BHILAI FGD

(2X250MW)

OF
NTPC Limited
(A Government of India Enterprise)

--------------------------------------------

TECHNICAL SPECIFICATION
FOR
MISCELLANEOUS FGD TANKS

SPECIFICATION NO.: PE-TS-468-167-A101

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR
PROJECT ENGINEERING MANAGEMENT
NOIDA, INDIA

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 2 X 250 MW BHILAI FGD SPECIFICATION No:PE-TS-468-167-A101
SECTION-I, SECTION-II & SECTION-III
MISC. FGD TANKS REV. 00
TECHNICAL SPECIFICATION Date: March, 2020

CONTENTS

SECTION - I

SUB- SECTIONS TITLE Page No.

Sub-Section-A INTENT OF SPECIFICATION 04

Sub-Section-B PROJECT INFORMATION WITH WIND AND SEISMIC DESIGN CRITERIA 08
Sub-Section-C TECHNICAL SPECIFICATIONS
Sub Section-C1 SPECIFIC TECHNICAL REQUIREMENT– MECHANICAL 38
C1-A SPECIFIC TECHNICAL REQUIREMENT-TANKS 39
C1-B SPECIFIC TECHNICAL REQUIREMENT- 48
RUBBER LINING
C1-C SPECIFIC TECHNICAL REQUIREMENT-FLAKE 52
GLASS LINING
Sub Section-C2 CUSTOMER SPECIFICATION 61
C2 - A TECHNICAL REQUIREMENT 62
C2 - B PROJECT SPECIFIC GENERAL REQUIREMENTS 77
INCLUDING:
GENERAL TECHNICAL REQUIREMENT, 78
PACKING PROCEDURE, DRAWINGS /
DOCUMENTS SUBMISSION PROCEDURE
QUALITY ASSURANCE 207
C2 - C PAINTING SPECIFICATION 214
Sub Section-D ANNEXURE-I LIST OF MAKES OF SUB-VENDOR ITEMS 245
ANNEXURE-II QUALITY PLANS 250
ANNEXURE-III INPUT DRAWINGS 256
ANNEXURE-IV MASTER DRAWING LIST WITH SCHEDULE OF 271
SUBMISSION

SECTION - II
SUB SECTIONS TITLE Page No.
Sub-Section-A STANDARD TECHNICAL STANDARD TANK SPECIFICATION 275
SPECIFICATIONS- GUIDANCE FOR DESIGNING AND 284
MECHANICAL FABRICATION OF STEEL CONSTRUCTIONS
FOR RUBBER LINING
Sub-Section-B FORMAT FOR OPERATION AND MANITENANCE 294
Sub-Section-C SITE STORAGE AND PRESERVATION GUIDELINES 298

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 2 X 250 MW BHILAI FGD SPECIFICATION No:PE-TS-468-167-A101
SECTION-I, SECTION-II & SECTION-III
MISC. FGD TANKS REV. 00
TECHNICAL SPECIFICATION Date: March, 2020

SECTION - III
SUB SECTIONS TITLE Page No.
Annexure-1 LIST OF DOCUMENTS TO BE SUBMITTED WITH BID 315
Annexure-2 COMPLIANCE CUM CONFIRMATION CERTIFICATE 317
Annexure-3 PRE BID CLARIFICATION SCHEDULE 320
Annexure-4 DEVIATION SHEET (COST OF WITHDRAWAL) 322
Annexure-5 LIST OF MAKES OF SUB VENDOR ITEMS 324
Annexure-6 LIST OF TOOLS & TACKLES 326
Annexure-7 LIST OF COMMISSIONING SPARES 328
Annexure-8 TANK SCHEDULE & GA DRAWING (TYPICAL) WITH AGITATOR 330
PLATFORM
Annexure-9 TANK NOZZLE SCHEDULE 336-338.

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TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-A
REV. 00
TECHNICAL SPECIFICATIONS FOR
Date: April, 2020
MISC. FGD TANKS

SECTION-I,
SUB-SECTION-A

INTENT OF SPECIFICATION

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PEM-6666-0
SPECIFICATION NO. PE-TS-468-167-A101
2 X 250 MW BHILAI FGD
SECTION I , SUB-SECTION-A
TECHNICAL SPECIFICATION FOR REVISION 00 DATE: April, 2020
MISCELLANEOUS FGD TANKS

1.0 SCOPE OF ENQUIRY/ INTENT OF SPECIFICATION

1.1 This specification includes, but not limited to Supply part, Services part comprising of design (i.e.
Preparation and submission of drawing /documents including “As Built” drawings and O&M
manuals), engineering, manufacture, fabrication, assembly, inspection / testing at vendor's & sub-
vendor’s works, painting, maintenance tools & tackles(as applicable) along with spares for
erection, start up and commissioning as required, forwarding, proper packing, shipment and
delivery at site, unloading, handling, transportation & storage at site, in-site transportation,
assembly, erection & commissioning, Rubber lining, Vinyl Ester Glass Flake lining, Epoxy lining, final
painting at site, minor civil work and carrying out Performance guarantee / Functional /
Demonstration tests at site (as applicable) and handover in flawless condition of Miscellaneous
FGD Tanks turnkey package specified above for 2 X 250 MW BHILAI FGD complete with all
accessories for the total scope defined as per BHEL NIT & tender technical specification,
amendment & agreements till placement of order.

1.2 The contractor shall be responsible for providing all material, equipment & services, which are
required to fulfil the intent of ensuring operability, maintainability, reliability and complete safety
of the complete work covered under this specification, irrespective of whether it has been
specifically listed herein or not. Omission of specific reference to any component / accessory
necessary for proper performance of the equipment shall not relieve them of the responsibility of
providing such facilities to complete the supply, erection and commissioning, performance and
guarantee/demonstration testing of Miscellaneous FGD Tanks within quoted price.

1.3 It is not the intent to specify herein all the details of design and manufacture. However, the
equipment / system shall conform in all respects to high standards of design, engineering and
workmanship and shall be capable of performing the required duties in a manner acceptable to
purchaser who will interpret the meaning of drawings and specifications and shall be entitled to
reject any work or material which in his judgement is not in full accordance herewith.

1.4 The extent of supply under the contract includes all items shown in the drawings, notwithstanding
the fact that such items may have been omitted from the specification or schedules. Similarly, the
extent of supply also includes all items mentioned in the specification and /or schedules,
notwithstanding the fact that such items may have been omitted in the drawing. Similarly, the
extent of supply also includes all items required for completion of the system for its safe, efficient,
reliable and trouble free operation and maintenance shall also be in supplier’s scope unless
specifically excluded and notwithstanding that they may have been omitted in drawings /
specifications or schedules.

1.5 Items though not specifically mentioned but needed to make the system complete as stipulated
under these specifications are also to be furnished unless otherwise specifically excluded.

1.6 The general terms and conditions, instructions to tenderer and other attachment referred to
elsewhere are hereby made part of the tender specifications. The equipment / material and works
covered by this specification is subject to compliance to all the attachments referred in the
specification. The tenderer shall be responsible for adherence to all requirements stipulated
herein.

1.7 While all efforts have been made to make the specification requirement complete & unambiguous,
it shall be bidders’ responsibility to ask for missing information, ensure completeness of
specification, to bring out any contradictory / conflicting requirement in different sections of the
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PEM-6666-0
SPECIFICATION NO. PE-TS-468-167-A101
2 X 250 MW BHILAI FGD
SECTION I , SUB-SECTION-A
TECHNICAL SPECIFICATION FOR REVISION 00 DATE: April, 2020
MISCELLANEOUS FGD TANKS

specification and within a section itself to the notice of BHEL and to seek any clarification on
specification requirement in the format enclosed under Sec.-III of the specification within 10 days
of receipt of tender documents. In absence of any such clarifications, in case of any contradictory
requirement, the more stringent requirement as per interpretation of Purchaser/Customer shall
prevail and shall be complied by the bidder without any commercial implication on account of the
same. Further in case of any missing information in the specification not brought out by the
prospective bidders as part of pre-bid clarification, the same shall be furnished by Purchaser/
Customer as and when brought to their notice either by the bidder or by purchaser/ customer
themselves. However, such requirements shall be binding on the successful bidder without any
commercial & delivery implication.

1.8 Deviations, if any, should be very clearly brought out clause by clause in the enclosed schedule
otherwise, it will be presumed that the vendor's offer is strictly in line with NIT specification.

1.9 In case all above requirements are not complied with, the offer may be considered as incomplete
and would become liable for rejection.

1.10 Unless specified otherwise, all through the specification, the word contractor shall have same
meaning as successful bidder/vendor and Customer/Purchaser/Employer will mean BHEL and/or
Customer as interpreted by BHEL in the relevant context. Please refer GCC/SCC for better clarity.

1.11 The equipment covered under this specification shall not be dispatched unless the same have been
finally inspected, accepted and dispatch release issued by BHEL/Customer.

1.12 BHEL’s Customer’s representative shall be given full access to the shop in which the equipment’s
are being manufactured or tested and all test records shall be made available to him.

1.13 Various codes and standards to be used shall be as indicated in various parts of the specification. In
case bidder uses any standard other than those indicated in the specification, the onus of
establishing equivalence of the same with the specified standards will rest with the bidder and
acceptance of the same shall be sole prerogative of customer. The bidder will also arrange for
BHEL a copy of the standards in ENGLISH language. The cost of such service will be deemed to have
been included by the bidder in the total cost of the package. BHEL will not entertain any additional
cost on account of the same.

1.14 All text/ numeric in the document / drawings to be generated by the successful bidder will be in
English language only.

1.15 The bidder’s offer shall not carry any sections like clarification, interpretations and /or
assumptions.

Note:
Bidder to note that BHEL reserves the right for drawing/document submission through web based
Document Management System. Bidder would be provided access to the DMS for
drawing/document approval and adequate training for the same. Detailed methodology would be
finalized during the kick-off meeting. Bidder to ensure following at their end.
• Internet explorer version – Minimum Internet Explorer 7.
• Internet speed – 2 mbps (Minimum preferred).
• Pop ups from our external DMS IP (124.124.36.198) should not be blocked.

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PEM-6666-0
SPECIFICATION NO. PE-TS-468-167-A101
2 X 250 MW BHILAI FGD
SECTION I , SUB-SECTION-A
TECHNICAL SPECIFICATION FOR REVISION 00 DATE: April, 2020
MISCELLANEOUS FGD TANKS

• Vendor’s internal proxy setting should not block DMS application’s link
(http://dmsserver.bhelpem.com/Wrench%20Web%20Access/Login.aspx.).

Page 7 of 338
 TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-B
REV. 00
TECHNICAL SPECIFICATION FOR
Date: April, 2020
MISC. FGD TANKS

SECTION-I,
SUB-SECTION-B
PROJECT INFORMATION WITH WIND AND
SEISMIC DESIGN CRITERIA

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CLAUSE NO. PROJECT INFORMATION

1.00.00 BACKGROUND
NSPCL has setup coal based thermal power plant of 2X250 MW capacity at BHILAI in
Chhattisgarh primarily to meet captive power requirement of SAIL, NSPCL is supplying
balance power to the beneficiaries in the western region. Both the units have been
commissioned during 2008-09 and commercialized during 2009-10.
1.01.0 LOCATION AND APPROACH
The NSPCL site is located at District Durg, Bhilai (East) having latitude and longitude of 21°
11' 25" N and 81°26'05" E, respectively. The nearest railhead on the Raipur- Nagpur section
of South Eastern Central Railway is Bhilai which is approx. 4 km from site. The site is
approachable from National Highway -6 which connects the site with both Durg and Raipur.
The nearest- airport is at Raipur, about 35kms away from the site. The nearest town is Bhilai,
approx. 10 km from the project site.
Vicinity plan of the proposed project is placed at Annexure-I.
1.02.00 LAND
Total land area for plant & dyke is 659 acres. Ash Dyke is constructed in 221 Acre land.
1.03.00 WATER
The make- up water requirement for the plant has been met from the existing system of Bhilai
CPP-1, CPP-2 and BSP i: e Maroda Tank-II, which is fed by Tandula Main Canal.
1.04.00 Coal Quality Parameters / Fuel Oil Characteristics& Plant Water details:
(i) The coal quality parameters and Fuel oil Characteristics are indicated in Table-1 &
Table-2 respectively below.
(ii) Process water: Process water quality based on COC given in Table-4.
(iii) Clarified water: Clarified water quality is indicated in Table-4.
(iv) DM water for Equipment cooling water system. DM water quality is indicated in
Table-5.
1.05.00 STEAM GENERATOR AND ESP DATA: Refer Table-6
1.06.00 Drawings are enclosed as per Table-7 for initial overview to the Bidder.
2.00.00 NOT USED
3.00.00 Capacity
Present proposal : 2 X 250 MW
4.00.00 Metrological Data
The metrological data from nearest observatory is placed at Annexure-II.

LOT-2 PROJECTS TECHNICAL SPECIFICATION SUB-SECTION-II-A5

FLUE GAS DESULPHURISATION (FGD) SECTION – VI, PART-A PROJECT INFORMATION PAGE 1 OF 30
SYSTEM PACKAGE BID DOC. NO.:CS-0011-109(2)-9 (BHILAI 2X250 MW)

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CLAUSE NO. PROJECT INFORMATION

5.00.00 CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND

a) Steel structures : 2%

b) Reinforced Concrete structures : 5%

c) Reinforced Concrete Stacks : 3%

d) Steel stacks : 2%

EQUIPMENT

All structures and equipment shall be designed for seismic forces adopting the site

specific seismic information provided in this document and using the other provisions

in accordance with IS:1893 (Part 1 to Part 4). Pending finalization of Part 5 of IS:1893,

provisions of part 1 shall be read along with the relevant clauses of IS:1893:1984, for

embankments.

A site specific seismic study has been conducted for the project site. The peak ground
horizontal acceleration for the project site, the site specific acceleration spectral
coefficients (in units of gravity acceleration ‘g’) in the horizontal direction for the
various damping values and the multiplying factor (to be used over the spectral
coefficients) for evaluating the design acceleration spectra are as given at Appendix-
I.

Vertical acceleration spectral values shall be taken as 2/3rd of the corresponding

horizontal values.

The site specific design acceleration spectra shall be used in place of the response
acceleration spectra, given at figure-2 in IS:1893 (Part 1) and Annex B of IS:1893
(Part 4). The site specific acceleration spectra along with multiplying factors specified
in Appendix-I includes the effect of the seismic environment of the site, the importance
factor related to the structures and the response reduction factor. Hence, the design
spectra do not require any further consideration of the zone factor (Z), the importance
factor (I) and response reduction factor (R) as used in the IS:1893 (Part 1 to Part 4).

Damping in Structures

The damping factor (as a percentage of critical damping) to be adopted shall not be
more than as indicated below for:

LOT-2 PROJECTS TECHNICAL SPECIFICATION SUB-SECTION-II-A5

FLUE GAS DESULPHURISATION (FGD) SECTION – VI, PART-A PROJECT INFORMATION PAGE 2 OF 30
SYSTEM PACKAGE BID DOC. NO.:CS-0011-109(2)-9 (BHILAI 2X250 MW)

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CLAUSE NO. PROJECT INFORMATION

Method of Analysis

Since most structures in a power plant are irregular in shape and have irregular
distribution of mass and stiffness, dynamic analysis for obtaining the design seismic
forces shall be carried out using the response spectrum method. The number of
vibration modes used in the analysis should be such that the sum total of modal
masses of all modes considered is at least 90 percent of the total seismic mass and
shall also meet requirements of IS:1893 (Part 1). Modal combination of the peak
response quantities shall be performed as per Complete Quadratic Combination
(CQC) method or by an acceptable alternative as per IS:1893 (Part 1).

In general, seismic analysis shall be performed for the three orthogonal (two principal
horizontal and one vertical) components of earthquake motion. The seismic response
from the three components shall be combined as specified in IS:1893 (Part 1).

The spectral acceleration coefficient shall get restricted to the peak spectral value if
the fundamental natural period of the structure falls to the left of the peak in the
spectral acceleration curve.

For buildings, if the design base shear (VB) obtained from modal combination is less
than the base shear (⎯VB) computed using the approximate fundamental period (Ta)
given in IS:1893:Part 1 and using site specific acceleration spectra with appropriate
multiplying factor, the response quantities (e.g. member forces, displacements, storey
forces, storey shears and base reactions) shall be enhanced in the ratio of ⎯VB/ VB.
However, no reduction is permitted if ⎯VB is less than VB.

Design/Detailing for Ductility for Structures

The site specific design acceleration spectra is a reduced spectra and has an in-built
allowance for ductility. Structures shall be engineered and detailed in accordance with
relevant Indian/International standards to achieve ductility.

LOT-2 PROJECTS TECHNICAL SPECIFICATION SUB-SECTION-II-A5

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SYSTEM PACKAGE BID DOC. NO.:CS-0011-109(2)-9 (BHILAI 2X250 MW)

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CLAUSE NO. PROJECT INFORMATION

APPENDIX – I

SITE SPECIFIC SEISMIC PARAMETERS FOR DESIGN OF STRUCTURES AND

EQUIPMENT

The various site specific seismic parameters for the project site shall be as
follows:

1) Peak ground horizontal acceleration : 0.10g

2) Multiplying factor to be applied to the site specific

horizontal acceleration spectral coefficients (in units of
gravity acceleration ‘g’) to obtain the design acceleration
spectra

a) for special moment resisting steel frames designed

and detailed as per IS:800 : 0.025

b) For special concentrically braced steel frames : 0.019

designed and detailed as per IS:800

c) For special moment resisting RC frames designed and

detailed as per IS:456 and IS:13920 : 0.015

d) for RCC chimney, RCC Natural Draft Cooling Tower : 0.05

e) for liquid retaining tanks : 0.03

f) for steel chimney, Absorber tower, Vessels : 0.038

g) for design of structures not covered under 2 (a) to 2 (f)

above and under 3 below, in general (excluding : 0.025
special structure/ configuration/materials)

3) Multiplying factor to be applied to the site specific

horizontal acceleration spectral coefficients (in units of
gravity acceleration ‘g’) for design of equipment and
structures where inelastic action is not relevant or not : 0.05
permitted

Note: g = Acceleration due to gravity

The horizontal seismic acceleration spectral coefficients are furnished in Annexure-

A.

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Annexure-A

HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS

(In units of ‘g’)

Damping Factor (as a percentage of critical damping)

Time Period
(Sec) 2% 3% 5%
0.000 1.000 1.000 1.000
0.030 1.000 1.000 1.000
0.050 1.810 1.679 1.509
0.098 3.935 3.325 2.596
0.101 3.935 3.438 2.660
0.107 3.935 3.438 2.789
0.150 3.935 3.438 2.789
0.200 3.935 3.438 2.789
0.250 3.935 3.438 2.789
0.300 3.935 3.438 2.789
0.350 3.935 3.438 2.789
0.400 3.935 3.438 2.789
0.450 3.935 3.438 2.789
0.485 3.935 3.438 2.789
0.503 3.791 3.438 2.789
0.531 3.591 3.254 2.789
0.600 3.178 2.880 2.467
0.650 2.934 2.658 2.277
0.670 2.846 2.579 2.209
0.700 2.724 2.469 2.114
0.750 2.543 2.304 1.973
0.800 2.384 2.160 1.850
0.850 2.244 2.033 1.741
0.900 2.119 1.920 1.644
0.950 2.007 1.819 1.558
1.000 1.907 1.728 1.480
1.050 1.816 1.646 1.410
1.100 1.734 1.571 1.345
1.150 1.658 1.503 1.287
1.200 1.589 1.440 1.233
1.250 1.526 1.382 1.184
1.300 1.467 1.329 1.138
1.350 1.413 1.280 1.096
1.400 1.362 1.234 1.057

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FLUE GAS DESULPHURISATION (FGD) SECTION – VI, PART-A PROJECT INFORMATION PAGE 5 OF 30
SYSTEM PACKAGE BID DOC. NO.:CS-0011-109(2)-9 (BHILAI 2X250 MW)

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Annexure-A

HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS

(In units of ‘g’)

Damping Factor (as a percentage of critical damping)

Time Period
(Sec) 2% 3% 5%
1.450 1.315 1.192 1.021
1.500 1.271 1.152 0.987
1.550 1.230 1.115 0.955
1.600 1.192 1.080 0.925
1.650 1.156 1.047 0.897
1.700 1.122 1.016 0.871
1.750 1.090 0.987 0.846
1.800 1.059 0.960 0.822
1.850 1.031 0.934 0.800
1.900 1.004 0.909 0.779
1.950 0.978 0.886 0.759
2.000 0.954 0.864 0.740
2.050 0.930 0.843 0.722
2.100 0.908 0.823 0.705
2.150 0.887 0.804 0.688
2.200 0.867 0.785 0.673
2.250 0.848 0.768 0.658
2.300 0.829 0.751 0.643
2.350 0.811 0.735 0.630
2.400 0.795 0.720 0.617
2.450 0.778 0.705 0.604
2.500 0.763 0.691 0.592
2.550 0.748 0.678 0.580
2.600 0.733 0.665 0.569
2.650 0.720 0.652 0.558
2.700 0.706 0.640 0.548
2.750 0.693 0.628 0.538
2.800 0.681 0.617 0.529
2.850 0.669 0.606 0.519
2.900 0.658 0.596 0.510
2.950 0.646 0.586 0.502
3.000 0.636 0.576 0.493
3.050 0.625 0.567 0.485
3.100 0.615 0.557 0.477

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Annexure-A

HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS

(In units of ‘g’)

Damping Factor (as a percentage of critical damping)

Time Period
(Sec) 2% 3% 5%
3.150 0.605 0.549 0.470
3.200 0.596 0.540 0.463
3.250 0.587 0.532 0.455
3.300 0.578 0.524 0.448
3.350 0.569 0.516 0.442
3.400 0.561 0.508 0.435
3.450 0.553 0.501 0.429
3.500 0.545 0.494 0.423
3.550 0.537 0.487 0.417
3.600 0.530 0.480 0.411
3.650 0.522 0.473 0.405
3.700 0.515 0.467 0.400
3.750 0.509 0.461 0.395
3.800 0.502 0.455 0.389
3.825 0.496 0.452 0.387
3.850 0.490 0.449 0.384
3.900 0.477 0.443 0.379
3.950 0.465 0.437 0.375
4.000 0.454 0.432 0.370

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6.00.00 CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES

AND EQUIPMENT

All structures shall be designed for wind forces in accordance with IS:875
(Part-3) and as specified in this document. See Annexure – B for site specific
information.

Along wind forces shall generally be computed by the Peak (i.e. 3 second
gust) Wind Speed method as defined in the standard.

Along wind forces on slender and wind sensitive structures and structural
elements shall also be computed, for dynamic effects, using the Gust Factor
or Gust Effectiveness Factor Method as defined in the standard. The
structures shall be designed for the higher of the forces obtained from Gust
Factor method and the Peak Wind Speed method.

Analysis for dynamic effects of wind must be undertaken for any structure
which has a height to minimum lateral dimension ratio greater than “5” and/or
if the fundamental frequency of the structure is less than 1 Hz.

Susceptibility of structures to across-wind forces, galloping, flutter, ovalling

etc. should be examined and designed/detailed accordingly following the
recommendations of IS:875(Part-3) and other relevant Indian standards.

It should be estimated if size and relative position of other structures are likely
to enhance the wind loading on the structure under consideration.
Enhancement factor, if necessary, shall suitably be estimated and applied to
the wind loading to account for the interference effects.

Damping in Structures

The damping factor (as a percentage of critical damping) to be adopted shall

not be more than as indicated below for:

a) Welded steel structures : 1.0%

b) Bolted steel structures : 2.0%

c) Reinforced concrete structures : 1.6%

: As per IS:6533 & CICIND Model Code

whichever is more critical.

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ANNEXURE-B

SITE SPECIFIC DESIGN PARAMETERS

The various design parameters, as defined in IS: 875 (Part-3), to be adopted

for the project site shall be as follows:

a) The basic wind speed “Vb” at ten

metres above the mean ground level : 44 metres/second

b) The risk coefficient “K1” : 1.06

c) Category of terrain : Category-2

7.00.00 FOUNDATION SYSTEM AND GEOTECHNICAL DATA

7.00.01 Geotechnical data and foundation system for the respective project are enclosed at Annexure-
III. The corresponding bore logs are enclosed at Annexure-IV.

7.00.02 The available soil data is of vicinity of proposed structures, therefore, bidder shall carryout his
own detailed soil investigation for facilities under this package and shall be as per the scheme
approved by owner. The scheme for geotechnical investigation shall be as given at Clause
7.07.00 and shall be approved by owner before execution. Geotechnical investigation work
shall got executed by the Contractor through the agencies as mentioned in Clause No. 7.07.03.
However, no time extension shall be given on account of soil investigation carried out by the
Bidder. The geotechnical investigation report shall be prepared with detailed recommendations
regarding type of foundation and allowable bearing pressure for various structures/ facilities
and other soil parameters. The report shall be submitted for Owner’s approval prior to
commencement of design of foundation.

7.00.03 The Bidder should note that nothing extra whatsoever on account of variation between soil
data collected by Owner and that found by the Bidder during geotechnical investigation by him
or during execution of works, shall be payable.

7.00.04 Tank Foundations

a) The tanks shall rest on flexible tank pad foundation, resting on sand with concrete ring
wall to retain sand. Base of the concrete ring wall shall not rest on the expansive soil,
if any.

b) Entire loose/ soft soil inside the concrete ring wall shall be removed and shall be filled
with sand. Sand for filling shall be clean and well graded conforming to IS 383 with
grading Zone I to III.

c) Sand shall be spread in layers not exceeding 30cm compacted thickness over the
area. Each layer shall be uniformly compacted by mechanical means like plate
vibrators, small vibratory rollers, etc to achieve a relative density of not less than 80%.

d) Other requirements of tank foundations shall be as per IS 803 and as specified

elsewhere in the specifications.

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7.02.00 Foundation System

The requirements for the foundation system to be adopted are as given in subsequent
clauses. Depending upon the depth of competent strata/stratum, type of structures,
functional requirement of facility, extent of cutting / filling, suitable foundation, open or
pile shall be adopted with approval of owner.
7.02.01 General Requirements

a) All structures/equipment shall be supported either on suitable open foundations

(isolated, combined, raft) or pile foundations depending on type of structures/facilities,
sub-strata, topography etc.

b) The roads, ground floor slabs, trenches, pipe pedestals, channels/drains and staircase
foundation with foundation loading intensity less than 4 T / M2 may be supported on
open / shallow foundations resting on virgin / controlled compacted filled up soil.

c) No other foundation (other than as mentioned in (b) above) shall rest on the filled up
ground / soil.

d) No foundation shall rest on the black cotton soil.

e) Before execution of work the bidder shall ensure that there is no obstruction to
underground/overground facilities like sewer lines, pipe lines etc. Any such damage
and remedial/ rectification measures shall be at the contractors cost.

f) Bidder shall also ensure that there is no damage to existing nearby foundations and
the foundations pertaining to this package are not placed at shallower depth than the
nearby foundations. If required depth of foundation is deeper than the existing
foundations, proper protection shall be provided to existing foundations.

g) All foundations shall be designed in accordance with relevant parts of the latest
revisions of Indian Standards.

h) The water table for design purpose shall be considered at Finished Ground Level.

i) A combination of open and pile foundations shall not be permitted under the same
equipment / structure / building.

j) Foundation for equipments on ground floor

For equipments of static weight upto 1.5 T, the equipment may be supported on the
ground floor slab by locally thickening the slab. Thickening of the ground floor slab shall
be done upto an extent of about 0.6 m beyond the plan area of the equipment on all the
sides. Further, the load intensity below the equipment shall be limited to 4T/m2. Other
requirements of floor slab and compaction below the floor slab shall be adhered, as
specified elsewhere in the specifications.

For equipment’s of static weight between 1.5 T and 20 T, the equipment may be
supported on compacted sand filling with the load intensity below the equipment limited
to 4T/m2. The minimum depth of foundation is 1.0m below FFL. Other requirements of
sand compaction below the foundation shall be adhered, as specified elsewhere in the
specifications.

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For equipment of static weight more than 20 T, the equipment foundation shall be taken
to the founding level or shall be built up with PCC from the level as mentioned in the
Table 2. The pedestal of equipment foundation or the foundation Block shall be isolated
from the adjoining floor slab by providing bitumen impregnated fiber board of minimum
50 mm thick, conforming to IS: 1838 all around the equipment pedestal for the full depth
of the floor slab.

7.02.02 Open Foundations

In case open foundations are adopted, following shall be adhered to.
a) The minimum width of foundation shall be 1.0 m.

b) Minimum depth of foundation shall be 1.0m below Ground Level.

c) It shall be ensured that all foundations of a particular structure/ buildings/ facility shall
rest on one bearing stratum.

d) Wherever the intended bearing sub-strata is virgin soil stratum but the actual stratum
encountered during foundation excavation consists of filled up soil at founding level,
under such cases either the foundation shall be lowered completely into the virgin
stratum or the filled up soil upto the virgin layers shall be removed and built up through
PCC (1:4:8) up to designed foundation level.
7.02.03 Pile Foundations –
(a.) In case piles are adopted, following shall be adhered to :
i) The pile foundation shall be of RCC, Cast-in-situ bored piles as per IS:2911.
Pile boring shall be done using Rotary Hydraulic Rigs. However, conventional
tripod rig may be allowed in inaccessible areas subject to site specific
conditions. Two stage flushing of pile bore shall be ensured by airlift technique
duly approved by the Employer.
If required, temporary or permanent MS liner may be provided for piling.
ii) The minimum diameter of pile shall be 600 mm. The allowable load capacity
of the pile in different modes (vertical compression, lateral and pullout) shall
be as per approved geotechnical report & as enclosed in relevant annexure:
iii) Only straight shaft piles shall be used. Minimum cast length of pile above cutoff
level shall be 1.0 m.
iv) The contractor shall furnish design of piles (in terms of rated capacity, length,
diameter, termination criteria to locate the founding level for construction of
pile in terms of measurable parameter, reinforcement for job as well as test
piles, pile load test arrangement, locations of initial test piles etc.) for
Engineer’s approval.

v) The piling work shall be carried out in accordance with IS:2911 (Relevant part)
and accepted construction methodology. The construction methodology shall
be submitted by the Contractor for Engineer's approval.

vi) Number of initial load tests to be performed for each diameter and rated
capacity of pile shall be subject to minimum as under.

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Vertical
Lateral Minimum of 2 Nos. in each mode.

Uplift
vii) The initial pile load test shall be conducted with test load upto three times the
pile capacity. In case of vertical compression test (initial test) the method of
loading shall be cyclic as per IS:2911 (relevant part).
viii) Load test shall be conducted at pile Cut-off Level (COL). If the water table is
above the COL the test pit shall be kept dry throughout the test period by
suitable de-watering methods. Alternatively the vertical load test may be
conducted at a level higher than COL. In such a case, an annular space shall
be created to remove the effect of skin friction above COL by providing an
outer casing of suitable diameter larger than the pile diameter.
ix) Number of routine pile load tests to be performed for each
diameter/allowable capacity of pile shall be as under :

i) Vertical : 0.5% of the total number of piles provided.

ii) Lateral : 0.5% of the total number of piles provided.
x) The routine tests on piles shall be conducted upto test load of one and half
times the allowable pile capacity. Piles for routine load tests shall be approved
by the Employer.
xi) In case, routine pile load test shows that the pile has not achieved the desired
capacity or pile(s) have been rejected due to any other reason, then the
Contractor shall install additional pile(s) as required and the pile cap design
shall accordingly be reviewed and modified, if required.

xii) Testing of piles and interpretation of pile load test results shall be carried out
as per IS:2911 (Part-4). Contractor shall ensure that all the measuring
equipment and instruments are properly calibrated at a reputed laboratory /
institute prior to their use. Settlement / movement of the pile top shall be made
by Linear Variable Differential Transducers (LVDT) having a least count of
0.01mm.

xiii) The test load on initial test piles shall be applied by means of reaction from
anchor piles / rock anchors alone or combination of anchor piles / rock anchors
and kentledge with concrete blocks.

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xiv) Low Strain Pile Integrity test shall be conducted on all test piles and job piles.
This test shall be used to identify the routine load test and not intended to
replace the use of static load test. This test is limited to assess the imperfection
of the pile shaft and shall be undertaken by an independent specialist agency
to be approved by Engineering department of Owner. The test equipment shall
be of TNO or PDI make or equivalent. The process shall confirm to ASTM.
High Strain Dynamic Load Test may be carried out for routine load testing of
xv) working piles. However, at least two numbers of static routine vertical load
tests shall be carried out on pile on which high strain dynamic load test has
already been carried out for establishing the correlation between the two tests.
In case of discrepancy if any between dynamic and static vertical load tests,
then additional static routine vertical load tests shall be conducted as decided
by the Engineer and the results of static routine vertical load shall prevail.
Number of routine vertical pile load tests as per clause 7.02.03 (ix) shall be
total of static routine vertical load test and high strain dynamic load tests.
The procedure to carry out the test shall be submitted to the Engineer. The
test and equipment shall conform to ASTM D4945-00. The test shall be
conducted by an experienced independent test agency approved by the
owner. Field data shall be submitted to the site engineer and shall include force
velocity curves, pile capacity, simulated static load test curve, net and total pile
displacement, pile integrity. A (Case pile wave analysis) CAPWAP or
equivalent software analysis shall be conducted on the field data for correct
capacity estimation and to evaluate end bearing and skin friction components
of the pile.
xvi) From load considerations, single pile may be used under a column/tower. In
that case, pile shall be connected with tie beams at pile cut off level in both
directions.
xvii) Contribution of frictional resistance of filled up soil if any, shall not be
considered for computation of frictional resistance of piles.

xviii) Reinforcement for job piles shall be designed as following:

(a) Compression + bending piles: For these piles, the allowable safe pile
capacities in compression and bending shall be considered.

(b) Tension + bending piles: For these piles, the actual pile forces to be
considered. However, maximum 3 types of combinations for varying
percentage of tension capacity + bending case may be designed &
adopted by contractor for the entire scope of work under this
package.

7.03.00 Special Requirements

7.03.01 Details of treatment for foundations / underground structures required to counteract soil / water
chemical environment shall be as per detailed geotechnical investigation to be carried out by

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contractor. Contractor shall carry out chemical analysis during detailed geotechnical
investigation and required treatment shall be provided accordingly.

7.04.00 Excavation, Filling and Dewatering

7.04.01 For excavation works, comprehensive dewatering with well point or deep wells arrangement,
if required, shall be adopted. Scheme for dewatering and design with all computations and
back up data for dewatering shall be submitted for the owner’s information. The water table
shall be maintained at 0.5m below the founding depth.

7.04.02 Excavation for shallow foundations shall be covered with PCC immediately after reaching the
founding level. In case of any local loosening of soil or any loose pockets are encountered at
founding level during excavation the same shall be removed and compensated by PCC M7.5.
The final layer of about 300 mm thickness above the founding level shall be excavated by
suitable means, so as to avoid disturbance to founding stratum.
7.04.03 Backfilling around foundations, pipes, trenches, sumps, pits, plinths, etc. shall be carried out
with approved material in layers not exceeding 300 mm compacted thickness (higher thickness
of layers upto 500mm with heavy mechanical compacting equipment) and each layer shall be
compacted to 90% of standard proctor density for cohesive soils and to 80% of relative density
for non-cohesive soils

Rock pieces having size less than 150 mm and interstices filled with soil may be used for
backfilling around foundation, plinths etc. and shall be compacted to minimum of 85% of
original stack of material after filling the interstices.

7.04.04 Founding level for trenches/channels shall be decided as per functional requirement. The
bottom of excavation shall be properly compacted prior to casting of bottom slab of trenches /
channels.

7.04.05 CBR tests for pavement/road design shall be carried out by the Contractor after earth filling (if
applicable) has been completed upto the formation level.

7.04.06 The contractor shall take all necessary measures during excavation to prevent the hazards of
falling or sliding of material or article from any bank or side of such excavation which is more
than one and a half meter above the footing by providing adequate piling, shoring, bracing etc.
against such bank or sides.
Adequate and suitable warning signs shall be put up at conspicuous places at the excavation
work to prevent any persons or vehicles falling into the excavation trench. No worker should
be allowed to work where he may be stuck or endangered by excavation machinery or collapse
of excavations or trenches.

7.05.00 EXCAVATION IN ROCK

Excavation in rock shall be carried out by mechanical means and if blasting is required for
founding of some of the structures under this package, control blasting only shall be carried
out.

7.05.01 Controlled blasting shall be done by a specialised agency duly approved by Engineer. All
controlled blasting shall be done by using time delay detonators (i.e. excel type).

7.05.02 a) Contractor shall engage an agency expert in blasting such as, NIRM (National Institute
of Rock Mechanics), CMPDIL, Central Institute of Mining and Fuel Research Dhanbad, Dept.
of Mining of Govt. Institutions etc. to design detailed blasting scheme and get the same
approved from Engineer before carrying out the blasting operation. All blasting shall be done

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as per the approved blasting scheme & initial blasting operations shall be done under the
supervision & guidance of the representative of the blasting expert.

b) All the statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards, etc.
pertaining to the acquisition, transport, storage, handling and use of explosives, etc. shall be
strictly followed.

c) The Contractor shall obtain Licenses from Competent Authorities for undertaking
blasting work as well as for procuring, transporting to site and storing the explosives as per
explosives act. The Contractor shall be responsible for the safe transport, use, custody and
proper accounting of the explosive Materials.
d) The Contractor shall be responsible and liable for any accident and injury / damage
which may occur to any person or property of the project or public on account of any operations
connected with the storage, transportation, handling or use of explosive and blasting
operations.

7.06.00 Sheeting & Shoring

The contractor shall ascertain for himself the nature of materials to be excavated and
difficulties, if any, likely to be encountered in excavation while executing the work. Sheet piling,
sheeting and shoring, bracing and maintaining suitable slopes, drainage, etc. shall be provided
and installed by the Contractor, to the satisfaction of the Engineer.

7.07.00 Geotechnical Investigation

The Contractor shall carry out detailed geotechnical investigation in the areas under
his scope for establishing the sub-surface conditions and to decide type of foundations
for the structures envisaged, construction methods, any special
requirements/treatment called for remedial measures for sub-soil/ foundations etc. in
view of soft sub-soils, aggressive sub-soils and water, expansive/swelling soils etc.
prior to commencement of detailed design/drawings. The Contractor shall obtain the
approval for the field testing scheme proposed by him from the Owner before
undertaking the geotechnical investigation work.
7.07.01.00 Scheme of geotechnical Investigation
7.07.02.01 Field test shall include but not be limited to the following:
Boreholes, Standard Penetration Test (SPT), Dynamic Cone Penetration Test
(DCPT), collection of disturbed samples (DS) and undisturbed soil samples (UDS),
Trial Pits (TP), Plate Load Tests (PLT), Electrical Resistivity Test (ERT), In situ field
permeability tests, collection of water samples, etc.
7.07.02.02 The diameter of borehole shall be minimum 150 mm in soil and 76 mm in rock. The
diameter of UDS sampler shall be 100 mm minimum. Core drilling in rock shall be done
by using hydraulically feed rotary drill & double tube core barrel with diamond bit.
7.07.02.03 The minimum tests are indicated in Clause No. 7.08.00. Adequate number of tests
shall be conducted up to sufficient depth for complete determination of subsoil
conditions. The depth of boreholes shall be as specified in Appendix A. SPT shall be
carried out in all types of soil deposits and in all rock formations with core recovery up
to 20%, met within a borehole. This test shall be conducted at every 3.0 m interval or
at change of strata, up to the final depth. SPT ‘N’ of 100 and above shall be referred
as refusal. UDS shall be collected at every 3.0 m interval or at change of strata up to
depth of borehole. UDS may be replaced by additional SPT, if SPT’N’ value in the
strata is above 50.

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7.07.02.04 Laboratory tests shall be done as per relevant IS codes. The laboratory tests, not be
limited to the following shall be conducted on disturbed and undisturbed soil samples,
rock samples & water samples collected during field investigations in sufficient
numbers.
Laboratory Tests on Soil Samples
Laboratory tests shall be carried out on disturbed and undisturbed soil samples for
Grain Size Analysis, Hydrometer Analysis, Atterberg Limits, Triaxial Shear Tests (UU),
Natural Moisture Content, Specific Gravity and Bulk Unit Weight, Consolidation Tests,
Unconfined Compression Test, Free swell Index, Shrinkage Limit, Swell Pressure
Test, Chemical Analysis test on soil and water samples to determine the carbonates,
sulphates, chlorides, nitrates, pH, organic matter and any other chemicals harmful to
concrete and reinforcement/ steel.
Laboratory Tests on Rock Samples
Moisture content, porosity & density, Specific Gravity, Hardness, Soundness, Slake
durability index, Unconfined compression test (Both at saturated and in-situ water
content), Point load strength index and deformability test (Both at saturated and in-situ
water content) shall be carried out on rock samples.
7.07.02.05 Geotechnical investigation (field & laboratory) shall be carried out in accordance with
the provisions of relevant Indian Standards.
On completion of all field & laboratory work, geotechnical investigation report shall be
submitted for Owner’s review/approval. The Geotechnical investigation report shall
contain geological information of the region, procedure adopted for investigation, field
& laboratory observations/ data/ records, analysis of results & recommendations on
type of foundation for different type of structures envisaged for all areas of work with
supporting calculations. Recommendations on treatment for soil, foundation, based
on subsoil characteristics, soft soils, aggressive chemicals, expansive soils, etc.
Recommendations on foundation system and the net allowable bearing pressures and
pile capacity shall be based on the conservative values of geotechnical investigation
data.
7.07.03.00 Geotechnical investigation work shall be got executed by the Contractor through the
following agencies.
1. C.E.TESTING COMPANY Pvt. Ltd, Kolkata
2. Cengrs Geotechnica Pvt. Ltd, New Delhi
3. KCT Consultancy Services, Ahemdabad
4. M.K. Soil Testing Laboratory, Ahemdabad

7.08.00 Geotechnical Investigation Scheme

a) Boreholes (Minimum)

Spacing/Number of Depth of Remarks

S.No Structure
borehole borehole
FGD Minimum 14 Nos. Depth of
1
boreholes shall
be 25m to 35m. Depth of
boreholes

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Crusher House Minimum 2 Nos. Depth of shall be as

2
boreholes shall mentioned in
be 25m to 35m. column
“Depth of
Gypsum and Lime Minimum 10 Nos. Depth of
3 Borehole” or
storage area boreholes shall
5m
be 15m to 25m
continuous
in rock with
Other Minimum 2 Nos.
4 15 to 20 m RQD > 25%
Structure/Facility boreholes under
whichever is
each area / facility
earlier.

Chimney Minimum 2 Nos.

5 30 to 35m

b) Other Field Tests (Minimum)

1 Cyclic Plate Load 3 nos Test Depth from 2 to 4 m

Test (CPLT)

2 TRIAL PIT (TP) 5 Nos. Depth - 3 m

3 IN SITU In minimum 3 Nos. of Tests shall be conducted
PERMEABILITY boreholes at depths of 1.0m, 3.0m,
TEST IN 5.0m, 8.0m and 12.0m.
BOREHOLES
4 Minimum 10 Nos.
ERT

• Depth and location of Boreholes and other field tests (PLT, ERT, field permeability
tests etc.) shall be approved by Owner before execution of geotechnical
investigation work.
• Investigation in any other building / structure / facilities / trestles which are not
mentioned above shall also be carried out, if required, by the bidder for the facilities
under his scope.

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ANNEXURE-I

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ANNEXURE-II

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Annexure-III

SOIL DATA AND FOUNDATION SYSTEM

Employer has carried out geotechnical investigation in vicinity to the proposed
area. Logs of available boreholes for bidder’s solely information in the vicinity
of proposed area are enclosed with this Annexure.
The bidder is required to carry out geotechnical investigation as per Clause No
7.08.00 and ascertain the bearing capacity. The onus of correct assessment /
interpretation and understanding of the existing subsoil condition / data is on
the Bidder. The existing ground level (EGL) is varying as per enclosed
contour/spot level drawing.

a) The foundation system to be adopted for different structures shall be as given

in Table – 1 below

Table – 1: Net Allowable Bearing Pressure

STRUCTURE TYPE OF
FOUNDATION TO
BE ADOPTED
FGD and related structures Open

b) Bidder is required to carry out geotechnical investigation in this area. The

allowable bearing pressure shall be adopted after approval of geotechnical
investigation report by owner. However, the maximum allowable bearing
pressure shall be as per the approved geotechnical report and shall be limited
to the values as furnished in Table-2.
Table – 2: Net Allowable Bearing Pressure
Founding Depth/ Stratum Net Allowable Bearing PressureT/m2

Isolated and Isolated Rafts (width >

combined and 6m) for 75mm
footings combined permissible
including raft footings for settlement in
for 25mm 40mm case of soil and
permissible permissible 12mm in case of
settlement in settlement rocky strata
case of soil in case of
and 12mm in soil and
case of 12mm in
rocky strata case of
rocky strata
Width upto 6.0m

In case of Soil

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2.0m below NGL 12 14 20

3.0m below NGL 15 20 25

In case of rocky strata

0.5m embedment into rock 30 30 30

1.0m embedment into rock 35 35 35

- For NGL, topographical survey drawing along with borehole details carried out by
bidder shall be referred.

The net allowable bearing pressure higher than above mentioned values shall
not be permitted. At intermediate levels the bearing capacity shall be same as
the net allowable bearing pressure corresponding to the immediate shallower
level mentioned above.

c) Permissible Settlement of Foundations:

For open foundations, the total permissible settlement and differential
settlement shall be governed by IS: 1904 and from functional requirements
whichever is more stringent. However, total settlement shall be restricted to the
following:
Isolated, Strip & Raft (Mill foundations/machine 25 mm
foundation)
Isolated & Strip (Other than Mill 40 mm
foundations/machine foundation)
Raft (widths greater than 6 m) (Other than Mill 75 mm
foundations/machine foundation)
Foundations in rock 12 mm
In case the total permissible settlement is to be restricted to less than as above
specified from functional requirements, then the net allowable bearing pressure
shall be reduced after review in consultation with Engineer.

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Annexure-IV

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Table-1
COAL AND ASH CHARACTERISTICS

S.N. Description Symbol Design Worst Best Coal

Coal Coal

A: PROXIMATE ANALYSIS (As received basis)

1 Total Moisture % 13 16 12
2 Ash % 42 46 38
3 Volatile matter % 21 18 24
4 Fixed carbon % 24 20 27
B: ULTIMATE ANALYSIS (As received basis)
1 Carbon C% 32.92 27.97 39.08
2 Hydrogen H2% 3.2 2.45 3.4
3 Nitrogen N2% 1.28 1.08 1.19
4 Oxygen (By difference) O2% 7.2 6.00 6.97
5 Sulphur S% 0.4 0.50 0.36
6 Total Moisture H2O% 13.00 16.00 11.00
7 Ash % 42.00 46.00 38.00
8 Gross Calorific Value KCal/Kg 3400 2800 4000
9 Hard grove index 55 50 60
C: ASH ANALYSIS
1 Silica (SiO2)% 58.78 61.30 55.70
2 Alumina (Al2O3)% 28.20 28.35 27.20
3 Iron Oxide (Fe2O3)% 7.5 6.00 10.00
4 Titania (TiO2)% 1.50 1.00 2.00
5 Lime (CaO)% 1.23 1.05 1.50
6 Magnesia (MgO)% 1.55 1.35 2.05
7 Sodium Oxide(Na2O) & % By 1.09 0.80 1.40
Potassium Oxide (K2O Difference
8 Phosphoric Anhydride (P2O5)% 0.05 0.05 0.05
10 Sulphuric Anhydride (SO3)% 0.10 0.10 0.10
D: ASH FUSION RANGE (Under reducing atmosphere)
a) Initial Deformation °C 1150 1200 1100
Temperature (IDT)
b) Hemispherical °C 1350 1400 1300
temperature
c) Flow temperature °C 1400 1400 1400

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SYSTEM PACKAGE BID DOC. NO.:CS-0011-109(2)-9 (BHILAI 2X250 MW)

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TABLE - 2
LIGHT DIESEL OIL CHARACTERISTICS
AS PER IS 1460-2000
Characteristics LDO

1. Pour Point (max) 21°C & 12°C for Summer and

Winter respectively

2. Kinematic viscosity in centistokes at 40 2.5 to 15.7

deg.C

3. Sediment percent by mass (max) 0.10

4. Total sulphur percent by mass (max) 1.8

5. Ash percentage by mass (max) 0.02

6. Carbon residue (Rans bottom) percent by 1.50

pass (max.)

7. Acidity in organic Nil

8. Flash point(Min.) - Pensky Martens 66 deg.C

9. Copper strip corrosion for3 hours at 100°C Not worse than No. 2

10. Water content, % by volume(max) 0.25

11. GCV (Kcal/kg) 10,000

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SYSTEM PACKAGE BID DOC. NO.:CS-0011-109(2)-9 (BHILAI 2X250 MW)

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CLAUSE NO. PROJECT INFORMATION

TABLE - 2
FUEL OIL CHARACTERISTICS

Sl. Characteristics Heavy Furnace Low Sulphur Heavy

No. oil IS 1953-1971 Heavy Stock Petroleum
Grade HV (LSHS) Stock (HPS)

Total Sulphur Content 4.5% Max 1.0% Max 4.5% Max

1.
Gross Calorific Value Of the order of Of the order of 9,500 (min)
2.
(Kcal/kg) 11,000 11,000
Flash point (Min) 66deg C 75 deg C 75deg C
3.
Water content by 1.0% 1.0% 1.0%
4.
volume (Max)
Sediment by weight 0.25% 0.25% 0.25%
5.
(Max)
Asphaltene content by 2.5% 2.5% 2.5%
6.
weight (Max)
Kinematic viscosity in 370 180 500
7.
centristrokes at 50 deg
C (Max)
Ash content by weight 0.1% 0.05% 0.1%
8.
(Max)
Addity (Inorganic) Nil Nil Nil
9.
Pour Point (Max) - 57Deg C 72 Deg C
10.
Sodium Content - - 100 ppm
11.
Vanadium content 25 ppm 25 ppm 25 ppm
12.
Specific heat below - 0.65 -
13.
pour point (Kcal/KG0C)

Table-3 NOT USED

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SYSTEM PACKAGE BID DOC. NO.:CS-0011-109(2)-9 (BHILAI 2X250 MW)

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Table-4
DESIGN CLARIFIED WATER ANALYSIS
S.No Constituent As mg/I
(except pH & turbidity)
1. Calcium CaCO3 38
2. Magnesium CaCO3 22
3. Chloride CaCO3 20
4. Sulphate CaCO3 17
5. Alkalinity CaCO3 54
6. Iron(total) Fe 0.1
7. Total Silica SiO2 07
8. pH value --- 7.5
9. Turbidity NTU 02

Note: Clarified water is used for CW system as make up & the CW system is
expected to operate at about 5.0 – 5.5 Cycles of Concentration (COC) with
suitable chemical treatment program using acid, scale & corrosion inhibitor
dozing. As CW blow down water is tapped from CW system, the water
quality of CW blow down shall accordingly be arrived by the bidder.

Table-5
ANALYSIS OF DM WATER

S.N. Characteristics Value

1. Silica (Max.) 0.02 ppm as SiO2

2. Iron (Fe) Nil

3. Total hardness Nil

4. pH value 6.8 to 7.2

5. Conductivity Not more than 0.1 μs/cm

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SYSTEM PACKAGE BID DOC. NO.:CS-0011-109(2)-9 (BHILAI 2X250 MW)

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CLAUSE NO. PROJECT INFORMATION

Table-6
STEAM GENERATOR DATA

1. Location Outdoor
2. Operation Base load
3. Type Pulverized coal fired
4. Maximum Continuous Rating 790 Tonns/hr.
5. Steam pressure at SH outlet 155 Kg/cm²(a)
6. Steam temperature at SH outlet 540°C
7. Oil for startup and flame stabilization LDO
7.5% of Boiler MCR for start-up by
8. Fuel oil system sizing
LDO, 40% of Boiler MCR by HFO
Pulverised coal size and 99% thru 50
9. Minimum 70% through 200 Mesh
mesh
10. Type of pulveriser Vertical spindle mills
11. Type of oil burners Air atomized for LDO
12. No. of air heaters One
13. No. of ID Fans Two (both working)

ESP DATA

1. Location: Downstream side of Air preheaters

2. Operation: Base load

3. Type: Rigid Discharge frame

4. Rapping: Intermittent

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Page 37 of 338
TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-C1
TECHNICAL SPECIFICATION FOR REV. 00 DATE: April, 2020
MISCELLANEOUS FGD TANKS

SECTION-I,
SUB-SECTION-C1

SPECIFIC TECHNICAL REQUIREMENT –

MECHANICAL

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 TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-C1
TECHNICAL SPECIFICATION FOR REV. 00 DATE: April, 2020
MISCELLANEOUS FGD TANKS

SECTION-I,
SUB SECTION-C1A
SPECIFIC TECHNICAL REQUIREMENT-TANKS

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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-A
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

1.0 SCOPE OF SUPPLY

1.1 Supply of Steel plates and fabrication of tanks at site under this specification shall be as per enclosed
FGD Tank schedule (Section-III, Annexure-8). Detailed GA & fabrication dwgs. of each type of tank shall
be submitted by bidder during detail engineering to suit good engineering practice to the satisfaction
of the customer.
1.2 General design, selection of rubber lining, Vinyl Ester (VE) Flake glass lining, Epoxy lining materials,
construction features, manufacturing, shop inspection, testing at manufacturer’s works, surface
preparation, lining, inspection & testing of the lined surface at 2 X 250 MW BHILAI FGD site. For detail
specification of rubber lining & Vinyl Ester Flake glass lining refer Sub Section-C1-B and Sub Section-C1-
C respectively of section-1.
1.3

a) The connections and accessories which are required to be supplied with each tank by the bidder shall
be as indicated in the enclosed FGD Tank schedule (Section-III, Annexure-8).

b) The piping material inside the tank shall be supplied by the bidder. All inlet piping shall be extended up
to the bottom of the tank and the clearance between the bottom of the tank and the edge of the inlet
piping shall be kept as 500 mm (maximum). The inlet pipes shall be lined with replaceable wear
resistant natural rubber lining of minimum 06 mm thickness from inside. Additional thickness of 2 mm
in rubber lining shall be provided at bends.

c) The inside piping shall be adequately supported and shall be provided with adequately sized vent (anti-
siphoner) connection at pipe top.

d) Weir plates of adequate thickness (minimum 8 mm) shall be provided for all inlet piping.

e) Pad plates on the tanks for supporting outside piping shall be provided by the bidder. Details of the
pad plates (sizes, quantity etc.) shall be informed to bidder during detail engineering.

f) Fabrication and supply of all flanges and counter flanges for all nozzles of tank connections shall be
included in the scope of work of the bidder. Necessary bolts, nuts and gaskets for these connections
shall also be supplied by the bidder. Further rubber lining / VE Flake glass lining of these nozzles
including flanges, counter-flanges shall be in bidder’s scope of work.

g) The manhole shall be of hinged and bolted type with nuts, bolts and gaskets in bidder’s scope of supply.
The size of the manhole shall be minimum 800 mm and subjected to customer approval. Bidder shall
provide two nos. manhole for each tank, i.e. one no. manhole on shell and one no. manhole at roof.

h) Supply and erection of vent valves shall be in bidder’s scope.

1.4 The scope of works shall also include supply and installation of special accessories including agitator
supporting arrangements, agitator platform, baffle plates etc. as indicated in FGD Tank schedule
(Section-III, Annexure-8). The necessary fixtures and other accessories for mounting these special
accessories shall be included in the scope of work of the bidder.

1.5 Baffle plates for the agitators shall be mounted on the tank. The supply and erection of the baffle plates
shall be in bidder’s scope of work. The minimum no. of baffle plates and minimum dimension of the

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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
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MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

baffle plates have been indicated in the FGD Tank schedule (Section-III, Annexure-8). The final quantity
and dimensions of the baffle plates shall be decided during detail engineering.

1.6 Quantity and size of spare nozzles as per FGD Tank schedule (Section-III, Annexure-8) shall be supplied
by the bidder.

1.7 Pipes, fittings, nozzles, flanges and counter flanges along with the rubber lining / VE Flake glass lining
shall be supplied by the bidder. The minimum requirement like quantity, size, type etc. are indicated
in the FGD Tank schedule (Section-III, Annexure-8) and may undergo change during detail engineering
stage and these shall be supplied by the bidder as per the approved drawings / documents for which
no commercial implication shall be entertained by BHEL. Material of construction of all pipes, fittings,
nozzles, flanges and counter flanges shall be as per tank schedule (Section-III, Annexure-8).

1.8 The minimum number of anchor bolts along with its size shall be finalized during detail engineering.
Further, any additional anchor bolts of higher size if found applicable during detailed Engineering as
per customer comment shall be provided by bidder without any commercial implication. The material
of construction for anchor bolts shall be IS 1367 Part-3.

1.9 Painting of the tanks is included in bidder’s scope of work. Painting specifications of storage tanks are
given under Painting schedule in Sub Section-C2-C, section-1. Painting requirement specified under
Painting schedule are minimum requirement. Any modification in painting requirement found
applicable during detained engineering, shall be under bidder’s scope without any commercial
implication.

1.10 Commissioning spares as required for commissioning of the tanks are in bidder’s scope.

1.11 Platforms, inter-connecting platforms, platforms for agitator maintenance, monkey ladder inside tank
and for agitator platform approach, staircase (hand railing, knee guard and toe guard (in stair case,
agitator platform and all along the periphery of roof of the tank) etc. as per the relevant design code /
good engineering practice (as indicated in the tank schedule) shall be included in bidder’s scope of
work. All staircase treads and platforms shall be 32 mm steel fabricated gratings. Gratings shall be
galvanized as given for handrails in painting specification.

2.0 SCOPE OF SERVICES

Services shall include but not be limited to the followings:

2.1 Design, engineering, preparation of detailed fabrication drawings, design calculation, bill of material,
tag and piece numbers, welding procedures etc. Stiffeners and other structural framing for supporting
the tank shall be designed by the fabricator and properly shown in the fabrication drawings.
Erection & Commissioning of Tanks. Erection of the agitators, agitator mounting arrgt., agitator
2.2 Erection & Commissioning
supporting of Tanks.
arrangements, shall be in bidder scope. The Agitator shall be provided by BHEL as a free issue
item.
2.3 Erection & Commissioning of rubber lining / VE Flake glass lining.

2.3 Erection of all foundation bolts / anchor bolts etc. as required for any equipment/ foundation
/concrete.

2.4 Minor civil work like chipping of foundation, grouting below base plate for all structures, equipment,
grouting of pockets, excavation & filling of earth for buried MS pipes if and as required.
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 SPECIFICATION NO. PE-TS-468-167-A101
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MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

2.5 Inspection & testing and carrying out demonstration test.

2.6 Inspection & testing and carrying out demonstration test for the rubber lining / VE Flake glass lining of
tanks.

2.7 Painting of tank and other equipment within the battery limit.

2.8 Any other equipment / material / services as required to make the installation complete in all respects
shall be deemed to be included in bidder’s scope of work whether mentioned above or not.

3.0 DESIGN CONSIDERATIONS

3.1 The successful bidder shall furnish design calculations to BHEL during detailed engineering stage for
approval along with the Xerox copies of relevant pages of authentic supporting literature e.g. Code,
Hand book, National / international Standards etc. Calculation shall be necessarily done in SI UNITS
only for the followings: -

a) Tanks shall be designed as per IS – 803 / API – 650 / AWWA – D 100 / IS –2825 / BS – 2594 / Good
engineering practice as applicable and referred code shall be of latest edition. However, requirement
of codes and standards shall be as indicated in the tank schedule, Annexire-8.

b) Weight calculation of plates, appurtenances, platforms & structures separately shall be included in the
Design calculation.

c) Design of roof and roof structures for vertical storage tanks along with agitators & agitator platforms
shall be designed based on guidelines given in the book titled “Process equipment design” by Brownell
and Young. Further, roof structure shall preferably be constructed on external side of roof.

d) Tank stability calculation (wind load / seismic / overturning stability) considering static and dynamic
loads of Agitator and its platforms and supporting arrangement shall be done as per API – 650/IS-803,
latest edition. However, factors / coefficients as required for the design of tank shall be obtained from
BHEL by the bidder after placement of order.

d) Vent sizing calculation shall be done as per API – 2000, latest edition

e) Sizing calculation for vent valve.

3.2 The successful bidder shall indicate references of all the clauses indicating their page number from
respective standard in the design calculation during detail engineering stage. All calculations shall
necessarily be done in SI units only. All steps including formulas and abbreviations shall be clearly
shown in the calculation. All inputs / assumptions shall be indicated in the first sheet of the calculation.

3.3

a) Bottom plate shall be 8.0 mm thick (minimum). Minimum 6 mm (excluding tolerance on plate as per
relevant IS) thick plates including corrosion allowance shall be provided for shell plates and minimum
8 mm for roof plates for all tanks. However, Auxiliary absorbent tank shall be provided with minimum
8 mm thickness for shell, refer min. shell plate thickness defined in tank schedule Annexure-8.
Calculation for the plate thickness shall be got approved from BHEL / Customer during detailed
engineering stage. However, if the addition / summation of calculated value of plate thickness
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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-A
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

(excluding tolerance on plate as per relevant IS) / nominal minimum thickness specified in the relevant
design code / standard and corrosion allowance of 1.5 mm comes out more than 6 mm then the
nearest available (higher side) plate thickness in the market shall be provided for shell and roof plates
without any commercial implication. For calculating shell plate thickness. IS 803 to be used. Further
minimum thickness of bottom, shell and roof plates have been specified in tank schedule Annexure-8.

b) Negative tolerance on plate thickness shall not be considered in the plate thickness calculation and
also shall not be provided in the tank. Only positive tolerance shall be considered.

3.4 All appurtenances and mountings shall also be designed as per relevant clauses of IS: 803 / API – 650.

3.5 Tank shall be suitably constructed for safe, proper and continuous operation under all conditions that
can be expected in a plant life without undue strain, corrosion or other operating difficulties.

3.6 In calculating the minimum plate thickness, the specific gravity of the liquid shall be taken as per tank
schedule (Section-III, Annexure-8).

3.7 For cylindrical tanks, the plates shall be cold rolled through plate bending machine by several number
of passes to true curvature.

3.8 Vessels seams shall be so positioned that they do not pass though vessel connections. For cylindrical
vessels consisting of more than two sections longitudinal seams shall be offset.

3.9 Wherever possible, the inside seam weld shall be ground smooth, suitable for application of corrosion
resistant primer.

3.10 Due consideration shall be given by the supplier for wind load and earthquake effect in the design of
tanks.

3.11 For the tanks being of diameter larger than 3.75 m added structural supports in the form of rafter shall
be provided.

3.12 Reinforcement in tanks shall be provided as per design code. The reinforced connection shall be
completely pre - assembled into shell plate.

3.13 The joint efficiency factor to be adopted for design calculation of shell thickness shall be 0.7.

3.14 All roofs and supporting structures shall be designed to support dead load plus a uniform live load of
not less than 150 kg/m2 of projected area. Further, the static and dynamic loads of the agitator
assembly along with the agitator platform shall be considered over and above the uniform live load.

3.15 Staircase / access ladder and hand railing shall be provided as per the relevant codes and standards
and tank schedule (Section-III, Annexure-8).

3.16 -VOID-

3.17 Code conformance for flanges / counter flanges shall be ANSI B 16.5. Code conformance for bolts and
nuts shall be SA 193 & 194 respectively. Further, all fasteners used in wetted condition must be of
Alloy 926 or better material so that even if it comes in contact with liquid by swelling of rubber,

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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-A
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

thread remains unaffected. Raw material of fastener must undergo Inter-Granular Corrosion test as
per ISO-3651, Part-1 for Nitric Acid test.

3.18 The number & size of nozzles (including flanges, counter flanges and inside piping) indicated in the tank
schedule (Section-III, Annexure-8) & Input dwgs (annexure-III, sub Section-D, Section-I) are tentative
and bidder guidance purpose only and the same may undergo change during detail engineering stage
for which no commercial implication shall be entertained by BHEL.

3.19 Bidder shall furnish the STADD calculation along with the roof structure calculation during detail
engineering for checking the stability of roof.

3.20 The tank shall be designed for filled water head / atmospheric pressure and design temperature for
the tank shall be as specified tank schedule (Section-III, Annexure-8).

3.21 Bidder to note that surface cleaning shall be of Blast clean type. However, Grit blasting shall be decided
during detail engineering for which no commercial implication shall be entertained by BHEL. Further,
the surface cleaning of the tanks shall be in line with the requirements specified in the specification for
rubber lining / VE Flake glass lining.

3.22 Bidder to note that foundation drawing along with loading data & anchor bolt details shall be provided
by bidder within two weeks’ time from the LOI. However, Bidder to provide minimum anchor bolts for
the Miscellaneous FGD tanks, as specified in the tank schedule (Section-III, Annexure-8).

3.23 All materials, furnished shall conform to the latest editions of America National Standard Code for
Pressure piping, Power piping, ANSI B311.1, ANSI B16.11, ASME Boiler and Pressure Vessel Codes, IBR
and other applicable ASME, ANSI and Indian Standards. Schedule numbers, sizes and dimensions of all
carbon steel, stainless steel and alloy seamless steel pipe shall confirm to ANSI B.36.10 and of stainless
steel pipe shall confirm to ANSI B 36.19 unless otherwise specified.

4.0 WELDING

4.1 Welding shall be in accordance with the requirement of IS: 803, 816, 817 and 823 or equivalent and as
specified in the specification for rubber lining / VE Flake Glass lining.

4.2 Welding sequence shall be adopted in such a way so as to minimize the distortion due to welding
shrinkage. Contractor shall indicate in his drawing the sequence of welding proposed by him, which
should meet prior approval of the Engineer.

4.3 All welders shall be BHEL / customer / consultant qualified as per the approved quality plan / field
quality plan which will be submitted by the successful bidder during detail engineering stage. WPS and
PQR shall be submitted by the successful bidder to BHEL / customer / consultant for review and
approval.

5.0 TEST AND INSPECTION

5.1 The particulars of the proposed tests and the procedure for the tests shall be submitted to the Owner
/ Engineer for approval before conducting the tests. The successful bidder shall submit FQP (field
quality plan) and demonstration test procedure for BHEL / customer / consultant’s approval during
detail engineering stage. In the event of any change in the field quality plan and demonstration test

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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-A
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

procedure, the same shall be incorporated by the bidder in the document and approved document
shall be adhered by the bidder without any commercial implication.

5.2 DPT / MPI on all welds (100%).

5.3 All cross / Tee joints and butt welds to be Radio graphed in line with the joint efficiency as specified in
the design code / Tank schedule, Annexure-8.

5.4 For the offered tanks, fill test shall be carried out for at least 24 hours. Atmospheric storage tanks on
inside surface shall be leak tested before painting / rubber lining / VE glass flake lining.

5.5 All quality plans / checklists for various items shall be furnished during detail engineering stage for
BHEL / customer’s approval and any changes required by BHEL / customer shall be incorporated in the
documents and adhered without any price implication. However, minimum requirement of MQP as
indicated in the technical specification shall be followed. All necessary items as required for inspection
and testing of the tank including instruments shall be arranged by the bidder.

6.0 MANDATORY SPARES:

Not Applicable.

7.0 LIST OF COMMISSIONING SPARES:

SL. DESCRIPTION OF ITEMS QUANTITY

NO.

1 Rubber Gasket of each size 2 nos.

2 Nuts, bolts & washers of each size (nos. of bolts, nuts & washers as 1 lot
required for each nozzle) as per approved Drg.
3 Any other item required for successful commissioning of the tanks 1 lot
including rubber lining / VE Flake Glass lining (to be specified clearly
by bidder)

8.0 TERMINAL POINTS

x Matching counter flanges for all nozzles mounted on the tank and its accessories. However,
counter flanges for all nozzles of tank shall be provided by the bidder.

9.0 EXCLUSIONS

1) Tank foundation & associated civil works, all instruments like level gauges, Level Transmitters, etc
are excluded from bidder’s scope of work. However, required no. of nozzles for the same shall be
in bidder’s scope of work.

2) All agitators including the agitator of drain pits/ sumps shall be provided as a free issue item to the
bidder. The erection and commissioning of the agitators shall be in bidder’s scope of work.
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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-A
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

However, BHEL shall arrange for the supervision of the erection and commissioning of the agitator
assembly to the bidder as a free issue service.

3) The Sumps/drain pits indicated in the tank schedule (Section-III, Annexure-8) is excluded from
bidder’s scope of work. However, the erection and commissioning of the agitators and VE Flake
glass lining within the sump/drain pits shall be in bidder’s scope of work.

4) All valves are excluded from bidder’s scope of work.

5) All external piping from the counter flange of the nozzles of respective tanks is excluded from
bidder’s scope of work. However, matching counter flanges for all nozzle shall be in bidder’s scope
of work. Further the supply and erection of the piping material inside the tank shall be in bidder’s
scope. The rubber lining / VE Flake glass lining of the inlet pipes shall be in bidder’s scope of work.

10.0 DRAWINGS AND DOCUMENTS TO BE SUBMITTED WITH THE BID

The bidder must submit the drawings / documents as mentioned under “CHECK LIST FOR DOCUMENT
TO BE SUBMITTED” (In Section-III, Annexure-I) along with their bid. In absence of any of these
documents, BHEL reserves right not to evaluate the offer of the concerned bidder.

11.0 DRAWINGS/ DOCUMENTS REQUIRED DURING DETAIL ENGINEERING

The successful bidder shall submit the drawing / documents as mentioned under SECTION-I, Sub-
Section-D, Annexure-IV during detail engineering for approval / information / reference (as the case
may be).

12.0 OTHER TECHNICAL REQUIREMENTS

1) 15 days’ time is required by BHEL to offer their comments on the drawings and documents being
submitted by the bidder (during detailed engineering stage in the event of L.O.I being placed) from the
date of receipt.

2) Bidder to depute competent designer (s) at BHEL’s office during detailed engineering stage to discuss
drawings and other technical documents as and when required by BHEL.

3) Bidder to assess the capability of their sub-vendors in terms of preparation of drawings, calculations,
documents, quality assurance, supply of material etc. as per project schedule before placing the order
on them. No deviations shall be entertained.

4) Commercial implication includes price implication as well as delivery implication.

5) Size of hand rails on stairway and tank roof / top shall be minimum 32 NB and shall conform to IS 1239
(M). Handrails shall be galvanized as per painting specification.

6) Type of roof for vertical cylindrical storage tanks shall be either supported cone roof or self-supporting
cone roof as per latest edition of relevant design code.

7) Commissioning of tanks will consist of installation of all accessories of tanks as per approved
drawing/specification, charging of tank, water-fill test (for minimum 24 hours after complete filling of

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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-A
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

tank), satisfactory functioning of all accessories, emptying of tank, subsequent painting of complete
tanks and changing of gaskets as per specification requirement.

8) Bidder to furnish prices and unit price of each item of proposed tanks as per BHEL’s price format only
along with the final price bid.

9) Bidder shall check that specifications of all the items are available in the NIT specification. However, in
the event of absence of specification for any item, bidder will approach BHEL to furnish the
specification of missing items and new specification will be adhered by the bidder for which no
commercial implication shall be entertained by BHEL.

10) All tools and plants including welding machines, crane, hydra, fork lift, batching plant etc. and
instruments as required for construction, erection and commissioning, trial run and functional
demonstration test at site shall be arranged by the bidder.

11) Bidder to furnish list of sub-vendors based on sub-vendor list enclosed with the specification during
detail engineering stage for BHEL’s / Customer review and approval and items shall be procured from
these suppliers only.

12) Dealers are not acceptable for any item of the package. Bidder shall procure all items including plates,
structural, flanges, counter flanges etc. from BHEL approved sub vendor only. No argument on this
account shall be entertained.

13) All rubber lined pipes shall be provided with flanged type connections only. In other words, Rubber
lined pipes shall be flange joined only.
14) Minimum staircase width to be considered as 1200 mm.

15) Bird screen for vents shall be provided by bidder.

16) Drop down pipe within the tanks, for each tank shall be provided by bidder.

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 TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-C1
TECHNICAL SPECIFICATION FOR REV. 00 DATE: April, 2020
MISCELLANEOUS FGD TANKS

SECTION-I,
SUB SECTION-C1B
SPECIFIC TECHNICAL REQUIREMENT-RUBBER
LINING

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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-B
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

1.0 SCOPE OF SUPPLY

1 Design, manufacture, testing and supply of rubber lining material for the duty condition for FGD
Tanks as specified in Annexure- 8 (Tank schedule).

2 Erection and Commission. Delivery of material at site, surface preparation for lining surfaces, lining
the surface to the satisfaction of the customer shall be under bidder's scope, cost for Erection and
Commission shall be included in the offer.

3 10 copies of Operation manuals containing all details of reference drawings and technical data shall
be furnished by the Bidder.

2.0 SURFACE PREPARATION

1 The Tanks surface to be lined should be blasted to a bright grey metal finish (Sa 2½ requirement),
free from rust, weld marks, oil and any other foreign matter. The blasting is carried out with the help
of dry grit (copper sludge)/Sand under dry air pressure of 7 kg/cm2 by Compressor. Surface
roughness shall be 50-60 Microns.

2 After blast cleaning, blasted surface will be applied by surface protecting primer to prevent the
corrosion. After 100% blasting of the particular Tank is completed, the surface is cleaned by
appropriate solvent, so as to see that all the small dust particles are removed. Sharp corner shall be
suitable rounded off. Surface should not have any sharp notch.

3 After this procedure suitable bonding agent and 3 to 4 coating of the specially formulated rubber
adhesive should be applied for proper bonding of the Rubber Sheets to be lined.

4 Compressor and any other facilities required for grit/shot blasting shall be arranged by vendor. Any
hoses provided in the compressed air line shall be tested with air before commencement of grit
blasting job.

5 The grit/shot blasting machine shall be provided with safety valve (safe trip) as a protection against
over pressure.

6 Scaffolding shall be done by the vendor. Any scaffolding provided by the vendor shall be of steel
only.

3.0 GUIDELINES FOR DESIGN & FABRICATION OF STEEL CONSTRUCTIONS FOR RUBBER LINING:
1 Please refer Section-II, Sub-Section-A

4.0 RUBBER LINING

1 The lining shall completely cover the roof, sides and internals of Slurry Tanks, support angle, insert
plates, openings, Man Hole / Inspection / Flange openings. etc.,

2 The rubber used for the lining of the tank is given below:

Refer Annexure-8

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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-B
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

Sl. Tank Rubber Lining

No
1 Auxiliary absorbent tank Bromine butyl rubber lining with
hardness 55±5 (Shore A
Hardness).
2 Limestone slurry Tank, Waste water Tank, Primary Bromine butyl rubber lining with
hydro cyclone Tank, Secondary Hydro cyclone Tank, hardness 55±5 (Shore A
Filtrate water Tank, , Process water Tank, Belt Filter Hardness).
Water Tank, Clarified (Cake wash) Water Tank,
Absorber Area Drain Pit, Gypsum Dewatering Area
Drain Pits, Ball Mill Area Drain Pit.

3 After Rubber sheet applied on the surface, rubber sheets should be systematically pressed to the
metal surface by the help of mechanical tools like Rubber Rollers and metal thin rollers to remove
the air between metal and rubber sheet. All rubber joints are properly overlapped by 25 to 35 mm
wide tapered cut rubber sheet. All the joints will be covered by 75 mm X 1.5 - 1.7 mm thick rubber
strip.

4 Vendor shall specify the shelf life of the rubber material being supplied and shall furnish the
storage methods to be followed at site to ensure that the rubber material shall not be spoilt
during storage.

5 Vendor shall submit the surface preparation and lining procedure to the purchaser for approval. The
lining work shall start only after obtaining approval from Purchaser.

5.0 INSPECTION AND TESTING OF RUBBER LINING

1 Ageing Test : 70°C for 24 hrs. (IS: 3400 Pt.4)
Change in Tensile Strength: ± 5%
Elongation at break: ± 10%
2 Abrasion Test : Wt. loss – Max. 25%
3 Tensile Strength : 35 kg/cm2 (min) for Bromo Butyl and
40 kg/cm2(min) for Chloro Butyl Rubber
4 Elongation at break : ≥ 300% minimum for 4mm thk rubber specimen
5 Peeling strength : ≥ 3 N/mm
6 Hardness : 55 ± 5° Shore A
7 Spark Test : 1.5 KV/ mm
8 Lining shall be visually inspected to ensure free from poorly weed out fibers, entrapped air and
exposed fires. Defects are to be repaired by slandering a generous area around the defected portion
and applying a layer of rubber material.
9 Spark test shall be carried out at appropriate areas in the presence of Purchaser. Vendor should
conduct test as per relevant standards.
10 After installation, the Rubber lining shall be subjected to testing at site as per relevant standards. If
the performance is found not to meet the requirements as specified, the Rubber lining shall be
rectified or replaced by the Vendor without any extra cost to the Purchaser.

5.1 FINISHING & INTERNAL TESTING

1 Rubber surface of all flanges and manhole of Equipment will be finished by the mechanical tools to
get leakage free surface during commissioning.

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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-B
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

2 After above finishing, 100% testing will be carried out for continuity by high frequency high voltage
spark tester. If there is any puncture, they are checked and rectified as per the standard procedure
of repair (Clause 6.1) as mentioned in procedure.

5.2 REPAIRING PROCEDURE

1 Faulty spots on the rubber lining are cut off down to be substrate and the seams of the remaining
rubber are beveled.
2 Rubber sheet with a broad bevel cut is glued on the substrate laid bare.
3 On spots to be repaired of a diameter < 300 mm a second layer of Rubber sheet is glued covering the
seams of the first layer.
4 Several spots to be repaired in a small area are jointly covered with a second layer of Rubber sheet.

6.0 PERFORMANCE GUARANTEE

The lining material shall be guaranteed for an uninterrupted minimum life of 25000 hrs.
Performance parameters to be guaranteed by the vendor and tolerances permitted shall be as
indicated in the data sheet. Rubber lining or any portion thereof is liable for rejection, if it fails to give
any of the guaranteed performance parameters. The lining should be guaranteed for faultless
material and workmanship. During Guarantee period any defects noticed due to faulty material and
workmanship, shall be rectified by vendor free of cost.

7.0 PACKING
1. The part items of the Rubber lining should be identified by Tag numbers and should be packed as to
minimize the possibility of damage during storage or transit. The packing should be suitable for
tropical conditions. Vendor should specify the storage requirements for the Rubber lining materials.
2. The list of items identified as dispatch able units shall be furnished along with unit weight and the
quantity for preparation of packing slip at BHEL end for dispatch to site and for easy identification,
storage and erection at site.
3. Please refer Sub Section- C2 – B, SECTION – I for Packing Procedure.

8.0 DOCUMENTATION

DATA TO BE FURNISHED BY THE VENDOR AFTER RECEIPT OF PURCHASE ORDER

1 List of Drawing and documents to be submitted for review, approval and information with submission
dates
2 Quality Assurance Plan to be submitted for approval.
3 Detailed dimensional General Arrangement drawing of the lining surfaces.
4 This drawing shall indicate all the design data and information about the material, scope of work and
weight of the material supply, Packing procedure etc.
5 Installation, operation and maintenance manual.
6 Surface preparation and Lining procedures.

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TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-C1
TECHNICAL SPECIFICATION FOR REV. 00 DATE: April, 2020
MISCELLANEOUS FGD TANKS

SECTION-I,
SUB SECTION-C1C
SPECIFIC TECHNICAL REQUIREMENT –
FLAKE GLASS LINING

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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-C
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

1. INTENT OF SPECIFICATION
a) This Specification defines the minimum requirements of glass flake lining of Slurry Tanks &
Slurry sumps in the Flue Gas Desulphurization (FGD) plant.

b) Tanks / Sumps to be lined contain Limestone Slurry / Gypsum Slurry / Process water. Slurry
Tank Details and Slurry conditions are given in Annexure-8 Tank Schedule. The glass flake
lining shall offer better resistance to corrosion/erosion and shall be based on Vinyl ester
resin. Thickness of glass flake lining required is 3 mm thk.

c) This specification covers the general design, selection of suitable glass flake material/resin,
manufacture, shop inspection (as per latest applicable statutes, regulation and safety
codes in the locality where the lining are to be carried out) and delivery at site, surface
preparation of lining surface, lining the surface to the satisfaction of the customer, jointly
calculation of total area lined, inspection of the lining at site, handling over to the ultimate
customer.

d) Compliance to this specification shall not relieve the vendor of the responsibility of
furnishing glass flake lining materials of proper design, materials and workmanship to meet
the specified requirements.

e) In case of deviation, it shall be listed in the vendor's proposal under separate section titled
as “list of deviations/exceptions” to the enquiry documents. Any deviation not mentioned
in this list , but mentioned elsewhere in the proposal will not be considered.

2.0 CODES AND STANDARDS:

The glass flake lining shall conform to the latest version of
Indian/British/American/International Standards. Nothing in this specification shall
construe to relieve the contractor of the required statutory responsibility. The Glass Flake
Lining material shall be designed for the corrosion protection of the Slurry tank. The lining
shall be glass flake filled vinyl ester based coating system. Only Proven material has to be
offered by the bidder

REFERENCE STANDARDS:

ASTM D 4285 Standard Test Method for Indicating Oil or Water in

Compressed Air

ASTM D 4541 Standard Test Method for Pull-Off Strength of Coating

Using Portable Adhesion Testers

ASTM E 337 Standard test Method for Relative Humidity by Wet and
Dry Bulb Psychrometer

ASTM D 4618 Standard Specification for Design and Fabrication of Flue

Gas Desulfurization System Components for Protective
Lining Application
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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-C
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

ASTM D 5162 Practice for Discontinuity (Holiday) Testing of Non-

Conductive Protective Coating on Metallic Substrates

NACE Standard RP0178-2003 Fabrication Details, Surface Finish Requirements, and

Proper Design Considerations for Tanks and Vessels to be
lined for Immersion Service

ISO 8501-1, 1988 Preparation of Steel Substrates Before Application of

Paints and Related Products - Visual Assessment of
Surface Cleanliness

SSPC”PA2 Measurement of Dry Paint Thickness with Magnetic

Gauges

3.0 SCOPE OF SUPPLY

a) Complete selection and procurement/manufacture of all materials required for lining,
storage, preparation of the surfaces for lining near site and installation of lining. All
equipments required for lining shall be arranged by the vendor. Testing and supply of glass
flake lining material for the duty condition specified in Table-1.

b) Erection and Commissioning of the glass flake lining as per the requirement. Delivery of
material to site, Storage of the material, surface preparation of the surfaces to be lined,
lining the surface to the satisfaction of the customer and testing the lined surface for
proper adhesion, complete coverage and intactness with the base material/surface shall
be under bidder's scope, cost for Erection and Commissioning shall be included in the offer.
The lining shall extend through all internal surfaces and over flange faces. The lining shall
cover all the baffles inside the tank.

c) To install the linings, full scaffolding access shall be provided to reach the internal walls and
the entire area. Scaffold shall be properly erected with full planking in all work areas.
Scaffolding shall not contact wall surfaces in work areas during lining application and
surface preparation

d) The execution of the surface preparation and lining shall be carefully planned in stages to
obtain optimum lining quality with freedom from contamination and overspray or damage
to lined surfaces from preparation in adjacent areas. Surface preparation will commence
from the top and proceed progressively to the wall base and floor.

e) Lining and preparation works shall be staggered or proceed progressively in order to meet
cleanliness requirements or over coating times indicated in this specification.

f) Air-Compressor, Airless Spray pumps, hopper, blasting hose, lining hose, spray tip, blasting
gun, spray gun and other equipment for blasting and spray application has to be arranged
by lining vendor. Power & water required will be as per NIT. In case of Diesel compressor,
vendor to arrange the diesel themselves. Compressed air and instrument air will not be
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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-C
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

provided. Any cold storage container, if required, shall be arranged by vendor. Any
scaffolding shall be made of Steel only. Scaffolding material shall be arranged by vendor.
All travel, TA/DA, Stay charges, site visit charges shall be in vendor’s scope.

g) Copies of Operation and Maintenance Manuals containing all details of reference drawings
and technical data shall be furnished by the Bidder as specified elsewhere in the
specification.

5.0 ATMOSPHERIC CONDITION REQUIREMENTS

This section deals with the atmospheric condition requirement to be checked while
undertaking the Glass Flake Lining at site.
1. Blasting or Coating shall not be applied if following conditions prevail.

ƒ When temperature of the surface to be coated is less than 3°C above the dew point,
or the relative humidity is higher than 85%.
ƒ When the base metal temperature is greater than 60°C.
ƒ When the atmospheric temperature is below 4°C.
ƒ When there is, in the opinion of lining Contractor, the likely hood of an unfavourable
change in the weather condition within 2 hours after coating.
ƒ When there is deposition of moisture in the form of rain or condensation.
ƒ Any other specific recommendations of lining manufacturer.

2. Humidity shall be calculated by bidder using whirling hygrometer whose thermometers

are calibrated.

3. Surface temperature shall be measured using suitable temperature gauge and calibration
certificate of the same shall be provided by bidder.

4. Record will be maintained throughout the execution period. Readings shall be taken once
in every 4 hours up to the time work is in progress. The frequency of reading should be
increased during adverse weather conditions.

5. While working in unfavourable weather conditions (like monsoons or winters or if

provided for in the contract or in large confined spaces where blasting and priming of the
entire surface cannot be completed in one day’s operation, use of dehumidifier shall be
resorted to. The dehumidification equipment will have to be maintained in such a way
that the humidity is around 65% -75% inside the sump at all times during the work. No
flash rusting of the blast surface should take place till the time it receives a primer coat.

6. Where dehumidification equipment is to be used the humidity readings are to be taken

inside and outside the equipments to be coated. Dehumidification machine shall be
arranged by vendor.

7. Dehumidification equipment may not be necessary for contained space working if work
is done at near ideal atmospheric conditions as described above.

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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-C
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

8. In cases where dehumidification is not possible, alternate methods of warming up the

work front like use of halogen lights, room heaters are to be adopted.

9. Humidity is to be taken at the location where the blasting coating operations taking
place.

5.1 APPLICATION & MEDIUM:

Glass flake lining is done in order to protect the slurry tanks & sumps which contain
limestone/gypsum slurry. Coated surfaces are exposed to slurry whose conditions are given in
Anexure-8.

6.0 PRELIMINARY CHECK REQUIREMENTS

This section deals with the preliminary check requirements to be done while doing the lining
work.

6.1 CHLORIDE CONTAMINATION TEST:

The 2% ferricyanide paper method will generally be used to determine the chloride
contamination as described below:
1. Apply de-mineralized water on approximate 12 cm² area of substrate and wait for 3 to
4 minutes.
2. Remove excess moisture by patting the substrate with clean lint free cloth.
3. Press a ferricyanide paper of approximate 12 cm² area against the substrate for
approximately 5 seconds and remove the paper.
4. Total absence of blue spots on paper indicates the substrate is free from soluble salts
5. Light speckling paper indicates the substrate has still contamination but it is as the
acceptance level. The component should be released for further process.
6. Large blue spots on the paper indicate the substrate is heavily contaminated.
7. In this case the following procedure to be done before coating.
i. Pressures wash the substrate with copious amount of town water.
ii. Dry the substrate completely.
iii. Re-blasts the surface.
iv. Follow the salt contamination checking procedure again till you get the desired
results.
8. The Ferricyanide papers should be stored by vendor in air tight container before and
after use and the shelf life of Ferricyanide paper shall be one month.

6.2 ABRASIVE DRYNESS CHECK:

The abrasive to be used will be checked for dryness by taking a small quantity of abrasive on a filter
/tissue paper and checking of traces of moisture absorbed in the filter/tissue paper. Frequency of
test shall be once in day prior to blasting operation.

6.3 COMPRESSED AIR DRYNESS CHECK:

Compressed air to be used for blasting shall be free from oil & moisture and shall be tested adopting
“Blotter Test” by vendor. A piece of blasting Paper will be held in front of blast hose nozzle to check
for traces of oil/moisture captured by the blotting Paper. Frequency of test shall be once in day prior
to blasting operation.
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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-C
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

7.0 SURFACE PREPARATION

This section deals with the methods of surface preparation before coating application
7.1 MASKING:
1. Bidder to ensure that areas not being coated are fully and adequately masked.
2. Bidder to ensure that stud holes, dowel/oil ways etc. are suitably masked or plugged to prevent
ingress of blasting abrasives.

7.2 SURFACE PREPARATION METHODS:

The method of surface preparation dry abrasive manual blasting shall be done as follows:
1. Surface to be coated shall be abrasive blasted. Before this operation, removal of existing coating
to be carried out by chipping, grinding or by other suitable means. The walls of the tanks are
painted with min 60μ DFT of Red Oxide Phosphate(rust proof primer), which is to be removed by
vendor during blasting. Clean & dry Copper Slag Abrasive shall be used for ferrous base substrate.

2. Bidder is requested to go through all sections of the Typical GAD drawing of Slurry tank. Vendor
my raise their observations during pre-bid query. Any other new requirements brought forward
during technical evaluation stage shall not be considered by BHEL.

3. The minimum recommended compressed air required for Blasting shall be 7.0 m3/min at 6 kg/cm²
pressure. NACE No.1/SSPC-SP-5 equivalent to SA 2½ of Swedish Standard blast profile (75 to 100
Microns) to be followed for cleaning the surface.

4. The blasted surface shall be cleaned with dry compressed air/vacuum cleaner or with clean brush
so that there is no presence of Dust & other foreign material. The surface will be then checked for
chloride contamination (Refer Clause.5.1 for Chloride contamination check procedure). If
contamination is found then the surface to be washed and reblasted till contamination gets
removed. Vendor to ensure that the blasted surface free from chloride contamination
5. When cleanliness and blast profile are acceptable, the masking tape adjacent to the area to be
coated shall be peeled back to prevent overlap and subsequent edge contamination.

6. If the blasted surface has not been primed within specified time or if there is any previous visible
sign of blast condition change then the surface shall be checked for metallic salt contamination
and shall be reblasted. Where large areas are required to be blasted in a day, blasting shall be
carried out from morning to evening ensuring weather condition. This shall be followed by a light
sweep blast of the entire area, before priming. The blast cleaned surface shall be blown off with
dry oil free compressed air or vacuum cleaned. A cell tape shall be thoroughly pasted to the
cleaned surfaces. The tape shall be removed after a minute to check presence of dust if any.
Comparator shall be used by vendor for checking the blast profile.

8.0 COATING APPLICATION

This section deals with the methods & requirements of coating application.

8.1 MIXING:
1. All coating material tins shall be individually stirred thoroughly to obtain a homogenous consistency.

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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-C
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

2. While doing spray application, the tins which come in pre measured kits will be fully mixed
individually using a pneumatic stirrer. While doing hand application only small batches of 1 Kg.
capacity shall be taken. Here the mixing will be done by using a metal spatula.
3. The mixing ratios as specified in the respective data sheet will be strictly adhered to. The base will
be weighed out in kgs using mechanical weighing machines calibrated at site using any standard
factory packed commercial product available freely in the market. The catalyst will be measured out
in ML using marked syringes or measuring cylinders.

8.2 APPLICATION PROCESS:

1. The preparation and application of coating is done as per relevant product data sheet. Reference
will be made to product datasheet or where appropriate, contract specifications for carrying out
coating.
2. Coating in confined spaces should be done when the ambient temperature is low to avoid excess
build up of styrene fumes.
3. The entire thickness will be built in multiple coating.
4. Each coat will consist of minimum two passes of wet on wet in perpendicular directions.
5. The Dry film thickness will built of each coat will be checked and recorded.
6. All the other people working with the paint will be provided with eye splash goggles and masks.
7. Glass flake lining material shall be chosen considering the slurry conditions given in Annexure-III
8. Minimum and maximum intercoat intervals are as follows.
a. For primer coat -At 20ºC minimum 2 hours, maximum 14 hours.
b. For build-up coats-minimum tack free of previous coat, maximum 3 days.
9. Primer coat shall be of 75-100 μm thickness
10. Built up Coat shall be of 3000-3100 μm in multiple coats.
11. Total System DFT: 3000 microns approx
12. All weld joints phase transition joints will receive a stripe coat by brush in the same sequence of
coating on the shell.

8.3 CURING & FINISH:

1. Curing:
The completed linings shall be allowed to cure for a minimum of 48 hrs at 30°C prior to being
placed in service. However, curing time shall be as per the datasheet provided by vendor for a
proven material.

2. Finish:
It is to be noted that the coating will follow the profile of substrate. Any unevenness or other
defects in the substrate may be reflected in the finish coating also. The finished coating shall have
a matt/semi-glossy finish. A few local paint sag marks will not affect performance of coating and
cannot be completely avoided. Hence this is permitted.

9.0 INSPECTION AND TESTING OF GLASS FLAKE LINING

After the completion of lining, the following tests shall be conducted by the vendor to assess the
quality of glass flake lined surfaces.

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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-C
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

1. Lining shall be visually inspected to ensure that it shall be free from poor weed out fibers,
entrapped air and exposed fires. The Glass flake lining shall also be subjected to testing at site as
per relevant standards.
2. Testing of coatings is normally carried out as soon as they are sufficiently cured to give true
thickness & to withstand damage by the test equipment. If defects are found, repair will be carried
out as per clause 10.0
3. Spark test shall be carried out at appropriate areas in the presence of Purchaser. Vendor should
conduct holiday test as per relevant standards. If the performance is found not to meet the
requirements as specified, the Glass flake lining shall be rectified or replaced by the Vendor
without any additional cost to the Purchaser. The repair shall be carried out as per clause 10.0
4. Proper documentation with details of tests conducted by the vendor for evaluation of glass flake
lining shall be submitted to the purchaser.

10.0 REPAIRING PROCEDURE FOR GLASS FLAKE COATING

1. If the exposed or damaged surface less than 10cm² then such repair can be carried out without
grit blasting. Any area in excess of this amount should be grit blasted using a vacuum blaster where
possible.
2. In case of damage area less than 10cm² then it can be repaired as following.
a. De-contaminate surrounding area by using a suitable solvent such as methylated spirit,
acetone, xylene etc. After washing clean and allow solvent to evaporate.
b. Roughen up exposed metal & clean using rotary wire brush or a coarse emery paper with at
least 60 grade grit. Brush away residues then further roughen surface of the existing coating
up to 100 mm away from the damaged area. Brush away residues & ensure the whole area
is clean.
c. Apply a thin coat of material to the surface of the exposed metal only taking care not to
cover more than a few millimetre of the existing coating. Allow this freshly applied material
to become tack-free.
d. Brush styrene monomer over the whole surface to be repaired (i.e. the whole area
roughened by emery) & allow to evaporate from the surface.
e. Apply at least 2 main coats material over the treated area taking care not to brush on to any
roughened or contaminated areas. The Glass flake should be allowed to harden sufficiently
to bear the weight of next coat before application of further coats. However, it does not
need to be tack-free between coats.

11.0 PERFORMANCE GUARANTEE

The lining shall be guaranteed for uninterrupted minimum life of 25,000 hrs. Performance
parameters to be guaranteed by the vendor and tolerances permitted shall be as indicated in the
data sheet. Glass Flake lining or any portion thereof is liable for rejection, if it fails to give any of
the guaranteed performance parameters. During Guarantee period any defects noticed due to
faulty material and workmanship, shall be rectified by vendor free of cost.

12.0 PACKING
The part items of the Glass flake lining should be identified by Tag numbers and should be packed
as to minimize the possibility of damage during storage or transit. The packing should be suitable for
tropical conditions. BHEL site will arrange for the space for storage. Vendor shall make arrangements
for storing the Glass flake lining materials in AC containers at site. The list of items identified as
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 SPECIFICATION NO. PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR
SECTION –I, SUB SECTION –C1-C
MISCELLANEOUS FGD TANKS
REVISION 00
2 X 250 MW BHILAI FGD
Date: April, 2020

despatchable units shall be furnished along with unit weight and the quantity for preparation of
packing slip at BHEL end for dispatch to site and for easy identification, storage and erection at site.

Notes:
1. Lining material chosen shall withstand a maximum service temperature of 85 deg C.
2. Procedure for lining application duly certified by lining manufacturer shall be submitted for
approval.

13.0 DOCUMENTATION
DATA TO BE FURNISHED BY THE VENDOR AFTER RECEIPT OF PURCHASE ORDER
1. List of Drawing and documents to be submitted for review, approval and information with
submission dates.
2. Quality Assurance Plan to be submitted for approval.
3. Detailed dimensional General Arrangement drawing of the lining surfaces. This drawing shall
indicate all the design data and information about the material, scope of work and weight of
the material supply, Packing procedure etc.
4. Installation, operation and maintenance manual.
5. Surface preparation and Lining procedures.

Page 60 of 338
TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-C2
REV. 00
TECHNICAL SPECIFICATION FOR
Date: April, 2020
MISC. FGD TANKS

SECTION-I,
SUB-SECTION-C2
CUSTOMER SPECIFICATION

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 TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-C2
REV. 00
TECHNICAL SPECIFICATION FOR
Date: April, 2020
MISC. FGD TANKS

SECTION-I,
Sub Section-C2 - A

CUSTOMER SPECIFICATION: TECHNICAL REQUIREMENT

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 TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-C2B
TECHNICAL SPECIFICATION FOR REV. 00
MISC. FGD TANKS
Date: April, 2020

SECTION-I,
SUB-SECTION-C2B
CUSTOMER SPECIFICATION: PROJECT SPECIFIC
GENERAL REQUIREMENTS

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 TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-C2B
REV. 00
TECHNICAL SPECIFICATION FOR
Date: April, 2020
MISC. FGD TANKS

SECTION-I,
SUB-SECTION-C2B
CUSTOMER SPECIFICATION: GENERAL TECHNICAL
REQUIREMENTS

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1.00.00 INTRODUCTION

This part covers technical requirements which will form an integral part of the
Contract. The following provisions shall supplement all the detailed technical
specifications and requirements brought out in Section-VI, the Technical
Specification and the Technical Data Sheets.

2.00.00 BRAND NAME

Whenever a material or article is specified or described by the name of a particular

brand, manufacturer or vendor, the specific item mentioned shall be understood to
be indicative of the function and quality desired, and not restrictive; other
manufacturer's products may be considered provided sufficient information is
furnished to enable the Employer to determine that the products proposed are
equivalent to those named.

3.00.00 BASE OFFER & ALTERNATE PROPOSALS

The Bidder's proposal shall be based upon the use of equipment and material
complying fully with the requirements specified herein. It is recognised that the
Contractor may have standardized on the use of certain components, materials,
processes or procedures different than those specified herein. Alternate proposals
offering similar equipment based on the manufacturer's standard practice will also be
considered, provided the base offer is in line with technical specifications and such
proposals meet the specified design standards and performance requirement and
are acceptable to the Employer. Sufficient amount of information for justifying such
proposals shall be furnished to Employer alongwith the bid to enable the Employer
to determine the acceptability of these proposals.

4.00.00 COMPLETENESS OF FACILITIES

4.01.00 Bidders may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant shall be engineered and designed in
accordance with the specification requirement. All engineering and associated
services are required to ensure a completely engineered plant shall be provided.

4.02.00 All equipments furnished by the Contractor shall be complete in every respect, with
all mountings, fittings, fixtures and standard accessories normally provided with such
equipment and/or those needed for erection, completion and safe operation of the
equipment and for the safety of the operating personnel, as required by applicable
codes, though they may not have been specifically detailed in the respective
specifications, unless included in the list of exclusions.

All same standard components/ parts of same equipment provided, shall be

interchangeable with one another.

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4.03.00 For the C&I systems, the Contractor shall be required to provide regular information
about future upgrades and migration paths to the Employer.

5.00.00 RULES, REGULATIONS, CODES & STANDARDS

5.01.00 In addition to the codes and standards specifically mentioned in the relevant
technical specifications for the equipment / plant / system, all equipment parts,
systems and works covered under this specification shall comply with all currently
applicable statutory regulations and safety codes of the Republic of India, NTPC
rules/codes of practices as well as of the locality where they will be installed,
including the following:

a) Indian Electricity Act

b) Indian Electricity Rules

c) Indian Explosives Act

d) Indian Factories Act and State Factories Act

e) Indian Boiler Regulations (IBR)

f) Regulations of the Central Pollution Control Board, India

g) Regulations of the Ministry of Environment & Forest (MoEF), Government of

India

h) Pollution Control Regulations of Department of Environment, Government of

India

i) State Pollution Control Board.

(j.) Rules for Electrical installation by Tariff Advisory Committee (TAC).

(k.) Building and other construction workers (Regulation of Employment and

Conditions of services) Act, 1996

(l.) Building and other construction workers (Regulation of Employment and

Conditions of services) Central Rules, 1998

(m.) Explosive Rules, 1983

(n.) Petroleum Act, 1984

(o.) Petroleum Rules, 1976,

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(p.) Gas Cylinder Rules, 1981

(q.) Static and Mobile Pressure Vessels (Unified) Rules, 1981

(r.) Workmen's Compensation Act, 1923

(s.) Workmen's Compensation Rules, 1924

(t.) NTPC Safety Rules for Construction and Erection

(u.) NTPC Safety Policy

(v.) Any other statutory codes / standards / regulations, as may be applicable.

5.02.00 Unless covered otherwise in the specifications, the latest editions (as applicable as
on date of bid opening), of the codes and standards given below shall also apply:

a) Bureau of Indian standards (BIS)

b) Japanese Industrial Standards (JIS)

c) American National Standards Institute (ANSI)

d) American Society of Testing and Materials (ASTM)

e) American Society of Mechanical Engineers (ASME)

f) American Petroleum Institute (API)

g) Standards of the Hydraulic Institute, U.S.A.

h) International Organisation for Standardisation (ISO)

i) Tubular Exchanger Manufacturer's Association (TEMA)

j) American Welding Society (AWS)

k) National Electrical Manufacturers Association (NEMA)

l) National Fire Protection Association (NFPA)

m) International Electro-Technical Commission (IEC)/European Norm (EN)

n) Expansion Joint Manufacturers Association (EJMA)

o) Heat Exchange Institute (HEI)

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p) IEEE standard

q) JEC standard

5.03.00 Other International/ National standards such as DIN, JIS, VDI, EN, BS, GOST etc.
shall also be accepted for only material codes and manufacturing standards, subject
to the Employer's approval, for which the Bidder shall furnish, adequate information
to justify that these standards are equivalent or superior to the standards mentioned
above. In all such cases the Bidder shall furnish specifically the variations and
deviations from the standards mentioned elsewhere in the specification together with
the complete word to word translation of the standard that is normally not published
in English.

5.04.00 Not used.

5.05.00 In the event of any conflict between the codes and standards referred to in the
above clauses and the requirement of this specification, the requirement of
Technical Specification shall govern.

5.06.00 Two (2) English language copies of all national and international codes and/or
standards used in the design of the plant, equipment, civil, structural and
architectural works shall be provided by the Contractor to the Employer within two
calendar months from the date of the Notification of Award.

5.07.00 In case of any change in codes, standards & regulations between the date of bid
opening and the date when vendors proceed with fabrication, the Employer shall
have the option to incorporate the changed requirements or to retain the original
standard. It shall be the responsibility of the Contractor to bring to the notice of the
Employer such changes and advise Employer of the resulting effect.

5.08.00 A detailed list of standards apart from those mentioned in the respective detailed
specifications in other parts of Section-VI to which all equipment/systems/civil works
should conform as indicated in this Part C and elsewhere in the specification.

6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE

6.01.00 The functional guarantees of the equipment under the scope of the Contract is given
in Section-VI Part - A of Technical Specifications. These guarantees shall
supplement the general functional guarantee provisions covered under Defect
liabilities Section-IV, General Conditions of Contract.

6.02.00 Liquidated damages for shortfall in meeting functional guarantee(s) during the
performance and guarantee tests shall be assessed and recovered from the
Contractor as specified elsewhere in this specification.

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7.00.00 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY CONSIDERATIONS

7.01.00 DESIGN OF FACILITIES

All the design procedures, systems and components proposed shall have already
been adequately developed and shall have demonstrated good reliability under
similar conditions elsewhere.

The Contractor shall be responsible for the selection and design of appropriate
equipments to provide the best co-ordinated performance of the entire system. The
basic requirements are detailed out in various clauses of the Technical
Specifications. The design of various components, assemblies and subassemblies
shall be done so that it facilitates easy field assembly and dismantling. All the
rotating components shall be so selected that the natural frequency of the complete
unit is not critical or close to the operating range of the unit.

7.02.00 MAINTENANCE AND AVILABILITY CONSIDERATIONS

Equipment/works offered shall be designed for high availability, low maintenance

and ease of maintenance. The Bidder shall specifically state the design features
incorporated to achieve high degree of reliability/ availability and ease of
maintenance. The Bidder shall also furnish details of availability records in the
reference plants stated in his experience list.

Bidder shall state in his offer the various maintenance intervals, spare parts and
man-hour requirement during such operation. The intervals for each type of
maintenance namely inspection of the furnace, inspection of the entire hot gas path
and the minor and major overhauls shall be specified in terms of fired hours , clearly
defining the spare parts and man-hour requirement for each stage.

Lifting devices i.e. hoists and chain pulley jacks ,etc. shall be provided by the
contractor for handling of any equipment or any of its part having weight in excess of
500 Kgs during erection and maintenance activities.

Lifting devices like lifting tackles, slings, etc. to be connected to hook of the hoist /
crane shall be provided by the contractor for lifting the equipment and accessories
covered under the specification.

8.00.00 DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY

CONTRACTOR

8.01.00 Bidders may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant and equipment shall be fully
integrated, engineered and designed to perform in accordance with the technical
specification. All engineering and technical services required to ensure a completely

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engineered plant shall be provided in respect of mechanical, electrical, control &

instrumentation, civil & structural works as per the scope.
Each main and auxiliary equipment/item of the plant including instruments shall be
assigned a unique tag number. The assignment of tag numbers shall be in
accordance with KKS system. In all drawings/documents/data sheet etc. KKS tag
number of the equipment/item/instrument etc. shall be indicated.
The Contractor shall furnish engineering data /drawings in accordance with the
schedule of information as specified in Technical Data Sheets and Technical
Specification.

A comprehensive engg and quality coordination procedure shall be finalized with

the successful bidder covering salient features as described in this section of
specifications.

8.02.00 The number of copies/prints/CD-ROMs/manuals to be furnished for various types of

document is given in Annexure-VI to this Part-C, Section-VI of the Technical
Specification.

8.03.00 The documentation that shall be provided by the Contractor is indicated in the
various sections of specification. This documentation shall include but not be limited
to the following:

8.03.01 A) BASIC ENGINEERING DOCUMENTATION

Prior to commencement of the detailed engineering work, the Contractor

shall furnish a Plant Definition Manual within 12 weeks from the date of the
Notification of Award. This manual shall contain the following as a minimum:

i) System description of all the mechanical, electrical, control &

instrumentation & civil systems.

ii) Technology scan for each system / sub-system & equipment.

iii) Selection of appropriate technology / schemes for various systems/

subsystems including techno-economic studies between various
options.

iv) Optimisation studies including thermal cycle optimisation.

v) Sizing criteria of all the systems, sub-systems/ equipments/

structures/ equipment foundations alongwith all calculations justifying
and identifying the sizing and the design margins.

vi) Schemes and Process & Instrumentation diagrams for the various
systems/ sub-system with functional write-ups.

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vii) Operation Philosophy and the control philosophy of the

equipments/system covered under the scope.

ix) General Layout plan of the FGD System incorporating all facilities in
Bidder's as well as those in the Employer's scope. This drawing shall
also be furnished in the form of CD-ROMs to the Employer for
engineering of areas not included in bidder's scope.

x) Basic layouts and cross sections of the main plant building (various
floor elevations), boiler, fuel oil area and other areas included in the
scope of the bidder.

xi) Documentation in respect of Quality Assurance System as listed out

elsewhere in this specification.

The successful bidder shall furnish within three (3) weeks from the
date of Notification of Award, a list of contents of the Plant Definition
Manual (PDMs) including techno-economic studies, which shall then
be mutually discussed & finalised with the Employer.

B) DETAILED ENGINEERING DOCUMENTS

i) General layout plan of the FGD System.

ii) Layouts, general arrangements, elevations and cross-sections

drawings for all the equipment and facilities of the plant.

iii) Flow diagram, process and instrumentation diagrams along with write
up and system description.

iv) Performance curves for Absorber

v) Piping isometric, composite layout and fabrication drawings.

vi) Piping engineering diagrams, pipe and fittings schedules, valve

schedules, hanger and support schedules, insulation schedules.

vii) Technical data sheets for all bought out and manufactured items.
Contractor shall use the Employer’s specifications as a base for
placement of orders on their sub vendors.

viii) Detailed design calculations for components, system, piping etc.,

wherever applicable including sizing calculations for all auxiliaries like
mills, fans etc. as per criteria specified elsewhere in specification.

ix) Absorber sizing calculations. Absorber performance data.

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x) Mass Balance Diagram

xi) Characteristic Curves/ Performance Correction Curves.

xii) Comprehensive list of all terminal points which interface with

Employer's facilities, giving details of location, terminal pressure,
temperature, fluid handled & end connection details, forces, moments
etc.

xiii) Power supply single line diagram, block logics, control schematics,
electrical schematics, etc.

xiv) Protection system diagrams and relay settings.

xv) Cables schedules and interconnection diagrams.

xvii) Cable routing plan.

xviii) Instrument schedule, measuring point list, I/O list, Interconnection &
wiring diagram, functional write-ups, and installation drawings for field
mounted instruments, logic diagrams, control schematics, wiring and
tubing diagrams of panels and enclosures etc. Drawings for open
loop and close loop controls (both hardware and software). Motor list
and valve schedule including type of actuator etc.

xix) Alarm and annunciation/ Sequence of Event (SOE) list and alarms &
trip set points.

xx) Sequence and protection interlock schemes.

xxi) Type test reports, insulation co-ordination study report

xxii) Control system configuration diagramsand card circuit diagrams and

maintenance details.

xxiii) Detailed Control system manuals.

xxiv) Detailed flow chart for digital control system.

xv) Mimic diagram layout, Assignment for other application

engg.drawings and documents.

xxvi) Civil and Structural works drawings and documents for all structures,
facilities, architectural works, foundations underground and
overground works and super-structural works as included in the

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scope of the bidder civil calculation sheets including structural

analysis and design alongwith output results.

xxvii) Underground facilities, levelling, sanitary, land scaping drawings.

xxviii) Geotechnical investigation and site survey reports (if and as

applicable).

xxix) Model study reports wherever applicable.

xxx) Functional & guarantee test procedures and test reports.

xxxi) Documentation in respect of Quality Assurance System, and

Documentation in respect of Commissioning, as listed out elsewhere
in this specification.

xxxii) Maintenance schedule for Absorber & auxiliaries clearly indicating

interval, duration if shutdown required, manhours required and tools &
tackles required for maintenance.

The Contractor's while submitting the above documents/ drawings for approval/
reference as the case may be, shall mark on each copy of submission the reference
letter alongwith the date vide which the submissions are made.

8.03.02 INSTRUCTION MANUALS

The Contractor shall make first submission of instruction manual for all the
equipments covered under the Contract as per agreed engineering information
schedule. The Instruction manuals shall contain full details required for erection,
commissioning, operation and maintenance of each equipment. The manual shall be
specifically compiled for this project. After finalisation and approval of the Employer
the Instruction Manuals shall be submitted as indicated in Annexure-IV. The
Contract shall not be considered to be completed for purposes of taking over until
the final Instructions manuals have been supplied to the Employer. The Instruction
Manuals shall comprise of the following.

A) ERECTION MANUALS

The erection manuals shall be submitted atleast three (3) months prior to the
commencement of erection activities of particular equipment/system. The
erection manual should contain the following as a minimum.

a) Erection strategy.

b) Sequence of erection.

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c) Erection instructions.

d) Critical checks and permissible deviation/tolerances.

e) List of tool, tackles, heavy equipments like cranes, dozers, etc.

f) Bill of Materials

g) Procedure for erection and General Safety procedures to followed

during erection/installation.

h) Procedure for initial checking after erection.

i) Procedure for testing and acceptance norms.

j) Procedure / Check list for pre-commissioning activities.

k) Procedure / Check list for commissioning of the system.

l) Safety precautions to be followed in electrical supply distribution

during erection.

B) OPERATION & MAINTENANCE MANUALS

a) The manual shall be a two rim PVC bound stiff sided binder able to
withstand constant usage or where a thicker type is required it shall
have locking steel pins, the size of the manual shall not be larger than
international size A3. The cover shall be printed with the Project
Name, Services covered and Volume / Book number Each section of
the manual shall be divided by a stiff divider of the same size as the
holder. The dividers shall clearly state the section number and title.
All written instructions within the manual not provided by the
manufacturers shall be typewritten with a margin on the left hand
side.

b) The arrangement and contents of O & M manuals shall be as follows:

1) Chapter 1 - Plant Description: To contain the following

sections specific to the
equipment/system
supplied

(a) Description of operating principle of equipment / system with

schematic drawing / layouts.

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(b) Functional description of associated accessories / controls. Control

interlock protection write up.

(c) Integrated operation of the equipment alongwith the intended system.

(This is to be given by the supplier of the Main equipment by taking
into account the operating instruction given by the associated
suppliers).

(d) Exploded view of the main equipment, associated accessories and

auxiliaries with description. Schematic drawing of the equipment
alongwith its accessories and auxiliaries.

(e) Design data against which the plant performance will be compared.

(f) Master list of equipments, Technical specification of the equipment/

system and approved data sheets.

(g) Identification system adopted for the various components, (it will be of
a simple process linked tagging system).

(h) Master list of drawings (as built drawing - Drawings to be enclosed in

a separate volume).

2) Chapter 2.0 - Plant Operation: To contain the following sections specific to the
equipment supplied

(a) Protection logics provided for the equipment alongwith brief

philosophy behind the logic, Drawings etc.

(b) Limiting values of all protection settings.

(c) Various settings of annunciation/interlocks provided.

(d) Startup and shut down procedure for equipment alongwith the
associated systems in step mode.

(e) Do's and Don'ts related to operation of the equipment.

(f) Safety precautions to be take during normal operation. Emergency

instruction on total power failure condition/lubrication failure/any other
conditions.

(g) Parameters to be monitored with normal value and limiting values.

(h) Equipment isolating procedures.

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(i) Trouble shooting with causes and remedial measures.

(j) Routine testing procedure to ascertain healthiness of the safety

devices alongwith schedule of testing.

(k) Routine Operational Checks, Recommended Logs and Records

(l) Change over schedule if more than one auxiliary for the same
purpose is given.

(m) Preservation procedure on long shut down.

(n) System/plant commissioning procedure.

3) Chapter 3.0 - Plant Maintenance- To contain the following sections specific to

the equipment supplied.

(a) Exploded view of each of the equipments. Drawings alongwith bill of

materials including name, code no. & population.

(b) Exploded view of the spare parts and critical components with
dimensional drawings (In case of Electronic cards, the circuit diagram
to be given) and spare parts catalogue for each equipment.

(c) List of Special T/ P required for Overhauling /Trouble shooting

including special testing equipment required for calibration etc.

(d) Stepwise dismantling and assembly procedure clearly specifying the

tools to be used, checks to be made, records to be maintained etc.
Clearance to be maintained etc.

(e) Preventive Maintenance schedules linked with running

hours/calendar period alongwith checks to be carried out.

(f) Overhauling schedules linked with running hours/calendar period

alongwith checks to be done.

(g) Long term maintenance schedules

(h) Consumables list alongwith the estimated quantity required during

normal running and during maintenance like Preventive Maintenance
and Overhauling.

(i) List of lubricants with their Indian equivalent, Lubrication Schedule

including charts showing lubrication checking, testing and
replacement procedure to be carried daily, weekly, monthly & at

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longer intervals to ensure trouble free operation and quantity required

for complete replacement.

(j) Tolerance for fitment of various components.

(k) Details of sub vendors with their part no. in case of bought out items.

(l) List of spare parts with their Part No, total population, life expediency
& their interchangeability with already supplied spares to NTPC.

(m) List of mandatory and recommended spare list along with

manufacturing drawings, material specification & quality plan for fast
moving consumable spares.

(n) Lead time required for ordering of spares from the equipment
supplier, instructions for storage and preservation of spares.

(o) General information on the equipment such as modification carried

out in the equipment from its inception, equipment population in the
country / foreign country and list of utilities where similar equipments
have been supplied.

8.03.03 After finalization and approval of the Employer, the O & M Manuals shall be
submitted as indicated in Annexure-VI. The Contract shall not be considered to be
completed for purposes of taking over until the final Instructions manuals (both
erection and O & M manuals have been supplied to the Employer.

If after the commissioning and initial operation of the plant, the instruction
manuals (Erection and /or O &M manuals) require modifications/additions/
changes, the same shall be incorporated and the updated final instruction
manuals shall be submitted by the Contractor to the Employer for records
and number of copies shall be as mentioned in Annexure-VI.

8.03.03 PLANT HANDBOOK AND PROJECT COMPLETION REPORT

8.03.03.01 PLANT HANDBOOK

The Contractor shall submit to the Employer a preliminary plant hand book
preferably in A-4 size sheets which shall contain the design and performance data of
various plants, equipments and systems covering the complete project including

i) Design and performance data.

ii) Process & Instrumentation diagrams.

iii) Single line diagrams.

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iv) Sequence & Protection Interlock Schemes.

v) Alarm and trip values.

vi) Performance Curves.

vii) General layout plan and layout of main plant building and auxiliary buildings

viii) Important Do's & Don't's

The plant handbook shall be submitted within twelve (12) months from the date of
award of contract. After the incorporation of Employer's comments, the final plant
handbook complete in all respects shall be submitted three (3) months before start-
up and commissioning activities.

8.03.03.02 PROJECT COMPLETION REPORT

The Contractor shall submit a Project Completion Report at the time of handing over
the plant.

8.03.04 DRAWINGS

a) i) All the FGD plant layouts shall be made in computerised 3D

modelling system. The Employer reserves the right to review the 3D
model at different stages during the progress of engineering. The
layout drawings submitted for Employer's review shall be fully
dimensioned and extracted from 3D model after interference check.

ii) All documents submitted by the Contractor for Employer's review

shall be in electronic form (soft copies) along with the desired number
of hard copies as per Annexure-VI of Part-C. The soft copies shall be
uploaded by the vendors in C-folders, a Web-based system of NTPC
ERP, for which a username and password will be allotted to the new
vendor by NTPC.

Similarly, the vendor can download the drawings/documents,

approved/ commented by NTPC, through above site.

The soft copies of identified drawings/documents shall be in pdf

format, whereas the attachments/reply to the submitted document(s)
can be in .doc, .xls, .pdf, .dwg or .std formats.

iii) Final copies of the approved drawings along with requisite number of
hard copies shall be submitted as per Annexure-VI of Part-C.
iv) Contractor shall prepare the model of all the facilities located in FLUE
GAS DESULPHURISATION (FGD) SYSTEM PACKAGE (including all

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facilities), and any other facility in an integrated & intelligent 3D

software solution using rule-based, data centric 3D Design software
with equipment drawings, data sheets, intelligent P&ID correlated with
intelligent 3D Model, BOQ, schematics and logic diagrams etc.
attached to the respective equipment / systems in the aforesaid 3D
model. Contractor shall make a presentation on 3D model every 3
months from LOA to enable NTPC to review the progress of
engineering. After the completion of engineering the corresponding
complete 3D review model shall be handed over to the employer for
its reference.

Contractor shall provide 3D model (which shall include visual

interference check, walk-through animation, video simulation for
major equipment placement and removal, visual effect, photo realism
etc), which is extracted from intelligent 3D model, for employer’s
review as & when desired by employer. However, all piping layouts,
equipment layouts, floor plans, ducting layout (Air/flue gas, A/C,
Ventilation etc.), General Arrangement drawings of major buildings,
structural arrangement drawings and RCC layout drawings shall
necessarily be extracted from the aforesaid 3D model and submitted
for employer’s review along with the 3D review model to enable
NTPC to review and approve these drawings.

b) All documents/text information shall be in latest version of MS Office / MS

Excel / PDF FORMAT as applicable.
c) All drawings submitted by the Contractor including those submitted at the
time of bid shall be in sufficient detail indicating the type, size, arrangement,
weight of each component for packing and shipment, the external
connection, fixing arrangement required, the dimensions required for
installation and interconnections with other equipments and materials,
clearance and spaces required between various portions of equipment and
any other information specifically requested in the drawing schedules.

d) Each drawing submitted by the Contractor (including those of subvendors)

shall bear a title block at the right hand bottom corner with clear mention of
the name of the Employer, the system designation, the specifications title,
the specification number, the name of the Project, drawing number and
revisions. If standard catalogue pages are submitted the applicable items
shall be indicated therein. All titles, notings, markings and writings on the
drawing shall be in English. All the dimensions should be in metric units.

e) The drawings submitted by the Contractor (or their subvendors) shall bear
Employer's drawing number in addition to contractor's (their sub-vendor's)
own drawing number. Employer's drawing numbering system shall be made
available to the successful bidder so as to enable him to assign Employer's
drawing numbers to the drawings to be submitted by him during the course of
execution of the Contract.

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The Contractor shall also furnish a "Master Drawing List" which shall be a
comprehensive list of all drawings/ documents/ calculations envisaged to be
furnished by him during the detailed engineering to the Employer. Such list
should clearly indicate the purpose of submission of these drawings i.e.
"FOR APPROVAL" or "FOR INFORMATION ONLY".

Similarly, all the drawings/ documents submitted by the Contractor during

detailed engineering stage shall be marked "FOR APPROVAL" or "FOR
INFORMATION" prior to submission. Further, space shall be identified on
each drawing for Approval stamp and electronic signature.

f) The furnishing of detailed engineering data and drawings by the Contractor

shall be in accordance with the time schedule for the project. The review of
these documents/ data/ drawings by the Employer will cover only general
conformance of the data/ drawings/ documents to the specifications and
contract, interfaces with the equipments provided by others and external
connections & dimensions which might affect plant layout. The review by the
Employer should not be construed to be a thorough review of all dimensions,
quantities and details of the equipments, materials, any devices or items
indicated or the accuracy of the information submitted. The review and/ or
approval by the Employer/ Project Manager shall not relieve the Contractor of
any of his responsibilities and liabilities under this contract.

g) After the approval of the drawings, further work by the Contractor shall be in
strict accordance with these approved drawings and no deviation shall be
permitted without the written approval of the Employer.

h) All manufacturing, fabrication and execution of work in connection with the

equipment / system, prior to the approval of the drawings, shall be at the
Contractor's risk. The Contractor is expected not to make any changes in the
design of the equipment /system, once they are approved by the Employer.
However, if some changes are necessitated in the design of the
equipment/system at a later date, the Contractor may do so, but such
changes shall promptly be brought to the notice of the Employer indicating
the reasons for the change and get the revised drawing approved again in
strict conformance to the provisions of the Technical Specification.

i) Drawings shall include all installations and detailed piping layout drawings.
Layout drawings for all piping of 65 mm and larger diameter shall be
submitted for review/ approval of Employer piror to erection. Small diameter
pipes shall however be routed as per site conditions in consultation with site
authority/ representative of Employer based on requirements of such piping
indicated in approved/ finalised Flow Scheme/ Process & Instrumentation
Diagrams and/or the requirements cropping up for draining & venting of
larger diameter piping or otherwise after their erection as per actual physical
condition for the entire scope of work of this package.

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Assessing & anticipating the requirement and supply of all piping and
equipment shall be done by the contractor well in advance so as not to
hinder the progress of piping & equipment erection, subsequent system
charging and its effective draining & venting arrangement as per site
suitability.

j) As Built Drawings

After final acceptance of individual equipment / system by the Employer, the

Contractor will update all original drawings and documents for the equipment
/ system to “as built” conditions and submit no. of copies as per Annexure
VI.

k) Drawings must be checked by the Contractor in terms of its completeness,

data adequacy and relevance with respect to Engineering schedule prior to
submission to the Employer. In case drawings are found to be submitted
without proper checking by the Contractor, the same shall not be reviewed
and returned to the Contractor for re-submission. The contractor shall make
a visit to site to see the existing facilities and understand the layout
completely and collect all necessary data/ drawings at site which are needed
as an input to the engineering. The contractor shall do the complete
engineering including interfacing and integration of all his equipment,
systems & facilities within his scope of work as well as interface engineering
& integration of systems, facilities, equipment & works under Employer's
scope and submit all necessary drawings/ documents for the same.

l) The Contractor shall submit adequate prints of drawing / data / document for
Employer's review and approval. The Employer shall review the drawings
and return soft copy to the Contractor authorizing either to proceed with
manufacture or fabrication, or marked to show changes desired. When
changes are required, drawings shall be re-submitted promptly, with
revisions clearly marked, for final review. Any delays arising out of the failure
of the Contractor to submit/rectify and resubmit in time shall not be accepted
as a reason for delay in the contract schedule.

m) All engineering data submitted by the Contractor after final process including
review and approval by the Project Manager/ Employer shall form part of the
contract documents and the entire works covered under these specification
shall be performed in strict conformity with technical specifications unless
otherwise expressly requested by the Project Manager in writing.
n) The Contractor shall submit drawings in line with the suggestive MDL covered
in Part-B, Section-VI of Technical Specification and which shall be duly
integrated with approved PERT network.
8.04.00 ENGINEERING INFORMATION SUBMISSION SCHEDULE

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Prior to the award of Contract, a Detailed Engineering Information Submission

Scheduler/Master Drawing List duly integrated with approved PERT network shall be
tied up with the Employer. For this, the bidder shall furnish a detailed list of
engineering information alongwith the proposed submission schedule. This list would
be a comprehensive one including all engineering data / drawings / information for
all bought out items and manufactured items. The information shall be categorized
into the following parts.

i) Information that shall be submitted for the approval to the Employer before
proceeding further, and

ii) Information that would be submitted for Employer's information only.

The Master Drawing List (MDL) shall be updated periodically and submitted to the
employer, highlighting the changes made in MDL.

The schedule should allow adequate time for proper review and incorporation of
changes/ modifications, if any, to meet the contract without affecting the equipment
delivery schedule and overall project schedule. The early submission of drawings
and data is as important as the manufacture and delivery of equipment and
hardware and this shall be duly considered while determining the overall
performance and progress.

8.05.00 ENGINEERING PROGRESS AND EXCEPTION REPORT

8.05.01 The Contractor shall submit every month an Engineering progress and Exception
Report giving the status of each engineering information including

a) A list of drawings/engineering information which remains unapproved for

more than four (4) weeks after the date of first submission

b) Drawings which were not submitted as per agreed schedule.

8.05.02 The draft format for this report shall be furnished to the Employer within four (4)
weeks of the award of the contract, which shall then be discussed and finalised with
the Employer.

8.06.00 Engineering Co-ordination Procedure

8.06.01 The following principal coordinators will be identified by respective organizations at

time of award of contract:

NTPC Engineering Coordinator (NTPC EC):

Name :

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Designation :

Address :

a) Postal :

b) Telegraphic / e-Mail :

c) FAX : TELEPHONE :

Contractor’s/ Vendor’s Engineering Coordinator (VENDOR EC):

Name :

Designation :

Address :

a) Postal :

b) Telegraphic / e-Mail :

c) FAX : TELEPHONE :

8.06.02 All engineering correspondence shall be in the name of above coordinators on

behalf of the respective organizations.

8.06.03 Contractor’s/Vendor’s Drawing Submission and Approval Procedure:

a) All data/information furnished by Vendor in the form of drawings/

documents/catalogues or in any other form for NTPC’s information/ interface
and or review and approval are referred by the general term “drawings”.

b) The ‘Master drawings list’ indicating titles, Drawing Number, Date of

submission and approval etc. shall be finalised mutually between Contractor
and Employer before the award of contract. This list shall be updated if
required at suitable interval during detailed engineering.

c) All drawings (including those of subvendor’s) shall bear at the right hand
bottom corner the ‘title plate’ with all relevant information duly filled in. The
Contractor shall furnish this format to his subvendor along with his purchase
order for subvendor’s compliance.

d) Employer and contractor shall follow their own numbering systems for the
drawings. However, Employer shall intimate the contractor, NTPC drawing
number on receipt of the first submission of each drawing. Vendor,

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thereafter, shall indicate NTPC’s drawing number in subsequent Submission,

in the space provided for this purpose in title plate, in addition to his own
drawing number.

e) The contractor shall make a visit to site to see the existing facilities and
understand the layout completely and collect all necessary data / drawings at
site which are needed as an input to the engineering. The contractor shall do
the complete engineering including interfacing and integration of all his
equipment, systems & facilities within his scope of work as well as interface
engineering & integration of systems, facilities, equipment & works under
Employer’s scope and submit all necessary drawings/ documents for the
same.

f) Drawings must be checked by the Contractor in terms of its completeness,

data adequacy and relevance with respect to engineering schedule prior to
submission to the Employer. In case drawings are found to be submitted
without proper endorsement for checking by the Contractor, the same shall
not be reviewed and returned to the Contractor for re-submission.

g) The Contractor shall submit adequate prints of drawing / data / document for
Employer’s review and approval. The drawings submitted by the
Contractor/vendor shall be reviewed by NTPC and their comments shall be
forwarded within four (4) weeks of receipt of drawings. Upon review of each
drawing, depending on the correctness and completeness of the drawing, the
same will be categorized and approval accorded in one of the following
categories :

CATEGORY- I : Approved

CATEGORY- II Approved, subject to incorporation of comments/

modification as noted. Resubmit revised drawing
incorporating the comments.

CATEGORY –III Not approved. Resubmit revised drawings for approval

after incorporating comments/ modification as noted.

CATEGORY -IV For information and records.

h) Contractor shall resubmit the drawings approved under Category II, III & IVR
within three (3) weeks of receipt of comments on the drawings, incorporating
all comments. Every revision of the drawing shall bear a revision index
wherein such revisions shall be highlighted in the form of description or
marked up in the drawing identifying the same with relevant revision Number
enclosed in a triangle (eg. 1, 2, 3 etc). Contractor shall not make any
changes in the portions of the drawing other than those commented. If
changes are required to be made in the portions already approved, the

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Contractor shall resubmit the drawing identifying the changes for Employer’s
review and approval. Drawings resubmitted shall show clearly the
portions where the same are revised marking the relevant revision
numbers and Employer shall review only such revised portion of
documents.

i) In case, the Contractor/ Vendor does not agree with any specific comment,
he shall furnish the explanation for the same to NTPC for consideration. In all
such cases the Contractor shall necessarily enclose explanations along with
the revised drawing (taking care of balance comments) to avoid any delay
and/or duplication in review work.

j) It is responsibility of the Contractor/ Vendor to get all the drawings approved

in the Category I & IV (as the case may be) and complete engineering
activities within the agreed schedule. Any delay arising out of submission and
modification of drawings shall not alter the contract completion schedule.

k) If Contractor/ Vendor fails to resubmit the drawings as per the schedule,

construction work at site will not be held up and work will be carried out on
the basis of comments furnished on previous issues of the drawing.

l) These comments will be taken care by the contractor while submitting the
revised drawing.

The contractor shall use a single transmittal for drawings. Submission. This
shall include transmittal numbers and date, number of copies being sent,
names of the agencies to whom copies being sent, drawing number and
titles, remarks or special notes if any etc.

9.00.00 TECHNICAL CO-ORDINATION MEETING

9.01.00 The Contractor shall be called upon to organise and attend monthly Design/
Technical Co-ordination Meetings (TCMs) with the Employer/Employer's
representatives and other Contractors of the Employer during the period of
contract. The Contractor shall attend such meetings at his own cost at NEW DELHI
/ NOIDA or at mutually agreed venue as and when required and fully co-operate with
such persons and agencies involved during the discussions.

9.02.00 The Contractor should note that Time is the essence of the contract. In order to
expedite the early completion of engineering activities, the Contractor shall submit all
drawings as per the agreed Engineering Information Submission Schedule. The
drawings submitted by the Contractor will be reviewed by the Employer as far as
practicable within three (3) weeks from the date of receipt of the drawing .The
comments of the Employer shall then be discussed across the table during the
above Technical Co-ordination Meeting (s) wherein best efforts shall be made by
both sides to ensure the approval of the drawing.

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9.02.01 The Contractor shall ensure availability of the concerned experts / consultants/
personnel who are empowered to take necessary decisions during these meetings.
The Contractor shall be equipped with necessary tools and facilities so that the
drawings/documents can be resubmitted after incorporating necessary changes and
approved during the meeting itself.

9.02.02 Should any drawing remain unapproved for more than six (6) weeks after it's first
submission ,this shall be brought out in the monthly Engineering Progress and
Exception Report with reasons thereof.

9.03.0 Any delays arising out of failure by the Contractor to incorporate Employer's
comments and resubmit the same during the TCM shall be considered as a default
and in no case shall entitle the Contractor to alter the Contract completion date.

10.00.00 DESIGN IMPROVEMENTS

The Employer or the Contractor may propose changes in the specification of the
equipment or quality thereof and if the parties agree upon any such changes the
specification shall be modified accordingly.

If any such agreed upon change is such that it affects the price and schedule of
completion, the parties shall agree in writing as to the extent of any changing the
price and/or schedule of completion before the Contractor proceeds with the change.
Following such agreement, the provision thereof, shall be deemed to have been
amended accordingly.

11.00.00 EQUIPMENT BASES

A cast iron or welded steel base plate shall be provided for all rotating
equipment which is to be installed on a concrete base, unless otherwise specifically
agreed to by the Employer. Each base plate shall support the unit and its drive
assembly, shall be of a neat design with pads for anchoring the units, shall have a
raised lip all around, and shall have threaded drain connections.

12.00.00 PROTECTIVE GUARDS

Suitable guards shall be provided for protection of personnel on all exposed rotating
and/or moving machine parts. All such guards shall be designed for easy installation
and removal for maintenance purpose.

13.00.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS

13.01.00 I. All the first fills of consumables and one years topping requirement of
consumables such as greases, oil, lubricants, servo fluids / control fluids,
gases and essential chemicals etc. which will be required to put the
equipment covered under the scope of specifications, into successful
commissioning / initial operation and to establish completion of facilities shall

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be supplied by the Contractor. Suitable standard lubricants as available in

India are desired. Efforts should be made to limit the variety of lubricants to
minimum.

Bidder shall supply a quantity not less than 10 % of the full charge or one (1)
year topping requirement mentioned above ( whichever is higher) of each
variety of lubricants, servo fluids, gases, chemicals etc ( as detailed above)
which is expected to be utilized during the first year of operation. The
additional quantity shall be supplied in separate container.

13.02.00 As far as possible lubricants marketed by the Indian Oil Corporation shall be used.
The variety of lubricants shall be kept to a minimum possible.

Detailed specifications for the lubricating oil, grease, gases, servo fluids, control
fluids, chemicals etc. required for the complete plant covered herein shall be
furnished. On completion of erection, a complete list of bearings/ equipment giving
their location and identification marks shall be furnished to the Employer alongwith
lubrication requirements.

14.00.00 LUBRICATION

14.01.00 Equipment shall be lubricated by systems designed for continuous operation.

Lubricant level indicators shall be furnished and marked to indicate proper levels
under both standstill and operating conditions.

15.00.00 MATERIAL OF CONSTRUCTION

15.01.00 All materials used for the construction of the equipment shall be new and shall be in
accordance with the requirements of this specification. Materials utilised for various
components shall be those which have established themselves for use in such
applications.

16.00.00 RATING PLATES, NAME PLATES & LABELS

16.01.00 Each main and auxiliary item of plant including instruments shall have permanently
attached to it in a conspicuous position, a rating plate of non-corrosive material upon
which shall be engraved manufacturer’s name, equipment, type or serial number
together with details of the ratings, service conditions under which the item of plant
in question has been designed to operate, and such diagram plates as may be
required by the Employer.

16.02.00 Each item of plant shall be provided with nameplate or label designating the service
of the particular equipment. The inscriptions shall be approved by the Employer or
as detailed in appropriate section of the technical specifications.

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16.03.00 Such nameplates or labels shall be of white nonhygroscopic material with engraved
black lettering or alternately, in the case of indoor circuit breakers, starters, etc. of
transparent plastic material with suitably coloured lettering engraved on the back.
The name plates shall be suitably fixed on both front and rear side.

16.04.00 Items of plant such as valves, which are subject to handling, shall be provided with
an engraved chromium plated nameplate or label with engraving filled with enamel.
The name plates for valves shall be marked in accordance with MSS standard SP-
25 and ANSI B 16.34 as a minimum.

16.05.00 Hanger/ support numbers shall be marked on all pipe supports, anchors, hangers,
snubbers and restraint assemblies. Each constant and variable spring support shall
also have stamped upon it the designed hot and cold load which it is intended to
support. Suitable scale shall also be provided to indicate load on support or hanger.

16.06.00 Valves, steam traps and strainers shall be identified by Employer's tag number of a
metal tap permanently attached to non pressure parts such as the yoke by a
stainless steel wire. The direction of flow shall also be marked on the body.

16.07.00 Safety and relief valves shall be provided with the following:

a) Manufacturer's identification.

b) Nominal inlet and outlet sizes in mm.

c) Set pressure in Kg/cm2 (abs).

d) Blowdown and accumulation as percentage of set pressure.

e) Certified capacity in Kg of saturated steam per hour or in case of liquid

certified capacity in litres of water per minute.

16.08.00 All such plates, instruction plates, etc. shall be bilingual with Hindi inscription first,
followed by English. Alternatively, two separate plates one with Hindi and the other
with English inscriptions may be provided.

16.09.00 All segregated phases of conductors or bus ducts, indoor or outdoor, shall be
provided with coloured phase plates to clearly identify the phase of the system.

17.00.00 TOOLS AND TACKLES

The Contractor shall supply with the equipment one complete set of all special tools
and tackles and other instruments required and other instruments for the erection,
assembly, disassembly and proper maintenance of the plant and equipment and
systems (including software). These special tools will also include special material
handling equipment, jigs and fixtures for maintenance and calibration / readjustment,

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checking and measurement aids etc. A list of such tools and tackles shall be
submitted by the Bidder alongwith the offer.

The price of each tool / tackle shall be deemed to have been included in the total bid
price. These tools and tackles shall be separately packed and sent to site. The
Contractor shall also ensure that these tools and tackles are not used by him during
erection, commissioning and initial operation. For this period the Contractor should
bring his own tools and tackles. In case these tools and tackles are used by the
Contractor during erection, commissioning or initial operation the same shall be
refurbished repaired/replaced as required to the satisfaction of the Employer before
handing over to the Employer. All the tools and tackles shall be of reputed make
acceptable to the Employer.

18.00.00 WELDING

18.01.00 If the manufacturer has special requirements relating to the welding procedures for
welds at the terminals of the equipments to be per formed by others the
requirements shall be submitted to the Employer in advance of commencement of
erection work.

19.00.00 COLOUR CODE FOR ALL EQUIPMENTS/ PIPINGS/ PIPE SERVICES

19.01.00 All equipment/ piping/ pipe services are to be painted by the Contractor in
accordance with Employer's standard colour coding scheme, which will be furnished
to the Contractor during detailed engineering stage.

20.00.00 PROTECTION AND PRESERVATIVE SHOP COATING

20.01.00 PROTECTION

All coated surfaces shall be protected against abrasion, impact, discoloration and
any other damages. All exposed threaded portions shall be suitably protected with
either metallic or a nonmetallic protection device. All ends of all valves and piping
and conduit equipment connections shall be properly sealed with suitable devices to
protect them from damage. The parts which are likely to get rusted, due to exposure
to weather, should also be properly treated and protected in a suitable manner. All
primers/paints/coatings shall take into account the hot humid, corrosive & alkaline,
subsoil or over ground environment as the case may be. The requirements for
painting specification shall be complied with as detailed out in Part-A & B of the
Technical Specification.

20.02.00 PRESERVATIVE SHOP COATING

All exposed metallic surfaces subject to corrosion shall be protected by shop

application of suitable coatings. All surfaces which will not be easily accessible after
the shop assembly, shall be treated beforehand and protected for the life of the

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equipment. All surfaces shall be thoroughly cleaned of all mill scales, oxides and
other coatings and prepared in the shop. The surfaces that are to be finish-painted
after installation or require corrosion protection until installation, shall be shop
painted as per the requirements covered in the relevant part of the Technical
Specification.

Transformers and other electrical equipments, if included shall be shop finished with
one or more coats of primer and two coats of high grade resistance enamel. The
finished colors shall be as per manufacturer's standards, to be selected and
specified by the Employer at a later date.

20.03.00 Shop primer for all steel surfaces which will be exposed to operating temperature
below 95 degrees Celsius shall be selected by the Contractor after obtaining specific
approval of the Employer regarding the quality of primer proposed to be applied.
Special high temperature primer shall be used on surfaces exposed to temperature
higher than 95 degrees Celsius and such primer shall also be subject to the approval
of the Employer.

20.04.00 All other steel surfaces which are not to be painted shall be coated with suitable dust
preventive compound subject to the approval of the Employer.

20.05.00 All piping shall be cleaned after shop assembly by shot blasting or other means
approved by the Employer. Lube oil piping or carbon steel shall be pickled.

20.06.00 Painting for Civil structures and equipment/system covered under this package shall
be done as specified under technical requirements on civil works in relevant part of
this specifications.

21.00.00 QUALITY ASSURANCE PROGRAMME

21.01.00 To ensure that the equipment and services under the scope of contract whether
manufactured or performed within the Contractor’s works or at his sub-contractor’s
premises or at the Employer’s site or at any other place of work are in accordance
with the specifications, the Contractor shall adopt suitable quality assurance
programme to control such activities at all points, as necessary. Such programmes
shall be outlined by the Contractor and shall be finally accepted by the
Employer/authorised representative after discussions before the award of the
contract. The QA programme shall be generally in line with ISO-9001/IS-14001. A
quality assurance programme of the contractor shall generally cover the following:

a) His organisation structure for the management and implementation of the

proposed quality assurance programme

b) Quality System Manual

c) Design Control System

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d) Documentation Control System

e) Qualification data for Bidder’s key Personnel.

f) The procedure for purchase of materials, parts, components and selection of

sub-contractor’s services including vendor analysis, source inspection,
incoming raw-material inspection, verification of materials purchased etc.

g) System for shop manufacturing and site erection control including process
controls and fabrication and assembly controls.

h) Control of non-conforming items and system for corrective actions.

i) Inspection and test procedure both for manufacture and field activities.

j) Control of calibration and testing of measuring testing equipments.

k) System for Quality Audits.

l) System for indication and appraisal of inspection status.

m) System for authorising release of manufactured product to the Employer.

n) System for handling storage and delivery.

o) System for maintenance of records, and

p) Furnishing of quality plans for manufacturing and field activities detailing out
the specific quality control procedure adopted for controlling the quality
characteristics relevant to each item of equipment/component as per formats
enclosed as Annexure-I and Annexure-II respectively.

22.00.00 GENERAL REQUIREMENTS - QUALITY ASSURANCE

22.01.00 All materials, components and equipment covered under this specification shall be
procured, manufactured, erected, commissioned and tested at all the stages, as per
a comprehensive Quality Assurance Programme. An indicative programme of
inspection/tests to be carried out by the contractor for some of the major items is
given in the respective technical specification. This is, however, not intended to form
a comprehensive programme as it is the contractor’s responsibility to draw up and
implement such programme duly approved by the Employer. The detailed Quality
Plans for manufacturing and field activities shall be drawn up by the Bidder and will
be submitted to Employer for approval. Schedule of finalisation of such quality plans
will be finalised before award on enclosed format No. QS-01-QAI-P-1/F3-R0.
Monthly progress reports shall be furnished.

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22.02.00 Manufacturing Quality Plan will detail out for all the components and equipment,
various tests/inspection, to be carried out as per the requirements of this
specification and standards mentioned therein and quality practices and procedures
followed by Contractor’s/ Sub-contractor’s/ sub-supplier's Quality Control
Organisation, the relevant reference documents and standards, acceptance norms,
inspection documents raised etc., during all stages of materials procurement,
manufacture, assembly and final testing/performance testing. The Quality Plan shall
be submitted on electronic media through C-folders, a web based system of NTPC
ERP in addition to hard copy, for review and approval. After approval the same shall
be submitted in compiled form on CD-ROM (As per format at Annexure-I)

22.03.00 Field Quality Plans will detail out for all the equipment, the quality practices and
procedures etc. to be followed by the Contractor’s "Site Quality Control
Organisation", during various stages of site activities starting from receipt of
materials/equipment at site (As per format at Annexure – II).

22.04.00 The Bidder shall also furnish copies of the reference documents/plant
standards/acceptance norms/tests and inspection procedure etc., as referred in
Quality Plans along with Quality Plans. These Quality Plans and reference
documents/standards etc. will be subject to Employer’s approval without which
manufacturer shall not proceed. These approved documents shall form a part of the
contract. In these approved Quality Plans, Employer shall identify customer hold
points (CHP), i.e. test/checks which shall be carried out in presence of the
Employer’s Project Manager or his authorised representative and beyond which the
work will not proceed without consent of Employer in writing. All deviations to this
specification, approved quality plans and applicable standards must be documented
and referred to Employer along with technical justification for approval and
dispositioning.

22.05.00 The contractor shall submit to the Employer Field Welding Schedule for field welding
activities in the format enclosed at Annexure-V. The field welding schedule shall be
submitted to the Employer along with all supporting documents, like welding
procedures, heat treatment procedures, NDT procedures etc. at least ninety days
before schedule start of erection work at site.

22.06.00 The contractor shall have suitable Field Quality Organization with adequate
manpower at Employer's site, to effectively implement the Field Quality Plan (FQP)
and Field Quality Management System for site activities. The contractor shall submit
the details of proposed FQA setup (organizational structure and manpower) for
employer's approval. The FQA setup shall be in place at least one month before the
start of site activities.
22.07.00 No material shall be despatched from the manufacturer’s works before the same is
accepted, subsequent to predespatch final inspection including verification of
records of all previous tests/inspections by Employer’s Project Manager/Authorised
representative and duly authorised for despatch by issuance of Material Despatch

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Clearance Certificate (MDCC).

22.08.00 All material used for equipment manufacture including casting and forging etc. shall
be of tested quality as per relevant codes/standards. Details of results of the tests
conducted to determine the mechanical properties; chemical analysis and details of
heat treatment procedure recommended and actually followed shall be recorded on
certificates and time temperature chart. Tests shall be carried out as per applicable
material standards and/or agreed details

22.09.00 All welding and brazing shall be carried out as per procedure drawn and qualified in
accordance with requirements of ASME Section IX/BS-4870 or other International
equivalent standard acceptable to the Employer.

All welding/brazing procedures shall be submitted to the Employer or its authorised

representative for approval prior to carrying out the welding/brazing.

22.10.00 All brazers, welders and welding operators employed on any part of the contract
either in Contractor’s/his sub-contractor’s works or at site or elsewhere shall be
qualified as per ASME Section-IX or BS-4871 or other equivalent International
Standards acceptable to the Employer.

22.11.00 Welding procedure qualification & Welder qualification test results shall be furnished
to the Employer for approval. However, where required by the Employer, tests shall
be conducted in presence of Employer/authorized representative.

22.12.00 For all IBR pressure parts and high pressure piping welding, the latest applicable
requirements of the IBR (Indian Boiler Regulations) shall also be essentially
complied with. However, other piping system ASME B31.1 or other relevant code as
applicable shall be followed. Similarly, any other statutory requirements for the
equipment/systems shall also be complied with. On all back-gauged welds MPI/LPI
shall be carried before seal welding

22.13.00 All the heat treatment results shall be recorded on time temperature charts and
verified with recommended regimes.

22.14.00 No welding shall be carried out on cast iron components for repair.

22.15.00 Unless otherwise proven and specifically agreed with the Employer, welding of
dissimilar materials and high alloy materials shall be carried out at shop only.

22.16.00 All non-destructive examination shall be performed in accordance with written

procedures as per International Standards. The NDT operator shall be qualified as
per SNT-TC-IA (of the American Society of non-destructive examination) or
equivalent. NDT shall be recorded in a report, which includes details of methods
and equipment used, result/evaluation, job data and identification of personnel
employed and details of co-relation of the test report with the job.

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In general all plates of thickness greater than 40mm & for pressure parts plates of
thickness equal to or greater than 25mm shall be ultrasonically tested otherwise as
specified in respective equipment specification. All bar stock/Forging of diameter
equal to or greater than 40 mm shall be ultrasonically tested.

22.17.00 The Contractor shall list out all major items/ equipment/ components to be
manufactured in house as well as procured from sub-contractors (BOI). All the sub-
contractor proposed by the Contractor for procurement of major bought out items
including castings, forging, semi-finished and finished components/equipment etc.,
list of which shall be drawn up by the Contractor and finalised with the Employer,
shall be subject to Employer's approval on enclosed format No. QS-01-QAI-P-01/F3.
The contractor’s proposal shall include vendor’s facilities established at the
respective works, the process capability, process stabilization, QC systems followed,
experience list, etc. along with his own technical evaluation for identified sub-
contractors enclosed and shall be submitted to the Employer for approval within the
period agreed at the time of pre-awards discussion and identified in "DR" category
prior to any procurement. Monthly progress reports on sub-contractor detail
submission / approval shall be furnished preferably on enclosed format at
Annexure-IV. Such vendor approval shall not relieve the contractor from any
obligation, duty or responsibility under the contract.

22.18.00 For components/equipment procured by the contractors for the purpose of the
contract, after obtaining the written approval of the Employer, the contractor’s
purchase specifications and inquiries shall call for quality plans to be submitted by
the suppliers. The quality plans called for from the sub-contractor shall set out,
during the various stages of manufacture and installation, the quality practices and
procedures followed by the vendor’s quality control organisation, the relevant
reference documents/standards used, acceptance level, inspection of
documentation raised, etc.

Such quality plans of the successful vendors shall be finalised with the Employer
and such approved Quality Plans shall form a part of the purchase order/contract
between the Contractor and sub-contractor. With in three weeks of the release of the
purchase orders /contracts for such bought out items /components, a copy of the
same without price details but together with the detailed purchase specifications,
quality plans and delivery conditions shall be furnished to the Employer on the
monthly basis by the Contractor along with a report of the Purchase Order placed so
far for the contract.

22.19.00 Employer reserves the right to carry out quality audit and quality surveillance of the
systems and procedures of the Contractor’s or their sub-contractor’s quality
management and control activities. The contractor shall provide all necessary
assistance to enable the Employer carry out such audit and surveillance.

22.20.00 The contractor shall carry out an inspection and testing programme during
manufacture in his work and that of his sub-contractor’s and at site to ensure the

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mechanical accuracy of components, compliance with drawings, conformance to

functional and performance requirements, identity and acceptability of all materials
parts and equipment. Contractor shall carry out all tests/inspection required to
establish that the items/equipment conform to requirements of the specification and
the relevant codes/standards specified in the specification, in addition to carrying out
tests as per the approved quality plan.

22.21.00 Quality audit/surveillance/approval of the results of the tests and inspection will not,
however, prejudice the right of the Employer to reject the equipment if it does not
comply with the specification when erected or does not give complete satisfaction in
service and the above shall in no way limit the liabilities and responsibilities of the
Contractor in ensuring complete conformance of the materials/equipment supplied to
relevant specification, standard, data sheets, drawings, etc.

22.22.00 For all spares and replacement items, the quality requirements as agreed for the
main equipment supply shall be applicable.

22.23.00 Repair/rectification procedures to be adopted to make the job acceptable shall be

subject to the approval of the Employer/ authorised representative.

22.24.00 Environmental Stress Screening

Environmental stress screening test process / procedure for eliminating infant mortile
components for DDCMIS / PLC based system & for other systems having
substantial electronics components (as determined by employer) like Electronic
transmitter, CCTV components, PA systems etc. shall be necessarily furnished for
any sub vendors proposed for vendor assessment and approval for this contract. For
other approved sub vendors of above mentioned systems, contractor shall furnish
the test procedure for eliminating infant mortile components in case, if it is asked for
by the employer before these items are offered for inspection / dispatched to site.
22.25.00 The Contractor / Sub-contractor shall carry out routine test on 100% item at
contractor / sub-contractor's works. The quantum of check / test for routine &
acceptance test by employer shall be generally as per criteria / sampling plan
defined in referred standards. Wherever standards have not been mentioned
quantum of check / test for routine / acceptance test shall be as agreed during
detailed engineering stage.

22.26.00 Software Reliability / Quality Certification

Certification from OEM’s authorized signatory that software offered with DDCMIS,
PLC, CCTV, PA, Pyrometer, CEMS, AAQMS, EQMS, BHMS etc. declaring that the
all the offered software(s) had gone through the established software quality test and
offered software is not of β-version and offered software is also free from all known
bugs as on date of approval of systems documents by NTPC as a part of quality
documentation review and approval process during detail engineering.
23.00.00 QUALITY ASSURANCE DOCUMENTS

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23.01.00 The Contractor shall be required to submit the QA Documentation in two hard copies
and two CD ROMs, as identified in respective quality plan with tick ( )mark.

23.01.01 Each QA Documentation shall have a project specific Cover Sheet bearing name &
identification number of equipment and including an index of its contents with page
control on each document.

The QA Documentation file shall be progressively completed by the Supplier’s sub-

supplier to allow regular reviews by all parties during the manufacturing.

The final quality document will be compiled and issued at the final assembly place of
equipment before despatch. However CD-Rom may be issued not later than three
weeks.

23.02.00 Typical contents of QA Documentation is as below:-

(a.) Quality Plan

(b.) Material mill test reports on components as specified by the specification and
approved Quality Plans.

(c.) Manufacturer / works test reports/results for testing required as per

applicable codes and standard referred in the specification and approved
Quality Plans.

(d.) Non-destructive examination results /reports including radiography

interpretation reports. Sketches/drawings used for indicating the method of
traceability of the radiographs to the location on the equipment.

(e.) Heat Treatment Certificate/Record (Time- temperature Chart)

(f.) All the accepted Non-conformance Reports (Major/Minor)/deviation, including

complete technical details / repair procedure).

(g.) CHP / Inspection reports duly signed by the Inspector of the Employer and
Contractor for the agreed Customer Hold Points.

(h.) Certificate of Conformance (COC) wherever applicable.

(i.) MDCC

23.03.00 Similarly, the contractor shall be required to submit two sets (two hard copies and
two CD ROMs), containing QA Documentation pertaining to field activities as per
Approved Field Quality Plans and other agreed manuals/ procedures, prior to
commissioning of individual system.

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23.04.00 Before despatch / commissioning of any equipment, the Supplier shall make sure
that the corresponding quality document or in the case of protracted phased
deliveries, the applicable section of the quality document file is completed. The
supplier will then notify the Inspector regarding the readiness of the quality
document (or applicable section) for review.

(a.) If the result of the review carried out by the Inspector is satisfactory, the
Inspector shall stamp the quality document (or applicable section) for
release.

(b.) If the quality document is unsatisfactory, the Supplier shall endeavor to

correct the incompleteness, thus allowing to finalize the quality document (or
applicable section) by time compatible with the requirements as per contract
documents. When it is done, the quality document (or applicable section) is
stamped by the Inspector.

(c.) If a decision is made for despatch, whereas all outstanding actions cannot be
readily cleared for the release of the quality document by that time, the
supplier shall immediately, upon shipment of the equipment, send a copy of
the quality document Review Status signed by the Supplier Representative to
the Inspector and notify of the committed date for the completion of all
outstanding actions & submission. The Inspector shall stamp the quality
document for applicable section when it is effectively completed. The
submission of QA documentation package shall not be later than 3 weeks
after the despatch of equipment.

23.05.00 TRANSMISSION OF QA DOCUMENTATION

On release of QA Documentation by Inspector, one set of quality document shall be

forwarded to Corporate Quality Assurance Department and other set to respective
Project Site of Employer.

For the particular case of phased deliveries, the complete quality document to the
Employer shall be issued not later than 3 weeks after the date of the last delivery of
equipment.

24.00.00 PROJECT MANAGER’S SUPERVISION

24.01.00 To eliminate delays and avoid disputes and litigation, it is agreed between the
parties to the Contract that all matters and questions shall be referred to the Project
Manager and without prejudice to the provisions of ‘Arbitration’ clause in Section
GCC, the Contractor shall proceed to comply with the Project Manager's decision.

24.02.00 The work shall be performed under the supervision of the Project Manager.

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The scope of the duties of the Project Manager pursuant to the Contract, will include
but not be limited to the following:

(a.) Interpretation of all the terms and conditions of these documents and
specifications

(b.) Review and interpretation of all the Contractor’s drawing, engineering data,
etc

(c.) Witness or his authorised representative to witness tests and trials either at
the manufacturer’s works or at site, or at any place where work is performed
under the contract

(d.) Inspect, accept or reject any equipment, material and work under the
contract

(e.) Issue certificate of acceptance and/or progressive payment and final

payment certificates

(f.) Review and suggest modifications and improvement in completion schedules

from time to time, and

(g.) Supervise Quality Assurance Programme implementation at all stages of the

works.

25.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES

25.01.00 The word ‘Inspector’ shall mean the Project Manager and/or his authorised
representative and/or an outside inspection agency acting on behalf of the Employer
to inspect and examine the materials and workmanship of the works during its
manufacture or erection.

25.02.00 The Project Manager or his duly authorised representative and/or an outside
inspection agency acting on behalf of the Employer shall have access at all
reasonable times to inspect and examine the materials and workmanship of the
works during its manufacture or erection and if part of the works is being
manufactured or assembled on other premises or works, the Contractor shall obtain
for the Project Manager and for his duly authorised representative permission to
inspect as if the works were manufactured or assembled on the Contractor’s own
premises or works.

25.03.00 The Contractor shall give the Project Manager/Inspector fifteen (15) days written
notice of any material being ready for testing. Such tests shall be to the Contractor’s
account except for the expenses of the Inspector’s. The Project Manager/Inspector,
unless the witnessing of the tests is virtually waived and confirmed in writing, will
attend such tests within fifteen (15) days of the date on which the equipment is

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noticed as being ready for test/inspection failing which the contractor may proceed
with test which shall be deemed to have been made in the inspector’s presence and
he shall forthwith forward to the inspector duly certified copies of test reports in two
(2) copies.

25.04.00 The Project Manager or Inspector shall within fifteen (15) days from the date of
inspection as defined herein give notice in writing to the Contractor, or any objection
to any drawings and all or any equipment and workmanship which is in his opinion
not in accordance with the contract. The Contractor shall give due consideration to
such objections and shall either make modifications that may be necessary to meet
the said objections or shall inform in writing to the Project Manager/Inspector giving
reasons therein, that no modifications are necessary to comply with the contract.

25.05.00 When the factory tests have been completed at the Contractor’s or sub-contractor’s
works, the Project Manager /Inspector shall issue a certificate to this effect fifteen
(15) days after completion of tests but if the tests are not witnessed by the Project
Manager /Inspectors, the certificate shall be issued within fifteen (15) days of the
receipt of the Contractor’s test certificate by the Project Manager /Inspector. Project
Manager /Inspector to issue such a certificate shall not prevent the Contractor from
proceeding with the works. The completion of these tests or the issue of the
certificates shall not bind the Employer to accept the equipment should it, on further
tests after erection be found not to comply with the contract.

25.06.00 In all cases where the contract provides for tests whether at the premises or works
of the Contractor or any sub-contractor, the Contractor, except where otherwise
specified shall provide free of charge such items as labour, material, electricity, fuel,
water, stores, apparatus and instruments as may be reasonably demanded by the
Project Manager /Inspector or his authorised representatives to carry out effectively
such tests on the equipment in accordance with the Contractor and shall give
facilities to the Project Manager/Inspector or to his authorised representative to
accomplish testing.

25.07.00 The inspection by Project Manager / Inspector and issue of Inspection Certificate
thereon shall in no way limit the liabilities and responsibilities of the Contractor in
respect of the agreed Quality Assurance Programme forming a part of the contract.

25.08.00 To facilitate advance planning of inspection in addition to giving inspection notice as

specified at clause no 25.03.00 of this chapter, the Contractor shall furnish quarterly
inspection programme indicating schedule dates of inspection at Customer Hold
Point and final inspection stages. Updated quarterly inspection plans will be made
for each three consecutive months and shall be furnished before beginning of each
calendar month.

25.09.00 All inspection, measuring and test equipment used by contractor shall be calibrated
periodically depending on its use and criticality of the test/measurement to be done.
The Contractor shall maintain all the relevant records of periodic calibration and

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instrument identification, and shall produce the same for inspection by NTPC.
Wherever asked specifically, the contractor shall re-calibrate the measuring/test
equipment in the presence of Project Manager / Inspector.

25.10.00 Associated document for Quality Assurance programme

25.10.01 Manufacturing Quality Plan Format No. : QS-01-QAI-P-09/F1-R1 enclosed at

Annexure-I.

25.10.02 Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R1 enclosed at Annexure-II.

25.10.03 List of items requiring quality plan and sub supplier approval. Format No.: QS-01-
QAI-P-01/F3-R0 (Annexure-III).

25.10.04 Status of items requiring Quality Plan and sub supplier approval. Format enclosed
at Annexure-IV.

25.10.05 Field Welding Schedule Format enclosed at Annexure-V.

25.11.00 Not Used

25.12.00 DEMONSTRATION OF APPLICATION ENGINEERING

25.12.01 Based on NTPC inputs, the Contractor shall prepare and submit typical implemented
scheme in their system (Control system & HMI) on sample basis. The typical cases
to be covered shall include but not be limited to the following.

(i) Logics/Loops:

a) Drive logics implementation for each type of binary drive along with its
display in HMI.

b) Sequence implementation along with its display in HMI.

c) Single non-cascade controller implementation.

d) Cascade loop implementation.

e) Master slave implementation with different slave combination.

f) Temperature & pressure compensation for flow signals & pressure

compensation for level signals as applicable.

(ii) HMI Functions:

a) LVS Annunciation.

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b) Graphics.

c) HSR

d) Logs/Reports.

e) Calculations ( Basic & Performance Calculations).

25.12.02 The above typical cases shall be finalized with the Employer through Technical Co-
ordination meetings.

After review and finalization of the typical cases, the implementation of each logic &
control loop shall be carried out by the Contractor based on NTPC inputs. After
implementation of these logics & loops, the Contractor shall test each logic /loop and
record the observations in a format to be provided by the Employer and demonstrate
to Employer at Employer premises during engineering finalization. Any modifications
as a result of the demonstration shall be done and documented as part of the test
report along with the final scheme. Similarly, HMI functions shall also be
demonstrated by the Contractor at Employer premises & the results shall be
documented as part of test report.

25.12.03 During the integrated testing at the Contractor’s works, only sample checks shall be
done by the Employer for the items covered in above application engineering
demonstration.

26.00.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES

26.01.00 (a) As soon as the facilities or part thereof has been completed operationally and
structurally and before start-up, each item of the equipment and systems
forming part of facilities shall be thoroughly cleaned and then inspected
jointly by the Employer and the Contractor for correctness of and
completeness of facility or part thereof and acceptability for initial pre-
commissioning tests, commissioning and start-up at Site. The list of pre-
commissioning tests to be performed shall be as mutually agreed and
included in the Contractor’s quality assurance programme as well as those
included in Part-D, Section-VI and elsewhere in the Technical Specifications.

(b) The Contractor’s pre-commissioning/ commissioning/start-up engineers,

specially identified as far as possible, shall be responsible for carrying out all
the pre-commissioning tests at Site. On completion of inspection, checking
and after the pre-commissioning tests are satisfactorily over, the
commissioning of the complete facilities shall be commenced during which
period the complete facilities, equipments shall be operated integral with sub-
systems and supporting equipment as a complete plant.

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(c) All piping system shall be flushed, steam blown, air blown as required and
cleanliness demonstrated using acceptable industry standards. Procedures
to accomplish this work shall be submitted for approval to the Employer six
months prior to the respective implementations. The Employer will approve
final verification of cleanliness.

(d) The time consumed in the inspection and checking of the units shall be
considered as a part of the erection and installation period.

(e) The check outs during the pre - commissioning period should be
programmed to follow the construction completion schedule. Each
equipment/system, as it is completed in construction and turned over to
Employer's commissioning (start-up) Engineer(s), should be checked out and
cleaned. The checking and inspection of individual systems should then
follow a prescribed commissioning documentation [SLs(standard check
list)/TS(testing schedule)/CS(commissioning schedule)] approved by the
employer.

(f) The Contractor during initial operation and performance testing shall conduct
vibration testing to determine the ‘base line’ of performance of all plant
rotating equipment. These tests shall be conducted when the equipment is
running at the base load, peak load as well as lowest sustained operating
condition as far as practicable.

26.01.00 Contractor shall furnish the commissioning organization chart for review &
acceptance of employer at least twelve months prior to the schedule date of
commissioning of 1st unit. The chart should contain:

(1.) Biodata including experience of the Commissioning Engineers.

(2.) Role and responsibilities of the Commissioning Organisation members.

(3.) Expected duration of posting of the above Commissioning Engineers at site.

26.02.00 Initial Operation

(a) On completion of all pre-commissioning activities/ tests and as a part of

commissioning the complete facilities shall be put on 'Initial Operation' during
which period all necessary adjustments shall be made while operating over
the full load range enabling the facilities to be made ready for the Guarantee
Tests.

(b) The 'Initial Operation' of the complete facility as an integral unit shall be
conducted for 720 continuous hours. During the period of initial operation of
720 hours, the FGD System shall operate continuously at full load for a
period not less than 72 hours.

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The Initial Operation shall be considered successful, provided that each item/
part of the facility can operate continuously at the specified operating
characteristics, for the period of Initial Operation with all operating
parameters within the specified limits and at or near the predicted
performance of the equipment/ facility.

The Contractor shall intimate the Employer about the commencement of

initial operation and shall furnish adequate notice to the Employer in this
respect.

(c) Any operational interruption in the FGD System due to constraints

attributable to the Employer shall be construed as Deemed to be in
operation.

(d) An Initial Operation report comprising of observations and recordings of

various parameters to be measured in respect of the above Initial Operation
shall be prepared by the Contractor. This report, besides recording the
details of the various observations during initial operation shall also include
the dates of start and finish of the Initial Operation and shall be signed by the
representatives of both the parties. The report shall have sheets, recording
all the details of interruptions occurred, adjustments made and any minor
repairs done during the Initial Operation. Based on the observations,
necessary modifications/repairs to the plant shall be carried out by the
Contractor to the full satisfaction of the Employer to enable the latter to
accord permission to carry out the Guarantee tests on the facilities.
However, minor defects which do not endanger the safe operation of the
equipment, shall not be considered as reasons for with- holding the aforesaid
permission.

26.03.00 Guarantee Tests

a) The final test as to prove the Functional Guarantees shall be conducted at

Site by the Contractor in presence of the Employer. The contractor's
Commissioning, start-up Engineer shall make the unit ready to conduct such
test before start of initial operation. Such test shall be conducted along with
the Initial Operations.

b) These tests shall be binding on both the parties of the Contract to determine
compliance of the equipment with the functional guarantee.

c) For performance/ demonstration tests instrumentations, of accuracy class

shall be as per specified test codes. The numbers and location of the
instruments shall be as per the specified test codes. In addition the values
of parameters shall be logged from the information system provided under
Employer's Distributed Digital Control Monitoring and Information system.
Test will be conducted at specified load points.

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d) Any special equipment, tools and tackles required for the successful
completion of the Guarantee Tests shall be provided by the Contractor, free
of cost.

e) The Guarantee tests and specific tests to be conducted on equipments have

been brought out in detail elsewhere in the specifications.

27.00.00 TAKING OVER

Upon successful completion of Initial Operations and all the tests conducted to the
Employer's satisfaction, the Employer shall issue to the Contractor a Taking over
Certificate as a proof of the final acceptance of the equipment. Such certificate shall
not unreasonably be with held nor will the Employer delay the issuance thereof, on
account of minor omissions or defects which do not affect the commercial operation
and/or cause any serious risk to the equipment. Such certificate shall not relieve the
Contractor of any of his obligations which otherwise survive, by the terms and
conditions of the Contract after issuance of such certificate.

28.00.00 TRAINING OF EMPLOYER'S PERSONNEL

28.01.00 Training for Employers O&M Personnel

The scope of service under training of Employer's engineers shall include a training
module covering upto six (6) man months in the areas of Operation & Maintenance.

Such training should enable the personnel to individually take the responsibility of
operating and maintaining the FGD system in a manner acceptable to the Employer.

28.02.00 Training for Employers Engineering Personnel

The scope of services under training for Employer's engineering personnel shall also
necessarily include three (3) man months. This shall cover all disciplines viz,
Mechanical, Electrical, C&I, & QA etc. and shall include all the related areas like
Design familiarization, training on product design features and product design
softwares of major equipment and systems, engineering, manufacturing, erection,
commissioning, training on operating features of equipment, quality assurance and
testing, plant visits and visits to manufacturer's works, exposure to various kinds of
problems which may be encountered in fabrication, manufacturing, erection, welding
etc. An indicative module of the training requirement of Employer's Engineering
personnel is attached as Annexure-VII.

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28.03.00 Bidder shall furnish in his offer, details of training module(s) covering above
requirements which shall be subject to Employer's approval. Consolidated training
period included above (i.e. 6 man months and 3 man months respectively for O&M
and Engineering) is indicative only. Employer reserves the right to re appropriate the
training period between O&M and engineering depending upon the details of training
module proposed by the Bidder.

28.04.00 Exact details, extent of training and the training schedule shall be finalised based on
the Bidder's proposal within two (2) months from placement of award.

28.05.00 In all the above cases, wherever the training of Employer's personnel is arranged at
the works of the manufacturer's it shall be noted that the lodging and boarding of the
Employer's personnel shall be at the cost of Contractor. The Contractor shall make
all necessary arrangements towards the same.

28.06.00 Take off prices (product wise) should be indicated by the Bidder in the Bid Proposal
Sheets. Employer reserves the right to include or exclude these item(s) during
placement of Award.

Note: For training purposes, one (1) man month implies 30 working days (excluding
all intervening holidays) per person.

29.00.00 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION

In addition to the requirements given in Erection Conditions of Contract (ECC) the

following shall also cover:

i) Working platforms should be fenced and shall have means of access.

ii) Ladders in accordance with Employer’s safety rules for construction and
erection shall be used. Rungs shall not be welded on columns. All the
stairs shall be provided with handrails immediately after its erection.

30.00.00 NOISE LEVEL

The equivalent 'A' weighted sound pressure level measured at a height of 1.5 m
above floor level in elevation and at a distance of one (1) metre horizontally from the
nearest surface of any equipment/machine, furnished and installed under these
specifications, expressed in decibels to a reference of 0.0002 microbar, shall not
exceed 85 dBA . However for Ball Mills the noise levels as per following shall also be
acceptable:

a) Ball Mill < 90 dBA

31.00.00 PACKAGING AND TRANSPORTATION

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All the equipments shall be suitably protected, coated, covered or boxed and crated
to prevent damage or deterioration during transit, handling and storage at Site till the
time of erection. While packing all the materials, the limitation from the point of view
of the sizes of railway wagons available in India should be taken account of. The
Contractor shall be responsible for any loss or damage during transportation,
handling and storage due to improper packing. The Contractor shall ascertain the
availability of Railway wagon sizes from the Indian Railways or any other agency
concerned in India well before effecting despatch of equipment. Before despatch it
shall be ensured that complete processing and manufacturing of the components is
carried out at shop, only restricted by transport limitation, in order to ensure that site
works like grinding, welding, cutting & preassembly to bare minimum. The
Employer's Inspector shall have right to insist for completion of works in shops
before despatch of materials for transportation.

32.00.00 ELECTRICAL EQUIPMENTS/ENCLOSURES

32.01.00 All electrical equipments and devices, including insulation, heating and ventilation
devices shall be designed for ambient temperature and a maximum relative humidity
as specified elsewhere in the specifications.

33.00.00 INSTRUMENTATION AND CONTROL

All instrumentation and control systems/ equipment/ devices/ components, furnished

under this contract shall be in accordance with the requirements stated herein,
unless otherwise specified in the detailed specifications.

33.01.00 All instrument scales and charts shall be calibrated and printed in metric units and
shall have linear graduation. The ranges shall be selected to have the normal
reading at 75% of full scale.

All scales and charts shall be calibrated and printed in Metric Units as follows:

1 Temperature - Degree centigrade (deg C)

2. Pressure - Kilograms per square centimetre
(Kg/cm2). Pressure instrument shall
have the unit suffixed with 'a' to
indicate absolute pressure. If nothing
is there, that will mean that the
indicated pressure is gauge pressure.

3. Draught - Millimetres of water column (mm wc).

4. Vacuum - Millimeters of mercury gauge (mm Hg)

or water column (mm Wcl).

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5. Flow (Gas) - Tonnes/ hour

6. Flow (Steam) - Tonnes/ hour

7. Flow (Liquid) - Tonnes / hour

8. Flow base - 760 mm Hg. 0 deg.C

9. Density - Grams per cubic centimeter.

33.02.00 All instruments and control devices provided on panels shall be of miniaturized
design, suitable for modular flush mounting on panels with front draw out facility and
flexible plan-in connection at rear.

33.03.00 All electronic modules shall have gold plated connector fingers and further all input
and output modules shall be short circuit proof. These shall also be tropicalised &
components shall be of industrial grade or better.

34.00.00 ELECTRICAL NOISE CONTROL

The equipment furnished by the Contractor shall incorporate necessary techniques

to eliminate measurement and control problems caused by electrical noise. Areas in
Contractor's equipment which are vulnerable to electrical noise shall be hardened to
eliminate possible problems. Any additional equipment, services required for
effectively eliminating the noise problems shall be included in the proposal. The
equipment shall be protected against ESD as per IEC-61000-2. Radio Frequency
interference (RFI) and Electro Magnetic Interference (EMI) protection against
hardware damage and control system mal-operations/errors shall be provided for all
systems as per EN-50082-2 (1995).

35.00.00 SURGE PROTECTION FOR SOLID STATE EQUIPMENT

All solid state systems /equipment shall be able to withstand the electrical noise and
surge as encountered in actual service conditions and inherent in a power plant and
shall meet the requirements of surge protection as defined in ANSI C37.90.1-1989
on its suitable equivalent class of IEC 254-4. Details of the features incorporated and
relevant tests carried out. The test certificates. etc. shall be submitted by the Bidder.

36.00.00 INSTRUMENT AIR SYSTEM

The instrument air supply system as supplied by the Bidder for various pneumatic
control & instrumentation devices like pneumatic actuators, power cylinders, E/P
converters, piping / tubing etc.

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Each pneumatic instrument shall have an individual air shut - off valve. The pressure
regulating valve shall be equipped with an internal filter, a 50 mm pressure gauge
and a built-in filter housing blow down valve.

37.00.00 TAPPING POINTS FOR MEASUREMENTS

Tapping points shall include probes, wherever applicable, for analytical

measurements and sampling.

For direct temperature measurement of all working media, one stub with internal
threading of approved pattern shall be provided along with suitable plug and washer.
The Contractor will be intimated about thread standard to be adopted.

The following shall be provided on equipment by the Bidder. The standard which is
to be adopted, will be intimated to the Contractor.

i) Temperature test pockets with stub and thermowell

ii) Pressure test pockets

38.00.00 SYSTEM DOCUMENTATION

The Bidder shall provide drawings, system overview & description, hardware/
software details, technical literature, functional & hardware schemes, bill of material,
parts list, interconnection diagrams, data sheets, erection/ installation/
commissioning procedures, instruction/ operating manuals, etc. for each of the C& I
system / sub-systems/ equipment supplied under this package. The documentation
shall include complete details of the C&I systems/ sub-systems/ equipment to enable
review by Employer during detailed engineering stage and to provide information to
plant personnel for operation & Maintenance (including quick diagnostics & trouble
shooting) of these C&I systems/ sub-systems/ equipment at site. The minimum
documentation requirements for C&I systems shall be as stipulated under C&I
"Techncial Data Sheets" Part of specifications. In addition to this, system
documentation for control system shall include as a minimum to that specified
elsewhere in the Technical Specification.

The exact format, submission schedule and contents of various documents shall be
as finalised during detailed engineering stage.

38.01.00 Bill of material (instrument list) for all C&I equipment/ devices shall be furnished by
the bidder in standard formats as approved by the Employer.

39.00.00 MAINTENANCE MANUALS OF ELECTRONIC MODULES

The Contractor shall have to furnish two (2) sets of all maintenance manual of each
and every electronic card/module as employed on the various systems and

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equipment including peripherals etc., offered by him. The Contractor will also have to
furnish the data regarding the expected failure rate of various modules and other
system components. Further , the contractor shall furnish a set of operating manuals
which should include block diagrams ,make, model/type ,details wiring and external
connection drawings etc as required to do the testing and maintenance of the
electronic modules.

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LIST OF CODES AND STANDARDS

Indian Title International and

Standards Internationally
recognised standards

IS:277 Galvanised steel sheets

(plain or corrugated)

IS:655 Specification for metal

air duct

IS:800 Code of practice for BS 449:1969

use of structural BS 5950
steel in general ASA A57, 1-1952
building construction

IS:807 Code of practice for Draft Revision of

design, manufacture, A.S. NO. CS.2
erection and testing SAA Crane and
(Structural portion) Hoist code
of cranes and hoists Doc:No. BU/4 Rev
6588 (Issued by
Standards Associa-
tion of Australia).
DIN 120:1936 (Sheet 1)
DIN 120:1936 (Sheet 2)
327 part-I, 1951
BS 466 part-II, 1960
BS 644:1960
BS 1757:1951
BS 2573:part-I:1960

IS:875 Code of practice for National Building

design loads (other than code of Canada
earthquake) for buildings (1953)-Part-IV
and structures
Leading standards Design section 4.1
(issued by Canadian
Standard)
DIN-1055-1955
(Issued by ASA)

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IS:1239 Mild steel tubes (ISO/R 65-1957)

Part-I (ISO/R-64-1958)
(ISO/R-65-1958)
(BS 1387 : 1957)

IS:1239 Mild steel tubulars and BS 1387 : 1967

Part-II other wrought steel pipe BS 1387 :1967
fittings BS 1740 :1965
IS:2825 Code for unfired vessels

IS:1520 Horizontal centrifugal

pumps for clear cold
and fresh water

IS:1600 Code for practice for

performance of constant
speed IC Engines for
general purpose

IS:1601 Specification for perform-

ance of constant speed
IC Engines for general
Purpose

IS:1893 Criteria for earthquake

resistant design of
structures

IS1978-1971 Line Pipe API Standards 5L

April 1969.

IS:2254-1970 Dimensions of vertical IEC Pub 72-1 part I

shaft motor for pumps NEMA Pub MG 1
1954

IS:2266 Steel wire ropes for BS :302 : 1968

general engineering
purposes

IS:2312 Propellant type

Ventilation fans

IS:2365 Steel wire suspension BS : 1957

ropes for lifts and
hoists

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IS:3346 Method for the determin- DIN 52612 (Deutscher

ation of thermal Normenausschuss)
conductivity of thermal ASTM C 163-1964
insulation materials (American Society of
(two slab guarded Testing and
hot plate method) materials)
ASTM C 167-1974
ASTM C 177-1963

IS:3354 Outline dimensions for

electric lifts.

IS:3401 Silica gel

IS:3588 Specification for electrical

axial flow fans

IS:3589 Electrically welded steel pipes

for water, gas and sewage
(200mm to 2000 mm Nominal
Diametre)

IS:3677 Unbonded rock and slag

wool for thermal
insulation

IS:3815 Point hook with shank BS 482 - 1968

for general engineering Doc.:67/3 1284
purposes (Revision of BS 2903)
(Issued BS)

IS:3895 Specification for monocry-

stallines semiconductor
rectifier cells and stacks

IS:3963 Roof extractor unit

IS:3975 Mild steel wires, strips

and tapes for armouring
cables

IS:4503 Shell and tube type heat

Exchanger

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IS:4540 Specification for monory-

stallines rectifire assembly
equipment

IS:4671 Expanded polystyrene for

thermal insulation purpose

IS:4736 Hot dip zinc coating on

steel tubes

IS:4894 Centrifugal fans

IS:5456 Code of practice for testing

of positive displacement type
air compressors and exhauster
(For Test Tolerance Only)

IS:5749 Forged ramshorn hooks Entwurf DIN 15402

Blett 1
Entwurf DIN 15402
BS 3017-1958

IS:6392 Steel pipe flanges BS 4504 : 1969

IS:6524 Code of practice for

Part-I design of tower cranes
Static and rail mounted BS 2799 : 1956

IS:7098 Cross linked Polyethylene Standard No. 1 to

insulated PVC sheathed IPCEA (USA) Pub.
cables No. 5-66-524

IS:7373 Specification for wrought

aluminium and aluminium
sheet and strips

IS:7938 Air receivers for compressed

air installation

ISO:1217 Displacement compressor-Acceplance test

ASHRAE-33 Methods of testing for rating of forced circulation air cooling

and air heating coils.

ASHRAE-52-76 Air cleaning device used in general ventilation for removing

particle matter.

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ASHRAE-22-72 Method of testing for rating of water cooled refrigerant

condensers.

ASHRAE 23-67 Methods of testing for rating of positive displacement

refrigerant compressors.

ARI-450-6 Standard for water cooled refrigerant condensers.

ARI-550 Standard for centrifugal water chilling packages.

ARI-410 Standard for forced circulation air cooling and air heating coils

ARI-430/435 Central station AHU/Application of Central Station AHU

BS:848 Fans
(Part-1,2)

BS:400 Low carbon steel cylinders for the storage & transport of
permanent gases.

BS:401 Low carbon steel cylinders for the storage & transport of
liquified gases.
CTI Code Acceptance test code for Water Cooling Tower.
ACT-105

ANSI-31.5 Refrigerant piping

ASME-PTC- Atmospheric Water Cooling Equipment

23-1958

AMCA A-21C Test Code for air moving devices

API:618 Reciprocating Compressor for general refinary services.

HYDRAULIC INSTITUTE STANDARDS.

HYDRANT SYSTEM MANUALS OF TAC.

TAC MANUALS OF SPRAY SYSTEM

NFPA USA/ NSC UK/ UL USA/ FM USA STANDARDS.

INDIAN EXPLOSIVES ACT.

INDIAN FACTORIES ACT.

STANDARD OF TUBULAR EXCHANGER MANUFACTURER'S ASSOCIATION.

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CODE AND STANDARD FOR CIVIL WORKS

Some of the applicable Standards, Codes and references are as follows:

Excavation & Filling

IS: 2720 (Part-II, IV TO VIII, XIV, XXI, XXIII, XXIV, XXVII TO XXIX, XL) Methods of
test for soils-determination for water content etc.

IS: 4701 Code of practice for earth work on canals.

IS: 9758 Guide lines for Dewatering during construction.

IS: 10379 Code of practice for field control of moisture and compaction of
soils for embankment and sub-grade.

Properties, Storage and Handling of Common Building Materials

IS: 269 Specification for ordinary Portland cement, 33 grade.

IS: 383 Specification for coarse and fine aggregates from natural sources
for concrete.

IS: 432 Specification for mild steel and (Parts 1&2) medium tensile steel
bars and hard-drawn steel wires for concrete reinforcement.

IS: 455 Specification for Portland slag cement.

IS: 702 Specification for Industrial bitumen.

IS: 712 Specification for building limes.

IS: 808 Rolled steel Beam channel and angle sections.

IS: 1077 Specification for common burnt clay building bricks.

IS: 1161 Specification of steel tubes for structural purposes.

IS: 1363 Hexagon head Bolts, Screws and nuts of production grade C.

IS: 1364 Hexagon head Bolts, Screws and Nuts of Production grade A & B.

IS: 1367 Technical supply conditions for Threaded fasteners.

IS: 1489 Specification for Portland-pozzolana cement:

(Part-I) Fly ash based.

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(Part-II) Calcined clay based.

IS: 1542 Specification for sand for plaster.

IS: 1566 Specification for hard-drawn steel wire fabric for concrete
reinforcement.

IS: 1786 Specification for high strength deformed bars for concrete
reinforcement.

IS: 2062 Specification for steel for general structural purposes.

IS: 2116 Specification for sand for masonry mortars.

IS: 2386 Testing of aggregates for concrete.

(Parts-I to VIII)

IS: 3150 Hexagonal wire netting for general purpose.

IS: 3495 Methods of tests of burnt clay building bricks.

(Parts-I to IV)

IS: 3812 Specification for fly ash, for use as pozzolana and admixture.

IS: 4031 Methods of physical tests for hydraulic cement.

IS: 4032 Methods of chemical analysis of hydraulic cement.

IS: 4082 Recommendations on stacking and storage of construction

materials at site.

IS: 8112 Specification for 43 grade ordinary portland cement.

IS: 8500 Medium and high strength structural steel.

IS: 12269 53 grade ordinary portland cement.

IS: 12894 Specification for Fly ash lime bricks.

Cast-In-Situ Concrete and Allied Works

IS: 280 Specification for mild steel wire for general engineering purposes.

IS: 456 Code of practice for plain and reinforced concrete.

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IS: 457 Code of practice for general construction of plain & reinforced
concrete for dams & other massive structures.

IS: 516 Method of test for strength of concrete.

IS: 650 Specification for standard sand for testing of cement.

IS: 1199 Methods of sampling and analysis of concrete.

IS: 1791 General requirements for batch type concrete mixers.

IS: 1838 Specification for preformed fillers for expansion joints in

(Part-I) concrete pavements and structures (non-extruding and resilient
type).

IS: 2204 Code of practice for construction of reinforced concrete shell roof.

IS: 2210 Criteria for the design of reinforced concrete shell structures and
folded plates.

IS: 2438 Specification for roller pan mixer.

IS: 2502 Code of practice for bending and fixing of bars for concrete
reinforcement.

IS: 2505 General requirements for concrete vibrators, immersion type.

IS: 2506 General requirements for concrete vibrators, screed board type.

IS: 2514 Specification for concrete vibrating tables.

IS: 2645 Specification for Integral cement water proofing compounds.

IS: 2722 Specification for portable swing weigh batches for concrete.
(single and double bucket type)

IS: 2750 Specification for Steel scaffolding.

IS: 2751 Code of practice for welding of mild steel plain and deformed bars
for reinforced concrete construction.

IS: 3025 Methods of sampling and test waste water.

IS: 3366 Specification for Pan vibrators.

IS: 3370 Code of practice for concrete structures for the storage of

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(Part I to IV) liquids.

IS: 3414 Code of practice for design and installation of joints in buildings.

IS: 3550 Methods of test for routine control for water used in industry.

IS: 3558 Code of practice for use of immersion vibrators for consolidating
concrete.

IS: 4014 Code of practice for steel tubular scaffolding.

(Parts I & II)

IS: 4326 Code of practice for earthquake resistant design and construction
of buildings.

IS: 4461 Code of practice for joints in surface hydro-electric power stations.

IS: 4656 Specification for form vibrators for concrete.

IS: 4925 Specification for batching and mixing plant.

IS: 4990 Specification for plywood for concrete shuttering work.

IS: 4995 Criteria for design of reinforced concrete bins for the storage
(Parts I & II) of granular and powdery materials.

IS: 5256 Code or practice for sealing joints in concrete lining on canals.

IS: 5525 Recommendations for detailing of reinforcement in reinforced

concrete work.

IS: 5624 Specification for foundation bolts.

IS: 6461 Glossary of terms relating to cement concrete.

IS: 6494 Code of practice for water proofing of underground water

reservoirs and swimming pools.

IS: 6509 Code of practice for installation of joints in concrete pavements.

IS: 7861 Code of practice for extreme weather concreting. (Parts I & II)

IS: 9012 Recommended practice for shot concreting.

IS: 9103 Specification for admixtures for concrete.

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IS: 9417 Recommendations for welding cold worked steel bars for
reinforced concrete construction.

IS: 10262 Recommended guidelines for concrete mix design.

IS: 11384 Code of practice for composite construction in structural steel and
concrete.

IS: 11504 Criteria for structural design of reinforced concrete natural draught
cooling towers.

IS: 12118 Specification for two-parts poly sulphide.

IS: 12200 Code of practice for provision of water stops at transverse

contraction joints in masonry and concrete dams.

IS: 13311 Method of non-destructive testing of concrete.

Part-1 Ultrasonic pulse velocity.
Part-2 Rebound hammer.

SP:23 Handbook of concrete mixes

SP: 24 Explanatory Handbook on IS: 456-1978

SP: 34 Handbook on concrete reinforcement and detailing.

Precast Concrete Works

SP: 7(PartVI/ National Building Code- Structural design of

prefabrication and Sec.7) systems building.

IS: 10297 Code of practice for design and construction of floors and roofs
using precast reinforced/prestressed concrete ribbed or cored
slab units.

IS: 10505 Code of practice for construction of floors and roofs using pre-cast
reinforced concrete units.

Masonary and Allied Works

IS: 1905 Code of Practice for Structural Safety of Buildings-Masonry walls.

IS: 2212 Code of Practice for Brickwork.

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IS: 2250 Code of Practice for Preparation and use of Masonry Mortar.

SP: 20 Explanatory hand book on masonry code.

Sheeting Works

IS:277 Galvanised steel sheets (plain or corrugated).

IS: 459 Unreinforced corrugated and semi-corrugated asbestos cement

sheets.

IS: 513 Cold-rolled carbon steel sheets.

IS: 730 Specification for fixing accessories for corrugated sheet

roofing.

IS: 1626 Specification for Asbestos cement building pipes and pipe
fittings, gutters and gutter fittings and roofing fittings.

IS: 2527 Code of practice for fixing rain water gutters and down pipe for
roof drainage.

IS: 3007 Code of practice for laying of asbestos cement sheets.

IS: 5913 Methods of test for asbestos cement products.

IS: 7178 Technical supply conditions for tapping screw.

IS: 8183 Bonded mineral wool.

IS: 8869 Washers for corrugated sheet roofing.

IS: 12093 Code of practice for laying and fixing of sloped roof covering using
plain and corrugated galvanised steel sheets.

IS: 12866 Plastic translucent sheets made from thermosetting polyster resin
(glass fibre reinforced).

IS: 14246 Specification for continuously pre-painted galvanised steel sheets

and coils.

Fabrication and Erection of Structural Steel Work

IS: 2016 Specification for plain washers.

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IS: 814 Specification for covered Electrodes for Metal Arc Welding for
weld steel.

IS: 1852 Specification for Rolling and Cutting Tolerances for Hot rolled
steel products.

IS: 3502 Specifications for chequered plate.

IS: 6911 Specification for stainless steel plate, sheet and strip.

IS: 3757 Specification for high strength structural bolts

IS: 6623 Specification for high strength structural nuts.

IS: 6649 High Tensile friction grip washers.

IS: 800 Code of practice for use of structural steel in general building
construction.

IS: 816 Code of practice for use of Metal Arc Welding for General
Construction.

IS: 4000 Code of practice for assembly of structural joints using high
tensile friction grip fasteners.

IS: 9595 Code of procedure of Manual Metal Arc Welding of Mild Steel.

IS: 817 Code of practice for Training and Testing of Metal Arc Welders.

IS: 1811 Qualifying tests for Metal Arc Welders (engaged in welding
structures other than pipes).

IS: 9178 Criteria for Design of steel bins for storage of Bulk Materials.

IS: 9006 Recommended Practice for Welding of Clad Steel.

IS: 7215 Tolerances for fabrication steel structures.

IS: 12843 Tolerance for erection of structural steel.

IS: 4353 Recommendations for submerged arc welding of mild steel and
low alloy steels.

SP: 6 ISI Hand book for structural Engineers.

(Part 1 to 7)

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IS: 1608 Method of Tensile Testing of Steel products other than sheets,
strip, wire and tube.

IS: 1599 Method of Bend Tests for Steel products other than sheet, strip,
wire and tube

IS : 228 Methods of chemical Analysis of pig iron, cast iron and plain
carbon and low alloy steel.

IS : 2595 Code of Practice for Radio graphic testing.

IS : 1182 Recommended practice for Radiographic Examination of fusion

welded butt joints in steel plates.

IS : 3664 Code of practice for Ultra sonic Testing by pulse echo method.

IS : 3613 Acceptance tests for wire flux combination for submerged Arc
Welding.

IS : 3658 Code of practice for Liquid penetrant Flaw Detection.

IS : 5334 Code of practice for Magnetic Particle Flaw Detection of Welds.

Plastering and Allied Works

IS : 1635 Code of practice for field slaking of Building lime and preparation
of putty.

IS : 1661 Application of cement and cement lime plaster finishes.

IS : 2333 Plaster-of-paris.

IS : 2402 Code of practice for external rendered finishes.

IS : 2547 Gypsum building plaster.
IS : 3150 Hexagonal wire netting for general purpose.

Acid and Alkali Resistant Lining

IS : 158 Ready mixed paint, brushing, bituminous, black, lead free, acid,
alkali & heat resisting.

IS : 412 Specification for expanded metal steel sheets for general

purpose.

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IS : 4441 Code of practice for use of silicate type chemical resistant

mortars.

IS : 4443 Code of practice for use of resin type chemical resistant

mortars.

IS : 4456 Method of test for chemical resistant tiles.

(Part I & II)

IS : 4457 Specification for ceramic unglazed vitreous acid resistant tiles.

IS : 4832 Specification for chemical resistant mortars.

Part I Silicate type

Part II Resin type

Part III Sulphur type

IS : 4860 Specification for acid resistant bricks.

IS : 9510 Specification for bitumasitc, Acid resisting grade.

Water Supply, Drainage and Sanitation

IS : 458 Specification for concrete pipes.

IS : 554 Dimensions for pipe threads, where pressure tight joints are made
on thread.

IS : 651 Specification for salt glazed stoneware pipes.

IS : 774 Flushing cisterns for water closets and urinals.

IS : 775 Cast iron brackets and supports for wash basins and sinks.

IS : 778 Copper alloy gate, globe and check valves for water works
purposes.

IS : 781 Cast copper alloy screw down bib taps and stop valves for water
services.

IS : 782 Caulking lead.

IS : 783 Code of practice for laying of concrete pipes.

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IS : 1172 Basic requirements for water supply, drainage and sanitation.

IS : 1230 Cast iron rain water pipes and fittings.

IS : 1239 Mild steel tubes, tubulars and other wrought steel fittings.

IS : 1536 Centrifugally cast (Spun) iron pressure pipes for water, gas and
sewage.

IS : 1537 Vertically cast iron pressure pipes for water, gas and sewage.

IS : 1538 Cast iron fittings for pressure pipe for water, gas and sewage.

IS : 1703 Ball valves (horizontal plunger type) including float for water
supply purposes.

IS : 1726 Cast iron manhole covers and frames.

IS : 1729 Sand cast iron spigot and socket, soil, water and ventilating pipes,
fittings and accessories.

IS : 1742 Code of practice for building drainage.

IS : 1795 Pillar taps for water supply purposes.

IS : 1879 Malleable cast iron pipe fittings.

IS : 2064 Code of practice for selection, installation and maintenance of

sanitary appliances.

IS : 2065 Code of practice for water supply in building.

IS : 2326 Automatic flushing cisterns for urinals.

IS : 2470 Code of practice for installation of septic tanks.

(Part-I & II)

IS : 2501 Copper tubes for general engineering purposes.

IS : 2548 Plastic seat and cover for water-closets.

IS : 2556 Vitreous sanitary appliances (vitreous china).

(Part 1 to 15)

IS : 2963 Non-ferrous waste fittings for wash basins and sinks.

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IS : 3114 Code of practice for laying of cast iron pipes.

IS : 3311 Waste plug and its accessories for sinks and wash basins.

IS : 3438 Silvered glass mirrors for general purposes.

IS : 3486 Cast iron spigot and socket drain pipes.

IS : 3589 Electrically welded steel pipes for water, gas and sewage
(200mm to 2000mm nominal diameter).

IS : 3989 Centrifugally cast (Spun) iron spigot and socket soil, waste and
ventilating pipes, fittings and accessories.

IS : 4111 Code of practice for ancillary structure in sewerage system.

(Part I to IV)

IS : 4127 Code of practice for laying of glazed stone-ware pipes.

IS : 4764 Tolerance limits for sewage effluents discharged into inland-

surface waters.

IS : 4827 Electro plated coating of nickel and chromium on copper and

copper alloys.

IS : 5329 Code of practice for sanitary pipe work above ground for
buildings.

IS : 5382 Rubber sealing rings for gas mains, water mains and sewers.

IS : 5822 Code of practice for laying of welded steel pipes for water
supply.

IS : 5961 Cast iron grating for drainage purpose.

IS : 7740 Code of practice for road gullies.

IS : 8931 Cast copper alloy fancy bib taps and stop valves for water
services.

IS : 8934 Cast copper alloy fancy pillar taps for water services.

IS : 9762 Polyethylene floats for ball valves.

IS : 10446 Glossary of terms for water supply and sanitation.

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IS : 10592 Industrial emergency showers, eye and face fountains and

combination units.

IS : 12592 Specification for precast concrete manhole covers and frames.

IS : 12701 Rotational moulded polyethylene water storage tanks.

SP: 35 Hand book on water supply and drainage.

- Manual on Sewerage and sewage treatment (Published by CPH &
EEO) As updated.

Doors, Windows and Allied Works

IS : 204 Tower Bolts

Part-I Ferrous metals.

Part-II Nonferrous metals.

IS : 208 Door Handles.

IS : 281 Mild steel sliding door bolts for use with padlocks.

IS : 362 Parliament Hinges.

IS : 420 Specification for putty, for use on metal frames.

IS : 1003 Specification for timber panelled and glazed shutters-

Part-I door (Part-I) shutters.

IS : 1038 Steel doors, windows and ventilators.

IS : 1081 Code of practice for fixing and glazing of metal (steel and
aluminium) doors, windows and ventilators.

IS : 1341 Steel butt hinges.

IS : 1361 Steel windows for industrial buildings.

IS : 1823 Floor door stoppers.

IS : 1868 Anodic coatings on Aluminium and its alloys.

IS : 2202 Specification for wooden flush door shutters (solid core type);
(Part-II) particle board face panels and hard board face panels

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IS:2209 Mortice locks (vertical type).

IS:2553 Safety glass

IS:2835 Flat transparent sheet glass.

IS:3548 Code of practice for glazing in buildings.

IS:3564 Door closers (Hydraulically regulated).

IS : 3614 Fire check doors; plate, metal covered and rolling type.

IS:4351 Steel door frames.

IS:5187 Flush bolts.

IS:5437 Wired and figured glass

IS:6248 Metal rolling shutters and rolling grills.

IS:6315 Floor springs (hydraulically regulated) for heavy doors.

IS:7196 Hold fasts.

IS:7452 Hot rolled steel sections for doors, windows and ventilators.

IS:10019 Mild steel stays and fasteners.

IS:10451 Steel sliding shutters (top hung type).

IS:10521 Collapsible gates.

R oof Water Proofing and AlliedWorks

IS:1203 Methods of testing tar and bitumen.

IS:1322 Specification for bitumen felts for water proofing and damp
proofing.

IS:1346 Code of practice for water proofing of roofs with bitumen felts.

IS:1580 Specification for bituminous compound for water proofing and

caulking purposes.

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IS:3067 Code of practice for general design details and preparatory work
for damp proofing and water proofing of buildings.

IS:3384 Specification for bitumen primer for use in water proofing and
damp proofing.

Floor Finishes and Allied Works

IS:1237 Specification for cement concrete flooring tiles.

IS:1443 Code of practice for laying and finishing of cement concrete

flooring tiles.

IS:2114 Code of practice for laying in-situ terrazzo floor finish.

IS:2571 Code of practice for laying in-situ cement concrete flooring.

IS:3462 Specification for unbacked flexible PVC flooring.

IS:4971 Recommendations for selection of industrial floor finishes.

IS:5318 Code of practice for laying of flexible PVC sheet and tile
flooring.

IS:8042 Specification for white portland cement.

IS:13801 Specification for chequered cement concrete flooring tiles.

Painting and Allied Works

IS:162 Specification for fire resisting silicate type, brushing, for use on
wood, colour as required.

IS:1477 Code of practice for painting of ferrous metals in buildings.

Part-I Pretreatment.
Part-II Painting.

IS:1650 Specification for colours for building and decorative finishes.

IS:2074 Specification for red oxide-zinc chrome, priming, ready mixed

paint air drying.

IS:2338 Code of practice for finishing of wood and wood based

materials.
Part-I Operations and workmanship

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Part-II Schedules

IS:2395 Code of practice for painting concrete, masonry and plaster

surfaces.
Part-I Operations and workmanship.
Part-II Schedule.

IS:2524 Code of practice for painting of nonferrous metals in buildings.

Part-I Pretreatment.

Part-II Painting.

IS:2932 Specification of synthetic enamel paint, exterior, under-coating

and finishing.

IS:2933 Specification enamel paint, under coating and finishing.

IS:4759 Code of practice for hot dip zinc coating on structural steel and
other allied products.
IS:5410 Specification for cement paint
IS:5411 Specification for plastic emulsion paint-for exterior use
(Part-I)
IS:6278 Code of practices for white washing and colour washing.
IS:10403 Glossary of terms relating to building finishes.
Piling and Foundation
IS:1080 Code of practice for design and construction of simple spread
foundations.
IS:1904 Code of practice for design and construction of foundations in
Soils; General Requirements.
IS:2911 Code of practice for designs and construction of Pile
foundations (Relevant Parts).
IS:2950 Code of practice for designs and construction of Raft
(Part-I) foundation.
IS:2974 Code of practice for design and construction of machine
(Part-I TO V) foundations.
IS:6403 Code of practice for determination of Allowable Bearing
pressure on Shallow foundation.

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IS:8009 Code of practice for calculation of settlement of foundation

subjected to symmetrical vertical loads.
Part-I Shallow foundations.
Part-II Deep foundations.
IS:12070 Code of practice for design and construction of shallow
foundations on rocks.
DIN:4024 Flexible supporting structures for machines with rotating
machines.
VDI:2056 Criteria for assessing mechanical vibrations of machines.
VDI:2060 Criteria for assessing rotating imbalances in machines.
Stop Log and Trash Rack
IS:4622 Recommendations for fixed - wheel gates structural design.
IS:5620 Recommendations for structural design criteria for low head slide
gates.
IS:11388 Recommendations for design of trash rack for intakes.
IS:11855 General requirements for rubber seals for hydraulic gates.
Roads
IRC:5 Standard specifications and Code of practice for road bridges,
section-I general Features of Design.
IRC:14 Recommended practice of 2cm thick bitumen and tar carpets.
IRC:16 Specification for priming of base course with bituminous
primers.
IRC:19 Standard specifications and code of practice for water bound
macadam.
IRC:21 Standard specifications and Code of practice for road bridges,
section-III - Cement concrete (plain and reinforced).
IRC:34 Recommendations for road construction in waterlogged areas.
IRC:36 Recommended practice for the construction of earth
embankments for road works.
IRC:37 Guidelines for the Design of flexible pavements.
IRC:56 Recommended practice for treatment of embankment slopes for
erosion control.
IRC:73 Geometric design standards for rural (non-urban) highways.
IRC:86 Geometric Design standards for urban roads in plains.

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IRC:SP:13 Guidelines for the design of small bridges & culverts.

IRC - Public- Ministry of Surface Transport (Roads Wing), Specifications
ation for road and bridge works.
IS:73 Specification for paving bitumen
Loadings
IS:875 Code of practice for design loads other than earthquake) for
(Pt. I to V) buildings and structures.
IS:1893 Criteria for earthquake resistant design of structures.
IS:4091 Code of Practice for design and construction of foundation for
transmission line towers & poles.
IRC:6 Standard specifications & code of practice for road bridges,
Section-II Loads and stresses.
M.O.T. Deptt. of railways Bridge Rules.
Safety
IS:3696 Safety code for scaffolds and ladders.
(Part I & II)
IS:3764 Safety code for excavation work.
IS:4081 Safety code for blasting and related drilling operations.
IS:4130 Safety code for demolition of buildings.
IS:5121 Safety code for piling and other deep foundations.
IS:5916 Safety code for construction involving use of hot bituminous
materials.
IS:7205 Safety code for erection on structural steelwork.
IS:7293 Safety code for working with construction machinery.
IS:7969 Safety code for handling and storage of building materials

IS:11769 Guidelines for safe use of products containing asbestos.

- Indian Explosives Act. 1940 as updated.

Architectural design of buildings

SP:7 National Building Code of India

SP:41 Hand book on functional requirements of buildings (other than

industrial buildings)

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Miscellaneous

IS:802 Code of practice for use of structural steel in

(Relevant parts) overhead transmission line towers.

IS:803 Code of practice for design, fabrication and erection of vertical

mild steel cylindrically welded in storage tanks.

IS:10430 Creteria for design of lined canals and liner for selection of type of
lining.

IS:11592 Code of practice for selection and design of belt conveyors.

IS:12867 PVC handrails covers.

CIRIA Design and construction of buried thin-wall pipes.

Publication

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Page 146 of 338

 ANNEXURE-I
MANUFACTURER’S NAME AND
ADDRESS MANUFACTURING QUALITY PLAN PROJECT :
ITEM : QP NO.: PACKAGE :
MFGR.’s REV.NO.:
LOGO CONTRACT NO. :
SUB-SYSTEM: DATE:
PAGE: …. OF…. MAIN-SUPPLIER:

SL. COMPONENT & CHARACTERISTICS CLASS TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO OPERATIONS CHECK OF CHECK DOCUMENT NORMS RECORD
M C/N M C N
1. 2. 3. 4. 5. 6. 7. 8. 9. D* ** 10. 11.

Page 147 of 338

LEGEND: * RECORDS, INDENTIFIED WITH “TICK” ( √ ) SHALL BE DOC. NO.: REV…… CAT…..
ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
** M: MANUFACTURER/SUB-SUPPLIER C: MAIN SUPPLIER, N: NTPC
P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE,
MANUFACTURER/ MAIN-SUPPLIER CHP: NTPC SHALL IDENTIFY IN COLUM “N” AS ‘ W” FOR
SUB-SUPPLIER NTPC
SIGNATURE USE REVIEWED BY APPROVED BY APPROVAL
SEAL
FORMAT NO.: QS-01-QAI-P-09/F1-R1 1/1 ENGG. DIV./QA&I

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FLUE GAS DESULPHURISATION (FGD) SECTION – VI GENERAL TECHNICAL REQUIREMENT
SYSTEM PACKAGE BID DOC. NO.:CS-0011-109(2)-9
 ANNEXURE-II
SUPPLIER’S NAME AND ADDRESS
FIELD QUALITY PLAN PROJECT :
ITEM : QP NO.: PACKAGE :
SUPPLIER’S REV. NO.:
LOGO SUB-SYSTEM: DATE: CONTRACT NO. :
PAGE: …. OF…. MAIN-SUPPLIER:

SL. ACTIVITY AND CHARACTERISTICS / INSTRUMENTS CLASS OF TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF REMARKS
NO OPERATION CHECK # CHECK OF CHECK DOCUMENT NORMS RECORD
1. 2. 3. 4. 5. 6. 7. 8. 9. D* 10.

Page 148 of 338

DOC. NO.: REV……
LEGEND: * RECORDS, INDENTIFIED WITH “TICK” (√) SHALL BE
ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
LEGEND TO BE USED: CLASS # : A = CRITICAL, B=MAJOR, C=MINOR;
‘A’ SHALL BE WITNESSED BY NTPC FQA, ‘B’ SHALL BE WITNESSED BY
MANUFACTURER/ MAIN-SUPPLIER NTPC ERECTION / CONSTRUCTION DEPTT. AND ‘C’ SHALL BE FOR
SUB-SUPPLIER WITNESSED BY MAIN SUPPLIER (A & B CHECK SHALL BE NTPC CHP NTPC
SIGNATURE STAGE) USE REVIEWED BY APPROVED BY APPROVAL SEAL
FORMAT NO.: QS-01-QAI-P-09/F2-R1 1/1 ENGG. DIV./QA&I

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FLUE GAS DESULPHURISATION (FGD) SECTION – VI GENERAL TECHNICAL REQUIREMENT
SYSTEM PACKAGE BID DOC. NO.:CS-0011-109(2)-9
 ANNEXURE-III
Project : Stage : LIST OF ITEMS REQUIRING QUALITY PLAN DOC. NO.:
Package : AND SUB-SUPPLIER APPROVAL REV. NO.:
Supplier : DATE :
Contractor No. : SUB-SYSTEM : PAGE : OF
Item QP/ QP No. QP Sub. QP Proposed sub- Place Sub- Sub- Remarks
S. Insp. Schedul approval supplier suppliers supplier
N. Cat. e schedule approval Details
status / submissi
category on
schedule

Page 149 of 338

LEGENDS
SYSTEM SUPPLIER/SUB-SUPPLIER APPROVAL STATUS CATEGORY (SHALL BE FILLED BY NTPC)
A – For these items proposed vendor is acceptable to NTPC. To be indicated with letter “A” in the list alongwith the condition of approval, if any.
DR – For these items “Detailed required” for NTPC review. To be identified with letter “DR” in the list.
NOTED – For these items vendors are approved by Main Supplier and accepted by NTPC without specific vendor approval from NTPC. To be identified with “NOTED.’
QP/INSPN CATEGORY:
CAT-I : For these items the Quality Plans are approved by NTPC and the final acceptance will be on physical inspection witness by NTPC.
CAT-II : For these items the Quality Plans approved by NTPC. However no physical inspection shall be done by NTPC. The final acceptance by NTPC shall be on the basis review of documents as per
approved QP.
CAT-III : For these items Main Supplier approves the Quality Plans. The final acceptance by NTPC shall be on the basis certificate of conformance by the main supplier.
UNITS/WORKS : Place of manufacturing Place of Main Supplier of multi units/works.

FORMAT NO.: QS-01-QAI-P-1/F3-R0 1/1 Engg. Div. / QA&I

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FLUE GAS DESULPHURISATION (FGD) SECTION – VI GENERAL TECHNICAL REQUIREMENT
SYSTEM PACKAGE BID DOC. NO.:CS-0011-109(2)-9
 ANNEXURE-IV
Project : Stage : STATUS OF ITEM REQUIRING QP& DOC. NO.:
Package : SUB-SUPPLIER APPROVAL REV. NO.:
Contractor : DATE :
Contractor No. : PAGE : OF
Item / Service QP/ QP Sub. Date Date Status Proposed Sub-suppliers Place of Approva Sub- Remarks
S. N. Insp. Schedule of of Code manufacturing l Status supplier
Cat. Approval sub- comm C/II/I works detail
schedule missio t Appl. submissio
n n schedule

Page 150 of 338

FORMAT 1/1 Engg. Div. / QA&I

LOT-IA PROJECTS TECHNICAL SPECIFICATION GENERAL TECHNICAL PAGE 79 OF 83

STEAM GENERATOR ISLAND PACKAGE SECTION – VI, PART-C REQUIREMENT
BID DOC.NO.:CS-0011-109(1A)-2
 ANNEXURE-V
Project : Stage : FIELD WELDING SCHEDULE DOC. NO.:
Contractor : (To be raised by the contractor) REV. NO.:
Contractor No. : Welding Code: ……………………………………… DATE :
System : PAGE : OF
DRG No. for Weld Descripti Matl. Dimensio Process Type of Electrode WPS. Min. Heat treatment NDT REF Remarks
Sl. Location and on of Spec. ns of welding Weld filler spec. No. pre- method/
No. Identification mark parts to heat Temp. Holding Quantum Spec. ACC Norm
welded time No. Ref.

Page 151 of 338

NOTES:

SIGNATURE

FORMAT 1/1 Engg. Div. / QA&I

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FLUE GAS DESULPHURISATION (FGD) SYSTEM PACKAGE SECTION – VI, PART-C REQUIREMENT
BID DOC.NO.:CS-0011-109(1A)-2
CLAUSE NO.
GENERAL TECHNICAL REQUIREMENTS (Annexure-VI)

S.No Description of Drgs/Docs No

of No of CD
Prints
ROMs/DVDs/Portable
Hard Disk
1 Drawings, Data sheets, Design calculations, Purchase specifications and
other documents
First submission and
submission with major
changes
 Layout (A0&A1 sizes) 4 -

 Other
Drawings/Documents 2 -
(A0&A1 sizes)
 P&ID (All sizes) 4 -

a) Final drawings/documents 6 2
(Directly to site)
b) “As Built” 6 2
Drawing/Documents
(Directly to site)
c) Analysis reports of
Equipments / piping 2 2
/structures
components/system
employing software
packages as detailed in the
specifications.
2 Erection Manual (Directly to 4 sets 2
site)
3 Operation & Maintenance
manual 1 set --
i) First Submission

ii) Final Submission 4 sets 2

(Directly to site)
4 Plant Hand Book
i) First Submission 1 1

5 Commissioning and
Performance Test Procedure
manual 1 set --
i) First Submission

ii) Final Submission 4 sets 2

(Directly to site)

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Annexure-VI

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CLAUSE NO.
GENERAL TECHNICAL REQUIREMENTS (Annexure-VI)

S.No Description of Drgs/Docs No of No of CD

Prints ROMs/DVDs/Portable
Hard Disk
6 Performance and Functional
Guarantee Test Report
i) First Submission 2 sets --

ii) Approved Copies 4 sets 2

(Direct to Site)

7 Project Completion Report 6 sets 2

(Directly to site)
8 QA programme including Organisation 1 --
for implementation and QA system
manual(with revisions)
9 Vendor details in respect of proposed 2 --
vendors including contractor’s
evaluation report.
10 Manufacturing QPs, Field QPs, Field
welding schedules and their reference
document like test procedures, WPS,
POR etc

i) For review/comment 1 --

ii) Approved final copies of Field 4 2

QPs, Field welding schedules
and their reference document
like test procedures, WPS,
POR etc (Direct to Site)

11 Welding Manual, Heat Treatment

Manuals, Storage & preservation
manuals
i) For review/comment 1 set --

ii) Approved copies

(Direct to Site) 4 sets 2

12 QA Documentation Package for items 2 sets 2

/ equipment manufactured and
despatched to site
13 QA Documentation Package for field 2 sets 2
activities on equipment/systems at
site

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Annexure-VI

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CLAUSE NO.
ERECTION CONDITIONS OF CONTRACT

1.00.00 GENERAL

1.01.00 The following provisions shall supplement the conditions already contained in the
other parts of these specifications and documents and shall govern that portion of
the work of this contract which is to be performed at site. The erection requirements
and procedures not specified in these documents shall be in accordance with the
recommendations of the equipment manufacturer, or as mutually agreed to between
the Employer and the Contractor prior to commencement of erection work.

1.02.00 The Contractor upon signing of the Contract shall, in addition to a Project Co-
ordinator, nominate another responsible officer as his representative at Site suitably
designated for the purpose of overall responsibility and co-ordination of the Works to
be performed at Site. Such a person shall function from the Site office of the
Contractor during the pendency of Contract.

2.00.00 REGULATION OF LOCAL AUTHORITIES AND STATUTES

2.01.00 In addition to the local laws and regulations, the Contractor shall also comply with
the Minimum Wages Act and the Payment of Wages Act (both of the Government of
India) and the rules made there under in respect of its labour and the labour of its
sub-contractors currently employed on or connected with the contract.

2.02.00 All registration and statutory inspection fees, if any, in respect of his work pursuant
to this Contract shall be to the account of the Contractor. However, any registration,
statutory inspection fees lawfully pay-able under the provisions of the Indian Boiler
Regulations and any other statutory laws and its amendments from time to time
during erection in respect of the plant equipment ultimately to be owned by the
Employer, shall be to the account of the Employer. Should any such inspection or
registration need to be re-arranged due to the fault of the Contractor or his Sub-
Contractor, the additional fees for such inspection and/or registration shall be borne
by the Contractor.

3.00.00 WELDING OF PRESSURE PARTS AND HIGH PRESSURE PIPING

The welding of all pressure parts and high pressure piping shall be in accordance
with the following requirements:

3.01.00 Qualification of Weld Procedures

Only qualified welding procedures as per ASME Section IX shall be used by

contractor at site. Procedure qualification records along with WPS shall be submitted
to NTPC for review. Welding procedure shall indicate all essential and non-essential
parameters as per ASME Section IX. Makes of welding consumables shall be
subject to employer's approval.

3.02.00 Welder's Qualification

Only welders who are qualified in accordance with the latest applicable requirements
of the Indian Boiler Regulations, shall be permitted to perform any welding work on
the pressure parts and its attachment welding. In addition to such statutory
qualification requirements, the welders shall also undergo a satisfactory

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pre-production qualification test to be conducted by the Contractor at site as per

ASME Sec IX in presence of employer's representative(s), prior to performing work
under these specifications. The services of an independent testing laboratory shall
be retained by the Contractor to perform welder qualification tests for welders.

All the welders carrying out welding at site shall carry an identification badge, which
shall indicate the category and the grade of welding for which they have been tested
and authorised to carry out welding.

3.03.00 Records

Welders performance shall be monitored regularly and record of their performance

shall be maintained by contractor in a manner acceptable to the employer.
Contractor shall maintain such records including record of procedure qualification &
welder qualification and hand-over to the employer at the end of work.

3.04.00 MARKING

On completion of each welded joint, the welder shall mark his regularly assigned
identification mark near the joint. The welder's identification numbers, inspection
stamps or code symbol stamps and any other information shall not be directly
stamped on any alloy steel piping. In alloy steel piping, all such information shall be
stamped on separate marking plate which shall be tack welded on pipe near the
weld.

4.00.00 HEAT TREATMENT

4.01.00 Pre-heating, post-heating and post-weld stress relief operations of all welds, shall be
performed in accordance with the requirements of applicable code. Local post weld
stress relieving heat treatments shall be adopted only in cases where it is normally
impracticable to subject the entire assembly as such for stress relieving operations.
Heating may be by means of electric induction coils or electric resistance coils. Oxy-
acetylene flame heating or exothermic chemical heating methods will not be
permitted. Complete recording of the temperatures through out the stress relieving
cycle of the material and the weld subjected to heat treatment shall be made by
means of a potentiometric recorder. Recorders other than those of potentiometric
type shall not be used for such temperature recording during stress relieving
operations.

The contractor & employer's representative, at start and at the end of HT Cycle shall
sign the time and temperature charts for heat-treatment.

4.02.00 Not Used.

4.03.00 After setting up the weld joint for heat treatment operation, the Employer's signature
shall be obtained on the strips chart of the recorder prior to starting of heat treatment
cycle. The right hand corner of the strip chart at the starting point of the heat
treatment cycle shall contain details like the weld number, material, diameter and
thickness, method of heating adopted, prescribed ranges of heat treatment
temperatures, date of heat treatment, reference to item number of the Field welding
Schedule (as specified at clause no 7.00.00- of this chapter) etc.

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ERECTION CONDITIONS OF CONTRACT

5.00.00 WELD EDGE PREPARATION

Preparation at site of weld joint shall be in accordance with details acceptable to the
Employer. Wherever possible, machining or automatic flame cutting shall be used
for edge preparation. Hand flame cutting will be permitted only where edge
preparation otherwise is impractical. All slag shall be removed from cuts and all the
hand cuts shall be ground smooth to the satisfaction of the Employer. Flame cutting
of alloy steel pipe shall be avoided. Wherever such cutting is done, a 200mm length
at the cut face shall be removed by machining. Pneumatic hand tools such as edge
preparation, tube cutting machine can be used.

6.00.00 CLEANING AND SERVICING

6.01.00 The inside of all tubes, pipes, valves and fittings shall be free from dirt, and loose
scales before being erected. All the pipelines shall be thoroughly blown and/or
flushed. Each steam and water tubes shall be blown with compressed air and shall
be subjected to 'ball test' before erection to ensure that no obstructions exist. A
system for recording of all such operations shall be developed and maintained in a
manner to ensure that no obstructions are left inside the tubes and no tubes are left
uncleaned and untested.

6.02.00 All valves and valve actuators, and dampers and damper actuators, if any, shall be
thoroughly cleaned and serviced prior to pre-commissioning tests and/or Initial
Operations of the plant. A system for recording of such servicing operation shall be
developed and maintained in a manner acceptable to the Employer and to ensure
that no valves or dampers including their actuators are left unserviced.

6.03.00 All interior surfaces of the turbine shall be thoroughly cleaned prior to boxing - up to
remove all traces of oil preservations.

7.00.00 FIELD WELDING SCHEDULE

The Contractor shall submit to the Employer, a certified and complete field welding
schedule for all the field welding activities to be carried out in respect of the pressure
parts involved in the equipment furnished and erected by him, at least 90 days prior
to the scheduled start of erection work at site. Such schedule will be strictly followed
by the Contractor during the process of erection. The above field-welding schedule
to be issued by the Contractor shall contain the following:

(a.) Drawing No (s)

(b.) Location of the weld

(c.) Size of the weld (outside diameter and thickness)

(d.) Type of joints

(e.) Material specifications

(f.) Size of fillet on backing ring, when the type of joint is with backing ring
(g.) Electrode/ filler metal specifications

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(h.) Number of welds per unit

(i.) Quantity of filler metal per weld

(j.) Indication of required Non-destructive Examination (NDE) for each weld

(k.) Pre-heat temperatures for welding

(l.) Process of welding

(m.) Post-welding heat treatment temperature ranges, duration, under as

specified at clause no 4.00.00 of this chapter entitled "Heat Treatment".

(n.) Qualification details of weld procedures to be adopted as specified at clause

no 3.01.00 of this chapter entitled 'Qualification of Weld Procedures'.

8.00.00 SITE RUN MISCELLANEOUS PIPING

Sketches or diagrams of the proposed routings of all piping, not already indicated
and routed on the shop drawings which were reviewed by the Employer, shall be
submitted to the Employer for review, Employer's acceptance of such site routings
shall be obtained before the piping is erected. All these site run piping shall be
installed in such a manner as to present an orderly and neat installation. They shall
be located as to avoid obstruction of access and passages. Valves, instruments or
any other special items shall be located convenient for operation by the operating
personnel. Pipe runs shall be plumb or level except where pitch for drainage is
required. Pipe runs that are not parallel to the building structure, walls or column
rows shall be avoided so that deflection of pipes between hangers does not exceed
6 mm. No miscellaneous pipe shall be routed and installed above or adjacent to
electrical equipment.

9.00.00 THERMAL EXPANSIONS

All piping installation shall be such that no excessive or destructive expansion forces
exist either in the cold condition or under condition of maximum temperature. All
bends, expansion joints and any other special fittings, necessary to provide proper
expansion, shall be incorporated. During installation of expansion joints and
anchors, care must be taken to make sure that full design movement is available at
all times for maximum to minimum temperature and vice-versa.

10.00.00 PIPING SUPPORTS

10.01.00 Hangers, supports and anchors shall be installed as required to obtain a safe,
reliable and complete pipe installation. All supports shall be properly levelled and
anchored when installed. The anchors shall be so placed that thermal expansion will
be absorbed by bends without subjecting the valves or equipment to excessive
strains.

10.02.00 The hanger assemblies shall not be used for the attachment of rigging to hoist the
pipe into place. Other means shall be used to securely hold the pipe in place till the
pipe support is completely assembled and attached to the pipe and building

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CLAUSE NO.
ERECTION CONDITIONS OF CONTRACT

structures and spring support is set to accommodate the pipe way. All temporary
rigging shall be removed in such a way that the pipe support is not subjected to any
sudden load. All piping, having variable spring type supports, shall be held securely
in place by temporary means during the hydraulic test of pipe system. Constant
support type spring hangers used during hydraulic test shall be pinned or blocked
solid during the test. After complete installation and insulation of the piping and filling
of the piping with its normal operating medium, the pipe support springs shall be
adjusted to the cold positions. If necessary, the spring support shall be re-adjusted
to the hot positions after the line has been placed for service at its normal maximum
operating temperature conditions. Electric arc welding only shall be used to weld all
pipe supports to structural steel members that form part of the building supporting
structure. The structural beams shall not be heated more than necessary during
welding of supports and such welds shall run parallel to the axis of the span. All lugs
or any other attachments welded to the piping shall be of the same material as the
pipe.

11.00.00 PRESSURE TESTING

11.01.00 On completion of erection of pressure parts, a hydraulic test in accordance with the
requirements of the Indian Boiler Regulations shall be performed by the Contractor.

11.02.00 All the valves, high pressure pipes and inter-connected pipes connecting the
pressure parts shall be tested along with pressure parts. All blank flanges or any
removable plugs required for openings not closed by the valves, and piping
provided, shall be furnished by the Contractor. The pressurization equipment
including water piping from the supply, needed for the above test shall also be
furnished by the Contractor. Any defects noticed during the testing are to be rectified
and the unit re-tested. If any welding is done on the pressure parts after the
Hydraulic test, the Hydraulic test for that portion of pressure parts shall be repeated.
Water as required for such pressure testing shall be provided by the employer.

11.03.00 Thy hydraulic test shall be considered successful only on certification to that effect
by the concerned inspecting Authority as per the provisions of the Indian Boiler
Regulations and the Employer.

12.00.00 THERMOWELLS AND FLOW NOZZLES

12.01.00 All the thermowells and flow nozzles in the equipment furnished under the technical
specifications shall be installed as a part of this work.

12.02.00 All thermowell connections incorporated in the steam service shall be plugged during
the pressure testing and the blow out of steam piping systems. Upon completion of
the blow out operation, all thermowells shall be installed and seam welded. Similarly,
all flow nozzles in the steam lines shall also be installed only on completion of steam
blowing operations unless otherwise agreed to by the Employer, depending upon the
sequence of cleaning and purging operations to be adopted by the Contractor at the
field.

13.00.00 INSULATION, LAGGING AND CLADDING

The provision of insulation, lagging and cladding of the various equipments and
portion of the equipment covered under the Contract, shall be furnished by the

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ERECTION CONDITIONS OF CONTRACT

Contractor as specified elsewhere or agree to separately in writing. Welds required

for holding insulation on pressure parts shall be carried out by IBR qualified welder.

13.01.00 Piping, Pipe Fittings & Valves

All piping insulation and metal cladding furnished with the equipment to be erected
shall be applied as specified herein.

13.01.01 Piping

The insulation on piping shall be applied using wire loops on 150mm centres. These
wire loops shall be thoroughly embedded into the outer insulation surface and all
cracks, voids and depressions shall be filled with insulating cement suitable for the
piping temperature so as to form a smooth base for application of cladding. The
wires used for piping insulation shall be of 16 SWG. The surface shall be smooth
and uniform before applying the outer covering. All piping insulation ends shall be
terminated at a sufficient distance from flanges to facilitate removal of bolts.

13.01.02 Flanges

Insulation on flanges shall be by means of blocks of insulating material securely

bound to the flange by wire loops. Such blocks of insulation shall be long enough to
overlap the adjacent pipe insulation by an amount equal to the thickness of adjacent
pipe insulation. Smooth finish shall be obtained by the application of insulating
cement. Alternatively, sectional pipe insulation of proper diameter may be used.
Insulation on flanges shall not be done until the pipe and equipment have been in
service during the initial operation and till all the flange bolts have been retightened.

13.01.03 Bends and Elbows

Insulation on bends and elbows shall be cut into sections sufficiently short to form a
reasonable smooth external surface. After the application of insulation material in
place, it shall be smoothly coated with insulating cement. Elbows may be insulated
as above or alternatively by means of specially moulded insulation enclosures.

13.01.04 Cladding

Cladding shall be of aluminium sheet of thickness as per details given in detail

Technical Specification or will be provided during detail engineering shall be
machine rolled and formed to accurately fit insulation curvatures. Cladding shall be
secured using self-tapping screws. Screws shall be adequate number and so
located as to produce tight joints. The spacing of screws shall be as far as possible
uniform and on centres not exceeding 150 mm. For outside diameters less than 230
mm, spacing of screws shall be on centres not exceeding 100 mm. adequate
number of screws shall be provided for fixing the cladding and be so placed in such
locations, as to produce a smooth cladding finish without bellying'. Insulated elbows
having insulated diameters less than 330 mm shall be provided with preformed
smooth aluminium elbow jackets. Wherever possible, all joints should be lapped a
minimum of 50 mm with joints facing downwards and so placed that they are
obscured from normal points of vision. All the joints in the cladding shall be made
with suitable provisions for expansions. All butt joints such as those at piping tees

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ERECTION CONDITIONS OF CONTRACT

shall be made using rolled seams. In addition, to prevent galvanic corrosion, suitable
action, as specified at clause no 13.02.00 of this chapter, shall be taken.

13.01.05 Valves and Fittings

All valves and fittings (above valve size of 2 inches) installed in the steam pipelines
shall also be applied with insulation and furnished with suitably shaped boxes so as
to facilitate easy dismantling of the fittings. The insulation thickness for valves, valve
fittings etc., shall be same as that used on the line on which they are installed. All
voids shall be properly filled up with insulating material and as per the directions of
the Employer.

13.02.00 Protection of Equipment during Insulation Applications

All equipment and structures shall be suitably protected from damage while applying
insulation after completion of insulation. All equipment and structures shall be
thoroughly cleaned and remove insulating materials which might have fallen on
them.

14.00.00 CODE REQUIREMENTS

The erection requirements and procedures to be followed during the installation of

the equipment shall be in accordance with the relevant Indian Electricity Rules &
Codes, Indian Boiler Regulations, ASME codes and accepted good practices, the
Employer's Drawings and other applicable Indian recognised codes and laws and
regulations of the Government of India.

15.00.00 ELECTRICAL SAFETY REGULATIONS

15.01.00 In no circumstances will the Contractor interfere with fuses and electrical equipment
belonging to the other Contractor or Employer.

15.02.00 Before the Contractor connects any electrical appliances to any plug or socket
belonging to the other Contractor or Employer, he shall:

(a) Satisfy the Employer that the appliance is in good working condition.

(b) Inform the Employer of the maximum current rating,voltage and phase of the
appliances.

(c) Obtain permission of the Employer detailing the socket to which the
appliances may be connected.

The Employer will not grant permission to connect unitl he is satisfied that

(d) The appliance is in good condition and is fitted with suitable plug.

(e) The appliance is fitted with a suitable cable having two earth conductors, one
of which shall be an earthened metal sheath surrounding the cores.

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15.03.00 No electric cable in use by the other Contractor/Employer will be disturbed without
permission. No weight of any description will be imposed on any such cable and
ladder or similar equipment will rest against or to be attached with it.

15.04.00 No reapir work shall be carried out on any live equipment. The equipment must be
declared safe by the Employer and a permit to work issued before any work is
carried out.

15.05.00 The Contractor shall employ the necessary number of qualified, full time electricians
to maintain his temporary electrical installation.

16.00.00 REMOVAL OF MATERIAL

No material brought to the Site shall be removed from the Site by the Contractor
and/or his Sub-Contractors without the prior written approval of the Employer.

17.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES

The provisions of the clause entitled Inspection, Testing and Inspection Certificates
given in Part - C of the Technical Specification, shall also be applicable to the
erection portion of the Works. The Employer shall have the right to re-inspect any
equipment though previously inspected and approved by him at the Contractor's
works, before and after the same are erected at Site. If by the above inspection, the
Employer rejects any equipment, the Contractor shall make good for such rejections
either by replacement or modification/ repairs as may be necessary to the
satisfaction of the Employer. Such replacements will also include the replacements
or re-execution of such of those works of other Contractors and/or agencies, which
might have got damaged or affected by the replacements or re-work done to the
Contractor's work.

18.00.00 ACCESS TO SITE AND WORKS ON SITE

18.01.00 Suitable access to site and permission to work at the Site shall be accorded to the
Contractor by the Employer in reasonable time.

18.02.00 In the execution of the Works, no person other than the Contractor or his duly
appointed representative, Sub-Contractor and workmen, shall be allowed to do work
on the Site, except by the special permission, in writing by the Employer or his
representative.

19.00.00 CONTRACTOR'S SITE OFFICE ESTABLISHMENT

The Contractor shall establish a Office at the Site and keep posted an authorised
representative for the purpose of the Contract. Any written order or instruction of the
Employer or his duly authorised representative, shall be communicated to the said
authorised resident representative of the Contractor and the same shall be deemed
to have been communicated to the Contractor at his legal address.

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20.00.00 CO-OPERATION WITH OTHER CONTRACTORS

20.01.00 Employer, who may be performing other works on behalf of the Employer and the
workmen who may be employed by the Employer and doing work in the vicinity of
the works under the Contract. The Contractor shall also arrange to perform his work
as to minimise, to the maximum extent possible, interference with the work of other
Contracts and their workmen. Any injury or damage that may be sustained by the
employees of the other Contractors and the Employer, due to the Contractor's work
shall promptly be made good at his own expense. The Employer shall determine the
resolution of any difference or conflict that may arise between the Contractor and
other Contractors or between the Contractor and the workmen of the Employer in
regard to their work. If the work of the Contractor is delayed because of the any acts
of omission of another Contractor, the Contractor shall have no claim against the
Employer on that account other than an extension of time for completing his works.
Employer shall have full access to visit the contractor's site at any time for inspection
and surveillance checks.

20.02.00 The Employer shall be notified promptly by the Contractor of any defects in the other
Contractor's works that could affect the Contractor's Works. The Employer shall
determine the corrective measures if any, required to rectify this situation after
inspection of the works and such decisions by the Employer shall be binding on the
Contractor.

21.00.00 DISCIPLINE OF WORKMEN

The Contractor shall adhere to the disciplinary procedure set by the Employer in
respect of his employees and workmen at Site. The Employer shall be at liberty to
object to the presence of any representative or employee of the Contractor at the
Site, if in the opinion of the Employer such employee has misconducted himself or is
incompetent, negligent or otherwise undesirable then the Contractor shall remove
such a person objected to and provide in his place a competent replacement.

22.00.00 CONTRACTOR'S FIELD OPERATION

22.01.00 The Contractor shall keep the Employer informed in advance regarding his field
activity plans and schedules for carrying out each part of the works. Any review of
such plan or schedule or method of work by the Employer shall not relieve the
Contractor of any of his responsibilities towards the field activities. Such reviews
shall also not be considered as an assumption of any risk or liability by the Employer
or any of his representatives and no claim of the Contractor will be entertained
because of the failure or inefficiency of any such plan or schedule or method of work
reviewed. The Contractor shall be solely responsible for the safety, adequacy and
efficiency of plant and equipment and his erection methods.

22.02.00 The Contractor shall have the complete responsibility for the conditions of the Work-
Site including the safety of all persons employed by him or his Sub-Contractor and
all the properties under his custody during the performance of the work. This
requirement shall apply continuously till the completion of the Contract and shall not
be limited to normal working hours. The construction review by the Employer is not
intended to include review of Contractor's safety measures in, on or near the Work-
Site, and their adequacy or otherwise.

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23.00.00 PHOTOGRAPHS AND PROGRESS REPORT

23.01.00 The Contractor shall furnish three (3) prints each to the Employer of progress
photographs of the work done at Site. Photographs shall be taken as and when
indicated by the Employer or his representative. Photographs shall be adequate in
size and number to indicate various stages of erection. Each photograph shall
contain the date, the name of the Contractor and the title of the photograph.

23.02.00 The above photographs shall accompany the monthly progress report detailing out
the progress achieved on all erection activities as compared to the schedules. The
report shall also indicate the reasons for the variance between the scheduled and
actual progress and the action proposed for corrective measures, wherever
necessary.

23.03.00 The Contractor shall submit the progress of work in soft and hard form (as decided
by employer) quarterly highlighting the progress and constraints at site.

24.00.00 MAN-POWER REPORT

24.01.00 The Contractor shall submit to the Employer, on the first day of every month, a man
hour schedule for the month, detailing the man hours scheduled for the month, skill-
wise and area-wise.

24.02.00 The Contractor shall also submit to the Employer on the first day of every month, a
man power report of the previous month detailing the number of persons scheduled
to have been employed and actually employed, skill- wise and the areas of
employment of such labour.

25.00.00 PROTECTION OF WORK

The Contractor shall have total responsibility for protecting his works till it is finally
taken over by the Employer. No claim will be entertained by the Employer or the
representative of the Employer for any damage or loss to the Contractor's works and
the Contractor shall be responsible for complete restoration of the damaged works to
original conditions to comply with the specification and drawings. Should any such
damage to the Contractor's Works occur because of other party not being under his
supervision or control, the Contractor shall make his claim directly with the party
concerned. If disagreement or conflict or dispute develops between the Contractor
and the other party or parties concerned regarding the responsibility for damage to
the Contractor's Works the same shall be resolved as per the provisions of the as
specified at clause no 21.00.00 of this chapter entitled "Co-operation with other
Contractors." The Contractor shall not cause any delay in the repair of such
damaged Works because of any delay in the resolution of such disputes. The
Contractor shall proceed to repair the Work immediately and no cause thereof will be
assigned pending resolution of such disputes.

26.00.00 EMPLOYMENT OF LABOUR

26.01.00 In addition to all local laws and regulations pertaining to the employment of labour to
be complied with by the Contractor pursuant to GCC, the Contractor will be expected
to employ on the work only his regular skilled employees with experience of the

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particular work. No female labour shall be employed after darkness. No person

below the age of eighteen years shall be employed.

26.02.00 All travelling expenses including provisions of all necessary transport to and from
Site, lodging allowances and other payments to the Contractor's employees shall be
the sole responsibility of the Contractor.

26.03.00 The hours of work on the Site shall be decided by the Employer and the Contractor
shall adhere to it. Working hours will normally be eight (8) hours per day - Monday
through Saturday.

26.04.00 Contractor's employees shall wear identification badges while on work at Site.

26.05.00 In case the Employer becomes liable to pay any wages or dues to the labour or any
Government agency under any of the provisions of the Minimum Wages Act,
Workmen Compensation Act, Contact Labour Regulation Abolition Act or any other
law due to act of omission of the Contractor, the Employer may make such
payments and shall recover the same from the Contractor's Bills.

27.00.00 FACILITIES TO BE PROVIDED BY THE EMPLOYER

27.01.00 Electricity

Refer clause 1.14.00 (Construction Power) Sub-Section III-B, Part-A, Section VI of

Technical Specification.

27.02.00 Water

Contractor shall make all arrangements himself for the supply of construction water
as well as potable water for labour and other personnel at the worksite/colony.
However, drawl of construction/potable water from bore-well shall be permitted if
found suitable. Any statutory clearance required shall be obtained by the contractor.
Assistance, if required shall be provided by the owner.

27.03.00 Communication

The Employer will extend the telephone facilities, if available at Site, for purposes of
Contract. The Contractor shall be charged at actuals for such facilities.

27.04.00 Railway Siding

Railway siding shall be provided by owner (up to plant entry point) for coal
transportation to site. However the same may not be available to the bidder for
material/supplies transport etc. Bidder has to plan its own arrangement for
movement of ODC consignment to plant site.

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28.00.00 FACILITIES TO BE PROVIDED BY THE CONTRACTOR

28.01.00 Contractor's site office Establishment
The Contractor shall establish a site office at the site and keep posted an authorized
representative for the purpose of the contract, pursuant to GCC. The site office will
include one conference meeting room for site meetings between the Contractor and
the Employer.

28.02.00 Tools, tackles and scaffoldings

The Contractor shall provide all the construction equipments, tools, tackles and
scaffoldings required for pre-assembly, installation, testing, commissioning and
conducting Guarantee tests of the equipments covered under the Contract. He shall
submit a list of all such materials to the Employer before the commencement of pre-
assembly at Site. These tools and tackles shall not be removed from the Site without
the written permission of the Employer. The Contractor shall arrange Dozer, Hydra,
Cranes, Trailer, etc. for the purpose of fabrication, erection and commissioning.

28.03.00 Testing Equipment and Facilities:

The contractor shall provide the necessary testing, equipment and facilities.

28.04.00 Site laboratory for civil works:

Contractor shall provide and maintain a site laboratory for the testing of construction
material under the direction and general supervision of employer.

28.05.00 First-aid

28.05.01 The Contractor shall provide necessary first-aid facilities for all his employees,
representatives and workmen working at the Site. Enough number of Contractor's
personnel shall be trained in administering first-aid.
28.05.02 The Employer will provide the Contractor, in case of any emergency, the services of
an ambulance for transportation to the nearest hospital.

28.06.00 Cleanliness

28.06.01 The Contractor shall be responsible for keeping the entire area allotted to him clean
and free from rubbish, debris etc. during the period of Contract. The Contractor shall
employ enough number of special personnel to thoroughly clean his work-area at
least once in a day. All such rubbish and scrap material shall be stacked or disposed
in a place to be identified by the Employer. Materials and stores shall be so arranged
to permit easy cleaning of the area. In areas where equipment might drip oil and
cause damage to the floor surface, a suitable protective cover of a flame resistant,
oil proof sheet shall be provided to protect the floor from such damage.

28.06.02 Similarly the offices shall be kept clean and neat to the entire satisfaction of the
Employer. Proper sanitary arrangements shall be provided by the Contractor, in the
work-areas and office areas of the Contractor.

29.00.00 LINES AND GRADES

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All the Works shall be performed to the lines, grades and elevations indicated on the
drawings. The Contractor shall be responsible to locate and layout the Works.
Basic horizontal and vertical control points will be established and marked by the
Employer at Site at suitable points. These points shall be used as datum for the
works under the Contract. The Contractor shall inform the Employer well in advance
of the times and places at which he wishes to do work in the area allotted to him so
that suitable datum points may be established and checked by the Employer to
enable the Contractor to proceed with his works. Any work done without being
properly located may be removed and/or dismantled by the Employer at Contractor's
expense.

30.00.00 FIRE PROTECTION

30.01.00 The work procedures that are to be used during the erection shall be those which
minimise fire hazards to the extent practicable. Combustible materials, combustible
waste and rubbish shall be collected and removed from the Site at least once each
day. Fuels, oils and volatile or flammable materials shall be stored away from the
construction and equipment and materials storage areas in safe containers.
Untreated canvas, paper, plastic or other flammable flexible materials shall not at all
be used at Site for any other purpose unless otherwise specified. If any such
materials are received with the equipment at the Site, the same shall be removed
and replaced with acceptable material before moving into the construction or storage
area.

30.02.00 Similarly corrugated paper fabricated cartons etc. will not be permitted in the
construction area either for storage or for handling of materials. All such materials
used shall be of water proof and flame resistant type. All the other materials such as
working drawings, plans etc. which are combustible but are essential for the works to
be executed shall be protected against combustion resulting from welding sparks,
cutting flames and other similar fire sources.

30.03.00 All the Contractor's supervisory personnel and sufficient number of workers shall be
trained for fire-fighting and shall be assigned specific fire protection duties. Enough
of such trained personnel must be available at the Site during the entire period of the
Contract.

30.04.00 The Contractor shall provide enough fire protection equipment of the types and
number for the warehouses, office, temporary structures, labour colony area etc.
Access to such fire protection equipment, shall be easy and kept open at all time.

31.00.00 SECURITY

The Contractor shall have total responsibility for all equipment and materials in his
custody stores, loose, semi-assembled and/or erected by him at Site. The
Contractor shall make suitable security arrangements including employment of
security personnel to ensure the protection of all materials, equipment and works
from theft, fire, pilferage and any other damages and loss. All materials of the
Contractor shall enter and leave the Employer Site only with the written permission
of the Employer in the prescribed manner.

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32.00.00 CONTRACTOR'S AREA LIMITS

The Employer will mark-out the boundary limits of access roads, parking spaces,
storage and construction areas for the Contractor and the Contractor shall not
trespass the areas not so marked out for him. The Contractor shall be responsible to
ensure that none of his personnel move out of the areas marked out for his
operations. In case of such a need for the Contactor's personnel to work out of the
areas marked out for him the same shall be done only with the written permission of
the Employer.

33.00.00 CONTRACTOR'S CO-OPERATION WITH THE EMPLOYER

In case where the performance of the erection work by the Contractor affects the
operation of the system facilities of the Employer, such erection work of the
Contractor shall be scheduled to be performed only in the manner stipulated by the
Employer and the same shall be acceptable at all times to the Contractor. The
Employer may impose such restrictions on the facilities provided to the Contractor
such as electricity, etc. as he may think fit in the interest of the Employer and the
Contractor shall strictly adhere to such restrictions and co-operate with the
Employer. It will be the responsibility of the Contractor to provide all necessary
temporary instrumentation and other measuring devices required during start-up and
operation of the equipment systems which are erected by him. The Contractor shall
also be responsible for flushing and initial filling of all the oil and lubricants required
for the equipment furnished and installed by him, so as to make such equipment
ready for operation. The Contractor shall be responsible for supplying such flushing
oil and other lubricants unless otherwise specified elsewhere in documents and
specifications.

34.00.00 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES

34.01.00 GENERAL

34.01.01 The Contractor upon completion of installation of equipments and systems, shall
conduct pre-commissioning and commissioning activities, to make the
equipment/systems ready for safe, reliable and efficient operation on sustained
basis. All pre-commissioning/commissioning activities considered essential for such
readiness of the equipment/systems including those mutually agreed and included in
the Contractor’s quality assurance programme as well as those indicated in clauses
elsewhere in the technical specifications shall be performed by the contractor.

34.01.02 The pre-commissioning and commissioning activities including Guarantee/

demonstration/ acceptability tests, checks and trial operations of the
equipment/systems furnished and installed by the contractor shall be the
responsibility of the Contractor as detailed in relevant clauses in Technical
Specification. The Contractor shall provide, in addition, test instruments, calibrating
devices etc. and labour required for successful performance of these operations. If it
is anticipated that the above test may prolong for a long time, the Contractor's
workmen required for the above test shall always be present at site during such
operations.

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34.01.03 The following activities shall be carried out by the contractor, 18 month prior to
schedule date of commissioning of the equipment/systems installed by him.

(a.) The contractor shall furnish the organization chart of his operation and
commissioning engineers for the acceptance of employer. Adequate number
of operation and commissioning engineers shall be deployed by the
contractor to effectively meet the requirement of round the clock operation in
shifts also, till the plant is taken over by the employer.

(b.) The contractor shall submit the bio-data containing the details of experience
of his operation and commissioning engineers for the acceptance of
employer.

(c.) The contractor shall furnish the deployment schedule of his operation and
commissioning engineers for the acceptance of the employer.

(d.) Apart from above, contractor shall ensure deployment of sufficient

skilled/semi-skilled/unskilled manpower during pre-commissioning and
commissioning activities.

34.01.04 It shall be the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and initial
operation of the equipment/systems which are installed by him.

34.01.05 The Contractor shall also be responsible for flushing and initial filling of all oils and
lubricants required for the equipment furnished and installed by him so as to make
such equipment ready for operation. The Contractor shall be responsible for
supplying such flushing oil and other lubricants unless otherwise specified elsewhere
in these specifications and documents.

34.02.00 COMMISSIONING DOCUMENTATION

34.02.01 The contractor shall submit the commissioning documentation, comprising of

Standard checklists, pre-commissioning procedures, testing schedules,
commissioning schedules and commissioning networks for various
equipment/systems covered under the contract, for the approval of employer.

34.02.02 Standard checklist, as the name suggests, shall be a fairly general documents,
containing the list of all checks required to be carried out for similar and repetitive
type of equipment to ensure consistent and thorough checking. An indicative list of
such equipment is enclosed as Annexure I.

34.02.03 The testing schedule is a document, designed for safe and systematic
commissioning of individual equipment/sub-system (for example compressor etc.)
Commissioning schedule is a document envisaged for commissioning of a system
(for example Compressed Air system, Unit commissioning etc.). The
testing/Commissioning schedule shall have a standard format in order to maintain
consistency of presentation, content and reporting. A brief write up on the contents
of the Testing Schedule/Commissioning Schedule is enclosed as Annexure-II.

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34.02.04 The contractor shall submit the list of commissioning documentation to be submitted
by him, along with their submission schedule for various equipment/systems covered
under the contract, with in 6(six) month from the date of award of contract, for the
acceptance of employer.

34.02.05 The Contractor shall submit the commissioning documentation, for various
equipment/covered under the contract, for the approval of employer, at least 18
months before the scheduled date of commissioning of the equipment/systems.

34.03.00 COMMISSIONING ACTIVITIES

34.03.01 Upon completion of pre-commissioning activities/tests, the contractor shall initiate

commissioning of facilities. During commissioning the Contractor shall carry out
system checking and reliability trials on various parts of the facilities.

34.03.02 Contractor shall carry out the checks/tests at site to prove to the Employer that each
equipment of the supply complies with requirements stipulated and is installed in
accordance with requirements specified.

34.03.03 Before the plant is put into initial operation the Contractor shall be required to
conduct test to demonstrate to the Employer that each item of the plant is capable of
correctly performing the functions for which it was specified and its performance,
parameters etc. are as per the specified/approved values. These tests may be
conducted concurrently with those required under commissioning sequence.

34.03.04 The Contractor shall also demonstrate the performance of all C&I equipment, the
tests on main equipment of prior to that as the case may be.

34.03.05 Other tests shall be conducted, if required by the Employer, to establish that the
plant equipment are in accordance with requirements of the specifications.

34.03.06 The Contractor shall conduct all the commissioning tests and undertake
commissioning activities pertaining to all other auxiliaries and equipments including
all electrical and C&I equipment/systems not specifically brought out above but are
within the scope of work and facilities being supplied and installed by the Contractor
and follow the guidelines indicated above or elsewhere in these technical
specifications.

34.05.00 Initial Operation

Upon completion of system checking/Tests as above and as a part of commissioning

of facilities, complete plant/facilities shall be put on initial operation as stipulated in
General Technical Requirements.

35.00.00 MATERIALS HANDLING AND STORAGE

35.01.00 All the equipments furnished under the Contract and arriving at Site shall be
promptly received, unloaded and transported and stored in the storage spaces by
the Contractor.

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35.02.00 Contractor shall be responsible for examining all the shipment and notify the
Employer immediately of any damage, shortage, discrepancy etc. for the purpose of
Employer's information only. The Contractor shall submit to the Employer every
week a report detailing all the receipts during the week. However, the Contractor
shall be solely responsible for any shortages or damage in transit, handling and / or
in storage and erection of the equipment at Site. Any demurrage, wharfage and
other such charges claimed by the transporters, railways etc. shall be to the account
of the Contractor.

35.03.00 The Contractor shall maintain an accurate and exhaustive record detailing out the
list of all equipment received by him for the purpose of erection and keep such
record open for the inspection of the Employer.

35.04.00 All equipment shall be handled very carefully to prevent any damage or loss. No
bare wire ropes, slings, etc. shall be used for unloading and/or handling of the
equipment without the specific written permission of the Employer. The equipment
stored shall be properly protected to prevent damage either to the equipment or to
the floor where they are stored. The equipment from the store shall be moved to the
actual location at the appropriate time so as to avoid damage of such equipment at
Site.

35.05.00 All electrical panels, controls gear, motors and such other devices shall be properly
dried by heating before they are installed and energised. Motor bearings, slip rings,
commutators and other exposed parts shall be protected against moisture ingress
and corrosion during storage and periodically inspected. Heavy rotating parts in
assembled conditions shall be periodically rotated to prevent corrosion due to
prolonged storage.

35.06.00 All the electrical equipment such as motors, etc. shall be tested for insulation
resistance at least once in three months from the date of receipt till the date of
commissioning and a record of such measured insulation values maintained by the
Contractor. Such records shall be open for inspection by the Employer.

35.07.00 The Contractor shall ensure that all the packing materials and protection devices
used for the various equipments during transit and storage are removed before the
equipment are installed.

35.08.00 The consumables and other supplies likely to deteriorate due to storage must be
thoroughly protected and stored in a suitable manner to prevent damage or
deterioration in quality by storage.

35.09.00 All the materials stored in the open or dusty location must be covered with suitable
weatherproof and flame-proof covering material wherever applicable.

35.10.00 If the materials belonging to the Contractor are stored in areas other than those
earmarked for him, the Employer will have the right to get it moved to the area
earmarked for the Contractor at the Contractor's cost.

35.11.00 The Contractor shall be responsible for making suitable indoor storage facilities to
store all equipment which require indoor storage. Normally, all the electrical
equipments such as motors, control gear, generators, exciters and consumables like

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electrodes, lubricants etc. shall be stored in the closed storage space. The
Employer, in addition, may direct the Contractor to move certain other materials,
which in his opinion will require indoor storage, to indoor storage areas which the
Contractor shall strictly comply with.

36.00.00 CONSTRUCTION MANAGEMENT

36.01.00 The field activities of the Contractors working at Site, will be coordinated by the
Employer and the Employer decision shall be final in resolving any disputes or
conflicts between the Contractor and other Contractors and tradesmen of the
Employer regarding scheduling and co- ordination of work. Such decision by the
Employer shall not be a cause for extra compensation or extension of time for the
Contractor.

36.02.00 The Employer shall hold weekly meetings of all the Contractors working at Site, at a
time and place to be designated by the Employer. The Contractor shall attend such
meetings and take notes of discussions during the meeting and the decisions of the
Employer and shall strictly adhere to those decisions in performing his Works. In
addition to the above weekly meeting, the Employer may call for other meeting either
with individual Contractors or with selected number of Contractors and in such a
case the Contractor if called, will also attend such meetings.

36.03.00 Time is the essence of the Contract and the Contractor shall be responsible for
performance of his works in accordance with the specified construction schedule. If
at any time, the Contractor is falling behind the schedule, he shall take necessary
action to make good for such delays by increasing his work force or by working
overtime or otherwise accelerate the progress of the work to comply with the
schedule and shall communicate such actions in writing to the Employer, satisfying
that his action will compensate for the delay. The Contractor shall not be allowed
any extra compensation for such action.

36.04.00 The Employer shall however not be responsible for provision of additional labour
and/or materials or supply or any other services to the Contractor except for the co-
ordination work between various Contractors as set out earlier.

36.05.00 Site management during construction phase till handing over of plant

Bidder shall ensure that the plant site within the plant boundary is managed in a
coordinated and professional way all through the construction phase till handing over
of plant, ensuring safe, easy & unhindered working conditions and a healthy &
hygienic working environment at site. He shall ensure the following measures at site
while executing the project.

a) Proper housekeeping by systematic and proper disposal of earth from excavations

(separately for usable & surplus earth), muck (from pile bores or otherwise), wastes
(from dismantling of pile tops, concrete works etc), packing & insulation wastes,
steel scrap, cable wastes etc generated during construction / erection works.
Suitable disposal sites for each of above shall be identified in the layout and at site
in the beginning of the project itself. It shall be ensured that all agencies engaged by
the bidder follow the discipline to dispose off of earth spoils and wastes at the

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designated places. Preferably once in a week suitable time slot will be identified for
housekeeping by all agencies and suitable instructions shall be issued in this regard.
Bidder may engage a separate agency or identify a gang for collection of wastes
and disposal to designated places. Suitable arrangement / tieup will also be made
for periodic disposal of wastes/ scrap from the designated places.

b) All fabrication areas shall be suitably hard crusted to provide a water free and proper
working platforms. Suitable sheds preferably pre engineered structures to be
provided for paint shops, fabrication workshops etc for ensuring all weather work
conditions for onsite structural works. For the main plant and auxiliary buildings,
bidder should preferably plan the works in such a way that structural fabrication is
done in suppliers' offsite works / workshops and onsite fabrication works are avoided
/ kept minimum.

c) Suitable onsite maintenance workshop for day to day breakdown maintenance

heavy plant and equipment like batching plants, cranes, earth moving equipment,
poclains, welding equipment etc. The workshop shall have stock of frequently
needed spares and suitable repair facilities with experienced technicians/mechanics.
A central test laboratory equipped with test equipment for routine tests like tests on
soil, concrete, bricks, aggregates, welds etc with experienced staff shall be
established at the start of the project itself.

d) All office and covered store buildings of the bidder and its agencies shall be of
prefab/ pre-engineered / porta cabin construction. Shabby semi finished
constructions in brickwork/ GI / asbestos roof etc shall not be permitted.

e) First aid facilities and amenities like rest rooms, suitable pre engineered toilets (
separate for men and women), drinking water fountains/tanks, canteen, crèche for
women workers shall be planned and established at the beginning of the project
itself. These facilities shall be located distributed over the plant area to enable easy
access by the construction workers and staff and shall be marked on the plant
layout. Suitable treatment for toilet discharge, like bio digesters etc shall be planned
and conventional septic tanks / soak pits etc shall be avoided.

f) Proper lighting of all construction / erection areas. Bidder shall erect adequate
number of high lighting masts in main plant, offsite, office and store areas for lighting
during night. DG sets of adequate capacity shall be provided for emergency backup.
The street lighting along the roads shall also be priortised along with road
construction. The construction power ring main shall be planned and erected
immediately after the award.

g) Well planned and coordinated storage and movement of plant, equipment and
construction materials. System wise / agency wise storage / laydown areas shall be
planned and marked on the plant layout at the beginning itself. Bidder shall ensure
that all its agencies comply to the areas allocated to them and follow the designated
storage and movement plans. Adequate covered storage shall be constructed for
storage of critical equipments like switchgears, MCCs, insulation etc.

h) Proper access control for construction workers, staff and visitors. Bidder shall ensure
that suitable electronic based gate pass system is in place from start of project itself

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to keep record and track of all workers, staff and visitors entering/exiting the plant
premises shift wise on daily basis.

i) Compliance to all safety requirements as specified elsewhere in the tender

documents. Bidders shall establish a safety centre at the start of the project itself. It
shall have a 24X7 manned safety control room in addition to a permanent safety
equipment display room, separate training / lecture hall with AV facilities for safety
training, store room with adequate stock of specified safety equipment, a first aid
room and other amenities. Bidder shall install CCTV cameras at all strategic
locations in the plant area which shall be linked to the safety control room.

j) Compliance to all environment and other conditions stipulated by the concerned

statutory authorities while according clearance / NOC to the project. Bidder shall
ensure adequate sprinkling of water by deploying water tankers to prevent the
fugitive dust nuisance during construction.

k) Development of suitable landscape & green belt areas and rainwater harvesting
within the plant premises. Bidder shall plan to develop the landscape & green belt
areas and rainwater harvesting from the start of the project itself. The landscape and
rainwater harvesting plan shall be finalized immediately after award of work and
suitable work plan with priority and schedule shall also be finalized thereafter. Top
soil before excavation shall be suitably preserved and stacked for landscape and
green belt development.

l) Provision of adequate shelters, water supply, sanitation and lighting in construction

workers and staff camps. No camps for workers and staff shall be permitted within
the plant premises and Bidder shall make separate arrangement outside the plant
premises for locating and development of camps for construction workers and staff.
The designated areas shall be suitably developed with infrastructure like roads,
drains, water supply and sewerage and shall be free from water logging. Suitable
low cost shelters will be provided for the workers. Complete area shall be secured by
fencing and shall be provided adequate area lighting. Suitable waste disposal,
shopping and recreation facilities will be developed in these camps.

Contractor shall ensure that due importance is given to site management as

discussed above and a detailed work plan considering the above aspects is finalized
immediately after the award. A senior level executive shall be identified who shall be
responsible for implementation of the work plan. Suitable format for progress
reporting on site management plan shall be developed and made part of the project
progress report. The progress on implementation of above work plan shall be
reviewed along with project progress in the monthly project review meetings with
owner. In case the progress on site management plan is unsatisfactory, Engineer-in
Charge may withhold upto 1% of the monthly running bill (for civil and site erection
works) till such time the required progress is demonstrated. Incase in the opinion of
Engineer-in-charge, bidder's actions on site management aspects is not adequate,
Engineer-in- charge may get the relevant work executed through a separate agency
and deduct the expenses incurred from Bidder's bill along with overheads @10 %.

37.00.00 FIELD OFFICE RECORDS

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The Contractor shall maintain at his Site Office up-to- date copies of all drawings,
specifications and other Contract Documents and any other supplementary data
complete with all the latest revisions thereto. The Contractor shall also maintain in
addition the continuous record of all changes to the above Contract Documents,
drawings, specifications, supplementary data, etc. effected at the field and on
completion of his total assignment under the Contract shall incorporate all such
changes on the drawings and other Engineering data to indicate as installed
conditions of the equipment furnished and erected under the Contract. Such
drawings and Engineering data shall be submitted to the Employer in required
number of copies.

38.00.00 CONTRACTOR'S MATERIALS BROUGHT ON TO SITE

38.01.00 The Contractor shall bring to Site all equipment, components, parts, materials,
including construction equipment, tools and tackles for the purpose of the Works
under intimation to the Employer. All such goods shall, from the time of their being
brought vest in the Employer, but may be used for the purpose of the Works only
and shall not on any account be removed or taken away by the Contractor without
the written permission of the Employer. The Contractor shall nevertheless be solely
liable and responsible for any loss or destruction thereof and damage thereto.

38.02.00 The Employer shall have a lien on such goods for any sum or sums which may at
any time be due or owing to him by the Contractor, under, in respect of or by
reasons of the Contract. After giving a fifteen (15) days notice in writing of his
intention to do so, the Employer shall be at liberty to sell and dispose off any such
goods, in such manner as he shall think fit including public auction or private treaty
and to apply the proceeds in or towards the satisfaction of such sum or sums due as
aforesaid.

38.03.00 After the completion of the Works, the Contractor shall remove from the Site under
the direction of the Employer the materials such as construction equipment, erection
tools and tackles, scaffolding etc. with the written permission of the Employer. If the
Contractor fails to remove such materials, within fifteen (15) days of issue of a notice
by the Employer to do so then the Employer shall have the liberty to dispose off such
materials as detailed under as specified at clause no 39.02.00 of this chapter and
credit the proceeds thereto to the account of the Contractor.

39.00.00 PROTECTION OF PROPERTY AND CONTRACTOR'S LIABILITY

39.01.00 The Contractor shall be responsible for any damage resulting from his operations.
He shall also be responsible for protection of all persons including members of
public and employees of the Employer and the employees of other Contractors and
Sub- Contractors and all public and private property including structures, building,
other plants and equipments and utilities either above or below the ground.

39.02.00 The Contractor will ensure provision of necessary safety equipment such as barriers,
sign - boards, warning lights and alarms, etc. to provide adequate protection to
persons and property. The Contractor shall be responsible to give reasonable notice
to the Employer and the Employers of public or private property and utilities when
such property and utilities are likely to get damaged or injured during the
performance of his Works and shall make all necessary arrangements with such

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Employers, related to removal and/or replacement or protection of such property and

utilities.

40.00.00 PAINTING

For painting refer Part-A, sub section-III, Section VI of Technical specification.

Painting for structures shall conform to the painting specification specified in Part-B
under Civil.

Painting for Electrical equipments/systems shall conform to the painting specification

given in Electrical portion of Part-A and Part-B of technical specifications.

41.00.00 INSURANCE

41.01.00 In addition to the conditions covered under the Clause entitled "Insurance" in Section
General Conditions of Contract (GCC), the following provisions will also apply to the
portion of works to be done beyond the Contractor's own or his Sub-Contractor's
manufacturing Works.

41.02.00 Workmen's Compensation Insurance

This insurance shall protect the Contractor against all claims applicable under the
Workmen's Compensation Act, 1948 (Government of India). This policy shall also
cover the Contractor against claims for injury, disability disease or death of his or his
Sub-Contractor's employees, which for any reason are not covered under the
Workmen’s Compensation Act, 1948. The liabilities shall not be less than the
following:

Workmen's Compensation - As per Statutory Provisions

Employee's Liability - As per Statutory Provisions

41.03.00 Comprehensive Automobile Insurance

This insurance shall be in such a form to protect the Contractor against all claims for
injuries, disability, disease and death to members of public including the Employer's
men and damage to the property of other arising from the use of motor vehicles
during on or off the Site operations, irrespective of the Ownership of such vehicles.
The liability covered shall be as herein indicated :

Fatal Injury : Rs.100,000 each person

: Rs.200,000 each occurrence
Property Damage : Rs.100,000 each occurrence

41.04.00 Comprehensive General Liability Insurance

41.04.01 The insurance shall protect the Contractor against all claims arising from injuries,
disabilities, disease or death of members of public or damage to property of others,

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due to any act or omission on the part of the Contractor, his agents, his employees,
his representatives and Sub-Contractors or from riots, strikes and civil commotion.
This insurance shall also cover all the liabilities of the Contractor arising out of the
Clause entitled "Defence of Suits" in Section General Conditions of Contract (GCC).

41.04.02 The hazards to be covered will pertain to all the Works and areas where the
Contractor, his Sub-Contractors, his agents and his employees have to perform work
pursuant to the Contract.

41.05.00 The above are only illustrative list of insurance covers normally required and it will
be the responsibility of the Contractor to maintain all necessary insurance coverage
to the extent both in time and amount to take care of all his liabilities either direct or
indirect, in pursuance of the Contract.

42.00.00 UNFAVOURABLE WORKING CONDITIONS

The Contractor shall confine all his field operations to those works which can be
performed without subjecting the equipment and materials to adverse effects during
inclement weather conditions, like monsoon, storms, etc. and during other
unfavourable construction conditions. No field activities shall be performed by the
Contractor under conditions which might adversely affect the quality and efficiency
thereof, unless special precautions or measures are taken by the Contractor in a
proper and satisfactory manner in the performance of such Works and with the
concurrence of the Employer. Such unfavourable construction conditions will in no
way relieve the Contractor of his responsibility to perform the Works as per the
schedule.

43.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS

The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc.
which he may come across during the course of performance of his Works either
during excavation or elsewhere, are properly protected and handed over to the
Employer. Similarly the Contractor shall ensure that the bench marks, reference
points, etc., which are marked either with the help of Employer or by the Employer
shall not be disturbed in any way during the performance of his Works. If, any work
is to be preformed which disturb such reference, the same shall be done only after
these are transferred to other suitable locations under the direction of the Employer.
The Contractor shall provide all necessary materials and assistance for such
relocation of reference points etc.

44.00.00 WORK & SAFETY REGULATIONS

44.01.00 General

i) The contractor shall comply with all the requirements of "The Building and
Other Construction Workers (Regulation of Employment & Conditions of
Service) Act," 1996 and its Central Rule 1998 / State Rules and any other
statutory requirements as applicable.

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ii) The Contractor shall follow NTPC Safety Rules as issued from time to time
with respect to safety in construction & erection.

iii) The contractor shall have the approved Safety, Health and Environment
(SHE) Policy in respect of Safety and health of Building Workers and it shall
be circulated widely and displayed at conspicuous place in Hindi and local
language understood by the majority of the workers. A copy of the safety
policy should be submitted to Engineer in charge.

iv) The contractor shall submit the safety plan comprising of methods to
implement the Safety Policy/ Rules, Risk assessment and ensuring Safety at
work areas, Safety audits, inspections and its compliance, Supervision and
responsibility to ensure Safety at various levels, Safety training to
employees, review of Safety and accident analysis, ensure Health and Safety
Procedures to prevent accidents to Engineer I/c for approval as per the
format of Safety plan as annexed at Annexure - III.

v) The Contractors shall ensure proper safety of all the workmen, materials,
plant and equipment belonging to him or to the Employer or to others,
working at the Site.

vi) All equipments used in construction and erection by the contractor shall meet
BIS / International Standards and where such standards do not exist, the
Contractor shall ensure these to be absolutely safe. All equipments shall be
strictly operated and maintained by the contractor in accordance with
manufacturer's operation manual. The contractor should also follow
Guidelines / Rules of the Employer in this regard.

vii) The Contractors shall provide suitable latest Personal Protective Equipments
of prescribed standard to all their employees and workmen according to the
need. The Engineer I/c shall have the right to examine these safety
equipments to determine their suitability, reliability, acceptability and
adaptability. The contractor should also ensure these before their use at
worksite.

viii) The Contractor shall provide safe working conditions to all workmen and
employees at his workplace including safe means of access, railings, stairs,
and ladders, scaffolding, work platforms, toe boards etc. The scaffoldings
shall be erected under the control and supervision of an experienced and
competent person. For erection of scaffolds, access, work platforms etc.
shall be good and the contractor shall use standard quality of material.

ix) The Contractor shall follow and comply with all the Safety Rules, standards,
code of practices of NTPC and relevant provisions of applicable laws
pertaining to the safety of workmen, employees, plant and equipment as may
be prescribed from time to time without any protest or contest or reservation.
In case of any unconformity between statutory requirement and the Safety
Rules of the Employer referred above, the latter shall be binding on the
Contractor unless the statutory provisions are more stringent. As and when
required he can refer / obtain copy of NTPC safety documents as stated
above.

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x) The contractor shall have his own arrangements with nearby hospitals for
shifting and treatment of sick and injured.

The medical examination of the workers employed in hazardous areas shall

be conducted as per Rule 223 0f The Building and Other Construction
Worker (Regulation of Employment and Condition of Service) Central Rule
1998 Their health records shall be maintained accordingly and to be
submitted to Engineer I/c when asked for. If any worker found suffering from
occupational health hazard, the worker should be shifted to suitable place of
working and properly treated under intimation to Engineer I/c. The medical
fitness certificate to be submitted to Engineer (I/c).

xi) First Aid boxes equipped with requisite articles as specified in the Rule 231
of The Building and Other Construction Worker (Regulation of Employment
and Condition of Service) Central Rule 1998 shall be provided at construction
sites for the use of workers. Training has to be provided on first aid to
workmen & office bearers working at site.

44.01.01 Emergency Action Plan

The contractor shall prepare an emergency action plan approved by his competent
authority to handle any emergency occurred during construction work. Regular mock
drills shall be organized to practice this emergency plan. The Emergency Action
Plan should be widely circulated to all the employees and suitable infrastructure
shall be provided to handle the emergencies.

44.01.02 Scaffolding

The contractor shall take all precautions to prevent any accidental collapse of
scaffolding or fall of persons from scaffolding. The contractor should ensure that
scaffolding are designed by a competent person and it erection and repairs should
be done under the expert supervision. The scaffolding shall meet the required
strength and other requirements for the purpose for which the scaffold is erected.
The material used for scaffold should conform to the BIS / International standards.

44.01.03 Opening

The contractor shall ensure that there is no opening in any working platform/any
floor of the building, which may cause fall of workers or material. When ever an
opening on a platform/any floor of the building is unavoidable, the opening should be
suitably fenced and necessary measures for protection against falling objects or
building workers from such platform are taken by providing suitable safety nets,
safety belts or other similar means.

44.01.04 Explosives
The contractor shall take all precautions while handling, using, storing or
transporting of all explosives. Before usage of any explosive necessary warning /
danger signals be erected at conspicuous places to warn the workers and general
public. The contractor should strictly ensure that all measures and precautions

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required to be complied for use, handling, storing or transportation of explosives

under the rules framed under the Explosives Act, 1884.

44.02.00 Fencing of Machinery

The contractor shall provide suitable fencing or guard to all dangerous and moving
parts of machinery.

The contractor shall not allow any of the employees to clean, lubricate, repair, adjust
or examine during machinery in motion, which may cause injury to the person.

44.03.00 Carrying of Excessive Weight by a Worker

The worker shall not be allowed to lift by hand or carry over his head, back or
shoulder more than the maximum limit set by the prescribed rules for the
construction Workers.

44.04.00 Dangerous and Harmful Gases / Equipment

The contractor shall ensure that the workers are not exposed to any harmful gases
during any construction activity including excavation, tunneling, confined spaces etc.

The contractor should not allow any worker to go into the confined space unless it is
certified by Engineer (I/c) to be safe and fit for the entry to such work place. Proper
record and work permits should be followed to carry out such works.

44.05.00 Overhead Protection

The contractor shall ensure that any area exposed to risk of falling materials, articles
or objects is roped off or cordoned off or otherwise suitably guarded from inadvertent
entry of any person.

Wherever there is a possibility of falling of any material, equipment or construction

workers while working at heights, a suitable and adequate safety net should be
provided. The safety net should be in accordance with BIS Standards.

44.06.00 Working at Heights

All working platforms, ways and other places of construction work shall be free from
accumulations of debris or any other material causing obstructions and tripping.

Wherever workers are exposed to the hazard of falling into water, the contractor
shall provide adequate equipment for saving the employees from drowning and
rescuing from such hazards. The contractor shall provide boat or launch equipped
with sufficient number of life buoys, life jackets etc. manned with trained personnel at
the site of such work.

Every opening at elevation from ground level through which a building worker,
vehicle, material equipment etc. may fall at a construction work shall be covered
and/or guarded suitably by the contractor to prevent such falls.

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Wherever the workers are exposed to the hazards of falling from height, the
contractor shall provide full harness safety belts fitted with fall arresting systems to
all the employees working at higher elevations and life line of 8 mm diameter wire
rope with turn buckles for anchoring the safety belts while working or moving at
higher elevations. Safety nets shall also be provided for saving them from fall from
heights and such equipment should be in accordance with BIS standards.

Wherever there is a possibility of falling of any material, equipment or construction

workers while working at heights, a suitable and adequate safety net should be
provided. The safety net should be in accordance with BIS Standards.

The contractor shall provide standard prefabricated ladders on the columns where
the workers are required to use them as an access for higher elevations till
permanent staircase is provided. The workers shall be provided with safety belts
fitted with suitable fall arresting system (Fall arrestors) for climbing/getting down
through ladders to prevent fall from height.

44.07.00 Handling of Hazardous Chemicals

The Contractor will notify well in advance to the Engineer I/c of his intention to bring
to the Site any container filled with liquid or gaseous fuel or explosive or petroleum
substance or such chemicals which may involve hazards. NTPC shall have the right
to prescribe the conditions, under which such container is to be stored, handled and
used during the performance of the works and the Contract shall strictly adhere to
and comply with such instructions. The Engineer I/c shall have the right at his sole
discretion to inspect any such container or such construction plant / equipment for
which material in the container is required to be used and if in his opinion, its use is
not safe, he may forbid its use. No claim due to such prohibition shall be entertained
by NTPC and NTPC shall not entertain any claim of the Contractor towards
additional safety provisions / conditions to be provided for / constructed.

Further, any such decision of the Engineer I/c shall not, in any way, absolve the
Contractor of his responsibilities and in case, use of such a container or entry
thereof into the Site area is forbidden by NTPC, the Contractor shall use alternative
methods with the approval of the NTPC without any cost implication to the NTPC or
extension of work schedule.

Where it is necessary to provide and / or store petroleum products or petroleum

mixtures and explosives, the Contractor shall be responsible for carrying-out such
provision and / or storage in accordance with the rules and regulations laid down in
Petroleum Act 1934, Explosives Act 1948, and Petroleum and Carbide of Calcium
Manual published by the Chief Inspector of Explosives of India. All such storage
shall have prior approval of the Engineer I/c. In case any approvals are necessary
from the Chief Inspector (Explosives) or any statutory authorities, the Contractor
shall be responsible for obtaining the same.

The Contractor shall be fully responsible for the safe storage of his and his Sub-
contractor's radio-active sources in accordance with BARC/DAE (Bhabha Atomic
Research Centre/ Department of Atomic Energy, Govt. of India) Rules and other
applicable provisions. All precautionary measures stipulated by BARC/DAE in

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connection with use, the contractor would take storage and handling of such
material.

The contractor shall provide suitable personal protective equipments to the workers
who are handling the hazardous and corrosive substances including alkalis and
acids.

As a precautionary measure the contractor should keep the bottles filled with distilled
water in cupboard / Boxes near work place for emergency eye wash by worker
exposed to such hazardous chemicals.

44.08.00 Eye Protection

The contractor shall provide suitable personal protective equipment to his workmen
depending upon the nature of hazards and ensure their usage by the workers
engaged in operations like welding, cutting, chipping, grinding or similar operations
which may cause injuries to his eyes.

44.09.00 Excavation

The contractor shall take all necessary measures during excavation to prevent the
hazards of falling or sliding material or article from any bank or side of such
excavation which is more than one and a half meter above his footing by providing
adequate piling, shoring, bracing etc. against such bank or sides.

Adequate and suitable warning signs shall be put up at conspicuous places at the
excavation work to prevent any persons or vehicles falling into the excavation
trench. No worker should be allowed to work where he may be stuck or endangered
by excavation machinery or collapse of excavations or trenches.
44.10.00 Electrical Hazards

The contractor should ensure that all electrical installations at the construction work
comply with the requirements of latest electricity acts / rules.

The contractor shall take all adequate measures to prevent any worker from coming
into physical contact with any electrical equipment or apparatus, machines or live
electrical circuits which may cause electrical hazards during the construction work.
The contractor shall provide the sufficient ELCBs / RCCBs for all the portable
equipments, electrical switchboards, distribution panels etc. to prevent electrical
shocks.

The contractor should ensure use of single / double insulated hand tools or low
voltage i.e., 110 volts hand tools.

The contractor should also ensure that all temporary electrical installations at the
construction works are provided with earth leakage circuit breakers.

44.11.00 Vehicular Traffic

The contractor should employ vehicle drivers who hold a valid driving license under
the Motor Vehicles Act, 1988.

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44.12.00 Lifting Appliances, Tools & Tackles, Lifting Gear And Pressure Plant &
Equipment etc.

The contractor shall ensure all the lifting appliances, tools & tackles including cranes
etc., lifting gear including fixed or movable and any plant or gear, hoists, Pressure
Plant and equipment etc. are in good condition and shall be examined by competent
person and only certified shall be used at sites. Periodical Examination and the
tests for all lifting / hoisting equipment & tackles shall be carried out. A register of
such examinations and tests shall be properly maintained by the Contractor and will
be promptly produced as and when desired by the Engineer I/c or by the person
authorized by him.

44.13.00 Excessive Noise, Vibration

The contractor shall take adequate measures to protect the workers against the
harmful effect of excessive noise or vibration. The noise should not exceed the
limits prescribed under the concerned rules, Noise Pollution (Regulation and
Control) Rules, 2000.

44.14.00 Electrical Installations

44.14.01 The Contractor shall not interfere or disturb electric fuses, wiring and other electrical
equipment belonging to the Employer or other contractors under any circumstances,
whatsoever, unless expressly permitted in writing by the Engineer I/c to handle such
fuses, wiring or electrical equipment.
Before the Contractor connects any electrical appliances to any plug or socket
belonging to the other contractor or the NTPC, he shall

i) Satisfy the Engineer I/C that the appliance is in good working condition;

ii) Inform the Engineer I/C of the maximum current rating, voltage and phases
of the appliances;

iii) Obtain permission of the Engineer I/C detailing the sockets to which the
appliances may be connected.

The Engineer I/C will not grant permission to connect until he is satisfied that:

The appliance is in good condition and is fitted with suitable plug; having
earth connection with the body.

Wherever armored / metallic sheathed multi core cable is used, the same
armored / sheathed should be connected to earth.

iv) No repair work shall be carried out on any live equipment. The Engineer I/c
must declare the equipment safe and a permit to work shall be issued by the
NTPC / contractor as the case may be to carry out any repair / maintenance
work. While working on electric lines / equipments whether live or dead,
suitable type and sufficient quantity of tools will have to be provided by the
contractor to electricians / workmen / Officers.

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v) The contractor shall employ necessary number of qualified, full time

Electricians / Electrical Supervisors to maintain his temporary electrical
installation.

The installations are provided with suitable ELCBs and RCCBs wherever
required.

44.15.00 Safety Organisation

44.15.01 The contractor employing more than 250 workmen whether temporary, casual,
probationary, regular or permanent shall employ at least one full time safety officer
exclusively to supervise safety aspects of the equipments and workmen, who will
coordinate with the NTPC Safety Officer. Further requirement of safety officers, if
any, shall be guided by Rule 209 of The Building and Other Construction Worker
(Regulation of Employment and Conditions of Service) Central Rule 1998. In case
the work is being carried out through subcontractor, the employees / workmen of the
sub contractor shall also be considered as the contractor's employees/workmen for
the above purpose.

In case of contractor deploying less than 250 workmen he should designate one of
his Engr / supervisor or the contractor himself (if he is directly supervising the work)
as safety officer in addition to his existing responsibilities. The Engr./ supervisor
should get atleast 2days safety training from any reputed organization or from NTPC
before resuming the work. If already trained in past the declaration along with trg.
certificate to be furnished to NTPC safety officer.

44.15.02 The name and address of such Safety Officer of the Contractor will be promptly
informed in writing to the EIC with a copy to the Project Safety Officer before he
starts work or immediately after any change of the incumbent is made during
currency of the Contract.

44.16.00 Reporting of Accident and Investigation

In case any accident occurs during the construction / erection or other associated
activities undertaken by the Contractor thereby causing any near miss, minor or
major or fatal injury to his employees due to any reason, whatsoever, it shall be the
responsibility of the Contractor to promptly inform the same to the Engineer I/C,
NTPC Safety Officer with a copy to NTPC Head of Project in the prescribed form
and also to all the authorities envisaged under the applicable laws.

44.17.00 Right to stop Work

44.17.01 The Engineer I/C shall have the right at his sole discretion to stop the work, if in his
opinion the work is being carried out in such a way that it may cause accidents and
endanger the safety of the persons and / or property, and / or equipments. In such
cases, the contractor shall be informed in writing about the nature of hazards and
possible injury / accident and he shall comply to remove shortcomings promptly.
The Contractor after stopping the specific work can, if felt necessary appeal against
the order of stoppage of work to the Project Manager within 3 days of such stoppage

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of work and decision of the Project Manager in this respect shall be conclusive and
binding on the Contractor.

44.17.02 The Contractor shall not be entitled for any damages / compensation for stoppage of
work, {Sub-Clause XVIII (I)} due to safety reasons and the period of such stoppage
of work shall not be taken as an extension of time for Completion of the Facilities
and will not be the ground for waiver of levy of liquidated damages.

44.18.00 Fire Protection

The contractor shall provide sufficient fire extinguishers at place /s of work. The fire
extinguishers shall be properly maintained as per relevant BIS Standards. The
employees shall be trained to operate the fire extinguishers / equipment.

44.19.00 Penalties
I If the Contractor fails in providing safe working environment as per the Safety
Rules of NTPC or continues the work even after being instructed to stop the
work by the Engineer I/C as provided in Clause XVIII (1) above, the
Contractor shall be penalized at the rate of Rs. 25,000/- per day or part
thereof till the instructions are complied with and so certified by the Engineer
I/C. However, in case of accident, the provisions contained in Sub-Clause
XX (II) below shall also apply in addition to the penalties mentioned in this
sub-clause.

II If the Contractor does not take all safety precautions and / or fails to comply
with the Safety Rules as prescribed by the Employer or under the applicable
law for the safety of the plant and equipment and for the safety of personnel
and the contractor does not prevent hazardous conditions which cause injury
to this own employees or employees of other contractors, or NTPC's
employees or any other person who are at the Site or adjacent thereto, the
Contractor shall be responsible for payment of penalty to NTPC as per the
following schedule:-

a) Fatal injury or accident causing death:

Penalty @10% of contract value or Rs. 5,00,000/- per person, which

ever is less.

b) Major injuries or accident causing 25% or more permanent

disablement to workmen or employees:

Penalty @2.5% of contract value or Rs. 1,00,000/- per person which

ever is less

Permanent disablement shall have the same meaning as indicated in

The Workmen's Compensation Act' 1923. The penalty mentioned
above shall be in addition to the compensation payable to the
workmen / employees under the relevant provisions of the Workmen's
Compensation Act' 1923 and rules framed there under or any other
applicable laws as applicable from time to time.

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III If any contractor worker found working without using the safety equipment
like safety helmet, safety shoes, safety belts, etc. or without anchoring the
safety belts while working at height the Engineer I/c / Safety Officer of NTPC
shall have the right to penalize the contractor for Rs. 200/- per person per
day and such worker shall be sent out of the workplace immediately and
shall not be allowed to work on that day. Engineer I/c / Safety Officer of
NTPC will also issue a notice in this regard to the contractor.

IV If two or more fatal accidents occur at same NTPC site under the control of
contractor during the period of contract and he has

(1) not complied with keeping adequate PPEs in stock or

(2) defaulted in providing PPEs to his workmen

(3) not followed statutory requirements / NTPC safety rules

(4) been issued warning notice/s by NTPC head of the project on non
observance of safety norms

(5) not provided safety training to all his workmen, the contractor can
be debarred from getting tender documents in NTPC for two years
from the date of last accident.

The safety performance will also be one of the overriding criteria for evaluation of
overall performance of the contractors by NTPC. The contractor shall submit the
accident data including fatal / non-fatal accidents for the last 3 years where he has
undertaken the construction activities Projects-wise along with the tender
documents. This will also be considered for evolution of tender documents. If the
information given by the contractor found incorrect, his contract will be liable to be
terminated.

44.20.00 The Contractor will make available minimum quantity of all safety equipments and
safety personal protection equipments (PPEs) of required specifications as per
suggestive list included bidding documents as a part of "List of minimum T & P".
Further Contractor will ensure availabilitty of additional requirement for individual
worker and safety equipment as per site requirement during execution of the
contract till its completion.

44.21.00 Award

If the Contractor's performance on safety front is found satisfactory i.e. without any
fatal/reportable accident in the year of consideration; he may be considered for
suitable award "ACCIDENT FREE SAFETY MERITORIOUS AWARD" as per
scheme of the employer.

44.22.00 The Contractor shall abide by the following during Construction and Erection
activities:

I. Chain pulley block shall not be used for loads more than 2 (Two) tonne.

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II. Hydra shall not be used for material transport.

III. Cage shall necessarily be provided to Monkey ladders of height more than 4
m.

IV. Fencing shall be provided to all Electrical Distribution boards and

transformers etc.

45.00.00 FOREIGN PERSONNEL

45.01.00 The Contractor shall submit to the Employer data on all personnel he proposes to
bring into India from abroad for the performance of the Works under the Contract, at
least sixty (60) days prior to their departure to India. Such data will include for each
person the name, his present address, his assignment and responsibility in
connection with the works, and a short resume of his qualification, experience etc. in
relation to the work to be performed by him.
45.02.00 Any person unsuitable and unacceptable to the Employer shall not be brought to
India. Any person brought to India, if found unsuitable or unacceptable by the
Employer, the Contractor shall within a reasonable time make alternate
arrangements for providing a suitable replacement and repatriation of such
unsuitable personnel.

45.03.00 No person brought to India for the purposes of the works shall be repatriated without
the consent of the Employer in writing, based on a written request from the
Contractor for such repatriation giving reasons for such an action to the Employer.
The Employer may give permission for such repatriation provided he is satisfied that
the progress of work will not suffer due to such repatriation.

45.04.00 The cost of passports, visas and all other travel expenses to and from India, incurred
by the Contractor shall be to his account. The Employer will not provide any
residential accommodation and/or furniture for any of the Contractor's personnel
including foreign personnel and Contractor shall make his own arrangements for
such facilities in the area allotted at Site, to him by the Employer for that purpose.

45.05.00 The Contractor and his expatriate personnel shall respect all Indian Acts, Laws,
rules and regulations and shall not in any way interfere with Indian political and
religious affairs and shall conform to any other rules and regulations which the
Government of India and the Employer may establish from time to time, on them.
The Contractor's expatriate personnel shall work and live in close co-operation and
coordination with their co-workers and the community and shall not engage
themselves in any other employment neither part-time nor full-time nor shall they
take part in any local politics.

45.06.00 The Employer shall assist the Contractor, to the extent possible, in obtaining
necessary permits to travel to India and back, by issue of necessary certificates and
other information needed by the Government agencies.

46.00.00 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT

BASES

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46.01.00 The surfaces of foundations shall be dressed to bring the top surface of the
foundations to the required level, prior to placement of equipment/equipment bases
on the foundations.

46.02.00 All the equipment/ equipment bases, shall be grouted and finished by bidder as per
these specifications unless otherwise recommended by the equipment
manufacturer.

46.03.00 The concrete foundation surfaces shall be properly prepared by bidder by chipping,
grinding as required to bring the top of such foundation to the required level, to
provide the necessary roughness for bondage and to assure enough bearing
strength.

46.04.00 Grout
The grout for equipment foundation shall be high strength grout having a minimum
characteristic compressive strength of 60 N/mm2 at 28 days. The grout shall be
ready mix non-shrink, chloride - free, cement based, free flowing, non-metallic grout
as recommended by equipment manufacturer. The ready mix grout shall be of
reputed make as approved by the Employer.

The Grout shall have good flowability even at very low water/ grout powder ratio.

The Grout shall have characteristics of controlled expansion to be able to occupy its
original volume to fill the voids and to compensate for shrinkage. Grout shall be of
pre-mix variety so that only water needs to be added before use.

The mixing of the Grout shall conform to the recommendations of the manufacturer
of the Grout.

46.05.00 Placing of Grout

46.05.01 After the base has been prepared, its alignment and level has been checked and
approved and before actually placing the grout, a low dam shall be set around the
base at a distance that will permit pouring and manipulation of the grout. The height
of such dam shall be at least 25mm above the bottom of the base. Suitable size and
number of chains shall be introduced under the base before placing the grout, so
that such chains can be moved back & forth to push the grout into every part of the
space under the base.

46.05.02 The grout shall be poured either through grout holes if provided or shall be poured at
one side or at two adjacent sides to make the grout move in a solid mass under the
base and out in the opposite side. Pouring shall be continued until the entire space
below the base is thoroughly filled and the grout stands at least 25 mm higher all
around than the bottom of the base. Enough care should be taken to avoid any air
or water pockets beneath the bases.

46.05.03 In addition to the above, recommendations of Grout manufacturer shall also be

followed.

46.06.00 Finishing of the Edges of the Grout

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The poured grout should be allowed to stand undisturbed until it is well set.
Immediately thereafter, the dam shall be removed and grout which extends beyond
the edges of the structural or equipment base plates shall be cut off, flushed and
removed. The edges of the grout shall then be pointed and finished with 1:2 cement
mortar pressed firmly to bond with the body of the grout and smoothened with a tool
to present a smooth vertical surface. The work shall be done in a clean and scientific
manner and the adjacent floor spaces, exposed edges of the foundations, and
structural steel and equipment base plates shall be thoroughly cleaned of any
spillage of the grout.

46.07.00 Checking of Equipment After Grouting

After the grout is set and cured, the Contractor shall check and verify the alignment
of equipments, alignment of shafts of rotating machinery, the slopes of all bearing
pedestals, centering of rotors with respect to their sealing bores, couplings, etc. as
applicable and the like items to ensure that no displacement had taken place
during grouting. The values recorded prior to grouting shall be used during such
post grouting check- up and verifications. Such pre and post grout records of
alignment details shall be maintained by the Contractor in a manner acceptable to
the Employer.

47.00.00 SHAFT ALIGNMENTS

All the shafts of rotating equipment shall be properly aligned to those of the matching
equipments to as perfect an accuracy as practicable. The equipment shall be free
from excessive vibration so as to avoid overheating of bearings or other conditions
which may tend to shorten the life of the equipment. The vibration level of rotating
equipments measured at bearing housing shall conform to Zone A of ISO 10816. All
bearings, shafts and other rotating parts shall be thoroughly cleaned and suitably
lubricated before starting.

48.00.00 DOWELLING

All the motors and other equipment shall be suitably doweled after alignment of
shafts with tapered machined dowels as per the direction of the Employer.

49.00.00 CHECK OUT OF CONTROL SYSTEMS

After completion of wiring, cabling furnished under separate specification and laid
and terminated by the Employer, the Contractor shall check out the operation of all
control systems for the equipment furnished and installed under these specifications
and documents.

50.00.00 COMMISSIONING SPARES

50.01.00 It will be the responsibility of the Contractor to provide all commissioning spares
including consumable spares required for initial operation till the Completion of
Facilities. The Contractor shall furnish a list of all commissioning spares within 60
days from the date of Notification of Award and such list shall be reviewed by the
Employer and mutually agreed to. However. such review and agreement will not

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absolve the Contractor of his responsibilities to supply all commissioning spares so

that initial operation do not suffer for want of commissioning spares. All
commissioning spares shall be deemed to be included in the scope of the Contract
at no extra cost to the Employer.

50.02.00 These spare will be received and stored by the Contractor atleast 3 months prior to
the schedule date of commencement of initial operation of the respective equipment
and utilised as and when required. The unutilised spares and replaced parts, if any,
at the end of successful completion of guarantee tests shall be the property of the
Contractor and he will be allowed to take these parts back at his own cost with the
permission of Employer.

51.00.00 CABLING

51.01.00 All cables shall be supported by conduits or cable tray run in air or in cable channels.
These shall be installed in exposed runs parallel or perpendicular to dominant
surfaces with right angle turn made of symmetrical bends or fittings. When cables
are run on cable trays, they shall be clamped at a minimum intervals of 2000mm or
otherwise as directed by the Employer.

51.02.00 Each cable, whether power or control, shall be provided with a metallic or plastic tag
of an approved type, bearing a cable reference number indicated in the cable and
conduit list (prepared by the Contractor), at every 5 meter run or part thereof and at
both ends of the cable adjacent to the terminations. Cable routing is to be done in
such a way that cables are accessible for any maintenance and for easy
identification.

51.03.00 Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC
insulted cables 1100 V grade shall be 15 D where D is the overall diameter of the
cable. Installation of other cables like high voltage, coaxial, screened,
compensating, mineral insulated shall be in accordance with the cable
manufacturer's recommendations. Wherever cables cross roads and water, oil,
sewage or gaslines, special care should be taken for the protection of the cables in
designing the cable channels.

51.04.00 In each cable run some extra length shall be kept at a suitable point to enable one or
two straight through joints to be made, should the cable develop fault at a later date.

51.05.00 Control cable terminations shall be made in accordance with wiring diagrams, using
identifying codes subject to the Employer's approval. Multicore control cable jackets
shall be removed as required to train and terminate the conductors. The cable
jacket shall be left on the cable, as far as possible, to the point of the first conductor
branch. The insulated conductors from which the jacket is removed shall be neatly
twined in bundles and terminated. The bundles shall be firmly but not tightly tied
utilising plastic or nylon ties or specifically treated fungus protected cord made for
this purpose. Control cable conductor insulation shall be securely and evenly cut.

51.06.00 The connectors for control cables shall be covered with a transparent insulating
sleeve so as to prevent accidental contact with ground or adjacent terminals and
shall preferably terminate in Elmex terminals and washers. The insulating sleeve
shall be fire resistant and shall be long enough to over pass the conductor insulation.

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All control cables shall be fanned out and connection made to terminal blocks and
test equipment for proper operation before cables are corded together.

52.00.00 EQUIPMENT DELIVERY AND ERECTION

52.01.00 General Requirements

(a.) This part covers Contractor's responsibilities for packing, shipping, ware-
housing and the installation of all equipment and materials furnished and
installed under this specification.

(b.) The Contractor shall submit for Employer's approval draft manual for
Equipment Delivery and Erection (EDE Manual) covering detailed
instructions, write up, technical data, drawings, check-lists, documentation
formats for all activities after equipment manufacture upto installation of
equipment. This manual shall cover general instructions for all equipment
and specific instructions for individual equipment wherever required and shall
include at least the following :

(1.) Instructions for packing, shipping, receiving handling, ware-housing

and storage.

(2.) Instructions for location and installation of equipment furnished by this

specification.

(3.) Installation drawings for field mounted equipment, panels, cubicles

and other equipment covered under this specification.

(4.) Instruction relating installation of piping/ tubing, support and routing

drawings of impulse pipes/signal tubes and tube/cable trays.

(5.) Check lists and quality assurance hold points.

(6.) Format for all related documentation.

(c.) The EDE Manual shall conform to the requirements of this specification, all
applicable codes and standards, recommendations of equipment
manufacturers and accepted good engineering practices and shall be subject
to Employer approval during detailed engineering.

(d.) The Contractor shall ensure that all work under this part shall be performed
as per the requirements of this specification, Employer approved EDE
Manual and drawing/documents approved by the Employer during detailed
engg.

52.02.00 Crating

(a.) All equipment and materials shall be suitably coated, wrapped, or covered
and boxed or crated for moist humid tropical shipment and to prevent
damage or deterioration during handling and storage at the site.

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(b.) Equipment shall be packed with suitable desiccants, sealed in water proof
vapour-proof wrapping and packed in lumber of plywood enclosures, suitably
braced, tied and skidded. Lumber enclosures shall be solid, not slatted.

(c.) Desiccants shall be either silica gel or calcium sulphate, sufficiently ground to
provide the required surface area and activated prior to placing in the
packaging. Calcium sulphate desiccants shall be of a chemical nature to
absorb moisture. In any case, the desiccant shall not be of a type that will
absorb enough moisture to go into solution. Desiccants shall be packed in
porous containers, strong enough to withstand handling encountered during
normal shipment. Enough desiccant shall be used for the volumes enclosed
in wrapping.

(d.) Review by the Employer of the Contractor's proposed packaging methods

shall not relieve the Contractor of responsibility for damage or deterioration to
the equipment and materials specified.

(e.) All accessory items shall be shipped with the equipment. ; Boxes and crates
containing accessory items shall be marked so that they are identified with
the main equipment. The contents of each box and crates shall be indicated
by markings on the exterior.

(f.) All boxes, crates, cases bundles, loose pieces, etc. shall be marked
consecutively from No.1 upward throughout all shipments from a given port
to completion of the order without repeating the same number.

(g.) An itemized list of contents shall be enclosed inside each case and one other
copy securely fastened to the outside of the case in a tin or light weight sheet
metal envelope or pocket. The lists shall be plainly marked and placed in
accessible locations to facilitate receipt and inspection. The packing list shall
indicate whether shipment is partial or complete and shall incorporate the
following information on each container, etc., according to its individual
shipping number:

a) Export case markings

b) Case number

c) Gross weight and net weight in Kilograms

d) Dimensions in centimeters

e) Complete description of material

(h.) Packaging or shipping units shall be designed within the limitations of

unloading facilities and the equipment which will be used for transport.
Complications involved with ocean shipment and the limitations of ports,
railways and roads shall be considered. It shall be the Contractor's
responsibility to investigate these limitations and to provide suitable
packaging to permit safe handling during transit and at the job site.

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(i.) Electrical equipment, control and instrumentation shall be protected against

moisture and water damage. All external gasket surfaces and flange faces,
couplings, motor pump shafts, bearing and like items shall be thoroughly
cleaned and coated with rust preventive compound as specified above and
protected with suitable wood, metal or other substantial type covering to
ensure their full protection.

(j.) Equipment having antifriction or sleeve bearings shall be protected by

weather tight enclosures.

(k.) Coated surfaces shall be protected against impact, abrasion, discolouration

and other damage. Surfaces which are damaged shall be repaired.

(l.) All exposed threaded parts shall be greased and protected with metallic or
other substantial type protectors. All female threaded openings shall be
closed with forged steel plugs. All pipings, tubing, and conduit equipment
and other equipment openings shall be sealed with metallic or other rough
usage covers and tapped to seal the interior of the equipment piping, tubing,
or conduit.

(m.) Provisions shall be made to ensure that water does not enter any equipment
during shipment or in storage at the plant site.

(n.) Returnable containers and special shipping devices shall be returned by the
manufacturer's field representative at the Contractor's expense.

(o.) While packaging the material, care shall be taken for the limitation from the
point of view of availability of railway wagon sizes in India.

52.03.00 Factory Assembly

(a.) Instrument enclosures shall be supplied and erected completely in the factory
with instrument, air supply and blow down piping with necessary valves,
fittings, etc. and also all electrical wiring between the instruments and the
enclosure terminal blocks. Control panel and cubicles shall also be fully
wired in the factory. Control panel mounted equipments are to be dismounted
from the panels before shipment and individually packed for shipment.
Electronic control modules of the plug-in type are to be removed from
equipment racks after factory checkout are individually packed for shipment.
Other equipment shall be fully assembled at the factory, except for necessary
shipping splits in panels.

(b.) All separately packaged accessories items and parts shall be shipped with
the equipment. Containers for separately packaged items shall be marked
so that they are identified with the main equipment. An itemized packing slip,
indicating what is in that carton only, shall be attached to the outside and
inside of each container used for packing.

A master packing slip covering all accessories items for a given piece of
equipment which are shipped in separate containers, shall be attached to
one container.

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52.04.00 Equipment Installation

(a.) General Requirements

(1.) The Contractor shall furnish all construction materials, tools and
equipment and shall perform all work required for complete
installation of all control and instrument equipment furnished under
this specification.

(2.) Contractor shall prepare detailed installation drawings for each

equipment furnished under this specification for Employer’s approval.
Installation of all equipment/systems furnished by this specification
shall be as per Employer's approval.

(3.) Erection procedures not specified herein shall be in accordance with

the recommendations of the equipment manufacturers. The
procedures shall be acceptable to the Employer.

(4.) The Contractor shall coordinate his work with other suppliers where
their instruments and devices are to be installed under specifications.

(b.) Installation Materials

All materials required for installation, testing and commissioning of the

equipment shall be furnished by the Contractor.

(c.) Regulatory Requirements

All installation procedures shall confirm with the accepted good engineering
practice and with all applicable governmental laws, regulations and codes.

(d.) Cleaning

All equipment shall be cleaned of all sand, dirt and other foreign materials
immediately after removal from storage and before the equipment is brought
inside the power plant building or to other installation sites. All piping and
tubes shall be air blown.

(e.) Equipment Assembly

Equipment installed under these specifications shall be assembled if shipped

unassembled. The equipment shall be dismantled and reassembled as
required to perform the installation and commissioning work described in
these specifications.

(f.) Equipment Setting

Field mounted instruments and accessories shall be bracket or sub panel

mounted on the nearest suitable firm steel work or masonry. The brackets,

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stands, supports and other miscellaneous hardware required for mounting

instruments and accessories such as receiver gauge, air set, valve manifold,
purge-meter etc. shall be furnished and installed. No field mounted
instruments shall be installed such that it depends for support or rigidity on
the impulse piping or on electrical connection to it.

Indicating type field mounted instruments shall be installed in such a way that
centre of indicating dial shall be about 1600-1800mm from operating floor
level. Non-indicating type field instruments shall be installed such that
operating handle of manifold block / isolating cock comes within 1600 mm
from operating floor level.

(g.) Free-Standing Equipment

Free-standing Cabinets shall be attached to the floor, concrete equipment

bases or supporting steel as indicated on the manufacturer's drawings and
the Employer's Plant Arrangement Drawings. The cabinets shall be
shimmed for proper alignment before bolting them to the floor. Adjacent
enclosures shall be shimmed to maintain mutually level appearance before
they are attached to floor. Vibration dampening mounts shall be installed
between supporting structures and panels when specified.

(h.) Non-free Standing Equipment

(1.) Non-free standing local enclosures and cabinets shall be mounted in

accessible locations on columns, walls, or stands in locations as
indicated on the Employer's Plant Arrangement Drawings. Bracket
and stands shall be fabricated as required to install the local
enclosures and cabinets in a workman like manner.

(2.) Rough edges and welds on all fabricated supports shall be ground
smooth. The supports shall be finished with two coats of primer and
two coats of paint as specified in this part.

(i.) Equipment Location

(1.) All individual items of equipment not located in cabinets or on panels

and racks are located approximately according to the floor elevation
and the nearest building column designated by the Employer.

(2.) Solenoid valves not located in enclosures or mounted on valves shall

be mounted in easily accessible protected locations near the
components with which they are associated.

(3.) All brackets, stands, supports and other miscellaneous hardware

required for mounting devices shall be furnished and installed.

(4.) Thermometers shall be installed in the process lines and ducts as

required and adjusted for ease in reading.

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(5.) Permanent temperature wells on the main steam, hot reheat and cold
reheat piping shall not be installed until steam blowing has been
completed. Temporary temperature wells shall be installed in the
main and reheat steam piping during steam blow and discarded after
completion.

(6.) Any required adapting hardware such as pipe bushings, nipples,

drilled caps and the like shall be provided for complete installation of
control devices into process connections.

For location of C&I related equipment/devices, the requirement

specified elsewhere in the technical specification may be referred.

(j.) Installation of Field Mounted Instruments and Devices

The Contractor shall submit installation drawings for all field mounted
equipment furnished under this specification for Employer's approval. These
drawings shall meet the requirements of this specification, installation
drawings, applicable codes and standards and recommendations of
manufacturers of instruments/devices. All installation work under this
specification shall be strictly as per installation drawings approved by the
Employer during detailed engineering stage.

In addition to above relevant Portion as specified elsewhere in technical

specification may be referred.

(k.) Piping Connections

(1.) All equipment having piping connections shall be levelled, aligned

and wedged in place but shall not be grouted or bolted prior to the
initial fitting and alignment of connecting piping. All equipment shall,
however, be grouted or bolted to its foundation prior to final bolting or
welding of the connection piping.

(2.) All flanged joints shall be checked and retightened after

approximately 10 days of operation at normal operating temperature.

(l.) Equipment Checkout

(1.) All equipment shall be cleaned after installation. Equipment subject

to pressure differentials shall be checked for leakage.

(2.) After erection, all equipment having moving parts, having electrical
apparatus, or subject to pressure differentials shall be trial-operated.

(m.) Defects

(1.) All defects in erection shall be corrected to the satisfaction of the

Employer and the Project Manager. The dismantling and reassembly
of Contractor furnished equipment to remove defective parts, replace

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parts, or make adjustments shall be included as a part of the work

under these specifications.

(2.) The removal of control and instrument equipment in order to allow

bench calibration, if required, and the re-installation of the said
equipment after calibration shall also be included as a part of the work
under these specifications.

(n.) Equipment Protection

(1.) All equipment to be erected under these specifications shall be

protected from damage of any kind from the time of contract award
until commissioning of each unit.

(2.) The equipment shall be protected during storage as described herein.

(3.) Equipment shall be protected from weld spatter during construction.

(4.) Suitable guards shall be provided for protection of personnel on all

exposed rotating or moving machine parts. All such guards with
necessary spares and accessories shall be designed for easy
removal and maintenance.

(5.) Equipment having glass components such as gauges, or equipment

having other easily breakable components, shall be protected during
the construction period with plywood enclosures or other suitable
means. Broken, stolen, or lost components shall be replaced by the
Contractor.

(6.) Machine finished surfaces, polished surfaces, or other bare metal

surfaces which are not to be painted, such as machinery shafts and
couplings shall be provided temporary protection during storage and
constructional periods by a coating of a suitable non- drying, oily type,
rust preventive compound.

53.00.00 WELDING - SPECIAL REQUIREMENTS

If the manufacturer has special requirements relating to the welding procedures for
welds at the terminals of the equipments to be performed under separate
specifications, the requirements shall be submitted to the Project Manager in
advance of commencement of erection work.

54.00.00 DEVIATIONS DISPOSITIONING:

Any deviation to the contract and employer approved documents shall be properly
recorded in the format prescribed by NTPC. All the deviations shall be bought to the
knowledge of employer's representative for suitable dispositioning.

55.00.00 NON-DESTRUCTIVE TESTING (NDT):

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The contractor shall record results of NDTs carried out at site in the format
acceptable to employer. All the radiographs & its report duly signed & correlated to
the job shall be handed over to the employer. Sensitivity of all the test equipment
shall be compatible to the job & acceptance norms agreed.

56.00.00 TESTING EQUIPMENT & FACILITIES:

Contractor shall provide the testing equipment and facilities necessary to carry out
tests & inspections.

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ANNEXURE-I

STANDARD CHECKLIST

This is an indicative list of items. The actual list shall depend on the Equipment /
System being supplied by the contractor.

MECHANICAL

VALVES

1. Manually Operated Valve

2. Electrically Operated Valve

3. Pneumatically Actuated Valve

4. Hydraulically Actuated Valve

5. Safety Valve

6. Electromatic Relief Valve

7. Steam Trap

8. Non Return Valve (including Hydraulic/ Pneumatic QCNRVS)

9. Control Valve

10. Relief Valve

11. Differential Pressure Regulating Valve

12. Pinch valve

TANKS & PRESSURE VESSELS

1. Limestone silos

2. Gypsum storage silos

3. Limestone slurry tanks

4. Filtrate tank

5. Waste water tank

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6. Secondary hydrocyclone feed tank

7. Lime dosing tank

8. Process water tank

9. Absorber

10. Auxiliary absorbent tank

11. Mill circuit tank

12. Any other tank not covered above

13. Vacuum tanks

14. Air Receiver(if any)

PUMPS

1. Slurry recirculation pumps

2. Gypsum bleed pumps

3. Limestone slurry pumps

4. Process water pumps

5. All other slurry pumps

6. Vacuum pumps

7. Sump pumps

PIPE WORK SYSTEM

1. Steam services

2. Water services

3. Slurry services

4. Air services

5. Constant load support

6. Spring supports

7. Hangers and other Supports

LOT-2 PROJECTS TECHNICAL SPECIFICATION PART-D PAGE

FLUE GAS DESULPHURISATION (FGD) SECTION – VI ERECTION CONDITIONS OF 46 OF 53
SYSTEM PACKAGE BID DOC. NO. CS-0011-109(2)-9 CONTRACT

Page 199 of 338

CLAUSE NO.
ERECTION CONDITIONS OF CONTRACT

STRAINER AND FILTER

1. Strainer / Filter Basket Type

2. Strainer Rotary (Low Pressure)

3. Filter & Strainers Centrifugal Separators

4. Filter & Strainer Y-Type

5. Filter & Strainer (Plate Type)

6. Purifier

7. Filter – Compressed Air Line

FANS & COMPRESSORS

1. Booster Fans (if provided) – Axial Flow pressure Lubricated

2. Oxidation Blowers/Compressors-General

DAMPERS & GATES

1. Manually Operated Damper

2. Pneumatically Operated Damper

3. Electrically Operated Damper

4. Manually Operated Gates

5. Pneumatically Operated Gate

6. Electrically Operated Gate

DUCT WORK

1. Flue Gas Ducting

2. Expansion Joints

3. Observation & Access Door

CRANES AND ELEVATORS

1. Crane

2. Hoists

LOT-2 PROJECTS TECHNICAL SPECIFICATION PART-D PAGE

FLUE GAS DESULPHURISATION (FGD) SECTION – VI ERECTION CONDITIONS OF 47 OF 53
SYSTEM PACKAGE BID DOC. NO. CS-0011-109(2)-9 CONTRACT

Page 200 of 338

CLAUSE NO.
ERECTION CONDITIONS OF CONTRACT

3. Passenger cum goods elevator

POWER TRANSMISSION

1. Power Transmission Gear Box

2. Bearings

3. Couplings

FGD & AUX.SYSTEM

1. Agitators

2. Air Motor

3. Process trustle

4. Limestone feeder

5. Vacuum belt filter

6. Limestone ball mill

7. Limestone Hydrocyclones

8. Primary Hydrocyclones

9. Secondary Hydrocyclones

10. Absorber internals

11. Absorber Auxiliaries

ELELCTRICAL

1. D.C. Motor

2. HV Squirrel Cage Induction Motor

3. 415 V Squirrel Cage Induction Motor

4. Motor Operated Actuators

5. Soot Blower (GGH)

6. Aux. Control and Relay Panel Desk

7. SWITCHGEARS/MCC

LOT-2 PROJECTS TECHNICAL SPECIFICATION PART-D PAGE

FLUE GAS DESULPHURISATION (FGD) SECTION – VI ERECTION CONDITIONS OF 48 OF 53
SYSTEM PACKAGE BID DOC. NO. CS-0011-109(2)-9 CONTRACT

Page 201 of 338

CLAUSE NO.
ERECTION CONDITIONS OF CONTRACT

(I.) STANDARD CHECLISTS FOR ALL TYPES OF RELAYS USED IN

SWITCHGEARS PROTECTION SYSTEM

(II.) PT CARRIAGE AND CUBICLES

(III.) CABLE/BUS DUCT/BUS BARS

(IV.) CONTRACTOR MODULE

(V.) SWITCH FUSE MODULE

(VI.) MASTER PANEL OF LUBE OIL PANEL

(VII.) FEEDER PANEL OF LUBE OIL PANEL

(VIII.) SPACE HEATER AND CABLE MODULE

(IX.) HT CIRCUIT BREAKER

(X.) 415 V CIRCUIT BREAKER

POWER CABLE

AUXILIARY CABLE

D.C. CABLE

EXPLOSION PROOF ELECTRICAL EQUIPMENT

JUNCTION BOX

CONTROL TRANSFORMER MODULE

BRUSH GEAR ASSEMBLY

AUX. CONTROL AND RELAY PANEL DESK

INDICATING INSTRUMENT

RECORDING INSTRUMENT

INTEGRATING INSTRUMENT

CONTROL & INSTRUMENTATION

1. Conductivity Measuring Equipment Including Test Procedures

2. pH Analyser Including Test procedure

LOT-2 PROJECTS TECHNICAL SPECIFICATION PART-D PAGE

FLUE GAS DESULPHURISATION (FGD) SECTION – VI ERECTION CONDITIONS OF 49 OF 53
SYSTEM PACKAGE BID DOC. NO. CS-0011-109(2)-9 CONTRACT

Page 202 of 338

CLAUSE NO.
ERECTION CONDITIONS OF CONTRACT

3. Silica Analyser

4. Level Switch (Float Actuated)

5. Level Switch (Electrode Type)

6. Level Switch (Displacer Actuated)

7. Transmitter (Float Operated Pneumatic Output including Testing procedures

8. Level indicator (Float/Pulley Type)

9. Local Temperature Indicator Including Test Procedure

10. Resistance Thermometer Element Including Test procedure

11. Thermocouple Element and Connecting Cable

12. Thermocouple and Resistance Thermometer Convertor/Transmitter Including

Test Procedures

13. Temperature Switch Including Test Procedure

14. Cold Junction Boxes

15. 02Analyser

16. SO2 analyzer

17. 02 in Hydrogen including Test procedures

18. Pressure and Vacuum Gauge

19. Pressure and Vacuum Switch Including Test procedures

20. Differential Pressure Transmitter including Test Procedures

21. Differential pressure switch including Test procedures

22. Flow indicator (Variable Area)

23. Orifice plate

24. Flow Switch

25. Nozzle

26. Flow Integrator (pneumatic input) including test procedure

LOT-2 PROJECTS TECHNICAL SPECIFICATION PART-D PAGE

FLUE GAS DESULPHURISATION (FGD) SECTION – VI ERECTION CONDITIONS OF 50 OF 53
SYSTEM PACKAGE BID DOC. NO. CS-0011-109(2)-9 CONTRACT

Page 203 of 338

CLAUSE NO.
ERECTION CONDITIONS OF CONTRACT

27. Flow indicator (Float Operated) Including Test Procedure

28. Venturi (Fluid)

29. Flow Switch (Magnetic Type)

30. Limit Switches

31. Turbine Supervisory Measuring System

32. Position Measurement & Indication Including Test procedures

33. Vibration Measurement

34. Digital Indicator

35. Moving Coil Indicator Including Test Procedures

36. Recorder Including Test procedure

37. Flame Scanner

38. Electrical Auto Manual Control Station

39. Push Button Module

40. Test Procedure for Electronic Modules of DDCMIS

41. Alarm Annunciator Equipment Including Test Procedure

42. Test procedure for Adjustment of Modulating Controller-PID Term

43. Test Procedure Indicating Controller-Electrical Input & Pneumatic Output

44. Density monitors

Note: The items which are not part of this specification may be considered as not
applicable.

LOT-2 PROJECTS TECHNICAL SPECIFICATION PART-D PAGE

FLUE GAS DESULPHURISATION (FGD) SECTION – VI ERECTION CONDITIONS OF 51 OF 53
SYSTEM PACKAGE BID DOC. NO. CS-0011-109(2)-9 CONTRACT

Page 204 of 338

CLAUSE NO.
ERECTION CONDITIONS OF CONTRACT

ANNEXURE-II

BRIEF WRITE UP ON THE CONTENTS OF TESTING

SCHEDULE / COMMISSIONING SCHEDULE

Testing Schedules should be designed to ensure that the plant area, equipment or
apparatus are tested and commissioned and will operate as per the employer's
specifications and good engineering practices.

Testing Schedule/Commissioning Schedule is required to be of a standard format in

order to maintain consistency of presentation, content and reporting.

Testing Schedule/Commissioning Schedule should contain the following sections to

make the document a self contained one:

1. Plant Details/Design data

2. Testing Objective/Proposals

3. State of the Plant

a) Erection Status with respect to Mech. Elect and C&I

b) Availability of the services required

c) Safety requirements as per Manufacturer's

4. Test method including completion/acceptance criteria

5. Results

6. Appendix

a) Testing Programme

b) Mech/Elect/C&I -Plant item completing list

c) List of Drawing/documents required for carrying out the testing.

LOT-2 PROJECTS TECHNICAL SPECIFICATION PART-D PAGE

FLUE GAS DESULPHURISATION (FGD) SECTION – VI ERECTION CONDITIONS OF 52 OF 53
SYSTEM PACKAGE BID DOC. NO. CS-0011-109(2)-9 CONTRACT

Page 205 of 338

CLAUSE NO.
ERECTION CONDITIONS OF CONTRACT

ANNEXURE - III

SAFETY PLAN

01. Safety Policy of the Contractor to be enclosed:

02. When was the Safety Policy last reviewed:
03. Details of implementation procedure / methods to implement Safety Policy /
Safety Rules:
04. Name, Qualification, experience of Safety Officer
05. Review of Accidents Analysis Method, Methods to ensure Safety and Health:
06. Unit executive responsible to ensure Safety at various levels in work area:
07. List of employees trained in safety employed before execution of the job. Give
the details of training:
08. Safety Training Targets, Schedules, methods Adopting to providing safety
training to all employees:
09. Details of checklist for different jobs / work and responsible person to ensure
compliance (copy of checklist to be enclosed):
10. Regular Safety Inspection Methods and Periodicity and list of members to be
enclosed:
11. Risk Assessment, Safety Audit by Professional Agencies, Periodicity:
12. Implementation of Recommendations of Audit / Inspections. Procedures for
implementation and follow up:
13. Provision for treatment of injured persons at work site:
14. Review of overall safety by top Management and Periodicity:
15. System for Implementation of Statutory legislations:
16. Issue of PPEs to employees, Periodicity / stock on hand etc:

Signature
Head of the Organisation
with date & stamp

LOT-2 PROJECTS TECHNICAL SPECIFICATION PART-D PAGE

FLUE GAS DESULPHURISATION (FGD) SECTION – VI ERECTION CONDITIONS OF 53 OF 53
SYSTEM PACKAGE BID DOC. NO. CS-0011-109(2)-9 CONTRACT

Page 206 of 338

 TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-C2B
REV. 00
TECHNICAL SPECIFICATION FOR
Date: April, 2020
MISC. FGD TANKS

SECTION-I,
SUB-SECTION-C2B
CUSTOMER SPECIFICATION: QUALITY ASSURANCE

Page 207 of 338

CLAUSE NO.
QUALITY ASSURANCE

1.05.00 TANKS / VESSELS:

1.05.01 Atmospheric tanks:

i) All welds joints shall be DP tested and complete tanks shall be water fill tested.
ii) All atmospheric storage tanks fabricated and erected at site shall be subjected
to tests (Hydro, NDT and Vacuum) according to design code as applicable.
iii) Rubber lining shall be tested for hardness and spark test, as applicable.

1.05.02 Pressure vessels:

1) NDT on weld joint shall be as per respective code requirements or the

minimum as specified as below:

i) 100% DPT on root run of butt weld, nozzle welds and finished fillet
welds.
ii) 10% DPT on all finished butt welds.
iii) 10% RT (covering all ‘T’/cross joints) of butt welds.

2) Butt welds of dished ends shall be stress relieved and subjected to 100% RT.

3) Each finished vessels shall be hydraulically tested to 150% of the design

pressure for a duration of 30 minutes.

1.06.00 HEAT EXCHANGER/HEATER:

1.06.01 All material shall be tested for chemical and mechanical properties and NDT as per
relevant standard.

1.06.02 NDT on welds and other checks shall be as per relevant code.

1.06.03 Air heaters shall be subjected to dimensional and clearance checks as per standard
practice

1.06.04 Lub. oil system, drive system, soot blowing system etc. of Air heaters shall be checked
suitably as per standard practice

1.07.00 PUMPS:

1.07.01 UT on shaft forgings (greater or equal to 40mm) and MPI/DPT shall be done on shafts
and impeller to ensure freedom from defects.

1.07.02 The pump casing shall be hydraulically tested at 200% of pump rated head or at 150%
of shut off head, whichever is higher. The test pressure shall be maintained for at least
half an hour.

1.07.03 The pump rotating parts shall be subjected to static and dynamic balancing.

1.07.04 All pumps shall be tested at shop for capacity, head efficiency and brake horse power
at rated speed as per relevant/applicable standard.

1.07.05 Noise and vibration shall be measured during the performance testing at shop.

LOT-2 PROJECTS TECHNICAL SPECIFICATION PART-B Page

FLUE GAS DESULPHURISATION (FGD) SECTION – VI SUB-SECTION-V-QM1 2 of 4
SYSTEM PACKAGE BID DOC. NO.:CS-0011-109(2)-9 FGD SYSTEM

Page 208 of 338

 SUPPLIERS NAME AND INDICATIVE FIELD QUALITY PLAN ANNEXURE- V
ADDRESS: QP NO. : 2 PROJECT:
LOGO ITEM : STRUCTURAL STEEL WORK
REV. NO .: 0 PACKAGE: FLUE GAS DESULPHURISATION SYSTEM PACKAGE
SUB-SYSTEM : FABRICATION & ERECTION DATE : CONTRACT NO.
PAGE : MAIN CONTRACTOR
Sl. No Activity and operation Characteristics / instruments Class# of Type of Check Quantum Of check Reference Document Acceptance Format of Remarks
check Norms Record

1 2 3 4 5 6 7 8 9 D* 10
1.00 MATERIALS
i Structural steel procured from A Review For each batch of SR
NTPC approved sources- each section delivered Correlated MTC shall be verified. In
Mechanical (YS, UTS, Elg, UT if at site Technical Specification and Construction the event of non submission of
√
specified),,and Chemical Drawings, IS 2062 MTC , sample shall be selected by
properties (CE as per IS) FQA for testing

2.00 FIT-UP
2.01 Marking and Cutting As agreed / B Visual & Each plate/ Section Tech Specs and Const. Drawings/ SR
required Measurement Approved cutting plan
2.02 Match markings for trial As agreed / B Physical Each fit-up SR
Tech Specs and Const. Drawings
assembled components required
2.03 Weld Fit Up As agreed / B Physical Each fit-up SR Edge Preparation/ Gap/ Alignment
Tech Specs and Const. Drawings √
required

3.00 PRE HEATING (wherever applicable)

3.01 Pre-Heating Temperature As agreed / B Measurement Each pre-heating Tech Specs and Const. Drawings, SR
√
required Approved WPS
3.02 Post Weld Heat Treatment As agreed / A Time & Each PWHT Tech Specs and Const. Drawings, SR
√
(PWHT), if required required Temperature Approved WPS

4.00 WELDING REQUIREMENTS

4.01 PQR and Welder's Qualification As agreed / A Physical Each welder Approved WPS/ PQR, AWS-D1.1/ASME- Test
√

Page 209 of 338

required IX, Tech Specs and Const. Drawings Report
4.02 Welding consumables As agreed / B Physical Random in each shift Approved WPS/ Owner Rationalized list SR
√
required of Electrodes.
4.03 Sequence of welding As agreed / B Physical Random in each shift Tech Specs and Const. Drawings, SR
required Agreed scheme
4.04 Removal/ grinding of temporary As agreed / B Measurement All cleats/ attachments Tech Specs and Const. Drawings, IS- SR
attachments required 7215/Approved Drg.
4.05 Completeness after welding- As agreed / B Visual Each structure SR
Tech Specs and Const. Drawings
Dimensions/ distortion required component

5.00 NON DESTRUCTIVE AND DESTRUCTIVE TESTING

5.01 Fillet Welds
5.01.01 Visual As required/ B Visual/ Each welded joint As per technical specifications and SR As per requirement of Owner
agreed Measurement construction drawings Engineer
5.01.02 Macro-Etch Examination B Physical Main fillet weld with SR
As required/ min one joint per built As per technical specifications and
up beam, columns and √
agreed construction drawings
crane girders

INDICATIVE FIELD QUALITY PLAN-STRUCTURAL STEEL FGD SYSTEM PACKAGE PAGE 33 OF 37

 SUPPLIERS NAME AND INDICATIVE FIELD QUALITY PLAN ANNEXURE- V
ADDRESS: QP NO. : 2 PROJECT:
LOGO ITEM : STRUCTURAL STEEL WORK
REV. NO .: 0 PACKAGE: FLUE GAS DESULPHURISATION SYSTEM PACKAGE
SUB-SYSTEM : FABRICATION & ERECTION DATE : CONTRACT NO.
PAGE : MAIN CONTRACTOR
Sl. No Activity and operation Characteristics / instruments Class# of Type of Check Quantum Of check Reference Document Acceptance Format of Remarks
check Norms Record

1 2 3 4 5 6 7 8 9 D* 10
5.01.03 Dye Penetration Test (DPT) B Physical 25% weld length of SR
tension member of
crane girder- For
crane girder
As required/ As per technical specifications and
5% of Weld length √
agreed construction drawings
with min. 300mm at
each location - Except
Crane Girder, for all
other Fillet Welds

5.02 Butt Welds

5.02.01 Visual As required/ B Visual Random in each shift As per technical specifications and SR
agreed construction drawings
5.02.02 Dye Penetration Test B Physical 100% DPT after back SR All butt welds to be back gouged
gouging on all butt before DPT
welds except for coal
As required/ bunker bins As per technical specifications and
agreed construction drawings
10% DPT after back
gouging-For coal
bunker bins
5.02.03 Mechanical testing on A Physical Min. one joint per built SR Test on production test coupons

Page 210 of 338

production test coupons As required/ up beams, coloums As per technical specifications and
and crane girder. √
agreed construction drawings

5.02.04 Radiography Test (RT) A Physical 100% RT on butt SR In case of failure of any welds in
welds of tension SPOT/RT or UT the % of retesting
flange (bottom flange) shall be doubled at that particular
of crane girders location. Acceptance criteria of
NDT on welds shall be as per AWS
5% spot RT on butt D1.1.
welds / at inaccessible
As required/ locations UT on butt As per technical specifications and Wherever RT is not feasible UT to
agreed welds- For coal bunker construction drawings
√ be carried out with the approval of
bins the Engineer

10% RT weld length of

each welder on butt
welds, except for
crane girders and coal
bunk

5.03 Full Penetration Welds (Other than butt welds)

INDICATIVE FIELD QUALITY PLAN-STRUCTURAL STEEL FGD SYSTEM PACKAGE PAGE 34 OF 37

 SUPPLIERS NAME AND INDICATIVE FIELD QUALITY PLAN ANNEXURE- V
ADDRESS: QP NO. : 2 PROJECT:
LOGO ITEM : STRUCTURAL STEEL WORK
REV. NO .: 0 PACKAGE: FLUE GAS DESULPHURISATION SYSTEM PACKAGE
SUB-SYSTEM : FABRICATION & ERECTION DATE : CONTRACT NO.
PAGE : MAIN CONTRACTOR
Sl. No Activity and operation Characteristics / instruments Class# of Type of Check Quantum Of check Reference Document Acceptance Format of Remarks
check Norms Record

1 2 3 4 5 6 7 8 9 D* 10
5.03.01 Ultrasonic Testing (UT) A Physical 100% UT on the web IR In case of failure of any welds in
to flange joint of crane SPOT/RT or UT the % of retesting
As required/ girder As per technical specifications and shall be doubled at that particular
√ loaction. Acceptance criteria of
agreed construction drawings
10% UT on other full NDT on welds shall be as per AWS
penetration joints D1.1.

5.04 NON DESTRUCTIVE AND DESTRUCTIVE TESTING FOR CHIMNEY STEEL LINER
i Visual examination B Visual 100% SR As per requirement of NTPC Engineer
As per technical specifications and
As required/ agreed √
construction drawings, IS 822, AWS D 1.1

ii DPT B Physical 100% IR

As per technical specifications and
As required/ agreed √
construction drawings, IS 822, AWS D 1.1

iii RT A Physical 10% FOR SHOP BUTT

WELD AND 15% FOR As per technical specifications and
As required/ agreed
SITE BUTT WELDS construction drawings, IS 822, AWS D 1.1

6.00 FOUNDATION CHECKS

6.01 Dimensions and levels As agreed / B Physical/ Each Foundation SR Shape, lines (including diagonal
Tech Specs and Const. Drawings √
required Measurement checks)
6.02 Foundation Bolts and As agreed / B Physical/ Each Foundation SR Measurement of Verticality, Levels,
Tech Specs and Const. Drawings

Page 211 of 338

√
Embedments required Measurement pitch distance

7.00 PRE-ASSEMBLY CHECKS

7.01 Punch Erection marks and B Visual/ Each structural Markings for -
match marks on members As agreed / Physical member Assembly designation, Part
Tech Specs and Const. Drawings
required number, Weight, Any other
important identifications.
7.02 Pre-assembly as per match As agreed / B Visual/ Each structural
Tech Specs and Const. Drawings
mark required Physical member
7.03 Camber, sweep and total length B Visual/ Each structural SR
As agreed /
after trial assembly of structure. Physical member Tech Specs and Const. Drawings √
required
7.04 Control assembly check at shop B Visual/ Every first and tenth
As agreed /
Physical set of identical Tech Specs and Const. Drawings
required
structure

8.00 ERECTION CHECKS

8.01 Alignment, slopes, level, As agreed / B Measurement Each structural SR
Tech Specs and Const. Drawings √
tolerances of erected member required member
8.02 Tightening of bolts including As agreed / B Visual/ Each structural SR
Tech Specs and Const. Drawings √
foundation bolts with lock nuts required Physical member

INDICATIVE FIELD QUALITY PLAN-STRUCTURAL STEEL FGD SYSTEM PACKAGE PAGE 35 OF 37

 SUPPLIERS NAME AND INDICATIVE FIELD QUALITY PLAN ANNEXURE- V
ADDRESS: QP NO. : 2 PROJECT:
LOGO ITEM : STRUCTURAL STEEL WORK
REV. NO .: 0 PACKAGE: FLUE GAS DESULPHURISATION SYSTEM PACKAGE
SUB-SYSTEM : FABRICATION & ERECTION DATE : CONTRACT NO.
PAGE : MAIN CONTRACTOR
Sl. No Activity and operation Characteristics / instruments Class# of Type of Check Quantum Of check Reference Document Acceptance Format of Remarks
check Norms Record

1 2 3 4 5 6 7 8 9 D* 10
8.03 Acceptance of erected structure As agreed / B Visual/ Each erected structure Tech Specs and Const. Drawings, IS SR
√
required Physical 7215 and IS 12843
9.00 INSTALLATION AND ALIGNMENT OF STEEL LINER
i Submission of Installation/ Erection B Approval Once prior to erection of Approved drawings and Technical SR √
Scheme/ methodology for all - each structure Specifications
structures
ii Check for Erection Marks - B Visual 100% Approved drawings and Technical SR
iii Check for Installation of Steel B Visual/ 100% Approved drawings and Technical SR
As required
Liners Acceptance Specifications
iv Check for Site Joints B Visual/ 100% Approved drawings and Technical SR
As required
Acceptance Specifications
v Check for Installation of Inlet B Visual/ 100% Approved drawings and Technical SR
As required
Transition Ducts Acceptance Specifications
vi Check for Installation of Insulations B Visual, Physical, 100% Approved drawings and Technical SR Each layer of expansion Compensator
and Expansion Compensators Acceptance Specifications tobe checked at shop for thickness,
As required unit weight, tensile strength &
elongation along with temp.
withstandability for composite joints
vii Ensure the Erection of all steel B Visual/ 100% Approved drawings and Technical SR
structures along with permissible As required Acceptance Specifications
tolerances and their acceptance
viii Check and approval for B Visual/ 100% Approved drawings and Technical SR
Dismantling, Modification and Re- As required Acceptance Specifications
erection, if required for any reason

Page 212 of 338

10.00 PAINTING SYSTEM
10.01 Paining Materials and As agreed / A Review of MTC Each batch of delivery SR/MTC Mfr.’s T.C. shall be correlated with
Tech Specs and Const. Drawings √
accessories required the consignment received.
10.02 Surface prepration As agreed / B Physical /visual Random in each shift Tech Specs and Const. Drawings, SR
√
required Relevant code/ standards
10.03 DFT of paint - Over steel surface As agreed / B Physical Each surface at SR
Tech Specs and Const. Drawings √
required random
10.04 Acceptance of painted surfaces As agreed / B Physical Each surface at SR
Tech Specs and Const. Drawings
required random

11.00 PERMANENT BOLTS AND NUTS AND WASHERS

11.01 Material A Physical and Once for each lot of SR/MTC Permanent mild steel Bolts, mild
MTC Review delivery steel Nuts, Mild steel Washers,
As agreed / High strength structural Bolts,
Tech Specs and Const. Drawings √
required Washers-Dimensions, properties,
storage along with MTC
11.02 Contact surfaces before bolting As agreed / B Physical Random before Tech Specs and Const. Drawings, IS SR
required asembly for bolting 4000

INDICATIVE FIELD QUALITY PLAN-STRUCTURAL STEEL FGD SYSTEM PACKAGE PAGE 36 OF 37

 SUPPLIERS NAME AND INDICATIVE FIELD QUALITY PLAN ANNEXURE- V
ADDRESS: QP NO. : 2 PROJECT:
LOGO ITEM : STRUCTURAL STEEL WORK
REV. NO .: 0 PACKAGE: FLUE GAS DESULPHURISATION SYSTEM PACKAGE
SUB-SYSTEM : FABRICATION & ERECTION DATE : CONTRACT NO.
PAGE : MAIN CONTRACTOR
Sl. No Activity and operation Characteristics / instruments Class# of Type of Check Quantum Of check Reference Document Acceptance Format of Remarks
check Norms Record

1 2 3 4 5 6 7 8 9 D* 10
11.03 Inspection of the assembled B Physical Randomly in each shift SR
As agreed / Tech Specs and Const. Drawings, IS
bolts for assembeled bolts
required 4000
11.04 Tensioning B Physical Randomly during snug SR
As agreed / Tech Specs and Const. Drawings, IS
tight test and after full √
required 4000
tensinoning
11.05 Acceptance of installed bolts As agreed / B Physical Each bolt SR
Tech Specs and Const. Drawings
required

12.00 STAINLESS STEEL HAND RAILS

12.01 Material A Physical/MTC Once for each lot of SR/MTC Also check grade of steel
As agreed / Review(In case delivery
Tech Specs and Const. Drawings √
required procured by
contractor)
12.02 DPT for welding A Physical Random for each SR/LB WPS shall be submited for Owner
As agreed / AWS D1.1 / 'Tech Specs and Const.
fabrication √ approval , electrodes used shall be
required Drawings
as specified in WPS
12.03 Acceptance of stainless steel As agreed / B Physical Each installation SR
Tech Specs and Const. Drawings
hand rails required

13.00 PTFE SLIDING BEARINGS AND ELASTOMERIC BEARINGS

13.01 Material from approved source As agreed / A Physical and Once for each lot of Tech Specs and Const. Drawings SR/MTC
√

Page 213 of 338

required MTC Review delivery
13.02 Acceptance of installation of As agreed / B Physical Each installation Tech Specs and Const. Drawings SR
bearings required

LEGEND: D * Records, indentified with “Tick” (√) shall be essentially included by supplier in QA DOC. NO.: REV: 0
Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR, TR, MTC, LB
Manufac Main-supplier Categorization Witnessing & Accepting (As per Owner QA&I System) For Owner USE
turer/ Category ‘A’ FQA Engineer in association with Executing Engineer, Category ‘B’ Executing Engineer, Category ‘C’
Sub- Executing Engineer ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate
supplier
Signature This document shall be read in conjunction with Owner Tech. Specifications, BOQ, Drawings REVIEWED BY APPROVED BY APPROVAL SEAL

INDICATIVE FIELD QUALITY PLAN-STRUCTURAL STEEL FGD SYSTEM PACKAGE PAGE 37 OF 37

 TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-C2C
TECHNICAL SPECIFICATION FOR REV. 00
MISC. FGD TANKS
Date: April, 2020

SECTION-I,
SUB-SECTION-C2C

CUSTOMER SPECIFICATION: PAINTING SPECIFICATION

Page 214 of 338

 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

1. FANS

1 Axial Fan tool & fixtures 55 000 Power Tool Red Oxide Zinc Phosphate Primer 60 Synthetic Enamel to IS 2932 40 100
(Clause 20.03.00 of Part- C Cleaning to st3 to IS: 12744 (Two coats) Shade: Grey white
Section VI) (SSPC-SP3) RAL 9002 (Two coats)
2 Booster Fan foundation 55 081 Temporary rust preventive fluid application as per PRQA 523
material DFT- 20μ
All Threaded and other surfaces of foundation bolt and its materials shall be coated with temporary rust
preventive fluid. During execution of civil works the dried film of coating will be removed using Organic
Solvents.
3 Booster Fan Handrails & 55 082 Blast cleaning to Hand rails, Gratings- Hot dip galvanizing to 610gms/sq.m (minimum) and to a coating
Insert Sa 2½/ Acid thickness of 87μm (min).
(Clause 31.06.00 of Sec.VI, pickling
Part-B, Subsection- IV-D)
4 Booster Fan Handrails & 55 082 Blast cleaning to Primer: One coat of Two 70 Finish: Two coats of two
Insert- Structural items Sa 2½ (Near component moisture curing zinc pack aliphatic isocyanate
other than the above white metal) with (ethyl) silicate primer coat (Min cured acrylic polyurethane 240
(Clause 31.03.00 of Sec.VI, surface profile 40- 80% metallic zinc content in dry paint to IS 13213 solid by 70
Part-B, Subsection- IV-D) 60μm conforming film, solid by volume minimum volume min.55%±2)

Page 215 of 338

to ISO 8501-1 60% ±2). Zinc dust composition DFT- 35μ/ coat
and properties shall be as per Shade: Grey white,
Type II as per ASTM D520-00 RAL 9002
DFT- 70μ With gloss retention (SSPC
paint spec no.36, ASTM
Intermediate: One coat of Two D4587, D2244, D523 of level
component polyamide cured 100 2 after min. 1000 hrs
epoxy with MIO content exposure, gloss less than 30
(containing lamellar MIO Min and colour change less than
30% on pigment, solid by 2.0Δ E)
volume min. 80%±2)
DFT- 100μ
5 Axial booster cooling/ seal 55 084 Blast cleaning to Primer: Two coats of Epoxy 100 Finish: One coat of Epoxy
fan Sa 2½ resin based Epoxy Zinc based finish paint to IS 75
(Clause 1.04.00 of Part- A phosphate primer to IS 13238 14209; DFT- 75μ
Section VI) DFT- 50μ/coat
300

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

Intermediate: One coat of Two Finish: One coat of acrylic

component epoxy based 100 aliphatic polyurethane paint 25
intermediate paint pigmented to IS 13213
with MIO/Tio2 DFT-25μ
DFT- 100μ Shade: Grey White, RAL9002

6 Booster fan canopy for 55 089 Blast cleaning to Primer: Two coats of Epoxy 100 Finish: One coat of Epoxy
motor Sa 2½ resin based Epoxy Zinc based finish paint to IS 75
(Clause 1.04.00 of Part- A phosphate primer to IS 13238 14209; DFT- 75μ
Section VI) DFT- 50μ/coat
300
Intermediate: One coat of Two Finish: One coat of acrylic
component epoxy based 100 aliphatic polyurethane paint 25
intermediate paint pigmented to IS 13213
with MIO/Tio2 DFT-25μ
DFT- 100μ Shade: Grey White, RAL9002

7 Axial booster fan rotor 55 287 Power Tool Two coats of Epoxy based Zinc 60 NIL -- 60
(Clause 20.03.00 of Part- C Cleaning to St3 phosphate primer (Two pack
Section VI) (SSPC-SP3) system) to IS 13238;

Page 216 of 338

DFT- 30μ/coat
8 Axial booster fan stator 55 587 Power Tool Red Oxide Zinc Phosphate Primer 60 Synthetic Enamel to IS 2932 40 100
(Clause 20.03.00 of Part- C Cleaning to St3 to IS: 12744 (Two coats) Shade: Grey white
Section VI) (SSPC-SP3) RAL 9002 (Two coats)
9 Axial booster fan coupling 55 880 Blast cleaning to Primer: Two coats of Epoxy 100 Finish: One coat of Epoxy
(Clause 1.04.00 of Part- A Sa 2½ resin based Epoxy Zinc based finish paint to IS 75
Section VI) phosphate primer to IS 13238 14209; DFT- 75μ
DFT- 50μ/coat
300
Intermediate: One coat of Two Finish: One coat of acrylic
component epoxy based 100 aliphatic polyurethane paint 25
intermediate paint pigmented to IS 13213
with MIO/Tio2 DFT-25μ
DFT- 100μ Shade: Grey White, RAL9002

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

10 Booster fan LOS with 55 980 Blast cleaning to Primer: Two coats of Epoxy 100 Finish: One coat of Epoxy
lubricant Sa 2½ resin based Epoxy Zinc based finish paint to IS 75
(Clause 1.04.00 of Part- A phosphate primer to IS 13238 14209; DFT- 75μ
Section VI) DFT- 50μ/coat
300
Intermediate: One coat of Two Finish: One coat of acrylic
component epoxy based 100 aliphatic polyurethane paint 25
intermediate paint pigmented to IS 13213
with MIO/Tio2 DFT-25μ
DFT- 100μ Shade: Grey White, RAL9002

11 Booster fan actuator 55 983 Blast cleaning to Primer: Two coats of Epoxy 100 Finish: One coat of Epoxy
(Clause 1.04.00 of Part- A Sa 2½ resin based Epoxy Zinc based finish paint to IS 75
Section VI) phosphate primer to IS 13238 14209; DFT- 75μ
DFT- 50μ/coat
300
Intermediate: One coat of Two Finish: One coat of acrylic
component epoxy based 100 aliphatic polyurethane paint 25
intermediate paint pigmented to IS 13213
with MIO/Tio2 DFT-25μ

Page 217 of 338

DFT- 100μ Shade: Grey White, RAL9002

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

2. FGD SYSTEM

1 Slurry recirculation pump FW 212 Power Tool Primer: Red Oxide Zinc Phosphate 60 Two coats of Synthetic 100 210
System Cleaning to St3 Primer to IS: 12744 (Two coats) Enamel to IS 2932,
(Referred from cl. 7.05.00 (SSPC-SP3) DFT- 50μ/ coat
of Section-VI, Part-B, Intermediate: One coat of Shade: Light blue
Sub section-I-M5) Synthetic Enamel intermediate 50 RAL 5012
coat to IS 2932; DFT- 50μ
2 Absorber System Internals – FW 213 Blast cleaning to Primer: Two coats of Epoxy resin 100 Finish: One coat of Epoxy
Structural items Sa 2½ based Epoxy Zinc phosphate based finish paint to IS 75
(Clause 1.04.00 of Part- A primer to IS 13238 14209; DFT- 75μ
Section VI) DFT- 50μ/coat
300
Intermediate: One coat of Two Finish: One coat of acrylic
component epoxy based 100 aliphatic polyurethane paint 25
intermediate paint pigmented with to IS 13213
MIO/Tio2 DFT-25μ
DFT- 100μ Shade: Grey White, RAL9002

3 Mist eliminator and FW 215 Blast cleaning to Primer: Two coats of Epoxy resin 100 Finish: One coat of Epoxy

Page 218 of 338

accessories, Absorber baffle FW 216 Sa 2½ based Epoxy Zinc phosphate based finish paint to IS 75
grating support, Mist FW 217 primer to IS 13238 14209; DFT- 75μ
eliminator support& FW 218 DFT- 50μ/coat
Absorber Spray pipe support 300
- Structural items Intermediate: One coat of Two Finish: One coat of acrylic
(Clause 1.04.00 of Part- A component epoxy based 100 aliphatic polyurethane paint 25
Section VI) intermediate paint pigmented with to IS 13213
MIO/Tio2 DFT-25μ
DFT- 100μ Shade: Grey White, RAL9002

4 Absorber System- Base FW 219 Blast cleaning to Primer: One coat of Two 70 Finish: Two coats of two
(Clause 31.03.00 of Sec.VI, Sa 2½ (Near component moisture curing zinc pack aliphatic isocyanate
Part-B, Subsection- IV-D) white metal) (ethyl) silicate primer coat (Min cured acrylic polyurethane 240
with surface 80% metallic zinc content in dry paint to IS 13213 solid by 70
profile 40-60μm film, solid by volume minimum volume min.55%±2)
60% ±2). Zinc dust composition DFT- 35μ/ coat

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

conforming to and properties shall be as per Shade: Grey white,

ISO 8501-1 Type II as per ASTM D520-00 RAL 9002
DFT- 70μ With gloss retention (SSPC
paint spec no.36, ASTM
Intermediate: One coat of Two D4587, D2244, D523 of level
component polyamide cured epoxy 100 2 after min. 1000 hrs
with MIO content (containing exposure, gloss less than 30
lamellar MIO Min 30% on pigment, and colour change less than
solid by volume min. 80%±2) 2.0Δ E)
DFT- 100μ

5 Absorber system structures, FW 220 Blast cleaning to Primer: One coat of Two 70 Finish: Two coats of two
Absorber shear plate, Duct FW 231 Sa 2½ (Near component moisture curing zinc pack aliphatic isocyanate
supports, Structures for RC FW 232 white metal) (ethyl) silicate primer coat (Min cured acrylic polyurethane 240
pump house& Hook up duct FW 233 with surface 80% metallic zinc content in dry paint to IS 13213 solid by 70
structure FW 234 profile 40-60μm film, solid by volume minimum volume min.55%±2)
(Clause 31.03.00 of Sec.VI, FW 236 conforming to 60% ±2). Zinc dust composition DFT- 35μ/ coat
Part-B, Subsection- IV-D) FW 238 ISO 8501-1 and properties shall be as per Shade: Grey white,
Type II as per ASTM D520-00 RAL 9002
DFT- 70μ With gloss retention (SSPC

Page 219 of 338

paint spec no.36, ASTM
Intermediate: One coat of Two D4587, D2244, D523 of level
component polyamide cured epoxy 100 2 after min. 1000 hrs
with MIO content (containing exposure, gloss less than 30
lamellar MIO Min 30% on pigment, and colour change less than
solid by volume min. 80%±2) 2.0Δ E)
DFT- 100μ
6 Absorber system casing FW 221 Blast cleaning to Primer: One coat of Two 70 Finish: Two coats of two
bottom- Outside surfaces Sa 2½ (Near component moisture curing zinc pack aliphatic isocyanate
(Clause 31.03.00 of Sec.VI, white metal) (ethyl) silicate primer coat (Min cured acrylic polyurethane 240
Part-B, Subsection- IV-D) with surface 80% metallic zinc content in dry paint to IS 13213 solid by 70
profile 40-60μm film, solid by volume minimum volume min.55%±2)
conforming to 60% ±2). Zinc dust composition DFT- 35μ/ coat
ISO 8501-1 and properties shall be as per Shade: Grey white,
Type II as per ASTM D520-00 RAL 9002
DFT- 70μ With gloss retention (SSPC
paint spec no.36, ASTM

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

Inside surfaces are of C276 Intermediate: One coat of Two D4587, D2244, D523 of level
cladded sheets, hence no component polyamide cured epoxy 100 2 after min. 1000 hrs
paint is envisaged. with MIO content (containing exposure, gloss less than 30
lamellar MIO Min 30% on pigment, and colour change less than
solid by volume min. 80%±2) 2.0Δ E)
DFT- 100μ
7 Absorber system casing top- FW 222 Blast cleaning to Primer: One coat of Two 70 Finish: Two coats of two
Outside surfaces Sa 2½ (Near component moisture curing zinc pack aliphatic isocyanate
(Clause 31.03.00 of Sec.VI, white metal) (ethyl) silicate primer coat (Min cured acrylic polyurethane 240
Part-B, Subsection- IV-D) with surface 80% metallic zinc content in dry paint to IS 13213 solid by 70
profile 40-60μm film, solid by volume minimum volume min.55%±2)
conforming to 60% ±2). Zinc dust composition DFT- 35μ/ coat
ISO 8501-1 and properties shall be as per Shade: Grey white,
Type II as per ASTM D520-00 RAL 9002
DFT- 70μ With gloss retention (SSPC
paint spec no.36, ASTM
Inside surfaces are of C276 Intermediate: One coat of Two D4587, D2244, D523 of level
cladded sheets, hence no component polyamide cured epoxy 100 2 after min. 1000 hrs
paint is envisaged. with MIO content (containing exposure, gloss less than 30
lamellar MIO Min 30% on pigment, and colour change less than

Page 220 of 338

solid by volume min. 80%±2) 2.0Δ E)
DFT- 100μ
8 Absorber system accessories FW 223 Power Tool Red Oxide Zinc Phosphate Primer 60 Synthetic Enamel to IS 2932 40 100
(Clause 20.03.00 of Part- C Cleaning to to IS: 12744 (Two coats) Shade: Grey white
Section VI) St3 (SSPC-SP3) RAL 9002 (Two coats)

9 Emergency Quench water FW 226 Blast cleaning to Primer: One coat of Two 70 Finish: Two coats of two
tank- Outside surfaces Sa 2½ (Near component moisture curing zinc pack aliphatic isocyanate
(Clause 31.03.00 of Sec.VI, white metal) (ethyl) silicate primer coat (Min cured acrylic polyurethane 240
Part-B, Subsection- IV-D) with surface 80% metallic zinc content in dry paint to IS 13213 solid by 70
profile 40-60μm film, solid by volume minimum volume min.55%±2)
conforming to 60% ±2). Zinc dust composition DFT- 35μ/ coat
ISO 8501-1 and properties shall be as per Shade: Grey white,
Type II as per ASTM D520-00 RAL 9002
DFT- 70μ

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

With gloss retention (SSPC

Intermediate: One coat of Two paint spec no.36, ASTM
component polyamide cured epoxy 100 D4587, D2244, D523 of level
with MIO content (containing 2 after min. 1000 hrs
lamellar MIO Min 30% on pigment, exposure, gloss less than 30
solid by volume min. 80%±2) and colour change less than
DFT- 100μ 2.0Δ E)
10 Emergency Quench water FW 226 Blast cleaning to
tank- Sa 2½ (Near Primer: Two coats of Red Oxide Zinc phosphate primer, DFT-30μ/coat; Total-60μ
Inside surfaces white metal) (Primer is only envisaged as lining is given in inside surfaces of the tank)
with surface
profile 35-50μm
11 Emergency quench system, FW 227 Power Tool Red Oxide Zinc Phosphate Primer 60 Synthetic Enamel to IS 2932 60 120
Handling Equipment RC FW 249 Cleaning to to IS: 12744 (Two coats) Shade: Grey white
pump St3 (SSPC-SP3) RAL 9002 (Two coats)
(Clause 20.03.00 of Part- C
Section VI)
12 Air oxidation system, FW 230 Power Tool Red Oxide Zinc Phosphate Primer 60 Synthetic Enamel to IS 2932 40 100
Viewing ports (Without FW 239 Cleaning to to IS: 12744 (Two coats) Shade: Grey white
glass) St3 (SSPC-SP3) RAL 9002 (Two coats)

Page 221 of 338

(Clause 20.03.00 of Part- C
Section VI)
13 Absorber W/D interface, FW 228 Blast cleaning to Primer: Two coats of Epoxy resin 100 Finish: One coat of Epoxy
W/D wash system, Slurry FW 229 Sa 2½ based Epoxy Zinc phosphate based finish paint to IS 75
distribution system, FW 243 primer to IS 13238 14209; DFT- 75μ
Oxidation Air distribution FW 244 DFT- 50μ/coat
system 300
(Clause 1.04.00 of Part- A Intermediate: One coat of Two Finish: One coat of acrylic
Section VI) component epoxy based 100 aliphatic polyurethane paint 25
intermediate paint pigmented with to IS 13213
MIO/Tio2 DFT-25μ
DFT- 100μ Shade: Grey White, RAL9002

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

14 Expansion Flue gas Power Tool Red Oxide Zinc Phosphate Primer 60 -- -- 60
joint swept Cleaning to to IS: 12744 (two coats)
between surface St3 (SSPC-SP3)
bypass Insulated FW 251 Power Tool HR Aluminium paint to IS 13183 40 NIL -- 40
(Clause surfaces Cleaning to Gr.II (upto 400 deg C)
20.03.00 of St3 (SSPC-SP3)
Part- C
Section VI)
15 Expansion Flue gas Power Tool Red Oxide Zinc Phosphate Primer 60 NIL -- 60
joint swept Cleaning to to IS: 12744 (Two coats)
(Clause surface St3 (SSPC-SP3)
20.03.00 of FW 252
Part- C Insulated Power Tool HR Aluminium paint to IS 13183 40 NIL -- 40
Section VI) surfaces Cleaning to Gr.II (upto 400 deg C)
St3 (SSPC-SP3)

16 Ducts Flue gas Power Tool Red Oxide Zinc Phosphate Primer 60 NIL -- 60
between swept Cleaning to to IS: 12744 (Two coats)
bypass duct surface St3 (SSPC-SP3)

Page 222 of 338

inlet& FW 255
booster fan Insulated Power Tool HR Aluminium paint to IS 13183 40 NIL -- 40
(Clause surfaces Cleaning to Gr.II (upto 400 deg C)
20.03.00 of St3 (SSPC-SP3)
Part- C
Section VI)

17 Ducts Flue gas Power Tool Red Oxide Zinc Phosphate Primer 60 NIL -- 60
between swept Cleaning to to IS: 12744 (Two coats)
Booster fan& surface St3 (SSPC-SP3)
Absorber FW 256
(Clause Insulated Power Tool HR Aluminium paint to IS 13183 40 NIL -- 40
20.03.00 of surfaces Cleaning to Gr.II (upto 400 deg C)
Part- C St3 (SSPC-SP3)
Section VI)

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

18 Ducts Flue gas Power Tool Red Oxide Zinc Phosphate Primer 60 NIL -- 60
between swept Cleaning to to IS: 12744 (Two coats)
Absorber& surface FW 257 St3 (SSPC-SP3)
Stack
(Clause Insulated Power Tool HR Aluminium paint to IS 13183 40 NIL -- 40
20.03.00 of surfaces Cleaning to Gr.II (upto 400 deg C)
Part- C St3 (SSPC-SP3)
Section VI)
19 Duct structure between Blast cleaning to Primer: One coat of Two 70 Finish: Two coats of two
bypass duct& Booster fan Sa 2½ (Near component moisture curing zinc pack aliphatic isocyanate
(Clause 31.03.00 of Sec.VI, white metal) (ethyl) silicate primer coat (Min cured acrylic polyurethane 240
Part-B, Subsection- IV-D) FW 260 with surface 80% metallic zinc content in dry paint to IS 13213 solid by 70
profile 40-60μm film, solid by volume minimum volume min.55%±2)
conforming to 60% ±2). Zinc dust composition DFT- 35μ/ coat
ISO 8501-1 and properties shall be as per Shade: Grey white,
Type II as per ASTM D520-00 RAL 9002
DFT- 70μ With gloss retention (SSPC
paint spec no.36, ASTM
Intermediate: One coat of Two D4587, D2244, D523 of level

Page 223 of 338

component polyamide cured epoxy 100 2 after min. 1000 hrs
with MIO content (containing exposure, gloss less than 30
lamellar MIO Min 30% on pigment, and colour change less than
solid by volume min. 80%±2) 2.0Δ E)
DFT- 100μ
20 Duct structure between Blast cleaning to Primer: One coat of Two 70 Finish: Two coats of two
Booster fan& Absorber Sa 2½ (Near component moisture curing zinc pack aliphatic isocyanate
(Clause 31.03.00 of Sec.VI, white metal) (ethyl) silicate primer coat (Min cured acrylic polyurethane 240
Part-B, Subsection- IV-D) FW 261 with surface 80% metallic zinc content in dry paint to IS 13213 solid by 70
profile 40-60μm film, solid by volume minimum volume min.55%±2)
conforming to 60% ±2). Zinc dust composition DFT- 35μ/ coat
ISO 8501-1 and properties shall be as per Shade: Grey white,
Type II as per ASTM D520-00 RAL 9002
DFT- 70μ With gloss retention (SSPC
paint spec no.36, ASTM
Intermediate: One coat of Two D4587, D2244, D523 of level
component polyamide cured epoxy 100 2 after min. 1000 hrs

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

with MIO content (containing exposure, gloss less than 30

lamellar MIO Min 30% on pigment, and colour change less than
solid by volume min. 80%±2) 2.0Δ E)
DFT- 100μ
21 Duct structure between Blast cleaning to Primer: One coat of Two 70 Finish: Two coats of two
Absorber & Stack Sa 2½ (Near component moisture curing zinc pack aliphatic isocyanate
(Clause 31.03.00 of Sec.VI, white metal) (ethyl) silicate primer coat (Min cured acrylic polyurethane 240
Part-B, Subsection- IV-D) FW 262 with surface 80% metallic zinc content in dry paint to IS 13213 solid by 70
profile 40-60μm film, solid by volume minimum volume min.55%±2)
conforming to 60% ±2). Zinc dust composition DFT- 35μ/ coat
ISO 8501-1 and properties shall be as per Shade: Grey white,
Type II as per ASTM D520-00 RAL 9002
DFT- 70μ With gloss retention (SSPC
paint spec no.36, ASTM
Intermediate: One coat of Two D4587, D2244, D523 of level
component polyamide cured epoxy 100 2 after min. 1000 hrs
with MIO content (containing exposure, gloss less than 30
lamellar MIO Min 30% on pigment, and colour change less than
solid by volume min. 80%±2) 2.0Δ E)

Page 224 of 338

DFT- 100μ

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

22 Foundation material for FW 280 Temporary rust preventive fluid application as per PRQA 523
duct structures, Absorber, FW 281 DFT- 20μ
Elevator, RC pump shed, FW 282 All Threaded and other surfaces of foundation bolt and its materials shall be coated with temporary rust
tanks, Silo Structure, pipe FW 283 preventive fluid. During execution of civil works the dried film of coating will be removed using Organic
racks FW 740 Solvents.
FW 760
FW 762
FW 763
23 Structures for Emergency FW 285 Blast cleaning to Primer: One coat of Two 70 Finish: Two coats of
Quench water tank FW 292 Sa 2½ (Near component moisture curing zinc two pack aliphatic
Structures for Elevator white metal) with (ethyl) silicate primer coat (Min isocyanate cured acrylic 240
(Clause 31.03.00 of Sec.VI, surface profile 40- 80% metallic zinc content in dry polyurethane paint to 70
Part-B, Subsection- IV-D) 60μm conforming film, solid by volume minimum IS 13213 solid by
to ISO 8501-1 60% ±2). Zinc dust composition volume min.55%±2)
and properties shall be as per DFT- 35μ/ coat
Type II as per ASTM D520-00 Shade: Grey white,
DFT- 70μ RAL 9002
With gloss retention
Intermediate: One coat of Two (SSPC paint spec no.36,
component polyamide cured 100 ASTM D4587, D2244,

Page 225 of 338

epoxy with MIO content D523 of level 2 after
(containing lamellar MIO Min 30% min. 1000 hrs
on pigment, solid by volume min. exposure, gloss less
80%±2) than 30 and colour
DFT- 100μ change less than
2.0Δ E)
24 Elevator and accessories FW 293 Power Tool Red Oxide Zinc Phosphate Primer 60 Synthetic Enamel to IS 60 120
(Clause 20.03.00 of Part- C FW 716 Cleaning to st3 to IS: 12744 (Two coats) 2932 Shade: Grey
Section VI) (SSPC-SP3 white
RAL 9002 (Two coats)

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

25 Structures for booster fan FW 310 Blast cleaning to Primer: One coat of Two component 70 Finish: Two coats of two
handling Sa 2½ (Near moisture curing zinc (ethyl) silicate pack aliphatic isocyanate
(Clause 31.03.00 of white metal) primer coat (Min 80% metallic zinc cured acrylic polyurethane 240
Sec.VI, Part-B, with surface content in dry film, solid by volume paint to IS 13213 solid by 70
Subsection- IV-D) profile 40-60μm minimum 60% ±2). Zinc dust volume min.55%±2)
conforming to composition and properties shall be DFT- 35μ/ coat
ISO 8501-1 as per Type II as per ASTM D520-00 Shade: Grey white,
DFT- 70μ RAL 9002
With gloss retention (SSPC
Intermediate: One coat of Two paint spec no.36, ASTM
component polyamide cured epoxy D4587, D2244, D523 of
with MIO content (containing 100 level 2 after min. 1000 hrs
lamellar MIO Min 30% on pigment, exposure, gloss less than
solid by volume min. 80%±2) 30 and colour change less
DFT- 100μ than 2.0Δ E)
26 Galleries and railings for
Stairs, Absorber, Dampers, FW 237

Page 226 of 338

Ducts, Tanks FW 610
(Clause 31.06.00 of FW 612 Blast cleaning to
Sec.VI, Part-B, FW 613 Hand rails, Gratings- Hot dip galvanizing to 610gms/sq.m (minimum) and to a coating
Sa 2½/ Acid
FW 722 thickness of 87μm (minimum)
Subsection- IV-D) pickling

27 Galleries and railings for Blast cleaning to Primer: One coat of Two component 70 Finish: Two coats of two
Stairs, Absorber, Dampers, Sa 2½ (Near moisture curing zinc (ethyl) silicate pack aliphatic isocyanate
Ducts, Tanks – Structures FW 237 white metal) primer coat (Min 80% metallic zinc cured acrylic polyurethane 240
other than the above FW 610 with surface content in dry film, solid by volume paint to IS 13213 solid by 70
(Clause 31.03.00 of FW 612 profile 40-60μm minimum 60% ±2). Zinc dust volume min.55%±2)
Sec.VI, Part-B, FW 613 conforming to composition and properties shall be DFT- 35μ/ coat
Subsection- IV-D) FW 722 ISO 8501-1 as per Type II as per ASTM D520-00 Shade: Grey white,
DFT- 70μ RAL 9002

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

With gloss retention (SSPC

Intermediate: One coat of Two paint spec no.36, ASTM
component polyamide cured epoxy D4587, D2244, D523 of
with MIO content (containing 100 level 2 after min. 1000 hrs
lamellar MIO Min 30% on pigment, exposure, gloss less than
solid by volume min. 80%±2) 30 and colour change less
DFT- 100μ than 2.0Δ E)
28 Slurry pumps & FW 701 Power Tool Primer: Red Oxide Zinc Phosphate 60 Two coats of Synthetic 100 210
accessories, Water pumps FW 702 Cleaning to Primer to IS: 12744 (Two coats) Enamel to IS 2932,
(Referred from cl. 7.05.00 St3 (SSPC-SP3) DFT- 50μ/ coat
of Section-VI, Part-B, Intermediate: One coat of Synthetic Shade: Light blue
Sub section-I-M5) Enamel intermediate coat to IS 50 RAL 5012
2932; DFT- 50μ
29 Monorail for hoist & cranes FW 710 Blast cleaning to Primer: One coat of Two component 70 Finish: Two coats of two
(Clause 31.03.00 of Sa 2½ (Near moisture curing zinc (ethyl) silicate pack aliphatic isocyanate
Sec.VI, Part-B, white metal) primer coat (Min 80% metallic zinc cured acrylic polyurethane 240
Subsection- IV-D) with surface content in dry film, solid by volume paint to IS 13213 solid by 70
profile 40-60μm minimum 60% ±2). Zinc dust volume min.55%±2)
conforming to composition and properties shall be DFT- 35μ/ coat
ISO 8501-1 as per Type II as per ASTM D520-00 Shade: Grey white,

Page 227 of 338

DFT- 70μ RAL 9002
With gloss retention (SSPC
Intermediate: One coat of Two paint spec no.36, ASTM
component polyamide cured epoxy D4587, D2244, D523 of
with MIO content (containing 100 level 2 after min. 1000 hrs
lamellar MIO Min 30% on pigment, exposure, gloss less than
solid by volume min. 80%±2) 30 and colour change less
DFT- 100μ than 2.0Δ E)
30 Handling Equipment- FW 713 Power Tool Red Oxide Zinc Phosphate Primer to 70 Synthetic Enamel to IS 60 130
Hoists& Man hole door FW 714 Cleaning to st3 IS: 12744 (Two coats) 2932 Shade: Grey white
(Clause 20.03.00 of Part- FW 717 (SSPC-SP3 Idler roller shall be applied with two RAL 9002 (Two coats)
C Section VI) coats of 70 microns at shop

31 Agitator support FW 721 Blast cleaning to Primer: One coat of Two component 70 Finish: Two coats of two
Clause 31.03.00 of Sec.VI, Sa 2½ (Near moisture curing zinc (ethyl) silicate pack aliphatic isocyanate
Part-B, Subsection- IV-D) white metal) primer coat (Min 80% metallic zinc cured acrylic polyurethane 240
with surface content in dry film, solid by volume 70

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

profile 40-60μm minimum 60% ±2). Zinc dust paint to IS 13213 solid by
conforming to composition and properties shall be volume min.55%±2)
ISO 8501-1 as per Type II as per ASTM D520-00 DFT- 35μ/ coat
DFT- 70μ Shade: Grey white,
RAL 9002
Intermediate: One coat of Two With gloss retention (SSPC
component polyamide cured epoxy paint spec no.36, ASTM
with MIO content (containing 100 D4587, D2244, D523 of
lamellar MIO Min 30% on pigment, level 2 after min. 1000 hrs
solid by volume min. 80%±2) exposure, gloss less than
DFT- 100μ 30 and colour change less
than 2.0Δ E)
32 Limestone silo structures FW 730 Blast cleaning to Primer: One coat of Two component 70 Finish: Two coats of two
Clause 31.03.00 of Sec.VI, Sa 2½ (Near moisture curing zinc (ethyl) silicate pack aliphatic isocyanate
Part-B, Subsection- IV-D) white metal) primer coat (Min 80% metallic zinc cured acrylic polyurethane 240
with surface content in dry film, solid by volume paint to IS 13213 solid by 70
profile 40-60μm minimum 60% ±2). Zinc dust volume min.55%±2)
conforming to composition and properties shall be DFT- 35μ/ coat
ISO 8501-1 as per Type II as per ASTM D520-00 Shade: Grey white,
DFT- 70μ RAL 9002

Page 228 of 338

With gloss retention (SSPC
Intermediate: One coat of Two paint spec no.36, ASTM
component polyamide cured epoxy D4587, D2244, D523 of
with MIO content (containing 100 level 2 after min. 1000 hrs
lamellar MIO Min 30% on pigment, exposure, gloss less than
solid by volume min. 80%±2) 30 and colour change less
DFT- 100μ than 2.0Δ E)

33 Limestone Silo- Outside FW 731 Blast cleaning to Primer: One coat of Two component 70 Finish: Two coats of two
surfaces Sa 2½ (Near moisture curing zinc (ethyl) silicate pack aliphatic isocyanate
Clause 31.03.00 of Sec.VI, white metal) primer coat (Min 80% metallic zinc cured acrylic polyurethane 240
Part-B, Subsection- IV-D) with surface content in dry film, solid by volume paint to IS 13213 solid by 70
profile 40-60μm minimum 60% ±2). Zinc dust volume min.55%±2)
conforming to composition and properties shall be DFT- 35μ/ coat
ISO 8501-1 as per Type II as per ASTM D520-00 Shade: Grey white,
DFT- 70μ RAL 9002

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

Intermediate: One coat of Two With gloss retention (SSPC

component polyamide cured epoxy paint spec no.36, ASTM
with MIO content (containing 100 D4587, D2244, D523 of
lamellar MIO Min 30% on pigment, level 2 after min. 1000 hrs
solid by volume min. 80%±2) exposure, gloss less than
DFT- 100μ 30 and colour change less
than 2.0Δ E)
34 Lime stone Silo- Inside FW 731 Blast cleaning to 60 NIL -- 60
surfaces Sa 2½ (Near Primer: Two coats of Red Oxide Zinc
(Conical portion) white metal) phosphate primer to IS: 12744
with surface
profile 35-50μm (SS lining is inside the Limestone silo
conforming to conical portion, hence primer is only
ISO 8501-1 envisaged; SS lining will be done at
shops itself)
35 Lime stone Silo- Inside FW 731 Primer Coat: One coat of two 70 -- -- 70
surfaces Blast cleaning to component moisture curing Inorganic
(Cylindrical portion) Sa 2½ (Near Ethyl Zinc Silicate Primer to IS 14946,
white metal) (Solid by volume- 60% (min)), (Metallic
with surface zinc content 80% (min))

Page 229 of 338

profile 40-60μm DFT = 70 μm per coat (min.)
conforming to Zinc dust composition shall be Type-II as
per ASTM D520-00
ISO 8501-1
36 Air cannon silo, Bag filter FW 723 Power Tool Red Oxide Zinc Phosphate Primer to 60 Synthetic Enamel to IS 40 100
& Fan assy, Nozzles& FW 724 Cleaning to IS: 12744 (Two coats) 2932 Shade: Grey white
Flanges FW 725 St3 (SSPC-SP3) RAL 9002 (Two coats)
(Clause 20.03.00 of Part-
C Section VI)
37 Limestone silo approach FW 733 Blast cleaning to Hand rails, Ladders, Gratings- Hot dip galvanizing to 610gms/sq. m (minimum) and to a
platform, Platform for Pipe FW 766 Sa 2½/ Acid coating thickness of 87μm (minimum)
racks& Sub pipe racks FW 767 pickling
(Clause 31.06.00 of
Sec.VI, Part-B,
Subsection- IV-D)

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SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

38 Limestone silo approach FW 733 Blast cleaning to Primer: One coat of Two component 70 Finish: Two coats of two
platform, Pipe racks, Sub FW 766 Sa 2½ (Near moisture curing zinc (ethyl) silicate pack aliphatic isocyanate
pipe racks platform- FW 767 white metal) primer coat (Min 80% metallic zinc cured acrylic polyurethane 240
Structures other than the with surface content in dry film, solid by volume paint to IS 13213 solid by 70
above profile 40-60μm minimum 60% ±2). Zinc dust volume min.55%±2)
(Clause 31.03.00 of conforming to composition and properties shall be DFT- 35μ/ coat
Sec.VI, Part-B, ISO 8501-1 as per Type II as per ASTM D520-00 Shade: Grey white,
Subsection- IV-D) DFT- 70μ RAL 9002
With gloss retention (SSPC
Intermediate: One coat of Two paint spec no.36, ASTM
component polyamide cured epoxy D4587, D2244, D523 of
with MIO content (containing 100 level 2 after min. 1000 hrs
lamellar MIO Min 30% on pigment, exposure, gloss less than
solid by volume min. 80%±2) 30 and colour change less
DFT- 100μ than 2.0Δ E)
39 Limestone Mill – Outside FW 735 Blast cleaning to Primer: Two coats of Epoxy resin 100 Finish: One coat of Epoxy
surfaces Sa 2½ based Epoxy Zinc phosphate primer based finish paint to IS 75
(Clause 1.04.00 of Part- A to IS 13238 14209; DFT- 75μ
Section VI) DFT- 50μ/coat
300

Page 230 of 338

Intermediate: One coat of Two Finish: One coat of acrylic
component epoxy based 100 aliphatic polyurethane paint 25
intermediate paint pigmented with to IS 13213
MIO/Tio2 DFT-25μ
DFT- 100μ Shade: Grey White,
RAL9002

40 Lime stone mill- Inside FW 735 Primer Coat: One coat of two 70 -- -- 70
surfaces Blast cleaning to component moisture curing Inorganic
Sa 2½ (Near Ethyl Zinc Silicate Primer to IS 14946,
white metal) (Solid by volume- 60% (min)), (Metallic
with surface zinc content 80% (min))
profile 40-60μm DFT = 70 μm per coat (min.)
conforming to Zinc dust composition shall be Type-II as
per ASTM D520-00
ISO 8501-1

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PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

41 Gypsum belt filter and FW 738 Blast cleaning to Primer: Two coats of Epoxy resin 100 Finish: One coat of Epoxy
accessories Sa 2½ based Epoxy Zinc phosphate primer based finish paint to IS 75
Structural items to IS 13238 14209; DFT- 75μ
(Clause 1.04.00 of Part- A DFT- 50μ/coat
Section VI) 300
Intermediate: One coat of Two Finish: One coat of acrylic
component epoxy based 100 aliphatic polyurethane paint 25
intermediate paint pigmented with to IS 13213
MIO/Tio2 DFT-25μ
DFT- 100μ Shade: Grey White,
RAL9002

42 Lime stone slurry storage FW 742 Blast cleaning to Primer: One coat of Two component 70 Finish: Two coats of two
tank, Auxiliary absorber FW 743 Sa 2½ (Near moisture curing zinc (ethyl) silicate pack aliphatic isocyanate
tank, Filtrate tank, FW 744 white metal) primer coat (Min 80% metallic zinc cured acrylic polyurethane 240
Wastage water tank, FW 745 with surface content in dry film, solid by volume paint to IS 13213 solid by 70
Hydro cyclone waste water FW 747 profile 40-60μm minimum 60% ±2). Zinc dust volume min.55%±2)
tank, Neutralization tank, FW 748 conforming to composition and properties shall be DFT- 35μ/ coat
Process Water tank, Belt FW 785 ISO 8501-1 as per Type II as per ASTM D520-00 Shade: Grey white,
filter washing tank, FW 786 DFT- 70μ RAL 9002

Page 231 of 338

Primary hydro cyclone FW 800 With gloss retention (SSPC
feed tank, Clarified water FW 802 Intermediate: One coat of Two paint spec no.36, ASTM
tank component polyamide cured epoxy D4587, D2244, D523 of
Outside surfaces with MIO content (containing 100 level 2 after min. 1000 hrs
(Clause 31.03.00 of lamellar MIO Min 30% on pigment, exposure, gloss less than
Sec.VI, Part-B, solid by volume min. 80%±2) 30 and colour change less
Subsection- IV-D) DFT- 100μ than 2.0Δ E)

43 Lime stone slurry storage FW 742 Blast cleaning to 60 NIL -- 60

tank, Auxiliary absorber FW 743 Sa 2½ (Near Red Oxide Zinc Phosphate Primer to
tank, Filtrate tank, FW 744 white metal) IS: 12744 (Two coats)
Wastage water tank, FW 745 with surface
Hydrocyclone waste water FW 747 profile 35-50μm (Liner is inside the tank, hence
tank, Neutralization tank, FW 748 primer is only envisaged; Protection
FW 749 till erection only)

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 Sl PRIMER FINISH TOTAL
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PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

Process Water tank, Belt FW 800

filter washing tank, FW 802
Primary Hydrocyclone feed
tank, Clarified water tank,
Tank internal structure
Inside surfaces

44 Process water pipe FW 751 Power Tool Primer: Red Oxide Zinc Phosphate 60 Two coats of Synthetic 100 210
accessories, Cooling pipe FW 752 Cleaning to Primer to IS: 12744 (Two coats) Enamel to IS 2932,
accessories St3 (SSPC-SP3) DFT- 50μ/ coat
(Referred from cl. 7.05.00 Intermediate: One coat of Shade: Grey white
of Section-VI, Part-B, Synthetic Enamel intermediate 50 RAL 9002
Sub section-I-M5) coat to IS 2932; DFT- 50μ Identification Tag:
Sea Green Shade no:
217 as per IS 5
45 Slurry pipe accessories FW 753 Power Tool Primer: Red Oxide Zinc Phosphate 60 Two coats of Synthetic 100 210
(Referred from cl. 7.05.00 Cleaning to Primer to IS: 12744 (Two coats) Enamel to IS 2932,

Page 232 of 338

of Section-VI, Part-B, St3 (SSPC-SP3) DFT- 50μ/ coat
Sub section-I-M5) Intermediate: One coat of Shade: Grey white
Synthetic Enamel intermediate 50 RAL 9002
coat to IS 2932; DFT- 50μ Identification Tag: Sea
Green Shade no: 217 as
per IS 5
46 Service Air pipe FW 754 Power Tool Red Oxide Zinc Phosphate Primer 60 Synthetic Enamel to IS 60 120
accessories Cleaning to to IS: 12744 (Two coat) 2932 Shade: Grey white
(Referred from cl. 10.00 St3 (SSPC-SP3) RAL 9002 (Two coats)-
.00 of Section-VI, Part-B, 30μ/ coat
Sub section-I-M3) Identification Tag: Sky Blue
Shade no: 101 as per IS 5
47 Instrument air pipe FW 755 Power Tool Red Oxide Zinc Phosphate Primer 60 Synthetic Enamel to IS 60 120
accessories Cleaning to to IS: 12744 (Two coat) 2932 Shade: Grey white
(Referred from cl. 10.00 St3 (SSPC-SP3) RAL 9002 (Two coats)-
.00 of Section-VI, Part-B, 30μ/ coat
Sub section-I-M3)

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PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

Identification Tag: Sky Blue

Shade no: 101 as per IS 5

48 All valves FW 815 Power Tool Red Oxide Zinc Phosphate Primer 60 Synthetic Enamel to IS 60 120
(Temp <95 deg C) to Cleaning to to IS: 12744 (Two coats) 2932 Shade: Grey white
(Clause 20.03.00 of Part- FW 851 St3 (SSPC-SP3) RAL 9002 (Two coats)-
C Section VI) 30μ/ coat

49 Structure for Pipe racks, FW 761 Blast cleaning to Primer: One coat of Two 70 Finish: Two coats of two
Sub pipe racks FW 765 Sa 2½ (Near component moisture curing zinc pack aliphatic isocyanate
Trestle for pipe racks, FW 768 white metal) (ethyl) silicate primer coat (Min cured acrylic polyurethane 240
Structures inside Gypsum FW 769 with surface 80% metallic zinc content in dry paint to IS 13213 solid by 70
dewatering building & Ball FW 787 profile 40-60μm film, solid by volume minimum volume min.55%±2)
mill building conforming to 60% ±2). Zinc dust composition DFT- 35μ/ coat
(Clause 31.03.00 of ISO 8501-1 and properties shall be as per Shade: Grey white,
Sec.VI, Part-B, Type II as per ASTM D520-00 RAL 9002
Subsection- IV-D) DFT- 70μ With gloss retention (SSPC
paint spec no.36, ASTM

Page 233 of 338

Intermediate: One coat of Two D4587, D2244, D523 of
component polyamide cured 100 level 2 after min. 1000 hrs
epoxy with MIO content exposure, gloss less than
(containing lamellar MIO Min 30% 30 and colour change less
on pigment, solid by volume min. than 2.0Δ E)
80%±2)
DFT- 100μ
50 Supports for cable trays, FW 779 Power Tool Red Oxide Zinc Phosphate Primer 60 Synthetic Enamel to IS 40 100
Air receivers, FW 798 Cleaning to to IS: 12744 (Two coats) 2932 Shade: Grey white
commissioning& FW 988 St3 (SSPC-SP3) RAL 9002 (Two coats)
Mandatory spares, Tools & FW 996
tackles
(Clause 20.03.00 of Part-
C Section VI)

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 Sl PRIMER FINISH TOTAL
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PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

3. GATES & DAMPERS

01 Gates & Dampers 57 540 Power Tool HR Aluminium paint to IS 13183 40 -- -- 40
> 95ͼ C Insulated 57 550 Cleaning to Gr.II (upto 400 deg C)
Surfaces& Uninsulated 57 583 St3 (SSPC-SP3)
surfaces
02 Seal air piping 57 141 Power Tool Red Oxide Zinc Phosphate 60 Synthetic Enamel to IS 60 120
Cleaning to Primer to IS: 12744 (Two coat) 2932
St3 (SSPC-SP3) Shade: Grey white
RAL 9002 (Two coats)-
30μ/ coat
Identification Tag: Sky
Blue Shade no: 101 as
per IS 5
03 Blower with Motor 57 491 Power Tool Red Oxide Zinc Phosphate 60 Synthetic Enamel to IS 40 100
Knife Gate valve 57 497 Cleaning to Primer to IS: 12744 (Two coats) 2932
Mounting bracket 57 209 St3 (SSPC-SP3) Shade: Grey white
Mandatory spares RAL 9002 (Two coats)

Page 234 of 338

04 Ladder, Cage for Ladder 57 466 Blast cleaning to Hot Dip Galvanizing to 610 gm per sq. Meter (minimum) and to a coating thickness of 87
Toe Guard 57 566 Sa 2½/ Acid μm (minimum)
Plate Floor Grill, Hand Pickling
Rails, Hand Rail Post
Clause 31.06.00 of
Sec.VI, Part-B,
Subsection- IV-D

05 Other Structural Items- 57 466 Blast cleaning to Primer: One coat of Two 70 Finish: Two coats of two
Other than sl.no. 3 of 57 566 Sa 2½ (Near component moisture curing zinc pack aliphatic isocyanate
above white metal) with (ethyl) silicate primer coat (Min cured acrylic 240
(Clause 31.03.00 of surface profile 40- 80% metallic zinc content in dry polyurethane paint to IS 70
Sec.VI, Part-B, 60μm conforming film, solid by volume minimum 13213 solid by volume
Subsection- IV-D) to ISO 8501-1 60% ±2). Zinc dust composition min.55%±2)
DFT- 35μ/ coat

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 Sl PRIMER FINISH TOTAL
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min.) min.) min.)

and properties shall be as per Shade: Grey white,

Type II as per ASTM D520-00 RAL 9002
DFT- 70μ With gloss retention
(SSPC paint spec no.36,
Intermediate: One coat of Two 100 ASTM D4587, D2244,
component polyamide cured D523 of level 2 after
epoxy with MIO content min. 1000 hrs exposure,
(containing lamellar MIO Min gloss less than 30 and
30% on pigment, solid by colour change less than
volume min. 80%±2) 2.0Δ E)
DFT- 100μ

Page 235 of 338

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 Sl PRIMER FINISH TOTAL
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No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

4. PAINTING OF DAMAGED AREAS

Areas where paint has deteriorated badly by erosion and areas where the paint film has lost its adhesion property and
where the steel has got rusted appreciably - these areas are to be repainted as per the following procedure:

SL SURFACE LOCATION SURFACE PREPARATION PRIMER, INTERMEDIATE & FINISH

NO
1 Paint damaged Components falling Hand/ Power Tool cleaning to Primer: Epoxy Zinc rich primer to IS 14589, DFT-70μ
under Sl.no. 04,05,06,09,10,11 of Bare metal to minimum 6 inches (If Metal surface exposed) followed by intermediate &
Fans, Sl no.02,03,04, 05,06,07, 09, peripheral area adjoining to finish coat as per respective scheme
13,19,20,21,23,25,27, 29, 31,32 damaged area If primer is intact- Intermediate & finish as per respective
33,38,39,41,42, 49 of FGD and Sl no. 5 scheme
of GAD.
2 Paint damaged components failing Power Tool Cleaning to Bare Primer and Finish : As given in respective scheme
under other Sl.nos of Fans, FGD& GAD metal

Page 236 of 338

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 Sl PRIMER FINISH TOTAL
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PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

GENERAL NOTES

1. No painting is required for Galvanized, non-ferrous & stainless steel items, except as indicated above.
2. Machined items are to be applied with coat of temporary rust preventive oil
3. PGMAs covered in sub-supplier (ie., Purchased) items viz., Agitator/ slide bearing and other sub-delivery components etc., are not indicated in the
above list. However, the Painting Schedule for all items supplied by all sub-suppliers and BOI under the scope of BHEL shall be same as for main
equipment covered in this document.
4. In sub-assy, wherever plates / sheets of thickness less than or equal to 5mm and rods are used, very minor items like clamps, small items etc -
Power Tool or Hand Tool Cleaning to SSPC - SP 3 / SP 2 shall be followed and painting under Sl no:01 of Fans shall be followed.
5. Ground shade/colour of finish paints and identification tag/band for equipments, fans, piping, pipe services, supporting structures and other
components is followed as per NTPC doc no: QS-01-DIV-W-4 at site.
6. All components covered under different PGMAs are to be painted. Incase any component is left out, the same shall deemed to be included under the
relevant section.
7. All threaded and other surfaces of foundation bolts and its materials, insulation pins, Anchor channels, Sleeves shall be coated with temporary rust
preventive fluid and during execution of civil works; the dried film of coating shall be removed using organic solvents.
8. Painting requirement for all electrical equipment shall be as per the details identified in specification for the respective equipment.
9. All steel structures shall be provided with painting as given in the specification. Further, painting system shall also meet the requirements of
corrosivity category C3 (durability high) as per ISO 12944.
10. Finish coat to be applied after an interval of min 10 hrs and within 6 months (after completion of intermediate coat).

Page 237 of 338

11. Primer coat on steel shall be applied in shop immediately after blast cleaning by airless spray technique.
12. For the portion of steel surfaces embedded in concrete, the surface shall be prepared by Manual cleaning and provided with Primer coat of
Chlorinated Rubber based Zinc Phosphate Primer of Minimum 50 Micron DFT.

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 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
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PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

PAINTING SCHEME- DETAILS OF PROCUREMENT & APPLICATION PROCESSES

SL TYPE OF PAINT SPECIFICATION NO OF VOLUME OF MODE OF MIN. OVER SHADE

NO OF PAINT PACK SOLIDS APPLICATION COATING
(% Min) INTERVAL
(hours)
01 Epoxy Zinc IS 13238 2 40 Spray 24 Grey
phosphate primer
02 Zinc Ethyl silicate IS 14946 2 60 Airless Spray only 24 Grey
primer (% Zn on dry At Shop
film= 80 (min))
03 Epoxy High solid- -- 2 80 Airless Spray only 16 Brown
Polyamide cured At Shop
Epoxy based MIO
pigmented
intermediate coat
04 Aliphatic isocyanate IS 13213 2 55 Spray 16 Corresponding
acrylic polyurethane At Shop shade no
paint

Page 238 of 338

05 Heat resistant IS 13183 Grade II 1 -- Brush/ Spray 24 --
aluminium paint
06 Long oil alkyd IS 2932 1 35 Brush/ Spray 12 Corresponding
Synthetic enamel shade no
finish paint
07 Synthetic Enamel IS 2932 1 40 Brush/ Spray 12 --
Intermediate coat
08 Red oxide Zinc IS 12744 1 -- Brush/ spray 12 --
phosphate primer

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min.) min.) min.)

PGMA DETAILS

SNO PGMA PGMA DESCRIPTION PGMA DETAILS

01 FW 212 Slurry recirculation pump system RC Pumps incl Shaft seal
Common Base Plate
Coupling and Guard
Gear Box
Expansion Bellow
Anchor Bolts & Fasteners
Special Tools
02 FW 219 Absorber system base Absorber tank bottom plate
03 FW 220 Absorber system structures Absorber tank structure
Absorber tower structure
Spray headers structure
04 FW 221 Absorber system casing bottom Absorber tank wall casing- bottom
05 FW 222 Absorber system casing top Absorber Tank wall casing –Top
Mist Eliminator supports
Spray pipe supports
Internal Beam
Shim plates in Absorber area
Internal Struts
06 FW 223 Absorber system accessories Nozzles and flanges

Page 239 of 338

Inspection doors & Man holes
Viewing ports
Antifoam dosing equipment
Suction strainers- FRP
07 FW 226 Emergency Quench water tank Base Plate & its supports
Roof, Shell
08 FW 227 Emergency Quench System Emergency Quenching Spray Pipe
Nozzle for Emergency Pipe
Fasteners
Gaskets
09 FW 230 Air oxidation System Oxidation Blowers
Common Base Plate
Coupling and Guard
Anchor Bolts & Fasteners
Expansion Bellow
Suction & Discharge Silencers
Acoustic Enclosure
Water Injection cooling system

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min.) min.) min.)

Pipe, Valves & Instruments

Special Tools

SNO PGMA PGMA DESCRIPTION PGMA DETAILS

10 FW 244 Oxidation air distribution System Pipe & Fittings
Flanges
Pipe Hanger, Bottom Elbow, Bottom sliding supports
11 FW 251 Expansion joint between bypass Expansion joints
Seal Plates & Fasteners
12 FW 252 Expansion joint between scrubbers Fabric & its fixing fasteners
Sleeves & Flanges
Gaskets
13 FW 255 Ducts between bypass duct inlet & Plates & Stiffeners
booster fan Guide Vanes
14 FW 256 Ducts between Booster fan & Plates & Stiffeners
Absorber Guide Vanes
15 FW 257 Ducts between Absorber & stack Plates & Stiffeners
Guide Vanes
16 FW 260 Duct structure between bypass Duct Supports
duct& Booster fan Gusset Plate

Page 240 of 338

Divider plate
Internal Struts
Support bearings
17 FW 261 Duct structure between booster fan& Duct Supports
FW 262 absorber & Absorber and Stack Gusset Plate
Divider plate
Internal Struts
Support bearings
18 FW 292 Structures for Elevator Columns
Seal Plate
Bracings
Enclosure (Purlin& sheeting)
19 FW 293 Elevator and accessories Base Frame
Buffer Spring
Mast Section
Cage
Control Panel & AC
Mandatory Spares

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min.) min.) min.)

SNO PGMA PGMA DESCRIPTION PGMA DETAILS

20 FW 310 Structures for booster fan handling Columns
Beams
Bracings
Seal plate
21 FW 610 Galleries & railings for Scrubbers, Stairs
FW 722 Tank Handrail
Step treads
Floor grills
Ladders
Foundation bolts
Fasteners
22 FW 701 Slurry pumps & accessories Slurry Pumps incl Shaft seal
Common Base Plate
Coupling and Guard
Belt & Pulley
Expansion Bellow
Anchor Bolts & Fasteners
Motor & accessories
Sump Pumps incl Shaft seal
Common Base Plate
Coupling and Guard

Page 241 of 338

Belt & Pulley
Anchor Bolts & Fasteners
Motor & accessories
23 FW 710 Monorail for hoist& cranes Insert Plate
Stiffener plate
Monorail beam
24 FW 721 Agitator support Channels & Beams
25 FW 730 Limestone silo structures Columns
Beams
Bracings
Seal plate
Angles, channels

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min.) min.) min.)

SNO PGMA PGMA DESCRIPTION PGMA DETAILS

26 FW 731 Limestone silo Base plate & its supports
Shell, Roof
27 FW 723 Air cannon Bag filter
FW 724 Bag filter Air cannon bin activator
FW 725 Nozzles & flanges Nozzles & Flanges

28 FW 733 Limestone silo approach platforms Stairs

Handrail
Step treads
Floor grills
Ladders
Foundation bolts
Fasteners
29 FW 734 Limestone mill Wet ball mill
Hydro cyclone- Mill area
Mill circuit pump
Mill separator tank with Agitator
30 FW 742 Lime stone slurry storage tank Base plate & its supports
Shell, Roof
31 FW 743 Auxiliary Absorber tank Base plate & its supports
Shell, Roof

Page 242 of 338

32 FW 744 Filtrate tank Base plate & its supports
Shell, Roof
33 FW 745 Wastage water tank Base plate & its supports
Shell, Roof
34 FW 747 Hydro cyclone waste water tank Base plate & its supports
Shell, Roof
35 FW 748 Process Water tank Base plate & its supports
FW 785 Belt filter washing tank Shell, Roof
FW 786 Primary Hydro cyclone feed tank
36 FW 751 Process water pipe accessories CS/FRP Pipes & Fittings
FW 752 Cooling water pipe accessories Sight Glass
R Orifice
Gaskets & Fasteners
37 FW 753 Slurry pipe accessories CSRL/FRP Pipes & Fittings
Strainer (Cone)
Expansion Joint-Rubber
R Orifice
Gaskets & Fasteners

PS- NABINAGAR 3X660 MW – FGD PACKAGE REV. 02 DATE 06.12.2019 Page 30 of 32

 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

SNO PGMA PGMA DESCRIPTION PGMA DETAILS

38 FW 754 Service air pipe accessories GI Pipes & Fittings
Flexible Hose
Expansion Joint (Metallic)
Hose connector
R Orifice
Gaskets & Fasteners
39 FW 755 Instrument air pipe accessories SS Pipes & Fittings
Strainer(Y Type)
Gaskets & Fasteners
40 FW 815 to FW 851 Valves and fittings Globe valves
Ball Valves
Butterfly Valves
Diaphragm Valves
Gate Valves
CheckValves
Pinch Valves
Knife Gate Valves
Control Valves
Relief Valves
41 FW 761 Structures for Pipe racks Bracings
FW 765 Structures for Sub pipe racks Columns

Page 243 of 338

42 FW 280 Foundation material for duct Foundation bolts
FW 281 structure Template
FW 282 Foundation material for absorber
FW 283 Foundation material for Tanks
FW 740 Foundation material for Pipe racks
FW 760 Foundation material for Elevator
FW 763 Foundation material for RC pump
shed
43 FW 766 Platforms for Pipe rack Stairs
Handrail
Step treads
Floor grills
Ladders
Foundation bolts
Fasteners
44 FW 768 Trestle for Main & sub Pipe racks Truss
FW 769 Beams, Supports for all Pipes
45 FW 779 Supports for cable tray Double Sup Channel & Base plates
Single Sup Channel & Base plates

PS- NABINAGAR 3X660 MW – FGD PACKAGE REV. 02 DATE 06.12.2019 Page 31 of 32

 Sl PRIMER FINISH TOTAL
SURFACE DFT DFT DFT IN
No SURFACE LOCATION PGMA
PREPARATION PAINT (μm PAINT (μm (μm
min.) min.) min.)

Cantilever Arm
Fasteners & clamps
Brackets
46 FW 996 Tools Erection , commissioning, special tools
SNO PGMA PGMA DESCRIPTION PGMA DETAILS
47 FW 798 Air receivers Instrument Air receivers
Any Instruments/Valves
48 FW 800 Clarified water tank Base plate & its supports
Shell, Roof
49 FW 802 Neutralization tank & accessories Base plate & its supports
Shell, Roof
50 FW 988 Commissioning spares & Mandatory Startup & commissioning spares
FW 997 spares Mandatory spares
FW 999

Page 244 of 338

PS- NABINAGAR 3X660 MW – FGD PACKAGE REV. 02 DATE 06.12.2019 Page 32 of 32
TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION-D
REV. 00
TECHNICAL SPECIFICATION FOR
Date: April, 2020
MISC. FGD TANKS

SECTION-I, SUB-SECTION-D

ANNEXURE-I

LIST OF MAKES

Page 245 of 338

Page 246 of 338
Page 247 of 338
Page 248 of 338
QUALIFYING REQUIREMENTS FOR RUBBER LINING & VINYL ESTER GLASS FLAKE FOR SLURRY
TANKS

Lining for the Wet Limestone based Flue Gas Desulphurisation (FGD) System offered by the Bidder shall be
only from such bidders(s) who has previously executed this lining application for coal based thermal power
station for Wet Limestone based FGD application or similar corrosive environment of min 2500 Sq.m for at least
1 project such that the lining should have been in successful operation for a period not less than two (2) year
reckoned as on the date of bid opening. Proof of such experience (End user certificate/performance certificate)
shall be submitted along with the offer.

Page 249 of 338

TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION- D
TECHNICAL SPECIFICATION FOR REV. 00
FGD TANKS
Date: April, 2020

SECTION-I, SUB-SECTION- D
ANNEXURE-II

QUALITY PLANS

Page 250 of 338

Page 251 of 338
Page 252 of 338
Page 253 of 338
Page 254 of 338
Misc. Tanks

Page 255 of 338

TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION- D
TECHNICAL SPECIFICATION FOR REV. 00
FGD TANKS
Date: April, 2020

SECTION-I, SUB-SECTION- D
ANNEXURE-III

INPUT DRAWINGS
INPUT DRAWINGS (GAD OF TANKS)

Page 256 of 338

 Sizing Calculation & Selection parameter for all tanks

1. Gas condition for Tank Sizing:

S.No. Gas Condition Feature

1 VWO FGD Design Point

2. Tank Sizing Basis

Tank size is decided as per the following

M
LL – Pump LL level m
L – LL + 0.2 m HH
H
H - Effective height m
Top
HH - H + 0.2 m
L
Top - HH + 0.5 m( If tank Ht. <10m)
LL
-HH + 0.8 m( If tank Ht. >10m)

D
Effective volume = 3.14 / 4 x Φ ^ 2 x (H-L)
Hold volume = 3.14 / 4 x Φ ^ 2 x (HH)

H/D ratio = 1-1.2

Page 257 of 338

S. Item No Service Design Process Design Basis
No Spec Parameter
1 00HTQ0 Process 4500 mmD X Process 146.2 m3/h (Refer Mass Flow Balance
0BB001/ Water 4500 mmH Capacity (Design Point) data stream no. (<801>
002 Tank + <802> + <803> + <804> + <805>/2
Quantity = 2 + <806>) x units).
nos. Retention 0.25 hr
Time
Required 146.2 m3/h x 0.25 hr = 36.55 m3
volume

Tank Level is designated as follows

Top 4.5
HH 4.0
HH=4.0 m
H 3.8
H=3.8 m
L 1.5
4.5 m
LL 1.3*
L=1.5 m
Effective volume
LL=1.3 m
= 4.5 m Φ ^ 2 / 4 x π x (3.8-1.5) m =
4.5 mD 36.58 m3 > 36.55 m3
Hold Volume
= 4.5 m Φ ^ 2 / 4 x π x 4.0 m = 63.62
m3

* LL level will be finalized by vendor’s information of Process water pump.

Page 258 of 338

 S. Item No Service Design Spec Process Design Basis
No Parameter
2 00HTQ0 Cake wash 3000 mmD X Process 5.724 m3/h (Refer Mass Flow
1BB001/ (Clarified 3000 mmH Capacity Balance Design Point data stream
002 water) Tank Quantity = 2 for each no.(<805>/2) x 2 units
nos. tank
Retention 1 hr
Time
Required 5.724 m3/h x 1.0hr = 5.724 m3
volume

Tank Level is designated as follows

Top 3.0
HH 2.5
HH=2.5 m
H 2.3
H=2.3 m
L 1.2
3.0 m
LL 1.0*
L= 1.2 m
Effective volume
LL=1.0 m
= 3.0 m Φ ^ 2 / 4 x π x (2.3-1.2) m

3.0 mD =7.77 m3 >5.724 m3

Hold Volume
= 3.0 m Φ ^ 2 / 4 x π x 2.0 m
=17.67 m3

*LL level is finalized by vendor’s information of Cake wash tank pump.

Page 259 of 338

 S. Item No Service Design Spec Process Design Basis
No Parameter
3 00HTM0 Belt Filter 3000 mmD X Process 5.724 m3/h (Refer Mass Flow
1BB001 Wash Tank 3000 mmH Capacity Balance Design Point data stream
Quantity = 2 for each no.(<805>/2) x 2 units
nos. tank
Retention 1 hr
Time
Required 5.724 m3/h x 1.0hr = 5.724 m3
volume

Tank Level is designated as follows

Top 3.0
HH 2.5
HH=2.5 m
H 2.3
H=2.3 m
L 1.2
3.0 m
LL 1.0*
L= 1.2 m
Effective volume
LL=1.0 m
= 3.0 m Φ ^ 2 / 4 x π x (2.3-1.2) m

3.0 m =7.77 m3 >5.724 m3

Hold Volume
= 3.0 m Φ ^ 2 / 4 x π x 2.0 m
=17.67 m3

*LL level is finalized by vendor’s information of belt filter wash tank pump.

Page 260 of 338

 S. Item No Service Design Process Design Basis
No Spec Parameter
4 00HTM 03 Filtrate 4000 mm D X Process 48.442 m3/h
BB001 water 4000 mmH Capacity (Stream No: <402> x 2 Units)

Tank Retention 0.5 Hr

Quantity = 1 Time
no (Common Required 48.442 m3/h x 0.5 hr
for two units) volume =24.221 m3

Tank Level is designated as follows

M Top 4.0
HH 3.5
HH=3.5 m H 3.3
H=3.3 m
L 1.2*
4.0 m
LL 1.0*
L=1.2 m
LL=1.0 m
Circular Tank
Effective volume
4.0 mD = 4.0 m Φ ^ 2 / 4 x π x (3.5-1.2) m
= 28.9 m3>24.221 m3

Hold Volume
= 4.0 m Φ ^ 2 / 4 x π x 3.5 m = 43.98m3

*L and LL level is finalized by vendor’s information of filtrate water pump and agitator.

Page 261 of 338

 S.No Item No Service Design Process Design Basis
Spec Parameter
5 00HTM00 Primary 5000 mm D Process 54.204 m3/h
BB001 Hydro X Capacity (Stream No: <201> x 2 Units)
cyclone 5000mmH- Retention 1 Hour
feed Tank Quantity = 1 Time
no. Required 54.204 m3/h x 1 hr
volume = 54.204 m3

Tank Level is designated as

M follows

HH = 4.5 m Top 5.0

H =4.3 m HH 4.5
5.0 m H 4.3

L = 1.2 m
L 1.2*
LL =1.0 m LL 1.0*
Circular Tank
5.0 mD
Effective volume
= 5.0 m Φ ^ 2 / 4 x π x (4.3-1.2)
m = 60.9 m3 > 54.204 m3

Hold Volume
= 5.0 m Φ ^ 2 / 4 x π x 4.5 m
=88.4 m3

*L and LL level is finalized by vendor’s information of hydro cyclone feed pump and agitator.

Page 262 of 338

 S.No Item No Service Design Process Design Basis
Spec Parameter
6 00HTM04 Secondary 4000 mm D Process 31.32 m3/h (Stream No: <202> x
BB001 Hydro X Capacity 2 Units)
cyclone 4500mmH- Retention 1 Hours
feed Tank Quantity = 1 Time
no. Required 31.32 m3/h x 1 hr
volume = 31.32 m3

Tank Level is designated as

M follows

HH = 4.0 m Top 4.5

H =3.8 m HH 4.0
4.5 m H 3.8

L = 1.2 m
L 1.2*
LL =1.0 m LL 1.0*
Circular Tank
4.0 mD
Effective volume
= 4.0 m Φ ^ 2 / 4 x π x (3.8-1.2)
m = 32.67 m3>31.32 m3

Hold Volume
= 4.0 m Φ ^ 2 / 4 x π x 4.0 m
=50.3 m3

*L and LL level is finalized by vendor’s information of hydro cyclone feed pump and agitator.

Page 263 of 338

 S. Item Service Design Process Design Basis
No No Spec Parameter
7 00HTM Waste 5500 mmD X Process 9.8 m3/h (Stream No: <205> x 2
05BB0 water 5500mmH- Capacity Units)
01 storage Quantity = 1 Retention 8.0 Hours
Tank no. Time
Required 9.8 m3/h x 8.0 hr = 78.4 m3
volume

Tank Level is designated as follows

M Top 5.5

HH = 5.0 m HH 5.0
H =4.8 m H 4.8
5.5 m L 1.2*

L = 1.2 m LL 1.0*
LL =1.0 m Circular Tank
Effective volume
5.5 mD
= 5.5 m Φ ^ 2 / 4 x π x (5.0-1.2) m
= 90.3 m3> 78.4m3
Hold Volume
= 5.5 m Φ ^ 2 / 4 x π x 5.0 m
=118.8 m3

*L and LL level is finalized by vendor’s information of Waste water pump and agitator.

Page 264 of 338

 S. Item No Service Design Spec Process Design Basis
No Parameter
8 00HTK0 Lime 9000 mmD X Process a) Limestone required = 4.662 TPH per
3BB001/ stone 10000mmH Capacity unit from (Stream No: <501> x 2 Units)
002 slurry for each b) 20% (w/w) Limestone slurry
storage Quantity = 2 tank = 4.662 TPH / 20% mass flow rate
Tank no. (1W+1S) = 23.31 TPH per unit
(Common for c) 20%(w/w) Limestone slurry density
two units) = 1.130 t/m3
d) 20% (w/w) Limestone slurry
= 23.31 TPH / 1.130 volume flow rate
= 20.63 m3/hr per unit
Retention 12.0 hr
Time
Required 20.63 m3/h x 2 x 12 hr = 495.12 m3
volume
Tank Level is designated as follows
Top 10.0
HH 9.5
M
H 9.3
HH =9.5 m L 1.2*
H =9.3 m
LL 1.0*
10.0 m Circular Tank
Effective volume
L = 1.2 m
LL =1.0 m = 9.0 m Φ ^ 2 / 4 x π x (9.3-1.2) m
= 515 m3 > 495.1 m3
9.0 mD
Hold Volume
= 9.0 m Φ ^ 2 / 4 x π x 9.5 m
= 604.4 m3
*L and LL level is finalized by vendor’s information of Limestone slurry Feed pump and agitator.

Page 265 of 338

 S. Item No Service Design Spec Process Design Basis
No Parameter
9 00HTK0 Auxiliary 10000mmDX Process Absorber Tank Volume = 724.8 m3
0BB001 Absorbent 10000mmH Capacity (with 20% margin)
Tank
Quantity = 1 Retention Batch Operation
no (Common Time
for two units) Required 724.8 m3
volume
` Tank Level is designated to be empty
during normal operation. Therefore the
volume from bottom to H is considered
as effective volume of tank.
M
Top 10.0
HH =9.5 m
HH 9.5
H =9.3 m
H 9.3
10.0 m
L 1.2*
LL 1.0*
Circular Tank

10.0 mD Effective volume

= 10.0 m Φ ^ 2 / 4 x π x 9.3 m
= 730.4 m3>724.8 m3
Hold Volume
= 10.0 m Φ ^ 2 / 4 x π x 9.5 m
= 746.13 m3

*L and LL level is finalized by vendor’s information of Auxiliary Absorbent tank pump and agitator.

Page 266 of 338

 S. Item No Service Design Spec Process Design Basis
No Parameter
10 10/20HTT Absorber 4000mmW X Process 25 m3
00BB001 Area 4000mmL X Capacity
Drain 4000mmH for each
Sump Quantity = 2 Sump
nos. for two Retention Batch Operation
Units Time
Required 25 m3
volume

Tank Level is designated as follows

Top 4.0
HH 3.5

M
H 3.3
L 1.6*
HH=3.5 m
H=3.3 m LL 1.4*
4.0 m D
Rectangular Tank
L= 1.6 m
Effective volume
LL=1.4 m
= 4.0 m x 4.0 m x (3.3-1.6) m = 27.2
m3 >25 m3
4.0 mW
Hold Volume
= 4.0 m x 4.0 m x 3.5 m = 56 m3
*L and LL level is finalized by vendor’s information of Sump pump and agitator.

Page 267 of 338

 S. Item No Service Design Process Design Basis
No Spec Parameter
11 00HTT01 Gypsum 4000mmW Process 25 m3
BB001 Area X 4000mmL Capacity
Drain X 4000mmH
Sump
Quantity = 1 Retention Batch Operation
no. Time
(Common Required 25 m3
for two volume
units)
Tank Level is designated as follows
Top 4.0
M HH 3.5
HH=3.5 m H 3.3
H=3.3 m
4.0 m D L 1.6*
L= 1.6 m LL 1.4*
LL=1.4 m
Rectangular Tank
Effective volume
4.0 mW = 4.0 m x 4.0 m x (3.3-1.6) m = 27.2
m3 >25 m3
Hold Volume
= 4.0 m x 4.0 m x 3.5 m = 56 m3
*L and LL level is finalized by vendor’s information of Sump pump and agitator.

Page 268 of 338

 S. Item No Service Design Process Design Basis
No Spec Parameter
12 00HTT02 Lime 4000mmW Process 25 m3
BB001 Stone X 4000mmL Capacity
Area X 4000mmH
Drain
Sump Quantity = 1 Retention Batch Operation
no.(Commo Time
n for two Required 25 m3
units) volume
Tank Level is designated as follows
Top 4.0
HH 3.5
H 3.3
M
L 1.6*
HH=3.5 m
H=3.3 m LL 1.4*
4.0 m D Rectangular Tank
L= 1.6 m
Effective volume
LL=1.4 m
= 4.0 m x 4.0 m x (3.3-1.6) m = 27.2
m3 >25 m3
4.0 mW
Hold Volume
= 4.0 m x 4.0 m x 3.5 m = 56 m3
*L and LL level is finalized by vendor’s information of Sump pump and agitator.

The above data is basic design data and may vary based on actual piping layout and selected vendor’s
recommendations.

Reference Documents
- Mass Flow Balance (Design Point) data – 9993-109-PVM-W-002

Page 269 of 338

Page 270 of 338
TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION- D
TECHNICAL SPECIFICATION FOR REV. 00
FGD TANKS
Date: April, 2020

SECTION-I, SUB-SECTION- D
ANNEXURE-IV

MASTER DRAWING LIST WITH SCHEDULE OF

SUBMISSION

Page 271 of 338

 TITLE: SPEC. NO.: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION- D,
TECHNICAL SPECIFICATION FOR ANNEXURE-IV
FGD TANKS REV. NO.: 00
DATE: April, 2020

DRAWINGS/ DOCUMENTS REQUIRED DURING DETAIL ENGINEERING

The successful bidder shall submit the following drawings / documents during detail engineering for approval / information / reference
(as the case may be): -

Schedule Resubmission after

Sl. BHEL Drawing /
Title Submission incorporating
No. Document No.
Date from LOI comments
FABRICATION DRAWING OF MISC. FGD TANK
1 PE-V0-468-167-A001 5 weeks Within 1 week
DESIGN CALCULATION OF MISC. FGD TANKS INCLUDING ROOF STRUCTURE Within 1 week
2 PE-V0-468-167-A002 3 weeks
WITH STAAD CALCULATION
Within 1 week

Page 272 of 338

3 PE-V0-468-167-A003 GA DRAWING OF MISC. FGD TANKS 4 weeks

DATASHEET & GA DRAWING OF RUBBER LINING & VINYL ESTER GLASS Within 1 week
4 PE-V0-468-167-A004 6 weeks
FLAKE FOR MISC. FGD TANKS
5 PE-V0-468-167-A005 DATASHEET & GA DRAWING OF COMPONENTS FOR MISC. FGD TANKS 6 weeks Within 1 week

6 PE-V0-468-167-A006 QAP OF RUBBER LINING & VINYL ESTER GLASS FLAKE FOR MISC. FGD TANKS 6 weeks Within 1 week

7 PE-V0-468-167-A007 QAP OF COMPONENTS FOR MISC. FGD TANKS 6 weeks Within 1 week

8 PE-V0-468-167-A008 SUB VENDOR LIST WITH INSPECTION CATEGORY FOR MISC. FGD TANKS 3 weeks Within 1 week

9 PE-V0-468-167-A009 SURFACE PREPARATION AND LINING PROCEDURES FOR MISC. FGD TANKS 7 weeks Within 1 week

10 PE-V0-468-167-A010 O&M MANUAL FOR RUBBER LINING & VINYL ESTER GLASS FLAKE 8 weeks Within 1 week

11 PE-V0-468-167-A011 O&M MANUAL FOR MISC. FGD TANKS 8 weeks Within 1 week
 TITLE: SPEC. NO.: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-I, SUB-SECTION- D,
TECHNICAL SPECIFICATION FOR ANNEXURE-IV
FGD TANKS REV. NO.: 00
DATE: April, 2020

NOTE: Drwg/ Document shall be uploaded by the successful bidder on WRENCH /DMS.Procedure for the same will be informed after award of contract.

COMPANY SEAL

SIGNATURE: ___________________

Page 273 of 338

NAME: _______________________

DESIGNATION: __________________

COMPANY: _____________________

DATE: __________________________
 2 X 250 MW BHILAI FGD SPECIFICATION No: PE-TS-468-167-A101
SECTION-II
MISC. FGD TANKS REV. 00
TECHNICAL SPECIFICATION Date: April, 2020

SECTION-II

Page 274 of 338

 2 X 250 MW BHILAI FGD SPECIFICATION No: PE-TS-468-167-A101
SECTION-II
MISC. FGD TANKS REV. 00
TECHNICAL SPECIFICATION Date: April, 2020

SECTION-II
SUB-SECTION-A

STANDARD TECHNICAL SPECIFICATIONS- MECHANICAL

Page 275 of 338

 SPECIFICATION NO. PE-TS-STD-167-A101
PEM-6666-0

SECTION II SUB-SECTION A
STANDARD TECHNICAL SPECIFICATION
REVISION 00 April 2020
FOR MISCELLANEOUS TANKS
PAGE 1 of 8

1.0 SCOPE

This specification covers design, engineering, supply of material, fabrication, assembly, inspection and
testing at shop as well as at site, erection and commissioning, painting and functional demonstration
testing at site.

2.0 CODES & STANDARDS

The design, fabrication & assembly, erection & performance of steel tanks shall comply with all latest
statutory regulations and safety codes applicable in the locality where the tanks are to be installed.
Tanks shall conform to the latest applicable Indian / British / USA standards. The vendor shall not be
construed to be relieved of his responsibility by virtue of this specification. The tank in general shall
conform to the latest editions, as applicable, out of the following standards.

I. IS-800: Code of practice for use of steel in general building construction

II. IS-803: Code of practice for design, fabrication and erection of vertical mild steel cylindrical welded oil
storage tank.

III. IS-804: Specification for rectangular pressed steel tanks

IV. IS-805: Code of practice for use of steel in gravity water tank.

V. IS-816: Code of practice for metal arc welding for general construction in MS.

VI. IS-817: Code of practice for training and testing for metal arc welder

VII. IS-2825: Code of practice for unfired pressure vessel

VIII. BS-2594: Specification for carbon steel welded horizontal cylindrical storage tank

IX. BS-2654: Specification for vertical steel welded storage tanks with butt welded shells for the petroleum
industry

X. Indian Factories Act

XI. American code for oil tanks API 650

XII. Material Specification as per relevant IS / or approved equal

XIII. American water works association standards (AWWA D100)

3.0 DESIGN REQUIREMENT

3.1 General Requirement

3.1.1 All tanks will be mild steel tanks. The tanks will be of welded construction and will be designed to
withstand satisfactorily the internal forces due to the liquid which these tanks have to hold as specified
and external forces due to wind and seismic forces without deformation or undue strain. The plates will
be cold rolled through plate bending machines by several no. of passes to the curvature.
Page 276 of 338
 SPECIFICATION NO. PE-TS-STD-167-A101
PEM-6666-0

SECTION II SUB-SECTION A
STANDARD TECHNICAL SPECIFICATION
REVISION 00 April 2020
FOR MISCELLANEOUS TANKS
PAGE 2 of 8

3.1.2 Tank thickness shall be calculated as per IS803 latest edition. Intermediary wind girder design, Wind
Design, Seismic design, anchor bolt design / selection etc. shall be done as per API 650 latest edition,
latest addendum available at the time of detail engineering.

3.1.3 All tanks will be designed for the capacities, dimensions and working conditions as specified in this
specification. The tanks will be provided with all necessary connections as specified. The design of tanks
will be such as to allow easy inspection, cleaning and repair. Due consideration will be given to wind
loading and adequate stiffening will be provided to prevent failure of tank due to buckling when it is
empty. A 1.5 mm corrosion allowance for shells, bottom and roofs above and beyond the required
thickness / calculated thickness / nominal thickness as specified in the design code shall be provided.

3.1.4 Vessel seams shall be so positioned that they do not pass through nozzle connections on vessel. For
vessels consisting of more than two sections, longitudinal seams shall be offset.

3.1.5 The inside seam should be ground smooth, suitable for application of corrosion resistant primer. If the
stiffening of shell, bottom and / or roof is necessary, tanks will be stiffened from outside.

3.1.6 Flange faces of all nozzles shall be machined and squared with the vessel center line.

3.1.7 All roofs and supporting structures shall be designed to support dead load plus a uniform live load of
not less than 150 kg/m2 of projected area.

3.1.8 The tanks shall be designed to have all courses truly vertical. Adequate distance between vertical joints
in adjacent courses shall be taken so that the distortion is reduced to minimum.

3.1.9 When removing temporary attachments from shell plates, care should be taken that parent plate is not
damaged. Holes in plate work to assist in fabrication / erection should be avoided as far as possible. The
location of holes and method of filling shall be indicated in the fabrication drawing. Any projection of
metal shall be chipped and ground flush with the plate surface. The plate shall not be gouged or torn in
process of removing lugs.

3.1.10 In the construction of shell, very care shall be taken to minimize distortion or lack of circularity due to
welding or for any other reason.

3.1.11 Material of construction of all tanks shall be mild steel conforms to IS – 2062 grade – B unless otherwise
specified in the specification. Material of construction for structure (angles, channels etc.) shall be IS
2062 Gr. A.

3.2 Alignment

3.2.1 Plates to be joined by butt-welding shall be matched accurately. Misalignment in completed vertical
joints shall not exceed 10% of the plate thickness or 1.5 mm for plates of 20 mm thick and under,
whichever is larger.

3.2.2 In completed horizontal butt joints, the upper plate shall not project beyond the face of the lower plate
at any point by more than 20% of the upper plate thickness with a maximum of 3 mm for plate
thickness exceeding 8 mm except that for plate thickness 8 mm and under, the maximum shall be 1.5
mm.

Page 277 of 338

 SPECIFICATION NO. PE-TS-STD-167-A101
PEM-6666-0

SECTION II SUB-SECTION A
STANDARD TECHNICAL SPECIFICATION
REVISION 00 April 2020
FOR MISCELLANEOUS TANKS
PAGE 3 of 8

3.2.3 Each tank shall be properly constructed ensuring perfect vertical alignment with 5 mm or as specified in
the relevant code / standard and tank circularity within 5 mm on diameter or as specified in the
relevant code / standard. Local bulging and / or depressions at any location of tank particularly shell
shall not be permitted.

3.3 WELDING

3.3.1 Tanks and other attachments shall be welded as per IS-816.

3.3.2 Welding sequence shall be so adopted that distortion due to welding shrinkage shall be minimum.
Welding procedure specification shall be submitted for approval of BHEL giving details of material,
welding position, sequence, type of electrode used, pre-heat & post weld requirement etc as per the
code of construction. Brand name of electrodes to be used with proper classification (e.g. E 6013) shall
be as per BHEL’s approval.

3.3.3 Welding shall not be carried out when the surface is wet and during periods of rain and high winds
unless the welder and the work are properly shielded which should meet the approval of the purchaser.

3.3.4 Inspection of all welds shall be carried out in accordance with the governing code of construction. All
material used by the purchaser such as electrodes, gaskets, bolts, nuts etc. shall be
conforming to relevant standards of repute and approved by the purchaser prior to use.

3.3.5 Each tank shall be complete with access staircase, ladder and safety cage and fittings like drain
connection, overflow connection(pipe) till bottom of tank, tank inlet and outlet covers, level gauge
glass, fittings with isolation cocks and protection covers, tank vent connection etc. all complete with
needed accessories for the completeness of the tanks.

3.3.6 All openings in tank plate shall be well reinforced in approved manner by adding pad plates of adequate
size and / or structural sections.

3.4 STAIRCASE / ACCESS LADDER AND HAND RAILING

3.4.1 All cylindrical vertical tanks shall be provided with spiral staircase and shall conform to the
requirements specified in design codes / standards unless specified otherwise. All stair treads shall be
32 mm steel fabricated gratings. Each tread, if needed, shall be housed in individual steel fabricated
frame which shall be adequately supported from the tank outer periphery. The staircase shall have
minimum 1200 mm clear width.

3.4.2 Access ladder, one (1) for each horizontal cylindrical / rectangular tank shall be provided for access to
the tank roof. It shall be steel fabricated having minimum 450 mm width. Ladder stringers shall be
heavy steel flats or angle section. All rungs shall be minimum 20 mm diameter rods spaced at not more
than 30 mm center to center. All ladders shall have steel fabricated safety cage to the approved
construction. Safety cage shall be provided about 2.5 m clear height of the ladder. Access ladder’s
stringers shall be widely spaced at top for free access to the tank roof.

3.4.3 All staircase and roofs of vertical cylindrical tanks shall be provided with pipe hand railings of effective
height as indicated in the relevant code / standard throughout. Handrails shall be constructed out of 32
mm medium class galvanized steel pipe conforming to IS- 1239: 1968. Handrail posts shall be arranged
at spacing not greater than 1850 mm. Two (2) sets of pipes horizontal runners all along the length shall
be provided. All welds joints in the handrails shall be ground flush to protect any person getting injured.
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STANDARD TECHNICAL SPECIFICATION
REVISION 00 April 2020
FOR MISCELLANEOUS TANKS
PAGE 4 of 8

Steel toe plates of 100 mm flats shall be used. Hand railing shall be fabricated and installed in an
approved manner as directed by purchaser in accordance with approved drawings.

3.4.4 Unless otherwise specified, for all flanged connections, vendor shall furnish suitable counter flanges
and necessary nuts, bolts and gaskets materials.

3.4.5 Unless otherwise specified, bolts and nuts shall be hexagonal head conforming to bolts and nuts shall
be SA 193 & 194 respectively.

3.4.6 Gaskets shall be 3 mm thick full-face rubber. On completion of hydraulic test / water fill test, contractor
shall replace the gaskets used during testing at his own cost.

3.4.7 During erection of tank, shell plates shall be suitably supported both for outside and inside to avoid
buckling / collapsing of tank due to high-speed wind, gust or severe storm, if any, occurring during
erection.

3.5 VERTICAL CYLINDRICAL STORAGE TANKS

3.5.1 The vertical cylindrical storage (non- pressure) tanks shall be of mild steel welded construction and shall
be designed in accordance with codes and standards as specified. The vertical cylindrical storage tanks
shall have slightly sloping bottom towards an adequately sized sump inside the tank to enable complete
draining of the tank. The tank shall be designed for a wind pressure and seismic coefficient as specified.

3.5.2 Conical roof shall be either self-supported or supporting. The roof shall have a slope as specified in the
relevant design code to ensure drainage of rainwater. Needed roof rafters and purlins adequately
designed shall be provided.

3.5.3 All plates to be used for fabrication of tank shall be checked and all sides trimmed to make them
square.

3.5.4 All bottom plates shall have butt weld joints to adequately support lining.

3.5.5 All shell course plates shall be taken during bending to prevent plate skewing. For butt weld joints,
edges shall be prepared which shall be uniform and smooth throughout. To maintain needed root
penetration gap at any butt weld joint, sufficient numbers of erection cleats shall be provided on all
sides of outer periphery of each shell plate. Plates for tanks shall be straightened by pressing or by
other non-injurious methods.

3.5.6 Each shell course shall be of uniform width throughout longitudinal weld in plates. Make up for the
course width shall not be permitted. Shell plates in each course width shall be so arranged that all
vertical joints be staggered having a minimum of 600 mm stagger. Shell thickness could be reduced in
upper courses depending on design requirements but in no case the plate thickness shall be less than 6
mm.

3.5.7 The tank height shall be completed by the provision of top curb/ angle which shall be butt-welded to
the adjacent tank plate courses. The outstanding leg of the curb angle shall be kept outside the tank
periphery. All butt weld joints shall be full strength welds but for design of shell plate thickness
adequate weld efficiency as recommended by applicable code(s) shall be used.

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 SPECIFICATION NO. PE-TS-STD-167-A101
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SECTION II SUB-SECTION A
STANDARD TECHNICAL SPECIFICATION
REVISION 00 April 2020
FOR MISCELLANEOUS TANKS
PAGE 5 of 8

3.5.8 Tank roof shall be either self-supported or supported from rafters / steel fabricated central column(s).
Adequately sized and spaced rafters and purlins shall be provided. All rafters shall have sliding bolted
connections at one end and preferably on the tank periphery side. The roof-supporting frame shall have
needed tie rods or bracing sets.

3.5.9 Roof plates shall have butt-joints to adequately support lining. No joint of roof plate over the
supporting frame shall be made.

3.5.10 Openings needed for mounting various specified accessories shall be well reinforced in accordance with
application codes and as approved. Manhole shall the bolted and hinged covers unless otherwise
specified.

3.5.11 All inlet pipe nozzles located at the top of tanks shall be provided with internal piping up to 500 mm
high above the tank’s bottom inside with suitable weir plate at bottom. The inside piping shall be
adequately supported and shall be provided with adequately sized vent connection at pipe top.

3.6 RECTANGULAR TANKS

3.6.1 Rectangular tanks shall be fabricated in steel material and shall be designed to withstand internal
hydrostatic pressure. In addition, these shall be checked for a wind pressure and seismic coefficient as
specified wherever applicable. While worst of these two shall be considered, the permissible stress
shall be increased as per good engineering practice when their effect considered with tank load.

3.6.2 Tank bottom and / or side plates shall be of minimum 8 mm thick plate. Corrosion margin of at least 1.5
mm shall be provided over the design thickness of bottom and / or side plates.

3.6.3 To support tank plates and to maintain required unsupported plate length, adequately sized and spaced
steel structural closed frame shall be provided inside the tank. Longitudinal and / or vertical structural
members to connect and adequately support these frames shall be provided at corners. Horizontal
diagonal members / sway bracings at corner shall also be provided.

3.6.4 Tank plates cut to size shall be welded on these frames. Plate butt weld joints at other locations shall be
eliminated to avoid warping of the plates at free joints. Adequate openings in the structural frames,
particularly at the bottom shall be provided to ensure complete unrestricted drainage of tank at one
point. Suitable sized drain valve of size minimum 25 NB unless otherwise specified, shall be provided
below the tank bottom for proper draining of the tank.

3.6.5 Complete assembled tank shall have at its bottom longitudinal steel fabricated bearer beams welded to
it. The tank with bearer will rest over number of concrete blocks to be provided by purchaser. The tank
shall be adequately bolted / welded to the concrete blocks. Needed inserts / anchor bolts shall be
furnished by the bidders. Grouting of tank over concrete blocks in approved manner shall be included in
bidder’s scope of work, if erection is also awarded to the bidder.

3.6.6 Where rectangular tanks are flushed in dual compartments the inside partition plate shall be well
reinforced to withstand hydrostatic test pressure completely on one side throughout the full height.

3.6.7 The rectangular tank shall be designed as per good engineering practice and reference shall be taken
from the book named “Theory of plates and shells” by Timoshenko. Design calculation shall be done in
accordance with the above mentioned book.

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STANDARD TECHNICAL SPECIFICATION
REVISION 00 April 2020
FOR MISCELLANEOUS TANKS
PAGE 6 of 8

3.6.8 Suitable steel structural e.g. channels shall be provided below the bottom plate so that tank can rest on
the foundation / slabs through the structural supports.

3.9 HORIZONTAL CYLINDRICAL TANK

3.9.1 The horizontal cylindrical tank with dished ends shall be of mild steel welded construction and shall be
designed in accordance with BS – 2594 / IS – 2825 / ASME as specified. The tank shall be designed for a
wind pressure and seismic coefficient as specified. While worst of these two shall be considered, the
permissible stress shall be increased as per relevant code / standard.

3.9.2 The shell and dished end plate thickness shall be chosen as per design requirement but in no case the
dished end and shell plate thickness shall be less than 8 mm.

3.9.3 All seams, longitudinal as well as circumferential, shall be butt-welded. Longitudinal seams should not
be situated in the lower one-third of a tank or on the top center line.

3.9.4 All tank shall be supplied with integral saddle support and shall be designed in accordance with BS-
2594 / IS – 2825 / ASME as specified.

4.0 TESTING AND INSPECTION AT MANUFACTURERER’S WORKS

4.1 General

4.1.1 The supplier shall provide inspection to establish and maintain quality of workmanship in his works and
that of his subcontractors to ensure the mechanical accuracy of components, compliance with drawings
identity and acceptability of all materials, parts and equipment. He shall conduct all tests required to
ensure that the equipment and material furnished shall conform to requirements of the acceptable
codes. All tests and test procedure proposed by manufacturer shall be submitted to the purchaser for
their prior approval.

4.1.2 All materials used for manufacture of the equipment under this specification shall be of tested quality.
Relevant test certificates shall be made available to the purchaser before the final shop inspection. In
case the relevant correlating test certificates are not available, the supplier shall arrange to carry out
the necessary tests required by codes at his own cost.

4.1.3 Alloy cast iron and cast steel components shall be tested for both physical and chemical properties in
absence of purchaser’s representatives. Test bears shall be either integral or taken from the same ladle
of material as the casting they represent.

4.1.4 All materials including valves, instruments, pipings, flanges, counter flanges etc. shall be procured from
BHEL approved manufacturer’s only. Dealers are not acceptable.

4.2 TESTING AND INSPECTION FOR TANKS

4.2.1 The scope of testing and inspection for pressure vessel covered in this specification shall generally
comprise of the following:

I. Examination and approval of fabrication drawings to ensure that design, materials and fabrication
details meet requirement of code and specifications. Purchaser will review these drawings for interface
problems and conformity with the general arrangement drawings and accord their approval.
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STANDARD TECHNICAL SPECIFICATION
REVISION 00 April 2020
FOR MISCELLANEOUS TANKS
PAGE 7 of 8

II. Examination of materials of construction and identification with material test certificates.

III. All the plates of thickness 50 mm or more shall be ultrasonically tested to ensure freedom from
laminations.

IV. Ensuring the relevant weld procedure and welder qualification tests are in accordance with stipulated
code requirements.

V. Inspection of dished end flanges and alloy steel bolting where required.

VI. Inspection during fabrication at appropriate stages including fit ups.

VII. For all butt welds, the root run and final run shall be subjected to dye-penetrate or magnetic particle
inspection. For all fillet welds the final run shall be subjected to dye-penetrate / magnetic particle
examination.

VIII. Examination of radiographs including radiographic techniques, supervision of other non - destructive
tests and heat treatment procedure as required by codes and specifications.

IX. Examination of internal cleanliness before final closure.

X. Dimensional examination of completed vessel including axis marking, proof marking, match marking
etc.

XI. Witnessing of hydrostatic, pneumatic or vacuum tests or special tests as required by the code and
specification. In case of hydrostatic tests, the test pressure must be kept for a minimum of two hours.

XII. Witnessing cleanliness, preservation, packing and marking.

XIII. Stamping of vessel and issue of certificates.

XIV. All tanks under this specification shall be tested as per the relevant design and testing code / standard.
Supplier shall submit the detailed testing procedure for the tanks during detail engineering stage for
BHEL / customer / consultant’s approval and approved document shall be adhered by them and testing
shall be done accordingly without any commercial implication.

4.2.2 NON - PRESSURE TANKS

The scope of testing and inspection for non-pressure tanks covered in this specification will comprise of
the following:

i. Identification of materials to manufacturer’s test certificates.

ii. Inspection of plate edges after edge preparation and checking curvature against templates if shell
plates sent after rolling.

iii. Checking of dimension and match marking.

iv. Bottom testing

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SECTION II SUB-SECTION A
STANDARD TECHNICAL SPECIFICATION
REVISION 00 April 2020
FOR MISCELLANEOUS TANKS
PAGE 8 of 8

a. After the bottom and bottom course of shell plates have been welded, the bottom shall be tested by
pumping air beneath the bottom plates to a pressure just sufficient to lift them off the foundation and
in any case not less than 100 mm water gauge. The pressure shall be held by construction of a
temporary dam of clay or other suitable material around the tank periphery. Soap suds or other
suitable material shall be applied to all joints for detection of leaks.

b. Fuel oil may be used instead of air and soap suds to test for leaks, subject to prior agreement and
approval of purchaser.

c. Alternatively, the bottom seams may be tested by vacuum box method subject to prior agreement and
approval of the purchaser. The vacuum box used shall comply with IS- 803, 1976 (figure-24)

v. Shell testing

The shell of fixed roof non - pressure tanks shall be tested after completion of roof. Testing shall be
done by filling the tank with water to the level of the top leg of the top curb angle and noting any leaks.

vi. Roof testing

The roof of the tank shall be tested by pumping air under the roof plates while the tank is still full of
water. In the non - pressure tank, the roof shall be tested to a pressure of 75 mm of water gauge and in
case of pressure roof tanks, to a pressure of one and a quarter times the pressure at which the pressure
sides of the pressure / vacuum relief valve is designed to open. Soap suds or other suitable material
shall be applied to all joints for detection of leaks.

vii. All field-testing shall be performed prior to any painting or coating application.

4.3 REPAIR OF LEAKS

4.3.1 All leaks detected during testing shall be repaired to the satisfaction of the purchaser and on
completion retested for leakage as per approved procedure.

4.3.2 In the joints between roof plates only, pin hole leaks may be repaired by mechanical caulking. However,
where there is any indication of considerable porosity, the leaks shall be sealed by laying down an
additional layer of weld over the porous sections.

4.3.3 In all other joints, whether between shell plates or bottom plates or both, leak shall be repaired only by
welding and if necessary, after first cutting out the defective part.

4.3.4 When the tank is filled with water for testing, defects in the shell joints shall be repaired with the water
level at least 300 mm below the joint being repaired.

4.3.5 No welding shall be done on any tank unless all lines connecting thereto have been completely blanked
off. No repairs shall be attempted on tanks while filled with oil, nor any tanks which have contained oil
until the tanks have been emptied, cleaned and freed from gas in a safe manner. No repair shall be
attempted on a tank which has contained oil except in a manner approved in writing by the purchaser,
and in absence of the purchaser’s inspector.

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TECHNICAL SPECIFICATION REV. 00
Date: April, 2020

SECTION-II

SUB-SECTION-A

GUIDANCE FOR DESIGNING AND FABRICATION OF STEEL CONSTRUCTIONS

FOR RUBBERLINING & VE GLASS FLAKE LINING

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TECHNICAL SPECIFICATION REV. 00
Date: April, 2020

1. INTRODUCTION:
This guidance covers the minimum requirements for the design and fabrication of
carbon steel vessels, equipment and pipes for rubber lining and VE Glass Flake
lining.

2. GENERAL:

2-1 : Structure of steel constructions should be designed to withstand mechanical

shocks under transportation and service. Particularly, hard rubber / VE Glass
Flake lined vessels should be paid full attention because these vessels are liable
to cause cracks when transported or installed.
2-2 : As the lining process is done manually, any constructions (except pipe)
inaccessible by hands should be split into accessible one, as shown in Fig. 1.

2-3 : The parts tend to wear must be designed to be able to dismount and check or
exchange easily as shown in Fig.2
2-4 : All lining surface should be designed as simple as possible and reinforcement
must be provided on the side not to be lined as shown in Fig.3.

2-5 : When heating is necessary, care must be taken not to raise the temperature partially
too high as shown in Fig.5 (b), or not to contact with rubber directly. It is
recommended to design as shown in Fig. 5(a) and keep the hating pipe at least 100
mm apart from the lining.

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Date: April, 2020

2-6 : When it is necessary to insert nozzles in vessels special attention should be paid
to dimensions securing enough room at overlap of rubber lining as illustrated in
Fig. 6.

3. WELDING AND FINISHING:

In order to get the optimum adhesion between the base metal and rubber sheet / VE
Glass Flake lining, or to prevent pinholes or other defects, designers and manufacturers of
pipes, vessels and other steel constructions are requested to give proper consideration to
the following points.

3-1 : Welds and flush on the side to be lined shall be ground smoothly and must be
free of cracks, undercuts, overlaps, pinholes and blowholes.

3-2 : Butt joint is preferable and overlap joint is not recommended for lining vessels.
Welding must be generally made from both sides as shown in Fig. 7.

3-3 : All corners should have the curvature of at least 3 mmR for convex surface and at
least 10 mmR for concave surface as shown in Fig. 8.

3-4 : All welds for lining vessels should be continuous as shown in Fig. 9.

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TECHNICAL SPECIFICATION REV. 00
Date: April, 2020

3-5 : When air pocket brought about by continuous welding cannot be avoided, air
vent-hole or intermittent weld must be provided as shown in Fig. 10.

4. PIPES AND FITTINGS:

Pipes and Fittings should have smooth surface on the side to be lined. Lining on surfaces
with sharp projection and irregularities should be avoided.
Flat-faced flanges shall be welded on square to pipes or fittings. The weld on the front face
should be continuous and ground to a smooth convex surface not less than3 mm in radius.

Pipings should be designed to use standard pipes and fittings and complied with following
requirement.

4-1 . STRAIGHT PIPES:

The maximum length of straight pipes, measured between flange face, which can be
satisfactorily lined are given below:

Nominal diameter (mm) Maximum length (mm)

Over 25 to 40 2750
Over 50 to 80 5500
Over 100 to 550 6000
Over 600 12000

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TECHNICAL SPECIFICATION REV. 00
Date: April, 2020

4-2. STRAIGHT PIPES:

The dimensions of Elbows and Bends which can be satisfactorily lined are as below:

DIMENSIONS OF BENDS AND ELBOWS ( STEEL ) FOR RUBBER LINING FEASIBILITY :

ALL DIMENSIONS IN MILLIMETRES:

NOM DIA. MAX L1 MAX L2, L3 MAX. L4

25 90 300 175
32 95 300 210
40 100 300 250
50 115 500 280
65 130 2000 325
80 150 3000 400
90 170 3000 450
100 190 3000 500
125 195 3000
150 230 3000
200 310 3000
250 385 3000
300 465 3000
350 540 3000
400 615 3000
450 692 1000
500 770 1000
550 838 5500
600 912 5500
650 990 5500
700 1000 12000

Note: The above tabulation shows sizes which can be fabricated and rubber lined satisfactorily.

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MISC. FGD TANKS SECTION-II
TECHNICAL SPECIFICATION REV. 00
Date: April, 2020

DIMENSIONS OF REDUCING PIPES (STEEL) FOR RUBBER LINING FEASIBILITY of CONCENTRIC

AND ECCENTRIC REDUCING PIPES.

4-3 REDUCING PIPES:

The dimensions of concentric and eccentric reducing pipes which can be satisfactorily lined
are given below. Pipes should be reduced by mechanical process or by high-frequency
reducers.
ALL DIMENSIONS IN MILLIMETERS

NOM.DIA L1 MAX. L2 MAX. NOM.DIA L1 MAX. L2 MAX.

25 100 2750 200 230 5500
32 120 2750 250 250 5500
40 120 2750 300 300 5500
50 130 5500 350 480 5500
65 150 5500 400 500 5500
80 150 5500 450 530 5500
90 160 5500 500 650 5500
100 160 5500 550 650 5500
125 200 5500 600 650 11000
150 220 5500 700 & above 2000 10000

Note:
x The above tabulation shows sizes which can be fabricated and rubber lined satisfactorily.

DIMENSIONS OF TEES, CROSSES AND BRANCHED PIPES (STEEL) FOR RUBBERLNING

FEASIBILITY.

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 2 X 250 MW BHILAI FGD SPECIFICATION No: PE-TS-468-167-A101
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TECHNICAL SPECIFICATION REV. 00
Date: April, 2020

THE DIAMETER OF THE BRANCH(S) SHOULD BE THE SAME OR LESS THAN THAT OF THE STRAIGHT
PIPE.
ALL DIMENSIONS IN MILLIMETERS

NOM.DIA L L1 MIN. L2 MAX.

25 2750 80 100
32 85 100
40 90 100
50 5500 100 100
65 115 100
80 125 150
90 135 150
100 5500 145 150
125 165 150
150 190 200
200 225 250
250 270 300
300 5500 310 500
350 340 500
400 370 500
450 410 500
500 450 500
550 490 500
600 & above 12000 see notes see notes
below below

Note: The above tabulation shows sizes which can be fabricated and rubber lined satisfactorily.

5. FLANGES AND GASKETS:

5-1 All branches and outlets of tank should be equipped with flange to allow the rubber lining
to over flange face. Typical flanged joints are illustrated in Fig.11.
5-2 Mating flange of sectional tank should be square and plumb, and sections should be made
to avoid distortion and when bolted together.
5-3 Normally, soft rubber gaskets should be interposed between lined flanges. If the flange
faces have to withstand very high loads, the flanges joint shown in Fig. 11(d) should be
used.

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Date: April, 2020

6. NOTES:

6-1 : Any surface of the base metal to be lined should not be coated with paint or oil.
6-2 : Any surface of the base metal to be lined should not be galvanized.
6-3 : Although it is possible to line on various construction materials, carbon steel is most
preferable as substrate. For cast materials special care should be taken to prevent
blowholes or cavities.

7. INSPECTION PROCEDURE AND STANDARD FOR LINING PIPES:

Each pipe should be confirmed whether it is ready for rubber lining through checking
dimensions, appearances and quality of weld etc. according to the drawings standard for
lining.

If any obstacle is detected, repairing should be requested to the fabricator of pipes.

7.1 INSPECTION OF WELD ZONE:

a) Visual inspection:
Weld lines shall be free from weld cavity and spatters shall be completely removed.
Under-cut shall be 0.3 mm or less.
Appearance shall be not unsightly.
b) Check Curved faces at corner :
Convex shall be 3 mm Radius at least, concave shall be 10 mm Radius at least.
c) Check height and width of weld bead :
Diameter 550 mm or less : Diameter 600 mm or larger :
Height - 0.1 ~ 0.2 mm Height - 1.0 ~ 1.5 mm
Width - 1.5 ~ 2.0 mm Width - not specified

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Date: April, 2020

d) Check finish of bead end:

e) Check butt joint when plates of different thickness is used:

W = (T1 – T 2) x 10 mm or longer
7-2 Visual inspection:
The flange faces to be lined shall be free from disadvantages irregularity.
7-3 Dimensional inspection:
a) Tolerance of length of pipes, bends and tees :

1= + 0, - 3 (for length of 1000 mm and less)

1= + 0, - 3 (for length over 1000 mm)

b) Inclination of flange: c) misalignment of bolt holes :

A = ± 1/2º A = ± 1.5 mm
B = max. 5 mm

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TECHNICAL SPECIFICATION REV. 00
Date: April, 2020

It should be noted that some tanks designed for operation, in vertical position, are to be
handled in horizontal position during the various stages of lining. Hence, such vessels should be
designed accordingly.

During operation of some rubber lined tanks, such as hydrochloric acid, the fumes / mist
emanating out of the tank, tend to corrode the external surface especially at the roof. It may be
advisable to provide rubber lining externally especially around the vent nozzles. In such of the
tanks, sometimes due to overflow etc. corrosion occurs at the bottom kerbs, also the corrosive
medium goes below the surface of the bottom plate. Care must be taken by suitable design to
prevent such situations.
In large size tanks, piping, process equipment, suitable lifting lugs should be provided.
If the vessels, pipes require external hot / cold insulation, the steel cleat for holding the
insulation should be welded before handing over the fabricated item for rubber lining.

Note:
1. In addition to above, Surface preparation, application including drying & curing of rubber
/ VE Glass Fake lining, packaging, storage, Inspection etc. shall be as ensured as
recommended by OEM’s of these lining.

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 2 X 250 MW BHILAI FGD SPECIFICATION No: PE-TS-468-167-A101
SECTION-II
MISC. FGD TANKS REV. 00
TECHNICAL SPECIFICATION Date: April, 2020

SECTION-II
SUB-SECTION-B

FORMAT FOR OPERATION AND MANITENANCE

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FormatforOperation&MaintenanceManual
WƌŽũĞĐƚŶĂŵĞ  ͗
WƌŽũĞĐƚŶƵŵďĞƌ  ͗
WĂĐŬĂŐĞEĂŵĞ  ͗
WKƌĞĨĞƌĞŶĐĞ  ͗
ŽĐƵŵĞŶƚŶƵŵďĞƌ ͗
ZĞǀŝƐŝŽŶŶƵŵďĞƌ ͗

Sl.no.& Description Tick()ifincludedin Remarks
Sections Manual
  Yes No Not 
Applicable
1.  Coverpage    
1.1 ProjectName    
1.2 Customer/consultantName    
1.3 NameofPackage    
1.4 Supplierdetailswithphone,FAX,emailaddress    
,EmergencyContactnumber
1.5 Nameandsignofpreparedby,checkedby&    
approvedby
1.6 RevisionhistorywithapprovalDetails    
2.0 Index    

2.1 showingthesections&relatedpagenos    
Allthepagesshouldbenumberedsectionwise
3.0 DescriptionofPlant/System    
3.1 Description/writeupofoperatingprincipleof    
systemequipment/associatedsubsystems&
accessories/controlssystem,operating
conditions,performanceparametersunder
normal,startupandspecialcases
3.2 EquipmentlistandbasicparameterwithTag    
numbers
3.3 DatasheetsapprovedbyCustomer/for    
informationandcataloguesprovidedbyoriginal
manufacturer
3.4 AssociatedotherpackagesandInterface    
/terminalpoints
3.5 P&ID&ProcessDiagrams    
3.6 GALayoutdrawings,Asbuiltdrawings,Actual    
photographofitems/system(DrawingsofA2&
biggersizesaretobeattachedinthelast)
3.7 Singleline/wiringdiagrams    
3.8 Controlphilosophy/controlwriteups    

Page1of3
Page 295 of 338
 4.0 CommissioningActivities(ifnotcovered    
inseparatedocumenti.e.erection
manual,commissioningmanual)
4.1 PreCommissioningChecks    
4.2 handlingofitemsatsite    
4.3 Storageatsite    
4.4 Unpacking&Installationprocedure    
5.0 OperationGuidelinesforplant    
personal/user/operator
5.1  Interlock & Protection logic along with the    
limiting values of protection settings for the
equipment along with brief philosophy behind
thelogic,drawingsetc.tobeprovided.

5.2  Startup,normaloperationandshutdown    
procedureforequipmentsalongwiththe
associatedsystemsinstepbystepmode.Valve
sequencechart,steplist,interlocksetc.with
Equipmentisolatingprocedurestobe
mentioned.
5.3  Do’s&Don’toftheequipments.    
5.4  Safetyprecautionstobetakenduringnormal    
operation.Safetysymbols,Emergency
instructionsontotalpowerfailure
condition/lubricationfailure/anyother
condition
5.5  Parameterstobemonitoredwithnormalvalues    
andlimitingvalues
5.6  Troubleshootingwithcausesandremedial    
measures
5.7  Routineoperationalchecks,recommendedlogs    
&records
5.8  Changeoverscheduleifmorethanoneauxiliary    
forthesamepurposeisgiven
5.9  Paintingrequirementandschedule    
5.10 Inspection,repair,Testingandcalibration    
procedures
6.0 Maintenanceguidelinesforplant    
personal
6.1 ListofSpecialToolsandTacklesrequiredfor    
Overhaul/Troubleshootingincludingspecial
testingequipmentrequiredforcalibrationetc.
6.2 Stepwisedismantlingandreassembly    
 procedureclearlyspecifyingthetoolstobe
used,checkstobemade,recordstobe
maintained,clearancesetc.tobementioned.
Tolerancesforfitmentofvariouscomponents
tobegiven.

Page2of3
Page 296 of 338
 6.3 Preventive Maintenance & Overhauling    
schedules linked with running hours/calendar
periodalongwithcheckstobegiven
6.4 Longtermmaintenanceschedulesespeciallyfor    
structural,foundationsetc.
6.5 Consumable list along with the estimated    
quantityrequiredduringcommissioning,normal
runningandduringmaintenancelikePreventive
Maintenances and Overhaul. Storage/handling
requirementofconsumables/selflife.

6.6 List of lubricants with their Indian equivalent,    
LubricationSchedule,Quantityrequiredforeach
equipment for complete replacement is to be
given
6.7 List of vendors & Subvendors with their latest    
addresses,servicecentres,TelephoneNos.,Fax
Nos.,MobileNos.,emailIDsetc.
6.8 Listofmandatoryandrecommendedspareparts    
list
6.9 TentativeLeadtimerequiredfororderingof    
sparesfromtheequipmentsupplier
6.10 Guaranteeandwarrantyclauses    
7.0 Statutoryandotherspecificrequirements    
considerations.
8.0 Listofreferencedocuments    
9.0 Bindingasperrequirement    


Page3of3
Page 297 of 338
 2 X 250 MW BHILAI FGD SPECIFICATION No: PE-TS-468-167-A101
SECTION-II
MISC. FGD TANKS REV. 00
TECHNICAL SPECIFICATION Date: April, 2020

SECTION-II
SUB-SECTION-C

SITE STORAGE AND PRESERVATION GUIDELINES

Page 298 of 338

PROJECT ENGINEERING MANAGEMENT, POWER SECTOR
BHARAT HEAVY ELECTRICALS LIMITED-NOIDA

Page 299 of 338

 CONTENT

1 SCOPE OF THE DOCUMENT

2 PURPOSE OF STORAGE & PRESERVATION

3 MEASURES TO BE TAKEN FOR STORAGE AND PRESERVATION

a) GENERAL STORAGE REQUIREMENTS

b) GENERAL PRESERVATION REQUIREMENTS

c) GENERAL INSPECTION REQUIREMENTS

4 TYPE OF STORAGE FOR VARIOUS EQUIPMENT

5. CONCLUSION

6. STACKING ARRANGEMENT FOR PLATES AND STRUCTURAL STEEL

Page 300 of 338

1. SCOPE OF THE DOCUMENT

This guideline is prepared in intent to provide proper site storage and preservation of the
Mechanical, Electrical and C & I items / equipment supplied under various bought out
packages/items. This storage procedure shall be followed at different power plant sites by
concerned agency for storage and preservation from the date of equipment received at
site until the same are erected and handed over to the customer.

2. PURPOSE OF STORAGE & PRESERVATION

Many of the items may be required to be kept in stores for long period. It shall therefore
be essential that proper methods of storage and preservation be applied so that items do
not deteriorate, loose some of their properties and become unusable due to atmospheric
conditions and biological elements.

3. MEASURES TO BE TAKEN FOR STORAGE, HANDLING & PRESERVATION

a) GENERAL STORAGE REQUIREMENTS

1. To the extent feasible, materials should be stored near the point of erection. The
storage areas should have adequate unloading and handling facilities with adequate
passage space for movement of material handling equipment such as cranes, fork lift
trucks, etc. The storage of materials shall be properly planned to minimise time loss
during retrieval of items required for erection.

2. The outdoor storage areas as well as semi-closed stores shall be provided with
adequate drainage facilities to prevent water logging. Adequacy of these facilities shall
be checked prior to monsoon.

3. The storage sheds shall be built in conformity with fire safety requirements. The stores
shall be provided with adequate lights and fire extinguishers. ‘No smoking’ signs shall
be placed at strategic locations. Safety precautions shall be strictly enforced.

4. Adequate lighting facility shall be provided in storage areas and storage sheds and
security personnel positioned to ensure enforcement of security measures to prevent
theft and loss of materials.

5. Adequate number of competent stores personnel and security staff shall be deployed
to efficiently store and maintain the equipment / material.

7. The equipment shall be stored in an orderly manner, preserving their identification

slips, tags and instruction booklets, etc., required during erection. The storage of
materials shall be equipment-wise. Loose parts shall be stored in sheds on racks,

Page 301 of 338 Page 1 of 13

 preserving the identification marks and tags in good condition. The group codes shall
be displayed on the racks

6. At no time shall any materials be stored directly on ground. All materials shall be
stored minimum 200 mm above the ground preferably on wooden sleepers

b) GENERAL PRESERVATION REQUIREMENTS

1. All special measures to prevent corrosion shall be taken like keeping material in dry
condition, avoiding the equipment coming in contact with corrosive fluid like water,
acid etc.

2. Materials which carry protective coating shall not be wrapped in paper, cloth, etc., as
these are liable to absorb and retain moisture. The material shall be inspected and in
case of signs of wear or damages to protective coating, that portion shall be cleaned
with approved solution and coated with an approved protective paint. Complete record
of all such observations and protective measures taken shall be maintained.

3. Generally equipment supplied at site are properly greased or rust protective oil is
applied on machined/ fabricated components. However periodic inspection shall be
carried out to ensure that protection offered is intact.

4. While handling the equipment, no dragging on the ground is permitted. Avoid using
wire rope for lifting coated components. Use polyester slings (if possible) otherwise
protective material (e.g. clothes, wood block etc.) should be used while handling the
components with rope / slings

5. For Equipment supplied with finished paint, touch paint shall be done in case any
surface paint gets peeled off during handling. Otherwise such surfaces shall
necessarily be wrapped with polythene to avoid any corrosion. Further for equipment
wherein finish coat is to be applied at site, site to ensure that equipment is received
with primer coat applied.

6. It shall be ensured by periodic inspection that plastic inserts are intact in tapped holes,
wherever applicable.

7. Pipes shall be blown with air periodically and it shall be ensured that there is no
obstruction.

8. Silica gel or approved equivalent moisture absorbing material in small cotton bags
shall be placed and tied at various points on the equipment, wherever necessary.

9. Heavy rotating parts in assembled conditions shall be periodically rotated to prevent

corrosion/jamming due to prolonged storage.

Page 302 of 338 Page 2 of 13

 10. All the electrical equipment such as motors, generators, etc. shall be tested for
insulation resistance at least once in three months and a record of such measured
insulation values shall be maintained.

11. Following preservatives/preservation methods can be used depending upon type of

equipment

a. Rust preventive fluid (RPF)

b. Rust protective paints

c. Tarpaulin covers, in case of outdoor storage

d. De-oxy aluminate for weld-ments

c) GENERAL INSPECTION REQUIREMENTS

1. Period inspection of materials with specific reference to –

• Ingress of moisture and corrosion damages.

• Damage to protective coating.

• Open ends in pipes, vessels and equipment -

- In case any open ends are noticed, same shall be capped.

2. Any damages to equipment / materials.

- In case of any damages, these shall be promptly notified and in all cases, the
repairs / rectification shall be carried out.
- Any items found damaged or not suitable as per project requirements shall be
removed from site. If required to store temporarily, they shall be clearly
marked and stored separately to prevent any inadvertent use.

Page 303 of 338 Page 3 of 13

4. TYPE OF STORAGE FOR VARIOUS EQUIPMENT

The types of storage are broadly classified under the following heads:
i Closed storage with dry and dust free atmosphere. (C )
The closed shed can be constructed by using cold-rolled / tubular components for
structure and corrugated asbestos sheets / galvanised iron sheets for roofing. Brick
walls / asbestos sheets can be used to cover all the sides. The floor of the shed can
be finished with plain cement concrete suitably glazed. The shed shall be provided
with proper ventilation and illumination.

ii Semi-closed storage. (S)

The semi closed shed can be constructed by using cold-rolled / tubular components
for structure and corrugated / asbestos sheets for roofing. The floor shall be brick
paved. If required a small portion of sides can be covered to protect components from
rainwater splashing onto the components.

Page 304 of 338 Page 4 of 13

iii Open storage (O )
The open yard shall be levelled, well consolidated to achieve raised ground with the
provision of feeder roads for crane approach along with access roads running all
sides. One part of the open yard shall be stone pitched, levelled and consolidated with
raised ground suitable for storing / stacking heavier and critical components with due
space to handle them by cranes etc . Adequate number of sleepers, concrete block
etc. to be provided to make raised platforms to stack critical materials.

A separate yard to be identified as “scrap yard” slightly away from main open yard to
store wooden/steel scraps, which are to be disposed off. This is required to avoid mix
up with regular components as well as to avoid fire hazard.
Some of the components, which are having both machined & un-machined surfaces
and are bulky, shall be stored in open storage area on a raised ground and suitably
covered with water proof / fire retardant tarpaulin.

Page 305 of 338 Page 5 of 13

The equipment listed below shall be stored and inspected as per requirement mentioned in the
table below.

Type of
Sl. No. Description of the equipment Check for Remarks
Storage

Raw material /mechanical items like pipes, plates, structure sections etc.)

Damage , paint,
Provide end
1. Steel pipes ( lined/unlined) S corrosion, rubber
cap
lining peeling

Damage, paint,
2. MS Plates S
corrosion

3. SS Plates S Damage

Provide end
4. Non-metallic pipes S Damage, cracks
cap

Provide end
5. Stainless steel pipes S Damage ,
cap

Damage, paint,
6. MS sections, beams S
corrosion

Damage, condition of
7. Cable trays S
preservations

8. Insulation sheets S Damage

9. Insulation C Damage, packing

Damage, paint,
10. Hangers Rods S
packing

Damage, paint , Provide end

11. Tubes S
packing cap

12. Hume pipes O Damage

Damage, paint,
13. Castings O
corrosion

Fabricated mechanical items (pressure vessels, tanks etc.)

Damage, paint, Covered

14. Pressure vessels (unlined) O
corrosion, nozzles

Covered
Atmospheric storage tanks Damage, paint, nozzles
15. O
(unlined) corrosion

Page 306 of 338 Page 6 of 13

 Type of
Sl. No. Description of the equipment Check for Remarks
Storage

Damage, paint,
16. Pressure vessels (lined) S corrosion, rubber
lining

Damage, paint,
17. Atmospheric storage tanks(lined) S corrosion, rubber
lining

Damage , paint,
18. Support structures O
corrosion

Damage , paint,
19. Flanges C
corrosion

Damage , paint, Provide end

20. Fabricated pipes S
corrosion cap

Damage , paint,
21. Vessels internals C
corrosion ,packing

Damage , paint,
22. Grills S
corrosion

Damage , paint,
23. Angles S
corrosion

Bridge mechanism/clarifier Damage , paint,

24. O
mechanism corrosion

Damage , paint,
25. Cranes, rails S
corrosion

Damage , paint,
26. Stair cases O
corrosion

Damage , paint,
27. Ladders/handrails O
corrosion

Damage , paint,
28. Fabricated ducts S
corrosion

Damage , paint,
29. Isolation Gates O
corrosion

Damage , paint,
30. Fabricated boxes/panels S
corrosion

Mechanical components like valves, fittings, cables glands, spares etc.)

31. Valves S Damage , packing

Page 307 of 338 Page 7 of 13

 Type of
Sl. No. Description of the equipment Check for Remarks
Storage

Provide end
32. Fittings S Damage , packing
cap

33. Cable glands C Damage , packing

34. Tools & tackles C Damage , packing

35. Nut , bolts, washers, C Damage , packing

36. Gasket & Packings C Damage , packing

Damage , packing, Provide end

37. Copper tubes C
corrosion cap

Provide end
38. SS tubing C Damage , packing
cap

Rotating assemblies (pumps, blowers, stirrers, fans, compressors etc.)

Damage , packing, Shaft

39. Pumps S
corrosion rotation

Damage , packing, Shaft

40. Blowers/Compressors S
corrosion rotation

Damage , packing, Shaft

41. Agitators/stirrers/radial launders C
corrosion rotation

Rollers for chlorine tonner Damage , packing,

42. C
mounting corrosion

43. Centrifuge S Damage , packing,

Damage , packing,
44. Gear box C
corrosion

Damage , packing,
45. Bearings C
corrosion

Damage , packing,
46. Fans S
corrosion

Damage , packing,
47. Dosing skids S
corrosion

Damage , packing,
48. Pump assemblies S
corrosion

49. Air washers( INTERNALS) S Damage , packing

50. Air conditioners ( split) C Damage , packing

Page 308 of 338 Page 8 of 13

 Type of
Sl. No. Description of the equipment Check for Remarks
Storage

Damage , packing,
51. Elevators( CONTAINERIZED) O
corrosion

52. Chillers/VA machines S Damage , packing

53. Air handling Unit/Package unit S Damage , packing

54. Chlorinators & Evaporators C Damage , packing

55. Ejectors C Damage , packing

56. Electrolyser C Damage , packing

Miscellaneous items like chain pulley blocks, hoists etc.

57. Chain pulley blocks S Damage, Packing

58. Electric hoists S Damage, Packing

59. Fire extinguishers C Damage, expiry date

60. Fork Lift Truck S Damage, Packing

61. Hydraulic Mobile Crane O Damage, Packing

62. Mobile Pick Up & Carry Crane O Damage, Packing

63. Motor boats O Damage, Packing

64. Safety showers S Damage, Packing

65. Diffusers/dampers S Damage, Packing

Chemicals and consumables ( acid, alkali, paints, oils, reagents and special chemicals)

Store in
canes/
storage
tank in Date of production/ hazardous
66. Hydro Chloric Acid (HCl)
dyke leakage/fumes chemical
area

Store in
canes/
storage
tank in Date of production/ hazardous
67. Sulphuric acid (H2SO4 )
dyke leakage/fumes chemical
area

Page 309 of 338 Page 9 of 13



Description of the Type of

Sl. No. Check for Remarks
equipment Storage

Store in canes/ hazardous

storage tank in Date of production/ chemical
68. Sodium hydroxide (NaOH) dyke area leakage/ fumes/ ,breather to be
breather checked for air
ingress

hazardous
chemical ,self-life
To be stored Date of production/ normally 15-30
69. Sodium hypo chlorite
under shed leakage/ fumes days after which
strength of
chemical decays

Store in closed
Date of production/ storage tanks,
70. Ammonia S
leakage/ fumes hazardous
chemical

Date of production , Store in closed

71. CW treatment chemicals S
Self-life canes

Date of production , Store in closed

72. RO/UF cleaning chemicals S
Self-life canes

Damage to packing , Prevent moisture,

73. Lime C
seepage rain

Prevent moisture,
74. Alum bricks C Damage to packing
rain

Store in closed
75. Poly electrolyte S
storage tanks

Laboratory chemicals( Damage, Packing self-

76. C
powder) life

Laboratory chemicals( Damage, Packing self-

77. C
liquid) life

78. Lubrication oils C Leakage

79. Paints S Leakage ,air tightness

80. Sand O Damage of packing No hooks

Damage of packing, Prevent moisture,

81. Salt (NaCl) C
water ingress rain

82. Anthracite S Damage of packing

83. Activated carbon S Damage of packing

Page 310 of 338 Page 10 of 13

 Description of the Type of
Sl. No. Check for Remarks
equipment Storage

84. Thermal insulation S Damage of packing

Prevent moisture,
85. Cement C Damage of packing
rain

86. Gravels O Damage of packing

Refer
87. ION exchange resins C Damage , packing manufacturer
guidelines

Refer
88. RO membranes C Damage , packing manufacturer
guidelines

Refer
89. UF membranes C Damage , packing manufacturer
guidelines

Refer
90. Cleaning chemicals C Damage , packing manufacturer
guidelines

Refer
Chemicals for
91. C Damage , packing manufacturer
analysers/calibration
guidelines

Electrical and C & I items (motors, cables etc.)

92. Motors C Damage , packing

93. Cable drums O Damage

Control Panel /control desk, UPS

94. S Damage, Packing
,JB

95. Instruments( gauges/analysers) C Damage

As per Manufacturer’s item, like Hydrogen cylinders,

Special items
Ozonator, Analyser, Chlorine dioxide generators etc.

Page 311 of 338 Page 11 of 13

5. CONCLUSION

Concerned storage agency at site should make sure that loss in equipment performance
and wear & tear are minimised through proper storage and preservation. The above are
broad guidelines and cover major equipment / materials. However specific storage
practices shall be followed as per manufacturer recommendation. All the necessary
measures even in addition to the ones mentioned above, if found necessary, should be
taken to achieve the objective.

Page 312 of 338 Page 12 of 13

 Figure – 1 – PLATE STACKING ARRANGEMENT

Figure – 2 – STRUCTURAL STEEL STACKING ARRANGEMENT

Page 313 of 338 Page 13 of 13

 SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-III
TECHNICAL SPECIFICATION FOR REV. 00
FGD TANKS
Date: April, 2020

SECTION-III

Page 314 of 338

 SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-III
TECHNICAL SPECIFICATION FOR REV. 00
FGD TANKS
Date: April, 2020

SECTION-III
ANNEXURE-1

LIST OF DOCUMENTS TO BE SUBMITTED WITH BID

Page 315 of 338

 2 X 250 MW BHILAI FGD SPECIFICATION No: PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR SECTION : III
FGD TANKS ANNEXURE-1
LIST OF DOCUMENTS TO BE SUBMITTED WITH
BID REV: 00
Date: April, 2020

BIDDER SHOULD SUBMIT THE SIGNED AND STAMPED COPY OF THE

FOLLOWING DOCUMENTS:

1. Compliance cum confirmation certificate (refer annexure-2 of section-III)

2. Pre-bid clarification schedule as per format given under Section-III (Annexure-3), in case
of any clarifications.
3. Deviation schedule as per format given under Section-III (Annexure-4), in case of any
deviations by bidder.
4. Un priced format for main package (mentioning quoted against each item)
5. Un priced format for Tools and Tackles (mentioning quoted against each item)
6. Un priced format for Commissioning spare (mentioning quoted against each item)
7. List of makes of sub vendor items (refer annexure- of section-III)
8. FGD Tanks Schedule & GA Drawing (Typical) with Agitator Platform (refer annexure-8 of
section-III)

Page 316 of 338

 SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-III
TECHNICAL SPECIFICATION FOR ANNEXURE-2
MISC. FGD TANKS
REV. 00
Date: April, 2020

SECTION-III
ANNEXURE-2

COMPLIANCE CUM CONFIRMATION CERTIFICATE

Page 317 of 338

 2 X 250 MW BHILAI FGD SPECIFICATION No:PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR SECTION : III
MISC. FGD TANKS ANNEXURE-2
COMPLIANCE CUM CONFIRMATION REV. NO. 00
CERTIFICATE Date: April, 2020

COMPLIANCE CUM CONFIRMATION CERTIFICATE

The bidder shall confirm compliance with following by signing / stamping this compliance
certificate (every sheet) and furnish same with the offer.

a) The scope of supply, technical details, construction features, design parameters etc. shall
be as per technical specification & there are no exclusions, other than those mentioned
under “exclusion and those resolved as per ‘Schedule of Deviations’, with regard to same.

b) There are no other deviations w.r.t. specifications other than those furnished in the
‘Schedule of Deviations’. Any other deviation, stated or implied, taken elsewhere in the
offer stands withdrawn unless specifically brought out in the ‘Schedule of Deviations’

c) Bidder shall submit QP in the event of order based on the guidelines given in the
specification & QP enclosed therein. QP will be subject to BHEL / CUSTOMER approval &
customer hold points for inspection / testing shall be marked in the QP at the contract
stage. Inspection / testing shall be witnessed as per same apart from review of various
test certificates/ Inspection records etc. This is within the contracted price without any
extra implications to BHEL after award of the contract.

d) All drawings/ data-sheets / calculations etc. submitted along with the offer shall not be
taken cognizance off.

e) The offered materials shall be either equivalent or superior to those specified in the
specification & shall meet the specified / intended duty requirements. In case the material
specified in the specifications is not compatible for intended duty requirements then same
shall be resolved by the bidder with BHEL during the pre-bid discussions, otherwise BHEL /
Customer’s decision shall be binding on the bidder whenever the deficiency is pointed out.

For components where materials are not specified, same shall be suitable for intended
duty, all materials shall be subject to approval in the event of order.

f) The commissioning spares shall be supplied on ‘As Required Basis’ & prices for same
included in the base price itself.

g) All sub vendors shall be subject to BHEL / CUSTOMER approval in the event of order.

h) Guarantee for plant/equipment shall be as per relevant clause of GCC / SCC / Other
Commercial Terms & Conditions

i) In the event of order, all the material required for completing the job at site shall be
supplied by the bidder within the ordered price even if the same are additional to
approved billing break up, approved drawing or approved Bill of quantities within the
scope of work as tender specification. This clause will apply in case during site
commissioning, additional requirements emerges due to customer and / or consultant’s
comments. No extra claims shall be put on this account
Page 318 of 338
 2 X 250 MW BHILAI FGD SPECIFICATION No:PE-TS-468-167-A101
TECHNICAL SPECIFICATION FOR SECTION : III
MISC. FGD TANKS ANNEXURE-2
COMPLIANCE CUM CONFIRMATION REV. NO. 00
CERTIFICATE Date: April, 2020

j) Schedule of drawings submissions, comment incorporations & approval shall be as

stipulated in the specifications. The successful bidder shall depute his design personnel to
BHEL’s / Customer’s / Consultant’s office for across the table resolution of issues and to
get documents approved in the stipulated time.

k) As built drawings shall be submitted as and when required during the project execution.

l) The bidder has not tempered with this compliance cum confirmation certificate and if at
any stage any tempering in the signed copy of this document is noticed then same shall be
treated as breach of contract and suitable actions shall be taken against the bidder.

m) Successful bidder shall furnish detailed erection manual for each of the equipment
supplied under this contract at least 3 months before the scheduled erection of the
concerned equipment / component or along with supply of concerned equipment /
component whichever is earlier.

n) Document approval by customer under Approval category or information category shall

not absolve the vendor of their contractual obligations of completing the work as per
specification requirement. Any deviation from specified requirement shall be reported by
the vendor in writing and require written approval. Unless any change in specified
requirement has been brought out by the vendor during detail engineering in writing
while submitting the document to customer for approval, approved document (with
implicit deviation) will not be cited as a reason for not following the specification
requirement.

o) In case vendor submits revised drawing after approval of the corresponding drawing, any
delay in approval of revised drawing shall be to vendor’s account and shall not be used as
a reason for extension in contract completion.

Page 319 of 338

 SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-III
TECHNICAL SPECIFICATION FOR ANNEXURE-3
FGD TANKS
REV. 00
Date: April, 2020

SECTION-III
ANNEXURE-3
PRE-BID CLARIFICATION SCHEDULE

Page 320 of 338

 2 X 250 MW BHILAI FGD
TECHNICAL SPECIFICATION FOR FGD TANKS

PRE-BID CLARIFICATION SCHEDULE

S.No. Section/Clause/ Statement of the referred Clarification required

Page No. clause

The bidder hereby certifies that above mentioned are the only clarifications required on the
technical specification for the subject package.

SIGNATURE: ___________________

NAME : ___________________

DESIGNATION: __________________

COMPANY: _____________________

DATE: __________________________

COMPANY SEAL

Page 321 of 338

 SPECIFICATION NO. PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-III
TECHNICAL SPECIFICATION FOR
MISC. FGD TANKS ANNEXURE-4
REV: 00
Date: April, 2020

SECTION-III
ANNEXURE-4

SCHEDULE OF TECHNICAL
DEVIATION

Page 322 of 338

 DEVIATION SHEET (COST OF WITHDRAWL)

PROJECT:-2 X 250 MW BHILAI FGD

PACKAGE:- MISC. FGD TANKS

TENDER ENQUIRY REFERENCE:-

NAME OF VENDOR:-

REFERENCE OF NATURE OF
PRICE SCHEDULE COST OF
TECHNICAL COST OF
SL VOULME/ PAGE COMPLETE DESCRIPTION OF ON WHICH COST WITHDRAWL OF REASON FOR QUOTING
CLAUSE NO. SPECIFICATION/ WITHDRAWL
NO SECTION NO. DEVIATION OF WITHDRAWL OF DEVIATION DEVIATION
TENDER DOCUMENT OF DEVIATION
DEVIATION IS (POSITIVE/
APPLICABLE NEGATIVE)

TECHNICAL DEVIATIONS

COMMERCIAL DEVIATIONS

PARTICULARS OF BIDDERS/ AUTHORISED REPRESENTATIVE

NAME DESIGNATIONS SIGN & DATE

NOTES:
1. For self manufactured items of bidder, cost of withdrawl of deviation will be applicable on the basic price (i.e. excluding taxes, duties & freight) only.

2. For directly dispatchable items, cost of withdrawl of deviation will be applicable on the basic price including taxes, duties & freight.

3. All the bidders have to list out all their Technical & Commercial Deviations (if any) in detail in the above format.

4. Any deviation not mentioned above and shown separately or found hidden in offer, will not be taken cognizance of.

5. Bidder shall submit duly filled unpriced copy of above format indicating "quoted" in "cost of withdrawl of deviation" column of the schedule above along with their Techno-commercial offer, wherever
applicable.

6. Bidder shall furnish price copy of above format along with price bid.

7. The final decision of acceptance/ rejection of the deviations quoted by the bidder shall be at discretion of the Purchaser.

8. Bidders to note that any deviation (technical/commercial) not listed in above and asked after Part-I opening shall not be considered.

9. For deviations w.r.t. Payment terms, Liquidated damages, Firm prices and submission of E1/ E2 forms before claiming 10% payment, if a bidder chooses not to give any cost of withdrawl of deviation
loading as per Annexure-VIII of GCC will apply. For any other deviation mentioned in un-priced copy of this format submitted with Part-I bid but not mentioned in priced copy of this format submitted with
Priced bid, the cost of withdrawl of deviation shall be taken as NIL.

10. Any deviation mentioned in priced copy of this format, but not mentioned in the un-priced copy, shall not be accepted.

11. All techno-commercial terms and conditions of NIT shall be deemed to have been accepted by the bidder, other than those listed in unpriced copy of this format.

12. Cost of withdrawl is to be given seperately for each deviation. In no event bidder should club cost of withdrawl of more than one deviation else cost of withdrawl of such deviations which have been
clubbed together shall be considered as NIL.

13. In case nature of cost of withdrawl (positive/negative) is not specified it shall be assumed as positive.

14. In case of descrepancy in the nature of impact (positive/ negative), positive will be considered for evaluation and negative for ordering.

Page 323 of 338

Page 1 of 1
 SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-III
TECHNICAL SPECIFICATION FOR ANNEXURE-5
MISC. FGD TANKS
REV. 00
Date: April, 2020

SECTION-III
ANNEXURE-5

LIST OF MAKES OF ITEMS

Page 324 of 338

 2 X 250 MW BHILAI FGD SPECIFICATION NO. PE-TS-468-167-A101
SECTION : III
MISC. FGD TANKS ANNEXURE :5
TECHNICAL SPECIFICATION
REV 00
Date: April, 2020

LIST OF MAKES OF ITEMS

S.N. ITEM NAME MANUFACTURER LOCATION

Page 325 of 338

 SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-III
TECHNICAL SPECIFICATION FOR ANNEXURE-6
MISC. FGD TANKS
REV. 00
Date: April, 2020

SECTION-III
ANNEXURE-6

SPECIAL TOOLS & TACKLES

Page 326 of 338

 SPECIFICATION NO. PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION : III
TECHNICAL SPECIFICATION FOR
ANNEXURE-6
MISC. FGD TANKS
REV 00
Date: April, 2020

Bidder shall supply a set of special tools and tackles required either for erection or
operation or maintenance of the Tanks units. A list of such tools and tackles shall be
submitted along with the offer.

Page 327 of 338

 SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION : III
TECHNICAL SPECIFICATION FOR
ANNEXURE-7
MISC. FGD TANKS
REV 00
Date: April, 2020

SECTION: III
ANNEXURE-7

LIST OF COMMISSIONING SPARES

Page 328 of 338

 SECTION- III, ANNEXURE-7
2 X 250 MW BHILAI FGD- MISC. FGD TANKS PACKAGE
LIST OF COMMISSIONING SPARES (Required for Commissioning of Misc. FGD Tanks
Break up price for COMMISSIONING SPARES
FREIGHT
Total Ex-
Sl. Inclusive Total price FOR
Description Qty. Unit Unit price Works Prices ED CST
no Service SITE
duly packed
Tax
1 CAF Gasket of each size 2 nos.
Nuts, bolts & washers of each size (nos. of 1 lot
2 bolts, nuts & washers as required for each
nozzle) as per approved Drg.
Any other item required for successful 1 lot
commissioning of the tanks including rubber
3
lining & VE Glass Flake lining (to be specified
clearly by bidder)
NOTE -
1. The items indicated in the above list are minimum. Any other spares if required shall be included by bidder in the above list.
2. Bidder shall furnish unit price of commissioning spares in above format alongwith the Bid. Any part even though not mentioned in list furnished but
required at later date shall be supplied free of cost.

3.Bidder to note that the items indicated in the above list shall be provided prior to commissioning of the Misc FGD Tanks. Further, items indicated in the list

Page 329 of 338

shall be supplied over and above the consummables that is supplied along with the Misc FGD Tanks prior to start up.
 TITLE: SPECIFICATION No: PE-TS-468-167-A101
2 X 250 MW BHILAI FGD SECTION-III
TECHNICAL SPECIFICATION FOR REV. 00
MISC. FGD TANKS
Date: April, 2020

SECTION-III
ANNEXURE-8

FGD TANKS SCHEDULE

&
GA DRAWING (TYPICAL) WITH AGITATOR
PLATFORM

Page 330 of 338

 TANK SCHEDULE (Signed and Stamped copy to be sumbmitted with the offer by Bidder)

Sl.no. Description Pit

tank
Belt wash tank
Cake wash tank

Waste water Tank

Filtrate water tank

Process Water tanks
Absorber Area Drain Pit

Auxiliary Absorbent Tank

LIMESTONE AREA DRAIN Pit

Secondary Hydrocyclone feed

Limestone Slurry Storage tank
Gypsum Dewatering Area Drain

Primary Hydrocyclone feed tank

1 Tank Sl No. 1 2 3 4 5 6 7 8 9 10 11 12

Vertical Type – (Center Vertical Type – (Center Vertical Type – (Center Vertical Type – (Center Vertical Type – (Center Marine Propeller – Vertical Type – Vertical Type – Vertical Type –
2 Type of agitator Not applicable Not applicable Not applicable
Mounted) Mounted) Mounted) Mounted) Mounted) Horizontal Type (Side Entry), (Center Mounted) (Center Mounted) (Center Mounted)

3 Medium to be handled Gypsum slurry Gypsum slurry Gypsum slurry Gypsum slurry Limestone slurry Gypsum slurry Process Water Process/Clarified Water Process/Clarified Water Gypsum slurry Gypsum slurry Limestone slurry
Intermittent -Whenever FGD
4 Duty Continuous Continuous Continuous Continuous Continuous Not applicable Not applicable Not applicable Intermittent Intermittent Intermittent
is under maintenance
5 Agitator Location Outdoor Outdoor Outdoor Outdoor Outdoor Outdoor Not applicable Not applicable Not applicable Outdoor Outdoor Outdoor
Intermittent -Whenever FGD
6 Operation Continuous Continuous Continuous Continuous Continuous is under maintenance Not applicable Not applicable Not applicable Intermittent Intermittent Intermittent

7 Pipe Mateial Specification

a) 150 Nb & below SA106 Gr.B (IIR) SA106 Gr.B (IIR) SA106 Gr.B (IIR) SA106 Gr.B (IIR) SA106 Gr.B (IIR) SA106 Gr.B (IIR) SA106 Gr.B (IIR) SA106 Gr.B (IIR) SA106 Gr.B (IIR) SA106 Gr.B (IIR) SA106 Gr.B (IIR) SA106 Gr.B (IIR)
b) Above 150 Nb IS: 3589 (IIR) IS: 3589 (IIR) IS: 3589 (IIR) IS: 3589 (IIR) IS: 3589 (IIR) IS: 3589 (IIR) IS: 3589 (IIR) IS: 3589 (IIR) IS: 3589 (IIR) IS: 3589 (IIR) IS: 3589 (IIR) IS: 3589 (IIR)
8 Tank details
Vertical cylindrical fixed Vertical cylindrical fixed Vertical cylindrical fixed Vertical cylindrical fixed cone Vertical cylindrical fixed cone Vertical cylindrical fixed cone Vertical cylindrical fixed Vertical cylindrical fixed Vertical cylindrical fixed
a) Tank Shape Rectangular Rectangular Rectangular
cone roof cone roof cone roof roof roof roof cone roof cone roof cone roof
Primary Hydrocyclone Secondary Hydrocyclone Absorber Area Drain Gypsum Dewatering Limestone Area Drain
c) Tank name Filtrate water tank Waste water Tank Limestone Slurry Storage tank Auxiliary Absorbent Tank Process water tanks Belt wash tank Cake wash tank
feed tank feed tank Pit Area Drain Pit Pit
d) Tank Quantity (in No.) 1 1 1 1 2 1 2 2 2 2 1 1
Capacity of Tank (in m3)
e) Capacity (Hold Volume) 88.40 43.98 50.30 118.80 604.40 746.13 63.62 17.67 17.67 56.00 56.00 56.00

f) Capacity (Effective) 60.90 28.90 32.67 90.30 515.00 730.40 36.58 7.77 7.77 27.20 27.20 27.20

Dimension (in m)

g) Diameter 5.0 4.0 4.0 5.5 9.0 10.0 4.5 3.0 3.0 - - -

h) Length - - - - - - - - - 4 4 4

Page 331 of 338

i) Breadth - - - - - - - - - 4 4 4

j) Height 5.0 4.0 4.5 5.5 10.0 10.0 4.5 3.0 3.0 4 4 4

2.7 Minimum liquid level in the tank 1.0 1.0 1.0 1.0 1.0 1.0 1.3 1.0 1.0 1.4 1.4 1.4

2.8 Normal liquid level in the tank 4.3 3.3 3.8 4.8 9.3 9.3 3.8 2.3 2.3 3.3 3.3 3.3

2.9 Maximum liquid level in the tank 4.5 3.5 4 5 9.5 9.5 4.0 2.5 2.5 3.5 3.5 3.5

3 (horizontaly mounted in
9 Quantity of Agitator per tank 1 1 1 1 1 Not applicable Not applicable Not applicable 1 1 1
One tank)
3 (horizontaly mounted in
10 Total quantity of agitators (for three units) 1 1 1 1 2 Not applicable Not applicable Not applicable 2 1 1
One tank)
11 (i) Slurry Analysis
a) Slurry to be handled Gypsum slurry Gypsum slurry Gypsum slurry Gypsum slurry Limestone slurry Gypsum slurry Water Water Water Gypsum slurry Gypsum slurry Limestone slurry

b) Maximum solid particle size 200 mesh (74 μ) 6-7 mm 200 mesh (74 μ) 200 mesh (74 μ) 200 mesh (74 μ) 200 mesh (74 μ) - - - 6-7 mm 6-7 mm 6-7 mm

c) Normal solid particle size, d50 325 mesh (44 μ) 6-7 mm 325 mesh (44 μ) 325 mesh (44 μ) 325 mesh (44 μ) 325 mesh (44 μ) - - - 6-7 mm 6-7 mm 6-7 mm
gypsum along with gypsum along with gypsum along with gypsum along with gypsum along with
gypsum along with Limestone gypsum along with Limestone Limestone +
d) Solid to be handled Limestone & other Limestone & other Limestone & other Limestone + impurities - - - Limestone & other Limestone & other
& other impurities & other impurities impurities
impurities impurities impurities impurities impurities
e) Chloride concentration max 25000 ppm max 25000 ppm max 25000 ppm max 25000 ppm max 1000 ppm max 25000 ppm - - - max 25000 ppm max 25000 ppm max 1000 ppm

f) Hardness of particle 5-7 mohs scale 5-7 mohs scale 5-7 mohs scale 5-7 mohs scale 5-7 mohs scale 5-7 mohs scale - - - 5-7 mohs scale 5-7 mohs scale 5-7 mohs scale

g) Slurry concentration, wt% 30 wt% 11% 16.60% 3% 30 wt% 30% - - - 30% 30% 30 wt%

h) Sp. Gravity of slurry 1.213 1.066 1.109 1.02 1.215 1.213 - - - 1.213 1.213 1.215

i) Sp. Gravity of Lime Stone & Gypsum 2.32(avg) 2.32(avg) 2.32(avg) 2.32(avg) 2.32(avg) 2.32(avg) - - - 2.32(avg) 2.32(avg) 2.32(avg)

j) Viscosity of Slurry 10 cP 4 cP 4 cP 3 cP 30 cP 10 cP - - - 10 cP 10 cP 30 cP

k) pH 4 to 8 4 to 8 4 to 8 4 to 8 5 to 8 4 to 8 - - - 4 to 8 4 to 8 5 to 8
 l) SiO2 Content 4 to 6 g/l 4 to 6 g/l 4 to 6 g/l 4 to 6 g/l 4 to 6 g/l 4 to 6 g/l - - - 4 to 6 g/l 4 to 6 g/l 4 to 6 g/l

Normal -62 deg C; Normal -58 deg C; Normal -62 deg C; Normal -62 deg C; Normal -45 deg C; Normal -62 deg C; Normal -58 deg C; Normal -58 deg C; Normal -62 deg C; Normal -62 deg C; Normal -45 deg C;
m) Temperature 36 deg C
Design-70 deg C. Design-70 deg C Design-70 deg C. Design-70 deg C. Design-55 deg C. Design-70 deg C. Design- 70 deg C. Design- 70 deg C. Design-70 deg C. Design-70 deg C. Design-55 deg C.
11(ii) Process water Analysis
a) Calcium as CaCO3 - - - - - - - - -
38 38 38
b) Magnesium as CaCO3 - - - - - - - - -
22 22 22
c) Chlorides as CaCO3 - - - - - - 20 20 20 - - -

d) Sulphate as CaCO3 - - - - - - 17 17 17 - - -

e) Alkalinity as CaCo3 - - - - - - 54 54 54 - - -

f) Total Iron as Fe - - - - - - - - -
0.1 0.1 0.1
g) Total Silica as SiO2 - - - - - - 7 7 7 - - -

h) pH - - - - - - - - -
7.5 7.5 7.5
Turbidity as NTU
i) - - - - - - - - -
2 2 2
12 Inside Lining of tank (Refer Note-3)

4MM thick of best 5MM

3MMthick
thickof best
Vinyl 5MM
3MMthick
thickof best
Vinyl 5MM
3MMthick
thickof best
Vinyl
5MM thick of best quality 4MM thick of best quality
quality bromine butyl Epoxy lining minimum Epoxy lining minimum Epoxy lining minimum quality bromobutyl
Ester based flake quality bromobutyl
Ester based flake quality bromobutyl
Ester based flake
3MM thick Vinyl Ester 3MM thick Vinyl Ester 3MM thick Vinyl Ester based bromobutyl rubber lining with bromine butyl rubber lining
a) Lining specification rubber lining with three coats of 150 three coats of 150 three coats of 150 glass lining
rubber lining with glass lining
rubber lining with glass lining
rubber lining with
based flake glass lining based flake glass lining flake glass lining hardness 55+/-5 (Shore A with hardness 55+/-5 (Shore
hardness 55+/-5 (Shore microns thickness microns thickness microns thickness hardness 55+/-5 hardness 55+/-5 hardness 55+/-5
hardness) A hardness)
A hardness) (Shore A hardness) (Shore A hardness) (Shore A hardness)

13 MATERIAL SPECIFICATION
Shell, Roff, Base and Baffle Plate IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR
a) NA NA NA
Structures IS:2062 E250 GRADE IS:2062 E250 GRADE IS:2062 E250 GRADE IS:2062 E250 GRADE A/BR IS:2062 E250 GRADE A/BR IS:2062 E250 GRADE A/BR IS:2062 E250 GRADE IS:2062 E250 GRADE IS:2062 E250 GRADE IS:2062 E250 GRADE IS:2062 E250 GRADE IS:2062 E250 GRADE
b)
A/BR A/BR A/BR A/BR A/BR A/BR A/BR A/BR A/BR
Stairways & Platforms IS:2062 E250 GRADE IS:2062 E250 GRADE IS:2062 E250 GRADE IS:2062 E250 GRADE A/BR IS:2062 E250 GRADE A/BR IS:2062 E250 GRADE A/BR IS:2062 E250 GRADE IS:2062 E250 GRADE IS:2062 E250 GRADE
c) NA NA NA
A/BR A/BR A/BR A/BR A/BR A/BR
Manhole IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR
d) NA NA NA
e) Nozzle A106 Gr B A106 Gr B A106 Gr B A106 Gr B A106 Gr B A106 Gr B A106 Gr B A106 Gr B A106 Gr B NA NA NA
Nozzle Flanges DN25 - DN600: IS 2062 DN25 - DN600: IS 2062 DN25 - DN600: IS 2062 DN25 - DN600: IS 2062 Gr.B DN25 - DN600: IS 2062 Gr.B DN25 - DN600: IS 2062 Gr.B DN25 - DN600: IS 2062 DN25 - DN600: IS 2062 DN25 - DN600: IS 2062
Gr.B (plate) SO FF ASME Gr.B (plate) SO FF ASME Gr.B (plate) SO FF ASME (plate) SO FF ASME B 16.5 (plate) SO FF ASME B 16.5 (plate) SO FF ASME B 16.5 Gr.B (plate) SO FF ASME Gr.B (plate) SO FF ASME Gr.B (plate) SO FF ASME
B 16.5 Cl.150 B 16.5 Cl.150 B 16.5 Cl.150 Cl.150 Cl.150 Cl.150 B 16.5 Cl.150 B 16.5 Cl.150 B 16.5 Cl.150
f) NA NA NA
DN650 - DN1800: IS DN650 - DN1800: IS 2062 DN650 - DN1800: IS DN650 - DN1800: IS 2062 Gr.B DN650 - DN1800: IS 2062 Gr.B DN650 - DN1800: IS 2062 DN650 - DN1800: IS 2062 DN650 - DN1800: IS 2062 DN650 - DN1800: IS 2062
2062 Gr.B (plate) SO FF Gr.B (plate) SO FF 2062 Gr.B (plate) SO FF (plate) SO FF AWWA-C207 Cl.D (plate) SO FF AWWA-C207 Cl.D Gr.B (plate) SO FF AWWA- Gr.B (plate) SO FF AWWA- Gr.B (plate) SO FF AWWA- Gr.B (plate) SO FF AWWA-
AWWA-C207 Cl.D AWWA-C207 Cl.D AWWA-C207 Cl.D C207 Cl.D C207 Cl.D C207 Cl.D C207 Cl.D

Page 332 of 338

Nozzle Reinforcement IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR
g) NA NA NA
h) Nozzle Necks IS:1239 IS:1239 IS:1239 IS:1239 IS:1239 IS:1239 IS:1239 IS:1239 IS:1239 NA NA NA
Hand Railing IS 1239 (MEDIUM), IS 1239 (MEDIUM), IS 1239 (MEDIUM), IS 1239 (MEDIUM), IS 1239 (MEDIUM), IS 1239 (MEDIUM), IS 1239 (MEDIUM), IS 1239 (MEDIUM), IS 1239 (MEDIUM), IS 1239 (MEDIUM), IS 1239 (MEDIUM), IS 1239 (MEDIUM),
i)
GALVANIZED GALVANIZED GALVANIZED GALVANIZED GALVANIZED GALVANIZED GALVANIZED GALVANIZED GALVANIZED GALVANIZED GALVANIZED GALVANIZED
j) Gaskets BUTYL RUBBER BUTYL RUBBER BUTYL RUBBER BUTYL RUBBER BUTYL RUBBER BUTYL RUBBER BUTYL RUBBER BUTYL RUBBER BUTYL RUBBER IS: 1367 CLASS 4.4 IS: 1367 CLASS 4.4 IS: 1367 CLASS 4.4
Bolts & Nuts SA 193 GR B7 & SA 194 SA 193 GR B7 & SA 194 SA 193 GR B7 & SA 194 SA 193 GR B7 & SA 194 GR 2H SA 193 GR B7 & SA 194 GR 2H SA 193 GR B7 & SA 194 GR 2H
SA 193 GR B7 & SA 194 SA 193 GR B7 & SA 194 SA 193 GR B7 & SA 194 SA 193 GR B7 & SA SA 193 GR B7 & SA SA 193 GR B7 & SA
k)
GR 2H GR 2H GR 2H GR 2H GR 2H GR 2H 194 GR 2H 194 GR 2H 194 GR 2H
Fittings DN25 - DN50: SW A234- DN25 - DN50: SW A234- DN25 - DN50: SW A234- DN25 - DN50: SW A234-WPB DN25 - DN50: SW A234-WPB DN25 - DN50: SW A234-WPB DN25 - DN50: SW A234- DN25 - DN50: SW A234- DN25 - DN50: SW A234-
WPB ASME-B16.11 WPB ASME-B16.11 WPB ASME-B16.11 ASME-B16.11 ASME-B16.11 ASME-B16.11 WPB ASME-B16.11 WPB ASME-B16.11 WPB ASME-B16.11
DN65 - DN500: BW DN65 - DN500: BW A234- DN65 - DN500: BW A234- DN65 - DN500: BW A234-WPB DN65 - DN500: BW A234-WPB DN65 - DN500: BW A234- DN65 - DN500: BW A234- DN65 - DN500: BW A234- DN65 - DN500: BW A234-
A234-WPB ASME-B16.9 WPB ASME-B16.9 WPB ASME-B16.9 ASME-B16.9 ASME-B16.9 WPB ASME-B16.9 WPB ASME-B16.9 WPB ASME-B16.9 WPB ASME-B16.9
l) DN550 & above: IS 2062 DN550 & above: IS 2062 DN550 & above: IS 2062 DN550 & above: IS 2062 Gr.B DN550 & above: IS 2062 Gr.B DN550 & above: IS 2062 Gr.B DN550 & above: IS 2062 DN550 & above: IS 2062 DN550 & above: IS 2062 NA NA NA
Gr.B (plate formed) Gr.B (plate formed) Gr.B (plate formed) (plate formed) ASME-B16.9 (plate formed) ASME-B16.9 (plate formed) ASME-B16.9 Gr.B (plate formed) Gr.B (plate formed) Gr.B (plate formed)
ASME-B16.9 ASME-B16.9 ASME-B16.9 ASME-B16.9 ASME-B16.9 ASME-B16.9

Earthing Lugs IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR IS:2062 E250 GRADE BR
m) NA NA NA
Anchor Bolt IS 1367 PART 3, CLASS IS 1367 PART 3, CLASS IS 1367 PART 3, CLASS IS 1367 PART 3, CLASS 4.4 IS 1367 PART 3, CLASS 4.4 IS 1367 PART 3, CLASS 4.4 IS 1367 PART 3, CLASS 4.4 IS 1367 PART 3, CLASS 4.4 IS 1367 PART 3, CLASS 4.4
n) NA NA NA
4.4 4.4 4.4
Fasteners used in wetted condition ALLOY 926 or BETTER ALLOY 926 or BETTER ALLOY 926 or BETTER ALLOY 926 or BETTER ALLOY 926 or BETTER ALLOY 926 or BETTER ALLOY 926 or BETTER ALLOY 926 or BETTER ALLOY 926 or BETTER ALLOY 926 or BETTER ALLOY 926 or BETTER ALLOY 926 or BETTER
o)
MATERIAL MATERIAL MATERIAL MATERIAL MATERIAL MATERIAL MATERIAL MATERIAL MATERIAL MATERIAL MATERIAL MATERIAL
14 DESIGN DATA
Design Code IS:803 1976 IS:803 1976 IS:803 1976 IS:803 1976 (REAFFIRMED IS:803 1976 (REAFFIRMED IS:803 1976 (REAFFIRMED IS:803 1976 IS:803 1976 IS:803 1976
a) (REAFFIRMED 2013) or (REAFFIRMED 2013) or (REAFFIRMED 2013) or 2013) or latest 2013) or latest 2013) or latest (REAFFIRMED 2013) or (REAFFIRMED 2013) or (REAFFIRMED 2013) or NA NA NA
latest latest latest latest latest latest
b) Roof Slope 5° 5° 5° 5° 5° 5° 5° 5° 5° NA NA NA
c) Design Pressure Hydrostatic Head Hydrostatic Head Hydrostatic Head Hydrostatic Head Hydrostatic Head Hydrostatic Head Hydrostatic Head Hydrostatic Head Hydrostatic Head NA NA NA
d) Operating Pressure Atmospheric Atmospheric Atmospheric Atmospheric Atmospheric Atmospheric Atmospheric Atmospheric Atmospheric NA NA NA
Hydro Testing Water filled head upto Water filled head upto Water filled head upto Water filled head upto Water filled head upto Water filled head upto Water filled head upto Water filled head upto Water filled head upto
e) NA NA NA
overflow nozzle overflow nozzle overflow nozzle overflow nozzle overflow nozzle overflow nozzle overflow nozzle overflow nozzle overflow nozzle
f) Joint Efficiency As per IS As per IS As per IS As per IS As per IS As per IS As per IS As per IS As per IS NA NA NA
g) Radiography As per IS As per IS As per IS As per IS As per IS As per IS As per IS As per IS As per IS NA NA NA
 Corrosion Allowance 1.5 MM for Shell & 1.5 MM for Shell & 1.5 MM for Shell & 1.5 MM for Shell & Bottom 1.5 MM for Shell & Bottom 1.5 MM for Shell & Bottom 1.5 MM for Shell & 1.5 MM for Shell & 1.5 MM for Shell &
h) NA NA NA
Bottom plate Bottom plate Bottom plate plate plate plate Bottom plate Bottom plate Bottom plate
i) Wind Code As per specification As per specification As per specification As per specification As per specification As per specification As per specification As per specification As per specification NA NA NA
j) Seismic Code As per specification As per specification As per specification As per specification As per specification As per specification As per specification As per specification As per specification NA NA NA
k) Roof Plate Thichness 8 8 8 8 8 8 8 8 8 NA NA NA
Shell Plate Thichness As per design code, min. As per design code, min. As per design code, min. As per design code, min. 6 mm As per design code, min. 10 As per design code, min. 10 As per design code, min. As per design code, min. As per design code, min.
6 mm 6 mm 6 mm mm for 1st coarse of shell and mm for 1st coarse of shell 6 mm 6 mm 6 mm
l) NA NA NA
8 mm min. for other coase of and 8 mm min. for other
shell coase of shell
m) Bottom Plate Thichness 8 8 8 8 8 8 8 8 8 NA NA NA
n) Insulation NA NA NA NA NA NA NA NA NA NA NA NA
15 Agitators load
15.1 Static Load (kg) 620 620 620 980 5250 5250 Not applicable Not applicable Not applicable 430 430 430
15.2 Dynamic load Not applicable Not applicable Not applicable
a) Vertical Axial load (kg) 1240 1240 1240 1960 10500 10500 Not applicable Not applicable Not applicable 860 860 860
b) Torsinal moment (Nm) 1500 1500 1500 2630 37200 37200 Not applicable Not applicable Not applicable 1250 1250 1250
c) Bending Moment (Mn) 1330 1330 1330 2330 23240 23240 Not applicable Not applicable Not applicable 710 710 710
16 Nozzles Details
16.1 Sizes & Qty. As per Annexure-9 As per Annexure-9 As per Annexure-9 As per Annexure-9 As per Annexure-9 As per Annexure-9 As per Annexure-9 As per Annexure-9 As per Annexure-9 As per Annexure-9 As per Annexure-9 As per Annexure-9
Notes
The absorber area Drain Pit, Gypsum dewateriag area Drain Pit, Limestone area Drain Pit is exluded from bidder scope of work. However, the supply, erection and commissioning of the VE Glass Flake lining within the pit shall be in bidder's scope. Further the erection of the agitators within the mentioned pits shall be in bidder's scope of work. The agitator shall be free
1
issued by BHEL, however the agitator mounting structure and access platform is in bidder's scope of supply. BHEL shall also arrange the supervision of Erection and commisssioning activity.
2 The loading details of agitator is for estimation purpose only. Bidder shall not claim any additional cost on account of change in agitator loading during detail endineering.
3 For detailed scope of work refer the technical specification.
4 For nozzle details for each type of tank, bidder to refer P&ID's of FGD's. Bidder shall not claim any additional cost on account of change in nozzle dimensions & quantity during detail endineering.
5 Outside nozzle projection is 200mm unless otherwise specified.
6 Nozzle reinforcements shall be as per is:803.
7 Nozzle projections are measured from tank shell inner to the flange face as applicable.
8 All reinforcement pads shall be provided with 6mm telltale hole.
9 Nozzle and flange details shall be as per is:803.
10 All bolt holes shall straddle vertical centerlines on shell and radial on roof.
11 All protrusions, sharp edges and spatter, etc. Shall be removed from the surface and all welds ground smooth without any cavities and imperfection before lining.
12 Hydro test shall be as per is803. Lining shall be carried-out after hydro test.
13 All longitudinal joints shall be staggered.
14 Bottom plate shall uniformly rest on the foundation.
15 The minimum size of weld shall be equal to the thickness of thinner member joint unless specified otherwise.
16 Earthing lug shall be welded to tank body at site to suit site requirement.
17 Painting shall be as per approved painting schedule.

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Page 334 of 338
Page 335 of 338
 PROJETCT: 2 X 250 MW BHILAI FGD
ANNEXURE-    
1.PRIMARY HYDRO CYCLONE FEED TANK
QTY
S.N. NOZZLE MARK SIZE (NB) SERVICE
(NOS)
1 N1 A/B 80 2 INLET TO TANK ON ROOF
2 N2 125 1 INLET TO TANK ON ROOF
3 A1 300 1 AGITATOR NOZZLE ON ROOF
4 MH1/MH2 800 2 MANHOLE ON SHELL AND ROOF
5 N3 250 1 TANK OVERFLOW
6 LT-1/LT-2 80 2 LEVEL TRANSMITTER ON ROOF
7 V1 80 1 VENT ON ROOF
8 N4 125 1 TANK DRAIN TO OVERFLOW
8 N6 125 1 TANK DRAIN
9 N5 A/B 150 2 PUMP SUCTION (OUTLET)

2.FILTERATE WATER TANK

QTY
S.N. NOZZLE MARK SIZE (NB) SERVICE
(NOS)
1 N1 A/B/C/D 150 4 INLET TO TANK ON ROOF
2 N2 A/B 100 2 INLET TO TANK ON ROOF
3 N3 100 1 INLET TO TANK ON ROOF
4 N4 50 1 INLET TO TANK ON ROOF
5 N5 150 1 INLET TO TANK ON ROOF
6 A1 300 1 AGITATOR NOZZLE ON ROOF
7 MH1/MH2 800 2 MANHOLE ON SHELL AND ROOF
8 N6 200 1 TANK OVERFLOW
9 LT-1/LT-2 80 2 LEVEL TRANSMITTER ON ROOF
10 V1 80 1 VENT ON ROOF
11 N7 100 1 TANK DRAIN TO OVERFLOW
12 N8 100 1 TANK DRAIN
13 N9 A/B 150 2 PUMP SUCTION (OUTLET)

3.SECONDARY HYDRO CYCLONE FEED TANK

QTY
S.N. NOZZLE MARK SIZE (NB) SERVICE
(NOS)
1 N1 A/B 200 2 INLET TO TANK ON ROOF
2 N2 100 1 INLET TO TANK ON ROOF
3 A1 300 1 AGITATOR NOZZLE ON ROOF
4 MH1/MH2 800 2 MANHOLE ON SHELL AND ROOF
5 N3 200 1 TANK OVERFLOW
6 LT-1/LT-2 80 2 LEVEL TRANSMITTER ON ROOF
7 N4 100 1 TANK DRAIN TO OVERFLOW
8 N5 100 1 TANK DRAIN
9 N6 A/B 125 2 PUMP SUCTION (OUTLET)
10 V1 80 1 VENT ON ROOF

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4. WASTE WATER TANK
QTY
S.N. NOZZLE MARK SIZE (NB) SERVICE
(NOS)
1 N1 A/B 150 2 INLET TO TANK ON ROOF
2 N2 50 1 INLET TO TANK ON ROOF
3 N3 50 1 INLET TO TANK ON ROOF
4 A1 350 1 AGITATOR NOZZLE ON ROOF
5 MH1/MH2 800 2 MANHOLE ON SHELL AND ROOF
6 N4 200 1 TANK OVERFLOW
7 LT-1/LT-2 80 2 LEVEL TRANSMITTER ON ROOF
8 AT-1/AT-2 80 2 ANALYSER TRANSMITTER ON ROOF
9 V1 80 1 VENT ON ROOF
10 N5 150 1 TANK DRAIN TO OVERFLOW
11 N6 100 1 TANK DRAIN
12 N7 A/B 100 2 PUMP SUCTION (OUTLET)

5. LIMESTONE SLURRY STORAGE TANKS - 2 NOS

QTY
S.N. NOZZLE MARK SIZE (NB) SERVICE
(NOS)
1 N1 A/B 150 2 INLET TO TANK ON ROOF
2 N2 A/B 80 2 INLET TO TANK ON ROOF
3 A1 450 1 AGITATOR NOZZLE ON ROOF
4 MH1/MH2 800 2 MANHOLE ON SHELL AND ROOF
5 N3 200 1 TANK OVERFLOW
6 LT-1/LT-2 80 2 LEVEL TRANSMITTER ON ROOF
7 DT-1/DT-2 80 2 DENSITY TRANSMITTER ON ROOF
8 V1 80 1 VENT ON ROOF
9 N4 200 1 TANK DRAIN TO OVERFLOW
10 N5 100 1 TANK DRAIN
11 N6 A/B 100 2 PUMP SUCTION (OUTLET)

6. AUXILIARY ABSORBENT TANK

QTY
S.N. NOZZLE MARK SIZE (NB) SERVICE
(NOS)
1 N1 A/B 250 2 INLET TO TANK ON ROOF
2 N2 A/B/C/D 200 4 INLET TO TANK ON ROOF
3 A1 / A2 / A3 300 3 AGITATOR NOZZLE ON SHELL
4 MH1/MH2 800 2 MANHOLE ON SHELL AND ROOF
5 N3 250 1 TANK OVERFLOW
6 LT-1 80 1 LEVEL TRANSMITTER ON ROOF
7 V1 80 1 VENT ON ROOF
8 N54 200 1 TANK DRAIN
9 N5 A/B 150 2 PUMP SUCTION (OUTLET)

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7. PROCESS WATER TANKS - 2 NOS
QTY
S.N. NOZZLE MARK SIZE (NB) SERVICE
(NOS)
1 N1 250 1 INLET TO TANK ON ROOF
2 N2 A/B/C/D 50 4 INLET TO TANK ON ROOF
3 N3 A/B/C/D 80 4 INLET TO TANK ON ROOF
4 MH1/MH2 800 2 MANHOLE ON SHELL AND ROOF
5 N4 250 1 TANK OVERFLOW
6 LT-1/LT-2 80 2 LEVEL TRANSMITTER ON ROOF
7 N5 80 1 VENT ON ROOF
8 N6 125 1 TANK DRAIN
9 N7 250 1 PUMP SUCTION (OUTLET)
10 N8 350 1 PUMP SUCTION (OUTLET)

8. BELT FILTER WASH TANKS - 2 NOS

QTY
S.N. NOZZLE MARK SIZE (NB) SERVICE
(NOS)
1 N1 50 1 INLET TO TANK ON ROOF
2 N2 32 1 INLET TO TANK ON ROOF
3 MH1/MH2 800 2 MANHOLE ON SHELL AND ROOF
4 N3 80 1 TANK OVERFLOW
5 LT-1/LT-2 80 2 LEVEL TRANSMITTER ON ROOF
6 V1 50 1 VENT ON ROOF
7 N4 80 1 TANK DRAIN
8 N5 A/B 50 2 PUMP SUCTION (OUTLET)

9. CAKE WASH (CLARIFIED WATER) TANKS - 2 NOS

QTY
S.N. NOZZLE MARK SIZE (NB) SERVICE
(NOS)
1 N1 150 1 INLET TO TANK ON ROOF
2 N2 A/B 50 1 INLET TO TANK ON ROOF
3 MH1/MH2 800 2 MANHOLE ON SHELL AND ROOF
4 N3 100 1 TANK OVERFLOW
5 LT-1/LT-2 80 2 LEVEL TRANSMITTER ON ROOF
6 V1 50 1 VENT ON ROOF
7 N4 80 1 TANK DRAIN
8 N5 A/B 100 2 PUMP SUCTION (OUTLET)

Notes
1: The above shown sizes and number of nozzles are indicative and for estimation purpose only. Final
number and sizes of nozzles shall be furnihsed during detailed engineering.

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