied
consumption. The hydro pneumatic system shall be complete with pressure sensor and
microprocessor based controller for flow control by means of frequency variation (in case of
VFD operated system). The controller should have time control switch to adapt pump
operation to actual requirement in peak load situation. The control panel should also have
manual operation.
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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

4.8.5 The pumping system shall perform the following functions:

 Shut off the pump at zero demand.

 Shut off the pump at zero suction(Dry Run protection)
 Protect the pump from overvoltage, under voltage, overload & earth fault.
 Vary the time of pump speed acceleration and deceleration
(For VFD operated Hydro pneumatic system).
 Compensate for higher friction losses at high flow rates.
 Send out a signal for remote monitoring of flow as well as pressure.
 Conduct automatic test run of pumps at set times.
 Keep track of run time for pumps.
 Perform run time equalization of all pumps in system.

4.8.6 Hydro pneumatic systems shall be mounted on a common base frame & installed as per
manufacturer's recommendations. Pump sets shall be mounted on machinery isolation cork
or any other equivalent vibration isolation fitting. The vibration isolation pads, foundation
bolts etc. shall be supplied by the Contractor. Contractor shall ensure that the foundation
bolts are correctly embedded.

Pump-sets shall be factory aligned, wherever necessary, site alignment shall be done by
competent persons. The entire system along with pumps & control panel must be sourced
from single manufacturer only for unit responsibility.

4.9 Non Clog Fully Submersible Waste Water/Sewage Water Pumps

4.9.1 Sump pump set shall be compact, mono-block, submersible type with non-clog free
flow open Bronze impellers, CI casing (Pump & Motor) and having solid handling capacity
of required size for lifting domestic sewage or muddy water/drainage as specified in
schedule of Quantities.

4.9.2 Pump shall inclusive of all necessary accessories like valves, piping, duck foot bend, lifting
arrangement of pull chain/ guide rail for the pump, dry running protection etc. as required.
The Contractor has to ensure for smooth and trouble free operation after the commissioning
of the entire system. Nothing shall be paid extra on this account. Below are the functions of
panel

4.9.3 All the working and standby pumps shall start/stop automatically and alternatively.

4.10 Pumps for Fire Water Application

Pumps for Fire Water Application shall also meet the following additional requirements:

4.10.1 Pumps shall meet the requirements of TAC (Tariff Advisory Committee), NFPA (National
Fire Protection Association) etc. as specified in the data sheet. The vendor shall also be
responsible for obtaining the necessary approvals as specified in inquiry.

4.10.2 Pumps shall be direct-coupled except in the case of engine-driven vertical turbine pumps
wherein gear drives shall be used. Belt driven pumps are not acceptable.

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

4.10.3 Parts of pumps like impeller, shaft sleeve, wearing ring etc. shall be of non-corrosive metal
preferably brass or bronze unless the quality of water dictates the use of special
metals/alloys which shall be insisted upon.

4.10.4 Pumps shall be capable of furnishing not less than 150 percent of rated capacity at a head
not less than 65 percent of the rated head.

4.10.5 Difference between NPSHA and NPSHR at 150 percent of the duty point shall not be less
than 0.6 meters.

4.10.6 The electrical motor shall be of continuous rating type and the rating shall be 110 percent
of the power at rated point or equal to maximum BKW rated impeller whichever is higher.

4.10.7 For Diesel engine drivers, the net continuous site power available after considering the
deration due to site condition and power losses, due to other parasitic loads and engine
driven auxiliaries shall be higher of the following two values:

(a) 20 percent in excess of the maximum BKW required to drive the pump at rated condition.

(b) Maximum BKW rated impeller as indicated by the manufacturer in the pump data sheets.

4.10.8 Trolley mounted electric driven Portable pump (as per manufacturer’s standard) of capacity
of at least 1 m3/hr along with flexible hose shall be provided along with diesel driven fire
water pump for filling of fuel tank. Portable pump vendor’s scope of supply shall include but
not limited to the following:
Fuel suction hose with filter (5m), fuel discharge hose (10m), quick connect coupling (fuel
suction/discharge), check valve fuel discharge side, shut-off valve (fuel discharge side).
Vendor shall note that adequate space for keeping the hoses to be provided on the trolley
or separate hose-reels to be provided & mounted on the trolley.

4.10.9 For operation & control philosophy of fire water Main pumps refer Schematic Diagram of
Fire Water System attached along with the Tender.

4.10.10 Engine cylinder cooling water shall be cooled through an external heat exchanger. The
schematic of the same is enclosed as per Annexure-A. Vendor shall refer the same for their
scope of supply. The diesel engine cooler shall be designed to the extent of shut-off head
of fire water pump.

4.10.11 The exhaust piping for diesel engine which shall consist of an exhaust silencer (residential
type), bellows, right angle bends, complete exhaust piping, required fittings (i.e. flanges,
bends, bolts/nuts, gaskets etc.), necessary supports, insulation material for the piping etc.
shall be supplied by the vendor. Flanges / companion flanges with nuts, bolts, gaskets (at
silencer & bellow etc.) shall also be provided by the vendor.

4.10.12 The exhaust piping shall be routed outside the firewater pump house and above the roof
top through the side-wall. Exhaust pipe shall suit to the requirements as per the fire water
pump house layout. Exhaust pipe shall be suitably insulated and cladded.

4.10.13 As a minimum, Diesel Engine driver for Fire water main pumps, along with auxiliary
equipment shall also conform to design requirements as specified in Clause no. 4.0 of this
Job spec.

5.0 BASIC DESIGN – DIESEL ENGINE

5.1 Diesel Engine shall be suitable to outdoor & unheated installation.

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

5.2 The Diesel Engine shall be vendor's standard model meeting the requirements as defined
in IS0:3046. It shall be 4 stroke cycles, water cooled, turbocharged (as per manufacturer
standard) suitable for delivering the power requirement of the driven equipment after
taking into consideration the transmission losses, site de- ration and power requirements of
auxiliaries and other parasitic loads.

5.3 Engine Manufacturer's de-ration calculations for the specified site conditions in duly
completed “Annexure-A “shall be furnished by the contractor post award. As a minimum,
the vendor shall consider the de- ration due to ambient temperature, altitude, relative
humidity, cooling water temperature, inlet and exhaust losses etc. De-ration factor shall
be worked out as per IS0:3046. In case, there is no de-ration for the specified site
conditions, the Engine Manufacturer's categorical statement along with proper technical
justification shall be furnished .

5.4 Standard reference conditions for diesel engine shall be as defined in ISO:3046-
1/ISO:8528-1.

5.5 No negative tolerance shall be allowed on the engine rating specified by the vendor/
contractor in the equipment datasheet.

5.6 Diesel Day Tank

Each engine shall have dedicated diesel storage day tank sized for 8 hours continuous
running of Diesel Engines at full load. The diesel day tank shall be kept outside the firewater
pump house, at suitable location to be decided during detail engineering. Diesel day tank
shall be supplied along with breathing valve, flame arrestor, vent, drain valve, inlet/outlet
connection, level gauge & level (low) alarm transmitter (as per Instrumentation spec.),
prefabricated vent pipe up to safe height and all connected pipes & fittings.

5.7 Engine Starting System

5.8 The engine shall be started through battery starting system. Independent batteries with
trickle charger for starting of diesel engine shall be supplied. For battery & battery charger,
refer Electrical Specs for details.

5.9 Cold Starting Aids

Cold starting aids (Cylinder jacket water heater and Lube oil heater) based on site ambient
temperatures shall be provided for the Diesel Engine. Vendor shall indicate such
requirement in their proposal.

5.10 Engine Cylinder Cooling/ Lube Oil Cooling

5.11 Engine cylinder cooling water shall be cooled through an external heat exchanger. The
schematic of the same is enclosed as per Annexure-A. Vendor shall refer the same for their
scope of supply. The diesel engine cooler shall be designed to the extent of shut-off head
of fire water pumps.

5.12 Exhaust System

5.13 The exhaust piping for diesel engine which shall consist of an exhaust silencer (residential
type), bellows, right angle bends, complete exhaust piping, required fittings (i.e. flanges,
bends, bolts/nuts, gaskets etc.), necessary supports, insulation material for the piping etc.
shall be supplied by the vendor. Flanges / companion flanges with nuts, bolts, gaskets (at
silencer & bellow etc.) shall also be provided by the vendor.

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

5.14 The exhaust piping shall be routed outside the firewater pump house and above the roof
top through the side-wall. Exhaust pipe shall suit to the requirements as per the fire water
pump house layout. Exhaust pipe shall be suitably insulated up to min. height of 3 m above
building height.

5.15 Noise And Exhaust Gas Emission

5.16 Any applicable legislation/ statutory requirements relating to the protection of environment
and to the health and safety of personnel, with regard to noise and exhaust gas emission,
as applicable to the place of installation shall be fully complied with by the Engine
manufacturer.

6.0 ACCESSORIES

6.1 Drivers

6.1.1 Electric motor drivers shall have a maximum continuous rating (MCR) (i.e. service factor
equal to 1) not lower than the following unless higher rating is dictated by the Note 1.

Motor Name plate Rating Motor MCR (% of Pump Rated BKW)

Less than 22 kW To suit maximum BKW indicated on pump data sheet or 125% of rated
pump BKW, whichever is higher.

22 kW - 55 kW 115% of rated pump BKW.

Higher than 55 kW 110% of rated pump BKW.

Note:

The motor namelpate rating for pumps under parallel operation shall not be less than the
max. BKW indicated on pump data sheet (the power at End of the curve for the rated
impeller) or shall have the specified margin as per this clause whichever is greater. The
pump motors shall also be suitable for start-up under open discharge valve condition.

6.2 Gears

6.2.1 Gear box shall be selected with a minimum of AGMA service factor of 1.75 over the driver
rating.

6.2.2 Wherever right angle gear box are required the same shall be supplied non-reversible
ratchet and shall allow for vertical adjustment of the impeller. Further the gearbox shall be
suitable for absorbing the maximum thrust under any case of operation.

6.3 Coupling

6.3.1 Unless otherwise specified, connection between pump and driver shall be made by a flexible
metallic coupling. A spacer (127 mm minimum normal length), shall be used to permit the
removal of coupling, bearings, seal and/or rotor as applicable without disturbing the driver,
the suction and discharge piping, or the casing top cover, for all horizontal pumps.

6.3.2 It shall be the responsibility of the pump vendor to obtain purchaser's approval for the
selected coupling, its make and rating.

6.3.3 However the coupling shall be rated using a service factor of not less than 1.25 for flexible
element coupling.
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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

6.3.4 Whether or not pump vendor is required to supply the driver, he shall still deliver the fully
machined coupling assembly along with the pump. The driver shaft dimensions and
tolerances shall be furnished by the Purchaser to the pump vendor.

6.3.5 Removable coupling guard shall be provided which shall be fabricated from non-sparking
material, and shall be open at the bottom to permit manual shaft rotation. The guard shall
be sufficiently rigid to withstand deflections as a result of bodily contact of nominally 100
kgs.

7.0 INSPECTION AND TESTING

7.1 General

7.1.1 Unless otherwise specified, all pumps shall be inspected and all tests shall be witnessed by
the Purchaser or by the Purchaser's authorised representative.

7.1.2 Purchaser's or their authorised representative shall have access to the plant including sub
vendors plants where work on or testing of equipment is being performed.

7.1.3 No surfaces of parts of pumps are to be painted until the inspection is completed.

7.1.4 Vendor shall give to the purchaser atleast 15 days’ notice prior to commencement of testing.

7.1.5 Vendor shall carry out all running tests and mechanical checks and satisfy himself prior to
purchaser's arrival for inspection and shall maintain desired log of tests.

7.1.6 Acceptance of shop test shall not constitute a waiver of requirement to supply equipment
as per specification and/or to meet field test under operating condition, nor does inspection
relieve the manufacturer of his responsibility in any way whatsoever.

7.2 Tests

The basic reference standard shall be the latest edition of Hydraulic Institute Standard or
IS:5120.

7.2.1 Hydrostatic Test

(i) Pressure casings including column pipe and discharge head shall be hydrostatically tested
with water at ambient temperature at 11/2 times the maximum allowable working pressure
specified in the data sheet.

(ii) Jackets for bearing, stuffing box, coolers, etc, shall be tested at 8 Kg/cm2g or 11/2 times
the maximum allowable jacket working pressure whichever is higher.

(iii) Hydrostatic test shall be maintained for a minimum period of 30 minutes.As a minimum
following tests shall be performed.

(iv) Hydrostatic test is under non-witness category & only review of manufacturer's shop test
reports is required.

7.2.2 Performance Test

(i) Performance test for Horizontal pumps for General Water Services GWS shall be carried
out as per following:-

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

Pumps with drivers upto 55KW Non witnessed. Only review of manufacturer's
shop test reports are required
Pumps with drivers from 55KW to One pump per tag/item no. to be witnessed
160KW
Pumps with drivers above 160 All pump units in an item to be witnessed
KW

However, in case of vertical pumps, all pumps in a tag needs to undergo witnessed
performance test.

(ii) Unless specifically agreed upon, pump shall be tested at the rated speed specified in the
data sheet with calibrated motors, at least for four hours. During the four hour run test,
complete data including pressure, capacity, power, vibration levels, bearing temperatures
and noise levels shall be recorded and guaranteed parameters verified.

(iii) Prior to start of test, manufacturer shall furnish the certificate of latest calibration /
recalibration of driver and measuring instruments. Unless electrical or mechanical failure
occurs, driver used for shop testing need not be recalibrated and original calibration
certificate shall remain valid. Duration of recalibration for all measuring instruments shall be
as per the recommendations of HI Standards and/or relevant standards of the country of
origin of the pump manufacturer.

(iv) The pump shall be tested with water at ambient temperature. Suitable rust inhibitor shall be
added in the water used during any internal testing / performance testing of the pumps, to
prevent rusting of pump internals.

Rated head : Zero negative tolerance.

Shut-off head : Positive tolerance permitted so long as it does not exceed

downstream design pressure. Negative tolerance permitted
so long as the curve is continuously rising to shut off without
any drooping & min 110% head rise to shut off shall be
available for pumps in parallel operation.

NPSH(r)/ Min Submergence

Reqd. : Zero Positive Tolerance

Rated BKW : Zero positive tolerance (However pumps may be accepted

upto 104 percent of Guaranteed BKW subject to Penalties as
defined elsewhere)

At least four to six values between duty point and shut off and two values on the right of
duty point including one point with discharge valve fully open, shall be measured and
recorded during tests. All the instruments used for conducting the tests shall be calibrated
before tests and calibration certificates furnished from a recognised testing institution to the
Inspector.

(v) For fire water application all engine driven horizontal and vertical pumps shall be subjected
to a 4 hour complete unit string test at the pump vendor's works during which mechanical
performance of the train shall be verified, in terms of vibration, bearing/oil temperature,
engine parameters and controls.

In case multiple units are ordered, only one number of diesel engine and gear box unit (if
used) may be brought to the pump vendor shop for complete unit (string) test for the fire
water pump unit. For the remaining pumps, complete unit (string) need not be done.

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

However, any modification required to be done on the first unit shall be uniformly done on
the remaining units also for proper unitization of the same at site.

7.2.3 NPSH Test/ Min. Submergence Test

Unless otherwise specified, NPSH test for Horizontal pumps for General Water Services
(GWS) shall be carried out as per following:

For pumps with driver rating upto 55KW Not Applicable

For pumps with driver rating between One pump tag/item to be witnessed
55KW to 160KW
For pumps with driver rating above All pump units to undergo witness test
160KW

Additionally, in case of vertical pumps, all pumps in a tag needs to undergo minimum
submergence test in addition to NPSH test.

7.2.4 Vibration Measurement

During performance test vibration shall be measured on the bearing housing for the capacity
ange of ±10 percent of rated capacity.

7.2.5 Dismantle Pump

Dismantle Inspection of pump after performance test shall be applicable only in case of
abnormality in mechanical behaviour (such as excessive noise & vibration, bearing
temperature rise etc.) during performance test.

7.2.6 Final Inspection

After the performance/dismantle test the pump and the job driver shall be unitised on the
job base plate, aligned and coupled to make a complete unit. The pump will then be checked
for visual inspection to confirm compliance to the GA drawings, nozzle dimension,
elevations, anchor bold position, direction of rotation etc.

7.3 If it is necessary to dismantle a pump after the performance test for the sole purpose of
machining impellers to meet the tolerances for differential head, no re-test will be required
unless the reduction in diameter exceeds 5 percent of the original diameter. The diameter
of the impeller at the time of shop test, as well as the final diameter of the impeller, shall be
recorded on a certified shop test curve that shows the operating characteristics after the
diameter of the impeller has been reduced.

7.4 If it is necessary to dismantle a pump for some other correction, such as improvement of
power, NPSH, or mechanical operation, the initial test will not be acceptable, and the final
performance test shall be run after the correction is made.

8.0 PACKAGING AND IDENTIFICATION

8.1.1 All packaging shall be done in such a manner as to reduce the volume. The equipment shall
be dismantled into major components, suitable for shipment and shall be properly packed
to provide adequate protection during shipment. All assemblies shall be properly match
marked for site erection.

8.1.2 Attachments, spare parts of the equipment and small items shall be packed separately in
wooden-cases. Each item shall be appropriately tagged with identification of main
equipment, item denomination and reference number of the respective assembly drawing.

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

8.1.3 Detailed packing list in water-proof envelope shall be inserted in the package together with
equipment.

8.1.4 Each equipment shall have an identification plate giving salient equipment data, make, year
of manufacture, equipment number, name of manufacturer etc.

8.1.5 Equipment Vendor shall furnish procedure for prolonged site storage of supplied
equipment/material.

9.0 SPARE PARTS

Contractor shall supply commissioning spares sufficient for trouble free commissioning of the
system at site. Any commissioning spares required during commissioning, over and above,
the commissioning spares supplied, shall be made available by the contractor without any
cost and time implication to purchaser. Any unused commissioning spares shall be handed
over to owner.

10.0 SPECIAL TOOLS/ TACKLES

Special tools & tackles (as recommended by equipment manufacturer) shall form part of the
supply of main equipment. As per equipment manufacturer’s recommendations, special
tools and tackles shall be supplied along with the main equipment.

11.0 VENDOR DATA REQUIREMENTS

The following drawings/documents marked “√” shall be furnished by the contractor post
award:

Sr. DESCRIPTION POST ORDER REMARKS

No. FOR FOR WITH
REVIEW RECORD DATA
BOOK
( FINAL )
1.0 General Arrangement & foundation √ √
drawing showing arrangement of main
equipment skid as well as associated
equipment( pump, motor, pulsation
dampeners, calibration pot, etc.) along
with interface connections, etc. as well
as details of foundation bolt pocket
dimensions, foundation load data (
static & dynamic ), recommended grout
thickness.
2.0 Data sheets along with performance √ √
curves- centrifugal Pump
3.0 List of recommended commissioning √ √
spares( indication exact name of the
part, part no. and material of
construction )
4.0 List of Special Tools & Tackles √ √
5.0 Quality assurance Plan √ √
6.0 Test certificates – Mechanical √ √
Performance Test Reports
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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

7.0 Performance Guarantee Test √ √

Procedure as applicable
8.0 Test Certificates – Material test √ √
certificates, Hydrotest reports
9.0 As Built drawings √

Notes:

1. Tick denotes applicability.

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

Annexure-A

SCHEMATIC FOR SECONDARY COOLING WATER SYSTEM

PUMP DISCHARGE NOZZLE

V1 PRV V1
NRV
S
O

V2

Note-6

TG PG
TO DRAIN ENGINE HEAT
EXCHANGER

TG
TG
TG

(Engine CW in/out)
LEGEND:
NRV  Non-Return Valve
V1  Isolation Valve (Gate type)
V2  Bypass Valve (Globe type)
S  Strainer (Y or T type) [Y type: upto 1.5”; T type: above 1.5”]
PRV  Pressure Regulating Valve
PG  Pressure Indicator / Gauge
TG  Temperature Indicator / Gauge

NOTES:
1. The above system shall be in pump vendor’s scope.
2. Velocity head at the outlet of the heat exchanger shall be sufficient for water to travel back to drain.
3. Vendor shall indicate the expected temperature & flow rate of the drain water in the secondary circuit, in the proposal.
4. Material of construction of all the wetted components including piping, fittings (including valves) shall be of Carbon
Steel. As a minimum following spec to be followed:
Piping (0.5”~2”)  Material: ASTM A 106 Gr. B (Sch. 160 for size upto 0.75”and Sch. XS for pipe size 2”)
Flanges (0.5”~1.5”)  WN; ANSI B16.5; Sch.: M; Material: A105; 150#, RF, 125 AARH
Flanges (2”~24”)  SO; ANSI B16.5; Material: A105; 150#, RF, 125 AARH
Fittings (0.5”~1.5”)  Material: A105; SW
Fittings (2”~6”)  Material: A234; BW; Sch.: STD
Valves (0.25”~1.5”)  Material: Body – A105, Trim: 13% Chr. Steel
Valves (2”~24”)  Material: Body – A216 Gr. WCB, Trim: 13% Chr. Steel
Gaskets (0.5”~24”)  Material: Non-asbestos BS7531 GR X; B-16.21-ANSI B16.5
Strainer (0.5”~1.5”)  Material: A105; SW; INT – SS 304
Strainer (2”~6”)  Material: A234 Gr. WPB; BW; INT – SS 304
5. To protect secondary CW Heat Exchanger (PRV failure case), a suitable PSV shall be provided.

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 DOCUMENT NO. B047-000-80-43-SP-0005 Rev A

Annexure-B:

SIZING OF DIESEL ENGINE

1. ISO Standard Power (as per ISO 3046-1) of the engine, [obtained after deducting power loss due to
essential dependent auxiliaries (Refer Note-1)]
Piso : kW

2. Deration on account of site conditions (refer specification / datasheet for ambient conditions) as per
ISO 3046-1

Temperature (around the engine) : % or kW

Altitude (d1) : % or kW
Humidity (d2) : % or kW
CW temp (d3) : % or kW
Inlet losses (d4) : % or kW
Exhaust back pressure (d5) : % or kW

Total Deration (Pderation = d1+d2+d3+d4+d5) : kW

3. Service Power (as per ISO 3046-1) of the Engine (i.e. at stated conditions @ rated RPM)
Service Power = Minimum Continuous Site Power Availability from diesel engine
Pservice = Piso - Pderation : kW

4a. 120% of Pump rated BKW : kW

4b. Pump maximum BKW @ rated impeller : kW
4c. Max. [4a, 4b] (Pload) : kW

5. Other transmission losses due to coupling etc. (PTrans2) : % or kW

6. Power consumed by independent auxiliaries (Paux) : kW

[As applicable]

7. Any other power loss applicable to the Diesel engine (Pmisc) : % or kW

8. Actual Power Required from Engine (Pactual)

Pactual = Pload + PTrans1 + PTrans2 + Paux + Pmisc : kW

Bidder shall ensure that Pservice > Pactual and shall furnish calculations / supporting documents.

Note: As per Annex-A of ISO-3046-1, the following describes the typical list of auxiliaries:

1. Essential dependent auxiliaries (as applicable)

a) engine-driven LO pressure pump; b) engine-driven LO scavenge pump for dry-sump engines;
c) engine-driven engine-cooling water pump; d) engine-driven raw-water pump;
e) engine-driven radiator-cooling fan; f) engine-driven engine-cooling fan for air-cooled engines;
g) engine-driven gaseous fuel compressor; h) engine-driven fuel-feed pump;
i) engine-driven fuel-pressure pump for common rail or servo-injection system;
j) engine-driven scavenge-air blower and/or charge-air blower;
k) engine-driven generator, air compressor or hydraulic pump when supplying power to items in list A.2 G of ISO 3046-1;
l) engine-driven cylinder lubricating pump; m) air cleaner or air silencer (normal or special);
n) Exhaust silencer (normal or special).

2. Essential independent auxiliaries (as applicable)

a) Separately driven auxiliaries as defined above from S. No. 1(a) to 1(l).
b) Governing or control system using power from an external source.

3. Non-essential dependent auxiliaries (as applicable)

a) engine-driven starting air compressor;
b) engine-driven generator, air compressor or hydraulic pump when supplying power to items not shown in list A.2 G of ISO 3046-1;
c) engine-driven bilge pump; d) engine-driven fire pump;
e) engine-driven ventilation fan; f) engine-driven fuel-transfer pump;
g) engine-integral thrust bearing.

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 CENTRIFUGAL PUMP
(HORIZONTAL- GENERAL Document No.
WATER SERVICE) B047-000-80-43-DS-0011
(TYPICAL) Rev. No. A
Page 1 of 2
1 GENERAL
2 Project: NEW DOMESTIC AIRPORT TERMINAL BUILDING, LEH Job No.: B047
3 Owner: AIRPORT AUTHORITY OF INDIA Site: LEH, J&K

4 Purchaser: Unit: Unit No:

5 Item No.: Service:
6 No. Reqd.: Working: Standby: Parallel Operation Required:  Yes  No
7 Applicable to  Proposal  Purchase  As Built
8  Scope option & Information specified by purchaser  Information Reqd. from & option left to vendor. Vendor to cross  the selected option.
9 Driver: Working Standby Driver Supplied & Mounted By:  Pump Mfr.  Other
10 OPERATING CONDITIONS (Refer Process Package)
11 Liquid Handled Capacity (m3/hr): Min/Nor/Rated:
12 Pumping Temp. (C): Normal Max. Discharge Pressure (kg/cm²,A):
13 Specific Gravity at P.T./15C: Suction Pressure: Nor./ Max. (kg/cm²,A):
14 Vapour Pressure at P.T. (kg/cm²,A): Diff. Pressure (kg/cm²) @ Rated Capacity:
15 Viscosity at P.T. (cP/cst): Corr./Eros. By: Diff. Head (m) @ Rated Capacity:
16 Solids in suspension  Yes  No Size: % NPSH Available (m):
17 MANUFACTURERS SPECIFICATIONS
18 Pump Manufacturer: Model No.:
19 CONSTRUCTION PERFORMANCE
20 Casing Mounting:  Centerline  Foot  Inline Proposal Curve No.
21 Casing Split:  Axial  Radial Visc. Corr. Factor: C CQ CH
22 Type:  Single Volute  Double Volute  Diffuser NPSH Reqd. (Water) (m): F/L Speed (rpm):
23 Casing Connection:  Vent  Drain  Gauge No. of stages: Efficiency (%):
24 Nozzles Size ANSI Rating Facing Position Rated BKW(0% Tol.): kW Max.BKW rtd. Imp.: kW
25 Suction BKW @ MCF(=1.0): kW Rec. Driver Rating: (kW) kW
26 Discharge Max.head rtd imp.(m): Cap@ BEP(m3/hr):
27 Imp.  (mm) Max: Rated: Min: Type: Closed / Semi open MCF (m3/hr):Stable Thermal
28 Brg.: Type/No. Radial: Thrust: Lub: Oil M.A.W.P @ 15 C/P.T./Design Temp.(kg/cm²,G):


29 Cplg.:Make/Type: Nonspark Guard  Yes  No Hydrostatic Test pressure (kg/cm²,G):

30 Driver Half cplg. mounted by:  Pump Mfr.  Others Rotation facing coupling end:  CW  CCW
31 Packing Type: Size: No. of rings: Seal flush/ Quench plan: Material:
32 Mech. Seal: Make Model: API Code: Ext. seal flush fluid: LPM: @ Kg/cm²G/ C
33 Base Plate Drain Rim Type :  Yes  No Fdn. Bolts:  Yes  No Seal Barrier fluid: LPM: @ Kg/cm²G/ C
34 Throat Bush:  Yes   No NoMatl.: Bal. Device:  Yes  No Ext. quench fluid: LPM: @ Kg/cm²G/ C

35 Materials (API-610 Matl. Class): (Rem.4) MOC ASTM Grades C.W. Plan : LPM: @ Kg/cm²G/ C
36 I - Cast Iron (Ductile) Casing Weight(kg): Pump+Base+Coupling: Driver:
37 B – Bronze Impeller AUXILIARY PIPING INTERFACE CONNECTIONS
38 S - Carbon Steel Inner Case parts (All interface conn.shall
(All interface betermntd.with
conn.shall be termntd.with a f/l.
a flng. block
block valve)
valves)

39 C - 11-13% Chr. Stl. Sleeve Packed Size Rating(ANSI) Facing

40 h – Hardened Sleeve Seal Lantern Ring Inlet/Outlet
41 f – Faced Casing ring H-BHN Ext. Seal flush fluid Inlet/Outlet
42 K -SS 304 Impeller ring 50(min) Seal Quench fluid Inlet
43 L -SS 316 Shaft Seal pot vent/ drain
44 X - AISI 410 Throttle Bush Casing vent/ drain
45 Y Throat Bush C.W Inlet/ Outlet
46 Z Balance Drum Base plate drain (only flanged)
47  Driver suitable for Pump starting with open Disc. Valve condition. Casing steam jacket

48 INSPECTION & TESTS (EACH PUMP) (Also refer respective ITP)

49 Witness Observe Witness Observe
50  Shop Test / Inspection    NPSH As Reqd.  Per Spec.  Mandatory  
51  Material Certificates    Dismantle Insp. & Re-assembly after Test (Rem. 6)  
52  Hydrostatic    Visual, dimension and skid completeness check  
53  Performance/Sound Level (Rem. 5)    Check for direction of rotation of pump.  
54 Applicable Specification: Job Specifications.
55 REMARKS:- 1) Max. allowable casing working pressure shall not be less than ________ kg/cm²g @ ___ C.
56 2) Down Stream Design Pressure is __ kg/cm²g. Maximum shut-off, considering max suction pressure, including all tolerances shall not exceed this value.
57 3) Accessories and Instrumentation shall be as per EIL approved vendors only.
58 4) MOC shall be as specified in process data sheet.
59 5) For Horizontal centrifugal pumps with driver rating up to 55kW, no witnessing of mechanical run test, NPSH test (as applicable) &
60 performance test is required at vendor’s shop – Reviewing of manufacturer’s shop test reports shall be considered as adequate.
61 For Horizontal Centrifugal pump above 55kW and upto 160 kW, witnessing of mechanical run test, performance test and NPSH test (as
62 applicable) shall be limited to 1/Tag. - Reviewing of manufacturer’s shop test reports shall be considered enough for balance units.
VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 162 OF 221
Format No. 1645-DS-101 Rev. 0 Copyrights EIL – All rights reserved
 CENTRIFUGAL PUMP
(HORIZONTAL- GENERAL Document No.
WATER SERVICE) B047-000-80-43-DS-0011
(TYPICAL) Rev. No. A
Page 2 of 2
63 Balance units.
64 6) Dismantle Inspection of pump after performance test shall be applicable only in case of abnormality in mechanical behavior (such
65 as excessive noise & vibration, bearing temperature rise, etc.) during performance test.
66 7) This is typical datasheet. Contractor shall fill the datasheet for each items separately for preparation of enquiry documents and
67 Owner/PMC’s approval.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 163 OF 221

Format No. 1645-DS-101 Rev. 0 Copyrights EIL – All rights reserved
 EXPERIENCE RECORD PROFORMA Document No.
CENTRIFUGAL PUMP (HORIZONTAL) B047-000-80-43-PTR-0004
Rev. No. A
Page 1 of 4

EXPERIENCE RECORD - CENTRIFUGAL PUMP (HORIZONTAL)

SERVICE :

ITEM NUMBER. :

VENDOR. :

INSTRUCTIONS TO BIDDERS :
1. This proforma duly filled in shall be submitted for each item separately after award of contract.
2. Since the information requested in this proforma will be utilised to assess provenness of offered model, it is in the interest of the equipment
manufacturer to pick up those cases out of total list of references which most closely match with the offered model. The equipment manufacturer
shall also ensure that each & every information asked for is furnished and the same is correct and complete in all respects.
3. While furnishing the materials, where asked for, the equipment manufacturer shall furnish ASTM equivalents also.
4. For the referred installations, the equipment manufacturer shall indicate the name of the person (alongwith his address, telephone no., fax
no./email-id etc.) who may be contacted by the Purchaser / his representative, if felt necessary.
5. The equipment manufacturer shall also furnish along with the bid his standard reference list for the offered equipment model manufactured and
supplied by him.
6. The equipment manufacturer shall clarify the meaning of each letter / digit used in the model designation below:

Description of Model designation system:

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 164 OF 221

 EXPERIENCE RECORD PROFORMA Document No.
CENTRIFUGAL PUMP (HORIZONTAL) B047-000-80-43-PTR-0004
Rev. No. A
Page 2 of 4

SL. PARAMETER INFORMATION ON INFORMATION ON REFERRED EXISTING INSTALLATIONS REMARKS

NO. PROPOSED MODEL
Ref.- 1 Ref.-2 Ref.-3
1. 2. 3. 4. 5. 6. 7.
1 GENERAL
1.1 Cross reference to manufacturer's Standard Reference list ----
1.2 Make
1.3 Model Number
1.4 Number of units supplied
1.5 Type of driver
(Electric Motor / Steam Turbine / Gas Turbine / IC Engine)
1.6 Driver rated kW / Speed(rpm)
1.7 Drive
(Fixed Speed / Variable Speed / Variable Frequency)
1.8 Shop where pump is designed, manufactured, packaged,
tested & supplied with address

2 OPERATING CONDITIONS
2.1 Fluid handled
2.2 Fluid temperature (Min / Max) C
2.3 Capacity (m3/hr)
2.4 Maximum Suction pressure (kg/cm²,a)
2.5 Differential Head, Rated (m)
2.6 Differential Pressure, Rated (kg/cm²)
2.7 NPSHR (m)
2.8 Efficiency
2.9 BKW, Rated
2.10 Minimum Continuous Stable Flow, (m 3/hr)
2.11 Rated Speed
2.12 Speed range for variable speed drive
VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 165 OF 221
 EXPERIENCE RECORD PROFORMA Document No.
CENTRIFUGAL PUMP (HORIZONTAL) B047-000-80-43-PTR-0004
Rev. No. A
Page 3 of 4

SL. PARAMETER INFORMATION ON INFORMATION ON REFERRED EXISTING INSTALLATIONS REMARKS

NO. PROPOSED MODEL
Ref.- 1 Ref.-2 Ref.-3
1. 2. 3. 4. 5. 6. 7.
2.13 MAWP casing (kg/cm²G)
@ 15C
@ pumping temperature
3 CONSTRUCTION
3.1 No. of stages (single / two)
3.2 Casing split (Axial / Radial)
3.3 Impeller diameter - Rated/ Maximum / Minimum (mm)
3.4 Whether the proposed model and reference models have
identical hydraulic design (for impeller / diffuser / volute)
3.5 Sealing Element (packing / mechanical seal)
3.6 Type of mechanical seal (Single / Double)
3.7 API Sealing Plan No.
3.8 API Cooling Plan

4 MATERIAL OF CONSTRUCTION
4.1 API - 610 Material Code
4.2 Casing
4.3 Impellers
4.4 Shaft
5 OTHER INFORMATION ON INSTALLATIONS
5.1 Date of supply of entire unit
5.2 Date of commissioning of entire unit
5.3 No. of operating hours completed as on the date of issue of
material requisition

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 166 OF 221

 EXPERIENCE RECORD PROFORMA Document No.
CENTRIFUGAL PUMP (HORIZONTAL) B047-000-80-43-PTR-0004
Rev. No. A
Page 4 of 4

SL. PARAMETER INFORMATION ON INFORMATION ON REFERRED EXISTING INSTALLATIONS REMARKS

NO. PROPOSED MODEL
Ref.- 1 Ref.-2 Ref.-3
1. 2. 3. 4. 5. 6. 7.
5.4 Major Problems encountered

5.5 Name of plant

5.6 Purchaser's Name and Address
Name (Company / Organization)
Name of Contact Person
Address

Telephone No.
Fax No.
email-id

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 167 OF 221

 SCOPE OF WORK AND SUPPLY
(ARCHITECTURAL)

TENDER: COMPOSITE WORKS FOR LEH AIRPORT

PROJECT : Construction of New Domestic Terminal Building

and associated works at Leh Airport, J&K”

OWNER : AIRPORT AUTHORITY OF INDIA (AAI)

Document No. : B047-000-81-41- SOW-8001 Rev. A

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 168 OF 221

 TABLE OF CONTENTS

1.0 SCOPE OF WORK

1.1 BROAD SCOPE OF WORK
1.2 DETAIL SCOPE OF WORK
2.0 SCOPE OF SUPPLY
2.1 OWNER’S SCOPE OF SUPPLY
2.2 CONTRACTOR’S SCOPE OF SUPPLY
3.0 LIST OF ATTACHMENTS
3.1 SPECIFICATIONS
3.2 STANDARDS
3.3 DRAWINGS
3.4 SCHEDULE OF RATES
4.0 PREAMBLE TO SCHEDULE OF QUANTITIES

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 169 OF 221

1.0 SCOPE OF WORK (ARCHITECTURAL)

1.1 Broad scope of work

The broad scope of work of the Contractor shall be execution of Architectural works
for Buildings or Sheds or Structures in accordance with detail scope of work,
construction drawings, standards, specifications, schedule of quantities/ rates,
contract provisions and as directed by Engineer-In- Charge including :
- Supply and provision of materials, labour, tools, tackles etc.
- Preparation and submission of fabrication or installation or execution drawings.
- Assistance for obtaining approvals from statutory or other Authorities.
- Co-ordination with other Contractors and agencies, Owner, Project Management
Consultant (PMC) etc.
- Preparation and submission of “As-built” drawings.
- Any other incidental works not specifically mentioned but required for completion
of the work.

1.2 Detail scope of work

1.2.1 Buildings or Sheds or Structures

Scope of work of the Contractor shall include (but not limited to) the following
Buildings or Sheds or Structures.

No. Building/ Shed/ Structure Structure type, Number Number

of floors etc.
1 Terminal Building Pre-engineered 1
structure.
2 Utility building including RCC frame, block wall 1
underground service tunnel (Basement, ground +1
connecting utility and terminal floor)
building
3 Gate house RCC frame, block wall 1
(Single storey)
4 Driver rest room, police out post RCC frame, block wall 1
(Single storey)
5 Boundary wall RCC frame, block wall

Buildings listed in clause 1.2.1 above are not exhaustive. Requirement of

buildings shall also include:

Any other building/ buildings indicated in Plot plan, scope of work &
specification etc. of other disciplines to meet the Operational, Maintenance,
HSE (Health, safety & Environmental) and statutory Requirements.

1.2.2 Architectural works

Architectural works in the scope of work of Contractor shall include

Architectural elements and finishes such as (but not limited to) Floor finishing,
Wood work, Doors & Windows, Plastering, Pointing, Painting, Polishing,
Insulated Roofing system, Waterproofing, Sanitary fittings & fixtures,

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 170 OF 221

 Insulation, Partition, False ceiling, False flooring, External façade system,
External & internal claddings, interior works, art installations, sculptures,
landscaping, signges, interior furniture etc. as applicable.

1.2.3 Supply and provision of materials, labour, tools, tackles etc.

Unless otherwise specifically mentioned, supply and provision (including

procurement, transportation, storage, fabrication, installation and execution
etc.) of all materials and products (consumables and non-consumables),
labour, tools, tackles, equipment, plant machinery, staging, scaffolding, HSE
(Health, safety, environment) gear etc as required for completion of work is
included in the scope of work of the Contractor.

1.2.4 Preparation and submission of fabrication or installation or execution

drawings

Preparation and submission of fabrication or installation or execution

drawings of roofing system, Façade system, Cladding system, Doors and
Windows, False flooring, False ceiling, Partitions etc. as applicable is included
in the scope of work of the Contractor. Installation or execution of the works
shall be in accordance with approved drawings.

1.2.5 Assistance for obtaining approvals from statutory or other Authorities

Contractor shall assist AAI or PMC or Engineer-In-Charge and do necessary

liaison activities as required for obtaining approvals from statutory or other
Authorities such as
1. Department of Fire & Emergency Services
2. Air Force.
3. Local Panchayet, Municipal, Development Authorities as applicable.
4. Any other Authority having jurisdiction.

Note: the above list is not exhaustive.

1.2.6 Co-ordination

Contractor shall do all required co-ordination activities with other Contractors

and agencies, Owner, Project Management Consultant (PMC) etc for smooth,
sequential and complete execution works.

1.2.7 Preparation and submission of “As-built” drawings

Contractor shall prepare “As-built” mark-up prints on construction drawings

and subsequently update the same in soft copy (Auto CAD) of the drawings.
Contractor shall submit hard copy and soft copy to Engineer-in-charge as
specified elsewhere in the Tender document.

1.2.8 Incidental works

Any other incidental works such as cleaning, cutting chases or holes, making
good of the damaged works, protection of works, handing over the works in
acceptable condition, which are not specifically mentioned but required for
completion of work are also included in the scope of work of Contractor.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 171 OF 221

2.0 SCOPE OF SUPPLY
2.1 Owner’s scope of supply
- Nil
2.2 Contractor’s scope of supply
- Refer clause 1.2.3 above

3.0 LIST OF ATTACHMENTS

3.1 Specifications

S.No. Specification No. of

Rev. Title
No. Sheets
1 CPWD Specifications-Volume-1
2 CPWD Specifications-Volume-2
3 B047-000-81- A Job Specification – Architectural
41-SP-8203 works

3.2 Drawings

S. No Drawing No. Rev Title

1. B047-003-81-41-03701 A Site - plan
TERMINAL BUILDING
2. B047-003-81-41-03706 C
PLAN - LEVEL 3, DEPARTURES
TERMINAL BUILDING
3. B047-003-81-41-03705 C
PLAN - LEVEL 2,
TERMINAL BUILDING
4. B047-003-81-41-03704 C
PLAN - LEVEL 1A,
TERMINAL BUILDING
5. B047-003-81-41-03703 C
PLAN - LEVEL 1, ARRIVAL
TERMINAL BUILDING
6. B047-003-81-41-03707 A
PLAN - ROOF PLAN
7. B047-003-81-41-03709 A SECTIONS - (SHEET-1)
8. B047-003-81-41-03708 A ELEVATIONS
9. B047-003-81-41-03714 A ROOFING DETAILS
10. B047-003-81-41-03713 A STRUCTURAL GLAZING DETAILS
11. B047-003-81-41-13715 A DOORS-WINDOW DETAILS
PLANS, SECTIONS &
12. B047-003-81-41-03725 A
ELEVATIONS
13. B047-003-81-41-03810 A LANDSCAPE LAYOUT PLAN
14. B047-003-81-41-03814 A LANDSCAPE DETAILS (SHEET-1)
15. B047-003-81-41-03815 A LANDSCAPE DETAILS (SHEET-2)
16. B047-003-81-41-03739 A LEVEL 3 - FALSE CEILING PLAN
17. B047-003-81-41-03738 A LEVEL 2 - FALSE CEILING PLAN

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 172 OF 221

 S. No Drawing No. Rev Title
18. B047-003-81-41-03737 A LEVEL 1A - FALSE CEILING PLAN
19. B047-003-81-41-03736 A LEVEL 1 - FALSE CEILING PLAN
20. B047-003-81-41-03748 A LEVEL 3 - FLOORING PLAN
21. B047-003-81-41-03747 A LEVEL 2 - FLOORING PLAN
22. B047-003-81-41-03749 A LEVEL 1A - FLOORING PLAN
23. B047-003-81-41-03746 A LEVEL 1 - FLOORING PLAN
INTERIOR WALL ELEVATION - A &
24. B047-003-81-41-13766 A
B
INTERIOR WALL ELEVATION - C,D
25. B047-003-81-41-13767 A
&E
INTERIOR WALL ELEVATION -F
26. B047-003-81-41-13768 A
(F1 & F2)
INTERIOR WALL ELEVATION - G,
27. B047-003-81-41-13770 A
H&I
LOCATION OF INTERIOR ART
28. B047-003-81-41-13774 A
WORK
29. B047-003-81-41-03760 A CHECK IN COUNTER DETAIL
30. B047-003-81-41-03761 A INFORMATION DESK DETAIL
SECURITY CHECK INSPECTION &
X-RAY MONITORING
31. B047-003-81-41-13762 A
TABLE DETAIL (T-2) &
INSPECTION DESK DETAIL (T-1)
SECURITY CHECK & STAMPING
32. B047-003-81-41-03764 A TABLE
PEDESTAL DETAIL (GENTS) (T-3)
SECURITY CHECK & STAMPING
33. B047-003-81-41-13765 A TABLE
PEDESTAL DETAIL (LADIES) (T-4)
34. B047-003-81-41-03816 A PAGODA DETAIL
35. B047-003-81-41-03779 A SIGNAGE DETAILS - 01
36. B047-003-81-41-03780 A SIGNAGE DETAILS - 02
37. B047-003-81-41-03781 A SIGNAGE DETAILS - 03
38. B047-003-81-41-03782 A SIGNAGE DETAILS - 04
39. B047-003-81-41-03783 A SIGNAGE DETAILS - 05
40. B047-003-81-41-03784 A SIGNAGE DETAILS - 06
41. B047-003-81-41-03785 A SIGNAGE DETAILS - 07
UTILITY BUILDING
42. B047-003-81-41-03800 B BASEMENT PLAN &
GROUND FLOOR PLAN
UTILITY BUILDING
43. B047-003-81-41-03801 B FIRST FLOOR PLAN &
TERRACE PLAN
UTILITY BUILDING
44. B047-003-81-41-03803 B
ELEVATION & SECTIONS
UTILITY BUILDING
45. B047-003-81-41-13804 A
DOORS-WINDOW DETAILS

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 173 OF 221

 Note:
Above mentioned drawings are not approved for construction drawings. The
drawings shall be revised as required during engineering and execution of works
shall be done in accordance with approved for construction drawings issued to the
Contractor.

3.4 Schedule of rates/ Quantities

SOQ- ARCHITECTURE

4.0 PREAMBLE TO SCHEDULE OF QUANTITIES

4.1 Rate quoted by the Contractor for the items shall be inclusive of all materials, labour,
tools, tackles etc. other scope or works elaborated in this document, and tender/
contract document and shall be applicable for all heights and locations.

4.2 Works shall be executed in accordance with Item description, corresponding

specification, standards, drawings and as directed by Engineer-In-Charge.

4.3 Items/sub-items against which no quantity is given shall not be quoted by the
Contractor and shall not be executed. Such items if any are for reference purpose
only.

4.4 Quantities of the items are not final and may vary, actual executed quantities shall be
paid.

4.5 All the items included in the schedule of quantities may not be executed.

4.6 Materials shall conform to items, specifications, standards and shall be as approved
by Owner or PMC or Engineer-In-Charge. Materials shall be procured from approved
Manufacturer or vendor, list of which is included in the Tender or contract document.

4.6.1 Only ‘first’ quality materials shall be used.

4.6.2 Owner/ PMC reserves the right to choose any of the approved make/ vendors
as per the vendor or Manufacturer’s list.
4.6.3 In case of products not indicated in the vendor list, BIS marked products shall
be used.
4.6.4 Specification of manufacturer’s item shall be checked against tender items
and specifications before selecting any product or brand name. In case of any
discrepancy, tender item/ specifications shall prevail, and any such brand of
item shall not be used which is not conforming to tender specifications even if
it is listed in this vendor list.

4.6.5 In case of non-availability of any material among approved vendors/ makes in

a particular site, alternate vendor/ make conforming to national or international
codes shall be used subject to approval by Owner/ PMC.

4.6.6 In case of non-availability of any vendor among approved vendors in a

particular site/ region, alternate vendor’s name shall be proposed along with
required credentials for Owner/ PMC approval.

4.6.7 In case of any product neither covered in the vendor list nor having
specifications, the contractor shall submit the proposed product along with
technical literature/ specifications (as/ bid), test certificates etc. and other
credentials of the manufacturer for Owner/ PMC approval.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 174 OF 221

 JOB SPECIFICATION
(ARCHITECTURAL)

TENDER: COMPOSITE WORKS FOR LEH AIRPORT

PROJECT : Construction of New Domestic Terminal Building

and associated works at Leh Airport, J&K”

OWNER : AIRPORT AUTHORITY OF INDIA (AAI)

Document No. : B047-000-81-41-SP-8203 Rev. A

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 175 OF 221

INDEX

1.0 GENERAL
2.0 ROOFING SYSTEM
3.0 METAL FALSE CEILLING
4.0 FURNITURE
5.0 CARPET
6.0 PRESSED STEEL DOOR/WINDOW /VENTILATORS
7.0 FRAMELESS SWING GLASS DOOR
8.0 AUTOMATIC SLIDING DOOR
9.0 VISION GLASS
10.0 TOILET CUBICLES
11.0 ALUMINUMS GLAZED PARTITION.
12.0 ACRYLIC SOLID SURFACE COUNTERS.
13.0 ACRYLIC SOLID SURFACE CLADDING over column, vanity & other
similar area.
14.0 GLASS FOR SS RAILING

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 176 OF 221

1.0 GENERAL

1.1 CODES & STANDARDS

i. Codes and standards indicated or referenced in the specifications form part of

the specifications.

ii. Alternate codes and standards meeting the requirements of referenced codes
and standards may be used with the approval of the OWNER OR COMPANY,
PMC

iii. It shall be CONTRACTOR’s responsibility to be, or to become knowledgeable

of the requirements of the codes and standards.

iv. Abbreviations

IS - Indian Standards
BS - British Standards
EN - European Standards
BS-EN - British Standards, European Standards
ISO - International Organization for Standardization
ASTM - American Society for Testing and Materials

1.2 MATERIALS

i. All materials shall conform to the specifications and obtained from approved
Manufacturer.

ii. CONTRACTOR shall get the samples of materials approved by the OWNER
OR COMPANY, PMC before ordering & procurement. Such approved
samples shall be properly identified as approved sample and shall kept as
record for future reference.

iii. CONTRACTOR shall furnish necessary test certificates etc. Further to that he
shall get the materials tested from approved Test House (if and as asked by
the OWNER OR COMPANY, PMC) at his own cost for which no extra
payment is admissible to him.

iv. OWNER OR COMPANY, PMC shall have the right to reject all or any of the
materials intended to be used and such materials shall immediately be
removed from the site by the CONTRACTOR at his own cost for which no
extra payment is admissible to him.

1.3 WORKMANSHIP

i. Workmanship shall conform to the highest standards of construction,

execution & installation practice to the complete satisfaction of the OWNER
OR COMPANY, PMC.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 177 OF 221

 ii. All works shall be undertaken by qualified skilled personnel having adequate
tools, equipment etc. Works shall be got executed, installed by approved
applicators, agencies.

iii. All required precaution, protection and measures shall be taken by

CONTRACTOR during & after completion of work to prevent damages till final
acceptance by the OWNER OR COMPANY, PMC. Damages if any, shall be
rectified by CONTRACTOR

1.4 MANUFACTURERS

i. Manufacturers indicated in the specifications are the acceptable

Manufacturers for that particular item.

ii. Wherever only single Manufacturer is indicated or specifications which are

based on one particular manufacturer’s product, purpose is to define the
acceptable quality & performance as reference.

iii. Products by other Manufacturers which are of equal quality and performance
may be considered for approval upon review of information as required and
submitted to the OWNER OR COMPANY, PMC. No time and cost implication
to the OWNER OR COMPANY, PMC is admissible for use of such approved
products and Manufacturers.

iv. Product data sheet, specifications, performance data, installation instructions

and other recommendations of approved Manufacturer shall form part of the
specifications.

v. Materials, installation method and other requirements for execution of any

item if required by Manufacturer’s installation instructions, recommendations
and requirements shall also from part of the specifications whether specified
or not.

1.5 PACKAGING, SHIPPING, DELIVERY & STORAGE

i. All material, items shall be delivered in Manufacturer’s original package

bearing related information.

ii. All material, items shall be stored, preserved and protected to safeguard
against all adverse environments.

iii. Specific requirement of packaging, shipping, storage, preservation & safety of

materials, items if any as per Manufacturer’s recommendation shall be
ensured by the CONTRACTOR.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 178 OF 221

 iv. Materials, items damaged in handling, storage shall not be used. These shall
be removed from site and replaced by CONTRACTOR at his own for which
no extra payment is admissible to him.

1.6 SUBMITTALS

i. If not specifically mentioned otherwise, CONTRACTOR shall submit following.

- Samples for materials, components, accessories.

- Test and other certificates in support of conformities to specifications,
codes and standards as specified.
- Shop, fabrication drawings.
- Product data sheets, installation & maintenance manuals.

1.7 RATE OF ITEMS

Rates of items of works quoted by the Contractor in SOR/BOQ shall include cost of
all materials, manpower, machinery, scaffolding, HSE protection equipments,
transportation, assembly, fabrication, installation, preparation of shop/ installation
drawings, certification, testing etc indicated in the item descriptions (read together
with the specifications, codes and standards) and as required for carrying out and
completion of the works for all heights.

Rates shall also include any other incidental requirements and works not specified
but required for correct execution.

1.8 NOTES :

i. In case of any conflict with specifications mentioned elsewhere, specifications

as indicated in this clause shall prevail.

ii. For specifications not covered herewith shall be prepared by contractor and
submitted for Owner/ PMC approval. The work shall be executed in
accordance with approved specifications.

iii. For any aspect of items not covered in the document, approved relevant
National/ International codes and standards or Manufacturer’s
recommendation or Good engineering practice shall be followed as approved
by Owner for materials, installation, testing etc.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 179 OF 221

2.0 ROOFING SYSTEM (For Item No A3.1 to A3.14)

2.1 General

The roofing system shall be weather and water system in desired shape and profile
including straight, inclined, trapezoidal, curved shape / profile in accordance with
approved drawings and shall consist of following:

1. Insulated Aluminium Alloy Roofing Sheet System.

2. Zinc Titanium Alloy Sheet Cladding System.
3. Poly-Carbonate Skylight System.
4. Rain Water Gutter and Drainage System.
5. Personal Fall Arrester system.
6. Walkway and Step Walkway System.
7. Roof Hatch System.
8. All required accessories, nut & bolts, screws, fasteners, flashing, copying,
capping, closures, facia, fillers, spares, trims, fittings, sealants etc to ensure
weather- tight, leakage proof roof and for accommodating thermal
movements.

The roofing system shall be able to withstand wind suction pertaining to wind
condition at site. Required supporting certificates from National/ International
agencies to this effect shall be submitted by the Contractor.

2.2 Codes and Standards

Requirements of conformity with codes and standards etc. pertaining to materials,

installation, testing etc. are specified in the specification in the respective clauses.

2.3 Insulated Aluminium Alloy Roofing Sheet System

The Roofing sheet system shall comprise of a top layer of Aluminium alloy sheet,
insulation layer, vapour control layer and bottom layer of pre-coated steel sheet.

The top layer of Aluminium alloy sheet shall be of self supported standing seam (with
concealed joints closed by zipping material) type.

The system shall be installed over steel structure.

2.3.1 Materials:

a. Aluminium alloy sheet (Top layer)

Aluminium alloy sheet in top layer shall be of 0.9 mm thick Aluminium alloy AA
3004conforming to BS-EN-1396 in approved colour and shall have following
properties.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 180 OF 221

 Thickness 0.9 mm
Ultimate tensile strength Minimum 200 N/mm2
0.2% Proof Stress Minimum 185 N/mm2
Modulus of elasticity 70,000 N/mm2
Width of sheet Minimum 400 mm
Height of the standing seam 65 mm
Intermediate ribs minimum 3 nos of along the widt
Top side coating Minimum 30 micron PVDF (Polyvinylidene fluoride)
coating including primer coat (5-7 micron).
Bottom side coating Minimum 5 micron epoxy coating including primer
coat.

Single length sheet (without joints/ laps) shall be provided along the slope direction.

The sheets shall be fixed to purlins through the layers below by means of aluminium
alloy Halters fixed to purlins with stainless steel (SS) 304 grade screws.

The Halters shall be manufactured from extruded aluminium alloy AA 6062-T6

conforming to ASTM B 557 having ultimate tensile strength of not less than 340 Mpa
and elongation not more than 16 % when tested according to ASTM B 557. The
Halters shall be fixed with 5 mm thick polyamide thermal barrier.

b. Insulation layer

The Insulation layer shall be provided below the top Aluminium alloy sheet layer.

Insulation shall be of required thickness (minimum 150 mm) of stone wool conforming
to ASTM C 612 having density of minimum 60 Kg/ cum or fibre glass conforming to
IS 8183, 3144 having density of minimum 24 Kg/ cum as required to achieve the
Thermal Transmittance (U-value) of of 0.26 W/sqm.K of the Roofing System.

The insulation shall be in rolls with protective Aluminium foil on top and bottom.

c. Vapour Control Layer

The Vapour Control Layer shall be of approved quality reinforced Polethylene film
(grade 200, heavy duty type) or 0.2 mm thick Aluminium foil laid below the insulation
layer.

The Vapour Control Layer shall have following properties:

Water vapour resistance 335 MNs/g when tested as per BS 3177

Water permeability 0.60 g/sqm/day when tested as per DIN 53122

d. Pre-coated steel sheet (Bottom layer)

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 181 OF 221

 Precoated, profiled steel sheets shall be made from cold rolled high tensile
Galvalume Steel of 550 MPA yield stress and shall conform to IS: 513, IS:15961 and
shall have following properties :

Base metal Cold Rolled Steel Sheet conforming to IS: 513.

Galvanisation By Hot-dip process as per IS: 277, having hot dip
metallic coating of aluminium- zinc alloy (coating
class AZ150, 150 grams per sq. mtr. total on both
sides.
Thickness of bare sheets Not less than 0.50 mm
Minimum weight 5.80 Kg/ Sq.M
Cover width of the sheets Minimum 1000 mm
Ribs Height of the main ribs shall be minimum 28 mm.
pitch shall be 195 mm to 255 mm. There shall be
intermediate ribs between the main ribs.
Top (exposed) side Minimum 20 micron polyester coating over 5 micron
coating primer coat
Bottom side coating Minimum 5 micron Alkyd backer coating over 5
micron primer coat.
Pencil Hardness H-2H
Bending Test 2-4 T
Impact Resistance No crack or peeling of the paint film on drop of a
500 gms mass from 600mm height
Salt Spray Test 750 hours (Exposed top side)
QUV – Wealterometer 1000 hours
Test
Humidity Test 1000 hours
Temperature Resistance 100 deg C for 24 hours
Fire Performance Class-I

Single length sheet (without joints/ laps) shall be provided along the slope direction.

The sheets shall be fixed to purlins with necessary fasteners (approved quality anti
corrosive polyester polymer coated, rivets, nuts, bolts, self drilling screws/ fasteners
with integral washers and EPDM seals, and nylon colour caps and natural cure type
joint sealants, Aluminum clips, SS 304 screws etc. as approved.

e. Flashing, Capping & other accessories

Flashing and capping shall be fabricated from the same quality, grade, thickness and
colour of the main roof sheet.

Fasteners, fastening devices shall be of SS- 304 grade.

Other accessories such as trims, closures, fillers, spacers, tapes, sealant etc. shall
be as recommended by the approved Manufacturer and as approved by the Owner.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 182 OF 221

2.3.2 Installation

The roofing sheet system shall be installed by approved agency in accordance with
specification, approved design and drawings and directions of Engineer-In –Charge.

2.3.3 Testing

Dye penetration test shall be done by the Contractor, in case of aluminium welding.

2.3.4 Submittals

Submittals by the Contractor shall be as follows:

1. The Contractor shall prepare and submit shop drawings for installation of the
system.
2. Test certificates/ certifications in support of specifications of materials,
installation, testing, performance etc.
.
2.4 Zinc Titanium Alloy Sheet Cladding System

Zinc Titanium Alloy Sheet Cladding System (flat-lock joint type) shall be provided at
facias, soffits, bull-nosing etc in desired colour, profile, shape including curved,
inclined, shape and profile.

The finished surface shall be smooth, uniform without any waviness.

The system shall be integrated with roofing system ensuring an integrated weather
and water tight system.

The system shall be able to withstand wind suction pertaining to wind condition at
site. Required supporting certificates from National/ International agencies to this
effect shall be submitted by the Contractor.

Zinc Titanium Alloy Sheet shall conform to BS EN 988 and shall have following
properties.

Thickness 0.8 mm
Composition Zinc – Z1, Copper - 0.08 - 1.0% , Titanium - 0.06 -
0.2% , Aluminium - 0.015%
Ultimate tensile strength Minimum 150 N/ sq mm
0.2% Proof Stress Minimum 100 N/ sq mm
Elongation at fracture Minimum 35 %
Bend test No cracks on fold
Creep resistance 0.1%
Width of sheet Minimum 400 mm
Finish Pigmented in desired colour, with primer, pre-
weathered, finished with 20 micron transparent
Poly-urarthane cotaing on visible side.

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 The cladding system shall consist of:
- Zinc Titanium Alloy Sheet panels
- Minimum 8 mm thick Synthetic (anti-abrasive membrane made of polypropylene)
mesh laid beneath Zinc Titanium Alloy Sheet.
- Bare galvalume corrugated sheet (0.45 mm base metal thickness,3.5 mm deep
ribs, pitch 48 mm, minimum yield strength- 550 Mpa, minimum 150 gsm/ sqm
coating as per AS 1397-Az 150) conforming to IS: 513, IS:15961 below synthetic
mesh.
The system shall be installed by approved agency by jointing the zinc titanium panels
by means of flat lock system using hot-dip galvanized clips, strips (made of
galvanized steel, 0.4mm thick) etc.

The bare galvalume corrugated sheet shall be fixed over the supporting structure.
The synthetic mesh shall be laid over the galvalume sheet. The Zinc Titanium Alloy
Sheet panels shall be fixed to bare galvalume corrugated sheet with SS-304 self
drilling screws and flat lock system clips (made of galvanized steel, 0.4mm thick)
through the synthetic mesh.

Flashings, cappings drip moulds etc. shall be of similar material as that of cladding of
minimum 0.7 mm thickness, upto 500mm in girth in required profile.

Submittals

Submittals by the Contractor shall be as follows:

1. The Contractor shall prepare and submit shop drawings for installation of
the system.
2. Test certificates/ certifications in support of specifications of materials,
installation, testing, performance etc.

2.5 Polycarbonate Skylight System

2.5.1 General

Polycarbonate skylight system shall be installed on metal roofing system in desired

shape and profile including curved shape/ profile as per drawing ensuring weather-
tightness and leakage proofing of the roofing system.

2.5.2 Materials

Polycarbonate sheet panels:

The system shall consist of polycarbonate sheet panels (minimum -16 mm thick, 900
mm wide) having vertical standing seam system, end caps, Aluminium alloy U/F
profile, Glazing Bar and shall be compatible with the roof sheeting system ensuring

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 184 OF 221

 proper fixing, integrity of the roofing system pertaining to water and weather-
tightness.

The polycarbonate sheet panels shall be co-extruded UV protected type having six
layers with angular walls in combination of opaque and clear translucent types for
achieving desired lux level of lighting. The poly carbonate sheet shall be of approved
colour and shall conform to IS : 14443.

The polycarbonate sheet panels shall be free from cracks, chipped edge corners or
other damages. All polycarbonate sheets shall usually be masked on both sides by
use of adhesive paper or plastic film which can be peeled off easily without damaging
the surface or leaving any mark of the adhesive.

The panels shall meet the following requirements:

Dart drop Panels must satisfy Dart drop impact test as per IS 14443 and shall
impact show no sign of breakage on Polycarbonate sheets which have
been exposed to UV for a min. of 500 Hours as per ASTM G 155.
Yellowness Yellowness Index shall not exceed 15 units (as per ASTM D 1925)
Index when tested on a sample exposed to UV for 500 Hours as per
ASTM G 155.

Accessories:

Flashing and capping shall be fabricated from the same quality, grade, thickness and
colour of the main roof sheet.

Fasteners, fastening devices shall be of SS- 304 grade.

Other accessories such as trims, closures, fillers, spacers, tapes, sealant etc. shall
be as recommended by the approved Manufacturer and as approved by the Owner.

2.5.3 Installation

The system shall be installed by approved agency in accordance with approved

design and drawings and directions of Engineer-In –Charge.

The panels shall be fixed and secured on roof structure by means of self drilling SS
screws and fasteners, in accordance with IS : 14443 and ensuring pull-out load of
minimum. 7000N (7KN) tested as per ISO 6892 and IS 1608.

All protective masking of the panel shall be removed during installation.

Suitable gaskets, sealants shall be provided at edges to take care of leakage,

expansion/ contraction of the panels.

Chemical compatibility of the sealing system with polycarbonate sheet shall be

established before use during installation. Where expansion and contraction of sheet

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 185 OF 221

 exceeds the limitation of such sealants, Neoprene or EPDM rubber gaskets of about
65 shore hardness shall be used.

Aluminum edge Profiles shall be provided to protect the lower edge of the sheets.

Other required accessories such as Aluminium channel, screws with PVC fillets,
masking tape, protective tape, backer rods, bolts, gasket shall be provided.

Poly carbonate sheets shall be cleaned with mild soap solution and soft cloth after
installation is over. In case of UV coated sheets, the coated side shall always face
the outside. No solvent should be used to clean this coated surface.

2.5.4 Submittals
Submittals by the Contractor shall be as follows:

1. The Contractor shall prepare and submit shop drawings for installation of the
system.
2. Test certificates in support of specifications of materials, installation, testing
etc.

2.6 Rain Water Gutter and Drainage System

The system shall comprise of Rain water gutters (eaves and valley) and connectors
from gutter to down take pipes and required accessories such as cover plate, end
cap, supporting brackets, flashings, eaves/ valley filler blocks, girts etc. ensuring
leakage proof smooth roof drainage.

Rain water gutter shall meet following :

Gutter material Aluminium alloy AA 1100 conforming to BS EN 1396

Gutter thickness Minimum 2 mm thick for insulated gutters
Minimum 3 mm thick for non insulated gutters
Insulation For insulated type Gutters, Insulation layer and Vapour
Control layer, both shall be of similar specification as that of
the insulated Aluminium alloy roofing sheet system.
Girth of the gutter Maximum 2000 mm for mm insulated gutter.
Maximum 1200 mm for insulated gutter.
Flashing and Shall be fabricated from the same quality, grade, thickness
cappings and colour of the main roof sheet.
Fasteners, SS- 304 grade
fastening devices
Accessories As recommended by the approved Manufacturer and as
approved by the Owner.

Full length sheets shall be used for fabricating the gutters to minimize number of
joints. Butt welding shall be done at joints with 100 mm strip. EPDM expansion joints
shall be provided at every 12000 mm length.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 186 OF 221

 Dye Penetration test to be conducted wherever aluminum welding has been done.

Other such as trims, closures, fillers, spacers, tapes, sealant etc. shall be provided as
required.

Submittals
Submittals by the Contractor shall be as follows:

1. The Contractor shall prepare and submit shop drawings for installation of the
system.
2. Test certificates in support of specifications of materials, installation, testing
etc.

2.7 Personal Fall Arrester System

Personal Fall Arrester System shall be provided over standing seam roof system for
ensuring safe stopping of persons already falling and for catering movement along
the roof periphery.

The system shall conform to BS EN 795, class C and PD CEN/TS 16415.The

Contractor shall submit certificates in support of these conformities.

The system shall comprise of :

A: Anchorage Posts
(End, intermediate, corner, stand-alone, cross-over, T-junction types as required)
Design Posts shall be energy (4500 joules) absorber type and
capable of minimum 3 users falling simultaneously.
Material Stainless steel 316 grade
B: Cable Termination
Design Wire rope shall be terminated through swaging action with
minimum
Material Stainless steel 316 grade
C: Shock Absorber
Design Shall provide shock absorption to the system to ensure that
the maximum load at the extremity anchor does not exceed
50%
Material Stainless steel 316 marine grade
D: Tensioner
Design Shall provide pre-tension to the line
Material Stainless steel 316 marine grade
E: Cable
Design Diameter 8mm, construction 7 x 7, breaking strength 38 KN
minimum

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 187 OF 221

 Material Stainless steel 316 marine grade
F. Self- Rescue Device
Design Harness with self-rescue system so that, in case of a fall the
user reaches to ground safely.
Material 1. Webbing: Polyester
2. Body: Aluminium
3. Kennmantle Rope : Dyneema/ Aramid
Test Compliance Static and dynamic tests according to EN 361:2002 and EN
341:2011, Type 1, Class D

The system shall be installed by approved agency.

Submittals
Submittals by the Contractor shall be as follows:

1. The Contractor shall prepare and submit shop drawings for installation of the
system.
2. Test certificates in support of specifications of materials, installation, testing
etc.

2.8 Walkways and Step Walkways System

2.8.1 Walkways System

The Walkways system shall be provided for safe walking over the roof on standing
seam profile roof system to cater all along the roof periphery, skylights and
gutters of the roof etc.

The Walkways system shall conform to BS EN 516. The Contractor shall submit
certificates in support of the conformity.

The Walkways system shall comprise of and meet the following ;

Walkways Shall consist of gratings formed out of Fibre reinforcement
plastic (FRP) / Unplasticized Polyvinyl chloride (uPVC) with
Aluminium Alloy accessories & SS nuts, bolts, fasteners.
Brackets Brackets of Stainless Steel 316 to hold the walkway on
standing seams. Angle of the brackets shall be adjustable to
negotiate the gradient of the roof for walkways in an even
plane
Nut & Bolts Stainless Steel 316
Size of Steps 500 mm minimum
Accessories Aluminium Alloy 6063/T6 or 6005/T6.
Seam Clips Seam Clips made of Aluminium Alloy 6063/T6 or 6005/T6 to
hold the walkways on standing seam.

2.8.2 Step Walkways System

The Step Walkways system shall be provided for safe walking over the roof on

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 188 OF 221

 standing seam profile roof system in upward or downward direction of the slope.

The Step Walkways system shall conform to BS EN 516. The Contractor shall
submit certificates in support of the conformity.

The Step Walkways system shall comprise of and meet the following ;
Steps Uncoated cast aluminum alloy AA 231
Brackets Aluminum alloy AA 231
Nut & Bolts Stainless Steel 316
Size of Steps 460 x 250mm and thickness of aluminum tread is
Minimum 4mm. Minimum 3 steps per running meter.
Angle 0 - 45 degrees
Adjustment

Submittals
Submittals by the Contractor shall be as follows:

1. The Contractor shall prepare and submit shop drawings for installation of the
system.
2. Test certificates in support of specifications of materials, installation, testing
etc.

2.9 Roof Hatch System

The Roof Hatch System shall be insulated and water tight construction including lift
assistance for roof access.

The Roof Hatch System shall comply with UL 790 Class A (burning brand test). The
Contractor shall submit certificates in support of the conformity.

The Roof Hatch System shall comprise of and meet the following ;
Leaf Single Leaf with interior and exterior turn handles, slam latch
Opening Size 914 mm x 914mm
Material Aluminium Cover & Frame in 11 Gauge (2.3mm thick)
Cover Break formed, hollow-metal design with 25.4mm concealed
fiberglass insulation, 76mm beaded, overlapping flange, fully
welded at corners, and internally reinforced for 195 kg/m2 live
load.
Curb 305 mm high with integral cap flashing, 25mm Fibre Board
Insulation, fully welded at all corners, mounting flange for
securing hatch to roof.
EPDM Gasket EPDM gasket fixed to the cover.
Hinge Heavy duty Pintle Hinge with SS-316 pins.
Lift Assistance Compression spring operator enclosed in telescopic tubes.
Shall have automatic hold-open arm with grip handle release.
(One number only for the whole building)

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 189 OF 221

 Hardware Aluminum engineered composite compression spring
tubes with steel compression springs in electro coated acrylic
finish. Hinges : SS 316
All other hardware shall be zinc plated/chromate sealed.

Submittals
Submittals by the Contractor shall be as follows:

1. The Contractor shall prepare and submit shop drawings for installation of the
system.
2. Test certificates in support of specifications of materials, installation, testing
etc.

2.10 Measurement, Unit of rate

Items/ Dimensions shall be measured in specified units as per IS : 1200.
Following table shall be followed.
Item Unit Remarks
Roofing Sheet SqM Actual area covered shall be measured.
System Deductions shall be made for openings/ cut outs
for Sky/ Roof light, Gutter, Hatches etc.
Zinc Titanium Alloy SqM Actual area covered shall be measured.
Sheet Cladding Deductions shall be made for openings/ cut outs
System for Sky/ Roof light, Gutter, Hatches etc.
Flashings RM
Poly Carbonate SqM Actual area covered shall be measured.
Skylight System
Gutter RM -
Personal Fall RM -
Arrester System
Walkways And Step RM -
Walkways System
Roof Hatch System Numbers -

2.11 Warranty
The Contractor shall provide warranty in prescribed form for 10 years for the
complete Roofing System including all individual systems, components, materials etc
against any damage in the system and water leakage.

In case of any damage, water leakage, The Contractor shall replace or rectify the
damaged works at his cost to the satisfaction of Acceptances Authority.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 190 OF 221

3.0 METAL FALSE CEILLING (For item no A4.3)
(Below Main Roofing)
3.1 General
The Aluminium Alloy plank metal ceiling system shall be provided in desired shape /
profile including curved shape/ profile as per design.

The Ceiling system shall comprise of and shall meet the following:

Perforated ceiling Aluminium Alloy 3105 or AA 3003 conforming to ASTM B

Plank material 209
Thickness Minimum 0.9 mm
Width Maximum 325 mm
Coating thickness Roof facing side : 5-7 micron primer.
Floor facing side : Minimum 50 micron Polyester including
5-7 micron primer.
Colour Wood Finish or As approved
Perforation Maximum 1.5 mm dia, covering maximum 18% of ceiling
area
NRC 0.7
Acoustical fleece Non-woven felt made of glass-reinforced fiber glued over
the perforation for sound absorption
Fire Performance Class A1 as per EN 1396
Panel fixing system Hook on type with necessary fixing accessories
Suspended system Suspension system shall be compatible to ceiling planks,
design and roofing system and shall be product of the
ceiling plank Manufacturer.

The system shall be in accordance with approved

Manufacturer’s recommendation and approved by Owner
and shall broadly consist of :
- GI “Ü” profile hangers fixed to roof by threaded rod @
1200 mm maximum.
- Secondary GI members connected to U profile
- Perimeter wall moulding
- Appropriate accessories such as splices, clips, clamps,
fasteners etc.
- Aluminium or GI special sections as required for
curvatures.
3.2 Installation

The system shall be installed as per approved Manufacturers recommendation in

accordance with design and approved drawings by approved agency.

The finished surface shall be air tight, smooth, with straight joints and shall be
integrated with roofing or other interface systems.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 191 OF 221

 Single length planks shall be used to minimize joints. The longer side of the planks
shall either be in shorter or longer side of the area where false ceiling is to be
provided.

Necessary cut outs, opening, sealing etc. shall be done for roof/ ceiling mounted
fixtures and fittings.

For steep sloped and curved ceiling, appropriate bracing and fasteners shall be
provided.

3.3 Submittals

Submittals by the Contractor shall be as follows:

1. The Contractor shall prepare and submit shop drawings for installation of the
system.
2. Test certificates in support of specifications of materials, installation, testing
etc.

3.4 Warranty
3. The Contractor shall provide warranty in prescribed form for 10 years for the
complete System including all individual systems, components, materials etc
against any damage in the system.

4. In case of any damage, The Contractor shall replace or rectify the damaged works
at his cost to the satisfaction of Acceptances Authority.

3.5 Measurement, Unit of rate & Rate

Items/ Dimensions shall be measured in specified units as per IS : 1200.
Actual area covered by false ceiling shall be measured in square meter for payment.

4.0 FURNITURE (for item no 9.1 to 9.7)

4.1 General

4.1.1 All furniture shall be Factory made, standard product of Manufacturer which shall be
customized as required and shall be procured by the contractor from Manufacturers
having Proven Track Record (PTR).

In order to establish the PTR, proof of successful supply to Airports offices or reputed
institutions / companies / corporate etc. shall be submitted for review and acceptance
by Engineer-In-Charge, AAI after award of work. However, the acceptance of PTR
will not absolve the contractor of his responsibilities of meeting the quality as per
technical specifications of this tender.

4.1.2 Product data sheet, specifications, performance data, installation instructions and
other recommendations of approved Manufacturer’s also form part of this

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 192 OF 221

 specification subject to compliance with other requirements specified herein.
Materials / Items not covered in this specification shall be as per approved
Manufacturer’s standard specification.

4.1.3 Colour/ texture/finishing of furniture shall be as approved by Owner/ PMC

4.1.4 Drawings/ photographs attached in the specification/ Tender are intended to clarify
the design and other requirements. Contractor shall design, fabricate, supply and
install the furniture in accordance with specifications, approved drawings prepared by
him and directions of Engineer-In-Charge.

4.1.5 For specification of Particle/ MDF Board, Laminate etc. reference shall be made to
CPWD Specification.

4.2 Materials & Accessories

4.2.1 Materials, accessories, fittings, finishing etc used for furniture shall be of first quality
and shall conform to Indian or other international standards.

4.2.2 If not mentioned otherwise, all metallic items of furniture shall be CRCA and all
metallic items shall have powder coating finish (50 micron).

4.2.3 If not mentioned otherwise, metallic items shall have following treatment.

A. Pre-treatment
Degreasing, De-rusting, Phosphating, Passivation for better adhesion of the
protective coating to the surface and greater corrosion resistance.

B. Primer
Primer surface gray shall be used as anti-corrosion resistance. All physical &
chemical properties shall conform to IS 101-1964.

C. End test
Salt spray test, scratch hardness test and impact test.

D. Phosphating
Phosphating shall be done to provide:
Clean, oil & grease free surface.
Fine crystalline corrosion inhibiting base for paint.
Non conducting bond between the base metal and paint.
Chemically inert surface to prevent the reaction between the metal surface
and paint ingredient.

E. Passivation
Passivation shall be done with Hexavalent Chromium

F. Water Rinse
Soft water shall be used which gives corrosion protection for a long time.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 193 OF 221

4.2.4 Particle/ MDF board
If not mentioned otherwise, thickness of Particle/ MDF board work surfaces such as
table top, shall be 25mm thick. For other application of Particle/ MDF board,
thickness shall be minimum 18mm

4.2.5 Lamination
If not mentioned otherwise, Particle/ MDF board of all furniture shall be prelaminated
on both sides. Thickness of Particle/ MDF board work surfaces such as table top,
shall be 1mm thick. For other external surfaces thickness shall be minimum 0.8mm.
For internal surfaces the thickness shall be minimum 0.6mm.

4.2.6 PVC edge strip

If not mentioned otherwise, all exposed Particle/ MDF board, wooden edges shall be
finished with 2mm thick PVC edge strip fixed with suitable adhesive matching with
the lamination.

4.2.7 Locks & Handles

All storages/ drawers/shutters shall have locking arrangement with 4 lever brass
body locks and Stainless Steel handles of approved design.

4.2.8 Leveling screws

Leveling screws shall be provided in partitions, and other furniture to take care of
unevenness in floor.

4.2.9 Sliding telescopic channel

All drawers, Key board trays, Mouse trays shall be provided with approved sliding
telescopic channels.

4.2.10 Gromets
Gromets (cut outs) shall be provided on all table tops for cabling. Gromets shall be
provided with PVC cover.

4.2.11 Key Board Tray and Mouse Tray

Key Board Tray and Mouse Tray shall be made out of minimum 0.8mm thick CRCA
Steel and shall be mounted below the table top.

4.2.12 CPU Trolley

CPU Trolley shall be made out of minimum 0.8mm thick CRCA Steel with four
numbers poly-propylene Castors, out of which front two castors shall be lockable.

4.2.13 Mobile pedestals

Mobile pedestals (450mm x 400mm) shall be placed below table top fitting the
available height and shall be made of 18mm thick prelaminated Particle/MDF board.
The sides of drawers and facia shall be of prelaminated particle / MDF board of
18mm and 25mm thickness respectively. Interior of drawers shall have 0.6mm thick
laminate finish. Pedestals shall have 3 drawer configurations (2 for personal and 1

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 194 OF 221

 for lateral files and 1 stationery tray) with sliding telescopic mechanism, single central
locking system, SS handles and four number poly-propylene castors.

4.10 VIP LOUNGE SOFAS

Sofas shall be of wooden or metal frame of approved design. The seat / back rest
shall consist of moulded Polyurethane foam having density = 28 +/- 2 Kg./cm3 with
additional top layer of supersoft PU foam of density 32 +/- 2 Kg./cm3. The upholstery
shall be Fabric or leatherette. The complete moulded seat/ back/side rest assembly
shall be covered with a replaceable leatherette upholstery cover. Understructure is
made of 12mm hot pressed plywood and pinewood of cross sections devoid of major
knots and surface defects. 6 nos. per seat and 3.8mm dia. Zigzag spring assembly is
mounted over understructure for cushioning purpose. The leg assembly shall be
Stainless steel tube and plate with plastic endcap.

Sizes:

One seater sofa 860 mm (W) x 905 mm (D) x 855 mm (H)

Two seater sofa 1460 mm (W) x 905 mm (D) x 855 mm (H)
Three seater sofa 2060 mm (W) x 905 mm (D) x 855 mm (H)

4.11 Airline Lounge sofas:

Structure: Structure shall consist of approved first quality Rubber

wood legs and MS pipes (25mm x 50m x1.6mm thick and
20 mm x 40mm x 1.6mm thick) and MS plate (3mm thick).
Nylon leg bushes shall all be provided.
Seat back part Seats and back part shall be of inset molded chemically
boarded P.U. foam (density 45 kg / cum , hardness – 20 )
with lining cloth cover in required thickness.
Back rest shall be supported by MS pipe (19 mm dia, 1.6
mm thck) Dymetrol stretchable fabric (100 s) shall be
provided.
Arm Part Arm part shall be of insent moulded, chemically bonded
P.U foam (desing-45 kg / cum, hardness – 20) with lining
cloth cover armrest shall be supported by MS pipe (19
mm dia, 1.6 mm thick )
Upholstery: Approved quality leather upholstery
Hardware: Nylon leg bushes and high quality standard hardware like
screw, nut, bolt, washer etc.

Sizes:

One seater sofa 900 mm (W) x 800 mm (D) x 735 mm (H)

Two seater sofa 1480 mm (W) x 800 mm (D) x 735 mm (H)
Three seater sofa 2040 (W) x 800 mm (D) x 735
mm (H)

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 195 OF 221

5.0 CARPET (for item no 9.1 to 9.23)

5.1 CARPET ROLLS

Carpet shall be of approved quality Flocked antimicrobial type antistatic carpet rolls
confirming to ISO 1765 in approved colour and pattern with resilient waterproof
backing.

The carpet roll shall have the following properties.

Appearance Retention confirming to: ISO 140-8
Friction Slip Resistance Test shall confirm to: EN 14041 Class DS,
Minimum thickness: 4.0mm as per ISO 1765
Minimum roll width: 1500 mm
Weight (Approx.) 1.8 kg/sqm
Dimensional stability As per ISO 2551 : <0.2%
Slip Resistance As per DIN 51097 : >0.7 Dry & Wet
Light fastness As per EN ISO 105 B02 : 6
Commercial heavy As per EN 685 : Class 33
Reaction to fire As per EN 13501-1 : Bfl-s1

Before starting the work, the contractor shall get the sample of carpet tiles approved by
Engineer in charge.

5.2 Adhesive
The adhesive shall be as recommended by approved manufacturer and approved by
the owner/ engineer in charge.

5.3 Laying
The carpet roll shall be laid by approved agency over leveled epoxy floor finishing.
The under surface shall be cleaned before laying the carpet rolls. The finished carpet
roll shall be leveled surface. All the junction boxes shall be covered & leveled to the
cemented surface. All the expansion joints shall be covered or leveled, Wall corners
& below the skirting (if applied) shall be dust free. Skirting work shall be completed
before laying carpet.

5.4 Measurement & Rate

Items/ Dimensions shall be measured in specified units as per IS : 1200.
Actual area covered by square shall be measured in square meter for payment.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 196 OF 221

6.0 PRESSED STEEL DOOR/WINDOW /VENTILATORS (Item no .7.1 to 7.3)

6.1 Pressed Steel Door/Window Frame

Pressed steel door/window frame shall conform to IS: 4351.

The frames shall be of specified sectional size, dimension and profile. The frame
shall be made of 16 SWG galvanized pressed steel profiled as required and filled
with concrete. The frame shall be provided with 3 mm thick MS flat spacer welded to
frame at @ 500mm c/c and at holdfast location. Joints between horizontal and
vertical frame members shall be mitred. All welding shall be finished smooth.

The frame shall be fixed to the masonry by means of 200 mm x 25 mm x 6 mm MS

hold fast welded to the spacers and grouted with M-20 grade concrete in minimum
250 mm x 100 mm x 100 mm sized hole in the masonry.

In case of concrete, the frames shall be fixed by minimum 100 mm long, 12 mm dia
metallic counter sunk type anchor fasteners through the frame and spacers.

Vertical frame member shall be tied together below floor finish by mean of
20mmx20mmx3mm MS Angle welded to both faces of frame.

40mmx150mmx3mm thick MS pad shall be welded to frame at all hinges and lock
locations. 18 SWG GI mortar guard shall be provided at the back of hinges and lock.

The frame surface shall be thoroughly cleaned of rust, mill scale, dirt, oil etc. and
then finished with painting or powder coating as specified. The thickness of powder
coating shall be subjected to verification at site (on random basis) as directed by
Engineer- in- Charge with appropriate measuring instruments supplied by contractor.

6.2 Pressed Steel Door Shutter

Pressed steel shutters shall be hollow type with 18 SWG Galvanized pressed steel
sheet welded at meeting of the sheets with pad plate of MS flat 3 mm thick all along
perimeter. The cavity shall be packed with Mineral Wool (48 kg/cum) to fully fit into
the cavity without gaps.

The shutter shall be formed by machine bending of steel sheet in form of hollow box
making an overall thickness of 40mm forming truly square edge in accordance with
the shutter profile. It shall further be braced with 18 SWG GI vertical stiffeners @200
c/c (Spacing to be adjusted for vision panel and fixed with flush riveting)

3mm thick MS pad plates shall be welded inside at required locations for fixing of
hardware such as tower bolt, aldrop etc.

2 mm thick 25x25 GI angles (vertical) welded to each shutter shall be provided at the
meeting point of double shutter doors

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 The frame surface shall be thoroughly cleaned of rust, mill scale, dirt, oil etc. and
then finished with painting or powder coating as specified. The thickness of powder
coating shall be subjected to verification at site (on random basis) as directed by
Engineer- in- Charge with appropriate measuring instruments supplied by contractor.

The shutters shall be fixed to the door frame by means of 100 mm long heavy duty
ball bearing hinges @ 600mm maximum. Vision panel shall be provided in the
shutters in accordance with project drawings.
Following Hardware shall be provided:
a. Overhead hydraulic door closer (heavy duty) for each shutter
b. MS holdfast 200mmx25mmx6mm thick @maximum 600 mm c/c
c. 100 mm long SS 304 grade heavy duty ball bearing hinge @600mm C/C
maximum for each shutter
d. SS 304 grade 16mm dia 250mm long aldrop on both sides.
e. Spring loaded heavy duty door stopper for each shutter
f. SS 304 grade 19 mm dia, long handle on both sides of each shutter
g. 10 mm dia SS 304 Tower bolt (250mm long for 2100mm height & 600mm long for
2500mm height) for each shutter

In case of air tight door shutters, approved quality continuous ’D’ Profile EPDM
Gasket shall be provided along frame rebate.

In case of partly glazed door shutter, Glass as specified shall be fixed with glazing
clips and solid drawn 10 mm x 10 mm, MS beading backed with putty and fixed by
countersunk screws. Necessary rebate for fixing the glass shall be provided by
arranging the shutter bracing accordingly.

The overall shutter shall ensure smooth operation, proper sizing and shaping as per
approved drawings.

The shutters shall be provided with locking device, handle and other hardwares as
specified.

6.3 Steel Windows & Ventilators

Steel windows, ventilators shall in general conform to IS: 1081, IS: 1038 and IS:
7452.

6.4 Materials

6.4.1 Rolled Steel Section

Rolled steel sections for the fabrication of steel windows, ventilators shall conform to
IS: 7452.

6.4.2 Glass panels

Glass panels for glazing purpose shall be as specified. All glass panes shall have
properly squared corners and straight edges. Glass panes shall be as specified.

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6.5 Workmanship
The profile and type of windows, ventilators (glazed, partly glazed/louvered, side
hung/top hung/fixed shutter, composite) shall be as per drawings.

The frames shall be constructed of sections cut to size and mitred. Corners shall be
welded to form a fused welded joint. Process of welding shall be flash butt welding.
The welded joints shall be grinded to square and flat edges.

Where larger units are to be formed by coupling individual units, the mullions,
transoms shall be bedded in mastic to ensure weather tightness. Mastic shall be
applied liberally to the channels of the outside frame sections before assembly, and
the two units being coupled shall be drawn together tight with clamps, the mastic
being squeezed out and cut off neatly when the units shall be screwed together
tight.

Where fixed glazing units are placed over openable units a push fit weather bar shall
be provided.

Before glazing, all opening parts shall be checked for their operational smoothness.
The frame shall be completely cleaned and bedding putty shall be placed in the
rebate before glazing. Glass then shall be cushioned into the bedding and shall be
fronted with front putty in a manner so as to enable the painting to be done up to the
sight line. The back putty oozing out over the glazing rebate shall be cut off square
and smoothed down.

For panels exceeding 600 x 300 mm in size, glass shall be secured by special
glazing clips inserted in holes already provided in the steel sections, before applying
the front putty.

For glazing of very large areas, rust proof steel beading with mitred corners shall be
provided with screws @ 10 cm. from each corner and @ 20 cm. apart from each
other. Putty shall be provided to the face of the bead in contact with glass, in addition
to back putty.

Side hung shutters shall be connected to the frame by means of friction hinges. The
handle for side hung shutters shall be of pressed brass mounted on a steel handle
plate welded to the opening shutter frame and shall not be removable easily after
glazing. The handle shall have a two point nose which shall engage with a brass
striking plate on the fixed frame in a slightly open as well as in a fixed position.

Top hung shutters shall be provided with steel butt hinges welded to the fixed frame
after cutting a slot in it. Top hung casements shall be provided with peg stay of 3
holes of pressed brass; 300 mm long which when closed shall be held tightly by the
locking bracket fitted to the fixed frame or to the window.

Before fixing the frames, the size of the opening shall first be checked and cleaned of
all obstructions. The positions of the unit in the reveal shall be taken off the drawings
and shall be marked on the reveal at the jambs using a plumb line.

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 In case of fixing with masonry, holes for fixing the lugs/hold fasts shall be cut at
required locations.
In case of concrete or stone, the frames shall be fixed by means of dash fasteners.
In case of masonry, the lugs shall be grouted in the holes with cement concrete, M-
15 Grade when fixing to steel work, mastic shall be applied to the sill of the opening
and the unit shall be placed on it with the jambs and head buttered with mastic and
the unit shall be fixed with special fixing dips or with nuts and bolts.

The windows/ ventilators shall be checked to ensure smooth operation, perfect level
and plumb.

All the steel surfaces shall be thoroughly cleaned free of rust, mill scale, dirt, oil etc.
by sand and shot blasting and then finished with painting by priming with red oxide
zinc chromate primer conforming to IS:2074 and painting conforming to IS:1477 (Part
II) or by hot dipped galvanizing conforming to IS:1477 Part (I). Putty shall also be
provided with painting in a manner so as to seal the putty glass junction. Surfaces
not meant for painting shall be cleaned of any strains of paint.

6.5 Measurement & Rate

Measurement & rates for item rate tender shall be on Sq.m basis as per item
description. Area shall be measured correct up to two places of decimal. Dimensions
shall be measured correct up to 0.5 cm.

A composite unit of various designations shall be first measured over all as a unit of
predominant designations and measurement for remaining designations shall be
deducted from the overall measurement of the composite unit in order to arrive at the
quantities for various designations. Mullions/Transoms/Coupling bars etc. at the
meeting points of various designations shall be equally distributed to all such
designations for measurement and rates.

Rate shall include cost of all materials, specified hardwares, labour, erection,
hoisting, scaffolding, removal of scaffolding, protective measures, conveyance,
handling, loading/unloading, storing etc. required for proper completion of the item of
work in accordance with the specification.

7.0 FRAMELESS SWING GLASS DOOR

Frameless Glass Swing Doors shall be of approx. size 1200mm x 2400mm using
12mm thick toughened glass of approved make for shutter with all necessary fittings
and hardware of approved make as specified below.

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 Door shutter 12mm thick toughened glass BS 952 Part – I
Toughening conform to ASTM 1048
Pivots SS finish
Patch fittings SS finish
Locking device Euro profile cylinder- single throw both side key operation
corner lock with lock keeper plate of SS finish
Handle SS Pull Handles (600mm*32mm)-1 set
Hinges SS
Floor spring Standard spindle conforming to EN 1154, tested for 500,000
cycles
Door closer half dome with 45 mm dia with fixing accessories in satin
chrome finish,
Structural Sealant Minimum tearing strength 6.0N/mm, sore A hardness 44
(ISO: 868), tensile strength (ISO: 8339-A) 1.06 N/Sq.

7.7 Measurement & Rate

Items/ Dimensions shall be measured in specified units as per IS : 1200.

Actual area covered by Door shall be measured in square meter for payment.

8.0 AUTOMATIC SLIDING DOOR

8.1 Automatic Bi Parting Sliding Door

Automatic bi‐parting sliding doors shall be of approx. clear opening (size 3000 x
2400mm) with heavy duty automatic operator, slim aluminium profiled framed door
of 12mm toughened sliding door panels (2nos.) and fixed panels (2nos.) each of size
1500mm x 2400mm, internal cover, eagle sensors on both sides, Electro mechanical
lock, light barriers and programmer switch. Operator & Frame Finish shall be Silver
Anodized E6/C0 with Operator Dimensions 100 x 180 mm and required length to suit
the size of opening, separate track profile from the main profile for enabling reduction
in vibration, Microprocessor controlled control unit, self‐learning, with adjustable
parameters for opening and closing speed, hold‐open time and opening and closing
force, reversing when encountered with obstruction, Class of protection IP 20 etc.,
having constant power supply 230V, 50/60Hz (by others), for various opening sizes.

8.1.1 AUTOMATIC SENSING DOORS – BI-Parting Sliding Panels

Automatic sliding door operator, modular design, including internal cover.
2-panel sliding door
Operator Dimensions (H x T): 100 x 180 mm.

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 Microprocessor control, self-learning, reversing when obstruction is encountered.
Clear Passage Width: 2-panel = 3000mm (1500mm X2)
Clear Passage Height: 2400mm
Door weight: Bi-Parting Door Panel, max. 2 x 120 kg.

Program modes:
Off, Automatic, Permanent open, Exit only, Self-regulating partial open, Exit only
partial opening, Night-bank facility. Compliant with future European standards and
specifications per EN 12650.

Microprocessor-controlled control unit. Self-learning, with adjustable parameters for

opening and closing speed, hold-open time and opening and closing force. With
pulse expansion for cheque card or code card reader or key switch. Class of
protection IP 20.

Produced according to the guidelines for power-operated windows, doors and gates
BGR 232, the UVV and the VDE regulations. TÜV design tested, tested according to
the low voltage guidelines, production according to ISO 9001 certification. Fulfils the
DIN V18650 (prEN 12650).
Environmental product declaration in accordance with ISO 14025
Programme holder: Institute Construction and Environment e.V.
Declaration number: EPD-DOR-2013511-E

Operator shall be of sturdy design with Self balancing Panel suspension system and
with Anti-Jump fitting.
• Adjustable Parameters Via parameter display and selection key at electronic module.
Adjustable closing Speed: 10 -40 Cm/S
Adjustable Opening Speed: 10 – 50 Cm/S
Hold Open time: 0.5 – 30 Sec
Night Bank Opening time: 0.5 – 30 Sec
Auto Error Display, with Error Code Display for error correction.
Read-out error store with error codes

• Emergency off – Connection for Emergency Off Button, On activation Operator will
Open Fully and Stop all functions, enabling passenger to pass through in case of
Panic.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 202 OF 221

 • Fail Safe / Fail Secure: Choice between emergency opening (Fail Safe) and
emergency closing (Fail Secure) in the event of a power cut (with battery pack).

Additional Equipment Integration:

• Connection for External 24V DC supply: Operator can be integrated and also supply
operating voltage of 24V DC for one external device e.g. Smoke Detector, alarm
system.

Safety devices:
• Inbuilt Obstruction detection feature with automatic reversing cycle on obstruction,
dynamic and static force limitation, emergency control unit (emergency stop),

• Safety Photocells: 2 Pair of Photo Cells are provided for safety of passenger
standing in line of motion of Moving Panel and for through-passage monitoring.
Connection: 230 V, 50/60 Hz, UPS Supply.
Activators: Light barriers, comprising receiver and transmitter -01 Pair
Locking: Electro-mechanical locking, Bistable
Colour light alloy parts: Silver, Anodized E6/C0 – standard
Program switch: 5-position, lockable, aluminum, white, flush-mounted version, 80 x
80 x 40 mm Key operated.

Profiles:
ST- Flex /Equivalent Profiles for Glass thickness 12 mm (minimum). Manufactured as
per Environmental product declaration in accordance with ISO 14025.

8.2 Automatic single side sliding door

8.2.1 General
Automatic single side sliding door shall be of approx. clear opening (size
1500x2400mm) with heavy duty automatic operator, with slim aluminium profiled
framed door of 12mm toughened sliding door panel and fixed panel each of size
1500mm x 2400mm, including internal cover, eagle sensors on both sides, Electro
mechanical lock, light barriers and programmer switch complete, Operator & Frame
Finish shall be Silver Anodized E6/C0 with Operator Dimensions 100 x 180 mm and
required length to suit the size of opening, having separate track profile from the
main profile for enabling reduction in vibration, Microprocessor controlled control unit,
self‐learning, with adjustable parameters for opening and closing speed, hold‐open
time and opening and closing force, reversing when ecountered with obstruction,
Class of protection IP 20 etc., having a constant power supply 230V, 50/60Hz (by
others), for various opening sizes.

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8.2.2 AUTOMATIC SENSING DOORS – Single Sliding Panels
Automatic sliding door operator, modular design, including internal cover.
2-panel sliding door
Operator Dimensions (H x T): 100 x 180 mm.
Microprocessor control, self-learning, reversing when obstruction is encountered.
Clear Passage Width: 1-panel = 1500mm
Clear Passage Height: 2400mm
Door weight: Single Leaf Door Panel, max. 1 x 120 kg.
Program modes:
Off, Automatic, Permanent open, Exit only, Self-regulating partial open, Exit only
partial opening, Night-bank facility. Compliant with future European standards and
specifications per EN 12650.

Microprocessor-controlled control unit. Self-learning, with adjustable parameters for

opening and closing speed, hold-open time and opening and closing force. With
pulse expansion for cheque card or code card reader or key switch. Class of
protection IP 20.

Produced according to the guidelines for power-operated windows, doors and gates
BGR 232, the UVV and the VDE regulations. TÜV design tested, tested according to
the low voltage guidelines, production according to ISO 9001 certification. Fulfils the
DIN V18650 (prEN 12650).
Environmental product declaration in accordance with ISO 14025
Programme holder: Institute Construction and Environment e.V.
Declaration number: EPD-DOR-2013511-E

Operator shall be of sturdy design with Self balancing Panel suspension system and
with Anti-Jump fitting.

• Adjustable Parameters Via parameter display and selection key at electronic module.
Adjustable closing Speed: 10 -40 Cm/S
Adjustable Opening Speed: 10 – 50 Cm/S
Hold Open time: 0.5 – 30 Sec
Night Bank Opening time: 0.5 – 30 Sec
Auto Error Display, with Error Code Display for error correction.
Read-out error store with error codes

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 204 OF 221

 • Emergency off – Connection for Emergency Off Button, On activation Operator will
Open Fully and Stop all functions, enabling passenger to pass through in case of
Panic.

• Fail Safe / Fail Secure: Choice between emergency opening (Fail Safe) and
emergency closing (Fail Secure) in the event of a power cut (with battery pack).

Additional Equipment Integration:

• Connection for External 24V DC supply: Operator can be integrated and also supply
operating voltage of 24V DC for one external device e.g. Smoke Detector, alarm
system.

Safety devices:
• Inbuilt Obstruction detection feature with automatic reversing cycle on obstruction,
dynamic and static force limitation, emergency control unit (emergency stop),

• Safety Photocells: 1 Pair of Photo Cells are provided for safety of passenger
standing in line of motion of Moving Panel and for through-passage monitoring.
Connection: 230 V, 50/60 Hz, UPS Supply.
Activators: Light barriers, comprising receiver and transmitter -01 Pair
Locking: Electro-mechanical locking, Bistable
Colour light alloy parts: Silver, Anodized E6/C0 – standard
Program switch: 5-position, lockable, aluminum, white, flush-mounted version, 80 x
80 x 40 mm Key operated.

Profiles: ST- Flex /Equivalent Profiles for Glass thickness 12 mm (minimum).

Manufactured as per Environmental product declaration in accordance with ISO
14025.

8.3 ELECTRICAL CABLING WORK

All power cables / controls cables shall be provided by the Contractor WITHOUT
ANY EXTRA COST.
.
8.4 STRUCTURAL SUPPORTS

Steel Work In Built Up Section (Welded)

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 205 OF 221

 • The steel work in built up sections (welded) such as in trusses, form work etc. is
specified in this clause.

• Laying out shall be as specified

• Fabrication: Straightening, shaping to form, cutting and assembling, shall be as per

10.3.2 as far as applicable, except that the words “riveted or bolted” shall be read as
“welded” and holes shall only be used for the bolts used for temporary fastening as
shown in drawings.

• Welding: Welding shall generally be done by electric arc process as per IS 816 and
IS 823.

• The electric arc method is usually adopted and is economical. Where electricity for
public is not available generators shall be arranged by the contractor at his own cost
unless otherwise specified. Gas welding shall only by resorted to using oxyacetylene
flame with specific approval of the Engineer-in-charge. Gas welding shall not be
permitted for structural steel work Gas welding required heating of the members to
be welded along with the welding rod and is likely to create temperature stresses in
the welded members. Precautions shall therefore be taken to avoid distortion of the
members due to these temperature stresses. The work shall be done as shown in
the shop drawings which should clearly indicate various details of the joint to be
welded, type of welds, shop and site welds as well as the types of electrodes to be
used. Symbol for welding on plans and shops drawings shall be according to IS 813.
As far as possible every efforts shall be made to limit the welding that must be done
after the structure is erected so as to avoid the improper welding that is likely to be
done due to heights and difficult positions on scaffolding etc. apart from the aspect of
economy. The maximum dia of electrodes for welding work shall be as per IS 814.
Joint surfaces which are to be welded together shall be free from loose mill scale,
rust, paint, grease or other foreign matter, which adversely affect the quality of weld
and workmanship.

• Precautions: All operation connected with welding and cutting equipment shall
conform to the safety requirements given in IS 818 for safety requirements and
Health provision in Electric and gas welding and cutting operations.

• Inspection and testing of welds shall be as per IS 822.

• Assembly: Before welding is commenced, the members to be welded shall first be

brought together and firmly clamped or tack welded to be held in position. This
temporary connection has to be strong enough to hold the parts accurately in place
without any disturbance. Tack welds located in places where final welds will be made
later shall conform to the final weld in quality and shall be cleaned off slag before
final weld is made.

• Erection: The specification shall be as described except that while erecting a welded
structure adequate means shall be employed for temporary fastening the members
together and bracing the frame work until the joints are welded. Such means shall

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 206 OF 221

 consists of applying of erection bolts, tack welding or other positive devices imparting
sufficient strength and stiffness to resist all temporary loads and lateral forces
including wind. Owing to the small number of bolts ordinarily employed for joints
which are to be welded, the temporary support of heavy girders carrying columns
shall be specially attended.

• Different members which shall be fillet welded, shall be brought into as close contact
as possible. The gap due to faulty workmanship or incorrect fit if any shall not
exceed. 1.5 mm if gap exceeds 1.5 mm or more occurs locally the size of fillet weld
shall be increased at such position by an amount equal to the width of the gap.

• Painting: Before the member of the steel structures are placed in position or taken
out of the workshop these shall be painted as specified.

8.5 Measurements & Rate

• The mode of measurements shall be the same as specified except that weight of
welding material shall not be added in the weight of members for payment and
nothing extra shall be paid for making and filling holes for temporary fastening of
members during erection before welding.

• The rate shall include the cost of all labour and materials involved in all the
operations described above.
No extra price shall be paid on account of structural supports required for mounting
doors, sensors, accessories etc.
All wooden/METAL frames for fixing doors, accessories etc. shall be provided by the
Contractor WITHOUT ANY EXTRA COST.

8.6 TECHNICAL DATA

TECHNICAL DATA TO BE FURNISHED WITH TENDER:

The Supplier / Contractor to submit the all relevant technical parameters as specified
in the BOQ for each doors as per the following format

Sl. No. Description of sliding doors Details to furnished

by tenderer
A Sliding Doors
1 Model
2 Manufacturing place
3 Overall Dimensions (LxWxH)
4 Operating Weight (Kgs.)
5 Minimum Clearance required all Around
6 Minimum clearance between adjacent doors
7 Provision of power supply required
8 Adjustable Opening Speed (Cm/S)
9 Adjustable Closing Speed (Cm/S)

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 207 OF 221

 10 Hold Open time (S)

9.0 VISION GLASS

9.1 General

Vision glass panels (IGUs) comprising of hermetically-sealed 35.52mm thick

Laminated D.G.U. consisting of outer 13.52mm laminated (6mm high performance
toughened clear Glass + 1.52mm PVB + 6mm high performance Toughened glass)
+ 16 mm Air Gap + inner 6mm heat strengthened high performance Glass vision
panel units of size and shape as required and specified, of approved colour and
shade with reflective soft / hard coating on surface # 2 , spacer tube 16mm wide,
including primary seal and secondary seal (structural silicone sealant) etc. all
complete for the required performances, as per the Architectural drawings, as per
the approved shop drawings, as specified and as directed by the Engineer-in-
Charge. The DGUs shall be assembled in the factory/ workshop of the glass
processor. “(Payment for fixing of DGU Panels in the curtain glazing is included in
cost of relevant item )“For payment, only the actual area of glass on face # 1 of the
glass panels (including the areas of the grooves and weather silicone
sealant)provided and fixed in position, shall be measured in sqm.“.

9.2 Material properties

Glass properties shall be
Visible Light transmittance (VLT) of minimum 43%,
Light reflection internal 10 to 22%,
Light reflection external 10 to 22 %,
SHGC less than or equal to 0.50 and
U value of less than 1.50 W/m2 degree K etc).

Laminated double Glass insulated panel shall be of sizes section details as shown
on the drawings. The details shown on the drawings indicate generally the
sizes of the components parts and general standards. These may be varied
slightly to suit the standards adopted by the manufacturer. Before proceeding with
any manufacturing the Contractor shall prepare and submit complete manufacturing
and installation drawings for approval of the Engineer in charge and no work shall
be performed until the approval of these drawings is obtained.

9.3 Glazing work

The glass panes shall be of the type and thickness specified in the item. Their sizes
shall be as shown in the drawings. The glass panes shall be of approved quality and
make. They shall have properly squared corners and straight edges. Damaged or
defective glass shall be replaced with new glass at no additional cost. Each piece of
glass shall be delivered with factory labels intact, indicating glass type, quality and
thickness. Labels shall not be removed until installation has been accepted.
Glass is to be protected from breakage immediately upon installation by applying
suitable warning markings. Silicone Sealants as specified by the manufacturers shall
be used.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 208 OF 221

9.4 Final cleaning
Protective coating and warning markings shall remain undisturbed until final
acceptance. Immediately prior to final inspection, temporary protective covering or
coating shall be removed and surfaces shall be washed with a suitable thinner and
left in a finished condition having approved uniform appearance and free from all
marks and blemishes. Both faces of the glass shall be washed and polished.

9.5 Inspection
Agency should arrange for factory inspection of all materials and glass to ascertain
the quality of material as per manufacturer’s standard / BS / ASTM standard,
including toughening of glass as per specification and standards for every 500 sqm
or part thereof.

9.6 Measurements & Rates

Items/ Dimensions shall be measured in specified units as per IS : 1200.

Actual area covered by Glazing shall be measured in square meter for payment.

10.0 TOILET CUBICLES

10.1 General
Toilet cubicles comprises of door, pilaster and divider of 18mm thick board both
side decorative compact laminate of required colour, shade and sizes as approved,
including stainless steel accessories (SS-304 grade), square top rail, Front panel
and divider wall with stripe shoe touching floor (No gap shall be at bottom of
divider/front panel except door), knob, thumb turn and indicator, twin coat hook,
door stopper, adjustable shoe, gravity hinges, and locking arrangement, SS
channel. The cubical unit shall be minimum 10 years guarantee for the board
against any moisture and 5 years guarantee for the hardware’s. (Cubical size =
(900mm width x1500mm depth), Cubical Height =2100mm, External Laminate
finish = Metallic).

a) L-shape toilet cubicles of size 900mm (width) X 1500mm (depth) X 2100mm

(height) with door ,External Laminate finish = Metallic
b) I-shape toilet cubicles of size 900mm (width) X 1500mm (depth) X 2100mm
(height) with door ,External Laminate finish = Metallic

10.2 Material

The Toilet cubical shall be of size and shape as shown on drawings for a unit of
3/4/5 WCs, erected at locations enclosed by corner masonry walls. Division,
frontal and nib panels shall be of 18 mm thick Decorative Thermosetting Synthetic
Resin Bonded Compact Laminated Sheets conforming to IS: 2046. Hardware and
fittings shall be of grade 304 stainless steel conforming to relevant IS codes. In
case of variation of this provision extra / deduction shall be made as per market

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 209 OF 221

 rates of the sqm area of panel provided.

All the material supplied and installed shall be as per the description and
specifications in the item. The following information shall be submitted by the
contractor for obtaining approval of the Engineer-in-charge before start of work.

Product data : Manufacturer's data sheets on each product to be used,

including preparation instructions and recommendations.
Storage and handling requirements and
recommendations. Details of construction and
fabrication. Installation methods.
Shop Drawings : Detailed plans and elevations, details of framing
members, anchoring methods, clearances, hardware,
and accessories clearly shown.
Name of : Approved by the manufacturer, specializing in
fabricator/installer performing work of this section with minimum two years’
experience.
Manufacturer’s Components of the toilet cubical for 10(ten) years
warranty against breakage, corrosion, and defects in factory
Workmanship. Manufacturer’s standard 5(five) year
guarantee against defects in material and workmanship for
stainless steel door hardware and mounting brackets. In
case any defect comes ,the manufacturer has to
replace it with new free of cost

10.2 Delivery, Storage, And Handling

Toilet cubical material and hardware shall be delivered and stored in
manufacturer’s unopened packaging until ready for fabrication and installation. It
shall be protected from damage.

10.3. Fabrication
The substrates shall be prepared including but not limited to blocking and supports
in walls and ceilings at points of attachment using methods recommended
by the manufacturer for achieving the best result. Area shall be inspected to
receive toilet cubicles for correct dimensions, plumpness of walls, and soundness
of surfaces that would affect installation of mounting brackets.

Spacing of plumbing fixtures shall also be verified to assure compatibility with

installation of compartment. Installations shall not be preceded until substrates
have been properly prepared with blocking and supports in walls and ceilings at
points of attachment and deviations from manufacturer’s recommended tolerances

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 210 OF 221

 are corrected. All the fabrication work shall be carried out as per approved shop
drawings.

10.4 Installation
All installation shall be carried out by the fabricator/installer approved by the
Engineer in-charge.. Installation shall be in accordance with manufacturer's written
instructions approved by the Engineer-in-charge.

Blocking and supports in walls and ceilings shall be verified that they have been
installed properly at points of attachment. Location should not interfere with door
swings or use of fixtures. Installation of cubical units should be rigid, straight, true
to plumb, and level. Evidences of drilling, cutting, and fitting to room finish shall be
concealed by capping / shoe box plate etc. U-channels and noise deafening tapes
shall be provided as per drawing. All the units shall be tested for proper operation.
The following fittings shall be provided in each toilet cubical.
1. Gravity hinge - 3 Nos.
2. Coat hook cum Door stopper - 1 no.
3. Door knob cum vacant / engaged position showing device - 1 No.
4. Lock set - 1 No.

10.5 Adjusting, Cleaning and Protection

Adjustment of hardware for proper operation after installation may be permitted
Provided it does not damage the unit either structurally or aesthetically. Hinge
cam may be set on in-swinging doors to hold doors open when unlatched and on
out-swinging doors to hold unlatched doors in closed position.
Touch-up, repair or replacement of damaged products shall be done with prior
approval of the Engineer-in-charge, whose decision shall be final and binding.
Exposed surfaces of compartments, hardware, and fittings shall be cleaned
thoroughly.

10.6 Testing
Required numbers of tests shall be performed on Decorative Thermosetting
Synthetic Resin Bonded Compact Laminated Sheets as per provision of IS: 2046.
Hardware and fittings shall be of grade 304 stainless steel shall also be tested
based on relevant IS codes as decided by the Engineer-in-Charge. Testing
charges shall be paid by the department.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 211 OF 221

10.7 Measurement & Rates
The measurement shall be recorded in numbers.
Rate for the item shall include the cost of all materials, plant, machinery and labour
involved in all operations described above, including all cartage and lifts, complete
for a successful completion of the work.

11.0 Aluminums glazed partition.

11.1 GENERAL
Specially designed aluminium vertical section and horizontal section of extruded
aluminium sections shall be of 6063‐T6 alloy with chemical composition and
mechanical properties as per IS: 733:1983 and I.S. 1285:2002. All the aluminum
sections shall be pure polyester powder coated to 60 microns as per I.S.:1868 of
approved colour OR as per direction of the Engineer in charge. All aluminum profiles
shall be wrapped with protective tapes during delivery at site to provide safety
against external scratches while loading and unloading. (Protective Tapes to be
removed as per the instructions of Engineer ‐In‐charge.
All components should be sealed for water proofing with weather silicon of approved
make for joint movement minimum + 50% according to ASTMC ‐920. (Silicone grade
shall be used as per the manufacturer’s recommendations).
The design and the details of aluminium partitions shall be as per approved drawing.
The detailed shop drawings of aluminium partitions works shall be submitted by the
specialized agency before execution and got approved by structural consultant
through Engineer‐ in charge.
The aluminium glazing frame shall be aligned for the entire height and for the entire
width by laser beam equipment to ensure 100 percent 'X' axis and 'Y' axis alignment.
The entire joints and periphery of glazing system must be properly sealed with
weather silicon of approved make / grade, to make the joint air tight and water tight.
The glass glazing shall be installed / fixed in aluminium framework to the satisfaction
of Engineer in charge.
Gaps up to 10 mm between the peripheral aluminium member (end member) and
Masonry / R.C.C. / Stone shall be sealed by inserting adequate size of backer rod
and weather silicon. Wherever the gaps are expected to be more than 10 mm, shall
be sealed by providing and fixing of 2mm thick aluminum sheet flashings bent to
required profile as per site, aluminum flashing sheet shall be pure polyester powder
coated to 60 Micron thickness in approved shade / colour or as per instruction of

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 212 OF 221

 E.I.C.. Detailed drawing of the flashings to be submitted by the contractor as per the
site conditions for the approval of Engineer‐in charge.
All Screws, Bolts, Nuts and Washers used in the glazing shall be only stainless steel
(S.S. grade 304) and of approved make. Guarantee of adhesion for weather /
structural silicones used for fixing with aluminium works shall be submitted by the
contractor to cover all risks against any failure of glass for a period of 10 years to
Engineer in charge on completion of the works. The above work shall be carried out
by approved specialized Agency to the satisfaction of Engineer‐in Charge.
Module / Size of glass panel – As per detailed drawings.

11.2 MATERIAL:‐
14.2.1 Clear Float Glass:‐
Float glass used for glazing shall be of approved quality conforming to ASTM C 1016
for clear and ASTM 1048 for toughened glass and of the thickness specified in the
item. The tolerance in thickness shall be + 0.08 mm for 10mm to 12mm.

14.2.2 Tempered / Toughened Glass:‐

Float glass conforming to BS 952 Part – I for clear and of the thickness specified in
the item shall be used for manufacturing toughened glass. Toughening, which shall
be carried out horizontally (without tong‐marks), shall conform to ASTM 1048. All
works such as cutting, grinding, drilling etc. on glass shall be carried out prior to
toughening. Once tempering is done, no work will be allowed on the glass.

14.2.3 E.P.D.M. Gaskets;‐

Heavy duty, best quality of EPDM gaskets shall be used as per drawings enclosed.
EPDM gasket should be having its property to last at‐least for minimum 10 ‐12 years,
during this time it should not lose its property of elasticity and should not become
brittle or plastic. It should be manufactured as per ASTM standards recommended
and adopted worldwide.

11.3 Mechanical Properties:-

Hardness, Shore A Durometer ‐ 40A ‐ 90A
Tensile Strength Mpa ‐ 7 ‐ 21
Compression Set B% ‐ 20 – 60
Density ‐ 0.90 to > 2.00 gcm3
Abrasion Resistance ‐ 450mm3

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 213 OF 221

11.4 Thermal Properties:‐
CTE, Linear 68 F ‐ 576 um/m‐ C
Maximum Service Temperature, Air ‐ 150 C
Minimum Service Temperature, Air ‐ 54 C
Glass Temperature ‐ 54 C
11.5 Backer Rod:‐
Backer rod should be composition of closed cell polyethylene light weight, resilient,
non-impregnated, non-staining and non-bleeding, inert sealant, will not adhere and
round with following specifications:‐
a) Water absorption ‐ 0.097 mg/cm2
b) Density ‐ 0.028 ‐ 0.30gm/cm3
c) Elongation ‐ 150 ‐ 175%
d) Thermal conductivity ‐ 10.027Kcalmhoc
e) Resiliency ‐ Excellent
f) Colour ‐ Neutral
g) Stability ‐ Excellent
h) Temp Resistance ‐30 c to +60c

11.6 Weather Silicon: ‐

Weather sealant should have minimum tearing strength 4.0N/mm, shore hardness 20
(ISO 868), joint movement capability +15% (As per ASTM C‐920), The silicon
weather proofing sealant is designed for sealing expansion and control joints, pre
cast panel joints, non-structural curtain wall mullion joints.

11.7 Powder Coating: ‐

Powder Coating of Aluminium Profile to be done having a minimum thickness of 50
microns using Super Coatings confirming to, BS6496,AS3715 , GB5237 with 10
years Guarantee against Peel Off , Film Integrity and Gloss Retention . Coating to be
done through Approved applicator, samples evaluated for the different specification
and then certified as accredited applicator.

11.8 Execution
a) GLAZING WORK:‐ The standard size of glass panels shall be as shown in the
drawings and thickness specified in the item. The glass panes shall be of approved
quality and make. They shall have properly squared corners and straight edges.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 214 OF 221

 Damaged or defective glass shall be replaced with new glass at no additional cost.
Each piece of glass shall be delivered with factory labels intact, indicating glass type,
quality and thickness. Labels shall not be removed until installation has been
accepted. Setting blocks shall be of hard P.V.C. They shall be high enough to
provide minimum edges clearance for glass. Glass is to be protected from breakage
immediately upon installation by applying suitable warning markings.
All components should be sealed for water proofing with approved make of silicon
sealants with joint movement minimum + 50% according to ASTMC ‐920.

b) REPLACEMENT OF GLASS:- In case of glass breakage during installation &

testing, the glass will have to be replaced by deglazing the glass at site & the
re‐glazing of the new glass will have to be done at site without any extra cost up to
defect liability period.

c) FINAL CLEANING:- Protective coating and warning markings shall remain

undisturbed until final acceptance. Immediately prior to final inspection, temporary
protective covering or coating shall be removed and surfaces shall be washed with a
suitable thinner and left in a finished condition having approved uniform appearance
and free from all marks and blemishes. Both faces of the glass shall be washed and
polished.

d) INSPECTION:‐ If desired by E. I. C., agency should arrange for factory inspection

of Aluminium section and glass to ascertain the quality of material i.e. aluminium and
glass as per manufacturer’s standard / BIS / ASTM standard, including anodizing /
P.P.C., toughening of glass as per specification and standards for every 500 sqm or
part thereof.

11.9 Handling & Storage: ‐

Glass shall be securely and safely crated for delivery, handling and storage.
Cushions shall be provided at edges of glass to prevent damage. Glass faces shall
be protected from scratches and abrasions. It shall be stored in a dry, well‐ventilated
location, carefully protected at all times from soiling, atmospheric.

11.10 Tests
a. The aluminium sections shall be of grade confirming to alloy 63400 WP with
chemical composition and mechanical properties as per IS: 733:1983 and IS

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 215 OF 221

 1285:2002. One sample of each section shall be checked for aluminium alloy content
for every 1000 kg Or part thereof.
b. The aluminium shall be pure polyester powder coated to 60 microns as per IS:
1868. The same shall be tested for 1000.00 kg Or part thereof.
c. Float glass shall confirm to BS 952 part – 1 for clear glass. The thickness of glass
shall be checked at any stage.
d. The cost of all testing shall be borne by the contractor.

11.11 Measurement & Rates

i) Length and breadth shall be measured correct to a centimetre and area calculated
in square meter correct to two places of decimal. No deduction shall be made for
extra paid for voids not exceeding 0.20 square meters. Deduction for ends of
dissimilar materials or other articles embedded shall not made for areas not
exceeding 0.10 sq. meters.
The rate shall include the cost of all materials as above like cost of toughened glass,
Aluminium sections, tools, ladders, scaffolding and labor involved in all the operations
Described above including cartage, lifts and all taxes etc. as applicable. However the
cost of M.S structural steel shall be paid separately.

12.0 ACRYLIC SOLID SURFACE COUNTERS. (Item no 9.9-9.15)

12.1 General
Counters such as check in counters, boarding gate Counter, Information Desk,
inspection Desk, check inspection & X-ray Monitoring table, security check &
stamping table etc. shall be as per approved design/ drawings consisting of
counter top, front and side panels made of 18 mm thick particle board, finished
with 12 mm thick antibacterial anti fungal, boiling water resistant heat resistant,
impact resistant, insulative non conductive, stain resistant, scratch resistant,
Green Guard certified Acrylic solid surface (LG Himac, Dupoint, Neonnex or
equivalent as approved) , colour and design, confirming to relevant standards, and
having minimum Specific Gravity 1.65 g/cm3, on counter tops, front and side
panels, 1.5 mm thick approved quality laminated finish on internal face including
hard wood section, for support, wire arrangement, buffing of surface, flushing of
joints, moulding of edges, necessary hardware, silicon sealants, with use of
suitable Low VOC adhesive etc. all complete as per direction of Engineer In
charge.

12.2 Materials

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 216 OF 221

 12 mm thick antibacterial anti fungal, boiling water resistant, heat resistant,
impact resistant, insulative non conductive, stain resistant, scratch resistant,
on porous, homogeneous, Green Guard certified Acrylic solid surface of approved
make.

12.3 Fixing:
Counter to be prepared with Acrylic Solid Surface as per approved drawing and
design made of 18 mm thick particle board, finished with 12 mm Acrylic solid
surface as approved), on counter tops, front and side panels, 1.5 mm thick
approved quality laminated finish on internal with silicon sealants, suitable Low
VOC adhesive etc to give joint less smooth surface complete as per satisfaction of
Engineer In charge. Any additional requirement for fixing is to be arranged by
contractor, Application of Acrylic Solid Surface to be done strictly as per
manufacture’s specification .Necessary moulding of solid surface etc also
included in the scope.

12.4 Workmanship
The workmanship shall be of the very best, all materials a properly qualified
foreman shall be constantly on the job while the work is proceeding. All surfaces
shall be cleaned free of all loose dirt and dust. Acrylic Solid surface joined using a
special adhesive should produce a visibly seamless look. Sanding, buffing and
finishing should be (matt/satin/ gloss) as required of superior quality.

12.5 Concealed Surfaces

All interior and exterior acrylic solid surface work shall be thoroughly similarly
finish and all surfaces and edges which will be concealed when installed. All
surfaces shall be neat and clean.

12.6 Protect and Clean

Contractor shall take care or repair of spills stains and scratches in Acrylic solid
surface and hand over finished component product.
Contractor shall protect not only his own work at all times. but shall also protect
all adjacent work and materials by suitable covering during progress of his work.
Upon completion of his work, he shall remove all unserviceable materials spots
from, walls, and other surfaces. Any defaced surfaces shall be cleaned and the
original finish restored. He shall remove from the premised all rubbish and
accumulated material and shall leave the .work in clean, orderly and acceptable

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 217 OF 221

 conditions

12.7 Measurement & Rates

The measurement of the specified size of the counters shall be recorded in
square meters correct to two places of decimal.
The rate shall include the cost of all the materials, machinery and labour involved in
all the operations described above including cartage, lifts and all taxes Like GST
etc. as applicable. Any incidental additional requirements for execution of this
item to the satisfaction of Engineer-in-charge shall also be treated as included
in the item and nothing extra will be paid for such extra work..

13.0 SOLID ACRYLIC SURFACE CLADDING over column, vanity counters & other
similar area. (Item no a 6.7)

13.1 General

Solid acrylic cladding over Colum, Wash basin vanity counters other similar areas
shall be as per approved design/ drawings with 12 mm thick antibacterial anti
fungal, boiling water resistant heat resistant, impact resistant, insulative non
conductive, stain resistant, scratch resistant, Green Guard certified Acrylic solid
surface of approved make, colour and design, confirming to relevant standards, and
having minimum Specific Gravity 1.65 g/cm3, over 12 mm thick FR grade ply board
board fixed to the M.S frame anchored to masonry surface with all mechanical
fixtures as per manufacturer's specification and guideline, including fascia and back
splash area with suitable Low VOC adhesive, moulding of edges, buffing of surface,
making of holes for plumbing fixtures, wire management wherever required, flushing
of joints, necessary hardware, silicon sealants, etc. all complete as per direction of
Engineer In charge. The plan and elevation area (horizontal and vertical) excluding
wash basin area will be measured for payment.

13.2 Materials
12 mm thick antibacterial anti fungal, boiling water resistant, heat resistant, impact
resistant, insulative non conductive, stain resistant, scratch resistant, on porous,
Homogeneous, Green Guard certified Acrylic solid surface of approved make.
13.3 Workmanship
The workmanship shall be of the very best, all materials a properly qualified foreman
shall be constantly on the job while the work is proceeding. All surfaces shall be
cleaned free of all loose dirt and dust. Acrylic Solid surface joined using a special

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 218 OF 221

 adhesive should produce a visibly seamless look. Sanding, buffing and finishing
should be (matt/satin/ gloss) as required of superior quality.
13.4 Concealed Surfaces
All interior and exterior acrylic solid surface work shall be thoroughly similarly finish
and all surfaces and edges which will be concealed when installed. All surfaces shall
be neat and clean.
13.6 Protect and Clean
Contractor shall take care or repair of spills stains and scratches in Acrylic solid
surface and hand over finished component product.
Contractor shall protect not only his own work at all times. but shall also protect all
adjacent work and materials by suitable covering during progress of his work. Upon
completion of his work, he shall remove all unserviceable materials spots from, walls,
and other surfaces. Any defaced surfaces shall be cleaned and the original finish
restored. He shall remove from the premised all rubbish and accumulated material
and shall leave the .work in clean, orderly and acceptable conditions

13.7 Wash Basin With Solid Acrylic.

oval shaped wash basin of minimum size 550 x 430 x200 mm in vanity counter shall
be made of moulded surface of 12 mm thick Acrylic solid of same Specification as
above, and in approved colour and design, all complete as per drawings,
specification .

13.7 Measurement & Rates

The measurement of the specified size of the counters shall be recorded in square
Meters correct to two places of decimal.
The measurement of the wash basin shall be recorded in numbers.
The rate shall include the cost of all the materials, machinery and labour involved.
Any incidental additional requirements for execution of this item to the satisfaction of
Engineer‐in‐charge shall also be treated as included in the item and no extra will be
paid for such extra work.

14.0 GLASS FOR SS RAILING

Glass for SS railing shall be 12 mm thick toughened glass of approved make and
including SS fittings, necessary SS fixtures, making necessary holes etc, all
complete .

14.1 GENERAL
Single glass panel shall be of sizes section details as shown on the drawings. The

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 219 OF 221

 details shown on the drawings indicate generally the sizes of the components parts
and general standards. These may be varied slightly to suit the standards
adopted by the manufacturer. Before proceeding with any manufacturing the
Contractor shall prepare and submit complete manufacturing and installation
drawings for approval of the Engineer in charge and no work shall be performed until
the approval of these drawings is obtained.

14.2 SHOP DRAWINGS

The Contractor shall submit the shop drawings as per architectural drawings to the
Architect / Engineer in charge for their approval.

14.3 SAMPLES (Glass, Hardware, Screws)

Samples of Glass / all hardware to be used for making railing shall be fabricated,
assembled and submitted to the Architect / Engineer in charge for his approval. They
shall be of sizes, types etc. as per detailed drawings.

14.4 FITTINGS
All Type of fittings shall be of approved make duly approved by the Engineer in
charge / Architect.

14.5 GLASS
Toughened / Tempered/ heat strengthen/ heat soaked glass shall be examined by
the glass manufacturer to detect and discard any glass which exceed the following
tolerance: 1.5mm bow in 600mm: 3mm bow in 1500mm ; 6mm bow in 3000mm ;
9mm bow in 4500mm. Where the strengthening process results in essentially
parallel ripples or waves, the deviation from flatness at any peak shall not exceed
0.13mm and the difference between adjacent peaks shall not exceed 0.13mm.
Where bow tolerance and wave tolerance differ, the stricter requirements shall
govern. Direction of ripples shall be consistent and in conformance with architectural
design.
Following test shall be also carried out by the contractor at his own cost as per
following provisions.
Thickness Impact Strength Fragmentation Surface Bending strength
compression

IS-2835-1987 IS-2553-PART-I IS-2553-PART-I ASTM C-1048-90 DIN1249-PART-12

i) Toughened Glass:-

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 220 OF 221

 Float glass conforming to BS 952 Part - I for clear and of the thickness specified in
the item shall be used for manufacturing toughened glass. Toughening, which shall
be carried out horizontally (without tong-marks), shall conform to ASTM 1048.

14.5 MEASURMENT & RATE

Length and breadth shall be measured correct to a centimeter and area calculated in
square meter correct to two places of decimal.
The rate shall include the cost of all materials as above like cost of toughened glass,
SS fittings, necessary SS fixtures, tools, ladders, scaffolding and labor involved in all
the operations described above including cartage, lifts and all taxes etc. as
applicable.

VOLUME-2 (CIVIL) SOW & SPECIFICATIONS PAGE NO. 221 OF 221

 Scope of Work
For
Electrical Works for Leh Airport

(B047-003-16-50-SOW-0001, REV. 0)

PROJECT : CONSTRUCTION OF AIRPORT AT LEH

CLIENT : AIRPORT AUTHORITY OF INDIA

LOCATION : LEH, JAMMU & KASHMIR

CONSULTANT : ENGINEERS INDIA LIMITED

JOB NO. : B047

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 1 OF 1216

 INDEX

S. No. Description
1. GENERAL

2. SCOPE OF WORK

3. SPECIFIC REQUIREMENTS

4. JOB SPECIFICATIONS

5. STATUTORY APPROVAL OF WORKS

6. INSPECTION, TESTING AND COMMISSIONING

7. SYSTEM TESTS AND START-UP

8. DRAWINGS

8. LIST OF ATTACHMENTS

1. GENERAL

1.1 INTRODUCTION

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 2 OF 1216

1.1.1 The intent of this specification, is to define the requirements for the supply (wherever specified),
installation, testing and commissioning of the electrical power distribution system consisting of
various electrical equipment, lighting system, earthing & lightning protection system and cabling
system and other miscellaneous works for Airport located at Leh.
1.1.2 The work shall be carried out in best workmanship-like manner, in conformity with these
specifications, approved drawings and the instructions, from time to time, of the Owner or Engineer-
in-Charge.
1.1.3 It shall be noted by the bidder/ contractor that the rating of the equipments/ components specified in
SOR/ SLD/ hard-ware data-sheets, etc. are without any de-ration due to site conditions mentioned in
Clause no. 1.4 below. It shall be the responsibility of the vendor to furnish the required de-rating
calculations for the offered equipments/ components as per relevant codes/ standards/ standard
engineering practice and obtain approval from the Owner. It may be please noted that no separate
cost or time implication shall be borne by Owner for the mentioned point.

1.2 STANDARDS

1.2.1 The work shall be performed in conformity with these specifications and standard specifications,
installation standards and Codes of Practice specified or referred in the tender. In case of any
conflict, the stipulations under these specifications shall govern.

1.2.2 In addition, work shall also conform to the requirements of latest editions/ amendments of the
following:

a. Fire Insurance Regulations

b. Regulations laid down by the Chief Electrical Inspectorate
c. Regulations laid down by the Factory Inspectorate
d. Applicable Codes of Practice of the Bureau of Indian Standards
e. Any other regulations laid down by the Central, State or Local Authorities from time to time and
during the execution of this contract.

In case of any conflict in requirement specified in various codes and standards referred above, the
more stringent requirement shall govern. Owner’s concurrence shall always be obtained in any such
matter.

1.3 GUARANTEE

1.3.1 The CONTRACTOR shall guarantee the installation against any defects of workmanship and
materials (supplied by the CONTRACTOR) for a period of 12 months from date of issue of
completion certificate. Any damage or defects connected with the erection of material(s)/ equipment
and with the materials/ equipment supplied by the contractor that may be undiscovered at the time of
issue of completion certificate or may arise or come to light thereafter, shall be rectified or replaced
by the CONTRACTOR at his own expense as deemed necessary and as per instructions of
Engineer-in-Charge/Owner, within time limit specified by the Owner/Engineer-in-Charge.

1.3.2 The above guarantee shall be applicable for the quality of the work executed as well as for all
equipment/ cables/ fixtures/ fittings/ other materials supplied by the contractor.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 3 OF 1216

1.4 SITE CONDITIONS

The equipment and the installation shall be suitable for continuous operation considering the
applicable derating factors under the following site conditions:

Maximum Ambient Temperature : +35°C

Minimum Ambient Temperature (Outdoor/Indoor) : -22°C/-5°C

Design Temperature : +40°C

Max. Relative Humidity : 30-100%

Altitude : 3515 m above MSL

Location : Leh, J&K

1.5 UTILIZATION VOLTAGES

HV distribution voltage : 11 kV ± 10%

MV motor voltage (415V AC) : Upto 160 kW

Battery chargers input : 415 V AC ± 10%

UPS System input : 415 V AC ± 10%

AC Lighting / Power Panel input : 415 V AC ± 10%

UPS Lighting Panel input : 230V SPN ± 10%

Welding Receptacles : 415 V AC ± 10%

Bulk loads like Process Heaters, etc. : 415 V AC ± 10%

Normal Lighting : 240 V AC SPN ± 10%

Convenience outlets : 240 V AC± 10%

Emergency lighting : 240 V AC SPN ± 10% (UPS)

Switchgear control : 110 V DC± 10%

1.6 BRIEF DESCRIPTION OF ELECTRICAL SYSTEM

The Leh Airport Project includes, but is not limited to, the following:

To meet the power supply requirements of the Airport, the power shall be made available through
1 no. 11 kV of dedicated feeder by Distribution Company/AAI at the HT Metering Room of Utility
Building of LEH airport. Upstream HT cable, cable laying activities including trench, HT cable
termination, etc. shall be in the scope of AAI/ SEB. 11kV grade HT power cable, termination &
cable trench/ tray required for the cable laying from HT metering room to HT-201 switchboard
shall be in the Contractor’s scope. However, site coordination/ support for above mentioned works
by AAI/ SEB shall be in the scope of contractor.

11 kV, HT-201 HV switchboard shall be installed at HT Room of Ground Floor- Utility Building.
Power shall be further stepped down to 415V using 3 nos. of 11kV / 0.433kV, 2000kVA Oil type

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 4 OF 1216

 transformers. Transformers shall have Remote Tap Changer Control Panel for automatic voltage
step-up/down.

415V power from 3 nos. of transformers shall be provided to downstream PCC-301 panel
(installed at basement floor of Utility Building) through air-insulated 415V Bus-Ducts.

All the loads of Airport have been considered as critical and hence DG sets have been provided to
cater all the loads of airport building. 3 nos. of 1500kVA (alternator rating) and 1 no. of 500 kVA
(alternator rating) DG set @ 415V have been considered at Utility Building to cater the overall
load.

415V, 2500A air-insulated Bus-Ducts shall transfer power from DG sets to EPCC-302 from 3 nos.
of 1500 kVA DG sets. MV cables shall be used for connecting 415V, 500 kVA DG set to EPCC-
302. It is the philosophy that all the DGs shall be controlled & operated from EPCC-302 which
shall be complete with AMF & synchronisation relay, Load Manager PLC and synchro-scope &
cut-off switch. However, control panels and other required items (which are not considered in
EPCC-302) to control the engine shall be considered by contractor separately.

3 nos. of 3000A ACB outgoing plant feeders of EPCC-302 shall provide emergency power to
PCC-301 through 415V Bus Ducts. The Load Manager PLC of EPCC-302 shall have the in-built
logic for selection and operation of DG sets as per the load requirement of Airport. It shall be the
responsibility of the DG vendor to ensure the operation philosophy of the DG sets through EPCC-
302 with the help/ inputs to Panel Vendor.

PCC-301 shall have 8 nos. of incomers. 3 nos. incomers from 11/0.433 kV, 2000kVA transformers
through 3000A bus-ducts, 3 nos. of incomers from EPCC-302 through 3000A Bus-ducts and 2
nos. of incomers from Solar Electric Power System.

Further, PCC-301 shall feed downstream ASB-1, ASB-2, Chiller DB, Water Pump Panel, UPS
panels, AHU panels, etc.

3 nos. of 415V, 600 kVAR APFC has been considered for maintaining power factor of the airport
to min. 0.98. 1 no. of APFC shall be connected to 1 no. of Bus each of PCC-301.

Power & control cables from Utility Building shall be laid to Terminal Building through service
tunnel. At terminal Building, each floor have 2 nos. of electrical rooms for distribution of power.
Rising mains have been considered for distribution of lighting system & power panels.

Lighting system shall consist of Normal and emergency (through UPS) lighting. It shall consist of
lighting distribution board (LDB), lighting panel, power panel, LED lighting fixtures, wiring etc.

Single line diagram shall illustrate the power distribution scheme in detail.

The contractor’s scope includes supply, installation, testing and commissioning of switchboard,
isolating breaker, distribution transformers, cabling, lighting, earthing & lightning protection
system, grid connected solar power system etc.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 5 OF 1216

1.7 Interface with other Building Systems

The following are the brief list of major Building Systems in which scope of electrical works
are as mentioned below:

1.7.1 HVAC Chillers

415V, 1250A, Chiller DB have been considered from which 3 nos. of Chillers (2 working + 1
standby) shall be energized. The VFD of chillers (to be supply in Chiller Package) shall be
fed from MCCB + Contactor feeder of Chiller DB. Further controlling of VFD or trip/ closed
of upstream power feeder of Chiller DB shall be done by Plant Manager of Chiller. Primary
pumps of chillers shall be Soft-starter fed (to be supplied along with pump-motor).
Secondary pumps of chillers shall be VFD fed (to be supplied along with pump-motor). All
the feeders shall be operated from either BMS/ Chiller Plant Manager.

1.7.2 AHUs

AHU Sub-Distributions boards (AHU-1, 2, 3, 4 & 5) have been considered to feed various
AHU DBs (15 nos. approx.) of different levels in terminal building & Utility Building. AHU
DBs shall provide bulk power to individual AHUs from where vendor shall provide their own
local Distribution panel as per the system requirement for power distribution & utilization.

During emergency situation such as fire, relay modules of Fire Alarm system shall provide
potential free-contact to the AHU after which AHU shall shut down and lower the dampers,
etc. as per fire norms.

1.7.3 Lift & Escalator Panels

2 nos. of Lift & Escalator panels have been considered to feed various Lift & Escalator of
different levels in terminal building & Utility Building. Bulk power to individual equipment
shall be provided at a single point from where vendor shall provide their own local
Distribution panel as per the system requirement for power distribution & utilization.

During emergency situation such as fire, relay modules of Fire Alarm system shall provide
potential free-contact to the equipments.

1.7.4 Pressurization Panels

Pressurization Panel shall have motor feeders to feed all fans of Smoke Extraction System,
Lift Well Fans and Staircase pressurization system. These fans shall be operated only in
case of occurrence of fire and hence, incomer of the panel has been provided with MCCB +
contactor feeder which shall obtain signal from relay module of Fire Alarm System.

1.7.5 Departure Check-In Panel

2 nos. of bulk power supply shall be provided at Electrical Rooms of Terminal Building at
Level-1 where Distribution Board shall be provided by Baggage Handling System Vendor.
415V, 25kA (1 sec.), fixed type, floor mounted, top cable entry , of required rating shall be
supplied by the vendor with 2 nos. of MCCB incomers with mechanical interlock, MCCB/
MCCB + contactor outgoing feeders as per requirement with min. 10% or min. 1 no. of
spare rated feeder of each type and shall be as per tender specifications. Further cable
laying, cable trays, etc. shall be in the scope of vendor.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 6 OF 1216

1.7.6 Arrival Check-In Panel

2 nos. of bulk power supply shall be provided at Electrical Rooms of Terminal Building at
Level-1 where Distribution Board shall be provided by Baggage Handling System Vendor.
415V, 25kA (1 sec.), fixed type, floor mounted, top cable entry , of required rating shall be
supplied by the vendor with 2 nos. of MCCB incomers with mechanical interlock, MCCB/
MCCB + contactor outgoing feeders as per requirement with min. 10% or min. 1 no. of
spare rated feeder of each type and shall be as per tender specifications. Further cable
laying, cable trays, etc. shall be in the scope of vendor.

1.8 Metering Requirements in Panels as per ECBC/ Griha

Apart from the metering requirement mentioned in SOR/ hard-ware data-sheets/ SLD,
vendor shall note the requirement/ considerations which shall be provided in the Panels in
order to comply with ECBC/ Griha norms.

2 SCOPE OF WORK

The scope of this tender includes but is not limited to the below mentioned works. The scope shall
also include handling, transportation of equipment/ material to the place of installation wherever
required.

2.1 Design, Supply, Installation, Testing and Commissioning of the following (Equipment/
Material supplied by contractor) considering the applicable derating factors as per the site
conditions mentioned in Cl. No. 1.4 :

2.1.1 11 KV, 630A, 25 KA for 3Sec., indoor type, floor mounted, metal clad, double front HV switchboard
(HT-201) having VCB incomer with Line PT, Bus PT and VCB outgoing feeders complete with lifting
truck & earthing truck, CTs, PTs, communicable MFM, metering & Numerical relays, Ethernet switch
and all other required accessories having copper bus bar in draw out execution as per data sheets
enclosed.
For details, refer datasheets, Instructions to vendor (B047-003-16-50-TR-0001) & Specification No.
6-51-0001 & 6-51-0055.
2.1.2 11 KV Power cabling to HT panel, from 11KV HT panel to the 11/.433 KV Transformers including the
end terminations, cable joints, cable trays & supports, related civil works as required.
2.1.3 11/0.433 KV, 2000KVA, Dyn11, ONAN outdoor distribution transformers with OLTC & RTCC. For
details, refer datasheet, Instructions to vendor (B047-003-16-50-TR-0002) & Specification No. 6-51-
0041. It may be noted that the rating mentioned above is the net output required and after de-rating
of the transformer rating as per the site conditions (either MVA method or temperature correction
method), the downstream fault-level of the electrical system shall not be exceeded and necessary
calculation shall be furnished along with the offer accordingly for owner’s approval.
2.1.4 415V, 50kA for 1 sec MV bus duct complete with horizontal & vertical bends, expansion joints,
copper flexible end connections, space heaters etc. Refer datasheet, Specification No. 6-51-0054.
415 V, 50Hz, TPN, 50kA (1 sec.) indoor type, double front, metal enclosed Power Control Centre
(PCC-301) in draw out execution. PCC shall have ACB incomers with line PT; Bus PT; Bus-
Couplers; ACB (EDO Type) outgoing feeders (for feeders rated 630A & above) & MCCB outgoing
feeders (for feeders rated below 630A) as required complete with CTs, PTs, communicable MFM,
THD meters, metering & Numerical relays, Ethernet switch as per tender data sheets and SOR. For
details, refer datasheets, Instructions to vendor (B047-003-16-50-TR-0003) & Specification No. 6-51-

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 7 OF 1216

 0018 & 6-51-0055.
2.1.5 415 V, 50Hz, TPN, 35kA (1 sec.) indoor type, double front, metal enclosed Auxiliary Switchboards
(ASB) in draw out execution. PCC shall have ACB incomers with line PT; Bus PT; Bus-coupler; ACB
(EDO Type) outgoing feeders (for feeders rated 630A & above) & MCCB outgoing feeders (for
feeders rated below 630A) as required complete with CTs, PTs, communicable MFM, THD meters,
metering & Numerical relays, Ethernet switch as per tender data sheets and SOR. For details, refer
datasheets, Instructions to vendor (B047-003-16-50-TR-0003) & Specification No. 6-51-0018 & 6-51-
0055.
2.1.6 415 V, 50Hz, TPN, 50kA (1 sec.) indoor type, single front, metal enclosed Emergency Power Control
Centre (EPCC-302) being fed from DG sets in draw out execution complete with PLC Load
manager, AMF and Synchronizing facilities. PCC shall have ACB incomers with line PT, Bus PT and
ACB outgoing feeders (for 630A & above) & MCCB outgoing feeders (for below 630A) as required
complete with CTs, PTs, communicable MFM, metering & Numerical relays, Ethernet switch as per
tender data sheets and SOR. For details, refer datasheets, Instructions to vendor (B047-003-16-50-
TR-0003) & Specification No. 6-51-0018 & 6-51-0055.
2.1.7 415 V, 50Hz, TPN indoor type, single front, metal enclosed MV Switchboards in fixed type execution
with MCCB incomer having mechanical interlock (as required) & MCCB outgoing feeders as per
tender datasheets & SOR. For details, refer datasheets, Instructions to vendor (B047-003-16-50-TR-
0003) & Specification No. 6-51-0012 & 6-51-0055.
2.1.8 Electrics for 3 Nos. of 415V, 1500kVA & 1 no. of 415V, 500kVA Alternator of DG set. For details,
refer datasheets, Specification No. 6-51-0040 & 6-51-0030. It may be noted that the rating
mentioned above is the net output required and after de-rating of the alternator rating as per the site
conditions (either MVA method or temperature correction method), the downstream fault-level of the
electrical system shall not be exceeded and necessary calculation shall be furnished along with the
offer accordingly for owner’s approval. Engine rating shall be as per specification referred elsewhere
in the tender.
2.1.9 415V, 3 phase, 50Hz, 600kVAr Indoor type APFC Panel for power factor improvement complete with
capacitors, reactors, PF regulator & controller, required protections and all other necessary
accessories etc.
2.1.10 415V, 3 phase, 50Hz. DOL and Star-Delta Starter Panels as per tender SOR.
2.1.11 415V, 3 phase, 50Hz. Dual speed DOL motor starter for tunnel ventilation fans.
2.1.12 Weatherproof type local push button stations with start push button, stop push button, three position
selector switch, ammeter, speed raise & speed lower push buttons (as required) per tender
requirements. For details, refer Specification No. 6-51-0014.
2.1.13 415V Variable Frequency Drive with in-built bypass feature. It shall have a provision of RS-485
communication port for interface requirements with BMS. For details, refer datasheets &
Specification No. 6-51-0038.
2.1.14 415V V/F controlled soft starter. It shall have a provision of RS-485 communication port for interface
requirements with BMS. For details, refer datasheets & Specification No. 6-51-0036.
2.1.15 415V, 200 kWp (min.) Solar grid-connected rooftop system without battery back-up complete with
PV Modules, Module Mounting structure, Inverters, Junction Boxes, DC & AC cables, switches,
breakers, connectors etc. and other required components/ accessories as per datasheets and Job
Specifications (B047-003-16-50-SP-1001).
2.1.16 Electric Heat Tracing System complete with electric heat tracers, insulation & cladding, LDP, cables,
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 8 OF 1216
 cable trays, junction boxes, thermostat, earthing & all necessary accessories for the completeness of
the system. For details, refer datasheets, Job Specifications (B047-003-16-50-SP-1003) &
Specification No. 6-51-0095.
2.1.17 Fire Alarm System having GUI based main network Fire Detection complete with Fire Alarm Panel,
battery back-up system, Manual call points, smoke detectors, heat detectors, response indicators,
fault isolator module, sounder, relay module, monitor module, hooter acknowledgement box, exit
sign boards, non-jelly filled FRLSH cables & conduits etc as required. For details, refer datasheets,
Instructions to vendor (B047-003-16-50-TR-0006) & Specification No. 6-51-0076.
2.1.18 Digital Public Address cum Emergency Sound System complete with controller, remote call station,
various type of speakers (as required), microphone, PC, non-jelly filled FRLSH cables & conduits
etc. having a provision of interface with BMS, FA system, CCTV & FIDS. For details, refer
datasheets, Job Specifications (B047-003-16-50-SP-1002) & Specification No. 6-51-0072.
2.1.19 110V DC System complete with VRLA Batteries, Battery Charger & DCDB. For details, refer
datasheets, Instructions to vendor (B047-003-16-50-TR-0005) & Specification No. 6-51-0019.
2.1.20 1100V grade MV cables for power, control, space heater and lighting with cable glands, lugs etc.
Refer datasheets & Specification No. 6-51-0051.
2.1.21 Parallel redundant UPS system with bypass (with 2X50% VRLA batteries) with 230V single phase
output for lighting system having a back up time of 30 minutes. UPS shall have a RS-485
communication port for interface requirements with BMS. For details, refer datasheet, Instructions to
vendor (B047-003-16-50-TR-0004) & Specification No. 6-51-0017 & 6-51-0048.
2.1.22 Parallel redundant UPS system with bypass (with 2X50% VRLA batteries) with 415V three phase
output for Instrumentation having a back up time of 30 minutes. UPS shall have a RS-485
communication port for interface requirements with BMS. For details, refer datasheet, Instructions to
vendor (B047-003-16-50-TR-0004) & Specification No. 6-51-0017 & 6-51-0048.
2.1.23 Prefabricated hot dip galvanized steel cable trays, fabricated out of hot rolled sheet steel including all
necessary accessories.
2.1.24 Gl fabricated raceways including removable 3mm thick cover with knockout holes and all the other
required accessories.
2.1.25 Digital Lighting Management System consisting of Main Lighting Management Panel (Part of BMS
System) , Bus Power Supply Modules, Addressable Day-Light & Occupancy Sensors, LED type
Lighting Fixtures, Lighting And Power Panels etc. including wiring requirements & LAN requirements.
2.1.26 Junction Boxes, switches, sockets, receptacles, ceiling fans, exhaust fans, including wiring
requirements & LAN requirements.
2.1.27 Complete cable trench work as required for cable laying.
2.1.28 Grounding system including GI earth electrodes in test pits, wire ropes, earth plate, earthing cables /
strips of various sizes, flexible connections, associated connectors and accessories etc.
2.1.29 Lightning protection system with required quantity of horizontal & vertical air termination system,
down conductors, earthing system including all the accessories.
2.1.30 Safety equipment/ fire extinguishers, safety mat, sand bucket, First Aid Box, discharge rod, rubber
hand gloves, Shock treatment chart in sub-stations and wherever specified in relevant drawings /
specifications.
2.1.31 Chequered plates for covering floor cutouts, unused cable trenches etc.
2.1.32 Fire proof sealing system including supply & fabrication of steel frames.
2.1.33 Gravel as required in transformer bays etc.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 9 OF 1216
2.1.34 Any other material not specifically mentioned above but required for completion of the work as per
specifications, drawings and instruction of Engineer-in-charge.
2.1.35 The scope shall also include handling, transportation of equipment/ material from owner's stores/
warehouse to the place of installation wherever required.
2.1.36 Civil foundations and steel structural for Transformers and for other equipments as required.
2.1.37 Single point power supply feeders for various packages like STP etc. shall be provided in the 415V
switchboard. However, the complete engineering and required electrical equipments/components for
the packages shall be in contractor’s scope.

Note: 1. Quantities given in SOR are tentative. Contractor shall take owner's approval before
ordering.

2.2 Miscellaneous

2.2.1 The job includes repairing of all civil works damaged during installation of electrical facilities and civil
works connected with grouting of equipment, providing foundations for control stations, lighting
poles, cable markers, earth pits etc. Scope of work under this contract shall be inclusive of breaking
of walls/ floors and chipping of concrete foundations necessary for the installation of equipment,
materials and making good of the same.
2.2.2 Coordination between various agencies/ equipment vendor/ other contractors working at site and
providing all assistance and interface connections as per drawings to enable others to take up
testing and commissioning activities of their equipment/ systems.
2.2.3 Supply and installation of all other accessories not specifically mentioned herein but nevertheless
necessary for completion of job.
2.2.4 Engineering and preparation of specifications and drawings for electrical equipment and installation
wherever applicable/ required by owner and submitting the same to owner for approval/ comments.
2.2.5 Correction and submission of all owners’ drawings for As-built status.
2.2.6 Obtaining clearance and approvals for installation/ drawings from Central Electricity Authority and
any other statutory authority for energizing the complete electrical facilities covered under this
tender. It may be noted that no separate payment shall be made for any statutory approvals and the
cost shall be deemed to be built in the rates quoted for various SOR items.
2.2.7 Sealing of openings made in walls/ floors, firewalls for cables etc., using acceptable practices and
standards.
2.2.8 Contractor shall intimate the discrepancies (if any) in the coordination of various cable trays and
raceways as applicable prior commencement of execution of works.

3 JOB SPECIFICATIONS

3.1 Various electrical works covered under this contract like equipment installation, cabling, lighting and
earthing works, etc. shall be performed in accordance with the following standards (certain clauses
of specifications which are applicable to equipment or systems not covered under this contract shall
be omitted):
6-51-0081 Specifications for Electrical Equipment Installation

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 10 OF 1216

 6-51-0082 Specifications for Cable Installation
6-51-0083 Specifications for Lighting Installation
6-51-0084 Specifications for Earthing Installation
6-51-0087 Specification for field inspection, testing and commissioning of electrical installations

3.2 Erection, testing and commissioning of equipment shall be performed in accordance with supplier’s
instructions and directions of the engineer-in-charge.
3.3 The installation shall also conform to specifications and installation standards attached with this
tender and referred therein.
3.4 Documents attached are as per ‘List of attachments’ included in this specification.
3.5 All electrical equipment shall be said to be installed and mechanically complete after circuit testing,
primary and secondary injection testing and loop simulation is complete. Due care and consideration
shall be given to the installation of all equipment, material and facilities.
3.6 Contractor shall coordinate with manufacturer of other equipment wherever required and shall freely
and readily supply all technical information for this purpose as and when called for.
3.7 All other Electrical equipment, materials and work not explicitly mentioned but nevertheless required
to fulfill the following minimum requirements shall be deemed to be included in the scope of the
CONTRACTOR with no additional cost and time implication to OWNER.
3.7.1 Achieving the plant equipment and personnel safety.
3.7.2 To meet the equipment and environment safety.
3.7.3 To suit site facilities and environmental conditions.
3.7.4 To meet the requirement of statutory approving authority.
3.7.5 To co-ordinate with other CONTRACTORS and agencies involved in at site for other activities and
site work.
3.7.6 Annexure-A of SOW shall be referred for specifications of raceway, wiring & conduit system along
with CPWD specifications.

4 STATUTORY APPROVAL OF WORKS

4.1 Contractor shall make an application on behalf of the owner for submission to CEA/ Electrical
Inspectorate along with copies of required certificates complete in all respects and submit to the
engineer-in-charge for onward transmission well ahead of time so that the actual commissioning of
system/ equipment is not delayed for want of inspection by the Inspector. Contractor shall arrange
the actual inspection of work by the Electrical Inspector. Necessary coordination and liaison work in
this respect shall be the responsibility of the contractor.
4.2 The Inspection and acceptance of work as above shall not absolve the Contractor from any of his
responsibilities under this contract.
4.3 Any other statutory approval of works required for the electrical installation (such as TAC, CCE, etc.)
is also included in contractor’s scope.

5 INSPECTION, TESTING AND COMMISSIONING

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 11 OF 1216

 Site inspection, testing and commissioning of electrical installation shall be carried out as per
enclosed Specification no. 6-51-0087 and Inspection and Test Plans included or referred in this
Tender.
5.1 All the equipment installed by the contractor shall be tested and commissioned, as required and no
separate payments shall be made unless otherwise specified in the Schedule of Rates. Contractor
shall carefully inspect all equipment before receiving them from owner for installation purposes. Any
damage or defect noticed shall be brought to the notice of the engineer-in-charge at that time.
5.2 Any work not conforming to the execution drawings, specifications or codes shall be rejected
forthwith and the contractor shall carry out the rectification at his own cost.
5.3 The contractor shall carry out all the tests as enumerated in the tender and technical specifications
and technical documents which may be furnished to him during performance of the work.
5.4 Before the electrical system is made live, the electrical contractor shall carry out suitable tests to
establish to the satisfaction of Engineer-in-Charge/ Owner that the installation of equipment, cabling/
wiring and connections have been correctly done and are in good working condition and that the
system/ equipment will operate as intended.
5.5 All tests shall be conducted in the presence of Owner/ Engineer-in-Charge or his authorized
representative unless he waives this requirement in writing. Contractor shall arrange testing
equipment, as required to carry out the tests. Test results shall be recorded on approved Performa
and certified records of the tests shall be submitted to Owner/ Engineer-in-Charge.
5.6 After the completion of all tests and rectification of all defects pointed out during final inspection,
plant start-up trials shall commence. During the start-up trials, contractor shall provide skilled/
unskilled personnel and supervision round the clock at his own cost. The engineer-in-charge/ owner
will decide the number and the category of workmen and their duration. Any defects noticed during
the start-up trials relating to the equipment supplied and work carried out by the contractor, shall be
rectified by the contractor at his own cost.
5.7 Owner/ Engineer-in-Charge shall have the right to get the defects rectified at the risk and cost of the
contractor if he fails to attend to the defects immediately as desired.
5.8 The following equipment/ items as included in Contractor's scope of supply shall be tested and
inspected by owner or his authorized representative before dispatch at the manufacturer's works.
Test certificates duly signed by Owner/ Owner’s authorized representative shall be submitted by the
contractor as part of the final document:
i. HV switchboard
ii. 11/0.433kV Distribution transformer
iii. 415V switchboard
iv. VFD / Soft starter
v. Cables.
vi. UPS
vii. Solar Power System
5.9 Contractor shall also avail OEM (Equipment manufacturer) services for testing and commissioning of
equipment as required.
5.10 Contractor shall furnish site acceptance test (SAT) procedures from the equipment supplier and get
it approved from OWNER before carrying out the same at site.
5.11 Contractor shall prepare detailed testing, pre-commissioning and commissioning procedures for the
entire installation. These shall include Performa for defining activities and recording of test results.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 12 OF 1216
6 SYSTEM TESTS AND START-UP

6.1 Complete testing of power distribution system at the Leh Airport would be carried out under the
supervision of the owner/ engineer-in-charge. The contractor shall provide as part of the works and
within his quoted rates, on round the clock basis, skilled personnel and supervisors to carry out the
plant testing. The number and category of skilled personnel to be deployed by the contractor shall
be decided by the engineer-in-charge and the contractor shall abide by his decision.
6.2 During start-up, the Contractor's responsibilities would be limited to attending to the defects
attributable to him in the plant as and when they are brought to his notice. Defects shall be rectified
at the risk and cost of the contractor if he fails to attend to these defects immediately.
6.3 After the operating conditions are fully achieved in all the plants and the requirement as stated in
General Conditions of Contract are fulfilled, the contractor would be eligible for applying for a
completion certificate.
6.4 Where the works are carried out at the cost of the contractor, the engineer-in-charge would recover
the cost incurred towards, labor, supervision and materials, consumables or otherwise, plus
overheads, from any pending bill of the contract or the security deposit, as referred elsewhere.
6.5 Contractor shall include painting and marking of all buses, individual incomers, all outgoing feeders
etc. with detail such as Tag no., feeder rating, sending end source reference etc. for all
switchboards. Fuse rating on all switchboards for outgoing feeders etc. shall also be marked.

7 DRAWINGS

7.1 The drawings accompanying the tender document are indicative of the nature of work and issued for
tendering purpose only. The purpose of these drawings is to enable the tenderer to make an offer in
line with the requirements of the owner. However, no extra claim, whatsoever, shall be entertained
for any variation between the ‘Approved for Construction (AFC)’ and ‘Tender Drawings’ regarding
any changes. Construction shall be carried out as per drawings/ specifications issued/ approved by
the engineer-in-charge during the course of execution of work. Detailed construction drawings on the
basis of which actual execution of work is to proceed will be furnished to the contractor progressively
based on the detailed construction program evolved after the award of work and also based on
construction progress achieved by the contractor.
7.2 Prospective tenderer shall be deemed to have studied the drawings enclosed with tender or
displayed for scrutiny and fully understood the nature and magnitude of the work before submitting
the bids.
7.3 Where the contractor has to prepare drawings, e.g. for fabrication of panels etc., contractor shall
submit the drawings to engineer-in-charge and the approval in writing of the engineer-in-charge shall
be obtained before commencing fabrication.
7.4 After the job completion, contractor shall prepare 'As-Built' drawings. Final certified ‘As- Built’
drawings shall be submitted by the contractor to owner in bound volumes with one set of
reproducible original sepia plus ten sets of prints.
7.5 Contractor shall submit equipment manufacturer’s drawing for supply items like HV switchboard,
11/0.433kV distribution transformer, 415V MV Switchboard, 110V DC System, Electric Heat Tracing
System, UPS System, HV cables, 415V cables, pushbutton stations, HV and MV panel Fixing
Frames, lighting fixtures etc. for the review of Engineer-in-Charge in five sets of prints and the

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 13 OF 1216

 approval in writing of the Engineer-in-Charge shall be obtained before commencing manufacture.
However, it is to be understood that the review of drawings shall not absolve the basic responsibility
of contractor to check total compliance to specifications included in tender document. Six sets of final
drawings in bound volumes with two sets of CDs shall be submitted by contractor along with supply
of materials at site.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 14 OF 1216

8 LIST OF ATTACHMENTS

8.1 List of Drawings

S No. Title Drawing No.

1. Single Line Diagram B047-003-16-50-00010
2. Lighting layout – Terminal Building Level 1 B047-003-16-50-02010
3. Lighting layout – Terminal Building Level 1A B047-003-16-50-02020
4. Lighting layout – Terminal Building Level 2 B047-003-16-50-02030
5. Lighting layout – Terminal Building Level 3 B047-003-16-50-02040
6. Lighting layout – Terminal Building Level 3A B047-003-16-50-02050
7. Fire Alarm Layout– Terminal Building Level 1 B047-003-16-50-05010
8. Fire Alarm Layout– Terminal Building Level 1A B047-003-16-50-05020
9. Fire Alarm Layout– Terminal Building Level 2 B047-003-16-50-05030
10. Fire Alarm Layout– Terminal Building Level 3 B047-003-16-50-05040
11. PA System Layout– Terminal Building Level 1 B047-003-16-50-06010
12. PA System Layout– Terminal Building Level 1A B047-003-16-50-06020
13. PA System Layout– Terminal Building Level 2 B047-003-16-50-06030
14. PA System Layout– Terminal Building Level 3 B047-003-16-50-06040
List of Standards
1. Symbols –Single line diagram 7-51-0002
2. Symbols –Wiring diagram 7-51-0011
3. Symbols –plans(layout drawings) 7-51-0021
4. Typical earth electrode for earthing system 7-51-0101
5. Typical earth electrode in test pit 7-51-0102
6. Typical earth plate fixing details 7-51-0103
7. Typical arrangement for earthing of Motors 7-51-0104
8. Typical arrangement for earthing of transformer 7-51-0105
9. Typical earth connection for push button station 7-51-0106
10. Typical earth connection for street lighting pole 7-51-0107
11. Typical arrangement for earthing of overhead cable tray
7-51-0109
and electric motor.
12. Typical earthing arrangement for process equipment. 7-51-0111
13. Fence and gate earthing (Transformer yard) 7-51-0115
14. Equipment earthing schedule. 7-51-0116
15. Typical details of directly buried earth electrode 7-51-0117
16. Typical installation of lighting fixture at ground level 7-51-0201
17. Typical open area flood light mounted on wall or column 7-51-0203
18. Typical installation of flood light fixtures (two)mounted on
7-51-0205
pole
19. Typical installation of street lighting fixture 7-51-0207
20. Typical marshalling box details for lighting poles 7-51-0208
21. Typical installation of fixture mounting in exposed conduit
7-51-0212
wiring system
22. Typical installation of recessed mounted fixture 7-51-0213
23. Typical installation of recessed mounted or below false
7-51-0214
ceiling mounted fixture.
24. Typical installation of recessed mounted lighting fixture
7-51-0215
block of four
25. Typical installation of high bay lighting fixture 7-51-0216

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 15 OF 1216

 26. Typical installation of bulkhead lighting fixture 7-51-0218
27. Typical installation of weatherproof lighting fixture 7-51-0224
28. Typical installation of lighting/ power panel wall (surface)
7-51-0226
mounted
29. Typical installation of lighting fixture mounting in concealed
7-51-0229
conduit system
30. Typical installation of lighting/power panel flush mounted 7-51-0230
31. Typical installation for metsec channel 7-51-0232
32. Marking of trenches for electric cables 7-51-0301
33. Typical section of cable trench in unpaved areas 7-51-0302
34. Typical section of RCC cable trench 7-51-0303
35. Installation details for conduit or cable support on
7-51-0305
wall/slab/beam.
36. Installation details for control station on structural channel
7-51-0306
in paved areas.
37. Installation details for control station on concrete / steel
7-51-0307
column in paved area
38. Installation detail for control station on structural channel in
7-51-0308
unpaved area
39. Connection details for motor and control station (cable in
7-51-0314
tray)
40. Installation details for Socket / Receptacle mounted on
7-51-0315
wall/ column (Cable below ground)
41. Installation details for socket / receptacle mounted on
7-51-0316
column (cable in tray)
42. Details of ERC below grade level 7-51-0322
43. Cable termination for motors (cable dropping from
7-51-0323
overhead trays)
44. Cable termination for motors cable dropping along column
7-51-0324
(for HV / MV motors)
45. Arrangement for termination of cables laid in trench (for
7-51-0326
HV / MV motors)
46. Safety measures for electrical installations during
7-51-0332
construction
47. Details for hot dip galvanized ladder type cable trays 7-51-0333
48. Typical installation details of electrical panels on false
7-51-0335
flooring
49. Typical installation details of electrical panels on cable
7-51-0336
trench
50. Limiting dimensions for distribution transformer upto 2500
7-51-0337
kVA

8.2 List of Specifications

S.N0. Description Spec. No.

1.
Specification for HV switchboards B047-003-SP-6-51-0001
2. Specification for medium voltage switchboards fixed type
B047-003-SP-6-51-0012
for package equipment
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 16 OF 1216
 S.N0. Description Spec. No.
3.
Specification for industrial type control stations. B047-003-SP-6-51-0014
4.
Specification for UPS system B047-003-SP-6-51-0017
5.
Specification for M.V. Switchboard. B047-003-SP-6-51-0018
6.
Specification for battery charger. B047-003-SP-6-51-0019
7.
Specification for engine starting battery and charger B047-003-SP-6-51-0030
8.
Specification for soft starters for motors B047-003-SP-6-51-0036
9.
Specification for MV variable frequency drive system B047-003-SP-6-51-0038

10. Specification for emergency generator B047-003-SP-6-51-0040

11. Specification for oil filled Transformers B047-003-SP-6-51-0041

Specification for stationary valve regulated lead acid
12. B047-003-SP-6-51-0048
batteries
13. Specification for MV Variable Frequency Drives B047-003-SP-6-51-0049
Specification for medium and high voltage cables &
14. B047-003-SP-6-51-0051
accessories.
15. Specification for Communication & Fire Alarm Cables B047-003-SP-6-51-0052

16. Specification for MV and HV bus duct. B047-003-SP-6-51-0054

17. Specification for numerical relays B047-003-SP-6-51-0055

18. Specification for energy efficient MV induction motors B047-003-SP-6-51-0064

19. Specification for fire detection and alarm system. B047-003-SP-6-51-0076

20. Specification for elect. Equipment installation B047-003-SP-6-51-0081

21. Specification for Cable installation B047-003-SP-6-51-0082

22. Specification for lighting installation B047-003-SP-6-51-0083

23. Specification for earthing installation B047-003-SP-6-51-0084

Specification for field testing and commissioning of
24. B047-003-SP-6-51-0087
electrical equipment
25. Specification for electrical motor operated valve actuators. B047-003-SP-6-51-0091

26. Specification for electric surface heating system B047-003-SP-6-51-0095

27. Design philosophy for electrical facilities B047-003-SP-6-51-0099

Technical specification for Diesel Engine Generating Set
28. B047-000-80-43-SP-0002

29. Instruction to Bidder –HV Switchboard B047-003-16-50-TR-0001

30. Instruction to Bidder –Distribution transformer B047-003-16-50-TR-0002

31. Instruction to Bidder – MV switchboard B047-003-16-50-TR-0003

32. Instruction to Bidder – UPS system B047-003-16-50-TR-0004

33. Instruction to Bidder – Battery & Battery Charger B047-003-16-50-TR-0005

34. Instruction to Bidder – FA System B047-003-16-50-TR-0006

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 17 OF 1216

 S.N0. Description Spec. No.

35. Job specification for Solar Power Plant System B047-003-16-50-SP-1001

36. Job specification for PA SYSTEM B047-003-16-50-SP-1002

37. Job specification for Electric Heat Tracing B047-003-16-50-SP-1003

Job specification for Automatic Power Factor Correction
38. B047-003-16-50-SP-1004
Panel
39. Job specification for ATS B047-003-16-50-SP-1005

40. EDB for Electrical System B047-003-16-50-EDB-0001

NOTE: Document nos. of Specification mentioned as 6-51-XXXX in the tender shall be read as B047-
003-SP-6-51-XXXX wherever indicated.

8.3 List of data sheets

S. No. Title Data Sheet No. Rev.

No.
1. HV SWBD Data sheet Incoming Feeder (From B047-003-16-50-DS-0001 A
Another Switchboard)
2. HV SWBD Data sheet Bus P.T. Panel B047-003-16-50-DS-0002 A
3. HV SWBD Data sheet Transformer Feeder B047-003-16-50-DS-0003 A
4. Typical System Architecture Substation B047-003-16-50-DS-0005 A
Automation
5. Data sheet for HV swbd-11 kV B047-003-16-50-DS-0006 A
6. Datasheet for MV bus duct B047-003-16-50-DS-0007 A
7. Data sheet for PCC/ MCC/ASB B047-003-16-50-DS-0008 A
8. Data sheet for MV SWBD Component B047-003-16-50-DS-0009 A
9. MV SWBD Data sheet for PCC Incomer from B047-003-16-50-DS-0010
A
transformer
10. Data sheet for PCC/ASB Incomer from another B047-003-16-50-DS-0011
A
MV SWBD
11. MV SWBD Data sheet Bus coupler B047-003-16-50-DS-0012 A
12. MV SWBD Data sheet for PDB incomer having 2 B047-003-16-50-DS-0013
A
incomer (MCCB+C) with mechanical interlock
13. MV SWBD Data sheet for Outgoing Breaker B047-003-16-50-DS-0014
A
Feeder with microprocessor release
14. MV SWBD Data sheet for FVNR motor Feeder B047-003-16-50-DS-0015 A
15. MV SWBD Data sheet for MCCB with contactor B047-003-16-50-DS-0016
A
outgoing feeder
16. MV SWBD Data sheet for Outgoing MCCB B047-003-16-50-DS-0017
A
feeder
17. MV SWBD Data sheet for Scheme for DC B047-003-16-50-DS-0018
A
Control supply
18. MV SWBD Data sheet Scheme for AC Control B047-003-16-50-DS-0019
A
supply
19. Data Sheet for MV Induction Motor B047-003-16-50-DS-0021 A
20. Data Sheet for numerical relay & Data
B047-003-16-50-DS-0022 A
Concentrator
21. Data sheet for HV Cable B047-003-16-50-DS-0023 A
22. Data sheet for MV Cable B047-003-16-50-DS-0024 A
23. Data sheet for Distribution Transformer B047-003-16-50-DS-0025 A
24. Datasheet for Soft starter B047-003-16-50-DS-0026 A
25. Data sheet for UPS (250kVA) B047-003-16-50-DS-0027 A
26. Data sheet for UPS (30kVA) B047-003-16-50-DS-0028 A
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 18 OF 1216
 27. Data sheet for VFD B047-003-16-50-DS-0029 A
28. Data sheet for FA system B047-003-16-50-DS-0030 A
29. Data sheet for PA system B047-003-16-50-DS-0031 A
30. Data sheet for Power Conditioning Unit B047-003-16-50-DS-0032 A
31. Data sheet for PV Solar Module B047-003-16-50-DS-0033 A
32. Data sheet for Battery & battery charger B047-003-16-50-DS-0034 A
33. Data sheet for Lighting Management System
B047-003-16-50-DS-0035 A
Architecture
34. Datasheet for MOV B047-003-16-50-DS-0036 A
35. Datasheet for Light Fixtures B047-003-16-50-DS-0037 A
36. Electrical I/O List B047-003-16-50-DS-0038 A
37. Datasheet for Outgoing Breaker Feeder With
B047-003-16-50-DS-0039 A
Numerical Relay
38. Datasheet for PDB incomer having 2 incomer
B047-003-16-50-DS-0041 A
(MCCB) with mechanical interlock
39. Datasheet for Outgoing breaker controlled motor
B047-003-16-50-DS-0042 A
feeder(55kW<kW<=160kW)
40. Datasheet for block diagram of Solar Power
B047-003-16-50-DS-0043 A
System
41. Datasheet for DG Set B047-003-16-50-DS-5551 A
42. Hardware data sheet of generator control panel B047-003-16-50-DS-5552 A
43. Datasheet for Engine starting Battery & Battery
B047-003-16-50-DS-5553 A
Charger
44. Data sheet for Diesel Engine (1500 kVA)
B047-000-80-43-DS-0008 A
45. Data sheet for Diesel Engine (500 kVA)
B047-000-80-43-DS-0009 A
46. Experience record proforma DG set B047-000-80-43-PTR-0001
A

47. Experience record proforma Diesel Engine B047-000-80-43-PTR-0002

A
48. Vendor data requirement – Electrical works A
B047-003-16-50-VDR-0001
package

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 19 OF 1216

 Annexure-A
SECTION – 1
POINT WIRING
1. Scope
This section covers the general technical requirements and measurement of the various
components in Internal Electrical Installation Works.

1.1 Terminology

The definition of terms shall be accordance with IS 732: 1989 (Indian Standard Code of Practice
for Electrical Wiring), except for the definitions of point, circuit and sub main wiring, which are
defined in Clause 1.2, 1.3 and 1.3.2 hereunder.

1.2 Point Wiring

1.2.1 Definition

A point (other than socket outlet point) shall include all works necessary in complete wiring to the
following outlets from the controlling switch or MCB. The scope of wiring for a point shall, however,
includes the wiring work necessary in tapping from another point in the same distribution circuit: -
a) Ceiling rose or connector (in the case of points for ceiling/ exhaust fan points, pre-wired light
fittings and call bells)
b) Ceiling rose (in case of pendants except stiff pendants)
c) Back plate (in the case of stiff pendants)
d) Lamp holder (in the case of gooseneck type wall brackets, batten holders and fittings which are
not pre-wired.

1.2.2 In the case of call bell points, the words ―from the controlling switch or MCB shall be read
as ― from the ceiling rose meant for connection to bell push.

1.2.3 Scope

i) Following shall be deemed to be included in point wiring :

a) Conduit, accessories for the conduit and wiring cables between the switch box and point outlet,
loop protective earthing of each fan/ light fixture.
b) All fixing accessories such as clips, nails, screws, Phil plug, rawl plug,etc. as required.
c) Metal switch boxes for control switches, regulators, sockets etc. recessed or surface type and
outer & inner cover plates in case of modular type switches.
d) Outlet boxes, junction boxes, pull-through boxes etc. but excluding metal boxes if any, provided
with switchboards for loose wires/ conduit terminations.
e) Control switch or MCB as specified.
f) Ceiling rose or connector as required.
g) Connections to ceiling rose, connector, lamp holder, switch etc.
h) Interconnection wiring between points on the same circuit, in the same switch box or from
another.
i) Protective (loop earthing) conductor from one metallic switch box to another in the distribution
circuits, and for socket outlets. (The length of protective conductor run along with the circuits/
submains is excluded from the scope of points)
j) Based conduit or porcelain tubing where wiring cables pass through wall etc.
k) Following shall be deemed to be included in group control point wiring:
Conduit, accessories for the conduit and wiring cables between the Switchboard/ MCBDB to the
first point or wiring cable between points forming a group including loop protective earthing of each
fan/ light fixture. (Providing MCB/Switch is not included in this scope and will be Measured
separately). All fixing accessories such as clips, nails, screws, Phil plug, rawl plug etc. as required.
Hexagonal type junction boxes, pull-through boxes etc. but excluding metal boxes if any, provided
with Switchboard/ MCBDB for loose wires/ conduit terminations. Ceiling rose or connector as

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 20 OF 1216

required. Connections to ceiling rose, connector & Switch/ MCB etc. Bushed conduit or porcelain
tubing where wiring cables pass through wall etc.
l. Ferrule shall be provided at both ends i.e. on switchboards/DB‘s as well as on fittings / fixture
side.
m. All the wires shall be terminated with copper lugs on both side i.e. on switchboards/DB‘s as well
as on fittings / fixture side.

1.3 Measurement

1.3.1 Point Wiring (Other than Socket Outlet Point)

Unless and otherwise specified, there shall be no linear measurement for point wiring for light
points, fan points, exhaust fan points and call bell points. These shall be measured on unit basis by
counting. No separate measurement will made for interconnections between points in the same
distribution circuit and for the circuit protective (loop earthing) conductors
between metallic switch boxes.

1.3.2 Point Wiring for Socket Outlet Points

i) The light plug (5 / 6 Amp) point and power(15 / 16 Amp) point wiring shall be measured on linear
basis, from the respective tapping point of live cable, namely, switchbox, another socket outlet
point, or the Sub distribution board as the case may be, upto the socket outlet.

ii) The metal box with covers, switch/ MCB, socket outlet and other accessories shall be measured
and paid as separate item.

iii) The power point may be 15/5 Amp or 16/6 Amp 6 pin socket outlet, where so specified in the
Tender documents. (2 pin or 5 pin socket outlet shall not be permitted.)

1.3.3 Switch Control Group Point Wiring

i) In the case of points with more than one point controlled by one switch, such points shall be
measured in part i.e. from switch to the first point outlet as one point and (from switch to first point
of group contolled point). Subsequent looping points i.e one point to another point in the same
group will be measured under group controlled point (from one point to another point).
ii) No recovery shall be made for non provision of more than one switch in such cases.

1.3.4 MCB Control Group Point Wiring

i) In the case of points with more than one point controlled by one MCB, such points shall be
measured in part i.e. from MCB to the first point outlet as one point and will be measured under
group controlled point (from MCB to first point of group controlled point). Subsequent looping
points i.e. one point to another point in the same group will be measured under group controlled
point (from one point to another point).
ii) Providing MCB is not covered in this scope and will be measured separately and shall be
separately paid for.

1.3.5 Twin Control Light Points Wiring

i) A light point controlled by two numbers of two way switches shall be measured as two points
from the fitting to the switches on either side.
ii) No recovery shall be made for non-provision of more than one ceiling rose or connector in such
cases.

1.4 Circuit and Sub main Wiring

1.4.1 Circuit Wiring

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 21 OF 1216

Circuit wiring shall mean the wiring from the distribution board upto the tapping point for the
nearest first point of that distribution circuit, viz. upto the nearest first switch box.

1.4.2 Sub main Wiring

Submain wiring shall mean the wiring from one Main/Distribution switchboard to another.
Measurement of circuit and submain wiring.
i) Circuit and submain shall be measured on linear basis along the run of the wiring. The
measurement shall include all lengths from end to end of conduit exclusive of interconnections
inside the switchboard etc. The increase on account of diversion or slackness shall not be included
in the measurement
ii) The length of circuit wiring with two wires shall be measured from the distribution board to the
first nearest switch box in the circuit irrespective of whether the neutral conductor is take to switch
box or not.
iii) When wires of different circuit are grouped in as single conduit the same shall be measured on
linear basis depending on the actual numbers and sizes of wires run.
iv) When circuit wires and wires of point wiring are run in the same conduit, circuit wiring shall be
measured on linear basis depending on the actual number and sizes of wires run in the existing
conduit. As far as, practicable circuit wiring and point wiring shall be drawn in different conduit.
v) Circuit wiring and submain shall not be run in the same conduit.
vi) Protective (loop earthing) conductors, which are run along the circuit wiring and the submain
wiring, shall be measured on linear basis and paid for separately.

1.5 Other Wiring Works

i) Except as specified above for point wiring, circuit wiring and submain wiring, other types of wiring
shall be measured separately on linear basis alongwith the run of wiring depending on the actual
number and sizes of wires run.

1.6 System of Distribution and Wiring

The main distribution board and branch distribution board shall be controlled or provided with
linked switch fuse unit or miniature circuit breaker (MCB) of specified rating on the phase or live
conductor or combined phase and neutral control gear for incoming and outgoing as indicated in
the BOQ. Distribution of submain and circuits.
As per final approved single line diagram.

1.6.1 Balancing of Circuits

i) The balancing of circuits in three wire or poly phase installations shall be arranged before
handling to the satisfaction of the Engineer-In-Charge.

1.6.2 Wiring System

i) Unless and otherwise specified in the tender documents, wiring shall be done only by the
―Looping System‖. Phase of live conductors shall be looped at the switch boxes and neutral
conductors at the point outlets.
ii) Lights, fans and call bell shall be wired in the ‗lighting‘ circuits. 15/ 16 Amp socket outlets and
other power outlets shall be wired in the ‗Power‘ circuits. 5/ 6Amp socket outlets shall be wired in
the ‗lighting circuits‘.
iii) The wiring throughout the installation shall be such that there is no break in the neutral wire
except in the form of linked switchgear
iv) The wiring shall be segregated as Essential and non-essential in all the building in the airports
except in the case of residential quarters.

1.6.3 Run of Wiring

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 22 OF 1216

The type of wiring shall be as specified in tender document, i.e. conduit. Surface wiring shall run,
as far as possible, along the walls and ceiling so as to be easily accessible for inspection.
In no case, the open wiring shall be run above the false ceiling without the approval of Engineer-In-
Charge. In all types of wiring, due consideration shall be given for neatness, good
Appearance and safety.

1.6.4 Passing through walls or floors

When wiring cables are to pass through a wall, these shall be taken through a protection
(Steel/PVC) pipe or porcelain tube of suitable size such that they pass through in a straight line
without twist or cross in them on either end of such holes. The ends of metallic pipe shall be neatly
bushed with porcelain, PVC or other approved material.
Where a wall pipe passes outside a building so as to be exposed to weather, the outer end shall be
bell mouthed and turned downwards and properly bushed on the open end.
All floor openings for carrying any wiring shall be suitably sealed after installation.

1.6.5 Joints in Wiring

i) No bare conductor in phase and/or neutral or twisted joints in phase, neutral, and/or protective
conductors in wiring shall be permitted.
ii) There shall be no joints in the through runs of cables. If the length of final circuit or submain is
more than the length of a standard coil, thus necessitating a through joint, such joints shall be
made by means of approved mechanical connectors in suitable junction boxes.
iii) Termination of multi-stranded conductors shall be done using suitable crimping type thimbles.

1.7 Conformity to IE Act, IE Rules and Standards

i) All electrical works shall be carried out in accordance with the provisions of Indian Electricity Act,
1910 and Indian Electricity Rules, 1956, amended upto date.
ii) The works shall also conform to relevant Indian Standard Codes of Practice shall be followed.

1.8 General Requirements of Components

1.8.1 Quality of Materials

All material and equipments supplied by the Contractor shall be new. They shall be of such design,
size and materials as to satisfactorily function under the rated conditions of operation and to
withstand the environmental conditions at site.

1.8.2 Conformity of Standards

a) All components shall conform to relevant Indian Standard Specification, wherever existing.
However, for conduits, wiring cables, piano switches and socket outlets, ISI marked materials shall
only be permitted.
b) The Indian Standards, including amendments or revisions thereof upto the date of tender
acceptance, shall be applicable.

1.8.3 Inter changeability

Similar parts of all switches, lamp holders, distribution fuse boards, switchgears, ceiling roses,
brackets, pendants, fans and all other fittings of the same type shall be interchangeable in each
installation.

1.8 Cables

1.9.1 Wiring Cables

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 23 OF 1216

Conductors of wiring cables (other than flexible cables) shall be of aluminium or copper, as
specified. Stranded aluminium conductor shall not be used in wiring cables upto and including
6 Sq.mm. size. Unless and otherwise specified, copper conductor of size 1.5 Sq.mm. and above
used for wiring shall be stranded and only FRLSH type wiring cables shall be used.

1.9.2 Flexible Cables

i) Conductor of flexible cables shall be of copper. The minimum cross sectional area of conductor
for flexible cable shall be 0.0006 Sq. inch (14/.0076‖ or 14/0.193 mm).
ii) Only 3 core flexible cables shall be used for connecting single-phase appliances.
iii) Unless armour, or tough rubber, or PVC sheath mechanically protects the flexible cables, these
shall not be used in workshops and other places where they are liable to mechanical damage.
iv) Flexible cable connection to bell push from ceiling rose shall be taken through steel conduit/
metallic casing and capping.

1.9 Wiring Accessories

1.10.1 Control Switches for Points

i) Combined switch cum socket shall not be permitted.

ii) Control switch shall be placed only in the live conductor of the circuit. No single pole switch or
fuse shall be inserted in the protective (earth) conductor, or earthed neutral conductor of the circuit.

1.10.2 Socket Outlets

i) 5/ 6Amp and 15/ 16Amp 6 Pin socket outlets shall be installed at the following positions, unless
otherwise specified.
a) Kitchen/ Pantry 23 cm above working platform and away from the likely positions of stove and
sink.
b) Toilets in non-residential building – 1.25 mt. Above floor level.
c) At all other places – 23 cm above floor level.

1.10.3 Switch box covers

Phenolic laminated sheet of 3 mm thick of approved shade shall be used for switch box covers in
case of piano type switches. For modular type switches/sockets suitable outer and inner cover
plates as specified shall be provided over the standard box as recommended by the manufacturers
of modular type switch/ sockets and no separate sheet cover is required to be provided.

1.10.4 Ceiling Rose

i) A ceiling rose shall not be used on circuit the voltage of which normally exceeds 250 Volts.
ii) Only one flexible cord shall be connected to ceiling rose. Specially designed ceiling roses shall
be used for multiple pendants.
iii) A ceiling rose shall not embody fuse terminal as an integral part of it.

1.10.5 Lamp Holders

i) The standard constructional feature of manufacturers (ISI approved) of lamp holders is

acceptable. Where the lamp holders are part of light fixtures the holders shall be suitable for the
type of lamps used.

1.11 Fittings

The type of fittings shall be as specified in BOQ of tender documents.

1.11.1 Indoor Type Fittings

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 24 OF 1216
i) The contractors shall supply the specified model and make of the fittings. The standard
constructional features of specified make and model as given in the tender document are
acceptable.
ii) Where conductors are required to be drawn through tube or channel leading to the fitting, the
tube or channel must be free from sharp angles or projection edge, and of such size as will enable
them to be wired with the conductors used for the final circuit without removing the braiding or
sheathing. A far as possible all such tubes or channels should be of sufficient size to permit looping
back.
iii) Pendants in verandahs and similar situations exposed to wind shall be of fixed rod type.
iv) Fittings using discharge lamps shall be complete with power factor correction capacitors, either
integrally or externally.An earth terminal with suitable marking shall be provided for each fitting for
discharge lamps.
v) Fittings shall be installed such that the lamp is at a height specified in approved drawings or as
directed by the Engineer-In-Charge.
vi) Copper chokes of Fluorescent Tube light fittings shall be of Electronics type or as specified in
BOQ.

1.12 Attachment of Fittings and Accessories

1.12.1 Conduit Wiring System

i) All accessories like switches, socket outlets, call bell pushed and regulators shall be fixed in flush
pattern inside the switch/ regulator boxes. Accessories like ceiling roses, brackets, batten holders,
stiff pendants etc. shall be fixed on metal outlet boxes.
ii) Brass screws shall be used to fix the accessories to their bases.
iii) The switch box/ regulator box shall normally be mounted with their bottom 1.25 m from floor
level, unless otherwise directed by the Engineer-In-Charge.

1.12.2 Fixing of Walls and Ceiling

i) PVC sleeves/ dash fasteners should normally be used for fixing to walls or
ceiling.
ii) Plugging of walls or ceiling can be done in a better way where neatness is the first consideration.
In all such cases, an approved type of asbestos or fiber fixing plug (rawl or Phil plug) with correct
size of tools shall be used and done in a workmanlike manner.

1.12.3 Workmanship

Good workmanship is an essential requirement to be complied with. The entire work of

manufacture/ fabrication, assembly and installation shall conform to sound engineering practice.
The work shall be carried out under the direct supervision of an engineer, employed by the
contractor, who shall rectify then and there the defects pointed out by the Engineer-In-Charge
during the progress of work. The qualification of engineer or supervisor for over all supervision and
to take instructions from the Engineer-In-Charge shall be as specified in the special conditions.

1.13 Testing of Installation

All the completed installations shall be tested as per specification for ―Testing of Installation

1.13.1 Drawings

i) The work shall be carried out in accordance with the drawings enclosed with the tender
documents and also in accordance with modification thereto from time to time as pproved by the
Engineer-In-Charge or as per the drawing prepared by the contractor based on inventory and
approved by Engineer-In- Charge.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 25 OF 1216

ii) All wiring diagrams shall be deemed to be ‗Drawings‘ within the meaning of the term as used in
the Conditions of Contract. They shall indicate the main switchboard, the distribution boards (with
circuit numbers controlled by them), the runs of various mains and submains and the position of all
points with their controls.
iii) All circuits shall be indicated and numbered in the wiring diagram and all points shall be given
the same number as the, circuit to which they are electrically connected.

1.14 Commissioning of Completion

1.14.1 Before the workman leaves the work finally, he must make sure that the installation
is commissioned, after due testing.

1.14.2 Completion Plan and Completion Certificate

i) For all work completion certificate after completion of work as required by AAI shall be submitted
to the Engineer-In-Charge.
ii) Completion plan drawn to a suitable scale in tracing sheet with three blue print copies of the
same shall also be submitted.
a) General Layout of the building.
b) Locations of main switchboard and distribution boards.
c) Position of all points and their controls indicating the circuit numbers controlled by them.
d) Types of fittings, viz. fluorescent, pendants, brackets, bulkhead, fans and exhaust fans etc.
e) Name of work, job number, accepted tender reference, actual date of completion, names of
Division/Sub-Division, and name of the firm who executed the work with their signature.
f) Final as built SLD / drawings.

SECTION –2
SPECIFICATIONS FOR METALLIC CONDUIT WIRING SYSTEM
1. Scope
This section covers the detailed requirements for wiring work in MS metallic conduits & flexible
conduits. This section covers both surface and recessed types of works.

1.1 Applications

Conduit system used shall be rigid. Flexible conduits may only be permitted for interconnections
between switchgear & DBs, junction box & light fixture and conduit terminations in wall.

All the interconnection wiring joints of group control shall be looped at fittings/fixtures using flexible
conduit. Nothing extra shall be paid on this account.

1.2 Materials

1.2.1 Conduits

i) All rigid conduit pipes shall be of Galvanized steel and be ISI marked. The wall thickness shall be
1.6mm (16 SWG) for conduits upto 32mm dia. And 2mm (14 SWG) for conduits above 32mm dia
and as per IS. These shall be solid drawn or reamed by welding, and finished with galvanized or
stove enameled surface.
ii) The maximum number of PVC insulated cables conforming to IS: 694-1990 that can be drawn in
one conduit is given size wise in Table I., and the number of cables per conduit shall not be
exceeded. Conduit sizes shall be selected accordingly in each run.
iii) No steel conduits less than 20mm in diameter shall be used.

1.2.2 Flexible conduits

All the flexible conduits pipes shall be high quality aluminum/ lead coated steel, heat resistant, 3
layer corrugated construction. Pipe should have high mechanical strength to stay at desire
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 26 OF 1216
direction without support. The minimum size of conduit shall be 25 mm & wall thickness shall be as
under with ±0.5 mm tolerance.
• The outer layer thickness of steel with Lead coating of 0.11mm or with
Aluminium foil of 0.14mm thickness.
• The middle layer is made up of high resistant craft paper having thickness of
0.2mm to 0.25mm.
• The Inner 3rd layer is made up of Aluminium foil having thickness of 0.14mm.
A silicone heat resistant coating shall be provided on the finished conduit to protect it from heat.

1.2.3 Conduits Accessories

i) The conduit wiring system shall be complete in all respects, including their accessories.
All conduit accessories shall be MS threaded type, and under no circumstances pin grip type or
clamp grip accessories shall be used.

Aluminium coupler shall be provided on both sides of flexible conduit and the weight of coupler
shall not be less than 30 grms.

ii) Bends, couplers etc. shall be solid type in recessed type of works and may be solid or inspection
type as required, in surface type of works.
iii) a) Saddles for surface conduit work on wall shall not be less than 0.55mm (24 gauge) for
conduits upto 25mm dia and not less than 0.9mm (20 gauge) for larger diameter. The
corresponding widths shall be 19mm and 25mm.
b) The minimum width and the thickness of girder clips used for fixing conduits to steel joints, and
clamps shall be as per Table below.
iv) flexible coupler shall be made of aluminum casting and having earthing provision including
screws.

1.2.4 Outlets

i) The switch box regulator box shall be made of galvanized metal on all sides, except on the front.
In case of welded mild steel sheet boxes the wall thickness shall not be less than 1.2mm (18
gauge) for boxes upto a size of 20 cm x 30 cm and above this size 1.6mm (16 gauge) thick MS
boxes shall be used. The metallic boxes shall be galvanized as per specification.
ii) a) Outlet boxes for light/ power sockets shall be of standard size of manufacturer to
accommodate required number of modular switches, socket outlet.
b) Where a large number of control switches and/ or fan regulators are required to be installed at
one place, these shall be installed in more than one outlet box adjacent to each other for ease of
maintenance.
iii) An earth terminal with stud and metal washers shall be provided in each DB/MS box for
termination of protective conductor and for connection to socket outlet/ metallic body of fan
regulator etc.
iv) A metal strip shall be welded/ screwed, to the metal box as support if fan regulators are to be
fixed herein.
v) Clear depth of the box shall not be less than 50mm, and this shall be increased suitably to
accommodate mounting of fan regulators in flush pattern.

vi) The fan regulators can also be mounted on the switch box covers, if so directed by the
Engineer-In-Charge.
viii) The size of the switch box in case of modular type switches shall be as per manufacturer‘s
standard.

1.3 Installation

1.3.1 Common aspects for recessed and surface conduit works.

i) Conduit Joints
a) The conduit work in each circuit or section shall be completed before the cables are drawn in.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 27 OF 1216
b) Conduit pipes shall be joined by means of screwed couplers and screwed accessories only.
Threads on conduit pipes in all cases shall be between 13 mm to 19mm long, sufficient to
accommodate pipes to full threaded portion of couplers or accessories.
c) Cut ends of conduit pipes shall have no sharp edges, nor any burrs left to avoid damage to the
insulation of the conductors while pulling them through such pipes.
d) The Engineer-In-Charge, with a view to ensuring that the above provision has been carried out,
may require that the separate lengths of conduit etc. after they have been prepared shall be
submitted for inspection before being fixed.
e) No bare threaded portion of conduit pipe shall be allowed, unless such bare threaded portion is
treated with anticorrosive preservative or covered with approved plastic compound.

ii) Bends in Conduit

a) All necessary bends in the system, including diversion, shall be done either by neatly bending
the pipes without cracking with bending radius of not less than 7.5 cm., or alternatively, by inserting
suitable solid or inspection type normal bends, elbows or similar fittings, or by fixing cast iron
inspection boxes, whichever is most suitable.
b) No length of conduit shall have more than the equivalent of four quarter bends from outlet to
outlet.
c) Conduit fittings shall be avoided as far as possible on conduit system exposed to weather.
Where necessary, solid type fittings shall be used.

iii) Outlets

a) All outlets such as switches, wall sockets etc. may be either flush mounting type, or of surface
mounting type, as specified in the additional specifications if any or as directed by the Engineer-In-
Charge.

1.3.2 Additional requirements for surface conduit works

i) Fixing Conduit on Surface

Conduit pipes shall be fixed by saddles, secured to suitable approved plugs with screws in an
approved manner at an interval of not more than one metre, but on either side of the couplers or
bends or similar fittings, saddles shall be fixed at a distance of 30 cm from the centre of such
fittings. Where conduit pipes are to be laid along the trusses, steel joists etc. the same shall be
secured by means of saddles or girder clips or clamps as required by the Engineer-In-Charge. In
long distance straight run of conduit, inspected type couplers at reasonable
intervals shall be provided, or running threads with couplers and jam nuts shall be provided.

ii) Fixing Outlet Boxes

Only a portion of the switch box shall be sunk in the wall, the other portion being projected out for
suitable entry of conduit pipes into the box.

1.3.3 Additional requirements for recessed conduit works

i) Making Chase

a) The chase in the wall shall be neatly made, and of ample dimensions to permit the conduit to be
fixed in the manner desired.
b) In the case of building under construction, the conduits shall be buried in the wall before
plastering, and shall be finished neatly after erection of conduit.
c) In chase of exposed brick/ rubber masonry work, only machine cutting shall be done to fix the
conduit and accessories in position along with the building work.

ii) Fixing Conduits in Chase

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 28 OF 1216

a) The conduit pipe shall be fixed by means of staples, J-hooks, or by means of saddles, not more
than 60 cm apart, or by any other approved means of fixing.
b) All threaded joints of conduit pipes shall be treated with some approved preservative compound
to secure protection against trust.

iii) Fixing Conduits in RCC work

a) The conduit pipes shall be laid in position and fixed to the steel reinforcement bars by steel
binding wires before the concreting is done. The conduit pipes shall be fixed firmly to the steel
reinforcement bars to avoid their dislocation during pouring of cement concrete and subsequent
tamping of the same.
b) Fixing of standard bends or elbows shall be avoided as far as practicable, and all curves shall
be maintained by bending the conduit pipe itself with all long radius, which all permit easy drawing
in of conductors.

iv) Fixing Inspection Boxes

Suitable inspection boxes to the minimum requirement shall be provided to permit inspection, and
to facilitate replacement of wires, if necessary. The distance between inspection/ junction boxes
shall not exceed 12.5 mts in straight run.
Location of inspection/ junction boxes in RCC work should be identified by suitable means to avoid
unnecessary chipping of the RCC slab subsequently to locate these boxes. These shall be
mounted flush with the wall or ceiling concrete. Minimum 65mm depth junction boxes shall be used
in roof slabs and the depth of the boxes in other places shall be as per IS : 2667-1977. Suitable
phenolic laminated sheet cover shall be provided on the inspection box. Suitable ventilating holes
shall be provided in the inspection box covers.

v) Fixing Switch Boxes and Accessories

Switch boxes shall be mounted flush with the wall. All outlets such as switches, socket outlets etc.
shall be flush mounting type, unless otherwise specified.

vi) Fish wire

To facilitate subsequent drawing of wires in the conduit, GI fish wire of 1.6mm / 1.2mm (16/ 18
SWG) shall be provided alongwith the laying of the recessed conduit.

vii) Bunching of Cables

a) Cables carrying direct current may, if desired, be bunched whatever their polarity, but cables
carrying alternating current, if installed in metal conduit shall always be bunched so that the
outgoing and return cables are drawn into the same conduit.
b) Where the distribution is for single phase loads only, conductors for these phases shall be
drawn in one conduit.
c) In case of three phase loads, separate conduits shall be run from the distribution boards to the
load points or outlets as the case may be.

1.3.4 Earthing Requirements

i) The entire system of metallic conduit work, including the outlet boxes and other metallic
accessories, shall be mechanically and electrically continuous by proper screwed joints, or by
double check nuts at termination. The conduit shall be continuous when passing through wall or
floors.
ii) Protective (loop earthing) conductor (s) shall be laid along the runs of the conduit between the
metallic switch boxes and the distribution boards/ switchboards, terminated thereto. The
conductors shall be of such size and material as specified. Depending upon their size and material,
the protective earth conductors shall be either drawn inside the conduits alongwith the cables, or
shall be laid drawn in outside the conduits. When laid external to the conduits, this shall be
properly clamped with the conduit at regularintervals.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 29 OF 1216

iii) The protective conductors shall be terminated properly using earth studs, earth terminal block
etc. as the case may be.
iv) Gas or water pipe shall not be used as protective conductor (earth medium).

NOTE:
1. The above table shows the maximum capacity of conduits for a simultaneous drawing in of
cables.
2. The columns headed 'S' apply to runs of conduits which have distance not exceeding 4.25m
between draw in boxes and which do not deflect from the straight by an angle of more than 15
degrees. The columns headed 'B' apply to runs of conduit which deflect from the straight by an
angle of more than 15 degrees.
3. Conduit sizes are the nominal external diameters.
TABLE - II
Girder clips or clamps
Size of Conduit Width Thickness
i) 20 mm - - - - 19 mm 0.9mm (20 SWG)
ii) 25 mm - - - - 19 mm 0.9mm (20 SWG)
iii) 32 mm & above - - - - 25 mm 1.2mm (18 SWG)

SECTION -4

RACEWAY, JUNCTION BOXES & DISTRIBUTION BOARDS (DB)

General

a. The powder coated Raceways and Trunking shall conform to the requirement of IEC 10842-1
Part 1 : General requirement and Part 2 Section 1 : Cable Trunking and Ducting Systems (CT/DS)
for electrical installations. Particular requirements for system intended for mounting on walls or
floors.
b. The Raceways and Trunking Systems (CT/DS) shall be factory built assemblies. The intention is
to have accurate dimensions and very little site work. The GI raceway shall be fabricated out of 1.6
mm thick GI sheets and cover shall be of 2mm thick.
c. The systems shall be assembled at site with minimum number of fasteners and least amount of
site work. All components of the system shall be supplied by the contractor without resorting to
shortcut solutions at site. For this purpose the supplier shall submit dimensional drawings of all the
components of the systems for example, right angle bends, junction boxes, etc.
d. The system shall be designed for installation with a temperature classification of 60 deg.C.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 30 OF 1216
e. The CT/DS shall give a degree of protection upto IP 42 as per IS 12063-1987.
f. The CT/DS shall be suitably treated against corrosion.
g. The access cover for the system shall be provided with synthetic rubber gasket and shall be
fixed with cadmium plated machine screws.
h. The CT/DS system shall be earthed throughout its length.
i. No sharp corners, edges shall be allowed in any part of the system.

1.0 Cable Management System

1.1 Under Floor Cable Trunking

Supply, installation, testing and commissioning of cable trunking system made up of Pre
Galvanized metal coated steel sheet Material Specification as per BS 2989 British Standards
(Equivalent Indian Standards IS 277-2003) Specially treated corrosion proof rectangular profiles for
high tensile strength. Maximum Tensile Strength of 500N/m2. Rectangular formed with top &
bottom plates double folded and spot welded together to the full height of Track to provide the
required rigidity and at the same time to prevent seepage of concrete or screed water. Aluminum
painting covers at all the welding spots to avoid corrosion. Corrosion resistance test complying IS
3854:1997 Standard Thickness – 1.6mm, Standard Length – 2.5 meters,

1.2 Access Outlet

Access Outlets shall be made of very high quality materials to withstand heavy load and corrosion.
Manufactured from high-pressure die cast material for strength & durability. The trap frame & trap
shall made of flame retardant material and Trap Frame can be easily removed by pulling either one
of the Nylon Bars to detach & remove the unit for servicing or installation of accessories to save
installation & servicing time. Patented screw less ratchet bar level adjusting system to match with
screed / floor height. The trap lid shall be self-adjustable to any floor finish thickness. Trap cover
shall be reinforced with a 2.5mm thick pre-galvanized steel plate to provide rigidity & added
strength. Trap lid to have a screw less knob-hinged design for quick mounting on to the frame
requiring minimum maintenance.
The Trap cover must have 8mm recessed for installation of carpet and tiles. Trap trim design to
protect carpet from damages and give the floor area added aesthetics. Trap lid shall be made of
Electrostatic Polyester Epoxy Coating to provide excellent and enhanced protection on visible parts
against chemical or saline corrosion. Strong and durable trap lifting handle on the trap cover is
made of similar color material and has special design for easy lifting, even with large fingers.
Cables are guided by Cable Retainers through generous cable outlet which open automatically and
lock into position when cables are present.
Trap cover of Access box shall be retained by Cable Grommets with high quality durable foam to
prevent the cable damage from exit position & also prevent ingress of dust when closed. Access
Outlet shall carry service plates for providing services i.e.: Power, Data & Telecom.
The system must accommodate and have three compartments to run Mains Voltage & Extra Low
Voltage cables. The system must have Positive Double Earthing connections.
Earth wire connector shall be provided in all the boxes, and complies with the requirement of
current IEE regulation. The complete system must have excellent protection against rust. Four side
blanks are made with removable perforations to suit ducts installation.
The system must comply with the relevant specification & IEC 61084 standards.
1.4 Crossovers

Crossovers are made of very high quality materials to withstand heavy load and corrosion.
Manufactured from high-pressure die cast material for strength & durability.
The trap lid is self-adjustable to any floor finish thickness using the leveling screws on all the four
corners.

The Trap cover is made of 2.5mm thick stainless steel plate to provide rigidity & added strength.
The Trap covers to have flexibility for quick mounting on to the base box requiring minimum
maintenance. The Trap cover must have 8mm recessed for installation of carpet and tiles. The
Cross Over shall have provision to Power, Data & Telecom services. The system

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 31 OF 1216

must accommodate to run Mains Voltage & Extra Low Voltage cables. The trap cover screws must
be made from Stainless Steel for extra protection. The system must have Positive Double Earthing
connections. Earth wire connector shall be provided in all the boxes, and complies with the
requirement of current IEE regulation. The complete system must have excellent protection against
rust. Four side blanks are made with removable perforations to suit ducts installation of up to 38-
mm height. The one-piece base frame design ensures minimum openings to prevent concrete
seepage into the box during casting of concrete or screening.
The system must comply with the relevant specification & IEC 61084 standards.

1.5 Junction Box

Junction boxes manufactured from high-pressure die cast material. The Trap Cover & Trap frame
of the box should be made of 2.3mm thick pre-galvanized steel plate made of Electrostatic
Polyester epoxy coating. The recess should be 8mm on the trap lid to accommodate the specified
flooring. The junction boxes should have the provision to route and distribute either the power or
networking cables. The system must have smooth curved die cast pillars for ease of pulling cables.
The system must have the provision to accommodate 25/38mm deep GI trunking, with width
knockouts to accommodate at least up to 225mm.
The system must comply with the relevant specification & IEC 61084.

2. Prewired DB

Only prewired MCB type DB‘s shall be used on account of their superior technical features,
compared to conventional DBs, which don‘t allow for proper wiring space and wiring termination.
Rewirable fuse type DBs shall not be used. Prewired DBs shall have following feature:
i) Recess/ Surface type with integral loose wire box.
ii) Phase/ neutral / earth terminal blocks for termination of incoming & outgoing wires.
iii) DIN Channel for mounting MCB‘s.
iv) Arrangement for mounting incomer MCB/RCCB/RCBO/MCCB as required.
v) Electrolytic Copper Bus bar & neutral link.
vi) Earthing terminals.
vii) Wiring from MCB‘s to phase terminal block.
viii) Interconnection between terminal block/ incoming switch / bus bar/ neutral terminal block/ earth
terminal connector with specified size of FRLS pre insulated copper conductor cable duly fitted with
copper lugs/ thimbles.
ix) Terminal blocks should be suitable for termination of conductor/ cable of required size but
minimum rated cross section of the terminal blocks should be 6 sq mm.
x) Terminal block shall be made of flame retardant polymide material.
xi) Colored terminal blocks and FRLS wires for easy identification of RYB Phases, Neutral and
Earth.
xii) The prewired DB shall have peel able poly layer on the cover for projection from cement,
plaster, paints etc during the construction period.
xiii) Detachable plate with Knock out holes shall provided at the top/ bottom of board. Complete
board shall be factory fabricated and pre-wired in factory ready for installation at site. The box and
cover shall be fabricated from 1.6 mm sheet steel, properly pretreated with powder coated finish.
(xiv) It shall be of double door construction provided with hinged cover in the front as per BOQ.
(xv) Wiring diagram of each DB shall be fixed inside the DB clearly indicating ferrule numbers.
(xvi) DB shall be compartmentalized in such a manner that incomer has separate compartment.
(xvii) MCB shall compile IS:8828 – 1978
(xviii) MCB use for light circuit shall be B series.
(xix) MCB use for power & motor circuit shall be C series.
(xx) DB use for indoor application shall compile IP-42.
(xxi) DB use for Outdoor application shall compile IP-65

Note : The above specifications in Annexure-A shall supercede the requirements mentioned in
specification no. 6-51-0082 for the items indicated.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 32 OF 1216

 JOB SPECIFICATION FOR
SOLAR POWER PLANT SYSTEM
(B047-003-16-50-SP-1001, Rev. A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 33 OF 1216

1. GENERAL
1.1 Contractor shall provide grid connected solar power plant units at roof top of Car parking
sheds and feed the generated solar power to the electrical system of the complex. The solar
power shall be generated at 415V, 3 phase / 240V, 1 phase, 50 Hz which can support loads at
0.8 p.f.
1.2 The scope of work for contractor includes design, manufacture, supply, erection, testing and
commissioning of grid connect interactive solar PV power plants without batteries on Car
parking sheds. Solar power unit shall be connected to the nearest 415V MV switchboard
(PCC-301) for export of solar power. The solar power systems shall remain synchronized with
the grid supply for generation of solar power.
1.3 Each photovoltaic solar panel shall be divided into small sub arrays to feed into Power
Conditioning Units (PCU). The series parallel connection of sub arrays shall be done through
panel junction boxes, Array junction boxes and main junction boxes. The AC output of the
PCUs shall be collected at the ACDB and shall feed the PCC-301 at two points. The required
power cable & its termination from the ACDB to the PCC-301 incomers shall be in solar
package vendor’s scope. The detailed scheme for power evacuation shall be worked out by
the contractor.
1.4 PV panels shall be installed on the roof top of Car parking sheds. Minimum 1 KWp solar
panels shall be located in each 12 m2 area.
1.5 The minimum guaranteed supply of energy from the solar power systems shall be 1400
KWh/year for 1 KWp PV panel. The contractor/manufacturer shall furnish the undertaking for
guaranteed supply of energy for the solar power systems provided by them.
1.6 Contractor shall engage the services of a separate specialist agency/manufacturer for
execution of solar power plants including design, engineering, sizing, selection & procurement
of equipment/material, installation, testing and commissioning of solar power plants. The
agency shall be an established manufacturer/supplier of complete SPV power system and
shall have adequate experience for carrying out similar SPV based solar power plants. The
agency should have designed, supplied, installed and commissioned SPV power plants of
cumulative installed capacity of 200 kWp or above, out of which atleast one plant should be of
100 kWP capacity operating satisfactorily for more than one year. The agency shall be
approved by PMC/Owner during detail engineering based on details furnished by contractor.
1.7 The PV solar panels shall be located on roof tops of Car parking sheds away from the shadow
area. The direction of solar panels shall be as per manufacturer recommendation. The PCU
shall be located within the building in Air conditioned room.
1.8 Complete cabling including supply, laying and termination of cables, cable trays, cable
trenches, material, hardware etc. within SPV power plant units and from power plant units to
MV switchboards for export of solar power is in contractor scope.
1.9 This Specification shall be read in conjunction with the other specification & details which are
part of bid document.

2. SITE CONDITIONS
The equipment offered and the installation shall be suitable for continuous operation
under the following site conditions:
i) Equipment design temperature : 40° C
ii) Maximum ambient temperature (Outdoor) : 35° C
iii) Min. ambient temperature (Outdoor) : -22° C
iv) Min. ambient temperature (indoor) : -5° C

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 34 OF 1216

 v) Relative humidity : 30-100%
vi) Seismic zone : As per IS:1893
vii) Altitude : 3515m above MSL
viii) Atmosphere : Cold Desert
ix) Location : Leh, J&K
x) Maximum wind velocity : To be collected by vendor

3. DESIGN OF SYSTEM
3.1 Contractor/manufacturer shall ensure proper system designing that would include studies on
peak sunshine data, resulting in the correct sizing of equipment for the solar energy system
and get the same approved from the PMC / Owner. It is important to form proper design
procedures and component sizing before any actual implementation. The design procedures
and component sizing shall be as per internationally acceptable standards. The contractor
shall show details with the help of software to establish the solar light / heat available during
various parts of the day/month/year and substantiate this with the help of data of the
generation capacity of plant being proposed by them.
3.2 Based on the insolation data, the solar PV systems shall be so designed that it shall take into
account the mean energy output after allowing for various losses, temperature corrections, on
an average day for each month of the year.
3.3 The auto & manual synchronization facility of solar power and complex power supply shall be
provided at PCU only. PCU shall adjust voltage & frequency levels to suit the complex power
supply. Synchronization at any other location in power plant unit is not envisaged.
4. SCOPE OF WORK
4.1 The equipment and materials for Grid Connected Solar PV Power Plants with associated
power evacuation system shall include but not be limited to the supply, erection, testing &
commissioning of following:
4.1.1 Solar PV modules including mounting frames, structures, array foundation and module inter
connection.
4.1.2 Array Junction boxes, Main Junction boxes and Fuse boxes / circuit breakers.
4.1.3 Power Conditioning Units (PCU), AC power evacuation panels with bus bars and circuit
breakers.
4.1.4 415V Associated Switchgear.
4.1.5 Metering and protection / Isolation systems.
4.1.6 MV Power and Control Cables including end terminations and other required accessories for
both AC & DC power.
4.1.7 Earthing system for PV Array, DC power system, AC power system equipment, PCU etc.,
Lightning protection system.
4.1.8 The civil erection work including civil foundation shall be performed with respect to the
following but not limited to:
a) Solar PV modules array, mounting frames.
b) Electrical room near car parking shed
c) Power & Control Cables.
d) Entire cable trays, supports, accessories.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 35 OF 1216

 e) Galvanized steel conduits and accessories, PVC pipes, ferrules, lugs, glands, terminal
blocks, galvanized sheet steel junction boxes, cable fixing clamps, nuts and bolts etc.
as required
f) Steel materials for field fabrication as required.
4.2 Transportation of equipments from Works to Site.
4.3 Unloading, Loading of all supplied equipments on foundations at their respective places.
4.4 Pre-commissioning & commissioning of all supplied equipments.
4.5 Test running of Grid Connected Solar Power Plants at site.
4.6 All relevant drawings, documents, data sheets, calculations, technical catalogues, type test
certificates etc.
4.7 Tools and tackles, accessories required for satisfactory and trouble free operation and
maintenance of above equipment.
4.8 Any other equipment required for safe and satisfactory operation of the system.
5. TECHNICAL SPECIFICATIONS
5.1 Solar PV modules
5.1.1 Solar PV module array shall consist of high efficiency Solar Modules utilizing Crystalline
Silicon solar PV cells. Power output Guarantee offered for the SPV Module shall not be less
than 25 years. Individual Solar module rating shall not be less than 300 Wp at standard test
conditions. Preference shall be given to manufacturers offering bigger Solar PV module (≥ 300
Wp).
5.1.2 Crystalline high power cells shall be used in the Solar Photovoltaic module. Solar module shall
be laminated using lamination technology with established polymer (EVA) and Tedlar /
Polyester laminate. The solar modules shall have suitable encapsulation and sealing
arrangements to protect the silicon cells from the environment. The arrangement and the
material of encapsulation shall be compatible with the thermal expansion properties of the
silicon cells and the module framing arrangement / material. The encapsulation arrangement
shall ensure complete moisture proofing during life of the solar modules.
5.1.3 All materials used shall be having a proven history of reliable and stable operation in external
outdoor applications.
5.1.4 Module rating is considered under standard test conditions, however solar modules shall be
designed to operate and perform in relative humidity up to 100% with ambient temperatures
varying between -22°C and +35°C and withstand gust as per the wind zone of the location
from back side of the panel. The Geological data of site shall be collected by the contractor for
designing solar system to get optimum generation.
5.1.5 Sample modules and production processes employed in the manufacture of the offered
module shall be in accordance with the requirements of IEC 61215 / IEC61730 with
appropriate certificate.
5.1.6 For the PV modules to be used in a highly corrosive atmosphere throughout their lifetime, they
must qualify to IEC 61701/IS 61701
5.1.7 The offered crystalline Solar PV modules must be manufactured in India.
5.1.8 Solar PV Module design shall conform to following requirements -
• Toughened, low iron content,
• High transmissivity front glass.
• Anodized Aluminium frame.
• Ethyl Vinyl Acetate (EVA) encapsulant.
• Silicon edge sealant around laminate.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 36 OF 1216

 • Tedlar/Polyester tri laminate back surface.
• Weatherproof DC rated connector and a cable coming out as a part of the module,
making connections easier and secure, not allowing for any loose connections.
• Resistant to water, abrasion, hail impact, humidity & other environment factor for the
worst situation at site.
5.1.9 Protective devices against surges at the PV module shall be provided. Low voltage drop
bypass diodes shall be provided
5.1.10 The offered module shall have a power warranty of 25 years with degradation of power
generated not exceeding 20% of the minimum rated power over the 25 year period and not
more than 10% after ten years period.
5.1.11 Each module shall have low iron tempered glass front for strength and superior light
transmission. It shall have back sheet for environment protection against moisture and high
voltage electrical insulation.
5.1.12 The fill factor of modules shall not be less than 0.70 (typical)
5.1.13 The PV modules offered must be tested and approved by one of the IEC authorized test
centres. PV module qualification test certificate as per IEC standard, issued by ETDC,
Bangalore or Solar Energy Centre India will also be valid.
5.1.14 The rated output power of any supplied module shall have tolerance of +/- 3%.
5.1.15 The peak-power point voltage and the peak-power point current of any supplied module and/or
any module string (series connected modules) shall not vary by more than 2 (two) per cent
from the respective arithmetic means for all modules and/or for all module strings, as the case
may be.
5.1.16 The module shall be provided with a junction box with either provision of external screw
terminal connection or sealed type and with arrangement for provision of by-pass diode. The
box shall have hinged, weather proof lid with captive screws and cable gland entry points or
may be of sealed type and IP-65 rated.
5.1.17 Each solar PV module used in solar power project must use a RF identification tag. The
following information must be mentioned in the RFID used in each module (This can be inside
or outside the laminate, but must be able to withstand harsh environmental conditions):
- Name of the manufacturer of PV Module.
- Name of the Manufacturer of Solar cells.
- Month and year of the manufacture (separately for solar cells and module).
- Country of origin (separately for solar cells and module).
- I-V curve for the module.
- Wattage, Im, Vm and FF for the module.
- Unique Serial No. and Model No. of the module.
- Date and year of obtaining IEC PV module qualification certificate.
- Name of the test lab issuing IEC certificate.
- Other relevant information on traceability of solar cells and module as per ISO 9000.
5.2 PV Array Configuration
The solar Array shall be configured in multiple no. of sub-arrays, providing optimum DC power
to suitable number of sub arrays. Contractor/Vendor shall furnish their own design indicating
configuration of PCU and respective sub arrays.
5.3 Module Mounting Structure

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 37 OF 1216

 The mounting structures shall be designed to sustain wind loading applicable as per the wind
zone and shall be hot dipped Galvanized sections of steel or Aluminium anodized. The entire
structure including array shall be earthed to an independent earth pit with redundant paths.
Mounting structures with fixed tilt shall be provided. The Hardware shall be made of SS304.
The array structure shall be so designed that it occupies minimum space without sacrificing
the output from SPV panels at the same time. The structure shall be designed for easy
replacement of any module.

The mounting structure steel shall be as per latest IS 2062: 1992 and galvanization of the
mounting structure shall be in compliance of latest IS 4759.
5.4 Junction Box
5.4.1 The J. Boxes (JBs) shall be made of GRP/FRP/Powder Coated Aluminium /cast aluminium
alloy with full dust, water & vermin proof arrangement with IP-65. The terminals shall be
connected to bus-bar arrangement of proper sizes to be provided. The junction boxes shall
have suitable cable entries fitted with cable glands of appropriate sizes for both incoming and
outgoing cables. Suitable markings shall be provided on the bus-bars for easy identification
and cable ferrules shall be fitted at the cable termination points for identification.
5.4.2 Each Array Junction Box shall have high quality suitable capacity metal oxide varistors
(MOVs) / SPDs, suitable Reverse Blocking Diodes. The Array Junction box shall also have
suitable surge protection. The Junction Boxes shall have suitable arrangement for the
following.
• Provide arrangement for disconnection for each of the groups.
• Combine groups of modules into independent charging sub-arrays that shall be wired into
the controller.
• Provide a test point for each sub-group for quick fault location
• To provide group array isolation.
• The current carrying ratings of the junction boxes shall be suitable with adequate safety
factor to inter connect the solar PV array.
5.5 Power Conditioning Unit
5.5.1 The PCU equipment shall comply with the requirements of latest revision of applicable IEC/
equivalent BIS standard for efficiency measurements and environmental tests as per standard
codes IEC 61683/IS 61683 and IEC 60068- 2(1,2,14,30) /Equivalent BIS Std. The charge
controller (if any) / MPPT units environmental testing should qualify IEC 60068-2(1, 2, 14,
30)/Equivalent BIS std. The junction boxes/ enclosures should be IP 65(for outdoor)/ IP 54
(indoor) and as per IEC 529 specifications
5.5.2 Power Conditioning Unit is critical equipment in Grid connected SPV power plant. The
equipment converts DC power generated by SPV array, into 3 phase medium voltage AC to
be connected to grid. It also provides necessary protections for Grid synchronization and Data
Logging/Monitoring. The DC energy, thus produced has to be utilized to maximum and
supplied to the DC bus for inverting to AC voltage with the help of power Conditioning Unit
using its MPPT (The efficiency of MPPT shall not be less than 94% & shall be designed to
meet the solar PV Array capacity control) to extract maximum energy from solar array and
provide 415V AC, 3-phase, 50Hz power to synchronize with power system.
a. The PCU shall have features such as, over current, short circuit, over temperature to
name a few.
b. The PCU shall be of very high quality having high efficiency (>93%) and shall be capable
of running in isolated mode.
c. The PCU shall be designed for continuous, reliable power supply as per specifications.
d. The PCU shall have internal protection arrangement against any sustained fault.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 38 OF 1216

 e. The PCU shall be designed to be completely compatible with the SPV array voltage and
power system supply voltage of 415V ± 10%, 50Hz ± 3%, 3 phase, 4 wire.
f. The dimension, weight, foundation details etc. of the PCU shall be clearly indicated in the
detailed technical specification to be furnished by contractor during detail engineering.
g. PCU shall have user friendly LCD display for programming and for viewing on line
parameters such as DC power input, DC input voltage, DC current, AC power output, AC
voltage (all the 3 phases and line) and AC current (all the 3 phases and line), power
factor, frequency etc.
h. The PCU shall have arrangement for adjusting DC input current and should trip against
sustainable fault downstream and shall not start till the fault is rectified.

The PCU shall automatically turn on and turn off successively as the available solar irradiation
varies over the day. The PCU shall have all necessary synchronization equipment installed.
The inverters shall also be configurable to operate on three, two or one phase depending on
the grid condition at any time. The voltage variation range shall be ±10% and frequency
variation range ±3%
The 3 phase Grid connected PCU shall be sourced from internationally reputed firms, which
shall incorporate latest Technological advances to provide highly reliable and efficient energy
conversion from DC to AC. The PCU shall incorporate system design which uses multiple
power stakes which work in tandem. Specifically the PCU shall be three phase static solid
state type power conditioning unit. Both AC & DC lines shall have suitable fuses and
contactors to allow safe start up and shut down of the system. Fuses used in the DC circuit
should be DC rated. The PCU shall have provision of input & output isolation through
switches/breakers. The PCU shall be complete with all protection, metering, alarm,
annunciation, indications as required.
The typical specification of PCU is listed out below:

AC side
Nominal AC power As per Manufacturer design
Output AC voltage As per Manufacturer design
Frequency As per Manufacturer design
Total Harmonic Distortion <3%
AC over/under voltage over/under Yes
frequency protection
Power factor (cos phi) 0.8

DC side

PV power As per Manufacturer design

Maximum DC voltage As per Manufacturer design

MPPT voltage range As per Manufacturer design

Maximum DC current As per string rating

DC over voltage protection Yes

DC voltage ripple <3%

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 39 OF 1216

 Others

Minimum Efficiency (CE) >95%

Ambient temperature range Refer site conditions

Humidity 30-100%

Quiescent power <1% of rated power

5.5.3 PCU shall have user friendly LCD display & keypad for system control, programming,
monitoring, change set points and for viewing on line parameters such as DC power input, DC
input voltage, DC current, AC power output, AC voltage (all the 3 phases and line) and AC
current (all the 3 phases and line), cumulative output energy in KWH, power factor, frequency,
PCU operating state status, various fault conditions etc.
5.5.4 PCU shall have communication facility and all the data related to metering, operating status,
faults etc. shall be hooked up to data monitoring system/BMS.
5.5.5 PCU Operational Requirement
a. The PCU shall be provided with auto wake up feature such that PCU inverter shall be able
to wake up when the available power from the PV array is more than the total loss of the
inverter system. Since available power from the PV array changes with weather condition,
the wake up algorithm shall be adaptive in nature.
b. The PCU shall be able to synchronize AC output with the complex power supply. The
PCU inverter shall close output contactor/ breaker when the synchronization parameters
(voltage difference, frequency difference and phase angle difference) framed by IEEE
1547 are complied.
c. The power control scheme of the PCU shall follow the maximum output from the PV array
determined by the level of solar radiation on the DC side and shall employ maximum
power point tracking (MPPT) control capable of constantly obtaining the maximum output
according to the quantity of solar radiation and temperature.
d. Modes of Operation
The PCU shall have following modes of operation:
I. Standby mode – The PCU shall operate in this mode when PV array does not have
enough power capacity to maintain PCU inverter losses or PCU has responded to a
fault condition and fault condition has been cleared. In this mode PCU shall remain
idle, disconnected from PV array as well as from grid. The inverter shall remain in this
mode until PV array voltage exceeds wake up value and enter into system wake up
test mode.
II. Wake up test mode – After PV array voltage exceeds wake up value, the PCU control
system shall continuously monitor PV array voltage for certain duration before making
transition to power tracking mode. If the PV array voltage drops below wake up value
during test duration, PCU shall enter into standby mode.
III. Power tracking mode – This shall be main operating mode of the PCU under normal
operating condition. In this mode maximum power point tracking algorithm shall be
functional which shall extract maximum power from PV array under varied conditions of
solar irradiance and temperature.
IV. Sleep mode – Whenever PCU output power drops below certain threshold limit, PCU
enters into sleep mode and wait for certain duration. Within this duration if PCU output
power exceeds threshold limit, PCU reenters into power tracking mode, otherwise PCU
goes into standby mode.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 40 OF 1216

 V. Shutdown mode – The PCU shall operate in this mode whenever fault conditions will
be responded. The PCU shall disconnect itself from PV array as well as from grid.
5.5.6 PCU Protective functions
a. The PCU shall be provided with anti-islanding control and protection such that in case of
complex power supply failure, PCU shall stop exporting power to the grid within 2 sec. as
per IEEE 1547/ UL 1741.
b. The PCU shall be able to sense the following situation and accordingly shutdown and
disconnect itself from the grid as well as from PV array:
- Complex power supply over voltage and under voltage.
- Complex power supply over frequency and under frequency AC over current and
ground fault.
- Loss of any phase of the complex power supply. The single phase open shall be
detected on both sides of the output transformer.
- DC bus over voltage and under voltage
- DC over current and ground fault.
- Device over temperature/ system temperature rise.
c. The PCU shall sense reverse polarity of DC connection and warn the installer and remain
in standby mode.
d. The PCU shall be provided with surge arrester (metal oxide varister) both at AC and DC
side to protect the system from lightning/ switching surges.
e. Forced ventilation of panel, if provided, shall be supplemented by 100% redundant fan. In
normal operation, normal & redundant fans shall run together.
5.6 MV Cables
5.6.1 1100V grade, Multi Strand, Annealed high conductivity copper conductor PVC type ‘A’
pressure extruded insulation or XLPE insulated, Armoured Cables shall be used for all MV
power & control Cables in the solar power plant. Overall PVC/XLPE insulation for UV
protection Armoured cable for underground laying. The voltage grade of the DC cables used
shall be suitable for solar system maximum DC system voltage continuously. A confirmation in
this regard from cable manufacturer shall be furnished for DC cables.
5.6.2 The cables shall be flexible, excellent resistance to heat, cold, water, oil, abrasion, UV
radiation.
5.6.3 Cables shall conform to IEC 60227/IS 694, IEC 60502/IS1554, IS /IEC 69947 standards
5.6.4 Sizes of cables between array interconnections, array to junction boxes, junction boxes to
Inverter etc. shall be so selected to keep the voltage drop (power loss) of the entire solar
system to the minimum. The cables (as per IS) should be insulated with a special grade PVC
compound formulated for outdoor use.
5.6.5 The Cable should be so selected that it should be compatible up to the life of the solar PV
panels i.e. 25years.
5.6.6 The size of each type of DC cable selected shall be based on minimum voltage drop however;
the maximum drop shall be limited to 1%.
5.6.7 The size of each type of AC cable selected shall be based on minimum voltage drop however;
the maximum drop shall be limited to 2 %.
5.7 Data Monitoring of Power plant
5.7.1 Data Logging Provision for plant control and monitoring, time and date stamped system data
logs for analysis with the high quality. Metering and Instrumentation for display of systems
parameters and status indication to be provided. The data logging shall have interface with
BMS.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 41 OF 1216

5.7.2 Solar Irradiance: An integrating Pyranometer / Solar cell based irradiation sensor (along with
calibration certificate) provided, with the sensor mounted in the plane of the array. Readout
integrated with data logging system/ BMS.
5.7.3 Temperature: Temperature probes for recording the Solar panel temperature and/or ambient
temperature to be provided complete with readouts integrated with the data logging system /
BMS
5.7.4 The following parameters are accessible via the operating interface display in real time
separately for solar power plant:
I. AC Voltage.
II. AC Output current.
III. Output Power
IV. Power factor.
V. DC Input Voltage.
VI. DC Input Current.
VII. Time Active.
VIII. Time disabled.
IX. Time Idle.
X. Power produced
XI. Protective function limits (Viz-AC Over voltage, AC Under voltage, Over frequency, Under
frequency ground fault, PV starting voltage, PV stopping voltage.
5.7.5 All major parameters available (the current values, previous values for up to a month and the
average values) on the logging facility shall be made available for energy auditing.
5.7.6 PV array energy production: Digital Energy Meters to log the actual value of AC/ DC voltage,
Current & Energy generated by the PV system provided. Energy meter along with CT/PT
should be of 0.5 accuracy class
5.7.7 DC String/Array monitoring and AC output monitoring shall be provided as part of the inverter
and/or string/array combiner box or separately.
5.7.8 String and array DC Voltage, Current and Power, Inverter AC output voltage and current (All 3
phases and lines), AC power (Active, Reactive and Apparent), Power Factor and AC energy
(All 3 phases and cumulative) and frequency shall be monitored.
5.7.9 AC energy monitoring shall be in addition to the digital AC energy meter.
5.7.10 Ambient / Solar PV module back surface temperature shall be also monitored on continuous
basis.
5.7.11 Simultaneous monitoring of DC and AC electrical voltage, current, power, energy and other
data of the plant for correlation with solar and environment data shall be provided.
5.8 Lightning & Over Voltage Protection
The SPV power plant shall be provided with Lightning and over voltage protection connected
to earth pits. The main aim of over voltage protection is to reduce the over voltage to a
tolerable level before it reaches the PV or other sub-system components. The source of over
voltage can be lightning or other atmospheric disturbance.
The Lightning Conductors shall be made as per applicable Indian Standards in order to
protect the entire Array from Lightning stroke. Necessary concrete foundation for holding the
lightning conductor in position shall be made after giving due consideration to maximum wind
speed and maintenance requirement at site in future.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 42 OF 1216

 The Lightning conductor shall be earthed through flats and connected to earth pits as per
applicable Indian Standards. Each Lightning conductor shall be fitted with individual earth pit
as required.
The contractor shall ensure adequate lighting protection to provide an acceptable degree of
protection as per IS for the array. Design calculations and detailed explanations shall be
furnished during detail engineering.
5.9 Earthing System
The earthing for array and power system shall be provided as per provisions of IS. Necessary
provision shall be made for bolted isolating joints of each earthing pit for periodic checking of
earth resistance.
Each Array structure of the SPV shall be grounded properly. The array structures shall be
connected to earth pits as per IS Standards.
The earthing for the power plant equipment shall be made as per provisions of IS.
The complete earthing system shall be mechanically & electrically connected to provide
independent return to earth. All three phase equipment shall have two distinct earth
connections.
All non-current carrying metal parts shall be earthed with two separate and distinct earth
conductors to the nearest earth grid.
5.10 Energy Meter
Energy meter, with communication facility, shall be provided for measurement of solar power
generated in each building/ system. Meter shall have an accuracy of energy measurement of
at least Class 0.2 for active energy and at least Class 0.5 for reactive energy according to IEC
60687, and shall be connected to Class 0.2 CT cores and Class 0.2 VT windings. The energy
meters shall be hooked up to the plant monitoring system.
6. INSPECTION & TESTING
6.1 Tests shall be carried out on various equipment and components mounted on the panels as
per relevant Indian & international standard specifications as applicable. Panels with all
equipment/components mounted and wired shall be subjected to following tests at the
manufacturer’s works.
a) Visual inspection for physical details and mounting of components.
b) Compliance with final approved drawings for internal arrangement and construction.
c) Operational tests.
d) Checks of wiring.
e) Insulation resistance test.
f) Power frequency applied test at 2 KV for 1 minute.
6.2 Testing to be conducted at Manufacturer’s workshop & at site
Details of Tests to be conducted at Test Bed at manufacturer’s facility and at site.
6.2.1 General
The test & inspection shall be carried out at manufacturer works and at site. The test &
Inspection shall be done in accordance with the relevant standards and the manufacturer’s
standard before the delivery to site as well as after the erection & commissioning at site. The
contractor shall give the list of tests that shall be carried out at site to show the performance of
plant.
A detailed ‘QAP’ for manufacturing & Inspection shall be submitted by the contractor for
PMC/owner’s approval. The data of each test and inspection shall be recorded and submitted
as soon as the test/trials are conducted and shall also be a part of final documentation.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 43 OF 1216

6.2.2 Shop Test & inspection of Solar power plant at Manufacturer factory/Test Bed
The shop test shall be carried out to prove the performance parameters of the offered model.
Manufacturer shall submit procedure for Test to be carried out at their Factory.
• Start up trials
• Load test
• Records & Measurements
• Safety device List
• Setting values for all sensors for speed and temperature
• Dimensional Check-up, Overall Inspection, Completeness of scope of supply.
• Shop Test/ Load Test for Solar Power plant.

All tests shall be carried out as per relevant standards at Vendor’s works. Testing and
inspection shall include but not necessarily limited to the following:
A) Solar PV Modules
A.1) Following environmental tests as per applicable IEC/IS shall be carried out on
photovoltaic modules on sampling basis. Minimum 2% of ordered modules or 1 No. module,
whichever is higher, shall be subjected to following tests and performance of module before
and after each test shall be tabulated and furnished. The tests shall be carried out sequentially
on each module selected for testing and the tested module shall be discarded after tests.
In case on account of testing:
• The overall deterioration in the performance of the tested modules after test exceed 5% of
rated performance, or
• The tested module exhibits any open circuits and or ground faults, or
• The tested module develops cracks or mechanical damage, or
• The tested module fails to pass the electrical isolation tests the entire ordered lot of modules
shall be rejected.
Sl.No. Test. Test Detail
(“To be filled by Vendor”)
1. Cold

2. Rapid Change of Temp.

3. Dry heat

4. Salt mist

5. Wind

6. Rain

7. Dust

Composite Temp /Humidity

8.
Test

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 44 OF 1216

 9. Mould Growth

10. Hail Storm test

11. Shock Test

* Vendor shall submit the test procedure for review for all the above mentioned tests. Vendor
shall indicate test conditions like temperature limits and duration etc. and also mention the name
of the applicable standards.

A.2) The following design qualification tests shall also be conducted:

i) Earth continuity test.
ii) Electrical isolation test.
iii) Hot spot endurance test* .

NOTE: Type test certificate can be accepted for the tests marked with asterisks (*).

B) Solar Controller
Tests in the following order shall be conducted for the panel:
i) General
ii) Earth Continuity Test
iii) Functional Tests
iv) Insulation Resistance Measurement
v) Heat Run Test

C) Burn out tests on the complete system in one assembly.

Further, Contractor shall ensure that type test certificates for equipments shall not be more
than five years old. In those cases where type test certificates are more than five years old,
contractor/ manufacturer shall carry out the type tests at authorized testing lab prior to
dispatch of equipment at his own cost and without any impact on delivery.
In the absence of specific confirmation to this stipulation, offered equipment shall be
summarily rejected. During fabrication, all the equipment shall be subject to inspection by
owner or by an agency authorized by the owner to assess the progress of work as well as to
ascertain that only quality raw material is used. All routine and acceptance tests as specified
by the applicable standards shall be carried out by the contractor/vendor/sub-vendor and
these tests shall be witnessed by owner or an agency authorized by owner any other test and
quality assurance requirements as defined elsewhere in the package shall also be complied.
All the equipment offered shall have valid type test certificates of recognized testing house.

6.2.3 Performance Test at site for Grid connected Solar Power Plant
Performance Test at Site for Grid connected Solar Power Plant shall be conducted at site as
per site conditions at available insolation and after performing all pre-commissioning check
and trials and after readiness of the entire Solar Power plant systems.
All the tests of Solar Power plant shall be carried out in presence of Owners representative at
site under site conditions and the parameters checked in accordance with the data sheet and
guaranteed parameters given by the Vendor.
All the equipments supplied by the vendor shall be tested as per relevant standard/ Quality
assurance plan at site conditions and their performance monitored.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 45 OF 1216

7. Make of the components
For solar power system components such as PV modules, PCU, cables etc. shall be MNRE
approved and contractor shall submit past track record for the proposed vendors and obtain
written approval from Owner before placing order.
8. Warranty
8.1 Duration of warranty shall be stipulated elsewhere in the Bid Document, however all the
mechanical structures, electrical works and overall workmanship of the grid connected solar
power plant must be warranted for a minimum of 5 years.
8.2 PV modules used in solar power plant must be warranted for output wattage, which should not
be less than 90% at the end of 10 years and 80% at the end of 25 years.
8.3 Contractor shall be fully responsible in respect of proper design, manufacture, quality
workmanship and operation of all the equipment, accessories etc. supplied by the Contractor
for the warranty period.
8.4 It shall be obligatory on the part of Contractor to modify and/ or replace any equipment/
component free of cost in case any malfunction is revealed even during on-line operation after
taking over within the warranty period.

Note: Refer tender attachments for Block Diagram of Solar Power System.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 46 OF 1216

 JOB SPECIFICATIONS
FOR
PUBLIC ADDRESS AND VOICE ALARM
SYSTEM
(B047-003-16-50-SP-1002, Rev. A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 47 OF 1216

 CONTENTS
S. No. Description

1. Overview

2. Scope of Work

3. Submittals

4. PA Design requirements/guidelines

5. Functional & Performance Requirements

6. Technical Requirements

7. Testing Requirements

8. Comprehensive Annual Maintenance Contract

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 48 OF 1216

PUBLIC ADDRESS AND VOICE ALARM (PAVA) SYSTEM
1. Overview

This specification defines a multi-function public address system which shall serve all PA Zones as
shown on the PA Drawings. The primary purpose of the PAVA system is to deliver clear intelligible
speech and voice alarms to areas as designated in the drawings. The system shall be a state-of-
the-art digital networked system and shall be scalable. The system shall interface with other
systems at the airport as detailed herein:

2. Scope of Work

(a) The Contractor’s scope of work is a turnkey solution, with responsibility for fully provisioning
the PA system including design, supply, installation, configuration, testing, commissioning,
maintenance and provision of defects liability for the following elements and services
throughout the Defects Liability Period:
i. PA Speaker
ii. PA Controllers, Servers and Workstations
iii. Power Amplifiers and Volume Controllers
iv. Digital Recording and Playback system
v. Automatic Digital Flight Announcement System
vi. Ambient Noise Analysis System including Noise Sensing Microphones
vii. Microphone Paging Stations
viii. Background music sources
ix. PA Racks, Cabling
x. Speaker line supervision, ground fault supervision, local and remote monitoring
xi. Self-testing and automatic backup amplifier capability

(b) Interfacing with the following systems:

i. Flight Announcement System
ii. Fire Alarm System
iii. Master Time Clock System
iv. Building Management System
v. Local Area Network (LAN)
vi. CCTV system
vii. Access Control System

(c) The testing and commissioning shall include the following:

Operation of ambient noise sensing system in various ambient noise environments

i. Onsite testing to confirm computer modelling layout of speakers (to be provided by
Contractor)
ii. Sound levels from paging consoles
iii. Checking of zones, particularly that concurrent paging of different messages into adjacent
zones operates satisfactorily at zone boundaries.

(d) The PAVA system for the proposed New Terminal Building should be integrated using an IP
and Microprocessor based Audio processor with public address sound management system
with an objective to allow announcement for the flight schedules & General Announcements
from more than one location having facility to play music during idle time. All announcements
should meet the target criterion of speech Intelligibility with presided by a pleasant chime.
(e) The contractor should integrate the system taking into consideration the acoustics of building,
geometry of space & other technical specifications & functional requirements given in the
tender. The tenderers should use computer Aided Simulation using 2D and 3D Mapping
Techniques to carry out Acoustics and Electro acoustics simulation and mapping of sound
distribution.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 49 OF 1216

(f) The Contractor shall carry out acoustic modelling of the areas requiring PA, as defined in this
specification and drawings and provision of all speakers, noise sensing microphones etc. as
required to meet the specified performance requirements, regardless of the bill of quantities
and layout shown on the drawings.

(g) Driven by acoustical parameters of public areas, speakers and associated components will be
designed to suit the new terminal building layouts.

(h) The required communication media (Fibre Optic and other cables) including their
lengths/termination and interface equipment shall be determined based on the locations of the
different type of PA equipment/device and shall be supplied by the bidder. Requisite
terminations and integration of FO cables with the main System shall be done by the bidder.

(i) The Technical specifications and functionality requirements are made for PAVA System
integration with Airport Flight Information, Fire Detection system, BMS and other systems as
per requirement by AAI. These technical specifications are to be used as guidelines for the
bidders to offer similar or better audio equipment.

(j) Some manufacturer’s specifications may have been taken as an example making technical
guidelines for bidders to give their Submittal. Such examples definitely are non-inclusive.

(k) The quantities of the cabling components (i.e. various types of cables and their laying)
mentioned in Price Schedule are indicative. The bidder has to submit prices for these
quantities as mentioned in Price schedule.

(l) Payments towards the cabling components as defined above shall be made as per actual,
subject to joint measurements, after successful completion of the work.

(m) The offered System shall be complete with all equipment and accessories including
connectors, patch cords, other networking accessories, mounting, and fixing hardware, plugs,
sockets, etc.

(n) Cost of Adaptors, Connectors, Patch Cords, Mounting/Fixing hardware, Electrical

Switches/Sockets inside the Racks and other accessories required for completion of work is
deemed to be included in the quoted prices. This also includes Cable Channel/ Tray to be
installed by the bidder in Equipment Room/Control room as per requirement.

(o) Testing of system components shall be done as per original equipment manufacturer’s
specifications and guidelines.

(p) The entire work has to be executed with total responsibility by bidder. All necessary technical
completeness shall be ensured by the bidder at the time of quoting/completion of works.

(q) Bidder shall be responsible to conduct Site Acceptance Test (SAT) and to supply detailed
documentation including as-built drawing in Hard/soft copy at all the Airports.

(r) All PA Amplifiers and other associated equipment active equipment shall be located at same
place.

(s) The Contractor shall provide required PA Workstations including all necessary software
licenses.

3. Submittals (After award of works)

(a) “Technical specification” of each item shall be the primary Criteria for technical evaluation of
documents after award of works. No deviations shall be acceptable at later date.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 50 OF 1216

 (b) The bidders shall submit the detailed schematic diagram for the PA system showing all the
components with Network Controller in hot standby configuration.
(c) The bidders shall submit their quote justifying the quantities and selections of loudspeaker
system and their type (such as Ceiling speakers, wall mounted box type speakers, Digitally
Controlled Line arrays speakers etc.) with Computer Simulation for the performance of the
Audio Equipment selection to meet the desired target parameters (refer section ‘Audio
Performance Criteria’) using Mapping of Sound field converge, Speech Intelligibility, Speech
Clarity and Direct Sound to Reverberation ratio.
(d) Drawings indicating locations of various types of speakers, noise sensing microphones,
announcements consoles etc. for PA system in terminal building & Car Calling system,
typical installation/fixing details of speakers, layout of equipment in PA system room, wiring
layout etc. should be submitted with documents after award of works.
(e) Break up of items sheet (i.e. BOQ) giving details of items & their quantity, but without filling
the unit rates and amount should be submitted by the contractor after award of works
(f) Detailed Schematic diagram of complete system offered with all the components/controls
their technical details/specifications of all equipment/modules/components etc. including
detailed inventory should be submitted with documents after award of works
g). The name of the software used for this simulation should be clearly mentioned in the
documents submitted by the bidder and a soft copy of the simulation in native data format shall
also be supplied along with the submittal to enable AAI to examine the simulation results.
h). The supporting documents with complete technical details for full evaluation of system shall
be submitted. The submission must include:
a. Cover Sheet
b. Assumptions and Considerations
c. Material Details for Each Surface
d. Direct & Total SPL (Map & Histogram)
e. STI (Map & Histogram)

4. PA Design requirements/guidelines:

a. The bidder shall carryout 3D and 2 D mapping of all the PA zones given in this tender
document and while doing the 3D mapping simulation he shall observe the following terms:
i. Name of Software used for this simulation should be submitted in tender
ii. After successful completion of the computer simulation as per the parameter given in
the tender document, the bidder shall pack the project and submit the packed project
file (in a CD) created on the simulation software. The bidder shall use commercially
available software to do his 3D computer simulation. The packed project file should
be importable in to the other commercially available software to evaluate and
scrutinize by AAI.
iii. Alternatively, if the bidder is using a proprietary computer Mapping and Simulation
software of an Audio Equipment manufacturer, it is mandatory that he will provide a
copy of the software in a CD (loadable on Windows latest version based PC) with his
Submittal to analyse and do technical scrutiny by the AAI officials. If the bidder does
not meet the above criteria of the tender requirement his Submittal shall be rejected.
iv. The packed project file should be compatible and importable in to the other
commercially available software to evaluate and scrutinize his Submittal by the
Airport Authority team.
b. The following simulation printouts need to be submitted to demonstrate the P.A. System
Integration:
i. The bidder shall construct a 3D model (using acoustics and electro acoustics
simulation software) of the areas for all the Zones under investigation and apply
acoustical material on to the walls, ceiling and floor as per the schedule of finishes.
ii. The proposed Loudspeakers by the bidder to be placed precisely in the 3D model at
X, Y and Z coordinates to achieve the desired target criteria. The firing angle of the
loudspeaker systems must be adjusted for the public audience area to achieve the
desired results.

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c. The system design shall take in to consideration - the height of the ceiling at various places
critical distance and directivity factor of the loudspeaker system.
d. Loudspeaker Technical data such as efficiency, directivity factor power rating, frequency
response, sound field coverage to be submitted.
e. All equipment technical data sheet along with the original catalogues to be submitted with
the Submittal.
f. The Bidders are required to submit coloured printouts of all the mapping parameters as
given above along with the packed project file in a CD with the Submittal to analyze his
proposed system integration and acceptance by the AAI.
g. Controlller, amplifier, call station, speaker shall be of same OEM.

4.1. Preparation of Spectrogram and its analysis of parameters

a) Spectrogram of Direct SPL at 85dB at listening plane (1.2 M above floor level) at frequency
band from 250 Hz to 4 KHz. The sound field coverage should be uniform for the complete
audience area within +3dB.
b) Spectrogram of Direct SPL at 85dB with split time of 7 ms (L7) at listening plane (1.2 M ht.)
at frequency band from 250 Hz to Three Octave. The sound field coverage should be
uniform for the complete audience area within +3dB.
c) Spectrogram of Total SPL at frequency band from 250 Hz to 4 KHz.
d) Spectrogram of Sound Field Overlap of Speakers at frequency band from 250 Hz to 4KHz.
e) Spectrogram of D/R (direct field and reverb field) Ratio at frequency band from 250Hz to 4
KHz.
f) Spectrogram of RaSTI (Rapid Speech Transmission Index) meeting target criteria as
described in the ‘Audio Performance Criteria’ Section where the announcements are made
with ambient noise level at 60dB at frequency band from 500 Hz to ThirdOctave.
g) Spectrogram of Critical Distance Analysis at frequency band from 250 Hz to 4 KHz.
h) Spectrogram of D/R ratio with split time of 7ms at frequency band from 250 Hz to 4KHz the
sound field coverage should be more than -15 dB for complete audience area.
i) Spectrogram of Speech Intelligibility at split time 50ms at frequency band from 250Hz to 4
KHz and the speech clarity should be – 1.0 dB (-1.0dB) or above.
j) Spectrogram of Articulation Loss Analysis for frequency band from 500Hz to ThirdOctave
should not be more than 7%.
k) Spectrogram of Articulation Index should be 0.90 or above. The packed project files in the
CD for evaluation of the Submittal of the bidder in a CD to be submitted with the Submittal to
evaluate and acceptance by AAI.
l) If the discrepancies are found while scrutinizing the data submitted in the CD and the
printouts his Submittal may be rejected.
m) All Mapping to be carried out at simulated noise level of 60 dB.
n) The PA system should be integrated so that it delivers all frequencies in the range of 100 Hz
to 12.5 KHz + 1 dB. Computer Simulation printouts for Frequency Response curve at listener
location in all the Zones must be submitted.
o) Design shall ensure that there are no echoes in the Arrival hall, Departure Hall,concourse,
customs, immigration, basement & others areas.

Noncompliance of the above will lead to rejection of the Submittal of the respective bidders. The
bidder shall also attach the colour printouts of all the mapping simulation of all the data as given
above this is required to evaluate and analyze his proposed system integration and simulation by
the AAI team.

5. Functional & Performance Requirements

a) A multi-function Public Address and Voice Alarm (PAVA) system provided shall be astate-of-
the-art digital networked system and shall be scalable.
b) The PAVA System shall be certified to International standards of Emergency Sound System
EN 54 (IEC 60849) certified with following features as a minimum and as required to make

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 52 OF 1216

 the system complete and operational in all respects as per specifications, drawings, and
standards as required. The systems shall have open interface for interfacing other services
such as Fire alarm system, FIDS and Building Integrated service software.
c) The PAVA system shall enable all day to day live announcements and pre-recorded audible
information along with emergency pre-recorded and live announcements triggered by the
Fire Detection/Alarm system.
d) The system shall provide an audible, manageable voice announcement system that will
support the fire strategy for the building through provision of automated voice alarm
instructions and support the operational processes of the building by enabling public address
announcements.
e) The system hardware shall be digital including microphone page stations and associated
queuing, telephone interfaces, distribution of announcements, to single, multiple or any
combination of zones (zone descriptions are provided in the drawings), background music,
recorded announcements, pre-recorded and assembled messages.
f) To achieve Life safety critical objectives the PAVA system shall be required to perform to the
highest achievable standards on a continuous basis (i.e. 24/7). All life safety critical parts of
PAVA system should be fully monitored, from MicrophonePaging Stations to each PA
speaker zones to ensure that any faults are dealt quicklyand efficiently.
g) The complete PAVA system shall be comprised of strategically distributed
subsystems,connected via the LAN, that when integrated together, form a completesystem
for announcement and message management.
h) The system shall include IVRS & ADAS feature with FIDS display -Automatic Displayof
Announcement System with AODB integration.The system architecture should be modular
for expansion in future and ease of maintenance.
i) All system components shall be digitally monitored, including and not limited to, Messages,
Amplifiers, and back up amplifiers, Speaker Circuits, Network Controllers, Paging
Microphone, Battery Charger and the 230 VAC line. Each amplifier / line circuit shall be
monitored individually and shall report any faults back to the Controller as well as the paging
microphone.
j) Each amplifier shall not be loaded more than 80% of its rated capacity and all the public area
zoning - every alternate speakers shall be connected with two (2) different amplifiers.
k) The offered distribution controller should be equipped with an audio switching and routing
matrix as required. Each of these outputs should be further distributed to several power
amplifiers that drive the loudspeakers located in the public address zones corresponding to
each output. The internal wiring of the offered distribution system controller should be made
installer friendly and should have provision of inter connections and termination of various
units and sub-units.
l) AGC (automatic gain control) circuit should also form part of the distribution system
controller and should have independent automatic volume control channels. In environments
such as an airport, the background noise level fluctuates constantly therefore the AGC is
must.
m) The system shall be capable of sending messages automatically to any zone at anytime
interval, without affecting the music in the other areas. In case of any system component
failure, the paging microphone shall override any defective unit and provide paging to the
required zone. This Bypass feature must comply with industrial standards.
n) The System shall be able to be programmed to provide any Cause & Effect programs after
integrating with the Fire Alarm System/FIDS, thus Alert/Evacuate messages can be
programmed and delayed as well as played on any zone / floor as per the Cause &Effect
approved by the Consulting Engineer/AAI.
o) The system shall be capable of being used for everyday background music and public
announcement duties with the fire alarm initiated emergency announcements overriding all
other facilities.
p) The voice alarm system shall be capable of broadcasting pre-recorded emergency alarm
messages and live speech in the event of fire.
q) The systems shall be capable of broadcasting four (min.) pre-recorded messages and 12 or
more different live calls to different zones or group of zones simultaneously.
r) Evacuate signal relates to a general evacuation message and alert message corresponds to
standby instructions.

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 s) In addition a Fire Drill, Bomb Alert, Earth quake alert and an All clear message shall be
incorporated into the operation. A fire alarm broadcast signal shall cancel any public address
operation and shall override it.
t) Provision to avoid echo during announcement a suitable feedback suppressor and audio
processor should be used in the system integration as may be required depending on the
analogue or digital interface.
u) Paging any zone shall not interrupt music in other zones.
v) Facility for switching ON and OFF of the music from equipment rack shall be provided.
w) The Terminal Building PA System shall be divided in to different PA Zones as indicated in
the drawings.
x) In the zones announcement could be made either individually or to all zones or
simultaneously.
y) Suitable marking should be provided in the announcement consoles for identifying the
Zones. By selection, the user should be able to transmit announcement to particular Zone in
the terminal building.
z) The control system should have total access matrix, completely programmable and
expandable having several inputs and outputs, each input can be directed to one or more
outputs according to the configuration and the priority levels defined.
aa) The control system should be easily configurable and programmable using front panel
controls or through external PC.
bb) In addition to the above: the system should have provision for installation and upgrading new
zones and more announcing stations. The system should also have in-built provision of
playing music & manual announcement and pre-recorded Announcements.
cc) The system should also be able to play different BGM (Back Ground Music) indifferent
zones. Normally music should be played through speaker network in all the selected Zones/
areas. However, the system should automatically override music of the relevant zone for
announcements to be heard.
dd) The announcements should not interrupt BGM in other zones than the ones being paged.
The system, in evacuation mode, should be able to override all settings and work in a pre-
configured setting, including announcement level.
ee) For announcement purpose microphones should be provided to ensure maximum isolation
from the ambient noise so that the system delivers highly intelligible announcements and
paging.
ff) Automatic pre-recorded announcement system shall be used for general announcement
information in form of pre-recorded (preferably by single person)messages in Hindi, English
and local language. However, there should be provision for manual announcement. For the
manual announcement professional microphones mounted on the announcement consoles
should feed the distribution system controller.
gg) Each announcement console should be provided with zone selection that should be
programmed to route the microphone inputs to one or several power amplifiers. These
amplifiers in turn should feed the loudspeakers located in the geographical and / or
functional zones with background music or announcements. However, the local
announcement consoles installed in the terminal building should be programmed to
automatically route the announcements originating from these local announcement consoles
to the corresponding local area only.
hh) The level of PA announcement shall be uniform at listening level of an adult person (1.2 M
ht. from the floor). For the STI requirements, refer the audio performance criteria section.(jj)
Reverberation time of each zone in the terminal should be measured and the Electro
acoustical adjustments should be carried out to achieve the target criterion specified the
relevant section.
ii) All Data of the System Integration Criterion shall be verified by the AAI Engineer In-charge.
jj) The bidders should use calibrated Acoustical measuring equipment to satisfy the system
integration criterion to the AAI Engineer In-charge as given in the tender document. The AAI
Engineer In-charge would do the technical assessment of the system integration and all
bidders should extend full cooperation to the AAI technical team.
kk) The system should be of programmable matrix type for sound system management and
control having modular structure for future expansion and up gradation to increase the zones
as may be required. For Finishing schedule of terminal building shall be referred in the

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 54 OF 1216

 relevant Architectural section in the bid document for Acoustics and Electro acoustics
parameters.
ll) The offered system should support broadcasting and routing of the digital announcements by
automatic announcement sub-system that is external to the PAsystem and should have
necessary provision for input as well as processing the announcements. The system should
have appropriate potential free /Analogue and Digital signal inputs for external audio feed.
mm) The system should support a priority mechanism with various priority levels for different
announcements. The system should have provision for automatically controlling the volume
of announcements in a given area depending upon the ambient noise level in that area.
nn) Suitable noise sensing microphone should be installed in Public zones to sense the ambient
noise level prior to the announcement.
oo) Volume regulation should be automatic for delivering the output of respective power amplifier
depending on the noise sensing microphone input and maintaining signal to noise ratio 16dB
to 20dB. The noise sensing system should continuously adjust level to maintain the S/N ratio
as specified above.
pp) The system should have a provision for playing continuous soft background music round the
clock in all public areas of the airport terminal with music level of 55-60dB max value should
be maintained. For inviting attention of announcement apleasing chime should precede
every announcement. The tone of the chime should be programmable to be different for
emergency announcements.
qq) The PA system should support the broadcasting and routing of the alarm / speech generated
by fire detection and alarm system (an independent system) with provision for connecting
audio line or Potential free contact interface for processing.

5.1. Audio Performance Criteria

(a) The PA system shall achieve a minimum Speech Intelligibility of:

Area Speech Intelligibility

Inside the terminal building -all Public areas 0.5 or better RASTI for 95% of each PA
zone
Departure – all public area 0.5 or better RASTI for 90% of each PA
zone
Outside the terminal building 0.3 or better RASTI for 90% of each PA
Zone

(b) In areas without ambient noise sensors, the system shall be designed to deliver the following
average speech sound levels within + or - 3dB for 90% of the area within the distortion limits and
shall not exceed 85dB for normal paging announcements for all the areas:

Area Speech Intelligibility

Quiet and Worship Areas 65dB
Back of House area 75dB
Restrooms 70 dB
Arrivals and Concourses 75dB

(c) In an open public space, the system shall deliver 15dB above average ambient sound level or
5dB above the maximum sound level, whichever is lesser.
(d) In a closed space, the system shall deliver 10dB above average ambient sound level or 5dB
above maximum sound level, whichever is lesser.

(e) The system should allow an undistorted speech reproduction of 75db (peak up to97db) SPL at
listening level. The system should also provide uniform coverage within+/-3dB for the entire area of
the terminal for the octave band 250Hz to 8 KHz. The frequency response of the PA system should
be 125 HZ to 12.5K Hz +/-1dB for Terminal Building.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 55 OF 1216

6. Technical Requirements

6.1. Network Controller

(a) The control unit is the heart of the public address system and shall be certified to International
standards of Emergency Sound System EN 54 (IEC 60849) certified. The unit shall be capable of
routing audio channels, delivering power to the system, fault reporting and controlling of the system.
(b) This unit shall be configured in N+N hot stand by configuration and shall work either in stand-
alone mode or with a PC connected to it. The PC connected to the network controller unit shall
show all status changes in the system with the configuration and diagnostic& logging software.
(c) There shall be control inputs, which should be freely programmable. These can be programmed
for actions to be done in the system and assigned priorities. The network controller shall have
analog audio line outputs for fire alarm signals, music sources etc.
(d) The network controller shall have the capability to handle at least 20 levels of priorities and 20
zones, 12 call stations. The network controller shall monitor the status of all Zones in the system
and report status changes.
(e) Attention and alarm tone definitions shall be stored in the network controller or recalled from an
external storage device through control ports. These tones shall be accessed by any call stations or
control inputs for announcement broadcast or alarm broadcast.
(f) The network control unit shall have extensive audio processing possibilities for audio inputs and
audio outputs. Parametric equalization, limiter, and gain can be adjusted with the configuration
software.
(g) The Controller shall meet the following specification as a minimum:
i) Frequency Response – 20Hz to 20 KHz (+/- 3 dB)
ii) Distortion: <0.05% @ 1 KHz
iii) Display: Front LCD/LED Display for Input/ Output/ Fault monitoring/Programming
iv) Interface: Ethernet for PC connectivity, Systems connection for call station/Amplifier on Fibre/
CAT-6.
(h)System shall be able to make emergency calls (all calls) even if the controller has failed.

6.2. Call Station with Key Pad

(a) EN 54 certified Remote call stations shall be used for making a manual or pre-recorded call to
any pre-assigned zones or executing a predefined action. The call station shall have a fixed
microphone to transmit speech over the network and apress-to-talk key.
(b) Digital Flush Mount/Table-top paging stations (CAT6/ Optical Connectivity) withkeypad,
configured for working zone selection facility for local or zonalannouncements along with high
quality dynamic/Condenser table stand Microphoneas per schedule.
(c) It should be possible to program different priority level for different announcement call station.
(d) The call station set with Goose neck microphone and 2 nos. of Call station keypad and 1 no. of
Numeric key pad with all required interface unit to be used for calling purpose and other applications
as below which connects via standard CAT-6 cable.
(e) Numeric keypad for zone selection and user access which has serial data and power interface to
call station, which shall be combined with normal call station keypads with LCD for user feedback.
(f) Call station key pad for live speech call, Selection recall, Call activation, and cancel selection,
BGM On/Off, BGM volume control, programmable key for any action.
(g) Select resources: BGM channel selection, pre-recorded message selection, attention and alarm
tone selection.
(h) The call station must show ‘BUSY’ indication as per priority announcements.
(i)Call-stacker shall be provided suitable to record calls for automatic playback to previously
occupied zones (by higher priority calls). Record and / or playback min. 8 calls simultaneously, and
stores min. 16 calls.

6.3. Digital Power Amplifiers

(a) Digital Power Amplifiers shall be EN 54 certified 19" rack mountable Digital Class-DAmplifier.
The main function of the power amplifier is the amplification of audio signals for the loudspeakers. It

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shall be possible to select the output voltages of 70or 100V. The power amplifiers are provided with
a LCD/ LED display for fault monitoring and status display.
(b) The amplifier should be either single or dual channel amplifier as per requirement ofzone.
(c) The amplifiers should have digital audio interface connection to network controller via Fiber
optics/CAT 5 and shall have the following features as a minimum: Failover(standby) amplifier in N+1
configuration where N >= 8 at each amplifier cluster locations/PA Rack.
(d) Automatic Amplifier Changeover to hot standby amplifier in case of failure of working amplifier
with internal relays. Faulty amplifier shall automatically switch to standby amplifier automatically
without any manual intervention.
(e) Amplifiers shall be 'Clustered' such that there is one redundant amplifier per cluster,so that in the
event of an amplifier failure the redundant amplifier within the cluster shall automatically be
activated to replace the faulty unit.
(f) The wiring of speakers in each Public area PA zone shall be interleaved and connected to at
least two (2) different PA Amplifier clusters such that the failure ofone PA Amplifier results in an
evenly degraded performance across the PA zone. Separate amplifiers or separate channels of
amplifiers for every zone should be considered.
(g) The system shall be configured such that no amplifier is running at more than 80%capacity.
(h) The Power Amplifier shall meet the following specification as a minimum:
i) Frequency Response: 60 Hz to 18 KHz
ii) S/N Ratio: Line Input/output: ≥ 80 dB at maximum Level
iii) Mic Input/output :≥ 60 dB at maximum Level
iv) Inputs /Outputs: ≥ 2 X Mic/Line Inputs ≥ 4 X Control Inputs (NO/NC Contacts)
Automatic Changeover contacts
v) Distortion at 1 KHz: <0.5% @ 1 KHz
vi) Display: Front LCD/LED Display for status and Fault Display.
vii) Power Wattage (rms): 2 x 240 W/ 1 x 480 W (As per requirement)

The amplifier should have the built in line and loud speaker supervision, automatic volume control
and automatic ventilation temperature control. The power amplifier shall be capable of monitoring
speaker lines (zones) connected to it through pilot tone supervision. The same shall visible in PC
software via controller for status.

6.4. Speakers – General

(a) All speakers shall be EN-54 certified for emergency voice alarm purpose.
(b) Ceiling-recessed type speakers shall be provided wherever a ceiling void is available
(c) Except as noted below, in all other areas where a ceiling-recessed speaker cannot be installed
due to unavailability of ceiling void, wall or column-type speakers;
(d) To meet the acoustic performance requirements within high ceiling areas, such as in the Check-
In, Security Screening and Baggage Reclaim Hall areas, Digitally Steerable Active Linear Array
Speakers shall be proposed.
(e) A mixture of different types of speakers within the same PA zone is acceptable subject to
meeting the acoustic performance requirements
(f) The proposed speaker locations and mounting configurations shall also meet the Architectural
intent.
(g) All speakers shall be rated to generate a continuous SPL of 95dB or greater and shall have multi
tap transformers (70 and 100 volt line at minimum);
(h) Bidder shall consider all required mounting brackets and other installation accessories to the
approval of architect.

6.5. Digital Active Line Array Speakers

(a) The Digital Line Arrays shall be column type loudspeaker with multiple drivers connected
individually with inbuilt amplifiers, ADC-DAC, network interfacewith software configurable vertical
coverage, ambience noise sensing microphone,thermal overload protection, with RJ-45 Ethernet
100 Mbps interface.
(b) The speaker shall be long through type to cover distance >= 20 Metres
(c) The speaker shall be long through type to cover distance >= 30 Metres.

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i) Audio beam steering coverage: Horizontal coverage: 130 degree. Vertical coverage shall be
software configurable.
ii) Frequency Range: 200Hz – 17KHz or better;
iii) Built in multichannel Amplifier and DSP technology for vertical beamsteering, amplifier: > 10/15
Watts per channel;
Integrated noise sensor for Automatic Volume Control shall be provided. Noise micro-phone shall be
connected to the Active Array directly.

6.6. Passive Line Array Speakers

(a) Passive Line array speakers shall be EN54 certified with multi tap for 60W (approx.)
configurations and shall meet the following specification as a minimum:
v) Rated Power: 60 W (approx.)
vi) SPL at 1W/1M @1 Khz: ≥ 90 dB
vii) Frequency Range: Better or equal to 200 Hz – 18KHz
viii) Rated Voltage: 100 V Switchable
ix) Opening Angle at 1 kHz/ 4 kHz : Horizontal : 200/130 degree ; Vertical : 50/20 degree

6.7. 30W outdoor cabinet loudspeaker

(a) 30W wall mount outdoor cabinet speaker shall meet the following
specification as a minimum.
i) Rated Power: ≥ 30W
ii) SPL at 1W/1M @1 Khz: ≥ 90 dB
iii) Frequency Range: Better or equal to 200 Hz – 18 KHz
ix) Opening Angle at 1 kHz/ 4 kHz : Horizontal : 160 / 80 degree ; Vertical : 150 / 80 degree

6.8. Indoor/outdoor bi-directional cabinet speaker

(a) Wall mount bi-directional cabinet speaker with excellent speech & music
reproduction. The cabinet should have two dual cone loudspeaker drivers, mounted
on an angled baffle, providing a wide opening angle. It shall meet the following
specification as a minimum.
i) Rated Power: 12 / 6 / 3 W
ii) SPL at 1W/1M @1 Khz: ≥ 84 dB
iii) Frequency Range: Better or equal to 200 Hz – 18 KHz
iv) Rated Input voltage – 70 / 100V
opening Angle at 1 kHz/ 4 kHz: 2570/ 160 degree

6.9. Ceiling speaker with fire dome

(a) Compact ceiling speakers, wide opening angle, with perforated metal grill and with
suitable fire dome of approved colour with the following specifications as a
minimum:
i) Rated Power: 6 W
ii) SPL at 1W/1M @1 Khz: ≥ 90 dB
iii) Frequency Range: Better or equal to 100 Hz – 18 KHz
iv) Rated Input voltage – 100V
opening Angle at 1 kHz/ 4 kHz: 180/ 45 degree

6.10. Omni Directional Noise Sensing Microphones

(a) High quality Noise sensing microphones with necessary cabling as required should be installed
in various Public PA zones. These noise sensing microphones shall be Omni directional

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microphones with a support construction including mounting rod and junction box suitable for
mounting on the flush/ceiling/wall to the approval of architect.
(b) The noise sensing microphones should sense the ambient noise level in the area in which they
are installed. The average of this noise level at an instant just before the announcement is
broadcast, should be sampled by the automatic gain control (AGC)circuit for adjusting the output of
its associated power amplifier in such a manner that the audio output from the corresponding power
amplifier during the announcement is held at 16dB to 20dB above the ambient noise level in that
area asmay be required.

6.11. Digital Ambient Noise Controller

(a) Digital ambient Noise Controller shall be of 19” rack mountable. It shall have ambient noise
control (ANC) function to automatically adjusts output gain to match changes in ambient noise
levels.
(b) Automatic level control feature maintains input signal at a constant level by adjusting input
signals to appropriate levels when the sound level is too low.
(c) Sound volume is controlled without losing nuances of speech or compromising background
music sound quality.

6.12. IP-based Auto Dialler

IP based Auto Dialer with Digital voice processor to access EPABX /telephone link for Fire tender
request. Auto dialer should be able to dial out minimum of 4telephone/mobile numbers and relay
digital message of Min. 20sec.

6.13. BGM MUSIC PLAYER/PC

(a) The PC based music player shall transmit all the music routed through the Central Equipment
rack to the zone / zones selected.
(b) PC for music system shall minimum configuration as per Control PC (Section 6.14)and Sound
card to support the latest MP3/MP4/WMA/AV1/WMV/DivX etc.,formats. Formatfor playing
instrumental music.

6.14. Control PC with client software

(a) The control PC along with Client Workstation shall be used to control, program and Monitor the
complete Digital Public address system. Using the control software, it shall be possible to program
audio routing, amplifier level, music level, AVC,equalization, Call station microphone level, Chime
tones, pre-recorded message,alarm inputs, define zone, priority level etc.
(b) It shall also be possible to view all systems operational and alarm/fault events log.The software
should show log all announcement details with time, zone etc.,amplifier failure, automatic amplifier
standby status, amplifier overload/short-circuit/ground short, main failure, system restart, call station
error/disconnection
etc.
(c) PC Control Software along with Desktop PC of minimum configuration for complete
administration
i) CPU: Minimum latest Generation Core i5 Intel Processor or higher operating at 2.6 GHz or more
with 8 MB Cache or higher. Memory: 2 x 8 GB RAM or higher – expandable
iii) Hard Drives: 1 TB or more
iv) Video Card: 2 GB graphic card or better dual port Graphics card.
v) RAID: supported
vi) Keyboard: Standard Keyboard with mouse
vii) Network Adapter (NIC): Two numbers of 10Gbps ports.
viii) Sound Card: In- Built with external portable speakers.
ix) DVD writer: DVD RW/ Blu Ray combo internal/external

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x) USB 3.0: 2 nos. at front panel
xi) Operating System: Licensed MS Windows or (Latest version)
xii) Anti-Virus Software: Anti-Virus Software compatible with Windows along with update
subscription valid till warranty and AMC period.

6.15. Interfaces

(a) The System shall be integrated with the Fire Alarm System/FIDS, thus appropriate
Alert/Evacuate messages can be configured to be displayed/played on any zone /floor as per the
Cause & Effect approved by the Consulting Engineer.
(b) The PA system shall be configured to treat the signal from FAS with highest priority.
(c) PA Contractor shall closely co-ordinate with the Fire alarm system / FIDS contractor to prepare
the Interface Control Document (ICD) to the approval of Consulting Engineer / AAI.

6.15.Fibre Optic Cable& HDPE

6.15.1 Single mode fiber optic cable of following specifications shall be supplied:

• The fibre shall fulfil latest ITU-T Recommendation G-652D for Single Mode optical fibre
• (Core / clad 9.2 / 125 mm).
• It shall have total 6 fibres.
• Armouring shall be corrugated steel tape (Electrolytically chrome plated low carbon steel).
• The outer sheath shall be PVC.
• Signal attenuation at wavelength 1550nm shall be £ 0.20 dB/km and at wavelength1310nm shall be £
0.35 dB/km.
• Fibre optic connectors shall comply with EIA/TIA-568. SC type connectors (IEC 60874-14) shall be
used.
• The related standards referred to herein and mentioned below shall be of the latest edition of the
following codes, standard practices & publications unless specified otherwise:

IEC 793-2 Optical fibres-Part 2: Product specifications

IEC 304 Fibre colour code
IEC 794-1-E & F Series Tests on optical fibre cable

6.15.2 All lengths shall be joint free single continuous lengths. Coating and the color of the fibre shall not
react with the surrounding jelly. Outer sheath shall be flame retardant low smoke (FRLS) type.
Desired operating life of cable; Better than 25 years. Drum length shall be informed during detail
engineering.
6.15.3 The optical fibre cable construction shall be of loose tube type and there shall be one fibre per tube.
The cable shall have central strength member, inner and outer sheaths, armour and moisture barrier
layers.
6.15.4 Fibre-optic data highway cable shall be suitable for water-submergence duty and high temperature
withstand as per the routing requirements in the plant. All lengths shall be joint-free continuous
lengths.
6.15.5 Optical fibres shall be coated with UV cured double acrylate resin. It should not have any reaction
with cladding or core material. The coatings should provide maximum resistance to micro bending &
abrasion and ensure mechanical & optical strength. The coatings shall be easily stripped with
mechanical tools.
6.15.6 The coatings shall be in various colours in order to facilitate fibre identification. Fibre colours shall
correspond to latest revision of IEC publication 60793-2 and 60304. The colours shall correspond
reasonably with standard colours and shall readily be identifiable and shall be durable. The colours
should have good colour fast properties also in the presence of other materials during the lifetime of
cable. The coating and the colour shall not react with the surrounding jelly.
6.15.7 The fibre optic cable shall be protected against damages from termite, rodent, fire, chemicals (such
as oil & natural gas, LPG and other petroleum products), moisture and water over the life time of the

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 60 OF 1216

 cable.
6.15.8 The outer surface of the cable shall be permanently & legibly marked with color in contrast to the
outer sheath at regular intervals not exceeding one meter with 'OPTICAL FIBRE CABLE'. All the
markings over OFC shall be by hot foil indentation and such that it should not be erased during field
use. The outer surface of each completed OFC shall have sequentially numbered metric length
markers spaced at regular intervals of one meter.
6.15.9 Moisture barrier – Polymer coated aluminium tape placed longitudinally over the cable core. The tape
shall form a close fit around the cable core with a sealed overlap of 6mm minimum. The thickness of
each polymer layer shall be 0.04 mm minimum. The thickness of fully annealed aluminium foil shall
be 0.15 mm minimum.
6.15.10 The armouring of the optical fibre cable shall be of corrugated steel (electrolytically chrome plated
low carbon steel) tape both side coated with ethylene acrylic copolymer, applied longitudinally with
minimum overlap of 6mm. The thickness of the steel tape shall be 0.15 mm minimum. The thickness
of each polymer layer shall be minimum 0.04 mm minimum.
6.15.11 The cable shall have sufficient strength to withstand a load of value T = 9.81×W Newton, where W =
mass of 1 km in kg. The load shall not produce total strain exceeding 0.25% in the fibre.
6.15.12 The termination enclosures of the optical fibre cable should be dust tight (No dust ingress) and
protected against immersion in water (suitable for continuous immersion in water) and should be
complete with all accessories including splice cassettes splice protection and all other accessories
including accessories for electrical continuity of metallic layers of optical fibre cable and OFC
preparation kit along with instruction sheet.
6.15.13 All fibres (including spare fibres) of a cable shall be terminated in the termination enclosure by
pigtails. Subsequent connection shall be by patch chords. Supply and erection of termination
enclosure, LIU, splices, pigtail, patch chord connection and end termination accessories i.e. end
connectors, splicing kit and other necessary tools/ consumables etc. as required for fiber optic (FO)
cables is in contractor/vendor’s scope. OTDR analysis/report shall form part of the testing activities of
the OFC network.
6.15.14 Contractor shall lay fibre optic cable in HDPE duct/ pipe for all applications. Each fibre optic cable
shall be laid in a separate HDPE duct/ pipe. HDPE duct of fire red colour (for Fire alarm system) shall
be supplied for fibre optic cable routing, shall be permanently solid lubricated/ with spiral groove, UV-
protected, fire retardant (Class V2 as per UL-94 and with limited oxygen index of 21 or higher as per
ASTM D2863), of 40 mm outer diameter (+5.0/-0.0 mm) minimum thickness 3.7 mm, suitable to
withstand load of 6 kg/m2. HDPE ducts shall be supplied in drum length of 500m.
6.15.15 All HDPE ducts shall be supplied along with accessories such as push fit coupler, bend and elbow,
end plug, simple plug, sonic head, etc. required for blowing cable into HDPE duct by compressed air
technology/ manual laying.
6.15.16 HDPE duct/ pipe of different colours shall be supplied for different applications i.e. feeder differential
relay pilot wire, fire alarm system data highway etc. Exact colors of HDPE duct/ pipe shall be
finalized during detail engineering or as per engineer in charge.
6.15.17 Vendor shall furnish past track record for the selected make of the fibre optic cable and HDPE duct
preferably for the past EIL projects during drawing review stage. Make of fibre optic cable & HDPE
duct shall be approved by Owner during drawing approval stage.

7. Testing Requirements

(a) The successful bidder shall carryout several tests to determine the quality and the performance
of the installed sound system. These tests should be carried out in all the zones of the building
using professional measuring test equipment.
(b) All the necessary test equipment required for measuring the various acoustic andelectro-
acoustic parameters should be arranged by the tenderer and shall not be provided by Airport
Authority.
(c) A computerized test report showing the measured values for the various acoustic
parameters in all the zones should be submitted by the tenderer, failing which the work would not be
treated as complete. The different tests that should be performed by the tenderer to ascertain the
audio quality, intelligibility, function and performance of the system should be as under.
i) Sound Pressure Level (SPL) of all zones in different areas.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 61 OF 1216

ii) Intelligibility Tests of all zones in different areas.
iii) Reverberation Time of all zones in different areas.
iv) Signal to Noise ratio of all zones in different areas.
v) Distortion of all zones in different areas.
vi) Frequency response of all zones in different areas.
vii) Functional Test of Priority levels of all the announcement sources of all zonesin different areas.
viii) Adjustment of equipment as required of all zones in different areas.
ix) Any other relevant test as may be required by AAI for assessment of the PAsystem and its
performance of all zones in different areas.

Note: All the tests should be measured in the presence of the AAI Engineer In charge and should be
carried out to the satisfaction of AAI Engineer In charge. If necessary AAI team may ask some
additional Electro acoustical measurements to carried out to evaluate the performance of the audio
system installation. All the above measurements shall be verified by the Airport Authority of India by
their own equipment or third party measurements shall be performed for verification of acoustical
data.
(d) Guideline for reverberation time measurement: Estimated reverberation Time of the halls shall
be 1.5 sec. to 2.0 sec. The tenderers are required to measure the RT60(reverberation time) of all
the Zones and submit the following:
i) Name, Model Number, calibration certificate & accuracy of the equipment’s used to measure the
RT60 should be submitted in tender.
ii) Measurement report of the RT-60 measurement to be submitted to the Engineer in charge.
iii) The Reverberation Time (RT-60) to be measured at the following frequencies.
1. 125Hz -
2. 250Hz -
3. 500Hz -
4. 1 KHz -
5. 2 KHz -
6. 4 KHz -
7. 8 KHz -
(e) Measured data of the STI of all the Zones at 6 (Six) locations in each Zone to be submitted to
AAI as and when the halls are ready.
8. STI at Listener location 1 –
9. STI at Listener location 2 –
10. STI at Listener location 3 –
11. STI at Listener location 4 –
12. STI at Listener location 5 –
13. STI at Listener location 6 –

8.Comprehensive Annual Maintenance Contract:

For Comprehensive Annual Maintenance Contract, refer SCC of tender.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 62 OF 1216

 JOB SPECIFICATION

FOR

ELECTRIC HEAT TRACING SYSTEM

(B047-003-16-50-SP-1003, Rev. A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 63 OF 1216

 CONTENTS

SECTION TITLE

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 SITE CONDITIONS

4.0 SCOPE OF SUPPLY

5.0 TECHNICAL REQUIREMENT

6.0 TESTING AND INSPECTION

7.0 VENDOR DATA REQUIREMENTS

8.0 CERTIFICATION

9.0 PACKING & TRANSPORTATION

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 64 OF 1216

1.0 SCOPE

This specification provides the minimum requirements for engineering, design,

selection, manufacture, testing, supply, installation, testing and commissioning of
electric heat tracing system for equipment, vessels and piping etc. to keep the fluids,
which gel, at ambient temperatures in the fluid state.

2.0 CODES AND STANDARDS

2.1 The equipments covered by this specification shall, unless otherwise specified, be in
line with the requirements of the latest applicable standards of:

BIS - Bureau of Indian Standards .

IEC - International Electro-technical Commission.
BSI - British Standards Institution.
NEMA - National Electrical Manufacturers Association.
IEEE - Institute of Electrical & Electronics Engineers.
API - American Petroleum Institute.
NEC - National Electrical Code
NFPA - National Fire Protection Association

2.2 Any other recognised international codes or standards may be used in lieu of the
above, subject to the approval of the AAI.

3.0 SITE CONDITIONS

The equipment offered and the installation shall be suitable for continuous operation
under the following site conditions:
(i) Equipment design temperature : 40° C
(ii) Minimum ambient temperature (Outdoor) : -22° C
(iii) Minimum ambient temperature (indoor) : -5° C
(iv) Relative humidity : 30-100%
(v) Seismic zone : As per IS:1893
(vi) Altitude : 3515m above MSL
(vii) Atmosphere : Cold Desert
(viii) Location : Leh, J&K
Note: The required calculations for de-rating for the equipments shall be submitted
by the Contractor.
4.0 SCOPE OF SUPPLY

The scope of supply through this specification includes, but not be limited to the
following:
(ix) Electrical Heat Tracers
(x) Distribution Panels
(xi) Earthing system, cables, cable glands, lugs etc.
5.0 TECHNICAL REQUIREMENTS

5.1 ELECTRICAL SURFACE HEATING

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 65 OF 1216

5.1.1 The design shall be based on continuous and reliable service, safety to personnel
and equipment, ease of maintenance and interchangeability, wherever applicable.

5.1.2 The design of the electric heating system shall be based on stabilized design
approach where the maximum surface temperature of the heating device shall be
determined without thermostatic control.
Product classification approach shall be followed for determining heating device’s
sheath temperature unless otherwise agreed.

All necessary type test certificates including those for ‘T’ rating, maximum continuous
exposure temperature and maximum intermittent exposure temperature shall be
furnished along with the bids.

5.1.3 The heating tapes shall have burn -out proof feature to avoid damage to the heating
tape in case of overlapping.

5.1.4 The heating tapes shall be suitable for use in area defined in data sheet . It shall be
provided with corrosion resistant metallic (tinned copper) braid for both safe and
hazardous area applications. An outer sheath over the metallic sheath shall also be
provided for corrosion resistance and additional mechanical protection.

5.1.5 The surface temperature of the heating tapes/electrical equipment intended to be

used in hazardous area shall not exceed 200 deg. C (T3 rating) unless otherwise
specified in the data sheet

5.1.6 The selection of heating tapes and other devices shall be done by the contractor
considering the following:
· Specified temperature requirements
· Minimum design ambient temperature
· Exposure temperature (continuous)
· Thermal insulation as specified elsewhere
· Tolerance on supply voltage and voltage drop on feeding cables
· Minimum heater output rating at operating conditions
· Site environment conditions
· Specified hazardous area classification and 'T' rating
· Design margin

5.1.7 The method of calculation of heat loss and related parameters shall be as per
guidelines given in the standards. The losses from each part of the surface shall be
calculated using the appropriate formula and added together to determine the total
heat loss. A minimum design margin of 10% shall be considered on the rate of heat
loss calculated.

5.1.8 The tracer shall withstand the highest equilibrium pipe temperature that occurs when
the heating cable is continuously energized at the maximum ambient temperature
and at the maximum operating voltage.

5.1.9 The heat output at the end of the heater tape shall meet the minimum heat loss
requirement, considering negative tolerance on supply voltage, voltage available at
the end of the tape and considering minimum heater output rating at operating
conditions.

5.1.10 Extra heater tape length shall be provided for valves, flanges, pipe supports and
similar heat sinks. The heater tapes shall be installed so as to permit easy
maintenance or removal of the valve, pipe support or similar heat sink.

5.1.11 Each heater circuit shall be controlled through independent thermostat (temperature
set point manually adjustable) for energy conservation requirements. The location of
thermostats shall be decided at the most strategic points which are governed by
process /site conditions. A single thermostat shall not be used to simultaneously

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 66 OF 1216

 provide control over both flowing and no-flow portion of pipelines. The capillary tube
shall have mechanical protection.

5.1.12 Number of circuits shall be decided considering all possible flow conditions.

5.1.13 Suitable flexible material (aluminium tape) shall be used for proper positioning of the
heater tape on pipeline, equipment. No increase in allowance on heat output shall be
permitted on this account.

5.2 ELECTRICAL POWER DISTRIBUTION

5.2.1 The heat tracing system shall be suitable for operation on 240V + 5%, 50 Hz, single
phase AC supply. The Power supply to the heater tapes shall be from local
distribution panels (LDPs) located in the field at strategic locations /load centres to be
decided by the contractor. However, the main Power Distribution Panel shall be
located in Switchgear Room in safe area.

5.2.2 Power cables from local distribution panels to the heater tapes shall be sized to limit
the voltage drop to maximum 3 % under full load condition, including maximum
heater output rating at operating conditions.

All power cables (from switchgear room to LDP and LDP to heater tape) shall be
properly sized to carry current without undue temperature rise under site derated
conditions. The derating shall take into account ambient air temperature, grouping
and proximity of cables with each other etc. as applicable for installation.

Further, the selected cable size shall also be adequate to carry the maximum
anticipated heater start up current while the heating device is at minimum
temperature, to facilitate in temperature maintenance application for the process fluid
to reach its maintenance temperature utilising the available extra heat capacity of
heater tapes provided.

5.2.3 Power and control cables shall be FRLS type, Copper conductor, armoured, as per
requirements given in data sheet and Specification-‘Medium Voltage Cables &
Accessories’. 3 core-armoured cables shall be used for power supply to heater tape
for single-phase circuits. (2 cores for phase and neutral and third core for earth
conductor)

5.2.4 The incoming cables to LDP shall be four core (conductor size for neutral shall be
same as that for phase conductors).

5.2.5 Thermostats, if used, in power circuit, as well as Components used in the local
distribution panels shall be sized for 125 % of starting current at rated voltage and
considering maximum heater output rating.

5.2.6 The load shall be balanced in all the 3 phases to the extent possible in each LDP.

5.2.7 Monitoring facility

Unless otherwise specified in the data sheet, the monitoring facility for power supply
healthiness of feeders in LDP feeders shall be done by providing in each feeder one
auxiliary contactor which shall remain energized under power supply healthy
condition. The contact (Normally open) of this auxiliary contactor of all feeders shall
be wired in series in each LDP to give one common alarm contact for remote
annunciation (open to alarm) against loss of voltage, earth leakage, and fault.

5.3 EQUIPMENT AND MATERIAL SPECIFICATIONS

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 67 OF 1216

 All materials to be used for the job shall be field proven in similar services and under
similar conditions. The workmanship shall be of high quality in every respect.

The main heater tape shall be as detailed in section 5.1. The requirements in respect
of other items are detailed below.

5.3.1 Local Distribution Panels (LDP)

The local distribution panel shall be metal enclosed, compartmentalized, floor

mounted, free standing, non-drawout type suitable for indoor installation.

a. The frame of individual vertical panels shall be fabricated using minimum 14 SWG
cold rolled sheet steel. Doors and covers shall be made of minimum 16 SWG cold
rolled sheet steel. All doors and covers shall be provided with neoprene gaskets.
LDPs intended for installation in outdoor safe areas shall be housed in outdoor kiosk
to make it totally weather protected. Necessary provision shall be made in outdoor
kiosk, so that the operator can monitor the energized / de-energized position of
different components from outside without opening the door and without taking any
special precautions.

b. The incomer feeder to LDP shall be MCCB feeder of required rating and the feeder
shall have ammeter, ammeter selector switch and pilot lamps for supply indication.
Each out going circuit shall comprise of MCCB/MCB with thermal over current and
magnetic short circuit releases, Earth Leakage Circuit Breaker (ELCB) (M9 Category),
power contactor of required rating. MCB rating shall be such that it shall not operate
on starting current. The ELCB shall have nominal 30 mA and 30-msec.-trip rating. In
case this setting results in nuisance tripping, ELCB may be selected above 30 mA but
not greater than 300mA and 150 msec, above any inherent capacitive leakage
characteristic of the heater as specified by manufacturer. Ammeter (CT operated) and
indication lamp for feeder status shall be provided for each outgoing circuit. LDP
shall have 20% spare feeders, which shall include minimum of one spare feeder of
each rating.

c. LDP shall be designed to ensure maximum safety during operation, inspection and
maintenance.
The maximum height of the operating handle /switches shall not exceed 1800 mm
and the minimum height shall not be below 300 mm. Suitable base frame shall be
supplied along with the panel. Panels shall be suitable for bottom entry of cables
unless otherwise specified.

Checking and removal of components shall be possible without disturbing adjacent

equipment. All connections, terminations etc. shall be done from the front to limit the
rear clearance requirements. A suitably sized earth bus shall be provided at the
bottom of the panel, with provision for earth connection at both ends. Cable entries
shall be by means of double compression cable glands.

d. All hardware shall be corrosion resistant. All joints and connections of the panel
members shall be made by cadmium plated high quality steel bolts, nuts and washers
secured against loosening.

e. Removable type lifting hooks or jacking lugs shall be provided on each panel or
shipping section. These hooks when removed shall not leave any opening in the
panels.

f. All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale,
rust, grease and dirt. The under surface shall be free from all imperfections and
prepared by applying a coat of phosphate paint and a coat of zinc chromate primer,
followed by two coats of epoxy based final paint.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 68 OF 1216

g. Flameproof and weather protected thermostats shall be used in classified areas. All
thermostats shall be factory calibrated, non-indicating type, equipped with internally
adjustable set point with enclosure having IP - 55 protection.

h. Junction boxes /power connectors used for power cable / heater tape termination
shall be weatherproof for use in safe areas. Flameproof weatherproof junction boxes /
power connectors shall be used for areas classified as Zone-2.

All weatherproof enclosures shall be provided with IP 55 protection.

Nickel plated brass double compression cable glands shall be used for cable
termination in all equipments except in flameproof equipments where cable glands
shall be flameproof type.

i. Heater tape termination and support clamps shall withstand the maximum
temperatures, temperature cycling and thermal expansion of piping or equipment to
be heated. These shall not be affected by rainwater, firewater spray and site
environment.

j. Electric surface heating system shall be complete with all accessories for fixing and
installing the heater tape and junction boxes, power connectors, T connectors, end
connectors etc.

k. Each heater shall be tagged with non-corrosive metallic tag indicating heater number,
type and pipe line/equipment number.

l. Pipe lines, instruments and vessels heated with heater tape shall be provided with
suitable metallic caution signs visible from all sections of the heated system. Caution
signs on traced pipe lines shall not be more than 6 m apart. In addition, each
instrument, level gauge, vessel etc. that by the nature of their function require
operation or maintenance, shall carry an individual sign. The sign shall read "Electric
surface heated " and shall be of size 200 mm x 60 mm (minimum).

m. All electrical equipments to be supplied by the contractor be epoxy painted. Unless

otherwise specified, the colour shade shall be shade 632 as per IS: 5. In general,
painting shall be as per Specification-‘Protective Coating’.

5.4 INSTALLATION

5.4.1 Heater tape

5.4.1.1 Before installation of heater tapes on pipes and other equipments, contractor shall
arrange to clean properly the surfaces to the extent required.

5.4.1.2 Installation shall be done in accordance with applicable standards.

5.4.1.3 Heating tapes shall not be installed until pipe lines and equipment have passed all
required tests and clearance is given by engineer-in-charge.

5.4.1.4 Heaters and controls shall be carefully located and installed to prevent damage
during normal operation and maintenance.

5.4.1.5 The electric surface heating for instruments, valves and flanges shall be done in such
a way that servicing of instruments, opening of valves and servicing of flanges is
possible with ease and without disconnecting wiring.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 69 OF 1216

5.4.1.6 Field installation works shall be carried out in such a manner that the work of other
agencies (piping, insulation contractor etc.) operating at the site is not hampered due
to any action of the contractor and proper coordination with other agencies shall be
contractor's responsibility.

5.5 CABLING SYSTEM

5.5.1 All cables shall run in cable trays and neatly clamped with cable number tags
attached at the terminations and where the cable changes its direction. All cable
trays shall be of fibre glass

5.5.2 All cable trays shall be accessible for easy removal/replacement/re-routing of the
cable.

5.5.3 All cables shall be of continuous length without intermediate joints. All cables shall be
identified close to their termination point by cable number (as per cable schedule). In
case of control cables, all cores shall be identified at both ends by their terminal
numbers using PVC ferrules as per interconnection diagrams.

5.5.4 All FRLS PVC cables up to 1.1 kV grade shall be terminated at the equipment by
means of double compression type cable glands and crimping type lugs. All cable
entries shall be through bottom only unless otherwise approved.

5.6 EARTHING SYSTEM

5.6.1 All metallic non current carrying parts of electrical apparatus, LDPs, Heater tape
mounting accessories, junction boxes, thermostats etc. shall be earthed.

5.6.2 For earth connections to LDP and other equipment and devices, contractor shall tap
from the nearest available existing main earth grid by providing two runs of 70mm2
copper strip.

6.0 TESTING AND INSPECTION

6.1 HEATER TAPE

After completion of manufacture of heater tapes and prior to dispatch, heater tapes
shall be subjected to all routine tests as defined in applicable standards.

6.2 POWER AND CONTROL CABLES

All cables shall be subjected to routine tests and acceptance tests as per applicable
specification.

6.3 LOCAL DISTRIBUTION PANELS AND ACCESSORIES

Acceptance tests shall be carried out as follows:

a) A general visual check shall be carried out. This shall cover measurement of overall
dimension, location, number and type of devices, terminal boxes, location and
connection of terminals etc,

b) Manual and electrical operation of switchgear components shall be checked under

the worst conditions of auxiliary supply voltage.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 70 OF 1216

c) Dry insulation test with power frequency voltage shall be conducted for the main and
auxiliary circuits.
d) Insulation resistance of the main and auxiliary circuits shall be checked before and
after High voltage withstand test.

e) Operation check shall be carried out for every control function as per the schematic
diagrams by manually simulating the conditions and operation of control
switches/relays etc.

f) For equipment bought from sub-suppliers, certified test reports of tests carried out at
the manufacturer’s works shall be submitted. The sub-supplier at his works shall
conduct normally all routine tests as specified in the relevant standards.

6.4 FIELD TESTING AND COMMISSIONING

6.4.1 Inspection during erection and after completion of installation shall be carried out by
contractor's adequately trained supervisor /engineer. Contractor at no extra cost to
the owner, shall rectify any defect pointed out by AAI representative.

6.4.2 Before any part of the electric surface heating system is energized, the pre-
commissioning tests shall be carried out. This shall include and be not limited to the
following:

a) Insulation resistance tests

b) Continuity test
c) Earth loop impedance

All pre-commissioning checks and tests both for power distribution and heating
system shall be carried out by the contractor in the presence of Engineer-in-charge.
Test readings are to be recorded by contractor and copies of test certificates shall be
furnished to AAI in triplicate.

6.4.3 After inspection and pre-commissioning tests are carried out, contractor shall obtain
necessary approval before energizing the installation. Current shall be noted at the
time of initial energisation of the circuits and again when readings have stabilized. All
results shall be recorded and furnished to AAI to form part of system documentation.

7.0 VENDOR DATA REQUIREMENTS

Vendor shall submit the following:

-Catalogues and brochures giving technical particulars of equipment / component

offered.
-Approval test certificates of heater strips, thermostats, junction boxes, power
connectors etc. for use in hazardous area.
-Heat loss calculations for each equipment/item/line.
-Layout drawing showing position and route of tracing cables, location of joints,
termination, thermostats etc.
-Break up of circuit used for each equipment/line to be heated.
-Total start-up and operating load along with breakup.
-Heater cable guaranteed power output curve indicating +ve and -ve tolerances.

8.0 CERTIFICATION

All offered equipment or equipment of similar design manufactured by same vendor:

-Shall have been type tested by an approved authority.
-Shall have been in continuous satisfactory service for a minimum period of two
years.
-Shall behave current certification/approval/listing by an approved agency or UL or
FM

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 71 OF 1216

9.0 PACKING AND TRANSPORTATION

The offered equipments along with their accessories shall be shipped to site packed
in wooden crates. They shall be wrapped with polythene sheets, before being placed
in the crates to prevent damage to finish. Crates shall have skid bottom for handling.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 72 OF 1216

 JOB SPECIFICATION FOR
AUTOMATIC POWER FACTOR CORRECTION
PANEL
(B047-003-16-50-SP-1004, Rev. A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 73 OF 1216

1.0 GENERAL

This specification covers the general requirement of Design, Manufacture, Factory testing, site testing and
Installation of Power Factor Correction equipment intended to be used with low voltage networks.
Power Correction equipment should be able to improve the power factor as per regulations and shall be
suitably rated to improve the system power factor form 0.85 to 0.99 based on the actual load. The Equipment
shall be manufactured by OEM as per approved make List, and installed in full compliance to this
specification, the International standards & in accordance to the Rules and regulations of Electrical
connections.

The power factor correction equipment shall normally be connected to the main LV Distribution Boards
through dedicated feeders.

This equipment’s installed shall be stand alone with LV Distribution Board.

Power Factor Correction Equipment’s would improve the power factor as per the local utility regulation.

This equipment’s shall be routine tested at manufacturer’s works at country of origin before dispatch.

2.0 APPLICABLE STANDARDS

Unless specified otherwise the capacitor banks shall conform in design, material, construction and
performance to the latest editions of the IEC standards, their corresponding British European /(BS EN)
standards and in particular to the following publications :

IEC 61921: Power capacitors – Low voltage power factor correction banks.
IEC 60831-1 & 2: Shunt power capacitors of the self-healing type for A.C.
systems having a rated voltage up to and including 1000 V
IEC 60076-6 Power transformers - Part 6: Reactors
IEC 60085-1 Electrical insulation – Thermal evaluation and designation.
IEC 60664 Insulation coordination for equipment within low-voltage
systems
IEC 61439-1 Low-Voltage Switchgear and Control gear Assemblies Part 1:
General Rules
IEC 60947-1 Low-voltage Switchgear and Control gear - Part 1: General
Rules
IEC 60947-2 Low-voltage Switchgear and Control gear - Part 2: Circuit-
Breakers
IEC 60947-4-1 Low-voltage Switchgear and Control gear – Part 4-1:
Contactors and Motor-starters
IEC 62208 Empty enclosures for low-voltage switchgear and control gear
assemblies – General requirements
IEC 60529 Degree of protection provided enclosures (IP code)
IEC 62262 Degrees of protection provided by enclosures for electrical
equipment against external mechanical impacts (IK code)
IEC 61000-6-4 Electromagnetic compatibility – Generic standards – Emission
standard for industrial environments
IEC 61000-6-2 Generic standards – Immunity for industrial environments
IEC 61000-3-6 Assessment of emission limits for the connection of distorting
installations to MV, HV and EHV power systems
IEEE 519-2014 IEEE Recommended Practices and Requirements for
Harmonic Control in Electric Power Systems.

In addition to the above listed standards, the Rules and Regulations for electrical installations issued by CEA
regulation shall also be adhered to.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 74 OF 1216

3.0 MARKING

The following minimum information shall be given by the manufacturer in an instruction sheet and on a rating
plate to be fixed on the assembly.
1) Manufacturer’s name or trademark.
2) Serial number.
3) Date of manufacture
4) Rated reactive power, Q N in kilovars (kVar).
5) Rated voltage, U N in volts (V).
6) Rated frequency, f N in hertz (Hz).
7) Minimum and maximum ambient temperatures in degrees Celsius (°C).
8) Degree of protection.
9) Short-circuit withstand strength, in amperes (A)
10) Number of stages
11) Step Size

4.0 CONSTRUCTION OF AUTOMATIC CAPACITOR BANK

The enclosure housing the capacitor units shall be of minimum 1.5 mm thick electro galvanized sheet steel
folded and welded construction, floor mounted, free standing or wall mounted type with a minimum degree of
protection of IP41 complete with a hinged lockable door.
The enclosure system for capacitor bank shall be of certified design as per IEC 62208.
The enclosure system should have a minimum of IK 10 certification (external mechanical impacts) in
accordance with IEC 62262.
All enclosures or partitions including locking means and hinges for doors shall be of a
Mechanical strength sufficient to withstand the stresses to which they may be subjected in normal service,
and during short-circuit conditions

The enclosure will be factory wired and comprise mainly of the following:

1. Power factor improvement 3 phase capacitors, arranged in a suitable number of

stages.
2. Detuned three phase iron cored series reactors for harmonic current suppression.
3. Microprocessor based power factor regulator for automatic power factor correction.
4. 3 pole contactors for capacitor switching.
5. MCCB for each capacitor stage.
6. Main incomer isolating switch / MCCB.

The automatic capacitor bank should be ready for field connection with all the components clearly labeled for
identification.

To ensure safety, reliability and accountability of component coordination, all the major capacitor bank
components such as capacitor Units, de tuning reactors, PF controllers,
Contactors called for in this specification should be preferably from a single manufacturer.
The Power Correction Equipment shall be installed in cool ventilated locations away from other heat radiating
elements
The Power Correction Equipment shall be of type tested design at an ambient temperature of 50 degree
Centigrade.
The Capacitor bank shall be designed for trouble free service under the arduous temperature conditions as
defined in Regulations and typical of Indian Continental. The capacitor banks shall be operable on 50 Hz and
shall meet or comply with IEC, IEC 61921 and IEC 61439-1.

The Design and component selection shall consider continuous operation at a maximum system voltage of
415V and ensure reliable performance in consideration of room ambient temperature of 50 degree
Centigrade.

All Components shall can withstand the dynamic, thermal and dielectric stresses resulting from prospective
short circuit currents without damage or injury to personnel. Due to the presence of harmonic currents and
to manufacturing tolerances, components (MCCB/ isolator, bus bar & power cables) shall be designed for
1.5 times nominal current.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 75 OF 1216

Ventilation fan and air inlet filter unit shall be provided for the capacitor banks to facilitate better heat
dissipation. The ventilation fan shall be operated by two numbers of thermostat set at 35 and 55 degree
Centigrade respectively.

Dimensional Details: Detailed Dimensional Details of the Enclosures has to be as per Annexure 1 below.

NOTES: The enclosure systems shall be manufactured in full compliance with and tested to the
requirements of the following IEC Publications.

IEC 62208: Empty enclosures for low-voltage switchgear and control gear assemblies –
General requirements
IEC 60529: Degree of protection provided enclosures (IP code)

IEC 62262: Degrees of protection provided by enclosures for electrical equipment against
external mechanical impacts (IK code)
5.0 BUS BARS

The bus bar section of power factor assemblies shall withstand, as a minimum, the fault current of the
system at the point where it is intended to be connected. Usually, these assemblies are connected onto a
section of the main installation where the fault current are quite high. Bus bars shall be tin plated copper,
rectangular and rigid construction.
The phase bus bar shall be arranged systematically and assembled using insulators.
The bus bars shall be protected poly carbonate shrouds from all sides. The bus bar assembly shall be fully
shrouded (at least IP20) so that no live parts are accessible.
Phase identification shall be done systematically.
The rating of the main bus bar assembly shall be to suit the incoming switching device rating. The main bus
bars of the capacitor banks are preferred and recommended to be in separate bus bar chamber, wherever
applicable.
Tin plated copper bus bar and earth bus bar shall be located on both sides of the incomer Bus bars shall be
provided with a suitable termination facility for connecting the main neutral and earth cable. Extra termination
shall be provided on the earth bar for the bonding purpose.

6.0 TECHNICAL REQUIREMENTS

6.1 CAPACITOR UNITS:

Capacitor units shall be/of/have

1. Dry type
2. Suitable for a network voltage of 415 volts and shall be rated at minimum 525V for 14% detuned banks.
3. Suitable for continuous operation line current of 1.3 times the current which occurs at rated sinusoidal
voltage and rated frequency excluding transients
4. Temperature category of the capacitor units shall be -5 / D. Casings shall be metallic. Completely
leakage proof
5. Self-healing ability, where a damage of some part of the dielectric due to a microscopic flaw in the
dielectric film, caused by over-voltage, can be self-healed quickly and returned to normal state.
6. A 3 phase pressure switch disconnector for protection against internal faults, over pressure, etc. should
be available. The pressure switch disconnector must isolate all the three phases simultaneously in the
event of fault. To ensure full functionality of the pressure switch disconnector, its elastic elements must
not be hindered, i.e.
a. Connecting lines must be flexible leads.
b. There must be sufficient space for expansion above the connections

7. The built-in discharge resistors shall not be accessible (factory fitted) and tamper proof. The discharge
resistors shall ensure reduction in capacitor voltage to less than 50 volts in 1 minute after switch off.
8. The total losses including discharge resistors to be less than 0.5 Watt/KVAR. Capacitance tolerance
shall be within +/- 5% of the rated value.
9. The Capacitor unit shall be capable of withstanding the inrush current up to 200 times of its rated
current.
10. The rated output of the capacitor Unit has to be at the supply voltage of 415V and 50 Hz frequency. The
capacitors used in conjunction with reactors shall be suitably de-rated to deliver the designed output at
415V.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 76 OF 1216

 NOTES: The capacitor unit shall be manufactured in full compliance with and tested to the requirements of
IEC 60831, Part-1 and Part-2.

6.2 DE-TUNING REACTORS:

Capacitors with detuned filtering technique shall be employed to correct power factor while avoiding the risk
of resonance condition. This shall be performed by shifting the resonance frequency to lower values where
no harmonic currents are present, by introducing a filter reactor in series with the capacitors, such that the
capacitor / reactor combination is inductive at the dangerous frequencies but capacitive at fundamental
frequency. The circuit should be tuned such that the series resonant frequency should be below the lowest
harmonic order expected to be present in the electrical network.
The de-tuning reactors shall be connected in series with each capacitor stage and shall be of iron cored
type.

The Detuned Reactor Should be equipped with Thermal Switch inside the Winding which should cut-off the
respective contactor in case of Over-temperature.
The capacitors used in conjunction with reactors shall be suitably de-rated to deliver the designed output at
415V.

The reactor insulation shall be Class “H” or above. The maximum temperature of the reactor at maximum
o o
continuous RMS amperage shall be no higher than 145 C at a 50 C ambient. The capacitor and reactors
rd
shall be tuned for 135 Hz and 14% relative impedance (2.7 tuning order) for 3 Harmonics present in the
network.

Tolerance of reactors shall not exceed +/-3% of rated value.

NOTES: The de tuning reactor shall be manufactured in full compliance with and tested to the requirements
of IEC 60076-6 Reactors

6.3 POWER FACTOR CONTROLLERS:

The power factor controller shall/ be able to:

1. Microprocessor based and shall be able to sense the reactive current requirement of the network and
shall switch ON / OFF the required stages of a capacitor bank.
2. Insensitive to wirings such as reversed CT connection, PT on a wrong phase etc.
3. Detect any stage size by automatic recognition and the switching sequences should be user defined.
Detect the capacitor bank size if in case the present capacitor is replaced by a new capacitor of
different rating
4. Is equipped with LCD display which shows at any time power factor, internal capacitor bank
temperature and monitors the line frequency.
5. Suitable for 1A or 5 A current input and operating in temperatures up to +50 degrees C. The capacitor
Bank and controller shall ensure that after the loss by fault of any one stage, it shall continue to
operate automatically and shall follow rotational switching.
6. Recognize the connection of CT and Voltage and be able to automatically adjust itself to the phase
angle difference. Regulator shall have capability to automatically search and set the C/K setting, it
shall be also possible to program the C/K setting manually.
7. Have a maximum time delay of 90 seconds for switching on a capacitor into circuit, from its last
disconnection from the circuit.
8. The ingress protection of the regulator shall be minimum IP 41.
9. The regulator must be panel mounted, shall be easily programmable and shall conform to safety
guidelines as per IEC 61010-1:2001
10. The regulator must be suitable for 1 A or 5 A current input and shall be sensitive to a minimum current
input of 40ma

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 77 OF 1216

 11. The threshold value for the operating temperature and system harmonics shall be programmable and
the regulator shall be able to switch off the connected capacitor stages if the actual values exceed
these thresholds
12. Be equipped with RS 485 communication port.
13. Dual Cos Phi – The Controller should have programmable dual cos phi to differentiate the need in
compensation (Cos Phi) when the operating condition changes. Like Peak Hour (5:00am-2:30pm,
when the target PF could be increased to 0.99) or Power factor correction needs with a utility supply
changes when the input power is from a in-house Generator.
14. The Power factor controller/regulator should allow the following readings.

o Automatic initialization and stage rating detection

o Any step sequence detection (User definable step sequence )
o Measurement of capacitance per stage
o Cap bank over load current ratio
o THD Voltage
o 4 Quadrant operation
o Active , reactive and apparent power
o Record of the Max temp internal of the capacitor bank since reset
o System Voltage (V AC)
o Frequency
o Apparent Power (kVA)
o Apparent current (A)
o Temperature (°C)
o Real time Cos phi
o kVAr value to target Cos phi

15. The controller shall initiate alarms and warnings in the following events.

o Temperature limit is exceeded

o Insufficient capacitor output
o Overload current ratio limit is exceeded
o Under voltage, Over voltage
o THDU limit is exceeded
o Low power factor/ under compensation.
o Over compensation
o Over current
o Capacitor step defective

NOTES: The automatic power factor controller shall be manufactured in full compliance with and tested to
the requirements of IEC 61326-1.
IEC 61326-1 Electrical equipment for measurement, control and laboratory use - EMC requirements - Part 1:
General requirements.

6.4 SHORT CIRCUIT AND OVER LOAD PROTECTION:

The capacitor bank shall be protected by a suitably rated MCCB/Isolator at the incomer. It shall have a
rotary front operating door mounted handle and should be interlocked with the door to ensure that the
capacitor bank is de-energized when door is open.

The MCCB/ Isolator shall be a three pole and shall fully comply with the requirements of the IEC 60947-1
& 2. The MCCB shall be rated for a minimum insulation voltage of 660 V and designed for an ambient
temperature of 50 degrees C. The current rating shall be at least 1.5 times the full load current of the
capacitor bank and shall have a mechanical endurance of a minimum 1000 operations. Each stage of the
capacitor bank shall also have a suitably rated MCCB with an electronic over-current relay for overload
protection. The electronic over-current relay shall be adjusted to trip if the RMS current of the stage
exceeds the overload setting.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 78 OF 1216

The combination of bus bars and stage breakers shall be designed and type tested for a short circuit
withstand of 50kA/1sec minimum

NOTES: The MCCB / SWITCH DISCONNECTOR shall be manufactured in full compliance with and tested
to the requirements of IEC 60947-1, 2 & 3.
IEC 60947-1: Low-voltage switchgear and control gear - Part 1: General rules

IEC 60947-2: Low-voltage switchgear and control gear - Part 2: Circuit-breakers.

IEC 60947-3: Low-voltage switchgear and control gear - Part 3: Switches, disconnectors, switch-
disconnectors and fuse-combination units

6.5 CONTACTORS (STAGE SWITCHING):

Electromagnetic contactors shall be provided for switching of stage capacitor. However, as per the
requirement of the system/ design, electronically controlled thyristorised contactor or thyristors may be
employed for very fast and transient free switching, that have a switching time of only a few milliseconds.

6.5.1 ELECTROMAGNETIC CONTACTOR:

The contactors shall be of type three poles, specially designed for switching capacitors and shall be able to
make against large transient current peaks at a high frequency of several kHz that can occur on capacitor
switching. The contactors shall isolate all the three supply phases to the capacitor on switch off. The
contactors shall have an electrical lifetime of 200,000 operations under capacitive switching conditions.
Contactors along with damping resistors (AC6b) shall be used where there is a possibility of high inrush peak
current to reduce it. The capacitor contactors shall be weld resistant up to a possible peak inrush current of
200 * IR.

In case capacitor banks are supplied with Harmonic Blocking Reactors, contactors for capacitor switching
shall be without damping resistors (AC3), because the peak current limitation is provided by Reactor
impedance.

The contactors shall conform to IEC 947-4-1/ IEC 947-5-1.They should have a current rating of not less than
1.3 times the rated three phase capacitor unit current. They shall be tested as per IEC 269 with a test
voltage 1.1x UN.

7 ENCLOSURE SYSTEM:

The enclosure system for capacitor bank shall be of certified design as per IEC 62208.

The enclosure system should have a minimum of IK 10 certification (external mechanical impacts) in
accordance with IEC 62262.

The enclosure system should have a certification for steady-state sinusoidal vibration in accordance with
standard IEC 60068-2-6.

Components such as capacitor units, series reactors, power factor controller, electro-magnetic / thyristor
switched contactors, switch-disconnector, MCCBs etc. shall be housed in this enclosure. The capacitor
bank shall be free-standing type and the doors must incorporate 3-point locking system.

The enclosure door shall be interlocked with the incomer MCCB / switch-disconnector. Doors shall not be
provided on the sides / rear of the capacitor bank.

NOTES: The enclosure systems shall be manufactured in full compliance with and tested to the
requirements of the following IEC Publications.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 79 OF 1216

 IEC 62208: Empty enclosures for low-voltage switchgear and control gear assemblies –
General requirements
IEC 60529: Degree of protection provided enclosures (IP code)

IEC 60068-2-11: Basic environmental testing procedures – Part 2-11: Tests – Test Ka: Salt mist

IEC 62262 Degrees of protection provided by enclosures for electrical equipment against
external mechanical impacts (IK code)

7.0 TESTING AND INSPECTION

7.1. ROUTINE TESTS:

All tests shall be carried out in the presence of engineer in charge, at such times as he may reasonably
require.
All samples used for testing shall be to the contractor’s expense and shall not affect the quantities to be
supplied under this contract.
All instrument used for testing purposes, shall be calibrated by an approved authority.
The cost of all tests shall be included in the contract price and shall not be quoted for separately.

a) Routine Tests on Capacitor Bank

All routine tests on the assembled Capacitor Bank shall be carried out in accordance with IEC 61921and
IEC 61439-1 as per the relevant clauses mentioned against each test.

Routine tests shall be carried out by the manufacturer on every Low voltage power factor correction banks
before delivery.
• Inspection of the assembly including inspection of wiring and, if necessary, an electrical operation test
• Dielectric test
• Checking of protective measures and of the electrical continuity of the protective circuit
• Verification of insulation resistance

b) Routine Tests on Capacitor Units

All routine tests shall be carried out in accordance with IEC 60831 as per the relevant clauses mentioned
against each test. Routine tests shall be carried out by the manufacturer on every capacitor unit before
delivery.
Capacitor Banks should accompany the test reports of the Capacitor Units used issued by the
manufacturer.

• Capacitance measurement and output calculation

• Measurement of the tangent of the loss angle (tan δ) of the capacitor
• Voltage test between terminals
• Voltage test between terminals and container
• Test of the internal discharge device
• Sealing test

7.2. TYPE TESTS:

Type tests certificates and reports shall be submitted from independent certification bodies and must include
the following:

a) Type Tests on Capacitor Bank

All type tests shall be carried out in accordance with the International Electro-technical Commission (IEC)
Publication No. IEC 61921 and IEC 61439-1 on complete Capacitor banks equipped with detuned reactors.
The following type tests shall include:

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 80 OF 1216

 • Verification of Temperature Rise limits at 130% of nominal current (with allowable temp rise values
considering 50degC as the base ambient temp)
• Verification of dielectric properties
• Verification of the short-circuit withstand strength
• Verification of the effectiveness of the protective circuit
• Verification of clearances and creepage distances
• Verification of mechanical operation
• Verification of the degree of protection

b) MCCB’s, Reactors, Current Transformers :

Complete type test certificates for all major components, like MCCB’s, Reactors, Current Transformers, etc.
shall be submitted as per the relevant IEC/BS standards along with the tender.

7.3. SITE TESTS:

The contractor is responsible for submitting all contract works to site inspection by the Engineer, before site
tests are commenced. Before commissioning, the contractor shall depute an experienced and qualified
testing Engineer from the manufacturer’s works to carry out the following tests on the equipment and such
other tests that may be considered necessary by the Purchaser.

The Site Acceptance Test (SAT) format for the capacitor bank shall be forwarded to the purchaser prior to
the SAT.

The contractor’s test engineer shall complete all pre-commissioning tests, commission all plant and
equipment supplied by him and hand over the entire contract works to the Purchaser in good shape. All the
charges connected with the pre-commissioning tests of the equipment shall be included in the tender price.

The contractor’s testing engineer shall carry out all commissioning tests in co-operation with and to the
satisfaction of the Purchaser’s engineer who will take part in all these tests.

The manufacturer shall provide all test equipment required for different test purposes at site. The following
test / inspections at site shall be carried out:

1. Mechanical Tests:

Visual inspection to verify degree of protection creepage and clearance distances. All conductors and cables
are checked for proper routing and all devices for proper mounting. Check effectiveness of all mechanical
devices, e.g. handles, locks, interlocks, operating devices, etc. Check panel conformity to drawing and
Engineer’s requirements.

(1) Checking of all mounting plates/fasteners.

(2) Checking of dimensions and components as per drawings.
(3) Electrical circuits fasteners tightness/ surface area contacts.
(4) Crimping and ferrules as per drawing.
(5) Labels / Identification/ Nameplate.
(6) All doors checking, safety and accessibility.
(7) APFC cabinet surface finish / smoothness.

2. Electrical Tests:

Insulation resistance test shall be carried out at all main circuits through to final terminals. Insulation
resistance shall exceed 10 mega ohms. Record all measurements. Function test of all circuit breakers
switches, contacts, etc. and every circuit to verify correct operation.

(1) Insulations resistance tests between phases and earth and between neutral and earth.
(2) Operational test on components.
(3) Switching ON / Off of capacitor bank on various KVAR requirement.
(4) Checking of Display parameters.
(5) Switching On / off logic verification.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 81 OF 1216

 (6) Data communication through Serial / optical port
(7) Verification of data/reports/functions in base computer software.

3. Final Inspection

Prior to energizing the capacitor bank the following checks shall be carried
Out at site:

• Operate the equipment through all design functions, including remote operation, actuation of alarm and
indicating devices, mechanical and electrical tripping and closing and operation of the protective devices.

• Insulation resistance measurements on the buses, phase to phase and phase to ground, with all breakers
in the fully connected position and contacts open.

• Control circuit insulation resistance to ground

• Inspect all relays and protective devices, and verify settings in accordance with the manufacturer’s
instructions. Inspect current transformers and relays for correct polarity of connections and the installation
of jumpers on unused current transformer circuits.

• Manually close and trip each breaker checking and adjusting the main contact alignment and wiring action
in accordance with the manufacturer’s instructions.

• Test protective relay operation for incomer air circuit breakers.

With the capacitor bank in operation, measurement of the power factor and system harmonics shall be
carried out after commissioning of equipment.

8.0 WARRANTY/DISCLAIMERS

The capacitor bank assemblies shall be warranted by the manufacturer to be free from defects for a period of
12 months from factory shipment.

9.0 DRAWINGS AND INFORMATION

The Manufacturer shall furnish the following drawings and documents placed inside the drawing pocket of
the equipment supplied.

• Dimensioned drawing showing outline of the capacitor bank

• Single line diagram showing all the major electrical components.
• Protection and control schematics of the capacitor bank
• Details of cable terminations and fittings.
• Technical Manual giving installation, operation and maintenance instructions

10.0 GROUNDING

All bank and enclosure shall be connected to a 25x5 mm earth copper bus bar.

11.0 HANDLING

A shock control shall be placed on the package of the capacitor bank. If the bank falls, this control will be
broken.
The equipment shall be provided with lifting rings, or provided with provision for using a forklift truck for
handling.
For installation, a 250 mm space shall be provided form the front of the bank, in order to have an optimal
position of the bank for good ventilation.

12.0 DOCUMENTS TO BE SUBMITTED BY MANUFACTURER FOR APPROVAL

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 82 OF 1216

A detailed technical submittal and shall obtain specific approvals for the capacitor banks. The technical
submittal shall include but not limited to the following.

The following are the minimum list of documents to be submitted :

1. Company profile
2. Industrial License
3. Certifications
4. Resources (HR, Manufacturing Facilities, Organization Chart, production asset details, testing facilities
etc.)
5. History of previous orders/executed project list and performance certificates
6. Audited Balance sheets for past three years
7. Enquiry, Product development, product delivery procedures
8. Purchase procedures for all components
9. Customer support procedures and Warranty
10. Quality Assurance Plan and Routine Test Plan
11. Testing Facilities and Calibration Certificates
12. Type test reports not exceeding five years
13. Component list including model number, type, ratings, and catalogue copies of each component
14. Standard General Arrangement drawings (Typical) of the capacitor bank
15. Compliance statement to the IEC Regulation and Specification.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 83 OF 1216

14.0 GENERAL PARTICULARS AND GUARANTEES

CAPACITOR BANKS

1) Manufacturer & Country of Manufacture.

2) Type and reference

3) Supply Voltage V

4) Highest System voltage V

5) Rated Frequency Hz

6) Rated Capacity of Complete Bank

7) Number and Capacity of each stage.

8) Connection configuration

9) Method of control

10) Electrical Clearances

a. Phase to phase

b. Phase to earth

CAPACITOR UNIT

1) Manufacturer/Country of Manufacture

2) Type reference

3) Standards Applicable

4) Rated Power kvar

5) Rated Voltage V

6) Rated Current A

7) Rated Frequency Hz

8) Rated Capacitance Μf

9) No.of Elements(Capacitors )

a) In Series

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 84 OF 1216

 b) In parallel

10)Continuous Over voltage withstand capability %

11) Maximum permissible Overload current %

12) Capacitor loss at rated Voltage W

13) Type of active element

14) Built in Discharge device resistance

15) Discharging time to achieve 50V

16) Service indoor/outdoor

POWER FACTOR CONTROLLER

1) Manufacturer/Country of Manufacture

2) Type

3) Rated Current

4) Supply Voltage

5) Measuring Accuracy

6) Regulation steps

7) Setting range

8) Over compensation monitoring Yes/No

9) Manual Mode Yes/No

10)Degree of Protection

11)Communications

12)Operating conditions Temp , Humidity

DE TUNING REACTORS

1)Tuning frequency

2)Detuning Factor

3)Inductance

4)Nominal Voltage

5)Insulation Temperature class

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 85 OF 1216

 ENCLOSURE

1) Type

2) Degree of Protection

3) Sheet Thickness

4) Painting thickness

5) Mechanical Protection

6) Compartments

7) Cooling arrangements and louvers

8) Dimensional details

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 86 OF 1216

 JOB SPECIFICATION FOR
AUTOMATIC TRANSFER SWITCH

(B047-003-16-50-SP-1005, Rev. A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 87 OF 1216

PART 1 – GENERAL
1.1 STANDARDS
A. The ATSE must comply with IEC 60947-6-1: (Low-voltage switchgear and control gear - Multiple
function equipment – Transfer switching equipment) and with IEC 60947-3: (Low-voltage
Switchgear and control gear – Switches, disconnectors IEC60947-1 for reference.

B. The product shall be tested in an accredited laboratory.

PART 2 – PRODUCTS
1.2 GENERAL CONSTRUCTION
A. The ATSE shall be composed of :
1. An open transition break before make architecture (I – 0 – II), with two back to back, fully
rated, IEC 60947-3 compliant, load break switch disconnects, with clear switch position
indication (I – 0 – II), on the motorisation module, Visible from Front
2. A maintenance free switch design that includes self-cleaning contacts on all poles, with
fully integrated robust mechanical interlock between both switches.
3. An independent switching mechanism free from external factors during transfer
4. Mounting lugs fit onto the switches (power section) independent of the motorisation.
5. A wide band (control voltage of 50Hz, 166-332Vac) motorisation module fit directly to the
switching mechanism.
6. An integrated ATS controller with dual power supply (DPS) and 3 phase sensing on both
source supplies. (Monitoring device and control module).
7. An easy to remove motorisation & control module. (With no disturbance to the load). It
shall be possible to remove the ATSE motor even while the ATSE is in operation on
loaded condition
8. Dual emergency manual operation, with the Manual handle possible to mount directly on
the ATSE body. It shall be possible to operate the ATSE in fully loaded condition, in the
Manual mode
9. Padlocking in the zero position with the use of up to 3 numbers of min. 8mm padlocks.
(LOTO Complied)
B. The ATSE shall be fully integrated in one device:
Besides customer I/O, no additional wiring between functional units other than the power
connections and voltage sensing shall be allowed the proper functioning of the ATSE. The
fully integrated Controller design will not have any External wiring connection or Wiring harness
between the ATSE and the Controller
C. The ATSE should include dual “Product Available Outputs” (one on the motorisation and one on
the ATS controls). The product should analyse / test its condition periodically and communicate
through dry contacts to report the ability of the transfer switching equipment to operate.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 88 OF 1216

1.3 DESIGN REQUIREMENTS:
A. The ATSE shall be electrically operated and fully automatic with the possibility to override the
automation and operate remotely via dry contact inputs for position orders
B. For ease of Termination and Ergonomic placement, Complete Line Load side reversibility shall be
possible on the ATSE
C. 100% Rated Neutral
D. Dual emergency manual operation shall be provided using an insulated handle directly through the
motorisation and on the switch mechanism with the motorisation removed.
E. The ATSE shall have a distinct manual / automatic mode selectable by turning a rotary switch or a
removable key switch located on the motorisation module. The Auto/Manual selector switch shall be
mounted on the ATS body
F. The neutral pole of the ATSE switches shall be fully rated and left or right configuration
G. The ATSE shall have no power consumption while in a stable position other than that required for the
ATS control unit.
H. ATSE motor operation band shall be a wide band with, operational range 166-332Vac
I. There shall be a fully isolated ZERO position
J. Settings of various parameters shall be possible via Keypad on the product and also through
Communication

1.4 SAFETY REQUIREMENTS & FEATURES:

A. All operating modes shall be inhibited when the product is padlocked.

B. Padlocking shall only be possible with the mode selector switch in manual position.
C. The ATSE should allow manual switching I-0-II at full load without damage to the contacts.
D. There shall be an integrated Watchdog relay to confirm product availability status
E. Min. 3 numbers Potential free contacts shall be available.

1.5 BASIC OPERATION:

A. The aux power of the ATSE shall be supplied by any one of the available supplies through a built-in dual
power supply (DPS).
B. An automatic retransfer function should be included with the facility to inhibit retransfer locally or
remotely through dry contacts.
C. The ATSE shall have the facility to inhibit the ATS controller and electrically change the switch state to
any position (I – 0 – II) through dedicated inputs and dry contacts.
D. The ATSE shall include a priority input to force the switch to the 0 position and inhibit the automation of
the ATS controller.

1.6 ATS CONTROLS

A. The ATSE shall have a fully integrated ATS Controller fixed directly on the motorisation.
B. The controller shall include an LCD display, LED’s and a keypad with front access.
C. Electrical motorised control (position I, O, II) should be available locally through the keypad, remotely
through dry contacts and optionally through communication.
D. Main Parameters:
1. The ATS controller shall include 3 phase and neutral sensing for the monitoring of voltage and
frequency on both source supplies.
2. Voltage settings shall be field adjustable in increments of 1%.
3. Frequency settings shall be field adjustable in 0.1% increments.
4. Setting configuration shall be adjustable through software as well as from the keypad

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 89 OF 1216

 5. The ATS Controller shall have phase sequence detection and allow the user to choose the
desired sequence (ACB or ABC).
6. Changeover shall be forbidden if the supply phase sequences are different.
7. The ATS Controller is to include an Auto-Configuration function for configuration of the source
supply voltage, frequency, phase rotation and neutral position.
8. The ATS Controller shall have the possibility to select the network type.
9. The ATS Controller shall allow the setting of the source priority.
10. The ATS controller shall be able to measure phase unbalance.
11. The ATS is to include 3 phase current transformer inputs for measurement of voltage,
currents, frequency, PF, power (apparent, positive & negative active and reactive energy).
These inputs are to allow for 5A /1A CT configurable in ATS Controller settings)
12.The ATS shall have provision to swap the power cables (SWI/SWII → SI or SII) so as to facilitate
for source power cable inversion in the panel. (Software configuration)
1.7 ATSE INTERFACE:
A. The ATS Controller is to be easily configurable via an HMI keypad directly on the controller, a remote
control and display unit and via dedicated ATSE software.
B. Status of the ATSE shall be clearly visible through LED’s on the front of the unit.

1.8 REAL TIME CLOCK / EVENTS

A. The ATSE shall have a built-in real time clock (RTC) with battery backup for event recording with
the possibility to save up to 3000 events (date and time stamped) in non-volatile memory. Events are
to be exportable and accessible through the software and Webserver.
1.9 COMMUNICATION
A. The ATSE is to include the possibility to plug in an optional communication modules with RS 485 or
Ethernet
1.10 TIMER SETTINGS:
A. Two adjustable timers of 0 to 60 seconds shall be provided to detect source 1 or source 2
failures, and to override any transient outages of the normal supply. (Source 1 Failure Timer, 1FT and
Source 2 Failure Timer, 2FT).
B. A timer of 0 to 60 seconds shall be provided for source 2 available so as to ensure stability of the
alternative network before transfer. (Source 2 Available Timer, 2AT).
C. A possibility to stay in switch position I or II shall be provided with an adjustment of 0 to 10 seconds
prior to return to the 0 position. (0 Timer, 1OT, 2OT). Only to be accessible with parameter RETURN to
0 activated.
D. An adjustable timer of 0 to 60 minutes shall be provided to detect priority network return to normal so
as to override any incorrect availability of the normal supply. (Main Return Timer, 1RT, 2RT).
E. Zero position timer, settable up to 20second
PART 3 – EXECUTION
3.1 TESTING
A. The ATSE shall be declared compliant to the IEC standards listed above by a testing laboratory having
delegation or working under contract for certification to UL and IEC standards under the IEC Electro-
technical Equipment (IECEE) certification body scheme.
B. After installation of the equipment, a test report is to be submitted to state that the equipment has
been installed and commissioned in accordance with the manufacturer’s instructions.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 90 OF 1216

 INSTRUCTIONS TO BIDDER
FOR
HV SWITCHBOARD

(B047-003-16-50-TR-0001, REV A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 91 OF 1216

1.0 SPECIAL INSTRUCTIONS TO BIDDERS

1.1. Bidder to ensure that the offered switchboards are type tested. The validity requirements for the
type test certificates for HV switchboards/ breakers etc. shall be as per the table given below:

Sr. Type Test Equipment Validity

No.

1 Short Circuit Switchboard Upto 5 years from the final bid opening
Withstand Capacity Panel date or design change whichever is earlier

2 Internal Arc Fault Switchboard Till any design change

Panel
3 Duty Cycle Circuit Till any design change
Breaker
4 Short Circuit 11kV Bus duct Upto 5 years from the final bid opening
Withstand Capacity date or design change whichever is earlier
5 Heat Run 11kV Bus duct Upto 5 years from the final bid opening
date or design change whichever is earlier

In case the type tests on the offered design of switchboards, circuit breaker and busduct do not
meet the above criteria, all required type tests shall be conducted by the successful bidder on the
offered design of equipments after order finalization without any extra cost and delivery impact.

1.2. Following in a tabular form for HV switchboard and VCB shall be furnished post order during
drawing review stage :

Continuous current rating, Short time rating, Model, type of switchgear, Model and type of circuit
breaker & Vacuum interrupter and busduct, Type test reference number and date of test for heat
run, short circuit, internal arc, impulse and power frequency withstand and for breaker short circuit
duty tests, busbar sizes offered, busbar sizes as per type tested design etc.

1.3. Contractor shall supply the HV switchboard as per tender requirements suitable for the site
conditions of LEH and shall submit the required de-rating calculations of the equipments.

2.0 TRAINING OF HV SWITCHBOARD, NUMERICAL RELAYS

Providing Training to Owner’s Engineers is included in Bidder’s scope as per the following:

a) Training to be conducted for 5 nos. Owner's Engineers/ Staff at site for Numerical Relays, etc.
Bidder shall be required to depute his representative for 5 number of days.

3.0 TESTING & COMMISSIONING OF RELAYS

All associated equipments required for testing & commissioning of numerical relays including
supply, installation and testing of application software to be installed in laptop for numerical relays
and other substation equipment integration are included in the bidder’s scope.

4.0 EARTHING TRUCK

Separate earthing carriage/ trucks shall be provided / supplied for cable side earthing and/or bus
side earthing of the HV switchboard.
For Cable side earthing required no. of earthing trucks shall be provided for 630A VCB outgoing
feeder panel in HV switchboard (with min. 1 no. earthing truck).

5.0 LIFTING TRUCK

2 Nos. of lifting truck and accessories shall be provided for HV switchboard for withdrawal of
cassette mounted type circuit breaker from the switchboard panel.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 92 OF 1216

6.0 SUBSTATION AUTOMATION SYSTEM

6.1 Substation Automation System for switchgears shall be provided. It shall include interconnecting
cables, Ethernet switches, etc. and software to be installed for interfacing with Numerical relays
over IEC-61850. The Numerical relays shall be provided with suitable hardware, software and
communication ports for communication with BMS.

However bidder’s scope shall include Ethernet switch for the HV switchboard and required laptop
complete with software.

Single laptop is envisaged for all the HV & MV switchboards. The licensed software/ keys
required for the HV & MV switchboard shall be supplied by the respective switchboard vendor.
However, the software required for the MV switchboards shall be installed by MV switchboard
vendor in the laptop supplied by HV switchboard vendor. Further, one set of original software in
CDs/ DVDs/ removable media shall be also provided by each switchboard vendor which shall be
handed over to client after commissioning.
Configuration of the laptop shall min. be as follows:
Laptop with Windows-10 or latest version and other required licensed softwares, hardwares,
accessories (data cables, VGA Cables, USB Cables etc.) and materials shall be supplied. The
communication port on laptop shall match as that provided on the front of numerical relay. System
configuration shall be latest proven model and upgradable. The minimum configuration for this
project shall be Intel i7 processor, 1TB HDD, 4 GB RAM, DVD R/W Multi Drive, 15” colour LED
screen or latest available, 4 nos. USB Ports (min.), Ethernet Port, RS-232 Serial Ports etc.

6.2 Supply, laying and termination of all interconnecting cables from HV switch boards to relay,
Ethernet switches including cable termination kits and accessories in substation is in bidder’s
scope. The scope shall be considered inclusive in tender.

7.0 JOB SPECIFIC REQUIREMENTS

In addition to the requirement of the enclosed standard specifications, HV switchboards shall also
comply with the following. In case of conflict among data sheet, standard specifications and the
job specification, the most stringent requirements shall govern.
7.1 HT switchboard shall be with single tier circuit breaker arrangement.

7.2 Selection, sizing and suitability of all components shall be the bidder’s responsibility. The
equipment as required for safe and satisfactory operation shall be considered included in bidder’s
scope even if not specifically mentioned in the tender.

7.3 The bidder shall be solely responsible to coordinate the relay characteristics with relay supplier for
the proper selection of all CTs with special care to select class PS CTs.

7.4 Hardware data sheet for feeders include only the major relays, meters and controls switches. Any
auxiliary relays, timers, switches, etc., as required, while developing the control schematics and
for safe operation, even if these are not specifically included, shall be supplied by the bidder
without any cost and time implication to Owner.

7.5 CT ratios of outgoing feeders are tentative. CT ratio shall be finalized during drawing review.
Bidder shall not raise any claim for additional price and time for these changes being done during
drawing review. The VA burden, knee-point voltage, CT resistance and magnetizing current shall
be calculated by the bidder for Owner’s review before proceeding with manufacturing.

7.6 All relays, metering and control components shall be mounted on the panel front only such that
they are easily readable to the person standing in front of the panel. The relays shall be mounted
at eye level.

7.7 The size of bus-bar from horizontal bus to breaker and breaker to outgoing shall be designed
based on breaker rating and not on CT/feeder rating.

7.8 Breaker rating as defined in the tender shall be in-panel rating.

7.9 Following type test certificates shall be furnished by the bidder:

i. Short time rating (short circuit withstand ability).

0
ii. Temperature rise test with values extrapolated for 40 C design ambient.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 93 OF 1216

 iii. Internal arc test for busbar, cable and breaker compartment.
iv. Breaker duty cycle test for breaker.
v. Dielectric Test
vi. Short circuit withstand capability for HV busduct
vii. Heat run test for HV busduct.

7.10 Following potential free annunciations shall be taken to Building Management System (BMS)
through Ethernet switch:

Incomer
• Breaker ON (in Service)
• Breaker OFF (in Service)
• Tripped on fault
• Under-voltage trip
• Trip circuit unhealthy
• Directional Protection Relay Operated

Transformer feeder
• Breaker ON (in Service)
• Breaker OFF (in Service)
• Tripped on fault
• Trip circuit unhealthy
• Transformer trouble summary contact
• Back-up Earth Fault Relay Operated
• REF Protection Relay Operated

Line PT / Bus PT
• PT Secondary MCB off
• U/V MCB Tripping

7.11 All outgoing transformer feeder trouble contacts (12 nos.) both for alarm/trip shall be wired to the
numerical relay as per hardware data sheet. The provision for wiring these contacts shall be
available in relay.

7.12 All the spare contacts of relays shall be wired up to terminal block in the panel.

7.13 Spare terminals in the terminal block shall be 20% for each panel.

7.14 Breaker control switch shall be hardwired type.

7.15 Terminal connectors of all CTs, PTs and other control terminals shall be screwed type only.

7.16 All HV switchboards shall have provision for positive LOTO implementation.

7.17 NUMERICAL RELAYS, OTHER RELAYS AND METERING

a) All numerical relays shall be communicable type of latest advanced version and shall comply
with enclosed standard specification B047-003-SP-6-51-0055 for numerical relays. All
numerical relays shall be comprehensive units including all protection and metering
functions. Controls and logic shall be through numerical relays i.e. all logics shall be built
inside numerical relay and not externally. Provision of adequate I/O count in the relays shall
be ensured. The communication protocol for relay network shall be IEC 61850.

b) All numerical relays for switchboard shall be of same make.

c) Under voltage and Overvoltage relay along with associated timers shall be part of the
numerical relay.

d) Master trip relay (86) shall be part of Numerical relay. LED and Binary output shall be
latched and shall reset manually.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 94 OF 1216

 e) Minimum 4 nos. spare binary inputs and 2 nos. spare binary outputs shall be provided in
each numerical relay.

f) The requirement of numerical relays and integration shall be in compliance with the
requirement given in attached data sheet, design basis, system architecture and
specification.

g) Even though data sheets define the requirement in terms of discreet relays
(electromechanical type) but numerical relay comprising the all required functions shall be
provided.

h) Separate terminal block in incomer feeder shall be provided for further wiring to upstream
breaker for tripping / interlock by owner.

n) Sizing calculation of surge arrestors in outgoing feeders shall be furnished during drawing
review stage.

o) Electrical interlock (in terms of buzzer/ alarm) shall be provided for rear door of HV
Switchboard. Further, a mechanical interlock such as a trapped key interlock mechanism that
does not permit opening of back cover if breaker is in service position shall be provided for
the HV switchboard.

p) Bidder shall indicate shipping section details such as dimensions, weight etc. on GA drawing
during drawing review stage.
th
q) 4-Pole MCB shall be considered in all the PT panels. 4 pole contact of the MCB shall be
used for blocking under voltage protection function.
r) Spring charging motors shall be suitable for 110V DC supply.
s) Emergency stop push button (with min. 2 NO & 2 NC contacts) of RED colour shall be
provided on each outgoing feeder panel. The STOP push button shall be mushroom type with
stay put feature and lockable in pressed position. Push button shall be provided with
protective hood to secure from accidental operation.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 95 OF 1216

 INSTRUCTIONS TO BIDDER
FOR
DISTRIBUTION TRANSFORMERS

(B047-003-16-50-TR-0002, Rev. A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 96 OF 1216

1.0 SPECIAL INSTRUCTIONS TO BIDDERS
1.1 Bidder to note that the equipment shall comply with the requirements of latest revision of codes &
standards referred with the tender document. In case of any conflict between the various documents,
the most stringent one shall be followed and Owners decision in this regard shall be final and binding.
1.2 Bidder shall include supply of one set of special tools and tackles as required for maintenance of
transformers.
1.3 Bidder’s scope shall include conducting the following test:
• Heat run test on one of the distribution transformers of each rating.
• As per Clause 12.3.2 and 12.3.3 of standard specification no. B047-003-SP-6-51-0041, vacuum
test & pressure test shall be conducted at vendor’s works on one transformer tank of each size.
1.4 Bidder to ensure that valid type test certificates for offered design of transformer are available for heat
run test, short circuit test and impulse test. The same shall also be furnished for Owner’s records
during detail engineering.
1.5 Fire Fighting System for the subject rating of transformers is not envisaged. Bidder to ensure that total
oil quantity of each transformer shall not exceed 2000 litres to meet requirements of CEA regulations
2010. If in any case the oil exceeds 2000 litres in quantity due to technical feasibility/ de-rating
mentioned in point no. 1.7 below, bidder shall note that scope of fire-fighting system shall be in the
bidder without any cost & time implication to owner. Bidder shall quote accordingly.
1.6 Overall dimension of distribution transformers shall be limited in accordance with sketch 7-51-0337
attached.
1.7 Bidder shall supply the Distribution transformer suitable for the site conditions of LEH and the required
de-rating calculations for the equipments shall be submitted by the bidder. Rating of the transformer
mentioned in the SOR (i.e. 2000 kVA) shall be the net output from transformer and necessary de-
rating due to altitude and temperature/ site conditions of Leh shall be done by the bidder at their end. It
shall be ensured by the bidder that the downstream panel’s fault level shall not be exceeded.

2.0 SPECIFIC REQUIREMENTS

2.1 Distribution transformer shall comply to latest IS-1180 (Part-1): 2014 and Gazette of India Order dtd.
16-Dec-2016 & 17-Feb-2017. Accordingly, efficiency of transformer at 50% and 100% load shall be
considered with total losses at 50% and 100% loading not exceeding maximum losses values
specified in Table-6 of IS-1180 (Part-1) for Energy Efficiency Level-2/ Star-1 as per Gazette of India.

2.2 The Transformer shall bear Standard Mark of the Bureau of Indian Standards in line with Gazette of
India Order dtd. 16-Dec-2016 & 17-Feb-2017. Copy of License obtained from Bureau of Indian
Standards shall be furnished in compliance to IS-1180 (Part-1).

2.3 Pressure test and vacuum test shall be conducted at vendor’s works on one transformer tank of each
size. In case of discrepancy, more stringent requirement of Specification No. B047-003-SP-6-51-0041
and IS-1180 (Part-1): 2014 shall be followed.

2.4 All contacts including ‘spare contacts’ and ‘contacts for Owner’s interface’ shall be duly wired &
terminated upto the terminal block.

2.5 Values of alarm and trip settings of OTI and WTI shall be indicated in the drawing post-order.

2.6 All cables and wires in bidder’s scope shall be with Copper conductor, XLPE insulated, outer sheath
FRLS type.

2.7 Makes of components/ devices shall be exactly as specified in the owner approved vendor list.

2.8 Refer cl. no. 2.1 of specification B047-003-SP-6-51-0041 and note that following IS is added to the
specification IS: 1180 (Part-1): 2014.

2.9 Temperature rise for winding and oil shall be as per Gazette of India Order dated 16-Dec-2016.

2.10 Transformer oil shall be as per IEC-216 (i.e. suitable for the site conditions of leh). Oil shall not freeze
during winter season at – 22 degree Celsius).

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 97 OF 1216

 INSTRUCTIONS TO BIDDER
FOR
MV SWITCHBOARDS, MV BUS DUCTS AND
NUMERICAL RELAYS

(B047-003-16-50-TR-0003, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 98 OF 1216

1.0 SPECIAL INSTRUCTIONS TO BIDDER

1.1 It shall be contractually binding on vendor to supply equipment conforming strictly to

tender requirements unless any unavoidable deviation is specifically highlighted.

1.2 In addition to the requirement of the enclosed standard specifications, MV Switchboard

shall also comply with relevant tender document. In case of conflict among data sheet,
standard specifications and the instruction to Vendor, the most stringent requirements
shall be followed.

1.3 Selection, sizing and suitability of all components shall be the bidder’s responsibility.
Bidder shall supply the equipments suitable for site conditions of LEH and shall submit
the necessary de-rating calculations for the equipments.
The equipment as required for safe and satisfactory operation shall be considered
included in bidder’s scope, even if not specifically mentioned in the tender.

1.4 Bidder’s scope includes testing and commissioning of numerical relays and Ethernet
switches for offered switchboards. Bidder to note that all commissioning spares required
for these items shall be provided by the Bidder.

1.5 One set of recommended tools, tackles and special equipment required for the
maintenance of the panels, breakers, relays, Busduct, etc. shall be supplied with the
equipment.

1.6 Numerical relays and multi function meters shall be connected to Ethernet switches.
Hence Ethernet switches shall have required port for incoming and outgoing data.

1.7 Makes of components/ devices are exactly as specified in Vendor list attached with the
tender.

1.8 All the offered switchboards and bus ducts are type tested. Copies of valid type test
certificates for the following tests conducted on identical design of offered equipments
required as per data sheets shall be furnished.
a) Short time current withstand test (for panel, breaker & bus duct).
b) Heat run test (for panel, breaker & bus duct).
c) Short circuit duty test (for breaker).

2 MV BUS DUCT

2.1 Lengths of bus ducts indicated in tender are tentative. Final payment shall be made on
the actual length of the bus ducts supplied at site and measured along the center-line of
the bus ducts in accordance with approved drawings.

2.2 Length of bus duct as mentioned in tender shall be inclusive of straight length, horizontal
and vertical bends, copper flexible, phase crossover, if any and no separate payment for
these items i.e. bends,/flexible/phase crossover, etc. will be made separately.

2.3 The length of the transformer end termination and switchboard end termination
chambers shall not be considered for measurement of the straight length of the bus
ducts.

4.0 TRAINING OF 415V SWITCHBOARDS, NUMERICAL RELAYS & SUBSTATION

AUTOMATION SYSTEM

Providing Training to Owner’s Engineers is included in Bidder’s scope as per the

following:

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 99 OF 1216

 a) Training to be conducted for 5 nos. Owner's Engineers at site for Numerical Relays,
etc. Bidder shall be required to depute his representative for 5 days as per site
requirement.

5.0 SUBSTATION AUTOMATION SYSTEM

5.1 Substation Automation System for switchgears shall be provided. It shall include
Ethernet switches in HV & MV switchboards and software to be installed for interfacing
with Numerical relays over IEC-61850. The Numerical relays shall be provided with
suitable hardware, software and communication ports for communication with minimum
two different client sources simultaneously.

5.2 Ethernet switch shall have provision of integration with Building Management System
(BMS).

5.3 Supply, laying and termination of all interconnecting cables from 415V switch boards to
Ethernet switches including cable termination kits and accessories is in bidder’s scope.

Refer Cl. No. 6 of doc. No. B047-003-16-50-TR-0001 for scope of software

requirements in laptop supplied with HV switchboard.

6.0 SPECIFIC REQUIREMENTS

In addition to the requirements of the enclosed standard specifications, MV switchboards

shall also comply with the following. In case of conflict among various standards and
specifications, the most stringent shall follow and owner’s decision in this regard shall be
final and binding.

6.1. Selection, sizing and suitability of all components shall be the bidder’s responsibility and
all equipment required for safe and satisfactory operation shall be included by the bidder
in his scope even if not specifically mentioned.

6.2. The bidder shall be solely responsible for coordinating the relay characteristics with
suppliers for the proper selection of all CTs.

6.3. Refer enclosed hardware datasheets for details of relay, metering and control facilities
to be provided for each feeder. However, note that only major relays, meters and
controls are indicated in the hardware data sheets. Any auxiliary relays, timers,
switches, etc, as required while developing the control schematic and felt necessary for
safe operation, even if these are not specifically included, shall be supplied by the
bidder without any cost and time implication to the Purchaser.

6.4. The motor data and characteristics for all motors shall be furnished to the bidder at the
time of drawing review. The motor protection relay characteristics and the
recommended settings for each motor feeder / other feeders shall be decided by the
bidder based on the motor characteristic / data supplied by the Owner.

6.5. The general arrangement of the panels having circuit breakers with incoming bus duct
connection ( in PCC-301) shall be such that, as far as possible, the center line distance
between incomers shall be provided approximately at 6000mm, so as to permit bus duct
connections preferably in a straight line without any horizontal bends. However the
exact orientation and bus duct routing viz-a-viz location of Incomer Panels shall be
decided during detail engineering based on panel layout of vendor and substation
building civil drawings made available to vendor. Dummy panels, if required shall be
provided.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 100 OF 1216

6.6. Proper alignment and co-ordination regarding phase sequence etc., between bus duct,
transformer and switchgear termination shall be the responsibility of the bidder.

6.7. Bus duct layout drawings shall be prepared by the bidder based on substation
equipment layout and Structural and Architectural drawings of substation and
transformer drawings which shall be made available to the Switchboard Vendor at the
time of detail engineering.

6.8. All outgoing ACBs (up to 1600A rating) shall be provided in double tier configuration in
PCC & MCC switchboards. Outgoing ACB feeders (up to 1600A rating) in Single Tier
configuration are not acceptable.

6.9. All the outgoing ACBs shall be provided with microprocessor based protection releases.

6.10. Incomer MCCBs (of all rating) & outgoing MCCBs (above 250A) for 415V Switchboards/
panels shall be provided with microprocessor based protection releases.

6.11. No separate AC control supply has been envisaged in the 415V MV switchboard for the
operation of contactors. Bidder shall ensure that the power for contactor operation shall
be tapped from the panel through control transformer.

6.12. Breaker rating as specified in the data sheet is ‘in-panel’ rating. Bidder to select higher
rating of breaker, if any derating factor is applicable for the selected breaker rating (in
air) for ‘in-panel’ rating.

6.13. The ratings of MCCB, contactor and bimetal relay range for outgoing feeders indicated
in the switchboard component data sheet are tentative only. The final range shall
depend on motor rating and make of component selected. The bidder shall furnish and
ensure Type‘2' co-ordination as per applicable codes and standards for the fuse,
BMR/MPR and contactor combination finally selected.

6.14. Outgoing feeder for APFC panel shall be provided with APFC protection relay. Wiring
for the same shall be done such that upstream transformer losses are also covered for
power factor correction.

6.15. MPR (Motor Protection Relay) used in circuit with 240V control voltage shall be
energized by DC supply.

6.16. All Motor Protection relay shall be programmable.

6.17. Bidder shall note that sizing of the switchboards shall be based on FVNR designations
as per MV switchboard component datasheet.

6.18. Bidder shall provide the CT and PT of adequate rating and burden. CT/PT application
check and sizing calculations shall be furnished during detail engineering. Any increase
in the VA burden shall be incorporated without any cost and time implication to Owner.

6.19. Bidder shall provide suitable terminals in the respective panel for interfacing incoming
contacts from Process/ Instruments/ Electrical from Field/Control room. Rating of
potential free contacts from MV switchboard to BMS shall be suitable for 240V, 5A AC
for MCC with contactor feeder & 110V, 2A DC for ACB feeders. Bidder to ensure the
adequacy of contact rating and if required shall provide auxiliary relays to meet the
making and breaking current requirements.

6.20. Metering and protection CT’s wherever shown separately for feeders having numerical
relays in switchboard hardware datasheets can be combined into one set of CT’s
ensuring that the same shall be suitable for combined purpose i.e. metering and
protection applications, meeting the accuracy class defined. However CT’s required for
remote metering (wherever applicable/specified in datasheets) shall be provided
separately.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 101 OF 1216

6.21. CT for Field Ammeters shall be provided for motors with rating 5.5 kW & above.

6.22. LOTO Arrangement

6.22.1 Pad locking arrangement shall be provided for rack in operation of breaker as well as for
the panel door meeting LOTO (Lock-Out Tag-Out) requirements.

6.22.2 LOTO arrangement shall be provided for each module of PCC/MCC/PDB/ASB and shall
include provision for the following:

a) Provision for hooking lockout devices by multiple lock arrangement to prevent opening
of panel door and racking-in of circuit breaker.

b) Provision for attaching tag-out device for warning against energisation and to provide
information regarding date of isolation, agency working on the equipment, etc

6.23. As a minimum, bidder shall provide the following potential free normally open contacts
for remote annunciation:

Incomer
* Breaker On/Off status
* Tripped on fault
* Under-voltage trip
* Trip circuit unhealthy
* DC Control supply failure

Bus coupler
* Breaker On/off status
* Tripped on fault
* Trip circuit unhealthy
* I/M switch in Manual Mode
* I/M switch in independent Mode
* Manual transfer completed
* Manual Transfer Blocked
* Supplies Paralleled

Motor feeder
* Tripped on fault
* Overload alarm

Line PT
* PT Secondary MCB off
* MCB U/V Tripping

Bus PT
* PT Secondary MCB off
* MCB U/V Tripping
* DC Control Supply failure

Outgoing breaker feeders for each bus section

* Tripped on fault

All these annunciation contacts from various feeders of a bus section shall be wired to
respective incomer or bus PT panel for remote wiring by purchaser for annunciation.

Required hardware and provision for interface for control, monitoring and status shall be
provided in the switchgear.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 102 OF 1216

 In addition to above, a common summary contact shall also be provided in each PCC for
remote annunciation to report any fault / abnormality.

6.24. Bidder shall provide adequate terminals / contacts, as required, for the following as
minimum, for each motor feeder and the same shall be duly wired to dedicated terminal
blocks in respective module/ feeder:

- Contactor ‘ON’ (Motor running) status (2 nos. for each motor feeder)
- Contactor ‘OFF’ (Motor stopped) status (2 nos. for each motor feeder)
- Process/PLC start command (Auto)
- Local/Field start command (Manual)
- Local/Field stop command (Manual)
- Process/PLC stop command
- Process/PLC trip indication
- Ready to start status/ feedback
- Status of A/M switch status in Local Control Station (in Auto)
- Status of A/M switch status in Local Control Station (in Manual)
- Trip alarm

However, for the motor feeders, final interface requirements of BMS shall be defined
during detail engineering and the same shall be suitably incorporated in the control logic
by the bidder without any cost and time implication to the owner.

Marshalling panel (minimum half height) of Double Front type shall be provided in each
bus section of MCCs. All control cables from individual motor modules for BMS / Control
room interface shall be brought to respective marshalling panel for onward wiring to BMS
/ Control room interface by owner.

6.25. The switches shall have a auxiliary pre-break contact to cut-off corresponding outgoing
contactor control circuit, prior to opening of the switch. Alternatively the switches shall
have 1NO + 1NC auxiliary contacts which shall be wired in the control circuitry.

6.26. Control transformer (415V/240V) shall be provided for each bus section.

6.27. A light source shall be provided inside each panel for maintenance work. The light
source shall be supplied from 240V space heater / auxiliary circuit bus of respective
switchboard.

6.28. CT ratios of outgoing feeders are tentative. CT ratio shall be finalized during drawing
review. Bidder shall not raise any claim for additional price and time for these changes
being done during review. The VA burden, knee-point voltage, CT resistance and
magnetizing current shall be calculated and submitted for Owner’s review before
proceeding with manufacturing.

6.29. All relay settings & relay parameterization for all numerical relays shall be undertaken by
the bidder. Bidder shall furnish the relay setting chart and relay coordination curves.
Motor data sheet and thermal characteristic curves shall be furnished to successful
bidder during detail engineering after placement of order.

6.30. All relays, metering and control components shall be mounted on the panel front only.

6.31. All CT’s shall be star-connected.

6.32. Nameplate details for outgoing feeders of MV switchboards shall have information such
as equipment description, tag number, kW rating as minimum.

6.33. Load details, cable sizes, feeder nos., name plate details etc. for all outgoing feeders of
MV switchboards shall be finalized at the time of review of equipment vendor drawings
and shall be taken care by the bidder without any impact on cost and time to Owner.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 103 OF 1216

6.34. Bill of material and rating of components of various feeders and list of feeders of each
switchboard submitted along with the offer shall be considered as reference documents
only. However, inclusion of all components /their rating for each type of feeder as per
requirement of data sheets/specifications and no. of all feeders of types as specified in
switchboard data sheet shall be bidder’s responsibility and shall be in bidder’s scope.

6.35. PCC shall be provided with three incomers and two bus coupler. The incomers and bus-
coupler shall be provided with ACB with auto/manual changeover facility between the
incomers and bus-coupler, to ensure that in normal operating conditions only two out of
three breakers are in operation. Auto/Manual Changeover scheme for switchboard with
three incomers and two bus-coupler breakers shall comply with the logic described
briefly in CL. No. 6.45. Safety interlocks as deemed necessary shall however be
considered during detailed engineering

6.36. ASB shall be provided with two incomers and one bus coupler. The incomers and bus-
coupler shall be provided with ACB with auto/manual changeover facility between the
incomers and bus-coupler, to ensure that in normal operating conditions only one out of
two breakers is in operation. Auto/Manual Changeover scheme for switchboard with two
incomers and one bus-coupler breakers shall comply with the logic described briefly in
CL. No. 6.44. Safety interlocks as deemed necessary shall however be considered
during detailed engineering

6.37. For draw-out TPN modules, isolable neutral must be provided with the switch or
provision for neutral isolation must be made.

6.38. Telescopic rails for module rack in and rack out should be fitted with nuts & bolts. Rails
should have ball bearing for smooth operations.

6.39. Bidder to note that breaker current rating is for design ambient temperature of 40oC and
for inside the panel at fully loaded condition. Bidder may select higher rating of breaker
if there is derating factor for ‘in-panel’ rating. Also, bidder shall ensure that the panel is
suitable for continuous operation at a minimum ambient temperature of -5 oC.

6.40. Gaskets/metal strips shall be supplied along with MV switchboards to seal inter-panel
air gaps between various panels of respective switchboards.

6.41. Bidder shall provide sufficient quantity of blanking plates for breaker/FVNR feeder
module for each switchboard to cover the openings left in event of withdrawal of
FVNR/breaker feeder modules.

6.42. Clearance between gland plate to cable termination point shall be minimum 300 mm in
all the switchboards.

6.43. NIL

6.44 Changeover scheme for switchboard with two incomers & one bus coupler.

Auto/ Manual Changeover scheme for switchboard with two incomers and one
bus-coupler

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 104 OF 1216

 Facility to be provided

a) Auto changeover between the two incomers and one bus-coupler shall be in such
a way those two incomer breakers are 'ON' at a time and bus-coupler breaker is
normally open.
b) Bus-coupler breaker is made 'ON' automatically in case the incoming supply at
incomer breaker no. 1 or 2 fails and the respective breaker trips on under voltage.
c) Manual closing of bus-coupler with momentary paralleling of both the incoming
supplies to facilitate taking out any incomer breaker for maintenance.
d) Blocking of auto transfer (i.e., closing of bus-coupler) if any incomer breaker trips
due to a fault.
e) Tripping of incomer on under voltage shall be blocked, if both the incomers
simultaneously experience an under voltage.

Normal operating condition

a) Incomer no. 1 and 2 breakers are 'ON'. Bus-coupler breaker is 'OFF'.

Initiation of auto changeover

a) When the incoming supply to breaker no. 1 or 2 fails the respective incomer is
tripped through under voltage relays and a timer. The time delay is in the range
of 0.5 to 5 sec. Breaker trip on under voltage is blocked in case of power failure
on both the
incomers.
b) The voltage on healthy bus section has been above the set value of normal
voltage
for a specified duration (settable through a timer 0.5-5 sec.) and the incomer
breaker of healthy bus is closed in service position.
c) Bus-coupler is open and in service position.
d) Auto/ Manual switch is set for ‘AUTO’ operation.

Closing of Bus-coupler breaker

Bus coupler will close if the following conditions are met:
a) One of the incomer breakers has tripped on under voltage.
b) The residual voltage on the bus that has lost supply is less than 40% of normal
voltage.
c) Incoming voltage of healthy incomer has been above 80% of normal voltage for a
specific duration of 3 sec. (Through timer 0.5 sec - 5.0 sec).
d) Auto/ Manual switch is set for 'AUTO' operation.

Specific Blocking of auto transfer

a) Bus-coupler should not close, if any of the two incomers trips due to faults.

Manual transfer

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 105 OF 1216

 a) It is possible to trip incomer no. 1 or 2 after closing the bus-coupler to facilitate
maintenance as required. Manual transfer would permit momentary paralleling
and as such check synchronizing relay shall be provided to ensure system safety.
b) When supply is again available at incomer breaker after auto changeover has
already taken place, it is possible to restore the system to normal operating
condition by operating selector switch (meant for tripping incomer no. 1 or 2 or
bus-coupler) and by setting auto/ manual switch in 'Manual' mode.
c) In manual transfer the closing circuit shall be checked through contacts of check
synchronizing relay.

6.45 Changeover scheme for three incomers and two bus-coupler

Auto changeover shall take place only when all the three incomers are operational.
Auto/Manual Changeover scheme for switchboard with three incomers and two bus-
coupler breakers shall comply with the logic described briefly as follows. Safety interlocks
as deemed necessary shall however be considered during detailed engineering.

Auto Changeover:
a) Auto changeover between the three incomers and two bus-couplers shall be in such a
way that all three incomer breakers(I/C-1, 2 & 3) are 'ON' at a time and both the bus-
coupler breakers (BC-1 & BC-2) are normally open.
b) Bus-coupler breaker (BC-1/BC-2) is made 'ON' automatically in case the incoming
supply at incomer breaker no. 1 or 3 fails and the respective breaker trips on under
voltage. In case there is incoming supply failure at incomer-2 breaker then either bus-
coupler-1 (BC-1) or buscoupler-2 (BC-2) is made ‘ON’ automatically and the incomer-
2 breaker trips.
c) Blocking of auto transfer (i.e., closing of bus-coupler) if any incomer breaker trips due
to a fault. Trip due to 51G, 64R shall allow the transfer.
d) Tripping of incomer on under voltage shall be blocked, if any two incomers or all the
three incomers simultaneously experience an under voltage.

Manual Changeover
a) Incomer no. 1, 2 and 3 breakers (I/C-1, 2 and 3) are 'ON'. Bus-coupler breakers (BC-1
& BC-2) are 'OFF'. Manual closing of bus-coupler(s) with momentary paralleling
(interlocked with check synchronizing relay) of the incoming supplies to facilitate
taking out any of the incomer breakers for maintenance.
b) Trip incomer 1 or 2 or 3 (pre-selected) after closing of Incomer 1 or 2 or 3 or couplers
to avoid continuous paralleling of incomers.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 106 OF 1216

 Initiation of auto changeover:
a) When the incoming supply to breaker no. 1, 2 or 3 fails, the respective incomer is
tripped through under voltage relays and a timer. The time delay is in the range of 0.5
to 5 sec. Breaker trip on under voltage is blocked in case of power failure on both the
incomers.
b) The voltage on healthy bus section has been above the set value of normal voltage
for a specified duration (settable through an off delay timer 0.5-5 sec) and the incomer
breaker of healthy bus is closed in service position.
c) Bus-coupler(s) is open and in-service position.
d) Auto/ Manual switch is set for 'AUTO' operation.

Closing of bus coupler breaker under auto operation:

a) One of the incomer breakers has tripped on under voltage.
b) The residual voltage on the bus that has lost supply is less than 40% of normal
voltage.
c) Incoming voltage of healthy incomer has been above 80% of normal voltage for a
specific duration of 3 sec. (Through timer 0.5 sec - 5.0 sec)
d) Auto/ Manual switch is set for 'AUTO' operation.

Manual transfer after auto changeover:

a) When supply is again available at incomer breaker after auto changeover has already
taken place, it is possible to restore the system to normal operating condition by
operating selector switch (meant for tripping incomer no. 1, 2 or 3 or bus-coupler) and
by setting auto/ manual switch in 'Manual' mode.

In manual transfer the closing circuit shall be interlocked through check synchronizing
relay

PCC shall be provided with 8 incomers and two bus couplers. Out of these 8 incomers,
3 shall be fed from normal power supply, the other 3 shall be fed by emergency power
supply and the remaining 2 shall be fed from solar system package. Auto change over
shall take place in 3 nos. of normal power supply feeders (fed through transformers) and
2 nos. bus couplers. DG incomers will be “ON” only when grid power supply in all the 3
nos. incomers is not available.

6.46 NUMERICAL RELAYS, OTHER RELAYS AND METERING

a. All numerical relays shall be communicable type of latest advanced version and shall
comply with enclosed standard specification B047-003-SP-6-51-0055 for numerical
relays. Further, all numerical relays shall support IEC-61850 protocol.

b. All numerical relays shall be comprehensive units including all protection and metering
functions. Controls and logic shall be through numerical relays i.e. all logics shall be built
inside numerical relay and not externally. Provision of adequate I/O count in the relays
shall be ensured.

c. Digital multi function meters shall be provided in incomers, bus-coupler, outgoing plant
feeders, and outgoing transformer feeders of HV switchboards. This shall be in addition
to metering as part of numerical relays and all multi-function meters shall be
communicable.

d. All numerical relays for all MV switchboards shall be of same make.

e. Minimum 4 nos. inputs and 2 nos. output spare I/Os shall be provided in each numerical
relay.

f. For System Architecture details, refer Document No. (B047-003-16-50-DS-0005).

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 107 OF 1216

g. All disturbances/events in numerical relay shall be displayed with time stamp.

h. All relays shall have provision for monitoring & control. The relays shall be integrated
based on basic system architecture.

i. Laser printer shall be provided configured for line by line printing.

j. The requirement of numerical relays and integration shall be in compliance with the
requirement given in attached data sheet, design basis, system architecture and
specification.

k. Substation automation system including Ethernet switch shall be sourced from relay
manufacturer of MV switchboard for ease of integration including data acquisition,
annunciation, relay parameterization and control.

l. All the data as available in the relay including the status of DI should be considered to be
communicated to BMS. The data required for final configuration shall be finalized during
engineering.

m. All graphics and navigation between different pages shall be configured to Owner’s
satisfaction and successful commissioning. Any modification as required to meet the
tender requirement and customization modification due to Owner’s site engineer in-
charge shall be carried out with no commercial implication to owner.

n. Under voltage and Overvoltage elements along with associated timers shall be part of
the numerical relay.

o. Breaker Controlled Motor Feeders shall be provided with timers for Delayed tripping on
bus-under voltage while the under voltage relay shall be common for the bus.

p. One no DC supply supervision relay (80) shall be provided for each incoming DC supply
to the PCC and ASB.

q. Motors feeders above 55 kW shall be provided with DC control supply for tripping,
closing and spring charging motor purpose.

r. Master trip relay shall be a part of the numerical relay for 415V feeders wherever
numerical relays are provided.

s. All relays, metering and control components shall be mounted on the panel front only. All
panels, relays and components shall be suitable for use under site conditions of LEH. All
relays shall be suitable for flush mounting, and fitted with dust-tight covers. The relay
shall have a provision for testing using an external power supply without disconnecting
the permanent wiring.

t. All numerical relays shall comply with the prevalent emission and immunity levels.
Necessary certificates as per IEC/EN shall be furnished/ made available during review of
documents/ detail engineering.

6.47 For motor feeder, following shall be provided :

a. R-C circuit shall be provided across the power contactor for all DOL motor starter
feeders in 415V MV switchboard

b. Low burden auxiliary contactors shall be provided in all DOL motor starter feeders for
receiving start/ stop commands from field.

c. Local mode of Local Remote selector switch (on switchboard) shall be used for
operating the feeder (in test position) from switchboard while remote mode of local

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 108 OF 1216

 remote selector switch (on switchboard) shall be used from operating the feeder in
service position from remote. In test mode, no interlock shall be there for closing the
breaker except anti pumping / spring charged and breaker OFF contact.

d. In remote mode, contact from manual mode of auto/manual selector switch in local
push button station shall be wired along with start PB (also in local push button station
in field) and contact from auto mode of auto/manual selector switch in local push
button station shall be wired along with start PB from PLC.

e. Ready to start contact shall be provided as binary output from the numerical relay (in
ACB fed motor feeders) and duly wired to terminal block and further the same shall
also be programmed on relay LED indication.

f. 2 Nos. of 86 relays shall be considered for MV breaker fed motors for ease of
differentiating between process & electric trip. Process trip relay shall be self reset
type. Process trip shall be wired through numerical relay and shall be fail safe.

g. LED in numerical relay shall be latched and Binary output shall be non- latched type.

h. Two nos. duly wired terminals (for owner’s use) to be provided in each of the closing
coil and tripping coil (in ACB fed motor feeders) and two nos. duly wired potential free
contacts shall be provided in control circuit of FVNR type DOL motor feeders.

6.48. All indicating lamps, wherever used in any panel, shall be clustered LED type (with
minimum 3 nos. LEDs preferably connected in parallel) mounted inside an enclosure of
minimum dia. of 15 mm. Indicating lamps shall be suitable for 240V AC.

6.49. 110V DC (as applicable) shall be provided by owner at each bus of the 415V
switchboards. Control AC supply distribution scheme shall be as per hardware data
sheet.
6.50. Any other power supply/ voltage required shall be generated/ derived by bidder. Any
distribution board required for distribution of power to various equipment along with
cabling is included in Bidder's scope.

6.51. Spare terminals on the terminal block shall be 20% for each panel.

6.52. Make of Electrical equipments/components shall be as per owner approved vendor list.

6.53. Spring charging motors shall be suitable for 110V DC supply.

6.54. Provision for connecting stop push button NC contact of motor LCS in closing circuit of
outgoing motor feeders along with indication on numerical relay shall be considered.

6.55. Emergency stop push button (with min. 2 NO & 2 NC contacts) of RED colour shall be
provided on each outgoing feeder panel. The STOP push button shall be mushroom
type with stay put feature and lockable in pressed position. Push button shall be
provided with protective hood to secure from accidental operation.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 109 OF 1216

 INSTRUCTIONS TO BIDDER
FOR
UPS SYSTEM
(B047-003-16-50-TR-0004, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 110 OF 1216

 SPECIAL INSTRUCTIONS TO BIDDERS

1 In addition to the requirement of the enclosed standard specifications, UPS system shall also
comply with the following. In case of conflict among data sheet, standard specifications and
the instruction to bidder, the most stringent requirements shall be followed.

2 Selection, sizing and suitability of all components shall be the bidder’s responsibility. The
equipments selected shall be suitable for the site conditions of LEH & the required de-rating
calculations shall be submitted by the bidder.
The equipment as required for safe and satisfactory operation shall be considered included in
bidder’s scope, even if not specifically mentioned in the tender.

3 One set of recommended tools and special equipment required for the maintenance of the
UPS system shall be supplied with the specified equipment.

4 UPS Systems shall comprise of, but not limited to the following:

a) Battery chargers/rectifiers
b) Transistorized inverters (IGBT)
c) Required no. of static switch assemblies
d) Bypass transformer with static voltage stabilizer
e) Make-before-break switch for manually bypassing the inverters & static switches
f) All accessories including protection, monitoring and control system.
g) AC distribution board
h) VRLA Battery Bank

5 Bidder shall guarantee the performance of complete UPS system consisting of inverter, battery
charger, battery, ACDB and cell booster.

6 Bidder’s scope of work shall be complete in all respects as specified in the tender and all other
equipment, materials and work not explicitly mentioned but nevertheless required to fulfill the
functional requirements shall be deemed to be included in the scope of bidder with no
additional cost and time implication to the owner.

7 All test equipment & tools required for testing and commissioning at site shall be brought by
bidder at his own expense.

8 Bidder shall provide a suitable, lockable, MCCB to facilitate on-load isolation of the battery for
the purpose of performing battery maintenance. The MCCB shall be installed adjacent to the
battery. This shall be in addition to MCCBs for battery located in respective UPS.

9 Batteries for the offered UPS system shall be sized for the full rating of the UPS system and
inverter efficiency value at 50% load shall be considered for calculation of battery current.
Following shall be considered for sizing the battery:
- Aging factor – 0.8
- Design margin – 10%
- Battery state of charge factor - 0.95
- Design ambient temperature for battery sizing - 10˚C
- Temperature correction factor (as applicable) – As per IEEE recommendations
- End cell voltage - 1.85V/ cell
- Backup time to be considered for sizing of battery for UPS shall be 30 minutes.

10 Battery and Charger/ inverter sizing calculations shall be subject to owner’s review during
detail engineering and batteries and chargers/ inverters of approved rating/ capacity shall be
supplied without any cost/ time implications.

11 All cables shall be FRLS, heavy duty type, 650 / 1100 V grade with Aluminium/ Copper
conductor, XLPE insulated, extruded inner sheathed, armoured and extruded overall
sheathed. Cables upto size 16 mm sq. shall be with Copper conductor and cable size above
16 mm sq. shall be with Aluminum conductor. All interconnecting wiring/Cabling between
different shipping sections of the UPS shall be supplied and shall be done internally through
the panel. Supply, laying and termination of power cables between UPS, ACDB & Battery shall

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 111 OF 1216

 also be in bidder’s scope. Cable sizing calculation shall be furnished post order for approval
prior to cable ordering.

12 Cable sizes for 415V incomers to the UPS as well as for outgoing feeders of ACDB will be
furnished post order. The UPS and ACDB panel shall be suitable for terminating these cable
sizes without any cost and time implication to the owner. Cable glands and lugs for the same
shall also be provided.

13 Bidder shall limit the maximum harmonic content in input current within permissible limits to
ensure that no undue harmful effects are caused on other equipments operating on same bus.

14 Bidder shall furnish the calculations for sizing the UPS Systems along with heat loss and
battery sizing calculations for UPS.

15 All shipping sections shall be of single panel/ suitable size for facilitating entry from corridor/
door to UPS room.

16 Battery Load Cycle test shall be carried out by bidder at Site for the Supplied UPS system.
Load for testing shall be arranged by bidder.

17 Clearances between gland plates to terminating point shall be minimum 300mm in all the
electrical equipments.

18 Earthing requirement for the UPS system supply shall be informed to the bidder during detail
engineering which shall be complied by bidder without any time and cost implications.

19 UPS system shall be suitable for feeding non-linear loads having crest factor 3:1.

20 Normally Open (NO) potential free contacts shall be wired up to terminal strip for connection to
BMS interface for the following conditions:

(1) Charger Failure

(2) Inverter Failure
(3) Battery Discharged
(4) Battery Isolated
(5) UPS load on inverter

NOTES:

1. All electrical equipment shall be brand new with state of art technology and proven track
record. No prototype shall be offered. In general, the selected equipment type shall have
been in operation in industry for a minimum period of one year.

2. Material shall be procured from any of Owner approved vendor list.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 112 OF 1216

 INSTRUCTIONS TO BIDDER
FOR
BATTERY AND BATTERY CHARGER

(B047-003-16-50-TR-0005, Rev. A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 113 OF 1216

1.0 SPECIAL INSTRUCTIONS TO BIDDER

1.1 Bidder to ensure that the rating of battery set, battery charger, DCDB and cell booster shall be
adequate for the specified load cycle and is at least equal to the minimum rating indicated in the
tender. In case during detail engineering, it is found that the ratings are inadequate as per the
given load cycle, correction factors, etc., the battery, charger and other equipment ratings shall
be increased without any impact on cost and time to owner.

1.2 Bidder shall supply the equipments suitable for the conditions of LEH and shall submit the
required de-rating calculations for the equipments.

1.3 All test equipments required for testing and commissioning at site, shall be brought by the Bidder
at his own expense including load for battery capacity test at site. Also, all commissioning spares
as required during commissioning shall be supplied by Bidder at no time & cost implication to
purchaser.

1.4 The Bidder shall ensure proper design of the chargers and distribution board for satisfactory
performance when connected to the battery. The chargers shall be completely suitable for the
sequential charging requirements of the battery.

1.5 The height of DCDB panel shall be same as that of battery charger.

1.6 10% design margin shall be considered while sizing the battery and battery charger.

1.7 In case the bidder offers battery rating higher than the minimum AH capacity specified in tender
to meet the duty cycle and design basis given in data sheets and specification, bidder shall
furnish battery sizing calculations to substantiate the rating offered.

1.8 In addition to the requirement mentioned in clause no. 5.2.2.7 of specification no. B047-003-SP-
6-51-0019, all PCB/PLC used in the battery chargers shall have anticorrosive protection.

1.9 Refer clause no. 5.3.9 of specification no. B047-003-SP-6-51-0019 and note that single
compression type nickel plated brass cable glands and tinned copper cable lugs for all external
cable connections to battery charger panels / DCDB shall be provided and the removable bolted
undrilled gland plates shall be provided by bidder.

1.10 All operational checks mentioned in clause no. 5.2.2 of specification no. B047-003-SP-6-51-0019
shall be performed as part of functional tests.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 114 OF 1216

 INSTRUCTION TO VENDOR
FOR
FIRE ALARM SYSTEM

(B047-003-16-50-TR-0006, Rev. A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 115 OF 1216

1.0 SPECIAL INSTRUCTIONS TO VENDORS
1.1 One set of recommended tools, tackles and special equipment required for the maintenance
of the CFAP, Battery & charger, power supply modules, Fibre optic cable, MCP, etc. shall be
supplied with the equipment.
1.2 Makes of components/ devices shall be exactly as specified in the TENDER.
1.3 Vendor to supply cable glands for all indoor and outdoor equipments including CFAP,
detectors, MCP, hooters, response indicators, relay modules, exit signs, JB’s, etc.
1.4 Contractor shall supply the FA system suitable for the site conditions of LEH and necessary
de-rating of the equipment shall be done by contractor. Necessary calculation of de-ration shall
be submitted by the Contractor.
1.5 It shall be the responsibility of the contractor to arrange technical support from the OEM during
any point of time of execution without any time & cost implication in order to complete the
overall FA system requirements.

2.0 TENDER ITEMS:

2.1 CFAP
2.1.1 Central Fire Alarm panel shall be located in Fire Control room of Terminal Building & shall
consist of 24 inch LED display desktop PC based work station for human machine interface,
printer, battery & charger and having all necessary hardware and software to achieve
integration of all equipments with BMS data acquisition, plant views, faults and fire alarms etc.
2.1.2 CFAP shall also include hardware and software for interface with client’s Communication
Systems (Public Address Systems) for announcing fire alarm conditions.
2.1.3 CFAP shall be complete with UPS for PC, printer, etc. / power supply unit.
2.1.4 Redundancy of the system shall be as per clause no. 8.1.5
2.2 SMOKE DETECTOR
2.2.1 Detectors shall be addressable analogue type & supplied with mounting base (suitable for true
ceiling and false ceiling detectors as required) and galvanised sheet steel junction boxes and
any other hardware for detector mounting/fixing.
2.2.2 The detectors shall be suitable for loop in / loop out of main detector loop cable and connection
of cable for response indicator.
2.2.3 Detectors shall be supplied with galvanized sheet steel junction boxes and hardware for
detector mounting.
2.2.4 Single compression type cable glands shall be provided.
2.3 ADDRESSABLE AUTOALIGN MOTORIZED LINEAR BEAM DETECTORS
2.3.1 Addressable autoalign motorized Linear Beam Detectors having transmitter and receiver at
same module with control panel and separate reflecting module suitable for 100 m (min.)
length coverage including all accessories required (hardware & software), etc. and all
associated items.
2.3.2 Single compression type cable glands shall be provided.
2.4 HEAT DETECTOR
2.4.1 The detector shall be suitable for sensing fixed temperature and rate of rise of temperature.
2.4.2 The detector and junction box for hazardous area shall confirm to IS/ IEC-60079-0, 60079-1,
60079-11, and 60079-25.
2.4.3 Single compression type cable glands shall be provided.
2.4.4 Intrinsically Safe type addressable detectors shall be provided along with required zener
barrier, accessories, etc. suitable to be installed in hazardous area. All the required
accessories shall be put into a galvanized box and installed at safe area.. The same shall be
assembled at manufacturer’s works before supply.
2.5 RESPONSE INDICATOR
2.5.1 Response indicator shall be provided for detectors located above false ceiling. The response
indicator shall be connected to the detectors.
2.5.2 Response indicators shall include Junction boxes as required.
2.6 MANUAL CALL POINTS (RESETTABLE TYPE DUAL ACTION)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 116 OF 1216

2.6.1 MCP for unclassified area shall be of indoor type addressable (resettable type) unit complete
with all the accessories mounted into one unit/ module with two nos. single compression cable
glands.
2.6.2 MCPs shall be provided with a LED indication for indicating acknowledgment of fire alarm at
the CFAP to which it is connected. 1 No. blanking plug shall be provided for 10% of the total
quantity of MCPs.
2.6.3 All MCPs shall be provided with separate board for displaying the message “Manual Call Point”
in tri lingual (Hindi, English & Local Language). Suitable hardware for mounting of the board
shall be provided.
2.6.4 MCP enclosure & canopy shall have Fire Red color to shade 536 of IS 5.
2.6.5 MCPs shall be complete with hardware and accessories required for mounting them on wall/
structure/ channel.
2.7 ADDRESSABLE LOOP POWERED HOOTER
2.7.1 All hooters to be provided shall be addressable type.
2.7.2 The hooter enclosure shall have Fire Red color to shade 536 of IS 5.
2.7.3 Facility shall be provided to reset the hooter from CFAP also.
2.7.4 Loops of FA system shall be suitable to power at least 5 nos. of Hooter in a single loop.
2.8 ADDRESSABLE HOOTER ACKNOWLEDGEMENT BOX
2.8.1 All hooter acknowledge box to be provided shall be addressable type. In case control relay
module (CRM) is required to make them addressable type same shall be provided along with
hooter acknowledgement box.
2.8.2 Each hooter acknowledges box shall be fabricated out of 16-gauge CRCA sheet. The box shall
have IP41 ingress protection as a minimum and shall be suitable for wall mounting. Cable entry
provision shall be from the bottom by means of cable glands.
2.8.3 The hooters acknowledge boxes shall be epoxy painted Fire Red to shade 536 of IS 5.
2.8.4 The hooter acknowledge box shall be used to mute the audible alarm in the building.
2.9 EXIT SIGN
The exit signs shall be suitable for continuous operation on the power supply available from the
CFAP. Max. power consumption of each face shall not be more than 5W.
2.10 CONTROL / RELAY MODULE
2.10.1 Control / relay modules shall be provided for giving potential free contacts for signaling/ tripping
of other external equipment such as air conditioning, fire dampers, PA system, etc.
2.10.2 The contact of the relay module shall be rated for 230VAC / 2A or 30 to 110 V DC/5A.
2.10.3 It shall be provided with galvanized sheet steel junction boxes.
2.11 MONITOR/ INPUT MODULE
2.11.1 Input modules shall be provided for giving address to the potential free contacts received from
various other equipment such as firefighting system, etc.
2.11.2 Input module shall be able to be programmed as either self reset or latching type depending on
the functional use.
2.11.3 It shall be provided with galvanized sheet steel junction boxes.
2.12 FIRE ALARM JUNCTION BOX
2.12.1 FAJB shall be provided with required number of terminals and suitable no. of cable entries as
per SOR.
2.12.2 The enclosure of the FAJB shall be of cast light metal alloy and shall be free from frictional
sparking hazard. The magnesium content in the alloy shall be as per IS-13346. The
temperature of external surfaces shall be limited to 200ºC, unless otherwise specified.
2.12.3 FAJB shall be suitable for use in outdoor open locations and shall have IP-55 degree of
protection. Galvanized sheet steel canopy shall be provided with all FAJBs.
2.12.4 The FAJBs and canopy shall have Fire Red color to shade 536 of IS 5.
2.13 TESTING & COMMISSIONING

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2.13.1 All software shall be windows based. All testing equipments required during testing and
commissioning of the complete Fire Alarm System at site shall be arranged by the
contractor/vendor at his own cost.
2.13.2 Multiple mobilizations at site for carrying out testing commissioning of Fire Alarm system,
depending on the work front availability, shall be considered by the contractor/vendor.
2.14 TRAINING
Vendor's scope includes providing training as below:
a) Providing training for THREE Nos. Owner's engineers for a period of minimum 2 days at
manufacturer's works. FA vendor shall ensure that manufacturer has full capability &
complete facility for training owner's Engineers for specified equipments.
b) Providing Training for 5 Nos. Owner's engineers for a period of minimum 3 days at project
site. However, bidder shall be required to depute his representative for actual number of
days as per site requirement

3.0 JOB SPECIFICATIONS FOR FIRE ALARM SYSTEM:

3.1 Design requirements
3.1.1 Central Fire Alarm Panel

3.1.1.1 Central Fire Alarm Panel consisting of CFAP, centralized PC based work stations shall
be located in Fire Station building. It shall be complete with PCs, printers, power supply
panel and suitable console for installation of same. The CFAP shall include PCs of
reputed make of latest generation (with DVD-ROM drive & HDMI ports as minimum)
and laser printers (of high letter and graphic quality). The PCs shall be loaded with the
vendor's graphics software. The display monitor for Engineering console shall be 24” or
higher with touch screen operation.
3.1.1.2 The display monitor shall be equipped to display the exact location of all detectors/
MCP on the corresponding area/ building layout drawings including on the overall plot
plan showing all MCPs. The display shall have three levels of penetration, which
permits zooming on to any area or any building. Further one may zoom into specific
rooms of the building and view the detectors below the false floor, above the false
ceiling or in the room cavity. The CFAP shall also display the location of fire/ fault when
such an event occurs.
3.1.1.3 The CFAP shall be provided with the required interface cards/ relay outputs to provide
initiation contacts for activating up to 20 automatic public address alarms over Plant
Communication System.
3.1.1.4 The system should provide monitoring facility from window based menu driven user-
friendly PC workstation with colour graphics and network system control capabilities.
Engineering Console & HMI console shall be treated as same as per tender
specification no. 6-51-0076.
3.1.1.5 For two way communication through serial link using MODBUS RTU protocol, RS 485
serial port & any interface card/ protocol converter, etc. required for achieving this
communication shall be provided.
3.1.1.6 Software back up of all the logic built in PLC of CFAP PC shall be handed over by
vendor to Owner.
3.1.1.7 The CFAP shall be equipped to sound a siren in case of a fire in the complex, as well
as, be capable of hook-up to the public address communication system and telephone
system for making necessary announcements. Provision shall be provided to sound a
siren from the operators console and only with operator’s intervention. The CFAP shall
have the provisions for periodic testing of sirens, both simultaneously and individually.
3.1.1.8 Surge protectors shall be provided in the device loops for protection against damage to
loop card due to lightning strikes
3.1.1.9 Cabling works for FA system shall be done with 1100 V grade, Copper Conductor,
XLPE insulated and armoured, FRLSH cables.
3.1.1.10 The FA System shall be integrated with the Access Control System through BMS so
that in case of fire alarm signal the doors are unlocked for emergency exit.
3.1.1.11 The FA System shall be interfaced with the CCTV system through BMS, so that upon
receipt of an alarm from the FA system, including activation of fire pull stations, the
CCTV system shall cue up the relevant cameras in the area of the alarm etc.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 118 OF 1216

3.2 SPECIFIC REQUIREMENTS

3.2.1 The vendor shall supply all necessary additional equipment (even if not specified) for safe and
satisfactory operation of the system and price of the same shall be included in the basic offer
price.

3.2.2 The detector address setup shall be settable either using dip switches/ card provided on the
detectors or shall be settable from the CFAP. Detectors provided with dip switches/ card, the
FA system vendor shall include the dip switch/ card setting along with the vendor documents
for implementation by vendor during installation.

3.2.3 System should be able to provide individual graphics floor plan for each building on the
existing control / monitoring station.

3.2.4 The Fire alarm layout drawing of building/units in AutoCAD/PDF format will be made available
to bidder after order placement during detail engineering for development of graphics/ detailed
FA Block Diagram by vendor.

3.2.5 Bidder shall supply suitable furniture for keeping PCs supplied along with CFAP.
3.2.6 Addresses of all FA devices should be programmable / editable from CFAP without any need
to open the detectors / devices for defining / updating their addresses.

3.2.7 The spare power supply card shall be fully wired and should come to live by switching on
MCB.

3.2.8 Slipper type PVC sleeves (cable shrouds) shall be used over cable glands for all cable entries.

3.2.9 Engineering PC shall be provided with engineering and monitoring application software for all
the detectors of Fire alarm system for the full period of warranty and AMC, no recurring fees
shall be charged to customer during warranty and AMC.

3.2.10 The logistics Support for system controllers and cards shall be minimum 10 years.

3.2.11 Address/ IP details/ stickers of each detector, manual call points and field devices shall be
printed and programmed before dispatch to site by the Contractor.

3.2.12 Vendor to include in scope and confirm that all software, exclusive of application software, is
the most recent revision that is applicable to the system hardware at the time of the delivery of
order.

3.2.13 All spare cores shall be terminated on the marshalling rack. No cable /core shall be left un-
terminated in the rack/cabinet. No terminals or terminal strips shall be located on the side
panel of the rack/cabinet.

3.2.14 All wiring in the raceways shall be properly clamped. Total wiring cross sectional area shall not
exceed 50% of the raceway cross sectional area.

3.2.15 The following shall be noted w.r.t various equipments supplied by the Bidder:
• Addressable smoke detectors for safe area shall be as per IS-2189:2008 and NFPA-72
(2007 Edition), BS EN54-7 and BS EN54-5.
• Addressable heat detectors for safe area shall be provided for as per IS-2189:2008 and
NFPA-72(2007 Edition), BS EN54-7 and BS EN54-5.
• Addressable intrinsic heat detectors for hazardous area shall be provided for as per IS-
2189:2008 and NFPA-72(2007 Edition), BS EN54-7 and BS EN54-5.
• Exit signs, hooters etc. shall be provided as per IS: 2189:2008 and NFPA-72(2007
Edition).
• Control relay modules for tripping of AHU system, closing of incomer of Ventilation Panel,
Smoke Extraction Panel, etc. shall be provided.
• Input modules for receiving signals from other systems such as clean agent system and
water sprinkler system shall be provided.

3.2.16 FAS system, PCs and printers shall be supplied with 36 months of warranty from date of
delivery at site.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 119 OF 1216

3.2.17 MCBs shall be flush type and redundant to prevent accidental operation causing trips.

3.2.18 All cabinet lighting shall be LED type.

3.2.19 SS tag plate shall be provided for all MCPs, Hooters, heat detectors, FO cable etc.

3.2.20 VRLA batteries shall be sized for minimum End cell voltage of 1.85 V/cell. An overall ageing
factor of 0.8 and a temperature correction factor corresponding to minimum temperature of 10
Deg C, 10% design margin, state of charge factor shall be considered for battery sizing.

3.2.21 Battery low voltage alarm shall be annunciated on the respective CFAP and Repeater Panel.

3.2.22 Bidder shall note that wiring for manual call points located in the plant shall be done using 1-
2
pair, 1.5mm , annealed tinned Copper conductor twisted pair, PVC insulated, PVC inner
sheathed, overall screened, armoured and overall PVC sheathed cables.

3.2.23 Bidders shall check the proposed cable sizes and type based on the system configuration and
block diagram and shall confirm suitability of the cable sizes and type envisaged by the Owner
for the various equipments/devices of FA system.

3.2.24 All testing equipments required during testing and commissioning of the complete Fire Alarm
System at site shall be arranged by the Vendor at his own cost.

3.3 Power Supply

3.3.1 The purchaser shall provide a 240V, 1-Ph, 50 Hz AC power supply at one point for CFAP.
3.3.2 Battery backup along with battery chargers for CFAP shall be provided, as specified.
3.3.3 The purchaser shall provide 240V AC UPS power supply for CFAP, PC, Printer, etc.
3.3.4 Battery sizing calculations shall be reviewed during detailed engineering and there shall be no
cost/time implication for providing adequately sized batteries and chargers of approved rating
during the order execution. Battery charger shall be located inside CFAP.
3.3.5 Batteries supplied by the vendor shall be suitable for panel mounting. In case the same is not
possible then suitable battery stand and inter-connecting cables/connectors/lugs etc. shall be
supplied by the bidder with each CFAP. Necessary cabling from battery to charge shall be
provided by vendor.
3.3.6 Batteries shall be sized for minimum End cell voltage of 1.85 V/cell.
3.3.7 Battery low voltage alarm shall be annunciated on the CFAP.
3.3.8 Siren shall be complete with starter & control module for activating & deactivating these
through external potential free contacts
4.0 Comprehensive Annual Maintenance Contract:

For Comprehensive Annual Maintenance Contract, refer Elsewhere.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 120 OF 1216

 SPECIFICATION
FOR
HIGH VOLTAGE SWITCHBOARDS
(B047-003-SP-6-51-0001, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 121 OF 1216

Abbreviations:

A Ampere
AC Alternating Current
BIS Bureau of Indian Standards
BS British Standard
CNT Close-Neutral-Trip
CPRI Central Power Research Institute
CRCA Cold Rolled Cold Annealed
CT Current Transformer
DC Direct Current
EPDM Ethylene Propylene Diene Monomer
FRP Fiber Reinforced Polyester
HV High Voltage
Hz Hertz
IAC Internal Arc Classification
IEC International Electro-Technical Commission
IEEE Institute of Electrical & Electronics Engineer
IP Ingress Protection
kV Kilo Volt
kW Kilo Watt
kWH Kilo Watt Hour
LED Light Emitting Diode
LOTO Lock-Out Tag-Out
LSC Loss of Service Continuity
MCB Miniature Circuit Breaker
MCC Motor Control Center
MCCB Moulded Case Circuit Breaker
NEMA National Electrical Manufacturers Association
NO Normally Open Contact
NC Normally Close Contact
PO Purchase Order
PT Potential Transformer
PU Polyurethane
PVC Poly Vinyl Chloride
RAL Reichs-Ausschuss fur Lieferbedingungen
SF 6 Sulphur Hexafluoride
SWG Standard Wire Gauge
VCB Vacuum Circuit Breaker
VDE Verband Deutscher Elektrotechniker
VFD Variable Frequency Drive
VT Voltage Transformer
XLPE Cross linked Poly Ethylene

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 122 OF 1216

 CONTENTS

1.0 SCOPE
2.0 CODES AND STANDARDS
3.0 GENERAL REQUIREMENTS
4.0 SITE CONDITIONS
5.0 DESIGN AND FABRICATION REQUIREMENTS
6.0 SWITCHBOARD COMPONENTS
7.0 INSPECTION, TESTING AND ACCEPTANCE
8.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 123 OF 1216

1.0 SCOPE
This specification covers the design, manufacture, testing, packing and supply of indoor,
drawout type High Voltage Switchboards up to and including 33 kV, incorporating Vacuum or
SF 6 circuit breakers.

2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the requirements of latest revision of the following standards
issued by BIS, unless otherwise specified:
IS: 5 Colours for ready mixed paints and enamels
IS: 1248 Direct acting indicating analogue electrical measuring instruments and their
accessories
IS: 2071 High Voltage Test Technique
IS: 2544 Porcelain post-insulators for systems with nominal voltage greater than1000V
IS: 2705 Current transformers
IS: 3156 Voltage transformers
IS: 3231 Electrical relays for power system protection
IS: 3427 AC Metal enclosed switchgear and control gear for rated voltages above 1kV
up to and including 52 kV
IS: 3618 Phosphate treatment of iron and steel for protection against corrosion
IS: 5082 Wrought aluminium and aluminium alloy bars, rods, tubes and sections for
electrical purposes
IS: 5578 Guide for marking of insulated conductors
IS: 6005 Code of practice for phosphating of iron and steel
IS: 9920 High voltage switches for rated voltage above 1kV
IS: 9921 AC disconnectors (isolators) and earthing switches for voltage above 1000V
IS: 10601 Dimensions of terminals of high voltage switchgear and controlgear
IS: 11353 Guide for uniform system of marking and identification of conductors &
apparatus terminals
IS: 12729 Common High voltage Switchgear and Controlgear standards
IS: 13118 High Voltage Alternating Current Circuit Breakers
IS: 13703 Low voltage fuses for voltages not exceeding 1000V AC or 1500V DC.
IEC 60282-1 High voltage fuses – Current Limiting fuses
IS/IEC 60470 High Voltage Switchgear Alternating Current Contactors and Contactor based
motor starters
IS/IEC 62271 High Voltage Switchgear and Controlgear
(Part 1, 102,
105, 200)
IEC 62271 High Voltage Switchgear and Controlgear
2.2 In case of imported equipment, standards of the country of origin shall be applicable, if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other
statutory regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by
IEC/BS/VDE/IEEE/NEMA or equivalent agency shall be applicable.
2.5 In case of any contradiction between various referred standards/specifications/data sheet and
statutory regulations the following order of priority shall govern:
- Statutory regulations
- Data sheets
- Job specification
- This specification
- Codes and standards

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 124 OF 1216

3.0 GENERAL REQUIREMENTS
The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.

4.0 SITE CONDITIONS

4.1 The switchboards shall be designed to operate under site conditions of LEH (Refer elsewhere).
Suitable de-rating factor shall be considered by vendor while selection of equipment rating.
4.2 All equipments described in this specification are intended for continuous duty operation, as
per nameplate rating under the specified ambient conditions.

5.0 DESIGN AND FABRICATION REQUIEMENTS

5.1 Enclosure and Protection
5.1.1 The High Voltage Switchboard shall be metal-enclosed and shall comprise of standard pre-
fabricated, cold-rolled, sheet steel units, assembled to form a rigid, freestanding, dead-front
structure. As a minimum, 2mm (14 SWG) CRCA sheet steel shall be used for all front and rear
doors and covers, and 1.6mm (16 SWG) CRCA sheet steel for inter-panel partitions. Wherever
required, stiffeners shall be provided to increase stiffness of large size doors and covers.
As an alternative to CRCA, Aluzinc/pre-galvanised sheet steel can also be provided for
internal inter-panel partitions only. However, all external surface shall be of CRCA with
specified paint shade.
5.1.2 Vertical panels shall be assembled to form a continuous line-up of uniform height both for HV
chamber as well as control chamber. Rear extension panels shall also be of full height.
5.1.3 The switchboards shall be totally enclosed and vermin-proof. If necessary, openings for
natural ventilation shall be provided. These shall be louvered and provided with wire mesh
having opening less than 1mm. Design of louvers/ opening shall be such that the arc does not
come out in case of internal arc. The same shall be type tested for internal arc, as specified.
The enclosure shall have complete protection against approach to live parts or contact with
internal moving parts (IP-4X) as per IS: 3427.
5.1.4 All openings, covers and doors shall be provided with suitable Neoprene/ XLPE/ EPDM
gaskets around the perimeter to make the switchboard dust and vermin proof.
5.1.5 Each unit of the switchgear shall have necessary internal sheet metal barriers to form separate
compartments for circuit breaker, busbars, instruments and relays, cable connections etc.
Compartments for cable connections shall allow cable termination and connection work with
the switchgear energised. Suitable interlock shall be provided such that cable compartment can
be opened only when earth switch is ON or Earthing truck is inserted.
5.1.6 The panel shall be internal arc tested as per IS/IEC 62271-200 requirements for full short
circuit current and for a duration of 0.1 second (minimum) unless specified otherwise in job
specification/ datasheet and shall be qualified to comply with all the 5 criteria as per IS/IEC
62271-200. Independent pressure relief devices shall be provided for all HV compartments,
i.e. bus bar, cable and breaker compartments and each compartment shall have type test
certificate for internal arc classification (IAC) as per IS/IEC 62271-200 for the short circuit
current and duration as specified. IAC test shall be conducted on the offered panel variants
such as smallest width panel, panel with louvers, panel with thermography window and any
other variants (as applicable) as per job requirements. The panel shall also be AFLR tested as
per IS/IEC 62271-200 requirements.
5.1.7 All identical equipment and corresponding parts shall be fully interchangeable.
5.1.8 Safety barriers / shutters shall be provided to permit personnel to work safely within an empty
compartment with the bus bars energised. Loss of Service Continuity (LSC) category of the
switchgear shall be LSC2B as per IS/IEC-62271-200.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 125 OF 1216

5.1.9 It shall be possible to extend the switchgear in either direction at a later date. Ends of bus bars
shall be suitably drilled for this purpose. Panels at extreme ends shall have openings, which
shall be covered with plates screwed to the panel. Details of drilled holes in bus bar and
openings in the panels, provided for future extension shall be clearly shown in the vendor
drawings.
5.1.10 The drawout carriage on the switchboard shall have three positions: "Service", "Test" and
"Drawout" viz:
- "Full in" or "Service" position - In this position both power and control circuits shall
be connected. This shall be the normal operating position of the circuit breaker.
- "Test" position - The power contacts shall be disconnected in this position but the
control connections shall not be disturbed, it shall be possible to close and trip the
breakers in this position.
- "Draw out" Position - both power and control circuits shall be disconnected in this
position. Alternatively, “Test Position” with the secondary control circuit disconnected
may be provided in lieu of “Draw out Position”
Circuit breaker operation shall be possible only in “Service” and “Test” positions. The circuit
breaker shall be lockable in "Test" / “Draw-out” positions. Automatic safety shutters shall be
provided to ensure the inaccessibility of all live parts after the carriage is drawn out.
There shall be a distinct overall door for the breaker compartment, which can be closed with
the carriage in drawout position and it shall be lockable type.
5.1.11 All circuit breaker modules of the same rating shall be inter-changeable. Suitable interlocks
shall be provided to prevent the following operations:
- "Plugging in" or "drawing out" of a closed breaker.
- "Plugging in" a breaker with the earthing isolator closed.
- "Closing" of the earthing isolator with the breaker "plugged in".
- Pulling out the auxiliary circuit plug with the breaker in the service position. Pushing
in the breaker to the service position, with the auxiliary circuit plug not in position.
Additionally, the following shall also be provided:
- All operations such as breaker rack-in, breaker rack-out, breaker On/Off, spring
charging, earth switch On/Off etc. shall be possible only with panel door closed.
- Pad locking arrangement shall be provided for rack in operation of breaker as well as
for the panel door meeting LOTO requirements.
LOTO arrangement shall include provision for the following:
a) Provision for hooking lockout devices by multiple lock arrangement to prevent
opening of panel door and racking-in of circuit breaker.
b) Provision for attaching tag-out device for warning against energisation and to
provide information regarding date of isolation, agency working on the
equipment, etc.
c) Provision for Hasp such that the same shall be put-in and closed in the locking
arrangement of the breaker/switch and panel door.
5.1.12 All hardware shall be corrosion-resistant. All joints and connections of the panel members
shall be made by zinc-passivated high-quality Grade 8.8 or superior steel bolts, nuts and
washers, secured against loosening.
5.1.13 Suitable eyebolts/ lifting clamps shall be provided for the lifting of the panel/shipping section.
The bolts, when removed shall not leave any opening in the panels.
5.1.14 If specified in datasheet, light/ arc/ pressure based sensors with controller shall be provided to
quickly detect internal arc and immediately initiate tripping action.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 126 OF 1216

5.1.15 Thermo-graphy window for infrared electrical inspection shall be provided. The switchgear
with thermo-graphy window shall be type tested and certified for internal arc faults as per
IS/IEC 62271-200 requirements.
5.2 Accessibility
5.2.1 All relays, metering, and control components shall be mounted on the panel front only.
However, auxiliary contact multiplier relays with auto reset can be mounted inside the panel.
5.2.2 The switchgear shall be considered to be accessible to authorized personnel having access all
around and shall be tested for following type of accessibility as per IS/IEC 62271-200:
Type of accessibility : AFLR
where
Accessibility type A : Restricted to authorised personnel only
F : for front side
L : for lateral side
R : for rear side
5.2.3 Checking and removal of components shall be possible without disturbing adjacent equipment.
All equipment shall be easily accessible. It shall be possible to set all measuring relays and
instruments in-situ without de-energising the switchboard. All mounted equipment shall have
identification tags of self-sticking PVC tapes at the rear also. In addition, permanent
identification details shall be provided on the panel. Mounting of relays for a particular
breaker feeder panel shall be limited to that particular feeder only.
5.2.4 All terminals shall be shrouded with plastic covers to prevent accidental contact.
5.3 Bus Bar
5.3.1 The switchboard shall comprise of 3-phase bus bars which shall extend through all units of the
switchgear line-up. The main bus bars shall have uniform cross-section throughout their length
and shall be sized to carry continuously the rated current specified in the data sheet.
5.3.2 Bus bars shall be of high conductivity electrolytic aluminium or copper supported on
insulators made of non-hygroscopic, non-inflammable material with tracking index equal to or
more than that defined in Indian standards. Self supporting busbars can also be accepted
provided the same is type tested design.
5.3.3 Bus bars shall be housed in a separate chamber and shall be accessible for inspection. Wire
guards /cover shall be provided inside the enclosure to avoid accidental contact when the cover
is removed.
5.3.4 Both bus bars and the supports shall be adequately sized and braced to withstand the specified
short-circuit current for 1 second. Dynamic stresses shall be calculated on the basis of the
specified peak short-circuit current. All bus supports shall be of non-carbonising material,
resistant to acids and alkalies.
5.3.5 Bus bars shall be insulated by using heat-shrinkable sleeves suitable for withstanding heat
under worst operating condition. The sleeves shall be rated to withstand the system line-to-line
voltage for 1 minute. This shall be verified by a type test in which the line voltage will be
applied between the sleeved main bus bar and an aluminium foil wrapped closely around the
insulation over a length of at least 500mm.
5.3.6 All bus bar joints and all tap-off connections from the main horizontal bus bars shall be
provided with removable FRP/PU/PVC shrouds. The material of the shrouds shall be flame
retardant (FR).
5.3.7 Bus bars shall be prominently marked with Red, Yellow and Blue colour rings/ stickers for
easy phase identification at regular interval and at every power tap off point.
5.3.8 The thermal design of the bus bars shall be based on installation of the switchgear in poorly
ventilated conditions. The cooling air volume shall take into account only the bus bar
enclosure.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 127 OF 1216

5.3.9 The hot spot temperature of busbars, including joints, at design ambient temperature shall not
exceed 900C under normal operating conditions while for silver plated joints, the allowable
maximum temperature shall be 1150C in line with IS/IEC-62271-1.
5.3.10 Only zinc passivated high tensile strength high-quality Grade 8.8 or superior steel bolts, nuts
and washers shall be used for all busbar joints and supports.
5.3.11 The current rating as defined for switchboard and components in data sheet/job specification
are for design ambient temperature at site conditions and for being inside the cubicle at fully
loaded condition. The vendor shall suitably derate the nominal rating to suit the above
condition.
5.4 HV Power Connections
5.4.1 The incoming power connection shall be through XLPE cables / busduct and outgoing power
connection shall be through XLPE cables, as indicated in the data sheet. Ample space for
connection of these cables shall be provided at the rear of the switchboards. In order to avoid
accidental contact in the cable compartment while carrying out inspection by opening the rear
cover, a removable expanded metal barrier/ wire mesh shall be provided in the cable
compartment. In order to facilitate infra-red electrical inspection through thermography
window, metal barrier/ wire mesh may not be provided. Unless otherwise specified, the power
cable shall enter the switchboard from the bottom. Non-magnetic cable gland plates shall be
provided for feeders wherever single core cables are used.
5.4.2 The switchboard shall be supplied complete with supports for clamping outgoing and
incoming cables. The head-room available between cable gland plate and terminal lugs shall
not be less than 600 mm for switchgear up to 11 kV, and 900 mm for 22 and 33 kV cables.
5.4.3 In case the standard panel depth cannot accommodate the specified number of cables, a rear
extension panel of full height shall be provided. An earth strip shall also be brought to this
extension panel.
5.4.4 Unless otherwise specified, all power cables shall enter the switchgear from the bottom.
5.5 Auxiliary Wiring and Terminals
5.5.1 Inside the cubicles, the wiring for control, signalling, protection and instrument circuits shall
be done with BIS approved, PVC insulated, flame retardant low smoke (FRLS) type, copper
conductor wire. The insulation grade shall be 660 V. The wiring shall preferably be enclosed
in plastic channels or neatly bunched together. Wiring between HV breakers or cable
compartments to relay and metering compartments shall be routed through flexible conduits.

5.5.2 A minimum of 10% spare terminals shall be provided on each terminal block. Conductors
shall be terminated with adequately sized compression-type lugs for connection to equipment
terminals and strips. Stranded conductors shall be soldered at the ends/ crimped with suitable
lugs before connections are made to the terminals. Sufficient terminals shall be provided on
each terminal block to ensure that not more than one outgoing wire is connected per terminal.
Terminal strips shall preferably be separated from power circuits by metal barriers or
enclosures. All spare contacts of auxiliary relays, timers, etc shall be wired up to the terminals.
5.5.3 Each wire shall be identified at both ends by correctly sized PVC ferrules. Shorting links shall
be provided for all CT terminals.
5.5.4 PVC insulated copper conductor of cross section 1.5 mm2 may normally be used provided the
control fuse rating is 10A or less. For 16A control fuse circuit 2.5 mm2 copper conductors shall
be used. Each wire shall be terminated at a separate terminal. CT Circuit wiring shall be done
with 2.5 mm2 copper conductors. Shorting links / suitable shorting arrangement for shorting
CT secondary shall be provided.
5.5.5 Unless otherwise specified, all control cables shall enter the switchgear from the bottom.
5.5.6 Supporting facilities shall be provided for clamping the control cables.
5.5.7 All inter-panel control wiring within each shipping section shall be by switchgear vendor. The
inter-panel wiring shall be taken through PVC sleeves or suitable grommets. For inter-panel

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 128 OF 1216

 wiring between the shipping sections, wires in rolls of the required length, connected at one
point, shall be supplied with the panel for connection at site.
5.6 Control and Indication
5.6.1 Breaker tripping, closing and spring charging devices shall be fed with DC control power
supply. The rated DC voltage shall be as specified in the data sheet. The power supply for
breaker opening, closing and indication devices shall be arranged as follows:
a. One DC feeder shall be provided for each bus section. The bus coupler panel may be
fed from any of the two supplies.
b. One separate, single-phase power supply shall be provided for each bus section for
feeding space heaters, etc. Supply voltage shall be 240 V AC, unless otherwise
specified.
Provision to receive DC and AC control supply shall preferably be provided in bus-coupler
panel / bus PT panel.
5.6.2 Breaker positions (CLOSE, OPEN, spring-charged, test position, service position) shall be
indicated mechanically. Electrical indications, with colours as given below, shall also be
provided:
Breaker ‘CLOSED’ : Red lamp
Breaker ‘OPEN’ : Green lamp
Breaker ‘Auto-trip’ : Amber lamp
Trip circuit healthy : White lamp
Spring charging : Blue lamp
5.6.3 A common DC control supply fail indication shall be provided for each bus section with a blue
coloured lamp.
5.7 Earthing Connections
All cubicles shall be connected to an earth bus bar running throughout the length of the
switchboard. The minimum earth bus bar size shall be 30 x 6 mm2 copper, up to short-circuit
withstand capacity of 31.5 kA, and 50 x 6 mm2 copper, for a short-circuit withstand capacity
above 31.5 kA. All doors and movable parts shall be connected to the earth bus with flexible
copper connections. Provision shall be made to connect the earthing bus bar to the plant
earthing grid at two ends. All non current-carrying metallic parts of the equipment and
components shall be earthed. The earth bus shall be brought back to the cable compartment,
and earthing bolts shall be provided to ground cable armour. The mating surfaces of all bolted
parts shall be zinc passivated to ensure continuity between them.
5.8 Space Heaters
The panels shall be provided with space heaters to prevent moisture condensation, and
maintain cubicle temperature 5oC above the ambient. The space heaters shall be located at the
bottom of the panel, and shall be controlled through a double pole MCB and a thermostat with
an adjustable setting range of 30 to 70ºC. The thermostat shall preferably be located in the
metering or relay chamber. Space heaters shall be supplied from 240V AC auxiliary bus for
space heater.
5.9 Panel Supporting Frame
The panels shall be suitable for installation on panel supporting frame, to be supplied by
others. The panels shall be suitable for tack welding, directly to this frame.
5.10 Nameplates
5.10.1 The switchgear shall be provided with durable and clearly legible nameplate in accordance
with Table-1 of IS/IEC 62271-200 requirements.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 129 OF 1216

5.10.2 A nameplate with the switchboard designation shall be fixed at the top of the central panel.
A separate nameplate giving details for each feeder compartment of all panels shall be
provided. Danger plate (Red) shall be provided at the front and rear for each panel.
5.10.3 The nameplates for feeder compartments shall be in two parts. One part shall have necessary
details pertaining to the compartment’s number of vertical panel of the switchboards. The
other parts shall be removable and shall contain all details regarding the feeder number for
drives/equipment controlled by the particular module as per approved single line diagram.
5.10.4 Blank nameplates shall be provided for all spare and vacant modules.
5.10.5 Nameplate or polyester adhesive stickers shall be provided for each equipment mounted inside
the switchboard. Special warning plates shall be provided on removable covers or doors giving
access to cable terminals and bus bars.
5.10.6 Special warning labels shall be provided inside the switchboards also, wherever considered
necessary. Identification tags shall be provided inside the panels matching with those shown
on the circuit diagram.
5.10.7 Engraved nameplates shall preferably be of 3- ply (Black-White-Black) lamicoid sheets or
anodised aluminium. However back engraved perspex sheet nameplates may also be
acceptable. Nameplates shall be fastened by screws and not by adhesives.
5.11 Painting
5.11.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease
and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The
under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc
chromate primer. Alternately, supplier’s standard paint procedure as per their ISO standard is
also acceptable. The under surface shall be made free from all imperfections before
undertaking the finishing coat.
5.11.2 After preparation of the under surface, the switchboard shall be spray painted with two coats
of epoxy based final paint or shall be powder coated.
5.11.3 Colour shade of final paint shall be as RAL 7032 unless specified otherwise.
5.11.4 The finished panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall
be free from imperfections like pinholes, orange peels, runoff paint etc. Vendor shall supply
final paint (1 litre per switchboard) in non-returnable container for final touch up at site.
5.11.5 All unpainted steel parts shall be Zinc passivated or suitably treated to prevent rust formation.
If these parts are moving elements then they shall be greased. Aluzinc/ pre-galvanised sheet,
wherever provided, need not be painted.

6.0 SWITCHBOARD COMPONENTS

6.1 Circuit Breakers
6.1.1 Vacuum or SF 6 circuit breakers shall be used in the switchboard. The exact type and rating of
breakers shall be as indicated in the data sheet. Breaker transport trolleys required for cassette-
mounted breakers shall be provided for each switchboard. Number of trolleys to be provided
shall be as per data sheet.
6.1.2 Vacuum circuit breakers shall be designed to have low switching-over voltage levels and with
a long switching life. The interrupter shall be leak-free.
6.1.3 In case of SF 6 circuit breaker, each pole shall be provided with a pressure switch to monitor
the gas pressure with local indication / lockout, and remote annunciation in the event of SF 6
gas leakage.
6.1.4 The breakers shall have at least 6 normally open (NO) and 6 normally closed (NC) spare
auxiliary contacts for purchaser’s use. If these are not available, auxiliary relays shall be used
to multiply the auxiliary contacts of the breakers.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 130 OF 1216

6.1.5 The breakers shall have a motor-operated, spring-charging mechanism. It shall also be possible
to charge the springs manually. The closing spring shall get re-charged (for subsequent
closing) soon after a closing shot and prior to breaker tripping. In case the limit switch fails to
cut out the spring-charging motor with the springs fully charged, the motor shall be
automatically de-coupled or else positive isolation (at both ends) of power supply to spring
charging motor shall be ensured. The control circuit shall be suitable for local as well as
remote control. Breakers shall be trip-free and shall have an anti-pumping device. The breaker
operating duty shall be O-3min.-CO-3min.-CO, unless otherwise agreed.
6.1.6 Operating Mechanism
a) Electric power operating mechanism shall be motor wound spring charged stored
energy type. However, manual-operating mechanism may be of the spring charging
stored energy type or spring assisted type. For circuit breakers with electrical power
operating mechanism, provision shall also be made for manual spring charging.
Closing time of circuit breakers with manual operating mechanism shall be
independent of the speed of the operating handle.
b) All stored energy operating mechanisms shall be equipped with the following features:
i) Failure of springs, vibrations or shocks shall not cause unintended operation
of breaker or prevent intended tripping operation.
ii) Closing of circuit breakers shall be prevented unless the spring is fully
charged.
c) All electrical power operating mechanisms shall be suitable for remote operation and
shall be equipped with following features:
i) Provided with motors operable on AC or DC control supplies as specified.
ii) Provided with emergency manual charging facility. The motor shall be
automatically, decoupled (mechanically) once the manual-charging handle is
inserted.
iii) Closing operation of circuit breaker shall automatically initiate charging of the
spring for the next closing operation without waiting for tripping of circuit
breaker.
iv) Closing operation shall be completed once the closing impulse is given and
the first device in the control scheme has responded even though the control
switch / Push Button is released, provided no counter trip impulse is present.
6.1.7 Circuit breaker trip and closing coils, in case of electrically operated breakers, and trip coil in
case of mechanically operated breakers and circuit breaker indication shall be suitable for
satisfactory operation on a control supply system indicated in data sheets/job specification.
Additional second shunt trip coil (operating on different control voltage supply) shall also be
provided if specified in the datasheet.

6.1.8 All circuit breakers shall be provided with mechanically operated emergency trip device. This
device shall be available on the front of the panel. Mechanically operated ‘closing’ device
shall be provided for all breakers. However mechanical closing shall be inhibited for all circuit
breakers in service position.

6.1.9 The breakers shall be provided with anti pumping & trip free feature. Each breaker shall be
also provided with an operation counter.

6.1.10 For all HV VFD feeders, breaker shall be provided with one no. shunt trip coil and with
undervoltage release. However, in case it is not possible to provide undervoltage release in the
standard design, as an alternative, two shunt trip coils shall be provided. One shunt trip coil
shall be suitable for switchgear DC control supply while second shunt trip coil shall be
suitable for external AC control supply. The control supply voltage level shall be as specified
in data sheet.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 131 OF 1216

6.1.11 Metal Oxide surge suppressors shall be provided on all outgoing vacuum circuit breakers to
limit the over voltage to a maximum of 2.2 p.u. rated peak line to earth voltage. Sizing
calculations for surge suppressor shall be provided post order.

6.1.12 Line PT shall be mounted in a separate drawout carriage. In case of truck mounted breaker, line
PT shall be provided in a separate panel.

6.1.13 The complete breaker assembly should have inter-changeability with breakers of identical
ratings.

6.1.14 For switchgears specified with double tier circuit breaker arrangement, the outgoing feeder
breakers shall have double tier arrangement and incomer breakers with Line/bus PT shall be
housed in one vertical panel. In double tier arrangement, sheet steel partitions shall be
provided for each compartment. Compartmentalization shall be such that maintenance of one
breaker is possible without disturbing the adjacent breaker compartment. Suitable trolley(s)
shall be supplied for drawing out the breakers in upper tier. The maximum height of the
operating handle/switches/reset knobs/pushbuttons shall not exceed 1900 mm and minimum
height shall not be below 300 mm.

6.1.15 An integral earthing system, or a separate earthing carriage/truck, shall be provided. In case of
a separate earthing carriage, the necessary trolleys for bus-side and cable-side earthing shall be
supplied. After withdrawing the circuit breaker, this can be inserted to facilitate earthing of
cables and bus bars. Earthing truck shall be complete with the PT and voltmeter, giving audio-
visual indication and solenoid interlock to prevent closing of bus side earthing truck on live
busbars. Suitable interlock shall also be provided for Earthing switch. Earthing truck/ earthing
switch operation shall be only with door closed.
Integral earthing truck/earthing switch shall be suitable for short time withstand current and
peak withstand current rating equal to the corresponding breaker withstand rating.

6.1.16 Number and type of earthing trucks shall be as specified elsewhere.

6.2 Fuse Contactor Units
For outgoing feeders requiring fuse contactor (as specified in job specification/ datasheet),
following shall be complied with:
Fuse contactors shall be fully drawable type.

Contactors shall comply with IS/IEC-60470 and shall be suitable for intermittent duty class
0.1 as well as for uninterrupted duties.
The minimum short circuit breaking capacity of the contactor shall be at least 6 kA at rated
voltage.

Anti-pumping device (APD) shall be included to prevent “pumping actions” of mechanisms.

Overvoltage surge diverters shall be installed if required to keep high over-voltages during
operating conditions within acceptable values.

Contactors for motor starters and capacitor Bank feeders shall be of the latched type. The
tripping supply shall be obtained from the DC tripping and closing supply. Motor contactor
panels shall be provided with restarting facilities as specified in job specification/ datasheet.

Fuse links shall be in accordance with IEC 60282-1 and shall have high rupturing capacity.
They shall be short circuit current limiting type. Fuses shall be provided with striker pin
arrangement tripping the contactor.

Fuses for motor starters shall have a time-current characteristic suitable for the method of
starting.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 132 OF 1216

 Correct discrimination shall be established between fuse characteristics and contactor breaking
capacities. This shall ensure that overload and fault currents are safely interrupted by the
appropriate devices avoiding any risk of welding or other damage to the contactor.

6.3 Instrument Transformers

Current and voltage transformers shall be cast-resin insulated. The primary and secondary
terminals shall be marked indelibly and easily approachable for termination and testing etc.
6.3.1 Current transformer
i) Current transformers shall conform to IS: 2705. The short-time rating shall be equal to
that of the switchboard. They shall be mounted on the stationary part of the
switchboard. The CT ratings shall be as shown in the data sheet. Protective CTs shall
have an accuracy class of 5P and an accuracy limit factor greater than 10. CTs for
instruments shall have an accuracy class of 1.0 and an accuracy limit factor less than
5.0. For numerical relays having protection and metering functions, dual rated CT
shall be provided suitable for protection class and metering class. One leg of the CTs
shall be earthed. Separate CTs shall be provided for Differential and Restricted Earth
fault protection.
ii) All CTs shall be star connected. Interposing CT (ICT) shall be provided (if required)
for differential protection of transformers having star-delta connection.
iii) Proper access to each set of CTs shall be provided for repair / maintenance.
6.3.2 Potential transformer
i) The potential transformers shall conform to IS: 3156. The potential transformers shall
be of drawout-type, and shall be provided with 4 pole miniature circuit breakers with
auxiliary contacts on the secondary side.
ii) The drawout mechanism shall disconnect the PT from the busbars. The primary
connection shall be disconnected before the PT becomes accessible. Neutral point of
the star connected PTs both on the primary and secondary sides shall be earthed.
iii) The PTs shall have an over-voltage factor of 1.9 for 30 seconds, and an accuracy class
of 1.0 from 10% to 120% of normal voltage. PT selected shall be compatible with
system grounding.
iv) The primary rated voltage shall be equal to the rated voltage V of the system, or V/√3,
if the PT is connected between phase and neutral.
v) If not otherwise specified, the secondary voltage shall be 110 V, or 110/√3 V. The
burden and class of accuracy shall be as specified in data sheets. For directional relays,
either a 3-phase 5-limb PT, or 3 single-phase PTs with secondary windings connected
in open delta shall be provided.

6.4 Measuring Instruments

All analogue instruments shall be of square pattern, 96 x 96 mm, flush-mounted type.
Measuring instruments shall be provided, as specified in the data sheet. All required auxiliary
equipment such as shunts, transducers, CTs, PTs, etc, shall be included in the scope of the
switchboard supplier. The accuracy class for all instruments shall be 1.0 as per IS: 1248.
Digital instruments shall also be acceptable, provided specific approval of EIL/Owner for
make and model is obtained before placement of switchboard order.
6.4.1 Ammeters and voltmeters
Analogue meters shall be of moving-iron type. The range shall be as indicated on the
drawings. Ammeters for motor feeders shall have a non-linear compressed scale above rated
current to indicate motor starting current.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 133 OF 1216

6.4.2 kW / kWh meters
The kW / kWh meters shall be suitable to measure unbalanced loads on a 3-phase, 3-wire
system. The kW meters shall operate on a PT secondary voltage of 110 V.
6.4.3 Frequency meters
These shall be of direct-reading or digital type and shall operate on a PT secondary voltage of
110V. The standard range shall be 45-50-55 Hz.
6.4.4 Power factor meters
Power factor meters shall operate on a PT secondary voltage of 110 V. The CT secondary
current shall be as shown on the relevant drawings. The standard range shall be 0.5 lead-1.0-
0.5 lag.
6.4.5 Digital meters shall be provided, if specified in job specification/data sheets. All digital meters
shall be highly reliable, accurate, compact and self powered. Digital meter data shall be saved
in case of power failure. Field programming from front of the meter shall be possible and shall
have RS232/485 port in case specified in the job specification/data sheet.

6.5 Relays
6.5.1 Type of relay i.e. electromechanical, static or numerical shall be as defined in data sheet / job
specification.
6.5.2 All electromechanical protective relays shall be back-connected, of drawout type, suitable for
flush mounting, and fitted with dust-tight covers. Alternatively, "plug-in" type relays will also
be acceptable. Auxiliary relays are acceptable in fixed execution.
6.5.3 The protective relay cases shall have a provision for insertion of a test plug at the front for
testing and calibration using an external power supply without disconnecting the permanent
wiring. The insertions of the test plug shall automatically short circuit the CTs and permit
extension of external power supply to the relay.
6.5.4 All protective relays shall have hand reset facility and clear operating indication, e.g. flags for
electro-mechanical type relays or light emitting diodes for static/numerical type relays. It shall
be possible to reset the flag without opening the relay case.
6.5.5 All tripping relays (electrical fault trip) shall be of lockout type with hand-reset contacts, and
shall be suitable to operate on the specified voltage. These relays shall have self coil cut off
contacts, and shall be provided with hand-reset operation indicators. However, for process trip,
the lock out relay shall be self reset type Tripping relays will be acceptable in non-drawout
cases.
6.5.6 The tripping relay shall be suitable for satisfactory operation from 50% to 110% of the
specified control supply voltage.

6.6 Auxiliary Equipment

6.6.1 Auxiliary relays and contactors:
Auxiliary relays and contactors shall generally be used for inter-locking and multiplying
contacts. Auxiliary contacts shall be capable of carrying the maximum anticipated current.
6.6.2 Control Switches:
i) All control switches shall be rotary type, having a cam-operated contact mechanism
otherwise stated. Circuit breaker control switches shall be 3-position CNT, spring return
to neutral from both Close and Trip positions. They shall have pistol-grip handles and
shall be lockable.
ii) Ammeter selector switches shall have a make-before-break feature on its contacts. The
selector switch shall generally have four positions, three positions for reading 3-phase

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 134 OF 1216

 currents and the fourth position for OFF. The voltmeter selector switch shall also have
four positions, three positions shall be used to measure phase-to-phase voltages and the
fourth position shall be for OFF.
6.6.3 Timers:
For re-acceleration duty, timers unless otherwise stated, shall be pneumatic type and shall have
adjustable time setting of 0-60 seconds. Alternatively static timer may be considered. The time
settings, where specified, shall be accurately set before despatch of the switchboard. Timer
provided for control of capacitor feeder shall have minimum setting of 0-5 minutes.
6.6.4 Indicating Lamps:
Clustered LED type indicating light with minimum 8mm diameter size shall be provided for
indications. The LED shall have a low glow voltage protection and shall not glow on voltage
leakage.

7.0 INSPECTION, TESTING AND ACCEPTANCE

7.1 During fabrication, the switchboard shall be subject to inspection by EIL / Owner, or by an
agency authorised by the Owner, to assess the progress of work, as well as to ascertain that
only quality raw material is used. The manufacturer shall furnish all necessary information
concerning the supply to EIL / Owner's inspectors.
7.2 For testing requirements refer Inspection & Test Plan No. 6-81-1001.

8.0 PACKING AND DESPATCH

The switchboard shall be divided into several shipping sections for protection and ease of
handling during transportation. All outgoing feeders shall be packed as separate shipping
sections. The equipment shall be properly packed for selected mode of transportation i.e.
ship/rail or trailer. The panels shall be wrapped in polyethylene sheets before being placed in
wooden crates/cases to prevent damage to the finish. Crates/cases shall have skid bottoms for
handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Weight’, ‘Owner’s particulars’,
‘PO number.’ etc., shall be clearly marked on the package together with other details as per
purchase order.
The equipment may be stored outdoors for long periods before installation. The packing
should also be suitable for outdoor storage in areas with heavy rains and high ambient
temperature unless otherwise agreed.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 135 OF 1216

 SPECIFICATION
FOR
MV SWITCHBOARDS FIXED TYPE
FOR PACKAGE EQUIPMENT
(B047-003-SP-6-51-0012, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 136 OF 1216

Abbreviations:

A Ampere IEEE The Institute of Electrical and

Electronics Engineers
AC Alternating Current
IP Ingress Protection
BIS Bureau of Indian Standards
IS Indian Standard
BS British Standard
kA kilo Ampere
CEA Central Electricity Authority
kW kilo Watt
CFL Compact Fluorescent Lamp
kWH kilo Watt Hour
CPRI Central Power Research
Institute LED Light Emitting Diode
CRCA Cold Rolled Cold Annealed MCB Miniature Circuit Breaker
CT Current Transformer MV Medium Voltage
DC Direct Current NEMA National Electrical
Manufacturer Association
DOL Direct On Line
NO Normally Open
EIL Engineers India Limited
NC Normally Closed
EPDM Ethylene Propylene Diene
Monomer PVC Poly Vinyl Chloride
FRLS Flame retardant low smoke V Volt
HDPE High-density polyethylene VDE Verband Deutscher
Elektrotechniker
HRC High Rupture Capacity
XLPE Cross-linked polyethylene
IEC International Electrotechnical
Commission

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 137 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 SITE CONDITIONS

5.0 DESIGN AND FABRICATION REQUIREMENTS

6.0 EQUIPMENT SPECIFICATION

7.0 INSPECTION, TESTING AND ACCEPTANCE

8.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 138 OF 1216

1.0 SCOPE

This specification covers the requirement of design, fabrication, testing, packing and supply of
Medium voltage fixed type switchboard in single front execution required for receipt, control
and distribution of power to various medium voltage consumers of the package equipment
such as Air conditioning plant, Pressurisation plant, etc.

2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the requirements of latest revision of the following
standards issued by BIS unless other wise specified.

IS : 5 : Colours for ready mixed paints and enamels

IS : 1248 : Direct Acting Indicating Analogue Electrical Measuring Instruments
and their Accessories
IS : 2705 : Current transformers
IS : 2824 : Method for determining the proof and the comparative tracking
indices of solid insulating materials.
IS : 3156 : Voltage transformers
IS : 3231 : Electrical relays for power systems protection.
IS : 5082 : Wrought aluminum and aluminum alloy bars, rods, tubes and sections
for electrical purposes.
IS : 5578 : Guide for marking of insulated conductor.
IS: 8623 : Low voltage switchgear and control gear assemblies.
IS : 11353 : Guide for uniform system marking and identification of conductors
and apparatus terminals.
IS : 13703 : Low voltage fuses for voltages not exceeding 1000V AC or 1500V
DC.
IS/ IEC: 60529 : Degree of protection provided by enclosures (IP Code).
IS/ IEC: 60947 : Low Voltage Switchgear and control gear.
2.2 In case of imported equipment, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of CEA Regulations with latest
amendments and other statutory regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by IEC/BS /
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.
2.5 In case of any contradiction between various referred standards/specifications/data sheet and
statutory regulations, the most stringent requirement shall govern and decision of owner/EIL
in this regard shall be final & binding.

3.0 GENERAL REQUIREMENTS

The offered equipment shall be brand new with state of art technology and having proven field
track record. No prototype equipment shall be offered.

4.0 SITE CONDITIONS

4.1 The switchboards shall be designed to operate under site conditions of LEH (Refer
elsewhere). Suitable de-rating factor shall be considered by vendor while selection of
equipment rating.
4.2 All the equipments described in this specification are intended for continuous duty with the
specified ratings under the specified ambient conditions unless indicated otherwise.

5.0 DESIGN AND FABRICATION REQUIREMENTS

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 139 OF 1216
5.1 The switchboard shall be free standing, suitable for flush mounting with the wall, with
complete front access for operation and maintenance. The switchboard shall be fixed type, in
single front execution, assembled in single line up, metal enclosed, fully compartmentalised,
totally segregated compartments for feeders, cables and bus bar, dust and vermin proof
suitable for indoor installation.
5.2 Switchboard enclosure shall provide a degree of protection not less than IP-41 as per
applicable IS/IEC.
5.3 The switchgear shall be assembled out of vertical panels of uniform height not exceeding 2450
mm. The maximum height of the operating handle/switches shall not exceed 1900 mm and the
minimum height not below 300 mm.
5.4 The switchboard shall be designed to ensure maximum safety during operation, inspection,
and connection of cables, relocation of outgoing circuits and maintenance with the bus bar
system energised and without taking any special precautions. The switchgear shall permit
maximum interchangeability and shall be extensible on either side.
5.5 The switchboard shall be sheet steel clad with the frame fabricated out of 2mm CRCA sheet
steel and doors/covers out of 1.6mm CRCA sheet steel, having integral base frame for each
vertical panel.
5.6 All hardware shall be corrosion resistant. All joints and connections of the panel members
shall be made of galvanised or zinc passivated cadmium plated high quality steel bolts, nuts
and washers, secured against loosening.
5.7 All openings, covers and doors shall be provided with gaskets of Neoprene/HDPE/EPDM or
equivalent around the perimeter to make the switchboard dust and vermin proof. Suitable
eyebolts/lifting hooks shall be provided for each shipping section for ease of lifting of
switchboard.These eyebolts/ lifting hooks, when removed shall not leave any opening in the
panels.
5.8 After preparation of the under surface, the panel shall be spray painted with two coats of
epoxy based final paint or shall be powder coated. The colour shade of final paint shall be as
631 of IS-5 / RAL-7032, unless specified otherwise. Panel finish shall be free from
imperfections like pinholes, orange peels, runoff paint, etc.
5.9 All unpainted steel parts shall be zinc passivated, cadmium plated or suitably treated to
prevent rust and corrosion. If these parts are moving elements, then these shall be greased.
5.10 The switchboard shall be suitable for top or bottom cable entry as mentioned in datasheet, and
shall be provided with removable gland plates. The gland plate thickness shall be minimum
3mm. Non-magnetic cable gland plates shall be provided for termination of single core cables.
The switchboard shall have a separate cable alley for each vertical panel with cable tying
arrangement. The width shall be sufficient to accommodate the required number of cables.
However, in any case it shall not be less than 200mm width. The cable alley shall be provided
with a suitable hinged door. Required number of single compression nickel plated brass cable
glands and tinned copper compression type lugs (for bolted terminals) for all power and
control cables shall be included in the vendor’s scope of supply.
5.11 The switch board shall comprise of incoming load break switch panel or air circuit breaker
panel, outgoing switch fuse, fuse switch contactors feeders, motor starter feeders, control
supply transformers, both power and auxiliary/control bus bars, cable termination
compartment etc. All these shall be housed in independent compartments separated from each
other by metallic barrier.
5.12 Main horizontal bus bars shall be provided at the bottom in separate compartment for
switchboards with top cable entry and at the top for switchboards with bottom cable entry.
Vertical bus bars required for connection between main bus bars and outgoing feeders shall be
in separate vertical chamber. One set of vertical bus bars can be provided for feeding outgoing
feeders in two panels on either side of the vertical bus bar.
5.13 All components including bus bars and cable termination shall be accessible only from the
front side for repair and maintenance.
5.14 Each outgoing feeder shall be in multitier arrangement having minimum height of individual
module as defined in switchboard data sheet. All feeders shall be of modular design with
height in multiples of standard unit size.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 140 OF 1216
5.15 All auxiliary devices for control, indication, measurement and protection except the bimetallic
relays shall be mounted on the front side of the respective compartment. Components
requiring frequent inspection during operation shall be easily accessible.
5.16 Each vertical panel shall be provided with anti condensation heater rated for 240V AC supply,
provided with a switch, fuse or double pole MCB and thermostat having variable setting range
of 30-70 °C. The panels shall be provided with suitable illuminating LED lamp with switch
and fuse or MCB.
5.17 Main bus bars shall be of high conductivity electrolytic aluminium/ copper having uniform
current rating throughout their length. Horizontal and vertical bus bars shall be sized
depending upon the maximum expected current and to limit the specified maximum operating
temperature at specified design ambient temperature.
5.18 The hotspot temperature of busbars, including joints, at design ambient temperature shall not
exceed 95°C under normal operating conditions. However, for silver plated joints, the
allowable maximum temperature shall be 115°C.
5.19 Minimum clearance between live parts, between live parts/neutral to ground shall be 19 mm.
5.20 Adequately sized auxiliary copper bus bars running horizontally in a separate enclosure shall
be provided for space heaters, control supply and metering requirements. Necessary tee-off
connections shall be used for distributing auxiliary supply to each vertical panel.
5.21 All horizontal and vertical bus bars shall be insulated with heat shrink PVC sleeves of 1100 V
grade and removable shrouds shall be provided for joints. All bus bars shall be prominently
marked with Red, Yellow and Blue colour rings for easy phase identification at regular
interval and at every power tap off point and designed to withstand specified short circuit
currents for one second.
5.22 Copper earth bus of 30x6 mm2 size for fault level upto 31.5 kA and 50x6 mm2 size for fault
level above 31.5 kA shall be provided throughout the length of the switchboard with provision
for interconnection to earthing grid at two ends. All non-current carrying metallic parts of the
mounted equipment shall be earthed. Doors and movable parts shall be earthed using flexible
copper connections.
5.23 Inside the switchboards, the wiring for power, control, signalling protection and instrument
circuits shall be done with FRLS, PVC/XLPE insulated copper conductors & BIS approved
having 660/1100 V grade insulation.
5.24 For modules rated above 100 A, preferably copper strip connections shall be used. The
controls connections shall be done with 660V grade PVC/XLPE insulated FRLS wires having
stranded copper conductors. Minimum size of control wire shall be 1.5 mm2 copper for
circuits having fuse rating 10 A or less. For higher fuse rating control circuits, minimum 2.5
mm2 copper conductor shall be used. Each wire shall be identified at both ends by self-
sticking wire marker tapes or PVC ferrules. Transparent shrouds shall be used on outgoing
power terminals.
5.25 Clamp type terminals shall be acceptable for wires upto 10 mm2 size, for conductors larger
than 10mm2 bolt type terminals with crimping lugs shall be provided. Each wire shall be
terminated at a separate terminal. A minimum of 10% spare terminal shall be provided on each
terminal block. Shorting links shall be provided for all CT terminals.
5.26 Components of similar modules of same sizes shall be identically located and wired. Control
supply change over switch shall be provided in case the switchboard is with two bus-sections.

5.27 Unless otherwise specified elsewhere, the switchboard assembly and components shall be
suitable for use in pollution degree 3 environment as per IS/IEC.

6.0 EQUIPMENT SPECIFICATION

6.1 All circuit breaker shall be air break type. All switches shall be load break, heavy duty/motor
duty, air break type with the operating handle mounted on the compartment door, complete
with necessary interlock and defeat mechanism. All switches drives other than rotary switches
shall be lockable in OFF position.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 141 OF 1216

6.2 All fuses shall be non-deteriorating HRC cartridge, pressure fitting link type and shall be BIS
approved.
6.3 The contactors shall be air break type having AC-3 or AC-4 duty rating as per package
requirement. All contactors shall be provided with 1 NO + 1 NC potential free spare auxiliary
contacts wired to the terminal block for owner’s use.
6.4 Thermal overload relays shall be three elements, positive acting ambient temperature
compensated type with adjustable setting range and built in protection feature against single
phasing. Bimetal relays shall be manually reset type with the reset push button provided on the
cubicle door.
6.5 Current transformers for metering shall have an accuracy class 1.0 and instrument safety
factor less than 5. However accuracy class of 3.0 is acceptable for ammeters only for outgoing
feeders. Protective current transformers shall have an accuracy class 5P and an accuracy limit
factor greater than 10.
6.6 All measuring AC instruments shall be moving iron, flush mounting type and of 96 x 96 mm
and 72 mm x 72 mm square pattern instruments for incomer and outgoing feeders respectively.
Accuracy class shall be 2.5 for kW/kWH meter and 1.5 for ammeter and voltmeter. Ammeters
for motor feeders shall have a non-linear compressed scale at the end to indicate motor starting
current and red mark for the normal current.
6.7 All selector switches shall be rotary back-connected types having a cam operated contact
mechanism with knob type handle. Ammeter selector switch shall have make before break
feature on its contacts.
6.8 Indicating lamps shall be cluster LED type of minimum 8mm-diameter size. The following
indicating colours shall be used.
Closed/on : Red
Open/off : Green
Fault trip : Amber
Control supply on : White
Push button colours shall be as follows:
Stop/open/emergency stop : Red
Start/close : Green
Reset/test : Yellow/Black/White
'Stop' push buttons for motor control feeders shall have stayput feature.
All motor starter feeders shall have Stop and Reset push buttons and On and Trip indication
lamps.
6.9 A centrally located engraved nameplate shall be provided for the switchboard. Each module
shall have engraved nameplate-bearing data as per approved drawings. Name plate shall be
provided for each equipment mounted on the switchboard. Identification tags shall be
provided inside the panels matching with those shown on circuit diagram. Special warning
labels shall be provided on removable covers or doors giving access to cable terminals and bus
bars.

7.0 INSPECTION, TESTING AND ACCEPTANCE

7.1 During fabrication, the switchboard shall be subject to inspection by EIL / Owner, or by an
agency authorised by the Owner, to assess the progress of work, as well as to ascertain that
only quality raw material is used. The manufacturer shall furnish all necessary information
concerning the supply to EIL / Owner's inspectors.
7.2 For testing requirements refer Inspection & Test Plan No. 6-81-1012. Prior notice of minimum
4 weeks shall be given to EIL/owner for witnessing the final testing of the complete assembly
to ensure satisfactory operation of all components. Tests shall be carried out at manufacturer's
works under his care and expense.
8.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 142 OF 1216

 All the equipment shall be divided in to several shipping sections for protection and ease of
handling during transportation .The equipment shall be properly packed for transportation by
ship/rail or trailer. The panels shall be wrapped in polyethylene sheets before being placed in
wooden crates /cases to prevent damage to the finish. Crates /cases shall have skid bottoms for
handling. Special precaution notations such as Fragile, This side up, centre of gravity, weight,
Owner’s particulars, Purchase order number etc. shall be clearly marked on the package
together with other details as per purchase order.
The equipment may be stored outdoors for long periods before installation. The packing
should be suitable for outdoor storage in areas with heavy rains and high ambient temperature
unless otherwise agreed. A set of instruction manuals for installation, testing and
commissioning, a set of operation & maintenance manuals and a set of final drawing shall be
enclosed in a waterproof cover along with the shipment.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 143 OF 1216

 SPECIFICATION
FOR
INDUSTRIAL TYPE CONTROL
STATIONS
(B047-003-SP-6-51-0014, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 144 OF 1216

Abbreviations:

AC Alternating Current
BIS Bureau of Indian standards
BS British Standards
CEA Central Electricity Authority
CT Current Transformer
DC Direct Current
FRP Fibre Reinforced Plastic
GI Galvanised Iron
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
IP Ingress Protection
IS Indian Standard s
LED Light Emitting Diode
LV Low Voltage
NC Normally Closed
NEMA National Electrical Manufacturers Association
NO Normally Open
PVC Poly Vinyl Chloride
SS Stainless Steel
SWG Standard Wire Gauge
VDE Verband Der Electrotechnik, Elecktronik und Information Stechnik

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 145 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 SITE CONDITIONS

5.0 TECHNICAL REQUIREMENTS

6.0 INSPECTION, TESTING AND ACCEPTANCE

7.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 146 OF 1216

1.0 SCOPE
This specification covers the requirements of design, manufacture, testing, packing and supply
of industrial type control stations and accessories suitable for installation in non-hazardous/
safe outdoor areas.

2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the requirements of latest revision of following standards
issued by BIS:

IS: 5 : Colours for ready mixed paints and enamels.

IS: 1248 (Parts 1 & 2) : Direct acting indicating analogue measuring instruments and their
accessories.
IS / IEC: 60529 : Degrees of protection provided by enclosures (IP code).
IS / IEC 60947 : LV switchgear and control gear.
2.2 In case of imported equipment, standards followed in the country of origin shall be applicable
if these standards are equivalent or more stringent than the applicable Indian Standards.

2.3 The equipment shall also conform to the provisions of CEA Regulations and other statutory
regulations with latest amendments currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.

2.5 In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent requirement shall govern. However, Owner’s/EIL’s decision in this
regard will be final and binding.

3.0 GENERAL REQUIREMENTS

The offered equipment shall be brand new with state of art technology and having proven field
track record. No prototype equipment shall be offered.

4.0 SITE CONDITIONS

The control stations shall be designed to operate under site conditions of LEH (Refer
elsewhere). Suitable de-rating factor shall be considered by vendor while selection of
equipment rating.

5.0 TECHNICAL REQUIREMENTS

5.1 Construction
5.1.1 The enclosures of the control stations shall be made of sheet steel.
5.1.2 The control stations shall be suitable for use in outdoor open locations and shall have
minimum IP-55 degree of protection. Suitable canopy shall be provided for protection against
rain from top and two sides. The separate canopy shall be made of at least 14 SWG (2mm)
galvanised sheet steel.

5.1.3 All control stations shall be suitable for 240V AC as well as for 110V/220V DC control
supply.

5.1.4 The control stations shall be provided with neoprene gaskets.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 147 OF 1216

5.1.5 All metal surfaces shall undergo manufacturer’s standard cleaning/ painting cycle. After
preparation of under surface, the equipment shall be painted with two coats of epoxy based
final paint with colour shade as dark admiralty grey, shade 632 of IS-5/ RAL 7031. All
unpainted steel parts shall be suitably treated to prevent rust formation. If these parts are
moving elements, then they shall be greased.

5.1.6 All accessories like nuts, bolts, washers etc and operating shaft of pushbuttons and switches
etc. shall be made of stainless steel SS-304.
5.1.7 The control stations shall be provided with two earthing studs with lugs on the external
surface of the enclosures suitable for termination of 8 SWG GI wire.
5.1.8 The control stations shall be provided with undrilled gland plate. However, double
compression nickel-plated brass cable gland shall be supplied loose to suit the specified cable
sizes.
5.1.9 The control stations shall have external fixing lugs for mounting on wall or column. The holes
provided on these lugs shall be of oblong type.
5.1.10 Engraved nameplate indicating Tag Number shall be permanently fixed on each control
station.

5.2 Component Specification

5.2.1 Push buttons for START and STOP shall be of GREEN and RED colour respectively. Each
push button shall have two NO and two NC contacts. The STOP push button shall be
mushroom type with stay put feature and lockable in pressed position.

5.2.2 All control switches shall be provided with a pistol grip handle. Circuit breaker control switch,
wherever specified, shall have three positions (START - NEUTRAL - STOP) with spring
return to neutral from START position and stay put in STOP position. All selector switches
shall have minimum two poles for each position. Each position of switch shall be indelibly
marked on the control station. Exact configuration of selector switch (LOCAL-OFF-
REMOTE or AUTO-OFF-MANUAL) shall be as per datasheet / MR requirement.
5.2.3 All ammeters shall be of moving iron type having an accuracy class of 3 and suitable for
1Ampere CT secondary. Unless otherwise specified, min. size of ammeter shall either be 72
mm x 72 mm or min. 65 mm dia., 80% of the scale length shall cover 100% of the CT primary
current uniformly and the balance 20% of the scale shall cover 100-800% of the CT primary.
A red mark corresponding to the full load current of the motor shall be provided on the
ammeter dial. The ammeter front glass shall be toughened.

5.2.4 Indicating lamp(s), wherever provided, shall be clustered LED type with minimum 3 numbers
LEDs, preferably connected in parallel, mounted inside an enclosure of minimum diameter of
15mm.

5.3 Terminals & Wiring

5.3.1 The control stations shall be provided with sufficient number of terminals. More than 2 wires
per terminal shall not be permitted. If required, additional terminal with shorting link may be
used. Each terminal for external cable connection shall be suitable for termination of 2.5 mm2
solid copper conductor. Tinned copper lugs shall be provided for cable termination wherever
applicable.

5.3.2 All internal wiring shall employ 1.5 mm2, 660V grade, FR type PVC insulated copper
conductor wires.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 148 OF 1216

6.0 INSPECTION, TESTING AND ACCEPTANCE
6.1 During fabrication, the equipment shall be subjected to inspection by EIL/ Owner or by an
agency authorised by the Owner, if specified/ agreed in Inspection Test Plan. Manufacturer
shall furnish all necessary information concerning the supply to EIL/ Owner's inspector. All
routine/ acceptance tests shall be carried out at manufacturer's works under his care and
expense.

6.2 For testing requirements refer inspection and test plan no. 6-81-1014.

7.0 PACKING AND DESPATCH

All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for the selected mode of
transportation, i.e. by ship/ rail or trailer, and shall be wrapped in polythene sheets before
being placed in crates/ cases to prevent damage to finish. The crates/ cases shall have skid
bottom for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Center of gravity’,
‘Weight’, ‘Owner’s particulars’, ‘PO no.’ etc., shall be clearly marked on the packages
together with other details as per purchase order.
The equipment may be stored outdoors for long periods before installation. The packing shall
be completely suitable for outdoor storage, in areas with heavy rains/ high ambient
temperature. A set of instruction manuals for installation, testing and commissioning, a set of
operation & maintenance manuals and a set of final drawing shall be enclosed in a waterproof
cover along with the shipment.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 149 OF 1216

 SPECIFICATION
FOR
UNINTERRUPTED POWER SUPPLY
SYSTEM
(B047-003-SP-6-51-0017, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 150 OF 1216

Abbreviations:

AC : Alternating Current
ACDB : AC Distribution Board
Ah : Ampere-hour
Amp : Ampere
BS : British Standard
CD : Compact Disk
CFL : Compact Fluorescent Lamp
CRCA : Cold Rolled Cold Annealed
DC : Direct Current
DCS : Distributed Control System
DG : Diesel Generator
EMC : Electromagnetic Compatibility
Hz : Hertz
IEC : International Electrotechnical Commission
IEEE : Institute of Electrical and Electronics Engineers
IGBT : Insulated Gate Bipolar Transistor
IP : Ingress Protection
IS : Indian Standards
LCD : Liquid Crystal Display
LED : Light Emitting Diode
MCCB : Moulded Case Circuit Breaker
MR : Material Requisition
NEMA : National Electrical Manufacturers Association
Ni-Cd : Nickel Cadmium
PC : Personal Computer
PCB : Printed Circuit Board
PIV : Peak Inverse Voltage
PO : Purchase Order
P.u. : Per Unit
PVC : Poly Vinyl Chloride
RFI : Radio Frequency Interference
ROM : Read Only Memory
RS : Recommended Standard
SMPS : Switch Mode Power Supply
SPN : Single Phase Neutral
UPS : Uninterrupted Power Supply
V : Volt
VDE : Verband Deutscher Electrotechniker
VRLA : Valve Regulated Lead Acid

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 151 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 SITE CONDITIONS

5.0 TECHNICAL REQUIREMENTS

6.0 INSPECTION, TESTING AND ACCEPTANCE

7.0 SITE ACCEPTANCE TESTS

8.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 152 OF 1216

1.0 SCOPE

The scope of this specification is to define the requirements of design, manufacture, testing,
packing and dispatch of static Uninterrupted Power Supply (UPS) system.

2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the requirements of latest revision of following standards:

IS: 5 : Colours for ready mixed paints and enamels

IS: 1248 : Direct acting indicating analogue electrical measuring (Part 1, 2, 4 and 9)
instruments and their accessories.
IS: 7204 : Stabilised power supplies D.C. output
(Part 1 to 4)
IS: 12021 : Control transformers for switchgear and control gear for voltages not
exceeding 1000V AC
IS: 13314 : Solid state inverters run from storage batteries
IS: 13703 : Low voltage fuses for voltage not exceeding 1000V AC or 1500V DC
(Part 1, 2 & 4)
IS: 13947 : Low voltage switchgear and control gear specification.
(Part-5/ Sec-2)
IEC-60146-1-1: General requirement & line commutated inverters (specification of base
requirements)
VDE-0875 : German EMC directive for broadband interference generated by
appliances.
IEEE-519 : Recommended practices and requirements for harmonic control in
electrical power systems

2.2 In case of imported equipments, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.

2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other statutory
regulations currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards issued by
IEC/BS/VDE/IEEE/NEMA or equivalent agency shall be applicable.

2.5 In case of any contradiction between various referred standards/specifications/ data sheet and
statutory regulations, the following order of priority shall govern:

- Statutory regulations
- Data sheets
- Job specification
- This specification

3.0 GENERAL REQUIREMENTS

3.1 The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.

3.2 The UPS system shall be an integrated system comprising static rectifiers, battery, static inverters,
static switches, manual by pass switch, AC distribution board, voltage stabiliser in bypass,
isolating and protection devices and all other equipment/ accessories required for completeness of
the system whether specifically mentioned herein or not, but necessary for completeness and
satisfactory performance of the system.

3.3 The UPS system shall be suitable to feed all loads connected to the output which are primarily
instruments, DCS, computers, disc drives and other SMPS equipment leading to high crest factor
of the load.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 153 OF 1216

3.4 The inverter shall be transistorised (IGBT) type or with the latest proven technology. All
components shall be of a high quality and reliability that satisfy with the requirements of a secure
AC power to vital equipment with respect to performance, controlling, monitoring and
safeguarding function in continuously operating petrochemical process units, petroleum refineries,
gas processing facilities, utility and other miscellaneous industrial plants. Components shall be
capable of withstanding the thermal and dynamic stresses resulting from internal and external
short circuits and switching surges etc.

3.5 The design of the UPS shall be such as to minimise the risk of short circuits and shall ensure
human and operational safety.

3.6 The vendor shall be responsible for design, engineering and manufacturing of the complete
system to fully meet the intent and requirements of this specification and enclosed data sheets.
Selection, sizing and suitability of all equipment and components used for UPS system shall be
vendor’s responsibility.

3.7 The UPS shall be single phase or three phase system as indicated in the data sheets.

3.8 The batteries shall meet the requirement of battery Data Sheet/ battery specifications attached with
the bid document

4.0 SITE CONDITIONS

The UPS system shall be suitable for installation and satisfactory operation in closed substation
with restricted natural air ventilation under site conditions of LEH as specified elsewhere. Suitable
de-rating factor shall be considered by vendor while selection of equipment rating.

5.0 TECHNICAL REQUIREMENTS

5.1 Input Power Supply

5.1.1 The UPS shall be suitable for input power supply as defined in the data sheet. If not specified
therein the UPS shall be suitable for the following input power supply.

Voltage : 415V ± 10%

Frequency : 50 Hz ± 5%

In addition to above variations, the input voltage may be subject to transient variations comprising
voltage dip to 80% of normal voltage during motor start-up and voltage interruption during short
circuit as well as frequency variations due to large motor start up. UPS system shall be designed
to operate satisfactorily while deriving the input power from an emergency diesel generator set.

UPS system shall also operate satisfactorily on input power supply having:

- the ratio of negative to the positive sequence components not exceeding 5% and total
harmonic distortion of not more than 5%.

Total Harmonic Distortion is the ratio in percentage of r.m.s. value of the harmonic content to the
r.m.s. value of the fundamental component of alternating quantity.

5.1.2 The manufacturer shall specify the current rating of input feeder to UPS from client switchboard
based on 150% overload at minimum battery voltage and including the UPS efficiency.

5.1.3 The UPS shall be designed to ensure that harmonic components in the input current are limited as
per IEEE519. Suitable filters as required shall be provided.

5.2 UPS Configuration and Operational requirements

The UPS system shall have one of the following basic configurations as specified in data sheet
and drawings.

5.2.1 Single
VOLUME-2 UPS with Bypass (Refer SOW
(ELECTRICAL) Sketch 1)
& SPECIFICATIONS PAGE NO. 154 OF 1216
 In UPS system having this configuration a single rectifier and inverter shall be provided. Under
normal conditions when AC mains power is available, the rectifier shall simultaneously feed DC
power to inverter as well as for float/rapid charging of the battery.

The AC supply to loads shall be fed from inverter output. In case of any fault in the inverter, the
load shall be automatically transferred to stabilized bypass supply and retransfer of load from
stabilized bypass supply to the inverter shall be possible in auto as well as in manual mode.

In case of AC input power failure or battery charger failure, the battery shall supply power to
inverter without any interruption. The charger shall be designed for simultaneously feeding
complete inverter load and for float/rapid charging the battery to its rated capacity. Charger shall
be equipped with ‘On Line’ automatic as well as manual charging facility.

5.2.2 Parallel Redundant UPS with bypass (With 1x100% battery)(Refer Sketch 2)

In UPS system having this configuration two sets of rectifiers and inverters shall be provided.
Under normal conditions, when AC mains power is available, both the rectifiers shall operate in
parallel and supply DC power for float/rapid charging the battery and simultaneously to inverters.
In case of failure in one rectifier, the other rectifier shall feed the complete load and the battery
without any interruption.

In case of incoming supply failure or failure of both rectifiers the battery shall feed the inverters
without any interruption. Each rectifier shall be designed for simultaneously feeding complete
inverter load and float/rapid charging of the battery to its rated capacity. Each rectifier shall be
equipped with `On Line' automatic as well as manual charging facility.

Normally both inverters will be synchronised with each other and with stabilized bypass supply.
Both inverters shall operate in parallel and share the load equally.

The load sharing controls shall not be subject to common mode failure and any failure of the load
sharing controls shall not result in the loss of vital power.

When a disturbance/fault occurs in any one of the inverters, the faulty unit shall automatically get
disconnected and the entire load shall be fed from the other inverter. In case both the inverters
develop a fault, the complete load shall be transferred to stabilized bypass supply through the
static switches and retransfer of load from stabilized bypass supply to the inverter shall be
possible in auto as well as in manual mode.

5.2.3 Parallel Redundant UPS with bypass (With 2x50% batteries)(Refer Sketch 3)

In UPS system having this configuration two sets of rectifiers and inverters shall be provided.
Under normal conditions, when AC mains power is available, both the rectifiers shall operate in
parallel and supply DC power for float/rapid charging the 2 x 50% batteries and simultaneously to
inverters. In case of failure in one rectifier, the other rectifier shall feed the complete load and the
battery without any interruption.

In case of incoming supply failure or failure of both rectifiers the 2 x 50% batteries shall feed the
inverters without any interruption. Each rectifier shall be designed for simultaneously feeding
complete inverter load and float/rapid charging of the 2 x 50% batteries to its rated capacity. Each
rectifier shall be equipped with `On Line' automatic as well as manual charging facility.

Normally both inverters will be synchronised with each other and with stabilized bypass supply.
Both inverters shall operate in parallel and share the load equally.

The load sharing controls shall not be subject to common mode failure and any failure of the load
sharing controls shall not result in the loss of vital power.

When a disturbance/fault occurs in any one of the inverters, the faulty unit shall automatically get
disconnected and the entire load shall be fed from the other inverter. In case both the inverters
develop a fault, the complete load shall be transferred to stabilized bypass supply through the
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 155 OF 1216
 static switches and retransfer of load from stabilized bypass supply to the inverter shall be
possible in auto as well as in manual mode.

5.2.4 Hot Stand-by Redundant UPS with bypass

In UPS system having this configuration, the arrangement of rectifiers/inverters and the operating
philosophy is same as described in Cl.5.2.2 and Cl.5.2.3 above, except that only one inverter shall
be operating at one time. The other inverter shall not be sharing the load but shall be
synchronised with the running inverter and stabilized bypass supply and remain ready to accept
the load in case of fault in the running inverter. Retransfer of load from stabilized bypass supply
to the inverter shall be possible in auto as well as in manual mode.
5.2.5 In all UPS configurations, the facility for uninterrupted manual transfer in either direction through
static switches shall also be provided.

5.2.6 For ease of maintenance, it shall be possible to isolate inverters and static switches from load
through manually operated make before break switches. In case of larger rating UPS, where it is
not possible to provide one power switch with make before break feature, combination of breakers
with the control scheme having make before break logic may be provided which ensures
momentary parallelling before tripping of selected breaker.

5.3 UPS Design and Performance Requirements

5.3.1 Incoming AC supply shall be converted to DC through three phase full wave controlled rectifiers.
The rectifiers shall operate according to the constant voltage current limiting principle and shall
incorporate a "Soft Start" feature to gradually accept load on initial energising.

5.3.2 The rectifier section of the UPS system shall be capable of precise regulation to prevent damage
to the battery. The output voltage of rectifier's DC bus without the battery shall be stabilised to
within ± 1% of set value during load variation between 0 to 100% of the rectifiers and specified
mains input supply voltage variation.

5.3.3 Suitable protection shall be provided in the control circuits to guard against instability of phase
controlled rectifiers due to electrical oscillations which may be present in the input supply as
caused by emergency DG set.
5.3.4 The UPS system including the stabilised by-pass shall be galvanically isolated from input power
supply system by providing double wound transformers having copper winding. All transformers
shall be natural air cooled, dry type suitable for location inside the panel. All rectifiers shall also
have a double wound transformer at its input.

5.3.5 An RFI filter shall be provided. The production of radio frequency interference voltage shall not
exceed the value of suppression grade N’ as defined in VDE-0875. The performance of UPS
system shall not get affected or in any way be degraded by the use of portable radio transmitter
receiver in the vicinity of the UPS system and or UPS room.

5.3.6 Transient/surge protection circuit shall be provided in the input circuit to rectifiers to protect the
UPS from surges & voltage spikes.

5.3.7 The UPS system shall be designed to draw power from mains supply at a minimum power factor
of 0.85 while working at rated load in normal operating UPS configuration.

5.3.8 The UPS shall be provided with automatic sequence and power walk in circuit(s) with time delay
of up to 15 sec. such that the rectifiers and inverters can start operating automatically when
incoming AC power is restored allowing the UPS to be loaded automatically.

5.3.9 Facility for initial charging of batteries shall also be provided at a voltage level recommended by
the battery manufacturer. The inverters may be disconnected during initial charging of the battery.

5.3.10 For battery sizing, the following factors shall be considered unless specified otherwise in the data
sheet:

a. Load Power Factor of 0.8

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 156 OF 1216
 b. Minimum ambient temperature as specified in Data sheet.

Inverter rated kVA x Rated load p. f.

c. Battery Current = -------------------------------------------------------------------------
Inverter Efficiency* x End cell voltage x No. of cells
* at 50% load on each inverter for parallel redundant UPS

d. Aging factor of 0.8

e. Back up time of 30 minutes in case of mains power failure unless specified otherwise in
data sheet
f. Minimum end cell voltage for lead acid/VRLA battery 1.75 V per cell and 1.0 V per cell
for Ni-Cd battery.
g. Battery state of charge factor of 0.95.

5.3.11 The rectifiers/chargers shall be designed to completely charge the Lead acid and Nickel cadmium
batteries in a maximum time of 10 hours after complete discharge and at the same time meeting
the inverter input requirements when the inverter is delivering its rated output at 0.8 p.f. Facilities
shall be provided to initiate battery rapid charge operation by manual & automatic means. An auto
charging sequence should be provided for the rapid and float charging based on current sensing.
Battery charger for VRLA battery shall be sized to provide boost charging of the battery up to
90% of rated Ampere hours within a duration of 24 hours and to 100% within 4 days. In addition
to above, the charging shall be transferred from rapid to float mode after a preset time adjustable
through 0-24 hours timer as back up protection against over charging.

5.3.12 The rectifiers shall be sized based on the maximum inverter input load when inverter is delivering
its rated output at 0.8 rated p.f. and recharge the battery to nominal rated capacity of the battery.
The DC load imposed by the inverters shall be considered under the most severe operating
conditions where only one rectifier is operating but the UPS load is equally shared by all the
inverters. The rating of each rectifier shall be not less than the value calculated as follows:

For Lead Acid Batteries = Inverter input current* + 0.14Ah (10 hr. Rating of the battery)
For Nickel- Cadmium Batteries = Inverter input current* + 0.2Ah (5 hr. Rating of the battery)
For VRLA Batteries = Inverter input current* + 0.2Ah (10 hr. Rating of the battery)

Rated kVA capacity of UPS X Rated load power factor

* where Inverter input current = -------------------------------------------------------------
Battery charging voltage X Inverter efficiency

5.3.13 The DC rectifiers shall sense the battery charging current and adjust the DC bus voltage to
maintain the charging current to preset level. A separate current limit circuit shall also be provided
for adjustment of battery current. The rectifiers shall be protected against reverse battery
connection at DC link voltage bus. Subsequent to a discharge cycle when battery is connected to
rectifier, the battery current shall be monitored, controlled and limited to set value automatically
irrespective of the inverter input current.

5.3.14 The battery may be taken out of service for maintenance, during which period it shall be possible
for the inverter to continue operation by drawing power from the rectifier. Ripple content at the
DC link shall not exceed 2% even with battery disconnected.

5.3.15 Battery/ DC link shall be provided with a sensitive earth leakage detection.
5.3.16 The inverter shall be of the current limiting type (short circuit proof) and have nominal output
voltage and frequency as specified in the data sheet. The inverter output voltage and frequency
shall not exceed the operational tolerances, as measured at the output terminals of the unit during
the following conditions of UPS loading:

- Load variations between 0-100% of the rated output of UPS

- Load power factor over the range of 0.7 lagging to unity.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 157 OF 1216

 - Load current waveform having a relative harmonic content varying between zero and 50%,
the latter waveform having a crest factor not exceeding 2.5 and individual harmonics not
exceeding the following values :

3rd harmonic - 44% of fundamental

5th harmonic - 33% of fundamental
7th harmonic - 18% of fundamental
9th harmonic - 7% of fundamental
11th harmonic - 10% of fundamental

The Relative harmonic content is the ratio of the r.m.s. value of the harmonic content to the
r.m.s. value of the total non-sinusoidal periodic waveform i.e. relative harmonic content =
rms value of the fundamental component of current or voltage
√[1- (------------------------------------------------------------------------------------ )²]
rms value of total waveform of current or voltage

- DC input voltages over the range corresponding to battery rapid charge and battery discharge
operation during the specified discharge times.

The UPS output voltage waveform shall be sinusoidal with a relative harmonic content not
exceeding 5% for both linear and non linear loads.

5.3.17 The inverter shall control the output voltage of the UPS such as to maintain synchronism with the
mains bypass voltage during variations in mains frequency up to the limits specified.

During variations in mains frequency exceeding these limits, the inverter shall revert to internal
frequency control.

5.3.18 It shall be possible to vary the inverter output voltage steplessly within ± 5% of the specified
output voltage. This adjustment shall be possible to be made when the inverter is in operation.

5.3.19 The steady state output voltage and frequency (free running) variation of inverters shall not
exceed ± 1% from the set value for specified input power supply conditions from no load to full
load condition and load power factor variation from 0.7 lag to 1.0.

5.3.20 The UPS system shall be able to operate satisfactorily on rated loads (in kVA) with power factors
in the range of 0.7 lag to 1.0. The overall efficiency of the UPS system shall not be less than 80%
at rated load and 0.8 pf.

5.3.21 The UPS shall have capacity to deliver a minimum overload of 125% for 10 minutes and 150%
for 1 minute. UPS shall be provided with current limit circuit to avoid excessive loading beyond
its permissible overload withstand capability.

5.3.22 The inverters shall be ‘phase locked’ to the stabilized bypass power supply as long as stabilized
bypass supply frequency remain within ± 4% of nominal. When bypass supply frequency
variation exceeds the above limits, the inverters shall be de-linked from mains. Free running
frequency tolerance limit shall not exceed ± 1%. Facility shall also be provided for adjustment of
range of synchronising frequency.

5.3.23 Unless otherwise specified, the UPS system output voltage variation shall not exceed ± 10% and
complete recovery to normal steady state shall be within 0.1 Sec. The phase angle disturbance
shall be less than 120° ± 3 % in case of 3 phase inverter. The above requirement shall be complied
for following transient disturbances.

a) 100% step load and unload (For single UPS and hot stand by UPS)
b) 50% step load (for parallel redundant UPS)
c) Momentary interruption in power supply
d) Load transfer to stabilized bypass supply
e) Complete load transfer to other healthy inverter when one of the two parallel inverters
develop a fault.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 158 OF 1216

5.3.24 For 3 phase UPS system, the maximum output voltage and angle variation between the phases
should not exceed 6% and 3 degrees respectively even under the condition of 100% unbalanced
loading of the 3 phase output.

5.3.25 UPS system shall be suitable both for floating output or earthing of one leg / star point in case of
single phase/ three phase system respectively.

5.3.26 The stabilized bypass supply shall be designed to regulate the output voltage within +2% of the
rated voltage over complete range of load from no load to full load and for specified input supply
voltage variation. The type of Voltage stabiliser in stabilized bypass supply shall be as indicated
in data sheet.

5.3.27 The stabilized bypass supply shall have a continuous current rating equivalent to the rated output
of the UPS unit and be capable of conducting a current ten times the rated output for the duration
more than the fault clearing time of the type of fuse provided. The load transfer devices shall
comprise of continuously rated static elements in both inverter and stabilized bypass supply.

5.3.28 Adequately rated static switches in required number & configuration shall be provided in the
inverter(s) output and stabilized bypass supply to ensure positive isolation of faulty inverter
section such that the other inverter and bypass circuits do not feed into the fault leading to under
voltage / trip. The short time rating of all the static switches shall be at least 10 times the rated
output for the duration more than the fault clearing time of the type of fuse provided.

5.3.29 Facility shall be provided to manually and automatically initiate transfer of the load from inverters
to the stabilized bypass supply and from stabilized bypass supply to the inverters. Under voltage
and over voltage sensing levels to initiate transfer shall be adjustable. The maximum transfer time
between inverters and bypass supply shall not exceed 4 msec and 20 msec in synchronous and
asynchronous mode respectively.
5.3.30 The criteria for load transfer:

A) Load transfer from inverter to the stabilized bypass supply shall be as follows:

(i) The load transfer shall only be possible when:

- The stabilised bypass output voltage is within + 5% of rated UPS output voltage
and
- The mains bypass frequency is within + 4%.

(ii) Auto-transfer of the load from inverter to stabilized bypass supply shall be initiated
when:

- The inverter output voltage drops below 95% of nominal output voltage under
steady state condition and/or if the inverter output voltage falls below 90% of
the nominal value under transient conditions.
OR
- The inverter output voltage exceeds 105% of the nominal output voltage under
steady state condition and/or if the inverter output voltage reaches 110% of the
nominal value under transient conditions.
OR
- The inverter output current exceeds its tolerable limits.

B) Retransfer of load from stabilized bypass supply to the inverter shall be as follows:

(i) The load transfer shall be possible when-

- The inverter output voltage is within ± 5% of nominal output voltage for more
than 5 sec. and inverter output and stabilised bypass supply are synchronised

Retransfer of load from stabilised by pass to the inverter shall be done manually
only unless otherwise specified in the data sheet
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 159 OF 1216
 If automatic retransfer of load to the inverter is specified in the data sheet, then the
retransfer of load to the inverter shall be inhibited following four automatic
transfers of load to stabilised by pass within a period of 5 minutes.
5.3.31 All breakers shall be adequately rated for continuous rating as well as breaking capacity as
applicable. Paralleling of breaker/ switch/ contactor poles to achieve the required current rating is
not acceptable. All output isolating device shall be double pole type.

5.3.32 All electronic power devices including thyristors, transistors (IGBTs), diodes etc. shall be rated
under operating conditions for approximately 200% of the maximum current carried by the
device. All other electrical components such as transformers, reactors, breakers, contactors,
switches, bus bars etc. shall be rated for at least 125% of the maximum required rating. No
electronic device shall be subjected to PIV greater than 50% of its rated value.

5.3.33 All the thyristors, power transistors, diodes and other electronic devices of UPS shall be protected
with high speed semiconductor fuses. I²t co-ordination between fuse and semi-conducting power
devices shall be ensured.

5.3.34 The outgoing circuits of ACDB shall be protected by semiconductor fuses. Each inverter shall be
designed to clear a fault in any of the branch circuits up to a minimum rating of 25% of the system
capacity without the assistance of the stabilized bypass supply. In case of any fault in branch
circuits, the load connected to the healthy circuits shall not get affected. The fault clearing time
shall be less than 4 msec.

5.3.35 All PCBs shall be provided with a transparent epoxy coating for environmental protection and
tropicalisation. They shall be suitably located away from heat sources.

5.3.36 All electronic control and monitoring printed circuit cards shall be installed in standardised
electronic equipment frames and shall be fitted with suitable means for easy removal. The frames
shall incorporate guides for PCB’s to facilitate correct insertion of PCB’s and shall allow access to
the wiring side of the connectors. All PCBs shall be placed in a manner to avoid replacement of a
PCB by a wrong spare PCB. Monitoring points shall be provided on each of the PCB’s and the
PCB shall be firmly clamped in position so that vibration or long usage do not result in loose
contacts. Failure of each PCB shall be indicated by visual alarms. Visual fault diagnostics shall
preferably identify faults up to various sections in the card.

5.3.37 Forced ventilation of panel, if provided, shall be supplemented by 100% redundant fan. In normal
operation, normal & redundant fans shall run together. The power supply for the fans shall be
tapped from the inverter output. However, the rating of the UPS as specified in the data sheet shall
be the net output of UPS after deducting power consumption for fans etc. However in case of non-
operation of 50% of running fans the UPS output shall not be affected. The fans shall be arranged
to facilitate removal of faulty fan for maintenance without requiring system shutdown. All fans
shall be equipped with monitoring facilities to provide an alarm in the event of fan failure.

5.3.38 Maximum noise level from UPS system at 1 metre distance, under rated load with all normal
cooling fans shall not exceed 75 dBA

5.4 Construction

5.4.1 Rectifier/charger and inverter, stabilized bypass supply and static switch sections shall be suitably
housed in sheet steel panels complete with all interconnections.

UPS panels, ACDB and cell booster enclosures shall be fabricated from structural/CRCA sheet
steel. The frames shall be fabricated by using minimum 2mm thick CRCA sheet steel while the
doors and covers shall be made from 1.6 mm thick CRCA sheet steel. Wherever, required suitable
stiffeners shall be provided.

The panels shall be free standing, fitted with suitable louvers for ventilation and cooling fans as
required. Hinged doors shall be provided at the front and back with dust tight gaskets. Inter-panel
sheet steel barriers shall be provided. The enclosure shall provide minimum IP-31 degree of
protection, if not specified otherwise in the data sheet. The maximum and minimum operating
height of the switches shall be 1800 mm and 300 mm respectively.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 160 OF 1216
5.4.2 Power cables shall be with aluminium / copper conductors and control cables shall be with copper
conductors. All the cable connections shall be from bottom and front of the panel, if not specified
otherwise in the data sheet. A removable bolted gland plate shall be provided along with single
compression type nickel plated brass cable glands for external cable connections. Clamp type
terminals shall be used for connection of all wires up to 10 mm². Bolted type terminals suitable for
cable lugs shall be provided for wire size above this. Tinned copper lugs for all external
connections shall be provided with the panels. Terminals shall be provided for all external
connections. Interconnection cables for cubicles located side to side shall be supplied. All
interconnecting cables, as required between UPS system and ACDB, UPS system and batteries
shall be in the scope of vendor.

5.4.3 Bus bars shall be used in all power circuits which are rated above 100 Amp. Copper conductors
PVC/XLPE insulated cables or wires of 660V grade shall be used for power circuits rated less
than 100 Amp. Bus bars shall be colour coded and live parts shall be shrouded to ensure complete
safety to personnel intending routine inspection by opening the panel doors. All the equipment
inside the panel and on the doors shall have suitable name plate and device tag numbers as per the
schematic diagram. All wires shall be ferruled and terminals shall be numbered.

5.4.4 MCCBs and load break power switches shall be mounted inside the panel. The control switches
shall be rotary type, mounted on the door and shall be externally operable. An 11W CFL lamp
controlled through a door switch shall be provided for illumination in each panel. All instruments
shall be analogue/digital, switchboard type, back connected, 72 x 72 mm. square (for Analogue
type). Analogue instruments shall be preferred. Analogue instruments’ scale shall have red mark
indicating maximum permissible operating rating. Separate test terminals shall be provided for
measuring and testing of the equipment to check the performance.

5.4.5 A suitably sized earth bus shall be provided at the bottom of the panels including ACDB running
through the panels line up with provision for earth connection at both ends to purchaser's main
earth grid. The minimum size of earth bus shall be 25 x 3 mm² copper (or equivalent aluminium).
All potential free metallic parts of various equipments shall be earthed suitably to ensure safety.

5.4.6 All panels shall be of same height so as to form a panel line up which shall have good aesthetic
appearance. ACDB can be of different height.

5.4.7 Inside the panels, the controls connections shall be done with 660V grade PVC/XLPE insulated
wires having stranded copper conductors. 1.5 mm² size wires shall normally be used for circuits
with control fuse rating of 10 Amp. or less. For control circuit having fuse of 16 Amps, 2.5 mm²
size wires shall be used. Control wiring for electronic circuits shall be through flat ribbon cable or
through copper wire minimum of 0.5 mm dia.

5.4.8 All control wiring shall preferably be enclosed in plastic channels or otherwise neatly bunched
together. Each wire shall be identified at both ends by PVC ferrules. Ferruling of wires shall be as
per relevant IS.

5.4.9 All metal surfaces shall be thoroughly cleaned and de-greased to remove mill scale, rust, grease
and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The
under-surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc
chromate primer. The under-surface shall be made free from all imperfections before undertaking
the finished coat.

5.4.10 After preparation of the under-surface, the panels shall be spray painted with two coats of epoxy-
based final paint or shall be powder-coated. Spray painted finished panels shall be dried in stoving
ovens in a dust-free atmosphere. Panel finish shall be free from imperfections like pinholes,
orange peels, runoff paint, etc.

5.5 Cell Booster

5.5.1 Cell booster shall be suitable for charging not only the new cells before being introduced to the
battery bank but also any treatment to be given to the individual weak cells. Quantity of such
boosters shall be as defined in the MR. Cell booster shall be suitable for 240 V ± 10%, 50 Hz ±
3%(ELECTRICAL)
VOLUME-2 SPN input power supply. CellSOWbooster output voltage shall be in the range
& SPECIFICATIONS of NO.
PAGE 0-18V
161 and 0-12V
OF 1216
 for Lead Acid and Nickel Cadmium batteries respectively. Cell booster current rating shall be as
under:

For Lead Acid battery = 0.14 x Ah of cell (10 hr. Rating of the cell)
For VRLA battery = 0.2 x Ah of cell (10 hr. Rating of the cell)
For Ni-Cd battery = 0.2 x Ah of cell (5 hr. Rating of the cell)

Cell booster shall have heavy duty switch fuse or MCCB on AC incomer and DC output, AC
voltmeter, DC ammeter and voltmeter, indicating lamp for AC/ DC power ON. The output voltage
and current of cell booster shall have manual control using a suitably rated variac or a full wave
controlled rectifier bridge. Suitable interlock shall be provided so as to ensure that the variac/
controlled rectifier is at its minimum position while switching on the cell booster. Cell booster
shall be portable type with wheels. Each cell booster shall be supplied with 5 m long flexible
copper conductor, PVC insulated and braided cable for AC incomer power supply and DC output
connection to the battery.

5.6 A.C. Distribution Board

Sheet steel enclosed AC distribution board shall be provided. It shall accommodate AC feeders as
indicated in the data sheet. The distribution board shall be floor mounted, fixed type with
compartmentalised construction unless otherwise indicated in the data sheet. The switchboard
shall be provided with 2 I/Cs (one from UPS & another from Bypass supply) with adequately
rated Switch/MCCB/ACB. It shall be possible to operate the switches without opening the doors.
Switches shall be provided with door interlock. Vertical cable alley of minimum 200mm width
with suitable supports shall be provided for the termination of outgoing cables. Suitable supports
shall be provided for supporting incoming and outgoing cables. All outgoing switches shall be air
insulated load break type. Fuses on outgoing feeders shall be fast acting semiconductor type and
cable entry shall be from bottom. Isolation transformers (if required) shall be mounted inside
ACDB. HRC fuses shall be provided for isolation transformer feeders. The gland plate of the
distribution board shall be non-magnetic type where single core cables are used as specified in the
data sheet. Cable glands shall be of brass and single compression type and cable lugs shall be of
tinned copper.

5.7 Alarm, Control, Indication and Metering Requirements

If not specified otherwise in the data sheets, following schedule shall be followed for alarm,
control, indication and annunciation. Any additional devices/features considered necessary for
reliable operation and maintenance shall also be included in various panels and same shall be
highlighted separately. An illuminated one line diagram indicating operational status shall be
provided on the front of the panel. Metering, indications, audio-visual alarm shall be provided.
Parameters/ information indicated shall be available by menu driven LCD display or by other
means directly or indirectly.

5.7.1 Metering

5.7.1.1 Rectifier

a) Incoming line voltages (For all the three phases).

b) Input line currents.(For all the three phases)
c) DC voltage at each rectifier output.
d) Battery current.

5.7.1.2 Inverters

a) AC voltage at each inverter output (AC voltages for 3 phase inverter)

b) AC current at each inverter output (AC currents for 3 phase inverter)
c) Frequency meter at each inverter output

5.7.1.3 Stabilised bypass supply

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 162 OF 1216
 a) Frequency meter for incoming supply.
b) Voltmeter with selector switch for incoming supply.

c) Ammeter with selector switch for incoming supply.

5.7.1.4 ACDB

Following shall be provided for each of the ACDB incomers:

a) Voltmeter (voltmeter selector switch shall also be provided for 3 phase inverter).
b) Ammeter (ammeter selector switch shall also be provided for 3 phase inverter).
c) Power factor meter

5.7.2 Indications

All indicating lamps shall be LED type. LEDs provided for indication shall be cluster type with
adequate brightness and minimum 2Nos LEDs chips per light. LEDs shall be connected in parallel
and each LED chip having diameter not less than 3mm. LEDs shall be provided for following:-

5.7.2.1 a) AC mains `ON' - Rectifier.

b) AC mains `ON' - Bypass.

5.7.2.2 Rectifiers (for each rectifier)

a) Rectifier output `ON'

b) Battery on float charge
c) Battery on rapid charge

5.7.2.3 Inverters (for each inverter)

a) DC input `ON'
b) Load on inverter.
c) Inverter synchronised with mains.
5.7.2.4 Load on bypass.

5.7.3 Audio-Visual Alarm (separately for each circuit)

5.7.3.1 a) Mains failure

b) Battery charger failure
c) Battery fault
d) Inverter temperature high
e) Low voltage from inverter
f) Load on bypass
g) Inverter overloaded
h) All power Fuse failures
i) DC earth fault
5.7.3.2 2 nos changeover contacts shall be wired to the terminal strip, 1 no for common remote alarm of
`UPS fault' in owner's panel and 1 no for `load on bypass supply' annunciation.

5.7.4 UPS shall also be provided with provision to hook up all indication and audio visual alarm, as
specified in clause no.: 5.7.2 and 5.7.3 above, with owner's PC through RS232/RS485 / fibre optic
port through serial interface.

5.7.5 Controls

a) All the switches for starting, shut down and testing sequence.
b) Primary input circuit breakers for feeding chargers, bypass line and dc bus from battery
including backup protection.
c) Inverter ON/OFF switch (to initiate inverter operation)
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 163 OF 1216
 d) Static switch transfer test Push Button.

5.8 Reliability

All necessary care shall be taken in selection, design, manufacture, testing and commissioning of
the equipment for ensuring high system reliability. Following design consideration shall be taken
into account to ensure maximum availability of the system.

5.8.1 There shall be no common device, between main and redundant units (e.g. master oscillators etc.)
in order to ensure that the failure of the same does not cause shutdown of more than one unit.

5.8.2 It shall be possible to take out any individual power circuit for maintenance without affecting the
total UPS supply.

5.8.3 Series-parallel combination of smaller devices to achieve required rating shall not be acceptable.

5.8.4 Vendors shall offer their nearest higher standard size that will meet the requirement of the
specified UPS rating.

5.9 Fault Diagnostic Unit

If specified in the data sheet, each UPS set shall have provision for adding microprocessor based
`ON line' fault diagnostic unit. This shall supervise the UPS operation continuously. It shall
identify and locate faults immediately so that corrective action can be taken. Fault Diagnostic unit
shall be compatible to hook up with owner's PC through RS232/RS485 interface. The software
shall be provided on a CD ROM.
The fault diagnostic unit shall have provision for automatic print out facilities for time,
input/output voltages, currents, frequency as a minimum under the following conditions.

- UPS power source changeover from mains to battery.

- UPS power source changeover from battery to mains.
- Changeover from inverter to stabilized bypass supply and vice versa.
- Changeover from one inverter to other inverter.
- Changeover time in case of inverter to stabilized bypass supply and from one inverter to other
inverter.
- UPS failure.
- Type of failure incident along with diagnostic report.

In addition to the above, any other feature which vendor feels may be useful shall be provided and
highlighted separately.

If any Additional equipment (e.g. bin connector, adaptor cards etc.) are required for connecting
this unit with UPS system as well as with owner's PC, the same are also to be included in the
vendor's scope.

6.0 INSPECTION, TESTING AND ACCEPTANCE

6.1 During fabrication, the equipment shall be subjected to inspection by EIL / Owner or by an
agency authorised by the Owner. Manufacturer shall furnish all necessary information concerning
the supply to EIL/ Owner's inspector. Tests shall be carried out at manufacturer's works under his
care and expense.

6.2 UPS system shall be tested in accordance with applicable standards. The following acceptance
tests shall be performed on each UPS system as a minimum. All tests shall be witnessed by owner
or its authorised representative and 4 weeks prior notice shall be given before the date of
commencement of tests. The tests certificates indicating test results shall be furnished.
Following system acceptance tests
VOLUME-2 (ELECTRICAL) shall
SOW be conducted on each UPS system:PAGE NO. 164 OF 1216
& SPECIFICATIONS
6.2.1 Insulation tests

Insulation tests shall be performed as per IEC 60146-1-1.

The insulation tests shall be carried out using an AC power frequency voltage or by using DC
Voltage at the choice of the vendor. In the case of AC power frequency voltage test, the test
voltage at the frequency available in the test facility or at the rated frequency, but not exceeding
100 Hz, of the full value starting at a maximum of 0.5 p.u. The unit on test shall withstand the
specified voltage for 1 minute.

In case DC voltage is used for the test, the value of DC voltage shall be equal to the crest value of
the test voltage specified in the table.

V p / √2
(V p is the highest crest voltage to be Test Voltage (AC rms value)
expected between any pair of
terminals)
≤ 60 V 500 V

≤ 125 V 1000 V

≤ 250 V 1500 V

≤ 500 V 2000 V

6.2.2 Interconnection cable check

The interconnection cables are to be checked for correct wiring, insulation and quality of the
terminations

6.2.3 AC input failure test

The test is performed with the test battery and carried out by tripping AC incoming circuit
breakers or by switching off rectifiers and bypass supply at the same time. Output voltage and
frequency variations are to be checked for specified limits.

6.2.4 AC input return test

The test is performed by closing AC incoming circuit breakers or is simulated by energising
rectifiers and bypass supply. Proper operation of rectifiers starting and voltage and frequency
variations of output are to be checked.

6.2.5 Simulation of parallel redundant UPS fault

The test is applicable for UPS with parallel redundant configuration. Fault of rectifier or inverter
are to be simulated and output transients are to be recorded.
6.2.6 Transfer test

Transients shall be measured during load transfer from inverter to bypass supply caused by
simulated fault and load retransfer after clearing the fault.

6.2.7 Regulation test

This test shall be carried out by measuring input voltage, input current, output voltage, output
current, DC link voltage, output distortion, input active power, output active power and frequency
at no load, 50% load and 100% load at 0.7 and 0.8 p.f.

Following parameters of rectifiers and inverters are to be measured:

Measurement shall be carried out in the rectifier float charge mode and in rapid charge mode.
Measurement shall be at nominal a.c. voltage and at no load, 50% load and 100% of rectifier full
load. Rectifier measurement shall comprise of :-

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 165 OF 1216

 - Input voltage, frequency, phase current and input power.

- DC output voltage and current.

- Ripple current at the DC link bus shall be recorded after isolating the test battery.

Inverter measurement shall also be at no load, 50% load and 100% load of inverter rated output
current and shall be repeated for inverter DC input voltages corresponding to battery float charge
operation as well as rated inverter maximum and minimum input DC voltage. Measurement shall
comprise of:

- Input voltage, input current.

- Output voltage, frequency and waveform distortion, output power and current.
6.2.8 UPS efficiency

This shall be determined by the measurement of the active power input and output at rated p.f. for
50%, 75% and 100% load.

6.2.9 Current division in parallel UPS

Load sharing between UPS units shall be measured with a dummy load under parallel redundant
UPS configuration.
6.2.10 Light load test

The test is to verify that all functions of the UPS system operate properly. The load applied is
limited to some percentage of rated load. The following points are to be checked.

(a) Output voltage and frequency and correct operation of meters.

(b) Operation of all control switches and other means to put UPS system into operation.
(c) Functioning of protective and warning devices
6.2.11 Burn-in test for Printed circuit boards

PCB’s and other electronic components sub assemblies shall undergo a burn- in test for 96 hours
at 50°C at a voltage varied between the maximum and minimum supply voltage. In case of failure
of any component during testing, the tests shall be repeated after replacement of the faulty
component. Supplier’s test certificates are also acceptable for this test.
6.2.12 Continuous full load test at 0.8 power factor with temperature rise measurement

The test is required to be performed by connecting resistive load or resistive and inductive load to
the UPS system output. The load shall be placed outside the test room to avoid influences of its
heat upon UPS ventilation. Supplier’s test certificates are also acceptable for this test.
UPS system in this test shall undergo a complete full load test for 32 hours at 0.8 power factor.
Out of these 32 hours, each inverter section shall be subjected to full load test for 8 hours, both
invertors sections operating in parallel shall be subjected to full load test for 8 hours and the for
remaining 8 hours; the by pass section shall be subjected to full load test. Steady state temperature
of rectifier transformer, rectifier set, D.C. choke, inverter set, static switch etc. shall be recorded
during the test. The temperatures of all UPS panels are also to be recorded.

6.2.13 Auxiliary equipment and control circuit tests

The correct functioning of all measuring instruments, alarms, indications, protection devices and
controls are to be verified. The functioning of auxiliary devices such as lighting, cooling fans,
annunciation etc. should be checked.

6.2.14 Synchronisation test

Frequency variation limits of inverter are to be tested by feeding bypass supply incoming line by
variable frequency generator and inverter synchronisation limit is to be checked as specified.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 166 OF 1216
6.2.15 Unbalanced load test (For 3 phase UPS only)

Unbalance load at specified limits is applied to the UPS system. The specified voltage and phase
angle variation shall be checked for compliance with specified values.

6.2.16 Output voltage unbalance (For 3 phase UPS only)

Output voltage unbalance shall be checked under symmetrical load conditions and unbalance load
conditions. Phase to phase and phase to neutral output voltage are to be observed. The voltage
unbalance is the ratio of highest phase voltage minus lowest phase voltage to the average value.
Phase angle variation may be measured for phase to phase and phase to neutral voltages

6.2.17 Overload capability test

Specified values of short time overload are to be applied for specified time interval. Values of
output voltage and output current are to be recorded.

6.2.18 Short circuit current capability test

Specified short circuit current capability is to be tested by application of a short circuit to UPS
output if necessary via a suitable fuse. Short circuit current is to be recorded.

6.2.19 Short circuit fuse test

Fuse tripping capability of the UPS system is to be tested by short circuiting the UPS system
output via a specified rating of fuse. The test is carried out at an appropriate UPS load under
normal operation.

6.2.20 Restart

Manual restart to be tested after complete shut down of UPS system.

6.2.21 Output over voltage

Operation of output over voltage protection is to be checked.

6.2.22 Dynamic Response test

Output recording at different loads and operating condition to be done.

6.2.23 Harmonic components

Harmonic components of output voltage are to be recorded at no load, 50% load and 100% load
conditions. Harmonic voltages caused by UPS system components in the AC incomer side shall
be recorded at site.

6.2.24 Earth fault test

An earth fault is to be applied to the output terminal of UPS system. UPS output transients are to
be measured. An earth fault is also to be applied to the battery terminal and UPS system output
transient shall be measured.

6.2.25 Audible noise test

The audible noise is required to be measured at 1 meter distance from UPS system in at least 4 to
5 locations and its value shall be within permissible limit.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 167 OF 1216

6.3 The detailed test schedule and test procedure shall be formulated in line with above. Before giving
call for the witness of the tests, vendor shall get EIL's approval on the test procedures. Vendor
shall also indicate the max. allowable tolerance for each test result, along with the test procedures.

If tests show that certain requirements of the specifications are not met, `vendor' shall make
necessary corrections to the equipment so that it satisfies all the requirements before acceptance is
made.

7.0 SITE ACCEPTANCE TESTS

Vendor shall furnish Site Acceptance Tests procedure to be followed. Final acceptance testing
along with the batteries shall be done at site. It shall be Vendor’s responsibility to arrange
necessary instruments and tools as required by their commissioning engineer for these tests.

8.0 PACKING AND DESPATCH

All the equipment shall be divided in to several shipping sections for protection and ease of
handling during transportation .The equipment shall be properly packed for transportation by
ship/rail or trailer. The equipment shall be wrapped in polyethylene sheets before being placed in
wooden crates /cases to prevent damage to the finish. Crates /cases shall have skid bottoms for
handling. Special notations such as Fragile’, ‘This side up’, ‘ centre of gravity’, ‘weight’,
‘Owner’s particulars’, ‘PO nos.’ etc. shall be clearly marked on the package together with other
details as per purchase order. The equipment may be stored outdoors for long periods before
installation. The packing shall be suitable for outdoor storage in areas with heavy rains and high
ambient temperature unless otherwise agreed.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 168 OF 1216

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 169 OF 1216
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 170 OF 1216
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 171 OF 1216
 SPECIFICATION
FOR
MEDIUM VOLTAGE SWITCHBOARD
(B047-003-SP-6-51-0018, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 172 OF 1216

Abbreviations:

A : Ampere kVA : kilo Volt Ampere

AC : Alternating Current kW : kilo Watt
ACB : Air Circuit Breaker LV : Low Voltage
ASB : Auxiliary Service Board LED : Light Emitting Diode
BIS : Bureau of Indian Standard LDB : Lighting Distribution board
BS : British Standard LOTO : Lock-Out Tag-Out
CEA : Central Electricity Authority mA : milli Ampere
CFL : Compact Fluorescent Lamp MCC : Motor Control Center
CT : Current Transformer MCB : Miniature Circuit Breaker
CPRI : Central Power Research MCCB : Moulded Case Circuit Breaker
Institute
NO : Normally Open
CRCA : Cold Rolled Cold Annealed
NC : Normally Closed
DC : Direct Current
NEMA : National Electrical Manufacturer
EIL : Engineers India Limited Association
EPDM : Ethylene Propylene Diene PCC : Power Control Center
Monomer
PMCC : Power cum Motor Control Center
FRLS : Flame Retardant Low Smoke
PT : Potential Transformer
HDPE High-density polyethylene
PVC : Poly Vinyl Chloride
HRC : High Rupture Capacity
R-C : Resistor-Capacitor
IEC : International Electrotechnical
SWG : Standard Wire Gauge
Commission
V : Volt
IEEE : The Institute of Electrical and
Electronics Engineers VA : Volt Ampere
IP : Ingress Protection VDE : Verband Deutscher
Elektrotechniker
IS : Indian Standard
XLPE : Cross-Linked Polyethylene
kA : kilo Amperes

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 173 OF 1216

 CONTENTS

1.0 SCOPE
2.0 CODES AND STANDARDS
3.0 GENERAL REQUIREMENTS
4.0 SITE CONDITIONS
5.0 DESIGN AND FABRICATION REQUIREMENTS
6.0 SPECIFIC REQUIREMENTS OF AIR CIRCUIT BREAKER PANELS
7.0 SPECIFIC REQUIREMENTS OF FEEDERS OTHER THAN ACB FEEDERS
8.0 SWITCHGEAR MODULES
9.0 SWITCHBOARD COMPONENTS
10.0 INSPECTION, TESTING AND ACCEPTANCE
11.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 174 OF 1216

1.0 SCOPE
1.1 This specification covers the requirements of design, manufacture, testing, packing and supply
of fixed and draw out type medium voltage switchboards.
2.0 CODES AND STANDARDS
2.1 The equipment shall comply with the requirements of the latest revision of the following
standards issued by BIS unless otherwise specified.
IS : 1248 : Direct Acting Indicating Analogue Electrical Measuring Instruments
and their Accessories
IS : 2705 : Current transformers
IS : 2824 : Method for determining the proof and the comparative tracking
indices of solid insulating materials.
IS : 3156 : Voltage transformers
IS : 3231 : Electrical relays for power systems protection.
IS : 3618 : Phosphate treatment of iron and steel for protection against corrosion.
IS : 5082 : Wrought aluminum and aluminum alloy bars, rods, tubes and sections
for electrical purposes.
IS : 5578 : Guide for marking of insulated conductor.
IS: 8623 : Low voltage switchgear and control gear assemblies. Particular
requirement for bus bar trunking system.
IS : 11353 : Guide for uniform system marking and identification of conductors
and apparatus terminals.
IS : 13703 : Low voltage fuses for voltages not exceeding 1000V AC or 1500V
DC.
IS/ IEC: 60529 : Degree of protection provided by enclosures (IP Code).
IS/ IEC: 60947 : LV Switchgear and control gear.
IEC-61439 : Low voltage switchgear and controlgear assemblies
IEC-61641 : Enclosed low-voltage switchgear and controlgear assemblies - Guide
for testing under conditions of arcing due to internal fault.
2.2 In case of imported equipments, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of CEA Regulations with latest
amendments and other statutory regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by IEC/BS /
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.
2.5 In case of any contradiction between various referred standards/specifications/data sheet and
statutory regulations, the most stringent requirement shall govern and decision of owner/EIL
in this regard shall be final & binding.
3.0 GENERAL REQUIREMENTS
The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.
4.0 SITE CONDITIONS
4.1 The switchboards shall be designed to operate under site conditions of LEH (Refer elsewhere).
Suitable de-rating factor shall be considered by vendor while selection of equipment rating.
4.2 All the equipment described in this specification shall be suitable for continuous duty with the
specified ratings under the mentioned ambient conditions.
5.0 DESIGN AND FABRICATION REQUIREMENTS
5.1 Medium voltage switchboard shall be metal enclosed fully draw out or fixed, as specified in
datasheet/ job specification, free standing, floor mounting, compartmentalised, modular type
suitable for indoor installation with form of internal separation “Form-4b” as per IEC-61439

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 175 OF 1216

 (except for fixed type switchboards), unless otherwise specified elsewhere. The switchboard
shall be a type tested assembly (TTA) as per IEC-61439.
5.2 The switchboard enclosure shall be dust and vermin proof and shall provide a degree of
protection not less than IP-41.
5.3 The switchboard shall be assembled out of vertical panels of uniform height, not exceeding
2450mm in a single line up.
5.4 It shall be possible to extend the switchboard, in either direction at a later date. End of bus
bars shall be suitably drilled for this purpose. Panels at extreme end shall have openings,
which shall be covered with plates screwed to the panel.
5.5 The switchboard shall be designed to ensure maximum safety during operation, inspection,
connection of cables, relocation of outgoing circuits and maintenance, with the bus bar system
energised and without taking any special precautions.
5.6 Adequate means shall be provided to prevent shorting of power and / or control terminals due
to accidental dropping of maintenance tools etc. inside the switchboard. Checking and
removal of components shall be possible without disturbing adjacent
equipment/modules/feeders.
5.7 All identical equipments and corresponding parts shall be fully interchangeable.
5.8 The frame, of individual vertical panels shall be fabricated using pressed and cold rolled sheet
steel. The sheet steel used for panel shall be of minimum 2mm (14SWG) CRCA except the
doors and covers that may be made of 1.6mm (16SWG) CRCA. Wherever required, stiffeners
shall be provided to increase mechanical strength of large size doors and covers.
As an alternative to CRCA, Aluzinc/pre-galvanised sheet steel can also be provided for
internal inter-panel partitions only as per vendor’s standard manufacturing practices.
However, all external surfaces shall be of CRCA with specified paint shade.
5.9 The switchboard shall be provided with integral base frame for each vertical panel. The
switchboard integral base frame shall be suitable for tack welding.
5.10 All openings, covers and doors shall be provided with gaskets of Neoprene/HDPE/EPDM or
equivalent around the perimeter to make the switchboard dust and vermin proof.
5.11 All hardware shall be corrosion resistant. All joints and connections of the panel members
shall be made of galvanized or zinc passivated or cadmium plated high quality steel bolts, nuts
and washers, secured against loosening.
5.12 Suitable removable type eyebolts/ lifting hooks shall be provided for lifting of the
panel/shipping section. These eyebolts/ lifting hooks, when removed shall not leave any
opening in the panels.
5.13 Non-magnetic cable gland plates (min. 3mm thick) shall be provided for termination of single
core cables.
5.14 The switchboard shall be formed using distinct vertical panels each comprising of the
following compartments.
5.14.1 A metal enclosed horizontal bus bar compartment running at the top or rear, unless otherwise
specified.
5.14.2 Individual feeder modules in multitier mode.
5.14.3 Vertical bus bars serving all feeder modules in the vertical panel.
5.14.4 Cable termination compartment.
5.14.5 Perforated sheet steel / insulating material enclosed, horizontal auxiliary bus bars for control,
interlock, indication and metering running horizontally.
5.15 Metal sheets shall be provided between two adjacent vertical panels running upto the full
useful height of the switchboard.
5.16 MCC/MCC part of PMCC shall be of single/double front execution as specified in data
sheet/job specification. However circuit breaker panels and fixed type switchboard shall be in
single front execution only.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 176 OF 1216
5.17 Motor starter and MCCB/switch fuse modules shall not be accommodated at front and rear of
ACB Incomer and bus coupler panels.
5.18 The MCC/ASB/LDB switchboards shall be provided with castle-key interlock between
incomers and bus-coupler for manual changeover of supplies unless otherwise specified
elsewhere.
5.19 All metering and protection equipment associated with a particular circuit, as specified in data
sheet, shall be housed in separate and independent compartment earmarked for that particular
circuit and in the fixed portion of the vertical panel in case of breaker panels.
5.20 All auxiliary devices for control, reset, indication, measurement and protection such as push
buttons, control and selector switches, indicating lamps, measuring instruments and protective
relays shall be mounted on the front side of the respective compartment. The design shall be
such that all power ON/OFF or START / STOP and relay reset operations shall be performed
without opening the panel door.
5.21 Unless otherwise specified elsewhere, the switchboard assembly and components shall be
suitable for use in pollution degree 3 environment as per IS/IEC.
5.22 In open doors condition of compartment, all live parts or terminals of all door-mounted,
internal components and bus contact openings shall be IP-2X protected.
5.23 LOTO arrangement
5.23.1 Pad locking arrangement shall be provided for rack in operation of breaker as well as for the
panel door meeting LOTO requirements.
5.23.2 LOTO arrangement shall be provided be provided for each module of draw-out switchboard
PCC/PMCC/MCC etc and shall include provision for the following:
a) Provision for hooking lockout devices by multiple lock arrangement to prevent opening
of panel door and racking-in of circuit breaker.
b) Provision for attaching tag-out device for warning against energisation and to provide
information regarding date of isolation, agency working on the equipment, etc.
c) Provision for Hasp such that the same shall be put-in and closed in the locking
arrangement of the breaker/switch and panel door.
5.24 Unless otherwise specified elsewhere, the switchboard shall be designed and tested to meet the
requirements of IEC-61641 for arcing due to an internal fault of full short circuit current for
duration of 0.1 sec such that the arc is confined in the section where it occurs and adjacent
sections are not affected.
5.25 Space Heaters & Panel Illumination
The switchboard panels shall be provided with space heaters to prevent moisture
condensation. The space heater shall be located in the bottom part of each panel and shall be
supplied from 240 V AC auxiliary buses for space heater. The space heater shall be provided
with a switch, fuse or double pole MCB and thermostat having adjustable setting range of 30-
70° C. Further, one number 240V AC, 6/ 16A, 5 Pin socket for owner’s use shall be provided
inside panels. The panels shall be provided with suitable illuminating LED LAMP with switch
and fuse or MCB.
5.26 Auxiliary Bus Bars
5.26.1 Auxiliary bus bars (solid – rectangular or circular), each of minimum size 18-mm2 copper,
shall be provided for the following applications.
a) Panel space heater supply and motor space heater supply.
b) AC Control supply.
c) DC Control supply.
d) AC PT supply for energy meters, voltage operated relays etc.
5.26.2 Tee-off connectors shall be used for distributing auxiliary supply to each vertical panel.
Rubber grommets shall be used for all wire entries to make the entries dust and vermin proof.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 177 OF 1216

5.26.3 Provision for hook up of external AC space heater/ DC control supply to be provided either in
bus PT panel or bus coupler panel.
5.27 Bus Bar
5.27.1 Bus bars shall be of high conductivity electrolytic aluminium or copper supported on
insulators made of non-hygroscopic, non-inflammable material with tracking index equal to or
more than that defined in Indian standards.
5.27.2 The main bus bars shall have uniform current ratings throughout their length as specified in
data sheet/job specification. The current rating of the neutral shall be half that of the phase bus
bars. Removable neutral links shall be provided on feeders to permit isolation of the neutral
bus bar.
5.27.3 Both horizontal and vertical bus bars, bus joints and supports shall be capable of withstanding
dynamic and thermal stresses of the specified short circuit currents.
5.27.4 Only zinc passivated or cadmium plated high tensile strength steel bolts, nuts and washers
shall be used for all bus bar joints and supports.
5.27.5 The hot spot temperature of bus bars, including joints, at design ambient temperature shall not
exceed 950 C under normal operating conditions. However, for silver plated joints, the
allowable maximum temperature shall be 115°C.
5.27.6 The current rating as defined for switchboard and components in data sheet/enquiry document
are for design ambient temperature at site conditions and for being inside the cubicle at fully
loaded condition. The vendor shall suitably derate the nominal rating to suit the above
condition.
5.27.7 All bus bars shall be insulated with heat shrunk PVC sleeves of 1100 V grade. Red, yellow
and blue colour shall be used for phase bus bars and black colour shall be used for neutral bus
bars. Alternatively, colour bands at suitable intervals along PVC sleeved bus bars may be
provided. Removable type shrouds shall be provided for joints & tap off points.
5.27.8 Minimum clearance between live parts, between live parts/neutral to earth shall be 19 mm.
However clearances between terminals at components shall be as per applicable individual
standards for respective components.
5.27.9 Vertical bus bars for circuit breaker panels shall be sized depending upon the rating and
number of breakers per vertical panel. However vertical bus bars of all other panels shall be of
uniform cross section.
5.28 Wiring and Terminals
5.28.1 Inside the switchboards, the wiring for power, control, signalling protection and instrument
circuits shall be done with BIS approved FRLS, PVC/XLPE insulated copper conductor wires
having 660/1100 V grade insulation. The wiring shall preferably be enclosed in flame
retardant plastic channels or neatly bunched together.
5.28.2 PVC insulated copper conductor of cross section 1.5 mm2 may normally be used provided the
control fuse rating is 10 A or less. For higher fuse ratings minimum 2.5 mm2 copper conductor
shall be used. Each wire shall be terminated at a separate terminal. CT circuit wiring shall be
done with 2.5mm2 copper conductor.
5.28.3 Shorting links/suitable arrangement for shorting CT secondary shall be provided.
5.28.4 Each wire shall be identified at both ends by PVC ferrules.
5.28.5 Inter panel wiring within each shipping section shall be switchboard vendor’s responsibility.
For wiring between shipping sections, vendor shall provide terminal blocks on adjoining
shipping sections and supply suitable jumpering wires. Inter-panel wiring shall be taken
thorough PVC sleeves or rubber grommets.
5.28.6 A minimum of 10% spare terminals shall be provided on each terminal block.
5.28.7 Required number of single compression nickel plated brass cable glands and tinned copper
compression type lugs (for bolted terminals) for all power and control cables shall be included
in the vendor’s scope of supply, if specified in the datasheet. Sufficient terminals shall be

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 178 OF 1216

 provided on each terminal block to ensure that not more than one outgoing wire is connected
per terminal.
5.28.8 Terminal strips shall preferably be separated from power circuits by metal barriers or
enclosures. All spare input and output contacts of numerical relays, auxiliary relays,
contactors, timers, etc shall be wired up to the terminal strips/block (ensuring that two
terminals are provided for each contact).
5.29 Earthing
5.29.1 All panels shall be connected to a tinned copper earth bus bar running throughout the length of
the switchboard at the bottom of the panels.
5.29.2 The minimum earth bus size shall be 30x6 mm2 copper for fault level up to 31.5kA and 50x6
mm2 copper for fault level above 31.5kA.
5.29.3 All doors and movable parts shall be earthed, using flexible copper connections, to the fixed
frame of the switchboard. Provision shall be made at the end panels of each switchboard to
connect the earthing bus bar to the plant-earthing grid at two ends.
5.29.4 All non-current carrying metallic parts of the mounted equipment shall be earthed. Minimum
4 nos, 10 mm diameter bolts with nuts shall be provided on the earth bus for termination of
fourth core of cable per vertical panel.
5.30 Nameplate
5.30.1 A nameplate with the switchboard designation shall be fixed at the top of the central panel. A
separate nameplate giving details for each feeder compartment of all panels shall be provided.
Danger nameplate shall be provided at the front and rear of each panel.
5.30.2 The nameplates for feeder compartments shall be in two parts. One part shall have necessary
details pertaining to the compartments number of vertical panel of the switchboards. The other
parts shall be removable and shall contain all details regarding the feeder number for
drives/equipment controlled by the particular module as per approved single line diagram.
5.30.3 Blank nameplates shall be provided for all spare and vacant modules.
5.30.4 Nameplate or polyester adhesive stickers shall be provided for each equipment mounted inside
the switchboard. Special warning plates shall be provided on removable covers or doors
giving access to cable terminals and bus bars.
5.30.5 Special warning labels shall be provided inside the switchboards also, wherever considered
necessary. Identification tags shall be provided inside the panels matching with those shown
on the circuit diagram.
5.30.6 Engraved nameplates shall preferably be of 3- ply (Black-White- Black) lamicoid sheets or
anodised aluminium. However back engraved perspex sheet nameplates may also be
acceptable. Nameplates shall be fastened by screws and not by adhesives.
5.31 Painting
5.31.1 After preparation of the under surface, the panel shall be spray painted with two coats of
epoxy based final paint or shall be powder coated. The colour shade of final paint shall be as
RAL-7032, unless specified otherwise. Panel finish shall be free from imperfections like
pinholes, orange peels, runoff paint, etc.
5.31.2 All unpainted steel parts shall be zinc passivated, cadmium plated or suitably treated to
prevent rust and corrosion. If these parts are moving elements, then these shall be greased.
6.0 SPECIFIC REQUIREMENTS OF AIR CIRCUIT BREAKER PANELS
6.1 The breaker panels shall have distinct bus bar, breaker and cable compartments.
6.2 The design of each compartment shall be such as to prevent movement of vermin from a
particular compartment to any other compartment of the panel when the breaker is withdrawn
and compartment door is closed.
6.3 In order to minimise accidental access and avoid accidents due to falling tools, all the
outgoing links shall be shrouded.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 179 OF 1216

6.4 Outgoing air circuit breaker can be mounted in a maximum of two-tier execution while the
incoming/bus coupler air circuit breaker shall be in single tier execution only.
6.5 Cable Compartment
6.5.1 Separate compartment, totally enclosed from all sides, shall be provided for cable termination,
on the rear side. Access to cables shall be from the rear side after opening the cabling
compartment cover.
6.5.2 The incoming / outgoing cable termination shall be staggered for each circuit and barriers of
sheet steel or insulating material shall be provided between terminations of two circuits such
that maintenance on one circuit could be carried out while the other circuit is live. Suitable
clamping arrangements shall be provided for cables and cable termination. Terminal blocks
shall not be used for supporting the cables.
6.5.3 The incoming supply for PCC/ PMCC panels shall be through top entry bus ducts or through
bottom entry cables unless specified otherwise. The outgoing cables shall have bottom entry
unless specified otherwise.
6.5.4 The cable terminations shall be suitably sized for receiving specified number of cables per
termination and provision shall be made for terminating each outgoing cable with a separate
bolted connection. In case the total number of cables entering a particular panel cannot be
accommodated in the cabling compartment of the panel, an extension panel of full height shall
be added to the cabling compartment for accommodating extra cables. Alternatively, in view
of extra cables, provision for back to back connections of cables may be offered.
6.6 Circuit Breaker Compartment
6.7.1 The circuit breaker compartment shall be fully draw-out. Suitable guides shall be provided to
facilitate easy withdrawal of the circuit breaker.
6.7.2 The current transformers for the ammeter/protection circuits shall be mounted on the fixed
portion of the compartment. However, current transformers associated with built-in releases
may be mounted on the breaker trolley.
6.7.3 All terminals except wiping/sliding type control terminals shall be shrouded with plastic
covers to prevent accidental contact. For direct termination, clip-on shrouded type terminals
shall be provided.
6.7.4 There shall be three positions for the draw out trolley viz:
- "Service" position - In this position both power and control circuits shall be
connected. This shall be the normal operating position of the circuit breaker.
- "Test" position - The power contacts shall be disconnected in this position but the
control connections shall not be disturbed, testing provision for the entire control
circuitry shall be available in test mode including close and trip of breakers.
- "Drawout” Position - both power and control circuits shall be disconnected in this
position and breaker removed from the cubicle.
6.7.5 The circuit breaker shall be lockable in "service” and "test" positions. Safety shutters shall be
provided when the breaker is in withdrawn/drawout position.
6.7.6 The earth connection must remain connected in "Test" position; Earthing of the unit shall be
done with a "pin" or with scrapping earth connections.
6.7.7 The earth connection shall make before the main power / control contacts make and break
after the power /control contacts are disconnected. Earthing connection through a plug and
socket connection shall not be acceptable
6.7 Interlocks
Following interlocks shall be provided:
6.7.1 Compartment doors shall be interlocked against opening when breaker is in closed condition.
However, it shall be possible to defeat this interlock for inspection purposes.
6.7.2 It shall not be possible to push "in " a drawn out circuit breaker in closed condition or
withdraw a circuit breaker in closed condition.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 180 OF 1216

6.7.3 It shall be possible to operate a circuit breaker only in the defined "Full in" or "service" and
"test' position inside the panel. It shall not be possible to operate the breaker in intermediate
positions while inserting or withdrawing circuit breaker.
6.8 Any unused circuit breaker compartment shall be fully equipped and provided with
compartment door, vertical busbars and control terminals/ wiring etc. such that the same could
be used for housing outgoing breakers in future without any modifications to the panel.
7.0 SPECIFIC REQUIREMENTS OF FEEDERS OTHER THAN ACB FEEDERS
7.1 The design of drawout feeder modules shall not change for single front or double front
execution. Separate vertical bus bars shall be provided for each front side modules.
7.2 All identical feeder modules shall be interchangeable.
7.3 Each vertical panel shall have a separate cable alley. The width of this cable alley shall be
sufficient to accommodate all the cables and shall have free access for cable terminations and
in any case shall not be less than 200mm minimum. Cable alleys shall be provided with
suitable doors.
7.4 Sheet steel barrier shall be provided between individual compartments and cable alley. This
barrier shall be provided with opening for power and control connections and it shall be
possible to safely carryout maintenance work on cable connections to any one circuit in the
cable alley with the busbars and the adjacent circuits live.
7.5 Maintenance and connection of cables to any modules shall be possible without having to take
out the modules from its position from the panel.
7.6 The outgoing feeder trolleys for drawout type switchboard shall be fully drawout and shall
have the following features.
7.6.1 It shall be possible to withdraw the trolley without having to unbolt or unscrew any power and
control connections to the equipment mounted on the withdrawable trolley.
7.6.2 Both power and control connections shall be drawout type. All line and bus PTs shall be in
drawout execution only. However, outgoing modules having size more than half of the useful
vertical height of the panel may be in mixed combination of drawout /fixed type.
7.6.3 Control supply transformer modules may be provided in fixed execution.
7.6.4 The trolley withdrawal shall be by means of crank and screw arrangement. Alternatively
movement on guided rollers or swivelling guide levers for self guided movement may also be
acceptable. Plug in operation shall be independent of manual force. An insulating handle for
racking in/ out modules shall be provided, as required.
7.6.5 For drawout type feeders of size equal to or greater than half the useful vertical height of
panel, positive clamping arrangement shall be provided on the top portion of the trolley in
addition to clamping arrangement at the bottom, to ensure all round positive pressure on the
power drawout contacts once the trolley is plugged in. Alternatively, fixed execution may be
acceptable for feeder with higher rating, equal to or greater than 400A.
7.6.6 Power drawout contacts shall preferably be located towards the bottom portion of each trolley.
The trolley shall be lockable in fully plugged in position and devices shall be provided to
ensure positive plugging in. In test position, power contacts shall be totally isolated and a
device shall be provided for indication of test position. In test position, testing provision for
the entire control circuitry shall be available.
7.7 The incomer and bus tie feeders with load break switches rated 800A and above may be in
fixed execution
7.8 Various compartment sizes in a vertical panel shall be multiples of a basic dimension.
However the minimum module size for switch fuse/MCCB feeder and motor startor/contactor
feeder shall not be less than that defined in data sheet/job specification. Vertical bus bars shall
be pre-drilled at regular intervals for complete flexibility for changes in size of modules.
7.9 All switch drives other than rotary control switches, shall be lockable in 'OFF' position.
7.10 The switches/Moulded case circuit breakers /MCB shall be interlocked with the compartment
door to prevent opening of the door when the switch/ moulded case circuit breaker is in 'ON'
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 181 OF 1216
 position and to prevent switching on when the door is open. A defeat mechanism for this
interlock shall also be provided.
7.11 The maximum height of the operating handle and switches shall not exceed 1900 mm and the
minimum height shall not be below 300 mm.
7.12 Unused modules in the panel shall be fully equipped with hinged door & vertical busbars and
shall be suitable for mounting power and control terminals for starter modules and cradle for
future use.
7.13 For all the contactor controlled starter/feeder modules of MCC/PMCC, R-C circuit across the
power contactor shall be provided. Further, low burden auxiliary contactors shall be provided
in each contactor controlled motor starter modules for receiving start and stop command from
remote.
8.0 SWITCHGEAR MODULES
8.1 Switchboard shall be completely lined up in one straight row with the type and quantities of
feeders as defined in switchboard data sheet. Generally the feeders of three main categories
are identified as circuit breaker, motor starters and MCCB or switch fuse.
8.2 Starter modules required for motor control shall be of the following types and internal control
wiring of all starter modules of each type shall be identical for all ratings.
8.2.1 FVNR Full Voltage Non -Reversing starter with minimum 18 control terminals.
8.2.2 FVR Full Voltage Reversing starter with minimum 24 control terminals.
8.2.3 FVNR - HD Full Voltage Non -Reversing Heavy Duty starter with long starting time such
as for compressors and fans etc. with minimum 18 control terminals.
8.3 Switch fuse/MCCB /contactor feeder modules shall be of following types and internal control
wiring of all modules of each type shall be identical for all ratings.
8.3.1 SFU/MCCB Switch Fuse Unit or MCCB modules with no control terminals.
8.3.2 SFC/MCCB+C Switch Fuse Contactor or MCCB with contactor modules with 18 control
terminals.
8.4 Control transformer shall be provided for each FVR/FVNR/SFC starter/MCCB+C
starter/feeder modules or bus section of the PMCC/MCC switchboard having contactor
control feeders as specified in the datasheet/job specification or elsewhere. Each control
transformer of starter/feeder module shall be sized for taking control supply load of all
components of starter module. In case control transformer is provided in bus section, same
shall be sized for control supply load of entire switchboard. Switchboard having two bus
sections and coupled by bus tie shall have manual changeover switch for the control
transformers. The control transformer shall have at least 10% spare capacity. The control
transformer secondary shall be earthed at one end.
8.5 To facilitate site modification due to changes in motor KW ratings and to minimise spares
inventory, overload relays and power fuse links shall meet the following requirements.
8.5.1 All bimetal overload relays shall be separately mounted type with connecting links rated for
the maximum rating of the contactor in a starter module.
8.5.2 Bimetal overload relays of various current ranges required for motors likely to be connected to
a contactor must be identical in dimension for inter-changeability. In case offered relays are
with different dimension for any particular starter module, special mounting plate suitable for
mounting different relays shall be provided in all the modules of that size.
8.6 Heavy duty starters shall be provided with saturable type, current transformer operated;
overload relays only, which shall be suitable for motor starting time of 15-60 seconds.
8.7 All contactor controlled starter feeders shall meet the requirements of type-2 co-ordination as
per IS/IEC: 60947. However, contactor controlled motor feeders shall meet the requirements
of type-2 co-ordination as per IS/IEC: 60947 considering energy efficient motors of IE-2 type,
unless otherwise specified elsewhere.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 182 OF 1216

9.0 SWITCHBOARD COMPONENTS
9.1 Circuit Breakers
9.1.1 Circuit breakers shall be air break, draw-out type and 3/4 poles as specified in the
datasheet/job specifications. However, all ACBs of PCC/PMCC incomers and bus-coupler(s)
shall be with 4 poles unless specified elsewhere.
9.1.2 The circuit breakers shall be provided with mechanically operated emergency tripping device.
This device shall be available on the front of the panel. Mechanically operated 'closing' device
shall be provided for all breakers. However mechanical closing shall be inhibited for all
breakers in service position.
9.1.3 The circuit breakers shall be provided with minimum 4 NO + 4 NC contacts, wired and
available for owner's use. In case contacts are directly not available in breaker, auxiliary
latching type relays shall be used to multiply the auxiliary contacts of the breakers.
9.1.4 Circuit breaker’s Open and closed positions; Service and test locations and spring charged
condition shall also be indicated mechanically in addition to electrical indications.
9.1.5 Unless otherwise specified, all circuit breakers in the switchboard shall be provided with
electrical power operating mechanism. Wherever circuit breakers are provided in place of
Isolators, Breaker can be manually operated type.
9.1.6 Operating Mechanism
a) Electric power operating mechanism shall be motor wound spring charged stored
energy type. However, manual-operating mechanism may be of the spring charging
stored energy type or spring assisted type. For circuit breakers with electrical power
operating mechanism, provision shall also be made for manual spring charging.
Closing time of circuit breakers with manual operating mechanism shall be
independent of the speed of the operating handle.
b) All stored energy operating mechanisms shall be equipped with the following
features:
i) Failure of springs, vibrations or shocks shall not cause unintended operation of
breaker or prevent intended tripping operation.
ii) Closing of circuit breakers shall be prevented unless the spring is fully charged.
c) All electrical power operating mechanisms shall be suitable for remote operation and
shall be equipped with the following features:
i) Provided with universal motor operable on AC or DC control supplies.
ii) Provided with emergency manual charging facility. The motor shall be
automatically, decoupled (mechanically) once the manual-charging handle is
inserted.
iii) Closing operation of circuit breaker shall automatically initiate charging of the
spring for the next closing operation without waiting for tripping of circuit
breaker.
iv) Closing operation shall be completed once the closing impulse is given and the
first device in the control scheme has responded even though the control switch /
Push Button is released, provided no counter trip impulse is present.
9.1.7 Circuit breaker trip and closing coils, in case of electrically operated breakers and trip coil in
case of mechanically operated breakers and circuit breaker indication shall be suitable for
satisfactory operation on a control supply system indicated in data sheets/job specification.
9.1.8 Circuit breakers shall be provided with anti-pumping and trip free feature.
9.1.9 Circuit breakers shall be provided with operation counters.
9.1.10 Releases are not required to be provided with breakers where relays are used. However
breaker-having AC control supply voltage shall be provided with under voltage release unless
specified otherwise.
9.2 Switches
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 183 OF 1216
9.2.1 All switches or fuse switches shall be air break type provided with quick make/break manual
operating mechanism. The operating handle shall be mounted on the door of the compartment
having the switch.
9.2.2 Rating of switches for starter module shall meet the requirements of AC-23 duty as per IS/
IEC 60947 and minimum rating shall be as specified in job specification/data sheets.
9.3 Fuses
9.3.1 Fuses shall be non-deteriorating HRC cartridge link type.
9.3.2 Power fuses shall be pressure fitted type and shall preferably have ribs on the contact blades to
ensure good line contact.
9.3.3 It shall be possible to handle fuses during off load conditions with full voltage available on the
terminals. Wherever required fuse pullers shall be provided. The fuse base shall be so located
in the modules to permit insertion of fuse pullers and removal of fuse links without any
problem.

9.4 Contactors
9.4.1 The contactors shall be air break type, equipped with three main contacts and minimum
1NO+1NC auxiliary contacts. The main contacts of a particular contactor for motor starter
module shall have AC-3 or AC4 ratings, as specified in data sheet
9.4.2 Unless specified otherwise, the coil of the contactor shall be suitable for operation on 240 V, 1
Phase, AC supply.
9.5 Thermal Overload Relay
9.5.1 Bimetal relays shall be provided for protecting the motor from thermal overload.
9.5.2 Bimetal relays shall be manually reset type with the reset push button brought out on the front
of the panel. The reset push button shall be capable of being operated without opening the
compartment door.
9.5.3 Bimetal relays shall be positive acting ambient temperature compensated type with adjustable
setting range.
9.5.4 Bimetal relays shall have built-in single phasing prevention feature, which operates even with
50% rated current at the time of single phasing.
9.6 Moulded Case Circuit Breakers
9.6.1 MCCBs shall be provided with spring assisted quick make/ break manually operated trip free
mechanism. Wherever specified, MCCB shall be suitable for remote tripping operation and
the tripping device shall be suitable for the specified control supply voltage.
9.6.2 MCCBs shall be provided with a tripping device with inverse time characteristic for over load
protection and instantaneous characteristics for short circuit protection and MCCB rated above
125A shall preferably have adjustable settings.
9.6.3 `ON' and `OFF’ position of the operating handle of MCCB shall be displayed and the
operating handle shall be mounted on the door of the compartment housing MCCB.
9.6.4 Each MCCB shall be provided with minimum 1 NO + 1 NC auxiliary contact and 1NO
contact for tripping indication/alarm for owner’s use.
9.6.5 MCCBs shall be provided with solenoid/ motorised closing mechanism to make them suitable
for remote closing operation if specified. The closing solenoid/motor shall be suitable for
specified control supply voltage.
9.6.6 MCCB's as part of motor starter module shall be current limiting type and type tested for type-
2 co-ordination as per IS/ IEC-60947 considering energy efficient motors of IE-2 type unless
otherwise specified elsewhere.
9.7 Relays
9.7.1 Type of relay shall be numerical, static or electro-mechanical type as specified in the data
sheet /job specification.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 184 OF 1216
9.7.2 All electro-mechanical protective relays shall be back connected, of drawout type, suitable for
flush mounting, and fitted with dust-tight covers. Alternatively, "plug-in" type relays will also
be acceptable. Auxiliary relays and lock out relays are acceptable in fixed execution.
9.7.3 The protective (static or electro-mechanical type) relay cases shall have a provision for
insertion of a test plug at the front for testing and calibration purpose using an external power
supply. It shall be possible to test the relays without disconnecting the wiring and without
withdrawing the relays. The insertion of the test plug shall automatically short circuit the CTs
and permits extension of external power supply to the relay.
9.7.4 Each protective relay shall be provided with minimum 2 numbers potential free contacts of
required configuration.
9.7.5 Each tripping relay shall be of lockout type with hand reset coil cut-off contact.
9.7.6 Protective relays shall be preferably mounted on the front side and upper part of the panel and
mounting of relays on the lower portion shall be avoided.
9.8 Instrument Transformers (CTs/PTs)
9.8.1 Current transformers shall generally conform to IS: 2705 and any special requirement with
respect to numerical relay shall be taken care by the vendor.
9.8.2 For general guidance the vendor shall note that the protective current transformers shall have
an accuracy class "5 P" and an accuracy limit factor greater than "10 ". However CTs for
restricted earth fault shall be of class "PS"/"PX". Vendor shall co-ordinate the knee point
voltage, magnetising current for PS class CTs to avoid saturation and mismatching of CTs
provided at other end by other vendor.
9.8.3 Current transformers for instruments shall have an accuracy class 1.0 and accuracy limit factor
less than 5.0.
9.8.4 The current transformers in breaker feeders shall be capable of withstanding the applicable
peak momentary short circuit and the symmetrical short circuit current.
9.8.5 The voltage transformers shall be cast resin type transformers and PT shall generally conform
to IS: 3156. PT shall be provided with HRC fuses on primary side and Miniature circuit
breakers with auxiliary contact on the secondary side.
9.9 Measuring Instruments
9.9.1 All measuring instruments shall be of 96 x 96 mm square pattern, flush mounting type for
incomer and outgoing feeders in the switchboard. The accuracy class for all instruments shall
be 1.0 as per IS: 1248.
9.9.2 All auxiliary equipment such as shunts, transducers, CT, PT, etc. as required shall be included
in the supply of the switchboard.
9.9.3 All AC ammeters and voltmeters shall be of moving iron type. Ammeters for motor feeders
shall have a non-linear compressed scale at the end to indicate motor starting current and red
mark for the full load current.
9.9.3 The KW/KWH meters shall be suitable to measure unbalanced loads on 3 phases 4-wire
system. Test terminal block shall be provided for KWH meters.
9.9.4 Digital meters shall be provided, if specified in job specification/data sheets. All digital meters
shall be highly reliable, accurate, compact and self powered. Digital meter data shall be saved
in case of power failure. Field programming from front of the meter shall be possible and shall
have RS232/485 port in case specified in the job specification/data sheet.
9.10 Control Switches
9.10.1 All control switches shall be rotary type, having a cam operated contact mechanism. Switch
shall have pistol grip handle for circuit breaker control and knob type handle for other
applications.
9.10.2 Ammeter selector switches shall have make before break feature on its contacts. The selector
switch shall generally have 4 positions, three for reading 3 phase currents and the fourth
position for off. The voltmeter selector switch shall also have 4 positions. Three positions shall
be used to measure phase-to-phase voltage and fourth shall be OFF position.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 185 OF 1216
9.11 Push Buttons
Push button colours shall be as follows:
Stop /open/emergency stop : Red
Start/close : Green
Reset/test Yellow / Black /white
The stop push button shall be stay put type.
9.12 Indication
9.12.1 Clustered LED type indicating light with minimum 8mm diameter size shall be provided for
indications.
9.12.2 Breaker positions (Close, Open, spring-charged, test position, service position) electrical
indications, with colors as given below, shall also be provided:
Breaker `Closed’/ ON : Red lamp
Breaker `Open’/ OFF : Green lamp
Breaker auto-trip : Amber lamp
Trip circuit healthy : White lamp
Spring charging : Blue lamp
9.12.3 Outgoing feeder (Close, Open, trip) electrical indications, with colors as given below, shall
also be provided:
`Closed’ : Red lamp
`Open’ : Green lamp
‘Trip’ : Amber lamp
9.13 Auxiliary Relays/Contactors
Auxiliary relays/contactors shall generally be used for interlocking and multiplying contacts.
However, in the case of numerical relays, the interlocking logic shall be built in the relay
itself.
9.14 Timers
For re-acceleration duty, timers shall be electronic type or static type. The time settings, where
specified, shall be accurately set before despatch of the switchboard. Timer provided for
control of capacitor feeder and re-acceleration feeders shall have minimum setting of 0-5
minutes.
9.15 Miniature Circuit Breaker
MCB shall provide high mechanical and electrical life, reliable protection of circuits against
overload and short circuit and shall have minimum breaking capacity of 9kA unless otherwise
specified. Positive ON/OFF indication shall be provided.
10.0 INSPECTION, TESTING AND ACCEPTANCE
10.1 During fabrication, the switchboard shall be subject to inspection by EIL / Owner, or by an
agency authorised by the Owner, to assess the progress of work, as well as to ascertain that
only quality raw material is used. The manufacturer shall furnish all necessary information
concerning the supply to EIL / Owner's inspectors.
10.2 For testing requirements refer Inspection & Test Plan No. 6-81-1018. Prior notice of minimum
4 weeks shall be given to EIL/owner for witnessing the final testing of the complete assembly
to ensure satisfactory operation of all components. Tests shall be carried out at manufacturer's
works under his care and expense.
10.3 Vendor shall provide certificates to prove that the design of switchgear/switchboard has been
successfully type tested as per IEC-61439 and IEC-61641(for arcing due to internal faults).

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 186 OF 1216

11.0 PACKING AND DESPATCH
All the equipment shall be divided into several shipping sections for protection and ease of
handling during transportation .The equipment shall be properly packed for selected mode of
transportation i.e. by ship/rail or trailer. The panels shall be wrapped in polyethylene sheets
before being placed in wooden crates /cases to prevent damage to the finish. Crates /cases
shall have skid bottoms for handling. Special precaution notations such as ‘Fragile’, ‘This side
up’, ‘Centre of gravity’, ‘weight’, Owner’s particulars, Purchase order number etc. shall be
clearly marked on the package together with other details as per purchase order.
The equipment may be stored outdoors for long periods before installation. The packing
should be suitable for outdoor storage in areas with heavy rains and high ambient temperature
unless otherwise agreed. A set of instruction manuals for installation, testing and
commissioning, a set of operation & maintenance manuals and a set of final drawing shall be
supplied duly enclosed in a waterproof cover along with the shipment.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 187 OF 1216

 SPECIFICATION
FOR
BATTERY CHARGER

(B047-003-SP-6-51-0019, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 188 OF 1216

Abbreviations:
AC : Alternating Current
Ah : Ampere-hour
BIS : Bureau of Indian Standards
BS : British Standard
CEA : Central Electricity Authority
CFL : Compact Fluorescent Camp
CRCA : Cold Rolled Cold Annealed
DC : Direct Current
DCDB : Direct Current Distribution Board
IEC : International Electrotechnical Commission
IEEE : Institute of Electrical and Electronics Engineers
IP : Ingress Protection
IS : Indian Standard
LED : Light Emitting Diode
MCB : Miniature Circuit Breaker
MCCB : Moulded Case Circuit Breaker
MR : Material Requisition
MSL : Mean Sea Level
NEMA : National Electrical Manufacturers Association
Ni-Cd : Nickel Cadmium
PO : Purchase Order
PVC : Poly Vinyl Chloride
RFI : Radio Frequency Interference
RMS : Root Mean Square
UPS : Uninterrupted Power Supply
V : Volt
VDE : Verband Der Elecktrotechniker, Elektronik und Information stechnik
VRLA : Valve Regulated Lead Acid

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 189 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 SITE CONDITIONS

5.0 TECHNICAL REQUIREMENTS

6.0 INSPECTION, TESTING AND ACCEPTANCE

7.0 PACKING & DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 190 OF 1216

1.0 SCOPE
This specification covers the design, manufacture, testing at manufacturer’s works, packing
and supply to site of Battery Chargers and Distribution Boards.
2.0 CODES AND STANDARDS
2.1 The equipment shall comply with the requirements of latest revision of the following
standards issued by BIS/ IEC:
IS 5 Colours for ready mixed paints and enamels.
IS 1248 Direct acting indicating analogue electrical measuring instruments and
accessories.
IS 3700 Essential rating and characteristics of semi-conductor devices.
IS 3715 Letter symbols for semi-conductor devices.
IS 4411 Code of designation of semi-conductor devices.
IS 5001 Guide for preparation of drawings for semi-conductor devices and
integrated circuits.
IS 5469 Code of practice for the use of semi-conductor junction devices.
IS 6619 Safety code for semiconductor rectifier equipment.
IS 7204 Stabilised power supplies DC output.
IS 12021 Control transformers for switchgear and controlgear for voltages not
exceeding 1000VAC.
IS 13703 Low voltage fuses for voltages not exceeding 1000VAC or 1500VDC.
IS/ IEC 60947 Low voltage switchgear and control gear.
IEC 60146 Semiconductor converters.

2.2 In case of imported equipment, the standards of the country of origin shall be applicable, if
these standards are equivalent or more stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of CEA regulations with latest
amendments and other statutory regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between various referred standards/ specifications/ datasheets and
statutory regulations, the most stringent requirement shall prevail and Owner’s/ EIL’s
decision in this regard shall be final and binding.
3.0 GENERAL REQUIREMENTS
The offered equipment shall be brand new with state of the art technology and a proven field
track record. No prototype equipment shall be offered.

4.0 SITE CONDITIONS

The Battery Chargers shall be suitable for installation and satisfactory operation under site
conditions of LEH as specified elsewhere. Suitable de-rating factor shall be considered by
vendor while selection of equipment rating.
5.0 TECHNICAL REQUIREMENTS
5.1 Input Power Supply
5.1.1 The Battery Chargers shall be suitable for input power supply as defined in the data sheet. If
not specified therein, these shall be suitable for the following input power supply:
Voltage : 415V + 10%
Frequency : 50 Hz + 3%

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 191 OF 1216

 In addition to the above variations, the input voltage may be subject to transient variations
comprising of voltage dips up to 20% of normal voltage during motor start-up, voltage
interruptions during short circuits as well as frequency variations due to large motor start-up.
The Battery Chargers shall operate satisfactorily with a total harmonic distortion of up to 5%
in the input power supply.
The Battery Chargers shall also be designed to operate satisfactorily while drawing input
power from an emergency diesel generator set.
5.1.2 The incoming power supply to the Battery Charger system shall be provided by 2
independent feeders. One feeder shall supply power to each rectifier.
5.2 Battery Charger
5.2.1 Design Basis
5.2.1.1 The Battery Charger system shall have two chargers (Charger-1 & Charger-2). Both
chargers shall be of identical design and rating. The battery to be connected to the chargers
shall be of Nickel Cadmium/ flooded electrolyte Lead Acid/ VRLA type as indicated in the
data sheet. Battery Chargers for flooded Lead Acid and Nickel Cadmium batteries shall be
sized to provide quick charging of the battery within a duration of 10 hours. Battery
Chargers for VRLA battery shall be sized to provide quick charging of the battery up to 90%
of rated Amperehours within a duration of 24 hours and to 100% within 4 days. Each
charger shall be sized for the most stringent of the following duty conditions, whichever is
higher:

a. Offline quick charging of the battery assembly. The charger shall be sized as under:

Charger rating in Amps. = 0.14 Ah(C 10 ) of battery (for Lead Acid battery)
= 0.2 Ah(C 10 ) of battery (for VRLA battery)
= 0.2 Ah(C 5 ) of battery (for Nickel Cadmium battery).

b. Online float charging of the battery assembly while feeding the complete DC load.
The charger shall be sized as under:

Charger rating in Amps. = 1.15 x Average DC load + float charging current

(Average DC load = Area under the battery duty cycle/ battery duty cycle duration).
5.2.1.2 Each charger shall have a 3 phase full wave, controlled rectifier bridge with protective
devices.
5.2.1.3 Independent current limits shall be provided for charger load current and battery charging
current. Subsequent to a discharge cycle and completion of quick charging, when battery is
connected to charger under float mode, the battery current shall be monitored, controlled and
limited to set value automatically irrespective of the value of load current. Fast acting semi-
conductor fuses shall be provided for protection against internal short circuits. In case of
external short circuits, the chargers shall be protected by rapid shutdown of the semi-
conducting power devices. The high speed semi-conductor fuses used for rectifier protection
shall be complete with trip indication.
5.2.1.4 Filter circuits consisting of smoothing choke and condenser, complete with protection to
limit the ripple content at the output, shall be provided.
5.2.1.5 Silicon blocking diodes shall be provided in the charger output circuit to prevent back-feed
from battery into the charger and filters.
5.2.1.6 Protection against reverse battery connection and DC earth fault relay for earth leakage
detection shall be provided.
5.2.1.7 Silicon blocking diodes (min. 4 nos.) connected to 80% tap of the battery bank shall be
provided to maintain continuity in the DC supply to the load.
5.2.1.8 Internal cooling of the charger unit shall preferably be by natural ventilation. If forced air
cooling is necessary, a redundant air cooling fan shall be provided. The charger components
shall be capable of delivering their rated output with one forced air cooling fan out of
service. Under this condition, maximum continuous temperature of components shall not
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 192 OF 1216
 exceed the permissible limits. In case of chargers with forced cooling, loss of ventilation
alarm/ trip with override facilities shall be provided.
5.2.1.9 Selection, sizing and suitability of all components used for various applications shall be
vendor's responsibility and the rating of components shall be increased, if required, to suit
associated components during execution of the order without any claim for extra price or
time.
5.2.1.10 The DC system shall be unearthed. However, a high impedance earth fault relay shall be
provided for the protection of the battery.
5.2.1.11 Each charger shall be galvanically isolated from the input power supply by providing a
double wound transformer at its input. The transformer shall be natural air cooled, dry type
suitable for location inside a panel.
5.2.1.12 An RFI filter shall be provided to suppress the radio frequency interference to permissible
limits. The production of radio frequency interference voltages shall not exceed the value of
suppression grade N as defined in VDE-0875.
5.2.1.13 Transient/ surge protection devices shall be provided in the input circuit of chargers to
protect them against surges & voltage spikes.
5.2.1.14 The Chargers shall be designed to draw power from mains supply at a minimum power factor
of 0.85 lag while sharing the rated load in normal operating configuration.
5.2.1.15 The chargers shall be designed to ensure that the harmonic component in the input currents
are limited so as not to cause undue harmful effects on other sensitive equipment operating
on the same supply bus. Suitable filters/ harmonic traps shall be provided, as required, for
this purpose.
5.2.1.16 All breakers shall be adequately rated for the required continuous rating and breaking
capacity as applicable. Paralleling of breaker/ switch/ contactor poles to achieve the required
current rating is not acceptable. All output isolating devices shall be double pole type. The
DC contactors shall be operated with a DC control supply using ON/ OFF selector switches
and not push buttons.
5.2.1.17 All the thyristors, diodes and other power electronic devices shall be protected with high
speed semiconductor fuses. I²t co-ordination between fuse and semi-conducting power
devices shall be ensured.
5.2.1.18 The Battery Chargers shall be specifically designed to limit float and quick charging voltages
to the battery to limits recommended by the battery manufacturer. Output voltage shall be
limited to maximum +10% of nominal system voltage when the battery is float charged
while feeding the load. Vendor shall specifically ensure that the charger output voltage does
not exceed the recommended limits of operation under any conditions of internal/ external
fault or operation, including:
- Filter capacitor fuse failure of either charger
- DC output switch OFF of either charger
- DC output fuse blown of either charger.
Other specific current/ voltage limits during normal charging/ operation of the chargers shall
also be incorporated in the design of the chargers.
5.2.2 Operation and Performance
5.2.2.1 Operation (Option – I)
The DC system shall comprise of 2 Nos. Float cum quick Chargers (each rated for 100%
capacity) with 1 set of battery (Refer typical scheme block diagram option – I).

a. Normal operation requires that the battery assembly shall be float charged
simultaneously by both Chargers-1 & 2 while feeding the DC load, the chargers thus
operating in parallel and equally sharing the total load.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 193 OF 1216

 b. However in case of failure of either of the chargers, the other charger shall float
charge the battery while feeding the complete DC load. Faulty charger shall
automatically get disconnected from the healthy system.
c. In case of AC mains failure, the battery shall continue to supply the load.
d. The process of changeover from float to quick charging and reverting from quick to
float charging shall be selectable in Automatic or Manual mode by means of an Auto/
Manual selector switch. In Automatic mode, the changeover from float to quick
charging shall be initiated through a current sensor, set at a preset value. Similarly, the
changeover from quick to float charging shall also be automatic based on current
sensing. In Manual mode, both change over from float to quick charging and from
quick to float charging shall be performed manually using push buttons. When quick
charging mode is selected, the battery charger shall initially charge the battery under
constant current mode followed by constant voltage (finishing charging) mode or as
per the battery manufacturer’s recommendation. Changeover from constant current to
constant voltage (finishing charging) mode shall be fully automatic. A backup
synchronous or digital timer shall also be provided for initiating the changeover to
float mode by default after a preset time period. The timer range shall be 0 to 24 hours
or the nearest available as per manufacturer’s standard range.
e. In the event of failure of the charger feeding the load, when battery is being quick
charged by the other charger, continuity in DC supply shall be maintained from the
battery to the load through 80% tap of the battery bank followed by full battery
supplying the load through contactor C-2 (refer block diagram Option – I).
f. Interlock shall be provided to ensure that when either of the chargers is selected in
quick charging mode, it will be disconnected from both the DC load and the other
charger operating under float charging mode.
g. The chargers shall have facility for manual mode of operation in the event of failure of
controller under closed loop control. The selection shall be done through Auto/
Manual selector switch.
h. Energisation of contactor for DC critical lighting shall be initiated by means of an AC
mains failure relay complete with Auto/ Manual selector switch, On/ Off push
buttons etc.

5.2.2.2 Operation (Option – II)

a) The DC system shall comprise of 2 nos. Float cum quick Chargers (each rated for
100% capacity) and 2 sets of Batteries (each of the battery sets rated for 50% AH
capacity unless specified otherwise in datasheet/ job specification). (For typical
scheme, refer block diagram Option - II).
b) Normal operation requires that Battery–1 shall be float charged by Charger-1 while
Battery-2 shall be float charged by Charger-2. In this case both the chargers 1 and 2
shall feed the DC load by operating in parallel and equally sharing the total load.
c) Selection of Float / quick mode shall be Automatic or Manual based on the position of
selector switch for Auto / Manual selection.
d) In case of failure of either of chargers, the other charger shall float charge both the
batteries while feeding the complete DC load. Faulty charger shall automatically get
disconnected from the healthy system.
e) In case of AC mains failure, both the batteries shall continue to supply the load.
f) After restoration of power supply, one of the Charger (say Charger-1) shall float
charge Battery-1 and also feed the complete DC load while the other Charger-2 shall
quick charge Battery-2. Upon completion of quick charge of Battery-2, Charger-2
shall switchover to float mode and shall float charge Battery-2 and also feed the
complete DC load while the other Charger-1 shall switchover to quick mode and shall
quick charge Battery-1.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 194 OF 1216

 g) The process of changeover from float to quick charging and reverting from quick to
float charging mode shall be selectable in Automatic or Manual mode by means of
Auto / Manual selector switch.
h) In automatic mode, the changeover from float to quick charging shall be initiated
through a current sensor set at a preset value. Similarly, the changeover from quick to
float charging shall also be automatic based upon current sensing and through timer.
i) In manual mode, both the changeovers i.e. from float to quick charging and from
quick to float charging shall be performed using push buttons. When quick charging
mode is selected, one of the battery charger (say Charger-1) shall initially charge the
battery under constant current mode followed by constant voltage (finishing charging)
mode or as per the battery manufacturer’s recommendation. Changeover from
constant current to constant voltage (finishing charging) mode shall be fully
automatic. A back-up synchronous or digital timer shall also be provided for initiating
the changeover to float mode by default after a preset time period. The timer range
shall be 0 to 24 hours or the nearest available as per manufacturer’s standard range.
j) In the event of failure of charger feeding the load (say Charger-1), when Battery-2 is
being quick charged by the other Charger-2, Charger-2 shall changeover to float mode
and continuity of 100% DC supply to the load shall be maintained from the Charger-2
while float charging both Battery-1 as well as Battery-2 after providing suitable time
delay.
k) In an event of AC mains failure, when one of the Charger (say Charger-1) is float
charging the Battery-1 and supplying the 100% DC load while the other Charger-2
was quick charging Battery-2, continuity of 100% DC supply to the load shall be
maintained from Battery-1 (through 100% tap). Further, Battery-2 (which was being
quick charged) shall also be made available, after providing suitable time delay, to
feed the DC load by operating in parallel with Battery-1 and sharing the total load.
l) Interlock shall be provided to ensure that when either of the chargers (say Charger-1)
is selected in quick charging mode, it will be disconnected from both the DC load as
well as the other Charger-2 operating under float charging mode.
m) The chargers shall have facility for manual mode of operation in the event of failure of
controller under closed loop control. The selection shall be done through Auto/Manual
selector switch.
n) Energisation of contactor for DC critical lighting shall be initiated by means of an AC
mains failure relay complete with Auto/Manual selector switch, On/Off push buttons
etc.
5.2.2.3 Performance
a. Both chargers shall be of solid state design, constant voltage and current limit type.
The output voltage shall be stabilised to within +1% of set value in float charging
mode for mains steady state voltage and frequency variation of +10% and +3%
respectively, and load variation of 10 to 100% at any temperature up to the design
ambient temperature specified in the data sheet. However, the variation in output
voltage can be up to +2% for chargers with rated output voltage up to 24V.
b. Under constant current quick charging condition, the DC output current shall be
maintained within +2% of set value.

The output voltage dynamic response of the charger unit with battery disconnected
shall not vary more than +10% of nominal output voltage in the event of step load of
up to 50% of the rated output. The output voltage shall be restored to a value within
the steady state limits within 250 msec.
c. The maximum allowable RMS ripple voltage, with battery disconnected, shall be
equal to or less than 2% of the nominal output voltage.
d. The maximum noise level from the chargers measured at 1 metre distance in any
position, at any load between 0- 100% with all normal cooling fans running shall not
exceed 75 dB(A).
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 195 OF 1216
5.2.2.4 Controls
The minimum controls shall include but not be limited to those shown in the block diagrams
(OPTION-I or OPTION-II as applicable):
5.2.2.5 Panel Metering and Indication
These shall include but are not limited to those shown in the block diagrams (OPTION-I or
OPTION-II as applicable):
LEDs provided for indication shall be cluster type with adequate brightness and minimum 2
Nos. LEDs chips per light. LEDs shall be connected in parallel and each LED chip having
diameter not less than 3mm.
5.2.2.6 Annunciation
Static type audio-visual annunciator with annunciation windows, acknowledge, test and reset
push buttons and hooter shall be provided on each charger for the following annunciations.
Any additional relays/ components, including DC undervoltage relay and current sensors,
required for this purpose shall be provided in the chargers. Facility for bypassing the audio
alarm on each charger shall also be provided.

- DC under voltage
- DC overvoltage
- DC earth leakage
- AC incoming power supply failure
- AC input fuse blown-off
- Thyristor/ diode failure or Thyristor/ diode protection fuse failure
- DC output fuse blown-off
- DC battery fuse blown-off
- Filter Capacitor fuse blown-off
- Load on Battery (using current direction sensing with time delay)
- Battery undervoltage/ Disconnected during discharge (using zero current sensing)
- Cubicle fan failure/ cubicle temperature high (for chargers with forced cooling).
One summary alarm potential-free contact each for Battery, Charger-1 and Charger-2 shall
be wired to terminal block for remote annunciation.

5.2.2.7 Printed Circuit Boards (PCBs)

PCBs used in the chargers shall be made of glass epoxy material. The PCBs shall be firmly
clamped in position so that vibration or continued usage do not result in loose contacts. All
PCBs shall be fitted in a manner to avoid replacement of a PCB by a wrong spare card. The
PCBs shall be provided with visual light emitting diode (LED) status indications, monitoring
points/ test connections and setting potentiometers in a readily accessible location which is
visible without removing the PCBs.
5.2.2.8 Vendor shall provide adequate protection to the system.
5.3 Construction of Chargers/ Distribution Board
5.3.1 Each Battery Charger and DC distribution board shall be housed in a separate free standing
cubicle with minimum IP-31 degree of protection. All panels shall be of the same height so
as to form a panel line up which shall have good aesthetic appearance. Chargers-1 & 2 shall
be installed side by side whereas DCDB may be located separately and interconnected to the
charger through cables. The DCDB shall accommodate outgoing feeders as desired. Each
panel shall be provided with a LED lamp of required wattage with a door operated switch
and a thermostatically controlled MCB protected space heater.
The DCDB shall be compartmentalised with each outgoing feeder housed in a separate
compartment. Cable alley of minimum 200mm width with suitable supports shall be
provided for the termination of cables for each vertical arrangement of outgoing feeders in
DCDB.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 196 OF 1216

5.3.2 The Chargers, DCDB and Cell Booster enclosures shall be fabricated from structural/ CRCA
sheet steel. The frames shall be fabricated by using minimum 2 mm thick CRCA sheet steel
while the doors and covers shall be made from minimum 1.6 mm thick CRCA sheet steel.
Wherever required, suitable stiffeners shall be provided. The panels shall be provided with
suitable louvers for ventilation backed by wire mesh. They must be suitable for use in a
tropical climate. Hinged doors shall be provided at the front and back as required. Inter panel
sheet steel barriers shall be provided.
5.3.3 Bus bars shall be colour coded and live parts shall be shrouded to ensure complete safety to
personnel intending routine inspection by opening the panel doors. All the equipment inside
the panel and on the doors shall have suitable nameplates and device tag numbers as per the
schematic diagram. All wires shall be ferruled and terminals shall be numbered.
5.3.4 The DCDB incomer and main bus bars shall be rated based on the maximum load current
considering an additional 10% design margin for contingencies. The rating shall be selected
from standard available ratings and shall be adequate for the expected short circuit current.
The bus bar voltage shall be higher than the recommended quick charging voltage for the
system. The insulation for all equipment where provided shall be heat resistant, moisture
proof and tropicalised.
5.3.5 All power and control switches shall be rotary/ cam operated type. All power switches shall
be air insulated load break type. Vendor shall ensure that all equipment/ components such as
incomer switches, outgoing DC switches, MCCBs, push buttons, indicating lamps, charger
mode selector switches, voltage control switches, annunciator windows etc. are suitably
located on the charger and distribution board door such that they can be operated without
opening the front door. Power switches shall be provided with a door interlock. In case of
difficulty in installation on the charger front panel door, the AC incoming power switches,
DC outgoing switches and MCCBs may be installed within the panel provided that they are
operable after opening the front panel door. However, all other selector/ control switches,
push buttons, indicating lamps, annunciators, meters etc. shall necessarily be installed on the
front panel door as specified above.
5.3.6 All instruments shall be switchboard type, back connected and maximum 96 x 96 mm
square size. Accuracy class of all meters shall be 1%. Digital meters capable of displaying
different parameters can be considered subject to Owner’s/ EIL’s approval. Analogue
instrument scales shall have a red mark indicating maximum permissible operating rating.
5.3.7 All fuses shall be link type and shall be located inside the panel. Diazed fuses shall not be
accepted.
5.3.8 All power and control wiring connections within the panels shall be carried out with 660V
grade, PVC insulated, Flame Retardant Low Smoke (FRLS), BIS marked wires having
stranded copper conductors. However, copper strip connections shall preferably be used for
currents exceeding 100A. Control wiring for electronic circuits/ components shall be
through flat ribbon cable or copper wire of minimum 0.5mm diameter. Ferruling of wires
shall be as per relevant IS.
5.3.9 For all cabling external to panels, power cables shall be with aluminium/ copper conductors
and control cables shall be with copper conductors. All cable connections shall be from the
bottom of the panel. Removable bolted undrilled gland plates shall be provided along with
single compression type nickel plated brass cable glands for all external cable connections.
Separate test terminals shall be provided for measuring and testing the equipment to check
performance.
5.3.10 A suitably sized earth bus shall be provided at the bottom of the panels running through the
panel line up with provision for earth connections at both ends to owner's main earth grid.
All potential free metallic parts of equipment shall be suitably earthed to ensure safety.
5.3.11 The maximum height of the operating handles/ switches shall not exceed 1800 mm and the
minimum height shall not be below 300 mm.
5.3.12 All components/ devices/ feeders shall be provided with screwed nameplates and lettering
shall be of minimum 6 mm height.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 197 OF 1216

5.3.13 Panels shall undergo manufacturer’s standard cleaning and painting cycle. After preparation
of the under surface, the panel shall be painted with two coats of epoxy based final paint.
Colour shade of final paint shall be 631 of IS 5/ RAL 7032. All unpainted steel parts shall be
suitably treated to prevent rust formation. If these parts are moving elements, then they shall
be greased.
5.4 Cell Booster
Cell booster shall be suitable for charging one to six cells within the time duration specified
at Cl.5.2.1.1. It shall be suitable for charging not only new cells before being introduced to
the battery bank but also for any treatment to be given to individual weak cells. Cell booster
shall be suitable for 240 V + 10%, 50 Hz + 3% SPN input power supply. Cell booster output
voltage shall be in the range of 0-18V and 0-12V for Lead Acid and Nickel Cadmium
batteries respectively. Cell booster shall be sized as under:

For Lead Acid battery = 0.14 x Ah(C 10 ) of cell

For VRLA battery = 0.2 x Ah(C 10 ) of cell
For NiCd battery = 0.2 x Ah(C 5 ) of cell.
Cell booster shall have a heavy duty switch fuse or MCCB on both AC incomer and DC
output sides, along with AC voltmeter, DC ammeter, DC voltmeter and indicating lamps for
AC/ DC power ON. The output voltage and current of cell booster shall be manually
controlled using a suitably rated variac or a full wave controlled rectifier bridge. Suitable
interlock shall be provided so as to ensure that the variac/ controlled rectifier is at its
minimum position while switching on the cell booster. Cell booster shall be portable type
with wheels. Each cell booster shall be supplied with 5 m long flexible copper conductor,
PVC insulated braided cables for both AC incoming power supply and DC output
connection to the battery. An industrial type 3 pin 15A plug shall be provided on AC
incoming cable end and lugs shall be provided on DC outgoing cable end.
5.5 Reliability
All necessary care shall be taken in selection, design, manufacture, testing and
commissioning of the equipment for ensuring high system reliability. The following design
considerations shall be taken into account to ensure maximum availability of the system:
5.5.1 There shall be no common device between the two units, the failure of which could cause
shutdown of more than one charger.
5.5.2 It shall be possible to attend to any individual power circuit for maintenance without
affecting the total DC supply.
5.5.3 Series-parallel combination of smaller devices to achieve specified rating shall not be
acceptable.
6.0 INSPECTION, TESTING AND ACCEPTANCE
6.1 During fabrication, the equipment shall be subjected to inspection by EIL / Owner or by an
agency authorised by the Owner. Manufacturer shall furnish all necessary information
concerning the supply to EIL’s/ Owner's inspector. Tests shall be carried out at
manufacturer's works under his care and expense.

7.0 PACKING & DESPATCH

All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for transportation by ship/ rail
or trailer. It shall be wrapped in polythene sheets before being placed in crates/ cases to
prevent damage to finish. The crates/ cases shall have skid bottoms for handling. Special
notations such as ‘Fragile’, ‘This side up’, ‘Center of gravity’, ‘Weight’, ‘Owner’s
particulars’, ‘PO Nos.’ Etc., shall be clearly and indelibly marked on the packages together
with other details as per purchase order.
The equipment may be stored outdoors for long periods before installation. The packing
shall be completely suitable for outdoor storage in areas with heavy rains and high ambient
temperature. A set of instruction manuals for installation, testing and commissioning, a set
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 198 OF 1216
 of operation & maintenance manuals and a set of final drawing shall be supplied along with
the shipment duly enclosed in a waterproof cover.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 199 OF 1216

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 200 OF 1216
 SPECIFICATION
FOR
ENGINE STARTING BATTERY
AND CHARGER
(B047-003-SP-6-51-0030, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 201 OF 1216

Abbreviations:

AC : Alternating current
Ah : Amperehour
BIS : Bureau of Indian Standards
BS : British Standards
CEA : Central Electricity Authority
DC : Direct Current
FRLS : Flame Retardant Low Smoke
Hz : Hertz
IEC : International Electrotechnical Commission
IEEE : Institute of Electrical & Electronics Engineers
IP : Ingress Protection
IS : Indian Standard
kA : KiloAmperes
LED : Light Emitting Diode
MSL : Mean Sea Level
NEMA : National Electrical Manufacturers Association
PCB : Printed Circuit Board
PIV : Peak Inverse Voltage
PO : Purchase Order
PVC : Polyvinyl Chloride
SPN : Single Phase and Neutral
TPN : Three Phase and Neutral
VDE : Verband der Elektrotechnik, Elektronik und Information stechnik
V : Volt
XLPE : Cross-linked polyethylene

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 202 OF 1216

 CONTENTS

1.0 SCOPE
2.0 CODES AND STANDARDS
3.0 GENERAL REQUIREMENTS
4.0 POWER SUPPLY AND SITE CONDITIONS
5.0 REQUIREMENTS FOR BATTERY UNITS
6.0 REQUIREMENTS FOR BATTERY CHARGER
7.0 CONTROL, PROTECTION, METERING AND INDICATION
8.0 SPECIAL REQUIREMENTS
9.0 INSPECTION AND TESTING
10.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 203 OF 1216

1.0 SCOPE

1.1 This specification covers the design, manufacture and testing at works of Engine Starting
Battery and Charger System. The offered system shall form a part of a larger package
involving a Diesel Engine as Prime Mover. It shall be completely integrated with and
suitable for the engine starting power requirements. All equipment and accessories
required for completeness of the system, whether specifically mentioned or not, but
considered essential for satisfactory performance shall be included as a part of the system.

1.2 Each engine shall be provided with separate batteries, charger and distribution panel.

2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the requirements of latest revision of the following
standards issued by BIS unless specified otherwise:

IS 5 Colours for ready mixed paints and enamels

IS 1248 Direct acting indicating analogue electrical measuring

Parts-1,2,8,9 instruments and their accessories

IS 7372 Lead Acid Storage Batteries for motor vehicles

IS 12021 Control transformers for switchgear and controlgear for

voltages not exceeding 1000V AC

IS 13703 Low voltage fuses for voltages not exceeding 1000V AC or

Parts-1 & 2 1500V DC

2.2 In case of imported equipment, the standards of the country of origin shall be applicable if
these standards are equivalent or more stringent than the applicable Indian standards.

2.3 The equipment shall also conform to the provisions of CEA regulations with latest
amendments and other statutory regulations currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.

2.5 In case of any contradiction between various referred standards/ specifications/ data sheets
and statutory regulations, the most stringent requirement shall prevail and owner’s/ EIL’s
decision in this regard will be final and binding.

3.0 GENERAL REQUIREMENTS

3.1 The offered equipment shall be brand new with state of the art technology and having
proven field track record. No prototype equipment shall be offered.

3.2 The vendor shall be responsible for design, engineering and manufacturing of the
complete system to fully meet the intent and requirements of this specification and
attached data sheets. The Battery Charger equipment shall be properly coordinated with
the selected Battery to ensure complete compatibility.

3.3 The Battery shall meet the requirements of data sheets and specifications attached with the
Material Requisition/ Bid document.

4.0 POWER SUPPLY AND SITE CONDITIONS

All equipment shall be designed to operate with power supply and site conditions as
specified below :

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 204 OF 1216

4.1 Power Supply

Unless specified otherwise, the power supply having below mentioned details shall be
provided by purchaser at one point for each engine:

Voltage : 415V + 10%, TPN / 240V±10%, SPN

Frequency : 50Hz + 5%

4.2 Site Conditions

The Engine starting battery and charger shall be suitable for operating satisfactorily under
site conditions of LEH as specified elsewhere, suitable de-rating factor shall be considered
by vendor while selection of equipment rating with minimum temperature of 100C for
battery sizing. Unless specified otherwise, all equipment shall be suitable for installation
and operation on the package skid, which shall be located in a closed building with
restricted ventilation.

5.0 REQUIREMENTS FOR BATTERY UNITS

5.1 The batteries shall be lead acid, high discharge automotive type conforming to IS 7372
and suitable for engine starting duty. The battery containers shall be of high quality
translucent plastic/ hard rubber. Terminal posts shall be properly sealed to prevent
electrolyte leakage. Venting device shall be anti-splash type. Batteries shall be placed on
battery stands made of mild steel with suitable epoxy painting/PVC coating. All
accessories like cell insulators, connectors, stand insulators etc. shall be supplied with each
set. All hardware shall be suitably coated/ plated to prevent corrosion.

5.2 Ampere-hour capacity of the battery shall be selected based on the load cycle (to be
decided by the vendor), Ageing factor of 0.8 and temperature correction factor for
specified minimum temperature. The battery capacity shall be adequate for six consecutive
starts of the engine under cold engine conditions without recharging, with an additional
10% spare capacity. All auxiliary loads for engine controls shall also be considered while
defining the load cycle. Also, refer clause 8.0 for Engines for Fire Water Pumps.

5.3 The battery shall be suitable for being quick charged from a fully discharged condition to a
fully charged condition within 10-14 hours.

5.4 The following accessories shall be provided for preventive and routine maintenance of the
batteries at each location where the engines are to be installed:

1 no. Hydrometer (syringe type)

1 no. Thermometer
1 no. Cell testing voltmeter with leads (Center zero type)
1 pair Rubber gloves
1 no. Spanner
1 no. Acid resistant jug and funnel
1 no. Teak wood holder for the hydrometer.

6.0 REQUIREMENTS FOR BATTERY CHARGER

6.1 The charger shall be suitable for both float charging the battery while feeding all loads,
other than engine starting motor, as well as for quick charging the battery from fully
discharged condition to fully charged condition within 10-14 hours. The sizing of the
battery charger shall be based on the maximum continuous rating required to meet the
above conditions, with an additional 10% spare capacity. All DC loads for engine controls
and continuously operating auxiliaries shall also be considered for this purpose.

6.2 The charger shall be of solid-state design, constant voltage and current limit type. The
output voltage shall be stabilized to +1% for mains variation of +10% and load variation
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 205 OF 1216
 of 0 to 100%. Each load shall be fed through a separate independent feeder. However, a
separate DC Distribution Board is not essential for this purpose and the outgoing feeder
circuits can form a part of the charger panel.

6.3 The charger shall be of three phase, full wave/ half wave controlled rectifier (as per
manufacturer's standard) consisting of thyristors, commutation circuits, diodes etc. and
their protective devices.. A suitable filter circuit shall be provided at the rectifier output to
obtain a smooth DC output voltage. The maximum ripple content in the charger output
voltage shall be lower than the safe value recommended by battery manufacturer, and in
any case, shall not exceed 5% with battery disconnected.

6.4 The charger shall have auto as well as manual control facility through a lockable selector
switch.

6.4.1 Auto Mode

In the Auto mode, the charger shall automatically control the battery charging current/
voltage to ensure optimum quick charging of the battery. After completion of boost
charging, the charger shall switch to float charging mode without any manual intervention.

6.4.2 Manual Mode

In the Manual mode, it shall be possible to charge the battery at any desired current, which
is safe for the battery. Fine control of the output voltage/ current shall be possible.

6.4.3 In both Auto and Manual modes, the battery charging current shall be limited to a safe
value as prescribed by battery manufacturer by means of adjustable potentiometer control.
A backup timer of 0-24 hrs. range with no-volts hold feature shall be provided for
switching the charger from quick charging to float charging mode after the set time, under
any mode of operation.

6.5 The charger shall be complete with all interconnections within the panel. All connections
shall be made using 660V grade copper conductor PVC/XLPE insulated FRLS wires/
cables with BIS marking for both power and control connections. Minimum 1.5mm2
conductor size shall be used for control connections. However, control wiring for
electronic circuits/ components may use flat ribbon cable or copper wire of minimum
0.5mm diameter. All control wiring shall be enclosed in PVC channels or otherwise neatly
bunched together. Each wire shall be suitably identified at both ends by PVC ferrules.
Crimping type lugs shall be used for termination.

6.6 All main and control transformers shall be natural air cooled, dry type suitable for location
inside a panel. All semiconductor devices shall be natural air cooled with absolute case
temperatures limited to 750C at highest load and ambient temperature. PCBs shall be of
copper clad glass epoxy laminate construction. PCB tracks shall be tinned and solder
masked. PCBs shall be tropicalised to render them immune to dust, moisture and fungal
growth.

6.7 Selection, sizing and suitability of all components used for various applications shall be
vendor's responsibility and the rating of components shall be increased, if required, to suit
associated components during execution of the order without any claim for extra price or
time. Series-parallel combination of smaller devices to achieve specified rating shall not
be acceptable.

6.8 A suitably sized earth bus of minimum size 25x3 mm² copper shall be provided at the
bottom of the panel with provision to connect it to the owner's main earth grid at both
ends.

6.9 The charger shall be preferably housed in a 1.6/ 2mm thick sheet steel enclosure having
minimum IP-41 degree of ingress protection. The panel shall be free standing, floor
mounted type with hinged doors and shall be suitable for bottom cable entry. The

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 206 OF 1216

 maximum and minimum operating height shall be 1800mm and 300mm respectively.
Eyebolts shall be provided on the top cover for lifting. When removed, the eyebolts shall
not leave any openings in the panel.

6.10 The charger panel surface shall be properly pretreated for final painting with 2 coats of
epoxy paint of shade 631 as per IS 5/RAL 7032. Epoxy based powder coating of adequate
thickness for rugged industrial use shall also be acceptable. Nameplates shall be of
anodized aluminium or stainless steel.

7.0 CONTROL, PROTECTION, METERING AND INDICATION

The Charger shall be provided with the following features:

7.1 Controls

• Auto/ Manual selector switch

• ON/ OFF switch for incoming power supply
• Float/ Quick charging selector switch
• Potentiometer for coarse and fine control of output voltage
• Backup Timer.

7.2 Protection

• Fault protection on input and output circuits

• Suitable semiconductor fuses for all thyristors and semiconducting power devices.

7.3 Metering

• AC input voltmeter and ammeter with selector switch

• DC output voltmeter and ammeter
All meters shall be of 72 x 72 mm square size with accuracy class 1.5.

7.4 Indication

The following minimum indications shall be provided:

• AC power ON (for each phase)

• Charger in ‘Float Charging’ condition (Yellow)
• Charger in ‘Quick Charging’ condition (Green)
• Charger failure (Amber)

Indicating lamps shall employ LEDs. LEDs provided for indication shall be cluster type
with adequate brightness and minimum 2Nos LEDs chips per light. LEDs shall be
connected in parallel and each LED chip having diameter not less than 3mm. In addition,
facility for remote indication of AC and DC failure shall be provided.

8.0 SPECIAL REQUIREMENTS

In addition to the above, Engines for Fire Water Pumps which are provided with backup
manual starting using an electric starter motor, shall have the following features:

8.1 A separate identical battery bank shall be provided for Manual starting.

8.2 The charger shall be suitable for charging both battery banks for Automatic and Manual
starting in position.

8.3 The battery charger shall be fully rated for trickle charging both the battery banks
simultaneously.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 207 OF 1216

8.4 Both battery banks for Automatic and Manual starting shall each be adequate for ten
consecutive starts without recharging with a cold engine under full compression in place
of six consecutive starts specified at clause 5.2.

9.0 INSPECTION AND TESTING

9.1 Batteries shall have been fully Type tested and certificates for the same shall be furnished.
In addition, the batteries shall be tested as per applicable standards at battery
manufacturer's works for the required duty cycle and other relevant acceptance tests.

9.2 High voltage withstand test (2 kV for 1 minute) shall be carried out on each charger.

9.3 Heat Run Test

Heat Run test at rated load and minimum supply voltage shall be carried out on each
charger for a period not less than 8 hours. During the test, the temperature of electronic
power devices should stabilize and remain constant for 1 hour, or the test shall be suitably
extended until this is achieved.

9.4 Functional tests shall be carried out on each charger to check the design and operation.

9.5 All equipment shall be subject to inspection by EIL/owner or by an agency authorized by

the owner, to assess the progress of work. The manufacturer shall furnish all the necessary
information concerning the supply to EIL/owner’s representative. EIL/owner’s
representative shall be given free access in the works from time to time for stage wise
inspection and progress reporting. Four weeks advance notice shall be given to witness the
final routine test and other tests as agreed upon.

10.0 PACKING AND DESPATCH

All the equipment shall be divided into multiple sections for protection and ease of
handling during transportation. The equipment shall be properly packed for selected mode
of transportation, i.e. by ship/ rail or trailer. It shall be wrapped in polythene sheets before
being placed in crates/ cases to prevent damage to finish. The crates/ cases shall have skid
bottoms for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Center of
gravity’, ‘Weight’, ‘Owner’s particulars’, ‘PO No.’ etc., shall be clearly and indelibly
marked on the packages together with other details as per purchase order.

The equipment may be stored outdoors for long periods before installation. The packing
shall be completely suitable for outdoor storage in areas with heavy rains and high
ambient temperature unless otherwise agreed. In order to prevent movement of equipment/
components within the crates, proper packing supports shall be provided. A set of
instruction manuals for erection, testing and commissioning, a set of operation and
maintenance manuals and a set of final drawings shall be supplied along with the shipment
duly enclosed in a waterproof cover.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 208 OF 1216

 SPECIFICATION
FOR
SOFT STARTERS
FOR
MOTORS
(B047-003-SP-6-51-0036, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 209 OF 1216

Abbreviations:
AC : Alternating Current
BIS : Bureau of Indian Standards
BS : British Standard
CEA : Central Electricity Authority
CFL : Compact Fluorescent Lamp
CIMFR : Central Institute of Mining and Fuel Research (formerly CMRI)
CRCA : Cold Rolled Cold Annealed
CW : Cooling Water
DC : Direct Current
DCS : Distributed Control System
DOL : Direct On Line
ECS : Electrical Control System
EM : Electromagnetic
HV : High Voltage
IEC : International Electro technical Commission
IEEE : Institute of Electrical and Electronics Engineers
IEGT : Injection Enhanced Gate Transistors
IGBT : Insulated Gate Bipolar Transistor
IGCT : Insulated Gate Commutated Transistor
I/O : Input/Output
IP : Ingress Protection
IS : Indian Standard
LED : Light Emitting Diode
mA : Milliampere
MCB : Miniature Circuit Breaker
MTBF : Mean Time Between Failure
MTTR : Mean Time to Repair
NEMA : National Electrical Manufacturer’s Association
PLC : Programmable Logic Controller
PO : Purchase Order
PVC : Poly Vinyl Chloride
SGCT : Silicon Gate Commutated Transistor
THD : Total Harmonic Distortion
V BO : Break Over Voltage
VDE : Verband Deutscher Electrotechniker

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 210 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 SITE CONDITIONS

4.0 GENERAL REQUIREMENTS

5.0 TECHNICAL REQUIREMENTS

6.0 INSPECTION, TESTING AND ACCEPTANCE

7.0 CERTIFICATION

8.0 PACKING AND DESPATCH

1.0 SCOPE
1.1 The scope of this specification is to define the minimum technical requirements for the
design, manufacture, testing and supply of Soft Starters for AC Motors.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 211 OF 1216
1.2 Soft starter shall be 3-phase, solid state, reduced voltage (V/F controlled or Voltage
controlled as specified in data sheet) type motor controller for controlling & ensuring smooth
starting of motors. Soft starter shall be provided with microprocessor based control to soft
start and stop the motor. Soft starters shall have ability to limit the starting current to the
specified limits as specified in data sheet. Soft starter shall have either anti-parallel
technology or V/F controlled type as defined in data sheet.
The Vendor shall be responsible for engineering and functioning of the complete system,
meeting the intent and requirement of this specification and data sheets.
2.0 CODES AND STANDARDS
2.1 The equipment shall comply with the latest editions of the following standards unless
specified otherwise:
IS:325 Three-phase Induction Motors
IS:3700 Essential Ratings and Characteristics of Semiconductor Devices
IS:3715 Letter symbols for semi-conducting devices
IS:4411 Code of designation of semi-conducting devices
IS:5001 Guide for preparation of drawings of semiconductor devices &
Integrated Circuits
IS:5469 Code of practice for the use of semiconductor Junction Devices

IS:8789 Values of Performance characteristics for Three Phase induction motor

IS:12615 Energy Efficient Induction Motors – Three Phase Squirrel Cage
IS:12729 Common specification for High-Voltage Switchgear and Controlgear
standards
IS:14901 Semi-conductor devices- Discrete devices & Integrated Circuits
IS:15880 Three Phase Cage Induction motors when fed from IGBT Converters-
Application Guide
IEC:60146-1-3 Semiconductor Convertors general requirements and line commutated
convertors-Transformer & reactors
IEC:61800 Adjustable speed electrical power drive systems
IEC: 61378-1 Converter transformer for industrial application

IEEE:519 Recommended Practices and requirements for Harmonics Control in

Electrical Power Systems
IS/IEC-60034-1 Rotating Electrical Machines Rating & Performance
IEC-62271-100 HV Switchgear & Controlgear – Circuit Breaker
IEC-62271-200 HV Switchgear & Controlgear
EN-50178 Electronic Equipment for use in Power Installation
2.2 In case of imported equipment, the standards of the country of origin shall be applicable if
these standards are equivalent or stringent than the applicable Indian standards.

2.3 The equipment shall also conform to the provisions of CEA Regulations and other statutory
regulations currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.

2.5 In case of any conflict between requirements specified in various applicable documents, the
most stringent one shall prevail. However, owner’s decision in this regard shall be final and
binding.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 212 OF 1216
3.0 SITE CONDITIONS
3.1 The `soft starter system shall be designed to operate under specified site conditions of LEH
(refer elsewhere). Suitable de-rating factor shall be considered by vendor while selection of
equipment rating.
3.2 The soft starter shall be installed indoors in a non-hazardous area, in non-air-conditioned /
pressurized room, as specified in data sheet.
3.3 All the equipment shall be designed suitable for continuous duty as per nameplate rating
under the specified ambient conditions.

4.0 GENERAL REQUIREMENTS

4.1 The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.
4.2 Vendor shall ensure proper co-ordination with the driven equipment supplier in selection /
sizing of offered soft starter system.

5.0 TECHNICAL REQUIREMENT

5.1 Performance Requirement:
5.1.1 The system shall be designed as standard product and shall provide very high reliability, low
vibration / wear & noise. It shall be easy to install in minimum time and expense and no
special tools shall be required for routine maintenance.
5.1.2 Soft Starters shall have a compact, solid-state, three-phase Electronic controllers consisting of
a set of thyristors/IGBT/IGCT/IEGT/SGCT in all three phases.
5.1.3 By-pass shall be provided by vendor for normal running of motor after soft start-up.
5.1.4 The sequence logic for control, start up and stoppage, shifting to bypass of soft starter shall be
built up as per the operating philosophy of the load.
5.1.5 In the soft start mode, the motor voltage shall be gradually increased with step less control of
voltage through phase control of the switching devices with acceleration ramp time. The
following modes of operation shall be provided in the controller as a minimum:
• Soft Start mode with selectable Kick start.
• Current Limit start mode with selectable Kick start.
• Soft stop.
If soft starter fails, it shall be possible to run the motor with bypass in circuit with full voltage.
5.1.6 The rated operating voltage of the soft starter shall be as specified in data sheet. The control
voltage shall be 240 V AC, 50 Hz, single phase unless specified otherwise in data sheet.
5.1.7 Separate parameter setting shall be possible such as staring voltage/current, ramp up etc.
5.1.8 The starting voltage shall be adjustable from 40% to 100% with stepless control.
5.1.9 Adjustable ramp up time for soft starting shall be provided, suitable for driven load
characteristic.
5.1.10 Soft Starter shall be able to adjust the starting current from 1.0 to 3.0 times the rated current of
the motor.
5.1.11 Reset / restarting option after overload tripping shall be settable in Manual / Automatic mode
It shall have built-in protection, diagnostic features, as well as the facility to communicate with
various network protocols.
5.1.12 The soft start system shall be designed to deliver the motor input current and torque for the
complete speed torque characteristics of the driven equipment, with input supply variation of
±10% and frequency variation of ±3%. The system shall be suitable for the load characteristics
and the operational duty of the driven equipment. It shall be capable of withstanding the
thermal and dynamic stresses and the transient mechanical torque, resulting from short-circuit.
5.1.13 All electrical components such as transformers, switches, contactors, reactors, bus bars etc.
shall be rated 125% of the maximum required rating. All electronic devices including
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 213 OF 1216
 thyristors, transistors, diodes, IGBT, IGCT, IEGT, SGCT (as applicable) etc. shall be rated
under operating conditions for approximately 200% of the maximum current carried by the
device.
5.1.14 The soft starter controller shall be equipped with microprocessor based digital regulator with
programmable functions. The power control regulator logic shall provide for an
acceleration/deceleration current limit curve and shall be capable of field adjustments without
shutting the system down. Linear acceleration and deceleration shall be separately
programmable from 0.1 to 20 seconds.
5.1.15 The total harmonic distortion (THD) of the voltage and current at inverter output shall be as
per IEC 61800 and same shall be also considered in the design of the motor. The dv/dt limits
& Vpeak shall also be as per IEC-61800-2.
5.1.16 Harmonics at the supply side of the soft starter system shall be restricted within the maximum
allowable levels of current and voltage distortion as per recommendations in the latest edition
of IEEE-519.
5.1.17 Maximum noise level from the soft starter system at 1-meter distance, under rated load with all
normal cooling fans operating shall not exceed 85 dBA.
5.1.18 Un-shielded cable shall be used for connection between soft starter & motor. Length between
soft starter & motor shall be considered as per data sheet & vendor shall supply the output
filter accordingly.
5.2 Control Requirement
5.2.1 The system shall be suitable for number of starts as per attached EIL specification / Data sheet.
5.2.2 The power controller shall be controlled to always start the motor in the forward direction.
Logic shall be provided to prevent the motor from being started in the reverse direction.
5.2.3 Soft starter shall be provided with synchronizing equipments and PT at input and/or output
side as specified.
5.3 Panel Construction
5.3.1 Upstream breaker `ON/OFF/TRIP’ indications and upstream breaker closing and trip push
buttons shall be provided on the front door.

5.3.2 Safety Interlock shall be provided so that power cabinet can’t be opened unless the upstream
breaker is disconnected, safety-grounding switch is closed and DC link capacitor is
discharged. Power source breaker can only be closed once the earthing switch is open and
panel door is closed with lock defeat facility.
5.3.3 The soft starter shall be suitably housed in sheet steel panels and shall be fabricated using cold
rolled sheet steel. The sheet steel used for the panel shall be of minimum 1.6 mm CRCA. The
panel shall be suitable for indoor installation, if not otherwise specified. The panel shall be
free standing with degree of enclosure protection as IP-41. Maximum and minimum operating
height shall be 1900 mm and 300 mm respectively.
5.3.4 Bolted un-drilled gland plate shall be provided at bottom. Clamp type terminals shall be used
for connection of all wires up to 10 mm2 and terminal for higher sizes shall be bolted type
suitable for cable lugs. Minimum space for power cable termination shall be 300 mm for upto
1100V system and 600mm for above 1100V system (unless specified otherwise) clear from
bottom of the cable gland plate. All equipment shall be complete with cable glands, lugs etc.
and cable glands shall be single compression type for indoor equipment unless specified
otherwise.
5.3.5 The soft starter system panel(s) shall have isolated compartments as follows:
- Main power bus and ground bus compartment
- Power cell compartment
- Low voltage compartment
5.3.6 Bus bars shall be of electrolytic aluminum, sleeved, color coded separately for AC and DC
system. All the live parts shall be sleeved / shrouded to ensure complete safety to personnel

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 214 OF 1216

 intending to carry out routine inspection by opening the panel doors. All the equipment inside
the panel and on the doors shall be provided with suitable nameplate.
5.3.7 All the switches, component and accessories which are essential for normal and emergency
operation shall preferably be mounted on the door and shall be operable externally. All the
analogue instruments, where provided, shall be switchboard type, back connected & of size
96x96mm. Scale shall have red mark indicating maximum permissible operating rating.
5.3.8 Each panel shall be provided with illuminating LED lamp with switch and fuse. 5/15A, 240V
power socket with switch and fuse shall be provided. Each panel shall have space heater with
switch fuse and variable setting thermostat.
5.3.9 Copper earth bus of min. 30x6 sq.mm. up to short circuit withstand capacity of 31.5kA and
50x6 sq.mm. for a short circuit withstand capacity above 31.5kA shall be provided in the panel
with provision for connection to owner’s plant earth grid. All the non-metallic
components/parts shall be connected to the main earth bus bar. Separate earth bus bar and stud
for electronic control system if required shall be provided.
5.3.10 All panels shall be of same height so as to form a uniform line-up & to give good aesthetic
appearance.
5.3.11 All the control wiring shall be enclosed in plastic/ metal channel. Each wire shall be identified
at both ends by self-sticking wire marker tapes or PVC ferrules. Power and control wiring
inside the panel shall be done with BIS approved, PVC insulated, fire retardant, low smoke,
copper conductor wire 1.5mm2 size wire shall normally be used provided the control fuse
rating is 10 Amps or less and 2.5 mm2 size for control fuse rating above 16 A for electrical
circuits and 0.5mm² for electronic circuits. All wires shall be ferruled and terminals shall be
properly numbered, minimum 20% spare terminals shall be provided.
5.3.12 All electronic modules and components shall be accessible from front of panel only. Modular
assemblies for both the system i.e. control electronic equipments and power electronic
equipments shall be used.
5.3.13 Low voltage compartment and cabling shall be electrically and physically separated from the
high voltage compartment. Metal or glass polyester barriers shall be provided between the low
voltage compartment and the power cell and/or main power bus compartment. Personnel shall
have access to the low voltage compartment, with the controller energized, without being
exposed to any High voltage.
5.3.14 DC link capacitor and pre-charging & discharging circuit shall be preferably mounted in the
rear of the panel.
5.3.15 Suitable eyebolts/ lifting clamps/ strap & cradle arrangement shall be provided for lifting of
the panel/shipping section. The bolts, when removed shall not leave any opening in the panel.
5.3.16 Acrylic type transparent insulating material shall be used for covering live components.
5.3.17 Soft start system keypad, operator control panel required for control, monitoring and
measurements shall be supplied and installed outside the panel on the front door. It shall be
accessible for operation without opening the front door and shall be non-removable type.
5.3.18 The soft starter panel shall be naturally cooled. Cooling system shall have adequate cooling
airflow path, module cooling fan and if necessary, panel cooling fan. Vendor shall ensure that
the panel dimensions and flow paths have been designed for continuous running at the
specified ambient without overheating. Necessary starters shall be provided within the panels
for the Ventilation fans. For fan cooled soft starters, redundant ventilating fans (N+1) shall be
provided. In case redundant cooling fan is not possible to be mounted in the panel, same shall
be supplied loose.
5.4 Equipment/ Component Specification
5.4.1 Converter Transformer/ Output transformer
a. The converter transformer shall be dry type or oil filled type as specified in the data
sheet. In case of the dry type transformer, it shall be mounted in the soft starter panel
unless specified otherwise in the datasheet. Offered transformer shall be as per
enclosed EIL Specifications/data sheet.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 215 OF 1216

 b. Converter duty transformer shall be sized based on the fundamental component of
current & voltage drawn by motor. Over & above the calculated fundamental apparent
power, K-factor to be considered as per respective IEC standard on account of
handling of non-linear device. Finally, heat run test to be conducted on job transformer
to ensure that temperature rise at winding is within acceptable limit (refer Table-3 of
IS-2026 Part-2).

c. Drive out put transformer considered only for the purpose of meeting standard rated
motor voltage i.e. 3300, 6600V, 11000V shall not be provided unless otherwise agreed
between purchaser and the manufacturer.
5.4.2 Power Converter
a. The static power converter shall consist of a line side power converter for operation as
a rectifier and a load side power converter for operation as a fully controlled inverter.
Power converter shall be fast switching, most efficient and low loss type.
b. Adequate short circuit and over voltage protection shall be provided for the converter
and inverter system.
c. All power converter devices shall include protective devices, snubber networks and
dv/dt networks as required.
d. All power diodes shall be of silicon type with minimum V BO rating as 2.5 times the
rated operating voltage.
e. The conversion devices and associated heat sinks shall be assembled such that
individual devices can be replaced without requiring the use of any special
precautions/tools.
f. The cooling system of the electronic components, if provided, shall be monitored and
necessary alarms shall be provided to prevent any consequential damage to the power
control devices.
g. Offered system shall also take into account the distance between Drive panel and
motor and system shall include all material and accessories such as filter to make
system suitable for a distance of 350m unless otherwise specified in the data sheet.
h. Soft starter shall have integral thermal sensor to trip and disengage the soft starter on
heat sink over temperature.
5.4.3 DC Link Reactor
a. Smoothing reactors for the DC link shall be designed to sufficiently decouple the
rectifier and inverter portion of the converter and to limit fault currents in this circuit.
b. Unless otherwise specified, the reactor shall be air-cooled or fan cooled type located
within the panel.
c. Reactor shall be suitable for operation with the non-sinusoidal current wave shapes
and DC components under all operational conditions of the system without exceeding
its temperature limits.
5.4.4 Output Filter
Soft starter output current waveform shall be inherently sinusoidal with harmonic limits as
specified in this specification. Output filter shall be provided, if required. Output filter
capacitors shall be provided with discharge circuits to ensure that all residual stored charge is
reduced to less than 50 V DC within 300 seconds after a loss of AC voltage. All capacitor
shall be maintenance-free and self-healing type.
5.4.5 Bypass Feature

a. Bypass feature along with motor protection relay and output side isolator/breaker shall
be provided by purchaser for input voltage 3.3kV & above whereas for input voltage
lower than the 3.3kV, same shall be provided by vendor unless otherwise specified in
the datasheet. All necessary interlocks as required for safe and reliable operation of
soft start system along with bypass feeder and output side isolator/breaker considered
by Purchaser shall be provided in the soft start system.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 216 OF 1216
 b. In case, bypass feature is provided by vendor, same shall be in separate compartment
and switching scheme shall be such that in case soft starter system mal-operation, the
motor could be taken on bypass control manually, while the soft starter could be
attended independently. Suitable interlock shall be provided such that bypass mode
and soft start mode shall not operate simultaneously.

c. Soft start panel with bypass feature shall also include MCB for motor space heater,
auxiliary power supply if required for local panel, panel space heater etc. in the bypass
section and same shall be included and mounted in an easily accessible location.

5.5 Protection, Control, Metering, Indication and Annunciation

5.5.1 The soft starter system vendor shall provide all the necessary system control, protection,
alarm and metering equipment for the entire drive system and its auxiliary equipment.
5.5.2 Automatic sequence control shall include start-up of cooling system, auxiliary system of the
motor, interlock checking, automatic start and run-up of drive, planned and emergency
shutdown. The same shall be processed through microprocessor-based system.
5.5.3 Operator Control Panel
a. Each drive shall be equipped with a front mounted operator control console consisting
of a backlit alphanumeric LCD display and a programmable keypad with keys for
parameterization and adjusting parameter which shall not be limited to Start/Stop,
Local/Remote, Auto/Manual, Increase/Decrease, menu navigation and protection and
measurement parameter selection, etc.
b. All parameter names, fault messages, warnings and other information shall be
displayed in complete english words or standard English abbreviations to allow the
user to understand the display without the use of a manual or cross-reference table.
This shall also be used for the modification of all electrical values, configuration
parameters, drive menu parameters, application and activity function access, faults,
local control, adjustment storage, self-test and diagnostics. Keypad shall be operable
with password for changing the protection setting, safety interlock etc. However, the
parameters such as measurements, setting, mode of drive etc. shall be allowed to be
viewed without any password.
c. Operator console shall have facility/ port to connect external hardware such as Laptop
etc. Console shall have facility to upload and download all parameter settings from
one drive to another identical drive for start-up and operation.
d. System control shall also have facility to receive tripping signal from upstream
breaker for tripping and also provision for closing upstream breaker after all required
process parameters are achieved.
e. User-friendly software for operation and fault diagnostic shall be loaded in the drive
system panel before commissioning.
5.5.4 Protective Features
The system shall incorporate adequate protective features, properly coordinated for the drive
control and for the motor but not limited to the following:
i. Incoming line surge protection
ii. Under / Over voltage protection
iii. Phase loss protection.
iv. Programmable over current protection and under load protection.
v. Inverter Fault.
vi. Over frequency/Over speed of motor
vii. Ventilation loss (In case same is not provided, drive shall generate an over
temperature fault alarm and suitable sensors, as required for same, shall be provided).
viii. Over temperature tripping of equipment by sensing temperature of heat sink .

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 217 OF 1216

 ix. Specific motor protection like no. of consecutive starts beyond acceptable limit, long
start time, locked rotor including motor winding, bearing temperatures, over-current,
overload, negative phase sequence and earth fault protections etc.
x. System earth fault protection.
xi. Shorted SCR.
xii. Prompt for modified / alteration in parameters setting
xiii. Additional protection, if any for the drive system
5.5.5 Control
The following controls shall be provided as a part of the Operator Control Panel or through
separate switches. Provision shall be provided for interfacing with field/ control room at soft
start as well as by-pass mode.
i. Start/Stop
ii. Auto/Manual /Test mode
v. Local/Remote
vi. Emergency stop
vii. Start/Stop for bypass starter (where specified)
viii. Trip-Remote Breaker
5.5.6 Indications
Vendor shall provide indications as required for normal operation and for ease of
maintenance, which shall not include but not limited to the following indications.
i. Motor running through Starter
ii. Motor running on by-pass (DOL)
iii. Starter in stop mode
iv. Inverter Fault
v. Rectifier fault
vi. Starter ready to start
vii. AC mains ON
viii. Motor over speed
ix. Rectifier output 'ON'
x. Motor zero speed
xi. Remote breaker trip
xii. Motor stopped
Above indications may be provided as a part of the operator control panel, i.e. door mounted
keypad or through hardwired LEDs. LEDs provided for indication shall be cluster type with
adequate brightness and minimum 2 Nos LEDs chips per light. LEDs shall be connected in
parallel and each LED chip having diameter not less than 3mm.
Potential free contacts shall be wired in terminal strip separately for remote indications in
DCS system.
5.5.7 Metering
Digital display of the following parameters shall be as a part of the Operator Control Panel,
selectable by the operator.
i. Output voltage
ii. Output current-soft start mode/ Bypass mode
iii Output frequency
iv Drive thermal state
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 218 OF 1216
 v. Motor speed
vi. Necessary transducer shall be provided with 4-20mA output for indicating motor
speed and motor current in DCS unless otherwise specified for other parameters.
5.5.8 Audio-visual Annunciations
a. The system shall incorporate audio-visual annunciations for protection, for various fault
conditions, for the Drive motor, Supply cables, DC Reactor and the Converter, out put
transformer etc.
b. Alarms shall also be included for the failure of various auxiliaries together with
identification of the failing unit, loss of cooling system, various protection devices
provided for converter transformer etc.
c. Audio-visual window annunciations shall be provided on the front of the panel. All
annunciations as required for normal and satisfactorily operation of the drive system
shall be included as per vendor standards. These annunciations can be part of operator
console panel or separately mounted type.
d. Vendor shall include audio-visual alarm as required for normal operation and
maintenance of the system including but not be limited to the following.
i. Rectifier fuse failure/Drive fault
ii. Main AC failure
iii. Inverter fuse failure/Drive fault
iv. Inverter overload
v. Inverter high temperature/Drive fault
vi. Cooling system failure
vii. Motor failed to start/Drive fault
viii. Transformer failure (if applicable)
ix. Motor temperature high
x. Harmonic filters monitoring
All drive internal faults will be annunciated as drive fault.

Common potential free contacts shall be provided for above annunciations and these
shall be wired up to terminal block for owner's use for remote alarm and monitoring.
5.6 Fault Diagnostic
Fault diagnostic shall be built into the system to supervise the operation and failure of the
system. Auxiliary supply to the system components or to the electronics (firmware) for the
diagnostics / display shall be taken care by the manufacturer for this purpose.
5.7 External Power supply for auxiliary and Control Circuit
Auxiliary power supply for devices external to soft starter module, space heater supply for
Motor (as applicable for Bypass feature), panel space heater, auxiliary power supply for
cubicle LED lamps, indicating lamps, digital meters etc. shall be 240 volts single phase AC
supply provided by purchaser.
Power supply for motor space heater shall be interlocked with bypass circuit.
All control circuit shall operate at maximum voltage of 240V AC or 220V DC unless
otherwise specified in the datasheet.
Vendor shall include supply of all control transformers, protective devices, associated
accessories etc. and any other control supply voltage required for the system shall be derived
by the vendor from the power supply made available by purchaser.
5.8 Reliability Features
The expected lifetime of the soft starter shall be min. 20 years.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 219 OF 1216

5.9 Software
PC based software for start-up & commissioning of soft starter shall be provided. The
software shall allow the user to perform the following:
- Setting of soft starter parameters
- Copying of parameter sets to and from a soft starter
- Document/print out set up
- Servicing & fault analysis set up
One CD-ROM of such software shall also be supplied along with soft starter panel.
5.10 Maintenance features
The controller design shall incorporate the following maintenance features:
- Modular construction
- All components shall be easily accessible.
- Standard diagnostics to aid maintenance personnel. These shall include LED or
alphanumeric displays, test or measurement points.
5.11 Painting
5.11.1 After preparation of the under surface, the panel shall be spray painted with two coats of
epoxy based final paint or shall be powder coated. The colour shade of final paint shall be as
RAL 7032, unless specified otherwise. Panel finish shall be free from imperfections like
pinholes, orange peels, runoff paint, etc.
5.11.2 All unpainted steel parts shall be zinc passivated, cadmium plated or suitably treated to
revent rust and corrosion. If these parts are moving elements, then these shall be greased.
6.0 INSPECTION, TESTING AND ACCEPTANCE
6.1 During fabrication, the soft starter shall be subject to inspection by EIL / Owner, or by an
agency authorized by the Owner, to assess the progress of work, as well as to ascertain that
only quality raw material is used. The manufacturer shall furnish all necessary information
concerning the supply to EIL / Owner's inspectors.
6.2 All tests shall be carried out at the manufacturer's works under his care and expense. The
tests shall be witnessed by EIL/ Owner or of an agency authorized by the owner. Prior notice
of minimum 4 weeks shall be given to the inspector for witnessing the tests.
6.3 All Routine & Type Tests shall be conducted as per the standards. However, combined test
for soft starter and motor at vendor’s works shall be carried out if specified in the datasheet.
6.4 String Test with driven equipment
If a string test with driven equipment is specified in the data sheet of the driven equipment, it
shall be carried out with the job equipment.
7.0 CERTIFICATION
The motors and associated soft starter system equipment shall have test certificates issued by
recognized independent test house (CIMFR/ BASEEFA/ LCIE/UL/FM or equivalent) as
applicable.
8.0 PACKING AND DESPATCH
All the equipment shall be divided in to several shipping sections for protection and ease of
handling during transportation. The equipment shall be properly packed for selected mode of
transportation i.e. ship/rail or trailer. The equipment shall be wrapped in polyethylene sheets
before being placed in wooden crates/cases to prevent damage to the finish. Crates/cases
shall have skid bottoms for handling. Special notations such as ‘Fragile’, ‘This side up’,
‘Weight’, ‘Owner’s particulars’, ‘PO nos.’ etc., shall be clearly marked on the package
together with other details as per purchaser for scrutiny.
The equipment may be stored outdoors for long periods before installation. The packing
shall be completely suitable for outdoor storage, in areas with heavy rains/high ambient
temperature.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 220 OF 1216

 SPECIFICATION
FOR
EMERGENCY GENERATOR
(B047-003-SP-6-51-0040, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 221 OF 1216

Abbreviations:

AC Alternating Current
AMF Automatic Start on Mains failure
AVR Automatic Voltage Regulator
BIS Bureau of Indian Standard
BS British Standards
CACA Closed circuit air cooling with air to air heat exchanger
CT Current Transformer
DC Direct Current
DG Diesel Engine Driven Generator
DOL Direct On Line
EIL Engineers India Limited
GI Galvanised Iron
IEC International Electro-technical Commission
IEEE Institute of Electrical & Electronics Engineers
IS Indian Standard
KVA Kilo Volt Amperes
MR Material Requisition
NEMA National Electrical Manufacturers Association
PCB Printed Circuit Board
PMG Permanent Magnet Generator
PO Purchase Order
PT Potential Transformer
PTR Proven Track Record
PVC Poly Vinyl Chloride
REF Restricted Earth Fault
RTD Resistance Temperature Detector
SWG Standard Wire gauge
TPN Three Phase and Neutral
VDE Verband Deutscher Elektrotechniker

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 222 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 SITE CONDITIONS

4.0 GENERAL REQUIREMENTS

5.0 PERFORMANCE REQUIREMENTS 5

6.0 DESIGN AND CONSTRUCTION

7.0 EXCITATION SYSTEM

8.0 SYSTEM OPERATION

9.0 GENERATOR CONTROL PANEL

10.0 INSPECTION TESTING AND ACCEPTANCE

11.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 223 OF 1216

1.0 SCOPE

This specification defines the minimum requirements for the supply of self-excited Internal
Combustion Engine driven Emergency Generator and associated electrics suitable for
installation in Unclassified / Safe area.
Unless otherwise specified in the Material Requisition (MR) / data sheet, the emergency
generator and associated electrics shall be complete with
a. Alternator with brushless excitation system complete with AVR.
b. Generator Control Panel to include AMF system, Auto / Manual control,
synchronization and auxiliary devices, battery and charger. This panel shall also
include generator breaker and generator protection relays if specified in the data sheet.
c. Any other part / accessories not specifically mentioned above but considered necessary
for safe and reliable operation.

2.0 CODES AND STANDARDS

2.1. The equipment shall comply with the requirements of latest revision of following standards
issued by BIS (Bureau of Indian standards) unless otherwise specified.

IS: 5 Colors for ready mix paints and enamels

IS : 2253 Designation for type of construction and mounting arrangement of rotating
electrical machines.
IS : 4722 Rotating electrical machines.
IS : 7372 Lead acid storage battery for motor vehicle.
IS : 7816 Guide for testing of insulation resistance of rotating machines.
IS : 12065 Permissible limits of noise level for rotating electrical machines.
IS : 13364 AC Generators up to 20 KVA driven by reciprocating internal combustion
Part-I engine.
IS : 13364 AC Generators above 20 and up to 1250 KVA driven by reciprocating
Part-II internal combustion engine.
IS/IEC 60947 Low voltage Switchgear and Control gear: General Rules.
Part-1

2.2. In case of imported equipments, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.

2.3. The equipment shall also conform to the provisions of CEA regulations and other statutory
regulations currently in force in the country.

2.4. In case Indian standards are not available for any equipment, standards issued by
IEC/BS/VDE/IEEE/NEMA or equivalent agency shall be applicable.

2.5. In case of any contradiction between various referred standards/specifications/data sheet and
statutory regulations the most stringent requirement shall govern and decision of owner in
this regard shall be final.

3.0 SITE CONDITIONS

Generator shall be designed to operate under specified site conditions of LEH (refer
elsewhere). Suitable de-rating factor shall be considered by vendor while selection of
equipment rating.

4.0 GENERAL REQUIREMENTS

The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 224 OF 1216

5.0 PERFORMANCE REQUIREMENTS

5.1 Name Plate Rating and Duty

Rating indicated in the datasheet indicates the continuous apparent power available at
terminals, when operated inside the enclosure (for machines with acoustic enclosure) and at
maximum ambient temperature, as specified in datasheet. Suitable de-rating shall be applied
to account for temperature rise due to operation within enclosure.

The specified maximum ambient temperature shall be considered outside the enclosure for
machines having acoustic enclosure. The temperature inside the acoustic enclosure shall be
suitably considered by manufacturer taking care of temperature rise inside the acoustic
enclosure during full load conditions. The enclosure ventilation system shall be designed
along with the proposed alternator model so as to generate the rated power while operating
inside enclosure.

5.2 The generator shall meet the required performance requirements specified in IS: 13364 (Part
1 & 2). The voltage characteristics of generator shall conform to the VG3 grade given in IS:
13364 (Part 1 & 2). For machines rated above 1250kVA, stipulations of IS:4722 shall be
applicable.

5.3 Motorized potentiometer shall be provided where remote control of voltage is envisaged if
specified in data sheet.

5.4 Parallel Operation

Where specified, generator and associated electrics shall be suitable for parallel operation
amongst themselves, or with other generating sets or with other sources (Grid supply) at
operating voltage and under the load conditions up to rated value and with the generator
neutral solidly earthed.

5.5 Excitation Support System

Excitation system shall be provided with short-circuit support equipment to maintain three
times the rated current for three seconds in case of short circuit to ensure proper fault
clearance in outgoing feeders.

5.6 Noise

Statutory noise control requirements as applicable and as stipulated in the Mechanical

Specifications shall be adhered to.

6.0 DESIGN AND CONSTRUCTION

6.1 Generator enclosure protection shall be IP – 23, as a minimum.

6.2 The generator shall be mounted on a common base frame together with prime mover unless
otherwise agreed. The generator shall be provided with necessary lifting hooks and two
earth terminals on opposite sides for connection to main earth grid.

6.3 Various generator winding (i.e. stator, rotor, exciter) shall be designed either for insulation
Class ‘F’ with temperature rise up to Class ‘B’ or with Class ‘H’ with temperature rise up to
Class ‘F’. The windings and overhangs shall be braced to withstand the short circuit forces.

6.4 Machines rated 1000 KVA and above shall have minimum six nos. RTDs (one per phase
between the coil sides to measure winding temperature and one per phase at the base of slots
to measure core temperature, each placed at 120° apart).

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 225 OF 1216

6.5 The stator winding shall be star connected and all windings shall be brought out to (3+3)
insulated terminals in a terminal box with provision of CTs as per details given in the data
sheet.

6.6 Where terminal box does not have sufficient space for accommodating CTs for protection, a
separate cubicle shall be provided by vendor, irrespective of the machine rating .In such case
all connections shall be brought to the cubicle, using cable / bus duct connection of sufficient
rating. Apart from accommodating CTs, formation of star point and neutral tee off point
shall be achieved in this cubicle. Out going power cable connection to owner’s power
distribution board shall also be done in this cubicle.

6.7 Generators rated above 500 KVA shall be supplied with REF CT, unless otherwise specified
in the data sheet.

6.8 Differential CTs shall be provided if specified in the data sheet.

6.9 Generators rated 1000kVA and above shall be provided with a separate neutral terminal box.
Neutral cubicle shall contain various CTs for protection. A suitably rated generator breaker
shall be provided, if specified in data sheet.

6.10 The terminal box (es) and cubicles shall have sufficient space for the termination of quantity
of cable or bus duct as specified in data sheet.

6.11 All terminals shall be stud type. The terminal boxes / cubicles shall be complete with tinned
copper lugs and single compression nickel plated brass cable glands for the quantity and type
of power cables as specified in the data sheet. Where single core cables are specified, gland
plates shall be of non magnetic material (Stainless steel or Aluminum)

6.12 All parts and accessories shall be suitable to withstand stresses due to over speed / over load/
short circuit conditions specified.

6.13 Bearings

6.13.1 Bearings shall be grease lubricated ball or roller bearing or of the manufacturer’s standard
type i.e. sleeve type supported with PTR. In all cases the bearings shall be chosen to give a
minimum L-10 rating of 5 years (40,000hrs) at rated operating conditions.

6.13.2 Grease lubricated bearings shall be capable of grease injection from outside without removal
of covers. The bearing boxes shall be provided with labyrinth seals to prevent loss of grease
or entry of dust or moisture. When grease nipples are provided those shall be associated,
where necessary, with appropriately located relief devices which ensure passage of excess
grease through the bearings.

6.14 The direction of rotation of the rotor of the machine shall be compatible with that of the
prime mover. A clear indication of the direction of rotation shall be given on either end of
the machine.

6.15 Space heaters shall be installed within the enclosure. Location and maximum surface
temperature of the heaters shall be such that no damage can be caused to any insulation.
Heaters shall be suitable for operation on a single-phase 240 V AC supply unless otherwise
specified.

6.16 Field winding shall have insulation class and temperature limitations as per para 6.3 above.
The field winding shall be capable of operating at 125 % of rated field voltage for at least
one minute starting from hot initial condition, i.e. stabilized temperatures at rated load
conditions. (Rated field voltage is the voltage applied at the field winding for producing rated
terminal voltage at rated load and speed).

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 226 OF 1216

6.17 All cabling on the generator skid shall be in GI perforated cable trays / conduits. All cables
shall be identified close to their termination point. Single compression type cable glands
shall be used for cable termination.

6.18 Auxiliary Terminal Boxes

Separate Terminal boxes of sturdy construction shall be provided for Space Heater and other
devices like RTDs, with sufficient space for connecting the cables as indicated in the
requisition.

6.19 Auxiliary Motors

All auxiliary motors shall be three phase, 415 V, 50 Hz squirrel cage type suitable for DOL
starting. All motors shall have IP - 55 enclosures and shall conform to relevant Indian
Standards.

6.20 Battery Bank

6.20.1 The battery shall be lead acid, high discharge automotive type suitable for engine starting
duty and conforming to IS: 7372. The battery shall be placed on battery stands made of steel
with suitable PVC coating. One no. each of the accessories viz. hydrometer, thermometer,
cell testing voltmeter, pair of rubber gloves, spanner, acid resistant jug and funnel, teak wood
holder for the hydrometer etc. shall be supplied with each battery set.

6.20.2 The battery capacity shall be adequate for six (3+3) consecutive starts of the engine under
cold engine condition, without recharging, with additional 10% spare capacity. The auto
starting system shall successively carry out 3 (three) automatic start attempts but if diesel
engine fails to start even after three attempts then an alarm shall be annunciated on this
account and remaining 3 (three) start attempts can be carried out manually as per operator’s
decision.

7.0 EXCITATION SYSTEM

7.1 The generator shall be self-exciting or with PMG, i.e. it shall generate its nominal voltage
without the use of external power sources, even after long idle periods or after a short circuit
.The generator shall be provided with brushless type solid state self-excitation system with
automatic voltage regulator. The excitation system shall include the automatic voltage
regulator, AC exciter and rotary rectifier.

7.2 The field of the exciter shall be fed from the stator winding and AVR. AC voltage generated
in the AC exciter shall be rectified by the rotary rectifier assembly and fed to the main field
circuits. The rotor winding of the AC exciter, the rectifier assembly, main field winding of
the generator and other accessories on rotor parts shall be rigidly fastened to the shaft and the
connection with different items shall be anti-loosening type. The exciter capacity shall be at
least 20 % more than the maximum requirement at any time. The exciter winding shall be
insulated as per para 6.3 above.

7.3 The rotary rectifier set shall consist of rectifiers, zener diodes, fuses, field discharge resistors,
condensers, etc. Rotor circuit shall be designed to take care of rectification of AC voltage
and for proper field suppression through discharge resistors. The rating of the Diode Bridge
and armature shall be such that the full load rated current can be supplied with one branch in
operation.

7.4 All components shall be mounted considering the effects of the centrifugal forces.

7.5 Automatic solid-state voltage regulator (AVR) shall be provided with the following features
as a minimum:
• Short circuit protection
• Auto voltage control
• Manual voltage control. Unless supplier’s standard design does not permit it which shall
be supported with proper justification.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 227 OF 1216
 • Voltage build up circuitry
• Over voltage protection

7.6 The AVR can be installed either in the generator control panel or at the generator. In later
case, the AVR shall be located in a separate housing or in a clearly segregated section of the
main terminal box.

8.0 SYSTEM OPERATION

8.1 Modes of Operation

The emergency generator and associated electrics shall normally be in an unattended area.
The control system shall be suitable for unattended operation. The control system shall
operate in fail-safe mode and shall include all controls and protection necessary for the safe
operation of the DG set. The generator and associated electrics shall function as per the
following schemes:
• Auto start on mains failure scheme (AMF), if specified.
• Manual start in Service/Test mode
• Manual stop upon supply restoration

8.1.1 Automatic start on mains failure

This shall be effective in Auto position of Auto / Manual selector switch located in local
control panel. The generator shall normally be at rest. Upon failure of normal supply, a start
impulse (in the form of changeover of a dry contact) shall be provided by others. Using this
impulse, generator shall start automatically and rated speed and voltage shall be built up.
Once the voltage-monitoring relay senses generator healthy voltage, an impulse shall be
given for closing of generator breaker or contactor.

All accessories required for starting and completion of various sequence of operation for the
above purpose shall be provided as part of generator.

8.1.2 Manual start

8.1.2.1 In Service Mode

This shall be effective in manual position of Auto/Manual switch and service position of
service / test selector switch located in control panel. The scheme of operation shall be same
as of auto mode as per clause 8. 1.1 above except that starting command shall be extended
manually using the push button (instead of command from AMF sequence) from the local
control panel. Provision shall also be kept for manual start from owner's remote control
panel.

8.1.2.2 In Test Mode

This shall be effective in test position of service / test selector switch. The scheme of
operation shall be same as that of manual start in service mode as per clause 8.1.2.1 above
except that the closing command for generator breaker /contactor shall not be extended
automatically.

If periodic load test-run of generator is envisaged as per data sheet, the generator breaker
shall be closed manually after synchronization with grid.
DG shall have provision along with necessary hardware for setting load on DG (0 to 100%)
during load test-run. Voltage signal shall be made available as below from bus side for
synchronizing purpose :
For alternator having terminal voltage of 415V : 415V±6%, 50Hz±3%, TPN signal or
110V±6%, 50Hz±3% TPN signal from PT secondary
For alternator having terminal voltage > 415V : 110V±6%, 50Hz±3% TPN signal from PT
secondary

8.1.3 Stop upon restoration of grid mains supply

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 228 OF 1216
 If specified in data sheet, in auto mode, AMF panel shall issue a command for closing of grid
breaker after synchronizing DG supply with grid. Once grid breaker is closed, AMF panel
shall issue a command for opening of DG breaker. Voltage signal shall be made available as
below from grid line side for synchronizing purpose :
For alternator having terminal voltage of 415V : 415V±6%, 50Hz±3%, TPN signal or
110V±6%, 50Hz±3% TPN signal from PT secondary
For alternator having terminal voltage > 415V : 110V±6%, 50Hz±3% TPN signal from PT
secondary

Unless specified otherwise in the datasheet, DG set shall be stopped MANUALLY using
push button. This shall be possible irrespective of the position of Auto / Manual selector
switch which is located in generator control panel.

8.2 Shut-down

It shall be possible to manually stop the generator in all operational cases including
emergency case by means of the push button provided in either generator control panel or
Owner's remote panel.
8.3 Starting Time

Unless specified otherwise, the total time from the receipt of the starting impulse for the
generator till the set reaches rated speed and generator reaches rated voltage shall not be
more than 30 seconds. If this time is exceeded, an annunciation in the local control panel
shall be provided with a facility for repeat annunciation in Owner's panel.

8.4 Black Start Facility

The generating unit shall be provided with all necessary 'black start' facilities. External
power at 415 V TPN shall be made available by purchaser at one point for battery charging
or any other auxiliary equipment operation during stand -still period of generator. This power
shall not be available during start-up of the generator.

8.5 DC Control Supply

Unless it is specified that the DC control supply required for AMF/generator relay and
control function is being provided by purchaser, all DC power supply requirement shall be
met by DC system consisting of battery and battery charger of suitable capacity to be
supplied by the DG set vendor.

If, the DC control supply for AMF / generator control panel is provided by purchaser, the
engine starting motor and other such special duty DC load required for DG system package
shall still be fed from the DC system battery & charger to be supplied by the DG set vendor.
During stand still period of DG set, charger of DC supplies shall be energized from the 415 V
feeder provided by purchaser as per para 8.4 above.

9.0 GENERATOR CONTROL PANEL

9.1 The local generator control panel for the generator shall include all interlock and controls for
the generator and its auxiliaries and comprise of the following unless otherwise specified in
the attached data sheet:
a. Local circuit breaker and generator protection relays, if specified.
b. Line Cubicle, as applicable.
c. Neutral cubicle, as applicable, having protection CTs
d. Metering CTs and CT/PTs for AVR
e. Metering equipments
f. Indicating instruments
g. Synchronizing equipment, if specified
h. Motor control gear section for generator auxiliaries
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 229 OF 1216
 i. Battery charger
j. Any other accessory necessary for generator operation.

9.2 In case, a generator breaker is required to be supplied, it shall form part of the line cubicle.
The breaker rating shall be as specified in the data sheet. This breaker shall serve the purpose
of local isolation. The breaker shall be in draw out execution. In case of 415 V generators,
breaker shall have four poles for isolation of phases and neutral.

9.3 All motor starters for DG set auxiliaries if required shall be ‘direct-on-line’ type in fixed
execution.

9.4 The battery charger with rated power out put in excess of 1000 W (i.e. for rating more than
40 Amps at 24 V) shall be 3 phase full wave type as per EIL specification 6-51-0030.

9.5 Single Phase Charger

Chargers for DC power out put up to 1000 W shall be conforming to the following
specifications:

9.5.1 The battery charger shall have 1-phase full wave controlled Rectifier Bridge with their
protective devices. The charger shall be of solid state design, constant voltage type with
current limiting feature suitable for automatic and manual, normal (float charging) and quick
(boost) charging of batteries. The output voltage shall be stabilized to + 1 % for mains
variation of + 10 % and load variation of 0 to 100%. The maximum ripple content in the
charger output voltage shall be lower than the safe value recommended by battery
manufacturer and in any case shall not exceed 5% with battery disconnected. The charger
shall be sized for boost charging the battery within 10-14 hours.

9.5.2 The charger shall have auto as well as manual control facility. In auto mode, the charger
shall automatically control the battery charging current/voltage to ensure optimum boost
charging of the battery. After completion of boost charging, the charger shall switch to float
charging mode without any manual intervention.

9.5.3 In the manual mode, it shall be possible to charge the battery at any desired current that is
safe for the battery. A backup timer of 0-24 hours range shall be provided for switching the
charger from boost to float mode after the set time, under any mode of operation.

9.5.4 Auto/manual selector switch, ON/OFF switch for incoming power supply, float/boost
selector switch, potentiometer for control of output voltage and backup timer shall be
provided on the front of the panel in addition to AC incoming voltmeter and ammeter with
selector switch and DC output voltmeter and ammeter. Indication lamps for AC power on,
charger in float, charger in boost, charger failure shall also be provided.

9.6 Generator Control Panel Construction

9.6.1 The generator control panel shall be free standing, metal enclosed fabricated with cold rolled
sheet steel of 2mm thickness, dust and vermin proof type with a hinged door and having a
degree of protection IP 41 unless otherwise specified. Power and control equipment shall be
segregated inside the panel as far as practicable.

9.6.2 The maximum height of the operating handle / switches shall not exceed 1800 mm and the
minimum height shall not be below 300 mm.

9.6.3 All hardware shall be corrosion resistant and bolts; nuts and washers shall be made of
galvanized, zinc passivated or cadmium plated high quality steel.
9.6.4 Unless otherwise specified, the panel shall be suitable for bottom cable entry. Necessary
removable type undrilled gland plate; single compression cable glands and cable lugs shall
be provided with the panel.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 230 OF 1216

9.6.5 All auxiliary devices for control, indication, measurement and alarm such as push button,
control / selector switches, indicating lamps, metering instruments, annunciations etc. shall
be mounted on the front door of the panel. Adequate number of potential free contacts shall
be provided in the control panel for any remote control, monitoring of the generator.

9.6.6 All switches shall be load-break, heavy-duty type. All fuses shall be non-deteriorating HRC
cartridge pressure fitted, link type. The contactors for auxiliary motor starters shall be of air-
break type having AC-3 duty rating. Thermal overload relays shall be three element, positive
acting, ambient temperature compensated type with adjustable setting range and built in
protection feature against single phasing.

9.6.7 All indicating instruments shall be moving iron, flush mounting type and of 72 mm. x 72
mm. square pattern. As an option, vendor may offer digital meters.

9.6.8 All control/ selector switches shall be rotary back-connected type having a cam-operated
contact mechanism with knob type handle. 'Stop' push buttons shall be stay-put type.

9.6.9 Wiring for power, control and signaling circuits shall be done with 660 V grade PVC
insulated, BIS approved, flame retardant low smoke type, copper conductors. Minimum size
of control wires shall be 1.5 mm2. Clamp type terminals shall be acceptable for wires up to
10 mm2 size and for conductors larger than 10 mm2 bolted type terminals with crimping lugs
shall be provided. A minimum of 10 % spare terminals shall be provided on each terminal
block.

9.6.10 50 x 6-mm2 Aluminum or equivalent copper earth bus shall be provided in the panel for
connection to the main earth grid. All non-current carrying metallic parts of the mounted
equipments shall be earthed. Doors and movable parts shall be earthed using flexible copper
connections.

9.6.11 Engraved nameplates shall be provided for all devices mounted on the front of the panel.
Nameplate or polyester adhesive stickers shall be provided for ach equipment mounted
inside the panel.

9.6.12 All metal surfaces shall be thoroughly cleaned of scale, rust, and grease etc. prior to painting.
Cleaned surfaces shall be given two coats of primer and prepared for final painting. Final
finish shall be free from all sorts of blemishes.

10.0 INSPECTION TESTING AND ACCEPTANCE

10.1 Unless otherwise specified, purchaser reserves the right to inspect and witness testing at the
vendor’s works as per the inspection test plan and the approved quality documents.

10.2 In the event, when the witness inspection is not carried out by purchaser as per approved
inspection test plan, the tests shall anyway be completed by vendor and documents for the
same shall be submitted to purchaser for scrutiny.

11.0 PACKING AND DESPATCH

11.1 All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for selected mode of
transportation i.e. by ship/rail or trailer. The equipment shall be wrapped in polythene sheets
before being placed in crates/cases to prevent damage to finish. Crates/cases shall have skid
bottom for handling. Suitable lifting lugs etc. shall also be provided and lifting points shall
be clearly marked on the package. Special notations such as `Fragile', `This side up', `Center
of gravity', `Weight, Owner’s particulars (PO nos.) etc., shall be clearly marked on the
package together with other details as per purchase order.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 231 OF 1216

11.2 The equipment may be stored outdoors for long periods before installation. The packing
shall be completely suitable for outdoor storage in areas with heavy rains/high ambient
temperature unless otherwise agreed.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 232 OF 1216

 SPECIFICATION
FOR
OIL FILLED TRANSFORMERS
(B047-003-SP-6-51-0041, Rev. A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 233 OF 1216

Abbreviations:

BS : British Standards
BIS : Bureau of Indian Standards
CBIP : Central Board of Irrigation & Power
CEA : Central Electricity Authority
CRCA : Cold Rolled Close Annealed
CT : Current Transformer
DCS : Distributed Control System
GI : Galvanised Iron
FM : Factory Mutual
FRLS : Flame Retardant Low Smoke
HV : High Voltage
IEC : International Electro Technical Commission
IEEE : Institute of Electrical and Electronics Engineers
IP : Ingress Protection
IS : Indian Standards
LV : Low Voltage
MSL : Mean Sea Level
MV : Medium Voltage
KV : Kilo Volt
KVA : Kilo Volt Ampere
NGR : Neutral Grounding Resistor
OLTC : On Load Tap Changer
ONAF : Oil Natural Air Forced
ONAN : Oil Natural Air Natural
OTI : Oil Temperature Indicator
PESO : Petroleum and Safety Explosives Organisation
PLC : Programmable Logic Controller
PO : Purchase Order
PVC : Poly Vinyl Chloride
PRV : Pressure Release Valve
RPRR : Rapid Pressure Rise Relay
RTCC : Remote Tap Changer Control
TCIV : Transformer Conservator Isolation Valve
TPN : Three Phases and Neutral
UL : Underwriters Laboratory Inc.
VDE : Verband Der Electrotechnik, Elecktronik und Information Stechnik
WTI : Winding Temperature Indicator
XLPE : Cross Linked Polyethylene

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 234 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 SITE CONDITIONS

5.0 CONSTRUCTION

6.0 TERMINALS AND MARSHALLING BOX

7.0 COOLING

8.0 TAPPINGS & CONTROL

9.0 ACCESSORIES

10.0 NOISE LEVEL

11.0 INSPECTION AND TESTING

12.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 235 OF 1216

1.0 SCOPE

The intent of this specification is to define the requirements for design, manufacture, testing, packing
and supply of oil filled power/distribution transformers alongwith nitrogen injection fire protection
system (if specified in MR/ Tender).

2.0 CODES AND STANDARDS

2.1. The equipment shall comply with the requirements of the latest revision of the following standards
issued by BIS.
IS:335 : New Insulating oils
IS:1180-1 : Outdoor Type Oil Immersed distribution Transformers upto And Including
2500 kVA, 33kV
IS:1271 : Thermal evaluation and Classification of electrical insulation.
IS:1866 : Code of practice for maintenance and supervision of mineral insulating oil
in equipment.
IS:2026 : Power transformers
IS:2099 : Bushing for Alternative voltages above 1000 V.
IS:2705 : Current transformers.
IS:3347 : Dimensions for porcelain Transformer Bushings
IS:3637 : Gas operated relays.
IS:3639 : Fitting & accessories for power transformers
IS:4201 : Application guide for CTs.
IS:6600 : Guide for loading of oil immersed transformers (IEC 76)
IS:8468 : On-load tap changers
IS:8478 : Application guide for ON-load tap changers
IS/IEC:60529 : Degree of protection provided by enclosures (IP Code)
IS/IEC:60947 : LV switchgear and control gear.
CBIP GP-317 : CBIP Manual on Transformer
GOI Order : Gazette of India Notification dated 16 December 2016 and 17 February
2017 and subsequent notifications, as applicable.
2.2. In case of imported equipment, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.
2.3. The equipment shall also conform to the provisions of CEA Regulations and any other statutory
regulations currently in force in the country.
2.4. In case Indian standards are not available for any equipment, standards issued by
IEC/BS/VDE/IEEE/NEMA or equivalent agency shall be applicable.
2.5. In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent one shall prevail. However Owner/ EIL decision in this regard will be
final and binding.

3.0 GENERAL REQUIREMENTS

The offered equipment shall be brand new with state of art technology and proven field track record.
No prototype equipment shall be offered.

4.0 SITE CONDITIONS

4.1. Transformershall be designed to operate under specified site conditions of LEH (refer elsewhere).
Suitable de-rating factor shall be considered by vendor while selection of equipment rating.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 236 OF 1216

5.0 CONSTRUCTION

5.1. Transformer tank shall be of welded sheet steel construction and provided with gasketed steel cover
plates. Base shall be suitably reinforced to prevent any distortion during lifting. Base channels shall
be provided with skids and pulling eyes to facilitate handling.

5.2. Transformer shall be double wound, core type with high grade cold rolled non-aging grain
oriented low loss, high permeability silicon steel laminations (M-4 or better grade) perfectly
insulated and clamped to minimise vibration and noise. Care shall be taken to insulate core-fastening
bolts to reduce losses and avoid hot spots. All parts of magnetic circuit shall be bonded to earth
system.

5.3. Transformers shall have conventional type of windings. Foil type windings are not acceptable.
Windings shall be of copper and shall be designed to withstand the applicable thermal and dynamic
short circuit stresses.

5.4. All covers and seals shall be oil and airtight and shall not be affected by mineral or synthetic oil
action. Detachable radiators (tank mounted) equipped with air vent, drain plug and lifting lugs shall
be provided with shut-off valves for transformer rated more than or equal to 500kVAto permit
removal of any radiator unit without emptying the tank. Radiators shall be securely braced to prevent
undue vibration.

5.5. All fasteners and bolts etc. shall be galvanised. All surfaces to be painted shall be thoroughly
cleaned, de-scaled, made free from rust and transformer shall be epoxy painted.

5.6. Different non-current carrying parts of transformers shall be connected by copper flexible for earth
continuity purpose.

5.7. Transformer shall be supplied with first filling of oil and 10% extra oil in non-returnabledrums. Oil
shall conform to IS-335.

5.8. Distribution transformer shall comply with latest IS-1180 (Part-1) (including amendments) and
Gazette of Indianotifications, as applicable. Accordingly, efficiency of transformer at 50% and 100%
load shall be considered with total losses at 50% and 100% loading not exceeding maximum losses
values specified in Table-6 of IS-1180 (Part-1): 2014 (including amendments)for Energy Efficiency
Level 2 / Table-3 of Gazette of India for Star 1 rated transformers. Higher energy efficiency levels/
star rating shall be provided, if specified in MR/ Tender.

5.9. The transformer shall bear standard mark of the Bureau of Indian Standards in line with Gazette of
India notifications. Copy of the license obtained from Bureau of Indian Standards shall be furnished
by vendor in compliance with IS- 1180 (Part-1).

5.10. Temperature rise limits shall be limited to limits of Temperature rise specified in Gazette of India
notifications/ IS-1180 (Part-1).

5.11. The guaranteed minimum value of efficiency shall be demonstrated during inspection.

6.0 TERMINALS AND MARSHALLING BOX

6.1. Windings shall be brought out and terminated on outdoor bushings, cable boxes or bus-duct
chamber, which will be located as specified in the data sheet.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 237 OF 1216

6.2. When outdoor bushings are specified these shall be supplied complete with terminal connectors
suitable for the specified conductor size.

6.3. Cable boxes shall be supplied with cable lugs and glands.

6.3.1. For HV XLPE Cables and MV PVC Power/control cables, double compression nickel plated brass
cable glands and crimped type tinned copper cable lugs shall be supplied. Gland plate shall be
removable type. For single core cables, gland plate shall be of non-magnetic material. HV cable box
shall be suitable for termination of specified size of XLPE insulated cable .The head-room available
between cable gland plate and terminals shall not be less than 600mm for cable upto 11 kV, and 900
mm for 22 kV and 33 kV cables. Cable box and disconnecting chamber shall be air insulated.

6.3.2. Cable box shall be weatherproof to minimum IP-55. For fixed portion of cable box, inspection cover
with lifting handle shall be provided.

6.3.3. Primary cable box (where applicable) shall be able to withstand specified primary system fault level
for 0.20 second.

6.4. Terminal chamber for bus-duct termination shall have a gasketed cover plate bolted to it and shall be
weatherproof to IP-55. A separate inspection cover with lifting handle shall be provided to facilitate
connection and inspection.

6.5. Marshalling box shall be mounted on transformer and shall be weatherproof to minimum IP-55. All
protective devices and neutral CTs shall be wired by means of PVC insulated copper conductor
armoured cables upto the marshalling box. Terminals shall be clamp type. Removable gland plate
with double compression type glands shall be provided. Lamp with switch & socket shall be
provided in the marshalling box. Preferably, marshalling box shall be located on the front side of
transformer.

6.6. For transformers having provisions for terminating TPN bus duct on the 433V side, neutral of the
star connected secondary winding shall be brought out to a secondary terminal chamber. CT(s) shall
be mounted (if specified) on the neutral terminal with CT secondary wired up to the marshalling
box.

6.7. A separate neutral bushing shall be provided for neutral earthing of transformers. The neutral CT(s)
shall be mounted as below:-.
a) CT for 51G shall be located in the earth path after bifurcation of neutral.
b) CT for 64 Rcan be located before bifurcation of neutral.
Supporting arrangement for GI strip/cable as applicable shall be provided for connection of neutral
bushing to earth/NGR.

6.8. All contacts including ‘spare contacts’ and ‘contacts for Owner’s interface’ shall be duly wired &
terminated at the terminal block.

7.0 COOLING

7.1. Type of cooling shall be in accordance with data sheet, i.e. ANON

8.0 TAPPINGS & CONTROL

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 238 OF 1216

8.1. These shall be provided on high voltage side and connected to off circuit or on-load tap changing
gear as specified in data sheet. Under conditions of external short circuit, the tap changing
equipment shall be capable of carrying the same current as the windings.

8.2. Off circuit tap changing gear:

Off circuit tap changing gear shall have an external operating handle mounted on the transformer
side and shall meet the following requirements:

a) Positive snap-action contact changing

b) The mechanism shall be such that it is impossible for the contacts to be set in a position
whereby the windings remain open-circuited or partly short-circuited.
c) Mechanical stops at the ends shall be provided to prevent overrun.
d) The driving rod through cover or tank wall shall be properly sealed against oil leakage under all
service conditions.

The handle shall be metallic and adequately sized in order to allow operation without the need of
tools and shall be located in a directly accessible position.

The handle shall be provided with padlock facilities to lock the tap changer in the desired position.

Tap positions shall be clearly marked in line with the data given on the rating plate.

8.3. On Load Tap Changer

8.3.1. High speed on load tap changing gear with number of steps as specified on the data sheet shall be
provided and mounted on the transformer. The OLTC gear shall have diverter resistance and the
current diverting contacts shall be housed in a separate oil chamber segregated from the main tank of
the transformer. The contacts shall be accessible for inspection and their tips shall be replaceable.

OLTC oil chamber shall have oil filling, drain and sampling facility. It shall be provided with oil
level indicator, connection orifices, valves and silica gel breather.

8.3.2. OLTC shall be provided with local and remote controls.

8.3.2.1. Local Control

a) Manual-Mechanical Control

The cranking device for operation of the OLTC gear shall be removable type and located at a height
not exceeding 1500mm above ground level for easy operation. The mechanism shall be complete
with normal accessories including at least the following:-

i. A mechanical tap position indicator (Rated tap voltages shall be marked on the diagram plate).
ii. A mechanical operation counter.
iii. Mechanical stops to prevent over cranking of the mechanism beyond extreme tap positions.

b) Electrical Control

Control circuit shall incorporate the following:

i. Local/remote manual electrical operation.
ii. Device to ensure a positive and full completion of tap change once it is initiated even if here is
loss of power.
iii. An interlock to cut-off electrical control automatically upon recourse being taken to manual
mechanical control in emergency.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 239 OF 1216

 iv. Electrical interlock to cut-off a counter impulse for a reverse tap change, being initiated during
a progressive tap change and until the mechanism comes to rest and resets circuits for a fresh
operation.
v. All auxiliaries and devices for electrical control of OLTC gear shall be housed in a weather-
proof cabinet mounted on the transformer and shall include:

− Local tap position indicator

− 5 digit operation counter
− Cubicle lighting
− Thermostatically controlled space heater.
− Miniature circuit breaker with magnetic and thermal overload devices for controlling the
incoming supply to the OLTC motor.
− Padlocking arrangement for the hinged cabinet door.
− Removable plate with cable glands.
− Inside tag with control scheme indelibly marked.

8.3.2.2 Remote Tap Changer Control Panel

a) Remote Tap Changer control panel shall comprise of the following:

− Individual/parallel control on Master follower sequence selector switch.

− Raise/lower control switch.
− Potentiometer type tap position indicator.
− Out of step relay.
− Time delay relay.
− Indicating lamp for out of step.
− Out of step buzzer.
− Indicating lamp for tap changer supply available.
− Indicating lamp for tap change in progress.
− Voltage Sensing Relay (If specified)

b) RTCC panel shall be dust & vermin proof, floor mounting, and freestanding type. The
enclosure shall be cold rolled sheet of 2.0 mm thickness. All doors and opening shall be
provided with neoprene gaskets.

8.3.3. OLTC, wherever called for, shall be suitable for bi-directional power flow.

9.0 ACCESSORIES

9.1. The following accessories shall be provided as a minimum:

a) Rating Plate
b) Terminal marking Plate
c) Two earthing terminals
d) De-hydrating breather
e) Conservator
f) Air release Device (for transformers with conservator)
g) Oil filling hole with cover
h) Oil Level indicator with alarm contact
i) Thermometer pocket
j) Oil temperature indicator with alarm & trip contacts
k) Winding temperature indicator with alarm & trip contacts (for transformers of rating 500 KVA
and above)
l) 4-20mA transducers for OTI & WTI (For Transformers rated above 1000kVA)
m) Pressure relief valve shall be provided (with alarm contact).

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 240 OF 1216

 n) Sampling valve
o) Conservator drain valve
p) Top oil filter valve
q) Drain cum bottom filter valve
r) Double float Buchholz relay
s) Separate neutral bushing outside terminal box with connector assembly
t) Inspection cover
u) Terminal box
v) Marshalling box
w) Lifting lugs
x) Jacking lugs
y) Cross channels with towing lugs
z) HV and LV bushings

9.2. Conservator shall be complete with oil filling plug and cap, oil drain valve, oil level gauge in
addition to magnetic oil level gauge. A flexible oil resistance air bag shall be provided for
conservator for transformer rated above 2500kVA. Air bag shall be designed to withstand repeated
expansion and contraction due to changes in oil level.

9.3. Separate buchholz relay shall be provided for main tank and OLTC chamber. This shall be double
float type for the main tank with separate normally open trip and alarm contacts. For the OLTC
chamber the relay shall be of single float type or oil surge relay with one trip contact. Isolating valve
shall be provided on either side of the relay and distance piece shall be supplied.

9.4. Size of valves for drain, filter and sampling shall be as per table below.

Transformer rating Size of drain Size of filter valve Size of sampling valve
(kVA) valve (mm) mm Mm

Upto 1600 25 25 15

>1600to10000 50 25 15

>10000to 25000 80 50 15

>25000 to 50000 100 50 15

>50000 100 50 15

9.5. ECS Interface signals as listed below shall be provided if specified in the data sheet / projects
specifications.

a) Selector switch status (OLTC/RTCC/Remote Control mode)

b) Master / Follower status
c) Auto/Manual mode status
d) Tap changer out of step status
e) Tap changer stuck status
f) Tap changer status signal (Digital) for each step
g) Control Supply failure for RTCC Panel / OLTC
h) Raise/Lower Control from ECS

10.0 NOISE LEVEL

Audible Noise level shall not exceed the limits indicated in CBIP manual.

11.0 INSPECTION AND TESTING

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 241 OF 1216

11.1. Owner's representative shall be given free access in the works from time to time for stage wise
inspection and progress reporting. Four weeks advance notice shall be given to witness the final
routine test as per relevant IS and other tests as agreed upon. These tests shall be performed on the
complete assembly at manufacturer's works. Test certificates duly signed by owner's representative
shall be issued as part of final document.

11.2. Routine tests and special tests as listed below shall be carried out on all transformers:
a) GA along with verification of all accessories
b) Dimensional & electrical clearance
c) Rating plate details
d) Terminal/ tapping markings
e) Earthing arrangement
f) Measurement of winding resistance
g) Measurement of voltage ratio and check of voltage vector relationship
h) Measurement of impedance voltage and load loss
i) Measurement of no- load loss and current
j) Induced over voltage withstand test
k) Separate-source voltage withstand test (HV Test)
l) Measurement of insulation resistance before and after HV test
m) Noise level check
n) Magnetic Balance test
o) Dielectric test
p) BDV on transformer oil
q) Tests on OLTC/ control panel (if applicable)
r) Measurement of power taken by fans & oil pumps (on sample basis on one transformer)

11.3. Additional Tests:

11.3.1. Oil leakage Test - All tanks and oil filled compartments shall be tested for oil tightness by being
completely filled with air/oil of a viscosity not greater than that of insulating oil to IS: 335 at an
ambient temperature and subjected to a pressure equal to the normal pressure plus 35 kN/m2
measured at the base of the tank. This pressure shall be maintained for a period of not less than 12
hours for oil and 1 hour for air, during which time no leakage shall occur.

11.3.2. Vacuum Test - One transformer tank of each size shall be subjected to the specified vacuum as in
table-1. The tanks designed for vacuum of 760mm of mercury shall be tested at a maximum internal
pressure of 3.33 kN/m2 (25mm of Hg) for one hour. The permanent deflection of flat plates after the
vacuum has been released shall not exceed the value specified in Table-2 without affecting the
performance of the transformer.

Table – 1
Highest System Vacuum Gauge
MVA Rating mm of Hg
Voltage pressure kN/m2
Upto 1.6 34.7 250
Upto 72kv above 1.6 &upto 20 68.0 500
Above 20
100.64 760
Above 72kv For all MVA ratings

Table – 2
Horizontal length of flat plate (in mm) Permanent deflection (in mm)
Upto and including 750 5
751 to 1250 6.5
1251 to 1750 8
1751 to 2000 9.5

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 242 OF 1216

 2001 to 2250 11
2251 to 2500 12.5
2501 to 3000 16
Above 3000 19

11.3.3. Pressure Test - One transformer tank of each size shall be subjected to a pressure corresponding to
twice the normal head of oil or to the normal pressure plus 35 kN/m2 whichever is lower measured
at the base of the tank and will be maintained for one hour. The permanent deflection of flat plates
after the excess pressure has been released shall not exceed the figure specified in Table-2.

11.3.4. One transformer of each rating shall be subjected to heat run test, if specified in data sheet.

11.3.5. Impulse test, if specified in the data sheet, shall be carried out on all three limbs of the transformer.

11.3.6. Transformer shall be subjected to short circuit test, if specified in the data sheet.

11.3.7. All the instruments, meters, etc., used for testing shall be duly calibrated at NABL laboratory
and necessary calibration certificate shall be made available during inspection.

12.0 PACKING AND DESPATCH

All the equipment shall be divided into several sections for protection and ease of handling during
transportation. The equipment shall be properly packed for the selected mode of transportation i.e.
by ship/ rail or trailer. The equipment shall be wrapped in polythene sheets before being placed in
the crates/ cases to prevent damage to the finish. Crates / cases shall have skid bottom for handling.
Special notations such as ‘Fragile’, ‘This side up’, ‘Centre of gravity’, ‘Weight’, ‘Owner’s
particulars’, ‘P.O. numbers’ etc., shall be clearly marked on the package together with other tag
numbers, P.O. number etc.

The equipment may be stored outdoors for long periods before erection. The packing shall be
suitable for outdoor storage in areas with heavy rains/ high ambient temperature.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 243 OF 1216

 SPECIFICATION
FOR
STATIONARY VALVE REGULATED
LEAD ACID BATTERIES
(B047-003-SP-6-51-0048, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 244 OF 1216

Abbreviations:

AC Alternating current
Ah Amperehour
BIS Bureau of Indian Standards
BS British Standard
CEA Central Electricity Authority
DC Direct current
EIL Engineers India Limited
IEC International Electrotechnical Commission
IEEE Institute of Electrical & Electronics Engineers
IS Indian Standard
MSL Mean Sea Level
NEMA National Electrical Manufacturers Association
PO Purchase Order
PVC Polyvinyl Chloride
UPS Uninterrupted Power Supply
VDE Verband der Elektrotechnik,Elektronik und Information stechnik
V Volt

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 245 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 SITE CONDITIONS

5.0 TECHNICAL REQUIREMENTS

6.0 PERFORMANCE

7.0 INSPECTION, TESTING AND ACCEPTANCE

8.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 246 OF 1216

1.0 SCOPE

This specification covers the design, manufacture, testing and supply requirements of Valve
Regulated stationary Lead Acid cell/batteries for DC Power System/ AC UPS application.

2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the requirements of the latest revision of the following
standards issued by BIS/other standard bodies:

IS-15549 Stationary valve regulated lead acid batteries

ANSI T1 330 Valve Regulated Lead-Acid Batteries used in the telecommunication
Environment.
ASTM D2863 Test method for measuring the minimum oxygen concentration to
support candle like combustion of plastics (Oxygen Index).
IEC 60896-21 Stationary lead-acid batteries - Part 21: Valve regulated types -
Methods of test
IEC 60896-22 Stationary lead-acid batteries - Part 22: Valve regulated types -
Requirements
IEC-60068-2 Environmental testing

2.2 In case of imported equipment, standards of the country of origin shall be applicable, if these
standards are equivalent or more stringent than the applicable Indian standards.

2.3 The equipment shall also conform to the provisions of CEA regulations with latest
amendments and other statutory regulations currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards issued by IEC/BS/
VDE/IEEE/NEMA or equivalent agency shall be applicable.

2.5 In case of any conflict between various referred standards/ specifications/ datasheets and
statutory regulations, the most stringent requirement shall prevail and Owner’s/ EIL’s decision
in this regard shall be final and binding.

3.0 GENERAL REQUIREMENTS

The offered equipment shall be brand new with state of the art technology and proven field
track record. No prototype equipment shall be offered.

4.0 SITE CONDITIONS

Valve Regulated stationary Lead Acid cell/battery shall be designed to operate under specified
site conditions of LEH (refer elsewhere). Suitable de-rating factor shall be considered by
vendor while selection of rating in addition to minimum temperature of 10oC for battery
sizing.

5.0 TECHNICAL REQUIREMENTS

5.1 The Valve Regulated cell/battery shall be suitable for float duty operation with a constant
voltage permanently applied to its terminals which is sufficient to maintain it in a state close to
full charge and shall be designed to supply load in the event of normal power supply failure.

5.2 The standard rated ampere hour capacity of the cell/ battery shall be at a reference temperature
of 27°C, constant current discharge at 10 hours rate (C10) and an end cell voltage of
1.85V/cell.

5.3 Ampere hour of the battery shall be selected based on the following criteria:

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 247 OF 1216

 a. Minimum site ambient temperature of 10oC
b. Discharge duty cycle
c. End cell voltage
d. Ageing factor of 0.8
e. Capacity rating factor

5.4 Number of cells and end cell voltage shall be decided by the vendor on the basis of maximum
permissible voltage to the load when batteries are float charged while feeding the load. The
system output voltage at the end of design duty cycle shall not be less than 95% for nominal
system voltage up to 48V DC and 90% for nominal system voltage of 110V DC and above.
However, the minimum number of cells and end cell voltage shall be as per datasheet.

5.5 On float, the cell/battery shall be suitable for being recharged to 90% of ampere hours within
24 hours and to 100% within 4 days.

5.6 The components such as containers, lids, covers and seals used in manufacture shall meet the
Fire, flame and smoke resistance rating as defined in IS 15549 and have an oxygen Index of at
least 28 in accordance with ASTM D-2863.

5.7 Each cell/battery shall have a separate container of 2.0V (nominal voltage). The cell container
shall be made of high strength acid resistant material and designed to withstand mechanical
stresses, shocks, vibrations and shall be consistent with the life of the battery.

5.8 The design of valve regulated cell shall be such that regulating valve shall not allow the gas
(air) to enter into the cell but shall allow the gas to escape from the cell above certain internal
pressure which shall not lead to deformation or cause container to crack or cause failure of
seals or shall not cause bulging/ cracking of cell cover.

5.9 The hydrogen released from valve regulated lead acid cells shall be sufficiently low to make
these cells suitable for use in office, control rooms and equipment environments. The gas
leakage rate of the cell shall be in limit as per relevant IS/IEC.

5.10 Valve Regulated stationary Lead Acid cells/battery shall be designed to withstand the
mechanical stresses encountered during normal transportation and handling.

5.11 Flame arrestor shall be mounted on the cell so that all the vented gasses diffuse through the
arrestor to the outside environment. The construction of the arrestor shall be such that
hydrogen burning on the external surface of the arrestor shall not propagate back in to the cell
to cause explosion.

5.12 The terminal posts shall be casted of lead alloy with copper/brass insert for enhancement of
conductivity. The terminals shall be suitable for maximum discharge current and short circuit
current without damage to the cell as a result of terminal heating.

5.13 The temperature of the valve regulated lead acid cells shall be sufficiently low to prevent
thermal runaway (critical condition arising due to constant voltage charging).

5.14 The following information shall be permanently marked on the cell.

- Nominal voltage
- Name of manufacturer/model reference
- Rated capacity in ampere hours (Ah) with end cell voltage
- Voltage for float operation at 27oC with tolerance of ±1%
- Month and year of manufacture
- Polarity marking

5.15 Each set of battery shall be supplied with all the necessary accessories, including, but not
limited to the following:
a. Battery stand in formation / steel modules for multi tier stacking as per data sheet. Mild
steel stand/module pretreated and epoxy painted /epoxy powder coated/ PVC coated.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 248 OF 1216

 b. Inter cell, inter row and inter bank connectors and end take offs. These shall be of lead
plated copper or flexible insulated copper cable or completely insulated solid copper
connectors.
c. Cell insulator as applicable.
d. Stand insulator
e. Cell number plates/permanent stickers, Lugs for cable termination, as required.
f. Other accessories and their quantity as per data sheet.

6.0 PERFORMANCE

Valve regulated Stationary Lead Acid batteries shall have been type tested to meet the
performance requirements for each design and Ah rating of cells as per the relevant Indian
standard referred in clause 2.1 above.

7.0 INSPECTION, TESTING AND ACCEPTANCE

Batteries shall be subject to inspection by EIL/owner or by an agency authorised by the owner,

to assess the progress of work. The manufacturer shall furnish all necessary information
concerning the supply to EIL/owner’s representative. EIL/owner’s representative shall be
given free access in the works from time to time for stage wise inspection and progress
reporting. Four weeks advance notice shall be given to witness the final routine test and other
tests as agreed upon.

The routine, acceptance & type testing shall be carried out as per Inspection & test plan for
stationary valve regulated lead acid battery (Standard no. 6-81-1048). Routine tests shall be
conducted on each cell/battery. Acceptance tests & Type tests shall be conducted on few
cells/batteries as per relevant Indian standard.

Battery load test shall also be performed at site after installation as part of commissioning.

8.0 PACKING AND DESPATCH

All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for transportation by ship/rail
or trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/
cases to prevent damage to finish. Crates/cases shall have skid bottom for handling. Special
notations such as ‘Fragile’, ‘This side up’, ‘Centre of gravity’, ‘Weight’, ‘Owner’s
particulars’, ‘PO nos.’ etc., shall be clearly marked on the package together with other details
as per purchase order.
The equipment may be stored outdoors for long periods before installation. The packing shall
be completely suitable for outdoor storage in areas with heavy rains/high ambient temperature.
A set of instruction manuals for installation, testing and commissioning, a set of operation &
maintenance manuals and a set of final drawing shall be supplied along with the shipment duly
enclosed in a waterproof cover.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 249 OF 1216

 SPECIFICATION
FOR
SMALL MV VARIABLE FREQUENCY
DRIVE SYSTEM
(B047-003-SP-6-51-0049, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 250 OF 1216

Abbreviations:

AC : Alternating Current
BIS : Bureau of Indian Standards
BS : British Standard
CBCT : Core Balance Current Transformer
CEA : Central Electricity Authority
CFL : Compact Fluorescent Lamp
CRCA : Cold Rolled Cold Annealed
DC : Direct Current
DCS : Distributed Control System
DOL : Direct On Line
ELR : Earth Leakage Relay
EM : Electromagnetic
IEC : International Electrotechnical Commission
IEEE : Institute of Electrical and Electronics Engineers
IGBT : Insulated Gate Bipolar Transistor
I/O : Input/Output
IP : Ingress Protection
IS : Indian Standard
LED : Light Emitting Diode
MCB : Miniature Circuit Breaker
MCCB : Moulded Case Circuit Breaker
MTBF : Mean Time Between Failure
NEMA : National Electrical Manufacturer’s Association
PCC : Point of Common Coupling
PLC : Programmable Logic Controller
PO : Purchase Order
PVC : Poly Vinyl Chloride
r.m.s : Root Mean Sqaure
THD : Total Harmonic Distortion
VDE : Verband Deutscher Electrotechniker
VFD : Variable Frequency Drive

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 251 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 SITE CONDITIONS

4.0 GENERAL REQUIREMENTS

5.0 TECHNICAL REQUIREMENTS

6.0 INSPECTION, TESTING AND ACCEPTANCE

7.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 252 OF 1216

1.0 SCOPE
The scope of this specification is to define the minimum technical requirements for the design,
manufacture, testing and supply of Medium Voltage, AC Variable Frequency Drive (VFD)
System of small ratings of air coolers and non critical applications (typically upto 55kW motor
ratings). The VFD system shall be complete with Squirrel Cage Induction motor as specified
in data sheet and field mounted local motor control panel.

The Vendor shall be responsible for engineering and functioning of the complete system,
meeting the intent and requirement of this specification and data sheets.

This specification applies to drives connected to line voltage up to 1000 V, AC.

2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the latest editions of the following standards unless
specified otherwise:
IS 325 : Three-phase Induction Motors
IS 3700 : Essential ratings and characteristic of semiconductor devices
IS 3715 : Letter symbols for semi-conducting devices
IS 4411 : Code of designation of semi-conducting devices
IS 5001 : Guide for preparation of drawings for semiconductor devices and
Integrated Circuits
IS-5469 : Code of practice for the use of semiconductor junction devices
IS-8789 : Values of Performance characteristics for Three Phase induction
motor
IS:12615 : Energy Efficient Induction Motors-Three Phase squirrel Cage
IS:14901 : Semiconductor devices-Discrete devices & Integrated Circuits
IS:15880 : Three Phase Cage Induction Motors when fed from IGBT
Converters-Application Guide
IS/IEC: 60947 : Low Voltage Switchgear and Control gear
IEC:60146-1-3 Semiconductor Convertors general requirements and line commuted
convertors- Transformer & reactors
IEC:61800 : Adjustable speed electrical power drive systems
IEEE:519 : Recommended Practices and requirements for Harmonics Control in
Electrical Power Systems

2.2 In case of imported equipment, the standards of the country of origin shall be applicable if
these standards are equivalent or more stringent than the applicable Indian standards.

2.3 The equipment shall also conform to the provisions of CEA Regulations and other statutory
regulations currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between requirements specified in various applicable documents, the
most stringent one shall prevail. However, owner’s decision in this regard shall be final and
binding:

3.0 SITE CONDITIONS

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 253 OF 1216

3.1 The AC drive system shall be designed to operate under site conditions of LEH (Refer
elsewhere). Suitable de-rating factor shall be considered by vendor while selection of
equipment rating.

3.2 The AC drive shall be installed indoors in a non-hazardous room, as specified in data sheet.

3.3 All the equipment shall be designed for continuous duty as per nameplate rating under the
specified ambient conditions.

4.0 GENERAL REQUIREMENTS

4.1 The offered equipment shall be brand new with state of the art technology and a proven field
track record. No prototype equipment shall be offered.

4.2 The vendor shall be responsible for design, engineering and manufacturing of the complete
VFD system to fully meet the intent and requirements of this specification and attached data
sheets.

5.0 TECHNICAL REQUIREMENTS

5.1 Performance Requirement

5.1.1 The system shall be energy efficient, and shall provide very high reliability, high power factor,
low harmonic distortion and low vibration / wear / noise. It shall be easy to install in minimum
time and expense and no special tools shall be required for routine maintenance.

5.1.2 The system shall be designed to deliver the motor input current and torque for the complete
speed torque characteristics of the load, with input supply variation of ±10% and frequency
variation of ±3%. The system shall be suitable for the load characteristics and the operational
duty of the driven equipment. It shall be capable of withstanding the thermal and dynamic
stresses and the transient mechanical torque, resulting from short-circuit.

5.1.3 The drive system shall meet the torque requirements and speed requirements of driven
equipment.

5.1.4 The drive controller shall be equipped with microprocessor based digital regulator with
programmable functions. The power control regulator logic shall provide for an
acceleration/deceleration current limit curve and shall be capable of field adjustments without
shutting the system down. Linear acceleration and deceleration shall be separately
programmable from 0.1 to 20 seconds.

5.1.5 The System shall be suitable for single quadrant operation and the speed variation shall be
with range 1:100 unless otherwise specified with speed set accuracy of ±1% of rated
maximum speed and steady state regulation of ±0.5% of rated speed.

5.1.6 The total harmonic distortion (THD) of the voltage and current at inverter output shall be as
per IEC 61800 and same shall be considered in the design of the motor. The dv/dt limits &
V peak shall also be as per IEC-61800-2.

5.1.7 The controller output overload capacity shall be 150% of rated current of motor for one minute
for constant torque applications, and 110% of rated current for one minute for variable torque
applications at rated voltage. If the motor load exceeds the limit, the drive shall automatically
reduce the frequency and voltage to the motor to guard against overload. If load demands
exceed the current limit for more than 1 minute, the drive shall shut down to prevent over
heating of the motor and damage to the drive.

5.1.8 During operation, the system shall be capable of developing sufficient torque under all load
conditions to respond to a 20% alteration in set point within a time limit up to 60 seconds.

5.1.9 The integrator action of the set point alteration shall be independently adjustable for both an
upward and a downward alteration. The minimum time interval between set point adjustments
by the distributed control systemSOW
VOLUME-2 (ELECTRICAL)
shall& be considered as 10 seconds.
SPECIFICATIONS PAGE NO. 254 OF 1216
5.1.10 Drive shall trip in case the speed exceeds 105%of the maximum operational speed and / or
reduces to 95% of the minimum operational speed for more than 10 seconds.

5.1.11 Maximum noise level from the drive at 1 meter distance, under rated load with all normal
cooling fans operating shall not exceed 75 dB(A).

5.1.12 Variable frequency drive shall be arranged so that it can be operated in an open circuit mode,
disconnected from the motor for start up adjustments and troubleshooting.

5.2 Control Requirement

5.2.1 The system shall operate on constant V/f supply with required voltage boost capability in low
frequency mode of operation.

5.2.2 Short time voltage dips upto 20% of nominal (e.g. in case of a large motor start up connected
to the same bus as VFD), shall not cause the control system to stop functioning and shall not
trip the drive system.

5.2.3 The system shall also be equipped with a facility which will restart the system in case of
voltage dip over 20% or power interruptions for less than 2 seconds, with recovery of the
voltage to its nominal value. The drive shall have the facility to block this feature, if required
by the operator. Upon restart, the converter shall be capable of re-synchronizing onto running
motor and develop full acceleration torque within 10 seconds.

5.2.4 The system shall be suitable for number of starts as per attached standard specification for
Medium Voltage Induction Motors.

5.2.5 The power controller shall be regulated to always start the motor in the forward direction.
Logic shall be provided to prevent the motor from being started in the reverse direction.

5.2.6 The drive motor shall be speed regulated corresponding to 4-20 mA or 0-10 V reference input
signal. Upon complete loss of the user's speed reference signal, the drive shall automatically
run at constant speed as determined by the last speed reference available prior to the loss of
signal.
5.2.7 It shall be possible to vary the speed of the drive in either manual or auto mode. Auto/manual
selection shall be from VFD panel unless otherwise specified.

a) With the selector switch in “manual” mode, the operator shall be able to set the speed
through key pad (mounted on front of the drive panel) or from speed increase/decrease
push buttons (from the field). Motor operated potentiometer shall be provided as a
speed set point device.

b) With the selector switch in “auto” mode, speed of the motor shall be controlled from a
4-20 mA signal, from owner’s PLC/DCS (Process Control) system. Necessary
equipment required for interfacing with PLC/DCS shall also be provided in the VFD
panel.

c) Local/Remote selector switch shall be provided in local control station (in Field). With
the selector switch in “Local” mode, the operator shall be able to start and set the
speed through local control station (in Field). With the selector switch in “Remote”
mode, speed of the motor shall be controlled either from VFD panel or from Owner’s
PLC/DCS as explained in a) and b) above. (For local control station, also refer Cl.
5.5.6 below).

5.2.8 The required provision for the interface with PLC/DCS (located at remote control room)
including the details of communication module and data transfer facility, I/O details shall be
furnished. The communication interface shall be via serial communication link with industry
standard open protocol i.e. MODBUS/Data Highway Plus/ IEC-61850/ RS-485 etc. and same
shall be coordinated with the interfacing equipment. In case the vendor is using their
proprietary software, the interface software for use with owner’s system (software) shall be
provided.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 255 OF 1216
5.3 Panel Construction

5.3.1 Each VFD system shall preferably be housed in separate stand alone panel fabricated using
cold rolled sheet steel. The sheet steel used for the panel shall be of minimum 2 mm CRCA
except the doors & covers that may be made of 1.6mm CRCA. Alternatively common panel(s)
for several VFD systems can be considered, provided suitable barrier for full height are
provided between different VFD module for safety, operation and maintenance.

The VFD panel(s) shall be suitable for indoor installation, if not otherwise specified. The
panel(s) shall be free standing with degree of protection as min. IP-41. The maximum and
minimum operating height shall be 1900 mm and 300 mm respectively.

5.3.2 Each VFD module shall include suitable isolating device (i.e. Circuit breaker/MCCB/ Switch
fuse) for main supply, contactors, semi conducting power devices (Diodes / IGBT) modules
with protective devices, reactors, filters, output isolating device (in case of Bypass), control
circuit, control accessories, indication and annunciation etc.

5.3.3 Main isolating device shall function as a manual disconnect and shall be an AC thermal-
magnetic circuit breaker or a fused switch with dual element fuse to trip automatically on fault
currents, as specified in data sheet. Devices shall be lockable in the open position and shall
have a minimum interrupting capacity as specified in data sheet. Interlock shall be provided
between the door, so that door cannot be opened unless the breaker/switch is open.

5.3.4 Bolted undrilled gland plate shall be provided at bottom with single compression type cable
gland. Clamp type terminals shall be used for connection of all wires up to 10 mm2 and
terminal for higher sizes shall be bolted type suitable for cable lugs. Minimum space for power
cable termination shall be 300mm clear.

5.3.5 Bus bars shall be of electrolytic copper/aluminium, color coded. All the live parts shall be
sleeved / shrouded to ensure complete safety to personnel intending to carry out routine
inspection by opening the panel doors. All the equipment inside the panel and on the doors
shall be provided with suitable nameplate. All wires shall be ferruled and terminals shall be
properly numbered, minimum 20% spare terminal shall be provided.

5.3.6 All the power and control switches shall preferably be mounted on the door and shall be
operable externally. All the analogue instruments, where provided, shall be switch board type,
back connected, 96x96mm. Scale shall have red mark indicating maximum permissible
operating rating.

5.3.7 Each panel shall be provided with illuminating LED lamp with switch and fuse. 5/15A, 240V
power socket with switch and fuse shall be provided. Each panel shall have space heater with
switch fuse and variable setting thermostat.

5.3.8 Copper earth bus of min. 30X6 mm size shall be provided at the bottom of the panel extending
outside the panel on both sides. All the non-metallic components/parts shall be connected to
the main earth bus bar. In case a separate earth bus for electronic control system is required,
the same shall be indicated in the drawings.

5.3.9 All panels shall be of same height so as to form a uniform line-up, to give good aesthetic
appearance.

5.3.10 All the control wiring shall be enclosed in plastic channel. Each wire shall be identified at both
ends by self-sticking wire marker tapes or PVC ferrules. Power and control wiring inside the
panel shall be done with BIS approved, PVC insulated, flame retardant, low smoke, copper
conductor wire. 1.5 mm2 size wire shall normally be used provided the control fuse rating is
10 Amps or less and 2.5 mm2 size for control fuse rating above 16 A for electrical circuits and
0.5 mm² for electronic circuits.

5.3.11 All electronic modules and components shall be accessible from front of panel only. Modular
plug-in/draw-out assemblies for both the system control electronic equipment and power
electronic
VOLUME-2 equipments shall be used.
(ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 256 OF 1216
5.3.12 Suitable removable type hooks shall be provided for lifting the panel(s).

5.4 Cooling

Cooling system shall include well-dimensioned panel, adequate cooling airflow path, module
cooling fan and if necessary, panel cooling fan. Vendor shall ensure that the panel dimensions
and flow paths have been designed for continuous running at the specified ambient without
overheating. For fan cooled drives, redundant ventilating fans (N+1) shall be provided.
Necessary starters shall be provided within the VFD panel for these fans. In case redundant
cooling fan is not possible to be mounted, same shall be supplied loose.

5.5 Equipment/ Component Specification

5.5.1 Motor

The motor shall be designed, constructed and tested in accordance with the attached standard
Specification for Medium Voltage Induction Motor, in addition to the following requirements:

a) The motor shall be inverter grade motor suitable for operation with a solid state power
supply consisting of an adjustable frequency inverter for speed control.

b) The motor shall be suitable for the current waveforms produced by the power supply
including the harmonics generated by the drive.

c) The motor shall be designed to operate continuously at any speed over the range
(1-100%) of rated speed or as specified in data sheet.

d) Motor shall be provided with thermistor type temperature detector.

e) The motors shall be provided with Class ‘F’ insulation with temperature rise limited to
Class ‘B’.

f) The permitted voltage variation should take into account the steady state voltage drop
across the AC drive.

g) Motors required to be transferred to DOL by-pass mode shall be rated for specified
variations in line voltage, frequency and starting current limitations as specified in
data sheet.

h) The motor shall be constructed to withstand torque pulsations resulting from

harmonics generated by the solid state power supply.

i) The motor insulation shall be designed to accept the applied voltage wave form,
within the V peak and dv/dt limits as per IEC-61800-2.

j) The drive manufacturer shall be solely responsible for proper selection of the motor
for the given load application and the output characteristics of the drive.

k) Induced voltage at the shaft end of the motor at no load shall not exceed 250 mV rms
for roller and ball bearings and 400 mV for sleeve bearings. The non driving end
bearing shall be insulated from the motor frame to avoid circulating current. The
insulated bearing end shield or pedestal shall bear a prominent warning.

5.5.2 Power Converter

a) The static power converter shall consist of a line side power converter for operation as
a rectifier and a load side power converter for operation as a fully controlled inverter.

b) Normally, for all output short circuits, the inverter shall interrupt the current before
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 257 OF 1216
 any semi-conductor fuse blows. For internal short circuits, semi-conductor fuse
protection shall be provided, and for faults upstream of semi-conductor fuses, the
converter shall be able to withstand a three-phase short circuit current until interrupted
by normal breaker operation. In case of fuseless design, the failure shall be limited to
the particular device, without causing any damage to other parts of the power module.
There must be clear annunciation of the failure of the device.

c) All power converter devices shall include co-ordination by peak voltage protecting
snubber networks and di/dt and dv/dt networks.

d) The current rating of the converter's semi-conductor components shall not be less than
120% of the nominal current flowing through the elements at full load of the VFD
through the whole speed range.

e) All power diodes shall be of silicon type with minimum V BO rating as 2.5 times the
rated operating voltage.

f) The power converter circuit shall be designed so that motor can be powered at its full
name plate rating continuously without exceeding its rated temperature rise due to
harmonic currents generated by the inverter operation.
g) The conversion devices and associated heat sinks shall be assembled such that
individual devices can be replaced without requiring the use of any special
precautions/tools.

h) The cooling system of the electronic components, if provided, shall be monitored and
necessary alarms shall be provided to prevent any consequential damage to the power
control devices.

i) All the power transistors, thyristors and diodes shall be protected with high-speed
semiconductor grade fuse. I²t particulars of the power controller devices and the fuses
shall be properly co-ordinated for the selection of fuses.

5.5.3 DC Link / AC Line Reactor (if required as per vendor standard design)

a) Smoothing reactors for the DC link shall be provided if required as per standard
design of vendor. AC line reactors, if provided as per standard vendor design, shall be
suitable for harmonic suppression and fault current limitation.

b) The reactor shall be dry type, air cooled or fan cooled type located within the panel.
In case of fan cooled type, operation of fans shall be monitored.

c) Reactor shall be suitable for operation with the non-sinusoidal current wave shapes
and DC components under all operational conditions of the system without exceeding
its temperature limits.

5.5.4 Output Filter

VFD output current waveform shall be inherently sinusoidal at all speeds, with harmonic
limits as per Cl.5.1.6. Output filter capacitors shall be provided with discharge circuits to
ensure that all residual stored charge is reduced to less than 50 V DC within 60 seconds after a
loss of AC voltage.

The VFD system shall inherently protect motor from high voltage dv/dt stress, independent of
cable length to motor. Output filter shall be an integral part of the VFD system and included
within the VFD enclosure.

5.5.5 Bypass Feature

5.5.5.1 Output contactor/Load Break Switch shall be provided for isolation between the output of the
controller and the motor for VFD systems with Bypass feature.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 258 OF 1216
5.5.5.2 Bypass feature shall be provided, if specified in the data sheet. Accordingly bypass feature
with Bypass starter shall meet the following requirements, unless otherwise specified in the
data sheet:-

- Bypass starter shall comprise of switch-fuse, contactor, and bimetal relay meeting the
requirements of Type-2 coordination as per IS/IEC-60947. CBCT and ELR shall be
provided for motors rated above 22kW unless otherwise specified in the data sheet.
Heavy duty starters shall be provided with saturable type current transformer operated
overload relay only, which shall be suitable for motor starting time of 15-60 seconds.

- Bypass starter shall be in separate compartment and it shall be possible to isolate and
maintain the VFD while drive motor runs in Bypass mode. Three contactors/ breakers
shall be used for this purpose, one contactor in the bypass and two contactors across
the drive, such that in case of drive mal-operation, the motor could be taken on bypass
control, while the drive could be attended by opening its contactors. Suitable interlock
shall be provided such that bypass mode and VFD mode shall not operate
simultaneously.

5.5.6 Local Control Station

The local control station shall conform to the attached standard specifications(s).

Meters in the local control station for motors rated above 5.5kW shall be suitable for 4-20mA
transducer outputs and shall be calibrated for the actual motor current unless specified
otherwise . Further, for drives with bypass facility, the meters shall be capable of reading
bypass full load and starting currents, as well as the drive current. Local-off-Remote selector
switch shall be provided in the LCS for selection of control from Local (i.e. LCS in Field) and
Remote (i.e. from VFD panel/ DCS/PLC).

5.6 Protection, Control, Metering and Indication / Annunciation

5.6.1 The manufacturer shall provide all the necessary system control, protection, alarm equipment
and metering for the entire drive system and its auxiliary equipment.

5.6.2 Automatic sequence control shall include start-up of cooling system, interlock checking,
automatic start and run-up of drive, planned and emergency shutdown. The same shall be
processed through microprocessor based system.

5.6.3 Operator Control Panel

Each drive shall be equipped with a front mounted operator control panel consisting of a
backlit alphanumeric display and a keypad with keys for Run/Stop, Local/Remote,
Increase/Decrease, menu navigation and parameter select/save. All parameter names, fault
messages, warnings and other information shall be displayed in Complete English words or
standard English abbreviations to allow the user to understand what is being displayed without
the use of a manual or cross-reference table. This shall also be used for the modification of all
electrical values, configuration parameters, drive menu parameters, application and activity
function access, faults, local control, adjustment storage, self test and diagnostics.

5.6.4 Protective Features

The system offered shall incorporate adequate protective features, properly coordinated for the
drive control and for motor but not limited to the following:

i) Under / Over voltage protection

ii) Phase loss, phase reversal protection
iii) Programmable Over current protection
iv) Inverter Fault protection
v) Over frequency/Over speed protection of motor
vi) Over temperature protection of equipment
vii) Complete motor protection
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 259 OF 1216
 viii) System Earth fault Protection

5.6.5 Alarms
The system shall incorporate protection alarms, required for various fault conditions, for the
Drive motor, Supply cables, DC Reactor, loss of cooling and the Converter.

5.6.6 Control
The controls shall be provided as a part of the Operator Control Panel as per clause 5.6.3
above.

5.6.7 Indications
The following indications shall be provided as a part of the Operator Control panel.

i) Motor running
ii) Motor stopped
iii) VFD System Fault
iv) System ready to start
v) AC mains ON
vi) Motor over speed
vii) Motor zero speed
viii) Remote breaker trip
Potential free contacts shall be wired separately for indications in DCS system.

5.6.8 Metering

Digital display of the following parameters shall be as a part of the Operator Control Panel,
selectable by the operator.

i) Output voltage
ii) Output current VFD / Bypass
iii) Output frequency
iv) Drive thermal state
v) Motor speed
vi) Motor energy meter
vii) Run hour meter
Necessary transducer shall be provided with 4-20mA output for indicating motor speed and
motor current in DCS.
5.6.9 Annunciations

Potential free contacts shall be provided for following annunciation and shall be wired up to
terminal block for owner's use for remote monitoring:

i) Drive fault

All drive internal faults will be annunciated as drive fault.

5.7 Fault Diagnostic

Fault diagnostic shall be built into the system to supervise the operation and failure of the
system.

5.8 External Control Circuit

Control supply for devices external to VFD module i.e contactors control, space heater supply
for Motor / VFD, indicating lamps, digital meters (Ammeter, Speedometer) etc. shall operate
on 240 volts control supply derived from single-phase control supply transformer, with switch-
fuse provided in primary and MCB in secondary, located inside the drive controller.

5.9 Reliability Features

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 260 OF 1216
 i) The expected life time of the VFD shall be minimum 20years. The VFD including all
individual components forming part of the system shall have an availability of minimum
0.997 and a minimum MTBF of 4 years.

ii) The controller design shall incorporate the following reliability features:
- Pre-tested components with power components to be 100% tested under dynamic
conditions.
- Printed circuit boards shall be computer tested and adjusted.
- Printed circuit boards shall be temperature cycled for a minimum of 40 hours.
- Printed circuit boards shall be treated for tropical, humid and corrosive environment.

5.10 Painting
5.10.1 All metal surfaces shall be thoroughly cleaned and de-greased to remove mill scale, rust,
grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of
acid. The under-surface shall be prepared by applying a coat of phosphate paint and a coat of
yellow zinc chromate primer. The under-surface shall be made free from all imperfections
before undertaking the finishing coat.

5.10.2 After preparation of the under surface, the panel shall be provided with epoxy based powder
coating. The color shade of the final paint shall be RAL-7032, unless otherwise specified.
Panel finish shall be free from imperfections like pinholes, orange peels, runoff paint, etc.

5.10.3 All unpainted steel parts shall be zinc passivated, cadmium plated or suitably treated to
prevent rust and corrosion. If these parts are moving elements, then these shall be greased.

6.0 INSPECTION, TESTING AND ACCEPTANCE

6.1 During fabrication, the VFD shall be subject to inspection by EIL / Owner, or by an agency
authorized by the Owner, to assess the progress of work, as well as to ascertain that only
quality raw material is used. The manufacturer shall furnish all necessary information
concerning the supply to EIL / Owner's inspectors.

6.2 All tests shall be carried out at the manufacturer's works under his care and expense. The tests
shall be witnessed by an inspector of EIL/ Owner or of an agency authorized by the owner.

6.3 All Routine & Type Tests shall be conducted as per the ITP for MV variable frequency drive
6-81-1038 on the complete VFD system (as defined in Cl.1.0 above) as per IEC 61800-2.
7.0 PACKING AND DESPATCH

All the equipment shall be divided in to several shipping sections for protection and ease of
handling during transportation. The equipment shall be properly packed for selected mode of
transportation i.e. ship/rail or trailer. The panels shall be wrapped in polyethylene sheets
before being placed in wooden crates/cases to prevent damage to the finish. Crates/cases shall
have skid bottoms for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Weight’,
‘Owner’s particulars’, ‘PO nos.’ etc., shall be clearly marked on the package together with
other details as per purchaser for scrutiny.

The equipment may be stored outdoors for long periods before installation. The packing shall
be completely suitable for outdoor storage, in areas with heavy rains/high ambient
temperature.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 261 OF 1216

 SPECIFICATION
FOR
MEDIUM AND HIGH VOLTAGE
CABLES & ACCESSORIES
(B047-003-SP-6-51-0051, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 262 OF 1216

Abbreviations:

ASTM : American Society for Testing and Materials

BIS : Bureau of Indian Standards
BS : British Standard
CEA : Central Electricity Authority
EPR : Ethylene Propylene Rubber
FR : Flame Retardant
FRLS : Flame Retardant Low Smoke
FS : Fire Survival
HR PVC : Heat Resistant Polyvinyl Chloride
ICEA : Insulated Cable Engineers Association
IEC : International Electro technical Commission
IS : Indian Standards
NEMA : National Electrical Manufacturers Association
PVC : Polyvinyl Chloride
UV : Ultra Violet
XLPE : Cross linked Polyethylene

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 263 OF 1216

 CONTENTS

1.0 SCOPE

2.0 STANDARDS.............................................................................................................

3.0 GENERAL CONSTRUCTION..................................................................................

4.0 CABLE ACCESSORIES............................................................................................

5.0 INSPECTION, TESTING AND ACCEPANCE

6.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 264 OF 1216

1.0 SCOPE

This specification along with data sheets covers requirements for design, manufacture, testing
at works and supply of Fire survival Medium voltage cables and Flame Retardant Low Smoke
Medium & High Voltage cables and cable jointing / terminating accessories for medium and
high voltage systems.

2.0 STANDARDS

2.1 The cables and cables jointing & terminating accessories shall comply with the latest edition
of the following standards as applicable:

IS: 209 : Specification for zinc.

IS: 1554 : PVC insulated (heavy duty) electric cables.
IS: 3961(Pt-2) : Recommended current ratings for cables: Part - 2 PVC Insulated and
PVC sheathed heavy-duty cables.
IS: 3975 : Mild steel wires, strips and tapes for armouring of cables.
IS: 5831 : PVC insulation and sheath of electric cables.
IS: 6380 : Specification for elastomeric insulation and sheath of electric cables.
IS: 7098 : Cross-linked polyethylene insulated PVC sheathed cables.
IS: 8130 : Conductors for insulated electric cables and flexible cords.
IS: 10418 : Drums for electric cables.
IS: 10462 (Pt-1) : Fictitious calculation method for determination of dimensions of
protective coverings of cables: Part - I Electrometric and thermo-
plastic insulated cables.
IS: 10810 : Methods of test for cables:
- Part 41: Mass of zinc coating on steel armour
- Part 58: Oxygen index test
- Part-61: Flame retardant test
- Part-62:Fire resistance test for bunched cables.
- Part-63: Measurement of Smoke density of Electric cables
under fire conditions
IS: 13573 : Joints and terminations for polymeric cables for working voltages
from 6.6kV up to and including 33kV.
IEC: 60331-21: Tests for electric cables under fire conditions circuit integrity –
Procedures and requirements – Cables of rated voltage up and
including 0.6/1.0kV.
IEC: 60332-1 Test of the fire behaviour on single core or single cable (flame
retardancy)
IEC: 60332-3 : Tests of the fire behaviour on bunched cables (reduced flame
propagation)
IEC: 61034 : Measurement of smoke density of cables burning under defined
condition
NEMA-WC70 : Standard for non shielded power cables rated 2000V or less for
the distribution of electrical energy.
NEMA-WC53 : Standard test methods for extruded dielectric power, control,
instrumentation and portable cables for test.
ASTM-G-154 : Standard practice for operating fluorescent light apparatus for UV
exposure of non metallic materials.
ASTM-D-2863 : Measurement of minimum oxygen concentration to support candle
like combustion of plastics
BS: 7846 : Electric cables- 600/1000V armoured fire resistant cables having
thermosetting insulation and low emission of smoke and corrosive
gases when affected by fire.

2.2 The cables and accessories shall also conform to the provisions of CEA Regulations and other
statutory regulations, as applicable.

2.3 In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent one shall prevail. However, Owner’s decision in this regard will be
final
VOLUME-2 and binding.
(ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 265 OF 1216
2.4 Cables shall be designed to operate under specified site conditions of LEH (refer elsewhere).
Suitable precautions / requirements shall be considered by vendor while manufacturing of
cables and accessories.

3.0 GENERAL CONSTRUCTION

3.1 The cables shall be suitable for laying in trays, trenches, ducts, and conduits and for
underground-buried installation with uncontrolled backfill and possibility of flooding by water
and chemicals.

3.2 Outer sheath of all cables shall be black in colour and the minimum value of oxygen index
shall be 29% at 27 ± 2 º C. In addition suitable chemicals shall be added into the PVC
compound of the outer sheath to protect the cable against rodent and termite attack. However,
for earthing cables; colour of outer sheath shall be green.

3.3 All cables covered in this specification shall be Flame Retardant Low Smoke (FRLS) or Fire
Survival (FS). The outer sheath of FRLS cables shall possess flame propagation properties
meeting requirements as per IS-10810 (Part-62) category AF. FRLS cable shall be identified
by indenting, embossing or printing the appropriate legend i.e. `FRLS, Category – C2’
throughout the cable length. FRLS properties shall be as per IS:10810 Part 61 & 62, IEC-
60332 Part 1 & Part 3, IEEE-383, IEC-61034, IEC-60754 Part 1, ASTM-D-2863.

3.4 Sequential marking of the length of the cable in metres shall be provided on the outer sheath at
every one metre. The embossing/engraving shall be legible and indelible.

3.5 The overall diameter of the cables shall be strictly as per the values declared by the
manufacturer in the technical information subject to a maximum tolerance of ±2 mm up to
overall diameter of 60mm and ±3mm for beyond 60mm.

3.6 PVC/ Rubber end caps shall be supplied free of cost for each drum with a minimum of eight
per thousand metre length. In addition, ends of the cables shall be properly sealed with caps to
avoid ingress of water during transportation and storage.

3.7 The joints in armour wire/strips shall be made by brazing or welding and any surface
irregularities shall be removed. A joint in any wire/strip shall be at least 300mm. from the
nearest joint in any wire/strip in the complete cable.

3.8 Medium Voltage Cables

3.8.1 All power/control cables for use on medium voltage systems shall be heavy-duty type,
650/1100V grade with aluminium/ copper conductor, PVC/XLPE (as mentioned in datasheet /
Material requisition) insulated, inner-sheathed, armoured/ unarmoured and overall PVC
sheathed. XLPE insulated cables shall meet the requirement specified in IS-7098 (Part-1).

3.8.2 The conductors shall be solid for conductor of nominal area up to and including 6mm² and
stranded beyond 6mm². Conductors of nominal area less than 16 mm2 shall be circular only.
Conductors of nominal area 16 mm2 and above may be circular or shaped as per IS 8130.
Cables with reduced neutral conductor shall have sizes as per Table 1 of IS 1554 (Part-1).

3.8.3 The core insulation shall be with PVC/XLPE compound applied over the conductor by
extrusion. PVC compound shall conform to the requirements of type 'C' compound as per IS:
5831. The thickness of insulation and the tolerance on thickness of insulation shall be as per
Table 2 of IS: 1554 (Part-1). Control cables having 6 cores and above shall be identified with
prominent and indelible Arabic numerals on the outer surface of the insulation. Colour of the
numbers shall contrast with the colour of insulation with a spacing of maximum 50 mm
between two consecutive numbers. Colour coding for cables up to 5 cores shall be as per
Indian standard.

3.8.4 The inner sheath shall be applied over the laid-up cores by extrusion and shall be of PVC
conforming to the requirements SOW
VOLUME-2 (ELECTRICAL) of Type ST-2 PVC compound as per IS: 5831.
& SPECIFICATIONS The266
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 thickness of inner sheath shall be as per Table-4 of IS: 1554 (Part-1). Single core cables shall
have no inner sheath.

3.8.5 All cables shall be provided with armour except those specifically specified as unarmoured.
For single core cables intended for use on AC system, the armouring shall be of non-magnetic
material. For multicore cables, the armour shall be by single round galvanised steel wires
where the calculated diameter below armouring does not exceed 13 mm and by galvanised
steel strips where this dimension is greater than 13 mm. Requirement and methods of tests for
armour material and uniformity of galvanisation shall be considered as per IS - 3975 and IS -
10810 (Part 41). The dimensions of armour shall be considered as per method (b) of IS - 1554
(Part -1). For single core cables, the armour shall be with H4 grade hard drawn aluminium
round wire of 2.5 mm diameter.

3.8.6 The outer sheath for the cables shall be applied by extrusion and shall be formulated for lower
smoke and shall be of PVC compound conforming to the requirements of type ST-2
compound as per IS: 5831. The minimum and average thickness of outer sheath for
unarmoured cables and minimum thickness of outer sheath for armoured cables shall be as per
Table-7 of IS: 1554 (Part -1).

3.8.7 If heat resisting PVC cables are specified in the data sheet, it shall be possible to continuously
operate the cable at a maximum conductor temperature of 85°C under full load condition and
160°C under short-circuit condition.

3.8.8 For XLPE insulated cables, it shall be possible to continuously operate the cable at a
maximum conductor temperature of 90°C under full load condition and 250°C under short-
circuit condition.

3.8.9 The fire survival cables shall meet the following additional requirements :
i) The insulation shall be of EPR or equivalent material with glass mica tape below or
above insulation.
ii) The cables shall meet requirement of circuit integrity test for a minimum period of 3
hours at maximum temperature of 950⁰ C.
3.9 High Voltage Cables

3.9.1 Power cables from 3.3kV and up to and including 33kV systems shall be Aluminium/ Copper
conductor, XLPE insulated, sheathed, armoured/ unarmoured and overall PVC sheathed.

3.9.2 The conductors shall be stranded and compacted circular for all cables.

3.9.3 All cables rated 3.8/ 6.6kV and above shall be provided with both conductor screening and
insulation screening. The conductors shall be provided with non-metallic extruded semi
conducting screen.

3.9.4 The core insulation shall be with cross linked polyethylene insulating compound dry cured,
applied by extrusion. It shall be free from voids and shall withstand all mechanical and
thermal stresses under steady state and transient operating conditions. It shall conform to the
properties given in Table-1 of IS: 7098 (Part -2).

3.9.5 The insulation screen shall consist of non-metallic extruded semi-conducting compound in
combination with a non-magnetic metallic copper screen. The copper screen for all the three
cores together shall be capable of carrying the single line to ground fault current value and the
duration specified in the data sheet. For single core cable, copper screen provided shall be
capable of carrying the single line to ground fault current value and the duration specified in
the data sheet.

3.9.6 The conductor screen, XLPE insulation and insulation screen shall all be extruded in one
operation by 'Triple Extrusion' process to ensure perfect bonding between the layers. The core
identification shall be by coloured strips or by printed numerals.

3.9.7 The inner sheath shall be applied over the laid up cores by extrusion and shall conform to the
VOLUME-2 (ELECTRICAL)of type ST 2 compound
requirements of IS: 5831. The extruded innerPAGE
SOW & SPECIFICATIONS sheath
NO.shall
267 OFbe of
1216
 uniform thickness. In case of single core cables, there shall be extruded inner sheath between
insulation metallic screen and armouring.

3.9.8 All cables shall be provided with armour except those specifically specified as unarmoured.
For single core cables intended for use on AC system, the armouring shall be of non-magnetic
material. For multicore cables, the armour shall be by galvanised steel strips. Requirement and
methods of tests for armour material and uniformity of galvanisation shall be as per IS - 3975
and IS -10810 (Part 41). The dimensions of armour shall be as per method (b) of IS - 7098
(Part -2). For single core cables, the armour shall be with H4 grade hard drawn aluminium
round wire of 2.5 mm diameter.

3.9.9 The outer sheath of the cables shall be applied by extrusion over the armouring and shall be of
PVC compound conforming to the requirements of Type ST 2 compound of IS: 5831. The
minimum and average thickness of outer sheath for unarmoured cables and minimum
thickness of outer sheath for armoured cables shall be as per IS: 7098 (Part-2).

3.9.10 The thickness of the insulation, inner sheath shall be governed by values given in Table-4 and
Table-5 of IS: 7098 (Part -2).

4.0 CABLE ACCESSORIES

4.1 The termination and straight through jointing kits for use on the systems shall be suitable for
the type of cables offered as per this specification and shall meet requirements of IS 13573.

4.2 The accessories shall be supplied in kit form. Each component of the kit shall carry the
manufacturer's mark of origin.
4.3 The kit shall include all stress grading, insulating and sealing materials apart from conductor
fittings and consumable items. An installation instruction sheet shall also be included in each
kit.

4.4 The contents of the accessories kit including all consumable shall be suitable for storage
without deterioration at a temperature of 45º C, with shelf life extending to more than 5 years.

4.5 Terminating Kits

The terminating kits shall be suitable for termination of the cables to an indoor switchgear or
to a weatherproof cable box of an outdoor mounted transformer/ motor. For outdoor
terminations, weather shields/ sealing ends and any other accessories required shall also form
part of the kit. The terminating kits shall be from one of the makes/ types mentioned in the
data sheet.

4.6 Jointing Kits

The straight through jointing kits shall be suitable for installation on overhead trays, concrete
lined trenches, and ducts and for underground burial with uncontrolled backfill and possibility
of flooding by water and chemicals. These shall have protection against any mechanical
damage and suitably designed to be protected against rodent and termite attack. The inner
sheath similar to that provided for cables shall be provided as part of straight through joint.
The jointing kits shall be from one of the makes/ types mentioned in the data sheet.

5.0 INSPECTION, TESTING AND ACCEPTANCE

The cables shall be tested and inspected at the manufacturer’s works. Manufacturer shall
furnish all necessary information concerning the raw material supply to EIL/ Owner's
inspectors. The inspector shall have free access to the manufacturer's works for the purpose of
inspecting the process of manufacture in all its stages and will have the power to reject any
material, which appears to be of unsuitable description or of unsatisfactory quality. For HV
cables, the vendor shall give at least 2 weeks advance notice to the purchaser, regarding the
date of testing to enable purchaser’s representative to witness the tests.

5.1 Cables
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 268 OF 1216
5.1.1 After completion of manufacture of cables and prior to despatch, the cables shall be subjected
to type, routine, acceptance and special tests as detailed below. The test reports for all cables
shall be got approved from the Engineer before despatch of the cables.

5.1.2 All routine tests, acceptance tests, type tests and additional type tests for improved fire
performance shall be carried out as listed in IS: 1554 (Part-1) and IS: 7098 (Part-2) on PVC
and XLPE insulated cables respectively.

5.1.3 The test requirements for PVC insulation and sheath of cables shall be as per latest revision of
IS: 5831.

5.1.4 Test for Resistance to Ultra Violet Radiation: This test shall be carried out as per ASTM-G-53
or ASTM-G-154 on outer sheath. The retention value of tensile strength and ultimate
elongation after the test shall be minimum 60 % of tensile strength and ultimate elongation
before the test. Test certificates with respect to this test (not older than one year) from
recognised testing laboratory to be furnished for review by EIL before despatch clearance of
cables. In case test certificates are not available, test is to be conducted by vendor at his own
cost in any recognised test laboratory or in house testing laboratory, before despatch clearance
of cables. Sampling for this test is to be done randomly once for each order, provided outer
sheath remains same.

5.1.5 Acceptance tests as per IS-1554 (Part-1) and IS-7098 (Part-2) and the following special tests
to be performed on the cables as per sampling plan for all cables. However these tests are
required to be witnessed by EIL/ Owner for HV cables.

a. Accelerated water absorption test for insulation as per NEMA-WC-70. (For PVC
insulated cables) and as per NEMA-WC-53 (for XLPE/ EPR insulated cables). Test
certificates with respect to this test (not older than one year) from recognised testing
laboratory to be furnished for review by EIL before despatch clearance of cables. In case
test certificates are not available, test is to be conducted by vendor at his own cost in any
recognized test laboratory or in house testing laboratory, before despatch clearance of
cables. Sampling for this test is to be done randomly once for each order, provided type of
insulation remains same.

b. Dielectric Retention Test: The dielectric strength of the cable insulation tested in
accordance with NEMA-WC-70 at 75 ± 1º C shall not be less than 50 % of the original
dielectric strength. (For PVC insulated cables). Test certificates with respect to this test
(not older than one year) from recognised testing laboratory to be furnished for review by
EIL before despatch clearance of cables. In case test certificates are not available, test is
to be conducted by vendor at his own cost in any recognized test laboratory or in house
testing laboratory, before despatch clearance of cables. Sampling for this test is to be done
randomly and once for each order.

c. Oxygen Index Test: The test shall be carried out as per IS-10810 (Part 58). Sampling to
be done for every offered lot/size as per sampling plan.

d. Flammability Test: The test shall be carried out on finished cable as per IS-10810 (Part 61
& 62). Sampling for these tests is to be done randomly once for each order, provided
outer sheath remains same. The acceptance criteria for tests conducted shall be as under:

Part-61-The cable meets the requirement if there is no visible damage on the test
specimen within 300 mm from its upper end

Part-62-The maximum extent of the charred portion measured on the test sample should
not have reached a height exceeding 2.5 m above the bottom edge of the burner at the
front of the ladder.

e. Test for rodent and termite repulsion property shall be done by analysing the property by
chemical method.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 269 OF 1216
5.1.6 Following tests shall be carried out to prove FRLS property of the cable.

a. Critical oxygen index as per ASTM-D-2863 i.e. Determination of % of oxygen required

for combustion at room temperature of FRLS sheath which shall remain as 29%(min.)

b. Temperature index as per ASTM-D-2863 i.e. to determine at what temperature normal

oxygen content of 29% in air will support combustion of FRLS sheath which shall remain
as 250ºC.

c. Halogen acid gas emission as per IEC-60754 Part 1 i.e. to determine the % of release of
hydrochloric acid gas from the FRLS sheath under fire which shall be 20% (max.)

d. Smoke Density Test shall be as per ASTM D - 2843 and Smoke Density Rating of FRLS
Sheath shall be 60% (max.).

5.1.7 The test for circuit integrity for fire survival cables shall be carried out as per IEC-60331
(Part-21).

5.2 Cable Accessories

Type tests should have been carried out to prove the general qualities and design of a given
type of termination/ jointing system as per IS-13573. The type test certificates from
independent testing laboratory shall be submitted before despatch.

6.0 PACKING AND DESPATCH

6.1 Cables shall be despatched in non-returnable wooden drums of suitable barrel diameter,
securely packed, with the take-off end fully protected against mechanical damage. Ferrous
parts used shall be treated with a suitable rust preventive finish or coating to avoid rusting
during transit or storage.

6.2 On the flange of the drum, necessary information such as project title, manufacturer’s name,
type, size, voltage grade of cable, length of cable in metres, drum no., cable code, BIS
certification mark, gross weight etc. shall be printed. An arrow shall be printed on the drum
with suitable instructions to show the direction of rotation of the drum.

6.3 Cables shall be supplied in drum lengths as follows:

6.3.1 MV Cables

- Multicore Power cables upto 6 mm2 : 1000 m

- Multicore Power cables from 10 mm2 up to 500 mm2 : 500 m
- Single Core Power cables upto 630 mm2 : 1000 m
- Control cables upto 61 cores : 1000 m

6.3.2 HV Power Cables Upto 11kV Grade

- Three Core cables upto 400 mm2 : 500 m

- Single Core cables upto 400 mm2 : 1000 m
- Single Core cables above 400 mm2 and upto 1000 mm2 : 750 m

6.3.3 HV Power Cables Above 11kV Grade and upto 33kV Grade

- Three Core cables upto 300 mm2 grade : 350 m

- Single Core cables upto 400 mm2 : 1000 m
- Single Core cables above 400 mm2 and upto 1000 mm2 : 500 m

However exact drum lengths shall be finalised during order execution. A tolerance of ± 3 %
shall be permissible for each drum. However overall tolerance on each size of cable shall be
limited to ± 2%.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 270 OF 1216
 SPECIFICATION
FOR
COMMUNICATION AND
FIRE ALARM CABLES
(B047-003-SP-6-51-0052, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 271 OF 1216

Abbreviations:

ASTM : American Society for Testing and Materials

BIS : Bureau of Indian Standards
BS : British Standard
CEA : Central Electricity Authority
DOT : Department of Telecommunications (Government of India)
FR : Flame Retardant
FRLS : Flame Retardant Low Smoke
FS : Fire Survival
HR PVC : Heat Resistant Polyvinyl Chloride
IEC : International Electro technical Commission
IEEE : Institute of Electrical and Electronics Engineers
IS : Indian Standards
LF : Low Frequency
NEMA : National Electrical Manufacturers Association
PE : Polyethelene
PO : Purchase Order
PVC : Polyvinyl Chloride
UV : Ultra Violet
VDE : Verband Deutscher Elecktrotechniker

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 272 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 SITE CONDITIONS

4.0 TECHNICAL REQUIREMENTS FOR NON JELLY FILLED CABLES

5.0 TECHNICAL REQUIREMENTS FOR JELLY FILLED CABLES

6.0 INSPECTION, TESTING AND ACCEPTANCE

7.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 273 OF 1216

1.0 SCOPE
The intent of this specification is to define the requirements for design, manufacture and
supply of Flame Retardant Low Smoke type and Fire Survival type PVC sheathed cables for
use in plant communication and fire alarm systems and jelly filled telecommunication cables.
2.0 CODES AND STANDARDS
The equipment shall comply with the requirements of the latest revision of the following
standards:

2.1 BIS and other Standards

ASTM D-883 : Standard terminology relating to plastics.

ASTM-D-2863 : Measurement of minimum oxygen concentration to support
candle like combustion of plastics
ASTM-G-154 : Standard practice for operating fluorescent light apparatus for
UV exposure of non-metallic materials.
IEC: 60331-21 : Tests for electric cables under fire conditions circuit integrity –
Procedures and requirements – Cables of rated voltage up and
including 0.6/1.0kV.
ASTM D-924 : Standard test method for dissipation factor (or power factor)
and relative permittivity (dielectric constant) of electric
insulating liquids.
BS-6234 : Specification for polythene insulation and sheath of electric
cables.
IS-694 : PVC insulated cables for working voltages upto and including
1100V.
IS-1554 (Part 1) : PVC insulated (heavy duty) electric cables (Part-1 for working
voltages up to and including 1100V).
IS-5831 : PVC insulation and sheath of electric cable.
IS-8130 : Conductors for insulated cables and flexible cords.
IS-9938 : Recommended colour for PVC insulation for LF wires and
cables.
IS-10418 : Drums for electric cables.
IS-10462 (Part 1) : Fictitious calculation method for determination of dimensions
of protective coverings of cables (Part-1: Elastomeric and
thermoplastic insulated cables).
IS-10810 (Part 58) : Methods of test for cables (Part 58: Oxygen index test).
IS-10810 (Part 61) : Methods of test for cables (Part 61: Flame retardant test)
IS-10810 (Part 62) : Methods of test for cables (Part 62: Fire resistance test for
bunched cables).
IS-12444 : Continuously cast and rolled electrolytic copper wire rods for
electrical conductors.

2.2 DOT Standards

GR/WIR-06/03 : Specification for cable - switchboard (Screened and

Unscreened) - Generic requirements.
GR/CUG-01/03 : Specification for solid polythene insulated fully filled,
polythene sheathed underground telecom cables.

2.3 In case of imported cables, standards of the country of origin shall be applicable, if these
standards are equivalent to or stringent than the applicable Indian standards.
2.4 The cables shall also conform to the provisions of the CEA Regulations and other statutory
regulations currently in force in the country.

2.5 In case Indian standards are not available for any material, standards issued by IEC/ BS/ VDE/
IEEE/ NEMA or equivalent agency shall be applicable.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 274 OF 1216

2.6 In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent one shall prevail. However, Owner’s decision in this regard will be
final and binding.

3.0 SITE CONDITIONS

Cables shall be designed to operate under specified site conditions of LEH (refer elsewhere).
Suitable precautions / requirements shall be considered by vendor while manufacturing of
cables and accessories.

4.0 TECHNICAL REQUIREMENTS FOR NON JELLY FILLED CABLES

4.1 Non jelly filled communication and fire alarm cables shall in general conform to the
requirements of DOT specification GR/WIR-06/03.
4.2 Conductors
4.2.1 The size of conductor shall be as per job requirement.
4.2.2 The conductors shall consist of annealed, high conductivity solid copper wire, smoothly
drawn, circular in cross-section, uniform in quality, free from defects and uniformly coated
with pure tin and shall conform to Cl. 3.0 of DOT specification GR/WIR-06/03.
4.3 Insulation
4.3.1 The core insulation shall be with PVC compound applied over the conductor by extrusion.
4.3.2 PVC insulation shall meet the following requirements:

Conductor Diameter Thickness of Insulation

Type of Insulation
(Area) (Minimum)
Up to 0.5mm (0.2mm2) 0.18 mm
Above 0.5mm (0.2mm2) &
0.26 mm
up to 0.71mm (0.4mm2)
Above 0.71mm (0.4mm2) &
0.31 mm
up to 0.9mm (0.63mm2)
Above 0.9mm (0.63mm2) & Type-A or B as per IS-5831
0.39 mm
up to 1.12mm (1mm2)
Above 1.12mm (1mm2) &
0.58 mm
up to 1.38mm (1.5mm2)
1.78mm (2.5mm2) 0.71 mm
2.26mm (4mm2) 0.80 mm

4.3.3 The colours used for insulation shall conform as nearly as practicable to the standard colours
as per IS-9938. The wire insulation shall have colours in accordance with Table-2 of DOT
specification GR/WIR-06/03. The applied colour shall neither have deleterious effect on the
electrical, mechanical or ageing properties of basic insulation nor shall get damaged by any
friction etc.
4.3.4 For single pair cables, the colour shall be incorporated in the insulation.
4.3.5 For multi pair cables, cores shall have uniform pattern of continuous spiral (Pitch not
exceeding 25mm) to facilitate easy identification. This may be done by the application of one
or more coloured strips on a base colour or by direct extrusion.
4.3.6 Alternately, colouring may consist of concentric coloured rings or dots or dashes on the base
colour. The coloured rings, dots or dashes shall have a width of not less than 1.0mm and shall
be repeated along the length of the insulation at an interval not less than 15mm and not more
than 25mm.
4.3.7 The dots or dashes shall be applied on diametrically opposite sides of the insulation, so that all
colours are visible when the insulation is viewed from any side.
4.4 Twisting

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 275 OF 1216

 The two insulated conductors of a pair shall be uniformly twisted with a suitable right hand
lay, which shall not exceed 80mm.
4.5 Core Formation
The core formation shall conform to Cl. 6.0 of DOT specification no. GR/WIR-06/03.
4.6 Screen
4.6.1 The cables shall be provided with overall screen. The screen shall be of aluminium tape with
minimum thickness of 0.04mm. The overlap shall be minimum 3mm for cables up to 50 pair &
minimum 6mm for cables above 50 Pair. The screen shall be backed by an outer protective
layer of 0.13mm PVC tape or other non-hygroscopic material lapped applied longitudinally or
helically with overlap.
4.6.2 The cables shall be provided with a drain wire. Drain wire shall have a minimum cross-section
of 0.5mm2, shall be composed of multistrand bare tinned annealed copper conductor. The drain
wire shall be in continuous contact with the aluminium side of the overall screen. The drain
wire resistance including screen shall not exceed 30 ohm/km.
4.7 Ripcord
A non-metallic ripcord of suitable quality shall be laid longitudinally under the inner sheath &
screen. The ripcord when pulled shall cut through the sheath and strip the core.
4.8 Inner Sheath
4.8.1 An extruded inner sheath of type ST2 PVC, as per IS-5831, with minimum thickness as per
Table-4 of IS-1554 (Part-1) shall be applied over the laid up core, by extrusion to fit closely on
it.
4.8.2 The inner sheath shall be as circular as possible. It shall be possible to remove the inner sheath
without damage to the insulation.
4.8.3 When one or more layers of non-hygroscopic tape is helically applied over the laid up cores, as
a binder, the thickness of such tape(s) shall not be construed as a part of the inner sheath.
4.9 Armour
4.9.1 The cables shall be provided with armouring, made of hot dip galvanised steel wire /strip over
the inner sheath.
4.9.2 The armour shall be by means of 1.4mm thick round wires for cables with under armour
diameter upto 13mm. For cables with an under armour diameter above 13mm, the armour shall
either be of steel strip or round wire with thickness as per IS-1554 (Part-1).
4.10 Outer Sheath
4.10.1 The cables shall be provided with an extruded PVC sheath for external protection. The PVC
shall be type ST2 PVC, as per IS-5831.

4.10.2 All cables covered in this specification shall be flame retardant low smoke (FRLS). The other
sheath shall be with oxygen index 29% at 27+20C and possess flame retardant low smoke
properties meeting the requirements of IS 10810 Part-62 category - AF. In addition, suitable
chemicals shall be added to the PVC compound of the outer sheath to protect the cable against
rodent and termite attack.
4.10.3 The thickness of outer sheath shall be as per IS-1554 (Part 1).
4.10.4 The outer sheath shall fit tightly on the armour and shall be applied in such a manner that no
undue residual strain is left in the material.
4.10.5 The outer sheath shall be red in colour for cables to be used for fire alarm system, grey in
colour for cables to be used for telephone & communication system and black in colour for all
other functions.
4.10.6 Sequential marking of the length of the cable, in meters, shall be provided on the outer sheath
at every one meter. The marking shall be legible and indelible by suitable method.
4.10.7 The overall diameter of the cables shall be strictly as per the values declared in the data sheet,
subject to a maximum tolerance of +2mm.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 276 OF 1216
4.11 The fire survival cables (if specified in data sheet) shall meet the following additional
requirements:
i) The insulation shall be of EPR or equivalent material with glass mica tape below or above
insulation.
ii) The cables shall meet requirement of circuit integrity test for a minimum period of 3
hours at maximum temperature of 950⁰ C.
iii) Vendor shall have the test certificate for circuit integrity test as per IEC: 60331-21.
4.12 Cable Capacitance
4.12.1 The core to core capacitance of the cables shall not exceed 100nF/km at 1kHz.
4.12.2 The core to screen capacitance for the screened cables shall not exceed 250nF/km at 1kHz.
5.0 TECHNICAL REQUIREMENTS FOR JELLY FILLED CABLES
5.1 Jelly filled telecom cables shall in general conform to the requirements of DOT specification
GR/CUG-01/03.
5.2 Conductors
5.2.1 The conductors shall consist of annealed, high conductivity solid copper wire, smoothly
drawn, circular in cross-section, uniform in quality, free from defects and uniformly coated
with pure tin and shall conform to Cl. 3.0 of DOT specification GR/CUG-01/03.
5.3 Insulation
5.3.1 Each conductor shall be insulated with insulating grade PE conforming to Cl. 4.0 of DOT
specification GR/CUG-01/03.
5.4 Twisting
The two insulated conductors of a pair shall be uniformly twisted with a suitable right hand
lay, which shall not exceed 150mm.
5.5 Core Formation
The core formation shall conform to Cl. 6.0 of DOT specification GR/CUG-01/03.
5.6 Filling Compound
5.6.1 The cable core shall be filled with a suitable stable water resistant compound, which shall be
compatible with the insulation, binders and tapes used in the cable.

5.6.2 It shall be homogeneous and uniformly mixed material containing an anti-oxidant.

5.6.3 The compound shall not obscure the identification of the colour of the insulation of the
conductors.
5.6.4 It shall not contain dirt, metallic particles or other foreign matter.
5.6.5 The compound shall be readily removable from the insulated conductors by wiping.
5.6.6 It shall be free from any unpleasant odour and shall have no toxic or dermatic hazards.
5.6.7 The flash point of the compound shall not be less than 200°C.
5.6.8 The volume resistivity measured at 100°C shall not be less than 1010 ohm-cm.
5.6.9 The permittivity at 1 MHz tested as per ASTM D-924 shall not be greater than 2.3 at 20°C.
5.7 Core Wrapping
At least one closed helical or longitudinal application of a nonhygroscopic and nonwicking
polyester tape or tape of any other suitable material shall be provided over the cable core.
5.8 Screen
5.8.1 The cables used for telephone system shall be provided with overall screen. The screen shall
be of aluminium tape with minimum thickness of 0.2mm. The overlap shall be minimum 3mm
for cables having maximum diameter over inner sheath < 30mm & minimum 6mm for cables
having maximum diameter over inner sheath ≥ 30mm. The screen shall be coated with 0.05
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 277 OF 1216
 mm nominal thickness polythene/copolymer on both sides. The thickness of the composite
tape shall be 0.3mm ± 15%.
5.8.2 The aluminium tape shall be electrically continuous through out the length of the cable.
5.9 Inner Sheath
5.9.1 The inner sheath shall be as circular as possible and free from pinholes and other defects. It
shall be possible to remove the inner sheath without damage to the insulation.
5.9.2 The inner sheath shall be of polythene conforming to type 03C or H03C of BS 6234 and shall
contain a suitable antioxidant system. The material shall be virgin as per ASTM D-883 and
meet the requirements of Cl. 10.1 of DOT specification no. GR/CUG-01/03.
5.9.3 The thickness of inner sheath shall conform to Table-6 of DOT specification no. GR/CUG-
01/03.
5.9.4 The maximum diameter over inner sheath shall conform to Table-7 of DOT specification no.
GR/CUG-01/03.
5.10 Armour
5.10.1 The cables shall be provided with bedding and armour over the inner sheath.
5.10.2 The bedding shall consist of two close helical lappings of polythene or polypropylene tape.
Each tape shall be applied with a minimum of 5% overlap.
5.10.3 The armour shall be made of hot dip galvanised steel tape of thickness as per Table-8 of DOT
specification GR/CUG-01/03.
5.11 Outer Sheath
5.11.1 The external protection shall consist of a polythene sheath conforming to the material
specification defined in Clause 5.9 above.
5.11.2 The thickness of outer sheath shall conform to Table-9 of DOT specification GR/CUG-01/03.
5.11.3 The outer sheath shall be as circular as possible and free from pinholes and other defects.
5.11.4 Colour of outer sheath shall be grey.

5.11.5 The maximum diameter over outer sheath shall conform to Table-7 of DOT specification
GR/CUG-01/03.
5.12 Cable Capacitance
The average mutual capacitance of the pairs measured at 800 to 1000Hz shall be 52 ± 3 nF/km.
However, the mutual capacitance of individual pairs shall be within the limits of 52 ± 4.5
nF/km.
6.0 INSPECTION, TESTING AND ACCEPTANCE
6.1 The cables shall be tested and examined at the manufacturer's works. All the materials
employed in the manufacture of the cable shall be subjected to examination, testing and
approval by EIL/ Owner. Manufacturer shall furnish all necessary information concerning the
supply to EIL/ Owner's inspectors. The inspector shall have free access to the manufacturer's
works for the purpose of inspecting the process of manufacture in all its stages and will have
the power to reject any material, which appears to be of unsuitable description or of
unsatisfactory quality.
6.2 The following acceptance tests shall be conducted on the completed jelly filled cables as per
the test procedures given in DOT specification GR/CUG-01/03 and this specification:

i. Measurement of diameter of conductor, over inner sheath & over outer sheath.
ii. Measurement of thickness of insulation, inner sheath, screen, armour & outer sheath.
iii. Measurement of resistance of conductor.
iv. Measurement of resistance unbalance.
v. Continuity check & measurement of resistance of Poly-al tape.
vi. Colour coding.
vii. Conductor continuity test.
viii. Mutual capacitance test.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 278 OF 1216
 ix. Capacitance unbalance test.
x. Cross talk test.
xi. Attenuation test.
xii. Insulation resistance test.
xiii. Dielectric strength test.
xiv. Drip test.
xv. Armour galvanisation test.
xvi. Conductor annealing test.
xvii. Measurement of drum length.

6.3 Following tests shall be carried out to prove FRLS property of the cable.

a. Critical oxygen index as per ASTM-D-2863 i.e. Determination of % of oxygen required

for combustion at room temperature of FRLS sheath which shall remain as 29% (min.)

b. Temperature index as per ASTM-D-2863 i.e. To determine at what temperature normal

oxygen content of 29% in air will support combustion of FRLS sheath which shall remain
as 250ºC.

c. Halogen acid gas emission as per IEC-60754 Part 1 i.e. To determine the % of release of
hydrochloric acid gas from the FRLS sheath under fire which shall be 20% (max.)

d. Smoke Density Test shall be as per ASTM D - 2843 and Smoke Density Rating of FRLS
Sheath shall be 60% (max.).
6.4 The test for circuit integrity for fire survival cables shall be carried out as per IEC-60331 (Part-
21).
6.5 The following tests shall be conducted on the completed non jelly filled cables as per the test
procedures given in DOT specification GR/WIR-06/03 and this specification:
6.5.1 Acceptance tests

i. Measurement of diameter of conductor, over inner sheath & over outer sheath.
ii. Measurement of thickness of insulation, inner sheath, screen, armour & outer sheath.
iii. Measurement of resistance of conductor.
iv. Colour coding.
v. Conductor continuity test.
vi. Mutual capacitance test.
vii. Capacitance unbalance test.
viii. Insulation resistance test.
ix. High voltage test.
x. Armour galvanisation test.
xi. Conductor annealing test.
xii. Measurement of drum length.

6.5.2 Special Tests

The non jelly filled cables shall also be subjected to following special tests.

i. Oxygen index test as per IS-10810 (Part 58).

ii. Flammability test on finished cable as per IS-10810 (Part 61 & 62).

The special test shall be conducted on one sample from each lot. The sample will be selected
by the inspector.
7.0 PACKING AND DESPATCH
7.1 Cables shall be dispatched in non-returnable steel drums of suitable barrel diameter, securely
packed, with the take-off end fully protected against mechanical damage.
7.2 On the flange of the drum, necessary information such as project title, manufacturer's name,
type, size, length of cable in meters, drum no., cable code, BIS certification mark, gross
weight, ‘Owner’s particulars’, ‘P.O. numbers’ etc., shall be printed. An arrow shall be printed
on the drum with suitable instructions to show the direction of rotation of the drum.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 279 OF 1216
7.3 The drum lengths for cables shall be as below:

- Upto 50 pairs : 1000 meters

- Above 50 pairs & upto 100 pairs : 500 meters
- Above 100 pairs : As per job requirement (subject to max.
length of 500 meters)
7.4 A tolerance of ± 5% shall be permissible for each drum. However overall tolerance on each
size of cable shall be limited to ± 2%.
7.5 For non jelly filled cable, PVC/ rubber end caps shall be supplied free of cost for each drum
with a minimum of eight per thousand meter length. In addition, ends of the cables shall be
properly sealed, with caps, to avoid ingress of moisture/ water during transit and storage.
7.6 For jelly filled telephone cables, the ends of the cable shall be sealed by thermo shrinkable end
caps of adequate wall thickness. Alternately ends may be sealed by enclosing them in rubber
or PVC caps of wall thickness not less than 1.8mm. The caps shall be secured to the outer
sheath with hose clips or ties or black adhesive tape or heat shrinkable sleeves.
7.7 The cables may be stored outdoors for long periods before installation. The packing shall be
completely suitable for outdoor storage, in areas with heavy rains and high ambient
temperature.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 280 OF 1216

 SPECIFICATION
FOR
MV AND HV BUS DUCT
(B047-003-SP-6-51-0054, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 281 OF 1216

Abbreviations:
AC : Alternating Current
BS : British Standard
BIS : Bureau of Indian Standard
CEA : Central Electricity Authority
CPRI : Central Power Research Institute
EIL : Engineers India Limited
HV : High Voltage
IEC : International Electrotechnical Commission
IEEE : Institute of Electrical and Electronic Engineers
IP : Ingress Protection
IS : Indian Standard
FRP : Fiber Reinforced Plastic
MV : Medium Voltage
kA : kilo Ampere
kV : kilo Volts
MCB : Miniature Circuit Breaker
NEMA : National Electrical Manufacturer Association
PVC : Polyvinyl Chloride
V : Volts
VDE : Verband Deuthscher Electrotechniker

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 282 OF 1216

 CONTENTS

1.0 SCOPE
2.0 CODES AND STANDARDS
3.0 SITE CONDITIONS
4.0 GENERAL REQUIREMENTS
5.0TECHNICAL REQUIREMENTS FOR BUSDUCT (COMMON FOR BOTH AIR INSULATED
AND SANDWICH TYPE BUSDUCT)
6.0 SPECIFIC TECHNICAL REQUIREMENTS FOR AIR INSULATED BUSDUCT
7.0 PAINTING
8.0 INSPECTION, TESTING AND ACCEPTANCE
9.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 283 OF 1216

1.0 SCOPE
This specification covers the requirements for design, manufacture, testing at manufacturer’s
works, packing and supply ofMediumVoltage &HighVoltage air insulated and Medium
Voltage sandwich busduct.
2.0 CODES AND STANDARDS
2.1 The equipment shall comply with the requirements of the latest revision of the following
standards issued by BIS (Bureau of Indian standards) unless otherwise specified.
IS:5 : Colours for ready mixed paints and enamels.
IS: 737 : Wrought aluminium and aluminium alloy sheet and strip for general
engineering purposes.
IS:4171 : Copper Rods and Bars for general engineering purpose.
IS:5082 : Wrought aluminum and aluminum alloy bars, rods, tubes and sections
for electrical purposes.
IS: 8084 : Interconnecting bus bars for AC voltage above 1 kV upto and
including 36 kV.
IS:8623(Part-2): Low voltage switchgear and control gear assemblies. Particular
requirement for bus bar trunking system.
IS:12729 : Common High voltage switchgear and controlgear standards.
IS/ IEC 60529 : Degree of protection provided by enclosures (IP Code).
IS/ IEC 60947 : Low Voltage switchgear and control gear.
2.2 In case of imported equipment, standard of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of CEA Regulations with latest
amendmentsand other statutory regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between various referred standards/specifications/data sheets and
statutory regulations, the most stringent requirement shall govern and decision of owner/EIL
in this regard shall be final & binding.
3.0 SITE CONDITIONS
Bus duct shall be suitable for installation and satisfactory operationunder specified site
conditions of LEH (refer elsewhere). Suitable de-rating factor shall be considered by vendor
while selection of equipment rating.

4.0 GENERAL REQUIREMENTS

The offered equipment shall be brand new and having proven field track record. No prototype
equipment shall be offered.

5.0 TECHNICAL REQUIREMENTS FOR BUSDUCT (COMMON FOR BOTH AIR

INSULATED AND SANDWICH TYPE BUSDUCT)
5.1 Busbars of busduct shall be made of high conductivity electrolytic aluminium or copper flats/
channels.
5.2 The enclosure of busduct shall be designed to withstand the maximum applicable mechanical
and electro-dynamic forces. The enclosure of air insulated bus duct shall be of box frame
construction having 3 mm thick cold rolled sheet steel, galvanised steel or aluminium alloy
suitably braced. The enclosure of the sandwich busduct system shall be of galvanised steel or
aluminium alloy painted to provide high protection and mechanical resistance for the phase
conductors along the entire length. The aluminium alloy sheet shall be grade 31000 H2 or
better as per IS: 737.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 284 OF 1216
5.3 The hotspot temperature of bus bars including joints at design ambient temperature shall not
exceed 95º C for normal operating conditions. However, for silver plated joints, the allowable
maximum temperature shall be 115º C.
5.4 The continuous current rating of the neutral bus bars shall be at least half that of the phase bus
bars.
5.5 The busbars, busduct construction and supports shall be adequately sized and braced such that
entire length shall be able to withstand dynamic and thermal stresses expected due to the
specified short time rating
5.6 The busbar installation shall be suitably designed to accommodate expansion and contraction
during all modes of operation.
5.7 Bus duct shall be manufactured in standard lengths. However maximum length of single
straight section generally shall not exceed 3000mm considering transportation and handling.
5.8 The construction of bus duct shall be such that all nuts/bolts shall be easily accessible at
siteduring installation and maintenance.
5.9 Necessary flanged opening shall be provided at the terminating ends of bus duct. These
flanges shall match with corresponding flanges in the equipment to which they are connected.
5.10 GI earth bus of minimum size 75 x 10 mm²shall run throughout the length of bus duct and all
metallic non-current carrying parts shall be connected to it. Sandwich busducts with
aluminium enclosureacting as earth conductor (integral earth) is acceptable, however the
aluminium enclosure shall be suitable to withstand rated short circuit current for specified
time and type test certificates for same shall be available with vendor. The earth bus shall have
provision to connect it either to the system earth bus or to the earth bus of the equipment on
which the bus duct is terminating, as the case may be. The earth bus shall run outside the bus
duct enclosure. Suitable provision shall be made to cross bus duct flanges/joints etc.
5.11 Proper alignment and co-ordination regarding phase sequence etc. between bus duct,
transformer installed outside the switchgear room, switchgear termination etc. shall be ensured
by the bus duct supplier.
5.12 Phase crossover chamber, if required, shall be provided.
5.13 Separate adapter chambers shall be provided at the transformer and switchgear ends, matching
with the transformer flange and switchgear flange respectively.
5.14 The termination of bus bars at the equipment end (e.g. transformer switchgear and generator
end)shall be done through copper flexible.
5.15 Copper flexible shall be thermally fused together at ends and the fused portion of the flexible
shall be tinned. Alternatively, tinned copper strips, riveted at ends, can also be used.
5.16 The bus duct shall be supplied with all the necessary hardware’s required for the site assembly
of shipping sections, including that for bus bar joints/coupling/termination etc. Only zinc
passivated high tensile strength steel bolts, nuts and washers shall be used for all bus bar joints
and supports.
5.17 Bus duct shall be suitably supported inside the switchgear room and for outdoor installation.
Suitable supporting arrangement shall be designed and supplied by the manufacturer with
busduct.
5.18 Each bus duct shipping section shall have details such as switchboard number, bus duct tag
number, section number, painted arrows on the shipping section for connection and easy
matching of adjacent bus duct sections, etc.
5.19 Bus duct drawings shall indicate shipping section markings and the same shall be marked on
crates and the bus duct to ease assembly.
5.20 Suitable wall frame assembly shall be provided at all the wall crossings.
6.0 SPECIFIC TECHNICAL REQUIREMENTS FOR AIR INSULATED BUSDUCT
6.1 High Voltage bus duct shall be phase-segregated type with metallic/ insulating material.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 285 OF 1216

6.2 The busbars of air insulated busduct shall be insulated by using heat shrinkable PVC sleeves
for flats and insulation coating in case of channels. The sleeves/ insulation coating shall be
rated to withstand the system line-to-line voltage for 1 minute.
6.3 All bus bar phases shall be identified with red, yellow, blue, black colour sleeves.
Alternatively colour bands may be used for bus bars identification at all cover openings and at
regular intervals not exceeding 600mm.
6.4 The bus duct shall meet the requirement of water tightness test and air tightness test as
perIS/IEC: 60529 or degree of protection IP-55. Additional canopy shall be provided for
outdoor horizontal portion of the bus duct.
6.5 All bus bar joints shall be provided with removable FRP shrouds.
6.6 Bus bars shall be supported at regular intervals on insulators made of high dielectric strength,
non-hygroscopic, non-inflammable material with tracking index equal to or more than that
defined in standards.
6.7 All joints and covers shall be provided with Neoprene/HDPE/EPDM or equivalent gaskets.
6.8 The covers shall be in suitable lengths for ease of removal and shall be arranged to give
complete accessibility to the bus bars, joints, bends, supports etc.
6.9 Suitable drain holes with drain pipes and plugs shall be provided for natural draining of any
water collecting within enclosure due to moisture condensation. Necessary slope shall be
provided for water drainage so that water does not fall on the switchgear /transformer.
6.10 One flexible, as a minimum, shall be provided for each 3000 mm long straight length of bus
duct. Copper flexible shall be used for expansion joints.
6.11 Bus bar chamber shall be provided with adequate number of space heaters rated at 240V and
shall be complete with MCB and thermostat having variable setting. Suitable connectivity
between different sections of the bus duct shall be provided for the space heaters power supply
6.12 Space heater junction box for termination of incoming cable for bus bar space heaters shall be
provided near switchgear end termination. All wiring/cabling beyond this junction box shall be
in the scope of bus duct supplier. The minimum degree of enclosure protection for junction
box shall be IP-31.
6.13 Bus duct shall be provided with easily accessible inspection covers at suitable intervals not
exceeding 3 meters. Inspection covers shall be provided at bends and bus bars joints.
Inspection covers having weight more than 5 kg shall have lifting hooks. Warning and caution
boards shall be fixed to these covers. Inspection cover shall be suitable for opening from the
bottom or top or sides as per the final bus duct layout.
6.14 Seal off bushings shall be provided inside the enclosure at wall/floor crossings to prevent
propagation of fire. The seal off bushings shall be type tested for the specified short time
rating.
7.0 PAINTING
After preparation of the under surface, the busduct shall be spray painted with two coats of
epoxy based final paint or shall be powder coated. The colour shade of the final paint shall be
631 of IS-5 / RAL-7032 and 632 of IS-5 / RAL-7031 for indoor and outdoor part of the bus
duct respectively, unless specified otherwise. busduct finish shall be free from imperfections
like pinholes, orange peels, runoff paint, etc.
All unpainted steel parts shall be zinc passivated, cadmium plated or suitably treated to
prevent rust and corrosion.
8.0 INSPECTION, TESTING AND ACCEPTANCE
8.1 During fabrication, the BUSDUCT shall be subject to inspection by EIL / Owner, or by an
agency authorised by the Owner, to assess the progress of work, as well as to ascertain that
only quality raw material is used. The manufacturer shall furnish all necessary information
concerning the supply to EIL / Owner's inspectors.
8.2 For testing requirements refer Inspection & Test Plan No. 6-81-1054. Prior notice of minimum
4 weeks shall be given to EIL/owner for witnessing the final testing of the complete assembly
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 286 OF 1216
 to ensure satisfactory operation of all components. Tests shall be carried out at manufacturer's
works under his care and expense.
9.0 PACKING AND DESPATCH
All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for the selected mode of
transportation, i.e. by ship/ rail or trailer, and shall be wrapped in polythene sheets before
being placed in crates/ cases to prevent damage to finish. The crates/ cases shall have skid
bottom for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Center of gravity’,
‘Weight’, ‘Owner’s particulars’, ‘PO no.’ etc., shall be clearly marked on the packages
together with other details as per purchase order.
The equipment may be stored outdoors for long periods before installation. The packing
should be suitable for outdoor storage in areas with heavy rains and high ambient temperature
unless otherwise agreed. A set of instruction manuals for installation, testing and
commissioning, a set of operation & maintenance manuals and a set of final drawing shall be
enclosed in a waterproof cover along with the shipment.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 287 OF 1216

 SPECIFICATION
FOR
NUMERICAL RELAYS
(B047-003-SP-6-51-0055, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 288 OF 1216

Abbreviations:

AC : Alternating Current LCD : Liquid Crystal Display

BS : British Standard LED : Light Emitting Diode
BTD : Bearing Temperature Detector HMI : Human Machine Interface
CBCT : Core Balance Current Transformer TCP-IP : Transmission Control Protocol-
Internet Protocol
CPU : Central Processing Unit MOG : Magnetic Oil Gauge
CT : Current Transformer NEMA : National Electrical Manufacturers
Association
DC : Direct Current NO : Normally Open
DCS : Distributed Control System OTI : Oil Temperature Indicator
ECS : Electrical Control Station PC : Personal Computer
EMI : Electromagnetic Interference PCB : Printed Circuit Boards
FIFO : First in first out PLC : Programmable Logic Controller
FO : Fibre Optic PT : Potential Transformer
GPS : Global Positioning System PVC : Poly Vinyl Chloride
HV : High Voltage REF : Restricted Earth Fault
I/O : Input/output RSTP : Rapid Spanning Tree Protocol
ICT : Intermediate Current Transformer RTD : Resistance Temperature Detector
IDMTL : Inverse Definite Minimum Time Lag RTU : Remote Terminal Unit
IEC : International Electrotechnical SNTP : Simple Network Time Protocol
Commission
IEEE : Institute of Electrical and Electronics SOE : Sequence of event
Engineers
IP : Ingress Protection VDE : Verband Deutscher Elecktrotechniker
IRIG- B : Inter-Range Instrumentation Group WTI : Winding Temperature Indicator
Subcarrier Channel-B
KEMA : Keuring Electrotechnisch Materieel
Arnhem
LAN : Local Area Network

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 289 OF 1216

 CONTENTS

1.0 SCOPE
2.0 CODES AND STANDARDS
3.0 SITE CONDITIONS
4.0 GENERAL REQUIREMENTS
5.0 TECHNICAL REQUIREMENTS
6.0 INSPECTION, TESTING AND ACCEPTANCE
7.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 290 OF 1216

1.0 SCOPE
The intent of this specification is to define the minimum requirement of design, manufacture,
testing, packing and dispatch of numerical relays. The specification also defines the requirement
of communication and integration for Substation Automation System.
2.0 CODES AND STANDARDS
2.1 The equipment shall comply with the requirements of latest revision of following IEC standards /
equivalent Indian Standards, unless otherwise specified:
IEC 60068 : Environmental Testing
IEC 60073 : Basic safety principles for man machine interface, marking & identification –
Coding principles for indicators and actuators
IS/IEC 60529 : Degree of protection provided by enclosure (IP Code)
IEC 60255 : Electrical relays
IEC 61000 : Electromagnetic compatibility (EMC)
IEC 61850 : Communication networks & systems in substations
2.2 In case of imported equipment, standards of the country of origin shall be applicable, if these
standards are equivalent or more stringent than the applicable IEC / Indian standards.
2.3 The equipment shall also conform to the provisions of CEA regulations and other statutory
regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by IEC / BS /
VDE / IEEE / NEMA or equivalent agency shall be applicable.
2.5 In case of any contradiction between various referred standard/ specification/ data sheet and
statutory regulation, most stringent requirements shall prevail. However, Owner’s decision in
this regard will be final and binding.
3.0 SITE CONDITIONS
3.1 The relay shall be tropicalised, for satisfactory operation when installed in a panel located in a
substation / MCC Room with restricted natural air ventilation. Relay shall be designed to
perform all its functions and operate under site conditions of LEH as specified elsewhere.
4.0 GENERAL REQUIREMENTS
The equipment offered shall be brand new with state of the art technology with proven field
track record of similar type and model or model in same series with additional features. No
prototype equipment shall be offered.
5.0 TECHNICAL REQUIREMENTS
5.1 Auxiliary Power Supply
Unless otherwise specified, numerical relays, Ethernet switches, gateway shall be suitable to
accept both AC/DC supplies with range 110V to 240V with tolerance of ± 15%. The auxiliary
power supply shall preferably be site-selectable requiring no additional hardware.
5.2 Basic Requirement and Construction Details
5.2.1 Relay shall be suitable for flush mounting. The relay enclosure front shall be dust tight having
degree of protection minimum as IP51.
5.2.2 Relay terminals shall be suitable for termination of 1.5/2.5/4 sq mm wires, for all hardwired
connections.
5.2.3 Relay shall be modular with plug in type PCB for easy replacement. The relay terminals shall be
easily accessible for testing and commissioning.
5.2.4 Current operated relay shall have provision for minimum 3 number phase CT inputs and 1
number CBCT input. Voltage operated relay shall have provision of minimum 3 numbers PT
inputs. The exact number of CT and PT inputs shall be based on the schematic requirements,
relays shall be selected accordingly.
5.2.5 CT shorting link shall be provided at terminal block as required.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 291 OF 1216

5.2.6 All numerical relays shall have key pad/ keys to allow relay setting from relay front. All hand-
reset relays shall also have reset button on relay front. Self reset or hand reset feature of the relay
shall be software selectable and password protected.
5.2.7 Relay shall be suitable for 1 A or 5A CT secondary. CT secondary 1A or 5A shall either be
software selectable or by providing suitable link. Selection between 1A or 5A should be possible
at site.
5.2.8 Relays shall have self-diagnostic feature with indication of relay failure on relay front. Relay
faults (Self- diagnostic) shall be communicated and annunciated to substation automation
system.
5.2.9 Relays shall, as a minimum, have protection functions as per feeder equipment data sheets. Other
functions such as metering and control shall be provided, if specified in data sheets/job
specifications.
5.3 Software Security
The relays shall be provided with suitable security (pass word protection) against unauthorized
WRITE ACCESS for change in relay setting. However it should be possible to view metering,
protection settings, status and event data as READ ONLY without password protection.
5.4 Display and Indication
5.4.1 All relays shall have LCD display along with LED indications for display of settings, status,
faults and events. Relays for generator protection, switchyard and GIS shall be provided with
medium size LCD display having facility for graphical display of mimic with upto 15 objects on
each page.
5.4.2 LCD display shall be backlit and temperature compensated up to 55°C for contrast and legibility.
5.4.3 Relays shall have 3 fixed LEDs for Relay ON/Control supply ON, fault trip & relay unhealthy
apart from freely configured LEDs.
5.5 Protection Functions
5.5.1 Over Current/Earth Fault Protection
i) This section describes over current & earth fault protection function, which mainly include
different setting stages such as low set, high set and high set instantaneous (51, 50, 51N,
50N). Over current protection function provided should have IDMTL characteristic for low
set and high set stages and definite time delay for high set instantaneous stage.
ii) Over current relay shall be three phase type with 4 elements; 3 elements for inverse and
definite time delay over current and one element for inverse and definite time delay earth
fault current. Selection of inverse or definite time feature shall be user selectable.
iii) The IDMTL characteristic (for 51 and 51N) shall be as per IEC. The inverse characteristics
shall include normal inverse, very inverse, extremely inverse, long inverse and shall be soft
ware selectable. Inverse element shall have two or more stages (low and high set) for
selection of required inverse characteristic to achieve close protection as required.
Definite time characteristic shall have minimum 2 stages with adjustable current and time
setting.
iv) Relay shall also have separate current input from CBCT for measured earth fault current
element. It shall be possible to connect earth fault element either through CBCT or to be
connected residually. Minimum setting current for sensitive earth fault element shall be 1%.
v) Directional overcurrent & earth fault element shall be provided, wherever required.
vi) Voltage biased overcurrent / earth fault element shall be provided wherever required.
5.5.2 Motor Protection
i) Motor protection relay shall have all protection function such as over current, thermal (over
load), locked rotor current, zero sequence, negative sequence, maximum number of start,
motor overload pre-alarm, motor re-acceleration, lock out, inhibit of over current protection
during motor starting through contactor feeders, hour run count, inhibit start after elapse of
maximum number of starts etc.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 292 OF 1216

 ii) The relay shall be provided with 6 Nos. RTD and 2 Nos. BTD analog inputs, if specified in
the data sheet / job specification. Alternatively, external RTD/BTD module having interface
with numerical relay can be provided. The numerical relay with RTD / BTD inputs shall be
suitable for shielded triad cable of conductor size 1.5sqmm copper, unless otherwise
specified.
iii) Separate motor differential protection shall be provided, wherever specified.
5.5.3 Transformer Protection
i) In addition to overcurrent & earth fault function, wherever required, the main numerical
relay shall also include standby earth fault protection function (51G) for the transformer.
The standby earth fault shall operate from a separate neutral CT input and shall have
definite time / IDMTL characteristics as per IEC.
ii) Wherever the transformer requires restricted earth fault protection (64R), separate
numerical relay shall be provided. 64R function can be included as a part of main
differential protection relay (87T), unless otherwise specified. For details of transformer
differential protection relay refer Cl. 5.5.6.
iii) Transformer auxiliary protection (OTI/WTI/Buchholz/MOG etc) shall be included as a part
of numerical relay.
iv) Transformer differential protection shall be provided, wherever specified.
5.5.4 Generator Protection
i) Medium Voltage Generators (415V) shall have all protection functions such as voltage
restrained overcurrent (51V), standby earth fault (51G), negative sequence (46), Reverse
power (32), under voltage (27), overvoltage (59), thermal overload (49), PT fuse failure
monitoring function (60), generator differential (87G) as a minimum.
ii) In addition to the above, HV generators (turbine / diesel engine driven) shall have additional
protection functions such as rotor back up earth fault (64R)-1st and 2nd stage, low forward
power flow (37), loss of excitation (40), under frequency (81U), rate of change of frequency
(df/dt) unless otherwise specified.
iii) If specified in the datasheet, additional protection functions such as field overcurrent, over
frequency (81O), back up impedance (21), over fluxing (99), out of step shall be provided
as a part of generator protection numerical relay.
iv) The generator protection functions can be included as a part of one numerical relay or a
separate numerical relays can be provided.
5.5.5 Voltage Operated Protection Functions
i) These functions include under voltage (27), over voltage (59), ON delay and OFF delay
timers, phase sequence voltage, neutral displacement and Synchro-check functions etc.
ii) The under voltage and overvoltage protective function shall have different stages with
IDMTL and definite time characteristics.
iii) If specified in datasheet, the relay shall have under and over frequency function along with
frequency supervised Rate of change or average rate of change of frequency function.
5.5.6 Differential Protection
Suitable differential protection shall be provided as required as per data sheet / job specification
for the specific application such as for generator, transformer, overall generator & transformer,
motor, feeder, bus section etc. The following requirements, as applicable, shall be complied:
i) Differential protection shall be either high impedance or low impedance type. In case of
high impedance type, suitable non linear resistor shall be provided to limit the peak
overvoltage.
ii) Transformer differential protection shall have suitable harmonic restraint feature to avoid
maltripping during switching.
iii) For transformer differential protection, necessary correction for ratio error and for
transformer primary and secondary vector grouping shall be taken care in the relay itself
without additional ICTs. The required relay setting for this shall be programmable.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 293 OF 1216

 iv) Bus differential relay shall have feature for CT supervision and check differential.
v) In case separate hard-wired relay is used for check differential, the status/ event of same
shall be communicated through the numerical relay provided for main differential
application.
vi) Unless otherwise specified, the differential relays such as generator differential, transformer
differential, overall generator transformer differential, motor differential, feeder differential
etc. shall be suitable for cable connection between CTs and relay using 2.5 sq.mm., Cu
conductor, PVC insulated, armoured cable. However for differential protections provided
for feeders having long lengths, armoured FO cable may be considered. In cases where FO
cable is not suitable, shielded twisted pair cable of conductor size 1.5sqmm copper shall be
specifically mentioned by the bidder in the offer for EIL/Owner’s acceptance on case to
case basis.
5.6 Metering Functions
The metering function shall be provided as required and same shall be built inside the numerical
relays.
5.7 Control Functions
5.7.1 The control function shall be built inside the numerical relays. For this purpose relays shall have
all graphical PLC/Boolean logic functions such that complete control logic of the feeder along
with all necessary interlocks as required can be developed inside the relay.
5.7.2 Relays for motor feeder shall be equipped with all control functions and interlocks related to
motor feeder. If reacceleration is a part of motor feeder, the control function shall also cover
reacceleration logic.
5.7.3 Relays shall have sufficient integral I/Os to take care of complete feeder logic. External I/O
module for implementation of logics is not acceptable.
5.8 Lock Out (86), Trip Circuit Supervision (95), Auxiliary Relays and Timer Functions
5.8.1 Unless otherwise specified the numerical relays shall have built in lock out function. For motor
feeders additional built-in lockout element shall be provided to receive process trip signals. Lock
out elements shall be self reset or hand reset and shall be software selectable.
5.8.2 The numerical relays shall have built in trip circuit supervision function, unless otherwise
specified.
5.8.3 Auxiliary relays/ Timers function etc as required for control schematics shall be programmable
as a part of numerical relay. The number of such elements as required for schematic shall be
considered.
5.8.4 Timer function shall be programmable for both ON/OFF delays.
5.9 Disturbance/ Event Recording and Data Storage
5.9.1 Breaker trip/ close status, relay faults, trip values, event data and disturbance record data shall be
stored in the relay in non-erasable memory or memory backed up by lithium battery. Under no
circumstances such as withdrawal of power to the relays shall the status, data and events in the
memory get erased. Unless otherwise specified, it should be possible to store total 10 seconds of
disturbance recording and 200 sequence of event records. Subsequent events shall be overwritten
following principle of FIFO.
5.9.2 All disturbances/ events shall be time stamped within the relay.
5.10 Input/ Output Interface, Filters and Galvanic Isolation
5.10.1 Voltage (through PT) input to relay, shall be 110V +/- 10%, unless otherwise specified.
5.10.2 Out put relays shall have 4 numbers spare NO contacts; each shall separately be programmable
for either hand reset or self- reset.
5.10.3 Contacts of pushbuttons from field, interlocks from DCS/ other switchboards shall be wired to
the relay as binary input using 1.5/2.5sqmm, multi core, copper conductor cables. The distance
between push buttons/ interlock to switchboard may be considered as 1000m, unless otherwise
specified. The pick-up voltage for BIs/BOs shall be site selectable. The additional components as
required to overcome the cable capacitance effect shall be considered as a part of supply of relay.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 294 OF 1216

 The binary input to relay from field contacts and interlocks shall be momentary type. Logic to
latch the momentary contact, as required shall be built as a part of protection relay.
5.10.4 All I/Os shall have galvanic isolation. Analog inputs shall be protected against switching surges,
harmonics etc.
5.11 Relay Communication
5.11.1 All numerical relay shall have RS232/RJ45/USB port on the front for hooking laptop.
5.11.2 At the rear numerical relays shall have suitable communication port for communication with data
concentrator/ HMI/ Station bus. The type of port shall be selected based on method of
communication (Serial or Ethernet) and type of physical transmission medium (twisted pair
copper or fiber optic). For serial communication, the relay port shall be RS485 or FO (fiber
optic) and for Ethernet (IEC 61850 based) communication same shall be RJ45or FO.
5.11.3 The communication protocol shall be selected to transfer all information including time stamp
data from relay to data concentrator/ substation HMI. The relays shall communicate on industry
open protocol such as IEC 60870-5-103/IEC 61850/ Modbus-RTU / Modbus TCP-IP or any
other open protocol.
5.11.4 For IEC 61850 based communication, each relay shall be suitable for communicating with
minimum three numbers client devices.
6.0 INSPECTION, TESTING AND ACCEPTANCE
6.1 During assembly, EIL / Owner or his authorized representative shall be permitted to assess the
progress of work as well as to ascertain that quality raw material is used for the same. All
assistance as required during inspection shall be given to inspector.
7.0 PACKING AND DESPATCH
The equipment shall be properly packed for transportation by ship/rail or trailer. All equipments
shall be wrapped in polyethylene sheets before being placed in wooden crates/ cases with fillers
to prevent damage to the finish. Crates/cases shall have skid bottoms for handling. Special
notations such as ‘Fragile’, ‘This side up’, ‘centre of gravity’, ‘weight’, ‘Owner’s particulars’,
‘PO nos.’ etc. shall be clearly marked on the package together with other details as per purchase
order.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 295 OF 1216

 SPECIFICATION
FOR
ENERGY EFFICIENT
MEDIUM VOLTAGE
INDUCTION MOTORS
(B047-003-SP-6-51-0064, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 296 OF 1216

Abbreviations:
AL : Aluminium
BASEEFA : British Approvals Service for Electrical Equipment in Flammable Atmospheres
BIS : Bureau of Indian Standards
BS : British Standards
CEA : Central Electricity Authority
CIMFR : Central Institute of Mines and Fuel Research
CPRI : Central power research institute
CT : Current Transformer
CU : Copper
DGMS : Directorate General of Mines Safety
DOL : Direct On Line
EIL : Engineers India Limited
ERTL : Electronics Regional test laboratory
FM : Factory Mutual
FRP : Fiber Reinforced Plastic
IEC : International Electro-technical Commission
IEEE : Institute of Electrical & Electronics Engineers
IP : Ingress Protection
IS : Indian Standard
JEC : Japanese Electro-technical Committee
KLPL : Karandikar laboratories Pvt. Ltd.
LCIE : Laboratoire Central des Industries Electriques
NEMA : National Electrical Manufacturers Association
PESO : Petroleum and Explosive Safety Organisation
PO : Purchase Order
PVC : Poly Vinyl Chloride
RPM : Revolutions per Minute
UL : Underwriter’s Laboratories
VFD : Variable Frequency Drive
VDE : Verband Deutscher Elektrotechniker

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 297 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 OPERATING CONDITIONS

5.0 PERFORMANCE

6.0 CONSTRUCTION DETAILS

7.0 MISCELLANEOUS ACCESSORIES

8.0 CRITICAL SPEEDS

9.0 PAINTING

10.0 INSPECTION AND TESTING

11.0 CERTIFICATION

12.0 PACKING AND DESPATCH

1.0 SCOPE
This specification covers the design, manufacture, testing, packing and supply of energy
efficient-High efficiency (IE2) three phase medium voltage squirrel cage induction motors.

2.0 CODES AND STANDARDS

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 298 OF 1216
2.1 The squirrel cage induction motors and their components shall comply with the latest editions of
following standards issued by BIS (Bureau of Indian Standards) unless otherwise specified:

IS - 5 : Colours for ready mixed paints and enamels.

IS - 325 : Three phase induction motors.
IS - 1076 : Preferred numbers.
IS - 1231 : Dimensions of three phase foot mounted induction motors.
IS - 1271 : Electrical insulation- Thermal evaluation and designation.
IS - 2223 : Dimensions of flange mounted AC Induction motors.
IS - 2253 : Designation for types of construction and mounting arrangement of
rotating electrical machines.
IS - 2254 : Dimensions of vertical shaft motors for pumps.
IS - 2968 : Dimensions of slide rails electric motors.
IS - 4029 : Guide for testing three phase induction motors.
IS - 4889 : Method of determination of efficiency of rotating electrical machines.
IS - 6362 : Designation of methods of cooling of rotating electrical machines.
IS - 7816 : Guide for testing insulation resistance of rotating machines.
IS - 8223 : Dimensions and output series for rotating electrical machines.
IS - 8789 : Values of performance characteristics for three phase induction
motors.
IS - 9283 : Motors for submersible pump sets.
IS - 12065 : Permissible limits of noise level for rotating electrical machines.
IS - 12075 : Mechanical vibration of rotating Electrical Machines with shaft
heights 56 mm and higher - measurement, evaluation and limits of
vibration severity.
IS – 12615 : Energy Efficient induction motors - Three phase squirrel cage.
IS - 12824 : Type of duty and classes of rating assigned to rotating electrical
machines.
IS - 13529 : Guide on effects of unbalanced voltages on the performance of three
phase cage induction motors.
IS - 13555 : Guide for selection and application of three phase induction motors
for different types of driven equipment.
IS - 14568 : Dimensions and output series for rotating electrical machines, frame
numbers 355 to 1000 and flange numbers 1180 to 2360.
IS / IEC60079-0: Electrical apparatus for explosive gas atmospheres (General
requirements)
IS/IEC-60079-1: Explosive atmospheres-Equipment protection by flame proof
enclosures “d”.
IS/IEC60079-2 : Explosive protection by pressurized enclosure “p”.
IS/IEC60079-7 : Explosive atmospheres-Equipment protection by increased safety –
“e”.
IS/IEC-60079-15: Construction, test & marking of type of protection “n” electrical
apparatus.
IS/ IEC: 60529 : Degree of protection provided by enclosures (IP Code)
IS/IEC 60034-1 : Rotating electrical machines:-Rating & Performance

IS/IEC-60034-5: Degrees of protection provided by the internal design of rotating

electrical machines.
IS/IEC 60034-8: Rotating electrical machines-Terminal marking and direction of rotation
IS/IEC 61241: Electrical apparatus for use in the presence of combustible dust

2.2 In case of imported motors, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian Standards.

2.3 The motors shall also conform to the provisions of CEA regulations and other statutory
regulations currently in force in the country.

2.4 In case Indian Standards are not available, standards issued by IEC/ BS/ VDE/ IEEE/
JEC/NEMA or equivalent agency shall be applicable.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 299 OF 1216

2.5 In case of any conflict between requirements specified in various applicable documents, the
most stringent one shall prevail. However, owner’s decision in this regard shall be final and
binding.

3.0 GENERAL REQUIREMENTS

The offered equipment shall be brand new with state of the art technology and proven field track
record. No prototype equipment shall be offered.

4.0 OPERATING CONDITIONS

4.1 Ambient Conditions

Motors shall be suitable for operating satisfactorily under specified site conditions of LEH (refer
elsewhere). Suitable de-rating factor shall be considered by vendor while selection of motor
ratings.

4.2 Frequency and Voltage Variations

Unless otherwise agreed, motors shall be designed for continuous operation at rated output
under the following conditions:

a) The terminal voltage differing from its rated value by not more than + 6 % or
b) The frequency differing from its rated value by not more the + 3 % or
c) Any combination of (a) and (b)

4.3 Starting

a) Motors shall be designed for direct-on-line starting or other method of starting as

specified in datasheet.
b) Motors shall be designed for re-acceleration under full load after a momentary loss of
voltage with the residual voltage being 100% and is in phase opposition to the applied
voltage.
c) Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds
under cold conditions and 8 seconds under hot conditions. In addition, Locked Rotor
withstand time under hot conditions at 75% & 100% voltages, shall be minimum 1.4
times the starting time at the corresponding voltage.

d) Unless otherwise specified, all motors shall be suitable for starting under specified load
conditions with 75 % of the rated voltage at the motor terminals.

e) Motors shall be designed to allow the minimum number of consecutive starts indicated
in Table below:

Starts Min. no. of consecutive starts

No. of consecutive start-ups with initial temp. of the
3
motor at ambient level (cold)
No. of consecutive start-ups with initial temp. of the
2
motor at full load operating level (hot).

4.4 Direction of Rotation

Motors shall be suitable for either direction of rotation. In case unidirectional fan is provided for
motors, direction of rotation for which the motor is designed shall be permanently indicated by
means of an arrow. Directional arrow should be manufactured from corrosion resistant material.
When a motor is provided with bi-directional fans, a double-headed arrow should be provided.

Normally, clockwise rotation is desired as observed from the driving (coupling) end, when the
terminals UVW are connected to a power supply giving a terminal phase sequence in the order
UVW. Counter-clockwise rotation of the motor shall be obtained by connecting the power
supply to terminals so that the phase sequence corresponds to the reversed alphabetical
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 300 OF 1216
 sequence of the terminal letters. Ample space shall be provided at the terminal box for
interchanging any two external leads for obtaining the reverse phase sequence.

5.0 PERFORMANCE

5.1 Motors shall be rated for continuous duty (S 1 ), unless otherwise specified.

5.2 Unless specified, the starting current (as % rated current) shall be limited to maximum 600-
700% (based on number of poles and KW rating) as per IS 12615:2011, subject to IS tolerance

5.3 In particular cases, when the starting current is to be limited, care shall be taken such that the
design values of torque meets the load requirement while at the same time complying to clause
4.3 above of this specification. Unless otherwise specified the minimum pull-up torque of
motors, at rated voltage & frequency shall be minimum 50% of the rated full load torque.

5.4 In particular cases, when the starting with reduced voltage is specified, care shall be taken such
that the design values of torque meets the load requirement while at the same time complying to
clause 4.3 above of this specification.

5.5 Starting torque and minimum torque of the motor shall be compatible with the speed torque
curve of the driven equipment under specified starting and operating conditions.

In case where characteristics of driven equipment are not available while selecting the motor,
minimum starting torque shall be 110% of rated value for motors up to 75 kW and shall be 90%
of rated value for motors above 75 kW.

5.6 The breakdown torque at the rated voltage shall be not less than 175% of the rated load torque
with no negative tolerance. Unless otherwise agreed, the breakdown torque shall not exceed
300% of the rated load torque.

In case of motors driving equipment with pulsating loads (e.g. reciprocating compressors,
crushers, ball mills) the minimum value of pull out torque at 75% of the rated voltage shall be
more than the peak value of pulsating torque and the current pulsation shall be limited to 40%.
5.7 Motors fed by variable frequency drive shall additionally meet the following requirements.

5.7.1 The motors shall be suitable for the current wave forms produced by the power supply including
harmonics generated by the drive. The necessary coordination by motor manufacturers with
drive manufacturers regarding harmonics generated by VFD shall be taken care and
incorporated in motor design suitably.

5.7.2 The motors shall be designed to operate continuously at any speed over the range as per process
requirement with minimum range as 10–100% of rated speed or as specified in data sheet. The
characteristics shall be based on the application – in terms of constant torque / variable torque as
per the driven equipment. Additional cooling fan shall be provided if required to limit the
temperature rise to specified limits, alternatively option of applying suitable de-rating may be
considered.

5.7.3 The motors shall withstand torque pulsation resulting from harmonics generated by the solid
state power supply.

5.7.4 The motors required to be transferred to DOL bypass mode shall be rated for specified
variations in line voltage and frequency.

5.8 The minimum values for performance characteristics of these motors shall be as given in the
tables 1, 2 & 3 of IS 12615-2011 for IE2 motors, subjected to tolerance as per IS/IEC. Motor
meant for application with VFD, the efficiency value can be one class lower as per IS.

6.0 CONSTRUCTIONAL DETAILS

6.1 Windings

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 301 OF 1216

6.1.1 Unless otherwise specified, motors shall be provided with class `B' insulation as a minimum. In
case of motors with class ‘F’ insulation, the permissible temperature rise above the specified
ambient temperature shall be limited to those specified in the applicable Indian standards for
class `B' insulation.

6.1.2 The winding shall be tropicalised. The windings shall preferably be vacuum impregnated.
Alternately the windings shall be suitably varnished, baked and treated with epoxy gel for
operating satisfactorily in humid and corrosive atmospheres.

6.1.3 Windings shall be adequately braced to prevent any relative movement during operation. In this
respect, particular care shall be taken for the stator windings for direct-on-line starting squirrel
cage motors. Insulation shall be provided between coils of different phases that lie together.
Core laminations must be capable of withstanding burnout for rewind at 350 ºC without damage
or loosening.

6.1.4 In case of motors driving equipment with pulsating loads, special care shall be taken for the
joints of rotor bars and end rings to avoid premature failures due to induced fatigue stresses.

6.1.5 The windings shall be connected in delta. However, for motors rated 2.2 kW and below, star
connection may be accepted. In case of motors with star-delta starting, the motor windings shall
be fully insulated for delta connection.

6.1.6 The ends of the windings shall be brought out into a terminal box. These shall be terminated by
means of terminals mounted on an insulating base made of non-hygroscopic and non-flammable
material.

6.1.7 All motors shall be provided with six terminals and suitable links to connect them in star or in
delta except for motors rated up to and including 2.2 kW which may be accepted with three
terminals.

6.2 Terminal Box and Cable Entries

6.2.1 Unless otherwise agreed, the terminal box shall be located on the right hand side as viewed from
the driving (coupling) end. The terminal box shall have side cable entry from non-driving end.
However, as a special case, terminal box located on top may also be accepted, particularly for
hazardous area motors, in case manufacturer has only top mounted terminal box design which is
duly tested/certified by CIMFR and approved by PESO for installation in hazardous area. The
terminal box design shall allow rotation in steps of 90 o C to facilitate cable entry from any
direction at site.

6.2.2 Terminal box cover shall be provided with handles to facilitate easy removal. However, for
terminal box covers weighing less than 5 kg., terminal box covers without handles can be
accepted.

6.2.3 The terminal box shall be provided entries for suitable cable glands corresponding to the size of
the specified cable. Crimp type tinned Copper lugs and nickel-plated brass (or aluminum if
specifically required), double compression type cable glands shall be supplied along with the
motors for the specified cable sizes for power and space heater cables.

6.2.4 For flameproof motors, terminal box can be provided in increased safety ‘Exe’ execution.

6.2.5 The terminals, cable lugs, terminal box, cable entries and cable glands shall be suitable for the
maximum cables sizes as specified below for 2 pole, 4 pole or 6 pole motors:

Motor rating up to and including Size of phase conductor (mm2)

2.2 kW and below 2.5 cu
3.7 kW 6 cu
5.5 kW 10 cu
7.5 kW 16 cu
9.3 kW 16 cu
11.0 kW 16 cu
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 302 OF 1216
 15.0 kW 50 Al.
18.5 kW 70 Al
22.0 kW 70 Al
30.0 kW 95 Al
37.0 kW 120 Al
45.0 kW 150 Al
55.0 kW 240 Al
75.0 kW 2x95 Al
90.0 kW 2x120 Al
110.0 kW 2x240 Al
125.0 kW/132 kW 2x240 Al
160.0 kW 2x240 Al

6.2.6 Cable sizes for motors having synchronous speeds 750 RPM and below shall be as agreed
between the purchaser and manufacturer.

6.3 Motor Casing and Type of Enclosure

6.3.1 The minimum degree of motor enclosures including terminal boxes and bearing housing shall
be IP-55 as per IS.

6.3.2 Motors for outdoor use shall be suitable for installation and satisfactory operation without any
protective shelter or canopy. Motor casing shall be provided with a suitable drain for removal of
condensed moisture except in case of flameproof motors (Type Ex d/Exde).

6.3.3 All internal and external metallic parts, which may come into contact with cooling air, shall be
of corrosion resistant material or appropriately treated to resist the corrosive agents, which may
be present in the atmosphere. Screws and bolts shall be of rust proof material or protected
against corrosion.

6.3.4 Unless otherwise agreed, motors shall have standard frame sizes (min.) for various output
ratings as stipulated in IS.

6.4 Bearing and Lubrication

6.4.1 Motors shall have grease lubricated ball or roller bearings. In all cases, the bearings shall be
chosen to provide a minimum L-10 rating life of 5 years, (40, 000 hours) at rated operating
conditions
(The L-10 rating life is the number of hours at constant speed that 90% of a group of identical
bearings will complete or exceed before the first evidence of failure).

6.4.2 The bearings shall be adequate to absorb axial thrust produced by the motor itself or due to shaft
expansion. Motors designed to handle external thrust from the driven equipment shall be
supplied with a thrust bearing at the non-driving end.

6.4.3 In cases such as pumps for hot liquids where the driven equipment operates at high
temperatures, bearings shall be cooled by a shaft-mounted fan. This shall ensure efficient
ventilation of the bearing and disperse the heat transmitted from the driven equipment by
conduction or convection.
6.4.4 Bearings shall be capable of grease injection from outside without removal of covers with
motors in the running conditions. The bearing boxes shall be provided with necessary features
to prevent loss of grease or entry of dust / moisture e.g. labyrinth seal/ oil seal/ V seal. Where
grease nipples are provided, these shall be associated, where necessary, with appropriately
located relief devices, which ensure passage of grease through the bearings.

6.4.5 Pre-lubricated sealed bearings may be considered provided a full guarantee is given for 4 to 5
years of trouble-free service without the necessity of re-lubrication.

6.5 Cooling System

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 303 OF 1216

 All motors shall be self ventilated, fan cooled. Fans shall be corrosion resistant or appropriately
protected. They shall be suitable for motor rotation in either direction without affecting the
performance of the motor. If this is not possible for large outputs, it shall be possible to reverse
the fan without affecting the balancing of the motor.

For motors operating in hazardous area, the fans shall be of an anti-static non-sparking material.

6.6 Rotor

The rotor shall be of squirrel cage type, dynamically balanced to provide a low vibration level
and long service life for the bearings. Die cast aluminum rotors for motors in hazardous areas
may be accepted provided the same are type tested and approved by competent authorities.

6.7 Shaft Extension

Motors shall be provided with a single shaft extension with key-way and full key. Motor shaft
shall be sized to withstand 10 times the rated design torque.

6.8 Lifting Hooks

All motors weighing more than 30 kg. shall be provided with lifting hooks of adequate capacity.

6.9 Earth Terminals

Two earth terminals located preferably on diametrically opposite sides shall be provided for
each motor. Necessary nuts and spring washers shall be provided for earth connection.

7.0 MISCELLANEOUS ACCESSORIES

7.1 Anti-Condensation Heaters

All motors rated 30 kW and above shall be provided with 240 V anti-condensation heaters,
sized and located so as to prevent condensation of moisture during shutdown periods.

For motors with heaters installed in hazardous atmospheres (Zone - 1 or Zone - 2), such heaters
shall conform to the provisions of applicable Indian Standards and temperature classification
specified in the motor data sheet.

The heater leads shall be brought out, preferably, to a separate terminal box which shall be of
the same specification and grade of protection as the main terminal box.

A warning label with indelible red inscription shall be provided on the motor to indicate that the
heater supply shall be isolated before carrying out any work on the motor.

7.2 Name Plates

In addition to the motor rating plate, a separate number plate for motor tag number shall be
fixed in a readily visible position. This number shall be as per the motor data sheets.

8.0 CRITICAL SPEEDS

The first actual critical speed of stiff rotors shall not be lower than 120 % of the synchronous
speed. For flexible rotors this shall be between 60 % and 80 % of the synchronous speed; the
second actual critical speed shall be above 120 % of the synchronous speed.

9.0 PAINTING

All metal surfaces shall undergo manufacturer’s standard cleaning /painting cycle. After
preparation of the under surface, the equipment shall be painted with two coats of epoxy based
final paint. Color shade of final paint shall be 632 of IS: 5/ RAL-7035. All unpainted steel parts
shall be suitably treated to prevent rust formation. If these parts are moving elements, then these
shall
VOLUME-2 be greased.
(ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 304 OF 1216
10.0 INSPECTION AND TESTING

10.1 All tests shall be carried out at manufacturer’s shop under his care and expense.

10.2 The manufacturer shall submit all internal test records of the tests carried out by him on the
bought-out items, motor sub-assembly and complete motor assembly.

10.3 The manufacturer shall carry out the following routine and acceptance tests as per applicable
Standards/ITP on all the motors.

a) Visual check (Nameplate, terminal box location, terminal type, clearance, size, entries,
space adequacy & gland size, direction of rotation etc.)
b) Dimension check (shaft height etc.)
c) Cable glands, cable lugs size and no. of entries in terminal box.
d) Winding resistance
e) No load test & measurement of voltage, speed, current, power input
f) Measurement of starting torque, starting current, full load torque, breakdown torque
g) Reduced voltage starting & running
h) Insulation resistance before and after high voltage test
i) High voltage
j) Vibration

10.4 The manufacturer shall submit the following type test certificates (one sample from each
type/rating):
a) Full load test & measurement of voltage, current, power slip, power factor, bearing,
noise
b) Efficiency & pf at 100%, 75% and 50% load
c) Temperature rise test
d) Momentary overload test
e) Vibration
f) Noise level
g) Over speed
h) Measurement of starting torque, starting current, full load torque.

10.5 For VFD fed motors, all tests as specified in the VFD specification shall be followed in addition
to the above.

11.0 CERTIFICATION

The motors and associated equipment shall have test certificates issued by recognised
independent test house (CIMFR/ CPRI/ ERTL/ BASEEFA/ LCIE/ UL/ FM/ KLPL or
equivalent). All indigenous motors shall conform to Indian standards and shall be certified by
recognized testing agencies. All motors (indigenous & imported) shall also have valid statutory
approvals (e.g. PESO, DGMS etc). as applicable for the specified location. All indigenous
flameproof motors shall have valid BIS license and marking as required by statutory authorities.

12.0 PACKING AND DESPATCH

All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for transportation by ship/rail or
trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/cases
to prevent damage to the finish. Crates/cases shall have skid bottom for handling. Special
notations such as ‘Fragile’, ‘This side up’, ‘Center of gravity’, ‘Weight’, ‘Owner’s particulars’,
‘PO Nos.’ etc. shall be clearly marked on the package together with other details as per purchase
order.

The equipment may be stored outdoors for long periods before installation. The packing shall
be completely suitable for outdoor storage in areas with heavy rains/high ambient temperature,
unless otherwise agreed.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 305 OF 1216

 SPECIFICATION
FOR
FIRE DETECTION
AND
ALARM SYSTEM
(B047-003-SP-6-51-0076, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 306 OF 1216

Abbreviations TPN Three phase and neutral
TAC Tariff Advisory Committee
BIS Bureau of Indian Standards UL Under Writers Laboratory
BASEEFA British Approvals Service for UPS Uninterrupted Power Supply
Electrical Equipment in VRLA Valve Regulated Lead Acid
Flammable Atmosphere (battery)
MCP Break glass unit VdS Verband der Sachversicherer
CEA Central Electric Authority e.V.
CFAP Central Fire Alarm Panel WP Weather Proof
CIMFR Central Institute of Mines and
Fuel Research (formerly
known as CMRI)
CPU Central Processing Unit
CRCA Cold Rolled Cold Annealed
EEPROM Electrically Erasable
Programmable Read Only
Memory
ERTL Electronic Regional Test
Laboratory
FAT Factory Acceptance Tests
FDD Floppy Disk Drive
FM Factory Mutual
FRP Fibre Reinforced Plastic
FO Fibre Optic
GUI Graphic User Interface
HDD Hard Disk Drive
HMI Human Machine Interface
HVAC Heating Ventilation Air
Conditioning
IEC International Electro-technical
Commission
IEEE Institute of Electrical and
Electronics Engineers
ISDN Integrated Service Digital
Network
IS Indian Standard
ITU-T International
Telecommunication
Union- (Telecom)
LCD Liquid Crystal Display
LED Light Emitting Diode
LPC Loss Prevention Council
LIFO Last In First Out
MCP Manual call point
MR Material Requisition
Ni-Cd Nickel Cadmium (battery)
NFPA National Fire Protection
Association
NEMA National Electrical
Manufacturers Association
PCB Printed Circuit Board
PESO Petroleum and Explosive
safety organization
PO Purchase Order
RF Radio Frequency
SAT Site Acceptance Tests
SOE Sequence Of Event
SMF Sealed Maintenance Free
SPN Single phase and neutral
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 307 OF 1216
 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 DEFINITIONS

5.0 SYSTEM AND SITE CONDITIONS

6.0 FIRE ALARM SYSTEM DESCRIPTION

7.0 CONVENTIONAL FIRE ALARM SYSTEM

8.0 MICROPROCESSOR BASED FIRE ALARM SYSTEM

9.0 INTEGRATION WITH VARIOUS PLANT SYSTEMS

10.0 PANEL CONSTRUCTION (CFAP, REPEATER)

11.0 CABLE AND CABLE ACCESSORIES

12.0 AUTOMATIC FIRE DETECTORS AND ACCESSORIES

13.0 FIELD DEVICES FOR HAZARDOUS AREA

14.0 ENGINEERING REQUIREMENTS

15.0 INSPECTION, TESTING AND ACCEPTANCE

16.0 PACKING AND DESPATCH

17.0 INSTALLATION AND COMMISSIONING

18.0 TRAINING

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 308 OF 1216

1.0 SCOPE

1.1 The intent of this specification is to define the functional and design requirements for an
Integrated Fire Alarm System for industrial plants and buildings. This specification covers the
requirements for selection, design and engineering, manufacture, testing at vendor's works,
supply and installation, testing at site and commissioning unless otherwise stated.

1.2 The Integrated Fire Alarm System shall be conventional or micro processor based analogue
addressable system comprising MCPs, detectors; conventional or microprocessor based Fire
Alarm panels and associated equipment detailed hereunder and in Project data sheets/
drawings.

2.0 CODES AND STANDARDS

2.1 The fire alarm system and the components used shall conform to the latest edition of the
following Codes/Standards, other relevant Indian Standards and International Standards as
applicable.

IS-5 Colours for ready Mixed Paint & Enamels.

IS – 513 Specification for cold rolled low carbon steel sheets and strips
IS – 1646 Code of practice for fire safety of buildings (general): Electrical
Installations
IS – 2175 Specification for heat sensitive fire detectors for use in automatic fire
alarm system
IS – 2189 Code of practice for selection; installation and maintenance of automatic
fire detection and alarm system.
IS – 3034 Code of practice for fire safety of Industrial buildings: Electrical
generating and distributing stations.
IS – 5469 Code of practice for the use of semi-conductor junction devices
(Applicable parts)
IS – 12459 Code of practice for fire safety in cable runs
IS/IEC 60079-0 General requirements for electrical apparatus for explosive gas
atmosphere
IS/IEC 60079-11 Specification for Intrinsically safe electrical apparatus and circuits
IS/IEC 61241-14 Electrical apparatus with protection of enclosure for use in the presence
of combustible dust
NFPA 72 National Fire Alarm code
LPC Loss prevention council recommendations.
BS – 5839 Specifications for manual call points. Part – 2
BS-EN 50081-1/2 EMC (Electromagnetic compatibility test)
BS-EN 50082-1/2 EMC (Electromagnetic compatibility test)

2.2 Standards of country of origin shall be applicable if these standards are equivalent or more
stringent than the applicable Indian Standards in case of imported equipment.

2.3 Equipment shall also conform to the provisions of CEA regulations and other statutory
regulations currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards issued by
IEC/BS/VDE/IEEE/NEMA/UL/FM/VdS or equivalent agency shall be applicable.

2.5 In case of any contradiction between various referred standards/specifications/data sheet and
statutory regulations, the most stringent requirement shall govern and decision of owner in
this regard shall be final.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 309 OF 1216

3.0 GENERAL REQUIREMENTS

3.1 Offered equipment shall be brand new with established state of the art technology and having
proven field track record. No prototype equipment shall be offered.

3.2 Vendor shall be responsible for design & engineering and manufacturing of the complete
system and equipment to fully meet the intent and requirements of this specification and
attached data sheets.

3.3 All equipment and accessories required for completeness of the system, whether specifically
mentioned or not but considered essential for satisfactory performance, shall be included by
the vendor as part of the offered system.

3.4 The system integrator shall coordinate with the manufacturers of various bought-out items
associated with the system as required, and shall freely and readily supply all technical
information as and when asked for.

3.5 All equipment required to be located in hazardous areas shall have test certificates issued by
recognized independent test house such as CIMFR, ERTL, BASEEFA, UL, FM or equivalent.
Indigenous equipment shall conform to Indian standards and shall be certified by Indian
testing agencies. Equipment (indigenous & imported) shall also have valid statutory approvals
e.g. PESO, DGMS as applicable for the specified location. Indigenous flameproof equipment
shall also have valid BIS license and marking as required by statutory authority.

4.0 DEFINITIONS
4.1 CFAP
It is the main or central fire alarm panel located in fire station or in disaster management
control room, which receives inputs from automatic and manual Fire alarm devices and
supplies power to detection and notification devices along with sub-systems where applicable.
CFAP provides interface with telephone exchange, plant’s public address system etc. and has
features, such as provision to activate plant-wide sirens. CFAP is supported by mimic/
graphical display for geographical depiction of alarms either on panel or HMI.
4.2 Integrated Fire Alarm System
It signifies a comprehensive fire alarm system comprising all the distributed fire alarm panels
(repeater panels etc) having integration with CFAP for fire/ fault monitoring of total plant/
buildings. It provides audio/ visual alarm building/plant-wide having provisions for
connectivity with telephone exchange and public address system. It shall provide interfaces
with fire protection system and other systems like pressurization systems, air conditioning,
clean agent system, water spray system, Fire & Gas detection system etc. via potential free
contacts.
4.3 Field Devices
Devices such as detectors, MCPs, exit signs, hooters, siren etc. are termed as field devices.
4.4 Signal Loop (Signaling Circuit)/Signaling Line Circuit
A circuit or path between any combination of circuit interfaces, control units, or transmitters
over which multiple system input signals or output signals, or both are carried.
4.5 Notification Appliance Circuit
A circuit or path directly connected to notification appliances (eg. Bell, horn, speaker, strobe,
printer etc.)
4.6 Zone
A defined area within protected premises. A zone may define an area from which a signal
can be received, an area to which a signal can be sent or an area in which a form of control
can be executed.

5.0 SYSTEM AND SITE CONDITIONS

All equipment shall be designed to operate with power supply and site conditions as specified
below:
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 310 OF 1216
5.1 Site Conditions
The offered equipment, fire alarm panels along with associated hardware shall be capable of
operating continuously and maintaining its guaranteed performance at the site ambient
conditions of LEH as specified elsewhere. For battery sizing, minimum ambient temperature
shall be considered as 10ºC.

5.2 Input Power Supply

5.2.1 Primary power supply will be provided by Owner at 240V, 50Hz, SPN at one point to each
Fire Alarm Panel. Suitable power distribution to various signaling and notification devices
shall be included in the vendor’s scope. For microprocessor based system, 240V, 50Hz, SPN
power supply to remotely located Repeater panel and sub-system, if any, shall be provided by
the Owner on the basis of actual system configuration and requirements.

5.2.2 Unless otherwise specified, secondary power supply for fire alarm panels shall be through
battery provided by the vendor. This shall have sufficient capacity to operate the fire alarm
system under quiescent load (system operating in a non-alarm condition) i.e. to operate a local
central station or proprietary Fire alarm system for a minimum of 24 hours. At the end of that
period, this shall be capable of operating all alarm notification devices used for evacuation
and to direct aid to the location of emergency for 5 minutes.

The secondary power supply for in-building fire emergency voice/alarm communication
service shall be capable of operating the system under quiescent load for a minimum of 24
hours and then be capable of operating the system during a fire and other emergency
conditions for 15 minutes at maximum connected load.

The secondary power supply capacity required shall include all power supply loads that are
not automatically disconnected upon the transfer to secondary power supply.

Battery sizing calculations shall be reviewed during detailed engineering and there shall be no
cost/time implication for providing adequately sized batteries and chargers of approved rating
during the order execution.

An overall ageing factor of 0.8 and a temperature correction factor corresponding to

minimum temperature of 10ºC shall be considered for battery sizing. The battery calculations
shall include a 10 percent safety margin to the calculated amp-hour rating.

Operation on secondary power shall not affect the required performance of a fire alarm
system or supervising station facility. The system shall produce the same alarm, supervisory
and trouble signals and indications.

The switch-over from primary source to secondary source, in the event of mains failure, shall
be automatic. Battery shall be VRLA/ SMF type as specified in the datasheet. Suitable
adequately rated battery charger shall be supplied as a part of secondary power source. Quick
charging of the battery from fully discharged state shall be attainable in 10-14 hours except
VRLA batteries, which shall follow the charging cycle according to supplier’s
recommendations.

6.0 FIRE ALARM SYSTEM DESCRIPTION

6.1 General
Fire alarm system, under this specification, is envisaged to provide fire monitoring in
industrial plants and buildings. The system shall be designed to detect incipient fires, smoky
fires and flaming fires and generate audio/ visual alarm on detection of smoke or fire.

The system shall consist of automatic fire detectors and break glass units. Automatic fire
detectors shall work on the principle of sensing of smoke, heat or infrared / ultraviolet rays.
Depending on type of smoke, optical or ionization type detectors shall be used. Detectors
shall generally be provided in plant/ buildings. MCPs shall be provided at exit doors of the
buildings, exit routes of industrial plants and along service roads surrounding protected areas.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 311 OF 1216
 Number of detectors and break glass units shall be decided as per guidelines given in
applicable codes and standards.

For FA system, Plant/ building shall be divided into fire monitoring zones. In defining zones,
care shall be taken to ensure that location of fire can be easily identified. No two buildings
shall be combined to form one zone. Detectors and MCPs at these buildings and plants shall
be connected to CFAP. These panels shall continuously monitor the state of these devices. On
sensing fire condition, an audio/ visual alarm shall be initiated identifying the zone where fire
is detected. Panels shall continuously monitor the health of the cabling and in case of short
circuit or open circuit fault alarm shall be activated. Fire alarm panels shall also have powered
outputs for switching on exit signs and hooters as specified in data sheet/ drawings. Further,
panels shall provide required output for interfacing with the Owner’s systems such as air
conditioning system or pressurization system or fire protection systems.

Alarms, if specified, shall be relayed to repeater panel provided in buildings like control
rooms/ administrative buildings to provide zone wise annunciation. In addition facility shall
be provided to actuate siren/ hooter.

For integrated fire alarm system where plant-wide large numbers of fire alarm panels are
envisaged, these panels shall be integrated to CFAP, which shall be located in fire station,
disaster management control room or in administrative control room of the building as per the
job requirements. The connectivity shall be achieved using data high way or dedicated cable
connection from each fire alarm panel to CFAP. In conventional system Mimic at CFAP shall
be provided for fire/ fault annunciation depicting geographical location in addition to the text/
LED on the CFAP. This will be in the form of graphics available at HMI in microprocessor
based system. If defined, CFAP shall have provision for automatic and manual actuation of
plant-wide siren as per operator’s choice. Interface with other systems such as telephone
exchange/ plant’s public address system shall be provided for communication required for
disaster management.

6.2 Conventional / Addressable fire alarm systems

6.2.1 Fire alarm system shall be addressable microprocessor based having addressable type field
devices as specified in data sheet.

6.2.2 Microprocessor based fire alarm system shall generally comprise but not be limited to the
following equipment used in conjunction with addressable automatic detectors and
addressable MCPs as a minimum.
• CFAP consisting of computer based graphic work station and engineering station.
• Sirens and starters/siren control panels
• Hooters & exit sign
• Interface with Owner’s systems
• Data Highway
[Copper/ FO cable data highway complete with redundant architecture for
communication, hardware including communication port, switches, processor and power
supply.]
• Any other hardware/ Software required for rendering system complete.

6.2.3 As specified in data sheet, the system shall be provided with siren/s to be located at a suitable
location/s in the plant and it shall be actuated manually and automatically as selected by
operator from CFAP located at fire station/ other buildings.

7.0 ANALOGUE ADDRESSABLE FIRE ALARM SYSTEM

7.1 Design Feature
7.1.1 Unless otherwise specified Microprocessor based FA system shall be analog addressable type.
The system shall be integrated as per ‘system architecture’ indicated in data sheets/ drawings.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 312 OF 1216

7.1.2 Fire alarm system shall be designed consistent with state of the art technology. All fire alarm
panels including repeater panel shall be networked through data high way. The system
supplied shall not pose any limitation for future expansion by way of networking of fire alarm
panels, data transfer, parameterization of addressable field devices, graphic displays etc.
7.1.3 The system shall be modular and shall facilitate future extension/ modification. Panel design
and component selections shall be done for future extension up to 10% of specified number of
loops or one loop whichever is maximum in each panel. The design of common facility and
hardware shall be provided for required future extension.

7.1.4 PCBs shall have watchdog feature for self-diagnostic. Each PCB shall have LED for
annunciating card failure. Following self-diagnostic features shall be considered as minimum
for the system.
i) Open loop detection
ii) Short circuit detection
iii) Earth fault detection
iv) Power supply failure e.g. low battery voltage, main incoming supply fail
v) System faults (PCB failure)

7.1.5 Unless specified otherwise in data sheet, system architecture shall have minimum redundancy
indicated below at CFAP, however not limited to the same.
i) Redundant at processor level (communication processor and I/O card processor)
ii) Redundant communication port
iii) Redundant data highway cable. (For data highway ring topology will be
preferred)
iv) Redundant microprocessor
v) Redundant power supply card at all fire alarm panels (but with non-redundant
battery backup)

7.1.6 Data highway shall be using Fibre optic or twisted pair shielded copper cable as specified in
data sheets. Whether specified or not, data highway shall include all necessary hardware such
as modem, repeaters, network switches/ hubs etc including power supply system as required
to suit the length of data highway.

7.1.7 The communication shall be peer to peer between CFAP and other system components
connected on fire alarm system data highway.

7.1.8 Any fault in Analogue detector addressable loop (signaling loop/ circuit), notification
appliance circuit and data highway shall not impair communication, i.e. Communication/ flow
of analogue signal shall be possible from either end.

7.1.9 The loop cabling for wiring detectors and MCPs shall be class A, fault tolerant type as per
NFPA 72.

7.1.10 Fire alarm logic shall be programmable type. The logic for zone protected with clean agent
system/ CO 2 , shall be programmed to provide output for actuation after ensuring that there is
no false alarm using alarm verification feature. Similarly logic to switch ON sounders.
Beacon and hooters shall be programmable type. Exit sign shall remain ON all the time.

7.1.11 The logic shall be so programmed that it will ensure silencing of the current alarm by
ACCEPT push button & shall not prevent annunciation of subsequent fire alarm received
from any other location.

7.1.12 Signal-to noise ratio shall be high to avoid spurious actuation due to noise induced in the field
wiring because of proximity with power cables. Unless otherwise specified, fire alarm cables
laid in buildings shall be twisted pair, screened and unarmoured and shall be laid in conduits
while cable laid outdoor in plant shall be twisted pair, screened and armoured. If required
noise filters shall be provided at fire alarm panel.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 313 OF 1216

7.1.13 Unless specified otherwise in data sheet, the minimum number of detectors/ MCPs/
addressable devices in a signal loop shall be 240.

7.1.14 Unless specified otherwise in data sheet, conductor size of loop cable shall be 1.5sqmm
copper. The allowable signal loop length shall not be less than 2 km.

7.1.15 Repeater panel shall have backlit alphanumeric LCD display to provide addresses and status
of each field device. In addition LEDs shall be provided for fire/ fault visual annunciation.
LED shall also be provided for Power supply healthy, Battery backup ON, Battery/ Charger
status.

7.1.16 Fire station shall be provided with redundant PC(s) with monitors for operator’s work
station and for engineering station. Any of the two should be possible to configure as
engineering station for programming off line. After Programming, the engineering station
will be connected to network as online operator’s workstation. Programming shall also
allow activating Siren from the keyboard in manual mode as per operator’s choice.

7.1.17 All field devices such as detectors and MCPs shall be addressable type. If available in
vendor’s design, hooters and exit signs may also be connected in addressable loop. Fault
isolators shall be provided to minimize outage of number of detectors/ MCPs in case of loop
cable fault. For hazardous area flame proof equipment shall be used. As far as possible, the
use of intrinsically safe field devices in hazardous area should be avoided. If unavoidable, due
care shall be taken care in design to avoid signal distortion and thus the mal-operation due to
cable capacitance and inductance.

7.1.18 System shall provide adequate EEPROM size to store minimum of 200 events fire/ fault. The
event shall be stored in LIFO structure. All events shall be time stamped.

7.1.19 Software access for either Zone programming or access to plant/ building graphic on monitor
shall be password protected. For viewing status of various field devices e.g. fire and fault
status password protection shall not be given.

7.1.20 All Fire alarm panels including repeater panels and CFAP shall be certified/ approved by an
international approving agency/ approving agency of country of origin as applicable.

7.2 CFAP with PC Based Monitoring Station or Work station

7.2.1 Vendor shall supply CFAP along with PC based work stations. Application software shall be
installed in PC as Graphic User Interface. The graphic shall include geographical display of
locations of various plant areas including locations of addressable detectors and MCPs.
The navigation between various graphic pages shall be user friendly. Screen shall have
defined area to display the latest fire or fault alarm and shall also have facility to pop up the
graphic displaying the location of fire event.

Where specifically indicated CFAP shall include network PC based monitoring station based
on vendor’s system design directly connected to data highway with other peripherals such as
network switches/ controller (HUB).

7.2.2 CFAP shall monitor the status of each addressable field device indirectly connected on data
highway.

7.2.3 Engineering workstation shall be used for programming off-line. After programming, the
changed parameters shall be down loaded to other PC to work in synchronism as normal
operation. This station shall also have one laser printers connected to PCs working as
engineering printer.

7.2.4 The monitoring station/work station shall be equipped to display the overall plot plan showing
all MCPs along the unit roads. The display shall have three levels of penetration, which
permits zooming on to any process unit/area or any building. Further one may zoom into
specific rooms of the building and view the detectors below the false floor, above the false

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 314 OF 1216

 ceiling or in the room cavity. The CFAP shall also display the location of fire/ fault when
such an event occurs.

7.2.5 Unless specified otherwise, adequately rated UPS with bypass shall be provided for the
workstations and printers of CFAP. Battery backup shall be sized as per criteria given under
5.2. Only normal supply shall be made available at one point by Owner at the location of
central fire alarm panel. Where both CFAP and PC based work stations are provided the
battery backup time for the UPS shall be 30 min. Battery back-up to CFAP shall be as per
clause 5.2.

7.2.6 It shall be possible to actuate plant-wide siren in auto/ manual mode. Unless otherwise
specified, manual actuation shall be done from keyboard of workstation. Auto actuation shall
be through software logic, which shall be finalized with end user during implementation.
Auto/Manual selection shall be provided at operator’s work station.

7.2.7 The minimum requirements for the PC and other peripherals shall be as stated below:
* Industrial type Latest generation PC
* DVD-RW
* Mouse and keyboard
* 24Inch coloured touch monitor
* Engineering laser jet coloured printer with 8 PPM

*Application software supporting graphics with no limitation on number of graphics, events,

alarms, number of field devices as required for any large plant like refinery, petrochemical
complex or large multistory building.

7.4.8 It shall be possible to provide multilevel access of fire alarm system. Read only access shall
not require password protection. Access for programming and access for controls from
keyboard shall be password protected. The levels of password protection shall be agreed with
plant operators at the time of commissioning of system.

7.4.9 Printer

Printer options shall include graphic laser printer. Printer used in the system shall provide real
time records of the system events and provide system reports on demand, and shall be
microprocessor controlled, high speed, read only (RO).

8.0 INTEGRATION WITH VARIOUS PLANT SYSTEMS

8.1 Fire Alarm System shall have required hardware to have interface with following plant
systems as specified in data sheet via potential free contacts.
a. Public Alarm Announcement system
b. Paging and plant communication systems
c. Plant data network
d. ISDN telephone exchange
e. Fire suppression system
f. Clean agent system
g. Fire & Gas detection system
h. Access Control System
9.0 NIL
10.0 PANEL CONSTRUCTION (CFAP)

10.1 All fire alarm Panels shall be free standing, floor mounting type unless specified otherwise and
shall be fabricated out of minimum 2mm thick CRCA sheets and doors shall be fabricated
out of minimum 1.6mm CRCA sheets. The panel shall be naturally ventilated in IP-41
enclosure protection as minimum.
The colour shade of final paint shall be 536 as per IS: 5, unless otherwise specified.

10.2 Equipment Mounting

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 315 OF 1216
10.2.1 All apparatus, display screen, instruments and indicating lamps mounted on the panel front
shall be flush mounting type. The external cabling shall not be terminated directly on the base
connector of PCBs but shall be terminated on separate terminal block. Further connection to
PCBs shall be as per manufacturer’s standard. Routine calibration, adjustments, programming
and operation shall be accessible from the front of the panel without opening the door.
External cabling shall preferably be done from the rear.

10.2.2 Power supply system including VRLA battery bank shall be mounted inside the panel.

10.2.3 Doors shall be provided with pistol grip handle with lock. Lamps shall be provided inside the
panel to provide adequate light for maintenance of equipment.

10.2.4 Cable entry shall be from bottom unless otherwise specified in the data sheet. Terminal strip
shall be provided for incoming / outgoing cables.

10.3 Wiring and Terminals

10.3.1 Wiring within the panel shall be harnessed in slotted plastic raceways enclosed with cover.
Control connections shall be done with 660V grade PVC insulated wires having stranded
copper conductors. 1.5mm2 size of wire shall normally be used for circuits with control fuse
rating of 10A or less. Control wiring for electronic circuits shall be through ribbon cable or
through copper wire minimum of 0.5mm dia. Panels shall be supplied completely pre-wired,
such that only field termination shall be required at site before it is energized.

10.3.2 PCBs for identical functions shall be interchangeable. PCBs shall be plug in type having
pin/edge connectors. PCBs shall be suitable for use in tropical, humid and dusty environment.
These shall be protected with anti fungus treatment.

10.3.3 Cables shall be terminated on terminal blocks. Clamp type terminals shall be of spring-
loaded, stacking type, mounted on rails. Terminals shall be sized to accept, as a minimum
2.5mm2 cross section conductors. Not more than one conductor shall be terminated on the
outgoing side of each terminal. At least 20 % spare terminals shall be provided in each panel
for termination of spare cores of cables.

10.4 Earthing

A common earth bar of minimum 25 mm x 3 mm. copper or equivalent aluminum shall be

provided throughout the length of the panel. All non-current carrying metallic parts of the
panel-mounted equipment shall be earthed. Flexible jumpers shall connect all doors and
movable parts to the earth bus. Two numbers earth lugs shall be provided outside the panel.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 316 OF 1216

10.5 Name Plates / Warning plates

10.5.1 All nameplates for panel shall be engraved out of 3 ply (black-white- black) lamicoid sheets
or anodized aluminum. Back-engraved Perspex sheet nameplates will also be acceptable.
Engraving shall be done with square groove cutters. Hard paper or self-adhesive plastic tape
nameplates shall not be acceptable.

10.5.2 Labels shall be provided for every component on the cards, connecting wires as well as for
the terminals in the terminal strip inside the panel. Wiring diagram shall be pasted inside the
panel door as required for termination and maintenance.

10.5.3 Special warning plates shall be provided on all removable covers or doors giving access to
energized metallic parts above 24 volts.

10.6 Painting

10.6.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust,
grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of
acid. The undersurface shall be made free from all imperfections before undertaking the
finishing coat.

10.6.2 After preparation of the undersurface, the panel shall be powder coated. The colour shade of
final paint shall be as approved by the Owner. The finished panels shall be dried in dust free
atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels, run-off
paint etc.

10.6.3 All unpainted steel parts shall be zinc passivated or suitably treated to prevent rust-corrosion.
Moving elements shall be greased.

11.0 CABLE AND CABLE ACCESSORIES

11.1 Supply and laying of FA cables shall be as per the requirement specified in the MR/data
sheet. Vendor shall provide JBs for detectors, MCPs, exit signs, hooters etc.

11.2 Where supply and installation of field cabling is excluded from vendor’s scope, terminations
of all cables (supplied by both vendor/ Owner) at both ends shall be in vendor’s scope.

11.3 Bidder, as a part of integration and selection of fire alarm equipment, shall furnish detailed
specifications for loop/zone cables, data highway cables, cables for hooter/exit signs etc
giving details such as type of cables, number of pairs, size of cable, inductance and
capacitance data, number of fibres/ connectors etc.

11.4 Data Highway Cables

11.4.1 Unless specified otherwise, vendor shall supply Copper cable/ FO type data highway cable to
suit system design and equipment specification. Copper cables, if supplied, shall be of
adequate size, twisted pair, PVC insulated, overall screened, PVC inner sheathed, armoured,
FRLS type PVC outer sheathed as the minimum requirement. Fibre Optic cables, if supplied,
shall be armoured, overall FRLS PVC outer sheathed and shall be as per ITU-T
recommendation as a minimum.

11.4.2 Vendor shall supply and install all hardware and cabling accessories as per data high way
design including modems, repeaters etc as part of the Fire Alarm system. Modems/ repeaters
shall be powered by the supply provided for CFAP.

11.5 Cable Glands / Accessories

11.5.1 All cable glands/ lugs/ connectors as required for the equipment shall be included in vendor's
scope and shall be supplied along with the system, irrespective of whether installation is to be
performed by vendor or not.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 317 OF 1216

11.5.2 All the cable glands for outdoor application shall be weatherproof, nickel-plated brass and
double compression type, whereas those for indoor application shall be single
compression type.

11.5.3 Cable glands for hazardous area equipments shall be flameproof, weatherproof and nickel-
plated brass double compression type.

12.0 AUTOMATIC FIRE DETECTORS AND ACCESSORIES

12.1 General Specifications

12.1.1 Detectors for conventional fire alarm system shall be conventional type. End of line resistor
shall be provided at the last detector in the zone. Detectors for microprocessor based
Analogue addressable FA system shall be addressable type. Detectors shall be plug-in type
and shall have twist lock action fitting. Multi-colour LEDs provided on the detectors shall
indicate Normal and Alarm state. Essential features of detectors are indicated as below.

12.1.2 Detectors shall be supplied with mounting bases. Mounting base shall be identical for all type
of detectors except special application detectors such as linear beam detectors etc. for
installation as well as cable connection. Detector housing (body and cover) shall be made up
of damage resistant, fire resistant polycarbonate and shall be suitable for either surface or
recess mounting. Detector base shall be mounted on Junction boxes having terminals for
cable termination. Where installation is included in vendor’s scope, all necessary installation
materials shall also be included in vendor’s scope.

12.1.3 Detectors shall be suitable for storage at ambient condition specified in data sheet.

12.1.4 All detectors shall be on the approved list of LPC, UL / FM/ equivalent international
approving agency as applicable.

12.1.5 All detectors shall be suitable for operation at DC power supply extended from fire alarm
panel.

12.1.6 The addressable detectors shall be continuously monitored to measure changes in their
sensitivity due to the environment (dirt, dust, temperature, humidity etc.). These detectors
shall give an advance indication to the panel regarding the need for maintenance. The
analogue reading sent by the detectors shall be sensed and if there is a rapid increase, an
alarm shall be generated. However, if there is a gradual increase in the analogue reading, a
maintenance alert shall be generated by the fire alarm panel. It shall be possible to generate
maintenance reports from the fire alarm panel. For the addressable detectors two-wire
operation shall be possible.

12.1.7 All addressable detectors shall have selectable settings for pre-alarm and alarm and preferably
have the facility to set the sensitivity and address from the fire alarm panel.

12.1.8 Break glass units for microprocessor based fire alarm system shall be addressable type.
Each device shall have its own address module.

12.1.9 All addressable detectors shall be suitable for installation using class-A, style - 7 wiring as
per NFPA72).

12.1.10 All detectors must have insect screen to prevent insect entry and cause false alarm.

12.1.11 All field devices shall be from the latest generation in the manufacturer’s range of products.
Commonly used field devices are listed below. The specification given shall be considered as
minimum requirements.

12.2 Heat Detectors

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 318 OF 1216

12.2.1 Heat detectors shall use negative temperature coefficient thermisters for sensing and for
reference. The detector shall be designed to give a response that depends on both absolute
temperature and rate of rise in temperature.

12.2.2 The rate of rise element shall be carefully calibrated to ignore any normal fluctuation in
temperature, but to respond quickly when the temperature rise is 9°C or more per minute.

12.2.3 The fixed temperature feature should be entirely independent of the rate of rise element. The
operating temperature of fixed temperature element should be factory set at 57° C ± 5° C.

12.2.4 The detector shall be self-restoring type ensuring repeated use and easy maintenance.

12.3 Smoke Sensor (Detector)

12.3.1 Multi sensor shall have combined & individual features of smoke detector and thermal sensor
(heat detector). Smoke activity shall be monitored by photoelectric sensing technology in a
single detector / base assembly. Heat detection shall be fixed with selectable rate of rise
settings. Multi sensor detectors shall be able to generate multiple alarm signals from any of
the sensors (smoke or heat) employed in design independently or in combination. Detectors
shall be analogue addressable.

12.3.2 The detector shall be able to sense incipient fire by detecting the presence of visible and
invisible products of combustion like wood, paper, ammonia processing paper, cloth, PVC,
bakelite, nylon, foam, acrylic, thermocol, Photo film, nylon, polyester, painted sheets, Teflon,
leather etc.

12.3.3 The sensitivity of the detector shall not vary with change in ambient temperature, humidity,
pressure or permissible voltage variation. Its performance shall not be affected by an air
current of 5 m/sec. It shall have an inbuilt arrangement such that puffs of smoke or hot air
pockets do not inadvertently trigger the alarm. The detector shall be protected against dust
accumulation/ ingress. It shall have insect resistant screen to prevent nuisance alarms.

12.3.4 In recess above ceiling designed to handle return air for HVAC, it shall be ensured that
detectors are compatible to air velocity. Where air velocity is expected to be too high for the
detectors to function normally, smoke guard/ baffle shall be used as per requirement.

12.6 Motorized Self Aligning Type Linear Beam Detector

12.6.1 Linear beam detector shall work on the principle of obscuration of infrared light beam by
particles of smoke. The sensitivity shall be such as to enable operation at 30% to 50%
obscuration.

12.6.2 Linear beam detector shall consist of transmitter and receiver. Linear beam detector shall be
suitable for application in high roofed locations (10 m & above) such as warehouses,
pressurization room, transformer room (if required) etc. The detector shall, preferably, be
powered from the loop signal itself. However, if external power supply is required the same
shall be explicitly stated by the vendor, which shall be covered under common power supply
for the fire alarm panel and devices connected with it.

12.7 Fault Isolator

12.7.1 Fault isolator shall be installed, if specified in the data sheet.

12.7.2 Fault isolator shall be designed to provide short circuit protection to an addressable detector
loop. It shall be possible to wire the fault isolator at any point in the detector loop.

12.7.3 On occurrence of a fault (short circuit), the isolator shall cut power to all devices installed
between the two isolators minimizing the outage of all the detectors in a loop.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 319 OF 1216

12.7.4 The fault isolator shall have the capability to continuously check the faulted side of the loop
to determine if the fault still exists. On rectification of the fault, the isolator shall
automatically reset itself.

12.7.5 Fault isolator modules shall be housed in a enclosure having IP-55 degree of protection as a
minimum. If located in hazardous area, it shall also be tested and approved for use in area
classification defined in the data sheet.

12.8 Manual Call - Point

12.8.1 Manual break glass unit shall be fabricated out of 14-gauge cold rolled sheet steel.
Alternately the break glass unit may be made of die cast aluminum alloy such as LM6.
12.8.2 The box shall be fabricated in such a way it can be mounted flush to the wall or on the surface
without any modification. Two nos. 19 mm knockouts shall be provided at the bottom of the
box to facilitate cable / conduit entry.

12.8.4 The enclosure shall be painted with fire red colour (shade 536 of IS-5) epoxy painting and an
inscription “Press in case of Fire”, shall be painted in white letters or riveted on the
enclosure by a steel nameplate. A suitable nickel-plated brass hammer, duly chained to the
box with stainless steel chain shall be provided with each box for breaking the glass. Each
box shall have a distinct identification number boldly painted on it.

12.8.5 One No. blanking plug shall be provided for 5% of the total quantity of MCPs.

12.9 Response Indicator

12.9.1 If specified in the data sheet, response indicators shall be provided suitable for wall/ ceiling
mounting. Response indicator shall be provided where the detector is located either above
false ceiling or below false floor or where detectors are not directly visible. The response
indicators shall be connected to the detectors directly and shall be complete with terminal
blocks suitable to accept cables with up to 1.5mm² copper conductor. In the normal state of
detector, the LED shall flicker, but in the event the detector goes into alarm condition, the
LED shall glow steadily. LEDs shall be red in colour with 5mm dia. as a minimum.

12.9.2 Use of Response indicators in addressable system is not envisaged unless otherwise specified
in data sheet.

12.10 Exit Signs

12.10.1 Exit signs shall be fabricated out of 1.6mm thick cold rolled sheet steel. This shall be suitable
for wall mounting or suspension from ceiling. Exit signs suspended from the ceiling shall
have text/ direction printed on both the side of exit sign.

12.10.2 Fire exit shall be displayed by means of 5mm dia LEDs or backlit text. It shall be powered
from the fire alarm panel. Exit sign shall operate on DC power supply.

12.10.3 The exit sign shall be either in red letters on white background or white letters on green
background.

12.10.4 Where specified in data sheet, self-luminous exit sign shall be provided. The same shall be as
per ECBC norms required for Griha Rating.

12.11 Hooters

12.11.1 The unit shall consist of solid-state circuitry on a printed circuit board, a loudspeaker and a
flashing lamp housed in a weatherproof dust tight, wall mounting type enclosure. The hooter
shall, at least, have 102 db (A) output measured at 1-meter distance. The unit shall be
powered from the fire alarm panel and operate on DC power. In the event of fire, the hooter
shall raise pulsating audio alarm and the lamp shall start flashing.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 320 OF 1216
12.12 Flashing Lights (Beacon)

12.12.1 The unit shall consist of solid-state circuitry on a printed circuit board and a red-capped
incandescent lamp and audio unit housed in a dust tight, wall/ ceiling mounting type
enclosure. It shall operate on DC supply.

12.12.2 Flashing lights shall be installed in the enclosed areas where clean agent/ CO 2 is to be
released. In the event a signal for clean agent/CO 2 release is given, the lamp shall start
blinking with a warning sound enabling operating personnel to evacuate the area. The audio
unit (hooter) shall have 102 db (A) output measured at 1-meter distance.

12.13 Clean Agent / CO2 Release and Inhibit Switches

12.13.1 This unit is required to be provided at the exit of the protected buildings/ rooms. This shall
consist of pull type release and inhibit switches clean agent / CO2. The unit shall be
fabricated out of 2mm thick cold rolled sheet steel suitable for wall mounting. Switches
shall be pulled to release or inhibit clean agent / CO2.
Release switches shall have inscription:
"PULL TO RELEASE CLEAN AGENT / CO 2 "
And inhibit switches shall have inscription:
"PULL TO INHIBIT CLEAN AGENT / CO 2 ".

12.14 Zener Barrier

12.14.1 Preferably flameproof (Ex ‘d’) equipment that does not require the use of Zener barrier shall
be used. When necessary, intrinsically safe (Ex ‘i’) detectors and MCPs, Zener barriers shall
be provided. These shall be located in unclassified/ non-hazardous areas.

12.14.2 Normally not more than 10 detectors shall be connected to one zener barrier. However vendor
shall indicate maximum number of detectors/ MCPs that can be connected to one Zener
barrier without compromising on working of loop/ zone. Vendor shall also indicate the
maximum loop length from zener barrier considering 1.5 mm2 copper conductor screened
cable.

12.14.3 In case loop length permits, zener barrier shall be located at CFAP itself, else it shall be
located in safe area nearest to the detector/ MCP.

12.14.4 Wherever zener barriers are provided in safe area outside the Zonal panel or CFAP, these
shall be housed in their own enclosure with IP-55 degree of protection as a minimum.

13. NIL
14.0 ENGINEERING REQUIREMENTS

Unless specified otherwise, vendor shall design entire fire alarm system including design of
system architecture with details of integration, cabling requirement and protocol selection etc.
Vendor’s scope shall also include basic design and preparation of layouts for fire alarm
system for plant/ buildings if specified in the data sheet/ purchase documents.

14.1 Addressable Fire Alarm System

i) Vendor shall develop a system architecture based on Owner’s requirement showing

details of various network elements such as CFAP, Work station, networking
hardware, redundancy, protocols, data highway etc. including the maximum
permissible loop length and length of data highway.

ii) The design and engineering shall include sizing and selection of various equipment
such as fire alarm panels, batteries, battery chargers, field equipment, siren/ siren
starter etc. including preparation of General Arrangement drawings of various
equipment.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 321 OF 1216

 iii) The layout engineering for buildings shall include the drawings showing location of
MCP/ Detector and other field devices, cable schedules, interconnection diagram,
equipment installation drawings etc. as minimum.

iv) The “Cause & effect” diagram of the system shall be developed by vendor during
detail engineering, in consultation with client.

v) The parameterization facilities of various field devices along with the geographic
mimic, annunciation, text messages etc shall be available on the fire alarm panel.

15.0 INSPECTION, TESTING AND ACCEPTANCE

15.1 All the equipment shall be tested to the defined specifications as per mutually agreed test
plan/ FAT procedure, which shall be submitted and got approved from Owner at least one
month before inspection. EIL/ Owner’s inspectors shall witness all the tests.

15.2 During manufacture, the equipment shall be subject to inspection as per agreed inspection
plan to assess the progress of work and to ascertain that the quality controls are being
maintained. Vendor shall provide all necessary assistance and information concerning the
supply to EIL/Owner’s inspectors.

15.3 Tests shall be carried out at the vendor's works under his care and expense and Owner
shall be informed at least 4 weeks in advance regarding this.

15.4 FAT shall include simulation of operational field conditions and test for functional adequacy
besides all routine and acceptance tests specified by applicable codes and standards.

15.5 For bought out items, the routine and acceptance tests shall be conducted at the respective
equipment manufacturer’s works.

15.6 At the time of inspection, vendor shall produce original of all the type test certificates, test
and approval certificates for hazardous area equipment from testing and approving authority
and any other certificates as required from statutory authority for the review of inspectors.

15.7 Vendor shall submit a SAT procedure for EIL/ Owner’s approval. All equipment and
systems shall be tested at site as per the approved SAT procedure

15.8 SAT shall be conducted by vendor after the entire fire alarm system is installed and inter
connected by cables. These tests shall establish the operational correctness of the system.
Vendor shall rectify deficiencies noticed during SAT with no commercial implication to
Owner including replacement of system components and supply of new component for
making system successfully operational.

16.0 PACKING AND DESPATCH

All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for selected mode of
transportation i.e. by ship/rail or trailer. The panels shall be wrapped in polythene sheets
before being placed in crates to prevent damage to finish. Crates shall have skid bottom for
handling. Special notations such as `Fragile', `This side up', `Center of gravity', `Weight' etc.,
shall be clearly marked on the package together with Tag nos., Purchase order Nos. etc.

The equipment may be stored outdoors for long periods before erection. The packing shall be
completely suitable for outdoor storage in areas with heavy rains/ high ambient temperature.

17.0 INSTALLATION AND COMMISSIONING

Where installation of the system is included in the scope of the vendor, vendor shall arrange
all necessary manpower and equipment required for the same. Commissioning of the
complete system is to be carried out by vendor in all cases irrespective of whether the
installation was performed by vendor or not. All tools, test equipment etc. for the successful
commissioning of the system shall be arranged by the vendor at his own cost. Only the
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 322 OF 1216
 cabling specifically excluded from vendor's scope shall be installed by others. However,
termination at panels for Owner’s cables shall be done by the vendor.

18.0 TRAINING
Vendor shall provide comprehensive training on various operation and maintenance aspects
of the Fire Alarm system as agreed during ordering at manufacturer’s works. Vendor shall
also provide training on various operation and maintenance aspects to Owner’s engineers at
site.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 323 OF 1216

 SPECIFICATION FOR
ELECTRICAL EQUIPMENT
INSTALLATION
(B047-003-SP-6-51-0081, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 324 OF 1216

Abbreviations:

AC : Alternating Current
ACDB : AC Distribution Board
AL : Aluminium
BIS : Bureau of Indian Standards
CCoE : Chief Controller of Explosives
CD : Compact Disc
CEA : Central Electricity Authority
CIMFR : Central Institute of Mining and Fuel Research
CT : Current Transformer
CTC : Carbon Tetrachloride
CU : Copper
DC : Direct Current
DCDB : DC Distribution Board
DGMS : Directorate General of Mines and Safety
Ex(d) : Flameproof
FRP : Fibre Reinforced Plastic
HV : High Voltage
IR : Insulation Resistance
IS : India Standard
LV : Low Voltage
HMI : Human Machine Interface
MV : Medium Voltage
OISD : Oil Industry Safety Directorate
OSR : Oil Surge Relay
OTI : Oil Temperature Indicator
PF : Power Factor
PI : Polarisation index
PRV : Pressure relief Valve
PT : Potential Transformer
SLD : Single Line Diagram
UPS : Uninterrupted Power Supply
VRLA : Valve Regulated Lead Acid
WTI : Winding Temperature Indicator

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 325 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 INSTALLATION OF EQUIPMENT

4.0 EQUIPMENT COMMISSIONING

5.0 LIST OF CONSTRUCTION EQUIPMENT

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 326 OF 1216

1.0 SCOPE

This specification defines the requirements for the installation, field inspection, testing and
commissioning of electrical equipment, forming part of electrical power distribution and
utilisation system, including Communication and Fire alarm system.

2.0 CODES AND STANDARDS

2.1 The work shall be carried out in the best workmanlike manner in conformity with this
specification, EIL Installation Standards, layout drawings and to the following specifications/
codes of practice of Bureau of Indian Standards and OISD standards.

SP-30 (BIS) National Electrical Code.

IS:7816 Guide for testing Insulation resistance of rotating machines.
IS:10028 (Part-2) Code of practice for selection, Installation and maintenance of
transformers; Part 2 : Installation.
OISD 137 Inspection of Electrical Equipment.
OISD 147 Inspection and safe practices during electrical installations

2.2 In addition to the above it shall be ensured that the installation conforms to the requirements
of the following as applicable:

a. CEA Regulations.
b. Regulations laid down by CEA/Electrical Inspectorate.
c. Regulations laid down by CCoE/DGMS (as applicable).
d. The petroleum rules (Ministry of Industry Government of India).
e. Any other regulations laid down by central/state/local authorities and Insurance
agencies.

3.0 INSTALLATION OF EQUIPMENT

Prior to start of installation of the electrical equipment, Contractor shall verify that equipment
and complete materials have been received. Handling, shifting to required site location,
installation, testing and commissioning of all electrical equipment shall be done by contractor
with utmost care. Manufacturer’s instructions and the requirements given in their technical
manuals shall be strictly adhered. The substation/switchgear room wherein the equipment
shall be installed shall be kept clean, dry and free from all debris. Panel floor cutouts not in
immediate use shall be suitably covered to avoid any mishap. When handling the switchboard
panels, care shall be taken to observe the correct lifting arrangements and to make sure that
slings are attached to the manufacturer’s designated lifting points, where applicable. No parts
shall be subjected to undue strains or sudden stresses which could cause damage to the
equipment.

The lifting position mark indicated on packing casing shall be adhered to strictly, for keeping
it in required vertical position.

Contractor shall check and report to the Engineer-in-charge about any damaged item and / or
missing component for getting the same replaced as per specifications. During installation, all
accessories and loose items shall also be inspected by the contractor before their
assembly/mounting.

3.1 Switchboards and Bus Ducts

3.1.1 The term switchboard here includes all HV / MV/ LV switchboard panels, motor control
centers, power and lighting distribution boards, UPS panels, ACDB, Battery charger panels,
DCDB etc.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 327 OF 1216
 The switchboard panels shall be handled with care, avoiding any impact to the equipment.
Dragging of the panels directly on floor shall be avoided. Roller bars may be used for shifting
of panels. Use of a crane and trailer shall be made for handling of equipment. The
switchboard panels shall be properly supported on the truck or trailer by means of ropes to
avoid any chance of tilting. The switchboards shall be lifted after ensuring that panel supports,
nuts and bolts are all intact and tightened. While lifting the panels in packed conditions,
utmost care shall be taken to avoid any damage to insulators, bushings, metering and
protective equipment and if specified in the tender document tyre mounted hydraulic trolley
shall be used.

The panels shall be preferably kept inside the packing cases till foundations are ready. Proper
rain/sun/dust protection shall be ensured till switchboards are installed.

3.1.2 The switchboard panels shall be installed on prepared foundations or floor cutouts. Steel base
channels shall be welded to inserts provided in floor slab. Cross members shall be provided at
the junctions of each shipping section and other places as required.. It shall be ensured that the
base plate level of HV switchboard shall match with the finished floor level.

The foundation pockets and the grouted bolts shall be cured for a minimum period of 48
hours. Proper level of base frames shall be maintained throughout and shall be checked with
water level/spirit level. Steel Shims shall be provided below base frame wherever required.

3.1.3 The switchboard panels shall be taken out from the packed cases and shifted one by one to
their proper place. All the panels shall be assembled, aligned and leveled. Alignment of
panels shall be checked in both longitudinal and lateral directions. It shall be ensured that
panel to panel coupling bolts, bus bar links etc. fit properly without any strain on any part. No
new holes for jointing of the panels other than those recommended by the vendor shall be
drilled. No gaps shall be left between the panels. Gap if any found between panels shall be
suitably sealed using sealing compound or T-profile. The lifting, racking in and out operation
of the breaker and all other motions shall be free from any obstruction.

The panels shall be checked for correct vertical position using Plumb line and spirit levels.
The switchboard panels shall be tack welded at suitable intervals to base channel.

After erection of switchboard panels, all uncovered portions of floor cutouts shall be covered
with 6 mm thick removable chequered plates finished with floor level. The design of the
chequered plates shall be such that the maximum allowable deflection is L/200 (where L is the
span of the chequered plates in meters) for a live load of 500 kg./sq. meters.

Additional stiffer shall be provided at the bottom if required. Suitable lifting arrangements
shall be provided for chequered plates. The chequered plates shall be painted with a coat of
red oxide zinc chromate primer after proper surface preparation as per specifications. Where
specified, panels’ cutouts provided for future use shall be filled with lean concrete.

3.1.4 After completion of Installation of switchboards, all the cubicles, switchboard components
such as switches, starters, CT and PT chambers, bus bar chamber shall be cleaned and
checked for tightness of all the components.

Vacuum circuit breakers shall be checked for integrity of bottle seals. All loosely supplied
items shall be fitted up. Bus bar sections or links shall be inserted and where specified, of high
voltage equipment shall be insulated. Interconnection wiring between shipping sections shall
be done by contractor.

All the wiring connections shall also be checked. Contact resistance of all bus bar joints and
contactors shall be checked. Insulator shall be checked for any damage. All the starters,
switches, contacts shall be cleaned with CTC where required.

All the moving parts shall be checked for easy and free movement. Hinges of panel doors
shall be lubricated to give free and noise less movement. All openings shall be kept
completely closed to avoid ingress of any foreign particles inside the panel.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 328 OF 1216
 Functional scheme verification of individual feeder shall be carried out and minor wiring
modifications in the panel wiring, if required shall be done as per the directions of Engineer-
in-charge. Special attention shall be paid to CT circuits’ polarity, wiring continuity and
correctness in the protection as well as measurement circuits. Auto transfer scheme shall be
simulated and verified. During the course of scheme verification tests, defective components
if any shall be taken out, after bringing to the notice of Engineer-in-charge. The same shall be
replaced by component supplied by owner.

3.1.5 Where switchboard is damp or having a low IR value due to damaged insulators/
bushings/any other insulated parts, or any other reason, the entire switchboard shall be dried-
up according to the instruction of the Engineer-in-charge for the IR value to improve to a safe
level for commissioning. Care shall be taken to protect the surrounding insulation from direct
local heating during the drying up process.

3.1.6 All the metering instruments, protective relays and other relays and contactors shall be tested
as per manufacturer's recommendations and according to the instructions of the Engineer-in-
charge. Protection relays shall be inserted and connected and settings adjusted as required by
the Engineer- in- charge

3.1.7 All moving parts, of closing/tripping mechanism, racking in and racking out mechanism,
spouts and shutter closing mechanism shall be checked for proper operation. All the auxiliary
contacts of breaker shall be checked-up, cleaned and contact pressure measured.

3.1.8 All the control wiring, PTs, bushings, bus bars, other live parts of switchgear, incoming and
outgoing cables shall be meggered.

3.1.9 Electrical simulation tests shall be carried out for all the protective, alarm and annunciation
relays and external interfaces to ascertain proper functioning.

3.1.10 Safety insulation mats of approved make and of required voltage grade shall be provided in
the sub-station.

3.1.11 Pre-Commissioning Check List

Before commissioning any switchboard, following points shall be checked and ensured for
safe energising of the switchboard:

i. That the installation of equipment to be commissioned is complete in all respects with

its auxiliaries and all other mounting including earthing. Openings in floor within and
outside panels have been sealed off. All cover and door gaskets are intact to make the
enclosure vermin proof.
ii. That all the metering instruments have been checked and found in working order.
Indicating lamps are healthy and are in correct position. All power and control fuses
are of proper rating.
iii. That the polarity test and ratio test of all the PTs and CTs is complete and phase
sequence of CTs conforms to the correct vector group connections. Wiring continuity
and correctness are ensured in the protection and measurement circuits. Polarity of
D.C. supply for all the circuits is correct.
iv. That the high voltage tests of incoming and outgoing cables have been conducted and
results are satisfactory.
v. That all the protective relays including both conventional and microprocessor based
numerical relays and thermal overload relays/electronic motor protection relays have
been tested for secondary injection tests. (Primary injection tests shall be carried out
for differential protection, Restricted Earth fault protection at full / reduced current to
ensure correctness of complete wiring). Relay settings, status indications, fault
annunciations, data logging, display of switchboard SLDs shall be verified from HMI
in case the same is provided.
vi. That IR Value has been recorded for bus bars, circuit breaker, incoming and outgoing
cables, control wiring and potential transformers. Where required joint resistance of
bus bars have been recorded and found to be satisfactory. All the surroundings and
panels have been cleanedSOW
VOLUME-2 (ELECTRICAL)
and&temporary earth leads have been removed.
SPECIFICATIONS PAGE NO. 329 OF 1216
 vii. Following tests shall be ensured for all CTs
- Insulation resistance test
- Ratio test through primary injection
- Polarity test
- Knee point voltage for class PS CTs
viii. Following tests shall be ensured for all PTs
- Insulation resistance test
- Ratio test through primary injection
- Polarity test
ix. Following tests shall be ensured for all breakers
- Insulation resistance test
- Breaker closing, opening sequence using 3 pole timers
- High voltage test both in open and close condition for HV breaker
- Contact resistance of all three poles using 100A DC Kit
x. Following tests shall be ensured for all meters
- Calibration of meters
- Functional verification and settings
xi. Following tests shall be ensured for all relays
- Secondary injection test
- Relay settings
- Timing check with timers
- Any other test recommend by the supplier
xii. Following tests shall be ensured for all bus bars
- Tightness of all nuts/bolts using Torque wrench
- IR value
- Contact resistance using 100A DC Kit
- Cleaning of bus bar chamber using vacuum cleaner
- Conducting jelly shall be applied on AL/CU joints as per manufacturer’s
recommendations
- HV test in case of HV switchboard

xiii Following tests/Checks shall also be performed on the switchboards

- Functional verification of individual feeders including all spare feeders
- Simulation test for under voltage tripping of related feeders such as motor
feeder, capacitor feeders etc
- Verification of control supply schemes
- Stability test for all differential protections
- Simulation test for bus auto/manual change over scheme
- Checks for all panel illuminations, indicating lamps, sockets
- All upstream and down stream interlocks

3.1.12 Bus Ducts

The bus ducts as per issued drawings will be supplied in parts and all the parts shall be
assembled and the bus bar connections shall be made at site. The insulators in bus ducts shall
be inspected for any possible damage during transit and the defective ones shall be replaced.
The insulators shall be cleaned. Contact surface of bus bars, bus bar bolts and nuts shall be
thoroughly cleaned. Petroleum jelly shall then be applied and bolted connection made. The
bus duct enclosure shall be checked for earth continuity and then earthed at two places. The
bus duct shall be properly supported between switchgear and transformer. The opening in the
wall where the bus duct enters the switchgear room shall be completely sealed to avoid rain
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 330 OF 1216
 water entry. Expansion joints, flexible connections etc. supplied by the manufacturer of the
bus duct shall be properly connected. The bus duct levelling shall be checked with spirit level
and pendulum weight.

Pre-commissioning check list

Before commissioning any bus duct, following points shall be checked and ensured for safe
energising of the bus ducts

- All joints are tightened using torque trench

- Cleaning of bus duct chamber with vacuums cleaner
- Silica gel breather shall be connected if supplied. If required, silica gel shall be
reactivated as per the instruction of engineer in charge.
- Space heater circuit shall be checked and tripping through thermostat shall be ensured
- Contact resistance shall be measured for all phases/neutral using 100A DC kit
- High voltage test in case of HV bus ducts

3.2 Transformers

Transformers on receipt at site shall be unloaded by means of crane or lifting devices of

adequate capacity. All lifting lugs shall be used to avoid unbalanced lifting and undue
stresses on lugs. Lifting lugs if any provided for partial lifting (e.g. for active part,
conservator) etc. shall not be used for lifting complete transformer. Parts other than those
identified for lifting of the transformer shall not be used for lifting. While slinging, care shall
be taken to avoid slings touching other parts.

3.2.1 Before lifting transformer, it shall be ensured that all cover bolts are tightened fully. In case
when it is necessary to use jacks for lifting, projections provided for the purposes of jacking
shall be used . Lifting jacks shall not be used under the valves or radiator tubes. For
transporting transformers from stores to site, the transformers shall be loaded on a suitable
capacity truck or trailer. The transformers shall be properly supported by steel ropes and
stoppers on the trailer to avoid tilting of the transformers in transit due to jerks and vibrations.
At no instance, the transformer shall be kept on bare ground. Where it is not possible to
unload the transformer directly on a foundation, it shall be unloaded on a properly built
wooden sleeper platform. A transformer shall never be left without putting stoppers to the
wheels.

3.2.2 Transformers shall be examined, for any sign of damage in transit. Particular attention shall
be given to the following in this regard.

i. Dents on tank wall or cooling tubes, radiators

ii. Damage to protruding parts like valves, sight glass etc.
iii. Loosening of bolts due to vibration in transit.
iv. Cracked or broken bushings.
v. Oil leakage particularly along welds.

If any thing adverse is noted, the same shall be brought to the notice of Engineer- in- charge.

3.2.3 Contractor shall examine the transformer base, oil pit, fire walls and foundations made by the
civil contractor. It shall be ensured that oil spills can not propagate along cable trenches. Any
discrepancy noted will be brought to the notice of Engineer- in- charge. Transformers shall be
placed on channels or rails over concrete foundations. The transformers shall be levelled,
aligned and checked for free movement on the channels or rails. Stoppers shall be provided to
the transformers immediately to prevent any movement. Normally transformers upto 1000
kVA rating shall be received duly fitted with radiator tubes, conservator tanks, valves, wheels
and other accessories. While the transformers of above 1000 kVA rating may be supplied with
loose accessories. All the accessories like radiators, cooling fans, valves, conservator tanks,
explosion vent pipe, bushings and other devices which are supplied in different packages
shall be checked for any transit damage and cleaned thoroughly before fixing on the
transformer. All loosely supplied parts shall be assembled as per manufacturer’s instruction
manuals/ drawings and documents. All the connections for CTs bushings and other wiring
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 331 OF 1216
 shall be checked for tightness and correctness before replacing the lid or tightening all the
bolts. Gravels shall be filled in the transformer bay, soak pit as per requirement.
3.2.4 Topping of transformer with oil

Before topping up with oil, transformer shall be fitted with all accessories such as valves,
gauges, thermometers etc. Oil samples shall be taken from each drum and tested for
determination of dielectric strength. Any sign of leakage of the barrel or of its having been
opened shall be recorded and reported. It is necessary to filter the oil before the transformers
are filled. It shall be ensured in oil filling operation that no air pockets are left in the tank and
that no dust or moisture enters the oil. All air vents shall be opened. Oil shall be filled
through a streamline oil filter using metal hose. To prevent aeration of the oil, the transformer
tank shall be filled through the bottom drain valve. In a transformer with conservator tank, the
rate of oil flow shall be reduced when the level is almost upto the bottom of the main cover to
prevent internal pressure from rupturing the pressure relief-pipe diaphragm. Sufficient time
shall be allowed for the oil to permeate the transformers and also for the locked -up air
bubbles to escape. Any air accumulation in the buchholz relay shall be released.
3.2.5 Transformer Oil

i. Sample of oil from the transformer shall be taken from the bottom of the tank.

ii. Testing of Oil

For dielectric test, the oil shall be tested as described in IS: 335. The oil shall also be
tested for acidity in accordance with the methods prescribed.
3.2.6 Drying out of the transformers, if required, shall be carried out and record maintained in
accordance with IS: 10028. Normally a streamline filter shall be used for drying-up. IR value
versus time of both windings along with OTI/WTI and filtrations machine temperature curve
for IR value Vs time shall also be plotted and recorded during the drying-up process.

Precautions when drying

i. The maximum sustained temperature to which transformer oil may be subjected shall
be limited to 800 C.

ii. The transformer shall be carefully monitored throughout the drying out process and
all observations shall be carefully recorded.

iii. Drying out shall be continued so that the insulation resistance as prescribed in the
standard code of practice is attained and the value remains constant for more than 12
hours. However, a minimum number of cycles shall be done for each transformer as
found necessary by the Engineer-in-charge. Generally a Megger reading of 2
megohms / kV at 600 C temperature. with a 5 kV Megger may be a rough indication
for stopping the dehydration.

3.2.7 The following work on transformers shall be performed by the contractor if specifically called
for:

i. Before finally commissioning the transformer it may sometimes be desired to run it

for a few hours on short-circuit, applying a low voltage, approximately equal to the
impedance voltage of the transformer. During this process, regular readings of the
insulation resistance of the winding to earth and winding to winding and temperature
against time shall be recorded.

ii. Testing of radiator tubes for any leakage and rectifying these by welding / brazing.

3.2.8 Pre-commissioning Check List

Before commissioning of any transformer, the following points shall be checked for safe
energisation of the transformer:

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 332 OF 1216

 i. All the accessories have been fixed properly and transformer body and neutral are
properly earthed. The transformer dehydration is over and results are satisfactory and
approved by the Engineer-in-charge. In case transformers are idle for more than one
month after dehydration, transformer oil has been given at least two circulations.
ii. Oil level, in the transformer conservator tank and all the bushings is upto the marked
point and the oil has been tested for dielectric strength and acidity.
iii. Silicagel is in reactivated condition. The breather pipe is clear from any blocking and
contains oil upto the proper level.
iv. The explosion vent diaphragm does not have any dents. Accumulation of any oil and
air had been released.
v. Operation of off-load and on-load tap changers on all the tap positions is satisfactory.
The mechanical parts of the on-load tap changer are lubricated. Motor IR value has
been taken and found satisfactory. Tap position mechanical indicator on the
transformer and tap position indication meter on the control panel are reading the
same tap positions. Tap changer limit switches are operating satisfactorily on the
maximum and minimum tap positions. On-load tap changer contact pressure and
resistance is as per manufacturers recommendations. Oil level of tap changer tank is
upto the required level and oil has been tested for dielectric strength. The tap setting
on which the off load tap switch is locked shall be recorded. Generally the off-load
tap switch shall be kept on nominal tap.
vi. Buchholz relay has been tested and checked up for any friction in the movement, and
floats are free. All the other protective relays, alarm and annunciation relays have
been tested.
vii. Metering equipment has been tested and polarity test of PT’s and transformer winding
is satisfactory. Phase sequence and connections have been checked for proper vector
group.
viii. Ratio test and winding resistance on all the tap positions is satisfactory.
ix. Gaps of arcing horns for the bushings where provided are in order and earth
connections for the surge diverters have been checked.
x. Winding and oil temperature thermometer pockets contain oil and the winding and oil
temperature settings on dial gauges are in order.
xi. Transformers fitted with fans for forced air cooling have been checked up for starting
and stopping of the fans both in manual and auto mode and air-displacement has been
verified.
xii. Simulation tests for all external interface connection alarm, annunciation and trip
circuits have been checked and are in order.
xiii. Insulation resistance of all the control circuits and IR value of the transformer
windings and all the incoming and outgoing cables have been checked.
xiv. Valves in the cooling system and valve between the buchholz relay and the
conservator tank are in open position.
xv. Setting of all the protective relays is at the desired value and DC Trip supply is
healthy.
xvi. Magnetic, current and magnetic balance test have been conducted
xvii Simulation test for WTI,OTI,PRV,OSR
xviii Settings of WTI/OTI as per the instruction of the manufacturer
xix Earth resistance value for the neutral earthing

3.2.9 Observations after Commissioning

After switching on the transformer the following points shall be observed and recorded.

i. The inrush magnetizing current and no-load current.

ii. Alarm, if any, or if any relay flag has operated.
iii. Voltage and current on all the three phases.
iv. Transformer hum or abnormal noise.
v. Circulation of oil and leakages.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 333 OF 1216
 vi. Record current, voltage, cooling air temperature, winding temperature and oil
temperature readings, hourly for 24 hours.
vii. Cable end boxes for any over-heating.

3.3. HV and MV MOTORS

3.3.1 All the motors generally would be erected by the mechanical contractor.

3.3.2 Electrical contractor shall keep the motor space heater energised as per the directions of
Engineer-in-charge. Electrical contractor shall measure the insulation resistance of motor
windings and PI in case of HV motors. Insulation resistance of the motors shall be measured
between the winding of the machine and its frame by means of a 500 / 1000 V Meggar in case
of 415 V motors. A minimum value of 1 megohm for 415 V motors shall be considered a safe
value. In case of lower I.R. Value, the insulation value shall be improved by any of the
following methods as directed by the Engineer-in-charge.

i. Blowing hot air from external source.

ii. Putting the motor in oven.
iii. Placing heaters or lamps around and inside after making suitable guarding and
covering arrangements so as to conserve the heat.

In case the insulation is low, the following method of drying has to be adopted, after
consultation with Engineer-in-charge. During drying the temperature rise of winding shall not
exceed the permissible value for the class of insulation used.

i. By locking the motor so that it can not rotate and then applying such a low voltage to
the stator terminals so as to pass full load current in the stator keeping the stator
winding temperature below 900 C . In this case a close watch shall be kept for any
possible overheating and I.R. Values vs. temperature shall be plotted and heating
continued till I.R. value becomes steady.

ii. By blasting hot air from external source, Maximum temperature of winding while
drying shall be 700 C to 800 C (thermometer) or 900 C to 950 C by resistance
method. Heating shall be done slowly first till steady temperature of winding is
reached after 4 to 5 hours, and for large machines after 10 hours. A record has to be
kept for drying process, with half an hour readings and, till steady temperature is
reached. In case it is essential, the drying process can be supplemented by blower.

3.3.3 It shall be ensured that the motor leads are correctly connected in the terminal box, as
indicated in the ‘Name Plate’. The covers of all terminal boxes shall be properly fixed, the
gaskets intact. The control circuit shall be tested for proper functioning as per circuit diagram.

3.3.4 In case of synchronous machines, slip rings and brush gear shall be polished and brushes shall
be fixed in their holders with clearance and pressure as recommended by the manufacturers.

3.3.5 Before commissioning, the ventilation and cooling system of the motor must be inspected. In
case of motor with forced ventilation the air inlet shall be examined to ensure that it is free
from moisture and any foreign material. It shall also be ensured that recommended flow and
pressure of air is available to produce the required cooling effect.

3.3.6 The motor control gear shall also be carefully examined, the over-load settings may be
reduced or time lags bypassed from protective gear to ensure rapid tripping of switchgear in
event of faults. The direction of rotation of a new motor specially of large capacity , and phase
sequence of supply shall be kept in view while joining and connecting to the motor terminals

3.3.7 Finally the motor shall be started on no-load after decoupling, and shall be allowed to run for
a minimum period of 4 hours, or for a time as instructed by Engineer-in-charge. Attention
shall be given to the proper running of the bearings, vibration or unusual noises if any.
Voltage, starting current, no load current, stator winding and bearing temperature shall be
recorded after every 1 hour during this test. Direction of rotation shall be checked and
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 334 OF 1216
 recorded. Normally the motors run in clockwise direction as viewed from the driving end
with reference to the phase sequence R, Y, B.

3.3.8 After switching off the motor, the insulation resistance of the motor shall be recorded under
hot and cold conditions.

3.3.9 If the no load test run is found satisfactory, the motor shall be allowed to run for 8 hours and
all readings shall be recorded.

3.3.10 The following work on motors, may be performed by the contractor if specifically called for.

i. The proper level of bearing oil has to be checked. The condition of grease in bearings
shall be checked and in case it is necessary, complete replacement of bearing with
specified grade of grease after proper cleaning of the bearing shall have to be done.
Wherever external greasing facility exists, the condition of grease may be checked by
pumping some new grease of specified grade at start. If the grease coming out is
deteriorated grease shall be replaced.

ii. All the motors, motor exciter set and induction generators directly coupled or coupled
through reduction gears shall be checked for abnormal vibration, if any Large rated
HV motors with journal type bearings are liable to get damaged from shock, rough
handling during transit. Any minor defect in a race or roller may give rise to
considerable amount of vibration and noise. Contractor shall check and bring to the
attention of Engineer-in-charge any defect noticed in this regard.

iii. Due care shall be taken to avoid any damage to bearing insulation wherever provided.

3.4. Batteries/Battery charger

Battery (Lead acid, Nickel Cadmium or VRLA type as specified) shall be erected on stands
and insulators supplied by the manufacturer of the batteries. The installation shall be done as
per the layout drawings and manufacturer’s instructions. Electrolyte if required / as applicable
shall be filled as per manufacturer's instructions. Interrow connections shall be made with the
leads supplied by the manufacturer. Functional check shall be done on the battery charger
including battery charging and discharging, recharging as per the recommendation of the
manufacturer.

3.5. Neutral Earthing Resistor

The neutral earthing resistor shall be inspected for any damage to the resistor grid and other
components. The resistor shall be levelled and installed. All covers etc. shall be checked for
tightness to ensure that the enclosure of the resistor is dust, vermin and weatherproof.
Earthing conductors shall be taken from the out end terminal of the resistor, for connection to
earth electrodes and to the main grid. Check such as IR, operation of space heater, earth
resistance shall be done before the commissioning.

3.6 Welding Receptacles

The welding receptacles shall be erected on steel/concrete structures as per the drawings. In
isolated places a separate support shall be fabricated and installed.

3.7 Push Button/Control Stations

The push buttons / control stations shall be installed near to the motors to be controlled.
Individual channel supports shall be installed as per EIL standard. If control stations for
hazardous areas are to be supplied by contractor, these shall be of Ex (d) type, tested by
CIMFR and approved by CCoE or other applicable certifying authorities. All outdoor push
buttons / control stations shall preferably have integral canopies for additional weather
protection. The canopy shall be made of 2 mm thick galvanized sheet steel or FRP where
these are not integral with the equipment.

3.8 Gang
VOLUME-2 operated Isolators/outdoor
(ELECTRICAL) SOWDisconnectors
& SPECIFICATIONS PAGE NO. 335 OF 1216
 The isolators shall be transported to site in the dismantled condition. All the insulators may be
also supplied loose. The contractor shall inspect, clean, assemble and install the isolator on the
base structure previously fabricated, erected and levelled by him. The operating mechanism
shall be installed on the structure and connected to the isolator poles. The operating
mechanism shall be tested by slowly bringing the isolator to the closed position and carrying
out the necessary adjustment as per the manufacturer’s instructions. The earthing switches,
frames and operating handle etc. shall be earthed.

3.9 Contractor shall provide the following items in substation, as per CEA Regulations.

3.9.1 Fire buckets filled with clean dry sand and ready for immediate use for extinguishing fires and
fire extinguisher (carbon dioxide, dry chemical extinguisher etc.) suitable for dealing with
electric fires shall be conspicuously marked and kept.

3.9.2 First aid boxes containing ointments and medicines for immediate treatment of injuries (As
prescribed by Indian Red Cross Society or equivalent).

3.9.3 Instructions of restoration of persons suffering from electric shock in English, Hindi and local
language of the district shall be affixed in a conspicuous place.

3.9.4 Danger boards (HV., MV.) shall be provided on transformer bay gate, switchboards, entrance
to switchgear room and at other places as required by Engineer-in-charge.

3.10 The Communication system and Fire alarm system panels and equipment shall be installed
complying to manufacturer’s instructions. The location of field station (call back station unit,
break glass unit, telephone set etc.) shown on the drawing are indicative. The exact location
shall be decided at site by contractor in consultation with Engineer-in-charge. Correct type of
equipment with regard to hazardous protection as specified on drawing shall be adhered to by
contractor, for installation.

4.0 EQUIPMENT COMMISSIONING

4.1 Field inspection, testing and commissioning of the complete electrical installation shall be
carried out as per EIL specification no. 6-51-0087.

After the equipment is installed properly in accordance with drawings and specifications,
contractor shall carry out all pre-commissioning checks and tests as per EIL format in the
presence of Engineer-in-charge and test readings shall be recorded and furnished to EIL in
triplicate.

4.2 All equipment layout drawings shall be marked by the Contractor for “AS BUILT STATUS”
and two sets of hard copies shall be submitted to EIL.

5.0 LIST OF CONSTRUCTION EQUIPMENT

The contractor shall have all necessary construction equipment, tools and tackles and testing
instruments to carry out the erection works and to commission the system as specified. These
shall include but not be limited to the following, and these shall be brought to site by
contractor before the start of work.

5.1 Equipment

i. Portable grinder.
ii. Portable welding machine.
iii Portable gas cutting / welding set.
iv. Pipe threading machine.
v. Pipe bending machine (hydraulic).
vi. Portable drill machine suitable to take up drilling for different sizes as per
requirement.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 336 OF 1216
 vii Dewatering pump sets (diesel driven).
viii. Power Hacksaw.
ix. Conduit dye set.
x. Hydraulic crimping machine with round/hexagonal dye set.
xi. Hand crimping tool.
xii. Portable electric blowers, vacuum cleaners.
xiii. Miscellaneous items such as slings, pulleys, tarpaulins, wooden sleepers, ladders. etc.
as required.
xiv. Safety belts, safety goggles, and gloves.
xv. Separate tool kit for each Electrician.
xvi. Hydraulic/Hand held grease gun

5.2 Test Instruments

i. Insulation tester 1000 V hand driven.

ii. Insulation tester 2500 V motor/hand driven.
iii. Insulation tester 5000 V motor/hand driven
iv. Phase sequence indicator.
v. Earth Resistance tester.
vi. Single phase variac
vii. 3 phase variac of adequate capacity.
viii. Secondary and primary injection testing kit.
ix. Multimeter, both analogue and digital
x. Portable Ammeters, Wattmeters, P.F. meters.
xi. Portable Voltmeters.
xii. Clip on meters of different ranges.
xiii. Tacho-meter.
xiv. Kelvins double bridge for measurement of very low resistance.
xv. D.C. high -pot test kit.
xvi. A.C. high -pot test kit.
xvii. Oil filtration machine of adequate capacity.
xviii. Lux Meter to measure illumination levels.
xix. Breaker timing 3 pole kit
xx. Timers
xxi. 100A DC milli volt drop(Contact resistance) kit
xxii. Vibration measuring Instrument
xxiii. Thermo meters

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 337 OF 1216

 SPECIFICATION
FOR
CABLE INSTALLATION

(B047-003-SP-6-51-0082, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 338 OF 1216

Abbreviations:

BIS : Bureau of Indian Standards

BS : British Standards
CCOE : Chief Controller of Explosives
CD : Compact Disc
CEA : Central Electricity Authority
CIMFR : Central Institute of Mining and Fuel Research
DC : Direct Current
DGFASLI : Directorate General Factory Advice Service & Labour Institutes
DGMS : Directorate General of Mines and Safety
EHV : Extra high voltage
ET : Electrical Thread
FGL : Finished Ground Level
FLP : Flame Proof
FRP : Fibre Reinforced Plastic
GI : Galvanized Iron
HV : High Voltage
IS : Indian Standards
ISMC : Indian Standard Medium Channel
MS : Mild Steel
OISD : Oil Industry Safety Directorate
PVC : Poly Vinyl Chloride
RCC : Reinforced Concrete Cement
SWG : Standard Wire Gauge

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 339 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 MATERIAL SPECIFICATIONS

4.0 CABLE LAYING

5.0 TERMINATIONS

6.0 TESTING AND COMMISSIONING

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 340 OF 1216

1.0 SCOPE

This specification defines the requirements for supply of materials, wherever applicable,
installation, testing and commissioning of cable installation.

2.0 CODES AND STANDARDS

2.1 The work shall be carried out in the best workman like manner in conformity with this
specification, EIL installation standards, layout drawings, the latest edition of relevant
specifications, codes of practice of Bureau of Indian Standards and OISD standards listed
below :

SP:30 (BIS) Special Publication - National Electrical Code.

IS:1255 Code of practice for installation and maintenance of power cables
upto and including 33 KV rating.
IS:10810(Part 43) Method of Test for cables ; Part 43 Insulation resistance.
IS:10810(Part45) Method of Test for cables ; Part 45 High voltage test.
OISD RP- 147 Inspection and safe practice during electrical installation
OISD 173 Fire prevention and protection system for electrical installation

2.2 In addition to the above it shall be ensured that the installation conforms to the requirements
of the following as applicable:

a. CEA Regulations
b. Regulations laid down by CEA/Electrical Inspectorate.
c. Regulations laid down by CCOE/DGMS/DGFASLI (as applicable).
d. The petroleum rules (Ministry of Industry, Government of India)(As applicable)
e. Any other regulations laid down by central/state/local authorities and insurance
agencies

3.0 MATERIAL SPECIFICATIONS

All materials and hard wares to be supplied by the contractor shall be new, unused and of best
quality and shall conform to the latest specifications of Bureau of Indian Standards.

3.1 Cable Trays

These shall be ladder type trays either prefabricated hot dip galvanized sheet steel trays or site
fabricated angle iron painted trays or FRP trays as specified in job specification.

3.1.1 Pre-fabricated hot dipped galvanized trays

The cable trays shall comply with the requirements specified in EIL installation standard
enclosed with the specification/Tender.

3.1.2 Site fabricated angle iron trays

Angle iron cable trays shall be fabricated from standard rolled angle iron sections of size
75x75x8 for runners for supporting spans limited to 3000 mm. Cross support shall be 25 x 6
mm MS flat for tray width upto 500 mm and 32 x 6 mm flat for tray of more than 500 mm
wide and spacing between two cross supports shall not exceed 250 mm.

3.1.3 Vertical supports for both the prefabricated and site fabricated type trays shall be fabricated
out of ISMC 100 and horizontal supports shall be with 65 x 65 x 6 mm angle iron sections.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 341 OF 1216
 Outer most tier of all vertical cable trays shall be covered with GI sheet for protection against
physical damage to cables.Bottom most cable tray shall also be provided with GI sheet from
the bottom side for the protection of the cables from the hydrocarbon pipes located below. GI
Covers also shall be provided for the top most cable trays located outdoors.

Cable racks and trays shall be covered by removable top covers on upper most tiers allowing
adequate ventilation in following cases where:

- Mechanical damage of cables is likely to occur during maintenance in the plant.

- Oil or spillage of chemicals can be expected.
- Protection from exposure to sun is required.

GI cover sheet shallallow adequate ventilation to the cables and shall be in standard length of
3000 mm, flanged on both sides for fixing on cable tray.

3.1.4 FRP type cable trays

The cable trays shall comply with the requirements specified in EIL standard specification
and installation standard enclosed with the specification/Tender

3.2 Cable Glands

Cable glands shall be of nickel plated brass unless otherwise specified. The single
compression type cable glands shall be used for indoor panels/equipment (e.g. substation,
control room etc). The cable glands for outdoor terminations shall be weather protected,
double compression type. Cable glands forming a part of relevant FLP enclosure shall be FLP
type, tested by CIMFR or any other recognized independent testing laboratory and approved
by CCoE/DGMS or any other statutory authority as applicable. Indigenous FLP glands shall
have valid BIS license as per the requirements of statutory authorities. All cable glands shall
comply with the requirements given in IS/IEC-60079 Part 0.

Entry thread of cable gland shall be compatible to the entry thread provided in the equipment
(BS, ET, NPT, PG as applicable). If required, suitable reducers/adopters shall be used.

3.3 Connectors

Terminations of cables with stranded conductor shall be made with crimped type tinned
copper solder less lugs which shall be suitable for the cable size mentioned in cable schedule.

3.4 Ferrules

Ferrules shall be of approved type and of size to suit core size mentioned and shall be
employed to designate the various cores of control/signalcable by the terminal numbers to
which the cores are connected, for ease of identification.Furrule shall be printed type.

4.0 CABLE LAYING

4.1 General

Cable installation shall include power, control, lighting, fire alarm, telephone and
communication cables. These shall be laid in trenches/ cable trays /Duct as detailed in the
cable layout drawings. Cable routing given on the cable layout drawings shall be checked in
the field so as to avoid interference with structures, heat sources, drains, piping,air-
conditioning duct etc. Any change in routing shall be done to suit the field conditions
wherever deemed necessary, after obtaining approval of Engineer-in-charge.

4.1.1 EHV,High voltage, medium voltage power and control cables shall be separated from each
other by adequate spacing or by running through independent pipes, trenches or cables trays,
as shown on layout drawings/installation standards. Details of cable routes and cable spacing
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 342 OF 1216
 not shown in detail on these drawing shall be determined by the contractor and approved by
the engineer-In-charge.

The individual cable fixing clamps and spacers for laying of single core cables shall be of
non-magnetic material. As a general practice, the metallic sheath, screen and armour of
single core cables shall be earthed at one point to keep the same at earth potential unless
otherwise stated. The continuity of armour and semiconductor screen shall be broken at each
joint. Singlecore cables, when laid in trefoil formation shall be braced by suitable clamps at a
distance, not exceeding 3 meters along the cable routing.

If straight through joints are required to be provided on single core cables, armour shall be
broken at joints as per manufacturer’s recommendations. For single core cables, armour shall
be earthed at one end for the cable run length as per manufacturer’s recommendation.The
armour& screen of EHV cables shall be earthed at one end/both end and surge voltage
limiters shall be installed at the straight through joints as specified in job specification/data
sheet.

The Telephone, Communication and Fire alarm cables shall run on instrument trays/ducts/
trenches in the units. Wherever these are not available, cables shall be taken in a separate
trench/tray with a minimum spacing of 300 mm from power and control cables

Telephone, fire alarm and plant communication cables shall be directly buried in road berm
area, (unless otherwise specified in cable layout drawings). These cables shall cross power
cables preferably at right angles. Street lighting cables shall be laid on the other side of road
berm area.

Fire barriers shall be deployed at locations where cable enter/exit the substation above ground
or/and cable enter/exit between cable cellar to switchgear room through cutouts. Fire barriers
shall be as per job specification.

At every 30 meter distances cable tray shall be painted with tray numbers as per cable layout
drawings for identification purpose.

The earth continuity of cable trays shall be maintained by providing bonding jumpers (25
mm2 flexible cu cable) while changing the level of cable trays.

4.1.2 The lengths indicated in the cables schedule are only approximate. The contractor shall
ascertain the exact length of cable for a particular feeder by measuring at site. All cable routes
shall be carefully measured .Before the start of cable laying, the contractor shall prepare cable
drum schedule and get that approved by Engineer-in-charge to minimize/avoid straight
through joints and then the cables cut to the required lengths, leaving sufficient lengths for the
terminations of the cable at both ends. The various cable lengths cut from the cable reels shall
be carefully selected to prevent undue wastage of cables. Extra loop length shall be given for
feeder cables where required as per the directions of Engineer-in-charge to meet
contingencies

Cables shall be laid in directly buried trench or in RCC trench (underground trench) or in
cable tray along pipe sleepers or in over head trays as shown on cable layout drawings.RCC
covers of trenches shall be effectively sealed to avoid ingress of chemicals and oils.

Overhead trays shall be installed 2700 mm (minimum) above grade level and 300mm above
FGL in case cable trays are installed along with pipe sleepers. At road crossings overhead
trays shall be installed at 7000 mm (minimum) above grade level or cables shall be routed
through cable tray culvert/ Electrical road crossings as per layout drawings.

Sufficient care shall be taken while laying cables to avoid formation of twist, sharp bend etc.
in order to avoid mechanical injuries to cables. Rollers shall be used for pulling of cables.

Cable installation shall provide minimum cable bending radii as recommended by cable
manufacturer.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 343 OF 1216
4.1.3 Cables shall be neatly arranged in the trenches / trays in such a manner that criss-crossing is
avoided and final take off to the motor / switchgear is facilitated. Arrangement of cables
within the trenches / trays shall be in line with cable layout drawings. Cable routing between
cable trench and equipment/motors shall be taken through GI pipe sleeves of adequate sizeor
branch cable trench as indicated in cable layout drawing. Pipe sleeves shall be laid at an angle
of maximum 45 to the trench wall. Bending radii of pipes shall not be less than 12D. It is to
be ensured that both the ends of GI pipe sleeves shall be sealed with approved weather proof
sealing plastic compound after cabling. In places where it is not possible, cables shall be laid
in smaller branch trenches. Different rows of cable trays in cable cellar below the cutout shall
be sofixed suchthat the trays don’t obstruct cable entry to the panels.

4.1.4 All cables shall be identified close to their termination point by cable tag numbers as per cable
schedule. Cable tag numbers shall be punched on stainless steel straps (2mm thick, 20 mm
wide and of enough length) securely fastened to the cable and wrapped around it.

Each underground cable shall be provided with cable tags of stainless steel strapssecurely
fastened every 30 m of its underground length with at least one tag at each end before the
cable enters/leaves the ground. In unpaved areas, cable trenches shall be identified by means
of cable markers as per installation drawing. These cable markers shall be placed at location
of changes in the direction of cables and at intervals of not more than 30 m and also at cable
straight through joint locations. Cable route markers shall extend 600mm above ground.

4.1.5 All temporary ends of cables must be protected against dirt and moisture to prevent damage to
the insulation. For this purpose, ends of cables shall be covered with an approved PVC end
cap or rubber insulating tape.

4.1.6 Each row of cables shall be laid in place and before covering with sand. All wall
openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage
of water inside building/lined trench. Every cable shall be given an insulation test in presence
of Engineer-in-charge/Owner before filling the cable trench with sand Any cable which is
found defective shall be replaced.

4.1.7 Where cables pass through foundation walls, the necessary openings shall be provided in
advance for the same by another agency. However, should it become necessary to cut holesin

existing structures for example floor slab etc., the electrical contractor shall determine their
location and obtain approval of the Engineer-in-charge before carrying out the same.

4.1.8 Cables for road crossings shall be taken through ERC (Electrical Road Crossing)/cable duct as
shown in the cable layout drawings and sleeves/ducts shall be effectively sealed thereafter.

At road crossing and other places where cables enter pipe sleeves, adequate bed of sand shall
be given so that the cables do not slack and get damaged by pipe ends.

4.1.9 Wherever cable trench crosses storm water, waste water channel/drain, cables shall be taken
through PVC/RCC pipes. Where cables are required to cross drains of depth more than 1200
mm, cables shall be taken over the drain on cable trays supported suitably using ISMC
150/200 sections.

4.1.10 Ends of cables leaving trench shall be coiled and capped and provided with protective cover
till such time the final termination to the equipment is completed.

4.2 Cables Laid Direct in Ground

Cables shall be laid underground in excavated cable trenches where specified in cable layout
drawings. Trenches shall be of sufficient depth and width for accommodation of all cables.
Cables shall be properly spaced as per installation standards. Maximum number of cable
layers in trench shall be preferably limited to 6 layers.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 344 OF 1216

 Minimum depth of directly buried cable trench shall be 750 mm for medium voltage and 900
mm for HV Cables. The depth and the width of the trench shall vary depending upon the
number of layers of cables as per EIL installation Standards.

Cables shall be laid in buried trenches at depth as shown in the cable layout drawings. It is to
be ensured by the contractor that the bottom of buried trenches shall be cleared of all rocks,
stones and sharp objects before cables are placed. The trench bottom shall be filled with a
layer of sand or stone dust. This sand /stone dust shall be leveled and cables laid over it.
These cables shall be covered with 150 mm of sand on top of the largest diameter cable and
sand shall be lightly compacted. A flat protective covering of 75 mm thick second class red
bricks or concrete tiles as per specification shall then be laid and the remainder of the trench
shall then be back -filled with natural soil, rammed and leveled.

4.3 Cables Laid in Concrete Trench

Cables shall be laid in 5 or 6 tiers in concrete trench as shown on layout drawings. Concrete
cables trenches shall be filled with sand /stone dust in hazardous area, switchyard and in
transformer bay to avoid accumulation of hazardous gases and oil. RCC covers of trenches
shall be effectively sealed to avoid ingress of chemical and oil in process area. Removal of
concrete covers where required for the purpose of cable laying and reinstating them in their
proper position after cables are laid shall be done by electrical contractor.

Minimum depth of RCC cable trench shall be 500mm for all voltage grades with 300mm
clearance between the bottoms of the trench cover and top of the cable. The depth and the
width of the trench shall vary depending upon the number of layers of cables and bending
radius required for cables as per EIL installation Standards

All wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid
seepage of water.

4.4 Above Ground Cables

4.4.1 Cables installed above grade shall be run in cable trays, clamped on walls, ceiling or
structures and shall be run parallel or at right angles to beams, walls or columns. Cable
routing shall be planned to be away from heat sources such as hot piping, gas, water, oil
drainage piping, air-conditioning duct etc. Each cable tray shall contain only one layer of
cables as far as possible for power cables. However control cables may be laid in multiple
layers in the cable trays.For power & control cables at least 20% space shall be kept as spare
in cable trays after completion of cable laying for future use.

4.4.2 Individual/small group of cables which run along steel/concrete structures shall be taken
through 60/100/150 mm slotted channel tray or channel ISMC-75/100.

4.4.3 Cable laid on supporting angle in cable trenches, structures, columns and vertical run of cable
trays shall be suitably clamped by means of GI saddles / clamps, whereas cables in horizontal
run of cable trays shall be tied by means of nylon cords. Distance between supporting angles
shall not exceed 600 mm.

4.4.4 All cable trays (other than galvanized/FRP trays) and supporting steel structures shall be
painted before laying of cables. The under surfaces shall be properly degreased, derusted,
descaled and cleaned. The painting shall be done with one coat of redoxide zinc chromate
primer. Final painting shall be done with two coats of approved bituminous aluminium paint
unless otherwise specified.

4.4.5 Where cables rise from trench to motor, lighting panel, control station, junction box etc., they
shall be taken in GI pipe for mechanical protection upto a minimum of 300 mm above grade
for outdoor area. Cable ends shall be carefully pulled through conduit to prevent damage to
cable.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 345 OF 1216

4.4.6 All GI Pipes shall be laid as per layout drawings and site conditions. Before fabrication of
various profiles of pipes by hydraulically operated bending machine (which is to be arranged
by the contractor) allthe burrs from the pipes shall be removed. GI Pipes having bends shall
be buried in soil / concrete in such a way that the bend shall be totally concealed. For G.I.
pipes buried in soil, bitumen coating shall be applied on the buried lengths, Installation of G.I.
pipes shall be undertaken well before paving is completed and necessary co ordination with
paving agency shall be the responsibility of Electrical Contractor.

Following guide shall be used for sizing of GI. pipe.

a) 1 cable in a pipe -53% of pipe cross-sectional area occupied by cables.

b) 2 cables in a pipe -31% of pipe cross-sectional area occupied by cables.

c) 3 and above cables in a pipe - 40% of pipe cross-sectional area occupied by cables.

4.4.7 After the cables are installed and all testing is complete, conduit ends above grade shall be
plugged with a suitable weatherproof plastic compound/bitumen/suitable sealing compound.
Alternatively rubber bushes shall be employed for the purpose of sealing.

4.4.8 Fire proofing of end of power cables at least 1 meter at each end as per OISD norms for the
refinery and Petroleum industry, shall be carried out as per the recommendation of the paint
supplier .Rates for the fire proofing of cables shall be included in the cable installation and no
separate payment shall be made for the painting.

5.0 TERMINATIONS

5.1 All cables up to 1100V grade and higher levels shall be terminated at the equipment by means
of compression type cable glands suitable for the cable size. They shall have a screwed nipple
with electrical threads and check nut. The cables shall be identified close to their
terminationpoints at both the ends of cable(cable numbers shall be punched on stainless steel
straps 2mm thick and securely fastened to the cable, wrapped around it) and also along the
route at regular intervals, by cable tag numbers.

All cable entries for outdoor termination shall be through bottom/side. Outdoor cable
termination through top of equipment shall not be permitted.

5.2 Power cables cores wherever colour coding is not available shall be identified with red,
yellow and blue PVC tapes. Where copper to aluminium connections are made, necessary
bimetallic washers shall be used.

5.3 In case of control cables, all cores shall be identified at both ends by their terminal numbers
by means of PVC ferrules suitable for core size. Wire numbers shall be as per schematic/
wiring/inter-connection diagram. All unused spare cores of control cables shall be neatly
bunched and ferruled with cable tag at both ends, for future use.

5.4 Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be of non-
magnetic material/ aluminium sheet in case of single core cables. All unused cable entries on
equipment/panels shall be plugged/sealed.

5.5 The cable shall be terminated at electrical equipment/switchboards through glands of proper
size. The individual cores shall then be dressed and taken along the cables ways or shall be
fixed to the panels with polyethylene straps. The cable glanding shall be done as per
manufacturer’s instructions. Cable armour shall not be exposed after termination is complete.

In case of termination of cables at the bottom of a panel over a cable trench having no access
from the bottom close fit holes shall be drilled in the gland plate for all the cables in one line,
then gland plate shall be split in two parts along the centreline of holes. After fixing bottom
plate, uncovered cable holes/gaps shall be sealed with cold setting compound.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 346 OF 1216

5.6 Crimping of lugs to cable leads shall be done by hand crimping / hydraulically operated tool
as per requirement. Insulation of the leads shall be removed before crimping. Conductor
surface shall be cleaned and shall not be left open. Suitable conducting jelly shall be applied
on the conductor lead. Lugs shall enclose all strands of cable core. Cutting of strands shall
not be allowed.

5.7 The contractor shall bring to the notice of Engineer-in-charge any mismatch in cable glands,
lugs provided with the equipment vis-à-vis to the cable size indicated in cable schedule for
taking corrective action.

5.8 The cable joints shall be avoided as far as possible. In case a joint is unavoidable, the
following shall be insured:

- The number of joints shall be restricted to minimum as far as possible.

- The location of joints shall be identified with permanent markers.

- No joints shall be allowed in hazardous areas without the approval of Engineer-in-

charge.

The jointing and termination of medium voltage power cables shall be carried out by trained
personnel only. Jointing and termination of high voltage and EHV cables shall be done by
skilled and experienced jointer duly approved by Engineer-in-charge. Only type tested
jointing and termination kits of approved make shall be used.

5.9 No unauthorized repairs, modifications shall be carried out on the hazardous area equipment
terminal boxes and junction boxes. Damaged enclosures of hazardous area equipment shall be
brought to the notice of Engineer-in-charge by contractor. After termination is complete, all
the bolts, nuts, hard wares of terminal box shall be properly placed in its position and
tightened.

5.10 All cables glands installed outdoor shall be provided with suitable sized shrouds and rates for
the same shall be included in the scope of the termination of the cable glands. No separate
payment is envisaged for the same.

6.0 TESTING AND COMMISSIONING

6.1 Field testing and commissioning of electrical installation shall be carried out as per EIL
specification.

6.2 Before energising, the insulation resistance of every circuit shall be measured from phase to
phase, phase to neutral and from phase/neutral to earth.

6.3 Where splices or terminations are required in circuits rated above 650 volts, insulation
resistance of each length of cable shall be measured before splicing and or / terminating. After
completion of splices and /or terminations, measurements shall be repeated.

6.4 The insulation resistance of directly buried cables shall be measured before cable trenches are
backfilled. Measurements shall be repeated after back filling.

For cables upto 1.1 KV grade 1000 V Megger and for H.V. Cables 2.5 KV / 5 KV Megger
shall be used.

6.5 D.C. High Voltage test shall be conducted on cables given below after installation.

a) All 1100 volts grade power cables in which straight through joints have been made.
b) All cables above 1100 V grade.
The DC High Voltage test shall be performed as detailed below in the presence of the
Engineer-in-charge or his authorized representative only.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 347 OF 1216
 Cables shall be installed in final position with the entire straight through joints complete.
During the high voltage test, all other electrical equipment related to the cable installation,
such as switches, instrument transformers, bus bars, etc., must be earthed and adequate
clearance shall be maintained from the other equipment and framework to prevent flash over.
In each test, the metallic sheath/screen/armour shall be connected to earth.

6.6 All checks and tests shall be made as per EIL standard test Performa available with site
engineer.

All test readings shall be recorded and submitted to EIL in triplicate sets.

6.7 Cable schedule, cable layout drawings, Interconnection drawings shall be revised and marked
by contractor for ‘AS BUILT STATUS’ and two sets of copies along with CD shall be
submitted to EIL.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 348 OF 1216

 SPECIFICATION
FOR
LIGHTING INSTALLATION

(B047-003-SP-6-51-0083, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 349 OF 1216

Abbreviations:

AC : Alternating Current
BIS : Bureau of Indian Standards
CCoE : Chief Controller of Explosives
CD : Compact Disc
CEA : Central Electricity Authority
CFL : Compact Fluorescent Lamps
CIMFR : Central Institute of Mining and Fuel Research
DC : Direct Current
DG : Diesel Generator
DGMS : Director General Mines and Safety
ELCB : Earth Leakage Circuit Breaker
FFL : Finished Floor Level
FRP : Fibre Reinforced Plastic
GI : Galvanised Iron
HPMV : High Pressure Mercury Vapour
HPSV : High Pressure Sodium Vapour
HRC : High Rupturing Capacity
IP : Ingress Protection
IS : Indian Standards
JB : Junction Box
LED : Light Emitting Diode
MCB : Miniature Circuit Breaker
MCCB : Moulded Case Circuit Breaker
MDB : Main Distribution Board
MS : Mild Steel
PE : Polyethelene
PVC : Polyvinyl Chloride
TPN : Three Phase and Neutral

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 350 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 EQUIPMENT SPECIFICATIONS

4.0 LIGHTING INSTALLATION

5.0 TESTING AND COMMISSIONING

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 351 OF 1216

1.0 SCOPE

This specification defines the requirements for the supply of equipment, materials,
installation, testing and commissioning of the lighting system (lighting fixtures, lighting
power distribution, telephone wiring etc.).

2.0 CODES AND STANDARDS

2.1 The work shall be carried out in the best workman like manner in conformity with this
specification, EIL installation standards, layout drawings, the latest edition of relevant
specifications, codes of practice of Bureau of Indian Standards and OISD standards listed
below :
SP:30 (BIS) Special Publication - National Electrical Code.
IS:5 Colours for ready mixed paints and enamels.
IS:3854 Switch for domestic & similar purpose
IS/IEC 60947 L.V. Switch gear and control gear
IS: 1293 Plugs & socket outlets of rated voltage upto and including 250V &
rated current upto 16A.
IS:9537 Conduits for electrical installations
IS 694 Polyvinyl Chloride insulated unsheathed & sheathed cables/cords
upto & including 450/750V
OISD RP- 147 Inspection and safe practice during electrical installation
OISD 173 Fire prevention and protection system for electrical installation

2.2 In addition to the above it shall be ensured that the installation conforms to the requirements
of the following as applicable:

a. CEA Regulations
b. Regulations laid down by CEA/Electrical Inspectorate.
c. Regulations laid down by CCoE/DGMS (as applicable).
d. The petroleum rules (Ministry of Industry Government of India).
e. Any other regulations laid down by central/state/local authorities and Insurance
agencies.

3.0 EQUIPMENT SPECIFICATIONS

All materials, fittings and appliances to be supplied by the contractor shall be new, unused and
of the best quality and shall conform to the specifications given hereunder. These shall be
manufactured in accordance with the latest revision of the specifications of Bureau of Indian
Standards/International standards. In the absence of any specifications for a particular item,
contractor shall bring material samples along with proven track record to site and get the same
approved by Engineer-in-Charge/Owner before installation.

3.1 Lighting and Power Panels

3.1.1 Lighting and Power panels (general purpose panels for safe area) shall be made of 1.6mm
thick sheet steel or polycarbonate material as specified and shall be dust and vermin proof.
All metal surfaces shall be cleaned free of rust, given a coat of red-oxide primer and finished
with two coats of epoxy based paint of shade 632 of IS 5. Panels shall be indoor/outdoor type
as specified. Indoor type panels shall have IP42 degree of protection and shall be suitable for
surface or flush mounting on wall surface as specified. Lighting and power panels located
outdoor shall be IP55 weather protected and shall also preferably have integral canopy for
additional weather protection. The canopy shall be made of 2mm thick galvanized sheet steel
or FRP where these are separate from the equipment.

3.1.2 Lighting and Power panels shall have TPN incoming feeder and single phase outgoing
feeders. Lighting circuit feeders shall be rated for 10 amps and power circuit feeders shall
have current rating of 16Amps.In power panels for window Air conditioning units, power
VOLUME-2 (ELECTRICAL)
circuit SOW
feeder shall be rated for 20 & SPECIFICATIONS
amps. PAGEand
Panels shall be equipped with phase NO. neutral
352 OF 1216
bus
 bars of required current carrying capacity. The outgoing feeders shall be provided with single
pole miniature circuit breakers (MCBs) for safe areas and double pole MCBs for hazardous
areas. The incomer shall be with MCB and ELCB unit unless otherwise specified. In case of
panel for Green Buildings incomer shall also be provided with Energy Meter as per GRIHA
requirements. Accordingly, CTs shall be provided in all the three phases for current
measurement and voltage shall be tapped directly from phases through control fuses.
Miniature circuit breakers shall be mounted in such a way that the operating levers project
outside the front Bakelite cover plates for ease of operation. A hinged door to cover the
operating knobs shall be provided. In addition, a circuit diagram indicating incomer details
and outgoing details viz. Circuit number, circuit rating, and load connected and details of the
load shall be pasted inside the panel. Also a laminated copy of the diagram shall be provided
inside the panel in a suitably designed pocket. Two external earthing studs for connection to
the plant earthing grid shall be provided on the panel. Further, the panel shall be provided
with an earth bus bar with terminal studs for connection to the third core of each outgoing
circuit. Each circuit phase and neutral shall be given ferrule numbers. Complete wiring inside
the panel, shall be neatly bunched with PVC tape and button. Sufficient terminals shall be
provided in the terminal block so as to ensure that not more than one wire (core) is connected
to a terminal. The panel shall have knock out holes or removable gland plate for the entry of
incoming and outgoing conduits or cables. The panels shall be complete with requisite
number of cable glands as specified.

3.1.3 The Main distribution board (MDB) where used, shall be made of 2mm thick sheet steel
panel, dust and vermin proof similar in construction to Lighting and Power panels but with
TPN MCCB or switch fuse incoming and TPN outgoings ( MCB with ELCB units and MCB
without ELCB unit as applicable) of required numbers as specified.

3.1.4 All MCBs shall be of M9 category as per IS 8828 and sensitivity of ELCBs shall be 100 mA-
300 mA unless otherwise specified.

3.1.5 Wherever the size of incoming cable to lighting, power panels/MDB is more than 35 sq.mm a
suitable cable adapter box shall be provided and attached to the panel. The incoming cable
leads shall be connected to terminal block (bolted type terminals) of required size. This
terminal block shall be connected to TPN incomer unit through separate PVC insulated copper
conductor wires/bus bars. Sufficient space shall be provided (minimum 300mm) between
gland plate and the bottom of terminal block for easy termination.

3.2 Lighting Fixtures

The types, makes and catalogue numbers of various types of lighting fixtures shall be as given
in Fixture schedule job data sheet. HPMV/HPSV/fluoroscent lighting fixtures shall be
complete with ballast, starters and capacitor, as required. Control gears for these fixtures shall
be integral or non-integral as specified in lighting layout drawings. Unless otherwise
specified, all fixtures shall be supplied complete with lamps. Ballast for fixture shall be
copper wound or electronic type. The fixtures shall be of high power factor type i.e. at least
0.9 or more.

3.3 Switches

Switches, manufactured in accordance with IS:3854 shall be used for non hazardous areas.
Switches in areas where concealed wiring has been adopted, shall be flush mounting piano
type unless otherwise specified. For surface conduit wiring, piano type switches in surface
mounted box shall be provided. Industrial Type switches (Weather protected) shall be used
for outdoor areas. Modular switches along with required boxes shall be provided for indoor
application in case shown in the layout.

3.4 Receptacles

Three pin type 5A/15A receptacles manufactured in accordance with IS: 1293 shall be used
for non hazardous areas. The receptacles and the controlling ON/OFF switch shall be mounted
VOLUME-2
in(ELECTRICAL)
the same enclosure box but SOW
these& shall
SPECIFICATIONS PAGEreplacement
be in separate units to facilitate NO. 353 OF 1216
by
 parts. Flush mounting type receptacles shall be used in areas where concealed wiring has been
adopted and surface type shall be used in other areas. For exhaust fans and wall mounted air
circulators, socket and switch enclosures shall be separate. In buildings such as sub-station,
DG. Shed, Workshop, maintenance shop etc. industrial type metal clad socket outlets and
plugs shall be provided. These sockets shall be supplied complete with plugs. Modular type
receptacles along with required boxes shall be provided for indoor application in case shown
in the layout

3.5 Outlet Boxes

The outlet boxes used as point outlets shall be prefabricated type 65mm deep junction boxes.
Outlet boxes custom fabricated for sockets, switches, fixtures and fan regulators etc. shall be
made of MS sheet having minimum thickness of 1.6mm.Outlet boxes shall be galvanized/
nickel plated after fabrication. These shall be complete with terminal block suitable for
connection of wires up to 4 sq. mm Front cover plate shall be of 3mm thick Bakelite / PE
sheet. The colour shall suit the shade of the walls or shall be white if the shade of the walls is
not finalised. The sheet shall extend at least 2 cm on all sides of outlet box. Cover plate shall
be fixed by cadmium plated brass screws and cup washers. Outlet boxes shall be provided
with adequate number of knock outs on all the sides for ease of wiring either with conduits or
without conduits.

3.6 Conduit and Accessories

Conduits for Electrical installations shall conform to IS: 9537. The type of conduit (steel / GI/
PVC) shall be as specified on drawing. Black enameled steel or GI conduit shall be of 1.6mm
thick and the minimum wall thickness of PVC conduit shall be 1.6mm. Generally PVC
conduits shall be used in concealed wiring and for surface wiring GI conduit (in plant
buildings) and black enameled steel conduit (in non plant buildings) shall be used.

3.7 Lighting Poles

Lighting poles shall be fabricated as per EIL installation standards enclosed with the
specification from ERW steel tubular pipes of specified section, with joints, swaged together
when hot and beveled on outside edges or hexagonal shape. Poles shall be coated with
bituminous preservative solution on the ground portion of the outside surface. Remainder of
the outside surface shall be given one coat of redoxide primer and finished with two coats of
aluminium paint. The pole shall have a marshalling box near the bottom to contain HRC
fuses, a neutral link, an earth stud and terminal block. FRP type lighting poles shall be
provided in case shown in the layout.

3.8 Lighting Mast

3.8.1 Lighting masts (Lattice tower) where used, shall be fabricated as per EIL Standard Drawing
enclosed with the tender/specification. They shall be complete with 2 nos. MS flats provided
at the base plate for connection to the plant earthing grid. A ladder, platform, handrail, a
weather protected TPN switch (at 1500mm from ground level) and a weather protected
distribution board fabricated out of sheet steel shall be provided at the top of mast. The TPN
Switch and the distribution board shall also have a canopy for additional weather protection.
The TPN switch shall be suitable for looping one more lighting mast from the same incoming
power supply. The distribution board shall have TPN bus bars of 30 Amps. rating and 12 Nos.
outgoing circuits each with a 6A single pole MCB. The distribution board shall have cable
entries from bottom. Necessary space provision and suitable mounting arrangement shall be
made on top of the tower for mounting of ballast (choke) and condensers for all the circuits
and the lighting fixtures. The masts shall be given one coat of red oxide primer and two coats
of aluminium paint. Distribution board shall be fabricated out of 2mm thick sheet steel and
shall be painted with two coats of enamel over a base coat of red oxide.

3.8.2 Unless otherwise specified the flood lighting high masts shall be telescopic type conforming
to EIL specification and data sheet.

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3.9 (ELECTRICAL)
Wires SOW & SPECIFICATIONS PAGE NO. 354 OF 1216
 Wires shall be PVC insulated and shall be of 660 Volts grade as per IS694. Conductor shall be
of stranded copper and size shall be minimum 1.5 Sq. mm for lighting, 2.5 Sq. mm for 15A
power socket circuits and 4 sq. mm for split A/C power socket circuits. Red/Yellow/blue
wires for phases, black wire for neutral and green wire for earth shall be used (size of earth
wire shall be same as for phase and neutral size). Wire size for air conditioning circuit feeders
shall be as indicated in the panel schedule.

3.10 Ceiling fan/Exhaust fan

Ceiling fans shall be of 1200mm sweep with BEE (Bureau of energy efficiency) rating of
minimum 3 star, unless otherwise specified with double ball bearing and regulator. The
suspension down rod shall be sturdy mild steel rod of adequate diameter and of minimum
length of 300mm with shackles suspension arrangement as per IS. For exhaust fans, the sweep
dia. and air CFM shall be as specified in job specification. Exhaust fans for battery room shall
be with anticorrosive blades suitable for use in acidic fumes. Exhaust fans shall be with BEE
rating of minimum 3 star.

3.11 Decorative switches and sockets

Decorative lighting switches and sockets where specified, shall be modular in design. All
these items shall fit into the same frame with overall standard dimensions. Frames shall be
suitable for surface and flush mounting in brick / concrete wall. The frames shall be suitable
for conduit entry from all the sides. Switches and sockets shall match colors of the frame and
cover plates to obtain a combination which shall match décor of the interiors of Control
Room, Administrative buildings, offices rooms etc.

4.0 LIGHTING INSTALLATION

4.1 General

4.1.1 The lighting fixtures in the plant shall be fed from lighting panel. All outdoor lighting shall be
group controlled manually or through synchronous timer or photocell. Lighting wiring
between panel and lighting fixtures shall be done with PVC insulated 3-core (phase, neutral
and earth) copper conductor armoured cable for hazardous areas. Wiring in the building shall
be done by means of 3-core copper, conductor PVC insulated, un-armoured cables, or PVC
insulated copper conductor wires in conduit/Metsec channel as specified. All joints of
conductors in Switch boards/JBs Fittings shall be made only by means of approved
mechanical connectors (nylon/PVC connectors). Bare twisted joints shall not be permitted any
where in the wiring system.

4.1.2 The lighting layouts furnished by owner will indicate approximate locations of lighting
fixtures. The electrical contractor shall determine, with approval of Engineer-in-Charge, the
exact locations of each fixture in order to avoid interference with piping or other mechanical
equipment and also with a view to obtain as much uniform illumination as practicable, and to
avoid objectionable shadows. Conduits shall be laid out by the contractor to suit field
conditions and as per directions of the Engineer-in-Charge.

4.1.3 On walkways, platforms and other outdoor area, lighting fixtures shall be located nearer to
landing of stairs or ladders, gauges, flow meters, panel boards and other equipment to provide
proper illumination.

4.1.4 The minimum height of any lighting fixture shall be preferably not less than 2.5 meters above
the floor level.

4.1.5 All outdoor cable terminations to outdoor junction boxes, panels, socket outlets etc. shall be
through bottom or from side. Top entries for cables shall be avoided to avoid water entry. All
cable glands for outdoor terminations shall be double compression type and the gland shall be
covered with PVC or rubber boot shroud. All unused cable entries shall be plugged with
suitable blanking plugs.

4.1.6 Mounting height of equipment shall be as under:-

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 355 OF 1216
 Top of Switch Box : 1200 mm from FFL (Finished floor level)
Top of Lighting/Power Panel : 1800mm from FFL
5/15 Amp. receptacle : 300mm from FFL unless otherwise specified (1200
mm for process areas and industrial sheds)
Lighting fixture : As indicated in layout drawing
Exhaust fan : In the cutout provided / as indicated in Layout
drawings.
4.1.7 Fixtures shall be firmly supported from the structures. Support clamps etc. may be bolted or
welded to the existing steel work or metal inserts. In case of concrete structures, where metal
inserts are not available, fixtures shall be suspended from concrete surfaces with the help of
anchor fasteners. In such cases special care shall be taken to see that anchoring is firm. In
places where ceiling fans are provided, lighting fixtures shall be suspended below the level of
fan to avoid shadow effect.

4.1.8 The lighting fixtures on various circuits shall be suitably interlaced so that failure of any one
circuit does not result in complete darkness.

4.1.9 Circuit cables in a group shall be cleated to structure by using galvanised strip clamps or cable
run in cable trays wherever trays are available. Spacers and cleats shall be of required size to
accommodate the cables. All hardware shall be galvanised or zinc passivated. Underground
lighting cables (in paved areas) shall be taken in suitable GI sleeves buried at a minimum
depth of 300mm from FFL. GI pipe sleeves shall be extended to 300mm above FFL. Exact
termination/layout of GI pipes (for protection of cables) shall be decided at site as per site
convenience in consultation with Engineer-in-charge.

4.1.10 Wiring for all outlet sockets shall be done with 3 cores of equal sizes for phase, neutral and
earth. The terminals of switch sockets shall be suitable to receive the size of wire specified.

4.1.11 All lighting fixtures shall be provided with terminal block with required terminals suitable for
connection of wire up to 2.5 sq. mm copper conductor.

4.1.12 The cable shall be straightened after unwinding it from the drum. All cables are clamped/laid
in straight run without any sag and kink.

4.1.13 For location where fan points are shown, fan hooks with junction box shall be provided during
concreting.

Where fan hooks and JBs. are provided separately JB shall be located within a distance of
300mm from hook for mounting of ceiling rose.

4.1.14 Industrial type plug sockets with 20A MCB or rating as per job specification shall be provided
at a height of 500mm from FFL for window AC units.

Socket outlets and plugs for installation in Sub-station building, DG shed, workshop, and
maintenance shop etc. shall be of industrial metal clad type.

4.1.15 Wiring for exhaust fans shall be terminated in receptacles as specified in layout drawing and
the connection from receptacle to the exhaust fan shall be by means of a flexible cord
equivalent in size to the main run of wires. Switch for exhaust fan shall be located in a
separate switch board along with other switches.

4.2 Conduit System

4.2.1 Surface or concealed conduit system of wiring shall be adopted, as specified in the drawings.
Required number of pull boxes shall be used at intervals to facilitate easy drawing of wires.
Separate conduit shall be run for lighting and power circuits. Further, conduits for Normal
lighting/Emergency lighting/DC critical lighting shall be separate. Conduit layout shall be
decided at site as per site conditions. Drop conduits for switch boards shall be decided by
contractor as per wall locations shown in Architectural drawings. All exposed run of conduits
on surface, shall be vertical or horizontal.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 356 OF 1216
4.2.2 Only threaded type conduit fittings shall be used for metallic conduit system. Pin grip type or
clamp type fittings are not acceptable. Conduit ends shall be free from sharp edges or burrs.
The ends of all conduits shall be reamed and neatly bushed.

Conduit shall be of minimum 25mm dia. Maximum number of wires permissible in a conduit
shall be seven/nine for wire size of 2.5 sqmm/1.5 sq.mm. respectively.

4.2.3 The exposed outer surface of the conduit pipes, including all accessories forming part of the
conduit system, shall be adequately protected against rusting. In all cases, bare threaded
portion of conduit pipe shall not be exposed unless such bare threaded portion is treated with
anti corrosive preservative or covered with approved plastic compound.

4.2.4 Conduit connection to outlet boxes shall be by means of screwed hubs or check nuts on either
side. Where concealed wiring is done, junction boxes (65mm deep) shall be used so as to rest
on shuttering properly. Conduits shall be laid above reinforcement. All conduit connections
shall be properly screwed and Junction box covers shall be properly fitted so as to avoid entry
of concrete slurry.

4.2.5 Conduit pipes shall be fixed by 1.6mm thick GI saddles on 3mm thick GI. saddle bars of
required width in an approved manner at intervals of not more than 50cms for straight run. At
places near junction boxes, bends, or similar fittings, saddle and bars shall be provided on
either side.

4.2.6 Where concealed wiring is to be adopted, conduits shall be laid in time before concreting of
the slab. Pull wire (GI or steel) shall be provided inside conduit for the ease of wire pulling.
The contractor shall coordinate his work with other agencies involved in the civil works in
such a way, that the work of the other agencies is not hampered or delayed. Vertical conduit
runs shall be made in wall before plastering is done so as to avoid chasing. Where chases are
made for conduit run contractor shall fill these chases or any other openings made by them
after completing the work and patch the surface. During installation, care shall be taken to see
that proper covers are provided to prevent rusting of conduits. Locations of all point outlets,
junction boxes shall be marked with brick powder or sand so that these are easily identified
after shuttering removal. As built conduit layout drawing shall be submitted by contractor
after completion of the work.

4.2.7 All junction boxes, bends and other accessories shall be of the same material as that of conduit
and shall have the same protective coatings.

4.2.8 After erection, the entire conduit system shall be tested, for mechanical and electrical
continuity and shall be permanently connected to earth by means of approved type of earthing
clamps.

4.3 Hazardous Area Installation

4.3.1 Wiring in hazardous area shall be done by using minimum 2.5mm² copper conductor
armoured cable.3rd core of the cable shall be used as earth conductor for earthing of lighting
fixture. Circuit wiring feeding hazardous areas shall be controlled by two pole
switches/MCBs (for phase as well as neutral isolation).Switches for lighting panels installed
in hazardous area shall have a pole to break the neutral in addition to poles for phases.

4.3.2 Correct type of lighting equipment (fixtures and JBs) with regard to hazardous protection as
specified in the drawing shall be installed for the areas classified as Zone 1, Zone 2 etc.

4.3.3 The terminations in the junction boxes and the lighting fittings shall be done avoiding
possibility of loose connections due to vibrations. After the terminations are made the cover of
the junction boxes and the lighting fittings shall be closed properly with all bolts and hard
wares in correct position, retaining its explosion and weather protections. In fixtures having
double cable entries, both the entries shall be used for looping in and looping out connection,
thus minimising the use of a separate junction box. Wherever separate control gear boxes (CG
box) are provided looping in and looping out connections shall be through CG box, thus
avoiding the use of an additional junction box. All unused cable entries shall be sealed with
suitable plugs.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 357 OF 1216
4.3.4 Circuit cables shall be firmly cleated in a group along columns/ beam/ladders/side
channels/platform using 1.6mm thick GI saddles on 25x3 mm GI saddle bar at intervals of
400mm to 500mm for straight run and on either side close to bending and at both termination
ends as per the directions of Engineer-in-charge. Where required 3 or more of cables shall be
taken in perforated150mm wide slotted channel cable tray after getting the approval of
Engineer-in-charge. Minimum straight run shall be 3000mm.Cables shall not be routed along
hand rails.

Where fire proofing column/structures are encountered, all cabling shall be taken in GI pipes
of required size and both ends shall be sealed, well before fire proofing is done. Similarly
equipment such as lighting fixture, control gear box, lighting/ power panels, field call stations,
junction boxes etc. shall be installed on suitable steel mounting frame/distance bracket,
thereby avoiding direct contact with the concrete used for fire proofing.

4.3.5 Cable glands for terminating cable on flameproof equipment shall be of double compression
FLP type. Any material/equipment specified to be supplied by contractor for installation in
hazardous areas, shall be tested by CIMFR and duly approved by CCoE or DGMS or any
other applicable statutory authority. All indigenous FLP equipment shall also have valid BIS
license as required by statutory authorities.

4.4 Building Lighting

4.4.1 The type of wiring system shall comprise surface/concealed conduit system or cable wiring as
specified on layout drawings.

4.4.2 Mounting details of fixtures shall be indicated on the drawings. If specified on the drawings, a
group of fluorescent lighting fixtures which are to be mounted end to end shall be fixed to
mild steel cold rolled sections of 50mm x 50mm and of 1.2mm thick (Metsec channel). The
entire assembly shall be fixed to the ceiling with necessary number of supports which may be
by means of steel conduit or chromium plated chain link as required. The `Metsec' Channel
shall run continuous in suitable sections from one end to other end of wall. The complete
channel shall be spray painted, with approved colour as per the directions of Engineer-in-
Charge. All wires inside channel shall be neatly bunched by nylon tape and buttons.

4.4.3 Wiring in areas above false ceiling shall be done in Surface Conduit (25mm dia GI conduit)
suitably clamped to the true ceiling. Vertical drops from true ceiling for panels, switches,
receptacles etc. shall be taken in 25mm dia PVC conduit concealed in walls upto
switchboards/panels. Lighting fixtures shall be supported from true ceiling. Exact location of
fixtures shall be finalised in co-ordination with air-conditioning duct diffuser layout, panel’s
layout and false ceiling grid layout. To facilitate easy maintenance `Looping back system` of
wiring shall be followed throughout. Accordingly supply tapping’s and other interconnections
including for earthing are made only at fixture connector blocks or at switch boards. Required
number of junction boxes shall be used at intervals for wire pulling and inspection.

4.4.4 All wires in conduit shall be colour coded as specified. Each circuit shall have independent
phase neutral and earth wire. However when group of circuits are run in a single conduit the
earth wire can be common.

4.4.5 Building conduit lighting system of wiring where measurement is done on point wiring basis
generally consists of two parts. The first part is the circuit wiring which includes the work
necessary from lighting panel up to switch box and from switch box to another switch box.
The second part is the point wiring which shall include the work necessary from tapping point
in the switch box upto various fixtures or fan outlets/ceiling roses.

4.4.6 Switches for light fixtures/exhaust fans in battery room shall be provided outside the Battery
room.

4.4.7 Lighting layouts for non-plant buildings (such as ware house, cement godown, gate house,
workshop, service building, rest room, etc.) shall be prepared by installation contractor as
defined in the scope of work.

The following basic data/document for preparation of layouts will be provided to the
VOLUME-2 (ELECTRICAL)
contractor. SOW & SPECIFICATIONS PAGE NO. 358 OF 1216
 i) Architectural drawings
ii) Illumination level required
iii) Type of lighting fixture
iv) Type of wiring (concealed/surface conduit/cable wiring etc.)

Based on the above input, contractor shall prepare and submit lighting layout drawings, panel
schedules, conduit layout drawings for concealed wiring, design calculations wherever
required, for review by purchaser before erection work is started. The lighting layout drawing
shall show the location, type and mounting details of lighting fixtures, receptacles, junction
boxes, layout of circuit indicating number of wires etc. The number of points in a circuit shall
not exceed ten and the load in each circuit shall be less than 1000 Watts.

The panel schedule shall include rating of incoming and outgoing feeders, number of outlets,
load for each outgoing circuit, etc.

All drawings shall be prepared preferably in A0 and A1 size. Panel schedules shall be in A4
size drawings. Final submission of drawings shall be in soft copies (CD form) and in bound
volumes.
4.5 Street Lighting

4.5.1 Street lighting poles to be located on road side shall be installed at a minimum distance of
300mm from the edge of the walkway of the road (road berm). Size of wires from marshalling
box upto fixture shall be 1.5mm²/2.5mm², copper conductor PVC insulated.

4.5.2 Each pole shall be earthed at two points by connecting to the plant earth grid as shown on
Installation standards.

4.5.3 Street lighting fixture shall be mounted on steel tubular poles as per standard drawings. The
foundation for the street lighting poles will be made by electrical contractor. Street lighting
poles shall be supplied with a base plate.

4.5.4 The poles shall be numbered as per the drawings/ directions of Engineer Incharge.

4.6 Mast Lighting

4.6.1 The lattice structure masts shall be installed on concrete foundations with the base plate bolted
on to the anchor bolts. The lattice structure shall be painted with a coat of primer and two
coats of aluminium paint, the second coat to be given just before handing over to the owner.
The masts shall be numbered as per drawings. The masts shall be connected to the plant earth
grid at two points

4.6.2 The main feeder upto the distribution board of lighting mast shall be through PVC insulated
armoured cable of size as specified in the respective drawing. Wiring from Distribution Board
to each flood-light fixture shall be by means of a 3-core 2.5sqmm, copper conductor PVC
insulated armoured cable. All the cables shall be neatly clamped to the structure at intervals
not exceeding 25 cms.

4.6.3 Exact orientation of flood lighting fixtures shall be decided at site to achieve optimum utility
of these fixtures.

4.7 Telephone Wiring

Conduits for telephone wiring in buildings shall be of 1.6mm thickness. 25mm dia black
enameled steel conduit/PVC as per IS 9537, installed on wall surface or concealed or as
specified in job specification.

Conduit installation system shall comply with the requirements given in clause 4.2 `conduit
system'. Required number of pull boxes shall be provided at interval for easy drawing of
wires. The telephone wiring shall be done with 0.63mm dia annealed copper conductor PVC
insulated 660V grade, twin flat wire, unless otherwise specified in job specification. One
telephone socket outlet shall be provided for connection to telephone instrument.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 359 OF 1216
5.0 TESTING AND COMMISSIONING

5.1 Lighting installation shall be tested and commissioned by installation contractor as per EIL
specifications. Precommissioning checks and tests shall include but not be limited to the
following:
(i) The insulation resistance of each circuit without the lamps (load) being in place shall
be measured and it should not be less than 500,000 ohms. (Between phases, phases to
neutral, phase/neutral to Earth).
(ii) Current and voltage of all the phases shall be measured at the lighting panel bus bars
with all the circuits switched on with lamps. If required load shall be balanced on the
three phases.
(iii) The earth continuity for all socket outlets shall be checked. A fixed relative position
of the phase and neutral connections inside the socket shall be established for all
sockets.
(iv) After inserting all the lamps and switching on all the circuits, minimum and
maximum illumination level shall be measured in the area and recorded.
(v) It shall be ensured that switch provided for ON/OFF control of point (light/fan/socket)
is only on LIVE side.
(vi) Operation of ELCB’s shall be checked.

Contractor shall duly fill in all the above test results and submit the test reports to Engineer-
in-Charge in triplicate.

5.2 All lighting layout drawings shall be marked by contractor for ‘AS BUILT STATUS’ and two
sets of hard copies plus 1 set of soft copy in CD, shall be submitted to EIL.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 360 OF 1216

 SPECIFICATION
FOR
EARTHING INSTALLATION

(B047-003-SP-6-51-0084, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 361 OF 1216

Abbreviations:

BIS : Bureau of Indian Standards

PESO : Petroleum and Explosive safety organization.
CD : Compact Disc
CEA : Central Electricity Authority
DGMS : Director General Mines and Safety
GI : Galvanized Iron
IS : Indian Standard
MS : Mild Steel
OISD : Oil Industry Safety Directorate
UPS : Uninterrupted Power Supply

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 362 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 MATERIAL SPECIFICATIONS

4.0 EARTHING NETWORK

5.0 INSTALLATION OF EARTH ELECTRODE

6.0 CONNECTION

7.0 TESTING AND COMMISSIONING

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 363 OF 1216

1.0 SCOPE

This specification defines the requirements for the supply of earthing and lightning protection
materials and installation of the earthing and lightning protection systems.

CPWD specifications for earthing shall be referred wherever not indicated in drawings/
tender.

2.0 CODES AND STANDARDS

2.1 The work shall be carried out in the best workman like manner in conformity with this
specification, EIL Installation Standards, layout drawings, the latest edition of relevant
specifications, codes of practice of Bureau of Indian Standards and OISD Standards listed
below :

SP:30 (BIS) Special Publication-National Electrical Code

IS:2309 Protection of buildings and allied structures against lightning.
IS:3043 Code of practice for earthing
IS:7689 Guide for control of undesirable static electricity.
OISD 110 Recommended practices on static electricity
OISD 147 Inspection and safe practice during electrical installation.
OISD GDN 180 Lightning protection.

2.2 In addition to the above it shall be ensured that the installation conforms to the requirements
of the following as applicable:

a. CEA Regulations
b. Regulations laid down by CEA/Electrical Inspectorate.
c. Regulations laid down by PESO/DGMS (as applicable).
d. The petroleum rules (Ministry of Industry Government of India).
e. Any other regulations laid down by central/state/local authorities and Insurance
agencies.
3.0 MATERIAL SPECIFICATIONS

3.1 All materials and hardware to be supplied by the contractor shall be new, unused and of best
quality and shall conform to the specifications given here under and to latest specifications of
Bureau of Indian Standards. Contractor shall bring material samples to site and get it approved
by Engineer-in-charge before installation.

3.2 The main earth grid conductor shall be hot dip galvanised M.S. flat unless otherwise specified.
Sizes for main conductors shall be as indicated on the earthing layout drawing .Amount of
galvanizing shall be 610gm per sq.metre. Earth electrodes and Earth plate shall be as per EIL
Installation Standards. .

4.0 EARTHING NETWORK

4.1 This consists of main earth conductor (grid conductor) forming a closed ring network with
required number of earth electrodes connected to it to provide a common earth for electrical
devices and metallic structures. From each earth electrode two distinct connections shall be
made to the main earth conductor. The earth plates shall be used for taking multiple earth
connections to two or more equipment.

4.2 The earth conductor shall be laid along cable trays/cable trench/pipe racks/ buried in

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 364 OF 1216

 pavement/ below finished grade level as indicated on the earthing layout drawing. Where
lined cable trenches are available, the earth conductor shall be preferably laid in the trenches
and shall be firmly cleated to the sidewall of concrete trenches using GI clamps at interval of
400 mm to 500 mm and near to the termination end. The earthing conductor shall run along
one of the cable trays along the overhead cable route. The earthing conductor shall be suitably
cleated and electrically bonded to all the other cable trays on the same cable route at a regular
interval of 25 to 30 meter. The earthing for equipment shall be tapped from the main earth
conductor and not from cable tray support structure. Earth conductor when laid underground
shall be at a depth of 500mm below finished grade level.

4.3 Joints and tapping’s in the main earth loop shall be made in such a way that reliable and good
electrical connections are permanently ensured. All joints below grade shall be welded and
shall be suitably protected by giving two coats of bitumen and covering with Hessian tape.
Earth strip laid above ground shall be welded across straight through joints and joints shall be
suitably protected by giving two coats of bitumen to avoid oxidation and insulation film
formation of the strip surface. When two earth strips are to be jointed by means of welding,
lap welding with an overlapping of strip equivalent to double the width of the strip and all
four sides shall be continuously welded. All joints at tappings above ground shall be by
means of connector/lugs. A minimum of two bolts of adequate size shall be used for this
purpose. Earthing strip joints at earth plate and equipment shall be through GI bolts, nut etc.

5.0 INSTALLATION OF EARTH ELECTRODE

5.1 Earth Electrode shall be installed as shown on installation standard and layout drawings.
The location shown on the layout drawings are indicative.

The exact location of earth electrodes in the field shall be determined by contractor in
consultation with the Engineer-in-charge, depending on the soil strata and resistivity. Earth
electrodes shall be located avoiding interferences with road, building foundation, column,
pipelines etc. The civil area drawings shall be referred for this. The distance between two
electrodes shall not be less than twice the depth of electrode.

5.2 Electrodes shall preferably be located in a moist soil which has a fine texture, grain size and
distribution. Wherever practicable the soil shall be dug up, all lumps broken and stones
removed from the immediate vicinity of the electrodes and soil packed by watering and
ramming as tight as possible.

5.3 The electrodes shall have a clean surface, not covered by paint, enamel, grease or other
materials of poor conductivity.

5.4 All earth electrodes shall be tested for earth resistance by means of standard earth test meter.
The tests shall take place in dry months, preferably after a protracted dry spell.

5.5 The disconnect facility shall be provided for the individual earth electrode to check its earth
resistance periodically.

5.6 Location of earth electrodes shall be marked by permanent markers for easy identification. All
earth Electrodes shall be serial numbered and also marked on ‘As Built’ drawing for future
reference.

5.7 Individual earth electrodes shall be provided for each lightning arrestor and flood light mast.

5.8 Earthing system provided for concrete paved area by other agency where applicable; shall be
connected to the plant earthing system below ground by minimum two earth connections.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 365 OF 1216

6.0 CONNECTION

The earth system connections shall generally cover the following:

- Equipment earthing for personnel safety
- System neutral earthing
- Static and lightning protection

6.1 The following shall be earthed.

- System neutral
- Current and potential transformer secondary neutral
- Metallic non-current carrying parts of all electrical apparatus such as transformers,
switchboards, bus ducts, motors, neutral earthing resistors, capacitors, UPS, battery
charger panels, welding receptacles, power sockets, lighting/power panels, control
stations, lighting fixtures etc.
- Steel structures/columns, rail loading platforms etc.
- Cable trays and racks, lighting mast and poles
- Storage tanks, spheres, vessels, columns and all other process equipment.
- Fence and Gate for electrical equipment (e.g. transformer yard etc.)
- Cable shields and armour
- Flexible earth provision for Wagon, Truck
- Shield wire

Conductor size for branch connection to various equipment shall be as per EIL Installation
Standards unless otherwise stated on earthing layout drawings.

6.2 Steel pipe racks in the process units and offsite area shall be earthed at every 24 meters.

6.3 Equipment/street light pole etc. located remote from main earth network may be earthed by
means of individual earth electrode and earth conductor unless otherwise stated in job
specifications/earthing layout drawing.

6.4 Lightning protection shall be provided for the equipment, structures and buildings as shown
on layout drawing. Self conducting structures shall not require separate aerial rod and down
conductors. These shall however be connected to the earthing system at two or more points as
shown on layout drawing. Each down conductor shall be provided with an earth electrode and
all earth electrodes shall be interconnected through underground strip. Lightning protection
earthing system may be bonded to electrical safety earthing system, inside ground. Lightning
down conductor shall be brought to earth electrode in shortest straight path as feasible to
minimise surge impedance.

6.5 The main earthing network shall be used for earthing of equipment to protect against static
electricity.

6.6 All medium and high voltage equipment (above 250V) shall be earthed by two separate and
distinct connections with earth.

6.7 Plant instrument system clean earthing, UPS system clean/safety earth, PLC etc shall be
separate from the electrical earthing system, if mentioned in job specification/ layout
drawings.

6.8 All paint, scale and enamel shall be removed from the contact surface before the earthing
connections are made.

6.9 All earthing connections for equipment earthing shall be preferably from the earth plate
mounted above ground wherever provided
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 366 OF 1216
 Equipment foundation bolts shall not be used for earthing connection.

6.10 Earth connections shall be made through compression type cable lugs/by welded lugs.

6.11 All hardware used for earthing installation shall be hot dip galvanised or zinc passivated.
Spring washers shall be used for all earthing connections and all connections adequately
locked against loosening.

6.12 Lighting fixtures and receptacles shall be earthed through the extra core provided in the
lighting circuit/cable for this purpose.

6.13 The reinforcements of sub-station building and the sub-station floor shall be connected to
main earth grid.

7.0 TESTING AND COMMISSIONING

7.1 Field inspection, testing and commissioning of electrical installation shall be done as per EIL
standard specification.Earthing systems/connections shall be tested as follows:

7.2 Resistance of individual earth electrodes shall be measured after disconnecting it from the grid
by using standard earth test meggar.

7.3 Earthing resistance of the grid shall be measured after connecting all the earth electrodes to
the grid. The resistance value of an earth grid to the general mass of earth shall be as follows:
- For the electrical system and equipment a value that ensures the operation of the
protection device in the electrical circuit but not in excess of 4 ohm. However for
generating stations and large sub-systems, the value shall not be more than 1 ohm.
- For lightning protection, the value of 5ohms as earth resistance shall be desirable, but
in no case it shall be more than 10 ohms.

7.4 The resistance to earth shall be measured typically at the following points:
a) At each electrical system earth or system neutral earth.
b) At each earth provided for structure lightning protections.
c) At one point on earthing system used to earth electrical equipment enclosures.
d) At one point on earthing system used to earth wiring system, enclosures, such as
metal conduits and cable sheaths or armour.
e) At one point on fence enclosing electrical equipment.

7.5 All earthing layout drawings shall be marked by contractor for ‘AS BUILT STATUS’ and
two sets of hard copies plus 1 set of soft copy, shall be submitted to EIL.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 367 OF 1216

 SPECIFICATION
FOR
FIELD INSPECTION, TESTING
AND
COMMISSIONING OF ELECTRICAL
INSTALLATIONS
(B047-003-SP-6-51-0087, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 368 OF 1216

Abbreviations:

AC : Alternating Current
AFC : Approved for Construction
BIS : Bureau of Indian Standards
CCOE : Chief Controller of Explosives
CEA : Central Electricity Authority
DC : Direct Current
DCS : Distributed Control System
DGMS : Director General for Mines and Safety
ECS : Electrical Control Station
GI : Galvanized Iron
HV : High Voltage
IS : Indian Standard
MV : Medium Voltage
OISD : Oil Industry Safety Directorate

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 369 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 FIELD INSPECTION, TESTING AND COMMISSIONING

4.0 RECORDS

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 370 OF 1216

1.0 SCOPE

This specification covers the requirements for the field inspection, testing and commissioning
of Electrical Equipment and Installation, forming part of electrical power distribution and
utilisation system.

2.0 CODES AND STANDARDS

2.1 The field inspection, testing and commissioning of electrical equipment shall be carried out in
line with this specification and the latest edition of following Indian Standards and OISD
standards.

SP-30(BIS) National Electrical Code.

IS 1255 Code of practice for installation and maintenance of power cables up
to & including 33 kV rating.
IS-7816 Guide for testing Insulation resistance of rotating machines.
IS 10810(Part 43) Method of Test for cables; Part 43 Insulation resistance.
IS 10810(Part 45) Method of Test for cables; Part 45 High voltage test.
IS 12729 HV Switchgears
OISD 137 Inspection of Electrical Equipment.
OISD 147 Inspection and safe practice during electrical installation.

2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of
the following as applicable:

a. CEA Regulations
b. Regulations laid down by CEA / Electrical Inspectorate.
c. Regulations laid down by Tariff Advisory Committee/Loss prevention council.
d. Regulations laid down by CCoE/DGMS (as applicable).
e. The petroleum rules (Ministry of Industry, Government of India).
f. Any other regulations laid down by central / state / local authorities / insurance
agencies

3.0 FIELD INSPECTION, TESTING AND COMMISSIONING

3.1 Contractor shall carry out complete field inspection, testing and commissioning of electrical
equipment as per Inspection & Test plans.

3.2 Before the completed installation or an addition to the existing installation is put into service,
inspection / pre-commissioning checks and tests shall be carried out by contractor. In the
event of defects being found out, the same shall be rectified and the installation retested as
applicable.

3.3 The pre-commissioning inspection among other requirements shall include visual inspection,
checking the workmanship of the installation, the rating of equipment, safety clearances, sizes
of cables installed, conformance to the AFC document, soundness of switchgear bus
connections, wiring properly dressed and labeled, sealing of unused cable entries, checking of
all safety interlocks, control/interface functions as per requirement etc.

3.4 Visual inspection for soundness of bus bar connections of busducts, terminal connections of
equipment/motor shall be carried out. It shall be ensured that no foreign materials are present
inside busduct and equipment terminal boxes. After the visual inspection, all the covers of
terminal boxes, inspection chambers shall be refitted with gaskets, bolts & nuts as per
equipment manufacturer’s instructions.

3.5 Pre-commissioning tests shall include but not be limited to the following:
- Continuity test for each winding and power and control circuits.
- Insulation test for each winding and power and control circuit
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 371 OF 1216
 - High voltage test for cables
- Dielectric strength test on transformer oil.
- Checking the correctness of wiring schemes, control circuit interlocks for intended
functioning.

- Verification of phase sequence.

- Testing of all types of relays/releases for required operation.
- Testing of measuring instruments for proper functioning.
- Earth continuity test for all circuits.
- Checking of safety features for correctness of operation, etc.
- Checking of all wired interface contacts (analogue, digital input/output contacts) for DCS
and ECS interface, at panel and equipment terminal chambers as applicable.

(Electrical contractor shall co-ordinate with other agencies involved for the above and
provide support services for checking interfaces of electrical equipment and the intended
functioning)

- Earth resistance measurement for each earth electrode, and the earthing system as a whole.
- Lighting installation shall be tested for correct illumination levels, with fittings installed.
Fittings shall be operated only with specified type of a lamp or tube.

3.6 After the above tests and inspection are completed, control circuits shall be tested for correct
operation under all operating combinations and proved correct before applying power to
main circuit.

3.7 Plant Communication, Fire alarm detection and telephone system shall be checked for correct
operation and intended function.

3.8 A close visual inspection of electrical equipment in hazardous areas shall be made to ensure
that equipment is suitable for the classified zone and gas group and correctly installed, with all
covers, bolts, nuts and hardwares intact and there is no physical damage mark seen on the
enclosure

3.9 Site Acceptance Test procedure for specific equipment shall be furnished by the respective
equipment vendor. The contractor shall provide necessary assistance to the equipment vendor
to perform Site acceptance testing to enable the equipment vendor to perform the same.

3.10 All pre-commissioning checks and tests shall be carried out as per the directions of Engineer-
in-charge. In addition to the equipment manufacturer’s instructions, pre-commissioning check
requirements shall also be complied. All tests shall be carried out by contractor in the presence
of EIL/Owner’s representatives

3.11 The contractor shall bring to site all required tools, tackles, and testing instruments for
carrying out field testing. Contractor shall use only calibrated measuring and test instruments
and shall maintain valid calibration records.

3.12 The Insulation Resistance test values for various electrical equipment shall be as below:

3.12.1 Cables

The insulation resistance test values for cables shall be as per following table:

Rated voltage of the Cable DC Test Voltage in Volts Minimum Insulation

resistance in Mega ohms
Lighting and power circuit
250 1
wiring
650/1100V grade cables 1,000 10
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 372 OF 1216
 1,900/3,300V grade cables 1,000 200
3,800/6,600V grade cables 1,000 200
6,350/11,000V grade cables 5,000 200
8,700/15,000V grade cables 5,000 200
12,700/22,000V grade cables 5,000 200
19,000/33000V grade cables 5,000 200

3.12.2 HV, MV and Miscellaneous Switchboards

The insulation resistance test values for the switchboards shall be as per following table:

Rated voltage of the DC Test Voltage in Volts Minimum Insulation

Switchboard resistance in Mega ohms
33,000V 5,000 200
11,000V 5,000 200
6,600V 1,000 200
3,300V 1,000 200
415V 1,000 100
240V 500 10
110V 500 10

3.12.3 Generators and Motors

3.12.4 The insulation resistance test values for the Generators and Motors shall be as per following
table:

Rated voltage of the DC Test Voltage in Volts Minimum Insulation

Generators and Motors resistance in Mega ohms at
40 °C
11,000V 5,000 120
6,600V 1,000 80
3,300V 1,000 50
415V 1,000 15
240V 500 12

3.12.5 Transformers

3.12.6 The insulation resistance test values for the Transformers shall be as per following table:

Rated voltage of the DC Test Voltage in Volts Minimum Insulation

Transformers resistance in Mega ohms at
40 °C
Up to 600V 1,000 100
601 to 5000V 2,500 1,000
5001 to 15,000V 5,000 5,000
15001 to 35,000V 5,000 10,000

3.12.7 It shall be ensured that during insulation tests, electronic devices and components that are
liable to get damaged on applied test voltage shall be disconnected from circuit. The
instructions of equipment/panel manufacturer shall be followed strictly in this regard.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 373 OF 1216
3.13 High-voltage Testing

3.13.1 DC high voltage test shall be conducted as per following table on all HV feeder cables and
also on 1100 V grade cables where straight through joints have been made.

Rated Voltage of TEST VOLTAGE (kV) BETWEEN Duration

Cable (kV) (Minutes)
U o / U* Any Conductor and Metallic Conductor to Conductor
Sheath/ Screen/Armour (For Unscreened Cables)
0.65/1.1 3 3 5
1.9/3.3 5 9 5
3.3/3.3 9 9 5
3.8/6.6 10.5 18 5
6.6/6.6 18 18 5
6.35/11 18 30 5
11/11 30 30 5
12.7/22 37.5 - 5
19/33 60 - 5
*U o : Phase Voltage
U : Line Voltage

The cable cores must be discharged on completion of DC high voltage test and cable shall be
kept earthed until it is put into service.

DC test voltage for old cables shall be 1.5 times rated voltage or less depending on the age of
cables, repair work or nature of jointing work carried out, etc. In any case, the test voltage
shall not be less than the rated voltage.

3.13.2 AC high voltage test shall be conducted as per following table on all HV Switchboards.

Rated Voltage Rated 1 Min. Power Frequency Withstand Voltage Duration in

(rms Value in (rms Value in kV) Minutes
kV)
U To Earth, Between Across the Isolating
Poles and Across Open Distance
Switching Device
3.6 10 12 1
7.2 20 23 1
12 28 32 1
24 50 60 1
36 70 80 1
72.5 140 160 1

The withstand voltage values across the isolating distances are valid only for switching
devices, where the clearance between open contacts is designed to meet the safety
requirements specified for disconnectors.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 374 OF 1216

3.14 All protective relays including thermal overload relays shall be tested by secondary injection
current. Primary injection tests shall be carried out for differential protection, restricted earth
fault protection at full/reduced current to ensure correctness of complete wiring.

3.15 Before energizing any equipment, ‘COMMISSIONING CLEARANCE FORM’ as per

standard format shall be duly filled in by contractor and submitted to EIL/owner.

3.16 It shall be ensured that the electrical inspectorate approval is available before energizing the
equipment

4.0 RECORDS

Contractor shall keep up-to-date records of all activities carried out and test results. Field
inspection / test reports shall be submitted to EIL / Owner by the contractor in bound volumes
(triplicate copies).

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 375 OF 1216

 SPECIFICATION
FOR
ELECTRICAL MOTOR OPERATED
VALVE ACTUATORS

(B047-003-SP-6-51-0091, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 376 OF 1216

Abbreviations:

CEA Central Electricity Authority

CIMFR Central Institute of Mines & Fuel Research
DGMS Director General of Mines & Safety
FM Factory Mutual Research Corporation
IEC International Electrotechnical Commission
LCIE Laboratoire Central des Industries Electriques
MOV Motor operated valve
PESO Petroleum and Explosives Safety Organisation
PVC Poly Vinyl Chloride
UL Underwriters Laboratory
.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 377 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 SITE CONDITIONS

5.0 POWER SUPPLY

6.0 TECHNICAL SPECIFICATIONS

7.0 EQUIPMENT FOR CLASSIFIED HAZARDOUS AREAS

8.0 FIREPROOFING

9.0 INSPECTION, TESTING AND ACCEPTANCE

10.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 378 OF 1216

1.0 SCOPE
The scope of this specification covers design, manufacture, assembly, shop testing and supply
of electrical motor operated valve actuators intended for fully/ partially opening and closing
valve duty with inching facility.

2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the requirements of latest revision of the following
standards issued by BIS (Bureau of Indian Standards) unless specified otherwise:

IS 5 Colours for ready mixed paints and enamels

IS 325 Three-phase Induction Motors
IS 4691 Degrees of protection provided by enclosure for rotating electrical machinery
IS 4722 Rotating electrical machines- Specification
IS 5571 Guide for Selection of Electrical Equipment for Hazardous area
IS 9334 Electric Motor Operated Actuators
IS 13947 Low Voltage Switchgear and Controlgear
(Parts-1, 3, 4 & 5)

2.2 In case of imported equipment, the standards of the country of origin shall be applicable if
these standards are equivalent or more stringent than the applicable Indian standards.

2.3 The equipment shall also conform to the provisions of Central Electricity Authority
Regulation - 2010 and other statutory regulations currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.

2.5 In case of any contradiction between various referred standards/ specifications/ data sheets and
statutory regulations, the most stringent requirement shall govern and decision of Owner in
this regard shall be final and binding.

3.0 GENERAL REQUIREMENTS

3.1 The offered equipment shall be brand new with state of the art technology having a proven
field track record. No prototype equipment shall be offered.

3.2 The vendor shall be responsible for design, engineering and manufacturing of the complete
actuator to fully meet the intent and requirements of this specification and attached data sheets.

4.0 SITE CONDITIONS

The electrical motor operated valve actuators shall be suitable for operating under site
conditions of LEH as specified elsewhere. Suitable de-rating factor shall be considered by
vendor while selection of equipment rating

5.0 POWER SUPPLY

The electrical motor operated valve actuators shall be suitable for power supply at 415V ±
10%, 50 Hz ± 3%, 3 phase, unless specified otherwise in the data sheet.

6.0 TECHNICAL SPECIFICATIONS

Each MOV actuator shall include the motor, actuator unit, gears, position indicators, limit
switches, handwheel, electrical starter and controls, terminal box etc. as a self-contained unit.
The actuator shall be sized to provide adequate torque and/ or thrust to ensure the complete
intended travel of the valve under the worst operating and electrical power supply conditions.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 379 OF 1216

6.1 Motor

6.1.1 The motor shall be 3-phase squirrel cage induction type unless specified otherwise in the data
sheet. It shall have totally enclosed non-ventilated and surface cooled construction.

6.1.2 The motor shall be designed for valve actuator service with high starting torque and shall be
suitable for Direct on line starting. It shall be rated for S2-15 minute duty and shall conform to
IS 325 or equivalent international standards.

6.1.3 The actuator assembly shall be provided with Thermostat(s) embedded in it to achieve
protection of motor against over-temperature.

6.1.4 The motor shall be suitable for starting under required torque with 75% of rated voltage at
motor terminals.

6.1.5 The motor shall have class ‘F’ insulation with temperature rise limited to class ‘B’ limits.
Motor winding shall be treated to resist corrosive agents and moisture.

6.1.6 Motor rotor shall preferably be of die-cast aluminium and, if brazed, shall be free from
phosphorous.

6.1.7 Motor installed in actuator shall be rated for minimum of 60 starts/stop per hour. This is
minimum requirement of actuator envisaged for ON-OFF duty only.

6.1.8 In case of intrusive type actuator, anti-condensation heater shall be provided irrespective of IP-
65 enclosure. However, in case of non-intrusive type actuator, space heater is not required.

6.2 Integral Starter and Control Transformer

The reversing starter, control transformer and local controls shall be integral with the valve
actuator, unless specified otherwise in the data sheet. Solid state control of valve actuator and
electrically isolated interface for remote control requirement shall be provided, wherever these
features exist in manufacturer’s design.

The integral starter shall be supplied with the following devices:

a) Electrically and mechanically interlocked reversing contactors for opening and closing
operations
b) Control transformer with necessary tapping and protected with suitable easily
replaceable fuses
c) Terminal block for external cable connection fully prewired for internal devices of
valve actuator.
d) MOV Actuators operating with AC power supply shall be provided with Instantaneous
Phase reversal protection.

6.3 Integral Push Button, Selector switches, Indications and Control devices

The following local control devices shall be provided integral with the MOV actuator:

a) Push buttons for ‘Opening/ Closing/ Stop’ or alternatively ‘Open/ Close’ selector
switch
b) ‘Local/ Off/ Remote’ selector switch, pad-lockable in each position
c) Local continuous position indication from ‘Valve fully open’ to ‘Valve fully closed’
position, which may be of analogue or digital type using mechanical indication/
Indicating lamps/ LEDs.

6.4 Torque and Travel Limit Switches

Torque limit switches shall be provided to protect the motor from over-loading by cutting-off
the power supply to motor during opening and closing operations. The limit switches shall be

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 380 OF 1216

 preset. However, it shall be possible to set the value of maximum torque during closing from
50% to 100% of rated torque of actuators. Travel limit switch shall be provided to cut-off the
power supply to the motor at the end of preset limit of valve travel. The switches shall be
provided with requisite number of potential-free contacts for valve actuator operation and for
indication on remote panels as specified in data sheet. Instead of mechanical torque limit
switches, magnetic pulse counter/encoders to measure and control the stroke of actuator may
be provided, wherever this feature exists in manufacturer’s design.

6.5 Control Facilities

The internal controls and monitoring circuits shall be incorporated within the integral starter
along with transformer and control unit of valve actuator.

Remote control facility shall be provided as a standard feature. The remote control circuits
shall be powered from internally derived control supply voltage. Common status contact
indicating the availability of the MOV actuator for remote control shall be provided by
monitoring the following:

- Loss of one or more phases of power supply

- Loss of control circuit supply
- Selector switch in local mode
- Local stop push button set to ‘Off’
- Motor thermostat tripped
- Any other local fault/ abnormal condition.

Where applicable, one number hand-held infrared/blue tooth remote programming device
required for site commissioning and reconfiguring (without the need of removal of the MOV
cover) shall be supplied for each group of 10 valve actuators (subject to minimum one
infrared/ Bluetooth remote setting device, even if number of valve actuators are less than ten).

6.6 Interface with Owner’s PLC/DCS / REMOTE PUSH BUTTON STATION

Potential free contacts for the following shall be provided in actuator assembly for hardwire
interface with Owner's DCS/PLC and/or Remote Push Button station:-

a) Run indication
b) Trip indication – 2 Nos.
c) Open status – 2 Nos.
d) Close status – 2 Nos.
e) Ready to start indication
f) Torque high indication
g) Thermostat status
h) Open command – 2 Nos.
i) Close command – 2 Nos.
j) Local/Remote

6.7 Hand Operation

A hand wheel with hand/ auto lockable lever shall be provided for emergency operation of the
MOV. The energisation of the motor shall automatically re-engage power operation.

6.8 Two-Wire Control system

Where specified in the data sheet, the MOV actuators shall be suitable for 2-wire control
system. These actuators shall have individual field units connectable to a master station
through a single 2-core cable loop for control and monitoring of the MOVs. The vendor shall
indicate the maximum number of field units that can be connected to a master station and the
maximum distance from the field unit to the master station. The vendor shall also indicate
maximum number of control inputs and control/ status outputs from each field unit that can be
handled through the 2-wire control system.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 381 OF 1216

 Each field unit/ MOV actuator shall be addressable from the master station through a unique
address code. All the field settable/ adjustable parameters of the MOV actuator shall be
settable from the master station. Similarly all the indications available on the MOV actuator
shall be available at the master station. Full diagnostic features for the MOV actuators shall be
available from the master station as well.

Suitable redundancy feature shall be provided, such that in case of a single fault at any
location in the cable, the field unit continues to communicate with the master station. The
master station shall be suitable for hook-up with the plant DCS system.

6.9 Digital Control System

If specified in data sheet, electric actuator shall be provided with an integrally mounted device
providing digital connectivity with Owner's PLC/DCS for actuator control, status indication &
monitoring. In this case, master station is not required any more. The control device shall meet
the appropriate recognized protocol or BUS standards. Selection of protocol shall be as per
data sheet only. Typical protocol/buses include:-

- Modbus RTU
- Profibus DP
- Device Net
- Foundation FieldBus

Terminal for hardwired communication shall also be provided in addition to digital

communication facility.

6.10 Remote Position Indicator

If requirement of remote position indication is specified in the data sheet, a 4-20 mA remote
position transmitter shall be provided in the valve actuator and a continuous position indicator
for mounting in purchaser's remote panel shall be supplied as a loose item. The remote
position indicator shall continuously indicate the position of travel of the valve.

6.11 Nameplate

Each motorized valve actuator shall be provided with a stainless steel nameplate furnishing
the following details, attached firmly to it at a place convenient for reading:

a) Actuator tag number as per data sheet

b) Motor kW rating, motor short time rating, motor supply voltage, nominal motor phase
current, auxiliary switch rating
c) Maximum torque setting
d) Actuator enclosure type, lubricant type
e) Actuator type, wiring diagram number/ catalogue number, actuator serial number.

A separate nameplate shall be provided for hazardous area application.

6.12 The enclosure of complete MOV actuator including motor, integral starter, control
transformer unit and all control devices shall have minimum IP-65 degree of protection
which shall include the ‘O’ ring for complete environmental protection.

6.13 Wiring and Terminals

All devices provided in the actuator shall be wired up to the terminal block. The contacts
for remote operation and indication shall also be wired up to the terminal block.
Minimum 10% spare terminals shall be provided for future interlocks. Internal wiring
for power and control circuits shall be appropriately sized for MOV actuator rating.
Each wire shall be identified at both ends using PVC ferrules. The terminal
compartment shall be separated from the inner electrical components of the actuator by

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 382 OF 1216

 means of a watertight seal so that the actuator electrical components are protected from
the ingress of moisture and foreign materials when the terminal cover is removed during
installation and maintenance.

6.14 The actuator shall be provided with minimum five adequately sized cable entries viz.,
one for power cable and two for control cables. However, the actual number of control
cable entries in actuators with 2-wire control system shall be provided based on job
requirements as specified in data sheets/specification for control systems for MOVs.
Suitable double compression cable glands shall be provided with each actuator for all
cable entries and sealing plugs for all control cable entries. The cable glands and plugs
shall be made of Nickel-plated brass. Plastic plugs shall not be acceptable.

7.0 EQUIPMENT FOR CLASSIFIED HAZARDOUS AREAS

7.1 Actuators meant for hazardous areas shall meet the requirements of IS 5571, IEC 60079 or
equivalent international standards and shall be suitable for Gas groups and Temperature class
as specified in the data sheet. Gas group IIB and Temperature class T3 (200°C) shall be
considered if not indicated in data sheet. The manufacturer shall possess valid test certificates
issued by a recognized independent test house (CIMFR/ Baseefa/ LCIE/ UL/ FM or
equivalent) for the offered actuators. All indigenous equipment shall conform to Indian
standards and shall have been tested and certified by Indian testing agencies. All equipment
(indigenous and imported) shall also have valid statutory approvals as applicable for the
specified hazardous locations from Petroleum and Explosives Safety Organisation (PESO /
DGMS) or any other applicable statutory authority. All indigenous flameproof equipment
shall have valid BIS license and corresponding marking as required by statutory authorities.

7.2 Apart from the nameplate indicating the tag no., a separate nameplate shall also be provided
on each actuator to indicate the details of the testing agency (CIMFR or equivalent), test
certificate number with date, statutory approval number with date, approval agency (PESO /
DGMS), BIS license number with date, applicable Gas group and Temperature class etc. The
nameplates shall be riveted/ fixed with screws and not pasted. In case any of the standard
details listed above are embossed on the enclosures, the same need not be repeated.

8.0 FIREPROOFING

8.1 Electric actuators shall be provided with fire proofing if specified in data sheet. The fire
proofing shall be rated for 30 minutes. Arrangement can be made by Intumescent paint/fire
resistant blankets/fire resistant boxes. Specific requirement of fire proofing arrangement shall
be mentioned in data sheet. In general case, if only fire proofing is required, Intumescent paint
(brand name: - K-Mass/ERS/Equivalent) shall be provided. The required certificates for the
fireproof rating shall be furnished from an independent test laboratory.

8.2 MOV Actuators with fireproofing shall be suitable for termination of mica insulated fire
survival type power and control cables.

9.0 INSPECTION, TESTING AND ACCEPTANCE

9.1 The equipment shall be subject to inspection by EIL/ Owner or by an agency authorized by the
owner. Manufacturer shall furnish all necessary information concerning the supply to EIL/
Owner’s inspector. During the course of manufacturing, the purchaser or his authorized
representative shall be free to visit the works and assess the progress of work and the
manufacturer shall render him all possible assistance to do so.

9.2 Following routine tests shall be carried out at the manufacturers’ works under his supervision
and at his own cost for all the actuators:-

9.2.1 Functional and calibration test for torque and limit switches

9.2.2 Response time test

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 383 OF 1216

9.2.3 Variation of supply voltage

9.2.4 Variation of frequency

9.2.5 Test on output shaft at 100% torque

9.2.6 Tests for motor(As per relevant IS/IEC)

9.3 Following type test certificates of offered model of actuator shall be submitted for review &
approval:-

9.3.1 Life test

9.3.2 Test on motor terminal box

9.3.3 Damp heat recycling test

Two weeks’ notice shall be given to Owner / EIL for witnessing the final testing of the
complete assembly to ensure satisfactory operation of the MOV actuators. Type test
certificates shall be furnished during detailed engineering. Final acceptance of MOVs at site
shall be subject to successful testing of the MOV actuators with the valves.

9.4 Type test certificates, original drawings referred in certificates and statutory approval
certificates and BIS license, where applicable, shall be shown to the inspection agency on
demand. The certificates and BIS license must be valid at the time of dispatch.
9.5 Test certificates of bought-out components shall be shown to the inspection agency on
demand.

10.0 PACKING AND DESPATCH

All the equipment shall be divided into multiple sections for protection and ease of handling
during transportation. The equipment shall be properly packed for the selected mode of
transportation, i.e. by ship, rail or trailer. The equipment shall be wrapped in polythene sheets
before being placed in crates/ cases to prevent damage to finish. The crates/ cases shall have
skid bottoms for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Center of
gravity’, ‘Weight’, ‘Owner’s particulars’, ‘PO no.’ etc. shall be clearly and indelibly marked
on the packages together with other details as per purchase order.

The equipment may be stored outdoors for long periods before installation. The packing shall
be completely suitable for outdoor storage in areas with heavy rains and high ambient
temperature unless otherwise agreed. In order to prevent movement of equipment/ components
within the crates, proper packing supports shall be provided. A set of instruction manuals for
erection, testing and commissioning, a set of operation and maintenance manuals and a set of
final drawings shall be enclosed in a waterproof cover along with the shipment

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 384 OF 1216

 SPECIFICATION
FOR
ELECTRIC SURFACE HEATING
SYSTEM

(B047-003-SP-6-51-0095, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 385 OF 1216

Abbreviations:

BASEEFA : British Approvals Service for Electrical Equipment for Flammable Atmospheres
BIS : Bureau of Indian Standards
CCOE : Chief Controller of Explosives
CEA : Central Electricity Authority
CIMFR : Central Institute of Mining and Fuel Research
CT : Current Transformer
DGMS : Directorate General of Mines Safety
ELCB : Earth Leakage Circuit Breaker
ERTL : Electronics Regional Test Laboratory
FM : Factory Mutual Research Corporation
GI : Galvanised Iron
IEC : International Electro Technical Commission
IEEE : Institute of Electrical & Electronics Engineers
IP : Ingress Protection
IS : Indian Standards
LCIE : Laboratorie Central Des Industries Electriques
LDP : Local Distribution Panel
MCB : Miniature Circuit Breaker
MS : Mild Steel
OISD : Oil Industry Safety Directorate
PDB : Power Distribution Board
PEM : Project Engineering Management
PESO : Petroleum and Explosives Safety Organisation
PO : Purchase Order
PVC : Polyvinyl Chloride
RTD : Resistance Temperature Detector
SWG : Standard Wire Gauge
TPN : Three Phase Neutral
UL : Underwriters Laboratories

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 386 OF 1216

 CONTENTS

1.0 GENERAL

2.0 CODES AND STANDARDS

3.0 SYSTEM DESIGN REQUIREMENTS

4.0 EQUIPMENT AND MATERIAL SPECIFICATIONS

5.0 INSPECTION, TESTING AND ACCEPTANCE

6.0 INSTALLATION

7.0 FIELD TESTING AND COMMISSIONING

8.0 CERTIFICATION AND APPROVALS

9.0 PACKING AND DESPATCH

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 387 OF 1216

1.0 GENERAL

1.1 This specification and project data sheets define the requirements for system design,
engineering, supply, installation, testing and commissioning of electric surface heating (ESH)
devices as applied to fluids/materials in piping and associated equipments, both in safe and
hazardous areas (classified as Zone -1 or Zone -2), in accordance with applicable standards.

1.2 Contractor shall ensure that the design, product selection and installation are carried out as per
good engineering practices, which shall also include the requirements of safety, reliability,
ease of maintenance and operation.

1.3 Compliance with this specification and /or approval of any of the contractor’s documents shall
not relieve the contractor of his responsibility towards the contractual obligation with regard
to the completeness and satisfactory operation of the electric surface heating system.

2.0 CODES AND STANDARDS

2.1 The equipments covered by this specification shall comply with the requirements of the latest
edition of applicable standards issued by BIS, IEC and IEEE including the following:

IS-5 : Colours for ready mixed paints and enamels

IS-1554 : PVC insulated (heavy duty) electric cables.
IS/IEC 60079-1 : Electrical apparatus for explosive gas atmosphere
IS-3043 : Code of practice for earthing
IS-5571 : Guide for selection of electrical equipment for hazardous area.
IS/IEC-60079-7 : Electrical apparatus for explosive atmosphere type ‘e’ increase
safety.
IS/IEC-60079-15 : Electrical equipment with type of protection ‘n’.
IS-8623 : Specification for low voltage switchgear and control gear
assemblies.
IS-12021 : Specification for control transformers for switchgear and control-
gear for voltages not exceeding 1000 V AC
IS/IEC-60079-0 : General requirements for electrical apparatus for explosive gas
atmosphere.

IS-13703 : Specification for low voltage fuses

IS/IEC-60947 : LV switchgear and control gear.
IS 14774 (Part 1) : Resistance trace heating in potentially explosive atmosphere
- Part-1, General & testing requirements
IS 14774 (Part 2) : Resistance trace heating in potentially explosive atmosphere
-Part-2, Informative application guide for design, installation and
maintenance
IS/IEC 60079-30-1 : Electrical apparatus for explosive gas atmosphere
Electrical resistance trace heating
Part-1, General & testing requirements
IS/IEC 60079-30-2 : Electrical apparatus for explosive gas atmosphere-Electrical
resistance trace heating
IEC 60751 : Industrial platinum resistance thermometer sensor
Part-2, Application guide for design, installation and maintenance
IS/IEC 60529 : Degree of protection provided by enclosures (IP Code)
IEEE-515 : Standards for the testing, design, installation and maintenance of
Electrical Resistance Heat Tracing for Industrial applications.
In case of conflict between requirements specified in various referred
standards/specification/data sheets/and the statutory regulations, the most stringent one shall
prevail. However, owner’s decision in this regard shall be final and binding.

2.2 In addition, work shall conform to the following statutory requirements as applicable.
• CEA regulations
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 388 OF 1216
 • Fire insurance regulations
• Regulations laid down by Chief Controller of Explosives/DGMS as applicable.
• Indian Petroleum Rules
• OISD guidelines/standards
• Regulations laid down by local authorities from time to time.

2.3 Where Indian Standards do not exist, the relevant IEC, British, IEEE standards shall apply.

3.0 SYSTEM DESIGN REQUIREMENTS

3.1 Electrical Surface Heating

3.1.1 The design shall be based on continuous and reliable service, safety to personnel and
equipment, ease of maintenance and interchangeability, wherever applicable.

3.1.2 The design of the electric heating system shall be based on stabilised design approach where
the maximum surface temperature of the heating device shall be determined without
temperature control.

Product classification approach shall be followed for determining heating device’s sheath
temperature unless otherwise agreed.

Systems approach may be permitted in those instances where the sheath temperature
determination as per product classification approach exceeds 200o C.

In exceptional cases requiring high maintenance temperatures as specified in project data

sheet, the design may be based on systems approach wherein the electric heating tape may not
necessarily be certified under product classification approach.

In case of higher maintenance and exposure temperature, double insulation technique as per
IEC/IEEE standards shall be utilised for locating the SLSR heater tape between the two layers
of insulation. The basic criteria of selection of the double insulation technique shall be to
determine the correct combination of inner and outer insulation type and thickness to achieve
the specified surface temperature limit for the heat tracer.

The heating tape shall be suitable for continuous/ intermittent exposure temperature under
power ON/power off condition as specified in project data sheet.

All necessary type test certificates including those for ‘T’ rating, service life bench mark
performance test shall be furnished.

3.1.3 Overlapping of heating tapes shall be permitted only in case of heating tapes with burnout
proof feature.

3.1.4 The heating tapes shall be suitable for use in area defined in project data sheet. It shall be
provided with corrosion resistant tinned copper braid for both safe and hazardous area
applications. For applications requiring high exposure temperature, the braid may be of nickel
plated copper. An outer sheath over the metallic braid shall also be provided for corrosion
resistance and additional mechanical protection.
3.1.5 The surface temperature of the heating tapes/electrical equipment intended to be used in
hazardous area shall not exceed 200 °C (T3 rating) unless otherwise specified in the project
data sheet.

3.1.6 The selection of heating tapes and other devices shall be done by the contractor considering
the following:

• Specified maintenance/heating temperature requirements,

• Minimum design ambient temperature
• Intermittent Exposure temperature
• Thermal insulation (Type and thickness)
• Tolerance on supply voltage and voltage drop on feeding cables
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 389 OF 1216
 • Minimum heater output rating at operating conditions
• Site environment conditions
• Specified hazardous area classification and 'T' rating
• Design margin

3.1.7 If specified in data sheet, for critical applications where heat up time is an important factor
during start up or power shut down, extra heating capacity shall be taken into design in
addition to that required for temperature maintenance.

Apart from above, there may be a need to heat up (to melt) the contents within a certain period
under specified ambient condition, additional heating capacity need to be installed for such
duty.

3.1.8 The method of calculation of heat loss and related parameters shall be as per guidelines given
in the standards. The losses from each part of the surface shall be calculated using the
appropriate formula and added together to determine the total heat loss. A minimum design
margin of 10% shall be considered on the rate of heat loss calculated.

3.1.9 The tracer shall withstand the highest equilibrium pipe temperature that occurs when the
heating tape is continuously energised at the maximum ambient temperature and at the
maximum operating voltage. The maximum continuous exposure temperature of the heating
tapes in “Power ON” condition shall be more than the highest equilibrium pipe/equipment
temperature or 20°C above the specified maintenance temperature of the pipes/equipment
whichever is higher.

3.1.10 Heat tracer shall have temperature withstand capacity of not less than the maximum operating
temperature

3.1.11 Heating tape used for piping and other equipments that will undergo periodic steam cleaning
shall have intermittent exposure minimum withstand temperature with power off as specified
in project data sheets. Tracer shall be suitable for withstanding exposure temperature for
“power OFF” condition for cumulative duration of at least 1000 hrs.

3.1.12 The heat output at the end of the heater tape shall meet the minimum heat loss requirement,
considering negative tolerance on supply voltage, voltage available at the end of the tape and
considering minimum heater output rating at operating conditions.

3.1.13 Extra heater tape length shall be provided for valves, flanges, pipe supports and similar heat
sinks. The heater tapes shall be installed so as to permit easy maintenance or removal of the
valve, pipe support or similar heat sink however, installation shall be done without
overlapping.

3.1.14 Each heater circuit shall be provided with independent thermostat (temperature set point
manually adjustable) / RTD with multi circuit control and monitoring system for energy
conservation requirements. The type of temperature sensing device i.e. thermostat or RTD
shall be as per data sheet. The location of thermostats/RTD shall be decided at the most
strategic points which are governed by process / site conditions. The capillary of the
thermostat tube shall have mechanical protection.

3.1.15 Number of circuits shall be decided considering all possible flow conditions.

3.1.16 Suitable flexible material shall be used for proper positioning of the heater tape on pipeline,
equipment. No increase in allowance on heat output shall be permitted on this account.

3.2 Electrical Power Distribution

3.2.1 Power supply shall be provided in owner’s substations for feeding power to the PDBs or
LDPs. In case bulk supply to heat tracing system is considered, PDBs shall be provided for
distributing power to LDPs. Power supply to the heater tapes shall be provided from LDPs
located in the field at strategic locations /load centres to be decided by the contractor.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 390 OF 1216

3.2.2 For power cable sizing, total voltage drop from owner’s switchgear to heater tape shall be
limited to 4% under full load condition. The voltage drop between owner’s switchgear to
PDB/LDP and PDB/LDP to heater tape shall be adjusted accordingly.

All power cables (from substation to PDB/LDP and LDP to heater tape) shall be properly
sized to carry current without undue temperature rise under site derated conditions. The
derating shall take into account ambient air temperature/ground temperature, grouping and
proximity of cables with each other, thermal resistivity of soil etc. as applicable for
installation.

Further, the selected cable size shall also be adequate to carry the maximum anticipated heater
start up current while the heating device is at minimum temperature.

3.2.3 3 core-armoured cables shall be used for power supply to heater tape for single-phase circuits.
(2 cores for phase and neutral and third core for earth conductor).

3.2.4 The incoming cables to PDBs / LDPs shall be four core (conductor size for neutral shall be
same as that for phase conductors).

3.2.5 Thermostats, if used, in power circuit, as well as Components used in the local distribution
panels shall be sized for 125 % of starting current at rated voltage and considering maximum
heater output rating.

3.2.6 The load shall be balanced in all the 3 phases to the extent possible in each LDP.

3.2.7 Monitoring Facility

Unless otherwise specified in the data sheet, the monitoring facility for power supply
healthiness of feeders in LDP feeders shall be done by providing one auxiliary contactor in
each feeder which shall remain energised under power supply healthy condition. The contact
(Normally open) of this auxiliary contactor of all feeders shall be wired in series in each LDP
to give one common alarm contact for remote annunciation (open to alarm) against loss of
voltage, earth leakage, and fault.

4.0 EQUIPMENT AND MATERIAL SPECIFICATIONS

All materials to be used for the job shall be field proven in similar services and under similar
conditions with proven track record. The workmanship shall be of high quality in every
respect.

The main heater tape shall be as detailed in section 3.1. The requirements in respect of other
items are detailed below.

4.1 Power Distribution Boards (PDB)/ Local Distribution Panels (LDP)

4.1.1 PDB/LDP shall conform to attached EIL specifications and data sheet. PDB shall preferably
be installed in outdoor safe areas.

4.1.2 PDBs/LDPs intended for installation in outdoor safe areas shall be housed in outdoor kiosk to
make it totally weather protected. Necessary glass windows shall be made in outdoor kiosk, so
that the operator can see all indications and energised / de-energised position of different
switches/ MCCB’s and other device from outside without opening the door and without taking
any special precautions.

4.1.3 The incomer feeder of PDB shall be isolator /breaker feeder and shall have voltmeter with
selector switch, ammeter, ammeter selector switch indication lamps .Outgoing feeder shall be
switch fuse feeder with ON/OFF/trip indication lamps.

4.1.4 LDP incomer shall be TPN load break switch feeder of required rating. The incomer feeder
shall
VOLUME-2 have voltmeter with selector
(ELECTRICAL) SOWswitch, ammeter, ammeter selector switch
& SPECIFICATIONS PAGEand
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 lamps for supply indication. Each out going circuit shall comprise of Miniature Circuit
Breaker (MCB) with thermal over current and magnetic short circuit releases, Earth Leakage
Circuit Breaker (ELCB) (M9 Category), power contactor of required rating if thermostat
rating is inadequate. MCB shall be double pole for single phase circuits. MCB rating shall be
such that it shall not operate on starting current. The ELCB shall have nominal 30 mA and 30-
msec.-trip rating, in case this setting results in nuisance tripping, ELCB may be selected above
30 mA but not greater than 300mA and 150 msec. Ammeter (CT operated) and indication
lamp for feeder status shall be provided for each outgoing circuit. Indication circuit shall
include the status of the thermostat (ON/OFF) installed in the field.

4.1.5 PDB/LDP shall have 20% spare feeders, which shall include minimum of one spare feeder of
each rating.

4.2 General Requirements

4.2.1 Junction boxes /power connectors used for power cable / heater tape termination shall be
weatherproof for use in safe areas. Increased safety/ Non sparking weatherproof junction
boxes /power connectors as per IS/IEC 60079-7/15 shall be used for areas classified as zone -2
and flameproof weatherproof junction boxes / power connectors as per IS/IEC 60079-1 shall
be used for areas classified as zone-1 as a minimum.

4.2.2 All power, control and signal cables shall be PVC insulated, extruded PVC inner sheathed, GI
wire/flat armoured, FRLS PVC outer-sheathed (60% smoke density) and shall conform to
attached EIL specifications. Copper conductor cable shall be provided for cable sizes up to 16
mm2 unless otherwise specified in the data sheet. Aluminium / Copper conductor cable shall
be used for power cables above 16 mm2. All control cables shall be of size 2.5 mm2 and with
cu conductor.

4.2.3 All outdoor enclosures shall be provided with IP 55 protection.

4.2.4 All equipments such as PDB’s/LDPs, thermostats etc intended for installation in hazardous
area shall be of flameproof type with, Temp. Class T3 and suitable for applicable gas group
(IIA, IIB or IIC) as per project data sheet. The enclosure shall also have IP-55 weather
protection. Canopy shall be provided for additional weather protection.

4.2.5 Nickel plated brass double compression cable glands shall be used for cable termination in all
equipments.

4.2.6 Heater tape termination and support clamps shall withstand the maximum temperatures,
temperature cycling and thermal expansion of piping or equipment to be heated. These shall
not be affected by rainwater, firewater spray and site environment.

4.2.7 Electric surface heating system shall be complete with all accessories for fixing and installing
the heater tape and junction boxes, power connectors, T connectors, end connectors etc.

4.2.8 Each heater shall be tagged with non-corrosive metallic tag indicating heater number, type and
pipe line/equipment number.

4.2.9 Pipe lines, instruments and vessels heated with heater tape shall be provided with suitable
metallic caution signs visible from all sections of the heated system. Caution signs on traced
pipe lines shall not be more than 6 m apart. In addition, each instrument, level gauge, vessel
etc. that by the nature of their function require operation or maintenance, shall carry an
individual sign. The sign shall read "Electric surface heated” and shall be of size 200 mm x 60
mm (minimum).

4.2.10 All electrical equipments to be supplied by the contractor be epoxy painted. Unless otherwise
specified, the colour shade shall be shade 632 as per IS: 5.

4.3 Local Thermostats

4.3.1 Capillary Type

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 392 OF 1216
 The capillary shall not be more than 5 m long. The contacts of thermostat used for direct
switching shall have a minimum rating of 16 A. Each contact shall not be loaded with more
than 75% of its nominal rating. The temperature setting accuracy shall be better than + 5% of
set value.

4.3.2 Flameproof and weather protected (IP-55) thermostats shall be used in classified areas. All
thermostats shall be factory calibrated, non-indicating type, equipped with internally
adjustable set point.

4.4 RTD with Multi Circuit Control and Monitoring Facility

4.4.1 RTD shall be 3 wire type with platinum element having 100 ohms resistance at 0°C, selected
for desired temperature range.

4.4.2 The element shall be of highly refined material of reference grade and shall have been stress
relieved. RTD calibration shall be as per IEC-60751-2.

4.4.3 Central monitoring system shall be provided in LDP for control and monitoring of heater
circuits. The RTDs shall be connected directly to central monitoring system in LDP or through
group control module provided locally in the field. The group control/monitoring modules
wherever provided shall be connected to central monitoring system in LDP in redundant mode
for both power and control circuits

4.4.4 All components for the system shall be suitable for hazardous area in line with area
classification requirements.

4.4.5 Provision for monitoring of following minimum alarm conditions shall be provided in LDP
for all circuits
- Low / high temperature
- RTD failure
- Communications failure
- Ground-fault
- Low / high current

4.4.6 Central monitoring system provided in LDP shall have provision to communicate with upper
level system/automation. The type of protocol for communication with upper level system
shall be as defined on the data sheet.

5.0 INSPECTION, TESTING AND ACCEPTANCE

5.1 All equipment and materials to be supplied by contractor shall be subject to inspection by
EIL/Owner, at manufacturer’s works. Manufacturer shall furnish all necessary information
concerning supply to EIL / owner’s inspectors. The inspector shall have free access to the
manufacturer's works for the purpose of inspecting the process of manufacture in all its stages
to assess the progress of works as well as to ascertain the quality of raw materials used.

5.2 All routine and acceptance tests as specified by the applicable standard codes and enclosed
EIL specifications shall be conducted. Shop tests shall be witnessed by Inspector of EIL /
Owner or of an agency authorised by owner.

5.3 For equipment bought from sub-suppliers, certified test reports of tests carried out at the
manufacturer’s works shall be submitted. The sub-supplier at his works shall conduct
normally all routine tests as specified in the relevant standards.

5.4 All sundry installation materials brought to site directly, will be inspected and approved by
Engineer-in-charge before installation.

6.0 INSTALLATION

6.1 Heater Tape

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 393 OF 1216
6.1.1 Before installation of heater tapes on pipes and other equipments, contractor shall arrange to
clean properly the surfaces to the extent required.

6.1.2 Installation shall be done in accordance with applicable standards.

6.1.3 Heating tapes shall not be installed until pipe lines and equipment have passed all required
tests and clearance is given by engineer-in-charge.

6.1.4 Heaters and controls shall be carefully located and installed to prevent damage during normal
operation and maintenance.

6.1.5 The electric surface heating for instruments, valves and flanges shall be done in such a way
that servicing of instruments, opening of valves and servicing of flanges is possible with ease
and without disconnecting wiring.

6.1.6 Field installation works shall be carried out in such a manner that the work of other agencies
(piping, insulation contractor etc.) operating at the site is not hampered due to any action of
the contractor and proper coordination with other agencies shall be contractor's responsibility.

6.2 Cabling System

6.2.1 Cable shall preferably be laid in overhead / surface mounted cable trays along the pipe rack/
pipe track wherever available. GI cable trays shall be used unless otherwise specified. Cable
trays shall be supported at a distance not exceeding 3000 mm. Tray widths shall be preferably
300 / 450 mm and shall be arranged in single/ multi-tiers as required. All supporting steel shall
be painted before laying of cables.

6.2.2 All power, control, signal cables in unpaved areas shall be directly buried unless specified
otherwise. After required earth excavation, cable shall be laid at a depth of not less than 750
mm and shall be covered with 150 mm of sand on top of the largest diameter cable followed
by a protective covering of 75 mm thick second-class red bricks. The remainder of the trench
shall then be back filled, rammed and levelled. Where underground cables cross roadways,
pipe sleepers at grade etc., they shall be taken through existing Electric Road Cross (ERC) or
duct. Cables rising from grade shall be protected by GI conduits up to a min. of 300 mm above
grade and open ends shall be sealed. Cable route markers shall be provided by contractor for
underground-buried cable trench at an internal of 30 m.

Cables in paved areas shall be taken in trenches provided by purchaser. The trench covers
shall be removed by contractor and shall be reinstated after cable laying. Trenches in
hazardous area shall be completely filled up with sand.

Where trenches are not available in paved areas, contractor shall take cables in GI sleeves to
be laid in paved area or through overhead cable trays.

6.2.3 All power and control cables shall be of continuous lengths without intermediate joints. All
cables shall be identified close to their termination point by cable number (as per cable
schedule), punched on 2 mm thick aluminium strap securely fastened to the cable. Each
underground cable shall be provided with identity tags made of lead securely fastened at every
30 m of its underground length with at least one tag at each end before the cable enter/leaves
the ground. In case of control cables, all cores shall be identified at both ends by their
terminal numbers using PVC ferrules as per interconnection diagrams.

6.2.4 All PVC cables up to 1.1 kV grade shall be terminated at the equipment by means of double
compression type cable glands and crimping type lugs. All cable entries shall be through
bottom only unless otherwise approved.

6.3 Earthing System

6.3.1 All metallic non current carrying parts of electrical apparatus, PDBs, LDPs, Heater tape
mounting accessories, junction boxes, thermostats etc. shall be earthed.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 394 OF 1216
6.3.2 For earthing of PDB/ LDP and other equipment and devices, contractor shall tap from the
nearest available existing main earth grid by providing two runs of 40 x 5 GI strip. Amount of
galvanizing shall be 610 g/sq. mm (Min).

Joints and tapings with the main earth grid shall be made in such a way that reliable and good
electrical connections are permanently ensured. All joints below grade shall be welded and
suitably protected by giving two coats of bitumen and covered with hessian tape. Earthing
network shall be augmented by providing additional earth electrode in test pits where required.

Multiple earth connections shall be taken from suitably located earth plates connected to earth
grid. Equipment handling more than 250 V power shall be earthed at two points. Size of strip/
conductor for LDP shall be same as that of the earth grid.

For connection from earth plate to different equipment mountings, and accessories of surface
heating system, GI wire rope/ PVC insulated aluminium conductor cable as specified on the
data sheet shall be used. Size of earth wire shall be such that the current rating is at least 60 %
of power cable rating / equipment rating. Minimum size shall however be 6 sq. mm. for
aluminium wire / 8 SWG for GI wire.

6.3.3 All hardware used for earthing installation shall be hot dip galvanised /zinc passivated /
chromium plated. Spring washers shall be used for all earthing connections of equipment.

7.0 FIELD TESTING AND COMMISSIONING

7.1 Inspection during installation and after completion of installation shall be carried out by
contractor's adequately trained supervisor /engineer in accordance with guidelines given in the
standards. Contractor at no extra cost to the owner shall rectify any defect pointed out by
EIL/OWNER’S site-in-charge.

7.2 Before any part of the electric surface heating system is energised, the precommissioning tests
shall be carried out. This shall include and be not limited to the following:

• Insulation resistance tests

• Continuity test
• Earth loop impedance

Field testing and commissioning procedure shall be submitted by the contractor for owner/EIL
approval.

All pre-commissioning checks and tests both for power distribution and heating system shall
be carried out by the contractor in the presence of Engineer-in-charge. Test readings are to be
recorded by contractor and copies of test certificates shall be furnished to EIL /owner.

7.3 After inspection and pre-commissioning tests are carried out, contractor shall obtain necessary
statutory approval of the system before energizing the installation. Current shall be noted at
the time of initial energization of the circuits and again when readings have stabilized. All
results shall be recorded and furnished to the owner to form part of system documentation.

8.0 CERTIFICATION AND APPROVALS

Electrical equipments for hazardous areas shall have type test certificates issued by recognised
independent test house such as CIMFR/ERTL/BASEEFA/LCIE/UL/FM. All equipment
(indigenous/imported) shall have valid statutory approvals (CCOE/DGMS) as applicable for
use in specified hazardous area. All Indigenous flameproof equipment shall have valid BIS
license and as required by statutory authorities.

9.0 PACKING AND DESPATCH

All equipment shall be divided into several sections for protection and ease of handling during
transportation. The equipment shall be properly packed for transportation by selected mode
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 395 OF 1216
 i.e. by ship/rail or trailer. The equipment shall be wrapped in polythene sheets before being
placed in the crates/cases to prevent damage to finish. Crates/Cases shall have skid bottom for
handling. Special notations such as ‘Fragile’, ‘this side up’, ‘centre of gravity’, weight, owner
particulars, PO No. etc. shall be clearly marked on the package together with other details as
per purchase order.

The equipment may be stored outdoors for long period before erection. The packing shall be
completely suitable for outdoor storage in areas with heavy rains/high ambient temperature,
unless otherwise agreed.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 396 OF 1216

 DESIGN PHILOSOPHY
FOR
ELECTRICAL FACILITIES
(B047-003-SP-6-51-0099, Rev A)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 397 OF 1216

Abbreviations:

A : Amperes kVAR : Kilo Volt Ampere Reactive

AC : Alternating Current kW : Kilo Watt
ACB : Air Circuit Breaker kWH : Kilo Watt Hour
ACDB : AC Distribution Board LAN : Local Area Network
ASB : Auxiliary Service Board LCIE : Laboratoire Central des Industries
Electriques
ATEX : Atmospheres EXplosibles LDB : Lighting Distribution Board
BIS : Bureau of Indian Standards LED : Light Emitting Diode
CEA : Central Electricity Authority LV : Low Voltage (Up to 250V)
CFL : Compact Fluorescent Lamp MCB : Miniature Circuit Breaker
CIMFR : Central Institute of Mining and Fuel MCC : Motor Control Centre
Research
CPRI : Central Power Research Institute MCCB : Moulded Case Circuit Breaker
CT : Current Transformer MOV : Motor Operated Valve
DB : Distribution Board MV : Medium Voltage (Above 250V and up
to 650V)
DC : Direct Current NEC : National Electric Code
DCDB : DC Distribution Board NFPA : National Fire Protection Association
DCS : Distributed Control System NGR : Neutral Grounding Resistor
DG : Diesel Generator NGT : Neutral Grounding Transformer
DGMS : Director General Mines Safety OISD : Oil Industries Safety Directorate
DOL : Direct On Line ONAF : Oil Natural Air Forced
ECS : Electrical Control System ONAN : Oil Natural Air Natural
EIL : Engineers India Limited PCC : Power Control Centre
ELCB : Earth leakage Circuit Breaker PDB : Power Distribution Board
ELR : Earth Leakage Relay PESO : Petroleum and Explosives Safety
Organisation
EOT : Electrically Overhead Travelling PMCC : Power Cum Motor Control Centre
ERTL : Electronic Regional Test PT : Potential Transformer
Laboratories
EHV : Extra High Voltage (Above 33 kV) PTB : Physikalisch-Technische Bundesanstalt
FM : Factory Mutual PVC : Polyvinyl Chloride
FRLS : Flame Retardant Low Smoke RCC : Reinforced Cemented Concrete
GI : Galvanised Iron RTCC : Remote Tap Changing Controller
GIS : Gas Insulated Switchgear RTD : Resistance Temperature Detector
HMI : Human Machine Interface RTU : Remote Terminal Unit
HV : High Voltage (Above 650V and up RVT : Residual Voltage Transformer
to 33 kV)
HVAC : Heating Ventilation and Air SVL : Surge Voltage Limiter
Conditioning
IEC : International Electro-Technical UL : Underwriter’s Laboratory
Commission
IES : Illumination Engineering Society UPS : Uninterrupted Power Supply
I/O : Input/ Output V : Voltage
IS : Indian Standards VFD : Variable Frequency Drive
kV : Kilo Volt VRLA : Valve Regulated Lead Acid
kVA : Kilo Volt Ampere XLPE : Cross Linked Poly Ethylene

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 398 OF 1216

 CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 STATUTORY REQUIREMENTS

4.0 SYSTEM DESIGN PHILOSOPHY

5.0 EQUIPMENT DESIGN PHILOSOPHY

6.0 SUBSTATION / MCC ROOM DESIGN PHILOSOPHY

7.0 INSTALLATION DESIGN PHILOSOPHY

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 399 OF 1216

1.0 SCOPE

This specification along with the applicable project design data sheet shall form the basis for
developing detailed design and engineering for electrical facilities including electrical power
system, Electrical equipment, Electrical control system, Plant communication system, Fire
detection and alarm system and electrical installation etc.

2.0 CODES AND STANDARDS

The main codes and standards, considered as minimum requirements, as applicable, are as
mentioned below. Latest version of these shall be followed:-
IS-1646 : Code of practice for the fire safety of buildings - Electrical
Installations
IS-2189 : Code of practice for selection: installation and maintenance of
automatic fire detection and alarm system
IS-2309 : Code of practice for the protection of buildings and allied structures
against lightning
IS-3034 : Code of practice for fire safety of industrial buildings - Electrical
generating and distributing stations
IS-3043 : Code of practice for Earthing
IS-3646 : Code of practice for Interior Illumination
IS-3716 : Application guide for Insulation Coordination
IS-4051 : Code of practice for installation and maintenance of electrical
equipment in mines
IS-5216 : Recommendation on safety procedures and practices in electrical
work
IS-5571 : Guide for selection and Installation of electrical equipment for
hazardous areas (Other than mines)
IS-5572 : Classification of hazardous areas (other than mines) having
flammable gases and vapours for electrical installations
IS-6665 : Code of practice for Industrial Lighting
IS-7689 : Guide for Control of undesirable static electricity
IS-7752 : Guide for improvement of power factor in consumer installations
IS-8478 : Application guide for on load tap changers
IS-9676 : Reference ambient temperature for electrical equipment
IS-10028 : Code of practice for selection, installation and maintenance of
transformer
IS-10118 : Code of practice for selection, installation and maintenance for
switchgear and control gear
IS-10561 : Application guide for Power Transformer
IS-12360 : Voltage bands for electrical installations including preferred voltages
and frequencies
IS-13234 : Guide for short circuit calculations in three phase AC systems
SP-30 : National Electrical Code (NEC) - BIS Publication
OISD-RP-110 : Recommended practices on static electricity
OISD STD-113 : Classification of Area for electrical installation at Hydrocarbon
processing and handling facilities
OISD-RP-147 : Inspection and safe practices during electrical installation
OISD RP-149 : Design aspects for safety in electrical systems
OISD STD 173 : Fire Protection System for Electrical Installations

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 400 OF 1216

 OISD GDN-180 : Lightning Protection
IS/IEC 60079-0 : Electrical apparatus for explosive gas atmospheres – General
requirements.
IS/IEC 60079-1 : Explosive Atmospheres: Equipment protection by flameproof
enclosures “d”
IS/IEC 60079-2 : Explosive protection by pressurized enclosures “p”
IS/IEC 60079-5 : Explosive Atmospheres: Equipment protection by powder filling “q”
IS/IEC 60079-6 : Explosive Atmospheres: Equipment protection by Oil immersion “o”
IS/IEC 60079-7 : Explosive Atmospheres: Equipment protection by increased safety
“e”
IS/IEC 60079-11 : Explosive Atmospheres: Equipment protection by intrinsic safety “i”
IS/IEC 60079-15 : Electrical apparatus for explosive gas atmosphere – Construction, test
and marking of type of protection ``n” electrical apparatus
IS/IEC 60079-20 : Electrical apparatus for explosive gas atmosphere: Data for
flammable gases and vapours relating to the use of electrical
apparatus.
IS/IEC 61241-0 : Electrical apparatus for use in the presence of combustible dust:
General Requirements
IS/IEC 61241-1 : Electrical apparatus for use in the presence of combustible dust:
Protection by enclosure “tD”
IS/IEC 61241-2-1 : Electrical apparatus for use in the presence of combustible dust: Test
Methods – Methods for determining the minimum ignition
temperature
IS/IEC 61241-2-3 : Electrical apparatus for use in the presence of combustible dust: Test
Methods – Methods for determining minimum ignition energy of
dust/ air mixtures.
IS/IEC 61241-10 : Electrical apparatus for use in the presence of combustible dust:
Classification of area where combustible dust may be present.
IS/IEC 61241-14 : Electrical apparatus for use in the presence of combustible dust:
Selection and Installation
IS/IEC 61241-18 : Electrical apparatus for use in the presence of combustible dust:
Protection by encapsulation mD

3.0 STATUTORY REQUIREMENTS

The latest version of the following statutory regulations shall be followed for design of
electrical system, as applicable for the particular project/ industry.

- Indian Electricity Act.

- Central Electricity Authority Regulations.
- The Factory Act.
- The Petroleum Rules.
- The Mines Act.
- Requirements of other statutory bodies as applicable, e.g. CEA/ State Electrical
Inspectorate, PESO, DGMS.

4.0 SYSTEM DESIGN PHILOSOPHY

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 401 OF 1216

4.1 General

The electrical system shall be designed to provide:

- Safety to personnel and equipment both during operation and maintenance.

- Reliability of Service.
- Minimal fire risk.
- Ease of maintenance and convenience of operation.
- Automatic protection of all electrical equipment through selective relaying system.
- Electrical supply to equipment and machinery within the design operating limits.
- Adequate provision for future extension and modification.
- Suitability for applicable environmental factors.

4.2 Area Classification and Equipment Selection

4.2.1 All the areas within the battery limits shall be classified for the degree and the extent of
hazard from flammable materials. Classification of hazardous areas shall be done in
accordance with Petroleum Rules, DGMS regulations (where applicable), IS-5572, IS-61241-
10, OISD standards and Process Licensors recommendations.

4.2.2 Following factors shall be considered for proper selection of electrical equipment for use in
hazardous area:

- Area classification i.e. Zone.

- Gas classification i.e. Group - The characteristic of the minimum gas or vapour involved
in relation to the ignition current or minimum ignition energy and minimum safe gap
data.
- Dust classification i.e. Group - The characteristic of the dust involved.
- Temperature classification - The ignition temperature of the gas, vapour or dust involved
or the lowest value of the ignition temperature if more than one combustible material is
present.
- Environmental conditions in which apparatus is to be installed - The selected electrical
apparatus shall be adequately protected against corrosive and solvent agencies, water
ingress, thermal and mechanical stresses as determined by the environmental conditions.

4.2.3 All electrical equipment installed in hazardous areas shall be selected as per IS-5571 and IS-
61241-14 and shall meet the requirements of relevant IS and Statutory regulations. Ordinary
industrial electrical equipment (even though permitted for use in Div.2 area as per NFPA-70)
shall not be used in Zone-2 areas. Type of hazardous area protection to be used for individual
equipment shall be as specified in the project design data sheet.

4.2.4 Electrical equipments for hazardous areas shall be certified by CIMFR/ ERTL/ Karandikar
Lab or equivalent recognised independent test house such as BASEEFA / ATEX/ LCIE / PTB
/ UL / FM. All equipment (indigenous and imported) shall also have valid statutory approvals
i.e. PESO/ DGMS as applicable for use in the specified hazardous area. All indigenous
flameproof equipments shall have valid BIS license and marking as required by statutory
authorities.

4.3 Power System Design

The distribution system shall be designed in accordance with project specification/ design
data taking into account all possible factors affecting the choice of the system to be adopted
such as required continuity of supply, flexibility of operation, operational costs, and reliability
of supply from available power sources, total load and the concentration of individual loads.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 402 OF 1216

 Special attention is drawn to chapter IX of CEA regulations, which includes requirements for
design of electrical system as applicable to Mines and oil fields installation.

4.4 Capacity of Electrical System

All the components of the electrical system shall be sized to suit the maximum load, under the
most severe operating conditions. The amount of electrical power consumed by each process
unit shall be calculated for its operation at the design capacity. System design shall permit
direct on line starting of all motors unless specified otherwise. Sizing factors for normal
loads, intermittent loads and standby loads shall be considered as mentioned in project design
datasheet.

4.5 System Voltages

System voltages shall be as defined in project design data sheet.

4.6 Voltage Drops

4.6.1 The maximum voltage drops in various sections of the electrical system under steady state
conditions at full load shall be within the limits stated in the following table:

Maximum
Sl.
System Element Permissible Voltage
No.
Drop
a) Cable between transformer secondary and Switchboards 0.5%
b) Cable between PCC/PMCC and MCC or auxiliary switchboard

i) MCC /Auxiliary Switchboard near PCC/PMCC 0.5% Note-3b

ii) MCC/Auxiliary Switchboard situated remote from 2 to 2.5% Note-3a
PCC/PMCC
c) Cables between HV Switchboard and HV Motor 3%
d) Cable between PCC/PMCC and motor 5.5%
e) Cable between MCC (situated near PCC / PMCC) and motors 5%
f) Cable between MCC (situated remote from PCC / PMCC) and 3%
motors
g) Cable between Auxiliary Switchboard / LDB and Lighting 1 to 1.5%
Panel/ Power panel (Note- 2)
h) Circuit between lighting panels and lighting points 4% (Note- 2)
i) DC Supply Circuit (Electrical Controls) 5%
j) DCDB to Control Room 2% (Note -1)
k) UPS outgoing circuit 5% (Note - 1)

Note-1

Minimum voltage available across any instrument in the field/ control room/ Satellite rack
room shall be as per instrumentation design basis. Distribution system for instrumentation
supplies shall be designed accordingly. In case of any conflict between electrical project
design data sheet and instrumentation design basis, the latter shall govern regarding
instrumentation power supplies.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 403 OF 1216

 Note-2

In case of difficulty in achieving specified voltage drops in cables up to lighting panel, 5%

drop from Auxiliary switchboard/ LDB up to lighting points may be permitted.

Note-3

a) Higher voltage drop may be permitted between PCC / PMCC and remote mounted
MCC/ASB, if overall voltage drop up to motor (from PCC / PMCC) is limited within
5.5%.

b) For large substations 1% drop may be permitted.

4.6.2 The maximum voltage drop at various buses during start-up of large motor and/or motor
reacceleration conditions shall be within the limits stated below:

S. Max. Permissible
System Element Operating Condition
No Voltage Drop
a) At the busbars of the worst Start -up of the large HV motor 15 %
affected Switchboard with other loads on the bus or
reacceleration of a group of HV
motors (Simultaneous start-up or
group reacceleration of HV
motors is not envisaged)
b) At the busbars of the worst Start up of large MV motor with 10 %
affected MV Switchboard other loads on the bus, or
(PCC/PMCC/MCC) reacceleration of a group of MV
motors.
c) Cables between HV Motor start-up or reacceleration 5%
Switchboard and motor (Note-a)
d) Cables between MV Motor start-up or reacceleration 15 %
switchboard (Note-a)
(PCC/PMCC/MCC) and
motor

Notes:

a) Higher voltage drop in motor cables may be permitted, in case the conditions given in
Note b), c) and d) are complied.
b) The voltage available at the motor terminals during start-up must be sufficient to ensure
positive starting or reacceleration of the motor (even with the motor fully loaded, if
required), without causing any damage to the motor.
c) For medium voltage motors, the voltage available at the motor terminals must not be less
than 75% of the rated value during start-up or reacceleration.
d) For high voltage motors, the voltage available at the motor terminals must not be less than
80% of the rated value during start-up or reacceleration.

4.7 System Earthing

System earthing for incoming supply and primary/secondary EHV/ HV distribution system
shall be as per project design data. The 415V system neutral shall be solidly earthed.
4.8 Short Circuit Capacities

Each short circuit interrupting device shall be designed to have rated short circuit breaking
capacity and making capacity equal to or higher than the maximum value of short circuit

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 current (rms) and peak value of short circuit current respectively, calculated at its location.
The related switchgear and bus-ducts shall withstand the above maximum available fault
current for a minimum period of one second. The minimum size of conductor & metallic
screen of high voltage cables and extra high voltage cables shall also be based on the short
circuit withstand capacity for a minimum time period as dictated by the protection system and
defined in project design data sheet.

4.9 Insulation System

The insulation of electrical facilities shall be designed considering the system voltage, the
system neutral earthing and the over voltages resulting due to system fault, switching or
lightning surges. Lightning arresters and surge absorbers shall be provided where necessary.

4.10 Protection and Metering Schemes

4.10.1 The protective system shall be selected and coordinated to ensure the following:

a) Protection of equipment against damage, which can occur due to internal or external short
circuits or atmospheric discharges.
b) Uninterrupted operation of those parts of the system, which are not affected by the fault.
c) Personnel and plant safety.

4.10.2 Protection relays shall be provided as specified in project design data sheet.

4.10.3 Metering shall be provided to keep a record of power consumption and supervision of all
concerned parameters like current, voltage, power, frequency, power factor etc. as specified in
project design data sheet.

4.11 DC Power Supply

Independent DC power supply systems shall be provided for the following (unless otherwise
specified):

- Plant shutdown system including DC instrumentation (if required, as per instrumentation

design basis).
- Electrical switchgear controls including critical lighting.

4.12 Emergency Power Supply

The emergency power supply system, wherever envisaged and required as per project design
datasheet, shall feed the following:

- Electrical loads essential for the safe shutdown of the plant.

- Emergency lighting.
- Communication system.
- Fire detection and alarm systems.
- D.C. Supply systems.
- UPS Systems.
- Fire fighting equipment excluding main firewater pump.
- Loads critical for process, plant and personnel safety.
Emergency power supply could be from a different power source or Emergency Generator as
per Project design data sheet. Where Emergency Generator is envisaged, emergency power
supply shall be made available within a time period of 30 seconds from the instant of failure
of normal supply.

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 The emergency generator shall, generally, not be required to run continuously in parallel with
the normal power supply system. However, short time paralleling facility shall be provided
for transferring load to normal power supply or other operational needs e.g. periodic testing
etc. as required.

4.13 Uninterrupted Power Supply (UPS)

Uninterrupted power supply system shall be provided, (as required) for meeting critical loads
that cannot withstand a momentary interruption in voltage (e.g. critical instrumentation,
control, HMI for substation automation system, ECS, communication system, LAN system,
and process loads, as defined in project design data sheet).

4.14 Power Factor Improvement

Capacitor banks shall be provided, as specified in Project design data sheet, to improve the
power factor to meet the minimum stipulated power factor by the power supply authorities.
Automatic power factor correction shall be provided, if specified in project design datasheet.

4.15 Plant Communication System

4.15.1 It shall consist of the following:

- Central exchange(s)/ Distributed intelligent nodes.
- Master control station(s) with inbuilt loudspeaker, microphone etc.
- Desk type call stations with inbuilt microphone, loudspeaker for installation in buildings.
- Wall/column mounting type call stations for hazardous/safe areas with external
loudspeaker as per Operational requirements.
- Flashing beacon for noisy areas.

4.15.2 Each exchange/ distributed intelligent node shall be designed to have at least 10% spare
capacity.

4.16 Fire Detection and Alarm System

4.16.1 The Fire Detection and Alarm System shall be an independent system comprising of
individual break glass type manual call points, automatic sensors e.g. smoke/heat detectors,
hooters, exit signs, main panel, zonal panel, battery, battery charger and other hardware. The
system shall be designed to provide audio-visual indication at the main fire alarm panel to be
located in fire station and zonal panels. Repeater panels shall be provided as specified in
project design data sheet.

4.16.2 Electrical sirens shall be provided to cover entire plant area.

4.16.3 Each panel and each loop / Zone shall have at least 10% spare capacity.

4.16.4 The fire detection system shall be interfaced with fire suppression system, HVAC system,
pressurization system and plant communication system, wherever specified.

4.17 Electrical Surface Heating System

4.17.1 Electrical surface heating system shall be provided for temperature maintenance of process
pipes and associated equipments, if required as per process design basis.

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4.17.2 The electrical equipments i.e. heat tracers, thermostat/ RTD, PDBs, Junction boxes,
connectors, splice boxes, etc. shall be suitable for applicable area classification, though PDBs
shall be preferably located in safe area.

4.17.3 In general, system shall be suitable for maintaining the temperature, unless otherwise
specified. In case process fluid heating is desired, time duration and other parameters shall be
as per process design data.

4.17.4 Skin effect electrical heat tracing system shall be provided for pipelines, if specified in project
design data sheet.

4.18 Electrical Control System

4.18.1 Electrical control system shall be provided (as required) to monitor and control electric power
generation and distribution network of the plant. ECS shall include distributed RTUs & I/O
panels, servers, HMI, printers, fiber optic data highway, network switches etc. Base
functionalities and advanced functionalities as specified in project design datasheet shall be
provided.

5.0 EQUIPMENT DESIGN PHILOSOPHY

5.1 General

The equipment shall in general conform to EIL standard specifications. Equipments shall be
selected and sized as per philosophy given below:

5.2 Transformers

5.2.1 All transformers except lighting transformers & isolation transformers shall generally be three
phase, oil immersed, double wound type suitable for outdoor use, unless otherwise specified.
Lighting transformers & isolation transformers shall be dry type, unless otherwise specified.
The transformers for variable frequency drive system shall be oil immersed or dry type as per
project requirement.

5.2.2 100% standby transformers (for power, distribution and lighting) shall be provided in all unit,
offsite and utility substations, unless otherwise specified.

5.2.3 In general kVA rating, percentage impedance & X/R ratio of each transformer shall be
selected to limit the rated current and short circuit current to values which are within the
current rating and interrupting capacity of associated switchgear available.

The kVA rating for power, distribution and lighting transformers shall be decided on the
following basis and should be as far as possible a standard value.

a) In systems having redundancy for transformers, with transformers having natural cooling
i.e. ONAN/AN, each transformer shall be rated equal to or greater than the 8 hour
maximum demand of the load plus 10% margin for future load growth.

b) In systems having redundancy for transformers, with transformers having forced cooling
i.e. ONAF, each transformer shall be rated equal to or greater than the 8 hour maximum
demand of the load plus 10% margin for future load growth (within 110% of it’s self
cooled (ONAN) rating) and shall be fitted with automatic forced air cooling fans.

c) Where redundancy in number of transformers is not provided, rating shall be equal to or

greater than 8 hour maximum demand plus 10% margin for future load growth. Fan

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 407 OF 1216

 cooled rating, where provided, shall be reserved as spare capacity for further future load
growth.

5.3 Switchgear

5.3.1 All switchgear and associated equipment fed from generators and transformers shall have
rating at least equal to the rating of respective generators and transformers feeding it, under
any circuit configuration. Generator incomer shall be rated w.r.t. maximum power output of
the generator set over entire operating temperature range. Transformer incomer shall be rated
at least equal to forced cooled rating of transformer or 110% of ONAN rating as applicable.

5.3.2 Bus tie circuit breakers shall have rating higher of the following:

a) Largest incoming circuit breaker.

b) Maximum running load on either side of bus section.

The tie breaker rating shall not be less than the bus-bar current rating, unless otherwise
specified.

5.3.3 All other switchgears not directly fed from generator and transformers shall have rating at
least equal to the maximum demand under any circuit configuration plus a provision for 10%
future load growth. Incomers of these switchgears shall be designed to cater to the complete
load including 10% margin for future load growth.

5.3.4 Spare outgoing feeders shall be provided in all switchgear. At least one number of each type
of outgoing feeder or 10% of each type of outgoing feeder, whichever is more, shall be
provided as spare in the HV and MV switchboards, except for capacitor feeder in HV
switchboard.

5.3.5 Circuit breakers/contactors controlling motor feeders shall have a rating of at least 125% of
the maximum continuous rating of the connected motors.

5.3.6 Separate feeders shall be provided in the switchboard for each load/motor. However, as an
exception maximum two numbers welding receptacles or flood light masts may be connected
to one power feeder.

5.3.7 All circuit breakers shall be of single break type having one pole per phase. Circuit breakers
for MV generator incomer shall be with four poles.

5.3.8 Rated short circuit breaking capacities and making capacities for all breakers and MCCBs
shall be equal to or higher than the maximum specified value of the short circuit current and
peak specified value of short circuit current respectively at the point of installation. MCCBs
with backup fuses shall not be acceptable.

5.3.9 Air circuit breakers (ACB) shall be provided in MV switchboards for all feeders rated above
400 A and switch fuse/MCCB/ACB shall be considered for feeder rated up to 400A. However
in the feeders feeding power to small rated MCCs/ASBs, switch-fuse feeders shall not be
used.

5.3.10 Circuit breakers/Switch fuse units for capacitors shall, have a current rating of at least 135%
of the capacitor rated current. Circuit breakers capability to interrupt applicable capacitive
current shall be specifically verified.

5.3.11 The switchboard components viz. circuit breakers, main horizontal and vertical bus-bars, bus-
bar joints, bus-bar supports etc. shall be designed to withstand the maximum specified short
circuit current for a minimum time of 1 second, unless otherwise specified.

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5.3.12 For motors rated above 5.5 kW, CT shall be provided in the switchgear for ammeter on the
local control station/local control panel.

5.3.13 The maximum rating of bus-bars for MCCs/ASBs/LDBs should preferably be limited to 1000
Amps. Heavy duty type load break switches/ACB/MCCB rated for maximum specified short
circuit current and duration shall be used for incomer and bus coupler and these shall have
suitable interlocks.

5.3.14 Gas Insulated Switchgear (GIS) shall be provided for EHV system and HV system if
specified in project design datasheet. Preferably GIS shall not be considered for voltages
below 33 kV.

5.4 Bus Duct

The rating of bus ducts connected to breakers shall have same continuous and short circuit
rating as that of breakers. Similarly bus ducts connecting two bus sections shall have same
continuous and short circuit rating as that of main bus bars.

5.5 Neutral Grounding Resistor

The NGRs shall be rated to withstand the fault current for 10 seconds.

5.6 Batteries

Batteries shall be of adequate capacity to meet the back-up requirements as envisaged in the
duty cycle. While sizing the battery, temperature correction factor and ageing factor shall be
considered in addition to the maintenance factor. Batteries shall be complete with battery
racks and accessories.

5.7 DC Power Supply System

5.7.1 DC power supply system shall include battery bank, charger-cum-rectifier, DC distribution
board and cell booster.

5.7.2 The battery charger/rectifier shall feed the load and keep the batteries under fully charged
condition. Provision shall also be made for necessary boost charging/initial charging of
battery.

5.7.3 The DC system shall have at least 10% spare capacity for future load growth.

5.7.4 Each battery charger and DCDB shall be sized to cater to selected battery capacity.

5.7.5 Each DCDB shall have at least 10% spare feeders with one no of each rating for future use.

5.7.6 Power switch outside battery room shall be provided for local isolation of battery during
maintenance.

5.8 Uninterrupted Power Supply System

5.8.1 UPS system shall include battery bank, rectifier transformer, rectifier-cum-charger, inverter,
set of filter circuit, static switches, bypass transformer, facility for manual transfer between
inverter supply and bypass line, facility for bypassing inverter and static switch for
maintenance, AC Distribution board, cell booster and other associated accessories.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 409 OF 1216

5.8.2 Each branch circuit of the UPS distribution system shall have a fused disconnect switch. The
fuse shall be fast clearing semiconductor type and the fuse rating shall be co-coordinated with
the rating of the UPS system. Normally the largest branch circuit load shall not exceed 25%
of the UPS system rating.

5.8.3 UPS system shall be sized to have at least 10% spare capacity for future load growth.

5.8.4 Each UPS ACDB shall have at least 10% spare feeders for future use by owner.

5.8.5 Power switch outside battery room shall be provided for local isolation of battery during
maintenance.

5.9 Motors

5.9.1 In general, three phase squirrel cage induction motors designed for direct on line starting shall
be used. Motors shall be totally enclosed, fan cooled type and suitable for continuous use.
Synchronous motors and motors with variable frequency operation shall be designed for
special application.

5.9.2 All motors shall be continuous maximum rated with possible exception of crane and hoist
motors, soot blowers, turbine/engine starting motors etc. which may be rated for the
envisaged duty cycle.

5.9.3 DOL start high voltage motors shall be suitable for starting under specified load conditions
with 80% of the rated voltage at the terminals and DOL start medium voltage motors shall be
suitable for starting under specified load conditions with 75 % of the rated voltage at the
terminals. If required, large size motor starting shall be through soft starter/ dedicated
transformer as per project design datasheet. Voltage available at the motor terminals which
are started through dedicated transformer shall be decided considering the speed torque
characteristics of the driven equipment and ensuring the voltage dip at the source bus does not
exceed the permissible limits as per project design datasheet.

5.10 HV Capacitor Banks

5.10.1 The capacitor banks shall be supplied with series reactor and RVT (residual voltage
transformer). All the capacitor bank equipment shall be suitable for outdoor location unless
otherwise specified.

5.10.2 The capacitor bank in conjunction with series reactor shall provide minimum net kVAR at
rated nominal voltage. The insulation system shall be designed to withstand continuous over
voltage of 110%.

5.11 Emergency Generator

5.11.1 The emergency generator set shall be designed to start automatically on power failure and
feed the selected loads. It shall be capable of taking care of the load variations (e.g. the
starting of the largest rated motor with specified base load). However, DG sizing shall not
include boost charging loads for UPS and DC system batteries (but shall only include float
charging and service loads).

5.11.2 The regulation of generator voltage shall be automatic and necessary instruments for metering
viz., Ammeter, Voltmeter, frequency meter, kWH meter, power factor meter, hour run
counter etc. shall be included in control panel. Warning of abnormal conditions shall be
incorporated prior to automatic trip to prevent unnecessary shutdown.

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5.11.3 The unit shall be complete with necessary engine starting equipment, associated control panel
and shall be suitable for remote starting. Emergency Generator shall have auto-starting
arrangement but only with manual switching off feature. ‘Fail to start’ annunciation shall be
provided, in case the engine fails to start.

5.11.4 The load shall be automatically switched on to the generator only after the requisite voltage
build-up.

5.11.5 The Emergency generator set shall have at least 10% spare capacity for meeting future
requirements.

5.12 Annunciation Panel

5.12.1 Audio-visual annunciation panels shall be provided, where specified in design data, to
monitor the switchgear and other electrical equipments. In case hardwired panel is not
envisaged, audio visual annunciations shall be provided as pert of the HMI system.

5.12.2 Detailed annunciation schedule shall be based on but not limited to the following:

a) EHV & HV Switchgear

- Breaker-wise fault trip alarm
- Auto-changeover completed
- Auto-changeover failure
- Trip circuit status for each breaker
- Differential and restricted earth fault relay operation alarm
- Transformer trouble alarm
- DC supply failure alarm (Bus wise)
- PT secondary MCB trip alarm for all line and bus PTs
- Bus wire supervision alarm
- Alarms for SF6 gas system

b) MV Switchgear
- Incomer/Bus coupler fault trip alarm
- Auto-changeover completed
- Auto-changeover failure
- Bus-wise group fault trip alarm for outgoing feeder breakers
- D.C. supply failure alarm (Bus-wise)
- PT secondary MCB trip alarm for all line and bus PTs

c) Operating status/fault conditions for UPS system.

d) Operating status/fault conditions for DC supply system.

e) Operating status/fault condition for DG sets.

f) Fault alarm for VFD panels

5.12.3 Annunciation panel shall be complete with acknowledge, test and reset pushbuttons. 10%
spare windows for future use shall be provided in the panel. Generally, annunciation panel
shall be fed from the UPS system/ DC system.

5.13 Cables and Wires

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 411 OF 1216

5.13.1 EHV cables shall be single core, dry cured XLPE insulated, armoured, extruded FRLS PVC
outer sheathed with conductive graphite coating and aluminum/copper conductor, as per
project design datasheet and shall be provided with conductor screening, insulation screening
and moisture barrier.

5.13.2 HV cables shall be dry cured XLPE insulated, armoured, extruded FRLS PVC outer sheathed
with aluminum/copper conductor, as per project design datasheet. All cables rated 3.3 kV and
above shall be provided with both conductor screening and insulation screening.

5.13.3 MV power cables shall be PVC insulated, armoured/ unarmoured, extruded FRLS PVC outer
sheathed with aluminum/copper conductor, as per project design datasheet.

5.13.4 The control cables shall be twisted pair, copper conductor, PVC insulated, armoured,
extruded FRLS PVC outer sheathed and overall shielded. Control cables without twisted pair
and shielding shall be provided for specialized applications i.e. for CT secondary current,
differential protection, restricted earth fault protection, etc.

5.13.5 The power cables shall be sized based on the maximum continuous load current, the voltage
drop, system voltage, system earthing and short circuit withstand criteria as applicable. The
derating due to design ambient air temperature, ground temperature, depth of laying, grouping
and proximity of cables with each other, thermal resistivity of soil, etc. shall be taken into
account.

5.13.6 Cables connected in parallel shall be of the same type, cross-section and terminations.

5.13.7 As an exception within substation areas, unarmoured cables may be used, if specifically
agreed upon.

5.13.8 All power and control cables shall be in continuous lengths without any splices or
intermediate joints. The cables used for lighting and wires in conduits shall have appropriate
junction boxes with adequately sized terminals. Unless otherwise agreed, cable joints in
hazardous areas shall not be permitted.

5.13.9 All incoming cables to switchgear/UPS/DC system/DBs and other equipment shall be sized
for maximum anticipated load including 10% future growth. Cable for capacitor banks shall
be sized for 135 % of the rated capacitor current.

5.13.10 The incoming cable for heat tracing power distribution panel shall be with four cores, the
neutral conductor being of same size as the phase conductors.

5.13.11 All control cables shall have minimum 10% spare pairs/ cores.

5.14 Control Station

5.14.1 Each motor shall be provided with a control station/control panel in the field, unless otherwise
agreed upon. Emergency stop push control station for air cooler motors at grade level, for
transformers in transformer bay and at intermediate levels for conveyers shall also be
provided.

5.14.2 The control station shall include the following equipment as per individual requirement:

- Start/stop push button

- Ammeter (as applicable)
- Auto/Manual or Local/Remote selector switch (if specified)
- Indication lamps etc. (if specified).

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5.14.3 Stop push button shall generally have stay put feature except in the case of critical drives such
as lube oil pump etc.

5.15 Convenience Receptacles

5.15.1 These shall have the necessary mechanical interlocks and earthing facilities. The enclosure
shall have suitable protection for site conditions specified (flame proof, weather proof, dust
proof, corrosion resistant, etc.).

5.15.2 Adequate number of welding receptacles shall be provided at suitable locations to ensure
accessibility with a 50 m length of trailing cable to any point in the process area and in
substations & control rooms. These shall be rated for 63A suitable for 415V, 3 phase system
with a scraping earth.

5.15.3 Adequate number of three-pin sockets for lamps and portable tools shall be provided at
suitable locations to ensure accessibility with a 15 m length of cable to all manholes of
process equipments, other important areas in the process units and in substation, control
rooms and other buildings. These shall be rated for 15A, 240 V single phase with earth
connection. Hand lamps and portable tools shall be earthed through flexible cords. In
hazardous areas, flameproof hand lamps shall be rated for 24V.

5.16 Actuators for Motor Operated Valve

MOVs shall be provided with integral starters. The necessary local/remote selector switch,
start/stop control switches or push buttons, torque limit switches etc. shall be provided on
actuator for local/remote control depending on the mode of selection. In case of failure of
torque limit switches, the mechanical design shall be adequate to stall and trip the motor
without damage. The control circuit may be A.C. operated for short distance and D.C.
operated for extended distances, where required. The type of MOV control i.e. conventional
type or 2 wire control or compatible with instrumentation field bus, etc. shall be as per
instrumentation design basis.

5.17 EHV System

The EHV power supply arrangement shall be provided with either conventional switchyard
having CT, PT, Disconnector, circuit breaker, lighting arrestor, etc. located in outdoor fenced
area or Gas Insulated Switchgear (GIS). The GIS panels shall be located indoor inside the
substation building.

6.0 SUBSTATION / MCC ROOM DESIGN PHILOSOPHY

6.1 The sub-stations shall be located in a safe area close to the load center. Proper access shall be
provided/ ensured for operation/ maintenance of indoor and outdoor equipment.

6.2 EHV and HV sub-station switchgear floor shall be raised above grade level and the space
below the switchgear room shall be utilized as cable cellar. The cable cellar floor shall be at
least 300 mm above the approach road level and shall be paved and cemented. The cable
cellar shall have a minimum clear height of 2.5 m and shall house all cable trays and their
supports.

6.3 The substation switchgear floor shall have a minimum clear height of 4.0 m. For switchgear
floor provided with air-conditioning, the minimum clear height shall be 4.0 m in case of false
ceiling and 4.5 m without false ceiling.

6.4 MV sub-stations and MCC rooms shall be elevated by compacting the soil so that

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 413 OF 1216

 - The finished floor level shall be above the approach road level to the building.
- The finished floor level shall be minimum 1000 mm above the surrounding grade level.
- The bottom of the cable trench within sub-station is minimum 150 mm above the
surrounding grade level.

6.5 In addition to the entry to substation for operating personnel, a separate entry of minimum 3m
(W) x 3.5m (H) with rolling shutter shall be provided for drawing in all equipment for
installation. The main entry for operating personnel for pressurized and air conditioning
substations shall be provided with double door system with an airlock lobby. The Sub-station
shall also have an emergency door opening outwards.

6.6 Sub-station wall adjacent to the transformer bays and walls separating transformers shall be
355 mm thick (inclusive of plastering) in case of brick construction or 230 mm thick in case
of RCC construction.

6.7 Sub-station building shall be without any columns within the switchgear room to ensure
optimum space utilization, unless otherwise specified.

6.8 Battery banks shall be located in a separate adequately ventilated room in the sub-station
buildings, alongwith the necessary exhaust system and water connection with sink. Floor of
the battery room and walls up to 1.5 m height shall have acid/alkaline resistant protective
epoxy coating. Separate battery room is not required in case of VRLA batteries, as the VRLA
batteries shall be located in the room housing chargers and UPS systems.
The battery rooms shall be provided with minimum two exhaust fans and louvered opening in
opposite wall/door.

6.9 UPS system and other electronics equipment e.g. data concentrator, HMI, RTCC, variable
frequency drive panels, battery chargers, thyristorised heater control panels, etc. shall be
located in air-conditioned room, unless otherwise specified in project design data sheet.

6.10 Sub-station shall have fire extinguishers, first aid boxes and other safety equipment as per
statutory requirements. Insulating mats of required voltage rating shall be provided in front
and rear of switchboards and GIS panels.

6.11 Separation walls between transformers in all substations and safe inter transformer distances
for switchyard transformers shall be as per OISD-STD-173.

6.12 Equipment like transformers, neutral grounding resistors, reactors and HV capacitor banks
shall be located in bays adjacent to the sub-station building. The requirement of roof for bays
shall be as defined in project design datasheet. All bays shall have well drained floor, surfaced
with gravel or other suitable material.

6.13 In order to prevent oil, whether from a small leakage or outflow from transformer tank, from
reaching and polluting the water bearing stratum, transformers shall have the following
provisions, depending on the oil capacity of the transformer

6.13.1 Oil Capacity upto 2,000 litres:

Transformers installed adjacent to sub-station/buildings or in Switchyards shall be provided

with a layer of 100 mm deep stones of about 40 mm granulation, all around the transformer,
for a width of 20% of the transformer height subject to minimum width of 800 mm. However
complete transformer bay/ fenced area shall be provided with stone gravels.

6.13.2 Oil Capacity exceeding 2,000 litres:

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 414 OF 1216

 Transformers installed adjacent to sub-station/building or in Switchyards shall be provided
with oil containing pits.

The oil containing pit may be shaped as per OISD STD-173. The pit shall extend all around
the transformer for a width of 20% of the transformer height, with a minimum width of about
800 mm around the transformer tank/radiator. In case oil capacity exceeds 9,000 litres, in any
chamber, provision shall be made for draining away of any oil, which may escape or leak
from the tanks, to a waste oil tank.

6.14 The substation building shall be sized to maintain adequate clearances between equipment for
ease of maintenance. The following minimum clearances around various equipment shall be
maintained:

Sl.
Location Clearance
No.
a) Front clearance for HV switchboard including HV GIS 2500 mm
b) Front clearance for all other switch boards/panels 2000 mm
Rear clearance for panels having maintenance access
Less than 200 mm or more
c)
from front only than 750 mm
Rear clearance for panels requiring maintenance from
1500 mm (HV swbd) &
d)
rear 1000 mm (MV swbd)
1000 mm after considering
Side clearance between two switch boards or from
e) space for future panels as
nearest obstruction
per cl. 6.15
f) All around clearance for transformers 1000 mm
1000 mm on two sides,
g) All around clearance for NGR
200 mm on other two sides
h) All around clearance for capacitor bank/ series reactor 1000 mm
i)
Battery rack to wall clearance for
- Single row, single/double tier
100 mm
- Double row, single tier
100 mm
- Double row, double tier
750 mm
- Multistep racks
750 mm
j) Battery rack to rack clearance 750 mm
Head room clearance below bus ducts or any other
k) 2000 mm
overhead equipment
l) Front clearance for wall mounted equipment 1000 mm
Front clearance for operation station/ annunciation/
m) 2500 mm
control panel

For EHV GIS, minimum all around clearance and vertical clearance shall be as per
manufacturer recommendation.

Vertical clearance above the top of the highest equipment shall be minimum 1000 mm
measured from the bottom of the lowest roof beam. However for the areas with false ceiling,
minimum clearance of 750 mm shall be provided between false ceiling and top of any
equipment.

6.15 In all Substations/ MCC rooms, space for future extension of switchboards shall be provided.
One panel extension space on each side (for each Bus section) or two panel extension space
on one side (in exceptional cases) shall be provided for all GIS, HV Switchboards, PCCs,

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 415 OF 1216

 MCCs and ASBs. In addition, space for future extension of the substation/ MCC room
building shall be considered, as specified in project design data sheet.

6.16 The DG sets shall be preferably located in a separate building other than the substation, in a
safe area to reduce noise level in substation. However in case the same is located in the
substation building, the DG set foundation shall be structurally delinked from the slab/floor of
the rest of the substation building. Exhaust of diesel engine shall be kept away from the
process/hydrocarbon handling areas and diesel day tanks shall be located outside the DG
room. Suitable ventilation system shall be provided to avoid heat accumulation in the DG
room.

6.17 Fire protection for transformers and switchgear room shall be provided to comply to
requirements of OISD-STD-173.

6.18 Overhead EOT crane of required capacity shall be provided in substation building/ area
housing EHV GIS panels.

7.0 INSTALLATION DESIGN PHILOSOPHY

7.1 General

The installation work for equipments, cabling system, earthing system and lighting system
shall generally conform to EIL standard specifications and installation standards.

7.2 Cabling System

7.2.1 Cabling system for various areas shall be as specified in Project design data sheet. Preferably,
total cable route connected to Fire Water pump/motors starting from receiving substation to
Fire Water pump house shall be directly buried underground.

7.2.2 The cable trenches shall be sized depending upon the number and voltage grade of cables.
The cable trenches in hazardous areas and in transformer bays/ substation cellar shall be filled
up with sand. Where underground cables cross road ways, pipe sleepers at grade etc. they
shall be protected by being drawn through sleeves/ducts to provide a permanent crossing.

7.2.3 RCC cable trenches shall be sealed against ingress of liquid and gases wherever the trenches
leave or enter a control room or substation. Pipes laid for mechanical protection shall be
sealed at both ends. In case of direct burial, cable route markers shall be installed at 30 m
interval all along the cable routes and where the direction of cable trench changes.
Additionally, markers shall be provided at cable straight through joint locations.

7.2.4 Above ground cables shall be well supported on cable trays and suitably protected against
mechanical damage. Routing shall be decided to avoid interference with hot surfaces or
places subject to undue fire risk. Requirement of walkway for cable trays on overhead
piperack shall be as specified in project design data sheet.

7.2.5 Cable trays, racks and trenches shall be sized to allow for 10 % space for future cables. Cable
installations shall provide minimum cable bending radii as recommended by cable
manufacturer. Separate trays shall be provided for EHV cables, HV Cables, MV power
cables, MV control cables and plant communication cables to the possible extent. However,
where specifically agreed upon in exceptional cases, HV and MV power, control cables may
be laid together, with a barrier plate separating HV and MV cables.

7.2.6 Separate cables shall be provided for AC and DC signal/control circuits, except for cables to
Local control stations/ local control panels/ MOVs.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 416 OF 1216

7.2.7 Cables connected in parallel shall run together so that their length remains the same.

7.2.8 Type of cable tray and accessories shall be as specified in project design data sheet. For tray
system design, in addition to self load and wind forces, following guidelines for design shall
be considered.

a) Maximum Support span : 3000 mm

b) Cable load for

i. 150 mm wide cable tray : 30 kg/linear meter
ii. 300 mm wide cable tray : 60 kg/linear meter
iii. 600 mm wide cable tray : 75 kg/linear meter
iv. 750 mm wide cable tray : 75 kg/linear meter.

c) In addition to this, 70 kg concentrated load at center span shall be considered. All

structural steel design shall be as per Indian Standards.

7.2.9 Bends, tees, reducers, crosses, droppers etc. shall have the required bending radii as required
for various cable sizes with a minimum radius of 300 mm.

7.2.10 All cables shall carry the cable tag numbers for easy identification.

7.2.11 Signal cables i.e. Instrument, communication, fire alarm, LAN and data highway, etc. shall
preferably not be laid in the same trench/ tray along with electrical cables. In case these are
laid in the same trench/ tray, a clearance of minimum 300 mm from electrical cables shall be
provided. The overall cable layouts shall be designed for minimum interference between
signal and power cables.

7.2.12 For single core EHV and HV cables, the armour & metallic screen shall have either single
point bonding or cross bonding scheme. Both side bonding shall not be considered due to
reduction in cable current carrying capacity. The bonding scheme for complete cable route
shall be finalized considering link boxes with/ without SVL as per screen/ sheath voltage
calculation.

7.2.13 GI or FRP cover shall be considered for top most cable tray and bottom of the lowest cable
trays shall also be covered with GI or FRP sheet. GI or FRP type sheet shall be selected based
on the type of cable trays. Tray cover shall be provided for the outermost trays of vertical
droppers.

7.3 Earthing System

7.3.1 It is recommended that all electrical equipment be suitably earthed. Earthing system shall, in
general cover the following:

- Equipment earthing for personnel safety.

- System neutral earthing.
- Protection against Static and Lightning discharges.
- Separate clean earth system for Instrumentation, DCS, ECS etc. as per specified
requirements.

7.3.2 Plant earthing design shall generally be carried out in accordance with the requirements of
CEA regulations and IS: 3043. The earthing system shall have an earthing network with
required number of earth electrodes connected to it. The following shall be earthed:

- System neutral

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 417 OF 1216

 - Current and potential transformer secondary neutral
- Metallic non-current carrying parts of all electrical apparatus such as transformers,
switchgears, motors, lighting / power panels, terminal boxes, control stations, lighting
fixtures, receptacles, feeder pillars, NGT/ NGR Panels, etc.
- Steel structures, loading platform etc.
- Cable trays and racks, lighting mast and poles.
- Storage tanks, spheres, vessels, columns and all other process equipment.
- Electrical equipment fencing (e.g. transformer, yard etc.)
- Cable shields and armour.
- Flexible earth provision for wagon, truck.
- Pump handling Hydrocarbon if its base Plate is separate from motor‘s base plate.
- Turbo driven pump handling hydrocarbon

7.3.3 Unless adequately connected to earth elsewhere, all utility and process pipelines should be
bonded to a common conductor by means of earth bars or pipe clamps and connected to the
earthing system at a point where the pipelines enter or leave the hazardous area except where
conflicting with the requirements of cathodic protection.

7.3.4 Where installed, lightning protection shall be provided as per the requirements of IS: 2309.
Self-conducting structures having metal thickness of more than 4.8 mm may not require
lightning protection with aerial rod and down conductors. They shall, however, be connected
to the earthing system, at least, at two points at the base. OISD-STD-180 may be referred for
details on lightning protection.

7.3.5 The resistance values of an earthing system to the general mass of earth should be as below:

- For the electrical system and equipment a value that ensures the operation of the
protective device in the electrical circuit but not in excess of 4 Ohms. However, the
generating stations and large sub stations, this value shall not be more than 1 Ohm.
- 10 Ohms in the case of all non-current carrying metallic parts of major electric apparatus
or any metallic object. For lightning protection, the value of 5 ohms as earth resistance
shall be desirable but in no case it shall be more than 10 ohms.
- Earthing of Tanks shall comply to OISD-STD-173.
- All joints in pipelines, valves, plants, storage tanks and associated facilities and
equipment for petroleum shall be made electrically continuous by bonding or otherwise;
the resistance value between each joint shall not exceed 1 Ohm.

7.3.6 Earth rods and conductors shall be designed to cope with the conditions imposed. The earth
conductor shall be adequately sized to carry the applicable maximum earth fault current
without undue temperature rise. All joints shall be protected against corrosion.

7.3.7 All the electrical equipment operating above 250 volts shall have two separate and distinct
connections to earth grid. Transformers, including lighting transformers shall be provided
with two dedicated earth electrodes for earthing of neutral and transformer tank earthing.

7.3.8 All earth connections should be visible for inspection to the extent possible. In all cases,
connection to earth should be made in accordance with IS: 3043.

7.3.9 The main earthing network shall be used for earthing of equipment to protect it against static
electricity. The lightning protection system shall be bonded with the main earthing network
below ground, minimum at two points.

7.3.10 An approach for removing fire or explosion danger is to provide means for adequate
dissipation and prevention of accumulation of static electricity, thereby ensuring that static

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 418 OF 1216

 discharges do not occur. One of the methods to eliminate risk of static electricity build up is
grounding and bonding.
The subject of static accumulation caused by flow of petroleum products and the mitigation
methods are dealt in detail in OISD-STD-110 and same should be followed.

7.3.11 Normally earthing system shall comprise of main earth grid alongwith suitably located
disconnecting plates to provide multiple earth connections between earth grid and equipment
and for connections between main earth grid and electrodes.

All connections shall be adequately secured against loosening.

Connections between earth electrode and the disconnecting plates shall be done by GI strip.
Connection between the disconnecting plate and various equipments shall be done by GI
strip, GI wire or GI wire rope.

7.4 Lighting System

7.4.1 Plant lighting system shall comprise:

a) Normal lighting
b) Emergency lighting
c) Critical lighting.

Normal and emergency lighting shall be fed by AC supply (415/240V, three phase four wire
except in case of Mines and Oil fields where it shall be in line with Chapter IX of CEA
regulations and statutory requirements) while critical lighting shall be fed by DC supply.
Additional precautions as per Chapter IX of CEA regulations to be adopted in mines and oil
fields shall not apply to apparatus above the ground level except where such apparatus may
directly affect the safety of the persons employed in underground mines, open cast mines and
oil fields.

7.4.2 All emergency and DC critical lighting (if specified) fixtures and associated Junction Boxes
in Hazardous areas shall be Flameproof type.

7.4.3 Normal lighting system shall provide enough illumination so as to enable plant operators to
move safely within the accessible areas of plant to perform routine operation including
reading of field instruments, operation of all valves etc. and to carry out all the necessary
maintenance and adjustment to equipment.

7.4.4 Areas requiring AC emergency lighting shall include, but not be limited to, the following:

- All Areas requiring DC critical lighting.

- Strategic locations in process, utility areas where specific safety/shutdown operation are
to be carried out.

Generally 20-25 % of the total lighting fixtures shall be fed from AC emergency supply.

7.4.5 Areas requiring DC critical lighting shall include, but not be limited to, the following:

- Control rooms
- Substations
- DG shed
- Central fire station
- Fire water pump house
- Compressor houses

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 419 OF 1216

 - Non plant buildings as specified in project design data sheet.

DC critical lighting shall be provided in the pipe rack, exit/entry point only in case considered
for process units

Adequate number of self contained portable hand lamps and battery operated emergency
lighting units shall be provided for immediate use for buildings where no DC supply is
available.

7.4.6 During normal operation, both emergency and normal lighting shall be fed by normal power
source. On failure of normal supply, emergency lighting load shall be transferred to
emergency power supply source. Critical (DC) lighting shall be normally kept ‘OFF’ and
during failure of AC power; battery bank shall feed the critical lighting system.

7.4.7 HPMV lamps shall generally be used for outdoor plant lighting. Keeping in view the restrike
time lag and to avoid complete darkness in case of a voltage dip/black out condition necessary
incandescent lamps may be judiciously distributed throughout the plant area. Fluorescent
lamps shall be used for indoor lighting for non-process buildings and control room. Safe area
street lighting and area lighting may employ sodium vapour lamps. All chemical handling
facilities shall be provided with chemical resistant fixtures. Sodium vapour lamps shall not be
installed in hazardous areas. DC critical lighting shall employ incandescent lamps or CFL
lamps as specified in project design basis. Tall structures shall have aviation obstruction
lighting as per statutory requirements. Energy efficient lighting with CFL/ LED lamps may
also be employed for indoor/ outdoor lighting, as specified in project design datasheet.

7.4.8 Telescopic tubular high masts shall be provided for illumination of tank farm/general area.
Where feasible, street lighting poles may be avoided where lighting high masts provide
adequate illumination. The high masts shall be of continuously tapered polygonal cross
section and fabricated out of steel plates. The masts shall be provided with motorized racking
mechanism for lowering and hoisting lantern carriage.

7.4.9 Lighting system shall consist of lighting transformers, lighting distribution boards (LDBs),
lighting and power panels, fixtures, junction boxes etc. as specified. All outdoor lighting
shall be automatically controlled by means of photoelectric cell/synchronous timers with
manual overriding control as specified. Lighting and power panels shall be fed from LDB
through 415/415V, Dyn-ll, dry type lighting transformer having taps up to ± 5% (Refer
clause 7.4.1 above for mine and Oil fields installations). The lighting and power panels shall
be provided with MCB and ELCB as incomer and Miniature Circuits Breakers (MCBs) for
outgoing feeders control and protection of lighting circuits. ELCBs shall not be provided at
the incomers of lighting and power panels, in case ELCBs are provided in the outgoing
feeders of LDBs/ASBs feeding to these lighting and power panels. MCBs shall not be loaded
beyond 80% of rated capacity. A minimum of 20% of miniature circuit breakers of each panel
shall be left as spares. In general, the load on each circuit shall be limited to 1.5 kW. In areas
having less lighting load, lighting transformer can be avoided.

7.4.10 Lighting Lux Levels

Lighting system design shall be based on average illumination levels as specified below:

S NO. AREA LUX

a) Main roads (along process units, power houses, workshops,
10
etc.)
b) Secondary roads (along storage tanks, settling basins, etc.) 5
c) Tank farm 10
d) Pump houses, Sheds 100
e) Main operation platforms & access stairs 60

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 420 OF 1216

 f) Ordinary platforms 20
g) Process areas, pipe racks, heat exchanger, heater, separators,
cooling tower, columns, pig launching/ receiving loading area, 60
flare etc.
h) Switchgear room, Rack room 200
i) Cable cellar 70
j) Transformer bay 100
k) Battery room 150
l) Control room (Console Area), Laboratory 400
m) Boiler house 150
n) Charger/ UPS rooms 200
o) Switchyard
Operating area 100
Other areas 50
p) Warehouse 100
q) Office, Operator Room 300
r) Compressor operating area 200
s) Watch room 100
t) Stairs 50
u) Corridors/ lifts 70
v) Tube well, Gate & watchman booth 100
w) Fire house, Garage 150

However, lighting levels in all areas shall take into consideration the requirements from point
of view of safety, ease of operation and maintenance.

7.4.11 Lighting design shall conform to relevant Indian and International Codes and Standards, IES
Hand Book and shall take into consideration the requirements from point of view of safety
and ease in operation and maintenance. A maintenance factor of 0.8 shall be assumed for
lighting illumination level calculations for normal areas. However for dusty areas,
maintenance factor as per relevant codes and standards shall be considered.

7.4.12 Wiring for lighting and convenience outlets in outdoor areas shall be carried out with PVC
insulated armoured FRLS cables run along the column/platforms and structures. Double
compression cable glands required for terminating armoured cables in lighting fixtures,
control gear boxes and junction boxes in hazardous areas shall meet the requirements of
IS/IEC 60079-0. For outdoor/ indoor safe area equipment, double/single compression cable
glands shall be used respectively.

7.4.13 Adequate number of ceiling fan points shall be provided in Administration Building, Offices,
rooms allocated for operating and maintenance personnel etc.

7.4.14 Two pole isolation devices shall be used for controlling lighting fixtures and sockets in
hazardous areas to isolate phase as well as neutral. (For all Mine and Oil field installations
refer clause 7.4.1 above).

7.4.15 For buildings with false ceiling, concealed conduit wiring shall be employed below the false
ceiling and surface conduit wiring above the false ceiling.

7.4.16 Adequate number of pull boxes shall be used to aid wire pulling and inspection. No joints
shall be allowed inside these pull boxes.

7.4.17 Battery room shall have fixtures mounted on wall in order to facilitate easy replacement of
fused lamps. Switches controlling the lighting fixtures and exhaust fan shall be installed

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 421 OF 1216

 outside the battery room. Lighting fixtures and exhaust fans in battery room shall be
flameproof type suitable for gas group IIC.

7.4.18 Locally mounted lighting fixtures on platforms, walkways, stairs shall be installed in such a
way that relamping can be done without the use of ladders.

7.4.19 Telephone wiring/ sockets and LAN wiring/ sockets (as required) shall be provided in plant
and non plant buildings/ rooms which are normally manned during operation and
maintenance of the plant.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 422 OF 1216

 TECHNICAL SPECIFICATION
FOR
DIESEL ENGINE GENERATING SET

(B047-000-80-43-SP-0002, Rev-B)

PROJECT : AIRPORT TERMINAL BUILDING

JOB NO. : B047

LOCATION : LEH

CLIENT : M/S AIRPORT AUTHORITY OF INDIA

PMC : ENGINEERS INDIA LIMITED

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 423 OF 1216

1.0 SCOPE

1.1 The intent of this document is to outline the requirement of the Owner for the design,
engineering, manufacturing, assembly, painting, supply, erection, testing,
commissioning and performance test run of Four (04) nos. of Diesel Engine
Generating Set as per the specifications and data sheet, required for New Airport
Terminal Building, LEH, J&K.

1.2 All equipment and materials supplied under these specifications shall be designed and
manufactured in accordance with sound engineering principles, good fabrication and
construction practices. No omission in these specifications shall relieve the bidder of
their responsibilities for complying with statutory regulations, codes as applicable. All
materials supplied shall be adequate for the intended service.

1.3 The equipment supplied shall be complete in every respect, ready for installation and
operation. Any item not specifically mentioned in this specification but required for
proper operation, maintenance and safety of the equipment / personnel shall deem to
have been specified and bidder shall include the same in his scope of supply.

1.4 All equipment shall be packed for an outside storage period of twelve (12) months
(Min.).

1.5 The initial fill of lubricants, sealing fluid, refrigerants & other consumables shall be
included in the scope of supply of equipment vendor.

1.6 In case of any conflict between this job specification and other enquiry documents, the
following preferential order shall govern:

i. Data Sheets
ii. This Job Specification
iii. Other Indian/International Standards attached herewith or referred to.

1.7 Compliance with these specifications shall not relieve the contractor of the
responsibility of furnishing equipment and accessories of proper design, materials and
workmanship to meet the specified start up and operating conditions (i.e. to generate
desired power at alternator terminal at site).

1.8 All equipment shall be of the class most suitable for working under the conditions
specified and shall withstand the atmospheric conditions without deterioration.

2.0 SITE INFORMATION

Location - LEH, Jammu & Kashmir, India

Altitude - 3514 above sea level

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 424 OF 1216

 Summer Design Temperature - 40 Deg. C

Winter Design Temperature - (-) 22 Deg. C.

Relative Humidity Range - 6-24%

3.0 CODE, STANDARDS AND REGULATIONS

3.1 Latest edition of the following codes and standards including amendments as on the
date of enquiry shall govern:

ISO:3046-1 : Reciprocating Internal Combustion Engines-

Performance Part 1: Standard reference
conditions, declarations of power, fuel and
lubricating oil consumptions and test
methods.

ISO:3046-3 : Reciprocating Internal Combustion Engines-

Performance Part 3: Test Measurements.

ISO:3046-4 : Reciprocating Internal Combustion Engines-

Performance Part 4: Speed Governing.

ISO:3046-5 : Reciprocating Internal Combustion Engines-

Performance Part 5: Torsional Vibrations

ISO:3046-6 : Reciprocating Internal Combustion Engines-

Performance Part 6: Overspeed Protection.

ISO:3046-7 : Reciprocating Internal Combustion Engines-

Performance Part 7: Codes for Engine
Power.

ISO:8528-1 : Reciprocating Internal Combustion Engine

driven alternating current generating sets;
Part 1: Application, ratings and performance.

ISO:8528-2 : Reciprocating Internal Combustion Engine

driven alternating current generating sets;
Part 2: Engines

ISO:8528-5 : Reciprocating Internal Combustion Engine

driven alternating current generating sets;
Part 5: Generating Sets

ISO:8528-6 : Reciprocating Internal Combustion Engine

driven alternating current generating sets;
Part 6: Test Methods

IS:5571 : Guide for selection and installation of

electrical equipment for hazardous area
(other than mine)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 425 OF 1216

 IS: 803 : Code of practice for design, fabrication and
erection of vertical mild steel cylindrical
welded oil storage tanks

API 650 : Welded steel tanks for oil storage

ASME : The American Society of Mechanical
Engineering Boiler and Pressure vessel
code, Section VIII, Rules for Construction of
Pressure Vessels, and Section IX, Welding
and Brazing Qualifications.

The editions of referenced publications that are in effect at the time of inquiry or at a
date specified in the inquiry documents shall be applicable.

3.2 For provisions not covered by the above codes & standards, applicable good
engineering practices and norms shall govern subject to prior approval of Purchaser.

3.3 National Law and statutory provisions together with any local bylaws for the state
wherein DG set is required to be installed shall be complied with.

4.0 SAFETY

The design of DG system shall consider following safety features:-

4.1 All the controls should operate in a fail- safe mode i.e. failure of any control should not lead to
running of Genset in unsafe mode.

4.2 All exposed rotating parts should be provided with adequate guards of non- sparking type.

4.3 All electrical accessories, connections enclosures, junction boxes and engine-mounted
auxiliaries should be conforming to the stipulations by the concerned statutory authorities of
Govt. of India or State Govt. for its use in the specified installation. In case of contravention of
any such stipulation brought out at any stage by the statutory authorities, the same will be
rectified immediately at no cost to the client.

4.4 All moving parts to be mechanically guarded to minimize hazard to operators.

4.5 The primary confinement system shall be constructed of fire resistant materials, and the
equipment shall be designed to prevent or minimize the potential flammable or explosive
conditions.

4.6 The layout of the equipment shall be so designed as to provide easy access to the equipment
and operating areas.

5.0 OPERATION METHODOLOGY

5.1 Emergency DG sets are considered to supply power to the airport terminal building in case of
the failure of the grid power supply.

5.2 The DG set shall start automatically upon failure of normal power supply and is expected to
come to full load within 30 second or less.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 426 OF 1216

5.3 The DG Set shall also be capable of starting and stopping manually.

5.4 DG sets shall run parallel/synchronized among themselves. In case of power resumptions DG
set shall able to run in momentarily parallel with grid supply to avoid interruptions.

6.0 CONTRACTOR'S SCOPE OF SUPPLY AND WORK

6.1 Contractor’s scope of supply shall pertain to the following equipment:

6.1.1 Three (3) Nos. DG Set of 1500 KVA (Prime Rating), 415 V, 0.8 PF along with acoustic
enclosure, all auxiliaries, instrumentation, Exhaust system with silencer etc.

6.1.2 One (1) No. DG Set of 500 KVA (Prime Rating), 415 V, 0.8 PF along with acoustic
enclosure, all auxiliaries, instrumentation, Exhaust system with silencer etc.

6.2 All Equipment drivers shall be procured from the respective driven equipment
manufacturers, complete with all associated auxiliary systems.

6.3 Contractor’s scope shall include complete supply, transportation of equipment

package from vendor’s shop to site, receipt of material at site, handling at site and
arrangement for storage at site as per the requirements indicated in the Tender
document.

6.4 Contractor shall include all Commissioning spares and all special tools & tackles, as
recommended by equipment manufacturers and the same shall form part of supply by
Contractor.

6.5 Contractor shall note that consumables, lubricants etc. required during erection,
commissioning and performance guarantee run of Equipment such as first fill of
lubricants etc. shall be Contractor’s scope.

6.6 Equipment, which is transported by sea, shall have sea-worthy packing. The
Contractor shall strictly follow the recommended preservation procedures during the
period of storage for all equipment.

6.7 Contractor shall carry out the erection of DG Set at the specified location on the
properly designed & cast foundation as per Tender document. Foundation of DG sets
including vibration isolation springs/ pads is in the scope of contractor.

6.8 Contractor shall carry out the pre-commissioning and commissioning activity at site.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 427 OF 1216

6.9 The design of DG set should provide automated operations of equipment and
processes wherever possible to minimize exposures to working personnel.

6.10 DG Set shall be supplied with acoustic enclosure. The noise level shall not exceed
75 dBA when measured at One-meter distance from the acoustic enclosure in any
direction. Vendor to demonstrate at site the noise level of 75 dBA @ 1m from acoustic
enclosure.

6.11 DG Set along with the acoustic enclosure (except exhaust stack) shall be installed
inside the DG room.

6.12 Contractor shall conceive & develop design & layout of DG set including the layout of
day oil tank, exhaust system etc. Design / layout of the complete DG room shall be
carried out by contractor such that space requirement is economized.

6.13 All statutory clearances applicable for entire plant (such as CPCB, CEIG etc) shall be
obtained by the Purchaser. Contractor to ensure that DG Package shall meet all
applicable statutory requirements. Contractor shall provide all necessary documents/
data needed by Purchaser to obtain the statutory clearances. However, any
clearances required for the equipments (such as CCoE approval for electrical
equipments), shall be obtained by the Contractor.

6.14 For Electrical scope, refer Electrical Specifications.

7.0 DESIGN CRITERIA

7.1 Diesel Engine

7.1.1 The Diesel Engine shall be vendor's standard model meeting the requirements as
defined in IS0:3046. It shall be 4 stroke cycles, water cooled, turbocharged (as per
manufacturer standard) suitable for delivering the power requirement of the
driven equipment (alternator etc.) after taking into consideration the transmission
losses, site de­ ration and power requirements of auxiliaries and other parasitic loads.

7.1.2 Engine Manufacturer's de-ration calculations for the specified site conditions in
duly completed “Annexure-A “shall be furnished by the contractor post award. As a
minimum, the vendor shall consider the de­ ration due to ambient temperature,
altitude, relative humidity, cooling water temperature, inlet and exhaust losses etc.
De-ration factor shall be worked out as per IS0:3046. In case, there is no de-ration for
the specified site conditions, the Engine Manufacturer's categorical statement
along with proper technical justification shall be furnished .

7.1.3 Standard reference conditions for DG set/ diesel engine shall be as defined in
ISO:3046-1/ISO:8528-1

7.1.4 The generator/ alternator used in the proposed DG set shall meet the requirements
as specified in electrical specifications.

7.1.5 The engine rated speed shall be suitable for the Generator and no speed reducing
device is acceptable. The engine shall be coupled directly to Generator through
flexible coupling only. The speed of the engine shall not exceed 1500 rpm.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 428 OF 1216

7.1.6 No negative tolerance shall be allowed on the engine rating specified by the vendor/
contractor in the equipment datasheet.

7.2 RATED POWER OUTPUT AND SPECIFIC FUEL CONSUMPTION

7.2.1 The power rating of the Genset is the net exportable power output available at the
alternator terminals after deducting the electrical power consumed by the essential
independent auxiliaries.

7.2.2 Engine shall be sized on the basis of Prime Power Rating (PRP) as per ISO 8528-1
provided the actual average power output of genset over 24 hours of operation
(excluding stop time) does not exceed 70% of the PRP or the permissible average
power output confirmed by engine manufacturer, whichever is higher.

7.2.3 Specific fuel consumption shall be indicated with reference to the engine power
required for delivering the rated electrical power at alternator terminal i.e. 100%
rating of the genset plus the electrical power consumed by essential independent
auxiliaries. The tolerances shall be as per ISO: 3046-1.

7.2.4 The contractor shall furnish a list of engine auxiliaries, which require electrical power.
All such auxiliaries shall be further categorized on the basis of:

• If these are required to run continuously I intermittently.

• If these are required to run before engine starting, during starting or required
to run after start-up.

• If the above are required to be fed from engine developed power (In such a
case, feeding arrangement shall be in vendor's scope).

The contractor shall clearly identify those auxiliaries, which will be required to be fed
by the Purchaser.

7.3 Engine Starting System

7.3.1 Diesel engine shall be provided with Battery starting system with necessary
instruments, controls and safety devices. Electrical specifications, attached elsewhere
with the tender, shall be referred for details of the battery & battery charger.

7.3.2 The DG set shall be designed suitable for black start condition. In case any additional
equipment/accessory is required on account of the same, contractor to include the
same in his scope of supply.

7.3.3 Engines shall be capable of starting without the use of cold starting aids for
ambient temperatures of 4 degree C and above.

The contractor/ Vendor shall provide suitable cold starting aids with engines for
quick starting at ambient temperatures of (-) 22°C and such aids shall be clearly
detailed out . Lubricating oil heaters shall not be used as a cold starting aid.

7.3.4 Vendor shall provide the necessary controls (Automatic-cum-manual) in the

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 429 OF 1216

 engine panel, the inter­ connecting wiring, piping/tubing from panel to the
engine and the starting/stopping equipment. A pilot lamp shall be provided in the
starting equipment/control panel to indicate that the controller is in automatic position.
In the event the engine does not start after three attempts the controller shall stop
further cranking and operate the audio visual alarm.

7.3.5 For engines requiring pre-lubrication immediately before startup, electric motor driven
pre­ lubrication pump connected to an emergency power source with timer, suitably
interlocked with the starting system, shall be provided by the vendor. The emergency
power source shall be furnished by the vendor.

7.3.6 For engines which do not require pre-lubrication immediately before start, but
require periodic pre-lubrication to keep engine lubricated for automatic start, an
AC motor driven pre-lubrication pump with automatic start-stop and timers, set for
specific running time to provide pre-lubrication after preset periods of intervals shall
be provided by the vendor. The logic to establish the pre-lubrication shall be provided
& implemented by the vendor in the engine control panel, supplied by them.

7.4 Engine Cooling System

7.4.1 Engine shall be provided with radiator cooling (closed circuit liquid cooled type).
Cooling system shall include, as a minimum, temperature regulating device, control
valve, make up tank, engine driven fan for radiator, Engine driven water-circulating
pump, engine outlet cooling water temperature high alarm & trip device, along with
necessary piping, valves, fittings instrumentation and supports.

7.4.2 The radiator, temperature control valve, expansion tank, radiator guard and other
necessary piping and valves shall be mounted on the engine base.

7.4.3 Contractor shall provide necessary water jacket heating system to prevent the
water from freezing at low temperature.

7.5 Engine Lubrication System

7.5.1 Engine lubrication shall be as per Manufacturer's standard. The DG Set shall be
suitable for automatic starting on Power failure. In order to keep the DG set in ready
to start condition at all times, a complete automatic pre-lubrication system (including
electric motor driven pre-lubrication pump etc) that lubricates the Engine at regular
intervals complete with Timer logic etc. shall be included in contractor's scope.

7.5.2 The frequency of starting of pre-lube pump shall be indicated in the datasheet.

7.6 Engine Fuel System

7.6.1 As separate fuel tank (s) shall be provided for each DG set.

7.6.2 The fuel day tank shall be, as a minimum, equipped with vent piping with flame
arrester, shielded level gauge, strainer and a hand hole of not less than 150 mm
diameter, besides the required fuel connections and a drain valve.

7.6.3 Fuel oil treatment system (if required) and fuel oil control system shall be supplied
by the contractor. This fuel treatment system shall be of vendor’s standard design
proven for the specified type of fuel.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 430 OF 1216

7.6.4 The height of installation of the day tank shall be indicated by the contractor in the
general arrangement drawing. In case, Fuel Day tank is mounted above engine
fuel connection level, a fuel float (surge) tank shall be provided along with its
interconnecting piping/ hoses to ensure that the system does not permit gravity
flow to the engine through fuel supply line during engine shutdown.

7.6.5 The Fuel day tank shall comply with the requirement of Design Code: API 650/
IS803.

7.7 Engine Jacket Cooling System

7.7.1 Engine jacket cooling system (primary circuit) shall be closed circuit liquid cooled
type including circulating pump, water jacket heating system, make up tank, heat
exchanger, temperature regulating device, engine outlet cooling water temperature
high alarm & trip device.

7.7.2 The Heat exchanger shall be air cooled type i.e. radiator type with engine driven or
electric motor driven fan.

7.7.3 For radiator cooled engines with engine driven radiator fans, the radiator,
temperature control valve, expansion tank, radiator guard and other necessary
piping and valves shall be mounted on the engine base.

For remote mounted radiator system, vendor shall supply electric motor driven
radiator fan and additional cooling water booster pump located in the engine return
line. Height of the expansion tank in the closed circuit cooling shall be at the highest
level in the complete circuit. Piping connections from cooling water outlet from the
top o the engine to the top portion of the radiator shall be continuously sloping
towards the engine without any pockets.

7.8 Combustion Air Intake & Engine Exhaust System

7.8.1 Complete Exhaust gas system shall comprise of exhaust piping, residential type
silencer, expansion bellow, fittings, insulation and structurally supported exhaust
piping including necessary clamps (excluding supporting structure), foundation
bolts, lightning arrester, aviation lamp etc.

7.8.2 The exhaust system from the DG sets shall meet the prevailing pollution control
board requirements besides meeting the requirements of this Job specification. DG
set Exhaust piping should be routed to safe height and the same shall be as per
CPCB norms and local governing pollution control board norms. The type and
location of air intake filter shall be vendor's standard and shall be suitable for the
climatic/environmental conditions applicable to the site of installation of the engine.

7.8.3 Vendor shall furnish details of the air intake, exhaust piping, design of supporting
system envisaged for the engine exhaust system during detailed engineering stage
for Owner/ PMC approval.

7.8.4 Exhaust from the DG set shall be routed outside the DG Room. The location of
exhaust piping shall be such that the exhaust gases from diesel engine do not enter
the DG set Enclosure nor it is taken as combustion air to diesel engine.

7.8.5 All DG sets shall be supplied with enclosure for noise control. The enclosure shall
be provided with vendor standard ventilation system designed to maintain the
temperature inside the engine room close to ambient temperature.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 431 OF 1216
7.8.6 Exhaust gas piping (as applicable) shall be provided with thermal Insulation &
 cladding for personnel protection. The insulation thickness shall be
adequate to limit the surface temperature at cladding not exceeding 60 deg C. The
extent of insulation and cladding shall be at least up to 3m of height from grade
including complete length of exhaust piping within engine room

7.8.7 Piping (prefabricated) & fittings (between engine skid and diesel day tank) shall be
preinstalled on the diesel engine skid. If due to transportation limitations, such
piping is required to be supplied as loose, the same shall be pre-fabricated along
with all fasteners, bolts/studs, nuts, gaskets & shall be properly match-marked.

7.9 Governing

7.9.1 The governing class shall be selected by the vendor suitable for meeting the
voltage and frequency variations specified in Electrical specifications.

7.9.2 In case of parallel running generators (i.e. for generators required to run in
synchronization, the governor and fuel injection pumps provided shall have identical
characteristics.

7.10 Noise And Exhaust Gas Emission

Any applicable legislation/ statutory requirements relating to the protection of

environment and to the health and safety of personnel, with regard to noise and
exhaust gas emission, as applicable to the place of installation shall be fully
complied with by the Engine manufacturer.

8.0 ACCESSORIES

8.1 Couplings and Guards

8.1.1 Couplings shall be sized for maximum continuous torque, which is based on the
potential maximum power of the diesel engine.

8.1.2 Couplings shall be of flexible type, however for generators upto 1000 KVA, the
coupling may be accepted as per vendor standard based on their past field proved
experience. The coupling used shall be successfully proven for the service being
used. The service factor shall be conservatively selected for the maximum
horsepower rating of the engine with a factor of not less than 1.7.

8.1.3 Non sparking guards are required over all moving parts. The guards shall be
securely attached to the base plate on foundation by means of bolts. The guards
shall be sufficiently rigid to withstand deflections as a result of bodily contact of
nominally 100 kgs.

8.2 Base Plate

8.2.1 A common baseplate for the complete unit (engine and alternator) shall be supplied
by vendor. A base plate shall be a single fabricated steel unit, unless the purchaser
and the vendor mutually agreed that it may be fabricated in multiple sections.

8.2.2 The base plate shall be suitable for column mounting i.e. of sufficient rigidity to be
supported at specified points without continuous grouting under structural
members.

VOLUME-2
8.2.3 The(ELECTRICAL) SOW & SPECIFICATIONS
base plate shall be provided with lifting lugs for a four PAGE
pointNO.lift.
432 Lifting
OF 1216 the
 baseplate complete with all equipment mounted shall not permanently distort or
otherwise damage the base plate or the machinery mounted on it.

8.2.4 The bottom of the base plate between structural members shall be open. When
installed on a concrete foundation, accessibility for grouting under all load carrying
structural members shall be provided.

9.0 INSTRUMENTATION

9.1.1 Vendor shall provide all necessary Instrumentation and Controls specified herein
and as required making the total system complete and suitable for the safe and
automatic operations of the emergency diesel generator. The intent of this section
is to provide the basic guidelines for supply of instruments as well as Indicative
guideline for nature and extent of Instrumentation and Control.

9.1.2 Vendor shall provide suitable control system for safe and efficient operation of DG
Set. Controller shall have dual redundant operation module, dual redundant power
supply, dual redundant communication module, dual redundant I/O module.

9.1.3 Vendor shall provide necessary field instruments including speed sensors, control
valves, solenoid valves, junction boxes, Instrument erection hardware etc. as
required for safe and efficient operation of the emergency DG set and all associated
auxiliaries as per the requirement provided.

9.1.4 Vendor shall provide differential pressure (DP) transmitter and differential pressure
gauge across filter/strainer. DP transmitter shall be connected to the Vendor’s
supplied Local Control Panel (LCP) for necessary alarm and interlock.

9.1.5 Vendor shall provide level transmitter for expansion tanks, pressure transmitter for
engine lube oil (LO) priming and turbocharger LO.

9.1.6 Vendor shall provide DP gauge and transmitter for fuel oil filter, pressure gauge and
temperature gauge for lube oil system.

9.1.7 Supply of instrumentation cables and special cables from field instruments to local
junction boxes and local junction boxes to LCP as required for complete installation
of DG set and auxiliaries shall be in Vendor’s scope.

9.1.8 Double compression cable glands shall be used for all cables under Vendor’s scope
of supply. Slipper type PVC sleeves (cable shrouds) shall be used over cable all
glands.

9.1.9 Vendor shall supply all Instrumentation items as per approved vendor list.

9.1.10 Vendor shall supply any other Instruments required for safe and trouble free
operation of DG set.

10.0 INSPECTION AND TESTING

10.1 The Inspector representing Purchaser shall have entry to the plant while and
wherever work for the equipment is being performed. The Vendor shall have the
responsibility of providing Purchaser's Inspector with all requisite facilities/
equipment for carrying out proper inspection and witnessing of test.

10.2 Engines of nominal rating up to 1000 KW shall be subjected to Engine

VOLUME-2 (ELECTRICAL)
Manufacturer’sroutine shopSOW & SPECIFICATIONS
test PAGE
and test certificates shall be NO. 433 OF 1216
submitted to the
 purchaser’s inspection for his review, provided the engine manufacturer is an
ISO:9000 certified vendor.
For all other cases, engines shall be witness tested in accordance with the latest
edition of IS0:3046. The routine load and fuel consumption test shall be of the
following duration:

a) Part Loads (50% & 75%) - 1/2 hour each

b) Full Load (100%) - 4 hours
c) 10% overload - 1 hour

After the specified tests have been completed satisfactorily, the fuel stop on the
fuel injection pump shall be set and sealed at the specified site rating including
provision for 10 percent overload.

10.3 The hydrostatic test certificates for the fuel tanks and other pressure vessels
shall be furnished to the Owner/ PMC for review at the time of load testing of the
diesel engine.

10.4 The Alternators shall be subjected to all Tests at Alternator manufacturer's shop as
defined in Electrical Specification and datasheet.

10.5 The engine control panel after assembly and wiring, shall be functionally tested at
the panel manufacturer’s works in the presence of the owner/ PMC.

10.6 In addition to the inspection and tests specified in clause 9.2 to 9.5 above,
Complete DG sets shall be tested at the packager's shop for 4 hrs at full load and 1
hour at 10% overload.

10.7 DG Set shall be tested at site at full load to generate the required power and
voltage at the alternator terminals. Electrical load and diesel required for site testing
shall be arranged by the contractor at their own expenditure.

11.0 SPARE PARTS AND SPECIAL TOOLS

11.1 Commissioning Spares

Contractor shall include in his offer the complete spares as required for erection
and commissioning of DG Package. Vendor to note that the cost of the
commissioning spares are to be included in the base price. However, if any
additional spare is required at the time of erection & commissioning of the DG
Package over and above the quoted spares, the same shall be supplied by the
contractor without any cost or time implication to the Purchaser. Spares not used
during commissioning shall be owner’s property.

11.2 Special Tools and Standard Normal Maintenance Kit

Special tools, Engine Cylinder Honing tool, Standard Normal Maintenance Kit and
tackles required, if any, for maintenance of the Diesel Engine Generator package
shall be included by the Contractor in his scope. DG Vendor shall furnish separate
list of such tools & tackles included in his scope of supply post award. Contractor to
note that the prices of above mentioned tools & tackles are to be included in the
base price.

12.0 SCOPE OF ERECTION AND COMMISSIONING

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 434 OF 1216
12.1 All the site activities including transportation from purchaser’s store to job site,
 unloading & storage at job site prior to erection, material handling for erection,
assembly/erection at job site, installation, pre-commissioning, commissioning, site
testing at available load, handing over to client and other field works including
residual engineering work etc. shall be the responsibility of the Contractor and
included in his scope.

12.2 Refer electrical specifications for electrical scope.

13.0 EQUIPMENT STORAGE

All equipment shall be packed for an outside storage period of twelve (12) months.
Vendor’s recommended extended storage and preservation procedure shall be
furnished to Purchaser/owner before dispatch.

Equipment vendor to ensure the following before dispatch:

- All the openings shall be plugged & sealed condition during dispatch
- Instruments like gauges, speed indicators, probes, oiler etc shall be removed
from the main equipment and dispatched separately to avoid the damage of
these components during transportation handling and erection.

14.0 INITIAL FILL

The initial fill of lubricants, other consumables is included in the scope of supply of
the contractor.

15.0 PARTICIPATION OF PURCHASER’S ENGINEERS DURING ASSEMBLY AND

OTHER IMPORTANT ACTIVITIES:

Owner and/or his Consultant may participate along with the Vendor’s inspectors in
any inspection and tests. The contractor shall notify to owner of all inspection and
tests atleast four weeks before the scheduled date of inspection and test and
reconfirm the same at least one week before the date of inspection and testing.

16.0 VENDOR DATA AND DRAWING REQUIREMENTS

16.1 Contractor shall furnish the Drawings / Documents for purchaser's review / approval
as per the Vendor data requirement. For vendor data requirement of Electrical &
Instrumentation, refer respective Electrical & Instrumentation specifications.

VENDOR DATA REQUIREMENT FOR DG SET

Sr. DESCRIPTION POST ORDER REMARKS

No. FOR FOR WITH
REVIEW RECORD DATA
BOOK
( FINAL )
1.0 Documents Control Index √
2.0 Filled in experience record √ √
proforma for Diesel Engine & DG
Set Unitization
3.0 Data Sheets for Diesel Engine √ √
along with
Deration calculations (As per ISO
VOLUME-2 (ELECTRICAL)
3046) SOW & SPECIFICATIONS PAGE NO. 435 OF 1216
 4.0 Equipment Layout drawing √ √
including DG Room Layout
showing acoustically enclosed DG
Set including all associated
accessories & auxiliaries like Air
Intake System, Exhaust System,
Cooling System, Fuel System,
Electrical/ Instrumentation Panels/
Gauge Boards (LCP, MCC,
Breaker Panel, Local Gauge Board
etc, as applicable) along with
interface connections/ terminal
point details including their location
co-ordinates, trench details,
maintenance space for frequently
maintained parts etc., erection &
maintenance weights etc.
5.0 Foundation drawing of DG Set [i.e. √
for Diesel Engine, drive
transmission system (as
applicable) & Alternator/ Generator]
including details of openings in the
foundation, load points location and
their details, foundation load data
(static & dynamic), foundation
bolts, their location, foundation bolt
pocket dimensions, details of insert
plates, recommended type of grout,
grout thickness, make, grade and
quantity, as required/ applicable
6.0 Foundation drawing of auxiliaries to √
be installed at grade such Diesel
Day Tank, exhaust stack including
support structure, Equipment
associated with sub- systems (like
Starting Systems, Air Intake
system, Exhaust Gas System, LO
System, etc.) Electrical/
Instrumentation Panels, drain pots
(as applicable), etc.
7.0 Back pressure calculations for √
Exhaust pipe and sizing of exhaust
piping
8.0 Utility consumption data including √ √
electric load data.
9.0 Schedule of lubricants, chemicals √ √
& consumables with their
specifications.
9.0 List of special Tools & tackles, if √ √
any
10.0 Installation, operation and √ √
maintenance manual containing all
certified drawings & documents

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 436 OF 1216

 11.0 General Arrangement drawing of √ √
DG skid
showing Diesel Engine, drive
transmission
system (as applicable) &
Alternator/ Generator placed in
acoustic enclosure, as required,
including all associated
accessories & auxiliaries on DG
skid
12.0 General Arrangement drawings of √ √
Diesel Day Tank & acoustic
enclosure
13.0 P&ID of Diesel Engine including all √ √
the auxiliary systems like Air
intake/ exhaust gas system,
starting system, lubrication system,
cooling system, fuel system
14.0 Quality assurance Plan √ √
15.0 Procedure for Load test & Fuel √ √
consumption test
16.0 List of commissioning spares √ √
17.0 Test Procedure(s) : Witness tests √ √
as specified in data sheets / other
specs enclosed in the inquiry / MR
or as required by approved
ITP/QAP
18.0 Torsional Analysis Report √ √
19.0 Installation, Operation & √ √
Maintenance manuals for complete
DG Package
20.0 Precommissioning & √ √
commissioning procedure for
complete DG Package
21.0 Other Electrical/ Instrumentation √ √
Documents

Notes:

1. Tick denotes applicability.

2. Also refer VDR for electrical.
3. Bill of material from part of the respective drawing

ANNEXURE-A
Deration Calculation for Diesel engine in Genset application

1. ISO Standard Power (as per ISO 3046-1) of the engine, (obtained after deducting power loss
due to essential dependent auxiliaries) (P iso )
Piso(ELECTRICAL)
VOLUME-2 SOW & SPECIFICATIONS : PAGE NO. 437 OF
kW 1216
2. Deration on account of site conditions (refer datasheet for ambient conditions) as per ISO
3046-1
Temperature (around the engine and alternator) : kW
Altitude (d1) : kW
Humidity (d2) : kW
CW temp (d3) : kW
Inlet losses (d4) : kW
Exhaust back press (d5) : kW
Total Deration (P deration = d1+d2+d3+d4+d5) : kW

3. Service Power (as per ISO 3046-1) of the Engine (i.e. at stated conditions)
Pservice = Piso - P deration : kW

4. Power Loss in the Alternator under stated conditions (P alt )

Palt [i.e. KVA*pf(100-η alt )/ η alt ] : kW

5. Power consumed by essential independent auxiliaries (P aux )

Paux : kW

6. Any other Power Loss applicable to the offered genset (P misc )

P misc : kW

7. Net output required for electrical consumption (P output )

(Poutput = _______ kW (minimum)) : kW

8. Actual Power Required from Engine (P actual )

Pactual = Poutput + P alt + P aux + P misc : kW

Ensure that Pservice ≥ Pactual and shall furnish calculations / supporting documents.

Note: As per Annex-A of ISO-3046-1, the following describes the typical list of auxiliaries:

1. Essential dependent auxiliaries (as applicable)

a) engine-driven LO pressure pump;
b) engine-driven LO scavenge pump for dry-sump engines;
c) engine-driven engine-cooling water pump;
d) engine-driven raw-water pump;
e) engine-driven radiator-cooling fan;
f) engine-driven engine-cooling fan for air-cooled engines;
g) engine-driven gaseous fuel compressor;
h) engine-driven fuel-feed pump;
i) engine-driven fuel-pressure pump for common rail or servo-injection system;
j) engine-driven scavenge-air blower and/or charge-air blower;
k) engine-driven generator, air compressor or hydraulic pump supplying power to items in sl. No. 2
below;
l) engine-driven cylinder lubricating pump;
m) air cleaner or air silencer (normal or special);
n) exhaust silencer (normal or special).

2. Essential independent auxiliaries (as applicable)

a) separately driven auxiliaries as defined above from Sl. no. a) to l).
b) governing or control system using power from an external source.

3. Non-essential dependent auxiliaries (as applicable)

a) engine-driven starting air compressor;
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 438 OF 1216
b) engine-driven generator, air compressor or hydraulic pump when supplying power to items not
shown in sl. No. 2 above;;
c) engine-driven bilge pump;
d) engine-driven fire pump;
e) engine-driven ventilation fan;
f) engine-driven fuel-transfer pump;

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 439 OF 1216

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 Datasheet No.
DATA SHEET B047-003-16-50-DS-0006
HV SWITCHBOARD Rev : A
Page 1 of 3
PURCHASER'S DATA

Project LEH AIRPORT Location LEH

Client M/S AAI Unit
A Site conditions
1 Maximum ambient temperature: 35 °C 3 System Breaking capacity 25 kA, 3 sec
2 Minimum ambient temperature (O/D): -22 °C 3.1 % D.C. Component As per IEC
Minimum ambient temperature (I/D): -5 °C
3 Design ambient temperature: 40 °C 4 System making capacity 2.55 times the
4 Relative humidity: 30-100% breaking capacity
5 Altitude above MSL: 3515 m 5 Type of Circuit Breaker VCB/SF6
[De-rating of equipment rating as per site conditions shall Shunt Trip Coil-1 : 110/220V DC
be in the scope of vendor/ bidder] Shunt Trip Coil-2 : N/A

6 Duty Cycle of C.B. 0-3min-CO-3 min-CO

6 Environment: Cold Desert 7 Suitability for Cap. Switching
B Operating conditions 8 Surge supressor for Motor Feeder.
1 Voltage 11 kV ± 6 % 9 IDMTL Relay type
2 Frequency 50 Hz ± 3 % 10 Provision of earthing
3 Number of Phases Three Earthing truck Required/ Not Required
4 System Fault Level 25kA for 3 sec Earthing switch Required/ Not Required
5 System Earthing Resistance earthed D Miscellaneous
6 Auxiliary Supply 1 Interface with BMS Reqd./Not Reqd.
a. AC 240 V ± 10%, 1 Ph 2 Incoming Power Entry Cable/Bus Duct
b. DC 110 V ± 10% 3 Cable Entry Top/Bottom
C Electrical Data 4 Separate bolted removable Reqd.(Gland plate
1 Busbar current rating (inside * As per SLD/SOR gland palte for cable entry drilled at side)
panel at design temp.) 5 Cable glands and lugs for
2 3sec. Short Circuit withstand * cable termination Required
capacity 25 kA 6 Painting/Paint shade RAL 7032

Note:
1) Marked particulars may be referred in respective switchboard feeder detail data sheet.
MANUFACTURER'S DATA
A Switchboards
1 Make 9 Recommended clearances
2 Type designation Front mm
3 Degree of protection Rear mm
4 Max. overall weight of C.B. panel Kg Above mm
5 Overall dimensions of C.B. panel 10 Shock loading on foundation
a Width mm 11 Max. size/no. of cables that can be
b Depth mm terminated inside the panel
c Height mm a. without rear extension panel
6 Overall dimensions of dummy / b. with rear extension panel
adaptor panel of each type c. size of rear extension panel
a Width mm 12 Clearance in air
b Depth mm a. Phase to Phase (min.) mm
c Height mm b. Phase to Earth (min.) mm
7 Overall weight and dimensions of 13 Busbar current rating at design
largest shipping section ambient temperature A
a Weight Kg 14 Busbar (separately for each swbd)
b Width mm a. Horizontal main busbar size
c Depth mm (No. of flats x size of each flat)
d Height mm b. Horizontal main busbar size as
8 Overall dimensions of each swbd. tested at CPRI for full short ckt.
including all dummy/adaptor/rear withstand as per specification
extension panels requirement (No. of flats x size
Width of each flat)
Depth c. Vertical dropper size
Height (No. of flats x size of each flat)

Note: Vendor shall furnish the dimensins of various types/ratings of swbds., CB panels and
dummy/adaptor panels separately.
A 08.05.2018 ISSUED WITH TENDER RR DR VKJ
Rev. No Date Purpose Prepared by Checked by Approved by

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 444 OF 1216

 Datasheet No.
DATA SHEET HV B047-003-16-50-DS-0006
SWITCHBOARD Rev : A
Page 2 of 3

15 Horizontal main busbar/Vertical b Removable FRP shrouds for all Yes/No

busbar material Cu busbar joints and tap-off
16 Insulating material (Busbar supports) connections provided
17 Earth busbar size mm2 c Arc propagation barrier in busbar Yes/No
18 Earth busbar material Copper compartment provided
19 1 min. power frequency withstand d Breaker service, test and drawn-
voltage (rms) kV out position provided Yes/No
19.1 Over voltage factor for PTs 1.9 for 30 sec. e Distinct overall lockable door for
20 Impuse withsatnd voltage (peak) kV breaker compartment provided Yes/No
24 Safety Features f Automatic safety shutter provided Yes/No
21 [De-rating of equipment rating as per site condition kA g Independent pressure release
22 be in the scope of vendor/ bidder] kA flaps provided for all HV
23 Windows at the rear side of panels Required compartments Yes/No
for thermography h Wire mesh for all louvered
openings provided Yes/No
a Heat shrinkable sleeves, rated to i Suitable intrlocks to prevent
withstand the system line to line faulty operation as per Cl. 4.4.10
voltage for one min., provided 11 Yes/No % of spec. 6-51-0001 provided Yes/No
on busbar %

B Circuit Breaker
1 Type VCB/SF6 16 Power required for closing W/VA
2nd shunt trip coil for VFD feeders Yes/No Interface with BMS
240 10%, 1 Ph
2 Make 17 Power required for spring
3 Type Designation charging motor W/VA
4 Circuit Breaker mounting in panel * As per SLD/SOR 18 Breaker is trip free Yes/No
5 No. of poles/phase 19 Closing mechanism
o
6 Current rating (in free air) A at C 20 Provision of manual spring
7 Current rating inside the panel at charging provided Yes/No
specified design tempeature A 21 Mechanical Trip PB provided Yes/No
8 Short time rating ( 1sec.) kA 22 Mech. On/Off indicator provided Yes/No
9 Symmetrical breaking capapcity kA 23 Operation counter provided Yes/No
9.1 % D.C. Component 24 Time taken for spring charging sec.
10 Peak making current kA 25 No. of aux. contacts and their NO +
11 1 min. dry withsatnd voltage current ratings NC , A
(power frequency) kV 26 Interrupter
12 Duty Cycle a Make
13 Total openeing time m sec. b Pressure switch for monitoring
14 Total closing time m sec. of SF6 gas pressure provided Yes/No
15 Power required for opening W/VA c Re-filling arrangement of SF6
27 LOTO (Lock-Out Tag-Out) Provided/Not Provide
Provision for mechanical
locking arrangement

@ Lifting truck shall be provided for cassette type circuit breaker.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 445 OF 1216

 Datasheet No.
DATA SHEET HV B047-003-16-50-DS-0006
SWITCHBOARD Rev : A
Page 3 of 3

27 Supressor
a Type designation
b Make
28 Derating reqd. for Cap. Switching %
29 Earthing System Integral earthing/
Separate earthing
carriage
30 Copies of following test cerificates
enclosed : Yes/No *
c Internal arc test
[De-rating of equipment rating as per site conditions shall
a. be in the scope of vendor/ bidder]
withstand)
b Heat run test

d Impulse and power freq. withstand

30.2 For each type of offered circuit
breaker (in panel) 11 %
a. Short Circuit test duties %

Interface with BMS

* Switchboard offered shall be of pr 240 10%, 1 Ph
certificates for an exactly identical design of offered switchboard shall be furnished by bidders. These
test reports shall not be more than 5 years old, as on the final bid opening date. In case these type tests
have not been conducted during * As per SLD/SOR
design of switchboard before despatch without any cost and delievery impact.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 446 OF 1216

 PART-I
(DATA TO BE FILLED-IN BY PURCHASER)

1.0 SITE CONDITIONS

1.1 Maximum ambient temp. : 35 °C
1.2 Minimum ambient temp. (Outdoor/Indoor) : -22°C/-5°C
1.3 Design Temp. : 40 °C
1.4 Relative humidity : 30-100% (Max.)
1.5 Altitude above MSL : 3515 m
1.6 Location : Leh, J&K
1.7 Atmosphere : Cold Desert

2.0 OPERATING CONDITIONS

2.1 Voltage : 415 kV ± 10%
2.2 Frequency : 50 Hz ± 3%
2.3 No. of phases : Three
2.4 System fault level : 50 kA for 1 second
2.5 Auxiliary supply AC : 240 V ± 6%, 1-Phase 50 Hz
3.0 BUSDUCT DETAILS
3.1 Rated Voltage : 415 V ± 10% for MV
3.2 Current rating : 3000A/2500A (refer SLD)
3.3 Short circuit rating : 50 kA for 1 sec.
3.4 Type : TPN non segregated
3.5 Location : Indoor/Outdoor
3.6 Paint shade of enclosure : RAL7032 for indoor & 632 for outdoor
3.7 Supporting arrangement of bus-duct : Required
3.8 Space heater and breather with silica gel in bus duct : Required
3.6 Wall frame assembly with seal off bushings and : Required
bus conductors

Note: Necessary de-rating in the equipment design and rating as per site conditions of LEH shall
be in the scope of vendor/ bidder.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 447 OF 1216

 PART-II
TO BE FILLED UP BY VENDOR ALONG WITH BID

1.0 Make :
2.0 Current rating :
3.0 Short circuit rating :
4.0 Type : Non-phase segregated
5.0 Degree of protection :
6.0 Canopy of outdoor bus duct : Provided/Not Provided
7.0 Busbar details
7.1 Busbar material :
7.2 Busbar size :
(No. of flats x size of each flat)
7.3 Busbar size as tested at CPRI for full short ckt
2
withstand : mm
(No. of flats x size of each flat)

7.4 Busbar insulator :

a) Type :
b) Tracking index :
7.5 Clearance :
Phase to phase : mm
Phase to earth : mm
7.6 Flexible Size / Qty :
7.7 Earth bus material/size :
7.8 Heat shrinkable sleeves, rated to withstand : Yes / No
the system line to line voltage for 1 min, provided
7.9 Removable FRP shrouds for all busbar : Yes / No
joints provided
8.0 Cross sectional dimensions of each bus duct : mm x mm
9.0 Space heater provided : Yes / No
10.0 Overall dimensions (LxBxH) :
11.0 Weight of each section of bus duct :
12.0 Type test certificates : Enclosed/ Not enclosed @
a) Short circuit (Peak & 1 sec withstand) :
b) Heat run test :
c) Degree of enclosure protection :

@ Bus duct offered shall be of proven design and shall have been successfully type tested. Type
test certificates for an exactly identical design of offered bus duct shall be furnished by bidders.
Type test reports shall not be more than 5 years old, as on the final bid opening date. In case
these three type tests have not been conducted during the last 5 years, bidder shall conduct
these type tests successfully on the offered design of busduct before despatch without any cost
and delivery impact.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 448 OF 1216

 Datasheet No.
DATA SHEET FOR B047-003-16-50-DS-0008
PCC/ASB/CHILLER DB Rev : A
Page 1 of 2
PURCHASER'S DATA
Project Leh Airport Location Leh, J&K
Client M/S AAI Unit
A Site conditions
1 Maximum ambient temperature: 35.0 °C 4 Relative humidity: 30-100 %
2 Minimum ambient temp.(O/D): -22 °C 5 Altitude above MSL: 3515m
Minimum ambient temp. (I/D): -5 °C
3 Design ambient temperature: 40 °C 6 Environment: Cold desert
B Operating Conditions
1 Voltage 415 V ± 10% TPN 6 Auxiliary supply
2 Frequency 50Hz +/- 3% AC 240 V ± 10% SPN
3 No of phases Three DC 110 V ± 10% DC
50kA for 1 sec. or as per Power supply for spring
4 System fault level 7 110 V AC/ DC
SLD
5 System earthing Solidly earthed charging motor
C Electrical Data
1 Short circuit withstand capacity Refer Elsewhere 7 Incoming power entry As per SOR
for 1 sec. 8 Cable entry (I/C & O/G) Required
2 Busbar current rating inside panel Refer Elsewhere 9 Bus duct entry Required
panel at specified ambient 10 Cable gland/lugs Included
3 Busbars Heat shrunk PVC sleeved 11 Colour shade Exterior RAL 7032
Single front/Double front
4 System breaking capacity kA 12 Feeder arrangement
as per SOR
5 System making capacity kA (peak) 13 Minimum motor starter module 240mm/Vendor standard
6 Circuit breaker size
Type ACB 14 Minimum switchfuse module 200mm/Vendor standard
Duty cycle 0-3 min-co-3 min-co size
Rating * 15 Floor fixing Integral base frame & tack
welding to the floor/steel channel
Note
* marked particulars may be referred in respective switchboard feeder detail data sheet
MANUFACTURER'S DATA
A Switchboards 12 Largest shipping section:
1 Tag no. Max. overall weight
2 Make Length*Depth*Height
3 Type designation 13 Recommended clearances for SWBD
4 Degree of protection Front*Rear*Above
5 CB panel 15 Max. size/no. of cables that
Overall weight can be terminated
Incomer kg with rear extension
Outgoing kg without rear extension
Overall dimensions 16 Size of rear extension panel
Length*Depth*Height mm 17 Clearance in air
6 Overall dimensions of MCC/ Phase to Phase mm
contactor controlled feeder panel: Phase to Earth mm
Length*Depth*Height mm 18 Main horizontal bus bar
7 Overall dimensions of each PCC Bus bar current rating at A
Length*Depth*Height mm design ambient temp.
8 Overall dimensions of each PMCC Main bus bar size
Length*Depth*Height mm Main bus bar material Al / Cu
9 Overall dimensions of each MCC Main bus bar location Top/ Bottom
Length*Depth*Height mm 19 Vertical bus bars
10 Overall dimensions of each ASB Bus bar current rating at
Length*Depth*Height mm design ambient temp. A
11 Overall dimensions of each LDB Bus bar size
Length*Depth*Height mm Bus bar material
14 Shock loading on foundation Bus bar location

A 08.05.2018 Issued with Tender RR DR VKJ

Rev. No Date Purpose Prepared by Checked by Approved by
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 449 OF 1216
 Datasheet No.
DATA SHEET FOR B047-003-16-50-DS-0008
PCC/ASB/CHILLER DB Rev : A
Page 2 of 2
20 Insulating material 23 Short circuit
21 Earth bus bar size mm² 1 second kA
Material Al / Cu Peak dynamic
22 1min power freq voltage kV 24 Whether adaptor panel required Yes/No
35 between PCC/MCC panel
If Yes, furnish dimensions
B Circuit breaker
1 Type designation 15 Power requirement
2 Make Opening W/VA
3 Mounting Closing W/VA
4 No. of poles/phases Spring charge motor W/VA
5 Current rating (in air) A at °C 16 Time for spring charging
50kA for 1 sec. or as per
6 Current rating (inside panel 17 Breaker is trip free Yes
SLD
at design temperature) 18 Closing mechanism
7 Short time rating (1 sec) 19 Provision of manual spring Yes
8 Sym breaking capacity kA charging As per SOR
% DC component 20 Tripping mechanism
9 Peak making capacity kA (peak) 21 Mechanical trip PB provided Yes
10 Power frequency withstand 22 Mechanical ON/OFF indicator Yes
11 Impulse withstand voltage provided
Single front/Double front
12 Duty cycle 23 Operation counter provided
as per SOR
13 Total opening time m sec 24 Time taken for spring charging sec
14 Total closing time m sec 25 No. of auxiliary contacts NO+ NC
26 Derating required for capacitor %
switching
C CONTACTOR
1 Type designation 9 Life
2 Make Electrical
3 Rated Voltage Mechanical
4 Rated current 10 Coil consumption - Pick up
AC-3 Duty 11 Coil consumption - Pick up
AC-4 Duty 12 Coil consumption - Hold on
5 Thermal rating 13 Closing time
6 Making capacity 14 Opening time
7 Breaking capacity 15 No of aux. contacts NO+ NC
8 Switching frequency 16 Maximum permitted back up fuse rating
D SWITCH
1 Rated voltage 6 Rated short circuit withstand
2 Rated current current with max. permissible
3 AC 23 rating rated fuses
4 Rated making capacity 7 Mechanical life
5 Rated breaking capacity 8 Maximum permitted back
up fuse rating
E THERMAL OVERLOAD RELAY
1 Make 5 Type of operation Direct / CT operated
2 Type 6 Maximum permitted back
3 Setting range up fuse rating
4 Single phasing preventor Intergral / Separate
F FUSES
1 Make 3 Current rating
2 Type
Note
1 Vendor shall furnish dimensions of various switchboards, CB panels and dummy/adaptor panels separately.
2 Vendor shall furnish technical particulars of various switchboards separately.
3 Switchboard offered shall be of proven design and shall have been successfully type tested. Type test
certificates for an exactly identical design of offered switchboard shall be furnished by bidders. These test
repo 08.05.2018 Issued with Tender
been conducted during the last 5 years, bidder shall conduct these type tests on the offered design of
switchboard
VOLUME-2 before despatch without any extra
(ELECTRICAL) SOW &cost and delivery impact.
SPECIFICATIONS PAGE NO. 450 OF 1216
 DATA SHEET
FOR
MV SWITCHBOARD COMPONENTS

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 451 OF 1216

 DATA SHEET FOR MEDIUM VOLTAGE SWITCHBOARD COMPONENTS
COMPONENT RATING (A)
MOTOR
FEEDER TYPE RATING MAX
CABLE CT CONTACTOR
KW MPR MCCB
SIZE RATIO (AC3)

FVNR-15 MOTOR PROTECTION

FVR-15 KW≤5.5 4*16 RELAY 32A 15/1 16A
FVNR-15HD (46,50,49,50N,51L/R,2)

FVNR-30 MOTOR PROTECTION

FVR-30 5.5<KW≤11 3.5*35 RELAY 63A 30/1 32A
FVNR-30HD (46,50,49,50N,51L/R,2)

FVNR-60 MOTOR PROTECTION 60/1

FVR-60 11<KW≤22 3.5*70 RELAY 100A (See 63A
FVNR-60HD (46,50,49,50N,51L/R,2) note1)

FVNR-100 MOTOR PROTECTION 100/1

FVR-100 22<KW≤45 3.5*150 RELAY 125A (See 100A
FVNR-100HD (46,50,49,50N,51L/R,2) note1)

FVNR-150 MOTOR PROTECTION 150/1

FVR-150 45< KW ≤55 3.5*185 RELAY 160A (See 150A
FVNR-150HD (46,50,49,50N,51L/R,2) note1)

MOTOR PROTECTION
ACB FEEDER 55< KW ≤160 2*3.5*185 RELAY ACB
(46,50,49,50N,51L/R,2)

MCCB WITH O/C & S/C

MCCB 3.5*50 - 32A -
PROTECTION – 32A

MCCB WITH O/C & S/C

MCCB 3.5*70 - 63A -
PROTECTION – 63A

MCCB WITH O/C & S/C

MCCB 3.5*120 - 100A -
PROTECTION – 100A

MCCB WITH SHUNT TRIP,

O/C, S/C & E/F RELEASES MCCB 2*3.5*120 125A - -
– 125A

MCCB WITH SHUNT TRIP,

O/C, S/C & E/F RELEASES MCCB 2*3.5*185 160A - -
– 160A

MCCB WITH SHUNT TRIP,

O/C, S/C & E/F RELEASES MCCB 2*3.5*300 250A 250/1 -
– 250A

MCCB WITH SHUNT TRIP,

O/C, S/C & E/F RELEASES MCCB 3*3.5*300 400A 400/1 -
– 400A

MCCB WITH O/C, S/C MCCB +

PROTECTION AND 3.5*50 32A 32A
CONTACTOR –32A CONTACTOR

MCCB WITH O/C, S/C MCCB +

PROTECTION AND 3.5*70 63A 63
CONTACTOR – 63A CONTACTOR

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 452 OF 1216

 DATA SHEET FOR MEDIUM VOLTAGE SWITCHBOARD COMPONENTS
COMPONENT RATING (A)
MOTOR
FEEDER TYPE RATING MAX
CABLE CT CONTACTOR
KW MPR MCCB
SIZE RATIO (AC3)

MCCB WITH O/C, S/C MCCB +

PROTECTION AND 3.5*120 100A 100A
CONTACTOR – 100A CONTACTOR

MCCB WITH SHUNT TRIP, MCCB +

O/C, S/C, E/F RELEASE 2*3.5*120 - 125A - 125A
AND CONTACTOR – 125A CONTACTOR

MCCB WITH SHUNT TRIP, MCCB +

O/C, S/C, E/F RELEASE 2*3.5*185 - 160A - 160A
AND CONTACTOR – 160A CONTACTOR

MCCB WITH SHUNT TRIP, MCCB +

O/C, S/C, E/F RELEASE 2*3.5*300 - 250A 250/1 250A
AND CONTACTOR – 250A CONTACTOR

MCCB WITH SHUNT TRIP, MCCB +

O/C, S/C, E/F RELEASE 3*3.5*300 - 400A 400/1 400
AND CONTACTOR – 400A CONTACTOR

NOTES:
1. TYPICAL MCCB RATINGS ARE SPECIFIED ABOVE, FINAL MCCB RATINGS SHALL BE
SELECTED BY THE MANUFACTURER MEETING THE TYPE-2 CO-ORDINATION AS PER IS-
13947.
2. CT FOR METERING SHALL BE PROVIDED AS PER SLD.
3. MAJOR COMPONENTS ARE SHOWN ABOVE, ALL OTHER ITEMS AS SPECIFIED IN
EQUIPMENT DATA SHEET AND SPECIFICATION 6-51-0018 SHALL ALSO BE IN VENDOR’S
SCOPE.
4. NUMERICAL RELAY (MPR) SHALL BE PROVIDED FOR ALL ACB AND MCCB MOTOR FEEDERS.
5. MPR FOR MOTOR FEEDERS UPTO 55 KW (FED FROM MCC) SHALL BE OF LOWER VERSION
HAVING BASIC PROTECTION MENTIONED ABOVE AND OF COMPACT SIZE.
6. NO. OF CORES OF CABLE FOR MOTOR FEEDER SHALL BE 3.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 453 OF 1216

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VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 463 OF 1216
 Datasheet No.
MEDIUM VOLTAGE SQUIRREL CAGE B047-003-16-50-DS-0021
INDUCTION MOTOR Rev : A
Page 1 of 1
PURCHASER's DATA
A. Site conditions
1 Ambient temp., minimum(outdoor): -22 °C 3 Atmospheric condition: Cold Desert
minimum(indoor): -5 °C 4 Altitude: 3515m
maximum: 35 °C 5 Location: Leh, J&K
design: 40 °C
2 Relative humidity: 30-100 %
B. Technical particulars
1 Motor tag no.: Refer Elsewhere
2 Driven equipment name:
3 Voltage: 415 V ±10% 16 Hazardous area classification: Note-2
4 Phase: Three 17 Gas group: Note-2
5 Frequency: 50 Hz ±3% 18 Type of explosion protection: N/A
6 Fault level: 50 kA 19 Type of ingress protection: IP 55
7 Method of starting: DOL/ Soft-starter/ VFD 20 Color shade: 632 as per IS 5
8 Winding connection: Delta 21 Thermisters: Required Not required
9 No.of terminals: 3 22 RTD: Required Not required
10 Cable size: Later mm² 23 BTD: Required Not required
11 Cable type: AYFY 24 RTD/BTD monitoring device: Required
12 Temperature rise: 80 °C Not required
13 Cooling: IC411 Efficiency Class: IE-3 Type as per IS: 12615
14 Insulation class: F with temp rise class limited to B 25 Applicable specification: 6-51-0064
15 26
DRIVEN EQUIPMENT MANUFACTURER's DATA
1 Suggested motor rating: kW 9 Torque required, starting: mkg
2 Manufacturer: maximum: mkg
3 BkW at full load: kW 10 GD2 of eqpt., including flywheel: kgm2
4 kW at end of curve: kW excluding flywheel: kgm2
5 Speed: RPM 11 Thrust, up: kg
6 Rotation viewed from coupling end: down: kg
7 Driven equipment: 12 Starting condition:
8 Coupling type:
MOTOR MANUFACTURER's DATA
1 Rating: kW 16 Space heater - voltage & power:
2 Manufacturer: 17 Efficiency at, 75% Load: %
3 No. of poles: 100% Load: %
4 Frame designation: 18 Power factor at, 75% Load:
5 Full load speed: RPM 100% load:
6 Mounting: 19 Moment of inertia, GD2: kgm2
7 Full load torque (FLT): mkg 20 NDE bearing type & no.:
8 Starting torque: % of FLT 21 DE bearing type & no.:
9 Break down or pull out torque: % 22 Type of lubrication:
10 Full load current (FLC): A 23 Weight of motor: kg
11 Starting current at 100% voltage: % of FLC 24 Thermisters, quantity: no.
12 Rotation viewed from coupling end: make: type:
13 Starting time at, 75% voltage: sec. 25 RTD, quantity: no.
100% voltage: sec. make: type:
14 Locked rotor withstand time (cold/hot) at, 26 BTD, quantity: no.
75% voltage: sec. make: type:
100% voltage: sec. 27 Shaft voltage: V
15 Time (Te) for Increased Safety motors sec. 28 Critical speed, 1st/2nd stage: RPM
at 100% Voltage 29 Canopy: Required Not required
1. Starting time calculations shall be based on operating conditions specified on Material Requisition eg. open valve ccondition/
closed valve condition, at no load/full load, as applicable.
2. All the motors shall be suitable SAFE area except for Diesel pumps where the Motor shall be flameproof suitable for Zone IIA/IIB, T3.

A 08.05.2018 ISSUED WITH TENDER RR DR VKJ

Rev. No. Date Purpose Prepared by Checked by Approved by
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 464 OF 1216
 Datasheet No.
NUMERICAL RELAY AND DATA B047-003-16-50-DS-0022
CONCENTRATOR Rev. A

Rev. Date Purpose Prepared Checked Approved

A 08.05.2018 ISSUED WITH TENDER RR DR VKJ

PURCHASER'S DATA
A PROJECT DATA TICK FOR SELECTION
1 Project details 2 SITE CONDITIONS
a Project : Leh Airport a Ambient tempeature (°C)
b Client : M/S AAI MIN -5(Indoor) MAX 35 Design 40
c Location : Leh, J&K b Humidity (%) : 30-100
d Unit : c Altitude Above MSL : 3515m
d Atmospheric condtion : Cold desert
e Installation : Indoor inside pnl

B RELAY SELECTION TICK FOR SELECTION

1 RELAY FUNCTIONS 4 INPUT POWER SUPPLY
a Only Protection a Site selectable feature
b Protection and metering b Input supply : 110V DC
c Protection and metering and control :
d Serial commuication :
e Password protection
a. For write
b. For both read and write
2 CONSTRUCTION FEATURE 5 CT/ PT INPUT TO RELAY
a Enclosure type : IP5X a Current operated relays
b Terminal size- sqmm : 2.5 for control a1 Main CT input :
for external wires : 4 for CT/ PT a2 CT for sensitive EF :
c Mounting : Flush or back up EF
d Drawout feature : as per SPEC. b Voltage operated relays
e Display type : AlphaNumeric LCD b1 PT input :
+ LED Indication
3 SPECIAL REQUIREMENT IF ANY c Comprehensive relay
a Applicable standards: IEC c1 Main CT input : 3 CTs, 4wire
b Distance for cable capacitance up to 1000 m c2 PT input : 3phase, 4wire
for application where field contacts are c3 CT for sensitive EF : 1 CT, 2 wire input
directly wired to relay e.g. Motor start/ stop or back up EF (Yes for IC& TR FDR)
d CT Secondary current : 5A for Protection CT
1A for Metering CT
C RELAY PROTECTION/ METERING FUNCTIONS TICK FOR SELECTION
(where no check box is shown, the requirement is minimum but not limited. Refer SWBD data sht for fdr wise protection)
1 Curernt operated relays R e q u i re d
T PN N o t re q u i re
SPN
d
2 Voltage operated relays
a. 3 phase O/C element (50, 51) a. 3 phase O/V element with time delay (59+2)
* I> * I >> * I>>> * OV> * OV>>
Characteristics as per IEC
* Inverse (normal, very, extremely, long) b. 3 phase U/V element with time delay (27+2)
and definite time for I > and I >> * UV> * UV>>
* Definite time for I >>> Characteristics as per IEC
* Inverse (normal, very, extremely, long)
b. E/F relay (50N, 51N, 51G) and definite time for UV > , UV>>
* IO > * IO >> * IO >>> c. Under/ Over Frequency element with time delay
Characteristics as per IEC (81U/ 81O)
* Inverse (normal, very, extremely, long) * Settable under voltage restraint
and definite time for I O >, I O >> * df/dt element
* Definite time for I O >>> * Number of stages with u/f
* Number of stages with df/dt
c. Metering/ event recording d. Synchrocheck function
* 3 phase/ line currents e. Metering/ event recording
* Disturbance record * 3 phase/ line Voltages
* Breaker trip/ close status * Disturbance record
* Relay faults * Breaker trip/ close status
* Trip Values * Relay faults
* Trip Values

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 465 OF 1216

 Datasheet No.
NUMERICAL RELAY AND DATA B047-003-16-50-DS-0022
CONCENTRATOR Rev. A

C RELAY PROTECTION/ METERING FUNCTIONS TICK FOR SELECTION

(where no check box is shown, the requirement is minimum but not limited. Refer SWBD data sht for fdr wise protection)
3 Motor Protection relay NA 5 Special protection relays
a. Protection elements * Part of main relay
* Thermal overload (49) * Separate relay
OC protection with doubling
* feature(50) a. Differential relays
* EF protection (50N) * BUS High/Low Imp, vendor to select
* Locked Rotor protection * Feeder High/Low Imp, vendor to select
* Maximum start time * Trafo With harmonic restraint
* Maximum number of starts * Machine Biased differential
* Negative phase sequence b. Distance relays (67, 67N)
* Under voltage delayed trip c. Restricted EF (64R) *
* EF Through CBCT d. Generator protection
* Single phasing e. Distance protection
b. Metering/ events f. Reverse power relay
* 3 phase/ line current
* Hour run 6 Other relay Features
* KW, KWH, pf a. Analog inputs 4-20mA
* Disturbance record * RTD/ BTD-MPR NOT REQD
* Plot start characteristic * WTI/ OTI-Trafo relay NOT REQD
* Trip values
* Start time WTI= Winding temperature indicator
* Start current OTI= Oil temperature indicator
c. Control
* Breaker close in test mode b. Out put relays
* Reacceleartion logic * Number of relays As required
* Breaker trip * Contact rating 2A, 110V DC
* RTD/BTD input * Reset Hand reset
FUNCTIONS part of numerical relay
4 Comprehensive numerical relay c. Lock out function (86)
a. Current op elements d. Trip circuit supervision(95)
(51, 50, 51N, 50N, 51G) e. Watch dog
b. Voltage op elements (59, 27, 2, 81U, 81O) f. Time stamp
c. Control function g. Modular construction
* Breaker close/ trip from relay for easy and quick replacement
* Breaker close/ trip on serial of faulty PCB/circuit
* PLC logic function for control scheme
* Digital I/P As per Spec. * 64R Relay can be combined with numerical relay for
transformer differential protection.
* Motor Feeder control function

D SERIAL COMMUNICATION AND RELAY INTEGRATION TICK FOR SELECTION

1 Relay integration 3 Redundancy requirement for DC/MMI
a Communication ports at Relay a Ports at Etherswitchs
* Relay front : RS 232/RJ45 * For each relay Non Redundant
* Relay back : During Detail Engineering * For DC Redundant
b Protocol : IEC 61850 b Data concentrator (DC)
of relay LAN * Power supply card Redundant
c Requirment of data concentrator (DC) * Communication port for Redundant
* Integraton through DC each relay LAN
* Directly to MMI * Communication Processor Redundant
d Topology Vendor to decide
e Data concentrators Separate for HV system
Separate for MV system 4 Serial communication from DC to MMI/ ECS RTU
(Refer system Architecture) a DC to MMI
2 Redundancy * Topology Vendor to decide
a Relay LAN /serial * Protocol Vendor to decide
* Redundant b DC to DCS Modbus- RTU Protocol
* Non redundant DC to CMS IEC-104
b From DC to MMI DC to upper level During Detail Engineering
system
* Redundant c Scan time As per spec.
* Non redundant 5 Other requirement
c From DC to ECS-RTU a Time synchronization Detail during engg
* Redundant b Remote relay parameterization
* Non redundant c Annunciation at MMI

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 466 OF 1216

 Datasheet No.
NUMERICAL RELAY AND DATA B047-003-16-50-DS-0022
CONCENTRATOR Rev. A

MANUFACTURER'S DATA
1 NUMERICAL RELAYS TYPES
Feeder type INCOMER BUS PT BUS TIE MOTOR TRANSFORMER MOTOR
Main relay
*Indicate equivalent
NEMA no. of element
offered inMainRelay
* lockout feature 86
* trip ckt sup 95
Relay selection

* relay model & extra

element for syn mot
Differential relay
CT circuit supervision
REF relay
Direction relay
Reverse Power
Impedance relay
* 86 with all special
protection relays
RS232
Nos of Serial

RS485
RS422
Port

FO

RTD -PT100
Analog input

BTD- PT100
WTI input
OTI input

* DI used by MFR
Nos of DI

* DI avaialble for
customer interlock
* DI for auto C/O logic
* Main relay
* Special relays
Protocol

* Protocol for relay

setting from remote
Any other data
REMARKS

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 467 OF 1216

 Datasheet No.
NUMERICAL RELAY AND DATA B047-003-16-50-DS-0022
CONCENTRATOR Rev. A

2 DATA CONCENTRATOR AND RELAY INTEGRATION

a Model no. g Serial Interface -ECS-RTU
Make * Topology
* Protocol
b Input power supply * Type of Port
* Voltage * Cable type
* Power reqt
h Number of Digital Input/ Aanalog Input (4-20mA)
c Redundancy * DI for substation eqpt
* Power supply * Spare DI
* Communication processor * AI as per project data sht
* Communication port * Spare AI
* Relay LAN /Serial communic
* ECS-RTU interface I Maximum Scan Time
* MMI interface * Status
* events
d Serial interface/ Relay LAN * Data acqusition (analog)
* Topology * Disturbance record download time
* Protocol j Other features
Nos o* * Spare capacity for
* Topology additional devices for
relay LAN
* Type of port * Time synchronization
* Cable type options
* Power walk in time
f Serial interface- MMI * Restoration time of communication of DC with NR & MMI
* Topology *After detecting break in serial loop
* Protocol *After switchover of supply from normal to reduandant
* Type of Port *After failure of normal & reduandant supply&restoration
* Cable type of same
*Time required for synchronisation with external
clock

3 Standard features of relay/ system architecture

Vendor to provide data as applicable for the product offered

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 468 OF 1216

 Datasheet No.
B047-003-16-50-DS-0023
DATA SHEET HV CABLE
Rev : A
Page 1 of 1
PURCHASER'S DATA
Project Leh Airport Location Leh
Client M/S AAI Unit
A Site conditions
1 Maximum ambient temperature: 35.0 °C 4 Relative humidity: 30-100 %
2 Minimum ambient temperature (Outdoor): -22 °C 5 Altitude (above MSL) 3515m
Minimum ambient temperature (Indoor): -5 °C
3 Ground temperature: °C 6 Environment: Cold desert

B Technical particulars
1 System voltage 3 Conductor material
Nominal Highest Voltage grade HV Power cable (33KV(E))
415 V 500 V 650/1100V HV Power cable (11KV(UE)) Aluminium
3.3kV(E) 3.6 kV 1.9/3.3kV MV control cable
3.3kV(UE) 3.6 kV 3.3/3.3kV
6.6kV(E) 7.2 kV 3.8/6.6kV 4 Insulation XLPE
6.6kV(UE) 7.2 kV 6.6/6.6kV
11kV(E) 12 kV 6.35/11kV 5 Applicable spec. 6-51-0051
11kV(UE) 12 kV 11/11kV
22kV(E) 24 kV 12.7/22kV
33kV(E) 36 kV 19/33kV
2 Frequency 50 Hz ± 3%

MANUFACTURER'S DATA
1 Name of manufacturer 9 Inner sheath
2 MR/PR item no. Type of compound
3 Cable type/ code Thickness mm
4 Conductor material 10 Nominal dia under armour mm
5 Conductor semiconducting screen (HV cables) 11 Calculated dia under armour mm
Material 12 Armour
Thickness mm Material
6 Insulation Type
Type of compound Size
Thickness mm 13 Nominal dia under outersheath mm
7 Insulation semiconducting screen (HV cables) 14 Calculated dia under outersheath mm
Material 15 Outersheath
Thickness mm Type of compound
8 Copper tape Thickness mm
Thickness mm 16 Nominal outer dia of cable mm
17 Tolerance on outer dia %
18 Weight of cable per km kg
19 Maximum drum length mtr.
Notes
1 Single line to ground fault current (applicable for HV cables) for sizing of insulation screening shall be as under :

Item no. Voltage grade Current value Duration(sec)

11 25 kA 3s

2 E- Earthed system
UE-Un Earthed system

3 Vendor to provide calculation for conducting screen.

A 08.05.2018 ISSUED WITH TENDER RR DR VKJ

Rev. No. Date Purpose Prepared by Checked by Approved by

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 469 OF 1216

 Datasheet No.
B047-003-16-50-DS-0024
DATA SHEET (ELECTRICAL) MV CABLE
Rev : A
Page 1 of 1
PURCHASER'S DATA
A Site conditions
1 Maximum ambient temperature: 40.0 °C 4 Relative humidity: 30- 100 %
2 Minimum ambient temperature (Outdoor): -22 °C 5 Altitude (Above MSL) 3515m
Minimum ambient temperature (Indoor): -5 °C
3 Ground temperature: °C 6 Environment: Cold Desert

B Technical particulars
1 System voltage 3 Conductor material
Nominal Highest Voltage grade HV Power cable NA
415 V 500 V 650/1100V MV Power cable Copper & Alu
3.3kV(E) 3.6 kV 1.9/3.3kV MV control cable Copper
3.3kV(UE) 3.6 kV 3.3/3.3kV
6.6kV(E) 7.2 kV 3.8/6.6kV 4 Installation under DGMS jurisdiction No
6.6kV(UE) 7.2 kV 6.6/6.6kV (See note-3)
11kV(E) 12 kV 6.35/11kV 5 Applicable spec. IS/IEC
11kV(UE) 12 kV 11/11kV
22kV(E) 24 kV 12.7/22kV
33kV(E) 36 kV 19/33kV
2 Frequency 50 Hz ± 3%

MANUFACTURER'S DATA
1 Name of manufacturer 9 Inner sheath
2 MR/PR item no. Type of compound
3 Cable type/ code Thickness mm
4 Conductor material 10 Nominal dia under armour mm
5 Conductor semiconducting screen (HV cables) 11 Calculated dia under armour mm
Material 12 Armour
Thickness mm Material
6 Insulation Type
Type of compound Size
Thickness mm 13 Nominal dia under outersheath mm
7 Insulation semiconducting screen (HV cables) 14 Calculated dia under outersheath mm
Material 15 Outersheath
Thickness mm Type of compound
8 Copper tape Thickness mm
Thickness mm 16 Nominal outer dia of cable mm
17 Tolerance on outer dia %
18 Weight of cable per km kg
19 Maximum drum length mtr.
Notes
1 Single line to ground fault current (applicable for HV cables) for sizing of insulation screening shall be as under :

MR/PR Item no. Voltage grade Current value (kA) Duration(sec)

2 E- Earthed system
UE-Un Earthed system
3 Where the installation falls under the jurisdiction of Directorate General of Mines Safety, cables shall comply
4 For MV Power cables, all cables upto 16 sq.mm shall be with Copper conductor.

A 08.05.2018 ISSUED WITH TENDER RR DR VKJ

Rev. No. Date Purpose Prepared by Checked by Approved by

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 470 OF 1216

 Datasheet No.
DATA SHEET B047-003-16-50-DS-0025
DISTRIBUTION TRANSFORMER Rev : A
Page 1 of 2

PURCHASER'S DATA
A Site conditions
1 Maximum ambient temperature: 35 °C 4 Relative humidity: 30-100 %
2 Minimum ambient temp. (Outdoor): -22 °C 5 Altitude above MSL: 3515m
Minimum ambient temp. (Indoor): -5 °C
3 Design ambient temperature: 40 °C 6 Environment: Cold Desert
B Technical particulars
1 Tag no.: TR-01/02/03 27 Explosion protection PRV

2 Duty: Continuous 28 Terminal location:

3 No. of windings: Two HV side Smaller side
4 Type of cooling: ONAN LV w.r.t HV 90°
5 Rated MVA 2.00 29 Terminal connection
6 Rated voltage HV side Cable box
HV winding 11 kV LV side Bus-duct
LV winding 0.433 kV 30 Cable size
1R x 3C x 150 sq mm AL
7 System earthing: HV side
ARMOURED XLPE 11KV (UE).

HV side Solidly earthed LV side Not Applicable

LV side Solidly earthed 31 Neutral CT specification:
1500/1A;
8 Rated frequency: 50 Hz ± 3% 51G
15VA,CL 5P10
9 No. of phases: Three 64R Not Applicable
10 Fault level on HV side: 25 kA, 3 sec Vk
11 Connection Im at Vk/2
HV side Delta RCT
LV side Star 32 Installation Outdoor
12 Vector group: Dyn11 33 Painting & colour Epoxy & shade 632 of IS - 5
13 Impedance at max. MVA: 6.25% 34 AC Auxiliary voltage 240 V ± 10% SPN
14 Insulation class: A 35 DC Auxiliary voltage 110 V ± 10% DC
15 Insulation level: 36 Bidirectional roller type Flat
P. f withstand 37 ¢ distance of flat rollers 1000 mm
HV winding 20 kV 38 Applicable specifications EIL std. 6-51-0041 ; IS1180
LV winding 39 Loss Capitalization Not applicable
16 Impulse withstand a Rate for copper loss Rs./kW:
HV winding 60 kVp b Rate for iron loss Rs./kW:
LV winding
17 Oil type Mineral (as per IEC-216) 40 Accessories requirement Following to be included
18 Winding insulation type: Uniform Sampling valve Yes
19 Clearance: Conservator drain valve Yes
Ph to Ph As per IS Top oil filter valve Yes
Ph to N As per IS Explosion vent/PRV Yes
20 Tap changer Air bag for conservator Yes
Location HV winding Dial type thermometer Yes
Type OLTC & contacts for OTI, WTI
Range +4.6% to -20.3% Drain cum bottom Yes
filter valve
No. of steps 1.56% per step Marshalling box (IP 55) Yes
21 Normal load: 30-40% Double float Buchholz Yes
22 Temp. rise at extreme tap See Note-4 Channels, towing lugs : Yes
having max. losses: Rollers Yes
oil 55°C [Note-6] Neutral bushing Yes
winding 50°C [Note-6] outside terminal box
23 Minimum Guaranteed efficiency See Note-2 with connector assembly
at 0.8 p.f at 40% of ONAN rating: Inspection cover Yes
24 Load at which max eff. occurs: as per IS-1180 Disconnecting chamber Yes
25 Power flow: Unidirectional WTI & OTI Yes
26 HV/LV phase sequence UVW/To suit switchgear Busduct flange on LV Yes
Lugs and cable glands Yes

A 08.05.2018 Issued With TENDER RR DR VKJ

Rev. No. Date Purpose Prepared by Checked by Approved by
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 471 OF 1216
 Datasheet No.
DATA SHEET DISTRIBUTION B047-003-16-50-DS-0025
TRANSFORMER Rev : A
Page 2 of 2
41 Tests requirements
Impulse test: Not required
Heat run test: Required
Vacuum test on tank: Required
Pressure test on tank: Required
Short circuit test: Not required

MANUFACTURER'S DATA
A Make:
B Performance: C Constructional Features
1 No load loss at 1 Location of terminals
100% Voltage; kW Primary
110% Voltage: kW Secondary
2 Full load copper loss at 75°C: kW 2 Location of Neutral CT
3 No load current at 3 Explosion protection PRV
100% Voltage: A
110% Voltage: A D Mechanical data (See Note-4)
4 Efficiency at full load at 75°C 1 Core & winding weight: Kgs.
at 0.8 p.f: % 2 Tank & fitting weight: Kgs.
at 1.0 p.f: % 3 Radiator without oil weight: Kgs.
5 Eff. at 50% load at 75°C 4 Total weight: Kgs.
at 0.8 p.f; % 5 Total quantity of oil: ltrs.
at 1.0 p.f: % 6 Quantity of oil in radiators: ltrs.
6 Maximum efficiency: 7 Overall dimensions: ltrs.
at 0.8 p.f: % Length mm
at 1.0 p.f: % Breadth mm
7 Load at which max eff. Occurs: Height mm
at 0.8 p.f: MVA
at 1.0 p.f: MVA
8 Regulation at 75°C
at 0.8 p.f: %
at 1.0 p.f: %
9 X1/R1 Ratio
X0/R0 Ratio
10 Zero sequence impedence, Z0
Note
1 Losses shall be inclusive of positive tolerance and shall be at nominal tap.
2 Minimum Guaranteed efficiency for transformers at 0.8 p.f & at 40% of ONAN rating shall be as per IS1180 and Gazette of
India order dated 16/12/2016.
3 Transducers for providing 4-20mA signal for OTI & WTI for owner's interface shall be provided.
4 Oil ; As per Gazette of India order dated 16/12/2016
Winding ; As per Gazette of India order dated 16/12/2017
5 All measurement of losses shall be carried out by using calibrated digital meters of class 0.5 or better accuracy and
certified by the manufacturer. All transformers would be equipped with additional metering class current transformers
(CTs) and potential transformers (PTs) additional to requirements of Utilities so that periodic loss monitoring study may be
carried out.
6 Temperature specified are applicable for altitude below 1000m altitude.
Vendor shall consider appropriate temperature de-rating for design of transformer as per site conditions.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 472 OF 1216

 DATA SHEET – MV V/F CONTROLLED SOFT STARTER
Part-I (Data to be filled in by purchaser)

1. Applicable standards : EIL spec. 6-51-0036 Rev 0

2. Rated output capacity (KW) : *
3. Rated Output voltage : 415 V
4. Motor Details
a) Drive System : Single
b) Motor tag no. : #
c) Type of motor : Squirrel Cage Induction motor
d) KW rating : *
e) Starting condition : Soft start
f) Frequency range : *
g) Voltage range : *
h) Full load current : *
i) Full load PF
- pf at lowest KW : *
- pf at Highest KW : *
j) Starting current : *
k) Load torque details : * (as per the requirement)

5. SITE CONDITIONS:
o o
a) Ambient temperature : Max. 48 C / Min.12 C
o
b) Design temperature : 40 C
c) Altitude : Less than 1000M
d) Installation : Indoor
e) Location : Indoor, Non Air Conditioned (Soft Starter shall
be designed for satisfactory operation in non air-conditioned atmosphere)

6. INPUT POWER SUPPLY SYSTEM CONDITIONS

a) No. of phases : 3
b) AC input voltage : 415 kV
c) Voltage fluctuation : ± 10 %
d) Rated frequency : 50 Hz
e) Frequency fluctuation : ± 3%
f) System fault level : 50 kA for 1 second
7. SYSTEM REQUIREMENTS
a) Speed range required : * (as per the requirement)
b) Adjustment of speed : * (as per the requirement)
c) Speed Reference by measurement of : *
the stator voltage frequency through
voltage transformer
d) Reference Signal : 4 - 20 mA (from PLC)
e) By pass Breaker/Contactor : required
f) Starting Current : 200%-250%
g) Acceleration time : *

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 473 OF 1216

 Deceleration time : *
h) Fault diagnostic : Not Required
i) Braking : Not required
j) Regeneration : Not required
k) Cable length between client’s Swbd and V/F controlled soft starter: 50
l) Cable length between V/F controlled soft starter and Motor : 50
m) Cable length between V/F controlled soft starter and PLC : 100
n) Communication facility with data : Required
concentrator on open protocol
p) Separate PE Conductor between SOFT STARTER & Motor : Not Envisaged

* - Data to be provided by vendor/equipment supplier

Note:
1. RS-485 serial port shall be provided for communication to PLC over Modbus TCP/IP.
2. Any special cable required between Soft Starter and motor including encoder cable shall be in
Soft Starter vendor’s scope.
3. Cable Interface document is to be submitted by the vendor.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 474 OF 1216

 PART-II (to be filled in by vendor and submitted with bid)
1. Make :
2. Model No. :
3. Rating :
4. Applicable code/standards :
5. Speed range :
6. Speed reference :
7. Input power supply ratings
a) Voltage : ± %
b) Frequency : ± %
8. Overload capability
a) 125% : minutes
b) 150% : secs.
c) Inrush current 250% I n for : secs.
9. Overall efficiency at
a) 100% load :
b) 75% load :
c) 50% load :
d) 25% load :
10. Overall power factor at
a) 100% load :
b) 75% load :
c) 50% load :
d) 25% load :
11. AC Output
a) Output voltage range :
b) Voltage accuracy :
c) Frequency range :
d) Frequency accuracy :
12. Transient voltage
a) fluctuation ratio :
b) Its recovery time :
13. Transient Torque
13.1 Max. Transient air gap torque/duration :
13.2 Max. Transient torque/duration :
Same shall be furnished at the coupling of V/F controlled soft starter, accounting for the motor and the
driven equipment in the case of a two and a three phase short-circuit at the motor terminal.
14. Wave form distortion factor (% harmonics) in output/
Input waveform :
(Number of harmonics and magnitude of each harmonic generated shall be furnished).
15. Output short circuit capability and duration :
16. Deration of motor at
a) Maximum speed :
b) Minimum speed :

17. Rectifier/Inverter
a) Make :
b) Type/Model No. :
c) Diodes/GTOs configuration :
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 475 OF 1216
 d) Total No. of Diodes/GTOs :
e) Cooling system
- Type :
- Redundancy in cooling Units :
f) Type of feedback for speed control :

18. DC Reactor
a) Make :
b) Type :
c) Rating :
d) Inductance of the reactor :
e) Air Core/Iron Core :
f) Efficiency :

19. Output Filter

a) Make :
b) Type / Model No. :
c) Rating :
d) Rated Voltage :

20. Output Power Isolating Device

a) Make :
b) Type :
c) Model No. :
d) Cont. Current Rating :
e) Short Circuit Rating :
f) Rated Voltage :
g) Applicable Standard :
h) Panel details
- Overall Length :
- Height :
- Depth :
- Degree of protection :

21. Main Transformer

a) Make :
b) Type of Transformer : Dry Type
c) KVA Rating :
d) Voltage ratio :
e) Vector group :
f) Impedance :
g) Overall dimension :
(LxBxH)

22. V/F CONTROLLED SOFT STARTER PANEL DETAILS

a) Overall Length :
b) Height :
c) Depth :
d) Weight of cubicle :
(Dimensional details of all panels shall be furnished)
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 476 OF 1216
 e) Degree of protection for enclosure. :
f) Paint shade :
g) Heat output of Panel :
h) Type of cooling :

23. Auxiliary Power Requirement:

a) KW :
b) Voltage :

24. LCS/LCP required as per spec : Yes

25. Requirement of earthing cable between :

motor & drive

26. Address of Manufacturing Location :

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 477 OF 1216

 a) All inte Datasheet No.
DATA SHEET B047-003-16-50-DS-0027
UPS SYSTEM (250KVA) Rev.No. A
Page 1 of 3

PURCHASER'S DATA
A Project details
1 Project name Leh Airport 3 Client M/S AAI
2 Location Leh, J&K 4 Unit
B Site conditions
1 Ambient temperature, 3 Altitude Above MSL : 3515m
- Maximum : 35 °C 4 Atmospheric condition : Cold Desert
- Minimum (outdoor): -22 °C 5 Location : Indoor- in airconditioned room
- Minimum (indoor): -5 °C
- Design : 40 °C 6 Applicable EIL specification 6-51-0017
2 Design temperature for battery sizing 10 °C 6-51-0048
C Input power supply
1 Voltage : 415V ±10% 3 Phase : TPN SPN
2 Frequency : 50Hz ±3% 4 System fault level : 50kA
D System requirements
1 Equipment tag no.: 11 Type of battery : VRLA
2 Type of inverter: Transistorised 12 Battery backup time : 30 mins.
3 Rating : 250 kVA(0.8 P.F.) Description kVA Backup time (mins.)
4 Phase : TPN SPN Instrumentation 30 mins.
5 Output voltage : 415V ±1% Telecom N/A
6 Output frequency : 50Hz ±1% PA system N/A
7 Mode of operation : Parallel redundant Lighting N/A
8 Load power factor, 13 Battery rack information : See Note-2
- Rated : 0.8 (lag) 14 Ingress protection of enclosure : IP 42
- Variation : 0.6-1.0 (lag) 15 Cable entry : Top Cable Entry LATER
9 Fault diagnostic unit : Required Not required 16 Colour shade : RAL 7032
10 Cell booster Required Not required
E AC distribution board (Outgoing feeder details)
1 Item no. Incomer rating No. of outgoing kVA rating of feeders Switch rating Fuse rating
as per MR (Amp.) feeders (Amp.) (Amp.)

Refer Elsewhere

2 Mounting of ACDB : Floor mounted 3 Type of ACDB Compartmentalised (fixed)

F Specific requirements
a) All interconnecting cables between all panels of UPS system are included in vendor's scope.
b) ECS Interface
Normally Open (NO) potential free contacts shall be wired upto terminal strip for connection by
purchaser to ECS interface, for the following conditions:
- Charger Failure - Battery Discharged
- Inverter Failure - Battery Isolated

Notes:
1 UPS battery bank shall be rated for 100 % of the UPS capacity.
2 The different type of battery rack formation that can be used are:
Double row double tier/Single row double tier/ Stepped arrangement.
3 UPS shall be suitable to provide data to BMS for fault-diagonoistic of UPS.
4 UPS shall meet the requirements of ECBC.

A 08.05.2018 ISSUED WITH TENDER RR DR VKJ

Rev. Date Purpose Prepared Checked Approved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 478 OF 1216

 Datasheet No.
a) All inte DATA SHEET B047-003-16-50-DS-0027
UPS SYSTEM Rev.No. A
Page 2 of 3

MANUFACTURER'S DATA
A UPS system
1 Make : 9 Noise level :
2 Type designation : 10 Guaranteed overall dimensions of UPS system
3 Rating : kVA at 0.8 p.f. except ACDB and battery,
4 Mode of operation : Altitude Above MSL : Length: mm
5 Output voltage distortion under the following c 35 - Depth: mm
- Minimum (outdoor): V± % - Height: mm
- Minimum (indoor): -5
- For 100% step load : V± % 11 Efficiency of each rectifier and inverter module
- For 100% step unload : V± % including input and output transformer
- Power supply interruption and - At 100% load : %
restoration : V± % - At 75% load : %
- Load transferred to bypass line : V± % - At 50% load : %
- When one inverter gets faulty and load - At no load : %
transferred to healthy inverter : V± % 12 Efficiency of bypass stabiliser including input
6 Phase angle distortion under the following conditions, transformer,
(for three phase inverter only) - At 100% load : %
- For 50% step load : 120°± % - At 75% load : %
- For 100% step load : 120°± % - At 50% load : %
- For 100% step unload : 120°± % - At no load : %
- Power supply interruption and 13 Heat loss for the total system : kW
restoration : 120°± % 14 Overall efficiency of UPS system (ratio of output
- Load transferred to bypass line : 120°± % load to input power drawn from mains when all
- When one inverter gets faulty and load charger and invTop Cable Entry
transferred to healthy inverter : 120°± % with bypass, operating at no load),
7 Maximum recovery time to reach steady state after - At 100% load : %
above disturbances (clause nos. 5 & 6) : milli sec. - At 75% load : %
8 Redundancy of cooling system : - At 50% load : %
B Inverter - At no load : %
1 Rating : kVA 10 Short circuit capacity & duration :
2 No. of phase(s) : 11 Output voltage/phase angles (for 3 phase only),
3 Refer Elsewhere deg.
- Nominal : V - For 40% unbalance load : V/ deg.
- Variation : V - For 50% unbalance load : V/ deg.
4 Output voltage adjustment range - For 100% unbalance load : V/ deg.
at rated load : 12 Type of control circuit :
5 Input DC voltage, 13 Max. allowable rating of outgoing feeders for fault
- Nominal : V clearance of feeder fault by UPS with mains bypass
- Range : V supply back up,
6 Frequency variation limit for inverter - With fast acting
when phase locked with mains : semiconducting fuses : amps.
7 Allowable unbalance between phases : - With normal HRC fuses : amps.
(for 3 phase only) 14 Max. allowable rating of outgoing feeders for fault
8 Harmonic distortion at inverter output at rated load, clearance of feeder fault by UPS without mains
- For linear load: bypass supply back up,
- For non linear load: - With fast acting
9 Overload capacity & duration : semiconducting fuses : amps.
- For 110% load: min. - With normal HRC fuses : amps.
- For 125% load: min. 15 Load Crest factor
- For 150% load: sec.
C Static switches
1 No. of static switches in the UPS system : 3 Type of static switch :
2 Current rating at specified ambient, 4 Transfer time,
3 UPS shall be suitable to provide data to BMS A - Synchronised mode : milli sec.
4 UPS shall meet the requirements of ECBC. A - Unsynchronised mode : milli sec.
D Battery charger
1 Current rating : A 3 Output voltage range under,
2 Type 08.05.2018 - Float charging condition : V
- Boost charging condition : V
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 a) All inte Datasheet No.
DATA SHEET B047-003-16-50-DS-0027
UPS SYSTEM Rev.No. A
Page 3 of 3

4 Output voltage accuracy under specified input 6 Maximum harmonic content in

5 Maximum ripple content on DC side with battery, input current :
- Connected : 7 Input transformer rating : kVA
- Disconnected :
E Manual transfer devices
1 Make : 3 Altitude Above MSL :
2 Type designation : 35 - Continuous :
Minimum (outdoor): - Short time :
Minimum (indoor): -5
F Battery
1 Make : 11 Overall rack dimension
2 Type designation : - Length : mm
3 Type : - Depth : mm
4 AH rating : - Height : mm
5 End cell voltage : 12 Battery charging requirements,
6 Nominal Voltage : - Nominal voltage/cell : V
7 Boost charging time : hrs. - Float voltage/cell : V
8 No. of cells in each bank : - Boost charging voltage/cell : V
9 No. of battery banks : 13 Container type :
10 No. of racks : 14 No. of recommended air changes/hour
for battery room : m3
G Stepdown bypass transformer with solid state voltage stabiliser
1 Make : 5 Accuracy of stabiliser : %
2 Type designation : 6 Type of control :
3 Rating : kVA 7 Type of cooling Top Cable Entry
4 Voltage ratio : V 8 Type of stabiliser :
H AC distribution board
1 Make : 5 Overall dimensions,
2 Type designation : - Length mm
3 Rating : A - Depth mm
4 Degree of protection - Height mm
5 No. of outgoing Feeder / rating of each ( Including max. & min operating Height )
I Refer Elsewhere
1 Make : 5 Overall dimensions,
2 Type designation : - Length mm
3 Voltage range : - Depth mm
4 Current range : - Height mm
J Reliability
1 Safety factor used for selecting the components, 2 MTBF/MTTR :
- Electronic devices : 3 Availability factor :
- Electrical devices :

3 UPS shall be suitable to provide data to BMS for fault-diagonoistic of UPS.

4 UPS shall meet the requirements of ECBC.

08.05.2018
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 480 OF 1216
 a) All inte Datasheet No.
DATA SHEET B047-003-16-50-DS-0028
UPS SYSTEM (30KVA) Rev.No. A
Page 1 of 3
PURCHASER'S DATA
A Project details
1 Project name Leh Airport 3 Client M/S AAI
2 Location Leh, J&K 4 Unit
B Site conditions
1 Ambient temperature, 3 Altitude Above MSL : 3515m
- Maximum : 35 °C 4 Atmospheric condition : Cold Desert
- Minimum (outdoor): -22 °C 5 Location : Indoor- in airconditioned room
- Minimum (indoor): -5 °C
- Design : 40 °C 6 Applicable EIL specification 6-51-0017
2 Design temperature for battery sizing 10 °C 6-51-0048
C Input power supply
1 Voltage : 415V ±10% 3 Phase : TPN SPN
2 Frequency : 50Hz ±3% 4 System fault level : 50kA
D System requirements
1 Equipment tag no.: 11 Type of battery : VRLA
2 Type of inverter: Transistorised 12 Battery backup time : 30 mins.
3 Rating : 30 kVA(0.8 P.F.) Description kVA Backup time (mins.)
4 Phase : TPN SPN Instrumentation N/A
5 Output voltage : 230V ±1% Telecom N/A
6 Output frequency : 50Hz ±1% PA system N/A
7 Mode of operation : Parallel redundant Lighting 30 mins.
8 Load power factor, 13 Battery rack information : See Note-2
- Rated : 0.8 (lag) 14 Ingress protection of enclosure : IP 42
- Variation : 0.6-1.0 (lag) 15 Cable entry : LATER
9 Fault diagnostic unit : Required Not required 16 Colour shade : RAL 7032
10 Cell booster Required Not required
E AC distribution board (Outgoing feeder details)
1 Item no. Incomer rating No. of outgoing kVA rating of feeders Switch rating Fuse rating
as per MR (Amp.) feeders (Amp.) (Amp.)

Refer Elsewhere

2 Mounting of ACDB : Floor mounted 3 Type of ACDB Compartmentalised (fixed)

F Specific requirements
a) All interconnecting cables between all panels of UPS system are included in vendor's scope.
b) ECS Interface
Normally Open (NO) potential free contacts shall be wired upto terminal strip for connection by
purchaser to ECS interface, for the following conditions:
- Charger Failure - Battery Discharged
- Inverter Failure - Battery Isolated

Notes:
1 UPS battery bank shall be rated for 100 % of the UPS capacity.
2 The different type of battery rack formation that can be used are:
Double row double tier/Single row double tier/ Stepped arrangement.
3 UPS shall be suitable to provide data to BMS for fault-diagonoistic of UPS.
4 UPS shall meet the requirements of ECBC.

A 08.05.2018 ISSUED WITH TENDER RR DR VKJ

Rev. Date Purpose Prepared Checked Approved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 481 OF 1216

 a) All inte Datasheet No.
DATA SHEET B047-003-16-50-DS-0028
UPS SYSTEM Rev.No. A
Page 2 of 3
MANUFACTURER'S DATA
A UPS system
1 Make : 9 Noise level :
2 Type designation : 10 Guaranteed overall dimensions of UPS system
3 Rating : kVA at 0.8 p.f. except ACDB and battery,
4 Mode of operation : Altitude Above MSL : Length: mm
5 Output voltage distortion under the following c 35 - Depth: mm
- For 50% step load : V± % - Height: mm
- For 100% step load : V± % 11 Efficiency of each rectifier and inverter module
- For 100% step unload : V± % including input and output transformer
- Power supply interruption and - At 100% load : %
restoration : V± % - At 75% load : %
- Load transferred to bypass line : V± % - At 50% load : %
- When one inverter gets faulty and load - At no load : %
transferred to healthy inverter : V± % 12 Efficiency of bypass stabiliser including input
6 Phase angle distortion under the following conditions, transformer,
(for three phase inverter only) - At 100% load : 30 %
- For 50% step load : 120°± % - At 75% load : %
- For 100% step load : 120°± % - At 50% load : %
- For 100% step unload : 120°± % - At no load : %
- Power supply interruption and 13 Heat loss for the total system : kW
restoration : 120°± % 14 Overall efficiency of UPS system (ratio of 30
- Load transferred to bypass line : 120°± % load to input power drawn from mains when all
- When one inverter gets faulty and load charger and inverters are on and synchronised
transferred to healthy inverter : 120°± % with bypass, operating at no load),
7 Maximum recovery time to reach steady state after - At 100% load : %
above disturbances (clause nos. 5 & 6) : milli sec. - At 75% load : %
8 Redundancy of cooling system : - At 50% load : %
B Inverter - At no load : %
1 Rating : kVA 10 Short circuit capacity & duration :
2 No. of phase(s) : 11 Output voltage/phase angles (for 3 phase only),
3 Steady state output voltage, - For 30% unbalance load : V/ deg.
- Nominal : V - For 40% unbalance load : V/ deg.
- Variation : V - For 50% unbalance load : V/ deg.
4 Output voltage adjustment range - For 100% unbalance load : V/ deg.
at rated load : 12 Type of control circuit :
5 Input DC voltage, 13 Max. allowable rating of outgoing feeders for fault
- Nominal : V clearance of feeder fault by UPS with mains bypass
- Range : V supply back up,
6 Frequency variation limit for inverter - With fast acting
when phase locked with mains : semiconducting fuses : amps.
7 Allowable unbalance between phases : - With normal HRC fuses : amps.
(for 3 phase only) 14 Max. allowable rating of outgoing feeders for fault
8 Harmonic distortion at inverter output at rated load, clearance of feeder fault by UPS without mains
- For linear load: bypass supply back up,
- For non linear load: - With fast acting
9 Overload capacity & duration : semiconducting fuses : amps.
- For 110% load: min. - With normal HRC fuses : amps.
- For 125% load: min. 15 Load Crest factor
- For 150% load: sec.
C Static switches
1 No. of static switches in the UPS system : 3 Type of static switch :
2 Current rating at specified ambient, 4 Transfer time,
- Continuous : A - Synchronised mode : milli sec.
3 UPS shall be suitable to provide data to BMS A - Unsynchronised mode : milli sec.
D 4 UPS shall meet the requirements of ECBC.
1 Current rating : A 3 Output voltage range under,
2 Type of charger : - Float charging condition : V
08.05.2018 - Boost charging condition : V
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 482 OF 1216
 a) All inte Datasheet No.
DATA SHEET B047-003-16-50-DS-0028
UPS SYSTEM Rev.No. A
Page 3 of 3
4 Output voltage accuracy under specified input 6 Maximum harmonic content in
5 Maximum ripple content on DC side with battery, input current :
- Connected : 7 Input transformer rating : kVA
- Disconnected :
E Manual transfer devices
1 Make : 3 Altitude Above MSL :
2 Type designation : 35 - Continuous :
- Short time :
F Battery
1 Make : 11 Overall rack dimension
2 Type designation : - Length : mm
3 Type : - Depth : mm
4 AH rating : - Height : mm
5 End cell voltage : 12 Battery charging requirements,
6 Nominal Voltage : - Nominal voltage/cell : V
7 Boost charging time : hrs. - Float voltage/cell : V
8 No. of cells in each bank : - Boost charging voltage/cell : 30 V
9 No. of battery banks : 13 Container type :
10 No. of racks : 14 No. of recommended air changes/hour
for battery room : m3
G Stepdown bypass transformer with solid state voltage stabiliser
1 Make : 5 Accuracy of stabiliser : 30 %
2 Type designation : 6 Type of control :
3 Rating : kVA 7 Type of cooling :
4 Voltage ratio : V 8 Type of stabiliser :
H AC distribution board
1 Make : 5 Overall dimensions,
2 Type designation : - Length mm
3 Rating : A - Depth mm
4 Degree of protection - Height mm
5 No. of outgoing Feeder / rating of each ( Including max. & min operating Height )
I Cell booster
1 Make : 5 Overall dimensions,
2 Type designation : - Length mm
3 Voltage range : - Depth mm
4 Current range : - Height mm
J Reliability
1 Safety factor used for selecting the components, 2 MTBF/MTTR :
- Electronic devices : 3 Availability factor :
- Electrical devices :

3 UPS shall be suitable to provide data to BMS for fault-diagonoistic of UPS.

4 UPS shall meet the requirements of ECBC.

08.05.2018
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 483 OF 1216
 DATA SHEET : PART - I
PURCHASER'S DATA

1. Reference standards : 6-51-0038, Rev.1

2. Rated output capacity : *
3. Motor Details
a) Drive system : Single
b) Type of motor : Squirrel cage induction motor
c) KW rating :
d) Starting condition : Through VFD (v/f type)
e) Frequency range : *
f) Voltage range : *
g) Full load current : *
h) Full load PF
AT lowest KW : *
AT Highest KW : *
i) Starting current : *
j) Load torque details : *
4. SITE CONDITIONS:
0 0 0
Ambient temperature : Max. 35 C / Min. Outdoor -22 C / Min. indoor -5 C
0
Design temperature : 40 C
Altitude Above MSL : 3515M
Installation : Indoor
Location :
5. INPUT POWER SUPPLY SYSTEM CONDITIONS
No. of phases : 3
AC input voltage : 415 V
Voltage fluctuation : ± 10%
Rated frequency : 50 Hz
Frequency fluctuation : ± 3%
System fault level : 50kA (Max) / 10kA (Min)
6. SYSTEM REQUIREMENTS
a) Speed range required : *
b) Adjustment of speed : Auto & Manual
c) Speed Reference by measurement of : *
the startor voltage frequency through
voltage transformer
d) Reference Signal : 4 - 20 mA.
e) By pass bkr. or starter : Not required
f) Acceleration time : *
Deceleration time : *
g) Short time voltage dip : *

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 484 OF 1216

 h) Harmonic limit on input : *
i) Fault diagnostic : Required
j) Braking : *
k) Regeneration : *
l) Cable length between swbd and VFD : *
n) Cable length between VFD and Motor : *
o) Cable length between VFD and DCS : *
p) Communication facility with Data : Required
Concentrator on open protocol :
q) Any other requirement :

* Data to be provided by Main equipment supplier

Note: Required de-rating in the equipment design/ rating shall be done by the bidder/ vendor as
per site conditions of LEH.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 485 OF 1216

 DATA SHEET : PART - II
TECHNICAL DATA FROM MANUFACTURER

1. Make / Model No. :

2. Rating :
3. Applicable code/standards :
4. Speed range :
5. Speed reference :
6. Input power supply ratings
Voltage : ± %
Frequency : ± %
7. Overload capability
a) 125% In for : minutes
b) 150% In for : secs.
c) Inrush current 250% In for : secs.
8. Overall efficiency at
a) 100% load :
b) 75% load :
c) 50% load :
d) 25% load :
9. Overall power factor at
a) 100% load :
b) 75% load :
c) 50% load :
d) 25% load :
10. AC Output
a) Output voltage :
b) Voltage accuracy :
c) Rated frequency range :
d) Frequency :
e) Voltage unbalance :
f) Field supply voltage :
g) Max. field current :
11. Transient voltage
a) fluctuation ratio :
b) Its recovery time :
12. Transient Torque
12.1 Max. Transient air gap torque/duration :
12.2 Max. Transient torque/duration :
Same shall be furnished at the coupling of VFDs, accounting for the motor and the driven equipment in
the case of a two and a three phase short-circuit at the motor terminal.
13. Wave form distortion factor (% harmonics) in output/
Input waveform :
(Number of harmonics and magnitude of each harmonic generated shall be furnished).
14. Output short circuit capability and duration. :

15. Deration of motor at

a) Maximum speed :
b) Minimum speed :

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 486 OF 1216

16. Permissible No. of starts
Hot : Uniformly distributed
Cold : in one hour
17. Controls
a) System start :
b) System stop :
c) Speed Raise :
d) Speed lower :
e) Drive frequency setting :
f) Auto/manual operation
i) At panel :
ii) At remote control :
g) Local/remote operation for controls :
i) At panel :
ii) At remote :
h) Jog mode :
i) Reversing :
j) Dynamic brake :
k) Remote breaker trip :
l) Motorised potentiometer for reference value
Selection :
m) Electronic Ramp function :
n) Speed and current controller :
18. Rectifier/Inverter
a) Make :
b) Type/Model No. :
c) Diodes/GTOs configuration :
Total No. of Diodes/GTOs :
d) Overall converter efficiency for complete range :
Converter efficiency at unity power factor
100%, 75%,50% load :
Efficiency of Inverter at unity power factor
100%, 75%,50% load :
e) Overall P.F. of complete system :
f) Cooling system
Type :
Redundancy in cooling Units :
g) Type of feed back for speed control :
h) Speed control accuracy :
i) List of controls provided at the front of panel :
j) List of status measuring devices provided at the :
front of Panel
k) List of status indication and Annunciation provided:
19. Type of Electronic Card mounting arrangement. :

20. DIMENSION
a) Length :
b) Height :
c) Depth :

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 487 OF 1216

 d) Weight of cubicle :
(Dimensional details of all panels shall be furnished).
21. Degree of protection for enclosure. :
22. Paint shade :
23. Heat output of Panel :
24. Whether Air Conditioning is required : Not applicable
25. Control supply voltage and Aux. Power requirement :
26. DC Reactor
a) Make :
b) Type :
c) Rating :
d) Type of cooling :
e) Overall Dimensions :
f) Heat output :
g) Inductance of the reactor :
h) Air Core/Iron Core :
i) Efficiency :
27. Local control station required as per spec : Yes
28 Cooling system for VFD drive : Air cooled
29 Requirement of earthing cable between motor & drive :

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 488 OF 1216

 Datasheet No.
DATA SHEET B047-003-16-50-DS-0030
FIRE ALARM SYSTEM Rev. No. A
Page 1 of 4

PURCHASER'S DATA
(to be filled by the purchaser)
A Site Conditions
1 Ambient Temperature 2 Relative humidity 30-100 %
- Maximum : 35.0 °C 3 Altitude Above MSL 3515m
- Minimum (Outdoor): -22.00 °C 4 Atmosphere Cold Desert
- Minimum (Indoor): -5.00 °C
- Design : 40 °C 5 Location Leh, J&K
B Area classification
1 Non plant Buildings Safe
2 Plant buildings/units Safe

C General Data
1 Max. Distance from Fire Alarm 3 KM
Panel to the farthest field device
2 Cable entries for Break Glass 2 Nos. from Bottom
Units
3 Cable entries for Fire alarm Panel Bottom/ Top
4 Cable entries for Repeater Panel N/A
5 Integration with Existing Fire Req./Not Req.
Alarm System
6 Integration with following Plant Comm. Systems:
a Public Alarm Announcement Req./Not Req. c Plant Data Network Not Req.
System(Public address system) d ISDN telephone exchange Req./Not Req.
b F&G PLC SYS Req./Not Req. e Fire Suppression System Req./Not Req.
f Plant security system Req./Not Req.
7 Ingress protection IP 41
D Power supply
1 Input power (Voltage/Frequency) 240V, 1PH, 50Hz 4 Temperature for battery sizing 10 °C
2 Battery type Ni-Cd/VRLA 5 Ageing factor 0.8
3 Duration for battery sizing (*Clause 5.2.3)
E Type of fire alarm system
1 Conventional N/A
2 Microprocessor based Req./Not Req.
analogue addressable
F Specific requirements for Fire Suppression
1 Status signals, alarms & As per specification
shutdown signal requirements
a Selector switches for clean agent/ Req./Not Req. e Deluge valve activation/test push- Req./Not Req.
CO2 supply buttons and activated status lamps
b Automatic signal for clean agent/ Req./Not Req. f Shutdown signals (potential free Req./Not Req.
CO2 supply contacts for air handling units)
c Manual push button for discharge Req./Not Req. g Fire water pump running indications Req./Not Req.
of clean agent/CO2 h Fire water pump start push buttons Req./Not Req.
d Clean agent/CO2 discharge inhibit Req./Not Req.
push-buttons
G Siren
a Control for Sirens N/A

H MISC.
a Detector configuration from FA panel: Req

* REFERENCE SPECIFICATION - 6-51-0076

Note: 1 --- Redundancy of HMI & Engineering console is not envisaged (reefr Cl. No. 8.1.5 of 6-51-0076.

A 08.05.2018 ISSUED WITH TENDER RR DR VKJ

Rev. No. Date Purpose Prepared By Checked By Approved By

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 489 OF 1216

 Datasheet No.
DATA SHEET B047-003-16-50-DS-0030
FIRE ALARM SYSTEM Rev. No. A
Page 2 of 4
MANUFACTURER'S DATA

A Make, type and model no. of following items

Make Type/Model No.

1 Heat detectors
Heat detectors
a Safe area
b Intrinsically safe area
2 Multi sensor detectors
a Safe area Safe
b intrincially safe area
3 Linear beam smoke detectors
a Safe area
b Hazardous area
4 Break Glass Units
a Safe area
b Hazardous area
6 Ultra-voilet Flame detectors
a Safe area
b Hazardous area
7 I/R detectors
a Safe area
b Hazardous area
8 Heat Sensing Cables
9 Response Indicators
10 Fault Isolators
11 Exit Signs
12 Hooters
a Hooter acknowledge boxes
13 Blinking lights
14 Halon/ CO2 release/ Inhibit switches
15 Siren

B Genaral Data
1 Exit Signs Self-Luminous/ Backlit
2 Max. Distance from Fire Alarm
Panel to Detector/ BGU

C Conventional Fire Alarm System NOT APPLICABLE

1 Central fire alarm panel
a Make & model no. e Dimensions (LXDXH)mm
b No. of zones f Mimic Integral/Non-integral
c Operating voltage & power g LED size
consumption h LEDs arrangement
d Ingress protection IP-41 As graphic mimic of plant/unit
2 Siren
a Siren Required/Not-required
b Output KW/ db at 1 meter e Siren Actuation Automatic/ Automatic
c Voltage V as well as Manual
Phase Phase f Power Supply Normal/ Emergency
Frequency Hz
d Starter for siren (IP-55) Required/Not-required
3 Mimic panel (if non-integral)
a Make & model no. c Mounting Floor mounting/Wall mounting
b Operating voltage d Dimensions (LXWXH)mm
4 Zonal fire alarm panel
a Make & model no. d Dimensions (LXDXH)mm
b Operating voltage & power e No.of zones
consumption f Max. No. of devices per zone

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 490 OF 1216

 Datasheet No.
DATA SHEET B047-003-16-50-DS-0030
FIRE ALARM SYSTEM Rev. No. A
Page 3 of 4

c Mounting Floor mounting/Wall mounting

6 Repeat alarm panel

a Make & model no. d Dimensions (LXDXH)mm
b Operating voltage& e LEDs arranged in a matrix
poweMinimum (Outdoor): f LEDs arranged on graphic mimic
poweMinimum (Indoor):
c Mounting Wall mounting

D Microprocessor Based Fire Alarm System

1 Central fire alarm panel (CFAP) Safe
a Make & model no. Scan frequency for devices
b Operating voltage & Redundancy (*Clause 8.1.5) :100% Note: 1
power consumption f Ingress protection :IP-41
c Software used g Dimensions (LXDXH)

2 Monitor
a Make & model no.
b Operating voltage &
power consumption

3 Printer
a Make & model no. d Speed & size
b Type e Dimensions (LXDXH)mm

4 Data gathering cum fire alarm panel (DGFAP)

a Make & model no. f Scan frequency for devices
b Max.and min.number of loops g Operating voltage & power
c Number of devices in each 120/ consumption
analogue loop h Ingress protection :IP-41
d Event history storage processing i Integration with Existing Fire Yes/ No
e Number of programmable outputs Alarm System

5 Repeat alarm panel

a Make & model no. c Display LCD/
b Operating voltage & d Ingress protection :IP-41
power consumption e Dimensions (LXDXH)mm
6 Integration with following Plant Comm. Systems:
a Public Alarm Announcement Yes/ No c Plant Data Network Yes/ No
system(Public address system) d ISDN telephone exchange Yes/ No
b Paging and Plant Comm. Yes/ No e Fire Suppression system Yes/ No
system

E Battery bank & charger details

1 Battery DGFAP CFAP Zonal panel
a Make
b Type/model no.
c AH Rating
d No. of cells
e Voltage per cell
f End cell voltage
g Dimensions (LXDXH)mm

2 Charger/ UPS Charger UPS

a Make
b Type/model no.
c Rating Amp KVA
d Dimensions (LXDXH)mm

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 491 OF 1216

 Datasheet No.
DATA SHEET B047-003-16-50-DS-0030
FIRE ALARM SYSTEM Rev. No. A
Page 4 of 4

F Communication Protocol Signal Loop/Data Highway

G Protocol for Integration with F&G PLC Serial/ Hardwired
1 Type of serial ports Bi-directional/ RS485
H Cables
1 Recommended cable / wire size & Type
(Conventional Fire Alarm System)

a Between zonal panel & detectors,

break glass units.
b Between CFAP & Zonal panel
c Between CFAP & Repeat alarm panel Safe
d Between zonal panel & repeat alarm
panel
2 Recommended cable / wire size & Type
(Microprocessor based Fire Alarm System)
a Between DGFAP & detectors 1.5mm2 Cu/
b Between CFAP & DGFAP FO
c Between CFAP & Repeat alarm panel
d Between DGFAP & Repeat alarm panel
f Data Highway N/A

3 Cable resistance (Max.per loop)

4 Cable capacitance (Max.per loop)

H Details of equipment certification/approval for hazardous

area application

Equipment MCP Heat detector Ionisation Optical detector Others

detector

SOR item no.

Explosion protection class
(as applicable)
Type reference no.
Reference no.& date of
other test
certificates of recognised test
authority
Reference no.& date of
approval certificate

BIS License no. & date

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 492 OF 1216

 Datasheet No.
DATA SHEET B047-003-16-50-DS-0031
PUBLIC ADDRESS SYSTEM Rev. No. A
Page 1 of 4
PART-I (PURCHASER'S DATA)
(to be filled in by the purchaser)
1 Site Conditions
1.1 Ambient Temperature 1.2 Relative humidity 30-100 %
- Maximum : 35.0 °C 1.3 Altitude 3515 m above mean sea level
- Minimum (Outdoor): -22.00 °C 1.4 Atmosphere Cold Desert
- Minimum (Indoor): -5.00 °C 1.5 Location Leh, J&K
- Design : 40 °C
2 Area classification
2.1 non plant Buildings Safe
2.2 Plant builduings/ units Safe

3Power supply
Incoming power supply from purchaser's 3.3 Type UPS/ NON UPS
mains supply at one point for each Central Exchange power supply
3.1 Voltage: 240V AC ± 6%
3.2 Frequency: 50Hz ± 3%
4 Central Exchange
4.1 Type Digital Intelligent 4.3 Capacity Refer else where
Microprocessor based
4.2 Ingress protection IP 41(Min.)
5 Material of construction of wall or LM-6/ Glass fibre
pedestal-mounted, explosion or reinforced polyester
weather proof type FCS and other
Field Communication Equipment
6 Ingress protection for field equip. IP 55(Min.)
7 Plant Communication facilities required ( Also Refer Job Specifications):
7.1 Paging(all call in voice mode) of the entire plant over loud speakers NO
from the master station(as per the enclosed speech diagram)
7.2 Selective call from the Master Station to any of the Field Call NO
Stations and call back by Field Call Stations(as per the enclosed
speech diagram)
7.3 Communication between Master Call Stations(as per the enclosed NO
speech diagram)
7.4 Initiation of call from any of the Field Call Stations to the Master NO
Station(as per the enclosed Speech Diagram)
7.5 Communication between any two Field Stations without interferance NO
of the Master Call Station(as per the enclosed DBR)
7.6 Communication between any two Field Call Stations only at the NO
discretion of the Master Call Station, except for the dedicated
speech connection shown in the enclosed Speech Diagram
7.7 Communication between different Exchanges, if provided NO
within the plant
7.8 Operating an alarm call from the Master Call Station over all the YES
loud speakers(through the 5 tone alarm generator)
7.9 Monitoring the health of the system YES
7.10 Muting facility for silencing the loud speaker connected to the YES
FCS/ Booster amplifier
7.11 Field programming facility for flexible speech diagram at site YES
7.12 Integration with Telephone Exchange (EPABX) YES
7.13 Integration with Fire Alarm System YES
7.14 Facility for recording conversation among MCS, FCS etc. YES
7.15 Digital audio recorder module YES

* REFERENCE SPECIFICATION - 6-51-0072

A 08.05.2018 ISSUED WITH TENDER RR DR VKJ

Rev. No. Date Purpose Prepared By Checked By Approved By

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 493 OF 1216

 Datasheet No.
DATA SHEET B047-003-16-50-DS-0031
PUBLIC ADDRESS SYSTEM Rev. No. A
Page 2 of 4
PART-II (MANUFACTURER'S DATA)
(to be filled in by the Vendor)
1 Utilisation voltage
1.1 Field Call Stations with built 1.3 25 W Booster amplifier and
in speaker/ amplifier loud speaker
1.2 Master Call Stations 35 1.4 Central Exchange
2 Total power requirement of the system
(list separately for each exchange) 1.5
2.1 Total AC power(in KVA) 2.3 Type UPS/ Non-UPS
2.2 Phase/ Voltage/ Frequency Power Supply
3 Recommended type and size, no. of
cores, conductor dia. of cable
to be used for the following:
Exchange (if any) Station(if any)
3.2 Central Exchange to Master 3.6 Field Call Station to Flashing
Call Station Beacon
3.3 Central Exchange to Field Call 3.7 Central Exchange to Telephone/
Station FA System interface
3.4 Field Call Station to paging
Loud speaker
4 Distance limitation(if any)
4.1 From Central Exchange to Central 4.5 From Field Call Station to Field
Exchange Call Station
4.2 From Central Exchange to Master 4.6 From Field Call Station to Flashing
Call Station Beacon
4.3 From Central Exchange to Field 4.7 From Central Exchange to
Call Station Telephone/ FA System
4.4 Plant Communication facilities required ( Also Refer Job Specificatiointerface
Loud speaker
5 Details of Equipment certification/ approval for Hazardous area application:
Booster
Field Call Station Field Call Station
amplifier(if External 25 W Flashing
Equipment without Booster with Booster
provided Loud speaker Beacon
amplifier amplifier
separately)
5.1 SOR item No.
Type Reference no./
5.2
model no.
Hazardous area
5.3 protection
class/designation

Ref. no. & date of

CIMFR/ other test
5.4
certificates of recognised
test authority

Ref. No. & date of CCoE

5.5
approval certificate

5.6 BIS License no. & date

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 494 OF 1216

 Datasheet No.
DATA SHEET B047-003-16-50-DS-0031
PUBLIC ADDRESS SYSTEM Rev. No. A
Page 3 of 4
6 Technical Particulars of Plant Communication Equipments:

Hazardous
area Material
Make/
MR item protection Dimension Weight of
Equipment Country Model no. Rating Type
No. class/designa (LxDxH) mm (Kg) Constru
of Origin
tion(as ction
applicable)

Field Call
Stations,
with/without
6.1 Booster
amplifier
1W(hazardous
area)

Field Call
Stations,
with/without
6.3 Booster
amplifier
4W(desk-top
type)

Booster
amplifier(outd
6.4 oor,hazardous
area)
25W,124db(A)

Booster
amplifier(weat
6.5
her proof)
25W,124db(A)

Loud
speaker(outdo
6.6 or,hazardous
area)
25W,124db(A)

Loud
speaker(weath
6.7
er proof)
25W,124db(A)

Box type
6.8 speaker
6W(min.)

6.9 Flashing
Beacon

6.10
Accoustic
Hood

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 495 OF 1216

 Datasheet No.
DATA SHEET B047-003-16-50-DS-0031
PUBLIC ADDRESS SYSTEM Rev. No. A
Page 4 of 4
Hazardous
area Material
Make/
MR item protection Dimension Weight of
Equipment Country Model no. Rating Type
No. class/designa (LxDxH) mm (Kg) Constru
of Origin
tion(as ction
applicable)
Master Call
6.11
Station
Central
6.12
Exchange 1.5
Programme
6.13
Unit
Fault
6.14
Diagnostic/
it i
7 Miscellaneous
7.1 Lamp Type, wattage and color of Flashing Beacon:
7.2 FCS type: Keys/ Full Keypad Matrix
7.3 Total No. of Keys in the following -
7.3.1 MCS
7.3.2 FCS(weather proof/ explosion proof)
7.3.3 Desk-top FCS
7.4 Canopy for outdoor equipment: Provided/ Not Provided
7.5 Heat loss of Central Exchange(for sizing Air conditioning package)
7.6 Types of alarm tones(5 nos.)

Plant Communication facilities required ( Also Refer Job Specifications):

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 496 OF 1216

 Datasheet No.
DATA SHEET FOR
B047-003-16-50-DS-0032
POWER CONDITIONING UNIT (SOLAR
Rev.No.A
POWER SYSTEM)
Page 1 of 1
PURCHASER'S DATA
Project Leh Airport Location Leh, J&K
Client M/S AAI Unit
A Site conditions
1 Maximum ambient temperature: 35 °C 4 Relative humidity: 30-100%
Minimum ambient temperature
2 -22°C/ -5°C 5 Altitude above MSL: 3515m
(Outdoor/Indoor):
3 Design ambient temperature: 40 °C 6 Environment: Cold Desert
MANUFACTURER'S DATA
1 Tag no. 8 Power Consumption
2 Make Normal operation
3 Model No. Standby operation
4 Input (DC) 9 Protection
Max PV power (Pdc max) Grid islanding Required
MPPT DC voltage range Grid overvoltage Required
Max DC voltage Grid undervoltage Required
Max DC Current Grid overfrequency Required
5 Outpur (AC) Grid underfrequency Required
Nominal AC output power AC overcurrent Required
Nominal AC current Ground fault AC/DC Required
AC output voltage DC bus overvoltage Required
AC output voltage variation DC bus undervoltage Required
Output frequency DC overcurrent Required
Frequency variation Device temp. rise Required
Voltage ripple Surge prot. AC side Required
Current harmonic distortion Surge prot. DC side Required
Power factor 10 Cable entry Top/Bottom
6 Efficiency 11 Access Front
100% load 12 Construction details
75% load Type of cooling Natural/ Forced
50% load Cooling fan redundancy Yes/No
10% load Dimensions(LxBxH)
7 Environmental limits Weight (in KG.)
Degree of protection Earth bus material and size
Ambient temperature range 13 Painting Epoxy paint,
Max. ambient temperature shadeRAL 7031
Relative humidity
Max. altitude
Max. noise level

A 08.05.2018 ISSUED WITH TENDER RR DR VKJ

Rev. No Date Purpose Prepared by Checked by Approved by
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 497 OF 1216
 Datasheet No.
B047-003-16-50-DS-0033
PV SOLAR MODULE DATA SHEET
Rev : A
Page 1 of 1
PURCHASER's DATA
A. Site conditions
1 Ambient temperature, maximum: 35 °C 3 Atmospheric condition: Cold Desert
minimum (Outdoor/ Indoor): -22 / -5 °C 4 Altitude: 3515m
Design Temperature: 40 °C 5 Location: Outdoor
2 Relative humidity: 30-100 % 6
B. Technical particulars
1 Rated Power Pdc at STC By manufacturer
2 No of PV cells (n) per module By manufacturer
3 PV Module type Mono/Poly crystalline
PV Module tracking option (fixed mount/ 1
4 Fixed
axis tracker/ 2 axis tracker)
5 Solar module frame material Anodised Aluminium/GI
6 Junction box Weather resistant HDPE (IP65)/GI
MANUFACTURER's DATA
1 Manufacturer 19 Module efficiency %
2 Model 20 Solar module frame material
3 Material 21 Module dimensions
4 No of PV cells (n) per module Length mm
5 Rated Power Pdc at STC W Width mm
6 Power tolerance % Depth mm
7 Voltage at Max power V 22 Module weight
8 Current at rated power A 23 Application Class

9 Open circuit Voltage (Voc) V 24 PV Mod. tilt angle (fixed mount) °

10 Short circuit current (Isc) A
11 Fill factor
12 Temperature coefficient of Isc
13 Temperature coefficient of Voc
14 Temperature coefficient of power
15 Maximum system voltage V
16 Maximum system voltage V
17 Maximum series fuse rating A
18 NOCT (Air 20°C, Sun 0.8kW/m², °C
wind 1m/s)

A 08.05.2018 ISSUED WITH TENDER RR DR VKJ

Rev. No. Date Purpose Prepared by Checked by Approved by
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 498 OF 1216
 Datasheet No.
DATA SHEET B047-003-16-50-DS-0034
BATTERY AND CHARGER Rev: A
Page 1 of 3

PURCHASER'S DATA
Project LEH- Airport Location LEH
Client AAI Unit
A Site conditions
1 Maximum ambient temperature: 35 °C 4 Relative humidity: 30-100 %
2 Min. amb temp (Outdoor) -22 °C 5 Altitude above MSL: 3515 m
Min. amb temp (Indoor) -5 °C
3 Design ambient temperature: 10 °C 6 Environment: Cold desert
B Technical particulars
1 Battery
a Type VRLA d Boost charging time 10 hours
b Plate construction
c Discharge duty requirements e Electrolyte liquid in containers Required
Item no. Nominal Duty cycle No. of cells (per bank) End cell voltage
as per DC First 1 Last 1 Lead Lead
Next 58 min. VRLA Ni-Cd VRLA Ni-Cd
tender voltage min. min. acid acid
190A 44.6A 73.7A 54 1.85 1.16 V

f Battery stand formation h Cable details between

g Accessories (Per battery set) battery & charger
i Hydrometer (syringe type) * 3 nos. Item no. Cable size
ii Thermometer * 3 nos.
iii Cell testing voltmeter (3V-0-3V) 1 no.
iv Rubber gloves 4 pairs
v Spanner 1 no.
vi Acid resistant jugs & funnels * 2 nos. each
vii Wall mounting teakwood holder * 1 no.
2 Battery charger
a System voltage 415 V±10% AC, TPN m Incoming cable details for
b System frequency 50 Hz ± 5% battery charger
c System neutral earthing Solidly earthed Item no. Cable size
d System fault level 50 kA
e Charger voltage range
Float charging voltage range/cell VRLA-2.05-2.25 V
Boost charging voltage range/cell VRLA-2.25-2.4 V
f Cable entry Bottom
g Mounting Free Standing,
Floor Mounted
h Access Front
i Earth Bus 25X6 mm2 Cu (Min)
Separate bolted removable
Required(Gland Plate
j undrilled gland plate for cable
shall be drilled at site)
entry
k Cable glands and lugs
l Painting
3 DC distribution board
a Type Compartmentalized
b Feeder requirements Refer SOR

A 08.05.2018 Issued with tender RR DR VKJ

Rev. No. Date Purpose Prepared by Checked by Approved by

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 499 OF 1216

 Datasheet No.
DATA SHEET B047-003-16-50-DS-0034
BATTERY AND CHARGER Rev: A
Page 2 of 3

4 BMS Interface
a Indication-Charger failure Required c Indication-Battery discharged Required
b Indication-Inverter failure Required d Indication-Battery isolated Required
Notes
1 NO (Normally Open) potential free contacts sh 35
owner, for the following conditions.
2 End cell voltage shall confirm to the values specified.
3 * Asterisk marked items are not applicable for Ni-Cd and VRLA batteries.
4 Cable details shall be furnished during post order document review.

MANUFACTURER'S DATA
A Battery B Battery charger
1 Item no. As per MR/PR 1 Item no. As per MR/PR
2 Tag. No. 2 Tag. No.
3 Manufacturer's name 3 Manufacturer's name
4 Type & Catalogue no. of cell 4 Rating
5 Ampere hour capacity Charger rating
6 No. of cells Output voltage
7 Nominal cell voltage Output current
8 Cell voltage at the end of full 5 Nominal voltage
discharge at 10 hrs/ 5 hrs rate Float charging
9 Specific gravity of electrolyte at the Quck charging
end of full charging at °C 6 Float chrging voltage range
10 Specific gravity of electrolyte at the 7 Quick charging voltage range
end of full discharge at 10 hrs/ 8 Min. efficiency of charger
5 hrs rate at °C at light load (40%)
11 Quantity of electrolyte per cell at rated load
12 Weight of cell with electrolyte 9 Power factor at rated voltage
13 Quick charging current & load
Max. safe quick charging rate 10 Max. RMS ripple voltage at
Permissible ripple content rated load
14 Suggested quick charging rate with battery connected
15 Quick charging voltage without battery
Max. quick charging voltage/cell 11 Method of volatege control
Quick charging voltage/cell for Float charging mode
constant voltage finish charging QuIck charging mode
16 Float charging voltage/cell 12 Method of current control
17 Float charging current Float charging mode
Float charging current range QuIck charging mode
Permissible ripple content 13 Safety factor for component
18 AH efficiency at 10 hrs/5 hrs rate selection
19 Short ckt current of battery bank 14 Charger dimensions
20 Short circuit withstand time Width
21 Max. allowable termp.of electrolyte Depth
the cells can withstand without Refer SOR Height

08.05.2018

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 500 OF 1216

 Datasheet No.
DATA SHEET B047-003-16-50-DS-0034
BATTERY AND CHARGER Rev: A
Page 3 of 3
22 Type of positive plate C DCDB
23 Type of negative plate 1 Item no. As per MR/PR
24 No. of positive plates/cell LEH- Airport 2 Tag. No. LEH
25 No. of negative plates/cell AAI 3 Manufacturer's name
26 Material & thickness of separators 4 DCDB dimensions
27 Ampere hour capacity at min. amb. 35 Width
10 hrs rate to end cell voltage Depth
specified at s.no. 8 above Height
5 hrs rate to end cell voltage 5 Degree of protection
specified at s.no. 8 above D Cell booster
2 hrs rate to end cell voltage 1 Item no. As per MR/PR
specified at s.no. 8 above 2 Tag. No.
1 hr rate to end cell voltage 3 Manufacturer's name
specified at s.no. 8 above 4 Current rating
30 min. rate to end cell voltage 5 Voltage range
specified at s.no. 8 above 6 Dimensions
28 Dimensions of each battery rack Width
Width Depth
Depth Height
Height
29 No. of battery racks

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 501 OF 1216

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 502 OF 1216
 Datasheet No.
DATA SHEET
B047-003-16-50-DS-0009
MOV ACTUATOR
Rev : A
Page 1 of 1
PURCHASER'S DATA
Project Leh Airport Location Leh, J&K
Client M/S AAI Unit
A Site conditions
1 Maximum ambient temperature: 35 °C 4 Relative humidity: 30-100%
2 Min. ambient temp. (outdoor/Indoor) -22°C/ -5°C 5 Altitude above MSL: 3515m
3 Design ambient temperature: 40 °C 6 Environment: Cold Desert
B Technical particulars
1 MOV tag no.
2 Supply voltage 415 V ± 10% 19 Position indication
3 Supply frequency 50 Hz ± 3% Local Required
4 System neutral earthing: Solidly earthed Remote Required
5 System fault level N.A 20 Travel limit switch Required
6 Duty S2 15 Min 21 Potential free contacts for
7 Area classification Safe area remote indication/ control
8 Gas group N/A Valve open Required
9 Temperature class N/A Valve close Required
10 Construction Safe area type Local/Remote switch Status Required
11 Ingress protection IP 65 Remote control operation
12 Painting Shade RAL7031 in progress Required(if specified
13 Fireproof requirement(See note-4) Not required elsewhere)
Fireproof rating 22 DCS interface/Remote PB Required
(Refer valve datasheet)
14 Valve duty 23 Max. time of operation
Full open & close Yes Opening Refer valve data
Partial open & close No Closing Refer valve data
15 Control requirement Local & remote 24 Cable glands & plugs for Required
16 Local/Remote/Off selector switch Required unused entries
17 Suitability for interfacing with Not required 25 Applicable standard 6-51-0091
2 wire control system

18 Setting of adjustable parameter NA

of actuator (2 wire control system)
MANUFACTURER'S DATA
A Actuator 6 Rated torque
1 Make 7 Average load current
2 Type & Catalogue no. C Basis for sizing & selection
3 Applicable wiring diagram of actuator
4 Valve duty D Test & Approval certificates
5 Max. permissible no. of open & E MOV actuator-2 wire system
close per hour 1 Max. no. of field units per
6 Internal control supply in actuator one master station
7 Recommended backup HRC fuse 2 Max. permissible distance
B Motor between field unit & master
1 Make station
2 KW rating 3 Max. no. of control inputs &
3 Rated speed in RPM control/status outputs from
4 Enclosure each field unit
5 Locked rotor (starting) current
Notes
1 The purchaser will provide single point power supply to each actuator. Any other control supply voltage required
shall be derived by the manufacturer within the actuator.
2 Remote input signals for opening/closing/stopping the MOV shall be provided through momentary closing of
potential free contacts in Purchaser's panel.
3 MOVs shall be suitable for terminations of cable of size upto 4x16 CYFY.however final cable size shall be intimated during detail engineering.
4 De-rating of equipment design/ rating shall be done by the bidder/ vendor as per site condition.

A 08.05.2018 ISSUED WITH BID PACKAGE RR DR VKJ

Rev. No. Date Purpose repared b Checked by Approved by

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 503 OF 1216

1.0 SITE CONDITIONS
1.1 Maximum ambient temp. : 35 °C
1.2 Minimum ambient temp. (Outdoor/Indoor) : -22°C/-5°C
1.3 Design Temp. : 40 °C
1.4 Relative humidity : 30-100% (Max.)
1.5 Altitude above MSL : 3515 m
1.6 Location : Leh, J&K
1.7 Atmosphere : Cold Desert

2.0 TECHNICAL PARAMETERS

S. No. Technical parameters Recommended Requirements

1 Efficiency of LED light fitting Min 95 Lumens I Watt or as mentioned in SOR item
(Efficacy) description
2 Life of LED light fitting Not less than 50000 burning Hours
3 Approved make for LED Nichia/Cree/ Osram / Phillips (Lumiled) / Sharp/ Seoul
(SEE NOTE BELOW)
4 CRI (Colour Rendering Index) Min 80 for indoor applications and Min 70 for outdoor
Applications unless otherwise specified in SOR description
5 THD (Total Harmonic Less than 10 %
Distortion)
6 Type of Housing Extruded aluminum I Standard alloy housing for indoor
applications.
High pressure die cast aluminium I Standard alloy for
outdoor applications.
7 IP Category IP 20 or higher for indoor applications and IP 65 or higher
for outdoor applications.
8 Surge Protection Shall be provided conforming to relevant IS standard I IEC
61643-11 class- 2 & EN 61643- II Type- 2.
9 Labeling I identification Mark Manufactures Name I Logo engraved I Embossed on
housing I body or Name I Logo on aluminium plate Labels or
Name I Logo printed on housing I body
10 Warranty period 5 years warranty from actual date of completion of work on
complete luminaries including driver I control gear, LED, all
accessories etc.
11 Power Factor Equal to 0.95 or More
12 Total Power consumption of Not More than 110 % of rated capacity of LED Light.
fitting

Note: An undertaking shall be obtained from fitting manufacturer regarding confirmation about use
of said make LED’s in their fittings.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 504 OF 1216

 ELECTRICAL I/O LIST

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 505 OF 1216

1.0 I/O LIST
1.1 HV I/O LIST (for HT-201):

Type Pt Signal description Set condition Reset condition Remarks

type description description
HV incomer I/O signals
AI A R phase current
AI A Y phase current
AI A B phase current
AI W 3-phase real power
AI R 3-phase reactive power
AI H Frequency
DI S CB in service & Closed Not closed
DI S CB in service & Open Not open
DI D Relay 86 Operated Reset
DI D Relay 95 Operated Reset
DI D Trip on under voltage Activated Reset
DI D Numerical Relay Unhealthy Healthy
HV line PT I/O signals
AI V R-Y line voltage
AI V Y-B line voltage
AI V B-R line voltage
DI D Line PT MCB Open Closed
HV bus PT I/O signals
AI V R-Y bus voltage
AI V Y-B bus voltage
AI V B-R bus voltage
DI D Bus PT MCB Open Closed
HV transformer feeder I/O signals
AI A R phase current
AI A Y phase current
AI A B phase current
AI W Real power
AI R Reactive power
DI S CB in service & Closed Not closed
DI S CB in service & Open Not open
DI D Relay 86 Operated Reset
DI D Relay 95 Operated Reset
DI D Transformer trouble Operated Reset
DI D Numerical Relay Unhealthy Healthy

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 506 OF 1216

1.2 MV I/O LIST: (PCC-301, PCC-302, ASB-1, ASB-2)

Type Pt Signal description Set condition Reset Remarks

type description condition
description
MV PCC/ ASB incomer I/O signals
AI A R phase current
AI A Y phase current
AI A B phase current
DI W Real power
DI R Reactive power
DI S CB in service & Closed Not closed
DI S CB in service & Open Not open
DI D Relay 86 Operated Reset
DI D Relay 95 Operated Reset
DI D Trip on U/V Activated Reset
DI D Numerical Relay Unhealthy Healthy
MV PCC/ASB line PT I/O signals
AI V R-Y line voltage
AI V Y-B line voltage
AI V B-R line voltage
DI D Line PT MCB Open Closed
MV PCC/ASB bus PT I/O signals
AI V R-Y bus voltage
AI V Y-B bus voltage
AI V B-R bus voltage
DI D Bus PT MCB Closed Open
MV PCC/ASB bus coupler I/O signals
DI S CB in service & Closed Not closed
DI S CB in service & Open Not open
DI D Relay 86 Operated Reset
DI D Relay 95 Operated Reset
DI D Auto-changeover Blocked Not blocked
DI D Numerical Relay Unhealthy Healthy
DI S Switchboard (A-I-M In auto mode Not in auto
selector switch) mode
DI S Switchboard (A-I-M In indep. Not in indep.
selector switch) mode mode
DI S Switchboard (A-I-M In manual Not in manual
selector switch) mode mode
MV PCC/ASB outgoing feeder I/O signals
AI A R phase current
AI A Y phase current
AI A B phase current
AI W Real power

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 507 OF 1216

Type Pt Signal description Set condition Reset Remarks
type description condition
description
AI R Reactive Power
DI S CB in service & Closed Not closed
DI S CB in service & Open Not open
DI D Relay 86 Operated Reset
DI D Relay 95 Operated Reset
DI D Numerical Relay Unhealthy Healthy
Miscellaneous I/O signals
DI D UPS Charger Failure Normal
DI D UPS Inverter Failure Normal
DI D UPS Battery Discharged Normal
DI D UPS Battery Isolated Normal
DI S UPS load on Inverter Bypass Trafo
DI D DC supply Charger - I Failure Normal
DI D DC supply Charger - II Failure Normal
Legends: S- Status; D- Alarm

Notes:

1. Acquisition of input/output (I/O) signals as hardwired or software:

a) All numerical relays shall be connected to ethernet switch. BMS shall communicate
with the ethernet switch to acquire relay and metering status I/O signals of the relays.

b) In case any of these data cannot be acquired over the relay, these signals have to be
provided as hardwired. For requirement of numerical relays, refer elsewhere in the
tender.

2. This I/O list is indicative only. Any other I/O required to meet the contract requirements
shall be identified and provided by CONTRACTOR.

3. Transformer oil temperature and transformer winding temperature shall be acquired

hardwired from 11/0.433 kV transformers only. These I/Os shall be acquired as a 4-20 mA
signal from the transformers.

4. For additional I/Os requirement of MV switchboards, refer Doc. No. B047-003-16-50-TR-

0003 (Instruction to Vendor – MV Switchboard).

5. In addition to above mentioned, I/Os shall also be considered for PA system, FA system,
Lighting Management System and Solar power package as per standard industrial practice
and same shall be reviewed during detail engineering.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 508 OF 1216

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 509 OF 1216
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 510 OF 1216
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 511 OF 1216
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 512 OF 1216
 DATA SHEET-EMERGENCY GENERATOR PACKAGE (LV)

PART 1 (SCOPE OF WORK)

Vendor's scope for Generator

S. No. Description Supply Installation Testing &

Commissioning

1. Emergency generator complete with Yes Yes Yes

brushless excitation and AVR system,
frame earthing connections &
lubrication system.
2.0 Generator control panel with AMF Yes Yes Yes
system and control, protection &
metering and auxiliary equipments (Part
of EPCC-302)
2.1 Line Cubicle for CT /PT Yes Yes Yes

2.2 Neutral Cubicle for CTs Yes Yes Yes

2.3 Line side breaker in cubicle NO

(See
note-3)
3 Synchronizing panel (Part of EPCC- Yes Yes Yes
302)
4 Synchroscope & Cut-off switch Yes Yes Yes

5 Power and Control cabling in between Yes Yes Yes

the package equipment (See
note-2)
6 Earthing within the battery Yes Yes Yes
limits and connection to main earthing (See
grid note-2)
7 Battery & battery charger/UPS for Yes Yes Yes
control power requirement of the
complete Generator set. (See note – 4)
8 Fabricated G.I. cable trays and racks as Yes Yes Yes
required for cabling in the battery limits
9 Required commissioning spares shall Yes
be provided by vendor
Notes:
1. ‘Yes’ indicates activity in Vendor’s scope.
2. Power & Control cable between various equipments within the package and earthing within the
package shall be done by bidder.
3. Line side breaker shall be provided in 415v switchboard.
4. Generator shall be suitable for black start operation. Hence all DC/ AC UPS required for the same
shall be considered by the Bidder.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 513 OF 1216

 DATASHEET : (PART 2)

1.0 Site Conditions

1.1 Maximum ambient temp : 35 °C

1.2 Minimum ambient temp (outdoor) : - 22 °C

1.3 Design temp : 40 °C

1.4 Altitude above MSL : 3515M

1.5 Location : LEH (J&K)

1.6 Atmosphere : Cold, Desert

1.7 Equipment location : Utility Building

1.8 Ventilation : Inadequate

2.0 Power Supply System

2.1 Main Power Supply : 415V ± 6% TPN

2.2 Fault Level : 50 kA for 1 sec

2.3 Neutral Earthing : Solid

2.4 DC Supply for controls : As per vendor’s standard design.

3.0 Power supplies available from mains

3.1 D.C supply for controls : NO

3.2 415V Normal supply : NO

4.0 Utilization voltage for auxiliaries to be supplied by vendor

Utility Voltage Phases Frequency

Motors Rated up to 160 KW 415V±6% 3 50Hz ±3%

Battery Charger with DC output up to 240V ±6% 1 50Hz ±3%

1000 W
Battery Charger with DC output above 415V ±6% 3 50Hz ±3%-
1000 W
Anti-condensation heaters/Enclosure 240V ±6% 1 50Hz ±3%
lighting

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 514 OF 1216

5.0 Technical Particulars
5.1 Alternator Data
a. Item No. : Refer Elsewhere
b. Duty : Continuous
c. No. of units : 1
d. Type of driver : Refer Elsewhere
e. Painting : Epoxy Based
f. Colour shade : As per vendor’s standard
g. Rated output : Refer Elsewhere
h. Rated Terminal voltage : 415V
i. Rated P.F. : 0.8 lag
j. Rated Frequency : 50Hz ± 3%
k. System neutral earthing : Solid
l. System fault level (kA) : 50 kA (1sec.)
m. Degree of protection : Minimum IP-23
n. Insulation class : H
o. Temp Rise limited to : F
p. Maximum Transient Reactance (Xd’) : * Vendor to indicate
q. Type of excitation system. : Brushless
r. Excitation support by PMG : * Vendor to decide
s. Type of cooling. : Alternator to be air cooled
t. Short time parallel operation with other supply : Required
u. Continuous parallel operation with other supply : Not required (See Remark-1)
v. Permissible voltage drop during starting : 15 %
w. Black Start Facility : Required
x. Generator start-up time : < 30 seconds
Remark:
1: It is required to carryout periodic load test run of generator without disturbing the loads which are
already being fed from the other supply. Facility shall be provided in the generator control panel for
manually closing the generator breaker on live bus after synchronization with the other supply. Load
sharing of generator shall be suitably taken care while operating the generator set in parallel with the
other supply. (Also refer enclosed Single Line Diagram)
2. It shall be the responsibility of the vendor to offer the DG after necessary de-rating required as
per above mentioned site conditions, so that net output of the DG sets shall be as per SOR
description, i.e. 415V, 1500 kVA/ 500kVA @ 0.8 p.f min. & 0.85 load factor.
3. The DG shall be suitable to supply the continuous rated output power for variable electrical load
for indefinite time period.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 515 OF 1216

 4. It shall be the responsibility of the vendor to design the DG sets & overall DG set system (refer
Load Manager details from SLD) such that the step size shall be suitable to the start following:
a). 75kW (IE3 motor, DOL starting) when base load is 2100kW approx.
b). 250kW (IE3 motor, VFD driven with starting current limited to 3 times) when base load is 1900
kW approx.
5. The DG shall be suitable to operate on min. 10% over-load for 1 hour for every 12 hours of
continuous operation and 50% overload for 15 sec.

5.2 Termination Details

a. Generator line side : Bus duct/ Cable (as per SLD)
b. Line side cable – Type/size : Refer SLD/ cable schedule
c. Neutral side cable- Type/size : By Vendor

5.3 Generator breaker : Not required (Part of EPCC-302 SWBD)

a. Generator Breaker Rating : NA
b. Breaking Capacity : NA
c. Making Capacity (Peak) : NA
d. Type of Circuit Breaker : NA

5.4 C.T.s /P.T.s : Required (as per table given below)

Current transformer for protection CT/PT for AVR

P-CT D-CT R-CT M-CT N-CT AVR CT AVR PT
Requirement Yes No No Yes Yes Yes Yes
Ratio */1 */1 */1 */1 */1 * *
Class 5P20 PS PS PS 5P20 * 1
Burden * * * * * * *
Function O/C & S/G Differential REF Metering Earth Regulation Regulation
Fault
Vk/Rct - - - -
Location <1> <6> <2> <3> <4> <6> <5>

* CT details and VA burden shall be finalized during detail engineering.

Protection CTs shall be physically located inside the terminal box / cubicle as given below:

<1> P-CT: CT for Over Current and Short Circuit Protection, to be located in employer’s
switchboard.
<2> D-CT: CT for Differential Protection, to be located just before the star point (neutral
formation point). CT for other end shall be located in Employer’s
switchboard.
<3> R-CT: CT for restricted earth fault protection in Neutral, to be located between star
point and the neutral tee off point. CT for other end shall be located in
Employer’s switchboard.
<4> M-CT: CT for Meters, to be located in employer’s switchboard.
<5> N-CT: CT for earth fault protection, to be localized between star point and neutral
tee off point.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 516 OF 1216

 <6> Star point for all CT’s in Employer’s switchboard shall be formed in
Employer’s switchboard itself. Terminals shall be provided accordingly.

(Refer the attached Key Single Line Diagram for details)

5.5 Protection Relays / Metering

Type Required Type Required

Voltage restrained O/C relay Yes P.T fuse failure relay Yes

O/V relay with time delay Yes Ammeter with selector switch Yes

Stand by earth fault relay Yes Voltmeter with selector switch Yes

Lockout relay Yes KWH meter Yes

Control supply failure relay Yes KW meter Yes

Check synchronizing relay Yes P.F. meter Yes

Winding R.T.D Yes Frequency meter Yes

Bearing R.T.D Yes Hour run counter Yes

Reverse power relay Yes Gen. differential relay No

Thermal overload relay Yes Loss of excitation relay Yes

Under voltage relay Yes Restricted earth fault relay Yes

Negative phase sequence Yes Rotor earth fault relay Yes

relay
Over/Under frequency Yes IDMT earth fault relay Yes

NOTE –
1) All protection functions shall be part of Gen controller. In case any protection
function is not available in the controller numerical relays.
2) All protection relays shall be numerical type of approved makes & shall comply
with enclosed specification and datasheet.
3) All relays shall have integral metering. In case any meter is not available in the
relay, separate meter shall be provided.

5.6 Control requirements

S.No. Control Function / Element LCP Employer’s annunciation panel

1 Gen Start/stop P.B. Yes Yes

2 Freq increase/decrease P.B. $$ Yes Yes

3 Voltage increase/decrease $$ Yes Yes

4 Gen C.B. control switch ** Yes Yes

5 Synchronizing equipment Yes No

6 Auto/Man sel. sw. for starting* Yes No

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 517 OF 1216

 7 Auto/Man sel. sw. for regulation Yes No

8 Local/remote switches Yes No

9 Annunciation windows Yes No

10 Annunciation accept/reset P.B Yes No

* Purchaser shall provide a potential free contact normally open, which shall CLOSE to
start the generator when kept in AUTO mode

** For auto closing of Employer’s generator breaker vendor shall provide a voltfree contact
normally open which shall CLOSE after full voltage build up.

$$ Frequency increase/decrease & voltage increase /decrease from Employer’s

annunciation panel shall be achievable by changeover of contacts (push button type).
Vendor to ensure governor suitability for this type of control

5.7 Indication & alarm

S. No. Function LCP Employer’s annunciation

panel
1 Load on mains/generator Yes Yes

2 Gen C.B (open/close/trip) Yes Yes

3 Control supply failure Yes Yes

4 Winding temp high Yes Yes

5 Bearing temp high Yes Yes

6 Start Failure Yes Yes

7 P.T. fuse failure Yes Yes

‘Yes’ indicates facility to be provided by Vendor, as applicable

NOTE –Employer’s annunciation panel shall be in Purchaser’s scope of supply. Emergency

generator vendor shall provide necessary facility enabling the above mentioned
control/monitoring functions to be transferred to Employer’s annunciation panel.

6.0 All equipments shall be of type tested design.

7.0 MAKES OF EQUIPMENTS & COMPONENTS

7.1 All equipments & components shall be of reputed makes with satisfactory track record and
complete test certificates.
7.2 For Approved Vendor List, refer elsewhere in the tender.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 518 OF 1216

 DATASHEET: PART 3 (by Vendor)

1.0 Rating & performance details:

a. Make :
b. Temp. inside acoustic enclosure : ° C higher than design ambient
c. Frame designation :
d. Rated output : KVA
e. Terminal voltage : KV
f. Enclosure :
g. Rated P.F. : Lag
h. Phase/connection/no.of terminals :
i. Full load current :
j. Speed : RPM
k. Rated frequency :
l. Cooling system :
m. Max permissible inductive loading :
n. Steady state 3-phase S.C. currents :
o. 3-phase S.C. withstand time :
p. Type of voltage regulator :
q. Insulation class :
r. Max. permissible impact load :
s. Temperature rise at full load :
t.
Efficiency % 25% Load 50% Load 75% Load 100% Load
Rated P.F.
Unity P.F.

2.0 Reactances (Mfr. to indicate tolerances)

S. no. Parameter Abbr. Tolerance % Value(pu)

a Direct axis transient reactance Xd’ ±
b Direct axis subtransient reactance Xd” ±
c Synchronous reactance Xd ±
d Zero sequence reactance X0 ±
e Negative sequence reactance X2 ±

3.0 Resistances and time constants

a. Armature resistance (25 c) : Ohm/phase

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 519 OF 1216

b. Armature resistance (100 c) : Ohm/phase
c. Transient time constant Td’ : Sec
d. Sub-transient time constant Td” : Sec

4.0 Local control panel

a. Make :
b. Dimension :
c. Type :
d. Degree of protection : IP-
e. Weight :
f. Colour shade :
5.0 Remote control panel : NA
a. Dimension :
b. Degree of protection : IP-
c. Weight :

6.0 Mechanical data

a. Alternator dimension (LxWxH) :
b. Stator weight :
c. Rotor weight :
d. Total weight :
e. Coupling : Direct / Through gear Box

7.0 Auxiliary Motors

a. Make :
b. Voltage/Frequency : 415 V, 3-Ph/240V 1-Ph, 50 Hz
c. Enclosure protection : IP- 55
d. Insulation class : 'F'
e. starting : DOL

8.0 D.C. power supply

8.1 Battery
a. Make :
b. Model :
c. Type :
d. No. of cells :
e. Nominal voltage :

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 520 OF 1216

f. Nominal capacity :
g. Dimension of rack :
h. Cell arrangement :

8.2 Battery charger

a. Make :
b. Model :
c. Input voltage :
d. Float voltage range :
e. Boost voltage range :
f. Float charge current :
g. Boost charge current :
h. Overall dimension LxWxH :

NOTE: ALL BLANK DATA IN THIS DATASHEET SHALL BE FILLED BY THE VENDOR.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 521 OF 1216

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 522 OF 1216
 Datasheet No.
DATA SHEET-ENGINE STARTING B047-003-16-50-DS-5553
BATTERY AND CHARGER Rev : A
Page 1 of 1
PURCHASER'S DATA
Project : Leh Airport Location : Leh,J&K
Client : M/S AAI Unit :
A Site conditions
1 Maximum ambient temperature: 35 °C 4 Relative humidity: 30-100%
2 Min. amb temp (outdoor) -22 °C 5 Altitude above MSL: 3515m
Min. amb temp (indoor) -5 °C
Min. temp for battery sizing 10 °C
3 Design ambient temperature: 40 °C 6 Environment: Cold Desert
B Technical particulars
1 Voltage 415 V±10% AC, TPN 4 System earthing Solidly Earthed
2 Frequency 50 Hz ± 3% 5 Installation Indoor
3 Fault level 50kA for 1 sec 6 Applicable standard 6-51-0030
MANUFACTURER'S DATA
A General 6 Nominal quick/ float voltage V/ A
1 Vendor 7 Incoming power requirement kW
2 Package/ Engine no. 8 Power factor at rated load
B Battery Set 9 Installation
1 Make: 10 Degree of protection-Panel IP -
2 Battery type Lead Acid 11 Dimension of panel (LxDxH) mm
3 Model no. 12 Suitability of charger for Yes
4 Ampere-hour capacity AH @ hour discharge trickle charging all battery
o
rate at C banks simultaneously
5 Nominal battery voltage V
6 No. of cells D Distribution
7 Nominal cell voltage V 1 Rating of DC loads
8 Cell voltage at the end of load V@ a Engine starting motor
cycle (for capacity sizing) hour discharge rate b Engine controls/Control panel
9 Max. cell boost charging voltage/ V c DC Lube oil pump motor
Current A d Others
10 Cell float charging voltage/ V 2 Max. simultaneous DC load
Current A (including float charging)
11 Dimension of battery panel/ 3 No. of outgoing feeders with
rack (LxDxH) mm ratings
12 No. of battery banks provided 4 Cable details (Size & Type)
C Battery charger a Charger to battery
1 Make b Charger to load
2 Model no.
3 Type of rectifier bridge
4 Method of control
5 Charger rating (Voltage & Amp)
a Quick charging mode Max. V/ A
b Float charging mode Max. V/ A

Notes
1 The vendor shall coordinate all necessary information regarding battery and chargers to ensure proper design
for optimum performance. The charger shall be completely suitable for the charging requirements of the
battery.
2 All un-filled data to be filled by vendor.
3 Necessary de-rating of equipment design/ rating shall be in the scope of vendor as per site conditions.

A 08.05.2018 ISSUED WITH TENDER RR DR VKJ

Rev. Date Purpose Prepared Checked Approved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 523 OF 1216

 1 GENERAL
2 Project: NEW AIRPORT TERMINAL, LEH Job No.: B047
3 Owner: M/s AAI Site: LEH, J&K
4 Purchaser: M/s AAI Unit: UTILITY BUILDING Unit No.:
5 Item No.: Service: Emergency DG Set
6 No. Reqd.: THREE Working: TWO Standby: ONE Driven Equipment Item no.:
7 Applicable to:  Proposals  Purchase  As built
8 Note:  Scope option / information specified by Purchaser  information required from / options left to vendor. Vendor to cross  the selected option.
9 SITE / INSTALLATION DATA (Refer Job Specification # B047-000-80-43-0002)
10 Site Conditions Location:
11 Barom. Pressure (kg/cm2 a): Highest:  Lowest:  Avg.:  Indoor  Outdoor  Grade
12 Height above Mean Sea Level (m):  Heated  Unheated
13 Ambient Air Temp.(°C):  Max.: 35  Min.: (-) 22  Under-roof  Partial Sides
14 Ambt. Air Temp. around the Engine(°C):  Highest  Lowest  Closed Room Without ventilation
15 Relative Air Humidity at the Max. Ambient Air Temp.(%): Electrical Area classification (Refer Electrical part)
16 Water Vapour Pressure at the Max. Ambient Air Temp.(kg/cm2A): Class Group Division
17 Wet Bulb Temp. (°C): Dry Bulb Temp. (°C):
18 Cooling Water Supply Temp. (°C):
19 UTILITY DATA
20 Cooling Water:
21 Cooling Water Temp(°C) Supply(Design/Max/Nor/Min): Return(Max):
22 Cooling Water Press(kg/cm²g) Supply(Design/Max/Nor/Min): Return(Min):
23 Cooling Water Characteristics: DM Water Consumption:
24 Instrument Air:
25 Supply Pressure(Design/Max/Nor/Min)(kg/cm2g):
26 Supply Temp.(Design/Max/Nor/Min)( °C): Dew pt.(°C)
27 Electric Power (Refer Electrical Specification)
28 Electric Supply: Volts Hz
29 Available during Engine  Starting  Operations  Shut-down
30 Fuel Oil:
31 Type of Fuel Oil: HSD Lower Calorific Value(kJ/kg):
32 Fuel Oil Characteristics:
33 APPLICABLE CODES & STANDARDS
34  EIL Standard spec.  ISO 3046/ BS 5514  ISO: 8528  Others: Job Spec (Doc. No. B047-000-80-43-SP-0001)
35 Noise specification:  Applicable to m/c Max. 75 dBA @ 1.0 m
36  Acoustic Housing :  Yes  No
37 Exhaust Gas Emission - Statutory requirement (if any): Refer Job Spec
38  Listing/Approval of Engine Required From:  UL/FM  TAC
39  Air Receiver for Starting Air System  Air Compressor for Starting Air System
40  Shell and Tube type Exchangers:  Auxiliary Pumps:
41  Air Cooled Heat Exchangers/Radiator: Manufacturer's Std.  Other Tanks and Vessels:
42 DRIVEN EQUIPMENT
43 Driven Equipment:  Elect. Generator  Pump  Other:
44 Duty:  Emergency  Intermittent  continuous
45 Probable Period For Continuous Running: As per ISO:8528 for Prime Power Rating (PRP)
46 Duration of Max. Load: Duration of Min. Load:
47  Minimum BKW of the driven eqpt. kW: @ RPM:
48  Rated BKW of the driven eqpt. kW: @ RPM:
49  Maximum BKW of the driven eqpt. kW: @ RPM:
50  For Mech. Drive Applications: Minimum site rating of the engine required kW @ RPM
51 (With 10 % Overload provision for One Hour within a period of 12 Hours of Operation ).
52  For DG set application: Prime power Rating (PRP) as per ISO: 8528. The Net Power available at Alternator Terminals shall be
53 1500 KVA @ 415 KV with rated P.F. of 0.8 after accounting for Engine Deration for Site conditions & Alternator Efficiency with
54 Engine Driving its all auxiliaries and power consumed by essential independent auxiliaries.
55 Direction of Rotation of driven equipment viewed from Coupling End:  CW  CCW
56 Method of Drive:  Thru universal joint  Direct thru Flexible Coupling  V-Belts  Gear Drive
57 CONSTRUCTION FEATURES
58 Manufacturer: Engine Model:
59 Type of Engine:  Two-Stroke  Four-Stroke Engine Cooling:  Air Cooled  Water Cooled
60  Mech. Pressure-charged  Turbo-Charged:  With Charge Air Cooler  Normally Aspirated
61  No. of Cylinders:  Cylinder Arrangement:

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 524 OF 1216

 62  Bore/Stroke(mm/mm):  Compression Ratio:
63  Speed (rpm): (< 1500)  Mean Piston Speed (m/sec.):
64 PERFORMANCE
65  Rated Engine Power at Standard operating conditions as per ISO 3046/ BS 5514 (ISO Std. Power): kW @ RPM
66 (Using only the essential dependent Auxiliaries and with 10% Overload provision for One Hour within a period of 12 Hours of Operation).
67  Rated engine Power at Site conditions (Service Std. Power) (Guaranteed, No Negative Tolerance): kW @ RPM
68 (Using only the essential dependent Auxiliaries and with 10% Overload provision for One Hour within a period of 12 Hours of Operation).
69  Min. Engine site power at which Engine can be Operated Continuously. kW @ RPM
70  Min. Engine Speed & corresponding site Power at which Engine can be Operated Continuously RPM @ kW
71  Starting time required for full load operation (Seconds):
72  Direction of Rotation of Engine viewed from Coupling End  CW  CCW
73 Air Flow Required for Operation of the Engine for:  Combustion & Scavenging  Cooling & Ventilation
74 Essential dependent Auxiliaries are:
75  Engine Shaft Driven Radiator Fan kW  Engine Shaft Main LO Pump kW
76  Engine Shaft Driven CW Pump kW  Engine Shaft Driven Fuel Oil Pump kW
77 Independent Auxiliaries are:
78  Electric Motor Driven Auxiliary LO Pump. kW  Electric Motor Driven Fuel Oil Transfer Pump. kW
79  Electric Motor Driven CW Pump. kW  Electric Motor Driven Starting Air Compressor. kW
80  Electric Motor Driven Radiator Fan kW  Electric Motor Driven Exhaust Fan KW
81 Electric Motor Driven Fresh Air Fan KW
82 Specific Fuel Consumption:
83 Description Fuel Consumption, gm/kW-hr @ reference conditions 
84 ISO 3046  Manufr's. Std.  Site  Manfr's. shop 
85 (a) Guaranteed Engine Rated Power
86 (100 % Rating)
87 (b) 75 % of (a)
88 (c) 50 % of (a)
89 (d) 110 % of (a)
90  Standard Reference Conditions:
91 -- Total Barometric Pressure, p r , kg/cm2A (100 kPa)
92 -- Atmospheric Temp. ,t r , OC 25 (298°K)
93 -- Relative Humidity ,φ r , % 30
94 -- Charge Air Coolant Temp.,t cr , OC 25 (298°K)
95 SPEED GOVERNING SYSTEM
96 Type:  Single Speed  Multiple Speed  All Speed (Variable Speed)
97 Class of Accuracy:  A 0  A1  A2  B1  B2
 Shall be suitable for frequency & voltage variation specified in Electrical Specs
98 Governor Type:  Electronic  Electro Hydraulic  Mechanical
99 Make: Model:
100 Governor Control Mechanism:  Manual  Remote/ Auto
101 STARTING SYSTEM
102 Method of Starting  Manual  Automatic (through AMF cum synchronizing panel)
103 Method of Stopping  Manual (Push button)  Automatic
104 Type of Cold Starting Aid:
105 Type of Starting System:
106  Hand Starting with Starting Handle  Battery Starting  Air Starting through Pneumatic Motor
107  Air Starting through Air Injection into Cylinders  Hydraulic Motor
108 Battery Starting System: (Also refer Electrical Specification Enclosed Elsewhere)
109 Battery Bank:  Number: Voltage AH Capacity Make:
110 Cells per Bank  Number Voltage AH Capacity
111  Starter Make/Rating:  Dynamo Make/Rating:
112  Regulator and Cut-out:
113  Battery charging equipment including transformer, Static Rectifier, D.C. Ammeter , D.C. Voltmeter, Charge Rate selector switch
114 and Charging Meter.
115  Inter connecting cable leads between battery charger & battery
116  Inter connecting cable leads between battery & engine Starter
117 Note: Battery Bank shall be sized to provide minimum SIX consecutive starts of the engine under cold condition
118 without recharging, with additional 10% spare capacity.
119
120

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 525 OF 1216

121 Starting Air System: NOT APPLICABLE
122  Air Compressor Type:  Reciprocating  Screw
123 Rated Capacity(m3/hr at Inlet Conditions): Discharge Pressure (Kg/cm²g): BKW: RPM:
124  Air Compressor Driven by:  Working by Electric Motor  Standby by Diesel Engine
125 Driver Rating kW: RPM: Volts/Ν/Hz.:
126  Air Receiver with Pressure Gauge, Relief Valve & Manual as well as Automatic (with Timer) Drain Valve:
127  Start-Stop Switch for Compressor  Manual  Automatic (Through Pressure switch on air receiver) with Selector switch
128 No. of Air Receiver:  One  Two Capacity of Each Air Receiver(M3):
129 Note: Total Capacity of each air Receiver shall be suitable for atleast Six (6) consecutive starts.
130 Other starting systems: Not applicable
131
132 COOLING SYSTEM (As per Manufacturer’s Standard)
133 Type:  Open Circuit Cooling with Engine driven water circulating Pump.
134  Closed circuit cooling including:
135  Water Pump driven by:  Driver Rating/Speed (KW/RPM):
136  Primary (Soft) circuit Piping with Temp. Control & Make-up tank.
137  Heat Exchanger with Anchor/Foundation Bolts
138  Secondary(Raw Water) circuit Piping with  Strainers  Pressure Regulating Valve
139 By-Pass Valve:  Check Valve:
140 Heat Exchanger Temp(ΕC) (Primary Circuit): Inlet: Outlet:
141 Heat Exchanger Temp(ΕC) (Secondary Circuit): Inlet: Outlet:
142 Water Pressure(Secondary circuit) Kg/cm²(g): Heat Exchanger Testing Pressure Kg/cm²(g):
143  Radiator Cooling including Interconnecting Piping &:
144  Radiator with Temp. Control Valve  Expansion/Make-Up water Tank
145  Fan Driven By: Engine Shaft Rating/Speed (KW/RPM):
146  Engine/Motor Driven Water circulating Pumps: No.: Rating/Speed (KW/RPM):
147  Engine Water Inlet/Outlet Temp(deg C):
148 FRAME LUBRICATION SYSTEM (As per Manufacturer’s Standard)
149 Type:
150  Splash Lubrication
151  Force Feed Lubrication including Valves, oil Pump, Piping &:
152  Oil cooler type: (As per manufacturer standards)
153  Oil Filters  Self Cleaning  Duplex  Paper Cartridge Simplex Filter self cleaning type (As per manufacturer standards)
154  Pre-lube Oil Pump driven by:
155 Pre-lubrication Manual  Automatic at intervals of hours. (Vendor to recommend)
156  Type/Grade of Lube Oil: Auto pre-lubrication pump shall be powered from mains.
157  Oil Sump capacity (litres):  Oil consumption (Lph):
158  Oil Cooler testing Pressure (Kg/cm²g):
159  Explosion Relief Valve for Crankcase
160 FUEL SYSTEM
161 Type: Gravity Feed System  Fuel Lift Pump including
162  Fuel Filters  Paper cartridge  Duplex
163  Fuel Injection Pump Make: Model:
164  Daily Service Fuel Tank:  Engine Mounted  Wall Mounted  Ground Mounted
165  Capacity of Daily Service Tank(litres)  900 litres  For 6 hrs of continuous operation @ full load
166  For 12 hrs continuous operation @ full load  For 24 hrs continuous operation @ full load
167  Fuel Float Tank Ground Mounting with Base Plate
168  Motor Driven Fuel Transfer Pump (For unloading fuel from fuel tanker to daily service tank)
169  Fuel Piping and Fittings:
170  Fuel Piping from Transfer Pumps to Daily Tank  Fuel Piping from Daily Tank to Engine
171  Overflow Pipes  Vent Connection for Fuel Tank with Flame Arrester
172  Drain Valve for Fuel Tank  Inspection and cleaning Hole for Fuel Tank (min 150 mm dia.)
173  Fill connection for Fuel Tank  Level Transmitter in Fuel tank
174  Gauge for fuel tank  Float valve in fill connection  Strainers
175 AIR INLET SYSTEM
176  Suction Air Filter  Air Inlet Ducting / Piping / Manifolds  Inlet Silencer
177  Expansion Bellows  All supports / Hangers
178 ENGINE EXHAUST SYSTEM
179  Exhaust Manifolds / Ducting / Piping Exhaust Silencer (Residential Type)
180 Expansion Bellows  Exhaust Stack/Chimney (excluding supporting structure)
181 Thermal Insulation for complete Exhaust Piping  All supports/Hangers

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 526 OF 1216

182 CONTROLS & INSTRUMENTATION
183 Hazardous Electrical Area Classification NEC: Class Div. Group (Refer Elec. Spec.)
184 ISO: Zone Gas Group
185
186 Electric Supply: Refer Electrical Specification
187 Lamps : + 24V; AC/DC; φ; + Hz.
188 Alarm Circuit : + 24V; AC/DC; φ; + Hz.
189 Trip Circuit + 24V; AC/DC; φ; + Hz.
190 Control Circuit : + 24V; AC/DC; φ; + Hz.
191 Solenoid Valves : + 24V; AC/DC; φ; + Hz.
192
193
194 Notes
195 1. Pre-Alarms to precede Trips.
196 2. Instruments to be connected to junction boxes on skid and consoles.
197 3. All Tubings, pipings, wiring between instruments and junction boxes, local gauge boards and local panels to be supplied by vendor.
198 4. Instruments, safety and control devices specified herein are minimum required by customer. In case, in the opinion of vendor,
199 additional devices are required, vendor shall specifically state so and include the same in his scope of supply.
200 5. Vendor shall also refer to P&ID's enclosed and any additional instruments required as per P&ID's shall be included
201 by vendor in his scope of supply.
202 6. All switching devices (hardware/software) for prealarms, trips, trip alarm, and interlocking shall be in the vendor's scope.
203
204 Location
205 Nomenclature Loose Locally LGB LCP UCP DCS
206 Supply Mtd. Mtd. Mtd.
207
208  AC Power On/Off Switch With Indication Lamp 
209  Control Power On/Off Switch With Indication Lamp 
210  Selector Switch A/M Station For L/O Pump Motor 
211  Selector Switch A/M Station For CW Pump Motor 
212  Start/Stop Push Button for L/O Pump Motor 
213  Start/stop Push Button for DG set 
214  Emergency Stop Push Button 
215  Lamp Test Push Button 
216  Alarm/Trip Acknowledge /Reset Push Button 
217  Lubricating Oil Heater `ON' Indicating lamp 
218  Motor Interlock Against Start Without Pre-lubrication 
219
220
221 NOTE:
222
223 Legend: LM: Local Mounted:  By Vendor  Others
224 LGB: Local Gauge Board:  By Vendor  Others
225 LCP: Local Control Panel:  By Vendor  Others
226 UCP: Unit Control Panel:  By Vendor  Others
227 PLC: Programmable Logic Control:  By Vendor  Others
228 DCS: Distributed Control System:  By Vendor  Others
229
230  Items under LGB to be housed in the Engine Mounted Gauge Board
231  Items under LCP to be housed in free standing type Local Engine Control Panel
232  Electric Switches for Alarm and shutdowns to have _________________________ Enclosures (Refer Electrical Specification)
233  Temp. gauges shall be Bimetallic Dial Type
234  All wiring piping between Engine - Gauge Board - Control Panel in Vendor's Scope
235
236
237
238
239
240

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 527 OF 1216

 CONTROLS AND INSTRUMENTATION
Indication A/V Annun. & Pre-Alarm Trip & A/V Alarm Annun.

Repeat Signal for

Repeat Signal to

Repeat Signal to
Indicator – UCP

High High- UCP

Low Low - UCP

High High - LP
Low Low - LP
Gauge- Local

PLC/DCS/MP

PLC/DCS/MP
S.No. DESCIPTION

Indicator -LP
Gauge- LGB
REQUIRED

High - UCP
Low - UCP

High - LP
Mounted

Low - LP
DCS/MP
241 LUBRICATION SYSTEM
242 - Reservoir Oil Level  
243 - Reservoir Temp.  
244 - Main/Std by L/O Pump Disch. Pr.  
245 - L/O Filter Diff. Pr.  
246 - L/O Supply Header Pressure    
247 - L/O Supply Header Temp.   
248 - Oil cooler Oil Outlet Temp.  
249 - Stand by Pump Start  
250 -
251
252 COOLING SYSTEM
253 - Oil Cooler CW outlet temp.  
254 - CW Supply header flow  
255 - Sight Flow CW return each Cooler & Header 
256 - Local mount TSV on each isolatable circuit 
257 - Water level in make up water tank / Radiator  
258 - Engine Jacket C.W. Supply Temp. 
(Outlet of Radiator)
259 - Engine Jacket C.W Return Temp.   
(Inlet of Radiator)
260 For Closed Circuit Cooling (as applicable):
261 - Coolant main/standby pump disch. Pr.
262 - Coolant stand by pump start
263 - Coolant supply header Pr.
264 - Coolant supply header temp
265 - Coolant cooler Outlet Temp.
266 - Coolant reservoir Level (Make up water tank)
267
268
269 STARTING SYSTEM (if applicable)
270 - Air Receiver Pressure   
271
272
273 FUEL SYSTEM
274 - Fuel Oil level in fuel tank    
275
276 INLET AIR SYSTEM
277 - Inlet Air filter - differential pressure  
278 - Boost Air (Turbo Charger) Disch. Pr. (if reqd.)  
279 -Charge Air Cooler Outlet - Air Temp. (if reqd.)  
280
281 MISCELLANEOUS
282 - Engine Vibrations  
283 - Engine Speed   
284 - Key Switch - Start & Push Button Stop  
285 - Engine Over-speed   
286 - Engine fails to start   
287 - Tacho-hour Meter  
288 -Engine running  
289
290 Note: Instrumentations specified as minimum required. vendor shall include any other instruments if required for smooth, safe
291 and Trouble free operation of the DG sets. Also refer respective instrumentation specs attached elsewhere.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 528 OF 1216

292 MATERIAL
293 Charge Air Cooler Shell: Tubes:
294 Water Cooler Shell: Tubes:
295 Air Cooler Shell: Tubes:
296 Air Receiver
297 Fuel Tank: MS
298 INSPECTION AND TESTING
299 Witness Observe
300  Stage Inspection during Manufacture  
301  Full Load Test at Engine Manufacturer’s Shop (Refer respective Job specification)  
302  Fuel consumption & Governing Test at Engine Manufacturer's Shop.  
303  Control Panel Functional Test at LP vendor's shop.  
304  Full Load Test for 4 hours & 10% overload test for 1 hour of Engine Generator set at Packager’s shop  
305  No load Mechanical Run test at Packager's/Driven Eqpt. Mfr. Shop  
306  Site Testing of the DG Set (Refer Remark- 1)  
307 Inspection/Testing Witnessed By: Others  Owner/ PMC/ Representative
308 WEIGHTS
309 Net Weight of Engine with Mounted Ancillaries (kg):
310 Heaviest part to be handled during erection and its weight (kg):
311 Heaviest part to be handled during normal maintenance and its weight (kg):
312 Recommended Crane capacity (Tons): Crane Hook Height (m):
313 MAINTENANCE DATA
314 Expected Period of Running Between Top Overhauls: Hours
315 Expected Period of Running Between Main Overhauls: Hours
316 The Type and Grade of Lubricating Oil Recommended
317 Lube Oil Consumption (kg/hr)/ (Litres/hr)
318 Change of Lubricating Oil After: Hours
319 ACCESSORIES
320  Flywheel with Barring Device
321  Guards for Moving Parts
322  Common Base Plate for Engine - Driven equipment
323  Foundation/ Anchor Bolts, grouting material
324  Acoustic enclosure with ventilation system
325  Anti Vibration Pads (if required)
326  First Fill of Lubricating Oil
327 Torsional analysis report on Engine & Generator
328  Quotation for 2 years spares parts for Normal Operation and Maintenance along with unit prices
329  Site Storage, Erection & commissioning of DG Set
330
331
332 REMARKS
333 1) DG Set shall be tested at site based on the available load so as to demonstrate power and voltage build- up at the alternator
terminals.
334 2) DG set shall be suitable for black start condition. For initial start as well as subsequent black start requirement, all facilities are
considered in the vendor scope.
335
336
337
338
339
340
341
342
343
344
345

04.05.2018 A SY AKM
Date Rev Job Engineer Rev. & Approved By

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 529 OF 1216

 1 GENERAL
2 Project: NEW AIRPORT TERMINAL, LEH Job No.: B047
3 Owner: M/s AAI Site: LEH, J&K
4 Purchaser: M/s AAI Unit: UTILITY BUILDING Unit No.:
5 Item No.: Service: Emergency DG Set
6 No. Reqd.: ONE Working: ONE Standby: Driven Equipment Item no.:
7 Applicable to:  Proposals  Purchase  As built
8 Note:  Scope option / information specified by Purchaser  information required from / options left to vendor. Vendor to cross  the selected option.
9 SITE / INSTALLATION DATA (Refer Job Specification # B047-000-80-43-0002)
10 Site Conditions Location:
11 Barom. Pressure (kg/cm2 a): Highest:  Lowest:  Avg.:  Indoor  Outdoor  Grade
12 Height above Mean Sea Level (m): 3514  Heated  Unheated
13 Ambient Air Temp.(°C):  Max.: 35  Min.: (-) 22  Under-roof  Partial Sides
14 Ambt. Air Temp. around the Engine(°C):  Highest  Lowest  Closed Room Without ventilation
15 Relative Air Humidity at the Max. Ambient Air Temp.(%): Electrical Area classification (Refer Electrical part)
16 Water Vapour Pressure at the Max. Ambient Air Temp.(kg/cm2A): Class Group Division
17 Wet Bulb Temp. (°C): Dry Bulb Temp. (°C):
18 Cooling Water Supply Temp. (°C):
19 UTILITY DATA
20 Cooling Water:
21 Cooling Water Temp(°C) Supply(Design/Max/Nor/Min): Return(Max):
22 Cooling Water Press(kg/cm²g) Supply(Design/Max/Nor/Min): Return(Min):
23 Cooling Water Characteristics: DM Water Consumption:
24 Instrument Air:
25 Supply Pressure(Design/Max/Nor/Min)(kg/cm2g):
26 Supply Temp.(Design/Max/Nor/Min)( °C): Dew pt.(°C)
27 Electric Power (Refer Electrical Specification)
28 Electric Supply: Volts Hz
29 Available during Engine  Starting  Operations  Shut-down
30 Fuel Oil:
31 Type of Fuel Oil: HSD Lower Calorific Value(kJ/kg):
32 Fuel Oil Characteristics:
33 APPLICABLE CODES & STANDARDS
34  EIL Standard spec.  ISO 3046/ BS 5514  ISO: 8528  Others: Job Spec (Doc. No. B047-000-80-43-SP-0001)
35 Noise specification:  Applicable to m/c Max. 75 dBA @ 1.0 m
36  Acoustic Housing :  Yes  No
37 Exhaust Gas Emission - Statutory requirement (if any): Refer Job Spec
38  Listing/Approval of Engine Required From:  UL/FM  TAC
39  Air Receiver for Starting Air System  Air Compressor for Starting Air System
40  Shell and Tube type Exchangers:  Auxiliary Pumps:
41  Air Cooled Heat Exchangers/Radiator: Manufacturer's Std.  Other Tanks and Vessels:
42 DRIVEN EQUIPMENT
43 Driven Equipment:  Elect. Generator  Pump  Other:
44 Duty:  Emergency  Intermittent  continuous
45 Probable Period For Continuous Running: As per ISO:8528 for Prime Power Rating (PRP)
46 Duration of Max. Load: Duration of Min. Load:
47  Minimum BKW of the driven eqpt. kW: @ RPM:
48  Rated BKW of the driven eqpt. kW: @ RPM:
49  Maximum BKW of the driven eqpt. kW: @ RPM:
50  For Mech. Drive Applications: Minimum site rating of the engine required kW @ RPM
51 (With 10 % Overload provision for One Hour within a period of 12 Hours of Operation).
52  For DG set application: Prime power Rating (PRP) as per ISO: 8528. The Net Power available at Alternator Terminals shall be
53 500 KVA @ 415 KV with rated P.F. of 0.8 after accounting for Engine Deration for Site conditions & Alternator Efficiency with
54 Engine Driving its all auxiliaries and power consumed by essential independent auxiliaries.
55 Direction of Rotation of driven equipment viewed from Coupling End:  CW  CCW
56 Method of Drive:  Thru universal joint  Direct thru Flexible Coupling  V-Belts  Gear Drive
57 CONSTRUCTION FEATURES
58 Manufacturer: Engine Model:
59 Type of Engine:  Two-Stroke  Four-Stroke Engine Cooling:  Air Cooled  Water Cooled
60  Mech. Pressure-charged  Turbo-Charged:  With Charge Air Cooler  Normally Aspirated
61  No. of Cylinders:  Cylinder Arrangement:

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 530 OF 1216

 62  Bore/Stroke(mm/mm):  Compression Ratio:
63  Speed (rpm): (< 1500)  Mean Piston Speed (m/sec.):
64 PERFORMANCE
65  Rated Engine Power at Standard operating conditions as per ISO 3046/ BS 5514 (ISO Std. Power): kW @ RPM
66 (Using only the essential dependent Auxiliaries and with 10% Overload provision for One Hour within a period of 12 Hours of Operation).
67  Rated engine Power at Site conditions (Service Std. Power) (Guaranteed, No Negative Tolerance): kW @ RPM
68 (Using only the essential dependent Auxiliaries and with 10% Overload provision for One Hour within a period of 12 Hours of Operation).
69  Min. Engine site power at which Engine can be Operated Continuously. kW @ RPM
70  Min. Engine Speed & corresponding site Power at which Engine can be Operated Continuously RPM @ kW
71  Starting time required for full load operation (Seconds):
72  Direction of Rotation of Engine viewed from Coupling End  CW  CCW
73 Air Flow Required for Operation of the Engine for:  Combustion & Scavenging  Cooling & Ventilation
74 Essential dependent Auxiliaries are:
75  Engine Shaft Driven Radiator Fan kW  Engine Shaft Main LO Pump kW
76  Engine Shaft Driven CW Pump kW  Engine Shaft Driven Fuel Oil Pump kW
77 Independent Auxiliaries are:
78  Electric Motor Driven Auxiliary LO Pump. kW  Electric Motor Driven Fuel Oil Transfer Pump. kW
79  Electric Motor Driven CW Pump. kW  Electric Motor Driven Starting Air Compressor. kW
80  Electric Motor Driven Radiator Fan kW  Electric Motor Driven Exhaust Fan KW
81 Electric Motor Driven Fresh Air Fan KW
82 Specific Fuel Consumption:
83 Description Fuel Consumption, gm/kW-hr @ reference conditions 
84 ISO 3046  Manufr's. Std.  Site  Manfr's. shop 
85 (a) Guaranteed Engine Rated Power
86 (100 % Rating)
87 (b) 75 % of (a)
88 (c) 50 % of (a)
89 (d) 110 % of (a)
90  Standard Reference Conditions:
91 -- Total Barometric Pressure, p r , kg/cm2A (100 kPa)
92 -- Atmospheric Temp. ,t r , OC 25 (298°K)
93 -- Relative Humidity ,φ r , % 30
94 -- Charge Air Coolant Temp.,t cr , OC 25 (298°K)
95 SPEED GOVERNING SYSTEM
96 Type:  Single Speed  Multiple Speed  All Speed (Variable Speed)
97 Class of Accuracy:  A 0  A1  A2  B1  B2
 Shall be suitable for frequency & voltage variation specified in Electrical Specs
98 Governor Type:  Electronic  Electro Hydraulic  Mechanical
99 Make: Model:
100 Governor Control Mechanism:  Manual  Remote/ Auto
101 STARTING SYSTEM
102 Method of Starting  Manual  Automatic (through AMF cum synchronizing panel)
103 Method of Stopping  Manual (Push button)  Automatic
104 Type of Cold Starting Aid:
105 Type of Starting System:
106  Hand Starting with Starting Handle  Battery Starting  Air Starting through Pneumatic Motor
107  Air Starting through Air Injection into Cylinders  Hydraulic Motor
108 Battery Starting System: (Also refer Electrical Specification Enclosed Elsewhere)
109 Battery Bank:  Number: Voltage AH Capacity Make:
110 Cells per Bank  Number Voltage AH Capacity
111  Starter Make/Rating:  Dynamo Make/Rating:
112  Regulator and Cut-out:
113  Battery charging equipment including transformer, Static Rectifier, D.C. Ammeter , D.C. Voltmeter, Charge Rate selector switch
114 and Charging Meter.
115  Inter connecting cable leads between battery charger & battery
116  Inter connecting cable leads between battery & engine Starter
117 Note: Battery Bank shall be sized to provide minimum SIX consecutive starts of the engine under cold condition
118 without recharging, with additional 10% spare capacity.
119
120

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 531 OF 1216

121 Starting Air System: NOT APPLICABLE
122  Air Compressor Type:  Reciprocating  Screw
123 Rated Capacity(m3/hr at Inlet Conditions): Discharge Pressure (Kg/cm²g): BKW: RPM:
124  Air Compressor Driven by:  Working by Electric Motor  Standby by Diesel Engine
125 Driver Rating kW: RPM: Volts/Ν/Hz.:
126  Air Receiver with Pressure Gauge, Relief Valve & Manual as well as Automatic (with Timer) Drain Valve:
127  Start-Stop Switch for Compressor  Manual  Automatic (Through Pressure switch on air receiver) with Selector switch
128 No. of Air Receiver:  One  Two Capacity of Each Air Receiver(M3):
129 Note: Total Capacity of each air Receiver shall be suitable for atleast Six (6) consecutive starts.
130 Other starting systems: Not applicable
131
132 COOLING SYSTEM (As per Manufacturer’s Standard)
133 Type:  Open Circuit Cooling with Engine driven water circulating Pump.
134  Closed circuit cooling including:
135  Water Pump driven by:  Driver Rating/Speed (KW/RPM):
136  Primary (Soft) circuit Piping with Temp. Control & Make-up tank.
137  Heat Exchanger with Anchor/Foundation Bolts
138  Secondary(Raw Water) circuit Piping with  Strainers  Pressure Regulating Valve
139 By-Pass Valve:  Check Valve:
140 Heat Exchanger Temp(ΕC) (Primary Circuit): Inlet: Outlet:
141 Heat Exchanger Temp(ΕC) (Secondary Circuit): Inlet: Outlet:
142 Water Pressure(Secondary circuit) Kg/cm²(g): Heat Exchanger Testing Pressure Kg/cm²(g):
143  Radiator Cooling including Interconnecting Piping &:
144  Radiator with Temp. Control Valve  Expansion/Make-Up water Tank
145  Fan Driven By: Engine Shaft Rating/Speed (KW/RPM):
146  Engine/Motor Driven Water circulating Pumps: No.: Rating/Speed (KW/RPM):
147  Engine Water Inlet/Outlet Temp(deg C):
148 FRAME LUBRICATION SYSTEM (As per Manufacturer’s Standard)
149 Type:
150  Splash Lubrication
151  Force Feed Lubrication including Valves, oil Pump, Piping &:
152  Oil cooler type: (As per manufacturer standards)
153  Oil Filters  Self Cleaning  Duplex  Paper Cartridge Simplex Filter self cleaning type (As per manufacturer standards)
154  Pre-lube Oil Pump driven by:
155 Pre-lubrication Manual  Automatic at intervals of hours. (Vendor to recommend)
156  Type/Grade of Lube Oil: Auto pre-lubrication pump shall be powered from mains.
157  Oil Sump capacity (litres):  Oil consumption (Lph):
158  Oil Cooler testing Pressure (Kg/cm²g):
159  Explosion Relief Valve for Crankcase
160 FUEL SYSTEM
161 Type: Gravity Feed System  Fuel Lift Pump including
162  Fuel Filters  Paper cartridge  Duplex
163  Fuel Injection Pump Make: Model:
164  Daily Service Fuel Tank:  Engine Mounted  Wall Mounted  Ground Mounted
165  Capacity of Daily Service Tank(litres)  900 litres  For 6 hrs of continuous operation @ full load
166  For 12 hrs continuous operation @ full load  For 24 hrs continuous operation @ full load
167  Fuel Float Tank Ground Mounting with Base Plate
168  Motor Driven Fuel Transfer Pump (For unloading fuel from fuel tanker to daily service tank)
169  Fuel Piping and Fittings:
170  Fuel Piping from Transfer Pumps to Daily Tank  Fuel Piping from Daily Tank to Engine
171  Overflow Pipes  Vent Connection for Fuel Tank with Flame Arrester
172  Drain Valve for Fuel Tank  Inspection and cleaning Hole for Fuel Tank (min 150 mm dia.)
173  Fill connection for Fuel Tank  Level Transmitter in Fuel tank
174  Level Gauge for fuel tank  Float valve in fill connection  Strainers
175 AIR INLET SYSTEM
176  Suction Air Filter  Air Inlet Ducting / Piping / Manifolds  Inlet Silencer
177  Expansion Bellows  All supports / Hangers
178 ENGINE EXHAUST SYSTEM
179  Exhaust Manifolds / Ducting / Piping Exhaust Silencer (Residential Type)
180 Expansion Bellows  Exhaust Stack/Chimney of minimum height of 30 meters (excluding supporting structure)
181 Thermal Insulation for complete Exhaust Piping  All supports/Hangers

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 532 OF 1216

182 CONTROLS & INSTRUMENTATION
183 Hazardous Electrical Area Classification NEC: Class Div. Group (Refer Elec. Spec.)
184 ISO: Zone Gas Group
185
186 Electric Supply: Refer Electrical Specification
187 Lamps : + 24V; AC/DC; φ; + Hz.
188 Alarm Circuit : + 24V; AC/DC; φ; + Hz.
189 Trip Circuit + 24V; AC/DC; φ; + Hz.
190 Control Circuit : + 24V; AC/DC; φ; + Hz.
191 Solenoid Valves : + 24V; AC/DC; φ; + Hz.
192
193
194 Notes
195 1. Pre-Alarms to precede Trips.
196 2. Instruments to be connected to junction boxes on skid and consoles.
197 3. All Tubings, pipings, wiring between instruments and junction boxes, local gauge boards and local panels to be supplied by vendor.
198 4. Instruments, safety and control devices specified herein are minimum required by customer. In case, in the opinion of vendor,
199 additional devices are required, vendor shall specifically state so and include the same in his scope of supply.
200 5. Vendor shall also refer to P&ID's enclosed and any additional instruments required as per P&ID's shall be included
201 by vendor in his scope of supply.
202 6. All switching devices (hardware/software) for prealarms, trips, trip alarm, and interlocking shall be in the vendor's scope.
203
204 Location
205 Nomenclature Loose Locally LGB LCP UCP DCS
206 Supply Mtd. Mtd. Mtd.
207
208  AC Power On/Off Switch With Indication Lamp 
209  Control Power On/Off Switch With Indication Lamp 
210  Selector Switch A/M Station For L/O Pump Motor 
211  Selector Switch A/M Station For CW Pump Motor 
212  Start/Stop Push Button for L/O Pump Motor 
213  Start/stop Push Button for DG set 
214  Emergency Stop Push Button 
215  Lamp Test Push Button 
216  Alarm/Trip Acknowledge /Reset Push Button 
217  Lubricating Oil Heater `ON' Indicating lamp 
218  Motor Interlock Against Start Without Pre-lubrication 
219
220
221 NOTE:
222
223 Legend: LM: Local Mounted:  By Vendor  Others
224 LGB: Local Gauge Board:  By Vendor  Others
225 LCP: Local Control Panel:  By Vendor  Others
226 UCP: Unit Control Panel:  By Vendor  Others
227 PLC: Programmable Logic Control:  By Vendor  Others
228 DCS: Distributed Control System:  By Vendor  Others
229
230  Items under LGB to be housed in the Engine Mounted Gauge Board
231  Items under LCP to be housed in free standing type Local Engine Control Panel
232  Electric Switches for Alarm and shutdowns to have _________________________ Enclosures (Refer Electrical Specification)
233  Temp. gauges shall be Bimetallic Dial Type
234  All wiring piping between Engine - Gauge Board - Control Panel in Vendor's Scope
235
236
237
238
239
240

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 533 OF 1216

 CONTROLS AND INSTRUMENTATION
Indication A/V Annun. & Pre-Alarm Trip & A/V Alarm Annun.

Repeat Signal for

Repeat Signal to

Repeat Signal to
Indicator – UCP

High High- UCP

Low Low - UCP

High High - LP
S.

Low Low - LP
Gauge- Local

PLC/DCS/MP

PLC/DCS/MP
DESCIPTION

Indicator -LP
Gauge- LGB
No.

REQUIRED

High - UCP
Low - UCP

High - LP
Mounted

Low - LP
DCS/MP
241 LUBRICATION SYSTEM
242 - Reservoir Oil Level  
243 - Reservoir Temp.  
244 - Main/Std by L/O Pump Disch. Pr.  
245 - L/O Filter Diff. Pr.  
246 - L/O Supply Header Pressure    
247 - L/O Supply Header Temp.   
248 - Oil cooler Oil Outlet Temp.  
249 - Stand by Pump Start  
250 -
251
252 COOLING SYSTEM
253 - Oil Cooler CW outlet temp.  
254 - CW Supply header flow  
255 - Sight Flow CW return each Cooler & Header 
256 - Local mount TSV on each isolatable circuit 
257 - Water level in make up water tank / Radiator  
258 - Engine Jacket C.W. Supply Temp. 
(Outlet of Radiator)
259 - Engine Jacket C.W Return Temp.   
(Inlet of Radiator)
260 For Closed Circuit Cooling (as applicable):
261 - Coolant main/standby pump disch. Pr.
262 - Coolant stand by pump start
263 - Coolant supply header Pr.
264 - Coolant supply header temp
265 - Coolant cooler Outlet Temp.
266 - Coolant reservoir Level (Make up water tank)
267
268 STARTING SYSTEM (if applicable)
269 - Air Receiver Pressure   
270
271
272 FUEL SYSTEM
273 - Fuel Oil level in fuel tank    
274
275 INLET AIR SYSTEM
276 - Inlet Air filter - differential pressure  
277 - Boost Air (Turbo Charger) Disch. Pr. (if reqd.)  
278 -Charge Air Cooler Outlet - Air Temp. (if reqd.)  
279
280 MISCELLANEOUS
281 - Engine Vibrations  
282 - Engine Speed   
283 - Key Switch - Start & Push Button Stop  
284 - Engine Over-speed   
285 - Engine fails to start   
286 - Tacho-hour Meter  
287 -Engine running  
288
289 Note: Instrumentations specified as minimum required. vendor shall include any other instruments if required for smooth, safe
290 and Trouble free operation of the DG sets. Also refer respective instrumentation specs attached elsewhere.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 534 OF 1216

291 MATERIAL
292 Charge Air Cooler Shell: Tubes:
293 Water Cooler Shell: Tubes:
294 Air Cooler Shell: Tubes:
295 Air Receiver
296 Fuel Tank: MS
297 INSPECTION AND TESTING
298 Witness Observe
299  Stage Inspection during Manufacture  
300  Full Load Test at Engine Manufacturer’s Shop (Refer respective Job specification)  
301  Fuel consumption & Governing Test at Engine Manufacturer's Shop.  
302  Control Panel Functional Test at LP vendor's shop.  
303  Full Load Test for 4 hours & 10% overload test for 1 hour of Engine Generator set at Packager’s shop  
304  No load Mechanical Run test at Packager's/Driven Eqpt. Mfr. Shop  
305  Site Testing of the DG Set (Refer Remark- 1)  
306 Inspection/Testing Witnessed By: Others  Owner/ PMC/ Representative
307 WEIGHTS
308 Net Weight of Engine with Mounted Ancillaries (kg):
309 Heaviest part to be handled during erection and its weight (kg):
310 Heaviest part to be handled during normal maintenance and its weight (kg):
311 Recommended Crane capacity (Tons): Crane Hook Height (m):
312 MAINTENANCE DATA
313 Expected Period of Running Between Top Overhauls: Hours
314 Expected Period of Running Between Main Overhauls: Hours
315 The Type and Grade of Lubricating Oil Recommended
316 Lube Oil Consumption (kg/hr)/ (Litres/hr)
317 Change of Lubricating Oil After: Hours
318 ACCESSORIES
319  Flywheel with Barring Device
320  Guards for Moving Parts
321  Common Base Plate for Engine - Driven equipment
322  Foundation/ Anchor Bolts, grouting material
323  Acoustic enclosure with ventilation system
324  Anti Vibration Pads (if required)
325  First Fill of Lubricating Oil
326 Torsional analysis report on Engine & Generator
327  Quotation for 2 years spares parts for Normal Operation and Maintenance along with unit prices
328  Site Storage, Erection & commissioning of DG Set
329
330
331 REMARKS
332 1) DG Set shall be tested at site based on the available load so as to demonstrate power and voltage build- up at the alternator
terminals.
333 2) DG set shall be suitable for black start condition. For initial start as well as subsequent black start requirement, all facilities are
considered in the vendor scope.
334
335
336
337
338
339
340
341
342
343
344

04.05.2018 A SY AKM
Date Rev Job Engineer Rev. & Approved By

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 535 OF 1216

 OFFERED MODEL:
DG SET PACKAGER:
(DG Packager to clarify the meaning of each letter/ digit in the Model designation)

SL. PARAMETER INFORMATION ON INFORMATION ON REFERRED EXISTING INSTALLATIONS REMARKS

NO. PROPOSED MODEL
Ref.- 1 Ref.-2 Ref.-3
1. 2. 3. 4. 5. 6. 7.
1 DG SET MODEL NUMBER/ NO. OF UNITS
2 DG Set rating (KVA/KW)
3 Place of Packaging/ Unitization
4 Make/ Model of Diesel Engine
5 Make/ Model of Alternator ----
6 Auxiliary Systems engineered & supplied by (Engine
Manufacturer/ DG set vendor)
7 Ait intake system (including air filter and inlet air ducting/
piping) engineered & supplied by (Engine Manufacturer/
DG set vendor)
8 Engine Exhaust System (including exhaust silencer and
exhaust gas ducting/ piping and thermal insulation)
engineered & supplied by (Engine Manufacturer/ DG set
vendor)
9 Primary Cooling System
10 Secondary Cooling System
11 Fuel System (*)
12 Air Starting System (*)
13 Battery Starting System
14 Gauge Boards
15 Electrical Panels (Note (*) excluding engine mounted
equipment & accessories supplied by engine manufacturer)
16 Coupling Make

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 536 OF 1216

SL. PARAMETER INFORMATION ON INFORMATION ON REFERRED EXISTING INSTALLATIONS REMARKS
NO. PROPOSED MODEL
Ref.- 1 Ref.-2 Ref.-3
1. 2. 3. 4. 5. 6. 7.
17 Skid Size (L X W x H) m
18 Skid Gross Weight (Engine + Alternator + Common skid/
baseplate), kgs
19 Date of supply of DG Set
20 Date of commissioning of DG Set
21 No. of operating hours completed as on the date of issue of
inquiry
Major Problems encountered
22

23 Name of plant
24 Purchaser's Name and Address

Name (Company / Organization)

Name of Contact Person
Address

Telephone No.
Fax No.
email-id

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 537 OF 1216

 EXPERIENCE RECORD - DIESEL ENGINE

SERVICE :

ITEM NUMBER. :

VENDOR. :
INSTRUCTIONS TO BIDDERS:

1. This proforma duly filled in shall be submitted for each item separately.
2. Since the information requested in this proforma will be utilised to assess provenness of offered model, it is in the interest of the equipment
manufacturer to pick up those cases out of total list of references which most closely match with the offered model. The equipment manufacturer
shall also ensure that each & every information asked for is furnished and the same is correct and complete in all respects.
3. While furnishing the materials, where asked for, the equipment manufacturer shall furnish ASTM equivalents also.
4. For the referred installations, the equipment manufacturer shall indicate the name of the person (alongwith his address, telephone no., fax
no./email-id etc.) who may be contacted by the Purchaser / his representative, if felt necessary.
5. The equipment manufacturer shall also furnish his standard reference list for the offered equipment model manufactured and supplied by him.
6. The equipment manufacturer shall clarify the meaning of each letter / digit used in the model designation below:
Description of Model designation system:

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 538 OF 1216

SL. PARAMETER INFORMATION ON INFORMATION ON REFERRED EXISTING INSTALLATIONS REMARKS
NO. PROPOSED MODEL
Ref.- 1 Ref.-2 Ref.-3
1. 2. 3. 4. 5. 6. 7.
1 GENERAL
1.1 Cross reference to manufacturer's Standard Reference list ----
1.2 Make
1.3 Model
1.4 No. of units supplied
1.5 Driven Equipment
1.6 Type of Drive Arrangement (Direct/Gear Box/Other)
1.7 Type of Driven Equipment
1.8 Shop where engine is designed, manufactured & tested
with location and complete address

2 OPERATING CONDITIONS
2.1 Fuel used
2.2 Maximum continuous rating, kW at Std oper. cond. (ISO
3046/BS 5514)
2.3 Net site rating of the Engine, kW
2.4 Engine rpm
2.5 BMEP at standard conditions (ISO/BS)/at rated conditions,
kg/cm²g
3. CONSTRUCTION
3.1 No. of Cylinders/Cylinder Arrangement
3.2 Bore x Stroke, mm.
3.3 Charging type
(Normally aspirated/Turbo charged/Inter cooled/After
cooled)
3.4 Engine Cooling (Air, Cooled/Water Cooled)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 539 OF 1216

SL. PARAMETER INFORMATION ON INFORMATION ON REFERRED EXISTING INSTALLATIONS REMARKS
NO. PROPOSED MODEL
Ref.- 1 Ref.-2 Ref.-3
1. 2. 3. 4. 5. 6. 7.
3.5 Engine frame provided with explosion relief device:
Yes/No/Not recommended by vendor
4 OTHER INFORMATION ON INSTALLATIONS
4.1 Date of supply of entire unit
4.2 Date of commissioning of entire unit
4.3 No. of operating hours completed as on the date of issue of
material requisition
4.4 Major Problems encountered

4.5 Name of plant

4.6 Purchaser's Name and Address
Name (Company / Organization)
Name of Contact Person
Address

Telephone No.
Fax No.
email-id

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 540 OF 1216

 ENGINEERING DESIGN BASIS
(ELECTRICAL)

(B047-003-16-50-EDB-0001, REV. 0)

PROJECT : LEH AIRPORT

CLIENT : AIRPORT AUTHORITY OF INDIA

CONSULTANT : ENGINEERS INDIA LIMITED

JOB NO. : B047

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 541 OF 1216

 CONTENTS

1. SCOPE

2. ABBREVIATIONS CODES AND STANDARDS

3. SITE CONDITIONS

4. POWER SOURCE DETAILS

5. POWER SUPPLY DISTRIBUTION SYSTEM

6. CONTROL - PROTECTION - METERING

7. SUBSTATION DESIGN

8. EQUIPMENT DESIGN

9. CABLING SYSTEM

10. EARTHING SYSTEM

11. LIGHTING SYSTEM

12. STATUTORY APPROVAL

13. CABLE SIZES FOR 415 V MOTORS

14. SPECIFIC REQUIREMENTS

15. SPARE PARTS

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 542 OF 1216

1.0 SCOPE

This electrical design basis defines the design requirements agreed by owner/clients in addition to EIL
standard design philosophy for electrical facilities no: 6-51-0099, In case of any conflict between the
statutory requirements, this design data document and Standard Design Philosophy document no.6-
51-0099, the most stringent requirement shall govern.

2.0 ABBREVIATIONS / Codes and Standards

2.1 ABBREVIATIONS

Code Description
AC Alternating Current
ACB Air Circuit Breaker
ASB Auxiliary Service Board
CBCT Core Balance Current Transformer
CEA Central Electricity Authority
CPP Captive Power Plant
DC Direct Current
DCP Data Concentrator Panel
DG Diesel Generator
DGMS Director General Mines Safety
DOL Direct On Line
ECS Electrical Control Station
EHV Extra High Voltage
ELCB Earth Leakage Circuit Breaker
EOT Electrical Overhead Travelling
EPC Emergency Power Control Centre
EPMCC Emergency Power cum Motor Control Centre
FRLS Flame Retardant Low Smoke
GI Galvanised Iron
GIS Gas Insulated Switchgear
GTG Gas Turbine Generator
HMI Human Machine Interface
HSR High Availability Seamless Redundancy
HV High Voltage
IEC International Electro-Technical Commission
LDB Lighting Distribution Board
LV Low Voltage
MCC Motor Control Centre
MCCB Moulded Case Circuit Breaker
MOV Motor Operated Valve
MV Medium Voltage
MVA Mega Volt Ampere
NGR Neutral Grounding Resistor
OLTC On Load Tap Changer
LCSS/PCC Power Control Centre
PESO Petroleum & Explosive Safety Organisation
PLC Programmable Logic Control
LCSS/PMCC Power Cum Motor Control Centre
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 543 OF 1216
 PRP Parallel Redundancy Protocol
PTB Physikalisch-Technische Bundesanstalt
ERC Electrical Road Crossing

2.2 Codes and Standards

The main codes and standards, considered as minimum requirements, as applicable, are as
follows –

S.NO. DESCRIPTION STANDARDS / EDITION

CODES
1. Code of practice for the fire safety of buildings - Electrical IS-1646 Latest
Installations.
2. Code of practice for selection: installation and maintenance of IS-2189 Latest
automatic fire detection and alarm system.
3. National building code Latest
4. Code of practice for protection against lightning IS/IEC 62305 Latest
5. Code of practice for fire safety of industrial buildings - Electrical IS-3034 Latest
generating and distributing stations.
6. Code of practice for Earthing. IS-3043 Latest
7. Code of practice for Interior Illumination. IS-3646 Latest
8. Application guide for Insulation Coordination. IS-3716 Latest
9. Code of practice for installation and maintenance of electrical IS-4051 Latest
equipment in mines
10. Guide for safety procedures and practices in electrical work IS-5216 Latest
11. Guide for selection of electrical equipment for hazardous areas. IS-5571 Latest
12. Classification of hazardous areas (other than mines) having IS-5572 Latest
flammable gases and vapours for electrical installations.
13. Code of practice for Industrial Lighting. IS-6665 Latest
14. Guide for Control of undesirable static electricity. IS-7689 Latest
15. Guide for improvement of power factor - consumer's installations. IS-7752 Latest
16. Application guide for on load tap changers. IS-8478 Latest
17. Reference ambient temperature for electrical equipment IS-9676 Latest
18. Code of practice for selection, installation and maintenance of IS-10028 Latest
transformer.
19. Code of practice for selection, installation and maintenance for IS-10118 Latest
switchgear and control gear.
20. Application guide for Power Transformer. IS-10561 Latest
21. Voltage bands for electrical installations including preferred IS-12360 Latest
voltages and frequencies.
22. Guide for short circuit calculations in three phase AC systems. IS-13234 Latest
23. Code of practice for the selection, installation and maintenance of IS-13408(Part- Latest
electrical apparatus for use in potentially explosive atmospheres. 1)
24. Guide to the use of electrical apparatus for potentially explosive IS- 15142 Latest
atmospheres in the presence of combustible dusts
25. National Electrical Code (NEC) - BIS Publication. SP-30 Latest
26. Electrical apparatus for explosive gas atmospheres - General IS/IEC 60079-0 Latest
requirements.
27. Equipment protection flameproof enclosures "d" IS/IEC 60079-1 Latest
28. Electrical apparatus for explosive gas atmospheres - Intrinsic IS 5780/IEC Latest
safety 'l' 60079-11
29. Electrical apparatus for explosive gas atmospheres Increased IS-6381/IEC Latest
safety type "e" 60079-7
30. Electrical apparatus for explosive gas atmospheres - Oil IS 7693/IEC Latest
immersion "o" 60079-6
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 544 OF 1216
 S.NO. DESCRIPTION STANDARDS / EDITION
CODES
31. Electrical Apparatus for explosive gas atmospheres - Powder IS 7724/IEC Latest
filling 'q' 60079-5
32. Classification of flammable gases or vapours with air with air IS 9570/IEC Latest
according to their maximum experimental safe gaps and minimum 60079-12
igniting currents
33. Electrical apparatus for explosive gas atmosphere -Part-15 IS/IEC 60079- Latest
Construction, test and marking of type of protection "n" electrical 15
apparatus
34. CPWD specifications Latest
35. Griha specifications Latest
36. Energy efficient induction motor 3 phase squirrel cage IS 12615 Latest
37. Outdoor type oil immersed distribution transformer up to and IS 1180 Latest
including 2500KVA
38. IEEE Recommendation practice and requirements for harmonic IEEE 519 Latest
control in electrical power system

3.0 Site conditions

1.1 Equipment design temperature (IS-9676) : 40 °C
1.2 Relative humidity : 30-100%
1.3 Soil Resistivity : 150 Ohm-meter
1.4 Minimum temperature. for battery sizing : 10°C
1.5 Altitude above mean sea level : 3515 m above MSL
1.6 Maximum/minimum temp. : 35 ºC / -22ºC

2.0 Power Source Details

2.1 General
2.1.1 Independent system or Existing system : Existing (11 kV grid supply from SEB)
2.2 Grid Supply : Yes
If No, below Clauses NA
2.2.1 Name of sub station : 66/11KV Receiving Substation (By M/s
AAI/SEB)
2.2.2 Number of feeders : One
2.2.3 Length of feeder : 200 Meter (approx)
2.2.4 Type /size of conductor/ cable size : 3Cx400 mm², Al. XLPE cable (as per 25KA, 3
sec fault level (assumed))
2.2.5 Voltage : 11 KV ±10%
2.2.6 Frequency : 50 Hz ± 3%
2.2.7 Design fault level : 25KA (3 sec.) (to be confirmed by AAI/ SEB)
2.2.8 Basic Insulation Level : * kV (Grid Data by AAI/ SEB)
2.2.9 System Neutral Earthing : *

2.2.10 Minimum power factor : * ( As per SEB)

2.2.11 Parallel operation of incomers : Not Applicable
2.2.12 PLCC requirement : NO
2.3 CPP and its configuration : Not Applicable

2.4 Emergency generator : Centralised

2.4.1 Generator Voltage : 415V
2.4.2 Parallel operation with other sources : Required (Momentary Paralleling only @
Manual Operation)
2.4.3 Auto Starting : Yes
2.4.4 Redundancy
VOLUME-2 (ELECTRICAL) : N + 1 configuration
SOW & SPECIFICATIONS PAGE NO. 545 OF 1216
(*) Data to be furnished by client

2.4.5 Black Start DG Envisaged : Yes

3.0 Power Supply Distribution System

3.1 Voltage and frequency variation
3.1.1 AC System
Voltage : 415V ± 6% and 11KV ± 10%
Frequency : 50 Hz ± 3%
(Refer clause no: 6.9 of this document for design voltage/frequency variation for motors)
3.2 Utilisation voltage
3.2.1 Primary EHV/HV distribution voltage : (NOT APPLICABLE)
3.2.2 Secondary HV distribution voltage : 11 kV
3.2.3 Primary HV distribution system neutral : (NOT APPLICABLE)
Earthing
3.2.4 Secondary HV distribution system Neutral : Resistance Earthed (to be confirmed by AAI/
Earthing SEB)
3.2.5 HV motor voltage for DOL (kW more than : (NOT APPLICABLE)
160kW)
3.2.6 MV motor voltage (0.18≤kW ≤160 ) : 415 V AC [except VFD/ Soft Starter fed motor]
3.2.7 AC Motors rated below 0.18 kW (except : 240V AC (1-phase)
MOVs)
3.2.8 DC Motor : Not Applicable
3.2.9 Motor operated valves : 415V AC, TP
3.2.10 Battery chargers incoming power supply : Not Applicable
3.2.11 UPS System incoming power supply : 415V AC,TPN
3.2.12 AC Lighting/Power Panels : 415V AC,TPN
3.2.13 Auxiliary Boards incoming power supply : 415V AC,TPN
3.2.14 Welding Receptacles : 415V AC,TPN
3.2.15 Bulk loads like Process Heaters etc : 415V AC,TPN
3.2.16 Emergency Lighting : 240V AC, SPN (100% lights are on emergency,
i.e. DG fed)

3.3 Utilisation voltage for critical supplies

3.3.1 Switchgear protection control power : 240V AC UPS
supply
3.3.2 Critical lighting power supply : 240V AC UPS ( 10% lights shall be on UPS)
3.3.3 Input power supply for Public Address : 240V AC UPS
system
3.3.4 Input power supply Fire alarm system : 240V AC SPN
power supply [With Dedicated battery back-up for 24 hours
(quiescent load) plus 15 minutes (max. fire
load)]
3.3.5 Power supply for electrical annunciation : NOT REQUIRED
panel
3.3.6 Normal Instrumentation power supply : Refer Instrumentation Design Basis
3.3.7 Critical instrumentation power supply : Refer Instrumentation Design Basis
3.3.8 Instrumentation Shut-down system power : Refer Instrumentation Design Basis
supply

3.4 Operating philosophy

3.4.1 Auto/Manual transfer at primary HV : Not Applicable
distribution voltage bus with momentary
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 546 OF 1216
 paralleling
3.4.2 Auto /Manual transfer at MV
a (At PCC, ASB & HVAC Panels) : Yes
b (Lighting Panel Level) : NA
c (Other Distribution Panel Level) : No (only Manual transfer)
3.4.3 Continuous Parallel operation of Incomers
a Primary EHV/HV voltage : NOT APPLICABLE
b Secondary HV voltage : NOT APPLICABLE
c PCC/ASB : No
3.5 Automatic Power Factor Correction : APFC at 415 V Bus of PCC-301

Power factor improvement capacitors- : 415V Bus

location
P.F. required at Transformer Primary : 0.97 minimum at 415 V Bus

3.6 Load shedding : No

Voltage level for Load Shedding Not Applicable
4.0 Control -Protection - Metering
4.1 Control Philosophy
4.1.1 Location of Protection relays for EHV/ HV
switchgear
a Primary voltage EHV 66 kV switch gear : By SEB
b Secondary Voltage HV 11 KV switchgear : On Switchgear
4.1.2 EHV/HV Switchgear control
a Primary voltage EHV 66 kV switch gear : By SEB
b Secondary Voltage HV 11 kV switchgear : On switchgear (at HT 201)
4.1.3 Numerical Protection/ Monitoring system
for
a EHV 66 kV system : By SEB
b HV Switchboard : Yes
c 415V PCC/ASB /HVAC Panel : Yes
d 415V PDB : No
4.1.4 Control and logic through numerical : Yes
relays
4.1.5 HMI/ Data concentrator panel NOT APPLICABLE
a Human machine interface system-HMI : NA
b Data concentrator panel at substation : NA
c Separate data concentrator panel for : NA
each EHV/ HV/ MV system
d Operator cum engineering console : NA
e Separate Operator console : NA
f Separate Engineering console : NA
g Interface with Building Management : YES
System
h Location of HMI : NA

i Common HMI for EHV/HV /MV system : NA

j Lap Top : Required (for parameterization of Numerical
relays)

4.1.6 Communication Requirements

a Communication protocol from Relay to : NA
DCP
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 547 OF 1216
 b Communication from Relay to Building : Open Protocol
Management System
c Communication from relay directly to HMI : Not Applicable
d Communication with VFD & UPS : Part of BMS
e Protocol for Communication with VFD & : MODBUS TCP/IP
UPS

4.1.7 Method of motor starting

a For motors greater than or equal to 5.5 : DOL
kW but less than 75 kW
b For motors > 75kW : Soft Starter
d. For motors with variable speed : VFD
requirement
c
4.2 Relay protection system
4.2.1 Protection devices for power distribution system shall be as indicated below
(Figure inside bracket refers to note below) √ - Applicable
RELAY DESCRIPTION RELAY HV TRANSFORMER HV OUTGOING INCOMER
NUMBER FEEDER MOTOR BREAKER
FEEDER FEEDER

(SECONDARY (SECONDARY HV MV HV MV
WINDING WINDING PLANT PCC/ PCC/
VOLTAGE VOLTAGE FEEDER PMCC PMCC
> 3.3 KV) < 0.433 KV)

IDMTL over-current relay 51 √ √ - √ √ √ (1) √

IDMTL earth-fault relay 51N √ (2) √ - √ √ √ (1) √

51G backup earth-fault relay 51G (11) √(23) √ (23) - - - - -

(earthed neutral)
Motor protection relay with 99 - - √ (3) - √ (3) - -
(50, 50N,46, 49, 50L/R,86,95
)
Instantaneous restricted 64R (11) - - - - - √ (24) √
earth-fault relay (Earthed
side)
Instantaneous over-current 50 √ √ - - - - -
relay
Instantaneous earth-fault 50N √(4) √ - - - - -
relay
Differential protection relay 87 √(5) - √ (6) √ (7) - - -

High speed tripping relay 86 (20) √ √ √ √ √ √ √

Trip circuit supervision relay 95 (20) √ √ √ √ √ √ √

Transformer auxiliary relay 63 √ √ - - - - -

Under-voltage relay with 27/2 - - √ - - √ (9) √ (9)

timer
Check synchronisation relay 25 - - - - - √ (10) √(10)

4.2.2 Power generation and External power supply

Minimum protection relays for Synchronous generator (GTG/STG), generator transformer
National power supply incomer and Synchronous motors shall be as follows √ -
Applicable

RELAY DESCRIPTION NEMA GENERATOR

CODE (NOT
APPLICABLE)
Distance protection 21
Synchronous check 25 √(27)

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 548 OF 1216

 RELAY DESCRIPTION NEMA GENERATOR
CODE (NOT
APPLICABLE)
Under voltage with 27 √
timer
Reverse power 32 √

Low power flow 37 √

Loss of excitation 40 √

Negative sequence 46 √

Over current 50
Earth fault relay 50N
Over current 51
Voltage restrained 51V √

Earth Fault back up 51G √

Over current E/F 51N

Over voltage with 59 √
timer
VT failure 60 √

Auxiliary relay for 63TX

transformer
Transformer 64R √(26)
Restricted Earth Fault
Stator back up earth 64G √
fault
Generator Rotor Earth 64R √
fault
Directional O/C 67
Directional E/F 67N
Under frequency/df/dt 81 √

Tripping relay 86 √

Gen differential 87G √

Gen and Transformer 87GT

differential
Transformer 87T
Différential
Feeder differential 87F
Bus bar differential 87B/
and check 87C
H
Trip circuit supervision 95 √

Dead bus charging 98 √(27)

relay
Over fluxing 99 √

Out of step 78 √

Thermal overload 49G √

Local breaker backup 50LB √

protection B
RTD/ BTD √

Notes for Clause 4.2:

1. In case of HV switchboards with continuous parallel operation of incomers, following additional
relays shall be provided:
a. One set of 87B (Bus differential) and 95 B (Bus wire supervision) for each bus section.
b. 67 and 67N (Directional IDMTL over current and earth fault) relays for the incomers.
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 549 OF 1216
2. Instantaneous earth fault (50N) shall be provided only for transformer with delta primary.
3. For breaker fed motor feeders (rated above 55 kW) Relay 50 shall not be provided for
contactor controlled feeders.
4. Directional IDMTL earth fault (67N) shall be provided for transformer with star primary.
5. For transformers rated 5 MVA and above.
6. For motors rated 1500 kW and above, excluding VFD fed motors.
7. For critical/long feeders and plant feeders connected to main power generation and distribution
bus. A plant feeder implies outgoing feeders from one switchboard to another switchboard of
same voltage level.
8. Trip circuit supervision relay 95 shall be provided as part of the numerical relay for HV/ MV
feeders wherever numerical relays are provided
9. Wherever auto-transfer feature is provided
10. For switchgears where continuous or momentary paralleling of Incomers is envisaged, check
synchronising relay shall be provided.
11. 51G and 64R relays for input transformer of VFD system shall be decided by VFD
Manufacturer.
12. The bus tie feeders in HV/ MV switchboards shall be provided with 51, 51N, 86 and 95 relays.
13. HV capacitor bank feeders shall be provided with 51, 51N, 59 (over voltage), 60
(Neutral displacement), 86 and 95 relays.
14. The following feeders shall be provided with timers for delayed tripping on bus under
voltage while the under voltage relay shall be common for the bus
a. HV and MV capacitor feeders
b. HV and MV breaker controlled motor feeders
c. Contactor controlled motor feeders with DC control supply.
Numerical relays where ever provided for motor and capacitor feeders shall use in built under
voltage relay and timer for delayed tripping on bus under voltage.
15. One no. DC supply supervision relay (80) shall be provided for each incoming DC supply to the
switchboard.
16. One set of bus differential relays (87B) and bus wire supervision relay (95 B) for each bus
section shall be provided for HV switchboards connected directly to generation buses.
17. In case of numerical relays, all relays shall be comprehensive units including all protection,
metering and control.
18. Under voltage and over voltage along with associated timer shall be part of the numerical
relays.
19. Auto changeover (if specified) logic between Incomers and bus coupler shall be built in the
numerical relay.
20. Tripping relays (86) & Trip Circuit supervision relay (95) shall be part of numerical relay for HV
& MV System, but EHV system these relay shall be separate relay.
21. 2 Nos. of 86 relays shall be considered for HV and MV breaker fed motor (rated more than
55KW) for ease of differentiating between process trip and electric trip and electric trip relay 86
shall be part of the Numerical relays wherever provided. Process trip 86 relay shall be
electromechanical, self reset type.
22. Breaker control switch shall be hardwired type.
23. Stand by earth fault relay 51G shall be provided in the incomer of switchboard fed from
transformers and transformer and switchboard located remotely from HV substation.
24. Restricted earth fault relay 64R shall be provided in the incomer of switchboard fed from
transformers having secondary voltage greater than 3.3KV or transformer rating > 2.5MVA and
secondary winding is star connected.
25. Relay 51V voltage controlled over current relay shall be provided on specific requirement
considering the rating of the outgoing feeders with respect to the Incomer rating. Generally this
relay shall be provided wherever CT primary current of outgoing feeders is exceeding 40% of
the CT primary current of the Incomer.
26. 415V DG set shall be provided with protection but not limited to 51V,51G,40,46,86,95,80, 64R
etc for generator rated above 500KVA and Generator rated less than 500KVA shall have 51V,
51G, 40, 46, 86, 95, 80 unless otherwise agreed with the owner.
27. Relay 87 and 64R shall be separate numerical relay. Hence shall not be part of main
comprehensive numerical relay. CT for 87 and 64R can be clubbed, as two core of single CT.
28. Stabilizing reactors shall be provided in residual earth fault connection for all motors and
transformers even in case of numerical relay to avoid spurious tripping during standby.

4.3 Metering
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 550 OF 1216
4.3.1 The metering devices in HV and MV switchboards shall be as below:
Type of metering : Analogue / As part of the Numerical relay @ HV
SWBD//PCC/ASB
FEEDER TYPE A V Hz PF MW MWH HM MVAR MVAH MVA
EHV/Grid Incomers √ √ √ √ √(2) √ - √(2) √(2) √(1,2)
EHV/Grid Bus Tie √
EHV/ Grid Transformer √ √ √
EHV / Grid Bus P.T. √
HV Incomer √ √ √ √ √ √ - √ √ √
HV Bus Tie √ - - - - - - - - -
HV Transformer √ - - - √ √ - - - -
HV Bus P.T. - √ - - - - - - - -
HV Plant Feeder √ - - - - √ - - - -
HV Motor √ - - - - √ kWh √ - - -
HV Capacitor √ √ - - - - - √ - -
LCSS/PCC/PMCC √ √ - √ - √ kWh - - - -
Incomer
LCSS/PCC/PMCC Bus √ - - - - - - - - -
Tie
LCSS/PCC Bus P.T. - √ - - - - - - - -
ACB Outgoing √ - - - - √ kWh - - - -
( Non motor)
MV Motor (>55kW) √ - - - - - - - - -
MCC/ASB Incomer √ √ - - - - - - - -
MCCB/SFU O/G (250A) √ - - - - √ kWh - - - -
LDB Incomer √ √ - - - √ kWh - - - -
DG Set-MV √ √ √ √ √ kW √ kWh √ - - -

Notes for Clause 4.3:

1. MVA meter in EHV external power supply Incomers shall include maximum demand indication
also.
2. Separate MW, MVAR, MVA and MVAH meters shall be provided for EHV external power
supply Incomers only.
3. Field Ammeters are to be provided for all motors rated above 5.5kW.
4. All metering shall be provided through numerical replays in case respective switchboard is
having numerical relay.
5. Separate 3 nos. of Voltmeters and 3 nos. ammeter shall be provided for EHV external power
supply incomers.

5.0 Substation Design :

5.1 EHV Switchyard : NOT APPLICABLE

5.2 Substation features

Description HV (SS) Substation Elect
(Note-1) (415V) Rooms
(Airport
Building)
5.2.1 Elevated with trays in cable cellar No No No
5.2.2 Raised with internal trenches No Yes (2) No
5.2.3 All top cable entry with trays below ceiling Yes (2) Yes (2) Yes (2)
5.2.4 Pressurisation against ingress of dust No No No
5.2.5 Air-conditioned room for operator / VFDs Yes Yes Yes
5.2.6 Roof slab for
a Power transformer (in switchyard) NA NA NA
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 551 OF 1216
 b Distribution transformer (in Substation / Yes No NA
Electrical Room)
5.2.7 Air conditioning of switchgear hall NO NO NO
5.2.8 EOT Crane in Substation NO NO NO
Note:
1. Substation having full-fledged HV Switchboard
2. Panels installed at Ground floor of Utility Building shall have Top Entry of cables. Panels
installed at Basement Floor shall have bottom entry of cables, as internal trenches are
provided at basement level. All Floor mounted panels to be installed at Airport Building shall
have top entry of cables.

5.3 Specific Equipment Locations

5.3.1 Batteries in substation and control : Separate room in substation / Battery Room in
Rooms Airport Terminal Building

5.3.2 DC Battery charger in substation : Yes (In Utility Building)

5.3.3 DC Battery charger in control room : NOT APPLICABLE
5.3.4 Variable speed drive panels : Air-conditioned rooms
5.3.5 UPS System : UPS Room in Airport Terminal Building (Air
conditioned room)
5.3.6 Lead-Acid and Nickel- Cadmium : Separate room – Non air-conditioned
5.3.7 Location of VRLA battery : Air conditioned room
5.3.8 Annunciation panel : NOT APPLICABLE
5.3.9 Lighting transformers : No

6.0 Equipment Design

6.1 EHV Outdoor Switchyard NOT APPLICABLE
6.1.1 Bus bar system :
6.1.2 Circuit breaker type :
6.1.3 Isolator type :
6.2 HV Switchboard
6.2.1 Execution : Draw out
6.2.2 Type of switchgear : Air insulated
6.2.3 Bus bar : Single bus
6.2.4 Circuit breaker type : VCB
6.2.5 Motor Control : NOT APPLICABLE

6.3 Current Transformer (CT) / Potential Transformer (PT)

6.3.1 CT Secondary :
a General Protection : 1A
b Special protection (87, 64R ,51G etc) : 1A
c Metering : 1A for conventional and remote metering
6.3.2 PT Secondary : 110 V AC

6.4 Transformers (Power/Distribution)

Transformer Voltage ratio Vector group Tap changer Cooling

6.4.1 Main power transformer NOT APPLICABLE
6.4.2 Generator unit transformer NOT APPLICABLE
6.4.3 Distribution transformer (< 2500 11/0.433 kV Dyn 11 On-Load TC ONAN
KVA) (3)
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 552 OF 1216
6.4.4 Lighting Transformer Not Applicable
Note:
1. Position of Oil Soak Pit & Oil Collection Pit for Transformers shall be as follows:
a) Oil Quantity ≤ 2000L – Not Required
b) 2000L < Oil Quantity ≤ 9000L: Soak Pit
c) Oil Quantity > 9000L: Soak Pit + Collection Pit
2. Fire fighting system shall be provided for transformers with Oil Quantity greater than 2000
litters.
3. On-Load Tap changer shall have range as per SOR has been decided as per the
feedback of M/s. AAI regarding voltage dip issues at LEH Location. However, same shall
be subject to changes/ updation as per Electricity Distribution Company’s directives
w.r.t. new 66/11 KV receiving substation’s parameters.

6.4.5 Execution
a PCC
(i) Breaker panels : Draw out, Single front
(ii) MCCB/Contactor feeders : Draw out, single / Double front
b MCC : NOT APPLICABLE
c ASB : Draw out /Fixed , Single /Double Front
d LDB : Draw out /Fixed, Single /Double Front
e Type of switchboard for small package : Compartmentalised and Fixed type
(AC system, Pressurisation system etc)

6.5 Medium voltage Motor Starter Type :

6.5.1 Contactor and switch fuse with overload : NA
relay
6.5.2 Contactor, switch fuse and overload : NA
relay with CBCT for earth fault
protection
6.5.3 Contactor and switch fuse with motor : NA
protection relay
6.5.4 Air circuit breaker with motor protection : Above 55kW up to 160 KW
relay
6.5.5 Contactor and MCCB/MPCB with : Up to 22 KW
overload relay
6.5.6 Contactor, MCCB and overload relay : Above 22kW up to 55kW

6.6 Medium voltage Outgoing feeder :

Type
6.6.1 Switch fuse : NA
6.6.2 Switch fuse with Contactor and CBCT : NA
for earth fault protection
6.6.3 MCCB with in-built O/L, S/C, E/F : Upto 630A
releases
6.7 Motor Controls : As per process package and operating
philosophy
6.7.1 Auto / Manual switch : Control room
6.7.2 Local/ remote switch : Near motor
6.7.3 Process interlock : As required
6.7.4 Reacceleration equipment : Switchgear/ Starter
6.8 Control supply voltage :

6.8.1 Breaker control : 110 V DC

6.8.2 Breaker spring charging : 110 V DC
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 553 OF 1216
6.8.3 Contactor feeder : 240V AC
6.8.4 Control supply for earth fault relay in : 110 V DC
contactor feeder
6.8.5 Control supply for contactor motor : Control transformer
starter
6.8.6 Control transformer for each bus : Yes
section
6.9 Motors
Motors High voltage 415 volts
(NOT APPLICABLE)
6.9.1 Enclosure
Indoor - IP55
Outdoor - IP65
6.9.2 Insulation class - F
(Temp. Rise limited to B)
6.9.3 Anti-condensation heater - 30 kW and Above
6.9.4 Additional canopy - Yes
(outdoor motors)
6.9.5 Design voltage variation - ±10%
6.9.6 Design frequency variation - ±3%
6.9.7 Combined voltage / - ±10 %
frequency variation (Design) Any combination of above
Note:
1.0 Motors for MOV actuator shall have F class of insulation with temperature rise limited to class-
B.

6.10 UPS System

6.10.1 Redundancy : 100%
6.10.2 Type of redundancy : Parallel redundant
6.10.3 Back-up time : For Lighting System: 30 mins.
For Inst. System: 30 mins.
6.10.4 Bypass transfer control : Auto
6.10.5 Separate fault diagnostic unit : No
6.10.6 Battery type : VRLA (2x50% configuration)

6.10.7 Type of UPS : IGBT

6.10.8 UPS Output Supply : For Lighting System: SPN
For Inst. System: TP+2N
6.10.9 UPS Output Voltage : For Lighting System: 230 V AC
For Inst. System: 415V AC (TPN)
6.11 Communication System
6.11.1 Public Communication System : Public address (1 way)
6.11.2 Telephone System : Refer Instrumentation DB
(No analogue telephone system & Fire Fighters
Telephone system is required)
6.11.3 Telephone system and plant : NOT APPLICABLE
Communication system
6.11.4 No. of external lines : NOT APPLICABLE
6.11.5 No. of Intercom lines : NOT APPLICABLE
6.11.6 Interface of Communication system :
a With fire alarm system : Yes
b With telephone system : Yes
c With BMS : Yes
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 554 OF 1216
6.12 Fire Detection and Alarm System
6.12.1 Type : Addressable
6.12.2 Name of buildings to be provided with : For complete Airport
Detectors
6.12.3 Detection System : Double Action Resettable type Manual Call
Points, Smoke Detectors/ Heat Detectors
(intrinsically safe)
6.12.4 Type of manual call point : Without call back facility
6.12.5 Qty. of Siren and location : Siren Not Required
6.12.6 Power supply for Siren : Not Applicable
6.12.7 Siren range : Not Applicable
6.12.8 Response indicator for rooms and : Not Required as the system is addressable
concealed area for conventional Fire system.
alarm system
Notes:
a). Repeater panel not required.
b). Fire Fighter Display not required.
c). Panic Bars shall be hooked up with
FA System.

6.13 DC System
6.13.1 Battery type
a Switchgear Protection Control : VRLA
b Instrumentation System ( UPS) : VRLA
c Diesel Engine Starting : Lead acid
d DC Motors : NOT APPLICABLE
e Fire alarm system : VRLA
f Plant communication system : NOT APPLICABLE
g Telephone system : Refer Instrumentation System
6.13.2 Battery back up time :
a Switchgear Protection and Control : 1 hours
b DC Critical lighting : NOT APPLICABLE
c Instrumentation : For Lighting System: 30 mins.
For Inst. System: 30 mins.
d Diesel Engine Starting : 10 starts (FW pumps) & 6 starts (others)
e DC Motors : As per equipment manufacturer’s
recommendation
f Fire alarm system : 24 hours Plus 15 minutes

6.14 Variable Frequency Drive

6.14.1 By pass feature required : As per process requirement [Note-7]
6.14.2 VFD rated output voltage :
a MV Inverter : i) Motor kW rating less than 315kW at 415V ,
ii) More than 315kW & up to 700kW at 690V
b HV Inverter : NOT APPLICABLE
6.15 Cables
The power and control cables shall have the following minimum cross sectional areas:
6.15.1 Medium voltage power cable : 2.5 mm² to 16 mm² (Copper)
Above 16 mm² (Aluminium)
6.15.2 Control cables : 1.5 mm² (Copper) [ Note 5 ]
6.15.3 Lighting : 2.5 mm² (Copper)
6.15.4 Communication system : 0.9 mm dia. (Copper)
6.15.5 Fire alarm system : 1 pair, 1.5 mm² (Copper)
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 555 OF 1216
Notes for clause 6.10 & 6.15:
1. For lighting inside the building, minimum 1.5 mm² copper conductor, PVC Insulated wire shall
be used in conduit system (for circuit and point wiring), with proper colour coding.
2. Cable sizes are indicative only and these shall be finalised as per the recommendations of the
equipment manufacturer.
3. Special cable type and size shall be decided on specific requirement.
2 2
4. All power cables up to 16mm shall be with copper conductor and above 16mm shall be with
aluminium conductor.
5. Control cable shall be twisted pair overall shielded cable.
6. Outer PVC sheathe of all cables shall be flame retardant type. Cables shall have low smoke
properties i.e. FRLS type with 60% (max) smoke density.
7. Bypass for VFD shall be provided as a standard practice unless not recommended from
Process or Driven equipment operation point of view.

7.0 Cabling System

7.1 Cable details

Design Criteria HV 415 volts
Loads located beyond 1 km Cable Cable
Loads located 200-1000 m 1-core cable/ 3-core 1-core / 3½-core cable
cable
Load located up to 200 m Cable Cable / Bus trunking
Loads beyond 1000A rating and located 1 core cable Bus duct
near the transformer.
Recommended limiting size of multi-core 400 300
cable (sq. mm²)
Short-circuit withstand time (seconds) Incomer from transformer Not Applicable
:
1 no. incomer from other
switch board : 0.6
Plant feeder :0.6
Motor/Transformer /
Capacitor feeder:0.2
Insulation voltage grade Unearthed Earthed
Type of cable insulation XLPE XLPE
Fire survival (Resistant) cable for Fire - Yes
proof MOV
Power Cables for Motors 3 core 3½- core

Cable Conductor Aluminium Aluminium / Copper

(Refer Note – 4 of cl.
6.15)

7.2 Cable Laying Philosophy

7.2.1 Airport Building : Overhead cable tray / RCC trench

7.2.2 Offsite paved area : Above Ground cable tray / RCC trench
7.2.3 Offsite unpaved area : Above Ground cable tray / directly buried.
7.2.4 Type of cable trays : Galvanized prefabricated
7.2.5 Road Crossings for underground cables : Hume Pipes / Cable culvert / ERC
7.2.6 Road Crossings for Above ground cables : Not Applicable
Note for clause 7.2:
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 556 OF 1216
1. Fire alarm cables shall be laid in instrumentation overhead cable trays / instrumentation
trenches as far possible. In case these are not available, cable shall be laid along berm of the
roads.

8.0 Earthing System

8.1 Earth electrode : Chemical Free Earth Electrode and CU Plate
earthing
8.2 Main earth loop material : GI strip
8.3 Substation earth loop : GI strip
8.4 EHV switchyard earth grid : Not Applicable

9.0 Lighting System

9.1 Supply System
9.1.1 Centralised with Lighting distribution : Yes
board-LDB
9.1.2 LDB at each substation / location : Yes
9.1.3 Lighting transformer required : No
9.1.4 100% Standby transformer for normal : N.A.
lighting system
9.2 Control Philosophy
9.2.1 External Lighting : With Timer (through BMS)
9.2.2 Street lighting : With Timer (through BMS)
9.2.3 Utility Building : Manual; Centralised (no Control Required)
9.2.4 Airport building : Auto/ Manual-Through Lighting Management
System (Part of Building Management System)
9.2.5 Type of Control : Switching/ Dimming
Note: Occupancy Sensors shall be used for
rooms only. Switching of circuits for common
areas such as arrival areas, departure areas,
etc. shall be through Day-light sensors only.
9.2.6 Lamp type for outdoor lighting including : LED
sheds
9.2.7 Lamp wattage for outdoor lighting : As required
9.2.8 Lamp type for emergency lighting : LED
9.2.9 ELCB at Incomer of Lighting / Power : Yes
Panels
9.2.10 Switch ON/OFF push button at substation : Yes
entry

9.3 AC Emergency Lighting

9.3.1 Name of buildings : Air port & Utility Building
9.3.2 Power supply source : UPS
(Note: 10 % of overall lighting shall be on UPS)

9.4 DC Critical Lighting for Escape Not Applicable (Considered UPS)

9.5 Wiring Type
9.5.1 Airport Building / Shed : Conduit / Armoured cable
9.5.2 Large service building : Armoured cable
9.5.3 Buildings with false ceiling : Surface conduit above false Ceiling
9.5.4 Substation (Switchgear Room) : Surface / concealed conduit
9.5.5 Other buildings : Conduit / Armoured cable
9.6 Specific Lighting Requirements

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 557 OF 1216

9.6.1 Aviation lighting : No (as no structure is above 30 m height)
9.6.2 Security lighting for peripheral road : Not Required
boundary wall
9.6.3 Type of high mast flood light : NOT REQUIRED
9.6.4 Type of Lighting Fixtures : LED only
10.0 Statutory Approval
Statutory Authority for Electrical Installation: State Electrical Inspectorate / CEA

11.0 CABLE SIZES FOR 415V MOTORS

11.1 As per Approved Cable Sizing Design Report/ cable schedule

12.0 Specific Requirements

12.1 LED Type of lighting fixture shall be used for indoor and outdoor lighting.
12.2 For Transformer sizing minimum 20% spare margin shall be considered for future load.
12.3 For Emergency PMCC the DG incomer shall be directly connected to it without any
intermediate Line side breaker cubicle.
12.4 All motors shall be Energy efficient, minimum IE3 type meeting the requirements of IS-
12615.
12.5 Earth fault protection shall be considered in incomers of Lighting Panels for all type of
lighting circuit (Indoor & outdoor).
12.6 For breaker fed 415V motors (above 55kW) separate lockout relay 86 for process trip need
to be provided.
12.7 All motors shall have local start/stop facility in the Local Control panel near motor in the field.
Motor status indications / command shall be provided as per process requirements in the
control room.

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 558 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 1 of 18

VENDOR DATA REQUIREMENTS

FOR
LEH AIRPORT

A 11-MAY-2018 ISSUED WITH TENDER RR DR VKJ

Rev. Date Purpose Prepared by Checked by Approved by
No.

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 559 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 2 of 18

VENDOR DATA REQUIREMENTS

The following drawings/documents marked " " shall be furnished by the bidder.

BATTERY & BATTERY CHARGER

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Vendor Drawing/ Document Submission
Schedule (Format EIL-1641-1923)
2. Data Sheets (Duly filled-in)
3. Dimensional/Assembly Drawings : GA Drawing
for Charger Panels, Cell Boosters and DCDB
4. Dimensional/Assembly Drawings : Battery Rack
Arrangement Drawing
5. Dimensional/Assembly Drawings : Sectional
View Drawing
6. Dimensional/Assembly Drawings : Cubical
Arrangement Drawing
7. Dimensional/Assembly Drawings : Installation
Plan/ Mounting Details/ Cable Cutout Details
8. Dimensional/Assembly Drawings : Bill of
Material
9. Electrical Wiring Drawings : Single Line
Diagram
10. Electrical Wiring Drawings : Block and Logic
Diagrams
11. Electrical Wiring Drawings : Control Schematics
12. Electrical Wiring Drawings : Wiring Diagram
and Terminal Details
13. Electrical Wiring Drawings : Interconnection
Diagrams
14. Calculations for : Battery Sizing
15. Calculations for : Charger Sizing
16. Calculations for : System Cables
17. QA Plan of Vendor
18. Inspection & Test Plan (ITP) -For review by
Client
19. Site Acceptance Test Procedure
20. Test Records
21. Type Test Certificates for similar equipment
22. Performance Curves of battery
23. List of Special Tools & Tackles
24. Data Books/ Manuals : Installation Manual
25. Data Books/ Manuals : Operating/ Maintenance
Manual
Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 560 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 3 of 18

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
26. Data Books/ Manuals : Catalogues/ Brochures
27. Equipment storage procedure at site

COMMUNICATION FIRE ALARM CABLES

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Data Sheets (Duly filled-in)
3. Dimensional Drawings : Cross sectional views
of cables
4. Dimensional Drawings : Crossectional view of
accessories
5. Test Records
6. Inspection & Test Plan (ITP) -For review by
Client
7. Type Test Certificate for similar cables
8. Data Books/ Manuals : Installation Manual
9. Data Books/ Manuals : Operating/ Maintenance
Manual
10. Data Books/ Manuals : Catalogues/ Brochures
11. Equipment storage procedure at site

ELECTRICAL SURFACE HEATING SYSTEM

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Data Sheets (Duly filled-in)
4. Dimensional Drawings : G.A. drawings of LDP
5. Dimensional Drawings : G.A. drawing of
accessories
6. Dimensional Drawings : Cross-sectional view of
surface heating cable
7. Dimensional Drawings : Cross-sectional view of
accessories
8. Heat loss calculations
Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 561 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 4 of 18

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
9. Electrical surface heating tape selection
calculations
10. Power cable sizing, voltage drop calculations
11. Single line diagram(s) of LDP(s)
12. Circuit wise load list
13. Block one line distribution diagram indicating
each LDP, feeding source, LDP load &
location, circuits
14. Wiring diagrams : LDP wiring diagrams

15. Wiring diagrams : Inter connection drawings

16. Cable schedule
17. Cable, Lighting, Earthing & Equipment layouts
of LDP rooms (if applicable) OR outdoor Kiosk
layout
18. Cable layout of LDPs in plant/ Unit ( if
applicable)
19. Earthing layout of LDPs in plant/ Unit (if
applicable)
20. Inspection & Test Plan (ITP) -For review by
Client
21. Type Test Certificate (For similar LDPs, Heat
tracing Cables)
22. CPRI test, CCE/ PESO approval certificates &
BIS license for equipment for hazardous area
application
23. Field testing and commissioning proceedure
24. Data Books/ Manuals : Installation Manual
25. Data Books/ Manuals : Operating/ Maintenance
Manual
26. Data Books/ Manuals : Catalogues/ Brochures
27. Equipment storage procedure at site

EMERGENCY GENERATOR PACKAGE

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Data Sheets (Duly filled-in)
4. Details of excitation system
5. Details of cooling system

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 562 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 5 of 18

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
6. GA drawing
7. Estimated capability curve
8. Open circuit characteristics
9. Short circuit characteristics
10. Short time under frequency operating limits
11. Control power requirements
12. Catalogues and brochures
13. Bill Of Material
14. Foundation/fixing arrangement drawings
15. Schematic diagrams
16. Logic diagrams
17. Interconnection/Wiring diagrams
18. Owner Interface Drawings
19. Testing procedure
20. Operation and maintenance manual
21. Site storage requirements
22. Test certificates
23. Inspection & Test Plan (ITP) -For review by
Client

ENGINE STARTING BATTERY & CHARGER

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Data Sheets (Duly filled-in)
4. Dimensional/Assembly Drawings : GA Drawing
for Charger panel
5. Dimensional/Assembly Drawings : Cubicle
Arrangement Drawing & Installation Details
6. Dimensional/Assembly Drawings : Battery Rack
Arrangement Drawing
7. Dimensional/Assembly Drawings : Bill of
Material
8. Electrical Wiring Drawings : Single Line
Diagram
9. Electrical Wiring Drawings : Logic Diagram

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 563 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 6 of 18

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
10. Electrical Wiring Drawings : Control Schematics
11. Electrical Wiring Drawings : Wiring Diagram/
Terminal Details/ Interconnection Diagram
12. Performance Curves of battery
13. Type Test certificates
14. Inspection & Test Plan (ITP) -For review by
Client
15. Calculations for : Battery Sizing
16. Calculations for : Charger Sizing
17. List of Special Tools & Tackles
18. Data Books/ Manuals : Installation Manual
19. Data Books/ Manuals : Operating/ Maintenance
Manual
20. Data Books/ Manuals : Catalogues/ Brochures
21. Equipment storage procedure at site

FIRE DETECTION AND ALARM SYSTEM

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Dimensional Drawings : GA Drawings for
Panels, Battery, Charger, UPS
4. Dimensional Drawings : Installation plan/
Mounting Details/ Cable cut-out details
5. Dimensional Drawings : Sectional View
Drawing
6. Dimensional Drawings : G.A. drawings of all
devices e.g. (Detectors, Call stations, Hooters,
Siren, Exit signs, Response indicators etc)
7. Dimensional Drawings : Cubicle arrangement
drawing
8. Dimensional Drawings : Mimic diagram
9. Dimensional Drawings : Battery rack
arrangement drawing
10. Dimensional Drawings : Name plate drawings
11. Dimensional Drawings : Bill of material
12. Electrical Wiring Drawings : Single Line
Diagram
13. Electrical Wiring Drawings : Block and Logic
Diagrams

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 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 7 of 18

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
14. Electrical Wiring Drawings : Control Schematics
15. Electrical Wiring Drawings : Wiring Diagram
and Terminal Details
16. Electrical Wiring Drawings : Interconnection
Diagrams
17. Performance Curves of battery
18. Test Records
19. Inspection & Test Plan (ITP) -For review by
Client
20. Calculations for : Selected quantity & location
of detectors
21. Calculations for : Battery Sizing
22. Calculations for : UPS, Battery charger sizing
23. Calculations for : System cable selection
24. Statutory approval certificate
25. Type Test Certificates for similar equipment
26. List of Special Tools & Tackles
27. Data Books/ Manuals : Installation Manual
28. Data Books/ Manuals : Operating/ Maintenance
Manual
29. Data Books/ Manuals : Catalogues/ Brochures
30. Equipment storage procedure at site

SOLAR POWER PACKAGE

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O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Eletcrical Design Basis
3. Equipment Sizing Calculation ( PV array, PCU,
Cables etc.)
4. Data Sheets (Duly filled-in) for major electrical
equipment i.e. PV modules, PCU, metrological
instruments, cables
5. Plant Earthing & Lightning Calculations
6. Single Line Diagram
7. Plant Electrical Equipment Layout
8. Control/ Protection/ Annunciation Scheme
9. Schematic Wiring Diagrams

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 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 8 of 18

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(FINAL)
10. Cable Layout
11. Earthing & Lightning Protection Layout
12. Cable Schedule
13. Equipment List
14. Software based report with annual energy
generation calculations at site conditions for 25
years
15. Operation & Maintenance Manual
16. Installation details of the PV modules and the
support structure
17. Type test certificates
18. Catalogues & Brochures
19. Bill of Material
20. Site acceptance test procedure
21. Inspection & Test Plan (ITP) -For review by
Client

HV SWITCHBOARD

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(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Data Sheets (Duly filled-in)
4. Dimensional/Assembly Drawings : GA
Drawings (Elevation and Plan) of switchboard
including clearance requirements
5. Dimensional/Assembly Drawings : Installation
Plan including foundation, cutout and mounting
details
6. Dimensional/Assembly Drawings : Cross
Sectional View
7. Dimensional/Assembly Drawings : Cubicle
Arrangement Drawing
8. Dimensional/Assembly Drawings : Component
Drawing
9. Dimensional/Assembly Drawings : Name Plate
Drawing
10. Dimensional/Assembly Drawings :
Arrangement of cable termination
11. Electrical Wiring Drawings : Single Line
Diagram
12. Electrical Wiring Drawings : Logic Diagram

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 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 9 of 18

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O. REVIEW RECORD BOOK
(FINAL)
13. Electrical Wiring Drawings : Control Schematics
14. Electrical Wiring Drawings : Wiring Diagram
and Terminal Details
15. Electrical Wiring Drawings : Interpanel Wiring
Diagram
16. Electrical Wiring Drawings : System
Architecture
17. Bill Of Material
18. Relay Characteristic Curve
19. Auxiliary Power Requirement Data (AC & DC)
20. Inspection & Test Plan (ITP) -For review by
Client
21. Test Records
22. Type Test Certificate for Panel & Breakers
23. List of Special Tools & Tackles
24. Data Books/ Manuals : Installation Manual
25. Data Books/ Manuals : Operating/ Maintenance
Manual
26. Data Books/ Manuals : Catalogues/ Brochures
27. Equipment storage procedure at site
28. Relay Parameterisation

MEDIUM VOLTAGE SWITCHBOARD

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(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Data Sheets (Duly filled-in)
4. Dimensional/Assembly Drawings : GA
Drawings
5. Dimensional/Assembly Drawings : Installation
Plan/Mounting Details
6. Dimensional/Assembly Drawings : Cross
Sectional View
7. Dimensional/Assembly Drawings : Bus Duct
GA Drawing
8. Dimensional/Assembly Drawings : Bus Duct
Termination Drawing
9. Dimensional/Assembly Drawings : Cubicle
Arrangement Drawing

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 567 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 10 of 18

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O. REVIEW RECORD BOOK
(FINAL)
10. Dimensional/Assembly Drawings : Name Plate
Drawing
11. Calculations for : CT/PT burdens, Vk, Im, RCT
etc. for class PS CT's
12. Electrical Wiring Drawings : Single Line
Diagram
13. Electrical Wiring Drawings : Block and Logic
Diagrams
14. Electrical Wiring Drawings : Control Schematics
15. Electrical Wiring Drawings : Wiring Diagram
and Terminal Details
16. Electrical Wiring Drawings : Interpanel Wiring
Diagram
17. Electrical Wiring Drawings : System
Architecture
18. Bill Of Material
19. Relay Characteristic Curve
20. Auxiliary Power Requirement Data (AC & DC)
21. Test Records
22. Inspection & Test Plan (ITP) -For review by
Client
23. Type Test Certificate for Panel, Breakers & Bus
ducts
24. List of Special Tools & Tackles
25. Data Books/ Manuals : Installation Manual
26. Data Books/ Manuals : Operating/ Maintenance
Manual
27. Data Books/ Manuals : Catalogues/ Brochures
28. Relay Parameterisation

MOV ACTUATOR

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O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Data Sheets (Duly filled-in)
3. G.A.Drawings and mounting details of
actuators
4. Wiring and Connection diagrams
5. Test Records
6. Type Test Certificates for Flameproof/
Explosionproof equipment

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 568 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 11 of 18

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S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
7. Inspection & Test Plan (ITP) -For review by
Client
8. List of Special Tools & Tackles
9. Equipment storage procedure at site
10. Data Books/ Manuals : Installation Manual and
Standards
11. Data Books/ Manuals : Operating/ Maintenance
Manual
12. Data Books/ Manuals : Catalogues/ Brochures
indicating complete technical details and data
for actuator selection

MV MOTOR

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N DESCRIPTION FOR FOR DATA REMARKS
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O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Data Sheets (Duly filled-in)
4. Dimensional/Assembly Drawings : GA Drawing
For motors < 75kW
5. Dimensional/Assembly Drawings : GA Drawing
For motors >= 75kW
6. Dimensional/Assembly Drawings : Installation
Plan/Mounting Details
7. Dimensional/Assembly Drawings : Terminal
Box Arrangement
8. Dimensional/Assembly Drawings : Name Plate
Drawing
9. Performance Curves : Speed Torque Curves
10. Performance Curves : Speed-Current/Time
Curves
11. Performance Curves : Thermal Withstand
Curves (Hot & Cold)
12. Performance Curves : P.f. & Efficiency Curves
13. Inspection & Test Plan (ITP) -For review by
Client
14. Test Records
15. Type Test Certificates for similar equipment
16. List of Special Tools & Tackles
17. Data Books/ Manuals : Installation Manual
18. Data Books/ Manuals : Operating/ Maintenance
Manual

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 569 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 12 of 18

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19. Data Books/ Manuals : Catalogues/ Brochures
20. Equipment storage procedure at site

MV VFD

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Dimensional/Assembly Drawings : GA
Drawings
4. Dimensional/Assembly Drawings : Installation
Plan/Mounting Details
5. Dimensional/Assembly Drawings : Terminal
Box Arrangement
6. Dimensional/Assembly Drawings : Name Plate
Drawing
7. Performance Curves : Speed Torque Curves
8. Performance Curves : Speed-Current/Time
Curves
9. Performance Curves : Thermal Withstand
Curves (Hot & Cold)
10. Performance Curves : P.f. & Efficiency Curves
11. Schemactic and Logic Diagram
12. Block Diagram/ Interconnection Diagram
13. Wiring Diagram
14. Inspection & Test Plan (ITP) -For review by
Client
15. Test Records
16. Combined Test Certificate (For similar Motor &
VFD)
17. List of Special Tools & Tackles
18. Data Books/ Manuals : Installation Manual
19. Data Books/ Manuals : Operating/ Maintenance
Manual
20. Data Books/ Manuals : Catalogues/ Brochures
21. Equipment storage procedure at site
22. Filled up PTR format wherever applicable

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 570 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 13 of 18

OIL FILLED TRANSFORMER (DISTRIBUTION)

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Data Sheets (Duly filled-in)
3. Dimensional/Assembly Drawings : GA Drawing
for Transformer
4. Dimensional/Assembly Drawings : GA Drawing
for HV & LV Termination Bushing/Box
5. Dimensional/Assembly Drawings : GA Drawing
for Marshalling Box
6. Dimensional/Assembly Drawings : Installation
Plan/Mounting Details
7. Dimensional/Assembly Drawings : Nameplate
Rating & Diagram
8. Dimensional/Assembly Drawings : List Of
Accessories & Make
9. Marshalling Box Wiring Diagram
10. Inspection & Test Plan (ITP) -For review by
Client
11. Test Records
12. Data Books/ Manuals : Installation Manual
13. Data Books/ Manuals : Operating/ Maintenance
Manual
14. Data Books/ Manuals : Catalogues/ Brochures

PACKAGED EQUIPMENT

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O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Guaranteed max. Power Consumption
4. Single line diagram
5. Electrical load data
6. Area classification
7. Block Diagram- FA & PA
8. Equipment layout
9. Cable layout
10. Sizing calculation

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 571 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 14 of 18

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N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
11. Cable schedule
12. Interconnection diagram
13. Electrical interface with owner
14. Technical details/Data sheets for major
equipment
15. Motor data sheet
16. GA and internal arrangement drawing for
panels
17. Schematic/Logic diagrams
18. Interconnection/Wiring diagrams
19. Bill Of Material
20. Type Test certificates
21. Inspection & Test Plan (ITP) -For review by
Client
22. Test certificates
23. Catalogues and brochures
24. Installation manual
25. Operation/maintenance manual
26. Equipment storage procedure at site

POWER/ CONTROL CABLES AND ACCESSORIES

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O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Data Sheets (Duly filled-in)
3. Dimensional Drawings : GA drawing for
terminating kits and jointing kits
4. Dimensional Drawings : Cross sectional views
of cables
5. Technical particulars of cables eg., impedance,
inductance, resistance, current carrying
capacity etc)
6. Inspection & Test Plan (ITP) -For review by
Client
7. Test Records
8. Type Test Certificate for similar cables
9. Type Test Certificate for cable accessories
10. Calculation for selection of copper screen for
HV cables

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 572 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 15 of 18

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N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
11. Data Books/ Manuals : Installation Manual
12. Data Books/ Manuals : Operating/ Maintenance
Manual
13. Data Books/ Manuals : Catalogues/ Brochures
14. Equipment storage procedure at site

PLANT COMMUNICATION SYSTEM

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N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Data Sheets (Duly filled-in)
4. Dimensional/Assembly Drawings : GA Drawing
for Central exchange
5. Dimensional/Assembly Drawings : GA Drawing
for Master control station
6. Dimensional/Assembly Drawings : GA Drawing
for Charger panel
7. Dimensional/Assembly Drawings : GA Drawing
for Field call station and loud speakers
8. Dimensional/Assembly Drawings : Sectional
View Drawing
9. Dimensional/Assembly Drawings : Cubical
Arrangement Drawing
10. Dimensional/Assembly Drawings : Battery Rack
Arrangement Drawing
11. Dimensional/Assembly Drawings : Installation
Plan/ Mounting Details/ Cable Cutout Details
12. Dimensional/Assembly Drawings : Bill of
Material
13. Electrical Wiring Drawings : Speech diagram
14. Electrical Wiring Drawings : Block diagrams
15. Electrical Wiring Drawings : Wiring Diagram
and Terminal Details
16. Electrical Wiring Drawings : Interconnection
Diagrams
17. Performance Curves of battery
18. Test Records
19. Inspection & Test Plan (ITP) -For review by
Client
20. Statutory approval certificate for each item
21. Calculations for : Battery Sizing

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 573 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 16 of 18

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N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
22. Calculations for : Charger Sizing
23. Calculations for : System Cables
24. List of Special Tools & Tackles
25. Data Books/ Manuals : Installation Manual
26. Data Books/ Manuals : Operating/ Maintenance
Manual
27. Data Books/ Manuals : Catalogues/ Brochures
28. Equipment storage procedure at site

UPS SYSTEM

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N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Data Sheets (Duly filled-in)
4. Dimensional/Assembly Drawings : GA
Drawings UPS Panels ,Cell booster and Aux.
Board
5. Dimensional/Assembly Drawings : Installation
Plan/ Mounting Details/ Cable Cutout Details
6. Dimensional/Assembly Drawings : Sectional
View Drawing
7. Dimensional/Assembly Drawings : Cubical
Arrangement Drawing
8. Dimensional/Assembly Drawings : Battery Rack
Arrangement Drawing
9. Dimensional/Assembly Drawings : Bill of
Material
10. Electrical Wiring Drawings : Single Line
Diagram
11. Electrical Wiring Drawings : Block and Logic
Diagrams
12. Electrical Wiring Drawings : Control Schematics
13. Electrical Wiring Drawings : Wiring Diagram
and Terminal Details
14. Electrical Wiring Drawings : Interconnection
Diagrams
15. Performance Curves of battery
16. Inspection & Test Plan (ITP) -For review by
Client
17. Test Records

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 574 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 17 of 18

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O. REVIEW RECORD BOOK
(FINAL)
18. Calculations for : Battery Sizing
19. Calculations for : Charger Sizing
20. Calculations for : Component Sizing(power
&electronic devices)
21. Calculations for : System Cables
22. Type Test Certificates for similar equipment
23. List of Special Tools & Tackles
24. Data Books/ Manuals : Installation Manual
25. Data Books/ Manuals : Operating/ Maintenance
Manual
26. Data Books/ Manuals : Catalogues/ Brochures

LIGHTING MANAGEMENT SYSTEM

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BID
O. REVIEW RECORD BOOK
(FINAL)
1. Schedule of Vendor Documents
2. Dimensional/Assembly Drawings : GA
Drawings
3. Dimensional/Assembly Drawings : Installation
Plan/Mounting Details
4. Electrical Wiring Drawings : Control Schematics
5. Operation & Control Philosophy
6. Dimensional/Assembly Drawings : Bill of
Material
7. Test Records
8. Electrical Wiring Drawings : Block and Logic
Diagrams
9. Inspection & Test Plan (ITP) -For review by
Client
10. Type Test Certificate
11. List of Special Tools & Tackles
12. Data Books/ Manuals : Installation Manual
13. Data Books/ Manuals : Operating/ Maintenance
Manual
14. Data Books/ Manuals : Catalogues/ Brochures
15. Equipment storage procedure at site

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 575 OF 1216

 Document No.
VENDOR DATA REQUIREMENTS B047-003-16-50-VDR-0001
FOR Rev. A
LEH AIRPORT Page 18 of 18

Notes :
1. "TICK" denotes applicability.
2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).
3. Refer - 6-78-0001: Specification for quality management system from Bidders.
4. Refer - 6-78-0002: Specification for documentation requirements from Contractors.
5. Refer - 6-78-0003: Specification for documentation requirement from Suppliers.
6. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall
be submitted in exceptional circumstances or as indicated in the MR/Tender.
7. Bill of Material shall form part of the respective drawing.
8. For additional Vendor Data Requirements of Electric Surface Heating System, refer Doc. B047-003-16-50-
SP-1003.
9. Final documentation shall be submitted in hard copy (Six prints) and soft copy( two CDs/DVDs ).
10. All technical details and documents furnished with bids shall be treated as data for engineering. These shall
however be subject to Purchaser¿s review after order placement and bidder shall comply to Tender
requirements without any cost & time implication to Owner.

Signature Not Verified

Digitally signed by SATYENDRA SINGH
Date: 2018.05.29 20:36:25 IST
Format No. EIL-1642-1924 Rev.1 Copyright EIL - All
Location: eProcurement rights reserved
System for
Central PSUs
VOLUME-2 (ELECTRICAL) SOW & SPECIFICATIONS PAGE NO. 576 OF 1216