Spec - Fuel Gas Conditioning System

2400 MW CCPP SAMALKOT
Expansion
Technical Specifications
for
Fuel Gas Conditioning System
Document No. REL-SKCCP- NEM-161-P-00001 (Rev.00)
RELIANCE INFRASTRUCTURE LIMITED

EPC Division, D-220, Sector-63, Noida
Technical Specifications for 2400 MW SAMALKOT CCPP
Fuel Gas Conditioning System EXPANSION
DOCUMENT CONTROL SHEET
0 10.12.10 Spec PT AKS KVH CS SSB KS AD NKG KBB SLK AS

HO
Functi Deptt.
D
Mech. Civil Elec. C&I onal Engg. Head / Project
Prep. Pkg. (En
Lead Lead Lead Lead special Mgr Func. Director
By Engr. gg)
ist Head
Rev Descri
Date
No. ption
Reviewed By Approved By
R INFRA
(This document is a property of Reliance Infrastructure Limited. This is not transferable and
shall not be used for any purpose other than for which it is issued.)
Technical Specifications for 2400 MW SAMALKOT
Fuel Gas Conditioning System CCPP EXPANSION
PART-I
SECTION 1 INFORMATION TO BIDDERS (ITB)
SPECIAL CONDITIONS OF CONTRACT (SCC)
COMMERCIAL EVALUATION FORMAT
SECTION 2 GENERAL CONDITIONS OF CONTRACT (GCC)
PART – II TECHNICAL SPECIFICATION
SECTION-A GENERAL TECHNICAL INFORMATION
1. Intent of Specification
2. Project Information
a. Project Information Data
b. Clarified Water Analysis
3. Qualifying Requirements for Bidders
4. System Description & Layout
5. Scope of Supply & Services
6. Terminal Points & Exclusions
7. Liquidated Damages for Shortfall in Performance
8. Bid Evaluation Criteria
9. Tender Drawings
SECTION-B COMMON TECHNICAL SPECIFICATION
1. System Design Basis & Operating Capability
2. Codes & Standards
3. Performance Guarantees
4. System Trial Operations
5. Performance Guarantee Test Procedure
REL-SKCCP- NEM-161-P-00001 (Rev.00) INDEX Page2 of 3

6. Spare Parts
7. Type Test & Type Test Charges
SECTION-C DETAILED TECHNICAL SPECIFICATION
MECHANICAL
ELECTRICAL
INSTRUMENTATION & CONTROL
PART-III
SECTION 1 GENERAL TECHNICAL REQUIREMENT (GTR)
SECTION 2 ERECTION CONDITIONS OF CONTRACT (ECC)
PART-IV DATA TO BE SUBMITTED BY THE BIDDERS
SECTION 1 TECHNICAL DATA SHEETS
SECTION 2 SCHEDULES
REL-SKCCP- NEM-161-P-00001 (Rev.00) INDEX Page3 of 3

PART II
SECTION -A
GENERAL TECHNICAL INFORMATION
REL-SKCCP-NEM-161-P-00001(Rev.00) PART II SECTION A Page 1 of 13

1.00.00 INTENT OF SPECIFICATION
1.01.00 This Bid document is intended to cover the design, engineering, manufacture,
supply, assembly/re-assembly, tests at manufacturer's works, forwarding, (duly
packed for transportation), transportation, delivery to the site, receiving at site,
unloading, handling, storage, and in-plant transportation at site, complete services
of erection, testing at site, successful commissioning, trial run, final painting and
handing over the plant in a flawless operating condition to the Owner of the fuel
gas conditioning system and as required for safe and trouble free smooth &
efficient operation for Samalkot Project. Samalkot CCPP shall be of 03 (three)
modules with each module having 2 Gas Turbine (GT) + 2 Heat Recovery Steam
Generator (HRSG) + 1 Steam Turbine (ST). Heat Balance Diagram (HBD) No.s
REL-SKCCP-NEG-E24-T-00001, REL-SKCCP-NEG-E24-T-00002, REL-SKCCP-
NEG-E24-T-00003 are attached for reference.
1.02.00 Any additional item, material, services which are not specifically mentioned here,
but are required to make the system complete in every respect in accordance with
the technical specification and for safe, trouble free & efficient operation and
guaranteed performance, shall be covered under the scope of this specification.
1.03.00 The equipment and services to be furnished and erected as required in Technical
Specification shall also meet all the requirements as stated in “General Conditions
of Contract” (GCC), “Special conditions of Contract”, and other schedules.
“Erection Conditions of Contract” (ECC) and “Technical Data Sheets” shall be
considered as a part of this technical specification.
1.04.00 It is not the intent to specify completely herein all aspects of design and
construction of equipment. Nevertheless, the equipment shall conform in all
respects to high standards of engineering, design and workmanship and shall be
capable of performing in continuous commercial operation.
1.05.00 Bidder is requested to carefully examine and understand the specifications and
seek clarifications, if required. Such clarifications shall reach Owner at least 15
days before the scheduled date of the opening of the bid documents. The Bidder’s
offer should not carry any sections like clarifications, interpretations and / or
assumptions
1.06.00 Any deviation or variation from the scope, requirement and / or intent of this
specification shall be clearly defined under Deviation Schedules of Bid Proposal
sheets’ irrespective of the fact that such deviations / variations may be standard
practice or a possible interpretation of the specification by the Bidder. Except for
those deviations / variations covered under Deviation Schedules which are
accepted by the Owner before the award of the contract, it will be the responsibility
of the bidder to fully meet the intent and the requirements of the specification within
the quoted price. No other deviation whatsoever from this specification, except for
the declared deviations submitted by the bidder with his proposal under “schedule
of deviations” shall be considered. Bids not complying with this requirement shall
be treated as non responsive and hence liable for rejection. The interpretation of
the Owner in respect of the scope, details and services to be performed by the
bidder, shall be binding, unless specifically clarified otherwise by the Owner in
writing before the award of the Contract.

2.00.0 PROJECT INFORMATION
2.01.0 PROJECT INORMATION DATA
1 Power Evacuation Generating Units shall be connected through

generator transformer to 400 kV buses, which in-turn
shall be connected with grid.
Generating units shall be capable of operating in
parallel with the other generating units of the plant
and the grid.
2 Location Vetlapalam , East Godavari District, Andhra
Pradesh.
Latitude: 17°2’25”N
Longitude: 82°8’10”E
3 Approach Road The proposed site is approachable from Samalkot

town, which is about 1 Km from the existing ADB
Road between Kakinada port and National
Highway No. 5.
4 Railway Approach The Site is 3 Km from the Samalkot Railway

Station on Vishakhapatnam - Vijayawada broad
gauge line..
5 Nearest Air Port The nearest airport is Vishakhapatnam Air port,
155 km & Rajahmundry Air port, 50 km
Nearest Port Kakinada Port
6 Land Availability The land area available for expansion is approx.
130 acres.
7 Fuel Availability Natural Gas with expected composition as per
Clause 2.2
8 Make-up Water The make up water requirement for the project
would be made available by Owner at Plant Raw
water reservoir.
Raw Water Analysis is as per Clause 2.3
9 Meteorological Data
9.1 Finished Ground Level
22-33 M above mean sea level
(FGL) of plant area
9.2 Max. Ambient DBT 470C with 20% RH
9.3 Min. Ambient DBT 140C with 90% RH
9.4 Relative Humidity (Min &
20%-90%
Max)
9.5 Design Ambient DBT/ 29°C/32°C/70%
Design Cooling water

temp/ Design RH
9.6 Annual Average WBT 27.40C
9.7 Basic Wind Velocity 50 m/s
9.8 Design Wind Velocity As per IS:875 Part-3(2003) & IS 15498 (2004)
9.9 Cyclonic effect 1.15 times basic wind speed
9.10 Annual average rain fall 1172 mm
9.11 Max. Rain fall intensity 501 mm per day
9.12 Normal Period of rain fall June – September
9.13 Earthquake Design Zone-III as per IS:1893 -Part-I (2002) & Part –IV
Criteria (2005) (Importance factor-1.75)
9.14 Maximum wind pressure including winds of short
Wind Design Criteria
duration shall be as per IS:875 Latest Issue.
9.15 General environment of Tropical Conditions with frequent cyclonic
site Condition
9.16 The existing geotechnical investigation
undertaken during Phase-I project ,indicates that
the site consists of surficial soil which is laterite in
nature(residual soils) to about 3 to 6m underlain
Soil Investigation and by very severely weathered shale and sandstone.
foundation consideration Before the commencement of civil / structural
design, detailed geo-technical investigation for the
expansion project should be carried out by the
Bidder.
9.17 As per the existing contour survey drawing from
Site Topography and Phase-I the existing ground level gradually slopes
up from south-west towards north-east. Finished
Grading.
grade level of site shall be decided based on site
topography and local HFL.
Note:
a. Design ambient temp for electrical equipments shall be 500C.
b. Bidders are advised to visit project site and collect data on local conditions to
enable them make a fully compliant bid and successful execution of the Contract
2.02.0 SPECIFICATION OF NATURAL GAS
Gas analysis
Property Unit
Composition Range Design
C1 Methane CH4 % Molar 80-100 99.55
C2 Ethane C2H6 % Molar 0-10 0.13
C3 Propane C3H8 % Molar 0-5 0.06

C4 IsoButane C4H10 % Molar 0-3 -

C4 N Butane C4H10 % Molar - -
C5 IsoPentane C5H12 % Molar 0-2 -
C5 N Pentane % Molar - -
C6 Hexanes % Molar - 0.03
C7 Tolune/Heptane % Molar - 0.04
C8 Octane -
C9 Nonane -
C10 Decane -
-
N2 Nitrogen % Molar 1 0.12
CO2 % Molar - 0.07
C2H2 (Acetylene) % Molar 0.1 -
H2 (Hydrogen ) % Molar 0.1 -
O2 - -
Total % 100
8010-
Net heating value (volume based) Kcal/scm 10680 8149
NHV KJ/Kg 49812
Ref temp for LHV Deg C 15.56
Density 0.685
Supply pressure, * Bar (g) 40-60
Supply temperature, Deg C < 55
Compressibility factor 'Z'
Maximum variation in Wobbe index (WI)
Contaminants :
Trace Metals
Pb+Zn ppm (wt) 0.5 (max)
Na+K ppm (wt) 0.3 (max)
Vanadium ppm (wt) 0.5 (max)
Calcium ppm (wt) 2.0 (max)
Magnesium ppm (wt) 2.0 (max)
Sum of heavy metals (Hg +V+Pb+Zn+Ni +Others) ppm (wt) 1.0 (max)
Liquid contents % wt Later
Kg/million
Moisture SCM 112 (max)
H2S (Hydrogen Sulphide) ppm (wt) 5 (max)
Total Sulphur (Including H2S ppm (wt) 10 (max)
* Exact pressure will be re-affirmed by Owner during detail engineering. However, Bidder shall
indicate the minimum pressure required at gas terminal point.

2.03.0 RAW WATER ANALYSIS (Canal water)
Sr.
Description Unit Min Max Avg
No.
1 pH Value 7.1 7.8 7.47
2 Conductivity ppm 130 430 192.3
3 Turbidity ppm 10 702 127
4 Residual Chlorine as Cl2 ppm 0 0 0
5 Iron as Fe ppm 0.1 0.35 0.13
6 Total Dissolved Solids ppm 80 270 125
7 Total Hardness as CaCO3 ppm 48 112 69
8 Calcium ppm 28 72 43
9 Magnesium ppm 20 40 26
10 P-Alkanity ppm 0 0 0
11 Total Alkanity ppm 52 114 77
12 Chloride ppm 19.8 89 31
13 Sulphate ppm 2.0 10 4
14 Dissolved Silica ppm 11.4 17.2 14
2.04.0 Godavari River-Dowlaiswaram Barrage water analysis
Sample collection dt:08.09.10

PARAMETER (Tentative) UNITS VALUE
pH - 7.65
Conductivity µS 146
Turbidity NTU 419
Total Hardness as CaCO3 mg/l 58.0
Calcium Hardness as CaCO3 mg/l 40.0
Magnesium Hardness as CaCO3 mg/l 18.0
Chlorides as Cl- mg/l 20.0
+2
Iron as Fe mg/l 0.21
Silica as SiO2 mg/l 15.3
P-Alkalinity as CaCO3 mg/l Nil
Total Alkalinity as CaCO3 mg/l 58

3.00.00 QUALIFYING REQUIREMENTS FOR BIDDER
Bidders shall have designed, manufactured, supplied, erected, and commissioned

minimum two nos. of Fuel gas conditioning system for similar capacity Combined
Cycle Power Plant (CCPP). Such systems shall be in successful operation for a
minimum period of two (2) years on the date set for opening of bid.
As an evidence of the qualification requirement, the bidder shall submit in his bid
the relevant information such as following.
a) Name of the project/ Purchaser

b) Order Value and Date of commissioning
c) Major supply of equipment involved in the system along with its capacity.
d) Documentary evidence that Scope included “Design, supply, erection and

commissioning” of Fuel gas conditioning system
e) Completion & Performance Certificate from purchaser stating that plant is in

operation for atleast two (2) years.
f) Period for which it is in successful operation.
4.00.00 SYSTEM DESCRIPTION
R-Infra intends to construct a Combined Cycle Power plant of total 2200MW at

Samalkot, Andhra Pradesh. The scheme envisaged Multi Shaft unit where one (1)
block consists of 2 Gas Turbines, 2 Heat Recovery Steam Generator, 1 Steam
Turbine. Selection of components of fuel gas conditioning system shall be based
on the maximum flow and pressure of fuel gas corresponding to maximum
capability of Gas Turbine at specified site ambient conditions.
Bidder shall design, manufacture, and supply the fuel gas conditioning system as
per scope specified under clause 5.00.00 for three (03) modules with all associated
auxiliaries. Erection, Commissioning and testing at site shall be in the Bidder
scope. All supporting structures as required for the work shall be in bidder scope.
Fuel gas conditioning system shall be designed for the gas composition specified
in clause 2.02.0 above.
The Fuel gas parameters at plant boundary are considered as below
Pressure* 60 Bar(g)
Temperature* 22° C
* These parameters shall be confirmed after finalization of contract with the Gas supply
pipe line vendor.

The parameters required at the Accessory module gas compartment inlet are as
below
Pressure 28.3 to 34.5 Bar(g)

Temperature 10° C super heat or 70 which ever is higher
to 185° C
Gas Quality As per GE document “GEI41040k”
5.00.00 SCOPE OF SUPPLY AND SERVICES
Scope of work in respect of equipment and systems shall be in accordance with

the provisions of various sections of the specifications and to deliver a fully
operational fuel gas conditioning system which meets the intent of the
specification.
The work shall be consistent with modern engineering and construction practices
and shall be in compliance with all applicable code, standards, guidelines and
safety requirements in force on the date of award of contract.
5.01.00 FUEL GAS CONDITIONING SYSTEM
5.01.01 Gas Conditioning system consisting of:
i) Emergency Stop Valve at the inlet to the gas system (one common for station)
ii) Knock Out Drum (1x100% for station)
iii) Gas flow metering devices- (1x100% for station)
iv) Filter separator (3x50% for station)
iv) Fuel Gas Startup Heater (2x50% for station)
v) Gas Pressure Reducing Station (3x50% for station)
vi) Absolute Filter units (2x100% for each GT-Total 12)
vi) Fuel Gas Efficiency Heater with temperature control valve on heating line and cold
leg bypass line to hot and cold mixing point (1x100% for each gas turbine-Total 6
Nos.)
vii) Scrubber (1x100 % for each Gas Turbine-Total 6)
viii) Gas condensate collection tank and disposal system complete with all piping and
fittings (one at Gas regulating Station area and one per GT for filters and scrubbers
- Total 7 )
ix) Nitrogen purging system for piping and equipments along with nitrogen cylinder.
x) All Electrical and C&I items for fuel gas conditioning plant.
xi) Complete piping, valves, safety valves, filters, and specialties in Fuel gas handling
system as specified and as required for safe and reliable operation. Necessary welding

neck counter flanges, gaskets & nuts and bolts at terminal connection to be provided.
The piping down stream of fine filter and by pass to efficiency heater shall be of
Stainless steal.
xii) Pipeline for LMS 100
xiii) Installation of Gas Chromatograph ( It will be supplied loose by owner)
xiv) Installation of Wobbe index meter ( It will be supplied loose by owner)
5.01.02 Heat insulation and cladding

5.01.03 Lifting lugs, eyebolts, access platform, etc.
5.01.04 Complete set of foundations bolts, nuts, shimming plates for horizontal; leveling,
connection bolt for protective earth grounding, etc. and embedded parts if
necessary.
5.01.05 Special Tools and tackles.
5.01.06 Surface preparation and painting at shop. Loose paint for touch up at site.
5.01.07 Erection, Commissioning, Performance guarantee test, reliability test.
5.01.08 Mandatory Spares and unit assemblies as applicable.
5.01.09 Start-up and commissioning spares.
5.01.10 Recommended spares for three (3) years normal operation and maintenance of
the plant at the option of the Owner.
5.01.11 Any other equipment/ system not specifically mentioned in the specification.
5.01.12 Control and Instrumentation
A. Scope of supply
The Bidder shall be responsible for providing all materials, equipment, field
instruments/ devices as per the process requirement and services specified or
otherwise which are required to fulfil the intent and ensuring operability,
maintainability and reliability of total work covered under the specification.
Complete Instrumentation & Control System required for safe and efficient
operation of the Fuel Gas Supply System shall be in the scope of the Bidder. The
scope of supply for C&I systems shall comprise the following as a minimum:
1. All required Measuring Instruments alongwith requisite process connection &

piping, viz. Pressure & Differential Pressure Transmitters/ Switches,
Temperature Indicators/ Elements, Mass Flow Meter, Level Switches etc.
required for safe & efficient operation of the system.
2. A complete Programmable Logic Controller (PLC) system, for control and

monitoring of complete Fuel Gas System, supplied by the Bidder.
The PLC shall be complete with the following as a minimum:

Redundant processors in hot standby configuration

All required Input/ output (I/O) modules, including Remote I/O modules/
panels
One PC based Operator cum Engineering Workstation including 21” TFT
monitor, mouse, Keyboard
All required software
Control desk/ furniture
OPC connectivity to Owner procured BOP PLC network system
All required cabinets
3. One complete adequately sized UPS system with 2x100% chargers/ inverters,
1x100% VRLA batteries for 1 hour backup, 1x100% solid state based standby
AC source, 2 x 100% ACDBs, interconnect cabling etc.
4. Control valves on the heating line for the Efficiency heaters, complete with
microprocessor based positioner, actuator and other accessories as specified.
5. All required Instrumentation & Control Cables, including fibre-optic cables with
sub-trays for signal transmission from field/ MCC-Switchgear/ other system
panels to PLC system/ Remote I/O cabinet, along with necessary laying,
termination, accessories and erection hardware viz. conduits, lugs, glands,
ferrules etc.
B. Scope of services
The C&I system offered by the Bidder shall be complete in all aspects and any item
or accessories not specifically mentioned in this specification, but essential for the
proper operation and maintenance of the system, meeting all the requirements and
intent of the specification, shall be supplied within the lump sum quoted price. The
following services shall be included under Bidder’s scope
1 Erection and commissioning of all C&I Instruments and Control equipments

supplied under this package including Cable laying, termination, continuity
check etc.. Bidder’s scope shall also include erection & commissioning
(including the cabling of the same) of on-line Gas Chromatograph, procured by
Owner under a separate package. Bidder shall provide an environment
controlled enclosure for mounting the same.
2 Complete Documentation including O&M manuals.
3 Training of Owner’s personnel for PLC system and UPS
6.00.00 TERMINAL POINTS & EXCLUSIONS

6.01.00 TERMINAL POINTS
• Fuel gas supply at plant boundry

• Hot water inlet and condensate outlet nozzles at Fuel Gas Efficiency Heater
• Inlet to Gas Turbine Accessory module gas compartment for six ,9FA Gas
Turbines and at inlet to two, LMS 100 Gas Turbines
• DM water make up at inlet nozzle to Water bath heater
• Condensate pump discharge line at down stream of discharge valve

• Power Supply:
Owner shall provide three nos. 415 V three phase 50 Hz. Feeders at one point
from the switchgear/ Power Distribution Board. Further cabling including
distribution to Bidder’s loads shall be in Bidder’s scope.
• Hardwired Signal exchange with other systems viz. GTG control system, Fire
Fighting system, Chromatograph etc.
Terminals of other systems’ panels. Cabling from other systems’ panels to
Bidder’s system shall be in Bidder’s scope.
• OPC connectivity to BOP PLC network system
Ports of Switches of Bidder’s PLC system. Onward cabling to Owner’s BOP
PLC network system is excluded from Bidder’s scope
6.02.00 EXCLUSIONS
Following items of work are excluded from the scope of the present package:
- Civil Works
- Construction water and power beyond the terminal point. These will be supplied
at one point for further distribution by the bidder as required.
- All utilities (service air, instrument air, de-mineralized water etc.) beyond terminal
points.
- BOP PLC network system and cabling upto the same

However, all required hardware/ software required at Bidder’s PLC end to
enable bi-directional OPC connectivity to Owner’s BOP PLC network system
shall be in Bidder’s scope.
- On-line Gas Chromatograph and Wobbe index meter

However, erection & commissioning of the same shall be in Bidder’s scope.
7.00.00 LIQUIDATED DAMAGES APPLICABLE FOR SHORTFALL IN PERFORMANCE
7.01.00 The Bidder shall guarantee that complete system specified in scope and detailed
specification, including all the Equipments offered individually shall meet the
ratings and performance requirement stipulated in this specification.
7.02.00 The performance shall meet the requirements stipulated in the Section B.
7.03.00 The noise from the condensing plant and ancillary equipment shall be guaranteed to
meet the Ministry of Environment and Forest (MoEF) stipulations set out in the
clearance letter i.e. 85 dB(A).
7.04.00 The design life for the condensing plant shall be guaranteed to be minimum of 25
years.

7.05.00 In case system fails to meet the contractual requirements as determined from the
PG test evaluation, RInfra reserves the right to reject / accept the above mentioned
equipments after levying the liquidated damages (LD). The liquidated damages
shall be pro-rated for the fractional parts of the deficiencies. The amount of
Liquidated damages shall be as per Part I, General Conditions of Contract.
7.06.00 Should the results of the performance test show that the equipments have
failed to meet the guarantees with respect to power consumption, the Contractor
shall carry out the modification, at his own cost, if considered necessary to meet
the guaranteed values. In such a case, the performance & guarantee test shall be
repeated by the Contractor within one (1) month from the date the equipment is
ready for retest. If the specified guarantees are not established within 90 days of
notification by the Owner, the owner may at his discretion reject the equipment
and recover the payments already made or accept the equipment after levying
Liquidated Damages as specified above.
7.07.00 For the following parameters Liquidated damages shall be applicable:
Gas quality Gas Turbine Accessory module gas compartment.
Pressure at Gas Turbine Accessory module gas compartment.
Temperature at Gas Turbine Accessory module gas compartment
8.00.00 BID EVALUATION CRITERIA CONSIDERING GUARANTEED PARAMETERS
8.01.00 Functional Guarantees
Following data’s shall be demonstrated by the bidder
Gas quality Gas Turbine Accessory module gas compartment.

Pressure at Gas Turbine Accessory module gas compartment.
Temperature at Gas Turbine Accessory module gas compartment
9.00.00 Tender Drawings
SL.NO DRAWING NO. TITLE
1. REL-SKCCP-NEM-161-P-00001 Flow Sheet- Fuel Gas conditioning System
2 REL-SKCCP-NEM-E15-B-00001 General plant layout
3 REL-SKCCP-NEG-E24-T-00001 Heat balance diagram: Base Load Operation

Evaporative Cooler OFF
4 REL-SKCCP-NEG-E24-T-00002 Heat balance diagram: Base Load Operation
Evaporative Cooler ON
5. REL-SKCCP-NEG-E24-T-00003 Heat balance diagram: 80% Net Equipment
Load Evaporative Cooler OFF
6. GEI41040k FuelGasSpec from GT supplier
7. ----- White paper on fuel gas heating

8. ----- Fuel Gas efficiency heater specification from

GE (Later)
9. 207D3883 schematic diagram Fuel gas system by GE
10. 143E2781 GE’s accessory module
11. 146E4069 Fuel gas Wobbe meter- GE drawing
12. 146E3454 Fuel gas chromatograph- GE drawing

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GEI 41040k
Revised, January 2009
GE Energy
Specification for Fuel Gases for Combustion in Heavy-Duty Gas

Turbines
These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to the GE Company.
© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.
GEI 41040k Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines
TABLE OF CONTENTS
I. INTRODUCTION ...................................................................................................................................... 4
II. FUEL GAS CLASSIFICATION............................................................................................................... 9
A. Natural Gas, Liquefied Natural Gas (LNG) and Liquefied Petroleum Gas (LPG)................................ 9
B. Gasification Fuels ................................................................................................................................ 10
C. Process Gases....................................................................................................................................... 11
III. FUEL PROPERTIES............................................................................................................................... 11
A. Heating Values..................................................................................................................................... 11
B. Modified Wobbe Index (MWI)............................................................................................................ 12
C. Superheat Requirement........................................................................................................................ 13
D. Hydrocarbon Dew Point ...................................................................................................................... 15
E. Moisture Dew Point ............................................................................................................................. 15
F. Flammability Ratio .............................................................................................................................. 16
G. Gas Constituent Limits ........................................................................................................................ 16
H. Gas Fuel Supply Pressure .................................................................................................................... 16
IV. CONTAMINANTS................................................................................................................................... 17
A. Particulates........................................................................................................................................... 17
B. Liquids ................................................................................................................................................. 17
C. Sulfur ................................................................................................................................................... 17
D. Trace Metals ........................................................................................................................................ 19
V. SOURCES OF CONTAMINANTS ........................................................................................................ 19
A. Particulates........................................................................................................................................... 19
B. Liquids ................................................................................................................................................. 19
C. Sulfur ................................................................................................................................................... 19
D. Trace Metals ........................................................................................................................................ 19
E. Air ........................................................................................................................................................ 20
F. Steam ................................................................................................................................................... 20
G. Water.................................................................................................................................................... 21
H. Fuel ...................................................................................................................................................... 21
LIST OF FIGURES
Figure 1. Hydrocarbon and Moisture Superheat Requirements ........................................................................... 15

Figure 2. Moisture Dew Point as a Function of Concentration and Gas Pressure for a
Typical Natural Gas Fuel...................................................................................................................... 16
LIST OF TABLES
Table 1a. Fuel Gas Classification........................................................................................................................... 5

Table 1b. Representative GE Fuels Experience ..................................................................................................... 5
Table 2a. Fuel Gas Specification (see Note 1 and 2) ............................................................................................. 6
Table 2b. Allowable Gas Fuel Contaminant Levels............................................................................................... 7
Table 3. Test Methods for Gaseous Fuels............................................................................................................ 9
2 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines GEI 41040k
APPENDIX
APPENDIX 1. DEFINITIONS.......................................................................................................................... 22
APPENDIX 2. PARTICLE SIZE LIMITATIONS ......................................................................................... 23
APPENDIX 3. EQUIVALENT CONTAMINANT RELATIONSHIPS

(ALL MACHINES EXCEPT FB, H-CLASS) ................................................................................................. 24
APPENDIX 4. MINIMUM GAS TEMPERATURE REQUIREMENT CALCULATIONS ...................... 25
APPENDIX 5. REQUESTED FUEL ANALYSIS DATA FOR GE EVALUATION .................................. 26
APPENDIX 6. RELATED SPECIFICATION DOCUMENTS ..................................................................... 27
© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 3

I. INTRODUCTION
General Electric heavy-duty gas turbines have the ability to burn a wide variety of gaseous fuels as
classified in Table 1a. The properties of these gases can vary significantly due to the relative
concentrations of the reactant and inert constituents. Because of GE’s long history and large installed
base, GE’s experience with various fuel gases is broad and extensive. Table 1b summarizes this
experience by frame size (B/E-class or F-class) and combustion system type (Dry Low NOx or
Diffusion).
The fundamental combustor operability criteria must be satisfied regardless of the fuel that is being
utilized by the turbine:
● Robustness to auto-ignition
● Robustness to flashback
● Emissions compliance (NOx, CO, UHC, Smoke)
● Acceptable combustion dynamic pressures
● Robustness to lean blowout
The composition, reactivity, heating value, and contaminant levels of the fuel lead to selection of
combustor design features to optimize these operability requirements. Prior to the mid-1970’s, diffusion
combustors were the standard choice for gas turbines because of their simplicity and relative fuel
flexibility. As emissions regulations became more stringent, water or steam injection systems were added
to these diffusion combustors to reduce flame temperatures and lower NOx emissions. Further tightening
of emissions requirements coupled with the desire for water-free low-emissions solutions led to the
introduction of lean-premixed combustors in the late 1980’s such as GE’s Dry Low NOx (DLN)
combustors. These lean-premixed combustion technologies were typically optimized for low-emissions
operation on natural gas fuels and had characteristically lower fuel-flexibility than diffusion combustors.
As technology advances to achieve higher efficiency and lower emissions, some models and combustion
systems impose restrictions on the physical and chemical properties of the fuel gases that can be utilized
in order to protect the gas turbine and to burn these fuels in an efficient and robust manner. These
restrictions are continually being updated as technology improves. Tables 2a and 2b provide a screen for
fuels that are acceptable across most frame sizes and combustor types. Table 2a specifies the allowable
fuel properties and constituents, and Table 2b lists the limitations on contaminants.
Fuels that fall outside of these limits are frequently acceptable for many specific applications; for
example, a high hydrogen fuel can be used with diffusion flame combustors in most cases. The
relationship between technologies can also be seen in the fuels experience shown in Table 1b. Additional
approaches such as fuel heating and transfer fuels can extend the range of usable fuels. Because GE is
continuously improving its products and increasing fuel flexibility, strict limits are not specified here by
combustion system. Consultation with GE will allow a determination of the options available for specific
fuel choices. Appendix 5 describes the information GE needs to evaluate potential fuel gases.
Table 3 identifies the acceptable test methods to be used for determining fuel gas properties shown in
Tables 2a and 2b and discussed in the balance of this fuel specification.
The balance of this fuel specification provides more detailed description of the factors used in evaluating
potential fuels as well as descriptions of the pretreatment that is sometimes required to ensure robust gas
turbine operation.

Table 1a. Fuel Gas Classification
FUEL LHV MAJOR COMPONENTS

Btu/scf
Natural Gas and Liquefied Natural Gas 800-1200 Methane
Liquefied Petroleum Gas 2300-3200 Propane, Butane

Gasification Gases
- Air Blown 100-150 Carbon Monoxide, Hydrogen, Nitrogen, Water Vapor
- Oxygen Blown 200-400 Carbon Monoxide, Hydrogen, Water Vapor
Process Gases 300-3000 Methane, Hydrogen, Carbon Monoxide, Ethane,
Ethene, Propane, Propene, Carbon Dioxide, Nitrogen
Table 1b. Representative GE Fuels Experience*

B/E-Class Experience F-Class Experience
Diffusion DLN Diffusion DLN
Constituent Limit, mole % Min Max Min Max Min Max Min Max Notes
Methane 0 100 74 100 0 100 85 100 % of reactant species
Ethane 0 58 0 26 0 15 0 15 % of reactant species
Propane 0 90 0 16 0 15 0 15 % of reactant species
Butane + higher paraffins (C4+) 0 100 0 7 0 5 0 5 % of reactant species
Hydrogen 0 95 0 18 0 47 0 3 % of reactant species
Carbon Monoxide 0 76 0 15 0 60 0 5 % of reactant species
Total Inerts (N2 + CO2 + Ar) 0 68 0 42 0 24 0 28 % of total (reactants + inerts)
*This experience is given as reference only and in no way guarantees robust operation on all combinations of fuels
within this experience. For Fuel Gas Specification, see Table 2a.

Table 2a. Fuel Gas Specification (see Note 1 and 2)
FUEL PROPERTIES MAX MIN NOTES

Gas Fuel Pressure Varies with Varies with See Note 3
unit and unit and
combustor type combustor type
Gas Fuel Temperature, °F see note 4 Varies With gas see Note 4
pressure
Lower Heating Value, Btu/scf 1160 775 See Note 5
Modified Wobbe Index (MWI) See Note 6
- Absolute Limits 54 40 See Note 7
- Range Within Limits +5% -5% See Note 8
Flammability Ratio See Note 9 2.2:1 Rich: Lean Fuel/Air
Ratio volume basis.
See Note 10
Constituent Limits, mole %
Methane 100 85 % of reactant species
Ethane 15 0 % of reactant species
Propane 15 0 % of reactant species
Butane + higher paraffins (C4+) 5 0 % of reactant species
Hydrogen Trace 0 % of reactant species
Carbon Monoxide Trace 0 % of reactant species
Oxygen Trace 0 % of reactant species
Total Inerts (N2+CO2+Ar) 15 0 % of total (reactants +
inerts).
Aromatics (Benzene, Toluene Report 0 See Note 11
etc.)
Sulfur Report 0 See Note 12

Table 2b. Allowable Gas Fuel Contaminant Levels

Turbine Inlet Limit, Xe Fuel Equivalent Limit, XFe (see Note 13)
ppbw ppmw
Machine Model Machine Model
MS3000 6C, FB, H- MS3000,MS5000 6C, FB, H-Class
MS5000 CLASS B, E and F- Class
B, E and F-
Turbine inlet flow/fuel Turbine inlet flow/fuel
Class
flow (B, E, F) (6C, FB, H)
Trace Metals 50 12 4 50 12 4
Lead (Pb) 20 20 1.00 0.240 0.080 1.00 0.240 0.080
Vanadium (V) 10 10 0.5 0.120 0.040 0.5 0.120 0.040
Calcium (Ca) 40 40 2.0 0.480 0.160 2.0 0.480 0.160
Magnesium (Mg) 40 40 2.0 0.480 0.160 2.0 0.480 0.160
Sodium + Potassium (see Note 14)

(Na/K)=28 20 See GEK 1.00 0.24 0.080 See GEK 107230 (1)
107230 (1)
(Na/K)=3 10 0.50 0.12 0.040
(Na/K)=<1 6 0.30 0.072 0.024
Particulates (see Note 15)
Total 600 600 30 7.2 2.4 30 7.2 2.4
Above 10 6 6 0.3 0.072 0.024 0.3 0.072 0.024
microns
Liquids: No Liquids allowed, gas must be superheated. (see Note 16)
Fuel Property and Contaminant Notes:
1. All fuel properties must meet the requirements from ignition to base load unless otherwise stated.
2. Values and limits apply at the inlet of the gas fuel control module, typically the purchaser’s
connection, FG1.
3. Minimum and maximum gas fuel supply pressure requirements are furnished by GE as part of the
unit proposal.
4. The minimum fuel gas temperature must meet the required superheat as described in section III–C.
Separate requirements are included for hydrocarbon and moisture superheat. The maximum
allowable fuel temperature is defined in GER 4189 (2).
5. Heating value ranges shown are provided as guidelines. Specific fuel analysis must be furnished to
GE for thorough analysis. (See section III–A).
6. See section III–B for definition of Modified Wobbe Index (MWI).
7. The upper and lower limits for MWI shown are what can be accommodated within the standard dry
low NOx fuel system designs. Fuels outside of this range can often be utilized and may need
additional design and development effort. Performance fuel heating may be restricted on fuel with
high inert content to stay above the minimum MWI limit.
8. Variations of MWI greater than + 5% or –5% may be acceptable for some applications, (i.e., on units
that incorporate gas fuel heating). GE must analyze and approve all conditions where the 5%
variation is to be exceeded. See also Section III-B for applications where the MWI varies between
the +-5% limits.
9. There is no defined maximum flammability ratio limit. Fuels with flammability ratio significantly
larger than those of natural gas may require a start–up fuel. Further discussion and documentation on
measurement and calculation of flammability limits are covered in references 5 and 6, Bureau of
Mines Bulletins.
10. Candidate fuels, which do not meet these limits, should be referred to GE for further review. All
fuels will be reviewed by GE on a case-by-case basis. (see section III–G).
11. When fuel heating for thermal efficiency improvements is utilized (e.g. Tgas > 300°F) there is a
possibility of gum formation if excess aromatics are present. Contact GE for further information.
12. The quantity of sulfur in gas fuels is not limited by this specification. Experience has shown that fuel
sulfur levels up to 1% by volume do not significantly affect oxidation/corrosion rates. Hot corrosion
of hot gas path parts is controlled by the specified trace metal limits. Sulfur levels shall be
considered when addressing HRSG Corrosion, Selective Catalytic Reduction (SCR) Deposition,
Exhaust Emissions, System Material Requirements, Elemental Sulfur Deposition and Iron Sulfide.
(refer to Section IV–C).
13. The contamination limits identified represent the total allowable limit at the inlet to the turbine
section. These limits will be reduced if comparable contaminants are present in the compressor inlet
air and combustion steam/water injection. Consult with GE for limits for specific applications.
14. Sodium and potassium, from salt water, are the only corrosive trace metal contaminants normally
found in natural gases. Na/K =28 is nominal sea salt ratio. Other trace metal contaminants may be
found in Gasification and Process Gases. GE will review these on a case-by-case basis.
15. The fuel gas delivery system shall be designed to prevent the generation or the admittance of solid
particulate to the gas turbine gas fuel system. This shall include but not be limited to particulate
filtration and non-corrosive (i.e. stainless steel) piping from the particulate filtration to the inlet of
the gas turbine equipment. Fuel gas piping systems shall be properly cleaned/flushed and maintained
prior to gas turbine operation. (See section IV–A).
16. The fuel gas supply shall be 100% free of liquids. Admission of liquids can result in combustion
and/or hot gas path component damage. (See section III–C) GE will require an input signal from the
conditioning system liquid level indication closest to the GE Speed Ratio Valve or Gas Control
Valve. This liquid level indication will be brought into the turbine controller and used as a signal to
stop Gas Turbine operation when the liquid level reaches a fault level. It is highly recommended that
this device have redundancy. The supplier of the gas conditioning system should provide this signal.

Table 3. Test Methods for Gaseous Fuels
PROPERTY METHOD
Gas Sampling Procedure GPA 2166(3)
Gas Composition to C6 + (gas ASTM D 1945
chromatography)
Extended Gas Composition to GPA 2286(4)
C14
Heating Value ASTM D 3588
Specific Gravity ASTM D 3588
Compressibility Factor ASTM D 3588
Dew Point (see Test Method ASTM D 1142
note 1)
Sulfur (see Test method note 2) ASTM D 3246
Test Method Notes:
1. Hydrocarbon and water dew points shall be determined by direct dew point measurement (Chilled
Mirror Device). If dew point cannot be measured, an extended gas analysis, which identifies
hydrocarbon components from C1 through C14, shall be performed. This analysis must provide an
accuracy of greater than 10 ppmv. A standard gas analysis to C6+ is normally not acceptable for dew
point calculation unless it is known that heavier hydrocarbons are not present, as is most often the
case with liquefied natural gases.
2. This test method will not detect the presence of condensable sulfur vapor. Specialized filtration
equipment is required to measure sulfur at concentrations present in vapor form. Contact GE for
more information.
II. FUEL GAS CLASSIFICATION

A. Natural Gas, Liquefied Natural Gas (LNG) and Liquefied Petroleum Gas (LPG)
Natural gases are predominantly methane with much smaller quantities of the slightly heavier
hydrocarbons such as ethane, propane and butane. Liquefied petroleum gas is propane and/or butane
with traces of heavier hydrocarbons.
1. Natural Gas
Natural gases normally fall within the calorific heating value range of 800 to 1200 Btu per
standard cubic foot. Actual calorific heating values are dependent on the percentages of
hydrocarbons and inert gases contained in the gas. Natural gases are found in and extracted from
underground reservoirs. These “raw gases” may contain varying degrees of nitrogen, carbon
dioxide, hydrogen sulfide, and contaminants such as salt water, sand and dirt. Processing by the
gas supplier normally reduces and/or removes these constituents and contaminants prior to
distribution. A gas analysis must be performed to ensure that the fuel supply to the gas turbine
meets the requirements of this specification.

2. Liquefied Natural Gas (LNG)
Liquefied natural gas is produced by drying, compressing, cooling and expanding natural gas to
approximately -260° F at 14.7 psia. The product is transported as a liquid and delivered as a gas
after pressurizing and heating to ambient temperature. The composition is free of inerts and
moisture and can be treated as a high quality natural gas. LNG can pick up moisture that is
present in the pipeline but it is not a source of the moisture.
The hydrocarbon dew point is typically less than -10° F at 500 psia but, depending on the
processing steps and tank size, the dew point may increase if the boil–off is continuously
extracted between deliveries. Cooling and recompression of the boil–off will avoid this potential
problem. The expected range in component concentrations should be obtained from the gas
supplier to determine the potential change in dew point.
3. Liquefied Petroleum Gases
The heating values of Liquefied Petroleum Gases (LPGs) normally fall between 2300 and 3200
Btu/ scf (LHV). Based on their high commercial value, these fuels are normally utilized as a
back-up fuel to the primary gas fuel for gas turbines. Since LPGs are normally stored in a liquid
state, it is critical that the vaporization process and gas supply system maintains the fuel at a
temperature above the minimum required superheat value. Fuel heating and heat tracing are
required to meet these requirements.
B. Gasification Fuels
Gasification fuels are produced by either an oxygen blown or air blown gasification process and are
formed using coal, petroleum coke or heavy liquids as a feedstock. In general, the heating values of
gasification fuel are substantially lower than other fuel gases. The reduced heating value of
gasification fuels result in the effective areas of the fuel nozzles being larger than those utilized for
natural gas fuels.
1. Oxygen Blown Gasification
The heating values of gases produced by oxygen blown gasification fall in the range of 200 to
400 Btu/scf. These fuels normally have a hydrogen (H2) content above 30% by volume and a
H2/CO mole ratio between 0.5 and 0.8. Oxygen blown gasification fuels are often mixed with
steam for thermal NOx control, cycle efficiency improvement and/or power augmentation. When
utilized, the steam is injected into the combustor by an independent passage. Due to the high
hydrogen content of these fuels, oxygen blown gasification fuels are normally not suitable for
Dry Low NOx (DLN) applications (see Table 2a). The high flame speeds resulting from high
hydrogen fuels can result in flashback or primary zone re-ignition on DLN pre-mixed
combustion systems. Utilization of these fuels requires evaluation by GE.
2. Air Blown Gasification
Gases produced by air blown gasification normally have heating values between 100 and 150
Btu/ scf. The H2 content of these fuels can range from 8% to 20% by volume and they can have a
H2 /CO mole ratio 0.3 to 3:1. The use and treatment of these fuels is similar to that identified for
oxygen blown gasification.
Gasification fuels provide a significant fraction of the total turbine mass flow rate. With oxygen
blown fuels the diluents addition (typically nitrogen) also assists with NOx control. Careful

integration of the gas turbine with the gasification plant is required to assure an operable system.
Due to the low volumetric heating value of both oxygen and air blown gases, a special fuel
system and fuel nozzles are required.
C. Process Gases
Many chemical processes generate surplus gases that may be utilized as fuel for gas turbines. (e.g. tail
or refinery gases). These gases often consist of methane, hydrogen, carbon monoxide, ethane, ethene,
propane, propene, and carbon dioxide that are normally byproducts of petrochemical processes. The
hydrogen and carbon monoxide contents of these fuels result in a high rich-to-lean flammability limit.
These types of fuels often require inerting and purging of the gas turbine gas fuel system upon unit
shutdown or a transfer to a more conventional fuel. When process gas fuels have extreme
flammability limits such that the fuel will auto ignite at turbine exhaust conditions, a more
“conventional” start-up fuel is required. Additional process gases that are utilized as gas turbine fuels
are byproducts of steel production. These are:
1. Blast Furnace Gases
Blast Furnace Gases (BFGs), alone, have heating values below the minimal allowable limits.
These gases must be blended with other fuels such as coke oven gas, natural gas or hydrocarbons
such as propane or butane to raise the heating value above the required lower limit.
2. Coke Oven Gases
Coke oven gases are high in hydrogen and methane and may be used as fuel for non-DLN
combustion systems. These fuels often contain trace amounts of heavy hydrocarbons, which may
lead to carbon buildup on the fuel nozzles. The heavy hydrocarbons must be “scrubbed” or
removed from the fuel prior to delivery to the gas turbine.
3. COREX Gases
COREX gases are similar to oxygen blown gasification fuels and may be treated as such. They
are usually lower in H2 content and have heating values lower than oxygen blown gasification
fuels.
III. FUEL PROPERTIES

A. Heating Values
The heat of combustion, heating value or calorific value of a fuel is the amount of energy generated
by the complete combustion of a unit mass of fuel. The US system of measurement uses British
thermal units (Btu) per pound or Btu per standard cubic foot when expressed on a volume basis. The
heating value of a gas fuel may be determined experimentally using a calorimeter in which fuel is
burned in the presence of air at constant pressure. The products are allowed to cool to the initial
temperature, and a measurement is made of the energy released during complete combustion. All
fuels that contain hydrogen release water vapor as a product of combustion, which is subsequently
condensed in the calorimeter. The resulting measurement of the heat released is the higher heating
value (HHV), also known as the gross heating value, and includes the heat of vaporization of water.
The lower heating value (LHV), also known as the net heating value, is calculated by subtracting the
heat of vaporization of water from the measured HHV and assumes that all products of combustion
including water remain in the gaseous phase. Both the HHV and LHV may also be calculated from
the gas compositional analysis using the procedure described in ASTM D 3588. For most gas fuels, a
standard gas analysis to C6+ is adequate for determination of heating value, but an extended C14

analysis (4) may also be used if available. Gas turbines do not operate with condensing exhaust
systems and it is common gas turbine industry practice to utilize the LHV when calculating the
overall cycle thermal efficiency.
B. Modified Wobbe Index (MWI)

Gas turbines can operate with fuel gases having a very wide range of heating values, but the amount
of variation that a specific fuel system design can accommodate is limited. The fuel nozzles are
designed to operate within a fixed range of pressure ratios, and changes in heating value can be
accommodated by increasing or decreasing the fuel nozzle area or gas temperature. A measure of the
interchangeability of gas fuels for a given system design is the modified Wobbe index, or MWI . This
term is used as a relative measure of the energy injected to the combustor at a fixed pressure ratio and
is calculated using the fuel lower heating value, the specific gravity with respect to air and the fuel
temperature. The mathematical definition is as follows:
LHV
Modified Wobbe Index = (1)
SGgas x Tgas
For an ideal gas this is equivalent to:
LHV
Modified Wobbe Index = ( 2)
MWgas
x Tgas
28.96
LHV = Lower Heating Value of the Gas Fuel (Btu/scf)
SGgas = Specific Gravity of the Gas Fuel relative to Air
MWgas = Molecular Weight of the Gas Fuel
Tgas= Absolute Temperature of the Gas Fuel (ºRankine)
28.96 = Molecular Weight of Dry Air
The allowable MWI range is established to ensure that required fuel nozzle pressure ratios are
maintained during all combustion/turbine modes of operation. When multiple gas fuels are supplied
and/or if variable fuel temperatures result in a MWI that exceed the 5% limitation, independent fuel
gas trains, which could include control valves, manifolds and fuel nozzles, may be required for
standard (diffusion flame) combustion systems. For DLN systems, an alternate control method may
be required to ensure that the required fuel nozzle pressure ratios are met. An accurate analysis of all
gas fuels, along with fuel gas temperature-time profiles shall be submitted to GE for proper
evaluation.
MWI Variability Within the +/-5% Range
This gas fuel specification is written to provide customers with the allowable limits of gas fuel
properties that can be tolerated with a specific set of hardware and permit the turbine to operate
within the normal limits for emissions and combustor dynamics. It was not written with the intent of
addressing fuel variability within the stated limits. The gas turbine can operate successfully within the
stated limits without the need for outages or for combustion system hardware modification such as

fuel nozzle changes. It is expected that as the fuel properties vary from one extreme limit to the next,
some controls adjustments to change combustor operation may be required to operate the combustion
system with optimum dynamics and emissions performance. Currently, these controls changes are
performed manually, on-line and without the need for an outage. Accordingly, if the variability
described above is encountered on a frequent (daily, weekly) basis, then an automatic compensation
system may be preferable to constant monitoring with manual intervention.
Exceptions to the fuel specification must be evaluated on a case-by-case basis.
C. Superheat Requirement
The superheat requirement is establish to ensure that the fuel gas supply to the gas turbine is 100%
free of liquids. Superheat is the temperature difference between the gas temperature and the
respective dew point. The requirement is independent of the hydrocarbon and moisture concentration.
Dependent upon their constituents, gas entrained liquids could cause degradation of gas fuel nozzles,
and, for DLN applications, premixed flame flashbacks or re-ignitions. Condensation of moisture must
be avoided to prevent the formation of gas hydrates and collection of water in low points of the gas
fuel system. The superheat requirement is specified to provide enough margin to compensate for the
temperature reduction as the gas expands across the gas fuel control valves. The requirements are
applicable at all operating conditions and apply to all units including those installed with either
standard or DLN combustion systems. Exceptions are units burning coal derived low Btu fuels, the
requirements for which must be determined on a case-by-case basis. The superheat requirements take
into account the gas temperature drop and the relationship of the moisture and hydrocarbon dew point
lines to the gas fuel pressure. Because of differences between the dew point line characteristics in the
region of interest (less than 700 psia), the opportunity for moisture condensation as the gas expands is
less than that for hydrocarbons. Advantage has been taken of this physical property to provide users
with two separate requirements in order to minimize the cost of superheating. In addition, the
superheat requirements depend on the expansion ratio across the control valves and can therefore be
expressed as a function of the incoming gas pressure at the inlet to the gas fuel control system.
To avoid hydrocarbon condensation the superheat requirement is:
Tsh = 2.33 x (Pgas

100
) - 2.8 x (Pgas
2
100
) (3)
where:
Tsh is the hydrocarbon superheat requirement in °F (incremental temperature above the hydrocarbon
dew point)
Pgas is the gas fuel delivery pressure at the inlet to the gas turbine control system, psia
To avoid moisture and hydrate formation the superheat requirement is:
Tsm = 5.15 x (Pgas

100
)- 7 (4)
where:
Tsm is the moisture superheat requirement in °F (incremental temperature above the moisture dew
point)

The superheat requirements are shown graphically on Figure 1 for moisture and hydrocarbons. Both
should be determined and added to the respective dew points (moisture and hydrocarbon) at the gas
turbine fuel delivery pressure. The higher of the two values, superheat plus dew point, will determine
the preliminary minimum gas fuel temperature that is required in order to meet the superheat
requirements. In some cases, the hydrocarbon dew point may be low enough that the requirement for
meeting the moisture superheat will dominate. However, if the hydrocarbon dew point is close to the
moisture dew point, and the hydrocarbon dew point varies sufficiently, the moisture and hydrocarbon
superheat requirements may reverse on which one dominates. In order to avoid this situation, GE has
developed a breakpoint strategy. The breakpoints that will be used are based on gas supply pressure,
as seen in the table below:
Gas Supply Pressure Hydrocarbon Dew Point Breakpoint
500 psia or less -25°F
501 psia to 600 psia -35°F
601 psia to 700 psia -50°F
Maximum Hydrocarbon Dew Point less than Breakpoint
If the maximum hydrocarbon dew point, calculated during the Order to Requisition process, is below
the breakpoint level, then GE will assume that the hydrocarbon superheat requirements are less than
the moisture superheat requirements. Therefore, the minimum gas temperature will be determined by
the moisture dew point plus the moisture superheat.
Maximum Hydrocarbon Dew Point greater than Breakpoint
However, if the maximum hydrocarbon dew point, calculated during the Order to Requisition
process, is above a breakpoint, then GE will assume the unconditioned gas is saturated. This will
require the full hydrocarbon superheat to be applied to the unconditioned gas. The resulting gas
temperature may be higher than just adding the hydrocarbon dew point and hydrocarbon superheat.
See Appendix 4 for a sample calculation.
Continuous Hydrocarbon Dew Point Measurement
An alternate approach to the use of a breakpoint is to provide instrumentation to measure the

hydrocarbon dew point continuously, and then to provide that signal to GE through the gas turbine
controller. The turbine controller will then use the hydrocarbon dew point, along with the moisture
dew point, provided during the Order to Requisition process, to determine if sufficient superheat has
been provided.
Non-superheated Gas Temperature Signal
GE will require an input signal, into the turbine controller, of the gas fuel temperature upstream of
any performance or superheating system. The turbine controller will take action if sufficient
superheat is not supplied.

Figure 1. Hydrocarbon and Moisture Superheat Requirements

D. Hydrocarbon Dew Point
The hydrocarbon dew point is the temperature at which the first droplet of hydrocarbon forms as the
gas temperature is reduced at a given pressure and is analogous to the moisture dew point. The
hydrocarbon dew point is very sensitive to small concentrations of heavy hydrocarbons (C6+) and
contamination of the gas sample during sampling can be an issue. The use of a sample probe and
following the sampling procedure described in GPA 2166(3), particularly with respect to sample
cylinder purging, can avoid these problems. For this reason the recommended method for
hydrocarbon dew point determination is by direct measurement using a chilled mirror instrument
(ASTM D 1142). If a direct measurement cannot be performed, the dew point may be calculated from
the extended C14 gas fuel analysis (4). Use of a C6+ analysis for dew point determination may result
in an under-estimation of 30°F to 40°F or more. Exceptions are fuels that do not contain heavy
hydrocarbons such as liquefied natural gas.
E. Moisture Dew Point

The gas fuel moisture dew point is dependent upon the moisture concentration and the gas fuel
pressure. When expressed in units of lbs/mmscft (pounds per million standard cubic feet), the
resulting dew point is practically independent of the gas fuel composition (other than moisture).
Typically, many pipeline tariffs limit the maximum allowable moisture content to 7 lbs/mmscft while
the actual value may be significantly less. It is the maximum allowable value, however, that
determines the design requirements for superheat. Figure 2 is included to provide a guide for
determining the expected moisture dew point from the moisture concentration and gas fuel pressure
of a typical natural gas. The actual dew point will vary slightly with gas composition changes.
Figure 2. Moisture Dew Point as a Function of Concentration and Gas Pressure for a Typical Natural
Gas Fuel
F. Flammability Ratio
Fuel gases containing hydrogen and/or carbon monoxide will have a ratio of rich-to-lean
flammability limits that is significantly greater than that of natural gas. Typically, gases with greater
than 5% hydrogen by volume fall into this range and require a separate startup fuel. GE will evaluate
the gas analysis to determine the requirement for a start-up fuel. Fuel gases with large percentages of
an inert gas such as nitrogen or carbon dioxide will have a ratio of rich-to-lean flammability limits
less than that of natural gas. Flammability ratios of less than 2.2 to 1 based on volume at ISO
conditions (14.696 psia and 59° F), may experience problems maintaining stable combustion over the
full operating range of the turbine.
G. Gas Constituent Limits

Gas constituent limits are specified to assure stable combustion through all gas turbine loads and
modes of operation. A detailed gas analysis must be furnished to GE for proper evaluation. See
reference (3) for the recommended sampling procedure and ASTM D1945 for a C6+ analysis
procedure.
H. Gas Fuel Supply Pressure

Gas fuel supply pressure requirements are dependent on the gas turbine model, the combustion
system design, the fuel gas analysis and unit specific site conditions. As part of the unit proposal, GE
will furnish minimum and maximum gas fuel supply pressure requirements.

IV. CONTAMINANTS
Dependent on the type of fuel gas, the geographical location and the forwarding means, there is the
potential for the “raw” gas supply to contain one or more of the following contaminants:
1. Tar, lamp black, coke

2. Water, salt water
3. Sand, clay
4. Rust
5. Iron sulfide
6. Scrubber oil or liquid
7. Compressor Lube oil
8. Naphthalene
9. Gas Hydrates
It is critical that the fuel gas is properly conditioned prior to being utilized as gas turbine fuel. This
conditioning can be performed by a variety of methods. These include, but are not limited to: media
filtration, inertial separation, coalescing and fuel heating. Table 2b identifies the trace metal, particulate
and liquid contamination limits. It is critical that fuel gas conditioning equipment be designed and sized
so that these limits are not exceeded. For further information on gas fuel conditioning, see publication
GER 3942 (8).
A. Particulates
Contamination limits for particulates are established to prevent fouling and excessive erosion of hot
gas path parts, erosion and plugging of combustion fuel nozzles and erosion of the gas fuel system
control valves. The utilization of gas filtration or inertial separation is instrumental in ensuring that
the particulate requirements as defined in Table 2b are met. GE recommends the use of stainless steel
piping downstream of this last level of filtration to prevent the generation of corrosion-derived
particulates.
B. Liquids
As identified in Table 2b, zero liquids are allowed in the gas turbine fuel gas supply. Refer to Note 16
of table 2b for current input requirements and turbine controller actions. The introduction of liquids
with gas fuel can result in nuisance and/or hardware damaging conditions. These include rapid
excursions in firing temperature and gas turbine load, primary zone re-ignition and flashback of pre-
mixed flames. In severe conditions, liquid carryover to the first stage turbine nozzle may result in
damage to downstream hot gas path components. When liquids are identified in the gas fuel supply,
phase separation and heating must be employed to achieve the required superheat level.
C. Sulfur
There are several concerns relative to the levels of sulfur contained in the fuel gas supply. Many of
these are not directly related to the gas turbine but to associated equipment and emissions
requirements. These concerns include but not limited to:

1. Hot Gas Path Corrosion
Typically, use of sulfur bearing fuels will not be limited by concerns for corrosion in the turbine
hot gas path. Experience has shown that fuel sulfur levels up to about 1% sulfur do not
significantly affect oxidation/corrosion rates. Specifying the fuel alkali levels to values shown in
Table 2b controls hot corrosion of hot gas path parts resulting from alkali sulfate formation.
Unless sulfur levels are extremely low, alkali levels are usually limiting in determining hot
corrosion of hot gas path materials. For low Btu gases, the fuel mass flow rate at the turbine inlet
is increased over that for natural gas, and the alkali limit in the fuel is therefore decreased.
2. HRSG Corrosion
If heat recovery equipment is used, the gas fuel sulfur concentration must be known so that the
appropriate design for the equipment can be specified. Severe corrosion from condensed
sulfurous acid results if a heat recovery steam generator (HRSG) has metal temperatures below
the acid dew point.
3. Selective Catalytic Reduction (SCR) Deposition
Units utilizing ammonia injection downstream of the gas turbine for NOx control can experience
the formation of deposits containing ammonium sulfate and bisulfate on low temperature
evaporator and economizer tubes. Such deposits are quite acidic and therefore corrosive. These
deposits and the corrosion that they cause may also decrease HRSG performance and increase
backpressure on the gas turbine. Deposition rates of ammonium sulfate and bisulfate are
determined by the sulfur content of the fuel, ammonia content in the exhaust gas, tube
temperature and boiler design. Fuels having sulfur levels above those used as odorants for
natural gas should be reported to GE. In addition, the presence of minute quantities of chlorides
in the compressor inlet air may result in cracking of ANSI 300 series stainless steels in the hot
gas path.
4. Exhaust Emissions
Sulfur burns mostly to sulfur dioxide, but 5%-10% oxidizes to sulfur trioxide. The latter can
result in sulfate formation, and may be counted as particulate matter in some jurisdictions. The
remainder will be discharged as sulfur dioxide. To limit the discharge of acid gas, some localities
may restrict the allowable concentration of sulfur in the fuel.
5. System Material Requirements
When considering fuel gases containing sulfur (sour gas fuels) material selection for system
piping and components shall comply with NACE Standard, MR0175 (9).
6. Elemental Sulfur Deposition
Solid elemental sulfur deposits can occur in gas fuel systems downstream of pressure reducing
stations or gas control valves under certain conditions. These conditions may be present if the
gas fuel contains elemental sulfur vapor, even when the concentration of the vapor is a few parts
per billion by weight. Concentrations of this magnitude cannot be measured by commercially
available instrumentation and deposition cannot therefore be anticipated based on a standard gas
analysis. Should deposition take place, fuel heating will be required to maintain the sulfur in
vapor phase and avoid deposition. A gas temperature of 130°F or higher may be required at the

inlet to the gas control valves to avoid deposition, depending on the sulfur vapor concentration.
The sulfur vapor concentration can be measured by specialized filtering equipment. Contact GE
for further information on this subject.
7. Iron Sulfide
The presence of sulfur in the gas may promote the formation of iron sulfides. Under certain
conditions, iron sulfide is a pyrophoric material that can auto ignite at atmospheric pressure and
temperature when exposed to air. Extreme care must be taken when servicing gas fuel cleanup
equipment to avoid accidental exposure to oxygen and subsequent combustion of filter material.
D. Trace Metals
Sodium is the only trace metal contaminant normally found in natural gas. The source of sodium in
natural gas is salt water. Limits on trace metals are established to prevent the formation of corrosive
deposits on hot gas path components. These deposits can be detrimental to gas turbine parts life. In
addition to sodium, additionally harmful trace metal contaminants can be found in gasification and
process gases. GE will determine limits on these contaminants on a case-by-case basis.
V. SOURCES OF CONTAMINANTS
A. Particulates
The major source of particulates is from corrosion products in the pipeline. These products are
continuously formed over the life of the pipeline at rates that are determined by the corrosive
components and water content of the gas. For this reason most gas suppliers control moisture content
to avoid the possibility of water condensing and forming acid with CO2 or H2S.
B. Liquids
Gas at the wellhead is typically produced in a wet saturated condition and is treated to remove water
and heavy hydrocarbon liquids. Depending on the degree of treatment and the supply pressure, the
gas may be delivered in a dry condition. After pressure reduction it is possible for condensates to
form as the gas cools during expansion. The condensates may be either water or hydrocarbons or
both. Carry over of lubricating oil from compressor stations is another source of liquids.
C. Sulfur
Sulfur is usually combined with either hydrogen as H2S or carbon as COS. It is produced with the
natural gas. Typically the gas supplier will limit H2S to a concentration of less than approximately 20
ppmv by removing sulfur in a treatment system. Sulfur may also be present in very low
concentrations (< 100 ppbv) in the form of elemental sulfur vapor.
D. Trace Metals
The details of various sources of alkali contaminants in the following text apply to MS 3000, MS
5000, B, E and F class machines. The sources of contaminants for 6C, FB and H-class machines are
discussed in GEK 107230 (1).
Contributions to the alkali content of the combustion gases can come from any of the material
streams supplied to the combustor; fuel, air, water or steam. The basic parameter which can be used
to define the allowable alkali metal content admitted to the turbine is Xt, the combined sodium and
potassium content of the combustion gas at the entry to the first stage nozzle. This concentration must
not exceed the values stated in Table 2b. Since there is no simple test method for measuring Xt in an

operating turbine, it must be calculated from the alkali metal contents of the fuel, air, water and steam
flows.
T(Xt) = A(Xa) + F(Xf ) + S(Xs) + W(Xw)
Where T = total flow to turbine (= A + F + S + W):
Xt = alkali contaminant concentration in total flow as Na.
A = Air flow,
Xa = contaminant concentration in air.
F = Fuel flow,
Xf = contaminant concentration in fuel
S = Steam flow,
Xs = contaminant concentration in steam.
W = water flow
Xw = contaminant concentration in water.
The allowable levels of alkali contamination in the different flows entering the gas turbine are
discussed below.
E. Air
There are four sources of alkaline metal contained in the compressor discharge air, (a) Inlet filter
carryover of sodium chloride in ambient air (b) carryover of sodium dissolved in water used for
evaporative cooling (c) carryover of sodium dissolved in water used for inlet fogging and (d)
carryover of sodium from water used for on-line water washing.
When concentrations of trace metals in fuel, water or steam are not precisely known, a value of 0.005
ppmw, GER 3419 (10), can be used for systems with or without evaporative coolers. This value, based
on experience, would cause an insignificant contribution to the overall contamination level and have
a minor impact on parts lives.
For systems with inlet foggers, the water carry over is 100% compared with approximately 0.003%
for evaporative coolers and the potential sodium carry over is therefore proportionally higher. The
maximum inlet fogging water flow rate is approximately 1/3 of the natural gas flow rate and,
depending on the sodium concentration, could use up a significant portion of the total allowed at the
turbine inlet. Refer to GEK 101944 (11) for information on water purity requirements. If it is
anticipated that the specification could be exceeded, General Electric should be consulted for
recommendations on the selection of the water source and use of proper air filtration equipment.
F. Steam
Steam for gas turbine injection is typically taken from a suitable extraction point on a steam turbine
or HRSG. The limiting purity requirements for this steam are those for the steam turbine. These
limits are defined in GEK 72281 (12).

G. Water
The maximum alkaline metal (sodium plus potassium) content of water to be used for injection is
discussed in GEK 101944 (11). The maximum water injection rate is approximately equal to the fuel
injection rate. If the alkali content approaches the maximum allowable value stated in GEK 101944
(11)
, it may use all of the allowable margin at the turbine inlet, leaving none available for the fuel. If it
is anticipated that the specification could be exceeded, General Electric should be consulted for
recommendations on the selection of the water source.
Note that the concentration of sodium in steam and water, at the levels specified, can be measured
directly using an on-line sodium analyzer or, in the laboratory, with an ion or pH meter fitted with a
“sodium specific” electrode or by an atomic absorption spectrometer fitted with a graphite furnace.
H. Fuel
The final source of contamination to be considered is the fuel. Most cases of alkaline metal
contamination and corrosion of hot gas path components are related to liquid fuel contamination. It is
rare that natural gas will contain trace metals, but gasification fuels may contain alkalis carried over
from the gas clean up system. The issues and requirements with gas fuels are discussed separately in
the prior sections.

APPENDIX 1
I. DEFINITIONS
A. Dew Point
This is the temperature at which the first liquid droplet will form as the gas temperature is
reduced. Common liquids found in gas fuel are hydrocarbons, water and glycol. Each has a
separate and measurable dew point. The dew point varies considerably with pressure, and both
temperature and pressure must be stated to define properly the gas property. Typically, the
hydrocarbon dew point will peak in the 300 to 600 psia range.
B. Dry Saturated Conditions
The gas temperature is at, but not below or above, the dew point temperature. No free liquids are
present.
C. Gas Hydrates
Gas hydrates are semi-solid materials that can cause deposits that plug instrumentation lines,
control valves and filters. They are formed when free water combines with one or more of the
C1 through C4 hydrocarbons. Typically the formation will take place downstream of a pressure
reducing station where the temperature drop is sufficient to cause moisture condensation in a
region of high turbulence. Because hydrates can cause major problems in the gas distribution
network, the moisture content is usually controlled upstream at a dehydration process station.
D. Gas Hydrate Formation Line
This is similar to the dew point line. A potential for hydrate formation exists if free water is
present. Calculations performed using the commercial software HYSYS (15) show that the
hydrate formation line is approximately 10°F above the moisture dew point line. Maintaining
the required degree of superheat above the moisture dew point will eliminate hydrate formation
problems. (see section III–C Superheat Requirement).
E. Glycol
Glycol is not a natural constituent of natural gas but is introduced during the dehydration
process. Various forms of glycol are used, di-ethylene and tri-ethylene glycol being two most
common. In some cases glycol is injected into the pipeline as a preservative. In most cases,
glycol may only be a problem during commissioning of a new pipeline or if an upset has taken
place at an upstream dehydration station.
F. Odorant
Odorants are injected into natural and LP gas to make leaks readily detectable. The odorant
commonly used for natural gas is tertiary butyl mercaptan, while ethyl mercaptan is used for LP
gas.
G. Superheat
This is defined as the difference, gas temperature minus liquid dew point. The difference is
always positive or zero. A negative value implies that the value is being measured at two
differing states of pressure and temperature and is not valid. A measured gas temperature below
the theoretical dew point means that the gas is in a wet saturated state with free liquids present.
H. Saturation Line
This is the same as the dew point line.
I. Wet (Saturated) Conditions
A mixture consisting of both vapor and liquids.

APPENDIX 2
I. PARTICLE SIZE LIMITATIONS
The effective particle size for erosion considerations is determined by a particle’s terminal settling
velocity. The size and density distribution of the solid particles must be such that not more than 1.0
percent by weight of the particles shall have a terminal settling velocity in air (70°F and 30 inches
Hg, absolute) greater than 14 inches per minute, and not more than 0.1 percent shall have a terminal
settling velocity in excess of 23 inches per minute. For a solid spherical particle, Stoke’s Law of
settling permits calculating the terminal settling velocity if the particle size and shape and particle
specific gravity are known. The following tabulation gives the spherical particle diameters equivalent
to the limiting terminal settling velocities for particles of specific gravity 2.0 and 4.
Settling Velocity Specific Gravity Equivalent Spherical

(inches/min) (relative to water) Particle Diameter (microns)
14 2 10
23 2 13
14 4 7
23 4 9

APPENDIX 3
I. EQUIVALENT CONTAMINANT RELATIONSHIPS (ALL MACHINES EXCEPT FB, H-

CLASS)
The following relationships can be used to determine turbine inlet contaminant and fuel equivalent
contaminant concentrations to compare to limits given in Table 2b. In general, for mass balances on
the flows and on the contaminants from fuel, air and steam/water at the turbine inlet.
E=F+A+S (5)
(XE) x E = (XF) x F + (XA) x A + (XS) x S (6)
where:
A, F, S and E are the mass flows of air, fuel, injected steam/water and combustion gases at the turbine
inlet, respectively
XA, XF, XS, and XE are the contaminant concentrations (ppm by weight) in the inlet air, in the fuel,
in the injected steam/water, and in the combustion gases at the turbine inlet, respectively.
The fuel equivalent concentration of contaminants (XFe ) is (dividing (5) and (6) by F)
XFe = XE x (1+ A/F + S/F) = XF + XA x (A/F) + XS x (S/F) (7)
For example for a natural gas contaminated with salt at a sodium concentration of 0.1 ppm, an air
sodium contamination of 5 ppb, and a steam contamination of 5 ppb, the equivalent sodium in the
fuel for A/F =50 and S/F=1 is from equation (7)
XFe = 0.1 + 0.005(50) + 0.005(1) = 0.355ppm (8)
This is the amount of sodium considered to come from a fuel source only, which gives the same
sodium concentration at the turbine inlet as from the combined three sources.
The turbine inlet concentration, XE, is found by rearranging (7)
XE = XFe /(1 + A/F + S/F) = 0.355/(1 + 50 + 1) = 0.006827 ppm = 6.827 ppb (9)
These values are well within the sodium specification values of 1 ppm on a fuel basis (XFe), and 20
ppb for the turbine inlet concentration (XE). XE and XFe values for all contaminants are given in
Table 2b.
For equivalent contaminant relationships in 6C, FB, and H-Class machines, refer to GEK 107230 (1).

APPENDIX 4
I. MINIMUM GAS FUEL TEMPERATURE REQUIREMENT CALCULATIONS
The gas fuel pressure at the purchaser’s connection FG1 should first be determined. The hydrocarbon
and moisture superheat can then be calculated from the equations depicted in Figure 1. For example,
at a gas fuel pressure of 490 psia, the moisture and hydrocarbon superheat requirements are 18°F and
42°F respectively.
For a typical pipeline gas the maximum allowable moisture content is 7 lbs/mmscft. At 490 psia the
moisture dew point can be determined from Figure 2 and is equal to 23ºF. The minimum gas
temperature to avoid moisture condensation is equal to the moisture dew point plus the required
superheat, or 23º+ 18º = 41ºF.
For hydrocarbons, the maximum expected hydrocarbon dew point should be determined by
consultation with the gas supplier and a review of historical data if available. The hydrocarbon dew
point will be dependent on the source of the gas, the degree of gas processing and may vary
seasonally with overall gas demand and the economics associated with liquids removal and recovery.
For a fuel with a maximum hydrocarbon dew point of, for example, 35ºF at 490 psia, the theoretical
minimum gas fuel temperature is 42º+ 35º= 77º F. The temperature, in this example, is higher than
the minimum required to avoid moisture condensation, therefore it establishes the minimum gas
temperature to avoid both hydrocarbon and moisture condensation. However, the actual minimum
gas fuel temperature will be based on the hydrocarbon dew point breakpoint. (see section III-C) In the
example above, the assumed hydrocarbon dew point was 35°F. (at 490 psia) The hydrocarbon dew
point for this case is higher than the breakpoint. (-25°F) Therefore, GE will assume that the gas
entering the superheating system is saturated, and will require the full hydrocarbon superheat be
applied. For example, if the gas entering the superheating system is at a temperature of 55°F, then the
minimum gas temperature would be 97°F. (55°F + 42°F) The 97°F temperature is what the turbine
controller will begin to take protective action on. The use of the 97°F temperature, instead of the
77°F temperature is based on GE’s experience of gas fuel dew point variation on sites.
For another example, if the hydrocarbon dew point is calculated as –30°F, (at 490 psia) then the
hydrocarbon dew point would be less than the breakpoint. (-25°F). Therefore, the minimum gas fuel
temperature would be based on the moisture dew point and superheat. Assuming a 7 lbs/mmscft, the
dew point is 23°F and superheat required is 18°F, resulting in a theoretical and actual minimum gas
temperature of 41°F. (23 °F + 18°F).

APPENDIX 5: REQUESTED FUEL ANALYSIS DATA FOR GE EVALUATION

Values
Property ASTM Method Nominal Min Max
Lower Heating Value, Btu/scf ASTM D 3588 _______ _______ _______
Wobbe Index (Gross/Higher or Net/Lower) _______ _______ _______
Gas Fuel Temperature, ˚F _______ _______ _______
Gas Fuel Pressure _______ _______ _______
Constituents, mole % ASTM D 1945 & GPA 2286
Oxygen (O2) _______ _______ _______
Nitrogen (N2) _______ _______ _______
Carbon Dioxide (CO2) _______ _______ _______
Water Vapor (H2O) _______ _______ _______
Argon (Ar) _______ _______ _______
Helium (He) _______ _______ _______
Methane (CH4) _______ _______ _______
Ethane (C2H6) _______ _______ _______
Propane (C3H8) _______ _______ _______
Isobutane (C4H10) _______ _______ _______
Butane (n-butane) (C4H10) _______ _______ _______
Pentane (C5H12) _______ _______ _______
Isopentane (C5H12) _______ _______ _______
Neopentane (C5H12) _______ _______ _______
N-Hexane (C6H14) _______ _______ _______
Ethene (C2H4) _______ _______ _______
Propylene (C3H6) _______ _______ _______
Butene (C4H8) _______ _______ _______
Pentene (C5H10) _______ _______ _______
Benzene (C6H6) _______ _______ _______
Toluene (C7H8) _______ _______ _______
Carbon Monoxide (CO) _______ _______ _______
Hydrogen (H2) _______ _______ _______
Acetylene (C2H2) _______ _______ _______
Propyne (C3H4) _______ _______ _______
Butyne (C4H6) _______ _______ _______
Pentyne (C5H8) _______ _______ _______
Other (Please specify) _______ _______ _______
Other Constituents & Contaminants, ppm
Hydrogen Sulfide (H2S) _______ _______ _______
Carbonyl Sulfide (COS) _______ _______ _______
Lead (Pb) _______ _______ _______
Vanadium (V) _______ _______ _______
Calcium (Ca) _______ _______ _______
Magnesium (Mg) _______ _______ _______
Sodium (Na) _______ _______ _______
Potassium (K) _______ _______ _______
Particulates _______ _______ _______
Siloxanes _______ _______ _______
Other (Please specify) _______ _______ _______

APPENDIX 6
I. RELATED SPECIFICATION DOCUMENTS
GER 3419 (10)- Includes specifications for compressor inlet air quality
GER 4189 (2)- Includes heated gas fuel temperature limits
GER 72281 (12)- Includes steam purity requirements in steam turbines
GER 101944 (11)- Includes water and steam purity requirements in gas turbines
GEK 106669 (13)- Includes cooling steam purity requirements for H class gas turbines
GEK 107230 (1)- Includes allowable alkali metal concentrations for 6C, FB and H class gas fuels
REFERENCES
1. GEK 107230 Specification for Alkali Metal Contamination in Fuels for the 6C, FB and H Model
Gas Turbines
2. GER 4189 Design Considerations for Heated Gas Fuel
3. Obtaining Natural Gas Samples for Analysis by Gas Chromatography, GPA Standard 2166, Gas
Producers Association, 6526 East 60th Street, Tulsa, Oklahoma
4. Tentative Method of Extended Analysis for Natural Gas and Similar Gaseous Mixtures by
Temperature Programmed Gas Chromatography, GPA Standard 2286, Gas Producers
Association, 6526 East 60th Street, Tulsa, Oklahoma 74145
5. Bureau of Mines Bulletin 503, Limits of Flammability of Gases and Vapors, 1952
6. Bureau of Mines Bulletin 622, Flammability Characteristics of Combustible Gases and Vapors,
1965
7. Wiley Critical Content - Petroleum Technology, Volumes 1-2. Hoboken: John Wiley & Sons,
Inc., 2007. 363
8. GER 3942 Gas Fuel Clean-up System Design Considerations for GE Heavy-Duty Gas Turbines
9. MR0175, NACE Standard, Sulfide Stress Cracking Resistant Metallic Material for Oilfield
Equipment
10. GER 3419 Gas Turbine Inlet Air Treatment
11. GEK 101944 Requirements for Water/Steam Purity in Gas Turbines
12. GEK 72281 Steam Purity Recommendations for Utility Steam Turbines
13. GEK 106669 Specification for Cooling Steam Purity for Closed Circuit Steam Cooled Gas
Turbine

14. ASME Handbook “Water Technology for Thermal Power Systems”, chapter 12
15. Aspen HYSYS, a process modeling tool for conceptual design and performance improvement of
petroleum and oil & gas processes. Aspen Technology, Inc., 200 Wheeler Road., Burlington MA
01803, +1-781-221-6400
g GE Energy
General Electric Company
www.gepower.com

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REVISIONS
THIS DOCUMENT SHALL BE
NOTES: REV DESCRIPTION DATE APPROVED
REVISED IN ITS ENTIRETY. ALL
1. FOR DETAILS SEE SPECIFIC MLI’S REFERENCED IN THE BLOCK DIAGRAM. SHEETS OF THIS DOCUMENT
2. THE TERM "OTHERS" USED ON THIS DRAWING IS DEFINED AS THE PLANT ARE THE SAME REVISION
LEVEL AS INDICATED.
DESIGNER AND/OR PLANT INSTALLER.
3. ALL INTERCONNECTION PIPING IS BY OTHERS.
4. PIPING DOWNSTREAM OF FINAL FILTER MUST BE STAINLESS STEEL.
5. THE ARRANGEMENT SHOWN DOWNSTREAM OF POINT A IS TYPICAL FOR
ONE GAS TURBINE.
6. PIPING BETWEEN FUEL GAS COALESCING FILTER AND FUEL GAS HEATER
MUST BE STAINLESS STEEL.
7. BYPASS LINE PIPING MUST BE STAINLESS STEEL.
FUEL GAS CHROMATOGRAPH FUEL GAS WOBBE METER
MLI-G023 SYSTEM-4035 MLI-G028 SYSTEM-4072
GAS FUEL FLOW

FROM GAS A FUEL GAS COALESCING MEASUREMENT SYSTEM FUEL GAS HEATING FUEL GAS SCRUBBER TO MLI 0422,
SUPPLY FILTRATION (BY OTHERS) (BY OTHERS) (IF REQUIRED BY OTHERS) FUEL GAS SYSTEM, "FG988"
SEE NOTE 5
MLI-0639 SYSTEM-0422
SEE NOTE 6
SEE NOTE 7
TO MLI 0422,
FUEL GAS SYSTEM, "FG992"
1 SPEC, SCHEMATICS AND DIAGRAMS 372A3671

IT. NOMENCLATURE IDENT
LIST OF COMPLEMENTARY DOCUMENTS
UNLESS OTHERWISE SPECIFIED SIGNATURES DATE
g
GENERAL ELECTRIC COMPANY
DIMENSIONS ARE IN INCHES
DRAWN
CLAUDIA LINAN 10-10-26
GE Energy GAS TURBINE
TOLERANCES ON CHECKED
2 PL DECIMALS ± SEE PLM 10-10-26

3 PL DECIMALS ± ENGRG
ANGLES ±
ISSUED
SEE PLM 10-10-26 DIAG - SCHEMATIC, FUEL GAS
FRACTIONS ±
SEE PLM 10-10-26
QUALITY
SYSTEM
THIRD ANGLE PROJECTION
© COPYRIGHT 2010 GENERAL ELECTRIC COMPANY FIRST MADE FOR: ML-9K1WFA141-1T6 0482
PROPRIETARY INFORMATION - THIS DOCUMENT CONTAINS
PROPRIETARY INFORMATION OF GENERAL ELECTRIC SIZE CAGE CODE DWG NO
COMPANY AND MAY NOT BE USED OR DISCLOSED TO
DISTR
OTHERS, EXCEPT WITH THE WRITTEN PERMISSION OF
GENERAL ELECTRIC COMPANY.
TO
SIM TO:
NONE SCALE SHEET 1 of 1
DT1N
MAXCASE: 0482, 71EA, REV.= 21
8 7 6 5 4 3 2 SIZE
E
DWG. NO.
146E4069
SH.
1
REV.
- 1
REVISIONS
1. SEE DEVICE SUMMARY MLI 0414 FOR DEVICE SETTINGS AND RATINGS. SHEETS OF THIS DOCUMENT
ARE THE SAME REVISION
2. THE REQUIREMENTS IN THE SYSTEM AND CLEANLINESS SPECIFICATION LEVEL AS INDICATED.
INCLUDED IN MLI 0438 APPLY. THIS DRAWING TO BE REVISED
3. THE TERM "OTHERS" USED ON THIS DRAWING IS DEFINED AS THE PLANT IN VISIO 2002 ONLY
DESIGNER AND/OR PLANT INSTALLER. THE SOURCE FILE IS STORED IN A
4. REFER TO MLI 4063 CONNECTION AND LINE LIST FOR PROCESS DATA AND SECURE DATABASE.
ASSOCIATED NOTES. CONNECTIONS MARKED WITH ”PC” INDICATE
H CONNECTION BY OTHERS. CONNECTIONS NOT MARKED WITH “PC” ARE H
GEE-GEE CONNECTIONS, REQUIRE NO INTERFACE BY OTHERS, AND ARE NOT
SHOWN ON MLI 4063.
5. FOR UPSTREAM AND DOWNSTREAM EQUIPMENT, SEE MLI 0482.
6. INITIAL HIGH AND LOW CALIBRATION GAS BOTTLES TO BE PROVIDED BY
WOBBE METER SUPPLIER. REPLACEMENT BOTTLES MUST BE SUPPLIED
BY OTHERS.
7. N/A.
8. TUBING AND HEAT TRACE FROM CONNECTION POINTS [FG1000 & FG1001] TO PC
CONNECTION POINTS [FG1002 & FG1003] MUST BE PREINSULATED, VTA
FG1004
SELF-REGULATING HEAT TRACE TUBING. TUBING MUST BE FULLY ANNEALED, SEE NOTE 11
HIGH QUALITY [TYPE 304 OR 316, SEAMLESS] ASTM A269 OR EQUIVALENT.
HEAT TRACE IS REQUIRED TO HOLD SAMPLE LINE TEMPERATURE AT
100°F [38°C].
9. ACTIVE AND SPARE SAMPLE STREAM TUBING SHALL BE SUPPLIED BY WOBBE
METER SUPPLIER AND INSTALLED BY OTHERS. TUBING SHALL HAVE A
MAXIMUM LENGTH OF LESS THAN 100 FT [30.48 M].
G 10. FG1002 AND FG1003 ARE 2.0 [50.6 MM] THRU HOLES WITH HEAT SHRINK
G
JACKET WHICH WILL ALLOW THE PRE-INSULATED SELF-REGULATING HEAT
TRACE TUBING TO BE FED THROUGH THE CABINET WALL AND TERMINATED
IN THE SAMPLE CONDITIONING OVEN.
11. VENT TO ATMOSPHERE ONLY, THE USE OF FLARES OR OTHER BACK
PRESSURE DEVICES ARE NOT ALLOWED. PC
FG1006
NO
INSTRUMENT AIR
(BY OTHERS)
NO NO NO
WOBBE METER WOBBE METER

F [WMA] [WMB] F
G028-WM-1 G028-WM-2
96WM-10 96WM-11
30WM-1 30WM-2
NO 30WM-3 30WM-4
GAS SUPPLY
E SEE NOTE 5 E
VTA
PI
PI-WM-1 G028-WM-3
PI
SEE NOTE 7
PC PI-WM-3
FG998
FG1000
NO NO FG1002 NO
ACTIVE SAMPLE STREAM
SEE NOTES 8 & 9 SEE NOTE 10

VPR83-1
D ACTIVE SAMPLE PROBE G028

D
NO
1
VTA 3
PS
2 VTA
PI 63WM-1
NO
PI-WM-2
PI
SEE NOTE 7
PC PI-WM-4
FG999 FG1001
VPR82-1
NC NO SPARE SAMPLE STREAM FG1003 NC
C TI
SEE NOTE 6 C
SEE NOTES 8 & 9 SEE NOTE 10
VPR83-2 PS
SAMPLE CONDITIONING OVEN G028 TI-WM-1 VTA
63WM-2
SPARE SAMPLE PROBE G028
VPR82-2
SEE NOTE 6
GAS SUPPLY
SEE NOTE 5
B FUEL GAS WOBBE METER G028

B
PC
FG1005
DRAIN
GE CLASS II
(INTERNAL NON-CRITICAL)
UNLESS OTHERWISE SPECIFIED SIGNATURES DATE GENERAL ELECTRIC COMPANY
© COPYRIGHT 2010 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. DIMENSIONS ARE IN INCHES
DRAWN
g GE Energy GAS TURBINE
ALL RIGHTS RESERVED. THE INFORMATION CONTAINED HEREIN IS GE
ENERGY GAS TURBINE PROPRIETARY TECHNICAL INFORMATION THAT SEE PLM
A BELONGS TO THE GENERAL ELECTRIC COMPANY, GE ENERGY (USA), LLC
AND/OR THEIR AFFILIATES, WHICH HAS BEEN PROVIDED SOLELY FOR
2 PL DECIMALS ±
3 PL DECIMALS ± ENGRG
SEE PLM
A
THE EXPRESS REASON OF RESTRICTED PRIVATE USE. ALL PERSONS,
ANGLES ±
FRACTIONS ± ISSUED DIAG,SCHEM PP-FUEL GAS
FIRMS, OR CORPORATIONS WHO RECEIVE SUCH INFORMATION SHALL BE SEE PLM
DEEMED BY THE ACT OF THEIR RECEIVING THE SAME TO HAVE AGREED QUALITY WOBBE METER
TO MAKE NO DUPLICATION, OR OTHER DISCLOSURE, OR USE WHATSOEVER
FOR ANY, OR ALL SUCH INFORMATION EXCEPT AS EXPRESSLY AUTHORIZED FIRST MADE FOR: ML-9K1WFA141-1 4072
THIRD ANGLE PROJECTION IN WRITING BY THE GENERAL ELECTRIC COMPANY, GE ENERGY (USA),
LLC AND/OR ITS AFFILIATES. SIZE CAGE CODE DWG NO
E 146E4069
DISTR
TO
SIM TO:
8 7 6 5 4 3 2 1
7 I 3
146E3454 1
REVISIONS
1. SEE DEVICE SUMMARY ML! 0414 FOR DEVICE SETTINGS AND RATINGS. SHEETS OF THIS DOCUMENT
ARE THE SAME REVISION
2. THE REQUIREMENTS IN THE SYSTEM AND CLEANLINESS SPECIFICATION LEVEL AS INDICATED.
INCLUDED IN MLI 0438 APPLY.
3. THE TERM "OTHERS" USED ON THIS DRAWING IS DEFINED AS THE PLANT
THIS DRAWING TO BE REVISED IN MICROSOFT VISIO ONLY
THE SOURCE FILE IS STORED IN A SECURE DATABASE
4. REFER TO MLI 4063 CONNECTION AND LINE LIST FOR PROCESS DATA AND
ASSOCIATED NOTES. CONNECTIONS MARKED WITH "PC" INDICATE
H CONNECTION BY OTHERS. CONNECTIONS NOT MARKED WITH "PC" ARE
GEE-GEE CONNECTIONS, REQUIRE NO INTERFACE BY OTHERS, AND ARE NOT
SHOWN ON MLI 4063.
FOR UPSTREAM AND DOWNSTREAM EQUIPMENT, SEE MLI 0482.
INITIAL CARRIER GAS BOTTLES TO BE PROVIDED BY CHROMATOGRAPH
SUPPLIER. CARRIER GAS MUST BE 99.999% ULTRA HIGH PURITY HELIUM.
REPLACEMENT BOTTLES MUST BE SUPPLIED BY OTHERS.
7. INITIAL CALIBRATION GAS BOTTLE TO BE PROVIDED BY CHROMATOGRAPH
SUPPLIER. FOR CALIBRATION GAS CONSTITUENTS SEE MLI G023/EG26
OUTLINE DRAWING. REPLACEMENT BOTTLES MUST BE SUPPLIED BY OTHERS.
8. REGULATOR IS BOTTLE TYPE TO BE MOUNTED DIRECTLY ON GAS BOTTLE.
9. N/A
10. TUBING AND HEAT TRACE FROM CONNECTION POINTS [FG264 & FG265] TO
CONNECTION POINTS [FG259 & FG260] MUST BE PREINSULATED,
SELF-REGULATING HEAT TRACE TUBING. TUBING MUST BE FULLY ANNEALED,
HIGH QUALITY [TYPE 304 OR 316, SEAMLESS] ASTM A269 OR EQUIVALENT.
HEAT TRACE IS REQUIRED TO HOLD SAMPLE LINE TEMPERATURE AT
G 100°F[38DC].
G
11. ACTIVE AND SPARE SAMPLE STREAM TUBING MUST BE INSTALLED BY OTHERS
AND SHALL HAVE A MAXIMUM LENGTH OF LESS THAN 100 FT [30.48 M].
12. O SYMBOL DENOTES GAS CYLINDER CHANGEOVER REGULATOR.
13. FG259 AND FG260 ARE 2.0 [50.6 MM] THRU HOLES WITH HEAT SHRINK JACKET
WHICH WILL ALLOW THE PRE-INSULATED SELF-REGULATING HEAT TRACE
TUBING TO BE FED THROUGH THE CABINET WALL AND TERMINATED ON THE
SAMPLE CONDITIONING OVEN.
GAS SUPPLY
SEE NOTE 5
C C
SEE NOTE 5
SPEC, SCHEMATICS AND DIAGRAMS 372A3671

NOMENCLATURE IDENT
DIMENSIONS ARE IN INCHES .S.SUDHAKAR 10-02-26

GE Energy GAS TURBINE
2 PL DECIMALS ± BRIAN GALLAGHER 10-02-26
3 PL DECIMALS ±
ANGLES ± JASON LONG 10-02-26 DIAG,SCHEM PP- HIGH TEMP FUEL
FRACTIONS ±
.S.SUDHAKAR 10-02-26 GAS CHROMATOGRAPH
(CJ COPYRIGHT 2010 GENERAL ELECTRIC COMPANY
FIRST MADE FOR: STANDARD 4035
PROPRIETARY INFORMATION OF GENERAL ELECTRIC CAGE CODE
GENERAL ELECTRIC COMPANY. SIM TO:
1
143E2320 SHEET 1 Of 1
DT1N 7 5 I 2
8 7 6 5 4 3 2 SIZE
E
DWG. NO.
143E2781
SH.
1
REV.
- 1
REVISIONS
1. SEE DEVICE SUMMARY MLI 0414 FOR DEVICE SETTINGS AND RATINGS. SHEETS OF THIS DOCUMENT
2. THE REQUIREMENTS IN THE SYSTEM AND CLEANLINESS SPECIFICATION ARE THE SAME REVISION
INCLUDED IN MLI 0438 APPLY. LEVEL AS INDICATED.
3. THE TERM "OTHERS” USED ON THIS DRAWING IS DEFINED AS THE PLANT
4. REFER TO MLI 4063 CONNECTION AND LINE LIST FOR PROCESS DATA AND
ASSOCIATED NOTES. CONNECTIONS MARKED WITH ”PC” INDICATE
H CONNECTION BY OTHERS, CONNECTIONS NOT MARKED WITH ”PC” ARE GEE H
GEE CONNECTIONS, REQUIRED NO INTERFACE BY OTHERS, AND ARE NOT
SHOWN ON MLI 4063.
5. FOLLOW API 14.3 / AGA REPORT 11 FOR INSTALLATION AND REQUIREMENTS
FOR PIPE LENGTH PRECEDING AND FOLLOWING METER TUBE, MG2-4.
6. N/A
7. A TEMPORARY CONICAL STRAINER SUPPLIED BY G.E. IS TO BE INSTALLED (SEE
MLI A179).
8. REFER TO GAS FUEL STRAINER INSPECTION, CLEANING AND MAINTENANCE
RECOMMENDATIONS INCLUDED ON MLI 0438.
9. CONNECTIONS BETWEEN COMBUSTOR END COVERS AND THE FUEL GAS
SUPPLY MANIFOLDS MUST BE PITCHED SO THAT THERE ARE NO LOW POINTS.
ALL LIQUIDS WILL DRAIN TO EITHER THE FUEL MANIFOLD FOR ALL LOWER
HALF COMBUSTION END COVERS AND/OR TO THE COMBUSTION CAN FOR ALL
UPPER HALF COMBUSTION END COVERS. LIQUID MUST NOT BE PERMITTED
TO DRAIN TO THE LOWER CANS.
10. LOW POINT DRAIN BLANKED FLANGE CONNECTION.
G 11. SLOPED LINE FROM GAS COMPARTMENT AND MANIFOLD TO LOW
POINT CONNECTION.
G
12. N/A.
13. OTHERS MUST PROVIDE AN ANSI CLASS VI ISOLATION VALVE UPSTREAM OF
G.E. SUPPLIED EQUIPMENT IN ORDER TO ALLOW THIS EQUIPMENT TO BE
ISOLATED FOR MAINTENANCE ETC.
14. N/A
15. GAS FUEL MUST MEET GAS FUEL SPECIFICATION PROVIDED ON MLI 0438.
16. PRESSURE TAP FOR DELTA P PRESSURE TRANSMITTERS (MLI 557T)
MUST BE LOCATED SUCH THAT THE LINE WILL SLOPE CONTINUOUSLY BACK
FROM THE PRESSURE TRANSMITTER ARRANGEMENT TO THE MANIFOLD AND
COMPRESSOR DISCHARGE CASING.
17. STRAINER VENTING VALVE HAS PROVISIONS FOR A LOCK AND MUST BE
LOCKED IN THE CLOSED POSITION DURING OPERATION. IN ORDER TO
REMOVE ELEMENTS FOR REPLACEMENT OR CLEANING FOLLOWING
SHUTDOWN, ISOLATE FUEL GAS SUPPLY VIA AN UPSTREAM ANSI CLASS VI
ISOLATION VALVE, VENT PRESSURE IN STRAINER AND ATTACHED PIPING BY
OPENING THE VALVE. VERIFY PRESSURE HAS COMPLETELY VENTED BY
F CHECKING PRESSURE GAUGE PI-FG-1 AND BY MONITORING OUTPUT F
TRANSMITTER PT 96FG-1 BEFORE REMOVING STRAINER ELEMENTS IN
ACCORDANCE WITH STRAINER MANUFACTURERS INSTRUCTIONS IN
SERVICE MANUAL.
18. ISOLATION VALVES HAVE LOCKING PROVISIONS. VALVES TO BE
LOCKED IN THE OPEN POSITION PRIOR TO OPERATION.
19. THE HOT AND COLD FUEL MIXING TEE MUST BE LOCATED AT LEAST 15 LINEAR FT
[4.57 M] OF PIPING FROM FG1 AND MUST NOT BE GREATER THAN 100 LINEAR FT
[6.10 M] FROM FG1.
20. THE SAFETY SHUT OFF VALVE AND SAFETY SHUT OFF VENT VALVE ARE TO
BE INSTALLED OUTDOORS. THE PIPING VOLUME BETWEEN THE OUTLET OF
THE SAFETY SHUT OFF VALVE AND FG1 MUST NOT EXCEED 63.5 CUBIC FEET
[1.8 CUBIC METERS]. THE SAFETY SHUT OFF VALVE AND SAFETY SHUT OFF
VENT VALVE MUST BE INSTALLED SUCH THAT THEY ARE PROTECTED
AGAINST ICING.
21. REFER TO MLI 0482 FOR ADDITIONAL INFORMATION CONCERNING FUEL GAS
HEATING AND CONDITIONING EQUIPMENT.
E E
D D
C C
B B
2 STRAINER MAINTENANCE RECOMMENDATIONS GEK 111154

DIMENSIONS ARE IN INCHES
DRAWN
g GE Energy GAS TURBINE
SEE PLM 10-10-26
A 2 PL DECIMALS ±
3 PL DECIMALS ±
ANGLES ±
ENGRG
SEE PLM 10-10-26
A
FRACTIONS ± ISSUED
SEE PLM 10-10-26 DIAG, SCHEM PP-FUEL GAS
QUALITY
THIRD ANGLE PROJECTION

© COPYRIGHT 2010 GENERAL ELECTRIC COMPANY
FIRST MADE FOR: ML-9K1WFA141-1T6 0422
PROPRIETARY INFORMATION OF GENERAL ELECTRIC SIZE CAGE CODE DWG NO
E 143E2781
DISTR
GENERAL ELECTRIC COMPANY.
TO
SIM TO:
8 DT1N 7 6 5 4 3 2 1
MAXCASE: 0422, 91FA, REV.= 156
8 7 6 5 4 3 2 SIZE
E
DWG. NO.
143E2781
SH.
2
REV.
- 1
H H
SEE NOTES 13 & 15 PT SEE NOTE 5

96FM-4 PC
FG21
GAS FUEL
MG2-4
SUPPLY
PC
FG20
INSTRUMENT AIR
SEE NOTE 5
FUEL GAS FLOW MEASUREMENT SYSTEM 0639
PT
VTA VTA
96GN-1
H L
G PC PC PC G
FG2 FG3 FG7
NO NO
FULL BORE ORIFICE FG166
SEE NOTE 16
TYPICAL 6 PLACES AD-5A FROM MLI 0417, CLG & SLG
INSTRUMENT AIR AIR SYSTEM, “ LINE AD-5A”
TO TO
PIGTAIL PIGTAIL Ø 0.136 [3.45 MM]
PC 17 #18 TYPICAL 18 PLACES
FG996
D5 MG1-1
SEE
VTA
20VTC-200 NOTE 9
F VTA
0637 F
TC COMBUSTION CHAMBER 0512
I/P PT-G1-2
TC TC
90VTC-200 ZS
PC SEE NOTE 7 PT-G1-1 PT-G1-3
FG997 96VTC-200
PC INSTRUMENT AIR PT
FG138
FG995 96GN-2
PC H L
FC SEE NOTE 20
PC FG440
VTC-200 0962 PITCH PITCH
FG992 NO NO
SEE NOTE 11
COLD FUEL GAS TEMPERATURE CONTROL VALVE 0588 FG167
SEE NOTE 10 SEE NOTE 16
E 20VG-8 TO TO
AD-5B FROM MLI 0417, CLG & SLG E
ZS AIR SYSTEM, “ LINE AD-5B”
PIGTAIL PIGTAIL Ø 0.136 [3.45 MM]
33VG-8 17 #18 TYPICAL 18 PLACES
SEE NOTE 21
ZS
VTA VTA 33VG-9

PC PM1 MG1-2
FG438 SEE NOTE 7
INSTRUMENT AIR
PC FO SEE
VA13-18 PT
FG439 FG139 NOTE 9
PC 96GN-3
FG990 SAFETY SHUT OFF VENT VALVE 0572
COMBUSTION CHAMBER 0512 H L
PC PITCH PITCH
0962
FG428A SEE NOTE 11 NO NO
INSTRUMENT AIR
D PC PC
SEE NOTE 10 SEE NOTE 16
FG168
D
SEE NOTE 20 AD-5C FROM MLI 0417, CLG & SLG
FG428B FG427
TO TO AIR SYSTEM, “LINE AD-5C”
20VTC-100 PIGTAIL PIGTAIL Ø 0.136 [3.45 MM]
VTA
17 #18 TYPICAL 18 PLACES
I/P 20VS4-4
ZS
33VS4-4
PM4 MG1-3
90VTC-100 ZS SEE NOTE 7
PC ZS
FG991 96VTC-100 SEE
VTA VTA 33VS4-5
PC PC FG140 NOTE 9
FG989 FG426
COMBUSTION CHAMBER 0512
PC FO PC FC PC PITCH PITCH
C FG988
VTC-100
FG425 VS4-4 FG1
0962
SEE NOTE 11
C
SEE SHEET 3
HOT FUEL GAS TEMPERATURE CONTROL VALVE 0588 ACCESSORY MODULE SEE NOTE 10
A160
GAS COMPARTMENT
SAFETY SHUT OFF VALVE 0572
SEE NOTE 19
GAS FUEL PIPING 0962
TRANSMITTER ARANGMENT 557T
B B
A A
GENERAL ELECTRIC COMPANY SIZE CAGE CODE DWG. NO.
g GE Energy
E 143E2781
DISTR
DRAWN
CLAUDIA LINAN
TO
ISSUED SCALE SHEET
SEE PLM 2 of 4
8 DT1N 7 6 5 4 3 2 1
8 7 6 5 4 3 2 SIZE
E
DWG. NO.
143E2781
SH.
3
REV.
- 1
PC PC
FG3 FG7
AL-87
AL-88
PT PT PT NO
ASW-44
H DL-51
PI H
96FG-2A 96FG-2B 96FG-2C
DL-52 FG-2
SEE NOTE 18 IA-2 TO MLI 0420, COOLING
WATER SYSTEM
2 2 2
3 3 3 NO PA-10 FROM MLI 0477, FUEL
1 1 1 PURGE, “LINE PA-10”
IA-1 TO MLI 0477, PURGE AIR
SYSTEM
PDS PI
63FGD-1 FG-1
G NO G
PDI PT
FG-3 96FG-1
NC 2 VTA
20VG-1 2
3 3
S
1
1
NO NO
SEE NOTE 17 FO
0507
PC OH-2
20VS4-1 ZS OH-2 ZS
FG2 0509
33VS4-1 33VG-4
OLT-2
F NC F
ZS H PI
VA13-15 OH-18
33VS4-2 H D5
OH-17
PC VTA VTA
GPL-6 GPL-1 GPL-2
FG1
NO
FC FC FC
VS4-1
VGC-1
TC TC TC VSR-1
FTG-1A FTG-1B FTG-1C SEE SHEET 4
0929 SEE SHEET 4
SEE NOTE 8 0507 FG138
FROM MLI 0477, FUEL PA-4
PURGE, “LINE PA-4”
OH-2
E OH-2
E
0509
OH-17
H PI
TO MLI 0434 OH-19 1.00T OH-19
HYDRAULIC OIL, “LINE OH-19” PM1
GPL-3
HYDRAULIC OIL, “LINE OH-17”
1.00T
NO
FC
TO MLI 0434
VGC-2
SEE SHEET 4
TO MLI 0434 OH-18
HYDRAULIC OIL, “LINE OH-18” FG139
D D
OH-2
0509
H PI
TO MLI 0434, HYDRAULIC OH-20 1.00T OH-20
OIL, “LINE OH-20” PM4
GPL-4
NO
FC
VGC-3
C C
SEE SHEET 4
SEE NOTE 18 FG140

FROM MLI 0477, FUEL PA-6
FROM MLI 0434,HYDRAULIC OH-2
PURGE, “LINE PA-6”
OIL, “LINE OH-2”
NO
B B
ACCESSORY MODULE GAS COMPARTMENT A160
A A
g GE Energy
E 143E2781
DISTR
DRAWN
CLAUDIA LINAN
TO
ISSUED SCALE SHEET
SEE PLM 3 of 4
8 DT1N 7 6 5 4 3 2 1
8 7 6 5 4 3 2 SIZE
E
DWG. NO.
143E2781
SH.
4
REV.
- 1
H H
PDI
FH7-1 0507
OH-2 IN
OUT
FH7-1
G G
90SR-1
OH-17 20FGS-1
VH5-1 ZE
96SR-1
F F
GPL-1
ZE
96SR-2
VSR-1
SEE SHEET 3
E E
D D
PDI PDI
PDI
FH8-2 FH8-3
FH8-1
OH-2 IN OH-2 IN
OH-2 IN OUT OUT
OUT
0509 0509
0509 FH8-2
FH8-1 FH8-3
C C
20FGC-2 65GC-2 20FGC-3 65GC-3

20FGC-1 65GC-1 OH-19 OH-20
OH-18
ZE ZE
ZE VH5-3 VH5-4
VH5-2
96GC-4 96GC-7
96GC-1
GPL-3 ZE GPL-4 ZE
GPL-2 ZE
96GC-5 96GC-8
96GC-2
ZE ZE
B ZE B
96GC-6 96GC-9
96GC-3
VGC-2 VCG-3
VGC-1
SEE SHEET 3 SEE SHEET 3
SEE SHEET 3
A A
g GE Energy
E 143E2781
DISTR
DRAWN
CLAUDIA LINAN
TO
ISSUED SCALE SHEET
SEE PLM 4 of 4
8 DT1N 7 6 5 4 3 2 1
ANNEXURE-1: MANDATORY SPARES AND UNIT ASSEMBLIES
Mandatory Spares
A. Mechanical
Sno. Item Description Quantity
Elements for Filter seperator/scrubber at Fuel Gas conditioning
1 Two Sets
system
Full set of gaskets, 'O' rings etc. and gland seals for all
2 Two sets of each type
islolation, control and bypass valve of the system
3 Element Filter separator for Fine Filter Four Sets
B. Control and instrumentstion

Sno. Item Description Quantity
1 Measuring Instruments
a. Pressure/ Differential pressure transmitters, switches, level switches, 1 no. of each type, range & model
gauges/ local indicators etc.
b. Mass Flow meter 1 no.
c. Temperature elements 1 no. of each type, range and length
2 PLC system
a. All Electronic modules like I/O, Controller or CPU, Communication, One no. of each type
Interface and Power supply module (as applicable).
b. Power supply (if applicable). Two no of each type and size.

c. Cooling Fan in PLC system/ cabinet One no.
d. Work station complete with all hardware, 1 set.
accessories and System & application and Engineering software
including monitor.
e. Batteries used for battery backup of RAM’s Two nos. of each type
f. Pre-fab cables with connectors One no. of each type
g. All type of fuses 20% of each type & rating
Relays 10% of each type, model & rating
3 UPS
All Electronic modules of Charger, Inverter and Bypass module. 10 % of each type/model OR
minimum one no whichever is
higher.(Any fraction to be
considered as next higher digit)
4 Process connection & piping
a. Valves of all types 10% of total population
b. Valve manifolds 10% of each type, class, size and

model
c. Fittings of each type 10%
d. Filter regulators 20% of each model
5 Control Valves
a. Actuator 1 no. of each type/ model/ rating
b. Valve trim (Cage, plug, stem, seat rings, guide bushings etc.) 1 set for each type of control valve
c. Diaphragms, ‘O’ rings’, seals etc. of all types 1 complete set for each type of
control valve
d. Positioner unit (Complete) 1 no. of each type
e. Air Lock relay 1 no. of each type
6 Solenoid valves One no. of each type & rating.
SAMALKOT CCPP EXPANSION SPECIFICATION FOR FUEL GAS CONDITIONING SYSTEM
Part II
SECTION - B
REL-SKCCP-NEM-161-P-00001(Rev.00) PART II SECTION B Page 1 of 9

1.00.00 SYSTEM DESIGN BASIS & OPEARTING CAPABILITY
1.01.00 General
The equipments of the Fuel gas conditioning system shall be designed to meet all
the operational condition that system is expected to run during normal and transient
operation.
Dry, clean natural gas should be supplied to the GT’s in order to prevent corrosion,
erosion and the formation of deposits on the system components.
The gas conditioning system should be designed considering that the pressure of the
natural gas at the skid outlet must be relatively constant regardless of the rate at
which it is supplied.
The purposes of the Fuel Gas Conditioning System are targeted to achieve the
following
a. Supply of fuel Gas to the Gas Turbine at required pressure and
temperature.
b. Remove the condensate and dust particles from Fuel Gas.
c. Metering of fuel gas supplied to the plant
d. Analysis of the fuel gas composition
e. Provide heating of fuel gas during startup and for improvement of
performance during normal operation of gas turbine.
1.02.00 Fuel Gas Conditioning System Performance
The system must be guaranteed to provide the Fuel gas at Gas Turbine Accessory
module gas compartment inlet as per attachment GEI41040k_FuelGasSpec.
1.03.00 Design Philosophy
Each equipment of the system shall be designed for the fuel gas flow and pressure
requirement corresponding maximum Gas Turbine output at Minimum ambient
temperature as specified in Part-II Section –C of this specification
1.04.00 Basic Design Parameters
The components of the fuel gas supply system shall be designed for the
parameter as specified in Part-II Section C of this specification
1.05.0 Design and Operating Conditions
The fuel gas conditioning system shall be designed for the gas flow when Gas
Turbine is running at Max. Capability point (EC ON, ISO condition)
REL-SKCCP-NEG-E24-P-00003, Rev.00 PART II SECTION B Page 2 of 9

1.06.00 Insulation and Cladding
Insulation shall be provided at all the equipments, piping, valves and fittings with
temperature more than 60°C
1.07.00 Control & Instrumentation
The equipments of Fuel gas supply system shall be provided controls and
instrumentation for the safe and efficient operation.
1.08.00 CONTROL & OPERATION PHILOSOPHY
An indicative control & operation philosophy is outlined below. The details of the
same shall be discussed & finalized during detailed engineering taking into
consideration Bidder’s standard practices and applicable codes/ standards.
The plant Emergency shutdown valve at the plant boundary shall close on major
hazardous conditions like fire etc. It would typically be gas operated with solenoid on
the gas line. The valve operation shall be safe and reliable. The design shall be such
that false trips are avoided.
The knock-out drum shall have auto draining facility on level/ operator selectable
timer.
The absolute filter/ Filter separator shall also have auto draining facility on level/
operator selectable timer (if applicable).
The Pressure reducing station shall be self-regulating type. The response shall be
fast enough to ensure meeting the requirements of the Gas turbines as outlined
elsewhere.
Temperature control shall be provided for the water bath heater as per the standard
practice of the Bidder. The control of the Water bath heater may be implemented
either by means of an integral microprocessor or by means of the PLC system being
supplied under the package. In case an integral microprocessor based controller is
provided with the Water Bath heater, then the same shall be connected to the PLC
system of the Fuel Gas system.
Temperature control at Efficiency heater outlet shall be by means of control valves

on the Steam line to the heater.
All required parameters shall be made available to the operator through suitable
displays on the Operator workstation along with alarms on the same exceeding pre-
set limits. As a minimum, these shall include instantaneous values of Fuel gas flow,
Fuel gas composition/ Calorific value (from Chromatograph), Fuel gas pressure,
temperature at different locations in the Gas path, alarm on Differential pressure
across Filter separators, high level in knock out drum, low pressure/ temperature,
high temperature, high level in condensate tank, fire etc. Further, integration of the
fuel gas flow shall also be incorporated in the PLC system to monitor cumulative
flow.
The drain pump from condensate tank shall be manually operable from the PLC
system HMI and Local PB station.

2.00.00 CODES AND STANDARDS
2.01.00 The design, manufacture, fabrication, installation, identification and testing of

equipment covered by this specification shall comply with the latest edition of the
appropriate standards of the following unless specified otherwise,
• American Society of Mechanical Engineers - Boiler and Pressure Vessels

Code.
• ASME Performance Test Codes
• American Society for Testing of Materials.
• Standards of the Heat Exchange Institute of USA.
• Standards of the Hydraulic Institute of USA.
• IEC Publication Nos. 45 & 46 on specification and rules for testing steam
turbines.
• Indian Electricity Act
• Indian Electricity Rules
• Tubular Exchanger Manufacturer’s Association Standards
• Other national equivalent or higher quality than stipulated above shall be
acceptable.
3.00.00 PERFORMANCE GUARANTEES
3.01.00 The bidder shall guarantee that the equipment offered shall meet the rated
performance and functional requirement stipulated in this specification. All
equipments and accessories shall be guaranteed to operate without pulsation,
noise or vibration while operating under normal operating conditions. The
contractor shall carryout the performance test for establishing the guarantee
parameters as mentioned in Part II Section A Clause No. 8.00.00 of the
specification.
3.02.00 If the equipment does not meet the guarantee in any respect or for any reason
whatsoever, it would be necessary for the manufacturer to make the alteration for
meeting the performance guarantee. The alterations shall be made and additional
test required showing the effect of such alteration shall be performed by the
manufacturer at no contractual obligation to the Owner.
4.00.00 SYSTEM TRIAL OPERATION
4.01.00 In accordance with the Part III Section I General Technical Requirement, after
commissioning the complete system described above & before handing over the
complete system shall be subjected to system trial operation and performance and
Guarantee Tests to demonstrate the guarantee of the system offered. Duration of
the trial operation of the complete equipment shall be (14) days with minimum
operation of 16 hrs a day out of which at least seventy two (72) hours shall be
continuous operation on full load
4.02.00 On completion of all pre commissioning activities/tests and as a part of

commissioning the complete facilities shall be put on 'Trial 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.

4.03.00 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 facility/equipment.
4.04.00 For the period of 'Trial Operation', the time of operation with any load shall be
counted. Minor interruptions not exceeding four (4) hours at a time caused during
the 14 days trial operation period shall not effect the total duration of Initial
Operation. If in the opinion of the Owner the interruption is long, the Trial
Operation shall be prolonged for the period of interruption.
4.05.00 A Trial Operation report comprising of observations and recordings of various

parameters to be measured in respect of the above Trial Operation shall be
prepared by the Contractor. This report, besides recording the details of the
various observations during trial operation shall also include the dates of start and
finish of the Trial Operation and shall be signed by the representatives of both the
parties. The report shall have log sheets, recording all the details of interruptions
occurred, adjustments made and any minor repairs done during the Trial
Operation. Based on the observations, necessary modifications/repairs to the plant
shall be carried out by the Contractor to the full satisfaction of the Project Manager
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.
5.00.00 PERFORMANCE AND GUARANTEE TEST PROCEDURE
5.01.00 The term “Performance Guarantees” wherever appears in the Technical

Specifications shall have the same meaning and shall be synonymous to
“Functional Guarantees”. Similarly the term “Performance Tests” wherever appears
in the Technical Specifications shall have the same meaning and shall be
synonymous to “Guarantee Test(s). The plant shall be subjected to performance
and guarantee tests on successful completion of trial operations. Detailed P&G test
procedure shall be submitted for Owner’s approval.
5.02.00 Performance Testing shall be done based on code subject to owner’s approval.
5.03.00 Test shall be conducted at the manufacturer’s works / site in accordance with the
specification and if the shop / site performance tests indicate the failure of the
guaranteed performance for the equipment concerned, it would be necessary for
the manufacturer to make good the deficiency at his own cost by incorporating the
necessary modification, alteration and replacement. The alterations shall be made
and additional test required showing the effect of such alteration shall be
performed by the manufacturer at no expense to the Owner.
5.04.00 Test Records: The certificates and records of all tests shall be submitted to the
owner for approval. The manufacturer shall maintain records of all tests required in
the specification during manufacturing, erection and commissioning. A list of
records shall be submitted to the owner on completion of the job. The Owner shall
be able to obtain certified copies of such records at any time.

6.00.00 SPARE PARTS
6.01.01 The contractor shall indicate and include in his scope of supply all the necessary
mandatory spares and recommended spares in the relevant schedules. The
variation in quantity of spares based on unit rates (rates as quoted for mandatory
spares and rates as mutually agreed for recommended spares), if desired by the
owner shall be acceptable to the contractor.
6.01.02 The owner reserves the right to buy any or all mandatory and recommended
spares. The contractor shall identify service expectancy period for all items of
spares, under normal operating conditions before order placement.
6.01.03 The Contractor shall also indicate the unit wise population of each item and the
service expectancy period for the spare parts (both mandatory and recommended)
under normal operating conditions before order placement.
6.01.04 All spares supplied under this contract shall be strictly interchangeable with the
parts for which they are intended for replacements. The spares shall be treated
and packed for long storage under the climatic conditions prevailing at the site, e.g.
small items shall be packed in sealed transparent plastic bags with desiccator’s
packs as necessary.
6.01.05 Each spare part shall be clearly marked or labeled on the outside of the packing
with the description. When more than one spare part is packed in single case, a
general description of contents shall be on the outside of such case and a detailed
list enclosed. All cases, containers and other packages must be suitably marked
and numbered for the purposes of identification.
6.01.06 Purchase specification & addresses of procurement sources of all mandatory

spares & recommended spares shall be furnished.
6.02.00 MANDATORY SPARE PARTS
6.02.01 The list of mandatory spares which are considered essential by the owner is
indicated in enclosed Annexure – I. The owner reserves the right to buy any or all
mandatory spares. The Bidder shall include all the mandatory spares in his
proposal. The bidder shall furnish in the relevant schedule of Bid Proposal sheets,
the item wise (including unit rates) and total price for these spares mentioned in the
Annexure I. Further whenever the spares are indicated in percentage and
numerical figures, arrived is in fraction, the same shall be converted to the next
whole number.
6.02.02 In line with the requirements, the prices for mandatory spares indicated separately
shall be used for bid evaluation purposes. All mandatory spares shall be delivered
at site at least two months before scheduled date of trial operation of the gas
conditioning and heating system. However, spares shall not be dispatched before
dispatch of corresponding main equipment.
6.03.00 RECOMMENDED SPARES
6.03.01 In addition to the spares mentioned above, the contractor shall also provide a list of
recommended spares with unit and total prices for 3 years of normal operation of
the equipment for indigenous spares and 5-years for imported spares in relevant
schedule of Bid Proposal Sheets. The recommended spare list shall take into
consideration the mandatory spares specified in Annexure – I and shall be

independent of the list of the mandatory spares. The Owner reserves the right to
buy any or all recommended spares. The recommended spares shall be delivered
at project site at least two months before the scheduled date of trial operation of
the equipment. However the same shall not be dispatched before the dispatch of
the main equipment.
6.03.02 Prices for recommended spares will not be used for evaluation of Bids. The prices
of these spares will remain valid up to 12 months after placement of order for
equipment. The Owner reserves the right to buy any or all recommended spares.
Further, the prices of recommended spares wherever common with the mandatory
shall be the same as those of mandatory spares. Prices of recommended spares
not listed as mandatory spares shall be reviewed by Owner and shall be mutually
agreed upon with the contractor. However, the contractor shall be liable to provide
necessary justification for the quoted prices for the spares described by the Owner.
6.04.00 START – UP COMMISSIONING SPARES
Start-up commissioning spares are those spares which may be required during the
start-up and commissioning of the equipment. All spares used until the system is
handed over to the owner shall come under this category. The contractor shall
provide for an adequate stock of such start-up commissioning spares to be brought
by him to the site for plant erection and commissioning. They must be available at
site before the equipments are energized and the unused spares, if any, should be
removed from there only after the issue of taking over certificate. All start up spares
which remain unused at that time shall remain the property of the Contractor. The
list of commissioning spares to be brought by the contractor to ensure smooth
commissioning of the plant shall be subject to Owner’s approval. The Contractor
shall submit a complete list of all such start-up commissioning spares. The cost of
above spares if any and that consumed before the handing over of the plant shall
be deemed to have been included in the lump sum proposal price of the package
and the Contractor shall have no claim on this account to the Owner. All cases,
containers, other packages are liable to be opened for such examination, as may
be considered necessary by the Owner.
7.00.00 TYPE TESTS & TYPE TEST CHARGES
7.01.00 All equipment to be supplied shall conform to type tests as per relevant standards
and proven type.
7.02.00 The Bidder / contractor shall furnish the reports of all the type tests carried out
within five years for electrical equipment / items from the date of bid opening as per
specification and relevant standards for all components / equipment/ systems. For
other equipment / systems, the type test shall be applicable as mentioned in the
Part II, Section C of the specification. These reports should be for the tests
conducted on identical / similar components / equipment / systems to those offered
/ proposed to be supplied under this contract.
7.03.00 In case contractor is not able to submit type test(s) reports conducted in the last
five years (applicable for electrical equipment / items only), or in case type test
reports are not found to be meeting the specification / relevant standard
requirements/ finalized document for any item/equipment, then all such tests shall
be conducted under this contract by the contractor, without any contractual
implications what so ever and reports shall be submitted for approval.

7.04.0 All acceptance and routine tests as per prevalent standard and specification shall be
carried out. Charges for these shall be deemed to be included in the bid price.
8.00.0 DATASHEET
8.01.0 Fuel Gas Supply System
Sl.No. Description Unit Data

1.0.0 Fuel Gas Supply System
1.1.0 Location of Supply point At one point in plant boundary.
Pr. 60 Bar (g) and
1.2.0 Terminal pressure/temperature 22 °C
Fuel gas design flow rate (Total for 3
modules at Max. GT capability+ 2 LMS
1.3.0 100 GTs) kg/s 100
2.0.0 Emergency Shutdown Valve

2.1.0 Numbers 1x100% for Station
Gas fuel design flow rate (Total for 3
2.2.0 modules at Max. GT capability) kg/s 100
2.3.0 Location Upstream of Metering station
2.4.0 Material of construction Carbon steel
3.0.0 Fuel gas Metering Staion

3.1.0 Numbers 1x100% for Station
Coriolis type mass flow
3.2.0 Type meter/ultrasonic type
3.3.0 Range Kg/sec Zero to 100
4.0.0 Knock out drum

4.1.0 Numbers 1 x 100% for Station
4.2.0 Rated Capacity kg/s 100
4.3.0 Internals Fixed/ double Cyclone
4.4.0 Construction code ASME Sec.VIII, Div. I
4.5.0 Material of construction(Shell, Head) ASTM A 106 Gr.B
5.0.0 Filter separator

5.1.0 Number 3x50 % skid for Station
5.2.0 Rated Capacity of each filter kg/s 50
6.0.0 Fuel Gas Startup Heater

2x50 % for Station
6.1.0 Numbers (Total 2 nos.)
6.2.0 Type Indirect Water bath/ Glycol Heater type
6.3.0 Rated Capacity kg/s 50
7.0.0 Gas Pressure Reducing Station

7.1.0 Numbers 3x50 % skid for Station
7.2.0 Type Self regulating type
7.3.0 Range of each skid Kg/sec Zero to 50

8.0.0 Absolute Filter

2x100 % for each Gas Turbine
8.1.0 Numbers (Total 12 Nos.)
8.2.0 Flow rate kg/s 14.5
8.3.0 Internals Fibre Glass Cartridge /AISI 316 Vanes
8.4.0 Droplet removal efficiency % As per “GEI41040k_FuelGasSpec”
8.5.0 Dust removal efficiency As per “GEI41040k_FuelGasSpec”
8.6.0 Construction code ASME Sec. VIII, Div. I
9.0.0 Fuel Gas Efficiency Heater

1x100 % for each Gas Turbine
9.1.0 Numbers (Total 6 Nos.)
9.2.0 Type Shell and tube
9.3.0 Flow rate kg/s 14.5
10.0.0 Scrubber skid

1x100 % each GT
10.1.0 Numbers (Total 6 nos.)
10.3.0 Rated Capacity of each kg/s 14.5
11.0.0 Condensate collection tank

Total 7 (One at plant boundary for
knockout drum + one each for 6 GTs
11.1.0 Numbers for absolute filters and scrubber)
11.2.0 Type Horizontal, Atmospheric
3 m3 (for Knockout drum)
11.3.0 Capacity* 1 m3 (for absolute filters and scrubber)
11.4.0 Fluid Natural gas condensate
* To be confirmed during detail engineering

PART II
SECTION C
MECHANICAL
CHAPTER – M 1
REL-SKCCP-NEM-161-P-00001 (Rev.00) Part II/ Section C Page 1 of 8

1.00.00 GENERAL
This Chapter describes the System description, Basic Design Criteria and Minimum
Technical Requirements of Fuel Gas Conditioning System
The fuel gas conditioning system shall be capable of providing clean, dry gas as
acceptable to the gas turbine's fuel gas quality requirements. The system shall be
capable of providing the required quantity under the maximum fuel consumption
condition without affecting the operation and efficiency of the gas conditioning system.
It is intended that Bidder shall offer his standard and proven equipment for this
specification. Material of construction, design and construction of components,
performance testing of equipment and system, etc. shall be in accordance with
- ASME - Code for pressure vessels section - VIII Division – 1
- Applicable standards of API
- ANSI standards
- IEC /VDE standards.
3.00.00 TECHNICAL REQUIREMENT
3.01.00 Fuel gas conditioning plant shall be designed to meet the 9FA & LMS 100 gas turbine
requirements and as a minimum arrest liquid droplets and solid particles with a
combined efficiency of 99% down to 1 micron or lower subject to the acceptable limit
of GT. Liquid carryover in the gas stream shall not be more than 0.25% by weight.
3.02.00 Gas conditioning plant including the main pressure reducing station shall be designed
to handle combined gas flow for unit (s) running at maximum load conditions. A slam
shut valve shall be provided to isolate the system in emergency. The piping between
the downstream of reducing station and individual GT should have buffer volume to
ensure safe changeover to between regulating valves, should the active control valve
fail.
3.03.00 Unit shall be capable of running smoothly through out the operating load range of GT
unit (s).
3.04.00 Equipment shall be installed in power plant battery limits and as such
the same shall be suitable considering the safety and environmental
requirements as per the statutory codes. T
3.05.00 The equipments and piping are to be assembled in a neat and compact
manner on skid with adequate maintenance access and shall be suitable for outdoor
installation.
3.06.00 The gas velocity through the pipes shall be restricted to 20 m/s.

3.07.00 Emergency Shut Down Valve (Slam Shut Off) (1x100% for 3 modules)
The Emergency Shut down Valve (ESD) valve shall be of solenoid operated
pneumatic valve type with manual isolation valves and shall have 100% capability by
pass valve.
(a) Design Pressure: 65 kg/cm2 (g)
(b) Design Temperature 50°C
(c) Flow range 0 to 100Kg/sec
3.08.00 Knock Out Drum (1x100% for 3 modules)
(a) Function: Shall separate any carry over liquid

in the incoming gas supply
(b) Material of construction ASTM A515 Gr. 70
(c) Design Pressure: 65 kg/cm2 (g)
(d) Design Temperature 50°C
(e) Flow range 0 to 100 Kg/sec
(f) Removal efficiency 100 % of particles > 8 microns
(f) Design Codes: ASME Boiler and unfired pressure

vessel code, Section-VIII, Div.1
(g) Accessories: Automatic level control and

Liquid control drain valves.
(h) Max allowable pressure drop 0.05 bar
3.08.01 Knock out drum shall be provided common for all three modules. Knockout drum shall
be designed to remove bulk suspended gas borne dirt and liquid particle in the gas
stream. The separator shall be of fixed internal type with double cyclone, feed
deflectors, liquid level controller, level gauges, relief valves, pressure gauges,
differential pressure indicator/transmitter, sludge drain, purging connection,
temperature gauge supports, etc.
3.08.02 Knockout drum shall be of vertical construction. A liquid collection zone with automatic
draining facility shall be provided in drum bottom for collection of any liquid separated
from the gas stream. A separate drain nozzle shall also be provided.
3.08.03 Gas supply line shall have tangential entry to the gas liquid vessel.

3.08.04 The equipment shall be fitted with drain valves, a lockable vent valve connection
leading to the vent system, a pressure safety valve and vessel purge connection
3.09.00 Fuel Gas Metering Station (1x100% for 3 modules)
A Gas flow meter in common supply line to three modules at a location downstream of
ESD valve shall be provided to measure the total fuel consumption for the plant The
Fuel gas flow metering station shall be of coriolis type mass flow meter/ultrasonic flow
meter. It shall have isolation as well as bypass valve arrangement. For further details
of the meter refer C&I portion of this specification in Section-C of this specification
3.10.00 Filter Seperator (3x50 % for station)
3X50% filter separator skid shall be provided for removing dust and moisture from the
fuel gas. The features of the filter separator shall be as follows
Material of construction Steel plate as per ASTM A 515

Design pressure 65 Kg/cm2
Design Temperature 50 °C
Flow range for each filter 0-50 Kg/sec
Design code ASME boiler and unfired pressure vessel code,
Section- VIII , Div. 1
Dust separation efficiency 99.5%, >=5 micron
Accessories Gauge glass for drain pots, pneumatically
operated drain control valve & liquid level
controller, a differential pressure switch,
pressure gauge at the outlet flange of each
seperaor.
3.11.00 Fuel Gas Startup Heater (2x50 % for three module)
The bidder shall check the gas analysis from the standpoint of hydrate formation
downstream of the pressure reducing station under the worst ambient temperatures
prevalent at site. Accordingly, a suitable rated natural gas fired water bath/ Glycol
heater shall be provided ahead of the pressure reducing station for individual gas
turbine units.
3.11.01 The heater shall be designed for getting Gas Temperature of 70ºC at inlet of fuel gas
accessory module of Gas Turbine. It shall be ensured that the temperature of gas
after pressure reducing station is at least 20 deg.C higher than the hydrate forming
temperature or the gas dew point, whichever is higher.
3.11.02 Control system shall ensure that the temperature of gas at the outlet of heater is
constant for gas flow range of 0-50% (0 to 50 Kg/sec).

3.11.03 The design pressure shall be 65 Kg cm2 (g)
3.11.04 A full capacity bypass of the heater shall also be provided.
3.11.05 Max. allowable pressure drop shall be 0.5 Bar
3.12.00 Gas Pressure reducing station (3x50 % for Station)
2X100% Gas pressure reducing stations with necessary control and instrumentation
suitable for each module. One low load control valve capable of handling 10% of full
flow of the control station shall be furnished for the low load and startup fuel demand
of the station. The pressure reducing station shall be designed to reduce maximum
incoming pressure to the pressure needed for the gas turbine after accounting for the
losses in the piping and valves.
(a) The pressure at outlet : 40 bar (to be confirmed during

detailed engineering)
(b) Maximum Fuel Gas Flow : 50 Kg/sec
(c) Minimum Temperature at inlet : 15 °C
(d) Maximum Temperature at inlet : Out let temp. of Start up heater
(e) Maximum Allowable downstream pressure : 59 bar
(f) Maximum Allowable inlet pressure : 60 bar
(g) Maximum allowable pressure drop : 0.5 bar
(h) The pressure reducing skid shall have self actuated pressure control vale, slam
shut off valve and safety blow off valve with all required instrumentation and
accessories. The Pressure control requirement shall be as follows
Closing time (Safety shut-off valve) s ≤1

Response time (Safety shut-off valve) s ≤ 0.3
Regulating precision steady state % +/- 2%
Regulating precision transient operation % +/- 5%
Closing precision % 2.5
Response pressure category % 3
Travel time full stroke (for pneum. Valve only) s 0.8
3.13.00 Absolute Filter (2x100 % for each Gas Turbine)
2x100 % Absolute filters shall be provided for each Gas Turbine to meet the quality of
gas as required by Gas turbine. These filters are provided on the fuel gas line
downstream of the fuel gas performance heater. The filter provides the final level of

filtration for Gas Turbine as per attached document “GEI41040k_FuelGasSpec” for

Gas quality
(a) Maximum Fuel Gas Flow : 14.5 Kg/sec

(b) Minimum Temperature at inlet : 15 °C
(c) Operating Temperature : Out let temp. of Start up heater
(d) Design pressure : 45 bar
(e) Maximum allowable pressure drop : 0.2 bar
Fine filter shall be equipped with differential pressure transmitter and pressure and
temperature indicator at inlet and outlet
3.14.00 Fuel Gas Performance/ Efficiency Heater(1x100 % for each Gas Turbine)
Performance heater shall be provided for individual gas turbine units. It shall be
designed for Gas Temperature of 185ºC at Heater Outlet. One IP water fuel gas
heater with flow from IP economizer and condensate going to the
condenser/condensate discharge pump line shall be provided. A gas separator shall
be provided downstream of the performance heater to avoid water intrusion in the
event of a tube leak. Furthermore, exit water shall be monitored and vented for gas
entrainment. The heater shall have temperature control valve on heating line and cold
leg bypass line up to the to hot and cold mixing point.
a) Design Temperature
Water side :260 °C
Gas Side :185 °C
b) Design Pressure
Water side :80 Bar g
Gas Side :45 Bar g
c) Min. Gas Temperature at inlet of heater : 15 °C
d) Max. Gas Temperature at inlet of heater : 50 °C
e) Gas Temperature at outlet of heater
Minimum : 62.2 °C
Maximum : 185 °C
Operating : 107 °C
f) Maximum Gas Flow : 14.5 Kg/sec
g) Maximum Allowable pressure drop
Water side : 0.7 bar
Gas Side : 0.5 bar

h) IP Economiser outlet parameters :38 Bar g and 230 °C (to be

confirmed during detail
engineering)
3.14.01 Shell and tube type design with u tubes is preferred Stainless steel material shall be
used on gas side.
3.14.02 Flanges shall be welded type
3.15.00 Scrubber units(1 x 100% for each GT):
(a) Material of construction: Steel plates as per ASTM A 515

grade 70.
(b) Design Pressure: 40 kg/cm2 (g)
(c) Design Temperature 200°C
(d) Flow range 0 to 14.5 Kg/sec
(e) Design Codes: ASME Boiler and unfired pressure

vessel code, section - viii, Div.1.
(g) Accessories: Gauge glass for drain pots, pneumatically

operated drain control valve & liquid level
controllers, a differential pressure switch,
pressure gauges at the outlet flange of each
separator.
(h) Max allowable pressure drop 0.2 bar
3.15.01 The 1x100% capacity Scrubber shall remove any leftover moisture in the gas.
3.15.02 Each type of separator shall be provided with a drain collection chamber with
automatic draining facility.
3.15.03 Filter unit shall be of horizontal / vertical construction. Liquid collection zone shall be
provided at the bottom with automatic draining facility.
3.16.00 Gas Vents
All vents and safety relief valves in the fuel gas system and condensate drain tanks
shall be sized to cope with the maximum gas flow. Vent lines shall be suitably routed
through individual pipes to a common cold stack for venting/flaring.
3.17.00 Fuel Condensate drainage
All hydrocarbon drains shall be connected to a suitably sized condensate drain

tank (one for Knock out drum and one for each module for Fine filters).

Necessary arrangements and means to collect the condensate in condensate

drain tank, and pumping it to a burning pit (located at an isolated place within the
plant boundary) or transferring to barrels meeting the entire statutory requirement
shall be provided by the bidder.
3.18.00 Valves
i) Ball valves shall be used in gas lines. All ball valves shall be of fire safe design
(class VI shutoff). The trims of all the ball valves, safety valves, slam shut off valves
and control valves etc. in the fuel gas system shall be made of stainless steel
material of suitable grade to avoid the possibility of corrosion.
ii) Proper access and operating platforms shall be provided for the operation and
maintenance of the equipments / valves etc.
3.19.00 The entire gas piping system shall have provision for nitrogen purging.
3.20.00 All Electricals and instruments in connection with fuel gas handling shall be of flame
proof / explosion proof type.
3.21.00 Welding shall be generally as per ASME. Stress relieving as required shall also
conform to the same.
3.22.00 Bidder shall submit sizing calculation for Gas supply system's equipment during
detailed engineering for Owner's approval.
3.23.00 The Fuel Gas supply Piping system shall be designed in accordance with the
applicable provisions of the latest editions of ANSI B 31.3 and ANSI B31.8.
3.24.00 All pressure vessels in the Gas Supply system i.e. knockout Drum, scrubber units,
and Fine filter separator units shall be provided with pressure Relief Valves. Relief
valves shall be designed such as to protect downstream equipment in case of
pressure rise above the safe limit.
3.25.00 All pressure vessels shall be constructed in accordance with ASME code for pressure
vessel section VIII Div. 1 with the exception of being required to by hydro-tested at 1.5
times the design pressure to allow for piping and equipment to be hydro-tested as a
system. The shell and the heads shall be provided with a corrosion allowance of 3
mm. In addition mill tolerance and thinning allowance shall be provided. All pressure
vessels shall be equipped with a sentinel relief to control overpressure due to
pressure changes as a function of ambient temperature variations.
3.26.00 Manhole of at least 500 mm diameter shall be provided for Knockout drum and filter
separator, if applicable, with suitable clean out connections at bottom, drain, vents,
etc.
Note: The design parameters given above for all the equipments are to be verified by
the vendor as basic engineering is in their scope. These parameters shall be
finalized during detail engineering.

Technical Specifications for Fuel 2400 MW SAMALKOT CCPP
Gas Conditioning System EXPANSION
PART II
SECTION C
MECHANICAL
CHAPTER- M 2
LP PIPING SYSTEM & ACCESSORIES

CHAPTER NO. BM8
LP PIPING SYSTEM & ACCESSORIES
INDEX
CLAUSE NO. DESCRIPTION
1.00.00 GENERAL INFORMATION
3.00.00 SCOPE OF SUPPLY / SERVICES
4.00.00 TECHNICAL REQUIREMENTS
5.00.00 INSPECTION AND TESTING

1.00.00 GENERAL INFORMATION
1.01.00 Interconnecting piping and valves for the systems which include Raw Water
Supply System, Circulating Water and Auxiliary Cooling Water System, Auxiliary
Water System, DM Water System, Compressed Air System, Gas Fuel, Effluent
lines, Service and Portable water supply and distribution system including Service
water tank and portable water tank etc. between various power plant equipment /
areas in the plant battery limit are covered in this specification.
1.02.00 It is not possible to specify all interconnecting piping and valves associated with
systems of balance of plant, however, piping and valves for any service whether
mentioned or otherwise required for completion of the system of power plant are
deemed to have been included in the scope of specification.
The design, manufacture, fabrication, installation and testing of piping covered by

this specification shall comply with latest edition of the appropriate equivalent
international standards, all currently applicable statutes, regulations and safety
codes in the locality where the piping shall be installed. Minimum following
standards or equivalent Indian / International standard shall be followed:
AISC American Institute of Steel Construction Specification
Manufacturers Standardization Society of the Valve

MSS
and Fittings Industry
Specification for sluice valves for water works
IS 780
purposes (50 to 300 mm size)
Code of practice for use of structural steel in general
IS 800
building construction
API 5L/6L Specification for Pipeline
API-598 Valve inspection and testing.
API-600 Steel gate valve (flanged or butt welding ends)
AWWA American water works association steel pipe manual.
EJMA Expansion Joint Manufacturers Association.
IS-8062 Code of practice for cathodic protection of steel

(Part II) structure
IS - 226 Structural Steel standard quality
Dimensions for pipe threads where pressure tight

IS-554
joints are required on the threads.

Gunmetal gate, globe and check valves for general

IS-778
purposes
IS-1239 Mild steel tubes, tubular and other wrought steel

(Part - I & II) fittings.
Black hexagon bolts, nuts and lock nuts (dia 6 to 39
IS-1363
mm) and black hexagon screws (dia 6 to 24mm)
Precision and Semi-precision hexagon bolts screws,
IS-1364
nuts and lock nuts (dia 6 to 39mm)
IS-2016 Plain Washers
IS-2062 Structural Steel (fusion welding quality).
Code of practice for selection, installation and

IS-2685
maintenance of sluice valves.
IS-3138 Hexagonal bolts and nuts (M 42 to M 150)
Electrically welded steel pipes for water, gas, sewage

IS - 3589
(200 to 2000mm nominal diameter)
IS-4682 Code of practice for lining of vessels and equipment
(Part-I) for chemical process - rubber lining.
IS-4736 Hot dip zinc coating on steel / steels.
3.00.00 SCOPE OF SUPPLY / SERVICES
3.01.00 The Scope of Low Pressure (LP) piping & Accessories shall cover complete piping
systems for the various systems as described in chapters of Part II, Seaction A &
Section C of this technical specification read together with the corresponding
P&IDs.
The scope shall include complete fuel gas piping from terminal point at plant
boundary upto the Fuel Gas Accessory compartment of individual Gas Turbine
consisting broadly of the following systems and any Other piping system as per
agreed schematic
(i) Pipes and fittings
(a) Piping, fittings, plugs, stubs, flanges and other accessories for the
piping systems identified above and as per approved schemes.
(b) The Bidder shall supply all standard and non-standard matching
pieces as may be needed within the piping system and for
connection of piping systems at various
equipments/tanks/vessels/valves and components.
(c) Pipe stubs for mounting thermo wells and other instrumentation
along with necessary reducers/matching pieces and instrument
tubing.

(ii) Valves and Specialities
(a) Valves, actuators and specialities including expansion joints, orifice

plate assemblies, steam traps, strainers, instrument root valves,
etc. for the systems specified and approved schemes.
(b) The Bidder shall also supply special accessories like floor stands,
chain operator, extended spindle etc. as required. Valves,
especially for which approach from existing floors are not possible
for O&M, bidder shall provide appropriate platforms with the access
ladders for the same.
(iii) Hangers and Supports
(a) All pipe supporting elements such as constant load spring hangers,
variable spring hangers, supports, guides, restraints, stops, etc.
and all associated auxiliary steel and hardware such as beams,
channels, insert plates section attachments to pipe supports, pipe
and beam clamps, straps, slings, stools, shoes, saddles, devices,
rods, turn buckles, graphite/Stainless steel plate/ Teflon sheet etc.
for all the systems specified.
(b) Dampers to control pipeline vibration.
(c) The Bidder shall also design and provide for additional guides/
stops/restraints etc. along with auxiliary steel for control of pipeline
vibration within allowance/acceptable limits
(iv) Snubbers
Snubbers or shock absorbers as required for the critical steam piping

systems to take up forces due to impact and surge forces arising from
sudden closure of turbine stop valves and blowing of safety valves etc.
The requirement of snubbers shall be decided based on the requirement of
dynamic analysis of the piping systems. The snubbers shall be of hydraulic
type. It shall be the responsibility of the Bidder to Owner and supply
snubbers required for the above piping systems.
(v) Terminal connections
a) The terminal connection in all cases shall be ASME dimensions unless

otherwise approved or specified.
b) Supply of all fittings, flanges, short pieces, etc. as necessary for

connection of piping at all terminal points shall be included in Bidder's
scope.
3.02.00 Scope of supply/ work/ services shall include but not be limited to Pipes, headers
and manifolds, bends, elbows, returns, tees, laterals, crosses,
reducers/expanders, caps and closures, couplings, plugs, sleeves, and saddles,
stubs and bosses, unions and other similar fittings, flanges, gaskets, fasteners

and sealants, ring joints, backing rings, all types of valves including drain/ vent/ air
release valves, 3-way valves (where applicable) with test connection for
instruments/ manifolds, actuators, specialities, orifices, flow nozzles, expansion
joints, bellows etc. as per finalised single line flow diagrams and layout drawings/
isometric drawings.
3.03.00 Bidder shall supply Condensate storage tank, Service water tank and portable
water tank. Quantity and capacity of the tank shall be as per finalised/approved
P&ID.
3.04.00 Flexibility analysis for piping systems wherever required.
3.05.00 Complete assemblies of hangers, supports anchor, guides, restraints, etc.

including welded attachments, clamps, clevises, rods, turn-buckles, springs and
spring cages, clamps, shoes, rollers, trapezes etc.
3.06.00 Weather hoods for pipes crossing ceilings and walls.
3.07.00 Instrument tapping and stub connections, root valves, 3-way valves (where
applicable) with test connections, drains & vents valves & expanders / reducers as
required, entire impulse pipings, fittings as indicated elsewhere for instruments
supplied by the Bidder.
3.08.00 Drain funnels, drip pans, moisture traps etc wherever required shall be provided.
3.09.00 Thrust/ anchor blocks where ever required shall be designed and provided by the
bidder and detail drgs. shall be submitted by him to the Owner.
3.10.00 All supporting attachments like plates, saddles, stools, shoes, base plate, special
plates, angles, channels, I-beams, trapeze, nuts, bolts, cleats, clamps, needed to
complete the erection of piping system covered under this specification. Valve
access platforms, associated support frame structure, etc. wherever required shall
be provided by the bidder.
3.11.00 Paints and varnishes, primers, thinners etc. as required for anti-corrosive
protection of piping/ equipment above ground. Surface preparation, priming and
painting of all non-insulated above ground piping and equipment except
galvanised steel pipings & surfaces and stainless steel pipings & surfaces.
3.12.00 Bidder shall provide anti-corrosive protection to all directly buried piping including
galvanised carbon steel piping and painting for all above ground piping except
galvanised pipes and stainless steel pipes. On the internal surface of all pipes
1000 mm and above, a coat of primer followed by a hot coat of coal tar enamel
paint or coal tar epoxy paint shall be applied. In case of pipes of size 1000 mm NB
and above, the bidder shall stiffen them and/or increase the thickness of pipe
adequately against ovality formation in use.
3.13.00 Bidder shall supply all necessary drains and vents with drain & vent valves
including anti-flash funnels and moisture traps for compressed air system as
required for the safe and effective draining-venting of the piping systems based on
the approved flow scheme / single line diagram. It is bidder’s responsibility to
identify the requirements of drains, vents, and supply the necessary pipe work,
fittings, hangers and supports etc. for the same.

3.14.00 Bidder shall supply and install necessary matching pieces as may be needed for
connection of piping systems with equipment terminals, valves and specialities.
3.15.00 The Bidder shall prepare the flow diagrams, detailed dimensional piping layout/
Isometric/ fabrication/ As built drawings of all the systems along with Cross
sectional drawings, showing all supports and equipment as required
3.16.00 In addition to submission of drawings as stipulated above bidder shall also furnish
the data/ documents with respect to following :
i) Support, Anchor, Thrust block design calculations.
ii) Calculation to establish adequacy of size and provision of Air Release

Valves in a piping system etc. Transient/surge analysis for long (1
kilometre or more) pipe lines, and/or large diameter (i.e. large volume)
pipe lines.
3.17.00 The Bidder shall include in his offer a complete set of special tools and tackles
required for handling the various equipment / piping system during maintenance.
3.18.00 All consumables, lubricants till handing over of the plant / equipment.
3.19.00 Start up and Commissioning spares.
3.20.00 Mandatory Spares.
3.21.00 Recommended spares for 3 (three) years of operation and maintenance.
3.22.00 Erection, Testing, Commissioning.
3.23.00 Scope of Other Services for power cycle piping
(i) The Bidder shall identify and satisfy all other statutory code requirements
as may be required for the piping systems covered in this specification.
(ii) All shop tests and field tests as required by the applicable codes (ANSI
standards, IBR and other standards enumerated .
(iii) Complete design, engineering, etc. for the power cycle piping systems and
other piping systems included in this specification shall be the
responsibility of the Bidder. Owner's responsibility/function in this
connection shall be limited to review and approval of Bidder's
design/calculation, engineering, drawings, and documents. Bidder's scope
of services for complete engineering of the misc cycle piping systems shall
include but not be limited to the following :
(a) Preparation of Engineering piping diagram indicating flow

schematic, flow parameter, pipe sizes, line designations and tag
nos. of various components etc. and submission of same to Owner
for review.

(b) Design parameter selection, pipe sizing calculation, pipe schedule,

valve schedule, insulation schedule, painting schedule, specialities
schedule, hanger schedule for the systems included in the Bidder's
scope and submission of same to Owner for their review.
(c) The Bidder shall carryout stress analysis of piping system and
submit for Owner's approval. Bidder shall carryout the dynamic
analysis of piping systems as required and submit for Owner's
approval. Bidder shall also provide soft copy of stress analysis
program files for Owner’s record and use.
The Bidder shall design in detail all piping supports including

restraints, guides, stops etc., after deciding the final location of
hangers and supports based on final stress analysis and hanger /
support load data originated by him.
.
(d) Preparation of preliminary as well as final composite piping layout
drawings of pipe size 65 mm NB & above and submission of same
to Owner for review and approval.
(e) Preparation of isometric drawings, fabrication/erection isometric

(with material take off) drawings for shop fabricated piping which
are of size 65 mm NB and above and submission of the same to
the Owner for review and approval. Piping isometric sketch may be
required to be prepared for certain important tubes and pipe lines
(<65 NB). The list of such lines shall be decided during detail engg.
Stage.
(f) Preparation of layout drawings & isometric drawings for site routed
piping and submission of the same to the Owner for records.
(g) Design and engineering of all temporary piping that are required for
the commissioning activities of misc cycle piping system.
(h) AS BUILT drawing of the piping layout shall also be prepared by

the Bidder based on any layout modifications made at site and
submitted to Owner for records.
4.00.00 TECHNICAL REQUIREMENTS
4.01.00 Piping
4.01.01 Design Basis
Inside diameter of piping shall first be calculated for the flow requirement of
various systems considering following design velocity.
(i) Water/Oil Application
Water/Oil Velocity in m/sec
Pipe Size Below 50-150 200 mm

50mm mm & above
(a) Pump suction < 1.0 1.2-1.5 1.2-1.8
(b) Pump discharge 1.2-1.8 1.8-2.4 2.1-2.5

and recirculation
(c) Header ------ 1.5-2.4 2.1-2.4
Pipeline under gravity flow shall be restricted to a flow velocity of 1 m/sec

generally. Channels under gravity flow shall be sized for a maximum flow velocity
of 0.6 m/sec.
WILLIAM & HAZEN formula shall be used for calculating the friction loss in piping
system with the following “C” value:
Carbon steel pipe : 100
C.I Pipe / Ductile Iron : 100
Rubberlined steel pipe : 120
Stainless steel pipe : 100
For calculating the required pump head for pump selection, at least 10% margin
shall be taken over the pipe friction losses and static head shall be calculated from
the minimum water level of the tank/ sump/ reservoir from which the pumps draw
water.
(ii) Compressed Air Application 6.0 – 10.0 m/sec.
(iii) Gas piping 15-25 m/s
4.01.02 Pipe wall thickness calculations shall be made on the basis of procedure and
formula given in ANSI B31. In any case the thickness selected shall not be less
than standard thickness specified in ANSI 36.10/IS-1239 heavy or as mentioned
in IS-3589.
4.01.03 Corrosion allowance of 1.6 mm or as per standard ANSI B31 for the piping shall
be added to the thickness calculated. Bend thinning allowance/ manufacturing
allowance shall be additionally taken, if required.
4.01.04 All high points in piping system shall be provided with vents. All low points shall be
provided with drains along with valve. Material of drain & vent shall be as that of
parent pipe. Drain & vents shall be adequately sized so as to clear condensate in
the lines.
4.01.05 Joints in piping system shall be welded / flanged / screwed.
4.01.06 Recirculation pipes along with valves, break-down orifices etc. shall be provided
for important pumping systems as indicated in respective processes and
instrumentation diagrams (P&IDs). The recirculation pipe shall be sized for

minimum 30% design flow of single pump operation or the recommended flow of
the pump manufacturer whichever is higher.
4.01.07 All low pressure piping systems shall be capable of withstanding the maximum
pressure in the corresponding lines at the relevant temperatures. However, the
minimum thickness as specified in the following clauses and or respective codes
for pipes and fittings shall be adhered to. The bidder shall furnish the pipe sizing/
thickness calculation as per the criteria mentioned under this Technical
Specification.
4.01.08 Piping and fittings coming under the purview of IBR shall be designed satisfying
the requirements of IBR as a minimum.
4.01.09 Supporting arrangement of piping systems shall be properly designed for systems
where hydraulic shocks and pressure surges may arise in the system during
operation. Bidder should provide necessary protective arrangement like anchor
blocks/anchor bolt etc. for the safeguard of the piping systems under above
mentioned conditions. The requirement shall be, however, worked out by the
bidder and he shall submit the detailed drawings for thrust/anchor block to the
Owner. External, and internal, attachments to piping shall be designed so as not
to cause flattening of pipes and excessive localised bending stresses.
4.01.10 Bends, loops, off sets, expansion or flexible joints shall be used as required in
order to prevent overstressing the piping system and to provide adequate
flexibility. Flexibility analysis (using software packages such as Caesar-II etc.)
shall be carried out for sufficiently long piping (wherever straight run more than
300M).
4.01.11 Wherever Bidder's piping coming under this specification, terminates at an

equipment or terminal point not included in this specification, the reaction and the
thermal movement imposed by bidder's piping on equipment terminal point shall
be within limits to be approved by the Owner.
4.01.12 The hot lines shall be supported with flexible connections to permit axial and
lateral movements. Flexibility analysis shall be carried out for pipelines, which
have considerable straight run as, indicated above and necessary loops/
expansion joint etc. shall be provided, as may be necessary depending on layout.
4.01.13 An approved manufacturer of repute shall manufacture piping and fittings. They
should be truly cylindrical of clear internal diameter, of uniform thickness, smooth
and strong, free from dents, cracks and holes and other defects.
4.01.14 For rubber lined ERW pipes, beads shall be removed.
4.01.15 Inspection holes shall be provided at suitable locations for pipes of 800 NB and
above as required for periodic observations and inspection purposes.
4.01.16 At all intersection joints, it is Bidder's responsibility to design and provide suitable
reinforcements as per the applicable codes and standards.
4.01.17 For large size pipes/ducts, at high point and bends/change of direction of flow, air
release valves shall be provided. Sizing criteria for air release valves shall be

generally on the basis of valve size to pipe diameter ratio of 1:8. Requirement
shall be decided as per relevant code.
Transient analysis /surge analysis where ever specified and required shall be
conducted in order to determine the location, number and size of the Air-Release
valve on certain long distance/high volume piping systems, if applicable within the
scope of work of the package.

4.02.00 Piping Material
S.No. Description Raw Clarified Drinking Water DM Water Fuel Gas/ Oil Air
Water Water
1 Pipe ASTM A- ASTM A-53 type E Stainless steel to ASTM-A-312 ASTM 306 ASTM A-53 type E Gr.B
Material 36/ASTM A-53 Gr.B galvanized/ Gr.304 ERW or seamless sch- upstream of galvanised/IS:1239 Gr.
type 'E'Gr.B/ IS- IS:1239 Gr. heavy 40 for sizes above 50mm and fine filter and heavy
3589 Gr. 410 /IS- galvanised/IS;3589 seamless for sizes 50mm and SS 316 galvanised/IS:3589 Gr.
1239 Heavy. Gr 410 galvanized below. downstream 410 galvanized to IS-
to IS-4736 or of fine filter 4736 or equivalent
equivalent.
2 Fittings
a - 200 NB & Fabricated fittings out of parent carbon Fabricated pipe fittings out of SS
larger steel pipe. material same as pipe.
b - 150 NB & Hot bends out of seamless carbon steel Fabricated pipe fittings out of SS Heavy class galvanized
below pipes with butt welding ends to ASA-B- stainless steel type 304 Sch- MS screwed fittings to
16.9, dimensions matching with IS:1239 10S thick. BW ends to ASA-B- IS: 1239 Part-II or
Heavy Class piping. 16.9. equivalent with screwed
ends to IS: 554
3 Flanges Single piece plate cut flanges out of IS: 150#ASA class carbon steel SS 150 # ASA galvanized
2062 plates drilled to 150#ASA B-16.5. rubber lined flanges drilled to screwed flanges drilled
Multi segment flanges for large dia pipes ASA-B-16.5 with a set of bolts, to ASA-B-16.5 with bolts,
shall be 100% radio graphed. nuts & gaskets nuts & gaskets.
4 Bolts and Hexagonal head machined carbon steel Stainless Steel SS Hexagonal head
nuts bolts and hot forged carbon steel machined carbon steel
hexagonal nuts to IS: 1367 Class 4.6 bolts and hot forged
carbon steel hexagonal
nuts to IS: 1367 Class
4.6
5 Gasket 3mm thick cloth inserted white rubber full 1.5 mm thick. compressed SS 3 mm thick cloth inserted
faced gaskets dimensions to suit asbestos, ring type gaskets white rubber full faced
associated flange drilling details dimensions to suit associated gaskets dimensions to

flange drilling details suit associated flange

drilling details
6 Joints
a 50 mm and Line joints socket welded type Line joints socket welded type SS Screwed
smaller
b - 65 mm Line joints butt welded type Flanged SS Screwed Flanged
and larger
c - joints at Socket weld/flanged for sizes 65 NB and Socket weld/flanged for sizes SS Screwed Flanged
valves above 50 NB and below
d Joints at As per Manufacturers Standard As per Manufacturers Standard SS As per Manufacturers
equipment Standard

4.03.00 Piping layout
4.03.01 Piping shall be grouped together where practicable and routed to present a neat
appearance.
4.03.02 Piping routing shall be such as to provide sufficient clearance for removal and
maintenance of equipment, easy access to valves, instruments and other
accessories. The piping shall not encroach on the withdrawal space of various
equipments.
4.03.03 Over head piping shall have a normal minimum vertical clearance of 2.5 meters
above walkways and working areas and 8M above roadways/railways. When
several pipe lines are laid parallel, flanged joints must be staggered. Welded and
flanged joints should as far as possible be located at one third span from
supports. If the support is situated right under the welded joints this joint must be
reinforced with a strap. Flanged and welded joints must be avoided in the middle
of the span. Valves should be located in such a manner so as to ensure their
convenient operation from the floor or the nearest platform.
4.03.04 Piping shall be erected as per approved drawing.
4.03.05 All piping shall be routed so as to avoid interference with other pipes and their
hangers and supports, electrical cable trays, ventilation ducting, structural
members, equipment etc. Adequate clearance shall be ensured with respect to
the above to accommodate insulation and pipe movements, if any.
4.03.06 Piping shall generally be routed above ground but where specifically
indicated/approved by the Project Manager the pipes may be arranged in trenches
or buried. Pipes at working temperature above the ambient shall however not be
buried.
4.03.07 Sufficient up stream and down stream lengths shall be provided for flow
measuring devices, control valves and other specialities.
4.03.08 All local instruments shall be located on pipe lines as to render them observable
from the nearest available platforms.
4.03.09 Openings provided in the wall for pipelines must be closed with bricks and mortar
with 10-12 mm clearance between brick work and pipe after taking care of
insulation and thermal movement, if any. The clear space must be filled with felt or
asbestos or approved filling compound.
4.04.00 Slope/Drains and Vents
4.04.01 Suitable slope shall be provided for all pipelines towards drain points. It is Bidder
responsibility to identify the requirements of drains and vents, and supply the
necessary pipe work, valves, fittings, hangers and supports etc. In addition to the
system requirement all low points in the pipelines shall be provided with suitable
draining arrangement and all high points shall be provided with vent connections
where air or gas pockets may occur. Vent for use during hydrostatic test shall be
plugged after the completion of the test. Vent shall not be less than 15mm size.
Drains shall be provided at low points and at pockets in piping such that complete
drainage of all systems is possible. Drain shall not be less than 15mm for line size

upto 150mm, not less than 20mm upto 300mm and not less than 25mm for
350mm to 600mm pipes and not less than 50mm for 600mm and above pipes.
4.04.02 Air piping shall be sloped so that any part of the system can be drained through
the shut-off drain valve or drain plugs.
4.05.00 Specification of Hydrogen, nitrogen and carbon-dioxide cylinders
The water holding capacity of each Hydrogen , nitrogen and CO2 cylinder shall be
46.7 litres.
The H2 , Nitrogen and CO2 cylinders shall conform to IS-8198 ; 2004 and IS-7285
/or equivalent standard and Gas cylinder Rules.
Design and Manufacturing of cylinder shall be approved by CCOE.
The Gas Cylinders shall be located in a separate facility. Each cylinder shall be
supplied with an integral isolating valve as per IS: 3224 including cap and neck
rings. The inlet side of these valves shall match with the threads of the cylinder neck
ring and the outlet shall be as per IS-3224 (latest revision)/equivalent standard for
further connection downstream.
Each cylinder shall be tested as per the guide lines of Chief Controller of Explosives,
Nagpur. Test certificates from Chief Controller of Explosives certifying suitability of
each cylinder for filling and transportation shall be submitted to client before
dispatch of the cylinder to site for approval. The cost of testing and furnishing test
certificates shall be included in the quoted price.
No. of H2 Cylinders: As per technical requirements

No. of N2 Cylinders: As per technical requirements
No. of CO2 Cylinders: As per technical requirements
4.06.00 Bends/elbows/mitre bends/ Tees/ Reducers & other fittings
4.06.01 Unless otherwise specified elbows shall be of long radius type.
4.06.02 For pipe sizes upto 65Nb, long radius forged elbows or seamless pipe bends shall
be used. Pipe bends, if used, shall be cold bent to a radius measured to the
centre line of pipe of 3 to 5 times the pipe diameter.
4.06.03 For steel pipes 80 Nb and above, seamless long radius forged elbows shall be
used. For pipe size 350Nb and above mitre bends may be used for all pipes
except rubber lined pipes. The bend radius shall be 1½ times the nominal pipe
diameter. 90 deg. bends (mitre) shall be in 4 pieces (3 cuts) and 45 deg. mitre
bends shall be in 3 pieces 22½ deg. Fabrication of mitre bends shall be as
detailed in BS 2633/BS534.
4.06.04 Mitre bends are not acceptable in case of rubber lined mild steel pipes, if
applicable for any piping system.
4.06.05 For pipe fittings such as reducers and tees, the material shall be to ASTM-A-234
Gr. WPB up to 300 NB. For pipe reducers and tees above 300 NB, the fittings

may be fabricated conforming to parent pipe material. Provision of compensation

pads shall be kept as per ANSI B 31.1. The fitting shall conform to the
dimensional standard of ANSI B-16.9.
However, for pipes up to 150 NB, pipe fittings may be supplied with material and
dimension conforming to IS 1239 in case parent pipes also conform to IS 1239.
For pipes, above 1200 NB, reducer and tees shall be to dimensional standard of
AWWA-C-208.
4.06.06 For stainless steel (SS) pipes, the fittings shall be of forged stainless steel
conforming to ASTM-A-403.
4.07.00 Flanges
4.07.01 Flanges shall be slip on type. Welding of flanges in tension is not permitted.,
4.07.02 All flanges and-flanged drilling shall be to ANSI B 16.5/BS EN-1092 of relevant
pressure/temperature class. Flanges shall be fabricated from steel plates
conforming to ASTM A 105/IS 2062 gr.B.
4.08.00 Specific technical requirement of laying buried pipe with anti corrosive
treatment
The pipe in general shall be laid with the top of the pipe minimum 1.0 (one) metre
below finished general ground level.
4.08.01 Trenching
(a) The trench shall be cut true to the line and level and shall follow the
gradient of the pipeline. The width of the trench shall be sufficient to give
free working space on each side of the pipe. Trenches shall conform to IS
5822.
(b) Free access shall be provided for the welding of the circumferential joints
by increasing the width and depth of the trench at these points. There
should be no obstruction to the welder from any side so that good welded
joint is obtained.
(c) The free working space shall conform to IS:5822. The trench shall be
excavated so as to provide minimum cover of 1000mm between the top of
the pipe and finished grade.
(d) Prior to lowering and laying pipe in any trench, the Bidder shall backfill and
compact the bottom of the trench or excavation in accordance with IS:5822
to provide an acceptable bed for placing the pipe.
(e) Coating and Wrapping shall be done as under
4.08.02 Preparation and cleaning of piping
(a) The pipeline shall be thoroughly cleaned of all rust, grease, dirt, weld
scales and weld burrs etc. moisture or other foreign matter by power

cleaning method such as sand blasting, power tool cleaning, etc. Grease
or heavy oil shall be removed by washing with a volatile solvent such as
gasoline. Kerosene shall not be permitted for cleaning. This cleaning
operation shall be immediately followed by priming with the mechanical
priming machine.
(b) Certain inaccessible portions of the pipe line (which otherwise not possible
to be cleaned by power cleaning methods) may be scrubbed manually with
a stiff wire brush and scrapped where necessary.
(c) The cleaning and priming operation shall be carried out at site. The entire
pipe length shall be cleaned but the ends of the pipes shall be left without
coating for a distance of 230mm for joints, which shall be coated manually
at site after laying, welding and testing the pipe.
(d) On the internal surface for pipes 1000 Nb and above, a coat of primer
followed by a hot coal-tar enamel or coal tar epoxy painting (cold) shall be
applied.
4.08.03 Coating and wrapping
(a) Burried piping shall be coated and wrapped, as per specification, after
completion of welded and/or flanged connections, and after completion
and approval of Hydro testing. Materials to be used for coating and
wrapping of underground pipelines are :
(1) Coating primer (coal tar primer)
(2) Coating enamel (coal tar enamel)
(3) Wrapping materials.
(b) All primer/coating/wrapping materials and methods of application shall

conform to IS:10221 except asphalt/bitumen material. Materials
(primer/coating/wrapping) as per AWWA-C-203 are also acceptable.
(c) Protective coating shall consist of coal tar primer, coal tar enamel coating,
glass fibre tissue inner wrap followed by coal tar impregnated glass fibre or
kraft paper outer wrap or finish coat.
(d) Number of coats and wraps, minimum thickness for each layer of
application shall be as per IS-10221. Number of coats and wraps shall be
decided based on soil corrosivity/ resistivity as indicated in IS-10221. Soil
data-for this purpose shall be collected by the Bidder, if required.
(e) Total thickness of completed coating shall not be less than 4.0 mm.
(f) Alternatively, the anti-corrosive protection can consist of anti-corrosive

protection Coal-tar tapes. material and application of tapes shall conform
to AWWA-C-203. These-tapes shall be applied hot over the cold coal tar
primer. The total thickness of the finished protective coating shall be 4mm
minimum.

4.08.04 Trench bed preparation and back filling
Prior to lowering and laying pipe in any excavated trench, the bottom of the trench
may require to be back filled and compacted (or as the case may be) to proved an
acceptable bed for placing the pipe. Bed preparation in general shall be as per
IS:5822.
Bed preparation and back filling of excavated trenches for buried pipes depend on
type of soil. Soil types are classified into 3 categories:
(a) Rocky Soil.
(b) Sandy/ silty soil (including non-expansive clay).
(c) Expansive soil (including water logged/ marshy soil).
The bidder shall note that the cross-country raw water piping as well as other in-
plant pipings may travel underground through all types of soils and combination of
soils described above.
4.08.05 Laying of galvanised steel (GI) pipes
All the joints shall be screwed or flanged. Screwed ends of GI pipes shall be
thoroughly cleaned and painted with a mixture of red and white lead before
jointing Threaded portion on either side of the socket joint shall be applied with
Zinc silicate paste.
All the provisions for trenching/bed preparation/laying the pipe application of

primer/coating/wrapping with tapes/back filling etc. as indicated for "laying of
burried piping" and " anti corrosive protection for burried piping" are applicable for
burried galvanised steel (GI) pipes also.
4.09.00 Valves
4.09.01 General
a. This covers specific technical requirements for gate, globe, check, angle,
butterfly, air release, float, safety and relief valves, alongwith all
accessories such as actuators, gear operators, extension spindles, integral
bypass valves, etc.
b. The design fabrication and testing of valves, shall generally conform to the
requirements of ANSI B 16.34 unless specified otherwise under valve code
specification.
c. All valves shall have full sized ports.
d. For globe and check valves the direction of flow shall be clearly embossed
on the body of the valve.
e. All valves shall be suitable for installation in horizontal as well as vertical

pipe line.

f. All globe / gate valves shall be capable of being closed against the design
pressure.
g. Where globe valve are to be required for regulation purpose, the disc shall
be tapered plug type and suitable for controlling through its lift.
h. All gate and globe valves shall have bonnet back seating arrangement to
facilitate easy replacement of packing with the valves in service.
i. Stop check valves shall have full floating and accurately guided discs.
j. The internal diameters of the valve ends shall be same as the internal
diameter of the connecting pipe at least for those valves which are of the
same nominal bore as the connecting pipe.
k. All valves shall be provided with embossed name plate giving details such
as tag number, type, size etc.
4.09.02 Hand Wheels
Hand wheels for all the valves shall close the valve in clockwise direction when
viewing from the top. All hand wheels shall be clearly marked indicating the
direction of opening / closing. Hand wheel shall be of malleable iron.
4.09.03 Position indicators.
a. All valves with rising stem shall have visual indication through plastic stem
covers. Others shall be provided with continuous mechanical position
indicators.
b. Wherever required for monitoring and control/purposes, valves shall be

provided with potentiometric type remote position indicators. Source
voltage for such transducers shall be 240 V AC / 220 V DC. These position
indicators shall conform to Section on valve actuator.
c. Limit switches on manual valves shall conform to Section on valve

Actuators.
4.09.04 Manual Gear Operators
Manual gear operators shall be provided to open / close the valve against the
maximum differential pressure across the valve such that the effort required to
operate does not exceed 25 kgf.
Manual gear operator shall be reputed make, proven quality conforming to
internationally accepted standards and suitable for outdoor installation.
4.09.05 Locking Arrangements
Locking arrangement where specified shall be of non-detachable type, subject to

approval of Owner.

4.09.06 Chain Wheel Operator
Chain & chain wheel shall be provided by bidder wherever required for easy
operation of valves. Chain wheel for the valves shall be constructed to five good
traction for the chain. Roller guides shall be provided to hold the chain to a greater
part of the circumference of the wheel to increase traction and to prevent the
chain from jumping off the wheel.
4.09.07 Floor stand and extension spindle
For floor stand and extension spindle arrangement for valves, the height of floor
stand shall be about one (1) meter from the floor / platform. The floor stand shall
be of sturdy construction with column, nut plate and hand wheel made of cast iron
conforming to material ASTM A 126 Gr B. Suitable thrust bearing shall be
provided between the hand wheel and the floor stand. The connection of the
extension spindle to the valve stem shall be through a flexible coupling and shall
be designed to permit valve thermal movements. Necessary nuts, bolts, etc. for
mounting the floor stand on platform shall be provided.
4.09.08 Rubber Lining of Valves
For rubber lined valves, following requirement are to be met.
a. Rubber shall be of Neoprene / Nitrile.
b. All wetted surfaces of valve internals shall be fully rubber lined extending
upto the edges of flanges with out any joint.
c. Lining shall be of manufacturer’s standard thickness subject to a minimum

of 3 mm.
d. Rubber lining shall be spark tested for checking the continuity.
4.09.09 Electric motor actuated valves
In case of motor operated valves, electric motor actuators shall conform to the
requirements of Section on valve actuators./ For all motor actuated valves, by
pass valves shall also be motor actuated.
4.09.10 Testing Requirements
a. All valves shall be tested as per the general requirement given in various
sections of this specification. Specific testing requirement are indicated
against valves specification codes below.
b. Where practical, each valve assembly shall be shop tested to open and
close against the maximum differential pressure specified in the
specification.
4.09.11 Valve Body Material
Valve body material for various services shall be as follows:

Valve body material for Raw water, service water, clarified water make-up to CW
system, clarified cooling water, DM cooling water, CW blow down water,
circulating water, compressed air & drinking water shall be as follows:
a) Cast iron for water and galvanised cast carbon steel for compressed air for
sizes 65NB and above
b) Gun-metal for sizes 50 Nb and below
c) DM water : SS body and disc alongwith SS internals
d) Condensate : Cast Carbon Steel
4.09.12 End Connections
The end connections, shall comply with the following :
Socket welding (SW) - ANSI B 16.11
Butt Welding (BW) - ANSI B 16.25.
Threaded (SC) - ANSI B 2.1
Flanged (FL) - ANSI B 16.5& AWWA-C-207(steel flanges), ANSI B 16.1 (Cast Iron
flanges)
All cast iron/ ductile-Ni iron body valves (gate, globe and non-return) shall have
flanged end connections, (screwed ends for cast iron D.2NI body valves are not
acceptable).
All steel and stainless steel body valves of sizes 65 mm and above shall have
flanged or butt welded ends. Valves of sizes below 65 mm shall have flanged or
socket welded ends. Compatibility of welding between valve body material and
connecting pipe material is a pre-requisite in case of butt-welded joints.
All gun metal body valves shall have screwed ends.
All flanged end valves/specialities shall be furnished alongwith matching counter

flanges, fasteners, gaskets etc. as required to complete the joints.
4.09.13 Material of Construction (Butterfly Valves)
Materials and other design details shall be as indicated below :
(a) Cast Iron Butterfly Valves
Body & Disc ASTM A48, Gr. 40 with 2% Ni/ IS:210 Gr. FG-260,
with 2% Ni and epoxy coated
Shaft BS 970 431 S:291 / EN 57, or AISI-410 or

AWWA-permitted shaft material equivalent
to EN-57/AISI-410 or better.

Seat ring 18-8 Stainless steel
Seal Nitrile Rubber
(b) Stainless Steel Butterfly Valves
Body & Disc ASTM A 351, Gr. CF8M
Shaft ASTM A 182, Gr. 316
Disc & Seat Rings EPT/BUNA-N/Neoprene
(c) Carbon steel Butterfly Valves
Body & Disc ASTM A 216, Gr. WCB
Shaft ASTM A 182, Gr. 304
Disc & Seat Rings EPT/BUNA-N/Neoprene
4.09.14 Material of Construction (Gate/Globe/Check valve)
The materials shall generally comply with the following :
(a) Cast Steel Valves
Body & bonnet ASTM A 216 Gr. WCB/ ASTM A 105
Disc for non-return valves ASTM A 216 Gr. WCB/ ASTM A 105
Trim. ASTM A 182 Gr. F6
(b) Stainless Steel Valves
Body & Bonnet ASTM A 351 Gr. CF 8M/ ASTM A 182 Gr.
304
Disc ASTM A 351 Gr. CF 8M/ ASTM A 182 Gr.

304
Trim. ASTM 182 Gr. F. 316
(c) Cast Iron Valves
Body & bonnet BS 1452 Gr. 14/ IS-210 Gr. FG 260
Seating surfaces and rings 13% chromium steel
Disc for non-return valves BS 1452 Gr. 14/IS-210 Gr FG 260
Hinge pin for non-return AISI 316

valves

Stem for gate globe valves 13% chromium steel
Back seat 13 % chromium steel
(d) Gun Metal valves
Body and bonnet IS:318 Gr.2/Equivalent Standard
Trim. IS:318 Gr.2/Equivalent Standard
(e) Cast iron body valves shall have stainless steel stem and seat.
(f) Material for counterflanges shall be the same as for the pipings.
4.09.15 Material of construction (Ball valve)
Body ASTM-A-216 Gr. WCB Galvanised/

ASTM-A-105 Galvanised
Ball ASTM-A-351 Gr. CF8M/ASTM-A-276 Type

316
Stem ASTM-A-276 Type 316
Gland ASTM-A-276 Type 316
Anti-Static Device SS-304
Stem Seal PTFE.
4.09.16 Gate Valves
a) All gate valves shall be of the full-way type, and when in the full open
position the bore of the valve shall not be constricted by any part of the
gate.
b) Gate valves shall be of the solid/elastic or articulated wedge disc and

rising stem type.
4.09.17 Globe Valves
Globe valves shall have the following characteristics:
a) Straight conveyed flow.
b) Right angle preferably, the valves shall be of the vertical stem type.
c) Globe valves shall preferably have radiused or spherical seating and discs
shall be free to revolve on the spindle.
d) The pressure shall preferably be under the disc of the valve. However,
globe valves, with pressure over the disc shall also be accepted provided
(i) no possibility exists that flow from above the disc can remove either the

disc from stem or component from disc (ii) manual globe valves can easily
be operated by hand. If the fluid load on the top of the disc is higher than
40-60 KN, bypass valve shall be provided which permits the downstream
system to be pressurised before the globe valve is opened.
e) Globe valves with NB smaller than or equal to 2" shall be of the integral
type. Valves of this type shall be so as to permit the easiest disassembly of
the internals (stem and disc).
f) For the regulating valves, valves with regulating plug & parabolic outline
disc type is preferred.
g) All motorised globe valves with regulating plug for which indication of
percentage (%) opening are required in the control room shall be provided
with necessary position transmitter.
4.09.18 Check Valves
Check valves shall comply with the following characteristics:
a) For bore greater than 2" the valves must be swing check type or dual plate
check type suitable for installation in all positions (vertical and horizontal);
b) For bore smaller than or equal to 2" the valves must be of the piston type
to be installed, in horizontal position.
c) In the case of swing check valves, the body seat shall be inclined at such
an angle from the vertical as shall facilitate closing and prevent chatter.
d) Drilling on flanges of flanged valves must correspond to the drilling on

flanges of the piping system on which the valves are to be installed.
e) All flanged valves intended for installation in steel piping systems shall
have their flanges drilled to ANSI B 16.5 (or equivalent) and according to
the pressure class.
f) Counter flanges to be installed on air pipes shall be screwed-on type

irrespective of size.
4.09.19 Butterfly Valves
The valves shall be designed for the design pressure/temperature of the system
on which it is installed and in accordance with AWWA-C-504, BS:5155 or any
other approved equivalent standard latest edition.
(a) The valves shall be suitable for installation in any position

(horizontal/vertical etc.) and shall be of double-flanged construction.
However, for sizes 150NB and below the valves shall be of either double-
flanged or wafer construction (U-Section type or double lugged type).
(b) The seals, both on the body (sleeve) and on the disc shall be of the
material specified. Necessary shaft seal shall be provided and adequately
designed to ensure no leakage across the seal. This seal shall be

designed so that they shall allow replacement without removal of the valve
shaft. The sealing ring on the disk shall be continuous type and easily
replaceable.
(c) For all types of valves, the design with shaft eccentric to the disc is
preferred. The shaft shall be solid type and shall pivot on bushings.
Bushings/sleeve type bearings shall be contained in the hub of valve body.
The bearing shall be self-lubricated type with low coefficient of friction and
should not have any harmful effect on water and on valve components.
(d) The design of the shaft shall be such that it shall safely sustain maximum
differential pressure across the closed valve. The shaft and any key (taper
pin etc.) for transmitting the torque between shaft and disc shall be
capable of withstanding the maximum torque required to operate the valve.
However, the shaft diameter shall not be less than the minimum shaft
diameter specified in relevant code. Necessary Torque Calculation and the
torque class selected on the basis of the same shall be furnished to the
Owner for information.
(e) The disc shall rotate from the full open to the tight shut position. The disc
shall be contoured to ensure the least possible resistance to flow and shall
be suitable for throttling operation. While the disc is in the throttled
position, valve shall not create any noise or vibration.
(f) The operating mechanism shall be mounted directly on or supported from

the valve body.
g) Limit and torque switches (if applicable) shall be enclosed in water tight
enclosures alongwith suitable space heaters for motor actuated valves,
which may be either for On-Off operation or inching operation with position
transmitter.
4.09.20 Ball Valves
a) Ball valves shall be manufactured as per standard BS-5351 latest version.
b) Ball position indicator shall be provided.
c) Anti static device shall be provided for the ball valves.
d) Galvanising of carbon steel parts such as Body, adapter, stud & nuts and
handle, etc. shall be done.
e) Body of stud & nuts shall be ASTM-A-193 Gr.-B-7 and A-194 Gr. 2H
respectively.
f) Fire safe design as per API-607 shall be provided.
g) For sizes 80 NB and above the design shall be full-port type. However for
sizes below 80 NB the reduced-bore design may be provided.
4.09.21 Float Operated Valves

a) Valve shall automatically control the rate of filling and shall shut off when a
predetermined level is reached and close to prevent over flow on pre-set
maximum water level. Valve shall also open and close in direct proportion
to rise or fall of water level.
b) Design and construction features
i) Valves shall be right angled or globe pattern.

ii) Valves shall be balance piston type with float ball.
iii) Leather liner shall not be provided.
c) The body and cover material shall be cast iron conforming to ASTM-A 126
Grade 'B' or IS:210 Grade 200 or equivalent, and Float shall be of copper
with epoxy painting of two (2) coats.
d) Valves shall be suitable for flow velocities of 2 to 2.5m/sec.
4.09.22 Air Release Valves
(a) The air release valves shall be of automatic double air valve with two
orifices and two floats. The float shall not close the valve at higher air
velocities. The orifice contact joint with the float shall be leak tight joint.
(b) The valve shall efficiently discharge the displaced air automatically from
ducts/pipes while filling them and admit air automatically into the
ducts/pipes while they are being emptied. The valve shall also
automatically release trapped air from ducts/pipes during operation at the
normal working pressure.
(c) Body material of automatic air release valves shall comply generally with
BS 1452 Gr. 14/IS:210 Gr. FG 260. and spindle shall conform to high
tensile brass.
(d) Air release valves shall not have any integral isolation device within them.
Each Air release valve shall be mounted, preceded by a separate isolation
gate/ butterfly valve.
4.09.23 Moisture Drain Trap
(a) Automatic ball float type moisture separator (trap) shall be provided in
compressed air distribution headers at strategic loacations warranted by
actual layout of Instrument/Plant air piping in order to achieve positive
shut-off in the absence of water and positive lift of float when trap is filled
with water.
(b) Design and Construction Features
Type Float type
Service Automatic draining of condensate
Operating pressure 8.0 kg/cm2(g)

Operating temperature 50deg.C
Design temperature 80 deg.C
Hydrotest pressure 15.0 kg/cm2(g)
Body Cl IS210 FG220
Cover Cl IS210 FG220
Valve seat SS type 410 ASTM A 276
Valve seat gasket SS type 304 ASTM A 240
Rivot frame assly SS type 304 IS 1364
Ball float & level SS type 304 ASTM A 240
Plug ASTM-A-105 ASME B16.11
Support frame SS type 304 ASTM A 240
Rivot frame SS type 304 ASTM A 240
Cover gasket Compressed asbestos fibre IS:2712
End connection Screwed BSPT
Max. differential pr. (Bars) 10
Strainer 'Y' type
Mesh size 40
Installation Horizontal
4.10.00 Hangers & Supports
The bidder shall design and detail all piping hangers and supports, restraints,
guides, stops, snubbers, anchors, dampers etc. including pipe attachments, etc.
The bidder’s design documents shall be submitted for Owner’s review / approval.
Hangers & supports / restraints shall be designed such that they do not become
disengaged due to normal piping movements / vibrations during operation.
Hanger / supports / restraint / snubber / anchor locations shall be indicated on the

pipe layout / isometric drawings furnished by the bidder. The hangers shall have
provision to lock at any position & the same shall be supplied at site after
adjusting for cold position. All springs shall be locked before by hydro testing.
The bidder shall check for interference of hangers and supports with structures,
piping, cable trays, others hangers, etc.

The bidder shall furnish detailed arrangement sketches for each support, restraint,
anchor, snubber etc. The sketches shall include the keyplan, identification no., bill
of quantities, design load, operating load, spring-stiffness, amount of pre-
compression, centre line elevation of pipe, springbox position / orientation etc.
Hanger for piping 65 mm NB and larger and all spring support assemblies
regardless of size shall be completely engineered in conformance with the
provision of power piping code ANSI B 31.1.
Hangers, saddles, supports etc. shall be capable of carrying the sum of all
concurrently acting loads and shall be fabricated from plates/ pipes sections
conforming to ASTM A 53/ IS:2062/ IS:226/ or equivalent. They shall be designed
to provide the required supporting effects and allow pipe line movements as
necessary. The structural steel work shall be as per IS:800/ BS:4360. Insulation
protection saddles shall be used at support point of all insulated piping.
The maximum spans of the supports of straight lengths shall not exceed the
recommended values indicated in ANSI B 31.1. All pipe supports shall be
designed to provide an absolute minimum head room of 2.5 m from floor in
passages/ walkways.
4.11.00 Metallic Expansion Joints
4.11.01 General
a. The design, material construction, manufacture, inspection, testing and

performance of the expansion joints shall comply with the currently
applicable requirements of EJMA, ASME boiler and pressure vessel code
section III, ANSI B 31.1 and all statutes, regulations and safety codes of
the locality where the equipment is to be located.
b. The expansion joints shall be designed to operate without malfunction,
under any conditions that can be reasonably expected in the operation of
power station from zero to full load.
4.11.02 Construction Details
a. Bellows
i. The bellow shall be hydraulically or roll formed from perfect

cylinders of single ply, 304 grade stainless steel.
ii The number of longitudinal weld seams shall be minimum and

there shall be no circumferential weld seam.
iii Cold formed stainless steel bellows shall not be heat treated.
iv. All bellow elements shall be pickled after forming.
v. Equalising rings, where required, shall be either from high quality

castings or from fabricated metal.
vi. Flanged expansion joints shall be provided with adequate pipe

stubs.

vii Butt welded expansion joints shall have adequate length of pipe so
that site welding does not impair or reduce the joints efficiency.
b. Sleeves
i. Expansion joints shall be furnished with internal sleeves of the

same material as the bellows and installed with sufficient clearance
to allow full rated deflection. The sleeves shall be welded on the
flow inlet end of the joints only.
ii. Bellows shall have external sleeves with an arrow indicating the
direction of flow on the outside. The external steel covers provided
to protect bellows from physical damage. It shall be suitable for
supporting insulation where necessary and shall be detachable.
c. Tie Bars
i. Joints shall be shipped provided with suitable knock-off type

temporary tie bars to prevent damage and misalignment during
transit and also with permanent tie bars along with necessary nuts,
bolts etc.
ii Tie rods on pressure balanced type expansion joints shall be

adequately sizes to prevent buckling in vacuum services or
services with other external loads.
4.11.03 Inspection and Tests
a. Bellows shall be subjected to all tests and inspections as called for by

applicable codes / standards specified herein. The bidder shall fully shop
assemble the bellow and test / demonstrate that its performance is
satisfactory.
b. All welds shall be dye penetrant tested as per ASTM E 165 method B.
c. Material test certificates (chemicals & mechanical) as per code

requirements shall be furnished.
d. The expansion joints shall be assembled and hydrostatically tested at shop

at 1.5 times the design pressure for a period of half an hour.
e. The expansion joints shall be subject to a vacuum test at shop at a

pressure of 12 mm Hg absolute for a period of half an hour.
4.11.04 The bidder shall furnish GA Drg. of bellows with complete BOM and data sheet
indicating type, type of construction, design code/standard and parameters, size,
test code / standard and duration of test, system, deflection, material of various
components etc. for Owner’s review and approval.
4.12.00 Rubber Expansion Joints

a. The design, material, construction, manufacture, inspection and testing of

rubber expansion joints shall comply with the requirement of Expansion
Joint Manufacturer Association (EJMA) standards, USA, Fluid Sealing
Association, USA.
b. The expansion joints shall be single bellow type. The arches of the
expansion joints shall be filled with soft rubber.
c. The design shall be suitable for working pressure, temperature and type
of fluid flowing through it.
d. The inner cover (tube) and the outer cover (outer) shall be made of
natural or synthetic rubber of adequate hardness. The shore hardness
shall not be less than 60 degrees for outer and 50 degrees for inner
cover. The carcass between the tube and cover shall be made of high
quality cotton duck preferably square woven to provide equal strength in
both directions of the weave. The fabric pipes shall be impregnated with
age resistant rubber or synthetic compound and laminated into a unit.
Reinforcements consisting of solid metal rings embedded in carcass shall
be provided.
e. The split retaining rings shall be galvanised steel of 10 mm thick to ASTM

A - 36 equivalent. Steel washers shall be provided at the bolt holes where
retaining rings are split.
f. All exposed surfaces of expansion joint shall be given a 3 mm thick

coating of neoprene. This surface shall be reasonably uniform and free
from blisters, porosity and surface defects.
g. Expansion joints shall be complete with stretcher bolt assembly. The

expansion joints shall be suitable to absorb piping movements and
accommodate mismatch between pipe lines.
h. The expansion joints shall be of heavy duty construction made of high

grade abrasion-resistant natural or synthetic rubber compound. The basic
fabric for the' duck' shall be either a superior quality braided cotton or
synthetic fibre having maximum flexibility and non-set characteristic.
i. The expansion joints shall be adequately reinforced, with solid steel rings,
to meet the service conditions under which they are to operate.
j. The expansion joints shall have integral fabric reinforced full-face rubber
flanges. The bolt on one flange shall have no eccentricity in relation to the
corresponding bolt hole on the flange on the other face. The end rubber
flanges shall be drilled to suit the companion pipe flanges.
k. Each control unit shall consist of two (2) numbers of triangular stretcher
bolt plates, a stretcher bolt with washers, nuts, and lock nuts. Each plate
shall be drilled with three holes, two for fixing the plate on to the
companion steel flange and the third for fixing the stretcher bolt.
l. Each joint shall have a permanently attached brass or stainless steel

metal tag indicating the tag numbers and other salient design features.

m. Bidder to note that any metallic part which comes in contact with DM
/corrosive water shall be of Stainless Steel material.
4.13.00 Tanks and Accessories
The designer and manufacturer of storage tanks shall comply with and obtain
approval of all currently applicable statutory regulations and safety codes in the
locality where the equipment shall be installed. The tanks shall conform to IS
803/IS804/IS 805/ IS 2825/BS1564/ API 650/ IS 4049/ IS 4682 (part-I) and IS
4864 to 4870/ ASME B & PV code as the case may be.
Actual quantity, capacity, sizing of each tank to be minimum supplied shall be as

covered in respective systems. However, It is bidder's responsibility to design/size
these tanks depending upon system requirement/ design during detail engg. and
submit the design calculations to Engineer for approval alongwith tank GA drg.
Additional Control & Instrumentation facilities specified elsewhere in the technical
specification shall also be incorporated by the bidder.
4.13.01 Design and Construction
Design of all vertical atmospheric storage tanks containing water, acid, alkali and
other chemical shall conform to IS:803 & API 650.
Design of all horizontal atmospheric storage tanks containing water, acid, alkali
and other chemicals shall generally conform to IS:2825 as regards to fabrication
and general construction taking care of combined bending, shear & hoop stresses
developed due to supporting arrangement.
Design temperature of vessels shall be 10 deg.C higher than the maximum

temperature that any part of the vessel is likely to attain during the course of
operation.
Tank shall be made from mild steel plates to BS 4360/IS-2062 Gr.B (or
equivalent). The material for flanges shall be of ASTM A 105/ IS-2062 Gr.B.
The joint efficiency factors to be adopted for design calculations shall be in

accordance with the specified design code. Tank shall be provided with suitable
supporting joints. All vessels shall be provided with lifting lugs, eye bolts etc. for
effective handling during erection.
For cylindrical tanks, the plates shall be cold rolled through plate bending machine
by several number of passes to true curvature. Vessel seams shall be so
positioned that they do not pass through vessel connections. For cylindrical vessel
consisting of more than two sections longitudinal seams shall be offset.
Tanks shall be provided with float operated level indicators/level gauges/level

transmitters and level switches, as required, with complete assembly. Suitable
flanged pads for level switches mounting shall also be provided. The level
indicator can be top or side mounted as the case may be.
In addition to inlet and outlet nozzles, the tanks shall be provided with vents,
overflow, drain nozzles complete for various connections on tanks. Drains &

overflow lines from storage tanks is to be routed to the nearest surface

drains/plant drains. For tanks containing DM water, Alkaline water or Power cycle
water the vent to atmosphere shall be through carbon-di-oxide absorber vessel
suitably mounted on the tank. CO2 absorber vessel shall be provided with the
initial fill of chemicals. Similarly for equipment cooling water overhead tank, the
overflow & drain from tank shall be combined together and shall be led to nearest
drain (at zero level) via. a seal-trough so as not to come directly in contact with
atmosphere.
Tanks shall have suitable stairs/ladders on inside and outside of the tanks,
manholes/inspection covers as required and also platform suitably located. Tank
supporting arrangement as approved by Owner shall be provided with all
plates/angles/joints/flats and supporting attachment including lugs, saddles, legs
etc.
Piercing nozzles/pipes from tank body / dish ends shall be adequately

compensated with suitable reinforcement pad as per relevant code.
Manholes shall be provided for easy access into the vessels. The size shall be
minimum 500 mm and shall be with cover plate, nuts bolts, etc. to ensure leak
tightness at the test pressure. Each tank, shall be provided with drilled cleats
welded to the tank for electrical grounding. Material of cleats shall be same as that
of the shell.
All tank /vessel roofs and supporting structures shall be designed to support dead
load plus a uniform live load of not less than 125 Kg/M2 of projected area and
wind load as specified. Flat heads, side plated etc. shall be adequately stiffened to
support the loads as specified.
Tank fabrication drg. and design calculations shall be approved by the Owner
Handrails shall be provided around the roof of the storage tanks. Toe (skid) plate
shall be provided
4.13.02 Corrosion Allowance & Protection
Corrosion allowance as per code requirement shall be considered for calculating

the plate thickness for tanks irrespective of whether a protective internal
lining/coating is provided or not.
Wherever corrosion allowance has not been specifically mentioned in code/std, a

minimum of 1.6 MM shall be considered over and above the calculated minimum
.thickness of plate.
Epoxy-coating shall be provided on the inside of vessel in three coats (minimum)

resulting in total thickness of not less than 150 micron wherever required, such as
equipment cooling water overhead tank, condensate storage tank/ Reserve feed
water tank, DM Water tank, Service Water tank , Portable water tanketc.
4.13.03 Cleaning & Painting

Inside surface of all tanks including inside ladder and appurtenances shall be
protected by anti-corrosive paints/coating as required and specified elsewhere.
For tanks/vessel requiring epoxy painting, all inside surface shall be blast cleaned
using non-siliceous abrasive after usual wire brushing.
Outside surfaces of all other vessels shall be provided with two coats of primer
with three (3) coats of epoxy resin based paint of approved colour.
4.13.04 Technical Particulars of Tanks and Accessories
-------------------------------------------------------------------------------------------------
Sl.No. Description Tech. Particulars
-------------------------------------------------------------------------------------------------
Condensate Storage Tank
i) Quantity per module/Total Quantity One (1) / Three(3)
ii) Useful Capacity of Each Tank Two hours make-up requirement

considering 5% cycle make-up
iii) Size (Dia. x length) Adequate
vi) Design Standard ASME Section-VIII. Div.I/

IS:2825 (Class-3)
vii) Material of Construction MS Plates to IS:2062 Gr.B/

ASTM A36.
xi) Accessories :
(a) Vent, overflow and drain Required
(b) Sample Connection Required
(c) Level Indicator Required (Gauge glass )
(d) Level Switch LO-LO, LO, High, Hi-Hi.
(e) Level Transmitter Required

-------------------------------------------------------------------------------------------------
Note: Number/capacity/size of tank are minimum for bidder's offer purpose. It is

bidder's responsibility to design/size these tanks depending upon system
requirement/ design during detail engg. and submit the design calculations
to Engineer for approval alongwith tank GA drg. Additional Control &
Instrumentation facilities specified elsewhere in the technical specification
shall also be incorporated by the bidder.
4.14.00 STRAINERS
4.14.01 Simplex type

The strainers shall be basket type and of simplex construction. The strainer shall
be provided with plugged drain/blow off and vent connections. The free area of the
strainer element shall be at least four (4) times the internal area of the connecting
pipe lines. The strainer element shall be 20 mesh. Pressure drop across the
strainers in new condition shall not exceed 1.5 MWC at full flow. Wire mesh of the
strainers shall be suitably reinforced, to avoid buckling under operation. Strainer
shall have screwed blow off connection fitted with a removable plug. The material
of construction of various parts shall be as follows:
(a) Body IS:318, Gr. 2 upto 50 mm Nb, and IS: 210

Gr. FG 260 above 50 mm Nb. (For DM
water/sea water Body : AISI 316 or equivalent)
(b) Strainer Element Stainless steel (AISI 316)
(c) End connection Screwed upto 50 mm Nb, and

Flanged above 50 mm Nb
4.14.02 Duplex type
The strainers shall be basket type and of duplex construction. The strainer shall
be provided with plugged drain/blow off and vent connections. The free area of the
strainer element shall be at least four (4) times the internal area of the connecting
pipe. The mesh of strainer element shall be commensurate with the actual service
required. Pressure drop across the strainer in new condition shall not exceed 4.0
MWC at full flow.
Wire mesh (if applicable) of the strainers shall be suitably reinforced. The material
of construction of various parts shall be as follows.
Body IS:318, Gr. 2 (SS-316 or Duplex S.S for sea-

water) upto 50 mm Nb, and IS:210, Gr. FG
260 or ASTM-A-515 Gr. 75/ IS-2062 Gr. B
& internally epoxy-painted above 50 mm NB.
Strainer element. Stainless steel (AISI 316)
End connection Screwed upto 50mm Nb, and flanged above

50 mm Nb. Gasket shall be of full face type
The strainer shall have a permanent stainless steel tag fixed on the strainer body
indicating the strainer tag number and service and other salient data.
The size of the strainer and the flow direction shall be indicated on the strainer
body casting.
Thickness of the strainer element should be designed to withstand the pressure

developed within the strainer due to 100% clogged condition exerting shut-off
pressure on the element.
Two shop coats of paint preceded by two coats of primer shall be applied to all
exposed surfaces as required to prevent corrosion. All parts shall be adequately

protected for rust prevention. The use of grease or oil other than light grade
mineral oils for corrosion protection is prohibited.
4.14.03 Cleaning
Prior to factory inspection, all manufacturing waste such as metal chips, fillings,
debris and foreign matters shall be removed from the interior. All rust, oil, grease,
chalk, crayon, paint marks shall be removed from interior and exterior surfaces.
4.14.04 Painting
Two (2) shop coats of primer followed by three (3) coats of synthetic enamel paint
as per approved colour code resulting in a DFT of at-least 150 micron shall be
applied to all exposed surfaces as required to prevent corrosion, after release has
been given for painting and dispatch. All parts shall be adequately protected for
rust prevention. The use of grease or oil other than light grade mineral oil for
corrosion protection is prohibited. If any part of the shop-finished paint is
damaged, the same shall be made good after erection with touch-up painting and
or repair painting.
5.00.00 INSPECTION & TESTING
A detailed quality assurance plan covering stagewise tests to be carried out during
the manufacturing of equipment / vessels including testing at site indicating
involvement of bidder, subvendor and Owner categorically shall be furnished
along with the bid.
5.01.00 Tests at manufacturing unit
The tests at manufacturing unit of vendor / subvendor shall include but not be
limited to following :
a) Physical and chemical properties of material of construction.
b) Dimensional check, Die penetration test, Radiography of all weld joints.
c) Hydrotesting at 1.5 times the design pressure for underground and over
ground piping.
The quality assurance plan shall be approved by Owner.
5.02.00 Testing at Site
All equipment shall be guaranteed by the bidder for workmanship, materials and
satisfactory performance. The guarantee for performance shall cover individual
items and systems.
5.02.01 Testing at site for L.P. Piping and associated auxiliaries shall generally include but
not limited to following:
a) Hydrotesting of pipe loops and system as a hole at 1.5 times the design
pressure.

b) Non destructive testing as per applicable manufacturing standard for

welding axes.
c) Satisfaction performance and functional test of associated auxiliaries i.e.

expansion joints, valves and actuators, etc.

DESIGN GUIDE FOR
CORE ENGG
DIVISION OF WORK FOR
ELECTRICAL
MECHANICAL PACKAGES
ANNEXURE A: DIVISION OF WORK MATRIX

General Notes:
The following points shall be appended below the DOW Matrix for every package
1. The vendor shall supply and erect all miscellaneous material, hardware, consumables, Secondary
earthing material, Treated-earth pit material, Lightning protection material, Fire protection coating
system material and Fire-proof sealing system material required for the complete installation under
his scope.
• Miscellaneous material: All foundation steels such as ISMC, ISA, base frame, base plate,
foundation bolts, anchor fastener, rubber mat, mounting brackets, insert plates etc.
• Hardware : GI bolts, nuts, washers, screws, brackets, supports, clamps, hangers, saddles,
cleats, sills, shims, ferrules, socket, PVC sleeve, cotton thread, adhesive / non adhesive PVC
tapes etc.
• Consumables : Welding rods and gas, oil and grease, cleaning fluids, paints, electrical tape,
soldering materials, cleaning cloths, cotton waste etc.
2. Cabling accessories include Termination Kits, Jointing Kits, Glands, Lugs, Ferrules, Cable Tags,
Dressing Material, Bricks, Sand and Slab for Buried Cables, Clamps, Cleats and Route Markers
etc.
3. Illumination includes Foundation Material, Installation of Foundation, Poles, Fixtures, Luminaries,
Lamps, Control Gear, Lighting Transformer, LDB, MLDB, LP, FPB, Portable Emergency Lighting
Unit, Ladder, DC-ELDB, Brackets, Fixing Accessories, Electrical Winch Operated High Mast,
Switchboxes, Cable, Wires, Conduits, Earth Wires, Receptacles, Ceiling Fans, JBs etc.
4. Abbreviations used:
ETC : Erection, Testing & Commissioning
R Infra : Reliance Infrastructure Limited
EEC : R Infra’s contractor for Electrical erection, testing & commissioning
LEC : R Infra’s contractor for Lighting erection
Vendor : R Infra’s contractor for mechanical package
MEC : R Infra’s contractor for Mechanical erection, testing & commissioning
ES : Equipment supplier
5. Variable Frequency Drives: This item may be added to the matrix of applicable packages, as per
project requirement. The Supply & ETC of all equipments and accessories as required from
Isolation / Rectifier / Step down Transformer like Isolation / Rectifier / Step down Transformer, VFD
panel, LV PMCC/MCC, Cables from transformer to motors, Cables from LV PMCC / MCC to
motors, Cable tray, Cabling accessories etc shall be in Vendor’s scope. The Supply & ETC of Air-
Conditioning System as required for VFD room shall also be in Vendor’s Scope.
Equipment Supply ETC Terminal Inclusion in Exclusion from

Description points vendor’s scope vendor’s scope
VFD complete Vendor Vendor Incoming As above
with all supply
accessories. terminals of
Isolation /
Rectifier /
Step down
Transformer
Document Number : REL-COENG-NEE-E21-P-000XX Sheet 1 / 3

DESIGN GUIDE FOR
CORE ENGG
ELECTRICAL
MECHANICAL PACKAGES
Equipment Supply ETC Terminal Inclusion in Exclusion from

Description points vendor’s scope vendor’s scope
MV switchgear NA NA
HT Cable NA NA
Auxiliary transformer NA NA
/ NGR
LT Busduct NA NA
PMCC / PCC / MCC NA NA
Charger / Battery / NA NA
DCDB
Sub DCDB NA NA
LT Power and Switchgear Supply and ETC of
Control cable R Infra EEC all cables to vendor
supplied equipment
Cable Tray / Support Switchgear
/ Conduits R Infra EEC
Cabling Accessories
R Infra EEC
Fire-Proof Coating / NA NA
Fire Protection
Sealing System
Secondary Earthing Vendor Vendor R Infra’s For all equipment
earth riser erected by the
vendor
Primary Earthing / R Infra Civil
untreated Earth pits
Treated Earth pits NA NA
Local starter panel Vendor Vendor
ACDB with 3 phase / R Infra EEC
single phase feeders
Three phase PDB NA NA
with single phase
feeders
Welding / Single NA NA
Phase Receptacles
LPBS Vendor Vendor
Motors and Actuators Vendor Vendor
with accessories/
Solenoid Operated
Valves
Illumination Vendor Vendor Skid illumination Indoor illumination
Lightning protection NA NA
Communication NA NA
(EPABX, PA system,
Wireless System)
Special Cable (if any) Vendor Vendor
NOTES:

DESIGN GUIDE FOR
CORE ENGG
ELECTRICAL
MECHANICAL PACKAGES
1. All supply and erection work related to the internal illumination and earthing of skid mounted
equipment shall be in the vendor’s scope. Bidder may refer to the Chapter E14 for Hazardous area
2. R Infra will connect up the power supply / secondary earth to the terminal points on the skid.

ELECTRICAL SYSTEM STANDARD
DESCRIPTION SPECIFICATION
E0 - ELECTRICAL SYSTEM DESCRIPTION
Document Number: Part II, Section C

Sheet 1 of 2
REL-COENG-NEE-E21-P0039 R0 Electrical Section (E0)
ELECTRICAL SYSTEM STANDARD
DESCRIPTION SPECIFICATION
1.0 System Voltage & Frequency

S.No. System Volt. & Fault Application Grounding
Frequency Level
1.1 6.6 kV ± 10%, 3Ph, 3 40 KA Motors above 200 kW Low Resistant
wire, 50 Hz ±5% (1 sec) earthed
1.2 415V ± 10%, 3Ph, 4 50 KA Motors up to 200 kW Effectively

wire, 50 Hz ±5% (1 sec) earthed
1.3 240V ± 10%, 1Ph, 2 50 KA Motors up to 200 W, Effectively

wire, 50 Hz ±5% (1 sec) Heaters up to 1 kW, earthed
Lighting, Control supply
1.4 110V ± 10%, 1Ph, 2 - MCC Control Supply Effectively
wire, 50 Hz ±5% Earthed
1.5 Combined variations of voltage & frequency are 10% in all above
1.6 220 V DC (-) 15% to 25 KA Control/Protection Unearthed
(+) 10%, 2 wire (1 sec) Supply, DC motors,
Emergency Lighting
Any other supply voltage (not covered above) if needed shall be developed through
transformation / rectification by the bidder.
2.0 Service Condition

2.1 Ambient air temperature -5°C to 50°C
2.2 Humidity 95%
2.3 Altitude ≤ 1000 meter
2.4 Ambient air pollution as per IEC 60068 3
2.5 Prevailing wind velocity Refer to the main specification
2.6 Seismic zone Refer to the main specification
2.7 Rain fall Refer to the main specification
3.0 Differential Protection

3.1 Differential protection will be provided for motor > 2000 kW
3.2 The bidder shall provide neutral terminal box & CT on neutral lead of each
phase

Sheet 2 of 2
STANDARD
LT MOTOR
SPECIFICATION
E1 – LT MOTOR

Sheet 1 of 7
STANDARD
LT MOTOR
SPECIFICATION
1.0 Not Used
2.0 Codes and Standards

The installation shall meet the requirements of Indian Electricity rules. Materials,
equipment and methods used in the manufacture shall conform to the latest edition of IS
and IEC standards, including the following. If standard other than IS/IEC are used in
design, manufacturing & testing, a copy of the same in English shall be submitted with
the Bid.
IEC 60034 Rotating electrical machines

IEC 60079-1 Equipment protection by flameproof enclosures "d"
IEC 60085 Electrical insulation - Thermal evaluation and designation
IS 325 Three-Phase Induction Motors
CEA Standardisation of Motors for Thermal Power Station Auxiliaries, April
93
NEMA Application Guide for AC Adjustable Speed Drive Systems
3.0 Design Parameters

3.1 Service condition Refer to Electrical system description
3.2 System parameter Refer to Electrical system description for system voltage
/ frequency / fault level / neutral earthing
3.3 Rated Continuous i. To be arrived at, with 10% margin over the maximum
Output required mechanical output
ii. If higher margin is specified in mechanical
specification, the same shall be provided
iii. The motor kW shall be chosen from the prescribed
series, and shall be more than the calculated value
iv. Up to 110 kW, Clause 8.3 of IS 325 shall be followed
v. Above 110 kW, R20 series (IS 1076) shall be
followed
3.4 Temperature Rise i. Shall not exceed the values given in Table-1 of IS
(above 50°C 12802
ambient) ii. For Air cooled motors - 70 deg. C by resistance
method for both class B&F insulation
iii. For outdoor motors exposed to sunrays, the effect of
solar radiation shall be considered
3.5 Motor type i. Unless otherwise specified, the AC motor shall be a
constant speed squirrel cage three phase induction
motor
ii. DC motor shall be continuous rated, shunt /
compound wound and shall be supplied with a
single-stage resistance starter panel
3.6 Duty Cycle / i. S1 / continuous for all general purpose motors
designation ii. S4 / Intermittent periodic duty with starting OR S5 /
Intermittent periodic duty with starting and electric
braking for crane duty motors
3.7 Method of Starting DOL unless exclusively specified elsewhere
3.8 Starting current in % i. Limited to 600% (with no positive tolerance) for AC
of full load current at motors
rated voltage ii. Limited to 200% (with no positive tolerance) for DC
motors

Sheet 2 of 7
STANDARD
LT MOTOR
SPECIFICATION
3.9 Minimum voltage at 80%

motor terminals
during starting
3.10 Operation at reduced i. Motor shall not stall at 70% voltage for a duration of
voltage 2 sec
ii. Motors shall run satisfactorily for at least five
minutes at 75% supply voltage, without injurious
heating
3.11 Number of i. Three for coal handling motors (conveyer & crusher)
successive hot starts ii. Two for all other motors
iii. If higher number of starts is specified in mechanical
specification, the same shall be provided
3.12 Number of equally i. Three
spread starts in an ii. If higher number of starts is specified in mechanical
hour specification, the same shall be provided
3.13 Relation between Locked-rotor withstand time (TLR ) - Starting time (TST)
starting time & shall be greater than 3 sec, at same voltage (applicable
locked-rotor at 80%, 100% and 110% voltages)
withstand time
3.14 Torque requirement i. Pull-out torque at the rated voltage shall not be less
than 205% of the rated torque with no negative
tolerance
ii. The torque characteristics shall be matched with
drive requirement over the range of operation
3.15 Vibrations Unless otherwise specified the vibration level shall meet
the requirement laid out in IS12075 for normal class &
also meet the drive requirement
3.16 Noise level at a 85 dB (A)
distance on 1.0
metre
3.17 Class of insulation i. Up to 0.2 kW - B (limited to class E Temp rise)
ii. Above 0.2 kW - F (limited to class B Temp rise)
3.18 Direction of rotation i. Motors shall be suitable for bidirectional rotation
unless otherwise exclusively specified elsewhere
ii. Wherever uni-directional is provided, mechanical
ratchet shall be provided to prevent reverse rotation
iii. Normal direction unless specified shall be clockwise
from the coupling end when ABC is the connection
3.19 Tropicalisation All motors shall have tropical protection involving special
treatment of insulation and metal for fungus protection
and corrosion protection.
3.20 Starting under Pump motor subject to reverse rotation shall be
reverse rotation designed to withstand the stresses encountered when
condition starting with shaft rotating at 125% rated speed in
reverse direction.
3.21 Over-speed 120% for 2 minutes
capability
3.22 Minimum power 0.85 at rated voltage, frequency and load
factor
3.23 Efficiency class Improved efficiency class-Eff2 as defined in IS 12615

Sheet 3 of 7
STANDARD
LT MOTOR
SPECIFICATION
4.0 Construction
4.1. Stator
4.1.1 Stator lamination Silicon steel / magnetic steel sheet varnished on both
sides and pressed to form a rigid core
4.2. Rotor
4.2.1 Assembly Rigid cage construction with die-cast aluminium / copper
alloy / copper bars firmly wedged in bar slots and brazed
to the end rings
4.3. Winding
4.3.1 Winding i. Electrolytic copper
ii. Shall be given special treatment to render them non-
hygroscopic, flame resistant and oil-resistant
4.4. Bearing
4.4.1 Type i. Antifriction type
ii. Sleeve type for special application
iii. Thrust & guide type for vertical motors (Motors
furnished with spherical roller thrust bearing will be
furnished with deep groove radial guide bearings)
iv. Motors with belt pulley coupling shall be provided with
roller bearing on DE side
v. For fractional kW motors bearing shall be double
sealed type
4.4.2 Bearing life i. At least 40,000 Hrs when direct coupled
ii. At least 20,000 Hrs when coupled with belt or chain
4.4.3 Bearing cooling
4.4.3.1 Self cooling Bearing shall be self cooled
4.4.4 Sealing / greasing It shall be effectively sealed against dust ingress and
shall be pressure grease gun lubricated type fitted with
grease nipple and shall have grease relief devices
4.5. Degree of Protection, Enclosure and Cooling

4.5.1 Motors installed IP 54 of IS 4691
indoor
4.5.2 Motors installed IP 55 of IS 4691
outdoor
4.5.3 Motors installed in According to the area classification, Flameproof /
hazardous area increased safety design confirming to Chapter E14 for
Hazardous Area.
4.5.4 Enclosure TEFC as per IC-0141 of IS 6362 (It shall be possible to

reverse the fan if required without effecting balance)
4.5.5 Drain plug All motors shall be provided with a drain plug to drain
condensed water
4.5.6 Lifting hook Adequate lifting hooks shall be provided

Sheet 4 of 7
STANDARD
LT MOTOR
SPECIFICATION
4.6. Coupling
4.6.1 Coupling Except when otherwise specified, the motor shall be
provided with a bare shaft extension having a key slot
and a key at DE
4.7. Terminal box

4.7.1 Main terminal box i. Shall be detachable type and can be turned 360° in
Power cable steps of 90°
termination ii. Removable, undrilled gland plates of thickness 3 mm
(hot/cold rolled sheet steel) or 4 mm (non magnetic
material for single core cables) shall be provided
iii. The terminals shall be clearly identified by phase
markings, with corresponding direction of rotation
marked on the NDE of the motor
iv. Rated Short circuit current (System fault level as
specified in Electrical section E0) withstand for
duration of at least 0.12 sec.
v. Stud type terminals shall be used
vi. Terminal box shall be suitable for XLPE/PVC
insulated, armoured, overall FRLS PVC sheathed
cable with stranded aluminium conductor
vii. The distance from the motor terminals to the cable
gland plate shall be adequate to accommodate
trifurcation requirement of three core cables. Final
dimensions will be decided during detailed
engineering based on the cable size
viii. The location (left, right or top) shall be subject to
approval of the purchaser during detail engineering
4.7.2 Terminal box for Dedicated terminal box shall be provided for space heater
space heater
4.8. Anti-condensation heaters

4.8.1 Application Motor rating 30 kW and above
4.8.2 Location It shall be placed in easily accessible position in the
lowest part of motor frame
4.8.3 Supply 240 V, 50Hz single phase supply
4.9. Earthing
4.9.1 Earthing conductor for phase TBs
i. Motor rating ≤ 5 kW 4 mm (dia) GI wire
ii. 5 kW < Motor rating ≤ 30 kW 25 X 3 mm GI strip
iii. 30 kW < Motor rating ≤ 90 kW 35 X 6 mm GI strip
iv. Motor rating > 90 kW 50 X 6 mm GI strip
4.9.2 Earthing conductor for other TBs 4 mm (dia) GI wire
4.9.3 Earthing points complete with i. Two points for motor body
hardware shall be provided (on ii. Two points each for phase terminal
opposite sides) box
iii. One point each for other terminal
boxes

Sheet 5 of 7
STANDARD
LT MOTOR
SPECIFICATION
4.10. Marking
The following indelible markings shall be provided on the rating plate fixed on each
motor:
4.10.1 Motor type
4.10.2 Name of manufacturer, Manufacturer’s number and frame reference
4.10.3 Rated voltage, Current, frequency and winding connections, Rated output in
kW, Service factor
4.10.4 Efficiency at rated output, Type of duty, Class of insulation, Degree of
protection
4.10.5 Speeds in revolutions per minute, at rated output
4.10.6 Bearing identification number, Lubricant, Lubrication material
4.10.7 Weight, Frame size
4.10.8 Direction of rotation
4.10.9 Location of insulated bearing
5.0 Inspection and Testing
5.1. Routine test

5.1.1 The motor shall be fully assembled and tested at the factory. Routine tests
shall be performed in accordance with IS 325 & IEC 60034-1 and as provided
below
5.1.2 Verification of dimensions
5.1.3 Insulation resistance / PI test As per clause 30.2 of IS 4722
5.1.4 Measurement of resistance of windings of
stator and wound rotor
5.1.5 Reduced voltage running up test at no load As per clause 23.2 of IS 325
(for squirrel cage motors up to 37 kW only
5.1.6 No load test at rated voltage to determine As per clause 23.1 of IS 325
input current power and speed
5.1.7 Locked rotor readings of voltage, current As per IS 4029
and power input at a suitable reduced
voltage
5.1.8 High voltage test As per IS 4029
5.1.9 Vibration measurement
5.1.10 Noise measurement
5.2. Type test

5.2.1 Type tests reports as listed below shall be submitted with the bid, and not be
older than 5 years on the date of submission
5.2.2 The type tested motor shall be identical to the offered motor in essential
details. The kW rating may be one step higher or lower in the kW series
(Clause 8.3 of IS 325 / R20 series of IS 1076 as applicable)
5.2.3 Full load test to determine efficiency power As per clause 23.5 of IS 325
factor and slip
5.2.4 Temperature rise test As per clause 14.0 of IS 325
5.2.5 Momentary overload test As per clause 13.1 of IS 325
5.2.6 Test for vibration severity of motor As per clause 15.0 of IS 325
5.2.7 Test for noise levels of motor As per clause 16.0 of IS 325
5.2.8 Test for degree of protection by enclosure As per clause 5.0 of IS 325

Sheet 6 of 7
STANDARD
LT MOTOR
SPECIFICATION
5.2.9 Temperature rise test at limiting values of

voltage and frequency variation
5.2.10 Over-speed test As per clause 26.0 of IS 325
5.2.11 Test on insulation system As per clause 27.0 of IS 325
5.2.12 Fault withstand test on terminal box
5.3. Special test

Apart from the above mentioned test, the following shall be performed on one motor of
each rating
5.3.1 Full load test (Efficiency, power factor and slip)
5.3.2 Temperature rise test
5.3.3 Momentary overload test
5.3.4 Speed – Torque characteristics
5.4. Test witness

5.4.1 At least 14 days’ advance notice shall be given to the Buyer / Owner to enable
them to witness the test, at their discretion
5.4.2 Routine tests of Motors shall be witnessed 100%
5.5. Test reports / Certificates

5.5.1 Routine Tests and Special tests: Certified reports to be submitted for approval.
The Motor shall be dispatched from works only after the Buyer’s written
approval is received
5.5.2 Tests reports shall be furnished for the Type tests, as specified. Otherwise, the
bidder shall get the Motor Type-tested to prove the design at his cost

Sheet 7 of 7
MOTOR OPERATED STANDARD
ACTUATOR SPECIFICATION
E3 – MOTOR OPERATED ACTUATOR

Sheet 1 of 8
1.0 Not Used

the Bid.
IEC 60034 Rotating electrical machines

IS 325 Three-Phase Induction Motors
IS 4722 Rotating Electrical Machines
IS 9334 Electric motor operated actuators
3.0 Design Parameters
3.1. Design inputs

3.1.1 Service condition Design ambient temperature Refer Electrical
Design humidity System
3.1.2 System parameter System Voltage & variations Description
System Frequency & variations
Combined voltage, frequency variations
Neural earthing, Fault level
3.2. Design criteria

3.2.1 Torque i. Sufficient torque will be provided to open or close the
requirement valve, gate, or damper against maximum differential
pressure, static pressure, and seating or unseating
torque at any voltage range between minimum and
maximum voltage range specified on the data sheets
ii. Shall be capable of meeting 150 percent of unseating
torque at specified voltage
3.2.2 Operating speeds, i. Included on the prime equipment data sheets,
differential and supporting lists, or other reports
static process line ii. The operating speeds and torques (if not specified)
pressures, and will be coordinated by the Supplier with the actuated
process line flow equipment requirements and will be acceptable to the
rates Purchaser
3.2.3 Performance i. Open and close the valve completely and make leak
requirement tight valve closure, without jamming
ii. Attain full speed operation before valve load is
encountered and impart an unseating blow to start the
valve in motion (hammer blow effect)
iii. Operate the valve stem at standard stem speed and
shall function against design differential pressure
across the valve seat
iv. The entire mechanism shall withstand shock resulting
from closing with improper setting of limit switches or
from lodging of foreign matter under the valve seat

Sheet 2 of 8
3.2.4 Gear trains i. It will have all-metal gear trains

ii. Fibre gears are not acceptable for the transmission
components developing output effort
iii. Gear ratios shall be self-locking
4.0 Construction
4.1. Actuator
4.1.1 Assembly The actuator will essentially comprise the drive motor,
torque/limit switches, gear train, clutch, hand wheel,
position indicator, position transmitter, motor starter,
control transformer, integral control station, space heater,
internal wiring and terminals
4.1.2 Hand wheel i. Actuators are to automatically revert back to motor
operation, disengaging the hand wheel, upon
energizing the motor
ii. Clockwise operation of the hand wheel will provide a
closing action of the valve, gate, or damper
iii. Declutching mechanism shall be provided to allow
hand wheel engagement at any time, except when the
motor is energized
iv. Rim pull will not exceed 18 kg
4.1.3 Dial position A local mechanical dial position indicator that
indicator continuously indicates the exact (0 to 100 %) position of
the valve, gate, or damper will be provided
4.1.4 Mounting The actuator will be designed for mounting in any position
without any lubricant leakage or operating difficulty
4.2. Motor
4.2.1 Type i. Surface cooled 3-phase squirrel cage induction
motors
ii. If direct current motor is used it will be of the shunt-
wound type
4.2.2 Starting Shall be direct on-line
4.2.3 Minimum starting 85% of the rated voltage
voltage
4.2.4 Capability during Shall be running for 5 minutes at
under voltage i. 80% of rated voltage
ii. 85% of rated voltage at 33% excess rated torque
4.2.5 Starting current Shall not exceed six times full load current
4.2.6 Insulation Class F non-hygroscopic standard insulation, suitable for
dusty and corrosive atmospheres
4.2.7 Temperature rise Embedded thermostat in motor winding should be
protection provided so as to disconnect the motor control circuit
when the maximum winding temperature is reached
4.2.8 Bearing i. Shall be antifriction
ii. Minimum rating life of not less than 15,000 hours
4.2.9 Motor flanges If used, will have dimensions in conformance with IS 9334
4.2.10 Sealing Preferably be “O” ring sealed for complete environmental
protection
4.2.11 Painting 2 coats of corrosion-proof epoxy resin paint

Sheet 3 of 8
4.3. Limit Switches

4.3.1 Type Shall be either changeover types or make-and-break
contact types
4.3.2 Auxiliary contacts All limit switches will have at least two NO and two NC
contacts
4.3.3 Switching capacity i. At least 5 amperes on 250 volt ac on resistive load
ii. At least 0.5 ampere on 250 volt dc
4.3.4 Number of Limit switches shall be capable of 6000 operations per
operations hour
4.3.5 Enclosure Limit switches shall be housed in a separate enclosure
with the same protection class as that of an actuator
4.3.6 Torque limit i. Two torque limit switches, one at each end of travel
switches ii. Each switch will be independently adjustable and will
permit settings between rated full load torque and
40% or less of that value
iii. Shall be used to limit the torque and thrust loads in
both closing and opening directions
iv. Shall function to stop motor on closing. Upon
actuation by the torque clutch, it is restricted in its
attempt to open or close, thereby causing an
overloading torque
v. Means shall also be provided to prevent the open
torque switch tripping while the initial unseating
hammer blow effect is applied
vi. Once the torque switch actuates and trips, the switch
shall not reset until the motor is energized in the
opposite direction (non self-reset type)
4.3.7 Position limit i. Four position limit switches, two for open and two for
switches close
ii. Each set of two switches will be independently
adjustable to trip at any position between the fully
open and fully closed positions
4.3.8 Travel / i. Requirement shall be finalised during detailed
Intermediate limit engineering
switch ii. Four travel / intermediate limit switch (if required)
4.4. Non modulating type actuator

4.4.1 Starting torque Will not be less than 500 percent of rated full load torque
4.4.2 The motor time rating for normal opening and closing service will not be less
than whichever of the following is greatest:
4.4.2.1 Electric actuators specified for non-modulating service will be capable of
three successive open-close operations with no time interval between
operations, when operating at an average load of 33 percent maximum
driven equipment torque in a 50°C ambient temperature
4.4.2.2 Fifteen (15) minutes at maximum driven equipment torque in a 50° C
ambient temperature
4.4.2.3 As specified elsewhere
4.4.2.4 As required for the service
4.5. Modulating type actuator

4.5.1 Starting torque Will not be less than 200 percent of rated full load torque

Sheet 4 of 8
4.5.2 The motor time rating for normal opening and closing service will not be less
than whichever of the following is greatest:
4.5.2.1 Electric actuators specified for modulating service will be capable of
continuous modulation with not less than 60 starts/stops per minute at full
rated torque without overheating or requiring separate cooling provisions
4.5.2.2 As specified elsewhere
4.5.2.3 As required for the service
4.6. Integral starter

4.6.1 Components Close-coupled power disconnect switch or circuit breaker
capable of being locked in the open position, forward and
reverse contactors, control power transformer 415/240 V,
and motor overload protection devices
4.6.2 Enclosure Power disconnect switch or circuit breaker shall be
protection weatherproof, dust-tight and suitable for outdoor service
4.6.3 Capacity against Rated to withstand (disconnect switch) or interrupt (circuit
short circuit breaker) the short-circuit current specified in the Electrical
System Description
4.6.4 Motor Overload i. Shall be wired to de-energize the contactors on motor
device overload, and will be capable of either automatic or
manual reset
ii. Motor thermal sensing devices with automatic reset
may be used instead of motor overload devices
provided it is the manufacturer’s standard practice
4.6.5 Interlocks The forward and reverse contactors will be mechanically
and electrically interlocked to ensure that only one
contactor coil can be energized at a time
4.6.6 Control power i. The primary winding of the control power transformer,
transformer complete with two primary fuses, will be connected to
two of the three incoming power source phases
ii. Each ungrounded conductor on the control power
transformer secondary will be fused
iii. The primary and secondary winding fuses will be
easily replaceable without removing any internal
components
iv. The control power transformer will have the necessary
taps and capacity as required to energize the
contactor coils, actuator and motor space heaters,
and internal electrical controls
4.6.7 For Direct Current i. Protective devices will not trip or open the contactor
motors for locked-rotor currents
ii. Overload devices will have contact closure for remote
alarm on motor overload
iii. The dc starter will be mounted separately from the
electric actuator
4.7. Enclosure, Degree of protection

4.7.1 Material Cast iron / cast aluminium alloy / steel
4.7.2 Type Totally enclosed, non-ventilated, dust-tight, and
weatherproof suitable for outdoor service without
necessity of any canopy

Sheet 5 of 8
4.7.3 Valve stem cover Weather tight, closed end, metallic valve stem cover of
the appropriate length
4.7.4 Ingress protection i. Minimum IP 55, weather proof type
ii. Shall be finalised during detailed engineering for
special applications
iii. If IP 67 enclosure is provided, it shall be capable of
submersion in water with 3 meters head for 48 hours
4.7.5 Installation in i. The surface temperature for electric actuators with
hazardous dust ignition proof features will not exceed 120° C
classified area ii. Shall have weatherproof features conforming to the
dust and water requirements of IP 65 enclosures
iii. The enclosure of the actuator shall have a nameplate
identifying hazardous area rating of the electric
actuators and the name of the certifying institution
iv. In confirmation with chapter E14 for Hazardous Area.
4.7.6 Drain plug If the Supplier’s design requires enclosures equipped with
drain plugs to control condensation, the drain plugs will
be combination water drain-breather type
4.8. Termination
4.8.1 The terminal boxes will be weatherproof and fitted with a removable cover
plate in front
4.8.2 Motor terminal box and actuator terminal box shall be provided with cable
glands to suit cable type and size. Cable glands shall be supplied by the bidder
4.8.3 Provisions will be provided to terminate Purchaser’s field cables at terminal
points that can be made accessible during operation of the actuator
4.8.4 The terminal box of motor shall be capable of being turned through 360° in
steps of 90°
4.8.5 Internal wiring diagram printed on corrosion resistant sheet shall be attached
on the inside cover of the terminal box
4.9. Anti-condensation heaters

4.9.1 Supply Shall be powered from the control transformer
4.10. Earthing
4.10.1 Size and material for 8SWG (4 mm dia) GI wire
earthing conductor
4.10.2 Earthing terminal Shall be provided either side of the motor
locations
5.0 Control
The following minimum controls shall be provided. Other requirements if any arising
during detailed engineering shall be provided by the bidder at no additional cost.
5.1. Local control

5.1.1 The actuator shall be provided with an integral control station
5.1.2 The control station will consist of an “open-stop-close” push-button station with
open/close indicating lights and an integral selector switch that is lockable in
the “local,” “remote,” and “off” positions

Sheet 6 of 8
5.1.3 The push buttons and selector switch will be accessible from outside the
enclosure
5.2. Remote Control

5.2.1 For modulating type actuator
5.2.1.1 Command Shall be a 4 to 20 mA signal from the control system,
proportional to the desired operator position. Positioning
and protection circuits are to be provided in the actuator
5.2.1.2 Status / Alarm (OPEN, CLOSE, FAULT) shall be potential-free contacts
feedback from the actuator
5.2.1.3 Continuous i. Will be a 2-wire (loop powered) optically isolated 4 to 20
position mA output signal which is proportional to operator
feedback position
ii. The accuracy of this system will be ±1 percent linear
over the full range of the output
5.2.2 For non-modulating type actuator
5.2.2.1 Command i. (OPEN, CLOSE) commands shall be potential-free
contacts from the Control system
ii. The interrogating voltage shall come from the actuator
iii. Interposing relays shall be provided inside the actuator
5.2.2.2 Status / Alarm (OPEN, CLOSE, REMOTE, FAULT) shall be potential-free
feedback contacts from the actuator
5.2.2.3 Logic building i. Open close command termination logic shall be inside
actuator
ii. All logics shall be freely configurable by the user
6.1. Routine Test

6.1.1 Routine test on motor As per clause 22.3.2. of IS325
6.1.2 Functional & calibration test for As per clause 9.2 of IS 9334
torque and limit switches
6.1.3 Response time test As per clause 9.4 of IS 9334
6.1.4 Variation of supply voltage As per clause 9.5 of IS 9334
6.1.5 Variation of frequency As per clause 9.7 of IS 9334
6.2. Acceptance Test

6.2.1 Acceptance tests on actuator As per clause 9.1.3 of IS 9334
6.3. Type Test

6.3.1 Type test on motor As per clause 9.1.1 of IS 9334
6.4. Test witness

6.4.1 At least 14 days’ advance notice shall be given to the Purchaser / Owner to
enable them to witness the test, at their discretion
6.5. Test reports / certificates

6.5.1 Routine / Acceptance Tests: Certified reports to be submitted for approval. The
Actuator shall be dispatched from works only after the Purchaser’s written
approval is received

Sheet 7 of 8
bidder shall get the Actuator Type-tested to prove the design at his cost

Sheet 8 of 8
STANDARD
MISCELLANEOUS LV BOARDS
SPECIFICATION
E-4 MISCELLANEOUS LV BOARDS
Document Number :
Part II, Section C
REL-COENG-NEE-E21-P-00043 Sheet 1 / 9
Electrical Section (E4)
Rev (00)
STANDARD
SPECIFICATION
1.0 GENERAL TECHNICAL INFORMATION
1.1 Service Condition

Refer to Electrical system description
1.2 Technical Parameters

For PDB / LSP
1. Rated operational voltage Ue 415Vac ± 10%
2. Rated insulation voltage Ui 1000Vac rms
3. Rated frequency 50 Hz (+3%, -5%)
4. Rated Normal Current Refer Attachment, Standard SLD for
Miscellaneous LV boards
5. Temperature rise of Bus and Bus i. Plain / tinned joints - 40°C
taps (over ambient of 50°C) ii. Silver plated joints - 55°C
6. Rated short time withstand current 50 kA rms
7. Rated duration of short time 1 Sec
withstand current
8. Control voltage for Contactor 110Vac±10%
Module
9. Service supply for heating, lighting 240Vac±10%, 50 Hz (+3%, -5%)
and power sockets (applicable for LSP)
10. System neutral earthing Effectively earthed
11. Number of phases Three phase + Neutral
12. Paint shade RAL7032 for complete panel
2.0 Not used
3.0 DETAILED TECHNICAL SPECIFICATION

The equipment shall meet the requirements of Indian Electricity rules. Materials,
equipment and methods used in the manufacture shall conform to the latest edition of
IS and IEC standards, including the following.
If standard other than IS/IEC are used in design, manufacturing and testing, a copy of
the same in English shall be submitted with the Bid.
IEC 60038 IEC Standard Voltages

IEC 60044-2 / Instrument Transformer - Inductive Voltage Transformer
IS 3156
IEC 60439 Low Voltage Switchgear and Controlgear assemblies - Type tested
and partially type tested assemblies
IEC 60529 Degrees of protection provided by enclosures (IP Code)
IEC 60947-1 Low Voltage Switchgear and Controlgear - General Rules
IEC 60947-4-1 Low Voltage Switchgear and Controlgear - Contactors and Motor
Starters
IS 5 Colours for Ready Mixed Paints and Enamels
IS 613 Copper Rods and Bars for electrical purposes
Document Number :
Part II, Section C
Rev (00)
STANDARD
SPECIFICATION
IS 694 PVC Insulated cables for working voltages up to and including 1100
V
IS 2551 Danger notice plates
IS 2544 Porcelain post insulators for system with nominal voltage greater
than 1000 V
IS 3231 Electrical Relays for power system protection
IS 3842 Application Guide electrical relays for ac system
IS 5082 Wrought Aluminium and Aluminium alloy bars, rods, tubes and
sections for electrical purpose
IS 6865 Control switches (switching devices for control and auxiliary circuits
including contactor relays) for voltages up to and including 1000 V
AC and 1200 V DC
IS 12021 Specification for Control Transformers for Switchgear and
Controlgear for Voltages not Exceeding 1 000 V ac
IS 13703 LV Fuses for voltage not exceeding 1000V ac or 1500V dc
IS 10118 Code of Practice for Selection, Installation and Maintenance of
Switchgear and Controlgear
3.2 Switchgear description

1. LSP (Local starter panel)
LSP shall mean a single panel with SDF operated incomer and SDF + contactor
operated feeders. LSP shall be three phase four wire type and shall be fed from
upstream PMCC / MCC. LSP shall provide complete control and protection for local
starting of one or several motors. It shall house Start / Stop / Overload reset push
buttons, SDF, contactor, overload relay and indicating lamp and any others required
for starting of the motors.
2. LPBS (Local Push Button Station)
LPBS shall mean a push button station with Emergency Stop push button and/or Start
push button.
3.3 Switchgear design criteria

3.3.1 PDB / LSP
1. Service i. PDB: Indoor
ii. LSP: Outdoor, with canopy
2. Type Metal Clad, Non compartmentalized
3. Mounting i. Structure / Wall
ii. Larger boards may be floor mounted on channel sills
4. Connections Cable entry - Bottom
5. Configuration Single front
6. Panel height <= 2500 mm
7. Enclosure degree i. Indoor : IP 52
of protection ii. Outdoor : IP 55
8. Spare feeder i. 20% spare outgoing feeders for each type and
rating, subject to minimum one number
ii. The spare feeder shall be fully equipped
9. Enclosure Material CRCA sheets
10. Enclosure Sheet i. Minimum 2.0 mm for load bearing members
Thickness ii. Minimum 1.6 mm for doors and covers
Document Number :
Part II, Section C
Rev (00)
STANDARD
SPECIFICATION
11. Short circuit The offered design should have been type tested for the
withstand Rated short time withstand current and Rated duration
mentioned in Technical parameters
12. Power Cable i. Suitable for XLPE insulated, armoured, PVC FRLSH
Termination sheathed cable with stranded aluminium conductor
ii. Size of cable shall be finalised by purchaser during
detailed engineering and design shall be adequate
13. Accessibility i. All equipment mounted inside the panels shall be so
located that their terminals and adjustments are
readily accessible for inspection or maintenance
ii. On opening of front door, access shall be provided
only to the operating and indicating components like
switches and lamps. Live parts shall not be exposed
14. Ratings Shall be as per requirement
15. Feeder sizing i. Continuous in-panel rating of feeders and their
associated electrical equipments shall be their
actual rating plus 10% margin, rounded off to the
next higher standard rating
ii. All motor feeders shall be continuously rated to their
name plate rating
16. Accessories for Refer to Chapter E14 Hazardous Area
LSP
3.3.2 LPBS
1. Service Indoor / Outdoor
2. Type Metal Clad with canopy for all outdoor LPBS
3. Mounting Structure / Wall
4. Connections Cable entry - Bottom
5. Enclosure degree i. Indoor : IP 54
of protection ii. Outdoor : IP 55
iii. In dusty area: IP 65
iv. Flame proof LPBS shall be suitable for the specified
Zone, Gas group and Temperature class
6. Enclosure Material CRCA sheets of minimum 1.6 mm
7. Push button guard Hinged MS guard shall be provided to prevent
inadvertent operation of push button
8. Type options As per requirement
9. Selection of Type Bidder shall select the type as per the application
Document Number :
Part II, Section C
Rev (00)
STANDARD
SPECIFICATION
3.4 Construction
3.4.1 Contactor
1. Type Unlatched, triple pole, air break type with non bouncing
silver/silver alloy contacts
2. Rated Duty Class-3
3. Utilization Category i. AC3 for unidirectional motors
according to IEC ii. AC4 for reversible motors
60947-4-1; Table-1
4. Rated operational Refer attachment, Standard SLD for Miscellaneous LV
current (Ie) boards
5. Number auxiliary 2 NO + 2 NC, rated 10 Amp at 240 V AC
contact
6. Permissible voltage Capable of pull-in at 85% of rated voltage and shall not
drop out at 70% of rated voltage or greater
7. Interlocking Contactors for forward and reverse direction of
provision reversible drives shall preferably be mechanically
interlocked
3.4.2 Meters
1. Voltmeter i. Flush mounted, 96 x 96 mm size, with 90° scale,
anti-glare glass
ii. Each meter shall have zero adjuster on the front
iii. Accuracy class 1.0
3.4.3 Lamps, Switches, Pushbuttons and Fuses

1. Lamps i. Shall be clustered type LED module pilot lights in
thermoplastic enclosure with polycarbonate lens and
diffuser
ii. LED shall be protected by in-built fuse with surge
suppressor and leakage voltage glow protection
iii. Lamp and lens shall be replaceable from front
2. Meter selector i. It shall be four position, maintained contact and
switch stay-put type, with knob handle
ii. Ammeter selector switches shall have make before
break contacts, to prevent open circuiting of CT
secondary
3. Switch details Dust protected, heavy duty, switchboard type, complete
with escutcheon plate
4. Push button i. Shall be heavy duty, shrouded
ii. Push to actuate type with coloured button and
inscription plate
iii. 2 NO + 2 NC contacts
iv. Emergency STOP push-buttons shall have
mushroom head actuator with press-to-latch and
key-to-release feature. Other push buttons shall be
of spring-return-to-normal type
Document Number :
Part II, Section C
Rev (00)
STANDARD
SPECIFICATION
5. Contact details i. Contacts shall be silver surfaced with conventional

enclosed thermal current of 10A
ii. Utilization category AC15, 3A rated operational
current at 240Vac
iii. Utilization category DC13, 1.1A rated operational
current at 250Vdc
3.4.4 Control and Indication

1. Control As per requirement
2. Indicating Lamps As per requirement
3.4.5 Wiring of Auxiliary and Control circuits

1. Wire i. Flexible, 650V grade, PVC insulated, with stranded
copper conductors
ii. 2.5 mm2 for current circuits
iii. 1.5 mm2 for control and voltage circuits
iv. 4 mm2 Bus wire for 220Vdc, 110 Vac and 240 Vac
2. Colour coding i. CT / PT wires shall be colour coded, as per phase
ii. Earth wires shall be Green and Neutral wires shall
be Black
3. Termination and i. Each wire shall be identified, at both ends, with
identification interlocking type permanent markers bearing wire
numbers (one additional red colour ferrule for all
wires in trip circuit)
ii. Wire termination shall be made with crimping type
connectors with insulating sleeves. Wires shall not
be spliced between terminals
iii. Each group shall be adequately supported along its
run to prevent sagging or strain on the termination
iv. Adhesive type support are not accepted
v. No of wires per terminal shall be limited to two (2)
3.4.6 Terminal Block

1. Terminal block i. Terminal blocks shall be located to allow easy access
ii. Wiring shall be so arranged that individual wires of an
external cable can be connected to consecutive
terminals
iii. 650V grade, with insulating cover complete with
mounting channel, binding screws and washers
iv. Marking strip for circuit identification shall be provided
for terminating the panel wiring
v. TBs shall be stud type for all CT, PT and 220V dc
control circuits
2. Control Terminals Suitable for 2 nos. 2.5 mm2 stranded copper conductor
3. Power terminals Suitable for one 10 mm2 stranded aluminium conductor
4. Spare terminals Equal to 20% of active terminals shall be provided for
each Terminal Block
5. TB shrouds and Moulded non- inflammable plastic material
separators
6. Clearance i. Between 2 rows of Terminal Box 100 mm
ii. With cable gland plate 250 mm
iii. Between AC / DC set of Terminal Box 100 mm
Document Number :
Part II, Section C
Rev (00)
STANDARD
SPECIFICATION
3.4.7 Cable Termination

1. Cable entry As specified in Design criteria
2. Power cable details Cable size will be finalized during detailed engineering
3. Gland plate and Removable, 3mm thick CRCA sheet steel for multi core
supports cables
4. Nut bolt and Cadmium plated Nut bolt and washer set for terminal
washer bus bars in cable compartment of each panel
3.4.8 Equipment Earthing

i. Earth bus 50 x 6mm GI bus provided with two holes with G.I. bolts
and nuts at each end to receive external earth conductor
1. External earth i. 50 x 6 mm GI flat (for PDB / LSP)
conductor ii. 8 SWG GI wire (for LPBS)
2. Each stationary unit Shall be connected directly to the earth bus
3. Earth connection of With two distinct connections
meters/relays
4. Hinged door Earthed through flexible insulated copper braid
5. CT and PT neutral Earthed at one place at the terminal blocks through links
so that earth of one circuit may be removed without
disturbing other.
3.4.9 Nameplate and Warning boards

1. Location of i. Switchgear nameplate at the front
nameplates ii. Feeder nameplate at the front and rear. This is to be
fixed on the frame and not on the removable covers
iii. Instruments and devices nameplate at the front and
rear
2. Warning symbol for On removable covers
dangerous voltages
as per IS 8923
3. Danger Sign Board On all four sides of switchgear
as per IS 2551
4. Material, text and Subject to approval during detailed engineering
size
5. Engraving With white letters on black background
3.4.10 Space heaters, Power socket and Illumination

1. Panel space heater i. Non exposed type, thermostat controlled
ii. To be provided to each panel / cable alley
iii. Shall maintain the enclosure at a temperature above
the dew point
iv. Shall be mounted on insulator base
2. Motor space heater i. Provided for Motor feeders rated 30kW and above
supply ii. Wired-up for feeding the motor space heater
through auxiliary contactor when the main Contactor
is off or isolated.
3. Power socket and Shall be provided in each panel / cable alley
Lighting
Document Number :
Part II, Section C
Rev (00)
STANDARD
SPECIFICATION
3.4.11 Painting and Tropical Protection

1. Surface preparation Surface shall be sand blasted, pickled and ground as
required to produce a smooth, clean surface free of
scale, grease and rust
2. Painting The surface shall be given a phosphate coating followed
by 2 coats of high quality primer. The coating shall be
done electro-statically followed by stoving
3. Tropical protection Shall have fungus protection, involving special treatment
of insulation and metal against fungus, insects and
corrosion
4. Suitability i. Shall withstand heat and weather conditions.
ii. Shall not scale - off or crinkle or get removed by
abrasion due to normal handling

3.5.1 Routine Test
1. The switchgear shall be fully assembled, wired and tested at the factory.
Routine tests shall be performed in accordance with IEC60439-1
2. The switchgear shall be operated under simulated service condition to
demonstrate accuracy of wiring, correctness of control scheme and proper
functioning of the equipment
3. Primary current and voltage shall be applied to all instrument transformers and
verified in all secondary devices like meters and relays
4. Verification of dimensions and clearances shall be demonstrated
5. Dielectric tests on Main and control circuits
3.5.2 Test Witness

1. At least 14 days’ advance notice shall be given to the Purchaser / Owner to
enable them to witness the test, at their discretion
3.5.3 Test Reports / Certificate

1. Routine Tests: Certified reports to be submitted for approval. The equipment
shall be dispatched from works only after the Purchaser’s written approval is
received
2. Tests reports shall be furnished for the Type tests, as specified. Otherwise, the
bidder shall get the equipment Type-tested to prove the design at his cost
3.6 Documentation
The bidder may note that the drawings, data and manuals listed herein are minimum
requirement only. The bidder shall ensure that all other necessary write-up, information,
etc required to fully describe the equipment are to be submitted.
The manual shall clearly indicate in English the installation and connection method.
Check up, maintenance and calibration method shall also be provided in the manuals.
S.No. Documents to be Submitted With After award

the For For
Bid approval reference
Document Number :
Part II, Section C
Rev (00)
STANDARD
SPECIFICATION
S.No. Documents to be Submitted With After award

the For For
Bid approval reference
1. Leaflets on equipment and other accessories
explaining their constructional details,
principle of operation, special features.
X
Components data on all electrical and control
devices being provided, including electrical
rating
2. Typical general arrangement drawing of the
equipment and foundation plan, Cable
Opening Size and Locations, Mounting X X
Details, and Cable Entry Area and Door
Swing Requirement
3. Feeder List (as per sample provided as
Attachment) filled in with Ratings and X X
Quantities
4. Proposal sheets (Data sheet) duly filled in X X
5. Bill of material with make / type of all
X X
components
6. Type test reports and certificates for the
X
specified type tests
7. Coordination report for Contactor starter to
demonstrate proper coordination between X
fuse and relay
8. Components data on all devices X
9. Sizing calculation of Bus bar X
10. Quality assurance plan X
11. Board-wise Single Line Diagram X
12. Control schematics X
13. Component selection chart for motor starters X
14. Certified reports of Routine tests, prior to
X
dispatch
X: Applicable
Document Number :
Part II, Section C
Rev (00)
STANDARD
HAZARDOUS AREA
SPECIFICATION
E14 – HAZARDOUS AREA

Sheet 1 of 3
REL-COENG-NEE-E21-P-00090 Electrical Section (E14)
STANDARD
HAZARDOUS AREA
SPECIFICATION

the Bid.
IEC 60079 Electrical Equipment for Explosive Gas Atmospheres

IS5571 Guide for the Selection of Electrical Equipment for Hazardous
Areas
IS 5572 Classification of Hazardous Areas for Electrical Installations
2.0 Area Classification and Selection of Electrical Equipment

The definition of areas shall be in accordance with IEC 60079, “Electrical
Equipment for Explosive Gas Atmospheres” or IS 5572, “Classification of
Hazardous Areas for Electrical Installations”.
Electrical equipment for use in a hazardous area shall be in accordance with IEC
60079, Electrical Equipment for Explosive Gas Atmospheres.
Electrical equipment shall be selected in accordance with IS5571 Guide for the
Selection of Electrical Equipment for Hazardous Areas. Unless otherwise
specified the following basis of selection shall be followed:
Zone 1 Areas (a) Flameproof or explosion proof, Ex(d) equipment

(b) Pressurised, Ex(p) equipment
(c) Intrinsically safe, Ex(ia) or Ex(ib) equipment
Zone 2 Areas (a) Non sparking, Ex(n) equipment
(b) Increased safety, Ex(e) equipment
(c) Equipment complying with the requirements for Zone
I areas
Unclassified Areas (a) Standard industrial equipment
(b) Equipment complying with the requirements for Zone
1 and 2 areas.
The bidder shall select his equipment to suit the gas-group and temperature
class in conformance with the hazardous area classification.
Earthing conductor should be designed such that the surface temperature is
limited to 200°C when carrying the designed short circuit current as per E0
Electrical System Description.
3.1. Type test

3.1.1 Type tests reports as listed below shall be submitted with the bid, and not be
older than 5 years on the date of submission
3.1.2 As per clause 26.5.1.3 of IEC
Maximum surface temperature rise Test
60079-0

Sheet 2 of 3
STANDARD
HAZARDOUS AREA
SPECIFICATION
3.1.3 Metallic Enclosures

Resistance to impact Test As per clause 26.4.2 of IEC
60079-0
Drop Test As per clause 26.4.3 of IEC
60079-0
Test for Degree of Protection As per clause 26.4.5 of IEC
60079-0
3.1.4 Non-metallic Enclosures
Group I, II & III Electrical equipments
Thermal Endurance to Heat Test As per clause 26.8 of IEC 60079-
0
Thermal Endurance to Cold Test As per clause 26.9 of IEC 60079-
0
Resistance to impact Test As per clause 26.4.2 of IEC
60079-0
Drop Test As per clause 26.4.3 of IEC
60079-0
Test for Degree of Protection As per clause 26.4.5 of IEC
60079-0
3.2. Other Tests for Ex(d) Equipment

3.2.1 Method of test for ascertainment of
As per IEC 60079-1-1
maximum experimental safe gap
3.2.2 Determination of explosion pressure As per clause 15.1.2 of IEC
(reference pressure) 60079-1
.
3.3. Test witness

3.3.1 At least 14 days’ advance notice shall be given to the Buyer / Owner to enable
them to witness the test, at their discretion
3.4. Test reports / Certificates

3.4.1 Equipment of Indian origin for installation in hazardous areas shall have a test
certificate from the Central Mining Research Institute (CMRI) and approval
certificates from the Chief Controller of Explosives (CCE).
3.4.2 Hazardous area equipment of non-Indian origin shall carry a valid test
certificate from a CENELEC listed testing authority.
3.4.3 For Ex n type equipment, certification as described above or a manufacturers

statement of compliance as stipulated in IEC 60079-15 shall be provided
bidder shall get the Equipment Type-tested to prove the design at his cost

Sheet 3 of 3
Guidelines for Lux
STANDARD
Level DOCUMENT
Minimum Illumination Levels to be maintained for Different Areas
Sr.
Location Lux Level
No.
1. Fuel Gas Supply & Conditioning Out Door Area 100
2. Gas Room 100
3. Office Rooms (without false Ceiling) 300
4. Office Room (With false ceiling) 300
5. Main road 20
6. Secondary road 10
Notes:
1. Lux level for A.C. Emergency lighting in control room, Emergency PMCC
Switchgear room, DG PCC room and DG Building will be 50 and for other
areas 20 lux.
2. Maintenance Factor for different areas shall be:
For Indoor Non-AC Area : 0.65
For Indoor AC Area : 0.75
For Outdoor Area : 0.5
3. The lux level mentioned above is in line with IS 3646.
Sheet 1 / 1
TECHNICAL SPECIFICATION FOR STANDARD
PACKAGE NAME SPECIFICATION
LT MOTOR DATA SHEET

The buyer’s requirements are specified in Section E2 and in column below
A-TO BE SUBMITTED ALONG WITH THE BID / AFTER AWARD

S.NO. DESCRIPTION DATA BY BUYER DATA BY BIDDER
1.0 GENERAL
1.1 Application/Driven Equipment
1.2 Quantity
1.3 Motor type
1.4 Service (Indoor / outdoor)
1.5 Make
1.6 Frame Size
1.7 Applicable Standard IS 325 & IEC 60034
2.0 RATING
2.1 Rated Continuous Output
2.1.1 At 40°C ambient (kW)
2.1.2 At 50°C ambient (kW)
2.2 Rated Voltage & % variation Refer section E0
2.3 Rated Frequency & % variation Refer section E0
2.4 Combined voltage & frequency variation Refer section E0
2.5 Rated speed (r.p.m.)
2.6 Over speed capacity 120% for 120 sec
2.7 Uni-directional or Bi-directional
2.8 Direction of rotation from NDE
2.9 Duty Cycle/Designation
2.9.1 For crane duty motors S4 / Intermittent
periodic duty with
starting OR S5 /
Intermittent periodic
duty with starting and
electric braking
2.9.2 For all general purpose motors S1 / continuous
2.10 Full load current (Amp)
2.11 No load current (Amp)
2.12 Full load torque (N-m)
2.13 Overload capacity % of full load torque 60% for 15 sec in hot
condition
3.0 PERFORMANCE
3.1 Method of Starting DOL
3.2 Maximum number of successive start at full Two (Three for coal
load in hot condition handling conveyor /
crusher motors)
3.3 Maximum number of equally spread starts Three
per hour
3.4 Starting Current in % full load current
Part II, Section 2

Document Number : Sheet 1 / 5
Technical Specification - Electrical
3.4.1 At 100% rated voltage

3.5 Starting Torque in % full load torque
3.5.1 At rated voltage
3.6 Minimum accelerating torque in % of full
load torque at rated voltage and frequency
3.7 Break down torque in % of full load torque
at rated voltage and frequency
3.8 Starting time (full load) TST
3.8.1 At 80% voltage
3.9 Locked rotor withstand time TLR
(hot condition)
3.9.1 At 80% voltage (TLR - TST) > 3 sec at
3.9.2 At 100% voltage same voltage
3.10 Locked rotor withstand time
(cold condition)
3.11 Power Factor (starting)
3.12 Power Factor (running) at rated V, f
3.12.1 At 100% load
3.12.2 At 75% load
3.12.3 At 50% load
3.12.4 At 25% load
3.13 Efficiency at rated voltage & frequency
3.13.1 At 100% load
3.13.2 At 75% load
3.13.3 At 50% load
3.13.4 At 25% load
3.14 Noise level at 1.0 metre in dB 85 dB (A)
3.15 Max. Vibration
3.15.1 At no load
3.15.2 At full load
4.0 CONSTRUCTION
4.1 Degree of Protection of Enclosure
4.2 Type of mounting
4.3 Method of motor Cooling
4.4 Insulation class
4.5 Temperature rise (over 50°C ambient) of
winding by winding resistance method (°C)
4.6 Treatment of insulation
Part II, Section 2

4.7 Tropicalisation required YES / NO

4.8 Winding Connection
4.8.1 Stator
4.8.2 Rotor
4.9 DE Bearings
4.9.1 Make
4.9.2 Type
4.9.3 Insulation from shaft current provided YES / NO
4.10 NDE Bearings
4.10.1 Make
4.10.2 Type
4.10.3 Insulation from shaft current provided YES / NO
5.0 TERMINATIONS
5.1 Motor Terminal Box
5.1.1 Fault current withstand with time
5.1.2 Position as viewed from NDE Left / Right
6.0 ACCESSORIES
6.1 Space Heaters (240Vac, 50Hz)
Nos. x Watt
6.2 Temperature indicators
6.2.1 Type
6.2.2 Nos. furnished
6.2.3 Location
7.0 SPECIAL CONSIDERATION
7.1 Area classification
7.1.1 Zone (1 / 2 / 3)
7.1.2 Temperature class (T1 / T2 / T3 / T4 / T5 /
T6)
7.1.3 Gas group (IIA / IIB / IIC)
7.1.4 Type of protection (ExN / Exe / Exd / Exp /
Ind)
7.1.5 Certifying authority
7.1.6 Certificate number
B-TO BE SUBMITTED AFTER AWARD

S.NO. DESCRIPTION DATA BY BUYER DATA BY BIDDER
1.0 CONSTRUCTION
1.1 DE Bearings
1.1.1 Recommended lubricant
1.1.2 Life in hours at rated speed
1.2 NDE Bearings
1.2.1 Recommended lubricant
1.2.2 Life in hours at rated speed
2.0 MISCELLANEOUS
2.1 Shaft orientation
2.2 Shaft extension if required YES / NO
Part II, Section 2

2.3 Type of coupling

2.4 Half coupling if required YES / NO
2.5 Grounding pads size, nos. & location
2.6 Moment of Inertia (GD2)
2.7 Weight of Motor in Kg
2.8 Overall dimensions (LxBxH) in mm
2.9 Paint shade
3.0 MOTOR PARAMETERS
3.1 Locked rotor impedance Zb (Ω @ 20°C) Data required for
3.2 Locked rotor reactance Xb (Ω @ 20°C) motors > 90kW
3.3 Rotor resistance Rr (Ω @ 20°C)
3.4 Stator resistance Rs (Ω @ 20°C)
3.5 Steady state reactance X (%)
3.6 Transient reactance X’ (%)
3.7 Sub-transient reactance X” (%)
3.8 X’’ / R ratio
3.9 Open circuit transient time constant T’do
3.10 Heating time constant (minute)
3.11 Cooling time constant (minute)
3.12 Rotor air gap (mm)
3.13 Rotor end float (±mm)
3.14 Rotor end play (mm)
3.15 Capacity derating applicable due to 10%
THD arising from static drives, VFDs
3.16 Losses
3.16.1 Iron loss (kW)
3.16.2 Copper loss (kW)
3.16.3 Friction, Windage & Stray losses (kW)
4.0 DRAWINGS / DOCUMENTS
4.1 Type test reports and certificates for the Submitted Yes / No
4.2 Equipment / component technical data sheet Submitted Yes / No
and brochure
4.3 Typical general arrangement drawing of the Submitted Yes / No
motor and foundation plan / Loading,
Mounting Details
4.4 Bill of material with Make / Type of all Submitted Yes / No
components
4.5 Individual datasheet Submitted Yes / No
4.6 Assembly and Erection drawings Submitted Yes / No
4.7 Cable termination box details/drawing Submitted Yes / No
Part II, Section 2

4.8 Following characteristic curves: Submitted Yes / No

i. Motor Current Vs Speed curves &
supporting tabulated data
ii. Superimposed motor driven equipment
Speed-Torque curves & supporting
tabulated data
iii. Superimposed thermal limit and Time-
Current curves & supporting tabulated
data
iv. Efficiency, power factor, slip, current
plotted against power output
v. Negative sequence current Vs time
curve
4.9 Quality assurance plan Submitted Yes / No
4.10 Certified reports of Routine tests and Submitted Yes / No
Special tests, prior to dispatch
4.11 Instruction manuals of Motors (Erection & Submitted Yes / No
Commissioning, Operation & Maintenance)
4.12 Manufacturer’s instruction for transport, Submitted Yes / No
storage & installation including unpacking,
lifting, assembly, mounting & connections
prior to dispatch
Stamp / seal of bidder - ……………………………….
Name of Bidder’s contact person
Email id
Telephone no
Address of the office
Part II, Section 2

STANDARD
TECHNICAL SPECIFICATION FOR
SPECIFICATION
PACKAGE NAME
LV SWITCHGEAR DATA SHEET
Instruction to bidders –
1. Bidder to fill up only “Data by Bidder” column and shall not change description in other column
2. Bidder to submit GTP with data in numerical values wherever asked
3. Bidder shall not use words like, ‘Adequate’, ‘As per standard’, ‘Later’, ‘After award’ etc. This will
be considered as a deviation
Design engineer to update as per requirement
S. Description Data by Data by

No. Purchaser Bidder
1.0 Technical parameters for LSP
1.1 Rated operational voltage Ue 415Vac ± 10%
1.2 Rated insulation voltage Ui 1000Vac rms
1.3 Rated frequency 50 Hz (+3%, -5%)
1.4 Rated short time withstand current 50 kA rms
1.5 Rated duration of short time withstand 1 Sec
current
1.6 Rated impulse (1.2/50 µs) withstand 6 kVpeak
voltage
2.0 Temperature rise (over ambient of 50ºC)
for all LV switchgear (AC and DC)
2.1 Contacts – Bare copper 40ºC
2.2 Contacts – Tin Plated 55ºC
2.3 Contacts – Silver Plated 60ºC
2.4 Accessible parts – manual operating means: 05ºC and 15 ºC
Metallic and Non-metallic respectively
2.5 Accessible parts – not intended to be 20ºC and 30 ºC
handled: Metallic and Non-metallic respectively
2.6 Exteriors of enclosures adjacent to cable 30ºC and 40 ºC
entries: Metallic and Non-metallic respectively
3.0 Design Parameters for LSP
3.1 Make
3.2 Type Metal enclosed, non
compartmentalized with
sloping roof
3.3 Reference Standard
3.4 Rated Normal Current
3.5 Mounting Floor / Structure / Wall
3.6 Connections Cable entry – Bottom
3.7 Panel height <= 2500 mm
3.8 Enclosure degree of protection i. Indoor : IP 52
ii. Outdoor : IP 55
3.9 Enclosure Material CRCA sheets
Part II, Section 2

STANDARD
SPECIFICATION
PACKAGE NAME
3.10 Enclosure Material Thickness i. Minimum 2.0 mm for

load bearing members
ii. Minimum 1.6 mm for
doors and covers
3.11 Power Cable Termination
3.12 Paint shade RAL9002 for complete
panel and RAL5012 for
end covers
4.0 Design Parameters for LPBS
4.1 Make
4.2 Type Metal enclosed with
sloping roof
4.3 Reference Standard
4.4 Mounting Structure / Wall
4.5 Connections Cable entry – Bottom
4.6 Enclosure degree of protection i. Indoor : IP 54
ii. Outdoor : IP 55
iii. In dusty area: IP 65
iv. For the classified area
LPBS should be
flameproof,
conforming to IS 2148
4.7 Enclosure Material CRCA sheets
5.0 Construction
5.1 Minimum clear space required at

i. Front for breaker withdrawal in mm
ii. Rear in mm
5.2 Typical vertical section (Overall dimension
(mm) and weight ( Kg))
i. Incomer
ii. Bus-coupler
iii. Motor feeder
iv. Line feeder
5.3 Relays, meters, control switches, selector Flush mounted type with
switches and indicating lamps touch proof terminals
6.0 Contactor / Fuse combination
6.1 Make and model number

6.2 Type
6.3 Reference standard
6.4 Rated operational current Ie
6.5 Rated making capacity (Isc)
6.6 Rated breaking capacity (Ima)
6.7 Rated duty Intermittent duty Class 3
Part II, Section 2

STANDARD
SPECIFICATION
PACKAGE NAME
6.8 Utilization Category

6.9 Coordination with SCPD Type-II as per IEC 60947
6.10 Control Voltage 110 V AC (90% - 110%)
6.11 Single phasing protection Required
6.12 Switching times
i. Opening time(Lower and Upper limit)
ii. Closing time(Lower and Upper limit)
6.13 Highest cut-off current of the SCPD
7.0 Thermal Overload Relay
7.1 Type
7.2 Resetting Manual and Auto reset type
7.3 Single phase preventer Shall be provided Yes/No
8.0 Bus and Bus Taps
8.1 Make
8.2 Material and grade of buses and joints
8.3 Reference standard
8.4 Cross sectional Area
8.5 Continuous Current (at site condition, 50°C
ambient) within cubicle
8.6 DC resistance at 85°C ohm/m/ph
8.7 Skin-effect ratio
8.8 Reactance ohm/m/ph
8.9 Losses-middle phase w/m/ph
8.10 Minimum clearance of bus bar and joints
i. Phase to phase (mm)
ii. Phase to ground (mm)
8.11 Bus bar insulation i. Heat shrinkable sleeves
rated for maximum
operating voltage
ii. Phase barriers
iii. Cast resin shrouds for
joint
8.12 Bus joints Silver
8.13 Bus bar support insulator
i. Spacing (mm)
ii. Make
iii. Type
iv. Reference standard
v. Voltage class (kV)
vi. Minimum creepage distance (mm)
vii. Cantilever strength (Kg/sq.cm.)
9.0 Ammeters and Voltmeters
Part II, Section 2

STANDARD
SPECIFICATION
PACKAGE NAME
9.1 Type Flush mounted, 96 x 96

mm size, with 90° scale,
anti-glare glass
9.2 Accuracy class 1.0 %
10.0 Control and Indications
10.1 Push Buttons

i. Make
ii. Type and Catalogue Number
iii. Contact rating at 220V dc
a. Make and continuous Amps 10A ac / dc at operating
voltage
b. Break (Inductive) Amps and circuit time 2A ac / dc at operating
constant voltage, time constant
20mS
10.2 LEDS
i. Make
iii. Watts/Voltage
iv. Series resistance (Ohm)
v. LEDS and Lens replaceable from front
(Yes/No)
10.3 Selector Switch
i. Make
iii. Contact rating at
a. Make and continuous Amps 10A ac / dc at operating
voltage
b. Break (Inductive) Amps and circuit time 2A ac / dc at operating
constant voltage, time constant
20mS
11.0 Wiring of Auxiliary and Control circuits
11.1 Type
11.2 Insulation
11.3 Conductor material
11.4 Minimum conductor size
i. Current circuit 2.5 mm2
ii. Control and voltage circuit 1.5 mm2
iii. 415Vac Bus wire for Service power 6.0 mm2
iv. 220Vdc, 240Vac and 110Vac Bus wire 4.0 mm2
11.5 Termination and identification
11.6 Colour coding
12.0 Terminal blocks
12.1 Make
12.2 Type
12.3 Cat. Number
Part II, Section 2

STANDARD
SPECIFICATION
PACKAGE NAME
12.4 Spare terminals Equal to 20% of active

terminals in each TB
12.5 Control terminal Suitable for 2 nos. 2.5 mm2
stranded copper conductor
12.6 Power terminal Suitable for one 10 mm2
stranded aluminium
conductor
13.0 Cable termination
13.1 Gland plate material and thickness for

i. Multi-core power cable
ii. Single-core power cable
13.2 Nut bolt and washer type for Power cables Cadmium plated
14.0 Earth bus
14.1 Material
14.2 Size
14.3 Earth bus rating To carry Rated short circuit
withstand current for rated
duration of short circuit
15.0 Painting
15.1 Painting procedure adopted (details of each

coat)
15.2 Finish of switchgear
i. Inside
ii. Outside
16.0 Tropical protection
16.1 Any special treatment for tropical

protection
17.0 Tests
17.1 Confirmation of routine tests to be Yes / No

performed as per Section 3.5.1 of
specification
17.2 Confirmation of Type tests to be performed Type test report
(or report submitted) as per Section 3.5.2 of number / date
specification
17.3 Dielectric tests on Main, Auxiliary and
Control circuits of assembled switchgear
17.4 Temperature rise Test of assembled
switchgear
17.5 Test for Internal arc classification of
assembled switchgear (preferable)
Part II, Section 2

STANDARD
SPECIFICATION
PACKAGE NAME
17.6 Verification of short circuit withstand

strength of the protective devices
17.7 Verification of rated making and breaking
capacities of Contactors
17.8 Coordination with fuse of Contactors
17.9 Ability of contactors to withstand overload
current
17.10 Verification of the degree
of protection
Email id
Telephone no
Part II, Section 2

MOTOR OPERATED ACTUATORS DATA SHEET

The purchaser’s requirements are specified in Specification and in column below
A-TO BE SUBMITTED ALONG WITH THE BID

S.NO. DESCRIPTION DATA BY DATA BY
PURCHASER BIDDER
1.0 ACTUATOR
1.1 Application
1.2 Make
1.3 Model
1.4 Type (modulating / non-modulating)
1.5 Type of enclosure (ingress protection)
1.6 Type of enclosure (hazardous classification)
1.7 Travel stroke/ Angular rotation mm/ Deg.
2.0 MOTOR
2.1 Type
2.2 Duty cycle/ Designation To match drive
requirement
2.3 Motor Rating
2.3.1 Output (KW)
2.3.2 Voltage/ phase/ frequency (V/ No./ Hz)
2.3.3 Speed (rpm)
2.3.4 Admissible voltage fluctuation
2.3.5 Admissible frequency fluctuation
2.3.6 Admissible voltage and frequency
fluctuation (absolute sum)
2.3.7 Full load torque (N-m)
2.3.8 Starting torque (N-m)
2.3.9 Power factor at full load
2.3.10 Full load efficiency
2.4 Motor Current
2.4.1 Starting (Amp)
2.4.2 Running (Amp)
2.4.3 Stalling (Amp)
2.5 Insulation Class Class F
2.6 Design ambient temperature °C 50°C
2.7 Method of Starting DOL
2.8 Type and No. of bearing
2.9 Lubrication (Motor)
3.0 LIMIT SWITCHES
3.1 No. of Limit Switches furnished
3.1.1 Torque limit switch
3.1.2 Position limit switch
3.1.3 Travel / Intermediate limit switch
Part II, Section 2

3.2 No. of N.O. + N.C contacts provided for each

limit switch
3.3 Switch Contact Rating
3.3.1 At 250Vac 5A
3.3.2 At 250Vdc 0.5 A
3.4 Torque limit switch type Non self- resetting type
3.5 Range of adjustment for:
3.5.1 Torque limit switch
3.5.2 Position limit switch
3.5.3 Travel / Intermediate limit switch
4.0 POSITION INDICATOR
4.1 Provided locally
4.2 Type
5.0 SPACE HEATER
5.1 No. x Watt
5.2 Voltage
6.0 INTEGRAL STARTER
6.1 Short circuit protection details
6.2 Overload protection details
6.3 Contactors’ mechanical interlock details
6.4 Control transformer details
7.0 CONTROLS
7.1 Integral Control Station
7.1.1 Local / Remote selector switch
7.1.2 Close / Open push buttons with indication
7.1.3 Accessibility of push buttons and selector Accessible from outside
switch
7.2 Internal Logics Freely configurable by
the user
7.3 Remote control for Modulating type
actuator
7.3.1 Control command signal type 4 to 20 mA
7.3.2 Status / Alarm feedback Potential-free contacts
from the actuator
7.3.3 Continuous position feedback 2-wire (loop powered)
optically isolated 4 to 20
mA
7.4 Remote control for Non-modulating type
actuator
7.4.1 Close / Open command Potential-free contacts
from the Control system
7.4.2 Status / Alarm feedback Potential-free contacts
from the actuator
8.0 TERMINATIONS
8.1.1 Sizes / quantity of glands provided
8.1.2 Type and Nos. of terminals brought out
Part II, Section 2

9.0 ACCESSORIES
9.1 Specify accessories if provided
B-TO BE SUBMITTED AFTER AWARD

S.NO. DESCRIPTION DATA BY DATA BY
PURCHASER BIDDER
1.0 DRAWINGS / DOCUMENTS
1.1 Type test reports and certificates for the Submitted Yes / No
1.2 Equipment / component technical data sheet Submitted Yes / No
and brochure
1.3 Typical general arrangement drawing of the Submitted Yes / No
Actuator / motor and Mounting Details
1.4 Bill of material with Make / Type of all Submitted Yes / No
components
1.5 Torque switch & limit switch contact Submitted Yes / No
development
1.6 Internal wiring diagram and suggested Submitted Yes / No
control schematic
1.7 Assembly and Erection drawings Submitted Yes / No
1.8 Cable termination box details/drawing Submitted Yes / No
1.9 Quality assurance plan Submitted Yes / No
1.10 Certified reports of Routine tests and Submitted Yes / No
Special tests, prior to dispatch
1.11 Instruction manuals of Actuators / Motors Submitted Yes / No
(Erection & Commissioning, Operation &
Maintenance)
1.12 Manufacturer’s instruction for transport, Submitted Yes / No
storage & installation including unpacking,
lifting, assembly, mounting & connections
prior to dispatch
Email id
Telephone no
Part II, Section 2

BASIC DESIGN CRITERIA STANDARD SPECIFICATION
I0 : BASIC DESIGN CRITERIA
DOC. NO.: REL-COENG-NEN-441-P-00001

SUB-SECTION: I-0 Page 1 of 6
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1.01.00 GENERAL REQUIREMENTS

1.01.01 The Contractor shall provide Control System, UPS, Relay based control system,
all required instruments and Instrumentation, Control & Power Supply Cables,
Process connection piping etc. as identified under Scope of C&I Works of this
specification. It may be noted that typical requirements for all C&I items are
enumerated in this section. Only those clauses which are relevant for the
equipment under the scope of the package shall be applicable for the package.
1.01.02 The Contractor shall provide all material, equipment and services so as to make a
totally integrated Instrumentation and Control System together with all accessories,
auxiliaries and associated equipments ensuring operability, maintainability and
reliability. This work shall be consistent with modern power plant practices and
shall be in compliance with all applicable codes, standards, guides, statutory
regulations and safety requirements in force.
1.01.03 Further Bidder shall also include in his proposal and shall furnish all equipment,
devices and services which may not be specifically stated in the specification but
are needed for completeness of the equipment/systems furnished by the Bidder
and for meeting the intent and requirements of the specification.
1.01.04 It is to be noted that where equipment or system for the generating units are
described, it shall be understood that the quantities described are to be provided
per unit basis i.e. identical sets to be furnished by the Contractor for each of the
units unless specifically indicated otherwise. Where equipment or systems for plant
common facilities are described, it will be understood that the quantities described
are the total quantities required. Wherever quantity has been specified as “On as
required” basis, the same is to be supplied by the contractor on as required basis
by the contractor within his quoted lump sum price.
1.01.05 Bidder shall include in his bid a detailed Bill of Material (BOM) for each of the
systems/ Instruments/ equipment.
1.01.06 In addition to requirements specified under this chapter, all C&I systems/ sub-
systems/ equipment/ devices shall also meet other requirements stipulated under
other chapters/ parts/ sections of specification.
1.01.07 Contractor also indicate KKS code for all instruments, drives, devices & equipment
etc in P&ID, I/O/ Drive/ Alarm & measurement point lists, logics etc.
1.02.00 PROVENNESS CRITERIA
I0.02.01 All field instruments and UPS offered for this package shall have at least two year’s
satisfactory operation as on the date of LOA in one power station having unit rating
of 200 MW or above. For PLC system refer relevant chapter.
I0.02.02 All equipment, systems and accessories furnished under this specification shall be
from the latest proven product range of a reputed experienced manufacturer whose
successful performance has been established by a considerable record of
satisfactory operation in coal fired utility power stations. Bidder shall furnish
satisfactory evidence regarding successful operation and high reliability of the

R0
proposed equipments/systems in coal fired utility stations for similar applications

for meeting this requirement as specified elsewhere.
I0.02.03 Not withstanding anything stated above, the Purchaser reserves the right to assess
the Bidder's capability and capacity to perform and to relax the qualifying
requirements, if necessary, in the light of overall interest of the Project.
I0.02.04 The Bidder shall furnish a complete list of bought out items (i.e., items not from
manufacturing range) which the Bidder has included in his proposal along with the
names of proposed sub-vendors as a part of his proposal. However the make and
model of all bought out items supplied by the Contractor shall be as approved by
Employer during detailed engineering stage.
1.03.00 RELIABILITY AND AVAILABILITY
I0.03.01 Each component and system offered by the Bidder shall be of established
reliability. The minimum target reliability of each piece of equipment like each
electronic module/card, Power supply, Peripheral etc. shall be established by the
Bidder, considering its failure rate/mean time between failures (MTBF), meantime
to repair (MTTR), such that the availability of the complete C&I system is assured
for 99.7%.
I0.03.02 When more than one device uses the same measurement or control signal, the
transmitter and other components/ module shall be fully equipped to provide all
signal requirements. All the 4-20 mA output signals from transmitters/other control
system shall be able to drive minimum 500 Ohms load resistance. The system
shall be arranged so that the failure of any monitoring device or control
components or spurious intermediate grounding in the signal path shall not open
the signal loop nor cause the loss or malfunction of signal to other devices using
the same signal.
I0.03.03 To ensure availability, adequate redundancy in system design shall be provided at
hardware, software and sensor level to satisfy the availability criteria mentioned
above. For the protection system, independent sensing devices shall be provided
to ensure adequate safety of plant equipment.
1.04.00 STANDARDISATION AND UNIFORMITY OF HARDWARE
I0.04.01 Bidder shall ensure that various C&I instruments /equipment that are being
furnished by the Bidder, are of the same make, series and family of hardware so as
to ensure smooth and optimal maintenance, easy interchangeability and efficient
spare parts management.
1.05.00 OPERABILITY & MAINTAINABILITY
I0.05.01 The design of the control systems and related equipment shall adhere to the
principle of ‘Fail Safe’ Operation wherever safety of personnel / plant equipment is
involved. ‘Fail Safe’ operation signifies that the loss of signal, loss of excitation or
failure of any component shall not cause a hazardous condition. However, it shall
also be ensured that occurrence of false trips are avoided / minimized.

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I0.05.02 The types of failure that shall be taken into account for ensuring operability of the
plant shall include but not be limited to:
— Failure of sensor or transmitter.
— Failure of main and/or redundant controller/other modules.
— Loss of motive power to final control element.
— Loss of control power.
— Loss of instrument air.
I0.05.03 The choice of hardware shall also take into account sound maintainability
principles and techniques. The same shall include but shall not be limited to the
following:
— Standardization of parts.
— Minimum use of special tools.
— Grouping of functions.
— Interchangeability.
— Malfunction identification facility/self surveillance facility.
— Easy modular replacement.
— Fool proof design providing proper identification and other features to

preclude improper mounting and installation.
— Appropriate de-rating of electronic components and parts.
I0.05.04 The equipment shall employ latest state of the art technology to guard against
obsolescence. In any case, Bidder shall be required to ensure supply of spare
parts for lifetime of the plant. In case, the Bidder feels that certain
equipment/component (barring HMI hardware and networking components) is likely
to become obsolete, the Bidder shall clearly bring out the same in his Bid and
indicate steps proposed to deal with such obsolescence. For HMI hardware and
networking components, Bidder need not bring out the same in the bid; but shall
inform the Employer in case of obsolescence so that Employer can take
appropriate actions as necessary ( both during the tenure and outside the tenure of
the contract ).

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1.06.00 ENVIRONMENTAL CONDITIONS

Instruments, devices and equipments for location in outdoors/indoor/air-
conditioned areas shall be designed to suit the environmental conditions indicated
below and shall be suitable for continuous operation in the operating environment
of a gas fired utility station and also during periods of air conditioning failure without
any loss of function, or departure from the specification requirements covered
under this specification.
Ambient Pressure Relative Atmosphere Required

Temperature humidity protection
(outside cabinets) Class of
panels/
cabinets /
desks to be
provided by
contractor.
Outdoor Location
55 degree C max. Atmosphere 100 % Max. Air (dirty) IP 65
4 degree C min. Atmosphere 5 % min. Air (dirty) IP 65
Indoor Location
55 degree C max. Atmosphere 95 % Max. Air IP 54**
4 degree C min. Atmosphere 5 % min. Air IP 54**
Air Conditioned Areas
24 +/- 5 degree C Atmosphere 95 % Max. Air IP 22***

normal
50 degree C max.* Atmosphere 5 %min. Air IP 22***
* During air conditioning failure.
**For non-ventilated enclosures. For ventilated enclosures, protection class shall be

IP 42.
***With a suitable canopy at the top to prevent ingress of dripping water, if required.
For Hazardous areas, the protection class shall be in accordance with the
requirements of the relevant NEC code for the location, i.e explosion proof enclosure
as per the area classification shall be provided.

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PCs, OWS/GUI, EWS, Servers, Network Switches, Printers, mini UPS and other
peripherals, maximum temperature limit shall be 35 Deg. C. For LVS, the same shall
be around 25 Deg. C
For the remote I/O cabinets mounted in non-AC areas, if the Remote I/O and other
electronic modules do not meet the requirement of maximum temperature of 10 Deg.
C above the maximum site ambient temperature {i.e. the design maximum
temperature of the modules is less than maximum site ambient temperature (outside
cabinet) + 10 deg C, considering a temperature rise of 10 deg C inside the Remote I/O
Cabinet}, then Contractor shall provide suitable cooling arrangement to meet the
specification requirement within the quoted lump sum price.
1.07.00 GROUNDING SYSTEM
All panels, desks, cabinets shall be provided with a continuous bare copper ground
bus. The ground bus shall be bolted to the panel structure on bottom on both
sides. The bolts shall face inside of panels.
The system ground shall be isolated from the panel ground with suitable isolators.
All internal component grounds or common shall be connected to the system
ground, which shall be fabricated of copper flat (size 25mm x 6mm min., length as
applicable).
Shield on instrumentation cables shall be grounded on panel side. When shielding

termination is required in cabinets furnished under this specification, suitable
terminals shall be furnished on copper flat forming system ground. System and
shield ground shall be connected to Employer provided earthing strip at suitable
location.
The Contractor shall submit with the offer recommended grounding scheme
required for his system. The exact grounding scheme shall be finalized during
detailed engineering.
Owner shall provide the redundant C&I Signal earth, Panel and Power supply
earth risers on their electrical earth mat away from the transformer/ Motor earth
point. Contractor scope shall be to supply, lay and terminate the redundant earth
cable from their Control system to the risers.

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Technical Specification for PLC
Standard
system with UPS
SUB-SECTION – I 1
TECHNICAL SPECIFICATION
FOR
PROGRAMMABLE LOGIC CONTROLLER SYSTEM ALONG WITH UPS
DOC. No. REL-COENG-NEN-442-P-00001 SUB-SECTION – I 1 Page 1 of 21

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system with UPS
1- SPECIFICATION FOR PLC SYSTEM WITH POWER SUPPLY
1.00.00 GENERAL REQUIREMENTS:
1.00.01 This chapter covers the specification requirement of PLC system.
1.00.02 The System shall perform effective Operation and Control of the Process/Equipments
and electrical (Incomers, isolator, bus coupler) equipment/drives etc and shall be
designed for maximum integrity and reliability.
1.00.03 The microprocessor based PLC system shall provide for Manual and Automatic,
Sequence & drive interlock & protection control for on/off & modulating drives, electrical
equipments(Incomers, isolator, bus coupler) monitoring, alarm, data logging, reporting,
calculations, Operator interfacing and printing.
1.00.04 Control system shall be designed to prevent abnormal swings due to loss of Control
System power supply, failure of any Control System component, open circuit/short-circuit
etc. On any of these failures the controlled equipment/ parameter shall either remain in
last position before failure or shall come to fully open/close or on/off state as required for
the safety of plant/ personnel/ equipment and as finalized during detailed engineering.
System shall be designed such that there will be no upset when power is restored.
1.00.05 The PLC Control system shall include on-line self-surveillance, monitoring and diagnostic
facility giving the details of the fault on the MMI. The diagnostic system shall ensure that
the faults are detected before any significant change in any controller output has taken
place. The faults to be reported on OWS/EWS shall include fault in main & standby
power supplies, sensor fault, Input/ Output card failure, Memory Status, Controller fault,
failure of Communication/ Network links to PLCs etc.
1.00.06 The PLC system shall provide safe operation under all plant disturbances and on any
hardware/software failure so that under no condition the safety of plant, personnel or
equipment is jeopardized. Control System shall be designed to prevent abnormal swings
due to loss of Control System power supply, failure of any Control System component,
open circuits/short circuits, instrument air supply failure etc. On any of these failures the
control system output shall either remain in last position before failure or shall come to
fully open/close or on/off state as required for the safety of plant/personnel/equipment
and as finalized during detailed engineering. System shall be designed such that there
will be no upset when power is restored.
1.00.07 The control system shall include the following components as a minimum:
• Redundant Processors (Hot, warm/cold as applicable, as indicated in Scope

Section)
• Input/ Output modules
• Power supplies
• PLC communication system.
1.00.08 It shall be possible to remove/ replace online various modules (like any I/O module,
interface module, controller etc.) from its slot for maintenance purpose without switching
off power supply to the corresponding rack. System design shall ensure that while doing
so, undefined signaling and releases do not occur and controller operation in no way is
affected (including controller trip to manual, etc) except that information related to

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system with UPS
removed module is not available to controller. The on-line removal/ insertion of controller,
I/O modules shall in no way jeopardize safety of plant and personnel.
1.00.09 The PLC system shall operate in air conditioned area and shall meet the minimum
requirements as specified below. However, PLC system shall be able to operate
satisfactorily even during periods of AC failure.
1.00.10 Bidder to provide I/O’s for the system as per specification and system requirement “On as
required basis” only within the quoted lump sum price. During any stage of the contract if
it is found that PLC system is not meeting the loop reaction time, spare capacity and
other parametric requirement, then Contractor is to provide additional sets of
processor/controller etc without any cost to the Owner.
1.00.11 The PLC system shall be complete in all respects and shall meet all the functional and
parametric requirements of the specification. Refer Drg. No. REL-COENG-NEN-442-J-
00001 for typical configuration. The basic configuration diagram is enclosed herewith.
However, other specific requirements like connectivity to other third party systems etc. as
defined in the scope section shall be taken care while finalizing the configuration.
1.01.00 PROGRAMMABLE LOGIC BASED CONTROL SYSTEM
1.01.01 PLC PROCESSOR
The processor shall be 100% redundant (Hot, warm/cold as applicable) and shall perform
the following functions as a minimum.
Receiving binary and analog signals from the field and providing command output to
MCC/ SWGR/ Drive etc. through Input / Output modules and operator initiated
commands from MMI.
Implementing all logic functions for control, protection and annunciation of the
equipment and systems.
Implementing modulating control function for certain application as specified
elsewhere in the specification.
Providing supervisory information for alarm, various types of displays, status

information, trending, historical storage of data etc.
Performing self-monitoring and diagnostic functions.
1.01.02 Bidder to provide the PLC system as specified in the scope section from the following
configuration options
(A) HOT REDUNDANT PROCESSOR
OR
(B) WARM/ COLD REDUNDANT PROCESSOR
HOT REDUNDANT PROCESSOR

One set of hot redundant processors/ Controllers, one for normal operation and one as
hot standby. In case of failure of Main working processor, there shall be an appropriate
alarm and simultaneously the hot standby processor shall take over the complete plant
operation automatically. The transfer from main processor to standby processor shall be
totally bumpless and shall not cause any disturbance. Both main & standby processor
should be completely identical and failure of any processor should not affect the
performance of other processor in any manner. In the event of both processors failing,
the system shall revert to fail safe mode. It shall be possible to keep any of the

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system with UPS
processors as master and other as standby. The main/ standby processor shall be
updated (including updation of tables, logic, database etc) automatically in line with the
changes made in any one of Main or standby processor. Further, forcing of any inputs
should be updated simultaneously in both main and standby processor.
WARM/ COLD REDUNDANT PROCESSOR
One set of redundant processors/controller, one for normal operation and one as
cold/warm standby. In case of failure of working processor, there shall be an appropriate
alarm and the system shall revert to fail safe mode, further operator/engineer can
manually replace the main faulty processor by means of cold/ warm standby processor.
The exact standby processor option of cold/ warm stand by shall be finalized during
detailed engineering and Owner decision will be final in this regard.
1.01.03 The memory shall be sufficient for the complete system Operation & Control and shall
have at least 20% spare capacity for future expansion. All dynamic memories shall be
provided with buffer battery back up for at least 360 hours. Low battery power
indication/alarm shall be provided. The entire memory rating shall be available for
program storage. Executive or housekeeping programs shall not be counted in the
memory size rating.
1.01.04 Priority of different commands shall be as follows:
Manual intervention shall be possible at any stage of operation. Protection commands
shall have priority over manual commands and manual commands shall prevail over auto
commands.
1.02.00 INPUT/OUTPUT MODULES
1.02.01 I/O module should be designed according to the location of the input/output cabinets as
specified.
1.02.02 Input / Output modules, as required in the Control System for all type of field input signals
(4-20 mA, RTD, Thermocouple, non change over/ change over type of contact inputs
etc.) and outputs from the control system (non change over/ change over type of contact,
24 VDC output signals for energizing interface or coupling relays, 4-20 mA output etc.)
are to be provided by the Contractor.
1.02.03 Suitable Electrical isolation with optical couplers between the plant input/output and
controller shall be provided on the I/O cards. The isolation shall ensure that any
inadvertent voltage or voltage spikes (as may be encountered in a plant of this nature)
shall not damage or mal-operate the internal processing equipment.
1.02.04 The Input/output system shall facilitate modular expansion in fixed stages. The individual
input/ output cards shall incorporate indications on the module front panels for displaying
individual signal status.
1.02.05 Individually fused output circuits shall be provided. Input circuits shall be provided with
fuses preferably for each input; alternatively suitable combination of inputs shall be done
and provided with fuses such that for any fault, fuse failure shall affect the particular drive
system only without affecting other systems. Suitable monitoring shall be provided for
these fuses provided in the I/O circuits.
1.02.06 All input/ output cards shall have quick disconnect terminations allowing for card
replacement without disconnection of external wiring and without switching off power
supply.
1.02.07 The Contractor shall provide the following monitoring features:
Power supply monitoring.

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system with UPS
Contact bounces filtering.
Optical isolation between input and output signals with the internal circuits
In case of power supply failure or hardware fault, the outputs shall be automatically
switched to the fail-safe mode. The fail-safe mode shall be intimated to the
successful Contractor during detailed engineering.
1.02.08 Binary Output modules shall be rated to switch ON/OFF coupling/interposing relays of
approx. 3 VA at 24 VDC. Analog output modules shall be able to drive a load impedance
of 500 Ohms minimum.
Interposing relay for MCC shall be provided inside MCC module and for Solenoid valves,
interposing relay shall be provided inside PLC termination cabinet.
1.02.09 Output module shall be capable of switching ON/OFF inductive loads like solenoid valves
through interposing relays and other auxiliaries relays without any extra hardware etc.
1.02.10 Only one changeover contact shall be provided in MCC for control and interlock
requirement. Further multiplication, if required, shall be done by the contractor in PLC
system.
1.02.11 All input field interrogation voltage shall be 24V DC minimum.
1.02.12 In case of loss of I/O communication link with the main processing unit, the I/O shall be
able to go to predetermined fail safe mode (to be decided during detailed engineering)
with proper annunciation.
1.02.13 Each of the triple redundant binary & analog inputs shall be wired to separate input
modules. Similarly each of the dual redundant binary & analog inputs shall be wired to
separate input modules. Implementation of multiple measurement schemes of these
inputs will be performed in the redundant hardware. Loss of one input module shall not
affect the signal to other modules. Other channels of these modules can be used by other
inputs of the same functional group.
1.02.14 All single analog & binary inputs including the limit switches of valves/ dampers MCC/
SWGR check-backs of all drives & information related signals may be wired to single (i.e.
non-redundant) input modules.
1.02.15 Inputs and Outputs related to each of the redundant drives/ equipments (eg. each of the
3x50 % drives, each of the storage vessel/ sump/ tank storing same fluid, each of the
streams and its related drives etc.) shall be wired to separate input and output modules.
1.02.16 The signal conditioning functions like multiple measurement schemes, square root
extraction for flow signals, pressure and temperature compensation, limit value
computation can be performed either in the controllers or in signal conditioning and
processing hardware outside controllers.
1.02.17 The maximum number of inputs/ outputs to be connected to each type of module shall be
as follows:
1. Analog input module 16
2. Analog output module 16
3. Binary input module 32
4. Binary output module 32
5. Analog input & output (combined) if applicable 16
6. Binary input and output (combined) if applicable 32

Standard
system with UPS
1.02.18 Any single sensor/ transducer/ transmitter failure alarm shall be provided on Engineering
work station screens for all sensors/ transducers/ transmitters. Similarly sensor break
alarm for thermocouples etc. shall also be displayed on the screens.
1.02.19 Remote I/O cabinet and I/O modules
Remote I/O cabinets with I/O modules shall be used to reduce field cabling costs under
the following cases.
(i) Where the BOP Package vendor’s furnished equipment includes multiple skids,
panels/cabinets with multiple signals.
(ii) Wherever it is possible to group sufficiently various Instruments/ drives in a particular
location and the cable route distance from I/O cabinets/ racks exceeds a distance of
at least 400 meters from the PLC system.
Remote I/O cabinets/ Racks shall be connected through Fiber optic/ coaxial cable to PLC
system meeting all other specification requirement.
1.03.00 HUMAN MACHINE INTERFACE SYSTEM (HMIS)

1.03.01 PC based OWS (Operator Work Station) shall be used to perform control, monitoring and
operation of all auxiliaries/ drives interacting with PLC based control system. It shall be
possible to use OWS as programming station of the PLC. In case the PC based OWS
can not be used as programming station of the PLC, then separate PC based
programming station shall be provided. Suitable industrial furniture for the Operator
workstations, engineer/ programmer station, printers etc. shall be provided by the
Contractor, details of which shall be finalized during detailed engineering.
The operator functions shall be achieved by GUI (wherever specified, as indicated in

Scope section). GUI shall as a minimum include Control System Operation (A/M
selection, raise/lower, set point/ bias change, on/off, bypassing criteria, sequence auto,
start/stop selection, drive auto selection, local-remote selection etc.); alarm acknowledge;
displays, reports etc.; printing of reports; retrieval of historical data; and any other
functions required for smooth operation as finalized during detailed engineering.
Wherever GUI is specified as the main Operator interface, a separate Laptop shall be
provided for programming functions if the same cannot be achieved from the GUI.
1.03.02 All OWSs of the HMIS shall be fully interchangeable i.e. all operator functions including control,
monitoring and operation of any plant area on drive shall be possible from any of the
OWSs at any point of time without the necessity of any action like downloading of
additional files. Operator shall be able to access all control/ information related data
under all operating conditions including a single processor/ computer failure in the HMI.
1.03.03 PLC system shall be time synchronized with Owner supplied master clock system. Owner
shall provide NTP signal for time synchronizing through BOP-PLC network system.
Incase, Bidder proposed system require different type of synchronizing signal then the
details of the same are to be included in his bid.
1.03.04 SPECIFICATIONS OF OPERATOR WORK STATION (OWS)
The minimum requirement for PC based OWS shall be as below:
CPU Latest generation CPU
Main memory 1 GB, minimum (Expandable to 5GB)
Drives 52 x CD ROM drive or latest version

Standard
system with UPS
Hard disk 80 GB, minimum(Expandable to 160 GB)
Removable bulk storage 6 GB (minimum)

drive (MOD / DVD /
DAT)
Removable Bulk Storage 10 nos

Media for above
Monitor 21" Full Flat TFT Resolution 1600 x 1280, refresh rate min
85 Hz.
Graphic Memory 16 MB Min.
Communication port 2 serial plus, one parallel, 1 USB port, Dual 100 Mbps
Ethernet.
Expansion slots 3
Other Features 101 Keys Keyboard and Optical Mouse
Power supply 230 V from UPS
Software a General MS Windows (latest), MS-Office, Microsoft

Visual Studio, Adobe Acrobat, anti-virus McAfee or
equivalent, etc.
b Application & Programming/Engineering software - to

suit project specific requirement
Note: Contractor to supply latest version available at the time of finalization of technical
datasheet.
1.03.05 SPECIFICATIONS OF GRAPHICAL INTERFACE UNIT (wherever specified):
Sl no. Features Description
1. Power supply 230 V AC from UPS
2. Display Type, size Color, TFT screen, 15 “
3. Humidity/ temperature 5-95%/ 55 Deg. C
4. Protection class IP-65 Enclosure shall be provided to prevent

ingress of dust.
5. Keys Function keys and numeric keys
6. Interfacing requirements Interface with respective control systems
7. Functional requirements Ability to operate drives locally using function

keys.
Ability to do programming. (In case programming
is not possible from the GUI, a separate laptop
with requisite software shall be provided for

Standard
system with UPS
programming.
Graphics display including alarms and operator
guidance messages.
8. Mounting On table Top/ panel as decided during detailed

engineering.
Note: Contractor to ensure that latest version is supplied.

1.03.06 Printer:
Bidder is to provide Heavy duty A4, high speed color laser printer of reputed make for
industrial application as per individual package specification requirement.
1.03.07 The Operator functions for each OWS shall as a minimum include Control System
operation (A/M selection, raise/lower, set point/ bias change, on/off, open/close
operation, mode/device selection, bypassing criteria, sequence auto, start/stop selection,
drive auto selection, local-remote/ other multi-position selection etc.); alarm acknowledge;
call all kind of displays, logs, summaries, calculation results, etc.; printing of logs &
reports; retrieval of historical data; and any other functions required for smooth operation,
control & management of the equipment, as finalized during detailed engineering.
1.03.08 When any drive or sequence is being controlled from one OWS, the system shall inhibit
control access of the same drive or sequence from other OWS.
1.03.09 The display selection process shall be optimized so that the desired display can be
selected with the minimum no. of operations. Navigation from one display to any other
should be possible efficiently through paging soft keys as well as through targets defined
on the displays. There should be no limitation on number of such targets.
1.03.10 The system shall have built-in safety features that will allow/ disallow certain functions
and entry fields within a function to be under password control to protect against
inadvertent and unauthorized use of these functions. Assignment of allowable functions
and entry fields shall be on the basis of user profile. The system security shall contain
various user levels with specific rights as finalized by the Employer during detailed
engineering. However, no. of user levels, no. of users in a level and rights for each level
shall be changeable by the programmer (Administrator).
1.04.00 PROGRAMMING FUNCTIONALITIES
Programming of the PLC Processor/ controller as well as programming of HMIS shall be

user friendly with graphical user interface and shall not require knowledge of any
specialized language. For example, the programming of PLC shall use either of the
following:-
- Flow-chart or block logic representing the instructions graphically (preferable).
- Ladder diagrams.
The programming of HMIS (like development and modification of data base, mimics, logs/
reports, HSR functionalities etc.) shall also be possible through user-friendly menus etc
All programming functionalities shall be password protected to avoid unauthorized

modification.
A forcing facility shall be provided for changing the states of inputs and outputs, timers
and flags to facilitate testing, commissioning, fault finding etc. It shall be possible to
monitor the signal flow during operation of the program.

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system with UPS
1.05.00 SOFTWARE REQUIREMENT
1.05.01 All necessary software required for implementation of control logic, operator station
displays / logs, storage & retrieval and other functional requirement shall be provided.
The programs shall include high level languages as far as possible. The contractor shall
provide sufficient documentation and program listing so that it is possible for the
Employer to carry out modification at a later date.
1.05.02 The Contractor shall provide all software required by the system for meeting the
functional/parametric requirements of the specification.
1.05.03 Industry standard operating system like MICROSOFT WINDOWS (latest version) etc. to
ensure openness and connectivity with other system in industry standard protocols (TCP-
IP/ OPC etc.) shall be provided. The system shall have user friendly programming
language & graphic user interface.
1.05.04 All system related software including Real Time Operating System, File management
software, screen editor, database management software. On line diagnostics/ debug
software, peripheral drivers software and latest versions of standard PC-based software
and MICROSOFT WINDOWS (latest) etc. and any other standard language offered shall
be furnished as a minimum.
1.05.05 All application software for PLC system functioning like input scanning, acquisition,
conditioning/ processing, control and communication and software for operator interface
of monitors, displays, trends, curves, bar charts etc. Historical storage and retrieval utility,
and alarm functions shall be provided. Software to enable communication with other third
party systems/ main plant DCS on Industry standard protocols like OPC etc. shall also be
included.
1.05.06 The Contractor shall provide software locks and passwords to Employer’s engineers at
site for all operating & application software so that Employer’s engineers can take backup
of these software and are able to do modifications at site.
1.06.00 PARAMETRIC REQUIREMENTS
The control system shall be designed such that under worst case loading conditions the
response time shall not be worst than the following:-
On/Off Command - The response time for screen update after the
execution of the control command from the time
the command is issued (for example command to
start a motor to the time the screen is updated)
shall be two seconds (excluding the drive
actuation time).
On screen Updating - 1 second.
All Control related displays - 1 second.
Bar Chart displays - 2 to 3 seconds.
Plant Mimic displays - 2 to 3 seconds.
Group review displays - 2 to 3 seconds.
X-T Plot Displays - 3 - 4 seconds.
Plant Summary Displays - 3 - 4 seconds.

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system with UPS
Even under worst case loading condition of HMIS and system Bus, each HMIS
processor shall have 50 % spare time when measured over any one minute period and
the system bus shall have at least 50 % spare duty cycle.
1.07.00 SYSTEM REACTION TIME
1.07.01 The reaction time of the programmable control system from input signals at the input
cards to output of the associated signals or commands of the output card inclusive of
programmed logic processing, comprising a mixture of logic gates, arithmetic operations
and other internal operations shall be less than 100 milli seconds under the worst case
operating conditions.
1.08.00 SYSTEM SPARES CAPACITY

1.08.01 Over and above the equipment and accessories required to meet the fully implemented
system as per specification requirements, Control System shall have spare capacity and
necessary hardware/ equipment/ accessories to meet following requirement for future
expansion at site:
1.08.02 10% spare channels in input/ output modules fully wired up to cabinets TBs.
1.08.03 Wired-in "usable" space for 20% modules in each of the system cabinets for mounting
electronic modules wired up to corresponding spare terminals in system cabinets. Empty
slots between individual modules/ group of modules, kept for ease in maintenance or for
heat dissipation requirement as per standard practice of Contractor shall not be
considered as wired-in "usable" space for I/O modules.
1.08.04 20% spare Terminal Blocks shall be provided for future expansion.
1.08.05 Each processor/ controller shall have 30% spare functional capacity to implement
additional function blocks, over and above implemented logic/ loops. Further, each
processor / controller shall have spare capacity to handle minimum 30% additional
inputs/ outputs of each type including above specified spare requirements, over and
above implemented capacity. Each of the corresponding communication controllers shall
also have same spare capacity as that of processor/controller.
1.08.06 The PLC COMMUNICATION SYSTEM shall have the capacity to handle the additions
mentioned above.
1.08.07 Ten (10) percent spare relays of each type and rating mounted and wired in cabinets
TBs. All contacts of relays shall be terminated in terminal blocks of cabinets.
1.08.08 The spare capacity as specified above shall be uniformly distributed throughout all
cubicles. The system design shall ensure that above mentioned additions shall not
require any additional controller/ processor/ peripheral drivers in the system delivered at
site. Further, these additions shall not deteriorate the system response time / duty cycle,
etc. from those stipulated under this specification.
1.09.00 PLC COMMUNICATION SYSTEM
1.09.01 The PLC COMMUNICATION SYSTEM shall include a redundant Bus from I/O modules
to the controller and from controller to HMIS. Other applicable bus systems like cubicle
bus, local bus, I/O bus etc shall be redundant except for backplane buses which can be
non-redundant.
The PLC COMMUNICATION SYSTEM shall have the following minimum features :
a Redundant communication controllers (if applicable) shall be provided to handle the

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system with UPS
communication between I/O Modules (including remote I/O) and PLCs and between
PLCs and operator work station.
b The design shall be such as to minimize interruption of signals. It shall ensure that a
single failure anywhere in the media shall cause no more than a single message to be
disrupted and that message shall automatically be retransmitted. Any failure or
physical removal of any station/ module connected to the system bus shall not result
in loss of any communication function to and from any other station/ module.
c If the system bus requires a master bus controller philosophy, it shall employ
redundant master bus controller with automatic switchover facility.
d Built-in diagnostics shall be provided for easy fault detection. Communication error
detection and correction facility (ECC) shall be provided at all levels of
communication. Failure of one bus and changeover to the standby system bus shall
be automatic and completely bumpless and the same shall be suitably
alarmed/logged.
e The design and installation of the system bus shall take care of the environmental
conditions as applicable.
f Data transmitting speed shall be sufficient to meet the responses of the system in
terms of displays, control etc. plus 25% spare capacity shall be available for future
expansion.
g Passive coaxial cables or fiber optic cables shall be employed.
The Contractor shall furnish details regarding the communication system like
communication protocol, bus utilization calculations etc.
1.09.02 If specified in the scope section, the PLC system shall be provided with necessary
interface hardware and software for dual fiber optic connectivity & interconnection with
BOP PLC NETWORK SYSTEM for two-way transfer of signals for the purpose of
operation & control from a remote centralized location. The Remote plant operation &
control shall be made available through an Ethernet link following TCP/ IP standard
through separate Owner procured BOP PLC NETWORK SYSTEM. The exact Operation
& control philosophy shall be finalized during detailed engineering and Owner’s decision
will be final and binding. The system shall be OPC compliant. The exact data structure
shall be as decided during detailed engineering. All required plant data shall be
transferred through this link ensuring complete security. The exact number of points to be
transferred through the above communication link and the format of the data shall be
finalized during detailed engineering. Further the Contractor is to ensure that link
response time as per process requirement is achieved successfully for remote operation
& control and in case for achieving the same, any additional hardware/ software is
required at PLC end, the same is to be provided by the bidder without any additional
price. In addition of providing all required inputs/data in proper agreeable formats,
Contractor to also provide all necessary assistance to the Owner’s BOP PLC NETWORK
SYSTEM supplier for smooth operation of the link.
1.10.00 OPERATOR INTERFACE DISPLAYS/ LOGS/ REPORTS
1.10.01 Suitable Operator Interface Displays/ Logs/ Reports for control operation & monitoring
shall be provided. The details shall be finalized during detailed Engg. Stage.

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system with UPS
Various displays on the OWS shall as a minimum include P&ID displays or mimic, bar
chart displays, X-Y & X-T plot (trend) displays, operator guidance
message displays, group displays, plant start-up/shutdown message
displays, system status displays etc. Number of displays and the exact
functionality shall be on as required basis and as finalized during detailed
engineering.
The assignment for the above will be done by the contractor as per the requirement of
operation of BOP systems as well as for maintenance. Provision shall be
kept for future modification/ addition of different types of displays.
1.11.00 HISTORICAL STORAGE AND RETRIEVAL SYSTEM (HSRS)
1.11.01 The HSRS shall collect, store and process system data from HMIS data base. The data
shall be saved online on hard disk and automatically transferred to erasable long term
storage media once in every 24 hours periodically for long term storage. Provision shall
be made to notify the operator when hard disk is certain percentage full. The disk
capacity shall be sufficient to store at least seven days data.
1.10.02 The data to be stored in the above system shall include alarm and event list, periodic
plant data, selected logs/ reports. The data/ information to be stored & frequency of
storage and retrieval shall be as finalized during detailed engineering. The system shall
provide user-friendly operator functions to retrieve the data from historical storage. It shall
be possible to retrieve the selected data on OWS or printer in form of trend/report by
specifying date, time & period. Further, suitable index files/directories shall also be
provided to facilitate the same. The logs/ reports for at least last seven (7) days shall be
available on the disk.
1.11.03 The bulk storage devices (DVD, Hard disk) shall be provided.
In addition to above, the system shall also have facility to store & retrieve important plant
data for a very long duration (plant life) on portable long term storage media). These data
will include any data from the database as well as processed/computed data based on
various calculations/ transformation. The retrieved data from long term storage media
should be possible to be presented in form of X-T display, X-Y display, logs, reports, etc.
1.12.00 CONTROL & POWER SUPPLY SCHEME
1.12.01 For PLC system, Contractor shall provide UPS system as described below. Further
requirement of low level AC/DC power conversion and/or stabilization for controller,
interrogation power etc required for PLC system shall be met by the Contractor by
providing redundant stabilized power supplies and any other additional equipment etc
within the quoted lump sum price. Power Supply module shall have 20% spare capacity
for future use.
1.12.02 Following are the two UPS configurations. Refer Drg. No. REL-COENG-NEN-442-J-
00002 for typical UPS configuration diagrams. Bidder to supply UPS system as specified
in the scope section.
UPS Configuration I
There will be 2 x 100% inverter and charger modules with 1x100% battery bank with 30
minutes back-up, 1X 100 % standby AC source with servo controlled stabilizer.
Each inverter shall be rated to cater the load of PLC System (Controllers, I/O Modules/
Communication Modules), HMI System and other instruments requiring 230 VAC. The
UPS power supply system shall be rated at 50 deg C and include 10% spare capacity for
future expansion. Each Inverter shall be so sized so that it can clear the maximum branch
circuit fuse on its own without bypass support. Necessary redundant transformers shall

Standard
system with UPS
be provided by the Contractor to derive power supply from 415 V, 3-phase incomers. The
static switch shall be provided to perform the function of transferring UPS loads
automatically without any break from -
i. faulty inverter to healthy inverter in case of failure of one of the two inverters
and
ii. faulty inverter to standby AC source in case of failure of both the inverters.
The transfer time shall be ¼ cycle maximum. Manual by-pass switch shall be provided to
isolate any inverter for maintenance or repair without interruption to the UPS load. The
switch shall have the facility of by-passing both the inverters during start-up at the option
of the operator. Contact shall be make-before-break type. The switch shall have current
rating equal to the full load inverter current and necessary short time load carrying and
interrupting capacity to meet the requirement of UPS system. The voltage stabilizer
should be servo controlled.
The chargers shall be self regulating, solid state silicon controlled, full-wave rectifier type
designed for single and parallel operation with battery and shall have automatic voltage
regulators for close voltage stability even when AC supply voltage fluctuates, effective
current limiting features and filters to minimize harmonics. The charger output regulation
shall be ± 1% from no load to full load with an input power supply variation of ± 10% in
voltage and ± 5% in frequency. The static inverter shall be of continuous duty, solid state
type using proven Pulse Width Modulation (PWM)/ Quasi square wave/ step wave
technique. The steady state voltage regulation shall be +/-1% or better. Frequency
regulation for all conditions of input supplies, loads and temperature occurring
simultaneously or in any combination shall be better than ± 0.1% (automatically
controlled). The total harmonic content shall be 5% maximum and content of any single
harmonic shall be 3% maximum. The inverter efficiency shall be at least 90% on full load
and 85% at 50% load.
UPS Configuration II
There will be 1 x 100% inverter and charger modules with 1x100% battery bank with 30
minute back up, 1X 100 % Standby AC source with solid state stabilizer.
The inverter shall be rated to cater the load of PLC System (Controllers, I/O Modules /
Communication Modules), HMI System and other instruments requiring 230 VAC. The
UPS power supply system shall rated at 50 deg. C and include 10% spare capacity for
future expansion. The Inverter shall be so sized so that it can clear the maximum branch
circuit fuse on its own without bypass support. Necessary redundant transformers shall
be provided by the Contractor to derive power supply from 415 V, 3-phase incomers. The
static switch shall be provided to perform the function of transferring UPS loads
automatically without any break from faulty inverter to standby AC source in case of
failure of the inverter.
The transfer time shall be ¼ cycle maximum. Manual by-pass switch shall be provided to
isolate inverter for maintenance or repair without interruption to the UPS load. The switch
shall have the facility of by-passing the inverter during start-up at the option of the
operator. Contact shall be make-before-break type. The switch shall have current rating
equal to the full load inverter current and necessary short time load carrying and
interrupting capacity to meet the requirement of UPS system. The voltage stabilizer
should be solid state.
The charger shall be self regulating, solid state silicon controlled, full-wave rectifier type
designed for single and parallel operation with battery and shall have automatic voltage
regulators for close voltage stability even when AC supply voltage fluctuates, effective

Standard
system with UPS
current limiting features and filters to minimize harmonics. The charger output regulation
shall be ± 1% from no load to full load with an input power supply variation of ± 10% in
voltage and ± 5% in frequency. The static inverter shall be of continuous duty, solid state
type using proven Pulse Width Modulation (PWM)/ Quasi square wave/ step wave
technique. The steady state voltage regulation shall be +/-1% or better. Frequency
regulation for all conditions of input supplies, loads and temperature occurring
simultaneously or in any combination shall be better than ± 0.1% (automatically
controlled). The total harmonic content shall be 5% maximum and content of any single
harmonic shall be 3% maximum. The inverter efficiency shall be at least 90% on full load
and 85 at 50% load. The details of the Power supply system shall be finalized during
detailed engineering and subject to Owner’s approval.
1.12.03 All the drives shall be switched ON/OFF through 24V DC coupling relays to be provided
in HT/LT SWGR panels.
1.12.04 Power supply distribution from Contractor’s power supply cabinets shall be in the scope
of Contractor. The exact power supply scheme shall be as approved by Employer during
detailed Engineering stage.
1.12.05 The battery shall be sealed maintenance-free Valve Regulated Lead Acid (VRLA)
batteries with long life and shall be able to provide a back-up for 30 minutes at full load
requirement of the complete control system.
1.12.06 For remote I/O cabinets, separate redundant power supplies, suitable for Employer
supplied redundant 415V, 3-phase redundant incomers, shall be provided. The
equipment of power supply unit can be mounted as an integral part of the enclosure and
the same shall provide all voltages necessary to power the processor and I/O modules.
All required redundant power packs etc. with inbuilt chargers; with minimum one hour
battery back-up shall be provided. Power supply module shall be of ample capacity to
supply all modules. In addition 20% spare capacity for future shall be provided. However,
the exact power supply scheme shall be as approved by Employer during detailed
Engineering stage.
1.12.07 Contractor shall provide power supply distribution panels/ cabinets/ boxes for sub-
distribution of main UPS/ DC/ Utility feeder(s) on as required basis. These shall include
necessary auto-change over circuitry, switch-fuse units, MCBs, terminal blocks etc.
suitable for the application. The design of these distribution panels/ cabinets/ boxes shall
be as approved by Owner during detailed engineering stage. Each of the control
cabinets, however, shall be provided with redundant DC/UPS feeders.
1.13.00 CONTROL CABINETS / PANELS / DESKS
1.13.01 The cabinets shall be IP-22 protection class. The Contractor shall ensure that the
packaging density of equipment in these cabinets is not excessive and abnormal
temperature rise, above the cabinet temperature during normal operation or air-
conditioning failure, is prevented by careful design. This shall be demonstrated to the
Employer during the factory testing of the system. The Contractor shall ensure that the
temperature rise is limited to 10 deg. C above ambient and is well within the safe limits
for system components even under the worst condition. Ventilation blowers shall be
furnished as required by the equipment design and shall be sound proof to the maximum
feasible extent. Dual blowers with blower failure alarm shall be provided in each cabinet
with proper enclosure and details shall be furnished with proposal. Suitable louvers with
wire mesh shall be provided on the cabinet.
1.13.02 The cabinets shall be designed for front access to system modules and rear access to
wiring and shall be designed for bottom entry of the cables.
1.13.03 The cabinets shall be totally enclosed, free standing type and shall be constructed with
minimum 2 mm thick steel plate frame and 1.6 mm thick CRCA steel sheet or as per

Standard
system with UPS
supplier's standard practice for similar applications. The cabinets shall be equipped with
full height front and rear doors. The floor mounting arrangement for other cabinets shall
be as required by the Employer and shall be furnished by the Contractor during detailed
engineering.
1.13.04 Cabinet doors shall be hinged and shall have turned back edges and additional bracing
where required ensuring rigidity. Hinges shall be of concealed type. Door latches shall be
of three-point type to assure tight closing. Detachable lifting eyes or angles shall be
furnished at the top of each separately shipped section and all necessary provisions shall
be made to facilitate handling without damage. Front and rear doors shall be provided
with locking arrangements with a master key for all cabinets. If width of a cabinet is more
than 800 mm, double doors shall be provided.
1.13.05 Two spray coats of inhibitive epoxy primer-surface shall be applied to all exterior and
interior surfaces. A minimum of 2 spray coats of final finish colour shall be applied to all
surfaces. The final finished thickness of paint film on steel shall not be less than 65-75
micron for sheet thickness of 2 mm and 50 microns for sheet thickness of 1.6 mm. The
finish colors for exterior and interior surfaces shall be finalized during detailed
engineering.
1.13.06 Paint films which show sags, checks or other imperfections shall not be acceptable.
1.13.07 As an alternative, single coat of anodic dip coat primer along with single textured powder
coating with epoxy polyester meeting the thickness requirement is also acceptable.
1.13.08 Suitable arrangement shall be made for system ground (electronic ground), panel body
grounding and power supply grounding.
1.13.09 The type of termination and terminal blocks to be used in the PLC Field Termination
cabinets shall be Cage clamp type .Screw type terminals are not acceptable. The
terminals used for terminating the spare cores/ pairs of field cables shall not be employed
for terminating the spare channels of I/O modules.
.”
1.14.00 ALARM SYSTEM
1.14.01 Only OWS based alarm system shall be provided with audio alarm facility (beep/tone
generator). No facia annunciation is envisaged in the control room. The system shall
display history of alarms in chronological order on any of the OWS. The HMIS shall have
the capability to store a minimum of 500 alarms each with paging features allowing the
operator to view any page. The system shall have all alarm functions and related
function keys like alarm acknowledge, reset, paging, summaries etc. Other design
features like set point/dead band adjustments, provision of alarm priority, manual
inhibition & automatic inhibition based on predefined logic etc. shall be provided and shall
be as finalized during detailed engineering. The alarm display/report format shall be as
approved by the Employer.
1.14.02 Facility of audio alarming shall be provided in OWS upon the occurrence OWS alarms
irrespective of whether alarms are displayed or not. Facility to disable the audio alarming
on OWS shall be provided.
1.14.03 At least three levels of alarm priority shall be available which will be displayed in different
colour. It shall be possible to display & print alarms of any of the three levels only on a
per OWS basis.
1.14.04 Alarm boxes shall be provided in each display to alert the operator about an alarm when
he is viewing some other picture. The number of alarm boxes shall be finalized during
detailed engineering for each process area & each priority therein.
1.15.00 SOFTWARE DOCUMENTATION AND SOFTWARE LISTINGS
1.15.01 All technical manuals, reference manuals, user’s guide etc. in English required for
modification/ editing/ addition/ deletion of features in the software of the PLC System

Standard
system with UPS
shall be furnished. The Contractor shall furnish a comprehensive list of all system/
application software documentation after system finalization for Employer’s review and
approval.
1.15.02 All the software listings including Source code for application software, all special-to-
project data files etc. shall be submitted by the Contractor.
1.16.00 SOFTWARE LICENCES
1.16.01 The Contractor shall provide software license for all software being used in Contractor’s
System. The software licenses shall be provided for the project (e.g. organization or site
license) and shall not be hardware/ machine-specific. That is, if any hardware/ machine is
upgraded or changed, the same license shall hold good and it shall not be necessary for
Employer to seek a new license/ renew license due to up gradation/ change of hardware/
machine in Contractor’s System at site. All licenses shall be valid for the continuous
service life of the plant.
1.16.02 As a customer support, the Contractor shall periodically inform the designated officer of
the Employer about the software upgrades/ new releases that would be taking place after
the system is commissioned so that if required, same can be procured & implemented at
site.
1.17.01 Bidder shall supply the PLC system complying the following Industry Standard codes and
standard as a minimum. All prevailing standard shall be complied for
IEEE 383/1974: Flammability test
IEC 754-1 Acid gas generation test
ASTM - D - 2843 Smoke generation test
IEEE - 1050 Guide for Instrumentation and Control

Equipment Grounding in Generating
Stations
ANSI C 37.90.1 Surge Withstand Capability (SWC) Tests
ISA-S 50.0:ANSI MC 12.1-1975 Compatibility of Analog Signals for

Electronic Industrial Process Instruments.
IEC 326 C Printed Circuit Boards
NEMA ICS Part-2-125, A600 Contact Rating for AC services
NEMA ICS Part-2-125, N600 Contact Rating for DC services
ISO 1745 Control procedures for Data

Communication System
NEMA Std. ICS-6-110.15 Types of enclosures

through 110.22 (Type 4 to 13).
EIA: RS-310-B Racks, panels, and associated

(ANSI C83.9 - 1972) equipments

Standard
system with UPS
IS-13947. Protection Class for Enclosure,

Cabinets, Control Panels and Desks
ISA RP 19.1-1979. Specifications and guides for the use of

general purpose annunciators
IEEE std.3.13. Relays and relay system associated

with electric power apparatus
BS 5887 Code of Practice for Testing of

Computer-based Systems
BS EN60801 Electromagnetic Compatibility for

Industrial Process Measurement and
Control
1.18.00 DOCUMENT SUBMITTAL REQUIREMENT
1.18.01 The Contractor during detailed engineering shall provide configuration diagram, write
ups, hardware/ software details, I/O & drive list(Owner format) ,MMI documents ,logic
diagram (Owner format)& write ups ,power supply diagram, load list, panel GA and layout
& wiring drawings , bill of material, Quality plan, Grounding scheme, technical data
sheets ,FAT procedure, spare parts list, cable interconnection diagrams, cable list ,optic
fiber cable laying details, O&M and installation manuals, etc. for complete PLC system
covered under this contract.
1.18.02 Data and documents to be furnished by the Bidder along with bid:
i. PLC Configuration, write ups, hardware/ software details, I/O & drive list
ii. Power supply and distribution arrangement.
iii. Bill of materials
iv. GA and layout drawing.
v. Schedule of type and routine tests
vi. Recommended grounding system.
vii. Quality assurance plan
viii. Final list of sub vendors as per Owner.
ix. Data requirements.
x. Details of post commissioning services
xi. Proposed delivery schedule
xii. Deviation sheet (if any) shall be furnished mentioning the specification clause
number against which the deviation has been sought and the specific deviation
taken against the clause. Any departure from the specification, not specifically
mentioned in the deviation sheet, shall be ignored even though deviation may be
mentioned, hinted or implied otherwise in any other section of the offer, it will be
presumed that Bidder shall comply with the specification in totality in the event of
award of contract.

Standard
system with UPS
1.19.00 PERFORMANCE TESTS

1.19.01 The system / equipment to be supplied under this specification shall meet the parametric
requirement stated in clause no. 1.06.00, 1.07.00, 1.08.00 when operated at the rated /
specified conditions. The acceptance of the system/ equipments shall be subject to
satisfying required parameters during shop test at vendor’s works and/ or at site
installation in complete assembled condition.
1.19.02 The vendor without any extra cost will rectify any decline in performance from the
guaranteed performance figures.
1.20.00 WORK SCHEDULE:
1.20.01 Bidder shall ensure that the delivery of the equipment/ instrument shall meet the project
schedule, which shall be furnished to the bidder during issuing of the tender documents.
1.20.02 Bidder shall indicate the phase wise design, engineering, manufacturing, testing and
delivery for the complete package in the form of a bar-chart to match the project schedule
in co-ordination with package vendor.
1.20.03 Bidder shall furnish a detailed supply programme for manufacturing and assembly for
approval and will be subsequently form a part of the contract document.
1.21.00 TYPE TEST REQUIREMENTS
1.21.01 General Requirements
The Contractor shall furnish the type test reports of all type tests as per relevant
standards and codes as specified by the owner. If the bidder proposes a different
standard/code from that indicated, same is acceptable provided the equivalence of the
proposed standard is established by the bidder.
(a) Submission of type test results and certificate shall be acceptable provided.
i. The same has been carried out by the Bidder/ sub-vendor on same series of
PLC system and similar rating of UPS as the equipment being offered.
ii. There has been no change in the components from the offered equipment &
tested equipment.
iii. The test has been carried out as per the latest standards along with
amendments as on the date of Bid opening.
(b) In case the approved equipment is different from the one on which the type test had
been conducted earlier or any of the above grounds, then the tests have to be
repeated and the cost of such tests shall be borne by the Bidder/ sub-vendor within
the quoted price and no extra cost will be payable by the Owner on this account.
1.22.00 TYPE TEST
1.22.01 PLC SYSTEM:-
The minimum type test reports, over and above the requirements of above clause, which
are to be submitted for the PLC systems shall be as indicated below:

Standard
system with UPS
i) Surge Withstand Capability ( SWC) for Solid State Equipments/ Systems
All solid state systems/ equipments shall be able to withstand the electrical noise
and surges as encountered in actual service conditions and inherent in a power
plant. All the solid state systems/ equipments shall be provided with all required
protections that needs the surge withstand capability as defined in ANSI 37.90.1/
IEEE-472. Hence, all front end cards which receive external signals like Analog
input & output modules, Binary input & output modules etc. including power supply,
data highway, data links shall be provided with protections that meets the surge
withstand capability as defined in ANSI 37.90.1/ IEEE-472. Complete details of the
features incorporated in electronics systems to meet this requirement, the relevant
tests carried out, the test certificates etc. shall be submitted along with the proposal.
As an alternative to above, suitable class of EN 61000-4-12 which is equivalent to
ANSI 37.90.1/ IEEE-472 may also be adopted for SWC test.
ii) Dry Heat test as per IEC-68-2-2 or equivalent.
iii) Damp Heat test as per IEC-68-2-3 or equivalent.
iv) Vibration test as per IEC-68-2-6 or equivalent.
v) Electrostatic discharge tests as per EN 61000-4-2 or equivalent.
vi) Radio frequency immunity test as per EN 61000-4-6 or equivalent.
vii) Electromagnetic Field immunity as per EN 61000-4-3 or equivalent.
Test listed at item no. v, vi, vii, above are applicable for electronic cards only as defined
under item (i) above.
1.22.02 UPS SYSTEM: -
Test certificates for the following test to be furnished for Owner’s review/approval.
Sr.No. TEST REQUIREMENT STANDARD

1 Degree of protection test IS-2147
2 Load Test For finalized capacity.
3 Audible Noise Test IEC 162
4 Fuse Clearing Capability As per specification
requirement.
5 Radio interference IEC-164
6 Synchronous transfer test IEC-164
7 Input Voltage Variation Test As per specification
requirement
8 Over Load Test on Inverter & charger As per specification
requirement
9 Insulation Test IEC 146
10 Restart Test IEC 146-2
11 Short Circuit current capability IEC 146-2
12 Output voltage & frequency tolerance IEC 146-2
13 Voltage Current Division IEC 146-2
14 Relative Harmonic content IEC 146-2

Standard
system with UPS
1.23.00 QUALITY REQUIREMENTS
1.23.01 The PLC shall meet the specification requirements and shall be manufactured / tested
(inclusive for functional tests also) as per applicable codes & standards as well as
approved quality assurance plans.
1.23.02 The manufacturer is to furnish a detailed quality plan indicating the practice and
procedure along with relevant supporting documents.
1.24.00 SPARES
1.24.01 Start-up and commissioning spares to be supplied with PLC.
1.24.02 Separate list of recommended spare for 5 years of the normal trouble free operation also
be quoted.
1.24.03 Mandatory spare as specified by the owner.
1.24.04 All spares required for operation/ maintenance by the owner shall be delivered in unused
new condition.
1.24.01 Spares, which may be required during tests, trial and commissioning, shall be arranged
separately.
1.25.00 TOOLS & TACKELS
1.25.01 The Bidder in his proposal shall indicate a list of tools & tackles, which may be required
for maintenance, overhaul, and replacement of instrument / equipment / component to be
supplied under this specification.
1.26.00 FACTORY ACCEPTANCE TESTS:
1.26.00 The Owner shall witness the factory acceptance test of PLC system at
manufacturer works as per approved FAT procedure.
1.27.00 TRAINING
1.27.00 Contractor shall provide training on PLC systems for Owner personnel at their works. Details shall
be worked out during detailed engineering.

SPECIFICATION FOR RELAY
BASED CONTROL SYSTEM/
STANDARD SPECIFICATION
PANELS
SUB-SECTION – I 10
FOR
RELAY/ MICROCONTROLLER BASED CONTROL PANELS/ LOCAL CONTROL
PANELS
DOC. NO.: REL-COENG-NEN-449-P-00001 R0 SUB-SECTION – I 10 Page 1 of 3

PANELS
1.01.00 RELAY BASED/ MICRO-CONTROLLER BASED CONTROL PANELS

Bidder shall supply complete relay based/ micro controller based control
panels, wherever required, with all requisite relays/ micro-controllers,
transformers, timers, push buttons, indicating lamps etc., so as to enable
control & operation of the various equipment being supplied under the
package, as per the operation philosophy. Suitable terminal blocks, gland
plates, vibration dampeners, illumination etc. shall be provided in the panels.
The panels shall meet the typical specifications outlined below. The details
shall be finalized during detailed engineering and subject to Owner’s approval.
1.02.00 LOCAL CONTROL PANELS WIRED THROUGH PLC SYSTEM

Bidder shall supply dummy local control panels wired through PLC System,
wherever required, with all requisite push buttons, indicating lamps etc., so as
to enable local control & operation of the various equipment being supplied
under the package, as per the operation philosophy. Suitable terminal blocks,
gland plates, vibration dampeners, illumination etc. shall be provided in the
panels. The panels shall meet the typical specifications outlined below. The
details shall be finalized during detailed engineering and subject to Owner’s
approval.
1.03.00 SPECIFICATIONS FOR PANELS

a. The panels shall be with protection class of IP-22 (for AC Room), IP-42
(for indoor ventilated location), IP-54 (for indoor non-ventilated location),
and IP-55 (for outdoor location). The Contractor shall ensure that the
packaging density of equipment in these cabinets is not excessive and
abnormal temperature rise is prevented and considering ease of access/
maintenance. Ventilation blowers shall be furnished as required by the
equipment design and shall be sound proof to the maximum feasible
extent. Suitable louvers with wire mesh shall be provided on the panel.
b. The cabinets shall be designed for front access to major components and
rear access to wiring and shall be designed for bottom entry of the cables.
c. The panels shall be totally enclosed, free standing type and shall be
constructed with minimum 2 mm thick steel plate frame and 1.6 mm thick
CRCA steel sheet. The panels shall be equipped with full height front and
rear doors, wherever applicable.
d. The doors shall be hinged and shall have turned back edges and
additional bracing where required ensuring rigidity. Hinges shall be of
concealed type. Door latches shall be of three-point type to assure tight
closing. Detachable lifting eyes or angles shall be furnished at the top of
each separately shipped section and all necessary provisions shall be

PANELS
made to facilitate handling without damage. Front and rear doors shall be
provided with locking arrangements with a master key for all panels. If
width of a cabinet is more than 600 mm, double doors shall be provided.
e. Two spray coats of inhibitive epoxy primer-surface shall be applied to all
exterior and interior surfaces. A minimum of 2 spray coats of final finish
color shall be applied to all surfaces. The final finished thickness of paint
film on steel shall not be less than 65-75 micron for sheet thickness of 2
mm and 50 microns for sheet thickness of 1.6 mm. The finish colors for
exterior and interior surfaces shall be finalized during detailed engineering.
f. Paint films which show sags, checks or other imperfections shall not be
acceptable.
g. As an alternative, single coat of anodic dip coat primer along with single
textured powder coating with epoxy polyester meeting the thickness
requirement is also acceptable.
h. Suitable arrangement shall be made for system ground (electronic
ground), panel body grounding and power supply grounding.

SPECIFICATION FOR
CONTROL VALVES, ACTUATORS & STANDARD SPECIFICATION
ACCESORIES
SUB-SECTION – I11
FOR
CONTROL VALVES, ACTUATORS & ACCESSORIES

SPECIFICATION FOR
ACCESORIES
1.01 GENERAL REQUIREMENTS
1.01.1 The control valves and accessories equipment furnished by the Bidder shall be
designed, constructed and tested in accordance with the latest applicable
requirements of code for pressure piping ANSI B 31.1, the ASME Boiler & pressure
vessel code, Indian Boiler Regulation (IBR), ISA, and other standards specified
elsewhere as well as in accordance with all applicable requirements of the "Federal
Occupational Safety and Health Standards, USA" or acceptable equal standards. All
the Control Valves, their actuators and accessories to be furnished under this Sub-
section will be fully suitable and compatible with the modulating loops covered under
the Specification. The specifications outlined below typically pertain to control valves
regulated from PLC system through suitable E/P converters.
1.01.2 All the control valves and accessories offered by the Bidder shall be from reputed,
experienced manufacturers of specified type and range of valves.
1.02 CONTROL VALVE SIZING & CONSTRUCTION
1.02.1 The design of all valve bodies shall meet the specification requirements and shall
conform to the requirements of ANSI (USA) for dimensions, material thickness and
material specification for their respective pressure classes.
1.02.2 The valve sizing shall be suitable for obtaining maximum flow conditions with valve
opening at approximately 80% of total valve stem travel and minimum flow conditions
with valve stem travel not less than 10% of total valve stem travel. All the valves shall
be capable of handling at least 120% of the required maximum flow. Further, the valve
stem travel range from minimum flow condition to maximum flow condition shall not be
less than 50% of the total valve stem travel. The sizing shall be in accordance with the
latest edition of ISA handbook on control valves. While deciding the size of valves,
Bidder shall ensure that valves trim exit outlet velocity as defined in ISA handbook
does not exceed 8 m/sec for liquid services, 150 m/sec. for steam services and 50% of
sonic velocity for flashing services. Bidder shall furnish the sizing calculations clearly
indicating the outlet velocity achieved with the valve size selected by him as well as
noise calculations, which will be subject to Employer's approval during detailed
engineering.
1.02.3 Control valves for steam and water applications shall be designed to prevent
cavitation, wire drawing, flashing on the downstream side of valve and down stream
piping. Thus for cavitation/flashing service, only valve with anti cavitation trim shall be
provided. Detailed calculations to establish whether cavitation will occur or not for any
given application shall be furnished. The control valves shall have leakage rate as per
leakage Class-IV.
1.02.4 The control valve induced noise shall be limited to 85 dBA at 1 meter from the valve
surface under actual operating conditions. The noise abatement shall be achieved by
valve body and trim design and not by use of silencers.

SPECIFICATION FOR
ACCESORIES
1.03 VALVE CONSTRUCTION
1.03.1 All valves shall be of globe body design & straightaway pattern with single or double
port, unless other wise specified or recommended by the manufacturer to be of angle
body type. Rotary valve may alternatively be offered when pressure and pressure
drops permit.
1.03.2 Valves with high lift cage guided plugs & quick-change trims shall be supplied.
1.03.3 Cast Iron valves are not acceptable.
1.03.4 Bonnet joints for all control valves shall be of the flanged and bolted type or other
construction acceptable to the Employer. Bonnet joints of the internal threaded or
union type will not be acceptable.
1.03.5 Plug shall be of one-piece construction cast, forged or machined from solid bar stock.
Plug shall be screwed and pinned to valve stems or shall be integral with the valve
stems.
1.03.6 All valves connected to vacuum on down stream side shall be provided with packing
suitable for vacuum applications (e.g. double vee type chevron packing)
1.03.7 Valve characteristic shall match with the process characteristics.
1.03.8 Flanged valves shall be rated at no less then ANSI press class of 300 lbs.
1.04 VALVE MATERIALS
Sr. No. Service Body material Trim Material

1 Heating line Alloy steel ASTM 217 316 SS stellited
Gr. WC9
-----------------------------------------------------------------------------------------------------------------------------
NOTE Valve body rating shall meet the process pressure and temperature requirement as per
ANSI B16.34.
However, Bidder may offer valves with body and trim materials better than specified
materials and in such cases Bidder shall furnish the comparison of properties including
cavitation resistance, hardness, tensile strength, strain energy, corrosion resistance
and erosion resistance etc. of the offered material vis-a-vis the specified material for
Employer's consideration and approval.
1.05 END PREPARATION
1.05.1 Valve body ends shall be either butt welded/ socket welded, flanged (Rubber lined for
condensate service) or screwed as finalised during detailed engineering and as per
Employer's approval. The welded ends wherever required shall be butt welded type as
per ANSI B 16.25 for control valves of sizes 65 mm and above. For valves size 50 mm

SPECIFICATION FOR
ACCESORIES
and below welded ends shall be socket welded as per ANSI B 16.11. Flanged ends
wherever required shall be of ANSI pressure-temperature class equal to or greater
than that of the control valve body.
1.06 VALVE ACTUATORS
1.06.1 All control valves shall be furnished with pneumatic actuators (pneumatically
operated). The Bidder shall be responsible for proper selection and sizing of valve
actuators in accordance with the pressure drop and maximum shut off pressure and
leakage class requirements. The valve actuators shall be capable of operating at 60
deg.C continuously.
1.06.2 Valve actuators and stems shall be adequate to handle the unbalanced forces
occurring under the specified flow conditions or the maximum differential pressure
specified. An adequate allowance for stem force, at least 0.15 Kg/ sq.cm. per linear
millimeter of seating surface, shall be provided in the selection of the actuator to
ensure tight seating unless otherwise specified.
1.06.3 The travel time of the pneumatic actuators shall not exceed 10 seconds.
1.07 CONTROL VALVE ACCESSORY DEVICES
1.07.1 All pneumatic actuated control valve accessories such as air locks, hand wheels/hand-
jacks, limit switches, Microprocessor based electronic Positioner with integral E/P
converter & Position transmitter, diffusers, external volume chambers, reversible pilot
for Positioner, tubing and air sets, solenoid valves and junction boxes etc. shall be
provided as per the requirements.
1.07.2 SPECIFICATIONS FOR MICROPROCESSOR BASED ELECTRONIC POSITIONER
1. Input Signal 4-20 mA

Hart Protocol Compatibility For Remote
Calibration & Diagnostics
(Super-Imposed HART Signal
On Input Signal(4-20 mA)
Power Supply Loop Powered from the output
Electrical card of Control System
Valve Position Position Sensing (Non Contact-
Sensing Type), 4-20 Ma O/P
Signal for Control System to be
provided.
2. Environment Protection Class IP-65 Minimum
3. Diagnostics Diagnostic/ Test Features Advanced Diagnostic Features
Like Stroke Counter Or Travel
Counter, Leakage In Actuators,
On Line Partial Closure Test,
Valve Signature Analysis, Step
Response Test, Valve Friction

SPECIFICATION FOR
ACCESORIES
/Jamming Detection Etc To Be

Provided
4. Factory Valve Signature Tests Reports (Pr Vs Valve Travel And Travel Vs I/P
Signal) are to be provided.
5. Valve Action Direct & Reverse acting
Modes Flow Characterization Possible To Fit Valve
Characteristic Curve Linear &
Equal Percentage.
6. Fail Safe/Fail Fail Safe/ Fail Freeze Feature is to be provided.

Freeze
7. Air Capacity Sufficient To Handle The
Valves Selected/ Boosters To
be supplied if required.
Pneumatic Air Supply Pressure To Suit The Air Supply
Pressure/ Quality Available.
Process Connection 1/4 Inch NPT
8. Performance Characteristic Deviation <=0.5 % Of Span
9. In Built Operator panel

Accessories Hand Held Hart Calibrator
Valves Mounting Assembly
Press Gauge Block
-----------------------------------------------------------------------------------------------------------------------------
1.08 TEST AND EXAMINATION
1.08.1 All valves shall be tested in accordance with the quality assurance programme agreed
between the Employer and Contractor, which shall meet the requirements of IBR and
other applicable codes mentioned elsewhere in the specifications. The tests shall
include but not be limited to the following:
1.08.2 Non Destructive Test as per ANSI B-16.34.
1.08.3 Hydrostatic shell test in accordance with ANSI B 16.34 prior to seat leakage test.
1.08.4 Valve closure test and seat leakage test in accordance with ANSI-B 16.34 and as per
the leakage class indicated above.
1.08.5 Functional Test: The fully assembled valves including actuators control devices and
accessories shall be functionally tested to demonstrate times from open to close
position.
1.08.6 CV Test: CV test shall be carried out as type test on each size, type and design of
the valves as per ISA 75.02 standard and test report shall be furnished for
Employer's approval.

SPECIFICATION FOR
PRESSURE MEASUREMENT STANDARD SPECIFICATION
INSTRUMENTS
SUB-SECTION: I 2
PRESSURE MEASUREMENT INSTRUMENTS
DOCUMENT NO.: REL-COENG-NEN-443-P-00001 R0 SUB-SECTION – I 2 Page 1 of 8

SPECIFICATION FOR
INSTRUMENTS
1.0 General
The specifications for the pressure measurement instruments viz. Pressure/ Differential
Pressure gauges/ switches, Pressure/ Differential pressure transmitters etc. are
outlined below. The technical specifications are outlined below. The ranges and other
particulars shall be as per the process requirement, finalized P&IDs, BOQ/ Instrument
List etc.. All required accessories for the completeness of the instruments shall be
supplied along with the instruments.
1.01 Codes & Standards
The design, manufacture, inspection, testing, site calibration and installation of all
equipment and systems covered under this specification shall conform to the latest
editions of codes and standards mentioned below and all other applicable ANSI,
ASME, IEEE, NEC, NEMA, ISA, DIN, VDE and Indian Standards and their
equivalents.
1.01.1 Pressure Measurement

a) Instrument and apparatus for pressure measurement - ASME PTC 19.2 (1964)
b) Bourdon tube pressure and vacuum gauges - IS 3624 – 1996
c) Specification for absolute and gauge pressure transmitters with electrical
outputs - BS 6447/ IEC 60770
1.01.2 Electronic measuring Instruments & Control hardware
a) Automatic null balancing electrical measuring instruments - ANSI C 39.4
(Rev. 1973)
b) Safety requirements for electrical and electronic measuring and controlling
instrumentation - ANSI C 39.5 - 1974.
c) Compatibility of analog signals for electronic industrial process instruments -
ISA-S 50.1: ANSI MC 12.1 - 1975.
d) Surge withstand capability (SWC) tests - ANSI C 37.90.1/ IEC - 254.1
e) Printed circuit boards - IPC TM-650, IEC 326 C
f) General requirements and tests for printed wiring boards -IS 7405 (Part-I) -
1973
g) Edge socket connectors - IEC 130-11.
h) Dimensions of attachment plugs & receptacles ANSI C73-1973.
i) Direct acting Electrical Indicating Instruments: IS-1248-1968.
1.01.3 Instrument Switches and Contacts

SPECIFICATION FOR
INSTRUMENTS
a) Contact rating - AC services NEMA ICS Part-2 125, A600

b) Contact rating - DC services NEMA ICS Part-2-125, N600.
1.01.4 Enclosures
a) Types of enclosures - NEMA Std. ICS-6-110.15 through 110.22 (Type 4 to 13).

b) Racks, panels, and associated equipment - EIA: RS-310-B (ANSI C83.9 -
1972)
c) Protection Class for Enclosure, Cabinets, Control Panels and Desks - IS-60947.
1.01.5 Apparatus, enclosures and installation practices in hazardous areas

a) Classification of hazardous area - NFPA Art. 500, Vol.70-1984.
b) Electrical Instruments in hazardous dust locations - ISA-RP 12.11
Notes:
1. All the field instruments shall also be provided with SS tag nameplate and double
compression type Nickel-plated brass cable gland. Counter and mating flange
shall also be included wherever required with instruments.
2. All instruments falling under hazardous area shall have suitable explosion proof
EExd housing or provided with an intrinsic barrier that shall meet the area
classification guidelines as per the service and applicability requirement.
3. The equipments shall be designed and constructed to withstand ambient
temperature extremes and relative humidity conditions as specified under project
environment conditions. For the various Instruments which are employed in the
sea side environment, suitable protective coating like epoxy coating etc. shall be
provided on the instruments body/ impulse piping etc. For applications where the
medium is sea water based, the wetted parts of the instruments shall be of
corrosion resistant material like Hastelloy C or Monel etc.

SPECIFICATION FOR
INSTRUMENTS
2.0 Technical specifications
2.01 Pressure/ Differential Pressure Gauge
01. Type : Bourdon / Bellows / Diaphragm
02. Sensing Element : AISI SS 316 ( Also Refer Note 3 )

Material
03. Movement Materials : AISI 304 SS
04. Case Material : Die cast aluminum
05. Protection Class IP 65 or better
06. Dial Size : 100 mm
07. Scale : Black lettering on white background in 270

°C arc
08. Range Selection : Normally operate at 75% of its maximum

pressure range. Instruments measuring
varying pressures shall operate in a band of
60%-80% of its maximum pressure range.
09. Over range : 150% of maximum range by internal stop.

Protection External stop below zero.
10. Adjustment : External Micrometer screw for zero

adjustment. Internal micrometer screw for
range adjustment.
11. Stop at Max. Reading : Shall be provided
12. Element Connection : Argon welding
13. Process Connection : ½” NPT(M) bottom connection for local

mounting, back connection for panel
mounting
14. Accuracy : +1.0% of span or better
15. Operating Ambient : 50 ˚C (Max. continuous)

Temperature
16. Safety Feature : Neoprene Safety Diaphragm (Blowout disc)

at the back
17. Feature : Shatter-proof glass

SPECIFICATION FOR
INSTRUMENTS
18. Chemical Seal Unit : SS 316 Flange and Diaphragm(Silver

coated for corrosive services), PTFE coated/
block, Silicone Oil filling fluid
19. Accessories : Pulsation dampers for pulsating fluid

applications / 3-way gauge cock / 2-valve
manifold / Pigtail / Siphon for steam service /
Gauge Saver, if maximum or Design
Pressure is very high than the Operating
Pressure/ Counter Flange/ Bolts, Nuts,
Gaskets / SS Tag Plate
2.02 Pressure / Differential Pressure Switch
01. Type : Diaphragm / Bourdon / Bellows / Piston

actuated – Teflon back-up sheath protection,
as required.
02. Sensing Element : AISI 316 SS ( Also Refer Note 3 )

material
03. Wetted Parts material : SS 316 ( Also Refer Note 3 )
04. Case Material : Epoxy coated Die Cast Aluminium
05. Setter Scale : Black graduation on white linear scale.

Graduation 0 – 100% with red pointer for set
points.
06. Over range for : 150% of maximum pressure

Pressure / Vacuum
Switch
07. Set Point : Adjustable in switch operating range.
08. Static Pressure for : Maximum Line Pressure or Static Pressure

Differential Pressure on either side without permanent
Switch deformation or loss of accuracy.
09. Adjustments Internal – set point
10. Process Connection : ½” NPT(M) bottom connected
11. Switch Configuration : 2 SPDT / 1 DPDT
12. Switch Rating : 230 V, 5A AC / 60 V, 0.1A DC

SPECIFICATION FOR
INSTRUMENTS
13. Switch Type : Snap acting, shock and vibration-proof
14. Terminal Block : Suitable for full ring lugs for 0.5 to 1.5
Sq.mm. cable connection
15. Cable Connection : ¾” ET conduit connection or compression

gland
16. Enclosure Class : IP 65 or better.
17. Performance a. Accuracy of setting : 1% of span up to

3Kg/cm2 & 0.5% of span for more than
3 Kg/cm2.
b. Repeatability : 0.5% of span
18. Operating Ambient : 50 Deg. C (maximum continuous)

Temperature
19. Accessories : a) Snubbers for pulsating fluid application.
b) Tag Number, service engraved in SS

tag plate.
c) i) Remote diaphragm seal with SS 316

armored capillary for viscous, slurry &
corrosive applications. MOC (Material
of Construction) of seal material shall
be as per process fluid requirement.
ii) Silver/ Teflon coated diaphragm for
highly corrosive services like
chlorinated water.
d) Retention ring and screws for surface

mounting.
e) 3-way Gauge Cock (SS 316) for PS / 5-

Valve Manifold (SS 316) for DPS.
f) ¾” ET double compression brass cable

gland etc.
2.03 Transmitters: PT / DPT
01. Type : 2-Wire, Smart (HART)
02. Output Signal : 4-20 mA signal superimposed with HART

signal.

SPECIFICATION FOR
INSTRUMENTS
03. Signal Processing : Microprocessor based

Unit
04. Static Pressure/ : Maximum line (or static) pressure on either

Overload Pressure side without permanent deformation or loss
for DPT, Static of accuracy, 150 percent of maximum span
Pressure/ Overload continuously, without affecting the
Pressure for PT calibration.
05. Turn-down Ratio : 10: 1 for vacuum/ very low pressure

applications.
30:1 for other applications.
06. Span and Zero : Continuously adjustable, non-interacting &

both local & remote calibration facility.
07. Enclosure Class : IP 65 or better with durable corrosion

resistant coating.
08. Zero Suppression/ : At least 100% of span

Elevation
09. Local Indicator : To be provided
10. Display : Digital LCD Integral Display (minimum 5

digit) Engineering Unit
11. Body and its rating
: a) Stainless Steel/ 1.5 times the maximum

fluid pressure for DPT.
b) Forged Carbon Steel Rating : 1.5 times

the maximum fluid pressure (minimum)
for PT.
12. MOC of Electrical : Aluminum Alloy or better

Housing
13. Ambient : 65 Deg. C

Temperature
14. Operating Voltage : 16 – 48 Volts DC
15. Load : 600 Ohms (minimum) at 24 Volts DC
16. Accuracy : ± 0.075% of span or better
17. Sealing / Isolation : i) Extended diaphragm with 5 mtrs. SS

SPECIFICATION FOR
INSTRUMENTS
armored capillary for corrosive, viscous and

dirty fluid applications. Material for separator
diaphragm, depending on application.
ii) Silver/ Teflon coated diaphragm for highly
corrosive services like chlorinated water.
18. Accessories : a) Universal mounting bracket suitable for

2 inch pipe and wall mounting.
b) High tensile carbon steel U-bolts.
c) Installation accessories as per relevant

installation drawing.
d) Snubbers for pulsating pressure,

siphons for steam and hot water
services.
e) 3-valve SS 316 manifold for DPT/ 2-

valves SS 316 manifold for PT/ 3-valve
SS 316 manifold whenever DPT are
used for pressure measurement,
constructed from bar stock. Manifold
shall be non-integral type. Manifold
process side and instrument side
connection shall be ½ NPT (F). Suitable
drain/ vent holes with caps shall be
provided.
f) Companion flange with nuts, bolts and

gaskets.
g) Brass, Double compression cable gland

with each instrument.

SPECIFICATION FOR
TEMPERATURE MEASUREMENT STANDARD SPECIFICATION
INSTRUMENTS
SUB-SECTION - I 3
FOR
TEMPERATURE MEASUREMENT INSTRUMENTS
DOC. NO.: REL-COENG-NEN-444-P-00001 R0 SUB-SECTION- I 3 Page 1 of 7

SPECIFICATION FOR
INSTRUMENTS
1.00 General
The specifications for the Temperature measurement instruments viz. Temperature

gauges/ switches, Resistance Temperature Detectors (RTDs) etc. are outlined below.
The technical specifications are outlined below. The ranges and other particulars shall
be as per the process requirement, finalized P&IDs, BOQ/ Instrument List etc.. All
required accessories for the completeness of the instruments shall be supplied along
with the instruments.

editions of codes and standards mentioned below and all other applicable ANSI,
ASME, IEEE, NEC, NEMA, ISA, DIN, VDE and Indian Standards and their
equivalents.
1.01.1 Temperature Measurement
a) Instrument and apparatus for temperature measurement ASME PTC 19.3
(1974)
b) Temperature measurement - Thermocouples ANSI-MC 96.1 - 1982.
c) Temperature measurement by electrical resistance thermometers-IS 2806,
DIN 43760.
d) Thermometer-element-platinum resistance - IS-2848.
a) Automatic null balancing electrical measuring instruments - ANSI C 39.4
(Rev. 1973)
ISA-S 50.1: ANSI MC 12.1 - 1975.
d) Dynamic response testing of process control instrumentation - ANSI MC
4.1 (1975): ISA-S26 (1968).
e) Surge withstand capability (SWC) tests - ANSI C 37.90.1
f) Printed circuit boards - IPC TM-650, IEC 326 C
g) General requirements and tests for printed wiring boards - IS 7405
(Part-I) - 1973
h) Edge socket connectors - IEC 130-11.
i) Dimensions of attachment plugs & receptacles ANSI C73-1973.
j) Direct acting Electrical Indicating Instruments: IS-1248-1968.

SPECIFICATION FOR
INSTRUMENTS

1.01.4 Enclosures
1972)
c) Protection Class for Enclosure, Cabinets, Control Panels and Desks - IS-
60947.

Notes:
1. All the field instruments shall also be provided with SS tag nameplate and
double compression type Nickel-plated brass cable gland. Counter and mating
flange shall also be included wherever required with instruments.
temperature extremes and relative humidity conditions as specified under
project environment condition later. For the various Instruments which are
employed in the sea side environment, suitable protective coating like epoxy
coating etc. shall be provided on the instruments body/ impulse piping etc. For
applications where the medium is sea water based, the wetted parts of the
instruments shall be of corrosion resistant material like Hastelloy C or Monel
etc.

SPECIFICATION FOR
INSTRUMENTS
2.0 Technical Specifications
2.01 Temperature Indicator (Temperature Gauge)
01. Type : Bimetallic type/ Mercury filled
02. Stem : SS 316
03. Movement Materials : SISI 304 SS / Direct Bourdon tip connection

to pointer spindle
04. Case Material : Die cast aluminium
Protection Class IP65 or better.
05. Dial Size : 100 mm
06. Scale : Black lettering on white background in 270 °C

arc
07. Adjustment : Micrometer screw for zero adjustment.

Internal micrometer screw for range
adjustment.
08. Pointer : Externally Adjustable
09. Range Selection : Normal Process Temperature – approximately

two third of Temperature range.
10. Stop at Max. Reading : Shall be provided
11. Over range Protection : 150% of FSD
12. Instrument Connection : Bottom connection for local mounting, back

connection for panel mounting.
13. Process Connection : ½” NPT with Thermowell
14. Accuracy : +1.0% of full scale or better
15. Operating Ambient : 50 ˚C (Max. continuous)

Temperature
16. Accessories : Counter Flanges / Bolts, Nuts, Gaskets / SS

Tag plate, SS Thermowell etc.
17. Feature : All angle type

SPECIFICATION FOR
INSTRUMENTS
2.02 Temperature Switch
1. Type : Bi-Metallic/ Mercury filled Type
2. Movement material : AISI 304 SS
3. Enclosure : Die cast aluminum conforming IP 65 or

better.
4. Setter scale : Black lettering on white background
5. Over range protection : 120 percent up to 400 Deg.C.
6. Instrument connection : Bottom connection for local mounting, back

connection for panel mounting
7. Switch configuration : 2 SPDT
8. Switch rating : 240V, 5A AC/60 V, 0.1 A DC
9. Switch type : Snap acting, shock and vibration proof
10. Adjustability : Set point adjustable over span range
11. Cable connection : 3/4” with cable gland
12. Performance
a) Accuracy : ±1.0% of full scale
b) Repeatability : Less than 0.5 percent of full range
c) Response time : Less than 8 Secs. Bared
2.03 Resistance Temperature Detector (RTD)
01. Type : Platinum ( Duplex) Ungrounded
02. Resistance : 100 ohm at 0 deg C
03. Base : Wound on Ceramic ( anti – inductive)
04 Wiring : 3 Wire
05 Response Time : < 15 seconds
06 Sheath Material & OD : 316 SS with swaged type Magnesium oxide

insulation, spring loaded & 6mm.

SPECIFICATION FOR
INSTRUMENTS
07 Accuracy & : As per DIN-43760 Class – A for RTD.

Characteristic
08 Immersion length/ : As required. Bidder shall furnish calculations for

Extension neck length length based on pipe size, fluid velocity etc..
Consideration for stub/ insulation etc. shall be
suitably kept.
09 Process Connection : ½ “ NPT (M) with thermowell
10 Head
Protection : IP 65
Material : Die Cast Aluminium.
11 Cable Connection : ¾ “ ET Brass, Double compression cable gland
12 Accessories : a) Adjustable Nipple-Union-Nipple with

thermowell
b) Compression fittings / unions
c) Flanges etc.
d) Thermowell
2.04 Thermo well
01. Material : a. AISI 316 SS drilled from bar stock, for normal
applications
b. Monel for corrosive services
02. Process connection : Based on equipment manufacturer process

connection/ stubs. Typically M33 x 2.
03. Max Internal bored dia : Shall match with temperature Element
04. Bore Connection : ±5% wall thickness
05. Identification Mark : Tag Number punched on head
06. Surface Treatment : Polish after machining
07. Element Connection : ½ “ NPT (F)
08. Certification : ASME Performance Test Code 19.3-1974

SPECIFICATION FOR
INSTRUMENTS
09. Accessories : Plug and chain for test thermowells

SPECIFICATION FOR
FLOW MEASUREMENT STANDARD SPECIFICATION
INSTRUMENTS/ FLOW ELEMENTS
SUB- SECTION – I 4
FOR
FLOW MEASUREMENT INSTRUMENTS/ FLOW ELEMENTS

SPECIFICATION FOR
1.00 General
The specifications for the flow measurement instruments viz. Flow gauges/ switches, Flow
transmitters, Flow meters etc. are outlined below. The technical specifications are outlined
below. The ranges and other particulars shall be as per the process requirement, finalized
P&IDs, BOQ/ Instrument List etc.. All required accessories for the completeness of the
instruments shall be supplied along with the instruments.

editions of codes and standards mentioned below and all other applicable ANSI, ASME,
IEEE, NEC, NEMA, ISA, DIN, VDE and Indian Standards and their equivalents.

a) Instrument and apparatus for pressure measurement - ASME PTC 19.2 (1964)
b) Bourdon tube pressure and vacuum gauges - IS 3624 – 1996
c) Specification for absolute and gauge pressure transmitters with electrical outputs -
BS 6447/ IEC 60770
1.01.2 Flow Measurement
a) The flow elements (Orifice plates) shall be designed in accordance with ASME
PTC – 19.5 (Pt – II), ISA RP3.2, 1960 or BS 1042.
b) The flow elements (Flow Nozzles) shall be designed in accordance with ASME
PTC – 19.5 (Pt – II), or BS 1042.
a) Automatic null balancing electrical measuring instruments - ANSI C 39.4 (Rev.

1973)
c) Compatibility of analog signals for electronic industrial process instruments - ISA-S
50.1: ANSI MC 12.1 - 1975.
d) Dynamic response testing of process control instrumentation - ANSI MC 4.1
(1975): ISA-S26 (1968).
e) Surge withstand capability (SWC) tests - ANSI C 37.90.1/ IEEE Std. 472 (1974).
IEC - 254.1
g) General requirements and tests for printed wiring boards - IS 7405 (Part-I) -
1973

SPECIFICATION FOR

i) Requirements and methods of testing of wire wrap terminations DIN 41611
Part-2.
j) Dimensions of attachment plugs & receptacles ANSI C73-1973.
k) Direct acting Electrical Indicating Instruments: IS-1248-1968.

1.01.5 Enclosures
b) Racks, panels, and associated equipment - EIA: RS-310-B (ANSI C83.9 - 1972)
c) Protection Class for Enclosure, Cabinets, Control Panels and Desks - IS-60947.

Notes:
compression type Nickel-plated brass cable gland. Counter and mating flange shall
also be included wherever required with instruments.
environment conditions. For the various Instruments which are employed in the sea
side environment, suitable protective coating like epoxy coating etc. shall be
medium is sea water based, the wetted parts of the instruments shall be of corrosion
resistant material like Hastelloy C or Monel etc.

SPECIFICATION FOR
2.01 Rotameter
01. Type : ON-LINE for line up to and including 50 mm NB

Bypass type with orifice for line size above 50 mm.
02. Metering tube : Borosilicate
03. Float material : AISI 316 SS unless the process fluid demands
some other material
04. End fittings : AISI 316 SS unless otherwise mentioned in the

data sheets
05. Packing material : Teflon / PTFE
06. Casing material : Die cast aluminum conforming to IP 65 or better
07. Gland Rings / : Steel

Followers material
08. Scale : 250 mm nominal length
09. Graduation : Direct reading
10. Process Connection : Flanged (RF) to line size as per ANSI standards
for on-line type & 1/4 inch 150 lbs (RF) ANSI
flange for bypass type.
11. Accuracy : +/- 2% of full scale reading
12. Reproducibility : Within 0.5% of instantaneous reading
13. Accessories : Slip-on orifice plate of 316 SS Carrier range

Orifice - for bypass type rotameters. (For line size
above 50mm)
2.02 Flow Switch
01. Type : Vane / Paddle Type
02. Switch Configuration : 2 SPDT / 1 DPDT , micro type
03. Switch Rating : 240 V, 5A AC / 60 V, 0.1A DC
04. Enclosure : Die cast aluminium conforming IP 65 or better

SPECIFICATION FOR
05. Repeatability : + / - 0.5% of FSD or better
06 Adjustments : a) Internal – set point adjustable in switch

operating range
b) ON-OFF differential
07 Connection type : Flanged / Screwed
2.03 Transmitters: DPT Type Flow Tx (to be provided along with flow element)
02. Output Signal : 4-20 mA signal superimposed with HART

signal.
03. Signal Processing : Microprocessor based

Unit
04. Static Pressure / : Maximum line (or static) pressure on either

Overload Pressure side without permanent deformation or loss
for DPT of accuracy, 150 percent of maximum span
continuously, without affecting the
calibration.
05. Turn-down Ratio : 10: 1 for vacuum/ very low pressure

applications.
06. Span and Zero : Continuously adjustable, non-interacting &

both local & remote calibration facility.
07. Enclosure Class : IP 65 or better with durable corrosion

resistant coating.

Elevation
10. Display : Digital LCD Integral Display (minimum 5

digit) Engineering Unit
: a) Stainless Steel/ 1.5 times the maximum

SPECIFICATION FOR
fluid pressure for DPT.
b) Forged Carbon Steel Rating : 1:5 times

the maximum fluid pressure (minimum)
for PT.

Housing
13. Ambient : 65 Deg. C

Temp
eratur
e
17. Sealing / Isolation : i) Extended diaphragm with 5 mtrs. SS

armored capillary for corrosive, viscous and
dirty fluid applications. Material for separator
diaphragm, depending on application.
ii) Silver/ Teflon coated diaphragm for highly
corrosive services like chlorinated water.
18. Accessories : a) Universal mounting bracket suitable for

2 inch pipe and wall mounting.

d) Snubbers for pulsating pressure,

siphons for steam and hot water
services.
e) 3-valve SS 316 manifold, oval flange

connection to transmitter body,
constructed from barstock. Manifold
shall be non-integral type. Manifold
process side and instrument side
connection shall be ½ NPT (F). Suitable
drain/ vent holes with caps shall be
provided.
f) Companion flange with nuts, bolts and

SPECIFICATION FOR
gaskets.
g) Brass, Double compression cable gland

with each instrument.
h) Two handheld Calibrators for each unit.
2.04 Electromagnetic Flow Meter / Transmitter
2.04.01 Sensor
01. Type : Sensor with flanges
02. Electrodes : 316 SS
03. Liner : Hard rubber or Neoprene
04. Enclosure : IP 65 or better with durable corrosion

resistant coating.
05. Accessories : Counter flanges, Mounting nuts, bolts,

gaskets etc.
06 Pipe Dia. As per P&ID/ Instrument List
2.04.02 Transmitter
01. Input Signal Processing : Microprocessor based
02. Display : Digital Display (LCD)
03. Output : 4-20 mA DC
04. Power Supply : 230 V AC, 50 Hz/ 24 V DC (loop powered)
05. Turn Down : 100 : 1
06. Accuracy : ±0.5% of calibrated span
07. Repeatability : ±0.05%
08. Housing : IP 65 or better with durable corrosion

resistant coating
09. Accessories : a) Counter Flanges as required for field

SPECIFICATION FOR
mounting
b) Handheld Configurator
c) Mounting U-bolts, nuts, bolts, prefab

cable etc.
d) ¾ “ ET Cable Gland.
e) SS Tag plate etc.
2.05 Ultrasonic Flow Meter/ Transmitter
01. Type : Transit time Clamp On Ultrasonic meter
02. Mounting Style Dual path with two sets of transceivers on

:
the same pipe
03. Flow measurement Instantaneous Flow rate as well as totalized

:
flow
04. Power supply : 230 V AC, 50 Hz/24 V DC (loop powered)
05. Outputs :
Analog Current Isolated 4-20mA linear outputs for each path
Binary Contact relay outputs, 2 NO + 2 NC for

: alarm
Communication ports RS 232 C digital

Hand held terminal port
06. Display/ Indication Flow meter with LCD screen backlight based
local display and keypad. If required,
transmitter shall be suitably located away
:
from the sensor for better access and
visibility.
07. Recording/ Totalizing/ Yes. Should be able to compute cumulative

Logging Facilities flow over intervals selectable by owner i.e.,
: daily, weekly, monthly etc. The data shall be
stored in the memory of flow computer for
access in future.
08. Software features Compensation for any cross path errors

:
Programming, configuration shall be

SPECIFICATION FOR
possible from front panel.
09. Diagnostics False signal tolerance , power supply failure

:
etc.
10. Protection class IP 65 or better, Weather protection against

: direct sunlight, rain etc for Flow meter and
suitable for Cooling water for Transducer
11. Accuracy : +/- 1%
12. Electrical connection : Plug and socket
13. Accessories All mounting hardware required like

clamping fixtures, mechanism to remove the
transducers online, interconnecting cables
: etc
All weather canopy for protection from direct
sunlight and direct rain.
Material of all fittings shall be SS 316.
2.06 Vortex Flow transmitter

02. Output Signal : 4-20 mA
03. Signal Processing Unit : Microprocessor based
04. Accuracy : 1.0% of reading
05. Repeatability : 0.5% of reading
06. Vortex Shedder : SS 316

07. Mounting : In Line
08. Construction : Stainless steel wetted parts with
ceramic/ Cast Aluminium transducers
09. Display : LCD Based
10. Enclosure :
IP 65
2.07 Parshall Flume type Flow Transmitter
For flow measurement in open channel, Parshall flume type flow meter shall be provided.
The flow shall be computed by measuring the head difference in the Parshall flume. The
level measurement shall be carried out by using ultrasonic type level transmitter. Bidder
shall provide all required primary sensors, transmitters, flow computation electronics,
SPECIFICATION FOR
flow indicator & totalizer and other required accessories. System shall be of reputed
make and acceptable to Owner / Engineer.
Flow signal from the system shall be in the form of analog output of 4 – 20 mA DC with
an accuracy of + 1 % or better.
Field mounted local flow indication facility shall also be provided.
The enclosure should conform to IP 65 or better and corrosion resistant.
Bidder shall provide all required details of weir/ flume construction and the
calculations.
2.08 Mass Flow Meter
This shall typically be used for fuel oil/gas flow metering.
Type : Smart
Working Principle : Coriolis principle
Output signal : 4-20 mA signal superimposed with HART signal
Operating Voltage : 16-48 V DC.
Transmission : 2-wire
Material Of Wetted : SS 316L

Parts
Enclosure Class : IP-65 with durable corrosion resistant coating/ Ex. Proof
as required.
Display : LCD for flow rate, temp, density & total flow.
Process connection : ANSI RF Companion flange with nuts, bolts and gaskets.
Performance
i)Accuracy : + 0.15% of span or better.

(Combined)
ii) Repeatability : + 0.5% of span or better.
Accessories : a) ANSI RF Counter Flange; rating as per process

pressure. Necessary nuts, bolts, gaskets etc.

SPECIFICATION FOR
Nameplate : Tag no. , range service, make, model no. etc. engraved
in stainless steel tag plate.
FLOW ELEMENTS
2.09 Orifice Plate
Concentric square edge type or Segmental bored

01. Type :
type as per type of process.
02. Design Standard : BS1042 / ISO 5167.
Material of Orifice Plate 316 SS, Orifice flange rating will be the same as the
03. :
& Rating piping class.
3 mm for the pipe diameter up to 300 mm and 6 mm

04 Thickness :
for the pipe diameter above 300mm.
05 Beta Ratio : Between 0.4 and 0.7
06 Pressure Tap : Flange type, 3 (Triple) sets
07 No. of Root Valves per : 1) Two for static pressure above 40kg/ cm2.
tapping 2) One for static pressure up to 40 kg/cm2.
08 Root valve type/ Globe valve/ 316 SS

material
09 Vent Hole / Drain Hole : Yes (Vent hole for liquid applications & Drain hole
for steam/ gas applications)
10 Accuracy : +/-1%
11 Accessories a) Orifice plate will be provided with a Handle. Tag

number, orifice plate material, measured bore
: and ID of the pipe will be stamped or deep
engraved on the upstream face of the Handle.
b) Jack bolt shall be provided for easier removal.
c) Male female carrier ring of SS316 material shall

be provided
d) Studs and nuts material shall be ASTM A193

Gr. B7 / A194 Gr. 2H

SPECIFICATION FOR
e) Other mounting accessories as applicable
12 Data/ Documents to be Beta Ratio calculation, DP Vs Flow curves,

submitted Assembly drawing, Calibration certificate
2.10 Flow Nozzle
01 Design Standard/ Type : BS 1042, ASME PTC 19.5 (1972)/ Long Radius,
welded type
02 Material of Nozzle : AISI 316 SS or better
03 Pressure Taps : D – D/2 taps– 3 Sets
04 Beta Ratio : Around 0.7
05 No. of Root Valves per : 1) Two for static pressure above 40kg/cm2.
tapping
2) One for static pressure up to 40 kg/cm2.
06
Root valve type/ material Globe valve/ 316 SS
07 Accessories : Mounting accessories including branch pipe/
spool piece of same material as main pipe,
as applicable
Vent Hole / Drain Hole
08 Yes (Vent hole for liquid applications &
Drain hole for steam applications)
09 Data/ Documents to be Beta Ratio calculation, DP Vs Flow curves,

submitted Assembly drawing, Calibration certificate
2.11 Impact Head Type Flow Element / Averaging Pitot Tube
This will typically be used for CW flow measurement.
01. Type : Flanged with opposite side support.
02. Number of Holes : As per Chebyshef Calculus
03. Material of Construction :

a) Sensor 316L SS
b) Instrument Head 316 SS
c) Instrument Valve Carbon Steel

SPECIFICATION FOR
d) Mounting Carbon Steel

Hardware
04. Piping Orientation : Horizontal
05. Accuracy : + 1.0 % of actual value or better
06. Repeatability : + 0.1 % of actual value or better
07. Flow Turn Down : Greater than 10:1
08. Process Connection : 3” ANSI 300#
09. Accessories : Mounting accessories as applicable, complete

flushing arrangement with requisite piping
valves etc. using instrument/ service air.

SPECIFICATION FOR
LEVEL MEASUREMENT STANDARD SPECIFICATION
INSTRUMENTS
SUB-SECTION - I 5
FOR
LEVEL MEASUREMENT INSTRUMENTS

SPECIFICATION FOR
INSTRUMENTS
1.00 General
The specifications for the level measurement instruments viz. level gauges, different types
of level switches, different types of level transmitters etc. are outlined below. The technical
specifications are outlined below. The ranges and other particulars shall be as per the
process requirement, finalized P&IDs, BOQ/ Instrument List etc.. All required accessories
for the completeness of the instruments shall be supplied along with the instruments.
editions of codes and standards mentioned below and all other applicable ANSI, ASME,
IEEE, NEC, NEMA, ISA, DIN, VDE and Indian Standards and their equivalents.
a) Specification for absolute and gauge pressure transmitters with electrical outputs -
BS 6447/ IEC 60770

a) Automatic null balancing electrical measuring instruments - ANSI C 39.4 (Rev.
1973)
ISA-S 50.1: ANSI MC 12.1 - 1975.
d) Dynamic response testing of process control instrumentation - ANSI
MC 4.1 (1975): ISA-S26 (1968).
e) Surge withstand capability (SWC) tests - ANSI C 37.90.1
g) General requirements and tests for printed wiring boards - IS 7405 (Part-I) -
1973
i) Dimensions of attachment plugs & receptacles ANSI C73-1973.
j) Direct acting Electrical Indicating Instruments: IS-1248-1968.


SPECIFICATION FOR
INSTRUMENTS
1.01.4 Enclosures
1972)
c) Protection Class for Enclosure, Cabinets, Control Panels and Desks - IS-
60947

Notes:
compression type Nickel-plated brass cable gland. Counter and mating flange shall
also be included wherever required with instruments.
environment condition later. For the various Instruments which are employed in the
sea side environment, suitable protective coating like epoxy coating etc. shall be
medium is sea water based, the wetted parts of the instruments shall be of corrosion
resistant material like Hastelloy C or Monel etc.

SPECIFICATION FOR
INSTRUMENTS
2.01 Level Indicator (Gauge Glasses)
01. Type : Reflex
02. Glass : Toughened in moulded borosilicate

resistant to thermal shock
03. Glass Cover : Carbon Steel
04. Gauge Body Material : Die cast aluminum conforming to IP 65

or better.
05. Integral Cocks and Valves : i) SS 316
ii Rubber lined corrosion resistant

) stainless steel (for Demineralised
and Osmosis water service)
06. Fittings : i) SS 316 / Rubber lined Steel / PVC

for Corrosive liquids,
Demineralised and Osmosis Water
Service).
ii 304 Stainless Steel for non-

) corrosive liquids
07. Packing material : Teflon
08. Scale : Aluminum
09. Scale Details : Graduated in mmwc (10 mm minimum)
10. Accuracy : +1.0% of span or better
11. Vessel Connection : ANSI Flanged SS 316 with SS 316

mating flanges, steel bolts and nuts,
CAF gaskets
12. Accessories : a) Integral Cocks
b) Drain Valves
c) Bolts, nuts and gaskets
d) Companion flange with fastener

SPECIFICATION FOR
INSTRUMENTS
13. Tests : Tested at two hundred (200) percent of

the maximum process pressure
14. Other Details : For larger lengths (greater than 1200

mm), additional gauge glasses shall be
provided with minimum of 50 mm
overlap.
2.02 Level Indicator (Float & Board)
01. Type : Float and Board
02. Float Material : ANSI : 316 SS
03. Pulley Material : Cast Aluminium pulley housing with SS 304

pulley and pulley shaft
04. Guide Wire : AISI : 316 SS
05. Scale Board : Anodized Aluminium with engraved marking

(minimum graduation 10 mm)
06. Flange : RF, ANSI 150, CS
07. Accuracy : + 10 mm or better
08. Protection Class : IP 65 or better
09. Accessories : All mounting accessories including SS 316

Anchor Bar
2.03 Float Operated External Cage Type Level Switch
01. Float Material : AISI 316 Stainless Steel
02. Wetted Parts : AISI 316 Stainless Steel
03. Float Chamber : Carbon Steel, Welded Construction
04. Float Chamber Mounting : Side Mounted
05. Fluid Connection : Side – Side
06. Size of the float chamber : To suit requirement
07. Fluid Connection Size : 1” ANSI RF Flange (rubber line, if

SPECIFICATION FOR
INSTRUMENTS
required).
08. Drain : ½” NPT(F) with Plug
09. Pressure Rating of : Minimum 1.5 times of design pressure

Chamber
10. Repeatability : ±1.5 mm or better
11. Accuracy : +15mm or better
12. Switch Housing : Die cast aluminum conforming IP-65 or

better
13. Type of Switch : Snap acting , shock and vibration-proof
14. Switch Configuration : 2 SPDT / 1 DPDT
15. Switching Differential : Preferably Adjustable
16. MOC of Switching : AISI 304 Stainless Steel

Mechanism
17. Contact Rating : 5A, 240 V AC / 0.1A, 60 V DC
18. Cable Entry : ¾” ET
19. Cable Gland : Brass, Double Compression
20. Accessories : a) Counter flange, nuts & bolts, suitable

gasket etc.
b) SS Tag Plate etc.
21. Preferred Feature : Switch operating point marked on cage.
2.04 Top Mounted Displacer Operated Level Switch
01. Displacer : SS 316
02. Displacer Assembly : ANSI SS 316 Stainless Steel
03. Wire Rope / Spring : SS 316
04. Guide Pipe : Mild Steel
05. Process : ANSI CS Flange with Gaskets, Nuts & Bolts

SPECIFICATION FOR
INSTRUMENTS
Connection
06. Repeatability : ±3 mm or better
07. Switch Housing : Die cast Aluminium with anti-corrosive paints
08. Switch Housing : IP-65

Protection
09. Type of Switch : Snap acting, vibration resistant, mercury bottle or

hermitically sealed micro switch type magnetically
coupled to the displacer.
10. Switch : 2 SPDT / 1 DPDT

Configuration
11. MOC of Switching : AISI 304 Stainless Steel

Mechanism
12. Contact Rating : 5A, 240 V AC / 0.1A, 60VDC
13. Cable Entry : ¾” ET
14. Cable Gland : Brass, Double compression
15. Accessories : Counter flange, nuts & bolts, suitable gasket etc.
SS Tag Plate etc
2.05 Capacitance Type Level Switch
1. Type : Capacitance type
2. Probe : a) Rod or suspended electrode
b) Stainless steel 1-1/2 ANSI RF Flange / ¾“ NPT

(M)
c) Material : SS 316
d) Insulation: Part / Full as required by service

condition (Polypropylene / Teflon).
e) Rope type probes may be used only where

required probe length is greater than 3 meters.
Rope shall be made of 316 SS.
f) Coated with PTFE sheath.

SPECIFICATION FOR
INSTRUMENTS
3. Pre-amplifier : a) Solid state electronic module to be mounted

on probe head
b) Protection class - IP -65.
c) Ambient temperatures-0 Deg.C. to 80 Deg.C.
(Automatic temperature compensated.).
d) Function: The pre-amplifier unit converts the
variation in capacitance into a variable voltage
signal.
4. Control Unit Function : The control unit converts the output of pre-amplifier
into contact output
5. Enclosure : Powder/Epoxy coated Die cast aluminium.
6. Ambient temperature : 0-80 ºC.
7. Supply voltage : 240V AC, 50Hz
8. Relay output : 2 SPDT
9. Contact rating : 5A, 240V AC / 0.1A, 60VDC
10. Cable connection : ¾” ET
11. Accessories : Counter flange, Cable gland, prefab / special cable

and stainless steel name plate engraved with
alpha-numeric.
2.06 RF Type Level switch
1. Sensing Probe : RF type
a) Material : SS 316
b) Mounting : Threaded / Flange
c) Enclosure Protection : IP 65
d) Enclosure Housing : Cast Aluminium.
e) Probe Insertion length : By Bidder (As per Vessel G.A)
f) Rated pressure and : By Bidder (As per process parameter) temperature

SPECIFICATION FOR
INSTRUMENTS
2. Electronic Controller :
a) Power Supply : 240VAC, 50 Hz
b) Relay Output : 2 SPDT
c) Contact Rating : 240V AC, 5A / 0.1A, 60VDC
d) Enclosure Protection : IP 65
e) Enclosure Housing : Cast Aluminium.
f) Repeatability : + / - 0.5% of FSD
3. Cable : Coaxial from probe to controller.
4. Gland : ¾ inch ET
5. Accessories : i) Mounting Hardware, as required.

ii) SS Tag plate
6. Application : ESP/ECO/AHP Hoppers
2.07 Oil Level switch for cooling towers gear box
As specified under scope of work, oil level switch shall be provided on the gear reducer for
cooling towers. The switch shall disengage the fan motor on low oil level. This shall be
typically external cage type float operated level switch. Suitable arrangement shall be
made to mount this instrument outside the fan enclosure.
2.08 DPT Type Level Transmitter
02. Output Signal : 4-20 mA signal superimposed with HART signal.
03. Signal Processing Unit : Microprocessor based
04. Static Pressure / : Maximum line (or static) pressure on either side
Overload Pressure for without permanent deformation or loss of accuracy,
DPT 150 percent of maximum span continuously, without
affecting the calibration.
05. Turn-down Ratio : 10: 1 for vacuum / very low pressure applications.

SPECIFICATION FOR
INSTRUMENTS
06. Span and Zero : Continuously adjustable, non-interacting & both local
& remote calibration facility.
07. Enclosure Class : IP 65 or better with durable corrosion resistant

coating.

Elevation
10. Display : Digital LCD Integral Display (minimum 5 digit)

Engineering Unit
: a) Stainless Steel/ 1.5 times the maximum fluid

pressure for DPT.
b) Forged Carbon Steel Rating : 1:5 times the

maximum fluid pressure (minimum) for PT.

Housing
13. Ambient Temperature : 65 Deg. C
17. Sealing / Isolation : i) Extended diaphragm with 5 mtrs. SS armored

capillary for corrosive, viscous and dirty fluid
applications. Material for separator diaphragm,
depending on application.
ii) Silver/ Teflon coated diaphragm for corrosive
services.
18. Accessories : a) Universal mounting bracket suitable for 2 inch

pipe and wall mounting.

d) Snubbers for pulsating pressure, siphons for

SPECIFICATION FOR
INSTRUMENTS
steam and hot water services.
e) 3-valve SS 316 manifold, oval flange

connection to transmitter body, constructed
from barstock. Manifold shall be non-integral
type. Manifold process side and instrument
side connection shall be ½ NPT (F). Suitable
drain/ vent holes with caps shall be provided.
f) Companion flange with nuts, bolts and gaskets.
g) Brass, Double compression cable gland with

each instrument.
h) Two handheld Calibrators for each unit.
1.01 Ultrasonic Level Transmitter
1.01.1 Signal processing : Microprocessor controlled Signal

Processing
1.01.2 Connection : 2 wire
1.01.3 Operating frequency : 10 KHz to 50 KHz (typical)
1.01.4 Display : Large alpha-numeric back lit LCD / LED
1.01.5 Calibration & : Accessible from front of panel

Configuration
1.01.6 Diagnosis : On-line
1.01.7 Status : For power, Hi / LO / V. Hi / V. LO-level

Indication, fault etc.
1.01.8 Construction : Plug-on board
1.01.9 Power supply : 24 V DC (loop powered)
1.01.10 Signal output : 4-20 mA DC (isolated)- 600 Ohm load.
1.01.11 Accuracy & : 0.25 % of span or better

Repeatability
1.01.12 Resolution : 0.1 % of span

SPECIFICATION FOR
INSTRUMENTS
1.01.13 Operating temp. : Transmitter- 50 deg C and Sensor - 80 deg C
1.01.14 Enclosure : IP 65 or better Epoxy painted die cast aluminium

or Polycarbonate housing.
1.01.15 Cable connection : ¾” ET
1.01.16 Mounting : 2” for sensor (Top / Vertically Mounted)

The transmitter shall be suitably mounted
locally or on panel- to be decided during
1.01.17 Accessories : Transducer & Counter Flange with Nuts, Bolts &
Gaskets.
SS Tag Plate etc
Brass, Double Compression Cable Gland.
1.02 Contact less Radar type level transmitter
Contact less radar type level transmitters shall be provided for level
measurements of the Sulphuric Acid tanks applications.
Type Contactless Radar
Principle Time of Flight

Probe Type & Material Coaxial, SS316/316L. If required, probe shall
be suitable for overfill prevention.
Signal o/p 4-20mA with HART signal suitable for overfill
prevention.
Display Integral
Power supply 24 VDC
Accuracy 5mm
Electromagnetic compatibility Shall meet EN 61326-1 (1997) and AmdtA1,
class A equipment/EN 50081-2 & EN 5008 1-
2 & EN 50082-2
Mounting Top mounted
The transmitters shall be provided with IP-65 protection class with durable
corrosion resistant coating.
The transmitters shall be able to provide digital signals super imposed on 4-20
mA signals as per HART protocol.

SPECIFICATION FOR
INSTRUMENTS
1.03 Ultrasonic Type Coal Bunker Level Monitoring System
1. Type of Sensor Non-contact Ultrasonic type with connecting cable

2. Sensor Material Corrosion resistant material to suit application
requirement.
3. Type of Microprocessor based
Transmitter
4. Output signal Galvanically isolated 4-20mA DC (Analog) – two
outputs – one for CHP and one for DCS, along with
local indication
5. Measurement +/- 2.0 % of calibrated span
Accuracy
6. Power supply 230 V AC/ 24 V DC By Contractor
7. Temperature To be provided integral with Sensor/Transmitter
compensation
8. Configuration It shall be possible to mount the Electronic unit at a
remote accessible location from the Sensor. All
cables and weather proof fittings to interconnect
Sensor to electronic unit shall be provided by
Bidder.
9. Housing Weather proof as per IP-65 with durable corrosion
resistant coating.
10. Zero and Span Continuous, tamper proof, adjustability from
adjustment instrument. It shall be possible to calibrate the
instrument without any level in the bunker.
11. False signal Transmitter shall be capable of ignoring false
Tolerance echoes from internal coal bunker obstructions. Also
transmitter shall have adjustable damping circuitry
12. Range As per coal Bunker height
13. Display Minimum 4 character LCD display with integral

keypad, access protected by user code
14. Diagnostics To be provided
15. Load Impedance 500 ohms minimum

16. Accessories • Canopy.
• All mounting hardware and accessories required
for erection and commissioning.
• Alignment (Aiming) System for each sensor

SPECIFICATION FOR
PROCESS CONNECTION AND STANDARD SPECIFICATION
PIPING
SUB-SECTION – I 8
FOR
PROCESS CONNECTION AND PIPING
DOC. NO.: REL-COENG-NEN-448-P-00001 R0 SUB-SECTION – I 8 PAGE 1 OF 4

SPECIFICATION FOR
PIPING
1.00.00 PROCESS CONNECTION PIPING

1.00.01 The Contractor shall provide, install and test all required material for completeness of Impulse
Piping System and Air Piping System as per the requirements of this Sub-section, on as required
basis for the connection of instruments and control equipment (provided by the Contractor) to the
process/ main equipment/ systems. The Contractor shall furnish during detailed engineering
Installation drawings, GA and fabrication drawings of Instrument racks, other relevant drawings,
material and technical data sheets of various items service wise for Owner's approval/ information.
1.00.02 All materials, furnished under this sub-section and the installation thereof shall conform to the
latest editions of American National Standard Code for Pressure Piping, Power Piping, ANSI B
31.1, ANSI B16.11, ASME Boiler and Pressure Vessel Codes, IBR and other applicable ASME,
ANSI and state standards.
1.00.03 All materials supplied under this Sub-section shall be suitable for intended service, process;
operating conditions and type of instruments used and shall fully conform to the requirements of
this specification. The bidder is responsible for the performance of equipment furnished under this
specification on system basis. The Bidder may offer suggestions for improvement based on his
experience, during detailed engineering, which shall be subjected to the Owner's approval.
1.00.04 Contractor to note that any reducers, nipple etc. for proper connection of the impulse piping
system to Owner’s root valves / isolation valves / stubs etc. (if applicable) shall be in Contractor’s
scope only, unless otherwise clearly excluded.
1.01.00 Impulse piping, tubing, fittings, valves and valve manifolds
1.01.01 All impulse pipes shall be of seamless type conforming to ANSI B36.10 for schedule numbers,
sizes and dimensions etc. The material of the impulse pipe shall be generally same as that of
main process pipe. For low pressure applications i.e. pressure less than 40 kg/ cm2, it may be
impulse tube of SS 316. For coastal projects, all impulse pipes, fittings etc shall be provided with
durable epoxy coating with poly urethane finish for protection against sea environment.
1.01.02 Stainless steel tube shall be provided inside racks from tee connection to valve manifold and then
to instrument. For high pressure/ temperature applications, the material shall be ASTM A 213 TP
316H it and for other applications material shall be ASTM A 213 TP 316L. The wall thickness of
the tube shall be in accordance with the ANSI B31.1 standard. The bending radius of the tube
shall be greater than 6D.
1.01.03 All fittings shall be forged steel and shall conform to ANSI B16.11. The material of forged tube
fittings for shaped application (e.g. Tee, elbow etc.) shall be ASTMA 182 Gr. 316 H for high
pressure/ temperature applications (as defined above) and ASTMA 182 Gr. 316L for other
applications. The material for bar stock tube fitting (for straight application) shall be 316 SS.
Metal thickness in the fittings shall be adequate to provide actual bursting strength equal to or
greater than those of the impulse pipe or SS tube, with which they are to be used.
1.01.04 The source shut-off (primary process root valve) and blow down valve shall be of 1/2 inch size
globe valve type for all applications except for air and flue gas service wherein no source shut-off
valves are to be provided. For various applications the valve body material, stem material and
pressure class shall be suitable for the service they are intended for. The end connections of
valves shall be of socket welded type. The disc and seat ring materials of carbon steel and alloy
steel valves be ASTM A-105 and ASTM A-182, Gr. F22, hard faced with stellite (minimum
hardness - 350 BHN.) The surface finish of 16 RMS or greater is required in the area of stem
packing. The valve design shall be such that the seats can be reconditioned and stem and disc
may be replaced without removing the valve body from the line.

SPECIFICATION FOR
PIPING
1.01.05 The valve manifolds shall be of 316 stainless steel with pressure rating suitable for intended
application. 2-valve manifold and 3-valve manifold shall be used for pressure measurements
using pressure transmitters/ pressure switches and differential pressure transmitter/ switches
respectively. 3-valve manifold shall be used for remaining applications like DP, flow and level
measurements.
1.01.06 For Pressure/ D.P gauges in fluid application, two-way globe valve on each impulse line to the
instrument and in Air/ Flue gas application two-way gate valve on each impulse line to the
instrument shall be provided near the instrument. These shall be in addition to the three ways
gauge cock provided along with the pressure/ D.P gauges.
1.02.00 Air supply piping
1.02.01 All pneumatic piping, fittings, valves, air filter cum regulator, purge Rotameter and other
accessories required for instrument air for the various pneumatic devices/ instruments shall be
provided. This will include as a minimum air supply to pneumatically operated valves, actuators,
instruments, continuous and intermittent purging requirements etc.
1.02.02 For individual supply line and control signal line to control valve, Stainless steel TP321 tubes shall
be employed. The fittings shall be of SS / brass.
1.02.03 All other air supply lines of 1/2 inch to 2 inch shall be of mild steel hot dipped galvanized inside
and outside as per IS-1239, heavy duty with threaded ends. The threads shall be as per ASA
B.2.1. Fittings material shall be of forged carbon steel A234 Gr. WPB galvanized inside and
outside, screwed as per ASA B2.1. Dimensions of fittings shall be as per ASA B16.11 of rating
3000 lbs.
1.02.04 An instrument air filter cum regulator set with mounting accessories shall be provided for each
pneumatic device requiring air supply. The filter regulators shall be suitable for 10-kg/ sq.cm max.
inlet pressure. The filter shall be of size 5 microns and of material sintered bronze. The air set
shall have 2-inch size pressure gauge and built in filter housing blow down valve. The end
connection shall be 1/4 inch / 1/2 inch / 3/4 inch NPT as per the requirement to be finalized during
1.02.05 All the isolation valves in the air supply line shall be gate valves as per ASTM B62 inside screw
rising stem, screwed female ends as per ASA B2.1. Valve bonnet shall be union type & trim
material shall be stainless steel, body rating 150 pounds ASA. The valve sizes shall be ½ inch to
2 inch.
1.03.00 Installation and routing
1.03.01 All instrument piping, tubing and its accessories shall be supported in a safe manner to prevent
excessive vibrations and anchored sufficiently to prevent undue strain on connected equipment.
Instrument piping & tubing shall not be routed across equipment removal areas, above or below
monorails, cranes, removable gratings, cable trays.
1.03.02 Instrument Piping System
For steam and liquid measurements, the impulse pipe should preferably slope downward from
source connection to instrument and instrument shall be installed below the source point. If due to
any reason instrument is installed above the source point, the impulse pipe should slope upwards
continuously and a 'pigtail' should be provided at the instrument to assure water seal for
temperature protection. For vacuum measurements instrument shall be installed above source
point and impulse pipe should slope upwards.

SPECIFICATION FOR
PIPING
(a.) Impulse piping for air and flue gas shall slope upwards and instrument shall be installed above
source point. If this requirement cannot be met special venting or drain provision shall be
provided with vent & drain lines along with isolation valves and other accessories including
drainpipes. This drain is to be connected to plant drain through open funnel also. Horizontal runs
must have a slope of not less than 40 mm per meter and must be adequately supported to
maintain a constant slope and to prevent sag in piping.
All impulse piping shall be installed to permit free movement due to thermal expansion. Wherever
required expansion loops shall be provided.
Special accessories such as condensing pots/ reservoirs/ chemical seals (along with requisite
capillary tubing to instrument) shall be provided and installed wherever required. In any case
condensing pots shall be provided for all level measurements in steam and water services, all
flow measurement in steam services and flow measurements water services above 120 Deg. C.
Chemical seal diaphragm shall be provided for all viscous, corrosive and dirty fluid (e.g. slurry)
applications.
Colour coding of all impulse pipes shall be done by the Contractor in line with the colour coding
being followed for the parent pipes.
1.03.03 Instrument Air & Service Air Piping/ Tubing System
The air supply headers, sub-headers and branch pipes shall be supported properly by clamps or
supports to be provided and fabricated by the Contractor. Air supply piping shall be installed with
a slope of over 1/100 to prevent accumulation of condensed water within the pipe. Signal/control
air tubing shall run with the minimum number of changes in direction. Suitable identification tags
shall be provided for easy link up and checking of proper connections. Single and multi tubes
shall run with the minimum number of changes in direction. Suitable identification tags shall be
provided for easy checkup and for connections.
1.04.0 Piping/ tubing support
Impulse piping shall be supported at an interval not exceeding 1.5 meters. Each pipe shall be
supported individually using slotted angle mounted clamps with necessary fixtures. Tubing shall
run in proper perforated trays with proper cover. Tubing shall be supported inside the trays by
aluminium supports. Hangers and other fixtures required for support of piping and trays shall be
provided, either by welding or by bolting on walls, ceilings and structures. Hanger clamps and
other fastening hardware shall be of corrosion resistant metals and hot-dip galvanized.
1.05.00 DRAWINGS AND DOCUMENTS
Bidder shall submit Instrument Installation drawings for each type of instrument showing clearly
the root valves, impulse piping/ fittings and all other accessories like Chemical seals, valve
manifolds etc. for Owner’s review & approval. The material and other details like schedule etc. for
the various components shall also be brought out in the instrument installation drawings.

SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
SUB- SECTION – I 9
FOR
INSTRUMENTATION AND CONTROL CABLES
DOCUMENT NO.: REL-COENG-NEN-404-

P-00001 R0 Sub-section – I 9 Page 1 of 14
SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
1.01.00 GENERAL REQUIREMENTS

1.01.01 All Instrumentation, Control and Special Cables like Pre fabricated, Optic fiber, Cat5e,
Coaxial and network cables as required for the interconnection of the various
instruments/ devices/ equipment/ cabinets/ HMI/ Switchgear with the PLC system shall
be supplied ,laid and terminated by the Bidder “On as required basis” .
1.01.02 Instrumentation, Control and Special Cables shall be supplied “On as required basis” as
per this specification, however for estimation purpose, Contractor can refer the attached
plot plan and cabling scope diagram attached.
1.01.03 Cables laid in trenches and buried in ground (typically out side buildings) shall be
armored.
1.01.04 All cables shall be flame retardant low smoke (FRLS) outer sheathed type having rodent
and termite repulsion property.
1.01.05 Single/ Multi-Pair cables with individual pair & overall shielding shall be used for analog
signals (4-20 mA, RTDs etc.). Multi-pair cables with overall shielding shall be used for
binary signals. Compensating/ extension cables (if applicable) shall be used for
Thermocouples.
1.01.06 Multi core cables of 1.5 sq mm shall be employed for carrying control signals, typically
the command extension from the control system to the solenoid-operated valves, power
supply wiring etc as finalized during detailed engineering.
1.01.07 Conductor size will be 1.5 mm2 for local short run cables (except thermocouple
extension cable) and 0.5 mm2 for trunk cables.
1.01.08 Two pair/ four pair 1.5 mm2 cables shall be used from analog instruments like
transmitters/ RTDS to field junction boxes and multi-pair 0.5-mm2 cables shall be used
from JB onwards up to marshalling cabinet/ PLC system with provision of 10% spare
pair in each multi-pair cable.
1.01.09 Four pair 1.5 mm2 cable shall be used from process switches to field junction boxes and
multi-pair 0.5 mm2 cables shall be used from JB onwards up to marshalling cabinet /
PLC system with provision of 10% spare pair in each multi-pair cable.
1.01.10 In case of duplex RTDs, both the elements shall be wired up to the local JB, from where
one of the elements shall be connected to the control/ monitoring system. Similarly in the
case of process switches (with two SPDT), the spare contact shall also be also be wired
up to the local JB.
1.01.11 All cables required for grounding of PLC cabinets, equipments etc. shall be provided by
the Bidder. All cables/ isolated flats etc. used for grounding shall be of copper or
aluminum of proper size to avoid any increase in ground potential. All the cables used
for grounding of the individual panels/ equipments/ instruments/ devices etc. and the
complete system shall be provided by the Contractor.
1.01.12 All data high way and network cables required for interconnecting PLC cabinets, Remote
I/O cabinets, HMI etc. supplied under this specification shall be Optical Fibre / Shielded
twisted pair Cat.-5e. All the hardware that may be required for installation of the same
SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
including cables sub-trays/ troughs, flexible & rigid conduits, GI/HDPE Conduits, fittings,
junction boxes, accessories etc. shall be provided by the Contractor within his quoted
lump sump price. The routing of these cables shall be separate from other
Instrumentation cables.
1.01.13 Contractor to furnish lay, terminate & test on both ends all power feeders, which provide
power to all equipments furnished by the bidder under this specification
1.02.00 SPECIFICATION OF INSTRUMENTATION CABLE

1.02.01 Common Requirements
S. Property Requirement
No.
1 Voltage grade 225 V (peak value)
2. Codes and standard All instrumentation cables shall
comply with VDE 0815, VDE 0207,
Part 4, Part 5, Part 6, VDE 0816, VDE
0472, SEN 4241475, ANSI MC 96.1,
IS-8784, IS-10810 (latest editions) and
their amendments read along with this
specification.
3. Continuous operation suitability At 70 deg. C for all types of cables
4. Progressive automatic on-line To be provided at every one meter on
sequential marking of length in outer sheath.
meters
5. Marking to read ‘FRLS’ To be provided at every 5 meters on
outer sheath.
6. Allowable Tolerance on overall +/- 2 mm (maximum) over the
diameter declared value in data sheet
7. Variation in diameter Not more than 1.0 mm throughout the
length of cable.
8 Ovality at any cross-section Not more than 1.0 mm
9 Others Durable marking at intervals not
exceeding 625 mm shall include
manufacturer’s name, insulation
material, conductor’s size, number of
pairs, voltage rating, type of cable,
year of manufacturer to be provided.
Cables shall be suitable for laying in
SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
S. Property Requirement
No.
conduits, ducts, trenches, racks and
underground-buried installation
Repaired cables shall not be
acceptable.
1.02.02 Specific Requirements
Specification Thermocouple Analog and Digital Type cable

Requirements Extension cable(if
applicable)
A. Conductors
Cross section 0.5 sq. mm

area
Note: For shorter analog and Digital signals, cables
from Instruments upto J.Box/LIE/LIR shall be 1.5 sq.mm
(Except T/C extension cable) .
Conductor ANSI type KX (K type TC High conductivity Annealed

material extension- Cr/Ni, Al/ Ni), TX (T bare copper
type TC Extension - Cu-
Constantan), RX/ SX
(Compensation cable for R/ S-
type TC- Cu, Cu/ Ni), EX (E
type TC Extension – Cr/ Ni,
Constantan)
Color code Yellow-Red Black-Red for As per VDE-815

for KX Sx/ Rx and
Purple –Red
Blue-Red for
for EX
TX
Conductor Grade As per ANSI MC 96.1 Electrolytic
No & dia of 7x0.3 mm (nom) for 0.5 mm2

strands
Note: For 1.5 sq. mm, Min 7 strands
No. of Pairs 2 2,4,8,12,16,24 for 0.5 mm2 cable

SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
and 1/2/4 pair for shorter run

cable of 1.5 sq.mm
Max. conductor As per ANSI MC 96.1 73.4 ohm (loop) for 0.5 sq.mm
resistance per Km
12.6 ohm per km for 1.5 sq.mm.
(in ohm) at 20
deg. C
Reference As per ANSI MC 96.1 VDE 0815

Standard
B. Insulation
Material PVC type YI 3 as per VDE 0207 part 4
Thickness in mm 0.25/0.3/0.35
(Min/Nom/Max)
Volume 1 x 1014 at 20 deg. C & 1x1011 at 70 deg. C.

Resistivity (Min)
in ohm-cm
Voltage Rating 225 V peak operating voltage
Reference VDE 0207 Part 4

Standard
Core diameter Suitable for cage clamp connector

above insulation
C. Pairing & Twisting
Max. lay of pairs 50

(mm)
Single layer of Numbered Tape Yes

Numbered binder
tape on each pair
provided
Unit formation of N.A. Yes

four pairs with
printing of no. of
Unit provided
Conductor /pair N.A. To be provided (color coding as
identification as per standard)
per VDE0815

SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
D. Shielding
Type of shielding Al-Mylar tape
Individual pair No To be provided for cables

shielding carrying analog signals.
Minimum No 28 micron
thickness of
Individual pair
shielding
Overall cable To be provided

assembly
shielding
Minimum 55 micron
thickness of
Overall cable
assembly
shielding
Shielding 100% with at least 20% overlap

coverage
Drain wire N.A. Yes (for Analog signal cable) 7-

provided for strand 20 AWG (0.51 mm2 )
individual shield annealed Tin coated copper
Drain wire Yes. 7-strand 20 AWG (0.51 mm2) annealed Tin coated
provided for copper
overall shield
E. Fillers
Non-hygroscopic, To be provided
flame retardant
F. Outer Sheath
Material Extruded PVC compound YM1 with FRLS properties
Minimum Thickness 1.8 mm

at any point
Nominal Thickness at >1.8 mm

any point

SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
Color Blue
Resistant to water, Required

fungus, termite &
rodent attack
Oxygen index as per Not less than 29%

ASTMD-2863
Temperature index Not less than 250 deg.C

as per ASTMD-2863
acid gas generation Maximum 20%

by weight as per IEC-
60754-1
Smoke Density Maximum 60%

Rating as per
(defined as the average area under the curve when the
ASTMD-2843
results of smoke density test plotted on a curve indicating
light absorption vs. time as per ASTMD-2843)
Reference standard VDE207 Part 5
G. Electrical
Parameters
Mutual Capacitance 200 nF/km 120 nF/km for Analog signal

Between Conductors cable
At 0.8 Khz (Max.)
100 nF/km for Digital signal
Cable
Insulation 100 M Ohm/Km

Resistance(Min.)
Cross Talk Figure 60 dB 60 dB

(Min.) At 0.8 Khz
Characteristic N.A. 320 ohm for Analog signal

Impedance (Max) At cable
1 Khz
340 ohm for digital signal
cable
Attenuation Figure At N.A. 1.2 db/km

1 Khz (Max)
H. Complete Cable

SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
Complete Cable Shall pass Swedish Chimney test as per SEN-SS 4241475
assembly class F3.
Flammability Shall pass flammability as per IEEE-383 read in

conjunction to this specification
I. Accessories
Cable accessories of Yes. (Accessories such as harnessing components,

flame retardant markers, bedding, cable jointer, binding tape etc.)
quality.
J Cable Drum
Type Non-returnable wooden drum (wooden drum to be

constructed from seasoned wood free from defects with
wood preservative applied to the entire drum) or steel
drum.
Outermost layer Yes

covered with
waterproof paper
Painting Entire surface to be painted
Length 1000 m + 5% for cable sizes up to & including 12 pairs

500 m + 5% for cable size above12 pairs
K. Type tests Type test reports for tests as per clause below
1.03.00 OPTICAL FIBER CABLE DESCRIPTION :-

1.03.01 Optic Fiber cable shall be 4/8/12/24 core, galvanized corrugated steel taped armored,
fully water blocked with dielectric central member for outdoor/indoor application so as to
prevent any physical damage. The cable shall have multiple single-mode fibers/ multi-
mode fibers on as required basis so as to avoid the usage of any repeaters. The core
and cladding diameter shall be 9 +/- 1 micrometer for single mode fibers and around
62.5 micrometer for multi mode fibers. The outer sheath shall have Flame Retardant, UV
resistant properties and are to be identified with the manufacturer’s name, year of
manufacturer, progressive automatic sequential on-line marking of length in meters at
every meter on outer sheath.
1.03.02 The cable core shall have suitable characteristics and strengthening for prevention of
damage during pulling viz. Steel central member, Loose buffer tube design, 4 fibers per
buffer tube (minimum), Interstices and buffer tubes duly filled with Thixotropic jelly etc.
SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
The cable shall be suitable for a maximum tensile force of 2000 N during installation,
and once installed, a tensile force of 1000 N minimum. The compressive strength of
cable shall be 3000 N minimum& crush resistance 4000 N minimum. The operating
temperature shall be –20 deg. C to 70 deg.C
1.03.03 All testing of the fiber optic cable being supplied shall be as per the relevant IEC, EIA
and other international standards.
1.03.04 Cables shall be suitable for laying in conduits, ducts, trenches, racks and under ground
buried installation.
1.04.00 CONTROL CABLES
1.04.01 Control cables shall be sized based on the following considerations:
(a) The minimum conductor cross-section shall be 1.5 sq.mm.
(b) The minimum number of spare cores in control cables shall be as follows:
No. of cores in cable Min. No. of spare cores
2C, 3C NIL
5C 1
7C-12C 2
14C & above 3
1.04.02 The Control Cables shall be of 1.1 KV Grade and have stranded copper conductor of 1.5
sq.mm.
1.04.03 The insulation shall be PVC and the inner (for armoured cables) and outer sheath shall
be PVC conforming to IS:1554. (Part-I). The outer sheath shall be FRLS type.
1.04.04 Cores of the cables shall be suitably identified by coloring of insulation.
1.05.00 TESTS
1.05.01 All equipments to be supplied shall be of type tested quality. The Contractor shall submit
for Owner’s approval the reports of all the type tests as listed in this specification and
carried out within last five years from the date of bid opening. These reports should be
for the tests conducted on the equipment similar to those proposed to be supplied under
this contract and the test(s) should have been either conducted at an independent
laboratory or should have been witnessed by a client.
1.05.02 In case the Contractor is not able to submit report of the type test(s) conducted within
last five years from the date of bid opening, or in case the type test report(s) are not
found to be meeting the specification requirements, the Contractor shall conduct all such
tests under this contract, free of cost to the Owner and submit the reports for approval.

SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
The reports for the following type tests shall be submitted on one size each type of
cables.
1.05.03 Type Tests for control cables
S.No. Type Test Remarks
For Conductor
1. Annealing test For copper conductor only.
2.
Resistance test
For Armour Wires/ Formed Wires
3. Measurement of Dimensions
4. Tensile Test
5. Elongation test
6. Torsion test For round wires only
7. Wrapping test For aluminum wires/formed wires only
8. Resistance test
9.(a) Mass of Zinc Coating test For G.S. Formed wires /wires only.
9.(b) Uniformity of zinc coating For G.S. Formed wires /wires only.
10. Adhesion test For G.S. Formed wires /wires only.
For PVC insulation & PVC Sheath
11. Test for thickness
12. Tensile strength & elongation tests before ageing and after ageing
13. Ageing in air oven
14. Loss of mass test For PVC insulation and sheath only
15. Hot deformation test For PVC insulation and sheath only
16. Heat shock test For PVC insulation and sheath only
17. Shrinkage test
18. Thermal stability test For PVC insulation and sheath only
19. Hot set test(Not for control For XLPE insulation only
cables)
20. Water absorption test (Not for For XLPE insulation only
control cables)
21. Oxygen index test For outer sheath only

SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
22. Smoke density test For outer sheath only
23. Acid gas generation test For outer sheath only
For completed cables

24 Insulation resistance test
(Volume resistivity method)
25 High voltage test
26 Flammability test as per IEC -

332 Part-3 (Category -B)
1.05.04 Type tests for Instrumentation Cables
01. Oxygen Index test as per ASTM-D-2863 : Min. 29 at room temp.
02. Acid Gas Generation test as per IEC 754 Part-I: Max. 20 % by weight
03. Temperature Index test as per ASTM-D-2863 : Min. 250 DEG C at 21Oxygen
Index
04. Smoke Density test as per ASTM-D-2843 Max. 60 %
05. Flammability Test: As per IEC 332 Part-I/ IEEE 383/1974
06. Swedish Chimney Test- As per SS-424-1475 (F3)
07. Insulation Resistance test
08. Water immersion test: As per VDE - 0815.
09. Fire resistance test to IS-5831 for 20 minutes (PVC insulation & sheath of
electrical cables)
10. Thermal EMF test as per ASME 96.1
11. Thermal stability at 200°C to IEC-540 for 100 meters
12. Heat shock test to IEC-502
13. Rodent & termite proof test

SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
1.06.00 CABLE LAYING AND ACCESSORIES
1 Cable laying: Cables shall be laid strictly in line with cable schedule.
2 Identification tags for cables.
Indelible tags to be provided at all terminations, on both sides of wall or floor

crossing, on each conduit/duct/pipe entry/exit, and at every 20 m in cable
trench/tray.
3 Cable tray numbering and marking.
To be provided at every 10m and at each end of cable way & branch
connection.
4 Joints for less than 250 meters run of cable shall not be permitted.
5 Buried cable protection
With concrete slabs; route markers at every 20 meters along the route & at
every bend.
6 Road crossings
Cables to pass through buried high density PE pipes encased in PCC. At least
300 mm clearance shall be provided between
- HT power & LT power cables,
- LT power & LT control/instrumentation cables,
Spacing between cables of same voltage grade shall be in accordance with the
derating criteria adopted for cable sizing.
A All cable associated with the unit shall be segregated from cables of other
units.
B Interplant cables of critical drives shall be segregated in such a way that not
more than half of the drives are lost in case of single incident of fire.
8 Cable clamping
All cables laid on trays shall be neatly dressed up & suitably clamped/tied to the
tray. For cables in trefoil formation, trefoil clamps shall be provided.

SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
9 Optical fiber cables shall be laid inside conduit on cable trays wherever
available and feasible. In areas where the same are required to be buried,
the same shall be buried in separate trench approx.1.6 meter depth, to be
laid in 2” GI/ rodent proof HDPE conduits covered with sand, brick and soil
along the pipe line route;
While crossing roads - to be laid in GI/ rodent proof HDPE conduits with
sand filling at bottom and sand, soil filling at top with cement concrete;
While crossing canals/ river- to be laid in GI/rodent proof HDPE conduits
within hume pipe.
1.06.01 Bidder shall supply and install all cable accessories as applicable and fittings like Light
Interface Units, Op to isolators, Interface Converters, Fibre Optic Card Cage, Fibre Optic
Line Driver, cable glands, grommets, lugs, termination kits etc. on as required basis.
1.06.02 Bidder shall furnish one complete new sets of cable termination kits like Crimping tools,
etc., which are required for maintenance of the system as per the type of termination
used.
1.06.03 Cables, which terminate in cabinets of draw out sections shall have sufficient cable
coiled in the bottom of the cabinet to permit full withdrawal of draw out sections without
disconnecting the cables.
1.06.04 The Bidder shall be responsible for proper grounding of all C&I equipment. Further,
proper termination of cable shields shall be verified and the grounding of the same shall
be coordinated so as to achieve grounding of all instrumentation cable shields at same
potential. This shall be completed prior to system tests. All the cables etc. required for
grounding of all equipments supplied under this package are to be supplied by the
Bidder.
1.06.05 The Contractor shall take full care while laying / installing cables as recommended by
cable manufacturers regarding pulling tensions and cable bends. Cables damaged in
any way during installation shall be replaced at the expense of the Contractor.
1.07.00 PACKING AND TRANSPORT
1.07.01 Cables shall be placed on drums in such a manner that it shall be protected from injury
during transit. Each end of cable shall be firmly and properly secured to the drum. The
end of each length shall be sealed before shipment. The drums shall be secured firmly in
position so that they do not shift during transit. Purchaser may advise Bidder about the
restriction of shipping length during detail engineering.
1.07.02 Drums shall be of heavy construction. On one side of the drum the purchase order’s
number, length of cable, size of conductor, number of cores, type of cable and voltage
for which it is suitable, shall be painted. A tag containing this information shall be
attached to the leading end of the cable. An arrow and suitable wording shall be marked
on the side of the drum to indicate the direction in which it should be rolled.

SPECIFICATION FOR
INSTRUMENTATION AND
CONTROL CABLES
1.07.03 Packing shall be sturdy and adequate to protect the cables and materials from injury by
corrosion, dampness, heavy rains, breakage and vibration encountered during
transportation, handling and storage at the plant site.
1.08.00 MARKING
1.08.01 All markings on the case shall be made of waterproof materials to prevent obliteration
during transit.
1.08.02 The following details shall be marked on the packing case
a. Project Name
b. Contract or Purchase Order No.
c. Case No.
d. Complete description of Cable
e. Net weight in Kilograms
f. Gross weight in Kilograms
g. Dimensions of packing case
h. Sling position & CG position
i. Storage position
j. Date of Shipment.

PART III
SECTION 1
GENERAL TECHNICAL REQUIREMENTS
REL-SKCCP-NEM-161-P-00001 (Rev.00) Part III Page 1 of 42

CONTENTS
CLAUSE NO. DESCRIPTION
G1.01.00 INTRODUCTION
G1.02.00 BRAND NAME
G1.03.00 BASE OFFER & ALTERNATE PROPOSALS
G1.04.00 COMPLETENESS OF FACILITIES
G1.05.00 CODES & STANDARDS
G1.06.00 EQUIPMENT FUNCTIONAL GUARANTEE
G1.07.00 DESIGN OF FACILITIES / MAINTENANCE & AVAILABILITY
CONSIDERATIONS
G1.08.00 DOCUMENTS, DATA, DRAWINGS AND ENGINEERING CO-
ORDINATION PROCEDURE
G1.09.00 PROTECTIVE GUARD
G1.10.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS
G1.11.00 MATERIAL OF CONSTRUCTION
G1.12.00 RATING PLATES, NAME PLATES & LABELS

G1.13.00 TOOLS AND TACKELS
G1.14.00 WELDING
G1.15.00 COLOR CODE FOR ALL EQUIPMENTS/ PIPINGS/ PIPE
SERVICES
G1.16.00 QUALITY ASSURANCE PROGRAMME
G1.17.00 PROTECTION AND PRESERVATIVE SHOP COATING
PROTECTION

G1.19.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES
G1.20.00 INITIAL OPERATION
G1.21.00 PERFORMANCE & GUARANTEE TEST
G1.22.00 TAKING OVER
G1.23.00 TRAINING OF EMPLOYER'S PERSONNEL
G1.24.00 NOISE LEVEL
G1.25.00 PACKAGING AND TRANSPORTATION
G1.26.00 ELECTRICAL ENCLOSURE
G1.26.00 INSTRUMENTATION AND CONTROL
G1.27.00 ELECTRICAL NOISE CONTROL

G1.00.00 GENERAL TECHNICAL REQUIREMENTS
G1.01.00 INTRODUCTION
This part covers technical requirements, which will form an integral part of the
Contract. The following provisions shall supplement all the detailed technical
requirements brought out in the Technical Specifications and the Technical Data
Sheets.
G1.02.00 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.
G1.03.00 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 recognized 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 may 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 Sufficient amount of
information for justifying such proposals shall be furnished to Employer along with
the bid to enable the Employer to determine the acceptability of these proposals.
G1.04.00 COMPLETENESS OF FACILITIES
G1.04.01 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 that a completely engineered plant is provided.
G1.04.02 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 & maintenance 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 similar standard components/ parts of similar standard equipment provided

shall be interchangeable with one another.
G1.05.00 CODES & STANDARDS

G1.05.01 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 as well
as of the locality where they will be installed, including the following:
1. Bureau of Indian Standards (BIS)

2. Building and Other Construction Workers (Regulation of Employment and
Conditions of Service) Act 1996.
3. Building and Other Construction Workers (Regulation of Employment and
Conditions of Service) Central Rules 1998.
4. Explosives Rules 1983 (Not Applicable)
5. Petroleum Act 1984(Not Applicable)
6. Petroleum Rules.1976(Not Applicable)
7. Gas Cylinders Rules 1981
8. Static & Mobile Pressure Vessels (Unified) Rules,1981
9. Workmen’s Compensation Act, 1923
10. Workmen Compensation Rules, 1924
11. RINFRA Safety Rules for Construction and Erection.
12. RINFRA Safety Policy
13. Indian electricity act
14. Indian electricity rules
15. Indian Explosives Act(Not Applicable)
16. Indian Factories Act and State Factories Act
17. Indian Boiler Regulations (IBR) (Not Applicable)
18. Regulations of the Central Pollution Control Board, India
19. Regulations of the Ministry of Environment & Forest (MoEF), Government of
India
20. Pollution Control Regulations of Department of Environment, Government of
India
21. State Pollution Control Board.
22. Rules for Electrical installation by Tariff Advisory Committee (TAC).
23. Any other statutory codes / standards / regulations, as may be applicable.
G1.05.02 The codes, and/or standards referred to in these specifications shall govern, in all
the cases wherever such references are made for design of various equipments
/system etc. Latest edition shall be followed by the Contractor for all the codes
and /or Standards. In case of a conflict between such codes and/or standards and
the specifications, the latter shall govern. Such codes and/or standard referred to
shall mean the latest revision, amendments/changes adopted and published by
the relevant agencies. In case of any further conflict in this matter the same shall
be referred to the Engineer, whose decision shall be final and binding.

G1.05.03 Other internationally acceptable standards which ensure equal or higher

performance than those specified shall also be accepted 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 referred. In all such
cases the Bidder shall furnish specifically the variations and deviations from the
standards mentioned else where in the specification together with the complete
word to word translation of the standard that is normally not published in English.
G1.05.04 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.
G1.06.00 EQUIPMENT FUNCTIONAL GUARANTEE
G1.06.01 The functional guarantees of the equipment under the scope of the Contract are
given elsewhere in the technical specification. These guarantees shall supplement
the general functional guarantee provisions covered under General Conditions of
Contract.
G1.06.02 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.
G1.07.00 DESIGN OF FACILITIES/MAINTENANCE & AVAILABILITY CONSIDERATIONS
G1.07.01 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 coordinated 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.
G1.07.02 MAINTENANCE AND AVAILABILITY CONSIDERATIONS
Equipment/facilities 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.

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.
All the valves and other equipments shall be provided with operating platforms,
ladders, lifting lugs etc as required by Employer and such appurtenances if
required during /after commissioning of the plant shall be provided by the
Contractor at plant within the contract price.
G1.08.00 DOCUMENTS, DATA, DRAWINGS AND ENGINEERING CO-ORDINATION

PROCEDURE.
G1.08.01 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 ensuring a
completely engineered plant shall be provided in respect of mechanical, electrical,
control & instrumentation, civil & structural works as per the scope.
The Contractor shall furnish engineering data/drawings and manuals in

accordance with the schedule of information as specified in Technical
Specification and data sheets.
G1.08.02 The number of copies/prints/floppy discs/CD-ROMs/manuals to be furnished for

various types of documents is given in Annexure-A of this Section.
G1.08.03 The documentation that shall be provided by the Contractor is indicated in the
various sections of specification. This documentation shall in general include
(whichever applicable for the package) but not be limited to the following as
mentioned below.
G1.08.03.01 DETAILED ENGINEERING DOCUMENTS

General layout
o Layouts, general arrangements, elevations and cross-sections drawings for
all the equipment and facilities of the plant.
o Flow diagrams, Process & Instrumentation Diagrams.
o Piping isometric /composite layout and fabrication drawings.
o Piping engineering diagrams, pipe and fittings schedules, valve schedules,
hanger and support schedules, insulation schedules.
o Technical data sheets for all bought out and manufactured items. Contractor
shall use the RINFRA specifications as a base for placement of orders on
their sub-vendors.
o Detailed design calculations for components, system, piping etc., wherever
applicable.

o Transient, hydraulic and thermal stress analysis of piping and system

wherever applicable & input and output data alongwith stress analysis
isometrics showing nodes.
o Characteristic Curves/ Performance Correction Curves applicable for various
equipments.
o 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.
o Power supply single line diagram, control schematics, etc.
o Operation and control write up.
o Logic diagram with write up.
o Interconnection cable and signal flow diagram, Cable list and Cables
schedules.
o Instrument schedule, Measuring point list, Alarm list, I/O and drive list.
o PLC documents such as Configuration ,Hardware/software details BOQ,
Cabinet GA drawing, Power supply diagram, MMI functions such as Graphics,
Log /Report, Alarm etc , Functional write-ups, implemented logic schemes,
FAT procedure , Type test reports Interconnection & wiring diagram, FAT
Reports , O&M Manuals ,Grounding scheme.
o UPS documents such as Technical datasheet, sizing, configuration, write
up,test report, etc.
o Control Room layout.
o Instruments technical data sheet, wiring diagram, O&M Manuals etc.
o Instrument and control, Optic fibre and cable datasheet, cross sectional
drawings, test reports.
o Civil drawings for architectural works, foundations and super-structural
works, civil calculation sheets including structural analysis and design along
with output results.
o Underground facilities, leveling, sanitary, landscaping drawings.
o Model study reports wherever applicable.
o Functional & guarantee test procedures and test reports.
o Documentation in respect of Quality Assurance System as listed out
elsewhere in this specification.
o Field Quality Plan entire scope of supply.
Electrical
Along With Bid
o Compliance with scope of work
o Technical Particulars
o Load list as per load list format
o Operation & Control Philosophy

o Type test certificates. (All equipments shall be type tested one, type
tested at third party reputed test agencies. Type test certificate
conducted not earlier than 5 years shall be submitted for all equipment
during drawing approval stage. Should the bidder is not able to meet this
criteria shall have to conduct at his own cost & time type tests as per
relevant standards and submit the certificates for purchaser's approval.
Implications any arise out of this shall be to bidders account)
Equipment/component technical data sheet/ brochure.
o Complete BOQ with Make
o Equipment/component technical data sheet/ brochure.
After the Bid

o Along with above documents and as mentioned in General Technical
Specifications for Electrical
o Detailed Engineering Documents/Drawings for all equipments.
o SLD, Control schematics, Logic diagram, Cable Schedule &
interconnection Scheme.
o Sizing Calculation of Transformer, Cable, Earthing.
o Layout Drawings with BOQ. i.e. Earthing ,cable route, equipment ,
conduit layout etc.
o Equipment erection drawings, Pre commissioning & commissioning
checks
o Calibration certificates for testing & measurement instruments shall be
submitted for approval before use at site.
o Motor characteristics curves.
o Relay setting.
o Notes & Details: Cabling, Earthing, Erection, Lightning, Illumination.
o Routine Test & Shop Test Certificates.
o Painting Procedure.
o FQP for entire scope of supply.
o QAP
o As built drawings.
o Manual: Equipment/component, Erection, Instruction, O&M.
o List of sub vendors for supply and erection.
Note: All documents/ drawings are subjected to approval from purchaser. The list
mentioned is suggestive only. It is to be elaborated during detailed
engineering.
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 along with the date vide which the submissions are made.

G1.08.03.02 INSTRUCTION MANUALS
The Contractor shall submit to the Employer, draft Instruction Manuals for all the
equipments and as well as for the complete system covered under the Contract
within the time agreed upon between the Employer and the Contractor. 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.
The Instruction Manuals shall comprise of the following:
i) Erection Manuals
The erection manuals shall be submitted at least 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.
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.
h) General safety procedures to be followed during erection/installation.
i) Procedure for initial checking after erection.
j) Procedure for testing and acceptance norms.
k) Procedure / Check list for pre-commissioning activities.
l) Procedure / Check list for commissioning of the system.
m) Safety precautions to be followed in erection all equipments and electrical
supply distribution during erection.
n) PG Test Procedure.
ii) Operation & Maintenance (O & M) 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.
(b) Functional description of associated Equipments/Systems / controls.
Control interlock protections write up.
(c) Integrated operation of the equipment along with 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 along with
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 & Interlock logics and Control loop diagram for the complete
System/equipment along with brief logic /loop write up
(b) Limiting values of all protection settings.
(c) Various settings of annunciation/interlocks provided.
(d) Startup and shut down procedure for equipment along with 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.
(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 along with 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 along with checks to be carried out.
(f) Overhauling schedules linked with running hours/calendar period along
with checks to be done.
(g) Long term maintenance schedules
(h) Consumables list along with 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 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 interchange ability with already supplied spares to RINFRA.
(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.
G1.08.03.03 After finalization and approval of the Employer, the O & M Manuals shall be
submitted as indicated in Annexure-A. 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-A.
G1.08.03.04 PROJECT COMPLETION REPORT

The Contractor shall submit a Project Completion Report at the time of handing
over the plant.
G1.08.04 ENGINEERING DATA / DRAWINGS
G1.08.04.01 All data/information furnished by Contractor /Vendor in the form of drawings/

documents/catalogues or in any other form for RINFRA’s information/ interface
and or review and approval are referred by the general term “drawings”.
G1.08.04.02 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-A . The soft copies to be supplied shall be either in CDs, Floppies or
through direct transfer via E-mail, etc. depending upon the nature/volume/size of
the document. The drawings submitted for approval shall be in the Image form /
AutoCAD drawing format / PDF format readable through Acrobat Reader as
mutually agreed to between Contractor and Employer before award of Contract.
All documents/text /calculations etc information shall be in MS Office application
such as MS – WORD or MS-Excel as the case may be.
G1.08.04.03 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.
G1.08.04.04 Each drawing submitted by the Contractor (including those of sub vendors of
Contractor) 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, noting, markings and writings on the drawing shall
be in English. All the dimensions should be in metric units.
G1.08.04.05 The drawings submitted by the Contractor (or their sub vendors) 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.
G1.08.04.06 The Contractor shall also furnish a “Master Document List” which shall be a
comprehensive list of all drawings/ documents/ calculations/QP/FQP/WPS/Test
Procedure envisaged to be furnished by him during the detailed engineering to
the Employer along with the schedule of submission of each drawing/document.
Such list should clearly indicate the purpose of submission of these drawings i.e.
“FOR APPROVAL” or “FOR INFORMATION ONLY”.
G1.08.04.07 The review of these drawings by the Employer will cover only general
conformance of the data to the specifications and documents interfaces with the
equipment provided under specifications, external connections, and of the
dimensions which might affect plant layout. This review by the Employer may

not indicate a thorough review of all dimensions, quantities and details of the
equipment, materials, any devices or items indicated or the accuracy of the
information submitted. This review and/or approval by the Employer shall not be
relieving the Contractor of any of his responsibilities and liabilities under this
Contract.
G1.08.04.08 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
G1.08.04.09 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.
G1.08.04.10 The Contractor is expected not to make any changes in the design of the
equipment /system, once they are approved by the 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.
G1.08.04.11 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 prior 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 / finalized 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.
G1.08.04.12 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.
G1.08.04.13 Final copies of the approved drawings shall be submitted in vector form on CD-
ROM along with the requisite number of hard copies as per Annexure-A.
G1.08.04.14 AS BUILT DRAWINGS

After final acceptance of individual equipment / system by the Employer at the
plant/site, the Contractor will update all original drawings and documents for the
equipment / system to “as built” conditions.
All engineering data submitted by the Contractor after final process including
review and approval by the Employer/Project Manager 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 Employer / Project Manager in writing.

G1.08.05 ENGINEERING INFORMATION SUBMISSION SCHEDULE
Prior to the award of Contract, a Detailed Engineering Information Submission

Schedule shall be tied up. For this, the bidder shall furnish a detailed list of
engineering information along with 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. (a) Information that shall be submitted for
the approval of the Employer before proceeding further, and (b) Information that
would be submitted for Employer’s information only.
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.
G1.08.06 Engineering Co-ordination Procedure
G1.08.06.01 The following principal coordinators will be identified by respective organizations

at time of award of contract:
RINFRA Engineering Coordinator (RINFRA EC):
Name :
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 :
G1.08.06.02 All engineering correspondence shall be in the name of above coordinators on

behalf of the respective organizations.
G1.08.06.03 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 RINFRA’s information/
interface and or review and approval are referred by the general term
“drawings”.

b) The ‘Master document list’ indicating titles, Document Number, Date of

submission and approval etc. shall be finalized 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 sub vendor’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 sub vendor along with his purchase
order for sub vendor’s compliance.
d) Employer and contractor shall follow their own numbering systems for the
drawings. However, Employer shall intimate the contractor, RINFRA drawing
number on receipt of the first submission of each drawing. Vendor,
thereafter, shall indicate RINFRA’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. 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 RINFRA 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- A : Approved
CATEGORY- B : Approved, subject to incorporation of comments/

modification as noted. Resubmit revised drawing
incorporating the comments.
CATEGORY –C : Not approved. Resubmit revised drawings for
approval after incorporating comments/ modification
as noted.
CATEGORY -D : For information and records.
h) Contractor shall resubmit the drawings approved under Category B, C & D

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
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 RINFRA 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 A & D (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.
m) 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.
G1.08.06.04 Engineering Progress Reporting /Exception Report
The contractor shall prepare every calendar month, at his own cost progress
reports describing the engineering activities in the reporting month, in a from
and size acceptable to the Engineering coordinator. The progress report shall be
in three sections.
In the first, all major engineering activities that took place during the reporting
month shall be clearly described, indicating major delays the agency responsible
and any corrective actions taken.
The second section shall show an exception report showing the list of
drawings/engineering information which remains unapproved for more than four
(4) weeks after the date of submission.
The third shall comprise drawings. Submission and approval status, listed
separately (i.e). for drawings submitted during the reporting month and drawings
commented and approved during the reporting month.

Lastly the fourth section shall contain the ordering status of bought out items.
The formats for ‘Drawing submission and approval Status’ and ‘Bought out’
items ordering status shall be furnished to the Bidder for his compliance, at the
time of award of contract.
G1.08.06.05 TECHNICAL CO-ORDINATION MEETING
a) The Contractor shall be called upon to organize 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
NOIDA or at mutually agreed venue as and when required and fully co-
operate with such persons and agencies involved during the discussions.
b) 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 four (4) 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.
c) The Contractor shall ensure availability of the concerned experts /

consultants/ personnel/sub-vendor 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.
d) 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.
e) 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.
G1.08.07 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.
G1.08.08 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 Each base plate which 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.
G1.09.00 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.
G1.10.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS
G1.10.01 The Bidder’s scope includes all the first fill and one year’s topping, requirements
of consumables such as oils, lubricants including grease, servo fluids, gases
and essential chemicals etc. Consumption of all these consumables during the
initial operation and final filling after the initial operation shall also be included in
the scope of the Bidder. Bidder shall also supply a quantity not less than 10% of
the full charge of each variety of lubricants, servo fluids; gases, chemicals etc.
used which is expected to be utilized during the first year of operation. This
additional quantity shall be supplied in separate Containers.
G1.10.02 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 along
with lubrication requirements.
G1.10.03 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.
G1.11.00 MATERIAL OF CONSTRUCTION

All materials used for the construction of the equipment shall be new and shall be
in accordance with the requirements of this specification. Materials utilized for
various components shall be those which have established themselves for use in
such applications.
G1.12.00 RATING PLATES, NAME PLATES & LABELS
a) 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
b) 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.
c) Such nameplates or labels shall be of white non-hygroscopic material with

engraved black lettering or alternately, in the case of indoor circuit breakers,
starters, etc. of transparent plastic material with suitably colored lettering
engraved on the back. The name plates shall be suitably fixed on both front
and rear sides.
d) Items of plant such as valves, which are subject to handling, shall be

provided with 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.
e) 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/hanger.
f) 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.
g) Safety and relief valves shall be provided with Manufacturer’s identification,

Nominal inlet and outlet sizes in mm, Set pressure in Kg/cm2 (abs), Blow
down and accumulation as percentage of set pressure and Certified capacity
in Kg of saturated steam per hour or in case of liquid certified capacity in
liters of water per minute.

h) 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.
i) All segregated phases of conductors or bus ducts, indoor or outdoor, shall

be provided with colored phase plates to clearly identify the phase of the
system.
G1.13.00 TOOLS AND TACKLES
The Contractor shall supply with the equipment one complete set of all special
tools and tackles and other instruments required 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, checking and measurement aids etc. A list of such tools and
tackles shall be submitted by the Bidder along with 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. All the tools and tackles shall
be of reputed make acceptable to the employer.
G1.14.00 WELDING
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. All welding procedures and welders shall be approved by
Employer prior to start of fabrication at site.
G1.15.00 COLOUR CODE FOR ALL EQUIPMENTS/ PIPINGS/ PIPE SERVICES
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.
G1.16.00 PROTECTION AND PRESERVATIVE SHOP COATING PROTECTION
G1.16.01 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 pipings 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.
G1.16.02 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 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 with at least two coats of primer unless otherwise mentioned in the
technical specification..
G1.16.03 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.
G1.16.04 All other steel surfaces which are not to be painted shall be coated with suitable
rust preventive compound subject to the approval of the employer.
G1.16.05 All piping shall be cleaned after shop assembly by shot blasting or other means
approved by the Lube oil piping or carbon steel shall be pickled.
G1.16.06 Painting for Civil structures shall be done as per relevant part of technical
specification
G1.17.01 The Contractor shall "Prepare, submit and get it approved by the employer” for
suitable quality assurance programme 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. 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 IS/ISO-9001.A quality
assurance programme of the contractor shall generally cover the following:
a) His organization structure for the management and implementation of the

proposed quality assurance programme
b) Quality System Manual
c) Design Control System

d) Documentation and Data 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 controls including process,
fabrication and assembly.
h) Control of non-conforming items and system for corrective actions and
resolution of deviations.
i) Inspection and test procedure both for manufacture and field activities.
j) Control of calibration and testing of measuring testing equipment.
k) System for Quality Audits.
l) System for identification and appraisal of inspection status.
m) System for authorizing release of manufactured product .
n) System for handling, storage and delivery.
o) System for maintenance of records, and
p) 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.
G1.17.02 GENERAL REQUIREMENTS - QUALITY ASSURANCE
G1.17.02.01 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 finalization of such quality plans will be finalized before award.
Monthly progress reports on Manufacturing Quality Plan (MQP)/ Field Quality
Plan (FQP) submission/approval shall be furnished on enclosed formats.
G1.17.02.02 MQP 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 Organization,
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 e.g. floppy or E-mail in addition to hard copy, for
review and approval. After approval the same shall be submitted in compiled
form on CD-ROM.

G1.17.02.03 FQPs will detail out for all the equipment, the quality practices and procedures
etc. to be followed by the Contractor’s "Site Quality Control Organization", during
various stages of site activities starting from receipt of materials/equipment at
site.
G1.17.02.04 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, 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 disposition.
G1.17.02.05 No material shall be dispatched from the manufacturer’s works before the same
is accepted, subsequent to pre dispatch final inspection including verification of
records of all previous tests/inspections by Employer’s Project
Manager/Authorised representative and duly authorised for dispatch by
issuance of Material Dispatch Clearance Certificate (MDCC).
G1.17.02.06 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.
G1.17.02.07 The contractor shall submit to the Employer Field Welding Schedule for field
welding activities in the enclosed format. The field welding schedule shall be
submitted to the Employer along with all supporting documents, like welding
procedures, heat treatment procedures, NDT procedures etc. it shall be "
submission of documents shall be within a month progressively after the
placement of the order"
G1.17.02.08 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
G1.17.02.09 All welding/brazing procedures shall be submitted to the Employer or its

authorized representative for approval prior to carrying out the welding/brazing.
G1.17.02.10 All brazers, welders and welding operators employed on any part of the contract
either in Contractor’s/sub-contractor 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.
G1.17.02.11 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.
G1.17.02.12 For all pressure parts and high pressure piping welding, the latest applicable
requirements of the IBR (Indian Boiler Regulations) shall also be essentially
complied with. 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.
G1.17.02.13 Unless otherwise proven and specifically agreed with the Employer, welding of
dissimilar materials and high alloy materials shall be carried out at shop only.
G1.17.02.14 No welding shall be carried out on cast iron components for repair.
G1.17.02.15 All the heat treatment results shall be recorded on time temperature charts and
verified with recommended regimes.
G1.17.02.16 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).
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.
All plates of thickness above 40mm & all bar stock/Forging above 40mm dia
shall be ultrasonically tested. For pressure parts, plate of thickness equal to or
above 25mm shall be ultrasonically tested.
G1.17.02.17 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 finalized
with the Employer, shall be subject to Employer's approval. 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 on enclosed on format. Such vendor
approval shall not relieve the contractor from any obligation, duty or
responsibility under the contract.

G1.17.02.18 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 organization,
the relevant reference documents/standards used, acceptance level, inspection
of documentation raised, etc. Such quality plans of the successful vendors shall
be finalized 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.
G1.17.02.19 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.
G1.17.02.20 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
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.
G1.17.02.21 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.
G1.17.02.22 For all spares and replacement items, the quality requirements as agreed for the
main equipment supply shall be applicable.
G1.17.02.23 Repair/rectification procedures to be adopted to make the job acceptable shall

be subject to the approval of the Employer/ authorized representative.
G1.17.02.24 Burn in and Elevated Temperature Test Requirement for Electronics Solid
State Equipment

Contractor/ Sub Contactor shall confirm that all solid state electronic
system/ equipment/ sub assembly is free from infant motile components and
established procedure is followed. In case during any stage of the contract,
if it is established that contractor and their sub-contractor haven’t followed
the established procedure then all liabilities arising out of this shall be born
by the contractor within the quoted lump sum price.
G1.17.03 QA DOCUMENTATION PACKAGE

G1.17.03.01 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.
G1.17.03.02 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 dispatch. However CD-Rom may be issued not later than
three weeks.
G1.17.03.03 Typical contents of QA Documentation are 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) Demineralization plant / 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
G1.17.03.04 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.
G1.17.03.05 Before dispatch / 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.
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.
If the quality document is unsatisfactory, the Supplier shall endeavor to correct

the incompleteness, thus allowing finalizing 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.
If a decision is made to dispatch, 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 dispatch of equipment.
G1.17.03.06 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.
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.
G1.17.04 PROJECT MANAGER’S SUPERVISION
G1.17.04.01 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 of Vol.I, the Contractor shall proceed to comply with the Project
Manager's decision.

G1.17.04.02 The work shall be performed under the supervision of the Project Manager.
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 Program implementation at all stages of the
works.
G1.17.05 INSPECTION, TESTING AND INSPECTION CERTIFICATES
G1.17.05.01 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.
G1.17.05.02 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.
G1.17.05.03 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 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.
G1.17.05.04 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.
G1.17.05.05 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.
G1.17.05.06 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.
G1.17.05.07 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.
G1.17.05.08 To facilitate advance planning of inspection in addition to giving inspection

notice as specified above 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.
G1.17.05.09 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 instrument identification, and shall produce
the same for inspection by RINFRA. Wherever asked specifically, the contractor
shall re-calibrate the measuring/test equipment in the presence of Project
Manager / Inspector.
G1.17.06 Associated Document for Quality Assurance Programme:

a) List of items requiring quality plan and sub supplier approval. (Annexure-
B).
b) Status of items requiring Quality Plan and sub supplier approval.
(Annexure-C).
c) Field Welding Schedule (Annexure-D).
d) Manufacturing Quality Plan (Annexure-E).
e) Field Quality Plan (Annexure-F).
G1.18.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES
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 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.
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.
g) Contractor shall furnish the commissioning organization chart for review &
acceptance of employer at least eighteen months prior to the schedule
date of synchronization of 1st unit. The chart should contain :
i) Biodata including experience of the Commissioning Engineers.
ii) Role and responsibilities of the Commissioning Organization members.
iii) Expected duration of posting of the above Commissioning Engineers at
site.
G1.19.00 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 duration of initial Operation of the complete equipment shall be fourteen

(14) days out of which at least seventy two (72) hours shall be continuous
operation on full load or any other duration as may be agreed to between the
Engineer and the Contractor.
c) The initial operation shall be considered successful provided that each item
of the equipment can operate continuously at the specified operating
characteristics, for the period of initial Operation. For the period of Trial
Operation, the time of operation with any load shall be counted. Minor
interruptions not exceeding four (4) hours at a time caused during the
continuous operation shall not affect the total duration of trial Operation.
However if in the opinion of the Engineer the interruption is long, the initial
operation shall be prolonged for the period of interruption.
d) An initial operation report comprising 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 run 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 repair done during
the initial operation. Based on the observations, necessary modifications/
repair to the plant shall be carried out by the contractor to the full satisfaction
of the engineer to enable to the latter to accord permission to carry out
performance and guarantee tests on the plant. 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.
G1.20.00 PERFORMANCE & GUARANTEE TEST
G1.20.01 The final test as to performance and guarantees shall be conducted at site by
the Contractor. Such tests will commence, with in a period of two (2) months

after successful completion of trial operations. Any extension of time beyond the
above two (2) months shall be mutually agreed upon.
G1.20.02 These tests shall be binding on both the parties of the contract tom determine
compliance of the equipment with the performance guarantees.
G1.20.03 The available instrumentation and control equipment will be used during such
tests and the Engineer will calibrate all such measuring equipment and devices
as far as practicable. However, unmeasurable parameters shall be taken in to
account in a reasonable manner by the Engineer, for the requirement of these
tests. The tests will be conducted at the specified load points and as near the
specified cycle condition as practicable. The engineer will apply proper
corrections in calculation, to take into account conditions which do not
correspond to the specified conditions.
G1.20.04 Any special equipment, tools and tackles required for the successful completion
of the Performance and Guarantee tests shall be provided by the Contractor,
free of cost.
G1.20.05 The guaranteed performance figures of the equipments shall be proved by the
Contractor during these Performance and Guarantee tests. Should the results of
these tests show any decrease from the guaranteed values, the Contractor shall
modify the equipments as required to enable it to meet the guarantees. In such
case, Performance and Guarantee tests shall be repeated within one month,
from the date the equipment is ready for retest and all cost for modifications
including labour, materials and the cost of additional testing to prove that the
equipment meets the guarantees shall be borne by the Contractor.
G1.20.06 The specific tests to be conducted on equipment have been brought out in the
Technical Specifications.
G1.20.07 Performance and Guarantee test shall make allowance for instrumentation
errors, as may be decided by the Engineer-in-Charge.
G1.21.00 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.
G1.22.00 TRAINING OF EMPLOYER'S PERSONNEL
G1.22.01 The scope of service under training of Employer’s engineers shall include a
training module in the areas of Operation & Maintenance.
Such training should cover the following areas as a minimum in order to enable
these personnel to individually take the responsibility of operating and maintaining
the complete system and all the equipments covered in this contract.

G1.22.02 The scope of services under training shall necessarily include training of
Employer’s O & M personnel covering a training module for a period mutually
agreed to between Employer and Contractor. This shall cover all disciplines
viz., Mechanical, Electrical, and C&I etc. and shall include all the related areas
like Basic design of the system, design basis of each equipment, trouble
shooting in plant operation, and O & M aspects of each equipment including all
the electrical and C&I equipments and associated operational software used for
the project covering all the Bidder’s equipments and as well as their sub-vendor
equipments.
G1.22.03 Such training shall be arranged in this project or in any other operating power
station where Bidder’s/Sub-vendor’s equipments are installed and/or at
manufacturer’s works of the equipment supplier. The details and module of
training shall be submitted and mutually agreed to between the Employer and
Contractor before the take over of the plant by exact details, extent of training
and the training schedule shall be finalized based on the Bidder's proposal later.
G1.22.04 All traveling and lodging/boarding expenses of the Employer's personnel to be

trained shall be borne by the In the event, any other expenditure is required
from Contractor's side for purpose of arrangement and/or giving training facilities
to get the operators trained, the same shall be borne by the contractor.
G1.23.00 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.
G1.24.00 PACKAGING AND TRANSPORTATION

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 dispatch of equipment.
Before dispatch 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 & pre-assembly to
bare minimum. The Employer's Inspector shall have right to insist for completion
of works in shops before dispatch of materials for transportation.
G1.25.00 ELECTRICAL ENCLOSURE

All electrical equipments and devices, including insulation, heating and

condensing devices shall be designed for ambient temperature and a maximum
relative humidity as specified elsewhere in the specification.
G1.26.00 INSTRUMENTATION AND CONTROL

All instrumentation and control systems/ equipment/ devices/ components,
furnished under this contract shall be in accordance with the requirements stated
in this specification.
G1.27.00 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-801-2.
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.
Annexure-A
S. No. Description Of Documents f Prints (Sets) NO. OF CD-ROMs
1. Drawings for Initial Submission (Either 8 1 Soft Copy (through
"FOR APPROVAL" or “FOR INFORMATION 1 no of CD-Rom or
Category) and re-submissions after review by through E-Mail)
RINFRA (including Data sheets/ Calculations,
all Equipment/instrument schedule, BOM etc)
2. Final Approved Drawings (Cat-I & Cat – IV 3 4 CD- ROMs
Approved) (As referred in Sl no: 1 above)
3. Documents / Drawings "AS BUILT " 3 4 CD- ROMs
4. Type test reports (Initial) 8 1 Soft Copy (through
1 no of CD-Rom or
through E-Mail)
5 Type test reports (Final) 1 2 CD-ROMs
6. Piping / Equipment Analysis (Transient) etc, 8 1 Soft Copy (through
Model study reports (Draft) Including the 1 no of CD-Rom or
input/ output data etc. through E-Mail)

Annexure-A
7. Piping / Equipment Analysis (Transient) etc, 2 4 CD-ROMs
Model study reports (Final Approved)
Including the input/ output data etc.
8 Erection manual "Draft " 4 sets 1 CD ROMS
8 Erection manual "Final " 4 sets 1 CD ROMS
9 Operation & Maintenance manual "DRAFT" 4 sets 2 CD ROMS
10 Operation & Maintenance manual "FINAL” 4 sets 4 CD ROMS
11 Commissioning Procedure (If applicable) 4 sets 1 CD ROMS
(DRAFT)
12. Commissioning Procedure (If applicable) 4 sets 1 CD ROMS
(FINAL)
13 Performance and Guarantee test Procedure 8 1 Soft Copy (through
(Draft) 1 no of CD-Rom or
through E-Mail)
14. Performance and Guarantee test Procedure 8 1 Soft Copy ( 1 no of

(Final) CD-Rom or through E-
Mail)
16 Progress Reports 8 Through e-mail

16 Project completion report 3 Sets 3CD ROMS
17 QA programme including Organization for 1 1 CD-ROM
implementation and QA system manual (with
revision-servicing)
18 Vendor details in respect of proposed vendors 1 1 CD –ROM
including contractor’s evaluation report.
19 Manufacturing QPs, Field QPs, Field welding

schedules and their reference documents like
test procedures, WPS, POR etc.
i) For review/comment - 3 1 set of soft copy
(ii) For final approval 1 4 1 CD ROM

set floppies
20 Welding Manual, Heat Treatment Manuals,
Storage & preservation manuals
Draft 4 sets
Final 4 sets 2 CD ROMS
21 Monthly Vendor Approval /QP approval status 2 sets 1 CD rom

Annexure-A
22 QA Documentation Package for items / 2 Sets 2 CD ROMS
equipment manufactured and dispatched to
site
23 QA Documentation 2 Sets 2 CD ROMS
Package for field activities on equipment /
systems at site

Technical Specifications for Fuel Gas 2400 MW CCPP SAMALKOT
Conditioning System Expansion
ANNEXURE-B
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
S. Item QP/ QP No. QP Sub. QP Proposed Place Sub- Sub- Remarks
N. Insp. Schedule approval sub- suppliers supplier
Cat. schedule supplier approval Details
status/ submissi
category on
schedule
REL -SKCCP-NEG-E24-P-00003 R0 Part III Page 37 of 42

LEGENDS
SYSTEM SUPPLIER/SUB-SUPPLIER APPROVAL STATUS CATEGORY (SHALL BE FILLED BY REL)
A – For these items proposed vendor is acceptable to REL. To be indicated with letter “A” in the list along with the condition of approval, if any.
DR – For these items “Detailed required” for REL review. To be identified with letter “DR” in the list.
NOTED – For these items vendors are approved by Main Supplier and accepted by REL without specific vendor approval from REL. To be identified with
“NOTED.’
QP/INSPN CATEGORY:
CAT-I: For these items the Quality Plans are approved by REL and the final acceptance will be on physical inspection witness by REL.
CAT-II: For these items the Quality Plans approved by REL. However no physical inspection shall be done by REL. The final acceptance by REL 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 REL 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.: 1/1 Engg. Div. / QA&I

ANNEXURE-C
Project : Stage : : STATUS OF ITEM REQUIRING QP& DOC. NO.:

Package : SUB-SUPPLIER APPROVAL REV. NO.:
Contractor : DATE :
Contractor No. : PAGE : OF
S. N. Item / Service QP/ QP Sub. Date Date Statu Proposed Place of Approval Sub- Re
Insp. Schedul of of s Sub- manufacturing Status supplie mar
Cat. e sub- com Code suppliers works r detail ks
Approva missio mt C/II/I submis
l n Appl. sion
schedul schedul
e e

Annexure-D
Project : Stage : FIELD WELDING SCHEDULE DOC. NO.:

Contractor : (To be raised by the contractor) REV. NO.:
Contractor No. : Welding Code: ……………………………………… DATE :
System : PAGE : OF
Sl. DRG No. for Weld Descriptio Matl. Dimension Process Type of Electrode WPS. Min. Heat treatment NDT REF Rema
No. Location and n of parts Spe of Weld filler No. pre- method/ rks
Identification mark to welded c s welding spec. heat Quantum
Temp. Holdin Spec. ACC
g time No. Norm
Ref.
NOTES:
SIGNATURE

Annexure-E
MANUFACTURER’S NAME MANUFACTURING QUALITY PLAN PROJECT :

MFGR.’s AND ADDRESS ITEM : QP NO.: PACKAGE :
LOGO REV.NO.: CONTRACT NO. :
SUB-SYSTEM: DATE:
PAGE: …. OF…. MAIN-SUPPLIER:
CHARACTERIS TYPE ACCEPTANC FORMAT AGENC REM

SL. COMPONENT & CLASS QUANTUM REFERENCE
TICS OF E OF Y ARK
NO OPERATIONS OF CHECK DOCUMENT
CHECK NORMS RECORD S
M C N
1. 2. 3. 4. 5. 6. 7. 8. 9. D* ** 10. 11.
LEGEND: * RECORDS, INDENTIFIED WITH “TICK” ( √ ) DOC. NO.:

SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA REV…… CAT…..
DOCUMENTATION.
** M: MANUFACTURER/SUB-SUPPLIER
C: SUPPLIER/NOMINATED INSPECTION AGENCY,
MANUFACTURER MAIN- FOR
N: REL
/ SUPPLIER REL
SUB-SUPPLIER P: PERFORM W: WITNESS AND V: VERIFICATION. AS USE
SIGNATURE APPROPRIATE, REVIEWE APPROV APPR
CT: REL SHALL IDENTIFIED IN COLUM “N” D BY ED BY OVAL
SEAL
Annexure-F

SUPPLIER’S NAME AND FIELD QUALITY PLAN PROJECT :

ADDRESS ITEM : QP NO.: PACKAGE :
REV.NO.: CONTRACT NO. :
MFGR.’s DATE:
SUB-SYSTEM :
LOGO PAGE: …. OF…. MAIN-SUPPLIER:
QUANTU
ACTIVITY REFERENC ACCEPTANC
SLN CHARACTERISTIC CLASS# OF TYPE OF M FORMAT OF REMA
AND E E
O S / INSTRUMENTS CHECK CHECK OF RECORD RKS
OPERATION DOCUMENT NORMS
CHECK
1. 2. 3. 4. 5. 6. 7. 8. 9. D* 10.
DOC. NO.:
LEGEND: * RECORDS, INDENTIFIED WITH “TICK” (√) SHALL BE REV…… CAT ….
MANUFACT ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
URER/ MAIN- LEGEND TO BE USED: CLASS # : A = CRITICAL, B=MAJOR,
SUB- SUPPLIER C=MINOR; ‘A’ SHALL BE WITNESSED BY REL FQA, ‘B’ SHALL BE
SUPPLIER WITNESSED BY REL ERECTION / CONSTRUCTION DEPTT. AND ‘C’
SHALL BE WITNESSED BY ERECTION SUPPLIER (A & B CHECK REVIE APPRO
FOR REL APPROV
SIGNATURE SHALL BE REL COOLIGN TOWER STAGE) WED VAL
USE ED BY
BY SEAL
Format No.: 1/1 Engg. Div./QA&I

Technical Specifications for Fuel Gas 2400 MW SAMALKOT
Conditioning System CCPP EXPANSION
PART III
SECTION 2
ERECTION CONDITIONS OF CONTRACT
PART III, SECTION 2

REL-SKCCP-NEM-161-P-00001(Rev.00) ERECTION CONDITIONS OF Page 1 of 45
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
Coordinator, 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 payable 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 RINFRA 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
PART III, SECTION 2
CONTRACT
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 authorized to carry out welding. All such badges shall be
countersigned by the Employer.
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 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.
PART III, SECTION 2
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
(h.) Number of welds per unit
PART III, SECTION 2

CONTRACT
(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 under 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 leveled 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
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
PART III, SECTION 2
CONTRACT
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.
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
Contractor as specified elsewhere or agree to separately in writing. Welds
PART III, SECTION 2

CONTRACT
required for holding insulation on pressure parts shall be carried out by IBR
qualified welder.
13.01.00 In case of equipment other than steam turbine, Lugs made out of MS rods of 5
mm dia conforming to IS280 or equivalent shall be welded on the surface at
intervals of 250 mm pitch zigzag to support insulation. Mineral wool mats with wire
netting on both sides shall be applied against the surface with lugs piercing
through. The edges of mattress shall be laced together with galvanized MS 0.71
mm dia (22 SWG) IS 280 or equivalent (soft) lacing wire. Galvanized binding wire
of 1.63 mm dia (16 SWG) IS 280 or equivalent (soft) will be used criss-cross
between lugs to hold it. The lugs will then be bent over the netting.
13.02.00 Unless otherwise specified, all equipment insulation shall be covered with
aluminium cladding/ jacketing. The thickness of aluminium sheet shall not be less
than 0.63 mm. Galvanic corrosion shall be prevented by carefully avoiding
permanent contact of aluminium cladding with copper, copper alloys, tin, lead
nickel or nickel alloys including monel metal. Where cladding is attached to carbon
steel or low alloy steels, the steel shall first be prime painted with zinc chromate
and then painted with aluminium paint. The use of lead base paints for this
purpose shall be avoided.
13.03.00 Prior to application of cladding, all surface imperfections such as ducts, cracks
and voids shall be filled with insulation cement so as to form a smooth base for
the final shall be machine rolled and formed. All overlaps at longitudinal joints
shall face downwards. The fixing of cladding shall be by means of screws and
they shall be adequate in number and be so place is such location as to produce
tight joints eliminating ' bellying'. The screws, as far as possible, shall be uniformly
placed and on centres not exceeding 150 mm except where insulated outside
diameters are smaller than 230 mm in which case spacing shall be on centres not
exceeding 100mm. Self tapping type screws, of 12 mm size of stainless
steel/aluminium alloy as per the requirements shall be used. All joints wherever
possible shall be lapped a minimum of 50 mm. The overlaps of longitudinal joints
shall be a 10 mm turn back edge. Butt joints such as those at piping tees, shall be
made using a rolled seam. Suitable provisions for expansion movement shall be
provided in joints. Hinged or sliding doors for convenience shall be provided in the
cladding at all access openings, non-projecting connections, important codes
stampings etc.
13.04.00 Piping, Pipe Fittings & Valves
All piping insulation and metal cladding furnished with the equipment to be erected
shall be applied as specified herein.
13.04.01 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
PART III, SECTION 2
CONTRACT
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.
13.04.02 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 re-tightened.
13.04.03 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.
13.04.04 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 shall be made using rolled seams. In addition, to prevent
galvanic corrosion, suitable action, as stipulated as specified at clause no
13.02.00- of this chapter, shall be taken.
13.04.05 Valves and Fittings

All valves and fittings installed in the pipelines shall also be applied with insulation
and furnished with suitably shaped boxes so as to facilitate easy dismantling of
PART III, SECTION 2

CONTRACT
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.
13.05.00 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 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.
16.00.00 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.
17.00.00 ACCESS TO SITE AND WORKS ON SITE

17.01.00 Suitable access to site and permission to work at the Site shall be accorded to the
Contractor by the Employer in reasonable time.
17.02.00 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.
18.00.00 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
PART III, SECTION 2
CONTRACT
said authorised resident representative of the Contractor and the same shall be
deemed to have been communicated to the Contractor at his legal address.
19.00.00 CO-OPERATION WITH OTHER CONTRACTORS

19.01.00 The Contractor shall co-operate with all other Contractors or tradesmen of the
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 minimize 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.
19.02.00 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.
20.00.00 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 mis-conducted 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.
21.00.00 CONTRACTOR’S FIELD OPERATION

21.01.00 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
PART III, SECTION 2

CONTRACT
method of work reviewed. The Contractor shall be solely responsible for the
safety, adequacy and efficiency of plant and equipment and his erection methods.
21.02.00 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.
22.00.00 PHOTOGRAPHS AND PROGRESS REPORT
22.01.00 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.
22.02.00 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.
22.03.00 The Contractor shall submit the progress of work in video cassettes (2 copies)
quarterly highlighting the progress and constraints at site.
23.00.00 MAN-POWER REPORT
23.01.00 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.
23.02.00 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 sched-
uled to have been employed and actually employed, skill- wise and the areas of
employment of such labour.
24.00.00 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 20.00.00- of this chapter
entitled “Co-operation with other Contractors.” The Contractor shall not cause any
PART III, SECTION 2
CONTRACT
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.
25.00.00 EMPLOYMENT OF LABOUR

25.01.00 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 particular work. No female labour shall be employed after
darkness. No person below the age of eighteen years shall be employed.
25.02.00 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.
25.03.00 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.
25.04.00 Contractor’s employees shall wear identification badges while on work at Site.
25.05.00 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.
26.00.00 FACILITIES TO BE PROVIDED BY THE EMPLOYER
26.01.00 Space
The Contractor shall advise the Employer within thirty (30) days from the date of
acceptance of the Notification of Award about his exact requirement of space for
his office, storage area, pre-assembly and fabrication areas, labour and staff
colony area, toilets, etc. The above requirement shall be reviewed by the
Employer and space as decided by Employer will be allotted to the Contractor for
construction of his temporary structures/ facilities like office, storage sheds, pre-
assembly and fabrication areas, labour and staff colony, toilets, etc. for
Contractor's as well as his Sub-Contractor’s use.
26.02.00 Electricity
The Contractor shall make all arrangement himself for the construction power
required by him as well as for his labour and other personnel at work site and
colony.
26.03.00 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.
PART III, SECTION 2
CONTRACT
26.04.00 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.
26.05.00 Cranes
Turbine hall EOT cranes may be used by the Contractor on chargeable basis for
erection of the units / equipments under this package. For the equipments which
cannot be handled by these Turbine hall EOT cranes, the Contractor shall make
his own arrangements.
27.00.00 FACILITIES TO BE PROVIDED BY THE CONTRACTOR

27.01.00 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.
27.02.00 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.
27.03.00 Testing Equipment and Facilities:

The contractor shall provide the necessary testing, equipment and facilities.
27.04.00 NOT USED
27.05.00 First-aid
27.05.01 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.
27.05.02 The Employer will provide the Contractor, in case of any emergency, the services
of an ambulance for transportation to the nearest hospital.
27.06.00 Cleanliness
27.06.01 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
PART III, SECTION 2
CONTRACT
protective cover of a flame resistant, oil proof sheet shall be provided to protect
the floor from such damage.
27.06.02 Similarly the labour colony, the offices and the residential areas of the
Contractor’s employees and workmen 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, office and residential areas of the Contractor.
28.00.00 LINES AND GRADES
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.
29.00.00 FIRE PROTECTION

Required Fire Protection Measures are described under Clause titled “WORK
&SAFETY REGULATIONS” of this Sub-section.
30.00.00 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.
31.00.00 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.
32.00.00 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
PART III, SECTION 2

CONTRACT
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.
33.00.00 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES

33.01.00 GENERAL
33.01.01 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.
33.01.02 The pre-commissioning and commissioning activities including Guarantee 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.
33.01.03 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.
PART III, SECTION 2

CONTRACT
(d.) Apart from above, contractor shall ensure deployment of sufficient

skilled/semi-skilled/unskilled manpower during pre-commissioning and
commissioning activities.
33.01.04 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.
33.01.05 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.
33.02.00 COMMISSIONING DOCUMENTATION
33.02.01 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.
33.02.02 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.
33.02.03 The testing schedule is a document, designed for safe and systematic
commissioning of individual equipment/sub-system (for example Boiler Feed
Pump, condensate pump, compressor etc) Commissioning schedule is a
document envisaged for commissioning of a system (for example feed system,
Condensate system, Compressed Air system, Fire water 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.
33.02.04 The contractor shall submit the list of commissioning documentation to be
submitted by him, alongwith 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.
33.02.05 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.
33.03.00 COMMISSIONING ACTIVITIES
33.03.01 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.
33.03.02 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.
PART III, SECTION 2
CONTRACT
33.03.03 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.
33.03.04 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.
33.03.05 Other tests shall be conducted, if required by the Employer, to establish that the
plant equipment are in accordance with requirements of the specifications.
33.03.06 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(Section-VI)
33.04.00 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.
34.00.00 MATERIALS HANDLING AND STORAGE

34.01.00 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.
34.02.00 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.
34.03.00 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.
34.04.00 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 equip-
ment at Site.
PART III, SECTION 2

CONTRACT
34.05.00 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.
34.06.00 All the electrical equipment such as motors, generators, 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.
34.07.00 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.
34.08.00 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 dete-
rioration in quality by storage.
34.09.00 All the materials stored in the open or dusty location must be covered with suitable
weatherproof and flameproof covering material wherever applicable.
34.10.00 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.
34.11.00 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 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.
35.00.00 CONSTRUCTION MANAGEMENT
35.01.00 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 coordination of work. Such decision by the
Employer shall not be a cause for extra compensation or extension of time for the
Contractor.
35.02.00 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.
PART III, SECTION 2
CONTRACT
35.03.00 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.
35.04.00 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.
36.00.00 FIELD OFFICE RECORDS
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.
37.00.00 CONTRACTOR’S MATERIALS BROUGHT ON TO SITE

37.01.00 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.
37.02.00 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.
37.03.00 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
PART III, SECTION 2
CONTRACT
38.02.00- of this chapter and credit the proceeds thereto to the account of the
Contractor.
38.00.00 PROTECTION OF PROPERTY AND CONTRACTOR’S LIABILITY
38.01.00 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.
38.02.00 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 Employers, related to removal and/or replacement or protection of such
property and utilities.
39.00.00 PAINTING
Unless otherwise mentioned in other sub-sections. all exposed metal parts of the
equipment including pipings, structure railings, etc. wherever applicable, after
installation unless otherwise surface protected, shall be first painted with at least
two coats of suitable primer which matches the shop primer paint used, after
throughly cleaning all such parts of all dirt, rust, scales, greases, oils and other
foreign materials by wire brushing, scraping or sand blasting and the same being
inspected and approved by the Employer for painting. Afterwards, the above
parts shall be finished painted with three coats of allowed resin machinery enamel
paints. The minimum thickness of paint film shall not be less than 100 microns.
The quality of the finish paint shall be as per the standards of Bureau of Indian
Standards (BIS) or equivalent and to be of the colour as approved by the
Employer.
40.00.00 INSURANCE
40.01.00 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.
40.02.00 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:
PART III, SECTION 2

CONTRACT
Workmen's Compensation - As per Statutory Provisions
Employee's Liability - As per Statutory Provisions
40.03.00 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
40.04.00 Comprehensive General Liability Insurance

40.04.01 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, 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).
40.04.02 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.
40.05.00 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.
41.00.00 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 unfavorable construction conditions will in no
way relieve the Contractor of his responsibility to perform the Works as per the
schedule.
42.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS
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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.
43.00.00 WORK & SAFETY REGULATIONS

43.01.00 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.
ii) The Contractor shall follow RINFRA 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 prepare 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 and
submit to Engineer-in-charge for approval as per the format of Safety plan as per
the Table below:
SAFETY PLAN
1) Safety policy of the contractor to be enclosed
2) When was the safety policy last reviewed
3) Details of implementation procedure/methods to implement Safety
Policy/Safety Rules
4) Name, qualification, experience of Safety Officer
5) Review of Accident, Analysis Method, Methods to ensure Safety and
Health
6) Unit executive responsible to ensure Safety at various levels in work
area
7) List of employees trained in safety employed before execution of the
job. Give the details of training.
8) Safety training Targets, Schedules, Methods adopting to provide
safety training to all employees
9) Details of checklist for different jobs/ work and responsible person to
ensure compliance (copy of checklist to be enclosed.)
PART III, SECTION 2
CONTRACT
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.
Head of the Organization With date & stamp
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 In charge 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 RINFRA 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
RINFRA safety documents as stated above.
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 of 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 In-charge when asked for. If any worker found
suffering from occupational health hazard, the worker should be shifted to suitable
PART III, SECTION 2
CONTRACT
place of working and properly treated under intimation to Engineer In-charge. The
medical fitness certificate to be submitted to Engineer In-charge.
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.
43.02.00 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.
43.03.00 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.
43.04.00 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.
43.05.00 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
required to be complied for use, handling, storing or transportation of explosives
under the rules framed under the Explosives Act, 1884.
43.06.00 Coffer Dam and Caissons
The Contractor shall ensure that the cofferdam and caissons are of good
construction and adequate strength. The cofferdam and caissons should be
provided with adequate means for workers to reach safely at the top of such dams
in the even of an in-rush of water. The workers should be allowed to work in a
cofferdam or caisson only after inspection and found safe by Engineer-in –charge.
Such inspection is to be maintained in a Register. Where the workers are
PART III, SECTION 2
CONTRACT
employed to work in a compressed air environment at the work site of cofferdam

or caissons a Construction Medical Officer assisted by a Nurse or trained first aid
attendant should be available at all the times during such work.
43.07.00 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.
Working Platforms should be fenced and shall have means of access
43.08.00 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.
43.09.00 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 in-charge 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.
43.10.00 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.
43.11.00 Working at Heights.
a) 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.
b) 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.
c) 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.
PART III, SECTION 2

CONTRACT
d) 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.
e) 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.
f) 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 arresters) for climbing/getting down
through ladders to prevent fail from height.
g) Rungs shall not be welded on columns. All the Stairs shall be provided with
handrails immediately after its erection.
43.12.00 Handling of Hazardous Chemicals.
a) The Contractor will notify well in advance to the Engineer-in-charge 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. RINFRA 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-in-charge
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 RINFRA and RINFRA shall not
entertain any claim of the Contractor towards additional safety provisions /
conditions to be provided for / constructed.
b) Further, any such decision of the Engineer-in-charge 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 RINFRA, the Contractor shall
use alternative methods with the approval of the RINFRA without any cost
implication to the RINFRA or extension of work schedule.
c) 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 In-charge In case any approvals
are necessary from the Chief Inspector (Explosives) or any statutory authorities;
the Contractor shall be responsible for obtaining the same.
d) 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
PART III, SECTION 2
CONTRACT
Research Centre/ Department of Atomic Energy, Govt. of India) Rules and other
applicable provisions- AU precautionary measures stipulated by BARC/DAE in
connection with use, the contractor would take storage and handling of such
material.
e) The contractor shall provide suitable personal protective equipments to the
workers who are handling the hazardous and corrosive substances including
alkalis and acids.
f) 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.
43.13.00 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.
43.14.00 NOT USED
43.15.00 Electrical Hazards.
a) The contractor should ensure that all electrical installations at the construction
work comply with the requirements of latest electricity acts / rules.
b) 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.
c) The contractor should ensure use of single / double insulated hand tools or low
voltage i.e., 110 volts hand tools.
d) The contractor should also ensure that all temporary electrical installations at the
construction works are provided with earth leakage circuit breakers.
e) No electric cable in use by the Contractor /Employer will be disturbed without prior
permission. No weight of any description will be imposed on any cable and no
ladder or similar equipment will rest against or attached to it.
f) The Contractor shall employ necessary number of qualified, full time
Electricians/electrical supervisors to maintain his temporary electrical installations.
43.16.00 Vehicular Traffic.
The contractor should employ vehicle drivers who hold a valid driving license
under the Motor Vehicles Act, 1988.
43.17.00 Lifting Appliances, Tools & Tackles. Lifting Gear And Pressure Plant
& Equipment etc.
The contractor shall ensure alt the lifting appliances, tools & tackles including
cranes etc., lifting gear including fixed or movable and any plant or gear, hoists,
PART III, SECTION 2
CONTRACT
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.
43.18.00 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.
43.19.00 Electrical Installations.
a) 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.
b) Before the Contractor connects any electrical appliances to any plug or socket
belonging to the other contractor or the RINFRA, he shall :-
♦ Satisfy the Engineer I/C that the appliance is in good working condition;
♦ Inform the Engineer I/C of the maximum current rating, voltage and phases of
the appliances;
♦ Obtain permission of the Engineer-in-Charge detailing the sockets to which the
appliances may be connected.
c) The Engineer in-charge 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.
d) No repair work shall be carried out on any live equipment. The Engineer-in-
Charge must declare the equipment safe and a permit to work shall be issued by
the RINFRA / 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.
e) The contractor shall employ necessary number of qualified, full time Electricians /
Electrical Supervisors to maintain his temporary electrical installation.
f) The installations are provided with suitable ELCBs and RCCBs wherever required.
43.20.00 Safety Organisation.
a)The contractor employing more than 250 workmen whether temporary, casual,
probationary, regular or permanent shall employ at least one full time safety officer
PART III, SECTION 2
CONTRACT
exclusively to supervise safety aspects of the equipments and workmen, who will
coordinate with the RINFRA 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.
b) In case of contractor deploying less than 250 workmen he should designate one
of his Engineer / supervisor or the contractor himself (if he is directly supervising
the work) as safety officer in addition to his existing responsibilities. The
Engineer./ supervisor should get at least 2 days safety training from any reputed
organization or from RINFRA before resuming the work. If already trained in past
the declaration along with training. Certificate to be furnished to RINFRA safety
officer.
c) 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.
43.21.00 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 in-
charge, RINFRA Safety Officer with a copy to RINFRA Head of Project in the
prescribed form and also to all the authorities envisaged under the applicable
laws.
43.22.00 Right to stop Work.
a) 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 of work and decision of the Project Manager in this
respect shall be conclusive and binding on the Contractor.
b) The Contractor shall not be entitled for any damages / compensation for stoppage
of work 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.
43.23.00 Fire Protection.
PART III, SECTION 2

CONTRACT
a) 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.
b) 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.
c) The work procedures that are to be used during the erection shall be those which
minimise fire hazards to the extent practicable. Combustible materials, combus-
tible 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.
d) 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.
e) 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.
43.24.00 Penalties.
a) If the Contractor fails in providing safe working environment as per the Safety
Rules of RINFRA or continues the work even after being instructed to stop the
work by the Engineer –in- Charge as provided 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 below shall also apply in addition to the penalties
mentioned in this sub-clause.
b) 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 RINFRA's employees or any
other person who are at the Site or adjacent thereto, the Contractor shall be
responsible for payment of penalty to RINFRA as per the following schedule; -
a) Fatal injury or accident causing Penalty @10% of contract value

death or Rs. 5,00,000/- per person,
PART III, SECTION 2
CONTRACT
death: which ever is less.

b) Major injuries or accident causing Penalty @2.5 % of contract value or
25% or more permanent disablement Rs.1,00,000/- per person, which ever
to workmen or employees. 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.
c) 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 in-charge / Safety Officer of RINFRA 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 in-charge / Safety Officer of RINFRA will also issue a
notice in this regard to the contractor.
d) If two or more fatal accidents occur at same RINFRA site under the control of
contractor during the period of contract and he has :-
(1) not complied with keeping adequate PPEs in stock,
(2) defaulted in providing PPR's to his workmen
(3) not followed statutory requirements /RINFRA safety rules
(4) been issued warning notice/s by RINFRA 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 RINFRA for two
years from the date of last accident.
e) The safety performance will also be one of the overriding criteria for evaluation of
overall performance of the contractors by RINFRA. 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.
43.25.00 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.
44.00.00 FOREIGN PERSONNEL
PART III, SECTION 2

CONTRACT
44.01.00 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.
44.02.00 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.
44.03.00 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.
44.04.00 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.
44.05.00 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 or full-time nor shall they
take part in any local politics.
44.06.00 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.
45.00.00 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/
EQUIPMENT BASES
45.01.00 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.
45.02.00 All the equipment/ equipment bases, shall be grouted and finished as per these
specifications unless otherwise recommended by the equipment manufacturer.
45.03.00 The concrete foundation surfaces shall be properly prepared 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.
PART III, SECTION 2

CONTRACT
45.04.00 Grout
The grout shall be high strength grout having a minimum characteristic
compressive strength of 60 N/mm2 at 28 days. The grout shall be chloride - free,
cement based, free flowing, non-metallic grout.
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.
45.05.00 Placing of Grout

45.05.01 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.
45.05.02 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.
45.05.03 In addition to the above, recommendations of Grout manufacturer shall also be
followed.
45.06.00 Finishing of the Edges of the Grout
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.
45.07.00 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,
PART III, SECTION 2
CONTRACT
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 checkup and verifications. Such pre and post
grout records of alignment details shall be maintained by the Contractor in a
manner acceptable to the Employer.
46.00.00 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 not
exceed forty (40) microns and shall conform to VDI 2056.All bearings, shafts and
other rotating parts shall be thoroughly cleaned and suitably lubricated before
starting.
47.00.00 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.
48.00.00 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.
49.00.00 COMMISSIONING SPARES

49.01.00 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
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.
49.02.00 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.
50.00.00 EQUIPMENT DELIVERY AND ERECTION
PART III, SECTION 2

CONTRACT
50.01.00 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.
50.02.00 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.
(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
PART III, SECTION 2
CONTRACT
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 :
(1.) Export case markings
(2.) Case number
(3.) Gross weight and net weight in Kilograms
(4.) Dimensions in centimeters
(5.) 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.
(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
PART III, SECTION 2
CONTRACT
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.
50.03.00 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.
50.04.00 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.
PART III, SECTION 2
CONTRACT
(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 commi ssioning 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,
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.
All free standing instrumentation cabinets and panels shall be located within the
construction tolerances of +/- 3 mm of the location dimensions indicated on the
Employer's plant arrangement drawings.
(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
PART III, SECTION 2

CONTRACT
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.
(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.
PART III, SECTION 2
CONTRACT
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
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.
PART III, SECTION 2

CONTRACT
(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.
51.00.00 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
specifi-cations, the requirements shall be submitted to the Project Manager in
advance of commencement of erection work.
52.00.00 DEVIATIONS DISPOSITIONING:

Any deviation to the contract and employer approved documents shall be properly
recorded in the format prescribed by RINFRA. Al the deviations shall be bought to
the knowledge of employer’s representative for suitable dispositioning.
53.00.00 NON-DESTRUCTIVE TESTING ( NDT):

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.
54.00.00 TESTING EQUIPMENT & FACILITIES:

Contractor shall provide the testing equipment and facilities necessary to carry out
tests & inspections.
PART III, SECTION 2

CONTRACT
ANNEXURE-I
STANDARD CHECKLIST –
COMMISSIONING/TESTING ESSENTIAL PRE-REQUISITE
(a.) Mechanical
Sl. No. DESCRIPTION
(1.) Valves- All Types as applicable
(2.) Tanks And Pressurre Vessels as Applicable
(3.) Pumps as applicable
(4.) Pipe Work System as applicable
(5.) Strainer And Filter as applicable
(6.) Heat Exchangers/ Cooling Towers/ Resin vessels as applicable
(7.) Fans And Compressors as applicable
(8.) Dampers & Gates as applicable
(9.) Duct Work as applicable
(10.) Cranes. Hoists And Elevators as applicable
(11.) Power Transmission (Gear Box, Bearings & Couplings) as applicable
(b.) Electrical
Shall be as per General Technical Specifications for Electrical
(c.) Control & Instrumentation
(1.) Conductivity Analysing Equipment including Test procedures
(2.) pH ANALYSER INCLUDING TEST PROCEDURE
PART III, SECTION 2

CONTRACT
(3.) Silica analyser
(4.) LEVEL SWITCH (FLOAT ACTUATED)
(5.) LEVEL SWITCH (ELECTRODE TYPE)
(6.) Level Switch Displaced actuated)
(7.) Transmitter (Float Operated Pneumatic Output)including testing

procedure
(8.) Level Indicator (Float/Pulley Type)
(9.) LOCAL TEMPERATURE INDICATORS 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/Thermostat including test procedures
(14.) COLD JUNCTION BOXES
(15.) ZENER BARRIER
(16.) O2 Analyser
(17.) O2 IN HYDROGEN INCLUDING TEST PROCEDURES
(18.) Pressure and Vacuum Gauge
(19.) PRESSURE AND VACUUM SWITCH INCLUDING TEST

PROCEDURE
(20.) Differential Pressure Transmitter including test procedure
(21.) Differential Pressure switch including test procedure.
(22.) Flow Indicator(variable area)
(23.) ORIFICE PLATE
(24.) TURBINE FLOW TRANSMITTER

(i.) FLOW SWITCH
(ii.) WEIR
(iii.) NOZZLE
PART III, SECTION 2
CONTRACT
(iv.) Flow Indicator(Pneumatic input)including test procedure

(v.) Flow integrator (Pneumatic input)including test procedure
(vi.) Flow indicator (float operated)including test procedure
(vii.) VENTURI (FLUID)
(viii.) Flow switch(Magnetic Type)
(ix.) AVERAGING INLET
(x.) LIMIT SWITCHES
(25.) TURBINE SUPERVISORY MEASURING SYSTEM
(26.) Position Measurement and indication including Test Procedures

(i.) TACHOMETER
(ii.) VIBRATION MEASUREMENT
(iii.) DIGITAL INDICATOR
(iv.) MOVING COIL INDICATOR INCLUDING TEST
PROCEDURE
(v.) RECORDER INCLUDING TEST PROCEDURE
(vi.) FLAME SCANNER
(vii.) ELECTRICAL AUTO MANUAL CONTROL STATION
(viii.) PUSH BUTTON MODULE
(ix.) ALARM ANNUNCIATOR EQUIPMENT INCLUDING TEST
PROCEDURE
(x.) Test procedure for electronic Modules of DDCMIS
(xi.) THERMO CONTROL VALVE
(xii.) Test Procedure for adjustment of modulating Controller –
PID Terms
(xiii.) Test Procedure indicating Controller-Electrical Input and
Pneumatic Output
Note: The items which are not part of this specification may be considered as not
applicable.
Annexure-II
BRIEF WRITE UP ON THE CONTENTS OF TESTING SCHEDULE /

COMMISSIONING SCEHDUELE
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:
(a.) Plant Details/Design data
PART III, SECTION 2

CONTRACT
(b.) Testing Objective/Proposals
(c.) State of the Plant
1) Erection Status with respect to Mech. Elect and C&i
2) Availability of the services required
3) Safety requirements as per manufacturer’s data
(d.) Test method including completion/acceptance criteria
(e.) Results
(f.) Appendix
(1.) Testing Programme
(2.) Mech/Elect/C&I –Plant item completing list
(3.) List of Drawing/documents required for carrying out the testing.
PART III, SECTION 2

CONTRACT
PART IV
SECTION 1
DATASHEET
REL-SKCCP-NEM-161-P-00001(Rev.00) Part IV Page 1 of 5

FUEL GAS CONDITIONING SYSTEM
1.00.00 Gas Conditioning System
i. Gas pipe line from terminal point
a. O.D. and thickness of pipe ...........................................

(mm x mm)
b. Material of pipe ...........................................
c. Insulating material ..........................................
d. Coating used ...........................................
d. No. of block valves ...........................................
e. Details of block valves ...........................................
f. Details of the metering facility ..........................................
ii) Emmergency stop valve
a. Type and make ..........................................
b. No. provided ...........................................
c. Pressure drop during full flow (Kg/cm2) .........................
d. Max design pressure (Kg/cm2) .........................
e. Material of construction
1. Body ...........................................
2. Seat ...........................................
3. Plug ...........................................
4. Stem ...........................................
iii) Fuel Gas metering station
a. Type and make ..........................................
b. No. provided ...........................................
c. Pressure drop during full flow (Kg/cm2) .........................
d. Max design pressure (Kg/cm2) .........................
e. Material of construction ...........................................

iv) Knock out drum
a. Type and make ..........................................
b. No. provided ...........................................
c. Number operating during full load ...........................................

operation
d. Pressure drop during full flow (Kg/cm2) .........................
e. Max design pressure (Kg/cm2) .........................
f. Max allowable solid content ...........................................

at separator outlet.
v) Filter separators
a. Type, make and material ...........................................
b. No. provided ...........................................
c. Number operating during full load …………..............................

operation
d. Size and mesh of strainer ..........................................
e. Pressure drop during full flow ..........................................

at filter outlet
vi) Startup Heater
b. No. provided ...........................................
c. Duty of Heater ...........................................
d. Pressure drop during full flow ..........................................
e. Max design pressure(Kg/cm2) ...........................................
vii) Pressure regulating control valve
a. Number ...........................................
b. Size (mm) ...............................
c. Type ...........................................
d. Pressure drop
1. at max load ..........................................

2. at no load ...........................................
e. Control valve characteristics ...........................................
f. Materials of construction
1. Body ...........................................
2. Seat ...........................................
3. Plug ...........................................
4. Stem ...........................................
g. Total Pressure drop across Fuel ...........................................

Gas conditioning system when
all gas turbines are operating
at full load
vii) Absolute filter
b. No. provided ...........................................
c. Number operating during full load …………..............................

operation

at filter outlet
viii) Efficiency Heater
b. No. provided ...........................................
c. Duty of Heater ...........................................
d. Pressure drop during full flow ..........................................
e. Max design pressure(Kg/cm2) ...........................................
Gas side ………………………………

Water side ………………………………..
vi) Scrubber
b. No. provided ...........................................

c. Number operating during ...........................................

full load operation

at filter outlet
g. Material of Pipeline downstream of filter ...........................................

Instrumentation & control Cables 2400 MW SAMALKOT
CCPP EXPANSION
Technical Data sheets
INSTRUMENTATION & CONTROL CABLES

TECHNICAL DATA TO BE FILLED IN BY THE BIDDER
Note: Bidder shall furnish technical datasheets for each type of cable coming under his
scope of supply.
Sr. No. Particulars To Be Filled Up By Bidder

1 GENERAL
Design ambient Temperature (Deg. C)
2 CABLES
Name of the Manufacturer
Place of manufacture
Cable type
Applicable specifications & Standards
Voltage grade
No. of pairs/ cores and size
Suitable for neutral earthed/ Unearthed

system (Yes/ No)
Permissible voltage and frequency
variation for satisfactory operation
Maximum conductor Temp.( For
Information only)
1) Continuous (Deg. C)
2) Short time (Deg. C)
3 Conductor
Material
Shape of conductor
Nominal cross section area (mm2)
Number of strands
Diameter of each strand (mm)
REL-SKCCP-NRM-161-P-00001 (Rev.00) Instrumentation & Control Cables Page 1 of 5

CCPP EXPANSION

Nom. Diameter (mm)
Conforming standard of conductor

material
Grade
Class
Shielding on Conductor
A) Material
B) Type/applicable standard
C) Thickness in mm
D) Tolerance of thickness
4 Insulation
Material
Thickness of insulation
Tolerance on thickness of insulation (%)
Diameter of core over insulation (mm)
Specific insulation resistance at eighty five

degrees centigrade (ohm-cm) and min.
volume resistivity at 27 deg C ( ohm-cm)
Type/applicable standard
Shielding on Insulator
A) Material
B) Type/applicable standard
C) Thickness in mm individual pair /

overall shield
D) Coverage / Overlap (%)
E) Material and size of drain wire
Approximate dia of cable over shielding
(Approx dia under inner sheath) mm

CCPP EXPANSION

5 Inner sheath (If applicable)
Material
Thickness (mm) Min
Diameter of cable over inner sheath (mm)
Type/Applicable standard
Colour
Filler material
6 Armouring (If applicable)
Material
Type of armouring
Diameter of wire (mm) / Strip size (mm)
Whether galvanized (Yes/No)
Diameter of cable over armoring(mm)
Calculated dia over inner sheath in mm
7 Outer sheath
Material
Thickness of sheath(mm)
Tolerance on Thickness of sheath (mm)
Overall diameter of cable(mm)
Colour Scheme for identification
8 Cable constants
DC resistance per core at (ohm/km)
Twenty degrees centigrade

CCPP EXPANSION

AC resistance per core at (ohm/km)
Twenty degrees centigrade
Reactance per core (ohm/km)
Capacitance per core (µf/km)
Dielectric constant
Maximum cable charging current at

normal operating voltage
9 Factory tests (Enumerate in detail for
each type of cable)
10 Is the offered cable guaranteed to safely
withstand continuous conductor
temperature of 70 degree C (Yes / No)
11 Cable weight (kg/km)
12 Recommended minimum bending radius

(mm)
13 Safe pulling force(kg)
14 Maximum allowable spacing for (mm)

angle iron supports
15 Length of cable per drum(m)
16 a. Tolerance of individual drum length
b. Tolerance on overall quantity
17 Cable drum
Drum Material
Drum weight (kg) for 100 mts
Cable weight (kg) for 100 mts
Shipping weight (kg) for 100 mts
18 Other technical information
Twisting lay ( for pair )
Marking on outer sheath
Properties of outer sheath

CCPP EXPANSION

i) Min.Oxy. ind as per ASTMD 2863
ii) Min.temp. ind as per ASTMD 2863
iii) Max HCL emission as per IEC-754-1
iv) Max.smoke density rating as per

ASTMD2843
v) Flammability test on completed cable
as per IEEE 383 (Yes/ No)
Min insulation resistance at 20 degC of
completed cable ( Mohm / Km )
Characteristic impedance of conductor at
0.8KHz (Max) (Ohms)
Attenuation at 1 KHz(dB/ Km)
Cross talk at 0.8kz (dB/ km)
Mutual capacitance at 0.8KHz
High voltage test
Conductor to conductor
Conductor to shield
Signature : .......................
SEAL OF COMPANY
Name : .......................
Designation :
......................

Measuring Instruments, VMS &
2200-2400 MW CCPP
Control Valves SAMALKOT Expansion
MEASURING INSTRUMENTS, VIBRATION MONITORING SYSTEM & CONTROL

VALVES
TECHNICAL DATA TO BE FILLED IN BY THE BIDDER
This is a typical requirement listing all types of instruments/ devices. Bidder has to fill the
data for the instruments/ devices which are in the scope of the Bidder under the package
1.00.01 Local Indicators
A) Temperature Indicator (Temperature Gauge)
Make :
Model No. :
Type :
Stem :
Movement Materials :
Case Material :
Dial size :
Scale :
Adjustment :
Pointer :
Range Selection :
Stop at Max. Reading :
Over range protection :
Instrument Connection :
Process Connection :
Performance
:
a) Accuracy
Measuring Instruments, VMS & Control
REL-SKCCP-NRM-161-P-00001 (Rev.00) Valves Page 1 of 23
2200-2400 MW CCPP
b) Response Time
Operating Ambient
:
Temperature
Accessories :
Feature :
Service :
B) LEVEL INDICATOR (FLOAT & BOARD)
Make :
Model No. :
Type :
Float Material :
Pulley material :
Guide wire :
Scale Board :
Flanges :
Accuracy :
Accessories :
Service :
C. ROTAMETER
Make :
Model No. :
Type :
Metering tube :
Float :
End fittings :

2200-2400 MW CCPP
Packing material :
Casing material :
Gland Rings /Followers
:
Scale
:
Graduation :
Process Connection
:
Accuracy :
Reproducibility
:
Accessories :
D) Pressure Indicators / Gauges
Make :
Model No. :
Type :
Sensing Element Material :
Movement material :
Case Material / Protection

:
class
Dial Size :
Scale :
Range Selection :
Over range Protection :
Adjustment :
Stop at Max. Reading :

2200-2400 MW CCPP
Element connection :
Process connection :
Accuracy :
Operating ambient
:
temperature
Safety feature :
Chemical Seal Unit :
Accessories :
Service :
E) Level Indicators (Gauge Glasses)
Make :
Model No. :
Type :
Glass :
Glass Cover :
Gauge Body :
Integral cocks and valves :
Fittings :
Accuracy :
Scale :
Scale details :

2200-2400 MW CCPP
Vessel Connection :
Accessories :
Tests :
Other details :
Service :
1.00.02 Process Switches
A) Pressure / Differential Pressure Switch/ Vacuum Switch
Make :
Model No. :
Type :
Sensing Element :
Wetted parts :
Case Material :
Setter Scale :
Over range :
Set Point :
Static Pressure for DPS :
Adjustments :
Switch configuration :
Switching Differential :
Switch Rating :

2200-2400 MW CCPP
Switch type :
Cable connection :
Enclosure Class :
Repeatability :
Operating ambient
:
temperature
Accessories :
Service :
B) Top Mounted Displacer operated Level Switch
Make :
Model No. :
Displacer :
Displacer Assembly :
Wire Rope / Spring :
Guide pipe :
Repeatability :
Switch housing Protection :
Type of switch :
MOC of Switching
:
mechanism
Contact rating :
Cable Entry :
Cable gland :
Accessories :
Service :

2200-2400 MW CCPP
C) Float Operated External Cage Type Level Switch
Make :
Model No. :
Float material :
Wetted parts :
Float chamber :
Float chamber mounting :
Fluid connection :
Size of the float chamber :
Fluid connection size :
Drain :
Pressure rating of chamber :
Repeatability :
Switch housing type :
Type of switch :
MOC of Switching
:
mechanism
Contact rating :
Cable Entry :
Cable gland :
Accessories :
Service :
D) Capacitance Type Level Switch

2200-2400 MW CCPP
Make :
Model No. :
Type :
Probe
a) Type
b) Mounting :
c) Material
d) Insulation
Preamplifier
a) Type
b) Protection class
:
c) Ambient Temp.
d) Function
Enclosure :
Contact rating :
Accessories :
Supply Voltage :
Relay output :
Service :
E) Flow Switch
Make :
Model No. :
Type :
Switch Configuration
:
Switch Rating
:
Enclosure
:
Repeatability
:

2200-2400 MW CCPP
Adjustments
:
Connection type
:
Accessories
:
Service
:
1.00.03 TRANSMITTERS
A) PT / DPT / DP Type Flow TX / DP Type Level TX / Vacuum Type
Make :
Model No. :
Type :
Output signal :
Signal Processing Unit :
Measuring Element :
Measuring Diaphragm or
:
Capsule Material
Static Pressure / Overload
:
Pressure for DPT
Static Pressure / Overload
:
Pressure for PT
Turn-down ratio :
Span and Zero :
Enclosure Class :
Zero suppression /
:
elevation
Output Indicator :
Display :

2200-2400 MW CCPP
Body and its rating :
MOC for Electrical

:
Housing
Ambient Temperature :
Operating Voltage :
Load :
Accuracy :
Repeatability :
Sealing/Isolation :
Accessories :
Service :
B) Ultrasonic Level Transmitter
Make :
Model No. :
Mounting :
Electronic Housing
:
Protection Class
Accuracy :
Resolution :
Power Supply :
Out Put :
Cable Length :
Accessories :
C) Electromagnetic Flow Transmitter

2200-2400 MW CCPP
Make :
Model No. :
Sensor
Type :
Electrodes :
Liner :
Enclosure :
Accessories :
Transmitter
Input Signal Processing :
Display :
Output :
Power supply :
Turn Down :
Accuracy :
Repeatability :
Housing :
Accessories :
Service :
D) Ultrasonic Flow Meter
Make :
Model No. :

2200-2400 MW CCPP
Type :
Mounting Style :
Power supply :
Outputs :
Display/ indication :
Recording/ Totalizing /
:
Logging Facilities
Electronic Housing
:
Protection Class
Display :
Accessories :
Accuracy :
Resolution :
Service :
E) Mass Flow Meter
Make :
Model No. :
Type :
Working Principle :
Output Signal :
Operating Voltage :

2200-2400 MW CCPP
Transmission :
Material of wetted parts :

Electronic Housing
:
Protection Class
Display :
Accessories :
Accuracy :
Resolution :
Service :
F. Guided wave radar type level transmitter
Make :
Model No. :
Type :
Principle :
Probe Type & Material :
Signal O/P :
Display :
Power Supply :
Accuracy :
Electromagnetic
:
Compatibility
Mounting :
Electronic Housing
:
Protection Class

2200-2400 MW CCPP
Service :
1.00.04 PRIMARY SENSORS
A) Resistance Temperature Detectors
Make :
Model No. :
Type :
Resistance :
Base :
Wiring :
Response time :
Sheath Material :
Accuracy :
Immersion Length /
:
Extension neck length
Head
Protection :
Material :
Cable connection :
Accessories :
Thermowell

2200-2400 MW CCPP
Make :
Model No. :
Material :
Max internal bored dia :
Bore concentricity :
Identification mark :
Surface treatment :
Element connection :
Certification :
Accessories :
Service :
B) Flow Elements
1) Orifice Plate
Make :
Model No. :
Type :
Design Standard :
Material of Orifice Plate
:
& Rating
Thickness :
Beta Ratio :
Pressure Tap :
No. of Root Valves per
:
tapping
Root valve type/ material :

2200-2400 MW CCPP
Vent Hole / Drain Hole :
Accuracy
Accessories :
Service :
2) Impact Head Type Flow Element / Averaging Pitot tube
Make :
Model No. :
Type :
Number of Holes :
Material of Construction
a) Sensor
b) Instrument Head
:
c) Instrument Valve
d) Mounting
Hardware
Piping Orientation :
Accuracy :
Repeatability :
Flow Turn Down :
Accessories :
Service :
1.00.05 Analysers
A) pH Analyser
Make :

2200-2400 MW CCPP
Model No. :
Type of Cell :
Case Material :
Analyzer power supply :
Output :
Accuracy :
Repeatability :
Resolution :
No. of Streams :
Response Time
:
Connection :
Operating ambient
Temperature
Temp. Compensation :
Mounting :
Calibration :
Enclosure Class :
Range
:
Accessories :
Service :
B) Turbidity Analyser
Make :
Model No. :
Type :

2200-2400 MW CCPP
Measurement Principle :
Case Material :
Analyzer power supply :
Output :
Accuracy :
Repeatability :
No. of Streams :
Response Time
:
Connection :
Operating ambient
Temperature
Mounting :
Calibration :
Enclosure Class :
Range :
Accessories :
Service :
Signature : .......................
SEAL OF COMPANY
Name : .......................
Designation :
......................

2200-2400 MW CCPP
1.00.06 Vibration Monitoring System
1. Vibration Pick-ups
01. Make
Model
02.
Type :
03.
04. Mounting :
05. Case material :
06. Connector :
07. Sensitivity :
08. Frequency response :
09. Environmental Temperature :
10. Relative Humidity :
11. Enclosure :
12. Accessories
2. Key Phasor
01. Make
Model
02.

2200-2400 MW CCPP
Type :
03.
04. Mounting :
05. Case material :
06. Connector :
07. Sensitivity :
08. Frequency response :
09. Environmental Temperature :
10. Relative Humidity :
11. Enclosure :
12. Accessories
3. Vibration Monitor/ Signal conditioning module
01. Make
Model
02.
No. of channels :
03.
04. Sensitivity :
05. Frequency Response :
06. Accuracy :
07. Transducer supply voltage :
08. Recorder output :

2200-2400 MW CCPP
09. Alarm contacts :
10. Contact rating :
11. Contact life :
12. Alarm Adjustment :
13. Operating temperature :
4. Power Supply
01. Make
Model
02.
Input Supply voltage :
03.
04. Output :
05. Rating :
06. Operating Temp :
07. Humidity :
08. Weight :
09. Overall :
Dimensions(WXHXD)
5. HMI/ GUI
01. Make
Model
02.

2200-2400 MW CCPP
Additional Information :
03.
Note: Bidder shall furnish technical datasheets for all other instruments, if not specified above
but coming under their scope of supply.
Signature : .......................
SEAL OF COMPANY
Name : .......................
Designation : ......................

2200-2400 MW CCPP
1.00.07 Control Valve

Formatted: Font: 11 pt
Make :
Model No. :
Valve Size & Type :

Design Parameters Min. Flow Normal Flow Max. Flow
1. Temperature
2. Pressure :
3. Flow
4. Valve opening
Body Material :
Trim (Stem, plug, cage)
Material
End Connection :
Positioner type, features as
: Yes/ No
specified
All required accessories
(AFR, volume booster,
: Yes/ No
Gauges etc.) provided as
per specification)
Air Filter Regulator Type :
Actuator Type :
Electronics items provided
with Explosion proof EExd : Yes / No
Housing
Valve position on air
:
supply failure
Valve position on signal
failure
Formatted: Font: 11 pt

PLC System 2400 MW SAMALKOT
CCPP EXPANSION
PLC SYSTEM
TECHNICAL DATA SHEETS
REL-SKCCP-NRM-161-P-00001 (Rev.00) PLC Page 1 of 6

CCPP EXPANSION
CONTENTS
SECTION TOPIC
TECHNICAL DATA SHEETS
1. Programmable Logic Controller
2. UPS

CCPP EXPANSION
1. PLC System
S.No Description Response
1 Make
2 Series/ Model No.
3 Place of Manufacture/ testing
4 PLC panel make
5 Confirmation of Erection & Commissioning of total PLC system

(Y/N)
6 Confirmation of scope of work as per spec. (Y/N)
Confirm that all additional hardware and software, over & above
7 those indicated in the proposal, if required during detail engineering
stage for fully meeting the intent and requirements of Specs, shall
also be supplied by the contractor within the quoted price
Supply of Spares:-
8 a) Commissioning spares list
b) Mandatory spares list
9 PLC System Architecture Diagram (Y/N)

10 Bill of material furnished at
11 Processor details (Make/ Model/ Data length- 32/ 64 bit etc.))
12 No. of Redundant Controllers proposed for each PLC system

Spare capacity requirement of Controller, I/O modules, cabinets etc
13
as per specification requirement. (Y/N)
Parametric requirements and loop reaction time as per specification
14
requirement (Y/N)
15 System goes to Fail safe mode on Power failure (Y/N)
On-line configuration via programmer console (engineering station)
16
(Y/N)
17 On-line diagnostic up to module level provided
18 I/O cards:
i) I/O modules shall be provided on as required basis. (Y/N)

CCPP EXPANSION
ii) Spare channels provided as specified (Y/N)

iii) Number of channels for each type of card
a) AI :
b) AO :
c) T/C :
d) RTD :
e) DI :
f) DO :
iv) Analog Signal Conditioning
a) Galvanic isolation of input Yes/No
b)Galvanic isolation of output : Yes/No
c)Current Limiting: Yes/No
d)Channel to Channel isolation :Yes/No
e)All inputs fuse protected on per point basis and short circuit proof :
Yes/No
f)Fuse monitoring :Yes/No
v)Binary Signal Conditioning :-
a)Contact interrogation voltage :
b)Contact bounce filtering: Yes/No
c)Per point fuse protection: Yes/No
d)Opto isolation of input : Yes/No
e)Interposing relay at output :Yes/No
f)Wire break monitoring: Yes/No
g)Differential input: Yes/No

vi)On line replacement of I/O module (Y / N)
19 Operator work station:

CCPP EXPANSION
a) Make & Model
b) Qty
c) Screen size of TFT monitor
d) Type/ Number/ Length of highway (Fibre optic/co-axial cable)
e) On-line diagnostics as specified (Y/N)

f) All HMI functions including HSRS functions provided as
specified (Y/N)
20 Panels / Cabinets
Panels/ Cabinets provided meeting specification requirements (Y/N)

21 HMI/ Programming station/ Printer Furniture provided (Y/N)
22 System Reliability
a) Surge protection for electronic control systems, annunciation
system and other solid state systems conforming to SWC test per
ANSI C 37.90a (IEEE standard 472)
b) Self Diagnostics :-
a)Online diagnostics down to the level of individual modules

displayed on OWS Yes/No
b) Local indication in the module and cabinet (Y/N)

c)Failure of controller, communication etc. (Y/N)
Colour Laser Printer :-
a) Make/Model No.
23
b) Speed
c) A4 Paper provided as specified (Yes / No)
24 Software Requirements
As per specification requirement (Y/N)
25 Documentation as per specification requirement confirmed . (Y/N)
26 Long term support details furnished: (Y/N)
2. UPS

CCPP EXPANSION
1.0.0 Make
2.0.0 Series/ model
3.0 Capacity at 50 Deg.C (after derating from lower temperature)
4.0 Specification requirement compliance (Y/N)
5.0 Write up, Configuration, BOM furnished (Y/N)

PART IV
SECTION 2
SCHEDULES
Part IV, Section 2

REL-SKCCP-NEM-161-P-00001(Rev.00) Page 1 of 33
SCHEDULES
LIST OF SCHEDULES
CONTENTS
SECTION
S SCHEDULES TOPIC
S0 Schedule of General Particulars of Bidder
S1 Schedule of Technical Evaluation
S2 Schedule of Mandatory Information
S3.1 Schedule of Load and Weight Data
S3.2 Schedule of Electrical Load data
S4 Schedule of Experience List of Bidder
S5 Schedule of Recommended Spares
S6 Schedule of Mandatory Spares
S7 Schedule of Deviation ( Technical)
S8 Schedule of Delivery Erection and Commissioning

Schedule of Drawing / Documents Submission &
S9
Distribution
S10 Schedule of Tools and Tackles
S11 Schedule of Sub-Vendors’ List
S12 Schedule of Performance Guarantees
S13.1 Schedule of price break-up of recommended spares

Schedule of price break-up of Start up & Commissioning
S13.2
spares.
S13.3 Schedule of price break-up of mandatory spares
S13.4 Schedule of price break-up of special tools & tackles
S13.5 Schedule of price summary
S13.6 Schedule of price for water & power at construction time

Schedule For Evaluation Of Concrete, Cement & Steel
S13.7
Involved In The Package
S14 Schedule of alternate proposals.
S15 Schedule of Engineering & Deliverables
S16 Schedule of Safety
Part IV, Section 2

SCHEDULES
S.0 – SCHEDULE OF GENERAL PARTICULARS OF BIDDER
The Bidder shall furnish the general particulars about the organization as
follows.
Details To be Filled by
S. No Description
Bidder
1 Name of Bidder with registered office address
2 Telephone No.
3 Fax No.
4 E – Mail
Name and Designation of the Official of the Bidder to

5
whom all reference shall be made
Financial Details
6
Enclose copies of Audited Balance sheet and Profit and

a) Yes / No
Loss Account for past three (3) years.
Indicate following for the past three (3) years with

projection for next three (3) years.
b)
I) Annual turnover:
ii) Annual profit:
Name and Address of the Bankers to the

c)
Company
Project organization chart showing staffing,
7 Yes / No
furnished
8 List of important personnel curriculum vitae, furnished Yes / No
……………………………
Bidder’s Stamp & Signature
Part IV, Section 2

SCHEDULES
S.1 – SCHEDULE OF TECHNICAL EVALUATION
The bidder shall furnish the general particulars about the organization as per the
following format:
Particulars
S. No. By Bidder
Parameter
1. Experience Details Please fill up Schedule S 2 with
details
2. Manufacturing Capabilities ( write up attached) Yes/No
3. Details of collaboration agreements if any is Yes/No
enclosed
4. In case of foreign bidder details of experience of
Indian counter part if any
5. List of major installations/orders in the relevant Yes/No
field executed during last 10 years enclosed.
6. Major equipment/ system supplied, (indicate
capacity of each equipment) for above installations
7. Extent of electrical, mechanical and
instrumentation works in above installations.
Compliance to Scope
8. Scope of work as per Technical Specification Yes / No
9. Scope of Work (Services) as per Technical Yes / No

Specification
10. List of Mandatory Spares as per Yes / No

Technical Specification
11 List of Recommended Spares as per Yes / No

12 Erection & Commissioning Spares as per Yes / No
13 List of Tools & Tackles to be deployed duly filled Yes / No
up as per Schedule S.10
14 Deviation from Scope of Supply and Services(If Yes / No
Yes, Please fill up Schedule S-7)
Deliverables
15. Schedule of completion period as Months
stipulated in bid documents.
Part IV, Section 2

SCHEDULES
Particulars
S. No. By Bidder
Parameter
16. Drawing/ Document Schedule attached along with Yes/ No
the Bid
17 Duly filled technical datasheets for all the items Yes/ No

specified in Technical Specifications
18. Guaranteed power consumption for applicable Yes/ No
fans have been filled up in Schedule S-12
Quality
19. Quality Control manual and facilities to be Yes/ No
established at site
a. Site facilities for testing Yes/ No
b. Procedures and compliance to quality Yes/ No
requirement as per technical specs
……………………………
Part IV, Section 2

SCHEDULES
S-2 SCHEDULE OF MANDATORY INFORMATIONS
The Bidder shall fill up the schedule of mandatory information’s as requested. The same
will be utilized for the evaluation of his offer. The bidder shall furnish documentary back
up against each and every item. The data is to be filled up for CONDENSING system
having capacity not less than that stipulated in Qualifying Requirements
Sl
Description of Item Project 1 Project 2
no
1. Name and address of system supplier
2. Name and address of the installation

3. Name, address and contact number of the client
4. Date of Order and Order Value
5. Date of commissioning
6. Capacity
7. Number of Units with above capacity supplied
8. Scope Included
a) Design
b) Supply
c) Erection
d) Commissioning
Performance certificate for satisfactory
9 operation of system for two years as on date of Yes/No Yes/No
bid opening attached?
As an evidence to other qualifying requirements,
10 copy of Purchase order, commissioning Yes/No Yes/No
certificate etc, attached?
……………………………
Part IV, Section 2

SCHEDULES
S-3.1 SCHEDULE OF LOAD & WEIGHT DATA
The Bidder shall fill up the schedule of mandatory information’s as requested. The
same will be utilized for the evaluation of his offer. The bidder shall furnish
documentary back up against each and every item.
S. No Item Description
A] LOADING DATA
1. Horizontal and Vertical -Static and Dynamic
Loads of each rotating equipment for foundation
Design (Kg.f.)
2. Horizontal and Vertical -Static and Dynamic
Loads of each static equipment for foundation
Design (Kg.f.)
B] WEIGHT DATA
1. Weight of eacfh part of condensing plant
2. Weight of the largest single piece to be handled

for :
a. Erection
b. Maintenance
3 Shipping weight (Kgs.) and volume (Cu.M) of all

specified components
4 Over all dimensions of other large items ( Please
specify)
……………………………
Part IV, Section 2

SCHEDULES
S-3.2 SCHEDULE OF ELECTRICAL LOAD DATA
LOAD LIST FORMAT
No. of Interposing
No. of Equipment Rating of each equipment Voltage Wires Nett Demand Feeder Rating Point of Control (Start/Stop) Relays
Duty / Efficiency of
Stand A- A- Utilization / Coincidenc Electrical
Working by Total KW KVA Running Starting Load factor e factor equipment KW KVA
Feeder
Type
Duty (Normal
Starting Speed Consumer Category AC/ Local Locatio
Descriptio time less of (415Vac / Type (Continious Emergen Local Vendor Push Voltage n
SI. n than 5 sec Motor 240Vac / (2W, 3W, (SFU / Starter / or (j)=(a)x(d)x( cy Location Starter Control Button of of
NO. System Tag No. of Loads (a) (b) (c) =(a)+(b) (d) (e) (f) yes/no (RPM) 220Vdc) 4W) DOL / RDOL) Intermittent) (g) (h) ('i) g) x(h)/('i) (k)=(j)/0.85 A kW kVA A AC/DC) of Drive DCS PLC Panel Panel Station relay coil relays
……………………………
Part IV, Section 2

SCHEDULES
S-4 SCHEDULE OF EXPERIENCE LIST OF BIDDER
The Bidder shall furnish a list of similar jobs executed by him to whom reference
may be made by the Purchaser in case the Purchaser considers such a
reference necessary.
Name & Contract

Order date Contact
S. No. Description of Value of Contract execution
& number Person
contract duration
……………………………
Part IV, Section 2

SCHEDULES
S-5 SCHEDULE OF RECOMMENDED SPARES
The bidder shall furnish this schedule for 3 years for Indian Origin / 5 years of
non-Indian origin for maintenance of the plant. The bidder shall indicate the unit
price in a separate cover which shall remain valid during the execution of the
contract..
Sl. No. Description Quantity
……………………………
Part IV, Section 2

SCHEDULES
S-6 SCHEDULE OF MANDATORY SPARES

The bidder shall furnish this schedule as a part of Supply.
Sl. No. Description Quantity
……………………………
Part IV, Section 2

SCHEDULES
S-7 SCHEDULE OF DEVIATION (TECHNICAL)
If the proposal has got any deviation from the technical specification the Bidder shall tabulate those deviations in this list. It is
understood that except these deviations as tabulated here in under the Bid is in complete agreement with the specification
requirements.
We have no deviation/ following deviations from the Technical specifications ( Strikeout whichever is not applicable)
Specification Reference Requirement as per Details of Deviations Bidder to indicate Remarks
Specifications alternative and the
reduction in price for
Sl. acceptance of such
No deviation.
Section Clause Page No
Date:
……………………………
Part IV, Section 2

SCHEDULES
S-8 SCHEDULE OF DELIVERY, ERECTION AND COMMISSIONING
The Bidder shall indicate below the period for design, manufacture, shop testing,
erection, site testing, and commissioning of the complete equipment under the
scope of this specification. A detailed schedule in the form of a network shall also
be furnished. Periods shall be counted from the data of issue of letter of intent.
Schedule should comply with the requirements of the specification as stipulated
in Bid document.
SL.
DESCRIPTION WEEKS AFTER L.O.I.
NO.
……………………………
Part IV, Section 2

SCHEDULES
S-9 SCHEDULE OF DRAWING / DOCUMENTS SUBMISSION & DISTRIBUTION
The Bidder shall submit a comprehensive drawing / documents submission and

distribution schedule covering all equipment, system, sub systems as described
in the specification.
Data of submission after issue

SL. NO. DRAWING / DOC. NO.
of L.O.I.
……………………………
Part IV, Section 2

SCHEDULES
S-10 SCHEDULE OF TOOLS AND TACKLES
The Bidder shall tabulate below the unpriced list of the tools & tackle for
operation, maintenance and replacement of equipment and components supplied
under the specification.
SL.
EQUIPMENT DESCRIPTION QUANTITY
NO.
……………………………
Part IV, Section 2

SCHEDULES
S-11 SCHEDULE OF SUB VENDORS’ LIST
The Bidder shall indicate the list of sub vendor for different equipment / sub
systems as indicated in the preferred list. The choice of sub vendor shall be
subject to the approval of the Employer.
SL. SUB VENDOR ‘S NAME &

ITEM PARTICULARS
NO. CONTACT DETAILS
……………………………
Part IV, Section 2

SCHEDULES
S-12 SCHEDULE OF PERFORMANCE GUARANTEES
The Bidder shall guarantee the performance of each and every equipment and
system components in line with the requirements of technical specification.
However, Following guaranteed parameters as declared by the bidder shall be
used for evaluation and Liquidated damages in case of shortfall in Performance.
Non submission of the same will lead to rejection of the Bid.
Sl. No Equipment Capacity Static Power

in Pressure consumption
CuM./Hr in at motor
mmWC input
terminals
per fan in
KW
……………………………
Part IV, Section 2

SCHEDULES
S 13.1 SCHEDULE OF PRICE BREAK-UP OF RECOMMENDED SPARES
Item
S. Sales tax on direct Total Price
Descri Qty Unit Price Total Price Local
No. transaction only FOR site
ption transportation
CIF (For Ex- CIF (For Ex-works Rate (%) Amount charges For spares For Indigenous
spares works spares (For (including inland supplied from spares
supplied (For supplied indigenou insurance, port abroad
from indigeno from s spares) clearance & port
abroad) us abroad) charges)
spares)
1 2 3 4 5 6=3x4 7=3x5 8 9 10 = 6 + 8 + 9 11 = 7 + 8 + 9
Note:
1. All the recommended spare parts indicating the item-wise cost shall be submitted along with the bid.
2. Continuation sheets of like size and format may be used as per Bidder’s requirements and shall be annexed to this schedule for each system separately.
*: Bidders at its option may quote the price of imported component in Indian Rupees (Bidders to specify).
……………………………
Part IV, Section 2

SCHEDULES
S.13.2 SCHEDULE OF PRICE BREAK-UP OF START UP & COMMISSIONING SPARES.
Item
spares)
1 2 3 4 5 6=3x4 7=3x5 8 9 10 = 6 + 8 + 9 11 = 7 + 8 + 9
Note :
1. All the mandatory spare parts indicating the item-wise cost shall be submitted along with the bid.
2. Continuation sheets of like size and format may be used as per Bidder’s requirements and shall be annexed to this schedule for each system
separately.
……………………………
S13.3 – SCHEDULE OF PRICE BREAK UP OF MANDATORY SPARES
Part IV, Section 2

SCHEDULES
Item
spares)
1 2 3 4 5 6=3x4 7=3x5 8 9 10 = 6 + 8 + 9 11 = 7 + 8 + 9
Note:
1. All the mandatory spare parts indicating the item-wise cost shall be submitted along with the bid.
……………………………
Part IV, Section 2

SCHEDULES
S 13.4 SCHEDULE OF PRICE BREAK-UP OF SPECIAL TOOLS & TACKLES
Item
spares)
1 2 3 4 5 6=3x4 7=3x5 8 9 10 = 6 + 8 + 9 11 = 7 + 8 + 9
Note:
1. All the tools indicating the item-wise cost shall be submitted along with the bid.
……………………………
Part IV, Section 2

SCHEDULES
S.13.5 SCHEDULE OF PRICE SUMMARY
1.00.00 Proposal Lump sum Price

Total proposal price for the CONDENSING & its auxiliaries System as specified, including design,
manufacture, fabrication, assembly/reassembly, testing at manufacturer's works, forwarding (duly
packed for transportation), transportation, delivery at site, loading/ unloading, storage at site,
handling and in plant transportation at site, erection, testing at site, commissioning, acceptance
testing and handing over, painting, Mandatory spare parts and special tools and tackles excluding
execution of civil & architectural works.. : Rs...........................
(Price shall be inclusive of all taxes & duties and also marine freight and insurance port handling
& clearance & customs duties for the imported components, if any.)
Transit Insurance from Indian works/ port of shipment to project site Shall be arranged by RInfra.
2.00.00 Separate lump sum prices for the following (included in Sl. No. 1.00.00 above)
Transportation from works/ port of shipment to project site
Transit Insurance
Excise Duty
Sales Tax
Octroi
Other taxes, if any

Supply (ex-works basis) of all mechanical, process and electrical equipment & accessories
complete with all instrumentation & controls for the entire CONDENSING & its auxiliaries
System other than imported components.
Part IV, Section 2

SCHEDULES
Complete Civil, Structural & Architectural work as specified for the System.
Unloading and storage at site, handling at site, complete erection, painting, sustained load test,
commissioning guarantee and acceptance testing for the entire CONDENSING System.
3.00.00 Price of Imported components/items (if any) as included in offer (included in Sl. No. 1.00.00 above).
a) Supply F.O.B. port of shipment of all mechanical, process (including instrumentation & controls,
if any) and electrical equipment & accessories.
b) Marine freight and insurance
c) Port handling & clearance
d) Customs duties
e) Other charges
Bidder's ex-works proposal price for supply of mandatory spares, properly packed for transportation
4.00.00
to Site (included in Sl. No. 1.00.00 above). (List and Unit price to be indicated in Schedule-S6)
4.01.00 Bidder's total charges on mandatory spare for :
4.01.01 Ocean freight
4.01.02 Marine Insurance
4.01.03 Port Clearance
4.01.04 Custom's Duty
Part IV, Section 2

SCHEDULES
4.01.05 Inland Transportation from Port of Delivery/ Station of Dispatch to Project Site.
4.01.06 Transit Insurance (Transit insurance is under RInfra’s scope).
4.01.07 Excise duty, if any
4.01.08 Sales Tax
4.01.09 Octroi
4.01.10 Other Taxes, if any

Charges indicated in clause 4.01.00 included in clause 4.00.00 above.
4.02.00
(Answer yes or no )
Bidder's total proposal price for mandatory spare F.O.R. site (sum of 4.00.00 + 4.01.00 through'
4.03.00
4.01.10)
Bidder's ex-works proposal price for supply of special tools & tackles, properly packed for
5.00.00 transportation to Site (included in Sl. No. 1.00.00 above). (List and Unit price to be indicated in
Schedule-S10)
5.01.00 Bidder's total charges on special tools & tackles for :
5.01.05 Inland Transportation from Port of Delivery/ Station of Dispatch to Project Site
Part IV, Section 2

SCHEDULES
5.01.06 Transit Insurance is under RInfra’s scope.
5.01.08 Sales Tax
5.01.09 Octroi

5.02.00
(Answer yes or no)
Bidder's total proposal price for special tools & tackles F.O.R. site (sum of 5.00.00 + 5.01.00
5.03.00
through' 5.01.10)
6.00.00 Separate lump sum prices for the major items
a) Transportation from works/ port of shipment to project site
b) Transit Insurance - is under RInfra’s scope.
c) Excise Duty
d) Sales Tax
e) Octroi
f) Other taxes, if any

g) Supply (ex-works basis) of all mechanical, electrical equipment & accessories complete with all
instrumentation & controls for the entire CONDENSING System other than imported
components.
Part IV, Section 2

SCHEDULES
h) Unloading and storage at site, handling at site, complete erection, painting, sustained load test,
commissioning guarantee and acceptance testing for the CONDENSING System.
Bidder's ex-work proposal price for supply of recommended spares for five (5) years' operation
7.00.00
properly packed for transportation to Site. (List and Unit prices indicated in Schedule-S5)
7.01.00 Bidder's total charges on recommended spares for :
7.01.05 Inland Transportation from Port of Delivery/ Station of Dispatch to Project Site
7.01.06 Transit Insurance - is under RInfra’s scope.
7.01.08 Sales Tax
7.01.09 Octroi

7.02.00
(Answer yes or no )
Bidder's total proposal price for recommended spare F.O.R. site (sum of 12.00.00 + 12.01.01
7.03.00
through' 12.01.10).
Part IV, Section 2

SCHEDULES
8.00.00 Optional Prices
8.00.01 By pass Stack
8.00.02 Guillotine Damper : Rs..............
8.00.03 Diverter Damper : Rs..............
8.00.04 Auxiliary boiler : Rs..............
8.00.05 Service Tax + Cess on Freight : Rs..............
8.00.06 Transit insurance : This shall be in R-Infra

Scope
8.00.07 Octroi & other charges : Rs.................
8.00.08 Other applicable taxes & duties, (Furnish details) : Rs................
8.00.09 All site services including Erection, testing & commissioning. : Rs.......................
8.00.10 Service Tax + Cess, above : Rs..............
9.00.00 Are the prices quoted firm till execution of contract? :
10.00.00 Bidder's proposal price for supply of final paints FOR site.
Part IV, Section 2

SCHEDULES
11.00.00 Bidder's proposal price for application of final paint to all equipment of CONDENSING System.
……………………………
Part IV, Section 2

SCHEDULES
S.13.6 SCHEDULE OF PRICE FOR WATER & POWER AT CONSTRUCTION TIME
Bidder is advised to quote optional price as per format enclosed incase both water & power are to be arranged by him.
S. No. Item Description

I CONSTRUCTION WATER
For making own arrangement for supply of water for construction activity we intent to make following
provisions:
(Bidder to elaborate the proposed arrangement)
We have included in our overall quoted price,the cost of provision of above mentioned facility which is
Rs...............................................
(Rupees.................................................)
II CONSTRUCTION POWER
For making own arrangement for supply of power for construction activity we intent to make following
provisions.
(Bidder to elaborate the proposed arrangement)
We have included in our overall quoted price,the cost of provision of above mentioned facility which is
Rs...............................................
(Rupees.................................................)
……………………………
Part IV, Section 2

SCHEDULES
S.13.7 SCHEDULE FOR EVALUATION OF CONCRETE, CEMENT & STEEL INVOLVED IN THE PACKAGE
Following table is given which will be filled up by the bidder along with his tender and will be considered for evaluation and also for arriving at
penal cost, if any during execution.
Item Quantity Grade Water to Rate to be Allowable Penal rate to Remarks

cement ratio considered for wastage be levied on
evaluation excess
quantity
Concrete
Cement
Reinforcement
steel
……………………………
Part IV, Section 2

SCHEDULES
S -14 -SCHEDULE OF ALTERNATE PROPOSAL
Bidder to furnish this schedule as per Clause 2.01.00 (Main and Alternate Proposals), completely filled in with the following details as sub-
sections:
i Design Criteria and Technical details of the alternate proposal.

ii Advantages over the Base Offer in terms of Capex, Opex (including recurring expenditure other than power consumption), and Area
required for Installation and life of equipments etc.
iii Guaranteed Effluent Parameters in line with the Specification.
iv Maintenance, availability of spares and Operation Ease.
….. …………………………
S.15 SCHEDULE OF ENGINEERING & DELIVERABLES
Part IV, Section 2

SCHEDULES
Bidder shall submit the under mentioned deliverables as per following schedule
S No. Deliverables Weeks from LOI

CIVIL
Mechanical GA drawing along with equipment load data, type of foundation to be adopted along
1
with the size of foundation, TOC for all items
ELECTRICAL
1 Preliminary Load List (90 % correct) 2
2 Sub-Vendor List 2
3 GA drawings and Single Line Diagram 4
4 Technical data sheet(final) 4
5 Final Load list (100% correct) 5
6 Balance drawings 5
……………………………
Part IV, Section 2

SCHEDULES
S16 SCHEDULE OF SAFETY
The bidder shall furnish the general particulars about the Safety Plan and Facilities as
per the following format:
S. No. Particulars Parameter By Bidder
1 Safety plan & facilities to be established at site
a. Safety facilities at site provided Yes/No

Bidder Confirms compliance to the Safety
b. Yes/No
requirements as specified in Technical Specification.
……………………………
Part IV, Section 2

SCHEDULES

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2400 MW CCPP SAMALKOT

Document No. REL-SKCCP- NEM-161-P-00001 (Rev.00)

RELIANCE INFRASTRUCTURE LIMITED

DOCUMENT CONTROL SHEET

0 10.12.10 Spec PT AKS KVH CS SSB KS AD NKG KBB SLK AS

SECTION 1 INFORMATION TO BIDDERS (ITB)

SPECIAL CONDITIONS OF CONTRACT (SCC)

COMMERCIAL EVALUATION FORMAT

SECTION 2 GENERAL CONDITIONS OF CONTRACT (GCC)

PART – II TECHNICAL SPECIFICATION

SECTION-A GENERAL TECHNICAL INFORMATION

4. System Description & Layout

5. Scope of Supply & Services

6. Terminal Points & Exclusions

7. Liquidated Damages for Shortfall in Performance

8. Bid Evaluation Criteria

SECTION-B COMMON TECHNICAL SPECIFICATION

1. System Design Basis & Operating Capability

2. Codes & Standards

4. System Trial Operations

5. Performance Guarantee Test Procedure

REL-SKCCP- NEM-161-P-00001 (Rev.00) INDEX Page2 of 3

7. Type Test & Type Test Charges

SECTION-C DETAILED TECHNICAL SPECIFICATION

INSTRUMENTATION & CONTROL

SECTION 1 GENERAL TECHNICAL REQUIREMENT (GTR)

SECTION 2 ERECTION CONDITIONS OF CONTRACT (ECC)

PART-IV DATA TO BE SUBMITTED BY THE BIDDERS

SECTION 1 TECHNICAL DATA SHEETS

REL-SKCCP- NEM-161-P-00001 (Rev.00) INDEX Page3 of 3

GENERAL TECHNICAL INFORMATION

REL-SKCCP-NEM-161-P-00001(Rev.00) PART II SECTION A Page 1 of 13

1.00.00 INTENT OF SPECIFICATION

REL-SKCCP-NEM-161-P-00001(Rev.00) PART II SECTION A Page 2 of 13

2.00.0 PROJECT INFORMATION

2.01.0 PROJECT INORMATION DATA

1 Power Evacuation Generating Units shall be connected through

3 Approach Road The proposed site is approachable from Samalkot

4 Railway Approach The Site is 3 Km from the Samalkot Railway

REL-SKCCP-NEM-161-P-00001(Rev.00) PART II SECTION A Page 3 of 13

a. Design ambient temp for electrical equipments shall be 500C.

2.02.0 SPECIFICATION OF NATURAL GAS

REL-SKCCP-NEM-161-P-00001(Rev.00) PART II SECTION A Page 4 of 13

C4 IsoButane C4H10 % Molar 0-3 -

REL-SKCCP-NEM-161-P-00001(Rev.00) PART II SECTION A Page 5 of 13

2.03.0 RAW WATER ANALYSIS (Canal water)

2 Conductivity ppm 130 430 192.3

3 Turbidity ppm 10 702 127

4 Residual Chlorine as Cl2 ppm 0 0 0

5 Iron as Fe ppm 0.1 0.35 0.13

6 Total Dissolved Solids ppm 80 270 125

7 Total Hardness as CaCO3 ppm 48 112 69

11 Total Alkanity ppm 52 114 77

12 Chloride ppm 19.8 89 31

13 Sulphate ppm 2.0 10 4

Redundant processors in hot standby configuration

Gas quality Gas Turbine Accessory module gas compartment.

,(+

5

,(+

5

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5